DE8527746U1 - Self-supporting sound insulation panel - Google Patents

Description

CA. Greiner and Sons GmbH & Co KG 7440 Nürtingen

Self-supporting sound insulation panel

The invention relates to a self-supporting sound insulation panel made of a foam layer which is covered on both sides by thinner layers of other material.

Such soundproofing panels are used, for example, in automobile construction to reduce the noise emissions of the engine when installed under the hood. However, they are also used in many other cases where the spread of sound needs to be reduced.

Self-supporting components of the type mentioned above are known, in which a layer of elastic foam made of soft polyurethane is supported on one side by a rigid carrier plate made of solid or foamed material drawn into shape. and on the other side by a Blanket made of the same material or of paper or plastic or metal foil (DE-GM 79 11 356)

Such a component is very heavy overall due to the high gross weight of the materials used and must - in order to have the required load-bearing capacity - have a certain thickness, which in turn increases the weight of the component.

The task of the ErfiaUuni AaV JdtemSgeiläß dl« was to design such a component to serve as a sound insulation panel as light as possible, without, however, compromising its inherent load-bearing capacity and sound absorption.

;'.' It solves this problem by the

< Main claim specified features. Rigid poly-

■V urethane, phenol or melamine resin foam with very

low density is characterized by an extremely low density and high inherent rigidity. Surprisingly, it has also been shown to have a very high sound absorption capacity.

. Since stiff polyurethane, phenol or melamine resin

foam is easily mechanically damaged, ^can be

; 15 rough mechanical impacts (scratches, etc.) slightly

be damaged. This is prevented by the mechanically sufficiently strong cover layers provided according to the invention. The dimensional stability of these cover layers, which is due to the high mechanical strength, leads to a surprising rigidity in the sandwich construction achieved by the arrangement of the layers according to the invention, in view of the low volume and surface weight of the entire formwork insulation board, and thus to the required self-supporting capacity.

The cover layers therefore have a dual function: they protect the mechanically easily damaged rigid polyurethane, phenol or melamine resin foam layer from damage and they take up space in the sandwich structure. which are caused by the weight of the structure and by the

The panels absorb the tensile and shear forces that occur and thus provide the rigidity and self-supporting capacity of the soundproofing panel.

The use of air-permeable materials for the covering layers allows the air to

Effect of sound pressure in the sound insulation panel

to penetrate or even penetrate through them. This is for the absorption of sound energy in the

Plate or*er

in* eifiim! b'eSalse'wen Zwischenrau

between the plate and the surface covered by the plate is of crucial importance. The covering layers are therefore made of (polyurethane) soft foam with only a very thin, still air-permeable skin and/or of naturally air-permeable fiber fleece. The proposed glass fiber fleece in particular is characterized by a low surface weight while still being highly dimensionally stable and highly permeable to air. Inflammability is inherent in the material glass anyway.

Furthermore, the air permeability of the sound insulation panel can be influenced by the choice of density and/or pore size of the foam layers and can be adapted to the requirements*

The purpose of the covering PU foam layer is to protect the sound insulation panel against the penetration of dirt and liquids.

The intended lamination ensures an intimate connection between the layers and thus the full effectiveness of the sandwich construction. The lamination can be carried out in any known way, for example by applying a spray adhesive, by using water-soluble or solvent-soluble binders or by inserting a plastic film that melts under the influence of heat and connects the layers after re-hardening.

By compression molding at elevated temperatures, the combination of layers, which in its raw state is more like a mat, is transformed into a dimensionally stable panel. This not only gives the sound insulation panel the necessary contour, which is determined by the contour of the surface to be covered. The resulting beads, surface angles, depressions,

Burrs, etc., increase the rigidity of the board even further. However, the foam layers of the board are not only permanently deformed under the pressure of the press and the effect of the increased temperature, but also compressed, thus also increasing their rigidity and dimensional stability.

Further advantageous embodiments of the invention are contained in the subclaims. The drawing shows schematic cross sections through sections of the sound insulation panel according to the invention;

C i « 1 ·· _A { *» 4- &Lgr; \ ** D^. Hm =» i- *- ä &ugr;/vt> /Jam Frhnm_ I X IJ « X £. t? X ^ l> UX U ·*&ngr;/&Igr;1&Igr;&Igr;&Igr;«^«***&ngr;&iacgr; VVK UUHl · &igr;^&bgr;···

press,
Fig. 2 shows a molded sound insulation panel

The main component of the sound insulation board is a layer 1 made of rigid polyurethane, phenol or melamine resin foam, which in the unpressed state can have a density of 5 kg/m ³ to 35 kg/m ³ and, depending on requirements (required sound absorption capacity, volume to be lined, dimensions of the board, etc.), a thickness of 5 mm to 50 mm.

On the upper side in the drawing, the polyurethane, phenol or melamine resin foam layer 1 is laminated with a cover layer 2 which consists of a dense but air-permeable material, preferably a cross-linked plastic fiber fleece with a surface weight of 20 g/m ² to 500 g/m ^2. In some cases it is also advantageous to use a thin plastic plate for this purpose.

On the lower side in the drawing, the polyurethane, phenol or melamine resin foam layer is laminated with a polyurethane soft block foam layer 3, which in the unpressed state should have a density of 10 kg/m ^J to 50 kg/m ³ and a thickness of about 3 mm to about 5 mm.

This PU soft block foam layer 3 is covered so thinly on its exposed side that it is air-permeable.

remains loose. During the skinning process, which is generally carried out by the action of elevated temperature and is associated with a temporary melting of the surface of the block foam layer 3, a thin fiber fleece, preferably a mineral or glass fiber fleece with a surface weight of about 10 g/m ² to about 100 g/m ² , can be melted into the resulting skin layer.

The sandwich-type layer combination prepared in this way is then pressed into the intended spatial shape in a press under the influence of an increased temperature of about 170 'C to about 230 ⁰ C. The layers soften and solidify in the intended spatial shape when the temperature drops.

Under the influence of the press pressure applied, the foam layers 1 and 3 are compressed by about 15 % to about 70 %, depending on the thickness of the panel in certain places. The thickness of the panel in the area of the bead 5 is reduced to about half, or the density at this point 6 increases to twice the initial value. In area 7, the reduction in thickness or the increase in density compared to the initial state is about 1/3, in area 8 only a slight change in thickness and density occurs.

Claims (1)

CA Greiner and Sons
GmbH & Co. KG
7'4' Nürtingen Self-supporting sound insulation panel 1. Self-supporting sound insulation panel made of a foam layer, which is covered on both sides by thinner layers of other material, characterized in that the foam layer (1) consists of rigid polyurethane, phenol or cellulose resin foam of very low density and the cover layers (2; 3) on both sides consist of a carrier material which is denser than the material of the foam layer (1), but is permeable to air, whereby the layers (1; 2; 3) are laminated to one another and molded together at high temperature. 2. Soundproofing panel according to claim 1, characterized in that the polyurethane, phenol or melamine resin foam layer (1) in the initial state has a bulk density of 5 l<g/ ^m² to 35 kPa/m² and a thickness of 5 mm to 50 mm. 3. Insulation panel according to claim 1, characterized _in that one of the cover layers (2) consists of a rigid plastic plate. k. Sound insulation panel according to claim 1, characterized in that one of the cover layers (2) consists of a flexible, dimensionally stable sheet-like structure. 5. Sound insulation panel according to claim k, characterized in that the sheet-like structure is a cross-linked fiber fleece with a basis weight of 20 g/m ² to 500 g/m'. 6. Sound insulation panel according to claim 1, characterized in that the other covering layer (3) consists of a soft polyurethane block foam layer with a thin skin on the outside in the initial state with a density of 10 kg/m ¹ to 50 'ig/m' and a thickness of 3 mm to 5 mm. 7. Sound insulation panel according to claim 1, characterized in that the other cover layer (3) consists of a nonwoven fabric with a basis weight of 10 g/m* to 100 g/m*. &bgr;. Sound insulation panel according to claim 6, characterized in that in the skinned outside of the A fibre fleece (4) is melted into the soft polyurethane block foam layer (3). 9. Sound insulation panel according to one of claims 5, 7 or &THgr;, characterized in that the fiber fleece is a mineral or clase fiber fleece. 10. Sound insulation panel according to claim 8, characterized in that the fiber fleece (k) has a basis weight of 10 g/m* to 100 g/m*. 11. Shell insulation board according to claim i, characterized in that the laminated layers (1; 2; 3) are molded at a temperature of 170 °C to 230 "C.