Composite sound absorber

• US 8,534,419 B2
• Filed: 10/16/2009
• Issued: 09/17/2013
• Est. Priority Date: 10/16/2008
• Status: Active Grant

• Current Assignee: Zephyros, Inc.
• Original Assignee: Zephyros, Inc.
• Inventors: Coates, Michael William, Kierzkowski, Marek, Gibbons, Philip John
• Primary Examiner(s): Phillips, Forrest M
• Application Number:
  US13/124,645
• Publication Number:
  US 20120024626A1
• Time in Patent Office: 1,432 Days
• Field of Search: 181/294, 181/284, 428/41.8
• US Class Current: 181/294
• CPC Class Codes: B32B 2262/0223 Vinyl resin fibres
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/04 Cellulosic plastic fibres, e.g. rayon
• CPC Class Codes: B32B 2262/062 Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2262/065 Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
• CPC Class Codes: B32B 2262/105 Ceramic fibres
• CPC Class Codes: B32B 2262/14 Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2307/102 Insulating
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/5825 Tear resistant
• CPC Class Codes: B32B 2307/72 Density
• CPC Class Codes: B32B 2307/732 Dimensional properties
• CPC Class Codes: B32B 37/1284 Application of adhesive
• CPC Class Codes: B32B 5/022 Non-woven fabric
• 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: B60R 13/0815 Acoustic or thermal insulation of passenger compartments wall or roof liners integrating the insulating function B60R13/02; insulating floor mats or carpets B60N3/04
• CPC Class Codes: C09J 2301/18 characterized by perforations in the adhesive tape
• CPC Class Codes: C09J 2301/204 : the adhesive coating being discontinuous
• CPC Class Codes: C09J 2400/263 : in the substrate
• CPC Class Codes: C09J 2433/00 : Presence of (meth)acrylic polymer
• CPC Class Codes: C09J 2483/005 : in the release coating
• CPC Class Codes: C09J 5/00 : Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
• CPC Class Codes: C09J 7/21 : Paper; Textile fabrics
• CPC Class Codes: C09J 7/38 : Pressure-sensitive adhesives [PSA]
• CPC Class Codes: D04H 1/593 : to layered webs
• CPC Class Codes: D04H 13/007 : strengthened or consolidated by welding together the various components
• CPC Class Codes: E04B 1/84 : Sound-absorbing elements
• CPC Class Codes: E04B 2001/742 : Use of special materials; Materials having special structures or shape
• CPC Class Codes: E04B 2001/7687 : Crumble resistant fibrous blankets or panels using adhesives or meltable fibres
• CPC Class Codes: G10K 11/168 : Plural layers of different materials, e.g. sandwiches
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 156/1052 : with cutting, punching, tearing or severing
• CPC Class Codes: Y10T 428/1476 : Release layer
• CPC Class Codes: Y10T 428/24851 : Intermediate layer is discontinuous or differential

Abstract

A sound absorbing material comprising a nonwoven fibrous acoustic insulation material and a flow resistive non-woven facing, wherein the flow resistive nonwoven facing is bonded to the insulation material and has an air flow resistance of from about 600 to about 1800 Rayls and a surface mass of from about 20 to about 150 g/m².

Claims

1. A sound absorbing material comprising:

a nonwoven fibrous acoustic insulation material comprising a thermally bonded vertically lapped fibrous web;

a flow resistive nonwoven facing, wherein the flow resistive nonwoven facing is bonded to the nonwoven fibrous acoustic insulation material and base surface mass of from about 20 to about 150 g/m²; and

a tape material adhered to the nonwoven fibrous acoustic insulation material on an opposite side to the flow resistive nonwoven facing, wherein the tape material comprises;

a thin flexible substrate;

a pressure sensitive adhesive (PSA) substance carried on a single side of the substrate, the PSA substance being provided in an intermittent pattern along a length of the substrate; and

a mesh carried on the single side, wherein the mesh is open to expose the PSA substance for adhesion;

wherein the PSA substance adheres the tape material to the nonwoven fibrous acoustic insulation material, and the thin flexible substrate is removable to reveal the PSA substance during use of the material.

2. The sound absorbing material of claim 1, wherein the sound absorbing material has formaldehyde emissions of less than about 5 mg/kg.

3. The sound absorbing material of claim 1, wherein the substrate is silicone coated and comprises plastic film release liner or a paper-based release liner.

4. The sound absorbing material of claim 1, wherein the intermittent pattern along the length of the substrate is a series of strips of PSA, substance and the substrate comprises one or more slits formed therein intermediate at least one pair of strips of PSA substance.

5. The sound absorbing material of claim 1, wherein the flow resistive nonwoven facing is bonded to the insulation material using a heat-activated adhesive.

6. The sound absorbing material of claim 1, wherein the flow resistive nonwoven facing is treated with a phosphate-derived flame retardant.

7. The sound absorbing material of claim 1, wherein the surface mass of the flow resistive nonwoven facing is about 40 to about 60 g/m² .

8. The sound absorbing material of claim 1, wherein the flow resistive nonwoven facing comprises a cellulose wet-laid nonwoven textile.

9. The sound absorbing material of claim 1, wherein the flow resistive nonwoven facing has an air flow resistance of from about 600 Rayls to about 1800 Rayls.

10. The sound absorbing material of claim 9, wherein the flow resistance is from about 600 to about 1000 Rayls.

11. The sound absorbing material of claim 10, wherein the flow resistance is from about 800 to about 900 Rayls.

12. A method of terming a sound absorbing material comprising:

laminating a flow resistive nonwoven facing to one side of a nonwoven vertically lapped fibrous acoustic insulation material, the flow resistive nonwoven facing having a surface mass of from about 20 g/m² to about 150 g/m²; and

laminating a tape material, to an opposite side of the nonwoven fibrous acoustic insulation material, wherein the tape material comprises;

a thin flexible substrate;

a pressure sensitive adhesive (PSA) substance carried on a single side of the substrate, the PSA substance being provided in an intermittent pattern along a length of the substrate; and

a mesh carried on the single side, wherein the mesh is open to expose the PSA substance for adhesion;

wherein the PSA substance adheres the tape material to the nonwoven fibrous acoustic insulation material;

removing the thin fiexible substrate to reveal the PSA substance during use of the material.

13. The method of claim 12, wherein the flow resistive nonwoven facing has an air flow resistance of from about 600 Rayls to about 1800 Rayls.

14. The method of claim 12, wherein the sound absorbing material has formaldehyde emissions of less than about 5 mg/kg.

15. The method of claim 12, comprising bonding the flow resistive nonwoven facing to the insulation material using a heat-activated adhesive.