US4828910A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Sound absorbing laminate
Assignee: Johnson Controls Technology Co
•
Filing: 1987-12-16
•
Granted: 1989-05-09
•
Expires: 2007-12-16
Abstract
Abstract There are provided laminate structures comprising a reinforcing fibrous mat integrally bonded to a resilient fibrous batt. The mat is preferentially a porous mat of resin-bonded chopped glass fiber. The batt is preferentially a porous bat of natural or synthetic fibers. Preferentially, the laminate comprises a core of resilient fibrous batt sandwiched between two facing sheets of reinforcing fibrous mat, with a decorative cover layer being laminated to the exterior surface of one reinforcing fibrous mat, the whole being bonded together by a thermoset binder into a unitary structure.
Inventors
- 👤 Reinhold Haussling
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 21:18
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/22; B32B5/24; B32B5/26; B29; B29C; B29C70/00; B29C70/04; B29C70/06; B29C70/08; B32B5/02; B32B5/06; B32B7/00; B32B7/04; B32B7/12; E; E04; E04B; E04B1/00; E04B1/62; E04B1/74; E04B1/82; E04B1/84; E04B1/8409; G; G10; G10K; G10K11/00; G10K11/16; G10K11/162; G10K11/168; B29K; B29K2101/00; B29K2101/10; B29K2105/00; B29K2105/06; B29K2105/08; B29K2105/0854; B29K2309/00; B29K2309/08; B29K2311/00; B29K2311/10; B29K2995/00; B29K2995/0001; B29K2995/0002; B29L; B29L2031/00; B29L2031/30; B29L2031/3005; B32B2260/00; B32B2260/02; B32B2260/021; B32B2260/04; B32B2260/046; B32B2307/00; B32B2307/10; B32B2605/00; B32B2605/08; B60; B60R; B60R13/00; B60R13/02; B60R13/0212; B60R13/0225; E04B2001/8457; E04B2001/8461; Y; Y10; Y10T; Y10T428/00; Y10T428/31504; Y10T428/31551; Y10T428/31598; Y10T428/31601; Y10T442/00; Y10T442/60; Y10T442/659; Y10T442/67; Y10T442/671
Claims Analysis
Total Claims: 66
Claim 1
Independent Claim
76 words
A moldable laminate structure comprising: a core defined by a resilient thermoformable, porous fibrous batt having a thickness of at least about one-quarter of an inch; a first reinforcing, porous fibrous mat on one surface of said batt and being coated with sufficient resin binder to impregnate said fibrous mat and its interface with said fibrous batt to effect adherence therebetween, but insufficient resin binder to form a porosity blocking film on a final molded product.
Claim 2
Dependent Claim
76 words
A moldable laminate structure comprising: a core defined by a resilient thermoformable, porous fibrous batt having a thickness of at least about one-quarter of an inch; a first reinforcing, porous fibrous mat on one surface of said batt and being coated with sufficient resin binder to impregnate said fibrous mat and its interface with said fibrous batt to effect adherence therebetween, but insufficient resin binder to form a porosity blocking film on a final molded product.
Claim 3
Dependent Claim
19 words
A moldable laminate structure in accordance with claim 1 wherein said resin binder comprises a curable thermosetting binder composition.
Claim 4
Dependent Claim
19 words
A moldable laminate structure in accordance with claim 1 wherein said resin binder comprises a curable thermosetting elastomer composition.
Claim 5
Dependent Claim
19 words
A moldable laminate structure in accordance with claim 3 wherein said resin binder comprises a thermosetting urethane elastomer composition.
Claim 6
Dependent Claim
71 words
A moldable laminate structure in accordance with claim 3 wherein the fibers of said resilient fibrous batt are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing fibrous mat are held together by a thermoplastic binder to facilitate thermoforming and whereby said batt and said mat can be permanently compressed along the marginal edges of the laminate structure to create strong, well defined marginal edges.
Claim 7
Dependent Claim
19 words
A moldable laminate structure in accordance with claim 5 wherein said resin binder comprises a thermosetting urethane elastomer composition.
Claim 8
Dependent Claim
36 words
A moldable laminate structure in accordance with claim 3 wherein said fibrous batt has an air porosity in the range from 10 to 60% and said fibrous mat has an air porosity of at least 90%.
Claim 9
Dependent Claim
69 words
A moldable laminate structure in accordance with claim 7 wherein the fibers of said resilient fibrous batt are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing mat are held together by a thermoplastic binder to facilitate thermoforming and whereby said batt and said mat can be permanently compressed along the marginal edges of the laminate structure to create strong, well-defined marginal edges.
Claim 10
Dependent Claim
19 words
A moldable laminate structure in accordance with claim 7 wherein said binder resin comprises a curable thermosetting urethane elastomer.
Claim 11
Dependent Claim
20 words
A moldable laminate structure in accordance with claim 9 wherein said fibrous batt has an air porosity of about 40%.
Claim 12
Dependent Claim
27 words
A moldable laminate structure in accordance with claim 3 having a decorative porous fabric cover layer laminated to the other face of said first reinforcing fibrous mat.
Claim 13
Dependent Claim
32 words
A moldable laminate structure in accordance with claim 11 wherein said resin binder comprises a curable thermosetting urethane elastomer composition which also adheres said cover layer to said first reinforcing fibrous mat.
Claim 14
Dependent Claim
81 words
A moldable laminate structure in accordance with claim 11 wherein said decorative porous fabric cover layer is thermoformable, the fibers of said resilient fibrous batt are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing mat are held together by a thermoplastic binder to facilitate thermoforming and whereby said decorative cover layer, batt and said mat can be permanently compressed along the marginal edges of said laminate structure to create strong, well defined marginal edges.
Claim 15
Dependent Claim
20 words
A moldable laminate structure in accordance with claim 13 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.
Claim 16
Dependent Claim
36 words
A moldable laminate structure in accordance with claim 13 wherein said fibrous batt has an air porosity in the range from 10 to 60% and said fibrous mat has an air porosity of at least 90%.
Claim 17
Dependent Claim
20 words
A moldable laminate structure in accordance with claim 13 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.
Claim 18
Dependent Claim
20 words
A moldable laminate structure in accordance with claim 16 wherein said fibrous batt has an air porosity of about 40%.
Claim 19
Dependent Claim
66 words
A moldable laminate structure in accordance with claim 3 having one face of a second reinforcing porous fibrous mat on the other surface of said resilient fibrous batt and being coated with sufficient resin to impregnate said second reinforcing mat and its interface with said fibrous batt to effect adherence therebetween, but insufficient resin binder to form a porosity blocking film on a final molded product.
Claim 20
Dependent Claim
20 words
A moldable laminate structure in accordance with claim 18 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.
Claim 21
Dependent Claim
70 words
A moldable laminate structure in accordance with claim 18 wherein the fibers of said resilient fibrous batt are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing fibrous mats are held together by a thermoplastic binder to facilitate thermoforming and whereby said batt and said mats can be permanently compressed along the marginal edges of said laminate structure to create strong well-defined marginal edges.
Claim 22
Dependent Claim
20 words
A moldable laminate structure in accordance with claim 20 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.
Claim 23
Dependent Claim
38 words
A moldable laminate structure in accordance with claim 18 wherein said resilient fibrous batt has an air porosity in the range from 10 to 60% and said reinforcing fibrous mat has an air porosity of at least 90%.
Claim 24
Dependent Claim
20 words
A moldable laminate structure in accordance with claim 22 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.
Claim 25
Dependent Claim
21 words
A moldable laminate structure in accordance with claim 23 wherein said resilient fibrous batt has an air porosity of about 40%.
Claim 26
Dependent Claim
69 words
A moldable laminate structure in accordance with claim 22 wherein the fibers of said resilient fibrous mat are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing mats are held together by a thermoplastic binder to facilitate thermoforming and whereby said batt and said mats can be permanently compressed along the marginal edges of said laminate structure to create strong, well-defined marginal edges.
Claim 27
Dependent Claim
19 words
A moldable laminate structure in accordance with claim 25 wherein said resin binder comprises a curable thermosetting elastomer composition.
Claim 28
Dependent Claim
21 words
A moldable laminate structure in accordance with claim 26 wherein said resilient fibrous batt has an air porosity of about 40%.
Claim 29
Dependent Claim
23 words
A moldable laminate structure in accordance with claim 3 having a release layer laminated to the other surface of said reinforcing fibrous mat.
Claim 30
Dependent Claim
70 words
A moldable laminate structure in accordance with claim 28 wherein the fibers of said resilient fibrous batt are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing fibrous mat are held together by a thermoplastic binder to facilitate thermoforming and whereby said batt and said mat can be permanently compressed along the marginal edges of said laminate structure to create strong well-defined marginal edges.
Claim 31
Dependent Claim
38 words
A moldable laminate structure in accordance with claim 29 wherein said resilient fibrous batt has an air porosity in the range from 10 to 60% and said reinforcing fibrous mat has an air porosity of at least 40%.
Claim 32
Dependent Claim
20 words
A moldable laminate structure in accordance with claim 30 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.
Claim 33
Dependent Claim
42 words
A moldable laminate structure in accordance with claim 18 having a decorative porous fabric cover layer laminated to the other face of said first reinforcing fibrous mat and a release layer laminated to the other surface of said second reinforcing fibrous mat.
Claim 34
Dependent Claim
20 words
A moldable laminate structure in accordance with claim 32 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.
Claim 35
Dependent Claim
80 words
A moldable laminate structure in accordance with claim 32 wherein said decorative porous fabric cover layer is thermoformable, the fibers of said resilient fibrous batt are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing mats are held together by a thermoplastic binder to facilitate thermoforming and whereby said cover layer, said batt and said mats can be permanently compressed along the marginal edges of said laminate structure to create strong, well-defined marginal edges.
Claim 36
Dependent Claim
20 words
A moldable laminate structure in accordance with claim 34 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.
Claim 37
Dependent Claim
36 words
A moldable laminate structure in accordance with claim 32 wherein said fibrous batt has an air porosity in the range from 10 to 60% and said fibrous mat has an air porosity of at least 90%.
Claim 38
Dependent Claim
20 words
A moldable laminate structure in accordance with claim 36 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.
Claim 39
Dependent Claim
20 words
A moldable laminate structure in accordance with claim 37 wherein said resilient batt has an air porosity of about 40%.
Claim 40
Dependent Claim
81 words
A moldable laminate structure in accordance with claim 36 wherein said decorative porous fabric cover layer is thermoformable, the fibers of said resilient fibrous batt are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing fibrous mat are held together by a thermoplastic binder to facilitate thermoforming and whereby said cover layer, said batt and said mats can be permanently compressed along the marginal edges of said laminate structure to create strong, well-defined marginal edges.
Claim 41
Dependent Claim
20 words
A molded laminate structure in accordance with claim 39 wherein said resin binder comprises a curable thermosetting urethane elastomer composition.
Claim 42
Dependent Claim
20 words
A molded laminate structure in accordance with claim 40 wherein said resilient batt has an air porosity of about 40%.
Claim 43
Dependent Claim
91 words
A moldable sound absorbing laminate structure comprising: a core defined by a thermoformable resilient porous fibrous batt having a thickness of at least about one-quarter inch, the fibers of said fibrous batt being held together by a thermoformable binder; at least a first porous fibrous reinforcing mat adhered to one surface of said batt by said thermoformable binder; and whereby said batt and said mat form a prelaminate which can be readily handled without delamination for subsequent impregnation with a thermosetting resin binder immediately prior to molding in a heated mold.
Claim 44
Dependent Claim
91 words
A moldable sound absorbing laminate structure comprising: a core defined by a thermoformable resilient porous fibrous batt having a thickness of at least about one-quarter inch, the fibers of said fibrous batt being held together by a thermoformable binder; at least a first porous fibrous reinforcing mat adhered to one surface of said batt by said thermoformable binder; and whereby said batt and said mat form a prelaminate which can be readily handled without delamination for subsequent impregnation with a thermosetting resin binder immediately prior to molding in a heated mold.
Claim 45
Dependent Claim
42 words
A moldable sound-absorbing laminate structure in accordance with claim 42 wherein the fibers of said resilient fibrous batt are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing mat are held together by a thermoplastic binder.
Claim 46
Dependent Claim
30 words
A moldable sound-absorbing laminate structure in accordance with claim 42 wherein a second porous fibrous reinforcing mat is adhered to an opposite surface of said batt by said thermoformable binder.
Claim 47
Dependent Claim
42 words
A moldable sound-absorbing laminate structure in accordance with claim 44 wherein the fibers of said resilient fibrous batt are thermoplastic and are held together by a thermoplastic binder and the fibers of said reinforcing mat are held together by a thermoplastic binder.
Claim 48
Dependent Claim
67 words
A molded contoured three-dimensional laminated structure comprising a first reinforcing porous fibrous mat laminated on one face thereof to one face of a resilient porous fabric batt having a thickness of at least about one-quarter inch, said first reinforcing mat and said resilient batt being bonded together by a thermoset binder composition into a unitary laminated structure, said laminated structure having permanently compressed, strong, well-defined marginal edges.
Claim 49
Dependent Claim
67 words
A molded contoured three-dimensional laminated structure comprising a first reinforcing porous fibrous mat laminated on one face thereof to one face of a resilient porous fabric batt having a thickness of at least about one-quarter inch, said first reinforcing mat and said resilient batt being bonded together by a thermoset binder composition into a unitary laminated structure, said laminated structure having permanently compressed, strong, well-defined marginal edges.
Claim 50
Dependent Claim
18 words
A laminated structure in accordance with claim 46 wherein said thermoset composition comprises a thermoset elastomer binder composition.
Claim 51
Dependent Claim
19 words
A laminated structure in accordance with claim 46 wherein said thermoset composition comprises a thermoset urethane elastomer binder composition.
Claim 52
Dependent Claim
35 words
A laminated structure in accordance with claim 47 wherein said resilient batt has an air porosity in the range from 10 to 60% and said reinforcing mat has an air porosity of at least 90%.
Claim 53
Dependent Claim
30 words
A laminated structure in accordance with claim 49 wherein said resilient batt has an air porosity of about 40% and said thermoset composition comprises a thermoset urethane elastomer binder composition.
Claim 54
Dependent Claim
26 words
A laminated structure in accordance with claim 47 having a decorative porous fabric cover layer laminated to the other face of said first reinforcing fibrous mat.
Claim 55
Dependent Claim
19 words
A laminated structure in accordance with claim 51 wherein said thermoset composition comprises a thermoset urethane elastomer binder composition.
Claim 56
Dependent Claim
35 words
A laminated structure in accordance with claim 51 wherein said resilient batt has an air porosity in the range from 10 to 60% and said reinforcing mat has an air porosity of at least 90%.
Claim 57
Dependent Claim
30 words
A laminated structure in accordance with claim 53 wherein said resilient batt has an air porosity of about 40% and said thermoset composition comprises a thermoset urethane elastomer binder composition.
Claim 58
Dependent Claim
28 words
A laminated structure in accordance with claim 47 having one face of a second porous fibrous reinforcing mat bonded to the other face of said resilient fibrous batt.
Claim 59
Dependent Claim
35 words
A laminated structure in accordance with ciaim 55 wherein said resilient batt has an air porosity in the range from 10 to 60% and said reinforcing mats have an air porosity of at least 90%.
Claim 60
Dependent Claim
35 words
A laminated structure in accordance with ciaim 55 wherein said resilient batt has an air porosity in the range from 10 to 60% and said reinforcing mats have an air porosity of at least 90%.
Claim 61
Dependent Claim
30 words
A laminated structure in accordance with claim 56 wherein said resilient batt has an air porosity of about 40% and said thermoset composition comprises a thermoset urethane elastomer binder composition.
Claim 62
Dependent Claim
26 words
A laminated structure in accordance with claim 55 having a decorative porous fabric cover layer laminated to the other face of said first reinforcing fibrous mat.
Claim 63
Dependent Claim
19 words
A laminated structure in accordance with claim 58 wherein said thermoset composition comprises a thermoset urethane elastomer binder composition.
Claim 64
Dependent Claim
35 words
A laminated structure in accordance with claim 58 wherein said resilient batt has an air porosity in the range from 10 to 60% and said reinforcing mats have an air porosity of at least 90%.
Claim 65
Dependent Claim
18 words
A laminated structure in accordance with claim 60 wherein said thermoset composition comprises a thermoset urethane elastomer composition.
Claim 66
Dependent Claim
19 words
A laminated structure in accordance with claim 61 wherein said resilient batt has an air porosity of about 40%.
References Cited (Backward Citations)
US2768026A
Cited
US3082143A
Cited
US3046173A
Cited
US3506532A
Cited
US3531367A
Cited
US3620906A
Cited
US4002567A
Cited
US4059660A
Cited
US4119749A
Cited
US4256797A
Cited
US4474846A
Cited
US4463043A
Cited
US4521477A
Cited
US4526831A
Cited
US4489126A
Cited
US4531994A
Cited
US4680219A
Cited
US4608104A
Cited
US4778717A
Cited
US4729917A
Cited
US4784898A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1992-05-08 | 1992-11-07 | 1993-05-09 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-05-08 | 1996-11-07 | 1997-05-09 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-05-08 | 2000-11-07 | 2001-05-09 | $7700.00 | Window Closed / Lapsed |