Classifications

• • 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
• • 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
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
• • 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
  • B32B15/00—Layered products comprising a layer of metal
  • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
• • 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
• • 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
• • 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
• • 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
  • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
  • D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends

Definitions

• the present invention relates generally to the field of acoustical and thermal insulation and, more particularly, to an under carpet shield and floor pan insulator for a vehicle.
• Acoustical and thermal insulators and liners for application to vehicles are well known in the art. These insulators typically rely 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. They also rely upon thermal shielding properties to prevent or reduce the transmission of heat from various heat sources (for example, engine, transmission and exhaust system), to the passenger compartment of the vehicle. Such insulation is commonly employed as an under carpet heat shield and a floor pan insulator.
• acoustical and thermal insulation in the form of liners are disclosed in a number of prior art patents including U.S. Patents 4,851,283 to Holtrop et al. and 6,008,149 to Copperwheat.
• U.S. Patents 4,851,283 to Holtrop et al. and 6,008,149 to Copperwheat As should be apparent from a review of these two patents, engineers have generally found it necessary to construct such liners from a laminate incorporating (a) one or more layers to provide the desired acoustical and thermal insulating properties and (b) one or more additional layers to provide some rigidity to allow ease of handling during installation.
• U. S. Patents 6,092,622 to Hiers et al. and 6,123,172 to Byrd et al. disclose needled composite thermal and acoustical insulators containing various layers of polymer fibers, glass fibers, metallic foils, scrims and other facings.
• the metallic foil facing is secured in place with an adhesive.
• the needling construction of the batt requires perforating the interior insulating layer, thereby providing numerous passageways for the passage of both heat and sound.
• shields and insulators While a number of adhesives, adhesive webs and binding fibers have been specifically developed over the years to secure the various layers of the laminates together, laminated shields and insulators have an inherent risk of delamination and failure. The potential is, in fact, significant mainly due to the harsh operating environment to which the shields and insulators are subjected. Many shields and insulators are located near and/or are designed to shield high heat sources such as the engine, transmission and exhaust system. As a result, the shields and insulators are often subjected to temperatures in excess of 93 °C (200°F) which have a tendency to degrade the adhesives and binders over time.
• Shields and insulators used for under carpet and floor pan applications also carry foot traffic and thus are subjected to repeated compression and decompression. This activity places very significant strain on the shields and insulators, often resulting in adhesive failure and delamination of the shield or insulator over time.
• an insulator also provides the desired mechanical strength and rigidity to allow simple and convenient installation while also providing a long service life characterized by reliable performance.
• That shield/insulator comprises a single, nonlaminate acoustical and thermal insulating layer of polymer fiber selected from a group consisting of polyester, polypropylene, polyethylene, rayon, nylon and any mixtures thereof.
• the thermal insulating layer is preferably a nonwoven fabric and may further include additional fibers selected from a group consisting of glass fibers and natural fibers to meet the specific performance requirements of a particular application.
• the acoustical and thermal insulating layer may include a relatively high density, non-laminate skin of polymer fiber along at least one face thereof. Still further, the insulator may include a first metal foil facing layer over a first face of the acoustical and thermal insulating layer. Similarly, a second metal foil facing layer may be provided over a second face of the acoustical and thermal insulating layer.
• the under carpet heat shield and floor pan insulator of the present invention may comprise a single nonlaminate acoustical and thermal insulating layer of polymer fiber selected from a group consisting of polyester, polypropylene, polyethylene, rayon, nylon and any mixtures thereof that shows no signs of any thickness increase, delamination, deterioration or any undesirable effect which may affect performance when subjected to a temperature of about 150°C (302°F) for a period of at least 330 hours.
• the shield/insulator may comprise a nonlaminate acoustical and thermal insulating layer of substantially 100% polyethylene terephthalate.
• Figure 1 is a schematical side elevational view of one possible embodiment of the present invention
• Figures 2-5 are schematical side elevational illustrations of other possible alternative embodiments of the present invention.
• the shield or insulator 10 comprises an acoustical and thermal insulating layer 12 of polymer fiber. More specifically, a single, nonlaminated layer 12 is provided with the necessary mechanical strength and rigidity to allow easy installation and the desired acoustical and thermal insulating properties.
• a light weight insulator 10 which may even be used in compact vehicles where fuel economy concerns lead manufacturers to seek weight savings wherever possible.
• the polymer fiber is not foamed and typically is a nonwoven fabric.
• the polymer fiber may be selected from a group of fibers consisting of polyester, polypropylene, polyethylene, rayon, nylon and any mixtures thereof.
• the acoustical and thermal insulating layer 12 is engineered to show no signs of any thickness increase, delamination, deterioration or any undesirable effect which may affect performance when subjected to a temperature of approximately 150°C (302°F) for a period of at least 330 hours.
• a shield or insulator 10 has a weight of between about 40-130 g/ft .
• the acoustical and thermal insulating layer 12 may comprise substantially 100% polyethylene terephthalate.
• a shield or insulator 10 made from 100% polyethylene terephthalate provides a number of advantages when compared to a state of the art shield made from a layer of glass fibers sandwiched between layers of polyester.
• the shield or insulator 10 of the present invention may be cut with a heat knife to give an edge.
• the shield or insulator 10 of the present invention can be premolded to accommodate different shapes and sizes and will eventually mold to the cavity size even when the cavity is uneven.
• the state of the art shield cannot shape adapt to the mounting cavity in the bodywork or framework of the vehicle in a like manner.
• the shield or insulator 10 of the present invention is dimensionally stable upon exposure to temperatures up to 232°C (450°F) at which slight yellowing may occur, the state of the art shield tends to disfigure and the phenolic binder is released, resulting in the production of an odor and browning of the shield.
• the shield or insulator 10 of the present invention is also free of glass fiber and, therefore, is installer friendly ( does not produce an itchy feeling for those contacting the material). While the glass fiber in the state of the art product is sandwiched between two layers of polyester, the product still tends to be more irritating to those coming into contact with it. Accordingly, for many applications it is necessary to coat the edge of the shield or insulator in order to avoid this potential irritation.
• the shield or insulator 10 also comprises a nonlaminate acoustical and thermal insulating layer 12 of polymer fiber (for example, a nonwoven fabric) selected from a group consisting of polyester, polypropylene, polyethylene, rayon, nylon and any mixtures thereof.
• the layer 12 also includes a relatively high density, nonlaminate or unitary skin 14 of that polymer fiber along at least one face thereof.
• the high density skin 14 will not delaminate from the layer 12 under the environmental conditions existing under the carpet and along the floor pan of the vehicle and also adds structural integrity and strength to the shield or insulator 10 which aids significantly in handling and fitting the part during installation.
• the high density skin 14 is also more aesthetically pleasing.
• the high density skin 14 eliminates the need to provide an additional facing layer of another type of material. This serves to eliminate any potential failure of the shield or insulator due to delamination. It also results in a shield or insulator made exclusively from one material that is, therefore, readily recyclable.
• the skin since the skin may be formed with a hot platen during the molding of the shield or insulator 10 to its desired shape, no additional processing step is required. This reduces production cost relative to a shield or insulator with a facing since such a facing must be adhered to the acoustical and thermal insulating layer in a separate processing step.
• the shield or insulator 10 includes a nonlaminate acoustical and thermal insulating layer of polymer fiber 12 (for example, a nonwoven fabric) selected from a group consisting of polyester, polypropylene, polyethylene, rayon, nylon and any mixtures thereof in combination with a metal foil facing layer 16 over a first face 18 of the acoustical and thermal insulating layer.
• the metal foil facing may be present in one or more layers.
• the shield or insulator 10 comprises a nonlaminate acoustical and thermal insulating layer 12 of polymer fiber as described above in combination with a first metal foil facing layer 16 covering a first face 18 thereof and a second metal foil facing layer 20 covering a second, opposite face 22 thereof.
• the second facing layer 20 may be constructed from the same or a different material as the first facing layer 16.
• the first and second facing layers 16, 20 maybe attached to the layer 12 by means of an appropriate adhesive or adhesive web in accordance with practices well known to those skilled in the art.
• the shield or insulator 10 comprises a single, nonlaminated acoustical and thermal insulating layer 12 of polymer fiber (for example, a nonwoven fabric) as described above in combination with a first metal foil facing 16 covering a first face thereof and a second metal foil facing 20 covering a second face 22 thereof.
• the shield or insulator 10 of this embodiment includes an additional acoustical and thermal insulating layer 24 of polymer fiber (for example, a nonwoven fabric) selected from a group consisting of polyester, polypropylene, polyethylene, rayon, nylon and any mixtures thereof.
• the first metal foil facing layer 16 is sandwiched between the two acoustical and thermal insulating layers 12, 24.
• the acoustical and thermal insulating layer 12 and or 24 may further include from about 10 - 60 weight percent of glass and/or natural fibers such as, but not limited to E-glass, S-glass, kenaf, hemp and mixtures thereof. Use of such glass and natural fibers may be desirable to meet the performance parameters necessary for some potential applications. In summary, numerous benefits result from employing the concepts of the present invention.
• An under carpet heat shield or floor pan insulator 10 constructed in accordance with the teachings of the present invention provides a unique combination of mechanical strength and rigidity as well as thermal and acoustical properties which are consistently and reliably maintained over a long service life even in the proximity of a high temperature heat source such as a catalytic converter, hi one of the embodiments of the present invention, a relatively high density, nonlaminate skin is provided which aids in handling, is aesthetically pleasing and maintains the full recycleability of the shield or insulator.
• the shield or insulator 10 could include a relatively high density nonlaminate skin 14 on both opposing faces and or along the edges of the shield or insulator.
• a shield or insulator 10 with one or more high density, nonlaminate skins 14 could also include one or more facings 16, 20 if required to meet acoustical, thermal, structural and/or aesthetic performance requirements of a particular application.

Landscapes

• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Acoustics & Sound (AREA)
• Physics & Mathematics (AREA)
• Chemical & Material Sciences (AREA)
• Mechanical Engineering (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Inorganic Chemistry (AREA)
• Multimedia (AREA)
• Laminated Bodies (AREA)
• Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
• Passenger Equipment (AREA)
• Soundproofing, Sound Blocking, And Sound Damping (AREA)
• Nonwoven Fabrics (AREA)

Applications Claiming Priority (3)

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• 2002
  • 2002-05-28 EP EP02739433A patent/EP1392547A1/en not_active Withdrawn
  • 2002-05-28 BR BR0209573-4A patent/BR0209573A/pt not_active IP Right Cessation
  • 2002-05-28 JP JP2003501718A patent/JP2004530925A/ja active Pending
  • 2002-05-28 CA CA2444641A patent/CA2444641C/en not_active Expired - Fee Related
  • 2002-05-28 KR KR10-2003-7015059A patent/KR20040002979A/ko not_active Application Discontinuation
  • 2002-05-28 MX MXPA03010863A patent/MXPA03010863A/es active IP Right Grant
  • 2002-05-28 WO PCT/US2002/016691 patent/WO2002098707A1/en active Application Filing

Non-Patent Citations (1)

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