WO2015085643A1 - 轻量化空气流阻可调节式多层结构声学部件的制备方法 - Google Patents

轻量化空气流阻可调节式多层结构声学部件的制备方法 Download PDF

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Publication number
WO2015085643A1
WO2015085643A1 PCT/CN2014/000145 CN2014000145W WO2015085643A1 WO 2015085643 A1 WO2015085643 A1 WO 2015085643A1 CN 2014000145 W CN2014000145 W CN 2014000145W WO 2015085643 A1 WO2015085643 A1 WO 2015085643A1
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Prior art keywords
fiber
flow resistance
air flow
pressure
molding
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PCT/CN2014/000145
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English (en)
French (fr)
Inventor
阮静
田秀杰
黄威
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无锡吉兴汽车声学部件科技有限公司
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Priority to JP2015551968A priority Critical patent/JP2016508901A/ja
Publication of WO2015085643A1 publication Critical patent/WO2015085643A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B29C2043/185—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles using adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B29C2043/189—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles the parts being joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/04—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using liquids, gas or steam
    • B29C35/049—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using liquids, gas or steam using steam or damp
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • B29K2105/128—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles in the form of a mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B32B2307/7242—Non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B32B2307/7242—Non-permeable
    • B32B2307/7244—Oxygen barrier
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars

Definitions

  • the invention relates to a method for manufacturing an acoustic component of an automobile, in particular to a method for controlling a multilayer structural acoustic component for realizing different acoustic effects by adjusting an air flow resistance, and belongs to the field of sound insulation and noise reduction technology for automobile components.
  • Sound absorption is the absorption of sound energy to weaken energy until it disappears.
  • the principle is that the incident sound wave must enter the material structure, the energy of the sound wave causes the elastic fiber in the material to vibrate, or the air molecules in the pores of the material interact with each other. Impact friction, in which the energy of the sound wave is converted into heat energy to attenuate the energy of the sound wave; the sound insulation is focused on reflecting or refracting the sound wave, thereby reducing the sound energy transmitted to the receiving point, that is, weakening the transmission by means of isolation The sound to the "receiving place”.
  • the two differ in the principle of action and the way they are used: In order to improve the sound absorption effect, the incident sound wave should be easily entered into the material structure to interact with the internal structure of the material to attenuate the energy; to improve the sound insulation effect, it should be reduced. Sound waves entering the interior of the material prevent sound waves from blocking. The above two mechanisms of action often interfere with each other. Therefore, it is difficult for a single layer of material to balance sound absorption and sound insulation. It is necessary to implement a specific sound absorption acoustic performance requirement by a multilayer composite method.
  • thermoplastic hot melt film is introduced, which is generally a PE or EAA single layer film or an EAA/PA/EAA three-layer composite film.
  • the raw material film used is generally a perforated film (as shown in Figure 2), that is, the film is opened at a certain interval, the diameter of the hole is generally 20-30 ⁇ ⁇ In this way, it is ensured that there is a communication channel between the two fiber layers connected to the film, so that the sound wave can enter the bottom fiber layer through the film after entering the surface fiber layer, and both the surface layer and the bottom fiber layer can occur. Interaction, so that the sound energy is maximally consumed, that is, good sound absorption performance is obtained.
  • connection between the EPDM or EVA layer and the fiber layer may also have problems: a) Using the steam heating process, the adhesive of EPDM or EVA is bonded to the fiber layer. Since EPDM or EVA is softened at the same time during heating, the mold is prone to release during demolding. Further, if during the demolding process, EPDM or EVA produces cracks, which will form waste products. The gaps in the soundproofing products will greatly reduce the sound insulation effect. b) If the EPDM layer and the fiber layer are bonded together by means of glue spraying, the manufacturing process will be increased and the production efficiency will be reduced. At the same time, the use of glue will also bring certain VOC problems.
  • the film improves the sound insulation performance of the multilayer fiber product under the premise of ensuring a certain sound absorption performance.
  • the present invention is an efficient, low-cost production process created to solve this problem.
  • the object of the present invention is to overcome the above-mentioned deficiencies and to provide a viable, low-cost, lightweight, air flow resistance adjustable acoustic component manufacturing method mainly by using a thermoplastic film used in a multilayer structure.
  • the control of the flow resistance is used to control the sound absorption function of the product separately.
  • a method for preparing a lightweight air flow resistance adjustable multilayer acoustic component is as follows:
  • Molding conditions Steam pressure: 0.6-3MPa ; Steam temperature: 170-220°C; Steaming time 25-35s Molding pressure: 9-12Mpa ; Molding time: 40-60s; Vacuum pressure: 0.015-0.03Mpa ; Vacuum Time: 50-70s; upper and lower mold temperature: 170-200 ° C;
  • Cooling and setting the pressed semi-finished product is placed in a cooling fixture for cooling and setting; the finalized semi-finished product is obtained, and the cooling time is 45-60 s;
  • the shape and the hole position of the shaped semi-finished product are cut by a punching device or a water knife to obtain the finished acoustic part; the breaking pressure of the punching device is 5-10Mpa, and the breaking time is 3-lOs The cutting pressure of the water jet is 40000-50000 psi, and the cutting pressure is 0.6-0.8Mpa;
  • thermoplastic gas impermeable film is an EAA gas impermeable film having a density of 25-70 g/m 2 .
  • the product has a lightweight air flow resistance adjustable multilayer structure acoustic component air flow resistance of 2000-9000 rayls (Ns/m 3 ) o
  • the product lightweight air flow resistance adjustable multilayer structure acoustic component flow resistance is 5000 -9000rayls (Ns/m 3 ).
  • thermoplastic film is an EAA gas impermeable film having a basis weight of 25 to 70 g/m 2 .
  • the fiber mat component is a polyester fiber having a mass fraction of 15%-20%, a low melting point polyester fiber of 15%-25%, and a recycled fiber of 50%-65% cotton fiber and chemical synthetic fiber; surface density.
  • SOO OOOg/m ⁇ The specific preparation process is as follows: a) Raw material is opened separately: 1 ⁇ 2 parts of polyester fiber, 5 ⁇ 7 parts of recycled cotton fiber, 2 ⁇ 3 parts of low-melting thermoplastic fiber, first of all kinds of raw materials Separate opening treatment, the cluster-like fiber material is broken into fluffy fiber bundles, and the bulk density of the fibers after dispersing is 50-80 kg/m 3 , and the scattered raw materials are sent to a large warehouse for mixing; b ) mixed open and remove impurities: remixed raw materials after mixing After further mixing and opening treatment and impurity treatment, a uniform mixture is obtained; C) air-laid: the mixture obtained in b) is laid in a cotton box through a paving device to form a fiber layer of a predetermined thickness, and then Input into the
  • the invention has the beneficial effects of using high-temperature steam heat transfer method to directly bond with a thermoplastic film during press molding, instead of manually coating the adhesive on site, which not only saves labor and increases productivity, but also greatly improves production. Efficiency, and ensuring the safety of the environment at the manufacturing site and the health of the operators.
  • the invention also adopts a gas-impermeable thermoplastic film EAA as an adhesive film between the fiber layers, and adjusts the air flow resistance of the acoustic component by selecting different melting point, gram weight film, and by controlling the steam heating time and the upper and lower mold temperatures. , to provide a new research direction for the optimization of acoustic performance without increasing the weight of the product and the manufacturing cost.
  • EAA gas-impermeable thermoplastic film
  • the acoustic component of the multi-layer structure to which the present invention relates can be used as a front wall drive sound insulation mat or a car main carpet under sound insulation mat.
  • Figure 2 is a schematic view of the perforated film of the present invention
  • Figure 3 is a plan view of the material of the present invention.
  • Molding conditions steam pressure: 0.6MPa; Steam temperature: 220 ° C; forming pressure steaming time 25s: Lompa; molding time: 45s; vacuum pressure: 0.015MPa; vacuum time: 50s; upper and lower die mold temperature: 170 ° C ;
  • Cooling and setting The pressed semi-finished product is placed in a cooling fixture for cooling and setting, and the semi-finished product is obtained; cooling time: 45s;
  • the total flow resistance of the finished acoustic component is 2000-3000 myls, and the acoustic component of the acoustic component has better sound absorption performance.
  • Molding conditions Steam pressure: 3MPa; Steam temperature: 170°C; Steaming time 35s Molding pressure: 12MPa ; Molding time: 60s; Vacuum pressure: 0.015Mpa; Vacuuming time: 70s; Upper and lower mold temperature: 200 °C ;
  • Cooling and setting The pressed semi-finished product is placed in a cooling fixture for cooling and setting, and the semi-finished product is obtained, and the cooling time is 60s;
  • the total flow resistance of the finished acoustic component is 7000-9000myl S , and the acoustic component of the acoustic component has better sound insulation performance.
  • Molding conditions Steam pressure: 2MPa; Steam temperature: 200°C ; Steaming time 30s Molding pressure: l lMPa; Molding time: 55s; Vacuum pressure: 0.02Mpa; Vacuuming time: 60s; Upper and lower mold temperature: 190° C ;
  • Cooling and setting Put the pressed semi-finished product into the cooling fixture for cooling and setting, and obtain the semi-finished product, cooling time: 60s;
  • the total flow resistance of the finished acoustic parts is 3000-5000 rayls, and the finished acoustic parts have good overall absorption/sound insulation properties.

Landscapes

  • Soundproofing, Sound Blocking, And Sound Damping (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

　本发明涉及汽车声学部件的制造方法，属于汽车部件隔音降噪技术领域。所述声学部件先将纤维毡、热塑性不透气ΕΑΑ薄膜和纤维毡的次序叠放，送入成型模具内，利用穿透力强的高温蒸汽对材料进行加热，同时进行模压成型，然后切割外形尺寸及孔位，经检验无缺陷后，即可获得多层结构声学部件。本发明上下两层纤维毡之间的粘结是通过热塑性薄膜在高温下熔化后所具有的粘结性来实现的，而非在现场以人工涂布粘结剂，不但可节省人工提升产能，大幅度提高了生产效率，且确保制造现场的环境的安全和操作人员的健康。本发明还采用热塑性不透气ΕΑΑ膜来调节隔音垫的空气流阻，在不增加重量和制造成本的基础上实现对声学制品声学性能的优化。

Description

轻量化空气流阻可调节式多层结构声学部件的制备方法 技术领域
本发明涉及汽车声学部件的制造方法， 尤其是通过调节空气流阻来达到实 现不同声学效果的多层结构声学部件的控制方法， 属于汽车部件隔音降噪技术 领域。
背景技术
声学部件就是能对噪音起到衰减或隔离作用的部件， 其作用机理包含两个 方面： 吸音或隔音。 吸音与隔音机理： 吸音是将声音能量吸收以使能量减弱直 至消失， 其原理是入射声波必须进入材料结构中， 声波的能量使材料内的弹性 纤维发生振动， 或使材料孔隙中的空气分子互相撞击摩擦， 在此过程中将声波 的能量转化为热能而使声波的能量得以衰减； 隔音则重在使声波发生反射或折 射， 从而减少传递到接收点的声能量， 即通过隔离的方式减弱传递到 "接收处" 的声音。 二者在作用原理及使用方式上有所区别： 为提升吸音效果， 应使入射 声波容易进入材料结构内部， 以与材料内部结构发生相互作用而使能量得以衰 减； 为提升隔音效果， 则应该减少进入材料内部的声波而使声波得以阻绝。 上 述两种作用机理经常会相互制约， 因此单层材料难以兼顾吸音与隔音效果， 必 须由多层复合方式来实现特定吸隔音声学性能要求。
近年来， 在降低制造成本及提升燃油经济性的强烈需求性下， 在声学部件 领域， 多层纤维毡制品正逐渐在取代传统的 EPDM+PU泡沬或 EVA+PU泡沬制 品， 在此过程中， 由于要将不同层的纤维层粘合在一起， 引入了热塑性热熔膜， 一般为 PE或 EAA单层膜或 EAA/PA/EAA三层复合膜， 采用这种纤维制品时， 因为考虑更多的是制品的吸音功能， 因此采用的原料膜一般为打孔膜 （如图 2 所示）， 即膜上按一定间隔大小开了小孔， 孔的直径大小一般为 20-30 μ ηι， 通过 这样的方式来确保膜所连接的两层纤维层之间有连通的通道， 以利于声波在进 入表面纤维层后能穿过薄膜继续进入底层纤维层， 与表层和底层纤维层都能发 生相互作用， 从而使声能量达到最大程度的消耗， 即获得良好的吸音性能。
但是单方面靠吸音， 并不能满足整车声学降噪要求： 尽可能的使乘客仓的 声压级最小。 吸声结构的声学部件对于降低整车噪音声压级的贡献仅限于 0.2〜1 dB， 要想更进一步的降低声压级， 还需要该材料结构能发挥隔音作用。 从前述 隔音机理得知， 多层结构中必须含有一层隔离层来阻隔或反射声波。 如果继续 使用传统的 EPDM或者 EVA作为隔离层， 一方面产品的重量增加了， 无法达成 轻量化的要求； 另一方面， EPDM或 EVA层与纤维层之间的连接也会出现问题： a) 如果利用蒸汽加热工艺， 利用 EPDM或 EVA的背胶与纤维层粘合， 由于在 加热过程中 EPDM或 EVA会被同时软化， 在脱模时容易出现粘模， 进一步如果 在脱模过程中， EPDM或 EVA产生破裂， 会形成废品， 隔音制品上的缝隙的会 极大程度的降低隔音效果； b)如果采用喷胶的方式将 EPDM层和纤维层粘合在 一起， 会增加制造工序， 降低生产效率， 同时胶水的使用也会带来一定的 VOC 问题。那么是否可以不使用传统 EPDM或 EVA作为声隔离层， 而直接利用热塑 性薄膜作为声隔离层， 在保证一定的吸音性能的前提下， 提升多层纤维制品的 隔音性能呢？ 本发明就是为了解决这个课题而创作的一种高效、 低成本的生产 工艺。
发明内容
本发明的目的在于克服上述不足之处， 提供一种可行的， 低成本， 轻量化 的， 空气流阻可调节的声学部件的制造方法， 该方法主要通过对多层结构中所 使用的热塑性薄膜的流阻的控制， 来分别实现对制品吸隔音功能的控制。
按照本发明提供的技术方案， 轻量化空气流阻可调节式多层结构声学部件 的制备方法， 步骤为：
( 1 )铺料：按由下至上的顺序铺放纤维毡、热塑性不透气薄膜和纤维毡（如 附图 3 ) ；
( 2 ) 压制成型： 将铺好的材料置入成型模具内进行模压， 在模压的同时下 模通蒸汽， 上模抽真空， 通过高温蒸汽对材料进行加热， 使上下层纤维中含有 低熔点纤维丝熔化， 在压力的作用下， 把周围的纤维丝粘合在一起， 同时热塑 性薄膜也被熔化， 把上下两层纤维层粘合在一起， 得到压制半成品； 在此过程 中， 通过对蒸汽加热时间及上下模具温度的控制， 来实现对薄膜熔化程度的控 制， 进而控制模压成型后薄膜的流阻： 如果需要提升制品的空气流阻， 则需要 减少蒸汽加热时间和上下模具温度， 从而减少薄膜的熔化， 这样可以得到大的 空气流阻， 大的空气流阻层即为声传递的隔离层， 反之亦然；
成型条件： 蒸汽压力： 0.6-3MPa; 蒸汽温度： 170-220°C ; 通蒸汽时间 25-35s 成型压力： 9-12Mpa; 成型时间： 40-60s; 抽真空压力： 0.015-0.03Mpa; 抽真空 时间： 50-70s; 上下模模具温度： 170-200°C ;
( 3 ) 冷却定型： 将所述压制半成品放入冷却治具进行冷却定型； 得定型半 成品， 冷却时间： 45-60s;
( 4)切割： 用冲断装置或水刀对所述定型半成品进行外形尺寸及孔位的切 割， 得到声学部件成品； 冲断装置的冲断压力为 5-10Mpa， 冲断时间为 3-lOs; 水刀的切割压力为 40000-50000psi， 切割气压为 0.6-0.8Mpa;
( 5 ) 检验： 所述声学部件成品经检验无缺陷合格后， 装箱入库。
所述热塑性不透气薄膜为 EAA不透气膜， 密度为 25-70g/m2。
所述产品轻量化空气流阻可调节式多层结构声学部件空气流阻为 2000-9000rayls(N.s/m3)o所述产品轻量化空气流阻可调节式多层结构声学部件流 阻为 5000-9000rayls (N.s/m3)。
所述热塑性薄膜为 EAA不透气膜， 克重为 25〜70g/m2。
所述纤维毡成分为质量分数 15%-20%的聚酯纤维， 15%-25%的低熔点聚酯 纤维和 50%-65%的棉纤维及化学合成纤维的再生纤维；表面密度. · SOO OOOg/m^ 具体制备过程为： a) 原料单独开松处理： 称取聚酯纤维 1〜2份、 再生棉纤 维 5〜7份、 低熔点热塑性纤维 2〜3份， 首先对各种原料单独进行开松处理， 将 团簇状的纤维材料打散成蓬松的纤维束， 打散后纤维的体密度为 50〜80kg/m3， 打散后的原料送入一个大仓进行混合； b)混开松及除杂： 混合好以后的原料再通 过进一步的混合开松处理及杂质处理得到开松均匀的混合料； C)气流成网： 将 b)中得到的混合料通过铺料设备在棉箱中铺成设定厚度的纤维层，再输入到气流 成网机中形成需要的纤维层； d)高温定型： 纤维层在烘箱中经高温处理定型； e) 裁片： 高温定型后再冷却后， 经裁剪处理， 即可获得设定尺寸与厚度的纤维毡。
本发明的有益效果： 利用高温蒸汽传热的方式， 在模压成型时直接利用热 塑性薄膜进行粘结， 而非在现场以人工涂布粘结剂， 不但可节省人工提升产能， 大幅度提高了生产效率， 且确保了制造现场的环境的安全和操作人员的健康。
本发明还采用不透气热塑性薄膜 EAA作为纤维层之间的粘合膜， 通过选择 不同熔点、 克重的薄膜， 及通过对蒸汽加热时间及上下模具温度的控制， 来调 节声学部件的空气流阻， 在不增加制品重量及制造成本的前提下为声学性能的 优化提供新的研究方向。
本发明所涉及的多层结构的声学部件可以用作前围驾仓隔音垫或汽车主地 毯下隔音垫。
附图说明
图 1本发明工艺流程图
图 2本发明打孔膜示意图
图 3本发明材料铺设图。
附图标记说明： 1、 纤维层； 2、 EAA膜； 3、 纤维层。
具体实施方式
本发明实施例工艺流程图如图 1所示。
实施例 1
( 1 ) 铺料： 按由下至上的顺序铺放纤维毡、 热塑性薄膜和纤维毡； 其中上 层纤维毡克重 1000 g/m2, 下层纤维毡克重为 1200 g/m2, 采用的薄膜克重为 25g/m2 ; 铺料顺序如图 3所示；
(2) 压制成型： 将铺好的材料置入成型模具内进行模压， 在模压的同时下 模通蒸汽， 上模抽真空， 通过高温蒸汽对材料进行加热， 使上下层纤维中含有 低熔点纤维丝熔化， 在压力的作用下， 把周围的纤维丝粘合在一起， 同时热塑 性薄膜也被熔化， 把上下两层纤维层粘合在一起， 得到压制半成品；
成型条件： 蒸汽压力： 0.6MPa; 蒸汽温度： 220°C ; 通蒸汽时间 25s成型 压力： lOMpa; 成型时间： 45s; 抽真空压力： 0.015MPa; 抽真空时间： 50s; 上 下模模具温度： 170°C ;
( 3 )冷却定型： 将压制半成品放入冷却治具进行冷却定型， 得定型半成品； 冷却时间： 45s;
( 4 ) 切割： 用冲断装置或水刀对定型半成品进行切割外形尺寸及孔位， 得 到声学部件成品； 冲断装置： 冲断压力： 8MPa， 冲断时间： 10s; 水刀： 切割压 力： 40000psi, 切割气压： 0.8MPa;
( 5 ) 检验： 声学部件成品经检验无缺陷合格后， 装箱入库。
最终声学部件成品的总流阻为 2000-3000myls， 所述声学部件成品吸音性能 比较好。 实施例 2
( 1 ) 铺料： 按由下至上的顺序铺放纤维毡、 热塑性薄膜和纤维毡； 其中上 层纤维毡克重 1200g/m2， 下层纤维毡克重为 1500g/m2， 采用的薄膜克重为 70g/m2 ; 铺料顺序如图 3所示；
( 2) 压制成型： 将铺好的材料置入成型模具内进行模压， 在模压的同时下 模通蒸汽， 上模抽真空， 通过高温蒸汽对材料进行加热， 使上下层纤维中含有 低熔点纤维丝熔化， 在压力的作用下， 把周围的纤维丝粘合在一起， 同时热塑 性薄膜也被熔化， 把上下两层纤维层粘合在一起， 得到压制半成品；
成型条件： 蒸汽压力： 3MPa; 蒸汽温度： 170°C ; 通蒸汽时间 35s成型压力： 12MPa; 成型时间： 60s; 抽真空压力： 0.015Mpa; 抽真空时间： 70s; 上下模模 具温度： 200 °C ;
(3 )冷却定型： 将压制半成品放入冷却治具进行冷却定型， 得定型半成品， 冷却时间： 60s;
( 4) 切割： 用冲断装置或水刀对定型半成品进行切割外形尺寸及孔位， 得 到声学部件成品； 冲断装置： 冲断压力： 8Mpa， 冲断时间： 10s; 水刀： 切割 压力： 45000psi , 切割气压： 0.7Mpa;
( 5 ) 检验： 声学部件成品经检验无缺陷合格后， 装箱入库。
最终声学部件成品的总流阻为 7000-9000mylS， 所述声学部件成品的隔音性 能比较好。
实施例 3
( 1 ) 铺料： 按由下至上的顺序铺放纤维毡、 热塑性薄膜和纤维毡； 其中上 层纤维毡克重 1200g/m2， 下层纤维毡克重为 1200g/m2， 采用的薄膜克重为 35g/m2 ; 铺料顺序如图 3所示；
(2) 压制成型： 将铺好的材料置入成型模具内进行模压， 在模压的同时下 模通蒸汽， 上模抽真空， 通过高温蒸汽对材料进行加热， 使上下层纤维中含有 低熔点纤维丝熔化， 在压力的作用下， 把周围的纤维丝粘合在一起， 同时热塑 性薄膜也被熔化， 把上下两层纤维层粘合在一起， 得到压制半成品；
成型条件： 蒸汽压力： 2MPa; 蒸汽温度： 200°C ; 通蒸汽时间 30s成型压力： l lMPa; 成型时间： 55s; 抽真空压力： 0.02Mpa; 抽真空时间： 60s; 上下模模 具温度： 190°C ;
( 3 )冷却定型： 将压制半成品放入冷却治具进行冷却定型， 得定型半成品， 冷却时间： 60s;
( 4) 切割： 用冲断装置或水刀对定型半成品进行切割外形尺寸及孔位， 得 到声学部件成品； 冲断装置： 冲断压力： 8Mpa， 冲断时间： 5s; 水刀： 切割压 力： 50000psi, 切割气压： 0.6Mpa;
( 5 ) 检验： 声学部件成品经检验无缺陷合格后， 装箱入库。
最终声学部件成品的总流阻为 3000-5000rayls， 这种声学部件成品具有良好 的综合吸 /隔音性能。

Claims

权 利 要 求 书
1、 轻量化空气流阻可调节式多层结构声学部件的制备方法， 其特征是歩骤 为：
( 1 ) 铺料： 按由下至上的顺序铺放纤维毡、 热塑性不透气薄膜和纤维毡；
( 2 ) 压制成型： 将歩骤 （1 ) 铺好的材料置入成型模具内进行模压， 在模 压的同时下模通蒸汽， 上模抽真空， 通过高温蒸汽对材料进行加热， 使上下层 纤维中含有低熔点纤维丝熔化， 在压力的作用下， 把周围的纤维丝粘合在一起， 同时热塑性薄膜也被熔化， 把上下两层纤维层粘合在一起， 得到压制半成品； 成型条件： 蒸汽压力： 0.6-3MPa; 蒸汽温度： 170-220°C ; 通蒸汽时间 25-35s 成型压力： 9-12Mpa; 成型时间： 40-60s; 抽真空压力： 0.015- 0.03Mpa; 抽真空 时间： 50-70s; 上下模模具温度： 170-200 °C ;
(3 ) 冷却定型： 将所述压制半成品放入冷却治具进行冷却定型， 得到定型 半成品； 冷却时间： 45-60s;
(4 ) 切割： 用冲断装置或水刀对所述定型半成品进行外形尺寸及孔位的切 割， 得到声学部件成品； 冲断装置的冲断压力为 5-lOMpa, 冲断时间为 3-lOs; 水刀的切割压力为 40000-50000psi， 切割气压为 0.6-0.8Mpa;
( 5 ) 检验： 所述声学部件成品经检验无缺陷合格后， 装箱入库。
2、 如权利要求 1所述轻量化空气流阻可调节式多层结构声学部件的制备方 法， 其特征是： 所述热塑性不透气薄膜为 EAA不透气膜， 密度为 25-70g/m2。
3、 如权利要求 1所述轻量化空气流阻可调节式多层结构声学部件的制备方 法， 其特征是： 所述产品轻量化空气流阻可调节式多层结构声学部件空气流阻 为 2000-9000rayls N.s/m3。
4、 如权利要求 1所述轻量化空气流阻可调节式多层结构声学部件的制备方 法， 其特征是： 所述纤维毡成分按重量份计为 15%-20%的聚酯纤维， 15%-25% 的低熔点聚酯纤维和 60%-65%的棉纤维及化学合成纤维的再生纤维； 表面密度 为 500-2000g/m2。
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