automotive sound-proofing and damping materials

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l l l l l l l l l l l l l l l l l l l l l l I l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l l

United S t a t e s

Patent

[ 1 9 ]

M a e d a e t

a l .

USOO5094318A

P a t e n t Number:

Date

o f P a t e n t :

[ 1 1 ]

[ 4 5 ]

5 , 0 9 4 , 3 1 8

M a r . 1 0 , 1 9 9 2

S H E E T

“IQ

b

4

[ 5 4 ] AUTOMOTIVE O U ND-PROOF [ 5 6 ] R e f e r e n c e s C i t e d

MATERIALS AND

DAMPING

MATERIALS

.

. NT DO UMENTS

THEREFOR U

FATE

4,101,704

7/1978 Hiles

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 296/39.3 X

4 , 4 5 6 , 7 0 5 6/1984 McCarthy . . 428/355

X

[75] Inventors: Takashi

Maeda;

Tsuyoshi Yamashita;

4,488,619 12/1984 O Neill .

.

.

.

.

.

.

.

.

.

.

. .

. . . 181/290

Mitsuo N a k a m u r a , a l l Of Wako; 4 , 5 7 4 , 9 1 5

3/1986

Gahlau e t

a ]

. . . . . . . . . 181/290

H i r o s h i Tokyo; Hideo F u j i i , 4 , 7 8 8 , 0 9 9

1 1 / 1 9 8 8

F u k u s h i m a ( i t

a l .

4 2 8 / 2 1 5

saitama’an fJapan 4 800 984 l/l989 Kerman

. . . . .

.

. . .

.

.

. .

.

.

. .

.. 181/290

9,734,323 3/1988

Sato

e t

a l .

. .

181/294 X

[ 7 3 ] A s s i g n e e s : Honda

G i k e n K o g y o

K . K . ; N i h o n FOREIGN PATENT

DOCUMENTS

Tokushu Two

3 0 - ,

L t d ”

b o t h o f

5 9 - 3 9 2 4 8

3 / 1 9 8 4 J a p a n

.

Japan 6 2 - 1 0 3 7 5 5

7 / 1 9 2 7 Japan

P r i m a r y

E x a m i n e r - B e n j a m i n R .

F u l l e r

[ 2 1 ]

A p p l .

N o . : 3 5 3 , 8 7 3

A s s i s t a n t

E x a m i n e r - A l r i c k

Bobb

A t t o r n e y ,

A g e n t , o r Firm-King & S c h i c k l i

[ 2 2 ]

F i l e d : May

1 8 ,

1 9 8 9

[ 5 7 ]

ABSTRACT

A o u n d - a b s o r p t i o n m a t e r i a l

f o r

a n a u t o m o b i l e

i n c l u d e s

[ 3 0 ] F o r e i g n

A p p l i c a t i o n P r i o r i t y

D a t a

a

damping

m a t e r i a l , a

s o u n d - a b s o r p t i o n

m a t e r i a l

a n d a

s u r f a c e

m a t e r i a l .

The

d a m p i n g , s o u n d - a b s o r p t i o n

a n d

? a y

[ 3 3 ; ]

j a p a n

s u r f a c e m a t e r i a l s a r e i n t e g r a t e d

t o g e t h e r . T h e

d a m p i n g

ay ’ [ 1 a pa n ' material includes a m o l d a b l e p l a s t i c constra ining mate

, r i a l a n d an adhesive damping s h e e t

c o n t a i n i n g

a

p e t r o

[ 5 1 ] I n t . C l . 5

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . E04B

1/82 leum

r e s i n . T h e sound-proof m a t e r i a l i s i n t e g r a l l y a t

[ 5 2 ]

US. l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.

181/290; 181/294; tachable to a n a utomotiv e

sheet materia l

such a s a dash

2 9 6 / 3 9 . 3 ; 4 2 8 / 3 5 5

b o a r d .

[ 5 8 ]

F i e l d

o f Search . . . . . . . . . . . . . . . 1 8 1 / 2 9 0 , 2 9 4 ; 296/393;

4 2 8 / 2 6 5 ,

3 5 5 3

C l a i m s ,

1

D r a w i n g

S h e e t

DAM P

N6 PM

3



US.

atent M a r . 1 0 ,

1 9 9 2

5,094,318

-FIG.I

4

; I . I I O I I I . I I I I . I ) L ‘ .

FIG.2

5 0

4O

P R E S E N T

E x .

20

l0“ \

S O U N DR O OF F E Td B )

I 0 0

2 6 0 5 5 0 1 6 0 0 2 6 0 0 5 6 0 0

F R E Q U E N C Y

( H z )



5 , 0 9 4 , 3 1 8

1

AUTOMOTIVE SOUND-PROOF MATERIALS

AND

DAMPING MATERIALS

THEREFOR

BACKGROUND

THE

INVENTION

1 . F i e l d o f t h e I n v e n t i o n

The p r e s e n t i n v e n t i o n r e l a t e s t o an automotive

sound

p r o o f m a t e r i a l

a n d a damping

m a t e r i a l t h e r e f o r e ,

a n d i s

c o n c e r n e d w i t h improvements i n o r

r e l a t i n g t o

t h e p e r

f o r m a n c e a n d w o r k i n g p r o p e r t i e s o f s u c h a s o u n d - p r o o f

m a t e r i a l

and a method f o r t h e

p r o d u c t i o n

t h e r e o f .

2 . S t a t e m e n t o f t h e P r i o r

Art

H e r e t o f o r e ,

a

s o u n d - p r o o f m a t e r i a l h a s b e e n a t t a c h e d

t o a n a u t o m o t i v e d a s h p o r t i o n f o r s o u n d - a b s o r p t i o n a n d

- i n s u l a t i o n p u r p o s e s t o p r e v e n t t h e e n t r a n c e o f n o i s e s

f ro m a n

engine compartment.

A

o u n d - p r o o f

m a t e r i a l o b t a i n e d

by

i n t e g r a t i n g

t o

g e t h e r

a

s o u n d - a b s o r p t i o n m a t e r i a l such a s f e l t and

a

s o u n d - i n s u l a t i n g s u rf a c e m a t er i a l o r by l a m i n a t i n g

a n

a d d i t i o n a l a s p h a l t s h e e t

on

t h e


mate

r i a l i s u s e d

a s a

s o u n d - p r o o f

m a t e r i a l f o r d a s h ,

and i s

a p p l i e d i n s u c h a manner

t h a t

t h e s o u n d - a b s o r p t i o n

m a t e r i a l

such

a s f e l t o r t h e a s p h a l t s h e e t

comes

i n

c o n t a c t

w i t h

a

d a s h p a n e l .

For

i n s t a n c e , J a p a n e s e U t i l

i t y

Model L a i d - O p e n P u b l i c a t i o n N o . 5 9 - 3 9 2 4 8

d i s

c l o s e s a s o u n d - p r o o f m a t e r i a l formed o f a

p l y w o o d - l i k e

t h r e e - l a y e r f o r m e d

s i l e n c e r c o m p r i s i n g

a

s o u n d - a b s o r p

. t i o n m a t e r i a l

interposed b e t w e e n a n d

laminated

onto

a

v i s c o u s foamed

m a t e r i a l

such a s

an a s p h a l t foam

mate

r i a l

and a s u r f a c e m a t e r i a l

such a s PVC

ith

t h e u s e of

a b o n d i n g a g e n t , s a i d

v i s c o u s f o a m e d

m a t e r i a l

b e i n g

c l o s e l y a t t a c h e d t o

a d a s h

p a n e l . J a p a n e s e U t i l i t y

Model

L a i d - O p e n

P u b l i c a t i o n N o . 6 2 - 1 0 3 7 5 5

d i s c l o s e s

a n o t h e r

s o u n d - p r o o f m a t e r i a l c o m p r i s i n g

a n

a s p h a l t foam m a t e

r i a l ,

a

s h e e t

formed

o f PVC,

t c . , a


m a t e r i a l

such

a s f e l t and

a

s h e e t formed

o f

PVC, e t c .

However, t i s now

d e s i r e d

t o a c h i e v e

f u r t h e r

r e d u c

t i o n s

o f

n o i s e s

g e n e r a t e d i n a c a r e n g i n e compartment

and

s o

t h e r e i s a n u r g e n t need

t o

p r o v i d e a sound-proof

m a t e r i a l

h a v i n g

a more improved s o u n d - p r o o f

e f f e c t

a t

4 0 °

t o

6 0 ° C . ,

e s p e c i a l l y

w h i l e a c a r i s r u n n i n g .

From

t h i s

p o i n t - o f - v i e w ,

a l t h o u g h

t h e s o u n d - p r o o f m a t e r i a l

o f

t h e

s t r u c t u r e

c o m p r i s i n g

t h e a s p h a l t s h e e t / s o u n d

a b

s o r p t i o n m a t e r i a l / s u r f a c e m a t e r i a l

i s

s u p e r i o r

t o

t h a t

o f

a

s t r u c t u r e i n c l u d i n g

no

a s p h a l t s h e e t ,

i t

s t i l l f a i l s t o

produce such a sound-proof

e f f e c t

a s

now

e s i r e d .

I n

o r d e r

t o

a t t a c h

s u c h

a


m a t e r i a l u s i n g

a n a s p h a l t s h e e t t o a

d a s h b o a r d , t h e

a s p h a l t

s h e e t i s

t h e r m a l l y f u s e d t o

t h e

d a s h b o a r d on t h e

c o a t i n g

and

b a k i n g

l i n e f o r a u t o m o t i v e b o d i e s

and

a n

i n t e g r a l

mem

b e r

of

a

sound-proof

m a t e r i a l

and

a s u r f a c e m a t e r i a l i s

a t t a c h e d t o t h e a s p h a l t

s h e e t . A

r o b l e m

w i t h

t h i s


m a t e r i a l

i s t h a t ‘ w h e n i t i s

i n t e n d e d

t o

a t

t a c h

t o

t h e d a s h b o a r d t h e a s p h a l t s h e e t

( o f

t h e i n t e g r a l

member

o f t h e a s p h a l t s h e e t / s o u n d - p r o o f m a t e r i a l / s u r

f a c e m a t e r i a l

p r e v i o u s l y

p r e p a r e d ) , t h e r e

i s no c h o i c e

b u t t o u s e two s t e p s ,

one s t e p

o f t h e r m a l l y

f u s i n g t h e

a s p h a l t s h e e t

t o t h e

d a s h b o a r d a n d t h e

o t h e r s t e p

o f

a t t a c h i n g

a n i n t e g r a l member o f t h e


m a t e r i a l / s u r f a c e m a t er i a l

t o

t h e a s p h a l t s h e e t , due

t o

t h e

t h e r m a l d e f o r m a t i o n o f

t h e


a n d

s o u n d - i n s u l a t i n g m a t e r i a l s o r o t h e r d i s a d v a n t a g e s .

SUMMARY OF THE INVENTION

A r s t

o b j e c t

o f

t h e

p r e s e n t

i n v e n t i o n

i s t o p r o v i d e a n

a u t o m o t i v e


m a t e r i a l

h a v i n g

a n

i m p r o v e d

2 5

45

6 0

6 5

2

sound-proof

e f f e c t even a t

a temperature a s high a s , e . g . ,

4 0 ° t o

6 0 °

C .

A

e c o n d

o b j e c t o f t h e p r e s e n t i n v e n t i o n i s t o a t t a c h

t h e

s o u n d - p r o o f m a t e r i a l t o

a n

a u t o m o t i v e d a s h p o r t i o n

a s

a n

i n t e g r a l m e m b e r

a t a s i n g l e

s t e p .

A h i r d o b j e c t o f t h e p r e s e n t i n v e n t i o n i s t o p r o v i d e a

damping

m a t e r i a l

f o r

t h e


m a t e r i a l s o

a s t o

a t t a i n t h e ? r s t

o b j e c t .

DETAILED DESCRIPTION

OF THE

INVENTION

The


m a t e r i a l

o f

t h e p r e s e n t i n v e n t i o n i s

d e s i g n e d

t o b e

a t t a c h e d t o ,

f o r i n s t a n c e , a d a s h b o a r d

o f

a c a r

which makes

a p a r t i t i o n between i t s engine com

p a r t m e n t

a n d

i t s

p a s s e n g e r c o m p a r t m e n t , a n d i s f o r m e d

o f a n i n t e g r a l arrangement o f a damping m a t e r i a l com

p r i s i n g a

damping s h e e t 1 a and

a c o n s t r a i n i n g m a t er i a l

1 b , a


m a t e r i a l

2

and a s u r f a c e m a t e ri a l

3 l a m i n a t e d t o g e t h e r

on

t h a t

o r d e r , a s

shown i n FIG.

1

by

way

o f e x a m p l e .

I t

i s

n o t e d

t h a t

r e f e r e n c e

n u m e r a l 4

denotes

a

dashboard.

.

A s t h e

above

s u r f a c e

m a t e r i a l ,

u s e

m a y

be m a d e of a

s o u n d - i n s u l a t i n g s h e e t i n g

m a t e r i a l

h e r e t o f o r e u s e d .

Used t o t h i s e n d a r e , f o r i n s t a n c e , s h e e t i n g m a t e r i a l s

o b t a i n e d by

kneading

t o g e t h e r a t l e a s t one

o r

two

o r

more

o f a

b i t u m i n o u s

m a t e r i a l such a s

s t r ai g h t a s p h a l t ,

blown a s p h a l t o r

a

m i x t u r e t h e ' r e o f ,

a

r u b b e r y

m a t e r i a l

s u c h a s s t y re n e - b u t a d i e n e b a s e s y n t h e t i c r u b b e r , b u t y l

b a s e

r u b b e r

and n a t u r a l

r u b b e r

and a s y n t h e t i c r e s i n

m a t e r i a l w i t h

s u i t a b l e ? l l e r s

s u c h a s c a l c i u m

c a r b o n a t e ,

t a l c ,

c l a y , b a r i u m s u l f a t e a n d m i c a a n d

f o r m i n g

t h e

kneaded product

i n t o a

s h e e t

with

r o l l s o r

e x t r u d e r s .

As t h e


m a t e r i a l , u s e m ay

be

m a d e

o f

foamed m a t e r i a l s o f s y n t h e t i c

r e s i n s

s u c h

a s

u r e t h a n e o r

v i n y l

c h l o r i d e

o r

f e l t s ,

b u l k y

nonwoven

f a b r i c s

o r

t h e

l i k e , which

comprise

one

or two o r m o r e

of

animal and

v e g e t a b l e ? b e r s , s y n t h e t i c r e s i n

? b e r s

a n d m i n e r a l f i

bers. '

As t h e c o n s t r a i n i n g

m a t e r i a l

o f t h e c l a m p i n g m a t e r i a l ,

u s e i s p r e f e r a b l y

m a d e

o f

f o r m a b l e

o r o t h e r w i s e

mold

a b l e p l a s t i c s , f o r i n s t a n c e , p o l y o l e ? n s s u c h a s

p o l y e t h y l

e n e a n d

p o l y p r o p y l e n e ,

v i n y l c h l o r i d e r e s i n s a n d s o o n .

I n o r d e r t o improve

an

damping e f f e c t a t 4 0 ° t o 6 0 °

C . ,

t h e damping s h e e t c o n t a i n s

a

p e t r o l e u m

r e s i n

s u c h a s

o n e

h a v i n g

a m e l t i n g p o i n t o f

6 0 ° t o 1 8 0 °

C .

The

damp

i n g s h e e t may

a l s o

c o n t a i n a d d i t i o n a l c o m p o n e n t s

s u c h

a s a component c o m p r i s i n g p o l y b u t a d i e n e , a n i s o c y a

n a t e and

a

c a t a l y s t ,

a s p h a l t ,

r u b b e r and

? l l e r s .

These

components

a r e

r o l l e d i n t o s h e e t s .

I n

o r d e r

t o

p r e p a r e

t h e d a m p i n g

s h e e t ,

t h e

a s p h a l t c o m p o n e n t h e a t e d a n d

m e l t e d

b y

h e a t i n g t o , e . g . , a b o u t 1 8 0 ° C . may b e

m i x e d

w i t h t h e ? l l e r , e t c . i n a h e a t e d

k n e a d e r , e x t r u d e d

and

t h e n r o l l e d t o a t h i c k n e s s of about s e v e r a l m i l l i m e t e r s .

R e f e r r i n g t o

t h e

a b o v e c o n s t i t u t i o n a l m a t e r i a l s ,

t h e

damping

s h e e t

1 0 and

c o n s t r a i n i n g m a t e r i a l 1 b a r e

b o n d e d t o g e t h e r

i n t o

t h e d a m p i n g m a t e r i a l

1

b y t h e

a d h e s i o n

o f

t h e

d a m p i n g

s h e e t , t h e s o u n d - a b s o r p t i o n

m a t e r i a l 2 and s u r f a c e m a t e r i a l 3 a r e i n t e g r a l l y molded

by

a f o r m i n g

m o l d ,

a n d t h e c o n s t r a i n i n g m a t er i a l

1 b

a n d


m a t e r i a l

2 a r e

i n t e g r a l l y

bonded t o

g e t h e r by means o f a b o n d i n g a g e n t .

The s o u n d - p r o o f m a t e r i a l

o f

t h e p r e s e n t i n v e n t i o n

m ay

a l s o

b e

p r e p a r e d

by

a

method

u s i n g

a n

i n j e c t i o n

m o l d .

More

s p e c i ? c a l l y , t h e

a b o v e

s u r f a c e m a t e r i a l

i s ? r s t

p l a c e d o n t o a bottom h a l f o f a n i n j e c t i o n m o l d , and t h e

a b o v e damping m a t e r i a l

f o r m e d i n t o

a

p r e d e t e r m i n e d

s h a p e

i s t h e n

s u c k e d

and

?xed t o

t h e

i n n e r f a c e o f

a t o p



5 , 0 9 4 , 3 1 8

3

h a l f o f t h e i n j e c t i o n mold u n d e r r e d u c e d p r e s s u r e ( o r

vacuum). The

t o p

and

bottom

h a l v e s a r e a s s e m b l e d

t o g e t h e r , a n d

a

l i q u i d

p o l y u r e t h a n e

foam m a t e r i a l i s

p o u r e d i n b e t w e e n t h e

s u r f a c e

d a m p i n g

m a t e r i a l s

f o r

f o a m i n g

i n c o n v e n t i o n a l m a n n e r s . T h u s , t h e

u r e t h a n e

foam

m a t e r i a l

i s

bonded

a s

t h e


mate

r i a l t o

t h e

s u r f a c e and

damping

m a t e r i a l s ,

s o

t h a t

t h e y

a r e i n t e g r a t e d t o g e t h e r .

The p o l y i s o c y a n a t e c o m p o n e n t s u s e d may i n c l u d e

t o l y l e n e d i i s o c y a n a t e

( T D I ) ,

4 , 4 - d i p h e n y l m e t h a n e d i

i s o c y a n a t e ( M D I ) , x y l e n e

d i i s o c y a n a t e

( X D I ) , 1 , 5

n a p h t h y l e n e

d i i s o c y a n a t e ( N D I ) , h e x a m e t h y l e n e d i i s o

c y a n a t e

( I - I D I ) ,

h y d r o g e n a t e d MDI, i s o p h o r o n e

d i i s o

c y a n a t e ( I P D I ) , l y s i n e i s o c y a n a t e ( L D I ) , i s o p r o p y l

i d e n e b i s ( 4 - c y c l o h e x y l i s o c y a n a t e ) ( I P C I ) a n d o t h e r

known socyanates.

The

p o l y o l s u s e d may i n c l u d e p o l y e t h e r

p o l y o l s ,

p o l y e s t e r

p o l y o l s , p o l y m e r p o l y o l s , p o l y c a r b o n a t e

d i o l s

and

t h e

l i k e .

As

t h e

c a t a l y s t s , u s e

m ay

b e m a d e

o f o r g a n i c m e t a l

compounds

s u c h a s o r g a n i c t i n

compounds a n d

o r g a n i c

l e a d

compounds a n d a m i n e

b a s e

compounds s u c h

a s

t r i e t h y l e n e d i a m i n e , which

a r e

p r e f e r a b l y

u s e d

i n combi

n a t i o n o r

a l o n e .

P a r t i c u l a r

p r e f e r e n c e

i s g i v e n t o

t h e

u s e

o f a n o r g a n i c

t i n

compound c o m p r i s i n g a t i n s a l t o f a

c a r b o x y l i c a c i d o r a n

o r g a n i c

t i n s a l t and a t e r t i a r y

a m i n e c o m p o u n d .

As t h e foaming a g e n t s , u s e m ay be m a d e o f , e . g . ,

~ t r i e h l o r o f l u o r o m e t h a n e , d i c h l o r o l l u o r o m e t h a n e , m e t h

y l e n e

c h l o r i d e

o r o t h e r h a l o g e n a t e d h y d r o c a r b o n s o r

w a t e r . With t h e

foaming a g e n t ,

a

foam

c o n t r o l l e r

s u c h

a s an o r g a n i c s i l a n e compound m ay

be

u s e d .

O t h e r a d d i t i v e s s u c h

a s

c r o s s - l i n k i n g

a g e n t s , e . g . ,

d i e t h a n o l a m i n e a n d t r i e t h a n o l a m i n e , f i r e - r e t a r d i n g

a g e n t s , c o l o r i n g a g e n t s a n d s t a b i l i z e r s

may b e

u s e d .

The s o u n d - p r o o f m a t e r i a l p r e p a r e d a s m e n t i o n e d

above may

e

a t t a c h e d t o , e . g . , a . d a s h b o a r d

due

t o t h e

a d h e s i o n

o f

t h e d a m p i n g s h e e t b y

p r e s s i n g

t h e

d a m p i n g

s h e e t a g a i n s t

t h e d a s h b o a r d

b y , e . g . ,

m a n u a l o p e r a t i o n

o n

t h e

a s s e m b l y l i n e

o f

a u t o m o t i v e p r o d u c t i o n l i n e s .

Such o p e r a t i o n m a y be c a r r i e d o u t a t

normal

o r ambient

t e m p e r a t u r e .

With t h e s o u n d - p r o o f m a t e r i a l a t t a c h e d

t o t h e

d a s h

board of

a car

i n t h i s manner, i t can produce an

i m

p r o v e d s o u n d - p r o o f e f f e c t u p o n

n o i s e s

g e n e r a t e d

f r o m

t h e

e n g i n e

c o m p a r t m e n t

t h r o u g h i t s

d a m p i n g , s o u n d

a b s o r p t i o n

a n d

s o u n d - i n s u l a t i o n

a c t i o n s ,

t h e r e b y

a c h i e v i n g a n i m p r o v e d s o u n d - p r o o f

e f f e c t

upon

n o i s e s

g e n e r a t e d

even t 4 0 °

t o

6 0 °

C .

w h i l e t h e c a r

i s r u n n i n g .

BRIEF

DESCRIPTION OF

THE DRAWINGS

FIG. 1

i s

a s e c t i o n a l view

o f

t h e s o u n d - p r o o f m a t e r i a l

o f

t h e p r e s e n t

i n v e n t i o n , a n d

FIG.

2 i s

a g r a p h i c a l vie w showing

t h e

r e s u l t s

o f e s t s

p e r f o r m e d i n t e r m s o f t h e

s o u n d - p r o o f e f f e c t

o f t h a t

m a t e r i a l .

ACTION

AND

EFFECT

OF

THE

INVENTION

A c c o r d i n g

t o t h e

p r e s e n t

i n v e n t i o n , s i n c e t h e

damp

i n g m a t e r i a l

i s

f o r m e d

o f

t h e

damping

s h e e t

a n d t h e

c o n s t r a i n i n g

m a t e r i a l

a n d

t h e

p e t r o l e u m r e s i n

i s

con

t a i n e d

i n t h e , damping

s h e e t

t o

i m p r o v e a

damping

e f f e c t

a t

4 0 ° 0 t o 6 0 ° C . , t h e s o u n d - p r o o f

m a t e r i a l

c a n be

a t t a c h e d

t o

t h e d a s h

p o r t i o n o f

a n a u t o m o b i l e by bond

i n g t h e

damping

s h e e t w i t h

i t s

a d h e s i o n t o t h e

d a s h ~

b o a r d a t

n o r m a l

t e m p e r a t u r e , whereby t h e c o n v e n t i o n a l

two s t e p s o f a t t a c h i n g a n

a s p h a l t s h e e t a n d

t h e n a n o t h e r

5

2 5

3 0

3 5

40

4 5

4

m e m b e r i n

p l a c e

can

be

reduced

t o

one

s t e p

t o improve

t h e e f f i c i e n c y o f p r o d u c t i o n .

The


l a y e r

i s

p r o v i d e d t o

i m p r o v e t h e

d a m p i n g

e f f e c t

o f

t h e d a m p i n g

s h e e t , t h e r eb y a c h i e v i n g

f u r t h e r

i m p r o v e m e n t s

i n

t h e s o u n d - p r o o f

e f f e c t .

EXAMPLES

The

p r e s e n t i n v e n t i o n

w i l l

now

b e e x p l a i n e d s p e c i ?

c a l l y b u t n o t e x c l u s i v e l y

w i t h r e f e r e n c e

t o FIGS. 1 a n d

2.

E x a m p l e l — S o u n d - P r o o f M a t e r i a l a n d

Damping

M a t e r i a l

Kneaded t o g e t h e r a r e 1 0 p a r t s b y

w e i g h t

o f a s p h a l t

( s t r a i g h t

a s p h a l n b l o w n a s p h a l t

= 5 5 z 4 5 ) ,

1 0 p a r t s b y

w e i g h t o f b u t y l b a s e r u b b e r , 5 p a r t s b y w e i g h t o f EVA

( a n

e t h y l e n e / v i n y l a c e t a t e c o p o l y m e r ) , 6 5 p a r t s

b y

w e i g h t o f c a l c i u m c a r b o n a t e a n d 1 0 p a r t s b y w e i g h t o f

process

o i l

t o

prepare

a surface m a t e r i a l

3 of

2 . 5

mm

n

_

t h i c k n e s s .

A f t e r t h e s u r f a c e m a t e ri a l

3 i s p l a c e d

on a bottom

h a l f

o f a n i n j e c t i o n

m o l d ,

a

l i q u i d

u r e t h a n e foam m a t e r i a l

c o m p r i s i n g

1 0 0

p a r t s b y

w e i g h t o f

p o l y e t h e r p o l y o l ,

2

p a r t s

b y w e i g h t o f a n a m i n e b a s e

c r o s s - l i n k i n g a g e n t ,

1

p a r t b y

w e i g h t

o f a n a m i n e b a s e c a t a l y s t ,

2

p a r t s

by

w e i g h t o f a foam c o n t r o l l e r , 2

p a r t s b y

w e i g h t o f a

f o a m i n g a g e n t

a n d

3 0 p a r t s b y w e i g h t o f c r u d e

i s o c y a

n a t e s MDI/T I ( 2 0 : 8 0 )

was

p o u r e d a n d foamed i n t h e

i n j e c t i o n

mold

t o i n t e g r a t e a n


mate

r i a l

2 o f

20

mm

n

t h i c k n e s s

with

t h e s u r f a c e m a t e r i a l

3 .

A

a m p i n g

m a t e r i a l 1 i s p r e p a r e d b y i n t e g r a t i n g a n

l-mm t h i c k c o n s t r a i n i n g m a t e r i a l

1 b

f o r m e d

o f

a

v i n y l .

c h l o r i d e s h e e t

w i t h

a damping s h e e t 1 0 o b t a i n e d by

k n e a d i n g t o g e t h e r

4 5

p a r t s b y

w e i g h t o f

b l o w n

a s p h a l t ,

3 5

p a r t s

b y w e i g h t o f p e t ro l e u m r e s i n ( w i t h a m e l t i n g

p o i n t o f 1 2 0 °

C . ) , 2 0

p a r t s b y

w e i g h t o f

p o l y b u t a d i e n e

a n d

2 p a r t s

b y

w e i g h t

o f MDI

h r o u g h

t h e a d h e s i o n o f

t h e d a m p i n g

s h e e t .

The


m a t e r i a l 1 b o f t he a b o v e d a m p i n g

m a t e r i a l and t h e s o u n d - a b s o r p t i o n m a t e r i a l 2 a r e

p u t

upon

e a c h

o t h e r

t h r o u g h a n a d h e s i v e

l a y e r

a n d bonded

t o g e t h e r u n d e r p r e s s u r e t o p r e p a r e a s o u n d - p r o o f mate

r i a l . This sound-proof

m a t e r i a l

was

bonded a s

a t e s t

sample t o a

0.8-mm

t h i c k

s t e e l

s h e e t e q u i v a l e n t t o

an

‘ automotive dashboard t o measure

i t s

sound-proof

c f

5 0

6 0

6 5

f e e t .

The

r e s u l t s

a r e

shown

by

a

s o l i d

l i n e i n

FIG.

2 .

The sound-proof e f f e c t t e s t s were c a r r i e d

out

with

a

t e s t i n g u n i t

d e s i g n e d t o s t r i k e a b o u t 2 0 0

m e t a l l i c

b a l l s

a g a i n s t

a

s t e e l

p l a t e o f 0 . 8 mm n t h i c k n e s s , t h e r e b y

making n o i s e s

s i m i l a r

t o

t h o s e

g e n e r a t e d

when a n

a c t u a l

a u t o m o b i l e i s

r u n n i n g . The n o i s e

l e v e l ( T 1 0 ) o f

t h e s t e e l

p l a t e was ? r s t

measured

a t 1 0 0 t o 5 , 0 0 0 H z , and t h e

n o i s e l e v e l ( T L 1 )

o f

t h e s t e e l p l a t e , t o WhlCh t h e s o u n d

p r o o f m a t e r i a l s a c c o r d i n g t o t h e e x a m p l e a n d c o m p a r i

son ex ample we r e attached

i n

the s a m e m a n n e r a s men

t i o n e d

a b o v e ,

was t h e n s i m i l a r l y m e a s u r e d .

P e r e a c h

f r e q u e n c y r e g i o n , t h e


e f f e c t

e x p r e s s e d

i n

t e r m s o f

ATL=TL<>~TL1 was c a l c u l a t e d f o r

p l o t t i n g .

Such measurement was c a r r i e d

out a t

a

temperature of

4 0 ° C .

A

amping e f f e c t t e s t was

a l s o

c a r r i e d o u t w i t h t h e

damping m a t e r i a l 1 ,

w h i l e

i t s w e i g h t was m e a s u r e d .

The

r e s u l t s a r e t a b u l a t e d i n a t a b l e t o be g i v e n l a t e r .

The d a m p i n g

e f f e c t

a n d w e i g h t o f t h e d a m p i n g m a t e

’ r i a l 1 were measured a s f o l l o w s .



5 , 0 9 4 , 3 1 8

5

Damping E f f e c t

T e s t

A c c o r d i n g t o t h e p r o c e d u r e s d e s c r i b e d i n

“ N o i s e

C o n t r o l

H a n d b o o k ” ,

p u b l i s h e d

o n

D e c . 2 5 ,

1 9 6 6

b y

t h e

J a p a n A c o u s t i c

M a t e r i a l A s s o c i a t i o n ,

p a g e 4 3 8 ,

t h e

resonance frequen cy

and

h a l f value

width

were

m e a

s u r e d

by

t h e

resonance method

and

t h e

l o s s

f a c t o r

1 ] was

c a l c u l a t e d a l o n g t h e p r o c e d u r e s d e s c r i b e d i n t h e a b o v e

l i t e r a t u r e .

I t

i s

n o t e d t h a t t h e

h i g h e r

t h e l o s s f a c t o r 1 ) ,

t h e h i g h e r t h e d a m p i n g e f f e c t , a n d

t h a t

t h e

l o w e r l i m i t

o f ; j u d g e d p r a c t i c a l l y e f f e c t i v e

f o r

d a m p i n g i s 0 . 0 5 .

R e f e r r i n g b r i e ? y

t o

t h e t e s t i n g m e t h o d a l o n g t h e

t e s t i n g p r o c e d u r e s

d e s c r i b e d

i n t h e a b o v e l i t e r a t u r e , t h e

damping m a t e r i a l

a s

o b t a i n e d a b o v e

was

p r e s s e d

a g a i n s t

or thermally

f u s e d

t o

a 0.8><20><200 mm t e e l

s h e e t

a t

l 5 0 ° C . f o r

30

m i n u t e s ,

and

i t s p o r t i o n

f o r c e d

o u t

t h e r e o f

was

c u t o u t

by

a k n i f e , e t c .

T e n

t e s t

p i e c e s were

p r e p a r e d a n d m e a s u r e d

a t 4 0 °

C . w i t h

t h e

r e s u l t i n g

m e a s u r e m e n t s

b e i n g e x p r e s s e d i n

t e r m s o f t h e

a v e r a g e .

W e i g h t Me a s u r e m e n t

T e n

200><200><2

mm

amping m a t e r i a l s were p r e

p a r e d

t o measure t h e i r s u r f a c e d e n s i t i e s (Kg/m2)

on a

p l a t f o r m s c a l e , which were t h e n a v e r a g e d

o u t .

C o m p a r i s o n E x a m p l e 1 — S o u n d - P r o o f M a t e r i a l

A .5-mm

t h i c k

a s p h a l t

s h e e t

formed

o f

a b i t u m i n o u s

m a t e r i a l was

bonded

t o

a 0.8-mm t h i c k s t e e l s h e e t

equiv

a l e n t t o

a n

a u t o m o t i v e

d a s h b o a r d

by h e a t i n g

t h r o u g h

t h e a d h e s i o n o f

a s p h a l t .

A f t e r w a r d s , a

member

f o r m e d

i n t e g r a l l y o f a 2.5-mm t h i c k s u r f a c e m a t e r i a l 3

and

a

2 0 - m i n

t h i c k s o u n d - a b s o r p t i o n m a t e r i a l

2

i n

a s i m i l a r

m a n n e r a s i n Ex. 1 was placed

on

t h e a s p h a l t

s h e e t

t o

p r e p a r e a s a m p l e i n c l u d i n g a s o u n d - p r o o f

m a t e r i a l

o f

the asphalt sheet - sound-proof material 2 - surface ma

t e r i a l 3

on

t h e

above s t e e l s h e e t .

The

s o u n d - p r o o f e f f e c t s o f t h e s o u n d - p r o o f

m a t e r i a l s

a c c o r d i n g

t o t h e a b o v e e x a m p l e a n d

c o m p a r i s o n ex am

p l e were m e a s u r e d . The r e s u l t s a r e p l o t t e d by s o l i d a n d

d o t t e d l i n e s .

C o m p a r i s o n E x a m p l e 2—Damping M a t e r i a l

F i f t y ( 5 0 ) p a r t s

b y

w e i g h t o f

a s p h a l t

( s t r a i g h t a s

p h a l t z b l o w n

a s p h a l t = 5 5 : 4 5 ) , 2

p a r t s

b y

w e i g h t

o f

s t y

r e n e - b u t a d i e n e r u b b e r ,

2 0

p a r t s b y

w e i g h t o f

c a l c i u m

c a r b o n a t e ,

2 0

p a r t s

b y

t a l c

a n d

1 8

p a r t s

b y

w e i g h t

o f

a s b e s t o s

were

kneaded

t o g e t h e r a t 1 2 0 ° C . i n a h e a t e d

k n e a d e r , e x t r u d e d

and r o l l e d

i n t o

a

damping

m a t e r i a l

having

a t h i c k n e s s of

2 . 0 mm.

That

damping m a t e r i a l was

t e s t e d

i n a

s i m i l a r

m a n n e r

a s d e s c r i b e d i n c o n n e c t i o n w i t h

t h e

damping m a t e r i a l o f

Ex. 1 . The

r e s u l t s , a r e s e t

o u t j u s t b e l o w .

e d 0

20

2 5

30

45

50

5 5

6 5

6

E x a m p l e C o m p a r i s o n E x a m p l e

L o s s F a c t o r

1 )

0 . 2 7

0 . 0 8

W e i g h t

2 . 5

K g / m z 3 . 0 K g / m z

From t h e r e s u l t s o f t h e

a b o v e e x a m p l e a n d c o m p a r i

s o n e x a m p l e

shown

n FIG.

,

i t i s

f o u n d t h a t

t h e s o u n d

p r o o f

m a t e r i a l a c c o r d i n g t o

t h e p r e s e n t

e x a m p l e

s s u p e

r i o r t o t h a t a c c o r d i n g t o

t h e

c o m p a r i s o n

e x a m p l e .

From

t h e

t a b l e g i v e n

j u s t a b o v e ,

i t

i s

a p p r e c i a t e d t h a t t h e

damping

m a t e r i a l

a c c o r d i n g

t o t h e p r e s e n t

i n v e n t i o n

d e c r e a s e s i n w e i g h t , a l t h o u g h i t s d a m p i n g e f f e c t i s i m

p r o v e d .

What s claimed

i s :

.

1 .

An a u t o m o t i v e s o u n d - p r o o f

m a t e r i a l c o m p r i s i n g a

damping m a t e r i a l ,

a s o u n d - a b s o r p t i o n

m a t e r i a l and

a

s u r f a c e m a t e r i a l , w h e r e i n :

s a i d d a m p i n g ,

s o u n d

a b s o r p t i o n

a n d

s u r f a c e m a t e r i a l s

a r e i n t e g r a t e d t o g e t h e r ;

s a i d d a m p i n g m a t e r i a l

i n c l u d i n g

a p l a s t i c


m a t e r i a l ,

moldable

a t ambient

t e m p e r a t u r e ,

s e

l e c t e d f r o m

a g r o u p

c o n s i s t i n g

o f p o l y o l e f m s

a n d

v i n y l c h l o r i d e r e s i n s a n d a n a d h e s i v e damping

s h e e t a l s o moldable a t a m b i e n t

t e m p e r a t u r e

and

formed from m a t e r i a l s s e l e c t e d from

a

group con

s i s t i n g

o f a s p h a l t ,

p e t r o l e u m r e s i n , p o l y b u t a d i e n e ,

i s o c y a n a t e , r u b b e r , f i l l e r

a n d

m i x t u r e s

t h e r e o f

e f

f e c t i v e

i n f o r m i n g

s a i d

d a m p i n g s h e e t ;

s a i d sound

a b s o r p t i o n m a t e r i a l

s e l e c t e d from

a group

c o n s i s t i n g

o f

f o a m e d s y n t h e t i c r e s i n s ,

f e l t s ,

n o n

woven

f a b r i c s , s y n t h e t i c r e s i n ? b e r s a n d

m i n e r a l

? b e r s ;

s a i d

s u r f a c e

m a t e r i a l ,

m o l d a b l e

a t

a m b i e n t

t e m p e r a

t u r e , being

formed i n t o

a

s h e e t

from

a t

l e a s t

one

or

more m a t e r i a l s s e l e c t e d from a group c o n s i s t i n g

o f

s t r a i g h t a s p h a l t , blown a s p h a l t , a

m i x t u r e

o f

s t r a i g h t a n d blown

a s p h a l t ,

a

r u b b e r y

m a t e r i a l s e

l e c t e d f r o m a g r o u p c o n s i s t i n g

o f

s t y r e n e - b u t a d i e n e

b a s e

s y n t h e t i c

r u b b e r , b u t y l b a s e

r u b b e r ,

n a t u r a l

r u b b e r and any

m i x t u r e s

t h e r e o f , and

a

s y n t h e t i c

r e s i n m a t e r i a l with s u i t a b l e ? l l e r s s e l e c t e d

from a

g r o u p c o n s i s t i n g o f c a l c i u m c a r b o n a t e , t a l c , c l a y ,

b a r i u m

s u l f a t e ,

m i c a a n d m i x t u r e s

t h e r e o f ;

w h e r e b y

s a i d s o u n d - p r o o f

m a t e r i a l

i s i n t e g r a l l y a t

t a c h a b l e

t o an

automotive s h e e t m a t e ri a l a t ambient

temperature.

.

2 .

An u t o m o t i v e s o u n d - p r o o f

m a t e r i a l

a s

c l a i m e d

i n

c l a i m 1 ,

w h e r e i n

s a i d p e t r o l e u m r e s i n

h a s

a m e l t i n g

p o i n t o f 6 0 ° C . t o

1 8 0 °

C .

3 .

An

u t o m o t i v e s o u n d - p r o o f m a t e r i a l a s c l a i m e d i n

c l a i m 2 ,

wherein

s a i d a u t o m o t i v e s h e e t m a t e r i a l i s a

d a s h b o a r d .

t i

i i t

automotive sound-proofing and damping materials

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