Insulating laminate
First Claim
1. A structurally stable, self-supporting insulating laminate, comprising:
- (a) a cloth-like finish lamina;
(b) a nonwoven fiber mat, impregnated with a polymeric resin, bonded to said finish lamina, said fiber mat including fibers of different fineness, including at least 20% by weight of fibers having a fineness of 5-20 denier and at least 20% by weight of fibers having a fineness of 15-30 denier;
(c) a high density at least partially closed cell polymeric foam lamina bonded to said fiber mat; and
(d) a fiber reinforcing scrim comprising at least 10% by weight of fiber glass and at least 50% by weight polyester fibers impregnated with a thermoset resin bonded to said high density foam lamina.
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0 Petitions
Accused Products
Abstract
An insulating laminate, which is particularly suitable for a sound attenuating barrier, such as a contoured vehicle headliner. The disclosed embodiment includes a finish lamina, which may be preferably cloth-like, and a substrate which is preferably structurally stable and self supporting and which may be adapted to absorb sound primarily at predetermined higher frequencies. In one preferred embodiment, a thin flexible film is located between the finish lamina and the substrate which is adapted to absorb sound primarily at relative lower predetermined frequencies. The film may include a pattern of openings or holes designed to absorb sound primarily at predetermined lower frequencies. In the disclosed embodiment, the substrate includes a porous fiber mat, preferably including fibers having a range of thicknesses to improve sound attenuation at higher frequencies, a structural foam lamina and a reinforcing scrim, preferably comprising spunbonded polyester filaments.
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Citations
24 Claims
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1. A structurally stable, self-supporting insulating laminate, comprising:
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(a) a cloth-like finish lamina; (b) a nonwoven fiber mat, impregnated with a polymeric resin, bonded to said finish lamina, said fiber mat including fibers of different fineness, including at least 20% by weight of fibers having a fineness of 5-20 denier and at least 20% by weight of fibers having a fineness of 15-30 denier; (c) a high density at least partially closed cell polymeric foam lamina bonded to said fiber mat; and (d) a fiber reinforcing scrim comprising at least 10% by weight of fiber glass and at least 50% by weight polyester fibers impregnated with a thermoset resin bonded to said high density foam lamina. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A contoured vehicle headliner, said headliner being formed of a composite laminate including a finish surface and an opposite substrate support surface adapted to be bonded to a vehicle roof, said composite laminate comprising:
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a finish lamina, a fiber mat impregnated with a polymeric resin bonded to said finish lamina, said fiber mat including a blend of fibers of different fineness ranging from 5 to 30 denier, a polymeric foam lamina bonded to said fiber mat and a scrim bonded to said foam lamina forming said substrate support surface, said scrim comprising randomly arranged nonwoven thermoset polymeric filaments having fineness of about two to ten denier, said filaments bonded at the filament junctions forming a support for said headliner and said substrate support surface. - View Dependent Claims (11, 12, 13)
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14. A contoured vehicle headliner, said headliner being formed of a composite laminate including a finish surface and an opposite substrate support surface adapted to be bonded to a vehicle roof, said composite laminate comprising:
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a finish lamina, a fiber mat impregnated with a polymeric resin bonded to said finish lamina, said fiber mat including a blend of fibers of different fineness ranging from 5 to 30 denier, a thermoplastic polymeric film having a thickness of less than five millimeters located between said finish lamina and said fiber mat, a polymeric foam lamina bonded to said fiber mat and a scrim bonded to said foam lamina forming said substrate support surface, said scrim comprising randomly arranged nonwoven thermoset polymeric filaments bonded at the filament junctions forming a support for said headliner and said substrate support surface. - View Dependent Claims (15, 16, 17)
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18. A contoured vehicle headliner, said headliner being formed of a composite laminate including a finish surface and an opposite substrate support surface adapted to be bonded to a vehicle roof, said composite laminate comprising:
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a finish lamina, a fiber mat impregnated with a polymeric resin bonded to said finish lamina, said fiber mat including a blend of fibers of different fineness ranging from 5 to 30 denier, a flexible, relatively thin film located between said finish lamina and said fiber mat, said film having a plurality of spaced openings in a predetermined pattern adapted to absorb sound primarily at predetermined frequencies in the low to mid ranges, a polymeric foam lamina bonded to said fiber mat and a scrim bonded to said foam lamina forming said substrate support surface, said scrim comprising randomly arranged nonwoven thermoset polymeric filaments bonded at the filament junctions forming a support for said headliner and said substrate support surface.
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19. A contoured vehicle headliner, said headliner formed of a composite laminate including a finish surface and an opposite substrate support surface to be bonded to a vehicle roof, said composite laminate comprising:
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a finish lamina; a fiber mat bonded to said finish lamina; a polymeric foam lamina bonded to said fiber mat; a scrim comprising thermoset polymeric filaments bonded at the filament junctions forming a support for said headliner and said substrate support surface; and a thin thermoplastic polymeric film having a thickness of less than 5 millimeters located between said finish lamina and said fiber mat bonding said finish lamina to said fiber mat. - View Dependent Claims (20, 21)
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22. A contoured vehicle headliner, said headliner being formed of a composite laminate including a finish surface and an opposite substrate support surface adapted to be bonded to a vehicle roof, said composite laminate comprising:
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a finish lamina, a support lamina having a predetermined density for absorbing sound at predetermined frequencies, and a scrim bonded to said support lamina, said scrim comprising randomly arranged nonwoven thermoset polymeric filaments bonded at the filament conjunctions, including at least 10% by weight of fiber glass and at least 50% by weight polyester fibers, forming a support for said headliner. - View Dependent Claims (23, 24)
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Specification