CN115302892A - 一种发动机隔音罩盖及其制备方法 - Google Patents
一种发动机隔音罩盖及其制备方法 Download PDFInfo
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- CN115302892A CN115302892A CN202210884399.9A CN202210884399A CN115302892A CN 115302892 A CN115302892 A CN 115302892A CN 202210884399 A CN202210884399 A CN 202210884399A CN 115302892 A CN115302892 A CN 115302892A
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- glass fiber
- plate
- fiber felt
- honeycomb
- fiber mat
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- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
Abstract
本申请涉及一种发动机隔音罩盖及其制备方法,包括蜂窝板、第一玻纤毡、第二玻纤毡、纤维毡和刚性板;所述第一玻纤毡和所述第二玻纤毡分别设置在所述蜂窝板上相对的两个表面,所述纤维毡设置在所述第一玻纤毡上背离所述蜂窝板的表面,所述刚性板设置在所述第二玻纤毡上背离所述蜂窝板的表面;所述蜂窝板和所述第一玻纤毡之间、所述蜂窝板和所述第二玻纤毡之间、所述第一玻纤毡和所述纤维毡之间、所述第二玻纤毡和所述刚性板之间通过聚氨酯发泡层粘接。本申请提供的结构,采用纤维毡复合蜂窝板及刚性板的结构,声波先后经过纤维毡、蜂窝板和刚性板的多重散反射和转化后被削弱,隔音效果较传统结构有较大提升,且重量较传统塑料或金属罩盖大幅减轻。
Description
技术领域
本申请涉及汽车零件技术领域,特别涉及一种发动机隔音罩盖及其制备方法。
背景技术
汽车发动机罩盖主要用于对发动机起保护作用,降低机械伤害和防尘防水,其结构一般由外板和内板组成,中间夹以隔热材料,几何形状由厂家选取,基本是骨架形式。为提高驾驶员和乘客的舒适性,现通常会在发动机罩盖上进一步设置隔音材料,以将发动机产生的噪音进行有效隔离。
市面上乘用车发动机常见引擎隔音盖罩,罩体一般为PA(尼龙)或PP(聚丙烯)塑料材料注塑而成的一定厚度的壳体隔音本体,必要时在本体内表面朝向发动机侧粘贴废纺毡或焊接有机棉等吸音材料而成,这种罩体对2000HZ以上的高频噪音具有较好的降噪效果,重量也较轻。
然而乘用车发动机罩体形式应用于商用车大型的柴油机时,还有一些局限性,例如零件壳体薄,刚性较差的问题,对柴油机产生的2000HZ以下频段噪声,改善效果不理想。
相关技术中,有采用GMT材料一次模压成型的罩体,简化了汽车隔音罩的开发和生产工序,GMT是PP(聚丙烯)和玻璃纤维的复合物,强度高,成本低。然而GMT密实体材料,吸隔音性效果并不理想,且密度偏大,实际罩体较重。
还有由内向外依次为岩棉或石棉隔热层、开孔型泡沫吸声层、耐高温沥青阻尼层和铅合金板组合的发动机隔音罩体,以降低柴油机上表面噪声。采用铅合金、沥青、石棉等材料,密度大,罩体沉重且制造工艺复杂,材料不环保。
还有采用玻璃钢本体罩体,双面胶粘贴隔音海棉的发动机罩盖。同样由于热固型的玻璃钢密度(约1.60-1.80g/cm3)比热塑型的GMT(约1.1-1.4g/cm3)材料和尼龙材料(约1.1-1.2g/cm3)明显增大,导致隔音罩体沉重,且双面胶不耐高温,容易开胶失效,隔音棉脱落。
发明内容
本申请实施例提供一种发动机隔音罩盖及其制备方法,以解决相关技术中发动机罩盖重量过重、隔音效果不理想的问题。
第一方面,本申请提供了一种发动机隔音罩盖,包括:蜂窝板、第一玻纤毡、第二玻纤毡、纤维毡和刚性板;
所述第一玻纤毡和所述第二玻纤毡分别设置在所述蜂窝板上相对的两个表面,所述纤维毡设置在所述第一玻纤毡上背离所述蜂窝板的表面,所述刚性板设置在所述第二玻纤毡上背离所述蜂窝板的表面;
所述蜂窝板和所述第一玻纤毡之间、所述蜂窝板和所述第二玻纤毡之间、所述第一玻纤毡和所述纤维毡之间、所述第二玻纤毡和所述刚性板之间通过聚氨酯发泡层粘接。
一些实施例中,所述聚氨酯发泡层渗透所述第一玻纤毡和所述第二玻纤毡,并且部分伸入所述蜂窝板的蜂窝孔内,所述聚氨酯发泡层在所述蜂窝孔内具有凹凸状外表面。
一些实施例中,还包括无纺布层,所述无纺布层设置在所述第一玻纤毡和所述纤维毡之间以及所述第二玻纤毡和所述刚性板之间。
一些实施例中,所述蜂窝板包括纸质蜂窝板、PE蜂窝板、PP蜂窝板或者铝蜂窝板。
一些实施例中,所述纤维毡包括聚丙烯腈纤维预氧丝毡、聚酯纤维毡、聚丙烯纤维毡、玻璃纤维毡、硅酸铝纤维毡或者碳纤维毡中的至少一种。
一些实施例中,所述刚性板包括ABS板、钢板、铝板、PE塑料板、PP塑料板、PA塑料板、纤维增强塑料板或者无机填料增强塑料板。
一些实施例中,所述刚性板的厚度为0.2mm~5mm;
所述蜂窝板的厚度为2mm~30mm;
所述纤维毡的厚度为2mm~60mm。
一些实施例中,所述聚氨酯发泡层是由聚氨酯发泡材料经发泡、固化后得到的发泡层;
所述聚氨酯发泡材料包括组分A和组分B,所述组分A包括多元醇类化合物,所述组分B包括异氰酸酯类化合物,所述组分A与所述组分B的重量比为1:1.7。
第二方面,本申请还提供了上述发动机罩盖的制备方法,包括如下步骤:
取蜂窝板,在其两侧表面覆盖第一玻纤毡和第二玻纤毡制成预制芯板;
将聚氨酯发泡材料喷涂在预制芯板外表面,然后放入置有刚性板的热模压机模具内腔;
将纤维毡铺放在预制芯板上,合模、保压成型。
在一些实施例中,还包括无纺布层,所述“取蜂窝板,在其两侧表面覆盖第一玻纤毡和第二玻纤毡制成预制芯板”包括:
取蜂窝板,在其两侧表面覆盖第一玻纤毡和第二玻纤毡,然后在第一玻纤毡和第二玻纤毡的外表面覆盖无纺布层,制成预制芯板;
“将聚氨酯发泡材料喷涂在预制芯板外表面,然后放入置有刚性板5的热模压机模具内腔”包括:
将聚氨酯发泡材料分别喷涂在两侧无纺布层的表面,其中,与第一玻纤毡2相邻的无纺布层表面的聚氨酯发泡材料的喷涂量占聚氨酯发泡材料总喷涂量的1/3~1/2;与第二玻纤毡3相邻的无纺布层表面的聚氨酯发泡材料的喷涂量占聚氨酯发泡材料总喷涂量的1/2~2/3,然后放入置有刚性板5的热模压机模具内腔。
本申请提供的技术方案带来的有益效果包括:本申请实施例提供的发动机隔音罩盖,一方面复合具有吸音性的多孔质或蓬松质纤维毡,纤维毡朝向噪声源,声波能量先被纤维毡部分吸收、振动衰减后,再通过蜂窝板的空腔通道以及壳壁的反复碰撞振动、摩擦粘滞以及散反射到纤维毡吸音层,再次使声能部份转化为热能而散失,从而提高隔音罩整体降噪效果,对发动机产生的低、中、高频噪音具有良好的隔音性能,采用蜂窝结构可满足轻量化要求,达到降低隔音罩重量的目的;另一方面,刚性板能够在确保发动机罩盖强度的同时减小发动机罩盖的厚度,降低整体重量,并能起到隔音、外部涂装和标识等作用,以聚氨酯发泡材料粘接各层结构,具有粘接持久、质量轻的优点;
本申请提供的发动机隔音罩盖的制备方法一次模压成型,工艺简单,有效提高发动机隔音罩盖的生产效率。
附图说明
为了更清楚地说明本申请实施例中的技术方案,下面将对实施例描述中所需要使用的附图作简单地介绍,显而易见地,下面描述中的附图仅仅是本申请的一些实施例,对于本领域普通技术人员来讲,在不付出创造性劳动的前提下,还可以根据这些附图获得其他的附图。
图1为本申请实施例提供的发动机隔音罩盖的***图;
图2为本申请实施例提供的发动机隔音罩盖的剖面图。
图中:1、蜂窝板;2、第一玻纤毡;3、第二玻纤毡;4、纤维毡;5、刚性板;6、聚氨酯发泡层。
具体实施方式
为使本申请实施例的目的、技术方案和优点更加清楚,下面将结合本申请实施例中的附图,对本申请实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例是本申请的一部分实施例,而不是全部的实施例。基于本申请中的实施例,本领域普通技术人员在没有做出创造性劳动的前提下所获得的所有其他实施例,都属于本申请保护的范围。
如图1-2所示,第一方面,本申请实施例提供了一种发动机隔音罩盖,包括:蜂窝板1、第一玻纤毡2、第二玻纤毡3、纤维毡4和刚性板5;
所述第一玻纤毡2和所述第二玻纤毡3分别设置在所述蜂窝板1上相对的两个表面,所述纤维毡4设置在所述第一玻纤毡2上背离所述蜂窝板1的表面,所述刚性板5设置在所述第二玻纤毡3上背离所述蜂窝板1的表面;
所述蜂窝板1和所述第一玻纤毡2之间、所述蜂窝板1和所述第二玻纤毡3之间、所述第一玻纤毡2和所述纤维毡4之间、所述第二玻纤毡3和所述刚性板5之间通过聚氨酯发泡层6粘接。
本申请实施例提供的发动机隔音罩盖,一方面复合具有吸音性的多孔质或蓬松质纤维毡,纤维毡朝向噪声源,声波能量先被纤维毡部分吸收、振动衰减后,再通过蜂窝板的空腔通道以及壳壁的反复碰撞振动、摩擦粘滞以及散反射到吸音层,再次使声能部份转化为热能而散失,从而提高隔音罩整体降噪效果,对发动机产生的低、中、高频噪音具有良好的隔音性能,采用蜂窝结构可满足轻量化要求,达到降低隔音罩重量的目的;另一方面,刚性板能够在确保发动机强度的同时减小发动机罩盖的厚度降低整体重量,并能起到隔音、外部涂装和标识等作用,以聚氨酯发泡材料粘接各层结构,具有粘接持久、质量轻的优点,无需二次焊接或者二次粘贴成型;各原材料不含重金属元素,安全环保。
本申请提供的发动机隔音罩盖尤其适用大型商用车发动机气缸罩盖,试用于TL71商用车11升柴油发动机气缸罩盖隔音罩(半包式结构方案),整车怠速,发动机上方1米、左方1米及右侧1米处噪声分别降低3.6dB(A)、2.3dB(A)、1.1dB(A),驾驶室司机耳旁噪声降低1.0dB(A),具有良好隔音效果。
在优选的实施例中,所述蜂窝板1上蜂窝孔的开口朝向所述第一玻纤毡2和所述第二玻纤毡3,以使所述第一玻纤毡2和所述蜂窝板1之间或者所述第二玻纤毡2和所述蜂窝板1之间形成封闭空腔,有利于提高声波在空腔内与空腔壁发生反复碰撞振动的频率、摩擦粘滞以及散反射到纤维毡4吸音层,再次使声能部份转化为热能而散失,进一步提高发动机隔音罩盖整体的降噪效果。
如图2所示,在一些实施例中,所述聚氨酯发泡层6渗透所述第一玻纤毡2和所述第二玻纤毡3,并且部分伸入所述蜂窝板1的蜂窝孔内,所述聚氨酯发泡层6在所述蜂窝孔内具有凹凸状外表面。
所述聚氨酯发泡层6部分伸入所述蜂窝板1的孔腔内,并且填充蜂窝孔的部分空间,所述聚氨酯发泡层6并未完全填充满蜂窝孔内腔,此设计的目的在于,使聚氨酯发泡层6与蜂窝孔内壁之间形成用于减弱声波的空腔;所述聚氨酯发泡层6在所述蜂窝孔内的外表面为不规则的带有凹凸结构的外表面,即所述聚氨酯发泡层6位于蜂窝孔内的外表面为非光滑、非平整结构,聚氨酯发泡层6的凹凸外表面,能够进一步提高声波的散反射效果和声能衰减程度,从而提高发动机隔音罩盖对不同频率噪音的隔音效果。
在一些实施例中,所述发动机隔音罩盖还包括无纺布层,所述无纺布层设置在所述第一玻纤毡2和所述纤维毡4之间以及所述第二玻纤毡3和所述刚性板5之间。
具体的,玻纤毡具有强度高质量轻的优点,复合聚氨酯发泡层6,能够形成高强度高刚性的玻璃纤维增强聚氨酯复合材料,在确保发动机罩盖强度的同时降低重量,本申请中第一玻纤毡2和第二玻纤毡3能够起到约束蜂窝板1、连接蜂窝板1和刚性板5以及连接蜂窝板1和纤维毡4的作用,有效提高发动机隔音罩盖的可靠性。
通过在第一玻纤毡2和第二玻纤毡3的外表面设置无纺布层,该无纺布层用于防止玻纤毡中的纤维外露飞扬,提高发动机隔音罩盖制备车间的安全性和环保性。
在优选的实施例中,所述第一玻纤毡2和所述第二玻纤毡3的面密度为245g/m2,所述无纺布层的面密度为35g/m2。
在一些实施例中,所述蜂窝板1包括纸质蜂窝板、PE蜂窝板、PP蜂窝板或者铝蜂窝板。
上述蜂窝板具有质轻的优点,发动机产生的噪音经纤维毡吸收大部分后进入蜂窝板的蜂窝孔内,声波引起蜂窝结构发生振动,致使声能衰减,空腔壁使声波散反射,内部空气摩擦阻滞,再次使声能部份转化为热能而散失,从而起到降噪的作用。
在优选的实施例中,所述蜂窝板1选自纸质蜂窝板,所述蜂窝板的蜂窝孔孔径为6mm,厚度为8mm,面密度为520g/m2。
在一些实施例中,所述纤维毡4包括聚丙烯腈纤维预氧丝毡、聚酯纤维毡、聚丙烯纤维毡、玻璃纤维毡、硅酸铝纤维毡或者碳纤维毡中的至少一种。
所述纤维毡具有多孔、蓬松结构,纤维毡吸收声波能量后,引起纤维毡振动,导致声波能量衰减。此外聚氨酯发泡层能够浸润蓬松、多孔纤维毡,有利于提高纤维毡与聚氨酯发泡层的粘结力,从而提高发动机罩盖的使用寿命。纤维毡具有良好的柔软和形变能力,用于热压成型模具中,不会对隔音罩盖的成型产生不良影响。
在优选的实施例中,所述纤维毡选自聚丙烯腈纤维预氧丝毡,所述聚丙烯腈纤维预氧丝毡由聚丙烯腈纤维经预氧化后得到的纤维制成,所述聚丙烯腈纤维预氧丝毡可以通过自制或者商购获得,例如,所述聚丙烯腈纤维预氧丝可以通过以下方式制得:
步骤S1,在室温下,将聚丙烯腈原丝置于质量分数为1-5%的磷酸二氢铵溶液中浸润10-60min,得到改性聚丙烯腈原丝;
步骤S2,将改性的聚丙烯腈原丝烘干;
步骤S3,在流动空气气氛中,对改性聚丙烯腈原丝进行预氧化处理,预氧化工艺控制升温速率为2-5℃/min,当升温至180-240℃后,保温10-30min;
步骤S4,自然冷却至室温,得到聚丙烯腈预氧丝。
所述聚丙烯腈纤维预氧丝毡具有耐高温、不燃、隔热等特性,有利于增强发动机罩盖的防火防灾特性。
在一些实施例中,所述刚性板5包括ABS板、钢板、铝板、PE塑料板、PP塑料板、PA塑料板、纤维增强塑料板或者无机填料增强塑料板。
所述刚性板一方面能够起到隔音的作用,另一方面刚性板能够在壳体最薄化的条件下提高发动机隔音罩盖的强度,能够满足商用大型车对零件强度的要求,此外刚性板作为发动机隔音罩盖的最外表面,可起到防水防灰尘的作用,并且可根据需要在其表面采用印刷、激光等方式进行涂装、装饰和产品标识等。
在优选的实施例中,所述刚性板选自ABS板,即丙烯腈/丁二烯/苯乙烯共聚物塑料板,所述ABS板具有刚性强,轻量化的优点,进一步的,所述刚性板的厚度为0.8mm,面密度为860g/m2。
在一些实施例中,所述刚性板5的厚度为0.2~5mm;
所述蜂窝板1的厚度为2~30mm;
所述纤维毡4的厚度为2mm~60mm。
所述刚性板、蜂窝板和纤维毡在上述厚度范围内,能够最轻量化的情况下提高发动机隔音罩盖的隔音效果。
在优选的实施例中,所述发动机隔音罩盖的总厚度为13mm,面密度为2860g/m2,总重量为2.04Kg,能够满足商用车中发动机气缸对罩盖的装配和使用技术需求。
在一些实施例中,所述聚氨酯发泡层6是由聚氨酯发泡材料经发泡、固化后得到的发泡层;
所述聚氨酯发泡材料包括组分A和组分B,所述组分A包括多元醇类化合物,所述组分B包括异氰酸酯类化合物,所述组分A与所述组分B的重量比为1:1.7。
所述聚氨酯发泡材料采用双组分体系,能够根据不同需求进行调配,所述组分A包括多元醇类化合物,所述组分B包括异氰酸酯类化合物,多元醇与异氰酸酯在特定条件下发生交联固化反应,进一步的,所述聚氨酯发泡材料还包括催化剂、扩链剂等。
所述组分A可以采用如巴斯夫公司生产的CE 3532/101C-A型号多元醇类化合物,所述组分B可以采用如巴斯夫公司生产的CE3531/104C-B型号异氰酸酯类化合物。
所述聚氨酯发泡材料在模压过程中,可以流动、延展、浸润各层结构,固化后起到将各组分粘结连接的作用,施工便利。
第二方面,本申请实施例提供了一种发动机隔音罩盖的制备方法,包括如下步骤:
取蜂窝板1,在其两侧表面覆盖第一玻纤毡2和第二玻纤毡3制成预制芯板;
将聚氨酯发泡材料喷涂在预制芯板外表面,然后放入置有刚性板5的热模压机模具内腔;
将纤维毡4铺放在预制芯板上,合模、保压成型。
本申请提供的发动机隔音罩盖的制备方法一次模压成型,工艺简单,有效提高发动机隔音罩盖的生产效率。
具体的,“将聚氨酯发泡材料喷涂在预制芯板外表面,然后放入置有刚性板5的热模压机模具内腔”包括:
将聚氨酯发泡材料喷涂到第一玻纤毡2和第二玻纤毡3的表面,,使第二玻纤毡3朝向刚性板5,将预制芯板放入置有刚性板5的热模压机模具内腔。
在优选的实施例中,喷涂到第一玻纤毡2表面的聚氨酯发泡材料的重量占聚氨酯发泡材料的总喷涂量的1/3~1/2,喷涂到第二玻纤毡3表面的聚氨酯发泡材料的重量占聚氨酯发泡材料的总喷涂量的1/2~2/3。
在优选的实施例中,“将纤维毡4铺放在预制芯板上,合模、保压成型”包括:
将纤维毡4铺放在预制芯板上,合模、锁模压力50bar,保压100秒。
具体的,所述刚性板可通过吸塑工艺成型,再铺放至热模压机模具内腔,所述吸塑成型工艺为本领域常用技术,在此不在赘述。
在一些实施例中,还包括无纺布层,所述“取蜂窝板1,在其两侧表面覆盖第一玻纤毡2和第二玻纤毡3制成预制芯板”包括:
取蜂窝板1,在其两侧表面覆盖第一玻纤毡2和第二玻纤毡3,然后在第一玻纤毡2和第二玻纤毡3的外表面覆盖无纺布层,制成预制芯板;
“将聚氨酯发泡材料喷涂在预制芯板外表面,然后放入置有刚性板的热模压机模具内腔”包括:
将聚氨酯发泡材料分别喷涂在两侧无纺布层的表面,其中,与第一玻纤毡相邻的无纺布层表面的聚氨酯发泡材料的喷涂量占聚氨酯发泡材料总喷涂量的1/3~1/2;与第二玻纤毡相邻的无纺布层表面的聚氨酯发泡材料的喷涂量占聚氨酯发泡材料总喷涂量的1/2~2/3,然后放入置有刚性板的热模压机模具内腔。
通过控制第一玻纤毡2表面的聚氨酯发泡材料喷涂量在总喷涂量的1/3~1/2,不仅可以使纤维毡4能够较好粘接,避免纤维毡4被过多浸润聚氨酯发泡材料后失去蓬松结构的吸声层;
通过控制第二玻纤毡3表面的聚氨酯发泡材料喷涂量在总喷涂量的1/2~2/3,以便牢固粘接刚性板5和蜂窝板1,并能在蜂窝板1该侧空腔内形成更厚的凸凹发泡体,与第二玻纤毡3和刚性板5形成更好的隔声层。
在上述范围内的喷涂量,可以保障蜂窝板1内部可形成具有有效空腔的、空腔表面凹凸状的复合材料隔音罩盖。
具体的,将聚氨酯发泡材料喷涂至预制芯板两侧无纺布层的外表面,所述聚氨酯发泡材料的喷涂量与上述一致,在此不在赘述。
以下通过实施例对本发明进行进一步的说明。
实施例1
本实施例用于说明本发明公开的发动机隔音罩盖及其制备方法,包括如下步骤:
取纸质蜂窝板,蜂窝孔孔径为6mm,厚度为8mm,面密度为520g/m2,在纸质蜂窝板两侧表面覆盖玻纤毡,玻纤毡为短切玻璃纤维毡,面密度为245g/m2,然后在两侧玻纤毡的外表面覆盖无纺布,无纺布面密度为35g/m2;
将巴斯夫CE 3532/101C-A与巴斯夫CE 3531/104C-B按重量比1:1.7比例混合,得到聚氨酯发泡材料;
将上述聚氨酯发泡材料喷涂至无纺布表面,得到预制芯板,其中一侧无纺布表面的聚氨酯发泡材料为180g/m2,另一侧无纺布表面的聚氨酯发泡材料为300g/m2;
取厚度为0.8mm,面密度为860g/m2的ABS板放入热压模具内腔;然后将上述喷涂完聚氨酯发泡材料的预制芯板放在ABS板上,其中表面聚氨酯发泡材料为300g/m2的无纺布与ABS板相邻,然后在预制芯板上铺设厚度为6mm,面密度为400g/m2的聚丙烯腈纤维预氧丝毡,合模、锁模压力50bar,保压100秒,使聚氨酯发泡材料充分发泡并粘牢组合的层间材料;
取压制成型的板材,裁切修边,得到厚度为13mm,面密度为2860g/m2,总重量为2.04Kg的发动机隔音罩盖。
实施例2
本实施例用于说明本发明公开的发动机隔音罩盖及其制备方法,包括如下步骤:
取纸质蜂窝板,蜂窝孔孔径为6mm,厚度为8mm,面密度为520g/m2,在纸质蜂窝板两侧表面覆盖玻纤毡,玻纤毡为短切玻璃纤维毡,面密度为245g/m2,然后在两侧玻纤毡的外表面覆盖无纺布,无纺布面密度为35g/m2;
将巴斯夫CE 3532/101C-A与巴斯夫CE 3531/104C-B按重量比1:1.7比例混合,得到聚氨酯发泡材料;
将上述聚氨酯发泡材料喷涂至无纺布表面,得到预制芯板,其中一侧无纺布表面的聚氨酯发泡材料为240g/m2,另一侧无纺布表面的聚氨酯发泡材料为360g/m2;
取厚度为1.5mm,面密度为1610g/m2的ABS板放入热压模具内腔;然后放入上述喷涂完聚氨酯发泡材料的预制芯板放在ABS板上,其中表面聚氨酯发泡材料为360g/m2的无纺布与ABS板相邻,然后在预制芯板上铺设厚度为6mm,面密度为400g/m2的聚丙烯腈纤维预氧丝毡,合模、锁模压力50bar,保压100秒,使聚氨酯发泡材料充分发泡并粘牢组合的层间材料;
取压制成型的板材,裁切修边,得到厚度为13mm,面密度为3720g/m2,总重量为2.66Kg的发动机隔音罩盖。
对比例1
本对比例用于对比说明本发明公开的发动机隔音罩盖及其制备方法,包括如下步骤:
取纸质蜂窝板,蜂窝孔孔径为6mm,厚度为8mm,面密度为520g/m2,在纸质蜂窝板两侧表面覆盖玻纤毡,玻纤毡为短切玻璃纤维毡,面密度为275g/m2,然后在两侧玻纤毡的外表面覆盖无纺布,无纺布面密度为35g/m2;
将巴斯夫CE 3532/101C-A与巴斯夫CE 3531/104C-B按重量比1:1.7比例混合,得到聚氨酯发泡材料;
将上述聚氨酯发泡材料喷涂至无纺布表面,得到预制芯板,其中一侧无纺布表面的聚氨酯发泡材料为240g/m2,另一侧无纺布表面的聚氨酯发泡材料为360g/m2;
将上述喷涂完聚氨酯发泡材料的预制芯板放入热压膜具内腔,其中表面聚氨酯发泡材料为360g/m2的无纺布位于最底部,然后在预制芯板上铺设厚度为6mm,面密度为400g/m2的聚丙烯腈纤维预氧丝毡,合模、锁模压力50bar,保压100秒,使聚氨酯发泡材料充分发泡并粘牢组合的层间材料;
取压制成型的板材,裁切修边,得到厚度为12mm,面密度为2140g/m2,总重量为1.53Kg的发动机隔音罩盖。
对比例2
本对比例用于对比说明本发明公开的发动机隔音罩盖及其制备方法,包括如下步骤:
取厚度为3mm的PA66板,在其表面覆盖厚度为10mm的吸音棉,得到发动机隔音罩盖,其中面密度为3830g/m2。
对比例3
本对比例用于对比说明本发明公开的发动机隔音罩盖及其制备方法,包括如下步骤:
取厚度为3mm的GMT板,在其表面覆盖厚度为10mm的吸音棉,得到发动机隔音罩盖,其中面密度为4420g/m2。
性能测试
对实施例1-2和对比例1-3制备得到的发动机隔音罩盖进行如下性能测试:
根据表1的测试结果可以看出,本申请提供的发动机隔音罩盖相对于对比例1和对比例2中传统的隔音罩盖,其平均隔音量得到明显提升,尤其在160Hz到1000Hz频段,隔音量提升显著,适用于商用车柴油机重点频段噪音的改善。
在罩盖单位面积重量上,在同等厚度下,本申请发动机隔音罩盖的重量较传统的隔音罩盖大幅减轻,符合汽车轻量化高性能发展趋势。
结合实施例1-2和对比例1的测试结果可以看出,本申请通过设置刚性板,能够进一步提高隔音罩盖的隔音效果。
在本申请的描述中,需要说明的是,术语“上”、“下”等指示的方位或位置关系为基于附图所示的方位或位置关系,仅是为了便于描述本申请和简化描述,而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作,因此不能理解为对本申请的限制。除非另有明确的规定和限定,术语“安装”、“相连”、“连接”应做广义理解,例如,可以是固定连接,也可以是可拆卸连接,或一体地连接;可以是机械连接,也可以是电连接;可以是直接相连,也可以通过中间媒介间接相连,可以是两个元件内部的连通。对于本领域的普通技术人员而言,可以根据具体情况理解上述术语在本申请中的具体含义。
需要说明的是,在本申请中,诸如“第一”和“第二”等之类的关系术语仅仅用来将一个实体或者操作与另一个实体或操作区分开来,而不一定要求或者暗示这些实体或操作之间存在任何这种实际的关系或者顺序。而且,术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含,从而使得包括一系列要素的过程、方法、物品或者设备不仅包括那些要素,而且还包括没有明确列出的其他要素,或者是还包括为这种过程、方法、物品或者设备所固有的要素。在没有更多限制的情况下,由语句“包括一个……”限定的要素,并不排除在包括所述要素的过程、方法、物品或者设备中还存在另外的相同要素。以上所述仅是本申请的具体实施方式,使本领域技术人员能够理解或实现本申请。对这些实施例的多种修改对本领域的技术人员来说将是显而易见的,本文中所定义的一般原理可以在不脱离本申请的精神或范围的情况下,在其它实施例中实现。因此,本申请将不会被限制于本文所示的这些实施例,而是要符合与本文所申请的原理和新颖特点相一致的最宽的范围。
Claims (10)
1.一种发动机隔音罩盖,其特征在于,包括:蜂窝板(1)、第一玻纤毡(2)、第二玻纤毡(3)、纤维毡(4)和刚性板(5);
所述第一玻纤毡(2)和所述第二玻纤毡(3)分别设置在所述蜂窝板(1)上相对的两个表面,所述纤维毡(4)设置在所述第一玻纤毡(2)上背离所述蜂窝板(1)的表面,所述刚性板(5)设置在所述第二玻纤毡(3)上背离所述蜂窝板(1)的表面;
所述蜂窝板(1)和所述第一玻纤毡(2)之间、所述蜂窝板(1)和所述第二玻纤毡(3)之间、所述第一玻纤毡(2)和所述纤维毡(4)之间、所述第二玻纤毡(3)和所述刚性板(5)之间通过聚氨酯发泡层(6)粘接。
2.如权利要求1所述的发动机隔音罩盖,其特征在于,所述聚氨酯发泡层(6)渗透所述第一玻纤毡(2)和所述第二玻纤毡(3),并且部分伸入所述蜂窝板(1)的蜂窝孔内,所述聚氨酯发泡层(6)在所述蜂窝孔内具有凹凸状外表面。
3.如权利要求1所述的发动机隔音罩盖,其特征在于,还包括无纺布层,所述无纺布层设置在所述第一玻纤毡(2)和所述纤维毡(4)之间以及所述第二玻纤毡(3)和所述刚性板(5)之间。
4.如权利要求1所述的发动机隔音罩盖,其特征在于,所述蜂窝板(1)包括纸质蜂窝板、PE蜂窝板、PP蜂窝板或者铝蜂窝板。
5.如权利要求1所述的发动机隔音罩盖,其特征在于,所述纤维毡(4)包括聚丙烯腈纤维预氧丝毡、聚酯纤维毡、聚丙烯纤维毡、玻璃纤维毡、硅酸铝纤维毡或者碳纤维毡中的至少一种。
6.如权利要求1所述的发动机隔音罩盖,其特征在于,所述刚性板(5)包括ABS板、钢板、铝板、PE塑料板、PP塑料板、PA塑料板、纤维增强塑料板或者无机填料增强塑料板。
7.如权利要求1所述的发动机隔音罩盖,其特征在于,所述刚性板(5)的厚度为0.2mm~5mm;
所述蜂窝板(1)的厚度为2mm~30mm;
所述纤维毡(4)的厚度为2mm~60mm。
8.如权利要求1所述的发动机隔音罩盖,其特征在于,所述聚氨酯发泡层(6)是由聚氨酯发泡材料经发泡、固化后得到的发泡层;
所述聚氨酯发泡材料包括组分A和组分B,所述组分A包括多元醇类化合物,所述组分B包括异氰酸酯类化合物,所述组分A与所述组分B的重量比为1:1.7。
9.如权利要求1所述的发动机隔音罩盖的制备方法,其特征在于,包括如下步骤:
取蜂窝板(1),在其两侧表面覆盖第一玻纤毡(2)和第二玻纤毡(3)制成预制芯板;
将聚氨酯发泡材料喷涂在预制芯板外表面,然后放入置有刚性板(5)的热模压机模具内腔;
将纤维毡(4)铺放在预制芯板上,合模、保压成型。
10.如权利要求9所述的发动机隔音罩盖的制备方法,其特征在于,还包括无纺布层,所述“取蜂窝板(1),在其两侧表面覆盖第一玻纤毡(2)和第二玻纤毡(3)制成预制芯板”包括:
取蜂窝板(1),在其两侧表面覆盖第一玻纤毡(2)和第二玻纤毡(3),然后在第一玻纤毡(2)和第二玻纤毡(3)的外表面覆盖无纺布层,制成预制芯板;
“将聚氨酯发泡材料喷涂在预制芯板外表面,然后放入置有刚性板(5)的热模压机模具内腔”包括:
将聚氨酯发泡材料分别喷涂在两侧无纺布层的表面,其中,与第一玻纤毡(2)相邻的无纺布层表面的聚氨酯发泡材料的喷涂量占聚氨酯发泡材料总喷涂量的1/3~1/2;与第二玻纤毡(3)相邻的无纺布层表面的聚氨酯发泡材料的喷涂量占聚氨酯发泡材料总喷涂量的1/2~2/3,然后放入置有刚性板(5)的热模压机模具内腔。
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