Heat-conducting noise-reducing material as well as preparation method and application thereof

Abstract

The invention discloses a heat-conducting noise-reducing material as well as a preparation method and application thereof, and belongs to the technical field of household appliances. The noise reduction material comprises the following components in percentage by mass: 85-95% of copper alloy powder; 3.5%-10% of a reinforcing phase; 1.5%-3.5% of a binder; wherein the copper alloy powder comprises 94%-98% of brass, 1.5%-4.5% of lanthanum, 1.5%-10% of aluminum, 0.1%-10% of zinc and 0.01%-0.1% of a deoxidizing agent; the reinforcing phase is carbon fiber. The noise-reducing material with high heat-conducting property can be obtained, can be suitable for a high-temperature environment, and keeps good noise-reducing property.

Description

Technical Field

[0001] The invention belongs to the technical field of household appliances, and in particular relates to a heat-conductive noise reduction material and a preparation method and application thereof. Background Art

[0002] As one of the most commonly used appliances in the kitchen, range hoods generally reduce noise by adding sound-absorbing cotton on the outside of the fan. Sound-absorbing cotton is generally made of polyurethane, polystyrene and other materials. This type of porous sound-absorbing material has many tiny gaps and continuous bubbles inside it. The internal friction of the material itself and the friction between the air in the pores inside the material and the pore walls can significantly absorb and attenuate the sound wave energy, thereby effectively absorbing the sound energy passing through the foam to achieve the purpose of sound insulation and noise reduction.

[0003] However, the operating temperature range of sound-absorbing cotton is generally below 100°C, which limits its scope of use and makes it unable to cope with high-temperature environments, such as the high-temperature environment generated by cooking flames. Summary of the invention

[0004] In order to solve the above technical problems, the present application further improves the existing noise reduction technology, in order to provide a noise reduction material with good thermal conductivity and applicable to high temperature environments. One of the purposes of the present invention is to provide a thermally conductive noise reduction material, the second purpose is to provide a corresponding preparation method, and the third purpose is to provide corresponding applications.

[0005] The specific technical solution is described below:

[0006] A heat-conductive noise reduction material, comprising, by mass percentage:

[0007] 85-95% copper alloy powder;

[0008] 3.5-10% reinforcement phase;

[0009] 1.5-3.5% binder;

[0010] in:

[0011] The copper alloy powder contains 94-98% brass, 1.5-4.5% lanthanum, 1.5-10% aluminum, 0.1-10% zinc and 0.01-0.1% deoxidizer;

[0012] The reinforcing phase is carbon fiber.

[0013] In the above technical solution, adding an appropriate amount of lanthanum to the copper alloy powder can refine the grains of the copper alloy, remove impurities, and thus improve the thermal conductivity of the copper alloy;

[0014] The thermal conductivity of carbon fiber is as high as 400-600W / mk. At the same time, the operating temperature of carbon fiber can be above 800°C. Therefore, the addition of carbon fiber can also increase the thermal conductivity of the noise reduction material. At the same time, carbon fiber itself has the function of strengthening the structure of the noise reduction material, which also helps to improve the noise reduction effect.

[0015] Preferably, the copper alloy powder has a D50 of 6.0 to 8.5 microns and a D90 of 10.5 to 2.9 microns.

[0016] Further preferably, the brass is selected from H62 brass alloy recycled from waste.

[0017] Preferably, the deoxidizer is phosphor copper.

[0018] Preferably, the average diameter of the carbon fiber is 0.05 nm-5 μm, and 20k-25k carbon fiber tows are selected.

[0019] Preferably, the binder is selected from one or more of a polymer binder, a wax binder, a resin binder, and a dextrin binder.

[0020] The method for preparing the noise reduction material described in any of the above technical solutions comprises the following steps:

[0021] (S.1): smelting the components contained in the copper alloy powder according to any one of claims 1 to 6, and then subjecting the smelting to high-pressure water atomization to powder making to obtain the copper alloy powder;

[0022] (S.2): mixing the copper alloy powder with short carbon fibers and a binder, granulating the mixture to obtain pellets, and forming a green body by injection molding the pellets;

[0023] (S.3): Degreasing the green body;

[0024] (S.4): the degreased green body is then sintered to obtain a green body;

[0025] (S.5): Processing the blank to obtain a noise reduction material with a desired shape and structure.

[0026] Preferably, in step (S.3), the degreasing process is:

[0027] Under the protection of inert atmosphere, heat up to 160-300°C at a heating rate of 0.1-10°C / min, keep warm for 20-120min, continue to heat up to 320-400°C at a heating rate of 0.1-5°C / min, keep warm for 20-120min, continue to heat up to 430-490°C at a heating rate of 0.1-5°C / min, keep warm for 20-120min.

[0028] Preferably, in step (S.4), the sintering process is:

[0029] After degreasing, the green body is not taken out, and the temperature is directly increased to 800-1000° C. at a heating rate of 0.1-10° C. / min under the protection of an inert atmosphere, kept at that temperature for 20-300 minutes, and then cooled to room temperature.

[0030] The application of the noise reduction material described in any of the above technical solutions, or the noise reduction material prepared by the preparation method described in any of the above technical solutions: used for noise reduction at the fan and / or smoke collection chamber wall panel of the range hood.

[0031] In summary, the technical solution of the present invention has the following main beneficial effects:

[0032] Compared with the prior art, the technical solution of the present invention can obtain a noise reduction material with high thermal conductivity, can be applied to high temperature environments, and maintain good noise reduction performance.

[0033] Further or more detailed beneficial effects will be described in detail in conjunction with specific examples in the specific implementation manner. DETAILED DESCRIPTION

[0034] The present invention is further explained with reference to the following embodiments:

[0035] The core technical problem faced by the technical solution of the embodiment of the present application comes from the inventor's accurate understanding of the prior art. Therefore, how to provide a noise reduction material suitable for high-temperature environments is a technical problem that the inventor urgently needs to solve.

[0036] At the same time, how to obtain excellent noise reduction performance is also a technical problem that the inventors want to solve simultaneously.

[0037] It should be noted that the embodiments do not constitute a limitation on the protection scope of the claims of the present invention. According to the technical concepts provided / proven by the embodiments, all technical solutions that can be reasonably anticipated by technicians in the relevant technical field should be included in the protection scope of the claims of the present invention.

[0038] The embodiments are described in detail as follows:

[0039] Example :

[0040] The preparation method of the heat-conductive noise reduction material in the embodiment is as follows:

[0041] (S.1): According to the requirements of component content, the recovered H62 brass alloy and other components are smelted and melted in a suspension smelting furnace according to corresponding proportions, and the smelting temperature is 1100-1200°C. After smelting, high-pressure water atomization is carried out at a pressure of 50-110 MPa to prepare a copper alloy powder, and the powder particle size D50 is 6.0-8.5 microns and D90 is 10.5-12.9 microns;

[0042] (S.2): mixing the copper alloy powder with short carbon fibers and a binder, granulating the mixture to obtain pellets, and forming a green body by injection molding the pellets;

[0043] (S.3): Degreasing the green body in an inert gas atmosphere of 10-60 KPa, wherein the degreasing process is as follows: heating the temperature to 160-300°C at a heating rate of 0.1-10°C / min, keeping the temperature for 20-120 min, continuing heating the temperature to 320-400°C at a heating rate of 0.1-5°C / min, keeping the temperature for 20-120 min, continuing heating the temperature to 430-490°C at a heating rate of 0.1-5°C / min, keeping the temperature for 20-120 min;

[0044] (S.4): After degreasing, without removing the green body, the temperature is directly raised to 800-1000°C at a heating rate of 0.1-10°C / min under the protection of an inert atmosphere, kept at this temperature for 20-300 minutes, and then cooled to room temperature to obtain a green body;

[0045] (S.5): The blank is forged to obtain the noise reduction material with the required shape and structure.

[0046] Example 1 : A thermally conductive noise reduction material composed of 94wt% copper alloy powder, 3.5wt% carbon fiber and 2.5wt% epoxy resin binder;

[0047] The copper alloy powder is composed of: 95wt% recycled H62 brass, 2.2wt% lanthanum, 1.62wt% aluminum, 1.14wt% zinc, and 0.04wt% phosphor copper;

[0048] The carbon fiber uses 20k carbon fiber tow, and the average diameter of the carbon fiber is 1.2μm.

[0049] The molding method of the above noise reduction material is:

[0050] The recovered H62 brass alloy and other components were smelted in a suspension smelting furnace according to corresponding proportions at a smelting temperature of 1100°C, and high-pressure water atomization was performed at a pressure of 60MPa to obtain a copper alloy powder with a powder particle size of 6.9 microns in D50 and 11.2 microns in D90;

[0051] The copper alloy powder is combined with short carbon fibers and a resin binder, and granulated by feeding; the obtained granules are formed into green bodies by injection molding;

[0052] Then, the debinding process is carried out in an inert gas atmosphere of 30KPa. The debinding process is as follows: the temperature is raised to 200°C at a heating rate of 3°C / min, and the temperature is kept for 90 minutes. The temperature is then raised to 350°C at a heating rate of 2°C / min, and the temperature is kept for 90 minutes. The temperature is then raised to 450°C at a heating rate of 5°C / min, and the temperature is kept for 90 minutes. The debinded blank is sintered under the protection of an inert atmosphere, and the ambient temperature is raised from 450°C to 900°C at a heating rate of 5°C / min, and the temperature is kept for 90 minutes, and then cooled to room temperature.

[0053] The prepared green body is processed into a porous noise reduction material through a forging process.

[0054] Example 2 : A thermally conductive noise reduction material composed of 89wt% copper alloy powder, 9.5wt% carbon fiber and 1.5wt% epoxy resin binder;

[0055] The copper alloy powder is composed of: 94wt% recycled H62 brass, 3.5wt% lanthanum, 1.4wt% aluminum, 1.05wt% zinc, and 0.05wt% phosphor copper;

[0056] The carbon fiber uses 20k carbon fiber tow, and the average diameter of the carbon fiber is 1.2μm;

[0057] The molding method is the same as in Example 1.

[0058] Example 3 : A thermally conductive noise reduction material composed of 92wt% copper alloy powder, 5wt% carbon fiber and 3wt% epoxy resin binder;

[0059] The copper alloy powder is composed of: 97wt% recycled H62 brass, 1.5wt% lanthanum, 0.91wt% aluminum, 0.56wt% zinc, and 0.03wt% phosphor copper;

[0060] The carbon fiber uses 20k carbon fiber tow, and the average diameter of the carbon fiber is 1.2μm;

[0061] The molding method is the same as in Example 1.

[0062] Example 4 : A thermally conductive noise reduction material composed of 95wt% copper alloy powder, 3.5wt% carbon fiber and 1.5wt% epoxy resin binder;

[0063] The copper alloy powder is composed of: 98wt% recycled H62 brass, 1.5wt% lanthanum, 0.5wt% aluminum, 0.49wt% zinc, and 0.01wt% phosphor copper;

[0064] The carbon fiber uses 20k carbon fiber tow, and the average diameter of the carbon fiber is 1.2μm;

[0065] The molding method is the same as in Example 1.

[0066] Comparative Example 1 : A heat-conductive noise reduction material, which is the same as Example 4, except that the lanthanum content in the copper alloy powder is reduced to 1.3wt%, and the aluminum content is increased to 0.7wt%;

[0067] The molding method is the same as in Example 1.

[0068] Comparative Example 2 : A heat-conductive noise reduction material, which is the same as Comparative Example 1, except that the carbon fiber content in the noise reduction material is reduced to 3.3wt%, and the content of the epoxy resin binder is increased to 1.7wt%;

[0069] The molding method is the same as in Example 1.

[0070] Comparative Example 3 : A heat-conductive noise reduction material, which is the same as Example 4, except that the lanthanum content in the copper alloy powder is reduced to 0wt%, and the aluminum content is increased to 2.0wt%;

[0071] The molding method is the same as in Example 1.

[0072] The noise reduction materials prepared in Examples 1 to 4 can be used for noise reduction at any location of the fan or smoke collecting chamber wall panel on the range hood, or can be used for noise reduction at the fan and the smoke collecting chamber wall panel at the same time.

[0073] The various properties of the prepared materials were tested, and the test results are shown in Table 1 below:

[0074] Table 1 Performance parameters of noise reduction materials prepared in Examples 1 to 4 and Comparative Examples 1 to 3

[0075] serial number Tensile strength MPa Sound absorption coefficient (average value) Thermal conductivity / W / (mk) Example 1 715 0.40 530 Example 2 735 0.43 560 Example 3 722 0.42 535 Example 4 710 0.38 515 Comparative Example 1 710 0.37 490 Comparative Example 2 550 0.30 450 Comparative Example 3 707 0.37 465

[0076] In Table 1 above, the tensile strength test refers to GB / T 13239-2006 "Methods for low temperature tensile test of metallic materials", and non-standard tests are performed according to the actual sample shape;

[0077] The sound absorption coefficient and thermal conductivity are tested in laboratories with corresponding qualifications.

[0078] In the above embodiments and comparative examples, adding an appropriate amount of lanthanum to the copper alloy powder can refine the grains of the copper alloy, remove impurities, and thus improve the thermal conductivity of the copper alloy;

[0079] The addition of carbon fiber can also increase the thermal conductivity of the noise reduction material. At the same time, carbon fiber itself has the function of strengthening the structure of the noise reduction material, which also helps to improve the noise reduction effect.

[0080] It can be seen from Table 1 that:

[0081] Compared with Example 4, the main difference of Comparative Example 1 is that the content of lanthanum in the copper alloy powder is reduced from 1.5wt% to 1.3wt%, and the thermal conductivity of the noise reduction material is reduced from 515W / (mk) to 490W / (mk). Relatively speaking, the applicability of the noise reduction material prepared in Comparative Example 1 in a high temperature environment is greatly reduced;

[0082] Comparative Example 2: Based on Comparative Example 1, the content of carbon fiber is reduced from 3.5wt% to 3.3wt%, and the thermal conductivity of the noise reduction material is greatly reduced from 490W / (mk) to 450W / (mk). At the same time, the tensile strength and sound absorption coefficient of the noise reduction material are also reduced synchronously. The performance of the noise reduction material prepared in Comparative Example 2 is greatly attenuated, and it is not suitable as a noise reduction material in a high temperature environment.

[0083] Compared with Example 4, the main difference between Comparative Example 3 is that the content of lanthanum in the copper alloy powder is reduced from 1.5wt% to 0wt%, and the thermal conductivity of the noise reduction material is reduced from 515W / (mk) to 450W / (mk). Relatively speaking, the performance of the noise reduction material prepared in Comparative Example 3 is greatly attenuated, and it is not suitable as a noise reduction material in a high temperature environment. It can be seen that carbon fiber alone is not enough, and an appropriate amount of lanthanum is also required to obtain a more ideal thermal conductivity effect.

[0084] In the description of this specification, the description with reference to the terms "embodiment", "basic embodiment", "preferred embodiment", "other embodiments", "example", "specific example", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner.

[0085] Although the preferred embodiments of the present invention have been described, those skilled in the art may make other changes and modifications to these embodiments once they have learned the basic creative concept. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments and all changes and modifications that fall within the scope of the present invention.

[0086] Obviously, those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include these modifications and variations.

Claims

1. A heat-conductive noise reduction material, characterized in that: In terms of mass percentage, they include: 85-95% copper alloy powder; 3.5-10% reinforcement phase; 1.5-3.5% binder; in: The copper alloy powder contains 94-98% brass, 1.5-4.5% lanthanum, 1.5-10% aluminum, 0.1-10% zinc and 0.01-0.1% deoxidizer; The reinforcing phase is carbon fiber.

2. The noise reduction material according to claim 1, characterized in that: The copper alloy powder has a D50 of 6.0 to 8.5 microns and a D90 of 10.5 to 2.9 microns.

3. The noise reduction material according to claim 1 or 2, characterized in that: The brass is selected from H62 brass alloy recycled from waste.

4. The noise reduction material according to claim 1, characterized in that: The deoxidizer is phosphor copper.

5. The noise reduction material according to claim 1, characterized in that: The average diameter of the carbon fiber is 0.05nm-5μm, and 20k-25k carbon fiber tow is selected.

6. The noise reduction material according to claim 1, characterized in that: The binder is selected from one or more of a polymer binder, a wax binder, a resin binder, and a dextrin binder.

7. The method for preparing the noise reduction material according to any one of claims 1 to 6, characterized in that: The steps include: (S.1): smelting the components contained in the copper alloy powder according to any one of claims 1 to 6, and then subjecting the smelting to high-pressure water atomization to powder making to obtain the copper alloy powder; (S.2): mixing the copper alloy powder with short carbon fibers and a binder, granulating the mixture to obtain pellets, and forming a green body by injection molding the pellets; (S.3): Degreasing the green body; (S.4): the degreased green body is then sintered to obtain a green body; (S.5): Processing the blank to obtain a noise reduction material with a desired shape and structure.

8. The preparation method according to claim 7, characterized in that: In step (S.3), the degreasing process is as follows: Under the protection of inert atmosphere, heat up to 160-300°C at a heating rate of 0.1-10°C / min, keep warm for 20-120min, continue to heat up to 320-400°C at a heating rate of 0.1-5°C / min, keep warm for 20-120min, continue to heat up to 430-490°C at a heating rate of 0.1-5°C / min, keep warm for 20-120min.

9. The preparation method according to claim 7, characterized in that: In step (S.4), the sintering process is: After degreasing, the green body is not taken out, and the temperature is directly increased to 800-1000° C. at a heating rate of 0.1-10° C. / min under the protection of an inert atmosphere, kept at that temperature for 20-300 minutes, and then cooled to room temperature.

10. Use of the noise reduction material according to any one of claims 1 to 6, or the noise reduction material prepared by the preparation method according to any one of claims 7 to 9, characterized in that: Used for noise reduction on the fan and / or smoke chamber wall of the range hood.