Sound-absorbing laminated board and processing device for decorative film in sound-absorbing laminated board

Abstract

The present invention relates to the field of sound-absorbing decorative materials. Disclosed are a sound-absorbing laminated board and a processing device for a decorative film in the sound-absorbing laminated board. The problem of appearance strip marks can be solved, more importantly, the noise reduction coefficient can be significantly improved, so as to better meet the requirement for sound-absorbing performance. According to the technical solution of the present invention, the sound-absorbing laminated board comprises a perforated substrate and a decorative film, wherein the decorative film covers the surface of one side of the perforated substrate, a plurality of micropores are formed in the decorative film, a plurality of through holes are formed in the perforated substrate, and all or part of the micropores are communicated with the through holes. The present invention effectively solves the problem of appearance strip marks caused by forming micropores in sheet metal in the prior art, and more importantly, the noise reduction coefficient can be significantly improved, so that the NRC reaches about 0.7.

Description

A sound-absorbing film-coated board and a processing device for the decorative film therein Technical Field

[0001] The present invention relates to the field of sound-absorbing decorative materials, and in particular to a sound-absorbing film-coated board with micropores and a processing technology thereof. Background Art

[0002] Acoustic panels are an ideal sound-absorbing decorative material. They offer advantages such as sound absorption, environmental friendliness, flame retardancy, heat insulation, thermal insulation, moisture resistance, mildew resistance, easy dust removal, easy cutting, parquetry adaptability, ease of construction, excellent stability, impact resistance, independence, and cost-effectiveness. Available in a wide variety of colors, they can meet the needs of various styles and levels of sound absorption and decoration. Therefore, acoustic panels are widely used in acoustic venues such as theaters, concert halls, cinemas, recording studios, studios, monitoring rooms, conference rooms, gymnasiums, exhibition halls, dance halls, KTV rooms, home theaters, factories, quiet rooms, courtrooms, lecture halls, and interrogation rooms.

[0003] Composite metal panels are a common sound-absorbing material. They are microporous metal sheets bonded to a perforated substrate, then coated with a decorative coating. For example, the applicant filed an invention patent application on March 29, 2022, titled "A Composite Metal Sound-Absorbing Panel," with application number "202220694154.5." However, this product has several issues: First, the punching die, which requires micropores to be punched into the metal plate, wears quickly, resulting in dimensional variations and prone to streaking. Second, the noise reduction coefficient (NRC) is not high enough, at approximately 0.6. Summary of the Invention

[0004] In response to the above problems, the present invention proposes a sound-absorbing laminated board, which can not only solve the problem of appearance stripes, but more importantly, can significantly improve the noise reduction coefficient, thereby better meeting the sound absorption performance requirements; this case also proposes a decorative film processing device with good micro-pore processing effect and high processing efficiency.

[0005] The technical solution of the present invention is as follows: the sound-absorbing film-coated board includes a perforated substrate 3 and a decorative film 1, the decorative film 1 is covered on one side surface of the perforated substrate 3, and a plurality of micropores are opened on the decorative film 1, and a plurality of perforations are opened on the perforated substrate 3, and all or part of the micropores are connected to the perforations.

[0006] The density of the micropores on the decorative film 1 is greater than the density of the perforations on the perforated substrate 3 , and the diameter of the micropores is smaller than the diameter of the perforations.

[0007] Preferably, the decorative film 1 has a perforation rate of 1.8%, a hole diameter of 0.3 mm, and a hole spacing of 2 mm. The perforation substrate 3 has a perforation rate of 24.2%, a hole diameter of 5 mm, and a hole spacing of 9 mm.

[0008] Furthermore, the perforated substrate 3 is a perforated inorganic plate, a perforated metal plate, or a perforated metal composite plate.

[0009] Furthermore, the decorative film 1 and the perforated substrate 3 are fixedly connected via an adhesive layer 2 .

[0010] Furthermore, the decorative film 1 is coated on the outer surface of the perforated substrate 3 , the inner side of the perforated substrate 3 is mounted on the wall 5 , and a cavity 4 is left between the perforated substrate 3 and the wall 5 .

[0011] The present invention effectively solves the problem of appearance stripes caused by traditional micropores in metal plates by opening micropores in the decorative film. More importantly, this case also overcomes the prejudice of traditional technology and breaks the technical barrier of traditional technology that uses decorative film to close the sound-absorbing holes. Micropores are directly opened in the decorative film. On the one hand, the holes in the metal plate can better receive and absorb sound waves. On the other hand, the vibration of the decorative film can absorb sound energy, which can ultimately significantly improve the noise reduction coefficient, so that the NRC reaches about 0.7.

[0012] The present invention takes into account that drilling micropores on a film is completely different from drilling micropores on a plate, and that it is difficult to control the aperture of the micropores on the film. The present invention also proposes the following decorative film processing device, which is as follows:

[0013] The processing device includes a discharger, a puncher, and a receiving machine in sequence; considering that the discharger and the receiving machine are extremely conventional existing technologies in the field of film processing, they will not be described in detail in this case;

[0014] The punching machine includes a frame 11, a needle roller 12, a rubber roller 13, a rubber roller lifting mechanism 14 and a rotary drive mechanism 15. The needle roller 12 is rotatably connected to the frame 11, and a plurality of needles 121 are provided on the surface of the needle roller 12. The rubber roller 13 is rotatably connected to the rubber roller lifting mechanism 14 and is located below the needle roller 12. The rubber roller 13 is driven to rise and fall by the rubber roller lifting mechanism 14. The rotary drive mechanism 15 is also connected to the frame 11 and is simultaneously connected to the needle roller 12 and the rubber roller 13. The needle roller 12 and the rubber roller 13 are driven to rotate synchronously by the rotary drive mechanism 15.

[0015] About the rubber roller lifting mechanism:

[0016] The rubber roller lifting mechanism 14 includes a motor 141 fixedly mounted on the frame 11 and two lifting drive assemblies respectively connected to the two ends of the rubber roller 13;

[0017] The lifting drive assembly includes a screw rod 142, a nut 143, a bearing seat 144, a guide rail 145 and a bearing 146. The screw rod 142 is vertically arranged and rotatably connected to the frame 11. The nut 143 is sleeved on the screw rod 142 and threadedly connected to the screw rod 142. The two screw rods 142 in the two lifting drive assemblies are simultaneously connected to the motor 141 and maintain synchronous movement. Specifically, a transmission shaft can be rotatably connected to the frame, and one end of the transmission shaft is connected to the output shaft of the motor 141. Then, two sets of reversing bevel gear sets are respectively arranged between the transmission shaft and the two screw rods 142, so that after the motor 141 drives the transmission shaft to rotate, the two screw rods 142 can be driven to rotate synchronously through the two sets of reversing bevel gear sets.

[0018] The guide rail 145 is vertically arranged and fixedly connected to the frame 11. The bearing seat 144 is slidably connected to the guide rail 145 and fixedly connected to the nut 143. The bearing 146 is sleeved on the end of the rubber roller 13 and fixedly installed in the bearing seat 144.

[0019] About the rotary drive mechanism:

[0020] The rotary drive mechanism 15 includes a main drive motor 152, a transmission gear box 152, and two universal joints 153. The housing of the main drive motor 152 and the housing of the transmission gear box 152 are fixedly connected to the frame 11. The transmission gear box 152 is rotatably connected to an input gear and two output gears. The two output gears are simultaneously engaged with the input gear and have the same transmission ratio.

[0021] The output shaft of the main drive motor 152 is connected to the center of the input gear. The centers of the two output gears are respectively connected to one end of two universal couplings 153. The other ends of the two universal couplings 153 are respectively fixedly connected to the needle roller 12 and the rubber roller 13. In this way, the main drive motor 152 can simultaneously drive the needle roller 12 and the rubber roller 13 to rotate synchronously. Moreover, due to the presence of the universal coupling 153, the rubber roller 13 can maintain synchronous rotation with the needle roller 12 after being raised or lowered.

[0022] Furthermore, the needle roller 12 includes a roller body 122, an inner sleeve 123, an outer sleeve 124 and two locking nuts 125. The two locking nuts 125 are connected to the roller body 122 by threads. The inner sleeve 123 is sleeved on the roller body 122 and is located between the two locking nuts 125. The outer sleeve 124 is sleeved on the inner sleeve 123 and is also located between the two locking nuts 125.

[0023] A plurality of needle mounting holes are evenly formed on the outer sleeve 124 , and the base of the needle 121 is inserted into the needle mounting hole and is interference-fitted with the needle mounting hole.

[0024] Furthermore, the outer sleeve 124 is composed of multiple sections, and two adjacent outer sleeves 124 are tightly fitted together. In this way, when the needle installed on a certain outer sleeve 124 is tilted or damaged, only a single outer sleeve needs to be replaced, which can significantly reduce maintenance and use costs.

[0025] The present invention utilizes a rubber roller to provide excellent support for the decorative film and a needle roller to perforate the film as it passes through. This allows micropores to form on the surface of the decorative film as it is guided between the needle and rubber rollers. During this process, a rubber roller lifting mechanism drives the rubber roller up and down, making the gap between the needle and rubber rollers adjustable. This gap can be adjusted to control the distance between the decorative film and the base of the needles, thereby adjusting the depth of penetration of the needles into the film. Combined with the needles' inherent tapered structure, the diameter of the resulting micropores can be adjusted. This technique of adjusting the diameter of the resulting micropores by adjusting the gap between the needle and rubber rollers not only provides greater control convenience but also allows for more precise micropore diameter control. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 is a schematic diagram of the structure of this case.

[0027] Figure 2 is a front view of the decorative film in this case.

[0028] Figure 3 is a reference diagram of the working state of this case;

[0029] It should be explained that Figures 1-3 are schematic diagrams of the present invention and do not represent the actual thickness, size, or proportions of the various parts. In the Figures, 1 is the decorative film, 2 is the adhesive layer, 3 is the perforated substrate, 4 is the cavity, 5 is the wall, and 50 is the leveling layer.

[0030] FIG4 is a perspective view of the processing device in this case,

[0031] FIG5 is an axial cross-sectional view of the needle roller;

[0032] In the figure, 11 is a frame, 12 is a needle roller, 121 is a needle, 122 is a roller body, 123 is an inner sleeve, 124 is an outer sleeve, 125 is a locking nut, 13 is a rubber roller, 14 is a rubber roller lifting mechanism, 141 is a motor, 142 is a screw rod, 143 is a nut, 144 is a bearing seat, 145 is a guide rail, 146 is a bearing, 15 is a rotary drive mechanism, 151 is a main drive motor, 152 is a transmission gear box, and 153 is a universal joint. DETAILED DESCRIPTION

[0033] In order to clearly illustrate the technical features of this patent, this patent is described in detail below through specific implementation methods and in combination with its accompanying drawings.

[0034] As shown in Figures 1-2, this embodiment comprises a perforated substrate 3 and a decorative film 1. The decorative film 1 is coated on one side of the perforated substrate 3 and is provided with a plurality of micropores, forming an ultra-microporous film. The perforated substrate 3 is also provided with a plurality of perforations, all or some of which are interconnected with the perforations. During processing, the decorative film can be perforated with a needle roller to create micropores. Due to the low rigidity of the decorative film, wear on the needle roller is virtually zero. Therefore, a uniform micropore pattern can be achieved by simply ensuring the needle diameter is consistent, effectively solving the problem of streaking caused by traditional micropores in metal sheets. After adhesive application, the metal sheet and the decorative film can be laminated and the film can be trimmed. This process reduces the need for shearing and improves material utilization. More importantly, the micropores are directly created in the decorative film. This not only allows the holes in the metal sheet to better receive and absorb sound waves, but also absorbs sound energy through the vibration of the decorative film, ultimately significantly improving the noise reduction coefficient (NRC) to approximately 0.7.

[0035] The density of the micropores on the decorative film 1 is greater than the density of the perforations on the perforated substrate 3, and the diameter of the micropores is smaller than the diameter of the perforations. This ensures that most of the micropores remain connected to the perforations, thereby enhancing the effectiveness of the decorative film in receiving and absorbing sound waves and absorbing sound energy through vibration.

[0036] Preferably, the decorative film 1 has a perforation rate of 1.8%, a hole diameter of 0.3 mm, and a hole spacing of 2 mm. The perforation substrate 3 has a perforation rate of 24.2%, a hole diameter of 5 mm, and a hole spacing of 9 mm.

[0037] The perforated substrate 3 is a perforated inorganic plate, a perforated metal plate, or a perforated metal composite plate. The metal composite plate is a plate composed of a metal material and an inorganic material or a non-metallic material, or a plate composed of different metal materials.

[0038] The decorative film 1 and the perforated substrate 3 are fixedly connected via an adhesive layer 2 .

[0039] The decorative film 1 is coated on the outer surface of the perforated substrate 3, the inner side of which is mounted on a wall 5. A cavity 4 is left between the perforated substrate 3 and the wall 5, and a leveling layer 50 is provided on the wall 5. In this way, the ultra-microporous metal mold, which has very low rigidity and is in a tensile state under tension, can be combined with an enclosed air layer (i.e., the cavity) of appropriate thickness to form a resonant system composed of the film and air layer, thereby achieving a significant sound absorption effect near the system's resonant frequency.

[0040] The sound absorption process of this design is shown in Figure 3. In contrast, traditional sound-absorbing panels consist of a decorative coating, microporous metal sheet, glue, perforated substrate, and cavity. This design utilizes a microporous film composite structure, consisting of a decorative film (an ultra-microporous film), an adhesive layer, a perforated substrate, and a cavity. Its sound absorption characteristics are as follows: when the incident sound wave frequency is close to the natural frequency, the air within the structure vibrates strongly, damping occurs, sound energy is lost, and high sound absorption occurs. As shown in the figure, the majority of the sound passes through the decorative film, where it resonates and dissipates some of the sound energy. The sound then passes through the perforated substrate, where it reflects back and forth within the cavity, continuing to absorb and dissipate most of the sound energy. Ultimately, only a small portion is reflected back into the interior, resulting in superior sound absorption compared to traditional technologies.

[0041] As shown in Figures 4-5, the processing device includes a discharger, a puncher, and a receiving machine in sequence. Considering that the discharger and the receiving machine are very common existing technologies in the field of film processing, they will not be described in detail in this case.

[0042] The punching machine includes a frame 11, a needle roller 12, a rubber roller 13, a rubber roller lifting mechanism 14, and a rotary drive mechanism 15. The needle roller 12 is rotatably connected to the frame 11 and is equipped with a plurality of needles 121 on its surface. The rubber roller 13 is rotatably connected to the rubber roller lifting mechanism 14 and is positioned below the needle roller 12. The rubber roller lifting mechanism 14 drives the rubber roller 13 up and down. The rotary drive mechanism 15 is also connected to the frame 11 and is connected to both the needle roller 12 and the rubber roller 13. The rotary drive mechanism 15 drives the needle roller 12 and the rubber roller 13 to rotate synchronously. This allows the rubber roller to provide good support for the decorative film as it passes between the needle roller and the rubber roller, while the needle roller punches the film as it passes through. This allows the decorative film to have micropores on its surface as it exits between the needle roller and the rubber roller. During this process, because the rubber roller lifting mechanism 14 can drive the rubber roller 13 to rise and fall, the gap between the needle rollers 12 and 13 is adjustable. This gap can be adjusted to control the distance between the decorative film and the base of the needles, thereby adjusting the depth of the needles' penetration into the decorative film. Combined with the tapered structure of the needles themselves, the diameter of the resulting micropores can be adjusted. This technique of adjusting the diameter of the resulting micropores by adjusting the gap between the needle rollers 12 and 13 is not only more convenient to control, but also provides more precise control of the micropore diameter.

[0043] In this case, the needle roller shaft has an outer diameter of ￠110 mm and a working surface width of 1600 mm. The rubber roller is a NBR roller with an outer diameter of ￠136 mm, a thickness of 15 mm, and a working surface width of 1600 mm. The drilling depth is 0 to 2 mm, with an adjustable range of 0 to 20 mm. The fine-tuning accuracy can reach 0.01 mm.

[0044] The rubber roller lifting mechanism 14 includes a motor 141 fixedly mounted on the frame 11 and two lifting drive assemblies respectively connected to the two ends of the rubber roller 13;

[0045] The lifting drive assembly includes a screw rod 142, a nut 143, a bearing seat 144, a guide rail 145 and a bearing 146. The screw rod 142 is vertically arranged and rotatably connected to the frame 11. The nut 143 is sleeved on the screw rod 142 and threadedly connected to the screw rod 142. The two screw rods 142 in the two lifting drive assemblies are simultaneously connected to the motor 141 and maintain synchronous movement. Specifically, a transmission shaft can be rotatably connected to the frame, and one end of the transmission shaft is connected to the output shaft of the motor 141. Then, two sets of reversing bevel gear sets are respectively arranged between the transmission shaft and the two screw rods 142, so that after the motor 141 drives the transmission shaft to rotate, the two screw rods 142 can be driven to rotate synchronously through the two sets of reversing bevel gear sets.

[0046] The guide rail 145 is vertically disposed and fixedly connected to the frame 11. The bearing seat 144 is slidably connected to the guide rail 145 and fixedly connected to the screw nut 143. The bearing 146 is sleeved onto the end of the rubber roller 13 and fixedly mounted in the bearing seat 144. In this way, the rotational power output by the motor 141 to the two screw rods 142 will drive the two screw nuts to rise and fall synchronously, thereby driving the bearing seat 144 to rise and fall synchronously along the guide rail 145, ultimately achieving the purpose of driving the rubber roller 13 to make precise lifting and lowering movements.

[0047] The rotary drive mechanism 15 includes a main drive motor 152, a transmission gear box 152, and two universal joints 153. The housing of the main drive motor 152 and the housing of the transmission gear box 152 are fixedly connected to the frame 11. The transmission gear box 152 is rotatably connected to an input gear and two output gears. The two output gears are simultaneously engaged with the input gear and have the same transmission ratio.

[0048] The output shaft of the main drive motor 152 is connected to the center of the input gear. The centers of the two output gears are respectively connected to one end of two universal couplings 153. The other ends of the two universal couplings 153 are respectively fixedly connected to the needle roller 12 and the rubber roller 13. In this way, the main drive motor 152 can simultaneously drive the needle roller 12 and the rubber roller 13 to rotate synchronously. Moreover, due to the presence of the universal coupling 153, the rubber roller 13 can maintain synchronous rotation with the needle roller 12 after being raised or lowered.

[0049] The needle roller 12 includes a roller body 122, an inner sleeve 123, an outer sleeve 124, and two locking nuts 125. The two locking nuts 125 are connected to the roller body 122 through threads. The inner sleeve 123 is sleeved on the roller body 122 and is located between the two locking nuts 125. The outer sleeve 124 is sleeved on the inner sleeve 123 and is also located between the two locking nuts 125.

[0050] A plurality of needle mounting holes are evenly formed on the outer sleeve 124 , and the base of the needle 121 is inserted into the needle mounting hole and is interference-fitted with the needle mounting hole.

[0051] The adjacent two sections of outer sleeves 124 are tightly fitted. Like this, when the thorn installed on a certain section of outer sleeve 124 tilts or is damaged, only a single section of outer sleeve needs to be replaced, which can significantly reduce maintenance and use costs.

[0052] There are many specific implementation ways of the present invention. The above is only the preferred implementation method of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements can be made without departing from the principles of the present invention. These improvements should also be considered as the scope of protection of the present invention.

Claims

1. A sound-absorbing film-coated board, characterized in that: The sound-absorbing film-coated board comprises a perforated substrate (3) and a decorative film (1), wherein the decorative film (1) is coated on one side surface of the perforated substrate (3), and a plurality of micropores are provided on the decorative film (1), and a plurality of perforations are provided on the perforated substrate (3), wherein all or part of the micropores are connected to the perforations.

2. The sound-absorbing film-coated board according to claim 1, characterized in that: The density of the micropores arranged on the decorative film (1) is greater than the density of the perforations arranged on the perforated substrate (3), and the diameter of the micropores is smaller than the diameter of the perforations.

3. The sound-absorbing film-coated board according to claim 1, characterized in that: The perforated substrate (3) is a perforated inorganic plate, a perforated metal plate, or a perforated metal composite plate.

4. The sound-absorbing film-coated board according to claim 1, characterized in that: The decorative film (1) and the perforated substrate (3) are fixedly connected via an adhesive layer (2).

5. A processing device for the decorative film in the sound-absorbing film-covered board according to claim 1, characterized in that: The processing device includes a punching machine; The punching machine comprises a frame (11), a needle roller (12), a rubber roller (13), a rubber roller lifting mechanism (14) and a rotary drive mechanism (15); the needle roller (12) is rotatably connected to the frame (11), and a plurality of needles (121) are provided on the surface of the needle roller (12); the rubber roller (13) is rotatably connected to the rubber roller lifting mechanism (14) and is located below the needle roller (12); the rubber roller (13) is driven to be lifted or lowered by the rubber roller lifting mechanism (14); the rotary drive mechanism (15) is also connected to the frame (11) and is simultaneously connected to the needle roller (12) and the rubber roller (13); the needle roller (12) and the rubber roller (13) are driven to rotate synchronously by the rotary drive mechanism (15).

6. A decorative film processing device according to claim 5, characterized in that: The rubber roller lifting mechanism (14) comprises a motor (141) fixedly mounted on the frame (11) and two lifting drive components respectively connected to the two ends of the rubber roller (13); The lifting drive assembly comprises a screw rod (142), a nut (143), a bearing seat (144), a guide rail (145) and a bearing (146); the screw rod (142) is vertically arranged and rotatably connected to the frame (11); the nut (143) is sleeved on the screw rod (142) and is threadedly connected to the screw rod (142); the two screw rods (142) in the two lifting drive assemblies are simultaneously connected to the motor (141) and maintain synchronous movement; The guide rail (145) is vertically arranged and fixedly connected to the frame (11); the bearing seat (144) is slidably connected to the guide rail (145) and fixedly connected to the nut (143); the bearing (146) is sleeved on the end of the rubber roller (13) and fixedly installed in the bearing seat (144).

7. The decorative film processing device according to claim 5, characterized in that: The rotary drive mechanism (15) comprises a main drive motor (152), a transmission gear box (152) and two universal couplings (153); the housing of the main drive motor (152) and the housing of the transmission gear box (152) are both fixedly connected to the frame (11); an input gear and two output gears are rotatably connected to the transmission gear box (152); the two output gears are meshed with the input gear at the same time, and the transmission ratios are consistent; The output shaft of the main drive motor (152) is connected to the center of the input gear, the centers of the two output gears are respectively connected to one end of two universal couplings (153), and the other ends of the two universal couplings (153) are respectively fixedly connected to the needle roller (12) and the rubber roller (13).

8. The decorative film processing device according to claim 5, characterized in that: The needle roller (12) comprises a roller body (122), an inner sleeve (123), an outer sleeve (124), and two locking nuts (125); the two locking nuts (125) are connected to the roller body (122) by threads; the inner sleeve (123) is sleeved on the roller body (122) and is located between the two locking nuts (125); the outer sleeve (124) is sleeved on the inner sleeve (123) and is also located between the two locking nuts (125); A plurality of needle mounting holes are evenly formed on the outer sleeve (124), and the base of the needle (121) is inserted into the needle mounting hole and is interference fit with the needle mounting hole.

9. A decorative film processing device according to claim 8, characterized in that: The outer sleeve (124) is composed of multiple sections, and two adjacent sections of the outer sleeve (124) are tightly fitted.

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