# US 7,744,143 B2 · Nonwoven panel and method of construction thereof

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- Number: US 7,744,143 B2
- Document ID: US7744143B2
- Status: Granted
- Kind: B2
- Application number: 11/971,484
- Filed: 2008-01-09
- Published: 2008-09-04
- Granted: 2010-06-29
- Earliest claimed: 2007-01-10
- Assignees: Federal-Mogul Powertrain LLC
- Inventors: Harry F. Gladfelter; Christopher A. Foy; David Briggs; Eric K. Staudt
- Web page: https://patentgrep.com/patent/US7744143B2

## CPC

- D04H 1/54: by welding together the fibres, e.g. by partially melting or dissolving (in combination with needling D04H1/485)
- D21H 13/10: Organic non-cellulose fibres
- D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B)
- D21H: PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR

## Abstract

A nonwoven material and method of construction thereof from post consumer mixed Asian cardboard for forming structural and/or acoustic and/or thermal panels. The method includes providing post consumer mixed Asian cardboard and comminuting the cardboard into pieces of a predetermined size. Further, combining the reduced sized cardboard pieces with heat bondable textile fibers to form a substantially homogenous mixture, and then, forming a web of the mixture, with the web having a predetermined thickness, in a dry nonwoven webbing process. Then, heating the web to bond the heat bondable material with the reduced size pieces of mixed Asian cardboard to form the nonwoven material.

## Claims

### Claim 1

A nonwoven vehicle panel, comprising:
a heat bondable textile material; and
a recycled post consumer Asian cardboard material, said recycled cardboard material being bonded with said heat bondable textile material.

### Claim 2 (depends on 1)

The vehicle panel of claim 1 wherein said Asian cardboard material comprises at least 5 weight percent of said vehicle panel.

### Claim 3 (depends on 2)

The vehicle panel of claim 2 wherein said Asian cardboard material comprises at least 25 weight percent of said vehicle panel.

### Claim 4 (depends on 1)

The vehicle panel of claim 1 further comprising a flame retardant coating on at least one of said heat bondable textile material or said recycled post consumer Asian cardboard material.

### Claim 5 (depends on 1)

The vehicle panel of claim 1 further comprising an anti-microbial coating on at least one of said heat bondable textile material or said recycled post consumer Asian cardboard material.

### Claim 6 (depends on 1)

The vehicle panel of claim 1 wherein said heat bondable textile material is PET.