Multi-density sound attenuating laminates and methods of making same
View Patent ↗Sound attenuating laminates, and methods of making the same, are provided. Heat is applied to a surface of a non-woven, fibrous layer of material to form a stratum of melted fibers having a density greater than that of the remainder of the fibrous layer. The density of the melted fibers is effective in attenuating noise traversing the fibrous layer of material. Upholstery material, such as carpeting, is attached to the surface of the heated fibrous layer. The fibrous layer and upholstery material are then subjected to compressive molding pressure to obtain a desired shape. The compressive molding pressure may further tune the sound attenuating properties of the fibrous layer by selectively changing the densities of portions of the fibrous layer.
1. A sound attenuating laminate configured to attenuate noise from a noise source, comprising:
a single non-woven, fibrous layer of material having a first stratum of molded fibers that has a first density and a second stratum of melted fibers that has a second density greater than the first density and that is effective to attenuate noise traversing the fibrous layer; and
upholstery material attached to a surface of the fibrous layer.
2. The sound attenuating laminate of claim 1 , wherein the first stratum of molded fibers has a thickness of between about four millimeters (4 mm) and about twenty six millimeters (26 mm), and wherein the second stratum of melted fibers has a thickness of between about one millimeter (1 mm) and about four millimeters (4 mm).
3. The sound attenuating laminate of claim 1 , wherein the fibrous layer comprises fibers selected from the group consisting of thermosetting fibers and thermoplastic fibers.
4. The sound attenuating laminate of claim 1 , wherein the fibrous layer comprises polyethylene terephthalate (PET) fibers.
5. The sound attenuating laminate of claim 1 , wherein the upholstery material comprises carpeting.
6. A sound attenuating laminate configured to attenuate noise from a noise source, comprising:
a first single non-woven, fibrous layer of material having a first stratum of molded fibers that has a first density and a second stratum of melted fibers that has a second density greater than the first density and that is effective to attenuate noise traversing the fibrous layer;
a second non-woven fibrous layer of material attached to the first non-woven, fibrous layer; and
upholstery material attached to a surface of the first fibrous layer.
7. The sound attenuating laminate of claim 6 , wherein the first stratum of molded fibers has a thickness of between about four millimeters (4 mm) and about twenty six millimeters (26 mm), and wherein the second stratum of melted fibers has a thickness of between about one millimeter (1 mm) and about four millimeters (4 mm).
8. The sound attenuating laminate of claim 6 , wherein the first and second fibrous layers comprise fibers selected from the group consisting of thermosetting fibers and thermoplastic fibers.
9. The sound attenuating laminate of claim 6 , wherein the first and second fibrous layers comprise polyethylene terephthalate (PET) fibers.
10. The sound attenuating laminate of claim 6 , wherein the upholstery material comprises carpeting.
11. A vehicle, comprising:
an interior compartment comprising a panel having a surface; and
sound insulating material attached to the panel surface, comprising a single non-woven, fibrous layer of material having a first stratum of molded fibers that has a first density and a second stratum of melted fibers that has a second density greater than the first density and that is effective to attenuate noise traversing the fibrous layer.
12. The vehicle of claim 11 , further comprising upholstery material attached to a surface of the fibrous layer.
13. The vehicle of claim 11 , wherein the first stratum of molded fibers has a thickness of between about four millimeters (4 mm) and about twenty six millimeters (26 mm), and wherein the second stratum of melted fibers has a thickness of between about one millimeter (1 mm) and about four millimeters (4 mm).
14. The vehicle of claim 11 , wherein the fibrous layer comprises fibers selected from the group consisting of thermosetting fibers and thermoplastic fibers.
15. The vehicle of claim 11 , wherein the fibrous layer comprises polyethylene terephthalate (PET) fibers.
16. The vehicle of claim 11 , wherein the upholstery material comprises carpeting.
17. A vehicle, comprising:
an interior compartment comprising a panel having a surface; and
sound insulating material attached to the panel surface, comprising:
a first single non-woven, fibrous layer of material having a first stratum of molded fibers that has a first density and a second stratum of melted fibers that has a second density greater than the first density and that is effective to attenuate noise traversing the fibrous layer; and
a second non-woven fibrous layer of material attached to the first non-woven, fibrous layer.
18. The vehicle of claim 17 , further comprising upholstery material attached to a surface of the first fibrous layer.
19. The vehicle of claim 17 , wherein the first and second fibrous layers comprises fibers selected from the group consisting of thermosetting fibers and thermoplastic fibers.
20. The vehicle of claim 17 , wherein the first and second fibrous layers comprises polyethylene terephthalate (PET) fibers.
21. The vehicle of claim 18 , wherein the upholstery material comprises carpeting.
22. A sound attenuating laminate configured to attenuate noise from a noise source, comprising a single non-woven, fibrous layer of material having a first stratum of molded fibers with a first density, a second stratum of molded fibers with a second density greater than the first density, and a third stratum of melted fibers with a third density greater that the second density, and wherein the first, second and third stratums are arranged with a unidirectional density gradient.
23. The sound attenuating laminate of claim 22 , further comprising upholstery material attached to a surface of the fibrous layer.
24. The sound attenuating laminate of claim 22 , wherein the third stratum of melted fibers has a thickness of between about one millimeter (1 mm) and about four millimeters (4 mm).
25. The sound attenuating laminate of claim 22 , wherein the first and second fibrous layers comprises fibers selected from the group consisting of thermosetting fibers and thermoplastic fibers.
26. The sound attenuating laminate of claim 22 , wherein the first and second fibrous layers comprises polyethylene terephthalate (PET) fibers.
27. The sound attenuating laminate of claim 23 , wherein the upholstery material comprises carpeting.
28. A sound attenuating laminate configured to attenuate noise from a noise source, comprising a single non-woven, fibrous layer of material having a first stratum of molded fibers with a first density, a second stratum of molded fibers with a second density greater than the first density, and a third stratum of melted fibers with a third density greater that the second density, and wherein the first, second and third stratums are arranged with a non-unidirectional density gradient.
29. The sound attenuating laminate of claim 28 , further comprising upholstery material attached to a surface of the fibrous layer.
30. The sound attenuating laminate of claim 28 , wherein the third stratum of melted fibers has a thickness of between about one millimeter (1 mm) and about four millimeters (4 mm).
31. The sound attenuating laminate of claim 28 , wherein the first and second fibrous layers comprises fibers selected from the group consisting of thermosetting fibers and thermoplastic fibers.
32. The sound attenuating laminate of claim 28 , wherein the first and second fibrous layers comprises polyethylene terephthalate (PET) fibers.
33. The sound attenuating laminate of claim 29 , wherein the upholstery material comprises carpeting.