Space filler with a vacuum cover

• US 10,011,238 B2
• Filed: 11/20/2017
• Issued: 07/03/2018
• Est. Priority Date: 08/09/2016
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Castro, Sergio, Garcia Ruiz, Emmanuel
• Primary Examiner(s): Luks, Jeremy
• Application Number:
  US15/817,890
• Publication Number:
  US 20180072245A1
• Time in Patent Office: 225 Days
• Field of Search: 181290, 296 393
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2250/04 4 layers
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2264/0292 Polyurethane particles
• CPC Class Codes: B32B 2266/0228 Aromatic vinyl resin, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2307/10 having particular acoustical properties
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/72 Density
• CPC Class Codes: B32B 2307/7242 Non-permeable
• CPC Class Codes: B32B 2307/732 Dimensional properties
• CPC Class Codes: B32B 2307/748 Releasability
• CPC Class Codes: B32B 2471/00 Floor coverings B32B2419/04 takes precedence
• CPC Class Codes: B32B 2605/00 Vehicles
• CPC Class Codes: B32B 2605/08 Cars
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/40 comprising polyurethanes
• CPC Class Codes: B32B 3/04 characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
• CPC Class Codes: B32B 3/06 for securing layers together; for attaching the product to another member, e.g. to a support , or to another product, e.g. groove/tongue, interlocking
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 37/1018 : using only vacuum
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/32 : at least two layers being foamed and next to each other
• CPC Class Codes: B32B 7/06 : permitting easy separation
• CPC Class Codes: B32B 7/08 : by mechanical means
• CPC Class Codes: B60R 13/0815 : Acoustic or thermal insulation of passenger compartments wall or roof liners integrating the insulating function B60R13/02; insulating floor mats or carpets B60N3/04
• CPC Class Codes: G10K 11/168 : Plural layers of different materials, e.g. sandwiches

Abstract

A vehicle having a space filling panel including a polystyrene layer, a polyurethane layer, and a polyethylene cover where the polyethylene cover forms a vacuum sealed space. The polystyrene layer and the polyurethane layer are both positioned in the polyethylene cover'"'"'s vacuum sealed space. In another embodiment, a space filling panel for a vehicle includes a polystyrene layer comprising a plurality of polyurethane chips. The polystyrene layer having the plurality of polyurethane chips is enclosed in a vacuum sealed space formed by a polyethylene cover.

Claims

1. A space filling panel for a vehicle comprising:

a polystyrene layer comprising a plurality of polyurethane chips; and

a polyethylene cover forming a vacuum sealed space;

wherein the polystyrene layer comprising the plurality of polyurethane chips is positioned in the vacuum sealed space.

2. The space filling panel of claim 1, wherein the polystyrene layer is an expanded polystyrene layer.

3. The space filling panel of claim 1, wherein the plurality of polyurethane chips are embeddingly coupled in the polystyrene layer.

4. The space filling panel of claim 1, wherein the plurality of polyurethane chips comprise at least 25 wt % of the space filling panel.

5. The space filling panel of claim 1, wherein the plurality of polyurethane chips comprise at least 35 wt % of the space filling panel.

6. The space filling panel of claim 1, wherein the vacuum sealed space has a pressure less than 1 atm.

7. The space filling panel of claim 1, wherein the vacuum sealed space has a pressure less than 0.5 atm.

8. The space filling panel of claim 1, wherein the polystyrene layer improves the space filling panel'"'"'s NVH properties.

9. A method for making a space filling panel in a vehicle comprising:

forming a first layer having a plurality of polymer chips disposed within the first layer; and

vacuum sealing the first layer with a polymeric cover to form the space filling panel;

wherein the space filling panel is disposed in a cabin floor of the vehicle.

10. The method of claim 9, wherein the polystyrene is an expanded polystyrene layer.

11. The method of claim 9, wherein the plurality of polymer chips comprise at least 25 wt % of the space filling panel.

12. The method of claim 9, wherein the plurality of polymer chips comprise at least 35 wt % of the space filling panel.

13. The method of claim 9, wherein the space filling panel has a pressure less than 1 atm.

14. The method of claim 9, wherein the space filling panel has a pressure less than 0.5 atm.

15. The method of claim 9, wherein the first layer having the plurality of polymer chips improves the space filling panel'"'"'s NVH properties.