CN105667040A - 一种汽车前围材料及其制作方法 - Google Patents

一种汽车前围材料及其制作方法 Download PDF

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CN105667040A
CN105667040A CN201610056273.7A CN201610056273A CN105667040A CN 105667040 A CN105667040 A CN 105667040A CN 201610056273 A CN201610056273 A CN 201610056273A CN 105667040 A CN105667040 A CN 105667040A
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front wall
wall material
film
automobile front
soft felt
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陈秋圣
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HP Pelzer Automotive Interior Systems Taicang Co Ltd
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Pelzer Automotive Interior Systems Taicang Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating

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  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)

Abstract

本申请公开了一种汽车前围材料及其制作方法，该汽车前围材料，包括软毡以及形成于软毡表面上的PE/PA膜。所述软毡为PET和PP的混合纤维。所述PE/PA膜上分布有多个通孔，相邻通孔之间的间距为1mm。本发明采用PE/PA膜上，一方面，解决了VOC排放问题，降低重量和成本；另一方面通过开孔，在保持隔音指标的情况下增加吸音性能。

Description

一种汽车前围材料及其制作方法
技术领域
本申请属于材料技术领域，特别是涉及一种汽车前围材料及其制作方法。
背景技术
传统手段中，汽车前围材料包括软毡以及复合于软毡上的硬毡或重涂层材料。其制作过程中，一般采用喷胶粘合工艺。其存在缺陷至少包括：
1、采用喷胶粘合工艺会引发VOC排放和气味超标的技术问题；
2、硬毡或重涂层材料成本高、重量偏重。
发明内容
本发明的目的在于提供一种汽车前围材料及其制作方法，以克服现有技术中的不足。
为实现上述目的，本发明提供如下技术方案：
本申请实施例公开了一种汽车前围材料，包括软毡以及形成于软毡表面上的PE/PA膜。
优选的，在上述的汽车前围材料中，所述软毡为PET和PP的混合纤维。
优选的，在上述的汽车前围材料中，所述软毡的密度为80～100g/m2。
优选的，在上述的汽车前围材料中，所述PE/PA膜的密度为50～500g/m2。
优选的，在上述的汽车前围材料中，所述PE/PA膜上分布有多个通孔，相邻通孔之间的间距为1mm。
相应的，本申请还公开了一种汽车前围材料的制作方法，包括步骤：
(1)、制作PE/PA膜；
(2)、制作软毡；
(3)、将软毡移到PE/PA膜上，然后进行热压成型。
优选的，在上述的汽车前围材料的制作方法中，所述步骤(1)和(3)中，采用吸附方式移动PE/PA膜或软毡。
优选的，在上述的汽车前围材料的制作方法中，所述步骤(3)中，热压成型时，合模保压时间为60～180秒，模具压力大于200吨，模具温度控制在200℃。
与现有技术相比，本发明的优点在于：本发明采用PE/PA膜上，一方面，解决了VOC排放问题，降低重量和成本；另一方面通过开孔，在保持隔音指标的情况下增加吸音性能。
附图说明
为了更清楚地说明本申请实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图仅仅是本申请中记载的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1所示为本发明具体实施例中汽车前围材料的结构示意图；
图2所示为本发明具体实施例中软毡的制作流程图；
图3所示为本发明具体实施例中软毡和PE/PA膜复合设备；
图4所示为有孔PE/PA膜与无孔PE/PA膜声学性能的对比曲线图。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行详细的描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动的前提下所获得的所有其他实施例，都属于本发明保护的范围。
结合图1所示，汽车前围材料，包括软毡2以及形成于软毡表面上的PE/PA膜1。软毡为PET和PP的混合纤维。
在该技术方案中，采用PE/PA膜上，解决了VOC排放问题，降低重量和成本
进一步地，软毡的密度为80～100g/m2。PE/PA膜的密度为50～500g/m2。
进一步地，PE/PA膜上分布有多个通孔，相邻通孔之间的间距为1mm。
在该技术方案中，通过开孔，在保持隔音指标的情况下增加吸音性能。
汽车前围材料的制作方法，包括步骤：
(1)、下料PE/PA膜
将PE/PA膜卷材放在特殊工装上，工装根据零件大小裁剪尺寸并用抓手吸附放置在工装上。
(2)、制作软毡
结合图2所示，不同纤维按特定比例依次经过纤维开松3、混合4、纤维精细开松5、HMP3纤维注塑6工艺后，制成软毡。
(3)、软毡和PE/PA膜复合
通过机器人或人工将制作后的软毡移到PE/PA膜工装，工装将膜吸附到软毡。
所采用的设备如图3所示，包括机器人7、工装8、压机9、模具10和模温机11。模具安装于压机9上，模温机11用以对模具温度进行控制，机器人用以移动软毡和PE/PA膜12。
(4)、软毡和PE/PA膜移到热模
通过机器人或人工将复合的软毡和PE/PA膜移到热模。
(5)、合模压制
压机闭合，合模保压时间60-180秒，模具压力大于200吨，模具控制在200度。
对所获得的复合材料的声学性能进行测试并以无孔的PE/PA膜作为对比，参图4所示，有孔PE/PA膜声学性能表现在大部分频段比无穿孔膜更好。
需要说明的是，在本文中，诸如第一和第二等之类的关系术语仅仅用来将一个实体或者操作与另一个实体或操作区分开来，而不一定要求或者暗示这些实体或操作之间存在任何这种实际的关系或者顺序。而且，术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含，从而使得包括一系列要素的过程、方法、物品或者设备不仅包括那些要素，而且还包括没有明确列出的其他要素，或者是还包括为这种过程、方法、物品或者设备所固有的要素。在没有更多限制的情况下，由语句“包括一个……”限定的要素，并不排除在包括所述要素的过程、方法、物品或者设备中还存在另外的相同要素。
以上所述仅是本申请的具体实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本申请原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为本申请的保护范围。

Claims (8)

1.一种汽车前围材料，其特征在于，包括软毡以及形成于软毡表面上的PE/PA膜。
2.根据权利要求1所述的汽车前围材料，其特征在于：所述软毡为PET和PP的混合纤维。
3.根据权利要求1所述的汽车前围材料，其特征在于：所述软毡的密度为80～100g/m2。
4.根据权利要求1所述的汽车前围材料，其特征在于：所述PE/PA膜的密度为50～500g/m2。
5.根据权利要求1所述的汽车前围材料，其特征在于：所述PE/PA膜上分布有多个通孔，相邻通孔之间的间距为1mm。
6.权利要求1至5任一所述的汽车前围材料的制作方法，其特征在于，包括步骤：
(1)、制作PE/PA膜；
(2)、制作软毡；
(3)、将软毡移到PE/PA膜上，然后进行热压成型。
7.根据权利要求6所述的汽车前围材料的制作方法，其特征在于：所述步骤(1)和(3)中，采用吸附方式移动PE/PA膜或软毡。
8.根据权利要求6所述的汽车前围材料的制作方法，其特征在于：所述步骤(3)中，热压成型时，合模保压时间为60～180秒，模具压力大于200吨，模具温度控制在200℃。
CN201610056273.7A 2016-01-26 2016-01-26 一种汽车前围材料及其制作方法 Pending CN105667040A (zh)

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108099331A (zh) * 2016-11-25 2018-06-01 上海新安汽车隔音毡有限公司 一种汽车用蓄电池罩盖隔音垫及其制作方法
CN109291356A (zh) * 2017-07-24 2019-02-01 佛吉亚汽车工业公司 用于机动车辆的隔音部件以及相关的制造过程
CN115366514A (zh) * 2022-08-19 2022-11-22 长春佩尔哲汽车内饰系统有限公司 一种汽车吸音毛毡前围材料及生产工艺

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2005179858A (ja) * 2003-12-22 2005-07-07 Asakura:Kk 手袋の製造方法及び当該製造方法により得られた不織布を構成材料とする手袋
CN203344862U (zh) * 2013-06-28 2013-12-18 上海通用汽车有限公司 一种消音复合垫层
CN103496244A (zh) * 2013-10-15 2014-01-08 湖北三环汽车工程塑料有限公司 一种棉毡隔音垫的生产方法

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2005179858A (ja) * 2003-12-22 2005-07-07 Asakura:Kk 手袋の製造方法及び当該製造方法により得られた不織布を構成材料とする手袋
CN203344862U (zh) * 2013-06-28 2013-12-18 上海通用汽车有限公司 一种消音复合垫层
CN103496244A (zh) * 2013-10-15 2014-01-08 湖北三环汽车工程塑料有限公司 一种棉毡隔音垫的生产方法

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108099331A (zh) * 2016-11-25 2018-06-01 上海新安汽车隔音毡有限公司 一种汽车用蓄电池罩盖隔音垫及其制作方法
CN109291356A (zh) * 2017-07-24 2019-02-01 佛吉亚汽车工业公司 用于机动车辆的隔音部件以及相关的制造过程
CN109291356B (zh) * 2017-07-24 2022-06-28 佛吉亚汽车工业公司 用于机动车辆的隔音部件以及相关的制造过程
CN115366514A (zh) * 2022-08-19 2022-11-22 长春佩尔哲汽车内饰系统有限公司 一种汽车吸音毛毡前围材料及生产工艺

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