Automobile environment-friendly front wall sound insulation pad

Abstract

The utility model provides an environment-friendly front wall sound insulation pad for an automobile. The environment-friendly front wall sound insulation pad for the automobile comprises an inner high-performance fiber reinforced composite material injection molding layer, a middle hot-melt net film layer and an outer thermoplastic felt layer, the thickness of the hot melting net film layer ranges from 0.05 mm to 0.3 mm. According to the automobile environment-friendly front wall sound insulation pad, the high-performance fiber reinforced composite material injection molding layer on the inner layer, the hot melting net film layer and the thermoplastic felt layer on the outer layer are combined, glue is abandoned to serve as an adhesive, the hot melting net film serves as the adhesive, and the scheme that the hot melting net film is subjected to steam melting in a steam mold to bond the outer layer and the inner layer is adopted; the VOC content is reduced, the odor is reduced, and the stripping force of a hard layer and a soft layer is increased; meanwhile, the sound insulation effect is effectively improved, and the health of the environment and operators is guaranteed.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automotive interior, and particularly relates to an automobile environmental protection front wall sound insulation pad. BACKGROUND

[0002] The automobile front wall sound insulation pad is a key component in the automotive interior system, which is mainly installed between the automobile front wall panel and the cockpit, and plays an important role in sound insulation, heat insulation and vibration reduction. It can effectively block the noise, heat and vibration from the engine compartment, create a quiet and comfortable driving environment for the passengers in the car, and at the same time, make an indispensable contribution to improving the overall acoustic performance and riding comfort of the automobile.

[0003] The traditional automobile front wall sound insulation pad usually adopts a multi-layer composite structure. Generally, it includes one or more layers of sound-absorbing materials, such as sound-absorbing cotton, which can absorb part of the noise energy, convert the sound energy into heat energy or other forms of energy and consume it. In addition, there will be one or more layers of sound insulation materials, commonly known as rubber plates or plastic plates, which can block the propagation of noise and reduce the transmission of sound through their own characteristics. These different functional material layers are combined together through bonding or other composite processes to form an overall sound insulation pad structure. The sound-absorbing cotton is usually made of fiber materials, such as polyester fiber sound-absorbing cotton, which has good sound-absorbing performance. The air gap between the fibers can make the sound wave reflect and refract multiple times, thereby achieving the sound-absorbing effect. The rubber plate in the sound insulation material, such as butyl rubber plate, has good damping characteristics and sound insulation performance, which can effectively prevent the propagation of sound. The plastic plate has certain rigidity and sound insulation performance, and the cost is relatively low, so it is also applied in the front wall sound insulation pad of some medium and low-end automobiles.

[0004] In the process of preparing the automobile front wall sound insulation pad, a glue spraying method is often used to combine various sound absorption materials together. However, this method has some disadvantages. During the glue spraying process, it is difficult to make the spraying amount of glue completely uniform. This is because the atomization effect of the spraying head, the fluidity of the glue, and the spraying pressure and other factors will affect the distribution of the glue on the surface of the sound insulation pad and the front wall component. For example, more glue may be sprayed near the center of the spraying head, while less glue may be sprayed at the edge. When the glue is not evenly distributed, the bonding strength will vary. During the driving of the vehicle, due to factors such as vibration, the area with weak bonding strength may cause the sound insulation pad to separate from the front wall, thereby affecting the sound insulation effect and the integrity of the component. Glue spraying may produce air bubbles. During the glue spraying process, if the humidity of the operating environment is high or air is mixed during the mixing of the glue, air bubbles are likely to form in the glue layer. These air bubbles will cause the sound insulation pad and the front wall to be not tightly bonded, forming gaps. When the automobile engine is running and other noises are generated, sound waves can propagate through these gaps, reducing the sound insulation performance of the sound insulation pad. Therefore, the use of glue spraying to combine the automobile front wall sound insulation pad will affect the sound insulation effect, and also cause harm to the environment and the health of the operating personnel. Utility model content

[0005] The present application provides an automobile environment-friendly front wall sound insulation pad to solve the problem that the use of glue spraying to combine the existing automobile front wall sound insulation pad will affect the sound insulation effect, and also cause harm to the environment and the health of the operating personnel.

[0006] The present application provides an automobile environment-friendly front wall sound insulation pad, which comprises:

[0007] a high-performance fiber reinforced composite material injection molding layer of an inner layer, a heat-soluble net film layer of a middle layer, and a thermoplastic felt layer of an outer layer; the thickness of the heat-soluble net film layer is 0.05-0.3 mm.

[0008] In some possible implementation manners, the high-performance fiber reinforced composite material injection molding layer, the heat-soluble net film layer, and the thermoplastic felt layer are sequentially arranged from the front wall sheet metal of the automobile to the cab.

[0009] In some possible implementation manners, the high-performance fiber reinforced composite material injection molding layer, the heat-soluble net film layer, and the thermoplastic felt layer are integrated.

[0010] In some possible implementation manners, the thermoplastic felt layer comprises a thermoplastic felt of an upper layer and a polyolefin elastomer rubber skin of a lower layer.

[0011] In some possible implementation manners, the heat-soluble net film layer is one of polyamide, polyester, polyethylene, and ethylene-vinyl acetate copolymer.

[0012] In some possible implementation manners, the thermoplastic felt layer has a specific gravity of 800±80 g / m 2 , and a thickness of 12±4 mm.

[0013] In some possible implementation manners, the high-performance fiber reinforced composite injection layer has a thickness of 5-35 mm.

[0014] From the above, the application provides an automobile environmental protection front wall sound insulation pad, which comprises a high-performance fiber reinforced composite injection layer as an inner layer, a hot-melt net film layer as a middle layer, and a thermoplastic felt layer as an outer layer; the hot-melt net film layer has a thickness of 0.05-0.3 mm. The automobile environmental protection front wall sound insulation pad provided by the application combines the high-performance fiber reinforced composite injection layer as the inner layer, the hot-melt net film layer, and the thermoplastic felt layer as the outer layer, discards glue as an adhesive, adopts a hot-melt net film as an adhesive, and uses a scheme of bonding the outer layer and the inner layer by steam melting the hot-melt net film in a steam mold to reduce VOC content, reduce odor, and increase the peeling force of the hard layer and the soft layer; meanwhile, the sound insulation effect is effectively improved, and the health of the environment and the operating personnel is ensured. BRIEF DESCRIPTION OF DRAWINGS

[0015] In order to more clearly illustrate the technical solutions of the application, the following will briefly introduce the drawings needed to be used in the embodiments. Obviously, for those skilled in the art, other drawings can also be obtained based on these drawings without any creative effort.

[0016] Figure 1 A structure schematic diagram of the automobile environmental protection front wall sound insulation pad provided by the embodiment of the application.

[0017] Illustration:

[0018] 101-high-performance fiber reinforced composite injection layer; 102-hot-melt net film layer; 103-thermoplastic felt layer; 1031-thermoplastic felt; 1032-polyolefin elastomer rubber. DETAILED DESCRIPTION

[0019] The embodiments will be described in detail below, and examples are shown in the drawings. When the following description refers to the drawings, the same numbers in different drawings represent the same or similar elements unless otherwise indicated. The embodiments described in the following embodiments do not represent all the embodiments consistent with the application. They are only examples of systems and methods consistent with some aspects of the application as described in detail in the claims.

[0020] The automobile front wall sound insulation pad is a key component in the automobile interior system, which is mainly installed between the automobile front wall panel and the driver's cabin, playing an important role in sound insulation, heat insulation and vibration reduction. It can effectively block the noise, heat and vibration from the engine compartment, creating a quiet and comfortable driving environment for passengers, and making an indispensable contribution to improving the overall acoustic performance and ride comfort of the automobile.

[0021] Traditional automobile front wall sound insulation pads usually adopt a multi-layer composite structure. Generally, it includes one or more layers of sound-absorbing materials, such as sound-absorbing cotton, which can absorb part of the noise energy and convert it into heat energy or other forms of energy to dissipate. In addition, there will be one or more layers of sound insulation materials, commonly rubber plates or plastic plates, which can block the propagation of noise and reduce sound transmission through their own characteristics. These different functional material layers are combined together through bonding or other composite processes to form an overall sound insulation pad structure. Sound-absorbing cotton is usually made of fibrous materials, such as polyester fiber sound-absorbing cotton, which has good sound-absorbing performance. The gaps between the fibers can make the sound waves reflect and refract multiple times, thereby achieving sound-absorbing effect. The rubber plate in the sound insulation material, such as butyl rubber plate, has good damping characteristics and sound insulation performance, which can effectively prevent the propagation of sound. Plastic plates have certain rigidity and sound insulation performance, and the cost is relatively low, so they are also used in some low-end automobile front wall sound insulation pads.

[0022] In the preparation process of automobile front wall sound insulation pad, various sound-absorbing materials are combined together by spraying glue. However, this method has some disadvantages. During the spraying process, it is difficult to make the glue spraying amount completely uniform. This is because the atomization effect of the nozzle, the fluidity of the glue and the spraying pressure, etc. will affect the distribution of the glue on the surface of the sound insulation pad and the front wall component. For example, the glue near the center of the nozzle may be sprayed more, while the edge position may be less. When the glue is not evenly distributed, the bonding strength will be different. During vehicle driving, due to factors such as vibration, the area with weak bonding strength may separate the sound insulation pad from the front wall, thereby affecting the sound insulation effect and the integrity of the component. Gluing may produce air bubbles. If the humidity of the operating environment is large or air is mixed during the mixing of the glue, air bubbles are easily formed in the glue layer. These air bubbles will make the bonding between the sound insulation pad and the front wall not tight, forming gaps. When the automobile engine operates and produces noise, sound waves can propagate through these gaps, reducing the sound insulation performance of the sound insulation pad.

[0023] Many glue used in spraying glue contains volatile organic compounds (VOC). During the drying process of spraying glue and glue, these VOCs will volatilize into the air, causing harm to the environment and the health of the operators. With the increasingly stringent environmental regulations, the emission of VOCs needs to be controlled, which requires enterprises to invest in ventilation equipment and waste gas treatment, increasing the production cost. At the same time, some environmentally friendly glues, although with lower VOC content, may not have as good bonding performance as traditional glues, or are more expensive, which also brings the enterprises the difficulty of balancing cost and performance. Therefore, the use of spraying glue in combination with the automobile front wall sound insulation pad will affect the sound insulation effect, and also cause harm to the environment and the health of the operators.

[0024] Based on this, the application provides an automobile environmentally friendly front wall sound insulation pad, which combines a high-performance fiber reinforced composite injection layer in the inner layer, a hot-melt film layer, and a thermoplastic felt layer in the outer layer, discards glue as an adhesive, uses hot-melt film as an adhesive, and through the scheme of steam melting hot-melt film to bond the outer layer and the inner layer in a steam mold, reduces the VOC content, reduces the odor, and increases the peeling force of the hard layer and the soft layer.

[0025] As shown in Figure 1 The application provides an automobile environmentally friendly front wall sound insulation pad, which includes:

[0026] a high-performance fiber reinforced composite injection layer 101 in the inner layer, a hot-melt film layer 102 in the middle layer, and a thermoplastic felt layer 103 in the outer layer; the thickness of the hot-melt film layer 102 is 0.05-0.3 mm. Among them, the hot-melt film layer 102 is one of polyamide, polyester, polyethylene, and ethylene-vinyl acetate copolymer.

[0027] In the assembly process of the sound insulation pad, a lightweight connection method is used. For example, hot melt glue or a new type of adhesive is used instead of traditional mechanical connection methods. The use of hot melt glue can reduce the weight of the connected parts, while achieving good connection strength and ensuring the tight connection between the parts of the sound insulation pad. Moreover, some new adhesives also have the additional functions of damping and sound absorption, which help to improve the acoustic performance of the sound insulation pad while connecting the materials. In addition, ultrasonic welding and other processes can be used to connect plastic parts, which not only have firm connection, but also do not increase additional weight, which helps to achieve the overall lightweight of the automobile front wall sound insulation pad material.

[0028] Therefore, the present application replaces the adhesive glue in the prior art with hot melt glue. Hot melt web film is a new product form of hot melt glue. It is mainly composed of thermoplastic high molecular polymers, and common materials include polyamide (PA), polyester (PET), polyethylene (PE), ethylene-vinyl acetate copolymer (EVA), etc. A 0.3mm thick hot melt web film is used in automotive interior decoration to bond between cushioning materials, and can play a certain role in filling and cushioning transition. Thicker hot melt web film (such as 0.3mm) can generally provide higher bonding strength. This is because thicker web film contains more hot melt glue material, which can fill larger gaps after being heated and melted, forming a thicker glue layer. For example, the bonding of the high-performance fiber reinforced composite injection molding layer 101 and the thermoplastic felt layer 103 in the automotive environmental front wall sound insulation pad needs to withstand a large pressure and friction force. Thick hot melt web film can better bond the two materials together, so that they are not easily separated during long-term use.

[0029] In some embodiments, the hot melt web film used in the present application is a polyamide (PA) hot melt web film: this material has a relatively high melting point, usually around 180-220℃. Its advantages are high strength, wear resistance, chemical corrosion resistance, and good adhesion to many materials, especially in some applications that require high strength bonding, such as the compounding of automotive interior parts and the bonding of leather products, etc. In the present application, the hot melt web film layer 102 is used as an adhesive to bond the high-performance fiber reinforced composite injection molding layer 101 and the thermoplastic felt layer 103 by steam melting the hot melt web film in a steam mold, thereby reducing VOC content, reducing odor, and increasing the peel force between the hard layer and the soft layer (to make it stickier).

[0030] In some embodiments, the high-performance fiber reinforced composite injection molding layer 101, the hot melt web film layer 102, and the thermoplastic felt layer 103 are arranged in sequence from the front wall sheet metal of the automobile to the driver's cabin.

[0031] In some embodiments, the high-performance fiber reinforced composite injection molding layer 101, the hot melt web film layer 102, and the thermoplastic felt layer 103 are integrated.

[0032] In some embodiments, the thermoplastic felt layer 103 includes an upper thermoplastic felt 1031 and a lower polyolefin elastomer rubber 1032. The thermoplastic felt layer 103 has a specific gravity of 800±80g / m2 and a thickness of 12±4mm.

[0033] The thermoplastic felt 1031 is mainly made of polyester fibers and processed through hot melt technology. The thermoplastic felt 1031 needs to go through high-temperature hot melting, pressing and molding processes, and the felt is made through carding, shrinking and pressing steps. The thermoplastic felt 1031 has excellent sound insulation and heat insulation effects due to its internal structure.

[0034] The polyolefin elastomer rubber 1032 in this application is a high-performance thermoplastic elastomer material, commonly composed of the following main components:

[0035] Base resin: usually polyethylene (PE) or polypropylene (PP) and other polyolefin resins, providing the basic physical properties and chemical stability of the material.

[0036] Elastomer phase: generally a copolymer of ethylene and alpha-olefins, such as ethylene-octene copolymer (EOC) or ethylene-butene copolymer (EBC), etc. The presence of the elastomer phase gives the POE rubber good elasticity and flexibility.

[0037] Additives: various additives such as antioxidants, ultraviolet stabilizers, lubricants, fillers, etc. may be added according to specific application requirements to improve the performance and processing properties of the material.

[0038] The good elasticity of POE rubber makes it play an important role in the manufacture of automobile seats. It can produce moderate deformation according to the changes in human sitting posture, providing comfortable support for the occupants. Compared with traditional materials, its flexibility can better fit the human body curve, reducing the feeling of fatigue after a long time of sitting. For example, in the surface material of some high-end car seats, POE rubber can provide a soft touch, while also having enough elasticity to maintain the shape of the seat.

[0039] In the manufacture of seals and gaskets for automotive interiors, the flexibility of POE rubber is crucial. Its elasticity effectively fills the gap between the thermoplastic felt and the hot melt net film, preventing the intrusion of dust, rain and noise. Moreover, the elasticity of POE rubber can still ensure that the seal returns to its original state and maintain good sealing performance during long-term use.

[0040] In some embodiments, the high-performance fiber-reinforced composite injection layer 101 has a thickness of 5-35 mm.

[0041] High-performance fiber reinforced composite injection molding material (HMP) is a kind of composite material prepared by using high-performance fibers as reinforcing materials and thermoplastic resin matrix through injection molding process. High-performance fiber reinforced composite injection molding material includes high-performance fibers, thermoplastic resin matrix and additives. Common high-performance fibers include carbon fibers, glass fibers, aramid fibers, etc. These fibers have excellent properties such as high strength, high modulus and low density, which can significantly improve the mechanical properties of the material. Thermoplastic resin matrix: such as polyamide (PA), polycarbonate (PC), polypropylene (PP) and other thermoplastic resins, which have good processing performance and recyclability, can bond fibers together, transfer load and provide certain toughness and corrosion resistance. Additives: In order to improve the performance of the material, some additives such as antioxidants, lubricants and coupling agents may also be added. Coupling agent can enhance the interfacial bonding force between fiber and resin and improve the overall performance of the material.

[0042] The high-performance fiber reinforced composite material in the present application has excellent strength and stiffness due to the addition of high-performance fibers, and can withstand large loads, suitable for manufacturing parts with high mechanical performance requirements. Some high-performance fibers and thermoplastic resins have high heat resistance, so that the material can still maintain good mechanical properties and dimensional stability at high temperature environment, and can meet the use requirements under some high temperature working conditions.

[0043] Perforate the high-performance fiber reinforced composite injection molding layer, and adjust the sound absorption performance by controlling the size, spacing of the holes and the thickness of the high-performance fiber reinforced composite injection molding layer. Sound waves produce friction and resonance in the small holes of the micro-perforated plate, converting sound energy into heat energy, thereby achieving sound absorption effect. Compared with traditional sound-absorbing cotton, micro-perforated plate has small density, light weight, and good high temperature resistance and moisture resistance, and will not have performance degradation problem in high temperature or high humidity environment like sound-absorbing cotton.

[0044] The automobile environmental protection front wall sound insulation pad in the embodiment of the present application has multiple micro-holes in the micro-porous structure of the inner layer of high-performance fiber reinforced composite injection molding layer 101, which can adsorb harmful gases in the car. The middle layer of hot melt film layer 102 contains more hot melt adhesive material, which can fill larger gaps after heating and melting, form a thicker adhesive layer, and bond the high-performance fiber reinforced composite injection molding layer 101 and the thermoplastic felt layer 103 together to increase the peeling force between the hard layer and the soft layer.

[0045] From the above embodiment, the application provides a car environmental protection front wall sound insulation pad, the car environmental protection front wall sound insulation pad includes: the high performance fiber reinforced composite material injection molding layer of inner layer, the hot melt net film layer of middle layer and the thermoplastic felt layer of outer layer, the thickness of hot melt net film layer is 0.05-0.3 millimeter.The car environmental protection front wall sound insulation pad provided by the application is the combination of the high performance fiber reinforced composite material injection molding layer of inner layer, hot melt net film layer and the thermoplastic felt layer of outer layer, discards glue as adhesive, adopts hot melt net film as adhesive, through the scheme of steam melting hot melt net film in steam mode to bond outer layer and inner layer, reduces VOC content, reduces smell, increases the peeling force of hard layer and soft layer, effectively increases sound insulation effect, and also guarantees the health of environment and operating personnel.

[0046] Similar parts between the embodiments provided by the application can be referred to each other, the specific implementation provided above is only several examples under the general concept of the application, and does not constitute the limitation of the protection scope of the application. For those skilled in the art, any other implementation extended according to the application scheme without creative labor belongs to the protection scope of the application.

Claims

1. An environmentally friendly car front wall sound insulation pad, characterized in that: The environmentally friendly front wall sound insulation pad of the automobile comprises: An inner high-performance fiber-reinforced composite material injection molding layer (101), a middle hot-melt mesh layer (102), and an outer thermoplastic felt layer (103); the hot-melt mesh layer (102) has a thickness of 0.05 to 0.3 mm.

2. The environmentally friendly automobile front wall sound insulation pad according to claim 1, characterized in that: The high-performance fiber-reinforced composite material injection molding layer (101), the hot-melt web film layer (102), and the thermoplastic felt layer (103) are sequentially arranged from the front panel metal of the automobile toward the driving cab.

3. The environmentally friendly automobile front wall sound insulation pad according to claim 1, characterized in that: The high-performance fiber-reinforced composite material injection molding layer (101), the hot-melt mesh film layer (102), and the thermoplastic felt layer (103) are composited into one body.

4. The environmentally friendly automobile front wall sound insulation pad according to claim 1, characterized in that: The thermoplastic felt layer (103) comprises an upper layer of thermoplastic felt (1031) and a lower layer of polyolefin elastomer rubber (1032).

5. The environmentally friendly automobile front wall sound insulation pad according to claim 1, characterized in that: The heat-melt mesh layer (102) is made of one of polyamide, polyester, polyethylene, and ethylene-vinyl acetate copolymer.

6. The environmentally friendly automobile front wall sound insulation pad according to claim 1, characterized in that: The thermoplastic felt layer (103) has a specific gravity of 800±80g / m 2 , hot melt felt with a thickness of 12±4mm.

7. The environmentally friendly automobile front wall sound insulation pad according to claim 1, characterized in that: The high-performance fiber-reinforced composite material injection molding layer (101) has a thickness of 5 to 35 mm.

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