Preparation method of flexible sound insulation material of centrifugal spinning encapsulated spacer fabric

Abstract

The present invention discloses a preparation method of a flexible sound insulation material of centrifugally spun encapsulated spacer fabric, which comprises the following steps: crushing discarded porous materials and fully filling them into a three-dimensional spacer fabric; simultaneously, centrifugal spinning is used to perform multi-directional alternating spinning on the spacer fabric; and the thickness and fiber bulk density of the fiber mesh layer are controlled so that a layer of fiber mesh layer with a rich interlayer structure is wrapped around the surface of the spacer fabric, thereby obtaining a flexible sound insulation material of centrifugally spun encapsulated spacer fabric. On the one hand, the fiber mesh layer is used to encapsulate the spacer fabric; on the other hand, since the fiber mesh layer is prepared by multi-directional alternating centrifugal spinning and has an interlayer structure with certain pores, the sound insulation effect of the flexible sound insulation material can be further improved, and the fiber mesh layer has a certain flexibility, and can also improve the sound insulation effect while making the material have better flexibility.

Description

Technical Field

[0001] The present invention relates to the technical field of flexible sound insulation materials, and in particular to a method for preparing a flexible sound insulation material made of centrifugal spinning packaged spacer fabric. Background Art

[0002] With the development of the times and the improvement of people's environmental awareness, noise pollution has become increasingly important to people, and the demand for sound insulation has also increased significantly. Three-dimensional spacer fabrics are three-dimensional structures composed of two surfaces, upper and lower, and a middle connecting layer. They have excellent compression elasticity, air and moisture permeability, structural stability, and recyclability. Currently, three-dimensional spacer fabric sound-absorbing materials have become a research hotspot in the field of sound absorption and noise reduction.

[0003] Since three-dimensional spacer fabrics are porous, they can be compounded with foams having good sound insulation properties to obtain sound insulation materials with even better sound insulation properties. The traditional compounding method is to encapsulate the two with resin. The shortcomings of this method are: on the one hand, the fluidity of the resin will closely combine with the spacer fabric, causing the original porous structure of the spacer fabric to be destroyed, thereby reducing its sound insulation performance; on the other hand, after the resin is cured, the hardness of the spacer fabric will increase significantly, making the composite material prone to brittle fracture.

[0004] Patent publication number CN104213322A discloses an impact-resistant flexible protective structure and manufacturing method. The structure comprises silicone rubber, a three-dimensional warp-knitted spacer fabric, and a shear thickening fluid containing nano-silica particles and polyethylene glycol. The shear thickening fluid is poured into the middle layer of the warp-knitted spacer fabric, and the silicone rubber encapsulates both sides and all sides of the warp-knitted spacer fabric, forming a leak-proof, bag-like sealed structure. While the silicone rubber encapsulation utilizes its soft properties to enhance the flexibility of the entire flexible protective structure, this approach, when applied to sound insulation materials, can damage the porous structure of the spacer fabric, thereby compromising its sound insulation performance.

[0005] In view of this, it is necessary to design a preparation method of a centrifugal spinning encapsulated spacer fabric flexible sound insulation material to solve the above problems. Summary of the Invention

[0006] The purpose of the present invention is to provide a preparation method of a flexible sound insulation material of a centrifugal spinning encapsulated spacer fabric, by crushing the discarded porous material and filling it into the spacer fabric, and encapsulating the spacer fabric by centrifugal spinning, thereby obtaining a flexible sound insulation material with good sound insulation effect and good flexibility, so as to meet the use scenarios that require flexibility of the sound insulation material.

[0007] To achieve the above-mentioned object of the invention, the present invention provides a method for preparing a flexible sound insulation material of a centrifugal spinning encapsulated spacer fabric, comprising the following steps:

[0008] S1. crushing the waste porous material with a crusher to obtain a filling material with a particle size within a certain range and uniform particle size;

[0009] S2. Fully mixing the filling material prepared in step S1 with the three-dimensional spacer fabric, and generating negative pressure in the three-dimensional spacer fabric so that the filling material is fully filled in the three-dimensional spacer fabric to obtain a spacer fabric filled with a porous material;

[0010] S3. Encapsulate the spacer fabric filled with porous material prepared in step S2 by centrifugal spinning, so that the outer layer of the filled three-dimensional spacer fabric is tightly wrapped with a fiber mesh layer, and obtain a centrifugally spun encapsulated spacer fabric flexible sound insulation material after drying.

[0011] As a further improvement of the present invention, in step S3, when the spacer fabric filled with porous material is encapsulated by centrifugal spinning, the spacer fabric filled with porous material rotates alternately in multiple directions, with a lateral rotation speed of 10-100 r / min and a lateral rotation time of 5-30s; a longitudinal rotation speed of 10-100 r / min and a longitudinal rotation time of 5-30s, and the number of alternating cycles is 3-30 times.

[0012] As a further improvement of the present invention, in step S3, the fiber mesh layer has a thickness of 1-6 mm and a fiber bulk density of 0.01-0.3 g / cm 3 .

[0013] As a further improvement of the present invention, the centrifugal spinning time is 30-900s, the rotation speed is 1000-7000r / min, the temperature is 30-60°C, and the ambient humidity is 30-50%.

[0014] As a further improvement of the present invention, the spinning solution raw material for centrifugal spinning includes any one of glass wool, polyester fiber wool, slag wool, rock wool and aluminum silicate wool.

[0015] As a further improvement of the present invention, in step S1, the waste porous material includes any one of polystyrene foam, polyurethane foam, polyethylene foam, polypropylene foam and polyvinyl chloride foam, or a mixture of several of them.

[0016] As a further improvement of the present invention, in step S1, the diameter of the particles of the crushed waste porous material is less than 1.5 mm.

[0017] As a further improvement of the present invention, in step S2, the three-dimensional spacer fabric has a structure of an upper layer, a lower layer and a connecting layer, and both the upper layer and the lower layer have mesh holes.

[0018] As a further improvement of the present invention, the void filling rate of the three-dimensional spacer fabric is 80%-98%.

[0019] As a further improvement of the present invention, in step S4, the drying temperature is 40°C.

[0020] The beneficial effects of the present invention are:

[0021] 1. The present invention crushes the discarded porous material and fully fills it into the three-dimensional spacer fabric. Compared with the existing method of injecting porous material into the spacer fabric for foaming reaction, the present invention can enhance the sound insulation effect of the spacer fabric while still maintaining its good flexibility. At the same time, multi-directional alternating spinning is performed on the spacer fabric by centrifugal spinning, so that a fiber mesh layer is wrapped around the surface of the spacer fabric. On the one hand, the fiber mesh layer is used to encapsulate the spacer fabric. On the other hand, since the fiber mesh layer is prepared by multi-directional alternating centrifugal spinning, it has an interlayer structure with certain pores, which can further improve the sound insulation effect of the flexible sound insulation material. The fiber mesh layer has a certain flexibility, and can also improve the sound insulation effect while making the material have better flexibility.

[0022] 2. The multi-directional alternating centrifugal spinning method adopted in the present invention, compared with the conventional method of completing transverse spinning first and then longitudinal spinning, can form a certain pore structure between adjacent fiber layers, thereby obtaining a fiber mesh layer with a rich interlayer structure. At the same time, by controlling the thickness and fiber bulk density of the fiber mesh layer, the sound insulation effect of the fiber mesh layer can be effectively improved.

[0023] 3. The present invention utilizes discarded porous materials to prepare flexible sound insulation materials, which can make full use of the waste materials and conform to the concept of green environmental protection. In addition, the preparation method of the present invention is simple, the raw materials are cheap, and the prepared sound insulation materials have good sound insulation effect and good flexibility, which can fully meet the demand for flexible sound insulation materials. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is a schematic diagram of centrifugal spinning packaging;

[0025] Figure 2 Schematic diagram of the three-dimensional spacer fabric before fiber encapsulation;

[0026] Figure 3 This is a schematic diagram of the three-dimensional spacer fabric after fiber encapsulation; DETAILED DESCRIPTION

[0027] In order to make the objectives, technical solutions and advantages of the present invention more clear, the present invention is described in detail below with reference to the accompanying drawings and specific embodiments.

[0028] It should also be noted here that, in order to avoid obscuring the present invention due to unnecessary details, only structures and / or processing steps closely related to the solutions of the present invention are shown in the drawings, while other details that are not closely related to the present invention are omitted.

[0029] In addition, it should be noted that the terms "comprises", "includes" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or apparatus that includes a series of elements includes not only those elements, but also includes other elements not explicitly listed, or also includes elements inherent to such process, method, article or apparatus.

[0030] The present invention provides a method for preparing a flexible sound insulation material of a centrifugal spinning encapsulated spacer fabric, comprising the following steps:

[0031] S1. Grinding the waste porous material with a grinder to obtain a filling material with a particle size of less than 1.5 mm and uniform particle size;

[0032] S2. Fully mixing the filling material prepared in step S1 with the three-dimensional spacer fabric, and generating negative pressure in the three-dimensional spacer fabric so that the filling material is fully filled in the three-dimensional spacer fabric to obtain a spacer fabric filled with a porous material;

[0033] S3. Encapsulate the spacer fabric filled with porous material prepared in step S2 by centrifugal spinning, so that the outer layer of the filled three-dimensional spacer fabric is tightly wrapped with a layer of fiber mesh, and dry at 40°C to obtain a centrifugally spun encapsulated spacer fabric flexible sound insulation material.

[0034] Specifically, in step S1, the waste porous material includes any one of polystyrene foam, polyurethane foam, polyethylene foam, polypropylene foam and polyvinyl chloride foam, or a mixture of several of them.

[0035] Specifically, in step S2, the three-dimensional spacer fabric comprises an upper layer, a lower layer, and a connecting layer, each of which has mesh openings. After being filled with the discarded porous material, the three-dimensional spacer fabric has a void filling rate of 80%-98%. By crushing the discarded porous material and then fully filling it into the three-dimensional spacer fabric, the sound insulation effect of the spacer fabric is enhanced while maintaining its good flexibility. This avoids the existing situation where porous material is injected into the spacer fabric and then foamed and filled, which causes the spacer fabric to lose its inherent flexibility.

[0036] Specifically, in step S3, when the spacer fabric filled with porous material is packaged by centrifugal spinning, the spacer fabric filled with porous material is subjected to multi-directional alternating rotation, with a lateral rotation speed of 10-100 r / min and a lateral rotation time of 5-30s; a longitudinal rotation speed of 10-100 r / min and a longitudinal rotation time of 5-30s, and an alternating cycle number of 3-30 times, thereby preparing a fiber mesh layer with a rich interlayer structure.

[0037] Specifically, in step S3, the fiber mesh layer has a thickness of 1-6 mm and a fiber bulk density of 0.01-0.3 g / cm 3 .

[0038] Specifically, the centrifugal spinning time is 30-900s, the rotation speed is 1000-7000r / min, the temperature is 30-60°C, and the ambient humidity is 30-50%; the spinning solution raw material for centrifugal spinning includes any one of glass wool, polyester fiber wool, slag wool, rock wool and aluminum silicate wool.

[0039] The preparation method of the flexible sound insulation material of the centrifugal spinning packaged spacer fabric provided by the present invention is described below with reference to specific embodiments.

[0040] Example 1

[0041] This embodiment provides a method for preparing a flexible sound insulation material by centrifugal spinning and encapsulating a spacer fabric, comprising the following steps:

[0042] S1. crushing the polyurethane foam with a crusher to obtain a filling material with a particle size of less than 1.5 mm and uniform particle size;

[0043] S2. Fully mixing the filling material prepared in step S1 with the three-dimensional spacer fabric, and generating negative pressure in the three-dimensional spacer fabric so that the filling material is fully filled in the three-dimensional spacer fabric to obtain a spacer fabric filled with a porous material, wherein the void filling rate of the spacer fabric is 90%;

[0044] S3. Encapsulate the spacer fabric filled with porous material prepared in step S2 by centrifugal spinning, so that the outer layer of the filled three-dimensional spacer fabric is tightly wrapped with a layer of fiber mesh, and dry at 40°C to obtain a centrifugally spun encapsulated spacer fabric flexible sound insulation material.

[0045] Furthermore, the spinning solution raw material of the centrifugal spinning is polyester fiber cotton, the centrifugal spinning time is 600s, the rotation speed is 5000r / min, the temperature is 45°C, and the ambient humidity is 40%.

[0046] Furthermore, the transverse rotation speed of the spacer fabric filled with porous material is 50 r / min, the transverse rotation time is 20 s; the longitudinal rotation speed is 60 r / min, the longitudinal rotation time is 20 s, and the number of alternating cycles is 15 times; the fiber mesh layer thickness is 4 mm, and the fiber bulk density is 0.2 g / cm 3 .

[0047] Examples 2 to 3 and Comparative Examples 1 to 4

[0048] Examples 2 to 3 and comparative examples 1 to 4 respectively provide a method for preparing a flexible sound insulation material of a centrifugal spinning encapsulated spacer fabric. Compared with Example 1, the relevant parameter adjustments are shown in Table 1. The remaining steps are consistent with Example 1 and will not be repeated here.

[0049] Table 1 Parameters of the preparation method of flexible sound insulation materials of Examples 1 to 3 and Comparative Examples 1 to 4

[0050]

[0051] Comparative Examples 5-6

[0052] Comparative Examples 5 and 6 respectively provide a method for preparing a flexible sound insulation material of a centrifugal spinning-encapsulated spacer fabric. Compared with Example 1, Comparative Example 5 adopts a centrifugal spinning method of first completing transverse spinning and then completing longitudinal spinning to prepare the fiber mesh layer. The transverse rotation speed is 50r / min, and the transverse rotation time is 300s; the longitudinal rotation speed is 60r / min, and the longitudinal rotation time is 300s.

[0053] Compared with Example 1, in Comparative Example 6, the centrifugal spinning packaging method in step S3 is replaced with resin packaging, the resin and the curing agent are mixed in a ratio of 2:1 to obtain a resin mixture, the resin mixture is evenly applied to the surface of the fabric by hand-paste method, and the fabric is placed in an oven for curing (90°C, 60 min).

[0054] The sound insulation effect and flexibility of the flexible sound insulation materials prepared in Examples 1 to 3 and Comparative Examples 1 to 6 were tested, and the relevant test results are shown in Table 2.

[0055] Table 2 Sound insulation and flexibility test results of flexible sound insulation materials prepared in Examples 1 to 3 and Comparative Examples 1 to 6

[0056] Example Sound insulation effect Stiffness Example 1 36dB 2.73 Example 2 27dB 1.65 Example 3 52dB 4.27 Comparative Example 1 22dB 1.56 Comparative Example 2 57dB 4.88 Comparative Example 3 19dB 1.23 Comparative Example 4 55dB 4.71 Comparative Example 5 29dB 2.93 Comparative Example 6 22dB 6.51

[0057] As shown in Table 2, the flexible sound insulation materials prepared by the method of the present invention have good sound insulation effect and softness. Compared with Example 1, when the thickness of the fiber mesh layer is reduced to 0.5 mm, the sound insulation effect of the sound insulation material prepared in Comparative Example 1 is poor; when the fiber bulk density is reduced to 0.005 g / cm 3When the thickness of the fiber mesh layer exceeds the range specified in the present invention, the sound insulation performance of the sound insulation material prepared in Comparative Example 3 is significantly reduced. Compared with Example 3, when the thickness of the fiber mesh layer exceeds the range specified in the present invention, the sound insulation effect of the sound insulation material prepared in Comparative Example 2 is improved to a certain extent, but at the same time, the stiffness shows a significant increase trend, resulting in poor softness of the sound insulation material. At the same time, the sound insulation material prepared in Comparative Example 4 has poor softness due to the fiber bulk density exceeding the range specified in the present invention.

[0058] Furthermore, the alternating spinning method of Comparative Example 1 enables the sound insulation material to possess a porous interlayer structure, thereby enhancing its sound insulation effect to a certain extent. However, the centrifugal spinning method of Comparative Example 5, which performs transverse spinning followed by longitudinal spinning, lacks this interlayer structure and therefore has poor sound insulation. Furthermore, the resin encapsulation method of Comparative Example 6 exhibits poor sound insulation performance because the resin's fluidity tightly bonds with the spacer fabric, destroying the fabric's original porous structure. Furthermore, curing the resin significantly increases the hardness of the spacer fabric, making the sound insulation material susceptible to brittle fracture.

[0059] In summary, the preparation method of the centrifugal spinning encapsulated spacer fabric flexible sound insulation material disclosed in the present invention is to crush the discarded porous material and fully fill it into the three-dimensional spacer fabric. Compared with the existing method of injecting the porous material into the spacer fabric for foaming reaction, it can enhance the sound insulation effect of the spacer fabric while still maintaining its good flexibility. At the same time, multi-directional alternating spinning is performed on the spacer fabric by centrifugal spinning, so that a layer of fiber mesh layer is wrapped around the surface of the spacer fabric. On the one hand, the fiber mesh layer is used to encapsulate the spacer fabric. On the other hand, since the fiber mesh layer is prepared by multi-directional alternating centrifugal spinning, it has a certain interlayer structure with a certain porosity, which can further improve the sound insulation effect of the flexible sound insulation material. The fiber mesh layer has a certain flexibility and can also improve the sound insulation effect while making the material have better flexibility. In addition, the multi-directional alternating centrifugal spinning method adopted by the present invention, compared with the conventional method of completing transverse spinning first and then longitudinal spinning, can form a certain pore structure between adjacent fiber layers, obtain a fiber mesh layer with a rich interlayer structure, and at the same time, by controlling the thickness and fiber bulk density of the fiber mesh layer, the sound insulation effect of the fiber mesh layer is effectively improved. The present invention utilizes discarded porous materials to prepare flexible sound insulation materials, which can make full use of the discarded materials and conform to the concept of green environmental protection. In addition, the preparation method of the present invention is simple, the raw materials are cheap, and the prepared sound insulation material has good sound insulation effect and good flexibility, which can fully meet the demand for flexible sound insulation materials.

[0060] The above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A method for preparing a flexible sound insulation material of centrifugal spinning encapsulated spacer fabric, characterized in that: The steps include: S1. crushing the waste porous material with a crusher to obtain a filling material with a particle size within a certain range and uniform particle size; S2. Fully mixing the filling material prepared in step S1 with the three-dimensional spacer fabric, and generating negative pressure in the three-dimensional spacer fabric so that the filling material is fully filled in the three-dimensional spacer fabric to obtain a spacer fabric filled with a porous material; S3, encapsulating the spacer fabric filled with the porous material prepared in step S2 by centrifugal spinning, so that the outer layer of the filled three-dimensional spacer fabric is tightly wrapped with a fiber mesh layer, and drying to obtain a centrifugally spun encapsulated spacer fabric flexible sound insulation material; The three-dimensional spacer fabric has an upper layer, a lower layer and a connecting layer structure, and both the upper layer and the lower layer have mesh holes; When the spacer fabric filled with the porous material is packaged by centrifugal spinning, the spacer fabric filled with the porous material is subjected to multi-directional alternating rotation, with a transverse rotation speed of 10-100 r / min and a transverse rotation time of 5-30 s; a longitudinal rotation speed of 10-100 r / min and a longitudinal rotation time of 5-30 s, and the number of alternating cycles is 3-30 times; The fiber mesh layer has a thickness of 1-6 mm and a fiber bulk density of 0.01-0.3 g / cm 3 .

2. The method for preparing a flexible sound insulation material made of centrifugal spinning encapsulated spacer fabric according to claim 1, characterized in that: The centrifugal spinning time is 30-900s, the rotation speed is 1000-7000r / min, the temperature is 30-60°C, and the ambient humidity is 30-50%.

3. The method for preparing a flexible sound insulation material of centrifugal spinning encapsulated spacer fabric according to claim 2, characterized in that: The spinning solution raw material for the centrifugal spinning includes any one of glass wool, polyester fiber wool, slag wool, rock wool and aluminum silicate wool.

4. The method for preparing a flexible sound insulation material of centrifugal spinning encapsulated spacer fabric according to claim 1, characterized in that: In step S1, the waste porous material includes any one of polystyrene foam, polyurethane foam, polyethylene foam, polypropylene foam and polyvinyl chloride foam, or a mixture of several of them.

5. The method for preparing a flexible sound insulation material of centrifugal spinning encapsulated spacer fabric according to claim 4, characterized in that: In step S1, the particle size of the crushed waste porous material is less than 1.5 mm.

6. The method for preparing a flexible sound insulation material of centrifugal spinning encapsulated spacer fabric according to claim 1, characterized in that: The void filling rate of the three-dimensional spacer fabric is 80%-98%.

7. The method for preparing a flexible sound insulation material of centrifugal spinning encapsulated spacer fabric according to claim 1, characterized in that: In step S3, the drying temperature is 40°C.

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