CN103692753A - 轻量化空气流阻可调节式多层结构声学部件的制备方法 - Google Patents

轻量化空气流阻可调节式多层结构声学部件的制备方法 Download PDF

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CN103692753A
CN103692753A CN201310676385.9A CN201310676385A CN103692753A CN 103692753 A CN103692753 A CN 103692753A CN 201310676385 A CN201310676385 A CN 201310676385A CN 103692753 A CN103692753 A CN 103692753A
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flow resistance
air flow
finished product
pressure
acoustic element
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阮静
黄威
田秀杰
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Wuxi Jixing Auto Acoustic Parts Technology Co Ltd
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Wuxi Jixing Auto Acoustic Parts Technology Co Ltd
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Priority to JP2015551968A priority patent/JP2016508901A/ja
Priority to PCT/CN2014/000145 priority patent/WO2015085643A1/zh
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Abstract

本发明涉及汽车声学部件的制造方法，属于汽车部件隔音降噪技术领域。所述声学部件先将纤维毡、热塑性不透气EAA薄膜和纤维毡的次序叠放，送入成型模具内，利用穿透力强的高温蒸汽对材料进行加热，同时进行模压成型，然后切割外形尺寸及孔位，经检验无缺陷后，即可获得多层结构声学部件。本发明上下两层纤维毡之间的粘结是通过热塑性薄膜在高温下熔化后所具有的粘结性来实现的，而非在现场以人工涂布粘结剂，不但可节省人工提升产能，大幅度提高了生产效率，且确保制造现场的环境的安全和操作人员的健康。本发明还采用热塑性不透气EAA膜来调节隔音垫的空气流阻，在不增加重量和制造成本的基础上实现对声学制品声学性能的优化。

Description

轻量化空气流阻可调节式多层结构声学部件的制备方法
技术领域
本发明涉及汽车声学部件的制造方法，尤其是通过调节空气流阻来达到实现不同声学效果的多层结构声学部件的控制方法，属于汽车部件隔音降噪技术领域。
背景技术
声学部件就是能对噪音起到衰减或隔离作用的部件，其作用机理包含两个方面：吸音或隔音。吸音与隔音机理：吸音是将声音能量吸收以使能量减弱直至消失，其原理是入射声波必须进入材料结构中，声波的能量使材料内的弹性纤维发生振动，或使材料孔隙中的空气分子互相撞击摩擦，在此过程中将声波的能量转化为热能而使声波的能量得以衰减；隔音则重在使声波发生反射或折射，从而减少传递到接收点的声能量，即通过隔离的方式减弱传递到“接收处”的声音。二者在作用原理及使用方式上有所区别：为提升吸音效果，应使入射声波容易进入材料结构内部，以与材料内部结构发生相互作用而使能量得以衰减；为提升隔音效果，则应该减少进入材料内部的声波而使声波得以阻绝。上述两种作用机理经常会相互制约，因此单层材料难以兼顾吸音与隔音效果，必须由多层复合方式来实现特定吸隔音声学性能要求。
近年来，在降低制造成本及提升燃油经济性的强烈需求性下，在声学部件领域，多层纤维毡制品正逐渐在取代传统的EPDM+PU泡沫或EVA+PU泡沫制品，在此过程中，由于要将不同层的纤维层粘合在一起，引入了热塑性热熔膜，一般为PE或EAA单层膜或EAA/PA/EAA 三层复合膜，采用这种纤维制品时，因为考虑更多的是制品的吸音功能，因此采用的原料膜一般为打孔膜（如图2所示），即膜上按一定间隔大小开了小孔，孔的直径大小一般为20-30μm，通过这样的方式来确保膜所连接的两层纤维层之间有连通的通道，以利于声波在进入表面纤维层后能穿过薄膜继续进入底层纤维层，与表层和底层纤维层都能发生相互作用，从而使声能量达到最大程度的消耗，即获得良好的吸音性能。
但是单方面靠吸音，并不能满足整车声学降噪要求：尽可能的使乘客仓的声压级最小。吸声结构的声学部件对于降低整车噪音声压级的贡献仅限于0.2~1 dB，要想更进一步的降低声压级，还需要该材料结构能发挥隔音作用。从前述隔音机理得知，多层结构中必须含有一层隔离层来阻隔或反射声波。如果继续使用传统的EPDM或者EVA作为隔离层，一方面产品的重量增加了，无法达成轻量化的要求；另一方面，EPDM或EVA层与纤维层之间的连接也会出现问题：a）如果利用蒸汽加热工艺，利用EPDM或EVA的背胶与纤维层粘合，由于在加热过程中EPDM或EVA会被同时软化，在脱模时容易出现粘模，进一步如果在脱模过程中，EPDM或EVA产生破裂，会形成废品，隔音制品上的缝隙的会极大程度的降低隔音效果；b）如果采用喷胶的方式将EPDM层和纤维层粘合在一起，会增加制造工序，降低生产效率，同时胶水的使用也会带来一定的VOC问题。那么是否可以不使用传统EPDM或EVA作为声隔离层，而直接利用热塑性薄膜作为声隔离层，在保证一定的吸音性能的前提下，提升多层纤维制品的隔音性能呢？本发明就是为了解决这个课题而创作的一种高效、低成本的生产工艺。
发明内容
本发明的目的在于克服上述不足之处，提供一种可行的，低成本，轻量化的，空气流阻可调节的声学部件的制造方法，该方法主要通过对多层结构中所使用的热塑性薄膜的流阻的控制，来分别实现对制品吸隔音功能的控制。
按照本发明提供的技术方案，轻量化空气流阻可调节式多层结构声学部件的制备方法，步骤为：
（1）铺料：按由下至上的顺序铺放纤维毡、热塑性不透气薄膜和纤维毡（如附图3）；
（2）压制成型：将铺好的材料置入成型模具内进行模压，在模压的同时下模通蒸汽，上模抽真空，通过高温蒸汽对材料进行加热，使上下层纤维中含有低熔点纤维丝熔化，在压力的作用下，把周围的纤维丝粘合在一起，同时热塑性薄膜也被熔化，把上下两层纤维层粘合在一起，得到压制半成品；在此过程中，通过对蒸汽加热时间及上下模具温度的控制，来实现对薄膜熔化程度的控制，进而控制模压成型后薄膜的流阻：如果需要提升制品的空气流阻，则需要减少蒸汽加热时间和上下模具温度，从而减少薄膜的熔化，这样可以得到大的空气流阻，大的空气流阻层即为声传递的隔离层，反之亦然；
成型条件：蒸汽压力：0.6-3MPa；蒸汽温度：170-220℃；通蒸汽时间25-35s成型压力：9-12Mpa；成型时间：40-60s；抽真空压力：0.015-0.03Mpa；抽真空时间：50-70s；上下模模具温度：170-200℃；
（3）冷却定型：将所述压制半成品放入冷却治具进行冷却定型；得定型半成品，冷却时间：45-60s；
（4）切割：用冲断装置或水刀对所述定型半成品进行外形尺寸及孔位的切割，得到声学部件成品；冲断装置的冲断压力为5-10Mpa，冲断时间为3-10s；水刀的切割压力为40000-50000psi，切割气压为0.6-0.8Mpa；
（5）检验：所述声学部件成品经检验无缺陷合格后，装箱入库。
所述热塑性不透气薄膜为EAA不透气膜，密度为25-70g/m2。
所述产品轻量化空气流阻可调节式多层结构声学部件空气流阻为2000-9000rayls(N.s/m3)。所述产品轻量化空气流阻可调节式多层结构声学部件流阻为5000-9000rayls (N.s/m3)。
所述热塑性薄膜为EAA不透气膜，克重为25~70g/m2。
所述纤维毡成分为质量分数15%-20%的聚酯纤维，15%-25%的低熔点聚酯纤维和50%-65%的棉纤维及化学合成纤维的再生纤维；表面密度：500-2000g/m2。
具体制备过程为：a）原料单独开松处理：称取聚酯纤维1~2份、再生棉纤维5~7份、低熔点热塑性纤维2~3份，首先对各种原料单独进行开松处理，将团簇状的纤维材料打散成蓬松的纤维束，打散后纤维的体密度为50~80kg/m3，打散后的原料送入一个大仓进行混合；b)混开松及除杂：混合好以后的原料再通过进一步的混合开松处理及杂质处理得到开松均匀的混合料；c)气流成网：将b)中得到的混合料通过铺料设备在棉箱中铺成设定厚度的纤维层，再输入到气流成网机中形成需要的纤维层；d)高温定型：纤维层在烘箱中经高温处理定型；e)裁片：高温定型后再冷却后，经裁剪处理，即可获得设定尺寸与厚度的纤维毡。
本发明的有益效果：利用高温蒸汽传热的方式，在模压成型时直接利用热塑性薄膜进行粘结，而非在现场以人工涂布粘结剂，不但可节省人工提升产能，大幅度提高了生产效率，且确保了制造现场的环境的安全和操作人员的健康。
本发明还采用不透气热塑性薄膜EAA作为纤维层之间的粘合膜，通过选择不同熔点、克重的薄膜，及通过对蒸汽加热时间及上下模具温度的控制，来调节声学部件的空气流阻，在不增加制品重量及制造成本的前提下为声学性能的优化提供新的研究方向。
本发明所涉及的多层结构的声学部件可以用作前围驾仓隔音垫或汽车主地毯下隔音垫。
附图说明
图1本发明工艺流程图。
图2本发明打孔膜示意图。
图3本发明材料铺设图。
附图标记说明：1、纤维层；2、EAA膜；3、纤维层。
具体实施方式
本发明实施例工艺流程图如图1所示。
实施例1
（1）铺料：按由下至上的顺序铺放纤维毡、热塑性薄膜和纤维毡；其中上层纤维毡克重1000 g/m2，下层纤维毡克重为1200 g/m2，采用的薄膜克重为25g/m2；铺料顺序如图3所示；
（2）压制成型：将铺好的材料置入成型模具内进行模压，在模压的同时下模通蒸汽，上模抽真空，通过高温蒸汽对材料进行加热，使上下层纤维中含有低熔点纤维丝熔化，在压力的作用下，把周围的纤维丝粘合在一起，同时热塑性薄膜也被熔化，把上下两层纤维层粘合在一起，得到压制半成品；
成型条件：蒸汽压力：0.6MPa；蒸汽温度： 220℃；通蒸汽时间25s成型压力：10Mpa；成型时间：45s；抽真空压力：0.015MPa；抽真空时间：50s；上下模模具温度：170℃；
（3）冷却定型：将压制半成品放入冷却治具进行冷却定型，得定型半成品；冷却时间：45s；
（4）切割：用冲断装置或水刀对定型半成品进行切割外形尺寸及孔位，得到声学部件成品；冲断装置：冲断压力：8MPa，冲断时间：10s；水刀：切割压力：40000psi，切割气压：0.8MPa；
（5）检验：声学部件成品经检验无缺陷合格后，装箱入库。
最终声学部件成品的总流阻为2000-3000rayls，所述声学部件成品吸音性能比较好。
实施例2
（1）铺料：按由下至上的顺序铺放纤维毡、热塑性薄膜和纤维毡；其中上层纤维毡克重1200g/m2，下层纤维毡克重为1500g/m2，采用的薄膜克重为70g/m2；铺料顺序如图3所示；
（2）压制成型：将铺好的材料置入成型模具内进行模压，在模压的同时下模通蒸汽，上模抽真空，通过高温蒸汽对材料进行加热，使上下层纤维中含有低熔点纤维丝熔化，在压力的作用下，把周围的纤维丝粘合在一起，同时热塑性薄膜也被熔化，把上下两层纤维层粘合在一起，得到压制半成品；
成型条件：蒸汽压力：3MPa；蒸汽温度：170℃；通蒸汽时间35s成型压力：12MPa；成型时间：60s；抽真空压力：0.015Mpa；抽真空时间：70s；上下模模具温度：200℃；
（3）冷却定型：将压制半成品放入冷却治具进行冷却定型，得定型半成品，冷却时间：60s；
（4）切割：用冲断装置或水刀对定型半成品进行切割外形尺寸及孔位，得到声学部件成品；冲断装置：冲断压力：8Mpa，冲断时间： 10s；水刀：切割压力：45000psi，切割气压：0.7Mpa；
（5）检验：声学部件成品经检验无缺陷合格后，装箱入库。
最终声学部件成品的总流阻为7000-9000rayls，所述声学部件成品的隔音性能比较好。
实施例3
（1）铺料：按由下至上的顺序铺放纤维毡、热塑性薄膜和纤维毡；其中上层纤维毡克重1200g/m2，下层纤维毡克重为1200g/m2，采用的薄膜克重为35g/m2；铺料顺序如图3所示；
（2）压制成型：将铺好的材料置入成型模具内进行模压，在模压的同时下模通蒸汽，上模抽真空，通过高温蒸汽对材料进行加热，使上下层纤维中含有低熔点纤维丝熔化，在压力的作用下，把周围的纤维丝粘合在一起，同时热塑性薄膜也被熔化，把上下两层纤维层粘合在一起，得到压制半成品；
成型条件：蒸汽压力：2MPa；蒸汽温度：200℃；通蒸汽时间30s成型压力：11MPa；成型时间：55s；抽真空压力：0.02Mpa；抽真空时间：60s；上下模模具温度：190℃；
（3）冷却定型：将压制半成品放入冷却治具进行冷却定型，得定型半成品，冷却时间：60s；
（4）切割：用冲断装置或水刀对定型半成品进行切割外形尺寸及孔位，得到声学部件成品；冲断装置：冲断压力：8Mpa，冲断时间：5s；水刀：切割压力：50000psi，切割气压：0.6Mpa；
（5）检验：声学部件成品经检验无缺陷合格后，装箱入库。
最终声学部件成品的总流阻为3000-5000rayls，这种声学部件成品具有良好的综合吸/隔音性能。

Claims (4)

1.轻量化空气流阻可调节式多层结构声学部件的制备方法，其特征是步骤为：
（1）铺料：按由下至上的顺序铺放纤维毡、热塑性不透气薄膜和纤维毡；
（2）压制成型：将步骤（1）铺好的材料置入成型模具内进行模压，在模压的同时下模通蒸汽，上模抽真空，通过高温蒸汽对材料进行加热，使上下层纤维中含有低熔点纤维丝熔化，在压力的作用下，把周围的纤维丝粘合在一起，同时热塑性薄膜也被熔化，把上下两层纤维层粘合在一起，得到压制半成品；
成型条件：蒸汽压力：0.6-3MPa；蒸汽温度：170-220℃；通蒸汽时间25-35s成型压力：9-12Mpa；成型时间：40-60s；抽真空压力：0.015-0.03Mpa；抽真空时间：50-70s；上下模模具温度：170-200℃；
（3）冷却定型：将所述压制半成品放入冷却治具进行冷却定型，得到定型半成品；冷却时间：45-60s；
（4）切割：用冲断装置或水刀对所述定型半成品进行外形尺寸及孔位的切割，得到声学部件成品；冲断装置的冲断压力为5-10Mpa，冲断时间为3-10s；水刀的切割压力为40000-50000psi，切割气压为0.6-0.8Mpa；
（5）检验：所述声学部件成品经检验无缺陷合格后，装箱入库。
2.如权利要求1所述轻量化空气流阻可调节式多层结构声学部件的制备方法，其特征是：所述热塑性不透气薄膜为EAA不透气膜，密度为25-70g/m2。
3.如权利要求1所述轻量化空气流阻可调节式多层结构声学部件的制备方法，其特征是：所述产品轻量化空气流阻可调节式多层结构声学部件空气流阻为2000-9000rayls N.s/m3。
4.如权利要求1所述轻量化空气流阻可调节式多层结构声学部件的制备方法，其特征是：所述纤维毡成分按重量份计为15%-20%的聚酯纤维，15%-25%的低熔点聚酯纤维和60%-65%的棉纤维及化学合成纤维的再生纤维；表面密度为500-2000g/m2。
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