Sound-absorbing and heat-insulating composite needled felt for ship cabin and preparation method thereof

Abstract

The invention discloses a sound-absorbing and heat-insulating composite needled felt for a ship cabin and a manufacturing method thereof, belongs to the technical field of ship interior materials, and aims to solve the problems that sound-absorbing and heat-insulating properties of sound-absorbing and heat-insulating materials commonly used in existing ship cabins are difficult to consider, the stability of a composite structure is poor, functional fillers are not uniformly distributed, and the adaptation to flame retardance and weather resistance is insufficient. The surface flow guide layer, the main sound absorption damping layer, the acoustic resonance heat insulation layer, the reflection blocking layer and the back lining attaching layer are sequentially arranged from the sound facing face to the back face, and during preparation, the full-frequency-band sound absorption blanket is prepared through fiber gradient laying, pre-needling, vacuum adsorption of seepage filler, main needling, curing at the temperature of 120-160 DEG C and hot-pressing compounding of the back layer. The composite material is resistant to ship vibration, stable in interlayer, flexibly adaptive to a complex bulkhead, efficient in construction, capable of solving the problems that an existing material is difficult to consider sound absorption and heat insulation, poor in stability and the like, and suitable for ship cabin noise and temperature difference control.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of ship interior materials, in particular to a ship cabin sound-absorbing and heat-insulating composite needle felt and a preparation method thereof. BACKGROUND

[0002] The ship cabin is the core area for the crew to work and live, and also accommodates power equipment such as engines, generators and propellers. It faces two core technical problems: noise pollution and temperature difference regulation. On the one hand, the medium and low frequency noise generated by the operation of the power equipment has strong penetrating power and is easily transmitted to the living cabin and control room through the bulkhead structure. Long-term exposure can cause hearing loss and fatigue of the crew, and even affect the accuracy of equipment operation. On the other hand, the ship sailing environment is complex, and the diurnal temperature difference on the sea can reach 15-20℃, and the heat dissipation temperature of the engine room equipment can reach 60-80℃. If the cabin heat insulation performance is insufficient, it will lead to a sharp increase in air conditioning energy consumption, and at the same time cause bulkhead condensation, accelerate the corrosion of metal structure, and shorten the service life of the ship.

[0003] The current sound-absorbing and heat-insulating materials commonly used in ship cabins mainly have the following technical defects: traditional glass wool felt and rock wool felt have certain sound-absorbing capacity, with a medium and high frequency sound-absorbing coefficient of about 0.6-0.7, but the thermal conductivity coefficient is ≥0.035 W / (m K), and the heat insulation effect is poor. The pure aerogel heat insulation material has a thermal conductivity coefficient of ≤0.02 W / (m K), but it has weak absorption capacity for medium and low frequency noise due to its single pore structure, and cannot meet the integrated needs of sound absorption and heat insulation in the cabin. The existing composite materials mostly use a layering and pasting process, such as bonding the sound-absorbing layer and the heat-insulating layer with glue, and then combining the reflecting layer. However, there is continuous vibration during ship sailing, and long-term use can easily cause interlayer peeling and delamination, leading to a sharp performance degradation, frequent maintenance and replacement, and some materials attempt to fill aerogel powder in the sound-absorbing layer, but due to the lack of effective penetration means, the aerogel is easy to accumulate on the surface of the fiber, and the internal pore filling rate is less than 30%, resulting in large fluctuations in heat insulation performance and easy settlement of the filler due to vibration, forming a heat insulation blind area. The ship cabin is a closed space, and the material has strict requirements on the flame retardant grade, but some existing materials use non-flame-retardant organic fibers or flame retardants that are easy to precipitate in the marine high-humidity and salt spray environment, resulting in the failure of the flame retardant performance, and the material has poor aging resistance and a service life of usually less than 3 years.

[0004] To solve the above problems, a ship cabin sound-absorbing and heat-insulating composite needle felt and a preparation method thereof are provided. SUMMARY

[0005] The present application aims to provide a ship cabin sound-absorbing and heat-insulating composite needle punched felt and a preparation method thereof, and solve the problems of the prior art that the sound-absorbing and heat-insulating performance of the commonly used sound-absorbing and heat-insulating material for ship cabins is difficult to balance, the composite structure has poor stability, the functional filler is unevenly distributed, and the flame retardation and weather resistance are not well adapted.

[0006] To achieve the above-mentioned object, the present application provides the following technical solutions: a ship cabin sound-absorbing and heat-insulating composite needle punched felt and a preparation method thereof, which comprises, from the sound-incident surface to the water-back surface, a surface flow guide layer, a main sound-absorbing layer, an aerogel composite layer, an aluminum foil reflection layer, and a backing adhesion layer; The surface flow guide layer is composed of superfine flame-retardant fibers, and the areal density is 80-120 g / m²; the main sound-absorbing and damping layer is composed of mixed fibers of flame-retardant organic fibers and inorganic fibers, and the density thereof increases from one side close to the surface flow guide layer to the other side; the acoustic resonance and heat insulation layer has an integral structure with the main sound-absorbing and damping layer, and is uniformly filled with a composite of silica aerogel powder and adhesive in the pores of the fiber matrix; the reflection and barrier layer is an aluminum foil composite glass fiber cloth or a flame-retardant polymer film; and the backing adhesion layer is a flame-retardant non-woven fabric or a glass fiber thin felt.

[0007] Preferably, the superfine flame-retardant fibers of the surface flow guide layer are 3-6 denier flame-retardant polyester staple fibers, and the fibers are hollow fibers.

[0008] Preferably, the mixed fibers of the main sound-absorbing and damping layer include, by mass percentage, 50% basalt fibers, 30% flame-retardant polyester fibers, and 20% low-melting-point polyester fibers, wherein the diameter of the basalt fibers is 15-25 μm.

[0009] Preferably, the adhesive in the acoustic resonance and heat insulation layer is a water-based flame-retardant adhesive.

[0010] Preferably, the flame-retardant polymer film of the reflection and barrier layer is a flame-retardant PET film.

[0011] Preferably, the method for manufacturing the ship cabin sound-absorbing and heat-insulating composite needle punched felt comprises the following steps: S1: fiber preparation and laying: prepare surface flow guide layer fibers and main sound-absorbing and damping layer fibers respectively; lay the surface flow guide layer fibers first, and then lay the main sound-absorbing and damping layer fibers on them by gradient to form a gradient density composite fiber web through a web laying machine; S2: pre-needling: pre-needle the gradient density composite fiber web to form a pre-needled felt; S3: functional filler infiltration: under vacuum adsorption conditions, spray a mixed slurry of silica aerogel powder and water-based adhesive to the pre-needled felt to make it uniformly infiltrate into the fiber web; S4: Main needling and solidification: the pre-needled felt with functional filler is subjected to main needling, and then is dried and shaped at - ℃ to make the low-melting-point fibers melt and solidify with the binder to form a composite felt body; S5: Composite back layer: the composite felt body is combined with a reflection barrier layer and a backing layer by hot-pressing to obtain the composite needled felt.

[0012] Preferably, the gradient lamination in step S1 is achieved by controlling the feeding amount of the main sound-absorbing damping layer fibers of the lapper to gradually increase the lamination density from one side close to the surface flow guide layer to the other side.

[0013] Preferably, the vacuum adsorption in step S3 is performed by applying vacuum negative pressure below the pre-needled felt and spraying on the top.

[0014] Preferably, the drying and shaping process in step S4 simultaneously completes the moisture evaporation and solidification of the binder and the thermal melting and bonding of the low-melting-point fibers.

[0015] Preferably, the dry mass ratio of the silica aerogel powder to the water-based binder in the mixed slurry in step S3 is 1:1.

[0016] Compared with the prior art, the present application has the following advantages: 1. The ship cabin sound-absorbing and heat-insulating composite needled felt and the preparation method thereof provided by the present application have the following advantages: the main sound-absorbing damping layer is designed with a density gradient, which gradually increases from one side close to the surface flow guide layer to the other side, and the hollow fiber structure of the surface flow guide layer can guide noise into deep pores, and the double effects of small-hole resonance and fiber friction can improve the sound absorption coefficient of the traditional glass wool felt in the medium and low frequency range, effectively weaken the noise of the power equipment, and further absorb high-frequency noise through the nanoscale pores of the aerogel composite layer, achieving full-band sound absorption coverage.

[0017] 2. The ship cabin sound-absorbing and heat-insulating composite needled felt and the preparation method thereof provided by the present application have the following advantages: the silica aerogel powder is uniformly filled in the fiber pores of the main sound-absorbing layer through vacuum adsorption, and the reflection barrier layer can block infrared thermal radiation, so that the overall thermal conductivity of the composite felt is greatly reduced compared with traditional materials, the air conditioning energy consumption is reduced, and condensation on the bulkhead is avoided.

[0018] 3. The ship cabin sound-absorbing and heat-insulating composite needled felt and the preparation method thereof provided by the present application have the following advantages: the main sound-absorbing damping layer and the aerogel composite layer are integrally formed with the fiber matrix through the vacuum infiltration filling process, the aerogel and the fiber are combined through the low-melting-point fiber melting and the water-based binder solidification to form a three-dimensional bonding network without interlayer interface, which can withstand the continuous vibration of the ship, and the reflection barrier layer and the backing layer are tightly combined with the composite felt body through hot-pressing, so that the overall structure has greatly increased anti-peeling strength.

[0019] 4. The present application provides a kind of ship cabin sound-absorbing and heat-insulating composite needle felt and its preparation method, by surface flow guide layer, main sound-absorbing layer, backing layer of adhesion layer are all used flame-retardant material, and the water-based adhesive of aerogel composite layer is flame-retardant, whole material vertical combustion no drip, no open fire, backing layer of adhesion layer uses flame-retardant non-woven fabric, material soft, can adapt to the complex structure such as ship cabin curved surface, corner. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 It is the overall structure diagram of the present application; Figure 2 It is the structure diagram of surface flow guide layer of the present application; Figure 3 It is the structure diagram of main sound-absorbing damping layer of the present application; Figure 4 It is the structure diagram of acoustic resonance heat insulation layer of the present application; Figure 5 It is the structure diagram of backing layer of adhesion of the present application.

[0021] In the figure: 1, surface flow guide layer;2, main sound-absorbing damping layer;3, acoustic resonance heat insulation layer;4, reflection barrier layer;5, backing layer of adhesion. DETAILED DESCRIPTION

[0022] The technical solutions in the embodiments of the present application will be described clearly and completely below in conjunction with the drawings in the embodiments of the present application.Obviously, the described embodiments are only part of the embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0023] In order to solve the problems that the sound-absorbing and heat-insulating performance of the sound-absorbing and heat-insulating materials commonly used in the existing ship cabin is difficult to consider, the composite structure stability is poor, the functional filler is unevenly distributed, and the flame-retardant and weather-resistant adaptation is insufficient, as shown in Figures 1-5 The following preferred technical solutions are provided: A composite needle-punched felt for sound absorption and heat insulation in ship cabins comprises, from the front to the back, the following layers in sequence: a surface guiding layer 1, a main sound-absorbing layer 2, an aerogel composite layer 3, an aluminum foil reflective layer 4, and a backing adhesive layer 5. The surface guiding layer 1 is composed of ultra-fine flame-retardant fibers with a surface density of 80-120 g / m². The main sound-absorbing damping layer 2 is composed of a mixture of flame-retardant organic and inorganic fibers, and its density increases gradually from the side closest to the surface guiding layer 1 to the other side. The acoustic resonance heat insulation layer 3 has a fiber matrix integrated with the main sound-absorbing damping layer 2, and the pores of the fiber matrix are uniformly filled with a composite of silica aerogel powder and adhesive. The reflective barrier layer 4 is an aluminum foil composite fiberglass cloth or a flame-retardant polymer film. The backing adhesive layer 5 is a flame-retardant non-woven fabric or a thin glass fiber felt.

[0024] Specifically, the surface guiding layer 1 material is made of 3-6 denier hollow flame-retardant polyester staple fiber with a surface density controlled at 100g / m², and the fiber flame retardant rating reaches V-0 level in GB / T2408-2021. Main sound-absorbing damping layer 2 material: Prepare mixed fibers according to mass percentage, of which 50% are basalt fibers with a diameter of 20μm, conforming to GB / T23265-2009 standard, 30% are flame-retardant polyester fibers with a limiting oxygen index ≥28%, and 20% are low-melting-point polyester fibers with a melting point of 110-120℃. Acoustic resonance insulation layer 3 filler: silica aerogel powder with a particle size of 5-10μm and a thermal conductivity ≤0.018W / (m²). K), and water-based flame retardant adhesive acrylate with a solid content of 40%, are mixed in a dry mass ratio of 1:1 to form a uniform slurry; Reflective barrier layer 4 material: aluminum foil composite fiberglass cloth, aluminum foil thickness 0.02mm, fiberglass cloth surface density 50g / m², flame retardant rating V-0; Backing and bonding layer 5 material: Flame-retardant non-woven fabric is made of polyester with a surface density of 60g / m² and a limiting oxygen index of ≥30%.

[0025] To further explain the above embodiments, the present invention also provides an implementation method: a method for preparing a sound-absorbing and heat-insulating composite needle-punched felt for ship cabins, comprising the following steps: Step S1: Fiber preparation and gradient layup: The surface guide layer fiber and the mixed main sound-absorbing damping layer fiber are fully opened by an opening machine. Using a double-curtain web laying machine, the surface guide layer fiber is laid first, and the areal density is controlled to be 100g / m². Then, during the layup of the main sound-absorbing damping layer fiber, the fiber feeding amount is linearly increased by controlling the feeding roller speed of the web laying machine. Specifically, in the initial stage near the surface guide layer, the feeding amount is set to 50%. When the total thickness is about 2 / 3, the feeding amount is gradually increased to 100% and maintained until the web laying is completed. Finally, a composite fiber web of surface guide layer and main sound-absorbing damping layer with obvious density gradient and a total areal density of 600g / m² is formed.

[0026] Step S2: Pre-needling: The above composite fiber web is fed into a pre-needling machine with a needle density of 80 needles / cm² and a needle depth of 8mm. After pre-needling, the fiber web gains preliminary strength and is easy to transport.

[0027] Step S3: Functional filler infiltration: The pre-needle-punched felt is introduced into a sealed vacuum spraying box. The conveyor belt at the bottom of the box has a porous structure and is connected to a vacuum pump to maintain a negative pressure of -0.05MPa. Multiple fan-shaped nozzles are set above the box to spray a uniform slurry prepared by mixing silica aerogel powder and water-based flame retardant adhesive at a dry mass ratio of 1:1 onto the surface of the felt. Under the suction of the vacuum negative pressure, the slurry is forced and uniformly penetrates through the entire thickness of the felt. By controlling the conveying speed and spraying amount, the final total weight gain of the felt reaches 35%.

[0028] Step S4: Main Needling and Curing: The wet felt body infiltrated with filler is fed into the main needle-punching machine. The needle density is 150 needles / cm², and the needle depth is 10mm. This step further entangles the fibers and firmly fixes the aerogel particles. Subsequently, the felt body enters a hot air drying and shaping machine and is treated at 145°C for 5 minutes. During this process, the water-based adhesive evaporates and cures, while the low-melting-point polyester fibers soften and melt, forming a strong bond with other fibers and aerogel particles, resulting in a composite felt body with excellent integrity. Step S5: Composite Backing Layer: Using a two-roller hot press laminating machine, the aluminum foil composite fiberglass cloth of the reflective barrier layer is stacked with the aluminum foil side facing outwards, the acoustic resonance heat insulation layer is in contact with the aluminum foil, and the backing bonding layer is stacked in sequence. The hot pressing temperature is 110°C, the pressure is 0.5MPa, and the speed is 3 meters / minute. The hot pressing ensures that the hot melt adhesive film pre-coated on each layer is firmly bonded, resulting in a final product with a total thickness of approximately 20mm.

[0029] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0030] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A composite needle-punched felt for sound absorption and heat insulation in ship cabins, comprising, from the sound-facing side to the backwater side: Surface guiding layer (1), main sound absorbing layer (2), aerogel composite layer (3), aluminum foil reflective layer (4) and backing bonding layer (5); The surface guiding layer (1) is composed of ultrafine flame-retardant fibers with a surface density of 80-120 g / m². The main sound-absorbing damping layer (2) is composed of a mixture of flame-retardant organic fibers and inorganic fibers, and its density increases in a gradient from one side close to the surface guiding layer (1) to the other side. The acoustic resonance heat insulation layer (3) has a fiber matrix integrated with the main sound-absorbing damping layer (2), and the pores of the fiber matrix are uniformly filled with a composite of silica aerogel powder and adhesive. The reflective barrier layer (4) is an aluminum foil composite fiberglass cloth or a flame-retardant polymer film. The backing bonding layer (5) is a flame-retardant nonwoven fabric or a glass fiber felt.

2. The sound-absorbing and heat-insulating composite needle-punched felt for ship cabins as described in claim 1, characterized in that: The ultrafine flame-retardant fiber of the surface guiding layer (1) is a 3-6 denier flame-retardant polyester short fiber, and the fiber is a hollow fiber.

3. The sound-absorbing and heat-insulating composite needle-punched felt for ship cabins as described in claim 1, characterized in that: The main sound-absorbing damping layer (2) comprises, by mass percentage: 50% basalt fiber, 30% flame-retardant polyester fiber and 20% low-melting-point polyester fiber, wherein the diameter of the basalt fiber is 15-25 μm.

4. The sound-absorbing and heat-insulating composite needle-punched felt for ship cabins as described in claim 1, characterized in that: The adhesive in the acoustic resonance heat insulation layer (3) is a water-based flame-retardant adhesive.

5. The sound-absorbing and heat-insulating composite needle-punched felt for ship cabins as described in claim 1, characterized in that: The flame-retardant polymer film of the reflective barrier layer (4) is a flame-retardant PET film.

6. A method for preparing the sound-absorbing and heat-insulating composite needle-punched felt for ship cabins as described in any one of claims 1-5, characterized in that, Includes the following steps: S1: Fiber preparation and laying: Prepare the surface flow guiding layer fiber and the main sound absorbing damping layer fiber respectively; first lay the surface flow guiding layer fiber with a web laying machine, and then lay the main sound absorbing damping layer fiber on it in a gradient to form a gradient density composite fiber web. S2: Pre-needling: The gradient density composite fiber web is pre-needled to form a pre-needled felt; S3: Functional filler infiltration: Under vacuum adsorption conditions, a mixture of silica aerogel powder and water-based adhesive is sprayed onto the pre-needled felt to allow it to penetrate evenly into the fiber web. S4: Main Needling and Curing: The pre-needled felt with infiltrated functional filler is needled, and then dried and shaped at 120-160℃ to melt the low melting point fiber and cure it together with the adhesive to form a composite felt. S5: Composite backing layer: The composite felt body is combined with the reflective barrier layer (4) and the backing bonding layer (5) by hot pressing to obtain the composite needle-punched felt.

7. The method for manufacturing the sound-absorbing and heat-insulating composite needle-punched felt for ship cabins according to claim 6, characterized in that: The gradient layup in step S1 is achieved by controlling the amount of fiber fed into the main sound-absorbing damping layer by the web laying machine, so that the layup density gradually increases from one side near the surface flow guide layer to the other side.

8. The method for manufacturing the sound-absorbing and heat-insulating composite needle-punched felt for ship cabins according to claim 6, characterized in that: The vacuum adsorption conditions described in step S3 are to apply a vacuum negative pressure below the pre-needle-punched felt while spraying is performed above it.

9. The method for manufacturing the sound-absorbing and heat-insulating composite needle-punched felt for ship cabins according to claim 6, characterized in that: The drying and shaping process described in step S4 simultaneously completes the moisture evaporation and curing of the adhesive and the hot-melt bonding of the low-melting-point fibers.

10. The method for manufacturing the sound-absorbing and heat-insulating composite needle-punched felt for ship cabins according to claim 6, characterized in that: In the mixed slurry described in step S3, the dry mass ratio of silica aerogel powder to water-based binder is 1:1.

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