GB2056360A - A process for producing a sound-insulating and sound- absorbing shaped part and a shaped part having a foam layer - Google Patents

A process for producing a sound-insulating and sound- absorbing shaped part and a shaped part having a foam layer Download PDF

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Publication number
GB2056360A
GB2056360A GB8024058A GB8024058A GB2056360A GB 2056360 A GB2056360 A GB 2056360A GB 8024058 A GB8024058 A GB 8024058A GB 8024058 A GB8024058 A GB 8024058A GB 2056360 A GB2056360 A GB 2056360A
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United Kingdom
Prior art keywords
sound
shaped part
foam layer
part according
mould cavity
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.)
Granted
Application number
GB8024058A
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GB2056360B (en
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Henkel Teroson GmbH
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Henkel Teroson GmbH
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Filing date
Publication date
Application filed by Henkel Teroson GmbH filed Critical Henkel Teroson GmbH
Publication of GB2056360A publication Critical patent/GB2056360A/en
Application granted granted Critical
Publication of GB2056360B publication Critical patent/GB2056360B/en
Expired legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/08—Insulating elements, e.g. for sound insulation
    • B60R13/0815—Acoustic or thermal insulation of passenger compartments
    • B60R13/083—Acoustic or thermal insulation of passenger compartments for fire walls or floors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/08—Insulating elements, e.g. for sound insulation
    • B60R13/0815—Acoustic or thermal insulation of passenger compartments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0001—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular acoustical properties
    • B29K2995/0002—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular acoustical properties insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B29L2031/3017—Floor coverings

Abstract

A sound-insulating and sound- absorbing shaped part (e.g. for vehicles or machine casings) having a foam layer is formed by placing a plastic material mixture to be foamed into a mould cavity into localised areas of which have been inserted sheet blanks. The foam embeds the blanks which define regions having different sound-absorbing/insulating properties.

Description

SPECIFICATION A process for producing a sound-insulating and sound-absorbing shaped part and a shaped part having a foam layer The invention relates to a process for producing a sound-insulating and sound-absorbing shaped part having a foam layer for application to a sound-radiating surface, particularly vehicle bodies and machine casings, in which process areas with a different weight per unit area are produced in the foam layer as a function of the vibration amplitudes at sources and sinks measured on the installed sound-radiating surface under operation conditions.
In a known process of this type (German Offenlegungsschrift 27 32 483) the shaped parts are produced from a supple heavy layer and a foam layer engaged on the sound-radiating surface and in order to obtain areas with different weights per unit area the foam layer is impregnated with different quantities and/or types of viscoelastic insulating materials and is generally impregnated in such a way that attenuation is increased in areas with higher acceleration values and source radiation. Furthermore, as a function of the measured acoustic values, the thickness of the foam layer and/or the heavy layer can be zonally varied in order to improve still further the insulation properties.
This known process is based on the finding that sound-radiating bodies or casings are not uniformly excited over the entire surface area and therefore do not uniformly vibrate and radiate.
Thus, in addition to strongly vibrating and radiating areas, there are weakly vibrating and almost quiet areas, which are in turn subdivided into sources which are to be damped or insulated and sinks which should as far as possible be left undamped. Maximum damping over the entire surface through impregnating the foam layer with a quantity of insulating material which is close to the saturation limit rigidifies the material to such an extent in the slightly oscillating areas of the surface that coincidence break-downs occur.
Necessarily, this results in a reduced absorption, i.e. increased radiation in the sound-absorbing sinks.
In the known solution, these difficulties are avoided in that in such relatively quiet areas, the foam layer is impregnated to a lesser extent with the damping or insulating material than in the significantly oscillating areas and can if necessary be reduced to zero in the very quiet areas and in the sinks.
A disadvantage of the known process is that the shaped parts have to be produced in several consecutive steps. Thus, initially, the heavy foil is deformed by deep drawing or is given the desired shape by an injection moulding process, after which the foam layer is applied to this heavy foil.
This is followed by the zonal impregnation of the foam layer with the viscoelastic insulating material. Such a production process is as a result relatively costly from the time and labour standpoint.
According to another proposal (U.S. Application Serial No. 968,872 filed on December 12, 1978), a plate-like or strip-like sound insulating material in the shape of foils or strips of open-pored foam is applied to sound-radiating surfaces, particularly vehicle bodies and machine castings, previously zonally impregnated with a viscoelastic material.
Impregnation is carried out in accordance with the previously described basic principles, i.e. the impregnation with the viscoelastic insulating material was distributed in accordance with the sound-radiating sources and sinks.
However, with this earlier process, it was also necessary to initially produce the foils or strips of foam material and then carry out the impregnation with the viscoelastic material in a separate operation.
It is an object of the invention to provide a process for producing sound-absorbing and sound-insulating shaped parts in which no additional operation is needed for producing the areas with different weights per unit area and/or rigidity.
Accordingly one aspect of the present invention provides a process for producing a soundinsulating and sound-absorbing shaped part having a foam layer for applying to a soundradiating surface, in which process at least one localised area with a different weight per unit area is produced in the foam layer as a function of the vibration amplitudes at sources and sinks measured on the installed sound-radiating surface under operating conditions, comprising introducing into localised area or areas of a mould cavity a sheet blank having a locally desired weight per unit area and a locally desired rigidity at the said localised area or areas, and subsequently forcing the plastic material mixture to be foamed into the mould cavity.
In the process according to the invention, there is no impregnation with a viscoelastic damping material for producing the areas with an increased weight per unit area, as in the known processes.
Instead, sheet blanks are placed in the corresponding areas of the mould cavity, whereby during the production of the shaped part, said blanks are connected to the plastic material mixture, i.e. the foam layer, by introducing foaming plastic mixture into the moulding cavity, so that areas with the desired weight per unit area and/or the desired rigidity are produced simultaneously with the foam layer of the shaped part, without any preshaping of the sheet blanks being necessary.
A suitable foam material for producing the layer is e.g. polyurethane, polyolefin or PVC, optionally introduced into the mould in the form of flakes and converted in the latter into a composite material.
For producing the shaped part, heavy sheet blanks can be introduced into the mould cavity having a specific gravity of more than 2.0 g!cm3.
Such sheet blanks may be constituted by plastics, e.g. ethylene/vinyl acetate copolymers (EVA) containing a high charge of heavy inorganic fillers like barium sulphate, calcium carbonate etc. (cf.
German Auslegeschrift 1,940,878). It is also possible to use mixtures of polyolefins containing a high charge and EVA types or mixtures of polyolefins and artificial rubber (EPDM polymers).
It is also possible to place in the mould cavity foam sheet blanks, which may consist of the same plastic material as the foam layer and which are impregnated with viscoelastic material e.g.
mixtures of waxes like natural waves or synthetic paraffin waxes, resins like fossil resins or synthetic hydrocarbon resins EVA types and acrylates, or even bitumen foil may be used as sheet blanks.
If the shaped part is used for the internal lining of cars, a correspondingly shaped carpet or composite carpet material can be placed in the mould cavity, whereby the side which is subject to wear is engaged with the cavity wall. In this way, the foam layer is joined to the carpet or composite carpet material during the production of the shaped part. It is optionally also possible to use the shaped carpet or composite carpet material as half of the mould for forming the mould cavity.
If sections, e.g. in the form of tubular ducts or curved parts whose edges engage on the sheet blank are placed in the mould cavity, it is possible to thus in this way form duct-like spaces in the shaped part which can serve as air ducts.
Another aspect of the present invention provides a shaped part having a foam layer as a lining for bringing about the sound-absorption and sound-insulation of sound-radiating surfaces, and having areas with different weights per unit area, wherein at least one preformed sheet blank has been incorporated into the foam layer.
At least one sheet blank of said shaped part can comprise a heavy foil with a specific gravity exceeding 2.0 g/cm3 and the heavy foil can be made from ethylene/vinyl acetate copolymers and/or ethylene/propylene rubber, filled with barite and/or limestone powder.
In addition, at least one sheet blank can comprise a polyurethane, polyvinyl chloride or polyolefin foam impregnated with a viscoelastic damping material, the latter being formed from polyolefins or organic resins and/or waxes in which are incorporated inorganic fillers, particularly chalk, ground shale or barite.
Bitumen foil blanks can also be incorporated into the foam layer and the bitumen foil comprising a bitumen-resin mixture can contain 60 to 80% fillers, particularly barite, limestone powder, ground shale and/or mica.
In order to be able to form ducts in the foam layer, which can for example serve as air ducts, sectional members can be incorporated into the foam layer formed from cubes or curbed in such a way that when their edge areas engage on a sheet blank, they form a duct together with said blank.
If the shaped part is to be used for lining the inner area of a car, a carpet or composite carpet material can be fixed to the outer surface of the foam layer. At least one of the surfaces of the foam layer can have an adhesive, for example a heat-activatable fusion adhesive or a self-adhesive covered with a removable protective coating.
The invention is described hereinafter relative to a non-limitative embodiment the attached drawings in which: Fig. 1 shows in a perspective partial representation, two shaped parts fixed to the body of a motor car in the vicinity of the passenger area; Fig. 2 shows the shaped parts according to Fig.
1 , the part of the foam layer above the blanks being removed; Fig. 3 shows a partial section through the shaped parts according to Fig. 1 in the area of the "transmission tunnel"; Fig. 4 shows a section through a shaped part.
The represented shaped parts with a foam layer 1, for example polyurethane soft foam are fixed to the body panel 10 by adhesion, the necessary areas for handles, instruments, etc., being hollowed out. Such shaped parts are shown in the fitted state in Fig. 1, but without the normally provided carpet. An air duct which will be explained hereinafter is shown in dotted line form.
As can be gathered from Fig. 2, where the foam layer 1 is partly removed, said foam layer contains a plurality of different formed and dimensioned sheet blanks, all of which are incorporated into the foam layer during the production thereof. Sheet blank 2 comprises a heavy foil with a specific gravity above 2.0 g/cm3, for example of ethylene/ vinyl acetate copolymers and/or ethylene/propylene rubber, into which is incorporated barite and/or limestone powder, whilst sheet blanks 3 are made from a viscoelastic impregnated foam, e.g. polyurethane, polyvinyl chloride or polyolefin foam, impregnated with viscoelastic material in such a way that an average damping is obtained. Sheet blanks 4 are made from a foam impregnated with viscoelastic material in such a way that a high damping level is obtained.Sheet blank 5 comprises a so-called plastic support foil, i.e. a layer of plastic, cardboard or metal foil coated with viscoelastic material and overall having an E-modulus higher by a factor of approximately 1 02 to approximately 104 than that of foam layer 1. Furthermore, the loss modulus d2 of the plastic support foil is higher than 0.5, this loss modulus being the same as the composite loss modulus d according to DIN 53 440, but without geometrical parameters.
In this way, the shaped parts with the soft foam leads to a certain sound-absorption and soundinsulation over the entire shaped part, whilst the various sheet blanks are positioned and constructed so as to be precisely adapted to the sound radiation of the body panel, leading in all to an optimum sound-absorption and soundinsulation.
It is pointed out that in the manner intimated in Fig. 4, the foam layer also contains hard foam tread support 6 which can also be incorporated into the mould cavity for forming the foam layer when producing the shaped part, so that no additional operation is necessary for applying the tread supports Fig. 3 shows that air ducts 8 are formed in the foam layer laterally of the transmission tunnel, said ducts being bounded on the one hand by blanks 5 and on the other by moulded articles 7, which are curved and whose edge areas engage in each case on the adjacent blank 5. These ducts 8 can be used for supplying hot or fresh air to the rear part of the passenger area.
As shown in Fig. 3, a carpet 9 can be fixed to the outer surface of the foam layer. The carpet can be joined to the foam layer during the production of the latter, so that on fitting the shaped parts, the carpet can be introduced with them into the passenger area.

Claims (20)

1. A process for producing a sound-insulating and sound-absorbing shaped part having a foam layer for applying to a sound-radiating surface, in which process at least one localised area with a different weight per unit area is produced in the foam layer as a function of the vibration amplitudes at sources and sinks measured on the installed sound-radiating surface under operating conditions, comprising introducing into localised area or areas of a mould cavity a sheet blank having a locally desired weight per unit area and a locally desired rigidity at the said localised area or areas, and subsequently forcing the plastic material mixture to be foamed into the mould cavity.
2. A process according to claim 1 , wherein the or each said sheet blank placed in the mould cavity has a specific gravity of at least 2.0 g/cm3.
3. A process according to claim 1 or claim 2, wherein the or each foam sheet blank placed in the mould cavity is impregnated with a viscoelastic material.
4. A process according to any one of claims 1 to 3, wherein the or each said sheet blank placed in the mould cavity is a bitumen foil blank.
5. A process according to any one of claims 1 to 4, wherein the shaped part is intended for the interior of a car, and a correspondingly shaped carpet or a correspondingly shaped composite carpet material is placed in the mould cavity, such that the side of the carpet or carpet material which is subject to wear is engaged with a cavity wall.
6. A process according to any one of claims 1 to 5, wherein sections for forming air ducts are incorporated into the mould cavity.
7. A shaped part having a foam layer as a lining for bringing about the sound-absorption and sound-insulation of sound-radiating surfaces, and having areas with different weights per unit area, wherein at least one preformed sheet blank has been incorporated into the foam layer.
8. A shaped part according to claim 7, wherein there are several said preformed sheet blanks in the foam layer.
9. A shaped part according to claim 8 wherein at least one said sheet blank comprises a heavy foil with a specific gravity of at least 2.0 g/cm3.
10. A shaped part according to claim 9 wherein said heavy foil is made from an ethylene/vinyl acetate copolymer, and/or from an ethylene/propylene rubber filled with barite and/or limestone powder.
11. A shaped part according to any one of claims 8 to 10 wherein at least one said sheet blank is made from polyurethane, polyvinyl chloride or polyolefin foam, impregnated with a viscoelastic insulating material.
12. A shaped part according to claim 11, wherein said insulating material is formed from polyolefin or organic resins and/or waxes, in which are incorporated an inorganic filler.
13. A shaped part according to claim 12, wherein said inorganic filler is chalk, ground shale and/or barite.
14. A shaped part according to any one of claims 8 to 13, wherein at least said one sheet blank is a bitumen foil.
15. A shaped part according to claim 14, wherein said bitumen foil comprises a bitumen - resin mixture containing 60% to 80% fillers.
16. A shaped part according to claim 15, wherein said fillers are barite, limestone powder, ground shale and/or mica.
17. A shaped part according to any one of claims 7 to 16 wherein sections forming ducts are incorporated into said foam layer.
18. A shaped part according to any one of claims 7 to 17, intended for the interior of a car, wherein a carpet or composite carpet material is fixed to that surface of said foam layer facing away from the car body panel to which the said foam layer is to be attached.
19. A process for producing a sound-insulating and sound-absorbing part, substantially as hereinbefore described with reference to the accompanying drawings.
20. A shaped part having a foam layer as a sound-absorbing and sound-insulating lining for a sound-radiating surface, such part being substantially as hereinbefore described with reference to, and as illustrated in, the accompanying drawings.
GB8024058A 1979-07-31 1980-07-23 Process for producing a sound-insulating and sound-absorbing shaped part and a shaped part having a foam layer Expired GB2056360B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE2930966A DE2930966C2 (en) 1979-07-31 1979-07-31 Process for the production of a sound-absorbing molded part

Publications (2)

Publication Number Publication Date
GB2056360A true GB2056360A (en) 1981-03-18
GB2056360B GB2056360B (en) 1983-02-09

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GB8024058A Expired GB2056360B (en) 1979-07-31 1980-07-23 Process for producing a sound-insulating and sound-absorbing shaped part and a shaped part having a foam layer

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JP (1) JPS5624157A (en)
DE (1) DE2930966C2 (en)
ES (1) ES8106854A1 (en)
FR (1) FR2462260A1 (en)
GB (1) GB2056360B (en)
IT (1) IT1131797B (en)
NL (1) NL8004319A (en)
SE (1) SE8005466L (en)

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EP0087855A2 (en) * 1982-01-15 1983-09-07 Winster Hose Limited Manufacture of reinforced hose
EP0121947A2 (en) * 1983-04-12 1984-10-17 Helmut Pelzer Layered product with flexible regions for reducing noise caused by an object and/or in the air from acoustically excited surfaces
GB2151757A (en) * 1983-12-21 1985-07-24 Stankiewicz Alois Dr Gmbh Sound barriers
EP0253376A2 (en) * 1986-07-18 1988-01-20 Stankiewicz GmbH Adhesive isolation system
EP0278393A2 (en) * 1987-02-10 1988-08-17 C.S.P. Centro Studi E Prototipi S.R.L. Soundproofing panels for applications in the automotive sector and their manufacturing procedure
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Cited By (25)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0062166A2 (en) * 1981-03-30 1982-10-13 Siemens Nixdorf Informationssysteme Aktiengesellschaft Sound-proofed apparatus housing, and method for its manufacture
EP0062166A3 (en) * 1981-03-30 1984-02-22 Siemens Nixdorf Informationssysteme Aktiengesellschaft Sound-proofed apparatus housing, and method for its manufacture
EP0087855A2 (en) * 1982-01-15 1983-09-07 Winster Hose Limited Manufacture of reinforced hose
EP0087855A3 (en) * 1982-01-15 1984-10-03 Winster Hose Limited Manufacture of reinforced hose
EP0121947A2 (en) * 1983-04-12 1984-10-17 Helmut Pelzer Layered product with flexible regions for reducing noise caused by an object and/or in the air from acoustically excited surfaces
EP0121947A3 (en) * 1983-04-12 1985-12-18 Helmut Pelzer Layered product with flexible regions for reducing noise caused by an object and/or in the air from acoustically excited surfaces
GB2151757A (en) * 1983-12-21 1985-07-24 Stankiewicz Alois Dr Gmbh Sound barriers
EP0253376A2 (en) * 1986-07-18 1988-01-20 Stankiewicz GmbH Adhesive isolation system
EP0253376A3 (en) * 1986-07-18 1988-10-12 Stankiewicz Alois Dr Gmbh Adhesive isolation system
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EP0278393A3 (en) * 1987-02-10 1989-05-03 C.S.P. Centro Studi E Prototipi S.R.L. Soundproofing panels for applications in the automotive sector and their manufacturing procedure
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Also Published As

Publication number Publication date
ES493805A0 (en) 1981-10-01
DE2930966C2 (en) 1983-12-22
IT1131797B (en) 1986-06-25
DE2930966A1 (en) 1981-02-12
NL8004319A (en) 1981-02-03
SE8005466L (en) 1981-02-01
ES8106854A1 (en) 1981-10-01
JPS5624157A (en) 1981-03-07
GB2056360B (en) 1983-02-09
IT8023819A0 (en) 1980-07-31
FR2462260A1 (en) 1981-02-13

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