Device for absorbing sound within the cabin of vehicle

• US 10,657,946 B2
• Filed: 02/17/2017
• Issued: 05/19/2020
• Est. Priority Date: 02/19/2016
• Status: Active Grant

• Current Assignee: Edward Gentile
• Original Assignee: Edward Gentile
• Inventors: Gentile, Edward
• Primary Examiner(s): San Martin, Edgardo
• Application Number:
  US15/435,324
• Publication Number:
  US 20170243573A1
• Time in Patent Office: 1,187 Days
• CPC Class Codes: B32B 2037/1253 curable adhesive
• CPC Class Codes: B32B 2037/243 Coating
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2255/102 synthetic resin or rubber layer being a foamed layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2266/0264 Polyester
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2266/06 Open cell foam
• CPC Class Codes: B32B 2305/022 Foam
• CPC Class Codes: B32B 2305/72 Cured, e.g. vulcanised, cross-linked
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/72 Density
• CPC Class Codes: B32B 2307/732 Dimensional properties
• CPC Class Codes: B32B 2309/02 Temperature
• CPC Class Codes: B32B 2309/04 Time
• CPC Class Codes: B32B 2327/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B32B 2367/00 Polyesters, e.g. PET, i.e. polyethylene terephthalate
• CPC Class Codes: B32B 2375/00 Polyureas; Polyurethanes
• CPC Class Codes: B32B 2605/003 Interior finishings
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 37/06 : characterised by the heating method
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/32 : at least two layers being foamed and next to each other
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B60R 13/083 : for fire walls or floors
• CPC Class Codes: G10K 11/168 : Plural layers of different materials, e.g. sandwiches

Abstract

A sound absorbing mat comprising a first polyurethane open cell polyester layer, wherein the first polyurethane open cell polyester layer is at least one quarter of an inch thick, a polyvinyl chloride layer having a top surface and a bottom surface, wherein the polyvinyl chloride layer is at least a quarter inch thick and the bottom surface is fused to the first polyurethane open cell polyester, a second polyurethane open cell polyester layer having a top surface and a bottom surface, wherein the second polyurethane open cell polyester layer is at least three quarters of an inch and the bottom surface of the second polyurethane open cell polyester layer is fused with the top surface of the polyvinyl chloride layer, and a urethane layer, wherein the urethane layer is at least a quarter inch thick and is mated to the top surface of the second polyurethane open cell polyester layer.

Claims

1. A sound absorbing mat for use within the interior compartment of a vehicle, comprising:

a first polyurethane open cell polyester layer having a predefined contour, wherein the first polyurethane open cell polyester layer is at least one quarter of an inch thick, wherein the first polyurethane open cell polyester layer forms to the space of the interior compartment;

a polyvinyl chloride, wherein the polyvinyl chloride is applied to and fuses with the first polyurethane open cell polyester, wherein the polyvinyl chloride takes on the contour of the first polyurethane open cell polyester layer once hardened and is substantially a quarter of an inch thick;

a second polyurethane open cell polyester layer having a top surface and a bottom surface, wherein the bottom surface has a predetermined contour and the top surface is substantially smooth, wherein the second polyurethane open cell polyester layer is at least three quarters of an inch thick and the bottom surface of the second polyurethane open cell polyester layer is fused with the polyvinyl chloride before it is hardened; and

a urethane layer having a grip surface, wherein the urethane layer is at least a quarter inch thick and is mated to the top surface of the second polyurethane open cell polyester layer.

2. The sound absorbing mat for use within the interior compartment of a vehicle of claim 1, wherein the first polyurethane open cell polyester layer has a thickness of approximately one quarter inches.

3. The sound absorbing mat for use within the interior compartment of a vehicle of claim 1, wherein the second polyurethane open cell polyester layer has a thickness of approximately three quarter of an inches.

4. The sound absorbing mat for use within the interior compartment of a vehicle of claim 1, wherein the polyvinyl chloride layer has a thickness of approximately one quarter of an inches.

5. The sound absorbing mat for use within the interior compartment of a vehicle of claim 1, wherein the urethane layer has a thickness of approximately three sixty-fourths of an inches.

6. The sound absorbing mat for use within the interior compartment of a vehicle of claim 1, wherein a top surface of the first polyurethane open cell polyester layer has a predetermined contour, so that when the polyvinyl chloride layer solidifies, the contours of the top surface are replicated in the polyvinyl chloride layer.

7. The sound absorbing mat for use within the interior compartment of a vehicle of claim 1, wherein a bottom surface of the second polyurethane open cell polyester layer has a predetermined contour, so that when the polyvinyl chloride layer solidifies, the contours of the bottom surface are replicated in the polyvinyl chloride layer.

8. A sound absorbing mat for use within the interior compartment of a vehicle, comprising:

a first polyurethane open cell polyester layer having a first surface and a second surface, wherein the first surface has a contour to substantially match the interior compartment surface, and the second surface has a contour to increase sound deflection;

a polyvinyl chloride applied to the seconds surface of the first polyurethane open cell polyester; and

a second polyurethane open cell polyester layer having a top surface and a bottom surface, wherein the bottom surface of the second polyurethane open cell polyester layer is fused with the top surface of the polyvinyl chloride layer; and

a urethane layer having a top side and a bottom side, wherein the bottom side is fused with the top surface of the second polyurethane open cell polyester layer and the top side is exposed to the interior compartment space.

9. The sound absorbing mat of claim 8, further comprising;

a urethane layer, wherein the urethane layer is mated to the top surface of the second polyurethane open cell polyester layer.

10. The sound absorbing mat of claim 9, wherein the urethane layer, wherein the urethane layer is at least a quarter inch thick.

11. The sound absorbing mat of claim 8, wherein the first polyurethane open cell polyester layer is at least one quarter of an inch thick.

12. The sound absorbing mat of claim 8, wherein the polyvinyl chloride layer is at least a quarter inch thick.

13. The sound absorbing mat of claim 8, wherein the second polyurethane open cell polyester layer is at least three quarters of an inch thick.