阅读说明：本技术 一种发动机进气歧管隔音罩及其制造方法 (Engine intake manifold sound-proof housing and manufacturing method thereof ) 是由 施家伟 张永强 于 2020-11-11 设计创作，主要内容包括：本发明涉及一种发动机进气歧管隔音罩及其制造方法,进气歧管隔音罩包括壳体(1)和设置在壳体(1)上的多个装配组件(2)；所述的壳体(1)包括依次设置的表面无纺布层(11)、玻璃纤维层(12)和底面无纺布层(13)。与现有技术相比,本发明具有对进气歧管包裹性强,吸声和隔音性强,且更耐高温等优点。(The invention relates to an engine intake manifold sound-proof housing and a manufacturing method thereof, wherein the intake manifold sound-proof housing comprises a housing (1) and a plurality of assembly components (2) arranged on the housing (1); the shell (1) comprises a surface non-woven fabric layer (11), a glass fiber layer (12) and a bottom surface non-woven fabric layer (13) which are arranged in sequence. Compared with the prior art, the invention has the advantages of strong wrapping property on the intake manifold, strong sound absorption and sound insulation, higher high temperature resistance and the like.)

1. An engine intake manifold soundproof cover, characterized by comprising a case (1) and a plurality of fitting assemblies (2) provided on the case (1); the shell (1) comprises a surface non-woven fabric layer (11), a glass fiber layer (12) and a bottom surface non-woven fabric layer (13) which are arranged in sequence.

2. The engine intake manifold soundproof cover according to claim 1, wherein the surface nonwoven fabric layer (11) is further provided with an aluminum foil (3), and the thickness of the aluminum foil (3) is 0.08 to 0.12 mm.

3. The engine intake manifold acoustic enclosure of claim 1,the glass fiber layer (12) is a phenolic resin type glass fiber layer, and the weight per unit area is 800-1200 g/m²。

4. The engine intake manifold soundproof cover according to claim 1, wherein the phenolic resin type glass fiber has a diameter of 5.5 to 7 μm, a length of 0.3 to 0.8mm, and a thermal conductivity of 0.033 to 0.04 w/m.k.

5. The engine intake manifold sound insulation cover according to claim 1, characterized in that the mounting component (2) is a vortex gasket, the vortex gasket comprises a base (21) and a top cover (22), the base (21) is provided with a conical part (23), and the top cover (22) is provided with a flange (24) matched with the conical part (23).

6. The engine intake manifold soundproof cover according to claim 5, wherein the vortex gasket is provided at an edge portion of the housing (1), the base (21) is provided below the housing (1), and the conical portion (23) penetrates through the housing (1) and is connected to the top cover (22) above the housing (1) through a flange (24).

7. The engine intake manifold soundproof cover according to claim 1, wherein the surface nonwoven fabric layer (11) and the bottom nonwoven fabric layer (13) have a weight per unit area of 110 to 130g/m²。

8. A method of manufacturing an engine intake manifold soundproof cover according to any one of claims 1 to 7, characterized by comprising the steps of:

the first step is as follows: placing the blank of the surface non-woven fabric layer (11), the glass fiber layer (12) and the bottom non-woven fabric layer (13) in a die cavity for hot pressing and molding;

the second step is that: opening the mold, and placing the product in the first step into a cooling tool for cooling;

the third step: taking out the cooled product, and removing the edge material to obtain a shell (1);

the fourth step: and arranging a plurality of assembly components (2) on the shell (1) obtained in the third step to obtain the engine intake manifold sound-proof housing.

9. The method for manufacturing the engine intake manifold soundproof cover according to claim 8, wherein in the first step, the hot press setting temperature is 210 to 250 ℃, the press pressure is 17 to 23MPa, the mold clamping pressure maintaining time is 110 to 130s, a device for fixing the aluminum foil is provided in the mold cavity, and the aluminum foil (3) is bonded to the surface non-woven fabric layer (13);

and in the second step, the temperature of the cooling tool is normal temperature, and the cooling time is 2-3 min.

10. The method of manufacturing an engine intake manifold acoustic enclosure according to claim 8, wherein said fourth step of said mounting assembly is arranged by: a base (21) for fixing a gasket is placed below a shell (1), a conical part (23) on the base (21) manually penetrates through the shell (1) and rotates along a notch of a part hole, the shell (1) is pre-bent according to an indentation generated by hot-pressing and shaping, and then a top cover (22) and the conical part (23) are screwed and fixed.

Technical Field

The invention relates to the technical field of sound-proof enclosures, in particular to an engine intake manifold sound-proof enclosure and a manufacturing method thereof.

Background

The intake manifold is a connecting pipeline between the intake pipe and the cylinder cover and is used for distributing gas in the intake pipe into each cylinder, when the gas flows through the intake manifold, the wall surface of the intake manifold vibrates due to the flowing of the gas, and the flowing sound of the gas penetrates through the wall surface of the intake manifold to generate noise.

The utility model patent CN204783374U discloses a pressure boost is directly spouted engine intake manifold's sound-proof structure, including intake manifold and sound-proof housing, the laminating is matchd with intake manifold's surface to the sound-proof housing internal surface, and the upper surface of sound-proof housing is the plane, and the internal surface of sound-proof housing is equipped with the arch of filling space between intake manifold's air flue and air flue, and this scheme can improve the noise reduction effect of engine intake manifold department. However, the soundproof cover has poor high temperature resistance, poor precision and limited soundproof effect.

The invention patent CN110920179A discloses an electric automobile battery sound-proof cover part and a manufacturing method thereof, the part comprises a non-woven fabric layer, a flame-retardant EPDM layer, a PU layer and a metal buckle arranged on the PU layer, the flame-retardant EPDM layer and the PU layer are sequentially arranged from top to bottom, the flame-retardant EPDM layer and the PU layer are placed into an oven, the heating is carried out to soften the surface of the EPDM, a blank is placed into a mold through a feeding device, the non-woven fabric, the heat-dried EPDM and the PU are sequentially arranged in the mold from top to bottom, then hot-pressing molding is carried out, cooling and shaping are carried out at room temperature, the residual materials are cut off, the metal buckle is additionally arranged on the obtained part, and the electric automobile battery sound-proof cover part is manufactured. However, the soundproof cover is thick in part, is limited in application to the intake manifold, is not strong in wrapping property to the intake manifold, is not strong in sound absorption and sound insulation, and is limited in high temperature resistance.

Disclosure of Invention

The present invention is directed to overcoming the above-mentioned drawbacks of the prior art, and providing an engine intake manifold soundproof cover and a method for manufacturing the same, which has a strong wrapping property for an intake manifold, a strong sound absorption and insulation property, and a better high temperature resistance.

The purpose of the invention can be realized by the following technical scheme: an engine intake manifold acoustic enclosure comprising a housing and a plurality of mounting assemblies disposed on the housing; the shell comprises a surface non-woven fabric layer, a glass fiber layer and a bottom surface non-woven fabric layer which are sequentially arranged. The glass fiber layer has good performances of high temperature resistance, oil stain resistance, corrosion resistance, sound insulation and the like, and the formed glass fiber layer can have good sound absorption performance due to the related combination of fibers and irregular shapes and gaps of capacity. After passing through the non-woven fabric of the fabric, the sound wave is repeatedly refracted on the glass fiber layer, so that the sound wave energy is greatly reduced, and the sound absorption performance is good.

Furthermore, the surface non-woven fabric layer is also provided with an aluminum foil, and the thickness of the aluminum foil is 0.08-0.12 mm. Mainly plays a role in reflecting heat of the engine so as to protect the intake manifold. The back of the aluminum foil is covered with an adhesive film, and the adhesive film is melted and stuck on the non-woven fabric during hot pressing.

The glass fiber layer is a phenolic resin type glass fiber layer, and the weight per unit area is 800-1200 g/m²。

The diameter of the phenolic resin type glass fiber is 5.5-7 mu m, the length of the phenolic resin type glass fiber is 0.3-0.8 mm, and the heat conductivity coefficient of the phenolic resin type glass fiber is 0.033-0.04 w/m.k.

The assembly component be the gasket of swirling, the gasket of swirling includes base and top cap, is equipped with the circular cone portion on the base, be equipped with on the top cap with circular cone portion matched with turn-ups. The vortex washer is made of 304 stainless steel and is not easy to rust.

Further, the vortex gasket is arranged at the edge of the sound-proof cover, the base is arranged below the shell, and the conical part penetrates through the shell and is connected with the top cover positioned above the shell through a flanging.

The unit area weight of the surface non-woven fabric layer and the bottom surface non-woven fabric layer is 110-130 g/m²The fabric has the advantages of fine surface, soft hand feeling and raised needle, is mainly used for middle-end vehicles, is used for preventing glass fibers from being exposed, and has the performances of flame retardance, chemical reagent resistance and the like.

A manufacturing method of the engine intake manifold sound-proof housing comprises the following steps:

the first step is as follows: placing the blanks of the surface non-woven fabric layer, the glass fiber layer and the bottom surface non-woven fabric layer in a die cavity for hot pressing and molding;

the second step is that: opening the mold, and placing the product in the first step into a cooling tool for cooling;

the third step: taking out the cooled product, and removing the edge materials to obtain a shell;

the fourth step: and arranging a plurality of assembly components on the shell obtained in the third step to obtain the engine intake manifold sound-proof housing.

Further, the hot-press setting temperature in the first step is 210-250 ℃, the press pressure is 17-23 MPa, the mold closing and pressure maintaining time is 110-130 s, a device for fixing the aluminum foil is arranged in the mold cavity, the aluminum foil can be conveniently pasted on the surface of the non-woven fabric layer, an indentation is reserved on the motor sound-proof cover shell in the hot-press setting process, and the motor sound-proof cover main body can be bent along the indentation, so that the subsequent assembly is convenient; and in the second step, the temperature of the cooling tool is normal temperature, and the cooling time is 2-3 min.

The setting mode of the assembly in the fourth step is as follows: the base of the vortex gasket is placed below the shell, the conical part on the base manually penetrates through the shell and rotates along the notch of the part hole, the shell is pre-bent according to an indentation generated by hot-press forming, and then the top cover and the conical part are screwed and fixed. The designed hole diameter of the part body is 1.5-2 mm larger than that of the conical part, and the fixing and fixing vortex washer can slide about 1.5-2 mm in the hole position.

Compared with the prior art, the invention has the following advantages:

1. the glass fiber layer is arranged, so that the engine intake manifold is stronger in high temperature resistance, bendable, capable of insulating sound, thinner, good in wrapping property on the engine intake manifold and stronger in sound absorption and sound insulation performance;

2. the glass fiber is used as a base material, the main component is silicon dioxide, the glass fiber is non-combustible, the chemical property is stable, the flame retardant property is excellent, the first combustion time of a single pattern is less than 10 seconds, and no molten drop exists;

3. the invention takes the glass fiber as the base material, has stable chemical performance, and can meet various high and low temperature environments, such as: no deformation, no structural and functional damage and the like in a temperature cycle experiment at the temperature of between 40 ℃ below zero and 120 ℃ for 30 periods (15 days);

4. the vortex washer is used for installing and fixing the engine intake manifold sound-proof cover, has the performance of rust prevention and the like, has the profile size slightly smaller than the design of the installation hole, and is convenient to install and disassemble.

Drawings

FIG. 1 is a schematic view of a partial configuration of an engine intake manifold acoustic enclosure of the present invention;

FIG. 2 is a schematic structural view of a vortex gasket according to the present invention;

FIG. 3 is a schematic view of the intake manifold acoustic enclosure assembly of the present invention;

FIG. 4 is a front view of an intake manifold sound enclosure assembly of the present invention;

FIG. 5 is a top view of an intake manifold sound enclosure assembly of the present invention;

in the figure: 1-shell, 11-surface non-woven fabric layer, 12-glass fiber layer, 13-bottom surface non-woven fabric layer, 2-assembly component, 21-base, 22-top cover, 23-conical part, 24-flanging, 3-aluminum foil and 4-intake manifold soundproof cover assembly.

Detailed Description

The invention is described in detail below with reference to the figures and specific embodiments. The following examples are carried out on the premise of the technical scheme of the invention, and detailed embodiments and specific operation processes are given, but the scope of the invention is not limited to the following examples.

Example 1

An engine intake manifold soundproof cover, as shown in fig. 1, comprises a housing 1 and a sound insulation cover disposed in the housing1, the shell body 1 comprises a surface non-woven fabric layer 11, a glass fiber layer 12 and a bottom surface non-woven fabric layer 13 which are sequentially arranged from outside to inside, and an aluminum foil 3 is further arranged on the surface non-woven fabric layer 11. The weight per unit area of the glass fiber layer 12 was 800g/m²The weight per unit area of the surface nonwoven fabric layer 11 and the bottom nonwoven fabric 13 is 110 to 130g/m²。

The housing 1 is produced by the following method:

the first step is as follows: placing blanks of the surface non-woven fabric layer 11, the glass fiber layer 12 and the bottom non-woven fabric layer 13 into a die cavity for hot press forming, wherein the hot press forming temperature is 210-250 ℃, the press pressure is 17-23 MPa, and the die closing and pressure maintaining time is 110-130 s;

the second step is that: opening the mold, and placing the product in the first step into a cooling tool to cool for 2-3 min at normal temperature;

the third step: and taking out the cooled product, and removing the edge material to obtain the shell 1.

The surface of the shell 1 generates an indentation in the hot-press forming process, and the shell 1 can be bent and assembled along the indentation.

The aluminum foil 3 is adhered to the surface nonwoven fabric layer 11 of the case 1.

The casing 1 with the aluminum foil 3 is assembled on an engine intake manifold of a general automobile through a plurality of assembly components 2, the assembly components 2 are arranged at the edge part of the casing 1, as shown in fig. 2, the assembly components 2 are vortex washers and comprise a base 21 and a top cover 22, the base 21 is provided with a conical part 23, and the top cover 22 is provided with a flange 24 matched with the conical part 23. The base 21 is arranged in the lower part of the housing 1 and the conical part 23 penetrates the housing 1 and is connected with the top cover 22 above the housing 1 through a flange 24. During assembly, a base 21 of a vortex gasket is placed below the shell 1, a conical part 23 on the base 21 manually penetrates through the shell 1 and rotates along a gap of a part hole, the shell 1 is pre-bent according to an indentation generated by hot press forming, then a top cover 22 and the conical part 23 are screwed and fixed, so that the shell 1 is installed on an intake manifold of a transmitter, and the obtained intake manifold sound-proof cover assembly 4 is shown in fig. 3-5.

Example 2

An engine intake manifold sound-proof cover, unit surface of glass fiber layer 12The bulk weight is 1000g/m²Otherwise, the engine intake manifold soundproof cover was attached to the engine intake manifold of the general-purpose automobile, as in example 1.

Example 3

The soundproof cover of the engine intake manifold, the unit area weight of the glass fiber layer 12 is 1200g/m²Otherwise, the engine intake manifold soundproof cover was attached to the engine intake manifold of the general-purpose automobile, as in example 1.

Comparative example 1

The engine intake manifold soundproof cover is assembled on an engine intake manifold of a general-purpose automobile according to the soundproof cover manufactured by the method of the invention patent CN 110920179A.

The soundproof covers of examples 1 to 3 and comparative example 1 were subjected to a performance test, and the obtained parameters are shown in the following table:

item	Example 1	Example 2	Example 3	Comparative example 1
					Average sound absorption	0.55	0.58	0.6	0.5
Maximum temperature resistance	180℃/200h	180℃/200h	180℃/200h	180℃/150h
					Flame retardant V0	Y	Y	Y	N

Compared with the prior art, the sound-proof shield has stronger sound absorption performance, higher high temperature resistance and more flame retardance.

The embodiments described above are described to facilitate an understanding and use of the invention by those skilled in the art. It will be readily apparent to those skilled in the art that various modifications to these embodiments may be made, and the generic principles described herein may be applied to other embodiments without the use of the inventive faculty. Therefore, the present invention is not limited to the above embodiments, and those skilled in the art should make improvements and modifications within the scope of the present invention based on the disclosure of the present invention.