US2012052283A1PendingUtilityA1
Foam laminate product and process for production thereof
Individually held — no corporate assignee on recordPriority: Feb 10, 2009Filed: Feb 9, 2010Published: Mar 1, 2012
Est. expiryFeb 10, 2029(~2.5 yrs left)· nominal 20-yr term from priority
Inventors:Neil P. Gehani
B32B 2307/102B32B 5/18B32B 2605/003B60R 13/0212B29C 43/003B29K 2105/128B32B 2305/20B32B 2266/0278B29C 44/5681Y10T428/249982B29K 2075/00B29L 2031/3023Y10T428/249953B32B 37/04B32B 5/28B32B 2305/022B29C 66/73182B32B 5/245
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Claims
Abstract
A laminate product comprising a foam core having a pair of opposed major surfaces and a cover layer secured with respect to each major surface is described. The cover layer contains a fibrous reinforcement layer that is substantially encapsulated by a polymer. It has been found that the use of a fibrous polymer layer (e.g., in place of conventional polyethylene film) results in a laminate product having significantly lower resistance to air flow resistance and significantly improved sound absorption properties.
Claims
exact text as granted — not AI-modified1 . A laminate product comprising a foam core having a pair of opposed major surfaces and a cover layer secured with respect to each major surface, the cover layer comprising a fibrous reinforcement layer that is substantially encapsulated by a polymer, the laminate product having an air flow resistance as measured in accordance with ASTM C522 of less than about 6,000 mks Rayls.
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6 . The laminate product defined in claim 1 , the laminate product having an air flow resistance as measured in accordance with ASTM C522 in the range of from about 500 to about 5,000 mks Rayls.
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11 . The laminate product defined in claim 1 , the laminate product having an air flow resistance as measured in accordance with ASTM C522 in the range of from about 700 to about 1,500 mks Rayls.
12 . The laminate product defined in claim 1 , wherein a first cover layer is adhered by the polymer to a first major surface of the foam core and a second cover layer is adhered by the polymer to a second major surface of the foam core.
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15 . The laminate product defined in claim 12 , wherein at least one of the first cover layer and the second cover layer comprises a plurality of fibrous reinforcement layers.
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21 . The laminate product defined in claim 12 , wherein each of the first cover layer and the second cover layer independently comprises from 1 to 15 fibrous reinforcement layers.
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24 . The laminate product defined in claim 12 , wherein each of the first cover layer and the second cover layer independently comprises from 1 to 5 fibrous reinforcement layers.
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30 . The laminate product defined in claim 1 , wherein the polymer comprises a polyolefin.
31 . The laminate defined in claim 30 , wherein the polyolefin is selected from the group consisting of a homopolymer, a copolymer and a terpolymer derived from the polymerization of at least one olefin monomer.
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52 . The laminate defined in claim 30 , wherein the polyolefin is polypropylene.
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55 . The laminate defined in claim 30 , wherein the polyolefin has a molecular weight (Mn) in the range of from about 40,000 to about 60,000.
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58 . The laminate product defined in claim 1 , wherein the foam core comprises an compression force deflection at 10% deflection in the range of from about 10 psi to about 80 psi when measured pursuant to ASTM 3574-D.
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60 . The laminate product defined in claim 1 , wherein the foam core comprises a polyurethane foam.
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67 . The laminate product defined in claim 1 , wherein the foam core comprises a thickness of greater than or equal to about 2 mm.
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71 . The laminate product defined in claim 1 , wherein the foam core comprises a thickness in the range of from about 3 mm to about 8 mm.
72 . The laminate product defined in claim 1 , wherein the foam core comprises a thickness in the range of from about 3 mm to about 6 mm.
73 . A vehicular headliner, a sunshade or a package tray comprising the laminate product defined in claim 1 .
74 . A process for producing a laminate foam product having a pre-determined shape, the process comprising the steps of:
positioning a blank in a heating device, the blank comprising a foam core having a pair of opposed major surfaces and a cover layer disposed on each major surface, each cover layer comprising at least one fibrous reinforcing layer and at least one fibrous polymer layer; heating the blank at temperature above the melting point of the at least one fibrous polymer layer to cause polymer to substantially encapsulate the at least one fibrous layer and adhere each cover layer to the foam core.
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