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.

Description

BACKGROUND OF THE INVENTION [0001] 1. Field of the Invention [0002] This invention relates to materials for sound absorption. More particularly it relates to thermo-formable acoustic products that have enhanced sound absorption properties and can be decoratively faced. [0003] 2. Description of the Related Art [0004] Sound absorption provides a useful means for noise reduction in a wide variety of industrial, commercial, and domestic applications. To achieve the optimum degree of sound absorption, it is desirable to use a composite assembly of different layers, such that the maximum sound absorption is achieved in the minimal possible space, with the lowest possible mass appropriate for the application. [0005] The sound absorption of a porous material is known to be a function of fundamental material properties, including thickness, air flow resistance, mass, stiffness, porosity, tortuosity etc, and application parameters, such as any air space behind the material, or alternatively, ...

AI Technical Summary

Benefits of technology

[0016] Preferably the acoustic sheet has a favorable aesthetic appearance. In one embodiment, the acoustic sheet is a decorative layer, such as a carpet, textile or other permeable film facing. In another embodiment, the acoustic sheet is formed by a decorative layer and at least one additional flow resistive layer.

[0035] The present invention, as detailed above, provides the advantages of a multi-purpose clean, energy efficient, low cost, recyclable material as a thermo-formable acoustic sheet with enhanced and consistent acoustical properties while providing a favorable aesthetic appearance in preferred embodiments. A further advantage is that the present invention provides an insulation that provides a lower resonance than current systems, has superior resilience and predictable mechanical properties.

[0036] A further advantage of the above process is that the product is formed in a fast cycle time, to provide cost-effective solutions for use as an insulation in original equipment, such as motor vehicles and dishwashers, wall and ceiling linings and other industrial commercial and domestic purposes.

[0037] It is a further advantage of this invention to produce an enhanced thermo-formable acoustic product with less energy than conventional systems, providing an improved environmental outcome.

Problems solved by technology

Flow resistive thermo-formable materials have been provided, however such prior art does not address the practicality of achieving an effective sound absorbing solution.

In particular, environmental, manufacturing and cost issues are a concern, whilst retaining the ability to vary the mechanical properties and maintaining or enhancing the sound absorbing properties of the product and combining this with the aesthetic quality of the product.

However these applications similarly do not address the practicality of achieving an effective sound absorbing solution as discussed above.

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