Process for production of foam laminate product
AssigneeProprietect L.P.
InventorNeil P. Gehani
Life of this patent
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Abstract
A laminate product comprising a foam core having a pair of opposed major surfaces and a cover layer secured with respect to each major surface is described. The cover layer contains a fibrous reinforcement layer that is substantially encapsulated by a polymer. It has been found that the use of a fibrous polymer layer (e.g., in place of conventional polyethylene film) results in a laminate product having significantly lower resistance to air flow resistance and significantly improved sound absorption properties.
Claims22
A process for producing a laminate foam product having a pre-determined shape, the process comprising the steps of:
- positioning a blank in a heating device, the blank comprising a foam core having a pair of opposed major surfaces and one or more cover layers disposed on each major surface, each cover layer comprising at least one fiberglass reinforcing layer, which is made of fiberglass containing a polymer material, and at least one spunbound fibrous polypropylene scrim layer, the blank being free of polyethylene film;
- heating the blank at temperature above the melting point of the at least one spunbound fibrous polypropylene scrim layer for a period of time sufficient to cause polymer of the at least one spunbound fibrous polypropylene scrim layer to wet out, fully permeate and substantially encapsulate the at least one fiberglass reinforcing layer and make each cover layer adhere to the foam core, wherein the encapsulated at least one fiberglass reinforcing layer is configured to maintain an air flow resistance of the laminate foam product, as measured in accordance with ASTM C522, to be less than about 6,000 mks Rayls.
A process for producing a laminate foam product having a pre-determined shape, the process comprising the steps of:
- positioning a blank in a heating device, the blank comprising a foam core having a pair of opposed major surfaces and one or more cover layers disposed on each major surface, each cover layer comprising at least one fiberglass reinforcing layer, which is made of fiberglass containing a polymer material, and at least one spunbound fibrous polypropylene scrim layer arranged in an alternating fashion such that there are N fiberglass reinforcing layers, each of which is made of fiberglass containing a polymer material, and N+1 spunbound fibrous polypropylene scrim layers and Nis an integer equal to 1 or more, the spunbound fibrous polypropylene scrim layer having a basis weight of from about 0.8 to about 2.8oz/yd2, the blank being free of polyethylene film;
- heating the blank at temperature above the melting point of the at least one spunbound fibrous polypropylene scrim layer for a period of time sufficient to cause polymer of the at least one spunbound fibrous polypropylene scrim layer to wet out, fully permeate and substantially encapsulate the at least one fiberglass reinforcing layer and make each cover layer adhere to the foam core, wherein the encapsulated at least one fiberglass reinforcing layer is configured to maintain an air flow resistance of the laminate foam product, as measured in accordance with ASTM C522, to be in the range of from about 700 to about 2,700 mks Rayls.
Dependencies are inferred from the claim text.