Method of making a sound absorbing laminate
OwnerReinhold Hausslinginventor
Life of this patent
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Abstract
There are provided laminate structures comprising a reinforcing fibrous mat integrally bonded to a resilient fibrous batt. The mat is preferentially a porous mat of resin-bonded chopped glass fiber. The batt is preferentially a porous batt of natural or synthetic fibers. Preferentially, the laminate comprises a core of resilient fibrous batt sandwiched between two facing sheets of reinforcing fibrous mat, with a decorative cover layer being laminated to the exterior surface of one reinforcing fibrous mat, the whole being bonded together by a thermoset binder into a unitary structure.
Claims21
A method of forming a three-dimensional sound-absorbing structure comprising:
- providing a first reinforcing porous, fibrous mat;
- providing a core defined by a resilient thermoformable porous fibrous batt having a thickness of at least about one quarter of an inch;
- laminating said mat to one surface of said batt by impregnating said mat and its interface with said batt with sufficient binder resin to effect adherence therebetween, but insufficient resin binder to form a porosity-blocking film;
- and
- thermoforming said laminate into a porous three-dimensional configuration.
A method of forming a porous temporary laminate which can be shaped to form a three-dimensional structure comprising;
- providing a core member defined by a resilient thermoformable porous fibrous batt having a thickness of at least about one quarter of an inch, said batt being impregnated with sufficient thermoplastic resin binder dispersed in a liquid carrier to bind the fibers of said batt together but insufficient thermoplastic binder resin to form a porosity-blocking film;
- providing a first porous fibrous reinforcing mat;
- laminating said mat to said batt to form a porous temporary laminate by placing said mat adjacent said batt before said thermoplastic binder resin is dried;
- and
- drying said porous temporary laminate to adhere said mat to said batt.
Dependencies are inferred from the claim text.