Lightweight acoustic package and air suspension system

Abstract

The invention provides a lightweight acoustic package and an air suspension system, the lightweight acoustic package comprises a shell, the shell comprises an upper shell and a lower shell, the edges of the upper shell and the lower shell are connected through concave-convex fit, so that the shell is sealed to form a mounting cavity; the shell is made of a mixture of nylon and glass fibers, and the upper shell and the lower shell are respectively and integrally formed in an injection molding mode. Therefore, the acoustic bag is made of plastic, light weight is achieved, the weight of the acoustic bag is greatly reduced, meanwhile, the injection molding technology is simple and easy to operate, equipment is easy to maintain, uniform products can be rapidly produced in batches, and the requirement for the technology is reduced. And the edges of the upper shell and the lower shell are connected in a concave-convex matching manner, so that the tight connection of the upper shell and the lower shell can be known, and the mounting cavity meets the sealing requirement, thereby meeting the acoustic performance requirement of the acoustic bag and effectively obstructing the noise transmission of equipment mounted in the acoustic bag.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile acoustic packages, and in particular to a lightweight acoustic package and an air suspension system. Background Art

[0002] The air supply units of existing air suspension systems are all designed with acoustic packages, which can effectively reduce the noise of the compressor (air pump) when it is working, bringing a significant riding experience to the car owner. At present, the acoustic package materials of various manufacturers are all made of steel. At present, steel acoustic packages have been accepted by OEMs, but the density of steel material itself is relatively high, reaching 7850Kg / m 3 , resulting in a heavier weight for the acoustic package. As the vehicle has strict weight requirements, the weight of the air supply unit needs to be continuously optimized to reduce the weight of the air supply unit assembly. At the same time, many fixed brackets are integrated on the entire air supply unit to fix and install pipelines, lines and other components and equipment. Currently, the fixed brackets are welded together with the upper and lower shells of the acoustic package through sheet metal parts; and each sheet metal fixed bracket requires the development of a mold, resulting in a large number of molds that need to be developed, increasing the welding process and making the production process more complicated, resulting in a higher production cost for the acoustic package.

[0003] Therefore, it is necessary to design a lightweight acoustic package and vehicle to solve the problems of heavy weight and complex production process of the above-mentioned acoustic package. Summary of the invention

[0004] In view of some of the shortcomings of the above prior art, the present invention provides a lightweight acoustic package and air suspension system, which effectively reduce the weight of the product by using suitable materials, and the injection molding process is simple and easy to operate.

[0005] To achieve the above-mentioned object and other related objects, the present invention provides a lightweight acoustic package, comprising:

[0006] The housing comprises an upper housing and a lower housing, the edges of the upper housing and the lower housing being connected by concave-convex fitting so that the housing is sealed to form an installation cavity;

[0007] The shell material is a mixture of nylon and glass fiber, and the upper shell and the lower shell are respectively integrally injection molded.

[0008] In one embodiment of the present invention, a groove portion is provided at the edge of the upper shell, and a protrusion portion is provided at the edge of the lower shell. The protrusion portion is inserted into the groove portion and welded by a vibration friction welding process.

[0009] In an embodiment of the present invention, the depth of the groove portion is smaller than the protruding height of the protruding portion.

[0010] In an embodiment of the present invention, the width of the groove portion is greater than the width of the protrusion portion.

[0011] In one embodiment of the present invention, grid ribs are disposed on the top and bottom surfaces of the shell, and vertical ribs are disposed on the side surfaces of the shell.

[0012] In one embodiment of the present invention, the rib plate thickness of each grid rib and vertical rib is more than 80% of the corresponding shell wall thickness.

[0013] In one embodiment of the present invention, the content of glass fiber in the mixture is 30%-35%.

[0014] In one embodiment of the present invention, a shell bracket and a distribution valve bracket are provided on the side of the shell, and a plurality of pipeline brackets are provided on the top surface, the bottom surface and the side surface of the shell.

[0015] In one embodiment of the present invention, the housing bracket, the distribution valve bracket, and each pipeline bracket are integrally formed with the corresponding housing.

[0016] To achieve the above-mentioned object and other related objects, the present invention further provides an air suspension system, comprising an air supply unit and the above-mentioned lightweight acoustic package, wherein the air supply unit is installed in the installation cavity of the lightweight acoustic package.

[0017] The beneficial technical effects of the present invention include at least:

[0018] (1) A lightweight acoustic package of the present invention includes a shell, the material of the shell is a mixture of nylon and glass fiber, and the shell includes an upper shell and a lower shell that are integrally injection molded. The edges of the upper shell and the lower shell are connected by concave-convex fitting, so that the upper shell and the lower shell are connected to form an acoustic package body with an installation cavity. Therefore, the acoustic package of the present invention can reduce the weight by 50% compared with the acoustic package made of metal materials, which has a significant weight reduction effect; at the same time, the injection molding process is simple, easy to operate, and the equipment is easy to maintain, and it can quickly mass-produce uniform products, reducing the technical requirements, and the upper shell and the lower shell are tightly connected, so that the installation cavity meets the sealing requirements, thereby meeting the acoustic performance requirements of the acoustic package and effectively blocking the noise propagation of the equipment installed therein.

[0019] (2) The raised part of the upper shell and the groove part of the lower shell are welded by vibration friction welding process. The raised part of the upper shell is placed in the groove part of the lower shell to ensure that the contact surface is clean and free of contaminants to ensure the welding quality. Then, high-frequency vibration friction is used to rub the contact surfaces of the raised part of the upper shell and the groove part of the lower shell against each other. During the friction process, the heat generated in the welding area causes the plastic material to soften locally, and axial pressure is applied to promote the plastic flow of the material. The excess overflow generated during the friction process will be squeezed and filled into the groove part corresponding to the outer side of the raised part. This process ensures a high degree of tightness of the welding surface. The welded overflow is firmly fixed by the side wall of the groove part, further improving the strength and sealing of the connection. Since the solid connection generated by welding effectively eliminates the gap between the upper and lower shells, the flat gasket used in traditional metal shells is no longer required to simplify the assembly process. The production efficiency is improved and the overall production cost is reduced. At the same time, the welded joint simplifies the structural design and improves reliability and strength.

[0020] (3) The pipe bracket and line bracket are integrally formed with the upper shell or the lower shell by injection molding, which improves the dimensional accuracy. The integrated design also reduces the number of parts, improves production efficiency, and reduces production costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 A schematic diagram of the structure of a lightweight acoustic package provided by one embodiment of the present invention;

[0022] Figure 2 for Figure 1 A top view of

[0023] Figure 3 for Figure 2 AA section view;

[0024] Figure 4 A diagram showing the use status of a lightweight acoustic package provided in one embodiment of the present invention.

[0025] Component Symbols:

[0026] Upper shell 1, lower shell 2, groove portion 11, protrusion 21, top surface 12, upper vertical surface 13, bottom surface 22, lower vertical surface 23, grid ribs 31, vertical ribs 32, shell bracket 41, distribution valve bracket 42, pipeline bracket 43, line bracket 432, pipeline bracket 431, a pair of fixed brackets 44, air pump mounting hole 51, pipe hole 52, and wire hole 53. DETAILED DESCRIPTION

[0027] The following describes the embodiments of the present invention by specific examples, and those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the following embodiments and features in the embodiments can be combined with each other without conflict.

[0028] It should be noted that the illustrations provided in the following embodiments are only schematic illustrations of the basic concept of the present invention, and thus the drawings only show components related to the present invention rather than being drawn according to the number, shape and size of components in actual implementation. In actual implementation, the type, quantity and proportion of each component may be changed arbitrarily, and the component layout may also be more complicated.

[0029] In the following description, numerous details are discussed to provide a more thorough explanation of the embodiments of the present invention. However, it is obvious to those skilled in the art that the embodiments of the present invention can be implemented without these specific details. In other embodiments, well-known structures and devices are shown in the form of block diagrams rather than in detail to avoid making the embodiments of the present invention difficult to understand.

[0030] It should be noted that the acoustic package is an acoustic material package designed to achieve the NVH performance of the whole vehicle, such as front surround sound insulation pads, carpets, engine hood insulation cotton, ceiling sound-absorbing cotton, spare tire cover, etc.; the acoustic package is a means of reasonably using the transmission path from the vehicle noise source (powertrain, assembly accessories, transmission system, intake and exhaust, tire noise, etc.) to the interior of the car, and is a practical method to effectively block the transmission of noise during the transmission process.

[0031] See also Figure 1 The present invention provides a lightweight acoustic package, including a shell, the shell including an upper shell 1 and a lower shell 2, the edges of the upper shell 1 and the lower shell 2 are connected by concave-convex fitting, so that the shell is sealed to form an installation cavity; the shell material is a mixture of nylon and glass fiber, and the upper shell and the lower shell are respectively integrally injection molded.

[0032] The above-mentioned lightweight acoustic package is made of plastic, which can greatly reduce the weight of the acoustic package. At the same time, the injection molding process is simple, easy to operate, and the equipment is easy to maintain. It can quickly mass-produce uniform products, reducing the technical requirements. In addition, the edges of the upper shell 1 and the lower shell 2 are connected by concave and convex fitting, so that the upper shell 1 and the lower shell 2 are tightly connected, so that the installation cavity meets the sealing requirements, thereby meeting the acoustic performance requirements of the acoustic package and effectively blocking the noise propagation of the equipment installed therein.

[0033] See also Figure 2and Figure 3 In one embodiment of the present invention, a groove portion 11 is provided on the edge of the upper shell 1, and a protrusion portion 21 is provided on the edge of the lower shell 2; wherein the protrusion portion 21 of the lower shell 2 is inserted into the groove portion 11 of the upper shell 1, so that the upper shell 1 and the lower shell 2 are connected to form an acoustic enclosure with a mounting cavity. The protrusion portion 11 of the upper shell 1 and the groove portion 21 of the lower shell 2 are welded by a vibration friction welding process.

[0034] In one embodiment of the present invention, a convex protrusion 21 is formed in the middle of the edge of the lower shell 2, and a concave groove 11 is formed in the middle of the edge of the upper shell 1. The depth of the groove 11 (welding wide rib) is less than the protruding height of the protrusion 21 (welding narrow rib), thereby ensuring the contact between the welding wide rib and the welding narrow rib. The width of the groove 11 is greater than the width of the protrusion 21, so that the overflow is filled into the gap during welding.

[0035] Specifically, the raised portion 11 of the upper shell 1 is placed in the groove portion 21 of the lower shell 2 to ensure that the contact surface is clean and free of contaminants to ensure the quality of welding; then high-frequency vibration friction is used to rub the contact surfaces of the raised portion 11 (welding narrow ribs) of the upper shell 1 and the groove portion 21 (welding wide ribs) of the lower shell 2 against each other. During the friction process, the heat generated in the welding area causes the plastic material to soften locally, and axial pressure is applied to promote the plastic flow of the material. The excess overflow generated during the friction process will be squeezed and filled into the groove portion 11 (welding overflow area) corresponding to the outer side of the raised portion 21. This process ensures a high degree of tightness of the welding surface. In addition, the welding overflow is firmly fixed by the side wall (welding rib) of the groove portion 11, further improving the strength and sealing of the connection. Since the solid-state connection generated by welding effectively eliminates the gap between the upper and lower shells, the flat gasket used in traditional metal shells is no longer required to simplify the assembly process. Therefore, the upper shell 1 and the lower shell 2 are welded by a vibration friction welding process, which reduces the need for bolt connections and gaskets in traditional metal shells, thereby significantly improving production efficiency and reducing overall production costs. At the same time, the welded joints simplify the structural design and improve reliability and strength.

[0036] In one embodiment of the present invention, the upper shell 1 includes a top surface 12 and an upper vertical surface 13, the upper vertical surface 13 is arranged perpendicular to the top surface 12, and the upper vertical surface 13 extends downward from the outer edge of the top surface 12, and the extension end is the edge of the upper shell 1. The lower shell 2 includes a bottom surface 22 and a lower vertical surface 23, the lower vertical surface 23 is arranged perpendicular to the bottom surface 22, and the lower vertical surface 23 extends upward from the outer edge of the bottom surface 22, and the extension end is the edge of the lower shell 2.

[0037] It should be noted that the shapes of the upper shell 1 and the lower shell 2 are not fixed and can be set as needed. It only needs the edge of the upper shell 1 to correspond to the edge of the lower shell 2 so that they can be welded together.

[0038] In one embodiment of the present invention, mesh ribs 31 are disposed on the top surface 12 and the bottom surface 22 of the shell, and vertical ribs 32 are disposed on the side surfaces of the shell.

[0039] Specifically, the outer surfaces of the top surface 12 and the bottom surface 22 are evenly provided with mesh ribs 31, and the outer surfaces of the upper vertical surface 11 and the lower vertical surface 21 are evenly provided with vertical ribs 32. The rib plate thickness of each mesh rib 31 and vertical rib 32 is more than 80% of the wall thickness of the corresponding shell.

[0040] It is necessary to explain that the longitudinal ribs of the grid ribs 31 and the corresponding vertical ribs 32 can be connected to form a vertical arrangement. The arrangement of the grid ribs 31 and the vertical ribs 32 enhances the strength of the shell. At the same time, since the acoustic bag is installed on the frame at the bottom of the vehicle, when the vehicle is driving, gravel may hit the acoustic bag body. The grid ribs 31 and the vertical ribs 32 can prevent the gravel from directly hitting the acoustic bag body and causing damage, affecting its performance.

[0041] In one embodiment of the present invention, the material of the upper shell 1 and the lower shell 2 is a mixture of nylon and glass fiber, wherein the content of the glass fiber is 30%-35%, and the content of the glass fiber is preferably 30%, 33% and 35%.

[0042] It should be noted that the density of the mixture of nylon and glass fiber is relatively low, and it can reduce the weight by 50% compared with the acoustic package made of metal materials. It has a significant weight reduction effect. The addition of glass fiber increases the toughness of the material.

[0043] In one embodiment of the present invention, a housing bracket 41 and a distribution valve bracket 42 are provided on the side of the housing, and a plurality of pipeline brackets 43 are provided on the top surface 12, the bottom surface 22 and the side of the housing. The housing bracket 41, the distribution valve bracket 42 and each pipeline bracket 43 are integrally formed with the corresponding housing.

[0044] Specifically, a housing support 41 and a distribution valve support 42 are integrally formed on the upper vertical surface 11 of the upper housing 1 , and a plurality of pipeline supports 43 are provided on the outer surfaces of the upper housing 1 and the lower housing 2 .

[0045] See also Figure 4 Specifically, during installation and use, a pair of fixing brackets 44 are respectively provided on both sides of the upper vertical surface 11 in the longitudinal direction, for fixing the acoustic package on the vehicle frame. The shell bracket 41 is provided in the middle of one side of the upper vertical surface 11, for further fixing the acoustic package. The distribution valve bracket 42 is provided with a distribution valve. When the gas of the gas supply unit is output through the pipeline, it first enters the distribution valve, and after being distributed on demand by the distribution valve, the gas is then delivered to the required equipment.

[0046] The upper vertical surface 11 of the upper shell 1 is respectively provided with an air pump mounting hole 51, a tube hole 52 and a wire hole 53 of the air supply unit. The tube hole 52 and the wire hole 53 are through holes for connecting the pipes and lines on the air supply unit. The air pump mounting hole 51 is used for bolting the air pump of the air supply unit on the acoustic package.

[0047] The pipeline support 43 further includes a pipeline support 431 and a plurality of line supports 432. The pipeline support 431 is integrally formed on the upper vertical surface 11 near the pipe hole 52, and the wound pipe can be tied and fixed by a rope. The plurality of line supports 432 are integrally formed on the upper shell 1 and the lower shell 2, wherein the shape of the line support 432 can be set to be U-shaped, plate-shaped or long strips as required.

[0048] Therefore, the above-mentioned pipeline support 43 is integrally formed with the upper shell 1 or the lower shell 2 through injection molding, thereby improving the dimensional accuracy; the integrated design reduces the number of parts, improves production efficiency, and reduces production costs.

[0049] See also Figure 4 To achieve the above and other related purposes, the present invention also provides an air suspension system, including an air supply unit and the above lightweight acoustic package, wherein the air supply unit is installed in the installation cavity of the lightweight acoustic package. The air supply unit is effectively blocked from transmitting noise when it is working, thereby meeting the NVH performance requirements of the whole vehicle.

[0050] In summary, the lightweight acoustic package and air suspension system of the present invention have at least the following beneficial technical effects:

[0051] (1) The acoustic package is made of plastic, which can greatly reduce the weight of the acoustic package. At the same time, the injection molding process is simple, easy to operate, and the equipment is easy to maintain. It can quickly mass-produce uniform products, reducing the technical requirements. In addition, the raised portion 21 of the lower shell 2 is inserted into the groove portion 11 of the upper shell 1, and the upper shell 1 and the lower shell 2 are connected to form an installation cavity. The upper shell 1 and the lower shell 2 are tightly connected, so that the installation cavity meets the sealing requirements, thereby meeting the acoustic performance requirements of the acoustic package and effectively blocking the noise propagation of the equipment installed therein.

[0052] (2) The raised portion 11 of the upper shell 1 and the groove portion 21 of the lower shell 2 are welded by vibration friction welding. The raised portion 11 of the upper shell 1 is placed in the groove portion 21 of the lower shell 2 to ensure that the contact surface is clean and free of contaminants to ensure the welding quality. Then, high-frequency vibration friction is used to rub the contact surfaces of the raised portion 11 (welding narrow rib) of the upper shell 1 and the groove portion 21 (welding wide rib) of the lower shell 2 against each other. During the friction process, the heat generated in the welding area causes the plastic material to soften locally, and axial pressure is applied to promote the plastic flow of the material. The excess flash generated during the friction process will be squeezed and filled into the groove portion 11 (welding flash area) corresponding to the outer side of the raised portion 21. This process ensures a high degree of tightness of the welding surface. The welding flash is firmly fixed by the side wall (welding rib) of the groove portion 11, further improving the strength and sealing of the connection. Since the solid connection generated by welding effectively eliminates the gap between the upper and lower shells, the flat gasket used in traditional metal shells is no longer required, simplifying the assembly process. It improves production efficiency and reduces overall production costs. At the same time, the welded joints simplify the structural design and improve reliability and strength.

[0053] (3) The pipeline support 43 is integrally formed with the upper shell 1 or the lower shell 2 by injection molding, which improves the dimensional accuracy. The integrated design also reduces the number of parts, improves production efficiency, and reduces production costs.

[0054] The flow chart and block diagram in the accompanying drawings illustrate the possible implementation architecture, function and operation of the method and computer program product according to various embodiments of the present invention. In this regard, each square box in the flow chart or block diagram can represent a module, a program segment, or a part of a code, and the module, program segment, or a part of a code contains one or more executable instructions for realizing the specified logical function. It should also be noted that in some alternative implementations, the functions marked in the square box can also occur in a sequence different from that marked in the accompanying drawings. For example, two square boxes represented in succession can actually be executed substantially in parallel, and they can sometimes be executed in the opposite order, depending on the functions involved. It should also be noted that each square box in the block diagram and / or flow chart, and the combination of the square boxes in the block diagram and / or flow chart can be implemented with a dedicated hardware-based system that performs a specified function or operation, or can be implemented with a combination of dedicated hardware and computer instructions.

[0055] The above embodiments are merely illustrative of the principles and effects of the present invention, and are not intended to limit the present invention. Anyone familiar with the art may modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by a person of ordinary skill in the art without departing from the spirit and technical concept disclosed by the present invention shall still be covered by the claims of the present invention.

Claims

1. A lightweight acoustic package, characterized in that: include: A housing, the housing comprising an upper housing and a lower housing, wherein the edges of the upper housing and the lower housing are connected by concave-convex fitting, so that the housing is sealed to form a mounting cavity; The shell material is a mixture of nylon and glass fiber, and the upper shell and the lower shell are respectively integrally injection molded.

2. The lightweight acoustic package according to claim 1, characterized in that: A groove portion is provided at the edge of the upper shell, and a convex portion is provided at the edge of the lower shell. The convex portion is inserted into the groove portion and welded by a vibration friction welding process.

3. The lightweight acoustic package according to claim 2, characterized in that: The depth of the groove portion is smaller than the protruding height of the protruding portion.

4. The lightweight acoustic package according to claim 3, characterized in that: The width of the groove portion is greater than the width of the protrusion portion.

5. The lightweight acoustic package according to claim 5, characterized in that: The top and bottom surfaces of the shell are provided with grid ribs, and the side surfaces of the shell are provided with vertical ribs.

6. The lightweight acoustic package according to claim 6, characterized in that: The rib plate thickness of each of the grid ribs and the vertical ribs is more than 80% of the corresponding shell wall thickness.

7. The lightweight acoustic package according to claim 6, characterized in that: The content of glass fiber in the mixture is 30%-35%.

8. The lightweight acoustic package according to claim 8, characterized in that: A shell support and a distribution valve support are provided on the side surface of the shell, and a plurality of pipeline supports are provided on the top surface, the bottom surface and the side surface of the shell.

9. The lightweight acoustic package according to claim 8, characterized in that: The housing support, the distribution valve support, and each pipeline support are integrally formed with the corresponding housing.

10. An air suspension system, comprising an air supply unit, characterized in that: It also includes the lightweight acoustic package according to any one of claims 1 to 9, wherein the air supply unit is installed in an installation cavity of the lightweight acoustic package.

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