Composite sound insulation product and preparation method thereof

Abstract

The invention relates to a composite sound insulation product and a preparation method thereof, the product comprises a first shell and a second shell, the second shell is partially coated with the first shell, the product further comprises a plurality of through holes penetrating through the first shell and the second shell, and the first shell is provided with sealing edges at the through holes. The preparation method comprises the following steps: preparation before preparation; preparing a first shell; and preparing the second shell. Compared with a traditional single-material foaming product, the composite sound insulation product has the advantages that through reasonable design of combination of the first shell and the second shell, the product has high noise absorption rate and noise isolation rate at the same time, the dual-impedance effect on noise is achieved, the noise absorption and isolation performance is optimized, and the sound insulation effect is improved. Therefore, a more comprehensive sound insulation effect is achieved. In addition, according to the preparation method, the light weight and the manufacturing cost of the material are considered, and the requirements of modern automobiles for energy conservation and economical efficiency are met.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile engineering, and in particular to a composite sound insulation product and a preparation method thereof. Background Art

[0002] In the modern automotive industry, noise control has become an important factor in improving vehicle comfort and user experience. With the popularity of electric vehicles and internal combustion engine vehicles, the diversification of noise sources has made the demand for sound insulation materials more urgent.

[0003] The current market mainly uses single-density polyurethane foam materials to make sound insulation products, such as motor sound insulation covers and engine sound insulation covers. When facing low-frequency and high-frequency noise, single-density materials can usually only effectively isolate sound waves within a certain frequency range, but their ability to absorb sound waves of different frequencies is limited, and their potential acoustic performance is not fully utilized. Especially in electric vehicles, the high-frequency noise generated by the operation of the motor is intertwined with the low-frequency noise of the engine. Traditional sound insulation solutions are often unable to effectively deal with it, which not only affects the driving experience, but also has a negative impact on the overall performance and market competitiveness of the vehicle. Summary of the invention

[0004] In view of the above-mentioned shortcomings of the prior art, an object of the present invention is to provide a composite sound insulation product and a preparation method thereof to solve one or more problems in the prior art.

[0005] To achieve the above object, the technical solution of the present invention is as follows: A composite sound insulation product comprises a first shell and a second shell, wherein the first shell is partially covered by the second shell, and the product further comprises a plurality of through holes penetrating the first shell and the second shell, wherein the first shell is provided with edge sealing at the through holes.

[0006] A preparation method, which is applied to the above-mentioned composite sound insulation product, comprises the following steps: Pre-production preparation, including mold and raw material preparation, where the raw materials include polyols and isocyanates; Preparation of a first shell; Preparation of the Second Shell.

[0007] Furthermore, the preparation of the first shell and the second shell includes the following steps: Heating of molds and raw materials; Inject the corresponding raw materials into the mold; The mold is closed and foamed; Demolding completes the preparation.

[0008] Furthermore, the temperature rise of the mold and the raw material is consistent in the preparation of the first shell and the preparation of the second shell, wherein the mold temperature is 45-60°C, and the raw material temperature is 20-28°C.

[0009] Furthermore, the corresponding raw materials are injected into the mold. For the preparation of the first shell, the injection pressure of the polyol is 100-180 bar, the flow rate is 83-89 g / s, and the injection pressure of the isocyanate is 100-180 bar, and the flow rate is 51-55 g / s.

[0010] Furthermore, the corresponding raw materials are injected into the mold. For the preparation of the second shell, the injection pressure of the polyol is 120-180 bar, the flow rate is 19-21 g / s, and the injection pressure of the isocyanate is 120-180 bar, and the flow rate is 9.5-10.5 g / s.

[0011] Furthermore, the mold closing and foaming are consistent in the preparation of the first shell and the preparation of the second shell, and the foaming time is greater than 180s.

[0012] Furthermore, the preparation of the second shell is combined with the preparation of the first shell.

[0013] Furthermore, before the second shell is prepared, the first shell is left standing for more than 2 hours after demoulding.

[0014] Furthermore, the demoulding of the first shell from the mold is completed based on a water-based demoulding agent.

[0015] Compared with the prior art, the beneficial technical effects of the present invention are as follows: Compared with traditional single-material foam products, the composite sound insulation product of the present invention has a strong noise absorption rate and noise isolation rate through a reasonable design of the combination of the first shell and the second shell, achieving a double impedance effect on noise, optimizing the absorption and isolation performance of noise, and thus achieving a more comprehensive sound insulation effect. In addition, the preparation method of the present invention also takes into account the lightweight of materials and manufacturing costs, meeting the requirements of modern automobiles for energy saving and economy. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 A schematic diagram showing the structure of a composite sound insulation product and a preparation method thereof according to an embodiment of the present invention Figure Ⅰ .

[0017] Figure 2 A schematic diagram showing the structure of a composite sound insulation product and a preparation method thereof according to an embodiment of the present invention Figure II .

[0018] Figure 3A partial structural schematic diagram of a through hole of a composite sound insulation product and a preparation method thereof according to an embodiment of the present invention is shown.

[0019] Figure 4 A schematic diagram of the product preparation process of a composite sound insulation product and a preparation method thereof according to an embodiment of the present invention is shown.

[0020] Figure 5 A schematic diagram of the process of preparing a first shell and a second shell of a composite sound insulation product and a preparation method thereof according to an embodiment of the present invention is shown.

[0021] Figure 6 A diagram showing the transmission of sound through a composite sound insulation product and a preparation method thereof according to an embodiment of the present invention.

[0022] Figure 7 The figure shows the experimental data of acoustic testing of a composite sound insulation product and a preparation method thereof according to an embodiment of the present invention.

[0023] Markings in the accompanying drawings: 1, first shell; 101, edge sealing; 2, second shell; 3, through hole. DETAILED DESCRIPTION

[0024] In order to make the purpose, technical scheme and advantages of the present invention clearer, the following is a further detailed description of a composite sound insulation product and its preparation method proposed by the present invention in combination with the accompanying drawings and specific embodiments. According to the following description, the advantages and features of the present invention will be clearer. It should be noted that the drawings are in a very simplified form and use non-precise proportions, which are only used to conveniently and clearly assist in explaining the purpose of the embodiments of the present invention. In order to make the purpose, features and advantages of the present invention more obvious and easy to understand, please refer to the accompanying drawings. It should be noted that the structure, proportion, size, etc. shown in the drawings of this specification are only used to match the content disclosed in the specification for people familiar with this technology to understand and read, and are not used to limit the limiting conditions for the implementation of the present invention, so they have no technical substantive significance. Any structural modification, change in proportional relationship or adjustment of size, without affecting the effect that the present invention can produce and the purpose that can be achieved, should still fall within the scope of the technical content disclosed by the present invention.

[0025] See also Figures 1 to 3 The composite sound insulation product of this embodiment includes a first shell 1 and a second shell 2. The first shell 1 is partially covered by the second shell 2 to form a double-layer structure. The product also includes a plurality of through holes 3 that penetrate the first shell 1 and the second shell 2. The first shell 1 is provided with edge sealing 101 at the through holes 3. The setting of the edge sealing 101 can prevent the second shell 2 from overflowing to the surface of the first shell 1 away from the second shell 2 after injection during preparation.

[0026] See also Figure 4 and Figure 5 The preparation method of this embodiment is applied to the above-mentioned composite sound insulation product, and comprises the following steps: Step 1: Pre-production preparation, including mold and raw material preparation, where the raw materials include polyols and isocyanates.

[0027] Prepare molds for making the first shell 1 and the second shell 2, as well as polyol and isocyanate. Preferably, the polyurethane material generated by mixing polyol and isocyanate in this embodiment has the characteristics of high density, high strength, high toughness, high wear resistance, etc.

[0028] Step 2: Preparation of the first shell 1 .

[0029] Step 2.1: Heating of mold and raw materials.

[0030] The temperature of the mold is 45-60° C., and the temperature of the raw material is 20-28° C. By heating the mold, the surface quality of the product after molding can be effectively improved and the deformation of the product can be reduced. The heating of the raw materials can promote the chemical reaction between them.

[0031] Step 2.2: Inject the corresponding raw materials into the mold.

[0032] For the preparation of the first shell 1, the injection pressure of the polyol is 100-180 bar, the flow rate is 83-89 g / s, and the injection pressure of the isocyanate is 100-180 bar, the flow rate is 51-55 g / s. In this embodiment, the first shell 1 is a high-density integral skin polyurethane material, which is used to improve the noise reduction performance of the product, and is preferably prepared by a high-flow high-pressure foaming machine.

[0033] Step 2.3: Mold closing and foaming.

[0034] The mold is closed and foaming is performed, and the foaming time is greater than 180 seconds. Sufficient foaming time can improve dimensional accuracy and product quality, shorten the molding cycle, and improve production efficiency, thermal insulation and noise reduction properties.

[0035] Step 2.4: Demolding completes the preparation.

[0036] The mold is opened and demolded, and the first shell 1 is left to stand for more than 2 hours after demolding. After being fully matured, the first shell 1 is placed into the mold and injected to prepare the second shell 2, which can avoid the shrinkage of the demolded product. In addition, the demolding of the first shell 1 from the mold is completed based on a water-based demolding agent to avoid the demolding effect being too good, resulting in failure to stick to the second shell 2.

[0037] Step 3: Preparation of the second shell 2 .

[0038] The preparation of the second shell 2 is combined with the preparation of the first shell 1 .

[0039] Step 3.1: Heating of mold and raw materials.

[0040] The temperature of the mold is 45-60° C., and the temperature of the raw material is 20-28° C. By heating the mold, the surface quality of the product after molding can be effectively improved and the deformation of the product can be reduced. The heating of the raw materials can promote the chemical reaction between them.

[0041] Step 3.2: Inject the corresponding raw materials into the mold.

[0042] For the preparation of the second shell 2, the injection pressure of the polyol is 120-180 bar, the flow rate is 19-21 g / s, and the injection pressure of the isocyanate is 120-180 bar, the flow rate is 9.5-10.5 g / s. In this embodiment, the second shell 2 is a high-density integral skin polyurethane material, which is used to improve the noise reduction performance of the product, and is preferably prepared by a small flow high-pressure foaming machine.

[0043] Step 3.3: The mold is closed and foaming is carried out.

[0044] The mold is closed and foaming is performed, and the foaming time is greater than 180 seconds. Sufficient foaming time can improve dimensional accuracy and product quality, shorten the molding cycle, and improve production efficiency, thermal insulation and noise reduction properties.

[0045] Step 3.4: Demolding completes the preparation.

[0046] The mold opens and the product is finally prepared.

[0047] For details, please refer to Figure 6 and Figure 7 After the sound waves from the noise source enter the product, the reflected sound waves are removed, and part of the remaining sound waves are absorbed by the second shell 2 and converted into internal energy, while the other part is blocked by the first shell 1. Through the above two layers of noise reduction, only part of the sound waves penetrate the surface of the product and are transmitted, thereby achieving the effect of sound insulation and noise reduction. Figure 7 As shown, in the acoustic test, the dual-impedance product structure of this embodiment consisting of the first shell 1 and the second shell 2 has certain advantages over the traditional single-impedance product structure in both sound insulation and sound absorption.

[0048] The technical features of the above-described embodiments can be combined arbitrarily. In order to make the description concise, all possible combinations of the technical features in the above-described embodiments are not described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification. The above-described embodiments only express several implementation methods of the present invention, and their descriptions are relatively specific and detailed, but they cannot be understood as limiting the scope of the invention patent. It should be pointed out that for ordinary technicians in this field, without departing from the concept of the present invention, several variations and improvements can be made, which all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention shall be based on the attached claims.

Claims

1. A composite sound insulation product, characterized in that: The product includes a first shell and a second shell, wherein the first shell is partially covered by the second shell, and the product further includes a plurality of through holes penetrating the first shell and the second shell, and the first shell is provided with edge sealing at the through holes.

2. A preparation method, which is applied to a composite sound insulation product as claimed in claim 1, characterized in that: The steps include: Pre-production preparation, including mold and raw material preparation, where the raw materials include polyols and isocyanates; Preparation of a first shell; Preparation of the Second Shell.

3. A preparation method according to claim 2, characterized in that: The preparation of the first shell and the second shell both include the following steps: Heating of molds and raw materials; Inject the corresponding raw materials into the mold; The mold is closed and foamed; Demolding completes the preparation.

4. A preparation method according to claim 3, characterized in that: The temperature rise of the mold and the raw material is consistent in the preparation of the first shell and the preparation of the second shell, wherein the mold temperature is 45-60°C, and the raw material temperature is 20-28°C.

5. A preparation method according to claim 4, characterized in that: The corresponding raw materials are injected into the mold. For the preparation of the first shell, the injection pressure of the polyol is 100-180 bar, the flow rate is 83-89 g / s, and the injection pressure of the isocyanate is 100-180 bar, and the flow rate is 51-55 g / s.

6. A preparation method according to claim 5, characterized in that: The corresponding raw materials are injected into the mold. For the preparation of the second shell, the injection pressure of the polyol is 120-180 bar and the flow rate is 19-21 g / s, and the injection pressure of the isocyanate is 120-180 bar and the flow rate is 9.5-10.5 g / s.

7. A preparation method according to claim 6, characterized in that: The mold closing and foaming are consistent in the preparation of the first shell and the preparation of the second shell, and the foaming time is greater than 180s.

8. A preparation method according to claim 7, characterized in that: The preparation of the second shell is combined with the preparation of the first shell.

9. A preparation method according to claim 8, characterized in that: Before the second shell is prepared, the first shell is left standing for more than 2 hours after demoulding.

10. A preparation method according to claim 9, characterized in that: The demoulding of the first shell from the mold is completed based on a water-based demoulding agent.

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