CN107666998A - 用于制造机动车用隔音内饰板的方法 - Google Patents

用于制造机动车用隔音内饰板的方法 Download PDF

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Publication number
CN107666998A
CN107666998A CN201680014018.4A CN201680014018A CN107666998A CN 107666998 A CN107666998 A CN 107666998A CN 201680014018 A CN201680014018 A CN 201680014018A CN 107666998 A CN107666998 A CN 107666998A
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China
Prior art keywords
gas permeability
sound
coating
absorbing structure
structure layer
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CN201680014018.4A
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CN107666998B (zh
Inventor
C·布洛姆
D·德勒泽
M·波蒂埃
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Serra LLC
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Serra LLC
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    • B29C43/021—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles characterised by the shape of the surface
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Abstract

本发明涉及一种方法，其包括下列步骤：提供热压模具，模具具有限定模腔(4)的阴模(2)和阳模(3)，通过闭合模具而密封模腔，阳模或者阴模具有带粒状结构的表面(5)；在阴模和阳模之间相继叠置地布置透气性覆盖层(6)、能热压模制的透气性吸音结构层(7)及热塑性密封薄膜(8)，覆盖层朝向所述表面，覆盖层和结构层处于能模制这些层的温度；闭合模具以密封模腔；在薄膜侧施加压力气体，以使薄膜压靠到结构层上来压缩所述结构层，及以使覆盖层压靠到所述表面上来使覆盖层带有粒状结构；在周边切割之后，将获得的隔音内饰板(1)脱模。

Description

用于制造机动车用隔音内饰板的方法
技术领域
本发明涉及用于制造机动车用的隔音内饰板的方法和用这种方法所获的隔音内饰板。
背景技术
尤其是从文献US-5 908 524中已知一种用于制造机动车用的隔音内饰板的方法，所述方法包括下列步骤：
–提供热压模具，热压模具具有限定模腔的阴模和阳模，所述阳模或者所述阴模具有带粒状结构的表面，
-在所述阴模和所述阳模之间相继叠置地布置密封覆盖层和能通过热压模制的透气性吸音结构层，透气性吸音结构层以彼此间用粘合剂粘结的纤维为基础，密封覆盖层朝向所述表面，所述透气性吸音结构层和密封覆盖层处于允许模制这些层的温度，
–闭合热压模具以压缩密封覆盖层和透气性吸音结构层，同时施加真空拉伸或者施加压力气体以使密封覆盖层压靠到所述表面上，来使密封覆盖层粒状化，
-在周边切割之后，将获得的隔音内饰板脱模。
使用这种方法允许获得这样一种隔音内饰板：其具有透气性吸音结构层所带来的良好刚性和密封覆盖层粒状化所带来的有利外观。
但是，这种方法不能应用于透气性覆盖层如无纺织物，这种透气性覆盖层不能通过压力气体推压到或吸附到带粒状结构的表面上。
在这种情况下，文献US-5 908 524提出为本质上透气性的覆盖层配置允许密封该覆盖层的密封下层。
但是，无论是在覆盖层本质上是密封的还是通过增加密封下层使覆盖层变密封的情况，最终获得的隔音内饰板都在覆盖层侧上不能吸音，这是因为由于覆盖层所产生的屏障，声波不能被吸收到结构层内。
不过，当想制造可在覆盖层侧上实现吸音的隔音内饰板时，可能希望使透气性覆盖层上设有粒状结构。
为此提出在透气性覆盖层上实现预先粒状化，在无纺织物型的覆盖层的情况下，粒状结构尤其是由编织线形成。
在这种情况下，通常会观察到粒状结构减小、甚至消除，这是因为覆盖层压紧到模具上，这种减小或者消除在覆盖层的强拉延区域中很突出。
在一些情况下，可通过采用高面密度的覆盖层来最大限度地减少这种现象。
在基于无纺织物的覆盖层的情况下，例如可以考虑约220克/平方米的面密度。
但是，即便使用这种高面密度的覆盖层，也并非始终会在强拉延区域中具有令人满意的外观。
不管怎样，覆盖层因其预先粒状化而具有一定的生产复杂性，要求使用大量原材料，这会大大影响其成本，从而影响到隔音内饰板的成本。
发明内容
本发明旨在提出一种允许以较低成本获得隔音内饰板的方法，这种隔音内饰板具有的透气性覆盖层带有在透气性覆盖层的所有区域中、特别是在与强拉延相对应的区域中具有令人满意外观的粒状结构(grainage)，所述隔音内饰板还允许在所述透气性覆盖层侧上吸音。
为此，根据第一方面，本发明提出一种用于制造机动车用的隔音内饰板的方法，所述方法包括下列步骤：
-提供热压模具，热压模具具有阴模和阳模，阴模和阳模限定模腔，通过闭合热压模具而密封模腔，阳模或者阴模具有带粒状结构的表面，
-在阴模和阳模之间相继叠置地布置透气性覆盖层、能热压模制的透气性吸音结构层、以及热塑性密封薄膜，透气性吸音结构层基于彼此间用粘合剂粘结的纤维，透气性覆盖层朝向所述表面，透气性覆盖层和透气性吸音结构层处于能模制所述透气性覆盖层和透气性吸音结构层的温度，
-闭合热压模具以密封模腔，
-在热塑性密封薄膜侧上施加压力气体，以使热塑性密封薄膜压靠到透气性吸音结构层上来压缩所述透气性吸音结构层，及以使透气性覆盖层压靠到所述表面上来使透气性覆盖层上带有粒状结构，
-在周边切割之后，将获得的隔音内饰板脱模。
不进行可在透气性覆盖层侧上实施的真空吸附、而是在热塑性密封薄膜侧上施加压力气体具有尤其以下优点：
-在吸附的情况下，必须使抽吸泵连续工作以实现粒状化和对透气性吸音结构层的压缩，而当施加压力气体时则不是这种情况，这是因为模腔通过热压模具闭合而密封，
-另外，由于在透气性吸音结构层中存在粘合剂，吸附工作会导致抽吸***阻塞的风险，而这是在气体增压时避免了的缺陷，
-最后，本申请人还发现：与实现透气性覆盖层不太强压贴的吸附相反的是，施加压力气体允许实现透气性覆盖层的非常强的表面粒状化；透气性覆盖层的粒状结构呈限定颗粒的多个相邻的凸起的形式，凸起的高度可尤其大于或者等于0.4毫米。
这里，应当指出，透气性覆盖层与透气性吸音结构层处于允许模制这些层的温度意味着：根据使用的是冷还是热的模具，这些层在布置于热压模具中之前或者之后被带到所述温度。
采用所提出的布置，透气性覆盖层的粒状结构由带粒状结构的模具表面赋予，而不是由预先在透气性覆盖层上实现的粒状结构来赋予。
因此确保了在透气性覆盖层上的所有区域、包括透气性覆盖层的强拉延区域中，存在完全明显的均匀的粒状结构。
此外可从容考虑使用低面密度的透气性覆盖层，这与无需进行透气性覆盖层的预先粒状化作业相结合，能降低隔音内饰板的成本。
这里观察到热塑性密封薄膜具有三重作用：
-一方面，压缩透气性吸音结构层，
-另一方面，使透气性覆盖层压靠到带粒状结构的表面上，以将粒状结构转移到透气性覆盖层上，
-最后，使隔音内饰板在与具有透气性覆盖层的所述表面相对的透气性吸音结构层表面上具有隔音性能，所述隔音内饰板还在所述透气性覆盖层侧上具有吸音性能。
最后，应当指出，使用热塑性密封薄膜来压缩透气性吸音结构层及使透气性覆盖层贴靠、而不是简单地压紧在热压模具的阴模和阳模之间的事实，允许容易在所述透气性吸音结构层中保持能实现吸音的至少一个低压缩区域。
根据第二方面，本发明提出用这种方法制成的隔音内饰板。
附图说明
根据下面参照附图所作的说明，本发明的其他特征和优点将体现出来，其中该唯一附图是模制过程中的隔音内饰板的局部剖面示意图。
具体实施方式
参照附图描述一种用于制造机动车用的隔音内饰板1的方法，所述方法包括下列步骤：
-提供热压模具，热压模具具有阴模2和阳模3，阴模和阳模限定通过闭合热压模具而密封的模腔4，所述阳模或者所述阴模具有带粒状结构的表面5，
-在所述阴模和所述阳模之间相继叠置地布置透气性覆盖层6、能热压模制的透气性吸音结构层7、以及热塑性密封薄膜8，所述透气性吸音结构层基于彼此间用粘合剂粘结的纤维，所述透气性覆盖层朝向所述表面，所述透气性吸音结构层和透气性覆盖层处在允许模制这些层的温度，
-闭合热压模具以密封所述模腔，
-在所述热塑性密封薄膜侧上施加压力气体，以使所述热塑性密封薄膜压靠到透气性吸音结构层上来压缩该透气性吸音结构层，及以使所述透气性覆盖层压靠到所述表面上来赋予透气性覆盖层以粒状结构，
-在周边切割之后，将获得的隔音内饰板1脱模。
这种隔音内饰板1尤其用于覆罩发动机、座舱壁、行李厢又或者这种行李厢的壁。
在所示的实施方式中，通过布置在与带粒状结构的表面5相对的表面11上的孔10施加压力气体。
透气性覆盖层6和透气性吸音结构层7在热压前尤其具有小于2500N.s.m-3的空气通过阻力。
如上面所指出的，透气性覆盖层6和透气性吸音结构层7处于允许模制这些层的温度这一事实意味着：根据使用的是冷还是热的模具，透气性覆盖层和透气性吸音结构层在布置于热压模具中之前或者之后被带到所述温度。
根据一实施方式，周边切割能以未示出的方式用集成于热压模具的刀片进行，这些刀片还允许实现模腔4密封。
根据所示的实施方式，表面5的粒状结构呈限定颗粒的多个相邻的凸起12的形式，凸起的高度13尤其大于或者等于0.5毫米。
根据一实施方式，凸起12的高度13小于或者等于3毫米。
根据一实施方式，透气性覆盖层6基于织物或无纺织物，无纺织物例如为植绒型，通过水射流或者胶接相接合。
根据一实施方式，透气性覆盖层6基于合成纤维，尤其是基于聚对苯二甲酸乙二醇酯。
根据一实施方式，透气性覆盖层6具有的面密度小于或者等于80克/平方米，尤其是小于或者等于40克/平方米。
根据一实施方式，透气性吸音结构层7具有的面密度为400-1200克/平方米之间。
根据一实施方式，透气性吸音结构层7在模制后具有的厚度为2-3毫米之间。
根据一实施方式，透气性吸音结构层7基于矿物纤维、尤其是玻璃纤维，或者基于天然纤维、尤其是棉纤维。
根据一实施方式，粘合剂为热固性、尤其是酚醛树脂或环氧树脂，或者粘合剂为热塑性、尤其是聚丙烯。
根据一实施方式，在热固性的粘合剂的情况下，透气性覆盖层6和透气性吸音结构层7以及热塑性密封薄膜8通过热压模具加热，热压模具尤其是被保持在约200℃的温度。
根据一实施方式，热塑性密封薄膜8是聚乙烯/聚酰胺/聚乙烯多层薄膜，其中聚乙烯层形成在模制温度下可熔的胶。
根据一实施方式，热塑性密封薄膜8具有的厚度为70-90微米之间。
根据所示的实施方式，另外在热塑性密封薄膜8上，与透气性吸音结构层7相对地设置有透气性吸音层9。
因此得到这样的隔音内饰板1：在热塑性密封薄膜8的两侧，隔音内饰板1具有实现吸音的相应两层7、9，所述热塑性密封薄膜实现在这两个吸音层之间的隔音。
根据一实施方式，透气性吸音层9基于泡沫塑料、尤其是聚氨酯。
根据一实施方式，透气性吸音层9在模制之前具有的密度为0.010-0.020之间，尤其是约为0.015。
最后描述一种用于机动车的隔音内饰板1，隔音内饰板用如上所述的方法制成，隔音内饰板相继具有带粒状结构的透气性覆盖层6、热压的透气性吸音结构层7、以及热塑性密封薄膜8，透气性吸音结构层基于彼此间用粘合剂粘结的纤维。
根据一实施方式，透气性覆盖层6具有的粒状结构呈限定颗粒的多个相邻的凸起的形式，凸起的高度尤其是大于或者等于0.4毫米，而知晓的是相对于在带粒状结构的表面5上布置的粒状结构来说，透气性覆盖层6上获得的粒状结构可以略小。
根据一实施方式，透气性覆盖层6具有的面密度小于或者等于80克/平方米，尤其是小于或者等于40克/平方米。
采用具有如此小的面密度的透气性覆盖层6，有助于获得成本最小化的隔音内饰板1。
当然，透气性覆盖层6可具有例如约100或者200克/平方米的更大的面密度。
根据所示的实施方式，隔音内饰板1还具有透气性吸音层9，透气性吸音层9与透气性吸音结构层7相对地布置在热塑性密封薄膜8上，该透气性吸音层尤其以泡沫塑料、特别是聚氨酯为基础。

Claims (10)

1.一种用于制造机动车用的隔音内饰板(1)的方法，其特征在于，所述方法包括下列步骤：
-提供热压模具，热压模具具有阴模(2)和阳模(3)，阴模和阳模限定模腔(4)，通过闭合热压模具而密封模腔，阳模或者阴模具有带粒状结构的表面(5)，
-在阴模和阳模之间相继叠置地布置透气性覆盖层(6)、能热压模制的透气性吸音结构层(7)、以及热塑性密封薄膜(8)，透气性吸音结构层基于彼此间用粘合剂粘结的纤维，透气性覆盖层朝向所述表面，透气性覆盖层和透气性吸音结构层处于能模制所述透气性覆盖层和透气性吸音结构层的温度，
-闭合热压模具以密封模腔，
-在热塑性密封薄膜侧上施加压力气体，以使热塑性密封薄膜压靠到透气性吸音结构层上来压缩所述透气性吸音结构层，及以使透气性覆盖层压靠到所述表面上来使透气性覆盖层上带有粒状结构，
-在周边切割之后，将获得的隔音内饰板(1)脱模。
2.根据权利要求1所述的方法，其特征在于，所述表面(5)的粒状结构呈限定颗粒的多个相邻的凸起(12)的形式，凸起的高度(13)大于或者等于0.5毫米。
3.根据权利要求1或2所述的方法，其特征在于，透气性覆盖层(6)基于织物或无纺织物。
4.根据权利要求1至3中任一项所述的方法，其特征在于，透气性覆盖层(6)具有的面密度小于或者等于80克/平方米，尤其是小于或者等于40克/平方米。
5.根据权利要求1至4中任一项所述的方法，其特征在于，另外在热塑性密封薄膜(8)上与透气性吸音结构层(7)相对地设置有透气性吸音层(9)。
6.根据权利要求5所述的方法，其特征在于，透气性吸音层(9)基于泡沫塑料。
7.根据权利要求5或6所述的方法，其特征在于，透气性吸音层(9)在模制之前具有的密度为0.010-0.020之间，尤其是约为0.015。
8.根据权利要求1至7中任一项所述的方法，其特征在于，透气性吸音结构层(7)基于矿物纤维或者天然纤维。
9.根据权利要求1至8中任一项所述的方法，其特征在于，粘合剂为热固性或者热塑性。
10.一种板(1)，其由根据权利要求1至9中任一项所述的方法制成，其特征在于，所述板相继具有带粒状结构的透气性覆盖层(6)、热压的透气性吸音结构层(7)、以及热塑性密封薄膜(8)，所述透气性吸音结构层基于彼此间用粘合剂粘结的纤维。
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FR1552275A FR3032374B1 (fr) 2015-02-05 2015-03-19 Procede de realisation d'un panneau d'habillage et/ou de protection acoustique
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PCT/FR2016/050030 WO2016124830A1 (fr) 2015-02-05 2016-01-07 Procédé de réalisation d'un panneau d'habillage et de protection acoustique pour véhicule automobile

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FR3092537B1 (fr) * 2019-02-08 2021-05-21 Treves Products Services & Innovation Ecran de protection acoustique pour compartiment à moteur de véhicule automobile

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FR3032374B1 (fr) 2017-03-24
FR3032374A1 (fr) 2016-08-12
FR3032373A1 (fr) 2016-08-12
WO2016124830A1 (fr) 2016-08-11
ES2804842T3 (es) 2021-02-09
FR3032373B1 (fr) 2017-03-03

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