Sound insulation with multilayer fiber insulation; and method of manufacturing the same
Disclosed is a floor covering insulation for a motor vehicle with a multi-layer, preferably flocked, fibre insulation which, by a soft/smooth coupling layer to the wear surface, realises a sound insulation floor covering with improved acoustic and mechanical-physical properties, with a simultaneous reduction in weight if possible. Also disclosed is a method for manufacturing the sound insulation.
1 . A method for producing a sound-insulating floor covering having a multilayer insulation device, wherein the insulation device extends along a longitudinal direction, a width direction and a thickness direction, and the insulation device has different acoustic, mechanical or physical properties in at least one of said directions, said method comprising the steps of:
(a) providing an insulation device comprising a coupling layer having a floor contacting layer in a form of a flocked fiber layer thereon;
(b) transporting the insulation device with the flocked fiber layer from step (al into a steam/vacuum tool and applying steam from an underside of the insulation device; and
(c) cooling, cutting and positioning the insulation device from step (b) to fit in a motor vehicle.
2 . The method according to claim 1 , further comprising:
providing a wear layer having a plurality of sublayers formed in a separate step and bonding the wear layer to the insulation device.
3 . The method according to claim 2 , further comprising:
separately trimming the insulation device and the wear layer in a separate trimming step.
4 . The method according to claim 2 , wherein the wear layer includes underlayers, and the method further comprises heating the wear layer with underlayers in a separate heating device.
5 . The method according to claim 1 , wherein the coupling layer comprises a fiber layer, and the method further comprises consolidating the coupling laver and the flocked fiber layer by application of steam.
6 . The method according to claim 5 , wherein the step of cooling the insulation device is performed following the application of steam in a calibration tool or a storage tray, before cutting and positioning the insulation device in the motor vehicle.
7 . The method according to claim 5 , further comprising:
depositing the insulation device on a gripping device using a flow tube, and employing the gripping device to transport the insulation device into the steam/vacuum tool.