초록 ▼

An improved acoustically and thermally insulating fire-retardant composite material suitable for use in structures such as buildings, appliances, and the interior passenger compartments and exterior components of automotive vehicles is provided. The material is comprised of at least one airlaid fibr

An improved acoustically and thermally insulating fire-retardant composite material suitable for use in structures such as buildings, appliances, and the interior passenger compartments and exterior components of automotive vehicles is provided. The material is comprised of 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-retardancy, 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. A process for the production of the fire retardant nonwoven material is also provided.

대표청구항 ▼

The invention claimed is: 1. A nonwoven material comprising a core, 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, wh

The invention claimed is: 1. A nonwoven material comprising a core, 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, where weight percentages in the core are based on the total weight of the core, and (C) a fire-retardant, such that the nonwoven material has a Burn Through Time in a fire barrier screening test of about 1 minute or greater; and 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. 2. The nonwoven material of claim 1, wherein the matrix fibers further comprise synthetic fibers. 3. The nonwoven material of claim 1, wherein the cellulosic fibers are cotton fibers or wood pulp fibers. 4. The nonwoven material of claim 1, wherein the nonwoven material has two or more strata. 5. The nonwoven material of claim 4, wherein the matrix fibers of one stratum include inherently fire-retardant fibers. 6. The nonwoven material of claim 1, wherein the fire-retardant is ammonium polyphosphate, sodium tetraborate decahydrate, or combinations thereof. 7. The nonwoven material of claim 1, wherein the fire-retardant is about 40% by weight of untreated material. 8. The nonwoven material of claim 1, wherein the nonwoven material is an airlaid nonwoven, spunbonded nonwoven, a meltblown nonwoven, a spunlaced nonwoven, or a combination thereof. 9. The nonwoven material of claim 8, wherein the nonwoven material is fabricated from airlaid nonwoven fibers. 10. The nonwoven material of claim 1, wherein the core binder is a bicomponent fiber binder, a latex binder, a thermoplastic powder or a mixture thereof. 11. The nonwoven material of claim 10, wherein the core binder is a mixture of a bicomponent fiber binder and a latex binder. 12. The nonwoven material of claim 1, wherein the basis weight of the core is from about 300 gsm to about 3000 gsm. 13. The nonwoven material of claim 1, wherein the density is from about 0.015 g/cc to about 0.08 g/cc. 14. The nonwoven material of claim 1, wherein the nonwoven material has a sound transmission reduction of 7 decibel or greater in a LSTT sound transmission test. 15. The nonwoven material claim 1, wherein the core contains: (A) from about 80 weight percent to about 60 weight percent matrix fibers, and (B) from about 40 weight percent to about 20 weight percent core binder, where weight percentages in the core are based on the total weight of the core. 16. The nonwoven material of claim 1, further comprising: (G) a woven or nonwoven carrier with a basis weight of from about 10 gsm to about 2000 gsm which is integral with a surface of the core. 17. The nonwoven material of claim 16, wherein the carrier is a nonwoven carrier containing synthetic fibers, cellulosic fibers or a mixture thereof. 18. The nonwoven material of claim 17, wherein the carrier is a synthetic spunbonded, meltblown or spunlaced carrier. 19. The nonwoven material of claim 17, wherein the carrier has cellulosic fibers. 20. The nonwoven material of claim 16, wherein the carrier is a woven carrier containing synthetic fibers, cellulosic fibers or a mixture thereof. 21. The nonwoven material of claim 16, wherein the carrier is a woven carrier which is a cloth, textile, unbacked carpeting, or other woven material. 22. The nonwoven material of claim 1, further comprising: (H) an auxiliary layer containing plastic material with a basis weight of from about 50 gsm to about 700 gsm present on an outer surface of the nonwoven material or present as a discrete inner layer within the core of the nonwoven material. 23. The nonwoven material of claim 22, wherein the auxiliary layer contains a dense filler material having a density of greater than 0.1 g/cc, and has a basis weight of from about 75 gsm to about 700 gsm. 24. The nonwoven material of claim 22, wherein the auxiliary layer is made from one or more latices. 25. The nonwoven material of claim 22, wherein the auxiliary layer is made from one or more latices and a filler. 26. The nonwoven material of claim 23, wherein the filler is calcium carbonate, barium sulfate, or a mixture thereof. 27. The nonwoven material of claim 22, wherein the auxiliary layer contains one or more thermoplastic fibers. 28. The nonwoven material of claim 22, wherein the auxiliary layer contains one or more hot melt adhesives. 29. The nonwoven material of claim 22, wherein the auxiliary layer contains from about 30 weight percent to 100 weight percent latex solids, and from 0 to about 70 weight percent filler. 30. The nonwoven material claim 1, wherein the nonwoven material has a sound absorption coefficient (a) as determined by ASTM E1050-98 at 1000 H.J of about 0.5 or greater. 31. The nonwoven material of claim 1, wherein the nonwoven material has a sound absorption coefficient (a) as determined by ASTM E1050-98 at 2500 H.J of about 0.85 or greater. 32. The nonwoven material of claim 1, wherein the nonwoven material has a SAMI of about 3 δdB/kgsm or greater. 33. The nonwoven material of claim 1, further comprising (I) a water-repellent anti-leachant. 34. The nonwoven material of claim 33, wherein the water-repellent anti-leachant is present in an amount of from about 3 gsm to about 50 gsm. 35. The nonwoven material of claim 33, wherein the water-repellent anti-leachant is dispersed in the individuali.Jed fibers. 36. The nonwoven material of claim 1, wherein the fire-retardant is present in the nonwoven material in an amount of from about 3 gsm to about 100 gsm. 37. The nonwoven material of claim 1, wherein the Burn Through Time in the Fire Barrier Test following a Standard Leaching Procedure is about 1 minute or greater. 38. A panel of the nonwoven material of claim 1 having an area of 50 meters square or less, which has been molded with an application of heat and pressure into a shape which is retained. 39. A panel of the nonwoven material of claim 1 having an area of 10 meters square or less, which has been formed from a continuous process and cut into a long roll suitable for shipping by truck or by rail. 40. A thermal insulating construct comprising a structural member or surface of a building, a vehicle, or an appliance and attached or applied thereto the nonwoven material of claim 1. 41. The thermal insulating construct of claim 40, wherein the core of the nonwoven material comprises: (J) fibers dosed with fibers, granules or microcapsules that can store heat or cold for later release. 42. A sound attenuating laminate comprising the nonwoven material of claim 1, and attached or applied thereto or otherwise in contact therewith upholstery material, carpeting or a structural member or surface. 43. A panel of the sound attenuating laminate of claim 42, which has been molded with the application of heat and pressure into a shape which is retained. 44. A package for an object comprising a container and a nonwoven material of claim 1. 45. A panel of the nonwoven material of claim 1 having an area of up to 1000 meters square, which has been formed from a continuous process, slit to a desired width, and rolled in a manner suitable for shipping by truck or by rail. 46. 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. 47. The process of claim 46, wherein the fire-retardant is deposited on a first surface of the nonwoven material, a second surface of the nonwoven material, the matrix fibers, or a combination thereof. 48. The process of claim 46, further comprising the steps of: (4) providing a comminution sheet of cellulosic fibers, wherein the comminution sheet is, optionally, pre-treated with a fire-retardant, or a water-repellent anti-leachant, or a combination thereof; and (5) comminuting the sheet into individuali.Jed cellulosic fibers. 49. The process of claim 46, wherein the fire-retardant is present in the nonwoven material in an amount of from about 3 gsm to about 100 gsm. 50. The process of claim 46 further comprising the step of: (6) optionally, depositing an water-repellent anti-leachant on the nonwoven material. 51. The process of claim 46, wherein at least some of the matrix fibers are inherently fire-retardant fibers. 52. The process of claim 46 further comprising the step of: (7) forming an auxiliary layer containing plastic material with a basis weight of from about 50 gsm to about 700 gsm present on an outer surface of the core. 53. The process of claim 52, wherein the auxiliary layer contains plastic material and a filler. 54. The process of claim 52, wherein the auxiliary layer is produced at an outer surface of the nonwoven material by hot calendaring or by radiant heating of a surface layer of the nonwoven material. 55. The process of claim 46, wherein the nonwoven material is produced with two or more strata from at least two different mixtures of matrix fibers, where one mixture of matrix fibers used to form one stratum contains inherently fire-retardant fibers. 56. The process of claim 55 wherein the stratum containing inherently fire-retardant fibers is produced first and used as a carrier upon which another. 57. The process of claim 46, wherein a carrier sheet is placed on the forming wire prior to deposition of airlaid fibers. 58. The process of claim 46, wherein the process is a continuous process. 59. A process for providing sound attenuation or thermal insulation in a building or vehicle comprising: providing a structural cavity or surface of the building or vehicle, and applying or attaching thereto the fire-retardant nonwoven material of claim 1. 60. A molded thermal insulating article for at least one vehicle part 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 individuali.Jed 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 (C) a fire-retardant, such that the molded thermal insulating article has a Burn Through Time in a fire barrier screening test of about 1 minute or greater; wherein the thermal insulating article is molded into a predetermined shape that is complementary to the at least one vehicle part. 61. The molded thermal insulating article of claim 60, wherein the at least one vehicle part is selected from the group consisting of a dash board, an engine side wall, a hood, a door panel, a trunk compartment, a passenger floor, a package tray, and an interior wheel well. 62. 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 individuali.Jed 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 (C) a fire-retardant, wherein the vehicle insulating article has a Burn Through Time in a fire barrier screening test of about 1 minute or greater. 63. A sound attenuating insulating article comprising: a fire-retardant 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 individuali.Jed 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 such that the nonwoven material has a Burn Through Time in a fire barrier screening test of about 1 minute or greater; and a decorative outer layer formed of a material that is different than the fire-retardant nonwoven material and has increased rigidity compared to the nonwoven core. 64. The sound attenuating insulating article of claim 63, wherein the article comprises a ceiling tile and the decorative outer layer has indicia formed as a part thereof. 65. The sound attenuating insulating article of claim 64, wherein the indicia comprises one of a stippled pattern, a decorative pattern embossed thereon, and a roughened surface. 66. The sound attenuating insulating article of claim 63, wherein the decorative outer layer is formed of a synthetic material. 67. The sound attenuating insulating article of claim 66, wherein the synthetic material is a layer of plastic material disposed on the core. 68. The sound attenuating insulating article of claim 63, wherein the decorative outer layer further includes an agent that inhibits surface growth of mold and mildew. 69. A molded article having a shape of a vehicle insulating panel insert comprising: an airlaid structure formed of a nonwoven material and 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, and also comprising a fire-retardant, the nonwoven material 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, where weight percentages in the core are based on the total weight of the core; and a substrate bonded to the airlaid structure; and wherein the nonwoven material has a Burn Through Time in a fire barrier screening test of about 1 minute or greater. 70. The article of claim 69, wherein the airlaid structure includes an opening formed therein to receive a vehicle part. 71. The article of claim 69, wherein the substrate is a carpet, a heavy paper board support member, or a plastic support member. 72. The molded article of claim 70, wherein the insert is a dashboard insert, a wheel well insert, an engine firewall insert, a door insert, a floor insert, a trunk insert or a hood underside insert. 73. 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. 74. The nonwoven structure of claim 73, wherein the basis weight of the scrim is from about 8 gsm to about 100 gsm. 75. The nonwoven structure of claim 73, wherein the nonwoven material has a basis weight of from about 10 gsm to about 1000 gsm. 76. The nonwoven structure of claim 73, wherein the basis weight of the polymeric coating deposited on the outer surface of the scrim is from about 1 gsm to about 25 gsm. 77. The nonwoven structure of claim 73, wherein the basis weight of the polymeric coating deposited on the outer surface of the scrim is from about 5 gsm to about 40 gsm. 78. The nonwoven structure of claim 73, wherein the second polymeric coating is present and the basis weight of the second polymeric coating deposited on the outer surface of the nonwoven material is from about 1 gsm to about 25 gsm. 79. The nonwoven structure of claim 73, wherein the basis weight of the second polymeric coating deposited on the outer surface of the nonwoven material is from about 5 gsm to about 40 gsm. 80. The nonwoven structure of claim 73, wherein the polymeric coating deposited on the outer surface of the scrim or the second polymeric coating deposited on the outer surface of the nonwoven material or both contains or binds one or more fillers, powders, or fire-retardants. 81. The nonwoven structure of claim 70, wherein the polymeric coating contains a fire-retardant. 82. The nonwoven structure claim 73, wherein the nonwoven material is an airfelt. 83. The nonwoven structure claim 73, wherein the nonwoven structure is an airlaid nonwoven structure. 84. The nonwoven structure of claim 73, wherein the caliper of the nonwoven structure is from about 1 mm to about 60 mm. 85. The nonwoven structure of claim 73, wherein the nonwoven structure has an airflow resistance of from about 500 to about 10,000 Rayls (NS/m3). 86. The nonwoven structure of claim 73, wherein the scrim is fabricated from cloth, unbacked carpet or textile. 87. The nonwoven structure of claim 73, wherein the scrim is fabricated from a nonwoven material that is needle-punched, spunlaid or spunbonded. 88. The nonwoven structure of claim 73, wherein the scrim is a spunbonded polypropylene being 15 to 500 gsm by weight. 89. The nonwoven structure of claim 73, wherein the matrix fibers further comprise synthetic fibers. 90. A nonwoven material 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; (b) an interior surface of a nonwoven substrate of matrix fibers and a binder, the nonwoven material having an interior surface and an outer surface and having a basis weight of from about 10 gsm to about 2000 gsm, the nonwoven substrate containing 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 the binder where the weight percentages are based on the total weight of the nonwoven substrate; and (c) the substrate having been treated with a fire-retardant so that the nonwoven material has a Burn Through Time in a fire barrier screening test of about 1 minute or greater. 91. The nonwoven material of claim 90, wherein the substrate is formed through an airlaid process. 92. The nonwoven material of claim 90, wherein the fire-retardant material contains inherently fire-retardant fibers. 93. The nonwoven material of claim 90, further comprising: (d) a latex binder. 94. The nonwoven material of claim 90, wherein the substrate is adjacent the interior surface of the scrim. 95. The nonwoven material of claim 90, wherein the substrate is integral with the interior surface of the scrim. 96. The nonwoven material of claim 90, wherein the fire-retardant is applied to the outer surface of the substrate. 97. The nonwoven material of claim 90, wherein the fire-retardant is ammonium polyphosphate, sodium tetraborate decahydrate, or combinations thereof. 98. The nonwoven material of claim 90, wherein the fire-retardant is about 40% by weight of untreated material. 99. The nonwoven material of claim 90, further comprising an water-repellent anti-leachant applied to the substrate. 100. The nonwoven structure of claim 90, wherein the scrim is a spunbond-meltblown-spunbond material, a spunbond-meltblown-meltblown-spunbond material, a cellulosic material, a textile, or woven or nonwoven polyester material. 101. 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. 102. 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. 103. The motorized vehicle of claim 102, wherein the barrier is a door.