Thermoplastic composites with improved sound absorbing capabilities
First Claim
1. A method of making an acoustic and thermally absorbent composite material comprising the steps of:
- at least partially opening bales of wet reinforcing fibers;
removing water from said at least partially opened wet reinforcing fibers to form dehydrated reinforcing fibers;
blending said dehydrated reinforcing fibers with organic fibers and acoustical enhancement fibers to form a substantially homogenous mixture of said dehydrated reinforcing fibers, said organic fibers, and said acoustical enhancement fibers;
forming said mixture into a sheet; and
bonding at least some of said dehydrated reinforcing fibers, said organic fibers, and said acoustical enhancement fibers to form a composite material.
2 Assignments
0 Petitions
Accused Products
Abstract
A composite material formed of reinforcement fibers, acoustical enhancing fibers such as polyethylene terephthalate (PET) fibers or modified polyethylene terephthalate fibers, and one or more organic fibers is provided. The acoustical enhancing fiber may be any fiber that provides increased or enhanced acoustical absorbance, particularly at low frequencies. The composite material may be formed by partially opening wet reinforcing fibers, acoustical enhancing fibers, and organic fibers, mixing the reinforcing, acoustical enhancement, and organic fibers, forming the fibers into a sheet, and bonding the fibers in the sheet. Preferably the reinforcing fibers are wet use chopped strand glass fibers. The composite material may be formed of a single layer of reinforcement, acoustical enhancement fibers, and organic fibers. Alternatively, the composite material may be a multi-layered composite in which the acoustical enhancement fibers are located in an acoustical layer laminated to a thermal layer formed of the organic fibers and reinforcement fibers.
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Citations
21 Claims
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1. A method of making an acoustic and thermally absorbent composite material comprising the steps of:
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at least partially opening bales of wet reinforcing fibers;
removing water from said at least partially opened wet reinforcing fibers to form dehydrated reinforcing fibers;
blending said dehydrated reinforcing fibers with organic fibers and acoustical enhancement fibers to form a substantially homogenous mixture of said dehydrated reinforcing fibers, said organic fibers, and said acoustical enhancement fibers;
forming said mixture into a sheet; and
bonding at least some of said dehydrated reinforcing fibers, said organic fibers, and said acoustical enhancement fibers to form a composite material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A method of forming a laminate composite product comprising the steps of:
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forming a first layered material including;
depositing a first adhesive layer formed of a first adhesive onto a first scrim;
positioning a layer of a first composite material on said first adhesive layer, said composite material including dehydrated wet reinforcing fibers, organic fibers, and acoustical enhancement fibers;
placing a second adhesive layer formed of a second adhesive on said first composite material layer;
forming a second layered material including;
depositing a third adhesive layer formed of a third adhesive onto a core layer, said core layer being formed of a member selected from the group consisting of polyethylene terephthalate fibers, modified polyethylene terephthalate fibers and combinations thereof;
placing a layer of a second composite material including said reinforcing fibers, said acoustical enhancement fibers, and said organic fibers on said third adhesive layer; and
depositing a fourth adhesive layer formed of a fourth adhesive onto said second composite material layer; and
positioning said second layered material and said first layered material such that said second adhesive layer is located adjacent to said core layer to form a laminate composite product. - View Dependent Claims (12, 13, 14, 15, 21)
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16. A method of making a composite material comprising the steps of:
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at least partially opening bales of wet reinforcing fibers;
removing water from said at least partially opened wet reinforcing fibers to form dehydrated reinforcing fibers;
blending said dehydrated reinforcing fibers with organic fibers to form a substantially homogenous mixture of said dehydrated reinforcing fibers and said organic fibers;
forming said mixture into a sheet;
bonding said reinforcing fibers and organic fibers in said sheet to form a first layer; and
affixing a second layer formed of acoustical enhancement fibers to said first layer to form a composite material, said acoustical enhancement fibers being selected from the group consisting of polyethylene terephthalate fibers and modified polyethylene terephthalate fibers. - View Dependent Claims (17, 18, 19, 20)
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Specification