A sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material and preparation method thereof

Abstract

The present invention relates to a phenolic aerogel perforated plate composite material with integrated sound insulation and heat insulation and a preparation method thereof. The method comprises: uniformly mixing a phenolic resin, a pore-forming agent and a curing agent to obtain a phenolic aerogel precursor; impregnating a piece of fiber fabric in the phenolic aerogel precursor, and then subjecting the mixture to curing, solvent replacement and vacuum drying to obtain a fiber-reinforced phenolic aerogel composite material; perforating the fiber-reinforced phenolic aerogel composite material, and then bonding another piece of fiber fabric to the back of the perforated fiber-reinforced phenolic aerogel composite material to obtain a phenolic aerogel perforated plate composite material with integrated sound insulation and heat insulation. The present invention prepares a composite material with excellent noise reduction and heat insulation properties in the full frequency band by perforating the fiber-reinforced phenolic aerogel composite material and combining it with the fiber fabric; the present invention combines the perforated plate with the porous material, and has both the low-frequency noise reduction performance of the perforated plate and the high-frequency noise reduction performance of the porous material.

Description

Technical Field

[0001] The invention belongs to the technical field of preparation of fiber-reinforced resin-based composite materials, and in particular relates to a sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material and a preparation method thereof. Background Art

[0002] Common noise reduction materials are divided into two categories: porous materials and resonant materials. The noise reduction mechanism of porous materials such as fiber braids and bubbles is to dissipate the sound energy by converting sound energy into heat energy through the complex pore structure inside. Resonant materials such as perforated plates and films usually use the cavity behind them to achieve regional resonance to achieve the purpose of noise reduction.

[0003] As the world enters the 21st century, the chemical, construction, and transportation fields are developing rapidly, and the noise pollution and energy crisis caused by them are becoming more and more serious. Living and working in noise for a long time can lead to a series of problems such as mania, insomnia, heart disease, and permanent hearing loss, which bring double harm to human physical and mental health. Due to its single structure, the sound energy loss of traditional porous materials is mainly generated by the friction between the air inside the material and the inner wall of the material. The higher the frequency, the greater the loss. Therefore, for high-frequency sound waves, porous materials show good noise reduction performance, but poor noise reduction performance at low frequencies. For resonant materials, according to their structure, they often have one or more resonant frequencies. At the resonant frequency, the material has a higher noise reduction performance, but the noise reduction performance in other frequency bands is poor. A single mechanism can no longer meet the current noise reduction needs for various frequency bands.

[0004] Introducing noise reduction materials (sound insulation materials) into wall materials can effectively reduce noise, improve indoor comfort, and prevent wall structure fatigue caused by sound wave vibration, which helps to extend the service life of buildings. However, as the energy crisis becomes increasingly serious, the requirements for thermal insulation performance of exterior wall materials are becoming higher and higher. Noise reduction materials with both thermal insulation performance will further expand their applications in the fields of construction (such as wall materials) and transportation.

[0005] Therefore, there is an urgent need to provide a sound insulation and heat insulation material with multi-mechanism synergistic effects that can be applied to the entire frequency band and has excellent thermal insulation and sound insulation properties, and a preparation method thereof. Summary of the invention

[0006] In order to solve one or more technical problems existing in existing acoustic materials, such as poor thermal insulation performance, poor noise reduction performance of porous materials in low-frequency bands, poor noise reduction performance of perforated plates at non-resonant frequencies, poor impedance matching between air and perforated plates, and difficulty in entering the interior of the material, resulting in poor noise reduction performance in high-frequency bands, the present invention provides a sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material and a preparation method thereof.

[0007] In a first aspect, the present invention provides a method for preparing a sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material, the preparation method comprising the following steps:

[0008] (1) uniformly mixing a phenolic resin, a pore-forming agent and a curing agent to obtain a phenolic aerogel precursor;

[0009] (2) impregnating a piece of fiber fabric in a phenolic aerogel precursor, and then curing, solvent replacement and vacuum drying to obtain a fiber-reinforced phenolic aerogel composite material;

[0010] (3) Perforating the fiber-reinforced phenolic aerogel composite material, and then bonding another piece of fiber fabric to the back side of the perforated fiber-reinforced phenolic aerogel composite material to obtain a sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material.

[0011] Preferably, in step (2), the thickness of the fiber fabric is 1 to 5 mm; and / or in step (3), the thickness of the fiber fabric is 10 to 30 mm.

[0012] Preferably, the pore-forming agent is at least one of ethylene glycol, acetone, methanol, and deionized water; the curing agent is at least one of hexamethylenetetramine, p-toluenesulfonic acid, and aniline; and / or the mass ratio of the phenolic resin, the pore-forming agent, and the curing agent is 1:(4-6):(0.05-0.25).

[0013] Preferably, in step (2) and / or step (3), the fiber fabric is a fiber felt, and the fiber felt is a quartz fiber felt, a glass fiber felt, an alumina fiber felt or a carbon fiber felt.

[0014] Preferably, the impregnation is vacuum impregnation, the vacuum degree of the vacuum impregnation is 0.08-0.1 MPa, and the time of the vacuum impregnation is 25-35 min.

[0015] Preferably, the curing is firstly carried out at 110-120° C. for 1.5-2 hours, then at 140-150° C. for 1.5-2 hours, and finally at 170-180° C. for 24 hours.

[0016] Preferably, the temperature of the solvent replacement is 60-80° C., the solvent is replaced every 24 hours, and the number of solvent replacements is 3-5 times.

[0017] Preferably, the vacuum degree of the vacuum drying is 0.08-0.1 MPa, and the temperature of the vacuum drying is 170-180°C.

[0018] Preferably, the perforation rate of the perforations is 0.05-0.15, and the aperture of the perforations is 1-4 mm.

[0019] Preferably, in step (3), before bonding another piece of fiber fabric, a carbon fiber honeycomb panel is first bonded to the back side of the perforated fiber-reinforced phenolic aerogel composite material, and then another piece of fiber fabric is bonded to the carbon fiber honeycomb panel.

[0020] In a second aspect, the present invention provides a sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material prepared by the preparation method described in the first aspect of the present invention.

[0021] Compared with the prior art, the present invention has at least the following beneficial effects:

[0022] (1) The present invention prepares a fiber-reinforced phenolic aerogel composite material perforated plate (porous aerogel perforated plate) by impregnating the fiber with a phenolic precursor solution. Compared with the traditional perforated plate structure, the fiber-reinforced phenolic aerogel composite material perforated plate has good thermal insulation performance. The uniform and dense nanopores and multi-level fractal channel microstructure can effectively prevent air convection, reduce thermal radiation and heat conduction, and the room temperature thermal conductivity can be only 0.030 W·m -1 ·K -1 ~0.042W·m -1 ·K -1 ; The porous aerogel perforated plate material selected in the present invention has better thermal insulation performance than steel plates, plastic plates, wooden plates and other materials.

[0023] (2) The present invention prepares a composite material with excellent sound insulation and heat insulation properties in the full frequency band by punching (perforating) a fiber-reinforced phenolic aerogel composite material and combining it with a fiber fabric; the present invention combines a perforated plate with a porous material, thereby combining the low-frequency noise reduction performance of the perforated plate with the high-frequency noise reduction performance of the porous material; the present invention uses porous aerogel as a perforated plate, which not only improves the noise reduction performance of the material in the low-frequency band, but also is different from ordinary non-porous materials. At high frequencies, sound can enter the interior of the material through the porous aerogel, rather than being limited to the perforations, which is beneficial to improving the high-frequency noise reduction performance of the perforated plate structure. In addition, the present invention uses a porous material (fiber fabric) to replace the cavity on the back of the traditional perforated plate structure, which is also beneficial to significantly improving the noise reduction performance of the material in the high-frequency band.

[0024] (3) The sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material prepared by the present invention exhibits excellent noise reduction performance at a frequency of 0 to 8000 Hz (full frequency), with a maximum noise reduction coefficient of more than 0.7, a sound insulation at a frequency of 0 to 8000 Hz (full frequency) of 30 to 42 dB, and a full-frequency noise reduction coefficient of 0.36 to 0.46. The maximum noise reduction coefficient at a frequency of 0 to 1000 Hz (low frequency) can also reach 0.6 to 0.7, and the low-frequency noise reduction coefficient of 0 to 1000 Hz can reach 0.26 to 0.35. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a preparation flow chart of some specific embodiments of the present invention;

[0026] Figure 2 This is a physical picture of the sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material prepared by the present invention;

[0027] Figure 3 It is a noise reduction coefficient curve of the sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material prepared in Example 1 and Example 2 of the present invention at a frequency of 0 to 6000 Hz;

[0028] Figure 4 It is a noise reduction coefficient curve of the sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material prepared in Examples 1 and 2 of the present invention and the perforated plate sound insulation material prepared in Comparative Example 1 at a frequency of 0 to 1500 Hz. DETAILED DESCRIPTION

[0029] In order to make the purpose, technical solution and advantages of the present invention clearer, the technical solution of the present invention will be clearly and completely described below in combination with the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0030] In a first aspect, the present invention provides a method for preparing a sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material, and a preparation flow chart, for example, as shown in Figure 1 As shown, the preparation method comprises the following steps:

[0031] (1) uniformly mixing a phenolic resin, a pore-forming agent and a curing agent to obtain a phenolic aerogel precursor; in the present invention, the pore-forming agent may be, for example, at least one of ethylene glycol, acetone, methanol and deionized water; the present invention does not specifically limit the type of phenolic resin, and any phenolic resin that can be dissolved in, for example, ethylene glycol, acetone, methanol or deionized water may be used;

[0032] (2) placing a piece of fiber fabric in a phenolic aerogel precursor for impregnation, and then curing, solvent replacement (solvent substitution) and vacuum drying to obtain a fiber-reinforced phenolic aerogel composite material; in the present invention, for example, a piece of fiber fabric is placed in a phenolic aerogel precursor, vacuum impregnated in a closed container, and then the impregnated fiber fabric is directly in-situ cured in a closed container, and then the cured material is solvent replaced and vacuum dried to obtain a fiber-reinforced phenolic aerogel composite material; during the curing process, the impregnated fiber fabric is not taken out of the phenolic aerogel precursor, but is directly in-situ cured in the phenolic aerogel precursor; the present invention does not specifically limit the amount of the phenolic aerogel precursor, and the fiber fabric can be completely immersed in the phenolic aerogel precursor;

[0033] (3) Perforating (punching) the fiber-reinforced phenolic aerogel composite material, and then bonding (pasting) another fiber fabric to the back of the perforated fiber-reinforced phenolic aerogel composite material to obtain a sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material; in the present invention, the front side of the fiber-reinforced phenolic aerogel composite material is perforated according to the set perforation rate and perforation size to obtain a perforated fiber-reinforced phenolic aerogel composite material, that is, to obtain a fiber-reinforced aerogel composite perforated plate, and then bonding another fiber fabric to the back of the fiber-reinforced aerogel composite perforated plate; the sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material prepared by the present invention comprises a perforated fiber-reinforced phenolic aerogel composite material layer and a fiber fabric layer (e.g., a fiber felt layer) bonded to the back of the perforated fiber-reinforced phenolic aerogel composite material; in the present invention, the aerogel in the fiber-reinforced phenolic aerogel composite material is a mesh phenolic aerogel; a physical picture of the sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material prepared by the present invention, for example, Figure 2 As shown; the present invention has no special requirements on the adhesive used for bonding, and those skilled in the art can make a conventional selection.

[0034] The present invention prepares a fiber-reinforced phenolic aerogel composite material perforated plate (porous aerogel perforated plate) by impregnating the fiber with a phenolic precursor solution. Compared with the traditional perforated plate structure, the fiber-reinforced phenolic aerogel composite material perforated plate has good thermal insulation performance. The uniform and dense nanopores and multi-level fractal channel microstructure can effectively prevent air convection, reduce thermal radiation and heat conduction, and the room temperature thermal conductivity can be only 0.030 W·m -1 ·K -1 ~0.042W·m -1 ·K -1; The porous aerogel perforated plate material selected in the present invention has better thermal insulation performance than steel plates, plastic plates, wooden boards and other materials. The present invention prepares a composite material with excellent sound insulation and thermal insulation performance in the full frequency band by punching (perforating) the fiber-reinforced phenolic aerogel composite material and combining it with a fiber fabric; The present invention combines the perforated plate with a porous material, which has both the low-frequency noise reduction performance of the perforated plate and the high-frequency noise reduction performance of the porous material; The present invention uses porous aerogel as a perforated plate, which can not only improve the noise reduction performance in the low-frequency band, but also is different from ordinary non-porous materials. At high frequencies, sound can enter the material through the porous aerogel, rather than being limited to the perforated place, which is beneficial to improving the high-frequency noise reduction performance of the perforated plate structure, and the present invention uses porous materials (fiber fabrics) to replace the cavity on the back of the traditional perforated plate structure, which is also beneficial to significantly improve the noise reduction performance of the material in the high-frequency band. The sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material prepared by the present invention shows excellent noise reduction performance at a frequency of 0 to 8000 Hz (full frequency), a maximum noise reduction coefficient can reach above 0.7, a sound insulation amount at a frequency of 0 to 8000 Hz (full frequency) can reach 30 to 42 dB, a full-frequency noise reduction coefficient can reach 0.36 to 0.46, a maximum noise reduction coefficient at a frequency of 0 to 1000 Hz (low frequency) can also reach 0.6 to 0.7, and a low-frequency noise reduction coefficient of 0 to 1000 Hz can reach 0.26 to 0.35.

[0035] According to some preferred embodiments, in step (2), the thickness of the fiber fabric is 1 to 5 mm (e.g., 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5 or 5 mm); and / or in step (3), the thickness of the fiber fabric is 10 to 30 mm (e.g., 10, 15, 20, 25 or 30 mm).

[0036] According to some preferred embodiments, the pore-forming agent is at least one of ethylene glycol, acetone, methanol, and deionized water; the curing agent is at least one of hexamethylenetetramine, p-toluenesulfonic acid, and aniline; and / or the mass ratio of the phenolic resin, the pore-forming agent, and the curing agent is 1:(4-6):(0.05-0.25).

[0037] According to some preferred embodiments, in step (2) and / or step (3), the fiber fabric is a fiber felt, and the fiber felt is quartz fiber felt, glass fiber felt, alumina fiber felt or carbon fiber felt; the present invention does not specifically limit the quartz fiber felt, glass fiber felt, alumina fiber felt or carbon fiber felt, and any product that can be directly purchased or prepared by an existing method can be used.

[0038] According to some preferred embodiments, the impregnation is vacuum impregnation, the vacuum degree of the vacuum impregnation is 0.08-0.1 MPa, and the time of the vacuum impregnation is 25-35 min.

[0039] According to some preferred embodiments, the curing is firstly kept at 110-120°C for 1.5-2h, then kept at 140-150°C for 1.5-2h, and finally kept at 170-180°C for 24h.

[0040] According to some preferred embodiments, the temperature of the solvent replacement is 60-80° C., the solvent is replaced every 24 hours, and the number of solvent replacements is 3-5 times; in the present invention, anhydrous ethanol is used as the solvent for the solvent replacement.

[0041] According to some preferred embodiments, the vacuum degree of the vacuum drying is 0.08-0.1 MPa, and the temperature of the vacuum drying is 170-180° C.; the present invention does not specifically limit the time of vacuum drying, and vacuum drying is performed until the weight of the material is constant.

[0042] According to some preferred embodiments, the perforation rate of the perforation is 0.05-0.15 (for example, 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13, 0.14 or 0.15), and the pore size of the perforation is 1-4 mm (for example, 1, 2, 3 or 4 mm). In the present invention, the perforation rate refers to the ratio of the total area of ​​the perforation to the total area of ​​the fiber-reinforced phenolic aerogel composite material; and / or when perforating the fiber-reinforced phenolic aerogel composite material, the depth of the perforation is equal to the thickness of the fiber-reinforced phenolic aerogel composite material.

[0043] In the present invention, preferably, the perforation rate is 0.05-0.15, and the pore size is 1-4 mm. The present invention finds that a suitable perforation rate can improve the noise reduction performance of the material, and can improve the attenuation and scattering of sound waves while ensuring the strength of the material, so that the sound energy is converted into heat energy, thereby improving the noise reduction effect. The control of a suitable perforation rate can also ensure that the thermal insulation performance of the material is not excessively affected. Too high a perforation rate will increase the heat conduction path and reduce the thermal insulation performance. The present invention finds that the pore size affects the absorption frequency of sound waves. A pore size between 1 and 4 mm can maintain good thermal insulation performance while ensuring the noise reduction effect. Reasonable pore size design can avoid excessive heat convection, thereby maintaining excellent thermal insulation performance.

[0044] According to some preferred embodiments, the aperture of the perforation decreases from the back to the front of the fiber-reinforced phenolic aerogel composite material, that is, the aperture of the perforation increases from the front to the back of the fiber-reinforced phenolic aerogel composite material; in the present invention, it is preferred that the aperture of the perforation gradually increases from the front to the back of the fiber-reinforced phenolic aerogel composite material, which helps to significantly improve the sound insulation and heat insulation properties of the final sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material, and reduce resonance by optimizing the absorption and conduction path of sound waves. Phenomenon, enhancing the attenuation of sound waves in multiple frequency bands. As the aperture gradually increases, the sound wave will experience multiple reflections and scattering when penetrating the material, which helps to enhance the material's dissipation capacity for sound waves of different frequencies. The gradual increase in the aperture causes the impedance encountered by the sound wave in the penetration process to gradually change. The sound wave will have different acoustic impedance matching when encountering different apertures, thereby improving the noise reduction performance. In addition, the design of the perforated aperture increasing in sequence increases the porosity, which is beneficial to improving the thermal resistance characteristics, can make the thermal resistance characteristics more gradual, optimize the thermal insulation effect of the material, reduce the heat transfer efficiency, and thus improve the thermal insulation performance.

[0045] According to some preferred embodiments, in step (3), before bonding another fiber fabric, a carbon fiber honeycomb panel is first bonded to the back of the perforated fiber-reinforced phenolic aerogel composite material, and then the other fiber fabric is bonded to the carbon fiber honeycomb panel to obtain a sound insulation and heat insulation integrated phenolic aerogel perforated panel composite material; in the present invention, the thickness of the carbon fiber honeycomb panel can be, for example, 1 to 3 mm; the present invention does not specifically limit the source of the carbon fiber honeycomb panel, and a product that can be directly purchased can be used; in the present invention, preferably, the carbon fiber honeycomb panel is also provided, which is beneficial to the improvement of the noise reduction performance and heat insulation performance of the finally obtained sound insulation and heat insulation integrated phenolic aerogel perforated panel composite material. The possible reason is that the honeycomb structure of the carbon fiber honeycomb panel has a large number of closed air pores, which can effectively capture and absorb sound waves. When the sound waves penetrate the honeycomb panel, they will be reflected and scattered multiple times in the honeycomb pores, thereby reducing the energy of the sound waves, and the high strength and elasticity of the carbon fiber make the honeycomb panel During the transmission of sound waves, it can effectively damp and reduce the energy of sound waves. This material property helps to reduce the propagation of sound waves in the material and improve the sound insulation effect. The carbon fiber honeycomb panel can act as an air gap layer, and work together with the perforated fiber-reinforced phenolic aerogel composite material layer and the fiber fabric layer on the back to form a multi-layer sound insulation structure. This multi-layer design optimizes the acoustic impedance matching, reduces the reflection and penetration of sound waves, and thus improves the overall noise reduction performance. In addition, the air layer in the carbon fiber honeycomb structure of the present invention has good thermal insulation performance. Air as a thermal insulation material can effectively block the conduction of heat and reduce the transfer of heat through solid materials. This air layer helps to form an effective thermal resistance, and the honeycomb structure can make the heat conduction path more complicated. The heat flow needs to pass through multiple different interfaces and gas layers in the honeycomb structure. Each interface and air layer can provide additional thermal resistance. This complex conduction path effectively reduces the direct transfer of heat flow, which is beneficial to improving the thermal insulation effect of the material.

[0046] In a second aspect, the present invention provides a sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material prepared by the preparation method described in the first aspect of the present invention.

[0047] The present invention will be further described below by way of examples, but the protection scope of the present invention is not limited to these embodiments.

[0048] Example 1

[0049] ①Phenolic resin, ethylene glycol and hexamethylenetetramine were mixed evenly in a mass ratio of 1:4:0.05 to obtain a phenolic aerogel precursor. ②Take a piece of glass fiber felt with a thickness of 5 mm, soak it in the phenolic resin aerogel precursor obtained in step ①, and vacuum impregnate it for 30 minutes at a vacuum degree of 0.08 MPa; the impregnated glass fiber felt was placed in a closed container for curing, and kept at 110°C for 2 hours, 140°C for 2 hours, and finally kept at 180°C for 24 hours. The cured material was subjected to solvent replacement at 60°C, and the solvent (with anhydrous ethanol as the solvent) was replaced every 24 hours, and repeated 3 times. The material was then placed in a vacuum drying oven and dried at 180°C at a vacuum degree of 0.08 MPa to constant weight to obtain a fiber-reinforced phenolic aerogel composite material.

[0050] ③ The front side of the fiber-reinforced phenolic aerogel composite material obtained in step ② is punched (perforated) according to a perforation rate of 0.05, a pore diameter of 1 mm, and a pore depth of 5 mm to obtain a fiber-reinforced phenolic aerogel composite material perforated plate; the back side of the fiber-reinforced phenolic aerogel composite material perforated plate is pasted on a glass fiber felt with a thickness of 15 mm to obtain a sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material.

[0051] The sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material prepared in this embodiment is measured to have a sound insulation of 35 dB at a frequency of 0 to 8000 Hz, a maximum noise reduction coefficient of 0.7 at a frequency of 0 to 8000 Hz, a noise reduction coefficient of 0.38 at a frequency of 0 to 8000 Hz, a noise reduction coefficient of 0.31 at a frequency of 0 to 1000 Hz, and a thermal conductivity of 0.035 W·m -1 ·K -1 The results are shown in Table 1. It is particularly noted that the noise reduction coefficient of the present invention at a frequency of 0 to 8000 Hz (full frequency) is the average noise reduction coefficient calculated at seven points of 125 Hz, 250 Hz, 500 Hz, 1000 Hz, 2000 Hz, 4000 Hz and 8000 Hz; the noise reduction coefficient of the present invention at a frequency of 0 to 1000 Hz (low frequency) is the average noise reduction coefficient calculated at four points of 125 Hz, 250 Hz, 500 Hz and 1000 Hz.

[0052] Example 2

[0053] ①Same as step ① of Example 1.

[0054] ② Take a piece of glass fiber felt with a thickness of 1 mm, soak it in the phenolic resin aerogel precursor obtained in step ①, and vacuum impregnate it for 30 minutes at a vacuum degree of 0.08 MPa; put the impregnated glass fiber felt into a closed container for curing, keep it at 110°C for 2 hours, keep it at 140°C for 2 hours, and finally keep it at 180°C for 24 hours. The cured material is subjected to solvent replacement at 60°C, and the solvent (with anhydrous ethanol as the solvent) is replaced every 24 hours, and repeated 3 times. The material is then placed in a vacuum drying oven and dried at 180°C at a vacuum degree of 0.08 MPa to constant weight to obtain a fiber-reinforced phenolic aerogel composite material.

[0055] ③ The front side of the fiber-reinforced phenolic aerogel composite material obtained in step ② is punched (perforated) according to a perforation rate of 0.05, a pore diameter of 1 mm, and a pore depth of 1 mm to obtain a fiber-reinforced phenolic aerogel composite material perforated plate; the back side of the fiber-reinforced phenolic aerogel composite material perforated plate is pasted on a glass fiber felt with a thickness of 15 mm to obtain a sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material.

[0056] It was measured that the sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material prepared in this embodiment has a sound insulation of 30 dB at a frequency of 0 to 8000 Hz, a noise reduction coefficient of 0.36 at a frequency of 0 to 8000 Hz, a noise reduction coefficient of 0.26 at a frequency of 0 to 1000 Hz, and a thermal conductivity of 0.042 W·m -1 ·K -1 , the results are shown in Table 1.

[0057] The sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material prepared in Example 1 and Example 2 of the present invention exhibits excellent noise reduction performance at a frequency of 0 to 8000 Hz, and the noise reduction coefficients at a frequency of 0 to 8000 Hz are 0.38 and 0.36, respectively; The present invention provides a noise reduction coefficient curve of the sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material prepared in Example 1 and Example 2 at a frequency of 0 to 6000 Hz, as shown in FIG. Figure 3 As shown; and has excellent noise reduction performance in the low-frequency region of 0 to 1000 Hz, and the low-frequency noise reduction coefficients reach 0.31 and 0.26 respectively. The present invention provides the noise reduction coefficient curves of the sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material prepared in Example 1 and Example 2 at a frequency of 0 to 1500 Hz, as shown Figure 4 shown.

[0058] Example 3

[0059] Embodiment 3 is substantially the same as Embodiment 1, except that:

[0060] ③ The front side of the fiber-reinforced phenolic aerogel composite material obtained in step ② was perforated with a perforation rate of 0.15, a pore diameter of 4 mm, and a pore depth of 5 mm to obtain a fiber-reinforced phenolic aerogel composite material perforated plate; the back side of the fiber-reinforced phenolic aerogel composite material perforated plate was pasted on a glass fiber felt with a thickness of 15 mm to obtain a sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material.

[0061] Example 4

[0062] Embodiment 4 is substantially the same as Embodiment 1, except that:

[0063] ③ The front side of the fiber-reinforced phenolic aerogel composite material obtained in step ② was perforated with a perforation rate of 0.04, a pore diameter of 0.5 mm, and a pore depth of 5 mm to obtain a fiber-reinforced phenolic aerogel composite material perforated plate; the back side of the fiber-reinforced phenolic aerogel composite material perforated plate was pasted on a glass fiber felt with a thickness of 15 mm to obtain a sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material.

[0064] Example 5

[0065] Example 5 is substantially the same as Example 1, except that:

[0066] ③ The front side of the fiber-reinforced phenolic aerogel composite material obtained in step ② was perforated with a perforation rate of 0.3, a pore diameter of 5 mm, and a pore depth of 5 mm to obtain a fiber-reinforced phenolic aerogel composite material perforated plate; the back side of the fiber-reinforced phenolic aerogel composite material perforated plate was pasted on a glass fiber felt with a thickness of 15 mm to obtain a sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material.

[0067] Example 6

[0068] Embodiment 6 is substantially the same as Embodiment 1, except that:

[0069] ③ The back side of the fiber-reinforced phenolic aerogel composite material obtained in step ② is punched so that the aperture of the perforations decreases from the back side to the front side of the fiber-reinforced phenolic aerogel composite material to obtain a fiber-reinforced phenolic aerogel composite perforated plate; the back side of the fiber-reinforced phenolic aerogel composite perforated plate is pasted on a glass fiber felt with a thickness of 15 mm to obtain a sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material; from the back side to the front side of the fiber-reinforced phenolic aerogel composite material, the aperture decreases in the manner of: 1 aperture per 1 mm thickness, the apertures are 4 mm, 3.5 mm, 3 mm, 2 mm and 1 mm, respectively, and the perforation rate is 0.05 at a thickness of 1 mm with an aperture of 1 mm.

[0070] Example 7

[0071] Example 7 is substantially the same as Example 1, except that:

[0072] ③ The front side of the fiber-reinforced phenolic aerogel composite material obtained in step ② is perforated with a perforation rate of 0.05, a pore diameter of 1 mm, and a pore depth of 5 mm to obtain a fiber-reinforced phenolic aerogel composite material perforated plate; the back side of the fiber-reinforced phenolic aerogel composite material perforated plate is pasted on a carbon fiber honeycomb plate with a thickness of 2 mm, and then a glass fiber felt with a thickness of 15 mm is pasted on the other side of the carbon fiber honeycomb plate to obtain a sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material.

[0073] Comparative Example 1

[0074] Take a 20mm thick glass fiber felt and punch holes with a perforation rate of 0.05, a hole diameter of 1mm, and a hole depth of 5mm as a perforated plate sound insulation material.

[0075] The present invention provides a noise reduction coefficient curve of the perforated plate sound insulation material prepared in Comparative Example 1 at a frequency of 0 to 1500 Hz, as shown in FIG. Figure 4 shown; from Figure 4 It can be seen that simply punching holes in the glass fiber felt cannot significantly improve the noise reduction performance of the material in the low-frequency area. An impedance difference is required between the perforated plate material and the back cavity material.

[0076] Comparative Example 2

[0077] ① The phenolic resin, ethylene glycol and hexamethylenetetramine were uniformly mixed in a mass ratio of 1:4:0.05 to obtain a phenolic aerogel precursor.

[0078] ② Take a piece of glass fiber felt with a thickness of 20 mm, soak it in the phenolic resin aerogel precursor obtained in step ①, and vacuum impregnate it for 30 minutes at a vacuum degree of 0.08 MPa; put the impregnated glass fiber felt into a closed container for curing, keep it at 110°C for 2 hours, keep it at 140°C for 2 hours, and finally keep it at 180°C for 24 hours. The cured material is subjected to solvent replacement at 60°C, and the solvent is replaced every 24 hours (with anhydrous ethanol as the solvent), and repeated 3 times. The material is then placed in a vacuum drying oven and dried at 180°C at a vacuum degree of 0.08 MPa to constant weight to obtain a fiber-reinforced phenolic aerogel composite material.

[0079] ③ The front surface of the fiber-reinforced phenolic aerogel composite material obtained in step ② was perforated with a perforation rate of 0.05, a pore diameter of 1 mm, and a pore depth of 5 mm to obtain a fiber-reinforced phenolic aerogel composite perforated plate as a perforated plate sound insulation material.

[0080] The present invention performs performance tests on the sound insulation and heat insulation integrated phenolic aerogel perforated plate composite materials prepared in various embodiments and the perforated plate sound insulation materials prepared in various comparative examples. The performance test results are shown in Table 1.

[0081] Table 1

[0082]

[0083] In Table 1, the symbol “ / ” indicates that the performance indicator has not been tested.

[0084] Parts of the present invention that are not described in detail are well known to those skilled in the art.

[0085] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for preparing a sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material, characterized in that: The preparation method comprises the following steps: (1) mixing phenolic resin, pore former and curing agent uniformly to obtain a phenolic aerogel precursor; the pore former is at least one of ethylene glycol, acetone, methanol and deionized water; the curing agent is at least one of hexamethylenetetramine, p-toluenesulfonic acid and aniline; the mass ratio of the phenolic resin, pore former and curing agent is 1:(4-6):(0.05-0.25); (2) impregnating a piece of fiber fabric in a phenolic aerogel precursor, and then curing, solvent replacement and vacuum drying to obtain a fiber-reinforced phenolic aerogel composite material; (3) Perforating the fiber-reinforced phenolic aerogel composite material, and then bonding another fiber fabric to the back of the perforated fiber-reinforced phenolic aerogel composite material to obtain a sound insulation and heat insulation integrated phenolic aerogel perforated plate composite material; the perforation rate of the perforation is 0.05 to 0.15, and the hole diameter of the perforation is 1 to 4 mm.

2. The preparation method according to claim 1, characterized in that: In step (2), the thickness of the fiber fabric is 1 to 5 mm; and / or In step (3), the thickness of the fiber fabric is 10 to 30 mm.

3. The preparation method according to claim 1, characterized in that: In step (2) and / or step (3), the fiber fabric is a fiber felt, and the fiber felt is a quartz fiber felt, a glass fiber felt, an alumina fiber felt or a carbon fiber felt.

4. The preparation method according to claim 1, characterized in that: The impregnation is vacuum impregnation, the vacuum degree of the vacuum impregnation is 0.08-0.1 MPa, and the time of the vacuum impregnation is 25-35 minutes.

5. The preparation method according to claim 1, characterized in that: The curing is firstly kept at 110-120° C. for 1.5-2 hours, then kept at 140-150° C. for 1.5-2 hours, and finally kept at 170-180° C. for 24 hours.

6. The preparation method according to claim 1, characterized in that: The temperature of the solvent replacement is 60-80° C., the solvent is replaced every 24 hours, and the number of solvent replacements is 3-5 times.

7. The preparation method according to claim 1, characterized in that: The vacuum degree of the vacuum drying is 0.08-0.1 MPa, and the temperature of the vacuum drying is 170-180°C.

8. The preparation method according to claim 1, characterized in that: In step (3), before bonding another piece of fiber fabric, a carbon fiber honeycomb panel is bonded to the back of the perforated fiber-reinforced phenolic aerogel composite material, and then another piece of fiber fabric is bonded to the carbon fiber honeycomb panel.

9. A phenolic aerogel perforated plate composite material having integrated sound insulation and heat insulation obtained by the preparation method according to any one of claims 1 to 8.

Images