WO2017128562A1 - 吸音件的制备方法和吸音件 - Google Patents

吸音件的制备方法和吸音件 Download PDF

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Publication number
WO2017128562A1
WO2017128562A1 PCT/CN2016/082476 CN2016082476W WO2017128562A1 WO 2017128562 A1 WO2017128562 A1 WO 2017128562A1 CN 2016082476 W CN2016082476 W CN 2016082476W WO 2017128562 A1 WO2017128562 A1 WO 2017128562A1
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Prior art keywords
sound absorbing
open
cotton
absorbing cotton
cell
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Ceased
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PCT/CN2016/082476
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English (en)
French (fr)
Inventor
曹晓东
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Goertek Inc
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Goertek Inc
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Priority to US16/073,632 priority Critical patent/US11437007B2/en
Publication of WO2017128562A1 publication Critical patent/WO2017128562A1/zh
Anticipated expiration legal-status Critical
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    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
    • G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/162—Selection of materials
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04R—LOUDSPEAKERS, MICROPHONES, GRAMOPHONE PICK-UPS OR LIKE ACOUSTIC ELECTROMECHANICAL TRANSDUCERS; ELECTRIC HEARING AIDS; PUBLIC ADDRESS SYSTEMS
    • H04R31/00—Apparatus or processes specially adapted for the manufacture of transducers or diaphragms therefor
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/02—Cotton wool; Wadding
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04R—LOUDSPEAKERS, MICROPHONES, GRAMOPHONE PICK-UPS OR LIKE ACOUSTIC ELECTROMECHANICAL TRANSDUCERS; ELECTRIC HEARING AIDS; PUBLIC ADDRESS SYSTEMS
    • H04R1/00—Details of transducers, loudspeakers or microphones
    • H04R1/20—Arrangements for obtaining desired frequency or directional characteristics
    • H04R1/22—Arrangements for obtaining desired frequency or directional characteristics for obtaining desired frequency characteristic only 
    • H04R1/28—Transducer mountings or enclosures modified by provision of mechanical or acoustic impedances, e.g. resonator, damping means
    • H04R1/2807—Enclosures comprising vibrating or resonating arrangements
    • H04R1/2811—Enclosures comprising vibrating or resonating arrangements for loudspeaker transducers

Definitions

  • the invention belongs to the technical field of material processing, and in particular to a method for preparing a sound absorbing member and a sound absorbing member.
  • the requirements for the sound quality level of the micro-speaker are getting higher and higher, and it is necessary to add a sound absorbing material inside the micro-speaker to improve the sound effect.
  • the commonly used sound absorbing materials mainly include foaming foam and non-foaming sound absorbing materials.
  • non-foaming sound absorbing materials have superior performance to acoustic performance gains than foaming foams.
  • the non-foaming type sound absorbing material is usually in the form of a powder, which is granulated by a person skilled in the art for use.
  • the sound absorbing material particles are prepared by a conventional processing technique such as oil column molding or boiling granulation, and it is necessary to form a powdery sound absorbing material into a granular structure. Therefore, those skilled in the art usually add a binder during processing to promote granulation of the powder.
  • the adhesive affects the sound absorbing effect of the non-foaming sound absorbing material, so the addition ratio of the adhesive should not be too high.
  • the amount of the binder added is too low, the resulting pellets have a low strength, and the edges are prone to edge and the sphericity of the particles is low. This situation causes the drop resistance and wear resistance of the sound absorbing material particles to decrease, and the particles are prone to powdering or even breakage in the speaker for a long time.
  • the inventors of the present invention considered that it is necessary to improve the preparation method of the sound absorbing material particles to improve the performance of the sound absorbing material particles.
  • a method of preparing a sound absorbing member comprising:
  • the open-cell sound absorbing cotton impregnated with the sound absorbing slurry is dried to remove the liquid in the open sound absorbing cotton.
  • the material of the open-cell sound absorbing cotton is polyurethane or melamine.
  • the apertured sound absorbing cotton is compressed in equal proportions to match the apertured sound absorbing cotton to a predetermined chamber size.
  • the sound absorbing material powder is zeolite powder or white carbon black.
  • the proportion of the cells having a pore diameter of less than 0.5 mm in all the cells is greater than 85%.
  • the templating agent accounts for 1% to 35% by mass of the sound absorbing slurry.
  • the sound absorbing slurry is doped with a binder
  • the binder is an inorganic silica sol or a fibrous resin
  • the binder accounts for 1% to 35% by mass of the sound absorbing slurry.
  • the sound absorbing slurry is doped with an auxiliary agent
  • the auxiliary agent is an antifoaming agent, a coagulant or a homogenizing agent
  • the auxiliary agent accounts for 0.02%-10% of the mass of the sound absorbing slurry.
  • the drying process has a temperature in the range of 40-150 degrees Celsius, and the dry treated atmosphere comprises nitrogen.
  • the open-cell sound-absorbing cotton is subjected to a calcination treatment
  • the roasting treatment temperature ranges from 120 to 420 degrees Celsius
  • the calcination heating rate ranges from 10 to 80 ° C/h, and is calcined.
  • the time range is 0.5-96h.
  • the present invention also provides a sound absorbing member, the sound absorbing member has an apertured sound absorbing cotton, the sound absorbing cotton powder is adhered to the open hole sound absorbing cotton, and the material of the open hole sound absorbing cotton is polyurethane or melamine.
  • the open-cell sound absorbing cotton the cells having a pore diameter of less than 0.5 mm account for more than 85% of the total cells, and the sound absorbing material powder includes at least zeolite powder or white carbon black.
  • the inventors of the present invention have found that in the prior art, although there are certain defects in the preparation method of the sound absorbing material particles, the sound absorbing material particles obtained by these preparation methods also have better performance in different aspects, for example, a kind
  • the sound absorbing material particles prepared by the preparation method have better sound absorbing effect, and the sound absorbing material particles prepared by the other preparation method have relatively better drop resistance and resistance. Grinding. Therefore, those skilled in the art do not consider improving the preparation method of the sound absorbing material particles, but select different preparation methods according to the properties of the desired sound absorbing material particles.
  • FIG. 1 is a block diagram showing the steps of a method for preparing a sound absorbing member provided by the present invention
  • FIG. 2 is a schematic structural view of the open-cell sound absorbing cotton in a specific embodiment of the present invention
  • Figure 3 is a schematic illustration of the sound absorbing slurry of a particular embodiment of the invention.
  • the invention provides a new technical solution for preparing a sound absorbing member.
  • this technical solution combines a traditional foaming sound absorbing material with a new non-foaming sound absorbing material, which provides good performance.
  • the sound absorbing effect improves the drop resistance of the sound absorbing member.
  • the open-cell sound absorbing cotton 1 is provided, and since the finally formed sound absorbing member needs to be filled inside the chamber of the rear cavity of the speaker module, the open hole sound absorbing cotton may be firstly used.
  • the structure of 1 is cut into a shape that matches the shape of the predetermined chamber, as shown in FIG.
  • the shape and size of the apertured sound absorbing cotton 1 need not be completely consistent with the predetermined chamber, and only needs to match the shape of the predetermined chamber or a part of the predetermined chamber, and the size of the apertured sound absorbing cotton 1 may be a predetermined chamber.
  • a slurry of a non-foaming sound absorbing material is prepared.
  • the crystal powder of the sound absorbing material may be mixed with a solvent and a templating agent to prepare a sound absorbing paste 2, as shown in FIG.
  • the uniformity of the sound absorbing slurry 2 should be increased as much as possible.
  • the crystal powder of the sound absorbing material when mixed with a solvent, it can be mixed by means of quantitative dropping, atomization, or the like to improve the sound absorbing slurry. 2 uniformity.
  • the apertured sound absorbing cotton 1 is immersed in the sound absorbing slurry 2 so that the sound absorbing slurry 2 can penetrate into the open sound absorbing cotton 1.
  • the sound absorbing material powder in the sound absorbing paste 2 can be uniformly adhered to the cell skeleton of the apertured sound absorbing cotton 1.
  • the present invention does not specifically limit the conditions such as the immersion time of the open-cell sound absorbing cotton and the temperature of the sound absorbing slurry during immersion, and those skilled in the art can set these conditions according to actual conditions, so that the sound absorbing member can achieve the desired acoustic performance. .
  • the open-cell sound absorbing cotton 1 impregnated with the sound absorbing slurry 2 is dried, and the liquid such as the solvent and the template which are sucked into the open sound absorbing cotton 1 is removed to obtain a sound absorbing member.
  • the sound absorbing material powder will remain in the cells of the open sound absorbing cotton 1 to provide a sound absorbing effect.
  • the sound absorbing member made by the method provided by the invention combines the sound absorbing mechanism of the foaming sound absorbing material and the non-foaming sound absorbing material, and the cell of the open sound absorbing cotton 1 can provide an attachment skeleton, strengthen the ventilation performance of the sound absorbing member, and prevent the sound absorbing member. Affecting the sensitivity of the speaker structure, the non-foaming sound absorbing material has finer micropores and can provide good sound absorption. Moreover, since the entire sound absorbing member is made of the open-ended sound absorbing cotton 1, the sound absorbing member can be appropriately generated when subjected to a drop impact. Deformation, buffering the impact force, no damage or powdering.
  • the material of the open-cell sound absorbing cotton may be a structure which is easy to uniformly foam such as polyurethane or melamine.
  • the invention does not specifically limit the material of the open-cell sound absorbing cotton, and those skilled in the art can select according to actual conditions.
  • the open-cell sound absorbing cotton material has a general foaming rule. During the foaming process, the larger the volume of a single cell, the more uniform the cell distribution in the open cell sound absorbing cotton; if the volume of the single cell is smaller, Then, the uniformity of the distribution of the cells in the entire sound-absorbing cotton is decreased.
  • the open-cell sound-absorbing cotton with a large volume and uniform distribution of the cells can be prepared first. Thereafter, the apertured sound absorbing cotton is cut into a structure that matches the shape of the predetermined chamber but is enlarged in size. Finally, the open-cell sound-absorbing cotton is integrally compressed, and the open-cell sound-absorbing cotton is compressed into a size that is the same size as the predetermined chamber. During the compression process, the volume of the cells can be uniformly reduced to achieve a suitable volume.
  • the apertured sound absorbing cotton or the apertured sound absorbing cotton after equal compression is not necessarily identical to the size of the predetermined chamber.
  • the rear cavity of the speaker needs to be completely filled with the open-cell sound absorbing cotton, which needs to be exactly the same size and shape as the predetermined chamber; and in other cases. It is only necessary to fill a part of the rear cavity of the speaker with the opening sound absorbing cotton, and the opening sound absorbing cotton only needs to conform to the size and shape of a part of the predetermined chamber.
  • the cell structure of the open-cell sound absorbing cotton is also different.
  • the apertured sound absorbing cotton has a cell aperture of less than 0.5 mm to provide a good adhesion skeleton for the sound absorbing material powder.
  • the uniform cell aperture can provide a better sound absorbing effect.
  • the pore size of the cells is preferably between 0.18 and 0.22 mm, and the cells reaching this pore size range are more than 85% of the total number of cells.
  • the sound absorbing material powder is usually a crystalline aluminosilicate powder, in the present invention
  • materials such as zeolite powder, silica, molecular sieves, and the like may be used alone or in combination as the sound absorbing material powder.
  • the present invention does not specifically limit the powder of the sound absorbing material. In the case where the micropores can be provided to achieve the sound absorbing effect, other materials can be used as the powder for the sound absorbing material.
  • the purity of the templating agent is higher than 95%, and the mass ratio in the sound absorbing slurry is from 1% to 35%.
  • the templating agent exerts an effect on the sound absorbing material powder.
  • an adhesive may be incorporated into the sound absorbing slurry.
  • the binder may be a silicone sol, an inorganic silica sol or a fiber value, etc., and those skilled in the art may choose to incorporate different binders into the sound absorbing slurry according to actual conditions.
  • the mass ratio of the adhesive in the sound absorbing slurry should not be too high, otherwise the sound absorbing slurry will be immersed in the open sound absorbing cotton and the sound absorbing performance.
  • the mass ratio of the binder in the sound absorbing slurry may not exceed 35%, and usually, the mass ratio of the binder is maintained at 1% to 20%.
  • an auxiliary agent may also be incorporated in the sound absorbing slurry.
  • the auxiliary agent may include a preparation of a coagulant, an antifoaming agent, a homogenizing agent and the like, and the auxiliary agent is used for uniformly mixing the sound absorbing material and the solvent to obtain a uniform sound absorbing slurry having a certain viscosity. More preferably, the auxiliary agent accounts for a mass ratio of the sound absorbing paste in the range of 0.02-10%, and if the amount of the auxiliary agent is too large, the sound absorbing performance of the produced sound absorbing member is affected.
  • the invention does not limit the kind of the auxiliary agent, and those skilled in the art can incorporate different kinds of auxiliary agents into the sound absorbing slurry according to actual conditions. For example, if foam is easily generated during the mixing process of the sound absorbing material and the solvent, an antifoaming agent may be incorporated into the sound absorbing slurry for eliminating the foam.
  • the drying treatment step is for removing a liquid such as a solvent immersed in the open-cell sound absorbing cotton to form a dry, good elasticity and sound absorbing property.
  • an inert gas may be used as a medium to prevent polar defect points in the microstructure of the sound absorbing material powder from reacting with active molecules in the air.
  • the inert gas may be nitrogen.
  • the ambient temperature of the drying treatment can be appropriately increased.
  • the dried shaped body may be placed in an inert gas having a temperature between 40 and 150 degrees Celsius. In this way, the liquid such as the solvent and the templating agent in the open-cell sound absorbing cotton can be discharged more effectively.
  • Those skilled in the art can adjust the parameters in the drying process according to the actual application to the speaker structure, and correspondingly set the specific temperature. Degree curve and drying medium.
  • the drying process since the drying process has a low temperature and a short time, it is impossible to discharge the water molecules between the molecules in the open-cell sound absorbing cotton and the sound absorbing material powder. Although the dried sound absorbing member can be put into use, the sound absorbing performance cannot be fully exerted. Therefore, it is more preferable to perform the baking treatment on the dried open-cell sound-absorbing cotton or directly on the impregnated open-cell sound-absorbing cotton. Since the material of the open-cell sound absorbing cotton is often low in temperature tolerance, the temperature of the baking treatment cannot be too high, and the temperature of the baking treatment is in the range of 120-420 degrees Celsius. The calcination time is allowed between 0.5 and 96 hours.
  • the relatively long calcination treatment is carried out at a relatively high temperature, and the liquid molecules and impurities in the open-cell sound absorbing cotton and the sound absorbing material powder can be discharged, thereby improving the acoustic performance of the sound absorbing member.
  • the heating rate of the calcination treatment cannot be too fast, otherwise the microscopic pore structure of the sound absorbing material powder and the cell structure of the open cell sound absorbing cotton are seriously damaged.
  • the calcination rate is in the range of 20-80 ° C / h.
  • the calcination rate can be selected at a temperature increase rate of 40 ° C / h, and the calcination time is 30 hours. In this way, liquid molecules can be substantially removed, and impurities such as templating agents and auxiliary agents can be discharged.
  • the present invention does not accurately limit the temperature, time, and temperature increase rate during firing, and those skilled in the art can adjust these parameters according to actual conditions.
  • the wide range of temperatures, times, and rate of temperature increase illustrated by the present invention encompasses situations that may be employed in special circumstances.
  • the present invention also provides a sound absorbing member which is produced by the method provided by the present invention.
  • the sound absorbing member has an apertured sound absorbing cotton, and the sound absorbing material powder is adhered to the open hole sound absorbing cotton.
  • the cell of the open-cell sound-absorbing cotton provides the porous skeleton of the sound-absorbing material powder.
  • the open-cell sound-absorbing cotton has good elastic deformation ability, and can play the role of buffering and damping.
  • the material of the open-cell sound absorbing cotton is polyurethane or melamine.
  • the cells having a pore diameter of less than 0.5 mm account for more than 85% of the total cells, and the open-cell sound absorbing cotton can provide better acoustic and mechanical properties.
  • the sound absorbing material powder includes at least zeolite powder or white carbon black. The present invention does not specifically limit the materials of the sound absorbing material and the material of the open cell sound absorbing cotton, and those skilled in the art can select other materials as the performance permits.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Multimedia (AREA)
  • Textile Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Signal Processing (AREA)
  • Soundproofing, Sound Blocking, And Sound Damping (AREA)

Abstract

一种吸音件的制备方法和吸音件。该吸音件的制备方法包括：制备与预定腔室形状匹配的开孔吸音棉（1）；将吸音材料粉体与溶剂、模板剂混合配制吸音浆料（2）；将所述开孔吸音棉（1）在所述吸音浆料（2）中浸渍预定时间；对浸有所述吸音浆料（2）的开孔吸音棉（1）进行干燥处理，去除开孔吸音棉（1）中的液体。

Description

吸音件的制备方法和吸音件 技术领域
本发明属于材料加工技术领域，具体地，涉及一种吸音件的制备方法和吸音件。
背景技术
目前，对微型扬声器的音质水平的要求越来越高，需要在微型扬声器的内部加入吸音材料，以提高声音效果。目前常用的吸音材料主要有发泡类泡棉和非发泡类吸音材料。其中非发泡类吸音材料较发泡类泡棉对声学性能增益表现更优越。非发泡类吸音材料通常为粉末状，本领域技术人员将其制成颗粒，以便使用。
采用现有的例如油柱成型法、沸腾制粒法等加工工艺制备吸音材料颗粒，需要使粉末状的吸音材料结成颗粒结构。所以，本领域技术人员通常在加工过程中添加粘接剂，促使粉末成粒。但是粘接剂会对非发泡吸音材料的吸音效果造成影响，所以粘接剂的添加比例不能过高。相对的，如果粘接剂的添加量过低，则制成的颗粒强度较低，且外形上容易出现棱角，颗粒球形度较低。这种情况会导致吸音材料颗粒的耐跌落性能和耐磨性能下降，颗粒在扬声器中长时间工作容易起粉甚至破损。
所以，本发明的发明人认为，有必要对吸音材料颗粒的制备方法进行改进，以提高吸音材料颗粒的性能。
发明内容
本发明的一个目的是提供一种制备吸音材料的新技术方案。
根据本发明的第一方面，提供了一种吸音件的制备方法，其中包括：
制备与预定腔室形状匹配的开孔吸音棉；
将吸音材料粉体与溶剂、模板剂混合配制吸音浆料；
将所述开孔吸音棉在所述吸音浆料中浸渍预定时间；
对浸有所述吸音浆料的开孔吸音棉进行干燥处理，去除开孔吸音棉中的液体。
可选地，所述开孔吸音棉的材料为聚氨酯或三聚氰胺。
可选地，对所述开孔吸音棉进行等比例压缩，使所述开孔吸音棉与预定腔室尺寸匹配。
可选地，所述吸音材料粉体为沸石粉或白炭黑。
可选地，在所述开孔吸音棉中，孔径小于0.5mm的泡孔在全部泡孔中所占的比例大于85％。
可选地，所述模板剂占所述吸音浆料的质量比例为1％-35％。
可选地，所述吸音浆料中掺有粘接剂，所述粘接剂为无机硅溶胶或纤维状树脂，所述粘接剂占所述吸音浆料的质量比例为1％-35％。
可选地，所述吸音浆料中掺有助剂，所述助剂为消泡剂、促凝剂或均匀剂，所述助剂占所述吸音浆料的质量比例为0.02％-10％。
可选地，所述干燥处理的温度范围在40-150摄氏度，干燥处理的气氛包括氮气。
可选地，在所述干燥处理之后，对所述开孔吸音棉进行焙烧处理，所述焙烧处理的温度范围为120-420摄氏度，焙烧的升温速率的范围为10-80℃/h，焙烧的时间范围为0.5-96h。
本发明还提供了一种吸音件，所述吸音件具有开孔吸音棉，所述开孔吸音棉中附着有吸音材料粉体，所述开孔吸音棉的材料为聚氨酯或三聚氰胺，在所述开孔吸音棉中，孔径小于0.5mm的泡孔在全部泡孔中所占的比例大于85％，所述吸音材料粉体至少包括沸石粉或白炭黑。
本发明的发明人发现，在现有技术中，虽然吸音材料颗粒的制备方法存在一定缺陷，但是，这些制备方法制得的吸音材料颗粒也在不同的方面具有较好的性能，例如，一种制备方法制得的吸音材料颗粒吸音效果更好，而另一种制备方法制得的吸音材料颗粒具有相对更好的耐跌落性和耐 磨性。所以，本领域技术人员并未考虑改进吸音材料颗粒的制备方法，而是会根据所需的吸音材料颗粒的性能选择不同的制备方法。因此，本发明所要实现的技术任务或者所要解决的技术问题是本领域技术人员从未想到的或者没有预期到的，而且，将吸音棉浸渍吸音浆料制备新型吸音件是本技术领域中不曾使用的方法，故本发明是一种新的技术方案。
通过以下参照附图对本发明的示例性实施例的详细描述，本发明的其它特征及其优点将会变得清楚。
附图说明
被结合在说明书中并构成说明书的一部分的附图示出了本发明的实施例，并且连同其说明一起用于解释本发明的原理。
图1是本发明提供的吸音件的制备方法的步骤框图；
图2是本发明具体实施例中所述开孔吸音棉的结构示意图；
图3是本发明具体实施例中所述吸音浆料的示意图。
具体实施方式
现在将参照附图来详细描述本发明的各种示例性实施例。应注意到：除非另外具体说明，否则在这些实施例中阐述的部件和步骤的相对布置、数字表达式和数值不限制本发明的范围。
以下对至少一个示例性实施例的描述实际上仅仅是说明性的，决不作为对本发明及其应用或使用的任何限制。
对于相关领域普通技术人员已知的技术、方法和设备可能不作详细讨论，但在适当情况下，所述技术、方法和设备应当被视为说明书的一部分。
在这里示出和讨论的所有例子中，任何具体值应被解释为仅仅是示例性的，而不是作为限制。因此，示例性实施例的其它例子可以具有不同的值。
应注意到：相似的标号和字母在下面的附图中表示类似项，因此， 一旦某一项在一个附图中被定义，则在随后的附图中不需要对其进行进一步讨论。
本发明提供了一种制备吸音件的新的技术方案，如图1所示，这种技术方案将传统的发泡类吸音材料与新的非发泡类吸音材料结合起来，既提供了良好的吸音效果，又提高了吸音件的耐跌落性能。在本发明提供的制备方法中，首先，提供开孔吸音棉1，由于最终制成的吸音件需要填装在扬声器模组后腔的腔室内部，所以，可以先将所述开孔吸音棉1的结构切割成与预定腔室的形状相匹配的形状，如图2所示。所述开孔吸音棉1的形状和尺寸无需与预定腔室完全一致，只需其形状与预定腔室或预定腔室的一部分相匹配即可，开孔吸音棉1的尺寸可以是预定腔室等比例放大的尺寸。第二，制备非发泡吸音材料的浆料。可以将吸音材料的结晶粉体与溶剂和模板剂混合，配制成吸音浆料2，如图3所示。特别地，应尽可能提高所述吸音浆料2的均匀度，例如，在将吸音材料结晶粉体与溶剂混合时，可以采用定量滴加、雾化加入等方式进行混合，以提高吸音浆料2的均匀度。第三，将所述开孔吸音棉1浸渍到所述吸音浆料2中，使所述吸音浆料2能够渗入所述开孔吸音棉1。这样，吸音浆料2中的吸音材料粉体能够均匀地附着在所述开孔吸音棉1的泡孔骨架上。本发明并不对开孔吸音棉的浸渍时间、浸渍时吸音浆料的温度等条件进行具体的限制，本领域技术人员可以根据实际情况对这些条件进行设定，从而使吸音件达到预期的声学性能。第四，对浸有吸音浆料2的开孔吸音棉1进行干燥处理，将开孔吸音棉1吸入的溶剂、模板剂等液体去除，得到吸音件。吸音材料粉体会留在开孔吸音棉1的泡孔中，提供吸音效果。干燥处理的过程中可以根据最终对吸音件的声学性能要求调整干燥的温度、气氛、时间等处理条件。经过本发明提供的方法制成的吸音件结合了发泡吸音材料和非发泡吸音材料的吸音机制，开孔吸音棉1的泡孔能够提供附着骨架，强化吸音件的通气性能，防止吸音件影响扬声器结构的灵敏度，非发泡吸音材料具有更细小的微孔道，能够起到良好的吸音作用。并且，由于整个吸音件以开孔吸音棉1作为基底，所以，当吸音件受到跌落冲击时能够产生适当的 形变，缓冲掉冲击作用力，不会产生破损、起粉的情况。
优选地，所述开孔吸音棉的材料可以采用聚氨酯或三聚氰胺等易均匀发泡的结构。本发明并不对所述开孔吸音棉的材料进行具体限制，本领域技术人员可以根据实际情况进行选择。特别地，开孔吸音棉材料具有普遍的发泡规律，发泡过程中，单个泡孔的体积越大，则开孔吸音棉中的泡孔分布越均匀；如果单个泡孔的体积越小，则泡孔在开孔吸音棉整体中的分布均匀程度下降。而为了获得更好的声学性能和耐跌落性能，本领域技术人员需要得到单个泡孔体积小且泡孔分布均匀的开孔吸音棉。所以更优地，在制备开孔吸音棉时，可以先制备泡孔体积较大、分布均匀的开孔吸音棉。之后，将开孔吸音棉裁切成与预定腔室形状相匹配但尺寸成一定比例放大的结构。最后，再对开孔吸音棉进行整体压缩，将开孔吸音棉压缩成尺寸与预定腔室一致的大小。在压缩过程中，泡孔的体积能够均匀的减小，从而达到合适的体积大小。通过上述等比例压缩处理，可以得到泡孔分布均匀且体积较小的开孔吸音棉。另外，开孔吸音棉或者经过等比例压缩后的开孔吸音棉并不一定与预定腔室的尺寸完全一致。根据扬声器的声学性能需要，在一些情况下，需要将扬声器的后腔完全填充上开孔吸音棉，所述开孔吸音棉需要与预定腔室的尺寸、形状完全一致；而在另一些情况下，只需将扬声器后腔的一部分填充上开孔吸音棉即可，所述开孔吸音棉只需与预定腔室的一部分的尺寸、形状一致即可。
为了适应不同扬声器对吸音件的需求，所述开孔吸音棉的泡孔结构也有所不同。一般地，所述开孔吸音棉的泡孔孔径小于0.5mm，以便为吸音材料粉体提供良好的附着骨架。优选地，均匀一致的泡孔孔径能够提供更好的吸音效果，例如，开孔吸音棉中达在上述孔径范围内的泡孔占总泡孔数的85％以上时，吸音效果更优。在本发明的一种实施例中，所述泡孔的孔径范围优选在0.18-0.22mm之间，达到这一孔径范围的泡孔占总泡孔数的85％以上。这样，最终制成的吸音件能够提供良好的吸音效果，且在各个方向上具有均匀的减震效果。
优选地，所述吸音材料粉体通常是晶态的硅铝酸盐粉体，在本发明 的一些实施例中，可以采用沸石粉、白炭黑、分子筛等材料单独或混合作为吸音材料粉体。本发明并不对吸音材料粉体进行具体的限制，在能够提供微孔以达到吸音效果的情况下，可以采用其它材料作为吸音材料粉体。
优选地，为了使吸音材料粉体中形成有均匀、足量的微孔，所述模板剂的纯度高于95％，在吸音浆料中的质量比例为1％-35％。当吸音材料粉体与溶剂和模板剂混合时，所述模板剂对所述吸音材料粉体产生作用。
优选地，为了提高吸音材料粉体在开孔吸音棉中的附着量，所述吸音浆料中还可以掺入粘接剂。所述粘接剂可以为有机硅溶胶、无机硅溶胶或者纤维数值等，本领域技术人员可以根据实际情况选择将不同的粘接剂掺入吸音浆料。所述粘接剂在吸音浆料中的质量比例不能过高，否则会影响到吸音浆料浸入开孔吸音棉以及吸音性能。所述粘接剂在吸音浆料中的质量比例不能超过35％，通常，粘接剂的质量比例维持在1％-20％。
优选地，在所述吸音浆料中还可以掺有助剂。所述助剂可以包括促凝剂、消泡剂、均匀剂等制剂，所述助剂用于使吸音原料与溶剂均匀混合，得到均匀的、具有一定粘稠度的吸音浆料。更优地，所述助剂占吸音浆料的质量比例应在0.02-10％的范围之内，如果助剂的用量过大也会影响制成的吸音件的吸音性能。本发明并不对助剂的种类进行限制，本领域技术人员可以根据实际情况，在吸音浆料中掺入不同种类的助剂。例如，若吸音原料与溶剂的混合过程时易产生泡沫，则可以在吸音浆料中掺入消泡剂，用于消除泡沫。
进一步地，所述干燥处理步骤用于除去开孔吸音棉中浸入的溶剂等液体，形成干燥、具有良好弹性和吸音性能的。特别地，在所述干燥过程中，可以使用惰性气体作为介质，防止吸音材料粉体的微观结构中的极性缺陷点与空气中的活性分子发生反应。所述惰性气体可以是氮气。另外，可以适当提高干燥处理的环境温度。可选地，可以将所述干燥成形体置于惰性气体中，所述惰性气体的温度在40-150摄氏度之间。这样可以更有效地将开孔吸音棉中的溶剂、模板剂等液体排出。本领域技术人员可以根据实际应用于扬声器结构的情况调整干燥过程中的参数，对应设置特定温 度曲线和干燥介质。
特别地，由于所述干燥处理的温度较低、时间较短，所以无法将开孔吸音棉以及吸音材料粉体中分子间的水分子排出。虽然经过干燥处理的吸音件已经可以投入使用，但是并不能完全发挥吸音性能。所以更优的，可以对经过干燥处理的开孔吸音棉或者直接对完成浸渍的开孔吸音棉进行焙烧处理。由于开孔吸音棉的材料高温耐受性往往较低，所以所述焙烧处理的温度不能过高，焙烧处理的温度范围为120-420摄氏度之间。焙烧的时间在0.5-96小时之间都是允许的。在较高的温度下进行时间相对较长的焙烧处理，能够将开孔吸音棉和吸音材料粉体中的液体分子、杂质排出，从而提高吸音件的声学性能。特别地，焙烧处理的升温速率不能过快，否则会严重破坏吸音材料粉体的微观孔道结构以及开孔吸音棉的泡孔结构。可选地，焙烧的升温速率范围为20-80℃/h，当焙烧温度选择适中，例如为300℃时，可以选择40℃/h的升温速率进行焙烧，焙烧时间为30小时。这样，基本可以将液体分子去除，并将模板剂、助剂等杂质排出。本发明并不对焙烧时的温度、时间以及升温速度进行准确的限制，本领域技术人员可以根据实际情况对这些参数进行调整。本发明说明的较宽的温度、时间以及升温速率范围包含了一些特殊情况下可以采用的情况。
本发明还提供了一种吸音件，该吸音件通过本发明提供的方法制备得到。该吸音件具有开孔吸音棉，所述开孔吸音棉中附着有吸音材料粉体。开孔吸音棉的泡孔为吸音材料粉体提供了多孔道的附着骨架，同时，开孔吸音棉具有良好的弹性形变能力，能够起到缓冲、减震的作用。优选地，所述开孔吸音棉的材料为聚氨酯或三聚氰胺。特别地，在所述开孔吸音棉中，孔径小于0.5mm的泡孔在全部泡孔中所占的比例大于85％，这种开孔吸音棉能够提供更好的声学、力学性能。进一步地，所述吸音材料粉体至少包括沸石粉或白炭黑。本发明并不对吸音材料粉体和开孔吸音棉的材料进行具体限制，本领域技术人员可以在性能允许的情况下选择其他材料。
虽然已经通过例子对本发明的一些特定实施例进行了详细说明，但是本领域的技术人员应该理解，以上例子仅是为了进行说明，而不是为了 限制本发明的范围。本领域的技术人员应该理解，可在不脱离本发明的范围和精神的情况下，对以上实施例进行修改。本发明的范围由所附权利要求来限定。

Claims (10)

  1. 一种吸音件的制备方法，包括：
    制备与预定腔室形状匹配的开孔吸音棉；
    将吸音材料粉体与溶剂、模板剂混合配制吸音浆料；
    将所述开孔吸音棉在所述吸音浆料中浸渍预定时间；
    对浸有所述吸音浆料的开孔吸音棉进行干燥处理，去除开孔吸音棉中的液体。
  2. 根据权利要求1所述的方法，其特征在于，所述开孔吸音棉的材料为聚氨酯或三聚氰胺。
  3. 根据权利要求1或2所述的方法，其特征在于，对所述开孔吸音棉进行等比例压缩，使所述开孔吸音棉与预定腔室尺寸匹配。
  4. 根据权利要求1-3任意之一所述的方法，其特征在于，在所述开孔吸音棉中，孔径小于0.5mm的泡孔在全部泡孔中所占的比例大于85％。
  5. 根据权利要求1-4任意之一所述的方法，其特征在于，所述吸音材料粉体为沸石粉或白炭黑。
  6. 根据权利要求1-5任意之一所述的方法，其特征在于，所述模板剂占所述吸音浆料的质量比例为1％-35％。
  7. 根据权利要求1-6任意之一所述的方法，其特征在于，所述吸音浆料中掺有粘接剂，所述粘接剂为无机硅溶胶或纤维状树脂，所述粘接剂占所述吸音浆料的质量比例为1％-35％。
  8. 根据权利要求1-7任意之一所述的方法，其特征在于，所述干燥处理的温度范围在40-150摄氏度，干燥处理的气氛包括氮气。
  9. 根据权利要求1-8任意之一所述的方法，其特征在于，在所述干燥处理之后，对所述开孔吸音棉进行焙烧处理，所述焙烧处理的温度范围为120-420摄氏度，焙烧的升温速率的范围为10-80℃/h，焙烧的时间范围为0.5-96h。
  10. 一种吸音件，其特征在于，所述吸音件具有开孔吸音棉，所述开 孔吸音棉中附着有吸音材料粉体，所述开孔吸音棉的材料为聚氨酯或三聚氰胺，在所述开孔吸音棉中，孔径小于0.5mm的泡孔在全部泡孔中所占的比例大于85％，所述吸音材料粉体至少包括沸石粉或白炭黑。
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