MXPA99000930A - Sound insulating layer with integral rib structure - Google Patents

Abstract

An acoustical barrier (10) for a vehicle having a barrier wall which includes a floor area (23) and a fire wall area (25) extending between a wheel well area (41) and a drive train area (42). The acoustical barrier (10) includes a mass layer (12) that covers at least a portion of the barrier wall. The mass layer (12) has an inner surface (16) that faces the barrier wall with an integrally formed peripheral rib (52) projecting therefrom. A first set of elongate ribs (48) intersects and joins with a second set of elongate ribs (50). The first and second sets of elongate ribs (48, 50) are located within the enclosed area. Each elongate rib (48, 50) includes an upper portion integrally formed with the inner surface (16) of the mass layer and a lower portion with an outer edge (54, 60) adapted to at least face the barrier wall. Each elongate rib (48) of the first set of ribs also has opposite ends integrally formed with the peripheral rib (52) to thereby strengthen the peripheral rib against bending moments due to compression forces applied to the outer surface of the mass layer. Each elongate rib (50) of the second set of ribs has opposite ends integrally formed with either adjacent ribs (48) of the first set of ribs or the peripheral rib (52) and an adjacent rib (48) of the first set of ribs to thereby further strengthen the peripheral rib (52) against bending moments. The first set of ribs projects from the inner surface of the mass layer a greater distance than the second set of ribs to provide increasing levels of impact resistance to the outer surface of the mass layer.

Description

SOUND INSULATING LAYER WITH INTEGRA NERVE STRUCTURE !.

Related Requests This application claims the benefit of U.S. Provisional Application No. 60 / 0-2 ---., 678, filed on July 26, 1996. BACKGROUND OF THE INVENTION Field of the Invention This invention is related to an insulating sound layer for a vehicle, and more particularly to an instrument panel mat having a dead pedal formed of integral way and / or compression ribs molded integrally in the breech areas of the vehicle. Description of Related Art < Ww In the most contemporary cars, a steel fire wall separates the engine compartment from the passenger compartment. To reduce the transmission of sound from the engine compartment through the fire wall and into the passenger compartment, a sound barrier mat (otherwise known as a dashboard mat) is typically molded as a single piece of an elastomeric material of substantially uniform thickness with limited impact absorption qualities. The dashboard mat is mounted to, and extends substantially over the fire wall, from ^^ so that an outer surface of the mat is in contact with a lower surface of the carpet of the vehicle 5 towards an upper portion of the fire wall behind the instrument panel. A dead pedal of the vehicle, which serves as a foot rest for a driver, is typically formed of steel or plastic and is subsequently installed with fasteners over the wheel cavity of a vehicle. After ^ TC an opening or projection is aligned over the dead pedal and the dashboard mat is attached with separate fasteners to the fire wall. The installation of the dead pedal and the dashboard mat in this manner requires a plurality of different parts and fasteners. The plurality of parts and fasteners results in an increased inventor, expenses, and installation time. ^^ Compendium of the Invention This and other problems of the prior art are solved by an acoustic barrier for a vehicle having a rib structure formed integrally in the breech area of the vehicle. According to the invention, an acoustic barrier for mounting to a barrier wall, such as the wall of a vehicle or other structure, comprises a layer of mass of a molded construction and damping characteristics sound, with an interior surface adapted to face the barrier wall and an adapted exterior surface ^^ to be turned towards the opposite side of the barrier wall. A peripheral rib has an upper portion formed integrally with the inner surface of the dough layer and a lower portion with an outer edge - which is adapted to be in contact with the barrier wall. The peripheral rib defines a closed area on the inner surface of the dough layer. A first set of elastic projections is ^) locate within the closed area. Each projection has a top portion formed integrally with the dough layer - and a lower portion with an outer edge for contacting the barrier wall. Each projection extends a first distance from the inner surface to the outer edge 15. A second set of elastic projections is located within the closed area. Each projection of the second The assembly includes an upper portion formed integrally with the dough layer and a lower portion with an outer edge to face the barrier wall. Each projection 20 of the second set extends a second distance from the inner surface towards the outer edge. Preferably, the second distance is smaller than the first distance. With this configuration, the first set of projections elastically resists the compressive forces that are applied to the outer surface of the dough layer at a first determined level. previously, and the second set of projections, together with the first set of projections, elastically resists ^^ the compressive forces at a second predetermined level higher than the first previously determined level. In a preferred embodiment, the first set of projections includes a plurality of first generally elongated ribs. Each rib has opposite ends formed integrally with the peripheral rib, to thereby strengthen the peripheral rib against the VT bending moments due to the compression forces that are applied to the outer surface of the dough layer. Similarly, the second set of projections includes a plurality of second generally elongated ribs extending in a transverse direction toward the first ribs. Each of the second ribs has opposite ends formed integrally with, either the ^ F first adjacent ribs or with the peripheral rib and an adjacent rib extending longitudinally, to further strengthen the same with the rib peripheral against bending moments. Additionally in accordance with the invention, the dough layer is adapted for installation in a vehicle having a barrier, including a floor area and a fire wall area extending between a wheel cavity and a transmission train area. The area of the fire wall intersects with, and extends generally up from the floor area. The dough layer also includes a wheel cavity section formed to conform to at least a portion of the shape of the wheel cavity area, and the fire floor and fire wall sections 5 formed to conform to at least a portion of the shape of the floor and fire wall areas, respectively, of the vehicle. In a further embodiment, a closed area that includes the first and second set of projections, comprises a ^ TO dead pedal zone extending along at least a portion of the fire wall section of the dough layer. The acoustic barrier may also include an absorbent layer having an outer surface in contact with a inner surface of the dough layer and an inner surface to contact the barrier wall. Preferably, The absorbent layer has an opening that is measured to receive the peripheral rib, so that the closed area is substantially free of the absorbent material. In accordance with the invention, an acoustic barrier for mounting to a barrier wall comprises a dough layer of a molded construction and sound damping characteristics with an interior surface adapted to face the barrier wall and a surface outside adapted to be turned towards the opposite side of the barrier wall. A peripheral rib has an upper portion formed integrally with the surface ^^ inside the dough layer and a lower portion with an outer edge that is adapted to be in contact with the barrier wall to thereby define a closed area on the inner surface of the dough layer. A first set of elongated ribs is located within the closed area. Each elongated rib includes an upper portion formed integrally with the inner surface of the dough layer and a ^ TO lower portion with an outer edge adapted to face the at least the barrier wall. Each elongate rib also has opposite ends formed integrally with the peripheral rib to thereby strengthen the peripheral rib against the bending moments due to the compression forces that are applied to the outer surface of the dough layer. • ^ Preferably, the elongated ribs generally extend in the same direction. A second set of elongated ribs located within the closed area 20 can be provided. Each rib of the second set has an upper portion formed integrally with the inner surface of the dough layer, a lower portion with an outer edge adapted to face the at least the barrier wall, and opposite ends formed integrally with either the 25 adjacent ribs of the first set of ribs or with the peripheral rib and an adjacent rib of the first set of ribs, to further strengthen the peripheral rib against the bending moments by means of the same. BRIEF DESCRIPTION OF THE DRAWINGS The invention will now be described with reference to the drawings, in which: Figure 1 illustrates a front view (as viewed from the driver's seat) of a dead pedal formed integrally with the mat of the driver; vehicle instrument panel. Figure 2 is a rear view of the dead pedal and the mat of the instrument panel. Figure 3 is a top perspective view of the assembly of the dashboard mat that is extends over the fire wall, which shows the breech area in accordance with the invention. FIG. 4 is a partial sectional view of the interior surface of the instrument panel mat with a sound absorbing layer showing the structure of the compression rib of the breech area, in accordance with the invention. Figure 5 is a cross-sectional view taken along line 5-5 of Figure 4, showing the variable height of the compression ribs. 25 Detailed Description of the Preferred Modalities Referring now to Figures 1-2, a dashboard mat assembly 10 includes a dough layer ^^ or dashboard mat 12, having a first outer surface 14 and a second inner surface 16. A 5 pedal dead 18 is formed integrally in one piece with the mat 12 and projects outwardly from the first surface 14. The dash assembly of the dashboard 10 is preferably formed of a filled elastomeric moldable polymer, eg, elastomeric polypropylene , and serves as a sound barrier layer to reduce the transmission of sound from the engine compartment through the fire wall and into the passenger compartment of a vehicle. A lower periphery 20 of dead pedal 18 is continuous with the outer surface of the mat of the instrument board 15, and is formed to conform to the surface of a wheel cavity of the vehicle (FIG. 3), so that a super fi upper 22 of the dead pedal 18 is facing the rear of a vehicle and in a convenient position for a driver's foot when installed. A peripheral wall 21 of the dead pedal is formed integrally with the lower periphery 20 and the upper surface 22 of the dead pedal 18. A plurality of circular recesses 24 extends inwardly from the upper surface 22 of the dead pedal to receive a fastener (not shown). Each notch includes an elongated slot 26 for receiving a fastener pin or arrow (not shown) that typically extends from the ^^ Fire wall of the vehicle. The slots 26 are sufficient, so that the mat of the 5 instrument board 12 and the dead pedal 18 can be adjusted with respect to the vehicle fire wall, with the bolts projecting through the slots during installation. Although only two grooves and grooves are shown, it should be understood that a single notch and groove or plurality can be provided.

^ K of these depending on the amount of security required.

In addition, the recesses and / or grooves can be removed and the dead pedal can float freely, depending on the type of vehicle in which the dashboard mat is installed. The recesses and / or the grooves can also be used for the installation of a decorative cover. With particular reference to Figure 2, a first ^ - A set of ribs 30 which generally extend longitudinally and a second set of ribs 32 extending generally laterally, project from an inner surface 28 of the dead pedal 18. The first and second sets of ribs 30, 32 extend approximately perpendicularly to one another and provide structural support to the dead pedal 18 to resist the forces applied by the driver's foot. The first and second sets of ribs 30, 32 also give the dead pedal sufficient force to mount a cover (not shown), directly to the dead pedal through the fasteners The outer edges 34 ^^ of the ribs 30 are adapted to embed the wheel cavity of a vehicle and, with the wall pepfepsa 21, to support the pedal 5 dead 18 is the same. The outer edges 36 of the ribs 32 are routed to the inner surface 28 and generally do not come into contact with the wheel cavity. In the installed position, the inner surface 16 of the dashboard mat 12 and the outer edges 3¿ of the ribs 30 face the fire wall 25 of the vehicle (Figure 3), while the outer surfaces 14, 22 are facing the underside of the vehicle mat (not shown). The outer surface 14 of the dashboard mat 12 can also be extend beyond the mat behind the dashboard. Although the invention finds particular use in automotive dashboards, it is to be understood that the invention also has use in other automotive or non-automotive applications, where it has to temporarily or permanently a panel or a layer of material having a bearing surface formed integrally, to a supporting surface. For example, the structure of the dead pedal, that is, the reinforcing ribs, the increased thickness of the mat, and / or the openings of the mat, can be formed. fastener, in other places on the board mat instruments to provide structural support for mounting electrical modules, HVAC boxes, decorative panels, and ^^ Other vehicle accessories. Furthermore, although the dead pedal has been illustrated with a particular figure, it should be understood that other figures may be formed on the mat of the instrument panel, depending on the proposed application. Referring now to Figures 3 and 4, a barrier wall includes a transmission train area 42, a wheel cavity area -11, and fire fighting floor and wall areas. ^ r? 23, 25, which extend between the area of the drive train and the area of the wheel cavity. The area of fire wall 25 is contacted with and extends generally upwardly from the floor area 23. The assembly of the dashboard mat 10 can, in addition to or alternatively 15 to dead pedal 18, includes a compression rib matrix 38 formed integrally with the surface ^ F inside 16 of the dashboard mat 12 in a pruning area or area 40. The pruning zone 40 is located at the intersection of the 23rd floor and the area of the fire wall 20 25 between the wheel well area. 41 and the area of the drive train 42. The pruning zone 40 is substantially divided into a lower pruning portion 44 and an upper podiatry portion 46. The lower breech portion 44 extends partially along the 23rd floor of the vehicle adjacent to the wall. sontra 25 fires 25 and is formed integrally are the porsión sup- rior 46, which extends partially upwards along the fire wall 25 adjacent to the floor 23. ™ With particular reference to Figure 4, which is a rear view in partial transverse section of the shoulder area. 40, the matrix of the compression rib 38 includes ribs 48 extending generally longitudinally and ribs 50 extending generally laterally projecting from an inner surface 16 of the dashboard mat of the breech area 40. The ribs 48 extend approximately perpendicular to the ribs 50, the ribs 48 having outer edges 54 and the ribs 50 having outer edges 60. A peripheral rib 52 forms the outer perimeter of the compression rib matrix 38. A central rib 58 is formed integrally with the peripheral rib 52 and is located at the intersection of the podal porsions Both the upper and lower ribs 44, 46. Both the peripheral rib 52, as well as the sentral rib 58 have outer edges 62 and 64, respectively. In the installed position, the outer edges 54 and 20 62 are normally brought into contact with the fire wall 25 and the floor 23; the outer edges 60 and the inner surface 16 are inisially facing the fire wall and the floor; and the outer edge 58 extends the length and contacts the intersection of the wall against 25 fires and the floor.

The acoustic barrier 10 may also include an absorbent sheet 56 which is shown between the inner surface 16 of the ^^ dashboard mat 12 and the fire wall 25 and / or the floor 23 outside the breech area 40. The surface 5 outer 14 of the dashboard mat 12 is facing the underside of the vehicle mat (not shown) and is substantially uniform across the breech area 40. Figure 5 is a cross-sectional view taken along the line 5-5 of Figure 4, showing an exemplary sonfiguration of the pressure ribs. The ribs 48, 50, 52 and 58 project from the interior surface 16 of the breech area 40 to varying lengths to conform to the shape of the floor 23 and the fire wall 25, and to provide variable resistance structural support. when a force is applied to the breech area 40. As it was illustrated, a first The set of ribs, comprising the ribs 48, the peripheral rib 52 and the central rib 58, project a first distance from the inner surface 16 so that the ribs 48, 58 and 52 separate the inner surface 16 of the mat from the dashboard a predetermined distance, from the fire wall 25 and the floor 23. A second set of ribs, comprising the ribs 50, projects a second distance from the inner surface 16. Preferably, the first distance is greater than the second distance, so that the outer surfaces 60 of the ribs 50 are initially spaced apart from the wall 25. ™ and the floor 23. An impact of sufficient force applied to the outer surface of the podium area 40, to the floor 23 and / or the fire wall 25, causes one or more of the ribs 48, 52 and 58 to flex , and dampen initially by the same impact force. The initial level of damping or impact resistance can be controlled by varying the number of ribs 48 and varying the thickness, the The height, length, spacing, shape and orientation of the ribs 48, 52 and 58, to achieve the desired amount of initial impact strength. If the impact force is large enough to exceed the initial impact strength from the first set of ribs, they are flexed by flexing one or more of the ribs of the first set, until one or more of the outer surfaces 60 of Ww the ribs 50 are put in sontaste with the floor 23 and / or the fire wall 25, to provide a second level of cushioning or impact resistance. Since they are the first set of ribs, the second level of damping or impact resistance can be controlled for the second set of ribs by varying the number of ribs 48 and varying the thickness, height, length, spacing , the shape and orientation of the ribs, to achieve the desired amount of secondary impact resistance. It can further controlling the degree of resistances to the impasto by surrounding the podial zone 40 with an absorbent layer 56 of the desired stiffness. The compression molded matrix 38 integrally molded provides different levels of stiffness to the breech zone 40 greater than a foam absorbing layer alone and improves shock impact absorption and passenger safety. If desired, more than two degrees of impact resistance can be provided by adding increasingly shorter sets of ribs. Although the invention encompasses particular use in the breech zone 40, it should be understood that the compression ribs can be integrally formed elsewhere in the dashboard mat, to provide "improved impact resistance, such as in the area. of the dead pedal located on the wheel cavity of a vehicle In addition, the invention is not limited to the particular sonfiguration of the ribs referred to in the drawings, therefore reasonable variations and modifiations are possible within the spirit of the previous descriptive memory and the drawings, without departing from the scope of the invention.

Claims (23)

1. CLAIMS 1. An acoustic barrier adapted to be mounted on a barrier wall, the acoustical barrier in shadow: a layer of mass of a molded construction and characteristics of sound deadening, the layer of mass having an internal surface that is adapted to look at the barrier wall and an external surface adapted to look away from the barrier wall; a first set of resilient projections located ^ K within a pre-defined area and having an upper portion formed integrally with the layer of dough and a lower portion with an outer edge adapted to make contact with the barrier wall; sada projection of the first set extending at a first distance from the inner surface to the outer edge; 15 a second set of resilient projections located within the pre-defined area and in close proximity to the first set of resilient projections, the second set of resilient projects having an upper portion formed integrally with the dough layer and a lower portion with a 20 edge external adapted to look at the barrier wall; each projection of the second set extending a second distance from the inner surface to the outer edge; where the first and second sets of projections are so configured that only the first set 25 of projections resist resiliently layer compression of mass in the pre-defined area to a first predetermined level and the second set of projections together with the first set of projections resiliently resists the compression of the mass sheet in the pre-defined area beyond the first predetermined level. .
2. 2. An acoustic barrier according to claim 1, wherein the second distance is smaller than the first distance.
3. 3. An acoustic barrier according to claim 1, and further comprising a peripheral rib having an upper portion integrally formed with the inner surface of the dough layer and a lower portion with an outer rim adapted to make contact with the barrier wall, the peripheral rib defining the pre-defined area on the 15 inner surface of the dough layer.
4. 4. An acoustic barrier according to claim 3, wherein the first set of projections includes a plurality of first generally elongated ribs, each first rib having opposite ends formed integrally with the peripheral rib for thereby strengthen the peripheral rib against bending moments due to compression forces applied to the outer surface of the dough layer.
5. 5. An asymmetric barrier according to claim 25, wherein the second set of projections includes a plurality of second generally elongate ribs which are generally crossed to the first ribs, the second rib having opposite ends integrally formed are first adjacent ribs or the peripheral rib to thereby further strengthen the peripheral rib against bending moments.
6. An asustica barrier according to claim 5, wherein the dough layer is adapted for installation in a vehicle having the barrier wall, the barrier wall ^ rf) comprising a floor area and a fire wall area that extends between a wheel cavity area and a rail train area, the fire wall area generally connecting with and extending upward from the floor area , the dough layer further comprising: a wheel savity section configured to conform to at least a portion of the shape of the tire wheel area; and floor and fire wall sections are configured to conform to at least a portion of the shape of the floor and fire wall areas, respectively.
7. An acoustic barrier according to claim 6, wherein the housed area including the first and second set of projections comprises a dead pedal zone extending along at least a portion of the 25 wheel cavity of the dough layer.
8. 8. An acoustic barrier of agreement is claim 6, and where the hosted area that includes the sets first ^^ and second of projections is placed in a breech zone extending along at least a portion of the floor and fire wall sections 5 of the dough layer.
9. 9. An acoustic barrier according to claim 8, wherein the first set of projections includes a laterally extending midrib that is adapted to match the intersection of the floor and fire wall areas of the vehicle.
10. 10. An asymmetric barrier according to claim 8, and further comprising an absorbent layer having an external surface in contact with an inner surface of the dough layer and an internal surface adapted to contact 15 is the barrier wall. .
11. 11. An acoustic barrier according to claim 10, wherein the absorbent layer has an opening that is dimensioned to receive the peripheral rib and the absorbent layer is located outside of the housed area.
12. 12. An acoustic barrier according to claim 5, wherein the first set of projections includes a central rib extending laterally intersecting each of the longitudinally extending ribs and the peripheral rib.
13. 13. An acoustic barrier according to claim 1, and further comprising an absorbent layer having an outer surface in stannate with an inner surface of the mass sheet and an inner surface adapted to make contact are the barrier wall.
14. 14. An asymmetric barrier according to claim 13, wherein the absorbent sheet has an opening that is dimensioned to receive the pre-defined area such that the absorbent sheet is located outside the pre-defined area. 15. An acoustic barrier adapted to be mounted on a r? barrier wall, the acoustic barrier comprising: a molded construssion dough layer and sound damping characteristics, the dough layer having an inner surface that is adapted to face the barrier wall and an external surface adapted to look away from the barrier wall; a peripheral rib having an upper portion l > \ w formed integrally with the inner surface of the dough layer and a lower portion with an outer edge adapted to make contact with the barrier wall, the peripheral rib 20 defining an area housed on the inner surface of the dough layer; elongate ribs located centrally of the housed area, each elongated rib having an upper portion formed integrally with the inner surface of the dough layer and a 25 porsión inferior with an external edge adapted to look at the barrier wall, each elongated rib having opposite ends formed integrally with the peripheral rib for ^^ with this strengthen the peripheral rib against bending moments due to compressive forces applied to the surface 5 external layer of dough. 16. An acoustic barrier according to claim 15, wherein a first set of the elongated ribs extends generally in the same direction and a second set of the elongated ribs has opposite ends formed integrally with either adjacent ribs of the first set of ribs or the peripheral rib and an adjacent rib of the first set of ribs to thereby further strengthen the peripheral rib against bending moments. 17. An acoustic barrier according to claim 16, wherein the first set of ribs is projected at a greater distance from the inner surface of the dough layer than the second set of ribs, whereby the outer edges of second set of ribs are normally 20 away from the barrier wall when the outer edges of the first set of ribs contact the barrier wall. 18. An acoustic barrier according to claim 17, wherein the first and second ribs are 25 resilient, whereby the first set of ribs resists resiliently the pressure forces applied to the outer surface of the dough layer at a predetermined first level ^ and the second set of ribs, together with the first set of ribs, resiliently resists the compression forces 5 at a second predetermined higher level than the first predetermined level. 19. An acoustic barrier according to claim 15, and further comprising an absorbent web having an outer surface in contact with an inner surface of the web. ^ 0 layer of dough and an internal surface adapted to make contact with the barrier wall. 20. An acoustic barrier of agreement is claim 19, wherein the absorbent layer has an opening that is dimensioned to receive the peripheral rib and the layer.
15. 15 Absorbent is located outside the enclosed area. 21. An acoustic barrier of agreement is claimed, wherein the dough layer is adapted for installation in a vehicle having the barrier wall, the barrier wall comprises a floor area and a wall area. of fire that 20 extends between a wheel cavity area and a traction train area, the fire wall area interspersing and extending generally up to the floor area, the layer of dough further comprising: a wheel savity session configured for 25 conform to at least a portion of the shape of the area of wheel savity; and floor and fire wall sessions are configured to be formed to at least one porsión of the shape of the floor and fire wall areas, respecly. 22. An acoustic barrier according to claim 21, wherein the housed area, including the first and second sets of projections, is welded in a breech zone extending along a portion of the floor and fire wall sections. of the layer of dough. 23. An acoustic barrier according to claim 21, wherein the housed area, including the first and second set of ribs, is soldered in a dead pedal zone extending along at least one portion of the cavity section. of wheels of the dough layer.