Sound absorption material and method of manufacturing sound absorption material

• US 8,365,862 B2
• Filed: 12/09/2008
• Issued: 02/05/2013
• Est. Priority Date: 05/23/2008
• Status: Active Grant

• Current Assignee: Zephyros, Inc.
• Original Assignee: Zephyros, Inc.
• Inventors: Coates, Michael William, Kierzkowski, Marek Henryk, Gibbons, Philip John
• Primary Examiner(s): Phillips, Forrest M
• Application Number:
  US12/994,103
• Publication Number:
  US 20110139543A1
• Time in Patent Office: 1,519 Days
• Field of Search: 181/290, 181/284
• US Class Current: 181/290
• CPC Class Codes: B32B 2037/1238 in the form of powder
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/12 Conjugate fibres, e.g. core/sheath or side-by-side
• CPC Class Codes: B32B 2305/22 Fibres of short length
• CPC Class Codes: B32B 2307/10 having particular acoustical properties
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/72 Density
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof
• CPC Class Codes: B32B 2605/00 Vehicles
• CPC Class Codes: B32B 27/02 in the form of fibres or filaments not used
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/306 comprising vinyl acetate or vinyl alcohol (co)polymers
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 comprising polyamides
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 37/04 characterised by the partial melting of at least one layer
• CPC Class Codes: B32B 37/1207 Heat-activated adhesive B32B37/04 takes precedence
• CPC Class Codes: B32B 37/15 : with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
• CPC Class Codes: B32B 37/203 : One or more of the layers being plastic
• CPC Class Codes: B32B 5/08 : the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: D04H 1/02 : Cotton wool; Wadding
• CPC Class Codes: D04H 1/54 : by welding together the fibres, e.g. by partially melting or dissolving in combination with needling D04H1/485
• CPC Class Codes: D04H 1/5412 : sheath-core
• CPC Class Codes: D04H 1/5418 : Mixed fibres, e.g. at least two chemically different fibres or fibre blends
• CPC Class Codes: D04H 1/558 : in combination with mechanical or physical treatments other than embossing
• CPC Class Codes: D04H 1/559 : the fibres being within layered webs
• CPC Class Codes: D04H 1/74 : the fibres being orientated, e.g. in parallel (anisotropic fleeces)
• CPC Class Codes: D04H 13/006 : strengthened or consolidated by the use of bonding agents in solid or liquid form
• CPC Class Codes: D04H 13/007 : strengthened or consolidated by welding together the various components
• CPC Class Codes: E04B 1/7662 : comprising fiber blankets or batts
• CPC Class Codes: E04B 1/8409 : sheet-shaped
• CPC Class Codes: E04B 2001/7687 : Crumble resistant fibrous blankets or panels using adhesives or meltable fibres
• CPC Class Codes: G10K 11/162 : Selection of materials

Abstract

Described embodiments relate to a method of manufacturing a sound absorption material. The method comprises: forming a low density fibrous web to act as a porous bulk absorber, the fibrous web containing a proportion of bi-component fibers, each bi-component fiber having a core material and a sheath material around the core material, the sheath material having a lower melting point than the core material; applying a thin facing layer to the low density fibrous web, wherein the facing layer is adhesively compatible with the sheath material; heating the fibrous web to a temperature sufficient to soften the sheath material of at least some of the bi-component fibers; and pressing the facing layer and fibrous web together under low pressure such that at least part of the facing layer contacts the softened sheath material of at least some of the bi-component fibers to form an adhesive bond between the facing layer and the fibrous web.

Claims

1. A method of manufacturing a sound absorption material, the method comprising:

forming a low density fibrous web to act as a porous bulk absorber, the low density fibrous web having a density of more than about 10 kg/m³ and less than about 120 kg/m³, and containing a proportion of bi-component fibers, each bi-component fiber having a core material and a sheath material around the core material, the sheath material having a lower melting point than the core material;

applying a thin facing layer directly to the low density fibrous web, wherein the facing layer is a non-adhesive type film that is adhesively compatible with the sheath material;

heating the low density fibrous web to a temperature sufficient to soften the sheath material of at least some of the bi-component fibers; and

pressing the facing layer and low density fibrous web together under low pressure such that at least part of the facing layer directly contacts the softened sheath material of at least some of the bi-component fibers to form an adhesive bond between the facing layer and the fibrous web, and the fibrous web remains a low density fibrous web after release of said low pressure.

2. The method of claim 1, wherein a thickness of the low density fibrous web after the pressing is reduced by about 5% to 80% of the thickness of the low density fibrous web before the pressing.

3. The method of claim 1, wherein the facing layer is a first facing layer applied to a first face of the low density fibrous web and the method further comprises applying a second facing layer directly to a second face of the low density fibrous web, the second facing layer being a non-adhesive type film that is adhesively compatible with the sheath.

4. The method of claim 3, further comprising pressing the second facing layer and the low density fibrous web together under low pressure such that at least part of the second facing layer directly contacts the softened sheath of at least some of the bi-component fibers to form an adhesive bond between the second facing layer and the low density fibrous web.

5. The method of claim 3, wherein the low density fibrous web is a first low density fibrous web and the method further comprises pressing a second low density fibrous web together with the second facing layer under low pressure to lightly bond a first side of the second low density fibrous web to the second facing layer, wherein the second low density fibrous web comprises a proportion of bi-component fibers each having a core material and a sheath material around the core material, the sheath material having a lower melting point than the core material.

6. The method of claim 5, further comprising, prior to pressing the second low density fibrous web together with the second facing layer, heating the first side of the second low density fibrous web to soften the sheath material of the bi-component fibers in the second low density fibrous web so that an adhesive bond can be formed between the second low density fibrous web and the second facing layer when pressed together under low pressure.

7. The method of claim 5, further comprising, prior to pressing the second low density fibrous web together with the second facing layer, applying an adhesive substance to the first side of the second low density fibrous web, the adhesive substance being adhesively compatible with the second facing layer.

8. The method of claim 7, further comprising:

applying a third facing layer to a second side of the second low density fibrous web, the third facing layer being a non-adhesive type film that is adhesively compatible with the sheath material of the bi-component fibers of the second low density fibrous web;

heating the second low density fibrous web to a temperature sufficient to soften the sheath material of at least some of the bi-component fibers; and

pressing the third facing layer and the second low density fibrous web together under low pressure such that at least part of the third facing layer contacts the softened sheath material of at least some of the bi-component fibers to form an adhesive bond between the third facing layer and the second low density fibrous web.

9. The method of claim 5, further comprising:

applying a third facing layer to a second side of the second low density fibrous web, the third facing layer being a non-adhesive type film that is adhesively compatible with the sheath material of the bi-component fibers of the second low density fibrous web;

heating the second low density fibrous web to a temperature sufficient to soften the sheath material of at least some of the bi-component fibers; and

pressing the third facing layer and the second low density fibrous web together under low pressure such that at least part of the third facing layer directly contacts the softened sheath material of at least some of the bi-component fibers to form an adhesive bond between the third facing layer and the second low density fibrous web.

10. A sound absorption material formed by the method of claim 1.

11. The method of claim 1, wherein said heating includes heating the low density fibrous web and the thin facing layer concurrently.

17. The method of claim 6, further comprising:

applying a third facing layer to a second side of the second low density fibrous web, the third facing layer being a non-adhesive type film that is adhesively compatible with the sheath material of the bi-component fibers of the second low density fibrous web;

heating the second low density fibrous web to a temperature sufficient to soften the sheath material of at least some of the bi-component fibers; and

pressing the third facing layer and the second low density fibrous web together under low pressure such that at least part of the third facing layer contacts the softened sheath material of at least some of the bi-component fibers to form an adhesive bond between the third facing layer and the second low density fibrous web.

12. A sound absorption material comprising:

a low density fibrous web to act as a porous bulk absorber, the low density fibrous web having a density of more than about 10 kg/m³ and less than about 120 kg/m³, and containing a proportion of bi-component fibers, each bi-component fiber having a core material and a sheath material around the core material, the sheath material having a lower melting point than the core material; and

a thin facing layer in the form of a non-adhesive type film directly adhered to the low density fibrous web by an adhesive bond formed between the sheath material of at least some of the bi-component fibers and the thin facing layer.

13. The material of claim 12, wherein the thin facing layer comprises material selected from the group consisting of polymer films, foils and fabrics.

14. The material of claim 12, wherein the thin facing layer comprises material selected from the group consisting of polyethylene, polyester, polyamide and polypropylene.

15. The material of claim 12, wherein the sheath material of the bi-component fibers is selected from the group consisting of polyethylene, polyamide, polypropylene and co-polyester.

16. The material of claim 12, wherein the thin facing layer has a thickness of between 5 and 100 microns.

18. A method of manufacturing a sound absorption material, the method comprising:

providing a low density fibrous web to act as a porous bulk absorber, the low density fibrous web having a density of more than about 10 kg/m³ and less than about 120 kg/m³, and containing a proportion of bi-component fibers, each bi-component fiber having a core material and a sheath material around the core material, the sheath material having a lower melting point than the core material;

supplying the low density web in a thermally bonded state and thereafter applying a thin facing layer in the form of a non-adhesive type film directly to the low density fibrous web;

heating the low density fibrous web to a temperature sufficient to soften the sheath material of at least some of the bi-component fibers; and

pressing the facing layer and low density fibrous web together under low pressure such that at least part of the facing layer directly contacts the softened sheath material of at least some of the bi-component fibers to form an adhesive bond between the facing layer and the fibrous web.