A device and method for avoiding breakage of an aluminum foil on a surface of a soundproofing mat part

Abstract

The present application relates to a kind of device and method for avoiding the rupture of aluminum foil on the surface of sound insulation mat parts, the device includes pre-pressing block (1) and preforming lower die (2) arranged below pre-pressing block (1), the top of pre-pressing block (1) is connected with cylinder (3) for driving its up and down movement, and cylinder (3) is installed on top fixed plate (4);The method is to pre-press the aluminum foil, to form the required feature shape in advance, and to reserve the stretching allowance in advance in the feature area with large drop and serious stretching.Compared with the prior art, the present application can improve production efficiency, reduce scrap rate, and reduce labor cost.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automobile parts processing, in particular to a device and method for avoiding aluminum foil rupture on the surface of sound insulation pad parts. BACKGROUND

[0002] In order to provide better sound insulation, heat insulation and flame resistance, etc., some sound insulation pad parts require a layer of aluminum foil on the surface of the product during production to achieve the required performance indicators. However, due to the poor tensile properties of aluminum foil compared to non-woven fabric, light foam, glass fiber, felt, PET, etc., once the product features have a large drop and frequent fluctuations, the aluminum foil cannot be stretched in place in these areas, resulting in aluminum foil rupture in the feature area, and ultimately the aluminum foil cannot completely cover the required area, resulting in performance that cannot meet the requirements. Currently, in order to alleviate such situations, the general solution is: preforming + later patching, that is, during product forming, the main product is preformed (leaving a 20mm gap) to form the approximate shape of the product, then the press is opened, the worker places the aluminum foil on the surface of the product, and manually presses the aluminum foil according to the features of the product to make the aluminum foil as close as possible to the surface of the product, reducing the stretching amount during the final forming and cutting process and reducing the risk of aluminum foil rupture. However, due to manual operation, the problem of aluminum foil rupture and non-adhesion to the main body of the product cannot be completely avoided during the final forming and cutting process, so an additional patching process is required, that is, the aluminum foil is manually adhered to the problematic area later, resulting in low production efficiency, increased scrap rate, and high labor cost for such products. SUMMARY

[0003] The purpose of the present application is to provide a device and method for avoiding aluminum foil rupture on the surface of sound insulation pad parts, improving production efficiency and reducing scrap rate.

[0004] The purpose of the present application can be achieved by the following technical solution: a device for avoiding aluminum foil rupture on the surface of sound insulation pad parts, comprising a pre-pressing block and a pre-forming lower die arranged below the pre-pressing block, wherein the top of the pre-pressing block is connected to a gas cylinder for driving its up and down movement, and the gas cylinder is installed on a top fixed plate.

[0005] Preferably, a plurality of gas cylinders are arranged on the top fixed plate, and each gas cylinder is connected to a pre-pressing block at the bottom.

[0006] Preferably, the top fixed plate and the pre-forming lower die are arranged on a rack.

[0007] A method for avoiding aluminum foil rupture on the surface of sound insulation pad parts uses the above device to pre-press the aluminum foil and form the required feature shape in advance.

[0008] Preferably, the aluminum foil is shaped in advance to the required characteristic shape, and a stretching allowance is reserved in advance in the area of the characteristic shape with large drop and serious stretching.

[0009] Further preferably, according to the different characteristic shapes of the acoustic insulation pad part, the part is divided into a gentle area and a concave-convex area, a gap is reserved between the upper and lower molds in the gentle area, and the height of the concave-convex area is reduced / lifted.

[0010] More preferably, a gap of 2-3 mm is reserved between the upper and lower molds in the gentle area, and the height of the concave-convex area is reduced / lifted by 1 / 2.

[0011] Preferably, for the area with low slope of the acoustic insulation pad part, the slope of the aluminum foil is increased while the stretching allowance is increased.

[0012] Further preferably, for the area with a slope of 70-90° of the acoustic insulation pad part, the slope of the aluminum foil is increased while the stretching allowance is increased.

[0013] More preferably, for the area with a slope of 70-90° of the acoustic insulation pad part, the slope of the aluminum foil is adjusted to be 1 / 2 of the initial angle while the stretching allowance is increased.

[0014] Compared with the prior art, the present application has the following advantages:

[0015] 1. The finished part aluminum foil of the present application is completely attached to the product body without rupture, greatly reducing the scrap rate.

[0016] 2. The present application can ensure that the aluminum foil is attached to the product profile, and there is enough aluminum foil for material stretching in the area with large drop, thereby ensuring that the aluminum foil is completely and comfortably covered on the product surface.

[0017] 3. The present application uses pneumatic instead of manual pre-pressing, which improves production efficiency, meets various performance requirements of the product, and reduces labor costs. BRIEF DESCRIPTION OF DRAWINGS

[0018] Fig. 1 The device structure diagram for avoiding the rupture of the aluminum foil on the surface of the acoustic insulation pad part of the present application;

[0019] Fig. 2 The structure diagram of the pre-pressing block and the pre-forming lower mold of the present application;

[0020] Fig. 3 The structure diagram of the aluminum foil stretching area before optimization of Example 1;

[0021] Fig. 4 The structure diagram of the aluminum foil stretching area after optimization of Example 1;

[0022] Fig. 5The contrast chart before and after the optimization of the aluminum foil stretching area of Example 1, orange is the initial, blue is after optimization;

[0023] Fig. 6 The traditional forming method of Comparative Example 1;

[0024] In the figure: 1-pre-press block, 2-pre-forming lower die, 3-cylinder, 4-top fixed plate, 5-machine frame. DETAILED DESCRIPTION

[0025] The application will be described in detail below in conjunction with the drawings and specific examples. The following examples are implemented on the premise of the technical solution of the application, and detailed implementation modes and specific operation processes are given, but the protection scope of the application is not limited to the following examples.

[0026] Example 1

[0027] A method for avoiding the rupture of the aluminum foil on the surface of the sound insulation pad part, a set of pneumatic aluminum foil pre-pressing tool is designed, the aluminum foil is formed into the required characteristic shape in advance, and the stretching allowance is reserved in advance in the characteristic area with large difference and serious stretching, so that when the aluminum foil is placed in the mold for forming and cutting, it can be ensured that the aluminum foil is completely fitted with the product profile, and there is enough aluminum foil for material stretching in the area with large difference, thereby ensuring that the aluminum foil is complete and neatly covered on the surface of the product.

[0028] As shown in Figs. 1-2 , the aluminum foil pre-pressing tool includes a pre-pressing block 1, a pre-forming lower die 2, a cylinder 3, a top fixed plate 4 and a machine frame 5, the pre-forming lower die 2 is arranged on the machine frame 5 and located below the pre-pressing block 1, the top fixed plate 4 is arranged on the machine frame 5, and the cylinder 3 is arranged on the top fixed plate 4, and the cylinder 3 is connected with the pre-pressing block 1.

[0029] The specific design scheme of the aluminum foil pre-pressing tool is as follows: according to the different characteristics of the profile, 2-3mm gap is reserved between the upper and lower modules in the flat area for forming the required characteristics of the product; in the area with serious difference, the concave-convex area needs to be lowered / higher by 1 / 2 of the height of the characteristics itself, which increases the space and reserves enough raw materials for stretching when integrated with the product; if the slope of the characteristics is not enough (the slope is 70-90°), the slope needs to be adjusted artificially while increasing the stretching allowance, so as to ensure that the aluminum foil will not be ruptured due to local severe stretching, and the slope adjustment is generally 1 / 2 of the initial angle.

[0030] The aluminum foil of the outer front wall sound insulation pad of a certain vehicle model is optimized by using the method of the example. As shown in Figs. 3-5 , the aluminum foil stretching area after pre-pressing has enough allowance, and by designing the stretching allowance in advance and using the pre-pressing tool to form the aluminum foil in advance, it can be ensured that the aluminum foil and the product are completely fitted without rupture when finally forming and cutting.

[0031] Comparative Example 1

[0032] like Fig. 6 As shown, in the traditional forming method, aluminum foil sheets need to be manually pressed and bonded to the product in the stretching area, resulting in low production efficiency, high scrap rate, and extremely high labor costs.

[0033] The above description of the embodiments is provided to enable those skilled in the art to understand and use the invention. It will be apparent to those skilled in the art that various modifications can be made to these embodiments, and the general principles described herein can be applied to other embodiments without inventive effort. Therefore, the present invention is not limited to the above embodiments, and any improvements and modifications made by those skilled in the art based on the disclosure of the present invention without departing from the scope of the invention should be within the protection scope of the present invention.

Claims

1. A method for avoiding breakage of an aluminum foil on a surface of a part of an acoustical insulation mat, characterized in that, The device for avoiding the rupture of the aluminum foil on the surface of the sound insulation pad part is used to pre-press the aluminum foil and form the aluminum foil into the required characteristic shape in advance; The device comprises a pre-pressing block (1) and a pre-forming lower die (2) arranged below the pre-pressing block (1), and the top of the pre-pressing block (1) is connected with a cylinder (3) for driving the pre-pressing block to move up and down, and the cylinder (3) is installed on a top fixing plate (4); A plurality of cylinders (3) are arranged on the top fixing plate (4), and the bottom of each cylinder (3) is connected with a pre-pressing block (1). The aluminum foil is formed into the required characteristic shape in advance, and a stretching allowance is reserved in advance in the characteristic area with a large drop and serious stretching; According to the different surface feature characteristics of the sound insulation pad part, the surface feature characteristics are divided into a flat area and a concave-convex area, and a gap is reserved between the upper die and the lower die in the flat area, and the height of the concave-convex area is reduced / lifted; A gap of 2-3 mm is reserved between the upper die and the lower die in the flat area, and the height of the concave-convex area is reduced / lifted by 1 / 2. For the area with an inclination of 70-90° of the sound insulation pad part, the inclination of the aluminum foil is adjusted to 1 / 2 of the initial angle while increasing the stretching allowance.

2. The method of claim 1, wherein, The top fixing plate (4) and the pre-forming lower die (2) are arranged on a rack (5).

Images