Low porosity facings for acoustic applications

• US 7,618,907 B2
• Filed: 08/02/2002
• Issued: 11/17/2009
• Est. Priority Date: 08/02/2002
• Status: Active Grant

• Current Assignee: Owens Corning Intellectual Capital, LLC (Owens Corning)
• Original Assignee: Owens Corning Intellectual Capital, LLC (Owens Corning)
• Inventors: Tilton, Jeffrey A.
• Primary Examiner(s): TORRES VELAZQUEZ, NORCA LIZ
• Application Number:
  US10/211,407
• Publication Number:
  US 20040023586A1
• Time in Patent Office: 2,664 Days
• Field of Search: 442/381, 442/400, 442/409, 442/387, 442/388, 442/393, 442/417, 264/113
• US Class Current: 442/381
• CPC Class Codes: D04H 1/4374 using different kinds of webs, e.g. by layering webs
• CPC Class Codes: D04H 1/559 the fibres being within layered webs
• CPC Class Codes: D04H 1/56 in association with fibre formation, e.g. immediately following extrusion of staple fibres
• CPC Class Codes: E04B 1/84 Sound-absorbing elements
• CPC Class Codes: E04B 2001/8461 layered
• CPC Class Codes: G10K 11/162 Selection of materials
• CPC Class Codes: Y10T 428/24992 Density or compression of components
• CPC Class Codes: Y10T 442/60 Nonwoven fabric [i.e., nonwoven strand or fiber material]
• CPC Class Codes: Y10T 442/608 Including strand or fiber material which is of specific structural definition
• CPC Class Codes: Y10T 442/659 Including an additional nonwoven fabric
• CPC Class Codes: Y10T 442/666 Mechanically interengaged by needling or impingement of fluid [e.g., gas or liquid stream, etc.]
• CPC Class Codes: Y10T 442/667 Needled
• CPC Class Codes: Y10T 442/668 Separate nonwoven fabric layers comprise chemically different strand or fiber material
• CPC Class Codes: Y10T 442/673 Including particulate material other than fiber
• CPC Class Codes: Y10T 442/68 Melt-blown nonwoven fabric
• CPC Class Codes: Y10T 442/69 Autogenously bonded nonwoven fabric
• CPC Class Codes: Y10T 442/699 Including particulate material other than strand or fiber material

Abstract

A fibrous blanket material is provided having a first fibrous layer selected from a group of fibers consisting of polyester, polypropylene, polyethylene, fiberglass, natural fibers, nylon, rayon and blends thereof and a layer of meltblown polypropylene fibers. In an alternative embodiment the blanket may also include a second fibrous layer made of the same material as the first layer where the layer of meltblown polypropylene fibers is sandwiched between the two fibrous layers.

Claims

1. A fibrous blanket material, comprising:

a first fibrous layer selected from a group of fibers consisting of polyester, polypropylene, polyethylene, fiberglass, natural fibers, nylon, rayon and blends thereof wherein said fibers have an average diameter of between about 10.0 and about 30.0 microns and a thickness of between about 0.5 and about 8.0 cm; and

a layer of meltblown polypropylene fibers having a thickness of between about 0.0127 to about 0.254 cm wherein said first fibrous layer and said layer of meltblown polypropylene fibers are bonded together by means of heat, spray adhesive or both.

2. A fibrous blanket material, comprising:

a first fibrous layer selected from a group of fibers consisting of polyester, polypropylene, polyethylene, fiberglass, natural fibers, nylon, rayon and blends thereof wherein said fibers have an average diameter of between about 10.0 and about 30.0 microns and a density of between about 0.5 and about 8.0 lbs/ft³; and

a layer of meltblown polypropylene fibers having a thickness of between about 0.0127 to about 0.254 cm wherein said first fibrous layer and said layer of meltblown polypropylene fibers are bonded together by means of heat, spray adhesive or both.

3. A fibrous blanket material, comprising:

a first fibrous layer selected from a group of fibers consisting of polyester, polypropylene, polyethylene, fiberglass, natural fibers, nylon, rayon and blends thereof wherein said fibers have an average diameter of between about 10.0 and about 30.0 microns;

a layer of meltblown polypropylene fibers; and

a second fibrous layer selected from a group of fibers consisting of polyester, polypropylene, polyethylene, fiberglass, natural fibers, nylon, rayon and blends thereof, wherein said layer of meltblown polypropylene fibers is sandwiched between said first and second fibrous layers wherein said first fibrous layer, said layer of meltblown polypropylene fibers and said second fibrous layer are bonded together by heat, spray adhesive or both;

said first fibrous layer having a thickness of between about 0.5 and about 5.0 cm, said layer of meltblown polypropylene fibers having a thickness of between about 0.0127 and about 0.254 cm and said second fibrous layer having a thickness of between about 0.5 and about 5.0 cm.

4. The fibrous blanket material of claim 3, wherein said layer of meltblown polypropylene fibers has a weight of between about 0.5 to about 10.0 ounces/sq. yard.

5. The fibrous blanket material of claim 3, wherein said layer of meltblown polypropylene fibers has a weight of between about 0.5 to about 3.0 ounces/sq. yard.

6. The fibrous blanket material of claim 3, wherein said meltblown polypropylene fibers have an average diameter of between about 2.5 to about 50.0 microns.

7. The fibrous blanket material of claim 3, wherein said meltblown polypropylene fibers have an average diameter of between about 5.0 to about 25.0 microns.

8. A fibrous blanket material, comprising:

a first fibrous layer selected from a group of fibers consisting of polyester, polypropylene, polyethylene, fiberglass, natural fibers, nylon, rayon and blends thereof having an average fiber diameter of between about 10.0 and about 30.0 microns, a density of between about 0.5 and about 8.0 lbs/ft³ and a thickness of between about 0.5 and about 8.0 cm; and

a layer of meltblown polypropylene fibers having a thickness of between about 0.0127 to about 0.254 cm, an average fiber diameter of between about 2.5 to about 50.0 microns and a weight of between about 0.5 to about 10.0 ounces/sq. yard wherein said first fibrous layer and said layer of meltblown polypropylene fibers are bonded together by means of heat, spray adhesive or both.

9. A fibrous blanket material, comprising:

a first fibrous layer selected from a group of fibers consisting of polyester, polypropylene, polyethylene, fiberglass, natural fibers, nylon, rayon and blends thereof;

a layer of meltblown polypropylene fibers having an average fiber diameter of between about 2.5 to about 50.0 microns and a weight of between about 0.5 to about 10.0 ounces/sq. yard; and

a second fibrous layer selected from a group of fibers consisting of polyester, polypropylene, polyethylene, fiberglass, natural fibers, nylon, rayon and blends thereof, wherein said layer of meltblown polypropylene fibers is sandwiched between said first and second fibrous layers wherein said first fibrous layer, said layer of meltblown polypropylene fibers and said second fibrous layer are bonded together by heat, spray adhesive or both;

said first fibrous layer having a thickness of between about 0.5 and about 5.0 cm, said layer of meltblown polypropylene fibers having a thickness of between about 0.0127 and about 0.254 cm and said second fibrous layer having a thickness of between about 0.5 and about 5.0 cm.