Vibration dampening laminate

• US 6,790,520 B1
• Filed: 07/20/2000
• Issued: 09/14/2004
• Est. Priority Date: 11/12/1997
• Status: Expired due to Fees

• Current Assignee: International Automotive Components Group North America (Lear Corporation)
• Original Assignee: Collins & Aikman Holdings SA de CV
• Inventors: Todd, John, Boyd, Robert S., Care, Melvyn J.
• Primary Examiner(s): RUDDOCK, ULA CORINNA
• Application Number:
  US09/619,873
• Time in Patent Office: 1,517 Days
• Field of Search: 428/40.1, 428/41.8, 428/606, 428/607, 428/304.4, 428/308.4, 428/317.1, 428/317.7, 428/318.4, 428/319.3, 428/319.7, 428/343, 428/344, 428/352, 428/355.AC, 428/85, 428/95, 521/671, 521/677, 521/678, 521/679, 181/284, 181/290, 181/292, 181/294, 188/378, 248/562, 248/636, 442/30, 442/221, 442/228, 442/232, 442/370, 442/376, 442/378
• US Class Current: 428/318.4
• CPC Class Codes: A47L 15/4209 Insulation arrangements, e.g. for sound damping or heat insulation
• CPC Class Codes: A47L 15/4246 Details of the tub A47L15/4272 takes precedence; insulation arrangements A47L15/4209
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/56 Damping, energy absorption
• CPC Class Codes: B32B 2311/24 Aluminium
• CPC Class Codes: B32B 2605/003 Interior finishings
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B60R 13/02 Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners B60R13/01 takes precedence ; padded linings for the vehicle interior B60R21/04; arrangements or adaptations of floor mats or carpets in vehicles B60N3/04; internal lining for trains B61D17/18
• 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: B60R 13/083 for fire walls or floors
• CPC Class Codes: G10K 11/168 Plural layers of different materials, e.g. sandwiches
• CPC Class Codes: Y10T 428/12431 Foil or filament smaller than 6 mils
• CPC Class Codes: Y10T 428/12438 Composite
• CPC Class Codes: Y10T 428/14 Layer or component removable to expose adhesive
• CPC Class Codes: Y10T 428/1476 Release layer
• CPC Class Codes: Y10T 428/23979 Particular backing structure or composition
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249958 Void-containing component is synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/249982 : With component specified as adhesive or bonding agent
• CPC Class Codes: Y10T 428/249985 : Composition of adhesive or bonding component specified
• CPC Class Codes: Y10T 428/249987 : With nonvoid component of specified composition
• CPC Class Codes: Y10T 428/249991 : Synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/249992 : Linear or thermoplastic
• CPC Class Codes: Y10T 428/28 : Web or sheet containing structurally defined element or component and having an adhesive outermost layer
• CPC Class Codes: Y10T 428/2804 : Next to metal
• CPC Class Codes: Y10T 428/2839 : with release or antistick coating
• CPC Class Codes: Y10T 428/2891 : including addition polymer from alpha-beta unsaturated carboxylic acid [e.g., acrylic acid, methacrylic acid, etc.] Or derivative thereof
• CPC Class Codes: Y10T 442/15 : Including a foam layer
• CPC Class Codes: Y10T 442/3325 : Including a foamed layer or component
• CPC Class Codes: Y10T 442/3382 : Including a free metal or alloy constituent
• CPC Class Codes: Y10T 442/3415 : Preformed metallic film or foil or sheet [film or foil or sheet had structural integrity prior to association with the woven fabric]
• CPC Class Codes: Y10T 442/647 : Including a foamed layer or component
• CPC Class Codes: Y10T 442/654 : Including a free metal or alloy constituent
• CPC Class Codes: Y10T 442/656 : Preformed metallic film or foil or sheet [film or foil or sheet had structural integrity prior to association with the nonwoven fabric]

Abstract

The present invention provides a vibration dampening laminate that is lightweight and has superior sound insulation and vibration dampening properties. The vibration dampening laminate comprises a constraining layer, a viscoelastic adhesive layer, a foam spacing layer and a pressure sensitive adhesive layer including a release layer. The pressure sensitive adhesive layer and release layer are contoured to fit a profile of the article being soundproofed and vibration dampened.

Claims

1. A vibration dampening laminate for vehicular use, comprising:

a polyurethane foam spacing layer having a flexular modulus of 10 to 300,000 psi and a thickness of about 0.1 inches to 1.0 inches, wherein the polyurethane spacing layer has opposite first and second surfaces;

a foil constraining layer adhesively secured to the first surface of the polyurethane foam spacing layer via a viscoelastic adhesive layer disposed therebetween, wherein the foil constraining layer comprises aluminum foil and has a thickness of between about 0.001 inches and about 0.01 inches;

a decorative fabric layer secured to the foil constraining layer;

a pressure sensitive adhesive layer disposed on the polyurethane foam spacing layer second surface; and

a release layer disposed on the pressure sensitive adhesive layer;

wherein the pressure sensitive adhesive layer and release layer are contoured to fit a profile of a portion of a vehicle; and

wherein the laminate is sufficiently shear stiff such that the viscoelastic adhesive layer experiences substantially all shear strain when the laminate is subjected to shear forces.

2. The vibration dampening laminate of claim 1, wherein the fabric layer comprises a carpet layer.

3. The vibration dampening laminate of claim 1, wherein the pressure sensitive adhesive layer comprises a water-based acrylic adhesive.

4. The vibration dampening laminate of claim 1, wherein the viscoelastic layer comprises a water-based acrylic.

5. The vibration dampening laminate of claim 1, wherein the vehicle portion comprises a floorpan of a vehicle.