Vehicle sound insulation component and manufacturing method thereof
By injecting foam precursors through pre-set openings in the sound barrier layer, a uniform foam sound absorber is molded, solving the problem of complex positioning of foam sound absorbers in traditional vehicle sound insulation materials, and improving acoustic performance and production efficiency.
Patent Information
- Application Number
- CN202411281974.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2024-08-26
- Filing Date
- 2024-09-13
- Publication Date
- 2026-03-03
AI Technical Summary
Existing vehicle sound insulation materials require manual positioning of a two-dimensional pile layer of uniform thickness during the manufacturing process, and the introduction of foam sound absorbers is complex and cannot be efficiently integrated into the sound barrier layer.
By pre-setting openings in the sound barrier layer, the foam precursor is injected into the mold cavity to form a foam sound absorber with uniform thickness, which replaces the traditional pile material and is integrated on both sides of the sound barrier layer.
It achieves automated positioning and uniform thickness control of foam sound absorbers, improves the acoustic performance of vehicle sound insulation materials, and simplifies the production process.
Smart Images
Figure CN121589967A_ABST
Abstract
Description
Technical Field
[0001] This disclosure relates to vehicle sound insulation components including a sound barrier layer, wherein foam is introduced on both sides of the sound barrier layer and wherein the foam can be configured to follow and adapt to various three-dimensional contours within the sound barrier layer. Therefore, the foam can replace the need for using sound-absorbing flocking materials. Background Technology
[0002] Most vehicles are equipped with sound insulation panels, designed to reduce noise emissions from the external environment and within the passenger compartment. These sound insulation panels are typically located in different locations on the vehicle's body-in-white. As used in this article, "body-in-white" refers to any part of the vehicle's chassis.
[0003] This type of sound insulation is typically located on the chassis panel between the engine and the passenger compartment. Vehicle sound insulation usually consists of a sound barrier layer and one or more sound absorbers applied to the surface of the sound barrier. These sound absorbers further suppress noise and have historically been made of felt or foam. Therefore, sound barrier layers are commonly used for the insulation and vibration damping of metal sheets and metal components in vehicles.
[0004] However, there has been a persistent need for improvement in the fabrication process of vehicle sound insulation materials, which include one or more foam absorbers, wherein a precursor foam formulation is introduced through openings in the sound barrier layer, and wherein, in the same processing step, the formed foam absorbers are positioned on both sides of the sound barrier layer without simultaneously puncturing it. Such a process would preferably eliminate the need for separate and manual positioning of a uniformly thick two-dimensional flocked layer. Summary of the Invention
[0005] A method for producing vehicle sound insulation components, the method comprising:
[0006] a. Provide the first mold part and the second mold part;
[0007] b. Provide a sound barrier layer having one or more openings for the passage of a foam precursor, the opening area of the one or more openings being limited to 1.0 cm². 2 Up to 10.0cm 2 Within the range;
[0008] c. Place the sound barrier layer between the first mold part and the second mold part and close the mold, wherein the sound barrier layer is sandwiched between the first mold part and the second mold part and defines a first lower cavity and a second upper cavity, the cavity thickness of each cavity being between 0.1 mm and 50.0 mm;
[0009] d. Inject the foam precursor into the first lower cavity and through the one or more openings into the second upper cavity; and
[0010] e. A foam with a thickness ranging from 0.1 mm to 50.0 mm is formed in the first lower cavity, and a foam with a thickness ranging from 0.1 mm to 50.0 mm is formed in the second upper cavity, wherein the density of the foam is 35 g / dm³. 3 Up to 95g / dm 3 between. Attached Figure Description
[0011] The features and advantages of this disclosure will become more apparent as the following detailed description proceeds and with reference to the accompanying drawings, wherein like reference numerals denote like parts, and wherein:
[0012] Figure 1 A cross-sectional view of a preferred vehicle sound insulation component is shown.
[0013] Figure 2 A perspective view of a preferred vehicle sound insulation component is shown.
[0014] Figure 3 A perspective view showing the preferred cross-sectional geometry of one or more openings 20.
[0015] Figure 4 A perspective view showing a preferred cross-sectional geometry of one or more openings 20 is provided.
[0016] Figure 5 A cross-sectional view of a preferred vehicle sound insulation component applied to the surface of the vehicle body-in-white (metal) is shown.
[0017] Figure 6A A cross-sectional view of the sound barrier located between the first mold section and the second mold section is shown.
[0018] Figure 6B A cross-sectional view of the first mold portion and the second mold portion in the closed position is shown.
[0019] Figure 6C A cross-sectional view of the first and second cavities of a mold filled with foam sound-absorbing material is shown.
[0020] Figure 6D A cross-sectional view of a vehicle sound insulation body produced by molding is shown.
[0021] Figure 7 The sound-absorbing layers of flocked material are shown at positions "A" and "B".
[0022] Figure 8 The sound-absorbing layer at positions “C”, “D” and “E” has been replaced with the identified foam sections on top of the sound barrier layer 11.
[0023] Figure 9 The acoustic performance of a vehicle sound insulation component that relies on napping is shown compared with that of a vehicle sound insulation component prepared in this paper, which provides foam on both sides of the sound barrier layer. Detailed Implementation
[0024] Preferred embodiments of the invention will now be described. First, a description of the formed vehicle foam sound insulation component will be included, followed by a description of the corresponding preferred molding process. Therefore, Figure 1 and Figure 2 A preferred configuration of the vehicle sound insulation component 10 formed in this invention is provided. More specifically, Figure 1 A cross-sectional view of a subsection of the preferred vehicle foam sound insulation component 10 is depicted. Figure 2 A perspective view depicting a subsection of a preferred vehicle foam sound insulation component is provided.
[0025] like Figure 1 and Figure 2 As shown, the preferred vehicle sound insulation component 10 includes a sound barrier layer 11 and one or more foam sound absorbers 12. The sound barrier layer preferably comprises a polymeric resin, preferably PE-EVA (polyethylene-ethylene-vinyl acetate) or a thermoplastic elastomer (TPE). In particular, thermoplastic polyolefin elastomers TPO or TPV, comprising polypropylene with up to 65% ethylene propylene [diene] rubber (EP[D]M), may be used. The sound barrier layer may also comprise a thermoplastic elastomer dependent on a polystyrene component combined with polyethylene and polybutadiene, i.e., the so-called SEBS resin. The sound barrier layer also preferably contains additives and fillers. The thickness of the sound barrier layer herein preferably ranges from 0.1 mm to 6.0 mm, including all individual values and increments therein, and the density range is preferably 0.6 kg / m³. 2 Up to 8.0 kg / m 2 Between, including all individual values and increments.
[0026] One or more openings 20 allow them to have variable geometry, and one or more openings 20 are preferably provided at 1.0 cm. 2 Up to 10.0cm 2 The area of the openings within the range, including all values and increments therein. More preferably, the area defined by one or more openings 20 in the sound barrier layer 11 is within 0.5 cm². 2 Up to 2.5cm 2 Within the range. Therefore, one or more openings 20 can be circular, elliptical, rectangular, square, triangular, polygonal, or a combination of these geometric shapes.
[0027] Figure 3A preferred embodiment of one or more openings 20 is shown, wherein the cross-sectional geometry can be described as a slot shape. Next... Figure 4 Another embodiment with one or more openings 20 is shown, wherein the cross-sectional geometry is circular. The total number of openings 20 in the sound barrier layer for the foam precursor to pass through during production can preferably be in the range of 1 to 10 openings, including all values and increments therein. More preferably, there can be 1 to 5 openings in the sound barrier layer 11. Furthermore, the foam precursor referred to herein refers to components typically used in the production of a given foam formulation, and thus the foam precursor includes reactants that form a selected polymer resin and a suitable blowing agent.
[0028] Now let's turn our attention to... Figure 5 The sound barrier layer 11 has a front surface 30, a rear surface 31, and one or more openings 20 extending between the front surface 30 and the rear surface 31, as indicated. One or more foam sound absorbers 12 have: a front portion 33 molded on the front surface 30 of the sound barrier layer 11, a rear portion 34 also molded on the rear surface 31 of the sound barrier layer 11, and an intermediate portion 35 connecting the rear portion 34 and the front portion 33 through one or more openings 20. Figure 5 As shown, the vehicle sound insulation component 10 can be installed on the vehicle body-in-white 50. Preferably, the vehicle sound insulation component 10 can be installed on a portion of the vehicle body-in-white 50 such that the front portion 33 of one or more foam sound absorbers 12 contacts the surface of the vehicle body-in-white 50.
[0029] One or more foam sound absorbers 12 preferably comprise polyurethane foam. The density of the one or more foam sound absorbers 12 is preferably 35 g / dm³. 3 Up to 95g / dm 3 Within the range, including all values and increments, where g / dm 3 This refers to grams per cubic decimeter. More preferably, the density of one or more foam sound absorbers 12 can be 50 g / dm³. 3 Up to 80g / dm 3 Within the range of... The front portion 33 of one or more foam sound absorbers 12 may have a thickness extending perpendicularly from a region on the front surface 30 of the sound barrier layer 11 to the surface 51 of the body-in-white 50. The thickness of the front portion 33 may preferably be in the range of 0.1 mm to 50 mm, including all values and increments therein, for example, more preferably in the range of 5 mm to 25 mm. The rear portion 34 of one or more foam sound absorbers 12 may have a thickness extending perpendicularly to the region on the rear surface 31 of the sound barrier layer 11 that contacts the rear portion 34. The thickness of the rear portion 34 may preferably be in the range of 0.1 mm to 50 mm, more preferably in the range of 5 mm to 15 mm.
[0030] Additionally, this disclosure relates to a method for producing automotive sound insulation materials, the automotive sound insulation materials comprising a sound barrier layer and one or more foam sound absorbers, such as... Figure 6A , Figure 6B , Figure 6C and Figure 6D As shown. Figure 6A As shown, a sound barrier layer 11 with one or more openings 20 is provided and placed between a first mold portion 80A and a second mold portion 80B of an injection mold. The first injection mold portion 80A preferably has a first mold cavity 81A, and the second injection mold portion 80B preferably has a second mold cavity 81B. The sound barrier layer 11 is then placed between the two injection mold portions 80A and 80B such that one or more openings 20 in the sound barrier layer 11 are located between the first mold cavity 81A and the second mold cavity 81B.
[0031] One of the first injection mold portion 80A or the second injection mold portion 80B preferably has an inlet 82 into which precursor foam sound-absorbing material can be injected. Figure 6B A first mold portion and a second mold portion are depicted in a closed position, with the sound barrier layer 11 sandwiched between them. The first injection mold portion 80A has an inlet 82 at which the foam sound-absorbing precursor material is injected into the first mold cavity 81A and flows through one or more openings 20 in the sound barrier layer 11 into the second mold cavity 81B. Therefore, it can be understood that the sound barrier layer sandwiched in the mold at this time defines a first lower mold cavity 81A and a second upper mold cavity 81B. The cavity thickness (CT) of each of the first lower mold cavity and the second upper mold cavity is preferably defined in the range of 0.1 mm to 50 mm, including all values and increments therein. It should be noted that the cavity thickness of the upper portion is more preferably in the range of 5.0 mm to 15.0 mm.
[0032] Figure 6C The first cavity, one or more openings 20 in the sound barrier layer 11, and the second cavity are depicted after they are filled and form the foam sound absorber 12 material. Figure 6D A cross-section of the vehicle sound insulation component 10 manufactured in the aforementioned steps is depicted after the removal of the first injection mold portion 80A and the second injection mold portion 80B. As shown, the sound barrier layer 11 has one or more foam sound absorbers 12, which are molded on both sides of one or more openings 20 in the sound barrier layer 11 and pass through the one or more openings.
[0033] Figure 7 The sound barrier layer 11 is shown, wherein at positions "A" and "B", previously, it relied on placing a flocking material on the sound barrier layer 11. Next, as... Figure 8 As shown, by placing multiple openings 20 in the sound barrier layer 11 and following the molding procedure discussed herein, a foam precursor can be introduced at locations “D”, “E” and “F” between the sound barrier layer and the white body, which can replace flocking and selectively form foam segments 34 on the rear surface 31 of the sound barrier layer.
[0034] Next, Figure 9 The acoustic performance of a vehicle sound insulation component that relies on a flocked structure is compared with that of a vehicle sound insulation component provided with foam on both sides of the sound barrier layer. Tests were conducted according to the current ISO 354 protocol (reverberation chamber absorption measurement). A graph showing the absorption coefficient (α) versus frequency is provided. As can be observed, the use of foam absorbers selectively introduced and positioned on both sides of the sound barrier layer 11 through selected openings 20 in the sound barrier layer provides significantly improved performance.
Claims
1. A method for producing vehicle sound insulation components, the method comprising: a. Provide the first mold part and the second mold part; b. Provide a sound barrier layer having one or more openings for the passage of a foam precursor, the opening area of the one or more openings being limited to 1.0 cm². 2 Up to 10.0cm 2 Within the range; c. Place the sound barrier layer between the first mold portion and the second mold portion and close the mold, wherein the sound barrier layer is clamped between the first mold portion and the second mold portion and defines a first lower cavity and a second upper cavity, the cavity thickness of each first lower cavity and second upper cavity being between 0.1 mm and 50.0 mm; d. Inject the foam precursor into the first lower cavity and through the one or more openings into the second upper cavity; and e. A foam with a thickness ranging from 0.1 mm to 50.0 mm is formed in the first lower cavity, and a foam with a thickness ranging from 0.1 mm to 50.0 mm is formed in the second upper cavity, wherein the density of the foam is 35 g / dm³. 3 Up to 95g / dm 3 between.
2. The method according to claim 1, characterized in that, The one or more openings in the sound barrier layer include one to ten openings.
3. The method according to claim 1, characterized in that, The one or more openings in the sound barrier layer include one to five openings.
4. The method according to claim 1, characterized in that, The sound barrier layer has a thickness ranging from 0.1 mm to 6.0 mm and a strength of 0.6 kg / m². 2 Up to 8.0 kg / m 2 Density within the range.
5. The method according to claim 1, characterized in that, The sound barrier layer comprises polymer resin.
6. The method according to claim 1, characterized in that, The foam includes polyurethane foam.
7. The method according to claim 1, characterized in that, The second upper cavity has a thickness between 5.0 mm and 15.0 mm.
8. A method for producing a vehicle sound insulation component, the method comprising: a. Provide the first mold part and the second mold part; b. Provide a sound barrier layer having one or more openings for the passage of a foam precursor, said one or more openings being defined at a depth of 1.0 cm. 2 Up to 10.0cm 2 The area of the opening within the specified range; c. Place the sound barrier layer between the first mold portion and the second mold portion and close the mold, wherein the sound barrier layer is sandwiched between the first mold portion and the second mold portion and defines a first lower cavity having a thickness in the range of 0.1 mm to 50.0 mm and a second upper cavity having a cavity thickness in the range of 5.0 mm to 15.0 mm; d. Inject the foam precursor into the first lower cavity and through the one or more openings into the second upper cavity; and e. A polyurethane foam with a thickness ranging from 0.1 mm to 50.0 mm is formed in the first lower cavity, and a foam with a thickness ranging from 0.1 mm to 15.0 mm is formed in the second upper cavity, wherein the density of the foam is between 35 g / dm³. 3 Up to 95g / dm 3 between.