Sound insulating vehicle body part

• US 5,567,922 A
• Filed: 02/22/1994
• Issued: 10/22/1996
• Est. Priority Date: 04/26/1991
• Status: Expired due to Fees

• Current Assignee: Matec Holding AG
• Original Assignee: Matec Holding AG
• Inventors: Buisson, Claude, Schmuck, Jean-Claude, Jeannot, Claude
• Primary Examiner(s): Gellner, M. L.
• Assistant Examiner(s): LEE, EDDIE C H
• Application Number:
  US08/200,538
• Time in Patent Office: 973 Days
• Field of Search: 181/284, 181/286, 181/288, 181/290, 181/291, 181/293, 181/294
• US Class Current: 181/284
• CPC Class Codes: B60R 13/08 Insulating elements, e.g. for sound insulation sound insulating linings for trains B61D17/185; drivers' cabs for load-carrying vehicles insulated against vibrations or noise B62D33/0604; thermal or acoustic insulation of engines F02B77/11; damping of sounds using compensation by electro-acoustic methods G10K11/178
• CPC Class Codes: B60R 13/0838 for engine compartments
• CPC Class Codes: B60R 2013/0807 Arrangements of fasteners or clips specially adapted therefore

Abstract

There is described a sound-insulating power vehicle part which includes a shaped outer sheet and an acoustically effective inside packing which together form an inherently stable lightweight composite part. To obtain this, a thermosetting plastic is used for the outer sheet while the inside packing is formed of a fiber-resin fleece, which is only slightly compacted in an acoustically effective main area and is closely compacted in its stabilizing areas.

Claims

1. Inherently stable self-supporting composite part for engine hoods for acoustic screening of noise sources, comprising:

a shaped outside sheet of thermosetting plastic material and having an inside form and an inner surface;

a noise-insulating inside packing fastened directly to the outside sheet, which inside packing has a continuous inner surface opposite said outside sheet inner surface, and where said inside packing is adapted corresponding to the inside form of the outside sheet and has countersunk deformations, which together with the outside sheet form open acoustically effective hollow spaces between said outside sheet inner surface and said inside packing continuous inner surface;

the inner packing comprising a fiber fleece adhered with a phenolic resin, and covered with a fiber mat in direct contact with said fiber fleece; and

said outer sheet and said inside packing cooperating to form a self-supporting structure, independent of the engine hood.

2. Composite part as defined in claim 1, wherein the inside packing has a main area which is slightly compacted;

the inside packing having at least one stabilizing, closely compacted area in which are arranged fin-shaped reinforcement zones and which further includes highly compacted proportional areas with adhesive or bonded zones and reinforcement zones; and

wherein the outside sheet is bonded at least with the highly compacted adhesive or bonded zones.

3. Composite part as defined in claim 2, further including a protective film on the inside packing;

and wherein the outside sheet includes a lacquer layer on a side more distant from the inside packing.

4. Composite part as defined in claim 1, further including holder elements mounted on the inside packing for fastening to the composite part.

5. Composite part as defined in claim 1, wherein all of the components of the composite part are made of disposable and preferably of decomposable biodegradable materials.

6. Composite part as defined in claim 1, wherein the inside packing is covered on both sides with a fiber mat coated with an amino resin mixture, one side of which includes a decorative layer over which is mounted a removable protective film.

7. Composite part as defined in claim 6, wherein the inside packing has a main area which is slightly compacted;

the inside packing having at least one stabilizing, closely compacted area in which are arranged fin-shaped reinforcement zones and which further includes highly compacted proportional areas with adhesive or bonded zones and reinforcement zones; and

wherein the outside sheet is bonded at least with the highly compacted adhesive or bonded zones.

8. A sound-insulating inside packing for the composite part of claim 1, wherein the inside packing is covered on both sides with a fiber mat coated with an amino resin mixture, one side of which includes a decorative layer over which is mounted a removable protective film.

9. The inside packing as defined in claim 8, further including tightly anchored fastening elements.

10. The inside packing as defined in claim 9, wherein fastening elements are made of plastic.

11. The inside packing as defined in claim 10, further including a microorganism-repelling reticulate layer between the fiber mat and the decorative layer.

12. Composite part as defined in claim 1, further comprising a removable protective film attached to an exposed surface of said inside packing.

13. An inherently stable self-supporting composite part for engine hoods for acoustic screening of noise sources, comprising:

an outer sheet of thermosetting material,

a noise-insulating inside packing comprising a fiber fleece adhered with a plastic resin and covered with a fiber mat in direct contact with said fiber fleece,

said inside packing including;

one or more acoustically effective countersunk deformations of a first thickness formed therein,

one or more stabilizing reinforcement zones formed peripherally around said acoustically effective countersunk deformations and of a thickness less than said first thickness, and

a supporting system comprising highly compacted bonded zones of a thickness less than said first thickness and surrounding said countersunk deformations and said reinforcement zones and contacting said outer sheet,

wherein said outer sheet and said countersunk deformations form open free spaces therebetween which serve as Helmholtz resonators and wherein said highly compacted bonded zones contacting said outer sheet provide the only support between said inside packing and said outer sheet and cooperate to form a self-supporting structure independent of the engine hood.

14. An inherently stable composite part as in claim 13, wherein said support system comprises fin-shaped highly compacted bonded zones.

15. Composite part as defined in claim 13, further including a protective film on the inside packing;

and wherein the outer sheet includes a lacquer layer on a side more distant from the inside packing.

16. Composite part as defined in claim 13, further including holder elements mounted on the inside packing for fastening to the composite part.

17. Composite part as defined in claim 13, wherein all of the components of the composite part are made of disposable and preferably of decomposable biodegradable materials.

18. Composite parts as defined in claim 13, wherein the inside packing is covered on both sides with a fiber mat coated with an amino resin mixture, one side of which includes a decorative layer over which is mounted a removable protective film.

19. A sound-insulating inside packing for the composite part of claim 13, wherein the inside packing is covered on both sides with a fiber mat coated with an amino resin mixture, one side of which includes a decorative layer over which is mounted a removable protective film.

20. The inside packing as defined in claim 19, further including tightly anchored fastening elements.

21. The inside packing as defined in claim 20, wherein fastening elements are made of plastic.

22. The inside packing as defined in claim 21, further including a microorganism-repelling reticulate layer between the fiber mat and the decorative layer.

23. Composite part as defined in claim 13, further comprising a removable protective film attached to an exposed surface of said inside packing.

24. Inherently stable self-supporting composite part for engine hoods for acoustic screening of noise sources, comprising a plurality of layers arranged in a normal direction:

a shaped outside sheet of thermosetting plastic material and having an inside form;

a noise-insulating inside packing fastened directly to the outside sheet, which inside packing is adapted corresponding to the inside form of the outside sheet and has countersunk deformations, which together with the outside sheet form acoustically effective hollow spaces continuous in a direction transverse to said normal direction;

the inside packing comprising a fiber fleece adhered with a phenolic resin, and covered with a fiber mat; and

said outside sheet and said inside packing cooperating to form a self-supporting structure, independent of the engine hood.

25. An inherently stable composite part for engine hoods for acoustic screening of noise sources, comprising a plurality of layers arranged in a normal direction:

an outer sheet of thermosetting material;

a noise-insulating inside packing comprising a fiber fleece adhered with a plastic resin and covered with a fiber mat;

said inside packing including;

one or more acoustically effective countersunk deformations of a first thickness formed therein;

one or more stabilizing reinforcement zones formed peripherally around said acoustically effective countersunk deformations and of a thickness less than said first thickness, and

a supporting system comprising highly compacted bonded zones of a thickness less than said first thickness and surrounding said countersunk deformations and said reinforcement zones and contacting said outer sheet;

wherein said outer sheet and said countersunk deformations form free spaces continuous in a direction transverse to said normal direction and which serve as Helmholtz resonators and wherein said highly compacted bonded zones contacting said outer sheet provide the only support between said inside packing and said outer sheet and cooperate to form a self-supporting structure independent of the engine hood.

26. Inherently stable self-supporting composite part for engine hoods for acoustic screening of noise sources, comprising:

a shaped outside sheet of thermosetting plastic material and having an inside form and an inner surface;

a noise-insulating inside packing fastened directly to the outside sheet, which inside packing has a continuous inner surface opposite said outside sheet inner surface, and where said inside packing is adapted corresponding to the inside form of the outside sheet and has countersunk deformations, which together with the outside sheet form open acoustically effective hollow spaces between said outside sheet inner surface and said inside packing continuous inner surface;

the inside packing comprising a fiber fleece adhered with a phenolic resin, and covered with a fiber mat in direct contact with said fiber fleece thereby providing a porous structure having a porosity formed without puncturing said inside packing; and

said outside sheet and said inside packing cooperating to form a self-supporting structure, independent of the engine hood.

27. An inherently stable self-supporting composite part for engine hoods for acoustic screening of noise sources, comprising:

an outer sheet of thermosetting material,

a noise-insulating inside packing comprising a fiber fleece adhered with a plastic resin and covered with a fiber mat in direct contact with said fiber fleece,

said inside packing including;

one or more acoustically effective countersunk deformations of a first thickness formed therein,

one or more stabilizing reinforcement zones formed peripherally around said acoustically effective countersunk deformations and of a thickness less than said first thickness, and

a supporting system comprising highly compacted bonded zones of a thickness less than said first thickness and surrounding said countersunk deformations and said reinforcement zones and contacting said outer sheet,

wherein said outer sheet and said countersunk deformations form open free spaces therebetween which serve as Helmholtz resonators confined between said outer sheet and said inside packing and wherein said highly compacted bonded zones contacting said outer sheet provide the only support between said inside packing and said outer sheet and cooperate to form a self-supporting structure independent of the engine hood.

28. Inherently stable self-supporting composite part for engine hoods for acoustic screening of noise sources, comprising a plurality of layers arranged in a normal direction;

a shaped outside sheet of thermosetting plastic material and having an inside form;

a noise-insulating inside packing fastened directly to the outside sheet, which inside packing is adapted corresponding to the inside form of the outside sheet and has countersunk deformations, which together with the outside sheet form acoustically effective hollow spaces continuous in a direction transverse to said normal direction;

the inside packing comprising a fiber fleece adhered with a phenolic resin, and covered with a fiber mat wherein said inside packing has a porosity formed without puncturing said inside packing; and

said outside sheet and said inside packing cooperating to form a self-supporting structure, independent of the engine hood.

29. An inherently stable composite part for engine hoods for acoustic screening of noise sources, comprising a plurality of layers arranged in a normal direction:

an outer sheet of thermosetting material;

a noise-insulating inside packing comprising a fiber fleece adhered with a plastic resin and covered with a fiber mat;

said inside packing including;

one or more acoustically effective countersunk deformations of a first thickness formed therein;

one or more stabilizing reinforcement zones formed peripherally around said acoustically effective countersunk deformations and of a thickness less than said first thickness, and

a supporting system comprising highly compacted bonded zones of a thickness less than said first thickness and surrounding said countersunk deformations and said reinforcement zones and contacting said outer sheet;

wherein said outer sheet and said countersunk deformations form free spaces continuous in a direction transverse to said normal direction and which serve as Helmholtz resonators confined between said outer sheet and said inside packing and wherein said highly compacted bonded zones contacting said outer sheet provide the only support between said inside packing and said outer sheet and cooperate to form a self-supporting structure independent of the engine hood.