Composite polyester fiber sound absorbing panel

Abstract

The utility model discloses a composite polyester fiber sound absorption board, including from outside to inside gradually composite fixed decoration protection layer, gradient sound absorption layer, damping noise reduction layer, honeycomb support layer and grid reinforcing polyester fiber base layer, the water-based environmental protection adhesive is bonded between each layer, ensures that the interlayer combines closely and meets the environmental protection requirement, and the overall structure cooperates along the thickness direction, and the sound absorption, support and decoration function are taken into account. The utility model aims at overcoming the single sound absorption frequency band of the existing polyester fiber sound absorption board, low structural strength, decorative and functional contradiction and the defects of insufficient environmental protection, provides a kind of composite polyester fiber sound absorption board that realizes multi-frequency band sound absorption, stable support, decoration protection integration and environmental protection by layered composite design.

Description

Technical Field

[0001] This utility model relates to the field of building decoration technology, specifically to a composite polyester fiber sound-absorbing board. Background Technology

[0002] Polyester fiber acoustic panels are widely used in interior acoustic decoration due to their advantages such as environmental friendliness, lightweight, and ease of processing. However, existing products have obvious defects in actual use and cannot meet diverse needs: Single sound absorption band: Traditional polyester fiber sound-absorbing panels mostly rely on a single fiber structure, which only has a good absorption effect on mid-to-high frequency noise, and has a weak absorption capacity for low frequency noise (such as air conditioner operation noise and equipment vibration noise), resulting in poor overall noise reduction effect; Insufficient structural strength: Most existing sound-absorbing panels are single-layer or simple composite structures with poor tensile and bending resistance. They are prone to deformation and cracking after long-term use. Especially when installed over a large area, additional reinforcement is required, which increases construction costs. The contradiction between decoration and function: Some sound-absorbing panels are covered with a thick decorative layer to enhance the decorative effect, which can easily clog the gaps between fibers and reduce the sound absorption performance; while products that focus on sound absorption effect are mostly solid colors or simple textures, which are not decorative enough. Environmental friendliness and bonding strength need improvement: Some products use solvent-based adhesives to bond the layers, which can easily release harmful gases and does not meet environmental protection requirements; moreover, the interlayer bonding strength is low, and delamination is likely to occur after long-term use, affecting the overall performance.

[0003] To address the aforementioned issues, a composite polyester fiber sound-absorbing board with good multi-band sound absorption, stable structure, strong decorative properties, and environmental friendliness was proposed and designed. Utility Model Content

[0004] This utility model aims to overcome the shortcomings of existing polyester fiber sound-absorbing panels, such as single sound absorption band, low structural strength, contradiction between decoration and functionality, and insufficient environmental protection. It provides a composite polyester fiber sound-absorbing panel that integrates multi-frequency sound absorption, stable support, decoration and protection through a layered composite design, and is also environmentally friendly.

[0005] Therefore, the specific technical solution adopted by this utility model is as follows: A composite polyester fiber sound-absorbing panel includes, from the outside to the inside, a decorative protective layer, a gradient sound-absorbing layer, a damping noise reduction layer, a honeycomb support layer, and a grid-reinforced polyester fiber base layer, which are sequentially composited and fixed. The layers are bonded together with water-based environmentally friendly adhesive to ensure tight interlayer bonding and compliance with environmental protection requirements. The overall structure works synergistically along the thickness direction, taking into account sound absorption, support, and decorative functions.

[0006] The decorative protective layer, as the outermost layer of the board, combines aesthetics and wear resistance, and includes a PVC decorative film and an epoxy wear-resistant coating. The PVC decorative film can be designed with different patterns according to the usage scenario to meet diverse decorative needs. The epoxy wear-resistant coating is applied to the outer surface of the PVC decorative film to improve the surface's scratch resistance and prevent scratches during daily use. At the same time, the inner surface of the PVC decorative film has serrated protrusions, which can be embedded and fixed with the outer polyester fiber layer of the gradient sound-absorbing layer to enhance the interlayer bonding strength and prevent peeling.

[0007] The gradient sound-absorbing layer is one of the core sound-absorbing structures, consisting of at least two layers of flame-retardant polyester fiber with gradually decreasing pore size. The pore size gradually decreases from the side closer to the decorative protective layer to the side closer to the damping noise reduction layer. The gradual pore size design can adapt to different frequency bands of noise: the outer large-pore fiber layer allows low-frequency noise to enter the interior of the board more easily, while the inner small-pore fiber layer can fully absorb mid- and high-frequency noise, achieving layered absorption of multi-frequency noise. In addition, the fiber layer is made of flame-retardant material, which improves the fire safety of the board.

[0008] The damping noise reduction layer uses a butyl rubber damping membrane. Butyl rubber has excellent damping performance and can dissipate sound wave energy through its own deformation, especially having a significant suppression effect on low-frequency vibration noise. The side facing the gradient sound absorption layer has uniformly distributed micro-protrusions. The micro-protrusions can increase the contact area between the damping membrane and the gradient sound absorption layer, improve the damping loss during sound wave transmission, and at the same time, the tiny gaps formed by the micro-protrusions can help absorb some noise, further enhancing the noise reduction effect.

[0009] The honeycomb support layer serves as the core of the structural support for the board and also assists in sound absorption. The honeycomb holes extend along the thickness direction of the board, forming a regular cavity structure. The cavity can dissipate sound wave energy through the vibration of the air column, thus enhancing the sound absorption effect. The honeycomb wall surface is integrally formed with cross-arranged reinforcing ribs, which can enhance the bending and deformation resistance of the honeycomb structure and prevent the honeycomb wall from collapsing under pressure. The polyester fiber sound-absorbing cotton filled in the honeycomb holes can further fill the cavity gaps, improve the absorption effect of mid-to-high frequency noise, and form a dual sound absorption structure of cavity and fiber with the honeycomb cavity.

[0010] The reinforced polyester fiber base layer serves as the bottom support for the board, and is composed of a polyester fiberboard and a fiberglass mesh. The polyester fiberboard itself has a certain supporting strength, and the fiberglass mesh embedded in it can significantly improve the tensile and tear resistance of the base layer, preventing deformation of the board during long-term use or large-area installation. The surface of the fiberglass mesh is coated with a silane coupling agent coating, which can enhance its bonding strength with the polyester fiberboard and prevent the mesh from separating from the polyester fiberboard.

[0011] Furthermore, the gradient sound-absorbing layer comprises an outer polyester fiber layer and an inner polyester fiber layer. The pore size of the outer polyester fiber layer is 1.5–2 mm, and the pore size of the inner polyester fiber layer is 0.5–0.8 mm. The overall thickness of the gradient sound-absorbing layer is 5–8 mm, and the thickness ratio of the outer polyester fiber layer to the inner polyester fiber layer is 2:1–3:1. This size design can balance the sound absorption effect of high and low frequency bands. The sufficiently thick outer layer with large pore size ensures that low frequency noise can enter, while the inner layer with small pore size ensures the adsorption of mid and high frequency noise.

[0012] Furthermore, the overall thickness of the butyl rubber damping membrane in the damping noise reduction layer is 0.8–1.2 mm; the cross-section of the micro-bumps is semi-circular, the diameter of a single micro-bump is 0.3–0.5 mm, the spacing between adjacent micro-bumps is 1–1.5 mm, and the height of the micro-bumps is 0.1–0.2 mm; the semi-circular micro-bumps can avoid damage to the gradient sound absorption layer by sharp structures, while the reasonable diameter, spacing and height can ensure the balance between the contact area and the gap space, and optimize the damping effect.

[0013] Furthermore, the honeycomb support layer has a regular hexagonal structure with a side length of 8–12 mm for each cell and a wall thickness of 0.4–0.6 mm. The regular hexagonal structure provides optimal mechanical stability and sufficient support while maintaining lightweight design. The reinforcing ribs have a cross-shaped structure with a width of 0.2–0.3 mm, and are integrally injection molded with the honeycomb wall to ensure structural integrity and prevent rib detachment. The polyester fiber sound-absorbing cotton is made of fluffy polyester fiber, with a filling amount of 60%–70% of the honeycomb cell volume. The fluffy fiber can effectively absorb noise, and the filling amount avoids excessive fiber clumping or insufficient filling leading to wasted cavity space.

[0014] Furthermore, the glass fiber mesh in the mesh-reinforced polyester fiber base layer has a bidirectional woven structure with a mesh count of 60-80 meshes and a thickness of 0.3-0.5 mm. The bidirectional weaving ensures uniform strength in all directions, and the mesh count and thickness can balance strength and lightweight. The overall thickness of the mesh-reinforced polyester fiber base layer is 10-15 mm, and the glass fiber mesh is embedded in the middle of the polyester fiber board. The central embedding allows the mesh to evenly distribute stress and improve the overall resistance to deformation.

[0015] Furthermore, the PVC decorative film of the decorative protective layer has a thickness of 0.15 to 0.25 mm to ensure flexibility and decorativeness; the epoxy wear-resistant coating has a thickness of 0.05 to 0.1 mm to ensure wear resistance while avoiding excessive coating thickness that could affect the texture; the height of the serrated protrusions matches the gap between the outer fibers of the gradient sound-absorbing layer to ensure a tight fit.

[0016] Furthermore, the thickness of the water-based environmentally friendly adhesive layer is 0.1 to 0.15 mm. The water-based adhesive does not release harmful gases, which meets indoor environmental protection requirements. The thickness of the adhesive layer can ensure the bonding strength, avoiding the increase in cost due to excessively thick adhesive layers or the poor bonding due to excessively thin adhesive layers.

[0017] Furthermore, the polyester fiber sound-absorbing cotton is polyester fiber that has been ultrasonically cleaned and dried, with a moisture content of ≤3% to avoid moisture residue causing fiber clumping or mold; the fiber length is 5-8mm to ensure inter-fiber entanglement and maintain a fluffy state.

[0018] Furthermore, the silane coupling agent coating on the surface of the glass fiber mesh is 0.01 to 0.02 mm thick. The thin coating can effectively improve the bonding strength and avoid the coating being too thick, which would affect the fusion of the mesh and the polyester fiber.

[0019] Compared with the prior art, the beneficial effects of this utility model are as follows: (1) The gradient sound absorption layer has a gradually changing pore size structure, which is suitable for the layered absorption of low-frequency and mid-to-high-frequency noise; the butyl rubber of the damping noise reduction layer is combined with micro-bumps to enhance the suppression of low-frequency vibration noise; the cavity of the honeycomb support layer and the sound-absorbing cotton form a double sound absorption, and the three work together to cover a wide range of noise, solving the problem of the single frequency band of traditional sound absorption panels.

[0020] (2) The hexagonal structure and cross-shaped reinforcing ribs of the honeycomb support layer provide excellent bending and collapse resistance; the glass fiber mesh of the polyester fiber base layer enhances the overall tensile and tear resistance; each layer is tightly bonded with water-based environmentally friendly adhesive to avoid delamination and ensure that the board is not easily deformed or cracked during long-term use.

[0021] (3) The PVC decorative film of the decorative protective layer can be designed with various patterns to meet different decorative styles; the epoxy wear-resistant coating improves the surface durability, and the sawtooth protrusion interlocking design avoids the decorative layer from affecting the performance of the sound absorption layer.

[0022] (4) Each layer is bonded with water-based environmentally friendly adhesive, which releases no harmful gases; the polyester fiber sound-absorbing cotton is cleaned and dried, with low moisture content and no impurities, which meets the requirements for indoor environmental protection and is suitable for homes, offices and other scenarios with high environmental protection requirements. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1This is an overall view of a composite polyester fiber sound-absorbing board according to an embodiment of the present utility model; Figure 2 This is a front view of a composite polyester fiber sound-absorbing panel according to an embodiment of the present utility model; Figure 3 This is a schematic diagram of the gradient structure of a composite polyester fiber sound-absorbing panel according to an embodiment of the present utility model; Figure 4 This is a schematic diagram of the split cross-sectional structure of a composite polyester fiber sound-absorbing board according to an embodiment of the present utility model.

[0025] Figure label: 1. Decorative protective layer; 11. PVC decorative film; 12. Epoxy wear-resistant coating; 13. Serrated protrusions; 2. Gradient sound-absorbing layer; 21. Outer polyester fiber layer; 22. Inner polyester fiber layer; 3. Damping noise reduction layer; 31. Butyl rubber damping membrane; 32. Micro-protrusions; 4. Honeycomb support layer; 41. Honeycomb wall; 42. Reinforcing ribs; 43. Polyester fiber sound-absorbing cotton; 5. Mesh-reinforced polyester fiber base layer; 51. Polyester fiberboard; 52. Fiberglass mesh cloth. Detailed Implementation

[0026] To further illustrate the various embodiments, the present invention provides accompanying drawings, which are part of the disclosure of the present invention. These drawings are mainly used to illustrate the embodiments and can be used in conjunction with the relevant descriptions in the specification to explain the operating principles of the embodiments. With reference to these contents, those skilled in the art should be able to understand other possible implementation methods and the advantages of the present invention. The components in the figures are not drawn to scale, and similar component symbols are usually used to represent similar components.

[0027] According to an embodiment of the present invention, a composite polyester fiber sound-absorbing board is provided.

[0028] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments, such as... Figure 1-4 As shown, a composite polyester fiber sound-absorbing board according to an embodiment of this utility model consists of, from the outside to the inside, a decorative protective layer 1, a gradient sound-absorbing layer 2, a damping noise reduction layer 3, a honeycomb support layer 4, and a grid-reinforced polyester fiber base layer 5. Each layer is bonded and fixed with a 0.12mm thick water-based environmentally friendly adhesive. The overall thickness is 30mm, and the size of a single board is 1200mm×600mm. It is suitable for splicing and installation on the walls of conference rooms ranging from 20 to 50 square meters.

[0029] Among them, the PVC decorative film 11 of the decorative protective layer 1 is 0.2mm thick and has a walnut wood texture printed on the surface, which is suitable for the decoration style of the conference room; the outer surface is coated with an epoxy wear-resistant coating 12 with a thickness of 0.08mm, which can resist minor daily scratches, and stains such as markers can be wiped away directly with a damp cloth; the inner surface of the PVC decorative film has serrated protrusions 13 with a height of 0.3mm, which are embedded in the gaps between the outer fibers of the gradient sound-absorbing layer 2 to enhance the interlayer bonding and prevent the adhesive layer from overflowing.

[0030] The gradient sound-absorbing layer 2 has an overall thickness of 6mm, including an outer polyester fiber layer 21 with a pore size of 1.8mm and a thickness of 4mm, and an inner polyester fiber layer 22 with a pore size of 0.6mm and a thickness of 2mm. Both layers are made of flame-retardant polyester fiber. The large pore size of the outer layer allows low-frequency noise of 80-150Hz generated by the air conditioning in the conference room to penetrate, while the small pore size of the inner layer adsorbs human voice noise of 500-1500Hz, achieving multi-band layered absorption.

[0031] The butyl rubber damping membrane 31 of the damping noise reduction layer 3 is 1.0 mm thick. A semi-circular micro-protrusion 32 is provided on the side facing the gradient sound absorption layer 2. The micro-protrusion has a diameter of 0.4 mm, an adjacent spacing of 1.2 mm, and a height of 0.15 mm. The micro-protrusion is in contact with the outer polyester fiber layer 21. It consumes the vibration noise transmitted from the air conditioning pipe to the wall through damping deformation. The gap between the micro-protrusions can allow some sound waves to be reflected and attenuated, further reducing the noise.

[0032] The honeycomb support layer 4 has regular hexagonal honeycomb cells with a side length of 10mm. The honeycomb wall 41 is made of 0.5mm thick PET material, with an integrally formed cross-shaped reinforcing rib 42 on the surface, 0.25mm wide, to enhance the honeycomb wall's resistance to collapse. The honeycomb cells are filled with fluffy polyester fiber sound-absorbing cotton 43, with a filling amount of 65% of the honeycomb cell volume. The sound-absorbing cotton is ultrasonically cleaned and dried, with a moisture content of 2.5% and a fiber length of 6mm. The vibration of the air column in the honeycomb cavity consumes low-to-mid frequency noise of 150-300Hz, while the sound-absorbing cotton absorbs mid-to-high frequency noise of 500-2000Hz, forming a double sound absorption.

[0033] The overall thickness of the reinforced polyester fiber base layer 5 is 12mm. An 80-mesh bidirectional woven glass fiber mesh 52 with a thickness of 0.4mm is embedded in the middle. The surface of the mesh is coated with a 0.015mm thick silane coupling agent coating, which is tightly integrated with the polyester fiber board 51. The base layer can bear the weight of the board, prevent the middle from sagging when installing a large area, and resist the shrinkage and tensile stress caused by temperature changes, preventing the board from warping and cracking. It can also absorb the small amount of high-frequency noise that penetrates to the bottom layer.

[0034] The composite polyester fiber sound-absorbing panel in this embodiment can effectively absorb noise of various frequency bands in the conference room after installation, maintaining a quiet indoor environment; the surface texture can match the decoration style and is easy to clean daily; it does not deform, delaminate, or mold after long-term use, and its overall performance is stable, meeting the long-term use needs of the conference room.

[0035] In this utility model, unless otherwise explicitly specified and limited, the terms "installation", "setting", "connection", "fixing", "screw connection", etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components or the interaction between two components. Unless otherwise explicitly limited, those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0036] 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.

[0037] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A composite polyester fiber sound-absorbing board, characterized in that, It includes a decorative protective layer (1), a gradient sound-absorbing layer (2), a damping noise reduction layer (3), a honeycomb support layer (4), and a grid-reinforced polyester fiber base layer (5), which are sequentially fixed from the outside to the inside. The gradient sound-absorbing layer (2) consists of at least two flame-retardant polyester fiber layers with gradually changing pore sizes, and the pore size gradually decreases from the side closer to the decorative protective layer (1) to the side closer to the damping noise reduction layer (3). The damping noise reduction layer (3) is a butyl rubber damping membrane (31), and its side facing the gradient sound absorption layer (2) is provided with uniformly distributed micro protrusions (32). The honeycomb support layer (4) has honeycomb holes extending along the thickness direction of the plate, and the honeycomb holes are filled with polyester fiber sound-absorbing cotton (43), and the surface of the honeycomb wall (41) is integrally formed with cross-arranged reinforcing ribs (42). The mesh-reinforced polyester fiber base layer (5) is a composite layer made of polyester fiber board (51) and glass fiber mesh cloth (52).

2. The composite polyester fiber sound-absorbing board according to claim 1, characterized in that, The gradient sound-absorbing layer (2) includes an outer polyester fiber layer (21) and an inner polyester fiber layer (22). The pore size of the outer polyester fiber layer (21) is 1.5 to 2 mm, and the pore size of the inner polyester fiber layer (22) is 0.5 to 0.8 mm. The overall thickness of the gradient sound-absorbing layer (2) is 5 to 8 mm, and the thickness ratio of the outer polyester fiber layer (21) to the inner polyester fiber layer (22) is 2:1 to 3:

1.

3. The composite polyester fiber sound-absorbing board according to claim 1, characterized in that, The butyl rubber damping membrane (31) of the damping noise reduction layer (3) has an overall thickness of 0.8 to 1.2 mm; the cross section of the micro-bump (32) is semi-circular, the diameter of a single micro-bump (32) is 0.3 to 0.5 mm, the spacing between adjacent micro-bumps (32) is 1 to 1.5 mm, and the height of the micro-bump (32) is 0.1 to 0.2 mm.

4. The composite polyester fiber sound-absorbing board according to claim 1, characterized in that, The honeycomb support layer (4) has a regular hexagonal structure with a side length of 8-12 mm for a single honeycomb cell and a thickness of 0.4-0.6 mm for the honeycomb wall (41). The reinforcing rib (42) has a cross-shaped structure with a width of 0.2-0.3 mm, and the reinforcing rib (42) and the honeycomb wall (41) are integrally injection molded. The polyester fiber sound-absorbing cotton (43) is a fluffy polyester fiber with a filling amount of 60%-70% of the honeycomb cell volume.

5. The composite polyester fiber sound-absorbing board according to claim 1, characterized in that, The glass fiber mesh (52) in the mesh-reinforced polyester fiber base layer (5) is a two-way woven structure with a mesh count of 60-80 meshes and a thickness of 0.3-0.5 mm; the overall thickness of the mesh-reinforced polyester fiber base layer (5) is 10-15 mm, and the glass fiber mesh (52) is embedded in the middle of the polyester fiber board (51).

6. The composite polyester fiber sound-absorbing board according to claim 1, characterized in that, The decorative protective layer (1) includes a PVC decorative film (11) and an epoxy wear-resistant coating (12). The thickness of the PVC decorative film (11) is 0.15 to 0.25 mm. The epoxy wear-resistant coating (12) is applied to the outer surface of the PVC decorative film (11) and the coating thickness is 0.05 to 0.1 mm. The inner surface of the PVC decorative film (11) is provided with serrated protrusions (13), which are embedded and fixed with the outer polyester fiber layer (21) of the gradient sound-absorbing layer (2).

7. The composite polyester fiber sound-absorbing board according to claim 1, characterized in that, The decorative protective layer (1) is bonded to the gradient sound-absorbing layer (2), the gradient sound-absorbing layer (2) is bonded to the damping noise reduction layer (3), the damping noise reduction layer (3) is bonded to the honeycomb support layer (4), and the honeycomb support layer (4) is bonded to the grid-reinforced polyester fiber base layer (5) by water-based environmentally friendly adhesive. The thickness of the adhesive layer is 0.1 to 0.15 mm.

8. A composite polyester fiber sound-absorbing board according to claim 4, characterized in that, The polyester fiber sound-absorbing cotton (43) is polyester fiber that has been ultrasonically cleaned and dried, with a moisture content of ≤3% and a fiber length of 5-8mm.

9. A composite polyester fiber sound-absorbing board according to claim 5, characterized in that, The surface of the glass fiber mesh (52) is coated with a silane coupling agent coating with a thickness of 0.01 to 0.02 mm to enhance the bonding strength with the polyester fiberboard (51).

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