초록 ▼

A laminated panel-type structure particularly suited for vehicle interior applications such as headliners and door panels has a multiple denier polyester fiber core and randomly oriented structural reinforcing fibers. The laminated structure has superior sound attenuation properties resulting from a

A laminated panel-type structure particularly suited for vehicle interior applications such as headliners and door panels has a multiple denier polyester fiber core and randomly oriented structural reinforcing fibers. The laminated structure has superior sound attenuation properties resulting from a core of intertwined polyester fibers of differing deniers, with preferably relatively larger denier fibers on exterior areas of the core and some bicomponent fibers, short non-woven reinforcing fiber strands which are randomly attached and intertwined with the core on opposing major sides of the core, an impervious polymer film with a low melt layer which retains the reinforcing fibers against one side of the core and is attached to a scrim layer, and a polymer web on an opposite side of the core which retains the reinforcing fiber strands on the opposing major side of the core and to which a cover stock is applied. The invention further includes a method of manufacturing the laminated structure wherein the various layers are sequentially unfurled from spools, passed through nip rollers at points of various subcombinations of materials and layers, the reinforcing fiber strands are randomly distributed on to the carrying layers from hoppers or directly from a fiber chopping device, and the completed laminated structure is cut and molded.

대표청구항 ▼

1. A method of manufacturing a laminate structure which can be molded into a relatively rigid structure and which is effective at absorbing sound, the method comprising the steps of:providing a fibrous core containing a plurality of intertwined polyester fibers of differing denier and applying a the

1. A method of manufacturing a laminate structure which can be molded into a relatively rigid structure and which is effective at absorbing sound, the method comprising the steps of:providing a fibrous core containing a plurality of intertwined polyester fibers of differing denier and applying a thermoset resin to the fibrous core, providing a polymer film which has a melting temperature less than a melting temperature of the fibrous core adjacent to the fibrous core, putting a plurality of reinforcing non-woven fiber strands into contact with the polymer film and a first side of the fibrous core, putting a plurality of reinforcing non-woven fiber strands into contact with a second side of the fibrous core generally opposite to the first side, applying a polymer web over the fiber strands applied to the second side of the fibrous core, and applying a cover stock to the polymer web.