US20120088073A1 - Method For The Production Of A Sound Insulation Molding With Mass And Spring - Google Patents
Method For The Production Of A Sound Insulation Molding With Mass And Spring Download PDFInfo
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- US20120088073A1 US20120088073A1 US13/330,533 US201113330533A US2012088073A1 US 20120088073 A1 US20120088073 A1 US 20120088073A1 US 201113330533 A US201113330533 A US 201113330533A US 2012088073 A1 US2012088073 A1 US 2012088073A1
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- Prior art keywords
- mass
- molding
- sound insulation
- spring
- layer
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- 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
- B29C44/04—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 consisting of at least two parts of chemically or physically different materials, e.g. having different densities
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- 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
- B29C44/34—Auxiliary operations
- B29C44/60—Measuring, controlling or regulating
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- 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
- B29C44/04—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 consisting of at least two parts of chemically or physically different materials, e.g. having different densities
- B29C44/0461—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 consisting of at least two parts of chemically or physically different materials, e.g. having different densities by having different chemical compositions in different places, e.g. having different concentrations of foaming agent, feeding one composition after the other
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- 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
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- 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
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- 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
- B60R13/0838—Insulating elements, e.g. for sound insulation for engine compartments
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24595—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness and varying density
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
- Y10T428/24992—Density or compression of components
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
Definitions
- the invention relates to a method for the production of a sound insulation molding with mass and spring, such a sound insulation molding, and the use thereof.
- the side which is to be seen can in particular have the shape of individual profiles in the manner of grooves or ribs.
- the spring, or foam layer can likewise be shaped.
- the molding can be adapted to certain developments of a surface to be sound insulated, to which the molding is to be attached.
- the spraying in is controlled so that for the formation of the mass the reaction substances and the fillers are supplied into the mold locally in different quantity and/or composition, and this in dependence upon sound damping to be locally achieved together with the spring.
- the invention thereby starts from the knowledge that a surface activated by a sound generator transfers the sound very differently, essentially frequency dependently but also partly in dependence upon location. In turn from this results that there is an optimal mass-spring combination for each surface region of a surface to be sound insulated, within the scope of production tolerances.
- the outlay of materials for the mass can therefore be optimized and with this for the molding as a whole. It is solely required to control the devices which bring about the spraying in or injection of the various materials for mass and spring so appropriately that locally the reaction substances (including expanding agents) and the fillers for the formation of the mass or heavy layer are delivered with the locally required quantity and composition.
- the filler content can in particular be varied in a simple way, typically between 0 and 50 volume per cent, the quantity of the supplied reaction substances can be varied such that different thicknesses of the mass or heavy layer are achieved, typically 0.5 mm and more (absolutely also 10 mm), and the makeup of the reaction substances can typically be adapted, for example for polyurethane materials over the complete range which is known from polyurethane chemistry.
- control of the devices delivering the materials is typically carried out automatically by means of computer control as this is in principle per se known for robot control.
- course of the control can be adapted quickly to changed conditions such as the assignment of another sound generator to a surface to be sound insulated. It is even possible therefore not only to produce small lots but also individual moldings in the desired number and order, as this is desired in just-in-time production. It can suffice for moldings identical in geometry, depending upon the quantity to be produced per unit time, to provide one single molding tool. Dependent on the size of the molding it may therefore even be possible to provide a mobile production facility which can flexibly be put to use on the spot.
- FIG. 1 in an isometric view and in section, the basic construction of a molding producible in accordance with the invention
- FIG. 2 schematically, in a view from above, a development of a molding with indication of different masses or heavy layer sections to be attained in accordance with the invention
- FIG. 3 a perspective view of a complicatedly formed body part as an example of a sound insulating surface with indication of surface sections in which certain mechanical characteristics in addition to acoustic characteristics are to be attained, as is possible by means of the invention
- FIG. 4 the application of the method according to the invention in the configuration of edges for e.g. through-openings and
- FIG. 5 in a view similar to that of FIG. 4 , the application of the invention in the configuration of elastic edges or lips.
- FIG. 1 shows a detail section through a molding 1 comprised of a mass 2 or heavy layer and a spring 3 or foam layer having the same material construction, preferably polyurethane.
- a mass 2 or heavy layer typically is cell-poor or cell-less and has a high weight per unit area which in substance is caused by fillers.
- the spring 3 or foam layer is, in contrast, rich in cells, has a low or not the slightest filler content and thus has a low weight per unit area.
- Mass 2 and spring 3 act in combination in a per se known way to achieve sound damping. Furthermore thickness and density as well as porosity have influence on the mechanical properties of the molding 1 at a certain location, as is also per se known.
- FIG. 1 illustrates schematically how, at a certain location of the molding 1 corresponding to the detail, the mass 2 is locally acted upon.
- the mass 2 is comprised of two discreet mass layers 4 and 5 .
- the first mass layer 4 can be provided for the complete molding 1 throughout in the same manner and define a carrier layer which influences the substantive mechanical properties.
- the second discreet mass layer 5 is locally applied so that the mass 2 is formed locally by the two layers 4 and 5 .
- the second discreet mass layer 5 can, but need not, have the same composition with regard to the reaction substances and the quantity of filler as the first discreet mass layer 4 and therefore be produced as a unit in the same working procedure. It also can be additionally applied after formation of the first discreet mass layer 4 in a mold according to the local conditions. From the above it follows that this local discreet second mass layer 5 can be formed also based on another composition of the reaction substances and/or another quantity of filler.
- the procedures upon allowing the reaction substances to react determine in the end whether it is more expedient for a certain location of the molding 1 to form the mass 2 as a plurality of layers, in the exemplary embodiment as two successive layers 4 , 5 , or in the form of a single layer, whereby the development of their thicknesses and densities is independent of each other.
- the spring 3 is generated in conventional manner by back foaming
- the formation of the mass 2 is effected expediently and in accordance with the invention directly in a mold-half of a mold shaped after the surface to be sound insulated.
- the formation of the foam layer of the spring 3 can then be carried out either in open or in closed mold, whereby the latter makes sense if the side of the spring 3 away from the mass 2 is to be or must be structured.
- the molding 1 can therefore be produced with mass 2 and spring 3 in one working procedure.
- the formation of the mass 2 can be effected also against a decorative part placed in a mold such as a carpet cutting or a web of material, but also the formation of the spring 3 can be effected between the mass 2 and a decorative part such as a carpet cutting or a web of material.
- FIG. 2 shows the development 6 of a molding, in which surface regions are indicated whose occupancy with mass 2 is different.
- surface regions 7 , 8 and 9 defined by different shadings or hatching, different weights per unit area (or densities) of the mass 2 and/or different thicknesses of the mass 2 are to be realized.
- regions which are similarly hatched or shaded are separated from each other by channel-like structures 10 .
- FIG. 3 shows schematically in a perspective view the complicated three-dimensional construction of a surface to be sound insulated—to be more precise, as an example, an end wall 11 of a typical motor vehicle.
- a non-illustrated molding which is be applied in form-fitting manner to this end wall 11 , is to have locally different characteristics which are illustrated by different borders and shadings. This involves combinations of both mechanical characteristics which can be represented by words and acoustic characteristics which are definable by masses per unit area or weight per unit area.
- the details are of course exemplary and real moldings, to be assigned to an arbitrary end wall 11 , can have both mechanical and acoustic characteristics which strongly deviate locally.
- surface regions 12 are to have high strength with a weight per unit area of about 1 kg/m2
- surface regions 13 are to be soft elastic with a weight per unit area of 2 kg/m2
- surface regions 14 are to be overall light weight with a weight per unit area of 1 kg/m2
- surface regions 15 are to have both high strength as well as being hard and have a weight per unit area of for example 4.5 kg/m2
- surface regions 16 are to be heavy with a weight per unit area of about 4.5 kg/m2
- remaining surface regions 17 are to have a weight per unit area of 2 kg/m2 without predetermined mechanical properties
- regions 18 are to be soft elastic with a weight per unit area of 1 kg/m2 and be formed to a run-out lip. From the above it arises that a mass 2 must be provided throughout with a weight per unit area of at least 1 kg/m2, whereby locally higher weights per units area are to be provided, wherein furthermore locally additional certain mechanical characteristics are to be attained.
- the mechanical properties are on the one hand possible by influencing the local composition of the reaction substance mixtures and the type and the proportion of the solid substances, but also by action on the foam formation.
- the latter is for example possible in the manner and way explained in EP 1 237 751 A1 of the present applicant. Influence can, however, also be exercised in other manners and ways on the mechanical properties.
- FIG. 4 and FIG. 5 show in section how by influencing the mass at peripheries and edges the mechanical properties thereof can be influenced. Thereby it is to be noted that the acoustic characteristics are of rather subordinate importance there.
- FIG. 4 shows in the case of a molding 1 comprised of mass 2 and spring 3 a physically distinctive edge 20 in the region of which both first discreet mass layer 4 and second discreet mass layer 5 are formed considerably more thickly than in adjacent regions.
- an outer edge region 21 in the case of which no further foam 3 can, if applicable, be provided for instance to define through openings, comparatively high stiffness is achieved in cooperation with the edge 20 .
- FIG. 5 also shows a distinctive edge 20 , whereby the two layers 4 and 5 of the mass 2 end within the molding, as illustrated at 22 , such that the foam of the spring 3 , as illustrated at 23 , forms a lip extending outwardly, which upon bearing on concrete elements can achieve an elastic termination.
- the invention is in particular applicable to the production of moldings for motor vehicles, in particular motor cars.
- bodywork constructions identical at least in sections, are associated with a variety of different engines.
- the different engines as sound generators, can excite in different ways, possibly in extremely different ways, surfaces to be sound insulated, both with regard to the transferred frequencies and also the respective intensity thereof, and also with regard to the disposition of the locations of maximum sound transmission.
- the conditions can change in the case of different vehicle types (such as car, convertible, estate car) for such body parts which are formed geometrically like, such as for example an end wall 11 in accordance with FIG. 3 between passenger space and engine compartment.
- the method according to the invention therefore is also suitable for the production of small lots and in particular also for making available moldings identical in geometry of different construction in a predetermined order, as this is required for example for just-in-time production.
- the at least one device for the introduction of the reaction substances and fillers into the mold for the production of the mass 2 is expediently controlled automatically in the manner of a robotic control, whereby programs for the automatic control of robots which serve for the coating of complicated three-dimensional areas, in principle for painting, are per se known. Additionally, however, there must be taken into account in the programming on the one hand the locally differing mixture, obtained by means the invention, of the supplied reaction substances for the attainment of the local mechanical and acoustic characteristics, as well as on the other hand also the necessary thickness of the mass 2 to be attained.
- a prototype of the surface to be sound insulated is examined together with a prototype of a sound generator with regard to the sound transfer behavior, for the mentioned typical employment of moldings produced according to the invention. It is then determined which surface regions of the surface to be sound insulated require a damping going beyond a minimum damping. Starting out from mechanical specifications and spatial specifications provided by the customer with regard to the design of the molding, in particular on the side away from the surface to be sound insulated, the ideal construction of a molding can then be determined.
- a classification can be carried out over surface regions in practice, since on the one hand production tolerances are taken into account or must be accepted in the production of the surface to be sound insulated and of the sound generator and on the other hand working tolerances in the control of the devices for the introduction of the reaction substances and fillers are taken into account or must be accepted. There is therefore provided an assignment and classification as has been explained with reference to FIG. 3 .
- a set of parameters or a parameter matrix can thus be produced, which are specified for the predetermined association of a certain sound generator with the surface to be sound insulated, which allows the specific control of the at least one device for the introduction of the reaction substances (including expanding agents) and fillers.
- the various different control programmes for the control of the at least one device for the introduction of the reaction substances and fillers into the mold corresponding to a predetermined surface to be sound insulated then can be called up freely selectably and used for the production of individual moldings.
- an apparatus for carrying out the method that is for the production of moldings formed according to the invention, can be constituted as a mobile unit, insofar as the geometry the molding and thus of the mold allows this.
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- Physics & Mathematics (AREA)
- Acoustics & Sound (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
- Soundproofing, Sound Blocking, And Sound Damping (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
- Stringed Musical Instruments (AREA)
- Electromechanical Clocks (AREA)
Abstract
The invention relates to a method of producing a sound insulation molding with mass (2) and spring (3), wherein both mass (2) and spring (3) are produced on the basis of the same material, in particular polyurethane. For the formation of a mass, reaction substances and fillers are brought into a mold, in particular sprayed in or injected, and brought to reaction. The spraying in or injection is thereby controlled such that the reaction substances and the fillers are supplied in locally different quantity and/or composition into the mold, dependent upon the sound damping to be locally achieved together with the spring, which is then formed on the so-formed mass (2) in the same mold through formation of foam. Through this, with surfaces to be sound insulated which are of the same geometry, three-dimensional moldings (1) of the same geometry can be produced with both different acoustic and also mechanical behavior in predetermined series.
Description
- The invention relates to a method for the production of a sound insulation molding with mass and spring, such a sound insulation molding, and the use thereof.
- From EP 0 882 561 A1 there is known a method for the production of a sound insulation molding with mass and spring, with which both the mass and the spring are produced on the basis of the same material, namely polyurethane. For the formation of a mass, reaction substances and fillers are sprayed or injected into a mold and brought to reaction, whereby by means of a die there is attained a forming of the mass as a mass layer. Foam is then formed in the same mold, as a spring on the mass, and this by means of a second molding through which the mass layer is foamed on the back. The features of the preamble of the
claim 1 are therefore known from this document. - With the known approach a continuous mass layer with essentially uniform thickness is obtained, whereby with appropriate configuration the side which is to be seen can in particular have the shape of individual profiles in the manner of grooves or ribs. The spring, or foam layer, can likewise be shaped. Through this the molding can be adapted to certain developments of a surface to be sound insulated, to which the molding is to be attached.
- The outlay of materials required in the production of the mass or heavy layer is substantial and thus cost-intensive. In addition, a somewhat economic production is possible only in the case of large quantities. Typical moldings of the described type are used in vehicles, in particular cars. Cars are offered, with the same bodywork construction, with very different engines, so that in the configuration of the molding and thereby in particular the mass or heavy layer the most unfavorable constellation of an engine as a sound generator and surface to be sound damped by the molding must be taken into account.
- Starting from this, it is the object of the present invention to indicate an approach by means of which a high sound insulation or soundproofing effect can be attained with low outlay of materials.
- In accordance with the invention the spraying in is controlled so that for the formation of the mass the reaction substances and the fillers are supplied into the mold locally in different quantity and/or composition, and this in dependence upon sound damping to be locally achieved together with the spring.
- The invention thereby starts from the knowledge that a surface activated by a sound generator transfers the sound very differently, essentially frequency dependently but also partly in dependence upon location. In turn from this results that there is an optimal mass-spring combination for each surface region of a surface to be sound insulated, within the scope of production tolerances. The outlay of materials for the mass can therefore be optimized and with this for the molding as a whole. It is solely required to control the devices which bring about the spraying in or injection of the various materials for mass and spring so appropriately that locally the reaction substances (including expanding agents) and the fillers for the formation of the mass or heavy layer are delivered with the locally required quantity and composition. The filler content can in particular be varied in a simple way, typically between 0 and 50 volume per cent, the quantity of the supplied reaction substances can be varied such that different thicknesses of the mass or heavy layer are achieved, typically 0.5 mm and more (absolutely also 10 mm), and the makeup of the reaction substances can typically be adapted, for example for polyurethane materials over the complete range which is known from polyurethane chemistry.
- Furthermore it is possible by further measures not only to have influence on the acoustic characteristics but also on mechanical characteristics such as mechanical strength or elasticity. For example, where in the finished manufactured molding through-openings are to be provided the mechanical strength can be increased, whilst where in the finished manufactured molding thick edges to other parts should be provided, the elasticity should be higher. In particular manner this can be achieved without impairment of the sound engineering or acoustic characteristics in that, with the retention of the same density, locally neighboring regions have different compositions of the reaction substances employed.
- It turns out that the control of the devices delivering the materials is typically carried out automatically by means of computer control as this is in principle per se known for robot control. In turn from this results that the course of the control can be adapted quickly to changed conditions such as the assignment of another sound generator to a surface to be sound insulated. It is even possible therefore not only to produce small lots but also individual moldings in the desired number and order, as this is desired in just-in-time production. It can suffice for moldings identical in geometry, depending upon the quantity to be produced per unit time, to provide one single molding tool. Dependent on the size of the molding it may therefore even be possible to provide a mobile production facility which can flexibly be put to use on the spot.
- In particular with the employment of exclusively PUR materials, due to the possibility of manufacturing individual moldings, special wishes can be taken into account, for example with regard to the color design.
- The invention is explained in more detail with reference to the exemplary embodiments illustrated in the drawings. There is shown:
-
FIG. 1 in an isometric view and in section, the basic construction of a molding producible in accordance with the invention, -
FIG. 2 schematically, in a view from above, a development of a molding with indication of different masses or heavy layer sections to be attained in accordance with the invention, -
FIG. 3 a perspective view of a complicatedly formed body part as an example of a sound insulating surface with indication of surface sections in which certain mechanical characteristics in addition to acoustic characteristics are to be attained, as is possible by means of the invention, -
FIG. 4 the application of the method according to the invention in the configuration of edges for e.g. through-openings and -
FIG. 5 in a view similar to that ofFIG. 4 , the application of the invention in the configuration of elastic edges or lips. -
FIG. 1 shows a detail section through amolding 1 comprised of amass 2 or heavy layer and aspring 3 or foam layer having the same material construction, preferably polyurethane. - A
mass 2 or heavy layer typically is cell-poor or cell-less and has a high weight per unit area which in substance is caused by fillers. Thespring 3 or foam layer is, in contrast, rich in cells, has a low or not the slightest filler content and thus has a low weight per unit area. -
Mass 2 andspring 3 act in combination in a per se known way to achieve sound damping. Furthermore thickness and density as well as porosity have influence on the mechanical properties of themolding 1 at a certain location, as is also per se known. -
FIG. 1 illustrates schematically how, at a certain location of themolding 1 corresponding to the detail, themass 2 is locally acted upon. In the exemplary embodiment themass 2 is comprised of two discreetmass layers first mass layer 4 can be provided for thecomplete molding 1 throughout in the same manner and define a carrier layer which influences the substantive mechanical properties. The seconddiscreet mass layer 5 is locally applied so that themass 2 is formed locally by the twolayers discreet mass layer 5 can, but need not, have the same composition with regard to the reaction substances and the quantity of filler as the firstdiscreet mass layer 4 and therefore be produced as a unit in the same working procedure. It also can be additionally applied after formation of the firstdiscreet mass layer 4 in a mold according to the local conditions. From the above it follows that this local discreetsecond mass layer 5 can be formed also based on another composition of the reaction substances and/or another quantity of filler. - The procedures upon allowing the reaction substances to react, taking into consideration take-up of fillers, determine in the end whether it is more expedient for a certain location of the
molding 1 to form themass 2 as a plurality of layers, in the exemplary embodiment as twosuccessive layers mass 2 thespring 3 is generated in conventional manner by back foaming - Since a surface to be sound insulated normally has a very complicated three-dimensional shape, the formation of the
mass 2, which must be contour-following, is effected expediently and in accordance with the invention directly in a mold-half of a mold shaped after the surface to be sound insulated. The formation of the foam layer of thespring 3 can then be carried out either in open or in closed mold, whereby the latter makes sense if the side of thespring 3 away from themass 2 is to be or must be structured. - The
molding 1 can therefore be produced withmass 2 andspring 3 in one working procedure. - It turns out that the formation of the
mass 2 can be effected also against a decorative part placed in a mold such as a carpet cutting or a web of material, but also the formation of thespring 3 can be effected between themass 2 and a decorative part such as a carpet cutting or a web of material. -
FIG. 2 shows thedevelopment 6 of a molding, in which surface regions are indicated whose occupancy withmass 2 is different. Insurface regions mass 2 and/or different thicknesses of themass 2 are to be realized. In thedevelopment 6 regions which are similarly hatched or shaded are separated from each other by channel-like structures 10. Through this it is illustrated that in the application of themass 2 in the appropriate surface regions of the real mold for the formation of the real molding, expediently different application procedures are to be provided due to the three-dimensional conditions, for example by means of other devices for the supply of the reaction substances and fillers or by means of a setting of the spatial disposition of the devices for the introduction of the reaction substances and the fillers that is to be adjusted. - Furthermore, from the above explanation it is apparent that, in considerably greater variety than indicated by
FIG. 2 , surface regions can be provided at which there can be achieved a structure differing in its composition determined by the reaction substances and quantity of filler, and also in its thickness, in themass 2 formed overall over the molding. -
FIG. 3 shows schematically in a perspective view the complicated three-dimensional construction of a surface to be sound insulated—to be more precise, as an example, anend wall 11 of a typical motor vehicle. A non-illustrated molding, which is be applied in form-fitting manner to thisend wall 11, is to have locally different characteristics which are illustrated by different borders and shadings. This involves combinations of both mechanical characteristics which can be represented by words and acoustic characteristics which are definable by masses per unit area or weight per unit area. The details are of course exemplary and real moldings, to be assigned to anarbitrary end wall 11, can have both mechanical and acoustic characteristics which strongly deviate locally. In theexample surface regions 12 are to have high strength with a weight per unit area of about 1 kg/m2,surface regions 13 are to be soft elastic with a weight per unit area of 2 kg/m2,surface regions 14 are to be overall light weight with a weight per unit area of 1 kg/m2,surface regions 15 are to have both high strength as well as being hard and have a weight per unit area of for example 4.5 kg/m2,surface regions 16 are to be heavy with a weight per unit area of about 4.5 kg/m2, remaining surface regions 17 are to have a weight per unit area of 2 kg/m2 without predetermined mechanical properties, andregions 18 are to be soft elastic with a weight per unit area of 1 kg/m2 and be formed to a run-out lip. From the above it arises that amass 2 must be provided throughout with a weight per unit area of at least 1 kg/m2, whereby locally higher weights per units area are to be provided, wherein furthermore locally additional certain mechanical characteristics are to be attained. - The mechanical properties are on the one hand possible by influencing the local composition of the reaction substance mixtures and the type and the proportion of the solid substances, but also by action on the foam formation. The latter is for example possible in the manner and way explained in
EP 1 237 751 A1 of the present applicant. Influence can, however, also be exercised in other manners and ways on the mechanical properties. -
FIG. 4 andFIG. 5 show in section how by influencing the mass at peripheries and edges the mechanical properties thereof can be influenced. Thereby it is to be noted that the acoustic characteristics are of rather subordinate importance there. - Similarly to
FIG. 1 ,FIG. 4 shows in the case of amolding 1 comprised ofmass 2 and spring 3 a physicallydistinctive edge 20 in the region of which both firstdiscreet mass layer 4 and seconddiscreet mass layer 5 are formed considerably more thickly than in adjacent regions. In anouter edge region 21 in the case of which nofurther foam 3 can, if applicable, be provided for instance to define through openings, comparatively high stiffness is achieved in cooperation with theedge 20. - Similarly to
FIG. 4 ,FIG. 5 also shows adistinctive edge 20, whereby the twolayers mass 2 end within the molding, as illustrated at 22, such that the foam of thespring 3, as illustrated at 23, forms a lip extending outwardly, which upon bearing on concrete elements can achieve an elastic termination. - Thus, in one mold, whose under-mold has a development adapted to a surface to be sound insulated, there can be associated moldings individually formed in accordance with the invention, as desired.
- Thereby there can be associated with a mold one or also several devices by means of which the supply of the reaction substances is adjustable in a way permissible for the production of the product, in selectable manner in accordance with quantity and proportions, whereby also fillers can be mixed in within the permitted range. An approach can for example be used in accordance with DE 101 61 600 A1 of the applicant, which permits the variable and simultaneous application of fillers into a reaction substance mixture spray.
- The invention is in particular applicable to the production of moldings for motor vehicles, in particular motor cars. As is known, bodywork constructions, identical at least in sections, are associated with a variety of different engines. This means, however, that the different engines, as sound generators, can excite in different ways, possibly in extremely different ways, surfaces to be sound insulated, both with regard to the transferred frequencies and also the respective intensity thereof, and also with regard to the disposition of the locations of maximum sound transmission. Thereby, the conditions can change in the case of different vehicle types (such as car, convertible, estate car) for such body parts which are formed geometrically like, such as for example an
end wall 11 in accordance withFIG. 3 between passenger space and engine compartment. On the other hand experience has shown that the association of a body part to a certain engine and therewith to a certain sound generator (with the same vehicle type), leads to a large extent to similar sound transmission conditions in the case of a surface to be sound insulated. By means of the invention there can therefore be attained on the one hand in simple manner an optimal acoustic design of a molding, taking into consideration mechanical specifications, whereby on the other hand a considerable material saving is already possible because the material can be adapted optimally for the mass and the mass has the largest material component. - Since in accordance with the invention this optimization is possible for each of the possible associations of a geometrically similar surface to be sound insulated with a sound generator, namely an engine, taking into consideration also the vehicle type, based on the same mold, which constructionally corresponds to the surface to be sound damped, each necessary molding can be produced optimally, individually and as required.
- The method according to the invention therefore is also suitable for the production of small lots and in particular also for making available moldings identical in geometry of different construction in a predetermined order, as this is required for example for just-in-time production.
- The at least one device for the introduction of the reaction substances and fillers into the mold for the production of the
mass 2 is expediently controlled automatically in the manner of a robotic control, whereby programs for the automatic control of robots which serve for the coating of complicated three-dimensional areas, in principle for painting, are per se known. Additionally, however, there must be taken into account in the programming on the one hand the locally differing mixture, obtained by means the invention, of the supplied reaction substances for the attainment of the local mechanical and acoustic characteristics, as well as on the other hand also the necessary thickness of themass 2 to be attained. - Firstly, a prototype of the surface to be sound insulated is examined together with a prototype of a sound generator with regard to the sound transfer behavior, for the mentioned typical employment of moldings produced according to the invention. It is then determined which surface regions of the surface to be sound insulated require a damping going beyond a minimum damping. Starting out from mechanical specifications and spatial specifications provided by the customer with regard to the design of the molding, in particular on the side away from the surface to be sound insulated, the ideal construction of a molding can then be determined. A classification can be carried out over surface regions in practice, since on the one hand production tolerances are taken into account or must be accepted in the production of the surface to be sound insulated and of the sound generator and on the other hand working tolerances in the control of the devices for the introduction of the reaction substances and fillers are taken into account or must be accepted. There is therefore provided an assignment and classification as has been explained with reference to
FIG. 3 . A set of parameters or a parameter matrix can thus be produced, which are specified for the predetermined association of a certain sound generator with the surface to be sound insulated, which allows the specific control of the at least one device for the introduction of the reaction substances (including expanding agents) and fillers. - This investigation and assessment and classification can now be carried out now for each association of the geometrically identical surface to be sound insulated with a different sound generator. Facilitation can be provided in the context of the investigation and assessment if the different sound generators are of similar type, as can be the case for example with car engines of different cubic capacities and the same mounting disposition. It can thereby arise that for several different sound generators in substance the same classifications arise, under consideration of the mentioned necessary tolerances. This would make the programming effort easier.
- The various different control programmes for the control of the at least one device for the introduction of the reaction substances and fillers into the mold corresponding to a predetermined surface to be sound insulated then can be called up freely selectably and used for the production of individual moldings.
- Since in particular in the case of polyurethane materials there are typically involved pumpable starting products for the reaction substances (polyols, isocyanates, and expanding agent) and fillers, an apparatus for carrying out the method, that is for the production of moldings formed according to the invention, can be constituted as a mobile unit, insofar as the geometry the molding and thus of the mold allows this.
- It is to be mentioned that furthermore it is possible bring into a mold also third party components such as additional construction elements before, during or after the formation of the
mass 2 in a mold, if this is necessary or is wished by the customer. - Finally it is to be mentioned that since the same materials are used for both mass and spring the recycling ability is increased considerably.
Claims (20)
1.-13. (canceled)
14. Sound insulation comprising:
a sound insulation molding to sound insulate a surface that requires different sound damping in different regions, the sound insulation molding comprising a mass of foam and a spring of foam formed of a same material;
wherein the mass includes a content of filler;
wherein the spring includes a content of filler which is less than the content of filler of the mass;
wherein the mass has two layers that each vary in thickness and/or composition;
wherein the mass has a weight per unit area of 1 kg/m2 to 4.5 kg/m2 at thicknesses of 0.5 mm to 10 mm; and
wherein the spring has a lower weight per unit area than the mass due to the lower content of filler.
15. The sound insulation of claim 14 wherein:
the two layers of the mass comprise a first layer and a second layer; and
the first layer provides a carrier layer; and
the second layer is locally applied to the first layer.
16. The sound insulation of claim 14 wherein:
the two layers of the mass are each formed with reaction substances.
17. The sound insulation of claim 14 wherein:
the two layers of the mass are each formed with a quantity of filler; and
the quantity of filler for each layer is different.
18. The sound insulation of claim 14 wherein:
the mass and the spring are each formed of polyurethane material.
19. The sound insulation of claim 14 wherein:
the two mass layers that each vary in thickness and/or composition vary in thickness and/or composition to vary local acoustic and mechanical characteristics.
20. The sound insulation of claim 14 wherein:
the spring is molded to the mass.
21. The sound insulation of claim 14 wherein:
the mass is formed against a decorative part.
22. The sound insulation of claim 14 wherein:
the sound insulation molding is to dampen sound of a motor vehicle.
23. The sound insulation of claim 22 wherein:
the sound insulation molding is to be used between an engine compartment and a passenger space of a motor vehicle.
24. A motor vehicle molding comprising:
a sound insulation molding to sound insulate a surface of a motor vehicle that requires different sound damping in different regions, the sound insulation molding comprising a mass of foam and a spring of foam formed of a same material;
wherein the mass includes a content of filler;
wherein the spring includes a content of filler which is less than the content of filler of the mass;
wherein the mass has two layers that each vary in thickness and/or composition;
wherein the mass has a weight per unit area of 1 kg/m2 to 4.5 kg/m2 at thicknesses of 0.5 mm to 10 mm; and
wherein the spring has a lower weight per unit area than the mass due to the lower content of filler.
25. The molding of claim 24 wherein:
the two layers of the mass comprise a first layer and a second layer; and
the first layer provides a carrier layer; and
the second layer is locally applied to the first layer.
26. The molding of claim 24 wherein:
the two layers of the mass are each formed with reaction substances.
27. The molding of claim 14 wherein:
the two layers of the mass are each formed with a quantity of filler; and
the quantity of filler for each layer is different.
28. The molding of claim 24 wherein:
the mass and the spring are each formed of polyurethane material.
29. The molding of claim 24 wherein:
the two mass layers that each vary in thickness and/or composition vary in thickness and/or composition to vary local acoustic and mechanical characteristics.
30. The molding of claim 24 wherein:
the spring is molded to the mass.
31. The molding of claim 24 wherein:
the mass is formed against a decorative part.
32. The molding of claim 24 wherein:
the sound insulation molding is adapted to be used between an engine compartment and a passenger space of a motor vehicle.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US13/330,533 US20120088073A1 (en) | 2004-08-13 | 2011-12-19 | Method For The Production Of A Sound Insulation Molding With Mass And Spring |
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE102004039438.5 | 2004-08-13 | ||
DE200410039438 DE102004039438A1 (en) | 2004-08-13 | 2004-08-13 | Method for producing a sound insulation molding with mass and spring |
PCT/EP2005/008642 WO2006018190A1 (en) | 2004-08-13 | 2005-08-09 | Method for producing a molded soundproof part comprising a mass and a springy part |
US65999008A | 2008-05-27 | 2008-05-27 | |
US13/330,533 US20120088073A1 (en) | 2004-08-13 | 2011-12-19 | Method For The Production Of A Sound Insulation Molding With Mass And Spring |
Related Parent Applications (2)
Application Number | Title | Priority Date | Filing Date |
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PCT/EP2005/008642 Division WO2006018190A1 (en) | 2004-08-13 | 2005-08-09 | Method for producing a molded soundproof part comprising a mass and a springy part |
US65999008A Division | 2004-08-13 | 2008-05-27 |
Publications (1)
Publication Number | Publication Date |
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US20120088073A1 true US20120088073A1 (en) | 2012-04-12 |
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Application Number | Title | Priority Date | Filing Date |
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US11/659,990 Active 2027-12-08 US8080193B2 (en) | 2004-08-13 | 2005-08-09 | Method for the production of a sound insulation molding with mass and spring |
US13/330,533 Abandoned US20120088073A1 (en) | 2004-08-13 | 2011-12-19 | Method For The Production Of A Sound Insulation Molding With Mass And Spring |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
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US11/659,990 Active 2027-12-08 US8080193B2 (en) | 2004-08-13 | 2005-08-09 | Method for the production of a sound insulation molding with mass and spring |
Country Status (8)
Country | Link |
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US (2) | US8080193B2 (en) |
EP (1) | EP1776219B1 (en) |
JP (1) | JP2008509028A (en) |
KR (1) | KR20070053220A (en) |
AT (1) | ATE506161T1 (en) |
DE (2) | DE102004039438A1 (en) |
ES (1) | ES2363520T3 (en) |
WO (1) | WO2006018190A1 (en) |
Families Citing this family (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2900110B1 (en) * | 2006-04-20 | 2008-07-11 | Faurecia Automotive Ind Snc | INTERIOR EQUIPMENT ASSEMBLY OF A MOTOR VEHICLE AND METHOD OF MAKING THE SAME |
WO2011023303A1 (en) | 2009-08-26 | 2011-03-03 | Bayer Materialscience Ag | Method for producing sound-absorbing flexible moulded foams |
WO2011023328A1 (en) | 2009-08-26 | 2011-03-03 | Bayer Materialscience Ag | Method for producing sound-absorbing polyurethane layers |
DE102012100422B4 (en) | 2012-01-19 | 2024-01-04 | Auria Solutions Uk I Ltd. | Device and method for producing an injection molded component, in particular a sound insulation component of a motor vehicle |
DE102012100419A1 (en) | 2012-01-19 | 2013-07-25 | International Automotive Components Group Gmbh | Injection molding tool for manufacturing sound insulation component of motor vehicle, has cavity with surface structure isolated by connection of inserts with corresponding segments of molded body to produce injection molding component |
PL2626854T3 (en) | 2012-02-09 | 2015-12-31 | Electrolux Home Products Corp Nv | Insulated component of a household appliance, in particular of a dishwasher, and method for manufacturing such a component |
US8881864B2 (en) | 2012-10-04 | 2014-11-11 | International Automation Components Group North America, Inc. | Motor vehicle acoustic insulator, methods of manufacture and use thereof |
DE202013003984U1 (en) * | 2013-04-27 | 2014-08-04 | GM Global Technology Operations LLC (n. d. Ges. d. Staates Delaware) | Schallisolierteil for a motor vehicle |
DE102016207742A1 (en) | 2016-05-04 | 2017-11-09 | Bayerische Motoren Werke Aktiengesellschaft | Vehicle component with protective element and method for producing a vehicle component with protective element |
AT519381A2 (en) * | 2016-11-24 | 2018-06-15 | Fill Gmbh | Process for producing a shaped body |
DE102018103462A1 (en) * | 2018-02-15 | 2019-08-22 | Adler Pelzer Holding Gmbh | Automotive carpeting |
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2004
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- 2005-08-09 WO PCT/EP2005/008642 patent/WO2006018190A1/en active Application Filing
- 2005-08-09 KR KR1020077003508A patent/KR20070053220A/en not_active Application Discontinuation
- 2005-08-09 ES ES05764314T patent/ES2363520T3/en active Active
- 2005-08-09 AT AT05764314T patent/ATE506161T1/en active
- 2005-08-09 JP JP2007525242A patent/JP2008509028A/en active Pending
- 2005-08-09 DE DE200550011283 patent/DE502005011283D1/en active Active
- 2005-08-09 EP EP20050764314 patent/EP1776219B1/en active Active
-
2011
- 2011-12-19 US US13/330,533 patent/US20120088073A1/en not_active Abandoned
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Also Published As
Publication number | Publication date |
---|---|
DE102004039438A1 (en) | 2006-02-23 |
WO2006018190A1 (en) | 2006-02-23 |
JP2008509028A (en) | 2008-03-27 |
DE502005011283D1 (en) | 2011-06-01 |
ATE506161T1 (en) | 2011-05-15 |
ES2363520T3 (en) | 2011-08-08 |
EP1776219B1 (en) | 2011-04-20 |
KR20070053220A (en) | 2007-05-23 |
EP1776219A1 (en) | 2007-04-25 |
US8080193B2 (en) | 2011-12-20 |
US20090110902A1 (en) | 2009-04-30 |
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