An improved acoustical system for inhibiting noise in a motor vehicle. The system comprises an impermeable layer and an underlayment adjacent to the impermeable layer. The underlayment includes a first fibrous layer and a second fibrous layer. The underlayment has an airflow resistance between about 2000 and about 5000 mks Rayls.
|
0. 17. An acoustical system comprising:
a water-impermeable layer;
an underlayment adjacent to the impermeable layer, the underlayment including a first layer and a second layer, the first layer having a density less than a density of the second layer, and a semi-permeable layer disposed between the first and second layers; and
the underlayment having a specific airflow resistance between about 2000 and about 5000 mks Rayls.
1. An acoustical system comprising:
a water-impermeable layer;
an underlayment adjacent to the impermeable layer, the underlayment including a first fibrous layer and a second fibrous layer, the first fibrous layer having a density less than a density of the second fibrous layer;
the underlayment having a specific airflow resistance between about 2000 and about 5000 mks Rayls; and
a semi-permeable layer disposed between the first and second fibrous layers.
0. 25. A carpet with noise-inhibiting characteristics for use in a motor vehicle, the carpet comprising:
a water-impermeable layer; and
an underlayment adjacent to the impermeable layer, the underlayment including a first layer and a second layer, the first layer having a density less than a density of the second layer;
the underlayment having a specific air flow resistance between about 2000 and 5000 mks Rayls;
wherein the first and second layers have a surface density between about 500 grams per square meter and about 1400 grams per square meter.
0. 32. A system for inhibiting noise in a motor vehicle, the system comprising:
an impermeable layer; and
an underlayment adjacent to the impermeable layer, the underlayment including a first layer, a second layer, and a semi-permeable layer, the first layer having a surface density between about 500 grams per square meter and about 1400 grams per square meter, and the second layer having a surface density between about 500 grams per square meter and about 1400 grams per square meter;
the underlayment having a specific airflow resistance between about 2000 and about 5000 mks Rayls.
9. A carpet with noise-inhibiting characteristics for use in a motor vehicle, the carpet comprising:
a water-impermeable layer; and
an underlayment adjacent to the impermeable layer, the underlayment including a first fibrous layer and a second fibrous layer, the first fibrous layer having a density less than a density of the second fibrous layer;
the underlayment having a specific airflow resistance between about 2000 and about 5000 mks Rayls;
wherein the first and second fibrous layers have a surface density between about 500 grams per square meter and about 1400 grams per square meter.
16. A system for inhibiting noise in a motor vehicle, the system comprising:
an impermeable layer; and
an underlayment adjacent to the impermeable layer, the underlayment including a first fibrous layer, a second fibrous layer, and a semi-permeable layer, the first layer having a surface density between about 500 grams per square meter and about 1400 grains grams per square meter, and the second layer having a surface density between about 500 grams per square meter and about 1400 grams per square meter;
the underlayment having a specific airflow resistance between about 2000 and about 5000 mks Rayls.
3. The acoustical system of
4. The acoustical system of
5. The acoustical system of
7. The acoustical system of
8. The acoustical system of
10. The carpet of
14. The carpet of
15. The carpet of
0. 18. The acoustical system of
0. 19. The acoustical system of
0. 20. The acoustical system of
0. 21. The acoustical system of
0. 22. The acoustical system of
0. 23. The acoustical system of
0. 24. The acoustical system of
0. 26. The carpet of
0. 27. The carpet of
0. 28. The carpet of
0. 29. The carpet of
0. 30. The carpet of
0. 31. The carpet of
|
This invention relates to acoustical systems.
The use of a permeable facing fabric or film on an acoustical absorber to improve its low frequency response has been shown in the literature and in numerous commercial applications, primarily in the building and construction field. Recently this concept has been applied to motor vehicle interior acoustical products. While these arrangements may demonstrate improved sound transmission loss in the mid-frequency range as compared to a double-walled system, they also typically exhibit decreased sound transmission loss at higher frequencies. Furthermore, a porous surface may cause several practical problems. When used on the floor of a motor vehicle, an acoustical absorber having a water-permeable facing is susceptible to water intrusion which may cause formation of mildew and odor in the underpad, as well as rust the floor pan in some cases.
This invention provides an improved acoustical system comprising a water-impermeable layer and an underlayment. The underlayment is adjacent to the impermeable layer, and includes a first fibrous layer and a second fibrous layer. The first fibrous layer has a density less than the density of the second fibrous layer, and the underlayment has an airflow resistance between about 2000 and about 5000 mks Rayls.
Accordingly, it is an object of the present invention to provide an improved acoustical system which functions sufficiently over a broad frequency range. Another object of the present invention is to provide an improved acoustical barrier which is not susceptible to water intrusion.
These and other objects, features, and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in conjunction with the accompanying drawings.
With reference to the drawing, the preferred embodiments of the present invention will be described.
The underlayment 14 is situated next to the impermeable layer 12, and includes a first or lofty fibrous layer 16 and a second or compressed fibrous layer 18. In a preferred embodiment, both of the layers 16 and 18 contain recycled, non-woven fibers which have been fluffed and combed to create a non-directional matrix or batt. Both layers 16 and 18 preferably have a surface density between about 500 grams per square meter and about 1400 grams per square meter.
A semi-permeable layer 20, comprising a fusible plastic film or cellulose filter scrim with a heat-settable adhesive, is preferably positioned between the layers 16 and 18 to provide additional airflow resistance and to help bond the layers together. In the case of a scrim, the material preferably has a surface density in the range of about 44 grams per square meter. A decorative layer 22 such as carpet or a face fabric may also be provided adjacent to the impermeable layer 12.
To make the acoustical system 10, approximately equal thicknesses of the layers 16 and 18 are first preferably heat set through an oven. One of the layers 16 or 18 is then bonded to the semi-permeable layer 20, and the combination bonded to the other layer 18 or 16. The resulting laminate is heated for about 30-40 seconds at about 400 to 450 degrees F, and then put into a cooled mold. When the mold is closed, the layers 16 and 18 are differentially compressed. The facing 22, which is first coated with the impermeable layer 12 of a 200-500 grams per square meter polyethylene to a thickness less than 1 mm, and more preferably about 0.1 mm, is then bonded to the underlayment 14 by heating the impermeable layer to near its melting point, and then transferring it to a cool mold into which the underlayment has been placed.
In the final product, the underlayment 14 preferably has a total thickness of 10-25 millimeters (mm), with the second or compressed layer 18 accounting for about 3 mm of that thickness and a resultingly higher as-molded density than the first or lofty layer 16. In this configuration, the underlayment has a specific airflow resistance between about 2000 and about 5000 mks Rayls, and preferably between about 2500 and 4500 mks Rayls. The system 10 can be placed on the sheet metal 24 of the motor vehicle so that the lofty layer 16 is next to the metal and the compressed layer 18 is next to the impermeable layer 12.
The invention is an improvement over the prior art. It modifies the construction for improved performance over a broad frequency range and eliminates the physical deficiencies. The sound transmission loss of this system is significantly improved over a typical heavy barrier system in the mid-range frequencies of about 200 to 1000 Hz, and is roughly equivalent to a heavy barrier system at high frequencies as well. These results were not expected based on experience with previous lightweight systems. Other lightweight systems all demonstrate a significant reduction in transmission loss at higher frequencies. Furthermore, the system 10 is preferably formed entirely from thermoplastics so as to be totally recyclable.
This invention is particularly applicable to floor systems for motor vehicles, but may have other vehicle or architectural noise attenuation applications. In some of those applications, such as dash insulators for motor vehicles, a carpet is not necessary. The design of the impermeable layer allows the acoustical properties of the construction to be tailored for transmission loss and/or sound absorption over specific frequency regions.
While the embodiments of the invention shown and described above constitute preferred embodiments of the invention, they are not intended to illustrate all possible forms thereof. It should also be understood that the words used are words of description rather than limitation, and various changes may be made without departing from the spirit and scope of the invention disclosed.
Wyerman, Barry, Gish, Laura E., Huang, Liangyu, Ebbitt, Gordon, Boyles, David
Patent | Priority | Assignee | Title |
7727915, | Jan 18 2006 | Glatfelter Corporation | Tacky allergen trap and filter medium, and method for containing allergens |
7785437, | Sep 26 2003 | L&P Property Management Company | Anti-microbial carpet underlay and method of making |
7837009, | Apr 01 2005 | Georgia-Pacific Nonwovens LLC | Nonwoven material for acoustic insulation, and process for manufacture |
7875343, | Sep 26 2003 | L & P Property Management Company | Anti-microbial carpet underlay and method of making |
7878301, | Apr 01 2005 | Glatfelter Corporation | Fire retardant nonwoven material and process for manufacture |
7918313, | Apr 01 2005 | Glatfelter Corporation | Nonwoven material for acoustic insulation, and process for manufacture |
7928025, | Oct 01 2008 | Nonwoven Network LLC | Nonwoven multilayered fibrous batts and multi-density molded articles made with same and processes of making thereof |
8157051, | Jul 25 2007 | FAURECIA AUTOMOTIVE INDUSTRIE | Moulded soundproofing component, and manufacturing method thereof |
8418806, | Jan 13 2012 | Janesville Acoustics, a Unit of Jason Incorporated | Sound attenuating device using an embedded layer for acoustical tuning |
8590669, | Jan 13 2012 | Janesville Acoustics, a Unit of Jason Incorporated | Sound attenuating device using an embedded layer for acoustical tuning |
8631899, | Oct 24 2007 | KONOA GMBH | Sound absorber |
Patent | Priority | Assignee | Title |
3948347, | Nov 25 1974 | GALLAGHER-KAISER CORPORATION | Acoustical panel |
4508774, | Mar 12 1984 | BASF Aktiengesellschaft | Cellular, molded polyurethane parts, process for their preparation by thermoforming of polyester-urethane foam and their use |
4741945, | Jul 30 1986 | ARCO CHEMICAL TECHNOLOGY, L P A PARTNERSHIP OF DE | Automotive trim panel |
4838524, | Sep 08 1987 | Cyclops Corporation | Noise barrier |
5079074, | Aug 31 1990 | POLYESTER FIBERS, LLC, A DELAWARE LIMITED LIABILITY COMPANY | Dual density non-woven batt |
5258585, | Feb 20 1991 | BBI ENTERPRISES GROUP, INC | Insulating laminate |
5334338, | Mar 24 1988 | Dr. Alois Stankiewicz GmbH | Process for manufacturing a sound insulating structure |
5459291, | Sep 29 1992 | SCHULLER INTERNATIONAL, INC | Sound absorption laminate |
5492580, | May 08 1992 | Gates Formed-Fibre Products, Inc. | Nonwoven moldable composite and method of manufacture |
5536556, | Feb 20 1991 | BBI ENTERPRISES GROUP, INC | Insulating laminate |
5549776, | Jul 02 1993 | BBI ENTERPRISES GROUP, INC | Self-supporting impact resistant laminate |
5565259, | Feb 20 1991 | BBI ENTERPRISES GROUP, INC | Self-supporting impact resistant laminate |
5684278, | Nov 18 1994 | ECESIS LLC | Acoustical ceramic panel and method |
5721177, | May 08 1992 | Gates Formed-Fibre Products, Inc. | Nonwoven moldable composite |
5824973, | Sep 29 1992 | JOHNS MANVILLE INTERNATIONAL, INC | Method of making sound absorbing laminates and laminates having maximized sound absorbing characteristics |
5866235, | Feb 21 1997 | Eften, Inc. | All synthetic fiber interior trim substrate |
5892187, | Dec 17 1997 | United Technologies Corporation | Tunable recyclable headliner |
5976295, | Aug 30 1996 | FCA US LLC | Method of molding a recyclable multi-layer component from plastics material |
6145617, | Oct 29 1996 | AUTONEUM INTERNATIONAL AG | Ultra-light, multifunctional sound-insulating kit |
6720068, | Mar 03 1998 | AUTONEUM INTERNATIONAL AG | Sound absorbent thin-layer laminate |
EP229977, | |||
EP732684, | |||
EP934180, | |||
GB2100620, | |||
GB2163388, | |||
GB2319998, | |||
JP4009898, | |||
JP6248545, | |||
WO9818656, | |||
WO9818657, | |||
WO9944817, |
Date | Maintenance Fee Events |
Mar 04 2009 | M1552: Payment of Maintenance Fee, 8th Year, Large Entity. |
May 10 2013 | REM: Maintenance Fee Reminder Mailed. |
Oct 02 2013 | EXP: Patent Expired for Failure to Pay Maintenance Fees. |
Date | Maintenance Schedule |
Mar 14 2009 | 4 years fee payment window open |
Sep 14 2009 | 6 months grace period start (w surcharge) |
Mar 14 2010 | patent expiry (for year 4) |
Mar 14 2012 | 2 years to revive unintentionally abandoned end. (for year 4) |
Mar 14 2013 | 8 years fee payment window open |
Sep 14 2013 | 6 months grace period start (w surcharge) |
Mar 14 2014 | patent expiry (for year 8) |
Mar 14 2016 | 2 years to revive unintentionally abandoned end. (for year 8) |
Mar 14 2017 | 12 years fee payment window open |
Sep 14 2017 | 6 months grace period start (w surcharge) |
Mar 14 2018 | patent expiry (for year 12) |
Mar 14 2020 | 2 years to revive unintentionally abandoned end. (for year 12) |