Sound insulation constructions and methods of using the same

Patent metadata

Field	Value
Publication number	US-9922634-B2
Application number	US-74339607-A
Country	US
Kind code	B2
Filing date	May 2, 2007
Priority date	Jun 30, 2006
Publication date	Mar 20, 2018
Grant date	Mar 20, 2018

Abstract

Sound insulation constructions, multilayer constructions for acoustically insulating a source of sound from a receiver that include one or more sound insulation constructions, structures comprising one or more sound insulation constructions and/or multilayer constructions, and a method for acoustically insulating a source of sound from a receiver. In some embodiments, the sound insulation construction includes a first layer and a second layer. The first layer can include a bonded fiber nonwoven web exhibiting a work of compression of at least about 0.7 kJ/m 3 and an airflow resistance of no greater than 10,000 Rayls/m. The second layer can exhibit an airflow resistance of greater than 10,000 Rayls/m. In some embodiments, the method includes coupling the first layer to a surface of a vehicle to attenuate sound in at least a portion of the vehicle.

First claim

What is claimed is:

1. A sound insulation construction comprising:
a first layer comprising a bonded fiber nonwoven web exhibiting a work of compression of at least about 0.7 kJ/m 3 and an airflow resistance of no greater than 10,000 Rayls/m; and
a second layer coupled to the first layer, the second layer having an airflow resistance greater than 10,000 Rayls/m and being air permeable,
wherein the bonded fiber nonwoven web comprises at least one of:
a) a lofty, open nonwoven web comprising first and second crimped, staple, organic thermoplastic fibers,
b) a uniform, lofty, nonwoven web comprising interlaced randomly disposed flexible organic thermoplastic fibers;
c) a lofty, open nonwoven web comprising extruded or melt-spun polymer filament bundles of inter-engaged continuous crinkled coarse filaments of resilient thermoplastic polymer, and
d) a lofty, sponge-like, compressible nonwoven web comprising randomly intermingled and randomly bonded hydrophobic fibers;
and wherein individual fibers of the bonded fiber nonwoven web of the first layer are bonded to each other at fiber-bonding points by melt bonding or by a binder that extends between the individual fibers, the fiber-bonding points being distributed throughout the entire thickness of the bonded fiber nonwoven web.

2. The sound insulation construction of claim 1 , wherein the first layer exhibits a maximum acceleration of no greater than about 10 g.

3. The sound insulation construction of claim 1 , wherein the first layer exhibits a maximum acceleration of no greater than about 3 g.

4. The sound insulation construction of claim 1 , wherein the sound insulation construction exhibits at least about 60% absorption at a frequency of 1500 hertz.

5. The sound insulation construction of claim 1 , wherein the second layer comprises at least one of headliner facing, carpeting, trunk liner facing, side panel facing, dash facing, hood liner facing, an outwardly facing layer of a wheel well liner, and an outwardly facing layer of an engine cover.

6. The sound insulation construction of claim 1 , wherein the second layer comprises a nonwoven web.

7. The sound insulation construction of claim 1 , wherein the bonded fiber nonwoven web exhibits an airflow resistance no greater than about 2000 Rayls/m.

8. The sound insulation construction of claim 1 , wherein the bonded fiber nonwoven web exhibits an airflow resistance no greater than about 1500 Rayls/m.

9. The sound insulation construction of claim 1 , wherein the bonded fiber nonwoven web exhibits an airflow resistance no greater than about 1000 Rayls/m.

10. The sound insulation construction of claim 1 , wherein the bonded fiber nonwoven web exhibits a work of compression of at least 1 kJ/m 3 .

11. The sound insulation construction of claim 1 , wherein the bonded fiber nonwoven web has an acoustic performance parameter of no greater than about 10,000 g-Rayls/m.

12. The sound insulation construction of claim 1 , wherein the nonwoven web of the first layer comprises fibers having a diameter in the range of from about 25 μm to about 250 μm.

13. The sound insulation construction of claim 12 , wherein the nonwoven web of the first layer comprises fibers having a denier of from about 6 to about 400.

14. The sound insulation construction of claim 1 , wherein the first layer exhibits a damping loss factor of at least about 0.012.

15. The sound insulation construction of claim 1 , wherein the first layer exhibits a density of at least about 15 kg/m 3 .

16. The sound insulation construction of claim 1 , wherein the first layer exhibits a basis weight of at least about 0.2 kg/m 2 .

17. The sound insulation construction of claim 1 , wherein the first layer exhibits a solidity of no greater than about 0.3.

18. The sound insulation construction of claim 1 , wherein the first layer has a thickness of least about 5 mm.

19. The sound insulation construction of claim 1 , wherein the nonwoven web of the first layer comprises fibers having a length of from about 1 cm to about 10 cm.

20. The sound insulation construction of claim 1 , wherein the first layer is adjacent and bonded to the second layer.

21. A multilayer construction coupled to a surface of a structure and adapted to acoustically insulate a source of sound from a receiver, the multilayer construction comprising the sound insulation construction of claim 1 .

22. The multilayer construction of claim 21 , wherein the structure is selected from the group consisting of machines, appliances, laboratory equipment, medical equipment, power tools, and architectural structures.

23. The multilayer construction of claim 21 , wherein the structure forms at least a portion of a motor vehicle and is selected from the group consisting of a wheel well, a trunk, a ceiling, a side panel, a rear gate, a floor panel, a dash panel, a hood, an engine cover, and combinations thereof.

24. The multilayer construction of claim 21 , wherein the sound insulation construction is further coupled to a barrier layer, a decoupler layer, and an optional mastic layer, and wherein the multilayer construction forms a carpet laminate.

25. The multilayer construction of claim 21 , wherein the sound insulation construction is further coupled to at least one of shoddy, needle punched shoddy, foam, plastic, woven web, nonwoven web, film, and perforated film, and any combinations thereof.

26. An assembly comprising:
a sound insulation construction comprising;
a first layer comprising a bonded fiber nonwoven web exhibiting a work of compression of at least about 0.7 kJ/m 3 and an airflow resistance of no greater than 10,000 Rayls/m;
a second layer coupled to the first layer, the second layer having an airflow resistance greater than 10,000 Rayls/m;
wherein the first layer of the sound insulation construction is coupled to an additional layer,
and wherein the bonded fiber nonwoven web comprises at least one of:
a) a lofty, open nonwoven web comprising first and second crimped, staple, organic thermoplastic fibers,
b) a uniform, lofty, nonwoven web comprising interlaced randomly disposed flexible organic thermoplastic fibers;
c) a lofty, open nonwoven web comprising extruded or melt-spun polymer filament bundles of inter-engaged continuous crinkled coarse filaments of resilient thermoplastic polymer, and
d) a lofty, sponge-like, compressible nonwoven web comprising randomly intermingled and randomly bonded hydrophobic fibers;
and wherein individual fibers of the bonded fiber nonwoven web of the first layer are bonded to each other at fiber-bonding points by melt bonding or by a binder that extends between the individual fibers, the fiber-bonding points being distributed throughout the entire thickness of the bonded fiber nonwoven web.

27. The assembly of claim 26 , wherein the additional layer comprises metal.

28. The assembly of claim 26 , wherein the additional layer comprises an element selected from the group consisting of metal, mastics, foam, chopped fiberglass, fabric, film, and combinations thereof.

29. A sound insulation construction comprising:
a first layer exhibiting a density of at least about 15 kg/m 3 , a basis weight of at least about 0.2 kg/m 2 , a solidity of no greater than about 0.3, a thickness of least about 5 mm and a maximum acceleration of no greater than about 10 g, with the first layer comprising a bonde

Assignees

• Thompson Jr Delton R
• Gerdes Ronald W
• Nelson Brian L
• 3M Innovative Properties Co

Inventors

• Thompson Jr Delton R
• Gerdes Ronald W
• Nelson Brian L

Classifications

• B60R13/0861

  for covering undersurfaces of vehicles, e.g. wheel houses · CPC title

• G10K11/168 Primary

  Plural layers of different materials, e.g. sandwiches · CPC title

• B60R13/083

  for fire walls or floors · CPC title

• B60R13/0884

  for mounting around noise sources, e.g. air blowers · CPC title

• B32B5/26

  another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} · CPC title