CA1089606A - Sound deadener sheet - Google Patents
Sound deadener sheetInfo
- Publication number
- CA1089606A CA1089606A CA277,700A CA277700A CA1089606A CA 1089606 A CA1089606 A CA 1089606A CA 277700 A CA277700 A CA 277700A CA 1089606 A CA1089606 A CA 1089606A
- Authority
- CA
- Canada
- Prior art keywords
- sheet
- weight
- binder
- sound deadener
- bitumen
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/08—Insulating elements, e.g. for sound insulation
- B60R13/0815—Acoustic or thermal insulation of passenger compartments
- B60R13/083—Acoustic or thermal insulation of passenger compartments for fire walls or floors
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L95/00—Compositions of bituminous materials, e.g. asphalt, tar, pitch
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Civil Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Acoustics & Sound (AREA)
- Mechanical Engineering (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
A sound deadener sheet softenable by heat to wilt into comformity and adhesive engagement with a contoured metal surface but resistant to running and flow at higher temperatures. The sheet is formed of a mixture of mineral filler and a binder. The binder comprises about 45% to about 70% by weight of asphaltic bitumen from the class consisting of natural asphalt and residue from the distillation of pertroleum, from about 5% to about 20% by weight of an elastomeric modifier compatible with the asphaltic bitumen and from about 1.5% to about 3.5% of the solid, non-thermoplastic product of reaction of vegetable unsaturated oil with sulfur, sulfur monochloride or sulfur dichloride coacting with the asphaltic bitumen to prevent running and flow of the sheet at higher temperatures. The weight percentages are based on the weight of the binder.
A sound deadener sheet softenable by heat to wilt into comformity and adhesive engagement with a contoured metal surface but resistant to running and flow at higher temperatures. The sheet is formed of a mixture of mineral filler and a binder. The binder comprises about 45% to about 70% by weight of asphaltic bitumen from the class consisting of natural asphalt and residue from the distillation of pertroleum, from about 5% to about 20% by weight of an elastomeric modifier compatible with the asphaltic bitumen and from about 1.5% to about 3.5% of the solid, non-thermoplastic product of reaction of vegetable unsaturated oil with sulfur, sulfur monochloride or sulfur dichloride coacting with the asphaltic bitumen to prevent running and flow of the sheet at higher temperatures. The weight percentages are based on the weight of the binder.
Description
~9~ 6 This invention relates to an improved sound deadening material.
Damping of vibration in thin sheet material such as the sheet metal floor pans of automobiles is important to reduce noise level. Presently, .
. .
vibration damping of metal floor pans is secured by adhering a composition sheet to the metal by placing the composition sheet on the metal floor pan before the automobile body goes through heating ovens employed in finishing the body. The heat of the oven softens the composition sheet so that it wilts into conformity with the floor pan and adheres to the metal surface. A variety of heat softenable compositions, usually mixtures of bitumen, fillers and/or fibers, and a natural or synthetic hydrocarbon rubber, e. g., a butadiene styrene copolymer synthetic rubber, have been tried for this use. .
Tests established for acceptance of materials for this use by automobile manufacturers require that the sheet material wilt into conformity with and adhere to the metal of the floor pans at temperatures at least as low as temp- :
eratures reached in the heating ovens during finishing of the body, but that flowing or running of the material at substantially higher temperatures shall not exceed a limited value. These tests can be met by using substantial proportions of a hydrocarbon rubber in the compositior . ~owever, use of such proportions of rubker, which is much more expensive than bitumen, :
markedly increases the cost of the sheet material and is believed to reduce the : : . `
vibration damping efficiency.
It is an object of the present invention to provide a less expensive sound . ~ .
deadening sheet material capable of meeting the temperature response require-ments for use in automobiles.
To this end, and in accordance with a feature of the present invention, there is provided a sheet composition based on bitumen and filler in which .
resistance to undesired high temperature flow together with good conformability and adhesion properties are secured through combination and interaction of a limited amount of a vulcanized vegetable oil with the bitumen.
According to a broad aspect of the present invention, there is provided a sound deadener sheet softenable by heat to wilt into conformity and adhesive engagement with a contoured metal surface but resistant to running and flow at higher temperatures. The sheet is formed of a mixture of mineral filler and a binder. The binder comprises about 45%
to about 70% by weight of asphaltic bitumen from the class consisting of natural asphalt and residue from the distilla-tion of petroleum, from about 5% to about 20% by weight of an elastomeric modifier compatible with the asphaltic bitumen and from about 1.5% to about 3.5% of the solid, non-thermo-plastic product of reaction of vegetable unsaturated oil with sulfur, sulfur monochloride or sulfur dichloride coact-ing with the asphaltic bitumen to prevent running and flow of the sheet at higher temperatures. The weight percentages are based on the weight of the binder. -~
The Figure is an angular elevational view of a contoured metal sheet used for testing thermal properties of sound deadener sheet material.
In accordance with the present invention, I have provided a filled bituminous sound deadener sheet having ;
an unexpected combination of characteristics in heated condition particularly fitting it for union with shaped metal, such as in use of the sheet material as a sound deadener for automobile floor pans. These unexpected proper-ties are secured through combination of relatively small proportions of a vulcanized vegetable oil with bitumen as binder for mineral filler. The binder preferably also : .
includes an elastomeric modifier to reduce brittleness and , improve elasticity and resistance to tearing.
,-~. '~. ' '
Damping of vibration in thin sheet material such as the sheet metal floor pans of automobiles is important to reduce noise level. Presently, .
. .
vibration damping of metal floor pans is secured by adhering a composition sheet to the metal by placing the composition sheet on the metal floor pan before the automobile body goes through heating ovens employed in finishing the body. The heat of the oven softens the composition sheet so that it wilts into conformity with the floor pan and adheres to the metal surface. A variety of heat softenable compositions, usually mixtures of bitumen, fillers and/or fibers, and a natural or synthetic hydrocarbon rubber, e. g., a butadiene styrene copolymer synthetic rubber, have been tried for this use. .
Tests established for acceptance of materials for this use by automobile manufacturers require that the sheet material wilt into conformity with and adhere to the metal of the floor pans at temperatures at least as low as temp- :
eratures reached in the heating ovens during finishing of the body, but that flowing or running of the material at substantially higher temperatures shall not exceed a limited value. These tests can be met by using substantial proportions of a hydrocarbon rubber in the compositior . ~owever, use of such proportions of rubker, which is much more expensive than bitumen, :
markedly increases the cost of the sheet material and is believed to reduce the : : . `
vibration damping efficiency.
It is an object of the present invention to provide a less expensive sound . ~ .
deadening sheet material capable of meeting the temperature response require-ments for use in automobiles.
To this end, and in accordance with a feature of the present invention, there is provided a sheet composition based on bitumen and filler in which .
resistance to undesired high temperature flow together with good conformability and adhesion properties are secured through combination and interaction of a limited amount of a vulcanized vegetable oil with the bitumen.
According to a broad aspect of the present invention, there is provided a sound deadener sheet softenable by heat to wilt into conformity and adhesive engagement with a contoured metal surface but resistant to running and flow at higher temperatures. The sheet is formed of a mixture of mineral filler and a binder. The binder comprises about 45%
to about 70% by weight of asphaltic bitumen from the class consisting of natural asphalt and residue from the distilla-tion of petroleum, from about 5% to about 20% by weight of an elastomeric modifier compatible with the asphaltic bitumen and from about 1.5% to about 3.5% of the solid, non-thermo-plastic product of reaction of vegetable unsaturated oil with sulfur, sulfur monochloride or sulfur dichloride coact-ing with the asphaltic bitumen to prevent running and flow of the sheet at higher temperatures. The weight percentages are based on the weight of the binder. -~
The Figure is an angular elevational view of a contoured metal sheet used for testing thermal properties of sound deadener sheet material.
In accordance with the present invention, I have provided a filled bituminous sound deadener sheet having ;
an unexpected combination of characteristics in heated condition particularly fitting it for union with shaped metal, such as in use of the sheet material as a sound deadener for automobile floor pans. These unexpected proper-ties are secured through combination of relatively small proportions of a vulcanized vegetable oil with bitumen as binder for mineral filler. The binder preferably also : .
includes an elastomeric modifier to reduce brittleness and , improve elasticity and resistance to tearing.
,-~. '~. ' '
- 2 -:
Vulcanized vegetable oil is a solid, non-thermo-plastic product of reacting vegetable unsaturated oil such as linseed oil, cottonseed oil, soybean oil or others with sulfur or with sulfur derivatives such as sulfur monochloride, sulfur dichloride, and the like. These materials are commercially available for example under the registered trademark "FACTICE" from the American Cyanamid Company. The product from reaction of the vegetable oil with sulfur is preferred for the present use. These vulcanized oils are most commonly used as extenders, processing aids or plasticizers for natural and synthetic rubbers. However, ;
in the present case, the vulcanized oil coacts with the bitumen to provide, in the mineral-filled bitumen sound deadener sheet of the present invention, a unique combination of good heat wilting characteristics for conforming and bonding to a ribbed and/or curved metal plate, and of ., . -resistance to running or flow at high temperatures.
The bitumens which can be employed in the binderfor compositions of the present invention are preferably asphaltic and may be either natural asphalt or residue from the distillation of petroleum. Thé asphaltic bitumens are commercially available in penetration values up to about 300 as determined by ASTM method D-5-73 at 77 F. Softening points (Ball and Ring), as determined by ASTM method D-36-70 should be in the range of from about ., ' ", ~ - 2a --,, ~ . . - . .
6~6 60F. to about 110F., preferably from about 60F. to about 80F.
~Iydrocarbon oil is preferably included in relatively small percentages as a component of -the binder to improve mixing of the bitumen with the mineral filler. Also, it has been found that addition of gilsonite to the composition materially improves the breaking strength and tear strength of the sound deadener sheet.
Elastomeric modifiers for inclusion ~n the compositions of the present invention may be hydrocarbon elastomers and co-polymers of ethylene with non-hydrocarbon monomers which may be known for inclusion in bituminous compositions.
Hydrocarbon rubber-like elastomers useful as modifiers for combination with bitumen and vulcanized vegetable oil in the binder for the sound deadening composition may be natural rubber, synthetic polymer Or copolymer rubbers or reclaim rubber. Suitable synthetic rubbers include styrene-butadiene copolymer synthetic rubbers, butadiene-styrene block copolymers, e.g. "Kraton"* 1107 manufactured by the Shell Chemical Co., butyl rubber, poLyisobutylene, ethylene-propylene copolymers t~PM), ethylene-propylene-diene terpolymers (EPDM) and mix-tures of these. A preferred range of Mooney values is from 20 to 35.
Preferred ethylene copolymers for use as elastomeric modifiers include bitumen-soluble copolymers containing from about 40% to about 98% preferably from about 60% to about 90%
by weight of ethylene with from about 60% to about 2% pre-ferab~y from about 40% to about 10% by weight of a mono-unsat-urated polymerizable compound such as a lower alkyl, i.e. 1 to 6 carbon atoms, acrylate or methacrylate.
Gilsonite which also forms a component of the binder is a natural hard thermoplastic hydrocarbon resin having a melt-
Vulcanized vegetable oil is a solid, non-thermo-plastic product of reacting vegetable unsaturated oil such as linseed oil, cottonseed oil, soybean oil or others with sulfur or with sulfur derivatives such as sulfur monochloride, sulfur dichloride, and the like. These materials are commercially available for example under the registered trademark "FACTICE" from the American Cyanamid Company. The product from reaction of the vegetable oil with sulfur is preferred for the present use. These vulcanized oils are most commonly used as extenders, processing aids or plasticizers for natural and synthetic rubbers. However, ;
in the present case, the vulcanized oil coacts with the bitumen to provide, in the mineral-filled bitumen sound deadener sheet of the present invention, a unique combination of good heat wilting characteristics for conforming and bonding to a ribbed and/or curved metal plate, and of ., . -resistance to running or flow at high temperatures.
The bitumens which can be employed in the binderfor compositions of the present invention are preferably asphaltic and may be either natural asphalt or residue from the distillation of petroleum. Thé asphaltic bitumens are commercially available in penetration values up to about 300 as determined by ASTM method D-5-73 at 77 F. Softening points (Ball and Ring), as determined by ASTM method D-36-70 should be in the range of from about ., ' ", ~ - 2a --,, ~ . . - . .
6~6 60F. to about 110F., preferably from about 60F. to about 80F.
~Iydrocarbon oil is preferably included in relatively small percentages as a component of -the binder to improve mixing of the bitumen with the mineral filler. Also, it has been found that addition of gilsonite to the composition materially improves the breaking strength and tear strength of the sound deadener sheet.
Elastomeric modifiers for inclusion ~n the compositions of the present invention may be hydrocarbon elastomers and co-polymers of ethylene with non-hydrocarbon monomers which may be known for inclusion in bituminous compositions.
Hydrocarbon rubber-like elastomers useful as modifiers for combination with bitumen and vulcanized vegetable oil in the binder for the sound deadening composition may be natural rubber, synthetic polymer Or copolymer rubbers or reclaim rubber. Suitable synthetic rubbers include styrene-butadiene copolymer synthetic rubbers, butadiene-styrene block copolymers, e.g. "Kraton"* 1107 manufactured by the Shell Chemical Co., butyl rubber, poLyisobutylene, ethylene-propylene copolymers t~PM), ethylene-propylene-diene terpolymers (EPDM) and mix-tures of these. A preferred range of Mooney values is from 20 to 35.
Preferred ethylene copolymers for use as elastomeric modifiers include bitumen-soluble copolymers containing from about 40% to about 98% preferably from about 60% to about 90%
by weight of ethylene with from about 60% to about 2% pre-ferab~y from about 40% to about 10% by weight of a mono-unsat-urated polymerizable compound such as a lower alkyl, i.e. 1 to 6 carbon atoms, acrylate or methacrylate.
Gilsonite which also forms a component of the binder is a natural hard thermoplastic hydrocarbon resin having a melt-
- 3 -j *Registered Trademark ,, ~ .
.. : . . . . ~ . :. : : . :
6~6 ing point of from 270F. to 280F. and a penetration at 77F. of less than 1~
A preferred formulation offering special advantages in the binder of the present sound deadener, involves combinin~ .
in balanced ranges of proportions, bitumen, elastomer modi-fier and gilsonite together with a small but effective amount of vulcanized vegetable oil to control the softening and .
flow properties together with good sound deadening efficiency ;. ...
and low cost~ Based on the~total weight of the binder, useful - .
proportions in terms of weight percentages will include from ~ .
45% to 70%, preferably about 50% to 60% by weight of bitumen, from about 50% to about 20%, preferably from about 10% to :
about 15% of elastomeric modifier, from about 15% to about 20% of gilsonite, and from about 1.5% to about 3.5%, prefer-ably from about 2% to about 2.5% of vulcanized vegetable oil. ; ..... ... :
Mineral filler for combination with the binder may be .-any of a variety of finely divided inorganic materials such as ground limestone, suitably a dolomitic limestone, whiting, :~
barytes, calcium carbonate, clay, slate, mica and so on. The particle size should be such that about 80% will pass a 200 mesh ,screen and none will be held on a 35 mesh screen~ The particles of mineral filler are of a size less than that which .
will pass a 325 mesh screen. .
The filler content of the sound deadener sheet of the present invention may be between about 60% to about 85% pre-ferably from about 75% to about 85% by weight and the binder correspondingly from about 40% to about 15% preferably from about 25% to about 15% by weight based on the weight of the sheet. . : .
The sheet may be compounded in any conventional ~anner as by mixing together the bitumen, elastomeric modifier, gilsonite and vulcanized vegetable oil in a heated ves~el
.. : . . . . ~ . :. : : . :
6~6 ing point of from 270F. to 280F. and a penetration at 77F. of less than 1~
A preferred formulation offering special advantages in the binder of the present sound deadener, involves combinin~ .
in balanced ranges of proportions, bitumen, elastomer modi-fier and gilsonite together with a small but effective amount of vulcanized vegetable oil to control the softening and .
flow properties together with good sound deadening efficiency ;. ...
and low cost~ Based on the~total weight of the binder, useful - .
proportions in terms of weight percentages will include from ~ .
45% to 70%, preferably about 50% to 60% by weight of bitumen, from about 50% to about 20%, preferably from about 10% to :
about 15% of elastomeric modifier, from about 15% to about 20% of gilsonite, and from about 1.5% to about 3.5%, prefer-ably from about 2% to about 2.5% of vulcanized vegetable oil. ; ..... ... :
Mineral filler for combination with the binder may be .-any of a variety of finely divided inorganic materials such as ground limestone, suitably a dolomitic limestone, whiting, :~
barytes, calcium carbonate, clay, slate, mica and so on. The particle size should be such that about 80% will pass a 200 mesh ,screen and none will be held on a 35 mesh screen~ The particles of mineral filler are of a size less than that which .
will pass a 325 mesh screen. .
The filler content of the sound deadener sheet of the present invention may be between about 60% to about 85% pre-ferably from about 75% to about 85% by weight and the binder correspondingly from about 40% to about 15% preferably from about 25% to about 15% by weight based on the weight of the sheet. . : .
The sheet may be compounded in any conventional ~anner as by mixing together the bitumen, elastomeric modifier, gilsonite and vulcanized vegetable oil in a heated ves~el
- 4 -,., ' ~ ~.. ' - , . - - . . ~ , . , ,. ~ .
,, ,, , ' ~Lf~1~9~6 and then adding the mineral filler to the hot mixture and mixing to uniformity. The mixture is then formed into a sheet by calendar rolls or other suitable deviceO For use as a sound deadener for sheet metal floor pans for automo- : :
blles, sheets are preferably from about 0.05 lnch to about 0.1 inch in thickness.
The sound deadener sheet for use with an automobile floor pan is merely laid on the upper surface of the floor pan and is required to soften and wilt into conformity with the contour of the floor pan during the heating used in :`
flnishing the automobile body, but must also not be softened to a condition in which lt runs excesslv21y so as to lose its uniformity and to run or flow past :
- 4a ~
- , . ;
- - . . . .
.
.. . . . . . .... . . ..
_ 5 _ ~ 60~;
the areas where it is desired. Tests for acceptance of sound deadener sheet material involve laying a 2 X 10" strip 10 of the sound deadener sheet across a metal sheet 12 contoured as shown in the Figure and heating the assembly to 275F. for one-half hour. As shown in the Figure, the metal sheet 12 has a flat, horizontally disposed first section 14, a section 16 extending downward :
at right angles to the first section and a further horizontally disposed section 18. The section 18 is formed with small grooves 20. It is required that after the heating, the strip 10 has sagged or wilted from its original position and flat shape shown in broken lines in the Figure into conformity not only with 10 the downwardly angled section 16 but also with the small grooves 20 so that there is not more than a 1/16" gap between the strip 10 and the contoured metal section 12 at any point. A further test to establish that the sheet does not flow or run excessively involves disposing a 2 X 6" strip 22 on the flat portion 14 ~ -of the contoured metal surface with a portion oE the strip, as shown in broken lines in the Figure, extending beyond the edge that flat portion 14 by an amount which would bring the edge 26 against an upper score mark 28, on the down-wardly extending portion 30 when the strip 22 has bent downwardly into engage-ment with the vertical portion 16 of the metal sheet 12. It is required that on heating the sample to 400F. the downwardly bent portion 30 of the strip 22 20 must not flow more than 3/8" in one hour, i. e. must not have flowed down to the lower score mark 32 on the vertical portion 16 of the metal surface.
Additional requirements are that the sheet have a breaking tensile strength of at least 0.1 pound per mil thickness and inch width.
The following examples are given to aid in understanding the invention but it i9 to be understood that the invention is not restricted to the particular procedures, materials or the like of the examples.
EXAMPLE ONE
The following is a formula of a sound deadener sheet for use in connection with an automobile floor pan.
', :, : ' ' ; ' ' :
- . , ... ~ .
6~6 , Finely divided dolomitic limestone 80 CaO 0. 6 Butadiene styrene copolymer rubber (Mooney viscosity 27 to 35) 3.2 Gilsonite 4 5 Low melting point bitumen 11.2 Vulcanized vegetable oil (Factice #11 Brown) 0. 5 The bitumen was a commercial product known as 22 L, obtained from Pioneer Division of Witco Chemicals Co. having a :Ball and Ring melting point of about 80F. and a nominal penetration value of 300 at 77F. by ASTM method of D-5-73. The finely divided dolomitic limestone had a particle si~e such that about 80% will pass a 200 mesh screen and none will be retained on a 35 mesh screen, the screens being U. S. Standard Sieve. -The butadiene styrene copolymer rubber, gilsonite and vulcanized vegetable oil were introduced into an internal mixer sold under the trademark ~:
BANE3URY and worked together at 320F. At this point, l/2 of the bitumen and l/2 of the finely divided dolomitic limestone were added and when they had been thoroughly mixed in, the remainder oE the components were added and thoroughly mixed in. The mixture was discharged from the mixer and sheeted out between the rolls of a calender to a thickness of 0 . 070" + 0 . 005" . ~;
The sheet material was subjected to the conformity and flow tests described above in the specification and successfully passed these tests.
A composition identical with the formula given above except that it did not include vulcanized vegetable oil was prepared and Eormed into a sheet.
.. . :. : :
When the sheet was subjected to conformit~ and flow tests, it was folmd that ~ :
the material flowed badly during the 400F. portion of the test. ~
: . ;
E~ aPLE TWO
,, ~.. ~. .i.. , .:
The following formula was prepared for use as a sound deadener sheet - for an automobile floor pan.
' :' ' ', ' ' ' .' " ' ' ' ' . ' " ' ' ' .. '' " ' ',. " " ', ' ', ,, ' '. . . ' , ~ ' ' . "~ ,, ., ' .' , ' ' ' ' ' .~ " ' ' .' ... ,. ' '', . ' , ' . ' ~ . , ' .. , . .. ,, ' ' " ',' . ' ' ' 1~ 6~i Parts by weiqht Finely divided dolomitic limestone 79.7 CaO 0.6 -Ethylene propylene diene terpolymer (EPDM) 1.0 Gilsonite 3.0 Intermediate melting point bitumen 15.2 Vulcanized vegetable oil 0.5 The composition was mixed and formed into a sheet follow-ing the procedure of Example One. The resulting sheet mater-ial was subjected to the conformity and flow tests described above in the specification and successfully passed these tests.
EXAMPLE THREE ;
.
The following formula was prepared for use as a sound deadener sheet material.
Parts by weiqht Finely divided dolomitic limestone (200 mesh) 80.5 CaO 0.6 Ethylene-propylene copolymer 3.2 Vulcanized vegetable oil 0.5 Low melting point bitumen 11.2 Gilsonite 4.0 The ethylene-propylene copolymer was the commercial product known as Vistalon 404*, a product of Enjay Chemical -Company having an ethylene content of about 40%, a propylene content of about 60% and a Mooney value of 35 to ~5 and the bitumen was the same bitumen material used in Example One.
The composition was mixed and formed into a sheet follow-ing the procedure of Example One. The re.sulting sheet was subjected to the conformity and flow tests described above in the specification and successfully passed these tests.
*Registered Trademark .~ .
. ' : , ' .
,, ,, , ' ~Lf~1~9~6 and then adding the mineral filler to the hot mixture and mixing to uniformity. The mixture is then formed into a sheet by calendar rolls or other suitable deviceO For use as a sound deadener for sheet metal floor pans for automo- : :
blles, sheets are preferably from about 0.05 lnch to about 0.1 inch in thickness.
The sound deadener sheet for use with an automobile floor pan is merely laid on the upper surface of the floor pan and is required to soften and wilt into conformity with the contour of the floor pan during the heating used in :`
flnishing the automobile body, but must also not be softened to a condition in which lt runs excesslv21y so as to lose its uniformity and to run or flow past :
- 4a ~
- , . ;
- - . . . .
.
.. . . . . . .... . . ..
_ 5 _ ~ 60~;
the areas where it is desired. Tests for acceptance of sound deadener sheet material involve laying a 2 X 10" strip 10 of the sound deadener sheet across a metal sheet 12 contoured as shown in the Figure and heating the assembly to 275F. for one-half hour. As shown in the Figure, the metal sheet 12 has a flat, horizontally disposed first section 14, a section 16 extending downward :
at right angles to the first section and a further horizontally disposed section 18. The section 18 is formed with small grooves 20. It is required that after the heating, the strip 10 has sagged or wilted from its original position and flat shape shown in broken lines in the Figure into conformity not only with 10 the downwardly angled section 16 but also with the small grooves 20 so that there is not more than a 1/16" gap between the strip 10 and the contoured metal section 12 at any point. A further test to establish that the sheet does not flow or run excessively involves disposing a 2 X 6" strip 22 on the flat portion 14 ~ -of the contoured metal surface with a portion oE the strip, as shown in broken lines in the Figure, extending beyond the edge that flat portion 14 by an amount which would bring the edge 26 against an upper score mark 28, on the down-wardly extending portion 30 when the strip 22 has bent downwardly into engage-ment with the vertical portion 16 of the metal sheet 12. It is required that on heating the sample to 400F. the downwardly bent portion 30 of the strip 22 20 must not flow more than 3/8" in one hour, i. e. must not have flowed down to the lower score mark 32 on the vertical portion 16 of the metal surface.
Additional requirements are that the sheet have a breaking tensile strength of at least 0.1 pound per mil thickness and inch width.
The following examples are given to aid in understanding the invention but it i9 to be understood that the invention is not restricted to the particular procedures, materials or the like of the examples.
EXAMPLE ONE
The following is a formula of a sound deadener sheet for use in connection with an automobile floor pan.
', :, : ' ' ; ' ' :
- . , ... ~ .
6~6 , Finely divided dolomitic limestone 80 CaO 0. 6 Butadiene styrene copolymer rubber (Mooney viscosity 27 to 35) 3.2 Gilsonite 4 5 Low melting point bitumen 11.2 Vulcanized vegetable oil (Factice #11 Brown) 0. 5 The bitumen was a commercial product known as 22 L, obtained from Pioneer Division of Witco Chemicals Co. having a :Ball and Ring melting point of about 80F. and a nominal penetration value of 300 at 77F. by ASTM method of D-5-73. The finely divided dolomitic limestone had a particle si~e such that about 80% will pass a 200 mesh screen and none will be retained on a 35 mesh screen, the screens being U. S. Standard Sieve. -The butadiene styrene copolymer rubber, gilsonite and vulcanized vegetable oil were introduced into an internal mixer sold under the trademark ~:
BANE3URY and worked together at 320F. At this point, l/2 of the bitumen and l/2 of the finely divided dolomitic limestone were added and when they had been thoroughly mixed in, the remainder oE the components were added and thoroughly mixed in. The mixture was discharged from the mixer and sheeted out between the rolls of a calender to a thickness of 0 . 070" + 0 . 005" . ~;
The sheet material was subjected to the conformity and flow tests described above in the specification and successfully passed these tests.
A composition identical with the formula given above except that it did not include vulcanized vegetable oil was prepared and Eormed into a sheet.
.. . :. : :
When the sheet was subjected to conformit~ and flow tests, it was folmd that ~ :
the material flowed badly during the 400F. portion of the test. ~
: . ;
E~ aPLE TWO
,, ~.. ~. .i.. , .:
The following formula was prepared for use as a sound deadener sheet - for an automobile floor pan.
' :' ' ', ' ' ' .' " ' ' ' ' . ' " ' ' ' .. '' " ' ',. " " ', ' ', ,, ' '. . . ' , ~ ' ' . "~ ,, ., ' .' , ' ' ' ' ' .~ " ' ' .' ... ,. ' '', . ' , ' . ' ~ . , ' .. , . .. ,, ' ' " ',' . ' ' ' 1~ 6~i Parts by weiqht Finely divided dolomitic limestone 79.7 CaO 0.6 -Ethylene propylene diene terpolymer (EPDM) 1.0 Gilsonite 3.0 Intermediate melting point bitumen 15.2 Vulcanized vegetable oil 0.5 The composition was mixed and formed into a sheet follow-ing the procedure of Example One. The resulting sheet mater-ial was subjected to the conformity and flow tests described above in the specification and successfully passed these tests.
EXAMPLE THREE ;
.
The following formula was prepared for use as a sound deadener sheet material.
Parts by weiqht Finely divided dolomitic limestone (200 mesh) 80.5 CaO 0.6 Ethylene-propylene copolymer 3.2 Vulcanized vegetable oil 0.5 Low melting point bitumen 11.2 Gilsonite 4.0 The ethylene-propylene copolymer was the commercial product known as Vistalon 404*, a product of Enjay Chemical -Company having an ethylene content of about 40%, a propylene content of about 60% and a Mooney value of 35 to ~5 and the bitumen was the same bitumen material used in Example One.
The composition was mixed and formed into a sheet follow-ing the procedure of Example One. The re.sulting sheet was subjected to the conformity and flow tests described above in the specification and successfully passed these tests.
*Registered Trademark .~ .
. ' : , ' .
Claims (9)
1. A sound deadener sheet softenable by heat to wilt into conformity and adhesive engagement with a contoured metal surface but resistant to running and flow at higher temperatures, said sheet being formed of a mixture of mineral filler and a binder, said binder comprising about 45% to about 70% by weight of asphaltic bitumen from the class consisting of natural asphalt and residue from the distilla-tion of petroleum, from about 5% to about 20% by weight of an elastomeric modifier compatible with said asphaltic bitumen and from about 1.5% to about 3.5% of the solid, non-thermoplastic product of reaction of vegetable unsaturated oil with sulfur, sulfur monochloride or sulfur dichloride coacting with the asphaltic bitumen to prevent running and flow of said sheet at higher temperatures, said weight percentages being based on the weight of said binder.
2. A sound deadener sheet as defined in claim 1 in which said mixture comprises from about 60% to about 85%
by weight of mineral filler and from about 40% to about 15%
by weight of said binder.
by weight of mineral filler and from about 40% to about 15%
by weight of said binder.
3. A sound deadener sheet as defined in claim 2 in which the elastomeric modifier is a hydrocarbon elastomer.
4. A sound deadener sheet as defined in claim 3 in which said elastomeric modifier is a copolymer of ethylene and propylene.
5. A sound deadener sheet as defined in claim 3 in which said elastomeric modifier is a terpolymer of ethylene, propylene and a diene.
6. A sound deadener sheet as defined in claim 3 in which said elastomeric modifier is a butadiene styrene copolymer rubber.
7. A sound deadener sheet as defined in claim 2 in which said elastomeric modifier is a copolymer of ethylene and a lower alkyl ester of acrylic or methacrylic acid in which the ethylene is at least about 50% of said copolymer.
8. A sound deadener sheet as defined in claim 2 in which said binder comprises from about 15% to about 25% by weight of gilsonite and in which said bitumen has a softening point (Ball and Ring) of from about 60°F to about 110°F.
9. A sound deadener sheet as defined in claim 8 in.
which said mixture comprises from about 75% to about 85% by weight of mineral filler, the particles of mineral filler being of a size less than that which will pass a 325 mesh screen and from about 25% to about 15% by weight of a binder and, said binder comprising from about 50% to about 60% by weight of bitumen having a softening point between about 60°F and about 80°F, from about 10% to about 15% by weight of an elastomeric modifier, from about 15% to about 25% by weight of gilsonite, and from about 2% to about 2.5% by weight of a vulcanized vegetable oil.
which said mixture comprises from about 75% to about 85% by weight of mineral filler, the particles of mineral filler being of a size less than that which will pass a 325 mesh screen and from about 25% to about 15% by weight of a binder and, said binder comprising from about 50% to about 60% by weight of bitumen having a softening point between about 60°F and about 80°F, from about 10% to about 15% by weight of an elastomeric modifier, from about 15% to about 25% by weight of gilsonite, and from about 2% to about 2.5% by weight of a vulcanized vegetable oil.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US69757576A | 1976-06-18 | 1976-06-18 | |
| US697,575 | 1976-06-18 | ||
| US74820176A | 1976-12-07 | 1976-12-07 | |
| US748,201 | 1976-12-07 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1089606A true CA1089606A (en) | 1980-11-18 |
Family
ID=27106042
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA277,700A Expired CA1089606A (en) | 1976-06-18 | 1977-05-04 | Sound deadener sheet |
Country Status (3)
| Country | Link |
|---|---|
| AU (1) | AU511196B2 (en) |
| CA (1) | CA1089606A (en) |
| GB (1) | GB1583892A (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2640078B2 (en) * | 1993-02-08 | 1997-08-13 | 株式会社神戸製鋼所 | Damping profiles and structures for transport aircraft |
-
1977
- 1977-05-04 CA CA277,700A patent/CA1089606A/en not_active Expired
- 1977-06-17 GB GB2534877A patent/GB1583892A/en not_active Expired
- 1977-07-17 AU AU26186/77A patent/AU511196B2/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| GB1583892A (en) | 1981-02-04 |
| AU2618677A (en) | 1978-12-21 |
| AU511196B2 (en) | 1980-07-31 |
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