CN109996674A - 用于制造吸音隔音元件的方法，以及吸音隔音汽车装饰元件 - Google Patents

用于制造吸音隔音元件的方法，以及吸音隔音汽车装饰元件 Download PDF

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Publication number
CN109996674A
CN109996674A CN201780073143.7A CN201780073143A CN109996674A CN 109996674 A CN109996674 A CN 109996674A CN 201780073143 A CN201780073143 A CN 201780073143A CN 109996674 A CN109996674 A CN 109996674A
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China
Prior art keywords
foam
layer
sound insulation
sound
fiber
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Pending
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CN201780073143.7A
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English (en)
Inventor
福尔克马尔·舒尔茨
赫尔穆特·贝克
沃尔克·库尔施
毛里西奥·塔雷洛
诺贝特·尼科莱
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Adler Per Ze Holdings Ltd
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Adler Per Ze Holdings Ltd
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Publication of CN109996674A publication Critical patent/CN109996674A/zh
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  • Engineering & Computer Science (AREA)
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  • General Chemical & Material Sciences (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Laminated Bodies (AREA)
  • Soundproofing, Sound Blocking, And Sound Damping (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Molding Of Porous Articles (AREA)

Abstract

本发明涉及一种用于制造吸音隔音汽车装饰元件的方法，该吸音隔音汽车装饰元件具有由第一泡沫层，第二泡沫层，非织造泡沫层和非织造织物层制成的四层结构。本发明还涉及一种吸音隔音汽车装饰元件。

Description

用于制造吸音隔音元件的方法，以及吸音隔音汽车装饰元件
技术领域
本发明涉及一种用于制造吸音隔音汽车装饰元件的方法，下面将进一步说明，包括由第一泡沫层，第二泡沫层，非织造泡沫层和非织造织物层制成的四层结构。
此外，本发明涉及一种吸音隔音汽车装饰元件，这将在本文中进一步说明，其中声音的吸收特别高。
根据现有技术，已知不同的隔音元件和相关的制备方法，通过这些隔音元件和相关的制备方法可以产生，特别是可以吸收声音的结构，例如来自发动机舱（的声音），以至于声音不会，或者只是在一定程度上，进入环境或进入汽车的乘客舱。
在现有技术中，已知隔音汽车装饰元件和相关制备方法的大量不同组合物，所有这些都使用不同的方法，并通过小但重要的差异来区分。在下文中，将阐述相关的现有技术。
从印刷文献DE 39 05 607 A1中，已知一种具有用于制备汽车隔音的层结构的地板饰板，其包括由泡沫和至少一种非织造物制成的声学有效层，其中至少一个声学有效层以中间片的形式引入。
从印刷文献DE 10 2013 104 715 A1中，已知一种隔音声学元件，其具有至少一个吸音非织造层，其中所述非织造层包括泡沫流动调节或泡沫流动抑制层，并且具有吸音泡沫层，其中后者通过材料锁定的后发泡粘合到多孔非织造物上，该渗透到达所述泡沫流动调节或抑制层。
此外，从印刷文献JP 2004 123090 A中，可以看到用于汽车的地垫，其中所述地垫具有实现隔音特性和吸音特性的设计。这样，地毯层和两层或更多层多孔体层就能被组合，其中在所述多孔体层之间提供包含形成相邻多孔体层的材料和泡沫树脂的复合层。
此外，从印刷文献EP 2 251 231 A1中，已知一种光和声保护板，其具有多孔层并且由在泡沫塑料的吸音器之间提供的热塑性纤维的稳定纤维织物片组成，其中短纤维片的材料和另一吸音材料的泡沫材料形成一个或多个隔音层。
总之，两种具有不同特性的不同的发泡***被组合，或者可以如下所述作现有技术中未知的进一步组合。
现有技术中的问题实质上在于，目前不可能制备出满足以下要求的廉价的高吸音隔音元件：
- 声音吸收高于现有技术中已知的隔音汽车装饰元件的声音吸收；
- 简单的制备和减少单个组件，以便在生产过程中降低成本是可能的，因为到目前为止，至少需要三个或四个单独元件的复杂***是必要的，其中这些单独元件首先必须以困难的方式进行组合，例如将分离片引入非织造物或相似的物质中；和
- 隔音汽车装饰元件的层结构的轻重量。
通常，在现有技术中描述的结构可以通过多层结构来描述，对于该多层结构，总是需要非常复杂的方法和保护机制，使得一种泡沫在后发泡期间不会完全渗透到非织造层中。
特别地，已经认识到，现有技术中没有能够满足所有这些要求的高吸音隔音汽车装饰元件。
本发明的目的在于提供一种廉价且高吸音的隔音元件及相关的制备方法，其中在实现生产成本效益的同时实现非常高的声学效果，其中仅使用少量单个组件的制备方法的简单性将是主要关注点，但同时有效性将得到提高和增强。
该目的通过根据主权利要求的用于制造吸音隔音汽车装饰元件的方法，以及根据另一独立权利要求的吸音隔音汽车装饰元件来实现。
用于制造吸音隔音汽车装饰元件的方法，包括由第一泡沫层，第二泡沫层，非织造泡沫层和非织造织物层制成的四层结构，包括以下步骤：
I）提供厚度为d的非织造织物；
II）将非织造织物压缩至压缩厚度d'；
III）借助于第一成型泡沫半模在所述压缩非织造织物层的顶表面上发泡第二泡沫，其中所述第二泡沫将至少部分地扩散到所述非织造织物层中以形成中间层，即密度增加的层，所述中间层由所述非织造织物层和所述第二泡沫的部分厚度组成;
IV）在远离非织造织物的第二泡沫的顶表面上发泡第一泡沫，其中在远离第二泡沫的第一泡沫的表面上形成外表面结构；
其中，
在步骤III）和/或IV）的发泡过程中，肋，泡罩，凸起和/或压痕表面结构的形成/制备在远离相应非织造织物的相应泡沫（11，12）的一侧上实现。
作为一个重要的优点，已经发现，在特别优选的变体中的步骤III）和/或IV）的发泡期间，肋，泡罩，凸起和/或压痕表面结构的形成/制备在远离相应非织造织物的相应泡沫的一侧上，第一和第二发泡***的不同特性出人意料地导致产品的噪音水平显著降低，从而首次实现了额外的隔音效果。然而，除了隔音外，由于不同的泡沫与制备的表面结构相结合，组件的结构也得到增强，因此，这两个优点相互补充，与期望相辅相成。
在开始时对非织造织物的压缩以这样的方式制备非织造织物，使得第二泡沫首先被施加到无纺布的表面，仅部分地而非完全地扩散到非织造织物中。
此外，通过使用两种具有不同特性的泡沫，满足了改善的吸音和减轻重量的要求，但是其中同时确保了组件所需的强度，尽管很小。
特别地，可以省去相应的阻挡层和分离层。
在步骤III）中，发泡可以在第一发泡模具中进行。此外，步骤IV）中的发泡可以在第二发泡模具中或在第一发泡模具中用替换的上泡沫模具进行。
如果第二泡沫的发泡***的表面结构与第一泡沫的表面结构相同，特别是在具有肋结构的设计中，那么第一和第二发泡***的发泡可以在相同的发泡模具中进行。当第一发泡***发泡时，仅改变间隙尺寸，即通过第一发泡***的厚度。这代表了相当大的成本优势，因为只需要一个发泡模具。
高吸音隔音汽车装饰元件，特别是并且优选地通过如本文所公开和描述的用于制造高吸音隔音汽车装饰元件的方法制备的，具有四层结构，其中所述结构包括：
- 第一泡沫层；
- 第二个泡沫层；
- 密度增加的层；和
- 非织造织物层；
其中，
- 泡沫层具有不同的密度，损耗因子和/或弹性模量；和
- 与非织造织物层相邻的泡沫部分地扩散到非织造织物中以形成密度增加的层；
其中
所述远离非织造织物的第一和/或第二泡沫层的顶表面上的第一和/或第二泡沫的表面具有肋，泡罩，凸起和/或压痕结构。
在另一个优选的实施方案中，非织造织物由PET纤维组成，或者由PET纤维和BiCo纤维组成的非织造织物，其中在后一种情况下非织造织物中BiCo纤维的比例为1-50 重量％，或8至20重量％，或10重量％。
此外，非织造织物可以
（a）包括选自聚酯纤维，特别是聚（对苯二甲酸乙二醇酯）纤维，聚酰胺纤维，特别是尼龙6和/或尼龙66，聚烯烃纤维，特别是聚丙烯纤维和/或聚乙烯纤维，和丙烯酸纤维以及它们的纤维混合物的合成纤维，包括双组分纤维和多组分纤维；
（b）包括选自原棉纤维，***纤维，椰子纤维，洋麻纤维，黄麻纤维和剑麻纤维及其混合物的天然纤维；或者
（c）含有（a）组和（b）组的合成纤维的混合物。
此外，特别地，非织造织物的单位面积质量可以为400 g/m2至1800 g/m2，优选600 g/m2至1200 g/m2，和/或密度增加的层的单位面积质量可以为300 g/m2至1500 g/m2，和/或优选350 g/m2至800 g/m2。
在这方面，可以额外使用PUR泡沫的CO2负载。负载可以在异氰酸酯或多元醇中进行，两者都可以负载。此外，有可能在混合头中负载。 也可以使用氮气，戊烷或压缩空气代替CO2负载。
优选地，第一和/或第二泡沫层可以包含气泡空隙。
在特别优选的实施方案中，发泡***由PUR组成。第一发泡***可具有40至90 g/l的密度，0.15至0.26的损耗因子，和/或45至180 kN/m2的弹性模量。此外，第二发泡***可具有50至150 g/l的密度，0.15至0.55的损耗因子，和/或20至300 kN/m2的弹性模量。
在本公开的含义内，吸音隔音汽车装饰元件1，特别是因为其相对于隔音的非常高的吸收率，可以被描述为高吸音隔音汽车装饰元件1，或者制造隔音汽车装饰元件的相应方法。
在下文中，参考附图1和在附图以及图像的描述中的图像1至5详细描述了本发明的实施例，其中后者应该解释本发明而不是限制性的。
图1示出了所公开的吸音隔音汽车装饰元件1的示意性示例；
图像1示出了成品吸音隔音汽车装饰元件1的表面结构的示例；
图像2以特写图示出了第一泡沫11的表面的肋结构的示例；
图像3以俯视图示出了根据图像2的第一泡沫11的表面的肋结构的示例；
图像4示出了以示例性方式制造的吸音隔音汽车装饰元件1的层结构的第一横截面；和
图像5示出了以示例性方式制造的吸音隔音汽车装饰元件1的层结构的第二横截面。
图1示出了所公开的吸音隔音汽车装饰元件1的示意性示例。
该吸音隔音汽车装饰元件1具有四层结构11，12，13，14。最底层是纯非织造织物层14。在其顶部，在复合材料中形成具有密度增加的层13，该层由非织造织物14的部分厚度和设置在其顶部的第二泡沫12形成。其中所述第二泡沫12在其制备过程中已扩散或有目的地引入非织造织物层14中。其中，所述扩散部分发生，即不完全发生。最顶层，因此第四层是第一泡沫11，其具有不同于第二层12的特性。
此外，任选地，这里用虚线表示，提供了在第二泡沫12的表面上制备的肋结构121（参见图像3）。
第一泡沫11的表面具有压痕111和凸起112。
因此，发泡***11和12的表面结构可以以相同的方式或以不同的方式设计。
图像1示出了成品吸音隔音汽车装饰元件1的表面结构的示例。
所看到的是必要的凹槽和凸起以及设有压痕111和凸起112的表面结构，分别作为压痕111和凸起112的示例。
图像2以特写图示出了第一泡沫11的表面的肋结构121的示例。
以示例性方式，制备具有肋121的表面结构，肋121具有约8mm的高度和约5mm的宽度。这样的肋121具有在第一泡沫11的表面和第二泡沫12的表面（即第一泡沫11和第二泡沫12之间的边界层）提供隔音的特性，因此来自发动机舱的声音，例如，进入乘客舱具有由这种特性所带来的额外吸音。
此外，图像3以俯视图示出了根据图像2的第一泡沫11的表面的肋结构121的示例。
这里指出，第二泡沫12的表面可以同等地形成为中间产品，例如具有肋结构121，其中在进一步的过程中将第一泡沫11施加到该表面。
图像4以示例性方式示出了制造的吸音隔音汽车装饰元件1的层结构的第一横截面。
吸音隔音汽车装饰元件1由四层结构构成，该层结构在该图像中是可识别的，即从底部到顶部，首先是非织造织物层14，在其上面是具有增加密度的层13，其成比例地由非织造织物14和第二泡沫12组成，其部分地扩散到非织造织物14中，接着是第二泡沫12的实际层，以及最后的最顶层，即第一泡沫11。
以示例性方式表示的该组件具有20mm的总厚度，其中具有15％BiCo纤维的PET细纤维非织造物首先被压缩或压模从第一厚度d= 25 mm至减小的厚度 d'= 5 mm。随后，将该压缩的非织造织物层14放入发泡模具中，并关闭发泡模具，其中，在完成模具的密封之后，通过第二发泡***12实现发泡，在非织造织物层14上具有密度为150 g/l，损耗因子为0.34，弹性模量为85 g/l的特性。因此，非织造织物层14通过第二泡沫12进行后发泡，其中，在后发泡期间，第二泡沫12已部分地扩散到非织造织物层14中。
在50 s的反应时间后，更换发泡模具的上半部分。新的顶模具具有相应的限定的肋结构121，其具有50mm×50mm的网格尺寸，肋高度为8mm，肋宽度为5mm的特性。
然后用第一发泡***11发泡，其具有密度为75 g/l，损耗因子为0.17，弹性模量为45kN/m2的特性，其中第二泡沫12已用第一发泡***11后发泡。
在60 s的反应时间之后，再次打开发泡模具，取出组件1，随后冲压成所需的最终形状。
在发泡过程中，第二发泡***12的泡沫部分地扩散到压缩的非织造织物层中以形成单位面积质量为500 g/m2的层，使得该层13与纯非织造织物层14不同。因为非织造织物层14的单位面积质量为800 g/m2。
图像5以示例性方式示出了制造的吸音隔音汽车装饰元件1的层结构的第二横截面。
在该横截面中也可以识别所公开的层结构，其中非织造织物层14，具有增加密度的层13，第二泡沫层12和第一泡沫层11的层再次彼此叠加。
此外，相应的测量结果显示在所附两个图表中，这进一步解释了本发明：
图表1示出了两种发泡***的噪声降低（噪音水平降低），将现有技术A中已知的非织造织物和PUR柔性泡沫***，与根据本发明D具有非织造织物和PUR多层泡沫***进行了比较。
可以看出，与现有技术的简单背面发泡非织造织物（A）相比，根据本发明（D）的装饰元件的降噪显著增加。
此外，图表2示出了从图表1中已知的两个装饰元件的吸音，其中这里可以看到两个***（A和D）的不同反应。
参考符号列表
1 吸音隔音汽车装饰元件
11 第一泡沫
111 压痕
112 凸起
12 第二泡沫
121 肋
13 具有增加密度的非织造织物层
14 非织造织物。

Claims (9)

1.一种用于制造吸音隔音汽车装饰元件的方法，包括由第一泡沫层（11），第二泡沫层（12），非织造泡沫层（13）和非织造织物层（14）制成的四层结构，包括以下步骤：
I）提供厚度为d的非织造织物（14）；
II）将非织造织物（14）压缩至压缩厚度d'；
III）借助于第一成型泡沫半模在所述压缩非织造织物层（14）的顶表面上发泡第二泡沫（12），其中所述第二泡沫（12）将至少部分地扩散到所述非织造织物层（14）中以形成中间层，即密度增加的层（13），所述中间层（13）由所述非织造织物层（14）和所述第二泡沫（12）的部分厚度组成；
IV）在远离非织造织物的第二泡沫（12）的顶表面上发泡第一泡沫（11），其中在远离第二泡沫的第一泡沫（11）表面的第一泡沫（11）上形成外表面结构；
其中
在步骤III）和/或IV）的发泡过程中，肋，泡罩，凸起和/或压痕表面结构的形成/制备在远离相应非织造织物的相应泡沫（11，12）的一侧上实现。
2.根据权利要求1所述的用于制造吸音隔音汽车装饰元件的方法，其特征在于，步骤III）中的发泡在第一发泡模具中进行。
3.根据权利要求1或2所述的用于制造吸音隔音汽车装饰元件的方法，其特征在于，步骤IV）中的发泡在第二发泡模具中进行，或者在所述第一发泡模具中进行，其中上半部分泡沫模具已被替换或维持。
4.一种吸音隔音汽车装饰元件（1），其由根据前述权利要求中任一项所述的用于制造高吸音隔音汽车装饰元件的方法制备，具有：
四层结构，包括：
- 第一泡沫层（11）；
- 第二泡沫层（12）；
- 密度增加的层（13）；和
- 非织造织物层（14）；
其中，
- 泡沫层（11，12）具有不同的密度，损耗因子和/或弹性模量；和
- 与非织造织物层（14）相邻的泡沫（12）部分地扩散到非织造织物（14）中以形成密度增加的层（13）；
其中，
所述远离非织造织物的第一（11）和/或第二泡沫（12）的顶表面上的第一（11）和/或第二泡沫（12）的表面具有肋，泡罩，凸起和 /或压痕结构。
5.根据前述权利要求所述的高吸音隔音汽车装饰元件（1），
其特征在于
所述非织造织物由PET纤维组成；或者
所述非织造织物由PET纤维组成并含有BiCo纤维，其中BiCo纤维比例为1-50重量％，或8-20重量％，或10重量％；或者
非织造织物包括选自a）组的合成纤维，即聚酯纤维，聚（对苯二甲酸乙二醇酯）纤维，聚酰胺纤维，尼龙6，尼龙66，聚烯烃纤维，聚丙烯纤维，聚乙烯纤维和/或丙烯酸纤维，以及它们的纤维混合物，包括双组分纤维和多组分纤维；或者
非织造织物包括选自b）组的天然纤维，即原棉纤维，***纤维，椰子纤维，洋麻纤维，黄麻纤维和/或剑麻纤维，包括其混合物；或者
非织造织物含有a）组和b）组的合成纤维的混合物。
6.根据前述两项权利要求中任一项所述的高吸音隔音汽车装饰元件（1），
其特征在于
所述非织造织物（14）的单位面积质量为800 g/m2，或者单位面积质量为400 g/m2至1800 g/m2，或者单位面积质量为600 g/m2至1200 g/m2；
和/或
所述密度增加的层（13）的单位面积质量为500 g/m2，或者单位面积的质量为300 g/m2至1500 g/m2，或单位面积的质量为350 g/m2至800 g/m2。
7.根据前述三项权利要求中任一项所述的高吸音隔音汽车装饰元件（1），
其特征在于
第一（11）和/或第二泡沫（12）层包含气泡空隙。
8.根据前述四项权利要求中任一项所述的高吸音隔音汽车装饰元件（1），
其特征在于
第一和/或第二发泡***（11，12）负载有CO2。
9.根据前述五项权利要求中任一项所述的高吸音隔音汽车装饰元件（1），
其特征在于
- 发泡***（11，12）由PUR组成；和/或
- 第一发泡***（11）的密度为40-90 g/l，损耗因子为0.15-0.26，和/或弹性模量为45-180 kN/m2；和/或
- 第二发泡***（12）的密度为50-150 g/l，损耗因子为0.15-0.55，和/或弹性模量为20-300 kN/m2；
其中第一（11）和第二发泡***的损耗因子，密度和/或弹性模量的特性是相互不同的。
CN201780073143.7A 2016-11-04 2017-11-01 用于制造吸音隔音元件的方法，以及吸音隔音汽车装饰元件 Pending CN109996674A (zh)

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