JPS63159562A - Freely moldable fiber composite structure and its production - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a fiber structure, and more particularly to a moldable fiber composite structure of inorganic fibers and organic fibers and a method for manufacturing the same.

(Prior art and problems to be solved by the invention) There are a wide range of industrial fields that require and require relatively thin, moldable heat-insulating and sound-insulating materials.For example, in the automobile industry, moldable heat and sound insulation materials are required. There is a demand for non-woven trunk liners, trunk bed liners, roof panels, etc. that have insulation and sound deadening properties. The building industry uses flooring, wall coverings,
There is a demand for ceiling materials.

In the past, products made from needle-bunched products or combinations of recycled wool fibers, such as wool fibers made from unfelted wool or wool scraps, were used for thermal and acoustic insulation. It was common to use it.

In fact, a recycled product with mastic-like material on the back was glued to this single needle punch. A product that combines a recycled product and one needle punch is first joined with mastic on the back side of the recycled product to create a product that can provide heat and sound insulation properties.

U.S. Pat. No. 4,522,876 by Hiya (1
Published June 11, 1985) teaches a non-woven needle-punched composite fabric suitable for filter media and insulation on automobile floorboards. The composite fabric is made of at least one layer of laminated and needled glass fibers and at least one layer of laminated and needled organic textile fibers, and the composite layers are combined in a fairly aggressive continuous needle-punching process. Needling is taught.

This intense needling results in a relatively dense product, with the fibers being tightly intertwined.

Because of this dense structure, this composite fabric is not easy to form; in fact, this patent does not describe the formability of the composite fabric disclosed therein; Because high-density fibers are needled vigorously, a relatively large portion of the fibers are broken compared to relatively low-density needle-punched fibers.

People U.S. Pat. No. 4,5fi8,581 (1
No. 98 [published February 4, 2003] discloses a moldable material suitable as a textile covering for the trunk compartment of a motor vehicle, etc. This material is made by molding heated nonwoven nibs made from a mixture of relatively high melting point fibers, such as polyester fibers, and relatively low melting point thermoplastic fibers, such as polyethylene fibers. These fibers are relatively long, so when molded using a normal molding machine,
Pulling or thinning along the curve
out) J occurs.

A thin, flat needle punch impregnated with thermoplastic latex is also used as a vehicle interior trim material. Because such materials are made in very thin sheets, they lack insulating properties and formability compared to the recycled and needle-punched combinations described above. Much thicker sheet materials impregnated with latex and needled provide improved insulation but are generally more expensive.

Commercially available materials such as those mentioned above generally have several manufacturing steps.1 For example, materials that use recycled products to obtain insulation properties require pre-processing such as cards because the recycled materials are not uniform. A process is required.

Furthermore, such materials cannot be easily or economically incorporated into current production techniques and methods such as common molding processes.

(Means for Solving the Problems) An object of the present invention is to overcome the above-mentioned problems as much as possible.

According to the present invention, a decorative trim material having heat insulating and sound insulating properties can be obtained. The composite structure has a base material, an intermediate layer, and a nonwoven top layer. The needable substrate consists of a lower surface and an opposite upper surface. The intermediate layer is made of relatively short inorganic fibers such that some of the inorganic fibers are prevented from interlocking with other fibers of the composite structure and impart the desired flexibility to the composite structure. It is considered to be the fiber length. This inorganic fiber has qualities suitable for imparting desired heat and sound insulation properties to the composite structure. Further, the top layer may include organic fibers, inorganic a
or a homogeneous mixture thereof, the fibers forming the top layer are long enough that during needling a sufficient amount of the fibers connect with the substrate to form a sufficiently stable structure. Furthermore, the top layer W4 males have sufficient strength,
The subsequent needling, molding, and combination thereof of the composite structure is of suitable quality to provide a top layer with a uniform cross-sectional area. Such a combination composition structure has approximately 62 to 465 pieces/
It has a punch density of cj (-400-3000 pieces/! direction inch).

A further aspect of the invention relates to a method of manufacturing such a composite structure.

Additional objects and features of the present invention will be readily apparent to those skilled in the art from the following detailed description, taken in conjunction with the figures and claims below.

The present invention provides a moldable fiber composite structure and a method for manufacturing the same. Further, the present invention contemplates a composite structure having a base material formed thereon of a non-am fiber intermediate layer having a relatively short tIa fiber length and a nonwoven top layer made of organic fibers alone or a mixture of inorganic fibers. It is something. Such composite structures are particularly useful as precursor materials for subsequent molding processes.

The substrate may be in the form of a thermoplastic resin film; examples of typical thermoplastic materials suitable as the film substrate include polyethylene, polypropylene, and polyester. Such a thermoplastic resin base material may be porous, or may be made porous through post-processing such as needling, to improve the shape retention of the molded composite structure. This is effective in improving the moldability of this composite structure and reducing the need to add molding processing aids such as binders, and the effect is to improve the moldability of the precursor material as described below. This will improve the

The substrate may also be in the form of a fibrous web, such a fibrous web substrate being an organic fiber.

It may be a woven fabric or a non-woven fabric made of inorganic fibers or a mixture thereof, and may be made by a method such as a spun bond method or a melt blow method.

Examples of typical fibrous web substrate materials that may be useful in the practice of this invention include polyethylene, polypropylene, polyester, polystyrene, nylon, mylar, and mixtures thereof. Special web substrate compositions may be selected from
For example, if the composite structure of the present invention is to be used for applications requiring molding, it would be preferable to use a polyester fiber base material because it has relatively excellent shape-imparting properties during molding.

The substrate is generally either in the form of a thermoplastic film or a fibrous web with enough "bulk" to act as a base, with relatively short inorganic fibers being further processed to form a sufficient amount of top layer fibers. in combination with, for example, a stable composite product in which both layers are virtually inseparable. It is believed that the upper limit of the "bulk" of the substrate is determined only by the processing limits of subsequent processing equipment.
For example, the substrate preferably should not be so thick that the degree of needling of the composite layer is excluded as unusual.

In the practice of the present invention, the substrate weighs between 16.98 and 1
Thicker substrates are generally known to be less flexible and, as a result, less formable. Additionally, the heavier the base material, the greater the strength.Relatively thick base materials are not suitable for composite structures that are deep-drawn. Also, when the lowest weight is desired as opposed to high strength, substrates with weights near the lower end of the above weight range are commonly used. , 18.98~508.67&#(-1/2~1
It has also been found that substrates weighing as low as 5 oz/yd are effective for extensive molding of the final composite structure.

The middle layer is made of inorganic fibers such as rock wool, which consists of a mixture of calcium, aluminum, magnesium and silicon. Although such inorganic fibers are relatively inexpensive compared to commercially available insulation materials, they provide substantial thermal and acoustic insulation to the composite structure. The inorganic Ia fibers of the intermediate layer are provided onto the substrate by a suitable method such as an air blow method or an air lay method, and impart moldability as well as substantial heat and sound insulation properties to the composite structure. For example, the inorganic fibers account for about 10 to 90% by weight of the fiber components of the composite structure, and the lower limit of the above range is used for fiber reinforcement applications, while the lower limit of the range is used for insulation applications. The upper limit of the range is used.

In general, a composite structure containing less than 10% by weight of the composite structure containing free rIIl#a males cannot provide a composite structure with sufficient heat and sound insulation properties. Therefore, it can be seen that a composite structure having inorganic fibers in an amount of about 20 to 90% by weight of the composite structure is effective for applications requiring additional durability. Furthermore, the amount of inorganic fibers of 10% by weight or less of the total weight of the multi-unit structure seems to be an inappropriate amount for obtaining a significant effect on moldability. In addition, when inorganic fibers account for more than 90% by weight of the entire composite structure, the amount of connecting fibers such as top layer fibers that connect with the base material during needling is too small compared to the inorganic fibers. This generally results in a lack of stability.

There does not seem to be a limit to the diameter of the inorganic fibers.

Therefore, it can be thin or thick.

It has been found that inorganic fibers with relatively short fiber lengths are preferred for the composite structures of the present invention, which are generally subsequently molded. In such composite structures, the staple fibers provide the composite structure of the present invention with improved flexibility, thus allowing said composite structure to be shaped along curved sections, such as are typically required during molding. can be curved. The desired degree of flexibility for this composite structure is that this composite structure is used
Many factors are involved, including the particular application, as determined empirically by one skilled in the art given the disclosure as provided herein. The use of staple fibers also substantially eliminates interlocking of the inorganic fibers of the intermediate layer with other inorganic fibers or other fibers of the composite structure. For such applications, the average fiber length is usually between 3.175 and 12.7 m.
Inorganic fibers in the range of m (=1/8 to 172 inches) are preferred.

Furthermore, it is recognized that in addition to the inorganic fibers, the intermediate layer may contain various organic fibers that serve as binders. For such applications, a powdered resin binder is typically used, and is premixed with the inorganic fibers of the intermediate layer.

The binder may be a dry fiber or particulate resin; these binders serve to bind the inorganic fibers to each other and to the substrate, such as polyvinyl chloride (1).
PVC), phenolic resin, polystyrene, nylon, polyester, or ABS resin can be selected. However, with a specific amount of binder used, the desired strength and sturdiness of the final composite structure.

Liquidity will change. The amount of binder used in terms of weight percent relative to the inorganic fibers is preferably 10 to 50%, but when this composite structure is used for road repair or construction,
The binder may be, for example, 200% or more by weight of the inorganic fibers.

A top layer of nonwoven fibers is formed on the fibrous intermediate layer with the intermediate layer fibers already disposed on the substrate and constitutes a precursor composite (i.e., a material that has not yet been needled). . This top fiber layer may be organic fibers or a homogeneous mixture of organic fibers and inorganic fibers, but a suitable amount of the top fiber layer may be organic fibers to provide suitable processing properties for subsequent processing, such as molding. A top layer containing, for example, at least about 10% by weight of organic fibers imparted to the composite structure is generally preferred.

The fibers of the top layer may be, for example, polypropylene, polyester, nylon, acrylic or glass fibers, depending on the application for which the composite structure is used.

The fibers in the top layer are typically used in greater amounts than the inorganic fibers in the middle layer, resulting in a stable composite structure that does not substantially separate upon needling. Therefore, the fibers in the top layer are usually about 1% of the total fiber content in the top layer and middle layer.
Does it account for 0-90%?

Alternatively, for composite structures having at least 20% by weight inorganic fibers, the top layer fibers will typically be about 10 to 80% by weight of the total fiber content of the top and intermediate layers.

Additionally, a suitable amount of the fibers in the top layer have a length suitable for interlocking with the substrate during needling.
．． Top layer fibers with average fiber lengths within the range of 5 to 5 inches were effective. Furthermore, the average am length is 1.27 to 12
．． Top layer fibers ranging from -172 to 5 inches have been particularly effective in the practice of this invention. Generally, the longer the top layer fibers are, the stronger and more stable the resulting composite structure will be, but it was found that the maximum fiber length for normal use is 17.78 cm (=74 notches). . The fibers in the top layer must have a suitable "gasa" to form a stable product.

It is connected to the base material by needling, and the short inorganic fibers of the intermediate layer are covered and integrated. Also, the fibers of this top layer generally have a substantially uniform cross-sectional area due to needling, molding, and combinations thereof of the precursor composite. It has the appropriate quality to obtain. Therefore, the top layer usually weighs between 101.73 and 878.2
3J)/wf (-3 to 20 oz/sq yd), particularly preferably 169.56 to B78.23J)#(wealth 5
−20 oz/f yd).

The top layer may be a composite structure in the conventional manner, such as cross-lapping, or in the form of a pre-needling, such as in the form of a needle butt as described below.

The precursor complex may be assembled by a wide variety of methods; for example, one preferred method is needle punching. This method consists of the steps of passing a plurality of long needles through the material and then removing them.

Integration by needle punching is a common method in textile processing. It is known that it is preferable to use a 36-gauge needle with a plurality of small barbs in a dense array for such needle-punching integration of materials. - A 36 gauge tlOB (high density barb) needle has been found effective in the practice of the present invention. The needles have a relatively short barb length compared to commercially available composite high density needles; moreover, the barbs of these needles have a relatively high density compared to the barb arrangement of commercially available needles. It is dense. Therefore, tlDB
Penetrating the top layer of the precursor composite with the needle results in substantially all of the barbs of the needle contacting the fibers of the top layer. The barbs allow these contacted top layer fibers to pass through the inorganic fibers of the intermediate layer without damaging them, thereby connecting the barbed top layer fibers and the substrate.

Also, because the barbs are dense, the needles are typically operated with relatively short strokes. Moreover, these needles substantially reduce penetration of the inorganic fibers of the interlayer between the substrates in contact therewith.

To effectively perform this integration, 62 to 465 pieces/c are required.
Punch densities of Ti (-400 to 3000 punches per square inch) have been found to be preferred and result in high strength products that cannot be easily separated.

For example, high-density composite structures, such as those with high punch densities, are not suitable for applications that undergo induced deep drawing; Suitable for high strength but relatively low workability applications such as backing shelves. In addition, punches with the lower limit of the punch density range described above are relatively suitable for use in trunk liners of ordinary automobiles (for example, those with a height of approximately 45.72 cm (=184:/cm) or less). Suitable for applications that require deep drawing.

For example, the punch density is 62 to 93 punches/ci (400 to 400 punches/ci)
60 parts/4 inches flat radius) composite structure exhibits significant tensile, elongation, and/or rJAt! It is particularly suitable for applications that receive A.

Punch density is 186 to 279 pieces/cm (-1200-
18 square inches) has a relatively small tensile force during molding and is suitable for use with relatively sturdy surfaces, such as backing shelves. Further, punch densities of 31 to 465 punches/as (*200 rows to 3,000 punches/square inch) are particularly suitable for architectural applications requiring thick and heavy insulation.

It has also been recognized that the addition of various materials to the composite structure can substantially increase its strength without compromising its formability. The layers can be layered on top of the substrate before being laid down, or layered on top of the intermediate layer fibers that have already been layered on the substrate. Glass fibers are strong and economical when compared to other materials. Because of its high physical appeal, it is a suitable material for such applications.

Although needling is shown to be performed on the top side of the composite structure, needling may be performed on both sides depending on the application.

FIG. 1 illustrates the manufacturing process of the above-mentioned composite structure, where this manufacturing process is designated by (10). First, a fibrous base material (
12) is held on the roller (14), and this manufacturing process (1
0), an intermediate layer (18) made of inorganic fibers (20) coming from an air lay device (21) & the base material (
Lay it on the top surface (22) of 12). Other methods for providing inorganic fibers on the substrate of this composite structure will be apparent to those skilled in the art, as already mentioned above.

The manufacturing step (lO) includes the above-mentioned pre-needled woven nonwoven top layer (20 is a roller (26
) and overlaid on the @2 intermediate layer (18), thus the inorganic fibers (20) of the intermediate layer (18)
12) and the top layer (24) to form a three-layer composite layer (30). The three precursor-composite layers (30) are then fed to a fifth stage integration device, such as a needle punch (32). This needle punch (32) has the effect of integrating and further strengthening the composite layer (30), through which the composite layer (30) becomes a needled composite structure (35).

At this point in the manufacturing process (10), a resin binder, as described above, may be added if necessary, this addition being indicated by the box (30).

The addition of the resin binder by the method shown in the box (34) may be added to the intermediate layer (18) having the resin binder premixed with the inorganic fibers (20), or may be used instead of it. For the binder resin, for example, you can spray a liquid binder.

Alternatively, it may be added to the paste side (40) of the substrate (20) of the needled composite structure (35) by any of a variety of methods, such as conventional roller coating or dipping methods.

In these methods using thermosetting resins that cure at high temperatures, the composite structure is subjected to various forces during curing of the binder resin. Therefore, in such a method, the precursor complex is formed in one layer, for example.

It is generally recognized that substantially symmetrical constructions, such as constructions of consistent weight, are preferred. Generally, in such a symmetrical precursor composite, the forces generated during curing of the resin.

It is substantially uniform throughout the structure, thereby minimizing the possibility of curvature (puck ring) resulting from uneven curing of the resin.

The use of thermosetting resins that require high temperatures has been found to be particularly useful in the production of architectural cores and other reinforced structures. Therefore, composite structures of the present invention used in such applications and containing thermosetting resins that cure at high temperatures are preferably made in a symmetrical shape.

In FIG. 2, another manufacturing process for manufacturing the composite structure described above is illustrated and designated by the number (50).

The manufacturing process (50) includes the manufacturing process (10) in Figure 1.
The fiber base material (12) is the same as in the case of , and the wrapping is done using a roller (14).
), an intermediate layer (18) made of inorganic fibers (20), an air lay device (21), etc. However, in this manufacturing process (50), the top layer is cross-wrapped (alternately laminated).
It is shown being supplied in a manner known as This cross-wrap device is designated by the number (52);
It has a wrapper apron (54) that moves laterally in a reciprocating manner over the substrate (12) and the intermediate layer (18) thereon, and is used to form a top layer on the intermediate layer. There is.

In all other respects, the manufacturing process (50) is almost the same as the manufacturing process (lO) shown in Figure 1.For example, in the second country, a three-layer precursor composite with a cross-wrapped top layer (42) is used. The body (44) is integrated through the needle punch (32) to form a needled composite structure (46).
If desired, a resin binder may optionally be added to the tip as shown in FIG.

Figures 3 and 4 show manufacturing steps (In', 50') similar to the manufacturing steps (10, 50) of Figures 1 and 2, respectively, which involve pre-mixing the resin binder. The inorganic fiber intermediate layer (18) is laminated from the air lay device (21) to the bottom thereof, and a resin binder is further added to impart desired properties to the resulting composite structure. This is different from the former. The three-layer precursor composites (30°, 44') shown in FIGS. 3 and 4, respectively, are sent to a needle punch (32) and integrated to form a needled composite structure (35°), respectively. ,
4B').

If necessary, one or more substrate layers may be inserted between the middle layer and the top layer of the precursor composite.

It is also recognized that the intermediate layer may be sandwiched between the substrates. Such additional substrates may be similar to the substrates described above and, for special applications, may be used as the first substrate of the composite structure with the same or different manufacturing factors, such as weight of constituent materials, etc. You can do it like this.

Addition of such additional substrates to the precursor composite results in a composite structure that has high strength upon needling but has little effect on processability.

The determination of whether additional substrates should be added, and if so, what materials and weights, will affect a number of factors, such as desired physical properties and end use, as discussed above. From this, a person skilled in the art can determine it empirically.

The following examples of products made in accordance with the present invention demonstrate specific ingredients and steps, and also disclose applications for the resulting products. As common knowledge.

It is hoped that all changes and modifications that fall within the scope of the invention will be protected, and the invention should not be construed as limited to the following examples.

(Example) Application Example 2: Needle-punch composite structure flat plate for truck floors that does not require post-processing.

[Rock wool inorganic fiber weighing 378.23 Jl# (=20 ounces/square yard) was air laid,
16.981# (-〇, 5 oz/sq yd) 0th order 1 weight 2 layered on a polyester substrate weighing 5 oz/sq yd.
71.29) A top layer of # (-8 oz/sq yd) polyester fiber is cross wrapped with a garnet machine over a rock wool batting cotton. /cj (sBOO book/square inch) needling to make vl dense. At this time, the composite structure is back coated with an acrylic latex binder and treated with a latex binder of 135.05 oz/inch.

Needle-punch composite structure flat plate for molding into fire autopsy unitrack parts and backing shelves.

Using the apparatus of Example 1, 62 composite layers/cnj (-4
Needling was performed at a punch density of 0.00 punches/square inch).

and 271. by dipping into PVC latex instead of back coating with acrylic latex.
The treatment was carried out under the same conditions except that a weight of #291) (=8 ounces/d) was applied.

The needled composite structure created in this way was then molded using a normal compression molding machine, and a large compression force was applied to create a highly rigid product. Typically, such compression molding machines provide at least 0.35 kf9/c+f (-7
lbs/in2) of pressure.

[β-: Same method as Example 2, but instead of dipping in polyvinyl chloride latex, polyethylene film weighing 339.12j/1 (-10 oz/yd) coated with. This film was an opaque film formed by an extrusion molding machine, and the shape retention of the composite structure was excellent during subsequent molding processing such as compression molding or vacuum molding.

IJjJ! Li: Same method as Example 2, but instead of soaking in 100% polyvinyl chloride latex, the composite structure was soaked in a mixture of multicomponent polyvinyl chloride latex and polyethylene powder. This mixture contained 40% by weight polyvinyl chloride latex and 60% by weight polyethylene powder. The composite layer was back coated with this mixture, and the multicomponent polyvinyl chloride latex was infiltrated into the composite structure, leaving the polyethylene powder on the underside of the substrate. When heated, the polyethylene fluidized into a film, and the resulting composite structure became a product suitable for subsequent vacuum forming. After this, the composite structure was vacuum formed.

Hitane Anatomy Ball: Needled composite structure plate for internal trim and insulation.

Rock wool inorganic fiber of 203.47Jl# (-ti oz/yd) was air-layed to 169°58 which is suitable for card machine! ! /si (=5 ounces/yard in V direction) laminated on a polyethylene fiber substrate-H, the weight is 305.20j/1 (=9 ounces/square yard) and the length is 10.18 cm ( = 4 (inches) of polypropylene organic LA fiber top layer was laminated on top of it, and 62 fibers/
Needling with a punch density of cj (*400 punches/square inch) is performed to make it denser and unified to a thickness of approximately 2.54cm.
Peng (-147chi)'s 21 Dring composite structure was obtained.

Hotane ■l: Polyvinyl chloride latex was foamed to form a foam, and then the composite structure of Example 5 was immersed in it to form 508
．． 67j/5f (=15 ounces/square yard). After the latex-containing composite structure obtained in this way is once heat-treated, it is molded using a suitable low-pressure compression molding method by applying a molding pressure of 0.21 am (-3 bonds/in2) or less. was completed.

Formable structural needling composite structures for boat and automobile exteriors.

The substrate was made by cross-lapping 6 denier polyester fibers weighing 135.05 #/j (-4 oz 7 yd). Place the glass fiber knitted fabric on this base material.

One layer of rock wool inorganic fiber core material weighing 878.231/j (-20 oz/f direction) was laminated on this glass fiber knitted fabric using the air lay method, 135
．． A layer of 6 denier polyester Iam) weighing 852# (-4 ounces/square yard) was cross-wrapped with a garnet machine onto the top surface of this inorganic fiber core. The obtained precursor composite was immersed in polyester resin.
Next, the composite structure is passed through a needle punching device at 217 needles/c in a zero order which prevents tension or tension of the composite structure before being compressed with a compression roller and needled.
Needling was performed at a punch density of m (="1400 punches/square inch).

The resulting needled composite structure was extremely uniform with a thickness of approximately 3 mm. As a result of needling a large number of polyester fibers in the base material and top layer, polyester fibers were embedded in the composite structure over a wide area. However, at such a high punch density, the length of the inorganic fibers became too short to achieve entanglement between polyester fibers and inorganic fibers, but in this case, the stiffness of the resulting composite structure increased. There was no inconvenience.

The above detailed description is for the purpose of clarifying the understanding of the present invention, and should not be construed as an unnecessary limitation, and modifications within the scope of the present invention will be obvious to those skilled in the art. .

[Brief explanation of the drawing]

FIG. 1 is a sectional view showing a typical example of a manufacturing apparatus and method for manufacturing a composite structure according to the present invention. FIGS. 2 and 4 are perspective plan views of another embodiment of the apparatus and method for manufacturing a composite structure according to the present invention. FIG. 3 is a cross-sectional plan view of another embodiment showing an apparatus and method for manufacturing a composite structure according to the present invention. 10.10゛...manufacturing process. 12...Base material. ts, t8'...Intermediate layer 5 20.20°...Inorganic fiber. 21... Air Ray device, 24...
...Top layer, 30.30゛...Composite layer. 32・・・・・・・・・Needle punch. 35, 35°... needling composite structure. 42...Top layer. 44, 44"...Precursor composite layer. 46, 48"...Needled composite structure. 50, 50'...manufacturing process. 52......Cross wrapping device.

Claims (4)

[Claims] (1) (a) Consists of a lower surface and an upper surface opposite thereto, 16.9
6~508.67g/m^2 (=0.5~15oz/
(b) a length adjacent to the top surface of said substrate having a weight of 3.18 to 12 square yards;
．． Consists of 7 mm (= 1/8 to 1/2 inch) inorganic fibers, the inorganic fibers account for 20 to 90% of the weight of the composite structure, and serve to provide heat and sound insulation properties to the composite structure. (c) a nonwoven top layer adjacent to the intermediate layer and made of organic fibers, inorganic fibers, or a mixture thereof, wherein the fibers of the top layer account for a total amount of fibers in the top layer and the intermediate layer; 1
It accounts for 0 to 80% by weight and is 38.1 to 127 mm (=
a nonwoven top layer having a length of 1.5 to 5 inches) and a weight of 169.6 to 678.28/m^2 (=5 to 20 ounces/square yard); and (d) the composite structure has 62 to 485 pieces/cm^2 (=
A moldable fiber composite structure having a punch density of 400 to 3000 punches/square inch). (2) (a) a first base material which can be freely needled and which constitutes a lower surface and an upper surface opposite thereto; (b) adjacent to the upper surface of the first base material, the inorganic fiber is the composite layer; The inorganic fibers have a short fiber length suitable to prevent them from interlocking with other fibers and to impart the desired flexibility to the composite layer, and the inorganic fibers provide the composite layer with the desired thermal insulation and an intermediate layer present in an amount suitable to provide sound insulation; and (c) a nonwoven top adjacent to said intermediate layer and forming a precursor composite on the opposite side of said substrate with respect to said intermediate layer. layer, the top layer is made of organic fibers or a homogeneous mixture of organic fibers and inorganic fibers, and the fibers of the top layer have a sufficient average fiber length so that when needling is performed, the top layer The fibers have a suitable amount to interlock with the first substrate to provide a stable composite layer, and after the fibers of the top layer are loose, the precursor composite is needled, molded, or and a nonwoven fabric top layer that has a strength suitable for imparting a uniform cross section to the top layer when both of these are performed, and is present in an amount thereof,
Furthermore, (d) the composite layer is 62 to 465 pieces/cm^2 (=4
1. A moldable fiber composite structure having a punch density of 00 to 3000 punches/square inch). (3) (a) 16.96-508.67g/m^2 (=0.5
on top of the substrate weighing ~15 oz/sq yd).
The composite structure is made of inorganic fibers having a length of 3.175 to 12.7 mm (=1/8 to 1/2 inch), and the base material constitutes a lower surface opposite to the upper surface, and the composite structure has heat insulation and sound insulation properties. (b) a nonwoven top layer of organic and inorganic fibers or a mixture thereof over the intermediate layer, the intermediate layer having a thickness effective to impart the The fibers in the top layer account for 10 to 80% by weight of the total fiber content in the top layer and the middle layer, and the fiber length is 38.1 to 127 mm (=1.5 to 5 inches)
and the weight is 169.6~678.2g/m^2 (=5~2
(c) then needle punching said three composite layers so that said composite layer has 62 to 465 fibers/cm^2;
A method for manufacturing a moldable fiber composite structure, comprising the steps of: making the structure have a punch density of 400 to 3000 punches/square inch. (4) (a) delivering a first needlable substrate constituting a lower surface opposite the upper surface; and (b) preventing some of the inorganic fibers from interlocking with other fibers of the composite layer. and an intermediate layer made of inorganic fibers having a short fiber length suitable for imparting desired flexibility to the first needlable base material on the upper surface of the composite layer,
(c) providing an interlayer having an amount of inorganic fibers suitable to impart the desired thermal and acoustic insulation properties to the composite layer; (c) disposing organic fibers or organic fibers and inorganic a nonwoven top layer comprising a homogeneous mixture of fibers, wherein the intermediate layer is arranged to form a precursor composite between the first substrate and the top layer, and the fibers of the top layer are arranged to form a precursor composite between the first substrate and the top layer; and in an amount suitable to provide a stable composite layer in conjunction with the first substrate when needled, and to provide a stable composite layer for subsequent needling, molding, or the like. (d) delivering a nonwoven top layer having a strength and quantity suitable to impart a uniform cross-section to the top layer when both processes are carried out; and (d) thereafter needling said precursor composite. A method for manufacturing a moldable fiber composite structure, comprising the step of obtaining the composite layer with a punch density of 62 to 465 punches/cm^2 (=400 to 3,000 punches/square inch).