Composite material with improved structural, acoustic and thermal properties

Abstract

A method of forming a multilayer insulation material formed of an acoustical composite layer and a first thermal layer is provided. The acoustical and insulting layer is formed of a polymer based thermoplastic material and reinforcing fibers. Preferably the reinforcing fibers are wet use chopped strand glass fibers (WUCS). The acoustical composite layer may be formed by opening the WUCS fibers, blending the reinforcement and polymer fibers, forming the reinforcement and polymer fibers into a sheet, and then bonding the sheet. A first thermal layer formed of one or more polymer based thermoplastic organic materials is then positioned on a first major surface of the acoustical composite layer. A second thermal layer of polymeric fibers may be optionally positioned on a second major surface of the acoustical composite layer. The multilayer acoustic material may be utilized in semi-structural and acoustical applications.

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       23 . A method of forming a fibrous polymer mat comprising the steps of:
 at least partially opening a bundle of first polymeric fibers;   at least partially opening a bundle of second polymeric fibers;   blending said at least partially opened first and second polymeric fibers to form a mixture of said at least partially opened first and second polymeric fibers;   forming said mixture into a sheet;   bonding said first and second polymeric fibers to form said fibrous polymer mat.   
   
   
       24 . The method of  claim 23 , further comprising the step of:
 adding a binder resin to said sheet prior to said bonding step.   
   
   
       25 . The method of  claim 24 , further comprising the step of:
 conveying said at least partially opened first and second polymeric fibers to a filling box tower prior to said forming step.   
   
   
       26 . The method of  claim 24 , wherein said forming step comprises the step of:
 passing said mixture through at least one sheet former.   
   
   
       27 . The method of  claim 24 , further comprising the step of:
 needling said first polymeric fibers and said second polymeric fibers prior to said bonding step to mechanically strengthen said fibrous polymer mat.