Foam-barrier-foam-facing acoustical composite

• US 4,488,619 A
• Filed: 04/11/1984
• Issued: 12/18/1984
• Est. Priority Date: 04/11/1984
• Status: Expired due to Fees

• Current Assignee: Justin T O'Neill
• Original Assignee: Justin T O'Neill
• Inventors: O'Neill, Justin T.
• Primary Examiner(s): Van Balen, William J.
• Application Number:
  US06/599,118
• Time in Patent Office: 251 Days
• Field of Search: 181/288, 181/290, 181/294, 181/DIG. 1, 428/198, 428/215, 428/286, 428/287, 428/316.6, 428/317.1, 428/317.5, 428/317.7, 428/319.3, 428/319.7, 428/421, 428/422, 428/473.5, 428/921
• US Class Current: 181/290
• CPC Class Codes: B32B 2266/0214 Materials belonging to B32B27/00
• CPC Class Codes: B32B 2266/06 Open cell foam
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/72 Density
• CPC Class Codes: B32B 2309/105 Thickness
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E04B 2001/8466 with an intermediate layer formed of lines or dots of elastic material
• CPC Class Codes: Y10S 428/921 Fire or flameproofing
• CPC Class Codes: Y10T 428/24826 Spot bonds connect components
• CPC Class Codes: Y10T 428/24967 Absolute thicknesses specified
• CPC Class Codes: Y10T 428/249981 Plural void-containing components
• CPC Class Codes: Y10T 428/249982 With component specified as adhesive or bonding agent
• CPC Class Codes: Y10T 428/249992 Linear or thermoplastic
• CPC Class Codes: Y10T 428/3154 Of fluorinated addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31721 Of polyimide
• CPC Class Codes: Y10T 442/2754 : Pressure-sensitive adhesive
• CPC Class Codes: Y10T 442/647 : Including a foamed layer or component
• CPC Class Codes: Y10T 442/676 : Vinyl polymer or copolymer sheet or film [e.g., polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, etc.]
• CPC Class Codes: Y10T 442/677 : Fluorinated olefin polymer or copolymer sheet or film [e.g., TeflonR, etc.]

Abstract

A foam-barrier-foam-facing acoustical composite is disclosed having improved acoustical and flame retardant properties. The acoustical composite is a multilayered laminated fabric composed of: (a) a flame retardant polyvinyl fluoride facing layer; (b) a fire resistant acrylic adhesive layer bonded to the polyvinyl fluoride facing layer; (c) a first polyimide open cell foam layer bonded to the adhesive layer; (d) a noise barrier layer bonded to the first polyimide open cell foam layer, and (e) a second polyimide open cell foam layer bonded to the noise barrier layer.

Claims

1. A multilayered laminated fabric having improved acoustical and flame retardant properties comprising:

(a) a flame retardant polyvinyl fluoride facing layer,

(b) a fire resistant acrylic adhesive layer bonded to said polyvinyl fluoride facing layer,

(c) a first polyimide open cell foam layer bonded to said adhesive layer,

(d) a noise barrier layer bonded to said first polyimide open cell foam layer, and

(e) a second polyimide open cell foam layer bonded to said noise barrier layer.

2. The article of claim 1, further comprising:

(f) at least one repeated unit comprising a second noise barrier layer bonded to a third polyimide open cell foam layer.

3. The article of claim 1, wherein said polyvinyl fluoride facing layer is 1/2 mil thick.

4. The article of claim 2, wherein said polyvinyl fluoride facing layer is 1/2 mil thick.

5. The article of claim 1, wherein said polyvinyl fluoride facing layer is reinforced with fiber.

6. The article of claim 2, wherein said polyvinyl fluoride facing layer is reinforced with fiber.

7. The article of claim 3, wherein said polyvinyl fluoride facing layer is reinforced with fiber.

8. The article of claim 4, wherein said polyvinyl fluoride facing layer is reinforced with fiber.

9. The article of claim 1, wherein said fire resistant acrylic adhesive layer is 5 mil thick.

10. The article of claim 2, wherein said fire resistant acrylic adhesive layer is 5 mil thick.

11. The article of claim 1, wherein said fire resistant acrylic adhesive layer is disposed in a criss-crossed pattern of stripes of adhesive material.

12. The article of claim 2, wherein said fire resistant acrylic adhesive layer is disposed in a criss-crossed pattern of stripes of adhesive material.

13. The article of claim 11, wherein said criss-crossed pattern comprises adhesive stripes crossing at 90°

angles on a 3-inch center distance.

14. The article of claim 12, wherein said criss-crossed pattern comprises adhesive stripes crossing at 90°

angles on a 3-inch center distance.

15. The article of claim 13, wherein said adhesive stripes are 1 inch wide.

16. The article of claim 14, wherein said adhesive stripes are 1 inch wide.

17. The article of claim 15, wherein said adhesive layer is a pressure-sensitive adhesive layer.

18. The article of claim 16, wherein said adhesive layer is a pressure-sensitive adhesive layer.

19. The article of claim 1, wherein said polyimide foam layers have a density of about 0.6 to one pounds per cubic foot.

20. The article of claim 2, wherein said polyimide foam layers have a density of about 0.6 to one pounds per cubic foot.

21. The article of claim 19, wherein said polyimide foam layers have a density of about 0.8 pounds per cubic foot.

22. The article of claim 20, wherein said polyimide foam layers have a density of about 0.8 pounds per cubic foot.

23. The article of claim 19, wherein said polyimide foam layers are 1/4 to 1/2 inch thick.

24. The article of claim 20, wherein said polyimide foam layers are 1/4 to 1/2 inch thick.

25. The article of claim 21, wherein said polyimide foam layers are 1/4 to 1/2 inch thick.

26. The article of claim 22, wherein said polyimide foam layers are 1/4 to 1/2 inch thick.

27. The article of claim 1, wherein said noise barrier layer is a flexible barium sulfate filled vinyl mass barrier.

28. The article of claim 2, wherein said noise barrier layer is a flexible barium sulfate filled vinyl mass barrier.

29. The article of claim 27, wherein said noise barrier layer has a surface density of 1/2 to 1 pound per square foot.

30. The article of claim 28, wherein said noise barrier layer has a surface density of 1/2 to 1 pound per square foot.

31. The article of claim 29, wherein said noise barrier layer has fabric reinforcement.

32. The article of claim 30, wherein said noise barrier layer has fabric reinforcement.

33. The article of claim 31, wherein said vinyl mass is polyvinyl chloride.

34. The article of claim 32, wherein said vinyl mass is polyvinyl chloride.

35. The article of claim 1, wherein said polyimide open cell foam layers are bonded to said noise barrier layers with a 5 mil thick adhesive.

36. The article of claim 2, wherein said polyimide open cell foam layers are bonded to said noise barrier layers with a 5 mil thick adhesive.

37. The article of claim 35, wherein said adhesive is a pressure sensitive adhesive.

38. The article of claim 36, wherein said adhesive is a pressure sensitive adhesive.

39. The article of claim 37, wherein said adhesive is a flame retardant acrylic adhesive.

40. The article of claim 38, wherein said adhesive is a flame retardant acrylic adhesive.