WO2017050081A1 - 大幅度降低噪音的汽车轻量化用的聚酯无纺布及其制备方法 - Google Patents

大幅度降低噪音的汽车轻量化用的聚酯无纺布及其制备方法 Download PDF

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WO2017050081A1
WO2017050081A1 PCT/CN2016/096303 CN2016096303W WO2017050081A1 WO 2017050081 A1 WO2017050081 A1 WO 2017050081A1 CN 2016096303 W CN2016096303 W CN 2016096303W WO 2017050081 A1 WO2017050081 A1 WO 2017050081A1
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layer
polyester
automobile
nonwoven fabric
noise
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PCT/CN2016/096303
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English (en)
French (fr)
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张云
丁荣华
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常州市泛亚汽车饰件有限公司
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B32B27/322—Layered products comprising a layer of synthetic resin comprising polyolefins comprising halogenated polyolefins, e.g. PTFE
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1284—Application of adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/26—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/06—Interconnection of layers permitting easy separation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1207—Heat-activated adhesive
    • B32B2037/1215—Hot-melt adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/26—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers
    • B32B2037/268—Release layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating

Definitions

  • the present invention relates to the field of nonwoven fabrics, and more particularly to a polyester nonwoven fabric for weight reduction of automobiles which greatly reduces noise and a preparation method thereof.
  • Car noise is divided into off-board noise and interior noise.
  • the noise outside the car refers to the noise radiated from the various parts of the car to the space outside the car.
  • In-vehicle noise refers to the part of the noise that is transmitted to the vehicle through various means of noise outside the vehicle, and the vibration transmission path of each part of the vehicle excites the structural vibration of the various parts of the vehicle body to radiate noise into the cabin. These noise sound waves are in the vehicle. Under the constraints of the acoustic characteristics of the inner space, a relatively complex reverberant sound field is generated, thereby forming interior noise.
  • Car noise not only increases the fatigue of the driver and the occupants, but also affects the driving safety of the car.
  • noise has serious adverse effects on the digestive system and cardiovascular system, which can cause indigestion, loss of appetite, nausea and vomiting, which leads to an increase in the incidence of stomach diseases and gastric ulcers, making hypertension, arteriosclerosis and coronary heart disease.
  • the incidence rate is significantly higher than normal.
  • Noise can also have an adverse effect on the visual organs.
  • the technical problem to be solved by the present invention is to provide a new requirement for meeting the weight reduction of automobiles, to expand the seating space in the automobile, to reduce the noise in the automobile, to improve the comfort of the personnel in the automobile, to reduce the noise fatigue, and to make the driving safer.
  • a polyester nonwoven fabric for lightweighting of automobiles which greatly reduces noise and a preparation method thereof.
  • a technical solution adopted by the present invention is to provide a polyester nonwoven fabric for lightweighting of automobiles which greatly reduces noise, comprising: a polyester fiber sheet layer and a damping rubber layer, along the polyester
  • the density decreasing direction of the fiber sheet layer in turn includes a compact layer, a semi-tight layer and a fluffy layer, and the surface of the compact layer is compounded with a damping rubber layer, and an expanded polytetrafluoroethylene film layer is composited on the surface of the bulk layer.
  • the surface of the damping rubber layer is compounded with a release paper protective layer that is removed during use.
  • a layer of hot-melt powder is disposed between the layers of the compact layer, the semi-tight layer and the bulk layer, and the three-layer structure is fixedly bonded by the hot-melt powder layer.
  • another technical solution adopted by the present invention is to provide a method for preparing a polyester nonwoven fabric for weight reduction of automobiles which greatly reduces noise, comprising the following steps:
  • the method for preparing a polyester fiber sheet comprises:
  • the flame retardant polyester staple fiber comprises polypropylene PP, polyethylene terephthalate PET or polyethylene PE flame retardant staple fibers.
  • the staple fiber opening is performed by pre-opening the staple fibers and then performing the main opening.
  • the invention has the beneficial effects that the invention satisfies the new requirements of automobile lightweighting, expands the riding space in the automobile and reduces the noise in the automobile; the damping glue can reduce the low frequency noise generated by the vibration of the vehicle during rapid driving, The damping material is unique. Improve the comfort of the people in the car and reduce noise Fatigue, driving is safer.
  • the expanded polytetrafluoroethylene microporous film can further improve the sound absorbing ability of the polyester nonwoven fabric.
  • the expanded polytetrafluoroethylene microporous membrane has the ability of water and oil repellent and anti-pollution, and is easy to clean.
  • 1 is a polyester nonwoven fabric for lightweighting of automobiles with greatly reduced noise according to the present invention and a preparation method thereof
  • an embodiment of the present invention includes:
  • a polyester non-woven fabric for lightweighting which substantially reduces noise, comprises: a polyester fiber sheet layer and a damping rubber layer 4, and the density decreases in the thickness direction along the thickness direction of the polyester fiber sheet layer, including compact layer 1 and half tightness. Layer 2 and fluffy layer 3.
  • the surface of the compact layer 1 is compounded with a damping rubber layer 4, and the surface of the damping rubber layer 4 is compounded with a release paper protective layer 5 which is removed during use, and the release paper protective layer 5 can transport and store the protective damping rubber layer 4 . After removing the release paper protective layer 5, it can be directly pasted, and the assembly efficiency of the automobile is higher.
  • an expanded polytetrafluoroethylene film layer 6 is compounded on the surface of the fluffy layer 3.
  • a layer of expanded polytetrafluoroethylene microporous membrane with a staggered and dense micron-sized pores is formed, and the expanded polytetrafluoroethylene membrane has numerous micropores, and the micropores are characterized by small pore size. (0 ⁇ 0.018mm), the holes are not twisted, When the sound wave passes through the micropores, it will rub against the air in the hole and be converted into heat energy, so that it can further improve the sound absorbing ability of the polyester nonwoven fabric.
  • a layer of hot-melt powder is disposed between each layer of the compact layer 1, the semi-tight layer 2 and the bulk layer 3, and the three-layer structure is fixedly bonded by the hot-melt powder layer.
  • a method for preparing a polyester nonwoven fabric for lightweighting of automobiles with greatly reduced noise comprising the following steps:
  • the release paper of the release paper protective layer 5 is laminated on the surface of the damping rubber, and after completion of the inspection, the preparation of the polyester nonwoven fabric for lightweighting of automobiles which greatly reduces noise is completed.
  • the preparation method of the polyester fiber sheet includes:
  • the polyester staple fiber to be flame-retarded includes polypropylene PP, polyethylene terephthalate PET or polyethylene PE flame-retardant staple fiber, and the staple fiber is pre-opened and then opened.
  • the damping rubber is made of RD-104 vibration-damping and noise-reducing damping glue, which is a white-like viscous paste special coating. After drying, a white solid with excellent strength is formed.
  • the product is made of long-lasting water-resistant polymer resin emulsion, which is refined by a unique process. It has excellent vibration and noise reduction effects, and has a heat-insulating sealing property, which can quickly eliminate the vibration and noise caused by vibration and impact.
  • This product is non-toxic, odorless, non-volatile and non-corrosive. It is a typical green viscoelastic high-tech damping material. It has a strong damping effect on the noise generated by running cars, locomotives, ships, airplanes, machinery, etc.
  • the composite loss factor is 0.169 ⁇ C at 20 °C, 0.191 ⁇ C at 10 °C, the damping performance is about 5 times that of PVC, and the loss factor of steel is 1*10-4.
  • the asphalt type damping material needs to be more than 3 mm thick. Taking the automobile as an example, due to the spraying process, no matter what complex structural surface, it is coated on the surface of the metal structure, such as the chassis, the top plate and the side plate of the vehicle, which can reduce the low frequency noise generated by the vibration of the vehicle during fast driving. . Unique in damping materials.
  • the vibration and noise reduction damping rubber has superior impact resistance and flexibility. 50cm impact, ⁇ 50mm/180° bending without cracking, no shedding, no hidden damage.
  • the dry plate was stable after being immersed in a 10% aqueous solution of sulfuric acid and a 10% aqueous solution of caustic soda for 24 hours; there was no change in the performance of immersion in 3% of saline for 30 days.
  • the dry board is soaked in tap water for a long time without blistering and no shedding.
  • the polyester non-woven fabric for automobile lightweighting which greatly reduces noise, satisfies the new requirements for lightweight vehicle, thereby improving the vehicle comfort index (expanding the space in the vehicle and reducing the noise inside the car): PE, PET and other flame-retardant polyester staple fibers are opened and fed to the carding machine (open short fibers).
  • the carding machine outputs fibers into a net, which is laid, and the short fibers are laid in the oven and bonded to the oven.
  • the control of the fiber webping ironing machine is carried out by pressing and pressing pressure and temperature (at the same time, high-temperature drying and sterilization), and forming a polyester fiber having a three-dimensional structure in which the density of the mesh layer is reduced by the density of the dense layer, the semi-tight layer and the bulk layer.
  • the sheet is layered by spraying an appropriate amount of LDPE hot-melt powder, which is firm and not easy to stratify, and has the requirements of meeting the flame retardant characteristics of automotive interior parts.
  • the polyester non-woven fabric for lightweighting that greatly reduces noise has better sound absorption and sound insulation effects for noises such as low frequency, intermediate frequency, and high frequency
  • the polyester nonwoven fabric for lightweight reduction of noise is light in weight.
  • Good damping strength, flame retardant, sound-absorbing and sound-insulating performance, environmentally friendly and odor-free can be used in automotive interior parts, play the role of sound insulation and reduce cost, because the thickness of the polyester non-woven fabric is relatively sound-absorbing. In comparison with cotton, the thickness is reduced and the weight is reduced, which can meet the new requirements of lightweight vehicles, thereby improving the car comfort index, expanding the space in the car and reducing the noise inside the car.
  • the sound absorption is mainly to solve the noise caused by the reflection of the sound, and the sound absorbing material can attenuate the reflection energy of the incident sound source, thereby achieving the attenuation effect on the original sound source.
  • Sound insulation mainly solves the transmission of sound
  • the main body feels noisy in the space, and the sound insulation cotton material can attenuate the transmission energy of the incident sound source, thereby achieving a quiet state of the main body space.
  • the outer surface of the fluffy layer of the polyester non-woven fabric is laminated with an expanded polytetrafluoroethylene film having a micron-sized pores with a staggered shape and a dense shape, thereby further improving the sound absorbing ability of the polyester non-woven fabric, and the polyester non-woven fabric is sucked.
  • the acoustic mechanism is that a dense layer with a dense density can reflect a part of the noise energy.
  • a part of the noise energy enters a large number of tiny connected pores inside the material.
  • Acoustic waves can penetrate deep into the material along the pores, causing vibration and aggregation of air molecules in the material gap.
  • the ester fiber friction converts the acoustic energy into heat energy, so that the polyester nonwoven fabric can cut off some of the noise energy.
  • the damping rubber on the non-woven fabric can reduce the low-frequency noise generated by the vibration of the vehicle during fast driving, and is unique among the damping materials.
  • the polyester non-woven fabric for lightweight reduction of noise is light in weight, good in damping and elasticity, flame retardant, sound-absorbing and sound-insulating performance is good, and environmentally friendly and odor-free can be used in a large number of automotive interior parts to provide sound insulation and vibration damping. And the effect of reducing the cost, because the thickness of the polyester non-woven fabric is thinner than that of the general sound-absorbing cotton, the weight is reduced, and the weight is small, which can meet the new requirements of lightweight automobile, thereby improving the automobile comfort index and expanding the scale. The space in the car and the noise inside the car.
  • Polyester nonwovens for lightweight vehicles that significantly reduce noise are particularly suitable for use in interior parts such as automobiles, trucks and buses.
  • the polyester non-woven fabric for automobile lightweighting with the adhesive damping layer of the invention is a high-efficiency fiber sound absorbing product, which has excellent sound absorption effect and different levels of attraction rate, and can meet different needs of users; Compact, flame retardant, in accordance with DIN 75200, VW TL 1010 and UL94-V0; volatile, atomized, odor and formaldehyde content below conventional limits; corrosion and moisture resistance, made by pure heat shaping Parts are not easily deformed.
  • the non-woven fabric is smoothed on one or both sides without the need to cover the non-woven cover.

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  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

一种大幅度降低噪音的汽车轻量化用的聚酯无纺布，沿着聚酯纤维薄片层厚度方向密度递减依次包括紧密层(1)、半紧密层(2)和蓬松层(3)，紧密层(1)表面复合有阻尼胶层(4)，在蓬松层(3)表面复合有膨体聚四氟乙烯膜层(6)；制备方法，在聚酯纤维薄片的紧密层(1)、半紧密层(2)和蓬松层(3)的层间碰洒热熔粉，在蓬松层(3)的表面喷洒热熔粉，加热后与膨体聚四氟乙烯膜层(6)的膨体聚四氟乙烯膜贴合；在紧密层喷涂阻尼胶层(4)的阻尼胶。通过上述方式，满足汽车轻量化的新要求，扩大了汽车内的乘坐空间和降低了汽车内的噪音；阻尼胶可降低车辆在快速行驶时因振动而产生的低频噪音，提升汽车内人员的舒适度，降低噪音疲劳，行车更安全。

Description

大幅度降低噪音的汽车轻量化用的聚酯无纺布及其制备方法 技术领域
本发明涉及无纺布领域，特别是涉及一种大幅度降低噪音的汽车轻量化用的聚酯无纺布及其制备方法。
背景技术
汽车噪声分为车外噪声与车内噪声。车外噪声是指汽车各部分噪声辐射到车外空间的噪声，主要有发动机噪声、排气噪声、轮胎噪声、制动噪声和传动系噪声等。车内噪声是指车厢外的汽车各部分噪声通过各种途径传入车内的那部分噪声以及汽车各部分振动传递路径激发车身各部件的结构振动向车厢内辐射的噪声，这些噪声声波在车内空间声学特性的制约下，生成较为复杂的混响声场，从而形成车内噪声。
汽车噪音对人体健康的影响是多方面的。噪音作用于人的中枢神经系统，使人们大脑皮层的兴奋与抑制平衡失调，导致条件反射异常，使脑血管张力遭到损害。这些生理上的变化，在早期能够恢复原状，但时间一久，就会导致病理上的变化，使人产生头痛、脑胀、耳鸣、失眠、记忆力衰退和全身疲乏无力等症状。如果孕妇长期乘坐噪音较大的车辆，噪音会通过作用于中枢神经系统影响胎儿发育。
汽车噪音不但增加驾驶员和乘员的疲劳，而且影响汽车的行驶安全。另一方面，噪音对消化系统、心血管系统也有严重不良影响，会造成消化不良，食欲不振，恶心呕吐，从而导致胃病及胃溃疡病的发病率提高，使高血压、动脉硬化和冠心病的发病率比正常情况明显提高。噪音对视觉器官也会造成不良影响。
现有技术有采用比如玻璃棉，岩棉，海绵，聚苯乙烯珍珠岩等材料，试图 解决隔音问题。但他们虽然能解决我们空间的隔音问题，却在我们生活中埋下了安全隐患，比如玻璃棉、岩棉，它会引起皮肤瘙痒，呼吸道过敏。清洗时易吸水，增加油耗，海绵等是易燃产品，而且在燃烧过程中会产生有毒气体。目前汽车内大量使用沥青阻尼减振垫板，隔音效果差，造成汽车内有异味，有的车型味道难闻。长久后头晕不舒适，影响汽车行车驾驶安全。目前市场上的吸音棉(仅是蓬松棉)的吸声系数很小，在汽车上应用后降噪效果一般，已满足不了汽车轻量化和汽车舒适性的更高要求。
发明内容
本发明主要解决的技术问题是提供一种能够满足汽车轻量化的新要求，扩大了汽车内的乘坐空间和降低了汽车内的噪音，提升汽车内人员的舒适度，降低噪音疲劳，行车更安全的大幅度降低噪音的汽车轻量化用的聚酯无纺布及其制备方法。
为解决上述技术问题，本发明采用的一个技术方案是：提供一种大幅度降低噪音的汽车轻量化用的聚酯无纺布，包括：聚酯纤维薄片层和阻尼胶层，沿着聚酯纤维薄片层厚度方向密度递减依次包括紧密层、半紧密层和蓬松层，所述紧密层表面复合有阻尼胶层，在蓬松层表面复合有膨体聚四氟乙烯膜层。
在本发明一个较佳实施例中，所述阻尼胶层表面复合有使用时揭除的离型纸保护层。
在本发明一个较佳实施例中，紧密层、半紧密层和蓬松层的各层之间均设有热熔粉层，通过热熔粉层将3层结构固定粘接。
为解决上述技术问题，本发明采用的另一个技术方案是：提供一种大幅度降低噪音的汽车轻量化用的聚酯无纺布的制备方法，包括以下步骤：
1)制备聚酯纤维薄片层的聚酯纤维薄片；
2)在聚酯纤维薄片的紧密层、半紧密层和蓬松层的层间碰洒热熔粉，通过 轧压工艺将三层结构牢固粘接；
3)在蓬松层的表面喷洒热熔粉，加热后与膨体聚四氟乙烯膜层的膨体聚四氟乙烯膜贴合；
4)经过检验合格后收卷，再放卷；
5)在紧密层喷涂阻尼胶层的阻尼胶；
6)在阻尼胶的表面复合离型纸保护层的离型纸，经检验合格后则完成大幅度降低噪音的汽车轻量化用的聚酯无纺布的制备。
在本发明一个较佳实施例中，聚酯纤维薄片的制备方法包括：
1)准备阻燃的聚酯短纤维，并对短纤维进行开松；
2)将开松后的短纤维梳理成纤维网；
3)进行铺网，将短纤维铺网后烘房内进行粘接；
4)通过铺网粘接后控制纤维网轧压的压强和温度大小，使网层在厚度方向形成紧密层、半紧密层和蓬松层密度递减的结构，同时高温烘干杀菌；
5)然后再进行针刺、风冷、分切修边、成卷、切断，检验合格后，即制成聚酯纤维薄片。
在本发明一个较佳实施例中，所述阻燃的聚酯短纤维包括聚丙烯PP、聚对苯二甲酸乙二醇酯PET或聚乙烯PE阻燃短纤维。
在本发明一个较佳实施例中，短纤维开松是先对短纤维进行预开松，再进行主开松。
本发明的有益效果是：本发明满足汽车轻量化的新要求，扩大了汽车内的乘坐空间和降低了汽车内的噪音；阻尼胶可降低车辆在快速行驶时因振动而产生的低频噪音，在阻尼材料中独树一帜。提升汽车内人员的舒适度，降低噪音 疲劳，行车更安全。膨体聚四氟乙烯微孔膜可起到进一步提高该聚酯无纺布的吸声能力。膨体聚四氟乙烯微孔膜具有拒水拒油抗污染的能力，容易清洁。
附图说明
为了更清楚地说明本发明实施例中的技术方案，下面将对实施例描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其它的附图，其中：
图1是本发明大幅度降低噪音的汽车轻量化用的聚酯无纺布及其制备方法
一较佳实施例的结构示意图；
具体实施方式
下面将对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅是本发明的一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其它实施例，都属于本发明保护的范围。
请参阅图1，本发明实施例包括：
一种大幅度降低噪音的汽车轻量化用的聚酯无纺布，包括：聚酯纤维薄片层和阻尼胶层4，沿着聚酯纤维薄片层厚度方向密度递减依次包括紧密层1、半紧密层2和蓬松层3。
所述紧密层1表面复合有阻尼胶层4，所述阻尼胶层4表面复合有使用时揭除的离型纸保护层5，离型纸保护层5可以在运输和储存保护阻尼胶层4。揭除离型纸保护层5后即可直接粘帖，汽车组装施工效率更高。
在蓬松层3表面复合有膨体聚四氟乙烯膜层6。在蓬松层3外表面复合一层拥有错层异形密集的微米级孔道的膨体聚四氟乙烯微孔膜，膨体聚四氟乙烯膜上有无数微孔，这些微孔的特点是孔径小(0～0.018mm)不等,孔道曲折不规则， 当声波通过微孔时就会与孔内的空气产生摩擦，转换成热能消耗掉，因此其可起到进一步提高该聚酯无纺布的吸声能力。
紧密层1、半紧密层2和蓬松层3的各层之间均设有热熔粉层，通过热熔粉层将3层结构固定粘接。通过在各层间喷适量的LDPE热熔粉烫平粘接牢固，不易分层，且具有符合汽车内饰件阻燃特性的要求。
一种大幅度降低噪音的汽车轻量化用的聚酯无纺布的制备方法，包括以下步骤：
1)制备聚酯纤维薄片层的聚酯纤维薄片；
2)在聚酯纤维薄片的紧密层1、半紧密层2和蓬松层3的层间碰洒热熔粉，通过整形烫平机轧压将三层结构牢固粘接；
3)在蓬松层3的表面喷洒热熔粉，加热后与膨体聚四氟乙烯膜层6的膨体聚四氟乙烯膜贴合；
4)经过检验合格后收卷，再放卷；
5)在紧密层喷涂阻尼胶层4的阻尼胶；
6)在阻尼胶的表面复合离型纸保护层5的离型纸，经检验合格后则完成大幅度降低噪音的汽车轻量化用的聚酯无纺布的制备。
其中，聚酯纤维薄片的制备方法包括：
1)准备阻燃的聚酯短纤维包括聚丙烯PP、聚对苯二甲酸乙二醇酯PET或聚乙烯PE阻燃短纤维，并对短纤维进行预开松，再进行主开松。
2)将开松后给梳理机供料，梳理机将短纤维梳理成纤维网，并输出，本发明优选双锡林双道夫梳理机。
3)进行铺网，将短纤维铺网后烘房内进行粘接；
4)通过铺网粘接后控制纤维网轧压的压强和温度大小，使网层在厚度方向 形成紧密层1、半紧密层2和蓬松层3密度递减的结构，同时高温烘干杀菌；
5)然后再进行针刺、风冷、分切修边、成卷、切断，检验合格后，即制成聚酯纤维薄片。
阻尼胶选用RD-104减振降噪阻尼胶，是一种类白色粘稠膏状物特种涂料。干固后形成强度极好的白色固体。该产品选用经久耐水高分子树脂乳液，采用独特工艺精制而成，具有优异的减振、降噪效果，兼具绝热密封特性，能迅即消除因振动、冲击形成的振波和噪音。本产品无毒、无味、无有害挥发成份、无腐蚀性，是典型的绿色环保黏弹性高科技型阻尼材料。对运行的汽车、机车、船舶、飞机、机械等产生的噪音具有较强的减振抑制作用。
其减振降噪阻尼胶特点和优势：
1、优异的阻尼和降噪性能。经铁科院权威检测：20℃时复合损耗因数为0.169ηC，10℃时达0.191ηC，其阻尼性能是PVC的5倍左右，而钢铁的损耗因子为1*10-4。要达到同样效果的损耗因子，沥青型阻尼材料需要3mm厚度以上。以汽车为例，由于采用喷涂工艺，无论是什么复杂结构表面，涂覆在金属结构表面，如车辆的底盘、顶板、侧板等部位，可降低车辆在快速行驶时因振动而产生的低频噪音。在阻尼材料中独树一帜。
2、该减振降噪阻尼胶具有超强的抗冲击和柔韧性。50cm冲击、Ф50mm/180°弯曲无开裂、无脱落、无隐性损伤。
3、卓越的耐腐蚀性。干板在10％的硫酸水溶液和10％烧碱水溶液中浸泡24h性能稳定；在3％的盐水中浸泡30d性能无变化。
4、优良的耐水性。干板在自来水中长期浸泡不起泡，无脱落现象。
5、该减振降噪阻尼胶附着力强，不燃烧，环境适应性好，使用寿命长。在高低温环境下长期使用，仍然能保持良好的阻尼效果。
6、作为汽车减振降噪阻尼胶和动车减振降噪阻尼胶，无毒、无味、无有害 挥发成份、无腐蚀性，是典型的绿色环保型阻尼特种材料。
本发明大幅度降低噪音的汽车轻量化用的聚酯无纺布满足汽车轻量化的新要求，从而提升汽车舒适性指标(扩大了汽车内的乘坐空间和降低了汽车内的噪音)：PE、PET等阻燃的聚酯短纤维经开松，给梳理机供料(开松的短纤维)，梳理机输出纤维成网，铺网，短纤维铺网后烘房粘接，通过铺网粘接后控制纤维网整形烫平机轧压压强和温度大小(同时高温烘干杀菌)，形成网层在厚度方向密度由紧密层、半紧密层和蓬松层密度递减的立体构成的聚酯纤维无纺布，此片材层间通过喷适量的LDPE热熔粉烫平粘接叫牢固，不易分层，且具有符合汽车内饰件阻燃特性的要求。
大幅度降低噪音的汽车轻量化用的聚酯无纺布的紧密层面与减振降噪阻尼胶结合，在阻尼胶上覆盖便于运输和储存离型纸保护层，在蓬松层外表面复合一层拥有错层异形密集的微米级孔道的膨体聚四氟乙烯微孔膜，膨体聚四氟乙烯膜上有无数微孔，这些微孔的特点是孔径小(0～0.018mm)不等,孔道曲折不规则，当声波通过微孔时就会与孔内的空气产生摩擦，转换成热能消耗掉，因此其可起到进一步提高该聚酯无纺布的吸声能力，经过上述工艺过程便生产出大幅度降低噪音的汽车轻量化用的聚酯无纺布。
大幅度降低噪音的汽车轻量化用的聚酯无纺布对低频、中频和高频率等噪声具有更优秀的吸音隔音效果，大幅度降低噪音的汽车轻量化用的聚酯无纺布其重量轻、阻尼弹性好、阻燃，吸音隔音性能效果好，环保无异味可以大量使用在汽车内饰件中，起到隔音减振和降低成本的作用，由于该聚酯无纺布厚度相对于一般吸音棉比较而言——厚度减薄，克重变小，可以满足汽车轻量化的新要求，从而提升汽车舒适性指标，扩大了汽车内的乘坐空间和降低了汽车内的噪音。
吸音主要是要解决声音的反射而产生的嘈杂感，吸音材料可以衰减入射音源的反射能量，从而达到对原有声源的衰减效果。隔音主要解决声音的透射而 使主体在空间内感觉吵闹感，隔音棉材料可以衰减入射音源的透射能量，从而达到主体空间的安静状态。在聚酯无纺布蓬松层外表面复合一层拥有错层异形密集的微米级孔道的膨体聚四氟乙烯膜，进一步提高该聚酯无纺布的吸声能力，聚酯无纺布吸声机理是密度较大的紧密层可以反射回一部分噪声能量，一部分噪声能量进入材料内部有大量微小的连通的孔隙，声波沿着这些孔隙可以深入材料内部，引起材料空隙中的空气分子振动与聚酯纤维摩擦将声能转化为热能，从而使得聚酯无纺布可以删减部分噪声能量。而无纺布上的阻尼胶可降低车辆在快速行驶时因振动而产生的低频噪音，在阻尼材料中独树一帜。
大幅度降低噪音的汽车轻量化用的聚酯无纺布其重量轻、阻尼弹性好、阻燃，吸音隔音性能效果好，环保无异味可以大量使用在汽车内饰件中，起到隔音减振和降低成本的作用，由于该聚酯无纺布厚度相对于一般吸音棉比较而言，厚度减薄，克重变小，可以满足汽车轻量化的新要求，从而提升汽车舒适性指标，扩大了汽车内的乘坐空间和降低了汽车内的噪音。
大幅度降低噪音的汽车轻量化用的聚酯无纺布尤其适用在汽车、卡车和客车等内饰件方面的应用。
热熔粉也可用低熔点小克重的无纺布替代用作层间粘结剂。
本发明的带有粘接阻尼层的汽车轻量化用聚酯无纺布是高效纤维吸音产品，吸音效果极佳，具有不同等级的吸引率，能够满足用户的不同需求；无纺布内部结构固结紧密，阻燃效果好，符合DIN 75200,VW TL 1010和UL94-V0标准；挥发、雾化、气味及甲醛含量低于常规限值；耐腐蚀、耐潮湿，通过纯热塑形制成的零部件不易变形。无纺布经过单面或双面磨平，无需加盖无纺布罩。
本发明满足汽车轻量化的新要求，扩大了汽车内的乘坐空间和降低了汽车内的噪音；阻尼胶可降低车辆在快速行驶时因振动而产生的低频噪音，在阻尼材料中独树一帜。提升汽车内人员的舒适度，降低噪音疲劳，行车更安全。膨 体聚四氟乙烯微孔膜可起到进一步提高该聚酯无纺布的吸声能力。膨体聚四氟乙烯微孔膜具有拒水拒油抗污染的能力，容易清洁。
以上所述仅为本发明的实施例，并非因此限制本发明的专利范围，凡是利用本发明说明书内容所作的等效结构或等效流程变换，或直接或间接运用在其它相关的技术领域，均同理包括在本发明的专利保护范围内。

Claims (7)

  1. 一种大幅度降低噪音的汽车轻量化用的聚酯无纺布，其特征在于，包括：聚酯纤维薄片层和阻尼胶层，沿着聚酯纤维薄片层厚度方向密度递减依次包括紧密层、半紧密层和蓬松层，所述紧密层表面复合有阻尼胶层，在蓬松层表面复合有膨体聚四氟乙烯膜层。
  2. 根据权利要求1所述的大幅度降低噪音的汽车轻量化用的聚酯无纺布，其特征在于，所述阻尼胶层表面复合有使用时揭除的离型纸保护层。
  3. 根据权利要求1所述的大幅度降低噪音的汽车轻量化用的聚酯无纺布，其特征在于，紧密层、半紧密层和蓬松层的各层之间均设有热熔粉层，通过热熔粉层将3层结构固定粘接。
  4. 根据权利要求1所述的大幅度降低噪音的汽车轻量化用的聚酯无纺布的制备方法，其特征在于，包括以下步骤：
    1)制备聚酯纤维薄片层的聚酯纤维薄片；
    2)在聚酯纤维薄片的紧密层、半紧密层和蓬松层的层间碰洒热熔粉，通过轧压工艺将三层结构牢固粘接；
    3)在蓬松层的表面喷洒热熔粉，加热后与膨体聚四氟乙烯膜层的膨体聚四氟乙烯膜贴合；
    4)经过检验合格后收卷，再放卷；
    5)在紧密层喷涂阻尼胶层的阻尼胶；
    6)在阻尼胶的表面复合离型纸保护层的离型纸，经检验合格后则完成大幅度降低噪音的汽车轻量化用的聚酯无纺布的制备。
  5. 根据权利要求4所述的大幅度降低噪音的汽车轻量化用的聚酯无纺布的制备方法，其特征在于，聚酯纤维薄片的制备方法包括：
    1)准备阻燃的聚酯短纤维，并对短纤维进行开松；
    2)将开松后的短纤维梳理成纤维网；
    3)进行铺网，将短纤维铺网后烘房内进行粘接；
    4)通过铺网粘接后控制纤维网轧压的压强和温度大小，使网层在厚度方向形成紧密层、半紧密层和蓬松层密度递减的结构，同时高温烘干杀菌；
    5)然后再进行针刺、风冷、分切修边、成卷、切断，检验合格后，即制成聚酯纤维薄片。
  6. 根据权利要求5所述的大幅度降低噪音的汽车轻量化用的聚酯无纺布的制备方法，其特征在于，所述阻燃的聚酯短纤维包括聚丙烯PP、聚对苯二甲酸乙二醇酯PET或聚乙烯PE阻燃短纤维。
  7. 根据权利要求5所述的大幅度降低噪音的汽车轻量化用的聚酯无纺布的制备方法，其特征在于，短纤维开松是先对短纤维进行预开松，再进行主开松。
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