CN113306071B - 利用发泡注射成型的汽车悬架装置用弹簧垫制造方法 - Google Patents

利用发泡注射成型的汽车悬架装置用弹簧垫制造方法 Download PDF

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CN113306071B
CN113306071B CN202010291629.1A CN202010291629A CN113306071B CN 113306071 B CN113306071 B CN 113306071B CN 202010291629 A CN202010291629 A CN 202010291629A CN 113306071 B CN113306071 B CN 113306071B
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insulator
injection molding
spring
spring pad
frame
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CN113306071A (zh
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金成述
金东义
金享峻
金享振
蒋炳求
申浚
李元旭
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Dmc Corp
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Abstract

本发明作为一种夹杂在用于汽车悬架装置的弹簧和支撑所述弹簧的上部及下部垫之间的汽车悬架装置用弹簧垫的制造方法，其特征在于，所述弹簧垫包括绝缘体，该绝缘体接触所述弹簧而吸收冲击并形成弹簧垫的主体，为了所述弹簧垫的轻量化，通过发泡注射成型来制造所述绝缘体。

Description

利用发泡注射成型的汽车悬架装置用弹簧垫制造方法
技术领域
本发明涉及一种汽车悬架装置用弹簧垫制造方法，更具体地说，涉及为了减轻重量而利用发泡注射成型的汽车悬架装置用弹簧垫制造方法。
背景技术
通常，汽车悬架装置连接车轴和车身，以减少车轴在行驶途中从路面受到的振动或冲击并将其传递到车身，不仅提高乘车舒适感，还防止车身和货物受损。
根据所述汽车悬架装置，下(lower)垫和上(upper)垫彼此隔开地设置在减震器(Shock absorber)汽缸，螺旋弹簧设置在所述下垫和上垫之间，弹簧垫分别设置在螺旋弹簧与下垫之间、螺旋弹簧和上垫之间。
其中，所述垫防止螺旋弹簧与下垫、螺旋弹簧与上垫的直接接触，从而吸收冲击并防止螺旋弹簧与垫的损伤。
这种弹簧垫通常使用单一材料，但是当被传递的荷重较大时，为了抵抗通过振动或冲击传递的力量，使用将钢材(steel)插入弹簧垫的内部制作而成的复合材料。
参照图1，制作如上所述的垫时，一般而言，首先通过第一次注射成型而形成硬质材料的框架。
然后，在所述框架上涂覆粘合剂，然后将框架插入(insert)注塑机。
然后，以框架被插入到注塑机的状态，通过第二次注射成型而形成绝缘体。
其中，一般而言，所述绝缘体使用作为弹性物质的橡胶(rubber)而成型。
在如上所述的传统的弹簧垫制造工艺中，粘合工艺需要检查粘合剂的涂覆量和涂覆面积，因此比较繁琐且需要较长的工作时间。
此外，涂覆粘合剂的产品的存储时间相对较短(7天以内)，并且采取了许多后续措施，例如在盐水老化等多种条件下通过粘合剂测试验证粘合强度，因此工艺数量较多，存在作业时间较长、生产率降低的问题。
并且，因橡胶(rubber)和钢材(steel)结合在一起而重量较重，无法回收再利用而成为环境污染的主要原因，并且造成巨大的废物处理费用。
现有技术文献
专利文献
(专利文献1)韩国授权专利公报第10-1459277号
(专利文献2)韩国授权专利公报第10-1490736号
(专利文献3)韩国授权专利公报第10-1911322号
(专利文献4)韩国授权专利公报第10-1887390号
(专利文献5)韩国授权专利公报第10-1882334号
发明内容
(要解决的技术问题)
本发明用于解决上述问题而提供一种利用发泡注射成型的汽车悬架装置用弹簧垫制造方法，其相比传统的由单一材料或复合材料即橡胶(rubber)和钢材(steel)制成的弹簧垫，采用发泡塑料工艺来简化制造工艺，减轻重量而实现轻量化，提高生产率，因利用热塑性材料而能够回收利用(recycle)。
然而，本发明的目的不限于上述目的，本领域技术人员可通过以下记载清楚地理解未提及的其他目的。
(解决问题的手段)
用于达成所述目的的本发明作为一种夹杂在用于汽车悬架装置的弹簧和支撑所述弹簧的上部及下部垫之间的汽车悬架装置用弹簧垫的制造方法，其特征在于，所述弹簧垫包括绝缘体，该绝缘体接触所述弹簧而吸收冲击并形成弹簧垫的主体，为了所述弹簧垫的轻量化，通过发泡注射成型来制造所述绝缘体。
并且，本发明提供一种弹簧垫制造方法，其特征在于，所述弹簧垫包括框架，该框架与所述绝缘体结合而提高绝缘体的刚度。
并且，本发明的特征在于，包括如下步骤：准备用于所述绝缘体的注射成型的第一成型装置的步骤(S110)；通过所述第一成型装置进行所述绝缘体的发泡注射成型的绝缘体发泡注射成型步骤(S120)。
并且，本发明的特征在于，包括如下步骤：准备用于所述绝缘体注射成型的第一成型装置和用于所述框架注射成型的第二成型装置的步骤(S210)；通过所述第一成型装置进行所述绝缘体的发泡注射成型的绝缘体发泡注射成型步骤(S220)；及向所述第二成型装置插入(insert)所述发泡注射成型的绝缘体而进行所述框架的注射成型的绝缘体插入框架注射成型步骤(S230)。
并且，本发明的特征在于，所述绝缘体发泡注射成型步骤(S120，S220)包括如下步骤：将所述绝缘体的材料供给到所述第一成型装置的汽缸而使其熔融的步骤(S121，S221)；向所述汽缸内供给被压缩的发泡用气体的步骤(S122，S222)；混合所述熔融的绝缘体材料和发泡用气体的步骤(S123，S223)；将与所述发泡用气体混合的绝缘体材料供给到所述第一成型装置的模具内而进行发泡注射成型的步骤(S124，S224)；将所述发泡注射成型的绝缘体冷却并取出的步骤(S125，S225)。
并且，本发明的特征在于，所述发泡用气体供给步骤(S122，S222)还包括如下步骤：利用减压装置，将所述发泡用气体减压到预设的供给压力。
并且，本发明的特征在于，所述发泡用气体的供给压力V满足以下公式1。
[公式1]
N(bar)＝V(bar)+5～50(bar)，其中N＝汽缸的内部压力(bar)
并且，本发明的特征在于，所述发泡注射成型注射步骤(S124，S224)包括如下步骤：与所述绝缘体材料混合的发泡用气体从汽缸被供给到模具内而压力下降的步骤；所述发泡用气体经过压力下降而膨胀，形成发泡气孔的步骤。
并且，本发明的特征在于，所述绝缘体的发泡率为10％至40％，所述发泡用气体为氮气。
并且，本发明的特征在于，所述绝缘体的材料和框架的材料由热塑性树脂形成，所述绝缘体材料的刚度软于所述框架材料的刚度，所述绝缘体材料的熔点低于所述框架材料的熔点，利用所述绝缘体材料与框架材料之间的熔点差，制造所述绝缘体与框架形成为一体的弹簧垫。
并且，本发明的特征在于，所述绝缘体插入框架注射成型步骤(S230)包括如下步骤：将所述绝缘体插入(insert)所述第二成型装置的模具的步骤(S231)；使所述框架材料熔融而将其注入所述第二成型装置的模具的步骤(S232)；因所述框架材料，所述绝缘体的表面熔融的步骤(S233)；在所述框架材料与所述绝缘体间的边界面，混合绝缘体的熔融的表面的一部分与框架材料的步骤(S234)；冷却所述框架材料，使所述绝缘体与框架结合成一体的步骤(S235)；取出所述绝缘体与框架形成为一体的弹簧垫的步骤(S236)。
并且，本发明的特征在于，所述绝缘体材料为热塑性聚酯弹性体(TPEE，Thermoplastic Polyester Elastomer)或热塑性聚氨酯(TPU，Thermoplastic PolyUrethane)、热塑性硫化橡胶(TPV，Thermoplastic Vulcanizates)或TPC。
并且，本发明的特征在于，所述框架材料为TPE(Thermoplastic elastomer)或尼龙(nylon)或PA6或PA66或聚对苯二甲酸丁二醇酯(PBT，Poly Butylene Terephthalate)或聚丙烯(PP，Poly Propylene)或ABS(Acrylonitrile Butadiene Styrene：丙烯腈丁二烯苯乙烯)或PC(Poly Carbonate：聚碳酸酯)。
并且，本发明的特征在于，所述绝缘体材料与框架材料的组合被设定为以下的(Case1)或(Case2)。
(Case1)：TPE+TPEE或TPE+PBT或PC或ABS或TPU
(Case2)：TPU+TPU或TPU+PA6或PA66或PC或ABS或TPE
并且，本发明的特征在于，相对于所述PBT及PA6(Polyamide)或PA66(Polyamide)中任意一个基片100重量份，所述框架材料被添加玻璃纤维(Glass Fiber；GF)10至60重量份及滑石(TALC，石粉)10至40重量份中的任意一个以上。
通过参考附图描述的具体实施方式，将更加清楚地理解本发明的特征及优点。
本说明书及权利要求书中使用的术语或词语不可解释成常用的或字典上的意思，应立足于发明人为了用最佳方法描述其发明而能够适当地定义术语概念的原则而解释为符合本发明的技术思想的意思和概念。
(发明的效果)
如上所述，本发明具有如下效果，用可回收利用(recycle)的热塑性材料替代橡胶(rubber)和钢材(steel)并利用发泡塑料工艺制作，因此相比传统的弹簧垫制造工艺，能够简化工艺而节省制造成本及能源，因可回收利用(recycle)而符合环保，通过减少成型时间提高了生产率，可以实现弹簧垫的轻量化。
附图说明
图1是示出传统弹簧垫制造工艺的顺序的框图。
图2是概略性示出本发明的一个优选实施例的包括绝缘体的弹簧垫的制造工艺的顺序。
图3是概略性示出本发明的一个优选实施例的包括绝缘体和框架的弹簧垫的制造工艺的顺序的顺序图。
图4是本发明的一个优选实施例的绝缘体发泡注射成型方法的顺序图。
图5是本发明的一个优选实施例的绝缘体插入框架注射成型方法的顺序图。
图6是概略性示出本发明的一个优选实施例的弹簧垫的立体图，(a)是用单一材料，(b)是用复合材料制作的弹簧垫的照片。
图7是本发明的一个优选实施例的第一成型装置的示意图。
附图标记
100：弹簧垫 110：绝缘体
120：框架 200：第一成型装置
210：汽缸 211：螺杆
212：喷嘴 220：料斗
230：模具 240：气体供给装置
具体实施方式
下面参照附图描述本发明的优选实施例。在此过程中，为了说明的便利和明确，附图中可能夸大示出线条的厚度或组件的大小等。
并且，后面的术语是考虑到其在本发明中的功能而定义的，可根据使用者、运用者的意图或惯例而改变。因此，这些术语的定义应基于本说明书的整体内容而定。
另外，以下实施例并不限制本发明的权利范围，而只是本发明的权利要求书中提及的组件的示例性事项，包含本发明整个说明书的技术思想且包括作为权利要求书的组件的等同物而可替代的组件的实施例可包括在本发明的权力范围内。
附图中图2是概略性示出本发明的一个优选实施例的包括绝缘体的弹簧垫的制造工艺的顺序，图3是本发明的一个优选实施例的弹簧垫的制造方法的顺序图，图4是本发明的一个优选实施例的绝缘体发泡注射成型方法的顺序图，图5是本发明的一个优选实施例的绝缘体插入框架注射成型方法的顺序图，图6是概略性示出本发明的一个优选实施例的弹簧垫的立体图，其中(a)是用单一材料，(b)是用复合材料制作的弹簧垫的照片，图7是本发明的一个优选实施例的第一成型装置的示意图。
如图2所示，本发明的特征在于，为了弹簧垫100的轻量化，利用发泡注射成型制造所述绝缘体110。
另外，本发明的弹簧垫100夹杂在用于汽车悬架装置的弹簧和支撑所述弹簧的上部及下部垫之间。
并且，所述弹簧垫100包括绝缘体110，该绝缘体接触所述弹簧而吸收冲击并形成弹簧垫的主体，为了所述弹簧垫的轻量化，通过发泡注射成型来制造所述绝缘体。
其中，所述弹簧垫100的制造方法包括如下步骤：准备用于所述绝缘体110的注射成型的第一成型装置200的步骤(S110)；通过所述第一成型装置200进行所述绝缘体110的发泡注射成型的绝缘体发泡注射成型步骤(S120)。
并且，所述弹簧垫100包括框架120，该框架与所述绝缘体110结合而提高绝缘体110的刚度。
其中，所述弹簧垫100的制造方法包括如下步骤：准备用于所述绝缘体110的发泡注射成型的第一成型装置200和用于所述框架120的注射成型的第二成型装置的步骤(S210)；通过所述第一成型装置200进行所述绝缘体110的发泡注射成型的绝缘体发泡注射成型步骤(S220)；及向所述第二成型装置插入(insert)所述发泡注射成型的绝缘体110而进行所述框架120的注射成型的绝缘体插入框架注射成型步骤(S230)。
其中，如上所述，经绝缘体110的成型即第一次成型后，插入(insert)第一次成型后的绝缘体而进行框架120的成型即第二次成型的工艺只是本发明的一个实施例而已，相反，也可采用先进行所述框架120的成型即第一次成型后，插入第一次成型后的框架而进行绝缘体110成型即第二次成型的工艺。
另外，所述第一成型装置200包括：螺杆211，可旋转地排列在汽缸210内部；料斗220，安装在汽缸210的一侧上端；加热器，设置在所述汽缸210而向汽缸210内供热；模具230，连接到汽缸210的另一侧末端喷嘴212；气体供给装置240，向所述汽缸210的内部供给高压发泡用气体。
并且，所述绝缘体发泡注射成型步骤(S120，S220)包括如下步骤：将所述绝缘体110的材料供给到所述第一成型装置200的汽缸210而使其熔融的步骤(S121，S221)；向所述汽缸210内供给被压缩的发泡用气体的步骤(S122，S222)；混合所述熔融的绝缘体材料和发泡用气体的步骤(S123，S223)；将与所述发泡用气体混合的绝缘体材料供给到所述第一成型装置的模具230内而进行发泡注射成型的步骤(S124，S224)；将所述发泡注射成型的绝缘体110冷却并取出的步骤(S125，S225)。
并且，所述发泡用气体供给步骤(S122，S222)还包括如下步骤：利用减压装置，将所述发泡用气体减压到预设的供给压力。
其中，所述发泡用气体的供给压力V(bar)满足以下[公式1]。
[公式1]
N＝V+(5～50)(bar)其中，N＝汽缸内的绝缘体材料压力(bar)
即，通过公式1，施加到汽缸内绝缘体的压力应大于发泡用气体的供给压力，实验结果，若大于5至50bar左右，可以进行顺畅的注射作业。
其中，汽缸内的绝缘体材料所受的压力与可旋转地排列在向绝缘体施加压力的汽缸210内部的螺杆211所受的压力。
并且，所述发泡注射成型注射步骤(S124，S224)包括如下步骤：与所述绝缘体材料混合的发泡用气体从汽缸210被供给到模具230内而压力下降的步骤；所述发泡用气体经过压力下降而膨胀，形成发泡气孔的步骤。
即，通过所述料斗220投入绝缘体材料，利用螺杆211输送绝缘体材料而其通过加热器的加热而熔融，并通过所述气体供给装置240向汽缸210内投入发泡用气体，使其与已经熔融的绝缘体材料混合。
并且，通过所述螺杆211的旋转，所述混合的熔融绝缘体材料被填充到模具230内而具有绝缘体110的形状。
其中，在所述汽缸210内，与熔融绝缘体材料混合的发泡用气体经过注塑机喷嘴212末端而开始被填充到模具230内时，压力从高压降低到大气压。
根据这种压力差，熔融的绝缘体材料内的发泡用气体形成气孔层而进行发泡。
并且，优选地，所述绝缘体的发泡率为10％至40％。
并且，优选地，若所述绝缘体110的发泡率超过40％，利用型芯背面(core back)工法实施发泡注射成型。
并且，所述发泡用气体可以是氮气。
并且，以下[表1]是比较由传统橡胶材料形成的绝缘体和本发明的发泡成型绝缘体的表格。
[表1]
(下表中NR＝天然橡胶Natural Rubber)
Figure GDA0004191108030000091
如[表1]所示，通过发泡注射成型来形成绝缘体110，可以实现绝缘体110的轻量化，减少成型时间而提高生产率。
另外，所述绝缘体的材料和框架的材料是热塑性树脂。
并且，所述绝缘体材料的刚度软于所述框架材料的刚度，所述绝缘体材料的熔点低于所述框架材料的熔点，利用所述绝缘体材料与框架材料之间的熔点差，制造所述绝缘体与框架形成为一体的弹簧垫。
其中，所述绝缘体插入框架注射成型步骤(S230)包括如下步骤：将所述绝缘体110插入(insert)所述第二成型装置的模具的步骤(S231)；使所述框架材料熔融而将其注入所述第二成型装置的模具的步骤(S232)；因所述框架材料，所述绝缘体的表面熔融的步骤(S233)；在所述框架材料与所述绝缘体间的边界面，混合绝缘体的熔融的表面的一部分与框架材料的步骤(S234)；冷却所述框架材料，使所述绝缘体与框架结合成一体的步骤(S235)；取出所述绝缘体与框架形成为一体的弹簧垫的步骤(S236)。
另外，所述第二成型装置包括：汽缸；可旋转地排列在汽缸内部的螺杆；安装在汽缸的一侧上端的料斗；设置在所述汽缸而向汽缸内供热的加热器；连接到汽缸的另一侧末端喷嘴部的模具。其中，利用所述螺杆和加热器，使框架材料熔融而将其注射到所述模具内。
上述的第二成型装置属于注塑成型工法中普遍使用的，因此省略详细的描述和图示。
另外，所述绝缘体材料可以是热塑性聚酯弹性体(TPEE，ThermoplasticPolyester Elastomer)、热塑性聚氨酯(TPU，Thermoplastic Poly Urethane)、热塑性硫化橡胶(TPV，Thermoplastic Vulcanizates)、TPC中的一个或两个以上的组合。
并且，所述框架材料可以是尼龙(nylon)、PA6、PA66、聚对苯二甲酸丁二醇酯(PBT，Poly Butylene Terephthalate)、聚丙烯(PP，Poly Propylene)、ABS、PC中的一个或两个以上的组合。
并且，所述绝缘体材料和框架材料的组合可以是以下(Case1)或(Case2)。
(Case1)：TPE+TPEE或TPE+PBT或PC或ABS或TPU
(Case2)：TPU+TPU或TPU+PA6或PA66或PC或ABS或TPE
并且，相对于所述PBT及PA6(Polyamide)或PA66(Polyamide)中任意一个基片100重量份，所述框架材料被添加玻璃纤维(Glass Fiber；GF)10至60重量份及滑石(TALC，石粉)10至40重量份中的任意一个以上。
如上所述，本发明的弹簧垫制造方法用可回收利用(recycle)的热塑性材料替代橡胶(rubber)和钢材(steel)，因可回收利用(recycle)而符合环保，通过减少成型时间提高了生产率，可以实现弹簧垫的轻量化。
以上通过具体实施例详细描述了本发明，但这仅是为了具体描述本发明，本发明并不局限于此，在本发明的技术思想范围内，本领域普通技术人员可对本发明实施变形或改良。
对本发明的单纯的变形至变更都属于本发明的范围内，本发明的具体保护范围将通过所附的权利要求书而变得明确。

Claims (3)

1.一种弹簧垫制造方法，作为一种夹杂在用于汽车悬架装置的弹簧和支撑所述弹簧的上部及下部垫之间的汽车悬架装置用弹簧垫的制造方法，其特征在于，
所述弹簧垫包括绝缘体，该绝缘体接触所述弹簧而吸收冲击并形成弹簧垫的主体，为了所述弹簧垫的轻量化，通过发泡注射成型来制造所述绝缘体；
所述弹簧垫包括框架，该框架与所述绝缘体结合而提高绝缘体的刚度；
绝缘体的材料和框架的材料是热塑性树脂；
包括如下步骤：
准备用于所述绝缘体注射成型的第一成型装置和用于所述框架注射成型的第二成型装置的步骤(S210)；
通过所述第一成型装置进行所述绝缘体的发泡注射成型的绝缘体发泡注射成型步骤(S220)；及
向所述第二成型装置插入所述发泡注射成型的绝缘体而进行所述框架的注射成型的绝缘体插入框架注射成型步骤(S230)。
2.根据权利要求1所述的弹簧垫制造方法，其特征在于，
所述绝缘体发泡注射成型步骤(S120，S220)包括如下步骤：
将所述绝缘体的材料供给到所述第一成型装置的汽缸而使其熔融的步骤(S121，S221)；
向所述汽缸内供给被压缩的发泡用气体的步骤(S122，S222)；
混合所述熔融的绝缘体材料和发泡用气体的步骤(S123，S223)；
将与所述发泡用气体混合的绝缘体材料供给到所述第一成型装置的模具内而进行发泡注射成型的步骤(S124，S224)；
将所述发泡注射成型的绝缘体冷却并取出的步骤(S125，S225)。
3.根据权利要求2所述的弹簧垫制造方法，其特征在于，
所述发泡用气体供给步骤(S122，S222)还包括如下步骤：利用减压装置，将所述发泡用气体减压到预设的供给压力。
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