In tool spray acoustic tuning layer

Abstract

A method of making a sound insulating layered composite structure contacting a padding layer having a preformed shaped with a curable liquid composition to form an uncured or partially cured cap layer disposed over at least a portion of the padding layer. An uncured or partially cured cap layer is then cured to form the sound insulating composite structure of the present embodiment. An automobile sound insulating component is made from the method.

1 . A method of making a sound insulating layered composite structure having a cap layer disposed over a padding layer, the method comprising: 
 a) providing a padding layer, the padding layer having a preformed shaped;    b) contacting a curable liquid composition with the padding layer to form an uncured or partially cured cap layer disposed over at least a portion of the padding layer; and    c) curing the uncured cap or partially cured cap layer to form the sound insulating layered composite structure such that the sound insulating layered composite structure has a predetermined air flow resistance.    
     
     
         2 . The method of  claim 1  wherein the sound insulating layered composite has a peak sound absorption at a sound frequency from about 500 and 6,400 Hz.  
     
     
         3 . The method of  claim 1  wherein the sound insulating layered composite has a peak sound absorption at a sound frequency from about 1500 and 5000 Hz.  
     
     
         4 . The method of  claim 1  wherein step b) comprises spraying the curable liquid composition onto the padding layer.  
     
     
         5 . The method of  claim 1  wherein step b) comprises 
 spraying the curable liquid composition onto a tool to form the uncured or partially cured cap layer; and    transferring the uncured or partially cured cap layer onto the padding layer.    
     
     
         6 . The method of  claim 1  wherein step b) comprises: 
 spraying the curable liquid composition onto an insert to form the uncured or partially cured cap layer disposed over the insert, the insert providing support to the padding layer;    positioning the insert in a mold;    positioning the padding layer in the mold proximate to the uncured or partially cured cap layer disposed over the insert to form a sound insulating assembly;    curing the sound insulating assembly;    removing the sound insulating assembly from the mold;    removing the insert from the assembly to form the sound insulating layered composite.    
     
     
         7 . The method of  claim 1  wherein the air flow resitance is from about 300 to about 6000 rayl.  
     
     
         8 . The method of  claim 1  wherein the curable liquid composition comprises a cross-linkable polymer.  
     
     
         9 . The method of  claim 1  wherein the curable liquid composition comprises a latex or polyurethane.  
     
     
         10 . The method of  claim 9  wherein the curable liquid composition comprises an acrylic latex, an ethylene vinyl acetate latex, a styrene butadiene rubber latex.  
     
     
         11 . The method of  claim 1  wherein the curable liquid composition comprises a two component system that is mixed prior to or during step b).  
     
     
         12 . The method of  claim 1  wherein the uncured or partially cured cap layer is substantially fully cured by heating.  
     
     
         13 . The method of  claim 1  wherein the cap layer has a thickness from about 0.3 mil to about 0.25 mm.  
     
     
         14 . The method of  claim 1  wherein the cap layer has a thickness from about 2 mil to about 10 mil.  
     
     
         15 . The method of  claim 1  wherein the padding layer comprises a component selected from the group consisting of fibrous padding and open cell foams.  
     
     
         16 . A method of making a sound insulating layered composite structure having a cap layer disposed over a padding layer, the method comprising: 
 a) providing a padding layer, the padding layer having a preformed shaped;    b) spraying a curable liquid composition onto an insert to form an uncured or partially cured cap layer disposed over the insert, the insert providing support to the padding layer;    c) positioning the insert in a mold;    d) positioning the padding layer in the mold proximate to the uncured or partially cured disposed over the insert to form a sound insulating assembly;    e) curing the sound insulating assembly;    f) removing the sound insulating assembly from the mold;    g) removing the insert from the assembly to form the sound insulating layered composite such that the sound insulating layered composite has a predetermined air flow resistance.    
     
     
         17 . The method of  claim 16  wherein the air flow resistance is from about 300 to about 6000 rayl.  
     
     
         18 . The method of  claim 17  wherein the curable liquid composition comprises an acrylic latex, an ethylene vinyl acetate latex, a styrene butadiene rubber latex.  
     
     
         19 . A method of making a sound insulating layered composite structure having a cap layer disposed over a padding layer, the method comprising: 
 a) providing a padding layer, the padding layer having a preformed shaped;    b) spraying a curable liquid composition onto a tool to form a uncured or partially cured cap layer;    c) transferring the uncured or partially cured cap layer onto the padding layer; and    d) curing the uncured cap or partially cured cap layer to form the sound insulating composite layer such that the sound insulating layered composite such that the sound insulating layered composite has a predetermined air flow resistance.    
     
     
         20 . The method of  claim 19  wherein the air flow resistance is from about 300 to about 6000 rayl.