U.S. patent application number 11/788879 was filed with the patent office on 2007-10-18 for multidensity liner/ insulator formed from multidimensional pieces of polymer fiber blanket insulation.
Invention is credited to Anthony L. Rockwell, Jeffrey A. Tilton.
Application Number | 20070243366 11/788879 |
Document ID | / |
Family ID | 34711023 |
Filed Date | 2007-10-18 |
United States Patent
Application |
20070243366 |
Kind Code |
A1 |
Tilton; Jeffrey A. ; et
al. |
October 18, 2007 |
Multidensity liner/ insulator formed from multidimensional pieces
of polymer fiber blanket insulation
Abstract
In accordance with the purposes of the present invention as
described herein, an improved acoustical, compressible, polymer
fiber blanket (10) of enhanced performance characteristics is
provided. The polymer fiber blanket of the present invention is
constructed of a plurality of individual pieces of polymer fiber
blanket (12) that have been bonded together via heat and
pressure.
Inventors: |
Tilton; Jeffrey A.;
(Shelbyville, KY) ; Rockwell; Anthony L.;
(Pickerington, OH) |
Correspondence
Address: |
OWENS CORNING
2790 COLUMBUS ROAD
GRANVILLE
OH
43023
US
|
Family ID: |
34711023 |
Appl. No.: |
11/788879 |
Filed: |
April 23, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10749084 |
Dec 30, 2003 |
7226879 |
|
|
11788879 |
Apr 23, 2007 |
|
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Current U.S.
Class: |
428/220 ;
264/109 |
Current CPC
Class: |
G10K 11/165 20130101;
Y10T 442/633 20150401; A47L 15/4209 20161101; B60R 13/08 20130101;
Y10T 442/637 20150401; Y10T 442/674 20150401; Y10T 442/60
20150401 |
Class at
Publication: |
428/220 ;
264/109 |
International
Class: |
B27N 3/04 20060101
B27N003/04; B32B 27/02 20060101 B32B027/02; D04H 1/00 20060101
D04H001/00 |
Claims
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22. A method of producing a compressible, flexible polymer fiber
blanket (10) comprising the steps of: a) providing a plurality of
individual pieces of polymer fiber blanket (12); b) laying said
plurality of pieces of polymer fiber blanket in a randomly oriented
pattern; c) applying sufficient heat and pressure to said plurality
of individual pieces of polymer fiber blanket to form said
compressible, flexible polymer fiber blanket.
23. The method of claim 22, wherein said wherein said individual
pieces of polymer fiber blanket are made of scrap polymer fiber
blanket.
24. The method of claim 22, wherein said individual pieces of
polymer fiber blanket are geometric in shape.
25. The method of claim 22, wherein said individual pieces of
polymer fiber blanket comprise a lofty, acoustically insulating
portion having a density of between substantially 8.0-80.0
kg/m.sup.3 and a relatively higher density skin along at least one
face thereof, said skin having a thickness of between substantially
0.25-10.0 mm and a density of between substantially 32.0-800.0
kg/m.sup.3.
26. The method of claim 22, wherein said blanket is an automotive
undercarpet.
27. The method of claim 22, wherein said pad is a nonlaminate.
28. The method of claim 22, wherein said polymer fiber blanket has
a percent wet compression of between about 15 to about 18
percent.
29. The method of claim 22, wherein said polymer fiber blanket has
a percent dry compression of between about 16 to about 21
percent.
30. The method of claim 22, wherein said polymer fiber blanket has
a percent dry wet recovery of between about 85 to about 87.5
percent.
31. The method of claim 22, wherein said polymer blanket is
thermally bonded to at least one layer of flexible, polymeric
fibrous material.
32. The method of claim 26, wherein said polymeric fibrous material
has a lofty, acoustically insulating portion having a density of
between substantially 8.0-80.0 kg/m.sup.3 and a relatively higher
density skin along a first face thereof, said skin having a
thickness of between substantially 0.25-10.0 mm and a density of
between substantially 32.0-800.0 kg/m.sup.3, said fibrous material
being selected from a group consisting of (a) thermoplastic polymer
staple fibers and thermoplastic bicomponent fibers,(b) glass staple
fibers and thermoplastic bicomponent fibers and (c) a combination
of (a) and (b).
33. The method of claim 31, wherein said fibrous material is
selected from a group of materials consisting of polyester,
polyethylene, polypropylene, nylon, glass fibers, natural fibers
and any mixtures thereof.
34. The method of claim 31, wherein said polymeric fibrous material
includes said relatively higher density skin along a second face
thereof.
35. The method of claim 22, wherein said blanket further comprises
at least one water barrier layer.
36. A compressible, flexible, polymer fiber blanket comprising a
plurality of individual pieces of polymer fiber blanket thermally
bonded together wherein said individual pieces of polymer fiber
blanket comprise fibrous material having a lofty, acoustically
insulating portion having a density of between substantially
8.0-80.0 kg/m.sup.3 and a relatively higher density skin along a
first face thereof, said skin having a thickness of between
substantially 0.25-10.0mm and a density of between substantially
32.0-800.0 kg/m.sup.3, said fibrous material being selected from a
group consisting of (a) thermoplastic polymer staple fibers and
thermoplastic bicomponent fibers,(b) glass staple fibers and
thermoplastic bicomponent fibers and (c) a combination of (a) and
(b).
37. (canceled)
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43. (canceled)
44. (canceled)
45. (canceled)
Description
RELATED PATENT APPLICATIONS
[0001] This patent application is related to copending U.S. patent
application Ser. No. 10/160,776; filed May 31, 2002 and copending
U.S. patent application Ser. No. 09/607,478, filed Jun. 30, 2002,
the full disclosures of both applications are incorporated herein
by reference in their entirely.
TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION
[0002] The present invention relates generally to a multilayer
acoustical and thermal liner/insulator formed from multidimensional
pieces of a polymeric material, which may be utilized to insulate
an environment such as a passenger compartment of a vehicle from
the heat and sound generated by mechanical components of that
vehicle during its operation. The material is especially useful in
automotive undercarpet products or in applications where
compression recovery is an important property. Other uses include
application in insulating appliances such as dishwashers and
clothes dryers and providing sound and thermal insulation for
furnaces, air conditioning units and ductwork in buildings
including homes, offices and industrial structures.
BACKGROUND OF THE INVENTION
[0003] Acoustical insulation is well known in the art. Acoustical
insulation typically relies upon both sound absorption, that is the
ability to absorb incident sound waves, and transmission loss, that
is the ability to reflect incident sound waves, in order to provide
sound attenuation. One of the more prevalent uses of such
insulation is in the motorized vehicle field where engine
compartments, fire walls, fender wells, doors, floor pans and other
components of the passenger compartment shell are commonly
acoustically insulated to reduce engine and road noise for the
benefit and comfort of passengers.
[0004] In the automotive undercarpet industry, it is important to
prevent compression of the carpet surrounding the area on which a
load, that is, a passenger's feet, is placed. By preventing
compression, acoustical and insulative properties to be maintained.
Various methods of manufacturing or fabricating acoustical and
thermal insulators are known in the art. Typically, an automotive
carpet is placed over a cotton shoddy or a uniform polymer based
mat. These undercarpets are typically produced by carding,
garnetting or air laid systems known in the art. Examples of other
methods and products are found in U.S. Pat. No. 5,266,374, and U.S.
publication Nos. 2003/0066708 A1 and 2003/0096079.
[0005] U.S. Pat. No. 5,266,374 teaches a carpet for vehicles that
prevents the transmission of sound and vibration into a vehicle
cabin. '374 teaches a rigid polyurethane sheet laid on a metal
panel, such as that of a vehicle floor. The polyurethane sheet
comprises an elastomeric rubber layer, which further comprises a
plurality of incompressible, square blocks which are intermittently
disposed between the rigid and elastomeric layers. The rigid blocks
are arranged so as to not come into contact with one another.
[0006] U.S. Pub. No. 2003/0096079 A1 teach a sound attenuating
laminate for use in vehicles including a substrate having opposite
first and second surfaces formed of foam, massback, thermoformable
fibrous material. A first surface is attached to a vehicle panel. A
non-porous polyurethane layer is applied to either portions of or
the entire substrate second surface. The laminate is formed by
forming the substrate in the shape of the article to which it is to
be applied and then spraying the polyurethane layer onto the
substrate.
[0007] U.S. Pub. No. 2003/0066708 A1 teach a sound attenuating
composite article for vehicles having several layers of material.
The first layer is either fiber batting or acoustic foam, the
second layer is a thermoplastic material fused to the surface of
the first layer, the third layer is a thermoplastic material fused
to the surface of the second layer, and the forth layer is a woven
or nonwoven mixture of fibers attached to the third layer of
material. The article is formed by providing the first layer and
then extruding a second layer of thermoplastic material onto the
first layer, compressing the first and second layers and then
extruding a third layer of thermoplastic material onto the second
layer. Scrim material is then attached to the third layer of
thermoplastic material and then all four layers are compressed via
nip rolls. Finally, the article is place in a heated mold and
heated via infrared radiation.
[0008] In many acoustical insulation applications and particularly
those relating to motorized vehicles, high compressive strength is
advantageous, especially in vehicle carpet applications so that the
acoustical properties are maintained. As demonstrated by these
prior art patents, it has generally been found necessary to coat a
uniform substrate with one or more layers of thermoplastic
material. A need is therefore identified for an improved insulation
providing enhanced acoustical properties while also exhibiting
compression-recovery. There is also a need for a product that can
be manufactured at a lower cost and reduces waste.
SUMMARY OF THE INVENTION
[0009] In accordance with the purposes of the present invention as
described herein, an improved acoustical, compressible, polymer
fiber blanket of enhanced performance characteristics is provided.
The polymer fiber blanket of the present invention is constructed
of a plurality of individual pieces of polymer fiber blanket that
have been bonded together via heat and pressure. The blanket is
manufactured by cutting pieces of polymer fiber blanket from a
uniform sheet of material that can be either pre-consumer or
post-consumer material. The pre-cut, uniform sheet is made of
staple fibers, that is, glass fibers and bicomponent thermoplastic
fibers such as polyester with copolyester bicomponent fibers. Other
polymers that may be used as thermoplastic fibers include
polypropylene, polyethylene and nylon. After pieces of the uniform
sheet are cut, they are laid down in a randomly oriented pattern.
The individual pieces of polymer fiber blanket are then bonded by
heat and pressure to form a polymer fiber blanket having enhanced
compressive qualities. In the formation of the blanket, the
individual pieces build thickness easily and allow lower density
products to be produced for a given thickness without sacrificing
compressive recovery properties.
[0010] The individual pieces of the polymer fiber blanket are cut
from a uniform sheet which includes a pad of fibrous material
having a lofty, acoustically insulating portion. The individual
pieces may be cut from a pre-made sheet of fibrous material or may
be cut from scrap material. The polymer fiber blanket also includes
a relatively higher density skin along at least one face
thereof.
[0011] The pad is a nonlaminate and, accordingly, the potential for
the relatively higher density skin to delaminate from the remainder
of the pad is eliminated. In one embodiment of the invention, the
pad includes a higher density skin along a second face thereof as
well.
[0012] In another embodiment of the present invention, the polymer
fiber blanket may be bonded to at least one uniform layer of
flexible, polymeric fibrous material, such as the uniform sheet
from which individual pieces of polymer fiber blanket are cut from,
as described above.
[0013] Still other objects of the present invention will become
apparent to those skilled in this art from the following
description wherein there is shown and described preferred
embodiments of this invention, simply by way of illustration of
several of the modes best suited to carry out the invention. As it
will be realized, the invention is capable of other different
embodiments and its several details are capable of modification in
various, obvious aspects all without departing from the invention.
Accordingly, the drawings and descriptions will be regarded as
illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The accompanying drawings incorporated in and forming a part
of the specification, illustrates several aspects of the present
invention and together with the description serves to explain the
principles of the invention. In the drawings:
[0015] FIG. 1 is a perspective view of the polymer fiber blanket of
the present invention.
[0016] FIG. 2 is a perspective view of another embodiment of the
present invention.
[0017] FIG. 3 is an end elevational view of the embodiment of the
present invention as depicted in FIG. 2.
[0018] FIG. 4 is an end elevational view of the embodiment of the
present invention as depicted in FIG. 1.
[0019] FIG. 5 is an end elevation view of uniform blanket used to
make the present invention as depicted in FIGS. 1-4.
[0020] FIG. 6 shows two graphs of compression and recoverability
data of the present invention.
[0021] FIG. 7 is a plan view of a preferred embodiment of the
present invention.
[0022] FIG. 8 is an perspective view of a cutting device used in
accordance with the present invention.
[0023] Reference will now be made in detail to the present
preferred embodiments of the invention, examples of which are
illustrated in the accompanying drawing.
DETAILED DESCRIPTION AND PREFERRED EMBODIMENTS OF THE INVENTION
[0024] Reference is now made to FIG. 1, which illustrates a first
embodiment of the compressible, flexible polymer fiber blanket
designated by reference numeral 10. The polymer fiber blanket 10 is
constructed of a plurality of individual pieces of polymer fiber
blanket 12 that have been bonded together by applying heat and
pressure. FIG. 4 is an end elevational view of the product 10 as
disclosed in FIG. 1 showing the bonded individual pieces 32.
[0025] The individual pieces 12 are produced from a thermally
bonded polymer blanket product that is typically made of a
combination of staple fibers and bicomponent fibers. The fibrous
material may take the form of (a) thermoplastic polymer staple
fibers and thermoplastic bicomponent fibers, (b) glass staple
fibers and thermoplastic bicomponent fibers and (c) a combination
of (a) and (b). The thermoplastic staple fibers and bicomponent
fibers may be selected from a group of materials including but not
limited to polyester, polyethylene, polypropylene, nylon and any
mixtures thereof. The glass fibers may include E-glass, S-glass or
basalt fibers. Natural fibers (for example hemp, kenaf) may also be
included.
[0026] FIG. 5 depicts a uniform, polymer blanket 16 from which the
individual pieces 12 (FIG. 1) are cut. The uniform blanket 16
includes a lofty, acoustically insulating portion 18 having a
density of between substantially 8.0-80.0 kg/m.sup.3 and a
relatively higher density skin 20 along one face thereof. The skin
16 has a thickness of between substantially 0.25-10.0 mm and a
density of between substantially 32.0-800.0 kg/m.sup.3. The density
of the skin 20 may be substantially constant throughout its
thickness or it may vary gradually lower from a maximum density
along the outer face thereof to a density just above that of the
insulating portion 18 along the inner portion thereof. Where the
density of the skin 20 varies, the average density for the skin
falls within the indicated range.
[0027] The uniform blanket 16 may not contain the skin 20 or, in
the alternative, may contain a first skin 20 and a secondary skin
(not shown). Further, the blanket may include a facing, on one or
both sides, to improve strength and/or surface appearance. Other
embodiments and details of the material that may be used with the
present invention are discussed in U.S. Pat. No. 6,669,265 issued
Dec. 30, 2003.
[0028] The blanket 10 is made by cutting pieces of polymer fiber
blanket from a uniform sheet of material that can be either
pre-consumer or post-consumer, that is, scrap material. A pre-cut,
uniform sheet is made of staple fibers, that is, glass fibers and
bicomponent thermoplastic fibers, as described above. The uniform
sheet is cut into a plurality of individual pieces, preferably
geometric shapes, that is, cubes. The uniform sheet may be cut by
any means known in the art. A preferable way of cutting the uniform
sheet is shown in FIG. 8. FIG. 8 shows uniform sheet 70 being drawn
in between splitter unit 72, having multiple blades, and guide
roller 71. Splitter unit 72 divides the sheet 70 into strips of
material 73. The strips of material 73 are then fed in between
cutting roller 74, having multiple blades, and guide roller 77
where the strips of material 73 are cut into individual pieces 76
by cutting roller 74. After the cutting process, the individual
pieces of blanket are then laid down onto a forming chain and then
bonded by heat and pressure.
[0029] As the pieces of blanket are compressed, they become
randomly oriented as depicted in FIG. 1. While being subjected to
heat and pressure, the bicomponent fibers from which the pieces of
blanket are made as described above, are activated causing the
fibers in the individual pieces to bond together forming a uniform
blanket.
[0030] As a result of the random orientation of the pieces 12 in
the blanket 10, as shown in FIG. 1, the blanket 10 exhibits
increased compressive resistance over a uniform blanket. As such,
the blanket 10 is suitable for use in automotive undercarpet
products or other applications where compressive resistance is
important such as cushioning for seating. To better control
compression of the polymer blanket, the individual pieces 12 may be
arranged in a controlled pattern instead of a random orientation.
Any pattern may be implemented; FIG. 7 shows a sample of such a
pattern, showing individual pieces 34 are arranged in a controlled
pattern on uniform blanket 36.
[0031] FIG. 6 shows compression and recovery data of the present
invention as compared to a uniform blanket. Graph 1 shows percent
recovery (wet and dry) of a 68 gsf uniform blanket compared to a
1'' (2.54 cm) 60 gsf cube and a 1'' 45 gsf cube of the present
invention. Graph 2 shows percent compression (wet and dry) of a 68
gsf uniform blanket compared to a 1'' 60 gsf cube and a 1'' 45 gsf
cube of the present invention. The test method used is SAE J1352
"Compression and Recovery Method BC". As shown in FIG. 6, the cubed
product of the present invention provides improved wet recovery and
improved wet and dry compression over the uniform blanket.
[0032] Although FIG. 1 depicts the individual pieces 12 in the
blanket 10 as being the same shape, for example, square, other
geometric shapes may be cut. The geometric shapes can be configured
in the cutting process to optimize compressive recovery results.
The pieces may be a variety of shapes, that is, triangular, square,
etc. or may be the same shape. The geometric shapes can be
configured in the cutting process to optimize compressive recovery
results. It is not critical that the pieces that make up the
blanket have the same shape or be composed of the same fibrous
material so long as the pieces can be bonded together. In certain
instances, it may be desirable to alter the geometry of the pieces
or fiber content to "tune" the desired physical properties. The
size of the individual pieces 12 may vary according to the use of
the blanket. Typical sizes of the individual pieces range from
about 0.5 to about 1.25 square inches (about 3.23 to about 8.06
square cm).
[0033] FIG. 2 illustrates a second embodiment of the present
invention. Blanket 22 is depicted as having individual pieces of
polymer fiber blanket 24 bonded to a uniform polymer blanket 26.
FIG. 3 is an end elevational view of the product 22 as disclosed in
FIG. 2 showing the individual pieces 30 bonded to the uniform
polymer blanket 28.
[0034] Both the individual pieces 24 and the uniform polymer
blanket 26 are described above in detail. The blanket 22 is made by
applying individual pieces of polymer fiber blanket 24 on top of a
uniform polymer blanket 26. Both the individual pieces 24 and the
uniform polymer blanket 26 are then bonded by heat and
pressure.
[0035] The use of the uniform polymer blanket 26 in combination
with the individual pieces 24 provides greater strength to the
product. There are several advantages to using the uniform blanket
in combination with individual pieces, that is, the uniform blanket
provides a smooth surface for bonding that is, bonding to an
automotive floor surface. Further, by adding or omitting individual
pieces, the properties of the product may be changes, that is,
creating a softer or stiffer product. The acoustics may also be
tuned by adding or omitting pieces on the uniform blanket.
[0036] In applications requiring superior heat insulative
characteristics, a facing layer 21 or 23, as shown in FIG. 5, may
be formed from a heat reflective material such as a metallic foil
(for example aluminum or other heat reflective metal). The facing
layer may be applied the uniform polymer blanket 16 (FIG. 5) and/or
the individual pieces 12 (FIG. 1) may be cut from and uniform
polymer blanket having a facing layer 21 or 23. Where a metallic
foil is used foil thickness is generally in the range of 0.025-0.25
mm. The thickness selected is based upon the temperature,
durability and structural requirements of the particular product
application.
[0037] The facing layer 21 or 23 may be reinforced or
non-reinforced. Reinforcements are included to add durability and
structural integrity. Reinforcements may take the form of fibrous
scrims, fibrous mats or fibrous webs. For many applications, the
reinforcement is made from a relatively strong fiber such as
fiberglass. The strands may be materials other than glass which
provide the desired properties (for example polyester).
[0038] Alternative reinforcement materials for the facing layer 21,
23 include but are not limited to glass mats, polymer mats and
blended mats. The reinforcement may be pre-attached to the metallic
foil. Alternatively loose laid reinforcement may be utilized. In
most applications, the foil layer reinforcement provides improved
tear resistance, strength and/or acoustical insulating properties.
However, in many applications, it should be appreciated that no
reinforcement is necessary.
[0039] The facing layer 21 or 23 (reinforced or non-reinforced) is
attached to the polymer based pad 18 by means of a heat activated
adhesive. The adhesive utilized may be a thermoplastic sheet or
thermoplastic web material that tends to melt and flow at
temperatures between 200.degree. F.-350.degree. F. (93.3.degree.
C.-176.6.degree. C.). Adhesives of this type are desirable because
they can be activated during the molding phase of production.
Besides thermoplastic sheets and webs, adhesives such as hot melts,
latex and various heat-activated resins may be utilized. The
adhesive may be a separate layer as illustrated or the adhesive may
already be attached to the facing layer 21 or 23.
[0040] Other embodiments of the present invention (not shown) may
be utilized. For example, the embodiment as disclosed in FIG. 2,
may have a double layer of uniform polymer blanket 26. In another
alternative, the polymer blanket 10 may comprise a double layer of
individual pieces 12. A water barrier may also be incorporated such
as that disclosed in U.S. Pat. No. 6,669,265 issued Dec. 30,
2003.
[0041] The foregoing description of preferred embodiments of the
invention has been presented for purposes of illustration and
description. It is not intended to be exhaustive or to limit the
invention to the precise form disclosed. Obvious modifications or
variations are possible in light of the above teachings.
[0042] The embodiments were chosen and described to provide the
best illustration of the principles of the invention and its
practical application to thereby enable one of ordinary skill in
the art to utilize the invention in various embodiments and with
various modifications as are suited to the particular use
contemplated. All such modifications and variations are within the
scope of the invention as determined by the appended claims when
interpreted in accordance with the breadth to which they are
fairly, legally and equitably entitled.
* * * * *