Sound attenuating material for use within vehicles and methods of making same

A sound attenuating composite article, comprising:

• a first layer of material, wherein the first layer of material is selected from the group consisting of acoustic fiber batting and acoustic foam;
• a second layer of thermoplastic material fused to a surface of the first layer of material, wherein the second layer of material comprises a thermoplastic material;
• and
• a third layer of material attached to a surface of the first layer of material in face-to-face relationship therewith, wherein the third layer of material comprises a blend of at least about 70% polyester fibers and at least about 13% polyolefin fibers;
• wherein one or more selected portions of the composite article are compressed relative to adjacent portions so as to have an acoustic impedance that is greater than an acoustic impedance of portions adjacent the one or more selected portions.

A method of producing a sound attenuating composite article, comprising:

• providing a first layer of material, wherein the first layer of material is selected from the group consisting of acoustic fiber batting and acoustic foam;
• extruding a second layer of thermoplastic material onto a surface of the first layer of material at a temperature of between about 350° F. and about 450° F. such that the second layer of material fuses to the first layer of material;
• compressing the first and second layers of material to a combined thickness of between about four millimeters and thirty millimeters (4-30 mm);
• extruding a third layer of thermoplastic material onto a surface of the second layer of thermoplastic material at a temperature of between about 300° F. and about 450° F. such that the third layer of material fuses to the second layer of material;
• and
• compressing the first, second, and third layers of material to a combined thickness of between about 4 mm and about 25 mm.

A method of producing a sound attenuating composite article, comprising:

• providing a first layer of material, wherein the first layer of material is selected from the group consisting of acoustic fiber batting and acoustic foam;
• extruding a second layer of thermoplastic material onto a surface of the first layer of material at a temperature of between about 350° F. and about 450° F. such that the second layer of material fuses to the first layer of material;
• and
• compressing the first and second layers of material to a combined thickness of between about four millimeters and thirty millimeters (4-30 mm).

A sound attenuating composite article, comprising:

• a first layer of material, wherein the first layer of material is selected from the group consisting of acoustic fiber batting and acoustic foam;
• a second layer of thermoplastic material fused to a surface of the first layer of material;
• a third layer of thermoplastic material fused to a surface of the second layer of thermoplastic material;
• and
• a fourth layer of material attached to a surface of the third layer of material in face-to-face relationship therewith, wherein the fourth layer of material comprises a blend of fibers and has a thickness of less than or equal to about 2 mm;
• wherein one or more selected portions of the composite article are compressed relative to adjacent portions so as to have an acoustic impedance that is greater than an acoustic impedance of portions adjacent the one or more selected portions.