A polyester fiber sound-absorbing board with high yield strength

Abstract

This invention discloses a high-yield-strength polyester fiber sound-absorbing panel, comprising, from top to bottom, a micro-perforated metal surface layer, a gradient-density polyester fiber layer, a honeycomb metal skeleton layer, and an elastic damping bottom layer, all stacked and fixed together with adhesive. Vertically distributed metal panels surround the sides of the micro-perforated metal surface layer, forming an integral structure with the micro-perforated metal surface layer. The metal panels enclose the gradient-density polyester fiber layer and the honeycomb metal skeleton layer. The honeycomb metal skeleton layer is not only glued to adjacent upper and lower layers but also secured to the metal panels with rivets. This invention effectively overcomes the strength deficiencies of traditional polyester fiber sound-absorbing panels through an innovative composite lamination design. The micro-perforated metal surface layer and the integrally formed metal panels constitute a rigid outer frame, protecting the internal fiber layers from mechanical damage and significantly improving the overall bending stiffness through the load-bearing capacity of the metal skeleton.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of architectural acoustics materials, in particular to a polyester fiber sound absorption board with high yield strength. BACKGROUND

[0002] In the field of architectural acoustics, polyester fiber sound absorption board exhibits significant technical advantages due to its unique material properties. From the perspective of acoustic performance, the material forms a multi-level pore network through a special fiber interlacing structure, which can effectively realize gradient absorption of wideband sound waves, especially showing excellent sound energy conversion efficiency in the medium and high frequency bands. Its porous structure not only provides a good sound wave attenuation channel, but also can achieve targeted frequency band optimization by adjusting the fiber arrangement density. In terms of environmental protection, polyester fiber material does not contain harmful volatile substances commonly found in traditional building materials, meets strict green building material standards, and has sustainable development characteristics of recyclability. In terms of processing technology, the material has excellent plasticity and decorative adaptability, which can not only realize complex curved surface modeling through hot pressing forming, but also can be compatible with various surface treatment processes, providing rich forms for architectural acoustics design.

[0003] However, polyester fiber material has inherent defects in mechanical properties. Its molecular structure characteristics result in insufficient overall bending stiffness of the material, and the yield strength is usually less than 50 MPa. Under long-term sound pressure load or mechanical vibration environment, it is easy to appear creep deformation, which affects the long-term stability of the structure. These mechanical performance deficiencies seriously restrict the application of the material in high mechanical load occasions, and it is urgent to improve through composite reinforcement or structural innovation. SUMMARY

[0004] The purpose of the present application is to provide a polyester fiber sound absorption board with high yield strength to solve the problems raised in the background art.

[0005] To solve the above technical problems, the present application provides the following technical solutions:

[0006] A polyester fiber sound absorption board with high yield strength, comprising a micro-perforated metal surface layer, a gradient density polyester fiber layer, a honeycomb metal framework layer and an elastic damping bottom layer fixed by glue stacking from top to bottom in sequence; a vertically distributed metal fence is provided around the side edge of the micro-perforated metal surface layer, the metal fence and the micro-perforated metal surface layer are an integral forming structure, and the metal fence wraps the gradient density polyester fiber layer and the honeycomb metal framework layer; the honeycomb metal framework layer is fixed to each other by rivets in addition to being fixed by glue with adjacent upper and lower layers.

[0007] The gradient density polyester fiber layer is embedded with a pre-stressed glass fiber material mesh cloth, the warp yarn diameter of the mesh cloth is 0.4-0.6 mm, the weft yarn diameter is 0.2-0.3 mm, the mesh aperture is 2-3 mm, and the warp yarn is applied with a pre-tension of 5-8 N per root. The introduction of the pre-stressed glass fiber mesh cloth fundamentally changes the mechanical properties of the traditional polyester fiber layer, unlike the simple fiber layer stacking, the application has the difference design of the specific parameters (warp yarn diameter 0.4-0.6 mm, weft 0.2-0.3 mm), and cooperates with the pre-tension of 5-8 N per root to build a spatial stress network in the material inside, this design not only greatly improves the tensile strength, but also realizes the stress gradient distribution through the asymmetric structure of the warp and weft yarns, greatly improves the yield strength, and solves the core defect of the insufficient strength of the polyester layer in the background technology through the precise matching of the fiber diameter and the tension.

[0008] The inner wall of the honeycomb cell of the honeycomb metal framework layer is a composite double-layer metal wall, the inner layer of the composite double-layer metal wall is an aluminum alloy with a thickness of 0.1 mm, the outer layer is a copper-nickel alloy with a thickness of 0.05 mm, and the two layers are combined by metallurgy to form a thermal expansion differential structure. The double-metal honeycomb wall structure realizes the innovation of the anti-creep mechanism through material compounding, the difference in the thermal expansion coefficients of the aluminum alloy and the copper-nickel alloy causes the honeycomb wall to generate self-tight stress when the temperature changes, and this internal stress field can continuously offset the deformation caused by external load, the metallurgical bonding interface ensures the cooperative deformation ability of the two layers of metal, avoiding the interlayer peeling risk of traditional adhesive bonding, and creatively applying the metal compounding technology to the sound absorption panel field, effectively reducing the creep amount and breaking through the long-term stability bottleneck.

[0009] The micro-perforated metal surface layer is uniformly and densely distributed with sound absorption holes, the sound absorption holes are conical holes with an inlet aperture of 0.3 mm and an outlet aperture of 0.1 mm, and the conical hole wall is attached with a 1-2 μm titanium nitride wear-resistant coating; the perforation rate of the micro-perforated metal surface layer is 15-20%. The combination of the conical hole and the hard anodization creates a new path for acoustic-mechanical synergistic reinforcement. The conical hole improves the low-frequency sound absorption effect through progressive acoustic impedance matching, and the titanium nitride wear-resistant coating suppresses the initiation of micro-cracks through surface hardening. This coupled design of hole shape and surface treatment not only optimizes the acoustic performance but also prolongs the fatigue life. The application of the titanium nitride wear-resistant coating in the sound absorption hole belongs to cross-field technical innovation, and its cooperation with the conical geometry produces an unexpected synergistic effect, greatly improving the fatigue life and forming a unique technical feature that is different from all existing technologies.

[0010] In a further embodiment, the density of the gradient density polyester fiber layer gradually increases from top to bottom along the range of 80-200 kg / m 3 .

[0011] In further embodiments, the gradient density polyester fiber layer is a whole or is formed by stacking several layers of polyester fiber layers with different densities.

[0012] In further embodiments, the honeycomb metal skeleton layer is filled with octadecane phase change microcapsules.

[0013] Preferably, the elastic damping bottom layer is a 3-5mm-thick polyurethane and rubber blended damping layer.

[0014] Preferably, the micro-perforated metal surface layer and the metal cladding are made of aluminum alloy or stainless steel.

[0015] Preferably, the length of each side of the honeycomb of the honeycomb metal skeleton layer is 3-8mm.

[0016] Preferably, the sound absorption hole has a diameter of 0.1-0.3mm, and the micro-perforated metal surface layer has a perforation rate of 15-20%.

[0017] Preferably, the micro-perforated metal surface layer and the metal cladding have a thickness of 0.3-0.5mm.

[0018] Compared with the prior art, the present application has the following advantages:

[0019] The present application effectively overcomes the strength defects of traditional polyester fiber sound absorption panels through innovative composite lamination design. The micro-perforated metal surface layer and the integrally formed metal cladding form a rigid outer frame, which not only protects the internal fiber layer from mechanical damage, but also significantly improves the overall bending stiffness through the load-bearing effect of the metal skeleton. The gradient density polyester fiber layer optimizes stress distribution while maintaining excellent sound absorption performance. The honeycomb metal skeleton layer as the core reinforcing unit not only achieves lightweight and high-strength mechanical support through the hexagonal cell structure, but also forms a three-dimensional reinforcement network through mechanical interlocking of rivets and cladding, effectively suppressing the creep deformation of the polyester fiber layer under dynamic load. The elastic damping bottom layer relieves impact stress through energy dissipation mechanism, forming a rigid-flexible composite system with the upper metal structure. This multi-layer collaborative design not only retains the acoustic advantages of polyester fiber, but also obtains structural strength close to pure metal plate through topological optimization of the metal skeleton, especially solving the inherent defects of traditional polyester sound absorption panels in impact resistance, temperature stability, and long-term load reliability. The cladding design of the metal cladding creates a closed acoustic cavity, enhancing the structure while unexpectedly improving the low-frequency sound absorption effect, achieving the collaborative optimization of mechanical and acoustic performance. BRIEF DESCRIPTION OF DRAWINGS

[0020] Fig. 1 The present application is a whole structure schematic diagram;

[0021] Fig. 2This is a schematic diagram showing the overall structure of the present invention broken down;

[0022] Fig. 3 This is a cross-sectional structural diagram of the present invention.

[0023] In the diagram: 1. Micro-perforated metal surface layer; 2. Gradient density polyester fiber layer; 3. Honeycomb metal skeleton layer; 4. Elastic damping bottom layer; 5. Metal enclosure; 6. Rivet; 7. Sound absorption hole. Detailed Implementation

[0024] 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.

[0025] Example 1

[0026] like Figs. 1-3 As shown, this embodiment provides a polyester fiber sound-absorbing panel with high yield strength, comprising, from top to bottom, a micro-perforated metal surface layer 1, a gradient density polyester fiber layer 2, a honeycomb metal skeleton layer 3, and an elastic damping bottom layer 4 composed of a 4mm thick polyurethane / rubber blend damping layer, which are stacked and fixed together by adhesive. A vertically distributed metal enclosure 5 surrounds the side of the micro-perforated metal surface layer 1. The metal enclosure 5 and the micro-perforated metal surface layer 1 are integrally formed aluminum alloy structures with a thickness of 0.4mm. The metal enclosure 5 encloses the gradient density polyester fiber layer 2 and the honeycomb metal skeleton layer 3. The gradient density polyester fiber layer 2 is composed of several layers of polyester fiber with different densities stacked together, with a density ranging from 80-200 kg / m³ from top to bottom. 3 The area gradually increases, and the gradient density polyester fiber layer 2 is embedded with a prestressed glass fiber mesh. The mesh has a warp yarn diameter of 0.5 mm, a weft yarn diameter of 0.25 mm, a mesh aperture of 2.5 mm, and a pretension of 6 N / thread applied to the warp yarn. The aluminum alloy honeycomb metal skeleton layer 3 is not only glued to the adjacent upper and lower layers, but also fixed to the metal enclosure 5 by rivets 6. The honeycomb is filled with octadecane phase change microcapsules. The inner wall of the cavity unit is a composite double-layer metal wall. The inner layer of the composite double-layer metal wall is an aluminum alloy with a thickness of 0.1 mm, and the outer layer is a copper-nickel alloy with a thickness of 0.05 mm. The two layers are metallurgically bonded to form a thermal expansion differential structure. The surface of the micro-perforated metal surface layer 1 is uniformly and densely distributed with sound-absorbing holes 7. The sound-absorbing holes 7 are conical holes with an inlet diameter of 0.3 mm and an outlet diameter of 0.1 mm. The walls of the conical holes are coated with a 1.5 μm titanium nitride wear-resistant coating. The perforation rate of the micro-perforated metal surface layer 1 is 18%.

[0027] Example 2

[0028] like Figs. 1-3 As shown, this embodiment provides a polyester fiber sound-absorbing panel with high yield strength, comprising, from top to bottom, a micro-perforated metal surface layer 1, a gradient density polyester fiber layer 2, a honeycomb metal skeleton layer 3, and an elastic damping bottom layer 4 composed of a 3mm thick polyurethane / rubber blend damping layer, which are stacked and fixed together by adhesive. A vertically distributed metal enclosure 5 surrounds the side of the micro-perforated metal surface layer 1. The metal enclosure 5 and the micro-perforated metal surface layer 1 are integral stainless steel structures with a thickness of 0.5mm. The metal enclosure 5 encloses the gradient density polyester fiber layer 2 and the honeycomb metal skeleton layer 3. The gradient density polyester fiber layer 2 is a single layer of polyester fiber with a density ranging from 80-200 kg / m³ from top to bottom. 3 The area gradually increases. The gradient density polyester fiber layer 2 is embedded with a prestressed glass fiber mesh. The mesh has a warp yarn diameter of 0.6 mm, a weft yarn diameter of 0.2 mm, and a mesh aperture of 3 mm. The warp yarn is pre-tensioned at 5 N / thread. The zinc alloy honeycomb metal skeleton layer 3 is not only glued to the adjacent upper and lower layers, but also fixed to the metal enclosure 5 by rivets 6. The honeycomb is filled with octadecane phase change microcapsules. The inner wall of the honeycomb unit of the honeycomb metal skeleton layer 3 is a composite double-layer metal wall. The inner layer of the composite double-layer metal wall is an aluminum alloy with a thickness of 0.1 mm, and the outer layer is a copper-nickel alloy with a thickness of 0.05 mm. The two layers are metallurgically bonded to form a thermal expansion differential structure. The surface of the micro-perforated metal surface layer 1 is uniformly and densely distributed with sound-absorbing holes 7. The sound-absorbing holes 7 are conical holes with an inlet diameter of 0.3 mm and an outlet diameter of 0.1 mm. The walls of the conical holes are coated with a 2 μm titanium nitride wear-resistant coating. The perforation rate of the micro-perforated metal surface layer 1 is 15%.

[0029] Example 3

[0030] like Figs. 1-3 As shown, this embodiment provides a polyester fiber sound-absorbing panel with high yield strength, comprising, from top to bottom, a micro-perforated metal surface layer 1, a gradient density polyester fiber layer 2, a honeycomb metal skeleton layer 3, and an elastic damping bottom layer 4 composed of a 5mm thick polyurethane / rubber blend damping layer, which are stacked and fixed together by adhesive. A vertically distributed metal enclosure 5 surrounds the side of the micro-perforated metal surface layer 1. The metal enclosure 5 and the micro-perforated metal surface layer 1 are integrally formed aluminum alloy structures with a thickness of 0.3mm. The metal enclosure 5 encloses the gradient density polyester fiber layer 2 and the honeycomb metal skeleton layer 3. The gradient density polyester fiber layer 2 is composed of several layers of polyester fiber with different densities stacked together, with a density ranging from 80-200 kg / m³ from top to bottom. 3The area gradually increases. The gradient density polyester fiber layer 2 is embedded with a prestressed glass fiber mesh. The mesh has a warp yarn diameter of 0.4 mm, a weft yarn diameter of 0.3 mm, and a mesh aperture of 3 mm. The warp yarn is subjected to a pretension of 8 N / thread. The magnesium alloy honeycomb metal skeleton layer 3 is not only glued to the adjacent upper and lower layers, but also fixed to the metal enclosure 5 by rivets 6. The honeycomb is filled with octadecane phase change microcapsules. The inner wall of the honeycomb unit of the honeycomb metal skeleton layer 3 is a composite double-layer metal wall. The inner layer of the composite double-layer metal wall is an aluminum alloy with a thickness of 0.1 mm, and the outer layer is a copper-nickel alloy with a thickness of 0.05 mm. The two layers are metallurgically bonded to form a thermal expansion differential structure. The surface of the micro-perforated metal surface layer 1 is uniformly and densely distributed with sound-absorbing holes 7. The sound-absorbing holes 7 are conical holes with an inlet diameter of 0.3 mm and an outlet diameter of 0.1 mm. The walls of the conical holes are coated with a 1 μm titanium nitride wear-resistant coating. The perforation rate of the micro-perforated metal surface layer 1 is 20%.

[0031] Comparative Example 1

[0032] Gradient density polyester fiber layer 2 is a mesh fabric made of non-prestressed glass fiber material, and the rest is the same as in Example 1.

[0033] Comparative Example 2

[0034] The inner wall of the honeycomb metal skeleton layer 3 has no composite double-layer metal wall, and the rest is the same as in Example 1.

[0035] Comparative Example 3

[0036] The sound-absorbing hole 7 is a regular straight hole, and the hole wall is not coated with titanium nitride wear-resistant coating.

[0037] Performance tests were conducted on Examples 1-3 and Comparative Examples 1-3, and the results are shown in Table 1.

[0038] Table 1

[0039]

[0040] The yield strength test followed GB / T 228.1-2021 "Metallic Materials - Tensile Testing"; the 2000-hour creep measurement method followed GB / T 2039-2022 "Metallic Materials - Uniaxial Tensile Creep Testing"; the fatigue life measurement method followed ISO 12107:2012 "Metallic Materials - Fatigue Testing"; and the low-frequency sound absorption coefficient measurement followed GB / T 20247-2006 "Acoustic Reverberation Chamber Method for Sound Absorption Measurement".

[0041] As shown in Table 1, the prestressed glass fiber mesh, the composite double-layer metal wall honeycomb metal skeleton layer 3, and the conical sound-absorbing holes 7 with titanium nitride wear-resistant coating on the hole walls of the present invention all significantly contribute to the improvement of the yield strength, 2000h creep, fatigue life, and low-frequency sound absorption coefficient of the sound-absorbing panel.

[0042] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A sound absorbing panel of polyester fiber having high yield strength, characterized by: It comprises micro-perforated metal surface layer (1), gradient density polyester fiber layer (2), honeycomb metal framework layer (3) and elastic damping bottom layer (4) fixed by adhesive stacking from top to bottom in turn; vertical distribution metal fence (5) is arranged around the side of the micro-perforated metal surface layer (1), the metal fence (5) and the micro-perforated metal surface layer (1) are integrated into one piece, and the metal fence (5) wraps the gradient density polyester fiber layer (2) and the honeycomb metal framework layer (3) therein. The honeycomb metal framework layer (3) is fixed to each other by rivets (6) and metal fence (5) in addition to being fixed by adhesive with adjacent upper and lower layers. The gradient density polyester fiber layer (2) is embedded with a grid cloth of prestressed glass fiber material, the warp yarn diameter of the grid cloth is 0.4-0.6mm, the weft yarn diameter is 0.2-0.3mm, the grid pore size is 2-3mm, and the warp yarn is applied with a prestress of 5-8N / root. The inner wall of the honeycomb unit of the honeycomb metal framework layer (3) is a composite double-layer metal wall, the inner layer of the composite double-layer metal wall is an aluminum alloy with a thickness of 0.1mm, the outer layer is a copper-nickel alloy with a thickness of 0.05mm, and the two layers are combined by metallurgy to form a thermal expansion differential structure. The micro-perforated metal surface layer (1) is uniformly and densely distributed with sound absorbing holes (7) on the surface, the sound absorbing holes (7) are conical holes with an inlet aperture of 0.3mm and an outlet aperture of 0.1mm, and the conical hole wall is attached with a 1-2μm titanium nitride wear-resistant coating; the perforation rate of the micro-perforated metal surface layer (1) is 15-20%.

2. The high yield strength polyester fiber acoustical panel according to claim 1, characterized by: The micro-perforated metal surface layer (1) and the metal fence (5) are made of aluminum alloy or stainless steel material, and the thickness of the micro-perforated metal surface layer (1) and the metal fence (5) is 0.3-0.5mm.

3. The high yield strength polyester fiber acoustical panel according to claim 1, characterized by: The density of the gradient density polyester fiber layer (2) gradually increases along the range of 80-200kg / m³ from top to bottom.

4. The high yield strength polyester fiber acoustical panel according to claim 3, characterized by: The gradient density polyester fiber layer (2) is a whole or is formed by stacking several layers of polyester fiber layers with different densities.

5. The high yield strength polyester fiber acoustical panel according to claim 1, characterized by: The length of each honeycomb of the honeycomb metal framework layer (3) is 3-8mm.

6. The high yield strength polyester fiber acoustical panel according to claim 1, characterized by: The honeycomb metal framework layer (3) is filled with octadecane phase change microcapsules.

7. The high yield strength polyester fiber acoustical panel according to claim 1, characterized by: The elastic damping bottom layer (4) is a 3-5mm thick polyurethane and rubber blended damping layer.

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