Acoustical insulating web
First Claim
1. A method for attenuating sound waves .Iadd.in a vehicle, said sound waves .Iaddend.passing from a source area to a receiving area, comprising the steps of:
- a) providing a nonwoven acoustical insulation web comprising thermoplastic fibers, said web having an average effective fiber diameter of less than about 15 microns, a thickness of at least about 0.5 cm, a density of less than about 50 kg/m3, and a pressure drop of at least about 1 mm water at a flow rate of about 32 liters/min.; and
b) positioning said web between said source area and said receiving area such that a major face of said web intercepts and thereby attenuates sound waves passing from said source area to said receiving area.
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Accused Products
Abstract
A method for attenuating sound waves passing from a source area to a receiving area comprises the steps of providing a nonwoven acoustical insulation web comprising thermoplastic fibers, the web having an average effective fiber diameter of less than about 15 microns, a density of less than about 50 kg/m3, and an air pressure drop across the web of at least about 1 Mm water at a flow rate of about 32 liters/min.; and positioning the web between the source area and the receiving area such that a major face of the web intercepts and thereby attenuates sound waves passing from the source area to the receiving area. Also, a laminate adapted to be applied to the inner panel of a vehicle door comprises the web and a second layer, such as a scrim, nonwoven fabric, film, or foil, laminated thereto. The laminate can be applied to the inner panel of a vehicle door so that the second layer provides water barrier protection and the web provides acoustical insulation. Also, a nonwoven acoustical insulation web comprising thermoplastic fibers, the web having an average effective fiber diameter of less than about 15 microns, a density of less than about 20 kg/m3, and a pressure drop of at least about 1 mm water at a flow rate of about 32 liters/min. The web typically comprises melt-blown microfibers and crimped bulking fibers in a weight percent ratio of about 40:60 to about 95:5, respectively.
122 Citations
43 Claims
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1. A method for attenuating sound waves .Iadd.in a vehicle, said sound waves .Iaddend.passing from a source area to a receiving area, comprising the steps of:
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a) providing a nonwoven acoustical insulation web comprising thermoplastic fibers, said web having an average effective fiber diameter of less than about 15 microns, a thickness of at least about 0.5 cm, a density of less than about 50 kg/m3, and a pressure drop of at least about 1 mm water at a flow rate of about 32 liters/min.; and b) positioning said web between said source area and said receiving area such that a major face of said web intercepts and thereby attenuates sound waves passing from said source area to said receiving area. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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21. A laminate comprising:
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a) a nonwoven acoustical insulation web comprising thermoplastic fibers, said web having an average effective fiber diameter of less than about 15 microns, a thickness of at least about 0.5 cm, a density of less than about 50 kg/m3, and a pressure drop of at least about 1 mm water at a flow rate of about 32 liters/min.; and b) a second layer laminated to said web, said laminate being applied to the inner panel of a vehicle door. - View Dependent Claims (22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38)
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39. A method for preventing sound and water from entering a vehicle interior, comprising the steps of:
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a) providing a laminate comprising a nonwoven acoustical insulation web and a second layer laminated to said web, said web comprising thermoplastic fibers and having an average effective fiber diameter of less than about 15 microns, a thickness of at least about 0.5 cm, a density of less than about 50 kg/m3, and a pressure drop of at least about 1 mm water at a flow rate of about 32 liters/min.; and b) securing sad laminate to a panel of a vehicle to attenuate sound waves which contact a major face of said web of said laminate and prevent the passage of water through the panel and into the vehicle interior.
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40. A process for manufacturing a vehicle door, comprising the steps of:
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a) providing a vehicle door having outer and inner panels secured together with a space therebetween for accommodating various mechanisms, the inner panel comprising a recessed area comprising at least one opening; b) providing a laminate comprising a nonwoven acoustical insulation web and a second layer laminated to said web, said web comprising thermoplastic fibers and having an average effective fiber diameter of less than about 15 microns, a thickness of at least about 0.5 cm, a density of less than about 50 kg/m3, and a pressure drop of at least about 1 mm water at a flow rate of about 32 liters/min.; and c) securing said laminate to the inner panel with said second layer of said laminate disposed adjacent to the inner panel so that said second layer can provide water barrier protection and said web can provide acoustical insulation. - View Dependent Claims (41)
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42. comprises microfiber microwebs..!..Iadd.54. A laminate comprising a nonwoven acoustical insulation web applied to the inner panel of a vehicle door, said web comprising thermoplastic fibers, said web having an average effective fiber diameter of less than about 15 microns, a thickness of at least about 0.5 cm, a density of less than about 50 kg/m3, and a pressure drop of at least about 1 mm water at a flow rate of about 32 liters/min. .Iaddend..Iadd.55. A method for preventing sound and water from entering a vehicle interior, comprising the steps of:
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a) providing a laminate comprising a nonwoven acoustical insulation web and a water barrier layer laminated to said web, said web comprising thermoplastic fibers and having an average effective fiber diameter of less than about 15 microns, a thickness of at least about 0.5 cm, a density of less than about 50 kg/m3, and a pressure drop of at least about 1 mm water at a flow rate of about 32 liters/min., said laminate being adapted for placement on an interior panel of a vehicle in a single step; and b) securing said laminate to a panel of a vehicle to attenuate sound waves which contact a major face of said web of said laminate and prevent the passage of water through the panel and into the vehicle interior. .Iaddend..Iadd.56. A process for manufacturing a vehicle door, comprising the steps of; a) providing a vehicle door having outer and inner panels secured together with a space therebetween for accommodating various mechanisms, the inner panel comprising a recessed area comprising at least one opening; b) providing a laminate comprising a nonwoven acoustical insulation web and a water barrier layer laminated to said web, said web comprising thermoplastic fibers and having an average effective fiber diameter of less than about 15 microns, a thickness of at least about 0.5 cm, a density of less than about 50 kg/m3, and a pressure drop of at least about 1 mm water at a flow rate of about 32 liters/min., said laminate being adapted for placement on the inner panel in a single step; and c) securing said laminate to the inner panel with said water barrier layer of said laminate disposed adjacent to the inner panel so that said water barrier layer can provide water barrier protection and said web can provide acoustical insulation. .Iaddend..Iadd.57. The process of claim 56 wherein said water barrier layer is a thermoplastic film. .Iaddend..Iadd.58. A method for attenuating sound waves in a small appliance, said sound waves passing from a source area to a receiving area, comprising the steps of; a) providing a nonwoven acoustical insulation web comprising thermoplastic fibers, said web having an average effective fiber diameter of less than about 15 microns, a thickness of at least about 0.5 cm, a density of less than about 50 kg/m3, and a pressure drop of at least about 1 mm water at a flow rate of about 32 liters/min.; and b) positioning said web between said source area and said receiving area such that a major face of said web intercepts and thereby attenuates sound waves passing from said source area to said receiving area. .Iaddend..Iadd.59. A method for attenuating sound waves in an article used in architectural applications, said sound waves passing from a source area to a receiving area, comprising the steps of; a) providing a nonwoven acoustical insulation web comprising thermoplastic fibers, said web having an average effective fiber diameter of less than about 15 microns, a thickness of at least about 0.5 cm, a density of less than about 50 kg/m3, and a pressure drop of at least about 1 mm water at a flow rate of about 32 liters/min.; and b) positioning said web between said source area and said receiving area such that a major face of said web intercepts and thereby attenuates sound waves passing from said source area to said receiving area. .Iaddend..Iadd.60. A method for attenuating sound waves in an article used for transportation, said sound waves passing from a source area to a receiving area, comprising the steps of; a) providing a nonwoven acoustical insulation web comprising thermoplastic fibers, said web having an average effective fiber diameter of less than about 15 microns, a thickness of at least about 0.5 cm, a density of less than about 50 kg/m3, and a pressure drop of at least about 1 mm water at a flow rate of about 32 liters/min.; and b) positioning said web between said source area and said receiving area such that a major face of said web intercepts and thereby attenuates sound waves passing from said source area to said receiving area. .Iaddend..Iadd.61. The method of claim 60 wherein said article comprises a vehicle. .Iaddend..Iadd.62. The method of claim 60 wherein said article comprises an airplane. .Iaddend..Iadd.63. The method of claim 60 wherein said article comprises a train. .Iaddend..Iadd.64. A laminate comprising a nonwoven acoustical insulation web comprising thermoplastic fibers, said web having an average effective fiber diameter of less than about 15 microns, a thickness of at least about 0.5 cm, a density of less than about 50 kg/m3, and a pressure drop of at least about 1 mm water at a flow rate of about 32 liters/min., said laminate comprising pressure molded reduced thickness areas alone its outer periphery, said reduced thickness areas having a thin gauge relative to other portions of said laminate. .Iaddend..Iadd.65. The laminate of claim 64 further comprising a second layer laminated to said web.
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43. Iaddend..Iadd.66. The laminate of claim 65 wherein said second layer is selected from the croup consisting of scrim, nonwoven fabric, film, and foil. .Iaddend..Iadd.67. The laminate of claim 65 wherein said second layer comprises a thermoplastic film. .Iaddend.
Specification