Sound and thermal insulating non-woven synthetic sheet material

• US 6,514,889 B1
• Filed: 06/02/2000
• Issued: 02/04/2003
• Est. Priority Date: 06/02/2000
• Status: Expired due to Term

• Current Assignee: Alter Invest II Fund l.P.
• Original Assignee: Soleno Textiles Techniques Inc.
• Inventors: Ducharme, Robert, Poirier, Alain, Théorêt, Richard
• Primary Examiner(s): Morris, Terrel
• Assistant Examiner(s): ROCHE, LEANNA M
• Application Number:
  US09/585,481
• Time in Patent Office: 977 Days
• Field of Search: 442/320, 442/324, 442/388, 442/394, 442/395, 442/402
• US Class Current: 442/320
• CPC Class Codes: A47L 15/4209 Insulation arrangements, e.g. for sound damping or heat insulation
• CPC Class Codes: B32B 2255/10 on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/205 Metallic coating
• CPC Class Codes: B32B 2307/206 Insulating
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/542 Shear strength
• CPC Class Codes: B32B 2307/72 Density
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 3/266 characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 5/00 Layered products characterised by the non- homogeneity or physical structure , i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
• CPC Class Codes: B32B 5/022 Non-woven fabric
• 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 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: D04H 11/08 formed by creation of a pile on at least one surface of a non-woven fabric without addition of pile-forming material, e.g. by needling, by differential shrinking needling machines D04H18/00
• CPC Class Codes: E04B 1/88 Insulating elements for both heat and sound
• CPC Class Codes: E04B 2001/7691 Heat reflecting layers or coatings
• CPC Class Codes: F16L 59/026 : Mattresses, mats, blankets or the like
• CPC Class Codes: G10K 11/162 : Selection of materials
• CPC Class Codes: Y10T 442/50 : FELT FABRIC
• CPC Class Codes: Y10T 442/56 : From synthetic organic fiber
• CPC Class Codes: Y10T 442/667 : Needled
• CPC Class Codes: Y10T 442/674 : Nonwoven fabric with a preformed polymeric film or sheet
• CPC Class Codes: Y10T 442/675 : Ester condensation polymer sheet or film [e.g., polyethylene terephthalate, etc.]
• CPC Class Codes: Y10T 442/682 : Needled nonwoven fabric

Abstract

A non-woven synthetic sheet material for use in sound insulation and/or thermal insulation is described. The sheet material is a felt or mat of substantially uniform synthetic fiber thickness and defines opposed flat surfaces. The sheet material is needle-punched from at least one of the opposed flat surfaces thereof to cause the synthetic fibers to intertwine to form a pliable sound and/or thermal insulating sheet. The insulating sheet has a density in the range of from about 100 to 1500 g/m² and a homogeneous integrity resistant to fragmentation. Preferably a polymeric film is interconnected to a surface of the synthetic fiber sheet by a further needle punch step the polymeric film is preferably a metalized polyethylene film. The material has a multitude of uses in the construction industry. The felt may also be provided in strip form for use in the framing of wooden structures to sound insulate interconnected parts.

Claims

1. A non-woven synthetic sheet materials for use in the construction of building structures for sound insulation of impact noise generated on a surface material disposed over said sheet material, said sheet material being a single felt of similar synthetic fibers of substantially uniform thickness and defining opposed flat surfaces, said sheet material being needle-punched from at least one of said opposed flat surfaces thereof and throughout said uniform thickness to cause said synthetic fibers to intertwine to form a pliable sound insulating sheet;

said sound insulating sheet having a weight density in the range of from about 100 to 1500 g/m², and having a homogeneous mechanical integrity resistance to fragmentation by the application of traction forces applied thereto during its intended use; and

further wherein a metalized polymeric film is secured by needle-punch to one of said opposed flat surfaces, wherein fibers project over said metalized polymeric film for contact with adhesive to enhance bonding with said surface material, said metalized polymeric film being in contact with said surface material to reflect thermal radiation there from, said polymeric film has a thickness in the range of from about 0.5 mil to 5.0 mils.

2. A sound insulating synthetic sheet material as claimed in claim 1 wherein said polymeric film is secured to said one of said opposed flat surfaces by a further needle-punch step or steps whereby said fibers and film interconnect by fibers in an immediate region of said synthetic sheet material adjacent said polymeric film by protruding fibers extending through orifices formed in said film by said needle-punching.

3. A sound insulating synthetic sheet material as claimed in claim 2 wherein said synthetic sheet material has a thickness of 1 to 15 mm.

4. A sound insulating synthetic sheet material as claimed in claim 1 wherein said synthetic sheet material is a thermo-acoustic sheet material.

5. A sound insulating synthetic sheet material as claimed in claim 4 wherein said thermo-acoustic sheet material has a thickness in the range of from about 1 to 15 mm.

6. A sound insulating synthetic sheet material as claimed in claim 1 wherein said non-woven synthetic sheet material is a strip of sheet material having a thickness in the range of from about 1 to 15 mm.

7. A sound insulating synthetic sheet material as claimed in claim 6 wherein said strip is provided with an adhesive binder on a rear one of said opposed flat surfaces for securing said strip to a surface to be sound and/or thermally insulated.