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WO2010144798A2 - Articles d'insonorisation acoustiquement accordables et leurs procédés de fabrication - Google Patents

Articles d'insonorisation acoustiquement accordables et leurs procédés de fabrication Download PDF

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Publication number
WO2010144798A2
WO2010144798A2 PCT/US2010/038311 US2010038311W WO2010144798A2 WO 2010144798 A2 WO2010144798 A2 WO 2010144798A2 US 2010038311 W US2010038311 W US 2010038311W WO 2010144798 A2 WO2010144798 A2 WO 2010144798A2
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WO
WIPO (PCT)
Prior art keywords
facing
sound absorption
air flow
flow resistance
cellulosic fibers
Prior art date
Application number
PCT/US2010/038311
Other languages
English (en)
Other versions
WO2010144798A3 (fr
Inventor
Richard James Bliton
Samuel Mark Gillette
Troy Raymond Buechler
Original Assignee
Precision Fabrics Group, Inc.
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Filing date
Publication date
Application filed by Precision Fabrics Group, Inc. filed Critical Precision Fabrics Group, Inc.
Publication of WO2010144798A2 publication Critical patent/WO2010144798A2/fr
Publication of WO2010144798A3 publication Critical patent/WO2010144798A3/fr

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B1/86—Sound-absorbing elements slab-shaped
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/425—Cellulose series
    • D04H1/4258—Regenerated cellulose series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4282—Addition polymers
    • D04H1/4291—Olefin series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/4334—Polyamides
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/435—Polyesters
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/49—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation entanglement by fluid jet in combination with another consolidation means
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B1/8409—Sound-absorbing elements sheet-shaped
    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
    • G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/162—Selection of materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/18—Cellulose, modified cellulose or cellulose derivatives, e.g. viscose
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/08—Insulating elements, e.g. for sound insulation
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B2001/742—Use of special materials; Materials having special structures or shape
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B2001/742—Use of special materials; Materials having special structures or shape
    • E04B2001/745—Vegetal products, e.g. plant stems, barks

Definitions

  • the present invention relates to a sound absorption material, and particularly to the use of sound absorption materials in acoustic applications such as vehicles, appliances, and buildings.
  • environments such as buildings, vehicles, i.e., equipment, etc.
  • the external noises namely road noise, wind noise, engine noise, vibrations as well as internal noises through the use of various acoustic materials.
  • scrim layers are often used over thick low density spacer materials and voids located in floor panels, headliners and door panels of a vehicle.
  • perforated films as described in U.S. Patent No. 4,097,633. It is believed, however, that various production and quality issues are problematic in this approach.
  • Microfiber scrims have also been proposed and used in a multilayer acoustically tuned sound absorbing composite such as described in U.S. Patent No. 6,631,785.
  • Other examples of various scrim layers include U.S. Patent Nos. 5,186,996; 5,298,694; 5,886,306; 6,145,617; 7,310,739; and U.S. Patent Application Publication No. 2007/051800.
  • an acoustically tunable sound absorption facing comprises cellulosic fibers entangled together, for example, via spunlacing. Such a sound absorption facing has controllable air flow resistance. The air flow resistance translates into acoustic performance measured in Rayls. A Rayl is one of two units of acoustic impedance.
  • the sound impedance is the ratio between the sound pressure and the particle velocity it produces.
  • the impedance is one Rayl if unit pressure produces unit velocity.
  • MKS units 1 Rayl equals 1 pascal-second per meter (Pa-s-m-1), or equivalently 1 newton-second per cubic meter (N-s-m-3).
  • SI base units that's kg-s-1 -m-2.
  • CGS units 1 Rayl equals 1 dyne-second per cubic centimeter (dyn-s-cm-3).
  • I CGS rayl 10 MKS Rayls.
  • a facing may be acoustically tuned to have air flow resistance in the range of about 245 rayls to about 2450 rayls. More preferably a facing may be tuned to have air flow resistance from about 400 rayls to about 1650 rayls, and more preferably, the facing may be tuned to have air flow resistance from about 800 rayls to about 1200 rayls.
  • an acoustically tunable sound absorption facing having controllable air flow resistance comprises cellulosic fibers and a nonwoven fiber batt entangled together.
  • the cellulosic fibers comprise between about 20 to 60 percent by weight of the sound absorption facing and the nonwoven batt comprises about 40 to 80 percent by weight of the facing.
  • the cellulosic fibers are in the form of a web or sheet.
  • the sound absorption facing has a basis weight of at least about 0.7 osy.
  • the sound absorption facing includes a flame retardant.
  • An acoustically tunable sound absorption facing can be used in combination with one or more other layers or substrates to provide a sound attenuating laminate. Such a laminate can be used in a wide variety of environments including, but not limited to, vehicles. Additionally, a facing may be treated with finishes or coatings to impart color, flame resistance, resistance to oils and greases, water repellency, anti-mold and mildew, corrosion resistance, and antimicrobial properties. [0011] An acoustically tunable sound absorption facing, according to embodiments of the present invention, may also be coated, printed, sintered, sprayed, or otherwise treated with an adhesive layer to enable bonding and molding of subsequent parts. These bonded and molded panels are typically comprised of a sound absorption facing, according to embodiments of the present invention, and a bulky, low density sound absorbing insulating panel.
  • an acoustically tunable sound absorption facing may be treated or fashioned in such a way to allow high levels of stretch when molded. This may be done by the incorporation of soft or elastomeric binders, soft or elastomeric fibers or a combination of such.
  • An acoustically tunable sound absorption facing can be used in combination with one or more other layers or substrates to provide a sound attenuating laminate.
  • This laminate comprises a layer of the surface facing fabric of the invention laminated to a thick low density material, comprised of materials such as fiberglass batting, resinated fiberglass panels, rock wool, plastic foam, urethane foam, shoddy pad from waste fiber, polyester batting or resinated fiberflll, aerogel, closed cell foam, reticulated foam and other insulation materials known to the art.
  • the addition of the facing fabric significantly improves the sound attenuation properties of the base absorber material, allowing for improved performance, and reduced weight.
  • the facing fabric may also be positioned on the top and bottom of the low density insulator to form a sandwich-type trilaminate.
  • Such a laminate can be used in a wide variety of environments including vehicles, appliances, buildings, homes, and office furniture (i.e. office partitions), aircraft, commercial buildings, trains and motor coaches, theaters, audio studios, home audio or theater rooms, sound insulation for noisy equipment and machines, or other applications where sound attenuation is desired.
  • office furniture i.e. office partitions
  • aircraft commercial buildings, trains and motor coaches, theaters, audio studios, home audio or theater rooms, sound insulation for noisy equipment and machines, or other applications where sound attenuation is desired.
  • Figure 1 is the measured influence of various developmental facings measured in the impedance tube.
  • Figure 2 is a predicted normal incidence sound absorption graph using ESI
  • Figure 3 is a predicted alpha cabin sound absorption graph using ESI modeling software.
  • an acoustically tunable sound absorption facing is provided by a cellulosic web or sheet and a nonwoven web entangled together.
  • the cellulosic web or sheet consists of a wet-laid or paper like sheet of cellulosic fiber. While wood fiber is preferred, other types of cellulosic fiber that can be wet-laid into a paper sheet could be used as the precursor cellulosic web. Additionally, minor amounts, not to exceed 49% of the cellulosic web could be comprised of synthetic fibers.
  • Useful cellulosic fibers include wood fibers (pulp) such as bleached Kraft, softwood or hardwood, high-yield wood fibers, cotton, viscose, and other fibers suitable for making into a paper sheet.
  • wood fibers such as bleached Kraft, softwood or hardwood, high-yield wood fibers, cotton, viscose, and other fibers suitable for making into a paper sheet.
  • Other natural fibers include bagesse, milkweed, wheat straw, kenaf, jute, hemp, bamboo, cotton, and these natural fibers may be blended with the cellulosic fibers.
  • Synthetic fibers that are prepared in very short fiber length may be formed into a wet-laid paper sheet. These fibers may be polyester, nylon, olefin, cellulose acetate, silk, wool, and other fibers known to the art.
  • the nonwoven web portion may contain randomly oriented fibers or substantially aligned fibers.
  • Exemplary fibers include, but are not limited to, polypropylene, polyethylene, polyethylene terephthalate, polyester, acetate, nylon, polylactic acid (PLA), glass, viscose and acrylic fibers, and blends thereof.
  • performance fibers such as Nomex or Kevlar (DuPont), Kermel (Rhone Poulenc), polybenzimidazole (PBI - Hoechst), Basofil (BASF), polyetheretherketone (PEEK - Zyex Ltd.), Visil (Kuitu Finland Oy), Ultem, Lexan or Valox (GE Plastics) fibers may be used.
  • the staple fiber batt may be made using 1.5 denier 1.5 inch long polyester drawn and crimped fibers which are known to spunlace well.
  • other length and denier fibers including microfiber and splittable staple fibers may also be used for the nonwoven portion of the sound absorption facing.
  • the basis weight for the facing fabric before finishing is from about 0.7 to about 5.0 ounces per square yard (osy).
  • the facing comprises 20-60 percent by weight cellulosic fibers by weight and 40-80 percent by weight other fibers.
  • the sound absorption facing can be further modified by finishing and/or calendaring. Stretching, bulking, drawing, drying and curing of the facing are additional steps that generally occur during the finishing or coating process. These processes are to modify and adjust the permeability and sound attenuating properties of the sound absorption facing so as to tune the sound attenuation properties.
  • the use of the scrim fabric of the invention on the face of a bulky and heavy sound absorber panel allows reduction in the weight and bulk, without a loss of performance.
  • the chemical finishing of the facing comprises application of chemistry that will form film structure or fill in the structure of the facing thereby reducing the air permeability, and increasing the sound attenuation properties of the product.
  • Emulsion and solution binders, adhesives, polymer dispersions, and thickeners may be used to reduce the permeability of the sheet.
  • the binder solutions may have added filler materials such as clay, talc, glass beads, ceramic beads and particles, graphite, calcium carbonate, barium sulfate, vermiculite, hydrated alumina, titanium dioxide, expandable fillers, expandable microspheres, swellable fillers, and other particulate filler materials to assist in decreasing the permeability of the sheet.
  • filler materials such as clay, talc, glass beads, ceramic beads and particles, graphite, calcium carbonate, barium sulfate, vermiculite, hydrated alumina, titanium dioxide, expandable fillers, expandable microspheres, swellable fillers, and other particulate filler materials to assist in decreasing the permeability of the sheet.
  • Auxiliary chemicals such as corrosion inhibitors, flame retardants, oil and water repellents, pigments and colors, antimicrobial agents, and adhesive promoters may be added to enhance the properties of the sheet for a particular end use. For example, an acoustic panel for use in an automobile
  • flame retardants may also be useful for finishing the sound absorption facing in order to impart flame retardant properties, low smoke generation and heat resistant properties and to increase the density or modify the air flow resistance of the facing. Flame retardants which are useful for this invention include durable, semi-durable and nondurable flame retardants, organic and inorganic flame retardants and combinations thereof.
  • alumina trihydrate ammonium polyphosphate
  • compounds containing alkali and alkaline earth metals borates, ammonium salts, nitrogen containing compounds, phosphates, phosphonates, halogens and sulfamates are useful for finishing and coating the facing.
  • Other types of flame retardants which are of utility in this application include intumescent systems, vapor phase flame retardants and systems, endothermic flame retardants and combinations thereof. The list of possible flame retardants for this application is vast and will be obvious to those skilled in the art of finishing and coating fabrics.
  • Any water based emulsion or dispersion commonly known as a binder or latex may also be used to modify the air flow resistance of the sound absorption facing and to impart additional functional properties to the facing.
  • Acrylic binders, vinyl acrylic binders, vinyl acetate binders, styrene containing binders, butyl containing binders, starch binders, polyurethane binders, and polyvinylalcohol containing binders are examples of binders that find utility in coating and finishing the facing.
  • the binders may be film forming so as to reduce the air flow resistance of the sound absorption facing.
  • the binders may also be loaded with a filler so as to reduce the air flow resistance of the sound absorption facing.
  • the binders may be salt tolerant so that they can be used in conjunction with ionic flame retardants.
  • the use of thermoplastic binders can provide adhesive properties to the sound absorption facing if the binder is on the surface of the facing and the facing is subsequently reheated to bond to another surface. Binders may also be thermoset to limit the degree of crushing during the calendaring process, thereby allowing for a controllable and small reduction in air flow resistance.
  • thermoplastic binders may be utilized to cause a large reduction in air flow resistance during the calendaring process.
  • Other properties that the binder may impart include, but are not limited to, improved crock resistance, increased grab tensile and greater tear strength. Selected binders may be applied to the sound absorption facing to modify its stiffness and flexibility and to cause the facing to retain its shape if it is post molded or "B staged.”
  • the concentration of binder in a pad finishing formulation is generally between 0 percent and 25 percent.
  • binders may comprise between 0 percent and 100 percent of the finish formulation.
  • flame retardants may comprise between 0 percent and 100 percent of a finishing formulation depending on application method and the properties that are being sought through finishing.
  • Pigment dispersions, water repellents, waxes, lubricants, dyes, antimicrobials, defoamers, profoamers, corrosion inhibitors, antimicrobials, thickening agents, wetting agents, fillers, and other coating additives are useful in the present invention.
  • the chemical modification of the scrim can be accomplished through solvent based, 100% solids based, powder application, hot melt application or other chemistry application methods known to the art.
  • the sound absorption facing may be used as a decorative layer, e.g., a fabric layer, or it may be covered with other layers to improve the aesthetic properties.
  • a decorative layer e.g., a fabric layer
  • the adhesive can be applied as a hot melt using a pattern engraved in a gravure roll, powder coating, adhesive web, adhesive film or net, by screen printing or foam coating a pattern of compounded powdered adhesive or adhesive onto the facing, or by spraying adhesive onto the facing.
  • the adhesive is selected according to the temperature desired for thermally reactivating the adhesive, according to the material that will be mated with the sound absorption facing and according to other factors such as the open time of the adhesive, the temperature capabilities of the processing equipment, adhesive viscosity, melt-flow index, and the strength and esthetic qualities of the bond.
  • the array of thermally reactivateable adhesives, application equipment, and application techniques is vast; however, someone trained in the art can quickly arrive at a suitable system for this application.
  • the types of adhesives that have been used to good effect include thermoplastic and thermoset adhesives such as polyester based adhesives, polyamide, urethane, and olefinic adhesives. When thermoset adhesives are applied to the facing it is important not to keep the adhesive below the cross linking temperature when it is applied.
  • the adhesive may be used to adjust the air flow resistance of the facing.
  • continuous or perforated films or nets or other nonwoven material comprising low density polyethylene, high density polyethylene, ethylene vinyl acetate, polypropylene, mealeic anhydride, or any olefinic materials manufacture using either the Ziegler Natta or a transition metal catalyst or any blends of these materials may be tacked to the surface of the air flow resistant scrim.
  • These films, nets, and nonwoven materials are attached to the scrim with the knowledge that they will melt into adhesive islands during subsequent processes and will have minimal effect on the final air flow resistance of the acoustic composite.
  • Spartan 987FR (Spartan Flame Retardants, Inc), a non-durable, nonfogging ionic flame retardant. Then we increased the volume to 100 gallons of water while stirring to complete the mix.
  • the 100 gallon pad bath mix was made to incorporate the following ingredients: 25 pounds of Amgard CT (Rhodia Corporation) a durable cyclic phosphonate, 33.5 pounds of Spartan 880FR (Spartan Flame Retardants, Inc), 70 pounds of Inmont S Black 6612 (BASF Corporation), and 125 pounds of Phobol 8315 (Ciba Corporation) a fluorocarbon based water repellent.
  • a nonwoven fiberglass batt having a density of 2.0 lbs/ft 3 was combined with a 1.7 ounce/square yard, 100% polyester thermal bonded nonwoven fabric, with a coating of low density polyethylene adhesive, from Textil perennial Hof, with a permeability of 50-100 rayls (average 60 rayls).
  • Figure 2 illustrates the predicted normal incidence sound absorption of

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Textile Engineering (AREA)
  • Acoustics & Sound (AREA)
  • Architecture (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
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  • Laminated Bodies (AREA)

Abstract

La présente invention porte sur un revêtement d'insonorisation accordable qui comprend une bande cellulosique et une bande non tissée entrelacées ensemble. Le revêtement a une résistance à un écoulement d'air commandable.
PCT/US2010/038311 2009-06-12 2010-06-11 Articles d'insonorisation acoustiquement accordables et leurs procédés de fabrication WO2010144798A2 (fr)

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CN113012673A (zh) * 2021-03-16 2021-06-22 合肥工业大学 一种吸声频带可调的吸声体
US11207863B2 (en) 2018-12-12 2021-12-28 Owens Corning Intellectual Capital, Llc Acoustic insulator
US11666199B2 (en) 2018-12-12 2023-06-06 Owens Corning Intellectual Capital, Llc Appliance with cellulose-based insulator
EP4458913A1 (fr) * 2023-05-02 2024-11-06 STO SE & Co. KGaA Composition sèche pour la fabrication d'une matière de revêtement pâteuse, matière de revêtement pâteuse pour un système acoustique et système acoustique

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US5186996A (en) 1989-12-29 1993-02-16 Matec Holding Ag Sound damping multi-layer structure
US5298694A (en) 1993-01-21 1994-03-29 Minnesota Mining And Manufacturing Company Acoustical insulating web
US6145617A (en) 1996-10-29 2000-11-14 Rieter Automotive Ag Ultra-light, multifunctional sound-insulating kit
US5886306A (en) 1997-07-22 1999-03-23 Kg Fibers, Inc. Layered acoustical insulating web
US6631785B2 (en) 2001-12-20 2003-10-14 Collins & Aikman Products Co. Sound attenuating composite articles incorporating scrim material and methods of making same
US7310739B2 (en) 2003-10-28 2007-12-18 Prolific Technology Inc. Universal serial bus and method for transmitting serial clock and serial data signals during power-saving mode
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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11207863B2 (en) 2018-12-12 2021-12-28 Owens Corning Intellectual Capital, Llc Acoustic insulator
US11666199B2 (en) 2018-12-12 2023-06-06 Owens Corning Intellectual Capital, Llc Appliance with cellulose-based insulator
CN113012673A (zh) * 2021-03-16 2021-06-22 合肥工业大学 一种吸声频带可调的吸声体
CN113012673B (zh) * 2021-03-16 2024-02-06 合肥工业大学 一种吸声频带可调的吸声体
EP4458913A1 (fr) * 2023-05-02 2024-11-06 STO SE & Co. KGaA Composition sèche pour la fabrication d'une matière de revêtement pâteuse, matière de revêtement pâteuse pour un système acoustique et système acoustique

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