Space filler with a vacuum cover

• US 9,849,845 B1
• Filed: 08/09/2016
• Issued: 12/26/2017
• 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:
  US15/232,349
• Time in Patent Office: 504 Days
• Field of Search: 296 393, 181290
• 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. An acoustically absorptive space filling panel for a vehicle comprising:

a polystyrene layer and a polyurethane layer with each layer having at least one surface with a non-planar surface geometry that couples the polyurethane layer to the polystyrene layer in a vacuum sealed space; and

a polyethylene cover forming the vacuum sealed space;

wherein the non-planar surface geometry does not extend entirely through either the polystyrene layer or the polyurethane layer.

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

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

4. The acoustically absorptive space filling panel of claim 1, wherein the polyurethane layer and the polystyrene layer each have at least one surface with a pyramidal surface geometry that interlockedly couples the polyurethane layer to the polystyrene layer.

5. The acoustically absorptive space filling panel of claim 1, wherein the polyurethane layer and the polystyrene layer each have at least one surface with a cylindrical surface geometry that interlockedly couples the polyurethane layer to the polystyrene layer.

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

forming a first layer having a first side with a non-planar surface geometry;

forming a second layer having a second side with a complementary non-planar surface geometry;

contacting the first side with the second side to couple the first and second layers; and

vacuum sealing the first and second layers with a polymeric cover;

wherein the space filling panel is disposed in the vehicle wherein the non-planar surface geometry and the complimentary non-planar surface geometry do not extend entirely through either the first layer or second layer.

7. The method of claim 6, wherein the first layer is a polystyrene and the second layer is a polyurethane.

8. The method of claim 6, wherein the first layer and the second layer each have at least one surface with a pyramidal surface geometry that interlockedly couples the polyurethane layer to the polystyrene layer.

9. The method of claim 6, wherein the first layer and the second layer each have at least one surface with a cylindrical surface geometry that interlockedly couples the polyurethane layer to the polystyrene layer.