Gas-duct with a sound absorbing component

Patent metadata

Field	Value
Publication number	US-12545005-B2
Application number	US-201917266234-A
Country	US
Kind code	B2
Filing date	Aug 6, 2019
Priority date	Aug 6, 2018
Publication date	Feb 10, 2026
Grant date	Feb 10, 2026

Abstract

The present teachings relate generally to a gas-duct whose channel body is manufactured from a plastic material, wherein the channel body has at least one region replaced by a sound absorbing component being made at least partially from at least one non-woven layer. The present invention further relates to a HVAC- and Battery- and/or battery-charge-system and to a method of producing a gas-duct.

First claim

The invention claimed is:

1 . A gas-duct having a channel body manufactured from a plastic material, wherein the channel body has at least one region replaced by a sound absorbing component having an inner surface and a generally opposing outer surface, the sound absorbing component made at least partially from a non-woven air permeable or porous material made from non-woven layers including a needle punched layer and a short fiber layer, wherein fibers of the short fiber layer have an average length of about 5 mm or less, and the non-woven layers having different levels of specific air flow resistance;
wherein a circumference of the sound absorbing component is connected to the channel body by an adhesive bond between the sound absorbing component and the plastic material of the channel body; wherein the adhesive bond is a connection due to overmold of the plastic material over a portion of the inner surface and/or generally opposing outer surface, but not both, penetrating the air permeable or porous material and solidifying there, resulting in an over-mold area at the sound absorbing component.

2 . The gas-duct according to claim 1 , wherein the sound absorbing component is locally weakened in a weakening region and folded around the weakening region.

3 . The gas-duct according to claim 1 , wherein the sound absorbing component is provided in an area of the channel body where a gas flow is turbulent.

4 . The gas-duct according to claim 3 , wherein the sound absorbing component is provided in an area of the channel body where RE of the gas flow is greater than about 2300.

5 . The gas-duct according to claim 1 , wherein the sound absorbing component comprises polypropylene terephthalate (PET) and/or polypropylene (PP).

6 . The gas-duct according to claim 1 , wherein a non-woven layer of the sound absorbing component at an inside of the sound absorbing component or a non-woven layer of the sound absorbing component at an interface to the over-mold area is a needle punched layer.

7 . The gas-duct according to claim 1 , wherein the gas-duct includes two or more needle punched layers.

8 . The gas-duct according to claim 1 , wherein the short fiber layer consists of polypropylene and polyethylene terephthalate fibers.

9 . The gas-duct according to claim 1 , wherein the short fiber layer is sandwiched between two needle punched layers.

10 . The gas-duct according to claim 1 , wherein the needle punched layer comprises PET.

11 . The gas-duct according to claim 1 , wherein the short fibers are made from PET and PP.

12 . The gas-duct according to claim 1 , wherein the overmold is located on the portion of the inner surface.

13 . The gas-duct according to claim 1 , wherein the overmold is located on the portion of the generally opposing outer surface.

14 . An HVAC-system comprising the gas-duct according to claim 1 .

15 . A battery- and/or battery-charge-system comprising the gas-duct according to claim 1 .

16 . A method of producing the gas-duct according to claim 1 , comprising:
providing the sound absorbing component having the inner surface and the generally opposing outer surface, the sound absorbing component made at least partially from the non-woven air permeable or porous material made from non-woven layers including the needle punched layer and the short fiber layer, wherein the fibers of the short fiber layer have an average length of about 5 mm or less, and wherein the non-woven layers have different levels of specific air flow resistance; placing the sound absorbing component in a die; overmolding the sound absorbing component around its circumference over the portion of the inner surface and/or generally opposing outer surface, but not both, by the plastic material of the channel body; and creating a material bond, after solidification of the plastic material, between the sound absorbing component and the plastic material of the channel body.

17 . The method of claim 16 , wherein the overmolding is over the portion of the inner surface.

18 . The method of claim 16 , wherein the overmolding is over the portion of the generally opposing outer surface.

19 . A method of producing the gas-duct of claim 1 , comprising:
locally compressing and/or locally weakening the sound absorbing component to form one or more hinges; folding the sound absorbing component to form a sound absorbing body.

20 . The method according to claim 19 , wherein the sound absorbing body is placed into a mold die to overmold the channel body at least partially.

Assignees

• Zephyros Inc

Inventors

• Chaut Christophe
• Thompson Greg
• Engel Marc

Classifications

• F24F13/24

  Means for preventing or suppressing noise · CPC title

• F24F13/02

  Ducting arrangements · CPC title

• B32B2262/0284

  Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT] · CPC title

• B32B2262/0253

  Polyolefin fibres · CPC title

• B32B7/12

  using interposed adhesives or interposed materials with bonding properties · CPC title