A car sound insulation composite heat insulation pad and a preparation device thereof

Abstract

The application discloses an automobile sound insulation and heat insulation composite pad and a preparation device, relates to the sound insulation and heat insulation pad manufacturing technical field, and comprises a sound insulation layer, the upper surface of the sound insulation layer is sequentially stacked with a heat insulation layer, an insulation layer and a protective surface layer, the upper surfaces of the sound insulation layer, the heat insulation layer and the insulation layer are all provided with a plurality of wave troughs in wave shape, the wave troughs are used for improving the interlayer connection tightness, the wave troughs on the upper surface of the sound insulation layer and the wave troughs on the upper surface of the heat insulation layer are in staggered distribution, the wave troughs on the upper surface of the heat insulation layer and the wave troughs on the upper surface of the insulation layer are in staggered distribution, four groups of compression roller assemblies are used for realizing the omnidirectional staggered nesting of the wave troughs between the sound insulation layer, the heat insulation layer and the insulation layer, forming a three-dimensional occlusion structure, and the peeling resistance and the shear resistance are remarkably improved, meanwhile, efficient heat dissipation channels in horizontal and vertical staggered modes are constructed, the heat dissipation channels can assist heat dissipation and inhibit bulging deformation, and the connection strength, the auxiliary heat dissipation and the deformation stability are considered.

Description

Technical Field

[0001] This invention relates to the field of automotive sound insulation and heat insulation pad manufacturing technology, specifically to an automotive sound insulation composite heat insulation pad and its preparation device. Background Technology

[0002] As the global automotive industry transforms and upgrades towards high-end, electrified, and intelligent vehicles, consumers' comprehensive requirements for vehicle ride comfort, cabin quietness, driving safety, and overall vehicle durability continue to rise. The vehicle chassis, as the core load-bearing component of the entire vehicle, is also the main pathway for road noise, transmission system mechanical noise, exhaust pipe radiant heat, and engine conductive heat to be transferred to the passenger compartment. Furthermore, it is constantly subjected to extreme and complex operating conditions such as gravel impact, mud and water erosion, alternating high and low temperatures, and continuous road vibration. Therefore, a special composite functional heat and sound insulation pad layer needs to be installed on the outer side of the chassis sheet metal to simultaneously achieve multiple core functions such as noise blocking, heat insulation, circuit insulation, sheet metal corrosion prevention, and impact protection. It is a key component ensuring the overall NVH performance and driving experience of the vehicle.

[0003] Currently, the mainstream composite heat and sound insulation pads for automotive chassis in the industry generally adopt a simple planar stacked structure of multiple flexible functional materials. The bottom layer is mostly made of non-woven fabric or felt-like bonding materials, the middle layer is made of heat and sound insulation substrates such as glass fiber cotton and polyurethane foam, and the surface layer is made of aluminum foil or flame-retardant PET film as a protective layer. The layers are only bonded by adhesives such as hot melt adhesive and pressure-sensitive adhesive, or directly by cold pressing to achieve interlayer connection. Although this connection method can meet the basic sound and heat insulation requirements and the manufacturing process is simple and inexpensive, the multi-layer material bonding is achieved by adhesives alone, without mechanical structure locking. Under long-term continuous vibration of the chassis and impact load of the road surface, interlayer slippage and local debonding are very likely to occur, eventually leading to material delamination and detachment, affecting the sound and heat insulation effect.

[0004] To address the aforementioned issues, there is an urgent need for innovative designs based on existing automotive sound and heat insulation pads. Summary of the Invention

[0005] The present invention addresses the problem of overly simplistic solutions in existing technologies by providing a significantly different solution. Specifically, the present invention aims to provide an automotive sound insulation composite heat insulation pad to solve the problems mentioned in the background section, such as insufficient interlayer bonding strength, easy delamination, and detachment in existing products.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a composite sound insulation and heat insulation pad for automobiles, comprising a sound insulation layer, wherein a heat insulation layer, an insulation layer, and a protective surface layer are sequentially stacked on the upper surface of the sound insulation layer, the upper surface of the sound insulation layer, the heat insulation layer, and the insulation layer are provided with a plurality of corrugated grooves, the corrugated grooves being used to improve the interlayer bonding tightness, the corrugated grooves on the upper surface of the sound insulation layer and the corrugated grooves on the upper surface of the heat insulation layer being staggered, and the corrugated grooves on the upper surface of the heat insulation layer and the corrugated grooves on the upper surface of the insulation layer being staggered, so as to form an omnidirectionally staggered three-dimensional interlocking interface;

[0007] The wave groove has a periodic undulating profile, and the undulation amplitude decreases gradually from the sound insulation layer to the insulation layer, forming a smoothly transitioning, gradually curved surface structure.

[0008] The upper surface of the sound insulation layer is provided with several corrugated heat dissipation channels, which are spaced apart between the wave grooves on the upper surface of the sound insulation layer to form a transverse heat dissipation channel. The upper surface of the heat insulation layer is provided with several strip heat dissipation channels, which are spaced apart between the wave grooves on the upper surface of the heat insulation layer. The troughs of the strip heat dissipation channels correspond one-to-one with the troughs of the wave grooves on the upper surface of the heat insulation layer to form a series of longitudinal heat dissipation channels. By constructing two layers of intersecting transverse and longitudinal heat dissipation channels, the heat from the car chassis can be actively and quickly diffused to the edges.

[0009] Preferably, the upper surface of the machine is provided with a first pressure roller assembly, a second pressure roller assembly, a third pressure roller assembly and a fourth pressure roller assembly in sequence from front to back along the material conveying direction.

[0010] Preferably, the first pressure roller assembly is used to roll the sound insulation layer to form a wave groove with the largest undulation amplitude and a corrugated heat dissipation channel on its upper surface; the second pressure roller assembly is used to roll the heat insulation layer to form a wave groove with a medium undulation amplitude and a strip heat dissipation channel on its upper surface; the third pressure roller assembly is used to roll the insulation layer to form a wave groove with the smallest undulation amplitude on its upper surface; and the fourth pressure roller assembly is used to perform multi-layer composite pressing of the sound insulation layer, the heat insulation layer, the insulation layer and the protective surface layer.

[0011] Preferably, the first pressure roller assembly includes a first main roller and a first auxiliary roller. A plurality of first protrusions are fixedly connected to one side of the outer wall of the first main roller, and a plurality of first grooves are provided on the outer wall of the first main roller corresponding to the positions of the first protrusions. The first main roller rotates to drive the first protrusions and the first grooves to roll and press the upper surface of the sound insulation layer to form a wave groove.

[0012] Preferably, an arc-shaped pressure plate is fixedly connected to the outer wall of the other side of the first main roller, and the outer wall contour of the arc-shaped pressure plate after it is unfolded matches the inner wall contour of the corrugated heat dissipation channel.

[0013] Preferably, the second pressure roller assembly includes a second main roller and a second auxiliary roller. A plurality of second protrusions are fixedly connected to one side of the outer wall of the second main roller, and a plurality of second grooves are provided on the outer wall of the second main roller corresponding to the positions of the second protrusions. By rotating the second main roller, the second protrusions and the second grooves are driven to roll-press the upper surface of the heat insulation layer to form a wave groove.

[0014] Preferably, a number of arc-shaped pressure rods are fixedly connected to the outer wall of the other side of the second main roller. After the arc-shaped pressure rods are unfolded, their outer wall contours are adapted to the inner wall contours of the strip-shaped heat dissipation grooves, and the number of arc-shaped pressure rods are aligned with the number of second protrusions one by one.

[0015] Preferably, the outer wall of the second protrusion is fixedly connected with a plurality of protrusions, and the protrusions are aligned one by one with the crests of the corrugated heat dissipation channel.

[0016] Preferably, the third pressure roller assembly includes a third main roller and a third auxiliary roller. A plurality of third protrusions are fixedly connected to one side of the outer wall of the third main roller, and a plurality of third grooves are provided on the outer wall of the third main roller corresponding to the positions of the third protrusions. By rotating the third main roller, the third protrusions and the third grooves are driven to roll-press the upper surface of the insulating layer to form a corrugated groove.

[0017] Preferably, the fourth pressure roller assembly includes a fourth main roller and a fourth auxiliary roller, and the fourth main roller and the fourth auxiliary roller are provided with smooth roller surfaces.

[0018] Compared with the prior art, the beneficial effects of the present invention are:

[0019] This invention utilizes four sets of pressure roller assemblies to create a staggered nested distribution of corrugated grooves in the sound insulation layer, heat insulation layer, and insulation layer. The first main roller forms the lower corrugated groove and corrugated heat dissipation groove in the sound insulation layer. The second main roller's second protrusion and second groove press out a corrugated groove with a smaller undulation amplitude on the upper surface of the heat insulation layer, and the middle corrugated groove is staggered from the corrugated groove on the sound insulation layer. At the same time, half of the arc-shaped pressure bar is used to squeeze the heat insulation layer, so that its lower surface forms a corrugated structure that matches the corrugated groove of the sound insulation layer, forming an interlocking structure that increases the effective contact area. The third pressure roller presses the insulation layer, so that the lower surface of the insulation layer is embedded with the middle corrugated groove. This interlocking structure significantly increases the effective contact area between layers, forming an omnidirectional staggered three-dimensional interlocking interface, which significantly improves the interlayer peel strength and shear creep resistance of the composite pad, and completely overcomes the structural defects of traditional planar hot pressing that are prone to delamination and warping.

[0020] This invention utilizes the coordinated operation of the side-mounted arc-shaped pressure plate of the first pressure roller assembly and the arc-shaped pressure rod of the second pressure roller assembly to press transverse corrugated grooves and longitudinal strip-shaped heat dissipation grooves into the sound insulation layer and heat insulation layer, respectively. By controlling the phase of the rollers, the longitudinal grooves are precisely aligned with the troughs of the transverse grooves, constructing two layers of intersecting heat dissipation channels. This allows the heat from the car chassis to diffuse rapidly laterally and escape directionally in the longitudinal direction, achieving efficient active heat dissipation while maintaining interlayer tightness and efficient heat dissipation. Furthermore, the reserved longitudinal and transverse grooves serve as thermal expansion volume and provide a thermal expansion buffer space for the material. The grooves can accommodate part of the expansion, preventing excessive expansion of the composite pad due to temperature changes and bulging, thereby extending the service life of the composite pad.

[0021] The protrusions and grooves of the first, second, and third pressure roller assemblies of this invention are precisely profiled, with the pressing depth and undulation amplitude decreasing sequentially from bottom to top. Combined with the smooth roller surface of the fourth pressure roller assembly, the final pressing and shaping are achieved, so that the insulation layer only forms a shallow interlock with the heat insulation layer. This maintains the integrity of the heat dissipation and sound insulation structure of the lower layer and achieves smooth attenuation of the amplitude. This gradient rolling process makes the composite pad form a gradually changing curved surface that transitions from a large amplitude at the bottom layer to a zero amplitude at the top layer. While ensuring the core function of the bottom layer, it generates a highly flat and fitting surface at the top layer, perfectly adapting to the complex contours of the car chassis, achieving zero installation gaps, uniform stress, and deformation stability under long-term complex working conditions. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0023] Figure 2 This is a schematic diagram of the four sets of pressure roller assemblies of the present invention.

[0024] Figure 3 This is a schematic cross-sectional view of the first main roller and the first auxiliary roller of the present invention.

[0025] Figure 4 This is a schematic cross-sectional view of the second main roller and the second auxiliary roller of the present invention.

[0026] Figure 5 This is a schematic diagram of the sound insulation composite heat insulation pad structure of the present invention.

[0027] Figure 6 This is a schematic diagram of the unfolded structure of the sound insulation composite heat insulation pad of the present invention.

[0028] Figure 7 This is a diagram showing the working state of the first main roller arc-shaped pressure plate of the present invention.

[0029] Figure 8 This is a diagram showing the working state of one side of the arc-shaped pressure bar of the second main roller in this invention.

[0030] Figure 9This is a diagram showing the working state of the second protrusion of the second main roller in this invention.

[0031] In the diagram: 1. Sound insulation layer; 2. Heat insulation layer; 3. Insulation layer; 4. Corrugated groove; 5. Corrugated heat dissipation channel; 6. Strip heat dissipation channel; 7. First main roller; 8. First auxiliary roller; 9. First protrusion; 10. First groove; 11. Arc-shaped pressure plate; 12. Second main roller; 13. Second auxiliary roller; 14. Second protrusion; 15. Second groove; 16. Arc-shaped pressure bar; 17. Protrusion; 18. Third main roller; 19. Third auxiliary roller; 20. Third protrusion; 21. Third groove. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] Please see Figures 5 to 9 The present invention provides a technical solution: a composite sound insulation and heat insulation pad for automobiles, including a sound insulation layer 1, a heat insulation layer 2, an insulation layer 3 and a protective surface layer are sequentially stacked on the upper surface of the sound insulation layer 1, the heat insulation layer 2 and the insulation layer 3 are provided with a plurality of corrugated grooves 4, the corrugated grooves 4 are used to improve the tightness of the interlayer connection, the corrugated grooves 4 on the upper surface of the sound insulation layer 1 and the corrugated grooves 4 on the upper surface of the heat insulation layer 2 are staggered, and the corrugated grooves 4 on the upper surface of the heat insulation layer 2 and the corrugated grooves 4 on the upper surface of the insulation layer 3 are staggered to form an omnidirectional staggered three-dimensional interlocking interface;

[0034] The wave groove 4 has a periodic undulating profile, and the undulation amplitude gradually decreases from the sound insulation layer 1 to the insulation layer 3, forming a smooth transition of the gradually curved surface structure.

[0035] The upper surface of the sound insulation layer 1 is provided with several corrugated heat dissipation channels 5, and the several corrugated heat dissipation channels 5 are distributed at intervals between the wave grooves 4 on the upper surface of the sound insulation layer 1 to form a horizontal heat dissipation channel. The upper surface of the heat insulation layer 2 is provided with several strip heat dissipation channels 6, and the several strip heat dissipation channels 6 are distributed at intervals between the wave grooves 4 on the upper surface of the heat insulation layer 2. The several strip heat dissipation channels 6 are aligned one-to-one with the troughs of the wave grooves 4 on the upper surface of the heat insulation layer 2 to form several vertical heat dissipation channels. By constructing two layers of horizontal and vertical heat dissipation channels, the heat of the car chassis can be actively and quickly diffused to the edge.

[0036] It should be noted that the overall design is a four-layer laminated composite automotive chassis sound and heat insulation pad. From bottom to top, it consists of a sound insulation layer 1, a heat insulation layer 2, an insulation layer 3, and a protective surface layer. Periodic corrugated grooves 4 are pressed onto the upper surfaces of the sound insulation layer 1, the heat insulation layer 2, and the insulation layer 3. The corrugated grooves 4 of adjacent layers are distributed in a phase-off staggered manner. First, the corrugated grooves 4 and corrugated heat dissipation channels 5 are arranged on the sound insulation layer 1. When the sound insulation layer 1 and the heat insulation layer 2 are pressed together, the corrugated grooves 4 of the sound insulation layer 1 are embedded in the lower surface of the heat insulation layer 2. At the same time, corrugated grooves 4 are formed in adjacent positions to connect with the insulation layer 3 above. Through this staggered nested structure design, the contact area between layers can be significantly increased. Combined with the undulating contour of the corrugated grooves 4, the layers form a kind of interlocking connection state. Moreover, the interlocking points of each layer are staggered, which effectively improves the overall structural stability and interlayer bonding strength of the composite pad and avoids problems such as delamination and warping during long-term use.

[0037] Meanwhile, the corrugated heat dissipation channels 5 on the sound insulation layer 1 and the strip heat dissipation channels 6 on the heat insulation layer 2 work together to form a three-dimensional cross heat dissipation network between the layers. When the car chassis generates heat, the heat of the gas between the sound insulation layer 1 and the heat insulation layer 2 can be quickly diffused to the left and right sides in the horizontal direction through the corrugated heat dissipation channels 5, and will not be concentrated inside. The heat between the heat insulation layer 2 and the insulation layer 3 can be transferred and escaped in the longitudinal direction along the front and rear sides through the strip heat dissipation channels 6. This multi-directional heat conduction method effectively improves the heat dissipation efficiency of the composite pad and avoids heat accumulation inside, which leads to performance degradation.

[0038] The wave groove 4 has a gradually decreasing undulation amplitude from the sound insulation layer 1 to the insulation layer 3, which makes the overall thickness of the composite pad transition smoothly. It forms a planar protective layer on the top layer, which can not only ensure the structural integrity and performance of the functional layers below, but also better fit with the mounting surface of the car chassis, reduce installation gaps, and improve the sound insulation and heat insulation effect.

[0039] Specifically, the following design is made based on the total thickness of the mainstream chassis sound and heat insulation pads in the automotive industry:

[0040] The sound insulation layer 1 uses a high-density butyl rubber composite closed-cell EPDM substrate with a thickness ranging from 3.8mm to 4.2mm. The undulation range H1 of the upper surface corrugated groove 4 ranges from 1.9mm to 2.1mm. The undulation range of the corrugated groove 4 is controlled within a reasonable range of its own substrate thickness, which not only ensures the structural load-bearing strength of the sound insulation layer 1, but also provides sufficient space for interlayer misalignment and interlocking. At the same time, it is combined with the corrugated heat dissipation channel 5 to provide sufficient thermal expansion buffer and lateral heat dissipation channel.

[0041] The heat insulation layer 2 uses a ceramic fiber composite aerogel substrate with a thickness ranging from 2.3mm to 2.7mm. The undulation amplitude H2 of the upper surface corrugated groove 4 ranges from 1.1mm to 1.3mm, with H2 being smaller than H1 overall, forming a gradient decreasing trend. This adapts to the staggered distribution requirements of the corrugated groove 4 of the sound insulation layer 1, ensuring that the lower surface of the heat insulation layer 2 can be stably embedded in the trough of the sound insulation layer 1, achieving a tight fit. At the same time, this undulation amplitude matches the depth of the strip heat dissipation groove 6, ensuring unobstructed longitudinal heat dissipation channels and balancing heat insulation performance and heat dissipation efficiency.

[0042] The insulation layer 3 is made of high flame-retardant PI composite fiberglass substrate with a thickness ranging from 1.4mm to 1.6mm. The undulation range H3 of the upper surface corrugated groove 4 is 0.6mm to 0.8mm. H3 is generally smaller than H2, continuing the gradient decreasing design, so that the overall thickness of the composite pad is smoothly transitioned. This ensures a tight fit between the insulation layer 3 and the heat insulation layer 2, and also provides a flat bonding surface for the upper protective layer, avoiding installation gaps.

[0043] The protective surface layer is made of aluminum foil composite flame-retardant non-woven fabric with a thickness ranging from 1.8mm to 2.2mm. It is flatly laminated on the upper surface of the insulation layer 3. The aluminum foil layer can further block the conduction of extreme high temperatures, while the non-woven fabric layer improves the surface wear resistance and flame retardant performance, making it suitable for harsh working conditions around the engine.

[0044] Furthermore, in this embodiment, the corrugated heat dissipation channel 5 and the strip heat dissipation channel 6 are not only heat dissipation channels, but also form empty channels in the spaced distribution between each layer. The empty channels can provide thermal expansion buffer space for the material. The empty channels can accommodate part of the expansion, avoiding excessive expansion of the composite pad due to temperature changes, which can lead to bulging and thus extend the service life of the composite pad.

[0045] Please see Figures 1 to 9 To adapt to the above-mentioned automotive sound insulation composite heat insulation pad, the present invention also proposes an automotive sound insulation composite heat insulation pad preparation device, including a machine base, and the upper surface of the machine base is provided with a first pressure roller assembly, a second pressure roller assembly, a third pressure roller assembly and a fourth pressure roller assembly in sequence from front to back along the material conveying direction.

[0046] The first pressure roller assembly is used to roll the sound insulation layer 1 to form a wave groove 4 with the largest undulation amplitude and a corrugated heat dissipation channel 5 on its upper surface. The second pressure roller assembly is used to roll the heat insulation layer 2 to form a wave groove 4 with a medium undulation amplitude and a strip heat dissipation channel 6 on its upper surface. The third pressure roller assembly is used to roll the insulation layer 3 to form a wave groove 4 with the smallest undulation amplitude on its upper surface. The fourth pressure roller assembly is used to perform multi-layer composite pressing of the sound insulation layer 1, the heat insulation layer 2, the insulation layer 3, and the protective surface layer.

[0047] In this embodiment, as Figures 1 to 4As shown, the first pressure roller assembly includes a first main roller 7 and a first auxiliary roller 8. Several first protrusions 9 are fixedly connected to one side of the outer wall of the first main roller 7. Several first grooves 10 are provided on the outer wall of the first main roller 7 corresponding to the positions of the first protrusions 9. By rotating the first main roller 7, the first protrusions 9 and the first grooves 10 are driven to roll the upper surface of the sound insulation layer 1 to form a wave groove 4.

[0048] An arc-shaped pressure plate 11 is fixedly connected to the outer wall of the other side of the first main roller 7. After the arc-shaped pressure plate 11 is unfolded, its outer wall contour matches the inner wall contour of the corrugated heat dissipation channel 5.

[0049] The second pressure roller assembly includes a second main roller 12 and a second auxiliary roller 13. A number of second protrusions 14 are fixedly connected to one side of the outer wall of the second main roller 12. A number of second grooves 15 are provided on the outer wall of the second main roller 12 corresponding to the positions of the second protrusions 14. By rotating the second main roller 12, the second protrusions 14 and the second grooves 15 are driven to roll the upper surface of the heat insulation layer 2 to form a wave groove 4.

[0050] Several arc-shaped pressure rods 16 are fixedly connected to the outer wall of the other side of the second main roller 12. After the arc-shaped pressure rods 16 are unfolded, their outer wall contours match the inner wall contours of the strip-shaped heat dissipation groove 6, and the several arc-shaped pressure rods 16 are aligned with the several second protrusions 14 one by one.

[0051] The outer wall of the second protrusion 14 is fixedly connected with several protrusions 17, and the protrusions 17 are aligned with the crests of the corrugated heat dissipation channel 5.

[0052] The third pressure roller assembly includes a third main roller 18 and a third auxiliary roller 19. Several third protrusions 20 are fixedly connected to one side of the outer wall of the third main roller 18. Several third grooves 21 are provided on the outer wall of the third main roller 18 corresponding to the positions of the third protrusions 20. By rotating the third main roller 18, the third protrusions 20 and the third grooves 21 are driven to roll the upper surface of the insulating layer 3 to form a wave groove 4.

[0053] The fourth pressure roller assembly includes a fourth main roller and a fourth auxiliary roller, and the fourth main roller and the fourth auxiliary roller are provided with smooth roller surfaces.

[0054] It should be noted that two feeding rollers and guide rollers are provided in front of the first pressure roller assembly, the second pressure roller assembly, the third pressure roller assembly, and the fourth pressure roller assembly. The corresponding roll material and hot melt film are placed on the two feeding rollers respectively, and they are bonded from front to back. The materials between each layer are pre-bonded by the hot melt film. Heating rods are inserted inside the first main roller 7, the second main roller 12, the third main roller 18, and the fourth main roller. A gear assembly is added to one side of each pressure roller assembly, and a take-up roller is added at the end of the machine to take up the finished product. Rolling and shaping are performed by the corresponding pressure roller assembly. The overall heating process of the pressure roller is existing technology, and the take-up roller is also existing technology, so it is not shown in the figure.

[0055] First, the sound insulation layer 1 roll is fed to the first pressure roller assembly via the feeding roller. The first protrusion 9 on the first main roller 7 cooperates with the first auxiliary roller 8 to roll out the corrugated groove 4 on the upper surface of the sound insulation layer 1. It enters the second pressure roller assembly at a uniform speed along with the sound insulation layer 1 substrate. When the first main roller 7 rotates, the first protrusion 9 and the first groove 10 on its outer wall apply periodic alternating pressure to the material. The contour shape of the first protrusion 9 matches the trough of the corrugated groove 4 on the lower sound insulation layer 1, while the second groove 15 matches the crest of the corrugated groove 4 on the lower sound insulation layer 1, thus pressing out the lower corrugated groove 4 with a larger undulation amplitude.

[0056] Meanwhile, the arc-shaped pressure plate 11 fixed to the other side wall of the main roller rotates synchronously with the roller body, and performs local deep pressing on a specific area of ​​the substrate to form a corrugated heat dissipation channel 5 with interval distribution. The sound insulation layer 1 after pressing is output smoothly with the transmission line. The corrugated heat dissipation channel 5 and the wave groove 4 are alternately distributed. The wave groove 4 of the sound insulation layer 1 is used to connect the lower surface of the heat insulation layer 2.

[0057] Secondly, the substrate of the heat insulation layer 2 enters the second pressure roller assembly through the feeding roller. The first pressure roller assembly and the second pressure roller assembly are precisely calculated so that when the area of ​​the sound insulation layer 1 with the corrugated groove 4 enters the second main roller 12, half of the area of ​​the second main roller 12 with the arc-shaped pressure bar 16 corresponds exactly to the trough position of the corrugated groove 4 of the sound insulation layer 1. At this time, through the pressing of the second main roller 12, on the one hand, the heat insulation layer 2 is squeezed by the half with the arc-shaped pressure bar 16, so that its lower surface forms a corrugated structure that matches the corrugated groove 4 of the sound insulation layer 1, forming an interlocking structure and increasing the effective contact area. At the same time, the arc-shaped pressure bar 16 can also press strip heat dissipation grooves 6 on the upper surface of the sound insulation layer 1 and the upper surface of the heat insulation layer 2. These strip heat dissipation grooves 6 correspond one-to-one with the trough position of the corrugated groove 4 of the heat insulation layer 2 itself, forming a longitudinal heat dissipation channel.

[0058] On the other hand, the outline of the second protrusion 14 on the outer wall of the other half of the second pressure roller is adapted to the trough of the wave groove 4 on the intermediate heat insulation layer 2, and the second groove 15 is adapted to the peak of the wave groove 4 on the intermediate heat insulation layer 2. The second protrusion 14 and the second groove 15 will press out the middle wave groove 4 with a smaller undulation amplitude on the upper surface of the heat insulation layer 2. The middle wave groove 4 is distributed alternately with the strip heat dissipation groove 6 and is staggered from the wave groove 4 on the sound insulation layer 1. The wave groove 4 is used to connect the upper insulation layer 3.

[0059] Meanwhile, during the rolling process, the protrusion 17 on the outer wall of the second protrusion 14 will be embedded into the crest of the corrugated heat dissipation channel 5 of the sound insulation layer 1. During the embedding process, the protrusion 17 can squeeze the hot melt film downward, so that the hot melt film melts at the crest of the corrugated heat dissipation channel 5 and bonds the lower surface of the heat insulation layer 2 to the crest of the corrugated heat dissipation channel 5. Since the initial pressing marks of the corrugated heat dissipation channel 5 are relatively deep, the protrusion 17 can make the middle section of the corrugated heat dissipation channel 5 effectively connected with the upper heat insulation layer 2, preventing it from being suspended and ensuring the structural stability of the heat dissipation channel.

[0060] In this embodiment, for example... Figure 7 , Figure 8 and Figure 9 As shown, the position of the strip-shaped heat dissipation groove 6 and the corrugated heat dissipation channel 5 of the lower sound insulation layer 1 form an intersecting layout in space. These intersecting channels create a crisscrossing airflow path inside the composite pad. When the car is running, the heat generated by the chassis is conducted to the composite pad. The heat first enters the corrugated heat dissipation channel 5 of the sound insulation layer 1 and spreads laterally. Some of the heat is absorbed by the sound insulation layer 1 material and transferred to the upper layer through heat conduction. The strip-shaped heat dissipation groove 6 of the heat insulation layer 2 transfers heat longitudinally back and forth, which can transfer the excess heat to the front and rear sides. The overall design takes into account the interlayer tightness and heat dissipation effect. At the same time, these channels can also provide thermal expansion buffer space for the materials. When the car is in high temperature conditions, the materials of each functional layer will undergo volume changes due to thermal expansion. At this time, the channels can accommodate part of the expansion, relieve interlayer stress, and prevent the composite pad from bulging due to excessive expansion, thereby extending the service life of the product.

[0061] Subsequently, after the heat insulation layer 2 and the sound insulation layer 1 are initially composited by the second pressure roller assembly, they are conveyed together to the third pressure roller assembly. At this time, the substrate of the insulation layer 3 enters the third pressure roller assembly simultaneously through the feeding roller. The contour shape of the third protrusion 20 on the third main roller 18 is adapted to the trough of the wave groove 4 on the upper insulation layer 3, and the third groove 21 is adapted to the peak of the wave groove 4 on the upper insulation layer 3. The wave groove 4 with the smallest undulation amplitude is rolled out on the upper surface of the insulation layer 3. The wave groove 4 is also staggered with the wave groove 4 on the upper surface of the heat insulation layer 2, so that the lower surface of the insulation layer 3 can be embedded in the wave groove 4 of the heat insulation layer 2, forming a further nested interlocking structure, further improving the interlayer bonding force of the overall composite pad.

[0062] It should be noted that the pressure of the third pressure roller assembly is adjusted by a lead screw, so that the pressure of the third main roller 18 is relatively smaller than that of the second pressure roller when it presses down. This results in the lower surface of the insulation layer 3 being partially fitted with the corrugated groove 4 of the heat insulation layer 2, while the corrugated groove 4 on the upper surface of the heat insulation layer 2 still has gaps to prevent the longitudinal heat dissipation channels from being blocked.

[0063] Finally, the sound insulation layer 1, heat insulation layer 2, insulation layer 3, and protective surface layer, which have undergone the previous treatment, are synchronously conveyed by the feeding rollers and then undergo multi-layer composite pressing under the action of the fourth pressure roller assembly. When entering the fourth pressure roller assembly, the smooth roller surfaces of the fourth main roller and the fourth auxiliary roller apply uniform composite pressure, and the stacked layers are rolled at a uniform speed under the set line pressure to fully press the hot melt film between each layer. The pressure adjustment process of each pressure roller assembly is a prior art technology, which ultimately ensures the density and stability of the overall structure and forms a composite heat insulation pad with sound insulation, heat insulation, insulation and protection functions.

[0064] The sound insulation layer 1, heat insulation layer 2, and insulation layer 3, which are independently pressed by four sets of roller pressing assemblies, are stacked in sequence in front of the fourth roller pressing assembly and covered with a protective surface layer. The multi-layer staggered wave groove 4 is designed to form a three-dimensional mechanical interlocking, which, together with the melting and bonding of the hot melt film, enables the functional layers to achieve a dual physical and chemical bond, significantly improving the interlayer peel strength.

[0065] Among them, the corrugated groove 4 of the sound insulation layer 1 has the largest undulation amplitude, providing structural support as the basic load-bearing layer; the heat insulation layer 2 is next, and the connection stability is enhanced by the staggered nesting with the sound insulation layer 1; the insulation layer 3 has the smallest undulation amplitude, which can not only form an effective interlock with the heat insulation layer 2, but also provide a relatively flat bonding surface for the upper protective layer. This gradient corrugated groove 4 design makes the overall thickness of the composite pad transition smoothly, which is convenient for close bonding with the car chassis mounting surface, reducing gaps and ensuring its stable use under long-term complex working conditions.

[0066] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A composite sound insulation and heat insulation pad for automobiles, comprising a sound insulation layer, characterized in that: The upper surface of the sound insulation layer is sequentially stacked with a heat insulation layer, an insulation layer, and a protective surface layer. The upper surfaces of the sound insulation layer, the heat insulation layer, and the insulation layer are all provided with a number of corrugated grooves. The corrugated grooves are used to improve the tightness of the interlayer connection. The corrugated grooves on the upper surface of the sound insulation layer and the corrugated grooves on the upper surface of the heat insulation layer are staggered and distributed to form an omnidirectional staggered three-dimensional interlocking interface. The wave groove has a periodic undulating profile, and the undulation amplitude decreases gradually from the sound insulation layer to the insulation layer, forming a smoothly transitioning, gradually curved surface structure. The upper surface of the sound insulation layer is provided with several corrugated heat dissipation channels, which are spaced apart between the wave grooves on the upper surface of the sound insulation layer to form a transverse heat dissipation channel. The upper surface of the heat insulation layer is provided with several strip heat dissipation channels, which are spaced apart between the wave grooves on the upper surface of the heat insulation layer. The troughs of the strip heat dissipation channels correspond one-to-one with the troughs of the wave grooves on the upper surface of the heat insulation layer to form a series of longitudinal heat dissipation channels. By constructing two layers of intersecting transverse and longitudinal heat dissipation channels, the heat from the car chassis can be actively and quickly diffused to the edges.

2. An apparatus for preparing automotive sound insulation composite heat insulation pads as described in claim 1, comprising a machine base, characterized in that: The upper surface of the machine is provided with a first pressure roller assembly, a second pressure roller assembly, a third pressure roller assembly, and a fourth pressure roller assembly in sequence from front to back along the material conveying direction.

3. The automotive sound insulation composite heat insulation pad preparation device according to claim 2, characterized in that: The first pressure roller assembly is used to roll the sound insulation layer to form a wave groove with the largest undulation amplitude and a corrugated heat dissipation channel on its upper surface. The second pressure roller assembly is used to roll the heat insulation layer to form a wave groove with a medium undulation amplitude and a strip heat dissipation channel on its upper surface. The third pressure roller assembly is used to roll the insulation layer to form a wave groove with the smallest undulation amplitude on its upper surface. The fourth pressure roller assembly is used to perform multi-layer composite pressing of the sound insulation layer, the heat insulation layer, the insulation layer and the protective surface layer.

4. The automotive sound insulation composite heat insulation pad preparation device according to claim 3, characterized in that: The first pressure roller assembly includes a first main roller and a first auxiliary roller. A number of first protrusions are fixedly connected to one side of the outer wall of the first main roller. A number of first grooves are provided on the outer wall of the first main roller corresponding to the positions of the first protrusions. The first main roller rotates to drive the first protrusions and the first grooves to roll and press the upper surface of the sound insulation layer to form a wave groove.

5. The automotive sound insulation composite heat insulation pad preparation device according to claim 4, characterized in that: An arc-shaped pressure plate is fixedly connected to the outer wall of the other side of the first main roller. After the arc-shaped pressure plate is unfolded, its outer wall contour matches the inner wall contour of the corrugated heat dissipation channel.

6. The automotive sound insulation composite heat insulation pad preparation device according to claim 3, characterized in that: The second pressure roller assembly includes a second main roller and a second auxiliary roller. A number of second protrusions are fixedly connected to one side of the outer wall of the second main roller. A number of second grooves are provided on the outer wall of the second main roller corresponding to the positions of the second protrusions. By rotating the second main roller, the second protrusions and the second grooves are driven to roll the upper surface of the heat insulation layer to form a wave groove.

7. The automotive sound insulation composite heat insulation pad preparation device according to claim 6, characterized in that: Several arc-shaped pressure rods are fixedly connected to the outer wall of the other side of the second main roller. After the arc-shaped pressure rods are unfolded, their outer wall contours match the inner wall contours of the strip-shaped heat dissipation grooves, and the several arc-shaped pressure rods are aligned with several second protrusions one by one.

8. The apparatus for preparing an automotive sound insulation composite heat insulation pad according to claim 6, characterized in that: The outer wall of the second protrusion is fixedly connected with several protrusions, and the protrusions are aligned with the crests of the corrugated heat dissipation channel.

9. The apparatus for preparing automotive sound insulation composite heat insulation pads according to claim 4, characterized in that: The third pressure roller assembly includes a third main roller and a third auxiliary roller. Several third protrusions are fixedly connected to one side of the outer wall of the third main roller. Several third grooves are provided on the outer wall of the third main roller corresponding to the positions of the third protrusions. By rotating the third main roller, the third protrusions and the third grooves are driven to roll-press the upper surface of the insulating layer to form a corrugated groove.

10. The apparatus for preparing automotive sound insulation composite heat insulation pads according to claim 3, characterized in that: The fourth pressure roller assembly includes a fourth main roller and a fourth auxiliary roller, and the fourth main roller and the fourth auxiliary roller are provided with smooth roller surfaces.

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