USRE39010E1 - Lightweight acoustical system - Google Patents
Lightweight acoustical system Download PDFInfo
- Publication number
- USRE39010E1 USRE39010E1 US10/171,181 US17118102A USRE39010E US RE39010 E1 USRE39010 E1 US RE39010E1 US 17118102 A US17118102 A US 17118102A US RE39010 E USRE39010 E US RE39010E
- Authority
- US
- United States
- Prior art keywords
- layer
- underlayment
- per square
- grams per
- square meter
- 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.)
- Expired - Fee Related
Links
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/08—Insulating elements, e.g. for sound insulation
- B60R13/0815—Acoustic or thermal insulation of passenger compartments
- B60R13/083—Acoustic or thermal insulation of passenger compartments for fire walls or floors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/08—Insulating elements, e.g. for sound insulation
- B60R13/0892—Insulating elements, e.g. for sound insulation for humidity insulation
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/10—Properties of the layers or laminate having particular acoustical properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/726—Permeability to liquids, absorption
- B32B2307/7265—Non-permeable
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2323/00—Polyalkenes
- B32B2323/04—Polyethylene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2471/00—Floor coverings
- B32B2471/02—Carpets
Definitions
- This invention relates to acoustical systems.
- 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.
- Another object of the present invention is 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.
- FIG. 1 is a cross-sectional view of an acoustical system according to the present invention.
- FIG. 1 shows a system 10 for inhibiting noise in a motor vehicle.
- the system 10 comprises a water-impermeable, relatively lightweight layer 12 and an underlayment 14 .
- 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 .
- 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.
- 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 .
- 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.
- 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 .
- 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.
- 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.
Landscapes
- Physics & Mathematics (AREA)
- Acoustics & Sound (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Multimedia (AREA)
- Laminated Bodies (AREA)
- Building Environments (AREA)
- Soundproofing, Sound Blocking, And Sound Damping (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
- Passenger Equipment (AREA)
Abstract
Description
Claims (32)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/171,181 USRE39010E1 (en) | 2000-06-02 | 2002-06-13 | Lightweight acoustical system |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/586,504 US6296075B1 (en) | 2000-06-02 | 2000-06-02 | Lightweight acoustical system |
US10/171,181 USRE39010E1 (en) | 2000-06-02 | 2002-06-13 | Lightweight acoustical system |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/586,504 Reissue US6296075B1 (en) | 2000-06-02 | 2000-06-02 | Lightweight acoustical system |
Publications (1)
Publication Number | Publication Date |
---|---|
USRE39010E1 true USRE39010E1 (en) | 2006-03-14 |
Family
ID=24346005
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/586,504 Ceased US6296075B1 (en) | 2000-06-02 | 2000-06-02 | Lightweight acoustical system |
US10/171,181 Expired - Fee Related USRE39010E1 (en) | 2000-06-02 | 2002-06-13 | Lightweight acoustical system |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/586,504 Ceased US6296075B1 (en) | 2000-06-02 | 2000-06-02 | Lightweight acoustical system |
Country Status (3)
Country | Link |
---|---|
US (2) | US6296075B1 (en) |
DE (1) | DE10126306B4 (en) |
GB (1) | GB2364958B (en) |
Cited By (18)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20060289231A1 (en) * | 2005-06-28 | 2006-12-28 | Priebe Joseph A | Acoustic absorber/barrier composite |
US20070039268A1 (en) * | 2004-12-01 | 2007-02-22 | L&P Property Management Company | Energy Absorptive/Moisture Resistive Underlayment Formed using Recycled Materials and a Hard Flooring System Incorporating the Same |
US20070122608A1 (en) * | 2003-09-26 | 2007-05-31 | L&P Property Management Company | Anti-microbial carpet underlay and method of making |
US20080017445A1 (en) * | 2006-07-21 | 2008-01-24 | Lear Corporation | Lightweight dash insulator construction |
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 |
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 |
US20090321183A1 (en) * | 2008-06-27 | 2009-12-31 | Camali Industries (Na) Inc. | Acoustic panel |
US20100065368A1 (en) * | 2008-09-15 | 2010-03-18 | Vatche Tazian | Lightweight, flexible, moldable acoustic barrier and composites including the same |
US20100081354A1 (en) * | 2008-10-01 | 2010-04-01 | Polymer Group, Inc. | Nonwoven Multilayered Fibrous Batts And Multi-Density Molded Articles Made With Same And Processes Of Making Thereof |
US20100095846A1 (en) * | 2006-01-18 | 2010-04-22 | Buckeye Technologies Inc. | Tacky allergen trap and filter medium, and method for containing allergens |
US20100200327A1 (en) * | 2007-07-25 | 2010-08-12 | Faurecia Automotive Industrie | Moulded soundproofing component, and manufacturing method thereof |
US20100307866A1 (en) * | 2007-10-24 | 2010-12-09 | Silenceresearch Gmbh | Sound absorber |
US20110073239A1 (en) * | 2004-12-01 | 2011-03-31 | L & P Property Management Company | Method of making recycled energy absorbing underlayment and moisture barrier for hard flooring system |
US7918313B2 (en) | 2005-04-01 | 2011-04-05 | Buckeye Technologies Inc. | Nonwoven material for acoustic insulation, and process for manufacture |
US8418806B1 (en) | 2012-01-13 | 2013-04-16 | Janesville Acoustics, a Unit of Jason Incorporated | Sound attenuating device using an embedded layer for acoustical tuning |
US20140262606A1 (en) * | 2013-03-14 | 2014-09-18 | Seiko Epson Corporation | Sound absorbing body and device |
Families Citing this family (41)
Publication number | Priority date | Publication date | Assignee | Title |
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AUPQ883000A0 (en) * | 2000-07-19 | 2000-08-10 | I.N.C. Corporation Pty Ltd | A thermoformable acoustic sheet |
CN1511092A (en) * | 2001-05-22 | 2004-07-07 | �����ɷ� | Sound absorptive protective mat |
US6802389B2 (en) * | 2001-12-07 | 2004-10-12 | Collins & Aikman Products Co. | Multi-density sound attenuating laminates and methods of making same |
US6631785B2 (en) * | 2001-12-20 | 2003-10-14 | Collins & Aikman Products Co. | Sound attenuating composite articles incorporating scrim material and methods of making same |
US8637414B2 (en) * | 2002-04-22 | 2014-01-28 | Lydall, Inc. | Gradient density padding material and method of making same |
EP1502254A2 (en) * | 2002-05-08 | 2005-02-02 | Johnson Controls Technology Company | Sound absorbing panel for a vehicle and its method of manufacture |
US7000729B2 (en) * | 2002-07-08 | 2006-02-21 | Acoustek Nonwovens | Five-layer sound absorbing pad: improved acoustical absorber |
AU2002334396A1 (en) * | 2002-08-06 | 2004-02-23 | Al.P S.R.L. | Noise reducing panel for air duct |
US7320739B2 (en) | 2003-01-02 | 2008-01-22 | 3M Innovative Properties Company | Sound absorptive multilayer composite |
US20040131836A1 (en) * | 2003-01-02 | 2004-07-08 | 3M Innovative Properties Company | Acoustic web |
US20040231914A1 (en) * | 2003-01-02 | 2004-11-25 | 3M Innovative Properties Company | Low thickness sound absorptive multilayer composite |
US20040180592A1 (en) * | 2003-03-12 | 2004-09-16 | Ray Kyle A. | Thermoformable acoustic sheet material |
US20040180177A1 (en) * | 2003-03-12 | 2004-09-16 | Ray Kyle A. | Thermoformable acoustic material |
CN101826322B (en) | 2003-03-26 | 2011-12-28 | 竹广股份有限公司 | Ultralight sound insulator |
JP4209723B2 (en) * | 2003-06-25 | 2009-01-14 | 林テレンプ株式会社 | Molded laying material |
WO2005015145A1 (en) * | 2003-07-18 | 2005-02-17 | Sound Solutions Gb Limited | Sound-deadening materials |
DE20314166U1 (en) * | 2003-09-11 | 2003-11-06 | Rieter Technologie Ag, Winterthur | Engine compartment absorber |
EP1682385B1 (en) * | 2003-10-31 | 2008-10-15 | Dow Global Technologies Inc. | Sound insulating system |
US7402537B1 (en) | 2003-12-17 | 2008-07-22 | Creative Foam Corporation | Air permeable, water repellent, acoustic door watershield |
US20050136212A1 (en) * | 2003-12-19 | 2005-06-23 | Lear Corporation | Porous interior trim system and method of manufacturing same |
EP1719113A1 (en) * | 2004-02-25 | 2006-11-08 | I.N.C. Corporation Pty. Ltd. | Thermoformable acoustic product |
US20070151658A1 (en) * | 2004-03-12 | 2007-07-05 | Surendra Khambete | Contoured mold for forming decouplers for attenuating sound in a vehicle |
US7566475B2 (en) * | 2004-11-09 | 2009-07-28 | International Automotive Components Group North America, Inc. | Acoustic insulator with controlled airflow resistance and method of making same |
US20070137926A1 (en) * | 2005-12-15 | 2007-06-21 | Lear Corporation | Acoustical component for enhancing sound absorption properties while preserving barrier performance in a vehicle interior |
US7686132B2 (en) * | 2005-12-29 | 2010-03-30 | 3M Innovative Properties Company | Porous membrane |
FR2903043B1 (en) * | 2006-06-28 | 2010-03-12 | Faurecia Automotive Ind | SOUND PIECE, ESPECIALLY DASHBOARD, AND METHOD OF MANUFACTURING THE SAME |
FR2913805B1 (en) * | 2007-03-15 | 2012-12-14 | Cera | ACOUSTIC PROTECTION SCREEN FOR A MOTOR VEHICLE, COMPRISING A COMPRESSION-SEALED ABSORBENT LAYER |
FR2923643B1 (en) * | 2007-11-12 | 2009-12-11 | Faurecia Automotive Ind | SEALED ELEMENT AND SOUNDPROOF ASSEMBLY HAVING POROUS DECORATION FUNCTION |
EP2062785B1 (en) * | 2007-11-20 | 2010-06-30 | DENSO THERMAL SYSTEMS S.p.A. | Gasket for the firewall of a motorvehicle |
US8100226B2 (en) * | 2009-12-22 | 2012-01-24 | Usg Interiors, Inc. | Porous nonwoven scrims in acoustical panels |
FR2978373B1 (en) * | 2011-07-28 | 2013-08-02 | Saint Gobain Adfors | ACOUSTIC ABSORBENT WALL COATING |
US20130078422A1 (en) * | 2011-09-23 | 2013-03-28 | Frank Warren Bishop, JR. | Acoustic insulation with performance enhancing sub-structure |
WO2014175809A1 (en) * | 2013-04-23 | 2014-10-30 | Artex Ab | Sound dampening device |
CA2918327C (en) * | 2013-07-15 | 2018-07-31 | Armstrong World Industries, Inc. | Acoustical structure having open celled core and facing sheets |
PL3015314T3 (en) * | 2014-10-30 | 2017-12-29 | Autoneum Management Ag | Light weight acoustic trim part |
US10113322B2 (en) | 2014-12-08 | 2018-10-30 | Zephyros, Inc. | Vertically lapped fibrous flooring |
EP3245105B1 (en) * | 2015-01-12 | 2021-03-03 | Zephyros Inc. | Acoustic floor underlay system |
WO2016118587A1 (en) | 2015-01-20 | 2016-07-28 | Zephyros, Inc. | Sound absorption materials based on nonwovens |
CN107667008A (en) | 2015-05-20 | 2018-02-06 | 泽菲罗斯公司 | More impedance composite materials |
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CN105832105A (en) * | 2016-05-13 | 2016-08-10 | 袁力坚 | Replaceable water absorption floor mat |
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US3948347A (en) * | 1974-11-25 | 1976-04-06 | Gallagher-Kaiser Corporation | Acoustical panel |
GB2100620A (en) | 1981-06-29 | 1983-01-06 | Albany Int Corp | Fabric for use as a carpet underlay |
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-
2000
- 2000-06-02 US US09/586,504 patent/US6296075B1/en not_active Ceased
-
2001
- 2001-05-30 DE DE10126306A patent/DE10126306B4/en not_active Expired - Fee Related
- 2001-06-01 GB GB0113324A patent/GB2364958B/en not_active Expired - Fee Related
-
2002
- 2002-06-13 US US10/171,181 patent/USRE39010E1/en not_active Expired - Fee Related
Patent Citations (32)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3948347A (en) * | 1974-11-25 | 1976-04-06 | Gallagher-Kaiser Corporation | Acoustical panel |
GB2100620A (en) | 1981-06-29 | 1983-01-06 | Albany Int Corp | Fabric for use as a carpet underlay |
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Also Published As
Publication number | Publication date |
---|---|
DE10126306B4 (en) | 2006-04-13 |
US6296075B1 (en) | 2001-10-02 |
GB2364958A (en) | 2002-02-13 |
GB2364958B (en) | 2003-12-10 |
DE10126306A1 (en) | 2002-01-03 |
GB0113324D0 (en) | 2001-07-25 |
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