Method of making sound absorbing laminates and laminates having maximized sound absorbing characteristics

• US 5,824,973 A
• Filed: 10/16/1995
• Issued: 10/20/1998
• Est. Priority Date: 09/29/1992
• Status: Expired due to Term

• Current Assignee: Johns Manville International, Inc. (Berkshire Hathaway Incorporated)
• Original Assignee: Johns Manville International, Inc. (Berkshire Hathaway Incorporated)
• Inventors: Haines, James Charles, Fay, Ralph Michael
• Primary Examiner(s): Dang, Khanh
• Application Number:
  US08/543,766
• Time in Patent Office: 1,100 Days
• Field of Search: 181/286, 181/290, 181/291, 181/292, 181/293, 181/294, 428/190
• US Class Current: 181/286
• CPC Class Codes: B32B 5/22 characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: E04B 2001/8461 layered

Abstract

A sound absorption laminate comprises a porous insulation substrate, such as, a glass, polymeric or natural fiber blanket or a foamed polymeric resin sheet and a facing sheet with a high air flow resistance. The facing sheet is superimposed upon a surface of the porous insulation substrate to augment the acoustical properties of the substrate. With the facing sheet the air flow resistance of the laminate is greater than the air flow resistance of the substrate and the laminate exhibits a higher sound absorption coefficient than the sound absorption coefficient of the substrate. Thus, the laminate exhibits better sound absorption properties than the substrate and is suitable for sound absorption applications for which the substrate alone would not be suitable.

Claims

1. A method of making a sound absorbing laminate comprising:

a) selecting a porous insulation substrate having low air flow resistance;

b) determining the optimized value of the acoustic resistance ratio for said substrate;

c) selecting a thin, semi-porous facing having an acoustic resistance ratio such that when superimposed upon a face of said substrate, a laminate is formed having an acoustic resistance ratio greater than the acoustic resistance ratio of said substrate and no greater than the optimized value of the acoustic resistance ratio for said substrate; and

d) superimposing said facing on said substrate to form a laminate having good sound absorbing characteristics.

2. The method of claim 1, including:

adhering said facing to said face of said substrate.

3. The method of claim 1, wherein:

said substrate is comprised of a material selected from the group of glass fibers, thermoplastic polymeric fibers, thermosetting polymeric fibers, cotton fibers, milkweed fibers, carbonaceous fibers, carbonized fibers, graphitized fibers and a polymeric foam.

4. The method of claim 1, wherein:

said facing selected has an acoustic resistance ratio that when superimposed upon said face of said substrate, a laminate is formed having an acoustic resistance ratio that is approximates or equals the optimized value of the acoustic resistance ratio for said substrate.

5. The method of claim 4, wherein:

said substrate is comprised of a material selected from the group of glass fibers, thermoplastic polymeric fibers, thermosetting polymeric fibers, cotton fibers, milkweed fibers, carbonaceous fibers, carbonized fibers, graphitized fibers, and a polymeric foam.

6. The method of claim 1, wherein:

said facing selected has an acoustic resistance ratio that approximates or equals the difference between the acoustic resistance ratio of said substrate and the optimized value of the acoustic resistance ratio for said substrate.

7. The method of claim 6, wherein:

said substrate is comprised of a material selected from the group of glass fibers, thermoplastic polymeric fibers, thermosetting polymeric fibers, cotton fibers, milkweed fibers, carbonaceous fibers, carbonized fibers, graphitized fibers, and a polymeric foam.

8. A laminate having maximized sound absorbing characteristics, comprising:

a) a porous insulation substrate having an air flow resistance less than that required to produce an optimum sound absorbing characteristic for said substrate; and

b) a thin, semi-porous facing superimposed upon a face of said substrate, said facing having an acoustic resistance ratio that when superimposed upon said face of said substrate, a laminate is formed having an acoustic resistance ratio that approximates or equals the optimized value of the acoustic resistance ratio for said substrate.

9. The laminate of claim 8, wherein:

said facing is secured to said substrate.

10. The laminate of claim 8, wherein:

said facing is adhered to said face of said substrate.

11. The laminate of claim 8, wherein:

said substrate is comprised of a material selected from the group of glass fibers, thermoplastic polymeric fibers, thermosetting polymeric fibers, cotton fibers, milkweed fibers, carbonaceous fibers, carbonized fibers, graphitized fibers and a polymeric foam.

12. A laminate having optimized sound absorbing characteristics comprising:

a) a porous insulation substrate having an air flow resistance less than that required to produce an optimum sound absorbing characteristic for said substrate; and

b) a thin, semi-porous facing superimposed upon a face of said substrate, said facing having an acoustic resistance ratio that approximates or equals to the difference between the acoustic resistance ratio of said substrate and the optimized value of the acoustic resistance ratio for said substrate.

13. The laminate of claim 12, wherein:

said facing is secured to said substrate.

14. The laminate of claim 12, wherein:

said facing is adhered to said face of said substrate.

15. The laminate of claim 12, wherein:

said substrate is comprised of a material selected from the group of glass fibers, thermoplastic polymeric fibers, thermosetting polymeric fibers, cotton fibers, milkweed fibers, carbonaceous fibers, carbonized fibers, graphitized fibers and a polymeric foam.