Covering element comprising a sound absorbing element
The present invention relates to a covering element comprising a carrier element of fibre-reinforced thermoplastic plastic material, at least one sound-absorbing element extending over at least a part of the surface of the carrier element, and an adhesive layer extending over and beyond at least a part of the surface of the sound-absorbing element, wherein at least a part of the adhesive layer is adhered to the carrier element such that the sound-absorbing element is at least partly enclosed between the adhesive layer and the carrier element, to a method for manufacturing the covering element and the use thereof.
1. Covering element, comprising:
a carrier element of fiber-reinforced thermoplastic plastic material,
at least one sound-absorbing element extending over at least a part of the surface of the carrier element, and
an adhesive layer extending over and beyond at least a part of the surface of the sound-absorbing element, wherein at least a part of the adhesive layer is adhered to the carrier element such that the sound-absorbing element is at least partly enclosed between the adhesive layer and the carrier element and wherein the covering element is at least partially moulded,
wherein the adhesive layer is separable from the carrier element to allow removal of the sound absorbing element from between the carrier element and the adhesive layer.
2. Covering element as claimed in claim 1 , wherein the sound-absorbing element is enclosed substantially wholly by the adhesive layer and the carrier element.
3. Covering element as claimed in claim 1 , wherein the adhesive layer is a foil or a fleece.
4. Covering element as claimed in claim 1 , wherein a second adhesive layer is arranged between the sound-absorbing element and the carrier element.
5. Covering element as claimed in claim 1 , wherein the thermoplastic plastic material is a polyolefin.
6. Covering element as claimed in claim 1 , wherein the fiber-reinforced thermoplastic plastic material of the carrier element has a fiber percentage in the range of 5 to 80% by weight.
7. Covering element as claimed in claim 1 , wherein the fibers of the carrier element comprise glass fibers and/or basalt fibers and/or natural fibers.
8. Covering element as claimed in claim 7 , wherein the natural fibers comprise hemp fibers, banana fibers, coconut fibers and/or flax fibers.
9. Covering element as claimed in claim 1 , wherein the sound-absorbing element comprises an open-cell structure.
10. Covering element as claimed in claim 9 , wherein the open-cell structure comprises a foam material.
11. Covering element as claimed in claim 1 , wherein the sound-absorbing element comprises felt-like material, glass wool or rock wool.
12. Covering element as claimed in claim 1 , wherein the sound-absorbing element comprises separate parts with differing sound-absorbing properties.
13. Covering element as claimed in claim 1 , wherein the sound-absorbing element is provided with openings such that the adhesive layer is adhered to the carrier element via the openings.
14. Covering element as claimed in claim 1 , wherein the adhesive layer comprises the same thermoplastic material as the thermoplastic plastic material of the carrier element.
15. Covering element as claimed in claim 1 , wherein the adhesive layer is impregnated with an oil-repellent and/or fuel-repellent agent.
16. Covering element as claimed in claim 1 , wherein a thermo stable element is arranged between the carrier element and the sound-absorbing element and/or between the adhesive layer and the sound-absorbing element.
17. Covering element as claimed in claim 16 , wherein the thermo stable element and the sound-absorbing element are integrated.
18. Covering element as claimed in claim 1 , wherein a part of the covering element is provided with a heat-resistant element.
19. Covering element as claimed in claim 1 , wherein the covering element is substantially flat.
20. Covering element as claimed in claim 1 , wherein the fiber-reinforced thermoplastic plastic material of the carrier element comprises a glass mat-reinforced thermoplastic (GMT) or a long fiber-reinforced thermoplastic (LFT).
21. Method for manufacturing a covering element comprising:
i) arranging in a mould a carrier element of fiber-reinforced thermoplastic plastic material at increased temperature, a sound-absorbing element and an adhesive layer, such that the adhesive layer extends over at least a part of the surface of the sound-absorbing element;
ii) bringing the carrier element, the sound-absorbing element and the adhesive layer into the desired shape in the mould at increased pressure for the purpose of forming a covering element, wherein the fiber-reinforced thermoplastic plastic material of the covering element is in a viscous phase such that the plastic material spreads over the sound-absorbing element and over a part of the adhesive layer;
iii) cooling the covering element in the mould such that the fiber-reinforced thermoplastic plastic material forms a solid carrier element which is adhered to a part of the adhesive layer, and wherein the sound-absorbing element is at least partly enclosed between the carrier element and the adhesive layer, wherein the adhesive layer is separable from the carrier element to allow removal of the sound absorbing element from between the carrier element and the adhesive layer.
22. Method as claimed in claim 21 , wherein step i) comprises of heating the carrier element to a temperature of at least 175 to 275 degrees Celsius; preferably between 200 and 220 degrees Celsius, and arranging the heated carrier element in the mould.
23. Method as claimed in claim 21 , wherein the adhesive layer extends over substantially the whole surface of the sound-absorbing element in step i) such that the sound-absorbing element is enclosed substantially in its entirety between the carrier element and the adhesive layer when step ii) is performed.
24. Method as claimed in claim 21 , wherein the adhesive layer is a foil or fleece.
25. Method as claimed in claim 21 , wherein a second adhesive layer is arranged between the sound-absorbing element and the carrier element.
26. Method as claimed in claim 21 , wherein the thermoplastic plastic material comprises a polyolefin.
27. Method as claimed in claim 21 , wherein the fiber-reinforced thermoplastic plastic material is introduced in viscous state into the mould.
28. Method as claimed in claim 21 , wherein the adhesive layer is first placed in the mould, and then the sound-absorbing element and the thermoplastic plastic material.
29. Method as claimed in claim 21 , wherein the thermoplastic plastic material is first introduced into the mould, and then the sound-absorbing element and the adhesive layer.
30. Method as claimed in claim 21 , wherein the sound-absorbing element and the adhesive layer are combined outside the mould, and placed as total package into the mould.
31. Method as claimed in claim 21 , wherein the fiber-reinforced thermoplastic material of the carrier element has a fiber percentage in the range of 5 to 80%.
32. Method as claimed in claim 21 , wherein the fibers of the carrier element comprise glass fibers and/or basalt fibers and/or natural fibers.
33. Method as claimed in claim 21 , wherein the natural fibers comprise hemp fibers, banana fibers, coconut fibers and/or flax fibers.
34. Method as claimed in claim 21 , wherein the sound-absorbing element comprises an open-cell structure.
35. Method as claimed in claim 34 , wherein the open-cell structure comprises a foam material, preferably polyurethane.
36. Method as claimed in claim 21 , wherein the sound-absorbing element comprises felt-like material, glass wool or rock wool.
37. Method as claimed in claim 21 , wherein the adhesive layer comprises the same thermoplastic material as the carrier element.
38. Method as claimed in claim 21 , wherein the adhesive layer is impregnated with an oil-repellent and/or fuel-repellent agent.
39. Method as claimed in claim 21 , wherein a thermostable element is arranged between the carrier element and the sound-absorbing element and/or between the adhesive layer and the sound-absorbing element.
40. Method as claimed in claim 39 , wherein the thermostable element and the sound-absorbing element are integrated.
41. Method as claimed in claim 21 , wherein a part of the covering element is provided with a heat-resistant element, preferably an aluminium element.
42. Method as claimed in claim 21 , wherein the fiber-reinforced plastic material is a glass mat-reinforced thermoplastic (GMT) or a long fiber-reinforced thermoplastic (LFT).
43. Method as claimed in claim 21 , wherein the sound-absorbing element is provided with openings such that the adhesive layer is adhered to the carrier element via these openings.
44. Method as claimed in claim 21 , wherein the sound-absorbing element is arranged in a plurality of separate parts on the carrier part.
45. Method as claimed in claim 44 , wherein the sound-absorbing element comprises a plurality of separate parts with differing sound-absorbing properties.
46. Covering element obtainable in accordance with the method of claim 21 .
47. Vehicle covering element comprising a covering element as claimed in claim 1 .
48. Use of a covering element as claimed in claim 1 for covering a vehicle, preferably a car or aircraft.
49. Covering element as claimed in claim 1 , wherein the thermoplastic plastic material is a polypropylene, polyamide or polyethylene.
50. Method as claimed in claim 21 , wherein the thermoplastic plastic material comprises a polypropylene, polyamide or polyethylene.
51. Covering element as claimed in claim 1 , wherein the adhesive layer is removable from the carrier element.
52. Covering element as claimed in claim 1 , wherein the adhesive layer is openable to allow removal of the sound-absorbing element from between the carrier element and the adhesive layer without removing the adhesive layer.
53. Method as claimed in claim 21 , wherein the adhesive layer is removable from the carrier element.
54. Method as claimed in claim 21 , wherein the adhesive layer is openable to allow removal of the sound-absorbing element from between the carrier element and the adhesive layer without removing the adhesive layer.