EP1534505A1 - Multi-ply sound-proofing and thermal insulation part - Google Patents

Multi-ply sound-proofing and thermal insulation part

Info

Publication number
EP1534505A1
EP1534505A1 EP03793613A EP03793613A EP1534505A1 EP 1534505 A1 EP1534505 A1 EP 1534505A1 EP 03793613 A EP03793613 A EP 03793613A EP 03793613 A EP03793613 A EP 03793613A EP 1534505 A1 EP1534505 A1 EP 1534505A1
Authority
EP
European Patent Office
Prior art keywords
layer
foam
insulation part
sound
elevations
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.)
Withdrawn
Application number
EP03793613A
Other languages
German (de)
French (fr)
Inventor
Christian GNÄDIG
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.)
Carcoustics Techconsult GmbH
Original Assignee
Carcoustics Tech Center GmbH
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
Application filed by Carcoustics Tech Center GmbH filed Critical Carcoustics Tech Center GmbH
Publication of EP1534505A1 publication Critical patent/EP1534505A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0285—Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/06—Open cell foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/003—Interior finishings

Definitions

  • the invention relates to a multilayer sound and heat insulation part, in particular for motor vehicles, with at least one three-dimensionally structured foam layer and at least one non-woven layer lying thereon, the foam layer having a multiplicity of elevations and / or depressions.
  • Such a sound and heat insulation part is known for example from WO 00/34943 AI.
  • the foam layer of the known insulation part consists of polyimide foam and runs zigzag-för ig, wherein in the gussets of the zigzag shape in cross-section approximately V-shaped cavities are present between the foam and the nonwoven layer.
  • the nonwoven layer is placed on the foam sheet without gluing, lamination or the like. The two layers are held together by an edge-welded wrapping film.
  • DE 198 21 532 AI describes a heat and sound-insulating covering for the engine compartment of motor vehicles.
  • This cladding consists of an engine-side cover layer, an acoustically insulating thermoplastic foam layer that is in contact with it and permanently temperature-resistant up to 180 ° C, an insulating layer of plastic foam or nonwoven fabric that is in contact with it, and one
  • the foam layer and the insulating layer made of plastic foam or nonwoven fabric in contact with it can have a raster-shaped profile, which consists for example of convex bulges.
  • the layers of the cladding are connected to each other by glue.
  • DE 198 21 532 AI does not contain a drawing of the cladding described.
  • the present invention had for its object to provide a multi-layer sound and heat insulation part of the type mentioned, which is particularly easy and inexpensive to manufacture.
  • this object is achieved in that the nonwoven layer is needled onto the foam layer in such a way that the nonwoven layer rests against the foam layer parallel to the contour and the elevations and / or depressions of the foam layer are also pronounced in the surface of the nonwoven layer facing away from it.
  • the composite of fleece layer and foam layer of the insulation part according to the invention is thus produced without adhesive, so that costs for adhesive are saved and the weight of the insulation part is reduced accordingly.
  • By avoiding the use of adhesive emissions caused by the adhesive and possibly polluting the environment can be avoided.
  • Dispensing with adhesive also simplifies the recycling of corresponding insulation parts.
  • the insulating part according to the invention has a relatively large nonwoven layer surface, since the nonwoven layer rests against the three-dimensionally structured foam layer and thus essentially does so
  • MY / sb 0_0S_5WO has the same profile as the foam bed with a large acoustically effective surface.
  • the shape of the surface profile of the foam layer in the nonwoven layer can also be advantageous with regard to the optical effect of the insulating part if the nonwoven layer represents the visible side of the insulating part.
  • the insulation part according to the invention can thus in particular also have a design function.
  • the needling of the nonwoven layer to the foam layer can be done mechanically or by means of water jet technology.
  • the elevations and / or depressions of the foam layer can be arranged regularly or irregularly. However, they are preferably arranged essentially uniformly, in particular in the form of a grid.
  • the grid can be square, rectangular or route-shaped.
  • the foam layer preferably consists of open-cell foam.
  • the foam layer can preferably be made of melamine resin foam.
  • the nonwoven layer can consist of a spunbonded web or a needle punched web.
  • the fibers of the nonwoven layer can in particular be synthetic fibers.
  • the nonwoven layer can also be formed from an aluminum fiber fleece.
  • An advantageous embodiment of the insulation part according to the invention consists in the fact that the nonwoven layer is needled in the area of depressions on the foam layer and in the area of elevations it lies without needling on the foam area. On the one hand, this prevents perforation of the nonwoven layer in the region of the elevations, which may be desirable for the visual appearance of the nonwoven layer, and on the other hand facilitates separation of the nonwoven layer and foam layer when the insulation part is recycled later.
  • Figure 1 is a perspective view of a portion of an insulation part according to the invention.
  • FIG. 2 shows a cross-sectional view of the insulation part according to FIG. 1;
  • FIG. 3 shows a cross-sectional view of an insulation part according to a second exemplary embodiment of the invention.
  • Fig. 4 is a schematic representation of a system for producing an insulation part according to the invention.
  • the insulation part 1 shows the visible side of a portion of an insulation part 1 according to the invention.
  • the insulation part 1 is essentially plate-shaped. It is made of a three-dimensionally structured foam layer 2
  • the foam layer 2 has a plurality of nub-shaped elevations 4 or trough-shaped depressions 5, which are arranged in a grid.
  • the elevations 4 and depressions 5 were produced in the foam layer 2, for example by profile cutting and / or compression molding before the nonwoven covering.
  • the layer thickness of the foam layer 2, including the elevations 4, is in the range of approximately 5 to 20 mm.
  • the layer thickness of the nonwoven layer 3 can be, for example, 1 to 5 mm.
  • the foam layer 2 is only structured on one side, i.e. the opposite side of the foam layer 2 is essentially flat. If necessary, however, the foam layer 2 can also be profiled on both sides and can also be provided on the underside with a further plastic or textile layer (see FIG. 3) and / or a plastic or metal foil (not shown).
  • the nonwoven layer 3 is needled on the foam layer 2, so that it lies against the foam layer 2 in parallel with the contour.
  • the elevations 4 and depressions 5 of the foam material 2 are thus also pronounced in the surface of the nonwoven layer 3.
  • the bond between the nonwoven layer 3 and the foam layer 2 is thus carried out without adhesive.
  • the needling of the nonwoven layer 3 on the foam layer 2 can be carried out by means of a lifting and lowering needle bar, which has a plurality of needles aligned parallel to one another.
  • the needling of the nonwoven layer 3 can also be done using water
  • MY / sb 0-06-5WO Blasting technology ie with a variety of fine high pressure water jets.
  • the needles or water jets pull a large number of fibers 6 of the nonwoven layer 3 into the foam material 2, so that sections of these fibers 6 are sufficiently firmly anchored or clawed in the foam material layer.
  • a large number of fibers 6 extend to the underside of the foam layer. 2
  • sections of these fibers 6 remain anchored or clawed in the nonwoven layer 3.
  • the nonwoven layer 3 is needled to the foam layer 2 essentially uniformly and over the entire surface.
  • the needling can also take place in such a way that the nonwoven layer 3 is needled only in the area of the depressions 5 and lies in the area of the elevations 4 without needling on the foam layer 2.
  • the foam layer 2 preferably consists of open-cell foam, for example of melamine resin foam. However, it is also possible to use an essentially closed-cell foam for the foam layer 2.
  • the exemplary embodiment shown in FIG. 3 initially differs from that in FIG. 2 in that the foam layer 2 is structured three-dimensionally on both sides.
  • the structuring consists on both sides of the foam layer 2 from a multiplicity of knob-shaped elevations 4 or trough-shaped depressions 5, which in turn are arranged in a grid. It can be seen that an elevation 4 on one side of the foam layer 2 is opposite a depression 5 on the opposite side, and vice versa.
  • the exemplary embodiment in FIG. 3 differs from that in FIG. 2 in that the profiled foam layer 2 is provided on both sides with a nonwoven layer 3, 3 '.
  • the second nonwoven layer 3 ' is also needled to the foam layer 2 in such a way that it rests on the foam layer 2 parallel to the contour. Accordingly, the elevations 4 and depressions 5 of the foam layer 2 facing it are clearly pronounced in their surface.
  • the two fleece layers 3, 3 ' can be formed from different fleece material.
  • the insulation part 1 according to the invention is particularly suitable for soundproofing and heat-insulating cladding of interior surfaces in motor vehicles.
  • the nonwoven layers 3, 3 ' are preferably formed from a spunbond, needle punch and / or aluminum fiber fleece.
  • the use of an aluminum fiber fleece is particularly advantageous when the insulation part 1 according to the invention is to be used as an acoustically effective heat shield.
  • the aluminum fiber fleece in particular has a heat-reflecting effect.
  • the foam layer 2 can in this case advantageously consist of melamine resin foam, which is known to have a relatively high temperature resistance.
  • the foam layer denoted by 2 is in the form of a material web which is first conveyed to a station 7, in which the foam layer 2 at least
  • MY / sb 020635WO is profiled on one side by contour cutting and / or compression molding.
  • a nonwoven layer 3, 3 ' is then applied to the profiled surface of the foam layer 2.
  • the fleece layer 3, 3 ' can also be present as a material web and can be fed from a supply roll.
  • the merged material webs 2, 3, 3 'then pass through a needling station, which is formed here by way of example from two needle bars 8, 9 that can be raised and lowered.
  • the opposing needle bars 8, 9 are prestressed by means of springs (not shown) or the like, so that they maintain a certain distance orthogonally to the material webs 2, 3, 3 'brought together.
  • the needle bars 8, 9 are each assigned a cam drive 10, 11, which moves the respective needle bar against the action of the spring on the material webs, so that the needles of the respective needle bar 8, 9 are intermittently inserted into the fleece layer 3 or 3 'and the foam layer Pierce 2 and connect the respective fleece layer 3, 3 'to the foam layer 2.
  • a needle bar instead of mechanical needling using a needle bar, hydraulic needling using water jets or the like can also be used.
  • the composite of foam layer 2 and nonwoven layer 3 or nonwoven layers 3, 3 'produced by the needling is finally wound up in roll form for transport to a further processing station, for example a cutting station for producing certain blanks. It goes without saying that the composite can also be further processed, in particular tailored, directly behind the needling station.

Landscapes

  • Laminated Bodies (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Nonwoven Fabrics (AREA)
  • Thermal Insulation (AREA)

Abstract

The invention relates to a multi-ply sound-proofing and thermal insulation part (1), in particular for motor vehicles, comprising at least one three-dimensionally structured foamed plastic layer (2), which has a plurality of elevations (4) and/or recesses (5), and at least one non-woven layer (3) lying adjacent to said plastic layer. The aim of the invention is to produce a lightweight insulation part of this type in a cost-effective manner. To achieve this, the non-woven layer (3) is tacked onto the foamed plastic layer (2), in such a way that the non-woven layer follows the contours of the foamed plastic layer and the elevations (4) and/or recesses (5) of the foamed plastic layer (2) are also pronounced in the surface of the non-woven layer (3) facing away from the plastic layer. The composite of the non-woven layer and foamed plastic layer of the insulation part is thus produced without adhesive, saving the cost of said adhesive and reducing the weight of the insulation part accordingly.

Description

Mehrlagiges Schall- und Wärmeisolationsteil Multi-layer sound and heat insulation part
Die Erfindung betrifft ein mehrlagiges Schall- und Wärmeisolationsteil, insbesondere für Kraftfahrzeuge, mit mindestens einer dreidimensional strukturierten Schaumstoffläge und mindestens einer daran anliegenden Vlieslage, wobei die Schaumstoffläge eine Vielzahl von Erhebungen und/oder Vertiefungen aufweist.The invention relates to a multilayer sound and heat insulation part, in particular for motor vehicles, with at least one three-dimensionally structured foam layer and at least one non-woven layer lying thereon, the foam layer having a multiplicity of elevations and / or depressions.
Ein derartiges Schall- und Wärmeisolationsteil ist beispielsweise aus der WO 00/34943 AI bekannt. Die Schaumstofflage des bekannten Isolationsteils besteht aus Polyimidschaumstoff und verläuft zick-zack-för ig, wobei in den Zwickeln der Zick-Zack-Form im Querschnitt etwa V-förmige Hohlräume zwischen der Schaumstoffl ge und der Vlieslage vorhanden sind. Die Vlieslage ist ohne Verklebung, Kaschierung oder dergleichen auf der Schaumstoffläge aufgelegt. Die beiden Lagen sind durch eine randverschweißte Umhüllungsfolie zusammengehalten.Such a sound and heat insulation part is known for example from WO 00/34943 AI. The foam layer of the known insulation part consists of polyimide foam and runs zigzag-för ig, wherein in the gussets of the zigzag shape in cross-section approximately V-shaped cavities are present between the foam and the nonwoven layer. The nonwoven layer is placed on the foam sheet without gluing, lamination or the like. The two layers are held together by an edge-welded wrapping film.
Weiter ist in der DE 198 21 532 AI eine wärme- und schalldämmende Verkleidung für den Motorraum von Kraftfahrzeugen beschrieben. Diese Verkleidung besteht aus einer motorseitigen Deckschicht, einer damit in Kontakt befindlichen, akustisch isolierenden, bis 180 °C dauertemperaturbeständigen, duroplastischen Schaumstoffschicht, einer damit in Kontakt befindlichen isolierenden Schicht aus Kunststoffschäum oder Faservlies, und einerFurthermore, DE 198 21 532 AI describes a heat and sound-insulating covering for the engine compartment of motor vehicles. This cladding consists of an engine-side cover layer, an acoustically insulating thermoplastic foam layer that is in contact with it and permanently temperature-resistant up to 180 ° C, an insulating layer of plastic foam or nonwoven fabric that is in contact with it, and one
MY/sb 0_063ΞWO damit in Kontakt befindlichen, der Motorseite abgewandten Deckschicht. Die Schaumstoffschicht und die damit in Kontakt befindliche isolierende Schicht aus Kunststoffschaum oder Faservlies können eine rasterför ige Profilierung aufweisen, die beispielsweise aus konvexen Ausbuchtungen besteht. Die Schichten der Verkleidung sind durch Kleber miteinander verbunden. Die DE 198 21 532 AI enthält keine Zeichnung der beschriebenen Verkleidung.MY / sb 0_06 3 ΞWO in contact with it, facing away from the motor side. The foam layer and the insulating layer made of plastic foam or nonwoven fabric in contact with it can have a raster-shaped profile, which consists for example of convex bulges. The layers of the cladding are connected to each other by glue. DE 198 21 532 AI does not contain a drawing of the cladding described.
Der vorliegenden Erfindung lag die Aufgabe zugrunde, ein mehrlagiges Schall- und Wärmeisolationsteil der eingangs genannten Art zu schaffen, das besonders leicht sowie kostengünstig herstellbar ist.The present invention had for its object to provide a multi-layer sound and heat insulation part of the type mentioned, which is particularly easy and inexpensive to manufacture.
Diese Aufgabe wird erfindungsgemäß dadurch gelöst, dass die Vlieslage an der Schaumstoffläge angenadelt wird, derart, dass die Vlieslage konturparallel an der Schaumstoffläge anliegt und die Erhebungen und/oder Vertiefungen der Schaumstoffläge auch in der davon abgewandten Oberfläche der Vlieslage ausgeprägt sind.According to the invention, this object is achieved in that the nonwoven layer is needled onto the foam layer in such a way that the nonwoven layer rests against the foam layer parallel to the contour and the elevations and / or depressions of the foam layer are also pronounced in the surface of the nonwoven layer facing away from it.
Der Verbund von Vlieslage und Schaumstoffläge des erfindungsgemäßen Isolationsteils wird somit ohne Klebstoff hergestellt, so dass Kosten für Klebstoff gespart werden und das Gewicht des Isolationsteils entsprechend reduziert wird. Durch einen Verzicht auf Klebstoff können zudem klebstoffbedingte, gegebenenfalls umweltbelastende Emissionen vermieden werden. Auch wird durch den Verzicht auf Klebstoff das Recycling von entsprechenden Isolationsteilen vereinfacht. Insbesondere besitzt das erfindungsgemäße Isolationsteil eine relativ große Vlieslagenoberfläche, da die Vlieslage konturparallel an der dreidimensional strukturierten Schaumstoffläge anliegt und somit im wesentlichen dasThe composite of fleece layer and foam layer of the insulation part according to the invention is thus produced without adhesive, so that costs for adhesive are saved and the weight of the insulation part is reduced accordingly. By avoiding the use of adhesive, emissions caused by the adhesive and possibly polluting the environment can be avoided. Dispensing with adhesive also simplifies the recycling of corresponding insulation parts. In particular, the insulating part according to the invention has a relatively large nonwoven layer surface, since the nonwoven layer rests against the three-dimensionally structured foam layer and thus essentially does so
MY/sb 0_0S_5WO gleiche Profil wie die Schaumstoffläge mit großer akustisch wirksamer Oberfläche aufweist.MY / sb 0_0S_5WO has the same profile as the foam bed with a large acoustically effective surface.
Die Ausprägung des Oberflächenprofils der Schaumstoffläge in der Vlieslage kann auch hinsichtlich der optischen Wirkung des Isolationsteils vorteilhaft sein, wenn die Vlieslage die Sichtseite des Isolationsteils darstellt. Das erfindungsgemäße Isolationsteil kann somit insbesondere auch eine Designfunktion besitzen.The shape of the surface profile of the foam layer in the nonwoven layer can also be advantageous with regard to the optical effect of the insulating part if the nonwoven layer represents the visible side of the insulating part. The insulation part according to the invention can thus in particular also have a design function.
Das Annadeln der Vlieslage an die Schaumstoffläge kann auf mechanischem Wege oder mittels Wasserstrahltechnik erfolgen.The needling of the nonwoven layer to the foam layer can be done mechanically or by means of water jet technology.
Die Erhebungen und/oder Vertiefungen der Schaumstoffläge können regelmäßig oder unregelmäßig angeordnet sein. Vorzugsweise sind sie edoch im wesentlichen gleichmäßig, insbesondere rasterfόrmig angeordnet . Das Raster kann dabei quadratisch, rechteckig oder routenförmig ausgebildet sein.The elevations and / or depressions of the foam layer can be arranged regularly or irregularly. However, they are preferably arranged essentially uniformly, in particular in the form of a grid. The grid can be square, rectangular or route-shaped.
Die Schaumstofflage besteht vorzugsweise aus offen- zelligem Schaumstoff. Zur Herstellung eines besonders leichten sowie schwerentflammbaren Isolationsteils kann die Schaumstofflage vorzugsweise aus Melaminharz- Schaumstoff hergestellt werden.The foam layer preferably consists of open-cell foam. To produce a particularly light and flame-retardant insulation part, the foam layer can preferably be made of melamine resin foam.
Die Vlieslage kann aus einem Spinnvlies oder einem Nadelvlies bestehen. Bei den Fasern der Vlieslage kann es sich insbesondere um synthetische Fasern handeln. Ferner kann die Vlieslage auch aus einem Aluminiumfaservlies gebildet sein.The nonwoven layer can consist of a spunbonded web or a needle punched web. The fibers of the nonwoven layer can in particular be synthetic fibers. Furthermore, the nonwoven layer can also be formed from an aluminum fiber fleece.
MY/sb 0_0635WO Eine vorteilhafte Ausgestaltung des erfindungsgemäßen Isolationsteils besteht darin, dass die Vlieslage im Bereich von Vertiefungen an der Schaumstoffläge angenadelt ist und im Bereich von Erhebungen unangenadelt an der Schaumstoffläge anliegt. Hierdurch wird einerseits eine Perforation der Vlieslage im Bereich der Erhebungen vermieden, was für das optische Erscheinungsbild der Vlieslage gegebenenfalls wünschenswert sein kann, und andererseits eine Trennung von Vlieslage und Schaumstofflage bei einem späteren Recycling des Isolationsteils erleichtert .MY / sb 0_06 3 5WO An advantageous embodiment of the insulation part according to the invention consists in the fact that the nonwoven layer is needled in the area of depressions on the foam layer and in the area of elevations it lies without needling on the foam area. On the one hand, this prevents perforation of the nonwoven layer in the region of the elevations, which may be desirable for the visual appearance of the nonwoven layer, and on the other hand facilitates separation of the nonwoven layer and foam layer when the insulation part is recycled later.
Nachfolgend wird die Erfindung anhand einer mehrere Ausführungsbeispiele darstellenden Zeichnung näher erläutert. Es zeigen:The invention is explained in more detail below on the basis of a drawing showing several exemplary embodiments. Show it:
Fig. 1 eine perspektivische Darstellung eines Abschnitts eines erfindungsgemäßen Isolationsteils;Figure 1 is a perspective view of a portion of an insulation part according to the invention.
Fig. 2 eine Querschnittansicht des Isolationsteils gemäß Fig. 1;FIG. 2 shows a cross-sectional view of the insulation part according to FIG. 1;
Fig. 3 eine Querschnittansicht eines Isolationsteils gemäß einem zweiten Ausführungsbeispiel der Erfindung; und3 shows a cross-sectional view of an insulation part according to a second exemplary embodiment of the invention; and
Fig. 4 eine schematische Darstellung einer Anlage zur Herstellung eines erfindungsgemäßen Isolationsteils .Fig. 4 is a schematic representation of a system for producing an insulation part according to the invention.
Fig. 1 zeigt die Sichtseite eines Abschnitts eines erfindungsgemäßen Isolationsteils 1. Das Isolationsteil 1 ist im wesentlichen plattenformig ausgebildet. Es ist aus einer dreidimensional strukturierten Schaumstoffläge 21 shows the visible side of a portion of an insulation part 1 according to the invention. The insulation part 1 is essentially plate-shaped. It is made of a three-dimensionally structured foam layer 2
MY/sb 020G35 O und einer daran vollflächig anliegenden Vlieslage 3 aufgebaut. Die Schaumstoffläge 2 weist eine Vielzahl von noppenförmigen Erhebungen 4 bzw. muldenförmigen Vertiefungen 5 auf, die rasterförmig angeordnet sind. Die Erhebungen 4 und Vertiefungen 5 wurden in der Schaumstofflage 2 beispielsweise durch Profilschneiden und/oder Formpressen vor der Vliesbelegung hergestellt. Die Schichtdicke der Schaumstoffläge 2 liegt einschließlich der Erhebungen 4 im Bereich von etwa 5 bis 20 mm. Die Schichtdicke der Vlieslage 3 kann beispielsweise 1 bis 5 mm betragen.MY / sb 020G35 O and a nonwoven layer 3 resting thereon over the entire surface. The foam layer 2 has a plurality of nub-shaped elevations 4 or trough-shaped depressions 5, which are arranged in a grid. The elevations 4 and depressions 5 were produced in the foam layer 2, for example by profile cutting and / or compression molding before the nonwoven covering. The layer thickness of the foam layer 2, including the elevations 4, is in the range of approximately 5 to 20 mm. The layer thickness of the nonwoven layer 3 can be, for example, 1 to 5 mm.
Die Schaumstoffläge 2 ist in diesem Ausführungsbeispiel nur einseitig strukturiert, d.h. die gegenüberliegende Seite der Schaumstoffläge 2 ist im wesentlichen eben ausgebildet. Bei Bedarf kann die Schaumstoffläge 2 jedoch auch beidseitig profiliert und auch an der Unterseite mit einer weiteren Kunststoff- oder Textillage (vgl. Fig. 3) und/oder einer Kunststoff- oder Metallfolie (nicht gezeigt) versehen sein.In this exemplary embodiment, the foam layer 2 is only structured on one side, i.e. the opposite side of the foam layer 2 is essentially flat. If necessary, however, the foam layer 2 can also be profiled on both sides and can also be provided on the underside with a further plastic or textile layer (see FIG. 3) and / or a plastic or metal foil (not shown).
Wie in Fig. 2 schematisch gezeigt, ist die Vlieslage 3 an der Schaumstoffläge 2 angenadelt, so dass sie konturparallel an der Schaumstoffläge 2 anliegt. Die Erhebungen 4 und Vertiefungen 5 der Schaumstoffl ge 2 sind somit auch in der Oberfläche der Vlieslage 3 ausgeprägt. Die Verbindung von Vlieslage 3 und Schaumstoffläge 2 erfolgt also ohne Klebstoff.As shown schematically in FIG. 2, the nonwoven layer 3 is needled on the foam layer 2, so that it lies against the foam layer 2 in parallel with the contour. The elevations 4 and depressions 5 of the foam material 2 are thus also pronounced in the surface of the nonwoven layer 3. The bond between the nonwoven layer 3 and the foam layer 2 is thus carried out without adhesive.
Das Annadeln der Vlieslage 3 an der Schaumstofflage 2 kann mittels eines heb- und senkbaren Nadelbalkens durchgeführt werden, der eine Vielzahl von parallel zueinander ausgerichteten Nadeln aufweist. Alternativ kann das Annadeln der Vlieslage 3 auch mittels Wasser-The needling of the nonwoven layer 3 on the foam layer 2 can be carried out by means of a lifting and lowering needle bar, which has a plurality of needles aligned parallel to one another. Alternatively, the needling of the nonwoven layer 3 can also be done using water
MY/sb 0-06-5WO Strahltechnik, d.h. mit einer Vielzahl feiner Hochdruck- Wasserstrahlen erfolgen. Die Nadeln bzw. Wasserstrahlen ziehen eine Vielzahl von Fasern 6 der Vlieslage 3 in die Schaumstoffl ge 2, so dass sich Abschnitte dieser Fasern 6 in der Schaumstoffläge hinreichend fest verankern bzw. verkrallen. Eine Vielzahl der Fasern 6 erstreckt sich dabei bis zur Unterseite der Schaumstoffläge . 2 Andererseits bleiben Abschnitte dieser Fasern 6 in der Vlieslage 3 verankert bzw. verkrallt.MY / sb 0-06-5WO Blasting technology, ie with a variety of fine high pressure water jets. The needles or water jets pull a large number of fibers 6 of the nonwoven layer 3 into the foam material 2, so that sections of these fibers 6 are sufficiently firmly anchored or clawed in the foam material layer. A large number of fibers 6 extend to the underside of the foam layer. 2 On the other hand, sections of these fibers 6 remain anchored or clawed in the nonwoven layer 3.
In dem dargestellten Ausführungsbeispiel ist die Vlieslage 3 im wesentlichen gleichmäßig und vollflächig an der Schaumstoffläge 2 angenadelt. Das Annadeln kann jedoch auch in der Weise erfolgen, dass die Vlieslage 3 nur im Bereich der Vertiefungen 5 angenadelt ist und im Bereich der Erhebungen 4 unangenadelt an der Schaumstoffläge 2 anliegt .In the exemplary embodiment shown, the nonwoven layer 3 is needled to the foam layer 2 essentially uniformly and over the entire surface. However, the needling can also take place in such a way that the nonwoven layer 3 is needled only in the area of the depressions 5 and lies in the area of the elevations 4 without needling on the foam layer 2.
Die Schaumstoffläge 2 besteht vorzugsweise aus offen- zelligem Schaumstoff, beispielsweise aus Melaminharz- Schaumstoff . Es ist jedoch auch möglich, für die Schaumstofflage 2 einen im wesentlichen geschlossenzelligen Schaumstoff zu verwenden.The foam layer 2 preferably consists of open-cell foam, for example of melamine resin foam. However, it is also possible to use an essentially closed-cell foam for the foam layer 2.
Das in Fig. 3 gezeigte Ausführungsbeispiel unterscheidet sich demjenigen in Fig. 2 zunächst dadurch, dass die Schaumstoffläge 2 beidseitig dreidimensional strukturiert ist. Die Strukturierung besteht an beiden Seiten der Schaumstoffläge 2 aus einer Vielzahl von noppenförmigen Erhebungen 4 bzw. muldenförmigen Vertiefungen 5, die wiederum rasterförmig angeordnet sind. Es ist zu erkennen, dass einer Erhebung 4 auf der einen Seite der Schaumstoffläge 2 jeweils eine Vertiefung 5 auf der gegenüberliegenden Seite gegenüberliegt, und umgekehrt.The exemplary embodiment shown in FIG. 3 initially differs from that in FIG. 2 in that the foam layer 2 is structured three-dimensionally on both sides. The structuring consists on both sides of the foam layer 2 from a multiplicity of knob-shaped elevations 4 or trough-shaped depressions 5, which in turn are arranged in a grid. It can be seen that an elevation 4 on one side of the foam layer 2 is opposite a depression 5 on the opposite side, and vice versa.
MY/sb 0-0635WO Des weiteren unterscheidet sich das Ausführungsbeispiel in Fig. 3 von demjenigen in Fig. 2 dadurch, dass die profilierte Schaumstoffläge 2 beidseitig mit je einer Vlieslage 3, 3' versehen ist. Die zweite Vlieslage 3' ist dabei an der Schaumstoffläge 2 ebenfalls in der Weise angenadelt, dass sie konturparallel an der Schaumstoff- l ge 2 anliegt. Dementsprechend sind in ihrer Oberfläche die ihr zugewandten Erhebungen 4 und Vertiefungen 5 der Schaumstoffläge 2 deutlich ausgeprägt. Die beiden Vlieslagen 3, 3' können dabei aus unterschiedlichem Vliesmaterial gebildet sein.MY / sb 0-0635WO Furthermore, the exemplary embodiment in FIG. 3 differs from that in FIG. 2 in that the profiled foam layer 2 is provided on both sides with a nonwoven layer 3, 3 '. The second nonwoven layer 3 'is also needled to the foam layer 2 in such a way that it rests on the foam layer 2 parallel to the contour. Accordingly, the elevations 4 and depressions 5 of the foam layer 2 facing it are clearly pronounced in their surface. The two fleece layers 3, 3 'can be formed from different fleece material.
Das erfindungsgemäße Isolationsteil 1 eignet sich insbesondere zur schall- und wärmeisolierenden Verkleidung von Innenflächen in Kraftfahrzeugen.The insulation part 1 according to the invention is particularly suitable for soundproofing and heat-insulating cladding of interior surfaces in motor vehicles.
Die Vlieslagen 3, 3' sind vorzugsweise aus einem Spinn- vlies, Nadelvlies und/oder Aluminiumfaservlies gebildet. Die Verwendung eines Aluminiumfaservlieses ist insbesondere dann vorteilhaft, wenn das erfindungsgemäße Isolationsteil 1 als akustisch wirksames Hitzeschild eingesetzt werden soll. Dem Aluminiumfaservlies kommt dabei insbesondere eine hitzereflektierende Wirkung zu. Die Schaumstoffläge 2 kann in diesem Fall vorteilhaft aus Melaminharzschaumstoff bestehen, der bekanntermaßen eine relativ hohe Temperaturbeständigkeit aufweist.The nonwoven layers 3, 3 'are preferably formed from a spunbond, needle punch and / or aluminum fiber fleece. The use of an aluminum fiber fleece is particularly advantageous when the insulation part 1 according to the invention is to be used as an acoustically effective heat shield. The aluminum fiber fleece in particular has a heat-reflecting effect. The foam layer 2 can in this case advantageously consist of melamine resin foam, which is known to have a relatively high temperature resistance.
In Fig. 4 ist eine Anlage zur Herstellung eines erfindungsgemäßen Isolationsteils schematisch dargestellt. Die mit 2 bezeichnete Schaumstoffläge liegt in Form einer Materialbahn vor, die zunächst in eine Station 7 gefördert wird, in der die Schaumstoffläge 2 zumindest4 schematically shows a system for producing an insulation part according to the invention. The foam layer denoted by 2 is in the form of a material web which is first conveyed to a station 7, in which the foam layer 2 at least
MY/sb 020635WO einseitig durch Konturschneiden und/oder Formpressen dreidimensional profiliert wird.MY / sb 020635WO is profiled on one side by contour cutting and / or compression molding.
Auf die profilierte Oberfläche der Schaumstoffläge 2 wird dann jeweils eine Vlieslage 3, 3' aufgebracht. Die Vlieslage 3, 3' kann dabei ebenfalls als Materialbahn vorliegen und von einer Vorratsrolle aus zugeführt werden. Die zusammengeführten Materialbahnen 2, 3, 3' durchlaufen anschließend eine Vernadelungsstation, die hier beispielhaft aus zwei heb- und senkbaren Nadelbalken 8, 9 gebildet ist. Die einander gegenüberliegenden Nadelbalken 8, 9 sind mittels Federn (nicht gezeigt) oder dergleichen vorgespannt, so dass sie orthogonal zu den zusammengeführten Materialbahnen 2, 3, 3' einen bestimmten Abstand einhalten. Den Nadelbalken 8, 9 ist jeweils ein Nockenantrieb 10, 11 zugeordnet, der den jeweiligen Nadelbalken gegen die Wirkung der Feder auf die Materialbahnen zubewegt, so dass die Nadeln des jeweiligen Nadelbalkens 8, 9 taktweise in die Vlieslage 3 bzw. 3' und die Schaumstoffläge 2 einstechen und die jeweilige Vlieslage 3, 3' mit der Schaumstoffläge 2 verbinden. Anstelle einer mechanischen Vernadelung mittels Nadelbalken kann allerdings auch eine hydraulische Vernadelung mittels Wasserstrahlen oder dergleichen angewandt werden. Der durch die Vernadelung erzeugte Verbund aus Schaumstoffläge 2 und Vlieslage 3 bzw. Vlieslagen 3, 3' wird schließlich für den Transport zu einer weiteren Bearbeitungsstation, beispielsweise einer Schneidestation zur Herstellung bestimmter Zuschnitte, in Rollenform aufgewickelt. Es versteht sich, dass der Verbund aber auch unmittelbar hinter der Vernadelungsstation weiterverarbeitet, insbesondere zugeschnitten werden kann.A nonwoven layer 3, 3 'is then applied to the profiled surface of the foam layer 2. The fleece layer 3, 3 'can also be present as a material web and can be fed from a supply roll. The merged material webs 2, 3, 3 'then pass through a needling station, which is formed here by way of example from two needle bars 8, 9 that can be raised and lowered. The opposing needle bars 8, 9 are prestressed by means of springs (not shown) or the like, so that they maintain a certain distance orthogonally to the material webs 2, 3, 3 'brought together. The needle bars 8, 9 are each assigned a cam drive 10, 11, which moves the respective needle bar against the action of the spring on the material webs, so that the needles of the respective needle bar 8, 9 are intermittently inserted into the fleece layer 3 or 3 'and the foam layer Pierce 2 and connect the respective fleece layer 3, 3 'to the foam layer 2. Instead of mechanical needling using a needle bar, hydraulic needling using water jets or the like can also be used. The composite of foam layer 2 and nonwoven layer 3 or nonwoven layers 3, 3 'produced by the needling is finally wound up in roll form for transport to a further processing station, for example a cutting station for producing certain blanks. It goes without saying that the composite can also be further processed, in particular tailored, directly behind the needling station.
MY/sb 020635 O Die Erfindung ist in ihrer Ausführung nicht auf das vorstehend beschriebene Ausführungsbeispiel beschränkt Vielmehr sind mehrere Varianten möglich, die auch bei grundsätzlich abweichender Gestaltung von dem in den Ansprüchen definierten Erfindungsgedanken Gebrauch machen.MY / sb 020635 O The embodiment of the invention is not limited to the exemplary embodiment described above. Rather, several variants are possible which make use of the inventive concept defined in the claims, even with a fundamentally different design.
MY/sb 0_0635WO MY / sb 0_0635WO

Claims

P A T E N T A N S P R Ü C H E PATENT CLAIMS
1. Mehrlagiges Schall- und Wärmeisolationsteil (1), insbesondere für Kraftfahrzeuge, mit mindestens einer dreidimensional strukturierten Schaumstoffläge (2) und mindestens einer daran anliegenden Vlieslage (3, 3'), wobei die Schaumstoffläge (2) eine Vielzahl von Erhebungen (4) und/oder Vertiefungen (5) aufweist, d a d u r c h g e k e n n z e i c h n e t , dass die Vlieslage (3, 3') an der Schaumstoffläge (2) angenadelt ist, derart, dass die Vlieslage (3, 3') konturparallel an der Schaumstoffläge (2) anliegt und die Erhebungen (4) und/oder Vertiefungen (5) der Schaumstoffläge (2) auch in der davon abgewandten Oberfläche der Vlieslage (3, 3') ausgeprägt sind.1. Multi-layer sound and heat insulation part (1), in particular for motor vehicles, with at least one three-dimensionally structured foam layer (2) and at least one non-woven layer (3, 3 ') lying thereon, the foam layer (2) having a plurality of elevations (4) and / or depressions (5), characterized in that the non-woven layer (3, 3 ') is needled on the foam sheet (2), such that the non-woven layer (3, 3') is contiguously parallel to the foam sheet (2) and the Elevations (4) and / or depressions (5) of the foam layer (2) are also pronounced in the surface of the nonwoven layer (3, 3 ') facing away from them.
2. Schall- und Wärmeisolationsteil nach Anspruch 1, d a d u r c h g e k e n n z e i c h n e t , dass die Erhebungen (4) und/oder Vertiefungen (5) rasterförmig angeordnet sind.2. Sound and heat insulation part according to claim 1, so that the elevations (4) and / or depressions (5) are arranged in a grid-like manner.
3. Schall- und Wärmeisolationsteil nach Anspruch 1 oder 2, d a d u r c h g e k e n n z e i c h n e t , dass die Erhebungen (4) und/oder Vertiefungen (5) durch Profil - schneiden und/oder Formpressen gebildet sind.3. Sound and heat insulation part according to claim 1 or 2, so that the projections (4) and / or depressions (5) are formed by profile cutting and / or compression molding.
4. Schall- und Wärmeisolationsteil nach einem der Ansprüche 1 bis 3,4. Sound and heat insulation part according to one of claims 1 to 3,
MY/sb 0_0635WO d a d u r c h g e k e n n z e i c h n e t , dass die Vlieslage (3) ohne Klebstoff mit der Schaumstoffläge (2) verbunden ist.MY / sb 0_0635WO characterized in that the non-woven layer (3) is connected to the foam layer (2) without adhesive.
5. Schall- und Wärmeisolationsteil nach einem der Ansprüche 1 bis 4, d a du r c h g e k e n n z e i c h n e t , dass die die Schaumstoffläge (2) aus offenzelligem Schaumstoff hergestellt ist.5. Sound and heat insulation part according to one of claims 1 to 4, so that the foam layer (2) is made of open-cell foam.
6. Schall- und Wärmeisolationsteil nach einem der Ansprüche 1 bis 7, d a d u r c h g e k e n n z e i c h n e t , dass die Schaumstoffläge (2) aus Melarrtinharz-Schaumstoff hergestellt ist.6. Sound and heat insulation part according to one of claims 1 to 7, d a d u r c h g e k e n z e i c h n e t that the foam sheet (2) is made of melarrtin resin foam.
7. Schall- und Wärmeisolationsteil nach einem der Ansprüche 1 bis 6, d a d u r c h g e k e n n z e i c h n e t , dass die Vlieslage (3, 3') aus einem Spinnvlies, Nadelvlies und/oder Aluminiumfaservlies besteht .7. Sound and heat insulation part according to one of claims 1 to 6, so that the fleece layer (3, 3 ') consists of a spunbonded, needle-punched and / or aluminum fiber fleece.
8. Schall- und Wärmeisolationsteil nach einem der Ansprüche 1 bis 7, wobei die Schaumstoffläge (2) eine Vielzahl von Erhebungen (4) und Vertiefungen (5) aufweist, d a d u r c h g e k e n n z e i c h n e t , dass die Vlieslage (3, 3') im Bereich der Vertiefungen (5) an der Schaumstoffläge (2) angenadelt ist und im Bereich der Erhebungen (4) unangenadelt an der Schaumstoffläge (2) anliegt .8. Sound and heat insulation part according to one of claims 1 to 7, wherein the foam layer (2) has a plurality of elevations (4) and depressions (5), characterized in that the fleece layer (3, 3 ') in the region of the depressions ( 5) is needled on the foam sheet (2) and lies in the area of the elevations (4) without needling on the foam sheet (2).
MY/sb 020635WO MY / sb 020635WO
9. Schall- und Wärmeisolationsteil nach einem der Ansprüche 1 bis 8, d a d u r c h g e k e n n z e i c h n e t , dass die Schaumstoffläge (2) beidseitig dreidimensional strukturiert ist.9. Sound and heat insulation part according to one of claims 1 to 8, d a d u r c h g e k e n z e i c h n e t that the foam layer (2) is three-dimensionally structured on both sides.
10. Schall- und Wärmeisolationsteil nach einem der Ansprüche 1 bis 9, d a d u r c h g e k e n n z e i c h n e t , dass die Schaumstoffläge (2) beidseitig mit je einer Vlieslage (3, 3') versehen ist.10. Sound and heat insulation part according to one of claims 1 to 9, d a d u r c h g e k e n z e i c h n e t that the foam layer (2) is provided on both sides with a non-woven layer (3, 3 ').
11. Schall- und Wärmeisolationsteil nach den Ansprüche 9 und 10 , d a d u r c h g e k e n n z e i c h n e t , dass die Schaumstoffläge (2) beidseitig jeweils eine Vielzahl von Erhebungen (4) und Vertiefungen (5) aufweist und auch die zweite Vlieslage (3') an der Schaumstoffläge (2) derart angenadelt ist, dass sie konturparallel an der Schaumstoffläge (2) anliegt und die ihr zugewandten Erhebungen (4) und/oder Vertiefungen (5) der Schaumstoffläge (2) in ihrer Oberfläche ausgeprägt sind.11. Sound and heat insulation part according to claims 9 and 10, characterized in that the foam layer (2) has on both sides a plurality of elevations (4) and depressions (5) and also the second non-woven layer (3 ') on the foam layer (2 ) is needled in such a way that it rests on the foam sheet (2) parallel to the contour and the elevations (4) and / or depressions (5) of the foam sheet (2) facing it are pronounced in their surface.
MY/sb 020635WO MY / sb 020635WO
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