EP1606969A2

EP1606969A2 - Acoustic element consisting of composite foam

Info

Publication number: EP1606969A2
Application number: EP04719873A
Authority: EP
Inventors: Rudolf Weingartner; Ulf Panzer; Dietmar Rammer
Original assignee: GREINER PERFOAM GmbH
Current assignee: GREINER PERFOAM GmbH
Priority date: 2003-03-14
Filing date: 2004-03-12
Publication date: 2005-12-21
Also published as: DE10311245A1; US20070026216A1; WO2004082319A2; WO2004082319A3

Abstract

The invention relates to an acoustic element (1) consisting of composite foam, and to a method for producing an acoustic element (1) consisting of particles (2) or little rods (11) of plastic foam which are interconnected by means of a binding agent (5). Said particles (2) or little rods (11) have surfaces (4) formed from planar and/or curved partial surfaces. Cavities (7) are formed between the particles (2) or little rods (11) in the acoustic element (1).

Description

Acoustic part made of composite foam

The invention relates to an acoustic part made of composite foam and a method for producing an acoustic part, corresponding to the features in the preamble of claims 1 and 27, respectively.

EP 0 657266 B1 discloses a device and a method for producing molded parts from plastic foam. In this process, flakes or granules, which are produced by comminuting plastic waste in a shredder, a cutting or tearing machine, a mill or the like, are mixed with a liquid raw material of a plastic, as a result of which the flakes of the plastic waste or of the recycled plastic on their surface be coated with the liquid raw material. The flakes coated in this way are then blown into a mold cavity until the volume of the mold cavity is filled with the flakes, after which the reaction of the raw material is triggered by the supply of pressure and / or temperature and / or water vapor and thus the

Flakes are connected to one another by a coherent cell structure of the binder or primary material. As materials for the flakes used in this process, “PUR” (polyurethane) soft foam waste, PUR cold and / or hot molded foam waste, PUR soft foam waste coated or laminated with textiles and / or foil, PUR composite foam waste, but also Rubber granules or cork granules with the addition of thermoplastic waste and / or natural and / or synthetic fibers in various lengths can be used with this process to enable a uniformly dense filling when inserting the materials into the mold cavity and to include any different spatial configurations The granulate-like structure or irregular outer shape of the flakes of the plastic foam results in an almost space-free accumulation or compact fulfillment of the entire volume of the molded part due to the granular structure or irregular outer shape of the flakes of the plastic foam s through the flakes.

DE 69425 044 T2 describes an agglomerated polyurethane foam and a method for producing such a polyurethane foam, which mainly consists of soft polyurethane foam particles. The particles bonded together by a glue are made from parts of the soft polyurethane foam by processing with a cutting machine. manufactured. Soft polyurethane foam with a density of 12 to 50 kg / m ^{3 is} used as the starting material. After adding the glue, the particles are compressed, whereupon the glue is cured in the compressed state. Essentially dust-free polyurethane foam particles with a volume of 0.15 to 25 cm ³ are used, the aguomerized polyurethane foam finally having a density of 15 to 50 kg / cm ³ . The aguomerized polyurethane foam serves as a filler, such as in pillows or mattresses.

It is the object of the invention to create an acoustic part made of composite foam.

This object of the invention is achieved by the acoustic part according to the features in the characterizing part of claim 1. It is advantageous that the cavities formed between the particles connected with the binder increase the degree of sound absorption of corresponding acoustic parts. If sound enters the interior of a cavity of the acoustic part 1, there are multiple reflections on the inner surfaces, sound energy being absorbed by being converted into heat by friction during the reflection on the inner surface.

The further developments of the acoustic part according to claims 2 and 3 are advantageous in that at least approximately prismatic or cylindrical or at least approximately rod-shaped particles can be produced relatively easily by machine from, for example, plastic foam waste and have a good adaptability to space during processing.

Particularly advantageous is the further development of the acoustic part according to claim 4. By cutting the particles from plastic foam, less dust is produced during their production and therefore a lower proportion of binder of a plastic or of binder is required to connect the particles to an acoustic part.

The further development of the acoustic part according to claims 5 and 6 has the advantage that it can be used to produce acoustic parts whose course of the degree of sound absorption largely corresponds to the sound development of motor vehicle engines. According to claim 7, particles with a volume between 0.003 cm ³ to 1.5 cm ³ , in particular from 0.003 cm ³ to 0.15 cm ³ , are used to produce an acoustic part. This has the advantage that complex acoustic part geometries can be produced with such small particles.

Through the development of the acoustic part according to claim 8, according to which the particles are at least approximately cuboid and with a volume or side lengths in the range from 0.1 cm x 0.1 cm x 0.5 cm to 0.4 cm x 0.4 cm x 2 cm, the advantage is achieved that complex acoustic part geometries can be produced with the correspondingly small particles made of plastic foam and, on the other hand, a higher proportion of voids is formed in the acoustic part during manufacture by the rod-shaped particles.

The further developments of the acoustic part according to claims 9 to 12 are also advantageous, since acoustic parts can thus be produced which are adapted to the frequency curve of the sound development of a specific sound source.

According to claim 13 it is provided that the proportion of the total volume of the voids between the particles corresponds to a value of 0% to 25% of the total volume of the acoustic part. This has the advantage that a sufficient strength of the acoustic parts and an increase in the degree of sound absorption can be achieved at the same time.

Also advantageous is the further development of the acoustic part according to claim 14, according to which the binder has a share of between 3% and 25% of the total weight of the acoustic part, since the acoustic parts can be produced inexpensively with a correspondingly low proportion of binder.

It is also advantageous to design the acoustic part according to claim 15, according to which the binder has a share of between 5% and 15% of the total weight of the acoustic part, since cavities with a correspondingly large volume are formed between the particles, but still at the same time sufficient strength of the connection of the particles can be achieved.

The further development according to claims 16 to 18 advantageously results in a good and sufficiently strong connection of the particles to each other is achieved.

Also advantageous are the developments according to claims 19 and 20, wherein the particles are embedded in a curved or elastically deformed state, or the particles of the acoustic part in a smaller than their free foam volume

Volume elastically compressed state in the cell structure of the plastic foam are embedded in the binder, since the mechanical stiffness of the acoustic part is increased by the internal tensioning or pre-tensioning of the particles thereby achieved.

The design of the acoustic part according to claim 21 achieves the advantage that it allows the outer shape of acoustic parts to be structured sufficiently well, e.g. for automotive parts. The intended particle size means that the particles mixed with the binder are so well incorporated in the commonly used forms that even relatively small or narrowly structured areas of the acoustic part are filled with particles or largely have the same particle density as other areas.

The further development of the acoustic part according to claim 22, according to which mass densities of different sizes are formed in different volume areas of the acoustic part, has the advantage on the one hand that the acoustic properties can be influenced thereby and on the other hand different mechanical strengths can be achieved, which facilitates the assembly of the acoustic parts can.

The further developments of the acoustic part according to claims 23 and 24 are also advantageous, since as a result the void volumes between the particles in different volume ranges of the acoustic part can be designed differently, and thus a wider one

Frequency spectrum for the frequency-specific sound absorption is accessible.

The one-piece design of the acoustic part, according to claim 25, has the advantage of a simpler and less expensive manufacture and also easier handling during assembly or further use.

The development of the acoustic part according to claim 26 is also advantageous, in that the acoustic part is formed with a molded cover layer, since such parts are used directly as clothing parts with a more visible surface, which is formed by the cover layer, can be produced.

The object of the invention is also achieved independently by a method for producing an acoustic part according to the features in the characterizing part of claim 27. The advantage here is that by blowing in the particles mixed with binder in the flow of a gaseous medium into a form provided for the production of the acoustic part, the density and the proportion that can be selected in a relatively wide range predeterminably in the cavities formed in the acoustic part.

By reducing the volume of the mold before triggering the curing of the binder, as is provided by the development of the method according to claim 28, the advantage is achieved that the void fraction as well as the particle density in different regions of the volume of the acoustic part are designed differently can.

The further development according to claim 29 is also advantageous, since as a result the particles are present with a significantly lower dust content and, subsequently, relatively small amounts of binder are sufficient for producing the acoustic parts.

Further advantageous developments of the method are specified by claims 30 to 35.

For a better understanding of the invention, this will be explained in more detail with reference to the following figures.

In a schematically simplified representation, they show:

Figure 1 shows an acoustic part made of composite foam, shown in perspective.

FIG. 2 shows an enlarged section of the acoustic part according to FIG. 1;

3 shows a detail of a further exemplary embodiment of an acoustic part with rod-shaped particles, shown in section; 4 shows a cross section of an acoustic part with a mass density increased in one area;

5 shows a cross section of an acoustic part with a layered structure, shown in section;

6 shows a detail of an exemplary embodiment of the acoustic part with rod-shaped elements

Particles and spaces filled by the binder, shown cut;

7 shows a detail of a further exemplary embodiment of an acoustic part with a

Top layer, shown cut;

8 shows a system for producing an acoustic part according to the invention in a simplified, schematic representation.

In the introduction, it should be noted that in the differently described embodiments, the same parts are provided with the same reference numerals or the same component names, and the disclosures contained in the entire description can be applied analogously to the same parts with the same reference numerals or the same component names. The location information selected in the description, e.g. above, below, laterally, etc. refer to the figure described and illustrated immediately and are to be transferred analogously to the new position in the event of a change in position. Furthermore, individual features or combinations of features from the different exemplary embodiments shown and described can also represent independent, inventive or inventive solutions.

1 shows a perspective view of an acoustic part 1 made of composite foam.

1 is a part that can be used, for example, in the interior of motor vehicles as a cladding element. The acoustic part 1 can also be used, for example, for filling cavities in other components or parts. The inner structure of the composite foam of the acoustic part 1 is formed by particles 2 made of plastic foam. This is shown in a simplified manner in FIG. 1 in a circular section.

FIG. 2 shows an enlarged section of the acoustic part 1 according to FIG. 1. A volume 3 of the acoustic part 1 is filled with irregularly aligned particles 2. The particles 2 are coated on their surface 4 with a binder 5 made of a plastic. The binder 5 has hardened or polymerized or has reacted to form a plastic foam, as a result of which particles 2 which are in contact with one another are connected to one another via a cell structure formed by the binder 5. The particles 2 are combined to form a firmly connected acoustic part 1.

Of course, it is possible that the surface 4 of the particles 2 is not completely coated with the binder 5 but only partially. This can be the case in particular when the quantitative proportion of the binder in the total weight of the acoustic part 1 is low or when the particles 2 are mixed with the binder 5 no completely uniform distribution of the binder 5 between the particles 2 is achieved.

The acoustic part 1 is produced from the particles 2 and the binder 5 in a manner known per se, e.g. according to the process according to EP 0 657266 B1, in which the particles 2 are first mixed with a liquid binder 5, whereby their surface is coated with the binder 5 and the particles 2 are then blown into a mold cavity provided for this purpose and then the reaction of the binder is triggered, whereby this solidifies and connects the particles 2 by a connected cell structure.

In the exemplary embodiment according to FIGS. 1 and 2, at least approximately cube-shaped particles 2 are used. An edge length 6 of the cube-shaped particles 2 has a value of approximately 0.4 cm. The particles 2 are obtained by cutting with appropriate machines from corresponding materials. It is thereby achieved that the particles 2 have surfaces 4 which are approximately superficial. Cutting machines are preferably used for producing the particles 2, by means of which particles 2 can be obtained which have an at least equally large cross section. In this way it can also be achieved that too regular and largely the same size particles are formed. The use of the cutting technique also has the advantage that less dust is produced or the particles 2 have only a small proportion of dust. When the acoustic part 1 is manufactured, the mixing of the particles 2 and the blowing into a shape provided for this results in an almost completely irregular alignment or stacking of the particles 2. If the proportion of the binder 5 is also correspondingly low, then this becomes so thereby promoting the formation of cavities 7 in the acoustic part 1. The cavities 7 are each delimited by inner surfaces 8 of the binder 5 surrounding the particles 2 or, in the event that the surface 4 of the particles 2 is not completely coated with binder, by partial regions of the surfaces 4 of the particles 2.

The formation of cavities 7 in the acoustic part 1 is favored by the small amount of dust with which the particles 2 are permeated. A small proportion of dust in the particles 2 also has the advantage that the proportion of the binder 5 can be kept very low, since only little of the binder 5 is required for wetting the dust particles and the largest proportion of the binder 5 for wetting the surfaces 4 of the particles 2 is available.

The voids 7 formed between the particles 2 improve the sound absorption by the acoustic part 1. The sound absorption level (a = absorbed energy / incident energy) is used to characterize the sound absorption. It is a known phenomenon that sound entering a cavity gradually loses energy due to the multiple reflections on the walls of the cavity, since the acoustic energy occurs due to the friction occurring in the particles of the walls as well as in the gaseous medium in the cavities is converted into heat. In the same way there is a corresponding sound absorption at the cavities 7 in the acoustic part 1. Sound entering the acoustic part 1 is partly reflected and partly transmitted at the interfaces formed by the surfaces 8 of the binder 5. If sound enters the interior of such a cavity 7, there is a multiple reflection on the surfaces 8 of the cavity 7 and thus the described energy loss or sound absorption. When the sound waves pass between the cavities 7 and the particles 2 or the hardened binder 5, there is always excitation of lattice vibrations of the atoms, which represent a dissipative energy component, the energy of which gie is removed from the sound and is thus converted into thermal energy as a disordered movement of the atoms. This effect is correspondingly amplified by the multiple reflections of the sound on the surfaces 8 of the cavity 7 and thus contributes to sound absorption. The formation of such cavities 7 in the acoustic part 1 thus improves the acoustic properties with regard to sound insulation or sound absorption.

By selecting particles 2 of different sizes or different edge lengths 6 of the cubes of particles 2 for different acoustic parts 1, the volume of the cavities 7 is also changed, as a result of which the frequency-specific sound absorption can be predetermined. However, the volume of the cavities 7 is also influenced by the proportion of the binder 5 with which the particles 2 are coated, and the preselection of the proportion of the binder 5 thus also represents a possibility of determining the fire sequence-specific sound absorption. The edge length 6 of the cube-shaped particles 2 is chosen so that a volume 9 of the particles 2 has a value from the range 0.05 cm to 1.5 cm. The volume 9 is preferably selected from a range from 0.1 cm to 0.15 cm. Another advantage of using correspondingly small particles 2 is that acoustic parts 1 with a surface 10 having a correspondingly low surface roughness can also be produced without the need for a separate reworking of the surface 10. By using correspondingly small particles 2, acoustic parts can also be used

1 can be manufactured with a relatively finely structured outer shape. Since also finely structured areas of the outer shape of such an acoustic part 1 when the particles are introduced

2 can be reached in a form of an acoustic part 1 intended for production from the particles 2 and can be filled by them. The outer surface 10 of the acoustic part 1 has a surface roughness corresponding to a value of the order of one

Particle size formed. The surface roughness of the acoustic part 1 has a value in the range from 0.1 cm to 0.5 cm. Due to the surface roughness, the outer shape of the acoustic part 1 has a larger surface in relation to a flat outer surface 10, which also increases the sound absorption.

FIG. 3 shows a detail of a further exemplary embodiment of an acoustic part 1 with rod-shaped particles 2, shown in section. According to this exemplary embodiment, the particles 2 are formed by rods 11. The volume 3 of the acoustic part 1 is through irregularly aligned rods 11 formed or filled. The rods 11 are coated with the binding agent 5, which has hardened and whose coherent cell structure connects the adjacent rods 11 to one another to form a spatial structure. Cavities 7 are in turn formed between the rods 11. The rods 11 are cuboid and have side lengths of 0.3 cm x 0.3 cm x 1.5 cm. The particles 2 designed as rods 11 result in a higher proportion of a volume 12 of the cavities 7 in relation to the total volume 3 of the acoustic part 1 during the production of the acoustic part 1, since the rods 11 do not lie as close together as cube-shaped ones during the manufacturing process Particles 2. The rods 11 are produced by a cutting machine, which can be adjusted so that their volume 9 or the side lengths in a range from 0.1 cm x 0.1 cm x 0.5 cm to a volume 9 or side lengths of 0.4 cm x 0.4 cm x 2 cm.

As shown in Fig. 3, some of the rods 11 are deformed or bent. This is a result of the manufacturing process in which the rods mixed with binder 5

11 are filled into a mold and the rods 11 are pressed against one another to different extents, depending on the pressure used for the filling, resulting in an elastic deformation of the rods 11. After the binder 5 has hardened or fully reacted, the particles 2 or rods 11 remain embedded in the acoustic part 1 in a gel-crumbled or elastically deformed state. On the one hand, this leads to a reduction in the volume 9 of the cavities 7, and on the other hand to the formation of an internal bracing of the rods 11 or the acoustic part 1. This internal bracing increases the mechanical rigidity of the acoustic part 1 and thus also influences its acoustic properties.

Of course, it is also possible to use rods 11 with a cross-section other than a square to produce the acoustic part 1. In addition to a rectangular or circular cross section, rods 11 with another at least approximately cylindrical or prismatic shape would also be conceivable, e.g. Particle 2 with a triangular or a hexagonal cross section. Particles 2 can also have a platelet shape.

In general, 1 particle is suitable for producing the acoustic part according to the invention 2, the surface 4 of which is formed from flat and / or curved partial surfaces. It is achieved by such surfaces 4 that cavities 7 which are largely sharply delimited are formed between the particles 2 in the acoustic part 1. In contrast to plastic flakes, such as those produced in the shredding of plastic waste in tearing machines or mills, the surfaces 4 of the particles 2 have no or only a very small proportion of fraying. Such fraying of the plastic flakes leads together with the binding agent 5 to clumping, whereby cavities 7 are practically not formed at all. Such fraying or protruding areas of plastic flakes have a lower material thickness than the core areas of the plastic flakes and are therefore easier to deform elastically, or it is possible that correspondingly protruding fraying of mutually adjacent plastic flakes gets caught in one another. The plastic flakes thus have an outer crumple zone, so to speak, so that adjacent plastic flakes can come closer together. Finally, it can also be advantageous for partial surfaces of the surfaces 4 of the particles 2 to be concave, since this means that the total volume of the

Cavities 7 is proportionately larger in relation to the total volume of the acoustic part 1. Particles 2 in the form of spherical half shells or pipe sections would be possible, for example. The acoustic parts 1 are preferably produced with a share of the total volume of the cavities 7 in the total volume of the acoustic part 1 with a value from a range of 0% to 25%.

The formation of cavities 7 in the acoustic part 1 between the rods 11 or particles 2, as has already been explained, now also leads to an improvement in the acoustic properties with regard to improved sound absorption. Sound that enters a cavity 7 is reflected several times on the inner surfaces 8 of the binder 5, with which the rods 11 are coated, and sound energy is extracted in the process.

4 and 5 show exemplary embodiments of acoustic parts 1 with different mass density of the composite foam in different volume ranges, shown in section. With known devices for producing acoustic parts from plastic foam, such as the device described in EP 0 547266 B1, it is possible, for example, to achieve a higher compression of the composite foam consisting of particles 2 and the binder 5 locally with movable mold inserts. 4 shows a cross section of an acoustic part 1 with an increased mass density in a region 13. In the region 13, the particles 2 are in an elastically compacted state in that they are embedded in the cellular structure of the hardened binder 5 of the plastic foam and are thus held in place. The particles 2 in the region 13 thus have a smaller volume than would correspond to their free foam volume, ie that their

Volume in the elastically undeformed state would correspond. The higher mass density in the region 13 is associated both with a higher mechanical strength and with a smaller volume 12 of the cavities 7. Due to the smaller cavities 7, however, the acoustic properties are also changed compared to the other areas of the volume 3 of the acoustic part 1.

5 shows a cross section of an acoustic part 1 with a layered structure, shown in section. Volume areas designed as layers 14, 15 and 16 are arranged in the acoustic part 1. The particles 2 in the layers 14, 15, 16 are compressed to different extents by means of a multi-stage production process, so that the bulk density of the composite foam in the layer 15 is greater than the bulk density in the layer 14 or the bulk density in the layer 16 than in layer 15. Compression during the manufacturing process also ensures that the volumes 12 of the cavities 7 in the different layers 14, 15 and 16 are of different sizes and thus have the corresponding acoustic properties, ie the frequency-specific degrees of sound absorption are expanded over a correspondingly broader frequency band. In the layers 14, 15 and 16 of the acoustic part 1, the cavities 7 between the particles 2 are formed with a different volume density. By means of a correspondingly controlled manufacturing process, however, it is also possible for the proportion of the binder 5 in the composite foam to be of different sizes in the layers 14, 15 and 16 of the acoustic part 1. That the mass density of the binder 5 in different layers 14, 15 and 16 of the acoustic part 1 is of different sizes.

As material for the particles 2 for the production of acoustic parts 1, PUR (polyurethane) can be mixed individually, but also in a predetermined, arbitrary ratio.

Soft foam waste, PUR cold and / or hot molded foam waste, PUR soft foam waste with textiles and / or film-coated or laminated, PUR composite foam waste, but also granulated rubber or rubber granules or cork granules can be used. Particles 2 with a density from a range of 15 kg / m ³ to 70 kg / m ³ can be used for the production of the acoustic parts 1. Particles 2 with a density range or a density from a range of 70 kg / m to 1,600 kg / m are preferably used.

The composite foam of the acoustic parts 1 according to the invention can have a density in the range from 40 kg / m to 300 kg / m; Acoustic parts 1 with a density from a range of 60 kg / m ³ to 200 kg / m ³ are particularly advantageous. Furthermore, light acoustic parts 1 with a density from a range of 60 kg / m3 to 70 kg / m3, medium-weight acoustic parts 1 with a density from a range of 70 kg / m3 to 130 kg / m3 and heavy ones

Acoustic parts 1 with a density from a range of 130 kg / m3 to 200 kg / m3 can be produced. These allow a specific adaptation of the acoustic parts 1 depending on the frequency curve of the sound development of the specific sound source. Various prepolymers of plastic foams can be used for the binder 5. Polyurethane or polyurethane foam, such as e.g. Soft foam or a

Hot molded foam. A polyurethane glue based on a prepolymer of TDI and / or MDI with ether polyols is particularly suitable as a binder for producing soft PU foams. The polyurethane glue can in particular contain up to 25% free NCO groups. In the production of the acoustic part 1, a proportion of the binder 5 from a range of 4% to 25% of the total weight of the acoustic part 1 is used. A proportion of 5% to 15% binder in the total weight of the acoustic part 1 is preferably used.

FIG. 6 shows a detail of an exemplary embodiment of an acoustic part 1 with rod-shaped particles 2 or rods 11 and intermediate spaces 17 filled by the binder 5, shown in section. If a plastic foam is used as the binder 5 or glue, the volume of the acoustic part 1 is increased during the reaction of the binder, so that the spaces 17 between the particles 2 are completely filled by the binder 5. If a binder 5 with a different density to the particles 2 after the reaction has been used, these intermediate spaces 17 also have a sound-absorbing effect corresponding to the cavities 7, according to FIGS. 2 to 5. Since the particles 2 on the one hand and the binder 5 on the other hand each have a different mass density, the surfaces 4 of the particles 2 represent interfaces at which sound can be reflected. Sound in the Acoustic part 1 penetrates now experiences a multitude of reflections on these surfaces 4, sound energy being converted into heat by friction.

If the mass density of the material of the particles 2 is greater than the mass density of the binder 5, the sound absorption effect corresponding to the cavities 7 according to FIGS. In the opposite case, if the mass density of the binder 5 is greater than the mass density of the material of the particles 2, the effect of the cavities 7, according to FIGS. 2 to 5, comes from the volumes 12 of the rods 11 or particles 2. Through the targeted use of a binder 5 with a different density in relation to the density of the rods 11 or particles 2, an improvement in the acoustic properties or an increase in the sound-absorbing effect of acoustic parts 1 can also be achieved.

In a further exemplary embodiment of an acoustic part 1, it is of course also possible for cavities 7 to be formed in addition to spaces 17 which are completely filled with binder 5. Scarf reflections in the sense of the sound-absorbing effect described are also possible at continuous density transitions in the material of the acoustic part 1 and not only at abrupt density transitions, as are present at the interfaces formed by the surfaces 4 and 8.

7 shows a detail of a further exemplary embodiment of an acoustic part 1 with a cover layer 18, shown in section. In the area of the surface 10 of the acoustic part 1, a covering layer 18 is connected to the particles 2 or rods 11 by molding. The cover layer 18 can be formed, for example, from a fiber mat, a fiber flow, a fabric, a grid, a net, but also a film. The cover layer 18 can also itself be formed from a composite foam and form a so-called heavy layer. A corresponding cover layer 18 can be produced, for example, by crushing hard plates made of pre-compressed material, for example EPDM, and connecting these particles in a conventional manner with a polyurethane foam to form a new block from which heavy layers, for example, are cut out. It is also possible for such a top layer 18, which is designed as a heavy layer, to be formed directly in the form provided for the production in a multi-stage process. A cover layer 18 designed as a heavy layer could also be produced from granulated rubber his. Such an acoustic part 11, which is formed with a cover layer 18, could be used, for example, as an interior trim part for motor vehicles.

8 shows a system 25 for producing an acoustic part 1 according to the invention (FIG. 1) in a simplified schematic representation. A control device 26 is provided for controlling the sequence of the method for producing the acoustic part 1. The particles 2 or rods 11 are removed from a receptacle 27 and, after the required amount has been determined, are fed to a mixing device 29 in a weighing device 28, where they are mixed with the binder 5 removed from a receptacle 30 and then transported to an intermediate storage container 31. The quantity of the particles 2 or rods 11 mixed with binder 5 required for filling a mold 32 is then determined in a further weighing device 33 and then introduced into the mold 32 by a conveying device 34 and a conveying fan 35.

The mold 32 is provided with ventilation openings 36, so that the particles 2 or rods 11 transported in a feed stream 37 of a gaseous medium generated by the conveying fan 35 can be blown into the mold, while the gaseous medium, as indicated by arrow 38, leaves the mold Form 32 can escape. The extent to which the particles 2 or rods 11 are pressed into the mold 32 or against one another can be determined both by the pressure of the conveying stream 37 generated by the conveying fan 35 and by a control drive arranged between the conveying fan 35 and the mold 32 39 can be specified.

In order to trigger or accelerate the hardening process of the binder 5, it is further provided that water vapor produced in a heat exchanger 40, indicated by arrow 41, can be supplied through the ventilation openings 36 or removed again by means of an exhaust duct 42 and a vacuum pump 43. After the particles 2 or rods 11 have been blown into the mold 32 under pressure in the feed stream of a gaseous medium, the curing process can then be carried out by vapor deposition and / or settling.

In a further embodiment variant of the method according to the invention, it is provided that the volume of the mold 32 mixes with the binder 5 after it has been filled. th particle 2 is reduced and then the curing of the binder 5 is triggered. This can be done, for example, in that the mold 32 has a movable mold insert 44 (shown in broken lines). This mold insert 44 can be pressed into the mold 32 after the filling process has been completed, the particles 2 being compressed at least in an area adjacent to the mold insert 44, as is shown, for example, in FIG. 4.

For the sake of order, it should finally be pointed out that, in order to better understand the structure of the acoustic part 1, these or their components have been partially shown to scale and / or enlarged and / or reduced.

The object on which the independent inventive solutions are based can be found in the description.

Above all, the individual in FIGS. 1, 2; 3; 4; 5; 6; 7; 8 Ausl rirungen shown

Form the subject of independent, inventive solutions. The relevant tasks and solutions according to the invention can be found in the detailed descriptions of these figures.

REFERENCE NUMBERS

Acoustic part Particle Volume Surface Binder Edge length Cavity Surface Volume Surface Stick Volume Area Layer Layer Layer Interspace Top layer System Control device Receptacle Weighing device Mixing device Receptacle Intermediate storage box Form Weighing device Conveying device Conveying fan Ventilation opening Flow arrow Control drive Heat exchanger Arrow Extraction channel Vacuum pump mold insert

Claims

Patent claims

1. Acoustic part (1) made of composite foam consisting of particles (2) or rods (11) made of plastic foam, which are connected to one another by a binder (5), characterized in that the particles (2) or rods (11 ) Have surfaces (4) which are formed from flat and / or cluttered partial surfaces and which have cavities (7) formed between the particles (2) or rods (11).

2. Acoustic part (1) according to claim 1, characterized in that the particles (2) or rods (11) are at least approximately prismatic or cylindrical.

3. Acoustic part (1) according to claim 1 or 2, characterized in that the particles (2) or rods (11) are at least approximately rod-shaped.

4. Acoustic part (1) according to one of the preceding claims, characterized in that surfaces (4) of the particles (2) or rods (11) are produced by cutting.

5. Acoustic part (1) according to one of the preceding claims, characterized in that the particles (2) or rods (11) have a density with a value from a range of 15 kg / m ³ to 70 kg / m ³ .

6. Acoustic part (1) according to one of claims 1 to 4, characterized in that the particles (2) or rods (11) have a density with a value from a range of 70 kg / m ³ to 1,600 kg / m ³ ,

7. Acoustic part (1) according to one of the preceding claims, characterized in that the particles (2) or rods (11) have a volume (9) with a value from a range from 0.003 cm ³ to 1.5 cm ³ , in particular from 0.003 cm ³ to 0.15 cm ³ .

8. Acoustic part (1) according to one of the preceding claims, characterized in that the particles (2) or rods (11) at least approximately cuboid with a volume (9) or edge lengths (6) from a range of 0.1 cm x 0.1 cm x 0.5 cm to 0.4 cm x 0.4 cm x 2 cm.

9. Acoustic part (1) according to one of the preceding claims, characterized in that the acoustic part (1) has a density with a value from a range of 60 kg / m ³ to 200 kg / m.

10. Acoustic part (1) according to one of the preceding claims, characterized in that the acoustic part (1) has a density with a value from a range of 60 kg / m ³ to 70 kg / m.

11. Acoustic part (1) according to one of claims 1 to 9, characterized in that the acoustic part (1) has a density with a value from a range of 70 kg / m to 130 kg / m.

12. Acoustic part (1) according to one of claims 1 to 9, characterized in that the acoustic part (1) has a density with a value from a range of 130 kg / m to 200 kg / m.

13. Acoustic part (1) according to one of the preceding claims, characterized in that a total volume of the cavities (7) has a share with a value from a range from 0% to 25% of a volume (3) of the acoustic part (1).

14. Acoustic part (1) according to one of the preceding claims, characterized in that the binder (5) has a proportion with a value from a range of 3% to 25% of the total weight of the acoustic part (1).

15. Acoustic part (1) according to one of the preceding claims, characterized in that the binder (5) has a proportion with a value from a range of 5% to 15% of the total weight of the acoustic part (1).

16. Acoustic part (1) according to one of the preceding claims, characterized in that the binder (5) consists of polyurethane, in particular a polyurethane foam.

17. Acoustic part (1) according to one of the preceding claims, characterized in that the binder (5) is formed by a soft foam.

18. Acoustic part (1) according to one of the preceding claims, characterized in that the particles (2) or rods (11) made of plastic foam are connected via a cell structure made of binder (5).

19. Acoustic part (1) according to one of the preceding claims, characterized in that the particles (2) or rods (11) are embedded in a curved or elastically deformed state.

20. Acoustic part (1) according to one of the preceding claims, characterized in that the particles (2) or rods (11) made of plastic foam in one compared to their

Free foam volume are embedded in a smaller volume of elastically compressed state in the cell structure of the binder (5).

21. Acoustic part (1) according to one of the preceding claims, characterized in that an outer surface (10) of the acoustic part (1) is formed with a surface roughness corresponding to a value of a particle size.

22. Acoustic part (1) according to one of the preceding claims, characterized in that different volume areas, in particular layers (14, 15, 16), of the acoustic part (1) are formed with different mass densities.

23. Acoustic part (1) according to one of the preceding claims, characterized in that different volume areas, in particular layers (14, 15, 16), of the acoustic part (1) are formed with a different volume density of the cavities (7).

24. Acoustic part (1) according to one of the preceding claims, characterized in that different volume areas, in particular layers (14, 15, 16), of the acoustic part (1) are formed with a different, average mass density of the binder (5).

25. Acoustic part (1) according to one of the preceding claims, characterized in that the acoustic part (1) is formed in one piece.

26. Acoustic part (1) according to one of the preceding claims, characterized in that in the area of the surface (10) of the acoustic part (1) with the particles (2) or rods (11) a cover layer (18) is connected by molding.

27. A method for producing an acoustic part (1) from particles (2) or rods

(11) made of plastic foam, in which the particles (2) or rods (11) are mixed with a liquid binder (5) and coated on the surface, whereupon they are introduced into a mold (32) and connected to form a coherent cell structure, in particular for producing an acoustic part (1) according to one of claims 1 to 26, characterized in that particles (2) or rods (11) are used which have surfaces (4) formed from flat and / or curved partial surfaces and the particles (2) or rods (11) in the flow of a gaseous medium are blown at a pressure into a mold (32) provided with ventilation openings (36) for outflow of the gaseous medium and, if appropriate, thereafter vapor deposition and / or reaction can be carried out, an amount of the binder (5) and / or the pressure of the gaseous medium being selected such that voids (7) are formed between the particles (2) or rods (11) be educated.

28. The method according to claim 27, characterized in that the volume of the mold (32) after being infested with the particles (2) or rods (11) mixed with the binder (5) is reduced at least in regions and then the curing of the binder (5) is triggered.

29. The method according to claim 27 or 28, characterized in that surfaces (4) of the particles (2) or rods (11) are produced by cutting.

30. The method according to any one of claims 27 to 29, characterized in that particles (2) or rods (11) with a density with a value from a range of 15 kg / m ³ to 70 kg / m ³ are used.

31. The method according to any one of claims 27 to 29, characterized in that particles (2) or rods (11) with a density with a value from a range of 70 kg / m ³ to 1,600 kg / m ³ are used.

32. The method according to any one of claims 27 to 31, characterized in that particles (2) or rods (11) with a volume (9) with a value from a range of 0.003 cm ³ to 1.5 cm ³ , in particular of 0.003 cm ³ to 0.15 cm ³ can be used.

33. The method according to any one of claims 27 to 32, characterized in that a proportion with a value from a range of 3% to 25% of the total weight of the acoustic part (1) is selected for the amount of the binder (5).

34. The method according to any one of claims 27 to 33, characterized in that a prepolymer based on MDI is used as the binder (5).

35. The method according to any one of claims 27 to 34, characterized in that the particles (2) or rods (11) in a curved or elastically deformed state are embedded in the binder (5).