Light Weight Engine Mounted Trim Part

Abstract

Engine mounted trim part for a vehicle engine comprising a fibrous carrier layer and at least one mounting system for mounting the trim part to a vehicle engine characterised in that the mounting system is built such that it can form a vibration-coupled connection upon mounting to the engine and the fibrous carrier layer is at least self-damping such that it can dampen the vibrational energy.

Claims

1. An engine mounted trim part for a vehicle engine comprising a fibrous carrier layer consisting of a consolidated fibrous material consisting of filler fibres and a binder, and further comprising at least one mounting system for mounting the trim part to a vehicle engine characterised in that the mounting system is vibration-coupled connected to the fibrous carrier layer by welding, establishing a vibration-coupling between the engine and the fibrous layer upon mounting to the engine and the fibrous carrier layer is at least self-damping such that it can dampen the vibrational energy.

2. The engine mounted trim part according to claim 1, whereby the area of connection is materially connected to the fibrous layer, and at least partly penetrating the fibrous material.

3. The engine mounted trim part according to claim 1, whereby the connection is a welded connection.

4. The engine mounted trim part according to claim 1, whereby the mounting system comprises at least a base area for materially connecting to the fibrous carrier layer and whereby the at least base area is made of a thermoplastic material.

5. The engine mounted trim part according to claim 1, whereby the mounting system comprises a snap-in connection, preferably with a female part and a male part.

6. The engine mounted trim part according to claim 1, whereby the mounting system is made of a rigid material, preferably a thermoplast or a metal or a combination of such materials.

7. The engine mounted trim part according to claim 1, wherein the binder of the consolidated fibrous material is a thermoplastic binder or a thermoset binder whereby the binder forms binding points between the fibers to consolidate the fibrous material.

8. The engine mounted trim part according claim 7, whereby the fibres are at least one of thermoplastic fibers, preferably polyester fibers, preferably polyethylene-terephthalate (PET) or polybutylene terephthalate (PBT), natural fibers, preferably cotton or flax fibers, or mineral fibers, preferably glass fibers, carbon, ceramic or basalt fibers or a mixture of such fibers.

9. The engine mounted part according to claim 8, whereby at least part of the thermoplastic fibers used are self-crimped fibers, preferably conjugate fibers, more preferably hollow conjugate fibers.

10. The engine mounted trim part according to claim 7, whereby the thermoplastic binder is either a copolymer of polyester, or polyamide or whereby the thermoset binder is a resinous type preferably phenolic resin.

11. The engine mounted trim part according to claim 1 further comprising an acoustic absorbing layer, preferably a fibrous layer or an open cell foam layer.

12. The engine mounted trim part according to claim 11, further comprising a film layer between the carrier layer and the absorbing layer which is permeable or becomes permeable during the moulding of the part, preferably a thermoplastic polyurethane film layer.

13. The engine mounted trim part according to claim 12, wherein the trim part has an overall air flow resistance of less than 4000 N.s.m.sup.3.

14. An engine for a vehicle comprising an engine mounted trim part comprising a fibrous carrier layer, consisting of a consolidated fibrous material consisting of filler fibres and a binder, and the trim part further comprising at least one mounting system for mounting the trim part to the engine, wherein the mounting system is welded to the fibrous layer and is vibration-coupling the fibrous carrier layer to the engine.

Description

DESCRIPTION OF DRAWINGS AND FURTHER EMBODIMENTS

[0083] FIG. 1 shows schematically the set-up of the engine cover mounted on the engine.

[0084] FIG. 2 shows preferred layouts for the material stacking according to the invention.

[0085] FIG. 1 shows a Engine mounted trim part for a vehicle engine 5 comprising a fibrous carrier layer 1 and at least one mounting system 4 for mounting the trim part to a vehicle engine whereby the mounting system is built such that it can form a vibration-coupled connection. The fibrous carrier layer is at least self-damping.

[0086] FIG. 1 further shows the connection area 6 of the base of mounting system 4 with the fibrous carrier layer 1. The connection area forming a material connection between the base material and the fibrous carrier layer.

[0087] FIG. 2A to D show preferred layouts for the material stacking according to the invention. The reference signs in these figures point to the same type of layer: [0088] 2 is a decorative surface layer; [0089] 1 is the carrier layer either in the form of a fibrous layer; [0090] 7 is an optional second film layer preferably also made of TPU; [0091] 8 is an optional absorbing layer. This layer can be either fibrous as shown in FIG. A or D, or a foam layer as shown in figure B or C. [0092] 3 is an optional scrim layer, for instance a nonwoven made of polyester material.

[0093] A layout in one preferred embodiment comprises of a surface material 2, for instance in the form of a textile fabric like a nonwoven, a knit or a woven fabric, a carrier layer 1 in the form of a fibrous layer made of 30 to 80% glass fibers and 20 to 50% of polyamide binder fibers are used.

[0094] Eventually the glass fibers can be replaced by up to 100% of cotton fibers and or polyester fibers as filling material. Preferably the polyester fibers used are Polyethylene terephtbalate (PET). They may be preferably self-crimped fibers.

[0095] All layers will be laminated to adjacent layers during the moulding process. The polyamide binder fibers will melt and form small droplets locally binding the glass fibers together, without impairing the airflow resistance of the fibrous material. Preferably the airflow resistance of the carrier layer after forming the part will be between 450 and 4000 Nsm.sup.3. The density of this layer can be between 100 and 800 kg/m.sup.3, preferably between 150 and 600 kg/m.sup.3.

[0096] Optionally an absorbing layer in the form of an open cell semi rigid polyurethane foam layer (8) (FIG. 8 or 9) or a second loftier fibrous layer (8) (FIG. 7 or 10) may be used. For the loftier fibrous layer the same fibrous material as for the carrier layer might be used; however with a lower density or a material comprising the same polyamide fibrous binder but having a polyester and or cotton as the main structural fibers. For the foam layer the area weight and or thickness of the slab stock material might be adapted.