Nonwoven material for acoustic insulation, and process for manufacture

A process for the production of a nonwoven material comprising:

• (1a) on a moving foraminous wire from one or more forming heads deposition of a mixture containing (A) from about 95 weight percent to about 40 weight percent matrix fibers, wherein the matrix fibers comprise individuali.Jed cellulosic fibers, (B) from about 60 weight percent to about 5 weight percent core binder, to form a core of the nonwoven material, where weight percentages in the core are based on the total weight of the core, and (C) a fire-retardant, followed by:
• (2a) heating the nonwoven material to consolidate the mixture of matrix fibers and binder, or, (1b) deposition on a moving foraminous wire of (A) a woven or nonwoven carrier with a basis weight of from about 10 gsm to about 2000 gsm;
• followed by (2b) deposition on the carrier from one or more forming heads of a mixture containing (B) from about 95 weight percent to about 40 weight percent matrix fibers, wherein the matrix fibers comprise individuali.Jed cellulosic fibers, (C) a fire-retardant, and (D) from about 60 weight percent to about 5 weight percent core binder, to form a core of the nonwoven material, where weight percentages in the core are based on the total weight of the core, and so that the carrier is integral with a surface of the core, followed by (3) heating the nonwoven material to consolidate the mixture of matrix fibers and binder, where (E) the core has a basis weight of from about 200 gsm to about 3000 gsm, (F) the core has a density of from about 0.015 glee to about 0.10 g/cc, and (G) the nonwoven material has sound transmission reduction of 5 decibel or greater in an LSTT sound transmission test.

A nonwoven structure comprising:

• (A) a scrim with an interior surface and an outer surface, the scrim having a basis weight of from about 8 gsm to about 200 gsm;
• and, (B) in contact with the interior surface of the scrim, an interior surface of a nonwoven material with an interior surface and an outer surface, the nonwoven material having a basis weight of from about 10 gsm to about 2000 gsm which contains from about 30 weight percent to about 95 weight percent matrix fibers, wherein the matrix fibers comprise individuali.Jed cellulosic fibers, and from about 5 weight percent to about 70 weight percent of a binder where the weight percentages are based on the total weight of the nonwoven material, and the nonwoven material also having a fire-retardant;
• and (C) deposited on the outer surface of the scrim from about 1 gsm to about 40 gsm of a polymeric coating;
• and, optionally, (D) deposited on the outer surface of the nonwoven material from about 1 gsm to about 40 gsm of a second polymeric coating;
• and wherein the nonwoven structure has a Burn Through Time in a fire barrier screening test of about 1 minute or greater.

A process for the production of a nonwoven structure, comprising;

• (1) providing a scrim with an interior surface and an outer surface, the scrim having a basis weight of from about 8 gsm to about 200 gsm;
• (2) airlaying a nonwoven material on the interior surface of the scrim, the nonwoven material having a basis weight of from about 10 gsm to about 2000 gsm which contains from about 30 weight percent to about 95 weight percent matrix fibers, wherein the matrix fibers comprise individuali.Jed cellulosic fibers, and from about 5 weight percent to about 70 weight percent of a binder where the weight percentages are based on the total weight of the nonwoven material;
• (3) depositing on the outer surface of the scrim from about 1 gsm to about 40 gsm of a polymeric coating;
• and, optionally, (4) depositing on the outer surface of the nonwoven material from about 1 gsm to about 40 gsm of a second polymeric coating;
• and (5) depositing a fire-retardant material onto an outer surface of either the nonwoven structure or the scrim, such that the nonwoven material has a Burn Through Time in a fire barrier screening test of about 1 minute or greater.

A motori.Jed vehicle having at least one barrier, the barrier being at least partially insulated by a nonwoven structure comprising:

• (A) a scrim with an interior surface and an outer surface, the scrim having a basis weight of from about 8 gsm to about 200 gsm;
• and (B) in contact with the interior surface of the scrim, an interior surface of a nonwoven material having an interior surface and an outer surface, the material having a basis weight of from about 10 gsm to about 2000 gsm which contains from about 30 weight percent to about 95 weight percent matrix fibers, wherein the matrix fibers comprise individuali.Jed cellulosic fibers, and from about 5 weight percent to about 70 weight percent of a binder where the weight percentages are based on the total weight of the pad;
• and (C) deposited on the outer surface of the scrim, from about 1 gsm to about 40 gsm of a polymeric coating;
• and, optionally, (D) deposited on the outer surface of the nonwoven material from about 1 gsm to about 40 gsm of a second polymeric coating;
• and the nonwoven structure being pre-cut to a desired geometry before installation into the barrier, and wherein the nonwoven material has a fire-retardant deposited on an outer surface, or dispersed within the matrix fibers such that the nonwoven structure has a Burn Through Time in a fire barrier screening test of about 1 minute or greater.