Sound absorbing laminate

• US 4,828,910 A
• Filed: 12/16/1987
• Issued: 05/09/1989
• Est. Priority Date: 12/16/1987
• Status: Expired due to Term

• Current Assignee: Prince (Wellman Holdings, Inc.)
• Original Assignee: Reinhold Haussling
• Inventors: Haussling, Reinhold
• Primary Examiner(s): Bell, James J.
• Application Number:
  US07/133,570
• Time in Patent Office: 510 Days
• Field of Search: 428/284, 428/285, 428/287, 428/300, 428/280, 428/282, 428/413.1, 428/425.6, 428/286
• US Class Current: 442/391
• CPC Class Codes: B29C 70/08 comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
• CPC Class Codes: B29K 2101/10 Thermosetting resins
• CPC Class Codes: B29K 2105/0854 in the form of a non-woven mat
• CPC Class Codes: B29K 2309/08 Glass
• CPC Class Codes: B29K 2311/10 Natural fibres, e.g. wool or cotton
• CPC Class Codes: B29K 2995/0002 insulating
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2307/10 having particular acoustical properties
• 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 5/26 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 13/0225 self supporting head liners
• CPC Class Codes: E04B 1/8409 sheet-shaped
• CPC Class Codes: E04B 2001/8461 layered
• CPC Class Codes: G10K 11/168 Plural layers of different materials, e.g. sandwiches
• CPC Class Codes: Y10T 428/31551 Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31601 Quartz or glass
• CPC Class Codes: Y10T 442/67 : Multiple nonwoven fabric layers composed of the same inorganic strand or fiber material
• CPC Class Codes: Y10T 442/671 : Multiple nonwoven fabric layers composed of the same polymeric strand or fiber material

Abstract

There are provided laminate structures comprising a reinforcing fibrous mat integrally bonded to a resilient fibrous batt. The mat is preferentially a porous mat of resin-bonded chopped glass fiber. The batt is preferentially a porous bat of natural or synthetic fibers. Preferentially, the laminate comprises a core of resilient fibrous batt sandwiched between two facing sheets of reinforcing fibrous mat, with a decorative cover layer being laminated to the exterior surface of one reinforcing fibrous mat, the whole being bonded together by a thermoset binder into a unitary structure.

Claims

1. A moldable laminate structure comprising:

a core defined by a resilient thermoformable, porous fibrous batt having a thickness of at least about one-quarter of an inch;

a first reinforcing, porous fibrous mat on one surface of said batt and being coated with sufficient resin binder to impregnate said fibrous mat and its interface with said fibrous batt to effect adherence therebetween, but insufficient resin binder to form a porosity blocking film on a final molded product.

2. A moldable laminate structure in accordance with claim 1 wherein said resin binder comprises a curable thermosetting binder composition.

3. A moldable laminate structure in accordance with claim 1 wherein said resin binder comprises a curable thermosetting elastomer composition.

4. A moldable laminate structure in accordance with claim 3 wherein said resin binder comprises a thermosetting urethane elastomer composition.

5. A moldable laminate structure in accordance with claim 3 wherein the fibers of said resilient fibrous batt are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing fibrous mat are held together by a thermoplastic binder to facilitate thermoforming and whereby said batt and said mat can be permanently compressed along the marginal edges of the laminate structure to create strong, well defined marginal edges.

6. A moldable laminate structure in accordance with claim 5 wherein said resin binder comprises a thermosetting urethane elastomer composition.

7. A moldable laminate structure in accordance with claim 3 wherein said fibrous batt has an air porosity in the range from 10 to 60% and said fibrous mat has an air porosity of at least 90%.

8. A moldable laminate structure in accordance with claim 7 wherein the fibers of said resilient fibrous batt are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing mat are held together by a thermoplastic binder to facilitate thermoforming and whereby said batt and said mat can be permanently compressed along the marginal edges of the laminate structure to create strong, well-defined marginal edges.

9. A moldable laminate structure in accordance with claim 7 wherein said binder resin comprises a curable thermosetting urethane elastomer.

10. A moldable laminate structure in accordance with claim 9 wherein said fibrous batt has an air porosity of about 40%.

11. A moldable laminate structure in accordance with claim 3 having a decorative porous fabric cover layer laminated to the other face of said first reinforcing fibrous mat.

12. A moldable laminate structure in accordance with claim 11 wherein said resin binder comprises a curable thermosetting urethane elastomer composition which also adheres said cover layer to said first reinforcing fibrous mat.

13. A moldable laminate structure in accordance with claim 11 wherein said decorative porous fabric cover layer is thermoformable, the fibers of said resilient fibrous batt are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing mat are held together by a thermoplastic binder to facilitate thermoforming and whereby said decorative cover layer, batt and said mat can be permanently compressed along the marginal edges of said laminate structure to create strong, well defined marginal edges.

14. A moldable laminate structure in accordance with claim 13 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.

15. A moldable laminate structure in accordance with claim 13 wherein said fibrous batt has an air porosity in the range from 10 to 60% and said fibrous mat has an air porosity of at least 90%.

16. A moldable laminate structure in accordance with claim 13 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.

17. A moldable laminate structure in accordance with claim 16 wherein said fibrous batt has an air porosity of about 40%.

18. A moldable laminate structure in accordance with claim 3 having one face of a second reinforcing porous fibrous mat on the other surface of said resilient fibrous batt and being coated with sufficient resin to impregnate said second reinforcing mat and its interface with said fibrous batt to effect adherence therebetween, but insufficient resin binder to form a porosity blocking film on a final molded product.

19. A moldable laminate structure in accordance with claim 18 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.

20. A moldable laminate structure in accordance with claim 18 wherein the fibers of said resilient fibrous batt are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing fibrous mats are held together by a thermoplastic binder to facilitate thermoforming and whereby said batt and said mats can be permanently compressed along the marginal edges of said laminate structure to create strong well-defined marginal edges.

21. A moldable laminate structure in accordance with claim 20 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.

22. A moldable laminate structure in accordance with claim 18 wherein said resilient fibrous batt has an air porosity in the range from 10 to 60% and said reinforcing fibrous mat has an air porosity of at least 90%.

23. A moldable laminate structure in accordance with claim 22 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.

24. A moldable laminate structure in accordance with claim 23 wherein said resilient fibrous batt has an air porosity of about 40%.

25. A moldable laminate structure in accordance with claim 22 wherein the fibers of said resilient fibrous mat are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing mats are held together by a thermoplastic binder to facilitate thermoforming and whereby said batt and said mats can be permanently compressed along the marginal edges of said laminate structure to create strong, well-defined marginal edges.

26. A moldable laminate structure in accordance with claim 25 wherein said resin binder comprises a curable thermosetting elastomer composition.

27. A moldable laminate structure in accordance with claim 26 wherein said resilient fibrous batt has an air porosity of about 40%.

28. A moldable laminate structure in accordance with claim 3 having a release layer laminated to the other surface of said reinforcing fibrous mat.

29. A moldable laminate structure in accordance with claim 28 wherein the fibers of said resilient fibrous batt are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing fibrous mat are held together by a thermoplastic binder to facilitate thermoforming and whereby said batt and said mat can be permanently compressed along the marginal edges of said laminate structure to create strong well-defined marginal edges.

30. A moldable laminate structure in accordance with claim 29 wherein said resilient fibrous batt has an air porosity in the range from 10 to 60% and said reinforcing fibrous mat has an air porosity of at least 40%.

31. A moldable laminate structure in accordance with claim 30 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.

32. A moldable laminate structure in accordance with claim 18 having a decorative porous fabric cover layer laminated to the other face of said first reinforcing fibrous mat and a release layer laminated to the other surface of said second reinforcing fibrous mat.

33. A moldable laminate structure in accordance with claim 32 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.

34. A moldable laminate structure in accordance with claim 32 wherein said decorative porous fabric cover layer is thermoformable, the fibers of said resilient fibrous batt are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing mats are held together by a thermoplastic binder to facilitate thermoforming and whereby said cover layer, said batt and said mats can be permanently compressed along the marginal edges of said laminate structure to create strong, well-defined marginal edges.

35. A moldable laminate structure in accordance with claim 34 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.

36. A moldable laminate structure in accordance with claim 32 wherein said fibrous batt has an air porosity in the range from 10 to 60% and said fibrous mat has an air porosity of at least 90%.

37. A moldable laminate structure in accordance with claim 36 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.

38. A moldable laminate structure in accordance with claim 37 wherein said resilient batt has an air porosity of about 40%.

39. A moldable laminate structure in accordance with claim 36 wherein said decorative porous fabric cover layer is thermoformable, the fibers of said resilient fibrous batt are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing fibrous mat are held together by a thermoplastic binder to facilitate thermoforming and whereby said cover layer, said batt and said mats can be permanently compressed along the marginal edges of said laminate structure to create strong, well-defined marginal edges.

40. A molded laminate structure in accordance with claim 39 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.

41. A molded laminate structure in accordance with claim 40 wherein said resilient batt has an air porosity of about 40%.

42. A moldable sound absorbing laminate structure comprising:

a core defined by a thermoformable resilient porous fibrous batt having a thickness of at least about one-quarter inch, the fibers of said fibrous batt being held together by a thermoformable binder;

at least a first porous fibrous reinforcing mat adhered to one surface of said batt by said thermoformable binder; and

whereby said batt and said mat form a prelaminate which can be readily handled without delamination for subsequent impregnation with a thermosetting resin binder immediately prior to molding in a heated mold.

43. A moldable sound-absorbing laminate structure in accordance with claim 42 wherein the fibers of said resilient fibrous batt are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing mat are held together by a thermoplastic binder.

44. A moldable sound-absorbing laminate structure in accordance with claim 42 wherein a second porous fibrous reinforcing mat is adhered to an opposite surface of said batt by said thermoformable binder.

45. A moldable sound-absorbing laminate structure in accordance with claim 44 wherein the fibers of said resilient fibrous batt are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing mat are held together by a thermoplastic binder.

46. A molded contoured three-dimensional laminated structure comprising a first reinforcing porous fibrous mat laminated on one face thereof to one face of a resilient porous fabric batt having a thickness of at least about one-quarter inch, said first reinforcing mat and said resilient batt being bonded together by a thermoset binder composition into a unitary laminated structure, said laminated structure having permanently compressed, strong, well-defined marginal edges.

47. A laminated structure in accordance with claim 46 wherein said thermoset composition comprises a thermoset elastomer binder composition.

48. A laminated structure in accordance with claim 46 wherein said thermoset composition comprises a thermoset urethane elastomer binder composition.

49. A laminated structure in accordance with claim 47 wherein said resilient batt has an air porosity in the range from 10 to 60% and said reinforcing mat has an air porosity of at least 90%.

50. A laminated structure in accordance with claim 49 wherein said resilient batt has an air porosity of about 40% and said thermoset composition comprises a thermoset urethane elastomer binder composition.

51. A laminated structure in accordance with claim 47 having a decorative porous fabric cover layer laminated to the other face of said first reinforcing fibrous mat.

52. A laminated structure in accordance with claim 51 wherein said thermoset composition comprises a thermoset urethane elastomer binder composition.

53. A laminated structure in accordance with claim 51 wherein said resilient batt has an air porosity in the range from 10 to 60% and said reinforcing mat has an air porosity of at least 90%.

54. A laminated structure in accordance with claim 53 wherein said resilient batt has an air porosity of about 40% and said thermoset composition comprises a thermoset urethane elastomer binder composition.

55. A laminated structure in accordance with claim 47 having one face of a second porous fibrous reinforcing mat bonded to the other face of said resilient fibrous batt.

58. A laminated structure in accordance with claim 55 having a decorative porous fabric cover layer laminated to the other face of said first reinforcing fibrous mat.

59. A laminated structure in accordance with claim 58 wherein said thermoset composition comprises a thermoset urethane elastomer binder composition.

60. A laminated structure in accordance with claim 58 wherein said resilient batt has an air porosity in the range from 10 to 60% and said reinforcing mats have an air porosity of at least 90%.

61. A laminated structure in accordance with claim 60 wherein said thermoset composition comprises a thermoset urethane elastomer composition.

62. A laminated structure in accordance with claim 61 wherein said resilient batt has an air porosity of about 40%.

56. A laminated structure in accordance with ciaim 55 wherein said resilient batt has an air porosity in the range from 10 to 60% and said reinforcing mats have an air porosity of at least 90%.

57. A laminated structure in accordance with claim 56 wherein said resilient batt has an air porosity of about 40% and said thermoset composition comprises a thermoset urethane elastomer binder composition.