Molded and shaped acoustical insulating vehicle panel and method of making the same
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B60R-013/08
B32B-003/26
B32B-005/06
B32B-005/26
D04H-013/00
D04H-001/541
D04H-001/485
D04H-001/558
B32B-005/14
출원번호
US-0285082
(2008-09-29)
등록번호
US-10144367
(2018-12-04)
발명자
/ 주소
Borchardt, Steven
Jarrard, Brian
출원인 / 주소
LYDALL, INC.
대리인 / 주소
Cantor Colburn LLP
인용정보
피인용 횟수 :
0인용 특허 :
9
초록▼
A molded and shaped acoustical insulating vehicle panel having a dry-laid needled fibrous composite composed of a first portion of about 50 to 80 percent meltable binder fibers and about 20 to 50 percent stable fibers and having a second portion of about 20 to 50 percent meltable binder fibers and 5
A molded and shaped acoustical insulating vehicle panel having a dry-laid needled fibrous composite composed of a first portion of about 50 to 80 percent meltable binder fibers and about 20 to 50 percent stable fibers and having a second portion of about 20 to 50 percent meltable binder fibers and 50 to 80 percent of staple fibers. The meltable binder fibers are in a molded and resolidified state such that the resolidified binder fibers of the first portion form a substantially continuous, semi-impervious, densified skin integrally associated with and bonded to a surface of the first portion. The molded composite is in such a heat and pressure molded state that the composite has over a predominance of its area a density of from about 12 to 22 lbs./cubic foot (192 to 352 kg/cubic meter) and the panel is sufficiently rigid as to be self-supporting.
대표청구항▼
1. A molded and shaped acoustical insulating vehicle panel, comprising: a nonwoven fibrous composite having a first portion of greater than 60 to 80 percent meltable binder fibers and less than 40 percent to 20percent staple fibers, and having a second portion of about 20 to 50 percent meltable bind
1. A molded and shaped acoustical insulating vehicle panel, comprising: a nonwoven fibrous composite having a first portion of greater than 60 to 80 percent meltable binder fibers and less than 40 percent to 20percent staple fibers, and having a second portion of about 20 to 50 percent meltable binder fibers and 50 to 80 percent staple fibers; andat least a portion of the meltable binder fibers of the first portion forming a substantially continuous, semi-impervious, densified skin integrally associated with and bonded to a surface of the first portion, wherein the densified skin is about 5 to about 20 percent of an overall thickness of the molded and shaped acoustical insulating vehicle panel,wherein the molded and shaped acoustical insulating vehicle panel has a density of from about 12 to 22 lbs/cubic foot (192 to 352 kg/cubic meter) over a predominance of an area defining the molded and shaped acoustical insulating vehicle panel, and is sufficiently rigid so as to be self-supporting. 2. The panel of claim 1, wherein the dry-laid and needled fibrous composite is carded. 3. The panel of claim 2, wherein the molded and shaped acoustical insulating vehicle panel has a density gradient from a back side to the skin side. 4. The panel of claim 1, wherein the skin of the molded and shaped acoustical insulating vehicle panel has a sufficient porosity so that water splashed thereinto may drain therefrom. 5. The panel of claim 4, wherein the molded and shaped acoustical insulating vehicle panel has the skin formed in a cool mold so as to cause melted and/or softened fibers to coalesce into the skin. 6. The panel of claim 1, wherein the molded and shaped acoustical insulating vehicle panel is in the form of a vehicle wheel well shield with a Flow Resistance of between 300 and 1000 MKS rayls. 7. The panel of claim 1, wherein the molded and shaped acoustical insulating vehicle panel is in the form of a vehicle wheel well shield with a Flow Resistance of between 350 and 800 MKS rayls. 8. The panel of claim 1, wherein the molded and shaped acoustical insulating vehicle panel is so self-supporting that it will retain its molded shape without supports. 9. A process for making the vehicle panel of claim 1, comprising: dry-laying a first portion of fibers having from about 50% to 80% meltable binder fibers and about 30% to 50% staple fibers;dry-laying a second portion of fibers on the first portion so as to form a composite thereof, with the second portion having about 20% to 50% meltable binder fibers and about 50% to 80% staple fivers;needling the composite sufficiently to form a consolidated composite;heating the consolidated composite to a temperature sufficient to soften and/or melt the meltable binder fibers such that the meltable binder fibers are moldable;molding the heated consolidated composite in a mold in the configuration of a vehicle panel until the meltable binder fibers resolidify such that at least some of the resolidified binder fibers of the first portion form a substantially continuous, semi-impervious, densified skin intimately adhered and bonded to the first portion and wherein the two portions have over a predominance of their area an insulation density of from about 12 to 22 lbs./cubic ft. (192 to 352 kg/cubic meter) and the molded panel is sufficiently rigid so as to be self-supporting. 10. The process of claim 9, wherein the consolidated composite is heated to a temperature of at least 300° F. (148.9° C.) and the mold is a cool mold with a temperature of no more than 200° F. (93.3° C.), so that the heated consolidated composite is shaped and cooled while in the mold and may be removed from the mold as a self supporting panel. 11. The process of claim 10, wherein the composite is needled with at least 300 needle punches per square inch (47 needle punches per square centimeter). 12. A molded and shaped acoustical insulating vehicle panel, comprising: a nonwoven fibrous composite having a first portion of greater than 60 to 80 percent meltable binder fibers and less than 40 percent to 20 percent staple fibers, and having a second portion of about 20 to 50 percent meltable binder fibers and 50 to 80 percent staple fibers;the composite having fibers from the first portion extending into the second portion and providing a high bond strength after molding between the first portion and the second portion to prevent peeling of the first portion from the second portion; anda substantially continuous, semi-impervious, densified skin comprising resolidified binder fibers of the first portion and being integrally associated with and bonded to a surface of the first portion, wherein the densified skin is about 5 to about 20 percent of an overall thickness of the molded and shaped acoustical insulating vehicle panel, andwherein the molded and shaped acoustical insulating vehicle panel has a density of from about 12 to 22 lbs/cubic foot (192 to 352 kg/cubic meter) over a predominance of an area defining the molded and shaped acoustical insulating vehicle panel, and the molded and shaped acoustical insulating vehicle panel is sufficiently rigid so as to be self-supporting. 13. The panel of claim 12, wherein the dry-laid composite is carded. 14. The panel of claim 13, wherein the molded and shaped acoustical insulating vehicle panel has a density gradient from a back side to the skin side. 15. The panel of claim 12, wherein the skin of the molded and shaped acoustical insulating vehicle panel has a sufficient porosity so that water splashed thereunto may drain therefrom. 16. The panel of claim 15, wherein the molded and shaped acoustical insulating vehicle panel has the skin formed in a cool mold so as to cause melted and/or softened fibers to coalesce into the skin. 17. The panel of claim 12, wherein the molded and shaped acoustical insulating vehicle panel is in the form of a vehicle wheel well shield with a Flow Resistance of between 300 and 1000 MKS rayls. 18. The panel of claim 12, wherein the molded and shaped acoustical insulating vehicle panel is in the form of a vehicle wheel well shield with a Flow Resistance of between 350 and 800 MKS rayls. 19. The panel of claim 12, wherein the molded and shaped acoustical insulating vehicle panel is so self-supporting that it will retain its molded shape without supports.
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