SE468162B - SELF-SUPPLYING SANDWICHARTAT SOUND INSULATION AND PROCEDURES FOR ITS PREPARATION - Google Patents

Description

46 8 162 the sound-absorbing element holding the support means is avoided, but the achieved sound-absorbing however, the attenuation values were not sufficient for all applications.

Furthermore, a building element for room sound insulation is also known - according to AT-PS 373 949 - in which the foam layer is bonded to a hard plate of mineral ralfibrer. The mineral fiber plate can also face the foam layer on its own side be covered with a layer of kraft paper. Through the use of a hard mine- Although the mechanical strength of the building element could be increased, an adaptation of the building element to different conditions of use was not either here always possible to the desired extent.

The present invention now has for its object to provide one self-supporting, sandwich-like sound insulation element, which can easily adapted to different conditions of use. In addition, the use of sound the insulating element may be possible, in particular in motor vehicles for attenuating the transmission between the motors and the building elements radiating outwards resp. between the sound-emitting building elements and the interior space of the vehicle. In addition the sound insulation element must be easy to manufacture.

This object of the invention is achieved in that the core layer has an i increasing density of the two cover layers and consists of a plastic with weighing open cells. By densifying the cell structure in both core layers edge areas, a good anchoring of the cover layers and a favorable oscillation behavior of the multilayer, self-supporting, sandwich-like sound insulation the element. Due to the deviating oscillation characteristic of the denser edge areas relative to the less dense central region of the core layer, a multi-part pivot is achieved. which attenuates sounds at different frequencies at each time and furthermore, a good overall effect is achieved, especially when damping it from engines or compressors emitted sound. In addition, this also offers as foam plastic designated plastics with predominantly open celléïïettsgott protection against impact damage from persons and is thus also suitable for the use of internal cladding of passenger cars or cabins by lorries. In a surprising way however, is achieved by the solution according to the invention due to the higher density. the area in the area of the two cover layers for normal operation is sufficient strength, whereby the advantage of the solution according to the invention also lies in that the thickness and also the density in the densified edge areas of the core layer can be adjusted sas to the cover layer directly connecting to different conditions.

According to another feature of the invention, it is proposed that it be densified the cell structure in the edge areas facing the two cover layers is formed by a mechanically and / or thermally densified foam with open cells. The advantage down 3 4-68 162 this solution lies in the fact that a uniform material with essentially the same elongation properties are achieved, which remains air permeable to achieve a better sound insulation. In addition, it is advantageous that this densification can take place in a work process independent of the production of the foam and consequent the residual deformation of the cell structure with open cells can the effect of pressure and / or temperature is precisely controlled depending on the desired turning criteria. An additional advantage of these under pressure and / or temperature The course of work is that in many cases it is possible to at the same time make a room deformation of the sound insulation element including the two the cover layers to produce desired room shapes, as required, for example for the inner lining of motor vehicles.

According to another advantageous embodiment variant, it is proposed that the volume weight of the foam cells of the core layer with open cells are different in the middle area and the edge area, preferably the edge area has a volume weight two to five times as high as the middle area. This is advantageously prevented at the same time as it arises a rupture in the cover layers or sound insulation element by the action of a force, ' especially from a pointed object.

However, it is also possible that the central area is formed by a soft foam. plastic, in particular with a bulk density of about 9 to 10 kg / m3, because thereby in addition to the good sound insulation behavior of the elastic material also a strong damping effect is achieved by blows from persons against surfaces thus clad depending on the elastic flexibility of the core layer.

According to another advantageous further development, it is proposed that the core layer consists of a soft foam with predominantly open cells, especially an MDI-driven one or crosslinked polyether or polyester foam plastic. Such foams stand out by high elasticity and tensile strength and has proved useful for the modern field of application.

According to a further feature of the invention, it is proposed that the layer in the edge areas facing the two cover layers comprises a densified cell structure, which exhibits a higher proportion of closed cells than the cell structure in a center area between these edge areas. Through the higher proportion of closed cells and the densified cell structure are counteracted by the passage of airborne noise a greater resistance, thereby delaying the propagation speed and its damping in the adjoining, less dense but softer areas of the core layer facilitates tas.

Furthermore, it is advantageous if the soft foam plastic consists of one of special MDI-driven or crosslinked polyether or polyester foam plastic and preferably the core layer is formed by a part of a soft foam block, because hereby one 468 162 4 exact structure with open cells and with low volume weight is achievable and a constant high-degree continuity is achieved in the cell structure over the thickness of the core layer. play.

Furthermore, it is also possible that it consists of the middle and edge areas the core layer is formed in one piece, whereby the number of separate parts for the position of the sound insulation element according to the invention can advantageously reduction.

However, it is also possible for the cover layer to be designed to be moisture-repellent. in particular as a polyethylene film, and the open cells in the edge region of the core layer is over openings in the cover layer, the adhesive layer or the polyethylene film bound with the ambient air, whereby the capillary action of the core layer with open cells are retained, however, moisture penetrated into this core layer can penetrate this core layer such as water vapor. On the other hand, however, it is also possible that in front of the moisture repellent the cover layer or polyethylene foil, on the side facing away from the core layer, a fiber mat with fibers or threads resistant to high temperatures is provided, which has openings distributed over the surface and is in particular reticulated whereby the sound insulation elements can be arranged even in the vicinity of the sound source. lor, which emit higher temperatures and in addition there is better protection against mechanical damage to the sound insulation elements. Through the stiffening of it to the edge area assigned to this fiber mat is already absorbed during the penetration of this part of the sound insulation element a large part of the incident sound and it is ensured by the availability resp. the air permeability thereof fiber mat that the air can freely enter the sound insulation element for sound the insulation.

It is then advantageous if the fibers or threads are formed of glass fibers and / or carbon fibers and / or metal fibers, since such fibers or wire mats allow a high mechanical and also thermal stress and also are resistant to the effects of oils and fats.

According to another embodiment variant, it is proposed that on it from the fiber mat facing the surface of the second cover layer is provided a mat of water-repellent fiber traps and / or of foam plastic, for example a soft foam with open cells, whose thickness constitutes a fraction of the thickness of the core layer, whereby they an open cell penetrating the sound waves of the sound advancing towards it surface to be protected is further attenuated before encountering this surface.

Furthermore, it is advantageous if the individual areas of the core layer are interconnected and / or the cover layer with the core layer and / or cover layer with the mat, previously arranged on the mat and / or the fibrous mat via a 5,468,162 adhesive layers, especially with the cell structure of the core layer, and adhesive layers the adhesive is air permeable, preferably the adhesive layer forms the cover layer, because thereby the absorbency of the core layer does not hinder between the individual layers of the sandwich soundproofing element. existing adhesive layers, wherein at a connection of the layers only with the cell structure further facilitates access to the open cell in the core layer.

Furthermore, it is an advantage if the adhesive layer is formed of it as melt foil formed the polyethylene foil, because thereby the process of bonding of the separate layers is simplified by the absence of the binder application.

However, it is also possible to in the core layer and / or in the area between the core layer and the fibrous mat or mat an elastically deformable carrier body is provided, which is designed in the direction of the cover layers of air and / or sound permeable. Sound insulation elements thus designed can be easily adapted to complicated room shapes, such as for example the inner shape of hoods or similar, and over the design enabling the support body to be attached to such parts.

According to another embodiment variant, it is proposed that the core layer is assigned an elastic, in particular permanently deformable support body and is connected thereto in terms of strength and / or form. Thereby, the deformation properties of those on The sound insulation elements produced in this way are adapted to the different uses. conditions and likewise corresponding tear-resistant fastening points come in these.

Furthermore, it is also possible that the core layer is two-part and consists of each of a plate, between which the elastically deformable support body is arranged, particularly glued in, because thus also in the device of the support body inside the core layer this can be formed by two plates, each of which consists of a part of a soft foam blocks.

According to another embodiment variant, it is proposed that the support body and / or the binding the medium layer and / or the cover layer and / or the fibrous mat and / or the mat are designed permeable to water vapor. This avoids deterioration in the sound insulation the efficiency of the learning element through moisture.

According to the invention, it is also possible for the fiber mat to be assigned to one sound source and the mat arranged on the opposite top is assigned to it component to be protected, the sound insulation element being arranged between the sound source and an envelope surrounding it, for example a bonnet, and via the connected to it, whereby without further means a sound-insulated making of the sound insulation element is possible on surfaces to be protected, such as for example sheet metal parts of a bonnet or the like. 468 162 6 Furthermore, it is also advantageous if the thickness of the central area is different. the play of the two edge areas of the core layer, preferably three times as large as of the edge areas, because due to the thickness of the different areas of the core layer an adaptation to the attenuation of different frequencies of sound waves is possible. On the other hand, it is also possible that the bulk density of the foam in the core the layer is different in the middle area and in the edge areas, preferably the edge the area has twice the volume weight of the central area, whereby the sound insulation the attenuation characteristics of the element are further adapted to the frequencies which should be dampened, and at the same time a protection of the very soft is achieved in a simple way the center area against mechanical damage.

According to another embodiment, it is proposed that the number of open cells in the middle council and in the edge area of the core layer are different and especially increase from the edge the council in the direction of the central area, whereby labyrinthine passages arise, in which the sound energy is absorbed.

Furthermore, it is also possible for one to face one edge area of the core layer cover layer is formed of a fabric or foil-shaped, deformable material and the cover layer facing the other edge area is formed by a fiber fold and / or a special carton soaked in unsaturated polyester resin and preferably is designed to be deformable and / or curable under temperature and / or print. Through the use of two flexible and deformable, flat cover layers a sandwich element is produced, which by the combination effect of the three materials The aluminum has a higher strength than each separate material. In addition by the corresponding design of the cover layers it can be achieved that during deformation the remaining profiling of the sound insulation element takes place and consequently, the production of the sound insulation properties can be combined with to a single pace of work.

According to another embodiment variant, it is also possible for a binder layer is arranged between the cover layers and the core layer, which is preferably formed of a polyethylene film formed as a melt foil and the core layer and / or the adhesive layer and / or the carrier body and / or one or both cover layers are designed air-permeable, especially moisture-repellent. Thereby it is achieved that on due to the air permeability a good sound absorption capacity is achieved in the the insulating element and at the same time a long service life, because the liquid is hindered by the liquid-repellent design of the cover and / or adhesive layers.

Another embodiment of the invention is also advantageous, according to which at least one of the cover layers and / or at least one of the two edge areas is provided with a moisture-repellent additive impregnation. By the corresponding the cover layers or edge areas are provided with a moisture-repellent impregnation, II 7 468 162 which is activated, for example, by the heating during the deformation of the element, can in an easy way an impermissible moisture absorption of the sound insulation elements and thus a reduction in the sound insulation effect is prevented.

Furthermore, it is also possible for the core layer to have distributed over the surface, different highly densified surface areas, whereby the weight of the core layer per unit area and the corresponding to the thickness in the various strongly densified surface areas is preferably essentially the same size. This design variant has the great advantage of being the production of sound insulation elements according to the invention can, as a starting point, materials are used flat materials of the same thickness. Thereby arises on surprisingly advantageous manner during the manufacture of the sound insulation elements according to the invention different densification in the surface areas which have been densified into a thicker or thicker wall thickness. Thus, thinner surface areas are densified more strongly and thus obtains a higher bulk density and a higher strength than thicker ones surface areas of these tiles. An automatic adjustment is thus achieved indirectly. the strength properties of the different thicknesses, as is usually the case with required for cladding elements for the interior of vehicles.

However, the invention also encompasses a process for the preparation of such sound-insulating elements, in which a plastic core layer consists of moderately connected with different cover layers.

This method is characterized by a foam block of soft foam plastic skimmed and divided into plates, after which the facing surfaces of one or two immediately adjacent plates, especially while heat and these are affected by a compressive force directed in the direction of the middle layer and the plate edge areas are plastically deformed. Through the heat and thickening treatment of foam the plastic plates, it is possible to achieve different densities and cell structures in one in one piece made element.

According to another variant of the method, it is proposed that the heat supply between the facing surfaces of two plates an adhesive layer is inserted or an adhesive foil and optionally a support body, in particular a wire mesh - or similar. By the simultaneous application of the cover layers during this heating treatment, an additional bonding process can be used to attach them to the core layer. its edge areas are saved.

Furthermore, it is advantageous, if by heat action cover layers at the same time applied to the facing surfaces of the core layer and bonded tightly with these, one cover layer being formed of a fiber mat and the other cover layer the layer of a carpet.

Furthermore, it is also possible that the core layer and the support body during heating and the force action is deformed in space, thereby reducing the cost of the formation of the nuclear layers is reduced and in addition a more uniform cell structure can 468 162 s be ensured over the entire thickness of the plate than in the separate production of torna. ' It is also advantageous if before the heating and densification of the The edge areas of the heat-sealable plastic foil are applied to the surfaces and through heat and power action are connected to the edge areas of the core layer, because through the heat effect during the densification of the edge areas is achieved at the same time as the melting or the attachment of the moisture-repellent plastic foils.

However, it is also possible that the height and time of the impact also the height and time of the temperature effect are variable depending on the desired damping conditions of the plate and in particular are equal in the two edge the areasÄ Via the control of the procedural criteria, such as the height and time of power impact resp. temperature effect, the proportion of closed cells in the the density as well as the density and volume weight are adapted to the desired damping properties. the creators.

Furthermore, it is advantageous if it is assigned to one cover layer the fiber mat and the mat associated with the second cover layer are applied together early and vigorously connected to the spaced apart surfaces of the cover layers, because thereby a cupping of the plates as well as a build-up of internal stresses ar avoided.

A further process variant is characterized in that at least a part of the core layer of the same thickness, preferably in common with at least one cover layer under the interposition of an adhesive layer, in particular a polyethylene hot-melt foil, introduced into a mold and under the simultaneous influence of pressure and temperature condensed in different surface areas to different thicknesses and the separate layers thereby simultaneously bond to each other and / or harden, after which preferably in the same working tempo sound insulation element is cropped to the desired circumferential shape. This procedures make it possible to easily produce the most at low cost various sound insulation elements. In doing so, however, the benefits of the good are maintained the sound insulation and the favorable relationship in case of accidents by the good ones the damping properties of such elements in the event of blows from persons.

For a better understanding of the invention, this is explained in more detail below. in connection with the embodiments shown in the drawings.

On the drawings shows Fig. 1 shows a sound insulation element according to the invention in perspective, simplified, schematic representation, Fig. 2 is a cross-section through an edge region of a core layer of a sound insulation elements according to the invention, from which they appear the connection points with a schematically indicated foil serving as a cover layer as well as the areas of the adhesive coating on the cell structure, 9 ~ 4-68 162 Fig. 3 is an end view of an engine compartment with a sound system arranged on the inside of the engine compartment; insulating elements according to the invention, as well as fastening devices for these sound insulation elements on the hood, Fig. 4 shows a sound insulation element according to the invention in perspective view, Fig. 5 is a cross-section through a sound insulation element seen from above, Fig. 6 shows a part of a core layer of a sound-insulating element according to the finding with schematic representation of the different cell structures in the densified the edge and in the center area in perspective view.

Fig. 1 shows a self-supporting, sandwich-like sound insulation element 1.

This sound-insulating element 1 comprises two cover layers 2, 3 and a core layer 4.

In the present exemplary embodiment, the core layer 4 consists of two plates 5, 6 of a nuku foam, which, as schematically indicated, in the middle of the core layer 4 area 7 has a smaller density than in the edge areas 8, 9 of the core layer 4. the central region 7 of the layer 4 is in the present exemplary embodiment between the counter facing surfaces of the two plates 5 and 6 provided with a support body 10, for example a wire mesh or a wire mesh or the like. The support body 10 is' preferably elastic and can be permanently deformed to arbitrary by the pressure action room shape.

For connecting the two plates 5, 6 and the support body 10 there is one adhesive layer 11, which may also be formed of, for example, a melt foil, e.g. pelvis and polyethylene film and the like

In the edge areas 8, 9, likewise, via an adhesive layer 12, 13, one fiber mat 14 resp. a mat 15, which form the cover layers 2, 3, connected to plates 5, 6.

The adhesive layer 12, 13 may again be formed of melt foils, such as empelvis polyethylene foils e.d. When using polyethylene films as binder layers, these are preferably provided with openings distributed over the surface, so that the air flow is ensured between the plates 5, 6 resp. these plates 5, 6 and fiber mat 14 resp. the mat 15. Through the arrangement of the openings 16 the air can pulsate in the cells of the plates, so that the air-sound oscillations are attenuated by them labyrinthine passages in the open cell structure of the nuclear layer 4 or in the the layer forming the plates 5, 6. In addition, through these openings 16 that any moisture penetrated into the sound insulation element 1 can be released into the gas shape, wherein by corresponding selection of the size and number of those on a surface unit the openings 16 provided penetration of water in liquid form as far as possible can be avoided.

For fastening the sound insulation element 1, holders 17 are attached to the support body 10, which cooperate with connectors 18 to secure the sound insulation the elements 1 on a building part 19, which are to be protected from the influence of sound from a 468 162 10 sound source 20. The connectors 18 can be formed, for example, on the building part fasten tie bolts or screws or the like.

Fibers or threads in the fiber mat 14 may, depending on the sound insulation uses, especially in areas with higher temperatures emitting sound sources, such as motors, compressors or the like, be formed of high temperature resistant glass fibers, metal fibers or carbon fibers or similar nande. By such a design of the fiber mat, the adhesive layer 12 is protected as well as the edge area 8 from the influence of too high temperatures.

The mat 15 assigned to the building part 19 - which is arranged on it from the sound source 20 facing the side of the sound insulation element - consists for example of a fiber trap or of a soft foam mat. The cover layer 2 or the fiber mat 14 resp. the cover layer 3 or the mat 15 has a thickness 22 resp. 23, which constitutes a fraction of a thickness 24 of the core layer 4. The mat 15 can then be formed of a water-repellent fiber trap or of a foam mat of a soft foam plastic with predominantly open cells.

As indicated in the schematic view of the center area 7 and the edge areas' 8, the core layer 4 has an increasing one in the direction of the two cover layers 2, 3 density. While the middle layer preferably has a bulk density of 10 kg / m 3, the volume weight of the soft foam plastic in the edge areas 8, 9 amounts to about 18 to 20 kg / m3. As a result, different sound transmission values are achieved over the thickness of the core layer 4. play, so that approximately equal sound insulation values are achieved for different frequencies with a sound insulation element 1. In addition, the higher volume weight in edge regions 8, 9 a higher strength and stability of the core layer 4 in the edge areas 8 and 9. Thus, favorable conditions for attachment of cover layers 2, 3 on the core layer. Due to the higher strength of the edge areas 8, 9 can the sound insulation element without further action only by connection with the cover layers are made self-supporting. It has proved advantageous to produce the different volume weight in the edge regions 8, 9 relative to the central region 7 of the core layer 4 in that plates with the same density by the action of pressure and temperature sealed in the edge areas. Thereby arises through the collapse of the cell structure with open cells due to the temperature effect in these densified areas a higher number of closed cells than in the central region 7. By a corresponding change of the thickness of the edge area 8, 9 resp. the volume weight relative to the center area 7 volume weight can an adaptation of the sound insulation element to different sound sources resp. to different frequencies of the sound waves emitted by such sound sources are remedied. With advantage is therefore used in the core layer plates, which are cut out of a soft foam plastic blocks. In the soft foam plastics used for the production of the plates it may be a specially MDI-driven or cross-linked polyether or 11 468 162 polyester foam plastic. The advantage of using tiles, which are cut out of one foam blocks, lies in the fact that the density and cell structure are as uniform as possible.

It is therefore irrelevant within the scope of the invention if the core layer 4 is made of a single plate or of two plates 5 and 6, as shown in Fig. 1, or of several plates with different density or cell structure, for example one plate for the central area 7 and each plate for the edge areas 8, 9.

For the production of such a sound isolating element 1, as shown in Fig. 1, the following procedure can be used: Slabs of a nüuk foam with substantially the entire thickness constant density is produced, in which, for example, one consisting of wire mesh or wire mesh support body 10 is foamed. Alternatively, however, it is also possible to out of one foam blocks of soft foam cut plates are used, between which a binder agent layer 11 and the support body 10 are applied. At the same time put in a heated press for producing the sound insulation element 1 during the spacing of a binder layer 12 resp. 13 cover layer 2 and 3.

In connection with this, the press is heated in the area of the cover layers 2, 3 more a temperature of about 100 to 150 ° C and on the sound insulation inlaid in the mold element 1 is applied to a corresponding surface load. Through the load distributed over the surface under simultaneous temperature influence breaks in the edge regions 8, 9 cell structure together and there is a decrease in the thickness of the core layer 4 due to this densification process. Through the collapse due to the simultaneous impact of pressure and temperature arises in the edge areas 8, 9 also a higher density and a higher volume weight of the foam. By appropriate choice of temperature and the pressure load, the thickness in the edge areas resp. the change in density and the volume weight is easily adapted to different use cases.

The adhesive used for the adhesive layer 11, 12 and 13 is preferably water-repellent but air-permeable, so that air can enter unhindered penetrate into the underlying areas of the plates 5, 6 resp. the core layer 4.

However, it is also possible for moisture insulation and for gluing them together separate layers of the sandwich-like sound insulation element 1 to instead melt foils used for the adhesive layers, for example polyethylene foils. When heating of the sound insulation element 1 melts this foil and acts as water-repellent protective layer and at the same time as an adhesive for bonding the separate layers of the sound insulation element 1.

Through the use of foams with open pores and with highly elastic properties in the area of the core layer 4 and in the area of the cover layer 3, sound the insulating element 1 according to the invention is mounted directly on a building part 19, which shall be protected from the incident sound. 468 162 H It is advantageous in this case if the connection between the connectors and the holder 17 on the support body 10 takes place via elastic intermediate elements, so that a pivoting and thus sound transmission from the sound insulation element to the building part 19 can be reliably avoided.

Fig. 2 shows a part of the core layer 4. As can be seen, this is assembled core layers of closed cells 25 and the interconnected open cells 26, which are formed by the network structure.

To now enable an air passage through the adhesive layer between the cover layer 3 and the core layer 4, an adhesive 27 is used, which has a con which does not allow a bridge of larger cavities to be bridged, so that the the means 27 is only applied to the network structure by the open cells 26 resp. on those closed cells 25. This ensures that in the connection surface between the layer 3 and core layer 4 air passages remain, through which air can flow in i resp. out of the core layer 4.

In Fig. 3, the device is composed of sound insulation elements 1 according to the finding on the inside of a bonnet 28, which consists of hood parts 29 and 30, which ~ for example, consists of fiberglass-reinforced plastic. Inside the hood 28 is, for example a diesel engine 31 is provided, which emits airborne sounds and sounds in all directions from the engine body, as symbolically indicated by arrows 32 and 33. The elements 1 are connected to the hood parts 29 via the support body 10 and connecting means 18 and 30.

As further shown in Fig. 3, it is through the formability of the separate ones the plates or elements of the sound insulation element according to the invention are possible it is possible to adapt this to arbitrary shapes of the hood parts 29 resp. 30 - so- which is shown in particular at the sound insulation element associated with the hood part 29 1.

Of course, according to the invention, instead of I MDI-driven foams can TTI-powered foams are also used. Also the choice of foam plastic volume weights in edge or the central areas can be correspondingly in order to achieve, for example, a better damping ratio country for more energy-rich energy fluctuations.

Furthermore, it is also possible to use a cotton fiber fold for the carpet 15 or a trap of synthetic fibers. For the adhesive layer, an adhesive is used. must be taken into account that this still retains its binding effect even after heating to approx. 150 ° resp. in this temperature range turns into liquid form, so that, for example, during the temperature and pressure load of the sound insulation be able to perform the gluing of the separate plates at the same time resp. layers, so that a lasting adhesive bond in the sandwich is obtained. 13. 468 162 For pressure and temperature influence of the sound insulation element during manufacture the molding or shaping, those known in the art can be heated the press devices are used.

Fig. 4 shows a sound insulation element 101, which consists of a cover layer 102, a cover layer 103 and a core layer 104 arranged therebetween. layer 104 has, as schematically indicated, a center region 105 and two edge areas 106, 107. This core layer 104 may consist in one piece of a foam plastic with predominantly open cells, especially a foam plate. It is, however also possible to join the edge areas and the center areas each of their own tiles.

As indicated by the sectional area in the area of the end face of the schematic image, the edge areas 106, 107 and the middle area 105 have different densities of foam plastic with open cells. These edge areas 106, 107 are then formed under pressure, i.e. by mechanical technical and / or thermally densified foam with open cells. Further used in this embodiment both for the center area 105 and for the edge areas 106, 107 foam plastic with equal properties. If a one-piece core layer 104 is used, it is created the edge areas 106, 107 by densification exerted in the surface area during simultaneous heating. supply. As further shown in Fig. 4, the surface areas 108 have a larger one thickness 109 than the surface areas 110, which have only one thickness 111. Such as As can be seen from the schematic drawing, the core layer 104 is in the surface region 110 more densely densified and, on the other hand, has a correspondingly higher density and thus a higher volume weight. This is done by the structure with open cells through it higher pressure in the surface areas 110 during the simultaneous thermal load taken stronger. In this case, it is also possible for the surface areas to be densified stronger also exposed to a higher temperature to facilitate the collapse or the permanent deformation of the plastic structure with open cells.

Advantageously, however, it has an element with the same surface in the surface area 110 with a smaller thickness 111 and in the surface area fíOä ”with a larger thickness 109 the same weight.

The cover layers 102 and 103 may be formed of moldable under pressure and temperature foils or mesh materials of fabric, fibers or other artificial or natural league material. Advantageously, it is possible to design one of the two cover layers 102, 103 also of a board impregnated with unsaturated polyester resin. In a performance in which a cover layer 102 is formed of a polyunsaturated polyester. resin soaked cardboard, this cover layer 102, for example in a vehicle, is arranged a body 112, for example the sheet metal parts of the cab space. The attachment between the sound insulation element 101 or the cover layer 102 and the body 112 can be done by gluing or with the corresponding plastic or metal fastener. The opposite The standing cover layer 103 may be formed of synthetic or natural fibers 468 162 14 carpets or leather or the like. If the cover layers 102 and 103 during manufacture the sound insulation elements 101 according to the invention should be bond to each other, for example, by using melt foils 113 - as indicated schematically in the lower part of Fig. 4 - it must be taken into account that the cover layers 102 and 103 enables a corresponding deformation and temperature load.

In the sound insulation element 101 shown, for example, it can be used the soft foam or the foam with an open cell structure exhibit one bulk density of about 9 to 10 kg / cm3 and is densified, for example, in the edge areas 106, 107, in particular also in the surface area 110, in which it only has a thickness 111, to a bulk density of about 40 to 50 kg / m 3. This leads to, due to the denser structure of the soft foam in the surface area 110, that a higher mobility of the sandwich element is achieved relative to the surface areas 108 in the areas in which due to the constructive conditions a thickness 109 of the sound insulation element 101 is not possible, and nevertheless a sufficient one is ensured strength against damage during normal operation. After all, such is achieved sound insulation element high elasticity and good damping property when tapped from * persons, because the firmer and higher densified surface areas 110 open directly into surface area 108 with higher elasticity and thus overall the strength is also densified surface area 110 more elastically cushioned than in post-foaming with plastic materials with predominantly closed cells.

By the corresponding force and temperature effect during the production of the sound insulation elements according to the invention can the sealing process in the edge areas 106 and 107 also decrease progressively towards the center area 105.

Fig. 5 shows a cross section through a sound insulation element 114, which can be used, for example, as a cladding element in an interior wallpaper vehicle. ring. As can be seen from this view of the sound insulation element 114, this exhibits this different thickness and different deformed surface areas 115, 116, 117 and 118. A core layer 119 and an associated cover layer 120 must allow an sufficient deformation to enable the profiling of without material destruction the sound insulation element. For this it is possible that in the very strongly densified and weakened surface areas 117 resp. 118 to enable adequate firmness for mounting connecting devices, at least in the individual surfaces the areas advantageously in the core layer 119 introduce support bodies 121, which after the core the design of the layer 119 holds and stabilizes these surface areas 117, 118 in it intended shape. The support body 121 may comprise with different resins or other binders mesh or foil soaked or also of metals or the like the formed grids and nets, which after the deformation and temperature treatment cures and holds the sound insulation element 114 in the desired shape. Of course is 15 468 162 with this sound-insulating element 114 it is also possible to put on that cover layer 120 opposite side of the core layer 119 provide an additional cover layer.

Fig. 6 shows a part of a core layer 122 and a cover layer 120 in solid form simplified form and in perspective. With this image, the mode of action of it mechanical and thermal densification of the edge areas 123 relative to a central area 124 is displayed graphically. As can be seen, in it is against a surface 125 of the core layer 122 facing the edge region 123 the open cells 126 formed by a space grid of plastic with a variety of strips 127, clamped by the mechanical and thermal the densification, whereby the approximately spherical cells resp. they are spherical the built-up strips 127 are compressed and broken and, for example, partially closed closed cells 128 assume an elliptical shape unlike the center region 124, in which they are approximately spherical. Through the pressure and temperature combined the open cells 126 resp. these forming lists 127, whereby both the strength and the density as well as the volume weight in the edge council 123 rises. If this densification occurs at the surface, it decreases in the direction of the area 124 linearly or progressively, depending on the selected processing criteria. to the central region 124, in which the original, unchanged cell structure one remains.

The solution according to the invention thus differs from the sound insulation elements in which a foaming with skin formation is used to at a soft core achieve a hard surface by bringing the edge zone densification within arbitrary limits is controllable by the applied temperature and pressure. In connection with Fig. 6 is schematically reproduced only for a better understanding of the basic idea of the solution according to the invention to change the properties of soft foam plates by corresponding spirit densification. Correspondingly, both in the strongly exaggerated can the size ratios and in the course of the strips in the structure with open cells arbitrary deviations occur and the solution according to the invention is limited to no way of the embodiment shown.

The method and device according to the invention are also not limited to the use of the cover layers shown. Thus, for example, fabrics, natural or artificial leather, fiber traps, nets or crochet materials are used as cover layers, whereby both natural and man-made fibers are useful. Advantageously, these cover layers can also be soaked or coated with moisture-repellent or non-flammable materials al. In this case, it is advantageous if these additional or introduced materials hardens only during the pressure and temperature treatment, after the formation of the sound the insulating elements in the desired shape. This reliably avoids a return suspension of the sound insulation elements in their initial position. 468 162 15 Likewise, for the support body 121, any material is used. bart. Thus, it is possible to use corresponding fiber traps, fiber nets or similar of metal, plastic or natural fibers and threads, preferably carbon fiber dar. Furthermore, it is advantageous if this support body is coated with an unsaturated polyester resin which thus retains the support body below temperature and / or the compressive stress after molding in this deformed state.

Of course, it is also possible to insert the support body between two corresponding the formed foam plates and via one or two adhesive layers, for example hot foils, connect them with these plastic layers.

Advantageously, these sound insulation elements according to the invention are useful for the interior equipment of motor vehicles, in particular for the cladding of passenger spaces or cabs for lorries. Of course, they are also involved advantage useful in the insulation of high-rise buildings or in the sound insulation of others work machines. get r-l Gßbæ flfl ith-ßßdlvb- fl »A Q-a I-l IÜ IN* (A) I-Û -ß l- fl U'I I-l 01 I-l \ | I-l æ I-l i-O IV ISLAND IÜ I-l hrs? IN\) IV O.) | \) -å I \ J UI l '\) O! N w IV æ l \> '-0 U.) @ (a) D-l (OUCH IV 33 17 4-68 162 layout of reference numerals. sound insulation element cover layer cover layer core layer plate pïatta my area edge area kanto fi advise carrying body binding medium layer binding medium layer binding medium layer fiber mat carpet opening håïïare bandages byggdeï ïjudkäïïa wire thick thickness thick ce11 ce11 glue hood hood hood diese1motor piï piï 101 1judiso1eringse1ement 102 cover layers 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 cover layer core layer míttområde edge area edge area surface area tjock1ek surface area tjock1ek body smäïtfoïie ïjudisoïeringseïement surface area surface area surface area surface area core layer tätkskíkt carrying body core layer edge area my area surface ce11 1íSt ce11

Claims (32)

468 162 18 Patent claims Self-supporting, sandwich-like sound-insulating element with two spaced-apart, different cover layers and a core layer arranged therebetween, consisting of foam plastic, characterized in that the core layer (104, 119, 122) has one in the direction of the two cover layers (102, 103, 120) increasing 'density and consists of a plastic with predominantly open cells (126), wherein the cell structure of the core layer in the edge areas (106, 107, 123) facing the cover layers is densified by mechanical and / or thermal wave. Sound insulation element according to claim 1, characterized in that the densified cell structure in the edge areas (106, 107, 123) is formed by a mechanically and / or thermally densified foam with open cells. Sound insulation element according to one of Claims 1 or 2, characterized in that the bulk density of the open-cell foam layer of the core layer (104, 119, 122) is different in the central region (105) and the edge region (106, 107, 123), preferably the edge region has two to five times the volume weight of the center area. Sound insulation element according to one of Claims 1 to 3, characterized in that the central area (105) is formed by a soft foam plastic, in particular with a volume weight of approximately 9 to 10 kg / m 3. Sound-insulating element according to Claim 4, characterized in that the soft foam plastic is formed from a separate MD1-driven methyl diocyanate or crosslinked polyether or polyester foam plastic and preferably from a part of a soft foam plastic block. Sound insulation element according to Claim 1, characterized in that the core layer (4) in the edge regions (8, 9) facing the two cover layers (2,3) has a higher proportion of closed cells (25) than the cell structure in a central region (7). ) between these edge areas (8,9). Sound insulation element according to Claim 6, characterized in that the core layer (4) consisting of middle and edge areas (7, 8, 9) is formed in one piece. Sound insulation element according to claim 1 or 2, characterized in that one of the cover layers (2) is formed moisture-repellent, wound-like as a polyethylene foil, and the open cells (26) in the edge region (8,9) of the core layer (4) are connected to the ambient air via openings in the cover layers (2,3) resp. the adhesive layer (12, 13) or the polyethylene film. Sound insulation element according to claim 8, characterized in that in front of the moisture-repellent cover layer (2) or the polyethylene foil, on the side facing away from the core layer (4), is a fiber mat (14) with fibers or wires (21) resistant to high temperatures, which shows over the surface distributed 468 162 19 openings (16) and each year is somewhat formed. Sound insulation element according to claim 9, characterized in that the fibers or wires (21) are formed of glass fibers and / or carbon fibers and / or metal fibers. Sound insulation element according to one of Claims 9 or 10, characterized in that a mat (15) of water-repellent fiber hem and / or of foam is arranged on the surface of the second cover layer (3) facing away from the fiber mat (14), for example a soft foam plastic with open cells, the thicknesses (22, 23) of the mats constituting a fraction of the thickness (24) of the core layer (4). Sound insulation element according to one of Claims 1 to 11, characterized in that individual areas of the core layer (4) are interconnected and / or the cover layers (2,3) are connected to the core layer (4) and / or to the mats arranged in front of them. (14,15) via an adhesive layer (11, 12, 13), especially with the cell structure of the core layer (4), and that the adhesive layers (11, 12, 13) are air-permeable, whereby preferably the mist layers (2, 3) are formed of adhesive layer. ' Sound-insulating element according to Claim 12, characterized in that the adhesive layers (11, 12, 13) are formed from polyethylene foils formed as melt foil. Sound insulation element according to one of Claims 1 to 13, characterized in that in the core layer (4) and / or in the region between the core layer (4) and the mats (14, 15) an elastically deformable support body (10) is arranged, which in the the direction of the layers (2, 3) is designed to be air and / or sound permeable. Sound insulation element according to claim 14, characterized in that the core layer (4) is in two parts, each consisting of a plate (5, 6), between which the elastically deformable stretcher body (10) is arranged, wound separately glued. Sound insulation element according to one of Claims 1 to 15, characterized in that the stretcher body (10) and / or the adhesive layers (11, 12, 13) and / or the cover layers (2,3) and / or the mats (14, 15) are designed to be permeable. for water vapor. Sound insulation element according to one of Claims 1 to 16, characterized in that the fiber mat (14) is associated with a sound source (20) and the mat (15) arranged on the opposite side is associated with a component (19) which is to be protected. wherein the sound insulation element (1) is arranged between the sound source (20) and a housing surrounding it, for example a bonnet (28), and is connected to it via the stretcher body (10). Sound insulation element according to one of Claims 1 to 17, characterized in that the thickness of the central area (7) is different from the thickness of the two edge areas (8,9) of the core layer (4), preferably three times as large as the edge areas (8,9). 468 162 20 Sound insulation element according to one of Claims 1 to 18, characterized in that the volume weight of the foam layer of the core layer (4) is different in the central region (7) and in the edge regions (8, 9), preferably the edge regions (8, 9) have a double volume as the central area (7). Sound insulation element according to claim 19, characterized in that the number of open cells (26) in the central area (7) and in the edge area (8,9) of the core layer (4) are different and in particular increase from the edge area (8, 9) towards the center - the council (7). Sound-insulating element according to one of Claims 1 to 20, characterized in that a cover layer (102) facing one edge area of the core layer (104, 119, 122) is formed of a fabric or foil-like, deformable material and the cover layer facing the other edge area. (103, 120) is formed of a fibrous fiber and / or a special sheet of unsaturated polyester resin soaked cardboard and is preferably formed deformable and / or curable under temperature and / or pressure. Sound-insulating element according to claim 21, characterized in that a binder layer is arranged between the cover layers (102, 103, 120) and the core layer (104, 119, 122), which is preferably formed by a polyethylene foil (113) formed as a melt foil, and that the core layer (104, 119, 122) and / or the binder layer and / or the support body (121) and / or one or both cover layers (102, 103, 120) are formed of air-permeable, particularly moisture-repellent. Sound insulation element according to one of Claims 1 to 22, characterized in that at least one of the cover layers (102, 103, 120) and / or at least one of the two edge regions (106, 107, 123) is provided with a moisture-repellent additive impregnation. Sound insulation element according to any one of claims 1-23, characterized in that the core layer (104, 119, 122) has distributed, different highly densified surface areas (108, 110; 115-118) over the surface, wherein preferably the core layer (104, 119, 122 ) weight attributed to the same surface unit and the corresponding thickness in the various strongly densified surface areas (108, 110; 115-118) are approximately equal in size. Process for the production of sound-insulating elements, in which a core layer consisting of plastics is forcibly connected to different cover layers, characterized in that a foam block of soft-composite foam is foamed and divided into plates, after which the mutually facing surfaces face each other. The plates, especially at the same time, are supplied with heat and, are applied with a compressive force directed in the direction of the middle layer and the edge areas of the plate are plastically deformed. * J H 468 162 21 Method according to claim 25, characterized in that during heat supply between facing surfaces of two plates, an adhesive layer or an adhesive foil and optionally a support body, in particular a wire grid or the like, is introduced. A method according to claim 25, characterized in that by heat action, cover layers are simultaneously applied to the facing surfaces of the core layer and are forcibly connected thereto, the cover layers being formed of mats, one of a fiber mat. Method according to one of Claims 25 to 27, characterized in that the core layer and the support body are deformed in the space under the influence of heat and force. Method according to one of Claims 25 or 28, characterized in that heat-sealable plastic foils are applied to the surfaces before the heating and densification of the plate edge areas and are connected by heat and force to the edge areas of the core layer. Method according to one of Claims 25 to 29, characterized in that the magnitude and time of the force influence, as well as the magnitude and time of the temperature influence, are variable depending on the desired damping ratio of the plate, and are particularly similar in both edge regions. Method according to one of Claims 25 to 30, characterized in that the fiber mat associated with one cover layer and the mat associated with the other cover layer are applied simultaneously and are forcibly connected to the surfaces of the cover layers facing each other. A method for producing sound-insulating elements, characterized in that at least a part of a core layer of constant thickness is introduced, preferably together with at least one cover layer interposed with an adhesive layer, in particular a polyethylene melt foil, in a mold and under the simultaneous influence of pressure and temperature in different surface areas are thickened to different thicknesses, the individual layers being simultaneously interconnected and / or hardened, after which, preferably at the same working pace, the sound insulation element is cut to the desired circumferential shape.