KR100494500B1 - Sound insulating layer with integral rib structure - Google Patents

Abstract

A vehicle dash mat assembly (10) having a shielding wall including a floor area (23) and a firewall area (25) extending between the wheel well area (41) and the drive train area (42). This dash mat assembly 10 includes a mass layer 12 covering at least a portion of the shielding wall. The mass layer 12 has an inner surface 16 facing the shielding wall in a state where the outer circumferential rib 52 formed integrally protrudes. The first elongated set of ribs 48 intersects and connects with the second elongated set of ribs 50. Elongated first and second sets of ribs 48, 50 are located within the enclosing area. Each elongate rib 48, 50 includes an upper portion formed integrally with the inner surface 16 of the mass layer and a lower portion having at least outer edges 54, 60 facing the shielding wall. Each elongated rib 48 of the first set of ribs has an opposite end formed integrally with the outer circumferential rib 52 to reinforce the outer circumferential rib against a bending moment due to a compressive force applied to the outer surface of the mass layer. Also have. Each elongate rib 50 of the second set of ribs may be adjacent ribs 48 and circumferential ribs 52 or the first set of ribs of the first set to further strengthen the outer ribs 52 against the bending moment. It has an opposing end formed integrally with the adjacent rib 48 of the rib. The first set of ribs protrudes from the inner surface of the mass layer by a distance greater than the second set of ribs to provide an increased level of impact resistance to the outer surface of the mass layer.

Description

Soundproofing layer with integral rib structure {SOUND INSULATING LAYER WITH INTEGRAL RIB STRUCTURE}

The present invention relates to a sound insulation layer for a vehicle, and more particularly, to a dash mat having compression ribs integrally formed in a scaffold area of a vehicle and / or a dead pedal integrally formed.

In most current vehicles, steel firewalls separate the engine compartment from the passenger compartment. To reduce the transmission of noise from the engine compartment through the firewall into the passenger compartment, the noise shield mat (or dash mat) is usually molded into a single piece of generally uniform thickness of elastomeric material with limited impact absorption. do. This dash mat is mounted on the firewall so that the outer surface of the mat contacts the bottom surface of the vehicle carpet and extends beyond the carpet to the upper part of the firewall behind the operation panel. The vehicle dead pedal, which acts as a foot rest for the driver, is usually formed of steel or plastic and installed as a fastener on the wheel well of the vehicle. The protrusions or openings in the dashmat are aligned on the dead pedal and the dashmat is attached to the firewall as a separate fastener. Installation of the dead pedal and dash mat in this manner requires a plurality of different parts and fasteners. Multiple parts and fasteners increase inventory, cost and installation time.

1 is a front view (as seen from the driver's seat) of a dead pedal integrally formed with a vehicle dash mat,

2 is a rear view of the dead pedal and dash mat,

3 is a perspective view of a dash mat assembly with a firewall showing a scaffolding area according to the present invention;

Figure 4 is a partial cross-sectional view of the inner surface of the dash mat with a sound absorbing material layer showing the compression rib structure of the scaffolding area according to the present invention;

5 is a cross-sectional view taken along line 5-5 of FIG. 4 showing various heights of the compression ribs.

These and other problems of the prior art are overcome by a dash mat assembly for a vehicle having a rib structure integrally formed in the footrest area of the vehicle.

According to the present invention, a dash mat assembly mounted on a shielding wall, such as a vehicle wall or other structure, has a molded structure and a mass layer of noise damping characteristics having an inner surface facing the shielding wall and an outer surface facing away from the shielding wall. mass layer). The outer circumferential rib has an upper portion integrally formed with the inner surface of the mass layer and a lower portion having an outer edge contacting the shielding wall. This circumferential rib forms an enclosed area on the inner surface of the mass layer. The first set of elastic projections is located in the enveloping area. Each protrusion has an upper portion formed integrally with the mass layer and a lower portion having an outer edge contacting the shielding wall. Each protrusion extends from the inner surface to the outer edge by a first distance. The second set of resilient protrusions is located in the enveloping area. Each protrusion of the second set includes an upper portion integrally formed with the mass layer and a lower portion with an outer edge facing the shielding wall. Each protrusion of the second set extends from the inner surface to the outer edge by a second distance. Preferably, the second distance is shorter than the first distance. With this arrangement, the first set of protrusions elastically resists the compressive force applied to the outer surface of the mass layer at a first predetermined level and the first set of protrusions and the second set of protrusions are greater than the first predetermined level. 2 Elastically resists a predetermined level of compressive force.

In a preferred embodiment, the first set of projections comprises a plurality of elongate first ribs. Each rib has an opposite end integrally formed with the outer rib to strengthen the outer rib against the bending moment due to the compressive force applied to the outer surface of the mass layer.

Likewise, the second set of protrusions includes a plurality of elongated second ribs that extend transversely to the first rib. Each second rib has an adjacent longitudinally extending rib and an opposite end formed integrally with the first rib or the outer rib, thereby further strengthening the outer rib against the bending moment.

According to the invention, the mass layer is suitable for installation in a vehicle having a shield comprising a firewall area and a floor area extending between the wheelwell area and the drive train area. This firewall zone intersects with and extends upwards from the floor zone. The mass layer also includes a wheelwell portion having a shape that matches at least a portion of the wheelwell region shape and a floor and firewall portion each having a shape that matches at least a portion of the shape of the floor region and the firewall region of the vehicle.

In one embodiment, the enclosing area comprising the first and second sets of protrusions comprises a scaffolding area extending along at least a portion of the floor and firewall portion of the mass layer.

In another embodiment, the enclosing area comprising the first and second sets of protrusions includes a dead pedal region extending along at least a portion of the wheelwell portion of the mass layer.

The dashmat assembly also includes an absorber layer having an inner surface in contact with the shielding wall and an outer surface in contact with the inner surface of the mass layer. Preferably, the absorber layer has an opening sized to receive the outer circumferential rib so that the surrounding area does not have an absorbent material.

In accordance with the present invention, a dash mat assembly mounted to a shielding wall comprises a molded layer having a mass structure with a damping characteristic and an inner surface facing the shielding wall and an outer surface facing away from the shielding wall. The outer circumferential rib has a lower portion having an outer edge contacting the shielding wall and an upper portion formed integrally with the inner surface of the mass layer to form an enveloping area on the inner surface of the mass layer. An elongated first set of ribs is located within the enclosing area. Each elongate rib comprises an upper portion integrally formed with the inner surface of the mass layer and a lower portion with at least an outer edge facing the shielding wall. Each elongate rib has an opposite end integrally formed with the outer rib, thereby strengthening the outer rib against the bending moment due to the compressive force applied to the outer surface of the mass layer.

Preferably, the elongate ribs extend in the same direction. An elongated second set of ribs located within the enclosing area may be provided. Each rib of the second set of ribs has an upper portion integrally formed with the inner surface of the mass layer, at least a lower portion with an outer edge facing the shielding wall, and adjacent and outer ribs of the first set of ribs or the first rib. The opposite ends of the sets of ribs integrally formed with adjacent ribs further strengthen the outer circumferential rib against the bending moment.

The invention is now described with reference to the drawings.

1 and 2, the dashmat assembly 10 includes a mass layer or dashmat 12 having a first outer surface 14 and a second inner surface 16. Dead pedal 18 is integrally formed with the mat 12 in one piece and protrudes outward from the first surface 14. The dashmat assembly 10 is preferably formed of a filled elastomeric moldable polymer, for example elastomeric polypropylene, and noise is transmitted from the engine compartment through the firewall into the passenger compartment of the vehicle. It acts as a noise shielding layer to reduce it. The lower outer circumference 20 of the dead pedal 18 is continuous with the dash mat outer surface 14 so that the upper surface 22 of the dead pedal 18 faces the rear of the vehicle in a position comfortable to the user's feet during installation. And has a shape coincident with the surface of the vehicle wheel well portion (FIG. 3). The dead pedal outer circumferential wall (or outer circumferential rib) 21 is formed integrally with the lower outer circumference 20 and the upper surface 22 of the dead pedal 18.

The plurality of circular recesses 24 extend inward from the dead pedal upper surface 22 to accommodate fasteners (not shown). Each recess typically includes an elongated slot 26 for receiving a fastener stud or shaft (not shown) extending from the vehicle firewall. This slot 26 is sufficient for the dashmat 12 and the dead pedal 18 to be adjusted against the vehicle firewall with the stud protruding through the slot during installation. Although only two recesses and slots are shown, single or multiple recesses and slots may be provided, depending on the amount of fixation required. Moreover, depending on the type of vehicle in which the dead mat is installed, this recess and / or slot can be removed and the dead pedal can float freely. This recess and / or slot may be used for the installation of the decorative cover.

In particular in FIG. 2, a first set of ribs 30 extending longitudinally and a second set of ribs 32 extending laterally protrude from the inner surface 28 of the dead pedal 18. The first and second sets of ribs 30, 32 extend approximately perpendicular to each other and provide structural support to the dead pedal 18 to resist the force exerted by the driver's feet. These first and second sets of ribs 30, 32 also give the dead pedal sufficient strength to mount a cover (not shown) directly to the dead pedal through the fastener. The outer edge 34 of the rib 30 is adjacent to the wheel well portion of the vehicle and supports the dead pedal 18 together with the outer circumferential wall 21. The outer edge 36 of the rib 32 is curved toward the inner surface 28 and does not contact the wheelwell.

In the installation position, the outer edge 34 of the rib 30 and the inner surface 16 of the dash mat 12 face the vehicle firewall 25 (FIG. 3), while the outer surfaces 14, 22 are car carpet. Toward the bottom of (not shown). The outer surface 14 of the dash mat 12 also extends behind the instrument panel past the carpet.

While the present invention represents a particular use in automotive dash mats, the present invention is directed to other automatic propulsion or non-automatic propulsion wherein a panel or layer of material having an integrally formed support surface is temporarily or permanently attached to the support surface. The use in the device may also be indicated. For example, the dead pedal structure, i.e., reinforcement ribs, increased mat thickness and / or fastener openings, may be provided in the dash mat to provide structural support for mounting electrical modules, HVAC cases, decorative panels and other vehicle accessories. Can be formed in position. In addition, although the dead pedal is illustrated in a particular shape, other shapes may be formed in the dash mat depending on the intended application.

3 and 4, the shielding wall includes a drive train area 42, a wheel well area 41, and floor and firewall areas 23 and 25 extending between the drive train area and the wheel well area. The firewall zone 25 intersects with the floor zone 23 and extends upwards from the floor zone 23. Dash mat assembly 10 includes compressed rib matrix 38 that is integrally formed with dash mat 12 inner surface 16 in scaffolding zone or region 40 in addition to or in place of dead pedal 18. Doing. Scaffolding zone 40 is located at the intersection of floor 23 and firewall zone 25 between wheelwell zone 41 and drive train zone 42. The scaffolding section 40 is divided into a lower scaffolding portion 44 and an upper scaffolding portion 46. The lower scaffold 44 extends partially along the vehicle floor 23 adjacent the firewall 25 and partially upwards along the firewall 25 adjacent the floor 23. It is formed integrally with

In particular, in FIG. 4, which is a partial cross-sectional rear view of the scaffolding zone 40, the compression rib matrix 38 has a longitudinally extending rib 48 and laterally protruding from the inner dash mat surface 16 of the scaffolding area 40. It includes a rib 50 extending to. With rib 48 having outer edge 54 and rib 50 having outer edge 60, rib 48 extends approximately perpendicular to rib 50. The outer circumferential ribs 52 form the outer circumference of the compression rib matrix 38. The central rib 58 is formed integrally with the outer circumferential rib 52 and is located at the intersection of the upper and lower scaffold portions 44 and 46. Both the outer circumferential rib 52 and the center rib 58 have outer edges 62 and 64, respectively.

In the installation position, the outer edges 54, 62 are in vertical contact with the firewall 25 and the floor 23, and the outer edge 60 and the inner surface 16 initially face the firewall and the floor, and the outer edges. 58 extends and contacts along the intersection of the firewall and the floor.

The dashmat assembly 10 also includes an absorber layer 56 arranged between the floor 23 and / or the firewall 25 outside the scaffolding area 40 and the inner surface 16 of the dashmat 12. Doing. The outer surface 14 of the dash mat 12 faces the underside of the vehicle carpet (not shown) and is constant over the scaffold area 40.

FIG. 5 is a cross-sectional view taken along the line 5-5 of FIG. 4 showing an example of the arrangement of the compression ribs. Ribs 48, 50, 52 and 58 are of varying lengths to provide structural support of various resistances when force is applied to scaffolding area 40 and to conform to the shape of floor 23 and firewall 25. It protrudes from the inner surface 16 of the scaffolding area 40. As illustrated, the first set of ribs, including ribs 48, circumferential ribs 52, and central ribs 58, protrude a first distance from the inner surface 16 to form ribs 48, 58, and 52. Is spaced apart from the firewall 25 and the floor 23 by a predetermined distance on the inner surface 16 of the dash mat. The second set of ribs including ribs 50 protrude from the inner surface 16 by a second distance. Preferably, the first distance is greater than the second distance such that the outer surface 60 of the rib 50 is initially spaced apart from the wall 25 and the floor 23. An impact of sufficient force on the outer surface of the scaffolding area 40 towards the floor 23 and / or firewall 25 causes the one or more ribs 48, 52 and 58 to bend, thereby initially damping this impact force. The initial level of impact resistance or damping is controlled by varying the number of ribs 48 and the thickness, height, length, spacing, shape and direction of the ribs 48, 52 and 58 to achieve a predetermined amount of initial impact resistance. Can be. If the impact force is large enough to exceed the initial impact resistance of the first set of ribs, the outer surface 60 of the one or more ribs 50 will contact the floor 23 and / or the firewall 25 to provide impact resistance or damping. The first set of one or more ribs continues to bend until it provides a second level of. As with the first set of ribs, the second level of impact resistance or attenuation for the second set of ribs is determined by the number of ribs 48 and the thickness, height, length of the ribs, in order to achieve a predetermined amount of secondary impact resistance. It can be controlled by varying the spacing, shape and direction. The degree of impact resistance can be further controlled by surrounding the scaffolding zone 40 with a predetermined rigid absorbent layer 56. The integrally molded compressed rib matrix 38 provides the scaffolding zone 40 with a different level of stiffness than the foam absorber layer, improving crash shock absorption and passenger safety. If desired, two or more impact resistance steps can be provided by adding a shorter set of ribs.

Although the present invention has shown a particular use in the scaffolding section 40, the compression ribs are integrally located at other locations within the dash mat to provide increased impact resistance, such as a dead pedal section located on the wheel well portion of the vehicle. Can be formed. Furthermore, the invention is not limited to the specific arrangement of ribs as shown in the figures.

Therefore, appropriate variations and modifications may be made within the spirit of the specification and drawings without departing from the scope of the invention.

Claims (24)

A shielding wall including a floor area 23 and a firewall area 25 extending between the wheelwell area 41 and the drive train area 42 is provided, and the firewall area 25 is upward from the floor area 23. In the dash mat assembly 10 for installation in a vehicle that is intended to intersect while extending, the dash mat assembly 10 A mass layer 12 of molded structure and noise damping characteristics having an inner surface 16 facing the shielding wall 24 and an outer surface 14 facing away from the shielding wall; A wheel well portion having a shape conforming to at least a portion of the shape of the wheel well region 41 of the shielding wall; And a floor and a firewall unit having a shape corresponding to at least a part of the shapes of the floor area 23 and the firewall area 25 of the shielding wall, respectively. A dead pedal 18 integrally formed with the mass layer wheelwell portion and formed by at least the first and second sets of integral ribs 21, 30, 32 is in contact with the wheelwell region 41 to provide a dead pedal leg support. And an outer circumferential rib (21) for forming an enclosed region, wherein the ribs form an enclosed region on an inner surface of the mass layer (12). 2. The dash mat assembly of claim 1, wherein the first set of ribs (30) has a lower portion positioned within the enclosing area and having an outer edge (34) contacting the shielding wall. 2. The dash mat assembly of claim 1, wherein the first set of dead pedal ribs (30) is integral with the outer circumferential ribs (21). 2. The dash mat assembly of claim 1, wherein the second set of ribs (32) is located within the enclosing area and intersects across the first set of ribs. 2. A dash mat assembly according to claim 1, wherein the second set of ribs (32) is integral with the outer circumferential rib (21). 6. The second set of ribs (32) according to any one of claims 3 to 5, wherein each second set of ribs (32) has a lower portion with an outer edge (36) facing the shielding wall and is external from the inner surface (16). A dash mat assembly, characterized in that it has a length shorter than the first set of ribs (30) to the edge (36). 6. The device according to claim 1, which is integrally formed in the mass floor and the firewall sections 44, 46 by at least third and fourth sets of integrally formed ribs 48, 50, 52. 7. And further comprising a second separate enclosing zone 38, wherein the second separate enclosing zone 38 forms a scaffolding zone 40 extending at least along the floor and firewall portion of the mass. Dash Mat Assembly. 8. The rib 58 of claim 7, wherein the rib formed integrally of the second separated enclosing region 38 extends laterally in the center in contact with the intersection of the floor region 23 and the firewall region 25 of the vehicle. A dash mat assembly comprising a. 8. The method of claim 7, wherein only the third set of ribs is elastically resistant to the compression of the mass layer in the second separate enclosing zone 38 that reaches the first predetermined level. A dash mat assembly, characterized in that the third and fourth sets of ribs are formed such that the three sets of ribs resiliently resist compression of the mass layer in the second separate enclosing zone 38 that deviates from the first predetermined level. . 6. An absorber layer (56) according to any one of the preceding claims, further comprising an absorber layer (56) having an outer surface in contact with the inner surface (16) of the mass layer and an inner surface in contact with the shielding wall. Dash mat assembly. 11. A dash mat assembly according to claim 10, wherein the absorber layer has an opening sized to receive the enveloping area of the dead pedal (18) and lies entirely outside of the enveloping area of the dead pedal (18). 11. The dashmat assembly of claim 10, wherein the absorber layer has an opening sized to receive a second separated envelopment region and lies entirely outside of the second separated envelopment region. A shielding wall including a floor area 23 and a firewall area 25 extending between the wheelwell area 41 and the drive train area 42 is provided, and the firewall area 25 is upward from the floor area 23. In the dash mat assembly 10 for installation in a vehicle that is intended to intersect while extending, the dash mat assembly 10 A mass layer 12 of molded structure and noise damping characteristics having an inner surface 16 facing the shielding wall and an outer surface 14 facing away from the shielding wall; A wheel well portion having a shape conforming to at least a portion of the shape of the wheel well region 41 of the shielding wall; And a floor and a firewall unit having a shape corresponding to at least a part of the shape of the floor area 23 and the firewall area 25 of the shielding wall, respectively. Enclosure 38 is integrally formed on mass floor and firewall portions 44, 46 by at least third and fourth sets of integral ribs 48, 50, 52, and enclosing region 38 is at least A dash mat assembly, characterized in that it forms a scaffolding zone (40) extending along the floor and firewall portion of the mass layer. 14. The rib according to claim 13, wherein the rib formed integrally in the enclosure area (38) comprises a rib (58) extending laterally in contact with the intersection of the floor area (23) and the firewall area (25) of the vehicle. And a dash mat assembly. 15. The fourth set according to claim 13 or 14, wherein only the third set of ribs is elastically resistant to the compression of the mass layer in the second separate enclosing zone 38 reaching a first predetermined level. The third and fourth sets of ribs are formed such that the ribs of the and the third set of ribs are elastically resistant to compression of the mass layer in the second separate enclosing region 38 that deviates from the first predetermined level. Dash mat assembly. 15. A dash mat assembly according to claim 13 or 14, further comprising an absorber layer (56) having an outer surface in contact with the inner surface of the mass layer and an inner surface in contact with the shielding wall. 17. The dashmat assembly of claim 16, wherein the absorber layer has an opening sized to receive the enveloping region and lies entirely outside of the enveloping region. 7. A second, separate enclosing zone according to claim 6, wherein the second separate enclosing zone is integrally formed in the mass floor and the firewall sections (44, 46) by integrally formed ribs of at least the third and fourth sets (48, 50, 52). (38), and wherein the second separate enveloping zone (38) defines a scaffolding zone (40) extending at least along the floor and firewall portion of the mass. 9. The method of claim 8, wherein only the third set of ribs is elastically resistant to compression of the mass layer in the second separate enclosing zone 38 that reaches the first predetermined level. A dash mat assembly, characterized in that the third and fourth sets of ribs are formed such that the three sets of ribs resiliently resist compression of the mass layer in the second separate enclosing zone 38 that deviates from the first predetermined level. . 7. A dash mat assembly according to claim 6, further comprising an absorber layer (56) having an outer surface in contact with the inner surface (16) of the mass layer and an inner surface in contact with the shielding wall. 8. The dash mat assembly of claim 7, further comprising an absorber layer (56) having an outer surface in contact with the inner surface (16) of the mass layer and an inner surface in contact with the shielding wall. 10. A dash mat assembly according to claim 8 or 9, further comprising an absorber layer (56) having an outer surface in contact with the inner surface (16) of the mass layer and an inner surface in contact with the shielding wall. . 12. The dash mat assembly of claim 11, wherein the absorbent layer has an opening sized to receive a second separated enveloping region and lies entirely outside of the second separated enveloping region. 16. The dash mat assembly of claim 15, further comprising an absorber layer (56) having an outer surface in contact with an inner surface of the mass layer and an inner surface in contact with a shielding wall.