CN113002089A - 一种高延展大拉伸的汽车发动机罩隔热垫及其制备方法 - Google Patents
一种高延展大拉伸的汽车发动机罩隔热垫及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种高延展大拉伸的汽车发动机罩隔热垫及其制备方法,发动机配件技术领域,包括自上向下依次层叠的第一无纺布层、热固型棉层、玻璃棉层和第二无纺布层,热固型棉层和玻璃棉层构成隔热垫的中间层,第一无纺布层和第二无纺布层之间设置有若干片补强棉,用于填充拉伸第一无纺布层和第二无纺布层时的上述隔热垫中间层的延展处。本发明提供的隔热垫在制备过程中高延展大拉伸部位不会产生拉撕折断等现象,按照本发明提供的方法所制备的隔热垫具备表面平整、过渡面光滑无拉撕、成型稳定性好的效果,产品不良率大幅下降,降低了产品的制备总成本。
Description
技术领域
本发明涉及发动机配件技术领域,特别是涉及一种高延展大拉伸的汽车发动机罩隔热垫及其制备方法。
背景技术
随着中国物流市场的进一步优化调整,不超载、轻量化、合规化运营将成为趋势,同时近百万辆国三卡车在2020年将基本被淘汰完毕,因此,重型汽车市场前景一片向好,国内经济向高质量发展的转变,物流运输效率的提升和新技术的应用也将加速重型汽车产品技术升级和更新换代。重型汽车对驾驶室内外的舒适度、功能化、智能化要求不断提升,驾驶人员对于车内噪音污染也愈发重视,因此,隔热垫在重型汽车上的配置愈来愈广泛,在现有技术中,由于车身高,发动机罩隔热垫的造型延展性很大(一般大于200mm),成型后折皱多,易拉撕,易变形,影响使用功能及寿命,而且在制作生产过程中也易造成大量不良品的报废。
一般情况下,型面深度大于200mm的隔热垫,按常规方法生产,材料层层铺放经过热模压制后,在最大拉伸处,热固型棉层及玻璃棉层易拉撕断裂,结果仅剩下表层和底层的两层布连着,中间芯层折断无强力。
发明内容
本发明的主要目的是为了提供一种高延展大拉伸的汽车发动机罩隔热垫及其制备方法,可以实现高延展的隔热垫具备表面平整、过渡面光滑无拉撕、成型稳定性好的效果。
本发明的目的可以通过采用如下技术方案达到:
一种高延展大拉伸的汽车发动机罩隔热垫,包括自上向下依次层叠的第一无纺布层、热固型棉层、玻璃棉层和第二无纺布层,所述热固型棉层和玻璃棉层构成隔热垫的中间层,所述第一无纺布层和第二无纺布层之间设置有若干片补强棉,用于填充拉伸第一无纺布层和第二无纺布层时的上述隔热垫中间层的延展处。
优选的,所述第一无纺布层和第二无纺布层均为PE无纺布层。
优选的,所述补强棉设置于第一无纺布层和热固型棉层之间,用于填充拉伸第一无纺布层和第二无纺布层时的热固型棉层的延展处。
优选的,所述补强棉设置于玻璃棉层和第二无纺布层之间,用于填充拉伸第一无纺布层和第二无纺布层时的玻璃棉层的延展处。
优选的,所述补强棉的横截面拐角处角度为非直角。
优选的,所述补强棉的横截面呈梯形形状,且上述梯形的两个底角均为锐角,且均为α。
优选的,所述α角度范围为45~60度。
一种高延展大拉伸的汽车发动机罩隔热垫的制备方法,包括
步骤A、加热升温具有热成型模具的成型压机,并调试成型压机的温度和压力参数;
步骤B、将第一无纺布层、热固型棉层、玻璃棉层和第二无纺布层进行堆叠,并将若干补强棉摆放在第一无纺布层和第二无纺布层之间,用于填充拉伸第一无纺布层和第二无纺布层时热固型棉层和玻璃棉层的拉伸部位;
步骤C、将步骤B中已被堆叠的材料送至步骤A的已被加热的模具中并对其进行压制,以形成隔热垫成品。
优选的,步骤A具体包括如下
步骤a1、将热成型模具安装于成型压机上;
步骤a2、对热成型模具进行加热升温操作,设定上述模具的上、下模温度,并将温度范围控制在:180~240℃;
步骤a3、设定成型压机的压力为15~25Mpa或200~300吨,且成型时间为120~200S;
步骤B具体包括如下
步骤b1、将第一无纺布层、热固型棉层、玻璃棉层和第二无纺布层依次堆叠,并将若干片补强棉摆放在热固型棉层上的待拉伸部位表面;
步骤C具体包括如下
步骤c1、将步骤b1中摆放好的隔热垫原材料放置于热成型模具中;
步骤c2、操控成型压机,对上述隔热垫原材料进行挤压拉伸,以形成隔热垫成品。
优选的,步骤b1中采用的补强棉的横截面呈梯形形状,其横截面的底部两对角角度相同,且角度范围均为45~60度。
本发明的有益技术效果:
1、本发明提供的隔热垫在制备过程中高延展大拉伸部位不会产生拉撕折断等现象,按照本发明提供的方法所制备的隔热垫具备表面平整、过渡面光滑无拉撕、成型稳定性好的效果,产品不良率大幅下降,降低了产品的制备总成本。
2、本发明提供的补强棉放置于中间层的待拉伸部位,可以在拉伸隔热垫原材料时对热固型棉层和玻璃棉层进行填充,避免在拉伸后隔热垫上出现褶皱而造成不良品报废,大幅度的降低了不良品的产生,保证了隔热垫中间层在延展拉伸过程中强有力。
附图说明
图1为按照本发明的第一实施例的隔热垫半成品剖面结构示意图;
图2为按照本发明的实施例的补强棉剖面结构示意图;
图3为按照本发明的第二实施例的隔热垫半成品剖面结构示意图;
图4为按照本发明的第二实施例的补强棉位置分布示意图;
图5为按照本发明的第一实施例的隔热垫补强前示意图;
图6为按照本发明的第一实施例的隔热垫补强后示意图;
图7为按照本发明的第二实施例的隔热垫成品中补强棉所处位置示意图;
图8为按照本发明的第二实施例的隔热垫补强前示意图;
图9为按照本发明的第二实施例的隔热垫补强后示意图;
图10为按照本发明的第一实施例的隔热垫成品中补强棉所处示意图。
图中:1-第一无纺布层,2-热固型棉层,3-玻璃棉层,4-第二无纺布层,5-补强棉。
具体实施方式
为使本领域技术人员更加清楚和明确本发明的技术方案,下面结合实施例及附图对本发明作进一步详细的描述,但本发明的实施方式不限于此。
如图1-图9所示,本实施例提供的一种高延展大拉伸的汽车发动机罩隔热垫,包括自上向下依次层叠的第一无纺布层1、热固型棉层 2、玻璃棉层3和第二无纺布层4,热固型棉层2和玻璃棉层3构成隔热垫的中间层,第一无纺布层1和第二无纺布层4之间设置有若干片补强棉5,用于填充拉伸第一无纺布层1和第二无纺布层4时的上述隔热垫中间层的延展处,也即补强棉5摆放在热固型棉层2的待拉伸的型面上时,当上述材料被模具挤压拉伸后,即使热固型棉层2和玻璃棉层3被拉撕,也有补强棉5补充,使隔热垫在成型时不会产生开裂折断等不良现象,设热固型棉层2的最大形变位置为中心线,那么上述中心线可与补强棉5的中心线重合,重合后补强棉5的宽沿自身的中心线两边各延伸150±10mm;
其中隔热垫的最大延展深度在200mm以上,此处对于第一无纺布层1、热固型棉层2、玻璃棉层3和第二无纺布层4的面密度、尺寸及厚度不作限定,可以根据应用的需求确定各层的面密度、尺寸及厚度。
在本实施例中,如图1和图3所示,第一无纺布层1和第二无纺布层4均为PE无纺布层。
在本实施例中,如图1和图3所示,补强棉5设置于第一无纺布层1和热固型棉层2之间,用于填充拉伸第一无纺布层1和第二无纺布层4时的热固型棉层2的延展处,避免隔热垫在成型后隔热垫的中间层出现开裂、折断等。
在本实施例中,补强棉5也可设置于玻璃棉层3和第二无纺布层 4之间,用于填充拉伸第一无纺布层1和第二无纺布层4时的玻璃棉层3的延展处,也可避免隔热垫在成型后隔热垫的中间层出现开裂、折断等。
在本实施例中,如图1~图3所示,补强棉5可以为热固型棉毡,补强棉5的横截面拐角处角度为非直角,因为补强棉5具有一定的厚度,补强棉5若为长方体结构(拐角处角度均为直角),会在无纺布表面形成一条肉眼可见的折痕,外观不能接受。
在本实施例中,如图1~图3所示,补强棉5的横截面呈梯形形状,且上述梯形的两个底角均为锐角,且均为α,补强棉5为棉层,难以剖切,可采用一种纤维毡的产品边料裁切装置ZL202021530690.0 来将补强棉5裁成具有α角的补强棉,此处,为使压制后隔热垫既有延展部位的补充强度又使无纺布表层无肉眼可见的折痕,α角取45~ 60度最佳。
一种高延展大拉伸的汽车发动机罩隔热垫的制备方法,包括
步骤A、加热升温具有热成型模具的成型压机,并调试成型压机的温度和压力参数;
步骤B、将第一无纺布层1、热固型棉层2、玻璃棉层3和第二无纺布层4进行堆叠,并将若干补强棉5摆放在第一无纺布层1和第二无纺布层4之间,用于填充拉伸第一无纺布层1和第二无纺布层4 时热固型棉层2和玻璃棉层3的拉伸部位;
步骤C、将步骤B中已被堆叠的材料送至步骤A的已被加热的模具中并对其进行压制,以形成隔热垫成品。
在本实施例中,如图1-10所示,步骤A具体包括如下
步骤a1、将热成型模具安装于成型压机上;
步骤a2、对热成型模具进行加热升温操作,设定上述模具的上、下模温度,并将温度范围控制在:180~240℃,此温度范围是让热固型棉层2和玻璃棉层3里的树脂固化所需要的设定温度;
步骤a3、设定成型压机的压力为15~25Mpa或200~300吨,此压力下模具切边可以切整齐,否则会出现切不断,且成型时间为 120~200S,由于隔热垫产品型面深,大于200mm,因此压制成型时间不能太短,需要在此范围内才能热定型稳定,具体根据产品的深度不同调整压制时间;
步骤B具体包括如下
步骤b1、将第一无纺布层1、热固型棉层2、玻璃棉层3和第二无纺布层4自上向下依次堆叠,并将若干片补强棉5摆放在热固型棉层2上的待拉伸部位表面;
步骤C具体包括如下
步骤c1、将步骤b1中摆放好的隔热垫原材料放置于热成型模具中;
步骤c2、操控成型压机,对上述隔热垫原材料进行挤压拉伸,以形成隔热垫成品。
实施例1:
在本实施例中,如图1、图2、图5、图6、图10所示,步骤A 具体包括如下
步骤a1、将热成型模具安装于成型压机上;
步骤a2、对热成型模具进行加热升温操作,设定上述模具的上、下模温度,并将温度范围控制为在185~225℃内即可;
步骤a3、设定成型压机的压力为22Mpa,且设定成型时间为 130~150S内即可;
步骤B具体包括如下
步骤b1、将第一无纺布层1、热固型棉层2、玻璃棉层3和第二无纺布层4依次堆叠,它们的尺寸均为1730*780mm,补强棉5尺寸为300*740mm,补强棉密度为600g/m2,并将2片补强棉5摆放在热固型棉层2上的待拉伸部位表面,左、右放置,补强棉5可以为热固型棉毡,补强棉5的正视图为梯形形状,且补强棉5的底部两对角均为α=60度,将补强棉5对应易拉撕位置摆放在热固型棉层2上即可,见图1、图2和图10;
步骤C具体包括如下
步骤c1、将步骤b1中摆放好的隔热垫原材料放置于热成型模具中;
步骤c2、操控成型压机,对上述隔热垫原材料进行挤压拉伸,以形成隔热垫成品,可见图6。
实施例2:
在本实施例中,如图3和图4以及图7~图9所示,步骤A具体包括如下
步骤a1、将热成型模具安装于成型压机上;
步骤a2、对热成型模具进行加热升温操作,设定上述模具的上、下模温度,并将温度范围控制为在185~225℃内即可;
步骤a3、设定成型压机的压力为25Mpa,且设定成型时间为160S;
步骤B具体包括如下
步骤b1、将第一无纺布层1、热固型棉层2、玻璃棉层3和第二无纺布层4依次堆叠,它们的尺寸均为2350*1600mm,补强棉5尺寸为300*450mm,补强棉密度为600g/m2,并将4片补强棉5摆放在热固型棉层2上的待拉伸折弯部位表面,左、右两两放置,补强棉5 可以为热固型棉毡,补强棉5的正视图为梯形形状,且补强棉5的底部两对角均为α=60度,将补强棉5对应易拉撕位置摆放在热固型棉层2上即可,见图2~图4;
步骤C具体包括如下
步骤c1、将步骤b1中摆放好的隔热垫原材料放置于热成型模具中;
步骤c2、操控成型压机,对上述隔热垫原材料进行挤压拉伸,以形成隔热垫成品,见图9。
在本实施例中,如图2所示,步骤b1中采用的补强棉5的横截面呈梯形形状,其横截面的底部两对角角度相同,且角度范围均为45~60度,为使压制后隔热垫既有补充强度又使无纺布表层无肉眼可见的折痕。
综上所述,在本实施例中,本实施例提供的隔热垫在制备过程中高延展大拉伸部位不会产生拉撕折断等现象,按照本发明提供的方法所制备的隔热垫具备表面平整、过渡面光滑无拉撕、成型稳定性好的效果,产品不良率大幅下降,降低了产品的制备总成本。
以上所述,仅为本发明进一步的实施例,但本发明的保护范围并不局限于此,任何熟悉本技术领域的技术人员在本发明所公开的范围内,根据本发明的技术方案及其构思加以等同替换或改变,都属于本发明的保护范围。
Claims (10)
1.一种高延展大拉伸的汽车发动机罩隔热垫,其特征在于:包括自上向下依次层叠的第一无纺布层(1)、热固型棉层(2)、玻璃棉层(3)和第二无纺布层(4),所述热固型棉层(2)和玻璃棉层(3)构成隔热垫的中间层,所述第一无纺布层(1)和第二无纺布层(4)之间设置有若干片补强棉(5),用于填充拉伸第一无纺布层(1)和第二无纺布层(4)时的上述隔热垫中间层的延展处。
2.根据权利要求1所述的高延展大拉伸的汽车发动机罩隔热垫,其特征在于:所述第一无纺布层(1)和第二无纺布层(4)均为PE无纺布层。
3.根据权利要求1所述的高延展大拉伸的汽车发动机罩隔热垫,其特征在于:所述补强棉(5)设置于第一无纺布层(1)和热固型棉层(2)之间,用于填充拉伸第一无纺布层(1)和第二无纺布层(4)时的热固型棉层(2)的延展处。
4.根据权利要求1所述的高延展大拉伸的汽车发动机罩隔热垫,其特征在于:所述补强棉(5)设置于玻璃棉层(3)和第二无纺布层(4)之间,用于填充拉伸第一无纺布层(1)和第二无纺布层(4)时的玻璃棉层(3)的延展处。
5.根据权利要求1所述的高延展大拉伸的汽车发动机罩隔热垫,其特征在于:所述补强棉(5)的横截面拐角处角度为非直角。
6.根据权利要求5所述的高延展大拉伸的汽车发动机罩隔热垫,其特征在于:所述补强棉(5)的横截面呈梯形形状,且上述梯形的两个底角均为锐角,且均为α。
7.根据权利要求6所述的高延展大拉伸的汽车发动机罩隔热垫,其特征在于:所述α角度范围为45~60度。
8.一种高延展大拉伸的汽车发动机罩隔热垫的制备方法,其特征在于:包括
步骤A、加热升温具有热成型模具的成型压机,并调试成型压机的温度和压力参数;
步骤B、将第一无纺布层(1)、热固型棉层(2)、玻璃棉层(3)和第二无纺布层(4)进行堆叠,并将若干补强棉(5)摆放在第一无纺布层(1)和第二无纺布层(4)之间,用于填充拉伸第一无纺布层(1)和第二无纺布层(4)时热固型棉层(2)和玻璃棉层(3)的拉伸部位;
步骤C、将步骤B中已被堆叠的材料送至步骤A的已被加热的模具中并对其进行压制,以形成隔热垫成品。
9.根据权利要求8所述的高延展大拉伸的汽车发动机罩隔热垫的制备方法,其特征在于:
步骤A具体包括如下
步骤a1、将热成型模具安装于成型压机上;
步骤a2、对热成型模具进行加热升温操作,设定上述模具的上、下模温度,并将温度范围控制在:180~240℃;
步骤a3、设定成型压机的压力为15~25Mpa或200~300吨,且成型时间为120~200S;
步骤B具体包括如下
步骤b1、将第一无纺布层(1)、热固型棉层(2)、玻璃棉层(3)和第二无纺布层(4)依次堆叠,并将若干片补强棉(5)摆放在热固型棉层(2)上的待拉伸部位表面;
步骤C具体包括如下
步骤c1、将步骤b1中摆放好的隔热垫原材料放置于热成型模具中;
步骤c2、操控成型压机,对上述隔热垫原材料进行挤压拉伸,以形成隔热垫成品。
10.根据权利要求9所述的高延展大拉伸的汽车发动机罩隔热垫的制备方法,其特征在于:步骤b1中采用的补强棉(5)的横截面呈梯形形状,其横截面的底部两对角角度相同,且角度范围均为45~60度。
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