CN111907141B - 一种吸音降噪阻燃材料及其制备方法 - Google Patents
一种吸音降噪阻燃材料及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种吸音降噪阻燃材料及其制备方法,涉及吸音阻燃材料加工技术领域,上述材料包括碳纤维5‑10份、再生棉纤维15‑30份、聚酯纤维2‑6份、低熔点热塑性纤维15‑20份以及无纺纤维20‑30份,上述制备方法包括开松处理、一次针刺、浸渍烘干、焙烘、水洗烘干、二次针刺、打蒸汽、合模成型及切割等步骤,本发明还公开了用于浸渍阻燃剂及烘干处理的浸渍烘干一体机,本发明的混合毡采用了多种材料进行混合,通过浸渍阻燃剂,不仅具有优良的吸音、阻燃性能,而且还具有良好的热塑成型性能,通过对二次针刺后的混合毡半成品进行打蒸汽,使其进一步蓬松,提高了吸音性能,同时具有一定的减震效果。
Description
技术领域
本发明属于吸音阻燃材料加工技术领域,具体涉及一种吸音降噪阻燃材料及其制备方法。
背景技术
国内汽车降噪毛毡的传统制造方法一般是使用杂棉、回纺棉与酚醛树脂等混纺制作成不同尺寸规格、面密度相同的毛毡片材,在对材料加热后,再经模压固化形成毛毡制品。上述材料虽具有一定的降噪功能,但仍然存在不足,且成型后的材料密度较大,虽然具有很好的强度和抗拉伸性能,但牺牲了较多的吸音降噪效果。
目前,市场上的隔音材料多种多样,不同成分的材料,其隔音效果及力学性能(如拉伸强度)会存在较大区别,且现有的混合毡的热塑成型性能有待提高,此外,传统的生产工艺需要在基材上浸渍阻燃剂,目前主要有两种方式:一种是将基材借助于导向辊弯曲并引入到盛有浸润剂的储液箱内,另外一种是处采用淋浴的方式。对于前者,引导辊需要给混合毡一个较大的张紧力,使得混合毡在经由引导辊时,其内部的阻燃剂容易被挤出而影响浸渍效果,同时也造成了引导辊的清理维护的不方便以及送料速度慢的缺陷,在浸渍阻燃剂后还需要经过扎液,容易造成混合毡在烘干后产生严重的褶皱、紧绷。对于后者,容易存在浸润不充分的情况。
发明内容
本发明的目的在于提供一种吸音降噪阻燃材料及其制备方法,以解决现有技术中导致的上述缺陷。
一种吸音降噪阻燃材料,包括如下重量份的材料:
碳纤维5-10份、再生棉纤维15-30份、聚酯纤维2-6份、低熔点热塑性纤维15-20份以及无纺纤维20-30份,上述材料的规格均为:粗度6-20D,长度20-100mm。
一种吸音降噪阻燃材料的制备方法,包括如下步骤:
(1)开松处理,按比例取一定量的碳纤维、再生棉纤维、聚酯纤维、低熔点热塑性纤维以及无纺纤维,分别经由五台电子开包机上料混合,再由混合机组输送帘将混合后的原料输送到精开松机进行开松打散,接着利用梳理机梳理均匀,然后经铺网机将上述混合纤维铺网形成混合纤维网面;
(2)一次针刺,将纤维网送入针刺机内进行第一道针刺,针刺针频为40-50HZ,针刺密度为310-330针/cm2,针刺深度为7-10mm,形成初步的混合毡;
(3)浸渍烘干,将初步的混合毡水平通过浸渍烘干一体机,混合毡先通过浸渍烘干一体机内的液态阻燃剂并在其表面浸渍阻燃剂,随后再经浸渍烘干一体机尾部的烘干组件进行迅速烘干,以烘干其表面的液态阻燃剂,此过程中混合毡的送料速度为10-15cm/s,烘干温度为185-200℃;
(4)焙烘,将上述烘干后的混合毡再经温度为150-170℃,时间为45-60s的焙烘处理;
(5)水洗烘干,将上述焙烘后的混合毡经水洗处理并烘干;
(6)二次针刺,将步骤(6)烘干后的混合毡再进行一次针刺处理,获得混合毡半成品,针刺针频为30-40HZ,针刺密度为230-250针/cm2,针刺深度为1-2mm;
(7)打蒸汽,将步骤(6)针刺后的混合毡半成品切成块状并放入到蒸汽模中,合上蒸汽模,通过蒸汽模将蒸汽机内的蒸汽打入到混合毡半成品内;
(8)合模成型及切割,将经蒸汽加热后的混合毡铺设于冷成型模内,共铺设两层,且在两层之间涂抹有胶黏物,冷成型模合模,成型结束后,由机械手抓取并置于切割设备上切割成特定尺寸,即可获得所需的产品。
优选的,所述步骤(7)中控制蒸汽机的压力为30-35MPa,蒸汽模的加热温度控制在230-235℃,加热时间保持在25-35s。
优选的,所述步骤(8)中模压机主缸压力为8-10MPa,保压时间为40-45s。
优选的,所述浸渍烘干一体机包括储液箱、进气箱、混合机构、稳流机构、抬升机构以及驱动机构,所述储液箱的底部安装有支腿,储液箱的两侧分别设有进料口和出料口,所述进气箱分别安装于进料口和出料口的外侧并用于将位于进料口、出料口内侧的液体吹开,位于出料口一侧的进气箱内还安装有烘干组件以实现混合毡的烘干处理,所述混合机构安装于储液箱内并用于对储液箱内的液体进行搅拌,使其形成环流,所述稳流机构安装于储液箱内并通过驱动机构驱动连接至位于出料口一侧的进气箱,以实现稳流机构的启闭,所述稳流机构用于促使储液箱两侧的液体趋于稳定,所述抬升机构安装于储液箱的底部并用于将储液箱内的液体抬升且在其到达最高点时能够驱动混合机构运作。
优选的,所述进气箱包括端板和罩体,罩体的上下两端均安装有进气管,端板和罩体上均设置有用于混合毡穿过的导向孔;
位于出料端一侧的进气箱的长度大于另外一个进气箱的长度,位于出料端一侧的进气箱内安装有导向块并将进入到进气箱内的气流分隔成两部分,一部分进入到储液箱内,另一部分进入到烘干组件内,所述烘干组件包括对称设置于进气箱内的电加热网和导风板,导风板上设有若干倾斜的透气孔,所述电加热网和导风板均水平安装于进风箱内,且导风板位于混合毡的上下两侧,电加热网、罩体、导向块构成了一个烘干室。
优选的,所述混合机构有两个并对称安装于储液箱内,具体包括转动架、齿圈、搅拌叶片以及转轴,所述转轴安装于转动架上且其一端转动连接于储液箱的侧壁上,所述齿圈安装于转动架的外圈上,齿圈一侧的转动架的外圈上安装有若干所述的搅拌叶片,上述搅拌叶片沿着转动架的轴心周向布置,两个转轴通过联轴器连接形成一体;
所述抬升机构包括底板、液压缸以及导柱,所述底板滑动连接于储液箱内,且其下端连接至液压缸的输出端,所述导柱固定于底板的底面并滑动连接于储液箱的底部,所述底板的顶面对称安装有两个动力机构,具体包括两个对称布置的支座,支座上转动连接有驱动齿轮,其中一个驱动齿轮连接至驱动电机的输出端。
优选的,所述稳流机构包括两个对称设置的稳流板,稳流板上设有若干通孔且稳流板上还设有与转轴相配合的U形缺口,稳流板的前后两侧安装有伸缩机构,所述伸缩机构借助于横板固定于储液箱内,伸缩机构包括活塞筒、活塞杆以及活塞,活塞筒安装于横板上,活塞杆的下端连接至所述的活塞并借助于活塞滑动连接于活塞筒内,活塞筒的下端设有进气口;
所述驱动机构包括直管、滑杆、驱动杆以及支板,所述直管上设有一横向的进风通道和排风通道且二者同轴设置,进风通道和排风通道通过连接管分别连接至烘干室和进气口,滑杆滑动连接于直管内且其下端连接至驱动杆,驱动杆安装于支板的一端,支板的另一端连接至导柱上,所述滑杆下部设有与进风通道相配合的连接孔,滑杆的上部设有L形的泄压孔,泄压孔的上端与大气连通。
本发明的优点在于:
(1)本发明的混合毡采用了多种材料进行混合,通过浸渍阻燃剂,不仅具有优良的吸音、阻燃性能,而且还具有良好的热塑成型性能(聚酯纤维的加入),生产过程中,通过控制好针刺参数、烘干温度及时间等,虽然厚度较薄,但产品最终达到了预期要求;
(2)本发明中通过对二次针刺后的混合毡半成品进行打蒸汽,使其进一步蓬松,提高了吸音性能,同时具有一定的减震效果;
(3)本发明中,采用了水平式的浸渍烘干处理方式,也即混合毡在合理的送料速度下经由抬升后的液态阻燃剂,直接浸渍阻燃剂,再由烘干组件烘干处理,无需弯曲混合毡以及设置引导辊,在不降低送料速度的前提下,混合毡能够锁住更多的阻燃剂,且由于引导辊没有与浸润剂直接接触,也降低了引导辊后期的清理维护难度,省去了扎液过程,降低了后期产品褶皱、紧绷的程度,采用较低深度的针刺即可实现混合毡蓬松的效果,提高了隔音效果;此外,由于进料口和出料口的高速气流的作用,能够将附着于混合毡表面的杂质及多余阻燃剂清除,以加速烘干过程。
附图说明
图1为本发明的工艺流程图。
图2为本发明中浸渍烘干一体机的结构示意图。
图3为出料口处进气箱部分的局部放大图。
图4为混合机构及动力机构所处位置的侧视图。
图5为稳流机构所处位置的侧视图。
其中,1-储液箱,2-进气箱,21-端板,22-罩体,23-进气管,24-导向孔,3-混合机构,31-转动架,32-齿圈,33-搅拌叶片,34-转轴,35-联轴器,4-稳流机构,41-稳流板,43-U形缺口,44-伸缩机构,441-活塞筒,442-活塞杆,443-活塞,445-进气口,5-抬升机构,51-底板,52-液压缸,53-导柱,6-驱动机构,61-直管,62-滑杆,63-驱动杆,64-支板,65-进风通道,66-排风通道,67-连接孔,68-泄压孔,7-动力机构,71-支座,72-驱动齿轮,73-驱动电机,8-进料口,9-出料口,10-烘干组件,101-导向块,102-电加热网,103-导风板,104-透气孔,11-液位传感器。
具体实施方式
为使本发明实现的技术手段、创作特征、达成目的与功效易于明白了解,下面结合具体实施方式,进一步阐述本发明。
实施例1
如图2所示,一种吸音降噪阻燃材料,包括如下重量份的材料:
碳纤维5份、再生棉纤维15份、聚酯纤维2份、低熔点热塑性纤维15份以及无纺纤维20份,上述材料的规格均为:粗度6D,长度100mm。
一种吸音降噪阻燃材料的制备方法,包括如下步骤:
(1)开松处理,按比例取一定量的碳纤维、再生棉纤维、聚酯纤维、低熔点热塑性纤维以及无纺纤维,分别经由五台电子开包机上料混合,再由混合机组输送帘将混合后的原料输送到精开松机进行开松打散,接着利用梳理机梳理均匀,然后经铺网机将上述混合纤维铺网形成混合纤维网面;
(2)一次针刺,将纤维网送入针刺机内进行第一道针刺,针刺针频为40HZ,针刺密度为310针/cm2,针刺深度为10mm,形成初步的混合毡;
(3)浸渍烘干,将初步的混合毡水平通过浸渍烘干一体机,混合毡先通过浸渍烘干一体机内的液态阻燃剂并在其表面浸渍阻燃剂,随后再经浸渍烘干一体机尾部的烘干组件进行迅速烘干,以烘干其表面的液态阻燃剂,此过程中混合毡的送料速度为10cm/s,烘干温度为185℃;
(4)焙烘,将上述烘干后的混合毡再经温度为150℃,时间为60s的焙烘处理;
(5)水洗烘干,将上述焙烘后的混合毡经水洗处理并烘干;
(6)二次针刺,将步骤(6)烘干后的混合毡再进行一次针刺处理,获得混合毡半成品,针刺针频为30HZ,针刺密度为230针/cm2,针刺深度为2mm;
(7)打蒸汽,将步骤(6)针刺后的混合毡半成品切成块状并放入到蒸汽模中,合上蒸汽模,通过蒸汽模将蒸汽机内的蒸汽打入到混合毡半成品内,控制蒸汽机的压力为30MPa,蒸汽模的加热温度控制在230℃,加热时间保持在35s;
(8)合模成型及切割,将经蒸汽加热后的混合毡铺设于冷成型模内,共铺设两层,且在两层之间涂抹有胶黏物,冷成型模合模,模压机主缸压力为8MPa,保压时间为45s,成型结束后,由机械手抓取并置于切割设备上切割成特定尺寸,即可获得所需的产品。
实施例2
一种吸音降噪阻燃材料,包括如下重量份的材料:
碳纤维7份、再生棉纤维20份、聚酯纤维5份、低熔点热塑性纤维18份以及无纺纤维25份,上述材料的规格均为:粗度12D,长度60mm。
一种吸音降噪阻燃材料的制备方法,包括如下步骤:
(1)开松处理,按比例取一定量的碳纤维、再生棉纤维、聚酯纤维、低熔点热塑性纤维以及无纺纤维,分别经由五台电子开包机上料混合,再由混合机组输送帘将混合后的原料输送到精开松机进行开松打散,接着利用梳理机梳理均匀,然后经铺网机将上述混合纤维铺网形成混合纤维网面;
(2)一次针刺,将纤维网送入针刺机内进行第一道针刺,针刺针频为45HZ,针刺密度为320针/cm2,针刺深度为8mm,形成初步的混合毡;
(3)浸渍烘干,将初步的混合毡水平通过浸渍烘干一体机,混合毡先通过浸渍烘干一体机内的液态阻燃剂并在其表面浸渍阻燃剂,随后再经浸渍烘干一体机尾部的烘干组件进行迅速烘干,以烘干其表面的液态阻燃剂,此过程中混合毡的送料速度为12cm/s,烘干温度为190℃;
(4)焙烘,将上述烘干后的混合毡再经温度为160℃,时间为50s的焙烘处理;
(5)水洗烘干,将上述焙烘后的混合毡经水洗处理并烘干;
(6)二次针刺,将步骤(6)烘干后的混合毡再进行一次针刺处理,获得混合毡半成品,针刺针频为35HZ,针刺密度为240针/cm2,针刺深度为1.5mm;
(7)打蒸汽,将步骤(6)针刺后的混合毡半成品切成块状并放入到蒸汽模中,合上蒸汽模,通过蒸汽模将蒸汽机内的蒸汽打入到混合毡半成品内,控制蒸汽机的压力为32MPa,蒸汽模的加热温度控制在232℃,加热时间保持在30s;
(8)合模成型及切割,将经蒸汽加热后的混合毡铺设于冷成型模内,共铺设两层,且在两层之间涂抹有胶黏物,冷成型模合模,模压机主缸压力为9MPa,保压时间为42s,成型结束后,由机械手抓取并置于切割设备上切割成特定尺寸,即可获得所需的产品。
实施例3
一种吸音降噪阻燃材料,包括如下重量份的材料:
碳纤维10份、再生棉纤维30份、聚酯纤维6份、低熔点热塑性纤维20份以及无纺纤维30份,上述材料的规格均为:粗度20D,长度20mm。
一种吸音降噪阻燃材料的制备方法,包括如下步骤:
(1)开松处理,按比例取一定量的碳纤维、再生棉纤维、聚酯纤维、低熔点热塑性纤维以及无纺纤维,分别经由五台电子开包机上料混合,再由混合机组输送帘将混合后的原料输送到精开松机进行开松打散,接着利用梳理机梳理均匀,然后经铺网机将上述混合纤维铺网形成混合纤维网面;
(2)一次针刺,将纤维网送入针刺机内进行第一道针刺,针刺针频为50HZ,针刺密度为330针/cm2,针刺深度为7mm,形成初步的混合毡;
(3)浸渍烘干,将初步的混合毡水平通过浸渍烘干一体机,混合毡先通过浸渍烘干一体机内的液态阻燃剂并在其表面浸渍阻燃剂,随后再经浸渍烘干一体机尾部的烘干组件进行迅速烘干,以烘干其表面的液态阻燃剂,此过程中混合毡的送料速度为15cm/s,烘干温度为200℃;
(4)焙烘,将上述烘干后的混合毡再经温度为170℃,时间为45s的焙烘处理;
(5)水洗烘干,将上述焙烘后的混合毡经水洗处理并烘干;
(6)二次针刺,将步骤(6)烘干后的混合毡再进行一次针刺处理,获得混合毡半成品,针刺针频为40HZ,针刺密度为250针/cm2,针刺深度为1mm;
(7)打蒸汽,将步骤(6)针刺后的混合毡半成品切成块状并放入到蒸汽模中,合上蒸汽模,通过蒸汽模将蒸汽机内的蒸汽打入到混合毡半成品内,控制蒸汽机的压力为35MPa,蒸汽模的加热温度控制在235℃,加热时间保持在25s;
(8)合模成型及切割,将经蒸汽加热后的混合毡铺设于冷成型模内,共铺设两层,且在两层之间涂抹有胶黏物,冷成型模合模,模压机主缸压力为10MPa,保压时间为40s,成型结束后,由机械手抓取并置于切割设备上切割成特定尺寸,即可获得所需的产品。
如图2至图5所示,本发明中,为了提高生产效率以及获得良好性能的产品,设计出了应用于本产品的浸渍烘干一体机,具体包括储液箱1、进气箱2、混合机构3、稳流机构4、抬升机构5以及驱动机构6,所述储液箱1的底部安装有支腿,储液箱1的两侧分别设有进料口8和出料口9,所述进气箱2分别安装于进料口8和出料口9的外侧并用于将位于进料口8、出料口9内侧的液体吹开,位于出料口9一侧的进气箱2内还安装有烘干组件10以实现混合毡的烘干处理,所述混合机构3安装于储液箱1内并用于对储液箱1内的液体进行搅拌,使其形成环流,所述稳流机构4安装于储液箱1内并通过驱动机构6驱动连接至位于出料口9一侧的进气箱2,以实现稳流机构4的启闭,所述稳流机构4用于促使储液箱1两侧的液体趋于稳定,所述抬升机构5安装于储液箱1的底部并用于将储液箱1内的液体抬升且在其到达最高点时能够驱动混合机构3运作。
在本实施例中,所述进气箱2包括端板21和罩体22,罩体22的上下两端均安装有进气管23,端板21和罩体22上均设置有用于混合毡穿过的导向孔24;
位于出料端一侧的进气箱2的长度大于另外一个进气箱2的长度,位于出料端一侧的进气箱2内安装有导向块101并将进入到进气箱2内的气流分隔成两部分,一部分进入到储液箱1内,另一部分进入到烘干组件10内,所述烘干组件10包括对称设置于进气箱2内的电加热网102和导风板103,所述电加热网102和导风板103均水平安装于进风箱内,且导风板103位于混合毡的上下两侧,导风板103上设有若干倾斜的透气孔104,电加热网102、罩体22、导向块101构成了一个烘干室。
在本实施例中,所述混合机构3有两个并对称安装于储液箱1内,具体包括转动架31、齿圈32、搅拌叶片33以及转轴34,所述转轴34安装于转动架31上且其一端转动连接于储液箱1的侧壁上,此处应做防水密封处理,所述齿圈32安装于转动架31的外圈上,齿圈32一侧的转动架31的外圈上安装有若干所述的搅拌叶片33,上述搅拌叶片33沿着转动架31的轴心周向布置,两个转轴34通过联轴器35连接形成一体;
所述抬升机构5包括底板51、液压缸52以及导柱53,所述底板51滑动连接于储液箱1内,且其下端连接至液压缸52的输出端,所述导柱53固定于底板51的底面并滑动连接于储液箱1的底部,所述底板51的顶面对称安装有两个动力机构7,具体包括两个对称布置的支座71,支座71上转动连接有驱动齿轮72,其中一个驱动齿轮72连接至驱动电机73的输出端。
在本实施例中,所述稳流机构4包括两个对称设置的稳流板41,稳流板41上设有若干通孔且稳流板41上还设有与转轴34相配合的U形缺口43,使得稳流板41在上下运动时,转轴34在U形缺口43内滑动,故不会对转轴34产生干涉,稳流板41的前后两侧安装有伸缩机构44,所述伸缩机构44借助于横板固定于储液箱1内,伸缩机构44包括活塞筒441、活塞杆442以及活塞443,活塞筒441安装于横板上,活塞杆442的下端连接至所述的活塞443并借助于活塞443滑动连接于活塞筒441内,活塞筒441的下端设有进气口445;
所述驱动机构6包括直管61、滑杆62、驱动杆63以及支板64,所述直管61通过其侧面的侧板固定在储液箱1的外侧,直管61上设有一横向的进风通道65和排风通道66且二者同轴设置,进风通道65和排风通道66通过连接管分别连接至烘干室和进气口445,由于活塞筒441有多个,故与活塞筒441连接的连接管形成“工”字形的连接布局,最终汇集到排风通道66处,滑杆62滑动连接于直管61内且其下端连接至驱动杆63,驱动杆63安装于支板64的一端,支板64的另一端连接至导柱53上,所述滑杆62下部设有与进风通道65相配合的连接孔67,滑杆62的上部设有L形的泄压孔68,泄压孔68的上端与大气连通。
本发明中的烘干涂胶一体机工作原理如下:
经一次针刺后的混合毡经由位于进料口8一侧的进气箱2的导向孔24以及进料口8进入到储液箱1内,再经由出料口9一侧的进气箱2的导向孔24及出料口9导出,此过程中,现有鼓风机向进气管23内通入高速气体,接着液压缸52启动,底板51上升并驱使储液箱1内的液态阻燃剂的液面上升至一定高度,该高度可由液位传感器11检测并传递给控制中心,当液面高度不足时,可向储液箱1内补充液态阻燃剂,高速气体经由进料口8和出料口9排入到储液箱1内,将进料口8和出料口9一侧的液态阻燃剂吹开,形成一个凹陷的缓冲区(无液态阻燃剂),抬升后的液面浸没混合毡,实现阻燃剂的浸渍处理,浸渍后的混合毡再经由烘干组件10时,电加热网102处于通电状态,经进气管23通入的高速气体也会进入到烘干室内,加热后的空气经由透气孔104吹至混合毡上,对其进行烘干处理,透气孔104的上端靠近出料口9方向;
上述过程中,稳流机构4及混合机构3的工作过程如下:
底板51上升至最高点后,驱动齿轮72与齿圈32接触,同时启动驱动电机73,驱动电机73驱动驱动齿轮72旋转,进而带动转动架31旋转,故而对液态阻燃剂进行混合搅拌,形成环流,有利于阻燃剂的均匀浸渍。
由于底板51的上升,导柱53也随之上升,带动驱动杆63及滑杆62上升,最终滑杆62上的连接孔67接通进风通道65和排风通道66,烘干室内的气流进入到活塞筒441内,驱使活塞杆442及稳流板41上升,稳流板41的上升可起到稳定进料口8及出料口9处液态阻燃剂的作用,避免因混合机构3的搅拌引起这两处的液面产生较大的波动,降低阻燃剂进入进料口8及出料口9的概率。当底板51下降并恢复至原位时,驱动齿轮72与齿圈32脱离接触,混合机构3停止运行,且滑杆62下降,泄压孔68与排风通道66接通,活塞筒441内的气体流至大气中,稳流板41下降并恢复至原位。
由技术常识可知,本发明可以通过其它的不脱离其精神实质或必要特征的实施方案来实现。因此,上述公开的实施方案,就各方面而言,都只是举例说明,并不是仅有的。所有在本发明范围内或在等同于本发明的范围内的改变均被本发明包含。
Claims (6)
1.一种吸音降噪阻燃材料的制备方法,其特征在于,所述吸音降噪阻燃材料包括如下重量份的材料:
碳纤维5-10份、再生棉纤维15-30份、聚酯纤维2-6份、低熔点热塑性纤维15-20份以及无纺纤维20-30份,上述材料的规格均为:粗度6-20D,长度20-100mm;
上述吸音降噪阻燃材料的制备方法,包括如下步骤:
(1)开松处理,按比例取一定量的碳纤维、再生棉纤维、聚酯纤维、低熔点热塑性纤维以及无纺纤维,分别经由五台电子开包机上料混合,再由混合机组输送帘将混合后的原料输送到精开松机进行开松打散,接着利用梳理机梳理均匀,然后经铺网机将上述混合纤维铺网形成混合纤维网面;
(2)一次针刺,将纤维网送入针刺机内进行第一道针刺,针刺针频为40-50HZ,针刺密度为310-330针/cm2,针刺深度为7-10mm,形成初步的混合毡;
(3)浸渍烘干,将初步的混合毡水平通过浸渍烘干一体机,混合毡先通过浸渍烘干一体机内的液态阻燃剂并在其表面浸渍阻燃剂,随后再经浸渍烘干一体机尾部的烘干组件进行迅速烘干,以烘干其表面的液态阻燃剂,此过程中混合毡的送料速度为10-15cm/s,烘干温度为185-200℃;
(4)焙烘,将上述烘干后的混合毡再经温度为150-170℃,时间为45-60s的焙烘处理;
(5)水洗烘干,将上述焙烘后的混合毡经水洗处理并烘干;
(6)二次针刺,将步骤(6)烘干后的混合毡再进行一次针刺处理,获得混合毡半成品,针刺针频为30-40HZ,针刺密度为230-250针/cm2,针刺深度为1-2mm;
(7)打蒸汽,将步骤(6)针刺后的混合毡半成品切成块状并放入到蒸汽模中,合上蒸汽模,通过蒸汽模将蒸汽机内的蒸汽打入到混合毡半成品内;
(8)合模成型及切割,将经蒸汽加热后的混合毡铺设于冷成型模内,共铺设两层,且在两层之间涂抹有胶黏物,冷成型模合模,成型结束后,由机械手抓取并置于切割设备上切割成特定尺寸,即可获得所需的产品;
所述浸渍烘干一体机包括储液箱(1)、进气箱(2)、混合机构(3)、稳流机构(4)、抬升机构(5)以及驱动机构(6),所述储液箱(1)的底部安装有支腿,储液箱(1)的两侧分别设有进料口(8)和出料口(9),所述进气箱(2)分别安装于进料口(8)和出料口(9)的外侧并用于将位于进料口(8)、出料口(9)内侧的液体吹开,位于出料口(9)一侧的进气箱(2)内还安装有烘干组件(10)以实现混合毡的烘干处理,所述混合机构(3)安装于储液箱(1)内并用于对储液箱(1)内的液体进行搅拌,使其形成环流,所述稳流机构(4)安装于储液箱(1)内并通过驱动机构(6)驱动连接至位于出料口(9)一侧的进气箱(2),以实现稳流机构(4)的启闭,所述稳流机构(4)用于促使储液箱(1)两侧的液体趋于稳定,所述抬升机构(5)安装于储液箱(1)的底部并用于将储液箱(1)内的液体抬升且在其到达最高点时能够驱动混合机构(3)运作。
2.根据权利要求1所述的一种吸音降噪阻燃材料的制备方法,其特征在于:所述步骤(7)中控制蒸汽机的压力为30-35MPa,蒸汽模的加热温度控制在230-235℃,加热时间保持在25-35s。
3.根据权利要求1所述的一种吸音降噪阻燃材料的制备方法,其特征在于:所述步骤(8)中模压机主缸压力为8-10MPa,保压时间为40-45s。
4.根据权利要求1所述的一种吸音降噪阻燃材料的制备方法,其特征在于:所述进气箱(2)包括端板(21)和罩体(22),罩体(22)的上下两端均安装有进气管(23),端板(21)和罩体(22)上均设置有用于混合毡穿过的导向孔(24);
位于出料端一侧的进气箱(2)的长度大于另外一个进气箱(2)的长度,位于出料端一侧的进气箱(2)内安装有导向块(101)并将进入到进气箱(2)内的气流分隔成两部分,一部分进入到储液箱(1)内,另一部分进入到烘干组件(10)内,所述烘干组件(10)包括对称设置于进气箱(2)内的电加热网(102)和导风板(103),导风板(103)上设有若干倾斜的透气孔(104),所述电加热网(102)和导风板(103)均水平安装于进风箱内,且导风板(103)位于混合毡的上下两侧,电加热网(102)、罩体(22)、导向块(101)构成了一个烘干室。
5.根据权利要求1所述的一种吸音降噪阻燃材料的制备方法,其特征在于:所述混合机构(3)有两个并对称安装于储液箱(1)内,具体包括转动架(31)、齿圈(32)、搅拌叶片(33)以及转轴(34),所述转轴(34)安装于转动架(31)上且其一端转动连接于储液箱(1)的侧壁上,所述齿圈(32)安装于转动架(31)的外圈上,齿圈(32)一侧的转动架(31)的外圈上安装有若干所述的搅拌叶片(33),上述搅拌叶片(33)沿着转动架(31)的轴心周向布置,两个转轴(34)通过联轴器(35)连接形成一体;
所述抬升机构(5)包括底板(51)、液压缸(52)以及导柱(53),所述底板(51)滑动连接于储液箱(1)内,且其下端连接至液压缸(52)的输出端,所述导柱(53)固定于底板(51)的底面并滑动连接于储液箱(1)的底部,所述底板(51)的顶面对称安装有两个动力机构(7),具体包括两个对称布置的支座(71),支座(71)上转动连接有驱动齿轮(72),其中一个驱动齿轮(72)连接至驱动电机(73)的输出端。
6.根据权利要求1所述的一种吸音降噪阻燃材料的制备方法,其特征在于:所述稳流机构(4)包括两个对称设置的稳流板(41),稳流板(41)上设有若干通孔且稳流板(41)上还设有与转轴(34)相配合的U形缺口(43),稳流板(41)的前后两侧安装有伸缩机构(44),所述伸缩机构(44)借助于横板固定于储液箱(1)内,伸缩机构(44)包括活塞筒(441)、活塞杆(442)以及活塞(443),活塞筒(441)安装于横板上,活塞杆(442)的下端连接至所述的活塞(443)并借助于活塞(443)滑动连接于活塞筒(441)内,活塞筒(441)的下端设有进气口(445);
所所述驱动机构(6)包括直管(61)、滑杆(62)、驱动杆(63)以及支板(64),所述直管(61)上设有一横向的进风通道(65)和排风通道(66)且二者同轴设置,进风通道(65)和排风通道(66)通过连接管分别连接至烘干室和进气口(445),滑杆(62)滑动连接于直管(61)内且其下端连接至驱动杆(63),驱动杆(63)安装于支板(64)的一端,支板(64)的另一端连接至导柱(53)上,所述滑杆(62)下部设有与进风通道(65)相配合的连接孔(67),滑杆(62)的上部设有L形的泄压孔(68),泄压孔(68)的上端与大气连通。
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