A thermoformable acoustic sheet formed by a compressed fibrous web includes high melt fibers and adhesive thermoplastic fibers in which the adhesive fibers are at least partially melted so that in the compressed web the adhesive fibers at least partially coat the high melt fibers and reduce the inte
A thermoformable acoustic sheet formed by a compressed fibrous web includes high melt fibers and adhesive thermoplastic fibers in which the adhesive fibers are at least partially melted so that in the compressed web the adhesive fibers at least partially coat the high melt fibers and reduce the interstitial space in the fiber matrix. Also included are methods of producing a thermoformable acoustic sheet which includes heating a fiber web including high melt and adhesive thermoplastic fibers to at least partially melt the adhesive fibers and compressing the web to form a sheet so that the adhesive fibers at least partially coat the high melt fibers to reduce the interstitial space in the fiber matrix.
대표청구항▼
The invention claimed is: 1. A thermoformable acoustic sheet formed by a compressed fibrous web comprising a fibre matrix, the fibre matrix including high melt fibres and adhesive thermoplastic fibres in which the adhesive fibres are at least partially melted so that in the compressed web the adhes
The invention claimed is: 1. A thermoformable acoustic sheet formed by a compressed fibrous web comprising a fibre matrix, the fibre matrix including high melt fibres and adhesive thermoplastic fibres in which the adhesive fibres are at least partially melted so that in the compressed web the adhesive fibres partially coat the high melt fibres and reduce interstitial space in the fibre matrix to create a labyrinthine structure that forms a tortuous path for air flow through the fibre matrix and provide a selected air flow resistance, said thermoformable acoustic sheet having a total air flow resistance between 275 and 1100 mks Rayls. 2. A thermoformable acoustic sheet according to claim 1 wherein the thermoplastic fibres are treated with an adhesive coating. 3. A thermoformable acoustic sheet according to claim 1 wherein the thermoplastic fibres are treated with a coating formed by one or more further webs of thermoplastic fibres. 4. A thermoformable acoustic sheet according to claim 1 having a low sag modulus at temperatures up to 150° C. 5. A thermoformable acoustic sheet according to claim 1 wherein the high melt fibre has a melting point above about 220° C. 6. A thermoformable acoustic sheet according to claim 1 wherein the adhesive fibre has a melting point between 100 and 160° C. 7. A thermoformable acoustic sheet according to claim 1 wherein the high melt fibres are about 6 denier or below. 8. A thermoformable acoustic sheet according to claim 1 wherein the adhesive fibres are about 6 denier or below. 9. A thermoformable acoustic sheet according to claim 1 wherein the web of thermoplastic fibres is produced from non-woven vertically aligned high loft thermally bonded fibres. 10. A thermoformable acoustic sheet according to claim 1 wherein the thermoplastic fibres are selected from polyethylene terephthalate (PET), polyethylene butylphthalate (PBT), polyethylene 1,4-cyclohexanedimethanol (PCT), polylactic acid (PLA) and/or polypropylene (PP). 11. A thermoformable acoustic sheet according to claim 1 wherein the web of thermoplastic fibres as a web weight of about 1000 g/m2 or below. 12. A thermoformable acoustic sheet according to claim 1 further including a flame retardant. 13. A thermoformable acoustic sheet according to claim 1 wherein the web of thermoplastic fibres has a substantial proportion of adhesive fibre or adhesive bicomponent fibre, is heated to a temperature between 180-220° C. and is compressed. 14. An acoustic sheet comprising a compressed fibre matrix, the fibre matrix including high melt fibres and adhesive thermoplastic fibres in which the adhesive thermoplastic fibres are at least partially melted so that in the compressed fibre matrix the adhesive thermoplastic fibres partially coat the high melt fibres and reduce interstitial spaces such that the acoustic sheet has a total air flow resistance between 275 and 1100 mks Rayls. 15. An acoustic sheet comprising a compressed fibre matrix, the fibre matrix including high melt fibres and adhesive thermoplastic fibres in which the adhesive fibres are at least partially melted so that in the compressed fibre matrix the adhesive fibres partially coat the high melt fibres and reduce interstitial space in the fibre matrix to create a labyrinthine structure that forms tortuous air flow paths through the fibre matrix, and the fibre matrix of thermoplastic fibres has a weight of about 1000 g/m2 or below. 16. The acoustic sheet of claim 15 wherein the acoustic sheet is configured to be installed in an automobile. 17. A thermoformed acoustic article formed by heating and compressing a fibrous web, the acoustic article comprising high melt fibres and adhesive thermoplastic fibres in which the adhesive fibres are at least partially melted so that in the compressed web a fibre matrix is formed in which the adhesive fibres partially coat the high melt fibres and reduce the interstitial space in the fibre matrix to create a labyrinthine structure that forms a tortuous path for air flow through the fibre matrix and provide a selected air flow resistance, said thermoformed acoustic article having a total air flow resistance between 275 and 1100 mks Rayls. 18. The thermoformed acoustic article of claim 17 wherein the thermoformed acoustic article has a sound absorption coefficient of about 0.6 or greater at 1000 Hz. 19. The thermoformed acoustic article of claim 17 wherein the fibrous web comprises a substantial portion, by weight, of the adhesive fibres, and the adhesive fibres are bicomponent fibres. 20. The thermoformed acoustic article of claim 17 wherein the adhesive fibres are bicomponent polyester fibres. 21. A thermoformable acoustic sheet formed by a compressed fibrous web comprising a fibre matrix, the fibre matrix including high melt fibres and adhesive thermoplastic fibres in which the adhesive fibres are at least partially melted so that in the compressed web the adhesive fibres partially coat the high melt fibres and reduce interstitial space in the fibre matrix to create a labyrinthine structure that forms a tortuous path for air flow through the fibre matrix and provide a selected air flow resistance, wherein the thermoplastic fibres are treated with a coating formed by one or more further webs of thermoplastic fibres. 22. A thermoformable acoustic sheet formed by a compressed fibrous web comprising a fibre matrix, the fibre matrix including high melt fibres and adhesive thermoplastic fibres in which the adhesive fibres are at least partially melted so that in the compressed web the adhesive fibres partially coat the high melt fibres and reduce interstitial space in the fibre matrix to create a labyrinthine structure that forms a tortuous path for air flow through the fibre matrix and provide a selected air flow resistance, said thermoformable acoustic sheet having a low sag modulus at temperatures up to 150° C. 23. A thermoformable acoustic sheet formed by a compressed fibrous web comprising a fibre matrix, the fibre matrix including high melt fibres and adhesive thermoplastic fibres in which the adhesive fibres are at least partially melted so that in the compressed web the adhesive fibres partially coat the high melt fibres and reduce interstitial space in the fibre matrix to create a labyrinthine structure that forms a tortuous path for air flow through the fibre matrix and provide a selected air flow resistance, wherein the high melt fibres are about 6 denier or below. 24. A thermoformable acoustic sheet according to claim 23 wherein the thermoplastic fibres are treated with an adhesive coating. 25. A thermoformable acoustic sheet according to claim 23 wherein the thermoplastic fibres are treated with a coating formed by one or more further webs of thermoplastic fibres. 26. A thermoformable acoustic sheet according to claim 23 having a low sag modulus at temperatures up to 150° C. 27. A thermoformable acoustic sheet according to claim 23 wherein the high melt fibre has a melting point above about 220° C. 28. A thermo formable acoustic sheet according to claim 23 wherein the adhesive fibre has a melting point between 100 and 160° C. 29. A thermoformable acoustic sheet according to claim 23 wherein the adhesive fibres are about 6 denier or below. 30. A thermoformable acoustic sheet according to claim 23 wherein the web of thermoplastic fibres is produced from non-woven vertically aligned high loft thermally bonded fibres. 31. A thermoformable acoustic sheet according to claim 23 wherein the thermoplastic fibres are selected from polyethylene terephthalate (PET), polyethylene butylphthalate (PBT), polyethylene 1,4-cyclohexanedimethanol (PeT), polylactic acid (PLA) and/or polypropylene (PP). 32. A thermoformable acoustic sheet according to claim 23 wherein the web of thermoplastic fibres has a web weight of about 1000 g/m2 or below. 33. A thermoformable acoustic sheet according to claim 23 further including a flame retardant. 34. A thermoformable acoustic sheet according to claim 23 wherein the web of thermoplastic fibres has a substantial proportion of adhesive fibre or adhesive bicomponent fibre, is heated to a temperature between 180-220° C. and is compressed. 35. A thermoformable acoustic sheet formed by a compressed fibrous web comprising a fibre matrix, the fibre matrix including high melt fibres and adhesive thermoplastic fibres in which the adhesive fibres are at least partially melted so that in the compressed web the adhesive fibres partially coat the high melt fibres and reduce interstitial space in the fibre matrix to create a labyrinthine structure that forms a tortuous path for air flow through the fibre matrix and provide a selected air flow resistance, wherein the adhesive fibres are about 6 denier or below. 36. A thermoformable acoustic sheet according to claim 35 wherein the thermoplastic fibres are treated with an adhesive coating. 37. A thermoformable acoustic sheet according to claim 35 wherein the thermoplastic fibres are treated with a coating formed by one or more further webs of thermoplastic fibres. 38. A thermoformable acoustic sheet according to claim 35 having a low sag modulus at temperatures up to 150° C. 39. A thermoformable acoustic sheet according to claim 35 wherein the high melt fibre has a melting point above about 220° C. 40. A thermoformable acoustic sheet according to claim 35 wherein the adhesive fibre has a melting point between 100 and 160° C. 41. A thermoformable acoustic sheet according to claim 35 wherein the web of thermoplastic fibres is produced from non-woven vertically aligned high loft thermally bonded fibres. 42. A thermoformable acoustic sheet according to claim 35 wherein the thermoplastic fibres are selected from polyethylene terephthalate (PET), polyethylene butylphthalate (PBT), polyethylene 1,4-cyclohexanedimethanol (PCT), polylactic acid (PLA) and/or polypropylene (PP). 43. A thermoformable acoustic sheet according to claim 35 wherein the web of thermoplastic fibres has a web weight of about 1000 g/m2 or below. 44. A thermoformable acoustic sheet according to claim 35 further including a flame retardant. 45. A thermoformable acoustic sheet according to claim 35 wherein the web of thermoplastic fibres has a substantial proportion of adhesive fibre or adhesive bicomponent fibre, is heated to a temperature between 180-220° C. and is compressed. 46. A thermoformable acoustic sheet formed by a compressed fibrous web comprising a fibre matrix, the fibre matrix including high melt fibres and adhesive thermoplastic fibres in which the adhesive fibres are at least partially melted so that in the compressed web the adhesive fibres partially coat the high melt fibres and reduce interstitial space in the fibre matrix to create a labyrinthine structure that forms a tortuous path for air flow through the fibre matrix and provide a selected air flow resistance, wherein the web of thermoplastic fibres has a web weight of about 1000 g/m2 or below. 47. A thermoformable acoustic sheet according to claim 46 wherein the thermoplastic fibres are treated with an adhesive coating. 48. A thermoformable acoustic sheet according to claim 46 wherein the thermoplastic fibres are treated with a coating formed by one or more further webs of thermoplastic fibres. 49. A thermoformable acoustic sheet according to claim 46 having a low sag modulus at temperatures up to 150° C. 50. A thermoformable acoustic sheet according to claim 46 wherein the high melt fibre has a melting point above about 220° C. 51. A thermoformable acoustic sheet according to claim 46 wherein the adhesive fibre has a melting point between 100 and 160° C. 52. A thermoformable acoustic sheet according to claim 46 wherein the web of thermoplastic fibres is produced from non-woven vertically aligned high loft thermally bonded fibres. 53. A thermoformable acoustic sheet according to claim 46 wherein the thermoplastic fibres are selected from polyethylene terephthalate (PET), polyethylene butylphthalate (PBT), polyethylene 1,4-cyclohexanedimethanol (PCT), polylactic acid (PLA) and/or polypropylene (PP). 54. A thermoformable acoustic sheet according to claim 46 further including a flame retardant. 55. A thermoformable acoustic sheet according to claim 46 wherein the web of thermoplastic fibres has a substantial proportion of adhesive fibre or adhesive bicomponent fibre, is heated to a temperature between 180-220° C. and is compressed. 56. A thermoformable acoustic sheet formed by a compressed fibrous web comprising a fibre matrix, the fibre matrix including high melt fibres and adhesive thermoplastic fibres in which the adhesive fibres are at least partially melted so that in the compressed web the adhesive fibres partially coat the high melt fibres and reduce interstitial space in the fibre matrix to create a labyrinthine structure that forms a tortuous path for air flow through the fibre matrix and provide a selected air flow resistance, wherein the web of thermoplastic fibres has a substantial proportion of adhesive fibre or adhesive bicomponent fibre, is heated to a temperature between 180-220° C. and is compressed. 57. A thermoformable acoustic sheet according to claim 56 wherein the thermoplastic fibres are treated with an adhesive coating. 58. A thermoformable acoustic sheet according to claim 56 wherein the thermoplastic fibres are treated with a coating formed by one or more further webs of thermoplastic fibres. 59. A thermoformable acoustic sheet according to claim 56 having a low sag modulus at temperatures up to 150° C. 60. A thermoformable acoustic sheet according to claim 56 wherein the high melt fibre has a melting point above about 220° C. 61. A thermoformable acoustic sheet according to claim 56 wherein the adhesive fibre has a melting point between 100 and 160° C. 62. A thermoformable acoustic sheet according to claim 56 wherein the web of thermoplastic fibres is produced from non-woven vertically aligned high loft thermally bonded fibres. 63. A thermoformable acoustic sheet according to claim 56 wherein the thermoplastic fibres are selected from polyethylene terephthalate (PET), polyethylene butylphthalate (PBT), polyethylene 1,4-cyclohexanedimethanol (PCT), polylactic acid (PLA) and/or polypropylene (PP). 64. A thermoformable acoustic sheet according to claim 56 further including a flame retardant.
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