Acoustically effective multicomponent system for a motor vehicle and method for producing an acoustically effective multicomponent system for a motor vehicle
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- CARCOUSTICS TECHCONSULT GMBH
- Filing Date
- 2025-12-22
- Publication Date
- 2026-07-02
Smart Images
Figure EP2025088773_02072026_PF_FP_ABST
Abstract
Description
[0001] CCT-02 / 24-PCT 1 22.12.2025
[0002] Acoustically effective multi-component system for a motor vehicle and method for manufacturing an acoustically effective multi-component system for a motor vehicle
[0003] The invention relates to an acoustically effective multi-component system for a motor vehicle and a method for manufacturing an acoustically effective multi-component system for a motor vehicle.
[0004] Modern motor vehicles incorporate a variety of acoustically effective multi-component systems, consisting of at least two layers that are permanently and inseparably bonded together. The purpose of such acoustically effective multi-component systems is to minimize noise pollution for the occupants of the vehicle. Examples include the body bulkhead (also known as the firewall), wheel arch linings, engine encapsulation, and floor lining. Particularly at high speeds, significant noise is generated by tire noise and the airflow around the vehicle. Furthermore, the vehicle's engine contributes to additional noise emissions.
[0005] Modern vehicles must be manufactured, operated, and recycled in a resource-efficient manner. Therefore, it is not only important to optimize the manufacturing process accordingly, but also crucial that the vehicle can be recycled as completely as possible after reaching the end of its service life, so that a large amount of material is returned to the cycle. During the manufacturing of individual vehicle components, it is also important that components deemed defective (not satisfactory), for example, during end-of-line testing, can be fully recycled. To achieve a high recycling rate, the individual vehicle components must be sorted according to their material types. If this is not possible, as is the case with multi-component systems where no single-material component exists, recycling is difficult or even impossible.CCT-02 / 24-PCT 2 22.12.2025.
[0006] Against the background described above, it is an object of the present invention to provide an acoustically effective multi-component system for a motor vehicle that can be recycled to a high degree. Furthermore, it is an object of the present invention to provide a method for manufacturing such an acoustically effective multi-component system for a motor vehicle.
[0007] The problem is solved by a multi-component system with the features of claim 1, and a method for producing a multi-component system with the features of claim 19.
[0008] The dependent claims relate to preferred embodiments or further developments of the present invention, the respective features of which may be freely combined with one another, within the limits of what is technically reasonable, possibly even across the category boundaries of the different claims.
[0009] Accordingly, an acoustically effective multi-component system for a motor vehicle is proposed, comprising a first layer having at least one recess, and a second layer comprising a foam material which projects at least partially into the recess to secure the second layer to the first layer by positive locking. The first and second layers comprise materials that are incompatible with each other for recycling purposes, and the first layer forms a heavy layer acting as a mass, while the second layer forms an absorber layer acting as a spring. According to the invention, the first and second layers can be separated from each other essentially without damage.
[0010] Thanks to the solution according to the invention, an acoustically effective multi-component system can be provided in which the first and second layers, made of materials incompatible with recycling, can be easily and quickly physically separated before being sent for recycling, thus enabling recycling in the first place. Because the foam protrudes into the recess of the first layer, holding the first and second layers together, this connection can be broken in the event of a pending recycling operation, allowing the first and second layers to be sent for independent recycling. In other words, the solution according to the invention ensures that the two layers can be made of any material. CCT-02 / 24-PCT 3 22.12.2025
[0011] without compromising later recycling. This allows for greater design freedom and eliminates restrictions on the choice of materials.
[0012] Materials incompatible with recycling technology are a combination or composition of materials that, due to their physical, chemical, or structural properties, cannot be efficiently recycled together. This incompatibility can be due to, for example, different melting points, reactivity, lack of separability, or negative interactions during the reprocessing process. In particular, if such materials remain in the recycling stream, they can contaminate the recycled product or hinder the recycling process as a whole.
[0013] The first layer and the second layer are understood to be two independent elements that are combined into a multi-component system by the foam protruding into the recess.
[0014] The acoustically effective multi-component system is a spring-mass system in which the absorber layer (second layer) acts as the spring and the heavy layer (first layer) forms the mass of the spring-mass system. The absorber layer serves to dampen sound, while the heavy layer is designed for sound insulation.
[0015] Sound attenuation reduces the volume or intensity of noise, while sound insulation aims to block or minimize the transmission of sound waves from one place to another. Preferably, the heavy layer thus forms an acoustic barrier.
[0016] In a preferred embodiment, the absorber layer is attached to or facing a vibrating surface of the vehicle. The sound emanating from the vibrating surface thus first enters the absorber layer and is dampened there. The remaining sound that has penetrated the absorber layer is prevented or almost completely prevented from propagating by the heavy layer, i.e., dampened. CCT-02 / 24-PCT 4 22.12.2025
[0017] Alternatively, the heavy layer can be attached to or facing the vibrating surface of the vehicle. In this case, the sound first encounters the heavy layer, where its propagation is halted or almost completely stopped, thus attenuating it. Any sound that manages to pass through the heavy layer despite this attenuation is then dampened by the absorber layer.
[0018] A recess within the meaning of the invention is to be understood as a depression, cavity, or opening within the first layer that enables a positive-locking, force-locking, or material-locking connection with the second layer. The recess can have a specific geometry, which is particularly designed to receive a portion of the second layer, which comprises a foam. The second layer projects at least partially into the recess, thereby fixing the second layer to the first layer. This fixing can be facilitated by the shape of the recess, by the elastic behavior of the foam, or by a combination of both. The recess is preferably designed to ensure stable and precise positioning of the second layer without impairing its functionality or material properties.
[0019] For the purposes of these inventions, motor vehicles are understood to be land vehicles that are moved by mechanical power and are not bound to railway tracks. These include, in particular, passenger cars, trucks, and buses.
[0020] In an advantageous further development, the second layer is foamed onto the first layer. The second layer, which comprises a foam, is foamed onto the first layer, with the recess in the first layer playing a crucial role in the bond between the two layers. During the foaming process, the foam penetrates the recess, creating a strong and permanent bond between the first and second layers. Foaming offers the advantage that the second layer is applied directly to the first, ensuring efficient manufacturing and a simple, high-precision, and tolerance-insensitive bond between the two layers. The recess serves as a receiving space for the still-liquid expanding foam. In other words, the CCT-02 / 24-PCT 5 22.12.2025
[0021] Recess is a cavity into which the foam enters when it is foamed onto the first layer to form the second layer.
[0022] It has been shown that, with suitable procedures, a material-bonded connection between the two layers is achieved when the second layer is foamed onto the first layer.
[0023] The resulting adhesion of the second layer to the first layer, and in particular the force required to separate the two layers, can be specifically adjusted, among other things, by treating the surface of the first layer to which the second layer is foamed (hereinafter also referred to as the contact surface). For example, the adhesion can be increased by pretreating the contact surface using methods known in the art, such as flame treatment.
[0024] Adhesion can also be selectively reduced by applying a release agent to the contact surface. This can be achieved, for example, by cutting a tool used to produce the first layer, at least in the area of the contact surface, i.e., by applying a release agent there. The resulting adhesion of the second layer, which is foamed onto the first layer, is influenced, among other things, by the choice of release agent and the amount applied. By appropriately adjusting these parameters, the resulting adhesion can be selectively brought to a desired level.
[0025] In addition, the material of the first layer, the material of the second layer, and the process parameters during foaming may also influence the resulting adhesion.
[0026] In a preferred embodiment of the invention, the second layer is connected both materially and form-fitted.
[0027] The material-bonded connection supports a bond between the two layers, particularly at the edges, which offers advantages in handling the corresponding components during further processing, e.g., the final assembly of a vehicle. Furthermore, this results in visual advantages. Finally, CCT-02 / 24-PCT 6 22.12.2025
[0028] the material bond between the two layers prevents the penetration of foreign bodies or liquids such as water or oil between the first and second layers at the edges.
[0029] In a further preferred embodiment, the first and second layers are bonded together at their edges, preferably circumferentially. This is also advantageous for a component that comprises, is manufactured from, or is based on a multi-component system according to the invention. Depending on the component to be manufactured, a full-surface bond between both layers is unnecessary if a bond between the edges of both layers is present. Such a multi-component system or component according to the invention therefore has at least a first region in which a strong bond exists, and a second region in which a weak or no bond exists. In a preferred embodiment, the first region is arranged at the edge and encloses the second region, preferably substantially completely.All these embodiments are encompassed by the present invention.
[0030] To separate the material bond between the first and second layers, a force must be applied, which in the context of the present invention is referred to as the separation force. Such a separation force can be characterized by the force required to separate the layers of a test strip consisting of a strip of the material of the first layer, which is materially bonded to a strip of the material of the second layer.
[0031] In a preferred embodiment, the separating force required to separate the material bond between the first and second layers is no greater than 20 Newtons, preferably no greater than 10 Newtons, for a test strip 10 millimeters wide. It is particularly preferably between 2 and 8 Newtons, and most preferably between 5 and 7 Newtons. Particularly in the case of an edge-side material bond, such a separating force ensures that, for example, during the transport or assembly of a component comprising, manufactured from, or based on a multi-component system according to the invention, no edge separation of the first and second layers occurs. CCT-02 / 24-PCT 7 22.12.2025
[0032] In the context of the present invention, an intensive bond is defined as a bond that requires a separation force of at least 2 Newtons. If the separation force is lower, the bond is referred to as weak.
[0033] The positive-locking connection between the first and second layers according to the invention is achieved via at least one positive-locking element that includes the recess provided in the first layer according to the invention. A separating force must also be applied to release such a positive-locking element, e.g., manually by a worker.
[0034] In a preferred embodiment, the at least one positive locking element is designed such that the force required to release the positive locking element is not greater than 200 Newtons, preferably not greater than 150 Newtons, and particularly preferably not greater than 100 Newtons.
[0035] In a further preferred embodiment, a design of the positive locking element is preferred in which the force required to release the positive locking element is not less than 20 Newtons, preferably not less than 30 Newtons and particularly preferably not less than 40 Newtons.
[0036] According to the invention, the second layer is detachably attached to the first layer. This means that the first and second layers can be separated from each other without damage. This, in turn, allows for the separation of the two layers without increased effort, enabling them to be sent to suitable recycling processes.
[0037] In the context of the invention, "effort" refers in particular to the force exerted, which has already been discussed in more detail above. In particular, a preferred range for the separation force has been specified, both for the positive-locking connection according to the invention, which in the context of the present invention is also referred to as a retaining structure or positive-locking element, and for the optional additional material-bonded connection between the two layers. In principle, however, the force required to separate the two layers is preferably greater than the weight of the layer with the greater mass. This applies in particular to the optional material-bonded connection required to separate the two layers.
[0038] Connection. This effectively prevents one layer from unintentionally separating from the other, for example during transport of the acoustically effective multi-component system.
[0039] Preferably, the releasable connection is designed such that no or only minimal residues (adhesions) of one layer remain on the other layer, which is considered non-destructive within the meaning of the present invention. Minimal residues are understood to be less than 0.1 percent by weight of the respective other layer, particularly preferably less than 0.5 parts per thousand by weight.
[0040] According to the invention, the second layer is positively locked to the first layer. Because the first and second layers are positively locked to each other, they can be connected particularly reliably. This positive locking can be released in the event of a recycling operation, so that the first and second layers can each be subjected to an independent recycling operation.
[0041] In a preferred embodiment, the recess is a through-hole. The recess is designed to extend completely through the first layer. This design allows the foam to penetrate the through-hole during the foaming process and spread out on the outlet side of the through-hole. This creates additional mechanical anchoring. Furthermore, a through-hole offers the advantage that no unwanted compression pressure arises during foaming, as would be the case with a blind hole. This prevents compressed air from hindering the foam's expansion during foaming and / or from penetrating the still-liquid foam and adversely affecting its structure.
[0042] In an advantageous embodiment, the recess may comprise at least a first section and a second section, wherein the first section has a smaller distance to the second layer than the second section and the second section has a greater radial extent than the first section. The recess may thus preferably be CCT-02 / 24-PCT 9 22.12.2025
[0043] be designed as a stepped recess that preferably extends through the first layer.
[0044] The first layer has a first side to which the second layer is foamed. This first side can also be referred to as the front. The first layer also has a second side facing away from the first side, which is also referred to as the back. The stepped recess comprises the first and second sections, with the first section positioned closer to the first side than the second section. Since the first section has a smaller radial extent than the second section, a positive-locking connection between the first and second layers can be provided in a simple and secure manner. In particular, the radial extent of the first and second sections can be understood as their diameters. During the foaming process, the foam initially penetrates the smaller first section and passes through it.After the liquid foam leaves the first section, it enters the larger second section, which forms an undercut. Once the foam has solidified, it is positively locked into the recess, preventing it from being pulled out, thus securely fixing the second layer to the first.
[0045] In a preferred embodiment, the first and second sections may have the same radial extent, i.e., the same diameter. However, to ensure a positive-locking connection despite the identical diameter, the sections are not arranged coaxially. The longitudinal axes of the sections are therefore spaced apart.
[0046] In another advantageous embodiment, the second section may be designed as channels extending radially outwards.
[0047] Alternatively or additionally, a retaining structure can be provided in the recess, which can be designed, for example, as ribs or webs. This offers the advantage that the foam can flow around these during the foaming process and thus form a positive fit after solidification. CCT-02 / 24-PCT 10 22.12.2025
[0048] In a preferred embodiment, the foam may extend into or through the recess, forming a retaining projection. The foam either extends into the recess or extends into and through the recess. The second layer thus has a section that extends into the recess, forming a kind of limb. At the end of this limb, a free end forms, which constitutes the head section of the retaining projection. Its geometric dimensions are such that it does not fit through the narrowest section of the recess, so that the second layer is positively locked to the first layer. This head section of the retaining projection can be located within the recess itself, for example, in the second section of the recess.Alternatively or additionally, this can protrude behind the first layer, so that the head section of the retaining projection comes into contact with the back of the first layer and, like a barb, prevents the first and second layers from separating unintentionally.
[0049] Preferably, the retaining projection is mushroom-shaped or hook-shaped. A mushroom-shaped retaining projection has a wider head (head section) that lies over a narrower shaft (shaft section) which is connected to the flat section of the second layer. The head extends radially beyond the circumference of the shaft section and forms a surface that projects beyond the shaft section and terminates in a rounded or flat curvature. This shape allows the mushroom-shaped projection to snap into or be held in place by the first layer, as the head prevents it from slipping out of the recess.
[0050] A hook-shaped projection is angled in one or more sections, preferably forming a claw-like shape. A design resembling a Christmas tree is also conceivable and possible. Such a shape allows for a secure yet detachable connection between the first and second layers.
[0051] It may be provided that the retaining projection does not extend beyond the back side of the first layer. The back side is the surface of the first layer facing away from the second layer. This preferred development offers the advantage, CCT-02 / 24-PCT 11 22.12.2025
[0052] that in the case of attaching the first layer to a vibrating surface, there is no direct transmission of vibrations to the second layer via the extremities, since the retaining projection is not in contact with the vibrating surface, i.e., it is contactless.
[0053] In an advantageous further development, a third layer may be provided, arranged on the side of the first layer facing away from the second layer, and designed as a textile element. This facing side corresponds to the reverse side of the first layer. The textile element may preferably be woven, braided, knotted, felted, or nonwoven. The fibers of the textile element preferably comprise natural fibers and / or synthetic fibers and / or mineral fibers. Thanks to the third layer being designed as a textile element, simple shaping combined with good acoustic absorption properties can be achieved.
[0054] In a preferred embodiment, the foam of the second layer penetrates the textile element. During the foaming process to form the second layer, the foam passes through the recess in the first layer and penetrates the textile structure of the third layer. The foam at least partially encloses some of the fibers of the third layer and becomes firmly embedded within them as it solidifies. The fibers enclosed by the foam permeate it like reinforcing elements. This allows for a secure yet also releasable connection between the layers.
[0055] In an advantageous further development, the foam can be bonded to the textile element in such a way that the first layer is held between the second and third layers. The first layer is thus sandwiched between the second and third layers and penetrated by the end of the second layer, which is connected to the third layer at its free end. The foam has thus penetrated the textile structure of the third layer. In this way, an effective bond can be established.
[0056] In an advantageous further development, the third layer is a nonwoven fabric. The textile element is thus designed as a nonwoven. A nonwoven is a textile structure consisting of a multitude of textile fibers bonded together by mechanical, thermal, and / or chemical bonding processes, without a CCT-02 / 24-PCT 12 22.12.2025
[0057] Textile weaving or interlacing of the fibers takes place. The nonwoven fabric is preferably formed from single-component or multi-component fibers. Multi-component fibers consist of two or more different materials combined with each other.
[0058] Preferably, the nonwoven fabric comprises or is made from polyethylene terephthalate. It has been shown that a nonwoven fabric made of polyethylene terephthalate is particularly easy and cost-effective to produce and is highly effective with regard to acoustic properties. Thanks to the third layer being a nonwoven fabric, its production is simple, while simultaneously providing excellent acoustic properties.
[0059] Preferably, the nonwoven fabric contains two-component fibers made of polyethylene terephthalate (PET). Two-component fibers are multi-component fibers. They consist of exactly two different PET materials and are also known as bicomponent fibers.
[0060] The multi-component fibers or the two-component fibers particularly preferably have a low-melting PET and a high-melting PET, i.e., the melting temperature of the low-melting PET is lower than the melting temperature of the high-melting PET.
[0061] In an advantageous further development, the third layer may be produced by a direct fiber blowing process and / or have fibers that are at least partially vertically oriented. In the direct fiber blowing process, the fibers, which may include, for example, synthetic, mineral, or natural fibers, are introduced into an airflow and blown directly into a mold. The airflow distributes and shapes the fibers within the mold to create a loose but uniform arrangement. Unlike laying or placement methods, the direct fiber blowing process combines the steps of nonwoven fabric formation and material placement.
[0062] In an advantageous further development, the third layer can be designed as a thermally formed element. The thermally formed element is produced by thermoforming, in which a raw part of the third layer is heated. CCT-02 / 24-PCT 13 22.12.2025
[0063] The third layer, or the raw part, is brought into a deformable state and then formed into the desired shape. Preferably, the third layer or the raw part is heated to a temperature that makes it plastically deformable, but below its melting point. This allows the third layer to be formed quickly, cost-effectively, and in high volumes into the desired shape.
[0064] In a preferred further development, the foam is either polyurethane (PU) or polyethylene terephthalate (PET). Thus, the second layer is made of either PU or PET foam. It was found that polyurethane is particularly well-suited to adequately fill the recesses during the foaming process. Polyethylene terephthalate foam also yielded very good results.
[0065] In an advantageous further development, the first layer may have a plurality of recesses into which the second layer extends, at least partially. The recesses may be of the same or different types and may be regularly or irregularly distributed within the first layer. Thus, it may be provided that similar recesses are arranged in a regular distribution. Alternatively, it may be provided that similar recesses are arranged in an irregular distribution. Alternatively, it may be provided that different recesses are arranged in a regular distribution. Alternatively, it may be provided that different recesses are arranged in an irregular distribution.
[0066] The recesses can be either identical or different from one another, with their geometric shape and size being variable to meet different functional requirements. Furthermore, the recesses can be arranged at regular intervals or in an irregular distribution within the first layer, thus enabling application-specific adaptation of the overall structure's properties.
[0067] To ensure optimal filling of the recesses by the expanding material during foaming, the positions of the foaming points and the size of the recesses can preferably be coordinated. CCT-02 / 24-PCT 14 22.12.2025
[0068] The diameter of the recesses is determined by their distance from the nearest injection point, with a larger diameter the further a recess is from an injection point. This coordinated design ensures uniform filling of the recesses and contributes to the harmonization of the flow fronts of the foamed material. This improves the quality of the bond between the first and second layers, as well as the mechanical and structural properties of the second layer.
[0069] Preferably, the materials of the first and second layers can have different mechanical, acoustic, and / or thermal properties. Particularly preferably, the materials of the first, second, and third layers can have different mechanical, acoustic, and / or thermal properties. This differentiation in material properties is especially advantageous for meeting the requirements placed on the multi-component system.
[0070] For example, at least one of the layers may be preferably made of a material with high mechanical strength, such as high tensile strength, compressive strength, or flexural strength. The mechanical properties of this layer allow it to function as a load-bearing layer that withstands the structural stresses to which the multi-component system is subjected during its use.
[0071] In a preferred embodiment, the first layer comprises or is formed from a thermoplastic elastomer (TPE). Advantageous alternative materials are polypropylene (PP), polyethylene (HDPE, LDPE), polyamide (PA6, PA66), polycarbonate (PC), polyoxymethylene (POM), polyetheretherketone (PEEK), and thermoplastic polyurethane (TPU).
[0072] In a further advantageous embodiment, the first layer is designed as an injection-molded element. The injection-molded element is preferably made of a plastic, in particular a thermoplastic or thermosetting plastic. By designing the first layer as an injection-molded element, complex geometric shapes can be produced cost-effectively. Thus, even CCT-02 / 24-PCT 15 22.12.2025
[0073] The cutouts in the first layer can be formed simply and cost-effectively without additional effort during the production of the first layer.
[0074] In a further advantageous embodiment, the first layer is formed as a deep-drawn part. This deep-drawn part is preferably made of a plastic, in particular a thermoplastic or thermosetting plastic. By forming the first layer as a deep-drawn part, more complex geometric shapes can be produced cost-effectively. Thus, the recesses in the first layer can also be formed easily and cost-effectively during the manufacturing process without any additional effort. Acrylonitrile butadiene styrene (ABS), polymethyl methacrylate (PMMA), polystyrene (PS), polyethylene (PE), and polypropylene (PP) have proven to be particularly suitable materials.
[0075] TPE has proven to be particularly advantageous as a material for the first layer, and foamed polyurethane for the second layer.
[0076] In a preferred embodiment, the acoustically effective multi-component system is designed as a bulkhead, wheel arch liner, trunk floor, kick plate, firewall insulation component, trunk insulation component, door insulation component, floor assembly insulation component, roof insulation component, powertrain insulation component, or engine insulation component for a motor vehicle. Its use as such components has proven particularly advantageous. It should also be noted that its use as an engine insulation component is suitable for both electric motors and internal combustion engines.
[0077] Furthermore, to solve the above-mentioned problem, a method for manufacturing an acoustically effective multi-component system for a motor vehicle is proposed, the method comprising the following steps:
[0078] - Providing a first layer that has a cutout;
[0079] - Providing a second layer of foam by foaming it onto the first layer in such a way that the foam enters the recess and thus secures the second layer to the first layer. CCT-02 / 24-PCT 16 22.12.2025
[0080] Thanks to the inventive method, an acoustically effective multi-component system can be produced in a simple and cost-effective manner. The inventive method allows for the production of an acoustically effective multi-component system in which the first and second layers, made of materials incompatible with recycling processes, can be easily and quickly physically separated before being recycled. Because the foam enters the recess during the foaming process, a bond is created between the first and second layers as the foam solidifies. This bond can be easily broken in the event of a recycling operation, allowing the first and second layers to be recycled independently.
[0081] In an advantageous further development, the first layer may be placed in a mold before the second layer is foamed. The mold serves to shape the second layer. Particularly preferably, the mold limits the flow of foam from the recesses.
[0082] In an advantageous embodiment of the process, the foam material passes through the recess during the foaming process and forms the retaining projection. The retaining projection, or rather its head section, is preferably formed by the molding tool. The molding tool thus has the negative shape of the head section.
[0083] In a further advantageous development of the process, suitable process control ensures that the surface of the first layer, which is oriented towards the second layer in the finished component, is covered with a release agent.
[0084] A suitable method is, for example, the application of the release agent during the production of the first layer. This is particularly preferably achieved by at least partially "separating" a tool / tool half used to produce the first layer. Such a tool could be, for example, an injection mold, a foam mold, or a thermoforming tool. CCT-02 / 24-PCT 17 22.12.2025
[0085] In a further advantageous embodiment, it can be provided that, prior to the provision of the second layer, a third layer made of a textile element is provided, which is arranged on the reverse side of the first layer, and that the second layer is arranged on the front side of the first layer, opposite the reverse side. Thus, it can be provided that, prior to the foaming of the second layer, the first and second layers are placed in the mold.
[0086] Preferably, the foam may be provided that during foaming passes through the recess and penetrates the textile element to provide a connection between the second layer and the third layer.
[0087] Preferably, the acoustically effective multi-component system produced by the process is designed according to one or more of the above-mentioned advantageous or preferred further developments.
[0088] It should be noted that the features of the specified further developments and advantageous configurations can be freely combined within the limits of technical feasibility, even if this is not explicitly stated in the text. This applies in particular even across the boundaries of the claim categories device and method.
[0089] Further advantages and features of the acoustically effective multi-component system according to the invention will become apparent from the following exemplary embodiments, which are explained in more detail with reference to the figures (Fig.).
[0090] These show:
[0091] Fig. 1: a schematic cross-section of an acoustically effective multi-component system according to the invention in a first embodiment variant,
[0092] Fig. 2: a schematic cross-section of an acoustically effective multi-component system according to the invention in a second embodiment variant, CCT-02 / 24-PCT 18 22.12.2025
[0093] Fig. 3: a schematic cross-section of an acoustically effective multi-component system according to the invention in a third embodiment variant.
[0094] In the various figures, identical parts are always marked with the same reference symbols and are therefore usually only named or mentioned once.
[0095] Fig. 1 shows a schematic cross-section of an acoustically effective multi-component system 1 according to the invention in a first embodiment. The multi-component system 1 has a first layer 2, which is designed as the heavy layer of a spring-mass system. The first layer 2 is preferably made of TPE and manufactured by injection molding. The first layer 2 has several recesses 20 that extend through the first layer 2 and are designed as stepped recesses. The first layer 2 has a first side 21, which is also referred to as the front. Furthermore, the first layer 2 has a second side 22 facing away from the first side 21, which is referred to as the back. The recess 20 extends from the front 21 to the back 22, the recess having a first section 23 and a second section 24.The first section 23 has a smaller diameter than the second section 24, with the first section 23 adjoining the front 21 and the second section 24 adjoining the rear 22. The first layer 2 has a plate-like basic structure and is manufactured as an injection-molded component.
[0096] Furthermore, the multi-component system 1 comprises a second layer 3, which is made of foam and forms an absorber layer of the spring-mass system. Preferably, the foam is made of polyurethane (PU). The second layer 3 was foamed onto the front surface 21 of the first layer 2. The foam flowed into and through the recesses 20 of the first layer 2 and solidified. Thus, retaining projections 30 of the second layer 3 project into the recesses 20, extending from a plate-shaped base structure of the second layer 3. The first layer 2 and the second layer 3 are made of materials that are incompatible with each other for recycling purposes. CCT-02 / 24-PCT 19 22.12.2025
[0097] The retaining projections 30 are designed as mushroom-shaped projections extending from the plate-like base structure of the second layer 3 and are essentially orthogonal to it. Each retaining projection 30, designed as a mushroom shape, comprises a shaft section 31 and a head section 32, with the respective retaining projection 30 extending into a respective recess 20 of the first layer 2, and the head section 32 not projecting beyond the rear surface 22 of the first layer 2. This offers the advantage that, in the case of the first layer 2 being attached to a vibrating surface, vibrations are not directly transmitted to the second layer 3. The diameter of the first section 23 corresponds to, or is equivalent to, the diameter of the shaft section 31.The head section 32 has a larger diameter than the shaft section 31 and the first section 23 of the recess 20, so that the head section 32 projects further outwards beyond the edge section of the first section 23 of the recess 20 and thus positively engages the second layer 3 with the first layer 2. Due to the stepped design of the recess 20, the first section 23 is positioned closer to the second layer 3 than the second section 24.
[0098] The multi-component system 1 is produced according to the method according to the invention.
[0099] In the acoustically effective multi-component system 1 according to the invention, it is possible to easily and quickly physically separate the first and second layers 2, 3 made of materials incompatible with recycling technology, such as TPE and PU, before they are sent for recycling and thus enable reuse.
[0100] To separate or disassemble the first layer 2 from the second layer 3, a corresponding disassembly force is required. The retaining projections 30 are pulled out of the recesses 20 without significant damage or shearing of the head section 32 from the respective recess 20. This results in elastic and / or plastic deformation of the second layer 3, but without leaving any significant components (residues or adhering materials) of the second layer 3 on the first layer 2, or vice versa. As already stated, esCCT-02 / 24-PCT 20 22.12.2025
[0101] Minimal residues or adhesions from one layer to another may remain after disassembly, but these are insignificant for the subsequent recycling operation. Tests have shown that adhesions of less than 0.1% by weight are harmless for recycling; preferably, the adhesion is less than 0.5% by weight.
[0102] Figure 2 shows a second embodiment of an acoustically effective multi-component system according to the invention. The multi-component system 1 has a first layer 2, which is designed as the heavy layer of a spring-mass system. The first layer 2 has several recesses 20 that extend through the first layer 2 and are designed as circular cylindrical recesses. The first layer 2 has a first side 21, which is also referred to as the front. Furthermore, the first layer 2 has a second side 22 facing away from the first side 21, which is referred to as the back 22. The recess 20 extends from the front 21 to the back 22 and has a constant diameter. The first layer 2 has a plate-like base structure, which is manufactured as an injection-molded component. Preferably, the first layer 2 consists of TPE.
[0103] Furthermore, the multi-component system 1 comprises a second layer 3 made of foam, with PU again proving particularly suitable for forming the second layer. The second layer 3 was foamed onto the front 21 of the first layer 2. The foam flowed through the recesses 20 of the first layer 2 and subsequently solidified. Thus, retaining projections 30 of the second layer 3 protrude into the recesses 20, extending from a plate-shaped base structure of the second layer 3. In this embodiment as well, the second layer 3 serves as an absorber layer for the spring-mass system. The first layer 2 and the second layer 3 are made of materials that are incompatible with each other for recycling purposes.
[0104] The retaining projections 30 are designed as mushroom-shaped projections extending from the plate-like base structure of the second layer 3 and are essentially orthogonal to it. Each retaining projection 30 comprises a shaft section 31 and a head section 32, the head section 32 projecting beyond the edge section of the recess 20 and connected to CCT-02 / 24-PCT 21 22.12.2025
[0105] The rear side 22 of the first layer 2 is in contact. The diameter of the recess 20 corresponds to the diameter of the shaft section 31. The head section 32 has a larger diameter than that of the recess 20, so that the head section 32 projects further outwards beyond the edge section of the recess 20 and thus positively locks the second layer 3 to the rear side 22 of the first layer 2.
[0106] Figure 3 shows a third embodiment of an acoustically effective multi-component system according to the invention. The multi-component system 1 has a first layer 2, which is designed as the heavy layer of a spring-mass system. The first layer 2 is again preferably made of TPE. It has several recesses 20 that extend through the first layer 2 and are designed as circular cylindrical recesses. The first layer 2 has a first side 21, which is also referred to as the front. Furthermore, the first layer 2 has a second side 22 facing away from the first side 21, which is referred to as the back. The recess 20 extends from the front 21 to the back 22 and has a constant diameter. The first layer 2 has a plate-like basic structure, which is manufactured as an injection-molded component.
[0107] Furthermore, the multi-component system has a third layer 4, which is arranged on the back side 22 of the first layer 2 and is formed as a nonwoven fabric. The nonwoven fabric comprises a PET, which is formed from multi-component fibers.
[0108] The multi-component system 1 further comprises a second layer 3, which is formed from foam, preferably PUR, and which is foamed onto the front surface 21 of the first layer 2. During the foaming process, the foam passes through the recess 20 of the first layer 2 and penetrates the textile structure of the nonwoven fabric of the third layer 4. The foam at least partially encloses some of the fibers of the third layer 4 and becomes firmly embedded within them as it solidifies. The fibers enclosed by the foam permeate it like reinforcing elements. Thus, a secure yet also releasable connection between the layers can be achieved. The first layer 2, the second layer 3, and the third layer 4 are made of materials that are incompatible with each other for recycling purposes. CCT-02 / 24-PCT 22 22.12.2025
[0109] All the illustrated embodiments are produced using the method according to the invention.
[0110] In advantageous embodiments of all the foregoing examples, at least the surface of the first layer 2 that faces the second layer 3 is covered with a release agent. The covering can be complete or only partial. In particular, the edge region of the surface in question can be free of release agent. Preferably, the edge region is completely free of release agent.
[0111] The release agent can advantageously be applied during the production of the first layer 2, e.g., by (partially) parting out the injection mold used for production. In particular, it is possible to keep the edge areas of the injection-molded first layer 2 free of release agent by targeted application of the release agent.
[0112] Alternatively, it is also possible to treat the surface of the injection-molded part intended for the formation of the first layer 2 in a further process step before bonding it with the second layer 3, using a method known from the prior art for homogenizing the surface properties, in order to create defined initial conditions for bonding with the second layer 3. Flame treatment has proven to be a suitable method for a first layer 2 formed from TPE. Here, too, it is possible to selectively treat only certain surface areas, e.g., to achieve improved adhesion / a material-bonded connection between the first layer 2 and the second layer 3 in these areas. These could, for example, be the edge areas of the first layer 2. CCT-02 / 24-PCT 23 22.12.2025
[0113] Reference symbol list
[0114] 1. Acoustically effective multi-component system 2. First layer
[0115] 20 Exclusion
[0116] 21 first page / front
[0117] 22 second page / back
[0118] 23 first section
[0119] 24 second section
[0120] 3 second layer
[0121] 30 Holding advantage
[0122] 31 shaft section
[0123] 32 Head section
[0124] 4 third layer
Claims
CCT-02 / 24-PCT 1 22.12.2025 Patent claims 1. Acoustically effective multi-component system (1) for a motor vehicle, comprising a first layer (2) having at least one recess (20) and a second layer (3) comprising a foam which projects at least partially into the recess (20) in order to fix the second layer (3) to the first layer (2) by positive locking, such that the first layer (2) and the second layer (3) can be separated from each other without damage, wherein the first layer (2) and the second layer (3) comprise materials that are incompatible with each other for recycling purposes and the first layer (2) forms a heavy layer acting as a mass and the second layer (3) forms an absorber layer acting as a spring.
2. Acoustically effective multi-component system (1) according to one of the preceding claims, characterized in that the second layer (3) is bonded to the first layer (2) in a materially bonded manner.
3. Acoustically effective multi-component system (1) according to one of the preceding claims, characterized in that the second layer (3) is foamed onto the first layer (2).
4. Acoustically effective multi-component system (1) according to one of the preceding claims, characterized in that the surface of the first layer (2), which is oriented towards the second layer (3), is covered with a release agent.
5. Acoustically effective multi-component system (1) according to one of the preceding claims, characterized in that the force required to mechanically separate a positive-locking connection between the first layer (2) and the second layer (3) is at least 40 Newtons and at most 200 Newtons, wherein this force relates to a single recess (20). CCT-02 / 24-PCT 2 22.12.2025 6. Acoustically effective multi-component system (1) according to one of the preceding claims, characterized in that the recess (20) is a through-recess.
7. Acoustically effective multi-component system (1) according to one of the preceding claims, characterized in that the recess (20) comprises at least a first section (23) and a second section (24), wherein the first section (23) has a smaller distance to the second layer (3) than the second section (24) and the second section (24) has a larger radial extent than the first section (23).
8. Acoustically effective multi-component system (1) according to one of the preceding claims, characterized in that the foam extends into or through the recess (20) and forms a retaining projection (30).
9. Acoustically effective multi-component system (1) according to claim 8, characterized in that the retaining projection (30) is mushroom-shaped or hook-shaped.
10. Acoustically effective multi-component system (1) according to one of the preceding claims, characterized in that a third layer (4) is provided, which is arranged on the side (22) of the first layer (2) facing away from the second layer (3) and is designed as a textile element.
11. Acoustically effective multi-component system (1) according to claim 10, characterized in that the foam of the second layer (3) has penetrated the textile element.
12. Acoustically effective multi-component system (1) according to claim 10 or 11, characterized in that the foam is connected to the textile element such that the first layer (2) is held between the second layer (3) and the third layer (4). CCT-02 / 24-PCT 3 22.12.2025 13. Acoustically effective multi-component system (1) according to one of claims 10 to 12, characterized in that the third layer (3) is a nonwoven fabric.
14. Acoustically effective multi-component system (1) according to claim 13, characterized in that the nonwoven fabric comprises a polyethylene terephthalate.
15. Acoustically effective multi-component system (1) according to one of the preceding claims, characterized in that the foam is based on a polyurethane or a polyethylene terephthalate.
16. Acoustically effective multi-component system (1) according to one of the preceding claims, characterized in that the first layer (2) has a plurality of recesses (20) into which the second layer (3) extends at least partially, wherein the recesses (20) are of the same or different characteristics and the recesses (20) are regularly or irregularly distributed in the first layer (2).
17. Acoustically effective multi-component system (1) according to one of the preceding claims, wherein the materials of the first layer (2) and the second layer (3) have different mechanical and / or acoustic and / or thermal properties.
18. Acoustically effective multi-component system (1) according to one of the preceding claims, characterized in that the first layer (2) is designed as an injection-molded element.
19. Acoustically effective multi-component system (1) according to one of the preceding claims, characterized in that it serves as a front wall, wheel arch liner, trunk floor, kick plate, firewall insulation component, trunk insulation component, door insulation component, floor assembly insulation component, roof skin insulation component, powertrain-CCT-02 / 24-PCT 4 22.12.2025 is designed as an insulation component or engine insulation component for a motor vehicle.
20. Learned to manufacture an acoustically effective multi-component system (1) for a motor vehicle, comprising the following steps: a. Providing a first layer (2) having a recess (20), b. Providing a second layer (3) of foam by foaming it onto the first layer (2) such that the foam enters the recess (20) and thus secures the second layer (3) to the first layer (2).
21. according to claim 20, characterized in that the surface of the first layer (2), which in the finished component is oriented towards the second layer (3), is covered with a release agent.
22. Method according to claim 21, characterized in that the release agent is applied during the production of the first layer (2).
23. Method according to claim 20, characterized in that the foam passes through the recess (20) during the foaming process and forms a retaining projection (30).
24. Method according to one of claims 20 - 23, characterized in that before the provision of the second layer (3) a third layer (4) is provided from a textile element, which is arranged on a back side of the first layer (2), and that the second layer (3) is arranged on a front side (21) of the first layer (2) facing away from the back side (22).
25. Method according to claim 24, characterized in that the foam passes through the recess (20) during the foaming process and penetrates the textile element to provide a bond between the second layer (3) and the third layer (4). CCT-02 / 24-PCT 5 22.12.2025 26. experienced according to one of claims 20 to 25, characterized in that the acoustically effective multi-component system (1) is designed according to one of claims 1 to 19.