CN117734084A - Integrated forming production process of carpet and sound insulation pad - Google Patents
Integrated forming production process of carpet and sound insulation pad Download PDFInfo
- Publication number
- CN117734084A CN117734084A CN202410094570.5A CN202410094570A CN117734084A CN 117734084 A CN117734084 A CN 117734084A CN 202410094570 A CN202410094570 A CN 202410094570A CN 117734084 A CN117734084 A CN 117734084A
- Authority
- CN
- China
- Prior art keywords
- carpet
- sound insulation
- die
- pad
- forming
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000009413 insulation Methods 0.000 title claims abstract description 81
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 24
- 239000002994 raw material Substances 0.000 claims abstract description 31
- 239000000463 material Substances 0.000 claims abstract description 26
- 238000004080 punching Methods 0.000 claims abstract description 26
- 238000003825 pressing Methods 0.000 claims abstract description 22
- 238000001816 cooling Methods 0.000 claims abstract description 20
- 238000010438 heat treatment Methods 0.000 claims abstract description 16
- 238000000034 method Methods 0.000 claims abstract description 14
- 238000007493 shaping process Methods 0.000 claims abstract description 7
- 238000003892 spreading Methods 0.000 claims abstract description 3
- 230000007480 spreading Effects 0.000 claims abstract description 3
- 230000008569 process Effects 0.000 claims description 11
- 239000000835 fiber Substances 0.000 claims description 6
- 238000009987 spinning Methods 0.000 claims description 6
- 239000002699 waste material Substances 0.000 claims description 6
- 238000005520 cutting process Methods 0.000 description 7
- 238000004026 adhesive bonding Methods 0.000 description 4
- 238000010025 steaming Methods 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000007723 die pressing method Methods 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 230000036541 health Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
Landscapes
- Carpets (AREA)
Abstract
The invention belongs to the technical field of automobile equipment, in particular to a production process for integrally forming a carpet and a sound insulation pad, which comprises the following steps: preparing carpet and sound insulation pad raw materials meeting requirements; steam heating and forming; firstly, feeding a blank material of the sound insulation pad into a female die of a hot steam forming die, spreading a tufted carpet of a carpet raw material upwards on the blank material, pressing the male die to the female die, and integrally pressing and maintaining the sound insulation pad blank material and the carpet raw material; cooling, shaping and punching; transferring the formed carpet sound insulation integrated pad from the hot steam forming die to a cooling punching die, confirming that the carpet sound insulation integrated pad is completely attached to the die, and then pressing a descending button until the press begins to maintain pressure; and (5) taking the total finished product off line and checking. The production line can be saved, multiple procedures are omitted, the environment-friendly performance in the vehicle is improved, the weight of the carpet product is reduced, and the light design requirement of the whole vehicle is met.
Description
Technical Field
The invention belongs to the technical field of automobile equipment, and particularly relates to a production process for integrally forming a carpet and a sound insulation pad.
Background
The automobile carpet is generally arranged at the bottom of the automobile, and plays roles in absorbing sound, insulating sound and enhancing pedal comfort. In modern automobiles, carpets are installed on the inner bottom wall of the automobile for attractive appearance and convenient cleaning and maintenance, the automobile carpets generally consist of carpets and carpet sound insulation pads, and some automobile carpets and automobile carpet sound insulation pads are separately supplied and paved together during the whole automobile installation, but the assembly mode increases the subsequent process difficulty of the total assembly line, and the two products have the problem of size matching.
In order to solve the problem, the carpet and the carpet sound insulation pad are assembled together before being paved, and then are paved, but most manufacturers bond the carpet and the sound insulation pad by using glue when the carpet and the carpet sound insulation pad are assembled in advance, and then re-press the tooling after bonding, so that the process is high in cost, and the bonded carpet has peculiar smell and more harmful components in peculiar smell gas, so that the health of a human body can be endangered. Meanwhile, the existing automobile carpet is large in weight and cannot meet the light-weight design requirement of the whole automobile.
Moreover, the present invention has been made in view of the above circumstances before assembly.
Disclosure of Invention
The invention provides a production process for integrally forming a carpet and a sound insulation pad, which can save production lines, omit a plurality of working procedures, improve environment-friendly performance in a vehicle, reduce the weight of a carpet product and meet the light design requirement of the whole vehicle.
The basic conception of the technical scheme adopted by the invention is as follows:
a production process for integrally forming a carpet and a sound insulation pad comprises the following steps:
step one, preparing carpet and soundproof pad raw materials meeting the requirements;
the carpet raw material is tufted carpet surface; the raw material of the sound insulation pad is waste spinning and bonding fiber;
step two, steam heating and forming;
firstly, feeding a blank material of the sound insulation pad into a female die of a hot steam forming die, spreading a tufted carpet surface of a carpet raw material on a blank material, pressing the male die to the female die, and integrally pressing and maintaining the sound insulation pad blank material and the carpet raw material;
step three, cooling, shaping and punching;
transferring the formed carpet sound insulation integrated pad from the hot steam forming die to a cooling and punching die, confirming that the carpet sound insulation integrated pad is completely attached to the die, and then pressing a descending button until the press begins to keep pressure and punching;
and fourthly, offline and checking the assembly product.
As an optimal technical scheme, the steam heating temperature of the medium-heat steam forming die in the second step is 150+/-10 ℃; the pressure of the press is 17+/-2 Mpa; the dwell time is 60+/-2 s; the steam input time was 40s.
As a preferable technical scheme, the pressure of the press for cooling the punching die in the third step is 18+/-2 Mpa; the dwell time is 20+/-2 s; the mold temperature is less than or equal to 40 ℃.
Compared with the prior art, the invention has the following beneficial effects:
1. the invention changes the prior art of respectively forming and cutting carpets and sound insulation mats into the prior art of simultaneously using the production line of the original sound insulation mats for one-step forming and cutting, and compared with the prior art, the invention saves one production line, and specifically comprises the following steps: two hydraulic presses are saved, one mould or one oven for independently heating carpets is saved, and one carpet water cutting device is saved; the procedures of heating raw materials of the carpet, cold mould pressing and forming, water cutting and gluing the carpet and the sound insulation pad are reduced; the equipment and manpower cost is reduced;
2. the production period of the integrated forming of a set of carpet and the sound insulation pad is far lower than the period of the original production and re-gluing of the carpet and the sound insulation pad respectively;
3. the carpet and the sound insulation pad are integrally formed into a component, so that the carpet is more compact than the original carpet and the sound insulation pad, and the problem of size matching of two products is solved;
4. the carpet and the sound insulation pad are combined together, and the sound insulation pad can play a part of supporting role, so that the carpet and the sound insulation pad assembly have better strength and supporting stability on the premise of the same weight; if necessary, the inner supporting framework of the carpet can be omitted, or the materials of the carpet and the sound insulation pad can be properly reduced;
5. the carpet and the sound insulation pad are integrally formed, so that the use requirement of a customer can be completely met, the gluing process is omitted, and the carpet and the sound insulation pad are more environment-friendly.
The following describes the embodiments of the present invention in further detail with reference to the accompanying drawings.
Drawings
FIG. 1 is a process flow diagram of a prior art process for producing carpet and acoustic insulation mat, respectively, using two production lines;
FIG. 2 is a process flow diagram of the present invention for producing carpet acoustical insulation integrated mats using a single manufacturing line.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions in the embodiments will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and the following embodiments are used to illustrate the present invention.
Example 1
A production process for integrally forming a carpet and a sound insulation pad specifically comprises the following steps:
step one, preparing raw materials of carpets and sound insulation mats;
firstly, preparing carpet raw materials (tufted carpet surfaces) meeting customer requirements;
secondly, preparing a sound insulation pad blank material (waste spinning and bonding fibers) meeting the requirements of customers;
the carpet material and the sound insulation mat blank material are of the prior art and will not be described in detail herein.
Step two, steam heating and forming;
according to the requirement that a piece of sound insulation pad is provided with a piece of carpet, firstly, a blank material of the sound insulation pad is sent into a female die of a hot steam forming die through a feeding robot, a carpet raw material cluster blanket is flatly laid on the blank material upwards, an operator operates a press to enable a male die to be pressed down to the female die, and the blank material of the sound insulation pad and the carpet raw material are integrally pressed and maintained;
the heating temperature of steam in the die is 160 ℃;
the pressure of the press is 19Mpa; dwell time is 62s; the steam input time is 40s;
step three, cooling, shaping and punching;
after the steaming and pressing is finished, transferring the formed carpet sound insulation integrated pad from the steam die to a cooling punching die, confirming that the carpet sound insulation integrated pad is completely attached to the cooling punching die, and then pressing a down button until the pressing machine starts to keep pressure and punching;
the pressure of the press is 20Mpa; dwell time is 22s; the mold temperature is less than or equal to 40 ℃.
And fourthly, offline and checking the assembly product.
Example 2
A production process for integrally forming a carpet and a sound insulation pad specifically comprises the following steps:
step one, preparing raw materials of carpets and sound insulation mats;
firstly, preparing a carpet raw material tufted carpet surface;
secondly, preparing waste spinning and bonding fibers for manufacturing the sound insulation pad blank;
step two, steam heating and forming;
according to the requirement that a piece of sound insulation pad is provided with a piece of carpet, firstly, a blank material of the sound insulation pad is sent into a female die of a hot steam forming die through a feeding robot, a carpet raw material cluster blanket is flatly laid on the blank material upwards, an operator operates a press to enable a male die to be pressed down to the female die, and the blank material of the sound insulation pad and the carpet raw material are integrally pressed and maintained;
the heating temperature of steam in the die is 150 ℃;
the pressure of the press is 17Mpa; dwell time is 60s; steam input time 40s
Step three, cooling, shaping and punching;
after the steaming and pressing is finished, transferring the formed carpet sound insulation integrated pad from the steam die to a cooling punching die, confirming that the carpet sound insulation integrated pad is completely attached to the cooling punching die, and then pressing a down button until the pressing machine starts to keep pressure and punching;
the pressure of the press is 18Mpa; the dwell time is 20s; the mold temperature is less than or equal to 40 ℃.
And fourthly, offline and checking the assembly product.
Example 3
A production process for integrally forming a carpet and a sound insulation pad specifically comprises the following steps:
step one, preparing raw materials of carpets and sound insulation mats;
firstly, preparing a carpet raw material tufted carpet surface;
secondly, preparing waste spinning and bonding fibers for manufacturing the sound insulation pad blank;
step two, steam heating and forming;
according to the requirement that a piece of sound insulation pad is provided with a piece of carpet, firstly, a blank material of the sound insulation pad is sent into a female die of a hot steam forming die through a feeding robot, a carpet raw material cluster blanket is flatly laid on the blank material upwards, an operator operates a press to enable a male die to be pressed down to the female die, and the blank material of the sound insulation pad and the carpet raw material are integrally pressed and maintained;
the heating temperature of steam in the die is 140 ℃;
the pressure of the press is 15Mpa; dwell time is 58s; steam input time 40s
Step three, cooling, shaping and punching;
after the steaming and pressing is finished, transferring the formed carpet sound insulation integrated pad from the steam die to a cooling punching die, confirming that the carpet sound insulation integrated pad is completely attached to the cooling punching die, and then pressing a down button until the pressing machine starts to keep pressure and punching;
the pressure of the press is 16Mpa; dwell time is 18s; the mold temperature is less than or equal to 40 ℃.
And fourthly, offline and checking the assembly product.
Comparative example
A production process for integrally forming a carpet and a sound insulation pad specifically comprises the following steps:
step one, preparing raw materials of carpets and sound insulation mats;
firstly, preparing carpet raw materials (tufted carpet surfaces) meeting customer requirements;
secondly, preparing a sound insulation pad blank material (waste spinning and bonding fibers) meeting the requirements of customers;
step two, steam heating and forming;
according to the requirement that a piece of sound insulation pad is provided with a piece of carpet, firstly, a blank material of the sound insulation pad is sent into a female die of a hot steam forming die through a feeding robot, a carpet raw material cluster blanket is flatly laid on the blank material upwards, an operator operates a press to enable a male die to be pressed down to the female die, and the blank material of the sound insulation pad and the carpet raw material are integrally pressed and maintained;
the heating temperature of steam in the die is 150 ℃;
the pressure of the press is 17Mpa; the dwell time is 20s; steam input time 15s
Step three, cooling, shaping and punching;
after the steaming and pressing is finished, transferring the formed carpet sound insulation integrated pad from the steam die to a cooling punching die, confirming that the carpet sound insulation integrated pad is completely attached to the cooling punching die, and then pressing a down button until the pressing machine starts to keep pressure and punching;
the pressure of the press is 18Mpa; the dwell time is 20s; the mold temperature is less than or equal to 40 ℃.
And fourthly, offline and checking the assembly product.
The process parameters of step two are verified by examples and comparative examples as follows:
as shown in fig. 1, two production lines are used in the prior art to mold and cut carpet and acoustic mat, respectively; in fig. 2, the production line of the original sound insulation pad can be used for simultaneously forming and cutting the carpet and the sound insulation pad, so that the cost is reduced, one production line is saved, and the process can be used for reducing the raw material heating, cold die pressing forming, water cutting and gluing processes of the carpet and the sound insulation pad; compared with the prior art, the invention saves two hydraulic presses, and independently heats one mould or oven 1 for the carpet, one carpet water cutting device and reduces the labor cost by more than half; the carpet sound insulation integrated pad can completely meet the use requirements of customers, and is more environment-friendly.
While the invention has been described in detail in the foregoing general description and specific examples, it will be apparent to those skilled in the art that modifications and improvements can be made thereto. Accordingly, such modifications or improvements may be made without departing from the spirit of the invention and are intended to be within the scope of the invention as claimed.
Claims (3)
1. The integrated forming production process of the carpet and the sound insulation pad is characterized by comprising the following steps of:
step one, preparing carpet and soundproof pad raw materials meeting the requirements;
the carpet raw material is tufted carpet surface; the raw material of the sound insulation pad is waste spinning and bonding fiber;
step two, steam heating and forming;
firstly, feeding a blank material of the sound insulation pad into a female die of a hot steam forming die, spreading a tufted carpet surface of a carpet raw material on a blank material, pressing the male die to the female die, and integrally pressing and maintaining the sound insulation pad blank material and the carpet raw material;
step three, cooling, shaping and punching;
transferring the formed carpet sound insulation integrated pad from the hot steam forming die to a cooling and punching die, confirming that the carpet sound insulation integrated pad is completely attached to the die, and then pressing a descending button until the press begins to keep pressure and punching;
and fourthly, offline and checking the assembly product.
2. The process for integrally forming a carpet and a sound insulation mat according to claim 1, wherein the steam heating temperature of the hot steam forming die in the second step is 150+ -10deg.C; the pressure of the press is 17+/-2 Mpa; the dwell time is 60+/-2 s; the steam input time was 40s.
3. The process for integrally forming a carpet and a sound insulation mat according to claim 1 or 2, wherein the press pressure of the cooling and punching die in the third step is 18±2Mpa; the dwell time is 20+/-2 s; the mold temperature is less than or equal to 40 ℃.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202410094570.5A CN117734084A (en) | 2024-01-23 | 2024-01-23 | Integrated forming production process of carpet and sound insulation pad |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202410094570.5A CN117734084A (en) | 2024-01-23 | 2024-01-23 | Integrated forming production process of carpet and sound insulation pad |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN117734084A true CN117734084A (en) | 2024-03-22 |
Family
ID=90277969
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202410094570.5A Pending CN117734084A (en) | 2024-01-23 | 2024-01-23 | Integrated forming production process of carpet and sound insulation pad |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN117734084A (en) |
-
2024
- 2024-01-23 CN CN202410094570.5A patent/CN117734084A/en active Pending
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US4378265A (en) | Process for producing molded parts from flat tangled fleece mats | |
| CN201856381U (en) | Compression molding die for prepreg | |
| CN101612788B (en) | Method for producing sound-heat insulated cushion of automobile | |
| JP4051396B1 (en) | Molding method for textile decorative resin products | |
| CN102795087B (en) | Production method of automobile ceiling | |
| CN105291372A (en) | Hot pressing injection mold and processing technology for integrally molding fibrilia plate and surface layer | |
| CN101088742A (en) | Automobile ceiling and its production process | |
| CN111204294B (en) | Integrally formed automobile EPP ceiling and preparation method thereof | |
| CN100569559C (en) | A kind of production method of vehicular coat and hat rack | |
| CN102765159B (en) | Composite forming device for making interior trim panel of automobile | |
| CN103240890A (en) | Method for preparing noise reduction felt for automobile | |
| CN104908674A (en) | In-vehicle cladding piece and forming method thereof | |
| CN117734084A (en) | Integrated forming production process of carpet and sound insulation pad | |
| CN112757663A (en) | Automatic filament-laying forming method for continuous fiber reinforced thermoplastic composite material | |
| CN103481837B (en) | Adopt thermal insulation material design vehicle ceiling skylight or front and back along the production technology of flange | |
| CN207128172U (en) | Polyurethane foam mould | |
| CN107554036A (en) | The production technology of Wet One-step ceiling flange | |
| CN110303693A (en) | A kind of compression-moulding methods of small-sized aerofoil Composite Sandwich part | |
| CN202863297U (en) | Automobile B pillar trim panel member | |
| CN2738987Y (en) | Glass-fiber felt reinforced thermal-plastic plastic sheet pressing mould | |
| CN110641036A (en) | Preparation method of insert type integrated hot-press forming non-woven fabric | |
| CN108001019A (en) | A kind of car carpeting hot-press molding method | |
| CN101024299B (en) | Method for making same material to form different density parts | |
| KR100243809B1 (en) | Production of glass fiber reform | |
| CN210062052U (en) | Heat preservation adhesive pressing machine |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination |