CN115593032A - 一种吸音隔音垫及其制备方法和应用 - Google Patents

一种吸音隔音垫及其制备方法和应用 Download PDF

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CN115593032A
CN115593032A CN202211337695.3A CN202211337695A CN115593032A CN 115593032 A CN115593032 A CN 115593032A CN 202211337695 A CN202211337695 A CN 202211337695A CN 115593032 A CN115593032 A CN 115593032A
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sound
woven fabric
absorbing
layer
density
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过佳伟
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Wuxi Jixing Auto Acoustic Parts Technology Co Ltd
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Wuxi Jixing Auto Acoustic Parts Technology Co Ltd
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    • B60R13/08—Insulating elements, e.g. for sound insulation
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Abstract

本发明提供了一种吸音隔音垫及其制备方法和应用。本发明的吸音隔音垫，包括从上至下依次设置的表层、中间层和底层，所述表层为高密度无纺布。本发明的吸音隔音垫，不增加整体的厚度和面密度的前提下，实现了隔音垫整体在较宽频段内保持较高的吸声性能。

Description

一种吸音隔音垫及其制备方法和应用
技术领域
本发明属于技术领域，涉及一种吸音隔音垫及其制备方法和应用。
背景技术
声学包零件是汽车噪声控制的一个重要手段，包含前围隔音垫、地毯隔音垫等兼具吸隔音性能的零件，以及机盖隔音垫、前围外隔音垫、轮弧罩、底护板等以吸音性能为主的零件。以吸音为主的零件主要布置于噪声源例如发动机、电机等的附近，从源头上对噪声进行吸收控制。
吸音型隔音垫通常由表层材料、多孔材料和底层材料复合而成。其中，多孔材料主要有玻璃棉、回纺棉、轻质PU等，对吸音性能起主要作用。现有技术中的表层材料一般采用普通无纺布，主要起到遮盖保护多孔材料和满足外观要求的作用，但是，普通无纺布对于整体的吸音性能无明显作用。
CN217197227U公开了一种高吸音隔音垫，包括复合而成的表层、中间层和底层，其中表层的外侧面设置为平面，用于反射部分声能，表层的与中间层贴合的内侧面上设置有阵列排布的凹槽，从而与中间层之间形成吸收中低频声音的空气腔，中间层用于吸收中高频声音。该高吸音隔音垫主要对现有隔音垫的表层进行了优化设计，在保证了隔音垫的中高频吸音性能的同时，提升了中低频吸音性能，不影响原结构厚度、面密度及工艺，保证了隔音垫整体能在较宽频段内保持较高的吸声水平，效果明显。但是，该高吸音隔音垫的表层采用单层纤维结构，纤维材质为PP、PET、PA、PLA中任一种，但其中低频吸音效果有待进一步提高。
CN109304923A公开了一种汽车发动机底部隔音垫的生产方法，其主要采用下层PET无纺布、玻璃棉、轻质PU和上层PET无纺布，通过原材料的铺放、热模保压成型带冲切、后处理和装箱制备得到产品汽车发动机底部隔音垫。本发明工艺流程简单，减少了生产环节和工装的投入，降低了人工成本，而且冲切产品尺寸稳定，有效的提高了生产效率、保证了产品质量，此外，生产过程无任何有害物质的产生，属于环保产品。该发明实现了发动机底部隔音垫轻量化、良好的吸音要求的指标，有效的降低了发动机的噪音，满足了整车声学设计的要求，但是，上下层均采用PET无纺布，中低频吸音效果同样需要进一步提高。
发明内容
针对现有技术的不足，本发明的目的在于提供一种吸音隔音垫及其制备方法和应用，制得的吸音隔音垫，不增加整体的厚度和面密度的前提下，实现了隔音垫整体的吸音性能在较宽频段内保持较高的吸声性能。
本发明的目的之一在于提供一种吸音隔音垫，为达此目的，本发明采用以下技术方案：
一种吸音隔音垫，包括从上至下依次设置的表层、中间层和底层，所述表层为高密度无纺布。
本发明的表层采用高密度无纺布，代替传统的无纺布，在不增加整体的厚度和面密度的前提下，使得隔音垫中低频吸音性能得到提升，且使中间层材料本身的中高频吸音作用继续保持，能够使隔音垫整体的吸音性能在较宽频段内保持较高的吸声性能。
本发明的表层为高密度无纺布，当入射声能到达表层时，会有部分声能被反射，部分通过表层达中间层。由于表层材料致密无较大的孔洞，低频声音在通过表层时在纤维交织形成的空腔时，摩擦转化的程度相对较高，使得低频较多的被吸收。
本发明中，所述高密度无纺布的克重为50-200gsm，例如为50gsm、60gsm、70gsm、80gsm、90gsm、100gsm、110gsm、120gsm、130gsm、140gsm、150gsm、160gsm、170gsm、180gsm、190gsm、200gsm等；所述高密度无纺布的密度为0.03-0.05g/cm3，例如为0.03g/cm3、0.035g/cm3、0.04g/cm3、0.045g/cm3、0.05g/cm3等。选用上述规格的高密度无纺布，在满足美观要求的同时还能对声学性能起到提升作用。
本发明的中间层用于吸收中高频声音，中间层采用具有多孔结构的多孔材料，声音进入多孔材料的内部，引起孔隙中空气的振动，通过空气的黏滞阻力、空气与多孔材料骨架之间的摩擦和热传导作用等，使得声能转化为热能而被耗散掉，从而达到吸音的目的。
本发明中，所述中间层为多孔材料。
所述多孔材料的克重为1000-1800gsm，例如为1000gsm、1100gsm、1200gsm、1300gsm、1400gsm、1500gsm、1600gsm、1700gsm、1800gsm等；厚度为10-25mm，例如为10mm、11mm、12mm、13mm、14mm、15mm、16mm、17mm、18mm、19mm、20mm、21mm、22mm、23mm、24mm、25mm等。
所述中间层为玻璃棉、回纺棉或轻质PU中的一种。
所述底层为针刺无纺布或高密度无纺布。
所述底层的克重为50-120gsm，例如为50gsm、60gsm、70gsm、80gsm、90gsm、100gsm、110gsm、120gsm等。
本发明的目的之二在于提供一种目的之一所述的吸音隔音垫的制备方法，包括如下步骤：
(1)材料铺放：将无纺布、玻璃棉、高密度无纺布叠加铺设在成型模具上；
(2)成型：将热成型模具闭合，保压使玻璃棉固化成型。
步骤(2)中，所述成型的温度为200-220℃，例如为200℃、205℃、210℃、215℃、220℃等；所述成型的压力为20-22MPa，例如为20MPa、21MPa、22MPa等；所述保压的时间为60-70s，例如为60s、61s、62s、63s、64s、65s、66s、67s、68s、69s、70s等。
本发明的目的之三在于提供一种目的之一所述的吸音隔音垫的应用，将所述吸音隔音垫用于汽车声学包零件的制备。
与现有技术相比，本发明的有益效果为：
本发明的吸音隔音垫，在不增加整体的厚度和面密度的前提下，实现了隔音垫整体的吸音性能在较宽频段内保持较高的吸声性能。具体的，制得的吸音隔音垫在1000Hz的吸音系数为0.87-0.99，耐热性良好，可耐100摄氏度的高温不变形；本发明的吸音隔音垫在使用相同中间层与底层的情况下，表层材料使用高密度无纺布，在400-4000Hz上吸声系数均高于普通无纺布，在5000-8000Hz上也有相当的水准。
附图说明
图1为本发明的吸音隔音垫的结构示意图；
图2为图1的表层高密度无纺布的表面的结构示意图；
图3为现有技术中普通无纺布的表面的结构示意图；
图4为实施例1与对比例1的吸音隔音垫的吸音效果对比图；
附图标记如下：
1-表层；2-中间层；3-底层。
具体实施方式
下面结合附图1-4，并通过具体实施方式来进一步说明本发明的技术方案。
如无具体说明，本发明的各种原料均可市售购得，或根据本领域的常规方法制备得到。
如图1所示，本发明的吸音隔音垫，包括从上至下依次设置的表层、中间层和底层，其中，表层为高密度无纺布。
如图2所示，高密度无纺布由长纤维丝制成，连续的长纤维在其表面随机交错堆叠，使其具有致密的表层，表面光滑无绒毛，相对于传统针刺无纺布来说，其没有常规针刺留下的针孔。
如图3所示，现有技术中中间层采用的普通无纺布，由短纤维针刺工艺制成。
实施例1
本实施例的吸音隔音垫，包括从上至下依次设置的表层、中间层和底层，其中，表层为高密度无纺布，克重为50gsm；中间层为玻璃棉，克重1200gsm，厚度20mm；底层为普通针刺无纺布，克重50gsm。
本实施例的吸音隔音垫的制备方法，包括如下步骤：
(1)材料铺放：将克重为50gsm的普通无纺布、克重为1200gsm的玻璃棉、克重为50gsm的高密度无纺布依次叠加铺设在成型模具上。
(2)成型：将热成型模具闭合，模具温度200℃，成型压力20MPa，保压60s使玻璃棉固化成型。
实施例2
本实施例的吸音隔音垫，包括从上至下依次设置的表层、中间层和底层，其中，表层为高密度无纺布，克重为120gsm；中间层为玻璃棉，克重1600gsm，厚度20mm；底层为普通针刺无纺布，克重100gsm。
本实施例的吸音隔音垫的制备方法，包括如下步骤：
(1)材料铺放：将克重为100gsm的普通无纺布、克重为1600gsm的玻璃棉、克重为120gsm的高密度无纺布依次叠加铺设在成型模具上。
(2)成型：将热成型模具闭合，模具温度200℃，成型压力20MPa，保压70s使玻璃棉固化成型。
实施例3
本实施例的吸音隔音垫，包括从上至下依次设置的表层、中间层和底层，其中，表层为高密度无纺布，克重为200gsm；中间层为玻璃棉，克重1800gsm，厚度25mm；底层为普通针刺无纺布，克重120gsm。
本实施例的吸音隔音垫的制备方法，包括如下步骤：
(1)材料铺放：将克重为120gsm的普通无纺布、克重为1800gsm的玻璃棉、克重为200gsm的高密度无纺布依次叠加铺设在成型模具上。
(2)成型：将热成型模具闭合，模具温度200℃，成型压力20MPa，保压70s使玻璃棉固化成型。
实施例4
本实施例与实施例1的区别之处在于，中间层替换为回纺棉，其他的与实施例1的均相同。
实施例5
本实施例与实施例1的区别之处在于，中间层替换为轻质PU，其他的与实施例1的均相同。
实施例6
本实施例与实施例1的区别之处在于，多孔材料的克重为2200gsm，厚度为25mm，其他的与实施例1的均相同。
对比例1
本对比例与实施例1的区别之处在于，表层高密度无纺布替换为普通的针刺无纺布，其他的与实施例1的均相同。
对比例2
本对比例与实施例1的区别之处在于，表层高密度无纺布替换为水刺无纺布，其他的与实施例1的均相同。
对比例3
本对比例与实施例1的区别之处在于，高密度无纺布的克重为10gsm，其他的与实施例1的均相同。
对比例4
本对比例与实施例1的区别之处在于，高密度无纺布的克重为400gsm，其他的与实施例1的均相同。
将实施例1-6与对比例1-4制得的吸音隔音垫进行性能测试，测试结果如表1所示，图4为实施例1与对比例1的吸音隔音垫的吸音效果对比图。
其中，吸音效果测试参照Alpha Cabin测试方法进行，尺寸为1m*1.2m的样件放置在中进行测试，环境温度22.3摄氏度，相对湿度64％，耐热性能参照本领域的常规测试方法，将产品放置于100摄氏度的恒温试验箱中，观察外观是否有变化，无明显变化为合格。
表1
Figure BDA0003915141880000071
Figure BDA0003915141880000081
由表1可以看出，本发明制得的吸音隔音垫在不增加整体的厚度和面密度的前提下，实现了隔音垫整体的吸音性能在较宽频段内保持较高的吸声性能。具体的，制得的吸音隔音垫在1000Hz的吸音系数为0.87-0.99，耐热性良好，可耐100摄氏度的高温不变形；本发明的吸音隔音垫在使用相同中间层与底层的情况下，表层材料使用高密度无纺布，在400-4000Hz上吸声系数均高于普通无纺布，在5000-8000Hz上也有相当的水准。
由图4可以看出，本发明的吸音隔音垫在使用相同中间层与底层的情况下，表层材料使用高密度无纺布，在400-4000Hz上吸声系数均高于普通无纺布，在5000-8000Hz上也有相当的水准。
本发明通过上述实施例来说明本发明的详细工艺设备和工艺流程，但本发明并不局限于上述详细工艺设备和工艺流程，即不意味着本发明必须依赖上述详细工艺设备和工艺流程才能实施。所属技术领域的技术人员应该明了，对本发明的任何改进，对本发明产品各原料的等效替换及辅助成分的添加、具体方式的选择等，均落在本发明的保护范围和公开范围之内。
以上详细描述了本发明的优选实施方式，但是，本发明并不限于上述实施方式中的具体细节，在本发明的技术构思范围内，可以对本发明的技术方案进行多种简单变型，这些简单变型均属于本发明的保护范围。
另外需要说明的是，在上述具体实施方式中所描述的各个具体技术特征，在不矛盾的情况下，可以通过任何合适的方式进行组合，为了避免不必要的重复，本发明对各种可能的组合方式不再另行说明。
此外，本发明的各种不同的实施方式之间也可以进行任意组合，只要其不违背本发明的思想，其同样应当视为本发明所公开的内容。

Claims (10)

1.一种吸音隔音垫，其特征在于，包括从上至下依次设置的表层、中间层和底层，所述表层为高密度无纺布，所述高密度无纺布的克重为50-200gsm，密度为0.03-0.05g/cm3。
2.根据权利要求1所述的吸音隔音垫，其特征在于，所述中间层为多孔材料。
3.根据权利要求2所述的吸音隔音垫，其特征在于，所述多孔材料的克重为1000-1800gsm，厚度为10-25mm。
4.根据权利要求1-3之一所述的吸音隔音垫，其特征在于，所述中间层为玻璃棉、回纺棉或轻质PU中的一种。
5.根据权利要求1-4之一所述的吸音隔音垫，其特征在于，所述底层为针刺无纺布或高密度无纺布。
6.根据权利要求1-5之一所述的吸音隔音垫，其特征在于，所述底层的克重为50-120gsm。
7.一种如权利要求1-6任一项所述的吸音隔音垫的制备方法，其特征在于，包括如下步骤：
(1)材料铺放：将无纺布、玻璃棉、高密度无纺布叠加铺设在成型模具上；
(2)成型：将热成型模具闭合，保压使玻璃棉固化成型。
8.根据权利要求7所述的制备方法，其特征在于，步骤(2)中，所述成型的温度为200-220℃，所述成型的压力为20-22MPa。
9.根据权利要求7所述的制备方法，其特征在于，步骤(2)中，所述保压的时间为60-70s。
10.一种如权利要求1-6任一项所述的吸音隔音垫的应用，其特征在于，所述吸音隔音垫用于汽车声学包零件的制备。
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Publication number Priority date Publication date Assignee Title
JP2006028708A (ja) * 2004-07-21 2006-02-02 Asahi Kasei Fibers Corp 吸音性積層体およびその製造法
JP2010085873A (ja) * 2008-10-02 2010-04-15 Kuraray Kuraflex Co Ltd 複層吸音材
CN104441876A (zh) * 2013-09-25 2015-03-25 东丽纤维研究所（中国）有限公司 一种汽车用复合层状吸音材料
CN217197227U (zh) * 2022-03-03 2022-08-16 无锡吉兴汽车声学部件科技有限公司 一种高吸音隔音垫

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2006028708A (ja) * 2004-07-21 2006-02-02 Asahi Kasei Fibers Corp 吸音性積層体およびその製造法
JP2010085873A (ja) * 2008-10-02 2010-04-15 Kuraray Kuraflex Co Ltd 複層吸音材
CN104441876A (zh) * 2013-09-25 2015-03-25 东丽纤维研究所（中国）有限公司 一种汽车用复合层状吸音材料
CN217197227U (zh) * 2022-03-03 2022-08-16 无锡吉兴汽车声学部件科技有限公司 一种高吸音隔音垫

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