Thermoplastic composites with improved sound absorbing capabilities

• US 20060137799A1
• Filed: 12/29/2004
• Published: 06/29/2006
• Est. Priority Date: 12/29/2004
• Status: Abandoned Application

• Current Assignee: Owens Corning Intellectual Capital, LLC (Owens Corning)
• Original Assignee: Owens Corning Intellectual Capital, LLC (Owens Corning)
• Inventors: Haque, Enamul, Blinkhorn, Arthur, Cheney, Terry
• Application Number:
  US11/027,925
• Publication Number:
  US 20060137799A1
• Time in Patent Office: Days
• US Class Current: 156/62.200
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2260/023 Two or more layers
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2260/048 Natural or synthetic rubber
• CPC Class Codes: B32B 2262/0284 Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/12 Conjugate fibres, e.g. core/sheath or side-by-side
• CPC Class Codes: B32B 2262/14 Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/31 Heat sealable
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls tiles for roofs B32B2419/06
• CPC Class Codes: B32B 2605/08 Cars
• 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 5/08 the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• 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: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B60R 13/08 : Insulating elements, e.g. for sound insulation sound insulating linings for trains B61D17/185; drivers' cabs for load-carrying vehicles insulated against vibrations or noise B62D33/0604; thermal or acoustic insulation of engines F02B77/11; damping of sounds using compensation by electro-acoustic methods G10K11/178
• CPC Class Codes: D04H 1/435 : Polyesters
• CPC Class Codes: D04H 1/43828 : sheath-core
• CPC Class Codes: D04H 1/4383 : sea-island
• CPC Class Codes: D04H 1/43832 : side-by-side
• CPC Class Codes: D04H 1/43835 : Mixed fibres, e.g. at least two chemically different fibres or fibre blends
• CPC Class Codes: D04H 1/48 : in combination with at least one other method of consolidation
• CPC Class Codes: D04H 1/485 : in combination with weld-bonding
• CPC Class Codes: D04H 1/54 : by welding together the fibres, e.g. by partially melting or dissolving in combination with needling D04H1/485
• CPC Class Codes: D04H 1/732 : by fluid current, e.g. air-lay

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.

Claims

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. The method of claim 1, wherein said bonding step comprises:

subjecting said sheet to a needling process to mechanically bond said dehydrated reinforcing fibers, said organic fibers, and said acoustical enhancement fibers.

3. The method of claim 1, wherein said bonding step comprises:

heating said sheet to a temperature above the melting point of at least one of said organic fibers and said acoustical enhancement fibers and below the melting point of said dehydrated reinforcing fibers to at least partially melt at least one of said organic fibers and said acoustical enhancement fibers.

4. The method of claim 1, further comprising the step of:

adding a bonding agent prior to said bonding step, said bonding agent being selected from the group consisting of resin powders, resin flakes, latex polymers, resin granules, adhesive foams and organic solvents.

5. The method of claim 1, wherein said forming step comprises:

passing said mixture through at least one sheet former.

6. The method of claim 5, further comprising the step of:

transporting said mixture to a filling box tower prior to said forming step, said filling box tower volumetrically feeding said mixture to said sheet former.

7. The method of claim 1, wherein said organic fibers are selected from the group consisting of bicomponent fibers, polyester fibers, polyethylene fibers, polypropylene fibers, polyethylene terephthalate (PET) fibers, polyphenylene sulfide (PPS) fibers, polyvinyl chloride (PVC) fibers, ethylene vinyl acetate/vinyl chloride (EVA/VC) fibers, lower alkyl acrylate polymer fibers, acrylonitrile polymer fibers, partially hydrolyzed polyvinyl acetate fibers, polyvinyl alcohol fibers, polyvinyl pyrrolidone fibers, styrene acrylate fibers, polyolefins, polyamides, polysulfides, polycarbonates, rayon, nylon and butadiene copolymers.

8. The method of claim 7, wherein said acoustical enhancement fibers are selected from the group consisting of polyethylene terephthalate (PET) fibers and modified polyethylene terephthalate fibers.

9. The method of claim 8, wherein said wet reinforcing fibers are wet use chopped strand glass fibers.

10. A composite mat made by the method of claim 1.

11. A method of forming a laminate composite product comprising the steps of:

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.

12. The method of claim 11, wherein said laminate composite product is a headliner for an automobile and said method further comprises the steps of:

trimming said laminate composite product; and

molding said trimmed laminate composite product into a headliner.

13. The method of claim 12, further comprising the step of:

heating said laminate composite product prior to said trimming step.

14. The method of claim 11, further comprising the step of forming said composite material, said forming step comprising:

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 said composite material.

15. The method of claim 11, wherein said first, second, third, and fourth adhesives have a form selected from the group consisting of a liquid form, a foam form and a powdered form.

21. The method of claim 15, further comprising the step of:

adding a bonding agent prior to said bonding step, said bonding agent being selected from the group consisting of resin powders, resin flakes, latex polymers, resin granules, adhesive foams and organic solvents.

16. A method of making a 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 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.

17. The method of claim 16, wherein said organic fibers are selected from the group consisting of bicomponent fibers, polyester fibers, polyethylene fibers, polypropylene fibers, polyethylene terephthalate (PET) fibers, polyphenylene sulfide (PPS) fibers, polyvinyl chloride (PVC) fibers, ethylene vinyl acetate/vinyl chloride (EVA/VC) fibers, lower alkyl acrylate polymer fibers, acrylonitrile polymer fibers, partially hydrolyzed polyvinyl acetate fibers, polyvinyl alcohol fibers, polyvinyl pyrrolidone fibers, styrene acrylate fibers, polyolefins, polyamides, polysulfides, polycarbonates, rayon, nylon and butadiene copolymers.

18. The method of claim 17, wherein said wet reinforcing fibers are wet use chopped strand glass fibers.

19. The method of claim 16, wherein said bonding step comprises:

heating said sheet to a temperature above the melting point of said organic fibers and below the melting point of said dehydrated reinforcing fibers to at least partially melt said organic fibers and bond at least a portion of said dehydrated reinforcing fibers and said organic fibers.

20. The method of claim 19, further comprising the step of:

subjecting said sheet to a needling process to mechanically bond said dehydrated reinforcing fibers and said organic fibers prior to said bonding step.