The present invention relates to moulded light weight carrier backed
polyurethane foam based noise insulation for automobile.
More particularly the present invention relates to for reduction in weight
and improvement in acoustical performance of noise insulation for
Commercial Vehicles such as tracks and busses but not limited to , and other
automobile noise insulation a like , for application in areas such as , Under
Body noise insulation , engine room noise shield , acoustical insulation for oil
sump bottom ,cab rear, gear box bottom , engine side LH side RH etc .
Prior Art
For many years Glass Wool or Phenolic resin based felts or PU Foams
with a carrier such as Polypropylene , HMHDPE , or FRP are widely used in
commercial vehicles for the propose of acoustical insulation of passenger
compartment and to meet the passer by noise government regulations
In recent years PU Foam with or with out a carrier of material such as PP ,
HMHDPE or Fiber Reinforced Plastic , mainly is being used in Heavy ,
Medium , Light Duty Commercial Vehicles such as trucks , busses and off
road vehicles as engine noise insulations. As the regulations are getting
stringent with time , and passenger demand is also growing ,industry is
experiencing more use of these materials.
According to wikipedia Polyurethane products have many uses. Over three
quarters of the global consumption of polyurethane products is in the form of
foams, with flexible and rigid types being roughly equal in market size. In both
cases, the foam is usually behind other materials: flexible foams are behind
upholstery fabrics in commercial and domestic furniture; rigid foams are inside

the metal and plastic walls of most refrigerators and freezers, or behind paper,
metals and other surface materials in the case of thermal insulation panels in the
construction sector. Its use in garments is growing: for example, in lining the
cups of brassieres. Polyurethane is also used for moldings which include door
frames, columns, balusters, window headers, pediments, medallions and
rosettes.
Polyurethane formulations cover an extremely wide range of stiffness,
hardness, and densities. These materials include:
• Low-density flexible foam used in upholstery, bedding, and automotive
and truck seating
• Low-density rigid foam used for thermal insulation and RTM cores
• Soft solid elastomers used for gel pads and print rollers
• Low density elastomers used in footwear
• Hard solid plastics used as electronic instrument bezels and structural
parts
• Flexible plastics used as straps and bands
Polyurethane foam is widely used in high resiliency flexible foam seating,
rigid foam insulation panels, microcellular foam seals and gaskets, durable
elastomeric wheels and tires, automotive suspension bushings, electrical potting
compounds, seals, gaskets, carpet underlay, and hard plastic parts (such as for
electronic instruments).
Disadvantages of prior art
A major disadvantage of use of conventional configuration of presently used
material is either it is not environmental friendly such as Glass Wool or

Phenolic Resin er- component weight becomes high ,there by reducing fuel
efficiency for combination of PU Foam with carrier of PP or HMHDPE or FRP.
How you propose overcoming prior art
For many years Glass Wool or Phenolic resin based felts or PU Foams
with a carrier such as Polypropylene , HMHDPE , or FRP are widely used in
commercial vehicles for the propose of acoustical insulation of passenger
compartment and to meet the passer by noise government regulationsr
In recent years PU Foam with or with out a carrier of material such as PP ,
HMHDPE or Fiber Reinforced Plastic , mainly is being used in Heavy ,
Medium , Light Duty Commercial Vehicles such as trucks , busses and off
road vehicles as engine noise insulations. As the regulations are getting
stringent with time , and passenger demand is also growing ,industry is
experiencing more use of these materials.
A major disadvantage of use of conventional configuration of presently
used material is either it is not environmental friendly such as Glass Wool or
Phenolic Resin or component weight becomes high , there by reducing fuel
efficiency for combination of PU Foam with carrier of PP or HMHDPE or FRPr
Brief manufacturing Process Example .
1 .Compression Moulding of Fibrous carrier
2.Cut to profile shape of Moulded Fibrous Carrier
3.Fire Resistant PUF injection on cut to shape of Moulded Fibrous Carrier

4.Finishing of Fire Resistant PUFoam and Lamination of Fire Resistant Non
Woven Fabric / Woven Fabric / PVC Film
Advantages of proposed material over prior art
The main features of this invention is PCP NS/UB 3512 having the
following properties:
a) Lighter in weight than similar products
b) Better acoustical property
c) Lower Fuel consumption due to being lighter in weight
d) Good. thermal property.
e) No degrading of material when soiled in water
f) Carrier and Absorber are recyclable
g) Absorber and cover is Fire Resistant.
These problems are over come by present invention which provides a composite
layer of acoustical insulation for mainly used as engine noise shields and
passenger cabin under body noise shield for Heavy, Medium and Light duty
commercial vehicle ,but not limited to, herein referred as PCP - NS / UB -
3512 having material composite layers consisting of a Carrier material made up
of either wholly or partially fibrous felt (fire resistance / non fire resistance)
with or without in combination of fire resistant rigid PU Foam with or without
film lamination having an acoustical absorber layer of fire resistant PU Foam
here in referred as PFRO a developed Polyurethane Foam (patent application no
936/KOL/2011) and the absorber is covered with Fire resistant Non woven or
Woven Fabric or Fire Resistant Film where in it maintains its formability ,
mouldability to different shape and size-as per the acoustical and ultimate

product design requirement for acoustical property similar to or better from
presently used such products in industry .
The carrier PCP NS-UB3512 can be used in engine compartment and passenger
compartment as noise insulation. A typical composition of PCP NS/UB 3512
consists of Carrier (fire resistance / non fire resistance ) of GSM ( Grams per
square meter ) 200 to 5500 , with PUFoam ( PFRO) density range 40 kg/m3 to
200 kg/m as per the acoustical property requirement with a property of no burn
rate and self extinguishing and covering material of Fire Resistant, Non Woven
or Woven or Film of 80 to 300 Grams per square meter.
The main features of this invention is PCP NS/UB 3512 having the following
advantages :
h) Lighter in weight than similar products
i) Better acoustical property
j) Lower Fuel consumption due to being lighter in weight
k) Good thermal property.
1) No degrading of material soiled in water .
m) Carrier and Absorber are recyclable
To assist with the understanding of the invention explanation of the invention
will now be made as below .
Carrier Material is made from commercially available regenerated or virgin
either wholly or partially Natural or Synthetic fibrous felt ( fire resistance/ non
fire resistance) with or without in combination of fire resistant rigid PU Foam
of gsm 200 to 5500 which acts as product shape retainer and also an
acoustical property enhancer with or without lamination of either or ,material
,such as but not limited to fire resistant woven or non woven fabric or film of
50 to 300 gsm .An acoustical absorber of fire resistant Paracoat developed PU

Foam PFRO of density 40 kg/m3 to 200 kg/m3 is injected on molded carrier ,and
after finishing of the part Fire resistant Non woven or woven fabric or film of
typical gsm 80 to 300 is pasted on absorber such that absorber surface is
wholly covered with fabric or film .
The PCP NS/UB-3512 thus formed is then tested namely but not limited to tests
such as acoustical property , density , fire resistance property, flame drip
property, water soiling and thermal property.
We shall now describe the present invention with accompanying drawings
which has given by way of illustration but does not restrict the scope of present
invention
Fig 1 of the accompanying drawing shows Film Laminated Carrier : 1200 (
±10%) grams /m2 + Fire resistance PU Foam PFRO of density 80 (■ ± 10 % )kg
/m3 + Fire resistance Film 80 (± 10%) grams /m2
2) Burn rate when tested as per IS 15061 Annex A :
a) Fibrous Carrier : ( Fire Resistance ) : Zero mm / minute ,No flame drip
Non Fire Resistance : Less than 100 mm ./ minute , No flame drip
b) FR Rigid PU Foam : Zero mm / Minute . No Burn Rate and self
extinguishing Absorber, no flame drip
c) PU Foam -( PFRO ) : Zero mm / Minute . No Burn Rate and self
extinguishing, no flame dripping '
d) Cover Cloth ( Non Woven / Woven), Film : Zero mm / Minute . No
Burn Rate and self extinguishing

According to the present invention there is provided moulded light weight
carrier backed polyurethane foam based noise insulation for automobile,
comprising acoustical insulation for mainly used as engine noise shields and
passenger cabin under body noise shield for Heavy , Medium and Light duty
commercial vehicle, herein referred as PCP - NS / UB - 3512 having material
composite layers consisting of a Carrier material made up of either wholly or
partially fibrous felt ( fire resistance / non fire resistance ) with or without in
combination of fire resistant rigid PU Foam with or without film lamination
having an acoustical absorber layer of fire resistant PU Foam here in referred
as PFRO Polyurethane Foam ( details given in patent application no
936/KOL/2011 ) and the absorber is covered with Fire resistant Non woven or
Woven Fabric or Fire Resistant Film where in it maintains its formability,
mouldability to different shape and size-as per the acoustical and ultimate
product design requirement for acoustical property similar to or better from
presently used such products in industry .
The said structure is lighter in weight than similar products;
The said structure is better acoustical property;
The said structure is moulded light weight carrier;
The said structure is lower Fuel consumption due to being lighter in
weight;
The said structure has good thermal property;

The said structure is no degrading of material when soiled in water;
The said structure Carrier and Absorber are recyclable;
The said structure Absorber and Cover is Fire Resistant;
This invention has been made keeping in mind the current and future
requirements, both regulatory and non regulatory , in the automotive industry
mainly for better noise insulation , weight reduction , enhanced durability ,
environment friendly and higher safety.
This invention helps in reduction of weight thereby leading to savings in fuel
consumption , which in turn helps the national economy by conservation of
scarce fossil fuel resources and also helps in conservation of foreign exchange
reserve.
This invention also helps in product being more environment friendly due
to high possibility of recycle .The invention of this product greatly enhances the
safety factor of both vehicle and its passengers by being fire resistant.
The product invention helps in not only achieving better acoustical property but
also enhanced durability compared to presently used similar products .

WE CLAIM
1. Moulded light weight carrier backed polyurethane foam based noise
insulation for automobile, comprising acoustical insulation for mainly used as
engine noise shields and passenger cabin under body noise shield for Heavy
Medium and Light duty commercial vehicle, herein referred as PCP - NS / UB
- 3512 having material composite layers consisting of a Carrier material made
up of either wholly or partially fibrous felt natural / synthetic , virgin /
regenerated ( fire resistance / non fire resistance ) with or without in
combination of fire resistant rigid PU Foam with or without film lamination
having an acoustical absorber layer of fire resistant PU Foam here in referred
as PFRO Polyurethane Foam ( details given in patent application ho
936/KOL/2011 ) and the absorber is covered with Fire resistant Non woven or
Woven Fabric or Fire Resistant Film where in it maintains its formability,
mouldability to different shape and size-as per the acoustical and ultimate
product design requirement for acoustical property similar to or better from
presently used such products in industry .
2. Moulded light weight carrier backed polyurethane as claimed in claim 1,
wherein the said structure is lighter in weight than similar products;
3. Moulded light weight carrier backed polyurethane as claimed in any one
of claim s 1 or 2, wherein the said structure is better acoustical property;

4. Moulded light weight carrier backed polyurethane as claimed in claim
any one of clams 1 to 3, wherein the said structure is lower Fuel consumption
due to being lighter in weight;
5. Moulded light weight carrier backed polyurethane as claimed in any one
of claims 1 to 4, wherein the said structure is good thermal property;
6. Moulded light weight carrier backed polyurethane as claimed in any of
claims 1 to 5, wherein the said structure is no degrading of material when soiled
in water;
7. Moulded light weight carrier backed polyurethane as claimed in any one
of claims 1 to 6, wherein the said structure is carrier and Absorbed are
recyclable;
8. Moulded light weight carrier backed polyurethane as claimed in any
one of claims 1 to 7, wherein the said structure is absorber and cover is Fire
Resistant. .

ABSTRACT

Moulded light weight carrier backed polyurethane foam based noise insulation
for automobile, comprising acoustical insulation for mainly used as engine
noise shields and passenger cabin under body noise shield for Heavy, Medium
and Light duty commercial vehicle, herein referred as PCP - NS / UB - 3512
having material composite layers consisting of a Carrier material made up of
either wholly or partially fibrous felt natural / synthetic , virgin / regenerated (
fire resistance / non fire resistance ) with or without in combination of fire
resistant rigid PU Foam with or without film lamination having an acoustical
absorber layer of fire resistant PU Foam here in referred as PFRO Polyurethane
Foam ( details given in patent application no 936/KOL/2011 ) and the absorber
is covered with Fire resistant Non woven or Woven Fabric or Fire Resistant
Film where in it maintains its fonnability, mouldability to different shape and
size—as per the acoustical and ultimate product design requirement for
acoustical property similar to or better from presently used such products in
industry.