A polyester fiber sound absorbing panel and a method of manufacturing the same

Abstract

The application belongs to the field of sound-absorbing materials and discloses a polyester fiber sound-absorbing plate and a preparation method thereof, which is composed of the following raw materials in parts by weight: polyester fiber 60-80 parts, aerogel particles 3-8 parts, silicon carbide whisker 2-6 parts, bamboo charcoal fiber 10-18 parts, polyurethane elastomer 5-12 parts, environment-friendly binder 4-9 parts, boron nitride nanosheet 1-3 parts, basalt continuous fiber 8-15 parts, chitin nanofiber 1-4 parts and graphene nanoribbon 0.5-2 parts. The application aims to provide a polyester fiber sound-absorbing plate and a preparation method thereof, which significantly improves the strength and sound-absorbing performance of the polyester fiber sound-absorbing plate by optimizing the material formula and innovating the preparation process, and endows the polyester fiber sound-absorbing plate with additional functions such as photocatalysis, so as to meet the application requirements in more fields.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of sound-absorbing materials, in particular to a polyester fiber sound-absorbing board and a preparation method thereof. BACKGROUND

[0002] The polyester fiber sound-absorbing board has good sound-absorbing performance, environmental protection and decoration, and is widely used in the fields of construction and transportation. However, the existing polyester fiber sound-absorbing board has problems such as insufficient strength and limited sound-absorbing performance, and it is difficult to meet the needs of some scenes with high requirements for sound insulation and structural strength.

[0003] For example, in some large venues, highway sound barriers and other application scenarios, the sound-absorbing board needs to effectively absorb noise while having sufficient strength to resist the influence of the external environment. To solve these problems, the existing technology mainly adjusts the ratio of polyester fiber or adds conventional reinforcing materials, but the effect is limited.

[0004] Therefore, a polyester fiber sound-absorbing board with high strength and excellent sound-absorbing performance and a preparation method thereof are proposed to solve the above problems. SUMMARY

[0005] The purpose of the present application is to provide a polyester fiber sound-absorbing board and a preparation method thereof, which significantly improve the strength and sound-absorbing performance of the polyester fiber sound-absorbing board by optimizing the material formula and innovative preparation process, and also endow it with additional functions such as photocatalysis to meet the application needs of more fields.

[0006] In order to achieve the above purpose, the present application provides the following technical scheme:

[0007] The technical scheme provided by the present application is: a polyester fiber sound-absorbing board, consisting of the following raw materials by weight: polyester fiber 60-80 parts, aerogel particles 3-8 parts, silicon carbide whiskers 2-6 parts, bamboo charcoal fiber 10-18 parts, polyurethane elastomer 5-12 parts, environmentally friendly adhesive 4-9 parts, boron nitride nanosheet 1-3 parts, basalt continuous fiber 8-15 parts, chitin nanofiber 1-4 parts, and graphene nanoribbon 0.5-2 parts.

[0008] The aerogel particles are silica aerogel with a particle size of 0.1-0.5mm;

[0009] The aspect ratio of the silicon carbide whisker is 20-50; the thickness of the boron nitride nanosheet is 5-20nm, and the lateral size is 1-5μm;

[0010] The bamboo charcoal fiber is subjected to surface oxidation treatment, and the surface carboxyl content is 0.8-1.2mmol / g;

[0011] The chitin nanofiber has a diameter of 10-50 nm and a length of 500-2000 nm, and a crystallinity of ≥75%; the graphene nanobelt has a width of 5-50 nm and a length of 0.5-5 μm, and a layer number of ≤10.

[0012] Further, the polyester fiber has a linear density of 1.8-2.8 dtex and a length of 40-50 mm; the bamboo charcoal fiber has a linear density of 1.2-2.0 dtex and a length of 35-45 mm; and the basalt continuous fiber has a monofilament diameter of 7-9 μm.

[0013] Further, the environment-friendly binder is a water-based acrylic resin binder, which has a solid content of 50-60% and a glass transition temperature of -10-5 ℃.

[0014] A preparation method of a polyester fiber sound-absorbing board, comprising the following steps:

[0015] S1, the polyester fiber is soaked in a silane coupling agent ethanol solution with a mass fraction of 5% for 20 min, and then dried at 80 ℃; the silicon carbide whisker is refluxed in a nitric acid solution with a mass fraction of 40% for 3 h, and then dried at 60 ℃ after water washing; the boron nitride nanosheet is mixed with ethanol at a mass ratio of 1:8, and then ultrasonically dispersed for 25 min; the aerogel particles are soaked in a silica sol with a mass fraction of 3% for 1 h, and then dried at 100 ℃ after taking out; the bamboo charcoal fiber is oxidized in a nitric acid solution with a concentration of 5 mol / L at 60 ℃ for 2 h, and then dried at 70 ℃ after water washing; the chitin nanofiber is mixed with deionized water at a mass ratio of 1:25, and then homogenized at a rotating speed of 18,000 rpm for 15 min under a pressure of 120 MPa, to obtain a chitin nanofiber dispersion; the graphene nanobelt is mixed with N-methyl pyrrolidone at a mass ratio of 1:10, and then ultrasonically dispersed for 40 min under inert gas protection at an ultrasonic power of 500 W, to obtain a graphene nanobelt dispersion;

[0016] The treated polyester fiber, the aerogel particles, the silicon carbide whisker, the bamboo charcoal fiber, the ultrasonically dispersed boron nitride nanosheet, the chitin nanofiber dispersion and the graphene nanobelt dispersion are put into a mixer, mixed at a rotating speed of 850 r / min for 30 min, and a fiber mixture is obtained.

[0017] S2, the basalt continuous fiber is woven into a net-like structure with a warp density and a weft density of 15 roots / cm, and a water-based acrylic binder diluent solution with a mass fraction of 8% (dilution ratio of water-based acrylic binder:water=1:3 by mass ratio) is uniformly sprayed on the surface of the net-like structure for standby;

[0018] S3, heating the polyurethane elastomer to 190℃ molten state, adding the fiber mixture, while adding 0.5% of the polyurethane elastomer by mass of dibutyltin dilaurate catalyst, continuing to stir for 12 min;

[0019] S4, adding an environmentally friendly adhesive and 15% of the total weight of the material to the material obtained in step S3, stirring at 550 r / min for 25 min to form a uniform slurry;

[0020] S5, laying a layer of basalt continuous fiber web obtained in step S2 on the bottom of the forming mold, pouring the slurry into the mold, and covering a layer of basalt continuous fiber web on the slurry, heating to 125℃ at a heating rate of 8℃ / min, hot pressing at a pressure of 4.5MPa, and holding for 25 min;

[0021] S6, drying the hot-pressed plate in a drying oven with a relative humidity of ≤30% and a temperature of 85℃ for 20h;

[0022] S7, immersing the plate in a dispersion liquid prepared by mixing nano-titanium dioxide (particle size 30nm), deionized water, and 0.8% sodium dodecylbenzenesulfonate by mass fraction at a mass ratio of 1:10:0.1 by ultrasonic (ultrasonic time 40min), immersing for 30min, and then taking out and drying at 105℃.

[0023] Further, 0.1% of sodium dodecyl sulfate is added as a dispersing aid during the dispersion of graphene nanoribbons in step S1.

[0024] Further, the dibutyltin dilaurate catalyst is added when the polyurethane elastomer is cooled to 180℃ after melting in step S3.

[0025] Further, the stirring process in step S4 uses a planetary stirring method.

[0026] The beneficial effects of the technical solution are:

[0027] (1) By adding reinforcing materials such as silicon carbide whiskers and basalt continuous fibers, and the chemical combination of polyurethane elastomer and fibers, the mechanical properties of the sound-absorbing panel are significantly improved. The flexible network formed by chitin nanofibers can effectively enhance the toughness of the panel, while the rigid planar structure of graphene nanoribbons can further strengthen the support of the panel. Silicon carbide whiskers have high hardness and high strength, which can effectively enhance the rigidity of the panel. The network structure formed by basalt continuous fibers provides good support. The polyurethane elastomer is combined with the fibers through chemical reaction, which enhances the adhesion between the fibers, greatly improves the bending strength and compressive strength of the sound-absorbing panel.

[0028] (2) The addition of aerogel particles, bamboo charcoal fibers, and boron nitride nanosheets optimized the pore structure and sound absorption characteristics of the sound-absorbing panel. Simultaneously, the porous network of chitosan nanofibers further refined the pore distribution, while graphene nanoribbons effectively improved low-frequency sound absorption performance by modulating low-frequency sound wave scattering through acoustic impedance matching. The porous structure and low density of the aerogel particles facilitated sound absorption and dissipation; bamboo charcoal fibers possessed a rich microporous structure, effectively adsorbing sound energy; and the unique layered structure of boron nitride nanosheets altered the sound propagation path, further enhancing the sound absorption effect.

[0029] (3) The nano-titanium dioxide coating on the surface gives the sound-absorbing panel photocatalytic properties, which can degrade harmful gases in the air (such as formaldehyde) under light conditions. The amino groups of chitin nanofibers can enhance the chemical adsorption of formaldehyde. The synergistic effect of the two significantly improves the efficiency of air purification and expands the application range of the sound-absorbing panel.

[0030] (4) The use of environmentally friendly water-based acrylic resin adhesive reduces the use of organic solvents and lowers the emission of volatile organic compounds (VOCs), which meets environmental protection requirements.

[0031] (5) Graphene nanoribbons can also work synergistically with boron nitride nanosheets, aerogel particles and other materials to regulate the thermal conductivity of the board, so that the sound-absorbing board has high strength and excellent sound absorption performance, while also having a certain thermal insulation performance, further improving the overall practicality of the product. Attached Figure Description

[0032] Figure 1 This is a data table for Example 1 of the polyester fiber sound-absorbing board and its preparation method proposed in this invention;

[0033] Figure 2 This is a data table for Example 2 of the polyester fiber sound-absorbing board and its preparation method proposed in this invention;

[0034] Figure 3 This is a data table for Example 3 of the polyester fiber sound-absorbing board and its preparation method proposed in this invention;

[0035] Figure 4 This is a data table for Example 4 of the polyester fiber sound-absorbing board and its preparation method proposed in this invention;

[0036] Figure 5 This is a data table for Example 5 of the polyester fiber sound-absorbing board and its preparation method proposed in this invention;

[0037] Figure 6 This is a data table for Example 6 of the present invention, which describes a polyester fiber sound-absorbing board and its preparation method.

[0038] Figure 7This is a data comparison table of various embodiments of the polyester fiber sound-absorbing board and its preparation method proposed in this invention. Detailed Implementation

[0039] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0040] The specific implementation process is as follows:

[0041] Example 1:

[0042] Please see Figure 1 and Figure 7 The present invention provides a technical solution: a polyester fiber sound-absorbing board and its preparation method, comprising, by weight, 60 parts polyester fiber, 3 parts aerogel particles, 2 parts silicon carbide whiskers, 10 parts bamboo charcoal fiber, 5 parts polyurethane elastomer, 4 parts environmentally friendly binder, 1 part boron nitride nanosheets, 8 parts basalt continuous fiber, 1 part chitin nanofiber, and 0.5 parts graphene nanoribbon.

[0043] Includes the following steps:

[0044] S1: Polyester fibers were soaked in a 5% (w / w) silane coupling agent ethanol solution (70% ethanol by volume) for 20 min, then dried at 80°C; silicon carbide whiskers were refluxed in a 40% (w / w) nitric acid solution for 3 h, washed with water, and dried at 60°C; boron nitride nanosheets were mixed with ethanol at a mass ratio of 1:8 and ultrasonically dispersed for 25 min; aerogel particles were soaked in a 3% (w / w) silica sol for 1 h, then dried at 100°C; bamboo charcoal fibers were placed in a 5 mol / L nitric acid solution and oxidized at 60°C for 2 h, then washed with water and dried at 70°C.

[0045] Chitosan nanofibers were mixed with deionized water at a ratio of 1:25 and homogenized at 18,000 rpm and 120 MPa for 15 min to obtain a chitosan nanofiber dispersion. Graphene nanoribbons were mixed with N-methylpyrrolidone at a ratio of 1:10 and ultrasonically dispersed at 500 W for 40 min under nitrogen protection. 0.1% sodium dodecyl sulfate was added to obtain a graphene nanoribbon dispersion.

[0046] The treated polyester fibers, aerogel particles, silicon carbide whiskers, bamboo charcoal fibers, ultrasonically dispersed boron nitride nanosheets, chitin nanofiber dispersion, and graphene nanoribbon dispersion were put into a mixer and mixed at 850 r / min for 30 min to obtain a fiber mixture.

[0047] S2. Weave basalt continuous fibers into a mesh structure with a warp and weft density of 15 threads / cm, and uniformly spray an 8% water-based acrylic adhesive diluent (dilution ratio of adhesive:water = 1:3 by mass) onto its surface for later use.

[0048] S3. Heat the polyurethane elastomer to a molten state at 190°C, add the fiber mixture, and simultaneously add 0.5% by mass of dibutyltin dilaurate catalyst to the polyurethane elastomer. After the polyurethane elastomer melts, cool it down to 180°C and add the catalyst. Continue stirring for 12 minutes to allow the polyurethane elastomer to combine with the functional groups on the fiber surface through a chemical reaction.

[0049] S4. Add an environmentally friendly binder and 15% water by weight of the total material to the material obtained in step S3. Stir at 550 r / min for 25 minutes using a planetary mixer to form a uniform slurry.

[0050] S5. Lay a layer of basalt continuous fiber mesh obtained in step S2 at the bottom of the molding mold, pour the slurry into the mold, cover the slurry with another layer of basalt continuous fiber mesh, raise the temperature to 125°C at a heating rate of 8°C / min, and hot press the mold under a pressure of 4.5MPa for 35 minutes.

[0051] S6. Place the hot-pressed sheet in a drying oven with a relative humidity of ≤30% and a temperature of 85℃ for 20 hours to dry.

[0052] S7. Immerse the plate in a dispersion prepared by ultrasonication (ultrasonication time 40 min, power 700 W, temperature controlled below 40℃) by mixing nano titanium dioxide (particle size 30 nm), deionized water, and sodium dodecylbenzenesulfonate (mass fraction 0.8%) in a mass ratio of 1:10:0.1. After immersion for 35 min, remove the plate and dry it at 105℃ to form a surface coating with photocatalytic properties.

[0053] Performance testing: The prepared sound-absorbing panels were subjected to performance testing.

[0054] Performance testing:

[0055] Flexural strength: According to GB / T17657-2022 "Test Methods for Physical and Chemical Properties of Wood-based Panels and Decorative Wood-based Panels", the three-point bending method was used for testing. The sample size was 40mm×40mm×10mm, the span was 30mm, and the loading rate was 5mm / min.

[0056] Noise Reduction Coefficient (NRC): According to GB / T16731-2023 "Classification of Sound Absorption Performance of Building Sound Absorption Products", the sound absorption coefficients at four frequencies of 250Hz, 500Hz, 1000Hz and 2000Hz were tested using the standing wave tube method, and the arithmetic mean was taken.

[0057] Formaldehyde 24h degradation rate: According to GB / T23761-2020 "Test Methods for Air Purification Performance of Photocatalytic Materials and Products - Formaldehyde Degradation", the degradation rate was measured within 1 hour. 3 The initial concentration of formaldehyde gas injected into the sealed chamber was 1.0 mg / m³. 3 Samples were collected and analyzed after 24 hours of UV irradiation.

[0058] According to GB / T 14206-1993 "Glass Fiber Reinforced Polyester Corrugated Board", a simple beam pendulum impact testing machine is used to apply a single impact bending load to the specimen, causing the specimen to break. The impact toughness of the material is measured by the energy absorbed per unit area when the specimen breaks.

[0059] Thermal conductivity: According to GB / T10294-2008 "Determination of steady-state thermal resistance and related properties of thermal insulation materials - protective hot plate method", a flat plate thermal conductivity meter was used for testing. The sample size was 300mm×300mm×25mm.

[0060] The results showed that the flexural strength was 8.5 MPa, the noise reduction coefficient (NRC) was 0.75, the 24-hour formaldehyde degradation rate was 85%, the impact toughness was improved by 20%, the thermal conductivity was reduced by 18%, and the 250Hz low-frequency sound absorption coefficient was improved by 0.12.

[0061] This embodiment uses a lower raw material ratio, and the prepared sound-absorbing panel shows certain improvements in strength, sound absorption performance, and photocatalytic performance. However, compared with subsequent embodiments, there is still room for improvement in some properties. This indicates that increasing the amount of raw materials within a certain range may further improve the overall performance of the sound-absorbing panel. From the beneficial effects, the addition of silicon carbide whiskers and basalt continuous fibers gives the sound-absorbing panel basic high-strength characteristics, and it can better withstand certain external forces compared with traditional polyester fiber sound-absorbing panels. The synergistic effect of aerogel particles, bamboo charcoal fiber, and boron nitride nanosheets endows it with certain sound absorption capabilities. The flexible network of chitin nanofibers enhances the toughness of the panel, and the layered structure of graphene nanoribbons initially improves the low-frequency sound absorption performance. The surface nano-titanium dioxide coating achieves an 85% formaldehyde degradation rate in 24 hours, initially demonstrating the function of photocatalytic air purification. The use of environmentally friendly binders also ensures the environmental friendliness of the product during production and use.

[0062] Example 2:

[0063] Please see Figure 2 and Figure 7The present invention provides a technical solution: a polyester fiber sound-absorbing board and its preparation method, comprising, by weight, 65 parts polyester fiber, 4 parts aerogel particles, 3 parts silicon carbide whiskers, 12 parts bamboo charcoal fiber, 6 parts polyurethane elastomer, 5 parts environmentally friendly binder, 1.5 parts boron nitride nanosheets, 9 parts basalt continuous fiber, 1.5 parts chitin nanofiber, and 0.8 parts graphene nanoribbons;

[0064] Includes the following steps:

[0065] S1-S7: Same as in Example 1;

[0066] Performance testing: Same as Example 1, flexural strength is 9.2 MPa, noise reduction coefficient (NRC) is 0.80, 24-hour formaldehyde degradation rate is 88%, impact toughness is improved by 22%, thermal conductivity is reduced by 20%, and 250Hz low-frequency sound absorption coefficient is improved by 0.15.

[0067] Compared with Example 1, appropriately increasing the amount of each raw material improved the flexural strength, sound absorption performance, and photocatalytic performance of the sound-absorbing board. This indicates that adjusting the raw material ratio has a significant impact on the performance of the sound-absorbing board. Increasing the amount of raw materials within a reasonable range is beneficial to improving product performance. From the perspective of beneficial effects, a higher proportion of silicon carbide whiskers and basalt continuous fibers enhances the rigidity and supporting structure of the board. The reinforcing effect of chitin nanofibers continuously improves the toughness of the board. The effect of graphene nanoribbons on regulating sound wave scattering is more obvious, resulting in a flexural strength of 9.2 MPa, which is suitable for scenarios with slightly higher strength requirements. The increased amount of aerogel particles, bamboo charcoal fiber, and boron nitride nanosheets optimizes the pore structure, improves sound absorption performance, and achieves a noise reduction coefficient of 0.80. The photocatalytic effect of the nano-titanium dioxide coating is enhanced, and the formaldehyde degradation rate in 24 hours increases to 88%, further purifying indoor air. The continued use of environmentally friendly adhesives ensures the environmental quality of the product.

[0068] Example 3:

[0069] Please see Figure 3 and Figure 7 The present invention provides a technical solution: a polyester fiber sound-absorbing board and its preparation method, comprising, by weight, 70 parts polyester fiber, 5 parts aerogel particles, 4 parts silicon carbide whiskers, 14 parts bamboo charcoal fiber, 8 parts polyurethane elastomer, 6 parts environmentally friendly binder, 2 parts boron nitride nanosheets, 11 parts basalt continuous fiber, 2 parts chitin nanofibers, and 1 part graphene nanoribbon.

[0070] Includes the following steps:

[0071] S1-S7: Same as in Example 1;

[0072] Performance testing: Same as Example 1, flexural strength is 10.5MPa, noise reduction coefficient (NRC) is 0.85, 24h formaldehyde degradation rate is 90%, impact toughness is improved by 25%, thermal conductivity is reduced by 22%, and 250Hz low-frequency sound absorption coefficient is improved by 0.18.

[0073] This embodiment further optimizes the raw material ratio, significantly improving all performance indicators of the sound-absorbing panel. Its high strength makes it resistant to damage under significant external forces, and its excellent sound absorption performance meets higher sound insulation standards. The good photocatalytic performance effectively purifies the air, demonstrating the superiority of this invention's technical solution. Specifically, the high strength is attributed to the composite reinforcing network formed by silicon carbide whiskers, continuous basalt fibers, and chitin nanofibers; the rigid planar structure of graphene nanoribbons further strengthens the panel's support. The improved sound absorption performance stems from the synergistic effect of various sound-absorbing materials, the porous structure of chitin nanofibers, and the acoustic impedance matching effect of graphene nanoribbons. A 90% formaldehyde degradation rate in 24 hours demonstrates strong photocatalytic purification capabilities. The use of environmentally friendly adhesives aligns with the development trend of green building materials.

[0074] Example 4:

[0075] Please see Figure 4 and Figure 7 The present invention provides a technical solution: a polyester fiber sound-absorbing board and its preparation method, comprising, by weight, 75 parts polyester fiber, 6 parts aerogel particles, 5 parts silicon carbide whiskers, 16 parts bamboo charcoal fiber, 10 parts polyurethane elastomer, 7 parts environmentally friendly binder, 2.5 parts boron nitride nanosheets, 13 parts basalt continuous fiber, 3 parts chitin nanofibers, and 1.5 parts graphene nanoribbons.

[0076] Includes the following steps:

[0077] S1-S7: Same as in Example 1,

[0078] Performance testing: Same as Example 1, flexural strength is 11.8MPa, noise reduction coefficient (NRC) is 0.90, 24h formaldehyde degradation rate is 92%, impact toughness is improved by 28%, thermal conductivity is reduced by 25%, and 250Hz low-frequency sound absorption coefficient is improved by 0.20.

[0079] With the increase in raw material usage, the performance of the sound-absorbing panel continues to improve. Its high strength makes it suitable for more scenarios with stringent structural strength requirements. The high sound absorption and photocatalytic performance further enhance the product's market competitiveness, verifying the feasibility of improving product performance through optimized raw material formulation. In terms of beneficial effects, the flexural strength of 11.8 MPa, combined with the flexible reinforcement of chitin nanofibers and the rigid support of graphene nanoribbons, allows the panel to be used in high-intensity outdoor environments. The noise reduction coefficient of 0.90 reflects the synergistic optimization of the dissipation effect of chitin nanofibers on mid-to-high frequency sound waves and the scattering effect of graphene nanoribbons on low-frequency sound waves. The 92% formaldehyde degradation rate further improves indoor air quality, and the environmentally friendly production process complies with current policy requirements.

[0080] Example 5:

[0081] Please see Figure 5 and Figure 7 The present invention provides a technical solution: a polyester fiber sound-absorbing board and its preparation method, comprising, by weight, 80 parts polyester fiber, 8 parts aerogel particles, 6 parts silicon carbide whiskers, 18 parts bamboo charcoal fiber, 12 parts polyurethane elastomer, 9 parts environmentally friendly binder, 3 parts boron nitride nanosheets, 15 parts basalt continuous fiber, 4 parts chitin nanofibers, and 2 parts graphene nanoribbons.

[0082] Includes the following steps:

[0083] S1-S7: Same as in Example 1;

[0084] Performance testing: Same as Example 1, flexural strength is 13.0 MPa, noise reduction coefficient (NRC) is 0.95, 24-hour formaldehyde degradation rate is 95%, impact toughness is improved by 30%, thermal conductivity is reduced by 28%, and 250Hz low-frequency sound absorption coefficient is improved by 0.22.

[0085] This embodiment utilizes the upper limit of the raw material ratio specified in the claims. The prepared sound-absorbing panel achieves high levels in strength, sound absorption performance, and photocatalytic performance. The three-dimensional network formed by chitin nanofibers and the conductive network of graphene nanoribbons work synergistically, resulting in high strength that makes it promising for applications in large-scale buildings and transportation facilities. Its excellent sound absorption and purification performance meets people's demand for a high-quality indoor environment. Specifically, the flexural strength of 13.0 MPa, combined with the enhanced biocompatibility of chitin and the high modulus of graphene, gives the panel extremely strong structural stability; the noise reduction coefficient of 0.95 achieves efficient absorption of sound waves across the entire frequency band; the microporous structure of chitin and the layered barrier of graphene jointly construct a multi-level sound absorption system; the 95% formaldehyde degradation rate in 24 hours enables rapid and efficient air purification; and the entire process uses environmentally friendly technology and materials to create a high-performance, green, and environmentally friendly sound-absorbing panel product, leading the industry's development direction.

[0086] Example 6:

[0087] Please see Figure 6 and Figure 7 The present invention provides a technical solution: a polyester fiber sound-absorbing board and its preparation method, comprising, by weight, 68 parts polyester fiber, 3.5 parts aerogel particles, 2.5 parts silicon carbide whiskers, 11 parts bamboo charcoal fiber, 5.5 parts polyurethane elastomer, 4.5 parts environmentally friendly binder, 1.2 parts boron nitride nanosheets, 8.5 parts basalt continuous fiber, 1.2 parts chitin nanofiber, and 0.6 parts graphene nanoribbon;

[0088] Includes the following steps:

[0089] S1-S7: Same as in Example 1;

[0090] Performance testing: Same as Example 1, flexural strength is 8.8 MPa, noise reduction coefficient (NRC) is 0.78, 24h formaldehyde degradation rate is 86%, impact toughness is improved by 21%, thermal conductivity is reduced by 19%, and 250Hz low-frequency sound absorption coefficient is improved by 0.13.

[0091] The raw material ratio in this embodiment is within the middle range, and the performance of the prepared sound-absorbing panel is between that of Examples 1-5. This indicates that within the raw material ratio range defined in the claims, different combinations of ratios can improve the performance of the sound-absorbing panel. Furthermore, the synergistic effect of chitosan nanofibers and graphene nanoribbons is not a simple linear relationship, and the synergistic effect of each raw material needs to be comprehensively considered. From the perspective of beneficial effects, the flexural strength of 8.8 MPa is matched with the moderate reinforcement of chitosan nanofibers and the limited sound scattering effect of graphene nanoribbons, making the sound-absorbing panel suitable for general building decoration and home sound insulation scenarios. The noise reduction coefficient of 0.78 and the formaldehyde degradation rate of 86% ensure basic performance, while the initial toughening of chitosan and the weak thermal conductivity regulation of graphene meet the basic needs of the public for home building materials, and the environmental protection characteristics meet conventional environmental protection standards.

[0092] Please see Figures 1-7 This technical solution revolves around high-strength polyester fiber sound-absorbing panels. In terms of material combination, it abandons the traditional single reinforcing and sound-absorbing materials and innovatively introduces new materials such as silicon carbide whiskers, aerogel particles, and boron nitride nanosheets. Silicon carbide whiskers and basalt continuous fibers form a rigid skeleton, which, together with the surface treatment of polyester fibers and the chemical bonding of polyurethane elastomers, forms a three-dimensional reinforcement system. This increases the flexural strength from ≤8MPa in traditional technology to 13.0MPa, an increase of 52.9%, effectively solving the problem of easy cracking of traditional sound-absorbing panels and meeting the needs of heavy-duty scenarios such as highway sound barriers.

[0093] In terms of sound absorption performance optimization, a multi-level porous structure is constructed using aerogel particles, bamboo charcoal fibers, and boron nitride nanosheets to target different frequency bands of sound waves. The large pores formed by the aerogel particles resonate and absorb low-frequency sound waves; at the mesoscopic level, the micropores of bamboo charcoal fibers dissipate mid-frequency sound waves; and the boron nitride nanosheets scatter high-frequency sound waves, achieving full-frequency sound absorption. The noise reduction coefficient (NRC) is increased from the common 0.6-0.7 to 0.95. The porous network of chitin nanofibers further refines the pore distribution, while the layered structure of graphene nanoribbons regulates the scattering of low-frequency sound waves through acoustic impedance matching, forming a multi-level sound absorption system of "resonance-dissipation-scattering," which far exceeds the current technology level and is suitable for places with stringent acoustic requirements such as recording studios. At the same time, the surface nano-titanium dioxide photocatalytic coating gives the product formaldehyde degradation function, with a degradation rate of 95% in 24 hours, breaking the limitation of the single function of traditional sound-absorbing panels.

[0094] The data from the examples show that even in Example 6 with the intermediate ratio, the performance did not show a linear decrease, which fully confirms the synergistic enhancement effect. Taking the increase in strength as an example, when the total amount of silicon carbide whiskers and basalt continuous fibers increased from 10 parts to 21 parts, the flexural strength increased by 4.5 MPa. The two work together to form a stable skeleton network, which enhances the rigidity of the board. In terms of sound absorption performance, the changes in the amount of aerogel particles, bamboo charcoal fiber and boron nitride nanosheets caused the NRC value to change accordingly, which reflects the synergistic sound absorption effect of the multi-level pore structure.

[0095] Furthermore, this solution achieves a comprehensive integration of functions. Besides basic sound absorption and enhancement, the nano-titanium dioxide coating generates hydroxyl radicals under ultraviolet light, which can degrade pollutants such as formaldehyde and benzene. The composite of boron nitride nanosheets and aerogel particles regulates the thermal conductivity of the board, giving it insulation properties as well. Simultaneously, the amino groups of chitosan nanofibers enhance the chemical adsorption of formaldehyde, and the synergistic effect of bamboo charcoal fiber and nano-titanium dioxide imparts antibacterial and anti-mildew properties to the board, with an antibacterial rate of ≥99%. This multifunctional integrated design gives the product unique advantages in places with high requirements for air quality and material performance, such as hospitals and schools.

[0096] The products of this technical solution demonstrate outstanding performance in engineering applications, environmental protection, and economy. In the engineering field, with a flexural strength of 13.0MPa and a noise reduction coefficient of 0.95, they can be widely used in high-rise building exterior walls, subway tunnels, and other scenarios. The 95% formaldehyde degradation rate makes them suitable for air quality sensitive areas such as hospitals and schools. In terms of environmental protection, the use of water-based acrylic resin adhesives significantly reduces VOC emissions. The nano-titanium dioxide coating is recyclable and pollution-free.

[0097] The above descriptions are merely embodiments of the present invention, and common knowledge regarding specific technical solutions or characteristics is not elaborated upon here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the technical solutions of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A polyester fiber sound-absorbing panel, characterized in that, By weight, it is composed of the following raw materials: 60-80 parts polyester fiber, 3-8 parts aerogel particles, 2-6 parts silicon carbide whiskers, 10-18 parts bamboo charcoal fiber, 5-12 parts polyurethane elastomer, 4-9 parts environmentally friendly binder, 1-3 parts boron nitride nanosheets, 8-15 parts basalt continuous fiber, 1-4 parts chitin nanofiber, and 0.5-2 parts graphene nanoribbon. The aerogel particles are silica aerogels with a particle size of 0.1-0.5 mm. The silicon carbide whiskers have an aspect ratio of 20-50; the boron nitride nanosheets have a thickness of 5-20 nm and a lateral dimension of 1-5 μm. The bamboo charcoal fiber undergoes surface oxidation treatment, resulting in a surface carboxyl content of 0.8-1.2 mmol / g. The chitin nanofibers have a diameter of 10-50 nm, a length of 500-2000 nm, and a crystallinity of ≥75%; the graphene nanoribbons have a width of 5-50 nm, a length of 0.5-5 μm, and ≤10 layers. Polyester fibers were soaked in a 5% (w / w) silane coupling agent ethanol solution for 20 min, then dried at 80°C. Silicon carbide whiskers were refluxed in a 40% (w / w) nitric acid solution for 3 h, washed with water, and dried at 60°C. Boron nitride nanosheets were mixed with ethanol at a mass ratio of 1:8 and ultrasonically dispersed for 25 min. Aerogel particles were soaked in a 3% (w / w) silica sol for 1 h, then dried at 100°C. Bamboo charcoal fibers were placed in a 5 mol / L nitric acid solution. In the solution, the chitin nanofibers were oxidized at 60℃ for 2 hours, washed with water, and dried at 70℃. Chitin nanofibers were mixed with deionized water at a mass ratio of 1:25 and homogenized at 18,000 rpm for 15 minutes under a homogenization pressure of 120 MPa to obtain a chitin nanofiber dispersion. Graphene nanoribbons were mixed with N-methylpyrrolidone at a mass ratio of 1:10 and ultrasonically dispersed under inert gas protection for 40 minutes at an ultrasonic power of 500 W to obtain a graphene nanoribbon dispersion. The treated polyester fibers, aerogel particles, silicon carbide whiskers, bamboo charcoal fibers, ultrasonically dispersed boron nitride nanosheets, chitin nanofiber dispersion, and graphene nanoribbon dispersion were put into a mixer and mixed at 850 r / min for 30 min to obtain a fiber mixture.

2. The polyester fiber sound-absorbing panel according to claim 1, characterized in that, The polyester fiber has a linear density of 1.8-2.8 dtex and a length of 40-50 mm; the bamboo charcoal fiber has a linear density of 1.2-2.0 dtex and a length of 35-45 mm; and the basalt continuous fiber has a monofilament diameter of 7-9 μm.

3. The polyester fiber sound-absorbing board according to claim 1, characterized in that, The environmentally friendly adhesive is a water-based acrylic resin adhesive with a solid content of 50-60% and a glass transition temperature of -10-5℃.

4. A method for preparing a polyester fiber sound-absorbing panel as described in any one of claims 1-3, characterized in that, Includes the following steps: S1. Polyester fibers were soaked in a 5% (w / w) silane coupling agent ethanol solution for 20 min, then dried at 80°C; silicon carbide whiskers were refluxed in a 40% (w / w) nitric acid solution for 3 h, washed with water, and dried at 60°C; boron nitride nanosheets were mixed with ethanol at a mass ratio of 1:8 and ultrasonically dispersed for 25 min; aerogel particles were soaked in a 3% (w / w) silica sol for 1 h, then dried at 100°C; bamboo charcoal fibers were placed in a 5 mol / L nitric acid solution... In an acidic solution, the chitin nanofibers were oxidized at 60°C for 2 hours, washed with water, and dried at 70°C. Chitin nanofibers were mixed with deionized water at a mass ratio of 1:25 and homogenized at 18,000 rpm for 15 minutes under a homogenization pressure of 120 MPa to obtain a chitin nanofiber dispersion. Graphene nanoribbons were mixed with N-methylpyrrolidone at a mass ratio of 1:10 and ultrasonically dispersed under an inert gas atmosphere for 40 minutes at an ultrasonic power of 500 W to obtain a graphene nanoribbon dispersion. The treated polyester fibers, aerogel particles, silicon carbide whiskers, bamboo charcoal fibers, ultrasonically dispersed boron nitride nanosheets, chitin nanofiber dispersion, and graphene nanoribbon dispersion were put into a mixer and mixed at 850 r / min for 30 min to obtain a fiber mixture. S2. Weave basalt continuous fibers into a mesh structure with a warp and weft density of 15 threads / cm. Spray an 8% (w / w) water-based acrylic adhesive diluent evenly onto its surface. The dilution ratio is water-based acrylic adhesive: water = 1:3 (w / w). Set aside. S3. Heat the polyurethane elastomer to a molten state at 190°C, add the fiber mixture, and simultaneously add 0.5% by mass of dibutyltin dilaurate catalyst of polyurethane elastomer, and continue stirring for 12 minutes. S4. Add an environmentally friendly binder and 15% water by weight of the total material to the material obtained in step S3, and stir at 550 r / min for 25 min to form a uniform slurry. S5. Lay a layer of basalt continuous fiber mesh obtained in step S2 at the bottom of the molding mold, pour the slurry into the mold, cover the slurry with another layer of basalt continuous fiber mesh, raise the temperature to 125°C at a heating rate of 8°C / min, and hot press the mold under a pressure of 4.5MPa for 25 minutes. S6. Place the hot-pressed sheet in a drying oven with a relative humidity of ≤30% and a temperature of 85℃ for 20 hours to dry. S7. Immerse the plate in a dispersion prepared by mixing and sonicating nano-titanium dioxide with a particle size of 30nm, deionized water, and sodium dodecylbenzenesulfonate with a mass fraction of 0.8% in a mass ratio of 1:10:0.1 for 40 minutes. After immersion for 30 minutes, remove the plate and dry it at 105℃.

5. The method for preparing the polyester fiber sound-absorbing panel according to claim 4, characterized in that, In step S1, 0.1% sodium dodecyl sulfate is added as a dispersing agent when dispersing the graphene nanoribbons.

6. The method for preparing the polyester fiber sound-absorbing panel according to claim 4, characterized in that, The dibutyltin dilaurate catalyst mentioned in step S3 is added when the polyurethane elastomer is melted and cooled to 180°C.

7. The method for preparing the polyester fiber sound-absorbing panel according to claim 4, characterized in that, The stirring process described in step S4 uses a planetary stirring method.

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