Multidensity liner/insulator having reinforcing ribs

• US 20050191921A1
• Filed: 02/27/2004
• Published: 09/01/2005
• Est. Priority Date: 02/27/2004
• Status: Abandoned Application

• Current Assignee: Owens Corning Intellectual Capital, LLC (Owens Corning)
• Original Assignee: Owens Corning Intellectual Capital, LLC (Owens Corning)
• Inventors: Rockwell, Anthony L., Tilton, Jeffrey A.
• Application Number:
  US10/789,144
• Publication Number:
  US 20050191921A1
• Time in Patent Office: Days
• US Class Current: 442/120
• CPC Class Codes: A47L 15/4209 Insulation arrangements, e.g. for sound damping or heat insulation
• CPC Class Codes: B32B 2307/10 having particular acoustical properties
• CPC Class Codes: B32B 2307/306 Resistant to heat
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2605/003 Interior finishings
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• 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 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: D04H 1/4209 Inorganic fibres
• CPC Class Codes: D04H 1/559 the fibres being within layered webs
• CPC Class Codes: D04H 1/70 characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
• CPC Class Codes: Y10T 442/2008 Fabric composed of a fiber or strand which is of specific structural definition
• CPC Class Codes: Y10T 442/2041 Two or more non-extruded coatings or impregnations
• CPC Class Codes: Y10T 442/2221 Coating or impregnation is specified as water proof
• CPC Class Codes: Y10T 442/25 Coating or impregnation absorbs sound
• CPC Class Codes: Y10T 442/2861 Coated or impregnated synthetic organic fiber fabric
• CPC Class Codes: Y10T 442/2992 Coated or impregnated glass fiber fabric
• CPC Class Codes: Y10T 442/608 : Including strand or fiber material which is of specific structural definition
• CPC Class Codes: Y10T 442/609 : Cross-sectional configuration of strand or fiber material is specified
• CPC Class Codes: Y10T 442/637 : 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
• CPC Class Codes: Y10T 442/638 : Side-by-side multicomponent strand or fiber material
• CPC Class Codes: Y10T 442/656 : Preformed metallic film or foil or sheet [film or foil or sheet had structural integrity prior to association with the nonwoven fabric]
• CPC Class Codes: Y10T 442/659 : Including an additional nonwoven fabric

Abstract

A liner/insulator including a base layer of fibrous material and a plurality of ribs of fibrous insulation material thermally bonded to said base layer. The fibrous material is constructed of either (a) thermoplastic polymer staple fibers and thermoplastic bicomponent fibers, (b) glass staple fibers and thermoplastic bicomponent fibers and (c) a combination of (a) and (b).

Claims

1. ) a liner/insulator, comprising:

a base layer of fibrous material;

a plurality of ribs of fibrous material thermally bonded to said base layer.

2. ) The liner/insulator of claim 1, wherein said fibrous material is selected from a group consisting of (a) thermoplastic polymer staple fibers and thermoplastic bicomponent fibers, (b) glass staple fibers and glass bicomponent fibers and (c) glass staple fibers and thermoplastic bicomponent fibers and (d) a combination of (a), (b) and (c).

3. ) The liner/insulator of claim 1, wherein said fibrous material is selected from a group of materials consisting of polyester, polyethylene, polypropylene, polyethylene terephthalate, glass fibers, natural fibers and any mixtures thereof.

4. ) The liner/insulator of claim 1, wherein said plurality of ribs are spaced apart at least about 0.25 inches.

5. ) The liner/insulator of claim 1, wherein said plurality of ribs extend parallel to one another.

6. ) The liner/insulator of claim 1, wherein said plurality of ribs extend perpendicular to one another.

7. ) The liner/insulator of claim 1, wherein said plurality of ribs extend diagonally to one another.

8. ) The liner/insulator of claim 1, wherein said plurality of ribs are between about 0.5 to about 3.0 inches wide.

9. ) The liner/insulator of claim 2, wherein said liner/insulator has a percent wet compression of between about 15 to about 18 percent.

10. ) The liner/insulator of claim 2, wherein said liner/insulator has a percent dry compression of between about 16 to about 21 percent.

11. ) The liner/insulator of claim 2, wherein said liner/insulator has a percent dry wet recovery of between about 85 to about 87.5 percent.

12. ) The liner/insulator of claim 1, wherein said liner/insulator is an automotive undercarpet.

13. ) The liner/insulator of claim 1, wherein said plurality of ribs are made of scrap fibrous material.

14. ) The liner/insulator claim 1, wherein said plurality of ribs comprise a lofty, acoustically insulating portion having a density of between substantially 8.0-80.0 kg/m³ and a relatively higher density skin along at least one face thereof, said skin having a thickness of between substantially 0.25-10.0 mm and a density of between substantially 32.0-80.0 kg/m³.

15. ) The liner/insulator of claim 1, wherein said liner/insulator is a nonlaminate.

16. ) The liner/insulator of claim 1, wherein said liner/insulator further comprises at least one facing layer.

17. ) The liner/insulator of claim 16, wherein said facing layer comprises metallic foil, glass mats, polymer mats and blends thereof.

18. ) The liner/insulator of claim 1, wherein said blanket further comprises at least one water barrier layer.

19. ) A method of producing a liner/insulator comprising the steps of:

a) providing a base layer of fibrous material;

b) providing a plurality of ribs of fibrous insulation material; and

c) thermally bonding said plurality of ribs of fibrous insulation material to said base layer of fibrous material.

20. ) The method of claim 19, wherein said fibrous material is selected from a group consisting of (a) thermoplastic polymer staple fibers and thermoplastic bicomponent fibers, (b) glass staple fibers and glass bicomponent fibers and (c) glass staple fibers and thermoplastic bicomponent fibers and (d) a combination of (a), (b) and (c).

21. ) The method of claim 19, wherein said fibrous material is selected from a group of materials consisting of polyester, polyethylene, polypropylene, polyethylene terephthalate, glass fibers, natural fibers and any mixtures thereof.

22. ) The method of claim 19, wherein said plurality of ribs are spaced apart at least about 0.25 inches.

23. ) The method of claim 19, wherein said plurality of ribs extend parallel to one another.

25. ) The method of claim 19, wherein said plurality of ribs extend diagonally to one another.

26. ) The method of claim 19, wherein said plurality of ribs are between about 0.5 to about 3.0 inches wide.

27. ) The method of claim 20, wherein said liner/insulator has a percent wet compression of between about 15 to about 18 percent.

28. ) The method of claim 20, wherein said liner/insulator has a percent dry compression of between about 16 to about 21 percent.

29. ) The method of claim 20, wherein said liner/insulator has a percent dry wet recovery of between about 85 to about 87.5 percent.

30. ) The method of claim 19, wherein said liner/insulator is an automotive undercarpet.

31. ) The method of claim 19, wherein said plurality of ribs are made of scrap fibrous material.

32. ) The method of claim 19, wherein said plurality of ribs comprise a lofty, acoustically insulating portion having a density of between substantially 8.0-80.0 kg/m³ and a relatively higher density skin along at least one face thereof, said skin having a thickness of between substantially 0.25-10.0 mm and a density of between substantially 32.0-80.0 kg/m³.

33. ) The method of claim 19, wherein said liner/insulator is a nonlaminate.

34. ) The method of claim 19, wherein said liner/insulator further comprises at least one facing layer.

35. ) The method of claim 34, wherein said facing layer comprises metallic foil, glass mats, polymer mats and blends thereof.

36. ) The method of claim 19, wherein said blanket further comprises at least one water barrier layer.

37. ) The method of claim 19, wherein said plurality of ribs are thermally bonded to said base layer at a temperature of between about 200°

F. to about 350°

F.

24. ) The method of 19, wherein said plurality of ribs extend perpendicular to one another.