CN111231386B - 用于制造防水毛毡管道的方法及防水毛毡管道 - Google Patents
用于制造防水毛毡管道的方法及防水毛毡管道 Download PDFInfo
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- CN111231386B CN111231386B CN201911194821.2A CN201911194821A CN111231386B CN 111231386 B CN111231386 B CN 111231386B CN 201911194821 A CN201911194821 A CN 201911194821A CN 111231386 B CN111231386 B CN 111231386B
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- waterproof
- nonwoven fabric
- waterproof felt
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Abstract
一种用于制造防水毛毡管道的方法和防水毛毡管道。所述方法可包括:(a)将防水膜层叠在第一无纺布的一侧上,并且将第二无纺布层叠在已层叠于第一无纺布上的防水膜上,以形成层叠体;(b)通过热粘合所述层叠体形成防水毛毡基础材料;(c)将防水毛毡基础材料切割成所需形状;(d)在使切割成所需形状的防水毛毡基础材料围绕具有蜗杆形状的成型模具的外表面环绕的同时,成型管道;(e)对成型的管道进行热处理;(f)冷却经热处理的管道;以及(g)将经冷却的管道从成型模具排出。
Description
技术领域
本发明涉及一种防水毛毡管道,并且更具体地,涉及一种用于制造在管道本身中具有防水性的防水毛毡管道的方法,以及通过该方法制造的防水毛毡管道。
背景技术
通常,当需要燃料和空气以操作作为一种动力源的内燃机以驱动车辆时,正常的外部空气通过进气系统从其外部供应到发动机。
车辆的进气系统可包括:设置成外部空气的流动路径的管道,具有过滤外来物质(诸如包含在流入空气中的灰尘或沙土)的功能的空气过滤器,以及多个单元(诸如用于减少振动和噪声的吸音板等),其中聚氨酯覆盖件分离地施加到进气系统以防止外来物质的流入并提供防水功能。
然而,由于进气系统设置有具有大体积的覆盖件,因此存在的一些问题在于:难以使进气系统自由地布置在发动机室的内部;由于用于组装覆盖件的分离过程而降低生产效率;以及由于随着时间的流逝从外部空气进入的水分等导致管道水解和损坏(即使覆盖件具有防水功能)而发生的进气系统的管道的劣化。
包含在本发明的该背景部分中的信息仅用于提高对本发明的一般背景的理解,并且可不作为对该信息形成本领域技术人员已知的现有技术的承认或任何形式的建议。
发明内容
本发明的各种方面旨在提供一种用于制造防水毛毡管道的方法,具有防水性的防水毛毡通过形成管道的主体的管道材料而不是通过施加用于确保防水性的分离的覆盖件而固定到该防水毛毡管道,并且也提供一种通过该方法制造的防水毛毡管道。
本发明的其它目的和优点可通过以下描述而被理解,并且通过参考本发明的示例性实施例而变得显而易见。同样,对于本发明所属技术领域的技术人员而言显而易见的是,本发明的目的和优点可通过所要求保护的手段及其结合而实现。
为了实现如上所述的目的,根据本发明的一个方面,提供了一种用于制造防水毛毡管道的方法,该方法包括:(a)将防水膜层叠在第一无纺布(nonwoven fabric,非织造织物)的一侧上,并且将第二无纺布层叠在已层叠于第一无纺布上的防水膜上,以形成层叠体;(b)通过热粘合该层叠体形成防水毛毡基础材料;(c)将防水毛毡基础材料切割成所需形状;(d)在使切割成所需形状的防水毛毡基础材料围绕具有蜗杆(worm gear)形状的成型模具(molding jig,成型夹具)的外表面环绕的同时,成型管道;(e)对成型的管道进行热处理;(f)冷却经热处理的管道;以及(g)将经冷却的管道从成型模具排出。
第一无纺布可以是包括占20%到40%重量的聚对苯二甲酸乙二醇酯和占60%到80%重量的低熔点纤维的无纺布。
防水膜可以是由聚乙烯膜和聚酰胺6膜(polyamide 6film)制成的层压件(laminate)。
第二无纺布可以是包括占60%到80%重量的聚对苯二甲酸乙二醇酯和占20%到40%重量的低熔点纤维的无纺布。
在步骤(a)中,层叠体形成为使得:参考在层叠体的纵向方向上的从层叠体的一个端部到另一个端部的长度,第一无纺布的长度比防水膜的长度短,并且第二无纺布的长度比防水膜的长度长。
在步骤(b)中,通过使层叠体在130到160℃的温度下和90到110kgf的压力下进行热粘合,来形成防水毛毡基础材料。
在步骤(d)中,随着成型模具的旋转,通过刀式弯曲工具(knife-type bendingtool)使围绕具有蜗杆形状的成型模具的外表面环绕的防水毛毡基础材料弯曲,而使管道成型。
在步骤(e)中,使成型的管道在电烤箱中在240至250℃的温度下热处理10分钟至60分钟。
在步骤(f)中,通过冷却空气在5至15℃的温度下使经热处理的管道冷却5至30分钟。
根据本发明的另外的方面,提供了一种通过如上所述的制造方法制成的防水毛毡管道,其中防水毛毡管道由具有多个粘合结构的防水毛毡基础材料制成,防水毛毡基础材料通过热粘合多个层叠体形成,每个层叠体包括第一无纺布、层叠在第一无纺布上的防水膜、和层叠在防水膜上的第二无纺布,并且其中,每个层叠体构造成使得:参考层叠体的从一个端部到另一个端部的长度,第一无纺布的长度比防水膜的长度短,并且第二无纺布的长度比防水膜的长度长。
防水毛毡基础材料是通过如下方式而形成:将这些层叠体布置成使得邻近的层叠体的第二无纺布容纳在一个层叠体的第一无纺布的一个端部处并且位于在第一无纺布上层叠的防水膜的下表面上,并且使层叠体附着到一起。
第一无纺布、防水膜、和第二无纺布与如上所述的第一无纺布、防水膜、和第二无纺布相同,并且因此,下文将不进行对它们的重复描述。
本发明的防水毛毡管道具有管道本身的防水功能,而没有分离的覆盖物,因此,其不需要任何分离的覆盖物,使得该防水毛毡管道不仅可以降低部件的数量并保护发动机室的内部空间,而且可以改善发动机室的美学外观。
此外,与现有管道相比,本发明的防水毛毡管道在噪声、振动和摩擦方面在防水性能和评估结果中是优越的。
应理解的是,本发明的前述一般描述和以下详细描述是示例性和解释性的,并且旨在提供如所要求保护的本发明的进一步解释。
本发明的方法和装置具有其它特征和优点,这些特征和优点从结合于此的附图和以下详细说明将是显而易见的或更加详细地阐述,附图和以下具体实施方式部分一起用于解释本发明的某些原理。
附图说明
图1是根据本发明的示例性实施例的用于制造防水毛毡管道的方法的流程图;
图2是示出根据本发明的示例性实施例的层叠体的横截面的图示;
图3是示出根据本发明的示例性实施例的防水毛毡基础材料的横截面的图示;
图4是示例性地示出了根据本发明的示例性实施例的使用具有蜗杆形状的成型模具和刀式弯曲工具来成型防水毛毡管道的过程的示意图;
图5是示出了根据本发明的示例性实施例制造的防水毛毡管道的外观的立体图;
图6是根据本发明的示例性实施例制造的防水毛毡管道的噪声评价结果;
图7是根据本发明的示例性实施例制造的防水毛毡管道在冷条件下的评价结果;以及
图8是根据本发明的示例性实施例制造的防水毛毡管道在热条件下的评价结果。
可理解的是,附图不是必须成比例,而是呈现为说明本发明的基本原理的各种特征的略微简化的表示。如本文所包括的本发明的特定设计特征(包括例如特定尺寸、取向、位置和形状)将部分地由具体的预期应用和使用环境确定。
在附图中,贯穿附图的若干图,相同参考数字指代本发明的相同或等同部分。
具体实施方式
现在将详细参考本发明的各种实施例,其示例在附图中示出并在下文描述。虽然本发明将结合本发明的示例性实施例描述,但是将理解的是,本描述并非旨在将本发明限制于那些示例性实施例。在另一方面,本发明/这些发明旨在不仅涵盖本发明的示例性实施例,而且涵盖可包括在由所附权利要求限定的本发明的精神和范围内的各种替换、修改、等同物和其它实施例。
下文中将参考本发明的示例性实施例和比较的示例更详细地描述本发明的构造和操作。然而,这仅是本发明的一些示例的代表,并且因此本发明不限制于此。
图1示出了根据本发明的示例性实施例的用于制造防水毛毡管道的方法的流程图。
如图1所示,根据本发明的示例性实施例的用于制造防水毛毡管道的方法包括:(a)通过以第一无纺布、防水膜和第二无纺布的顺序层叠以形成层叠体(S110);(b)通过热粘合这些层叠体形成防水毛毡基础材料(S120);(c)将防水毛毡基础材料切割成所需形状(S130);(d)使用切割成所需形状的防水毛毡基础材料来成型管道(S140);(e)对管道进行热处理(S150);(f)冷却管道(S160);以及(g)排出管道(S170)。
称为S110的步骤(a)是形成用于制作防水毛毡基础材料的层叠体的步骤,其中防水膜被层叠在第一无纺布的一侧上,并且第二无纺布被层叠在层叠于第一无纺布上的防水膜上,以形成层叠体。
第一无纺布可以是由占20%到40%重量的聚对苯二甲酸乙二醇酯和占60%到80%重量的低熔点纤维制成的无纺布,并且优选地,可以是包括占30%重量的聚对苯二甲酸乙二醇酯和占70%重量的低熔点纤维的无纺布。
防水膜是由聚乙烯膜和聚酰胺6膜制成的层压件,每层膜具有预定厚度,并提供防水性。
第二无纺布可以是由占60%到80%重量的聚对苯二甲酸乙二醇酯和占20%到40%重量的低熔点纤维制成的无纺布,并且优选地,是包括占70%重量的聚对苯二甲酸乙二醇酯和占30%重量的低熔点纤维的无纺布。
在步骤(a)中,层叠体100形成为使得:参考在层叠体的纵向方向上的从层叠体的一个端部到另一个端部的长度,第一无纺布10的长度比防水膜的长度短,并且第二无纺布20的长度比防水膜30的长度长。层叠体100的横截面构造为如图2所示。
称为S120的通过热粘合这些层叠体形成防水毛毡基础材料的步骤(b)是通过使在步骤(a)中产生的多个层叠体堆叠并将它们热粘合到一起而形成防水毛毡基础材料的步骤。
图3是示出根据本发明的示例性实施例的防水毛毡基础材料的横截面的图示。
如图3所示,防水毛毡基础材料是通过以下方式形成:将这些层叠体100布置成使得邻近的层叠体的第二无纺布21、22、23、24、25、26、27、28容纳在一个层叠体100的第一无纺布11、12、13、14、15、16、17和18的一个端部处,并且位于在第一无纺布11、12、13、14、15、16、17和18上层叠的防水膜31、32、33、34、35、36、37和38的下表面上,并且使这些层叠体100连续地粘合到一起。在瞬时,通过使这些层叠体在130到160℃的温度下和90到110kgf的压力下热粘合来形成防水毛毡基础材料。在使顶部部分保持在160℃且底部部分保持在130℃的同时,在100kgf的压力下使热粘合执行大约30秒。
如上所述的所形成的防水毛毡基础材料具有改善防水性能的结构,因为具有防水性的防水膜以缠绕第一无纺布和第二无纺布的方式联接。
在被称为S130的步骤(c)中,将通过热粘合形成防水毛毡基础材料切割成所需形状。在这种情况下,防水毛毡基础材料可切割成具有例如大约32mm的宽度。然而,防水毛毡基础材料的宽度不限于上述宽度,而是可在之后待执行的形成管道的过程中根据管道的弯曲的距离和节距进行调整。
接下来,在被称为S140的使用切割成所需形状的防水毛毡基础材料来成型管道的步骤(d)中,随着具有蜗杆形状的成型模具的旋转,防水毛毡基础材料围绕成型模具410的外部缠绕,并且之后由于缠绕的防水毛毡基础材料通过刀式弯曲工具420弯曲,形成了具有波纹管形状的管道200,如图4所示。
在被称为S150的对管道进行热处理的步骤(e)中,为了使经弯曲并成型成波纹管形状的防水毛毡基础材料的无纺布之间执行热熔化粘合,对成型的管道进行热处理,使得成型的管道在其围绕成型模具缠绕时放置在电烤箱中并在240至250℃下热处理10分钟至60分钟。热处理在245℃的温度下进行30分钟。
在被称为S160的冷却该管道的步骤中,经热处理的管道可放置在冷却器中,并通过冷却空气在5至15℃下冷却5至30分钟。在冷却步骤S160中经冷却的管道从成型模具排出,这被称为S170。
通过上述制造方法形成的防水毛毡管道如图5所示。该防水毛毡管道由具有多个粘合结构的防水毛毡基础材料制成,其中防水毛毡基础材料通过热粘合多个层叠体形成,每个层叠体包括第一无纺布、层叠在第一无纺布上的防水膜、和层叠在防水膜上的第二无纺布,并且其中,每个层叠体构造成使得:参考层叠体的从一个端部到另一个端部的长度,第一无纺布的长度比防水膜的长度短,并且第二无纺布的长度比防水膜的长度长。
为了将其中应用有如上所述的根据本发明的示例性实施例制造的防水毛毡管道的发动机和车身中产生的噪声和振动与现有管道中的噪声和振动进行比较,对噪声、振动和不平顺性6(NVH)进行评估,并且结果在图6至图8中示出。
图6示出了在加速期间在驾驶员的座位处的噪声的对比结果。注意到的是,相比于现有的批量生产的管道,在所有的座位中防水毛毡管道均示出了高达10dB(A)的差异,并且在防水毛毡管道中出现的噪声小。
图7和图8分别是在冷条件和热条件下的现有管道和本发明的防水毛毡管道之间的对比的结果。
如图7所示,在冷条件(即,在车辆的发动机被加热到某个适当的温度之前)下,现有的批量生产的管道所产生的最大噪声超过70dB(A),然而本发明的防水毛毡管道(WPF)所产生的最大噪声低于65dB(A),这证实了在防水毛毡管道中产生的噪声总体上小。
如图8所示,在热条件(即,在车辆的发动机被加热到某个适当的温度之后)下,现有的批量生产的管道所产生的最大噪声超过65dB(A),然而本发明的防水毛毡管道所产生的最大噪声低于60dB(A)。因此,这证实了冷条件和热条件下在防水毛毡管道中产生的噪声相似或小于现有的批量生产的管道中产生的噪声。
为了方便解释和所附权利要求中的准确定义,术语“上部”、“下部”“内”、“外”、“上”、“下”、“向上”、“向下”、“前”、“后”、“后部”、“内侧”、“外侧”、“向内”、“向外”、“内部”、“外部”、“内”、“外”、“向前”和“向后”用于参考附图中所示的这些特征的位置来描述示例性实施例的特征。
已经出于说明和描述的目的呈现了本发明的特定示例性实施例的前述描述。它们并非旨在是穷举的或将本发明限制于所公开的精确形式,并且显然根据上述教导可进行许多修改和变化。选择和描述该示例性实施例以解释本发明的某些原理及其实际应用,以使本领域其他技术人员能够制造和利用本发明的各种示例性实施例、以及其各种替换和修改。本发明的范围旨在由所附权利要求及其等同物限定。
Claims (17)
1.一种用于制造防水毛毡管道的方法,所述方法包括:
步骤a,将防水膜层叠在第一无纺布的一侧上,并且将第二无纺布层叠在已层叠于所述第一无纺布上的所述防水膜的一侧上,以形成多个层叠体;
步骤b,通过热粘合多个所述层叠体形成防水毛毡基础材料;
步骤c,将所述防水毛毡基础材料切割成目标形状;
步骤d,在使切割成所述目标形状的所述防水毛毡基础材料围绕具有蜗杆形状的成型模具的外表面环绕的同时,成型管道;
步骤e,对成型的管道进行热处理;
步骤f,将经热处理的管道进行冷却;以及
步骤g,将经冷却的管道从所述成型模具排出;
其中,在步骤a中,所述层叠体形成为使得:相对于在所述层叠体的纵向方向上的从所述层叠体的第一端部到第二端部的长度而言,所述第一无纺布的长度比所述防水膜的长度短,并且所述第二无纺布的长度比所述防水膜的长度长;
并且其中,在步骤b中,所述防水毛毡基础材料是通过如下方式而形成:将多个所述层叠体布置成使得邻近的层叠体的第二无纺布容纳在一个层叠体的第一无纺布的端部处并且位于在所述第一无纺布上层叠的所述防水膜的下表面上,并且使多个所述层叠体粘合到一起。
2.根据权利要求1所述的用于制造防水毛毡管道的方法,其中,所述第一无纺布包括占20%到40%重量的聚对苯二甲酸乙二醇酯和占60%到80%重量的低熔点纤维。
3.根据权利要求2所述的用于制造防水毛毡管道的方法,其中,所述第一无纺布包括占30%重量的聚对苯二甲酸乙二醇酯和占70%重量的低熔点纤维。
4.根据权利要求1所述的用于制造防水毛毡管道的方法,其中,所述防水膜是由聚乙烯膜和聚酰胺6膜制成的层压件。
5.根据权利要求1所述的用于制造防水毛毡管道的方法,其中,所述第二无纺布包括占60%到80%重量的聚对苯二甲酸乙二醇酯和占20%到40%重量的低熔点纤维。
6.根据权利要求5所述的用于制造防水毛毡管道的方法,其中,所述第二无纺布包括占70%重量的聚对苯二甲酸乙二醇酯和占30%重量的低熔点纤维。
7.根据权利要求1所述的用于制造防水毛毡管道的方法,其中,在所述步骤b中,在130℃到160℃的温度下和90kgf到110kgf的压力下热粘合所述防水毛毡基础材料。
8.根据权利要求1所述的用于制造防水毛毡管道的方法,其中,在使所述防水毛毡基础材料的顶部部分保持在160℃且所述防水毛毡基础材料的底部部分保持在130℃的同时,在100kgf的压力下使所述热粘合执行30秒。
9.根据权利要求1所述的用于制造防水毛毡管道的方法,其中,在所述步骤d中,随着所述成型模具的旋转,通过刀式弯曲工具使围绕具有所述蜗杆形状的所述成型模具的外表面的所述防水毛毡基础材料弯曲,而使所述管道成型。
10.根据权利要求1所述的用于制造防水毛毡管道的方法,其中,在所述步骤e中,使成型的所述管道在电烤箱中在240℃至250℃的温度下热处理10分钟至60分钟。
11.根据权利要求1所述的用于制造防水毛毡管道的方法,其中,在所述步骤f中,通过空气在5至15℃的温度下使经热处理的所述管道冷却5至30分钟。
12.一种防水毛毡管道,由具有多个粘合结构的防水毛毡基础材料制成,其中,所述防水毛毡基础材料通过热粘合多个层叠体而形成,每个所述层叠体包括第一无纺布、层叠在所述第一无纺布的一侧上的防水膜以及层叠在所述防水膜的一侧上的第二无纺布,并且其中,每个层叠体构造成使得:相对于每个层叠体从第一端部到第二端部的长度而言,所述第一无纺布的长度比所述防水膜的长度短,并且所述第二无纺布的长度比所述防水膜的长度长;
其中,所述防水毛毡基础材料是通过如下方式而形成:将多个所述层叠体布置成使得邻近的层叠体的第二无纺布容纳在一个层叠体的第一无纺布的端部处并且位于在所述第一无纺布上层叠的所述防水膜的下表面上,并且使多个所述层叠体粘合到一起;
并且其中,所述防水毛毡基础材料被切割成目标形状,并且在使切割成所述目标形状的所述防水毛毡基础材料围绕具有蜗杆形状的成型模具的外表面环绕的同时,成型管道。
13.根据权利要求12所述的防水毛毡管道,其中,所述第一无纺布包括占20%到40%重量的聚对苯二甲酸乙二醇酯和占60%到80%重量的低熔点纤维。
14.根据权利要求13所述的防水毛毡管道,其中,所述第一无纺布包括占30%重量的聚对苯二甲酸乙二醇酯和占70%重量的低熔点纤维。
15.根据权利要求12所述的防水毛毡管道,其中,所述防水膜是由聚乙烯膜和聚酰胺6膜制成的层压件。
16.根据权利要求12所述的防水毛毡管道,其中,所述第二无纺布包括占60%到80%重量的聚对苯二甲酸乙二醇酯和占20%到40%重量的低熔点纤维。
17.根据权利要求16所述的防水毛毡管道,其中,所述第二无纺布包括占70%重量的聚对苯二甲酸乙二醇酯和占30%重量的低熔点纤维。
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