EP1922716B1 - Panneau d'isolation acoustique - Google Patents

Panneau d'isolation acoustique Download PDF

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Publication number
EP1922716B1
EP1922716B1 EP06764288.4A EP06764288A EP1922716B1 EP 1922716 B1 EP1922716 B1 EP 1922716B1 EP 06764288 A EP06764288 A EP 06764288A EP 1922716 B1 EP1922716 B1 EP 1922716B1
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EP
European Patent Office
Prior art keywords
layer
panel
thickness
range
areas
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP06764288.4A
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German (de)
English (en)
Other versions
EP1922716A2 (fr
Inventor
Paolo Scudieri
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Adler Plastic SpA
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Adler Plastic SpA
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Publication date
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Priority to PL06764288T priority Critical patent/PL1922716T3/pl
Publication of EP1922716A2 publication Critical patent/EP1922716A2/fr
Application granted granted Critical
Publication of EP1922716B1 publication Critical patent/EP1922716B1/fr
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Classifications

    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
    • G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/162—Selection of materials
    • G10K11/168—Plural layers of different materials, e.g. sandwiches

Definitions

  • the present invention relates to an insulation panel, specifically a sound-proofing and sound-insulating insulation panel, which is adaptable and capable of perfectly coupling to the surfaces to be mechanically dampened and acoustically insulated.
  • such insulation panels have several disadvantages, as excessive weight, e.g. for the panels using lead foils, size, high cost, poor mechanical resistance, as e.g. for bituminous panels, the performance of which deteriorates as much with aging as because of exposure to low temperatures and/or temperature variations and which may easily dry and crack under the influence of vibrations and may also detach from their support. Even the most modern insulations obtained combining EPDM-based rubber layers as "mass" or panel base and polymer foams exhibit several disadvantages.
  • the EPDM film may directly be produced in the mould by injection of liquid EPDM and subsequent cross-linking.
  • the present invention intends to achieve the above discussed objects by obtaining a sound-insulating panel defining a distinctive extension plane and a distinctive thickness, wherein the plane has a greater extension as compared to thickness, which, according to claim 1, comprises a first layer in the direction of thickness made of a first non-expanded compact material and a second layer made of a second expanded material, wherein said first layer comprises one or more first areas having physical and/or size characteristics such that a higher sound absorption is obtained than by one or more second areas of the same first layer.
  • the panel of the present invention exhibits a lower weight and size as compared to any panel of the known art having the same predetermined sound performances, by means of the differentiation in different areas of the first layer, or "mass" or base, of size characteristics, as thickness and surface extension, and/or of physical characteristics, as the density of the material.
  • the panel of the invention has far better sound-proofing and sound-insulating characteristics.
  • the differentiation of the "mass" of the panel is obtained by a simple spraying operation of the material forming the first layer, preferably polyurethane, on the surface of one of the two parts of the mould.
  • a spraying operation is programmed depending on predetermined physical and/or size characteristics of the different areas of the first layer of the panel.
  • the insulation panel object of the present invention, comprises a first layer 1 made of a compact polyurethane resin or any other equivalent material carrying a uniformly dispersed neutrally charged material, coupled to a second layer 2 made of an expanded viscoelastic polyurethane resin or any other equivalent material, the latter also carrying a uniformly dispersed neutrally charged material.
  • Said second layer 2 of the insulation panel is preferably made of an expanded viscoelastic polyurethane resin prepared in a known way by reacting together (i) at least one compound selected from ethylene oxides and at least one compound selected from propylene oxides, named compound A, and (ii) one isocyanic compound, named compound B, an inert micronized compound, named compound C, being uniformly dispersed in said poly-urethane resin and being selected from glass fibres, artificial and natural textile fibres, silica, silicates, carbonates and the like, neat or mixed together.
  • ethylene oxides and propylene oxides have molecular weight in the range from 300 to 8000, preferably from 350 to 6500, with a hydroxyl number in the range from 20 to 1000, preferably from 20 to 800, and functionality in the range from 3 to 8.
  • Such compounds are used mixed together, according to what is known.
  • the isocyanic compound is selected from the group comprising toluene diisocyanate, polymethylene-polyphenyl-isocyanates, diphenylisocyanates, having molecular weight in the range from 300 to 7500, preferably from 350 to 6000.
  • the micronized material exhibits size in the range from 10 to 500 ⁇ m, preferably from 50 to 200 ⁇ m; in any case, possible particle size distribution is in the range from 10 to 50 ⁇ m, preferably from 10 to 30 ⁇ m.
  • compound A is in a weight percentage in the range from 30 to 75%
  • compound B is in a weight percentage in the range from 20 to 65%
  • compound C is in a weight percentage in the range from 5 to 50%.
  • Such second layer has a thickness in the range from 2 to 500 mm, preferably from 5 to 400 mm and a specific weight in the range from 30 to 200 Kg/m 3 , preferably from 30 to 150 Kg/m 3 .
  • the material forming first layer 1 is a compact polyurethane resin instead, also prepared in a known way by reacting the same above-described compounds A, B, and C together.
  • ethylene oxides and propylene oxides have molecular weight in the range from 300 to 8000, preferably from 350 to 6500, with a hydroxyl number in the range from 20 to 1000, preferably from 25 to 700, and functionality in the range from 3 to 8.
  • Such compounds are used neat (only ethylene oxides or only propylene oxides) or mixed together, according to what is known.
  • the isocyanic compound B has a molecular weight in the range from 350 and 7000, preferably from 400 to 6000.
  • the micronized material has size in the range from 10 to 500 ⁇ m, preferably from 50 to 300 ⁇ m; in any case, possible particle size distribution is in the range from 10 to 50 ⁇ m and from 10 to 30 ⁇ m.
  • compound A is in a weight percentage in the range from 30 to 75%
  • compound B in a percentage in the range from 30 to 55%
  • compound C in a percentage from 10 to 60 %.
  • This first layer has a thickness in the range from 2 to 50 mm, and a basic weight in the range from 1 to 10 Kg/m 2 .
  • said first layer 1 has an uneven thickness with first areas 3 having greater thickness as compared to that of second areas 4, in which said greater thickness defines higher sound absorption characteristics.
  • the position, the thickness and the surface extension of first areas 3 is determined depending on the sound intensity peaks detected on the surface to coat with the panel, previously to the production of the panel.
  • Second layer 2 comprises in turn distinctive first 4' and second 3' areas having thickness and/or surface extension complementary to those of corresponding second and first areas 4, 3 of first layer 1 of the panel, at the joining surface of the first and second layers.
  • second layer 2 adhering to the first layer, has a constant thickness for the whole of its surface extension, as shown in Figure 2 .
  • second layer 2 comprises distinctive first and second areas 4', 3' having thickness such that the total thickness of the panel is constant for the whole of its surface extension.
  • a further advantageous embodiment of the panel of the invention provides instead that the higher sound absorption characteristics of first areas 3 as compared to second areas 4 of the first layer are defined by a different density of the material sprayed in these areas.
  • first and second areas 3, 4 of first layer 1 of the panel may or may not have the same thickness.
  • the last advantageous embodiment of the panel provides that the different sound absorption characteristics of the different areas of the first layer are defined by the combination of the different density of the material sprayed in these areas and of the different size characteristics, i.e. thickness and surface extension.
  • the panel comprising said first and second layers, has an overall thickness in the range from 4 to 550 mm, preferably from 5 to 400 mm, and a specific weight in the range from 40 to 250 Kg/m 3 .
  • the first and second layers of the panel, object of the present invention are directly coupled in the mould by means of a manufacturing process comprising the following steps:
  • spraying is carried out in an open mould, preferably with an opening of about 90°, by means of an anthropomorphic robot controlling the displacement of the spray gun.
  • a displacement and spraying is programmed depending on the intensity of the sound waves hitting the surface to be insulated. Therefore, the thickness and surface extension of the areas of first layer 1 of the panel may e.g. be differentiated by stopping the spray gun longer on the areas of the mould which correspond to the surface parts for which the sound intensity peaks are predicted to be higher, more or less wide, visible from a predetermined intensimetric mapping.
  • the even thickness of the first layer is determined with reference to the highest intensity peak, resulting in an enormous waste of material and an increase of weight of the whole panel, generally having a basic weight of about 6 kg/m 2 .
  • a second step follows, in which expanded polyurethane is injected in the mould, which is then closed.
  • the expanded polyurethane resin further expands until it "grips" or adheres to said first layer, thus producing the second layer.
  • the mould is opened and the end product is extracted.
  • such a process for the manufacturing of the panels of the invention provides one step less as compared to the previously adopted processes and also provides the use of a simpler and less expensive technology.
  • a preferred composition of the end panel comprises a layer of expanded viscoelastic polyurethane resin having density in the range from 30 to 150 Kg/m 3 , preferably 40-100 Kg/m 3 , containing the prescribed quantities of micronized material, in a weight percentage in the range from 10 to 50%, preferably from 15 to 45 %, and a layer of compact polyurethane resin having basic weight in the range from 1 to 10 Kg/m 2 , preferably from 2 to 8 Kg/m 2 , containing the prescribed amounts of micronized material in a weight percentage in the range from 10 to 50%, preferably from 20 to 50%.
  • said panel has both sides provided with imprints having generally curved, preferably circular, oval or elliptic profile, and having maximum transverse size in the range from 5 to 15 mm, preferably from 7 to 13 mm, depth in the range from 1 to 10 mm, preferably from 2 to 6 mm, and distance between centres in the range from 1,10 to 1,80 times said maximum transverse size.
  • the sides of the panel may take the most various shapes so as to conform to different surface configurations in order to acoustically isolate e.g. parts of a car body or engine compartments.
  • the sides of the panel of the invention may therefore also have uneven surfaces and surfaces complementary to complex shape surfaces to be isolated.
  • Panels comprising a second layer made of an expanded polyurethane material obtained by reacting a mixture comprised of 40% of a material named SPECFLEX NS 747 (manufactured by DOW CHEMICAL), 50% SPECFLEX Ns 540, 10% carbonate, having density equivalent to 50 Kg/m 3 , coupled to a first layer made of compact polyurethane material obtained by reacting a mixture comprised of 40% SPECFLEX Ns 768 (manufactured by DOW CHEMICAL), 20% SPECFLEX Ns 540, 40% carbonate, having basic weight equivalent to 5 Kg/m 2 , and thickness of respectively 20, 30, 45 mm, have been subjected to transmission loss sound-proofing experiments according to ASTM E1050-90 and ASTM C384-95.
  • Panels comprising a second layer made of an expanded polyurethane material obtained by reacting a mixture comprised of 40% of a material named SPECFLEX Ns 747 (manufactured by DOW CHEMICAL), 50% SPECFLEX Ns 540, 10% carbonate having density of 50 Kg/m 3 , coupled to a first layer made of a compact polyurethane material obtained by reacting a mixture comprised of 40% SPECFLEX Ns 768, 20% SPECFLEX Ns 540, 40% Carbonate, having basic weight equivalent to 3 Kg/m 2 , and thickness of respectively 20, 30, 45 mm, have been subjected to transmission loss sound-proofing experiments according to ASTM E1050-90 and ASTM C384-95.
  • differential mass panels according to the present invention exhibit higher sound-proofing performance as compared to those obtained with known panels.
  • the difference experimentally found is considerable and is equivalent to about 2 ⁇ 4 dB at the different frequencies.
  • the insulation panel of the invention Compared with an equal weight and size of other similar products, the insulation panel of the invention thus diminishes noise considerably better or, performance being equal, the panel exhibits a lighter weight.

Landscapes

  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Acoustics & Sound (AREA)
  • Multimedia (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Building Environments (AREA)
  • Laminated Bodies (AREA)

Claims (11)

  1. Panneau d'isolation phonique définissant un plan d'extension respectif et une épaisseur respective, dans lequel le plan a une extension supérieure à l'épaisseur, comprenant une première couche (1) dans le sens de l'épaisseur, constituée d'un premier matériau compact non expansé et une seconde couche (2) constituée d'un second matériau expansé, compris dans la classe des polyuréthanes transportant un matériau à charge neutre et uniformément dispersé, caractérisé en ce que ladite première couche est une résine de polyuréthane compacte comprenant une ou plusieurs premières zones (3) ayant une densité et/ou des caractéristiques de taille telles que l'absorption phonique obtenue est supérieure à celle obtenue par une ou plusieurs secondes zones (4) de la première couche, dans lequel la première couche (1) a une épaisseur dans la plage de 2 à 50 mm et un poids basique dans la plage de 1 à 10 kg/m2, contient des oxydes d'éthylène et des oxydes de propylène ayant un poids moléculaire dans la plage de 300 à 8000, un indice hydroxyle dans la plage de 20 à 1000, le matériau à charge neutre est micronisé et a une taille dans la plage de 10 à 500 µm.
  2. Panneau selon la revendication 1, dans lequel ladite seconde couche (2) comprend des première et seconde zones distinctives (4', 3') ayant une épaisseur et/ou une extension de surface complémentaire à celles des seconde et première zones correspondantes (4, 3) de la première couche du panneau, à la surface de jonction de la première et la seconde couche.
  3. Panneau selon la revendication 2, dans lequel ladite seconde couche (2) a une épaisseur uniforme pour l'ensemble de son extension de surface.
  4. Panneau selon l'une quelconque des revendications précédentes, dans lequel l'épaisseur totale du panneau est constante sur l'ensemble de son extension de surface.
  5. Panneau selon l'une quelconque des revendications précédentes, dans lequel la position sur le panneau des premières zones (3) de la première couche (1) est prédéterminée en fonction des pics d'intensité sonore émis par une source sonore à isoler par ledit panneau.
  6. Panneau selon l'une quelconque des revendications précédentes, dans lequel ladite seconde couche (2) a une épaisseur dans la plage de 2 à 500 mm.
  7. Panneau selon la revendication 6, dans lequel ladite seconde couche a un poids spécifique dans la plage de 30 à 200 kg/m3.
  8. Panneau selon l'une quelconque des revendications précédentes, ayant une forme permettant de se conformer à une partie d'une carrosserie de voiture.
  9. Procédé de fabrication d'un panneau selon la revendication 1, dans lequel les étapes suivantes sont effectuées :
    a) vaporisation d'un premier matériau compact non expansé sur une surface interne d'un moule afin de produire une première couche (1) du panneau, ajusté par des moyens de contrôle dépendant d'une densité prédéterminée du premier matériau et/ou d'une épaisseur et/ou d'une extension de surface desdites première et seconde zones (3,4) de la première couche ;
    b) injection d'un second matériau expansé à l'intérieur du moule pour produire la seconde couche (2) du panneau,
    dans lequel, avant l'étape a), une cartographie des première et seconde zones (3, 4) de la première couche (1) est définie, sur la base de laquelle lesdits moyens de contrôle sont programmés pour ajuster la vaporisation du premier matériau.
  10. Procédé selon la revendication 9, dans lequel les étapes a) et b) sont réalisées dans un moule partiellement ouvert.
  11. Procédé selon la revendication 10, dans lequel lesdits moyens de contrôle comprennent un robot anthropomorphique et un pistolet vaporisateur.
EP06764288.4A 2005-08-05 2006-08-02 Panneau d'isolation acoustique Active EP1922716B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL06764288T PL1922716T3 (pl) 2005-08-05 2006-08-02 Płyta izolacji akustycznej

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT000429A ITRM20050429A1 (it) 2005-08-05 2005-08-05 Pannello di isolamento.
PCT/EP2006/064929 WO2007017422A2 (fr) 2005-08-05 2006-08-02 Panneau d'isolation

Publications (2)

Publication Number Publication Date
EP1922716A2 EP1922716A2 (fr) 2008-05-21
EP1922716B1 true EP1922716B1 (fr) 2014-03-12

Family

ID=37603208

Family Applications (1)

Application Number Title Priority Date Filing Date
EP06764288.4A Active EP1922716B1 (fr) 2005-08-05 2006-08-02 Panneau d'isolation acoustique

Country Status (4)

Country Link
EP (1) EP1922716B1 (fr)
IT (1) ITRM20050429A1 (fr)
PL (1) PL1922716T3 (fr)
WO (1) WO2007017422A2 (fr)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110305865A1 (en) 2009-03-04 2011-12-15 Dow Global Technologies Inc. (Formerly Known as Dow Global Technologies Inc.) Sound-dampening polyurethane-based composite
WO2010118358A2 (fr) 2009-04-10 2010-10-14 Saint-Gobain Performance Plastics Corporation Compositions d'amortissement acoustique
US9637913B2 (en) 2009-04-10 2017-05-02 Saint-Gobain Performance Plastics Corporation Acoustic damping compositions having elastomeric particulate

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19607895C2 (de) * 1996-03-01 1999-02-04 Goesele Karl Schalldämmplatte sowie schalldämmende Verkleidung mit einer Schalldämmplatte
DE19909046B4 (de) * 1999-03-02 2005-04-14 Faist Automotive Gmbh & Co. Kg Akustischer Mehrschichtenabsorber, Verfahren zu dessen Herstellung und dessen Verwendung
US6705268B2 (en) * 2001-09-21 2004-03-16 Basf Aktiengesellschaft Engine noise barrier
FR2848904B1 (fr) * 2002-12-23 2006-09-08 Faurecia Automotive Ind Procede pour realiser une piece d'insonorisation d'epaisseur variable.

Also Published As

Publication number Publication date
EP1922716A2 (fr) 2008-05-21
ITRM20050429A1 (it) 2007-02-06
WO2007017422A2 (fr) 2007-02-15
PL1922716T3 (pl) 2014-09-30
WO2007017422A3 (fr) 2007-04-26

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