CN1711058A - 用于形成吸音层系统的直接发泡背衬的方法 - Google Patents

用于形成吸音层系统的直接发泡背衬的方法 Download PDF

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CN1711058A
CN1711058A CNA200380102694XA CN200380102694A CN1711058A CN 1711058 A CN1711058 A CN 1711058A CN A200380102694X A CNA200380102694X A CN A200380102694XA CN 200380102694 A CN200380102694 A CN 200380102694A CN 1711058 A CN1711058 A CN 1711058A
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福尔克马尔·舒尔策
戴维·施皮策
斯特凡·楚梅尔
米夏埃多·博普
卡斯*·曼泰
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Hp- Shemi Pell Ce Research Development Corp
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Abstract

本发明涉及一种生产密实层—吸音层系统的方法，该系统具有热稳定性良好的隔音装置，降噪效果，尤其用于汽车的发动机室。本发明公开了用于吸音层系统的直接泡沫背衬方法，该吸音层包括泡沫层(2)或毛层(4)，其一侧或两侧带有覆盖层(3)。所述方法的特征在于：密度非常低的吸音层的密实层一侧具有不透泡沫的覆盖层(3)，吸音层安置在发泡工具中，并且在发泡成型工艺开始前，通过封闭发泡工具内与密实层相反的一侧，在吸音层中产生一定的压力。

Description

用于形成吸音层系统的直接发泡背衬的方法
技术领域
本发明涉及一种制造密实层—吸音层系统的方法，该系统具有热变形温度更高和降噪效果更强的隔音装置，尤其用于汽车发动机室。
背景技术
在汽车发动机室中采用纯吸音层，具有密实层的吸音层，弹性层—密实层系统以及振动阻尼系统，以及具有吸音能力和赫尔姆霍茨共振器(Helmholtz resonator)的热防护罩用于降低噪声。
可以参考DE198 21 532A，DE197 26 965A，DE197 34 913A，DE199 09 046A，WO02/09977，DE197 39 778A和WO01/12470以及DE299 15 429U。
现有技术已经公开了由无纺布材料和/或开孔泡沫材料制备的单层和多层吸音层，其具有或没有一厚重层，通常具有夹层结构。
目前，弹性层—密实层系统主要是通过对厚重板进行深拉延成型或挤出成型而形成，所述厚重板具有由聚氨酯(PUR)柔性泡沫以及高度填充泡沫材料(通过反应注射成型即RIM制备的紧实聚胺酯泡沫)构成的泡沫背衬。通过在PUR柔性泡沫的表面涂覆一层塑料薄膜或喷雾薄膜剂，或者通过模内涂层可以增加其抗介质性能。
通常，具有密实层的吸音层系统包括无纺布材料或者高膨胀率冲切泡沫以及厚重板，所述泡沫经常与表面覆盖有无纺布覆层或传声板的三聚氢胺树脂泡沫结合。无纺布材料和泡沫本身又可以具有多层结构。厚重板主要是共聚物板，高度填充(致密的RIM材料或)泡沫材料，或者是注射成型部件。
该制备方法包括以下步骤：
—模压成型所述吸音层；
—制备厚重板或密实层(深拉，挤出，反应注射成型(RIM)发泡成型，注射成型)
—连接吸音层和密实层；以及
—冲切成型。
也已经知道以一步工艺或两步工艺模压吸音层和柔性厚重板的方法。
但是，目前，吸音层和密实层主要通过粘接剂接合，夹紧或焊接方法连接在一起。
粘接剂接合包括局部或整个表面涂覆粘接剂。这一方面需要清洁密实层板，例如通过清洗或喷沙，从而使密实层板和吸音层之间具有足够好的粘接面，另一方面，其需要将吸音层和密实层粘接在一起的辅助工艺步骤。实际上，经常发现粘接不牢靠的情况。而且，粘接剂粘接是很繁琐的方法，残留粘接剂经常会污染装置，工具以及工作场所。
也可以作为辅助工艺步骤的夹紧和焊接是局部进行的，因此经常不能保证密实层—吸音层系统的尺寸以及隔音功能。当开动汽车时，夹紧系统由于各层之间的气流而导致不期望的噪声，并且夹紧和焊接系统会使吸音层和厚重板产生破损并使破损扩大。
另外，由于焊接需要昂贵的设备而使焊接的成本非常高，并且不是所有的材料都适合用焊接(以满足功能要求的方式)来结合。
另外，还已经知道：具有热塑性和热固性粘接剂的无纺布材料(优选是棉混纤维无纺布)以夹层结构配备有通过喷雾、刀涂法(knife-coating)，挤出或涂膜法涂覆的阻挡(厚)层。
另外，由现有技术已知，带热塑性和热固性粘接剂的模压成型的无纺布材料由于本身具有很高的强度(压缩强度)，因此可以直接加泡沫背衬，从而使吸音层结构不容易被压力损坏，或者根本不会被压力损坏。
在具有多层结构以及包括一或多层覆盖层，支承层以及吸音层的吸音层的(热)模压成型中，由现有技术已知，在模压成型过程中，通过压缩空气管将压缩空气引入模具，其目的是更好地进行模具填充，在各层之间的可靠连接(positive connection)，以及完全的固化。而且，可以通过在各层之间，尤其是各吸音层之间涂覆(气密性)隔层或阻挡板/层而改善声音效果，见DE197 34 913A。
目前尚不能制作出具有泡沫材料、尤其是高度填充致密层、可选具有微细胞、RIM材料或泡沫材料的高膨胀率泡沫吸音层的直接泡沫背衬，这是由于在发泡模具内建立的压力压坏或损坏高膨胀率泡沫(吸音层)结构，因而不能达到吸音层的吸音效率、尺寸以及功能。另外，根据声音和结构确定的密实层的厚度容许误差不能够保持。
另外，在打开模具中发泡成型，也就是说，将吸音层插入到发泡模具中，在吸音层上自由发泡以及随后关闭模具是不能实现的，这是因为，由于相互作用(热流变动力学)和相关泡沫的流动性，用泡沫填充轮廓是不可靠的，因此不能使用带密实层的吸音系统。
另外，带高度填充PUR致密层的系统由于存在非常严重的磨损，其喷雾涂覆不能大批量的实现，或者说存在很大的问题。这需要对装置和工具进行不断的维修，成本很高。另外，由于喷雾涂覆，因此不能以适合于加工过程的方式来检测需要检测的预定的密实层厚度容许公差。
发明内容
本发明的一个目的是提供一种可应用于工业并且能够实现带高度填充(致密的聚亚氨酯)泡沫材料的(高膨胀率)泡沫吸音层或无纺布吸音层的直接泡沫背衬。
根据本发明的目的通过下述方法实现：通过在密实层一侧为吸音层的表层涂覆不透泡沫的无纺布材料或不透泡沫的塑料片，不具有或具有传音装置以及因此在与密实层相反的一侧上具有气体可通过的无纺布材料，在发泡模具中定位所述吸音层，关闭发泡模具，并通过气体可通过的无纺布材料或直接对吸音层施以压缩空气，然后开始发泡成型工艺。
下面将以汽车的发动机室中使用的典型的密实层—吸音层系统为例说明本发明的工艺。
根据本发明的工艺能够克服现有技术中密实层和吸音层接合/连接选择所存在的缺陷，能够改进制备方法和功能，并且能够免除连接这一工艺步骤。
因此，本发明的第一实施例涉及一种用于吸音层系统的直接泡沫背衬的工艺，其中，吸音层包括一泡沫层或无纺布层，在其一侧或两侧带有一覆盖层，其特征在于，具有非常低的密度的吸音层在密实层一侧具有不透泡沫的覆盖层，将所述吸音层置于发泡模具内，并且在发泡成型工艺开始前，在封闭发泡模具中，从与所述密实层相反的一侧在吸音层内建立压力。
在另一实施例中，本方法的特征在于：气体状态下的介质，尤其是(压缩)气体，被用作施压介质，以及，在吸音层内利用气体状态下的介质建立从0.5巴-7巴的压力，尤其是1巴-3巴的压力。
根据一个优选实施例，采用无纺布材料或塑料板作为密实层一侧的不透泡沫的覆盖层。
在又一实施例中，采用泡沫密度在5kg/m3到38kg/m3范围内的开孔泡沫或混合胞粒(mixed-cell)泡沫作为吸音层。
优选地，根据又一实施例，采用密度在35kg/m3到190kg/m3范围内的发泡成型的冷泡沫(foam-molded cold foam)作为吸音层。并且，在密实层一侧，这些吸音层具有不透泡沫的覆盖层。
在又一实施例中，采用在密实层一侧具有不透泡沫的覆盖层的非压缩无纺布材料作为吸音层。
在泡沫背衬工艺之前在吸音层内建立的压力被控制和/或者调节，例如通过阀。
在泡沫背衬方法之前在吸音层内建立的压力，在整个发泡成型工艺过程中通过阀确定、控制和调节。
在又一实施例中，本方法的特征在于，在泡沫背衬方法之前在吸音层内建立的压力，在整个发泡成型工艺过程中可以被控制，并且其通过与密实层相反的发泡模具部件的部分结构，在发泡模具中从与密实层相反一侧进行局部具有不同强度的控制和调节。
本发明的又一实施例包括一吸音层系统，其中，所述吸音层包括在一侧或两侧具有覆盖层的一泡沫层或无纺布层以及一泡沫层。
优选地，根据本发明，发泡模具应该具有在模具上表面上方100mm处的气体喷嘴，其直接朝向与所述密实层相反的吸音层表面，并且当发泡模具关闭时，所述吸音层应该通过气体可通过无纺布或直接被施加2巴的气体压力。
根据所述吸音层的构成与结构，可以通过发泡模具中的气体喷嘴装置以及施加的气体压力对所述吸音层的变形稳定性进行调节。
附图说明
图1示出作为带密实层的吸音层系统的外传输通道1的隔音装置，其中，高膨胀率泡沫吸音层2在密实层一侧的表层涂覆有不透泡沫的无纺布3，在与密实层相反的一侧表面涂覆有气体可通过的无纺布4。根据本发明的工艺，吸音层可以用高度填充(致密的RIM)泡沫5直接作为泡沫背衬。
具体实施方式
可根据本发明的工艺制备的密实层吸音系统，尤其是优选的隔音装置是外管道，发动机室的前壁以及机组室的前壁。
实施例：
高膨胀率泡沫吸音层通过模压成型方法制备，其具有材料结构：不透泡沫的无纺布(在密实层一侧)Azetin GPV MH 50/45 PE，泡沫密度为12kg/m3，厚度为18mm的高膨胀率泡沫，气体可通过的无纺布(与密实层相反的一侧)Coatilphoob Z21PE。
这种吸音层被插入到发泡(泡沫背衬)模具中，然后模具关闭。通过配备有空气喷嘴的冲模，吸音层具有压缩空气通过气体可通过的无纺布。然后，利用通过商业途径可得到的致密的(RIM)泡沫开始发泡成型工艺。在发泡成型工艺完成后，冲裁出形状。
带直接背衬的吸音层：
在表面上的带直接背衬的密实层的厚度为3.0±0.5mm。密实层和吸音层之间的接合非常牢固。如果要将密实层和吸音层分开，只能破坏吸音层。因此，能够获得密实层—吸音层系统的尺寸和功能。

Claims (12)

1.一种用于形成吸音层系统的直接泡沫背衬的方法，其中，吸音层包括一泡沫层或无纺布层，在其一侧或两侧带有一覆盖层，其特征在于，具有非常低的密度的吸音层在密实层一侧具有不透泡沫的覆盖层，将所述吸音层置于发泡模具内，并且在发泡成型工艺开始前，在封闭的发泡模具中，从与所述密实层相反的一侧在吸音层内建立压力。
2.根据权利要求1所述的方法，其特征在于，气体状态下的介质，尤其是(压缩)气体，被用作施压介质。
3.根据权利要求1或2所述的方法，其特征在于，在吸音层内利用气体状态下的介质建立从0.5巴-7巴的压力，尤其是1巴-3巴的压力。
4.根据权利要求1-3中任一所述的方法，其特征在于，采用无纺布材料或塑料板作为密实层一侧的不透泡沫的覆盖层。
5.根据权利要求1-4中任一所述的方法，其特征在于，采用泡沫密度在5kg/m3到38kg/m3范围内的开孔泡沫或混合胞粒泡沫作为吸音层。
6.根据权利要求1-5中任一所述的方法，其特征在于，采用在厚重层一侧具有不透泡沫的覆盖层的发泡成型的冷泡沫作为吸音层。
7.根据权利要求6所述的方法，其特征在于，采用密度在35kg/m3到190kg/m3范围内的发泡成型的冷泡沫作为吸音层。
8.根据权利要求1-7中任一所述的方法，其特征在于，采用在密实层一侧具有不透泡沫的覆盖层的非压缩无纺布材料作为吸音层。
9.根据权利要求1-8中任一所述的方法，其特征在于，在泡沫背衬工艺之前在吸音层内建立的压力被阀控制和/或者调节。
10.根据权利要求1-9中任一所述的方法，其特征在于，在泡沫背衬方法之前在吸音层内建立的压力，在整个发泡成型工艺过程中通过阀确定、控制和调节。
11.根据权利要求1-10中任一所述的方法，其特征在于，在泡沫背衬方法之前在吸音层内建立的压力，在整个发泡成型工艺过程中可以被控制，并且其通过与密实层相反的发泡模具部件的部分结构，在发泡模具中从与密实层相反一侧进行局部具有不同强度的控制和调节。
12.一种吸音层系统，其中，所述吸音层包括在一侧或两侧具有覆盖层的一泡沫层或无纺布层，以及可根据权利要求1-11所述的方法获得的一泡沫层。
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