Multi-layered fibrous structures for moderate temperature

Patent metadata

Field	Value
Publication number	US-11794445-B2
Application number	US-202017777683-A
Country	US
Kind code	B2
Filing date	Nov 16, 2020
Priority date	Nov 22, 2019
Publication date	Oct 24, 2023
Grant date	Oct 24, 2023

Abstract

An article comprising: (a) one or more nonwoven material layers comprising a lofted fibrous material; and (b) one or more molded material layers having a fibrous matrix, wherein the article is configured to at least partially thermally insulate an item or compartment and the article absorbs external heat or cold to substantially prevent amplitude of temperature fluctuation of the item or within the compartment.

First claim

What is claimed is:

1. An article comprising:
(a) one or more nonwoven material layers comprising a lofted fibrous material;
(b) one or more molded material layers having a fibrous matrix; and
(c) one or more infrared (IR) reflective layers disposed on one or more exterior surfaces of the article;
wherein at least one of the one or more molded material layers is a fiber cement layer, and wherein the article is configured to thermally insulate an item or compartment and the article absorbs external heat or cold to substantially prevent amplitude of temperature fluctuation of the item or within the compartment.

2. The article of claim 1 , wherein the item to be insulated is a cabin of a vehicle.

3. The article of claim 2 , wherein the external heat radiates from an engine bay.

4. The article of claim 1 , wherein the article is temperature resistant and temperature absorbent at a temperature range of about −30° C. to about 350° C.

5. The article of claim 4 , wherein the fibrous matrix includes fibers selected from polyester, polyacrylonitrile, oxidized polyacrylonitrile, aramid, olefin, polyamide, imide, polyetherketone, polyetheretherketone, poly(ethylene succinate), mineral, ceramic, natural, another inorganic fiber, or another polymeric fiber.

6. The article of claim 4 , wherein the lofted fibrous material is selected from polyester, polyacrylonitrile, oxidized polyacrylonitrile, aramid, olefin, polyamide, imide, polyetherketone, polyetheretherketone, poly(ethylene succinate), mineral, ceramic, natural, another inorganic fiber, or another polymeric fiber.

7. The article of claim 1 , wherein the one or more molded material layers are thermoformed.

8. The article of claim 1 , wherein one or more air pockets are located between the one or more nonwoven material layers and the one or more molded material layers.

9. The article of claim 8 , wherein the one or more nonwoven materials layers and the one or more molded materials layers are secured to one another via stitching to form the article.

10. The article of claim 9 , wherein the article is flexible, formable, or both.

11. The article of claim 1 , wherein the lofted fibrous material includes fibers that are generally vertically or near-vertically oriented.

12. The article of claim 1 , wherein the fibrous matrix includes fibers that are generally vertically or near-vertically oriented.

13. The article of claim 11 , wherein the lofted fibrous material and the fibrous matrix are made from generally the same fibers.

14. The article of claim 11 , wherein the lofted fibrous material and the fibrous matrix are made from different fibers.

15. The article of claim 1 , wherein the article includes at least two abutting nonwoven material layers sandwiched between at least two molded material layers.

16. The article of claim 1 , wherein the one or more IR reflective layers are aluminum laminated glass cloth, aluminum foil, or both.

17. The article of claim 1 , wherein the one or more nonwoven material layers and the one or more molded material layers each have a thickness of no greater than 50 mm.

18. The article of claim 17 , wherein the fibers of the lofted fibrous material have a weight of about 400 to about 800 GSM.

19. The article of claim 1 , wherein the one or more IR reflective layers are a coating applied to at least one of the one or more exterior surfaces of the article.

20. The article of claim 1 , wherein the lofted fibrous material includes fibers that are carded and lapped into a three-dimensional structure.

Assignees

• Zephyros Inc

Inventors

• Taxak Manish
• Kumaraguru Sivansankaran

Classifications

• B32B5/266 Primary

  next to one or more non-woven fabric layers · CPC title

• B32B5/022

  Non-woven fabric · CPC title

• B32B5/073

  characterised by the fibrous or filamentary layer being mechanically connected to another layer by sewing, stitching, hook-and-loop fastening or stitchbonding · CPC title

• B32B2255/02

  on fibrous or filamentary layer · CPC title

• B32B2307/304

  Insulating · CPC title