US20050191925A1 - Layered polymer fiber insulation and method of making thereof - Google Patents
Layered polymer fiber insulation and method of making thereof Download PDFInfo
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- US20050191925A1 US20050191925A1 US10/789,143 US78914304A US2005191925A1 US 20050191925 A1 US20050191925 A1 US 20050191925A1 US 78914304 A US78914304 A US 78914304A US 2005191925 A1 US2005191925 A1 US 2005191925A1
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- liner
- layer
- insulator
- fibers
- layers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
- D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
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- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/10—Properties of the layers or laminate having particular acoustical properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/306—Resistant to heat
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/728—Hydrophilic
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/73—Hydrophobic
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2419/00—Buildings or parts thereof
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
- Y10T442/638—Side-by-side multicomponent strand or fiber material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
- Y10T442/64—Islands-in-sea multicomponent strand or fiber material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/637—Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
- Y10T442/641—Sheath-core multicomponent strand or fiber material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/659—Including an additional nonwoven fabric
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/659—Including an additional nonwoven fabric
- Y10T442/66—Additional nonwoven fabric is a spun-bonded fabric
- Y10T442/663—Hydroentangled
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/659—Including an additional nonwoven fabric
- Y10T442/671—Multiple nonwoven fabric layers composed of the same polymeric strand or fiber material
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/689—Hydroentangled nonwoven fabric
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/69—Autogenously bonded nonwoven fabric
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/696—Including strand or fiber material which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous compositions, water solubility, heat shrinkability, etc.]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/697—Containing at least two chemically different strand or fiber materials
Definitions
- the present invention relates generally to a multilayer, wet processed, polymer-based mats having bicomponent and polymer staple fibers, where the layers are bonded together using heat and pressure.
- This acoustical and thermal liner/insulator may be utilized to insulate an environment such as a passenger compartment of a vehicle from the heat and sound generated by mechanical components of that vehicle during its operation.
- Other uses include application in insulating appliances such as dishwashers and clothes dryers and providing sound and thermal insulation for furnaces, air conditioning units and ductwork in buildings including homes, offices and industrial structures.
- Acoustical insulation is well known in the art. Acoustical insulation typically relies upon both sound absorption, i.e. the ability to absorb incident sound waves, and transmission loss, i.e. the ability to reflect incident sound waves, in order to provide sound attenuation.
- Sound absorption i.e. the ability to absorb incident sound waves
- transmission loss i.e. the ability to reflect incident sound waves
- One of the more prevalent uses of such insulation is in the motorized vehicle field where engine compartments, fire walls, fender wells, doors, floor pans and other components of the passenger compartment shell are commonly acoustically insulated to reduce engine and road noise for the benefit and comfort of passengers. Acoustical insulation is also prevalent in appliances such as dishwashers and heating and air conditioning units.
- U.S. Pat. No. 6,008,149 discloses a moldable nonwoven fibrous composite article including at least two functional layers, which are made of the same nonwoven thermoformable polymeric chemical substance or material.
- the composite articles are molded from separate rolls or sheets of variable compression and formable fabric layers.
- Each of U.S. Pat. Nos. 6,156,682 and 6,364,976 discloses a laminated structure having a core of polymeric fibers, a thermosetting resin impregnated into the core, and individual chopped fibers randomly applied to opposite sides of the core layer.
- the preferred method of bonding the fibers together is by a bicomponent fiber, in which an outer layer of fibers is constituted by a low melt temperature polymer, and an inner core layer of fibers which constitutes a polymer with a relatively higher melt temperature.
- U.S. Pat. No. 4,780,359 discloses a nonwoven textile panel constructed of three layers of nonwoven textile fibers of polyphenylene sulfide fibers and Nomex® brand aramid fibers that have been carded, cross-lapped, needled-punched and thermally bonded by heating the panel to the temperature softening point of the polyphenylene sulfide fibers.
- U.S. Pat. No. 5,501,898 discloses a support part for automobile roof linings.
- the part may have from one to three layers consisting exclusively of polyester fibers.
- the part contains no binder resin, connective fibers or glass fibers. All of the layers are pressed and compacted into the intended shaped by the action of pressure and heat.
- U.S. Pat. No. 5,709,925 discloses a multi-layered laminated body used as an interior trim panel for an automobile.
- the panel includes a three-layer substrate which includes a layer of natural fiber filler material embedded in a thermoplastic matrix and two cover layers comprising natural fibers, glass fibers or polyester fibers in a thermoplastic matrix material.
- the panel further includes a foam intermediate layer and a decorative surface layer. The panels are produced by hot-laminating the individual layers of the substrate together and then laminating and molding the decorative surface layer onto the substrate.
- an improved acoustical, compressible, polymer fiber liner/insulator is provided.
- the blanket is made of multiples layers of wet process polymer based mats formed of bicomponent fiber and polymer staple fibers bonded together using heat and pressure.
- the liner/insulator is typically used in automotive applications such as automobile doors or automobile passenger compartments to insulate the compartments from the heat and sound.
- the thermal/acoustical liner may also be used in appliances such as dishwashers, heating and air conditioning units, marine applications and commercial interiors.
- FIG. 1 is a cross-sectional view of the liner/insulator of the present invention.
- FIG. 2 illustrates a wet-processing line for forming the liner/insulator of FIG. 1 .
- FIG. 1 illustrates the liner/insulator designated by reference numeral 1 .
- the polymer fiber blanket 1 is constructed of a plurality of layers 2 , 4 , and 6 .
- Layers 2 , 4 and 6 are individual layers of wet processed mat.
- FIG. 3 illustrates a typical processing line 50 .
- a combination of polymer staple fibers 22 and the bicomponent fibers 24 are added to a whitewater chemical dispersion 52 within a mixing tank 56 to form thick whitewater slurry 54 at consistency levels of approximately 0.2 to 1 percent.
- the thick slurry 54 formed is maintained under agitation in a single tank 56 or series of tanks.
- the whitewater chemical dispersion 52 is used to obtain reasonable filamentation of the polymer staple fibers 22 and the bicomponent fibers 24 through steric, thermodynamic, and charge colloidal interactions.
- the preferred whitewater dispersion 52 includes a viscosity modifier, a defoamer and a surfactant.
- the viscosity modifiers used in the whitewater dispersion 52 are commonly used in nonwoven-type applications.
- One preferred class of viscosity modifiers is a polyacrylamide viscosity modifier such as Nalco 7768, Magnifloc 1886A, and HyChem AE 874.
- Another preferred viscosity modifier is a hydroxyethylcellulose, such as Natrosol 250HHBR.
- other possible viscosity modifiers or flocculants that may be used include high molecular weight, water-soluble polymers that are well known to those of ordinary skill in the art.
- the surfactants, or cationic dispersants, used in the whitewater dispersion aid in the wetting of the polymer staple fibers and the bicomponent fiber so that bundles of the fibers will disperse into individual filaments.
- One class of surfactants utilized are ethoxylated alkylamine dispersants such as Schercopol DS-140, Nalco 8493, or Rhodameen VP532.
- other dispersants may be used as well, including fatty acid amine oxides and polyethoxylated derivatives of amide condensation of fatty acid products.
- preferred defoamers utilized in the whitewater dispersion 52 include Nalco PP04-3840 and GEO FM LTX.
- the thick slurry 54 is then delivered through a control valve 58 and combined with a whitewater stream 76 from a silo 78 to form a lower consistency slurry 80 in the former 82 .
- the ratio of thick slurry 54 to the silo stream 78 in the lower consistency slurry 80 will typically be in the range of 1:10 and 1:40.
- the former 82 functions to equally distribute and randomly align the fibers 22 , 24 onto a moving woven fabric, or forming wire 96 , therein forming the filament network 14 .
- Formers 82 that can accommodate the initial fiber formation include Fourdrinier machines, Stevens Former, Roto Former, Inver Former, cylinder, and VertiFormer machines. These formers offer several control mechanisms to control fiber orientation within the network 14 such as drop leg and various pond regulator/wall adjustments.
- Deposited fibers forming the network 14 are partially dried over one or more suction boxes 94 .
- the dewatered network 14 is then run through a drying oven 97 at a temperature sufficient to remove any excess water and sufficient to melt the sheath of the bicomponent fibers 24 , typically about 130 to 180 degrees Celsius.
- the sheath material cools and adheres to polymer staple fibers 22 , therein forming one of the insulating layers.
- the wet process is preferred over various dry-laid processes because the wet process provides an insulating layer with a more consistent weight per unit area.
- the wet process also provides more intimate mixing of the fiber blends and more random fiber orientation. Compared with dry-laid processes, the wet process is capable of high production rates, thus providing a less costly insulating layer.
- the layers 2 , 4 and 6 are preferably made of thermoplastic polymer fibers including thermoplastic polymer bicomponent fibers and thermoplastic polymer staple fibers.
- the thermoplastic staple fibers and bicomponent fibers may be selected from a group of materials including but not limited to polyester, polyethylene, polypropylene, nylon, rayon, acetate, natural fibers (i.e., kenaf or hemp), polyethylene terephthalate and any mixtures and/or copolymers thereof. Further examples of fibers used can be found in commonly assigned U.S. patent application Ser. No. 10/636,078, filed Aug. 7, 2003.
- the mat is made of 100% polymer fibers (polymer bicomponent fibers and polymer staple fibers).
- the bicomponent fibers bond the fibers together within each individual layer of the mat. Heat and pressure is then applied to the mat and the multiple layers 2 , 4 and 6 are bonded together. Conventional flow-through ovens used in the art are used to heat and apply pressure to the layers 2 , 4 and 6 .
- a surface-treating device may be used to bond the layers together such as that described in commonly assigned U.S. patent application Ser. No. 10/609,947, filed Jun. 30, 2003 herein incorporated by reference in its entirety.
- the preferred temperature used to bond the layers 2 , 4 , 6 is between about 250° to about 400° F.
- the amount and type of bicomponent fibers selected for the fiber formulation determines the strength of the bond formed between the multiple layers.
- the layers 2 , 4 and 6 are typically between about 0.05 to about 0.30 inches thick.
- the thickness of the final product is between about 0.125 and about 1.5 inches thick.
- the layers 2 , 4 , 6 can have the same thickness, weight, fiber formulation or the layers can have two or more different combinations of fiber formulations, thickness and weight.
- base layer 6 may be formulated to have a high heat resistance and/or have hydrophilic properties.
- fibers such as high-melting bicomponent fibers, semi-crystalline fibers, thermoset polymer fibers or fibers coated with a heat resistant resin may be used.
- hollow or shaped polymer fibers may be utilized. Further, the fibers may be coated with a water-swellable coating.
- Another layer such a layer 4 may be composed of a fiber formulation that provides a barrier to moisture (hydrophobic fibers).
- fibers in layer 4 include, but are not limited to, polyolefins, polyacetate and fibers having small pores or micro-denier fibers may be utilized.
- Layer 2 may be composed of a fiber formulation that absorbs sound. Examples of sound absorbing fibers include, but are not limited to, natural fibers such as hemp and kenaf.
- the liner/insulator may include a facing, on one or both sides, to improve strength and/or surface appearance.
- a facing on one or both sides, to improve strength and/or surface appearance.
- Other embodiments including facings and fiber combinations that may be used with the present invention are discussed in U.S. Pat. No. 6,669,265, which is incorporated herein by reference in its entirety.
- a facing may be applied to the liner/insulator by heating one side of the liner/insulator, while the other side remains relatively cool.
- a pressure is then applied for sufficient time to allow the polymer binding fiber to soften near the hot surface but not near the cold surface. When this occurs under compression, the hot side is reshaped into a higher density surface layer.
- the cool side of the polymer binding fiber does not soften and, therefore, when the pressure is removed, the base zone retains most of its original thickness and density characteristics.
- the intermediate zone undergoes only moderate densification.
- This technique may be performed in a standard molding press where one platen runs hot and the other runs cool. This is followed by the printing of a selected face of the facing layer with desired graphics, patterns, designs or indicia. This process is described in detail in U.S.
Abstract
Description
- The present invention relates generally to a multilayer, wet processed, polymer-based mats having bicomponent and polymer staple fibers, where the layers are bonded together using heat and pressure. This acoustical and thermal liner/insulator may be utilized to insulate an environment such as a passenger compartment of a vehicle from the heat and sound generated by mechanical components of that vehicle during its operation. Other uses include application in insulating appliances such as dishwashers and clothes dryers and providing sound and thermal insulation for furnaces, air conditioning units and ductwork in buildings including homes, offices and industrial structures.
- Acoustical insulation is well known in the art. Acoustical insulation typically relies upon both sound absorption, i.e. the ability to absorb incident sound waves, and transmission loss, i.e. the ability to reflect incident sound waves, in order to provide sound attenuation. One of the more prevalent uses of such insulation is in the motorized vehicle field where engine compartments, fire walls, fender wells, doors, floor pans and other components of the passenger compartment shell are commonly acoustically insulated to reduce engine and road noise for the benefit and comfort of passengers. Acoustical insulation is also prevalent in appliances such as dishwashers and heating and air conditioning units.
- U.S. Pat. No. 6,008,149 discloses a moldable nonwoven fibrous composite article including at least two functional layers, which are made of the same nonwoven thermoformable polymeric chemical substance or material. The composite articles are molded from separate rolls or sheets of variable compression and formable fabric layers.
- Each of U.S. Pat. Nos. 6,156,682 and 6,364,976 discloses a laminated structure having a core of polymeric fibers, a thermosetting resin impregnated into the core, and individual chopped fibers randomly applied to opposite sides of the core layer. The preferred method of bonding the fibers together is by a bicomponent fiber, in which an outer layer of fibers is constituted by a low melt temperature polymer, and an inner core layer of fibers which constitutes a polymer with a relatively higher melt temperature.
- U.S. Pat. No. 4,780,359 discloses a nonwoven textile panel constructed of three layers of nonwoven textile fibers of polyphenylene sulfide fibers and Nomex® brand aramid fibers that have been carded, cross-lapped, needled-punched and thermally bonded by heating the panel to the temperature softening point of the polyphenylene sulfide fibers.
- U.S. Pat. No. 5,501,898 discloses a support part for automobile roof linings. The part may have from one to three layers consisting exclusively of polyester fibers. The part contains no binder resin, connective fibers or glass fibers. All of the layers are pressed and compacted into the intended shaped by the action of pressure and heat.
- U.S. Pat. No. 5,709,925 discloses a multi-layered laminated body used as an interior trim panel for an automobile. The panel includes a three-layer substrate which includes a layer of natural fiber filler material embedded in a thermoplastic matrix and two cover layers comprising natural fibers, glass fibers or polyester fibers in a thermoplastic matrix material. In additional to the substrate, the panel further includes a foam intermediate layer and a decorative surface layer. The panels are produced by hot-laminating the individual layers of the substrate together and then laminating and molding the decorative surface layer onto the substrate.
- In the past, it has been common practice of produce cotton shoddy or polymer-based insulation blanket by methods such as carding, garneting or using an air laid system. This is a need for an improved insulation providing enhanced acoustical properties. Further there is a need for a polymer-based that is produced from layers of wet process mat to a thickness and fiber formulation that yields a unique combination of properties that cannot be obtained by single, uniformly produced materials. There is also a need for a product that can be manufactured at a lower cost.
- In accordance with the purposes of the present invention as described herein, an improved acoustical, compressible, polymer fiber liner/insulator is provided. The blanket is made of multiples layers of wet process polymer based mats formed of bicomponent fiber and polymer staple fibers bonded together using heat and pressure. The liner/insulator is typically used in automotive applications such as automobile doors or automobile passenger compartments to insulate the compartments from the heat and sound. The thermal/acoustical liner may also be used in appliances such as dishwashers, heating and air conditioning units, marine applications and commercial interiors.
- It is an object of the present invention to provide a liner/insulator having multiple layers of wet process polymer based mats bonded together to yield a desired thickness with unique acoustical properties.
- It is a further objection of the present invention to provide a liner/insulator having multiple layers of wet process polymer based mats which are of varying thickness and varying fiber formulation.
- It is a further objection of the present invention to provide a liner/insulator, which is made by a low cost manufacturing process that provides a uniformity of fiber distribution in the final product.
- It is a further objection of the present invention to provide a polymer based liner/insulator product comprised of built up layers of wet process mat to a thickness and fiber formulation that yields a unique combination of properties that cannot be obtained by single, uniformly produced materials.
- Still other objects of the present invention will become apparent to those skilled in this art from the following description wherein there is shown and described preferred embodiments of this invention, simply by way of illustration of several of the modes best suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.
- The accompanying drawings incorporated in and forming a part of the specification, illustrates several aspects of the present invention and together with the description serves to explain the principles of the invention. In the drawings:
-
FIG. 1 is a cross-sectional view of the liner/insulator of the present invention. -
FIG. 2 illustrates a wet-processing line for forming the liner/insulator ofFIG. 1 . - Reference will now be made in detail to the present preferred embodiments of the invention, examples of which are illustrated in the accompanying drawing.
- Reference is now made to
FIG. 1 , which illustrates the liner/insulator designated byreference numeral 1. Thepolymer fiber blanket 1 is constructed of a plurality oflayers Layers - The wet process which is used to make the individual layers of the liner/insulator is described in commonly assigned U.S. patent application Ser. No. 10/636,078, filed Aug. 7, 2003, which is herein incorporated by reference in its entirety.
FIG. 3 illustrates atypical processing line 50. A combination ofpolymer staple fibers 22 and thebicomponent fibers 24 are added to a whitewaterchemical dispersion 52 within amixing tank 56 to formthick whitewater slurry 54 at consistency levels of approximately 0.2 to 1 percent. Thethick slurry 54 formed is maintained under agitation in asingle tank 56 or series of tanks. - The whitewater
chemical dispersion 52 is used to obtain reasonable filamentation of thepolymer staple fibers 22 and thebicomponent fibers 24 through steric, thermodynamic, and charge colloidal interactions. Thepreferred whitewater dispersion 52 includes a viscosity modifier, a defoamer and a surfactant. - The viscosity modifiers used in the
whitewater dispersion 52 are commonly used in nonwoven-type applications. One preferred class of viscosity modifiers is a polyacrylamide viscosity modifier such as Nalco 7768, Magnifloc 1886A, and HyChem AE 874. Another preferred viscosity modifier is a hydroxyethylcellulose, such as Natrosol 250HHBR. However, other possible viscosity modifiers or flocculants that may be used include high molecular weight, water-soluble polymers that are well known to those of ordinary skill in the art. - The surfactants, or cationic dispersants, used in the whitewater dispersion aid in the wetting of the polymer staple fibers and the bicomponent fiber so that bundles of the fibers will disperse into individual filaments. One class of surfactants utilized are ethoxylated alkylamine dispersants such as Schercopol DS-140, Nalco 8493, or Rhodameen VP532. However, other dispersants may be used as well, including fatty acid amine oxides and polyethoxylated derivatives of amide condensation of fatty acid products. Also, preferred defoamers utilized in the
whitewater dispersion 52 include Nalco PP04-3840 and GEO FM LTX. - The
thick slurry 54 is then delivered through acontrol valve 58 and combined with awhitewater stream 76 from asilo 78 to form alower consistency slurry 80 in the former 82. The ratio ofthick slurry 54 to thesilo stream 78 in thelower consistency slurry 80 will typically be in the range of 1:10 and 1:40. - The former 82, or headbox, functions to equally distribute and randomly align the
fibers wire 96, therein forming thefilament network 14.Formers 82 that can accommodate the initial fiber formation include Fourdrinier machines, Stevens Former, Roto Former, Inver Former, cylinder, and VertiFormer machines. These formers offer several control mechanisms to control fiber orientation within thenetwork 14 such as drop leg and various pond regulator/wall adjustments. - Deposited fibers forming the
network 14 are partially dried over one ormore suction boxes 94. The dewaterednetwork 14 is then run through a dryingoven 97 at a temperature sufficient to remove any excess water and sufficient to melt the sheath of thebicomponent fibers 24, typically about 130 to 180 degrees Celsius. Upon removal from theoven 97, the sheath material cools and adheres topolymer staple fibers 22, therein forming one of the insulating layers. - The wet process is preferred over various dry-laid processes because the wet process provides an insulating layer with a more consistent weight per unit area. The wet process also provides more intimate mixing of the fiber blends and more random fiber orientation. Compared with dry-laid processes, the wet process is capable of high production rates, thus providing a less costly insulating layer.
- The
layers - Preferably, the mat is made of 100% polymer fibers (polymer bicomponent fibers and polymer staple fibers). The bicomponent fibers bond the fibers together within each individual layer of the mat. Heat and pressure is then applied to the mat and the
multiple layers layers layers - In a preferred embodiment, the
layers layers - By utilizing different combinations of fiber formulations, weight and thickness, in the individual layers, the final product can be “tuned” to meet acoustical and thermal requirements. For example,
base layer 6 may be formulated to have a high heat resistance and/or have hydrophilic properties. To provide high heat resistance, fibers such as high-melting bicomponent fibers, semi-crystalline fibers, thermoset polymer fibers or fibers coated with a heat resistant resin may be used. To provide hydrophilic properties, hollow or shaped polymer fibers may be utilized. Further, the fibers may be coated with a water-swellable coating. - Another layer, such a
layer 4, may be composed of a fiber formulation that provides a barrier to moisture (hydrophobic fibers). Examples of such fibers inlayer 4 include, but are not limited to, polyolefins, polyacetate and fibers having small pores or micro-denier fibers may be utilized.Layer 2 may be composed of a fiber formulation that absorbs sound. Examples of sound absorbing fibers include, but are not limited to, natural fibers such as hemp and kenaf. - In another embodiment of the present invention, it may be advantageous to use one or more layers of the wet processed mat, as described above, in conjunction with a layer of polymer-based fibrous mat insulation.
- Optionally, the liner/insulator may include a facing, on one or both sides, to improve strength and/or surface appearance. Other embodiments including facings and fiber combinations that may be used with the present invention are discussed in U.S. Pat. No. 6,669,265, which is incorporated herein by reference in its entirety.
- A facing may be applied to the liner/insulator by heating one side of the liner/insulator, while the other side remains relatively cool. A pressure is then applied for sufficient time to allow the polymer binding fiber to soften near the hot surface but not near the cold surface. When this occurs under compression, the hot side is reshaped into a higher density surface layer. The cool side of the polymer binding fiber does not soften and, therefore, when the pressure is removed, the base zone retains most of its original thickness and density characteristics. The intermediate zone undergoes only moderate densification. This technique may be performed in a standard molding press where one platen runs hot and the other runs cool. This is followed by the printing of a selected face of the facing layer with desired graphics, patterns, designs or indicia. This process is described in detail in U.S. patent application Ser. No. 10/421,565, filed Apr. 23, 2002 and Ser. No. 10/749,087, filed Dec. 30, 2003, which are herein incorporated by reference in their entirety.
- The embodiments were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.
Claims (23)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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US10/789,143 US20050191925A1 (en) | 2004-02-27 | 2004-02-27 | Layered polymer fiber insulation and method of making thereof |
PCT/US2005/006213 WO2005084934A1 (en) | 2004-02-27 | 2005-02-25 | Layered polymer fiber insulation and method of making thereof |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US10/789,143 US20050191925A1 (en) | 2004-02-27 | 2004-02-27 | Layered polymer fiber insulation and method of making thereof |
Publications (1)
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US20050191925A1 true US20050191925A1 (en) | 2005-09-01 |
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US10/789,143 Abandoned US20050191925A1 (en) | 2004-02-27 | 2004-02-27 | Layered polymer fiber insulation and method of making thereof |
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WO (1) | WO2005084934A1 (en) |
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DE102005048603A1 (en) * | 2005-10-06 | 2007-04-26 | J.H. Ziegler Gmbh & Co. Kg | Non-woven plastic laminate infiltratable for the production of fiber-reinforced plastic parts |
US20070270071A1 (en) * | 2006-05-18 | 2007-11-22 | Greer J Travis | Nonwoven fabric towel |
US20080003907A1 (en) * | 2006-06-28 | 2008-01-03 | Samuel Keith Black | Facing Product for Vehicular Trim |
US20080083279A1 (en) * | 2005-12-28 | 2008-04-10 | Lear Corporation | Random incident absorber approximation |
DE102007033635A1 (en) * | 2007-03-20 | 2008-12-11 | Johann Borgers Gmbh & Co Kg | Nonwoven molding for vehicles |
US20100287860A1 (en) * | 2006-02-28 | 2010-11-18 | Fernandez-Cano Pedro Luis | Insulated Facade System |
DE102009059975A1 (en) | 2009-12-22 | 2011-06-30 | Sitech Sitztechnik GmbH, 38442 | Seat structure, particularly seat part or seat back of individual single or rear seat system for vehicle, has carrier part that is made of light-weight material and is formed as base body |
DE102017123283A1 (en) * | 2017-10-06 | 2019-04-11 | J.H. Ziegler Gmbh | Device, in particular fiber composite production device |
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DE102009059975A1 (en) | 2009-12-22 | 2011-06-30 | Sitech Sitztechnik GmbH, 38442 | Seat structure, particularly seat part or seat back of individual single or rear seat system for vehicle, has carrier part that is made of light-weight material and is formed as base body |
DE102017123283A1 (en) * | 2017-10-06 | 2019-04-11 | J.H. Ziegler Gmbh | Device, in particular fiber composite production device |
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