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WO1992019398A1 - Procede de production d'une piece d'enceinte a antisonique pour automobile et article ainsi produit - Google Patents

Procede de production d'une piece d'enceinte a antisonique pour automobile et article ainsi produit Download PDF

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Publication number
WO1992019398A1
WO1992019398A1 PCT/US1992/003756 US9203756W WO9219398A1 WO 1992019398 A1 WO1992019398 A1 WO 1992019398A1 US 9203756 W US9203756 W US 9203756W WO 9219398 A1 WO9219398 A1 WO 9219398A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
metal
viscoelastic
enclosure
constraining
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US1992/003756
Other languages
English (en)
Inventor
Dan T. Moore, Iii
Austin W. Moore
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Soundwich Inc
Original Assignee
Soundwich Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Soundwich Inc filed Critical Soundwich Inc
Priority to JP4512009A priority Critical patent/JPH06510703A/ja
Publication of WO1992019398A1 publication Critical patent/WO1992019398A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/095—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D22/00—Shaping without cutting, by stamping, spinning, or deep-drawing
    • B21D22/20—Deep-drawing
    • B21D22/205—Hydro-mechanical deep-drawing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/06—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of natural rubber or synthetic rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/085—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01M—LUBRICATING OF MACHINES OR ENGINES IN GENERAL; LUBRICATING INTERNAL COMBUSTION ENGINES; CRANKCASE VENTILATING
    • F01M11/00—Component parts, details or accessories, not provided for in, or of interest apart from, groups F01M1/00 - F01M9/00
    • F01M11/0004—Oilsumps
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B77/00—Component parts, details or accessories, not otherwise provided for
    • F02B77/11—Thermal or acoustic insulation
    • F02B77/13—Acoustic insulation
    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
    • G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/162—Selection of materials
    • G10K11/168—Plural layers of different materials, e.g. sandwiches
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0001—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular acoustical properties
    • B29K2995/0002—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular acoustical properties insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01M—LUBRICATING OF MACHINES OR ENGINES IN GENERAL; LUBRICATING INTERNAL COMBUSTION ENGINES; CRANKCASE VENTILATING
    • F01M11/00—Component parts, details or accessories, not provided for in, or of interest apart from, groups F01M1/00 - F01M9/00
    • F01M11/0004—Oilsumps
    • F01M2011/0029—Oilsumps with oil filters
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2225/00—Synthetic polymers, e.g. plastics; Rubber
    • F05C2225/02—Rubber

Definitions

  • the present invention relates to a novel method for producing sheet metal automotive power train component en- closures which are designed to reduce structure-borne noise by increasing the internal damping of the enclosure.
  • the invention applies specifically to sheet metal oil pans, valve covers, timing chain covers, air cleaner covers, transmission side covers, drive shaft components, and disk brake rotor covers, but can be used for any sheet metal stamping or similar enclosure requiring damping.
  • the component enclosures described above are made by either stamping sheet metal or by casting the components. In both cases, the component and/or enclosure is easily excited by the typical vibration that emanates from a power train system, and since they are made of materials that have very little internal damping, they have a tendency to radiate noise.
  • Methods for producing damped automotive enclosures include the following: 1. Covering the component with an elastomeric barrier. Typically, this includes a "spring layer" loosely attached to a limp mass. The noise radiating from the component is absorbed to some degree by the spring layer of the composite--typically, either a foam or fiber material—and is confined within the limp mass layer, which is typically a limp but heavy specific gravity rubber or elastomer. It is expensive and heavy, and creates corrosion problems by trapping moisture against the metal.
  • drawing means to stretch
  • forming means to bend
  • deforming includes, but is not limited to, drawing and forming.
  • U.S. Patent No. 4,851,271 an oil pan or other automotive component enclosure or automotive enclosure is prepared by drawing and forming an outer housing from a sheet of metal; forming a conforming constraining layer from sheet metal in a separate operation; disposing a cut out viscoelastic layer, which contains a blowing agent and which expands upon activation, between the constraining layer and the outer housing; spot welding the constraining layer onto the housing; and then painting and baking to complete the process of expanding the viscoelastic layer to fill the space between the two metal layers.
  • composition of this patent does not have an outer constraining layer and is intended for use in "free layer", or limp mass, damping.
  • the present invention is concerned with a more cost-effective way for producing a damped stamping. Instead of having to combine two separate stampings with a visco- elastic layer in between, this invention teaches how to stamp both the outer and the inner metal layers with the visco- elastic layer in between simultaneously. Since the two sheet metal layers are stamped together, the fit is tighter, making it possible to eliminate the need for a blowing agent, and thereby creating better damping and hence reducing the radiated noise. Objects of the Invention
  • Another object of the invention is to provide a simplified method for producing an oil pan or other housing or enclosure having excellent sound-damping qualities, the method requiring considerably less labor and expense than other methods heretofore used, and resulting in a product with very closely and accurately conforming layers in close engagement or contact or tolerance or parallelism with each other.
  • a method of producing a three-dimensional sound- dampening automotive enclosure having a metal housing layer, a metal constraining layer, and a viscoelastic layer disposed therebetween comprises the following steps.
  • the metal housing layer, metal constraining layer, and viscoelastic layer are disposed in a press.
  • the metal constraining layer is urged into deforming contact with the metal housing layer by means of the press while the viscoelastic layer is disposed between the two metal layers to deform at least a significant portion of at least one of the metal layers into a three-dimensional shape.
  • a flange is provided on the enclosure, said flange being a single layer.
  • This method produces a sound-dampened automotive enclosure wherein the metal constraining layer and the viscoelastic layer closely conform and complimentarily conform to the shape of the adjacent portions of the metal housing layer.
  • the viscoelastic layer is in sufficient solid or physical contact with the two adjacent metal layers over a sufficient area to provide effective sound-dampening qualities.
  • a blowing agent is not utilized to ensure that the viscoelastic layer sufficiently contacts the two metal layers between which it is disposed and to ensure that the viscoelastic layer fills that space.
  • the article thus produced is also disclosed.
  • FIG. 1 shows a perspective view of an oil pan made in accordance with the invention, said oil pan having one metal constraining layer;
  • FIG. 2 shows a perspective view of an oil pan made in accordance with the invention, said oil pan having two metal constraining layers;
  • FIG. 3 shows a plan view of tab and slit means for attaching the viscoelastic layer to the metal constraining layer;
  • FIG. 4 shows a perspective view of a metal con- straining layer with a pattern of ridges or crinkles or waffles
  • FIG. 5 shows an exploded schematic perspective of the individual components of the oil pan in FIG. 1 as they are aligned prior to the stamping operations;
  • FIG. 6 shows a cross section of a press with blanks therein prior to initiation of a stamping operation
  • FIG. 7 shows a cross section of the blanks and press shown in FIG. 6 with the metal constraining layer and viscoelastic compound layer beginning to be formed;
  • FIG. 8 shows a cross section of the blanks and press shown in FIGS. 6 and 7 at a further stage of the stamping operation
  • FIG. 9 shows a cross section of the blanks and press shown in FIGS. 6, 7, and 8 at the conclusion of a stamping operation
  • FIG. 10 shows a cross section of an assembly of blanks positioned in a matched-metal die press
  • FIG. 11 shows a cross section of blanks placed with respect to the die surfaces of a press prior to initiation of a stamping operation, the press including a hydraulic counterpressure fluid-forming portion;
  • FIG. 12 shows a cross section of the blanks and press shown in FIG. 11 at an intermediate stage of the stamping operation
  • FIG. 13 shows a cross section of the blanks and press shown in FIGS. 11 and 12 at the conclusion of the stamping operation.
  • FIG. 14 shows a cross section of an assembly of blanks positioned in a hydraulic counterpressure fluid forming press prior to initiation of a stamping operation.
  • the method of the present invention will be described utilizing, as an example, an oil pan.
  • the method of the present invention can also be used to make other automotive component housings or containers or cavities or enclosures, including, but not limited to, valve covers, timing belt covers, and others.
  • the enclosures are three- dimensional and can be pan-shaped, box-like, or other shapes. Three-dimensional means something which is not flat, and which has its portions significantly displaced out of its plane to form a shape such as a pan, bowl, box, etc.
  • the enclosures are typically mounted on the engine or motor of the motor vehicle.
  • FIG. 1 is shown an example of the typical geometry for a 4-cylinder sound-dampening oil pan 10 made in accordance with the invention.
  • the oil pan in this example consists of an outer metal housing 11 which is typically sheet metal, a constraining layer 13 of sheet metal, and a viscoelastic dampening layer (not shown, but beneath layer 13).
  • the viscoelastic layer is tightly sandwiched between the outer housing and the constraining layer.
  • the constraining layer comes substantially up the side of the housing.
  • Suitable sheet metal materials for use with the invention include steel, particularly drawing-quality steel, and aluminum.
  • the constraining layer is preferably steel, due to its lower cost.
  • the outer housing is preferably drawing-quality steel.
  • the viscoelastic layer has approximately the same size and shape as the corresponding overlapping or constraining layer 13, subject to cutouts, etc.
  • the lateral and transverse dimensions of the viscoelastic layer are typically less than or equal to those of its corresponding constraining layer, and the lateral and transverse dimensions of the constraining layer (after it is formed) are less than those of the outer housing layer (after it is drawn and formed).
  • the metal constraining layer is spaced in from the majority of the edge or perimeter of the metal outer housing.
  • Patent Application Serial No. 07/573,370, filed August 27, 1990 are incorporated herein by reference.
  • Such compounds include those comprising from about 30% to about 70% by weight of at least one urethane polymer and from about 10% to about 30% by weight of a high molecular weight olefin polymer, and an effective amount of filler.
  • the urethane polymer could be a polyester urethane derived from an aromatic diisocyanate and hydroxy-terminated polyester or a polyether urethane derived from an aromatic diisocyanate and hydroxy-terminated polyether. Normally these compounds will be made or formulated or compounded without blowing agents, although in some cases, as discussed hereinafter, blowing agents may be required.
  • the constraining layer 13 in FIG. 1 has a cutout 15.
  • the oil pan also has a drain hole 21.
  • the perimeter of the housing, largely or completely comprised of the flange, is devoid of a second layer or covering along at least a substantial portion of its extent. This substantial portion or flange provides an area for attachment to another body, such as the engine block.
  • FIG. 2 shows an oil pan similar to the oil pan illustrated in FIG. 1, except that the oil pan in FIG.
  • FIG. 2 has two metal constraining layers, a left half or portion 14 and a right half or portion 16, each covering a portion of the housing, whereas, the oil pan of FIG. 1 has a single con- straining layer.
  • FIG. 2 there is a separate viscoelastic layer under each constraining layer. Multiple constraining and viscoelastic layers may be utilized where, for example, different sound frequencies need to be dampened at different locations, in which case the different viscoelastic layers could have different sound-dampening characteristics. Alternatively, one constraining layer could cover both a multiple or different viscoelastic layers.
  • FIG. 1 has two metal constraining layers, a left half or portion 14 and a right half or portion 16, each covering a portion of the housing, whereas, the oil pan of FIG. 1 has a single con- straining layer.
  • FIG. 2 there is a separate viscoelastic layer under each constraining layer. Multiple constraining and viscoelastic layers may be utilized where, for example, different sound frequencies need to be dampened at
  • FIG. 5 is an exploded perspective view illustrating an embodiment of the layered arrangement of the metal constraining layer blank 32, the viscoelastic layer blank 34, and the outer housing or main blank 36 prior to stamping.
  • the three layers may be precut or blanked. They each have an outside edge or perimeter which defines a boundary. There may be apertures or holes inside the boundary. Cutouts 38 and 40 are provided in the constraining layer blank 32 and the matching viscoelastic layer blank 34, respectively, to accommodate installation of a drain hole such as indicated at 21 in FIG. 1. If required, a set of matching cutouts 37, 39 in the constraining layer blank 32, and the viscoelastic layer blank 34, respectively, can be provided to prevent excessive heat build-up in the oil pan during engine opera- tion.
  • Cutouts are generally not essential. They are provided where useful.
  • the blanks can be cut to any configuration, as required. Projections, such as indicated at 33 and 35, can be provided. These projections can extend into portions of the enclosure, such as the right-hand side of an oil pan such as illustrated in FIG. 1, to dampen that part of the pan.
  • Each of the three layers or blanks is typically of a uniform or relatively uniform thickness.
  • the shapes of the constraining sheet metal layers and viscoelastic layers as shown are for illustrative purposes only.
  • the actual shapes, sizes, compositions, thicknesses, and locations of individual layers or pieces will depend on a variety of considerations unique to the particular application, such as the type of enclosure, the noise dampening characteristics desired at particular sites within the enclosure, the frequencies sought to be damped, the stiffness of the metal layers, temperature, weight, and heat transfer considerations. Thus, different enclosures can be individually “fine tuned.”
  • the constraining layer blank, viscoelastic layer blank, and main blank are not necessarily the same size before stamping. The first two may be larger or smaller than the third before stamping.
  • the principal purpose of the constraining layer is to constrain the viscoelastic layer to provide sound- dampening. Typically, the constraining layer will at least cover the area covered by the viscoelastic layer.
  • the constraining layer blank it is preferable to design the constraining layer blank so that when it is formed as hereinafter described, it is bent into simple curves and not compound curves. Compound curves are much harder to form; the metal may crease or wrinkle. Also, for particular applications, it may be desirable to have more than one constraining sheet metal layer and one correspond- ing viscoelastic layer. Multiple viscoelastic layers or pieces can be used with one constraining layer.
  • viscoelastic layers it may be desirable to make them from different types of polymer compositions to provide different 1) sound-dampening qualities, 2) resistances to environmental elements such as oils, detergents, salts, etc., 3) stiffness, 4) thermoconductivities, and/or 5) temperature resistances, at various locations within an automotive enclosure such as an oil pan.
  • the automotive enclosure above has been shown with the constraining and viscoelastic layers inside the housing. Alternatively, in some applications it may be preferable to place these layers on the outside of the housing, although in these situations environmental elements, such as road salt, become more important.
  • An important feature of the present invention is that only those areas of the automotive enclosure which need to be sound-dampened are sound-dampened.
  • the entire surface area of the metal housing is not sound-dampened.
  • the flange is not sound-dampened.
  • Smaller plains or flat surfaces tend to resonate less. Stiffening or ribbing reduces noise.
  • typically only the larger, flatter, unribbed, unstiffened areas of the enclosure tend to have to be dampened.
  • only a portion of each of certain walls of an enclosure will need to be sound-dampened in order to sufficiently sound-dampen the entire enclosure.
  • only certain portions of the internal surface of the pan will typically need to be sound- dampened with the constraining layer and the viscoelastic layer in order to provide sufficient sound-dampening.
  • the present invention has distinct cost of material and heat retention advantages over the Antiphon or Prefinish Metals approach using laminated metal, where the entire enclosure, including the flange, has two metal layers and an adhesive layer therebetween.
  • a laminated metal oil pan such as Antiphon of approximately equal steel thickness and/or approximately equal weight has a flange which is less stiff. This is because Antiphon's laminated metal, including the flange, has two layers of steel, each about 0.025 inches thick, while the metal housing layer of the present invention is only one layer and is typically and preferably about 0.044 inch thick before stamping, resulting in a flange of steel which is a single layer and about 0.044 inch thick.
  • a solid layer of steel 0.044 inch thick is typically stiffer than an adhesive laminate of two layers of steel, each 0.025 inch thick.
  • the flange of the present invention is stiffer than the Antiphon flange and thus tends to resonate less.
  • the metal housing blank of the present invention is preferably drawing quality steel and 0.030 to 0.060 inch thick, preferably about 0.044 inch thick, before stamping.
  • the metal constraining layer is preferably steel and 0.010 to 0.032 inch thick, more preferably about 0.020 inch thick, before stamping.
  • the viscoelastic layer is preferably 0.005 to 0.030 inch thick, and, more preferably, about 0.008 to about 0.020 inch thick, and, most preferably, about 0.010 inch thick, before stamping, in the typical application.
  • a preferred embodiment of the invention is illus- trated in FIGS. 6-9, wherein drawing and forming techniques are utilized in conjunction with matched metal dies to permanently and inelastically deform the metal layers.
  • This method has the advantage of using conventionally available tooling techniques, e.g., it can be run on a conventional double-acting mechanical or hydraulic press, and if it is used on a mechanical press, can yield faster cycle times.
  • the housing or main blank 60 to be deformed into the enclosure such as an oil pan is placed between the draw ring 54 and the female die 62.
  • the con- straining layer blank 48 which may be combined with the viscoelastic layer blank 50 as hereinafter described, is placed in a fixtured location between the draw ring 54 and the male die 46.
  • the outer ram 44 closes, closing the draw ring 54 tightly around the main blank 60 as seen in FIG. 7.
  • the draw beads 56 squeeze the main blank 60 against the female die 62 utilizing draw bead receiving cavities 58, with the proper pressure to allow the appropriate amount of slippage of the metal through the draw bead as the main blank is being drawn.
  • a second set of draw beads may be added, if necessary.
  • the curves being formed are simple, not compound, curves.
  • rollers 52 may be employed to assist in the forming process. Rollers would be useful to prevent or minimize tearing and/or abrading of the viscoelastic layer and/or twisting or removal of tabs at this stage of the process. The rollers would have to be comparatively heavy. They would probably be no more than about 1/2 inch in diameter.
  • deforming contact includes the situation where one layer is being urged or pushed or pressed against another layer, although a third layer is disposed between the first two layers and prevents actual physical contact therebetween.
  • the draw beads 56 are adjusted so that the main blank is pulled past the ring evenly as much as possible, elongating and drawing the metal or steel of the main blank uniformly so as not to create either wrinkles or tears.
  • FIG. 9 illustrates the enclosure after the male die has reached the bottom of the female die. It can be seen that at least a significant, major, substantial portion of the constraining and housing layers have been deformed. A significant or major or substantial portion is more than is deformed with spot welding or other incidental deformation.
  • the purpose of having the constraining layer blank and the viscoelastic layer blank formed above the housing or main blank is threefold: 1. Since the constraining layer is being formed and is not being drawn, it allows the use of a con- straining layer that reaches up higher on the side of the enclosure; it also allows the use of a constraining layer blank with lateral dimensions larger than those defined by the draw-beads; 2.
  • the enclosure being produced is shallow, one strike or hit may be sufficient. If the enclosure must be deeply drawn, more than one draw will generally be required, perhaps 2 or 3 or more. These draws will generally be made in separate dies. Thus, the three layer assembly would be removed and placed in a separate die and rehit or restruck. It is normally necessary after the drawing and forming operation to hit or stamp the assembly one or more times to form the flange area, pierce holes, including screw holes in the flange and the drain hole, and roll the edges of the surface that mates to the engine block or other surface. Flange and holes (such as in an oil pan) are stamped after the main blank is drawn and formed, to assure accurate size and location.
  • the viscoelastic layer can be placed or affixed on top of the main blank, and only the constraining layer will be formed through the draw ring.
  • the constraining layer blank may be larger than the main blank initially, since the main blank will be stretched and the constraining layer blank will be formed only. However, when the stamping is complete, the main blank will have more surface area than the constraining layer.
  • the constraining layer blank and viscoelastic layer blank are positioned together above the draw ring or at other times, it is generally necessary or useful to attach or affix them together. This can be done by heat-bonding, gluing, cementing, stapling, using grommets, or other mechanical or adhesive means.
  • FIG. 3 can also be affixed as illustrated in FIG. 3 by attaching the viscoelastic layer to spears or tabs stamped into the constraining layer.
  • a tab is stamped in the constraining layer 23 along a outline 24.
  • the base of the tab is indicated at 25 and the tip is indicated at 26, indicated with a broken line since it is hidden under the viscoelastic layer 27.
  • a slit is cut in the viscoelastic layer at 28 and the tab inserted therethrough to hold or affix the viscoelastic layer 27 next to the constraining layer 23.
  • the constraining layer can be formed separately and then fitted around the male die 46.
  • the viscoelastic layer can then be fitted around the constraining layer or otherwise positioned between the constraining layer and the main blank. Then the male die can draw the main blank in the female die with or without going through the opening 55 in the draw ring 54. In this step the constraining layer will be pressed against or towards or into the main blank as the main blank is drawn. Alternatively, the main blank can be drawn separately into a housing and left or placed in a female die such as indicated at 62 and then the constraining layer and viscoelastic layer can be formed directly in the previously drawn and formed housing. With reference to another embodiment of the invention shown in FIG. 10, there is shown a mechanical or hydraulic press with matched metal dies having a frame 63 to which is attached an upper blankholder 65.
  • a male die 66 is attached to the ram 67. Disposed in the press beneath the male die is an assembly comprising the constraining layer 70, the viscoelastic layer 71, and the housing or main blank 69.
  • the female die 68 has attached thereto bottom blankholder 64. Preferably, the three layers of the assembly are affixed or attached together.
  • Mechanical or adhesive means can be employed, including spot welding, undercuts, undercut buttons, heating to make the viscoelastic layer sticky and adhesive to both metal surfaces, gluing, Tog-L-Loc from BTM Corp., Marysville, MI 48040, or Tox from Tox Corporation, Addison, IL 60101, the last two of which are similar to undercut buttons.
  • the frame 63 lowers the upper blankholder 65 until the perimeter or edge of the main blank 69 is engaged and retained and held securely between the upper and lower blankholders. It is preferable that the constraining layer 70 and the viscoelastic layer 71 not be engaged between the blankholders. In this way, the con- straining and viscoelastic layers will be formed but not drawn, while the main blank will be drawn and formed. This requires that the lateral and transverse dimensions of the constraining and viscoelastic layers be shorter or smaller than those of the main blank and that their respective surface areas be smaller.
  • the ram 67 then forces the male die 66 towards the female die 68 until the stamping is completed.
  • the main blank is drawn and formed, and the other two layers are formed, all in a single, mutual, simultaneous operation or stamping.
  • the constraining layer is formed in a substantial manner while the metal housing layer is drawn, that is, more than an insignificant or insubstantial bending of the constraining layer occurs, such as in a spot weld; a major part of the constraining layer is bent or formed. A close- fitting final product is thus produced.
  • the drawing may occur in one or more steps. If the enclosure being produced is shallow, one strike or hit may be sufficient. If the enclosure must be deeply drawn, more than one draw will generally be required, perhaps 2 or 3 or more. These draws will generally be made in separate dies. The assembly would be removed and placed in a separate die and rehit or restruck.
  • the flange which is formed only from the main blank, is thereafter flattened and is then trimmed and curled over.
  • the holes are then punched in the flange and the drain hole added. Since the pieces or layers are drawn and/or formed in a single stamping operation or at least to some extent at the same time, the layers fit together very closely. Particularly if spot welding is used to affix the two metal layers together and if there is no heating after stamping, the two metal layers may have sufficient residual stress between them after stamping to compress at least a portion of the viscoelastic layer therebetween, thereby enhancing the sound-dampening characteristics of the resulting product.
  • FIGS. 11-13 there is shown another embodiment of the invention. A double acting press very similar to that illustrated in FIG.
  • FIG. 11 The principal difference is that the lower portion of the press shown in FIG. 11 is a hydraulic counterpressure fluid-forming press rather than a matched metal die press.
  • the housing or main blank 79 to be deformed is placed between the draw ring 77 and the liquid die or chamber 81.
  • the constraining layer blank 75 and the viscoelastic layer blank 76 are placed in a fixtured location between the draw ring 77 and the male die 73.
  • the constraining layer blank and the viscoelastic layer blank may be attached or fixed to one another as described with respect to FIG. 6.
  • the outer ram 74 closes, closing the draw ring 77 tightly around the main blank 79 as seen in FIG. 12.
  • the draw ring 77 firmly engages and restrains and holds the perimeter of the main blank against the flexible high strength diaphragm 80, which serves as a seal to prevent liquid from squirting out or leaking out from the liquid die or chamber 81 during the stamping operation.
  • the liquid 83 is typically oil or water.
  • the constraining layer blank 75A and the viscoelastic layer blank 76A are pressed in deforming contact against the main blank 79A by the male die 73 and the drawing process of the main blank begins.
  • the flexible high strength diaphragm 80 extends horizontally over the entire surface of the liquid die 81.
  • a gasket-type seal can be provided to prevent leakage.
  • the male die is forceably moved downward into the liquid die or chamber while the pressure in the chamber is increased by pumping liquid in through conduit 82.
  • Conduit 82 is connected to a valve for purposes of regulating pressure.
  • Hydraulic counterpressure causes the main blank 79A to extend in the direction opposite to that of the movement of the male die along the region between the die and the inner perimeter of the liquid chamber 81.
  • the main blank is drawn directly in the liquid chamber with a pressure-regulated hydraulic cushion which forces the blank onto the downward acting male die and eliminates the need for a female die.
  • FIG. 13 illustrates the arrangement of the layers after the male die has completed its downward acting stroke.
  • the constraining layer blank and the viscoelastic layer blank formed in the manner described with respect to FIGS. 6 - 13 will closely conform to the shape of adjacent portions of the metal housing layer, and the viscoelastic layer will be capable of being adhered to sufficient areas of the two adjacent metal layers to be effective at sound-dampening.
  • FIG. 14 there is shown a hydraulic counterpressure fluid forming press which forms an enclosure in much the same way as the matched metal die press illustrated in FIG. 10.
  • the constraining layer 95, the viscoelastic layer 94 and the main blank 93 are disposed in the press and may be attached or fixed as described above.
  • the frame 86 has attached thereto an upper blankholder 87.
  • a male die is shown at 96.
  • the three layer assembly is placed over a liquid die or chamber 90 having therein liquid 91 which is typically oil or water.
  • a flexible high strength diaphragm 88 extends horizontally over the entire surface of the liquid chamber and over at least a portion of the lower blankholder 89.
  • a gasket-type seal can be provided to prevent leakage.
  • the periphery of the main blank 93 also extends over at least a portion of the lower blankholder 89.
  • the upper blankholder 87 which is attached to the frame 86, is lowered onto the outer periphery of the main blank 93.
  • a sufficient force is transmitted downward to cause the upper and lower blankholders to retain the outer periphery of the main blank in a fixed position during the stamping operation.
  • the constraining layer may occupy up to about 90% (particularly if it is a shallow draw) of the surface area of the main blank without being retained by the blankholders and without being subjected to drawing forces.
  • the male die 96 is forceably moved downward into the chamber while the pressure in the chamber is increased by pumping liquid in through conduit 92.
  • Conduit 92 is connected to a valve for purposes of regulating pressure. Hydraulic counterpressure causes the main blank to extend in the direction opposite to that of the movement of the male die along the region between the male die and the blank- holders.
  • the main blank 93 is drawn directly in the liquid chamber 90 with a pressure-regulated hydraulic cushion which forces the blank onto the downward acting male die and eliminates the need for a female die.
  • the constraining layer blank and the viscoelastic layer blank are formed in a single operation to achieve a very close fit between the constraining layer, the viscoelastic layer, and the housing or main blank.
  • hydraulic liquid die acts uniformly over the surface of the main blank, it is possible to draw a thinner blank more reliably and with more even wall thickness, which has the effect of reducing cost. It is useful if oil pans and other sound-dampening automotive enclosures made in accordance with the method of the present invention have constraining layers with approxi- mately the same stiffness as the outer housing layer. If the constraining layer is less stiff than the outer housing, it will tend to deform when the outer housing begins to resin- ate, resulting in a diminished dampening effect.
  • a thinner constraining layer can be utilized without diminished damping effect if it is suitably crinkled or creased or waffled or ridged to increase its stiffness to approximately equal that of the outer housing layer.
  • FIG. 4 there is shown a portion of a waffled or crinkled constraining layer 29 having a pattern of ridges or raised portions 30. It is possible to crinkle or waffle a constraining layer in a separate operation using methods known in the art, before the subsequent stamping operation, and it is believed that such crinkles or waffles or ridges can be made to sufficiently survive the subsequent stamping operation in order to provide stiffness.
  • Ridges or depressions or creases or raised portions can also be imparted after the drawing and forming operation described above by overstriking the constraining layer while the outer housing layer is firmly held against a smooth or flat face to prevent it from receiving crinkles or waffles.
  • the ridges may be projecting into the viscoelastic layer rather than away from it.
  • the constraining layer into the viscoelastic layer, in one preferred embodiment getting a series of ridges or waffles approximately 0.0050 inch thick. Even this small amount will substantially enhance the stiffness of the constraining layer.
  • the viscoelastic layer can be extruded with ridges.
  • the ridges When stamping occurs, the ridges will read through and cause or form ridges in the adjacent constraining layer.
  • the metal constraining layer By urging the metal constraining layer into deforming contact with the metal housing layer with a die in a press while the viscoelastic layer is disposed between the two metal layers to deform at least a significant portion of at least one of the metal layers into a three-dimensional shape, a very close, snug, and uniform fit or engagement between the layers is achieved. Because of this, the resulting product has a constrained sound-dampening visco- elastic layer preferably of uniform or substantially or generally uniform thickness in very close contact with the housing and constraining sheet metal layers. For the most part, the viscoelastic layer of the finished product will not have a large deviation in thickness.
  • the metal layers of the resulting product are consequently free of substantial or major deviation in spacing between each other.
  • the degree of spacing between the metal layers is such that it will permit the viscoelastic layer to be adhered to or be in surface contact with or be touching sufficient surface area of the metal layers to be effective for sound-dampening, preferably without the use of a blowing agent or foaming agent.
  • the viscoelastic layer of the finished product does not have gross variation in thickness.
  • a layer does not have gross variation in thickness if the vast majority of the area of the layer does not vary in thickness by more than 200%, preferably 100%. Locations around corners, edges, bends, etc. can vary by more than these amounts.
  • different parts of the viscoelastic layer may be intentionally of different thicknesses, as may be necessary for specific applications.
  • a greater variety of viscoelastic materials including those which are thinner and those which do not require a foaming or blowing agent, can be used.
  • a blowing agent may still be necessary.
  • the constraining layer since it is being formed, may have a tendency to spring back to its old shape and away from the housing layer.
  • the constraining layer springs back an excessive amount from the housing layer, it may be difficult to use a thin, generally uniform, layer of viscoelastic material and still achieve a filling of the void between the two metal layers. In this case, as little blowing agent as is possible is used. Use of a blowing agent results in the visco- elastic layer having pores or porosity or being foam or foamlike. In the preferred embodiment of the invention, no blowing agent is used and the viscoelastic layer is compounded free of and devoid of a blowing agent and is consequently free of porosity resulting from the use thereof. The elimination of the blowing agent in the viscoelastic layer can generally provide better dampening and improved adhesion to metal.
  • the viscoelastic layer is a constrained layer, constrained between and held in place by the housing and the constraining layer. It is in full or nearly 100% or substantial contact with those two layers and is generally adhered to them. It is not intended to be loose between the two metal layers.
  • the process parameters will be fine- tuned and adjusted so that the viscoelastic layer will be in solid or physical contact with sufficient areas of the metal layers to provide effective sound-dampening of noise, vibration, etc. associated with or emanating from or produced by the enclosure.
  • this heating can or will be done automatically when the enclosure is painted and then placed in a bake oven where the temperature is typically 275-400°F.
  • the viscoelastic layer will be under compression and some may not be touching the adjacent metal layer.
  • the viscoelastic layer will flow to fill the open spaces and relieve the compressive forces. If it is found that friction is insufficient to hold the three layers together after stamping and prior to baking as described above, a tackifier may be added to the viscoelastic composition to make the viscoelastic layer tackier so that it can help hold the metal layers together prior to baking.
  • the polymer can be heated to make it tackier before or after stamping or the metal layers can be mechanically attached such as by spot welding (preferably after removal from the press) or by crimping with the Tox technique previously referenced.
  • different kinds of polymers can be utilized in different viscoelastic layers or pieces and these different viscoelastic layers or pieces can be posi- tioned at different locations within the housing, to dampen different frequencies which may arise at different locations, to handle different temperatures at different locations, to provide different stiffness at different locations of the housing, or combinations thereof.
  • heat retention within the housing can be controlled by varying the extent to which the viscoelastic layer covers the inside or outside surface of the housing. Cutouts, such as indicated in FIGS. 1, 2, and 5, can be made in the viscoelastic layer and constraining layer to reduce heat retention.
  • the assembled layers may also be heated prior to, during, and/or after the stamping operation to enhance adhesion. As described above, if it is found that the layers are not close enough together after the stamping operation, the process may be modified by adding a blowing agent to the formulation of the viscoelastic layer.
  • the blowing agent can be activated by heating after the stamping operation, thus foaming the viscoelastic layer and filling any voids which may exist between the two sheet metal layers.
  • the necessary heat would generally be provided in the paint and bake cycle.
  • One advantage, realized with oil pans, is that the constraining layer is protected from road salt.
  • automotive enclosures can be fabricated with the viscoelastic layer or sound-dampening material and constrain- ing layer on the outside of the enclosure using a stamping technique analogous to that illustrated in FIGS.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Multimedia (AREA)
  • Laminated Bodies (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)

Abstract

Procédé de production d'une pièce d'enceinte antisonique pour automobile, tel qu'un carter d'huile (10), doté d'une couche de contrainte en métal (13) ainsi que d'une couche de logement en métal (13) entre lesquelles est prise en sandwich une couche viscoélastique. Dans un mode de réalisation préféré, la couche de contrainte ainsi que la couche viscoélastique est placé entre la couche de logement et la matrice pendant que la couche de logement est étirée. Ainsi, l'on obtient un ajustage très étroit et à frottement doux entre les couches, ce qui améliore l'efficacité de l'armortissement des bruits. L'article ainsi produit est également décrit.
PCT/US1992/003756 1991-05-09 1992-05-06 Procede de production d'une piece d'enceinte a antisonique pour automobile et article ainsi produit Ceased WO1992019398A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP4512009A JPH06510703A (ja) 1991-05-09 1992-05-06 制音型の自動車用のカバーを製造する方法及び該方法により製造される製品

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US69780291A 1991-05-09 1991-05-09
US697,802 1991-05-09

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WO1992019398A1 true WO1992019398A1 (fr) 1992-11-12

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0734853A3 (fr) * 1995-03-29 1997-03-12 Nichias Corp Matériau amortissant les vibrations du type contrainte
EP0884139A3 (fr) * 1997-06-12 1999-06-23 Socomec - Societa' Costruzioni Meccaniche Societa' per Azioni Marteau à percussion hydraulique
WO2002024370A3 (fr) * 2000-09-22 2002-07-04 Univ Michigan State Hydroformage de matériaux composites
EP4446099A1 (fr) * 2023-04-12 2024-10-16 The Boeing Company Outils d'estampage souples, systèmes et procédés pour estamper une pièce à usiner

Families Citing this family (5)

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Publication number Priority date Publication date Assignee Title
JP4518699B2 (ja) * 2001-05-01 2010-08-04 本田技研工業株式会社 ２枚重ね製品のプレス成形装置
JP4518698B2 (ja) * 2001-05-01 2010-08-04 本田技研工業株式会社 ２枚重ね製品のプレス成形装置
DE10357175B4 (de) * 2003-12-06 2006-03-16 Mtu Friedrichshafen Gmbh Bodenplatte für ein Kurbelgehäuse
WO2011159567A2 (fr) * 2010-06-16 2011-12-22 Shiloh Industries, Inc. Pièce d'absorption du bruit
CN103547485B (zh) * 2011-03-22 2015-12-23 夏伊洛工业公司 具有多层消声补片的面板组件

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Publication number Priority date Publication date Assignee Title
US3489242A (en) * 1969-04-01 1970-01-13 Du Pont Acoustical panel comprising viscoelastic material with heavy filler particles
US4315971A (en) * 1979-05-23 1982-02-16 Massey-Ferguson Services N.V. Sound deadening
US4472955A (en) * 1982-04-20 1984-09-25 Amino Iron Works Co., Ltd. Metal sheet forming process with hydraulic counterpressure
US4678707A (en) * 1984-06-29 1987-07-07 Kawasaki Steel Corporation Vibration damping composite laminate
US4851271A (en) * 1987-10-01 1989-07-25 Soundwich Incorporated Sound dampened automotive enclosure such as an oil pan

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Publication number Priority date Publication date Assignee Title
US3489242A (en) * 1969-04-01 1970-01-13 Du Pont Acoustical panel comprising viscoelastic material with heavy filler particles
US4315971A (en) * 1979-05-23 1982-02-16 Massey-Ferguson Services N.V. Sound deadening
US4472955A (en) * 1982-04-20 1984-09-25 Amino Iron Works Co., Ltd. Metal sheet forming process with hydraulic counterpressure
US4678707A (en) * 1984-06-29 1987-07-07 Kawasaki Steel Corporation Vibration damping composite laminate
US4851271A (en) * 1987-10-01 1989-07-25 Soundwich Incorporated Sound dampened automotive enclosure such as an oil pan

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0734853A3 (fr) * 1995-03-29 1997-03-12 Nichias Corp Matériau amortissant les vibrations du type contrainte
US5939179A (en) * 1995-03-29 1999-08-17 Nichias Corporation Constraint type vibration damping material
EP0884139A3 (fr) * 1997-06-12 1999-06-23 Socomec - Societa' Costruzioni Meccaniche Societa' per Azioni Marteau à percussion hydraulique
WO2002024370A3 (fr) * 2000-09-22 2002-07-04 Univ Michigan State Hydroformage de matériaux composites
US6631630B1 (en) 2000-09-22 2003-10-14 Board Of Trustees Of Michigan State University Hydroforming of composite materials
EP4446099A1 (fr) * 2023-04-12 2024-10-16 The Boeing Company Outils d'estampage souples, systèmes et procédés pour estamper une pièce à usiner

Also Published As

Publication number Publication date
CA2102708A1 (fr) 1992-11-10
JPH06510703A (ja) 1994-12-01

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