CN106671492A - 一种汽车隔音垫制造方法 - Google Patents
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Abstract
本发明公开了一种汽车隔音垫制造方法,包括饰面层、混合层和底面蜂窝层;所述饰面层位于最上方,混合层位于饰面层、底面蜂窝层之间;所述饰面层采用PC/ABS合金材料,混合层采用低熔点PET纤维、再生纤维、涤纶纤维材料;所述底面蜂窝层与混合层之间喷涂设置无机纤维喷涂层,无机纤维喷涂层采用植物纤维喷涂,无机纤维喷涂层喷涂厚度为20‑35mm;本发明无气味、韧性高、重量轻、吸音效果好,可回收再利用,符合现代汽车轻量化、环保化和舒适性的要求;其结构对汽车内气味和VOC管控具有一定贡献,并且能提高低频波吸声系。
Description
技术领域
本发明涉及汽车隔音垫,具体是一种汽车隔音垫制造方法。
背景技术
汽车内饰件一般安装于汽车车身内部,起到美化、防护以及隔音吸音等作用,汽车隔音垫可应用于汽车发动机舱、乘客舱、行李箱等各部位,具有减震、吸引、隔热等特点,在越来越追求高性能、环保型、轻量化、舒适度的时代,汽车内饰与汽车外形一样成为人们选车的一个重要因素,因此对汽车内饰件的要求越来越高,目前汽车隔音垫主要以再生纤维毡和PU发泡料为主;存在以下技术问题:酚醛树脂加固的纤维毡气味大,容易污染环境;纤维毡裸露,容易引起挥发性有机化合物不合格,另外,隔音垫的低重量、高强度、隔音性、吸音性等性能指标成为瓶颈,制约着隔音垫的发展,现有技术中重量大、价格高、利用率低的隔音垫已经无法满足人们日益增长的需求,迫切需要开发性能更优越、具备多种功能的汽车隔音垫以增加市场竞争力,提高汽车内饰品质。
发明内容
本发明的目的在于提供一种无气味、韧性高、重量轻、吸音效果好的汽车隔音垫制造方法,以解决上述背景技术中提出的问题。
为实现上述目的,本发明提供如下技术方案:
一种汽车隔音垫制造方法,包括饰面层、混合层和底面蜂窝层;所述饰面层位于最上方,混合层位于饰面层、底面蜂窝层之间;所述饰面层采用PC/ABS合金材料,混合层采用低熔点PET纤维、再生纤维、涤纶纤维材料;所述底面蜂窝层与混合层之间喷涂设置无机纤维喷涂层,无机纤维喷涂层采用植物纤维喷涂,无机纤维喷涂层喷涂厚度为20-35mm。
进一步的:所述饰面层中PC/ABS合金材料的具体制作方法包括以下步骤:
1)PC/ABS合金材料按下列组分配比选取:PC树脂60份、ABS树脂39.5份、纳米二氧化硅5.5份、双十八烷基醇季戊四醇二亚磷酸醋0.55份、脂肪酸酞胺0.55份;
2)将纳米二氧化硅通过超声波振荡设备分散于纯净水中形成无机纳米粒子分散液,分散液通过液体喂料泵注入双螺杆挤出机,并与ABS树脂共混,将水全部蒸发并留下无机纳米粒子与ABS树脂形成的混合物;
将混合物与PC树脂、双十八烷基醇季戊四醇二亚磷酸酷和脂肪酸酞胺加入混合搅拌机中进行混合,并通过双螺杆挤出机共混造粒,机筒温度为210-290摄氏度,制得低收缩率高韧性的PC/ABS合金材料,得到饰面层。
进一步的:所述述混合层的具体制作方法包括以下步骤:
1)将低熔点PET纤维由喂棉机送入梳理机进行梳理,形成低熔点纤维网,将低熔点纤维网输送给铺棉机,铺叠形成低熔点纤维层,将低熔点纤维层在针刺机上进行针刺加固,针刺速度为200-300转/分钟,得到产物A;
2)将再生纤维、涤纶纤维和低熔点PET纤维按重量比50:25:25混合均匀,得到混合纤维,将混合纤维由喂棉机送入梳理机进行梳理,形成混合纤维网,将混合纤维网输送给铺棉机,铺叠形成混合纤维毡,将混合纤维毡在针刺机上进行针刺加固,针刺速度为400-800转/分钟,得到产物B;
3)从下至上依次铺设产物A-产物B-产物A,在针刺机上进行针刺加固,针刺速度为1000-1200转/分钟,得到混合层的半成品C,其中,产物A的厚度为0.7-1.5mm;
4)将半成品C置于成型模具内进行模压成型:首先上模抽真空,抽真空时间为10-20秒,压力为0.01-0.02MPa,在抽真空的同时通入高温蒸汽,保持真空度,继续通入高温蒸汽进行加热成型,其中,高温蒸汽压力为0.6-2MPa,高温蒸汽温度为105-115摄氏度,加热成型的压力为5-10MPa,成型时间为40-60秒;
将模压成型处理后半成品C放入冷却治具,在常温下进行冷却定型,冷却时间为30-45秒,从而得到混合层,混合层的厚度为8-12mm。
与现有技术相比,本发明的有益效果是:
本发明中,饰面层无任何气味,由于纳米二氧化硅的存在,使得PC/ABS合金材料拥有较低模具收缩率的同时保持了较高的韧性;
本发明重量轻、吸音效果好、环保、可以回收再利用,符合现代汽车轻量化、环保化和舒适性的要求;其中,采用“三明治”结构,对汽车内气味和VOC管控具有一定贡献,并且能提高低频波吸声系。
附图说明
图1为汽车隔音垫制造方法的结构示意图。
具体实施方式
下面结合具体实施方式对本专利的技术方案作进一步详细地说明。
请参阅图1,一种汽车隔音垫制造方法,包括饰面层1、混合层2和底面蜂窝层3;所述饰面层1位于最上方,混合层2位于饰面层1、底面蜂窝层3之间;所述饰面层采用PC/ABS合金材料,混合层2采用低熔点PET纤维、再生纤维、涤纶纤维材料;所述底面蜂窝层3与混合层2之间喷涂设置无机纤维喷涂层,无机纤维喷涂层采用植物纤维喷涂,无机纤维喷涂层喷涂厚度为20-35mm;
所述饰面层1中PC/ABS合金材料的具体制作方法包括以下步骤:
3)PC/ABS合金材料按下列组分配比选取:PC树脂60份、ABS树脂39.5份、纳米二氧化硅5.5份、双十八烷基醇季戊四醇二亚磷酸醋0.55份、脂肪酸酞胺0.55份;
4)将纳米二氧化硅通过超声波振荡设备分散于纯净水中形成无机纳米粒子分散液,分散液通过液体喂料泵注入双螺杆挤出机,并与ABS树脂共混,将水全部蒸发并留下无机纳米粒子与ABS树脂形成的混合物;
5)将混合物与PC树脂、双十八烷基醇季戊四醇二亚磷酸酷和脂肪酸酞胺加入混合搅拌机中进行混合,并通过双螺杆挤出机共混造粒,机筒温度为210-290摄氏度,制得低收缩率高韧性的PC/ABS合金材料,得到饰面层1;
所述述混合层2的具体制作方法包括以下步骤:
5)将低熔点PET纤维由喂棉机送入梳理机进行梳理,形成低熔点纤维网,将低熔点纤维网输送给铺棉机,铺叠形成低熔点纤维层,将低熔点纤维层在针刺机上进行针刺加固,针刺速度为200-300转/分钟,得到产物A;
6)将再生纤维、涤纶纤维和低熔点PET纤维按重量比50:25:25混合均匀,得到混合纤维,将混合纤维由喂棉机送入梳理机进行梳理,形成混合纤维网,将混合纤维网输送给铺棉机,铺叠形成混合纤维毡,将混合纤维毡在针刺机上进行针刺加固,针刺速度为400-800转/分钟,得到产物B;
7)从下至上依次铺设产物A-产物B-产物A,在针刺机上进行针刺加固,针刺速度为1000-1200转/分钟,得到混合层的半成品C,其中,产物A的厚度为0.7-1.5mm;
8)将半成品C置于成型模具内进行模压成型:首先上模抽真空,抽真空时间为10-20秒,压力为0.01-0.02MPa,在抽真空的同时通入高温蒸汽,保持真空度,继续通入高温蒸汽进行加热成型,其中,高温蒸汽压力为0.6-2MPa,高温蒸汽温度为105-115摄氏度,加热成型的压力为5-10MPa,成型时间为40-60秒;
将模压成型处理后半成品C放入冷却治具,在常温下进行冷却定型,冷却时间为30-45秒,从而得到混合层2,混合层2的厚度为8-12mm。
本发明中,饰面层无任何气味,由于纳米二氧化硅的存在,使得PC/ABS合金材料拥有较低模具收缩率的同时保持了较高的韧性;
本发明重量轻、吸音效果好、环保、可以回收再利用,符合现代汽车轻量化、环保化和舒适性的要求;其中,采用“三明治”结构,对汽车内气味和VOC管控具有一定贡献,并且能提高低频波吸声系。
上面对本专利的较佳实施方式作了详细说明,但是本专利并不限于上述实施方式,在本领域的普通技术人员所具备的知识范围内,还可以在不脱离本专利宗旨的前提下做出各种变化。
Claims (3)
1.一种汽车隔音垫制造方法,包括饰面层(1)、混合层(2)和底面蜂窝层(3);其特征在于,所述饰面层(1)位于最上方,混合层(2)位于饰面层(1)、底面蜂窝层(3)之间;所述饰面层采用PC/ABS合金材料,混合层(2)采用低熔点PET纤维、再生纤维、涤纶纤维材料;所述底面蜂窝层(3)与混合层(2)之间喷涂设置无机纤维喷涂层,无机纤维喷涂层采用植物纤维喷涂,无机纤维喷涂层喷涂厚度为20-35mm。
2.一种如权利要求1所述的汽车隔音垫制造方法的制备方法,其特征在于,所述饰面层(1)中PC/ABS合金材料的具体制作方法包括以下步骤:
1)PC/ABS合金材料按下列组分配比选取:PC树脂60份、ABS树脂39.5份、纳米二氧化硅5.5份、双十八烷基醇季戊四醇二亚磷酸醋0.55份、脂肪酸酞胺0.55份;
2)将纳米二氧化硅通过超声波振荡设备分散于纯净水中形成无机纳米粒子分散液,分散液通过液体喂料泵注入双螺杆挤出机,并与ABS树脂共混,将水全部蒸发并留下无机纳米粒子与ABS树脂形成的混合物;
3)将混合物与PC树脂、双十八烷基醇季戊四醇二亚磷酸酷和脂肪酸酞胺加入混合搅拌机中进行混合,并通过双螺杆挤出机共混造粒,机筒温度为210-290摄氏度,制得低收缩率高韧性的PC/ABS合金材料,得到饰面层(1)。
3.一种如权利要求1所述的汽车隔音垫制造方法的制备方法,其特征在于,所述述混合层(2)的具体制作方法包括以下步骤:
1)将低熔点PET纤维由喂棉机送入梳理机进行梳理,形成低熔点纤维网,将低熔点纤维网输送给铺棉机,铺叠形成低熔点纤维层,将低熔点纤维层在针刺机上进行针刺加固,针刺速度为200-300转/分钟,得到产物A;
2)将再生纤维、涤纶纤维和低熔点PET纤维按重量比50:25:25混合均匀,得到混合纤维,将混合纤维由喂棉机送入梳理机进行梳理,形成混合纤维网,将混合纤维网输送给铺棉机,铺叠形成混合纤维毡,将混合纤维毡在针刺机上进行针刺加固,针刺速度为400-800转/分钟,得到产物B;
3)从下至上依次铺设产物A-产物B-产物A,在针刺机上进行针刺加固,针刺速度为1000-1200转/分钟,得到混合层的半成品C,其中,产物A的厚度为0.7-1.5mm;
4)将半成品C置于成型模具内进行模压成型:首先上模抽真空,抽真空时间为10-20秒,压力为0.01-0.02MPa,在抽真空的同时通入高温蒸汽,保持真空度,继续通入高温蒸汽进行加热成型,其中,高温蒸汽压力为0.6-2MPa,高温蒸汽温度为105-115摄氏度,加热成型的压力为5-10MPa,成型时间为40-60秒;
5)将模压成型处理后半成品C放入冷却治具,在常温下进行冷却定型,冷却时间为30-45秒,从而得到混合层(2),混合层(2)的厚度为8-12mm。
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CN107696611A (zh) * | 2017-10-14 | 2018-02-16 | 镇江长江汽车内饰件有限公司 | 一种制备阻燃隔音垫的方法及阻燃隔音垫 |
CN110015243A (zh) * | 2017-11-30 | 2019-07-16 | 西川橡胶工业股份有限公司 | 隔音性海绵件、汽车用密封件和挡风条 |
CN110015243B (zh) * | 2017-11-30 | 2023-07-04 | 西川橡胶工业股份有限公司 | 隔音性海绵件、汽车用密封件和挡风条 |
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