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Molded and shaped acoustical insulating vehicle panel and method of making the same

Abstract

A molded and shaped acoustical insulating vehicle panel having a dry-laid needled fibrous composite composed of a first portion of about 50 to 80 percent meltable binder fibers and about 20 to 50 percent stable fibers and having a second portion of about 20 to 50 percent meltable binder fibers and 50 to 80 percent of staple fibers. The meltable binder fibers are in a molded and resolidified state such that the resolidified binder fibers of the first portion form a substantially continuous, semi-impervious, densified skin integrally associated with and bonded to a surface of the first portion. The molded composite is in such a heat and pressure molded state that the composite has over a predominance of its area a density of from about 12 to 22 lbs./cubic foot (192 to 352 kg/cubic meter) and the panel is sufficiently rigid as to be self-supporting.

Filed on: 2008-09-29; Application Number: 12285082

Applicant(s)

Steven Borchardt
Brian Jarrard

Agent

BIRCH STEWART KOLASCH BIRCH

Assignee

Lydall Inc