Stamping bubble sheet with damping enhancement

Abstract

The cover plate includes a shaped first metal plate having a plurality of spaced apart protrusions formed therein. A plurality of sound insulation pads is applied to the shaped first metal sheet. The second metal plate is fixed to the shaped first metal plate.

Description

Technical Field

[0001] The present disclosure relates to a cover member formed as a formed bubble sheet with enhanced damping. Background Art

[0002] The information provided in this section is for the purpose of generally introducing the background of the present disclosure. To the extent described in this section, the work of the currently named inventors and aspects that may not constitute prior art descriptions at the time of filing are neither expressly nor implicitly admitted to be prior art against the present disclosure.

[0003] Many vehicle components and industrial systems emit vibrations that are undesirable for vehicle occupants or industrial system operators. Some systems are installed in compartments that can be designed to contain and / or dampen the propagation of unwanted vibrations and noise. Summary of the Invention

[0004] The present disclosure relates to a cover or panel that includes a formed first sheet having a plurality of spaced-apart protrusions formed therein. A plurality of sound insulation pads are applied to the formed first sheet. A second sheet is fixed to the formed first sheet.

[0005] According to another aspect, the plurality of sound insulation pads include patches adhered to a stamped first metal sheet.

[0006] According to another aspect, the plurality of sound insulation pads are liquid-applied sound insulation materials.

[0007] According to another aspect, each of the plurality of sound insulation pads is applied between adjacent protrusions.

[0008] According to another aspect, the plurality of sound insulation pads are compressed by the second sheet.

[0009] According to another aspect, the first sheet and the second sheet are made of metal and welded to each other.

[0010] According to another aspect, the second sheet is adhered to the first sheet.

[0011] According to another aspect, the formed first sheet has an outer peripheral edge raised to the same height as the plurality of spaced-apart protrusions.

[0012] According to another aspect, the formed first sheet and the second sheet are made of one of aluminum, magnesium, titanium, polymer composite, carbon fiber composite, and steel.

[0013] According to another aspect, the second metal sheet is flat.

[0014] The present invention provides the following technical solutions:

[0015] 1. A cover plate, comprising:

[0016] A formed first sheet having a plurality of spaced-apart protrusions formed therein;

[0017] A plurality of sound insulation pads applied to the formed first sheet; and

[0018] A second sheet fixed to the formed first sheet.

[0019] 2. The cover plate according to claim 1, wherein the plurality of sound insulation pads include a plurality of patches adhered to the formed first sheet.

[0020] 3. The cover plate according to claim 1, wherein the plurality of sound insulation pads are a liquid-applied sound insulation material.

[0021] 4. The cover plate according to claim 1, wherein each of the plurality of sound insulation pads is applied between two adjacent protrusions.

[0022] 5. The cover plate according to claim 1, wherein the plurality of sound insulation pads are compressed by the second sheet.

[0023] 6. The cover plate according to claim 1, wherein the first sheet and the second sheet are made of metal and are welded together.

[0024] 7. The cover plate according to claim 1, wherein the second sheet is adhered to the formed first sheet.

[0025] 8. The cover plate according to claim 1, wherein the formed first sheet has an outer peripheral edge raised to the same height as the plurality of spaced-apart protrusions.

[0026] 9. The cover plate according to claim 1, wherein the formed first sheet and the second sheet are made of one of aluminum, magnesium, titanium, polymer composite material, carbon fiber composite material, and steel.

[0027] 10. The cover plate according to claim 1, wherein the second sheet is flat.

[0028] 11. A method of manufacturing a cover plate, comprising:

[0029] Stamping a first flat metal plate panel to include a plurality of spaced-apart protrusions and a raised outer peripheral surface formed therein;

[0030] Forming a second metal plate panel;

[0031] Applying a plurality of sound insulation pads to one of the stamped first metal plate panel and the second metal plate panel; and

[0032] Fixing the second metal plate panel to the stamped first metal plate panel.

[0033] 12. The method according to embodiment 11, wherein the plurality of sound insulation pads include patches adhered to the stamped first metal plate panel.

[0034] 13. The method according to embodiment 11, wherein the plurality of sound insulation pads are liquid-applied sound insulation materials.

[0035] 14. The method according to embodiment 11, wherein each of the plurality of sound insulation pads is applied between adjacent protrusions.

[0036] 15. The method according to embodiment 11, wherein the plurality of sound insulation pads are compressed by the second metal plate panel.

[0037] 16. The method according to embodiment 11, wherein the second metal plate panel is welded to the stamped first metal plate panel.

[0038] 17. The method according to embodiment 11, wherein the second metal plate panel is adhered to the stamped first metal plate panel.

[0039] 18. The method according to embodiment 11, wherein the outer peripheral surface of the stamped first metal plate panel rises to the same height as the plurality of spaced-apart protrusions.

[0040] 19. The method according to embodiment 11, wherein the stamped first metal plate panel and the second metal plate panel are made of one of aluminum, magnesium, titanium, and steel.

[0041] 20. The method according to embodiment 11, wherein the second metal plate panel is flat and is fixed to the raised outer peripheral surface of the first stamped metal plate panel.

[0042] Additional application areas of the present disclosure will become apparent from the detailed description, claims, and drawings. The detailed description and specific examples are for illustrative purposes only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The present disclosure will be more fully understood from the detailed description and the drawings, wherein:

[0044] Figure 1 is a plan view of a formed first sheet panel of a cover assembly according to the principles of the present disclosure;

[0045] Figure 2 is a plan view of a second sheet panel of a cover assembly according to the principles of the present disclosure;

[0046] Figure 3 is a plan view of a formed first sheet panel according to the principles of the present disclosure, the first sheet panel having a damping pad applied thereto; and

[0047] Figure 4 A cross-sectional view of a lid assembly in accordance with the principles of the present disclosure.

[0048] In the figures, reference numerals may be reused to identify similar and / or identical elements. DETAILED DESCRIPTION

[0049] Reference Figure 1 , there is shown a formed first sheet panel 10 of a lid assembly. The formed first sheet panel 10 may be made of aluminum, magnesium, titanium, polymer composite, carbon fiber composite, or steel. The stamped first metal sheet panel 10 may be stamped from a flat sheet to include a plurality of protrusions 12. As shown, the protrusions 12 may be circular with conical sidewalls 12a, but other shapes may be used, including square, oval, rectangular, elongate, letters, logos, and other shapes. The protrusions 12 may provide additional strength to the formed first sheet panel 10. The protrusions 12 may be formed by stamping or molding. The outer peripheral edge 14 of the stamped first metal sheet panel 10 may also be raised to a height equal to or greater than the height of the pits 12. The outer peripheral edge may include inclined sidewalls 14a that extend upward from the remainder of the panel. The outer peripheral edge 14 of the stamped first metal sheet panel 10 may include a plurality of mounting holes 16 formed therein.

[0050] As Figure 2 shown, the second sheet panel 20 has an outer peripheral shape that is the same as the outer peripheral shape of the formed first sheet panel 10. The second sheet panel 20 may be made of aluminum, magnesium, titanium, polymer composite, carbon fiber composite, or steel. Although the second sheet panel 20 is shown as flat, the second sheet panel 20 may also include protrusions formed therein. As needed, the protrusions may be circular, square, oval, rectangular, letters, logos, and other shapes. The protrusions may provide increased strength to the second sheet panel 20. The second sheet panel also includes a plurality of mounting holes 22 that are aligned with the mounting holes 16 of the stamped first metal sheet panel 10.

[0051] Reference Figure 3 , the formed first sheet panel 10 shown includes a plurality of damping pads 30 applied to the formed sheet panel 10 between the protrusions 12. The damping pads 30 may be made of metal, silicone, rubber, foam, or other materials. The damping pads 30 may be adhered to the formed first sheet panel 10 in the pattern shown or an alternative pattern. The damping pads 30 may also be a liquid-applied sound insulating material, where the pad is applied as a liquid that cures when dried or cured.

[0052] The second panel 20 is fixed to the formed first panel 10 around the outer peripheral edge 14 to form a cover assembly 40. The second panel 20 can be laser welded, adhered, or otherwise fixed to the formed first panel 10. The damping pad 30 can be higher than the raised outer peripheral edge 14 of the formed first panel 10 and is made of a compressible material that can be compressed by the second panel 20. Alternatively, the damping pad 30 can be shorter than the raised outer peripheral edge 14 of the formed first panel 10 so that the damping pad 30 does not contact the second panel 20. The material, size, weight, and position of the damping pad 30 can be selected to isolate the vibration and noise frequencies known to emanate from the system for which the lid is designed. The damping pad 30 can also alternatively or additionally be applied to the second panel 20.

[0053] The cover assembly 40 can be applied to the housings of various vehicle components and industrial machines to isolate the vibration and noise emanating therefrom. Due to the increased stiffness / strength of the preformed sheet, the cover assembly 40 provides a lightweight structure with reduced mass. The formed protrusion design accommodates the application of damping material inside the panel. Tests conducted on the composite structure have shown a significant improvement in damping and NVH performance and higher stiffness. The formed pattern can be customized to include an artistic design to enhance the attractiveness of the panel. The protrusion 12 strengthens the cover assembly 40, and the damping pad 30 attenuates the vibration and noise frequencies generated by the vehicle components.

[0054] The foregoing description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure can be implemented in a variety of forms. Thus, while the disclosure includes specific examples, the true scope of the disclosure should not be so limited since other modifications will become apparent after study of the drawings, the specification, and the appended claims. It should be understood that one or more steps within a method can be executed in a different order (or concurrently) without altering the principles of the disclosure. Further, although each embodiment above is described as having certain features, any one or more of those features described with respect to any embodiment of the disclosure can be implemented in and / or combined with the features of any other embodiment, even if the combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and permutations of one or more of the embodiments with each other are still within the scope of the disclosure.

[0055] Various terms, including "connected", "joined", "coupled", "adjacent", "next to", "on", "above", "below", and "disposed", are used to describe the spatial and functional relationships between various elements (e.g., between modules, circuit elements, semiconductor layers, etc.). Unless explicitly described as "direct", when the relationship between a first element and a second element is described in the foregoing disclosure, the relationship can be a direct relationship in which no other intermediate element exists between the first element and the second element, but can also be an indirect relationship in which one or more intermediate elements (spatially or functionally) exist between the first element and the second element. As used herein, the phrase "at least one of A, B, and C" should be interpreted to mean a logic (A or B or C) using non-exclusive logic "or", and should not be interpreted to mean "at least one of A, at least one of B, and at least one of C".

Claims

1. A cover plate, comprising: a shaped first sheet having a plurality of spaced-apart projections formed therein; a plurality of sound insulation mats applied to the formed first sheet; and A second sheet is secured to the formed first sheet.

2. The cover plate according to claim 1, wherein: The plurality of sound insulation pads include a plurality of patches adhered to a formed first sheet material.

3. The cover plate of claim 1, wherein the plurality of sound insulation pads are liquid applied sound insulation materials. The cover plate according to claim 1 , wherein each of the plurality of sound insulation pads is applied between two adjacent protrusions. The cover panel of claim 1 , wherein the plurality of sound insulation pads are compressed by the second sheet material.

6. The cover plate according to claim 1, wherein: The first plate and the second plate are made of metal and are welded together.

7. The cover plate according to claim 1, wherein: The second sheet is adhered to the formed first sheet.

8. The cover plate according to claim 1, wherein: The formed first sheet has a peripheral edge that is elevated at the same height as the plurality of spaced apart projections.

9. The cover plate according to claim 1, wherein: The shaped first and second sheets are made of one of aluminum, magnesium, titanium, a polymer composite, a carbon fiber composite, and steel.

10. The cover plate according to claim 1, wherein: The second sheet is flat.

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