Acoustic Composite and Twin-Shell Lightweight Trim Part Comprising Such a Composite
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Accused Products
Abstract
A twin-shell lightweight acoustic trim part (11), in particular a self-supporting vehicle'"'"'s headliner or a rear parcel shelf comprises a thermoplastic acoustically effective structural composite (5). This composite comprises at least three layers (2, 3, 4), in particular on its front side a skin layer (4), preferably a binder layer made of a thermoplastic non-woven or grid, a stiffening layer (3) made of a non-woven comprising polypropylene and glass fibres, and on its rear side a soft layer (2) consisting of a polyolefin foam. These layers are needle-punched together in order to set a desired airflow resistance R in the range of 200 Nsm−3 to 5000 Nsm−3. In a preferred embodiment, the twin-shell lightweight acoustic trim part (11) comprises a core layer (8) which contains 50 parts of elastomeric foam sticks, 20 parts of glass fibres, 10 parts of polypropylene fibres material, and 20 parts bicomponent polyester fibres and preferably comprises additional 15% of recycled elastic foam material. This trim part is designed such that the thermoplastic bonded and acoustically effective structural composite (5) allows to absorb the uneven pressure forces of the elastomeric foam material (9) of the core layer (8) in order to achieve a smooth and soft touch feeling.
50 Citations
28 Claims
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1-13. -13. (canceled)
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14. A twin-shell acoustic trim part, comprising:
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a needle-punched thermoplastic structural composite with a skin layer at a front side of said structural composite, a soft foam layer at a rear side of said structural composite, and a stiffening layer between said skin layer and said soft layer; said skin layer, said soft foam layer, and said stiffening layer being needle punched together such that said structural composite comprises an airflow resistance R value between 200 Nsm−
3 and 5000 Nsm−
3;said needle-punched structural composite disposed at a front side of said acoustic trim part; a multi-layer skin structure at a back side of said acoustic trim part, said multi-layer skin structure being substantially impermeable to air flow; and said structural composite and said multi-layer skin structure being vacuum formed together. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28)
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Specification