A COMPOSITE UNDER VEHICLE PROTECTION

Abstract

Disclosed is a rigid and monolithic composite under-vehicle protector containing phenolic felt and a polyurethane material applied by spraying on the phenolic felt. A production method for the under vehicle protector is also disclosed.

Claims

1. A composite under-vehicle protection with phenolic felt content, characterized by comprising a polyurethane material which is applied by spraying on the said phenolic felt so as to form the said composite structure as rigid and integral.

2. The composite under-vehicle protection according to claim 1, wherein said polyurethane material is a filling material consisting of at least one of calcite, barite, and zeolite.

3. The composite under-vehicle protection according to claim 1, wherein the use ratio of phenolic felt in the said composite structure is between 60-90% and preferably 75%.

4. The composite under-vehicle protection according to claim 1, wherein the use ratio of polyurethane in the said composite structure is between 10-40% and preferably 25%.

5. The composite under-vehicle protection according to claim 1, wherein the use ratio of at least one of the mentioned calcite, barite, and zeolite is between 5-35% of the said polyurethane content and preferably 5%.

6. A production method of under-vehicle protection using phenolic felt which is cut in appropriate sizes and placed in shaping molds, characterized by comprising of the following steps: a) spraying polyurethane material without filling material or by adding calcite, barite, and zeolite filling materials to create a homogeneous distribution on the phenolic felt surface placed in forming molds, b) shaping/forming the sprayed polyurethane material and phenolic felt under temperature and pressure in press molds to provide a composite structure which is rigid and integral, c) removing the formed composite structure from the molds and resting it.

7. The production method of under-vehicle protection according to claim wherein the temperature of the press mold in the said step (b) is preferably between 60-200° C.

8. The production method of under-vehicle protection according to claim 6, wherein the pressure in the press mold in the said step (b) is preferably applied as 250-450 tons for 30 seconds to 5 minutes.

9. The production method of under-vehicle protection according to claim 6, wherein the resting process in the said step (c) is preferably performed for 3 to 12 hours.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0030] In this detailed description, the composite under-vehicle protection of the invention is explained only for a better understanding of the subject matter and without any restrictive effect.

[0031] The under vehicle protection of the invention is adapted to the vehicle so as to cover the vehicle underbody. Offering a lightweight composite structure, the under-vehicle protection provides sound and impact insulation, chemical resistance and fire resistance. The under-vehicle protection consists of felt and polyurethane material, which are combined to form a composite structure.

[0032] Felts are materials that can be produced for a wide variety of purposes and in a various ways according to the needs in many industries. It is especially used in various areas in providing sound and impact insulation. Phenolic and thermoplastic derived felts with binding material in them gain a more rigid structure and become more resistant to impact as a result of melting the binder inside them under temperature. Due to these features, phenolic felt has been preferred as the main component of under-vehicle protection structure. Thermoplastic felt or epoxy felt can also be used instead of phenolic felt in alternative embodiments of the invention. The use ratio of the phenolic felt in the composite structure, which forms the under-vehicle protection, is between 60-90% and preferably 75%.

[0033] Polyurethanes are one of the most important materials used in the automotive industry. It can be produced in various density, hardness, and shapes according to the needs. They are produced according to the purpose of use by making formulation changes and various additive-filler additions. Polyurethane is mainly used in the production of sound and impact absorbing parts in the automotive industry. Because of these features, MDI-type polyether-based polyurethane was preferred in the under-vehicle protection of the invention. The use ratio of the polyurethane in the composite structure, which forms the under-vehicle protection, is between 10-40% and preferably 25%.

[0034] In order to provide the necessary hardness and low porosity in polyurethane in the composite structure, the filling material can also be added in different proportions. Calcite, barite and zeolite are preferably used as the said filling material. The said filling materials can be added separately, in binary groups, or together in polyurethane. The total use ratio of calcite, barite, and zeolite is between 5-35% and preferably 5% of polyurethane content.

[0035] Obtaining the under-vehicle protection composite structure of the invention is carried out with the following process steps;

[0036] A. Cutting the felt in sizes appropriate for the area of use

[0037] B. Placement of the cut felt in the forming mold

[0038] C. Application of polyurethane on felt

[0039] It is sprayed on the felt without polyurethane filling material to be applied or by adding calcite, barite and zeolite filling materials. The spraying process is carried out with the spray polyurethane machine to ensure uniform distribution on the entire felt surface. The polyurethane material applied by spray method swells very little compared to other production methods. Polyurethane, which is sprayed on the felt by spray method, acts as resin on the surface and adheres to the felt. In addition, it infiltrates the pores of the felt, providing a more robust structure after curing.

[0040] D. Shaping/forming the felt that is sprayed with polyurethane

[0041] The polyurethane-sprayed felt is preferably placed in a press mold at a temperature of 60-200° C. and is preferably shaped (cured) under a pressure of 250-450 tons for a period of 30 sec to 5 min. The cured material is removed from the mold and preferably rested for 3 to 12 hours and get ready for assembly. During the forming phase, polyurethane material infiltrates into the felt. The density and pore structure of the felt used here, which will allow polyurethane to leak into the felt, is an important factor in selecting the phenolic felt. The composite structure becomes rigid with the activation of the binder in the phenolic felt under the effect of the temperature during the curing process and the polyurethane infiltrating into the felt. Therefore, the resulting under-vehicle protection has sound, impact and chemical insulation properties and is also a lightweight monolithic part.

[0042] The under-vehicle protection of the invention is shaped in one step and obtained with a very fast production process. The resulting under-vehicle protection comfortably meet the lightness feature, which is one of the most important elements needed in today's vehicles, with polyurethane and phenolic felt in its structure. At the same time, with the fire resistance of the polyurethane, a structure with high fire resistance is obtained. Thanks to this material, which is lightweight and has high fire resistance, the components located at the underbody of the vehicles are protected against various impacts, thus providing a safer drive. However, the sound isolation issue, which is one of the most important demands of vehicle manufacturers and which felt and polyurethane can provide at a very good level alone, is raised to a very high level by combining the two components.