Thermoformable acoustic product

Abstract

A thermo-formed acoustic product formed from an acoustic sheet with a relatively high flow resistance, and a layer of porous flow resistive spacer material attached to one side of the acoustic sheet and having a flow resistance substantially smaller than the acoustic sheet. The acoustic product has locally reactive acoustic behavior and an overall air flow resistance of between 2800 Rayls and 8000 Rayls. A decorative facing can be applied to the acoustic sheet.

1 . A thermo-formed acoustic product formed from an acoustic sheet with a relatively high flow resistance, and a layer of porous flow resistive spacer material attached to one side of the acoustic sheet and having a flow resistance substantially smaller than the acoustic sheet, wherein the acoustic product has locally reactive acoustic behavior and an overall air flow resistance of between 2800 Rayls and 8000 Rayls.  
     
     
         2 . A thermo-formed acoustic product according to  claim 1  wherein the acoustic sheet has a favorable aesthetic appearance.  
     
     
         3 . A thermo-formed acoustic product according to  claim 2  wherein the acoustic sheet is a decorative layer, such as a carpet, textile or a fabric facing.  
     
     
         4 . A thermo-formed acoustic product according to  claim 3  wherein the decorative layer is selected from the group consisting of a carpet, a textile and a permeable film facing.  
     
     
         5 . A thermo-formed acoustic product according to  claim 2  wherein the acoustic sheet includes a decorative layer and at least one additional flow resistive layer.  
     
     
         6 . A thermo-formed acoustic product according to  claim 1  wherein the porous locally reactive flow resistive spacer material is a fibrous web.  
     
     
         7 . A thermo-formed acoustic product according to  claim 6  wherein the fibrous web spacer material has a vertically-lapped construction so that the fibers are oriented in a plane normal to that of the acoustic sheet.  
     
     
         8 . A thermo-formed acoustic product according to  claim 7  wherein the fibers of the fibrous web spacer material are at least partially thermally bonded together.  
     
     
         9 . A thermo-formed acoustic product according to  claim 8  wherein the fibrous web spacer material is formed from high melt and low melt fibers.  
     
     
         10 . A thermo-formed acoustic product according to  claim 9  wherein the low melt fibers are a bi-component fiber.  
     
     
         11 . A thermo-formed acoustic product according to  claim 9  wherein the low melt fibers are a mono-component fiber.  
     
     
         12 . A thermo-formed acoustic product according to  claim 1  wherein the acoustic sheet includes a flow resistive layer formed from high melt and low melt fibers.  
     
     
         13 . A thermo-formed acoustic product according to  claim 12  wherein the flow resistive layer is compressed to give the desired air flow resistance.  
     
     
         14 . A thermo-formed acoustic product according to  claim 12  wherein the low melt fibers are selected to have a temperature resistance that is applicable to the intended use.  
     
     
         15 . A thermo-formed acoustic product according to  claim 1  wherein the thermo-formed acoustic product has an overall air flow resistance of between 3000 Rayls to 5000 Rayls.  
     
     
         16 . A thermo-formed acoustic product according to  claim 15  wherein the thermo-formed acoustic product has an overall air flow resistance of between 3200 Rayls to 4500 Rayls.  
     
     
         17 . A thermo-formed acoustic product according to  claim 1  wherein the porous spacer material has an air flow resistance of between 100 Rayls to 800 Rayls.  
     
     
         18 . A thermo-formed acoustic product according to  claim 17  wherein the porous spacer material has an air flow resistance of between 200 Rayls to 400 Rayls.  
     
     
         19 . A thermo-formed acoustic product according to  claim 1  wherein the porous spacer material has a density of 150-2000 g/m 2 .  
     
     
         20 . A thermo-formed acoustic product according to  claim 1  wherein the acoustic sheet has a density of 150-2000 g/m 2 .  
     
     
         21 . A thermo-formed acoustic product according to  claim 1  wherein the acoustic product has a sag resistance to temperatures at or about 150° C.  
     
     
         22 . A method of forming a thermo-formed acoustic product formed from an acoustic sheet with a relatively high flow resistance, and a layer of porous flow resistive spacer material attached to one side of the acoustic sheet and having a flow resistance substantially smaller than the acoustic sheet, including the steps of heating the porous flow resistive layer and acoustic sheet, and molding the acoustic sheet and porous flow resistive layer wherein the acoustic product has locally reactive acoustic behavior and an overall air flow resistance of between 2800 Rayls and 8000 Rayls and the porous flow resistive spacer material is attached to one side of the acoustic sheet.  
     
     
         23 . A method of forming a thermo-formed acoustic product according to  claim 22  wherein the porous flow resistive spacer material attached to one side of the acoustic sheet during molding.  
     
     
         24 . A method of forming a thermo-formed acoustic product according to  claim 22  wherein the porous flow resistive spacer material attached to one side of the acoustic sheet prior to molding.  
     
     
         25 . A method of forming a thermo-formed acoustic product according to  claim 24  wherein the porous flow resistive spacer material is laminated to the acoustic sheet prior to being molded.  
     
     
         26 . A method of forming a thermo-formed acoustic product according to  claim 22  wherein the acoustic sheet and porous flow resistive layer are supplied to the molding process in roll form.  
     
     
         27 . A method of forming a thermo-formed acoustic product according to  claim 22  wherein the acoustic sheet and porous flow resistive layer are supplied to the molding process in sheet form.  
     
     
         28 . A method of forming a thermo-formed acoustic product according to  claim 22  wherein the acoustic product is molded in a cold molding tool.  
     
     
         29 . A thermo-formed acoustic product formed by the method of  claim 28  wherein fibers used to form the flow resistive spacer material are crystalline fibers.  
     
     
         30 . A method of forming a thermo-formed acoustic product according to  claim 22  wherein the acoustic product is molded in a hot molding tool.  
     
     
         31 . A thermo-formed acoustic product formed by the method of  claim 30  wherein fibers used to form the flow resistive spacer material are amorphous fibers.  
     
     
         32 . A method of forming a thermo-formed acoustic product formed according to  claim 22  wherein heating the acoustic product is achieved with infra red radiation, hot air, or a combination of hot air and infra red radiation.  
     
     
         33 . A thermo-formed acoustic product according to  claim 1  wherein the acoustic product is formed from predominantly one polymer type.  
     
     
         34 . A thermo-formed acoustic product according to  claim 33  wherein the acoustic product is formed predominantly from polyester fibers or polypropylene fibers.