초록 ▼

A fibrous insulation media is formed from a non-woven mat of thermoplastic fibers having a mean diameter of less than about 15 microns. Preferably, when used as an acoustical insulation, the media is formed of fibers having a mean diameter of less than about 13 microns; the media has a density of le

A fibrous insulation media is formed from a non-woven mat of thermoplastic fibers having a mean diameter of less than about 15 microns. Preferably, when used as an acoustical insulation, the media is formed of fibers having a mean diameter of less than about 13 microns; the media has a density of less than about 60 Kg/m.sup.3 ; and the media has a Fraiser air permeability of less than 75 cubic feet per minute per square foot of surface area. The media has first and second major surfaces and a fibrous core with at least one of the major surfaces having an integral skin thereon. The skin is formed by melting fibers at and immediately adjacent the major surface of the mat formed into the media to form a thermoplastic melt layer which is subsequently solidified into a skin on the major surface of the mat. The thermoplastic fibers of the mat are point bonded together at spaced apart locations to increase the integrity of the mat.

대표청구항 ▼

[ What is claimed is:] [1.]1. A method of forming a fibrous insulation medium of thermoplastic fibers, comprising:air laying thermoplastic fibers having a mean fiber diameter of less than about 15 microns to form a mat having first and second major surfaces and a density of less than 60 kilograms pe

[ What is claimed is:] [1.]1. A method of forming a fibrous insulation medium of thermoplastic fibers, comprising:air laying thermoplastic fibers having a mean fiber diameter of less than about 15 microns to form a mat having first and second major surfaces and a density of less than 60 kilograms per cubic meter;melting the thermoplastic fibers at and immediately adjacent the first major surface of the mat to form a thermoplastic melt layer on the first major surface of the mat; subsequently cooling the thermoplastic melt layer to form an integral thermoplastic skin on the first major surface of the mat; andsubsequent to the formation of the integral thermoplastic skin on the first major surface of the mat, penetrating the first major surface of the mat with pins at spaced apart locations to point bond the thermoplastic fibers of the mat together to increase the integrity of the mat and to form the integral thermoplastic skin on the first major into an integral thermoplastic skin having a Fraiser air permeability number of less than 75 cubic feet per minute per square foot of surface area to enhance the acoustical performance of the mat; wherein;the thermoplastic fibers are point bonded together at the spaced apart locations by heating the thermoplastic fibers at the spaced apart locations solely through the application of pressure to the thermoplastic fibers at the spaced apart locations.