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CN110293916B - Sound insulation assembly for a motor vehicle and associated manufacturing method - Google Patents

Sound insulation assembly for a motor vehicle and associated manufacturing method Download PDF

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Publication number
CN110293916B
CN110293916B CN201910222298.3A CN201910222298A CN110293916B CN 110293916 B CN110293916 B CN 110293916B CN 201910222298 A CN201910222298 A CN 201910222298A CN 110293916 B CN110293916 B CN 110293916B
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CN
China
Prior art keywords
porous
upper region
component
dispersed
assembly
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CN201910222298.3A
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Chinese (zh)
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CN110293916A (en
Inventor
哈维尔·巴特利耶
弗朗西斯·吕利耶
黄明新
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Adler Pelzer France Grand Est SAS
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Faurecia Automotive Industrie SAS
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/144—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding
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    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Textile Engineering (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Soundproofing, Sound Blocking, And Sound Damping (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

The invention relates to a sound-insulating assembly for a motor vehicle and to a relative manufacturing method, the sound-insulating assembly comprising an absorbent structure (16) comprising an absorber (18). The absorber (18) comprises in its thickness: a porous upper region (22) comprising a particulate component (24) dispersed between fibers (20); a porous lower region (26) that does not contain the dispersed particulate component (24) or the concentration of the dispersed particulate component (24) is less than the concentration of the dispersed particulate component (24) of the porous upper region (22). The porous upper region (22) has a resistance to passage of air that is at least 100N.m greater than the resistance to passage of air of the porous lower region (26) ‑3 S, the impedance of the porous lower region (26) to the passage of air is greater than 15000N.m ‑4 .s。

Description

Sound insulation assembly for a motor vehicle and associated manufacturing method
Technical Field
The invention relates to a sound insulation assembly for a motor vehicle, comprising:
-a spring mass structure;
-an absorbing structure assembled on the spring mass structure.
Background
Such assemblies are intended to address acoustic problems that occur in substantially enclosed spaces, such as the cabin of motor vehicles (carpets, roofs, door panels, etc.), in the vicinity of noise sources such as engines (baffles, etc.), or the contact of tires with roads (wheel arches, etc.).
Typically, in the low frequency domain, sound waves generated by the noise sources described above are "damped" by acoustic attenuation of a material in the form of a single or double sheet (pre-stressed sandwich) with viscoelastic behavior, or a porous and elastic mass spring system.
Within the meaning of the present invention, the sound-insulating assembly ensures "sound insulation" mainly by reflected waves towards the noise source or outside the sound-insulating space when preventing medium-and high-frequency sound waves from entering the sound-insulating space.
The acoustic barrier assembly operates by "acoustic absorption" (in the mid and high frequency domains) when the energy of the sound waves is dissipated in the absorbing material.
The high-efficiency sound insulation system should at the same time function by ensuring good sound insulation and by absorption. To characterize the performance of such an assembly, the concept of the sound reduction index NR is used, which considers two concepts of sound insulation and absorption: the index can be calculated by the following equation:
NR(dB)＝TL-10log(S/A)，
TL is an acoustic weakening index (hereinafter referred to as weakening index) reflecting sound insulation. The higher the index, the better the sound insulation.
A is the equivalent absorption area. The higher a, the better the absorption. S is the area of the part. [ to be confirmed ]
In order to achieve good sound insulation, for example for a motor vehicle cabin, it is desirable to implement a material assembly that will function judiciously in both magnitudes. This is described in many papers, particularly in the article "Buddha Ji Yasheng light weight Concept (Faurecia Acoustic Light-weight Concept)" published in the le Mang SIA/CTTM 2002 conference.
In order to provide good acoustic insulation, it is known to use a mass spring assembly formed of a porous and resilient base layer on which an impermeable heavy layer is provided. Such impermeable heavy layers generally have a high surface quality, in particular greater than 1kg/m 2 And also has a weight of about 1500kg/m 3 To 2000kg/m 3 Is a high volume mass of (c).
Such an acoustic assembly provides good acoustic insulation but is relatively heavy. Moreover, it has poor performance in terms of absorption.
To reduce the mass of the acoustic barrier assembly, US 2006/013146 discloses a "double-permeable" acoustic assembly in which the heavy layer is replaced by a porous layer. A thin and acoustically transparent intermediate membrane is placed between the base spring layer and the porous layer.
Such an assembly effectively reduces the structure of the vehicle but proves particularly effective in terms of absorption but does not provide satisfactory sound insulation compared to conventional mass spring systems.
In order to improve the sound insulation while absorbing, for example, a four-layer assembly of the above-mentioned type is known from WO2013026847, which comprises a spring layer, a heavy layer, an absorption layer and a resistive nonwoven layer, which has a greater resistance to the passage of air than the absorption layer.
The first two layers form a spring mass structure which mainly ensures the sound insulation function. The upper two layers form an absorbent structure which allows to obtain sufficient absorption according to the principle of double osmosis described above.
A synergistic effect is established between the layers, in particular when the absorbing layer is rigid, so that both the sound-insulating and absorbing properties are optimized. The total mass of the assembly is significantly reduced without affecting the acoustic performance of the assembly.
However, such assemblies are relatively expensive to manufacture. Four layers should be provided and then assembled with each other, which requires a large number of manufacturing steps.
In addition, some of the layers used are relatively expensive. This is especially the case for a nonwoven fabric with a resistance, which is achieved by very fine fibers, depending on the fine process to be carried out. Also, obtaining a lightweight heavy portion requires the use of a large amount of polymer in terms of filler content to ensure sufficient rigidity. This increases the cost of the part.
Finally, the assembly between each layer requires a specific type of glue for each interface. For example, the assembly of an absorbent layer with a nonwoven layer requires that porosity be maintained at the interface between the layers. In contrast, the assembly between the base spring layer and the heavy layer should be very strong.
Finally, the parts obtained have a limited stiffness, which makes it sometimes difficult to operate on an assembly line.
Disclosure of Invention
The object of the present invention is to obtain a sound-insulating assembly which is very efficient both in terms of sound insulation and absorption, while being simple and inexpensive to manufacture and easy to operate.
To this end, the subject of the invention is an assembly of the above-mentioned type, characterized in that the absorbent structure comprises an absorbent body comprising a plurality of interwoven and/or bonded fibers, the absorbent body comprising in its thickness:
* A porous upper region comprising a particulate component dispersed between fibers;
* A porous lower region having no dispersed particulate component or a concentration of the dispersed particulate component thereof lower than a concentration of the dispersed particulate component of the porous upper region;
the porous upper region has a resistance to air passage that is at least 100n.m higher than the resistance to air passage of the porous lower region -3 S, the impedance of the porous lower region to air passage is greater than 15000N.m -4 .s。
An assembly according to the invention may comprise one or more of the following features, taken alone or in any technically possible combination:
-the spring mass structure comprises a matrix comprising a plurality of interwoven and/or bonded fibers, the matrix comprising in its thickness:
* Sealing the upper region comprising additional particulate component dispersed between the fibers and a fusion bonding component connecting the additional particulate component to the fibers;
* A porous elastic lower region having no dispersed additional particulate component or a concentration of the dispersed additional particulate component that is less than a concentration of the dispersed additional particulate component of the sealed upper region;
-the density of the additional particulate component present in the sealed upper region is greater than the density of the particulate component present in the porous upper region;
-the surface quality of the sealing upper region is greater than 100g/m 2 In particular between 100g/m 2 And 4000g/m 2 Between them;
-the adhesive component sealing the upper region is formed by a melted fusible powder or a melted fiber;
the thickness of the sealing upper region is smaller than the thickness of the porous elastic lower region;
the porous upper region has a resistance to the passage of air greater than 250N.m -3 S, especially between 250N.m -3 S and 1500N.m -3 S.
The thickness of the porous upper region is less than 15mm;
-the flexural rigidity of the porous lower zone is greater than 0.1n.m;
the absorber is formed in one piece and the matrix is formed in one piece.
The invention also relates to a method for manufacturing a sound insulation component of a motor vehicle, comprising the steps of:
* Forming an absorbent structure comprising:
-providing an absorbent body comprising a plurality of interwoven and/or bonded fibers;
-blending particulate components between the fibers of the porous upper region of the absorbent body;
-maintaining the porous lower region of the absorbent body free of dispersed particulate component or the concentration of dispersed particulate component of the porous lower region of the absorbent body lower than the concentration of dispersed particulate component of the porous upper region;
the porous upper region has a resistance to air passage that is at least 100n.m higher than the resistance to air passage of the porous lower region -3 S, the impedance of the porous lower region to air passage is greater than 15000N.m -4 .s；
* The absorber structure is assembled with the spring mass structure.
The method according to the invention may comprise one or more of the following features, taken alone or in any technically possible combination:
the method comprises the step of forming a spring mass structure comprising:
* Providing a matrix comprising a plurality of interwoven and/or bonded fibers;
* Blending the dispersed additional particulate component and binder component between the fibers in the upper region of the matrix;
* The concentration of the dispersed additional particulate component that maintains the porous elastic lower region free of dispersed additional particulate component or the porous elastic lower region is less than the concentration of the dispersed additional particulate component of the upper region;
* At least partially melting the bonding composition to form a sealed upper region;
the method comprises depositing an absorber provided with a particulate component on a substrate provided with an additional particulate component and a coupling component between a blending step and a melting step, the melting step comprising simultaneously heating the absorber provided with a particulate component and the substrate provided with an additional particulate component and a coupling component;
-the assembly step is carried out after simultaneously heating the absorber provided with the granular composition and the matrix provided with the additional granular composition and the coupling composition, the assembly step comprising jointly introducing the absorber provided with the granular composition and the matrix provided with the additional granular composition and the coupling composition into the cavity of the mould to thermoform the absorbent structure and the spring mass structure in the cavity of the mould;
the assembly comprises fixing the upper region of the matrix to the lower region of the absorbent body by penetrating at least part of the melted adhesive composition from the upper region of the matrix into the lower region of the absorbent body.
Drawings
The invention will be better understood by reading the following description, by way of example only, with reference to the accompanying drawings, in which:
fig. 1 is a schematic cross-section of a first acoustic baffle assembly according to the present invention;
figures 2 and 3 are views showing the steps of loading the matrix and the absorbent body with the granular component and the binding component, respectively;
figure 4 shows a subsequent step of depositing a matrix on the absorber;
figure 5 shows a subsequent step of thermoforming the matrix and the absorber simultaneously.
Detailed Description
In all the following, the orientation is generally the general orientation of the motor vehicle. However, the terms "upper", "lower", "upper" and "lower" extend in an opposite manner with respect to a reference surface of the motor vehicle, opposite which the sound-insulating member is arranged. Thus, the term "lower" is understood to be closest to the surface and the term "upper" is furthest from the surface.
A first acoustic baffle assembly 10 according to the present invention is shown in fig. 1. The assembly 10 is intended to be disposed facing a surface 12 of a motor vehicle.
The surface 12 is, for example, a sheet metal surface of a vehicle, which defines, in particular, a floor, a roof, a door, a baffle separating the cabin of the nacelle, a bonnet or a wheel arch of a motor vehicle.
The assembly 10 is intended to be applied directly to a surface 12. The assembly may be fixed to the surface 12, advantageously by pins (for example in the case of a baffle) or placed on the aforesaid surface (for example in the case of a carpet). In one variation, the assembly 10 is glued to the surface 12.
Referring to fig. 1, the assembly 10 includes a spring mass structure 14 for application to the surface 12 and an absorbent structure 16 applied to the mass spring 14 opposite the surface 12.
According to the present invention, the absorbent structure 16 includes a unitary absorbent body 18, the absorbent body 18 being formed from a plurality of interwoven and/or bonded fibers 20. The absorbent body 18 includes a resistive and porous upper region 22 that includes a particulate component 24 dispersed between the fibers 20; and a porous lower region 26 having no dispersed particulate component 24 or having a concentration of dispersed particulate component 24 that is less than the concentration of dispersed particulate component 24 in porous upper region 22.
Advantageously, the porous upper region 24 further includes a bonding component 28 for bonding the particulate component 24 to the fibers 20.
In this example, the absorber 18 is formed from felt or a single piece of fabric.
By "unitary" is meant that the absorbent body 18 is formed from a single layer of interwoven and/or bonded fibers, rather than a layer of layers bonded to one another.
"felt" in the sense of the present invention means a mixture of base fibers and binder. The base fibers may be precious and/or recycled fibers, natural or synthetic fibers having one or more properties. Examples of natural fibers that may be used are flax, cotton, bamboo, and the like. Examples of synthetic fibers that can be used are mineral fibers (e.g. glass fibers) or organic fibers (e.g. kevlar, polyamide, acrylic, polyester, polypropylene).
The binder is preferably formed from fusible fibres, in particular polyolefin fibres, in particular polypropylene fibres. As a modification, the adhesive is formed of a thermosetting resin, particularly a polyester resin.
In a variant, the felt comprises a high percentage of microfibres, for example more than 50% and advantageously 80% of microfibres.
"microfiber" means a fiber having a size of less than 0.9dtex, advantageously 0.7 dtex.
In a variant, the felt contains recycled material, such as waste originating from internal or external sources, in particular part waste of motor vehicle equipment or part waste at the end of the life of the vehicle. The waste is for example crushed and incorporated into the felt in the form of pieces of dispersed material consisting of fragments, flakes or granules. The waste components may be separated prior to or during comminution.
"fabric" refers to a mass of fibers substantially based on thermoplastic polymers, such as polypropylene, polyester or polyamide, which is assembled mechanically by needling without the use of a chemical binder. Such blocks may contain a percentage of thermoplastic recycled fibers or fibers of natural origin.
Referring to fig. 1, the absorber 18 has a lower surface 30 and an upper surface 32, the lower surface 30 being secured to the spring mass 14 and the upper surface 32 being for opposite orientation to the spring mass 14.
The absorbent structure 16 has a total thickness ET, taken perpendicular to the surface 12, between the lower surface 30 and the upper surface 32, greater than 2mm and in particular between 5mm and 25 mm.
The particulate component 24 is, for example, a filler in powder form. Examples of fillers are ground or cellulosic chalk, barite and/or vermiculite.
The granular component 24 has an average size calculated as a number average of less than 1mm and in particular between 5 μm and 500 μm. The average size is measured, for example, according to ISO 13320-1.
The density of the material constituting the granular component 18 is less than 5 and in particular between 0.8 and 2.
The adhesive component 28 is formed, for example, from a polymer powder, such as a polyolefin powder, in particular a polypropylene powder.
In the absorbent structure 16, the bonding component 28 at least partially melts to bond the fibers 20 to the particulate component 24 without melting the particulate component 24.
Thus, particulate component 24 is held in place relative to fibers 20 by bonding component 28.
As described above, the concentration of particulate component 24 in porous upper region 22 is at least 10% greater than the concentration of particulate component 24 in porous lower region 26.
The presence of particulate component 24 in porous upper region 22 closes the interstices that exist between fibers 20, which increases tortuosity and reduces the porosity of porous upper region 22 while maintaining non-zero porosity.
Thus, the porous upper region 22 has a resistance to air passage that is at least 100N.m greater than the resistance to air passage of the porous lower region 26 -3 S, in particular at least 250N.m greater than the resistance of the porous lower region 26 to the passage of air -3 .s。
In absolute terms, the porous upper region 22 has a resistance to the passage of air greater than 250n.m -3 S, and in particular between 250N.m -3 S and 1500N.m -3 Between s, in particular 300N.m -3 S and 1000N.m -3 S.
The resistance to the passage of air or its impedance is measured by the method described in Michel HENRY, paper, university of le, 3 d 10, 1997, "measurement of parameters characterizing porous media, experimental study of acoustic properties of low frequency foams (Mesures des param. Mu. Tres caract un milieu pore x. Etude exp rimentale du comportement acoustique des mousses aux basses fr e sequences)".
The thickness of the porous upper region 22 is generally less than the thickness of the region 18. The thickness ES of the porous upper region 22 is for example less than 15mm, in particular between 1mm and 10 mm.
In some cases, it may be locally sought to add weight and thus completely fill layer 16. Another advantage of the powder is that deposition can be performed locally more or less.
The porous upper region 22 has a surface mass of greater than 500g/m 2 And is between 500g/m 2 And 3500g/m 2 Between, advantageously between 1000g/m 2 And 2000g/m 2 Between them.
The porous lower region 26 has a shape suitable for exhibiting an advantageous range between 15000n.m for the passage of air -4 S and 80000N.m -4 Between s, in particular between 20000N.m -4 S and 50,000N.m -4 Porosity of the impedance ratio between s.
The volumetric surface mass of the porous lower region 26 is typically between 20kg/m 3 And 400kg/m 3 Between, in particular between 50kg/m 3 And 300kg/m 3 Between them.
The thickness EI of the porous lower region 20, taken perpendicular to the surface 12, is advantageously comprised between 2mm and 35mm, for example between 5mm and 25 mm.
The porous lower region 26 is rigidized. The porous lower region 26 advantageously has a bending stiffness B per unit width which is greater than 0.01n.m, in particular between 0.1n.m and 1n.m, in particular between 0.1n.m and 0.5 n.m.
The bending stiffness B is calculated from the following equation:
B＝E.h 3 and/12, where h is the thickness of the porous upper region 16 and E is its Young's modulus.
Young's modulus or modulus of elasticity is measured, for example, by the method described in the article of "polynomial for quasi-static mechanical characterization of anisotropic materials (Polynomial for quasistatic mechanical characterization of variousotropic materials)" published by C Langlois, R Panneton and N atlala, J.Acoust.SOC.Am.110,3032-3040 (2001).
Spring mass structure 14 includes a single piece matrix 34 formed from a plurality of interwoven and/or bonded fibers. Substrate 34 has a sealed upper region 36 that includes additional particulate component 38; and an elastic porous lower region 40 having no additional particulate component 38 dispersed therein or having a concentration of additional particulate component 38 less than the concentration of additional particulate component 38 dispersed in porous upper region 36.
The upper region 36 of the spring mass structure 14 also includes a melt adhesive composition 42 that adheres the additional particulate composition 38 to the fibers 35 and closes the interstices between the fibers 35 to achieve tightness in the upper region 36.
In this example, the substrate 34 is formed from a felt or single piece of fabric, as described above.
Referring to fig. 1, the chassis 34 has a lower surface 44 and a lower surface 46, the lower surface 44 being for orientation toward the surface 12, preferably for application to the surface 12, and the upper surface 46 being for orientation opposite the surface 12, the lower surface 30 of the absorbent structure 16 being secured to the upper surface 46.
Substrate 34 has a total thickness ET' taken perpendicular to surface 12. ET' is typically greater than the total thickness ET of the absorbent structure 16.
The additional particulate component 38 is, for example, a filler in powder form. The filler is for example barite, chalk or clay.
The additional particulate component 38 has an average size calculated as a number average value of less than 1mm and in particular between 5 μm and 500 μm.
The average size is measured, for example, according to the ISO 13320-1 standard.
The density of the material constituting the additional granular component 38 is greater than 2 and in particular is comprised between 3 and 5.
The density of the additional granular component 38 present in the sealed upper region 36 is greater than the density of the granular component 24 present in the porous upper region 22.
The concentration of the additional granular component 38 in the sealing upper region 36 is at least 10% greater than the concentration of the additional granular component 38 in the elastic lower region 40.
The adhesive component 42 is formed, for example, from a material powder, such as a polymer powder, such as a polyolefin powder, that can be melted at a temperature below 200 ℃.
In the spring mass structure 14, the meltable material powder at least partially melts to bond the fibers 35 to the additional particulate component 38 without melting the additional particulate component 38.
Thus, the additional particulate component 38 is held in place relative to the fibers 35 by the melted bonding component 42.
The molten bonding composition 42 also seals the interstices between the fibers 35 to achieve tightness.
Thus, the upper region 36 is sealed. The resistance to air passage of the sealed upper region 36 is too high to be measured by the method of measuring resistance to air passage described above.
The thickness ES' of the sealing upper region 36 is, for example, between 0.5mm and 5mm, and in particular between 1mm and 3 mm. .
The surface quality of the sealing upper region 36 is greater than 100g/m 2 And is between 100g/m 2 And 4000g/m 2 Between, advantageously between 800g/m 2 And 2000g/m 2 Between them.
The surface quality of the porous lower region 40 is typically 80g/m 2 And 8000g/m 2 Between, in particular between 200g/m 2 And 4000g/m 2 Between them.
The thickness EI' of the porous lower region 40, taken perpendicular to the surface 12, is advantageously comprised between 2mm and 100mm, for example between 5mm and 50 mm.
To exhibit spring characteristics, the porous lower region 40 advantageously has an elastic modulus greater than 5000 Pa. The modulus is advantageously between 20000Pa and 100000Pa, in particular between 30000Pa and 40000 Pa.
The modulus of elasticity is measured, for example, by the method described in the article "polynomial for quasi-static mechanical characterization of anisotropic materials (Polynomial for quasistatic mechanical characterization of various otropic materials)" published by C Langlois, R Panneton and N atlala, J.Acoust.SOC.Am.110,3032-3040 (2001).
The method of manufacturing the acoustic baffle assembly 10 according to the present invention is implemented in the apparatus schematically shown in fig. 2-5.
The apparatus includes a station 60, shown in fig. 2, for preparing the substrate 34 to deposit additional particulate component 38 to the substrate 34 and a station 62, shown in fig. 3, for preparing the absorber 18 to deposit particulate component 24 to the absorber 18.
The apparatus further includes a placement station 64 for placing the absorber 18 provided with the granular ingredients 24 on the base 34 provided with the additional granular ingredients 38, a cutting station 65, and a forming and assembling station 66 for the spring mass structure 14 and the absorber structure 16.
Referring to fig. 2, preparation station 60 includes a supply unit 72 for supplying substrate 34, a conveyor 74 for displacing substrate 34, at least one deposition unit 76 for depositing additional particulate component 38 and binder component 42 on substrate 34, and a blending unit 78 for blending additional particulate component 38 into substrate 34.
The preparation station 60 also advantageously includes a unit 80 for initially activating the adhesive composition 42.
The unit 72 for supplying the matrix 34 can form the matrix 34 from fiber blocks or provide a preformed matrix 34 in a bagged form.
The conveyor 74 is capable of advancing the bodies 14 from the supply unit 72 along the longitudinal axis A-A' such that the bodies face the deposition unit 76, the blending unit 78, the activation unit 80.
The deposition unit 76 includes a reservoir 84 of the additional granular ingredients 38 and at least one dispenser 86, the dispenser 86 being capable of depositing the additional granular ingredients 38 in successive layers on the upper surface 46 of the substrate 36. The dispenser 86 includes, for example, guides 90 for rollers 88 and opening onto the upper surface 46.
Blending unit 78 includes, for example, a source 92 for generating an electromagnetic field, and in particular, a source 92 that generates a variable electric field that is applied to additional particulate component 38, such that additional particulate component 38 penetrates into matrix 34 at a given thickness.
Advantageously, blending unit 78 also includes a vibration source (not shown) to facilitate blending additional particulate component 38 into matrix 34.
The blending unit 78 is formed, for example, byA forming machine.
The activation unit 80 here includes a heat source capable of heating the adhesive composition 42 above its melting temperature to melt the adhesive composition 42. The heat source comprises, for example, an infrared lamp.
Referring to fig. 3, preparation station 62 has a similar structure as preparation station 60. The preparation station 62 comprises a supply unit 102 for supplying the absorbent body 18, a conveyor 104 for displacing the absorbent body 18, at least one deposition unit 106 for depositing the granular component 24 and the adhesive component 28 on the absorbent body 18, and a blending unit 108 for blending the granular component 24 into the absorbent body 18.
The preparation station 62 also advantageously includes a unit 110 for initially activating the adhesive composition 42.
The supply unit 102 for supplying the absorber 18 can form the absorber 18 from a fiber mass or can supply the preformed absorber 18 in the form of a belt.
Similar to conveyor 74, conveyor 104 is capable of advancing the absorbent body 18 from the supply unit 102 along a longitudinal axis B-B' such that the absorbent body 18 passes facing the deposition unit 106, the blending unit 108, and the activation unit 110.
The deposition unit 106 has a similar structure to the deposition unit 76. The deposition unit 106 includes a reservoir 114 of granular ingredients 24 and at least one dispenser 116, the at least one dispenser 116 being capable of depositing the granular ingredients 24 in a continuous layer on the upper surface 32 of the absorbent body 18. The dispenser 116 includes, for example, a roller 118 and a guide 120 that opens onto the upper surface 32.
The blending unit 108 has a structure similar to that of the blending unit 78. Blending unit 108 includes, for example, a source 122 for generating an electromagnetic field, and in particular, a source 122 for generating a variable electric field that is applied to particulate component 24, such that particulate component 24 penetrates into matrix 34 at a given thickness.
Advantageously, blending unit 108 also includes a vibration source (not shown) to facilitate blending particulate component 24 into absorber 18.
Activation unit 110 herein includes a heat source capable of heating adhesive composition 28 above its melting temperature to at least partially melt adhesive composition 28. The heat source comprises, for example, an infrared lamp.
Positioning the stand 64 can allow the application of the lower surface 30 of the absorber 18 provided with the granular ingredients 24 to the upper surface 46 of the base 34 provided with the additional granular ingredients 38 to form the stack 130.
Advantageously, the stations 60 or 62 are placed in series with the production line for the felt or fabric of the present invention.
The cutting station 65 is capable of cutting the stack 130 to the size of the acoustic baffle assembly 10 to be formed.
The assembly station 66 includes at least one heating device (not shown) and a mold 132, the mold 132 defining a molding cavity 134 capable of effecting the shaping of the absorbent structure 16 and the spring mass structure 14 and their simultaneous assembly with each other.
The heating means advantageously comprise means capable of generating a flow of hot gas intended to be directed towards the absorber 18 and towards the matrix 34 so as to pass through the absorber 18 and the matrix 34.
The hot gas is, for example, air. The hot gas is advantageously heated to a temperature above 120 ℃, in particular between 120 ℃ and 200 ℃.
The hot gas is capable of heating the adhesive composition 28,42 of the cut laminate 130 to at least partially melt the adhesive composition and, in particular, to allow the molten material to penetrate from the upper region 36 of the substrate 34 into the lower region 26 of the absorbent body 18.
The mold 132 has at least one cooling surface 136 that is capable of allowing molten material present in the stack 130 to solidify.
The surface 136 of the mold 132 is cooled, for example, to a temperature below 15 ℃, in particular between 10 ℃ and 20 ℃.
A manufacturing method of manufacturing the soundproof assembly 10 according to the present invention will now be described.
First, substrate 34 is supplied by supply unit 72 either by being manufactured directly in supply unit 72 or by being unwound from inventory present in supply unit 72.
The substrate 34 in the form of a belt is placed on the conveyor 74 to continuously face the deposition unit 76, the blending unit 78, and the activation unit 80. As substrate 34 passes toward deposition unit 76, additional particulate component 38 is delivered from reservoir 84 and deposited on upper surface 46 of substrate 34 by dispenser 86 and rollers 88.
The amount of additional particulate component 38 added is controlled by dispenser 86 according to the speed of travel of body 34 on conveyor 74.
Then, in blending unit 78, a variable magnetic field is applied across matrix 34 to cause additional particulate component 38 to penetrate into upper region 36 of matrix 34, as described above. Binding component 42 is also introduced either simultaneously with additional particulate component 38 or separately from additional particulate component 38.
Then, the base 34 passes through the facing activation unit 80. The binder composition 42 is then at least partially melted to plug the interstices between the fibers 35 of the matrix 34 and the additional particulate composition 38. The additional particulate component 38 is then mechanically coupled to the fibers 35.
Furthermore, the absorbent body 18 is supplied by the supply unit 102 by being manufactured directly in the supply unit 102 or by being spread out from an inventory present in the supply unit 102.
The absorber 18 in the form of a belt is placed on the conveyor 104 to continuously face the deposition unit 106, the blending unit 108, and the activation unit 110.
As the absorber 18 passes facing the deposition unit 106, the particulate component 24 is delivered from the reservoir 114 and deposited on the upper surface 32 of the absorber 18 by the dispenser 116 and the roller 118.
The amount of particulate component 24 added is controlled by the dispenser 116 according to the speed of travel of the absorbent body 18 on the conveyor 104.
Then, in the blending unit 108, as described above, a variable electromagnetic field is applied through the absorber 18 to cause the granular component 24 to penetrate into the upper region 22 of the absorber 18. The binding component 28 is also introduced either simultaneously with the particulate component 24 or separately from the particulate component 24.
Then, the absorber 18 passes through the activation unit 110 facing. The bonding composition 28 is then at least partially melted to mechanically connect the particulate composition 24 to the fibers 20 while maintaining open interstices between the fibers 20 and the particulate composition 24.
Then, in the setting station 64, the lower surface 30 of the absorber 18 provided with the adhesive component 28 is set in contact with the upper surface 46 of the base 34 provided with the additional granular component 38.
The stack 130 thus formed is introduced into the cutting station 65 to be cut to the size of the acoustic baffle assembly 10.
Then, after additional heating in the heating device described above, the cut stacks 130 are introduced into the molding cavities 134 of the mold 132.
The mold 132 is closed, causing compression of the stack 130, and in particular the absorber 18 and the matrix 34.
Upon such compression, the adhesive composition 28 cures and maintains the thickness of the absorbent body 18 less than it occupied prior to being introduced into the mold 132. The absorber 18 is formed with an upper region 22 that remains porous, and a porous lower region 26, which porous lower region 26 has less resistance to the passage of air than the porous upper region, as described above.
Binding component 42 is distributed in the interstices between additional particulate component 38 and fibers 35 to block these interstices and to prevent air from passing through upper region 36 of matrix 34. On the other hand, at least a partially melted portion of the additional particulate component 38 penetrates the porous lower region 26 of the absorber 18 to adhere the porous lower region 26 of the absorber 18 to the sealed upper region 36 of the substrate 34.
Then, the mold 132 is opened again. Under the action of the elasticity, the porous lower region 40 of the matrix 34 increases its thickness with respect to the thickness it occupies in the mould 132.
Thereby forming a sound insulating assembly 10 comprising four regions 22,26,36,40 having different characteristics wherein the porous upper region 22 has a greater resistance to the passage of air than the porous lower region 26, and then the sealing upper region 36 and the porous lower region 40 have each of the aforementioned characteristics.
Since the assembly of the bodies 18,34 and the forming of the parts to good dimensions is achieved in a single step, the acoustic baffle assembly 10 is formed in a simple manner.
In addition, having the porous upper region 22 have a relatively high resistance to the passage of air is simple and does not require the provision and assembly of a non-woven resistant fabric. Thus, the cost of the assembly 10 is greatly reduced.
In addition, the sealing upper region 36 can be manufactured in an inexpensive manner with a suitable surface quality while having sufficient rigidity.
In a variant, to further increase the rigidity, a non-meltable fiber-based nonwoven, such as a glass fiber-based nonwoven, is added between the absorber 18 provided with the granular component 24 and the matrix 34 provided with the additional granular component 38.
A second manufacturing method of manufacturing the soundproof assembly 10 according to the present invention will now be described.
The absorbent body 18 made of felt or fabric from the station 62 is cut to the desired size and placed by contact in a heated station made up of two heated plates, the absorbent body 18 comprising in its upper region 22 a granular component 24 and a binding component.
At the same time, the substrate 34 formed of felt or fabric from station 60 is cut to the desired size and placed in contact in a second heated station, the substrate 34 having additional granular composition 38 in its upper region 36 and binder composition.
The plate is heated above the melting temperature of the adhesive composition, which causes the adhesive composition to melt. In practice, the upper plate is in contact with the respective upper regions 22 and 36 and transfers heat from the upper plate to the entire thickness of the upper regions 22 and 36.
This results in melting of the adhesive component.
The thus cut preforms are then transferred to a cold mold, the temperature of which is adjusted to below 30 ℃, in particular close to 15 ℃, and the preforms are placed on top of each other.
Closing the mold has the effect of forming the part 10.
Excess adhesive composition from the upper region 36 of the matrix 34 migrates through the lower region 26 of the absorber 18 and thus ensures bonding between the structures 14 and 16 after cooling, allowing the component 10 to be constructed.
Compression applied by the mold during thermoforming densifies the upper region 36, which has the effect of sealing the upper region 36.
Once the entire part 10 has cooled, the part 10 is removed from the mold.

Claims (16)

1. A sound insulation assembly (10) for a motor vehicle, comprising:
-a spring mass structure (14) comprising a base body (34);
-an absorbing structure (16) assembled on the spring mass structure (14);
characterized in that the absorbent structure (16) comprises an absorbent body (18) having a plurality of interwoven and/or bonded fibers (20), the absorbent body (18) comprising in its thickness:
* A porous upper region (22) comprising a particulate component (24) dispersed between the fibers (20);
* A porous lower region (26) having no dispersed particulate component (24) or a concentration of dispersed particulate component (24) that is less than a concentration of dispersed particulate component (24) of the porous upper region (22);
the porous upper region (22) has a resistance to passage of air that is at least 100N.m greater than the resistance to passage of air of the porous lower region (26) -3 S, the porous lower region (26) has an impedance to the passage of air greater than 15000N.m -4 .s，
The absorber (18) is formed as a single piece and the base (34) is formed as a single piece.
2. The assembly (10) of claim 1, wherein the matrix comprises a plurality of interwoven and/or bonded fibers (35), the matrix (34) comprising in its thickness:
-sealing an upper region (36) having additional particulate components (38) dispersed between the fibers (35) and a fusion bonding component (42) connecting the additional particulate components (38) to the fibers (35);
-a porous elastic lower region (40) having no dispersed additional particulate component (38) or a concentration of dispersed additional particulate component (38) lower than the concentration of dispersed additional particulate component (38) of the sealed upper region (36).
3. The assembly (10) of claim 2, wherein the additional granular component (38) present in the sealed upper region (36) has a density greater than the density of the granular component (24) present in the porous upper region (22).
4. An assembly (10) according to claim 2 or 3, wherein the surface quality of the sealing upper region (36) is greater than 100g/m 2 。
5. The assembly (10) of claim 4, wherein the surface quality of the sealing upper region (36) is between 100g/m 2 And 4000g/m 2 Between them.
6. An assembly (10) according to claim 2 or 3, wherein the adhesive component (42) of the sealing upper region (36) is formed from a melted fusible powder or from melted fibres.
7. An assembly (10) according to claim 2 or 3, wherein the thickness of the sealing upper region (36) is smaller than the thickness of the porous elastic lower region (40).
8. An assembly (10) according to any one of claims 1 to 3, wherein the porous upper region (22) has a resistance to passage of air greater than 250n.m -3 .s。
9. An assembly (10) according to any one of claims 1 to 3, wherein the porous upper region (22) has a resistance to the passage of air of 250n.m -3 S and 1500N.m -3 S.
10. An assembly (10) according to any one of claims 1 to 3, wherein the porous upper region (22) has a thickness of less than 15mm.
11. An assembly (10) according to any one of claims 1 to 3, wherein the bending stiffness of the porous lower region (26) is greater than 0.1n.m.
12. A method of manufacturing a sound insulation assembly (10) for a motor vehicle, comprising the steps of:
* Forming an absorbent structure (16), comprising:
providing an absorbent body (18) comprising a plurality of interwoven and/or bonded fibers (20),
-blending particulate components (24) between the fibers (20) of the porous upper region (22) of the absorber (18);
-maintaining the porous lower region (26) of the absorber (18) free of dispersed particulate component (24) or the concentration of dispersed particulate component (24) of the porous lower region (26) of the absorber (18) is less than the concentration of dispersed particulate component (24) of the porous upper region (22);
the porous upper region (22) has a resistance to passage of air that is at least 100N.m greater than the resistance to passage of air of the porous lower region (26) -3 S, the porous lower region (26) has an impedance to the passage of air greater than N.m -4 .s；
* The absorbent structure (16) is assembled with a spring mass structure (14).
13. The method of claim 12, comprising the step of forming the spring mass structure (14), comprising:
-providing a matrix (34) comprising a plurality of interwoven and/or bonded fibers (35);
blending dispersed additional particulate component (38) and binding component (42) between the fibers (35) of the upper region of the matrix (34),
-maintaining the porous elastic lower region (40) free of dispersed additional particulate component (38) or the concentration of dispersed additional particulate component (38) of the porous elastic lower region (40) is less than the concentration of dispersed additional particulate component (38) of the upper region;
-at least partially melting the adhesive composition (42) to form a sealed upper region (36).
14. The method of claim 13, comprising disposing the absorber (18) provided with the granular component (24) on the matrix (34) provided with the additional granular component (38) and binding component (42) between a blending step and a melting step, the melting step comprising simultaneously heating the absorber (18) provided with the granular component (24) and the matrix (34) provided with the additional granular component (38) and binding component (42).
15. The method according to claim 13, wherein the assembling step is performed after simultaneously heating the absorber (18) provided with the granular composition (24) and the matrix (34) provided with the additional granular composition (38) and the binding composition (42), the assembling step comprising jointly introducing the absorber (18) provided with the granular composition (24) and the matrix (34) provided with the additional granular composition (38) and the binding composition (42) into a cavity (134) of a mould (132) and thermoforming the absorbent structure (16) and the spring mass structure (14) in the cavity (134) of the mould (132).
16. The method according to any one of claims 13 to 15, wherein assembling comprises fixing the upper region (36) of the matrix (34) on the lower region (26) of the absorber (18) by penetrating an at least partially melted adhesive composition (42) from the upper region (36) of the matrix (34) into the lower region (26) of the absorber (18).
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FR1852463A FR3079181B1 (en) 2018-03-22 2018-03-22 MOTOR VEHICLE SOUNDPROOFING ASSEMBLY AND MANUFACTURING METHOD THEREOF

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FR3079181A1 (en) 2019-09-27
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