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US 2012/0115387 A1Published application
Mat material and method for manufacturing the same
AssigneeNakagawa Sangyo Co., Ltd.
InventorNoriaki Nakagawa
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Abstract
A lightweight mat material having excellent sound absorption and thermal insulation properties comprises a mixture of glass fibers and sheath-core composite fibers, wherein the melting temperature of the sheath portion is lower than the melting temperature of the core portion. The glass fibers are fused with the sheath portions of the composite fibers by melting on at least one surface of the sheet-shaped mat material.
Claims20
A mat material comprising a mixture of:
- an inorganic fiber and
- a sheath-core composite fiber, wherein the melting temperature of a thermoplastic resin at least substantially comprising a sheath portion of the composite fiber is lower than the melting temperature of a thermoplastic resin at least substantially comprising a core portion of the composite fiber,
- wherein the mat material is formed in substantially a sheet-shape and the inorganic fiber is melt-fused with the sheath portion of the composite fiber on at least one surface of mat material.
A method for manufacturing a mat material, comprising:
- mixing an inorganic fiber with a sheath-core composite fiber, wherein the melting temperature of a thermoplastic resin at least substantially comprising a sheath portion thereof is lower than the melting temperature of a thermoplastic resin at least substantially comprising a core portion thereof;
- forming the mixed fibers substantially into a sheet-shape and intertwining the mixed fibers using a needle punch, thereby forming a nonwoven sheet material;
- heating the nonwoven sheet material so to melt the sheath portion of the sheath-core composite fiber, whereby the inorganic fiber fuses with the melted sheath portion;
- and
- cooling the nonwoven sheet material, thereby obtaining the mat material.
2 more elements
Dependencies are inferred from the claim text.