Super wear-resistant mute felt material and preparation method thereof

Abstract

The invention discloses a super wear-resistant mute felt material and a preparation method thereof. The felt material comprises the following preparation raw materials in percentage by mass: 30-70% of nylon fiber / bio-based polyamide fiber; 6-15% of graphene polyester fiber; 20-60% of polypropylene fiber; the thickness of the felt material ranges from 1 mm to 24 mm, and the gram weight ranges from 300 gsm to 2400 gsm. According to the invention, the material ratio is optimized, the performance advantages of each component material are fully exerted, the bio-based material and the environment-friendly finishing agent are selected, the influence on the environment is reduced, the interwoven structure and porosity among the fibers are improved by adjusting the physical characteristics of the fibers, such as thickness, length and cross section shape, the attraction coefficient can reach 0.72-0.81, and the mechanical properties of the fibers are improved. The felt has the advantages that the felt is high in wear resistance, can resist reciprocating wear for 200,000 times at most, can effectively control sound absorption, sound insulation balance and super wear resistance, is endowed with excellent waterproof, oil-proof and antifouling properties, can be applied to various occasions, and has a good application prospect.

Description

Technical Field

[0001] The invention relates to the technical field of layered products, in particular to the form of fibers or filaments, and specifically to a super wear-resistant and sound-proof felt material and a preparation method thereof. Background Art

[0002] Felt, as a commonly used industrial tool, is mostly made of wool, but also of cow hair or fiber, and is processed and bonded. In modern industry and daily life, felt, as an important multifunctional material, is widely used in many fields such as sound insulation, shock absorption, wear resistance, and thermal insulation.

[0003] Traditionally, polyester polypropylene (PET / PP) or wool polypropylene (Wool / PP) blended felt is favored due to its low cost and good processing performance. However, with the advancement of science and technology and the increase in market demand, these two traditional felt materials have gradually revealed obvious limitations in sound insulation and wear resistance, and it is difficult to meet the high standards for material performance in high-end applications.

[0004] The pore structure of traditional polyester polypropylene or wool polypropylene felt is often relatively simple, lacking in layering and complexity, making it difficult to effectively absorb and scatter sound waves, resulting in sound waves easily penetrating the material and poor sound insulation. At the same time, although polyester polypropylene fiber has good wear resistance, it is still prone to wear and even breakage under high load or long-term friction; although wool polypropylene mixed felt increases softness, the wear resistance of wool fiber is relatively poor, resulting in limited overall wear resistance.

[0005] Therefore, it is necessary to improve the deficiencies in the prior art to solve the above problems. Summary of the invention

[0006] The invention overcomes the shortcomings of the prior art and provides a super wear-resistant and sound-proof felt material and a preparation method thereof.

[0007] In order to achieve the above object, the technical solution adopted by the present invention is: a super wear-resistant and silent felt material, wherein the felt material comprises the following raw materials in percentage by mass: Nylon fiber / bio-based polyamide fiber 30-70%; Graphene polyester fiber 6-15%; Polypropylene fiber 20-60%; The felt material has a thickness of 1 to 24 mm and a gram weight of 300 to 2400 gsm.

[0008] In a preferred embodiment of the present invention, the nylon fiber is one of nylon 66 and nylon 6; the mass ratio of the nylon fiber to the bio-based polyamide fiber is 1:0.4-0.7.

[0009] In a preferred embodiment of the present invention, the graphene polyester fiber is prepared by copolymerizing and spinning polyester fiber and graphene particles, and the graphene particles account for 1.5-2.5% of the total mass of the polyester fiber.

[0010] In a preferred embodiment of the present invention, the nylon fiber and the bio-based polyamide fiber have a thickness of 5 to 10D and a length of 64 to 81 mm; the polyester fiber adopts a three-dimensional hollow fiber with a thickness of 3 to 6D and a length of 31 to 64 mm; the polypropylene fiber has a thickness of 5 to 12D and a length of 50 to 70 mm.

[0011] In a preferred embodiment of the present invention, the cross-sectional shapes of the nylon fiber, the bio-based polyamide fiber, the polyester fiber and the polypropylene fiber are all Y-shaped or triangular.

[0012] The present invention provides a method for preparing a super wear-resistant and sound-proof felt material, comprising the following steps: S1. Weigh nylon fiber / bio-based polyamide fiber, graphene polyester fiber and polypropylene fiber according to proportion, loosen and mix, spray three-proof finishing agent during the process, mix, and let stand to obtain mixed fiber; S2, combing and laying the mixed fibers to obtain a fiber layer; S3, stacking a plurality of fiber layers and performing a needle punching process to obtain a stacked fiber layer; S4. Hot pressing the laminated fiber layers to obtain a felt material.

[0013] In a preferred embodiment of the present invention, in step S1, the mixing time is 1 to 2 hours, the three-proofing finishing agent accounts for 2 to 6% of the total mass of the felt material; and the standing time is 10 to 40 minutes.

[0014] In a preferred embodiment of the present invention, in step S3, the acupuncture treatment is performed by 4 to 6 acupunctures, and the acupuncture frequency is 900 to 1000 acupunctures per minute.

[0015] In a preferred embodiment of the present invention, in step S3, the stacking method is: folding a single fiber layer in half, and stacking it with other folded fiber layers in a staggered manner.

[0016] In a preferred embodiment of the present invention, in the step S4, the temperature of the hot pressing is 200-300°C.

[0017] The present invention solves the defects existing in the background technology and has the following beneficial effects: The present invention provides a super wear-resistant and silent felt material and a preparation method thereof. By adopting nylon fiber / bio-based polyamide fiber, graphene polyester fiber and polypropylene fiber as main raw materials and optimizing the ratio, the performance advantages of each component material are fully utilized to achieve performance complementarity. Bio-based materials and environmentally friendly finishing agents are selected to reduce the impact on the environment. By adjusting the physical properties of the fibers such as the thickness, length and cross-sectional shape, the interwoven structure and porosity between the fibers are improved, the attraction coefficient can reach 0.72-0.81, and the felt can withstand up to 200,000 reciprocating wears, so that the felt can effectively control the sound absorption, sound insulation balance and super wear-resistant effects, and at the same time, it is endowed with excellent waterproof, oil-proof and anti-fouling properties, can be suitable for use in a variety of occasions, and has good application prospects.

[0018] In the present invention, by regulating the mixing mass ratio of nylon 66 / bio-based polyamide fiber, the mechanical stability of nylon 66 and the specific pore characteristics of bio-based polyamide fiber are combined to form a more compact interwoven structure, which not only enhances the overall stability of the fiber layer, but also helps to improve the complexity of the propagation path and the attenuation efficiency of the sound wave in the material, so that it can achieve better synergistic effect, and help optimize the sound absorption performance of the felt. It optimizes the bonding force between the felt materials, can reduce the shedding and breakage of the fibers when they are worn, and can better disperse and resist the wear force when subjected to external forces, thereby extending the service life and improving its wear resistance.

[0019] In the present invention, by adopting polyester fibers containing a certain concentration of graphene particles, utilizing the extremely high specific surface area, strength, and toughness of graphene, as well as the complex interwoven structure of graphene polyester fibers, a porous structure and a binding force between fibers are formed, so that the pores thereof can effectively absorb and scatter sound waves, reduce the reflection and transmission of sound waves, and better resist wear and breakage when subjected to external forces, thereby significantly improving the sound insulation and wear resistance of the felt material.

[0020] In the present invention, the needle punching frequency in the preparation of the fiber layer is conducive to the full interweaving and bonding between the fibers, forming a stable fiber network structure, enhancing the integrity and tensile resistance of the felt, and making the pore structure of the felt neither too tight nor too loose, which is conducive to the absorption and scattering of sound waves, thereby making the felt have excellent wear resistance and sound insulation effects. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art are briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative work. Figure 1 It is a flow chart of a method for preparing a super wear-resistant and silent felt material according to a preferred embodiment of the present invention; DETAILED DESCRIPTION

[0022] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only 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.

[0023] In the following description, many specific details are set forth to facilitate a full understanding of the present invention, but the present invention may also be implemented in other ways different from those described herein. Therefore, the protection scope of the present invention is not limited to the specific embodiments disclosed below.

[0024] It should be noted that the raw materials, equipment and reagents used in the present invention can be purchased from the market or obtained through the preparation methods of existing technologies.

[0025] A super wear-resistant and silent felt material and a preparation method thereof, wherein the felt material comprises the following raw materials in the following mass percentages: Nylon fiber / bio-based polyamide fiber 30-70%; Graphene polyester fiber 6-15%; Polypropylene fiber 20-60%; The thickness of the felt material is 1 to 24 mm, and the weight is 300 to 2400 gsm.

[0026] In some specific embodiments, the nylon fiber is one of nylon 66 or nylon 6; the mass ratio of the nylon fiber to the bio-based polyamide fiber is 1:0.4-0.7.

[0027] In some specific embodiments, the graphene polyester fiber is prepared by copolymerizing and spinning polyester fiber and graphene particles, and the graphene particles account for 1.5-2.5% of the total mass of the polyester fiber.

[0028] In some specific embodiments, the thickness of nylon fiber and bio-based polyamide fiber is 5-10D and the length is 64-81mm; the polyester fiber adopts three-dimensional hollow fiber with a thickness of 3-6D and a length of 31-64mm; the thickness of polypropylene fiber is 5-12D and the length is 50-70mm.

[0029] In some specific embodiments, the cross-sectional shapes of the nylon fiber, the bio-based polyamide fiber, the polyester fiber, and the polypropylene fiber are all Y-shaped or triangular.

[0030] It should be noted that the Y-shaped or triangular cross-sectional shape of nylon fiber, bio-based polyamide fiber, polyester fiber and polypropylene fiber is ensured by adopting a spinneret with a Y-shaped cross-section or a triangular cross-section to prepare fibers with such a cross-sectional shape. The preparation process of such fibers is prior art and is known to those skilled in the art, so it will not be described in detail here.

[0031] like Figure 1 As shown, the present invention provides a method for preparing a super wear-resistant and silent felt material, comprising the following steps: S1. Weigh nylon fiber / bio-based polyamide fiber, graphene polyester fiber and polypropylene fiber according to proportion, loosen and mix, spray three-proof finishing agent during the process, mix, and let stand to obtain mixed fiber; S2, combing and laying the mixed fibers to obtain a fiber layer; S3, stacking a plurality of fiber layers and performing a needle punching process to obtain a stacked fiber layer; S4. Hot pressing the laminated fiber layers to obtain a felt material.

[0032] In some specific implementation schemes, in step S1, the mixing time is 1 to 2 hours, the three-proof finishing agent accounts for 2 to 6% of the total mass of the felt material; and the standing time is 10 to 40 minutes.

[0033] In some specific embodiments, in step S3, the acupuncture treatment is performed by 4 to 6 acupunctures, and the acupuncture frequency is 900 to 1000 acupunctures per minute.

[0034] In some specific embodiments, in step S3, the stacking method is: fold a single fiber layer in half, and stack it with other folded fiber layers in a staggered manner.

[0035] In some specific embodiments, in step S4, the temperature of hot pressing is 200-300°C.

[0036] The following is a detailed description of the overall implementation of the present invention in conjunction with specific examples.

[0037] The raw material ratios of Examples 1-6 are different, as shown in Table 1, and the raw materials are measured in mass percentage.

[0038] Table 1: Example 1

[0039] A super wear-resistant and silent felt material comprises the following steps: S1, opening nylon 66 / bio-based polyamide fiber, graphene polyester fiber and polypropylene fiber with a mixing mass ratio of 1:0.5, mixing in a mixer for 1 hour, spraying a three-proof finishing agent with a concentration of 5wt% during the mixing, and standing for 30 minutes after mixing to obtain a mixed fiber; S2, combing and laying the mixed fibers to obtain a fiber layer; S3, folding the single fiber layer in half, overlapping it with other folded fiber layers in a staggered manner, and performing 5 needling treatments at a needling frequency of 950 punctures / minute to obtain a stacked fiber layer; S4. The laminated fiber layers are hot-pressed at 230° C. by a hot press to obtain a felt material with a thickness of 10 mm.

[0040] Among them, the thickness of nylon 66 / bio-based polyamide fiber is 6.5D, the length is 61mm, and the cross-sectional shape is Y-shaped; the concentration of graphene particles in the graphene polyester fiber is 2wt%, the thickness of the polyester fiber is 3.5D, the length is 52mm, and the cross-sectional shape is a triangular three-dimensional hollow fiber; the thickness of the polypropylene fiber is 7.5D, the length is 61mm, the cross-sectional shape is Y-shaped, and the gram weight of the felt material is 1200gsm. Example 2

[0041] This embodiment is basically the same as embodiment 1, except that the raw materials and proportions are different, as shown in Table 1. Example 3

[0042] This embodiment is basically the same as Embodiment 1, except that: the raw materials and proportions are different, as shown in Table 1; in step S1, the mixing mass ratio of nylon 6 / bio-based polyamide fiber is 1:0.4; in step S4, the temperature of hot pressing is 300°C; wherein, the thickness of nylon 6 / bio-based polyamide fiber is 9D, the length is 72 mm, the cross-sectional shape is triangular, and the concentration of graphene particles in the graphene polyester fiber is 1.5wt%. Example 4

[0043] This embodiment is basically the same as Embodiment 1, except that: the raw materials and proportions are different, as shown in Table 1; in step S3, the needling frequency is 1000 needlings / minute, and 4 needling treatments are performed; in step S4, the hot pressing temperature is 200°C; wherein, the concentration of graphene particles in the graphene polyester fiber is 2.5wt%, and the gram weight of the felt material is 800gsm. Example 5

[0044] This embodiment is basically the same as Embodiment 1, except that: the raw materials and proportions are different, as shown in Table 1; in step S1, the mixing mass ratio of nylon 66 / bio-based polyamide fiber is 1:0.7, and the spraying concentration of the three-proof finishing agent is 6wt%; in step S3, the needling frequency is 900 punctures / minute, and 6 needling treatments are performed; wherein, the polyester fiber has a thickness of 6D, a length of 43mm, a three-dimensional hollow fiber with a triangular cross-section shape, and a gram weight of the felt material is 1600gsm. Example 6

[0045] This embodiment is basically the same as Embodiment 1, except that: the raw materials and proportions are different, as shown in Table 1; in step S1, the spraying concentration of the three-proof finishing agent is 2wt%, and the standing time is 10min; wherein, the thickness of nylon 6 / bio-based polyamide fiber is 5D, the length is 81mm, and the cross-sectional shape is Y-shaped, and the thickness of polypropylene is 5D, the length is 70mm, and the cross-sectional shape is triangular.

[0046] Performance testing: The felt materials obtained in the above Examples 1-6 were trimmed into circular felts with a diameter of 100 mm to obtain the finished felt products of Examples 1-6, and the sound insulation, wear resistance, waterproofness, oil resistance and antifouling performance tests were performed on the finished felt products of Examples 1-6 in turn.

[0047] Sound insulation performance test: Refer to MW14177-2014 and GMW14618-2015 to test the sound absorption coefficient in different frequency bands.

[0048] Wear resistance test: Referring to the Martindale method, wear resistance tests were carried out for 50,000 times, 100,000 times and 200,000 times respectively.

[0049] Waterproof performance test: refer to GB / T4745-2012 "Testing and evaluation of waterproof performance of textiles - water dipping method" for testing.

[0050] Oil repellency test: Test in accordance with GB / T19977-2014 "Test for Oil Repellency and Hydrocarbon Resistance of Textiles".

[0051] Antifouling performance test: refer to GB / T30159.1-2013 "Testing and evaluation of antifouling performance of textiles Part 1: Stain resistance" for testing.

[0052] The test results of the sound insulation, wear resistance, water resistance, oil resistance and antifouling properties of Examples 1-6 are shown in Table 2.

[0053] Table 2:

[0054] It can be seen from Table 2 that: By comparing Example 1 with Example 2, it can be seen that when nylon fiber is blended with nylon 66 and bio-based polyamide fiber at a certain ratio compared with nylon 6, the wear resistance of the finished felt product is improved to a certain extent. Since nylon 66 has higher wear resistance and fatigue resistance than nylon 6, it can effectively improve the wear resistance of the finished felt product in the functional characteristic scenario of reciprocating wear resistance. It can be seen from the test results of Examples 1-6 that the present invention adopts nylon fiber / bio-based polyamide fiber, graphene polyester fiber and polypropylene fiber as the main raw materials, and the ratio is optimized. It fully utilizes the performance advantages of each component material and achieves performance complementarity. It uses bio-based materials and environmentally friendly finishing agents to reduce the impact on the environment. By adjusting the physical properties of the fibers such as thickness, length and cross-sectional shape, the interweaving structure and porosity between the fibers are improved. The attraction coefficient can reach 0.72-0.81, and it can withstand up to 200,000 reciprocating wear, so that the felt can effectively control the sound absorption, sound insulation balance and super wear-resistant effect. At the same time, it has excellent waterproof, oil-proof and anti-fouling properties, and can be used in a variety of occasions, with good application prospects.

[0055] In order to further make the purpose and effect of the present invention simple and easy to understand, the present invention is further described in conjunction with specific comparative examples.

[0056] Comparative Example 1 This comparative example adopts commercially available wool polypropylene felt with a thickness of 10 mm and a wool content of 99%.

[0057] Comparative Example 2 This comparative example uses a commercially available polyester felt with a thickness of 10 mm and a polyester fiber content of 100%.

[0058] Comparative Example 3 This comparative example is basically the same as Example 1, except that the weight of the felt material is 200 gsm.

[0059] Comparative Example 4 This comparative example is basically the same as Example 1, except that the weight of the felt material is 2500 gsm.

[0060] Comparative Example 5 This comparative example is basically the same as Example 1, except that in step S1, the mixing mass ratio of nylon 66 / bio-based polyamide fiber is 1:0.9.

[0061] Comparative Example 6 This comparative example is basically the same as Example 1, except that in step S1, the mixing mass ratio of nylon 66 / bio-based polyamide fiber is 1:0.3.

[0062] Comparative Example 7 This comparative example is basically the same as Example 1, except that the concentration of graphene particles in the graphene polyester fiber is 3.4wt%.

[0063] Comparative Example 8 This comparative example is basically the same as Example 1, except that the concentration of graphene particles in the graphene polyester fiber is 1.1 wt %.

[0064] Comparative Example 9 This comparative example is basically the same as Example 1, except that the thickness of the nylon 66 / bio-based polyamide fiber is 12D and the cross-sectional shape is circular.

[0065] Comparative Example 10 This comparative example is basically the same as Example 1, except that the thickness of the nylon 66 / bio-based polyamide fiber is 4D and the cross-sectional shape is circular.

[0066] Comparative Example 11 This comparative example is basically the same as Example 1, except that the thickness of the polyester fiber is 7D and the cross-sectional shape is circular.

[0067] Comparative Example 12 This comparative example is basically the same as Example 1, except that the thickness of the polyester fiber is 2D and the cross-sectional shape is circular.

[0068] Comparative Example 13 This comparative example is basically the same as Example 1, except that the thickness of the polypropylene fiber is 14D and the cross-sectional shape is circular.

[0069] Comparative Example 14 This comparative example is basically the same as Example 1, except that the thickness of the polypropylene fiber is 3D and the cross-sectional shape is circular.

[0070] Comparative Example 15 This comparative example is substantially the same as Example 1, except that in step S3, the acupuncture frequency is 840 acupunctures / minute.

[0071] Comparative Example 16 This comparative example is basically the same as Example 1, except that in step S3, the acupuncture frequency is 1100 acupunctures / minute.

[0072] Comparative Example 17 This comparative example is substantially the same as Example 1, except that in step S3, the temperature of hot pressing is 180°C.

[0073] Comparative Example 18 This comparative example is substantially the same as Example 1, except that in step S3, the temperature of hot pressing is 310°C.

[0074] The felt material obtained in the above-mentioned comparative example 1-18 was trimmed into a circular felt with a diameter of 100 mm to obtain the finished felt product of comparative example 1-18, and the sound insulation and wear resistance performance tests were carried out using the same performance testing standards as in Example 1-6.

[0075] The sound insulation and wear resistance test results of Comparative Examples 1-18 are shown in Table 3.

[0076] Table 3:

[0077] It can be seen from Table 3 that: By comparing Example 1 with Comparative Example 1 and Comparative Example 2, it can be learned that in Example 1, through specific materials and scientific proportions, the unique properties of nylon 66 / bio-based polyamide fiber, graphene polyester fiber and polypropylene fiber are utilized to make different fibers complement each other in performance, and they are interwoven and combined with each other during the needling and hot pressing process to form a tight fiber network, which not only improves the strength and wear resistance of the felt, but also increases the propagation path and attenuation space of sound waves in the material, so that the prepared felt has excellent sound insulation and wear resistance. At the same time, although the wool polypropylene felt also has certain sound absorption performance, it is limited to some specific noise frequency bands, making it difficult to achieve comprehensive sound insulation effect, and the wear resistance is relatively poor. In addition, since it is difficult to form a relatively stable fiber network structure inside the polyester felt, it is deficient in the absorption of medium and low frequency noise, so that the sound insulation and wear resistance cannot achieve a better use effect.

[0078] By comparing Example 1 with Comparative Examples 3 and 4, it can be seen that the appropriate gram weight makes the felt prepared therefrom have a moderate density, which is helpful to form a stable pore structure, plays a role of absorption and scattering in the process of sound wave propagation, increases the propagation path and attenuation space of sound waves in the material, and finally converts them into heat energy and dissipates them. In addition, the compact structure helps to enhance the integrity and tensile resistance of the felt, improves its stability when subjected to external forces, can effectively disperse the wear force, and avoid fiber breakage due to excessive friction, which helps to maintain the balance of energy dissipation and avoid energy over-dissipation. The concentration of density leads to fiber breakage, which in turn results in good wear resistance and sound insulation performance. At the same time, the lower gram weight leads to a lower density of the felt, and the arrangement of the fibers is relatively loose, which has weaker ability to absorb and dissipate sound waves. Sound waves are more likely to penetrate the felt or reflect in it, and are more likely to deform and wear when subjected to external forces. In addition, too high a gram weight causes the material to become too dense, making it difficult for sound waves to enter the felt for energy conversion, and makes the felt too thick and stiff, making it more likely to deform and damage when subjected to external forces, thereby reducing its sound insulation and wear resistance.

[0079] By comparing Example 1 with Comparative Examples 5 and 6, it can be learned that by mixing nylon 66 / bio-based polyamide fibers at a certain mass ratio, the mechanical stability of nylon 66 and the specific pore characteristics of bio-based polyamide fibers are combined to form a tighter interwoven structure, which not only enhances the overall stability of the fiber layer, but also helps to improve the complexity of the propagation path of sound waves in the material and the attenuation efficiency, so that it can achieve better synergy, and help optimize the sound absorption performance of the felt. It optimizes the bonding force between the felt materials, can reduce the shedding and breakage of fibers when worn, and can better disperse and resist wear when subjected to external forces, thereby extending the service life and improving its wear resistance. At the same time, too high or too low a proportion of bio-based polyamide fibers can easily weaken the bonding force between the fibers, making the material more prone to fiber shedding or breakage when worn, thereby reducing the wear resistance, and directly affecting the overall density of the felt material, changing the interwoven structure and porosity between the fibers, thereby further affecting its sound insulation performance.

[0080] By comparing Example 1 with Comparative Examples 7 and 8, it can be learned that by using polyester fibers containing a certain concentration of graphene particles, the extremely high specific surface area, strength, toughness of graphene, and the complex interwoven structure of graphene polyester fibers are utilized to form a porous structure and a bonding force between fibers, so that the pores thereof can effectively absorb and scatter sound waves, reduce the reflection and transmission of sound waves, and better resist wear and breakage when subjected to external forces, thereby significantly improving the sound insulation and wear resistance of the felt material; when the concentration of graphene particles is too high, agglomerates are easily formed inside the fibers, resulting in a decrease in the uniformity of the fibers, and some pores are blocked, resulting in obstruction of the propagation path of sound in the material, and too low a concentration cannot effectively exert its effect, thereby not only hindering the effective bonding between fibers, but also affecting the performance of the felt.

[0081] By comparing Example 1 with Comparative Examples 9-14, it can be learned that a reasonable pore structure can be formed through a certain fiber thickness. When sound waves enter the material, they will be reflected and scattered multiple times between the pores, consuming the energy of the sound waves. The Y-shaped cross-section of the fiber has a complex surface morphology and a high porosity, which increases the number of scattering times and the contact area, so that the sound waves are better attenuated and absorbed inside the material, achieving a sound insulation effect. At the same time, the appropriate fiber thickness can make the contact pressure distribution more uniform when subjected to friction. The unique morphology of the Y-shaped and triangular cross-section fibers can disperse the friction force to a wider area when subjected to friction, thereby reducing local wear and improving wear resistance.

[0082] By comparing Example 1 with Comparative Examples 15 and 16, it can be learned that the needling frequency in the preparation of the fiber layer is conducive to the full interweaving and bonding of the fibers, forming a stable fiber network structure, enhancing the integrity and tensile resistance of the felt, and making the pore structure of the felt neither too tight nor too loose, which is conducive to the absorption and scattering of sound waves, so that the felt has excellent wear resistance and sound insulation effects; too high acupuncture frequency will increase the friction and traction between the needles and the fibers, causing excessive stretching and breakage of the fibers, destroying the fiber network structure, reducing wear resistance, and causing the pore structure of the felt to become too tight, reducing the propagation path and attenuation space of sound waves, which is not conducive to improving sound insulation performance; too low acupuncture frequency cannot make the fibers fully interwoven and bonded, resulting in a loose structure, low strength, and reduced wear resistance of the felt, and at the same time making the pores of the felt too large, which is conducive to the scattering of sound waves, but will also lead to enhanced sound wave penetration and reduced sound insulation effect.

[0083] By comparing Example 1 with Comparative Examples 17 and 18, it can be learned that the hot pressing molding treatment of the felt can fully soften and shape the fibers, enhance the bonding force between the fibers, improve the integrity and wear resistance of the felt, maintain the stability of the pore structure of the felt, improve the absorption and scattering of sound waves, and thus enhance the sound insulation effect; however, too high a hot pressing temperature causes the fibers to melt and deform, severely damages the fiber network structure, causes the felt to lose its original performance characteristics, and causes irreversible changes in the pore structure of the felt; at the same time, too low a hot pressing temperature cannot fully soften and shape the fibers, resulting in insufficient bonding force between the fibers, reduced integrity and wear resistance of the felt, and affecting the instability of the pore structure of the felt, further causing the problem of poor sound insulation effect.

[0084] The above is based on the ideal embodiment of the present invention. Through the above description, it is obvious to those skilled in the art that the present invention is not limited to the details of the above exemplary embodiments, and the present invention can be implemented in other specific forms without departing from the spirit or basic characteristics of the present invention. Therefore, no matter from which point of view, the embodiments should be regarded as exemplary and non-restrictive. The scope of the present invention is limited by the attached claims rather than the above description, and it is intended to include all changes within the meaning and scope of the equivalent elements of the claims. Any figure mark in the claims should not be regarded as limiting the claims involved.

[0085] In addition, it should be understood that although the present specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

Claims

1. A super wear-resistant and silent felt material, characterized in that: The felt material includes the following raw materials in percentage by weight: Nylon fiber / bio-based polyamide fiber 30-70%; Graphene polyester fiber 6-15%; Polypropylene fiber 20-60%; The felt material has a thickness of 1 to 24 mm and a gram weight of 300 to 2400 gsm.

2. The super wear-resistant and sound-proof felt material according to claim 1, characterized in that: The nylon fiber is one of nylon 66 and nylon 6; the mass ratio of the nylon fiber to the bio-based polyamide fiber is 1:0.4-0.

7.

3. The super wear-resistant and sound-proof felt material according to claim 1, characterized in that: The graphene polyester fiber is prepared by copolymerizing and spinning polyester fiber and graphene particles, and the graphene particles account for 1.5-2.5% of the total mass of the polyester fiber.

4. The super wear-resistant and sound-proof felt material according to claim 3, characterized in that: The nylon fiber and the bio-based polyamide fiber have a thickness of 5 to 10D and a length of 64 to 81mm; the polyester fiber is a three-dimensional hollow fiber with a thickness of 3 to 6D and a length of 31 to 64mm; the polypropylene fiber has a thickness of 5 to 12D and a length of 50 to 70mm.

5. The super wear-resistant and sound-proof felt material according to claim 3, characterized in that: The cross-sectional shapes of the nylon fiber, the bio-based polyamide fiber, the polyester fiber and the polypropylene fiber are all Y-shaped or triangular.

6. A method for preparing a super wear-resistant and sound-proof felt material according to any one of claims 1 to 5, characterized in that: The following steps are involved: S1. Weigh nylon fiber / bio-based polyamide fiber, graphene polyester fiber and polypropylene fiber according to proportion, loosen and mix, spray three-proof finishing agent during the process, mix, and let stand to obtain mixed fiber; S2, combing and laying the mixed fibers to obtain a fiber layer; S3, stacking a plurality of fiber layers and performing a needle punching process to obtain a stacked fiber layer; S4. Hot pressing the laminated fiber layers to obtain a felt material.

7. The method for preparing a super wear-resistant and sound-proof felt material according to claim 6, characterized in that: In the step S1, the mixing time is 1 to 2 hours, the three-proofing finishing agent accounts for 2 to 6% of the total mass of the felt material; and the standing time is 10 to 40 minutes.

8. The method for preparing a super wear-resistant and sound-proof felt material according to claim 6, characterized in that: In step S3, the acupuncture treatment is performed by 4 to 6 needlings, and the needling frequency is 900 to 1000 needlings per minute.

9. The method for preparing a super wear-resistant and sound-proof felt material according to claim 6, characterized in that: In the step S3, the stacking method is: fold a single fiber layer in half, and stack it with other folded fiber layers in a staggered manner.

10. The method for preparing a super wear-resistant and sound-proof felt material according to claim 6, characterized in that: In the step S4, the temperature of the hot pressing is 200-300°C.

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