US20060090958A1 - Thermoformable acoustic product - Google Patents

Thermoformable acoustic product Download PDF

Info

Publication number
US20060090958A1
US20060090958A1 US11/210,462 US21046205A US2006090958A1 US 20060090958 A1 US20060090958 A1 US 20060090958A1 US 21046205 A US21046205 A US 21046205A US 2006090958 A1 US2006090958 A1 US 2006090958A1
Authority
US
United States
Prior art keywords
acoustic
thermo
product according
acoustic product
sheet
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US11/210,462
Other languages
English (en)
Inventor
Michael Coates
Marek Kierzkowski
John Simmons
Bruce Gascoigne
Philip Gibbons
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Zephyros Inc
Original Assignee
INC Corp Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2004900927A external-priority patent/AU2004900927A0/en
Application filed by INC Corp Pty Ltd filed Critical INC Corp Pty Ltd
Assigned to I.N.C. CORPORATION PTY. LTD. reassignment I.N.C. CORPORATION PTY. LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: COATES, MICHAEL WILLIAM, GASCOIGNE, BRUCE REGINALD, GIBBONS, PHILIP JOHN, KIERZKOWSKI, MAREK HENRYK, SIMMONS, JOHN CAMPBELL
Publication of US20060090958A1 publication Critical patent/US20060090958A1/en
Assigned to EMAN8 PTY LTD reassignment EMAN8 PTY LTD ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: I.N.C. CORPORATION PTY LTD
Assigned to ZEPHYROS, INC. reassignment ZEPHYROS, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: EMAN8 PTY LTD
Abandoned legal-status Critical Current

Links

Images

Classifications

    • 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
    • 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
    • G10K11/168—Plural layers of different materials, e.g. sandwiches

Definitions

  • This invention relates to materials for sound absorption. More particularly it relates to thermo-formable acoustic products that have enhanced sound absorption properties and can be decoratively faced.
  • Sound absorption provides a useful means for noise reduction in a wide variety of industrial, commercial, and domestic applications.
  • the sound absorption of a porous material is known to be a function of fundamental material properties, including thickness, air flow resistance, mass, stiffness, porosity, tortuosity etc, and application parameters, such as any air space behind the material, or alternatively, the acoustic and mechanical properties of any other material situated behind the porous material, such as a spacer layer, an isolation layer, or acoustic underlay.
  • Adding a third dimension to a sound absorbing assembly provides aesthetic and practical physical properties such as stiffness and conformance to contoured shapes, such as found in motor vehicle trim, such as, for example, for the floorpan, firewall, trunk, or parcel shelf.
  • the sound absorbing composite should have a decorative finish that does not detract from the sound absorption. Even more desirably, the decorative facing should have properties that actually enhance the sound absorption by becoming an integral component of the sound absorbing composite assembly. In certain applications, such as a motor vehicle floor assembly, it is desirable that the composite conforms to the shape of a surface, for example, or otherwise retains a particular shape, for example as an aesthetic feature for wall decoration.
  • the sound-absorbing composite should have sufficient strength that it can support light loads and resist mechanical damage.
  • the sound absorbing assembly, and any decorative facing can be heat molded to the required shape in a simple and cost effective process.
  • the applicant is the applicant for Australian Patent Application No. 48754/00, which describes a Pinnable Acoustic Panel, comprising a decorative layer, a high flow resistive layer and a foam spacer layer.
  • the high flow resistive layer has sufficient stiffness and density that it will retain pins used to attach papers and such to the panel. The content of this is incorporated herein by cross-reference.
  • PCT/AU01/00880 discloses a thermoformable acoustic sheet, the content of which is also incorporated herein by cross-reference.
  • a sound absorbing composite assembly includes, but are not limited to, interior insulation for motor vehicles, and commercial decorative wall, ceiling, and floor finishes. In most instances, a decorative facing is required for aesthetic purposes or for mechanical protection.
  • thermo-formable materials have been provided, however such prior art does not address the practicality of achieving an effective sound absorbing solution.
  • environmental, manufacturing and cost issues are a concern, whilst retaining the ability to vary the mechanical properties and maintaining or enhancing the sound absorbing properties of the product and combining this with the aesthetic quality of the product.
  • a decorative layer may also be included on, or attached to, the flow resistive thermo-formable material.
  • these applications similarly do not address the practicality of achieving an effective sound absorbing solution as discussed above.
  • thermo-formable acoustic product with enhanced acoustic properties, and a method of producing such a product that will overcome or at least ameliorate the disadvantages of the prior art or at least provide a useful alternative.
  • the present invention provides a thermo-formed acoustic product formed from an acoustic sheet with a relatively high flow resistance, and a layer of porous flow resistive spacer material attached to one side of the acoustic sheet and having a flow resistance substantially smaller than the acoustic sheet, wherein the acoustic product has locally reactive acoustic behavior and an overall flow resistance of between 2800 Rayls and 8000 Rayls.
  • the acoustic sheet has a favorable aesthetic appearance.
  • the acoustic sheet is a decorative layer, such as a carpet, textile or other permeable film facing.
  • the acoustic sheet is formed by a decorative layer and at least one additional flow resistive layer.
  • the porous flow resistive spacer material is a fibrous web.
  • the fibrous web spacer material has a vertically-lapped construction so that the fibers are oriented in a plane normal to that of the acoustic sheet.
  • the fibers of the fibrous web spacer material are at least partially thermally bonded together.
  • the fibrous web spacer material is thermally molded.
  • the molding can be to a final shape or an intermediate shape for further molding or processing.
  • the fibrous web spacer material is formed from high melt and low melt fibers.
  • the low melt fibers are a bi-component fiber.
  • the low melt fibers are a mono-component fiber.
  • the acoustic sheet includes a flow resistive layer formed from high melt and low melt fibers.
  • the flow resistive layer is compressed to give the desired air flow resistance.
  • the low melt fibers are selected to have a temperature resistance that is applicable to the intended use.
  • the thermo-formed acoustic product has a total air flow resistance of between 3000 Rayls to 5000 Rayls. More preferably, the thermo-formed acoustic product has a total air flow resistance of between 3200 Rayls to 4500 Rayls.
  • the fibrous web spacer material has an air flow resistance of between 100 Rayls to 800 Rayls. Even more preferably, the fibrous web spacer material has an air flow resistance of between 200 Rayls to 400 Rayls.
  • the fibrous web spacer material has a density of 150-2000 g/m 2 .
  • the density of the fibrous web spacer material is determined by the specific acoustic and physical properties desired of the overall system.
  • the acoustic sheet has a density of 150-2000 g/m 2 . The density is selected on the basis of the acoustic and physical properties desired of the overall system.
  • thermo-formed acoustic product can be used for a multiplicity of purposes, including, but not exclusive to insulation for machinery and equipment, motor vehicle insulation, domestic appliance insulation, dishwashers and commercial wall and ceiling panels.
  • the acoustic product has a sag resistance to temperatures at or about 150° C.
  • the part should exhibit minimal sag at operating temperatures.
  • the present invention is a method of forming a thermo-formed acoustic product formed from an acoustic sheet with a relatively high flow resistance, and a layer of porous flow resistive spacer material attached to one side of the acoustic sheet and having a flow resistance substantially smaller than the acoustic sheet, including the steps of heating the porous flow resistive layer and acoustic sheet, and molding the acoustic sheet and porous flow resistive layer wherein the acoustic product has locally reactive acoustic behavior and an overall air flow resistance of between 2800 Rayls and 8000 Rayls and the porous flow resistive spacer material attached to one side of the acoustic sheet.
  • porous flow resistive spacer material is attached to one side of the acoustic sheet during molding. In another embodiment the porous flow resistive spacer material is attached to one side of the acoustic sheet prior to molding. Preferably the porous flow resistive spacer material is laminated to the acoustic sheet prior to being molded.
  • the acoustic sheet and porous flow resistive layer are supplied to the molding process in roll form.
  • the acoustic sheet and porous flow resistive layer are supplied to the molding process in sheet form.
  • the acoustic product is molded in a cold molding tool.
  • a thermo-formed acoustic product is formed by a flow resistive spacer material having crystalline fibers.
  • the acoustic product is molded in a hot molding tool.
  • a thermo-formed acoustic product is formed by a flow resistive spacer material having amorphous fibers.
  • the heating the acoustic product is achieved with infrared radiation, hot air, or a combination of hot air and infra red radiation.
  • the acoustic product is formed from predominantly one polymer type.
  • the acoustic product is formed predominantly from polyester fibers or polypropylene fibers.
  • the acoustic properties of the acoustic product are assisted by the three-dimensional geometry of the molded product.
  • the present invention provides the advantages of a multi-purpose clean, energy efficient, low cost, recyclable material as a thermo-formable acoustic sheet with enhanced and consistent acoustical properties while providing a favorable aesthetic appearance in preferred embodiments.
  • a further advantage is that the present invention provides an insulation that provides a lower resonance than current systems, has superior resilience and predictable mechanical properties.
  • a further advantage of the above process is that the product is formed in a fast cycle time, to provide cost-effective solutions for use as an insulation in original equipment, such as motor vehicles and dishwashers, wall and ceiling linings and other industrial commercial and domestic purposes.
  • thermo-formable acoustic product with less energy than conventional systems, providing an improved environmental outcome.
  • FIG. 1 Schematic illustration of one embodiment of the thermo-formed acoustic product according to the present invention.
  • FIG. 2 Schematic illustration of another embodiment of the thermo-formed acoustic product according to the present invention.
  • FIG. 3 Schematic illustration of another embodiment of the thermo-formed acoustic product according to the present invention.
  • FIG. 4 Schematic illustration of an embodiment of the thermo-formed acoustic product according to the present invention.
  • FIG. 5 Schematic illustration of an embodiment of the thermo-formed acoustic product according to the present invention.
  • FIG. 6 A plot of transmission loss versus frequency for the composite formed in Example 1.
  • FIG. 7 A plot of sound absorption coefficient versus frequency for the composite formed in Example 1.
  • FIG. 8 A plot of sound absorption coefficient versus frequency for different average fiber size with a fiber blend of 600 gsm.
  • FIG. 9 A plot of sound absorption coefficient versus frequency for two samples having a 23 mm thick spacer layer and a 13 mm thick spacer layer.
  • FIG. 10 A plot of transmission loss versus frequency for two samples having a 23 mm thick spacer layer and a 13 mm thick spacer layer.
  • FIG. 11 A plot of stiffness and loss factor versus density for samples with 2.5 denier average fiber size.
  • FIG. 12 A plot of stiffness and loss factor versus density for samples with 3.7 denier average fiber size.
  • the actual sound absorption achieved in a practical example of application can be less than that inferred from laboratory testing. This has been shown to result from the effect of sound transmission behind and parallel to the sheet. In acoustic terms, this material is installed in a non-locally reactive situation.
  • thermo-formable acoustic sheet behave in a locally reactive manner.
  • thermo-formable acoustic product 1 which is formed from an acoustic sheet 2 , and a layer of porous flow resistive spacer material 4 .
  • the product is typically applied to a surface 5 , usually conforming to that shape.
  • the acoustic sheet 2 has a favorable aesthetic appearance by virtue that the acoustic sheet is a decorative layer, such as a carpet.
  • the acoustic sheet 2 can be a flow resistive layer only where a favorable aesthetic appearance is not required.
  • thermo-formable acoustic product 6 which is formed from a decorative layer 9 , a compressed flow resistive acoustic layer 7 , and a layer of porous flow resistive spacer material 10 .
  • the product is typically applied to a surface 11 , usually conforming to that shape.
  • the decorative layer may be an automotive carpet, or a commercial textile.
  • the decorative layer is a decorative fabric which has been previously coated with an adhesive resin so as to bind the fibers and to control the air permeability.
  • an adhesive resin so as to bind the fibers and to control the air permeability.
  • Such a coating may be applied in any of the well-known means of coating textiles.
  • the coating is preferably a thermoplastic adhesive powder, web or film, extruded thermoplastic resin or a liquid coating. The coating process must be finely controlled so as to ensure a consistent and even coating of the decorative fabric and a pre-determined air flow resistance, and hence the performance of the decorative layer as an element of the acoustic product.
  • the flow resistive compressed acoustic sheet 7 is formed by a similar processes as described in PCT/AU01/00880, and has an air flow resistance in the range of 2800-7000 mks Rayls, more preferably in the range 3000-5000 mks Rayls and even more preferably in the range of 3200-4500 mks Rayls.
  • the preferred flow resistance range is limited by the practical application of the product, however the preferred range of flow resistance for the enhanced thermoformable acoustic sheet has been selected to provide the optimum acoustic properties for the intended applications.
  • the increased flow resistance is achieved by increasing the compaction density and further reducing the volume of the interstatial spaces within the acoustic sheet. This is achieved through controlling the process parameters of time, temperature and pressure, applied to the fibrous web during manufacture of the acoustic sheet.
  • further optimisation of the fiber blend, and web density makes it possible to achieve a flow resistance in the preferred range.
  • the product must have a temperature resistance appropriate for the intended application.
  • the sheet must have a low sag modulus at temperatures up to about 150° C.
  • the product can be formed into a three dimensional shape, so providing an air space and structural rigidity.
  • a shape can also form partially enclosed cells, such as a honeycomb, or egg-carton type structure, that will provide local reactivity and increase the acoustical performance of the thermo-formed acoustic product.
  • the sheet 7 is produced from a fibrous web of 150-2000 g/m 2 . It is clear that for cost minimisation, the lowest practical web weight is desired. The web is compressed by between 15 and 25 times. The thickness of the web has an influence on the air flow resistance, however the inventors have demonstrated through modelling and practice, that the desired acoustic properties can be achieved through a combination of different fiber selections and ratios, thicknesses and processing conditions.
  • the flow resistive material 10 is produced in planar form and may be presented as a roll or as a sheet.
  • the flow resistance of the material can be achieved or enhanced through the application of an adhesive resin.
  • the resin may be applied in a powder, fiber or film form, preferably in a dry lamination or coating process.
  • the resin can be selected from a range of thermoplastic, or thermoset, polymers.
  • Preferred thermoplastic resins include, but are not limited to, polyester and polyproylene.
  • thermo-formable acoustic product is produced from one individual polymer system so that it can be readily recycled, in particular polyester or polypropylene.
  • the web of fibrous material used to produce the flow resistive acoustic sheet 7 is preferably produced from a vertically-lapped web of high loft thermally bonded material as produced by the vertical-lapping process, known as the STRUTO process under Patent WO 99/61963, although other processes for producing a vertically, or rotary, lapped web would also be suitable.
  • Suitable low and high melt materials can be used as the respective fibers, which can of mono- or bi-component form.
  • Alternative web forming systems, such as cross-lapping, air laid, and needle punching can also be used, however these have been found to result in a web with less consistent acoustic properties.
  • the web is consolidated by heating and compressing, as described in PCT/AU01/00880.
  • the consolidation of the fibrous web can be conducted as an in-line process immediately following production of the fibrous web.
  • the fibrous web is preferably formed as previously described by the vertical lapping process, but other web forming processes, such as cross-lapping, and/or needle punching and/or thermal bonding can also be used. A more consistent acoustic performance is obtained through the vertical lapping process.
  • a flow resistive screen does not behave in a locally reactive manner unless the air space behind the screen provides some acoustic impedance. To induce locally reactive behavior in the thermo-formed acoustic product, it is necessary to insert a flow resistive material into the air space, or alternatively to break up the air space into a cellular or honeycomb structure as previously described.
  • a vertically lapped fibrous web is used as a flow resistive spacer material to fill the void created by the air space, however other forms of porous materials can also serve this purpose, for example polyurethane foam, needle punched fibrous webs or a cross lapped thermally bonded fibrous webs.
  • the mechanical and acoustical properties of the spacer material are critical to ensuring the optimum acoustic performance of the composite.
  • the fibrous web spacer material can be attached to the thermo-formable acoustic sheet by lamination or by mechanical means, for example riveting, coupling or plastic welding.
  • an adhesive 3 , 8 may also be used between the acoustic sheet and the fibrous web spacer material.
  • this adhesive can be heat reacted to act as an adhesive for the fibrous web spacer material. This can be achieved through contact heating, hot air impingement, or indirect heating, such as infrared, or other similar means.
  • the adhesive system that controls the flow resistance of the sheet is in the fibrous form
  • the use of such an adhesive layer can also be used to control the final flow resistance of the sheet and fibrous web spacer material composite.
  • the fibers selected for fibrous web spacer material influence the final acoustic properties significantly. Accordingly the fibrous web spacer material is preferably formed from fibers within the range of 0.5 to 6 denier, preferably 0.5 to 3 denier, and more preferably from 0.5 to 1 denier. These fiber sizes are nominated on the basis of staple fiber, however the melt blown process can produce fibers in even smaller deniers, producing higher flow resistance and an even more beneficial result.
  • the denier of a fiber relates to the mass per 9000 m of fiber.
  • a polymer with a low specific gravity will have more fibers per unit of mass, and volume for a given mass.
  • a low density polymer, such as polypropylene will have more fibers, at the same denier, than the equivalent mass of say polyester fiber.
  • a fibrous web spacer material produced from a low density polymer, such as polypropylene is a preferred form of this invention.
  • thermo-formed acoustic product is formed by heating the acoustic sheet and porous layer, and molding them to a desired three dimensional shape. After molding, the acoustic sheet is attached to the porous layer to form an integral acoustic product.
  • the three dimensional shape could be an intermediate shape or a final shape.
  • the heating of the acoustic sheet and porous layer can be conducted before or during molding.
  • the porous layer is laminated to the acoustic sheet, it is possible to also thermoform the spacer material in the same process.
  • the spacer material can be selected from a fibrous web comprising fibers with an appropriately selected melting range.
  • the porous layer may consist of fibers with a substantially higher melting range than the thermo-formable acoustic sheet, and may remain unaffected by the molding process. Attachment of the porous layer may be achieved by lamination as described, or by mechanical means, such as staples or other form of mechanical fastener.
  • the spacer material may optionally be placed into the molding tool prior to the placement of the heated acoustic sheet into the molding tool.
  • the heat retained in the sheet is often sufficient to cause adhesion to the pieces placed into the mold, however an adhesive layer may be required for more secure adhesion.
  • sheets or pieces of porous layer may be separately adhered to the thermoformed sheet, after the molding process. Once again these pieces may be adhesively or mechanically secured. In some cases the pieces may be installed independently onto the panel to which the thermoformed acoustic sheet is attached.
  • the selection of the fibers used to form the fibrous web spacer material is important.
  • crystalline fibers have been found to increase the sag resistance compared to amorphous fibers.
  • amorphous fibers have been found to increase the sag resistance compared to crystalline fibers.
  • the fibrous web spacer material of the preferred embodiment has previously been described as a vertically lapped, thermally bonded non-woven produced by the STRUTO, or other, process.
  • this fibrous web spacer material is thermoformed with, or without, the thermo-formable acoustic sheet, the vertical fibers adopt a v-orientation by flexing at the centre-line of the web.
  • the fibers may adopt a z-orientation, by flexing at the outer layers of the web. In both instances, this results in a change in the mechanical properties of the web, making it behave more effectively as a spring, improving resilience and resulting in a lower cut-off frequency.
  • thermo-formable acoustic product 12 is shown which is formed from a decorative layer 13 , a compressed flow restive acoustic layer 15 , a layer of porous flow resistive spacer material 17 , and a second flow resistive acoustic sheet 19 may also be used to further mechanically stabilise the product, or assist in the attachment to another surface 20 .
  • the surface may also have holes 21 .
  • an adhesive layer 14 , 15 and 18 may also be provided to assist attachment.
  • thermo-formable acoustic product 28 is shown which is formed from a decorative layer 22 , a compressed flow resistive acoustic layer 24 , and a layer of porous flow resistive spacer material 26 and adhesive layers 23 and 24 between those layers.
  • the product is applied to a surface 27 , conforming to that shape.
  • thermo-formable acoustic product 35 is shown which is formed from a decorative layer 29 , a compressed flow resistive acoustic layer 30 , and a layer of porous flow resistive spacer material 31 and adhesive layers 32 and 33 between those layers.
  • the product is thermo-formed to conform the shape of the surface 34 .
  • a compressed flow resistive sheet comprising both high melt and low melt bicomponent polyester fibers was formed in accordance with PCT/AU01/00880.
  • the sheet comprised 70% 4 denier low melt bicomponent fibers, and 30% 6-denier high melt polyester staple fibers.
  • the total mass of the flow resistive sheet was 1000 g/m 2 .
  • the resultant product had a total flow resistance of 3200 Rayls and was 23 mm thick.
  • the composite was tested in an alpha cabin, using Toyota test specification TSL 0600G—Test method for acoustic materials, for sound absorption and transmission loss and the results were compared with a target specification based on the prior art, with the same total mass.
  • the product of the current invention demonstrated improved low frequency sound absorption as shown in FIG. 7 and a higher transmission loss as shown in FIG. 6 .
  • Three samples of spacer layers similar to the spacer layer formed in Example 1 were formed using 2.5, 3.7 and 6 denier average fiber size except that the spacer layer had a total mass of 600 gsm.
  • a plot of the sound absorption coefficient versus frequency of the three samples is shown in FIG. 8 .
  • FIGS. 9 and 10 show the effect of the thickness of the spacer layer on the sound absorption coefficient and the transmission loss at frequencies between 200 Hz and 6300 Hz.
  • Example 2 A similar product was formed to the product formed in Example 2 except four samples having densities of 400, 600, 800 and 1000 grams per square meter were formed using a blend of fibers having a 2.5 denier average fiber size. The dynamic properties of stiffness and loss factor were measured for each sample and a plot of stiffness and loss factor versus density appears as FIG. 11 .
  • Example 2 A similar product was formed to the product formed in Example 2 except four samples having densities of 400, 600, 800 and 1000 grams per square meter were formed using a blend of fibers having a 3.7 denier average fiber size. The dynamic properties of stiffness and loss factor were measured for each sample and a plot of stiffness and loss factor versus density appears as FIG. 12 .

Landscapes

  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Acoustics & Sound (AREA)
  • Multimedia (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Laminated Bodies (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
US11/210,462 2004-02-25 2005-08-24 Thermoformable acoustic product Abandoned US20060090958A1 (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
AU2004900927 2004-02-25
AU2004900927A AU2004900927A0 (en) 2004-02-25 Thermoformable acoustic sheet
AU2004901262 2004-03-11
AU2004901262A AU2004901262A0 (en) 2004-03-11 Decorative thermoformable acoustic product
PCT/AU2005/000239 WO2005081226A1 (en) 2004-02-25 2005-02-25 Thermoformable acoustic product

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU2005/000239 Continuation-In-Part WO2005081226A1 (en) 2004-02-25 2005-02-25 Thermoformable acoustic product

Publications (1)

Publication Number Publication Date
US20060090958A1 true US20060090958A1 (en) 2006-05-04

Family

ID=34888007

Family Applications (1)

Application Number Title Priority Date Filing Date
US11/210,462 Abandoned US20060090958A1 (en) 2004-02-25 2005-08-24 Thermoformable acoustic product

Country Status (5)

Country Link
US (1) US20060090958A1 (https=)
EP (1) EP1719113A1 (https=)
JP (1) JP2007523773A (https=)
KR (1) KR20070056000A (https=)
WO (1) WO2005081226A1 (https=)

Cited By (33)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060289231A1 (en) * 2005-06-28 2006-12-28 Priebe Joseph A Acoustic absorber/barrier composite
US20080022645A1 (en) * 2006-01-18 2008-01-31 Skirius Stephen A Tacky allergen trap and filter medium, and method for containing allergens
US20080050565A1 (en) * 2005-04-01 2008-02-28 Buckeye Technologies Inc. Fire retardant nonwoven material and process for manufacture
US20080081163A1 (en) * 2000-07-19 2008-04-03 I.N.C. Corporation Pty Ltd. Thermoformable acoustic sheet
US20080121461A1 (en) * 2005-04-01 2008-05-29 Gross James R Nonwoven material for acoustic insulation, and process for manufacture
US20090019825A1 (en) * 2007-07-17 2009-01-22 Skirius Stephen A Tacky allergen trap and filter medium, and method for containing allergens
US20100000640A1 (en) * 2005-10-31 2010-01-07 I.N.C. Corporation Pty Ltd In Tyre Sound Absorber
US20100095846A1 (en) * 2006-01-18 2010-04-22 Buckeye Technologies Inc. Tacky allergen trap and filter medium, and method for containing allergens
US20100314195A1 (en) * 2009-06-12 2010-12-16 Richard James Bliton Acoustically Tunable Sound Absorption Articles and Methods of Making Same
US7918313B2 (en) 2005-04-01 2011-04-05 Buckeye Technologies Inc. Nonwoven material for acoustic insulation, and process for manufacture
US20110114414A1 (en) * 2009-06-12 2011-05-19 Precision Fabrics Group, Inc. Acoustically tunable sound absorption articles and methods of making same
US20130069505A1 (en) * 2011-09-21 2013-03-21 Whirlpool Corporation Dishwasher with multi-piece tub
US20130192921A1 (en) * 2008-05-23 2013-08-01 Zephyros, Inc. Sound Absorption Material and Method of Manufacturing Sound Absorption Material
US20140014439A1 (en) * 2008-10-16 2014-01-16 Zephyros, Inc. Composite sound absorber
US20140245797A1 (en) * 2011-09-30 2014-09-04 Owens Corning Intellectual Capital, Llc Method of forming a web from fibrous material
US20150118932A1 (en) * 2013-10-31 2015-04-30 Precision Fabrics Group, Inc. Porous polymer coatings
US9546439B2 (en) 2014-05-15 2017-01-17 Zephyros, Inc. Process of making short fiber nonwoven molded articles
US9714480B2 (en) 2011-05-24 2017-07-25 Owens Corning Intellectual Capital, Llc Acoustically insulated machine
WO2017192529A1 (en) * 2016-05-02 2017-11-09 Zephyros, Inc. Skinned fibrous composite
JP2017533142A (ja) * 2014-10-30 2017-11-09 オートニアム マネジメント アクチエンゲゼルシャフトＡｕｔｏｎｅｕｍ Ｍａｎａｇｅｍｅｎｔ ＡＧ 軽量音響トリム部品
US9845564B2 (en) 2010-12-31 2017-12-19 Owens Corning Intellectual Capital, Llc Appliance having a housing dampening portion and method
US20180158444A1 (en) * 2006-06-30 2018-06-07 3M Innovative Properties Company Sound insulation constructions and methods of using the same
US10113322B2 (en) 2014-12-08 2018-10-30 Zephyros, Inc. Vertically lapped fibrous flooring
US20190051282A1 (en) * 2015-10-16 2019-02-14 Auralex Acoustics Acoustic system and method
US10460715B2 (en) 2015-01-12 2019-10-29 Zephyros, Inc. Acoustic floor underlay system
WO2020072412A1 (en) 2018-10-03 2020-04-09 Zephyros, Inc. Composite structure
US10755686B2 (en) 2015-01-20 2020-08-25 Zephyros, Inc. Aluminized faced nonwoven materials
CN113439023A (zh) * 2019-02-14 2021-09-24 泽费罗斯股份有限公司 缓冲地板衬垫
US11478760B2 (en) * 2013-08-30 2022-10-25 Nitto Denko Corporation Waterproof gas-permeable membrane, waterproof gas-permeable member and waterproof gas-permeable structure including same, and waterproof sound-permeable membrane
US11541626B2 (en) 2015-05-20 2023-01-03 Zephyros, Inc. Multi-impedance composite
US11820102B2 (en) 2017-02-06 2023-11-21 Zephyros, Inc. Nonpermeable composite material
IT202300012879A1 (it) * 2023-06-22 2024-12-22 Dalessandro Giuseppe Pannello poroso semilavorato in fibre sintetiche e processo per ottenerlo.
US12590393B2 (en) 2011-09-30 2026-03-31 Owens Corning Intellectual Capital, Llc Method of forming a web from fibrous materials

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2900419B1 (fr) * 2006-04-26 2009-02-13 Schlumberger Sa N Procede de fabrication de non-tisse en trois dimensions, ligne de fabrication pour la mise en oeuvre de ce procede et produit non-tisse en trois dimensions obtenu
KR101658628B1 (ko) 2008-12-04 2016-09-22 제피로스, 인크. 단섬유들로부터 만들어지는 부직포
JP6427354B2 (ja) * 2013-08-05 2018-11-21 テクノＵｍｇ株式会社 外観性に優れた軋み音低減樹脂部品、複合構造体及び軋み音の低減方法
KR102322387B1 (ko) * 2017-09-07 2021-11-04 현대자동차주식회사 차량용 플로워 카페트 언더패드 및 그 제조방법
EP3608601B1 (en) 2018-08-06 2024-06-12 Zephyros Inc. Gas-duct with a sound absorbing component
DE102020125477A1 (de) 2020-09-30 2022-03-31 Adler Pelzer Holding Gmbh Vernadelte Sandwich-Vliesstruktur, und Verfahren zu dessen Herstellung
DE102021108602A1 (de) 2021-04-07 2022-10-13 Adler Pelzer Holding Gmbh Verfahren zur Herstellung einer Schallisolierung mit Vlies-Isolation und Schallisolierung

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5824973A (en) * 1992-09-29 1998-10-20 Johns Manville International, Inc. Method of making sound absorbing laminates and laminates having maximized sound absorbing characteristics
US6145617A (en) * 1996-10-29 2000-11-14 Rieter Automotive Ag Ultra-light, multifunctional sound-insulating kit
US6296075B1 (en) * 2000-06-02 2001-10-02 Lear Corporation Lightweight acoustical system
US20030066708A1 (en) * 2001-10-05 2003-04-10 Allison T. J. Sound attenuating material for use within vehicles and methods of making same
US20030099810A1 (en) * 2001-11-26 2003-05-29 Allison T. J. Porous carpeting for vehicles and methods of producing same
US20040131836A1 (en) * 2003-01-02 2004-07-08 3M Innovative Properties Company Acoustic web
US20040231915A1 (en) * 2003-01-02 2004-11-25 3M Innovative Properties Company Sound absorptive multilayer composite

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0593716B1 (en) * 1992-05-08 1998-10-14 Gates Formed-Fibre Products Inc. Nonwoven moldable composite and method of manufacture
US5459291A (en) * 1992-09-29 1995-10-17 Schuller International, Inc. Sound absorption laminate
JP3213252B2 (ja) * 1997-03-03 2001-10-02 カネボウ株式会社 吸音材およびその製造方法

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5824973A (en) * 1992-09-29 1998-10-20 Johns Manville International, Inc. Method of making sound absorbing laminates and laminates having maximized sound absorbing characteristics
US6145617A (en) * 1996-10-29 2000-11-14 Rieter Automotive Ag Ultra-light, multifunctional sound-insulating kit
US6296075B1 (en) * 2000-06-02 2001-10-02 Lear Corporation Lightweight acoustical system
US20030066708A1 (en) * 2001-10-05 2003-04-10 Allison T. J. Sound attenuating material for use within vehicles and methods of making same
US20030099810A1 (en) * 2001-11-26 2003-05-29 Allison T. J. Porous carpeting for vehicles and methods of producing same
US20040131836A1 (en) * 2003-01-02 2004-07-08 3M Innovative Properties Company Acoustic web
US20040231915A1 (en) * 2003-01-02 2004-11-25 3M Innovative Properties Company Sound absorptive multilayer composite

Cited By (56)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20080081163A1 (en) * 2000-07-19 2008-04-03 I.N.C. Corporation Pty Ltd. Thermoformable acoustic sheet
US7749595B2 (en) * 2000-07-19 2010-07-06 I.N.C. Corporation Pty Ltd Thermoformable acoustic sheet
US7878301B2 (en) 2005-04-01 2011-02-01 Buckeye Technologies Inc. Fire retardant nonwoven material and process for manufacture
US20080050565A1 (en) * 2005-04-01 2008-02-28 Buckeye Technologies Inc. Fire retardant nonwoven material and process for manufacture
US20080121461A1 (en) * 2005-04-01 2008-05-29 Gross James R Nonwoven material for acoustic insulation, and process for manufacture
US7918313B2 (en) 2005-04-01 2011-04-05 Buckeye Technologies Inc. Nonwoven material for acoustic insulation, and process for manufacture
US7837009B2 (en) 2005-04-01 2010-11-23 Buckeye Technologies Inc. Nonwoven material for acoustic insulation, and process for manufacture
US20060289231A1 (en) * 2005-06-28 2006-12-28 Priebe Joseph A Acoustic absorber/barrier composite
US9278586B2 (en) * 2005-10-31 2016-03-08 Zephyros, Inc. In tire sound absorber
US20100000640A1 (en) * 2005-10-31 2010-01-07 I.N.C. Corporation Pty Ltd In Tyre Sound Absorber
US9868319B2 (en) 2005-10-31 2018-01-16 Zephyros, Inc. In tire sound absorber
US20100095846A1 (en) * 2006-01-18 2010-04-22 Buckeye Technologies Inc. Tacky allergen trap and filter medium, and method for containing allergens
US7727915B2 (en) 2006-01-18 2010-06-01 Buckeye Technologies Inc. Tacky allergen trap and filter medium, and method for containing allergens
US20080022645A1 (en) * 2006-01-18 2008-01-31 Skirius Stephen A Tacky allergen trap and filter medium, and method for containing allergens
US20180158444A1 (en) * 2006-06-30 2018-06-07 3M Innovative Properties Company Sound insulation constructions and methods of using the same
US20090019825A1 (en) * 2007-07-17 2009-01-22 Skirius Stephen A Tacky allergen trap and filter medium, and method for containing allergens
US20130192921A1 (en) * 2008-05-23 2013-08-01 Zephyros, Inc. Sound Absorption Material and Method of Manufacturing Sound Absorption Material
US9033101B2 (en) * 2008-05-23 2015-05-19 Zephyros, Inc. Sound absorption material and method of manufacturing sound absorption material
US20150129355A1 (en) * 2008-10-16 2015-05-14 Zephyros, Inc. Composite sound absorber
US20140014439A1 (en) * 2008-10-16 2014-01-16 Zephyros, Inc. Composite sound absorber
US9623627B2 (en) * 2008-10-16 2017-04-18 Zephyros, Inc. Composite sound absorber
US8950549B2 (en) * 2008-10-16 2015-02-10 Zephyros, Inc. Composite sound absorber
US8607929B2 (en) 2009-06-12 2013-12-17 Precision Fabrics Group, Inc. Acoustically tunable sound absorption articles and methods of making same
US20100314195A1 (en) * 2009-06-12 2010-12-16 Richard James Bliton Acoustically Tunable Sound Absorption Articles and Methods of Making Same
US8439161B2 (en) 2009-06-12 2013-05-14 Precision Fabrics Group, Inc. Acoustically tunable sound absorption articles
US8403108B2 (en) 2009-06-12 2013-03-26 Precision Fabrics Group, Inc. Acoustically tunable sound absorption articles and methods of making same
US20110114414A1 (en) * 2009-06-12 2011-05-19 Precision Fabrics Group, Inc. Acoustically tunable sound absorption articles and methods of making same
US9845564B2 (en) 2010-12-31 2017-12-19 Owens Corning Intellectual Capital, Llc Appliance having a housing dampening portion and method
US9714480B2 (en) 2011-05-24 2017-07-25 Owens Corning Intellectual Capital, Llc Acoustically insulated machine
US9549657B2 (en) * 2011-09-21 2017-01-24 Whirlpool Corporation Dishwasher with multi-piece tub
US20130069505A1 (en) * 2011-09-21 2013-03-21 Whirlpool Corporation Dishwasher with multi-piece tub
US20140245797A1 (en) * 2011-09-30 2014-09-04 Owens Corning Intellectual Capital, Llc Method of forming a web from fibrous material
US12590393B2 (en) 2011-09-30 2026-03-31 Owens Corning Intellectual Capital, Llc Method of forming a web from fibrous materials
US11939255B2 (en) * 2011-09-30 2024-03-26 Owens Corning Intellectual Capital, Llc Method of forming a web from fibrous material
US11478760B2 (en) * 2013-08-30 2022-10-25 Nitto Denko Corporation Waterproof gas-permeable membrane, waterproof gas-permeable member and waterproof gas-permeable structure including same, and waterproof sound-permeable membrane
US10563068B2 (en) * 2013-10-31 2020-02-18 Precision Fabrics Group, Inc. Porous polymer coatings
US20150118932A1 (en) * 2013-10-31 2015-04-30 Precision Fabrics Group, Inc. Porous polymer coatings
US10329701B2 (en) 2014-05-15 2019-06-25 Zephyros, Inc. Method of forming a nonwoven molded article
US9546439B2 (en) 2014-05-15 2017-01-17 Zephyros, Inc. Process of making short fiber nonwoven molded articles
JP2017533142A (ja) * 2014-10-30 2017-11-09 オートニアム マネジメント アクチエンゲゼルシャフトＡｕｔｏｎｅｕｍ Ｍａｎａｇｅｍｅｎｔ ＡＧ 軽量音響トリム部品
US10457225B2 (en) * 2014-10-30 2019-10-29 Autoneum Management Ag Light weight acoustic trim part
US20170361785A1 (en) * 2014-10-30 2017-12-21 Autoneum Management Ag Light weight acoustic trim part
US10113322B2 (en) 2014-12-08 2018-10-30 Zephyros, Inc. Vertically lapped fibrous flooring
US11542714B2 (en) 2014-12-08 2023-01-03 Zephyros, Inc. Vertically lapped fibrous flooring
US10460715B2 (en) 2015-01-12 2019-10-29 Zephyros, Inc. Acoustic floor underlay system
US10755686B2 (en) 2015-01-20 2020-08-25 Zephyros, Inc. Aluminized faced nonwoven materials
US11541626B2 (en) 2015-05-20 2023-01-03 Zephyros, Inc. Multi-impedance composite
US20190051282A1 (en) * 2015-10-16 2019-02-14 Auralex Acoustics Acoustic system and method
US11955106B2 (en) * 2015-10-16 2024-04-09 Auralex Acoustics Inc Acoustic system and method
WO2017192529A1 (en) * 2016-05-02 2017-11-09 Zephyros, Inc. Skinned fibrous composite
US11820102B2 (en) 2017-02-06 2023-11-21 Zephyros, Inc. Nonpermeable composite material
WO2020072412A1 (en) 2018-10-03 2020-04-09 Zephyros, Inc. Composite structure
US12083754B2 (en) 2018-10-03 2024-09-10 Zephyros, Inc. Composite structure
US20220105701A1 (en) * 2019-02-14 2022-04-07 Zephyros, Inc. Cushioning flooring underlayment
CN113439023A (zh) * 2019-02-14 2021-09-24 泽费罗斯股份有限公司 缓冲地板衬垫
IT202300012879A1 (it) * 2023-06-22 2024-12-22 Dalessandro Giuseppe Pannello poroso semilavorato in fibre sintetiche e processo per ottenerlo.

Also Published As

Publication number Publication date
JP2007523773A (ja) 2007-08-23
WO2005081226A1 (en) 2005-09-01
EP1719113A1 (en) 2006-11-08
KR20070056000A (ko) 2007-05-31

Similar Documents

Publication Publication Date Title
US20060090958A1 (en) Thermoformable acoustic product
CA1243256A (en) Thermoformable composite articles
US6204209B1 (en) Acoustical composite headliner
EP3297821B1 (en) Multi-impedance composite
US7137477B2 (en) Sound absorbers
US7226879B2 (en) Multidensity liner/insulator formed from multidimensional pieces of polymer fiber blanket insulation
CN100450823C (zh) 用于汽车的模制内部装饰安装材料
EP1438467A2 (en) Sound attenuating material for use within vehicles and methods of making same
WO1996013377A1 (en) Self-supporting impact resistant laminate
US20250269623A1 (en) Nonwoven composite for air flow applications
US10460715B2 (en) Acoustic floor underlay system
US20170088750A1 (en) High temperature moldable pressure sensitive adhesive system
US11820102B2 (en) Nonpermeable composite material
US20050191921A1 (en) Multidensity liner/insulator having reinforcing ribs
AU2005203796A1 (en) Thermoformable acoustic product
EP3413302B1 (en) Sound attenuation sheet

Legal Events

Date Code Title Description
AS Assignment

Owner name: I.N.C. CORPORATION PTY. LTD., AUSTRALIA

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:COATES, MICHAEL WILLIAM;KIERZKOWSKI, MAREK HENRYK;SIMMONS, JOHN CAMPBELL;AND OTHERS;REEL/FRAME:017010/0295

Effective date: 20051216

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION

AS Assignment

Owner name: EMAN8 PTY LTD, AUSTRALIA

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:I.N.C. CORPORATION PTY LTD;REEL/FRAME:025644/0588

Effective date: 20100710

AS Assignment

Owner name: ZEPHYROS, INC., MICHIGAN

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:EMAN8 PTY LTD;REEL/FRAME:028762/0128

Effective date: 20120627