Nonwoven infrared reflective fiber materials
An acoustic material including a lofted porous absorber layer and a facing layer. The lofted porous absorber layer may include polymeric fibers having a metallic coating for impeding heat transfer. The acoustic material may also include an optional adhesive layer, an optional pressure sensitive adhesive layer, or both. An acoustic material may be assembled using a method including coating a plurality of polymeric fibers with a metallic coating; forming a lofted porous absorber layer including the polymeric fibers; and adhering a facing layer onto a first surface of the absorber layer.
1 . An acoustic material comprising:
a) a nonwoven carded and vertically lapped layer, including:
i) polymeric fibers having a metallic coating located thereon that impedes heat transfer, wherein the polymeric fibers having a metallic coating located thereon are dispersed throughout the entire thickness of the nonwoven and vertically lapped layer, wherein the entirety of the polymeric fibers have an average staple length of about 30 mm to about 70 mm; and
ii) bi-component fibers including a core material and a sheath material, wherein the sheath material has a lower melting point than the core material; and
wherein the nonwoven carded and vertically lapped layer includes a plurality of nonwoven materials of differing densities to form a composite product with a desirable level of air permeability;
b) a permeable facing layer directly secured to the nonwoven carded and vertically lapped layer, wherein the permeable facing layer is attached to a first surface of the nonwoven carded and vertically lapped layer by an adhesive layer, and wherein the adhesive layer does not plug perforations of the permeable facing layer, and wherein the permeable facing layer is aluminized to provide infrared heat reflection; and
c) a pressure sensitive adhesive layer located on an opposing second surface of the nonwoven carded and vertically lapped layer, wherein the pressure sensitive adhesive layer includes a removable release liner for adhering the acoustic material to a substrate;
wherein the acoustic material reflects heat and provides acoustic absorption;
wherein the nonwoven carded and vertically lapped layer has a bulk density of about 40 kg/m 3 or less and an air flow resistivity of about 275,000 Rayls/m or less; and
wherein the acoustic material is adapted for use within an engine compartment.
2 . The acoustic material of claim 1 , wherein the bi-component fibers are metallized.
3 . The acoustic material of claim 1 , wherein the permeable facing layer has an air flow resistance of about 600 Rayls to about 1800 Rayls.
4 . The acoustic material of claim 1 , wherein the permeable facing layer is an outermost layer configured to be located adjacent a noise source.
5 . The acoustic material of claim 1 , wherein the permeable facing layer is a scrim, a fabric, a film, or a foil.
6 . The acoustic material of claim 5 , wherein the permeable facing layer is a perforated reinforced aluminum foil.
7 . The acoustic material of claim 5 , wherein the permeable facing layer is a perforated polymeric film.
8 . The acoustic material of claim 5 , wherein the permeable facing layer is a fibrous permeable fabric.
9 . The acoustic material of claim 1 , wherein the permeable facing layer has a thickness of about 0.003 mm to about 0.009 mm.
10 . The acoustic material of claim 1 , wherein the pressure sensitive adhesive layer is applied in longitudinal strips along the second surface, and the pressure sensitive adhesive layer is an acrylic resin that is curable under ultraviolet light.
11 . The acoustic material of claim 1 , wherein the permeable facing layer includes openings aligned in rows and/or columns across the permeable facing layer that account for about 40 percent of the facing layer or less.
12 . An acoustic material comprising:
a) a nonwoven carded and vertically lapped layer, including:
i) polymeric fibers having an aluminum coating that impedes heat transfer, wherein the polymeric fibers having an aluminum coating are dispersed throughout the entire thickness of the nonwoven and vertically lapped layer, wherein the entirety of the polymeric fibers have an average staple length of about 30 mm to about 70 mm; and
ii) bi-component fibers including a core material and a sheath material, wherein the sheath material has a lower melting point than the core material, wherein the polymeric fibers include a corrosion resistant coating applied to the aluminum coating;
b) a permeable facing layer directly secured to a first surface of the nonwoven carded and vertically lapped layer by lamination, adhesive, or both, wherein the permeable facing layer is a scrim, a fabric, a film, or a foil; and
c) a pressure sensitive adhesive layer on an opposing second surface of the nonwoven carded and vertically lapped layer; and
wherein the permeable facing layer is a metalized outer layer configured to provide infrared heat reflection;
wherein the permeable facing layer has a thickness of about 0.003 mm to about 0.009 mm;
wherein the permeable facing layer includes openings that create open space accounting for about 90 percent of the facing layer or less;
wherein the acoustic material reflects heat and provides acoustic absorption;
wherein the nonwoven carded and vertically lapped layer has a bulk density of about 40 kg/m3 or less and an air flow resistivity of about 275,000 Rayls/m or less; and
wherein the acoustic material is adapted for use within an engine compartment.
13 . The acoustic material of claim 12 , wherein the permeable facing layer is attached to a first surface of the nonwoven carded and vertically lapped layer by an adhesive layer, and wherein the adhesive layer does not plug perforations of the permeable facing layer.
14 . The acoustic material of claim 12 , wherein the pressure sensitive adhesive layer includes a removable release liner for adhering the acoustic material to a substrate.
15 . The acoustic material of claim 12 , wherein the nonwoven carded and vertically lapped layer includes a plurality of nonwoven materials of differing densities to form a composite product with a desirable level of air permeability.
16 . The acoustic material of claim 12 , wherein the openings create open space accounting for about 40 percent of the permeable facing layer or less.
17 . An acoustic material consisting of:
a) a nonwoven carded and vertically lapped layer, including:
i) polymeric fibers having a metallic coating located thereon that impedes heat transfer, wherein the polymeric fibers having a metallic coating located thereon are dispersed throughout the entire thickness of the nonwoven carded and vertically lapped layer, wherein the entirety of the polymeric fibers have an average staple length of about 30 mm to 70 mm; and
ii) bi-component fibers including a core material and a sheath material, wherein the sheath material has a lower melting point than the core material;
b) an outermost permeable facing layer directly secured to the nonwoven carded and vertically lapped layer by lamination, adhesive, or both, wherein the permeable facing layer is aluminized to provide infrared heat reflection; and
c) a pressure sensitive adhesive layer;
wherein the acoustic material reflects heat and provides acoustic absorption;
wherein the nonwoven carded and vertically lapped layer has a bulk density of about 60 kg/m3 or less and an air flow resistivity of about 275,000 Rayls/m or less; and
wherein the acoustic material is adapted for use within an engine compartment.
18 . The acoustic material of claim 17 , wherein the permeable facing layer is a scrim, a fabric, a film, or a foil.
19 . The acoustic material of claim 17 , wherein the nonwoven carded and vertically lapped layer includes a plurality of nonwoven materials of differing densities to form a composite product with a desirable level of air permeability.
20 . The acoustic material of claim 17 , wherein the permeable facing layer is attached to a first surface of the nonwoven carded and vertically lapped layer by the adhesive.