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US 7,918,313 B2Granted
Nonwoven material for acoustic insulation, and process for manufacture
AssigneeBuckeye Technologies Inc.
InventorsJames R. Gross, Jeffrey S. Hurley, Brian E. Boehmer, Ronald Timothy Moose
Life of this patent
Estimating the term…
Abstract
An improved acoustically and thermally insulating composite material suitable for use in structures such as buildings, appliances, and the interior passenger compartments and exterior components of automotive vehicles, comprising at least one airlaid fibrous layer of controlled density and composition and incorporating suitable binding agents and additives as needed to meet expectations for noise abatement, fire, and mildew resistance. Separately, an airlaid structure which provides a reduced, controlled airflow therethrough useful for acoustic insulation is provided, and which includes a woven or nonwoven scrim.
Claims83
Nonwoven material comprising a core, containing:
- (A) from about 95 weight percent to about 40 weight percent matrix fibers, wherein the matrix fibers comprise individualized cellulosic fibers,
- (B) from about 60 weight percent to about 5 weight percent core binder, where weight percentages in the core are based on the total weight of the core, and where
- (C) the core has a basis weight of from about 200 gsm to about 3000 gsm,
- (D) the core has a density of from about 0.015 g/cc to about 0.10 g/cc, and
- (E) the nonwoven material has sound transmission reduction of 5 decibel or greater in an LSTT sound transmission test.
2 more elements
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 individualized 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, 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, and
- (C) 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
- (D) the core has a basis weight of from about 200 gsm to about 3000 gsm,
- (E) the core has a density of from about 0.015 g/cc to about 0.10 g/cc, and
- (F) the nonwoven material has sound transmission reduction of 5 decibel or greater in an LSTT sound transmission test.
11 more elements
A molded thermal insulating article, comprising:
- a nonwoven material including a core that has a basis weight of from about 200 gsm to about 3000 gsm, the core containing (A) from about 95 weight percent to about 40 weight percent matrix fibers, wherein the matrix fibers comprise individualized cellulosic fibers, (B) from about 60 weight percent to about 5 weight percent core binder, where weight percentages in the core are based on the total weight of the core;
- and a fire retardant;
- wherein the thermal insulating article is molded into a predetermined shape that complementary to the at least one vehicle part.
A vehicle insulating article comprising:
- an airlaid structure formed of a nonwoven material including a core that has a basis weight of from about 200 gsm to about 3000 gsm, the core containing (A) from about 95 weight percent to about 40 weight percent matrix fibers, wherein the matrix fibers comprise individualized cellulosic fibers, (B) from about 60 weight percent to about 5 weight percent core binder, where weight percentages in the core are based on the total weight of the core.
A sound attenuating insulating article comprising:
- a nonwoven material comprising a core that has a basis weight of from about 200 gsm to about 3000 gsm, the core containing (A) from about 95 weight percent to about 40 weight percent matrix fibers, wherein the matrix fibers comprise individualized cellulosic fibers, (B) from about 60 weight percent to about 5 weight percent core binder, where weight percentages in the core are based on the total weight of the core;
- and
- a decorative outer layer formed of a material that is different than the nonwoven material and has increased rigidity compared to the nonwoven core.
A molded article having a shape of a vehicle insulating panel insert comprising:
- an airlaid structure formed of a nonwoven material and a core containing:
- From about 95 weight percent to about 40 weight percent matrix fibers, wherein the matrix fibers comprise individualized cellulosic fibers, and
- From about 60 weight percent to about 5 weight percent core binder, where weight percentages in the core are based on the total weight of the core;
- wherein the article is molded into a shape that is retained, the nonwoven material having sound transmission reduction of 5 decibel or greater in an LSTT sound transmission test, a substrate bonded to the airlaid structure.
1 more element
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 individualized 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
- (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.
4 more elements
A nonwoven structure comprising:
- (A) a scrim with a first surface and a second surface, the scrim having a basis weight of from about 8 gsm to about 200 gsm;
- (B) deposited on the first surface of the scrim, from about 1 gsm to about 40 gsm of a polymeric coating;
- and, optionally,
- (C) deposited on the second surface of the scrim from about 1 gsm to about 40 gsm of a second polymeric coating;
- Wherein the structure comprises a core, containing
- (D) From about 95 weight percent to about 40 weight percent matrix fibers, wherein the matrix fibers comprise individualized cellulosic fibers, and
- (E) From about 60 weight percent to about 5 weight percent core binder, where weight percentages in the core are based on the total weight of the core.
4 more elements
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 individualized 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.
2 more elements
A motorized vehicle 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 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.
5 more elements
Dependencies are inferred from the claim text.