EP1430473A1

EP1430473A1 - Sound-shielding, soundproofing and/or sound-absorbing device, use thereof and production of the same

Info

Publication number: EP1430473A1
Application number: EP02779269A
Authority: EP
Inventors: Franz Schweiggart; Klaus Pfaffelhuber
Original assignee: Faist Automotive GmbH and Co KG
Current assignee: Faist Automotive GmbH and Co KG
Priority date: 2001-09-27
Filing date: 2002-08-20
Publication date: 2004-06-23
Also published as: WO2003030144A1; DE10147645A1

Abstract

The aim of the invention is to improve the production of thin panels, in particular that are provided with a pattern of recesses or protuberances and/or slit-type perforations. To achieve this, the recesses (13) or prominent sections (12) are slit on at least one side; the slits (2) can be offset individually and/or in groups (12, 12a) in relation to one another, in such a way that part of each slit (2) or group of slits (2) is offset in relation to neighbouring slits (2a) or groups of slits (12a).

Description

Device for shielding, insulating and / or damping sound, and use and method for

Making the same

The invention relates to a device of the type mentioned in the preamble of claim 1 and to uses and methods for producing the same.

Sound shielding elements are already known (WO 00/68039), which are used to protect against sound propagation from the noise area of a room into a neighboring room and / or to cover sound reflecting and / or sound generating components. Although such sound shielding elements have already proven themselves, despite a relatively small perforation area ratio (proportion of the plate area or layer area occupied by perforations in the total area of the plate or layer), problems arise during deformation, for example with relatively low bending rates, which often lead to cracks in the plate or shift. This difficulty arises especially when the sound shielding element is not covered with additional layers, but instead consists for example of only a single metal layer or metal foil. The invention is based on the problem of crack formation, in particular when deforming, in a simple manner and / or to simplify production.

The invention is characterized in claims 1, 20, 21 and 23. Particular embodiments of the invention are claimed in subclaims.

In the invention, the slots are arranged individually and / or in groups offset from one another such that at least a part of a slot or a group of slots is offset with respect to the adjacent slots or adjacent groups of slots with respect to the slot orientation, as is e.g. is shown in Fig. 13. The longitudinal directions of the slots can run parallel, provided that the slots opposite adjacent slots e.g. are laterally offset. However, there may also be a partial overlap of slot parts of adjacent slot groups or rows of slots, as is the case e.g. is shown in Fig. 3. However, an overlap is not a prerequisite for the invention.

The offset can also be done by offset the longitudinal direction of the slots e.g. 2 take place. It is advisable to offset the longitudinal alignment of adjacent slots or adjacent groups of slots from 70 ° to 110 °, in particular approximately 90 °, from one another. This gives the slotted plate or layer according to the invention optimal structuring with regard to subsequent non-cutting deformation processes.

An arrangement is particularly preferred in which a slot has a certain orientation both at its ends and is arranged in the region of its center at a distance from such adjacent slots, the longitudinal slot direction (alignment) of which is arranged orthogonally or at right angles to the slot alignment of the first-mentioned slot. This results in a kind of “weave pattern”, for example according to FIG. 2.

However, it is also possible to arrange all the slots in a common alignment with their longitudinal axes in the plate or layer in such a way that parallel rows of slots running one behind the other are created. A slot in a row should be spaced apart from adjacent slots in an adjacent row so that the former slot covers not only the distance between the adjacent slots in the adjacent row, but also a partial length of these adjacent slots in the adjacent row.

In the case of the alignment of slots of adjacent rows, in particular offset by 90 °, it may also be advisable to have these rows of slots aligned in the same way in each case in a wave-like or stair-shaped manner, for example according to the figure.

A chessboard-like grouping of slots, for example according to FIG. 6, also offers particular advantages, according to which groups of slots of the same direction are alternated by neighboring groups of slots of different directions.

For the slot width b, dimensions between 0.05 mm and 0.15 mm and slot lengths 1 from 0.8 mm to 8 mm are recommended. The slots should have a spacing A between 0.5 mm and 5 mm, in particular between 1 mm and 3 mm, from one another.

The slot area ratio, i.e. the area ratio of the slots to the total area of the plate should be between 0.001 and 8%, in particular between 0.1 and 6%.

The slots are expediently produced by means of lifting knives, as are e.g. used for the production of expanded metal, or by punching tools with knife inserts or cutting edges. Rotary rollers with sharp edges or cutting edges are also preferred.

Furthermore, an embodiment is preferred in which the cutting tool for forming a slot has an upper punch provided with a cutting edge and a lower punch provided with a pocket-shaped recess. The cutting edge forms the part of the plate or layer material that it has contacted into the recess and shears - to form a slit - a part of the formed material part, in particular from the unmolded material part.

In another embodiment of the invention, it is ensured that slots are formed at the sharp-edged transition points between floors of depressions or elevations on the one hand and the adjacent wall parts on the other hand, so that the floors are connected to adjacent wall parts only on opposite sides. The bottoms are then, as it were, broken out or sheared off on two sides from the plane of the plate, in particular knob plate, which is done in a very simple manner by the interlocking being sufficiently deep Embossing teeth of embossing rollers or embossing wheels or the like takes place.

So-called. "Knob plates" are known per se (EP 0149844 A), but have no such slots.

It is advisable to run the slits in parallel rows with the spacing given by the width of the relevant floor or recess. For this purpose, the tooth width b of the embossing teeth is preferably chosen between 0.1 mm and 20 mm, in particular between 0.5 mm and 2 mm.

Preferred embodiments of the invention are described below with the aid of the drawing, which are particularly recommended for use in components which serve to shield noise sources, such as in motor vehicles or in mechanical engineering. Show:

1 shows a partial view of a motor vehicle built-in part in which the sound shielding element according to the invention is produced as a molded part and is used to cover part of the engine;

FIG. 2 shows a pattern of slots designed and arranged according to the invention, in a plan view of the plate or layer in question, to be precise on a large scale;

FIG. 3 shows another pattern of the slot arrangement with parallel rows of slots;

FIG. 4 shows a slit pattern in which rows of identically aligned slits are each arranged in a wave shape; Figure 5 is a plan view of a plate with angled slots;

FIG. 6 shows a plan view of a plate with a checkerboard pattern constructed according to the invention, each of groups of slots oriented in the same direction in the vicinity of groups of slots oriented orthogonally thereto.

Figure 7 is a greatly enlarged plan view of part of a knob plate designed according to the invention and

FIG. 8 shows a partial section (A-A) through this,

Figure 9 is a partial oblique view of a knobbed plate according to the prior art;

FIG. 10 shows a schematic cross section on the area of a pair of embossing rollers or embossing wheels, which forms sheet-like material into the knobbed plate;

Figure 11 is a schematic plan view of the embossing roller or embossing wheel pair with the center distance A between the two;

Figure 12 schematically shows a multi-curved sound shield plate;

Figure 13 is a plan view of a portion of a sound shield plate;

Figure 14 is a section A-A of Figure 13;

FIG. 15 shows a schematic cross section through a tool during shear-forming and 16a, b and c three different upper punches for the tool shown in FIG.

The soundproofing or shielding element according to FIG. 1 serving as the motor cover is made from a thin plate (1) with a thickness of 0.8 mm. Over almost the entire area, the sound shielding element is provided with many small openings, most of which openings are in the form of slots (2) and are assembled here in a checkered pattern of groups 12, 12a of differently inclined slots. Part of the sound shielding element can also be broken through in the form of round holes (2d). Larger openings or cutouts (3) are used for fastening to the chassis of the motor vehicle by inserting screws through the openings (3) and screwing the sound shielding element tight. This represents a kind of three-dimensionally deformed plate (1), is shaped according to the formations of the motor housing and has small connecting flanges (4) on the outside. Also in the area of strong curvature, i.e. with a small bending radius, for example on the side (10), tearing during deformation has been avoided due to the slot arrangement according to the invention. The slots (2) and holes (2d) are also used for "deadening" since they significantly change the vibration behavior of the three-dimensionally deformed plate (1) despite the small dimensions.

According to Figure 2, rows of slots (2) are arranged, the longitudinal direction of which point in the same direction (from top to bottom). The slots (2) of these rows are interleaved with neighboring slots (2a) of rows of slots in such a way that the orientations or longitudinal directions of these neighboring slots (2a) are orthogonal, ie at right angles (α = 90 °) to the alignment the first mentioned slots (2), here from right to left. The slot width (b) is 0.1 mm and the slot length (1) is 3 mm. The distance (A) is 2 mm, so that there is a distance (AI) of about 0.5xA, more precisely 0.95 mm.

In the embodiment of Figure 3, the slot width (b) is about 0.1 mm with a slot length (1) of 6 mm and a distance (A) of slots (2) of the same row of slots of 2 mm. As a result, the ends of the slot (2) each overlap a partial length (T1) of the slots (2) of the row 6 adjacent to a row 5. The slot arrangement is symmetrical, i.e. that the center line (M) of a slot (2) of the row 6 runs exactly between the ends of the adjacent row 5. The distance (A) of the rows 5, 6 is about 2.6 mm.

4, the slot width (b) is 0.1 mm, while a slot length (1) of 1.5 mm was chosen. The distances (A) between adjacent slots (2a) of the same slot row 5 as well as between slots (2, 2a) of adjacent rows 6 are here about 1 mm, if this is possible. However, due to the undulating course of the rows 5, 6 of the slots (2, 2a), there is inevitably sometimes a greater distance.

In the case of the angular slots (2b) according to FIG. 5, the slot arms (2c) are angled at right angles α1 = 90 ° to one another. The slot arms (2c) of adjacent angle slots (2b) arranged in a row also run at an equal angle α of 90 °. Here too the slot width is 0.1 mm and the slot lengths (11) of the slot arms (2c) 1.5 mm. This results in distances (A) between adjacent slots of adjacent rows between 1 mm and 1.5 mm. The distance (AI) between the points pointing away from each other in the center of adjacent and offset angular slots (2b) is 3 mm and the distance (A2) of the tips from adjacent angular slots (2b) of the same row is approximately 2.9 mm.

FIG. 6 shows three different checkerboard patterns a, b and c of slot groups. A group (12) of four rectified slots (2) in this example is arranged on the four sides of the square-shaped group (12) by a neighboring group (12a) of adjacent slots (2a) oriented orthogonally to the first slots (2) ,

According to FIG. 7, a pattern of elevations 12 and depressions 13 is embossed from the plane of the plate 1, in particular aluminum with a plate thickness d of 0.5 mm, as is shown better and enlarged in the partial cross section of FIG. The most embossed bottoms 14 of the elevations 22 and depressions 13 are at their ends 17 via the wall parts 15 in connection with the plate material, but are separated on their longitudinal sides from this material, so that there are the slots 2 which barely noticeable in the view of FIG. 7, but clearly appear in the cross section according to FIG.

The slits 2, in conjunction with the nubbed plate configuration, that is to say marked by elevations 22 and depressions 13, enable sound-absorbing quality on the one hand and, on the other hand, better two-dimensional and three-dimensional deformability around bending curves. According to FIGS. 10 and 11, two embossing rollers 20, 20a are located at an axial distance A from one another. These embossing rollers 20, 20a are each provided with a number of embossing wheels 21, 21a, which alternately have large and small outer diameters, which are determined by the embossing teeth 122. The width b of the embossing teeth 122 should be between 0.1 mm and 20 mm, in particular between 0.5 and 2 mm. The width b is limited by relatively sharp edges.

The tooth flanks 23 of the embossing teeth 122 define the wall parts 15, which form transitions from the bottoms 14 of the depressions 13 or elevations 22 of the plate 1. The tooth heads 18, on the other hand, determine the shape of the bottoms 14. The tooth heads 18 are as flat as possible and in particular flat.

According to FIG. 10, flat web-shaped material 25 is pressed into the spaces between intermeshing embossing teeth 122, in particular by means of an auxiliary roller 24, with deformation. The center distance A between the embossing rollers 20, 20a is set so that the bottoms 14 are embossed out of the material to form the slots 2. The knob plate 1 formed in this way leaves the pair of rollers via the auxiliary roller 26 in a straight plane 27, from which the three-dimensional deformation, for example to engine covers, can be carried out without the knob plate tearing in places of small bending radii.

The device shown schematically in FIG. 12 is a heat plate from the tunnel area of the exhaust line of a passenger car (passenger car), which at the same time provides sound-shielding and, because of its structure-borne sound damping, also soundproofing. The plate 1 is bent with relatively small bending radii along the bending lines B, whereby essentially flat plate parts 28, 29, 30 and 31 result. The following bending angles are used, for example:

ß = 45 ° γ = 30 ° δ = 10 °.

The largest areas of these surfaces are provided with slot-like openings or slits, which are not shown in FIG. 12 for the sake of clarity. The area F around a mounting hole - and possibly some other areas - are not perforated with slots.

The type and arrangement of the slots is shown schematically in FIGS. 13 and 14: Here, parallel double rows of slots 2 and adjacent slots 2a are arranged in such a way that the slots 2 in their extension are each in a space between the adjacent slots 2a of the neighboring row or group of neighbors Plate 1 run. According to the section AA of FIG. 13, FIG. 14 shows that the adjacent slots 2a - and accordingly also the slots 2 - are formed on the one hand by reshaping the material part of the plate 1 in question from the plane of the plate and on the other hand by separating the material, in part by shearing are, so that there are pocket-shaped depressions 13, each of which has the slot 2, 2a on one side, but with its other side run uninterruptedly, ie unslotted, into the plane of the plate 1. The manufacture of these pocket-like depressions 13a and slots 2 is illustrated in FIG. 15: The upper punch 32 of a tool is moved in the direction of the arrow toward the lower punch 33 such that the triangular or wedge-shaped shear edge 34 running in the direction of the arrow on one wall 35a of the pocket-shaped Recess 35 of the lower punch 33 slides along. The shear edge 34 presses on the material of the plate 1 in such a way that it is first pressed into the recess 35 with the material part forming the recess 13a and is sheared off at the edge 1b at the edge 1b to form the slot 2 if the material part that has just been deformed sufficiently. At the end of the pocket-like wall part 15 deflected from the plane of the plate there is the sheared edge la. In this type of production, in contrast to the device shown, for example, in FIGS. 7 and 8, each recess 13a has only one slot 2. The slitting and deformation is a kind of punching process of a "punching tool".

The shaping and perforation or slit formation of the device shown in FIG. 12 takes place by means of such a punching tool, which is composed of parts of different angles of inclination β, γ and δ according to FIGS. 16a, b and c; 16, a large number of such upper punches with shear edges 34a, 34b and 34c, as shown in FIG. 16, are distributed over the surfaces 28, 30 and 31 in question, while the essentially flat plate parts 31 are perforated by tool parts, which result from upper punches 32 with the shear edges 34 Figure 15 put together. The production of such a combination tool, which not only bends a flat plate around the bending lines B and carries out additional three-dimensional deformations, but also performs the perforation or slot formation in the manner according to the invention, does indeed require some technical manufacturing effort, but leads to a reduction in mass production costs, since a single operation - the back and forth movement of the upper punch in relation to the lower punch - causes the deformation, shaping and perforation. Another advantage of this manufacturing method is that particularly critical edges and bending line areas remain imperforate, since the perforation or slit formation can be selectively distributed and flat plate material can be used instead of material previously provided with knobs.

The devices designed according to the invention are preferably used for sound insulation and sound shielding, but also for sound damping. It has been shown that the slotted plates have less tendency to emit sound in certain frequency ranges, but instead have a specific structure-borne sound absorption that is comparable to felt material.

Deformable metal sheet made of aluminum, for example, is particularly suitable for the material, which due to its high thermal conductivity also ensures that heat is quickly dissipated from the engine compartment to the surroundings. Such a sound shielding element is stable up to very high temperatures and can therefore also be used as a heat shield in high-temperature areas in which plastic parts are less suitable.

The invention is also applicable to molded plastic parts.

Claims

Expectations

1. Device for shielding, damping and / or damping sound with at least one plate (1) or layer of a thickness (d) between 0.01 and 50 mm, the many small slot-like openings or slots (2, 2a) of a slot width between 0.001 and 2 mm with a slot area ratio between 0.001 and 8%, characterized in that the slots (2, 2a) are arranged individually and / or in groups (12, 12a) offset from one another in such a way that in each case at least part of a slot (2) or a group (12) of slots (2) with respect to neighboring slots (2a) or neighboring groups (12a) of slots (2a) and / or that slots (2) on at least one side of depressions (13) or elevations (22) of the plate (1) are arranged, while the unslit sides of the depressions (13) or elevations (22) are connected to adjacent plate parts or wall parts (15).

2. Device according to claim 1, characterized in that the depressions (13) form bottoms (14).

3. Apparatus according to claim 2, characterized in that slots (2) are arranged on opposite sides of floors (14).

4. Device according to one of the preceding claims, characterized in that slots (2, 2a) and / or groups (12, 12a) of slots (2, 2a) with their longitudinal directions or orientations at an angle α of about 70 ° to 110 ° to each other.

5. Device according to one of the preceding claims, characterized in that slots are formed as angle slots (2b), the slot arms (2c) are angled at an angle α of about 70 ° to 110 ° to each other.

6. Device according to one of the preceding claims, characterized in that slots (2, 2a) alternate in such a way that in each case one slot (2) of a certain orientation both at the ends and in particular centrally on both sides of adjacent slots (2a) is adjacent, which are aligned by approximately 90 ° to the alignment of the first-mentioned slot (2).

7. Device according to one of the preceding claims, characterized in that slots (2) are aligned substantially parallel to one another in parallel rows (5,6) such that the slots (2) of a row (5) both the distance A from be - adjacent slots (2) of the adjacent rows (6) and a partial length T1 of these adjacent slots (2) overlap.

8. Device according to one of the preceding claims, characterized in that the slots (2, 2a) of a common orientation are each distributed along wavy or staircase-shaped rows.

9. Device according to one of the preceding claims, characterized in that groups (12) of slots (2) of the same direction are each adjacent to neighboring groups (12a) of slots (2a) which are oriented differently in such a way that a checkerboard-like group pattern results.

10. Device according to one of the preceding claims, characterized in that depressions (13) are designed as pocket-like formations (13a) of the plate (1).

11. The device according to claim 10, characterized in that the slots (2, 2a) are formed by shearing off one side of the pocket-like formations (13a) from the in particular flat plate material.

12. Device according to one of the preceding claims, characterized in that that slots (2, 2a) are in the plate parts (28, 29, 30) which are bent relative to the flat part (31) of the plate (1) by a bending angle (β, γ, δ).

13. Device according to one of the preceding claims, characterized in that the slots (2, 2a) have a width b of 0.05 mm to 0.15 mm and a length 1 of 0.8 mm to 8 mm.

14. Device according to one of the preceding claims, characterized in that the slots (2, 2a) are arranged at a distance A of 0.5 mm to 5 mm from each other.

15. Device according to one of the preceding claims, characterized in that the slots (2) run in parallel rows.

16. Device according to one of the preceding claims, characterized by a three-dimensional deformation of the plate (1) or layer.

17. Use of a device according to one of the preceding claims as a sound shielding element.

18. Use of a device according to one of the preceding claims as a vibration-damped component.

19. A method for producing an in particular three-dimensionally deformable device according to claim 1, in which a thin web (25) or plate of the plate material between embossing rollers (20, 20a) or embossing wheels (21, 21a) is deformed, which have tooth-shaped deformation elements or embossing teeth (122) in cross section, the tooth flanks (23) of which are the shape of wall parts (15) and the tooth heads (18) of which are the shape of the bottoms of depressions (13) or elevations (22) of the Determine plate (1), characterized in that narrow embossing teeth (122) with a tooth width b between 0.1 mm and 20 mm, in particular between 0.5 mm and 2 mm, are used and that the engagement of the embossing teeth (122) of the embossing rollers (25, 25a) or embossing wheels (21, 21a) is set so deep that the web (25) or blank slits or breaks when passing through the roll gap at the edges of the embossing teeth (122) to form slots (2) becomes.

20. A method for producing an in particular three-dimensionally deformable device according to claim 1, in which a thin web (25) or plate of the plate material is deformed in a pressing tool which has tooth-shaped deformation elements or compression or embossing teeth (122) on deformation surfaces in cross section. whose tooth flanks (23) determine the shape of wall parts (15) and whose tooth tips (18) determine the shape of the bottoms of depressions (13) or elevations (22) of the plate (1), characterized in that narrow embossing teeth (122) one Tooth width b between 0.1 mm and 20 mm, in particular between 0.5 mm and 2 mm, are used and that the engagement of the embossing teeth (122) of the deformation surfaces of the pressing tool is set so deep that the web (25) or blank during the pressing process on the edges of the embossing teeth (122) to form slots (2).

21. The method according to claim 19 or 20, characterized in that the thin web (25) or board is alternatively provided with slots (2) in an additional process step before and / or after the embossing (or pressing).

22. A method for producing a device according to claim 1, in which the plate (1) or layer are provided with the openings or slots (2, 2a) by means of a tool, characterized in that a punching tool is used as the tool, the upper stamp (32) have a shear edge (34) and its lower punch (33) has a pocket-shaped recess (35) for receiving the depression (13) or elevation (22) formed when the plate material is formed, and that the upper punch (32) is so far open the lower punch (33) is moved so that the shear edge (34) not only reshapes the plate material, but also shears it off to form a slit.