Technical Field

The invention relates to a composite panel intended to be used for providing heat insulation, meeting acoustic requirements, preventing vibrations and reducing the weight of vehicles. The invention in particular relates to a composite panel with an integrated structure comprising acoustic, adhesive lamination and shock absorbing layers placed over a main layer, and a method for manufacturing this composite panel.

Background Art Use of multilayer structures in manufacturing of engineered insulation coating materials that are used in automotive, construction, white goods, road construction, tunnel construction and other industrial areas is becoming more widespread. Composite structures may be made of a combination of synthetic and natural raw materials. In the recent years, recyclable raw materials also took their place among such raw materials. In the prior art, parts are manufactured by forming sheet metal materials. The insulation part is formed by a separate process and mounted to this sheet part using lamination technique.

A large number of manufacturing processes are used in the background art, resulting in increased product costs. Furthermore, a heavyweight product is obtained since the product mostly consists of sheet metal raw material.

The partition sheet metal that is used as a separating panel in vehicles is observed to have a negative effect on the comfort parameter during road testing due to the noises caused by vibrations and flexion of it, creating a discomfort for the driver and the passengers.

Turk Patent Enstitusu (Turkish Patent Institute) application document no. TR2014/15445 describes a manufacturing method for a lightweight flooring material for land, air and water-borne vehicles. The invention relates to a method for manufacturing panels and especially flooring (floor cover) of land, air and water-borne motor vehicles from a lightweight, but with a high strength composite material, that is organic and compatible with human health standards, in order to keep the curb weight of these vehicles at a minimum level.

Turk Patent Enstitusu (Turkish Patent Institute) application document no. TR2014/15512 describes an elevated flooring panel made from a composite panel with an aluminum honeycomb core. The invention relates to an elevated flooring panel made form a composite panel with an aluminum honeycomb core. The elevated flooring panel comprises an element formed as the lower panel, an aluminum honeycomb core placed inside this element, and an aluminum panel which covers the both. There are noise and vibration problems associated to the metal material. Another object of the invention is to provide shock absorbance in order to increase the level of life safety against accidents.

Therefore, all of the aforementioned factors has made it necessary to make a development in the related field.

Object of the Invention

All of the aforementioned factors has made it necessary to make a development with the invention in the related field.

Objects of the invention:

• Reduce the curb and parts weight of the vehicle,

· Decrease parts manufacturing costs,

• Decrease assembling labor and cost of the parts,

• Reduce vibrations and acoustic problems to a minimum target level,

• Provide shock absorbance in order to increase the level of life safety against accidents,

· Improve safety coefficient during crash tests,

• Reduce the noise level inside the vehicle due to vibrations,

• Increase the use of recyclable materials,

• Enhance the parts strength. In order to meet all of the aforementioned objects along with those that will become apparent with the detailed description below, the present invention provides a composite panel intended to be used to prevent heat, noise and vibrations; characterized in that it comprises at least one acoustic layer placed over the main layer, an adhesive lamination layer which is placed over the acoustic layer, and a shock absorbing layer placed over the adhesive lamination layer.

A preferred embodiment of the invention comprises an undercoating introduced over the acoustic layer.

A preferred embodiment of the invention comprises a cover coating introduced over the acoustic layer.

Furthermore, the invention provides a method for manufacturing a composite panel. This comprises the following process steps: a) Placing acoustic layers at bottom and top sides of a main layer,

b) Heating the layers together as a whole,

c) Forming the layers by molding,

d) Placing an adhesive lamination layer over the layers,

e) Placing a shock absorbing layer over the adhesive lamination layer,

f) Binding all of the layers together by applying adhesive,

g) Cutting all of the layers using the desired dimensions.

Brief Description of Drawings

Figure 1 represents a side view of the internal structure of the composite panel. Figure 2 shows a partition wall made of composite panel.

Figure 3 shows the composite panel when it is used as a partition wall inside a vehicle.

Reference Numbers Used In the Drawings 10. Composite panel

11. Cover coating

12. Shock absorbing layer 13. Adhesive lamination layer

14. Acoustic layer 15. Main layer

16. Undercoating 20. Partition wall

Detailed Description of the Invention The composite panel (10) of the invention is described herein the detailed description to help better understand the subject matter, without being limiting in any manner.

The invention relates to a composite panel (10) intended to be used to prevent heat, noise and vibrations.

Figure 1 represents a side view of the internal structure of the composite panel (10). The composite (10) panel is characterized in that it comprises at least one acoustic layer (14) placed over a main layer (15), an adhesive lamination layer (13) which is placed over the acoustic layer (14), and a shock absorbing layer (12) placed over the adhesive lamination layer (13). It is further characterized in that it comprises an undercoating (16) and a cover coating (1 1 ) placed over the acoustic layer (14). Preferably, a fabric suitable for forming, with high acoustic performance and made of knitted fabric is chosen for the cover coating (1 1 ) material. The cover coating (1 1 ) is first of all connected to the shock absorbing layer (12) during manufacturing.

The shock absorbing layer (12) preferably has a low density PU or PES based sponge structure. It absorbs the incident impacts and provides sound absorption. It is combined with the cover coating (1 1 ) surface using flame lamination and prepared for the coating.

The adhesive lamination layer (13) is a Z adhesive film layer which laminates the shock absorbing layer (12), which have been applied with cover coating (1 1 ), and the layers (14, 15). The lamination is obtained by applying the adhesive lamination layer (13) at the fabric coating cabin. It also improves the sound absorption level. It also has the capability of clogging fiber pores.

The acoustic layer (14) establishes the formability ability of the composite panel (10) and provides a structural filling for the main layer (15). It meets the acoustic requirements/intents. It has the form of thermoplastic or thermoset felt. It consists of low density, natural and synthetic fibers. It also contains glass fiber or carbon fiber ores to support the main layer (15). The main layer (15) is the main bearer frame element which protects the integrity of the composite panel (10) and supports its form strength. It provides rigidity. It is designed as a custom engineered plastic.

Preferably, a fabric suitable for forming, having a high acoustic performance made of knitted fabric is used as undercoating (16) material. It has vibration preventing and sound absorbing properties.

Figure 2 shows a partition wall (20) made of composite panel (10). The partition wall (20) can be utilized in a vehicle as seen in Figure 3.

The invention is a composite panel (10) which is obtained using a method which enables manufacturing of composite panels (10). The method of the invention comprises the following process steps: a) Placing acoustic layers (14) at bottom and top sides of a main layer (15), b) Heating the layers together (14, 15) as a whole,

c) Forming the layers (14, 15) by molding,

d) Placing an adhesive lamination layer (13) over the layers (14, 15),

e) Placing a shock absorbing layer (12) over the adhesive lamination layer (13), f) Forming all of the layers (12, 13, 14, 15) as a whole,

g) Binding all of the layers (12, 13, 14, 15) together by applying adhesive,

h) Cutting all of the layers (12, 13, 14, 15) as a whole using the desired dimensions.

The process steps are implemented as follows: obtaining a whole by scaling the layers (14, 15) and the undercoating (16) by stacking them. These layers (14, 15, 16) are placed into a custom design heating furnace. Top and bottom layer temperatures are set to 180-200C and the furnace separation is set to 35mm. The layers (14,15,16) are heated for 3-5 minutes until the forming temperature is achieved. The process is executed in a heating and lamination furnace. When the layers (14,15,16) reach the forming temperature, they are transferred to a cold mold and preferably maintained under 400 tons pressure and 7-10 ^< C surface temperature for 120-150 seconds. The layers (14,15,16) are part formed using pressure and shock cooling and become ready for molding. The process is executed in a forming press. During the application of adhesive and inside the fabric coating cabin, an adhesive lamination layer (13) (Z adhesive film) is obtained on the outside surfaces of the shock absorbing layer (12), to which cover coating (1 1 ) has been applied, and layers (14, 15) facing each other. The adhesive lamination layer (13) is left for drying for 5-10 minutes. After completion of the preconditions for lamination of the adhesive lamination layer (13) (after completion of the charging period), coating and lamination process is again applied to all of the layers (12, 13, 14, 15) by exerting pressure under room temperature using a forming press.