U.S. patent application number 11/427179 was filed with the patent office on 2008-01-03 for facing product for vehicular trim.
Invention is credited to Samuel Keith Black, Quentin Kampf, Sean Morin.
Application Number | 20080003907 11/427179 |
Document ID | / |
Family ID | 38846557 |
Filed Date | 2008-01-03 |
United States Patent
Application |
20080003907 |
Kind Code |
A1 |
Black; Samuel Keith ; et
al. |
January 3, 2008 |
Facing Product for Vehicular Trim
Abstract
A composite facing material is disclosed that may be used in
combination with, e.g. foam, fibers and/or shoddy in a vehicular
application. The composite may provide heat insulation and/or sound
attenuation in a vehicular trim panel. The facing material may
include a layer of staple fibers with a spunbonded continuous
filament web layer. The layers may be intermittently thermally
bonded in a desired pattern.
Inventors: |
Black; Samuel Keith;
(Raleigh, NC) ; Kampf; Quentin; (Mattapoisett,
MA) ; Morin; Sean; (Raymond, NH) |
Correspondence
Address: |
GROSSMAN, TUCKER, PERREAULT & PFLEGER, PLLC
55 SOUTH COMMERICAL STREET
MANCHESTER
NH
03101
US
|
Family ID: |
38846557 |
Appl. No.: |
11/427179 |
Filed: |
June 28, 2006 |
Current U.S.
Class: |
442/327 |
Current CPC
Class: |
Y10T 442/60 20150401;
B32B 5/26 20130101; B60R 13/02 20130101; B32B 2262/14 20130101;
B32B 2605/00 20130101; D04H 3/14 20130101; B32B 7/12 20130101; B32B
7/02 20130101; B32B 2272/00 20130101; B32B 2307/102 20130101; B32B
2262/02 20130101; B32B 5/08 20130101; B32B 2262/06 20130101; B32B
2250/40 20130101; B32B 5/022 20130101; B32B 5/00 20130101; B32B
2262/04 20130101; B32B 7/05 20190101; D04H 1/559 20130101 |
Class at
Publication: |
442/327 |
International
Class: |
D04H 13/00 20060101
D04H013/00 |
Claims
1. An automotive trim panel comprising; a non-woven composite
facing material and one or more backing layers, wherein the facing
material comprises at least one layer of a non-continuous
thermoplastic staple fiber and at least one spunbonded web layer
comprising continuous thermoplastic filaments; wherein bonds
between said layers of said facing material are formed as thermal
bonds with said thermoplastic fibers over at least a portion of
confronting surfaces between said layers, said thermal bonds being
point-bonded.
2. The automotive trim panel of claim 1 wherein said layer of a
non-continuous thermoplastic staple fiber may comprise one or a
plurality of polymers.
3. The automotive trim panel of claim 1 wherein said spun bonded
web layer may comprise one or a plurality of polymers.
4. The automotive trim panel of claim 3 wherein said spun bonded
layer comprises at least two polymers, each of said polymers having
different melting points.
5. The automotive trim panel of claim 1 wherein said layer of
staple fiber comprises at least 15% thermoplastic fiber.
6. The automotive trim panel of claim 1 wherein said composite
facing material has a surface area said thermal bonds being point
bonded to cover about 5-40% of said surface area of the composite
material.
7. The automotive trim panel of claim 1 wherein said composite
facing material has a surface area and said thermal bonds being
point bonded are intermittent over about 5-40% of the surface area
of the composite material.
8. The automotive trim panel of claim 1 comprising two layers of
spun bonded fibers and a layer of staple fibers between said two
layers of spun bonded fibers.
9. The automotive trim panel of claim 1 comprising two layers of
staple fibers and a layer of spun bonded fibers between said two
layers of staple fibers.
10. The automotive trim panel of claim 1 wherein said one or more
backing layers is comprised of one or a combination of a foam,
natural fibers, synthetic fibers, and shoddy.
11. The automotive trim panel of claim 1 wherein said trim panel
comprises a first backing layer, a second layer of non-continuous
thermoplastic staple fibers, and a third outer spunbonded web
layer.
12. The automotive trim panel of claim 1 wherein said panel is
employed as a headliner, a hood liner or engine cover, or a dash
insulator for a vehicle.
13. A non-woven composite facing material, comprising; a layer of
non-continuous, thermoplastic staple fiber having a first melting
point Tm.sub.1, opposed to a layer of spunbonded web comprising
continuous thermoplastic filaments having a second melting point
Tm.sub.2 wherein Tm.sub.1<Tm.sub.2 thermal bonds between said
layers formed from heat softened portions of said thermoplastic
fibers, said thermal bonds being point bonds; and wherein said
staple fiber layer acts as an adhesive layer when the facing
material is combined with one or more backing layers.
14. The facing material of claim 13 wherein said staple fiber
comprises one or a plurality of polymers, at least one of said
polymers having said first melting point Tm.sub.1.
15. The facing material of claim 13 wherein said composite facing
material has a surface area, said thermal bonds being point bonded
to cover about 5-40% of said surface area of the composite
material.
16. The facing material of claim 13 wherein said composite facing
material has a surface area and said thermal bonds being point
bonded are intermittent over about 5-40% of the surface area of the
composite material.
17. The facing material of claim 13 wherein said one or more
backing layers is comprised of one or a combination of a foam,
natural fibers, synthetic fibers, and shoddy.
18. A non-woven composite facing material, comprising; a layer of
non-continuous, thermoplastic staple fiber having a first melting
point Tm.sub.1, opposed to a layer of spunbonded web comprising
continuous thermoplastic filaments having a second melting point
Tm.sub.2 and a third melting point Tm.sub.3 wherein
Tm.sub.1<Tm.sub.2 and/or Tm.sub.1<Tm.sub.3; thermal bonds
between said layers formed from heat softened portions of said
thermoplastic fibers, said thermal bonds being point bonds; and
wherein said staple fiber layer acts as an adhesive layer when the
facing material is combined with one or more backing layers.
19. The non-woven composite facing material of claim 18 wherein
said staple fiber comprises one or a plurality of polymers, at
least one of said polymers having said first melting point
Tm.sub.1.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to a laminate for
use as a facing product on automotive trim components, and more
particularly, to a facing product for vehicular components, such as
headliners, hood liners and dash insulators.
BACKGROUND OF THE INVENTION
[0002] Non-woven sheets made of synthetic fibers have been used as
substrates in a variety of applications, e.g., carpets, tiles, wall
coverings, coatings, etc. Non-woven fabric laminates such as
spun-bonded/melt-blown/spun-bonded (SMS) laminates are useful,
e.g., for towels, industrial garments, medical garments and drapes,
sterile wraps, diapers, etc. Non-woven sheets may be manufactured
by a dry or wet process, or by extrusion of a molten mass in the
form of filaments (i.e., a spun-bonded sheet).
[0003] Generally, these articles require high dimensional stability
and the ability to withstand, especially during manufacture,
simultaneous mechanical and thermal stresses. Such stresses may
result in risks of distortion during aging of the laid article,
e.g., lengthwise elongation, transverse shrinkage, and inverse
distortions, due to "elastic recovery".
[0004] A spun-bonded web layer may be made from continuous,
randomly deposited filaments of synthetic polymers. Such webs may
not in themselves possess textile-like or drapability qualities,
but may be thin, paper-like layers with an open, uneven fleece
appearance. These webs may possess good tensile and tear strength
and have dimensional stability.
[0005] In contrast, a firmly bonded drylaid non-woven, i.e., made
from short staple fibers, may have poor dimensional stability and
poor tensile and tear strength. However, such non-woven product may
provide drapability and textile quality.
SUMMARY OF THE INVENTION
[0006] In a first exemplary embodiment the present invention
relates to an automotive trim panel comprising a non-woven
composite facing material and one or more backing layers. The
facing material may comprise at least one layer of a non-continuous
thermoplastic staple fiber and at least one spun bonded web layer
comprising continuous thermoplastic filaments. Bonds between the
layers of the facing material may be formed as thermal bonds with
the thermoplastic fibers over at least a portion of confronting
surfaces between the layers, the thermal bonds being
point-bonded.
[0007] In a second exemplary embodiment the present invention
relates to a non-woven composite facing material comprising a layer
of non-continuous, thermoplastic staple fiber having a first
melting point Tm.sub.1 and an opposed to a layer of spun bonded web
comprising continuous thermoplastic filaments having a second
melting point Tm.sub.2 wherein Tm.sub.1<Tm.sub.2. The facing
material may further include thermal bonds between the layers
formed from heat softened portions of the thermoplastic fibers, the
thermal bonds being point bonds wherein the staple fiber layer may
act as an adhesive layer when the facing material is combined with
one or more backing layers.
[0008] In a third exemplary embodiment the present invention
relates to a non-woven composite facing material comprising a layer
of non-continuous, thermoplastic staple fiber having a first
melting point Tm.sub.1, opposed to a layer of spun bonded web
comprising continuous thermoplastic filaments having a second
melting point Tm.sub.2 and a third melting point Tm.sub.3 wherein
Tm.sub.1<Tm.sub.2 and/or Tm.sub.1<Tm.sub.3. Thermal bonds
between the layers may be formed from heat softened portions of the
thermoplastic fibers, the thermal bonds being point bonds wherein
the staple fiber layer may act as an adhesive layer when the facing
material is combined with one or more backing layers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] These and other objects, features and advantages of the
present invention will become apparent to those skilled in the art
upon reference to the following written description and
accompanying drawings in which:
[0010] FIG. 1 is a schematic drawing of a composite facing material
having a staple fiber layer and a spun-bonded non-woven web
layer.
[0011] FIG. 2 is a schematic drawing of a composite facing material
having a staple fiber layer sandwiched between two spun-bonded
non-woven web layers.
[0012] FIG. 3 is a schematic drawing of a composite facing material
having a spun-bonded non-woven web layer sandwiched between two
staple fiber layers.
[0013] FIG. 4 is a schematic drawing of the external surface of one
side of a composite facing material of the invention, in which the
material is point-bonded continuously over approximately 10% of its
surface area.
[0014] FIG. 5 is a schematic drawing of the external surface of one
side of a composite facing material of the invention, in which the
material is bonded intermittently over approximately 20% of its
surface area.
[0015] FIG. 6 is a schematic drawing of a section of an automotive
trim panel illustrating a composite facing material attached to a
backing layer for use as a headliner, hoodliner or dash
insulator.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The present invention is described more fully hereinafter
with reference to the accompanying drawings, in which preferred
embodiments of the invention are shown. This invention, may,
however, be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein; rather,
these embodiments are provided so that this disclosure will be
thorough and complete, and will fully convey the scope of the
invention to those skilled in the art.
[0017] The invention relates in one exemplary embodiment to
composite fabric-like materials suitable for use as a facing layer
for automotive trim components, particularly panels which may
require sound attenuating or heat insulating properties. Thus, the
facing layer may feature a non-woven composite material which may
include a layer of staple fiber and a spunbonded web layer, the
latter comprising continuous filament thermoplastic fibers forming
at least a portion of the layer. The layers may be thermally bonded
over at least a portion of their confronting surface area.
[0018] The staple fiber layer and the spunbonded web layer may be
opposed surface-to-surface and point-bonded in any desired pattern
and may be continuous over the entire surface area. In addition,
the opposed layers may be intermittently bonded over 5-40% of the
surface area of the composite material. As used herein,
"continuous" thermally bonded over a portion of confronting surface
layers' refers to heat bonding of layers both along the width and
length of the surface area of the material comprising the layers
(as opposed to bonding only at the edges of the layers), and
substantially evenly over that area; "point"-bonded refers to
bonding of the layers at discrete points which may optionally
include a desired pattern of point bonding; "intermittently" bonded
refers to a bonding pattern in which the layers are bonded within
discrete areas over the entire surface area of the material.
Continuous or intermittent bonding, according to the invention, may
therefore occur across the width and along the length of the
material, rather than simply at the edges, and confer integrity to
the composite material along its length and width.
[0019] The term "fiber", as used herein, may be taken to mean a
unit of matter characterized by having a length of at least two
orders of magnitudes greater than its diameter or width and which
can be formed into a fabric web.
[0020] Various methods of making the non-woven composite facing
material are described in U.S. Pat. No. 5,653,041, which is
assigned to the assignee of the present invention and included
herein by reference in its entirety. One procedure may include the
steps of: (a) positioning a layer of staple fiber and a layer of
spunbonded continuous filament web in surface-to-surface alignment;
and (b) bonding the layers together by applying heat and pressure
substantially evenly or at selected points over the entire surface
area. "Substantially evenly" refers to the application of heat and
pressure across the width and along the length of the aligned
layers.
[0021] Another method of making the non-woven composite facing
material may include the steps of: (a) positioning a layer of
staple fiber and a layer of spunbonded continuous filament web in a
surface-to-surface alignment, wherein the layer of spunbonded web
includes a filament of a thermoplastic polymer having a melt point
which facilitates bonding of the layers; and (b) bonding the layers
by applying heat continuously over the surface area of one layer
together with pressure, wherein the heat is high enough to induce
softening of the thermoplastic polymer.
[0022] "Non-woven spunbonded web" refers to a web of material which
has been formed without the use of a weaving process and which has
a construction of individual fibers, filaments or threads which are
substantially continuous and randomly disposed. "Substantially
continuous" fibers means that a majority of polymeric filaments of
a web are unbroken or uncut fibers. "Staple" fibers are
non-continuous, i.e., cut filament fibers. A "staple fiber batt" or
"layer" refers to a batt or layer of staple fibers of uniform
weight held together by fiber to fiber cohesion and having limited
dimensional stability. "Bonding" of a fiber or filament refers to
the attachment of a polymer fiber or filament upon reaching at or
near its melt point (Tm) to another fiber.
[0023] Non-woven composite facing materials of the invention may be
useful in manufactured goods such as automotive trim components
when combined with layers of fiberglass, foam, shoddy or other
materials to form sound attenuating or heat insulating panels.
Laminates so formed may be used as headliners, hood liners and dash
insulators. The facing material may further be treated to provide
fire retardancy and/or repel water. The facing materials of the
present invention may provide improved moldability and drapability
due to their isotropic nature. They may further provide improved
coverage (hiding) as well as reduced weight and reduced cost.
[0024] Accordingly, one aspect of the invention relates to the
manufacture of non-woven facing materials that may exhibit
isotropic tensile and tear strength as well as drapability and/or a
textile-like appearance for use as a facing layer in automotive
trim panel applications. By isotropic tensile strength it is meant
that the tensile strength of the facing material in either a
horizontal (width) or vertical (length) direction is within .+-.10%
of either value, including all values and increments therein. For
example, if the tensile strength in the vertical direction is 7500
psi, the tensile strength in the horizontal direction may also be
between about 6750 psi to 8250 psi. Similarly, the tear strength,
which may be measured, e.g., according to the Elmendorf ASTM D-1922
test, may also be evaluated in a horizontal (TH) and vertical
direction (TV) and may be reported in grams. According, the value
of TH/TV will have no units and may have a value between 0.9-1.1.
Materials of the invention may include composites of one or more
layers of spunbonded web made from continuous and randomly
deposited fibers of thermoplastic polymers and one or more layers
of carded polymeric staple fibers. Spunbonded fabrics and fabrics
using staple fibers are discussed in "Encyclopedia of Textiles,
Fibers and Non-woven Fabrics", Ed. M. Grayson, John Wiley and Sons,
NY, 1984, pages 252-304, hereby incorporated by reference.
[0025] As used herein, "thermoplastic polymer" refers to polymers
which are capable of melting or softening (e.g. passing through a
Tg) and therefore becoming suitable for molding or shaping when
subject to heat. One or a plurality of different thermoplastic
polymers may be employed in either or both of the spunbonded web
layer and/or the staple fiber layer of the composite material of
the invention. These polymers may form filaments which may be used
in combination with other filaments which have different melt
points, particularly in the spunbonded web layer. Thus, in some
embodiments of the invention, the thermoplastic fibers of the
layers may be composed solely of one type of thermoplastic, whereas
in other embodiments, they may be composed of mixtures of two or
more types of thermoplastic polymers. See, for example, the webs
described in U.S. Pat. No. 4,906,507, hereby incorporated by
reference. In the spunbonded web, these polymers may form
continuous filaments, whereas in the staple fiber layer,
non-continuous fibers may be used. Thermoplastic polymers of the
invention include, but are not limited to polyesters or polyamides,
polyamides based upon nylon-6, 66, and 12, polypropylene,
polyethylene, polybutane, polymethylpentene, ethylenepropylene
copolymers, polystyrene, thermoplastic elastomers such as
polyurethanes, or thermoplastic polymers such as
polytrifluorochloroethylene or mixtures thereof, as well as
mixtures of these thermoplastic polymers and/or co-polymers. In
addition, the polymers may include ethylene vinyl acetate polymers,
synthetic polymers comprising 40% or more of polyurethane,
polyetheresters, polyetherurethane, polyamide elastomeric
materials, and polyester elastomer materials, polyester and
polyurethane elastomeric materials. For example, polyethylene
terephthalate (PET) alone or in combination with polybutylene
terephthalate (PBT) may be used as a polyester-based filament, the
polymers being spun together in the form of a twin component or
spun separately and arranged side-by-side or coaxially.
[0026] Any of the fiber-forming thermoplastic polymers including
fiber forming hot melt adhesives, and viscoelastic hot melt
adhesives may also be used in the spunbonded web as a bonding
agent. The invention is not limited to the above polymers, for any
polymer, co-polymer or mixture (with the same or different melting
or softening points) capable of forming a heat-sensitive plastic
filament or fiber is suitable in the invention. The softening
points of a fiber made from any of the above polymers will be known
to those of skill in the art and, if not known, may be readily
determined according to conventional means.
[0027] Thermoplastic fibers useful in the invention may have a
melting point or softening point (e.g. Tg) of at least about 120
degrees C. The upper limits and preferred ranges will depend on
practical consideration of the intended uses and processes of
manufacture. The invention is not limited to the use of any
particular fiber, but takes advantage of many properties of
different fibers. For example, the spunbonded web layer may be
composed of one, two or more of these thermoplastic polymers and
comprises not only a thermoplastic component, but also may include
other type of fibers, e.g., natural or manmade fibers, including
textile threads or yarns composed of cotton, rayon, hemp, etc.
Where the spunbonded layer comprises different melt point polymers,
the fiber polymer having the lower melt point may act as the
bonding agent upon heat bonding of not only the spunbonded web
structure, but also of the composite structure.
[0028] Forming spunbonded material may be accomplished via
conventional methods. Any method for forming a non-woven web having
continuous fibers of a polymer is encompassed for use in the
invention. For example, the spunbonded web may be made by extrusion
of a molten mass in the form of filaments, Thus, the non-woven
spunbonded web 14 may be prepared in conventional fashion as
described, e.g., in Dorschner et al., U.S. Pat. No. 3,692,618;
Kinney, U.S. Pat. Nos. 3,338,992 and 3,3411,394; Levy, U.S. Pat.
No. 3,502,538; Hartmann, U.S. Pat. Nos. 3,502,763 and 3,909,009;
Dobo et al., U.S. Pat. No. 3,542,615; and Appel et al., U.S. Pat.
No. 4,340,563; the disclosures of which are hereby incorporated by
reference.
[0029] Non-woven spunbonded webs made from continuous fibers may
generally be made from a polymer which is continuously extruded
through a spinnerette in discrete fibers. The fibers may be drawn
mechanically or pneumatically without breaking in order to orient
the polymer fibers. The continuous fibers may then be deposited in
a substantially random manner onto a carrier belt to form a web.
The continuous fiber layer generally may a thickness in the range
of about 0.01 to about 1 mm, including all values and increments
therein. A non-woven fleece-like web may be characterized by an
extreme entanglement of the fibers, which provides coherency and
strength to a web and also confers on the web increased dimensional
strength. As the aspect ratio (ratio of length to diameter) of the
fibers of the web approaches infinity, i.e., the fibers may be
considered essentially continuous. The fibers may be relatively
long and entangled sufficiently such that it is generally
impossible to remove one complete fiber from the mass of fibers or
to trace one fiber from beginning to end.
[0030] The polymeric staple fiber layer or layers, which may
provide softness, absorbency, and/or drapability, may be made from
one or a plurality of fibers sourced from different polymers.
Staple fiber herein may be understood as a fiber that is not
continuous within the layer. Such fibers may include fibers that
have therefore been cut to a desired length. The fiber composition
of the staple fiber layer may contain at least 15%, preferably 20%,
25%, or 30%, up to 100% thermoplastic fibers, including all values
and increments therein. The preferred fiber blend for the layer or
layers of staple fiber may act as a bonding agent for the staple
fiber layer and also contribute to the bonding to the adjacent
fiber layers. The layer of staple fiber may be formed by any
conventional method, including air-laying, carding, garneting, or
similar batt-forming techniques. The fiber length of the staple
fiber may range from about 1.0 inches to about 4.5 inches,
including all values and increments therein. The denier may be
between about 0.7 and about 50, including all values and increments
therein. Preferably, the denier may be between about 1 and about 6
denier. The staple fiber layer may be in the weight range of about
5 to about 100 gm/sq. meter.
[0031] The bonding method for bonding the composite facing material
is preferably thermal-bonding. The bonding may be preferably done
with calendar rolls, one or both of which may be heated and one or
both of which may be embossed, which may allow discrete point or
area bonding across the surface area of at least one of the layers
to thereby bond two layers together. That is, if one calendar roll
is heated and embossed, the aligned spunbonded continuous-filament
layer and staple fiber layer are passed between two calendar rolls
and the layer closest to the heated and embossed calendar roll may
become bonded to the remaining layer(s). Preferably, both rollers
may be heated. While non-woven materials of the invention are not
limited to a particular bonding pattern, the ability of the polymer
fibers to bond at the discrete bonding points or areas may be
significant to formation of a composite structure having high
tensile and tear strength. Bonding according to the invention may
occur both across the width and along the length of the composite
material, and thus may strengthen the composite material over all
of its surface area. Point or area bonding may serve to hold the
layers of the composite together across their surfaces as well as
to provide integrity to each individual layer by bonding fibers
within each layer.
[0032] Thermal bonding for thermoplastic polymers may be achieved
by heating the rollers sufficiently in conjunction with pressure to
bond with melting. The corresponding temperature to which the
calendar roll may be heated in order to achieve the desired
temperature may be approximately the same, or slightly above, the
desired softening point temperature. Pressure may be exerted on the
layers as they are passed between the two calendar rolls, which may
cause the layers to bond and may be a function of the area bonded
between rollers.
[0033] A typical embossing or bonding pattern may have round or
square pin bonding points wherein each embossing pin has a side
dimension of, e.g., 0.010-0.050 inch, including all values and
increments therein. The pin may have a spacing between pins of
e.g., 0.010-0.100 inch, and a depth of bonding of, e.g.,
0.015-0.070 inch, including all values and increments therein. The
resulting pattern may have a bonded area of, e.g., between 10 and
40%, including all values and increments therein. The spunbonded
web or webs and the layer or layers of the staple fiber web may be
bonded together by positioning them in a surface-to-surface
alignment and melting or softening one or more components within
the structure which may be achieved by a combination of heat and
pressure. The heat and pressure may be applied over the total
surface area of the composite material. Preferably, the heat and
pressure may be applied in a well-defined intermittent point
pattern which may expose between five and forty or fifty percent of
the surface area of the composite structure, including all values
and increments therein.
[0034] The heat and pressure applied to the composite structure may
be high enough to induce softening of at least one of the
thermoplastic polymer components. Heat and pressure bonding of the
continuous, randomly deposited fibers of thermoplastic polymer into
the composite structure may confer isotropic tensile and tear
strength. The resultant composite material may be subjected to
relatively high stress and strain.
[0035] FIGS. 1-3 illustrate preferred composite facing materials of
the invention. For example, in FIG. 1 the composite facing material
10 comprises a single layer of staple fiber 16 and a single layer
of spunbonded web 14. The layers may be surface to surface and
point-bonded in discrete areas 24' of the material. In FIG. 2, the
composite facing material 10' includes a staple fiber layer 16
sandwiched between two spunbonded web layers 14, 14'. This material
may also be point-bonded in discrete areas 24, 24'. In FIG. 3, the
composite facing material 10'' includes a layer of spunbonded web
14 sandwiched between two layers of staple fiber 16, 16' and
point-bonded in discrete areas 24''.
[0036] FIG. 4 is a schematic drawing of the external surface of one
side of a composite facing material 10 of the invention, in which
the material is point-bonded continuously over approximately 10% of
its surface area. FIG. 5 is a schematic drawing of the external
surface of one side of a composite facing material 10 of the
invention, in which the material is bonded intermittently over
approximately 20% of its surface area.
[0037] FIG. 6 is a cross-sectional view of the exemplary facing
material 10 of the present invention in combination with one or
more layers 20 of backing materials which may form a trim panel 22
for a vehicle application. Preferably, the panel may find use in
applications where heat resistance, sound attenuation, water
resistance and/or heat insulation are important, such as
headliners, hood liners (engine covers) and dash insulators.
[0038] One important selling point for vehicles today is reduced
noise, both from external and internal sources. The present
invention may therefore serve to reduce external and/or internal
noise. External noise may include noise from the engine, the
transmission, the road, vibrations, etc. Internal noise may emanate
from the passenger compartment, such as radio noise, etc.
Automotive trim panels such as headliners, dash insulators and hood
liners (also known as engine covers) may therefore be prepared
according to the present invention. The present invention as a
facing layer may therefore be used to provide coverage (hiding of
backing layers) and/or to encapsulate loose materials and to assist
in forming the product to shape.
[0039] Dash insulators, in particular, also are designed to reduce
the transfer of engine heat into the passenger compartment. The
present invention when used as a facing material over other
materials is also contemplated for use to regulate heat transfer
from the engine compartment to the passenger compartment.
[0040] One particular application for the present invention is a
vehicle headliner which may separate the passenger compartment from
the sheet metal forming the roof of the vehicle. While providing an
aesthetically pleasing finish, as alluded to above, the headliner
of the present invention may be designed to attenuate sounds from
within the passenger compartment as well as sounds originating
outside the passenger compartment. By attenuate it is meant to
absorb, reduce the transmission, insulate or serve as a barrier to
sound. Headliners have been made with impregnated fiberglass
batting, with synthetic fibers, with foam layers and with
combinations thereof. Because of their complex shape, headliners
are generally molded or formed to shape. A facing layer 10 for
headliners according to the present invention may then preferably
have good moldability and drapability properties in order to
conform to the desired molded shape. In addition, low weight and
low cost may be important factors when selecting a facing material.
The facing materials of the present invention have properties
making them uniquely suitable for use as facing materials for
headliners.
[0041] With attention again directed to FIG. 6, a headliner 22 may
comprise the facing layer 10 of the present invention backed by one
or more layers 20 of one or a combination of foam, fibers or
shoddy. For headliners comprising fiberglass batting, the facing
materials of the present invention may be used on both sides of the
batt and essentially encapsulate the fiberglass, controlling
dispersion into the atmosphere.
[0042] Dash insulators are often mounted to a vehicle firewall
which may separate the passenger compartment from the engine
compartment. They may be designed to reduce the intrusion of heat
and noise from the engine compartment, vehicle transmission, etc.
into the passenger compartment. Dash insulators generally comprise
an open-cell polyurethane foam layer, a felt layer or a resinated
fiber pad and a barrier sheet of heavily filled thermoplastic
material. The barrier sheet may comprise EVA (ethylene vinyl
acetate) or PVC (polyvinyl chloride) and a high mass filler such as
glass, calcium carbonate or barium sulfate. A porous (foam or
fiber) decoupler layer may also be included. In FIG. 6, 22
therefore may also identify a dash insulator and may comprise the
facing layer 10 of the present invention backed once again by one
or more layers 20 of one or a combination of foam, fibers, barrier
sheet or shoddy. Where shoddy may be employed as the backing layer,
the facing materials of the present invention may provide coverage
(hiding) of the somewhat varied and bright color of the shoddy,
making the insulator more attractive.
[0043] As noted above, hood liners or engine covers are generally
attached to the underside of a vehicle hood to reduce the
transmission of noise and heat from the engine. One or more layers
of heat and sound insulative materials are generally covered by an
outer facing layer. Hood liners have the added requirement of
functioning under extreme environmental conditions, including
temperatures of approximately 150.degree. C. for extended periods
of time, as well as exposure to water, oil, steam, etc. Facing
materials may provide a pleasing appearance and withstand the
environmental conditions. In FIG. 6, item 22 may also represent a
hood liner or engine cover that may again comprise the facing layer
10 of the present invention backed by one or more layers 20 of one
or a combination of foam, fibers or shoddy. The outer facing layer
10 may be preferred to also package the layers and to again provide
an attractive outer surface. In one embodiment, a facing layer may
be provided on both sides of the combined layers of insulative
materials to encapsulate them and improve handling. Encapsulating
sound attenuating fibrous materials such as glass fibers, synthetic
fibers, resinated cotton or shoddy provides a cleaner workplace and
neater product. In addition, the facing material of the present
invention may be rendered water repellent, to act as a water
barrier, and flame retardant. This may be accomplished by treating
the fibers/filaments before or after formation of the facing
material 10.
[0044] While three different laminate constructions for use as
facing layers are described in FIGS. 1-3, a particularly preferred
construction comprises a layer of spunbonded web pointbonded to a
layer of staple fibers having a first melting point (Tm.sub.1) or
combination of melting points (in the case of a plurality of
different polymers) that are less than the melting point of the
spunbonded web layer, which may be characterized as having a second
melting point Tm.sub.2. Thus, the melting point of the staple fiber
layer Tm.sub.1 is less than the second melting point Tm.sub.2. When
combined with any of the aforementioned backing layers for use as
an automotive trim component, the staple fiber layer may be placed
in contact with the backing layer and therefore act as an adhesive
layer when the component is formed, as the outer continuous layer
would not experience melting. This may then eliminate the need for
a separate adhesive layer in the construction of the component.
[0045] In addition, it should be appreciated that the facing layer
may also include a layer of non-continuous, thermoplastic staple
fiber having a first melting point Tm.sub.1, opposed to a layer of
spunbonded web comprising continuous thermoplastic filaments having
a second melting point Tm.sub.2 and a third melting point Tm.sub.3
wherein Tm.sub.1<Tm.sub.2 and/or Tm.sub.1<Tm.sub.3.
[0046] The weight of the layers which may comprise the laminate
facing material of the present invention may vary depending on the
application and specific properties desired (coverage, cost,
weight, etc.). The spunbonded web layer may range from about 5 to
about 50 grams/sq. meter, and the staple fiber layer form about 5
to about 100 grams/sq. meter, including all values and increments
therein in connection with such properties. As a facing material
for fiberglass, it has been found that facing materials of the
present invention may be useful when of a range of about 20 to
about 35 grams/sq. meter, including all values and increments
therein. To provide hiding of an underlying distracting color, it
has been found that facing materials of the present invention may
be useful when of a range of about 65 to about 130 grams/sq. meter,
including all values and increments therein.
[0047] A unique facing material for encapsulating one or both sides
of a heat or sound insulative composite therefore may be provided
by the present invention. The facing material may provide
advantages in moldability, coverage, cost and weight. In addition,
the present invention may provide a fabric-like composite material
that may include isotropic tensile and tear strength. The invention
may also provide a tear-resistant fabric-like material which may
provide drapability and textile-like surface properties. The
present invention may also provide a fabric-like composite material
that may be useful as a facing product for automotive trim
components, particularly panels that may find use as sound
attenuators or heat insulators when the composite is combined with
one or more layers of another material, such as fiberglass, shoddy,
foam, etc.
[0048] The description and drawings illustratively set forth the
presently preferred invention embodiment. We intend the description
and drawings to describe this embodiment and not to limit the scope
of the invention. Obviously, it is possible to modify these
embodiments while remaining within the scope of the following
claims. Therefore, within the scope of the claims one may practice
the invention otherwise than as the description and drawings
specifically show and describe.
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