CN114599511A - 用于车辆的噪声衰减装饰部件 - Google Patents

用于车辆的噪声衰减装饰部件 Download PDF

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CN114599511A
CN114599511A CN202080074321.XA CN202080074321A CN114599511A CN 114599511 A CN114599511 A CN 114599511A CN 202080074321 A CN202080074321 A CN 202080074321A CN 114599511 A CN114599511 A CN 114599511A
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layer
pile
noise attenuating
component
trim part
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雅恩·伯杰
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Alto Management Co ltd
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Alto Management Co ltd
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  • Laminated Bodies (AREA)
  • Carpets (AREA)
  • Tires In General (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
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  • Soundproofing, Sound Blocking, And Sound Damping (AREA)

Abstract

用于车辆的噪声衰减装饰部件，其包括绒头层、粘合质量层和背衬层，其中粘合质量层粘合到相邻层，其中粘合质量层至少包括填料含量为至少55％的热塑性弹性体聚烯烃基复合材料(TPO)，并且其中粘合质量层具有1.4至1.75kg/dm3的密度、小于50.000mPa.s的粘度和高于250的MFI，并且其中粘合质量层邻近绒头层并且部分渗透到绒头的下部区域中，从而在绒头内粘合纤维和/或长丝和/或簇绒。

Description

用于车辆的噪声衰减装饰部件
技术领域
本发明涉及一种用于车辆的噪声衰减装饰部件以及这样的装饰部件的用途。
背景技术
在汽车工业中，需要可以在不显著增加部件厚度的情况下在部件中引入重量的高填充材料，因为对于大多数部件来说，只有有限的空间可用于汽车的声学处理。大多数情况下，不超过至多30mm可用于实际处理。
特别地，对于内前围(inner dash)和地板部件，汽车制造商需要声学功能。这可以是增加噪声吸收的透气解决方案，和/或声质量层与去耦层组合以形成质量弹簧系统的组合形式的隔离解决方案。吸收解决方案通常用于衰减空气传播的噪声，而隔离解决方案用于衰减振动噪声。也可以使用将两者组合的混合解决方案。
已知在汽车装饰部件中使用重度填充的热塑性弹性体层。这些层可以基于热塑性弹性体(如EP-二烯橡胶(EPDM)或苯乙烯乙烯丁二烯苯乙烯共聚物(SBS))作为基质，并填充有至高90％的惰性颗粒。这样的弹性体层的示例可以在例如WO 2015/135815中找到，其公开了基于优选含有LLDPE或LDPE并且填料含量在35％和90％之间的乙烯聚合物混合物的阻挡层。从填充等级高于50％材料开始，材料的粘度增加，就像厚的面团，并且变得难以加工，需要重型设备。
目前为这些类型的材料提出的方法是挤出与压延或压缩模制的组合。例如，可以通过压延生产坯件或片材。将片材切割成形状和/或尺寸，并使用真空成型工艺将其最终与附加层(如去耦层)一起成形为最终形状。所述工艺包括多个步骤并且难以获得可变的厚度。
对于模制层解决方案，需要注射和压缩的组合工艺来填充整个空腔，该解决方案可以包括偏远地区和较小的细节。在这些工艺中，材料可能在冷却期间被推挤，增加了半固化区域开沟(streaking)和结对(pairing)的风险。在最终部件的模制步骤期间以及在汽车中使用部件期间，这些区域可能易于破裂或折断。模具可以在填充期间打开，以降低推挤所需的压力和吨位，并在工艺的后期闭合，以增加将材料推向成型的角落的压力。
在20世纪80年代，已知使用低粘度和至高80％的高填料等级的EVA基热熔胶。在生产期间，这种材料易于加工，不太需要重型机器。然而，低熔化温度(高于90℃时变成液体)使得这种材料不可能用于汽车，因为低的温度会在使用期间造成部件剥离的风险，特别是在靠近热源的排气管上方的隧道区域和/或在炎热的夏天汽车在充足的阳光下时。
由于汽车制造商对降低乘客舱外部噪声的噪声要求增加，因此需要在不增加部件厚度的情况下增加部件的重量。然而，这不能用目前的材料和工艺解决方案经济地实现。
本发明的目的是提供粘合质量层材料，其能够使得工艺条件更容易，降低生产成本和机器的磨损。然而，当用作汽车装饰部件的弹簧质量声学系统中的背衬层和/或屏障时，满足产品的要求。
发明内容
该目的通过根据主要权利要求1的用于车辆的噪声衰减装饰部件以及这样的装饰部件的用途来实现，该噪声衰减装饰部件具有至少绒头层、背衬层和粘合质量层。
特别是通过能够粘合到相邻层的粘合质量层来实现，该粘合质量层至少包含填料含量为至少55％的热塑性弹性体聚烯烃基复合材料(TPO)，并且具有1.4至1.75kg/dm3的密度、小于50.000mPa.s的粘度和高于250的MFI，并且其中粘合质量层邻近绒头层并且部分渗透到绒头的下部区域中，从而在绒头内粘合纤维和/或长丝和/或簇绒。
此外，通过使用具有权利要求1给定特征的TPO基复合材料，可以使用重度填充材料作为重量增加层以及在绒头表面层和相邻背衬层之间的粘合剂层。令人惊讶的是，粘合质量层不仅能够粘附到绒头层的表面，而且能够渗透到绒头层中，因此它能够起到绒头层的纤维和/或簇绒锁定的作用。因此，对于良好的簇绒或纤维锁定，不再需要传统使用的簇绒锁定层或纤维锁定层(例如乳胶)，进一步优化了必要的生产工艺步骤。
根据2012年的ISO 1133-1在190℃下测量熔体流动指数(MFI)。根据1995年的ISO11443在190℃下测量粘度。
粘合质量层可以进一步包括至少一种脂肪酸和任选的添加剂，其中惰性填料为总粘合质量层的55至70重量％，脂肪酸含量为总粘合质量层的0.2至0.8重量％。令人惊讶的是，脂肪酸使得能够增加粘合质量层中的填料含量的同时防止材料变得易碎和易于破裂。脂肪酸的量可以根据最终的填料量来调节，因此需要粘合质量层的密度。
脂肪酸可以至少包括具有至少14个脂肪链，优选具有16和/或18个脂肪链的脂肪酸。
根据本发明的粘合质量层包含TPO复合材料、填料、至少一种脂肪酸和任选的其他添加剂。
用于复合材料的TPO由以下组成：由至少一种部分无定形聚烯烃，优选无定形聚α-烯烃APAO组成的第一组分；和由具有无规亚乙基重复分布的聚丙烯乙烯(PP Ethylene)组成的、比密度小于0.87kg/dm3的第二组分。
优选地，第一组分为总粘合阻挡层的至少3重量％，第二组分为总粘合阻挡层的至少7重量％。
然而，第一和第二组分一起优选为总粘合阻挡层的10-48重量％。
噪声衰减装饰部件可在部件表面上具有恒定的或局部可变的面积重量的粘合阻挡层。优选地，粘合质量层的面积重量在100至980g/m2之间。
令人惊讶的是，发现可以调节粘合质量层的孔隙率。在400g/m2以下，该层将总是可渗透的，而在600g/m2以上，该层将总是不可渗透的。然而，在大约400至600g/m2的面积重量下，可以通过在应用期间调整机器参数来将孔隙率调节为可渗透的或不可渗透的。如果该层是可渗透的，则它可以用作部件内的气流阻力层，这意味着噪声可以穿过该层并到达下面的开孔泡沫或多孔纤维层形式的可能的噪声吸收层。
绒头层可以是针刺或簇绒地毯层，其面积重量可以在200至800g/m2之间。
例如，绒头层可以是由簇绒到主背衬层中的BCF纱线组成的簇绒地毯层。
绒头层还可以是针刺地毯层，其具有致密的底部区域和由基本垂直于表面直立的环状纤维形成的表面区域，所述环状纤维包括优选为实心纤维、中空纤维、粘合纤维或双组分纤维中的至少一种的纤维。
根据前述权利要求中的一项所述的噪声衰减装饰部件，其中绒头层纤维和/或长丝和/或纱线由至少一种聚合物或共聚物制成，所述聚合物或共聚物选自：聚酯，优选聚对苯二甲酸乙二醇酯(PET)；或聚酰胺，优选聚酰胺-6(PA6)或聚酰胺-66(PA66)；或聚烯烃，优选聚丙烯(PP)或聚乙烯(PE)；或这些聚合物和/或共聚物中的2种或更多种的混合物。纤维、长丝和/或纱线可以基于生物来源的、回收的或再循环的材料，或者可以包括这样的类型的源材料。
噪声衰减装饰部件在其基本构型中包括绒头层、根据本发明的粘合质量层和背衬层，其中粘合质量层粘合到相邻层，并且其中粘合质量层至少邻近绒头层并且部分渗透到绒头的下部区域中，从而在绒头内粘合纤维和/或长丝和/或簇绒。
背衬层可以是纤维层(优选粗劣的、再循环的或回收的纤维网中的一种)或泡沫层(优选板状泡沫或模内反应性泡沫层，优选聚氨酯泡沫)中的至少一种。优选地，泡沫层是开孔泡沫，优选不具有表层或具有多孔表层。
如果粘合质量层的面积重量小于800g/m2并因此是多孔的，则整个部件起到吸收性地毯层的作用，并且可以用作地板或内前围，但是也可以用作汽车前行李箱或后行李箱中的存储区域中的覆层。令人惊讶的是，粘合质量层的额外填料含量使部件更硬，因此该层不易弯曲或滑动。此外，基本布局已经显示出良好的耐磨性能，可与带有乳胶第二背衬的普通标准部件相当。
在另一个优选的实施方案中，除了绒头层、根据本发明的粘合质量层和背衬层的基本构型之外，噪声衰减装饰部件进一步包括附加层，该附加层优选为高密度热塑性弹性体层、膜层或气流阻力为至少1000Rayl的气流阻力纤维层中的一种。
一个或多个附加层可以以补片的形式仅局部放置或作为整层放置。
例如，具有绒头层、粘合质量层和附加的高填充热塑性层或补片以及背衬层的部件将表现为声学质量弹簧系统。该部件将主要隔离噪声，其中可以增加粘合质量层的面积重量以进一步优化附加层的质量效果。
在另一种调整的构型中，粘合质量层可以以接近其最大重量使用，并起到噪声阻隔装饰部件中的薄质量层的作用。热塑性材料的补片可用于进一步增加局部振动热点的重量。这使得部件的调整只在那些需要额外噪声衰减的区域中放置更多的重量，而整体上该部件用作轻质噪声隔离部件。
优选地，高密度热塑性弹性体层或补片是不可渗透的并且具有800至2000g/m2的面积重量。
高密度热塑性弹性体层或补片可以由与粘合质量层相同或相似的材料制成，例如通过在粘合质量层的背面施加第二层或局部补片，或通过在模制期间结合两个粘合质量层。
可选地，高密度热塑性层可以由传统的质量层或重质层材料制成，如EPDM、LDPE或其他填充的热塑性材料。
优选地，噪声衰减装饰部件被模制成适合于适合车辆中的专用空间所需的形状的3D形状。
根据本发明的噪声衰减装饰部件作为汽车地板、内前围、外前围、声学装饰板或行李箱盖的用途。
附图说明
图1示出了根据现有技术的汽车地毯系统(1)，其具有以下连续层(这些层没有以彼此的实际厚度关系绘制：
·由绒头(2)形成的地毯的可见表面。绒头可以是簇绒绒头(3)，由环状和/或切割构型的纱线簇绒组成。纱线被簇绒在称为第一背衬层(4)的织物中。绒头也可以是针刺型面层，其中由于可变的针刺步骤，例如叉形针和冠形针的交替步骤，模仿了簇绒绒头的外观。(未示出)
·施加到与绒头相对的表面上的背涂层或预涂层(5)。背涂层的功能是在结构内粘合纤维或长丝，和/或在簇绒绒头的情况下将簇绒粘合到主背衬上。背涂层防止拉出单根纤维、长丝和/或完整的簇绒。在大多数情况下，乳胶涂层用作背涂层，以准备表面并使得能够与下一层良好地层压。乳胶涂层旨在渗透绒头的下部区域并最终渗透主背衬层，为了获得这种效果，将泡沫或发泡乳胶(frothed or foamed latex)施加在背面。这导致乳胶不能完全覆盖表面和/或涂层不均匀。出于环境原因，包括含有乳胶的废物和报废产品的回收，乳胶是不希望的。
·另一背涂层(6)，也称为第二背涂层，用于增强绒头层的刚度和耐用性。它特别增强了绒头的耐磨性。
如此形成的地毯系统可以放置在顶部或层压到隔离质量弹簧系统上，该系统具有通常由高度填充的热塑性材料的挤出坯件形成的质量层(也称为重质层)(7)和由泡沫或毡材料制成的软去耦层(8)。
令人惊讶的是，根据本发明的粘合质量层能够代替根据图1的传统系统中由背涂层(5)、第二背衬层(6)和阻挡层(7)形成的背衬层(B)，然而保持了这些层的功能。
图2和3示出了具有根据本发明的布局的噪声衰减装饰部件。
图2示出了根据本发明的基本结构，其中绒头(2)由簇绒在主背衬(4)中的簇绒纱线(3)形成。
图3示出了根据本发明的具有针刺地毯层(9)的基本结构，其中通过叉形针和/或冠形针的交互作用，由纤维垫制成具有致密区域(9b)和模仿簇绒外观和手感的疏松顶部区域(9a)的地毯表面层。
在根据本发明的两种绒头地毯系统中，如图1所示的现有技术的预涂层、第二背衬层和阻挡层被一个单层，即粘合质量层(10)代替。令人惊讶的是，该层能够在簇绒绒头中粘合纤维或长丝和簇绒与主背衬，或者在针刺绒头层中粘合纤维，以增强地毯结构的刚度，并根据其重量在大约400g/m2以上而起到阻挡层的作用。
使用根据本发明的粘合质量层产生了能够代替3层的多用途层，从而简化现有技术的地毯结构并相应地减少生产工艺步骤。节省材料和资源。
图4示出了根据本发明的绒头地毯系统的一个优选的生产过程。通过一个或两个料斗20、21，可以将热塑性聚烯烃基树脂、填料和添加剂定量给料至单螺杆挤出机22。将材料混合、加热并熔化至优选应用温度。
如此制备的材料29在定量给料辊24和涂布辊25之间定量给料。定量给料辊使得由涂布辊拾取的粘合质量材料的均匀铺展层成为可能。
第一辊26将绒头层输送到反压辊，该反压辊将绒头层的背表面压在带有粘合材料的涂布辊上，从而将粘合质量材料转移到绒头层的表面，产生粘合载体材料到绒头层中的轻微渗透。令人惊讶的是，可以用高度填充的粘合材料产生良好的层压以及良好的均匀层。令人惊讶的是，这种简单的应用系统能够输送高达至少980g/m2的根据本发明的高填充低粘度粘合质量材料。
令人惊讶的是，在随后的步骤中模制产品之后，固化层不破碎或失去其柔性。此外，目标层在模制步骤期间不会迁移以使该层受损。
在将粘合材料施加到载体背衬上之后，第二层压辊28将背衬层输送到反压辊。将背衬层压在粘合物质的表面上，形成所有3种材料的夹层。根据产品的最终布局，背衬层可以是膜或稀松布，以便在下一步骤中部件能够背面发泡，或者它可以是毡层，最终固结。
如此形成的材料可以储存在辊上或切割成坯件。与所选择的背衬层无关，该材料可以在热转化过程中使用具有预热步骤的冷模制或热模制最终成形。
令人惊讶的是，可以用涂布辊拾取高填充载体背衬，并将该材料作为均匀层转移到纤维层上，最终厚度在可接受的公差内，并且表面没有主要缺陷如折叠或拉伸痕迹。
在背衬层是毡材料的情况下，该材料可以被模制以适合汽车的特定底板的轮廓，最终修整边缘并最终穿过用于器具的孔，形成最终的车辆底板部件。图4给出了这样的模制结构的例子。
在背衬层是泡沫的情况下，可以使用与毡相同的模制步骤来预成型绒头层结构，并且使用第二模制步骤来使泡沫背靠背衬层的背表面，以形成去耦层。背衬层可以是单层或多层的轻质稀松布层或相容的膜层。
令人惊讶的是，根据本发明的粘合质量材料能够通过简单的施加或涂覆过程来转移。然而，在固化之后，该层足够刚性以形成良好的隔音阻挡层，同时它足够柔性以被模制，并在模制成最终部件之后保持其阻隔性能。
使用这种粘合质量材料和优选的方法，现在可以用更少的步骤和相同的声学和刚度要求来制造经济的地毯结构。
图3示出了根据本发明的本发明的优选生产方法。通过一个或两个料斗20、21，可以将热塑性树脂、填料和添加剂定量给料至单螺杆挤出机。将材料混合、加热并熔化至优选应用温度。
如此制备的材料29在定量给料辊24和涂布辊25之间定量给料，定量给料辊使得由涂布辊拾取的粘合阻隔材料的均匀铺展层成为可能。
第一辊26将载体背衬输送到反压辊，该反压辊将绒头层的背表面压在带有粘合材料的涂布辊上，从而将粘合质量材料转移到绒头层的表面，产生粘合载体材料到绒头层中的轻微渗透。令人惊讶的是，可以用高度填充的粘合材料产生良好的层压以及良好的均匀层。
在将粘合材料施加到载体背衬上之后，第二层压辊28将背衬层输送到反压辊。将背衬层压在粘合阻挡层的表面上，形成所有3种材料的夹层。根据产品的最终布局，背衬层可以是膜或稀松布，以便在下一步骤中部件能够背面发泡，或者它可以是最终固结的毡层或板状泡沫层。
如此形成的材料可以储存在辊上或切割成坯件。与所选择的背衬层无关，该材料可以在热转化过程中使用具有预热步骤的冷模制或热模制最终成形。
在背衬层是毡材料的情况下，该材料可以被模制以适合汽车的特定底板的轮廓，最终修整边缘并最终穿过用于器具的孔，形成最终的车辆底板部件。图4给出了这样的模制结构的例子。
在背衬层是泡沫的情况下，可以使用与毡相同的模制步骤来预成型绒头层结构，并且使用第二模制步骤来使泡沫背靠背衬层的背表面，以形成去耦层。背衬层可以是单层或多层的轻质稀松布层或相容的膜层。
令人惊讶的是，根据本发明的粘合阻隔材料能够通过简单的施加或涂覆过程来转移。然而，在固化之后，该层足够刚性以形成良好的隔音阻挡层，同时它足够柔性以被模制，并在模制成最终部件之后保持其阻隔性能。
使用这种粘合阻隔材料和优选的方法，现在可以用更少的步骤和相同的声学和刚度要求制造经济的地毯结构。

Claims (15)

1.用于车辆的噪声衰减装饰部件，其包括绒头层、粘合质量层和背衬层，其中粘合质量层粘合到相邻层，其特征在于，粘合质量层至少包括填料含量为至少55％的热塑性弹性体聚烯烃基复合材料(TPO)，并且其中粘合质量层具有1.4至1.75kg/dm3的密度、小于50.000mPa.s的粘度和高于250的MFI，并且其中粘合质量层邻近绒头层并且部分渗透到绒头的下部区域中，从而在绒头内粘合纤维和/或长丝和/或簇绒。
2.根据权利要求1所述的用于车辆的噪声衰减装饰部件，其特征在于，所述粘合质量层进一步包括至少一种脂肪酸和任选的添加剂，并且其中惰性填料为总粘合质量层的55至70重量％，脂肪酸含量为总粘合质量层的0.2至0.8重量％。
3.根据前述权利要求中的一项所述的用于车辆的噪声衰减装饰部件，其中所述粘合质量层的面积重量在100至980g/m2之间。
4.根据前述权利要求中的一项所述的噪声衰减装饰部件，其中所述TPO由以下组成：由至少一种部分无定形聚烯烃，优选无定形聚α-烯烃APAO组成的第一组分；和由具有无规亚乙基重复分布的聚丙烯乙烯组成的、比密度小于0.87kg/dm3的第二组分。
5.根据权利要求4所述的噪声衰减装饰部件，其中所述第一组分为总粘合阻挡层的至少3重量％，且第二组分为总粘合阻挡层的至少7重量％。
6.根据权利要求5或6所述的噪声衰减装饰部件，其中所述第一组分和第二组分一起为总粘合阻挡层的10-48重量％。
7.根据权利要求2至6中的一项所述的噪声衰减装饰部件，其中所述脂肪酸至少包含具有至少14个脂肪链，优选具有16和/或18个脂肪链的脂肪酸。
8.根据前述权利要求中的一项所述的噪声衰减装饰部件，其中所述粘合阻挡层在所述部件的表面上具有恒定的面积重量。
9.根据前述权利要求中的一项所述的噪声衰减装饰部件，其中所述绒头层的面积重量在400至2000g/m2之间。
10.根据前述权利要求中的一项所述的噪声衰减装饰部件，其中所述绒头层是簇绒地毯层或针刺地毯层中的一种，所述簇绒地毯层由簇绒到主背衬层中的BCF纱线组成，所述针刺地毯层具有致密的底部区域和由基本垂直于所述表面直立的环状纤维形成的表面区域，所述环状纤维包括实心纤维、中空纤维、粘合纤维或双组分纤维中的至少一种。
11.根据前述权利要求中的一项所述的噪声衰减装饰部件，其中绒头层纤维和/或长丝和/或纱线由至少一种聚合物或共聚物制成，所述聚合物或共聚物选自：聚酯，优选PET；或聚酰胺，优选PA6或PA66；或聚烯烃，优选聚丙烯(PP)或聚乙烯(PE)；或这些聚合物和/或共聚物中的2种或更多种的混合物。
12.根据前述权利要求中的一项所述的噪声衰减装饰部件，其中所述背衬层是纤维层或泡沫层中的至少一种，所述纤维层优选为粗劣的、再循环的或回收的纤维网中的一种，所述泡沫层优选为板状泡沫或模内反应性泡沫层，优选聚氨酯泡沫。
13.根据前述权利要求中的一项所述的噪声衰减装饰部件，其进一步包括至少部分地位于所述粘合阻挡层与所述去耦层之间的至少一个附加层或补片，所述附加层或补片优选为高密度热塑性弹性体层、膜层或气流阻力为至少1000Rayl的气流阻力纤维层中的一种。
14.根据权利要求16所述的噪声衰减装饰部件，其中所述高密度热塑性弹性体层是不可渗透的并且具有800至2000g/m2的面积重量。
15.根据权利要求1至15中的一项所述的噪声衰减装饰部件作为汽车地板、内前围、外前围、声学装饰板或行李箱盖的用途。
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