RU51943U1 - NOISE COATING PARTS KIT FOR VEHICLE SALON - Google Patents

Abstract

The proposed utility model relates to the transport industry, namely, to the production of noise insulation coatings for the vehicle interior and relates to a set of parts. What is new is that the kit includes two parts - the front floor mat and the rear floor mat, with each detail being integrally formed and repeating the surface and the outline of the relief of the mating body part; each part is made of material, including: 1) a heavy layer of thermoplastic sheet: material 2-3 mm thick and a surface density of 3-4.5 kg / m based on a combination of ethylene-propylene rubber with polyethylene or a copolymer of ethylene with vinyl acetate; 2) a layer of porous polyurethane foam obtained by reacting at least a polyol and an isocyanate, taken in a ratio of 100 / 40-100 / 50; 3) carpet. The set is distinguished by high rates of sound insulation, lightness, environmental friendliness, ease of manufacture and installation in the passenger compartment.

Description

The proposed utility model relates to the transport industry, namely, to the production of noise insulation coatings for the vehicle interior and relates to a set of parts.

Currently, the automotive industry is actively developing soundproof coatings.

Sound insulation coatings, made in the form of a system of modules, casings, special gaskets and facings, are widely used. The collection, installation, installation and fastening of these coatings in the car interior is often a lot of difficulties.

So, for example, for the assembly of a noise insulation coating according to the patent RU U ₁ 5959, the authors developed a special scheme-instruction for installing individual noise-vibration damping modules on the panels of the passenger compartment. The modules have a different configuration with a complex system of through-cuts, cut-outs of blind holes to ensure tight installation on embossed surfaces of the interior panel and tight coverage of functional elements attached to them.

In the form of separate modules, a noise insulation coating according to the patent Ru U ₁ 7391. is also made. The assembly of the modules is carried out using the mosaic principle.

Complex part systems with many holes of a certain size and configuration are also described in the patents Ru U ₁ 25871, Ru U ₁ 27026, Su 183593, Ru C ₁ 2042547 and others. Such kits, as has already been said, are extremely difficult to mount and fix in the cabin a car.

The difficulty in ensuring a tight fit of noise insulation coatings to the embossed surfaces of the vehicle interior makes it necessary to develop additional complex elements of noise insulation coatings. So,

for example, in application No. 2002116046, special fasteners are described, in copyright certificate No. 522969 - magnetized gaskets.

The objective of the utility model is the possibility of improving the set of parts of the noise insulation coating for the vehicle interior, repeating the surface of the body.

The new technical result consists in the fact that the proposed parts of the noise insulation kit are integral and repeat the surface and shape of the mating part of the body, more effective in noise insulation (noise is reduced from 1.5 to 2 dB) and at the same time are lightweight, environmentally friendly, provide good surface fit bodywork, simple and quick installation when installed in the vehicle interior. Simplification and acceleration of installation is also achieved due to the fact that the kit consists of 2 parts (front floor mat, rear floor mat), and not, for example, from a complex system of numerous modules.

Due to the fact that the carpet is glued directly to the part, it is possible to make the part in one step (and facilitate assembly), while earlier, when assembling the car, noise insulation material was first mounted, and then the carpet was attached as a separate stage.

The task is achieved in that the kit includes two parts - the front floor mat and the rear floor mat, with each detail being integrally formed and repeating the surface and the outline of the relief of the mating body part; each part is made of material, including: 1) a heavy layer of thermoplastic sheet material with a thickness of 2-3 mm and a surface density of 3-4.5 kg / m ² based on a combination of ethylene-propylene rubber with polyethylene or a copolymer of ethylene with vinyl acetate; 2) a layer of porous polyurethane foam obtained by reacting at least a polyol and an isocyanate, taken in a ratio of 100 / 40-100 / 50; 3) carpet.

Figure 1 shows the proposed set of parts (schematic drawings).

Figure 2 shows the layout of the layers of material for the manufacture of the proposed set of parts.

Figure 1-2 indicated:

1 - front floor mat;

2 - rear floor mat;

3 - carpet;

4 - heavy layer;

5 - layer of porous polyurethane foam.

The proposed set of parts is made as follows. A sheet of heavy material is heated in an electric furnace to a temperature of 150 ± 10 ° C and laid out in a mold (the mold temperature depends on the polyurethane foam system used), the mold is closed and foam is injected through the filler neck of the mold. The forming time of the part is 2-4 minutes.

Each part is made with a uniform heavy layer thickness over the entire surface and a different thickness of the polyurethane foam layer, which is determined experimentally depending on the degree of noise emission from the zone. In the zones of the smallest noise radiation, the thickness of the foam layer is the smallest, and in the zones of the greatest noise radiation the largest.

As a heavy material, a thermoplastic sheet material of 2-3 mm thickness and a surface density of 3.2-4.5 kg / m ² based on the combination of ethylene-propylene rubber with high-pressure polyethylene or a copolymer of ethylene with vinyl acetate is used. When using thermoplastic sheet material with a thickness of less than 2 mm, the noise-absorbing properties of the material deteriorate, and when using a thermoplastic sheet material with a thickness of more than 3 mm, the cost and weight of the part increase with a slight improvement in the noise-absorbing properties of the material.

As a porous sound-absorbing material, highly elastic open-porous polyurethane foam (density 50-70 kg / m ³ , elastic modulus) is used.

polyurethane foam 50-250 N / m ² ) obtained by the interaction of two components: polyol and isocyanate. Depending on the scope and frequency range, it is possible to choose the most effective option by changing the ratio of components and introducing auxiliary substances (catalysts, blowing agents, stabilizers). The preferred ratio of the amounts of polyol and isocyanate is a ratio of 100 / 40-100 / 50. When using a quantity of isocyanate of less than 40 in the ratio of polyol and isocyanate, the physical and mechanical characteristics of the material deteriorate - strength, life, during the manufacture of the part, in this case, defects appear on the surface of the material. When using an amount of isocyanate in the ratio of the polyol and isocyanate of more than 50, the polymerization and manufacturing time of the part increases, the noise-absorbing properties of the material deteriorate, because it becomes stiffer, defects appear on the surface of the material during manufacture.

The third layer is carpet. Rolling a blank from a non-canon sheet is carried out before polymerization of the polyurethane layer.

A set of parts for the noise insulation coating is installed in the passenger compartment as follows: front floor mat - on the floor of the front of the body between the front panel and the front row seats; rear floor mat - on the floor of the middle part of the body under the seats of the first and second row to the panel separating the vehicle’s interior from the luggage compartment.

This technology for the production of parts for noise insulation of a car floor allows for accurate repetition of the surface of the body, which ensures the most tight fit and, accordingly, the improvement of sound insulation properties. At the same time, by changing the thickness of the part over the surface in certain areas of the strongest noise radiation, we also have the opportunity to increase the efficiency of this product.

The following are examples of specific parts.

Production Part 31105.5109012 - Front Floor Mat with Soundproofing and Cover

Number of operas. Name and description of the operation Equipment Tool 005 Cutting Unwind a roll of Abris-Avto 2.0 mm thick into the size of a workpiece with a length of L = 1 m. Separate Abris-Avto from the protective film. Cut the blank Abris-Auto with dimensions of 1 × 1.6 m. After cutting, fold the blanks in a stack. Cutting table Abris Auto Knife for cutting workpieces 010 Transportation: Transport the sliced Abris-Avto blanks to the heating section. 015 Heat Lay the blank Abris-Avto on the filling frame of the furnace. Heat Abris-Auto in the oven to T = 150 ± 10 ° C for 80 seconds. Oven COMAU. 020 Molding The temperature of the lower half-mold is 50-60 ° С. Lay out the heated sheet of Abris-Auto on the lower half-form. Close the casting mold, tighten with screw clamps (locks) and turn on the vacuum, press the carousel power button. Vacuum liquid ring pump ZRVN 1-3, vertical vacuum receiver; Lower mold cooler Heated casting mold 020 * Molding Lay out the preheated Abris-Auto sheet manually on the lower half-mold. Close the filling mold, tighten the screw clamps (locks) and press the carousel power button. Heated casting mold

Number of operas. Name and description of the operation Equipment Tool 025 Pouring The car The form The temperature of the form is 50-60 ° C. The temperature of the components is 30-35 ° C. Remove filler caps. Bring the head of the filling machine to the filling nozzles of the mold. Pour polyurethane foam for 5.3 seconds (approximately) into each neck, close the plugs. Press the carousel power button. casting PK-40 Heater for molds; Component Heater heated filling 030 Parts extraction The form Unscrew the screw clamps and open the upper mold half. Take out the filled part and place it in a storage place for subsequent transfer to trim. heated filling 035 Application of release agent Brush Apply Siberian Release Agent 312 on the upper half-mold with a brush over the entire surface in a uniform layer. 040 The control Perform 100% visual inspection of cast billets. PPU leakage, through cracks, shells and mechanical damage are not allowed on the workpieces. 045 Transportation Transport manufactured workpieces to the cutting area

Number of operas. Name and description of the operation Equipment Tool 050 Contour cropping Edged Trim the workpiece blank by hand in a trimmed jig. After the operation, raise the upper mold conductor knife 055 Gluing Dispensing Edged Without removing parts from the edged conductor, apply a uniform polyurethane layer of Litur 50 X-3 over the entire surface onto Abris-Auto by spraying and, prior to polymerization of the polyurethane layer, roll the blank from non-woven fabric 3110-5109014. Fix the part in the edged conductor with the upper half-mold. installation of high pressure for spraying multicomponent chemical systems "POLISPREY 3500 conductor 060 Cutting down Edged Cut through holes, cut notches. Remove the part from the trimmed jig. conductor, knife, punches 065 The control Control Place the part in the test fixture. Check the presence and location of all cutting holes, perforations and dimensions of the part. fixture, control plugs 070 Packaging Pack the parts in polyethylene and place them in a container. Put a packing label with the OTK stamp in each place. Tara * - bypass technology

Parts manufacturing 31105.5109042 - rear floor mat with sound insulation

Number of operas. Name and description of the operation Equipment Tool 005 Cutting Cutting table Slicing knife Unwind the Abris-Avto roll 2.0 mm thick into the size of a workpiece with a length of L = 0.8 m. Separate Abris-Avto from the protective film. Cut the blank Abris-Auto with dimensions 0.8 × 1.6 m. After cutting, fold the blanks in a stack Abris Auto blanks 010 Transportation Transport chopped Abris-Avto blanks to the heating section. 015 Heat Oven COMAU. Lay the blank Abris-Avto on the filling frame of the furnace. Heat Abris-Auto in the oven to T = 150 ± 10 ° C for 80 seconds. 020 Molding Vacuum Casting mold The temperature of the lower mold half is 50-60 ° C. Lay out the preheated Abris-Auto sheet on the lower half-form. Close the casting mold, tighten with screw clamps (locks) and turn on the vacuum, press the carousel power button. liquid ring pump ZRVN 1-3, vertical vacuum receiver, vacuum form; Lower mold cooler heated 020 * Molding Casting mold Lay out the preheated Abris-Auto sheet manually on the lower half-mold. Close the filling mold, tighten the screw clamps (locks) and press the carousel power button. heated

Number of operas. Name and description of the operation Equipment Tool 025 Pouring Pouring machine PK-40 Heater for molds; Component Heater Heated casting mold The temperature of the form is 50-60 ° C. The temperature of the components is 30-35 ° C. Remove filler caps. Bring the head of the filling machine to the filling nozzles of the mold. Pour polyurethane foam for 4.2 seconds (approximately) in each neck, close the plugs. Press the carousel power button. 030 Parts extraction Heated casting mold Unscrew the screw clamps and open the upper mold half. Take out the filled part and place it in a storage place for subsequent transfer to trim. 035 Application of release agent Apply Siberian 312 release agent on the upper mold half with a brush over the entire surface with a uniform layer. Brush 040 The control Perform 100% visual inspection of cast billets. PPU leakage, through cracks, shells and mechanical damage are not allowed on the workpieces. 045 Transportation Transport manufactured workpieces to the cutting area 050 Contour cropping Edged conductor, knife, punch. Trim the workpiece blank by hand in a trimmed jig. After doing

Number of operas. Name and description of the operation Equipment Tool operations raise the upper half-mold 055 Gluing Dispensing Edged Without removing parts from the edged conductor, apply a uniform polyurethane layer of Litur 50 X-3 over the entire surface onto Abris-Auto by spraying and, prior to polymerization of the polyurethane layer, roll the blank from non-woven fabric 3110-5109044-10. Fix the part in the edged conductor with the upper half-mold. installation of high pressure for spraying multicomponent chemical systems "POLISPREY 3500 conductor 060 Cutting down Edged Cut through holes, cut notches. Remove the part from the trimmed jig. conductor, knife, punches 065 The control Control Place the part in the test fixture. Check the presence and location of all cutting holes, perforations and dimensions of the part. fixture, control plugs 070 Packaging Tara Pack the parts in polyethylene and place them in a container. Put a packing label with the OTK stamp in each place. * - bypass technology

Claims (4)

1. A set of parts for the noise insulation coating for the vehicle interior, characterized in that it includes two parts — the front floor mat and the rear floor mat, each detail being integrally formed and repeating the surface and the outline of the relief of the mating body part; each part is made of a material including a heavy layer of thermoplastic sheet material with a thickness of 2-3 mm and a surface density of 3-4.5 kg / m ² based on a combination of ethylene-propylene rubber with polyethylene or a copolymer of ethylene with vinyl acetate, a layer of porous polyurethane foam obtained by interaction at least polyol and isocyanate, taken in a ratio of 100 / 40-100 / 50, carpet. 2. A set of parts according to claim 1, characterized in that in addition to the preparation of a layer of porous polyurethane foam, catalysts and / or blowing agents and / or stabilizers are used. 3. The set of parts according to claim 1, characterized in that each part has a uniform heavy layer thickness over the entire surface and a different thickness of the polyurethane foam layer, determined by the degree of noise emission from the zone. 4. The set of parts according to claim 3, characterized in that in the zones of the smallest noise radiation the thickness of the polyurethane foam layer is the smallest, and in the zones of the greatest noise radiation the largest.