An electric bridge acoustic package and an integrated molding processing method

Abstract

An embodiment of the present invention discloses an electric bridge acoustic package and an integrated molding processing method. For the electric bridge acoustic package of the present invention, the motor part, the reducer part and the electronic control unit part are integrally designed, and from top to bottom in sequence are: a first black flame-retardant non-woven fabric, a V0-grade thermoplastic elastomer or a felt material mixed with polyester and pre-oxidized polyester fibers, an LDPUR semi-open-cell lightweight foam, and a second black flame-retardant non-woven fabric. The electric bridge acoustic package of the present invention can effectively solve the sound insulation problem of the electric bridge.

Description

Technical Field

[0001] The embodiments of the present invention relate to the technical field of vehicles, and in particular, to an electric bridge acoustic package and an integral molding processing method. Background Art

[0002] When the electric bridge works on the vehicle, it will emit order single-frequency noise, which is then transmitted into the vehicle. The noise transmitted into the vehicle through the air propagation path is called air noise. To improve the in-vehicle sound quality of the vehicle and reduce the air noise radiated by the electric bridge into the vehicle, currently, the form of increasing the electric bridge acoustic package is mostly adopted to suppress the influence of the air noise generated by the electric bridge on the vehicle interior. Similar to general sound insulation measures, the current electric bridge acoustic packages are mostly separated, that is, the motor, the reducer, and the high-voltage electric control unit are respectively coated, and the coating mainly includes a sound insulation layer and a sound absorption layer. The sound insulation effect of this structure is not very ideal. Summary of the Invention

[0003] The embodiments of the present invention provide an electric bridge acoustic package and an integral molding processing method, which can effectively solve the sound insulation problem of the electric bridge.

[0004] The embodiments of the present invention provide an electric bridge acoustic package, including: a motor part, a reducer part, and an electric control unit part;

[0005] The motor part, the reducer part, and the electric control unit part are integrally designed, and from top to bottom, they are: the first black flame-retardant non-woven fabric, a V0-grade thermoplastic elastomer or a felt material mixed with polyester and pre-oxidized polyester fibers, LDPUR semi-open-cell lightweight foam, and the second black flame-retardant non-woven fabric.

[0006] Adopting this technical solution can not only reduce the intrusion of noise at the gaps, but also cooperate with the characteristics of the four-layer material to make the electric bridge acoustic package better fit the electric bridge, achieving better molding and sound insulation and sound absorption effects.

[0007] In a feasible solution, the second black flame-retardant non-woven fabric adopts a specification of 50-150 g / m 2 and a thickness of 0.5-1 mm.

[0008] Adopting this technical solution is to make the electric bridge and the electric bridge acoustic package have good flame retardancy, and during long-term use, maintain a certain stable property between the electric bridge and the second black flame-retardant non-woven fabric, avoiding the overall failure of the entire electric bridge acoustic package when the inner layer of the second black flame-retardant non-woven fabric fails during long-term use.

[0009] In a feasible solution, the thermoplastic elastomer is a sheet with a thickness of 1-5 mm extruded by mixing TPU / EVA materials.

[0010] Adopting this technical solution is to ensure flame retardancy while providing good sound insulation ability and mechanical properties after deformation, and after deformation, the first black flame-retardant non-woven fabric and the second flame-retardant non-woven fabric can better adhere to the outside of the bridge; if the size is too large, it is easy for the first black flame-retardant non-woven fabric to be deformed too much after adhesion, easy to tear or lift up after long-term use; if the size is too small, the sound insulation effect is not good, and it is not easy to maintain the shape after adhesion.

[0011] In a feasible solution, the LDPUR semi-open-cell lightweight foam is selected with a density of 8 - 20 kg / m 3 and a thickness of 5 - 25 mm.

[0012] Adopting this technical solution is to ensure good sound absorption effect, and at the same time, make it cooperate with the thermoplastic elastomer to make the service life of the bridge acoustic enclosure longer.

[0013] In a feasible solution, the felt material mixed with polyester and pre-oxidized polyester fibers uses a black hard layer felt with a surface density of 800 - 1500 g / m 2 and a thickness of 1 - 5 mm.

[0014] Adopting this technical solution is to ensure a certain flame retardant effect while improving the abrasion resistance to extend the service life.

[0015] The present invention also provides an integral molding processing method for a bridge acoustic enclosure, including the following steps:

[0016] S1. Stack the first black flame-retardant non-woven fabric, V0-grade thermoplastic elastomer or felt material mixed with polyester and pre-oxidized polyester fibers, and after heating at 130 - 200 °C, laminate and bond them together to form an upper sheet; stack the LDPUR semi-open-cell lightweight foam and the second black flame-retardant non-woven fabric, and after heating at 130 - 200 °C, laminate and bond them together to form a lower sheet;

[0017] S2. Place the upper sheet in the lower mold, cool and shape it to a temperature of 0 - 20 °C, and attach it to the inner side of the lower mold of the molding die;

[0018] S3. Place the lower sheet in the upper mold and heat it to 180 - 230 °C;

[0019] S4. With a pressure of 180 - 300 tons, press and mold the upper sheet and the lower sheet in the upper mold and the lower mold respectively, and maintain for 30 seconds;

[0020] S5. Place the upper sheet, the already molded part, and the lower sheet in the shear die in sequence, heat it to 80 - 85 °C, press and bond them together, and punch and remove the required holes and the surrounding waste materials at one time.

[0021] Adopting this technical solution can achieve a very good one-piece molding effect. At the same time, it enables the second black flame-retardant non-woven fabric to maintain a certain stiffness, avoiding problems such as peeling after long-term use, which affects the service life. Also, due to the treatment method of cooling first and then hot pressing, it can improve the anti-deformation and anti-wear capabilities of the outermost layer while ensuring the sound insulation and sound absorption effects.

[0022] In a feasible solution, step S1 specifically includes:

[0023] S101. Brush a layer of adhesive on the outer side of the V0-grade thermoplastic elastomer;

[0024] S102. Attach the first black flame-retardant non-woven fabric to the outer side of the V0-grade thermoplastic elastomer.

[0025] Adopting this technical solution can achieve an auxiliary shaping effect by adding an adhesive, and at the same time make the bonding between layers more firm, with better sound insulation and sound absorption effects.

[0026] In a feasible solution, step S1 specifically includes:

[0027] S111. Heat the inner side of the first black flame-retardant non-woven fabric to 180 ± 5 °C, and the outer side temperature shall not exceed 130 °C;

[0028] S112. Attach the high-temperature side of the first black flame-retardant non-woven fabric to the outer side of the V0-grade thermoplastic elastomer, and expel the gas to make it fit tightly.

[0029] In this technical solution, the first black flame-retardant non-woven fabric and the thermoplastic elastomer are bonded together by hot pressing. On the one hand, this is to improve the bonding strength between the two, and on the other hand, it is to make the noise transmission resistance between the two higher. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, the drawings in the following description are some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0031] Figure 1 It is a partial cross-sectional view of the bridge acoustic package in Embodiment 1 of the present invention;

[0032] Figure 2 It is a view of the bridge acoustic package after molding in Embodiment 1 of the present invention;

[0033] Figure 3Schematic diagram of the assembly relationship between the bridge acoustic package and the bridge in the first embodiment of the present invention;

[0034] Figure 4 Flow chart of the one - piece forming processing method of the bridge acoustic package in the third embodiment of the present invention.

[0035] Reference numerals in the figure:

[0036] 1. First black flame - retardant non - woven fabric; 2. V0 - grade thermoplastic elastomer; 3. LDPUR semi - open - cell lightweight foam; 4. Second black flame - retardant non - woven fabric. Detailed implementation manners

[0037] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are some, but not all, of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0038] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "transverse", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "axial", "radial", "circumferential", etc. indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as a limitation to the present invention.

[0039] In the present invention, unless otherwise clearly specified and defined, the terms "installed", "connected", "connected", "fixed", etc. should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral one; it can be a mechanical connection, an electrical connection, or a communication connection; it can be a direct connection or an indirect connection through an intermediate medium, and can be the internal communication of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations. The technical solutions of the present invention will be described in detail below with specific embodiments. These specific embodiments can be combined with each other, and the same or similar concepts or processes may not be repeated in some embodiments.

[0040] The electric bridge is the collective name of the motor, reducer, and high-voltage electronic control unit. All three generate noise in the vehicle, which is transmitted into the vehicle interior and constitutes air noise. This air noise in the vehicle greatly affects the sound quality inside the vehicle. To eliminate this part of the air noise, currently, the three sub-components are usually wrapped separately, and the sound insulation materials used are mostly simple sound insulation layers and sound absorption layers. The sound insulation effect of this structure is not very ideal at present.

[0041] Embodiment 1

[0042] Figure 1 FIG. is a partial cross-sectional view of the electric bridge acoustic wrapping in Embodiment 1 of the present invention. Figure 2 FIG. is a view of the electric bridge acoustic wrapping after molding in Embodiment 1 of the present invention. Figure 3 FIG. is a schematic diagram of the assembly relationship between the electric bridge acoustic wrapping and the electric bridge in Embodiment 1 of the present invention.

[0043] As Figures 1 to 3 shown, the electric bridge acoustic wrapping provided by the embodiment of the present invention includes: a motor part, a reducer part, and an electronic control unit part.

[0044] The motor part, the reducer part, and the electronic control unit part are integrally designed, and from top to bottom, they are: the first black flame-retardant non-woven fabric 1, the V0-class thermoplastic elastomer 2, the LDPUR semi-open-cell lightweight foam 3, and the second black flame-retardant non-woven fabric 4.

[0045] As Figure 1 shown, it is a partial cross-sectional view of the electric bridge acoustic wrapping. It can be seen that the electric bridge acoustic wrapping uses four layers of materials. Among them, the V0-class thermoplastic elastomer 2 and the LDPUR semi-open-cell lightweight foam 3 are respectively located between the upper and lower black flame-retardant non-woven fabrics.

[0046] At the same time, since the electric bridge acoustic wrapping is integral, the motor, reducer, and electronic control unit are all integrally wrapped in the electric bridge acoustic wrapping. On the one hand, this is to reduce the noise transmitted from the gaps when using separate wrapping. On the other hand, it is to cooperate with the material structure to achieve the molding effect and sound insulation and sound absorption effects of the electric bridge acoustic wrapping.

[0047] It should be noted that the main function of the V0-class thermoplastic elastomer 2 is sound insulation. The main functions of the first black flame-retardant non-woven fabric 1 and the second black non-woven fabric 4 are sound absorption and flame retardancy. The main function of the LDPUR semi-open-cell lightweight foam 3 is sound absorption. The first black flame-retardant non-woven fabric 1 and the second black flame-retardant non-woven fabric 4 are respectively arranged inside and outside, cooperating with the V0-class thermoplastic elastomer 2 and the LDPUR semi-open-cell lightweight foam 3 to cooperate with each other for shaping. And during the use after shaping, due to the characteristics of the material properties, the electric bridge acoustic wrapping can better wrap on the electric bridge and is not easy to fall off.

[0048] With this technical solution, it is possible to reduce the ingress of noise at the gap and, in combination with the characteristics of the four-layer material, make the acoustic wrapping of the bridge fit better with the bridge, achieving better forming and sound insulation and absorption effects.

[0049] Optionally, for the acoustic wrapping of the bridge provided in the embodiments of the present invention, the second black flame-retardant non-woven fabric has a specification of 50-150 g / m 2 and a thickness of 0.5-1 mm.

[0050] With this technical solution, it is to achieve good flame retardancy between the bridge and the acoustic wrapping of the bridge, and during long-term use, maintain a certain stable property between the bridge and the second black flame-retardant non-woven fabric, avoiding the overall failure of the entire acoustic wrapping of the bridge due to the failure of the inner layer of the second black flame-retardant non-woven fabric during long-term use.

[0051] Optionally, for the acoustic wrapping of the bridge provided in the embodiments of the present invention, the thermoplastic elastomer with V0-level flame retardancy is a sheet with a thickness of 1-5 mm extruded by mixing TPU / EVA materials.

[0052] With this technical solution, it is to ensure flame retardancy while providing good sound insulation ability and improving the mechanical properties after deformation; sound insulation can reduce noise, and after deformation, it can make the first black flame-retardant non-woven fabric and the second flame-retardant non-woven fabric fit better on the outside of the bridge; if the size is too large, it is easy to have excessive deformation of the first black flame-retardant non-woven fabric after fitting, being prone to tearing or peeling up after long-term use; if the size is too small, the sound insulation effect is not good, and it is not easy to maintain the shape after fitting.

[0053] Optionally, for the acoustic wrapping of the bridge provided in the embodiments of the present invention, the LDPUR semi-open-cell lightweight foam has a density of 8-20 kg / m 3 , and a thickness of 5-25 mm. Preferably, at 13 kg / m 3 , and a thickness of 11-12 mm.

[0054] With this technical solution, it is to ensure good sound absorption effect and, at the same time, cooperate with the thermoplastic elastomer to make the acoustic wrapping of the bridge have a longer service life.

[0055] Embodiment 2

[0056] The embodiments of the present invention further provide an acoustic wrapping of a bridge. On the basis of Embodiment 1, from top to bottom, there are a first black flame-retardant non-woven fabric, a felt material mixed with polyester and pre-oxidized polyester fibers, an LDPUR semi-open-cell lightweight foam, and a second black flame-retardant non-woven fabric.

[0057] Replace the V0 grade thermoplastic elastomer with a felt material mixed with polyester and pre-oxidized polyester fibers. The felt material mixed with polyester and pre-oxidized polyester fibers uses a black hard layer felt with a surface density of 800-1500 g / m 2 and a thickness of 1-5 mm. Preferably, it is a felt material mixed with polyester and pre-oxidized polyester fibers with a surface density of 1250 g / m 2 and a thickness of 3.5-3.7 mm.

[0058] With this technical solution, in order to ensure a certain flame retardant effect while improving the anti-wear ability and extending the service life; at the same time, the mechanical properties of the bridge acoustic package are higher, the sound insulation effect is slightly improved compared with the original solution, and it is not easy to age.

[0059] Example Three

[0060] Figure 4 This is the flowchart of the one-piece forming processing method of the bridge acoustic package in the third embodiment of the present invention. As Figure 2 shown, the third embodiment of the present invention provides a one-piece forming processing method for a bridge acoustic package, including the following steps:

[0061] S1. First, form the upper sheet material. Stack the first black flame retardant non-woven fabric, V0 grade thermoplastic elastomer or felt material mixed with polyester and pre-oxidized polyester fibers, and after heating at 130-200 °C, laminate and bond them together. At the same time, form the lower sheet material; stack the LDPUR semi-open cell lightweight foam and the second black flame retardant non-woven fabric, and after heating at 130-200 °C, laminate and bond them together to form the lower sheet material.

[0062] S2. Place the upper sheet material in the lower mold, cool and shape it to a temperature of 0-20 °C, and attach it to the inner side of the lower mold of the forming mold.

[0063] A possible cooling method is: liquid nitrogen spraying cooling.

[0064] S3. Place the lower sheet material in the upper mold and heat it to 180-230 °C. The heating method can be infrared heating.

[0065] S4. With a pressure of 180-300 tons, press and form the upper sheet material and the lower sheet material in the upper mold and the lower mold respectively, and hold for 30 seconds.

[0066] S4. Place the upper sheet material, the already formed part, and the lower sheet material in the shearing die in sequence, heat it to 80-85 °C, press and bond them together, and punch and remove the required holes and the surrounding waste materials at one time.

[0067] Adopting this technical solution can achieve a very good one-piece molding effect. At the same time, it keeps the second black flame-retardant non-woven fabric with a certain stiffness, avoiding problems such as peeling after long-term use and affecting the service life. Meanwhile, due to the treatment method of cooling first and then hot pressing, it can improve the anti-deformation and anti-wear capabilities of the outermost layer while ensuring the sound insulation and sound absorption effects.

[0068] Optionally, in the one-piece molding processing method of the bridge acoustic package provided in Embodiment 3 of the present invention, step S1 specifically includes:

[0069] S101. Brush a layer of adhesive on the outer side of the V0-grade thermoplastic elastomer.

[0070] Currently, there are many adhesives for bonding thermoplastic elastomers to black flame-retardant non-woven fabrics, which need to be determined according to the specific physical properties of the thermoplastic elastomers, and all belong to the prior art.

[0071] S102. Attach the first black flame-retardant non-woven fabric to the outer side of the V0-grade thermoplastic elastomer.

[0072] Adopting this technical solution can achieve an auxiliary shaping effect by adding an adhesive, and at the same time make the bonding between layers more firm, with better sound insulation and sound absorption effects.

[0073] Optionally, in the one-piece molding processing method of the bridge acoustic package provided in Embodiment 2 of the present invention, step S1 specifically includes:

[0074] S111. Heat the inner side of the first black flame-retardant non-woven fabric to 180 ± 5 °C, and the outer side temperature shall not exceed 130 °C.

[0075] S112. Attach the high-temperature side of the first black flame-retardant non-woven fabric to the outer side of the V0-grade thermoplastic elastomer, and expel the gas to make them fit tightly.

[0076] In this technical solution, the first black flame-retardant non-woven fabric and the thermoplastic elastomer are bonded together by hot pressing. On the one hand, this is to improve the bonding strength between the two, and on the other hand, it is to make the noise transmission resistance between the two higher.

[0077] In the present invention, unless otherwise clearly specified and limited, the first feature being "on" or "under" the second feature may be that the first feature is in direct contact with the second feature, or the first feature and the second feature are indirectly in contact through an intermediate medium.

[0078] Moreover, for the first feature being "above", "over" and "on top of" the second feature, it may mean that the first feature is directly above or obliquely above the second feature, or simply indicates that the first feature has a higher horizontal height than the second feature. For the first feature being "below", "under" and "beneath" the second feature, it may mean that the first feature is directly below or obliquely below the second feature, or simply indicates that the first feature has a lower horizontal height than the second feature.

[0079] In the description of this specification, the descriptions with reference to terms such as "one embodiment", "some embodiments", "example", "specific example" or "some examples", etc. mean that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms are not necessarily directed to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, without contradiction, those skilled in the art can combine and combine the different embodiments or examples described in this specification and the features of different embodiments or examples.

[0080] Finally, it should be noted that: the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that: they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements on some or all of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An integrated molding processing method for a bridge acoustic package, characterized in that, Including the following steps: S1. Stack the first black flame-retardant non-woven fabric and a V0-class thermoplastic elastomer, or stack the first black flame-retardant non-woven fabric and a felt material mixed with polyester and pre-oxidized polyester fibers, and after heating at 130 - 200 °C, laminate and bond them together to form an upper sheet; stack the LDPUR semi-open-cell lightweight foam and the second black flame-retardant non-woven fabric, and after heating at 130 - 200 °C, laminate and bond them together to form a lower sheet; S2. Place the upper sheet in the lower mold, cool and set the temperature to 0 - 20 °C, and attach it to the inner side of the lower mold of the forming mold; S3. Place the lower sheet in the upper mold and heat it up to 180 - 230 °C; S4. Under a pressure of 180 - 300 tons, press and form the upper sheet and the lower sheet in the upper mold and the lower mold respectively, and hold for 30 seconds; S5. Place the upper sheet, the already formed part, and the lower sheet in the shearing die in sequence, heat it up to 80 - 85 °C, press them together, and punch and remove the required holes and the surrounding waste materials at one time.

2. The one-piece forming method according to claim 1, characterized in that, Step S1 specifically includes: S101. Brush a layer of adhesive on the outer side of the V0-class thermoplastic elastomer; S102. Attach the first black flame-retardant non-woven fabric to the outer side of the V0-class thermoplastic elastomer.

3. The one-piece forming method according to claim 1, characterized in that, Step S1 specifically includes: S111. Heat the inner side of the first black flame-retardant non-woven fabric to 180 ± 5 °C, and the outer side temperature shall not exceed 130 °C; S112. Attach the high-temperature side of the first black flame-retardant non-woven fabric to the outer side of the V0-class thermoplastic elastomer, expel the gas, and make them fit tightly.

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