Abstract: The present invention provides a fibrous veil having a plurality of densified portions formed thereon for improved airflow resistance. The airflow resistance may be tuned to meet the needs of a particular application by selecting the size, density and location of the densified portions. The veil may be used independently or in combination with other sound control materials. The present invention also provides a fibrous blanket having a plurality of densified portions formed on one or both major surfaces thereof for improved airflow resistance. The airflow resistance may be tuned to meet the needs of a particular application by selecting the size and density of the densified portions. A method of manufacturing the materials of the present invention by applying heat and/or pressure to portions of the material is also presented.

Abstract: An apparatus and method are provided for forming a densified surface layer on a thermoplastic blanket. The apparatus includes first and second continuous belts, a treatment zone defined between those belts, first and second heating and densifying units and a cooler downstream from the heating and densifying units. The method includes the steps of continuously forming a densified surface layer on a face of a thermoplastic blanket and making the thermoplastic blanket with the densified surface layer to a desired thickness within strict dimensional tolerances. A densified thermoplastic blanket product is also disclosed.

Abstract: An acoustical and thermal insulator provided which is suitable for use in a vehicle. The insulator includes a nonlaminate acoustical and thermal insulating layer of blend of polymer fibers and natural fibers. The fiber blend provides a lower cost material with similar acoustical, thermal properties. The insulator includes a relatively high density, nonlaminate layer of the fiber blend and/or one or more facing layers constructed from various materials.

Abstract: A liner/insulator include including at least two individual layers of wet processed mat wherein the layers including thermoplastic polymer staple fibers and thermoplastic bicomponent fibers. The layers are bonded together by heat and pressure to provide “tunable” acoustical and thermal properties.

Abstract: A liner/insulator including a base layer of fibrous material and a plurality of ribs of fibrous insulation material thermally bonded to said base layer. The fibrous material is constructed of either (a) thermoplastic polymer staple fibers and thermoplastic bicomponent fibers, (b) glass staple fibers and thermoplastic bicomponent fibers and (c) a combination of (a) and (b).

Abstract: A process for forming a multilayer composite insulator includes: (a) forming an insulator precursor by orienting an insulation insert in a desired location between a first facing layer of and a layer of a polymer based blanket material; (b) closing the insulator precursor in a molding press; (c) heating the insulator precursor in the molding press to a temperature sufficiently high to soften polymer binding fiber in the polymer based blanket material and cause reshaping; and (d) cooling the insulator precursor in the molding press so as to set the insulator precursor in its molded shape and complete formation of the insulator. Other relates processes are also disclosed.

Abstract: In accordance with the purposes of the present invention as described herein, an improved acoustical, compressible, polymer fiber blanket of enhanced performance characteristics is provided. The polymer fiber blanket of the present invention is constructed of a plurality of individual pieces of polymer fiber blanket that have been bonded together via heat and pressure.

Abstract: A method of forming a box-like acoustical substrate is provided. Portions of an acoustical substrate having a decorative surface are compressed to form a flange, a first compressed region, a second compressed region, and a third compressed region. First, second, central, and third uncompressed regions are positioned respectively adjacent to the compressed regions. A left first surface and a right first surface of the acoustical substrate may be folded toward the back surface of the substrate until the second compressed region and the third compressed regions are flush with the central uncompressed region. An outer portion of the left surface may then be folded towards the back surface until the flange is flush with the right edge. The acoustical product may be used as an acoustical trap or duct. When the acoustical product is utilized as a duct, an air impermeable sheet may be positioned on the external surface.

Abstract: A trim panel insulator is provided for a vehicle. The insulator includes a nonlaminate acoustical and thermal insulating layer of polymer fiber. The insulator may include a relatively high density, nonlaminate skin of polymer fiber and/or one or more facing layers constructed from various materials.

Abstract: The present invention relates to an acoustical insulation material containing a first layer formed from a nonwoven web having a density of at least 50 kg/m3 wherein the nonwoven web is formed from thermoplastic [meltblown] fibers having an average fiber diameter of less than about 7 microns; and a second layer of a high loft material. The high loft material of the present invention provides bulk to the first layer and may or may not have sound attenuating properties. Examples of the high loft material include, for example, fiberglass and high loft nonwoven webs. Also disclosed in a method of attenuating sound waves passing from a sound source area to a second area.

Abstract: An apparatus and method are provided for forming a densified surface layer on a thermoplastic blanket. The apparatus includes first and second continuous belts, a treatment zone defined between those belts, first and second heating and densifying units and a cooler downstream from the heating and densifying units. The method includes the steps of continuously forming a densified surface layer on a face of a thermoplastic blanket and making the thermoplastic blanket with the densified surface layer to a desired thickness within strict dimensional tolerances. A densified thermoplastic blanket product is also disclosed.

Abstract: An under carpet heat shield/floor pan insulator is provided for a vehicle. The shield/insulator includes an acoustical and thermal insulating layer of polymer fiber that shows no signs of any thickness increase, delamination, deterioration or any undesirable effect which may affect performance for at least 330 hours when maintained at a temperature of at least approximately 150° C. The shield/insulator may include a relatively high density, nonlaminate skin of polymer fiber and/or one or more facing layers constructed from polymer material.

Abstract: An insulating element includes a sheet of polymer based blanket material having multiple panels and at least one hinge for interconnecting the multiple panels. A method for making such an insulating product includes the forming of a sheet of polymer based blanket material with multiple panels and at least one hinge for interconnecting the multiple panels and erecting the sheet of polymer based blanket material into a three dimensional insulating product by folding the sheet about the hinge.

Abstract: A decorative panel includes a body constructed from a single layer of a polymer based blanket material having a surface zone. Printing is directly applied to an exposed face of that surface zone. The surface zone may be densified relative to the remainder of the body to tune the acoustical and physical properties of the panel for a particular application and/or to allow for high definition printing.

Abstract: A fibrous blanket material is provided having a first fibrous layer selected from a group of fibers consisting of polyester, polypropylene, polyethylene, fiberglass, natural fibers, nylon, rayon and blends thereof and a layer of meltblown polypropylene fibers. In an alternative embodiment the blanket may also include a second fibrous layer made of the same material as the first layer where the layer of meltblown polypropylene fibers is sandwiched between the two fibrous layers.

Abstract: A decorative laminate material includes a base layer of fibers selected from a group consisting of polyester, polypropylene, polyethylene, fiberglass, natural fibers, nylon, rayon and blends thereof having a density of between about 0.5 and about 15.0 pcf and a facing layer of polyester fibers having a density of between about 10 pcf and about 100 pcf. The facing layer has an exposed, printed face.

Abstract: A liner/insulator includes a pad of fibrous material having a lofty, acoustically insulating portion and a relatively higher density skin along a first face thereof that may function as a water barrier. The acoustical liner is a non-laminate made from polyester, polyethylene, polypropylene, polyethylene terephthalate, glass fibers, natural fibers and any mixtures thereof. For certain applications the liner/insulator may incorporate a facing on one or even two opposing faces thereof. A method of insulating a door including an exterior body panel and an interior fascia panel as well as a door for a vehicle are also provided.

Abstract: An insulating material is constructed in weight percent from about 20-60% low melt bicomponent fiber, 10-40% high melt bicomponent fiber and 20-60% staple fiber. The material provides a unique combination of strength, acoustical insulating and even thermal insulating properties heretofore unavailable in the art.

Abstract: A trim panel insulator is provided for a vehicle. The insulator includes a nonlaminate acoustical and thermal insulating layer of polymer fiber. The insulator may include a relatively high density, nonlaminate skin of polymer fiber and/or one or more facing layers constructed from various materials.

Abstract: A liner/insulator includes a pad of fibrous material having a lofty, acoustically insulating portion and a relatively higher density skin along a first face thereof that may function as a water barrier. The acoustical liner is a non-laminate made from polyester, polyethylene, polypropylene, polyethylene terephthalate, glass fibers, natural fibers and any mixtures thereof. For certain applications the liner/insulator may incorporate a facing on one or even two opposing faces thereof. A method of insulating a door including an exterior body panel and an interior fascia panel as well as a door for a vehicle are also disclosed and claimed.