EP0588182B1 - Elément composite pour isoler la température ou le son, son procédé de fabrication et l'utilisation - Google Patents

Elément composite pour isoler la température ou le son, son procédé de fabrication et l'utilisation Download PDF

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Publication number
EP0588182B1
EP0588182B1 EP93114133A EP93114133A EP0588182B1 EP 0588182 B1 EP0588182 B1 EP 0588182B1 EP 93114133 A EP93114133 A EP 93114133A EP 93114133 A EP93114133 A EP 93114133A EP 0588182 B1 EP0588182 B1 EP 0588182B1
Authority
EP
European Patent Office
Prior art keywords
powder
foamed
workpiece
aluminium
sound
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Revoked
Application number
EP93114133A
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German (de)
English (en)
Other versions
EP0588182A3 (fr
EP0588182A2 (fr
Inventor
Stefan Dr. Lahner
Manfred Roller
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Faist Automotive GmbH and Co KG
Original Assignee
M Faist GmbH and Co KG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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Application filed by M Faist GmbH and Co KG filed Critical M Faist GmbH and Co KG
Publication of EP0588182A2 publication Critical patent/EP0588182A2/fr
Publication of EP0588182A3 publication Critical patent/EP0588182A3/fr
Application granted granted Critical
Publication of EP0588182B1 publication Critical patent/EP0588182B1/fr
Anticipated expiration legal-status Critical
Revoked legal-status Critical Current

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Classifications

    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
    • G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/162—Selection of materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • B22F3/1121—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers
    • B22F3/1125—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers involving a foaming process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/002—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature
    • B22F7/004—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part
    • B22F7/006—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part the porous part being obtained by foaming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/105—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding
    • B22F2003/1052—Sintering only by using electric current other than for infrared radiant energy, laser radiation or plasma ; by ultrasonic bonding assisted by energy absorption enhanced by the coating or powder

Definitions

  • the invention relates to a thermally and acoustically insulating composite body in lightweight construction using a foam body and to a method for its production and its use.
  • Such composite bodies are already known from DE-A-2 735 153, but are only acoustically effective. They have the task of forming the greatest possible resistance to the passage of sound waves from one side to the other of the component, which is referred to as "sound-absorbing".
  • such composite bodies occasionally also have the task of damping the formation of sound waves on one side of the component, that is to say of performing a "sound-absorbing" function, for which purpose the composite body directly with the sound-emitting element, for example a body panel, by pressing or gluing and connecting clips.
  • metal for example an aluminum alloy
  • stabilizing particles for example aluminum oxide
  • the foam components used primarily for sound insulation purposes mostly have plastics such as polyurethane (DE-OS 27 35 153).
  • the cell walls represent more or less pliable cuticles.
  • For special tasks it is also known to connect open-cell foam structures with those foam structures which are closed-cell or which are filled or impregnated with fillers. The manufacturing costs of such double structures are relatively high. This also applies to open-pore foam fleece (DE-PS 36 24 427).
  • there are also problems with the disposal of constructions that are no longer usable such acoustically effective components are equipped.
  • Thermally insulating laminate elements are also known (DE-A-38 21 468 and DE-U-92 03 734). These laminate elements are partly also acoustically effective. These components are each made up of several different layers of one or more materials, that is to say in a complicated manner. Because they are not self-supporting, you need additional stiffening, usually in the form of an aluminum support plate. With the variants, which are made of different materials, there is also the problem of recycling.
  • the invention has for its object to improve the composite body of the type mentioned in such a way that with good acoustic effectiveness it also has good thermal insulation properties, is easy to manufacture, has lightweight construction features and offers advantages over other materials in disposal.
  • the foam body is designed in a special way.
  • the foam body is formed from a workpiece which has a compacted mixture of powdered aluminum or a powdered aluminum alloy on the one hand and powdered blowing agent or blowing agent on the other hand and, if required, powdered aluminum oxide compounds.
  • the workpiece can For example, be prepared by the method described in DE-PS 40 18 360 and it has been shown that the use of that method, ie the circumvention of the method described in US Pat. No. 4,713,277, is acoustically more effective in producing the material Leads components.
  • This compacted workpiece is placed, for example, in a mold, the cavity walls of which determine the outer contours of the finished foam body.
  • the shape can be made from such that the top is open.
  • the aluminum powder is melted by heating and the blowing gas or blowing gas is released when the blowing agent or blowing agent decomposes, which transforms the aluminum melt into a foam structure with preferably essentially closed cells.
  • the open design With the open design, the possibility of free foaming is given.
  • foamed workpieces By subsequent upsetting free, without thickness limitation, foamed workpieces, the normally relatively round to polygonal foam pores are flattened with increasing degree of compression and molded in an ellipsoidal manner or the cell webs fold in perpendicular to the direction of upsetting. This leads to an anisotropic heat conduction behavior, which leads to a reduction in the heat conduction in the workpiece thickness direction and a slightly increased heat conduction in the workpiece plane direction, ie, a higher thermal insulation of the workpiece.
  • such a mat-shaped pressed workpiece made of the aluminum blowing agent powder mixture into cavities between components and to heat the workpiece so that it inflates between the opposite walls of the components and essentially completely fills the intermediate space.
  • such a component also acts as a vibration-damping unit that dampens the adjacent components and also stiffens the overall construction.
  • the invention therefore offers a simple possibility of forming composite bodies with both mechanical and acoustically damping or insulating functions.
  • the composite body according to the invention favors disposal, since it can be easily separated from other materials of the overall assembly and can be reused without the formation of harmful and polluting gases and vapors in the usual metal separation and processing process. It is therefore also possible to use recyclable aluminum materials for the production of the compacted workpiece and therefore of the sound wave damping or insulating and heat insulating component.
  • a blackening of the workpiece produced on one side leads to a significant increase in the emission coefficient and thus to an increase in thermal insulation.
  • powdered aluminum in large excess over the proportions of the blowing agent powder, in a ratio between 10: 1 and 1000: 1. It is advisable to add compounds containing aluminum oxide in proportions of 0-30% (based on the total amount of powder). In all cases, it should Blowing agents, as well as other constituents, are largely homogeneously distributed in the aluminum powder, unless certain areas of the workpiece from the powder mixture are to foam less when heat is applied.
  • the powder mixture is compacted to the workpiece under a pressure of advantageously between 10 and 500 MPa. Temperatures in the range between 400 and 900 ° C should be used for heating and foaming.
  • the component according to the invention can also be cold-formed even after foaming in order to adapt it even better to certain space requirements.
  • the component according to the invention is particularly preferably used in motor vehicles and machine systems, specifically as a sound-absorbing partition and / or sound-absorbing cover for vibrating wall parts and / or sound-absorbing thermal insulation of the entire exhaust line.
  • components with cell walls made of aluminum or aluminum alloys of the foamed cells forming the foam form a multifunctional structural component which not only corresponds to the wishes of an acoustically good effectiveness, but also solves the above-mentioned object and also has other advantages brings:
  • the aluminum structure is dimensionally stable and therefore self-supporting, but also much better thermally insulating compared to compact aluminum .
  • the total weight is relatively low in the extent of the void formation. Disposal can be done together with the other metal components aluminum in particular without separating. The very costly segregation of plastic parts is avoided, particularly when used in automobile construction. The result is a simple recycling process.
  • FIG. 1 schematically shows in cross section part of a type of “front shell” which, with its curved outer side 2, faces the passenger compartment within a motor vehicle.
  • the component consists of an abundance of hollow cells 3, the cell walls 3a of which, as shown in FIG. 3, consist of aluminum. While the surface 2 facing the passenger compartment has an essentially closed, non-porous, thin aluminum skin which extends to the edge part 5, the sound-generating engine compartment can face the open-cell inner side 1, so that the sound enters the cells 3 or in spaces 3c can penetrate between adjacent cells 3.
  • the inherently rigid foam body 8 from the hollow cells absorbs part of the sound waves that pass through the openings 3b in the cell walls 3a and / or into the spaces 3c penetrate neighboring cells 3, which do not, as at the connection point 3c of adjacent cells 3, frit and / or fuse together in the heat used in the foam formation.
  • the aluminum skin 4 and the edge part 5 of the component are formed, for example, by fusing or frying the cell walls 3a.
  • the component according to the exemplary embodiment of FIG. 1 is provided on the inside 1 with recesses 6;
  • the component has a zone B of less thickness at this point than in the other zones A.
  • the minimum thickness of the component should be 2 mm; the layer thickness of the edge part 5 of the component of FIGS. 1 and 2 is approximately 3 mm, while the layer thickness in the zones A is of the order of cm.
  • the distribution of layer thicknesses, cell and cavity sizes and cell wall thicknesses depends on the functions of sound absorption. In many cases, it is advisable to alternate zones of very good sound absorption with zones per se of less good sound absorption, as a result of which very specific overlay functions can be formed.
  • the mixture in a compacting stage under a pressure of, for example, 50 MPa becomes that in FIG. 4 schematically in cross section shown workpiece 7 pressed together.
  • this can have relatively large dimensions and can be designed like a mat or profile.
  • the workpiece 7 can be made like any other workpiece made of normal aluminum or aluminum alloy without additions using known machining methods, such as Bending, milling, cutting, drilling, punching, extrusion, can be brought into any two or three-dimensional shape 7a.
  • the workpiece 7 is foamed in a heating and deformation stage, for example within a hollow mold, to give the foam body 8 shown schematically in cross section in FIG. 4, which has an essentially open-cell foam structure of the cells 3, but can be covered on the outside with a thin skin 4, without significantly affecting the acoustic effectiveness.
  • a temperature of 750 ° C. is sufficient for heating in order to form a foam body 8 with an average porosity of approximately 80% and an average cell size of approximately 0.8 mm.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Multimedia (AREA)
  • Composite Materials (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Soundproofing, Sound Blocking, And Sound Damping (AREA)
  • Powder Metallurgy (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Building Environments (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Golf Clubs (AREA)
  • Electric Suction Cleaners (AREA)
  • Stringed Musical Instruments (AREA)

Claims (16)

  1. Corps composite, isolant thermiquement et acoustiquement, en construction légère, par utilisation d'un corps en mousse (8), formé à partir d'une pièce d'oeuvre (7), déformée par chauffage, qui présente un mélange compacté d'aluminium pulvérulent ou d'alliage d'aluminium (9) et d'agent gonflant et d'agent moussant (10) pulvérulent et au besoin de composé d'oxyde d'aluminium (11) pulvérulent, et avec une porosité moyenne comprise entre 60 et 90 %.
  2. Corps composite selon la revendication 1, caractérisé en ce qu'un grand nombre des cellules (3) du corps en mousse (8) est ouvert.
  3. Corps composite selon la revendication 1 ou 2, caractérisé en ce qu'une partie de la surface (2) du corps en mousse (8) est recouverte d'une mince pellicule d'aluminium (4) non poreuse, sensiblement fermée.
  4. Corps composite selon l'une des revendications précédentes, caractérisé en ce que le corps en mousse (8) présente des zones (A) de plus grande épaisseur et d'autres zones (B) de moindre épaisseur.
  5. Corps composite selon l'une des revendications précédentes, caractérisé en ce que le corps en mousse (8) présente une grosseur de pore ou une grosseur de cellule moyenne entre 0,1 et 1,5 mm et/ou une densité comprise entre 0,3 et 2,0 g/cm3.
  6. Corps composite selon l'une des revendications précédentes, caractérisé en ce que le corps en mousse (8) est noirci sur une face.
  7. Procédé de fabrication d'un corps en mousse (8), dans lequel la poudre (9) présente de l'aluminium ou un alliage d'aluminium, avec une poudre (10) d'un agent moussant dans un rapport compris entre 10 : 1 et 1 000 : 1 (poudre d'aluminium par rapport à la poudre d'agent moussant) mélangée en un mélange réparti de façon sensiblement homogène et compactée pour donner la pièce d'oeuvre (7), par pressage, sous une pression comprise entre 10 et 500 MPa et expansée ensuite en un corps en mousse (8) avec cellules ouvertes, au moins sur une face, par chauffage entre 400 et 900 °C, caractérisé en ce que la poudre (9) présentant l'aluminium ou un alliage d'aluminium et la poudre d'agent moussant (10) avec une poudre (11) présentant de l'oxyde d'aluminium, celle-ci dans une proportion pouvant aller jusqu'à 30 % du mélange de poudre totale, sont mélangées et le chauffage est conduit de manière qu'il en résulte une porosité moyenne comprise entre 60 et 90 % du corps en mousse (8) isolant thermiquement et acoustiquement.
  8. Corps composite selon la revendication 7, caractérisé en ce que la pièce d'oeuvre (7 ou 7a) est chauffée, dans une forme sensiblement fermée, de manière qu'elle remplisse totalement celle-ci lors de l'expansion et se déforme dans la forme d'un corps en mousse (8), tout en n'étant pas absolument nécessaire que la pièce d'oeuvre (7a) doive être adaptée dans sa forme à la forme du corps en mousse (8) définitif, avant l'expansion.
  9. Corps composite selon la revendication 7, caractérisé en ce que la pièce d'oeuvre (7 ou 7a) est librement expansée puis est plus ou moins fortement comprimée et amenée ainsi à l'épaisseur définitive.
  10. Corps composite selon l'une des revendications 7 à 9, caractérisé en ce que le corps en mousse (8) est en supplément déformé à froid.
  11. Procédé selon l'une des revendications 7 à 10, caractérisé en ce que la pièce d'oeuvre est noircie sur une face par graphitage.
  12. Utilisation d'un élément de construction selon l'une des revendications 1 à 6 en tant qu'élément de construction d'isolation phonique, par exemple cloison, dans des véhicules automobiles, des avions, des bateaux ou des installations motrices.
  13. Utilisation d'un élément de construction selon l'une des revendications 1 à 6 en tant que couverture d'isolation phonique de parties de paroi vibrantes dans des véhicules automobiles, des avions, des bateaux ou des installations motrices.
  14. Utilisation d'un élément de construction selon l'une des revendications 1 à 6 en tant qu'élément de construction d'isolation thermique dans des véhicules automobiles, des avions, des bateaux ou des installations motrices.
  15. Utilisation d'un élément de construction selon l'une des revendications 1 à 6 en tant qu'élément de construction d'isolation ou d'amortissement du bruit et d'isolation thermique dans des véhicules automobiles, des avions, des bateaux ou des installations motrices.
  16. Utilisation d'un élément de construction selon l'une des revendications 1 à 6 en tant qu'élément de construction structurel autoporteur dans des véhicules automobiles, des avions, des bateaux ou des installations motrices.
EP93114133A 1992-09-18 1993-09-03 Elément composite pour isoler la température ou le son, son procédé de fabrication et l'utilisation Revoked EP0588182B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE9212607U 1992-09-18
DE9212607U DE9212607U1 (de) 1992-09-18 1992-09-18 Schallwellen dämpfendes und/oder dämmendes Bauelement aus Schaumstoff

Publications (3)

Publication Number Publication Date
EP0588182A2 EP0588182A2 (fr) 1994-03-23
EP0588182A3 EP0588182A3 (fr) 1995-05-31
EP0588182B1 true EP0588182B1 (fr) 1997-05-07

Family

ID=6883912

Family Applications (1)

Application Number Title Priority Date Filing Date
EP93114133A Revoked EP0588182B1 (fr) 1992-09-18 1993-09-03 Elément composite pour isoler la température ou le son, son procédé de fabrication et l'utilisation

Country Status (7)

Country Link
EP (1) EP0588182B1 (fr)
AT (1) ATE152851T1 (fr)
CZ (1) CZ282028B6 (fr)
DE (2) DE9212607U1 (fr)
ES (1) ES2102566T3 (fr)
HU (1) HU215772B (fr)
PL (1) PL172699B1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7682577B2 (en) 2005-11-07 2010-03-23 Geo2 Technologies, Inc. Catalytic exhaust device for simplified installation or replacement
US7682578B2 (en) 2005-11-07 2010-03-23 Geo2 Technologies, Inc. Device for catalytically reducing exhaust
US7722828B2 (en) 2005-12-30 2010-05-25 Geo2 Technologies, Inc. Catalytic fibrous exhaust system and method for catalyzing an exhaust gas

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AT406649B (de) * 1996-05-02 2000-07-25 Mepura Metallpulver Verfahren zur herstellung von porösen matrixmaterialien, insbesondere formkörpern, auf basis von metallen, und von halbzeug dafür
DE19852277C2 (de) * 1998-11-13 2000-12-14 Schunk Sintermetalltechnik Gmb Verfahren zur Herstellung eines metallischen Verbundwerkstoffes sowie Halbzeug für einen solchen
DE19927837C1 (de) * 1999-06-18 2001-01-25 Schwaebische Werkzeugmaschinen Verfahren zum Herstellen eines Metallbauteils aus Metallschaum für eine Werkzeugmaschine
DE10034301C2 (de) * 2000-07-14 2002-06-13 Bruss Dichtungstechnik Schallgedämpftes Gehäuse für Geräusch erzeugende Maschinen
US6820923B1 (en) * 2000-08-03 2004-11-23 L&L Products Sound absorption system for automotive vehicles
GB0019913D0 (en) 2000-08-15 2000-09-27 Ventures & Consultancy Bradfor Sound absorbing material
US6793274B2 (en) 2001-11-14 2004-09-21 L&L Products, Inc. Automotive rail/frame energy management system
US7043815B2 (en) 2002-01-25 2006-05-16 L & L Products, Inc. Method for applying flowable materials
GB0203472D0 (en) * 2002-02-14 2002-04-03 Acoutechs Ltd Sound absorbing material
DE10246596C5 (de) * 2002-10-05 2010-01-28 J. Eberspächer GmbH & Co. KG Schalldämpfer, insbesondere für Heizgerät
US7180027B2 (en) 2004-03-31 2007-02-20 L & L Products, Inc. Method of applying activatable material to a member
DE202005006240U1 (de) * 2005-04-18 2005-10-20 Seeliger, Hans-Wolfgang Metallschaum-Sandwichs
US7211232B1 (en) 2005-11-07 2007-05-01 Geo2 Technologies, Inc. Refractory exhaust filtering method and apparatus
DE102006025933A1 (de) * 2006-05-10 2007-11-22 WKW Erbslöh Automotive GmbH Dachreling sowie Verfahren zur Herstellung einer solchen Dachreling
GB201207481D0 (en) 2012-04-26 2012-06-13 Zephyros Inc Applying flowable materials to synthetic substrates
PL241832B1 (pl) * 2018-04-19 2022-12-12 Akademia Gorniczo Hutnicza Im Stanislawa Staszica W Krakowie Sposób recyklingu wiórów z aluminium lub jego stopów
CN111824061A (zh) * 2019-04-16 2020-10-27 宁波均胜汽车安全系统有限公司 一种安全带降噪装置

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7682577B2 (en) 2005-11-07 2010-03-23 Geo2 Technologies, Inc. Catalytic exhaust device for simplified installation or replacement
US7682578B2 (en) 2005-11-07 2010-03-23 Geo2 Technologies, Inc. Device for catalytically reducing exhaust
US7722828B2 (en) 2005-12-30 2010-05-25 Geo2 Technologies, Inc. Catalytic fibrous exhaust system and method for catalyzing an exhaust gas

Also Published As

Publication number Publication date
PL300380A1 (en) 1994-03-21
ES2102566T3 (es) 1997-08-01
HUT68467A (en) 1995-06-28
EP0588182A3 (fr) 1995-05-31
PL172699B1 (pl) 1997-11-28
CZ193693A3 (en) 1994-04-13
HU215772B (hu) 1999-02-01
DE9212607U1 (de) 1994-02-24
DE59306374D1 (de) 1997-06-12
EP0588182A2 (fr) 1994-03-23
CZ282028B6 (cs) 1997-04-16
HU9302579D0 (en) 1994-03-28
ATE152851T1 (de) 1997-05-15

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