JP4119006B2 - Thermal insulation and sound insulation cover - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a heat-insulating and sound-insulating cover that thermally covers high-temperature equipment such as an engine exhaust manifold, a turbocharger, or an exhaust manifold communication pipe of a V-type engine.
[0002]
[Prior art]
As an example of the heat insulating and sound insulating cover, FIG. 9 shows a perspective view of the exhaust manifold 100 of the engine and the cover 101 that covers the heat insulating cover. The cover 101 is attached to the exhaust manifold by an appropriate number of bolts 102, but is attached so as to leave an appropriate gap between the exhaust manifold and the main body of the cover. In FIG. 9, only one mounting bolt 102 is shown, and the others are not shown.
[0003]
Such a cover is required to have a performance of insulating the noise of the engine or the like while simultaneously covering the high-temperature equipment such as the exhaust manifold in a heat-shielding manner. A cover formed by overlapping one steel plate or two steel plates on such a cover and covering the high-temperature equipment part may be used. However, since the sound insulation effect is insufficient, two sheets are used. A heat insulating and sound insulating cover having a structure in which a sound absorbing material layer is sandwiched between steel plates is often used.
[0004]
[Problems to be solved by the invention]
The heat insulating and sound insulating cover in which the sound absorbing material layer is sandwiched between the two steel plates mentioned above, after the two steel plates and the sound absorbing material layer are respectively formed by drawing into a cover shape. Alternatively, after the two steel plates and the sound-absorbing material layer are overlapped and formed into a cover shape by drawing, the peripheral portion is cut into a predetermined shape, and then the peripheral portions of the two steel plates are They are joined by spot welding or by partial folding.
[0005]
Conventionally, as described above, the peripheral edge of the cover is cut after the steel plate and the sound absorbing material are overlapped and formed into a cover shape, so that the sound absorbing material layer is not clogged in the peripheral edge of the cover. Usually, there is a portion, and the area of the missing portion varies in various ways. For this reason, the sound insulation effect of a cover falls and there exists a difficulty that the dispersion | variation in the sound insulation effect for every product becomes large.
[0006]
Moreover, since the peripheral portions of the inner and outer two-layer steel plates are merely joined by spot welding or partial folding, the sound-absorbing material layer moves due to vibrations transmitted from the high-temperature equipment or the like or by thermal expansion and contraction, There is a problem in that the function is lost or damaged due to the fact that it protrudes from the peripheral edge of the glass and further breaks off and falls off.
[0007]
In order to solve the above problems, the inventor cut the inner and outer two flat steel plates and the sound-absorbing material layer in advance into the required plane shape, and after superposing them, the peripheral edge of one steel plate is attached to the other. A folded portion folded back on the other steel plate so as to wrap around the peripheral edge of the steel plate is formed over almost the entire peripheral edge, and the two steel plates and the sound-absorbing material layer are joined together, and then this is drawn. It was considered to form into a cover shape.
[0008]
However, since the sandwich-like flat plate in which almost the entire peripheral portion is integrally joined by the folded portion is formed into a three-dimensional cover shape, the sandwiched sound absorbing material is difficult to extend, so the elongation at the time of molding is large. It has been found that not only is it difficult to form a curved portion with a small radius of curvature, it is difficult to ensure the shape, but the sound absorbing material is liable to break during molding.
[0009]
The present invention solves the above-mentioned problem, and consists of two layers of inner and outer metal plates and a sound-absorbing material layer sandwiched between them, and in a heat-insulating and sound-insulating cover formed into a shape covering a high-temperature device part, The sound absorbing material is filled to the corners of the cover without any missing parts, so that sound insulation is good, the sound absorbing material layer does not move or protrude during use, and a curved part with a small radius of curvature is formed. The present invention provides an improved heat-insulating and sound-insulating cover that is easy and does not cause breakage of the sound-absorbing material, and a method for manufacturing the same.
[0010]
[Means for Solving the Problems]
The heat-insulating and sound-insulating cover of the present invention that solves the above problems comprises a two-layer surface plate made of a metal plate and a sound-absorbing material layer sandwiched between the surface plates, and each surface plate and the sound-absorbing material layer are required respectively. And a folded portion formed by laminating the peripheral portion of one surface plate over the other surface plate so as to wrap the sound absorbing material layer and the peripheral portion of the other surface plate over almost the entire peripheral portion. A cover formed by drawing a laminated flat plate having a shape that covers a high-temperature device such as an engine exhaust manifold, and the cover is bent in a curved portion having a small radius of curvature at or near the curved portion. It is characterized by having a folded portion.
[0011]
In addition, the manufacturing method of the heat-insulating and sound-insulating cover according to the present invention includes forming inner and outer two-layer surface plates made of metal plates and a sound-absorbing material layer sandwiched between the surface plates into a required planar shape, and laminating Then, the peripheral portion of one surface plate is folded back on the other surface plate so as to wrap the peripheral portion of the sound absorbing material layer and the other surface plate over almost the entire peripheral portion of the laminated plate, and is smaller than that of drawing forming described later. A laminated molded flat plate is formed by forming a pair of folding beads extending substantially in parallel with each other at a folding width or inclining to each other at or near a portion to be molded into a curved portion having a radius of curvature. Later, when the laminated flat plate is formed into a cover shape that covers the high-temperature equipment portion by heat-shielding, the laminated flat plates are folded in opposite directions at the pair of folding beads. It is characterized in that to form a folded portion which is folded double.
[0012]
In the present invention, as described above, the two surface plates and the sound-absorbing material layer sandwiched between them are each molded into a predetermined planar shape and laminated to form a folded portion over almost the entire peripheral edge of the laminated plate. Since the laminated molded flat plate is formed in the shape of the cover, the sound absorbing material is clogged up to every corner of the peripheral portion of the cover, and there is no missing filling portion of the sound absorbing material. Therefore, the sound insulation characteristics are not impaired, and the variation in the sound insulation characteristics from product to product is small.
[0013]
Further, in the heat-insulating and sound-insulating cover of the present invention, a folded portion is formed by folding the peripheral portion of one surface plate so as to wrap the peripheral portion of the sound absorbing material layer and the other surface plate over almost the entire peripheral portion of the cover. Since the peripheral edge of the cover is sealed, and the sound absorbing material layer is filled to every corner of the peripheral edge of the cover as described above, the sound absorbing material layer moves due to vibration or thermal expansion / contraction, It does not protrude from the peripheral edge of the cover. Therefore, there is less damage during use than the conventional heat insulating and sound insulating covers, and the durability is excellent.
[0014]
The heat-insulating and sound-insulating cover of the present invention has a bent portion with a small radius of curvature or a fold portion in the vicinity thereof, and when the laminated flat plate is formed into a cover shape covering the high temperature equipment portion, the bent portion with a small radius of curvature is mainly used. Since it is formed by narrowing down by forming the folded portion, it is possible to reduce the extension of the laminated molded flat plate at the time of forming the curved portion. Therefore, the curved portion can be easily formed without difficulty, and the hard-to-extend sound absorbing material layer sandwiched between the surface plates is not broken.
[0015]
DETAILED DESCRIPTION OF THE INVENTION
Details and embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a perspective view of a main part of a heat insulating and sound insulating cover according to an embodiment of the present invention, FIG. 2 is an enlarged sectional view taken along line AA in FIG. 1, and FIG. It is an expanded sectional view by a line. As shown in FIGS. 1 to 3, a heat-insulating and sound-insulating cover 1 according to the present invention is formed by laminating inner and outer two metal plates 2 and 3 and a sound-absorbing material layer 4 sandwiched between them. No. 1 is formed in a cover shape that covers a high-temperature device such as an exhaust manifold of an engine in a heat-shielding manner with a gap of an appropriate interval.
[0016]
The cover 1 is folded back on the surface plate 3 so that the periphery 21 of the outer surface plate 2 is wrapped around the periphery 41 of the sound absorbing material layer 4 and the periphery 31 of the inner surface plate 3 over almost the entire periphery. Part 5 is provided. In addition, the cover 1 is formed with a hook-like portion 7 having a peripheral edge that is widened outwardly. The flange 7 is formed to reinforce the rigidity of the cover, but it can be omitted. The bent portion 6 in which the laminated plate is folded twice in the bending direction is formed in the bent portion C having a small curvature radius of the cover 1, and the bending in the bent portion C is mainly formed by narrowing down along with the formation of the folded portion. ing. Details thereof will be described later. Reference numeral 61 denotes a fold line of the fold portion that appears on the outer surface of the cover 1.
[0017]
The surface plates 2 and 3 are formed of a metal plate having moderate strength and rigidity, which does not generate rust or has been subjected to a rust prevention treatment, and preferably has a thickness of 0.20 to 0.55 mm, a rust prevention steel plate and an aluminum coating. It is formed of a steel plate, a stainless steel plate or the like. For the sound absorbing material layer sandwiched between the surface plates 2 and 3, glass wool, ceramic wool sheet or mat, for example, trade name glass mat GE T / 4517, silica mat T / # 4518 manufactured by NICHIAS CORPORATION, Toshiba Monoflux A trade name Zimara Blanket # 130 manufactured by Co., Ltd. or a sheet formed with inorganic or organic fibers, a filler and a binder, such as a product name Vermosal T / # 6750 manufactured by NICHIAS Corporation, is preferably used. The thickness of the sound absorbing material layer 4 is preferably in the range of 0.70 to 1.20 mm.
[0018]
In the present invention, the surface plates 2 and 3 and the sound-absorbing material layer 4 are first formed by punching or cutting into required planar shapes in which the cover 1 of the present invention is developed in a plane. This planar shape includes a squeezing allowance of the folding portion for drawing into a cover shape covering the high temperature equipment portion, and a folding allowance for a filter for forming the folding portion 5 in the surface plate 2. FIG. 7 shows a process of forming the laminated flat plate 8 from the punched or cut sheets of the surface plates 2 and 3 and the sound absorbing material layer 4.
[0019]
A peripheral edge portion 21 is set up substantially perpendicular to the plate surface for folding at the peripheral edge of the cut sheet of the front surface plate 2, and the sound absorbing material layer 4 and the front surface plate 3 are punched on the plate surface on which the peripheral edge portion 21 is set up. The cut sheets are stacked and stacked (FIG. 7 (a)). The surface plates 2 and 3 and the sound absorbing material layer 4 stacked by bending the peripheral edge portion 21 of the surface plate 2 are temporarily fixed to each other ((b) in FIG. 7). Next, the peripheral portion 21 of the surface plate 2 is pressure-bonded onto the surface of the surface plate 3, and the peripheral portion of the surface plate 2 forms the folded portion 5 that encloses the peripheral portion of the surface plate 3 and the sound absorbing material layer. A pair of circular ridge beads 81 and 82 for forming a folded portion are formed at a portion where a curved portion having a small curvature radius when formed into a cover shape covering the same, and the laminated flat plate 8 is formed.
[0020]
The pair of beads 81 and 82 are substantially parallel to each other in a direction substantially perpendicular to the bending direction of the bending portion to be formed, spaced substantially parallel to each other, or close to each other on one end side and away from each other on the other end side. Thus, one bead 81 projects in a direction projecting from the surface plate 2, the other bead 82 projects in a direction projecting from the surface plate 3, and both beads project in opposite directions. FIG. 7C shows a case where beads 81 and 82 extend in a direction substantially parallel to the peripheral edge of the laminated molded flat plate 8, unlike FIGS. 4 and 6 described later.
[0021]
FIG. 4 shows a top view of the laminated molded flat plate obtained as described above. And the expanded sectional view by the DD line of FIG. 4 is shown in FIG. 5, The E arrow side view of FIG. 4 is shown in FIG. As shown in FIG. 5, the sound absorbing material layer 4 is clogged up to every corner of the laminated molded flat plate, and there is no missing portion of the sound absorbing material layer. Further, the sound absorbing material layer 4 and the peripheral portion of the surface plate 3 are sealed by the folded portion of the surface plate 2.
[0022]
The heat-insulating and sound-insulating cover 1 of the present invention is formed by drawing the above-mentioned laminated molded flat plate 8 by drawing into a cover shape that covers the high-temperature device part in a heat-insulating manner with a gap therebetween. In the present invention, the bending at the bending portion having a small curvature radius is mainly formed by narrowing down the laminated flat plate 8 by forming the folding portion. Therefore, the extension of the laminated molded flat plate in forming the curved portion is small, and the curved portion can be easily formed into a desired shape without difficulty. Therefore, the hard-to-extend sound absorbing material layer sandwiched between the surface plates 2 and 3 is not broken.
[0023]
FIG. 8 is an explanatory view for explaining the formation of the folded portion when the laminated flat plate is formed into a cover shape by drawing. The drawing process for forming the cover shape is performed by press forming using a drawing die. When the drawing process is started, the beads 81 and 82 of the laminated molded flat plate 8 are displaced in the direction in which the beads protrude (FIG. 8 (A)), and are bent at the beads 81 and 82, and the beads 81 and 82 are bent. The position relationship between the left and right directions with respect to 82 is changed to the position relationship opposite to the initial position (FIG. 8 (b)), and the laminate-formed flat plate 8 is folded twice at the bead 81 and bead 82 portions. (Fig. 8 (c)), and this is crimped to form the folded portion 6 (Fig. 8 (d)), and the folding width of the folded portion 6 varies depending on the shape of the diaphragm and takes a fairly wide range of values. However, it is about 10 mm, for example.
[0024]
【The invention's effect】
The heat insulating and sound insulating cover of the present invention as described above has the following effects. (1) Since the outer and inner surface plates and the sound-absorbing material layer are each molded and laminated into a predetermined planar shape that expands the shape of the cover that covers the high-temperature device part, all the corners of the peripheral part of the cover Since the sound-absorbing material layer is clogged and there is no missing filling portion of the sound-absorbing material layer, the sound insulating property is good and the variation in the sound insulating property from product to product is small.
[0025]
(2) The cover of the present invention is folded over so that the peripheral portion of one surface plate wraps around the sound absorbing material layer and the peripheral portion of the other surface plate, and the peripheral portion is sealed over almost the entire peripheral portion. In combination with the fact that the sound absorbing material layer is filled to every corner of the peripheral edge as described in (1) above, the sound absorbing material layer moves during use due to vibration, thermal expansion and contraction, etc. Since it does not protrude or be cut off, it has less damage during use than the conventional heat insulating and sound insulating covers, and has excellent durability.
[0026]
(3) A curved portion having a small radius of curvature or a fold portion that is double-folded in the curved direction in the vicinity thereof is provided, and when the laminated flat plate is formed by drawing into a cover shape that covers the high temperature equipment portion, the radius of curvature is small. Since the bending portion is mainly formed by narrowing down by forming the folding portion, the extension of the laminated molded flat plate at the time of bending portion formation can be reduced, and the bending portion can be easily formed into a desired shape without difficulty. Therefore, the hard-to-extend sound absorbing material layer sandwiched between the surface plates 2 and 3 is not broken.
[0027]
(4) The cover of the present invention increases the rigidity of the cover by the folded portion at the peripheral portion thereof, and when the hook-shaped portion is formed at the peripheral portion of the cover, the cover-shaped portion also.
[Brief description of the drawings]
FIG. 1 is a perspective view of a main part of a heat insulating and sound insulating cover according to an embodiment of the present invention.
FIG. 2 is an enlarged cross-sectional view taken along line AA in FIG.
3 is an enlarged cross-sectional view taken along line BB in FIG.
FIG. 4 is a plan view of a laminated molded flat plate formed on the cover of the present invention.
5 is an enlarged cross-sectional view taken along the line DD in FIG.
6 is a side view taken along the arrow E in FIG. 4;
FIG. 7 is an explanatory diagram of a process of forming a laminated flat plate according to the present invention.
FIG. 8 is an explanatory diagram of forming a folding part.
FIG. 9 is a perspective view for explaining a cover that covers the exhaust manifold of the engine in a heat-shielding manner.
[Explanation of symbols]
2, 3 Surface plate 4 Sound absorbing material layer 5 Folded portion 6 Folded portion 8 Laminated molded flat plate 81, 82 Bead

Claims (6)

It consists of a two-layer surface plate made of a metal plate and a sound absorbing material layer sandwiched between the surface plates, and each surface plate and the sound absorbing material layer are molded and laminated in a required planar shape, High temperature equipment parts such as engine exhaust manifolds, etc., having a laminated plate having a folded portion folded back on the other surface plate so as to wrap the peripheral part of one surface plate over the sound absorbing material layer and the other surface plate. A cover formed by drawing into a shape that covers the heat shield, and the cover includes a bent portion having a small radius of curvature or a fold portion that is double-folded substantially in the bending direction in the vicinity thereof. Characteristic heat insulation and sound insulation cover. The heat-insulating and sound-insulating cover according to claim 1, wherein the folded portion extends in a direction substantially perpendicular to the bending direction of the bending portion. The heat-insulating and sound-insulating cover according to claim 1, further comprising a bowl-shaped part having a peripheral part that is widened outward. The inner and outer two-layer surface plate made of a metal plate and the sound absorbing material layer sandwiched between the surface plates are each molded into a required planar shape, laminated, and then one of the entire peripheral edge of the laminated plate Folding the peripheral portion of the surface plate on the other surface plate so as to wrap the peripheral portion of the sound absorbing material layer and the other surface plate, and at or near the site to be formed into a curved portion with a smaller radius of curvature for drawing molding, A cover for forming a laminated flat plate by forming a pair of folding beads extending substantially in parallel with each other across a folding width or inclined to each other, and then covering the high-temperature equipment portion with the thermal insulation by covering the laminated flat plate When forming into the shape of the above by drawing, the pair of folding beads are folded in opposite directions to form a folded portion that is folded twice. To heat insulation, method of manufacturing a sound insulation cover. The method for manufacturing a heat insulating and sound insulating cover according to claim 4, wherein the pair of folding beads protrudes in opposite directions from the surface of the laminated molded flat plate. The method for manufacturing a heat-insulating and sound-insulating cover according to claim 4, wherein the folded portion extends in a direction substantially perpendicular to the bending direction of the bending portion.

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