Cascade Engineering, Inc.

Dow Global Technolgoies LLC

Michael T Campbell

Andrew Skestone

Andrew R Skestone

Eric G Owen

An acoustic fiber silencer for a motor vehicle includes a first sound absorbing layer and a second sound insulating layer. The layers are formed of lightweight fibrous material, and the sound insulating layer is quilted. The acoustic fiber silencer includes a frame to which the sound absorbing and sound insulating layers are secured. The frame provides structural support and shape to the sound absorbing and sound insulating layers. The acoustic fiber silencer is lightweight while maintaining excellent noise attenuation properties.

Acoustic fiber silencer

A hybrid acoustic silencer for a motor vehicle includes an insertion loss layer tuned for good insertion loss properties at specific frequencies and an absorption layer tuned for good absorption properties at specific frequencies. The insertion loss layer is configured to be adjacent to a sound radiating surface of the motor vehicle and the absorption layer is configured to face outward from the sound radiating surface of the motor vehicle.

Hybrid acoustic silencer

An acoustic barrier that achieves excellent noise insulating properties, and is relatively thin and relatively light in weight includes a flexible thermoplastic barrier layer having a plurality of apertures defining a latticed structure which includes apertures for pass-through components and non-pass-through apertures. The non-pass-through apertures are located where noise levels are expected or known to be relatively low. Effective acoustic performance can be maintained by completely eliminating material from the relatively thick and dense barrier layer at the low noise levels areas, and providing only absorptive decoupler material and/or lightweight sheet material such as plastic films in those areas.

Vehicle acoustic barrier

An acoustic barrier systems that reduces the amount of noise entering the passenger compartment of a vehicle includes a secondary acoustic attenuator that extends from a primary acoustic barrier to a vehicle component case to envelop space around a conduit passing from the engine compartment to the component case. In one embodiment, the secondary acoustic attenuator extends from the primary acoustic barrier to the component case, with the secondary acoustic attenuator enveloping space around the conduit between the vehicle component case and the primary acoustic barrier. In another embodiment, the secondary acoustic attenuator is hingedly connected to the primary acoustic barrier to allow the secondary acoustic attenuator to be pivoted, from an orientation that allows installation of the vehicle component case, to another orientation wherein the secondary acoustic attenuator engages the vehicle component case to envelop space around the conduit between the vehicle component case and the primary acoustic barrier.

Secondary acoustic attenuator for vehicle

A dash mat for blocking the transfer of sound from a vehicle engine compartment, through a firewall, and into a passenger compartment. The dash mat being mounted to the firewall and comprising a planar sheet in which is formed a channel for receiving a vehicle accessory, such as a wiring harness, and a pair of resilient fingers positioned on opposite sides of and overlying the channel to hold the vehicle accessory within the channel.

Mat with integral wire harness fastener and channel

A dash mat for blocking the transfer of sound from the vehicle engine compartment, through the firewall, and into the passenger compartment. The dash mat comprising a planar sheet having a pair of opposed doors aligned with an opening in the firewall through which passes a vehicle accessory. The doors move between an open position, where the vehicle accessory can be passed through, and a closed position, where the doors seal the vehicle accessory relative to the planar sheet.

Mat with integrally molded door

An acoustical barrier (10) for mounting to the fire wall (20) of a motor vehicle includes a sound barrier layer (12) of a molded construction and sound dampening characteristics. The sound barrier layer (12) has an integrally molded boot (40) for receiving and acoustically sealing a steering column (70). The boot (40) has a base portion (42) integrally molded with a convolute portion (48), and a cap portion (56) integrally molded with the convolute portion (48). The convolute portion (48) includes a continuous outer wall section (50) surrounding an opening (46) in the sound barrier layer (12). The continuous outer wall section (50) has an upper end integrally formed with a flexible bight portion (54). A continuous inner wall (52) has an upper end integrally formed with the bight portion (54) and a lower end integrally formed with the cap portion (56). The cap portion (56) has an opening coincident with the openings (46, 78) in the sound barrier layer (12) and fire wall (20), respectively. The thickness of the convolute portion (48) is less than the thickness of the base portion (42), cap portion (56) and sound barrier layer (12) to prevent distortion of the sound barrier layer (12) during installation of the steering column (70). An absorber layer (14) can be mounted between the sound barrier layer (12) and fire wall (20).

Sound insulating layer with integral boot

An acoustical barrier (10) for a vehicle having a barrier wall which includes a floor area (23) and a fire wall area (25) extending between a wheel well area (41) and a drive train area (42). The acoustical barrier (10) includes a mass layer (12) that covers at least a portion of the barrier wall. The mass layer (12) has an inner surface (16) that faces the barrier wall with an integrally formed peripheral rib (52) projecting therefrom. A first set of elongate ribs (48) intersects and joins with a second set of elongate ribs (50). The first and second sets of elongate ribs (48, 50) are located within the enclosed area. Each elongate rib (48, 50) includes an upper portion integrally formed with the inner surface (16) of the mass layer and a lower portion with an outer edge (54, 60) adapted to at least face the barrier wall. Each elongate rib (48) of the first set of ribs also has opposite ends integrally formed with the peripheral rib (52) to thereby strengthen the peripheral rib against bending moments due to compression forces applied to the outer surface of the mass layer. Each elongate rib (50) of the second set of ribs has opposite ends integrally formed with either adjacent ribs (48) of the first set of ribs or the peripheral rib (52) and an adjacent rib (48) of the first set of ribs to thereby further strengthen the peripheral rib (52) against bending moments. The first set of ribs projects from the inner surface of the mass layer a greater distance than the second set of ribs to provide increasing levels of impact resistance to the outer surface of the mass layer.

Sound insulating layer with integral rib structure

A mold for molding thermoplastic parts having a plurality of pinholes wherein at least one of the mold cavities has a number of projections in the form of three-dimensional tapering shapes, for example, cones, which extend to a point near to but spaced from the confronting surface of the other mold half cavity. The taper of the angle of the projection and spacing between the apices of the projection and the surface of the other mold half are selected so that molten thermoplastic freezes before it covers the apices of the projections during the molding process to thereby form pinholes in the resulting plastic part. A method for molding plastic parts with pinholes with the use of the mold cavity with multiple projections is also disclosed.

Injection molding parts with pinholes

A barrier wall (24) separating a passenger compartment from an engine compartment of a motor vehicle has an acoustical barrier assembly (102) mounted thereto. The acoustical barrier assembly (102) includes first and second mat portions (104, 106) juxtaposed to each other in overlapping relationship. Each mat portion (104, 106) is preferably of a molded construction and has sound dampening characteristics. The first and second mat portions (104, 106) each have a terminal edge (130, 122). The terminal edge (130) of the second mat portion is in engagement with one of the surfaces of the first mat portion to thereby acoustically seal the first and second mat portions together. Spacer ribs (124, 132) are integrally with the first and second mat portions (104, 106). Each ribs (124, 132) extends from its corresponding mat portion to the other mat portion. The spacer ribs (124, 132) are preferably adjacent to but spaced from the terminal edges (122, 130) of their respective mat portions to space the mat portions from each other.

System for fastening sheet materials together

A barrier wall (20) separating a passenger compartment from an engine compartment of a motor vehicle has an acoustical barrier assembly (10) mounted thereto. The acoustical barrier assembly (10) includes a sound barrier layer (12) of a molded construction and sound dampening characteristics. At least one fastener (28) is integrally molded as a single piece with the sound barrier layer (12). The fastener (28) includes a plurality of outer spacer ribs (30) that project laterally from a tube (32) and space an inner surface (24) of the sound barrier layer (12) away from the barrier wall (20). A circumferentially extending flange head (34) is integral with the tube (32) and includes a first frusto-conical section (36) and a second inverse frusto-conical section (38). The annular bases of the first and second sections (36, 38) are integrally formed together while a lower end of the second section (38) is integrally formed with the tube (32), such that insertion of the flange head (34) through a barrier wall aperture (46) requires less force than removal of the flange head therefrom.

System and method for fastening insulating layers to a support structure

An acoustical barrier (10) is mounted to the barrier wall (20) of a motor vehicle. The acoustical barrier (10) includes a mass layer (12) of molded construction and sound dampening characteristics. The mass layer (12) includes a plurality of grommets (14, 14', 14', 54) integrally molded as a single piece with a lower surface of the mass layer. Each grommet (14, 14', 14', 54) has a continuous wall with an inner peripheral surface (27, 27', 27') with an upper portion of the wall integrally formed with the inner surface (18) of the mass layer and a lower portion of the wall having a lower edge (22, 22', 22') abutting the barrier wall (20). The inner surface (27, 27', 27') of the continuous wall defines an opening in each grommet (14, 14', 14', 54). A plurality of openings (25, 25', 25') in the mass layer are in communication with at least some of the grommet openings. Various fasteners (26, 70), shafts or sleeves (62), cables (64), wires, and other vehicle accessories can extend through one or more of the grommets and through corresponding openings (29) in the vehicle barrier wall (20)

Insulating layer with integral grommets

An integral fastener particularly for use in mounting a sheet material to a structural member with a plurality of threaded studs. The integral fastener in one embodiment is connected to the sheet by a web adjacent an aperture in the sheet. The fastener has an opening that defines multiple flaps. To fasten the sheet material to the stud, the stud is inserted through the sheet aperture and the fastener is pressed on the stud so that it extends through the fastener opening, deflecting the flaps, which engage the threads of the stud. In another embodiment, the fastener is formed within the sheet and defines an opening through which the stud passes. In a third embodiment, the stud comprises a T-shaped flange and the fastener has a slotted opening at an acute angle to the plane of the T-shaped flange to retain the fastener on the T-shaped flange.

Growing community of inventors

Grand Rapids, MI, United States of America

Michael T Campbell