Method for manufacturing a sound insulating structure and the structure produced thereby

A process for manufacturing a sound insulating structure comprising a textile panel having interior and exterior faces, a generally non-permeable polymeric layer overlying the exterior face and a backing layer overlying the polymeric layer, comprising the steps of:

• preheating the panel to a controlled temperature;
• positioning the preheated panel in a forming mold such that the perimeter of the panel is retained in a fixed position relative to the mold;
• closing the forming mold with controlled pressure sufficient for expanding the panel to conform it to the mold and form voids in the polymeric layer to produce a permeability of 500 rayls (N s/m3) or less as measured by concentric airflow resistance equipment through the panel;
• and
• allowing the panel to cool.

A process for manufacturing a permeable laminated product from a generally non-permeable laminated sound attenuation panel comprising:

• a) providing a generally non-permeable laminated sound attenuation panel of textile material having interior and exterior sides, a non-permeable polymeric layer overlying the exterior side and a backing layer overlying the polymeric layer;
• b) heating the laminated sound attenuation panel of a) to a sufficient temperature to cause the polymeric layer to flow into the textile material;
• c) presenting the product of b) to a forming mold that fixes its perimeter relative to the mold;
• and
• d) closing the forming mold under a controlled pressure, heat and time cycle sufficient to conform the product of c) to the mold, while maintaining its perimeter fixed, and form voids in the polymeric layer to render an expanded permeable laminated product having a permeability of no more than 500 rayls (N s/m3).

A process for manufacturing a sound attenuation panel comprising:

• providing a textile material having interior and exterior sides, a polymeric layer overlying the exterior side and a backing layer overlying the polymeric layer to form a generally non-permeable laminated product;
• heating the laminated product for 25-30 seconds under a heat intensity of 10-15 watts per square inch of laminated product to cause wicking of the polymeric layer into the textile material;
• presenting the laminated product to a forming mold such that the perimeter of the laminated product is retained in a fixed position relative to the mold;
• refrigerating the forming mold to a temperature of 45 degrees F.;
• and
• closing the forming mold under 1.5-4.0 PSI of mold pressure for about 45 seconds to conform the laminated product to the mold and form voids in the polymeric layer to render a permeable sound attenuation panel that is expanded by 7-10 percent over the laminated product.