MXPA99000931A - Insulating layer with integral grommets - Google Patents

Abstract

An acoustical barrier (10) is mounted to the barrier wall (20) of a motor vehicle. The acoustical barrier (10) includes a mass layer (12) of molded construction and sound dampening characteristics. The mass layer (12) includes a plurality of grommets (14, 14', 14", 54) integrally molded as a single piece with a lower surface of the mass layer. Each grommet (14, 14', 14", 54) has a continuous wall with an inner peripheral surface (27, 27', 27") with an upper portion of the wall integrally formed with the inner surface (18) of the mass layer and a lower portion of the wall having a lower edge (22, 22', 22") abutting the barrier wall (20). The inner surface (27, 27', 27") of the continuous wall defines an opening in each grommet (14, 14', 14", 54). A plurality of openings (25, 25', 25") in the mass layer are in communication with at least some of the grommet openings. Various fasteners (26, 70), shafts or sleeves (62), cables (64), wires, and other vehicle accessories can extend through one or more of the grommets and through corresponding openings (29) in the vehicle barrier wall (20).

Description

INSULATING LAYER WITH METAL IN-EE-GRALES EYELETS BACKGROUND OF THE INVENTION Field of the Invention This invention relates to insulating layers for structural supports, and more particularly to an insulating sound layer for vehicles, which has integrally molded metal eyelets for attaching accessories to the insulating layer and for seal the passenger compartment of the outside environment. Description of Related Art In most contemporary automobiles, a steel fire wall separates the engine compartment from the passenger compartment. To reduce the transmission of sound from the engine compartment through the fire wall, and inside the passenger compartment, a sound barrier mat is typically molded (otherwise known as a wood panel mat). instruments) of an elastomeric material. The dashboard mat is mounted to, and substantially extends over, the fire wall, such that an outer surface of the mat is in contact with a lower surface of the mat. of the vehicle and extends beyond the mat to an upper portion of the fire wall behind the dashboard Intrusive. On the dashboard mat, the ~ form multiple openings to receive a corresponding number of mounting bolts, which project from the fire wall to secure the dashboard mat to them. Other openings in the dashboard mat are aligned with openings in the fire wall for the passage of cable guides, electric cables, brake reinforcement arrows, accessory assemblies, and so on. ^ successively. The dashboard mat is typically separated from the fire wall by another absorbent layer that is usually constructed of open cell foam or fiberglass material. To install the sound insulating layer in a vehicle, each opening is aligned with its corresponding bolt and pushed on it until the insulating layer (or absorbent layer if so equipped) has contact with the wall against • fires. The inner peripheral edges of the openings are subject to damage by the bolt when the dashboard mat is in the installed position. Eventually, the opening can be deformed and the dashboard mat can be separated from the bolt and fire wall. As a result, any seal that may have existed between the engine and passenger compartments can be broken. Therefore, noise, air, water, etc., could be undesirably transferred from the engine compartment to the co- passenger through the broken seal. ^ Compendium of the Invention According to the invention, an acoustic barrier adapted to be mounted to the barrier wall of a vehicle or other structure includes a dough layer of a molded construction and sound damping characteristics. The dough layer has an internal surface that is adapted to face the barrier wall, and an external surface that & is adapted to be turned towards the opposite side of the barrier wall. A metal eyelet is integrally molded as a single piece with the same layer. The metal eyelet includes a continuous wall with an upper portion of the wall formed integrally with the inner surface of the dough layer and a lower portion of the wall having a lower edge adapted to have contact with the barrier wall. An internal surface of the continuous wall defines an opening in the metal eyelet. An opening extends through the layer of dough between the inner and outer surfaces of the same, with the opening in the metal eyelet being in communication with the opening in the layer of dough. The invention also comprises one or more fasteners with an elongated pin and a head formed at one end of the bolt. The bolt extends preferably at least through one of the openings of the metal eyelets and the dough layer In one embodiment, the subject head is located inside the opening in the metal eyelet; and the area between the cross dimensions of the head and the metal eyelet opening is smaller than the area between the cross dimensions of the bolt and the opening of the dough layer, so that wear between the bolt is prevented. and the opening of the dough layer. The sleeve can be a threaded sleeve when the bolt is threaded, or alternatively a safety catch that grips the outer surface of the bolt. ^ In another modality, the subject head is located inside the metal eyelet opening, and abuts the inner surface of the dough layer. A safety sleeve is placed on a free end of the bolt, opposite the fastening head to secure the fastener to the dough layer. You can mount a vehicle accessory that has a wall, directly to the dough layer in the vicinity of the metal eyelet, by sandwiching the attachment wall between the outer surface of the dough layer and the sleeve. If the vehicle accessory is electrically energized, the wires extending from it can be received in a bore that extends to through the bra. In this way, the wires can be directed through the barrier wall from the vehicle accessory, without being exposed in the passenger compartment of the vehicle. In accordance with yet another modality, the axis central of the metal eyelet opening is coextensive with a the central axis of the opening of the dough layer, and the central axes extend at an acute angle to the plane of the outer surface of the dough layer in the area of the metal eyelet. Furthermore, in accordance with the invention, a barrier wall of a motor vehicle has an acoustic barrier mounted thereto. The acoustic barrier includes a dough layer of a molded construction, and sound damping characteristics, with an internal surface facing the barrier wall, and an external surface that is turned over. to the opposite side of the barrier wall. A metal eyelet is integrally molded as a single piece with the dough layer. Preferably, the metal grommet has a continuous wall with an upper portion of the wall integrally formed with the inner surface of the dough layer, and a lower portion of the wall having a lower edge that abuts the barrier wall. An internal surface of the continuous wall defines an opening in the metal eyelet. An opening is also extended through the dough layer, between the inner and outer surfaces thereof, with the opening in the metal eyelet being in communication with the opening in the dough layer. According to one embodiment, a fastener having an elongated pin and a head formed at one end thereof, extends through the opening of the dough layer, the opening of the metal eyelet and the opening of the barrier wall with the clamping head abutting one of the wall of barrier and the layer of dough. A safety cuff is placed on one free end of the bolt and abuts the other of the barrier wall and the dough layer to secure the dough layer to the barrier wall. According to another embodiment, the opening in the dough layer is separated laterally and outwards from the opening in the barrier wall. A central axis of the opening in the metal eyelet is coextensive with a central axis of the opening f ^ in the layer of mass, with the axes extending at an acute angle to the plane of the outer surface of the dough layer in the area of the metal eyelet, and the opening in the barrier wall. With this configuration, the inner surface of the metal eyelet wall serves as a guide for installing accessories through the offset openings in the barrier wall15 and the layer of dough. Also, in accordance with the invention, an acoustic barrier is mounted to the barrier wall of a motor vehicle. The acoustic barrier includes a layer of molded construction dough and sound damping characteristics. The layer of dough includes a plurality of metal eyelets integrally molded as a single piece with a lower surface of the dough layer. Each metal eyelet has a continuous wall with an internal peripheral surface with an upper portion of the wall formed integrally with the inner surface of the layer of dough, and a lower portion of the wall having a shore bottom that abuts the barrier wall. The internal surface of the continuous wall defines an opening in each metal eyelet. A plurality of openings in the dough layer are in communication with at least some of the openings in the metal eyelet 5. Various fasteners, arrows or sleeves, cables, wires, and other vehicle accessories can be extended through one or more of the metal eyelets, and through the corresponding openings in the vehicle's barrier wall. ^ h Brief Description of the Drawings 10 The invention will now be described with reference to the drawings in which: Figure 1 is a perspective view of a dashboard mat assembly, having many integrally formed metal eyelets, according to the invention. Figure 2 is a cross-sectional view of the assembly of ^ - dashboard mat taken along line 2-2 of Figure 1, and illustrating a fastener assembly attached thereto. Figure 3 is a cross-sectional view of the dashboard mat assembly, similar to Figure 2, and illustrating a different fastener assembly, in accordance with a second embodiment of the invention. Figure 4 is a cross-sectional view of the dashboard mat assembly, which has a metal eyelet integrally formed, in accordance with a third modality of the invention. ^ Detailed Description of the Preferred Modes Referring now to Figures 1 and 2, an instrument panel mat assembly 10 includes a sound barrier mat or instrument panel mat in the form of a layer 12 of dough and a eyelet 14 of integrally molded metal, which preferably are formed of a filled elastomeric moldable polymer, eg, elastomeric polypropylene. The mat assembly 10 of the instrument board is attached to the fire wall of a vehicle from the passenger compartment side. The mat assembly 10 of the instrument panel serves as a sound barrier layer, to reduce the transmission of sound from the engine compartment, through the fire wall, and inside the passenger compartment of a vehicle. An outer surface 16 of the sound barrier mat 12 typically faces the underside of a vehicle mat. { not shown) and extends beyond the mat, behind the dashboard. An internal surface 18 of the mat 12 typically faces the fire wall 20. The metal eye 14 is formed integrally with the mat 12 of the instrument panel during the molding process, and extends perpendicularly from the surface 18 internal. An outer edge 22 of the metal eyelet 14 is adapted to have contact with an exterior surface 24 of the wall 20 _ against fire when installed against it, to form a seal between the engine and passenger compartments of the vehicle. The metal eyelet 14 additionally serves to separate the mat 12 of the instrument panel of the fire wall 20, to form a dead air space 21 therebetween. The dead air space 21 acts as an additional insulating layer against noise, vibration, etc., which could ^ Be present in the engine compartment. The height of the metal eyelet 14 may vary depending on the total volume of dead air space desired. The metal eye 14 can thus replace the absorbent layer, which is typically connected between the mat 12 of the instrument panel and the fire wall 20, at least in some places.

An opening 25 extends through the thickness of the mat 12 of the dashboard, and is centrally located with respect to the inner peripheral surface 27 of the metal or the metal. The opening 25 can be aligned with an opening 29 in the fire wall 20 when the assembly is installed 10 of the dashboard mat on it. A bolt 30 of a fastener 26 is inserted through the opening 25 in the dashboard mat, while a head 28 of the fastener 26 abuts the inner surface 18 of the mat of the bulkhead board. A perforation 32 extends through an axial center of the fastener 26 of the fastener-26, and adapted to receive - electric wires, cables, etc., that could be extended between the engine and passenger compartments, through the openings 25, 29. Alternatively, the perforation 32 5 can receive, in safety gear, a bolt (not shown) that extends from the fire wall and into the passenger compartment, to secure the dashboard mat to the fire wall. A ring of ^ k safety slide or sleeve 34 frictionally engages an external surface 36 of the bolt 30, for gluing the fastener 26 to the mat 12 of the dashboard. In the past, an internal peripheral surface 38 of the opening 25 of the bolt 30 has been subjected to friction and deformation. To eliminate this problem, and in accordance with the invention, the dimension "A" between the peripheral surface 27 of the metal eyelet, and an outer peripheral surface 40 of the clamping head 28 is smaller than the dimension "B" between the external surface 36 of the pin 39, and the inner surface 38 of the opening 35. Therefore, the head 28 fastener will have contact with the metal eye 14, and avoid contact between the pin 30 and the inner surface 38 ~. Any slippage between the fastener and the dashboard mat is prevented by means of the metal grommet, thereby eliminating wear and deformation of the opening 25 that otherwise would happen.

A variety of metal eyelets can be formed integrally on the mat 12 of the dashboard, and can be formed in different shapes, as "illustrated in Figure 1. The metal eyelet 14 ', for example, is oblong, while the metal eyelet 14"is hexagonal, it will be understood, however, that other profiles can be formed.It is only necessary that the inner peripheral surface (27, 27 ', 27") and the surface (22, 22 ', 22") of metal eyelets (14, 14', ^ 14"), respectively, be continuous, in order to seal the opening (25, 25 ', 25") of the space 21 insulator when installed against the fire wall 40. With the present configuration, a housing 41 can be attached directly to the mat 12 of the instrument panel, by inserting the bolt 30 into an opening 15 of the housing, and then installing the slip ring 34 - ^^^ on the safety plate, as illustrated in Fig. Figure 2. Housing 41 may be part of an electrical splice block, an accessory assembly, or other similar device. The thickness of the mat 12 of the instrument panel in the vicinity of the metal eyelet 14, as well as the metal eyelet itself, may be different to directly support the weight of the different accessories. The perforation 32 of the fastener 26 can be in direct communication with the housing 41, as illustrated in Figure 2, in such a way that the wires, cables, tubes, etc., which are directed from the engine compartment, can be attached directly to the vehicle accessory associated with ^ the housing 41. Turning now to Figure 3, a different fastening configuration is illustrated for the 5-panel assembly of the dashboard, where the same parts in the previous embodiment they are represented by the same numbers. A fastener 70 having a threaded bolt 72 extends into the passenger compartment, and is either welded to the inner surface of the fire wall 20 (not shown), or as shown, includes a head 74. The opening 38 in the mat 12 of the dashboard is aligned with the bolt, and the dashboard mat is pressed towards the fire wall 20. The opening 38 is preferably dimensioned to receive frictionally, and is sealed around the bolt 72. A pulley 76 is inserted into the bolt until it contacts the outer surface 16 of the dashboard mat. A threaded nut or sleeve 78 is then installed on the arrow and twisted until the nut is adjusted. As in the configuration of Figure 2, a fixture or accessory housing (not shown) can also be mounted to the bolt, and secured directly to the dashboard mat by means of the nut and the sheave. Depending on the size and thickness of the metal eyelet 14, the continuous wall thereof will tend to warp-lightly under the pressure exerted by the fastener.

The thickness of the wall of the metal can be increased or decreased, depending on how much force the metal eyelet will support. In the configuration described above, the metal eyelet functions as a compression limiter when the dashboard mat is attached to the fire wall, or when attachments are attached to the dashboard mat. This function protects the tabletop mat from instruments against being damaged if the fastener is tightened.

In addition, many accessories attached in the manner described above to the dashboard mat, are insulated from the vibrations of the vehicle. This isolation of vibration is especially important for electrical equipment and other devices sensitive to vibrations. 15 With reference now to Figure 4, there is shown a ^^ assemble 50 of dashboard mat, in accordance with a second embodiment of the invention, wherein the same parts in the previous mode are represented by the same numbers. The board mat assembly 50 instruments include a second sound barrier mat or instrument panel mat 52, and one or 54 integrally molded metal. The metal grommet 54 has a central axis extending at an acute angle with respect to an inner surface 58 of the mat 52 of the instrument panel. A The axial opening 60 in the metal eyelet 54 is dimensioned for receive an arrow 62 from a vehicle accessory. How I know »Illustrates, the arrow 62 is in the form of a cable sleeve, and extends at a sharp angle to the fire wall 20 when installed. A cable 64 associated with a lever changes, clutch pedal, control valve, etc., is received inside the sleeve and can be slid with respect to it. The angle of the metal eyelet 54 can be varied to accommodate the angle of the sleeve or the arrow to be installed. g ^ The mat assembly 50 of the instrument panel is installed in the fire wall 20 by first aligning the opening 60 in the metal eyelet 54 with the opening 29 in the fire wall. The opening 29 typically extends transverse to the fire wall 20. Then the sleeve 62 is inserted into the opening 60 and slides until a portion of the sleeve extends into the engine compartment. The opening 60 of the metal eyelet is ^^ dimension to frictionally retain the sleeve, while providing a seal around it. In this way, the buttonhole 54 metal serves as a separator to create a space 21 insulator, and to seal the space 21 of the engine compartment. In addition, the metal grommet 54 serves as a guide when the sleeve 62 is installed, to ensure that the sleeve is easily inserted through the opening 23 in the fire wall. This unique feature is an improvement over the systems of the prior art, where one should insert a cuff or arrow at an acute angle through both a dashboard mat and a fire wall separated from it In the past, the separate dash mat has made it difficult to locate the 5 hole in the wall against fires, especially when the sleeve or arrow is to be inserted at an acute angle with respect to it. ough the present invention has been described with particular reference to 10-car dash mats, the invention also finds use. in other automotive or non-automotive applications, where decorative panels, covers, accessories, etc. can be attached temporarily or permanently to a support surface. Reasonable variations and modifications within the spirit of the specification and prior drawings are possible without departing from the scope of the invention.

Claims (23)

1. SUBMISSIONS - 1. An acoustic barrier adapted to be mounted on a barrier wall, the acoustic barrier comprising: a dough layer of a molded construction and characteristics of sound damping, the dough layer having an internal surface that is adapted to look at the barrier wall and with an external surface adapted to look away from the barrier wall; ^^ a buttonhole molded integrally as a single piece with 10 the dough layer, the eyelet having a continuous wall with an upper portion of the wall formed integrally with the inner surface of the dough layer and a lower portion of the wall having a lower edge adapted to contact the wall barrier, an inner surface of the continuous wall 15 defining an opening in the eyelet; and an opening extending through the dough layer between its inner and outer surfaces, the opening in the buttonhole being in communication with the opening in the dough layer.
2. 2. An acoustic barrier according to claim 1, and further comprising a fastener having an elongate cross member and a head formed at one end thereof, the elongate cross member extending through at least one of the openings.
3. 3. An acoustic barrier according to claim 25, wherein the head of the fastener is located within the opening in the buttonhole; and the area between the transverse dimensions of the head and the eyelet aperture is less than the area between the transverse dimensions of the cross member and the dough layer opening such that wear between the cross member and the cross member is prevented. 5 dough layer opening.
4. 4. An acoustic barrier according to claim 3, wherein the fastener has a central bore extending therethrough.
5. 5. An acoustic barrier according to claim 2, wherein the head of the fastener is located within the eyelet opening and abuts on the inner surface of the dough layer; and further comprising a closure sleeve positioned on a free end of the cross member opposite the head of the fastener to secure the fastener to the dough layer.
6. 6. An acoustic barrier according to claim 5, and further comprising a vehicle accessory having a walled wall between the outer surface of the dough layer and the sleeve to thereby secure the fixture directly to the dough layer.
7. 7. An acoustic barrier according to claim 6, wherein the fastener has a central bore extending therethrough and the fixture includes received electrical wires within the central bore.
8. 8. An acoustic barrier according to claim 1, wherein a central axis of the eyelet aperture is co-exten- It has a central axis of the dough layer opening, and also ^ where the central axes extend at an acute angle to the plane of the outer surface of the dough layer in the area of or.
9. 9. In a motor vehicle having a barrier wall separating a passenger compartment from a motor compartment and an acoustic barrier mounted on the barrier wall, the barrier wall having an opening extending from through it, the acoustic barrier including a dough layer 10 of a molded construction and sound damping characteristics, the dough layer having an inner surface facing the barrier wall and an outer surface facing away from the wall of barrier; the improvement comprising: one or the molded integrally as a single piece with 15 the layer of dough, the eyelet having a continuous wall with an upper portion of the wall formed integrally with the inner surface of the dough layer and a lower portion of the wall having a lower edge that abuts the wall barrier, an internal surface of the wall continues defining a 20 opening in the buttonhole; and an opening extending through the dough layer between the inner and outer surfaces thereof, the opening in the grommet being in communication with the opening in the dough layer.
10. 10. The improvement according to claim 9, and further comprising a fastener having an elongate cross member and a head formed at one of its ends, the elongate cross member extending at least through the bulk layer opening.
11. 11. The improvement according to claim 10, wherein the elongate cross member extends further through the eyelet opening and the barrier wall opening with the head of the fastener bumping into the barrier wall or the ^ k layer. dough; and a closure sleeve positioned on a free end of the cross member and bumping into the other element of the barrier wall or the dough layer to secure the dough layer to the barrier wall.
12. 12. The improvement according to claim 10, wherein the head of the fastener is located within the opening 15 in the buttonhole and it hits the inner surface of the dough layer; and further comprising a closure sleeve positioned on a free end of the cross member to secure the fastener to the dough layer.
13. The improvement according to claim 12, and further comprising a vehicle accessory having a walled wall between the outer surface of the dough layer and the sleeve, thereby securing the accessory directly to the dough layer.
14. 14. The improvement according to claim 13, wherein the fastener has a central perforation extending through it and the fixture includes electric wires received ^ inside the central hole.
15. 15. The improvement according to claim 9, wherein the opening in the dough layer is laterally separated 5 and out of the opening in the barrier wall, a central axis of the opening in the eyelet being co-extensive with a central axis of the opening in the layer e mass, the axes extending at an acute angle with the plane of The outer surface of the layer of dough in the eyelet area and the opening in the barrier wall, whereby the inner surface of the eyelet wall serves as a guide for installing accessories through openings in the wall. barrier wall and the layer of dough.
16. 16. The improvement according to claim 15, wherein the holder has a central bore extending 15 through it. ^ -
17. 17. The improvement according to claim 10, wherein the head of the fastener is located within the opening in the or al; and the area between the transverse dimensions of the head and the eyelet opening is smaller than the area between the 20 transverse dimensions of the cross member and the dough layer opening, such that wear between the cross member and the opening of the dough layer is prevented.
18. 18. In a motor vehicle acoustic barrier assembly, having a barrier wall separating a passenger compartment from an engine compartment and a barrier acoustic mounted on the barrier wall, the barrier wall ^ having a plurality of openings extending therethrough, the acoustic barrier including a dough layer of a molded construction and sound damping characteristics, the dough layer having an inner surface facing the barrier wall and an external surface facing away from the barrier wall, the dough layer further having an opening in communication with each opening of the plurality of openings > ^ on the barrier wall; the improvement comprising: a plurality of eyelets integrally molded as one piece with the dough layer, each eye having a continuous wall with an upper portion of the wall formed integrally with the inner surface of the dough layer and a lower portion of the wall having a lower edge that abuts the barrier wall; and ^^ each of the eyelets surrounding an opening of said plurality of barrier wall openings and one of the openings of the dough layer.
19. 19. The acoustic barrier according to claim 18, and further comprising: a first fastener having an elongate cross member and a head formed at one of its ends, the elongate crosspiece extending through the opening of a first eyelet of the plurality of eyelets, a corresponding first opening of the 25 dough layer of the plurality of openings in the dough layer, and a first corresponding opening of the barrier wall of the plurality of openings of the barrier wall, the head of the fastener abutting on an element of the barrier wall and the dough layer; and a closure sleeve positioned on a free end of the cross member and contacting the other element of the barrier wall and the dough layer to secure the dough layer to the barrier wall.
20. 20. The acoustic barrier according to claim 19, and further comprising a second fastener having an elongate cross member and a head formed at one of its ends, the head of the second fastener being located within the opening of a second eye of the plurality of eyelets and bumping into the inner surface of the dough layer, the crosspiece extending through a corresponding second opening of the dough layer; and further comprising: a second closure sleeve positioned on a free end of the cross member of the second fastener to secure the second fastener to the ground layer; a vehicle accessory having a wall walled between the outer surface of the dough layer and the second closure sleeve to thereby secure the accessory directly to the dough layer in the vicinity of the second eyelet.
21. The acoustic barrier according to claim 20, wherein the second fastener has a central perforation extending therethrough and the accessory includes wires received inside the central perforation. ^
22. 22. An acoustic barrier according to claim 21, wherein the plurality of buttonholes includes a third eyelet with a third eyelet aperture, the plurality of ground layer openings 5 including a third ground layer aperture, the third dough layer opening being laterally and outwardly separated from an additional barrier wall opening, a central axis of the third eyelet opening being coextensive A with a central axis of the third dough layer opening; axes extending at an acute angle to the plane of the outer surface of the dough layer in the area of the third eyelet and intersecting the additional opening in the barrier wall, whereby the inner surface of the third eyelet serves as a guide for installing accessories to through the third opening of the dough layer and the additional opening of the barrier wall. ^^
23. 23. An acoustic barrier according to claim 20, wherein the area between the transverse dimensions of the head of the second fastener and the second eyelet opening is smaller than the area between the transverse dimensions of the second fastener cross-member and the cross-section. second opening of the dough layer, such that wear is prevented between the second cross member of the fastener and the second opening of the dough layer.