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Moldable fibrous composite and methods
Assignee: Foss Manufacturing Co Inc
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Filing: 1987-07-06
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Granted: 1989-07-25
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Expires: 2007-07-06
Abstract
Abstract A moldable fibrous composite having thermal and acoustical insulating characteristics and methods of production thereof are provided. The composite structure comprises a substrate, a middle layer and a non-woven top layer. The substrate may be in the form of a fibrous web or, alternatively, a thermoplastic film. The middle layer comprises mineral fibers of a sufficiently short length to substantially preclude interlocking of any of the mineral fibers with other fibers of the structure and to provide the structure with desired flexibility. The mineral fibers are present in a quantity sufficient to impart desired heat and sound insulating properties to the structure. The top layer may be made of organic fibers or a substantially uniform mixture of organic and inorganic fibers. In making the invention composite structure, the middle layer and the top layer are introduced onto the substrate, respectively. The three layers are thereafter consolidated, such as through needle punching. In addition, binders may be added to the composite structures so as to impart desired properties such as improved moldability.
Inventors
- 👤 Conrad D'Elia
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 05:10
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/02; B32B5/06; D; D04; D04H; D04H1/00; D04H1/40; D04H1/44; D04H1/46; D04H1/48; B32B27/00; B32B27/06; B32B27/08; B32B27/30; B32B27/304; B32B27/34; B32B5/22; B32B5/24; B32B5/26; D04H1/54; D04H1/56; B32B2307/00; B32B2307/20; B32B2307/206; B32B2325/00; B32B2327/00; B32B2327/06; B32B2377/00; Y; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T156/1043; Y10T428/00; Y10T428/13; Y10T428/131; Y10T428/1314; Y10T428/1317; Y10T428/1321; Y10T428/1352; Y10T428/1362; Y10T428/1366; Y10T428/1372; Y10T428/24; Y10T428/24058; Y10T428/24124; Y10T428/24628; Y10T442/00; Y10T442/60; Y10T442/659; Y10T442/666; Y10T442/667
Claims Analysis
Total Claims: 50
Claim 1
Independent Claim
251 words
A stable moldable needled fibrous composite structure, comprising: a first substrate defining a base side and a face side on opposite sides thereof, a middle layer adjacent to said face side of said first substrate, said middle layer comprising mineral fibers of sufficiently short length to substantially preclude interlocking of said mineral fibers with other fibers of said needled structure and to provide said structure with a desired degree of flexibility, said middle layer of mineral fibers initially having lacked structural integrity before being made an integral part of said composite structure, said mineral fibers being present in a quantity sufficient to impart desired heat and sound insulating properties to said structure, a non-woven top layer adjacent to said middle layer and opposite said substrate relative to said middle layer, said top layer comprising organic fibers or a substantially uniform mixture of organic and inorganic fibers with the organic fibers comprising more than 10 percent of said uniform mixture, said fibers of said top layer being of sufficient average length whereby a sufficient portion of said fibers of said top layer interlock with said first substrate as a result of needling said fibers through the top layer, middle layer and first substrate to provide a substantially stable structure, said fibers of said top layer being of sufficient strength and present in sufficient quantity to provide said top layer with a substantially uniform cross-sectional area, said needled structure having a punch density of between about 400 to 3,000 penetrations per square inch.
Claim 2
Dependent Claim
251 words
A stable moldable needled fibrous composite structure, comprising: a first substrate defining a base side and a face side on opposite sides thereof, a middle layer adjacent to said face side of said first substrate, said middle layer comprising mineral fibers of sufficiently short length to substantially preclude interlocking of said mineral fibers with other fibers of said needled structure and to provide said structure with a desired degree of flexibility, said middle layer of mineral fibers initially having lacked structural integrity before being made an integral part of said composite structure, said mineral fibers being present in a quantity sufficient to impart desired heat and sound insulating properties to said structure, a non-woven top layer adjacent to said middle layer and opposite said substrate relative to said middle layer, said top layer comprising organic fibers or a substantially uniform mixture of organic and inorganic fibers with the organic fibers comprising more than 10 percent of said uniform mixture, said fibers of said top layer being of sufficient average length whereby a sufficient portion of said fibers of said top layer interlock with said first substrate as a result of needling said fibers through the top layer, middle layer and first substrate to provide a substantially stable structure, said fibers of said top layer being of sufficient strength and present in sufficient quantity to provide said top layer with a substantially uniform cross-sectional area, said needled structure having a punch density of between about 400 to 3,000 penetrations per square inch.
Claim 3
Dependent Claim
19 words
The composition structure of claim 1 wherein said substrate comprises a fibrous web formed by a melt blown process.
Claim 4
Dependent Claim
19 words
The composite structure of claim 1 wherein said substrate comprises a fibrous web formed by a spun bonded process.
Claim 5
Dependent Claim
13 words
The composite structure of claim 1 wherein said substrate comprises a thermoplastic film.
Claim 6
Dependent Claim
24 words
The composite structure of claim 4 wherein said thermoplastic film is porous and is selected from the group consisting of polyethylene, polypropylene, and polyester.
Claim 7
Dependent Claim
28 words
The composite structure of claim 3 wherein said fibrous substrate comprises a material selected from the group consisting of polyethylene, polypropylene, polyester, polystyrene, nylon, mylar and combinations thereof.
Claim 8
Dependent Claim
13 words
The composite structure of claim 1 wherein said mineral fibers comprise rock wool.
Claim 9
Dependent Claim
16 words
The composite structure of claim 1 wherein said mineral fibers comprise calcium, aluminum, magnesium and silicate.
Claim 10
Dependent Claim
20 words
The composite structure of claim 1 wherein said mineral fibers are air blown onto said face side of said substrate.
Claim 11
Dependent Claim
22 words
The composite structure of claim 1 wherein said top layer fibers are cross-lapped onto said mineral fibers of said adjacent middle layer.
Claim 12
Dependent Claim
17 words
The composite structure of claim 1 wherein said fibers of said top layer comprise a needled batt.
Claim 13
Dependent Claim
16 words
The composite structure of claim 1 additionally having an effective amount of a binder applied thereto.
Claim 14
Dependent Claim
23 words
The composite structure of claim 12 wherein said binder is selected from the group consisting of PVC, phenolic, polystyrene, nylon, polyester and ABS.
Claim 15
Dependent Claim
18 words
The composite structure of claim 12 wherein said binder is sprayed on said base side of said substrate.
Claim 16
Dependent Claim
15 words
The composite structure of claim 12 wherein said binder is roller coated to said composite.
Claim 17
Dependent Claim
18 words
The composite structure of claim 12 wherein said binder is applied by saturating said composite with said binder.
Claim 18
Dependent Claim
29 words
The composite structure of claim 12 wherein said binder comprises a resin which requires a relatively high temperature to cure, wherein said composite structure comprises a generally symmetrical structure.
Claim 19
Dependent Claim
14 words
The composite structure of claim 12 wherein said middle layer additionally comprises said binder.
Claim 20
Dependent Claim
19 words
The composite structure of claim 18 wherein said binder is pre-mixed with said mineral fibers of said middle layer.
Claim 21
Dependent Claim
23 words
The composite structure of claim 1 additionally comprising at least one additional needleable substrate interposed between said middle layer and said top layer.
Claim 22
Dependent Claim
22 words
The composite structure of claim 1 additionally comprising a layer of glass fibers interposed between said middle layer and said top layer.
Claim 23
Dependent Claim
21 words
The composite structure of claim 1 additionally comprising a layer of glass fibers interposed between said middle layer and said substrate.
Claim 24
Independent Claim
285 words
A method for the production of a moldable fibrous composite structure, said method comprising the steps of: introducing a first needleable substrate, said substrate defining a base side opposite a face side, introducing a middle layer comprising mineral fibers of sufficiently short length to substantially preclude interlocking of any of said mineral fibers with other fibers of said structure and to provide said structure with a desired degree of flexibility onto the face side of said first needleable substrate, said middle layer of mineral fibers initially lacking structural integrity, said mineral fibers being present in a quantity sufficient to impart desired heat and sound insulating properties to said structure, introducing a non-woven top layer comprising organic fibers or a substantially uniform mixture of more than ten percent organic fibers with inorganic fibers onto said middle layer whereby said middle layer is disposed between said first substrate and said top layer to form a precursor composite, said fibers of said top layer being of a sufficient average length whereby a sufficient portion of said top layer fibers interlock with said first substrate upon needling said fibers completely through the top layer, middle layer and first substrate to provide a substantially stable structure, said fibers of said top layer being of sufficient strength and present in sufficient quantity to provide said top layer with a substantially uniform cross-sectional area upon subsequent needling of said precursor composite, and thereafter needling said precursor composite by driving the needles completely through the top layer and middle layer and into the first substrate whereby said structure having a punch density of between about 400 to 3,000 penetrations per square inch is attained and said structure being producible on a continuous basis.
Claim 25
Independent Claim
285 words
A method for the production of a moldable fibrous composite structure, said method comprising the steps of: introducing a first needleable substrate, said substrate defining a base side opposite a face side, introducing a middle layer comprising mineral fibers of sufficiently short length to substantially preclude interlocking of any of said mineral fibers with other fibers of said structure and to provide said structure with a desired degree of flexibility onto the face side of said first needleable substrate, said middle layer of mineral fibers initially lacking structural integrity, said mineral fibers being present in a quantity sufficient to impart desired heat and sound insulating properties to said structure, introducing a non-woven top layer comprising organic fibers or a substantially uniform mixture of more than ten percent organic fibers with inorganic fibers onto said middle layer whereby said middle layer is disposed between said first substrate and said top layer to form a precursor composite, said fibers of said top layer being of a sufficient average length whereby a sufficient portion of said top layer fibers interlock with said first substrate upon needling said fibers completely through the top layer, middle layer and first substrate to provide a substantially stable structure, said fibers of said top layer being of sufficient strength and present in sufficient quantity to provide said top layer with a substantially uniform cross-sectional area upon subsequent needling of said precursor composite, and thereafter needling said precursor composite by driving the needles completely through the top layer and middle layer and into the first substrate whereby said structure having a punch density of between about 400 to 3,000 penetrations per square inch is attained and said structure being producible on a continuous basis.
Claim 26
Dependent Claim
12 words
The method of claim 23 wherein said substrate comprises a fibrous web.
Claim 27
Dependent Claim
13 words
The method of claim 23 additionally comprising the step of forming said substrate.
Claim 28
Dependent Claim
24 words
The method of claim 25 wherein said substrate comprises a fibrous web and said step of forming said substrate comprises a melt blown process.
Claim 29
Dependent Claim
24 words
The method of claim 25 wherein said substrate comprises a fibrous web and said step of forming said substrate comprises a spun bonded process.
Claim 30
Dependent Claim
12 words
The method of claim 23 wherein said substrate comprises a thermoplastic film.
Claim 31
Dependent Claim
20 words
The method of claim 28 wherein said porous thermoplastic is selected from the group consisting of polyethylene, polypropylene, and polyester.
Claim 32
Dependent Claim
26 words
The method of claim 23 wherein said substrate comprises a material selected from the group consisting of polyethylene, polypropylene, polyester, polystyrene, nylon, mylar and combinations thereof.
Claim 33
Dependent Claim
12 words
The method of claim 23 wherein said mineral fibers comprise rock wool.
Claim 34
Dependent Claim
15 words
The method of claim 23 wherein said mineral fibers comprise calcium, aluminum, magnesium and silicate.
Claim 35
Dependent Claim
26 words
The method of claim 23 wherein said step of introducing said middle layer comprises air blowing said mineral fibers onto said face side of said substrate.
Claim 36
Dependent Claim
23 words
The method of claim 23 wherein said step of introducing said top layer comprises cross-lapping said top layer to said adjacent middle layer.
Claim 37
Dependent Claim
17 words
The method of claim 23 additionally comprising the step of pre-needling said fibers of said top layer.
Claim 38
Dependent Claim
19 words
The method of claim 23 additionally comprising the step of applying an effective amount of binder to said structure.
Claim 39
Dependent Claim
22 words
The method of claim 36 wherein said binder is selected from the group consisting of PVC, phenolic, polystyrene, nylon, polyester and ABS.
Claim 40
Dependent Claim
24 words
The method of claim 34 wherein said step of applying said binder comprises spraying said binder onto said base side of said substrate web.
Claim 41
Dependent Claim
20 words
The method of claim 36 wherein said step of applying said binder comprises roller coating said composite with said binder.
Claim 42
Dependent Claim
19 words
The method of claim 36 wherein said step of applying said binder comprises saturating said composite with said binder.
Claim 43
Dependent Claim
26 words
The method of claim 36 wherein said binder comprises a resin requiring a high temperature to cure, wherein said composite structure comprises a generally symmetrical structure.
Claim 44
Dependent Claim
27 words
The method of claim 36 wherein said step of applying said binder comprises the step of pre-mixing said binder with said mineral fibers of said middle layer.
Claim 45
Dependent Claim
36 words
The method of claim 23 wherein said step of needling said three layer composite comprises punching said three layer composite with a plurality of needles each having a plurality of small barbs in a densified arrangement.
Claim 46
Dependent Claim
34 words
The method of claim 23 additionally comprising the step of introducing at least one additional needleable substrate onto said middle layer prior to said introduction of said top layer to form said precursor composite.
Claim 47
Dependent Claim
33 words
The method of claim 23 additionally comprising the step of introducing a layer of glass fibers onto said middle layer prior to said introduction of said top layer to form said precursor composite.
Claim 48
Dependent Claim
28 words
The method of claim 23 additionally comprising the step of introducing a layer of glass fibers onto said substrate prior to said introduction of said middle layer thereto.
Claim 49
Dependent Claim
54 words
The method of claim 43 wherein the depth and spacing of the barbs on the needles are such that the barbs will pick up one or more fibers which will fill the barb, said needles penetrating said top layer, middle layer and substrate for locking the fibers of the top layer with the substrate.
Claim 50
Dependent Claim
28 words
The composite structure of claim 1 wherein said top layer of substantially uniform mixture of organic and inorganic fibers is comprised of at least 90 percent organic fibers.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1992-07-24 | 1993-01-23 | 1993-07-25 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-07-24 | 1997-01-23 | 1997-07-25 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-07-24 | 2001-01-23 | 2001-07-25 | $7700.00 | Window Closed / Lapsed |