LIGHTWEIGHT, SOUND-INSULATING LINING FOR A BODY PART OF A MOTOR VEHICLE, AND METHOD FOR THE PRODUCTION THEREOF

• US 20100065366A1
• Filed: 04/16/2008
• Published: 03/18/2010
• Est. Priority Date: 05/02/2007
• Status: Active Grant

• Current Assignee: Covestro Deutschland AG
• Original Assignee: Bayer Materialscience AG (Covestro AG)
• Inventors: Soltau, Dirk, Gross, Thomas, Hansen, Michael, Ulbrich, Dagmar
• Granted Patent: US 7,980,358 B2
• Time in Patent Office: Days
• US Class Current: 181/286
• 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

Abstract

The invention relates to a lightweight sound insulating lining (1) for a body component of a motor vehicle, in particular in the form of a lightweight front wall lining, comprising a sound absorbing layer, a sound insulating layer which is directly connected to the sound absorbing layer and substantially air tight, as well as an adjoining foam layer (1.3), wherein the sound absorbing layer (1.1) is made of a porous absorber, preferably a fiber fleece or a foam, which has an air permeability in the range of 150 to 2000 liters/m²s at a test pressure of 100 Pa. The sound insulating layer (1.2) is formed by an integral skin layer of the foam layer (1.3) with a thickness of at least 0.5 mm, and is integrally joined to the porous absorber by back-foaming the porous absorber substantially without foam penetration therethrough. Furthermore, a method for manufacturing such a lining is disclosed.

Claims

1. A lightweight sound insulating lining (1) for a body component of a motor vehicle, in particular in the form of a lightweight front wall lining, comprising a sound absorbing layer, a sound insulating layer which is directly connected to the sound absorbing layer and substantially air tight, as well as an adjoining foam layer (1.3), wherein the sound absorbing layer (1.1) is made of a porous absorber, preferably a fiber fleece or a foam, wherein the porous absorber has an air permeability in the range of 150 to 2000 liters/m²s at a test pressure of 100 Pa, wherein the sound insulating layer (1.2) is formed by an integral skin layer of the foam layer (1.3) with a thickness of at least 0.5 mm and integrally joined to the porous absorber by back-foaming the porous absorber substantially without penetration of foam.

2. The lining according to claim 1, wherein the porous absorber has a length-specific flow resistance in the range of 5 kNs/m⁴ to 40 kNs/m⁴, preferably in the range of 5 kNs/m⁴ to 25 kNs/m⁴.

3. The lining according to claim 1, wherein the porous absorber has a substantially uniform density as well as a substantially uniform flow resistance across its cross section.

4. The lining according to claim 1, wherein the porous absorber has a weight per area of 100 g/m² to 1600 g/m² and/or a thickness in the range of 2 mm to 30 mm.

5. The lining according to claim 1, wherein the porous absorber is made of a fiber fleece made of polyethylene fibers, polypropylene fibers, a mixture of polyethylene and polypropylene fibers, cotton fibers or a mixture of polyethylene and natural fibers.

6. The lining according to claim 1, wherein the sound insulating layer (1.2) has a thickness in the range of 1 mm to 5 mm.

7. The lining according to claim 1, wherein the sound insulating layer (1.2) has a raw density in the range of 0.08 to 2.0 g/cm³, preferably in the range of 0.08 to 1.4 g/cm³.

8. The lining according to claim 1, wherein the sound insulating layer (1.2) locally has areas of different thickness, the difference in thickness being at least 1 mm.

9. The lining according to claim 1, wherein the foam layer (1.3) has a raw density in the range of 0.02 to 0.1 g/cm³.

10. The lining according to claim 1, wherein the total weight per area is less than 2500 g/m², preferably less than 2000 g/m².

11. The lining according to claim 1, wherein the sound insulating layer (1.2) covers substantially the entire surface of the porous absorber (1.1).

12. The lining according to claim 1, wherein the sound insulating layer (1.2) is covered only partially by the porous absorber (1.1).

13. The lining according to claim 1, wherein solely its sound absorbing layer (1.1) forms a flexible sealing lip (12′

).

14. The lining according to claim 1, wherein has a temperature resistance of at least 150°

C.

15. The lining according to claim 1, wherein the porous absorber (1.1) is made of a flame retardant fiber fleece, preferably of polyester fleece.

16. A method for manufacturing a lightweight sound insulating lining (1) for a body component of a motor vehicle, in particular a lightweight front wall lining, wherein a porous sound absorbing layer (1.1) is directly back-foamed with a reactive mix containing polyol and isocyanate in a foaming mold (6, 6′

), wherein as a porous sound absorbing layer (1.1) an absorber is used which has an air permeability in the range of 150 to 2000 liters/m²s at a test pressure of 100 Pa, wherein the reactive mix is fed into the foaming mold substantially parallel to the backside of the sound absorbing layer (1.1) and/or parallel to the bottom surface (8.1) of a cavity of the foaming mold, and wherein a predetermined portion of the surface of the foaming mold is temperature-controlled in such a way and/or the mixture ratio of polyol to isocyanate is altered during feeding in such a way that a foam layer (1.3) results from the reactive mix, said foam layer has a substantially air-tight, integral skin layer (1.2) with a thickness of at least 0.5 mm which is firmly bonded to the sound absorbing layer substantially without foam penetration therethrough.

17. The method according to claim 16, wherein a limited volume of the reactive mix is fed into the foaming mold (6, 6′

) in such a way that the reactive mix does not contact the porous sound absorbing layer (1.1) at first, wherein the integral joint between the reactive mix and the porous sound absorbing layer (1.1) occurs subsequently upon fully curing of the reactive mix.

18. The method according to claim 16, wherein back-foaming of the porous sound absorbing layer (1.1) is performed in an open foaming mold (6).

19. The method according to claim 16, wherein back-foaming of the porous sound absorbing layer (1.1) is performed in a closed foaming mold (6′

).

20. The method according to claim 19, wherein the reactive mix is injected into the closed foaming mold (6′

) using a deviating device (22), wherein the deviating device (22) forces the reactive mix into an injection flow direction (E) directed substantially parallel to the backside of the porous sound absorbing layer (1.1).

21. The method according to claim 16, wherein the porous sound absorbing layer (1.1) used has a substantially uniform density as well as a substantially uniform flow resistance across its cross section.

22. The method according to claim 16, wherein the porous sound absorbing layer (1.1) has a length-specific flow resistance in the range of 5 kNs/m⁴ to 40 kNs/m⁴, preferably in the range of 5 kNs/m⁴ to 25 kNs/m⁴.

23. The method according to claim 16, wherein the porous sound absorbing layer (1.1) has a weight per area of 100 g/m² to 1600 g/m² and/or a thickness in the range of 2 mm to 30 mm.

24. The method according to claim 16, wherein the porous sound absorbing layer (1.1) used is made of polyethylene fibers, polypropylene fibers, a mixture of polyethylene and polypropylene fibers, cotton fibers or a mixture of polyethylene and natural fibers.