U.S. patent application number 13/330533 was filed with the patent office on 2012-04-12 for method for the production of a sound insulation molding with mass and spring.
This patent application is currently assigned to STANKIEWICZ GMBH. Invention is credited to Thomas FRESER-WOLZENBURG, Maik GROSSMANN, Georg-Wilhelm PRAHST, Eberhard PUSCHMANN.
Application Number | 20120088073 13/330533 |
Document ID | / |
Family ID | 35169728 |
Filed Date | 2012-04-12 |
United States Patent
Application |
20120088073 |
Kind Code |
A1 |
FRESER-WOLZENBURG; Thomas ;
et al. |
April 12, 2012 |
Method For The Production Of A Sound Insulation Molding With Mass
And Spring
Abstract
The invention relates to a method of producing a sound
insulation molding with mass (2) and spring (3), wherein both mass
(2) and spring (3) are produced on the basis of the same material,
in particular polyurethane. For the formation of a mass, reaction
substances and fillers are brought into a mold, in particular
sprayed in or injected, and brought to reaction. The spraying in or
injection is thereby controlled such that the reaction substances
and the fillers are supplied in locally different quantity and/or
composition into the mold, dependent upon the sound damping to be
locally achieved together with the spring, which is then formed on
the so-formed mass (2) in the same mold through formation of foam.
Through this, with surfaces to be sound insulated which are of the
same geometry, three-dimensional moldings (1) of the same geometry
can be produced with both different acoustic and also mechanical
behavior in predetermined series.
Inventors: |
FRESER-WOLZENBURG; Thomas;
(Garbsen, DE) ; PUSCHMANN; Eberhard; (Nienhagen,
DE) ; PRAHST; Georg-Wilhelm; (Lauenau, DE) ;
GROSSMANN; Maik; (Adelheidsdorf, DE) |
Assignee: |
STANKIEWICZ GMBH
Adelheidsdorf
DE
|
Family ID: |
35169728 |
Appl. No.: |
13/330533 |
Filed: |
December 19, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11659990 |
May 27, 2008 |
8080193 |
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PCT/EP2005/008642 |
Aug 9, 2005 |
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13330533 |
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Current U.S.
Class: |
428/156 ;
428/170; 428/212; 428/218 |
Current CPC
Class: |
B29C 44/0461 20130101;
B29C 44/60 20130101; Y10T 428/24992 20150115; Y10T 428/249953
20150401; Y10T 428/24595 20150115; Y10T 428/24479 20150115; B60R
13/08 20130101; Y10T 428/24942 20150115; B60R 13/083 20130101; B60R
13/0838 20130101 |
Class at
Publication: |
428/156 ;
428/218; 428/170; 428/212 |
International
Class: |
B32B 3/00 20060101
B32B003/00; B32B 7/02 20060101 B32B007/02 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 13, 2004 |
DE |
10 2004 039 438.5 |
Claims
1.-13. (canceled)
14. Sound insulation comprising: a sound insulation molding to
sound insulate a surface that requires different sound damping in
different regions, the sound insulation molding comprising a mass
of foam and a spring of foam formed of a same material; wherein the
mass includes a content of filler; wherein the spring includes a
content of filler which is less than the content of filler of the
mass; wherein the mass has two layers that each vary in thickness
and/or composition; wherein the mass has a weight per unit area of
1 kg/m.sup.2 to 4.5 kg/m.sup.2 at thicknesses of 0.5 mm to 10 mm;
and wherein the spring has a lower weight per unit area than the
mass due to the lower content of filler.
15. The sound insulation of claim 14 wherein: the two layers of the
mass comprise a first layer and a second layer; and the first layer
provides a carrier layer; and the second layer is locally applied
to the first layer.
16. The sound insulation of claim 14 wherein: the two layers of the
mass are each formed with reaction substances.
17. The sound insulation of claim 14 wherein: the two layers of the
mass are each formed with a quantity of filler; and the quantity of
filler for each layer is different.
18. The sound insulation of claim 14 wherein: the mass and the
spring are each formed of polyurethane material.
19. The sound insulation of claim 14 wherein: the two mass layers
that each vary in thickness and/or composition vary in thickness
and/or composition to vary local acoustic and mechanical
characteristics.
20. The sound insulation of claim 14 wherein: the spring is molded
to the mass.
21. The sound insulation of claim 14 wherein: the mass is formed
against a decorative part.
22. The sound insulation of claim 14 wherein: the sound insulation
molding is to dampen sound of a motor vehicle.
23. The sound insulation of claim 22 wherein: the sound insulation
molding is to be used between an engine compartment and a passenger
space of a motor vehicle.
24. A motor vehicle molding comprising: a sound insulation molding
to sound insulate a surface of a motor vehicle that requires
different sound damping in different regions, the sound insulation
molding comprising a mass of foam and a spring of foam formed of a
same material; wherein the mass includes a content of filler;
wherein the spring includes a content of filler which is less than
the content of filler of the mass; wherein the mass has two layers
that each vary in thickness and/or composition; wherein the mass
has a weight per unit area of 1 kg/m.sup.2 to 4.5 kg/m.sup.2 at
thicknesses of 0.5 mm to 10 mm; and wherein the spring has a lower
weight per unit area than the mass due to the lower content of
filler.
25. The molding of claim 24 wherein: the two layers of the mass
comprise a first layer and a second layer; and the first layer
provides a carrier layer; and the second layer is locally applied
to the first layer.
26. The molding of claim 24 wherein: the two layers of the mass are
each formed with reaction substances.
27. The molding of claim 14 wherein: the two layers of the mass are
each formed with a quantity of filler; and the quantity of filler
for each layer is different.
28. The molding of claim 24 wherein: the mass and the spring are
each formed of polyurethane material.
29. The molding of claim 24 wherein: the two mass layers that each
vary in thickness and/or composition vary in thickness and/or
composition to vary local acoustic and mechanical
characteristics.
30. The molding of claim 24 wherein: the spring is molded to the
mass.
31. The molding of claim 24 wherein: the mass is formed against a
decorative part.
32. The molding of claim 24 wherein: the sound insulation molding
is adapted to be used between an engine compartment and a passenger
space of a motor vehicle.
Description
[0001] The invention relates to a method for the production of a
sound insulation molding with mass and spring, such a sound
insulation molding, and the use thereof.
[0002] From EP 0 882 561 A1 there is known a method for the
production of a sound insulation molding with mass and spring, with
which both the mass and the spring are produced on the basis of the
same material, namely polyurethane. For the formation of a mass,
reaction substances and fillers are sprayed or injected into a mold
and brought to reaction, whereby by means of a die there is
attained a forming of the mass as a mass layer. Foam is then formed
in the same mold, as a spring on the mass, and this by means of a
second molding through which the mass layer is foamed on the back.
The features of the preamble of the claim 1 are therefore known
from this document.
[0003] With the known approach a continuous mass layer with
essentially uniform thickness is obtained, whereby with appropriate
configuration the side which is to be seen can in particular have
the shape of individual profiles in the manner of grooves or ribs.
The spring, or foam layer, can likewise be shaped. Through this the
molding can be adapted to certain developments of a surface to be
sound insulated, to which the molding is to be attached.
[0004] The outlay of materials required in the production of the
mass or heavy layer is substantial and thus cost-intensive. In
addition, a somewhat economic production is possible only in the
case of large quantities. Typical moldings of the described type
are used in vehicles, in particular cars. Cars are offered, with
the same bodywork construction, with very different engines, so
that in the configuration of the molding and thereby in particular
the mass or heavy layer the most unfavorable constellation of an
engine as a sound generator and surface to be sound damped by the
molding must be taken into account.
[0005] Starting from this, it is the object of the present
invention to indicate an approach by means of which a high sound
insulation or soundproofing effect can be attained with low outlay
of materials.
[0006] In accordance with the invention the spraying in is
controlled so that for the formation of the mass the reaction
substances and the fillers are supplied into the mold locally in
different quantity and/or composition, and this in dependence upon
sound damping to be locally achieved together with the spring.
[0007] The invention thereby starts from the knowledge that a
surface activated by a sound generator transfers the sound very
differently, essentially frequency dependently but also partly in
dependence upon location. In turn from this results that there is
an optimal mass-spring combination for each surface region of a
surface to be sound insulated, within the scope of production
tolerances. The outlay of materials for the mass can therefore be
optimized and with this for the molding as a whole. It is solely
required to control the devices which bring about the spraying in
or injection of the various materials for mass and spring so
appropriately that locally the reaction substances (including
expanding agents) and the fillers for the formation of the mass or
heavy layer are delivered with the locally required quantity and
composition. The filler content can in particular be varied in a
simple way, typically between 0 and 50 volume per cent, the
quantity of the supplied reaction substances can be varied such
that different thicknesses of the mass or heavy layer are achieved,
typically 0.5 mm and more (absolutely also 10 mm), and the makeup
of the reaction substances can typically be adapted, for example
for polyurethane materials over the complete range which is known
from polyurethane chemistry.
[0008] Furthermore it is possible by further measures not only to
have influence on the acoustic characteristics but also on
mechanical characteristics such as mechanical strength or
elasticity. For example, where in the finished manufactured molding
through-openings are to be provided the mechanical strength can be
increased, whilst where in the finished manufactured molding thick
edges to other parts should be provided, the elasticity should be
higher. In particular manner this can be achieved without
impairment of the sound engineering or acoustic characteristics in
that, with the retention of the same density, locally neighboring
regions have different compositions of the reaction substances
employed.
[0009] It turns out that the control of the devices delivering the
materials is typically carried out automatically by means of
computer control as this is in principle per se known for robot
control. In turn from this results that the course of the control
can be adapted quickly to changed conditions such as the assignment
of another sound generator to a surface to be sound insulated. It
is even possible therefore not only to produce small lots but also
individual moldings in the desired number and order, as this is
desired in just-in-time production. It can suffice for moldings
identical in geometry, depending upon the quantity to be produced
per unit time, to provide one single molding tool. Dependent on the
size of the molding it may therefore even be possible to provide a
mobile production facility which can flexibly be put to use on the
spot.
[0010] In particular with the employment of exclusively PUR
materials, due to the possibility of manufacturing individual
moldings, special wishes can be taken into account, for example
with regard to the color design.
[0011] The invention is explained in more detail with reference to
the exemplary embodiments illustrated in the drawings. There is
shown:
[0012] FIG. 1 in an isometric view and in section, the basic
construction of a molding producible in accordance with the
invention,
[0013] FIG. 2 schematically, in a view from above, a development of
a molding with indication of different masses or heavy layer
sections to be attained in accordance with the invention,
[0014] FIG. 3 a perspective view of a complicatedly formed body
part as an example of a sound insulating surface with indication of
surface sections in which certain mechanical characteristics in
addition to acoustic characteristics are to be attained, as is
possible by means of the invention,
[0015] FIG. 4 the application of the method according to the
invention in the configuration of edges for e.g. through-openings
and
[0016] FIG. 5 in a view similar to that of FIG. 4, the application
of the invention in the configuration of elastic edges or lips.
[0017] FIG. 1 shows a detail section through a molding 1 comprised
of a mass 2 or heavy layer and a spring 3 or foam layer having the
same material construction, preferably polyurethane.
[0018] A mass 2 or heavy layer typically is cell-poor or cell-less
and has a high weight per unit area which in substance is caused by
fillers. The spring 3 or foam layer is, in contrast, rich in cells,
has a low or not the slightest filler content and thus has a low
weight per unit area.
[0019] Mass 2 and spring 3 act in combination in a per se known way
to achieve sound damping. Furthermore thickness and density as well
as porosity have influence on the mechanical properties of the
molding 1 at a certain location, as is also per se known.
[0020] FIG. 1 illustrates schematically how, at a certain location
of the molding 1 corresponding to the detail, the mass 2 is locally
acted upon. In the exemplary embodiment the mass 2 is comprised of
two discreet mass layers 4 and 5. The first mass layer 4 can be
provided for the complete molding 1 throughout in the same manner
and define a carrier layer which influences the substantive
mechanical properties. The second discreet mass layer 5 is locally
applied so that the mass 2 is formed locally by the two layers 4
and 5. The second discreet mass layer 5 can, but need not, have the
same composition with regard to the reaction substances and the
quantity of filler as the first discreet mass layer 4 and therefore
be produced as a unit in the same working procedure. It also can be
additionally applied after formation of the first discreet mass
layer 4 in a mold according to the local conditions. From the above
it follows that this local discreet second mass layer 5 can be
formed also based on another composition of the reaction substances
and/or another quantity of filler.
[0021] The procedures upon allowing the reaction substances to
react, taking into consideration take-up of fillers, determine in
the end whether it is more expedient for a certain location of the
molding 1 to form the mass 2 as a plurality of layers, in the
exemplary embodiment as two successive layers 4, 5, or in the form
of a single layer, whereby the development of their thicknesses and
densities is independent of each other. After formation of the mass
2 the spring 3 is generated in conventional manner by back
foaming
[0022] Since a surface to be sound insulated normally has a very
complicated three-dimensional shape, the formation of the mass 2,
which must be contour-following, is effected expediently and in
accordance with the invention directly in a mold-half of a mold
shaped after the surface to be sound insulated. The formation of
the foam layer of the spring 3 can then be carried out either in
open or in closed mold, whereby the latter makes sense if the side
of the spring 3 away from the mass 2 is to be or must be
structured.
[0023] The molding 1 can therefore be produced with mass 2 and
spring 3 in one working procedure.
[0024] It turns out that the formation of the mass 2 can be
effected also against a decorative part placed in a mold such as a
carpet cutting or a web of material, but also the formation of the
spring 3 can be effected between the mass 2 and a decorative part
such as a carpet cutting or a web of material.
[0025] FIG. 2 shows the development 6 of a molding, in which
surface regions are indicated whose occupancy with mass 2 is
different. In surface regions 7, 8 and 9, defined by different
shadings or hatching, different weights per unit area (or
densities) of the mass 2 and/or different thicknesses of the mass 2
are to be realized. In the development 6 regions which are
similarly hatched or shaded are separated from each other by
channel-like structures 10. Through this it is illustrated that in
the application of the mass 2 in the appropriate surface regions of
the real mold for the formation of the real molding, expediently
different application procedures are to be provided due to the
three-dimensional conditions, for example by means of other devices
for the supply of the reaction substances and fillers or by means
of a setting of the spatial disposition of the devices for the
introduction of the reaction substances and the fillers that is to
be adjusted.
[0026] Furthermore, from the above explanation it is apparent that,
in considerably greater variety than indicated by FIG. 2, surface
regions can be provided at which there can be achieved a structure
differing in its composition determined by the reaction substances
and quantity of filler, and also in its thickness, in the mass 2
formed overall over the molding.
[0027] FIG. 3 shows schematically in a perspective view the
complicated three-dimensional construction of a surface to be sound
insulated--to be more precise, as an example, an end wall 11 of a
typical motor vehicle. A non-illustrated molding, which is be
applied in form-fitting manner to this end wall 11, is to have
locally different characteristics which are illustrated by
different borders and shadings. This involves combinations of both
mechanical characteristics which can be represented by words and
acoustic characteristics which are definable by masses per unit
area or weight per unit area. The details are of course exemplary
and real moldings, to be assigned to an arbitrary end wall 11, can
have both mechanical and acoustic characteristics which strongly
deviate locally. In the example surface regions 12 are to have high
strength with a weight per unit area of about 1 kg/m2, surface
regions 13 are to be soft elastic with a weight per unit area of 2
kg/m2, surface regions 14 are to be overall light weight with a
weight per unit area of 1 kg/m2, surface regions 15 are to have
both high strength as well as being hard and have a weight per unit
area of for example 4.5 kg/m2, surface regions 16 are to be heavy
with a weight per unit area of about 4.5 kg/m2, remaining surface
regions 17 are to have a weight per unit area of 2 kg/m2 without
predetermined mechanical properties, and regions 18 are to be soft
elastic with a weight per unit area of 1 kg/m2 and be formed to a
run-out lip. From the above it arises that a mass 2 must be
provided throughout with a weight per unit area of at least 1
kg/m2, whereby locally higher weights per units area are to be
provided, wherein furthermore locally additional certain mechanical
characteristics are to be attained.
[0028] The mechanical properties are on the one hand possible by
influencing the local composition of the reaction substance
mixtures and the type and the proportion of the solid substances,
but also by action on the foam formation. The latter is for example
possible in the manner and way explained in EP 1 237 751 A1 of the
present applicant. Influence can, however, also be exercised in
other manners and ways on the mechanical properties.
[0029] FIG. 4 and FIG. 5 show in section how by influencing the
mass at peripheries and edges the mechanical properties thereof can
be influenced. Thereby it is to be noted that the acoustic
characteristics are of rather subordinate importance there.
[0030] Similarly to FIG. 1, FIG. 4 shows in the case of a molding 1
comprised of mass 2 and spring 3 a physically distinctive edge 20
in the region of which both first discreet mass layer 4 and second
discreet mass layer 5 are formed considerably more thickly than in
adjacent regions. In an outer edge region 21 in the case of which
no further foam 3 can, if applicable, be provided for instance to
define through openings, comparatively high stiffness is achieved
in cooperation with the edge 20.
[0031] Similarly to FIG. 4, FIG. 5 also shows a distinctive edge
20, whereby the two layers 4 and 5 of the mass 2 end within the
molding, as illustrated at 22, such that the foam of the spring 3,
as illustrated at 23, forms a lip extending outwardly, which upon
bearing on concrete elements can achieve an elastic
termination.
[0032] Thus, in one mold, whose under-mold has a development
adapted to a surface to be sound insulated, there can be associated
moldings individually formed in accordance with the invention, as
desired.
[0033] Thereby there can be associated with a mold one or also
several devices by means of which the supply of the reaction
substances is adjustable in a way permissible for the production of
the product, in selectable manner in accordance with quantity and
proportions, whereby also fillers can be mixed in within the
permitted range. An approach can for example be used in accordance
with DE 101 61 600 A1 of the applicant, which permits the variable
and simultaneous application of fillers into a reaction substance
mixture spray.
[0034] The invention is in particular applicable to the production
of moldings for motor vehicles, in particular motor cars. As is
known, bodywork constructions, identical at least in sections, are
associated with a variety of different engines. This means,
however, that the different engines, as sound generators, can
excite in different ways, possibly in extremely different ways,
surfaces to be sound insulated, both with regard to the transferred
frequencies and also the respective intensity thereof, and also
with regard to the disposition of the locations of maximum sound
transmission. Thereby, the conditions can change in the case of
different vehicle types (such as car, convertible, estate car) for
such body parts which are formed geometrically like, such as for
example an end wall 11 in accordance with FIG. 3 between passenger
space and engine compartment. On the other hand experience has
shown that the association of a body part to a certain engine and
therewith to a certain sound generator (with the same vehicle
type), leads to a large extent to similar sound transmission
conditions in the case of a surface to be sound insulated. By means
of the invention there can therefore be attained on the one hand in
simple manner an optimal acoustic design of a molding, taking into
consideration mechanical specifications, whereby on the other hand
a considerable material saving is already possible because the
material can be adapted optimally for the mass and the mass has the
largest material component.
[0035] Since in accordance with the invention this optimization is
possible for each of the possible associations of a geometrically
similar surface to be sound insulated with a sound generator,
namely an engine, taking into consideration also the vehicle type,
based on the same mold, which constructionally corresponds to the
surface to be sound damped, each necessary molding can be produced
optimally, individually and as required.
[0036] The method according to the invention therefore is also
suitable for the production of small lots and in particular also
for making available moldings identical in geometry of different
construction in a predetermined order, as this is required for
example for just-in-time production.
[0037] The at least one device for the introduction of the reaction
substances and fillers into the mold for the production of the mass
2 is expediently controlled automatically in the manner of a
robotic control, whereby programs for the automatic control of
robots which serve for the coating of complicated three-dimensional
areas, in principle for painting, are per se known. Additionally,
however, there must be taken into account in the programming on the
one hand the locally differing mixture, obtained by means the
invention, of the supplied reaction substances for the attainment
of the local mechanical and acoustic characteristics, as well as on
the other hand also the necessary thickness of the mass 2 to be
attained.
[0038] Firstly, a prototype of the surface to be sound insulated is
examined together with a prototype of a sound generator with regard
to the sound transfer behavior, for the mentioned typical
employment of moldings produced according to the invention. It is
then determined which surface regions of the surface to be sound
insulated require a damping going beyond a minimum damping.
Starting out from mechanical specifications and spatial
specifications provided by the customer with regard to the design
of the molding, in particular on the side away from the surface to
be sound insulated, the ideal construction of a molding can then be
determined. A classification can be carried out over surface
regions in practice, since on the one hand production tolerances
are taken into account or must be accepted in the production of the
surface to be sound insulated and of the sound generator and on the
other hand working tolerances in the control of the devices for the
introduction of the reaction substances and fillers are taken into
account or must be accepted. There is therefore provided an
assignment and classification as has been explained with reference
to FIG. 3. A set of parameters or a parameter matrix can thus be
produced, which are specified for the predetermined association of
a certain sound generator with the surface to be sound insulated,
which allows the specific control of the at least one device for
the introduction of the reaction substances (including expanding
agents) and fillers.
[0039] This investigation and assessment and classification can now
be carried out now for each association of the geometrically
identical surface to be sound insulated with a different sound
generator. Facilitation can be provided in the context of the
investigation and assessment if the different sound generators are
of similar type, as can be the case for example with car engines of
different cubic capacities and the same mounting disposition. It
can thereby arise that for several different sound generators in
substance the same classifications arise, under consideration of
the mentioned necessary tolerances. This would make the programming
effort easier.
[0040] The various different control programmes for the control of
the at least one device for the introduction of the reaction
substances and fillers into the mold corresponding to a
predetermined surface to be sound insulated then can be called up
freely selectably and used for the production of individual
moldings.
[0041] Since in particular in the case of polyurethane materials
there are typically involved pumpable starting products for the
reaction substances (polyols, isocyanates, and expanding agent) and
fillers, an apparatus for carrying out the method, that is for the
production of moldings formed according to the invention, can be
constituted as a mobile unit, insofar as the geometry the molding
and thus of the mold allows this.
[0042] It is to be mentioned that furthermore it is possible bring
into a mold also third party components such as additional
construction elements before, during or after the formation of the
mass 2 in a mold, if this is necessary or is wished by the
customer.
[0043] Finally it is to be mentioned that since the same materials
are used for both mass and spring the recycling ability is
increased considerably.
* * * * *