Ultralight trim composite

• US 7,322,440 B2
• Filed: 12/08/2003
• Issued: 01/29/2008
• Est. Priority Date: 12/09/2002
• Status: Expired due to Fees

• Current Assignee: Autoneum Management AG (Autoneum Holding AG)
• Original Assignee: Rieter Technologies AG
• Inventors: Tessendorf, Steven D., Khan, Hameed S., Fisher, James H., Ehrler, Peter
• Primary Examiner(s): Donovan; Lincoln
• Assistant Examiner(s): PHILLIPS, FORREST M
• Application Number:
  US10/538,494
• Publication Number:
  US 20060113146A1
• Time in Patent Office: 1,513 Days
• Field of Search: 181/256, 181/284, 181/285, 181/291, 181/292, 181/293, 181/294
• US Class Current: 181/286
• CPC Class Codes: B32B 2305/022 Foam
• CPC Class Codes: B32B 2323/04 Polyethylene
• CPC Class Codes: B32B 2329/04 Polyvinylalcohol
• CPC Class Codes: B32B 2377/00 Polyamides
• CPC Class Codes: B32B 2605/00 Vehicles
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/28 comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
• CPC Class Codes: B32B 27/30 comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/306 comprising vinyl acetate or vinyl alcohol (co)polymers
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 comprising polyamides
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• 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: G10K 11/168 Plural layers of different materials, e.g. sandwiches

Abstract

An ultra light, noise reducing composite (1) comprises an acoustically transparent, light weight film (6) between an underlay layer (5) and an air flow resistance layer (4). This composite allows to easily tune the acoustic properties by balancing the absorption and sound transmission behaviour of the composite (1). This air flow resistance layer (4) has an air flow resistance of between 500 Ns/m3 and 10,000 Ns/m3 and an area mass between 200 g/m2 and 3,000 g/m2. The underlay layer (5) has a stiffness value in the range between 100 Pa and 100,000 Pa. The light weight film (6) may consist of a synthetic foil and preferably has a thickness of 0.01 mm.

Claims

1. An ultralight trim composite (1) comprising a first acoustically effective layer (4) and a second underlay layer (5), characterized in that for the balancing of the absorption and sound transmission behaviour of the composite, the first acoustically effective layer (4) has an air flow resistance R between 500 Ns/m³ and 10,000 Ns/m³ and has an area mass m_A between 200 g/m² and 3,000 g/m2, the second underlay layer (5) has a very low compression force deflection modulus, i.e. a stiffness value S_D in the range between 100 Pa and 100,000 Pa and in addition comprises an acoustically transparent, very thin and light weight film (6) between the second underlay layer (5) and the first acoustically effective layer (4), which film interacts with this underlay layer (5) in the manner of an acoustic foil absorber (9).

2. Composite according to claim 1, wherein the second underlay layer (5) is a backfoamed layer.

3. Composite according to claim 1, wherein the second foam underlay layer (5) consists of a foam slab.

4. Composite according to claim 3, wherein the foam slab comprises an open pored skin.

5. Composite according to claim 1, wherein the film (6) is perforated in order to increase the absorption properties.

6. Composite according to claim 5, wherein the film (6) is microperforated.

7. Composite according to claim 1, wherein the film (6) is unperforated in order to increase the transmission loss.

8. Composite according to claim 1, wherein the first acoustically effective layer (4) has a thickness of 0.5 mm to 8.0 mm.

9. Composite according to claim 8, wherein the first acoustically effective layer (4) has an area weight of about 1 kg/m².

10. Composite according to claim 1, wherein the second foam underlay layer (5) acting as a decoupler layer, has a thickness of about 20 mm.

11. Composite according to claim 1, wherein the film layer has a thickness of about 0.01 to 1.0 mm.