Fabric sound-absorbing material filled with light and soft three-dimensional cavity structure units and preparation method and application thereof

Abstract

The present application relates to a kind of filled light fabric sound-absorbing material of three-dimensional cavity structure unit and its preparation method and application.The fabric sound-absorbing material and its preparation method include: design periodic hollow tissue fabric, weave in hollow layer in one or more light three-dimensional cavity unit, obtain the fabric sound-absorbing material filled with light three-dimensional cavity structure unit;Light three-dimensional cavity unit is by long non-woven fabric, is formed vertical fold by ultrasonic wave, non-woven fabric is folded at a certain angle, again it is fixed angle with hot melt adhesive and is pasted plane non-woven fabric at its bottom layer, and its cross section is rectangle, sector or honeycomb shape etc.The fabric sound-absorbing material combines porous and resonance sound-absorbing principle, realizes wideband sound absorption, and the average sound absorption coefficient in the frequency range of 200~1700Hz can reach 0.70 at most;Fabric sound-absorbing material prepared is light, preparation method is simple, sound absorption is good, is suitable for building and interior decoration, automobile and high-speed rail interior decoration and other noise control fields.

Description

Technical Field

[0001] This invention belongs to the field of fiber sound-absorbing materials and their preparation, and particularly relates to fabric sound-absorbing materials filled with flexible three-dimensional cavity structural units, their preparation methods and applications. Background Technology

[0002] As a porous material, woven fabrics primarily experience sound attenuation when sound enters. Firstly, the sound waves cause vibrations in the air between the yarns and fibers, resulting in viscous loss due to intense friction against the pore walls. Secondly, the sound waves cause continuous compression and recovery of the air within the material, leading to heat exchange and the conversion of sound energy into mechanical and thermal energy. Mid-to-high frequency sound waves exhibit more intense vibrations, with significant viscous and thermal conduction effects, resulting in greater sound energy dissipation. Conversely, low-frequency sound waves dissipate less sound energy, leading to weaker low-frequency sound absorption and noise reduction performance. Typically, an air cavity is left behind the woven sound-absorbing material. Utilizing the cavity resonance principle, a resonant absorption peak is generated, thereby improving the low-frequency sound absorption effect of the woven sound-absorbing material. However, this also significantly reduces the sound absorption effect in the frequency range behind the absorption peak.

[0003] This invention combines the characteristics of random fiber entanglement and softness within nonwoven fabrics with a special fabric structure design. It utilizes ultrasonic bonding technology to prepare soft, three-dimensional cavity structure units, each containing both a cavity structure and porous flexible material. These units are filled into the interior of a specially structured fabric, forming an integrated sound-absorbing structure that combines the cavity and porous material, thereby improving the low-frequency sound absorption performance of the fabric. Furthermore, by designing the cross-sectional shape of the soft, three-dimensional cavity structure units to be square, rectangular, fan-shaped, or honeycomb-shaped, the three-dimensional cavity is divided into multiple smaller cavities of different shapes, further increasing the reflection attenuation of sound waves within the three-dimensional cavity structure units, enhancing the sound absorption performance of the fabric, and achieving a broadband sound absorption effect. Summary of the Invention

[0004] The technical problem to be solved by this invention is to provide a fabric sound-absorbing material filled with a flexible three-dimensional cavity structure unit, its preparation method, and its application. The fabric sound-absorbing material prepared by this method has excellent low-frequency sound absorption performance. In the frequency range of 200~1700Hz, the average sound absorption coefficient of the fabric sound-absorbing material filled with the flexible three-dimensional cavity structure unit can reach up to 0.70, and the maximum sound absorption coefficient of the fabric sound-absorbing material filled with the flexible three-dimensional cavity structure unit can reach 0.98 at a low frequency of 1074Hz. The fabric sound-absorbing material prepared by this invention has a wide low-frequency sound absorption band, and the sound absorption coefficient of the fabric sound-absorbing material filled with the flexible three-dimensional cavity structure unit is greater than 0.30 in the frequency range of 500~1700Hz. The fabric sound-absorbing material prepared by this invention combines the principles of porous and resonant sound absorption, which improves the low-frequency sound absorption performance of the fabric sound-absorbing material. The prepared fabric sound-absorbing material is flexible, the preparation method is simple, and the sound absorption effect is good, making it suitable for application in noise control fields such as building and interior decoration, automobile and high-speed rail interiors.

[0005] A fabric sound-absorbing material filled with flexible three-dimensional cavity structure units is characterized in that: the fabric sound-absorbing material is composed of flexible three-dimensional cavity structure units and a fabric containing periodic hollow layers; the flexible three-dimensional cavity structure unit is composed of a three-dimensional nonwoven fabric structure and a bottom planar nonwoven fabric, wherein the cross-sectional edges and internal frame of the three-dimensional nonwoven fabric structure are both nonwoven fabric, and the cross-sectional shape of the three-dimensional nonwoven fabric structure is square, rectangular, fan-shaped, or honeycomb-shaped, etc.; the fabric containing periodic hollow layers is composed of upper and lower layered fabrics and a single layer structure, the upper and lower layered fabrics having a plain weave, honeycomb, etc., and the single layer structure having a plain weave, twill weave, or warp weave, etc.; the nonwoven fabric is a nonwoven fabric that is imitation adhesive, meltblown, or needle-punched; the number of flexible three-dimensional cavity structure units filled in the periodic hollow layers of the fabric is 1 to 4, the height of each flexible three-dimensional cavity structure unit is 0.30 to 2.20 cm, and the cavity bottom area is 1.91 to 30.55 cm². 2 The thickness of the fabric sound-absorbing material filling the flexible three-dimensional cavity structure unit is 0.40~2.50cm, and the basis weight of the fabric sound-absorbing material is 0.60~1.60kg / m³. 2 .

[0006] The method for preparing the fabric sound-absorbing material filled with a flexible three-dimensional cavity structural unit according to the present invention includes:

[0007] The nonwoven fabric is cut into several strips. Using an ultrasonic bonding machine, hot pressing is performed along the short side of the nonwoven fabric strips to create vertical creases. This is repeated along the long side of the nonwoven fabric at equal intervals to create multiple vertical creases. The nonwoven fabric is then folded at a certain angle along the creases. Hot melt adhesive is used to bond the beginning and end edges and the middle part of the nonwoven fabric strips according to the design shape to form a three-dimensional nonwoven fabric structure with a square, rectangular, fan-shaped, or honeycomb cross-section. Finally, hot melt adhesive is used to attach a flat nonwoven fabric to the bottom layer of the three-dimensional nonwoven fabric structure to form a flexible three-dimensional hollow structure unit.

[0008] Based on a double-layer structure, the front warp and back warp are arranged in a 1:1 ratio. By setting joints at the intersection of the front warp and back weft, the warp yarns of the front structure are lifted during the weaving of the back structure and do not participate in the weaving of the back structure, thus creating two layers of fabric. The warp yarns of the front and back layers are arranged in parallel, and the weft yarns are in a spiral shape. Then, a single-layer structure is used to continuously connect the four edges of the upper and lower layers of fabric of a certain size, forming a fabric with a periodic hollow layer that is connected at the four edges and separated in the middle. During the weaving of the fabric with the periodic hollow layer, one or more flexible three-dimensional cavity structure units are filled into the periodic hollow layer of the fabric, and then sealed by a single-layer structure, finally obtaining a fabric sound-absorbing material filled with flexible three-dimensional cavity structure units.

[0009] The invention relates to the application of a fabric sound-absorbing material filled with a flexible three-dimensional cavity structure unit. This fabric sound-absorbing material is used in noise control fields such as building and interior decoration, automobile and high-speed rail interiors.

[0010] Beneficial effects

[0011] The fabric sound-absorbing material prepared by this invention exhibits excellent low-frequency sound absorption performance. Within the frequency range of 200~1700Hz, the average sound absorption coefficient of the fabric sound-absorbing material filled with a flexible three-dimensional cavity structure unit can reach up to 0.70. Among them, the maximum sound absorption coefficient of the fabric sound-absorbing material filled with a flexible three-dimensional cavity structure unit can reach 0.98 at a low frequency of 1074Hz. The fabric sound-absorbing material prepared by this invention has a wide low-frequency sound absorption band, and the sound absorption coefficient of the fabric sound-absorbing material filled with a flexible three-dimensional cavity structure unit is greater than 0.30 in the frequency range of 500~1700Hz.

[0012] The fabric sound-absorbing material prepared by this invention absorbs mid-to-high frequency sound waves through a porous sound absorption mechanism. The flexible three-dimensional cavity structure unit, made of lightweight and easily processed non-woven fabric, also absorbs mid-to-high frequency sound waves through a porous sound absorption mechanism, further enhancing the mid-to-high frequency sound absorption performance of the fabric sound-absorbing material. At the same time, the flexible three-dimensional cavity structure unit can produce a resonant sound absorption effect in the low-frequency range. Combining the cavity and porous material into an integrated sound-absorbing structure, a fabric sound-absorbing material filled with a flexible three-dimensional cavity structure unit is obtained, which significantly improves the low-frequency sound absorption performance of the fabric sound-absorbing material. The prepared fabric sound-absorbing material is flexible, the preparation method is simple, and the sound absorption effect is good, making it suitable for application in noise control fields such as building and interior decoration, automobile and high-speed rail interiors. Attached Figure Description

[0013] Figure 1 The sound absorption coefficient curves of fabric sound-absorbing materials filled with flexible three-dimensional cavity structural units and their comparison with the sound absorption coefficients of unfilled ordinary fabrics are presented. The flexible three-dimensional cavity structural units include: flexible square three-dimensional cavity structural units, flexible fan-shaped three-dimensional cavity structural units, and flexible honeycomb three-dimensional cavity structural units. The comparison sample is unfilled ordinary fabric. During the sound absorption test, the distance between all materials and the rigid wall behind them was set to 2 cm.

[0014] Figure 2(a)-Figure 2(b): Simplified structural diagrams of fabric sound-absorbing material filling a flexible three-dimensional cavity structural unit and the flexible three-dimensional cavity structural unit. Figure 2(a) is a simplified structural diagram of fabric sound-absorbing material filling a flexible three-dimensional cavity structural unit, and Figure 2(b) is a simplified structural diagram of a flexible three-dimensional cavity structural unit with square, fan-shaped and honeycomb cross-sectional shapes.

[0015] The meanings of the components represented by each number in the attached diagram are listed below:

[0016] 1: Upper layer of the periodic hollow layer; 2: Middle layer of the periodic hollow layer; 3: Lower layer of the periodic hollow layer; 4: Flexible three-dimensional cavity structure unit; 5: Three-dimensional nonwoven fabric structure; 6: Bottom layer planar nonwoven fabric. Specific implementation methods

[0017] The present invention will be further illustrated below with reference to specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. Furthermore, it should be understood that after reading the teachings of this invention, those skilled in the art can make various alterations or modifications to the invention, and these equivalent forms also fall within the scope defined by the appended claims.

[0018] Example 1

[0019] The nonwoven fabric is cut into several strips with a width of 2cm, a length of 3cm, and a length of 2.60cm. Using an ultrasonic bonding machine, vertical creases are created by hot-pressing along the short sides of the strips, parallel to their lengths. This is repeated multiple times along the long sides of the nonwoven fabric at equal intervals, creating multiple vertical creases. The nonwoven fabric is then folded at a certain angle along these creases. Hot melt adhesive is used to bond the edges and middle sections of the strips according to the designed shape, forming a three-dimensional nonwoven fabric structure with a square cross-section. A flat nonwoven fabric is then glued to the bottom layer of this square three-dimensional nonwoven fabric structure using hot melt adhesive, creating a flexible square three-dimensional cavity structure unit. This is achieved through a double-layer weave. Based on this structure, the front warp and back warp are arranged in a 1:1 ratio. By setting joints at the intersections of the front and back weft yarns, the warp yarns of the front weave are lifted during the weaving of the back weave and do not participate in its construction. This creates two separate layers of fabric, with the warp yarns of the front and back layers arranged in parallel and the weft yarns in a spiral pattern. A single-layer plain weave is then used to continuously connect the four edges of the two layers of fabric of a certain size, forming a fabric with a periodic hollow layer that is connected at the four edges and separated in the middle. During the weaving of this periodic hollow layer fabric, a prepared flexible square three-dimensional cavity structure unit is filled into the periodic hollow layer of the fabric. The opening is then sealed with a single-layer plain weave, ultimately obtaining a fabric sound-absorbing material filled with the flexible square three-dimensional cavity structure unit. The number of flexible square three-dimensional cavity structure units filling the periodic hollow layer of the fabric is one, with a height of 2.20 cm and a cavity bottom area of ​​7.29 cm². 2 The thickness of the fabric sound-absorbing material filling the flexible square three-dimensional cavity structure unit is 2.27 cm, and the basis weight of the fabric sound-absorbing material is 0.86 kg / m³. 2 .

[0020] Example 2

[0021] Nonwoven fabric is cut into several strips, each 2cm wide and 3cm long. Using an ultrasonic bonding machine, vertical creases are created by hot-pressing along the short sides of the strips, parallel to their length. This is repeated multiple times along the long sides of the nonwoven fabric at equal intervals, creating multiple vertical creases. The nonwoven fabric is then folded at a certain angle along these creases to form 10 fan-shaped sections. Hot melt adhesive is used to bond the edges and middle sections of the nonwoven strips according to the designed shape, forming a three-dimensional nonwoven fabric structure with a fan-shaped cross-section. Then, hot melt adhesive is used to attach a flat nonwoven fabric to the bottom layer of this fan-shaped three-dimensional nonwoven fabric structure, creating a flexible fan-shaped three-dimensional cavity structure unit. This double-layer structure... Based on this, the front warp and back warp are arranged in a 1:1 ratio. By setting joints at the intersections of the front and back weft yarns, the warp yarns of the front weave are lifted during the weaving of the back weave and do not participate in its construction. This creates two separate layers of fabric, with the warp yarns of the front and back layers arranged in parallel and the weft yarns in a spiral pattern. A single-layer plain weave is then used to continuously connect the four edges of the two layers of fabric of a certain size, forming a fabric with a periodic hollow layer that is connected at the four edges and separated in the middle. During the weaving of the fabric with the periodic hollow layer, a prepared flexible fan-shaped three-dimensional cavity structure unit is filled into the periodic hollow layer of the fabric. The opening is then sealed with a single-layer plain weave, ultimately obtaining a sound-absorbing fabric filled with flexible fan-shaped three-dimensional cavity structure units. The periodic hollow layer of the fabric contains one flexible fan-shaped three-dimensional cavity structure unit, with each fan having a side length of 1.50 cm, a height of 2.20 cm, and a cavity bottom area of ​​7.07 cm². 2 The thickness of the fabric sound-absorbing material filling the flexible fan-shaped three-dimensional cavity structure unit is 2.28 cm, and the basis weight of the fabric sound-absorbing material is 1.03 kg / m³. 2 .

[0022] Example 3

[0023] The nonwoven fabric is cut into several strips, each 2cm wide and 6cm long. Using an ultrasonic bonding machine, vertical creases are created by hot-pressing along the short sides of the strips, parallel to their lengths. This is repeated multiple times along the long sides of the nonwoven fabric at equal intervals, creating multiple vertical creases. The nonwoven fabric is then folded at a certain angle along these creases, and hot-melt adhesive is used to bond the edges and middle sections of the strips according to a designed shape, forming a three-dimensional nonwoven fabric structure with a honeycomb cross-section. The honeycomb structure consists of 10 regular hexagonal cells. Finally, flat nonwoven fabric is glued to the bottom layer of the honeycomb structure using hot-melt adhesive, creating a soft honeycomb effect. The fabric employs a three-dimensional hollow structure unit. Based on a double-layer weave structure, the front and back warp yarns are arranged in a 1:1 ratio. By setting joints at the intersections of the front and back warp yarns, the warp yarns of the front weave are lifted during the weaving of the back weave and do not participate in its construction. This creates two separate layers, with the warp yarns of the front and back layers arranged in parallel and the weft yarns in a spiral pattern. A single-layer plain weave is then used to continuously connect the four edges of the two layers of fabric of a certain size, forming a fabric with a periodic hollow layer that is connected at the four edges and separated in the middle. During the weaving of the fabric with the periodic hollow layer, the prepared flexible honeycomb-shaped three-dimensional hollow structure unit is filled into the periodic hollow layer of the fabric. The opening is then sealed with a single-layer plain weave, ultimately obtaining a sound-absorbing fabric filled with flexible honeycomb-shaped three-dimensional hollow structure units. The number of flexible honeycomb-shaped three-dimensional hollow structure units filling the periodic hollow layer of the fabric is one, with each cell having a side length of 0.54 cm, a height of 2.20 cm, and a cavity bottom area of ​​7.58 cm². 2 The thickness of the fabric sound-absorbing material filling the flexible honeycomb-shaped three-dimensional cavity structure unit is 2.28 cm, and the basis weight of the fabric sound-absorbing material is 1.06 kg / m³. 2 .

[0024] Comparative Example 1

[0025] Based on a double-layer structure, the front warp and back warp are arranged in a 1:1 ratio. By setting joints at the intersections of the front and back weft yarns, the warp yarns of the front weave are lifted during the weaving of the back weave and do not participate in its construction. This creates two separate layers, with the warp yarns of the two layers arranged in parallel and the weft yarns in a spiral pattern. A single-layer plain weave is then used to continuously connect the four edges of the two layers of fabric of a certain size, forming a plain fabric without filling, with four connected edges and a separated center, containing a periodic hollow layer. The thickness of the plain fabric without filling is 0.10 cm, and its weight is 0.61 kg / m². 2 .

[0026] Compared to unfilled ordinary fabrics, fabric sound-absorbing materials filled with flexible square three-dimensional cavity structural units, flexible fan-shaped three-dimensional cavity structural units, and flexible honeycomb three-dimensional cavity structural units exhibit superior low-frequency sound absorption performance. This indicates that filling with flexible three-dimensional cavity structural units is beneficial for improving the low-frequency sound absorption performance of fabric sound-absorbing materials. Furthermore, since the three-dimensional cavity structural units are flexible porous nonwoven fabrics, they can increase the porous sound absorption effect while achieving cavity resonance, thus ensuring that the sound absorption curve remains high in the mid-to-high frequency range after the sound absorption resonance peak. Compared to fabric sound-absorbing materials filled with flexible square and fan-shaped three-dimensional cavity structural units, fabric sound-absorbing materials filled with flexible honeycomb three-dimensional cavity structural units have a wider sound absorption bandwidth and better low-frequency sound absorption performance. This indicates that filling with flexible honeycomb three-dimensional cavity structural units is more beneficial for improving the low-frequency sound absorption performance of fabric sound-absorbing materials and achieving a broadband sound absorption effect.

Claims

1. A fabric sound-absorbing material filled with a flexible three-dimensional cavity structure unit, characterized in that: The fabric sound-absorbing material consists of flexible three-dimensional cavity structure units and a fabric containing periodic hollow layers. The flexible three-dimensional cavity structure units are composed of a three-dimensional nonwoven fabric structure and a bottom layer of planar nonwoven fabric. The cross-sectional edges and internal framework of the three-dimensional nonwoven fabric structure are made of nonwoven fabric, and the cross-sectional shape of the three-dimensional nonwoven fabric structure is square, rectangular, fan-shaped, or honeycomb-shaped, etc. The fabric containing the periodic hollow layers consists of upper and lower layered fabrics and a single layer. The upper and lower layered fabrics have plain weave, honeycomb, etc., and the single layer has plain weave, twill weave, or warp-faced weave, etc. The nonwoven fabric is a nonwoven fabric made of imitation adhesive, meltblown, or needle-punched fabric. The periodic hollow layers of the fabric are filled with 1 to 4 flexible three-dimensional cavity structure units, each with a height of 0.30 to 2.20 cm and a cavity bottom area of ​​1.91 to 30.55 cm². 2 The thickness of the fabric sound-absorbing material filling the flexible three-dimensional cavity structure unit is 0.40~2.50cm, and the basis weight of the fabric sound-absorbing material is 0.60~1.60kg / m³. 2 .

2. The method for preparing a fabric sound-absorbing material filled with a flexible three-dimensional cavity structure unit according to claim 1, comprising: (1) Cut the nonwoven fabric into several strips, use an ultrasonic bonding machine to heat press along the short side of the nonwoven fabric strips to form vertical creases on the nonwoven fabric. Heat press along the long side of the nonwoven fabric at the same intervals multiple times to form multiple vertical creases. Then fold the nonwoven fabric at a certain angle along the creases. Use hot melt adhesive to bond the beginning and end edges and the middle part of the nonwoven fabric strips according to the shape design to form a three-dimensional nonwoven fabric structure with square, rectangular, fan-shaped or honeycomb cross-section. Then use hot melt adhesive to paste the flat nonwoven fabric to the bottom layer of the three-dimensional nonwoven fabric structure to form a flexible three-dimensional cavity structure unit. (2) Based on the double-layer structure, the outer warp and inner warp are arranged in a 1:1 ratio. By setting the joint point at the intersection of the outer warp and inner weft, the warp yarn of the outer structure is lifted during the weaving of the inner structure and does not participate in the weaving of the inner structure, so that the upper and lower layers of fabric are layered. The warp yarns of the outer and inner layers are arranged in parallel and the weft yarns are in a spiral state. Then, the four edges of the upper and lower layered fabrics of a certain size are continuously connected by a single-layer structure to form a fabric with a periodic hollow layer that is connected at the four edges and separated in the middle. During the weaving process of the fabric with the periodic hollow layer, one or more flexible three-dimensional cavity structure units are filled into the periodic hollow layer of the fabric, and then sealed by the single-layer structure. Finally, the sound-absorbing material of the fabric filled with flexible three-dimensional cavity structure units is obtained.

3. The application of the fabric sound-absorbing material filled with a flexible three-dimensional cavity structure unit according to claim 1, characterized in that: Fabric sound-absorbing materials can be applied to noise control in fields such as building and interior decoration, automobile and high-speed rail interiors.

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