Oleophobic insulating shield and method of making
View Patent ↗According to some embodiments, a material and a method of providing thermal and acoustical insulation with an insulating shield that is moldable and self-supporting insulating shield, is presented. The shield includes a nonwoven material and an oleophobic coating applied to the outer surface of the nonwoven material. The oleophobic coating includes a percent add-on (% AO) of less than approximately 3% AO and a penetration into the surface of the nonwoven material of less than approximately 10%.
1. A moldable, self-supporting insulating shield comprising:
a needle punch felted polyethylene terephthalate (PET) material operable to provide thermal and acoustical insulation; and
an oleophobic polytetrafluoroethylene (PTFE) coating ultrasonically sprayed onto a plurality of outer surfaces of the PET material,
wherein:
the PTFE coating comprises a percent add-on (% AO) of less than approximately 1% AO; and
the PTFE coating comprises a penetration into the outer surfaces of the needle punch felted PET material of less than approximately 0.5 millimeters.
2. The shield of claim 1 , wherein the oleophobic material comprises a penetration into the outer surfaces of the needle punch felted PET material of less than approximately 10%.
3. The shield of claim 1 , wherein the oleophobic material comprises a penetration into the outer surfaces of the needle punch felted nonwoven material of less than approximately 5%.
4. The shield of claim 1 , wherein the needle punch felted nonwoven material comprises a density of approximately 240 kilogram (kg) per cubic meter to approximately 667 kg per cubic meter.
5. The shield of claim 1 , wherein the needle punch felted nonwoven material comprises approximately 100% PET material.
6. The shield of claim 1 , wherein the shield meets flammability standards when exposed to approximately 200 milliliters of engine oil and tested in a horizontal cabinet.
7. The shield of claim 1 , wherein the PTFE coating comprises a solids content of up to approximately 19%.
8. The shield of claim 1 , wherein the needle punch felted PET material comprises up to 40% of low melt fibers and up to 60% of staple fibers.
9. The shield of claim 1 , wherein the oleophobic coating comprises a water repellant.
10. The shield of claim 1 , wherein the oleophobic coating comprises a percent add-on of approximately 0.05% AO.
11. The shield of claim 1 , wherein the shield comprises an air flow resistance of less than approximately 5000 MKS Rayls.
12. The shield of claim 1 , wherein the shield comprises an air flow resistance of less than approximately 1600 MKS Rayls.
13. The shield of claim 1 , wherein the penetration of the PTFE coating into the outer surfaces is about 4 fibers to about 6 fibers deep.
14. The shield of claim 1 , further comprising a layer attached to at least one of the outer surfaces of the needle punch felted PET material.
15. The shield of claim 14 , wherein the layer is one or more of melamine foam, resonated fiberglass batting and aluminum.