Sound insulation with multilayer fibre insulation; and method of manufacturing the same

Abstract

Disclosed is a floor covering insulation for a motor vehicle with a multi-layer, preferably flocked, fibre insulation which, by a soft/smooth coupling layer to the wear surface, realises a sound insulation floor covering with improved acoustic and mechanical-physical properties, with a simultaneous reduction in weight if possible. Also disclosed is a process for manufacturing the sound insulation.

Claims

1-13. (canceled)

14. A sound-insulating floor covering for a motor vehicle, which has an insulating device comprising fibres, wherein this insulating device extends along a longitudinal direction, a width direction and a thickness direction and wherein this insulation device preferably has different acoustic and/or mechanical-physical properties in at least one of these directions, wherein this floor covering has a material structure which preferably has at least one nonwoven element and at least one film element wherein the insulating device has a multilayer structure and at least one layer of this insulating device is apreferably flockedlayer with fibres, or a layer containing fibres, or a foam layer, and this insulating device is connected to a wear surface of the insulating device and/or arranged thereon by a coupling layer, wherein this coupling layer having a compression hardness which is in a range between 0.2 kPa and 5 kPa, preferably 0.5 kPa to 2 kPa.

15. The sound-insulating floor covering according to claim 14, wherein the floor covering has at least one layer or ply which is selected from a group of layers or plies which contains contact and/or foil fleeces, an acoustic and/or stiffening fleece, a heavy foil, in particular with a sealing foil, a coating, a binding layer and a carpet layer.

16. The sound insulating floor covering according to claim 14, wherein the insulation device contains binder and/or filler material.

17. The sound insulating floor covering according to claim 16, wherein the filler material is selected from a group of filler materials consisting of natural fibres, plastic fibres, lumpy filling material made of plastic, in particular based on foamed PP (EPP, PEPP), foamed PS (EPS), PUR chips or natural substances, in particular cork granulate or rayon.

18. The sound insulating floor covering according to claim 16, wherein the filler material, and in particular the rayon, comprises solid individual phases having a multi-leg cross-sectional shape with at least three legs, in which preferably the legs of the cross-sectional profile each have a length/width ratio of at least 2:1 and/or the individual titre is 0.5 to 5 dtex.

19. The sound insulating floor covering according to claim 14, wherein a wear layer of the floor covering with a multilayer insulation device, of which preferably at least one is flocked, and is configured to be positioned in a form-fitting manner in a motor vehicle.

20. The sound insulating floor covering according to claim 14, wherein the insulation device comprises thermoplastic binders in fibre form, which are formed in particular on the basis of PP, PET-BiCo, A-PET and/or PE.

21. A motor vehicle with a floor covering according to claim 14.

22. A method for producing a sound-insulating floor covering with a multilayer flocked insulation device, wherein first a first and then a second layer is flocked in a flocking device, wherein the sequence of the material quality being selected in such a way that the layer which later faces the wear surface has a predetermined compression hardness and in particular a compression hardness in the range from 0.2 kPa to 5 kPa, preferably 0.5 kPa to 2 kPa, and the other layer has a predetermined compression hardness and in particular a compression hardness in the range from 5 kPa to 30 kPa, preferably 10 kPa to 20 kPa.

23. The method according to claim 22, wherein by applying steam, a binder present in the insulation device is activated and preferably at least the two-layer insulation device solidifies in itself.

24. The method according to claim 22, wherein a wear layer with at least one dense underlayer is inserted with its rear side over the preformed layer of the insulation device, which contains a binder, into the steam/vacuum tool and the two-layer fibre insulation is bonded to the wear layer with at least one underlayer by the secondpreferably flockedfibre layer.

25. The method according to claim 22, wherein by applying steam, in particular from the underside of the two-layer insulation device, in the insulation devicewhich contains a binderthe binder is activated and the wear layer, which is preformed in a separate process step, is bonded to the two-layer fibre insulation.

26. The method according to claim 22, wherein the steam pressure is reduced by lower pressure on the upper side compared to the pressure on the lower side of the two-layer insulation device.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0077] Further advantages and embodiments can be seen in the attached figures. In the drawings:

[0078] FIG. 1 shows a roughly schematic representation of a composite according to the invention; and

[0079] FIG. 2 shows a diagram showing the acoustic behaviour of the insulation device.

DETAILED DESCRIPTION OF THE INVENTION

[0080] FIG. 1 shows a composite according to the invention or a sound-insulating floor covering 1 for a motor vehicle according to the invention. This floor covering 1 has an insulation device 2 and a material structure 4 connected to this insulation device. This material structure is the wear layer with its sub-layers.

[0081] The insulation device 2 has a coupling layer 24 and a flocked fibre layer 22. These two layers preferably each have consolidated binders.

[0082] The material structure 4 again has a plurality of sub-layers. The reference sign 28 refers to a heavy foil, and the reference sign 26 refers to a sealing foil. The heavy foil 28 and the sealing foil 26 are preferably formed together. The reference sign 32 identifies a stiffening and/or acoustic fleece. The reference sign 34 indicates a coating and the reference sign 36 indicates a binding, which serves in particular to bind the wear layer or the top layer. This layer 38 can preferably be formed as a tufted carpet and this advantageously has yarn (pile) 38a and a carrier 38b.

[0083] FIG. 2 shows a diagram illustrating the acoustic behaviour of the insulation device according to the invention or the floor covering according to the invention.

[0084] In order to prove the improvement of the in particular acoustic effectiveness by an at least two-layer flocked fibre insulation compared to the floor covering insulations made of PUR foam, which can be found in particular in the premium segment, different samples, in particular heavy foil plus viscoelastic PUR foam and heavy foil plus fibre flock insulation, were produced and measured.

[0085] FIG. 2 shows the result (insertion insulation according to ISO 15186-1 in the horizontal window test rig): The improved acoustic behaviour of the fibre flock (HMP) insulation can be clearly seen. Compared to the viscoelastic PUR foam, an additional weight reduction of approx. 32% has been achieved with the fibre flock (HMP) insulation of 50 g/l.

[0086] The applicant reserves the right to claim all features disclosed in the application documents as essential to the invention, provided they are individually or in combination new compared to the prior art. It is further pointed out that the individual figures also describe features which may be advantageous in themselves. The skilled person immediately recognises that a certain feature described in a figure can also be advantageous without adopting further features from this figure. Furthermore, the skilled person recognises that advantages can also result from a combination of several features shown in individual figures or in different figures.