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 method for manufacturing the sound insulation.

Claims

1-12. (canceled)

13. A method for producing a sound-insulating floor covering with a multilayer insulation device, wherein this insulation device extending along a longitudinal direction, a width direction and a thickness direction, and this insulation device having different acoustic and/or mechanical-physical properties in at least one of these directions, wherein this floor covering having a material structure which has at least one nonwoven element and at least one film element, wherein a fibre layer facing a motor vehicle floor in an installed state is flocked in a flocking device and at least this fibre layer is transported into a steam/vacuum tool and a binder present in the insulation device is activated by applying steam from an underside of the insulation device towards the wear layer, and furthermore the insulation device is cooled, cut and positioned in a motor vehicle.

14. The method according to claim 13, wherein a wear layer with sublayers underneath is formed in a separate process.

15. The method according to claim 13, wherein the floor covering comprises a coupling layer and this coupling layer is preformed by application of or suction by air.

16. The method according to claim 15, wherein the coupling layer is transported into the flocking device.

17. The method according to claim 16, wherein the coupling layer and the fibre layer are transported into the vacuum steam tool.

18. The method according to claim 14, wherein the deformed wear layer with the sublayers as well as the insulation device are trimmed in separate processes in each case and are joined to one another or are positioned as a floor covering system in a motor vehicle.

19. The method according to claim 18, wherein the deformed wear layer with the sublayers is bonded to the insulation device, subsequently cut and then positioned in a motor vehicle.

20. The method according to claim 14, wherein a wear layer with underlayers is heated in a separate heating device.

21. The method according to claim 13, wherein the fibre layer is deposited in the steam/vacuum tool and also the wear layer including the underlayers and the coupling layer is deposited in the steam/vacuum tool.

22. The method according to claim 13, wherein the wear layer with underlayers is heated in a separate heating station, the coupling layer is preformed, the preformed coupling layer is transported into the flocking device and the fibre layer located there is taken up, the two superimposed fibre layerswhich contain a binderare deposited in the steam-vacuum tool and by transferring the heated wear layer with underlayers is deposited over the fibre layer and coupling layer, by applying steam, from the underside of the fibre insulation which contains a binder, this binder is activated and the fibre layers are consolidated.

23. The method according to claim 22, wherein the wear layer with the sublayers, is bonded to the fibre insulation and the coupling layer, then the floor covering system is cooled in a calibration tool or a storage tray, then trimmed and the floor covering system is positioned in the motor vehicle.

24. The method according to claim 22, wherein by means of a flow tube a layer is deposited on a gripping device using a flow tube and this gripping device is transported with this layer into the flocking device and the fibre layer located there is picked up and the two superimposed layers are transported to the steam-vacuum tool.

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 with 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.