Acoustical insulating barrier and method of making the barrier
First Claim
1. A needled composite acoustical barrier, comprising:
- (1) a non-woven first layer (13) of needleable textile first fibers (13a), said first layer (13) having a thickness of between about 0.01 inch and 0.5 inch and a density of between about 1.0 and 10 lbs. per cubic foot;
(2) a non-woven, low density second layer (15) of textile second fibers (15a), said second layer (15) having a thickness of between about 0.2 inch and 5 inches and a density of between about 0.1 and 4.0 lbs. per cubic foot;
(3) a high-density intermediate acoustical barrier layer (14) disposed between the first and second layers (13,
15), said intermediate barrier layer (14) having a thickness of between about 0.01 inch and 0.5 inch, a density of at least about 50 lbs. per cubic foot, and said barrier layer comprising a substantially continuous film of high-density needleable polymeric material; and
(4) a plurality of needled stitches (19) formed from the first fibers (13a) and extending from the first layer (13), through the intermediate barrier layer (14) and at least into the second layer (15).
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Accused Products
Abstract
A needled composite acoustical barrier is provided. The barrier has a non-woven first layer (13) of needleable textile first fibers (13a); the layer (13) has a thickness of between about 0.01 inch and 0.5 inch and a density of between about 1.0 and 10 lbs. per cubic foot. A non-woven, low density second layer (15) of textile second fibers (15a) is provided; the second layer (15) has a thickness of between about 0.2 inch and 5 inches and a density of between about 0.1 and 4.0 lbs. per cubic foot. A high-density intermediate acoustical barrier layer (14) is disposed between the first and second layers (13, 15); the intermediate barrier layer (14) has a thickness of between about 0.01 inch and 0.5 inch, a density of at least 50 lbs. per cubic foot, and the barrier layer has a substantially continuous film of high-density needleable polymeric material. A plurality of needled stitches (19), formed from the first fibers (13a), extend from the first layer (13), through the intermediate barrier layer (14) and at least into the second layer (15).
54 Citations
62 Claims
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1. A needled composite acoustical barrier, comprising:
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(1) a non-woven first layer (13) of needleable textile first fibers (13a), said first layer (13) having a thickness of between about 0.01 inch and 0.5 inch and a density of between about 1.0 and 10 lbs. per cubic foot; (2) a non-woven, low density second layer (15) of textile second fibers (15a), said second layer (15) having a thickness of between about 0.2 inch and 5 inches and a density of between about 0.1 and 4.0 lbs. per cubic foot; (3) a high-density intermediate acoustical barrier layer (14) disposed between the first and second layers (13,
15), said intermediate barrier layer (14) having a thickness of between about 0.01 inch and 0.5 inch, a density of at least about 50 lbs. per cubic foot, and said barrier layer comprising a substantially continuous film of high-density needleable polymeric material; and(4) a plurality of needled stitches (19) formed from the first fibers (13a) and extending from the first layer (13), through the intermediate barrier layer (14) and at least into the second layer (15). - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31)
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32. A method of producing a composite acoustical barrier, comprising:
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(1) assembling a composite of (i) a non-woven first layer (13) of needleable textile first fibers (13a), said first layer (13) having a thickness of between about 0.01 inch and 0.5 inch and a density of between about 1.0 and 10 lbs. per cubic foot, (ii) a non-woven, low density second layer (15) of textile second fibers (15a), said second layer (15) having a thickness of between about 0.2 inch and 5 inches and a density of between about 0.1 and 4.0 lbs. per cubic foot, and (iii) a high-density intermediate acoustical barrier layer (14) disposed between the first and second layers (13,
15), said intermediate barrier layer (14) having a thickness of between about 0.01 inch and 0.5 inch, a density of at least 50 lbs. per cubic foot, and said barrier layer comprising a substantially continuous film of high-density needleable polymeric material; and(2) needling the composite with about 100 to 600 stitches per square inch, such that stitches (19) formed from the first fibers (13a) extend from the first layer (13), through the intermediate barrier layer (14), and at least into the second layer (15). - View Dependent Claims (33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62)
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Specification