WO2023051260A1 - 一种轻量化隔音垫及其制备方法和应用 - Google Patents

一种轻量化隔音垫及其制备方法和应用 Download PDF

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WO2023051260A1
WO2023051260A1 PCT/CN2022/118913 CN2022118913W WO2023051260A1 WO 2023051260 A1 WO2023051260 A1 WO 2023051260A1 CN 2022118913 W CN2022118913 W CN 2022118913W WO 2023051260 A1 WO2023051260 A1 WO 2023051260A1
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sound
layer
weight
parts
lightweight
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PCT/CN2022/118913
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English (en)
French (fr)
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曾凤
黄威
朱可达
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无锡吉兴汽车声学部件科技有限公司
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Publication of WO2023051260A1 publication Critical patent/WO2023051260A1/zh

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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
    • 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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • B32B5/08—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 structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • 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
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • 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
    • 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
    • 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
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/08—Insulating elements, e.g. for sound insulation
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • 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
    • 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 embodiment of the present application relates to the technical field of automobile interior decoration, for example, a lightweight sound insulation pad and its preparation method and application.
  • the sound insulation pad in the front wall of the car is mainly located in the front part of the car and the lower part of the instrument panel. It overlaps with the front carpet to isolate the engine noise and reduce the engine noise from entering the car.
  • the material structure of the sound insulation pad in the front wall of a conventional car is a combination of hard layer felt, heavy coating (EPDM or EVA) and soft layer felt.
  • CN210881221U discloses a heat-insulating and sound-insulating pad for automotive interiors, comprising a sound-insulating pad body, the inner bottom of the sound-insulating pad body is provided with a bottom layer, and the top of the sound-insulating pad body is provided with a PVC skin layer, and the top of the bottom layer is A sponge layer is arranged on the surface, and the base layer and the sponge layer are bonded by a vinyl acetate copolymer adhesive, and a sound-insulating felt layer is arranged on the top surface of the sponge layer.
  • the utility model is equipped with a sound-absorbing layer body, and the sound enters the sound-absorbing cotton through the sound-absorbing hole, and then enters the sound-absorbing layer, so as to eliminate the sound again, improve the sound insulation effect of the sound-insulating pad body, and solve the problem of poor sound-insulating effect of the sound-insulating pad body
  • the fireproof layer and wear-resistant layer are set up to ensure that it will not be burned in the event of a fire, and will not intensify or expand the combustion range, which increases the wear resistance of the sound insulation mat body and prolongs the service life of the sound insulation mat body .
  • CN105538841A discloses a sound-insulating mat for automobile interior and its preparation process.
  • the sound-insulating mat for automobile interior is formed by bonding a sound-absorbing layer and a sound-insulating layer with adhesive, and the sound-absorbing layer is made of the following raw materials in proportion by weight: Composition: 30-60 parts of bamboo charcoal fiber, 50-80 parts of hemp fiber, 20-40 parts of polyester fiber, and 10-30 parts of glass fiber.
  • the sound-absorbing layer not only has the effect of sound-absorbing, but also is non-toxic and tasteless, waterproof and moisture-proof, and has good air permeability.
  • the sound-insulating layer not only has the effect of sound insulation, but also has the effects of heat insulation, dust insulation, sealing, and shock absorption.
  • CN110216950A discloses a car sound-insulating mat and its preparation method and application.
  • the car sound-insulating mat includes successively stacked EPDM layers, PE film layers and thermoplastic back-spun cotton layers.
  • the car sound insulation mat involved in this application uses a combination of three materials: EPDM, PE film and thermoplastic back-spun cotton, in which the PE film acts as an adhesive; the combination of EPDM and thermoplastic back-spun cotton can ensure that the sound insulation mat Under the premise of satisfying low weight and high strength, its sound insulation performance is also very good.
  • the production process of the automobile sound insulation mat is simple and easy to operate compared with related technologies.
  • the product is formed in one step, and there is no need to use a punching device or water jet equipment to cut the product, which also greatly reduces the production cost; and the whole production process is not harmful. Material production, safety and environmental protection.
  • the sound insulation pads provided in the above-mentioned related technologies have better sound insulation performance, the sound absorption performance is relatively weak, and the weight of the heavy coating material used is relatively high, which does not meet the requirements of light weight, low energy consumption and low emission of the whole vehicle. development trend.
  • the embodiment of the present application provides a lightweight sound-insulating mat and its preparation method and application.
  • the lightweight sound-insulating mat includes a sound-absorbing layer, an adhesive layer, an airgel coating, and a sound-insulating layer arranged in sequence; through the above-mentioned structural design, and An airgel coating is provided on one side of the sound-insulating layer to obtain a sound-insulating pad with stable acoustic performance and light weight.
  • an embodiment of the present application provides a lightweight sound-insulating mat, which includes a sound-absorbing layer, an adhesive layer, an airgel coating, and a sound-insulating layer arranged in sequence.
  • FIG. 1 The schematic diagram of the cross-sectional structure of the lightweight sound-insulating pad provided by the application is shown in Figure 1, wherein, 1 represents the sound-insulating layer, 2 represents the airgel coating, 3 represents the bonding layer, and 4 represents the sound-absorbing layer; the sound-insulating layer 1 mainly The effect of sound insulation is played; the material of the airgel layer 2 is aerogel, and as one of the lightest solids in the world, aerogel has a high specific surface area and nano-scale pores, and has excellent thermal and acoustic performance. Excellent, therefore, setting the airgel layer 2 on one side of the sound insulation layer 1 helps to realize the sound insulation pad has the advantages of light weight while having stable acoustic performance, which in turn helps to reduce the weight of parts and improve the performance of fuel vehicles.
  • the adhesive layer 3 is used to connect the sound insulation layer 1 and the sound absorption layer 4 with an airgel coating; the sound absorption layer 4 is matched with the sound insulation layer 1, so that the obtained sound insulation pad has both excellent
  • the excellent sound absorption and sound insulation effects can effectively isolate the wind noise, tire noise and other noise outside the cockpit, and finally a lightweight sound insulation pad with excellent sound insulation and sound absorption performance is obtained.
  • the lightweight sound-insulating pad provided by the application When the lightweight sound-insulating pad provided by the application is applied in the front wall of a car, it consists of a sound-absorbing layer, an adhesive layer, an airgel coating and a sound-insulating layer in sequence from the outside of the cockpit to the inside of the cockpit.
  • the thickness of the sound-absorbing layer is 3-20mm, such as 4mm, 6mm, 8mm, 10mm, 12mm, 14mm, 16mm, 18mm or 20mm.
  • the grammage of the sound-absorbing layer is 850-1250gsm, such as 900gsm, 950gsm, 1000gsm, 1050gsm, 1100gsm, 1150gsm or 1200gsm.
  • the thickness of the sound-insulating layer is 2-8mm, such as 2.5mm, 3mm, 3.5mm, 4mm, 4.5mm, 5mm, 5.5mm, 6mm, 6.5mm, 7mm or 7.5mm.
  • the weight of the sound insulation layer is 800-1000gsm, such as 820gsm, 840gsm, 860gsm, 880gsm, 1000gsm, 1020gsm, 1040gsm, 1080gsm, 1100gsm, 1120gsm, 1140gsm, 1160gsm, 1170gsm, 1180gsm or 1190gsm.
  • the sound-absorbing layer and the sound-insulating layer are made of felt.
  • the raw materials for the felt include a combination of PET fibers and cotton fibers.
  • the PET fibers include a combination of low-melting PET fibers and ordinary PET fibers.
  • the "low-melting PET fiber” refers to PET fiber with a melting point of 100-130°C
  • the “common PET fiber” refers to PET fiber with a melting point of 240-260°C.
  • the raw materials for the felt of the sound-absorbing layer and the felt of the sound-insulating layer independently include the following components in parts by weight: 10-30 parts by weight of low-melting PET fibers, 50-80 parts by weight of cotton fibers and 10 parts by weight of ordinary PET fibers. ⁇ 25 parts by weight.
  • the low melting point PET fiber can be 12 parts by weight, 14 parts by weight, 16 parts by weight, 18 parts by weight, 20 parts by weight, 22 parts by weight, 24 parts by weight, 26 parts by weight or 28 parts by weight.
  • the cotton fiber can be 53 parts by weight, 56 parts by weight, 59 parts by weight, 62 parts by weight, 65 parts by weight, 68 parts by weight, 71 parts by weight, 74 parts by weight or 77 parts by weight.
  • the common PET fiber can be 12 parts by weight, 14 parts by weight, 16 parts by weight, 18 parts by weight, 20 parts by weight, 22 parts by weight or 24 parts by weight, etc.
  • the lengths of the PET fibers and the cotton fibers are each independently 30-80 mm, such as 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm or 75 mm.
  • the linear densities of the cotton fibers and PET fibers are each independently 4-8dtex, such as 4.5dtex, 5dtex, 5.5dtex, 6dtex, 6.5dtex, 7dtex, 7.5dtex or 8dtex, etc.
  • the felt of the sound-absorbing layer is prepared by the following method, the preparation method comprising: performing punch felting of cotton fibers and PET fibers to obtain the felt of the sound-absorbing layer.
  • the felt of the sound-insulating layer is obtained by pressing the felt of the sound-absorbing layer.
  • said pressing is carried out in a hot press flat die.
  • the pressing temperature is 150-180°C, such as 153°C, 156°C, 159°C, 162°C, 165°C, 168°C, 171°C, 174°C or 177°C.
  • the pressing pressure is 5-8 MPa, such as 5.3 MPa, 5.6 MPa, 5.9 MPa, 6.2 MPa, 6.5 MPa, 6.8 MPa, 7.1 MPa, 7.4 MPa or 7.7 MPa.
  • the holding time of the pressing is 50-90s, such as 55s, 60s, 65s, 70s, 75s, 80s or 85s.
  • the preparation method of the felt of the sound insulation layer comprises the steps:
  • PET fiber and cotton fiber are carried out punch felting, obtain the felt of sound-absorbing layer;
  • step (2) Place the felt of the sound-absorbing layer obtained in step (1) in a hot-pressed flat mold, apply a pressure of 5-8 MPa at 150-180° C. for 50-90 seconds, and cool to obtain the felt of the sound-insulating layer.
  • the adhesive layer includes any one of polypropylene film, polyethylene film, polyamide film or polyvinyl chloride film.
  • the grammage of the adhesive layer is 20-60gsm, such as 25gsm, 30gsm, 35gsm, 40gsm, 45gsm, 50gsm or 55gsm.
  • the airgel coating has a thickness of 1-3mm, such as 1.2mm, 1.4mm, 1.6mm, 1.8mm, 2mm, 2.2mm, 2.4mm, 2.6mm or 2.8mm.
  • the raw materials for preparing the airgel coating include a combination of silicon airgel, water-based acrylic resin and solvent.
  • the preparation raw materials of the airgel coating include a combination of silicon aerogel, water-based acrylic resin and solvent; the silicon aerogel is the most common airgel material, and its porosity Higher, larger specific surface area and lower thermal conductivity.
  • the raw materials for preparing the airgel coating include the following components in parts by weight: 25-40 parts by weight of silicon airgel, 15-20 parts by weight of water-based acrylic resin and 40-60 parts by weight of solvent.
  • the silica airgel can be 27 parts by weight, 29 parts by weight, 31 parts by weight, 33 parts by weight, 35 parts by weight, 37 parts by weight or 39 parts by weight, etc.
  • the water-based acrylic resin can be 15.5 parts by weight, 16 parts by weight, 16.5 parts by weight, 17 parts by weight, 17.5 parts by weight, 18 parts by weight, 18.5 parts by weight, 19 parts by weight or 19.5 parts by weight.
  • the solvent comprises water.
  • the embodiment of the present application provides a method for preparing a lightweight sound-insulating mat as described in the first aspect, and the preparation method includes the following steps:
  • step (2) Connecting the sound-absorbing layer, the bonding layer and the airgel coating in the composite layer obtained in step (1) sequentially, and hot pressing to obtain the lightweight sound-insulating pad.
  • the coating method in step (1) includes any one of brush coating, spray coating or roller coating.
  • the step (1) further includes a drying step after coating.
  • the hot pressing in step (2) is carried out in a steam flat mold.
  • step (2) the step of vacuumizing and filling with steam is also included.
  • the pressure of the system after vacuuming is -0.01 ⁇ -0.08MPa, such as -0.02MPa, -0.03MPa, -0.04MPa, -0.05MPa, -0.06MPa or -0.07MPa, etc.
  • the temperature of the hot pressing in step (2) is 150-200°C, such as 155°C, 160°C, 165°C, 170°C, 175°C, 180°C, 185°C, 190°C or 195°C.
  • the hot pressing in step (2) is carried out under the condition of 6-15 MPa (such as 7 MPa, 8 MPa, 9 MPa, 10 MPa, 11 MPa, 12 MPa, 13 MPa or 14 MPa, etc.).
  • the holding time of the hot pressing in step (2) is 60-150s, such as 70s, 80s, 90s, 100s, 110s, 120s, 130s or 140s.
  • the preparation method includes the following steps:
  • step (2) connecting the sound-absorbing layer, the bonding layer and the airgel coating in the composite layer obtained in step (1) successively, placing them in a steam flat mold, and vacuuming so that the pressure of the system is -0.01 ⁇ -0.08MPa, Filling with steam, applying a pressure of 6-15MPa at 150-200°C for 60-150s to obtain the lightweight sound-insulating mat.
  • the embodiment of the present application provides an application of the lightweight sound insulation pad as described in the first aspect in the front wall of a car.
  • the lightweight sound-insulating pad provided by the embodiment of the present application includes a sound-absorbing layer, a bonding layer, an airgel coating and a sound-insulating layer arranged in sequence; airgel coatings are selected to replace the existing recoating materials, which can ensure the obtained sound insulation
  • the cushion has excellent sound insulation and sound absorption effects, which can effectively isolate the wind noise, tire noise and other noise outside the cockpit, and meet consumers' needs for driving comfort.
  • the lightweight sound insulation pad provided by the embodiment of the present application realizes the lightweight of the sound insulation pad under the premise of ensuring stable acoustic performance, thereby reducing the weight of the components using it, and helping to improve the fuel efficiency of fuel vehicles or the cruising range of electric vehicles; and the raw material of the airgel coating is water-based paint, which has no peculiar smell and low VOC emissions when applied to automotive interiors, has no effect on the air quality in the car, and meets the requirements for the volatile air in the car. Control requirements for organic matter.
  • Fig. 1 is a schematic cross-sectional structure diagram of a lightweight sound-insulating pad provided by an embodiment of the present application, wherein, 1-sound-insulating layer, 2-airgel layer, 3-adhesive layer, 4-sound-absorbing layer;
  • Fig. 2 is the frequency-sound absorption coefficient spectrogram of the sound insulation pad that embodiment 1 ⁇ 3 and comparative example 1 obtain;
  • Fig. 3 is the frequency-sound insulation spectrogram of the sound insulation mat obtained in Examples 1-3 and Comparative Example 1.
  • a kind of soft felt, thickness is 10mm, and grammage is 850gsm;
  • Its preparation raw material comprises 20 weight parts low melting point PET fibers (melting point is 120 °C), 60 weight parts cotton fibers and 20 weight parts common PET fibers (melting point is 120 °C) according to weight parts; 250°C);
  • the preparation method of the soft felt obtained in this preparation example comprises: preparing the soft felt by air-laying low melting point PET fibers, cotton fibers and common PET fibers.
  • a kind of soft felt, thickness is 5mm, and gram weight is 950gsm;
  • Its preparation raw material comprises 10 weight parts low-melting point PET fibers (melting point is 120 °C), 50 weight parts cotton fibers and 10 weight parts common PET fibers (melting point is 120 °C) according to weight parts; 250°C);
  • the preparation method of the soft felt obtained in this preparation example comprises: preparing the soft felt by air-laying low melting point PET fibers, cotton fibers and common PET fibers.
  • a hard felt with a thickness of 2 mm its preparation method comprises: placing the soft felt obtained in Preparation Example 1 in a hot-pressed plate mold and applying a pressure of 8 MPa at 165° C. for 90 seconds to obtain the hard felt.
  • a hard felt with a thickness of 4 mm its preparation method comprises: placing the soft felt obtained in Preparation Example 1 in a hot-pressed plate mold and applying a pressure of 6 MPa for 70 seconds at 160° C. to obtain the hard felt.
  • a hard felt with a thickness of 5 mm its preparation method comprises: placing the soft felt obtained in Preparation Example 1 in a hot-pressed flat mold and applying a pressure of 6 MPa for 60 seconds at 160° C. to obtain the hard felt.
  • a lightweight sound-insulating pad comprising a sound-absorbing layer 4, an adhesive layer 3, an airgel coating 2 and a sound-insulating layer 1 arranged in sequence;
  • sound-absorbing layer 4 is the soft felt that preparation example 2 obtains
  • Adhesive layer 3 is a polyethylene film with a grammage of 25gsm
  • the thickness of the airgel coating 2 is 2mm, and the preparation raw material is silicon airgel coating;
  • Sound insulation layer 1 is the hard felt that preparation example 3 obtains
  • step (1) Connect the sound-absorbing layer, the polyethylene film, and the silicon airgel coating in the composite layer obtained in step (1) sequentially, place it in a steam flat mold, and vacuumize the system so that the pressure of the system is -0.02MPa, and keep it for 10s , filled with steam, applied a pressure of 8 MPa at 170°C for 90s, opened the mold, and cooled to room temperature to obtain the lightweight sound insulation mat.
  • a lightweight sound-insulating pad comprising a sound-absorbing layer (the soft felt obtained in Preparation Example 2) arranged in sequence; Layer (thickness is 2mm, and preparation raw material is silicon airgel paint (Hunan Yantuo, YTAC-001-A) and sound insulation layer (the hard felt that preparation example 4 obtains);
  • step (2) Connect the sound-absorbing layer, polyethylene film and the silicon airgel coating in the composite layer obtained in step (1) in sequence, place it in a steam flat mold, and vacuumize the system so that the pressure of the system is -0.04MPa, and keep it for 10s , filled with steam, applied a pressure of 10 MPa at 180°C for 120s, opened the mold, and cooled to room temperature to obtain the lightweight sound insulation mat.
  • a lightweight sound-insulating pad the cross-sectional structure of which is the same as in Example 1; comprising a sound-absorbing layer (the soft felt obtained in Preparation Example 2) arranged in sequence; Layer (thickness is 3mm, and preparation raw material is silicon airgel coating (Hunan Yantuo, YTAC-001-A) and sound insulation layer (the hard felt that preparation example 5 obtains);
  • step (2) Connect the sound-absorbing layer, the polyamide film and the silicon airgel coating in the composite layer obtained in step (1) sequentially, place it in a steam flat mold, and vacuumize the system so that the pressure of the system is -0.01MPa, and keep it for 10s , filled with steam, applied a pressure of 12MPa at 200°C for 150s, opened the mold, and cooled to room temperature to obtain the lightweight sound insulation mat.
  • a kind of sound insulation pad its difference with embodiment 1 is only, adopt EPDM heavy coating (preparation raw material is EPDM coating (Wuhan Wuerde) to replace the silicon airgel coating in embodiment 1, other structures and parameters Same as Example 1.
  • EPDM heavy coating preparation raw material is EPDM coating (Wuhan Wuerde) to replace the silicon airgel coating in embodiment 1, other structures and parameters Same as Example 1.
  • the sound insulation performance of the sound insulation mat obtained in Examples 1 to 3 is equivalent to that of the sound insulation mat obtained in Comparative Example 1, even in the middle and high frequency bands. (1000 ⁇ 10000Hz) has a slight advantage, which proves that its sound insulation and absorption performance is obviously better than that of the sound insulation mat obtained in Comparative Example 1.
  • the lightweight sound-insulating mat provided by the present application is lighter in weight than the sound-insulating mat obtained in Comparative Example 1. Specifically, the weight of the sound-insulating mat obtained in Example 1 is reduced by 27% compared with the sound-insulating mat obtained in Comparative Example 1; Example 2. Compared with the weight of the sound-insulating pad obtained in Comparative Example 1, the weight of the sound-insulating pad obtained in Example 2 was reduced by 18%; compared with the weight of the sound-insulating pad obtained in Comparative Example 1, the weight of the sound-insulating pad obtained in Example 2 was reduced by 10%; Pads have the advantage of being lightweight.
  • this application illustrates a lightweight sound-insulating mat and its preparation method and application through the above examples, but this application is not limited to the above process steps, that is, it does not mean that this application must rely on the above process steps to be implemented.
  • Those skilled in the art should understand that any improvement to the present application, the equivalent replacement of the raw materials selected in the present application, the addition of auxiliary components, the selection of specific methods, etc., all fall within the scope of protection and disclosure of the present application.

Abstract

本文公布一种轻量化隔音垫及其制备方法和应用，所述轻量化隔音垫包括依次设置的吸音层、粘结层、气凝胶涂层和隔音层；所述轻量化隔音垫通过上述层级结构设计，以及采用气凝胶涂料替换传统的重涂层材料，可以保证得到的轻量化隔音垫兼具优异隔音效果和轻量化的优势，不仅有效隔绝了驾舱外的风噪、胎噪等噪音，还可以降低零部件的重量，进而有助于提升燃油车的燃油效率或电动车的续航里程；且所述气凝胶涂料无异味、低VOC排放，对车内空气质量无影响，满足对于车内空气挥发性有机物的管控要求，适合批量化生产和应用。

Description

一种轻量化隔音垫及其制备方法和应用 技术领域
本申请实施例涉及汽车内饰技术领域，例如一种轻量化隔音垫及其制备方法和应用。
背景技术
随着车辆制造技术的不断革新，驾乘人员更加关注车辆噪声问题，特别是驾驶室噪声水平直接影响着车辆舒适性。汽车在行驶过程中，会产生很多噪音，包括发动机噪音、风噪、路噪等，这些噪音穿过汽车传播入车内，给用户带来不好的体验，使人心烦。因此，现有的汽车一般会在汽车内部配置隔音垫用于隔离吸收噪音，提高用户的舒适感。
汽车前围内隔音垫，作为整车中主要隔音零件之一，主要位于汽车内前部、仪表盘下部，与前地毯搭接，起隔绝发动机噪声、减少发动机噪音传入车内的作用。
常规汽车前围内隔音垫的材料结构为：硬层毛毡、重涂层(EPDM或EVA)和软层毛毡的组合。CN210881221U公开了一种汽车内饰隔热隔音垫，包括隔音垫本体，所述隔音垫本体的内部底端设置有垫底层，且隔音垫本体的顶端设置有PVC表皮层，所述垫底层的顶端表面设置有海绵层，且垫底层与海绵层之间通过醋酸乙烯共聚物胶粘剂粘接，所述海绵层的顶端表面设置有隔音毡层。该实用新型设置了吸音层本体，声音通过吸音孔进入到吸音棉中，随后进入到吸音层中，达到对声音的再次清除，可提高隔音垫本体的隔音效果，解决了隔音垫本体隔音效果差的问题，设置了防火层以及耐磨层，能保证在起火的时候不被烧着，也不会使得燃烧范围加剧、扩大，增加了隔音垫本体的耐磨性能，延长隔音垫本体的使用寿命。CN105538841A公开了一种汽车内部用隔音垫及其制备工艺，所述汽车内部用隔音垫，由吸音层与隔音层用粘合胶粘合而成，吸音层由以下按重量份配比的原料制成：竹炭纤维30～60份、麻纤维50～80份、聚酯纤维20～40份、玻璃纤维10～30份，该申请得到的汽车内部用隔音垫，采用双层材料粘合而成，吸音层不但具有吸音的效果，而且无毒无味、防水防潮、透气性良好，隔音层不但具有隔音的效果，而且还具有隔热、隔尘、密封、减 震的效果，粘合在一起不但可以降低车内金属共振产生的声响，而且有效的隔绝外界与车内的音频环境，让车内更加安静，还能进一步提升车内音响的效果。CN110216950A公开了一种汽车隔音垫及其制备方法和应用，所述汽车隔音垫包括依次相叠的EPDM层、PE膜层和热塑性回纺棉层。该申请所涉及的汽车隔音垫采用EPDM、PE膜和热塑性回纺棉三种材料的组合方式，其中PE膜起到类似粘合剂的作用；EPDM与热塑性回纺棉的组合方式能保证隔音垫在满足低重量、高强度的前提下，其隔音性能也十分优良。且该汽车隔音垫的生产工序相对于相关技术简单易操作，产品一步成型，无需再利用冲断装置或水刀设备进行产品的切割，也大幅度地减少了生产成本；且整个生产过程没有有害物质产生，安全环保。
但是，上述相关技术中所提供的隔音垫虽然隔音性能较好，但是吸音性能偏弱，且采用的的重涂层材料的克重较高，进而不符合整车轻量化、低能耗和低排放的发展趋势。
因此，开发一种吸音效果、隔音效果优异且轻量化的隔音垫，是本领域急需解决的技术问题。
发明内容
以下是对本文详细描述的主题的概述。本概述并非是为了限制权利要求的保护范围。
本申请实施例提供一种轻量化隔音垫及其制备方法和应用，所述轻量化隔音垫包括依次设置的吸音层、粘结层、气凝胶涂层和隔音层；通过上述结构设计，并在所述隔音层的一侧设置气凝胶涂层，得到了一种声学性能稳定且轻量化的隔音垫。
第一方面，本申请实施例提供一种轻量化隔音垫，所述轻量化隔音垫包括依次设置的吸音层、粘结层、气凝胶涂层和隔音层。
本申请提供的轻量化隔音垫的剖面结构示意图如图1所示，其中，1代表隔音层，2代表气凝胶涂层，3代表粘结层，4代表吸音层；所述隔音层1主要起到隔音的效果；所述气凝胶层2的材料为气凝胶，气凝胶作为世界上最轻的固体之一，具有较高的比表面积以及纳米级孔洞，在热学和声学方面性能优异，因此，在隔音层1的一侧设置气凝胶层2，有助于实现隔音垫在具有声学性能稳 定的同时具有轻量化的优势，进而有助于降低零部件的重量，提升燃油车的燃油效率或电动车的续航里程；粘结层3用于连接具有气凝胶涂层的隔音层1和吸音层4；所述吸音层4搭配隔音层1，使得到的隔音垫兼具优异的吸音效果和隔音效果，可以有效隔绝驾舱外的风噪、胎噪等噪音，最终得到了隔音性能和吸音性能均优异的轻量化隔音垫。
本申请提供的轻量化隔音垫在应用于汽车前围内时，从驾舱外向驾舱内依次为吸音层、粘结层、气凝胶涂层和隔音层。
优选地，所述吸音层的厚度为3～20mm，例如4mm、6mm、8mm、10mm、12mm、14mm、16mm、18mm或20mm等。
优选地，所述吸音层的克重为850～1250gsm，例如900gsm、950gsm、1000gsm、1050gsm、1100gsm、1150gsm或1200gsm等。
优选地，所述隔音层的厚度为2～8mm，例如2.5mm、3mm、3.5mm、4mm、4.5mm、5mm、5.5mm、6mm、6.5mm、7mm或7.5mm等。
优选地，所述隔音层的克重为800～1000gsm，例如820gsm、840gsm、860gsm、880gsm、1000gsm、1020gsm、1040gsm、1080gsm、1100gsm、1120gsm、1140gsm、1160gsm、1170gsm、1180gsm或1190gsm等。
优选地，所述吸音层和隔音层的材料均为毛毡。
优选地，所述毛毡的制备原料包括PET纤维和棉纤维的组合。
优选地，所述PET纤维包括低熔点PET纤维和普通PET纤维的组合。
在本申请中，所述“低熔点PET纤维”指的是熔点为100～130℃的PET纤维，而所述“普通PET纤维”指的是熔点为240～260℃的PET纤维。
优选地，所述吸音层的毛毡和隔音层的毛毡的制备原料按照重量份各自独立地包括如下组分：低熔点PET纤维10～30重量份、棉纤维50～80重量份和普通PET纤维10～25重量份。
所述低熔点PET纤维可以为12重量份、14重量份、16重量份、18重量份、20重量份、22重量份、24重量份、26重量份或28重量份等。
所述棉纤维可以为53重量份、56重量份、59重量份、62重量份、65重量份、68重量份、71重量份、74重量份或77重量份等。
所述普通PET纤维可以为12重量份、14重量份、16重量份、18重量份、20重量份、22重量份或24重量份等。
优选地，所述PET纤维和棉纤维的长度各自独立地为30～80mm，例如35mm、40mm、45mm、50mm、55mm、60mm、65mm、70mm或75mm等。
优选地，所述棉纤维和PET纤维的线密度各自独立地为4～8dtex，例如4.5dtex、5dtex、5.5dtex、6dtex、6.5dtex、7dtex、7.5dtex或8dtex等。
优选地，所述吸音层的毛毡通过如下方法制备得到，所述制备方法包括：将棉纤维和PET纤维进行刺毡，得到所述吸音层的毛毡。
优选地，所述隔音层的毛毡通过将吸音层的毛毡进行压制得到。
优选地，所述压制在热压平板模中进行。
优选地，所述压制的温度为150～180℃，例如153℃、156℃、159℃、162℃、165℃、168℃、171℃、174℃或177℃等。
优选地，所述压制的压力为5～8MPa，例如5.3MPa、5.6MPa、5.9MPa、6.2MPa、6.5MPa、6.8MPa、7.1MPa、7.4MPa或7.7MPa等。
优选地，所述压制的保压时间为50～90s，例如55s、60s、65s、70s、75s、80s或85s等。
作为优选技术方案，所述隔音层的毛毡的制备方法包括如下步骤：
(1)将PET纤维和棉纤维进行刺毡，得到吸音层的毛毡；
(2)将步骤(1)得到的吸音层的毛毡置于热压平板模中，在150～180℃下施加5～8MPa的压力50～90s，冷却，得到所述隔音层的毛毡。
优选地，所述粘结层包括聚丙烯膜、聚乙烯膜、聚酰胺膜或聚氯乙烯膜中的任意一种。
优选地，所述粘结层的克重为20～60gsm，例如25gsm、30gsm、35gsm、40gsm、45gsm、50gsm或55gsm等。
优选地，所述气凝胶涂层的厚度为1～3mm，例如1.2mm、1.4mm、1.6mm、1.8mm、2mm、2.2mm、2.4mm、2.6mm或2.8mm等。
优选地，所述气凝胶涂层的制备原料包括硅气凝胶、水性丙烯酸树脂和溶剂的组合。
作为本申请的优选技术方案，所述气凝胶涂层的制备原料包括硅气凝胶、水性丙烯酸树脂和溶剂的组合；所述硅气凝胶为最常见的气凝胶材料，其孔隙率较高、比表面积大且热传导率低。
优选地，所述气凝胶涂层的制备原料按照重量份包括如下组分：硅气凝胶 25～40重量份、水性丙烯酸树脂15～20重量份和溶剂40～60重量份。
所述硅气凝胶可以为27重量份、29重量份、31重量份、33重量份、35重量份、37重量份或39重量份等。
所述水性丙烯酸树脂可以为15.5重量份、16重量份、16.5重量份、17重量份、17.5重量份、18重量份、18.5重量份、19重量份或19.5重量份等。
优选地，所述溶剂包括水。
第二方面，本申请实施例提供一种如第一方面所述轻量化隔音垫的制备方法，所述制备方法包括如下步骤：
(1)将气凝胶涂层的制备原料涂覆在隔音层的一侧，得到复合层；
(2)将吸音层、粘结层和步骤(1)得到的复合层中的气凝胶涂层依次连接，热压，得到所述轻量化隔音垫。
优选地，步骤(1)所述涂覆的方法包括刷涂、喷涂或辊涂中的任意一种。
优选地，步骤(1)所述涂覆后还包括干燥的步骤。
优选地，步骤(2)所述热压在蒸汽平板模中进行。
优选地，步骤(2)所述热压前还包括抽真空以及充入蒸汽的步骤。
优选地，所述抽真空后体系的压力为-0.01～-0.08MPa，例如-0.02MPa、-0.03MPa、-0.04MPa、-0.05MPa、-0.06MPa或-0.07MPa等。
优选地，步骤(2)所述热压的温度为150～200℃，例如155℃、160℃、165℃、170℃、175℃、180℃、185℃、190℃或195℃等。
优选地，步骤(2)所述热压在6～15MPa(例如7MPa、8MPa、9MPa、10MPa、11MPa、12MPa、13MPa或14MPa等)的条件下进行。
优选地，步骤(2)所述热压的保压时间为60～150s，例如70s、80s、90s、100s、110s、120s、130s或140s等。
作为本申请的优选技术方案，所述制备方法包括如下步骤：
(1)将气凝胶涂层的制备原料刷涂、喷涂或辊涂在隔音层的一侧，得到复合层；
(2)将吸音层、粘结层和步骤(1)得到的复合层中的气凝胶涂层依次连接，置于蒸汽平板模中，抽真空使得体系的压力为-0.01～-0.08MPa，充入蒸汽，在150～200℃下施加6～15MPa的压力60～150s，得到所述轻量化隔音垫。
第三方面，本申请实施例提供一种如第一方面所述的轻量化隔音垫在汽车 前围内的应用。
相对于相关技术，本申请实施例具有以下有益效果：
(1)本申请实施例提供的轻量化隔音垫包括依次设置的吸音层、粘结层、气凝胶涂层和隔音层；选择气凝胶涂料代替现有重涂材料，可以保证得到的隔音垫具有优异的隔音和吸音效果，可以有效隔绝驾舱外的风噪、胎噪等噪音，满足消费者对于驾乘舒适度的需求。
(2)本申请实施例提供的轻量化隔音垫在保证声学性能稳定的前提下，实现了隔音垫的轻量化，进而降低了使用其的零部件的重量，有助于提升燃油车的燃油效率或电动车的续航里程；且所述气凝胶涂层的原料为水性涂料，应用于汽车内饰时，无异味、低VOC排放，对车内空气质量无影响，满足对于车内空气挥发性有机物的管控要求。
在阅读并理解了附图和详细描述后，可以明白其他方面。
附图说明
附图用来提供对本文技术方案的进一步理解，并且构成说明书的一部分，与本申请的实施例一起用于解释本文的技术方案，并不构成对本文技术方案的限制。
图1为本申请实施例提供的轻量化隔音垫的剖面结构示意图，其中，1-隔音层，2-气凝胶层，3-粘结层，4-吸音层；
图2为实施例1～3和对比例1得到的隔音垫的频率-吸音系数谱图；
图3为实施例1～3和对比例1得到的隔音垫的频率-隔声量谱图。
具体实施方式
下面通过具体实施方式来进一步说明本申请的技术方案。本领域技术人员应该明了，所述实施例仅仅是帮助理解本申请，不应视为对本申请的具体限制。
制备例1
一种软毛毡，厚度为10mm，克重为850gsm；其制备原料按照重量份包括20重量份低熔点PET纤维(熔点为120℃)、60重量份棉纤维和20重量份普通PET纤维(熔点为250℃)；
本制备例得到的软毛毡的制备方法包括：将低熔点PET纤维、棉纤维和普通PET纤维通过气流成网制备成所述软毛毡。
制备例2
一种软毛毡，厚度为5mm，克重为950gsm；其制备原料按照重量份包括10重量份低熔点PET纤维(熔点为120℃)、50重量份棉纤维和10重量份普通PET纤维(熔点为250℃)；
本制备例得到的软毛毡的制备方法包括：将低熔点PET纤维、棉纤维和普通PET纤维通过气流成网制备成所述软毛毡。
制备例3
一种硬毛毡，厚度为2mm；其制备方法包括：将制备例1得到的软毛毡置于热压平板模中在165℃下施加8MPa的压力时间为90s，得到所述硬毛毡。
制备例4
一种硬毛毡，厚度为4mm；其制备方法包括：将制备例1得到的软毛毡置于热压平板模中在160℃下施加6MPa的压力70s，得到所述硬毛毡。
制备例5
一种硬毛毡，厚度为5mm；其制备方法包括：将制备例1得到的软毛毡置于热压平板模中在160℃下施加6MPa的压力60s，得到所述硬毛毡。
实施例1
一种轻量化隔音垫，其剖面结构示意图如图1所示，包括依次设置的吸音层4、粘结层3、气凝胶涂层2和隔音层1；
其中，吸音层4为制备例2得到的软毛毡；
粘结层3为克重为25gsm的聚乙烯膜；
气凝胶涂层2的厚度为2mm，制备原料为硅气凝胶涂料；
隔音层1为制备例3得到的硬毛毡；
本实施例得到的轻量化隔音垫的制备方法包括如下步骤：
(1)将硅气凝胶涂料(湖南岩拓、YTAC-001-A)刷涂在隔音层的一侧，得到复合层；
(2)将吸音层、聚乙烯膜和步骤(1)得到的复合层中的硅气凝胶涂层依次连接，置于蒸汽平板模中，抽真空使得体系的压力为-0.02MPa，保持10s，充入蒸汽，在170℃下对施加8MPa的压力90s，开模，冷却至室温，得到所述轻量化隔音垫。
实施例2
一种轻量化隔音垫，其剖面结构与实施例1相同；包括依次设置的吸音层(制备例2得到的软毛毡)；粘结层(克重为30gsm的聚乙烯膜)、气凝胶涂层(厚度为2mm，制备原料为硅气凝胶涂料(湖南岩拓、YTAC-001-A)以及隔音层(制备例4得到的硬毛毡)；
本实施例得到的轻量化隔音垫的制备方法包括如下步骤：
(1)将硅气凝胶涂料刷涂在隔音层的一侧，得到复合层；
(2)将吸音层、聚乙烯膜和步骤(1)得到的复合层中的硅气凝胶涂层依次连接，置于蒸汽平板模中，抽真空使得体系的压力为-0.04MPa，保持10s，充入蒸汽，在180℃下对施加10MPa的压力120s，开模，冷却至室温，得到所述轻量化隔音垫。
实施例3
一种轻量化隔音垫，其剖面结构与实施例1相同；包括依次设置的吸音层(制备例2得到的软毛毡)；粘结层(克重为30gsm的聚酰胺膜)、气凝胶涂层(厚度为3mm，制备原料为硅气凝胶涂料(湖南岩拓、YTAC-001-A)以及隔音层(制备例5得到的硬毛毡)；
本实施例得到的轻量化隔音垫的制备方法包括如下步骤：
(1)将硅气凝胶涂料刷涂在隔音层的一侧，得到复合层；
(2)将吸音层、聚酰胺膜和步骤(1)得到的复合层中的硅气凝胶涂层依次连接，置于蒸汽平板模中，抽真空使得体系的压力为-0.01MPa，保持10s，充入蒸汽，在200℃下对施加12MPa的压力150s，开模，冷却至室温，得到所述轻量化隔音垫。
对比例1
一种隔音垫，其与实施例1的区别仅在于，采用EPDM重涂层(制备原料为EPDM涂料(武汉伍尔德)替换了实施例1中的硅气凝胶涂层，其他结构和参数与实施例1相同。
性能测试：
(1)吸音性能：按照标准《GB/T 20247-2006》提供的测试方法进行测试；
(2)隔音性能：按照标准《GB/T 31004.1-2014》提供的测试标准进行测试；
(3)重量：测试大小为0.6m×0.6m的隔音垫的重量。
按照上述测试方法(1)～(2)对实施例1～3和对比例1得到的隔音垫进行 测试，测试结果如图2和图3所示，其中，图2为实施例1～3和对比例1得到的隔音垫的频率-吸音系数谱图，从图2可以看出，实施例1～3得到的隔音垫在400～6300Hz波段的吸音系数明显高于对比例1，证明其吸音性能明显优于对比例1得到的隔音垫；图3为实施例1～3和对比例1得到的隔音垫的频率-隔声量谱图，从图3可以看出，由于气凝胶材料的密度低、孔径小，与丙烯酸树脂、水性溶剂充分融合，涂料干燥后材料致密，因此，实施例1～3得到的隔音垫的隔音性能与对比例1得到的隔音垫性能相当，甚至在中、高频段(1000～10000Hz)有轻微优势，证明其隔吸音性能明显优于对比例1得到的隔音垫。
按照上述测试方法(3)对实施例1～3和对比例1得到的隔音垫进行测试，测试数据如表1所示：
表1
  重量(g)
实施例1 940
实施例2 1020
实施例3 1090
对比例1 1200
根据表1数据可以看出：
本申请提供的轻量化隔音垫相较于对比例1得到的隔音垫重量轻，具体而言，实施例1得到的隔音垫相较于对比例1得到的隔音垫重量降低了27％；实施例2得到的隔音垫相较于对比例1得到的隔音垫重量降低了18％；实施例2得到的隔音垫相较于对比例1得到的隔音垫重量降低了10％；证明本申请提供的隔音垫具有轻量化的优势。
申请人声明，本申请通过上述实施例来说明一种轻量化隔音垫及其制备方法和应用，但本申请并不局限于上述工艺步骤，即不意味着本申请必须依赖上述工艺步骤才能实施。所属技术领域的技术人员应该明了，对本申请的任何改进，对本申请所选用原料的等效替换及辅助成分的添加、具体方式的选择等，均落在本申请的保护范围和公开范围之内。

Claims (15)

  1. 一种轻量化隔音垫，其中，所述轻量化隔音垫包括依次设置的吸音层、粘结层、气凝胶涂层和隔音层。
  2. 根据权利要求1所述的轻量化隔音垫，其中，所述吸音层的厚度为3～20mm。
  3. 根据权利要求1或2所述的轻量化隔音垫，其中，所述吸音层的克重为850～1250gsm。
  4. 根据权利要求1～3任一项所述的轻量化隔音垫，其中，所述隔音层的厚度为2～8mm。
  5. 根据权利要求1～4任一项所述的轻量化隔音垫，其中，所述隔音层的克重为800～1000gsm。
  6. 根据权利要求1～5任一项所述的轻量化隔音垫，其中，所述吸音层和隔音层的材料均为毛毡；
    优选地，所述毛毡的制备原料包括棉纤维和PET纤维的组合；
    优选地，所述PET纤维包括低熔点PET纤维和普通PET纤维的组合；
    优选地，所述吸音层的毛毡和隔音层的毛毡的制备原料按照重量份各自独立地包括如下组分：低熔点PET纤维10～30重量份、棉纤维50～80重量份和普通PET纤维10～25重量份；
    优选地，所述棉纤维和PET纤维的长度各自独立地为30～80mm；
    优选地，所述棉纤维和PET纤维的线密度各自独立地为4～8dtex。
  7. 根据权利按要求1～6任一项所述的轻量化隔音垫，其中，所述吸音层的毛毡通过如下方法制备得到，所述方法包括：将PET纤维和棉纤维进行刺毡，得到所述吸音层的毛毡；
    优选地，所述隔音层的毛毡通过将吸音层的毛毡进行压制得到；
    优选地，所述压制在热压平板模中进行；
    优选地，所述压制的温度为150～180℃；
    优选地，所述压制的压力为5～8MPa；
    优选地，所述压制的保压时间为50～90s。
  8. 根据权利要求1～7任一项所述的轻量化隔音垫，其中，所述粘结层包括聚丙烯膜、聚乙烯膜、聚酰胺膜或聚氯乙烯膜中的任意一种；
    优选地，所述粘结层的克重为20～60gsm。
  9. 根据权利要求1～8任一项所述的轻量化隔音垫，其中，所述气凝胶涂层的厚度为1～3mm；
    优选地，所述气凝胶层的克重为800～1500gsm；
    优选地，所述气凝胶涂层的制备原料包括硅气凝胶、水性丙烯酸树脂和溶剂的组合；
    优选地，所述气凝胶涂层的制备原料按照重量份包括如下组分：硅气凝胶25～40重量份、水性丙烯酸树脂15～20重量份和溶剂40～60重量份；
    优选地，所述溶剂包括水。
  10. 一种如权利要求1～9任一项所述轻量化隔音垫的制备方法，其包括如下步骤：
    (1)将气凝胶涂层的制备原料涂覆在隔音层的一侧，得到复合层；
    (2)将吸音层、粘结层和步骤(1)得到的复合层中的气凝胶涂层依次连接，热压，得到所述轻量化隔音垫。
  11. 根据权利要求10所述的制备方法，其中，步骤(1)所述涂覆的方法包括刷涂、喷涂或辊涂中的任意一种。
  12. 根据权利要求10或11所述的制备方法，其中，步骤(1)所述涂覆后还包括干燥的步骤。
  13. 根据权利要求10～12所述的制备方法，其中，步骤(2)所述热压在蒸汽平板模中进行。
  14. 根据权利要求10～13所述的制备方法，其中，步骤(2)所述热压前还包括抽真空以及充入蒸汽的步骤；
    优选地，所述抽真空后体系的压力为-0.01～-0.08MPa；
    优选地，步骤(2)所述热压的温度为150～200℃；
    优选地，步骤(2)所述热压在6～15MPa的条件下进行；
    优选地，步骤(2)所述热压的保压时间为60～150s。
  15. 一种如权利要求1～9任一项所述的轻量化隔音垫在汽车前围内的应用。
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