CN114379061B - Preparation method of heavy commercial vehicle air inlet channel - Google Patents
Preparation method of heavy commercial vehicle air inlet channel Download PDFInfo
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- CN114379061B CN114379061B CN202210057583.6A CN202210057583A CN114379061B CN 114379061 B CN114379061 B CN 114379061B CN 202210057583 A CN202210057583 A CN 202210057583A CN 114379061 B CN114379061 B CN 114379061B
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- 238000002360 preparation method Methods 0.000 title claims abstract description 20
- 238000000071 blow moulding Methods 0.000 claims abstract description 91
- 238000005187 foaming Methods 0.000 claims abstract description 41
- 239000000463 material Substances 0.000 claims abstract description 41
- 239000004698 Polyethylene Substances 0.000 claims abstract description 31
- -1 polyethylene Polymers 0.000 claims abstract description 31
- 229920000573 polyethylene Polymers 0.000 claims abstract description 31
- 239000004088 foaming agent Substances 0.000 claims abstract description 23
- 230000009471 action Effects 0.000 claims abstract description 22
- 239000002245 particle Substances 0.000 claims abstract description 21
- 229920003023 plastic Polymers 0.000 claims abstract description 21
- 239000004033 plastic Substances 0.000 claims abstract description 21
- 238000002347 injection Methods 0.000 claims abstract description 20
- 239000007924 injection Substances 0.000 claims abstract description 20
- 238000002844 melting Methods 0.000 claims abstract description 20
- 230000008018 melting Effects 0.000 claims abstract description 20
- 239000004594 Masterbatch (MB) Substances 0.000 claims abstract description 15
- 238000010438 heat treatment Methods 0.000 claims abstract description 10
- 238000002156 mixing Methods 0.000 claims abstract description 7
- 238000003756 stirring Methods 0.000 claims abstract description 7
- 238000000034 method Methods 0.000 claims description 39
- 230000008569 process Effects 0.000 claims description 24
- 238000000465 moulding Methods 0.000 claims description 16
- 238000007664 blowing Methods 0.000 claims description 12
- 238000004519 manufacturing process Methods 0.000 claims description 12
- UIIMBOGNXHQVGW-UHFFFAOYSA-M Sodium bicarbonate Chemical compound [Na+].OC([O-])=O UIIMBOGNXHQVGW-UHFFFAOYSA-M 0.000 claims description 10
- 230000000694 effects Effects 0.000 claims description 10
- 239000000203 mixture Substances 0.000 claims description 6
- 229920013716 polyethylene resin Polymers 0.000 claims description 6
- 239000011148 porous material Substances 0.000 claims description 6
- 229910000030 sodium bicarbonate Inorganic materials 0.000 claims description 5
- 235000017557 sodium bicarbonate Nutrition 0.000 claims description 5
- 238000001816 cooling Methods 0.000 claims description 4
- 229920001903 high density polyethylene Polymers 0.000 abstract description 3
- 239000004700 high-density polyethylene Substances 0.000 abstract description 3
- 238000004458 analytical method Methods 0.000 description 10
- 230000000052 comparative effect Effects 0.000 description 8
- 238000012360 testing method Methods 0.000 description 6
- 238000009826 distribution Methods 0.000 description 4
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- 238000001228 spectrum Methods 0.000 description 4
- 239000006260 foam Substances 0.000 description 3
- 230000007246 mechanism Effects 0.000 description 3
- 238000011056 performance test Methods 0.000 description 3
- 239000013585 weight reducing agent Substances 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
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- 230000005284 excitation Effects 0.000 description 2
- 238000009472 formulation Methods 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
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- 230000008859 change Effects 0.000 description 1
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
- B29C49/04—Extrusion blow-moulding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/42—Component parts, details or accessories; Auxiliary operations
- B29C49/64—Heating or cooling preforms, parisons or blown articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/42—Component parts, details or accessories; Auxiliary operations
- B29C49/78—Measuring, controlling or regulating
- B29C49/783—Measuring, controlling or regulating blowing pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/42—Component parts, details or accessories; Auxiliary operations
- B29C49/78—Measuring, controlling or regulating
- B29C49/786—Temperature
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
- C08J9/06—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a chemical blowing agent
- C08J9/08—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a chemical blowing agent developing carbon dioxide
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2023/00—Tubular articles
- B29L2023/22—Tubes or pipes, i.e. rigid
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2203/00—Foams characterized by the expanding agent
- C08J2203/02—CO2-releasing, e.g. NaHCO3 and citric acid
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
- C08J2323/04—Homopolymers or copolymers of ethene
- C08J2323/06—Polyethene
Abstract
The invention discloses a preparation method of an air inlet channel of a heavy commercial vehicle, which comprises the steps of stirring and mixing polyethylene plastic particles and foaming agent master batches according to a preset proportion to obtain a primary mixed material; adding the primary mixed material into blow molding equipment for heating to obtain mixed melt, injecting the mixed melt from a mold cavity of the blow molding equipment, and forming a product initial parison when a forming mold is closed; and injecting compressed air into the product initial parison clamped in the forming die under the action of preset blow molding pressure to obtain a target blow molding product. The invention adopts the foaming agent master batch to carry out micro-foaming on polyethylene plastic particles, and extrudes the polyethylene plastic particles from blow molding equipment with specific melting temperature and specific injection pressure, and under the action of specific preset blow molding pressure, the finished product of micro-foaming high-density polyethylene, namely a target blow molding product, can be obtained, thereby realizing the light weight and high apparent performance of the product.
Description
Technical Field
The invention relates to the field of part preparation, in particular to a preparation method of an air inlet channel of a heavy-duty commercial vehicle.
Background
The light weight of the automobile plays a vital role in reducing oil consumption and emission, and is one of main competitiveness measuring the technical level of the automobile industry, and as the air inlet system of the commercial automobile is generally composed of an air inlet pipe assembly, an air filter assembly and other structures, the weight of the air inlet pipe part is heavier and the cost is higher, so that the market competitiveness of the product is better improved, and the product with low cost and light weight is required to be developed. At present, the weight of the air inlet pipe is reduced by a modified formula and a traditional blow molding process in the industry, but the air inlet pipe obtained by the traditional blow molding process has the problem of poor apparent properties such as uneven distribution of bubbles, broken holes and cells.
Disclosure of Invention
The invention mainly aims to provide a preparation method of an air inlet channel of a heavy commercial vehicle, and aims to solve the technical problems of poor apparent properties such as bubbles, broken holes and uneven cell distribution of an existing air inlet pipe obtained based on a traditional blow molding process.
In order to achieve the above purpose, the invention provides a method for preparing an air inlet of a heavy-duty commercial vehicle, which comprises the following steps:
stirring and mixing polyethylene plastic particles and foaming agent master batches according to a preset proportion to obtain a primary mixed material;
adding the primary mixed material into blow molding equipment for heating to obtain mixed melt, injecting the mixed melt from a mold cavity of the blow molding equipment, and forming a product initial parison when a forming mold is closed;
and injecting compressed air into the product initial parison clamped in the forming die under the action of preset blow molding pressure to obtain a target blow molding product.
Further, the melting temperature in the blow molding equipment is 150 to 220 ℃,
the step of adding the primary mixed material into a blow molding device for heating to obtain a mixed melt comprises the following steps: the primary mixed material is added into a blow molding device for heating, the primary mixed material is melted and the foaming agent master batch is decomposed to generate gas at the melting temperature of 150-220 ℃, and the primary mixed material and the gas are melted and mixed to form the mixed melt.
Further, the injection pressure at the time of injection is 40 to 90 megapascals,
the step of injecting the mixed melt from the cavity of the blow molding apparatus to form a product preform when the mold is closed, comprises:
injecting the mixed melt from the die cavity of the blow molding equipment under the action of injection pressure of 40 to 90 megapascals, and extruding a tubular parison through an extruder head;
when the length of the tubular parison reaches a preset value, the forming mold is closed to form the product initial parison.
Further, in the process of injecting compressed air into the product initial parison held in the molding die under the effect of a preset blow pressure of 1 to 3mpa, the blowing time of injecting the compressed air into the product initial parison is 100 to 200 seconds.
Further, the step of injecting compressed air into the product initial parison held in the molding die under the action of a preset blow molding pressure to obtain a target blow molded product includes:
injecting compressed air into the product initial parison clamped in the forming die under the action of preset blow molding pressure until the product initial parison is attached to the forming die, so as to obtain a micro-foaming product;
and (3) curing the micro-foaming product to obtain the target blow molding product.
Further, in the process of obtaining the target blow molding product after the micro-foaming product is subjected to the curing treatment, the time of the curing treatment is 30 seconds.
Further, the curing process includes a finishing operation, a cooling operation, and a curing operation.
Further, the polyethylene plastic particles are polyethylene resin, and the foaming agent master batch is sodium bicarbonate foaming agent.
Further, the polyethylene resin is a polyethylene composition having a molecular weight of 300000 and a weight average molecular weight of 30.
Further, the target blow molded product is an air intake duct of an automobile, the air intake duct has a cell density of 107 cells per cubic centimeter, and the cells have a pore size of 50 to 120 micrometers.
According to the preparation method of the heavy commercial vehicle air inlet channel, polyethylene plastic particles and foaming agent master batches are stirred and mixed according to the preset proportion, so that a primary mixed material is obtained; adding the primary mixed material into blow molding equipment for heating to obtain mixed melt, injecting the mixed melt from a mold cavity of the blow molding equipment, and forming a product initial parison when a forming mold is closed; and injecting compressed air into the product initial parison clamped in the forming die under the action of preset blow molding pressure to obtain a target blow molding product.
The invention adopts the foaming agent master batch to carry out micro-foaming on polyethylene plastic particles, and extrudes the polyethylene plastic particles from blow molding equipment with specific melting temperature and specific injection pressure, and under the action of specific preset blow molding pressure, the finished product of micro-foaming high-density polyethylene, namely a target blow molding product, can be obtained, thereby realizing the light weight and high apparent performance of the product. The experimental results show that: the target blow molding product prepared under the conditions of a melting temperature of 165 ℃, a injection pressure of 70MPa, a blow molding pressure of 1.5MPa, a blow time of 150s and a curing time of 30s has a pore diameter of 80 mu m, the weight of the product is reduced by 35%, the apparent performance of the product is high, and NVH (Noise, vibration, harshness, noise, vibration and harshness) performance is high.
Drawings
FIG. 1 is a schematic flow chart of an embodiment of a method for manufacturing an air intake duct of a heavy-duty commercial vehicle according to the present invention;
FIG. 2 is a chart showing the apparent performance of the blow molded object of example 1 of the present invention;
FIG. 3 is a chart showing the apparent performance of the blow molded object of example 4 of the present invention;
FIG. 4 is a graph of the noise analysis results of the present invention during idle conditions of the whole vehicle;
FIG. 5a is a graph of noise analysis for a fixed ramp-up condition of the present invention;
FIG. 5b is a graph of the noise spectrum at set-up ramp conditions in accordance with the present invention.
The achievement of the objects, functional features and advantages of the present invention will be further described with reference to the accompanying drawings, in conjunction with the embodiments.
Detailed Description
The following description of embodiments of the present invention will be made clearly and fully with reference to the accompanying drawings, in which it is to be understood that the specific embodiments described herein are for purposes of illustration only, and are not intended to be limiting of the invention in any way. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
In addition, the technical solutions of the embodiments may be combined with each other, but it is necessary to base that the technical solutions can be realized by those skilled in the art, and when the technical solutions are contradictory or cannot be realized, the combination of the technical solutions should be considered to be absent and not within the scope of protection claimed in the present invention.
The invention provides a preparation method of an air inlet channel of a heavy commercial vehicle.
Referring to fig. 1, fig. 1 is a schematic flow chart of a first embodiment of a method for manufacturing an air intake duct of a heavy-duty commercial vehicle according to the present invention.
The embodiments of the present invention provide embodiments of a method of manufacturing an air intake for a heavy-duty commercial vehicle, it being noted that although a logical sequence is shown in the flowchart, in some cases the steps shown or described may be performed in a different order than that shown.
The preparation method of the air inlet channel of the heavy commercial vehicle comprises the following steps:
and step S100, stirring and mixing the polyethylene plastic particles and the foaming agent master batch according to a preset proportion to obtain a primary mixed material.
And uniformly mixing polyethylene plastic particles and foaming agent master batches in a low-speed stirrer according to a preset proportion to obtain a primary mixed material.
Further, in the present embodiment, the polyethylene plastic particles are polyethylene resins, and the polyethylene resins are preferably materials with high melt strength.
Further, in the present embodiment, the high melt strength material may be a polyethylene composition having a molecular weight of 300000 and a weight average molecular weight of 30. Such as polyethylene plastic particles of Nanjing Polyon technologies Co., ltd., trademark EN 0B-F02.
Further, the foaming agent master batch can be sodium bicarbonate foaming agent, and the foaming agent has the characteristics of low odor and environmental protection. Such as the foaming agent master batch of Nanjing polymeric technology Co., ltd.
Specifically, for example, high melt strength polyethylene plastic particles and low odor master batch sodium bicarbonate foaming agent are mixed uniformly in a low speed mixer according to a certain proportion, and a primary mixed material is obtained.
And step 200, adding the primary mixed material into a blow molding device for heating to obtain a mixed melt, injecting the mixed melt from a mold cavity of the blow molding device, and forming a product initial parison when the forming mold is closed.
Placing the primary mixed material into a container, raising the temperature of the container to a melting temperature, and melting and mixing the primary mixed material in the container under the action of screw stirring to obtain a mixed melt.
In this embodiment, the blowing agent masterbatch in the primary mixed material is decomposed at the melting temperature to generate a gas, and the gas is melt-mixed with the primary mixed material to form a uniform micro-foamed polyethylene melt, i.e., a mixed melt.
Further, in this embodiment, the container may be a blow molding apparatus or a micro-foaming blow molding apparatus, where the blow molding apparatus includes a temperature control device and a pressure control device, the temperature control device may realize accurate temperature control of 80-400 ℃ (celsius degrees), and the pressure control device may realize accurate pressure control of 1-100MPa (megapascals).
Further, in the present embodiment, the injection pressure (i.e., die blow pressure) at which the mixed melt is injected from the cavity of the blow molding apparatus, the blow molding pressure (i.e., blow molding pressure) at which the compressed air is injected into the product preform held in the molding die, and the opening and closing pressure (i.e., blow pin jack cylinder pressure) of the molding die in the blow molding apparatus are separately controlled.
Further, in this embodiment, the melting temperature is 150-220 ℃ during the process of placing the primary mix material in the container and raising the container temperature to the melting temperature. The melting temperature in the range is higher in solubility of the mixed melt to gas, and the solubility of the gas is reduced through pressure reduction, so that the mixed melt expands to improve the coating property of the expanded mixed melt to the gas, so that the gas is not easy to overflow from the polyethylene material, and the uniformity of the size of the internal cell size and the distribution of the cell of the target blow-molded product is realized.
Specifically, for example, the primary mixed material is added into a barrel of a blow molding apparatus, the temperature is heated to 150-220 ℃, the primary mixed material is melted under the action of screw stirring, and the foaming agent master batch is decomposed to generate gas, and the primary mixed material is melted and mixed with the gas to obtain a mixed melt. The mixed melt is obtained by micro-foaming polyethylene plastic particles, and has good coating property on gas, so that the gas is not easy to overflow from the polyethylene material, and the size of the inner cell size and the uniformity of cell distribution of a target blow molding product are realized.
Further, the step of injecting the mixed melt from the cavity of the blow molding apparatus to form a product preform when the molding die is closed, comprises:
step A1, under the action of injection pressure of 40 to 90 megapascals, injecting the mixed melt from a die cavity of the blow molding equipment, and extruding a tubular parison through an extruder head;
and A2, closing the forming die when the length of the tubular parison reaches a preset value, and forming the product initial parison.
In this embodiment, the mixed melt is ejected from the cavity of the blow molding apparatus, a tubular parison is extruded through the extruder of the blow molding apparatus, and when the length of the tubular parison reaches a preset value, the closing of the clamping mechanism for obtaining the target blow molded product is performed to form the product preform.
Further, the injection pressure at which the mixed melt is injected from the cavity of the blow molding apparatus is 40 to 90MPa to achieve uniformity of cell size inside the target blow molded product.
Further, the preset value is designed according to the target blow molding product, the molding mold and the blow molding pressure, and the tubular parison can be obtained only by performing blow molding process treatment in the molding mold, so that the preset value is smaller than the length of the molding mold, namely the length of the tubular parison is smaller than the length of the molding mold.
Further, the clamping mechanism comprises a forming die, and the clamping mechanism can also be a forming die, and the tubular parison is molded in the forming die to obtain the target blow molding product.
Specifically, for example, a micro-foamed polyethylene melt is ejected from a cavity under an ejection pressure of 40 to 90MPa, a tubular parison is extruded through an extruder, and when the length of the tubular parison reaches a preset value, a molding die is closed to form a product initial parison.
And step S300, injecting compressed air into the product initial parison clamped in the forming die under the action of preset blow molding pressure to obtain a target blow molding product.
Further, in the process of injecting compressed air into the product initial parison held in the molding die under the effect of the preset blow pressure, the preset blow pressure is 1 to 3MPa, and the blowing time of injecting the compressed air into the product initial parison is 100s to 200s (seconds). By controlling the preset blow molding pressure between 1 and 3MPa, the cell size and the cell uniformity can be controlled.
Further, the step of injecting compressed air into the product initial parison held in the molding die under the action of a preset blow molding pressure to obtain a target blow molded product includes:
step B1, injecting compressed air into the product initial parison clamped in the forming die under the action of preset blow molding pressure until the product initial parison is attached to the forming die, so as to obtain a micro-foaming product;
and step B2, curing the micro-foaming product to obtain a target blow molding product.
Further, in the process of obtaining the target blow molding product after the micro-foaming product is subjected to the curing treatment, the time of the curing treatment is 30s.
Further, the curing process includes a finishing operation, a cooling operation, and a curing operation.
Specifically, for example, under the action of a preset blow-molding pressure of 1-3MPa, compressed air is injected and clamped in a product initial parison in a molding die, the product initial parison is inflated until being attached to the molding die, and after 100-200 s of blowing, a micro-foaming product is obtained. After trimming, cooling and solidifying the micro-foaming product for 30s, a hollow blow-molded product with a certain shape is obtained, namely a target blow-molded product.
Further, the target blow molded product is an air intake duct of an automobile, and the density of cells in the air intake duct is 10 7 cells/cm 3 The pore size of the cells is 50-120um (micrometers).
In the embodiment, the primary mixed material is obtained by stirring and mixing polyethylene plastic particles and foaming agent master batches according to a preset proportion; adding the primary mixed material into blow molding equipment for heating to obtain mixed melt, injecting the mixed melt from a mold cavity of the blow molding equipment, and forming a product initial parison when a forming mold is closed; and injecting compressed air into the product initial parison clamped in the forming die under the action of preset blow molding pressure to obtain a target blow molding product. The invention adopts the foaming agent master batch to carry out micro-foaming on polyethylene plastic particles, and extrudes the polyethylene plastic particles from blow molding equipment with specific melting temperature and specific injection pressure, and under the action of specific preset blow molding pressure, the finished product of micro-foaming high-density polyethylene, namely a target blow molding product, can be obtained, thereby realizing the light weight and high apparent performance of the product. The experimental results show that: the target blow molding product prepared under the conditions of a melting temperature of 165 ℃, a injection pressure of 70MPa, a blow molding pressure of 1.5MPa, a blow time of 150s and a curing time of 30s has a pore diameter of 80 mu m, the weight of the product is reduced by 35%, the apparent performance of the product is high, and NVH (Noise, vibration, harshness, noise, vibration and harshness) performance is high.
Further, the target blow molding product prepared by the preparation method of the heavy commercial vehicle air inlet channel is subjected to light weight test and apparent performance test. The specific test process is as follows:
according to the preparation method of the heavy commercial vehicle air inlet, four examples and a group of comparative examples are prepared by specifically adjusting the formulation fraction and the components of the primary mixed materials, and the specific formulation is shown in the following table 1:
table 1: the examples and comparative examples parameters are as follows:
| process parameters | Comparative example 1 | Example 1 | Example 2 | Example 3 | Example 4 |
| Melting temperature | 180 | 180 | 180 | 165 | 165 |
| Injection pressure | 40 | 40 | 40 | 40 | 70 |
| Blow molding pressure | 6 | 3 | 1.5 | 1.5 | 1.5 |
| Time of blowing | 100 | 150 | 150 | 100 | 150 |
| Curing time | 30 | 30 | 30 | 30 | 30 |
In comparative example 1, polyethylene plastic particles were in an unfoamed state, and a target blow molded product was prepared according to a common process. Example 1, example 2, example 3 and example 4 are the target blow-molded products prepared according to the preparation method of the heavy commercial vehicle air inlet channel.
The performance results of the prepared inlet channel products are shown in the following table 2 by the parameters in table 1:
table 2: the performance results of the examples and comparative examples are as follows:
| detecting items | Comparative example 1 | Example 1 | Example 2 | Example 3 | Example 4 |
| Cell size | / | 100um | 110um | 90um | 80um |
| Weight reduction ratio | 0 | 12％ | 30％ | 35％ | 35％ |
| Appearance of the product | Smooth and glossy | Roughness of | Roughness of | Slightly rough | Smooth and glossy |
Referring to fig. 2, the product appearance of the target blow molded product of example 1, and referring to fig. 3, the product appearance of the target blow molded product of example 4. As can be seen from fig. 2 and 3, the product appearance of the target blow molded product prepared in example 4 tended to be smoother than that of example 1.
Specifically, example 1 and example 2 were produced by adjusting the blowing pressure on the basis of comparative example 1, since the process of blowing foaming was completed instantaneously in the process of lowering the molten material (mixed melt) from the die, and the final closed-die blow molding process was a process of suppressing the foaming effect thereof. Therefore, as the blowing pressure decreases, the foaming effect of the target blow molded product is better.
Further, example 3 relatively decreased the melting temperature based on example 2, and the solubility of the primary mixed material to gas was increased due to the decrease of the melting temperature, resulting in an increase of the nuclear point in the foaming process, the larger the cell density, the finer and uniform the cells. Therefore, when the melting temperature is lowered, the foaming effect of the product is slightly increased, and the appearance of the product of the target blow-molded product is improved, but the appearance cannot meet the requirement of an air inlet passage.
Further, example 4 increased shot pressure based on example 3, since the greater the shot pressure, the higher the solubility of the mixed melt to gas and the more closely the mixed melt is to the forming mold, the smoother the appearance of the target blow molded product. Therefore, the injection pressure is increased, the appearance of the product becomes smooth, and the foaming ratio of the product is not affected.
Combining the performance results and product appearance of comparative example 1 and example 1, example 2, example 3, example 4, it can be seen that for higher melt temperatures, the larger the cells, the smaller the cell density, the worse the apparent properties, and the temperature has relatively less effect on the weight loss ratio; for the larger injection pressure, the smaller and more uniform the cells, the appearance tends to be smooth; the foaming of the polyethylene material can be realized under the action of small pressure for blow molding pressure, and when the pressure is too large, the polyethylene material is basically not foamed, so that the molding pressure is a key factor influencing the foaming multiplying power of the product.
Further, according to the target blow-molded product obtained by the preparation method of the heavy commercial vehicle air inlet channel, the weight is reduced by more than 30%, and the product weight is reduced.
Further, the target blow-molded product obtained according to the preparation method of the heavy commercial vehicle air inlet channel has a cell density of 10 7 cells/cm 3 The pore diameter of the foam holes is 50-120um.
Further, NVH (Noise, vibration, harshness, noise, vibration and harshness) performance test is performed on the target blow molding product obtained by the preparation method of the heavy commercial vehicle air inlet channel. The specific test process is as follows:
it should be noted that the objects of the NVH performance test are a micro-foamed air inlet and an unfoamed air inlet, wherein the micro-foamed air inlet is a target blow-molded product prepared according to the preparation method of the air inlet of the heavy-duty commercial vehicle, and the unfoamed air inlet is a target blow-molded product prepared according to the common process.
The results of comparative analysis of the modal analysis of the micro-foamed air inlet and the unfoamed air inlet are shown in table 3:
table 3: the analysis result for the first 6 th order modal frequencies:
as can be seen from table 3, for the low frequency modal analysis, the modal frequencies of the first six orders of the micro-foamed air inlet channel were slightly higher than that of the unfoamed air inlet channel by about 1 Hz.
Further, the front 6-order modal frequencies of the micro-foaming air inlet channel are all 1-2dB (decibel) higher than those of the unfoamed air inlet channel, so that the rigidity and the performance of the air inlet channel are improved.
Further, in the working state of the inflating pump, noise testing of the micro-foaming air inlet channel and the unfoamed air inlet channel under the idle working condition and the fixed speed increasing working condition of the whole vehicle is carried out. The obtained analysis results of the noise in the whole vehicle under the idle speed working condition and the fixed speed increasing working condition are shown in the accompanying drawings 4, 5a and 5 b. Wherein, fig. 4 is the noise analysis result of the micro-foaming air inlet and the unfoamed air inlet in the idle working condition of the whole vehicle, and fig. 5a and fig. 5b are the noise analysis results of the micro-foaming air inlet and the unfoamed air inlet in the fixed speed-raising working condition.
The result shows that the noise in the idle speed of the micro-foaming air inlet channel is reduced by 1dB compared with the noise in the non-foaming air inlet channel when the air pump works under the idle speed working condition of the whole vehicle; under the working condition of fixed speed rise, after the air pump is started, the noise in the micro-foaming air inlet channel is reduced by 1-2dB compared with the noise in the unfoamed air inlet channel, namely the noise in the air inlet channel is reduced by 1-2dB in idle speed rise.
It should be noted that fig. 5a shows the noise analysis of the engine at different speeds (different frequencies), and the noise of the micro-foam air inlet is lower than that of the unfoamed air inlet.
Fig. 5b is a noise spectrum, the ordinate is the engine speed, the abscissa is the resonance frequency of the transmitter, the upper graph of fig. 5b is a noise spectrum of an unfoamed air inlet channel in an original state, and the lower graph of fig. 5b is a noise spectrum of a new material, namely a micro-foamed air inlet channel. Based on fig. 5b, it can be seen that the noise of the micro-foam air inlet at 650Hz resonance frequency is reduced compared to the unfoamed air inlet, and the larger the resonance area, the larger the noise caused by the more noise corresponding to 650Hz resonance frequency. Therefore, the micro-foaming air inlet channel obtained by the preparation method of the heavy commercial vehicle air inlet channel has no obvious change at 650Hz resonance frequency. The main reason is that a large number of closed micropores appear in the middle of the micro-foaming product, and the micro-foaming new material has an optimized effect on the excitation response of the inflating pump, so that the excitation response of the inflating pump is reduced, and the noise effect in the vehicle is improved. It should be noted that, although the theory of the middle size of the foamed product is from ten-several closed micropores of several tens micrometers, the two sides maintain a compact skin structure, and meanwhile, due to the foaming action, the whole wall thickness of the micro-foaming air inlet channel is improved by more than 10% compared with that of the unfoamed air inlet channel, so that the modal rigidity of the part product can be improved.
In combination with NVH performance analysis test of the parts of the air inlet pipe, the embodiment 4 completely meets the requirement of the heavy truck air inlet pipe, meets the requirements of weight reduction, high appearance and high performance, and provides direct technical support for weight reduction and material cost reduction of the heavy truck. In summary, the embodiment 4 completely accords with the micro-foaming heavy truck air inlet channel product, can be widely applied to the current heavy truck market, namely, the target blow molding product prepared under the conditions of the melting temperature of 165 ℃, the injection pressure of 70MPa, the blow molding pressure of 1.5MPa, the blow time of 150s and the curing time of 30s, realizes light weight, and has high apparent performance and high NVH performance.
In combination with the above tests, the target blow molding product prepared by the preparation method of the air inlet channel of the heavy-duty commercial vehicle is prepared by using a chemical blow molding foaming method, and the preparation of the target blow molding product comprises the steps of selecting a high melt strength modified polyethylene raw material and a low odor master batch sodium bicarbonate foaming agent master batch. The target blow molding product obtained by foaming the polyethylene plastic particles is light and weight, and the apparent performance and NVH performance of the product are ensured.
It should be noted that, in this document, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or system that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or system. Without further limitation, an element defined by the phrase "comprising one … …" does not exclude the presence of other like elements in a process, method, article, or system that comprises the element.
The foregoing embodiment numbers of the present invention are merely for the purpose of description, and do not represent the advantages or disadvantages of the embodiments.
The foregoing description is only of the preferred embodiments of the present invention, and is not intended to limit the scope of the invention, but rather is intended to cover any equivalents of the structures or equivalent processes disclosed herein or in the alternative, which may be employed directly or indirectly in other related arts.
Claims (10)
1. The preparation method of the air inlet channel of the heavy-duty commercial vehicle is characterized by comprising the following steps of:
stirring and mixing polyethylene plastic particles and foaming agent master batches according to a preset proportion to obtain a primary mixed material;
adding the primary mixed material into blow molding equipment for heating to obtain mixed melt, injecting the mixed melt from a mold cavity of the blow molding equipment, and forming a product initial parison when a forming mold is closed; when the forming mould is closed, applying blowing needle top cylinder pressure to the mixed melt;
injecting compressed air into the product initial parison clamped in the forming die under the action of preset blow molding pressure to obtain a target blow molding product; the preset blow pressure is 1 to 3 megapascals;
wherein the injection pressure, the blowing needle top cylinder pressure and the preset blowing pressure when the mixed melt is injected from the die cavity of the blowing equipment are independently and separately controlled.
2. The method for manufacturing an air intake duct for a heavy-duty commercial vehicle according to claim 1, wherein the melting temperature in the blow molding equipment is 150 to 220 degrees celsius,
the step of adding the primary mixed material into a blow molding device for heating to obtain a mixed melt comprises the following steps: the primary mixed material is added into a blow molding device for heating, the primary mixed material is melted and the foaming agent master batch is decomposed to generate gas at the melting temperature of 150-220 ℃, and the primary mixed material and the gas are melted and mixed to form the mixed melt.
3. The method for manufacturing an air inlet channel of a heavy commercial vehicle according to claim 1, wherein the injection pressure is 40 to 90mpa during the injection,
the step of injecting the mixed melt from the cavity of the blow molding apparatus to form a product preform when the mold is closed, comprises:
injecting the mixed melt from the die cavity of the blow molding equipment under the action of injection pressure of 40 to 90 megapascals, and extruding a tubular parison through an extruder head;
when the length of the tubular parison reaches a preset value, the forming mold is closed to form the product initial parison.
4. The method for manufacturing an air intake duct for a heavy-duty commercial vehicle according to claim 1, wherein the air blowing time for injecting the compressed air into the product initial parison held in the molding die is 100 to 200 seconds during the injection of the compressed air into the product initial parison under the effect of a preset blow pressure.
5. The method for manufacturing an air intake duct for a heavy-duty commercial vehicle according to claim 1, wherein said step of injecting compressed air into said product initial parison held in said forming mold under the effect of a preset blow pressure to obtain a target blow molded product comprises:
injecting compressed air into the product initial parison clamped in the forming die under the action of preset blow molding pressure until the product initial parison is attached to the forming die, so as to obtain a micro-foaming product;
and (3) curing the micro-foaming product to obtain the target blow molding product.
6. The method for manufacturing an air intake duct for a heavy-duty commercial vehicle according to claim 5, wherein the curing process is performed for 30 seconds in the process of obtaining the target blow-molded product after the curing process is performed on the micro-foamed product.
7. The method for manufacturing an air intake duct for a heavy-duty commercial vehicle according to claim 5, wherein the solidifying process includes a finishing operation, a cooling operation, and a solidifying operation.
8. The method for manufacturing an air intake duct for a heavy-duty commercial vehicle according to claim 1, wherein the polyethylene plastic particles are polyethylene resin, and the foaming agent master batch is sodium bicarbonate foaming agent.
9. The method for manufacturing an air intake duct for a heavy-duty commercial vehicle according to claim 7, wherein the polyethylene resin is a polyethylene composition having a molecular weight of 300000 and a weight average molecular weight of 300000.
10. The method of manufacturing an air intake for a heavy duty commercial vehicle according to any of claims 1-7, wherein said target blow molded product is an air intake for an automobile, said air intake having a cell density of 107 cells per cubic centimeter, said cells having a pore size of 50 to 120 microns.
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