CN111016373A - Light acoustic sound insulation pad for vehicle and manufacturing method thereof - Google Patents

Light acoustic sound insulation pad for vehicle and manufacturing method thereof Download PDF

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Publication number
CN111016373A
CN111016373A CN202010127916.9A CN202010127916A CN111016373A CN 111016373 A CN111016373 A CN 111016373A CN 202010127916 A CN202010127916 A CN 202010127916A CN 111016373 A CN111016373 A CN 111016373A
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China
Prior art keywords
layer
cotton felt
sound insulation
pressure
cotton
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Pending
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CN202010127916.9A
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Chinese (zh)
Inventor
杨杉苗
鲁娟
张曲
王可以
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Ningbo Tuopu Group Co Ltd
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Ningbo Tuopu Group Co Ltd
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Priority to CN202010127916.9A priority Critical patent/CN111016373A/en
Publication of CN111016373A publication Critical patent/CN111016373A/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/12Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10Methods 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00Ancillary operations in connection with laminating processes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00Ancillary operations in connection with laminating processes
    • B32B38/0004Cutting, tearing or severing, e.g. bursting; Cutter details
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered 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
    • B32B5/02Layered 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered 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
    • B32B5/02Layered 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
    • B32B5/022Non-woven fabric
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered 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
    • B32B5/22Layered 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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered 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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26Layered 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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04Interconnection of layers
    • B32B7/12Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60RVEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/08Insulating elements, e.g. for sound insulation
    • B60R13/0815Acoustic or thermal insulation of passenger compartments
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02Synthetic macromolecular fibres
    • B32B2262/0276Polyester fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02Synthetic macromolecular fibres
    • B32B2262/0276Polyester fibres
    • B32B2262/0284Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/10Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102Insulating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/30Properties of the layers or laminate having particular thermal properties
    • B32B2307/306Resistant to heat
    • B32B2307/3065Flame resistant or retardant, fire resistant or retardant
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/714Inert, i.e. inert to chemical degradation, corrosion
    • B32B2307/7145Rot proof, resistant to bacteria, mildew, mould, fungi
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/718Weight, e.g. weight per square meter
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00Vehicles
    • B32B2605/08Cars

Abstract

The invention discloses a light acoustic sound insulation pad for a vehicle, which comprises an upper layer cotton felt, a middle layer barrier film and a lower layer cotton felt which are sequentially connected from top to bottom, wherein the upper layer cotton felt and the lower layer cotton felt are prepared by mixing one or more of LPET fibers and fibers such as PET, PP, PA, PLA and the like, and the hardness of the upper layer cotton felt is more than or equal to that of the lower layer cotton felt; the invention also discloses a manufacturing method of the light acoustic sound insulation pad for the vehicle, which comprises the steps of preparing each layer, paving materials, forming in one step and finally shaping; the invention has good sound absorption and insulation effect, lighter weight, better flame retardant property and mildew resistance, and higher commercial value.

Description

Light acoustic sound insulation pad for vehicle and manufacturing method thereof
Technical Field
The invention relates to the technical field of automotive interior parts, in particular to a light acoustic sound insulation pad for an automobile and a manufacturing method thereof.
Background
With the increasing frequency of daily trips of people, the requirements of people on automobiles are higher and higher, the requirements on basic performances such as driving speed, stability and the like of the automobiles are met, more requirements on comfort of the automobiles are met, and the sound insulation performance of the automobiles serving as an important index is also brought into evaluation indexes of automobile manufacturers and automobile owners.
The automobile sound insulation pad plays a vital role in the field of automobile sound insulation as an important automobile part capable of effectively insulating sound, shock and heat in an automobile, and is prepared from EVA (ethylene-vinyl acetate copolymer) + PU (polyurethane) foam materials or traditional recycled cotton materials in the production and application of traditional automobile parts. The PU foam is attached to a metal plate of a vehicle body, the EVA is arranged on one side of a passenger compartment, and although the structure can achieve better sound insulation and noise reduction effects, the material has the defect that the material has higher weight to achieve certain sound insulation performance due to the double-wall resonance principle, and the EVA material is a non-sound-absorbing material and provides lower sound absorption performance for the passenger compartment; the base material of the re-spun cotton material is a recycled textile, the natural cotton fiber with high content in the re-spun cotton does not have the flame retardant property, the added flame retardant can bring negative effects to the smell of the parts, and the re-spun cotton fiber is easy to go moldy and has musty smell of cotton, so that the requirement of a user on the smell of the whole vehicle cannot be met.
Disclosure of Invention
In view of the above problems, it is an object of the present invention to provide a sound insulation and noise reduction sheet having excellent sound insulation and noise reduction properties and a light weight (having a grammage of 1000 to 3000g/m according to the demands of customers for light weight and acoustics of a finished automobile2Compared with the traditional EVA + PU foaming or reconstituted cotton material, the automobile lightweight acoustic sound insulation pad has the advantages of 15-60% weight reduction, no peculiar smell, good flame retardance and mildew resistance, and can be used for automobile acoustic sound insulation pads such as front and back walls, carpets, center channels, inner wheel covers, clothes and hat racks, spare tire bins and the like.
In order to solve the problems, the invention provides a light-weight acoustic sound insulation pad for a vehicle, which comprises an upper layer cotton felt, a middle layer barrier film and a lower layer cotton felt which are sequentially connected from top to bottom, wherein the upper layer cotton felt and the lower layer cotton felt are prepared by mixing one or more of LPET fibers and fibers such as PET, PP, PA, PLA and the like, the hardness of the upper layer cotton felt is greater than or equal to that of the lower layer cotton felt, and the LPET fibers are low-melting-point PET fibers.
According to the preferable scheme, the upper layer cotton felt and the lower layer cotton felt are both 0.1D-15D in denier, and the mass ratio is 10% -80%: 20-90% of LPET fiber and one or more of PET, PP, PA, PLA and the like.
As preferred scheme, upper cotton felt thickness be less than or equal to lower floor's cotton felt, just upper cotton felt's hardness is greater than or equal to lower floor's cotton felt adopts such design, can inhale, the effectual weight that reduces sound insulation pad under the prerequisite of sound insulation to lightweight acoustic celotex board also can reduce partial cost, the great also purpose that can be better completion final sound insulation of thickness of lower floor's cotton felt. (the scheme of the side weight sound insulation or the sound absorption is established according to the actual requirement, the thickness distribution of the upper layer cotton felt and the lower layer cotton felt can be properly improved to achieve the aim)
As a preferred scheme, a layer of non-woven fabric or sound-absorbing cotton (prepared by mixing one or more of LPET, PET, PP, PA, PLA and other fibers) is further arranged on the upper layer of cotton felt, the sound-insulating composite material can achieve a better sound-insulating effect through the combination of the cotton felt, the barrier film and the cotton felt, and the appearance of the product can be further improved and the sound-absorbing and sound-insulating effects can be further enhanced by further adding non-woven fabric/sound-absorbing cotton and other acoustic fabrics.
Preferably, the interlayer barrier film is a nonporous or apertured film, and the gram weight of the interlayer barrier film is 10-200 g/m2The material of the interlayer barrier film is one or more of EAA, EVA, PE, PP, PA, TPU, PES and the like or the modification thereof, and the material of the adhesive layer is one or more of EAA, EVA, PE, PP or the modification low melting point PA, PES and the like. The sound insulation cushion is characterized in that membranes such as EAA, EVA, PE, PP, PA, TPU and PES are adopted as a main body of the middle-layer barrier membrane, so that sound insulation can be well achieved, membranes such as EAA, EVA, PE and PP or modified low-melting-point PA and PES can achieve a good fixing effect in the forming process of the sound insulation cushion, and the bonding layer and the cotton felt can be heated through high-temperature steam, so that the bonding and shaping effects can be achieved.
The invention also provides a manufacturing method of the acoustic sound insulation pad for the vehicle, which comprises the following specific steps:
(1) according to the weight ratio of 10% -80%: feeding LPET fibers and one or more fibers of PET, PP, PA, PLA and the like in a mass ratio of 20-90%, and processing the mixture by needling, carding and lapping or air-laying equipment to obtain an upper cotton felt and a lower cotton felt (Micropro cotton felt), and preparing barrier film materials made of EAA, EVA, PE, PP, PA, TPU, PES and the like or modified substances thereof;
micropro is the sound insulation cushion material of the invention, which is the uniform name of the cotton felt in the invention, and the name is the same below
(2) Paving materials according to the sequence of the upper layer cotton felt, the middle layer barrier film and the lower layer cotton felt, and covering non-woven fabrics or sound-absorbing cotton on the upper layer cotton felt according to requirements to obtain a paved product;
(3) and (3) putting the material prepared in the step (2) into a preheated forming die, closing the die, introducing high-pressure steam, maintaining the pressure for a certain time to complete the assembly of the sound insulation pad, exhausting air until the air pressure in the die cavity is one atmosphere, and opening the die. The step adopts a one-step forming process to obtain a product with different thicknesses of the soft layer and the hard layer. The opening and closing of the steam system valve are controlled, and the pressure difference of the upper die cavity and the lower die cavity of the die is controlled by combining a vacuum auxiliary forming process, so that the material structure with different thicknesses of the soft layer and the hard layer can be obtained.
(4) And (4) transferring the product prepared in the step (3) to a shaping and punching die for cooling and shaping, and then carrying out water cutting or punching on hole sites and waste edges of the parts as required to obtain the acoustic sound insulation pad for the vehicle.
Preferably, in the step (3), the temperature of the forming mold is 120-250 ℃, the pressure of the high-pressure steam is 2-20 bar, the ventilation time is 2-100 s, and the pressure maintaining time is 0-100 s; the step (3) is a one-step forming process, and the specific equipment and process are as follows: the steam mould is provided with 4 steam connecting valves (2 in each of the upper and lower mould cavities) for butting the air inlet and outlet valves of the steam control system. The opening and closing of each valve of the steam control system can be independently controlled through a PLC program, and each air inlet and outlet is provided with a pressure sensor for feeding back the pressure change near the air inlet and outlet in the die cavity in real time. The opening and closing of the valve of the steam system are controlled, and a vacuum auxiliary forming process is combined. When the upper die cavity and the lower die cavity of the die are controlled to form a certain pressure difference, the thickness difference of the soft layer and the hard layer is generated, namely the thickness of the hard layer is smaller than that of the soft layer, and the soft layer is used as an acoustic scheme for emphasizing sound insulation. When the pressure of the upper die cavity and the lower die cavity of the die is controlled to be equal, a material structure with the hard layer thickness basically equal to the soft layer thickness is obtained and is used as an acoustic scheme for emphasizing sound absorption.
In the step (3), a one-step forming process is adopted, so that a certain pressure difference is generated in the upper die cavity and the lower die cavity, and a product with the hard layer thickness smaller than the soft layer thickness is obtained. The conventional forming process (i.e., the two-step forming method) is to pre-press the upper layer cotton felt into a thin thickness as a hard layer in advance before the step (2), and then to perform the operation after the step (2). Compared with the conventional forming process, the one-step forming process shortens the production steps, reduces the production cost and improves the production efficiency.
Compared with the prior art, the invention has the beneficial effects that:
the invention prepares the cotton felt by reasonably mixing the LPET fiber and one or more of the PET, PP, PA, PLA and the like, adds the barrier layer between two layers of cotton felts to form a multilayer structure, preliminarily absorbs the noise through the first layer of cotton felt and the sound-absorbing cotton/non-woven fabric, then the noise enters the barrier film, the barrier film filters the noise again, and finally the lower layer of cotton felt carries out final treatment on the noise, so the invention has better sound insulation effect; the raw materials of the cotton felt in the invention adopt superfine fibers, hollow fibers, triangular, cross-shaped, trilobal, multilobal, flat, H-shaped and other special-shaped PET, PP, PA, PLA fibers and binding fibers LPET, thus effectively improving the mildew resistance and flame retardant property of the sound insulation pad; the hardness of the upper cotton felt and the lower cotton felt of the sound insulation pad prepared by the invention is adjustable, and the thickness distribution of the upper cotton felt and the lower cotton felt is adjustable, so that the acoustic performance of the whole structure is better, compared with the conventional sound insulation pad, lighter materials can be used to achieve the same sound insulation effect, and the purposes of light weight and environmental protection are achieved.
Drawings
FIG. 1 is a schematic view of the acoustic insulator pad for a vehicle according to the present invention; FIG. 2 is a graph of pressure versus time for a single molding operation of the present invention in an example;
in the figure 1, an upper layer cotton felt, 2, a middle layer barrier film, 3, a lower layer cotton felt, 4, a bonding layer, 5 and a sound absorption layer.
In fig. 2, in the pressure-time curve of the one-step molding, the pressure value is larger than that of the pressure value of 0-8 s and is the curve of the upper mold cavity, and the pressure value is smaller than that of the lower mold cavity.
Detailed Description
The principles and features of this invention are described below in conjunction with examples which are set forth to illustrate, but are not to be construed to limit the scope of the invention.
As shown in fig. 1, fig. 1 is a schematic structural diagram of the present invention, which includes an upper layer cotton felt 1, a middle layer barrier film 2 and a lower layer cotton felt 3, the upper layer cotton felt 1 and the lower layer cotton felt 3 are made of the same material, and are made by blending bonding fibers (10% -80% of LPET) and one or more of fibers (20% -90% of ultrafine fibers, hollow fibers, triangular fibers, cross-shaped fibers, trilobal fibers, multilobal fibers, flat fibers, H-shaped fibers, etc.) such as PET, PP, PA, PLA, etc., and the hardness of the upper layer cotton felt 1 is greater than or equal to that of the lower layer cotton felt 3, and the thickness of the upper layer cotton felt 1 is less than or equal to that of the lower layer cotton felt 3; a middle layer barrier film 2 is arranged between the upper layer cotton felt 1 and the lower layer cotton felt 3, and the middle layer barrier film 2 comprises a middle main body layer and/or two side bonding layers 4;
in the invention, the raw material ratio of the upper layer cotton felt 1 and the lower layer cotton felt 3 is preferably as follows: the ratio of the LPET fiber to PET, PP, PA, PLA and other fibers is 10-80%: 20% -90%, the hardness of the cotton felt can be adjusted through the proportion, so that the sound insulation and absorption performance can be adjusted and the best performance can be achieved;
the barrier film of the middle layer is generally made of one or more of EAA, EVA, PE, PP, PA, TPU, PES and the like or modifications thereof, and the bonding layers 4 on the two sides of the middle layer are generally made of one or more of EAA, EVA, PE, PP or modified low-melting-point PA, PES and the like;
in some embodiments, the upper part of the present invention, i.e. the upper layer cotton felt 1, may further be provided with a sound absorption layer 5, wherein the sound absorption layer 5 is made of sound absorption cotton or non-woven fabric (prepared by mixing one or more of LPET, PET, PP, PA, PLA, etc.). In the actual production process, the sound absorption layer 5 is placed on the upper cotton felt 1 and is heated by high-temperature steam together with other layers to be formed. Or other layers are formed and then the sound absorbing layer 5 is connected with the sound absorbing layer by bonding or welding.
The preparation process of the invention is as follows:
(1) feeding LPET fibers and PET fibers according to a proper mass ratio, processing by needling, carding and lapping or air-laying equipment to obtain upper and lower layers of cotton felts, and preparing barrier film materials made of EAA, EVA, PE, PP, PA, TPU, PES and the like or modified substances thereof;
(2) paving materials according to the sequence of the upper layer cotton felt, the middle layer barrier film and the lower layer cotton felt, and covering non-woven fabrics or sound-absorbing cotton on the upper layer cotton felt according to requirements to obtain a paved product;
(3) and (3) putting the material prepared in the step (2) into a preheated forming die, closing the die, introducing high-pressure steam, maintaining the pressure for a certain time to complete the assembly of the sound insulation pad, exhausting air until the air pressure in the die cavity is one atmospheric pressure or negative pressure, and then opening the die.
(4) And (4) transferring the product prepared in the step (3) to a shaping and punching die for cooling and shaping, and then carrying out water cutting or punching on hole sites and waste edges of the parts as required to obtain the acoustic sound insulation pad for the vehicle.
Specifically, the manufacturing process of the acoustic insulator mat product: and (3) putting the upper cotton felt, the membrane and the lower cotton felt which are sequentially paved into a preheated steam die (the temperature of the die is 120-250 ℃, according to the molding requirement of a product, the lower die of the steam die is set as a hard layer, and the upper die of the steam die is set as a soft layer). And (3) opening an air inlet of the upper die and allowing air to enter the upper die for 2-100 s, and closing an air inlet of the lower die and an air outlet of the upper die and an air outlet of the lower die for the same time. After air intake is completed, all valves are closed to perform pressure maintaining (0-100 s), and a corresponding time pressure curve is shown in fig. 2. And then the lower film and/or the upper film are/is pumped, and the pressure in the die cavity is rapidly reduced to atmospheric pressure or negative pressure by combining the assistance of a vacuum system, and then the die is opened. And obtaining a pre-formed front wall semi-finished product, transferring the front wall semi-finished product into a shaping and punching die to be cooled and shaped, and then carrying out water cutting or punching on hole sites and waste edges of parts according to requirements to obtain a front wall sound insulation pad product.
Due to the existence of the barrier layer in the material structure, the layering material in the die cavity is divided into an upper die cavity and a lower die cavity which are independent. In the first air inlet stage, the pressure difference between the upper mold cavity and the lower mold cavity is the largest, namely the pressure of the upper mold cavity is greater than that of the lower mold cavity, so that the material is heated and the material of the lower mold cavity is thinned. In the second pressure maintaining stage, the barrier layer is heated to melt micropores gradually, so that the pressure difference in the upper and lower die cavities is reduced and tends to be balanced. At this point the material in the upper and lower cavities has been heated to completion. In the third air extraction stage, the upper die cavity and the lower die cavity simultaneously or independently control one side to extract air, and further control or maintain the thickness distribution of the soft layer and the hard layer.
Example (c):
the LPET fiber and PET, PP, PA, PLA and other fibers are adopted in a mass ratio of 10-80%: 20% -90% of the prepared cotton felt is applied to the acoustic sound insulation pad for the vehicle, and the sound insulation pad, which is made of EVA + PU materials produced by a conventional method and traditional reconstituted cotton materials, is used as a comparative example to carry out related data test and comparison as follows:
the sound absorption coefficient test (test standard ISO 354) is carried out on 2 multi-layer flat sound insulation mats, and the results show that the sound insulation mat material, Micropro material (2500 g/m2), of the invention has better sound absorption performance than the traditional EVA (2000g/m2) + PU (65kg/m 3).
The sound insulation test (test standard ASTM E2249) was carried out on 2 multi-layer flat sound insulation mats, and the results showed that the Micropro material of the invention (2500 g/m2) reduced the weight by about 24% while having sound insulation properties comparable to those of the conventional EVA (2000g/m2) + PU (65kg/m3) materials.
The 2 multi-layer flat sound insulation mats were subjected to a flame retardant performance test (test standard GB 8410-. Under the same test conditions, the burn rate of a conventional reconstituted cotton material (1000 g/m2) was 51.7mm/min and that of a Micropro material according to the invention (1000 g/m2) was 0 mm/min. The result shows that the sound insulation cushion material of the invention has better flame retardant property compared with the traditional reconstituted cotton material.
The mildew test (test standard GMW 3259) was carried out on 2 multi-layer flat sound-insulating mats, and under the same test conditions, the conventional reconstituted cotton material (2500 g/m2) showed mildew and heavy musty, whereas the Micropro material of the invention (2500 g/m2) did not develop mildew and had no musty. The result shows that the sound insulation cushion material of the invention has better anti-mildew performance compared with the traditional reconstituted cotton material.
Odor performance testing (test standard VDA 270) was performed on 2 multi-layer flat acoustic insulator mats. Under the same test conditions, the traditional reconstituted cotton material has cotton musty and oil odor at normal temperature, the odor grades are 3 grades at 23 ℃, 3.5 grades at 40 ℃ and 4 grades at 80 ℃, the Micropro material of the invention has no obvious odor at normal temperature, and the odor grades are 2 grades at 23 ℃, 2.5 grades at 40 ℃ and 3 grades at 80 ℃. The results show that the sound-insulating pad material of the invention has better odor performance compared with the traditional reconstituted cotton material.
From the above experiments and data comparison, it can be known that the lightweight acoustic sound insulation pad for vehicles of the present invention has superior performance in all aspects compared to the conventional EVA + PU and conventional reconstituted cotton material sound insulation pads, and has great advantages in sound absorption performance, flame retardancy, mold resistance, odor performance and lightweight degree, so that the present invention has sufficient practical value and commercial value.
While the foregoing description shows and describes several preferred embodiments of the invention, it is to be understood, as noted above, that the invention is not limited to the forms disclosed herein, but is not intended to be exhaustive of other embodiments, and is capable of use in various other combinations, modifications, and environments and is capable of changes within the scope of the inventive concept as described herein, commensurate with the above teachings, or the skill or knowledge of the relevant art. And that modifications and variations may be effected by those skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims.

Claims (8)

1. The utility model provides an automobile-used lightweight acoustics gives sound insulation and fills up, its characterized in that, includes upper cotton felt, intermediate level barrier film and the cotton felt of lower floor that from top to bottom connects gradually, upper cotton felt and the cotton felt of lower floor be LPET fibre and PET, PP, PA, PLA fibre in one or more mix and join in marriage cotton preparation and form, just the hardness of the cotton felt of upper strata is more than or equal to the cotton felt of lower floor.
2. The automotive lightweight acoustic sound insulation pad according to claim 1, wherein the total gram weight of the upper layer cotton felt and the lower layer cotton felt is 1000-3000 g/m2Each denier being 0.1D-15D, the mass ratio is 10% -80%: 20-90% of LPET fiber and one or more of PET, PP, PA, PLA and the like.
3. The automotive lightweight acoustic insulator mat of claim 1, wherein said upper layer cotton felt is less than or equal in thickness to said lower layer cotton felt.
4. The automotive lightweight acoustic sound insulation pad according to claim 1, wherein a sound absorption layer is further disposed on the upper cotton felt, the sound absorption layer is made of non-woven fabric or sound absorption cotton, and the sound absorption layer is prepared by mixing one or more of fibers such as LPET, PET, PP, PA and PLA.
5. The automotive lightweight acoustic sound insulating mat according to claim 1, wherein the intermediate layer barrier film is a non-porous or open-porous film having a grammage of 10 to 200g/m2The material of the interlayer barrier film is one or more of EAA, EVA, PE, PP, PA, TPU, PES and the like or the modification thereof, and the material of the adhesive layer is one or more of EAA, EVA, PE, PP or the modification low melting point PA, PES and the like.
6. A method for preparing the light-weight acoustic sound insulating pad for the vehicle as claimed in any one of claims 1 to 5, comprising the steps of:
(1) according to the weight ratio of 10% -80%: feeding LPET fibers and one or more fibers of PET, PP, PA, PLA and the like in a mass ratio of 20-90%, and processing the mixture by needling, carding and lapping or air-laying equipment to obtain an upper layer cotton felt and a lower layer cotton felt, and preparing a film material of one or more materials of EAA, EVA, PE, PP, PA, TPU, PES and the like or a modifier thereof as a middle layer barrier film;
(2) sequentially paving the upper layer cotton felt, the middle layer barrier film and the lower layer cotton felt from top to bottom to obtain a paved product;
(3) putting the material prepared in the step (2) into a preheated forming die, closing the die, introducing high-pressure steam, maintaining the pressure for a certain time to complete the assembly of the sound insulation pad, exhausting air until the air pressure in the die cavity is one atmospheric pressure or negative pressure, and then opening the die;
(4) and (4) transferring the product prepared in the step (3) to a shaping and punching die for cooling and shaping, and then carrying out water cutting or punching on hole sites and waste edges of the parts as required to obtain the acoustic sound insulation pad for the vehicle.
7. The method for preparing the vehicular lightweight acoustic sound insulation pad according to claim 6, wherein the specific process of the step (3) is as follows: and (3) placing the paved material into a forming die with the preheated temperature of 120-250 ℃, opening an air inlet at the upper layer of cotton felt and allowing air to enter for 2-100 s after die assembly, maintaining pressure after air inlet is finished, opening an air exhaust port at the lower layer of cotton felt and/or the upper layer of cotton felt for air exhaust, combining a vacuum system to rapidly reduce the pressure in the die cavity to atmospheric pressure or negative pressure, and then opening the die.
8. The method for manufacturing a lightweight acoustic soundproof pad for vehicle according to claim 6, wherein in the step (3), the steam pressure of the high pressure steam is 2 to 20bar, the ventilation time is 2 to 100s, and the pressure holding time is 0 to 100 s.
CN202010127916.9A 2020-02-28 2020-02-28 Light acoustic sound insulation pad for vehicle and manufacturing method thereof Pending CN111016373A (en)

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