Flexible sound barrier and rigid mounting assembly and mounting method

Abstract

A flexible sound barrier and rigid mounting assembly and method of attaching to a vehicle. The sound barrier assembly includes a rigid substrate, a flexible noise barrier layer, and an insulating layer. The insulating layer and the noise barrier layer are bonded, and an adhesive bonds the insulating layer to the substrate. The insulating layer and the noise barrier layer are fixedly held in place by the substrate. The substrate may include a slot that fits onto a mounting stud on a vehicle wall. The noise barrier layer and the insulating layer may include mounting holes extending through the two layers, wherein the mounting holes are aligned with the slots and fit to the mounting studs. The assembly may be mounted on the mounting studs, and a stud fastener may fit through the mounting hole without compressing the noise barrier layer and the insulating layer, and the rigid substrate surrounding the slot is sandwiched between the stud fastener and the vehicle wall.

Description

Technical Field

[0001] The present disclosure relates to a vehicle sound barrier, and more particularly to a sound barrier installed in a cab of a vehicle. Background Art

[0002] The cab of various types of vehicles (e.g., agricultural vehicles) may have a noise barrier layer inside the rear wall of the cab. The material used for the noise barrier layer is generally soft and dense to act as a sound barrier on the sound path. The sound barrier layer can be separated from the rear wall of the cab (usually made of sheet metal) by bonding the fiber layer to the noise barrier layer. A pressure-sensitive adhesive may be applied to the fiber layer to mount the complete sound barrier assembly to the wall of the cab. The sound barrier assembly is heavy and flexible, and is difficult to form to conform to the contour of the rear wall of the cab. The pressure-sensitive adhesive may reposition the sound barrier assembly minimally after contacting the wall of the cab. After the sound barrier assembly has been positioned in the cab, a manual roller may be used to provide pressure to the sound barrier assembly to firmly adhere the pressure-sensitive adhesive to the wall of the cab. The weight of the sound barrier layer of the assembly tends to slide down along the wall of the cab, which subjects the fiber layer of the assembly to shear forces. The shear forces tend to peel the pressure-sensitive adhesive off the rear wall of the cab. Sheet metal brackets may be used to increase the shear strength of the sound barrier assembly and to minimize the chance that the sound barrier assembly will slide out of position on the rear cab wall during the cab assembly process. Over time and with vehicle use, the noise barrier assembly may slide down the wall and out of an area leaving no sound barrier in the path of the noise.

[0003] It would be desirable to attach a sound barrier assembly to the rear wall of a vehicle cab that is easier to install and better remains in place over time during assembly of the vehicle and during use of the vehicle. Summary of the invention

[0004] A sound barrier assembly for attachment to a wall of a vehicle cab is disclosed, wherein the sound barrier assembly includes a rigid substrate, a noise barrier layer, an isolation layer, and an adhesive layer. The isolation layer has a first side and a second side, wherein the first side is bonded to the noise barrier layer, and the adhesive layer bonds the second side to the rigid substrate. The isolation layer and the noise barrier layer are fixedly held in place by the rigid substrate. The rigid substrate may be made of a formable fibrous material. The rigid substrate may include a reinforcing wall surrounding at least a portion of the periphery of the rigid substrate. The noise barrier layer may be flexible and made of mass-loaded polyvinyl chloride (PVC). The isolation layer may be flexible and made of polyurethane foam.

[0005] The wall of the vehicle cab may include barrier mounting studs; and the rigid substrate may include slots, wherein each slot is configured to fit on one of the barrier mounting studs. When two or more slots fit on two or more barrier mounting studs, the sound barrier assembly supports itself on the two or more barrier mounting studs. The noise barrier layer and the insulation layer may include mounting holes extending through both the noise barrier layer and the insulation layer, wherein each mounting hole is aligned with one of the slots of the rigid substrate and fits on one of the barrier mounting studs. The sound barrier assembly may also include stud fasteners fastened to the barrier mounting studs. When a specific stud fastener is fastened to a specific barrier mounting stud extending through a specific slot and a specific mounting hole, the specific stud fastener fits through the specific mounting hole without compressing the noise barrier layer and the insulation layer, and the rigid substrate surrounding the specific slot is sandwiched between the specific stud fastener and the wall of the vehicle cab. Each stud fastener may include a threaded bolt threadably attached to one of the barrier mounting studs.

[0006] The rigid substrate may include a separate left-hand portion and a right-hand portion, the noise barrier layer may include a separate left-hand portion and a right-hand portion, the isolation layer may include a separate left-hand portion and a right-hand portion, and the adhesive layer may include a separate left-hand portion and a right-hand portion, wherein the left-hand portion and the right-hand portion are separated. A first side of the left-hand portion of the isolation layer may be bonded to the left-hand portion of the noise barrier layer, and a first side of the right-hand portion of the isolation layer may be bonded to the right-hand portion of the noise barrier layer. The left-hand portion of the adhesive layer may bond a second side of the left-hand portion of the isolation layer to the left-hand portion of the rigid substrate. The right-hand portion of the adhesive layer may bond a second side of the right-hand portion of the isolation layer to the right-hand portion of the rigid substrate. The left-hand portions of the isolation layer and the noise barrier layer may be fixedly held in place by the left-hand portion of the rigid substrate, and the right-hand portions of the isolation layer and the noise barrier layer may be fixedly held in place by the right-hand portion of the rigid substrate.

[0007] A method of constructing a sound barrier assembly for attachment to a wall of a vehicle cab is disclosed, wherein the method includes: forming a rigid substrate to fit to the wall of the vehicle cab; bonding a first side of an insulating layer to a noise barrier layer; applying an adhesive to at least one of the rigid substrate and a second side of the insulating layer, and bonding the second side of the insulating layer to the rigid substrate using the adhesive, such that the insulating layer and the noise barrier layer are fixedly held in place by the rigid substrate. Forming the rigid substrate may include forming a reinforcing wall around at least a portion of the periphery of the rigid substrate. The wall of the vehicle cab may include a barrier mounting stud; and the method may further include: making a slot in the rigid substrate that is sized and shaped to fit on the barrier mounting stud. The method may further include: cutting the bonded noise barrier layer and insulating layer to fit the rigid substrate; and making mounting holes extending through both the noise barrier layer and the insulating layer, wherein the mounting holes are aligned with the slots in the rigid substrate, and the mounting holes are sized to fit on the barrier mounting studs.

[0008] A method of constructing and mounting a sound barrier assembly to a wall of a vehicle cab is disclosed, wherein the wall includes mounting studs. The method includes: forming a rigid substrate to fit to the wall of the vehicle cab; bonding a first side of an insulating layer to a noise barrier layer; applying an adhesive to at least one of the rigid substrate and a second side of the insulating layer; bonding the second side of the insulating layer to the rigid substrate using the adhesive; suspending the bonded rigid substrate, insulating layer, and noise barrier layer on the wall of the vehicle cab using mounting studs; and attaching the bonded rigid substrate, insulating layer, and noise barrier layer to the wall of the vehicle cab using stud fasteners. The insulating layer and the noise barrier layer are fixedly held in place by the rigid substrate.

[0009] Forming the rigid substrate may include forming a reinforcing wall around at least a portion of a periphery of the rigid substrate. Attaching the bonded rigid substrate, insulation layer, and noise barrier layer to a wall of a vehicle cab may include fitting the reinforcing wall of the rigid substrate tightly to the wall of the vehicle cab.

[0010] The method may also include making a slot in the rigid substrate, the slot being sized and shaped to fit over the mounting studs. The method may also include: cutting the bonded noise barrier layer and the insulation layer to fit over the rigid substrate; and making mounting holes extending through both the noise barrier layer and the insulation layer, wherein the mounting holes are aligned with the slots in the rigid substrate, and the mounting holes are sized and shaped to fit over the barrier mounting studs. Suspending the bonded rigid substrate, insulation layer, and noise barrier layer over the wall of the vehicle cab may include: placing the slots in the rigid substrate over the mounting studs. For each stud fastener, attaching the bonded rigid substrate, insulation layer, and noise barrier layer to the wall of the vehicle cab using the stud fastener may include: placing the stud fastener over the associated barrier mounting stud; passing the stud fastener through one of the mounting holes along the associated barrier mounting stud without pressing against the noise barrier layer or the insulation layer; and sandwiching the rigid substrate between the stud fastener and the wall of the vehicle cab.

[0011] The method may also include cutting the rigid substrate into separate left-hand and right-hand portions, cutting the bonded noise barrier layer and the isolation layer into separate left-hand and right-hand portions, bonding the second side of the left-hand portion of the isolation layer to the left-hand portion of the rigid substrate using an adhesive, and bonding the second side of the right-hand portion of the isolation layer to the right-hand portion of the rigid substrate using an adhesive. The method may also include suspending the left-hand portion of the bonded rigid substrate, isolation layer, and noise barrier layer from the wall using mounting studs; and suspending the right-hand portion of the bonded rigid substrate, isolation layer, and noise barrier layer from the wall using mounting studs. The method may also include attaching the bonded left-hand portion of the rigid substrate, isolation layer, and noise barrier layer to the wall using stud fasteners, and attaching the bonded right-hand portion of the rigid substrate, isolation layer, and noise barrier layer to the wall using stud fasteners.

[0012] The method may also include making slots in the left and right hand portions of the rigid substrate, the slots being sized and shaped to fit over the barrier mounting studs. The method may also include: making mounting holes in the left and right hand portions of the bonded noise barrier and insulation layers, wherein the mounting holes: extend through both the noise barrier and insulation layers; align with the slots in the rigid substrate; and are sized and shaped to fit over the barrier mounting studs. The method may also include: placing the slots in the left and right hand portions of the rigid substrate over the mounting studs; placing stud fasteners over the barrier mounting studs; passing the stud fasteners through the mounting holes along the barrier mounting studs without compressing the noise barrier or insulation layers; and clamping the rigid substrate between the stud fasteners and a wall of a vehicle cabin. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The above aspects of the present disclosure and the manner of obtaining these aspects will become more apparent, and the present disclosure itself will be better understood by referring to the following description of the embodiments of the present disclosure in conjunction with the accompanying drawings, in which:

[0014] Figure 1 An exemplary embodiment of a sound barrier assembly attached to a cab frame of a cab of a vehicle is shown;

[0015] Figure 2 showing a cross section of an exemplary embodiment of a sound barrier assembly attached to a rear wall of a cab frame; and

[0016] FIG. 3 shows a prior art sound barrier assembly attached to the rear wall of the cab frame.

[0017] Corresponding reference numerals are used to indicate corresponding parts throughout the several views. DETAILED DESCRIPTION

[0018] The embodiments of the present disclosure described below are not intended to be exhaustive or to limit the present disclosure to the precise forms described in the following detailed description. Rather, the embodiments are selected and described so that other persons skilled in the art can understand and appreciate the principles and practices of the present disclosure.

[0019] Figure 1 An exemplary embodiment of a sound barrier assembly 120 is shown attached to a cab frame 110 of a cab of a vehicle. The cab frame 110 includes a rear wall 112 extending between a center frame crossbar 114, a left side frame portion 115, a right side frame portion 116, and a base frame portion 118. One or more barrier mounting studs 130 and other mounting hardware (e.g., one or more harness attachments 134) may be located on the rear wall 112 of the cab frame 110.

[0020] Figure 2A cross section of an exemplary embodiment of a sound barrier assembly 120 attached to a rear wall 112 of a cab frame 110 is shown. The rear wall 112 is typically made of sheet metal and may include a damping coating 206, such as a liquid spray damped sound barrier (LASD) material, which is applied or sprayed onto the sheet metal and heat treated to bond to the sheet metal of the rear wall 112. The damping coating 206 may have voids 208 that are not sprayed or covered by the damping material so that the barrier mounting studs 130 and / or other components may be directly attached to the sheet metal of the rear wall 112. In the exemplary embodiment, the sound barrier assembly 120 includes a rigid substrate 210, an adhesive layer 220, an isolation layer 230, and a noise barrier layer 240. The rigid substrate 210 may include a reinforcing wall 212 around all or a portion of its periphery, wherein the reinforcing wall 212 may be molded during the formation of the rigid substrate 210. The rigid base plate 210 may also include a slot 216 for each barrier mounting stud 130 and harness attachment 134. The insulation layer 230 and the noise barrier layer 240 may include mounting holes 242 that extend through the insulation layer 230 and the noise barrier layer 240 and align with the slots 216 in the rigid base plate 210 for the barrier mounting studs 130. A stud fastener 250 may be configured to attach to each barrier mounting stud 130 to hold the sound barrier assembly 120 in place against the rear wall 112 of the cab frame 110.

[0021] The rigid substrate 210 can be made of a formable fibrous material, such as polyethylene terephthalate (PET), that is formed into a rigid shape that conforms to some or all of the contours of the rear wall 112 of the cab frame 110. The substrate 210 can be cut to provide clearance for adjacent components and can have a reinforcing wall 212 around the periphery of the substrate 210. The reinforcing wall 212 can be sized and shaped to fit tightly against one or more of the intermediate frame crossbar 114, the left side frame portion 115, the right side frame portion 116, and the base frame portion 118. The rigid substrate 210 provides a rigid surface for mounting the sound barrier assembly 120 against the rear wall 112. The rigid substrate 210 does not have to conform to every contour of the rear wall 112 of the cab frame 110, for example, Figure 2 A cavity 202 is shown formed between a rigid substrate 210 and the rear wall 112. After the substrate 210 is formed, a slot 216 may be cut or drilled in the substrate 210 for mounting the substrate 210 to the rear wall 112.

[0022] The noise barrier layer 240 is made of a sound material, such as mass loaded polyvinyl chloride (PVC). The isolation layer 230 is constructed to have one side bonded to the rigid substrate 210 and the other side bonded to the noise barrier layer 240. The isolation layer 230 can also be made of a material that helps absorb sound, such as polyurethane foam. The noise barrier layer 240 can be bonded to the isolation layer 230 to act as a single combined layer. The combined isolation layer 230 and the noise barrier layer 240 can then be cut to fit the shape to the rigid substrate 210. A flat pattern can be made that has a desired shape that fits the combined isolation layer 230 and the noise barrier layer 240 to the rigid substrate 210. The combined isolation layer 230 and the noise barrier layer 240 can be placed flat on the pattern and cut into a desired shape. The mounting hole 242 can be cut out in the combined isolation layer 230 and the noise barrier layer 240, while being flat and having a desired shape. The mounting holes 242 can be made large enough to provide clearance for the stud fasteners 250 used to mount the sound barrier assembly 120 to the rear wall 112 of the cab frame 110. The adhesive material forming the adhesive layer 220 can be applied to the rigid substrate 210 and / or to the exposed side of the insulation layer 230 on the combined insulation layer 230 and noise barrier layer 240. The flat, cut combined insulation layer 230 and noise barrier layer 240 can then be bonded to the rigid substrate 210 through the adhesive layer 220. The combined insulation layer 230 and noise barrier layer 240 conforms to the contours of the rigid substrate 210. When the insulation layer 230 and noise barrier layer 240 are bonded to the rigid substrate 210, the mounting holes 242 in the insulation layer 230 and noise barrier layer 240 are positioned to align with the slots 216 in the rigid substrate 210.

[0023] The barrier mounting studs 130 mounted on the rear wall 112 of the cab frame 110 are used to suspend the sound barrier assembly 120 on the rear wall 112. The barrier mounting studs 130 may be welded studs welded to the rear wall 112 of the cab frame 110. When the sound barrier assembly 120 is located at a desired position against the rear wall 112 of the cab frame 110, each slot 216 in the rigid base plate 210 is positioned to align with one of the mounting studs 130. The slots 216 are large enough to fit the mounting studs 130 through. The mounting holes 242 are preferably large enough to fit the mounting studs 130 and the stud fasteners 250 through. Through holes may also be formed through the rigid base plate 210, the insulation layer 230, and the noise barrier layer 240 to access other mounting points on the rear wall 112, such as access to the harness attachment 134. The sound barrier assembly 120 may be suspended on the barrier mounting studs 130 and be self-supporting when the stud fasteners 250 are installed. The stud fasteners 250 fasten the rigid base plate 210 to the mounting studs 130 and the rear wall 112 of the cab frame 110 .

[0024] The sound barrier assembly 120 may be composed of multiple parts, for example, the sound barrier assembly 120 may include a left sound barrier portion 122 and a right sound barrier portion 124 that meet along a seam 126. Each of the left sound barrier portion 122 and the right sound barrier portion 124 includes a left portion and a right portion of a rigid substrate 210, an adhesive layer 220, an isolation layer 230, and a noise barrier layer 240, respectively. The left and right portions of the rigid substrate 210 may be formed separately, or the entire rigid substrate 210 may be formed and then cut along the seam 126. The combined isolation layer 230 and the noise barrier layer 240 may be cut into the shape of the left and right portions of the rigid substrate 210, respectively, or may be cut into the shape of the entire rigid substrate 210 and then cut along the seam 126. Each of the left and right portions of the rigid substrate 210 includes two or more slots 216 positioned to align with the mounting studs 130 when the left and right portions 122, 124 of the sound barrier assembly 120 are positioned at desired locations against the rear wall 112 of the cab frame 110. The left portion of the combined insulation layer 230 and noise barrier layer 240 includes mounting holes 242 positioned to align with the slots 216 of the left portion of the rigid substrate 210 when the left portion of the combined insulation layer 230 and noise barrier layer 240 is bonded at desired locations on the left portion of the rigid substrate 210. Similarly, the right portion of the combined isolation layer 230 and noise barrier layer 240 includes a mounting hole 242 that is positioned to align with the groove 216 of the right portion of the rigid substrate 210 when the right portion of the combined isolation layer 230 and noise barrier layer 240 is bonded to a desired position on the right portion of the rigid substrate 210.

[0025] The stud fastener 250 may include a nut 252 and a washer 254. Each mounting stud 130 is threaded, and the nut 254 of each stud fastener 250 may be configured to be screwed onto the associated mounting stud 130 to attach the noise barrier assembly 120 to the rear wall 112 of the cab frame 110. The mounting holes 242 in the insulation layer 230 and the noise barrier layer 240 and the size of the stud fastener 250 are set so that the stud fastener 250 does not press against or squeeze the insulation layer 230 and the noise barrier layer 240. If the stud fastener 250 squeezes the noise barrier layer 240 or the insulation layer 230, the sound barrier assembly 120 is no longer in an isolated state because the insulation layer 230 is pressed against and is not allowed to move independently of the rigid substrate 210 and the cab frame 110. When the sound barrier assembly 120 is not separated from the rigid substrate 210, the effectiveness of the sound barrier assembly 120 is reduced.

[0026] When the stud fastener 250 is attached to the associated mounting stud 130, the rigid substrate 210 is sandwiched between the stud fastener 250 and the rear wall 112 on the associated mounting stud 130. When the stud fastener 250 includes a nut 252 and a washer 254, the washer 254 is disposed on the mounting stud 130 after the sound barrier assembly 120 and before the nut 252, such that when the stud fastener 250 is attached to the associated mounting stud 130, the washer 254 is sandwiched between the nut 252 and the rigid substrate 210 on the associated mounting stud 130. In embodiments where the slot 216 and the mounting hole 242 have a generally circular shape, the diameter of the mounting hole 242 is greater than the diameter of the slot 216, and the outer diameter of the stud fastener 250 is less than the diameter of the mounting hole 242 and greater than the diameter of the slot 216. In this case, when the specific stud fastener 250 is fastened to the specific barrier mounting stud 130 extending through the specific slot 216 and the specific mounting hole 242, the specific stud fastener 250 is fitted through the specific mounting hole 242 without being pressed against the noise barrier layer 240 and the isolation layer 230, and the rigid base plate 210 surrounding the specific slot 216 is sandwiched between the specific stud fastener 250 and the wall 112 of the cab frame 110.

[0027] The mounting holes 242 in the isolation layer 230 and the noise barrier layer 240 are larger than the slots 216 in the rigid substrate 210 and are slightly larger than the stud fasteners 250 so that the stud fasteners 250 do not press against or squeeze the isolation layer 230 and the noise barrier layer 240 when the stud fasteners 250 are attached to the associated mounting studs 130. Figure 2 As shown, when the stud fastener 250 is attached to the associated mounting stud 130 , the isolation layer 230 and the noise barrier layer 240 surround the stud fastener 250 rather than being sandwiched between the stud fastener 250 and the rigid substrate 210 .

[0028] In contrast, FIG3 shows an existing noise barrier assembly 300 attached to the rear wall 112 of the cab frame 110. The existing noise barrier assembly 300 includes a pressure-sensitive adhesive layer 310, a lofted fiber insulation layer 320, and a barrier layer 330. The lofted fiber insulation layer 320 and the barrier layer 330 are attached to each other using an adhesive. On the cab assembly line, a pressure-sensitive adhesive is applied to the exposed side of the rear wall 112 and / or the lofted fiber insulation layer 320 to form the adhesive layer 310. The combined fiber insulation layer 320 and the barrier layer 330 are then positioned on the rear wall 112, and pressure is applied, for example, by a manual roller to contact and attach the insulation layer 320 to the rear wall 112 using the pressure-sensitive adhesive of the adhesive layer 310. The weight of the combined fiber insulation layer 320 and noise barrier layer 330 causes the existing noise barrier assembly 300 to tend to slide downwardly away from the rear wall 112, and the fiber insulation layer 320 may be subject to shear forces due to the weight of the barrier layer 330. One or more retaining clips 350 may be attached to the cab frame 110 to try and help prevent the existing noise barrier assembly 300 from sliding downwardly away from the rear wall 112. The proximal end 352 of the retaining clip 350 is attached to the cab frame 110 using bolts 360, and the distal end 354 of the retaining clip 350 presses the fiber insulation layer 320 and barrier layer 330 against the rear wall 112 of the cab 110. Therefore, the installation of the existing noise barrier assembly 300 on the cab assembly line requires the application and utilization of a pressure-sensitive adhesive to mount the combined fiber insulation layer 320 and barrier layer 330 on the rear wall 112; and an additional bracket 350 needs to be installed to press against the existing noise barrier assembly 300 and hold the noise barrier assembly 300 in place during the cab assembly process.

[0029] The sound barrier assembly 120 disclosed herein provides a noise barrier in the sound path that is isolated from the rigid substrate 210 and mounted directly to the rear wall 112 of the cab frame 110. On the cab assembly line, the installation of the sound barrier is simplified because the sound barrier assembly 120 only needs to be suspended on the barrier mounting studs 130, and then the sound barrier assembly 120 will self-support in place when the stud fasteners 250 are attached. The rigid substrate 210 supports the isolation layer 230 and the noise barrier layer 240 in a relatively fixed position. The problems caused by using pressure sensitive adhesives to mount components on the cab assembly line are eliminated. Because the sound barrier assembly 120 is already mounted on and supported by the rigid substrate 210, and is already formed to conform to the contours of the cab frame 110, no additional brackets are required to hold the sound barrier assembly 120 in place during the cab assembly process.

[0030] Although the present disclosure has been shown and described in detail in the drawings and the foregoing description, such showing and description should be regarded as exemplary rather than restrictive, and it should be understood that the illustrative embodiments shown and described and all changes and modifications that fall within the spirit of the present disclosure are expected to be protected. It should be noted that alternative embodiments of the present disclosure may not include all of the features described, but may still benefit from at least some of the advantages of these features. An ordinary technician in the field can easily design an embodiment that combines one or more features of the present disclosure, and the embodiment falls within the spirit and scope of the present invention as defined by the appended claims.

Claims

1. A sound barrier assembly for attachment to a wall of a vehicle cab, the wall of the vehicle cab including a plurality of barrier mounting studs, the sound barrier assembly comprising: a rigid base plate comprising a plurality of slots, each of the plurality of slots being configured to fit over one of the plurality of barrier mounting studs; Noise barrier layer; an insulation layer having a first side and a second side, the first side being opposite the second side, and the first side of the insulation layer being bonded to the noise barrier layer; as well as an adhesive layer configured to bond the second side of the release layer to the rigid substrate; a plurality of stud fasteners, each of the plurality of stud fasteners being configured to fasten to one of the plurality of barrier mounting studs; wherein the isolation layer and the noise barrier layer are fixedly held in place by the rigid substrate, wherein the noise barrier layer and the isolation layer include a plurality of mounting holes extending through both the noise barrier layer and the isolation layer, each of the plurality of mounting holes being configured to align with one of the plurality of slots of the rigid substrate, and each of the plurality of mounting holes being configured to fit over one of the plurality of barrier mounting studs, The diameter of the mounting hole is larger than the diameter of the slot of the rigid substrate, and the outer diameter of the stud fastener is smaller than the diameter of the mounting hole and larger than the diameter of the slot, wherein, when a specific stud fastener among the plurality of stud fasteners is fastened to a specific barrier mounting stud among the plurality of barrier mounting studs extending through a specific slot among the plurality of slots and a specific mounting hole among the plurality of mounting holes, the specific stud fastener fits through the specific mounting hole without compressing the noise barrier layer or the isolation layer, and sandwiches the rigid substrate surrounding the specific slot between the specific stud fastener and the wall of the vehicle cab.

2. The sound barrier assembly according to claim 1, wherein: The rigid substrate is made of a formable fiber material.

3. The sound barrier assembly according to claim 2, wherein: The rigid base plate includes a reinforcing wall surrounding at least a portion of a periphery of the rigid base plate.

4. The sound barrier assembly according to claim 1, wherein: The noise barrier layer is flexible and made of mass loaded polyvinyl chloride (PVC), and the isolation layer is flexible and made of polyurethane foam.

5. The sound barrier assembly according to claim 1, wherein: Each of the plurality of stud fasteners includes a threaded bolt configured to be threadably attached to one of the plurality of barrier mounting studs.

6. The sound barrier assembly of claim 1, wherein: The rigid substrate comprises a left-hand portion and a right-hand portion, wherein the left-hand portion and the right-hand portion of the rigid substrate are separate; The noise barrier layer comprises a left-hand portion and a right-hand portion, wherein the left-hand portion and the right-hand portion of the noise barrier layer are separate; The isolation layer comprises a left-hand portion and a right-hand portion, wherein the left-hand portion and the right-hand portion of the isolation layer are separate; The adhesive layer comprises a left-hand portion and a right-hand portion, the left-hand portion and the right-hand portion of the adhesive layer being separate; and wherein a first side of a left-hand portion of the isolation layer is bonded to a left-hand portion of the noise barrier layer, and a first side of a right-hand portion of the isolation layer is bonded to a right-hand portion of the noise barrier layer; wherein the left-hand portion of the adhesive layer bonds the second side of the left-hand portion of the isolation layer to the left-hand portion of the rigid substrate, and the right-hand portion of the adhesive layer bonds the second side of the right-hand portion of the isolation layer to the right-hand portion of the rigid substrate; and Wherein, the left hand portions of the isolation layer and the noise barrier layer are fixedly held in place by the left hand portion of the rigid substrate, and the right hand portions of the isolation layer and the noise barrier layer are fixedly held in place by the right hand portion of the rigid substrate.

7. The sound barrier assembly according to claim 6, wherein: The vehicle cab wall includes a plurality of barrier mounting studs; and The rigid base plate includes a plurality of slots, at least two of the plurality of slots being located on a left hand portion of the rigid base plate, and at least two of the plurality of slots being located on a right hand portion of the rigid base plate; each of the plurality of slots being configured to fit over one of the plurality of barrier mounting studs; the noise barrier layer and the isolation layer comprising a plurality of mounting holes extending through both the noise barrier layer and the isolation layer, each of the plurality of mounting holes being configured to align with one of the plurality of slots of the rigid base plate, and each of the plurality of mounting holes being configured to fit over one of the plurality of barrier mounting studs; wherein the noise barrier layer and the left hand portion of the isolation layer are fixedly held in place by the left hand portion of the rigid substrate over the first group of two or more barrier mounting studs among the plurality of barrier mounting studs when two or more of the plurality of slots on the left hand portion of the rigid substrate engage over the first group of two or more barrier mounting studs among the plurality of barrier mounting studs; and Wherein, when two or more of the plurality of grooves located on the right-hand portion of the rigid substrate are engaged with a second group of two or more of the plurality of barrier mounting studs, the right-hand portions of the noise barrier layer and the isolation layer are fixedly held in place by the right-hand portion of the rigid substrate on the second group of two or more of the plurality of barrier mounting studs.

8. A method of constructing a sound barrier assembly for attachment to a wall of a vehicle cab, the wall of the vehicle cab including a plurality of barrier mounting studs, the method comprising: forming a rigid base plate including a plurality of slots having a first diameter, the rigid base plate being configured to mate to a wall of the vehicle cab, each of the plurality of slots being configured to mate over one of the plurality of barrier mounting studs; bonding a first side of the insulation layer to the noise barrier layer; forming a plurality of mounting holes having a plurality of second diameters extending through both the noise barrier layer and the isolation layer, wherein the second diameters are greater than the first diameters; applying an adhesive to at least one of the rigid substrate and a second side of the release layer, wherein the second side of the release layer is opposite the first side of the release layer; bonding the second side of the isolation layer to the rigid substrate using the adhesive such that the isolation layer and the noise barrier layer are fixedly held in place by the rigid substrate, wherein each of the plurality of mounting holes is aligned with one of the plurality of slots of the rigid substrate and each of the plurality of mounting holes is configured to fit over one of the plurality of barrier mounting studs, selecting a plurality of stud fasteners configured to fasten a plurality of mounting studs such that when a specific stud fastener of the plurality of stud fasteners is fastened to a specific barrier mounting stud of the plurality of barrier mounting studs extending through a specific slot of the plurality of slots and a specific mounting hole of the plurality of mounting holes, the specific stud fastener fits through the specific mounting hole without compressing the noise barrier layer or the insulation layer and sandwiches the rigid substrate surrounding the specific slot between the specific stud fastener and a wall of the vehicle cabin, The outer diameter of the stud fastener is smaller than the diameter of the mounting hole and larger than the diameter of the slot of the rigid substrate.

9. The method according to claim 8, wherein: The forming of the rigid substrate includes forming a reinforcing wall around at least a portion of a periphery of the rigid substrate.

10. The method according to claim 8, further comprising: The bonded noise barrier and insulation layers are cut to fit the rigid substrate.

11. A method of constructing and mounting a sound barrier assembly to a wall of a vehicle cab, wherein the wall includes a plurality of mounting studs, and the method comprising: forming a rigid base plate to fit to a wall of a cab of the vehicle; fabricating a plurality of slots in the rigid substrate, each of the plurality of slots being sized and shaped to fit over one of the plurality of barrier mounting studs; bonding a first side of the insulation layer to the noise barrier layer; manufacturing a plurality of mounting holes extending through both the noise barrier layer and the isolation layer, wherein each of the plurality of mounting holes is positioned to align with one of the plurality of slots in the rigid base plate, and each of the plurality of mounting holes is sized and shaped to fit over one of the plurality of barrier mounting studs; applying an adhesive to at least one of the rigid substrate and a second side of the release layer, wherein the second side of the release layer is opposite the first side of the release layer; bonding the second side of the release layer to the rigid substrate using the adhesive; suspending the bonded rigid substrate, the insulation layer, and the noise barrier layer from a wall of the vehicle cab by placing a plurality of slots in the rigid substrate over the plurality of mounting studs, the insulation layer and the noise barrier layer being fixedly held in place by the rigid substrate; as well as attaching the bonded rigid substrate, the insulation layer, and the noise barrier layer to a wall of the vehicle cab using a plurality of stud fasteners, wherein attaching the bonded rigid substrate, the insulation layer, and the noise barrier layer to the wall of the vehicle cab using a plurality of stud fasteners comprises: for each of the plurality of stud fasteners: disposing the stud fastener on an associated barrier mounting stud of the plurality of barrier mounting studs; passing the stud fastener through one of the mounting holes along the associated barrier mounting stud without compressing the noise barrier layer or the insulation layer; and sandwiching the rigid substrate between the stud fastener and a wall of the vehicle cab, The diameter of the mounting hole is larger than the diameter of the slot of the rigid substrate, and the outer diameter of the stud fastener is smaller than the diameter of the mounting hole and larger than the diameter of the slot.

12. The method according to claim 11, wherein: The forming of the rigid substrate includes forming a reinforcing wall around at least a portion of a periphery of the rigid substrate; and Wherein attaching the bonded rigid substrate, the insulating layer, and the noise barrier layer to the wall of the vehicle cab includes: tightly fitting the reinforcing wall of the rigid substrate to the wall of the vehicle cab.

13. The method according to claim 11, further comprising: The bonded noise barrier layer and the insulating layer are cut to fit the rigid substrate.

14. The method according to claim 11, further comprising: cutting the rigid substrate into two separate portions, a left-hand portion of the rigid substrate and a right-hand portion of the rigid substrate; cutting the bonded noise barrier layer and the insulating layer into two separate parts, a left-hand part of the bonded noise barrier layer and the insulating layer and a right-hand part of the bonded noise barrier layer and the insulating layer; Wherein, applying the adhesive to at least one of the rigid substrate and the second side of the isolation layer comprises: applying the adhesive to at least one of the left-hand portion of the rigid substrate and the second side of the left-hand portion of the isolation layer, and applying the adhesive to at least one of the right-hand portion of the rigid substrate and the second side of the right-hand portion of the isolation layer; wherein bonding the second side of the isolation layer to the rigid substrate using the adhesive comprises: bonding the second side of the left-hand portion of the isolation layer to the left-hand portion of the rigid substrate using the adhesive, and bonding the second side of the right-hand portion of the isolation layer to the right-hand portion of the rigid substrate using the adhesive; and wherein suspending the bonded rigid substrate, the isolation layer, and the noise barrier layer on the wall of the vehicle cab using the plurality of mounting studs comprises: suspending a left-hand portion of the bonded rigid substrate, the isolation layer, and the noise barrier layer on the wall using the plurality of mounting studs, and suspending a right-hand portion of the bonded rigid substrate, the isolation layer, and the noise barrier layer on the wall using the plurality of mounting studs; and Wherein, using multiple stud fasteners to attach the bonded rigid substrate, the isolation layer and the noise barrier layer to the wall of the vehicle cab includes: using the multiple stud fasteners to attach the left-hand portion of the bonded rigid substrate, the isolation layer and the noise barrier layer to the wall, and using the multiple stud fasteners to attach the right-hand portion of the bonded rigid substrate, the isolation layer and the noise barrier layer to the wall.

15. The method according to claim 14, further comprising: fabricating a first plurality of grooves in a left-hand portion of the rigid substrate and a second plurality of grooves in a right-hand portion of the rigid substrate; each slot in the first plurality of slots and the second plurality of slots is sized and shaped to fit over one of the plurality of barrier mounting studs; making a first plurality of mounting holes in a left hand portion of the bonded noise barrier layer and the insulating layer, and making a second plurality of mounting holes in a right hand portion of the bonded noise barrier layer and the insulating layer, wherein each mounting hole of the first plurality of mounting holes and the second plurality of mounting holes extends through both the noise barrier layer and the insulating layer, aligns with each of the first plurality of slots and the second plurality of slots, respectively, and is sized and shaped to fit over one of the plurality of barrier mounting studs; and wherein suspending the bonded rigid substrate, the isolation layer, and the noise barrier layer on the wall of the vehicle cab comprises: arranging the first plurality of slots in the left-hand portion of the rigid substrate on a first plurality of mounting studs, and arranging the second plurality of slots in the right-hand portion of the rigid substrate on a second plurality of mounting studs; and wherein attaching the bonded rigid substrate, the insulation layer, and the noise barrier layer to the wall of the vehicle cab using a plurality of stud fasteners comprises: for each of the plurality of stud fasteners: disposing the stud fastener on an associated barrier mounting stud of the plurality of barrier mounting studs; Passing the stud fastener along the associated barrier mounting stud through one of the first and second sets of mounting holes without compressing the noise barrier layer or the insulation layer; and The rigid substrate is sandwiched between the stud fastener and a wall of the vehicle cab.

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