Molded and shaped acoustical insulating vehicle panel and method of making the same

• US 10,144,367 B2
• Filed: 09/29/2008
• Issued: 12/04/2018
• Est. Priority Date: 09/28/2007
• Status: Active Grant

• Current Assignee: L International IP Holdings LLC
• Original Assignee: Lydall Incorporated
• Inventors: Borchardt, Steven, Jarrard, Brian
• Primary Examiner(s): Steele, Jennifer A
• Application Number:
  US12/285,082
• Publication Number:
  US 20090085378A1
• Time in Patent Office: 3,718 Days
• Field of Search: 442402, 442403, 442405, 442407, 442362, 442364, 442382, 442383, 442389, 28107-109, 28111-117, 296198, 2961461
• CPC Class Codes: B32B 3/26 characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205; characterised by an apertured layer
• CPC Class Codes: B32B 5/06 characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• CPC Class Codes: B32B 5/14 characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces
• CPC Class Codes: B32B 5/26 another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B60R 13/0815 Acoustic or thermal insulation of passenger compartments wall or roof liners integrating the insulating function B60R13/02; insulating floor mats or carpets B60N3/04
• CPC Class Codes: B60R 13/0861 for covering undersurfaces of vehicles, e.g. wheel houses
• CPC Class Codes: D04H 1/485 in combination with weld-bonding
• CPC Class Codes: D04H 1/5412 sheath-core
• CPC Class Codes: D04H 1/5418 Mixed fibres, e.g. at least two chemically different fibres or fibre blends
• CPC Class Codes: D04H 1/558 in combination with mechanical or physical treatments other than embossing
• CPC Class Codes: D04H 13/005 by needling
• CPC Class Codes: Y10T 442/667 Needled
• CPC Class Codes: Y10T 442/688 Containing polymeric strand or fiber material
• CPC Class Codes: Y10T 442/692 Containing at least two chemically different strand or fiber materials

Abstract

A molded and shaped acoustical insulating vehicle panel having a dry-laid needled fibrous composite composed of a first portion of about 50 to 80 percent meltable binder fibers and about 20 to 50 percent stable fibers and having a second portion of about 20 to 50 percent meltable binder fibers and 50 to 80 percent of staple fibers. The meltable binder fibers are in a molded and resolidified state such that the resolidified binder fibers of the first portion form a substantially continuous, semi-impervious, densified skin integrally associated with and bonded to a surface of the first portion. The molded composite is in such a heat and pressure molded state that the composite has over a predominance of its area a density of from about 12 to 22 lbs./cubic foot (192 to 352 kg/cubic meter) and the panel is sufficiently rigid as to be self-supporting.

Claims

1. A molded and shaped acoustical insulating vehicle panel, comprising:

a nonwoven fibrous composite having a first portion of greater than 60 to 80 percent meltable binder fibers and less than 40 percent to 20percent staple fibers, and having a second portion of about 20 to 50 percent meltable binder fibers and 50 to 80 percent staple fibers; and

at least a portion of the meltable binder fibers of the first portion forming a substantially continuous, semi-impervious, densified skin integrally associated with and bonded to a surface of the first portion, wherein the densified skin is about 5 to about 20 percent of an overall thickness of the molded and shaped acoustical insulating vehicle panel,

wherein the molded and shaped acoustical insulating vehicle panel has a density of from about 12 to 22 lbs/cubic foot (192 to 352 kg/cubic meter) over a predominance of an area defining the molded and shaped acoustical insulating vehicle panel, and is sufficiently rigid so as to be self-supporting.

2. The panel of claim 1, wherein the dry-laid and needled fibrous composite is carded.

3. The panel of claim 2, wherein the molded and shaped acoustical insulating vehicle panel has a density gradient from a back side to the skin side.

4. The panel of claim 1, wherein the skin of the molded and shaped acoustical insulating vehicle panel has a sufficient porosity so that water splashed thereinto may drain therefrom.

5. The panel of claim 4, wherein the molded and shaped acoustical insulating vehicle panel has the skin formed in a cool mold so as to cause melted and/or softened fibers to coalesce into the skin.

6. The panel of claim 1, wherein the molded and shaped acoustical insulating vehicle panel is in the form of a vehicle wheel well shield with a Flow Resistance of between 300 and 1000 MKS rayls.

7. The panel of claim 1, wherein the molded and shaped acoustical insulating vehicle panel is in the form of a vehicle wheel well shield with a Flow Resistance of between 350 and 800 MKS rayls.

8. The panel of claim 1, wherein the molded and shaped acoustical insulating vehicle panel is so self-supporting that it will retain its molded shape without supports.

9. A process for making the vehicle panel of claim 1, comprising:

dry-laying a first portion of fibers having from about 50% to 80% meltable binder fibers and about 30% to 50% staple fibers;

dry-laying a second portion of fibers on the first portion so as to form a composite thereof, with the second portion having about 20% to 50% meltable binder fibers and about 50% to 80% staple fivers;

needling the composite sufficiently to form a consolidated composite;

heating the consolidated composite to a temperature sufficient to soften and/or melt the meltable binder fibers such that the meltable binder fibers are moldable;

molding the heated consolidated composite in a mold in the configuration of a vehicle panel until the meltable binder fibers resolidify such that at least some of the resolidified binder fibers of the first portion form a substantially continuous, semi-impervious, densified skin intimately adhered and bonded to the first portion and wherein the two portions have over a predominance of their area an insulation density of from about 12 to 22 lbs./cubic ft. (192 to 352 kg/cubic meter) and the molded panel is sufficiently rigid so as to be self-supporting.

10. The process of claim 9, wherein the consolidated composite is heated to a temperature of at least 300°

F. (148.9°

C.) and the mold is a cool mold with a temperature of no more than 200°

F. (93.3°

C.), so that the heated consolidated composite is shaped and cooled while in the mold and may be removed from the mold as a self supporting panel.

11. The process of claim 10, wherein the composite is needled with at least 300 needle punches per square inch (47 needle punches per square centimeter).

12. A molded and shaped acoustical insulating vehicle panel, comprising:

a nonwoven fibrous composite having a first portion of greater than 60 to 80 percent meltable binder fibers and less than 40 percent to 20 percent staple fibers, and having a second portion of about 20 to 50 percent meltable binder fibers and 50 to 80 percent staple fibers;

the composite having fibers from the first portion extending into the second portion and providing a high bond strength after molding between the first portion and the second portion to prevent peeling of the first portion from the second portion; and

a substantially continuous, semi-impervious, densified skin comprising resolidified binder fibers of the first portion and being integrally associated with and bonded to a surface of the first portion, wherein the densified skin is about 5 to about 20 percent of an overall thickness of the molded and shaped acoustical insulating vehicle panel, and

wherein the molded and shaped acoustical insulating vehicle panel has a density of from about 12 to 22 lbs/cubic foot (192 to 352 kg/cubic meter) over a predominance of an area defining the molded and shaped acoustical insulating vehicle panel, and the molded and shaped acoustical insulating vehicle panel is sufficiently rigid so as to be self-supporting.

13. The panel of claim 12, wherein the dry-laid composite is carded.

14. The panel of claim 13, wherein the molded and shaped acoustical insulating vehicle panel has a density gradient from a back side to the skin side.

15. The panel of claim 12, wherein the skin of the molded and shaped acoustical insulating vehicle panel has a sufficient porosity so that water splashed thereunto may drain therefrom.

16. The panel of claim 15, wherein the molded and shaped acoustical insulating vehicle panel has the skin formed in a cool mold so as to cause melted and/or softened fibers to coalesce into the skin.

17. The panel of claim 12, wherein the molded and shaped acoustical insulating vehicle panel is in the form of a vehicle wheel well shield with a Flow Resistance of between 300 and 1000 MKS rayls.

18. The panel of claim 12, wherein the molded and shaped acoustical insulating vehicle panel is in the form of a vehicle wheel well shield with a Flow Resistance of between 350 and 800 MKS rayls.

19. The panel of claim 12, wherein the molded and shaped acoustical insulating vehicle panel is so self-supporting that it will retain its molded shape without supports.