MULTILAYER MOULDED FOAM STRUCTURE FOR VEHICLE COMPONENTS

FIELD OF THE INVENTION

The present invention generally relates to, a multilayered foam structure, said layered foam structure used to line vehicle components. In particular, the present invention relates to, the multilayered moulded foam structure, said foam structure being used to line vehicle components, especially, the hood of vehicles. Further still, the present invention relates to, the multilayered moulded foam structure, said structure being useable to line the hood of agricultural vehicles for e.g., Tractor(s).

BACKGROUND OF THE INVENTION

Tractors are indispensable in modern day agriculture, to meet rising demands of food grain consumption in developing countries and developed countries. While usage of tractors in agriculture ensures a high agricultural produce, however due to the environment in which agriculture is conducted, and also the continual operation of the tractors and other agricultural vehicles in the same league, it has been observed that, the noise generated is a health hazard to farmers and personnel who are employed to operate the agricultural vehicles for e.g., tractors. Conventionally, to deal with noise pollution generated due to tractors, a foam layer is employed to line the vehicle component for instance, the hood of the tractor. The foam layered on the hood portion acts as an acoustic shield, thereby, preventing the driver of the tractor or a farmer from the health hazards of noise pollution. A few foam layers which are employed for the purpose of acoustic shielding of the driver, have been revealed in the state of the art. The foam layers as revealed in the state of the art are not found to be satisfactory, since, foams conventionally used suffer from peel - off issues and water soaking, fire hazard etc.

There is therefore, a need in the art, for a multilayer molded foam, which can be used in both flat as well as, uneven surfaces. There is a further need in the art, for a multilayer molded foam, which can be used in smooth, as well as irregular surfaces with a lot of bends. There is a still further need in the art, for a multilayer molded foam, which can be adapted to be molded into any shape and is useful to accommodate, wherever the clearance is less. There is yet another need in the art, for a multilayer molded foam, which comprises a layer which is capable of preventing water ingress into the portions between the layers of the multilayer and increase transmission loss. There is yet another need in the art, for a multilayer molded foam, which provides better adhesion with the hood surface.

OBJECTIVES OF INVENTION

The present invention as embodied by a multilayer moulded foam structure for vehicle components, succinctly fulfils the abovementioned need(s) in the art. The objectives of the present invention are, as broadly enumerated in the present disclosure. However, it would be perfectly clear to a person skilled in the art that, inasmuch as the objectives have been enumerated, such objectives are only indicative of the scope and general coverage of the present invention. This statement of enumerated objectives should be considered as merely indicative, and is in no way restrictive of the scope and ambit of the present invention in its entirety. Not only the objectives as enumerated in the present disclosure should be considered as indicative of the scope and ambit of the present invention, in addition, any combination(s), variation(s), functional equivalent(s) and/or any structural alternative(s) should also be construed to be within the broad scope of the present invention, even though, such a scope of the present invention has not been explicitly stated herein or elsewhere in the present disclosure.

An objective of the present invention is a multilayer molded foam which can be used in both flat as well as, uneven surfaces. Yet another objective of the present invention is, a multilayer molded foam which can be used in smooth, as well as irregular surfaces with a lot of bends. Still another objective of the present invention is, a multilayer molded foam which can be adapted to be molded into any shape and variable thickness and is useful to accommodate, wherever the clearance is less. Further still another objective of the present invention is, a multilayer molded foam which comprises a layer which is capable of preventing water ingress into the portions between the layers of the multilayer. Further still another objective of the present invention is, a multilayer molded foam, which will provide better adhesion with the vehicle hood surface.

SUMMARY OF INVENTION

The present invention is embodied by a multilayer molded foam structure for vehicle components, so as to fulfill the above-mentioned objectives, said objectives sought to be fulfilled by the present invention. A person skilled in the art, is very well aware that, the objective(s) as enumerated and described in the present disclosure as embodied in the present invention, are merely illustrative of the scope and purview of the present invention, as described in the present disclosure. However, such an illustration may not be construed to restrict the present invention in any manner. It will be very clear to a person skilled in the art that, any additional variation(s), functional equivalent(s) and/or any structural altemative(s) to the present invention, may also be understood to be within the scope and purview of the present invention, as described in the present disclosure. The present invention may be embodied in other specific forms without departing from the spirit or essential attribute(s) thereof. The present invention discloses a multilayered acoustic moulded foam layer. The present invention embodied as a multilayer acoustic vehicle hood foam can be used in both flat and uneven surfaces. When the surface is not smooth, and is irregular, with lot of bends, the moulded foam as embodied by the present invention will be very useful.

The multilayer foam is adaptable to be moulded into any shape and variable thickness, and is useful to accommodate wherever the clearance is less. The said properties of the multilayer foam are achieved due to the multilayer structure of the moulded foam as embodied by the present invention. The present invention discloses a multilayer acoustic molded foam structure The acoustic molded foam structure comprises a layer of non-woven fabric. A first adhesive layer made of water insoluble adhesive is provided as an intermediate layer between layer of non-woven fabric and Poly Vinyl Chloride Foil Layer ensuring strong adhesion between the layer and Foil Layer solving the problem(s) of peeling and instability of the prior art multilayer foam structures. Layer prevents water ingress and increases transmission loss. A second reinforcing adhesive layer made of water insoluble adhesive is provided as an intermediate layer between the layer of Poly Vinyl Chloride (PVC) Foil Layer and Polyurethane Foam Layer further solving the problem(s) of peeling and instability of the prior art multilayer foam structures. Over the Polyurethane Foam Layer, a transfer coat layer is provided.

BRIEF DESCRIPTION OF DRAWINGS

The description of the present invention in conjunction with the drawings, illustrating the present invention and in application(s) illustrative of the present invention, explain in detail, the working of the present invention. It will be amply clear to a person skilled in the art, that the application(s) as disclosed in the drawings are merely illustrative of the scope of the present invention and not exhaustive of the scope of the present invention, in its entirety.

FIG. 1 shows the perspective view of a vehicle component layered with the multilayer moulded foam, as embodied by the present invention, and a specific view showing the layered component.

FIG. 2 shows the sectional view of the multilayer moulded foam, showing the individual layers in detail, as embodied by the present invention.

DETAILED DESCRIPTION OF DRAWINGS

To deal with noise pollution generated due to agricultural vehicle(s) in general and tractor(s) in particular, a foam layer is employed to line the vehicle component for instance, the hood of the tractor. The foam layered on the hood portion acts as an acoustic shield, thereby, preventing the driver of the tractor or a farmer from the health hazards of noise pollution.

FIG. 1 shows the perspective view of a vehicle component layered with the multilayer moulded foam, as embodied by the present invention and a specific view showing the layered component. In this context, the present invention discloses a multilayer acoustic molded foam structure (MF) The acoustic molded foam structure (MF), comprises a layer of non-woven fabric (NW). A first adhesive layer (A1) made of water insoluble adhesive is provided as an intermediate layer between layer of non-woven fabric (NW) and Poly Vinyl Chloride Foil Layer (P2) ensuring strong adhesion between the layer (NW) and Foil Layer (P2) solving the problem(s) of peeling and instability of the prior art multilayer foam structures. Layer (P2) prevents water ingress and increases transmission loss. A second reinforcing adhesive layer (A2) made of water insoluble adhesive is provided as an intermediate layer between the layer of Poly Vinyl Chloride (PVC) Foil Layer (P2) and Polyurethane Foam Layer (P1) further solving the problem(s) of peeling and instability of the prior art multilayer foam structures. Over the Polyurethane Foam Layer (P1), a transfer coat layer (T) is provided. The above-mentioned multilayer structure is illustrated in detail in conjunction with FIG. 2.

ADVANTAGES

The below-mentioned advantage(s) arising out of the present application in conjunction with the enclosed drawing(s) are merely indicative and are not to be considered as exhaustive of the entire advantage(s) arising by the deployment of the present invention. It will be amply clear to person(s) skilled in the art that, any primary advantage(s) arising out of the present invention as against the problem(s) in the conventional arrangements are to be construed to be well within the scope and purview of the present invention. Further, any secondary advantage(s) arising as a result of the primary advantage(s) are also to be construed to be well within the scope and purview of the present invention. In an advantageous aspect of the present invention, the multilayer foam can be used in both flat as well as uneven surfaces. When the surface is not smooth, irregular, with lot of bends the molded foam will be very useful for that kind of application.

The molded foam can be adapted to any shape and variable thickness and it is useful to accommodate wherever the clearance is less. In an advantageous aspect of the present invention, PVC layer of the multilayer foam will prevent water ingress and provide better transmission loss and the adhesive used will provide better adhesion with the hood surface. The adhesive employed in the present invention is water insoluble. This combination will provide better noise absorption characteristics which is the primary function of the present invention while solving the adhesion problems of the multilayer foam structures that form part of the state of the art. Further, in an advantageous aspect of the present invention, the multilayer foam structure has fire resistance and is also water resistant.

We claim:

1. A multilayer acoustic molded foam structure (MF), said molded foam structure (MF) comprising:
a. a layer of fabric (NW);
b. a first adhesive layer (A1) provided as an intermediate layer between the layer of fabric (NW) and a Foil Layer (P2);
c. a second reinforcing adhesive layer (A2) provided as an intermediate layer between the foil layer (P2) and a foam layer (P1);
d. a transfer coat layer (T), said transfer coat layer (T) provided over. the foam layer (P1).

2. The multilayer moulded foam structure for vehicle components, as claimed in Claim 1, wherein, the vehicle component is a hood.

3. The multilayer moulded foam structure for vehicle components, as claimed in Claim 1, wherein, the foam layer (P1) is composed of polymeric material, said material being Poly Urethane Foam.

4. The multilayer moulded foam structure for vehicle components, as claimed in Claim 1, wherein, the transfer coat layer (T) provided over. the Foam Layer (P1) is water insoluble.

5. The multilayer moulded foam structure for vehicle components, as claimed in Claim 1, wherein, the fabric layer (NW) comprises non-woven fabric material.

6. The multilayer moulded foam structure for vehicle components, as claimed in Claim 1, wherein, foil layer (P2) is composed of polymeric material, said polymeric material being poly vinyl chloride (PVC).