A waterproof and sound-absorbing polycarbonate board and its preparation method

Abstract

This invention discloses a waterproof sound-absorbing polycarbonate board and its preparation method, relating to the field of polycarbonate boards, including TPO rolls, PC composite boards, sound insulation cotton, adhesive layers, perforated layers, honeycomb embossed sheets, and honeycomb patterns. This invention employs a top layer of TPO waterproof rolls and a middle layer of PC board with interlocking honeycomb patterns to enhance bonding stability and prevent slippage and peeling; the middle layer has honeycomb perforated cavities inside, combined with continuous PC board support at the bottom, reducing weight while improving sound absorption performance; the bottom layer has independent sound-absorbing cotton with an adhesive layer, facilitating quick and easy overall installation. The overall structure is lightweight and high-strength, with excellent waterproof and noise reduction effects, suitable for various architectural acoustics and protection scenarios.

Description

Technical Field

[0001] This invention relates to the field of polycarbonate sheets, and more particularly to a waterproof and sound-absorbing polycarbonate sheet and its preparation method. Background Technology

[0002] Polycarbonate sheets are high-performance engineering plastic sheets made from polycarbonate (PC) resin through processes such as extrusion or injection molding. They possess excellent transparency, impact resistance, high temperature resistance, weather resistance, and flame retardancy. Their light transmittance is close to that of glass, but their weight is only half that of glass. Furthermore, their impact strength is 250 times that of ordinary glass. Therefore, they are often used to replace glass in applications such as building lighting, curtain walls, skylights, awnings, greenhouses, advertising light boxes, and bulletproof glass. In addition, polycarbonate sheets have good processability, are easy to cut, drill, and hot-bend, and are suitable for various fields such as industrial manufacturing, electronics, mechanical protection, and safety protection. They are a multi-purpose material that combines safety and functionality. Adding thermoplastic polyolefin waterproof membrane to polycarbonate sheets can achieve stable waterproofing.

[0003] A sound-insulating polycarbonate board, Chinese Patent Application No. CN201721163603.9, includes: a sound-insulating layer and an upper polycarbonate board on the upper side and a lower polycarbonate board on the lower side of the sound-insulating layer. Both the upper and lower polycarbonate boards have protrusions on their sides that mate with the sound-insulating layer. Correspondingly, the upper and lower sides of the sound-insulating layer have grooves that mate with the protrusions. This double-layer polycarbonate board structure with the sound-insulating layer sandwiched inside creates two contact surfaces of different materials, allowing noise to be gradually attenuated. The use of protrusions and grooves is a snap-fit ​​design. After dry heating and pressurization, this structure ensures a strong and close connection between the three layers. This invention has a simple structure and novel design. The use of polycarbonate material solves the problem of the fragility of glass and effectively shields most noise, improving people's living environment.

[0004] The aforementioned patents and existing technologies have the following problems in actual use: the overall composite panel structure is relatively simple, resulting in weak sound insulation and waterproofing effects, as well as weak bonding stability; and during the production process, the adhesive components need to be manually disassembled and cleaned, which is labor-intensive and reduces work efficiency. Summary of the Invention

[0005] Therefore, in order to overcome the above-mentioned shortcomings, the present invention provides a waterproof sound-absorbing polycarbonate board and a preparation method thereof.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a waterproof sound-absorbing polycarbonate board and its preparation method, comprising TPO roll material, wherein a PC composite board is disposed at the bottom of the TPO roll material, sound insulation cotton is disposed at the bottom of the PC composite board, and an adhesive layer is disposed at the bottom of the sound insulation cotton. The lower end of the PC composite board has a hollow layer, the top of the PC composite board has honeycomb tabs, and the bottom bonding surface of the TPO roll has a honeycomb pattern that matches the honeycomb tabs.

[0007] Preferably, the specific steps are as follows: S1: Preparation of PC composite board: Select high transparency and high impact resistance polycarbonate material particles, pre-dry at 110°C for 4~6 hours, control the moisture content <0.02%, use double-sided mold injection molding to form honeycomb convex sheets on the top of the PC board; hollow layer engraving: use precision CNC engraving inside the PC board to open hollow cavities, and keep the bottom PC board continuous and intact. S2: The preparation of TPO roll material involves selecting thermoplastic polyolefin waterproof roll material with excellent aging resistance, UV resistance and flexibility. A honeycomb pattern is pressed on the bottom surface of the TPO roll material through a calender. The honeycomb size is required to correspond precisely with the honeycomb convex pattern. After pressing, the surface is treated with corona discharge. S3: Intermediate adhesive coating treatment. An auxiliary adhesive coating device is used to apply adhesive to the top bonding surface of the PC composite board. A thermoplastic composite adhesive is selected, and the thickness is controlled between 50 and 100 μm. The bottom of the TPO roll is not coated separately. S4: Hot pressing and lamination. The honeycomb convex sheets of the PC composite board and the honeycomb texture of the TPO roll are aligned to ensure precise interlocking of the honeycomb texture. Pre-pressing and degassing are performed to avoid air bubbles. The temperature is 120-140℃, the pressure is 0.2-0.5MPa, and the holding time is 30-60s. Then, the roll is cooled and shaped at room temperature. S5: Add the sound insulation cotton layer C. Select PET fiber hot-pressed sound insulation cotton, apply adhesive and stick it to the bottom of the PC composite board. Then, apply a layer of pressure-sensitive adhesive to the bottom of the sound insulation cotton using a spraying machine. Finally, cover it with a PE release film.

[0008] Preferably, the auxiliary adhesive application device includes a fixed seat with a notch at the inner right end, a cleaning component located at the left front end of the fixed seat, a pushing mechanism located at the bottom of the fixed seat, a contact plate installed on the left side of the notch in the fixed seat, a blocking plate located at the inner right end of the fixed seat, and an adhesive application component installed on the top of the pushing mechanism.

[0009] Preferably, a drive motor is provided on the left side of the back of the fixed base, and a set of rotating rollers is provided on the left and right sides of the lower end of the fixed base. The left rotating roller is connected to the output shaft of the drive motor, and the two sets of rotating rollers are connected on the outside by a scraping belt.

[0010] Preferably, the bottom right end of the fixing base has an opening, which corresponds to the glue application component, and magnets are provided at both ends of the inner side of the opening.

[0011] Preferably, the cleaning assembly includes a housing located at the left front end of the fixed base and communicating with it, a water injection pipe located on the left side of the housing, a water spray pipe located at the upper end of the housing and connected to the water injection pipe, and a scraping block located at the upper end of the housing near the housing.

[0012] Preferably, inclined protrusions are provided at the upper left and right positions of the inner side of the box.

[0013] Preferably, the pushing mechanism includes a fixed guide frame located at the lower end of the fixed base, a first cylinder connected to the left front end of the fixed guide frame, a connecting plate connected to the push rod of the first cylinder, a connecting rod connected to the back of the connecting plate, a support rod hinged to the left and right ends of the connecting rod, guide wheels located at both ends of the back of the connecting rod, and a support column fixed to the right front end of the connecting rod. An adhesive application assembly is located above the connecting plate.

[0014] Preferably, the rear end of the fixed guide frame is in the shape of a guide rail, and the guide wheel is movably embedded into the rear end of the fixed guide frame.

[0015] Preferably, the adhesive application assembly includes a fixed shell with its top corresponding to the opening of the fixed seat, adhesive injection tubes at both ends of the front end face of the fixed shell, an adhesive application mesh at the upper end of the fixed shell, a connecting lug installed at the bottom of the fixed shell and connected to the other end of the support rod, a second cylinder at both ends of the bottom of the fixed shell, the top of the second cylinder pushing out a rod that contacts the adhesive application mesh, a partition in the middle of the fixed shell, and an electromagnet embedded in the left and right positions of the inner side of the fixed shell.

[0016] The beneficial effects of this invention are: This invention employs a top layer of TPO waterproof membrane and a middle layer of PC board with a honeycomb pattern that interlocks to enhance bonding stability and prevent slippage and peeling. The middle layer has a honeycomb hollow cavity inside, which, combined with the continuous PC board support at the bottom, reduces weight and improves sound absorption performance. The bottom layer has independent sound-absorbing cotton with an adhesive layer, which facilitates quick and easy installation. The overall structure is lightweight and high-strength, with excellent waterproof and noise reduction effects, making it suitable for various architectural acoustics and protection scenarios.

[0017] This invention utilizes an auxiliary gluing device in the gluing process. The auxiliary gluing device has a built-in pushing mechanism, with a gluing component connected to the top of the pushing mechanism. The gluing component can contact the wood it passes through along with the pushing mechanism to achieve automatic gluing. Furthermore, the gluing area inside the gluing component can be changed, and the gluing mesh 63 inside can be automatically removed to work with the cleaning component and scraper belt for efficient cleaning. This invention has good automation, reduces manual operation, and effectively improves work efficiency. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of the present invention.

[0019] Figure 2 This is a schematic diagram of the bonding surface structure of the TPO roll material and PC composite board of the present invention.

[0020] Figure 3 This is a schematic diagram of the auxiliary adhesive application device of the present invention.

[0021] Figure 4 This is a schematic diagram of the internal structure of the auxiliary adhesive coating device of the present invention.

[0022] Figure 5 This is a schematic diagram of the pushing mechanism structure of the present invention.

[0023] Figure 6 This is a partial structural diagram of the pushing mechanism of the present invention.

[0024] Figure 7 This is a schematic diagram of the adhesive coating component structure of the present invention.

[0025] The components include: TPO roll material-a, PC composite board-b, sound insulation cotton-c, adhesive layer-d, perforated layer-b1, honeycomb convex sheet-b2, honeycomb pattern-a1, auxiliary glue application device, fixed seat-1, cleaning component-2, pushing mechanism-3, contact plate-4, blocking plate-5, glue application component-6, drive motor-11, rotating roller-12, scraping belt-13, box body-21, water injection pipe-22, water spray pipe-23, scraping block-24, fixed guide frame-31, first cylinder-32, connecting plate-33, connecting rod-34, support rod-35, guide wheel-36, support column-37, fixed shell-61, glue injection pipe-62, glue application mesh-63, connecting ear-64, second cylinder-65, partition plate-66, electromagnet-67. Detailed Implementation

[0026] To further explain the technical solution of the present invention, a detailed description is provided below through specific embodiments.

[0027] Please see Figure 1 and Figure 2 This invention provides a waterproof and sound-absorbing polycarbonate board and its preparation method, comprising a TPO roll a, the bottom of which is attached to the top of a PC composite board b, a sound insulation cotton c at the bottom of the PC composite board b, an adhesive layer d attached to the bottom of the sound insulation cotton c, a perforated layer b1 at the lower inner end of the PC composite board b, a honeycomb protrusion b2 on the top bonding surface of the PC composite board b, and a honeycomb pattern a1 on the bottom bonding surface of the TPO roll a that matches the honeycomb protrusion b2.

[0028] This invention provides a method for preparing a waterproof and sound-absorbing polycarbonate board. S1: Preparation of PC composite board b: Select high-transparency, high-impact polycarbonate material particles, pre-dry at 110°C for 5 hours, controlling the moisture content to <0.02%, and use double-sided mold injection molding to form honeycomb protrusions b2 on the top of the PC board; Carving of the hollow layer b1: Precision CNC carving is used inside the PC board to create hollow cavities, maintaining the continuity and integrity of the bottom PC board; S2: Preparation of TPO roll material a: Select thermoplastic polyolefin waterproof roll material raw materials with excellent aging resistance, UV resistance, and flexibility; Press honeycomb patterns onto the bottom surface of TPO roll material a using a calender, requiring the honeycomb size to precisely correspond to the honeycomb protrusions b2; After pressing, perform surface corona treatment; S3: Intermediate adhesive coating: Apply adhesive to the top bonding surface of PC composite board b using an auxiliary adhesive coating device, selecting a thermoplastic composite adhesive, with a thickness controlled between 75μm; the bottom of TPO roll material a is not separately coated with adhesive. S4: Hot-press lamination. Align the honeycomb protrusions b2 of PC composite board b with the honeycomb texture a1 of TPO roll a to ensure precise honeycomb texture fitting. Pre-press to remove air bubbles and avoid residual air bubbles. Temperature: 130℃, pressure: 0.35MPa, holding time: 30-60s. Then, cool and roll-press at room temperature for shaping. S5: Adding sound insulation cotton c layer. Select PET fiber hot-pressed sound insulation cotton c, apply adhesive and stick it to the bottom of PC composite board b. Then, apply a layer of pressure-sensitive adhesive to the bottom of sound insulation cotton c using a spraying machine. Finally, cover with PE release film.

[0029] Please see Figure 3 and Figure 4 The auxiliary adhesive application device includes a fixed base 1 for support, a cleaning component 2 installed at the bottom left front end of the fixed base 1, a pushing mechanism 3 installed at the lower end of the fixed base 1, a notch opened at the right rear end of the fixed base 1, a contact plate 4 welded to the left side of the notch, a blocking plate 5 installed at the right end of the fixed base 1, and an adhesive application component 6 installed at the top right end of the pushing mechanism 3. An opening is provided at the bottom right end of the fixed base 1, which corresponds to the glue application component 6. Magnets are provided at both ends of the inner side of the opening. A drive motor 11 is provided at the left end of the back of the fixed base 1. A set of rotating rollers 12 is provided at the lower left and right positions inside the fixed base 1. The left rotating roller 12 is connected to the output shaft of the drive motor 11. The two sets of rotating rollers 12 are connected to each other by a scraping belt 13. The cleaning component 2 includes a housing 21, which is connected to the interior of the mounting base 1. A water injection pipe 22 is provided on the left side of the housing 21. A water spray pipe 23 connected to the water injection pipe 22 is installed at the upper end of the housing 21. A water outlet is provided at the upper end of the water spray pipe 23. A scraper block 24 is locked at the upper end of the housing 21. Inclined protrusions are provided on the left and right sides of the upper end of the inner side of the housing 21 to block the water column and concentrate it on the scraper block 24. A sealing cover is provided at the bottom of the housing 21 for easy drainage.

[0030] Please see Figure 5 and Figure 6 The pushing mechanism 3 includes a fixed guide frame 31 fixed at the lower end of the fixed base 1. The rear end of the fixed guide frame 31 is in the shape of a guide rail, and a first cylinder 32 is hinged to the left front end of the fixed guide frame 31. The push rod on the right side of the first cylinder 32 is hinged to the connecting plate 33. The glue application assembly 6 is located above the connecting plate 33. A connecting rod 34 is fixed to the back of the connecting plate 33. Grooves are provided at both ends of the back of the connecting rod 34, and a set of support rods 35 are hinged to each end of the front end of the connecting rod. The other end of the support rod 35 is connected to the glue application component 6. A guide wheel 36 is installed inside the groove. The guide wheel 36 is movably embedded into the rear guide rail position of the fixed guide frame 31. A support column 37 is fixed to the lower right end of the front end of the connecting rod 34. The support column 37 is used to support the connecting rod 34.

[0031] Please see Figure 7 The glue application assembly 6 includes a fixed shell 61. The front end of the fixed shell 61 is provided with glue injection tubes 62 for connecting to external glue supply equipment. A glue application mesh 63 is embedded in the upper part of the fixed shell 61. The bottom left and right ends of the fixed shell 61 are welded with connecting ears 64 for hinged support rods 35. A set of second cylinders 65 is provided on the left and right sides of the bottom middle of the fixed shell 61. The top push rod of the second cylinder 65 contacts the glue application mesh 63. A partition 66 for diverting glue is installed in the middle of the fixed shell 61. Electromagnets 67 are embedded on the left and right sides of the inner side of the fixed shell 61 for adsorbing the glue application mesh 63.

[0032] The specific implementation process is as follows: When glue application is required, an auxiliary glue application device is needed. First, connect both ends of the device to the board conveying equipment. When the board enters the device, the pushing mechanism 3 is started to work. The first cylinder 32 pushes the connecting plate 33. During the movement of the connecting plate 33, the rear end is guided by the guide wheel 36 on the back of the connecting rod 34. Under continuous movement, the right end support rod 35 is blocked by the blocking plate 5 and can swing. The two sets of support rods 35 can lift the glue application component 6 connected to the other end, so that it is placed at the notch position on the right end of the fixed seat 1 and contacts the board that has passed. After contacting the board, the glue is supplied by an external glue supply device, enters the fixed shell 61 through the glue injection tube 62, and then exits from the glue coating screen 63 to start the glue coating process. When it is necessary to clean the glue-applying mesh 63 or apply glue to a large area, the glue-applying assembly 6 is reset by starting the first cylinder 32, so that the glue-applying mesh 62 is placed in the opening position at the bottom of the fixed base 1. Then, the second cylinder 65 is started to lift the glue-applying mesh 62. At the same time, the electromagnet 67 needs to be released from the attraction of the glue-applying mesh 62. When it is placed in the opening, it is attracted by the magnets at both ends to complete the removal of the glue-applying mesh 62. Then, the first cylinder 32 is started again to apply glue to a large area of ​​the wood through the partition 66. As the top of the coating mesh 62 contacts the scraper belt 13, the drive motor 11 is started and starts working. The drive motor 11 drives the rotating roller 12 to rotate. When the rotating roller 12 rotates, the scraper belt 13 can move along with it, and at the same time scrapes off the excess glue on the coating mesh 62. It works in conjunction with the passing scraper block 24 to clean the surface. Meanwhile, external water is injected through the water injection pipe 22 and sprayed out through the water spray pipe 23 to achieve efficient cleaning of the scraper belt 13.

[0033] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for preparing a waterproof and sound-absorbing polycarbonate board, characterized in that: The specific steps are as follows: S1: Preparation of PC composite board: Select high transparency and high impact resistance polycarbonate material particles, pre-dry at 110°C for 4~6 hours, control the moisture content <0.02%, use double-sided mold injection molding to form honeycomb convex sheets on the top of the PC board; hollow layer engraving: use precision CNC engraving inside the PC board to open hollow cavities, and keep the bottom PC board continuous and intact. S2: The preparation of TPO roll material involves selecting thermoplastic polyolefin waterproof roll material with excellent aging resistance, UV resistance and flexibility. A honeycomb pattern is pressed on the bottom surface of the TPO roll material through a calender. The honeycomb size is required to correspond precisely with the honeycomb convex pattern. After pressing, the surface is treated with corona discharge. S3: Intermediate adhesive coating treatment. An auxiliary adhesive coating device is used to apply adhesive to the top bonding surface of the PC composite board. A thermoplastic composite adhesive is selected, and the thickness is controlled between 50 and 100 μm. The bottom of the TPO roll is not coated separately. S4: Hot pressing and lamination. The honeycomb convex sheets of the PC composite board and the honeycomb texture of the TPO roll are aligned to ensure precise interlocking of the honeycomb texture. Pre-pressing and degassing are performed to avoid air bubbles. The temperature is 120-140℃, the pressure is 0.2-0.5MPa, and the holding time is 30-60s. Then, the roll is cooled and shaped at room temperature. S5: Add the sound insulation cotton layer C. Select PET fiber hot-pressed sound insulation cotton, apply adhesive and stick it to the bottom of the PC composite board. Then, apply a layer of pressure-sensitive adhesive to the bottom of the sound insulation cotton using a spraying machine. Finally, cover it with PE release film. The auxiliary adhesive application device includes a fixed seat with a notch at the inner right end, a cleaning component at the front left end of the fixed seat, a pushing mechanism at the bottom of the fixed seat, a contact plate installed on the left side of the notch in the fixed seat, a blocking plate at the inner right end of the fixed seat, and an adhesive application component installed on the top of the pushing mechanism. A drive motor is provided on the left side of the back of the fixed base, and a set of rotating rollers is provided on the left and right sides of the lower end of the fixed base. The left rotating roller is connected to the output shaft of the drive motor, and the two sets of rotating rollers are connected on the outside by a scraping belt. The cleaning assembly includes a housing located at the left front end of the fixed base and connected to it, a water injection pipe located on the left side of the housing, a water spray pipe located at the upper end of the housing and connected to the water injection pipe, and a scraping block located at the upper end of the housing near the housing. The pushing mechanism includes a fixed guide frame located at the lower end of the fixed base, a first cylinder connected to the left front end of the fixed guide frame, a connecting plate connected to the push rod of the first cylinder, a connecting rod connected to the back of the connecting plate, a support rod hinged to the left and right ends of the connecting rod, guide wheels located at both ends of the back of the connecting rod, and a support column fixed to the right front end of the connecting rod. The connecting plate is equipped with an adhesive application assembly. The adhesive application assembly includes a fixed shell with a top opening corresponding to the fixed seat opening, adhesive injection tubes at both ends of the front end face of the fixed shell, an adhesive application mesh at the upper end of the fixed shell, a connecting lug installed at the bottom of the fixed shell and connected to the other end of the support rod, a second cylinder at both ends of the bottom of the fixed shell, the top of the second cylinder pushing out a rod that contacts the adhesive application mesh, a partition in the middle of the fixed shell, and an electromagnet embedded in the left and right positions of the inner side of the fixed shell. An opening is provided at the bottom right end of the fixing base, corresponding to the glue application component, and magnets are provided at both ends of the inner side of the opening.

2. The method for preparing a waterproof and sound-absorbing polycarbonate board according to claim 1, characterized in that: Inclined protrusions are provided on the upper left and right sides of the inner side of the box.

3. The method for preparing a waterproof and sound-absorbing polycarbonate board according to claim 1, characterized in that: The rear end of the fixed guide frame is in the shape of a guide rail, and the guide wheel is movably embedded into the rear end of the fixed guide frame.

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