Layered polymer fiber insulation and method of making thereof

Abstract

A liner/insulator include including at least two individual layers of wet processed mat wherein the layers including thermoplastic polymer staple fibers and thermoplastic bicomponent fibers. The layers are bonded together by heat and pressure to provide “tunable” acoustical and thermal properties.

1 . A liner/insulator comprising: 
 a) a first layer of wet processed mat;    b) a second layer of wet processed mat;    wherein said first and second layers comprise thermoplastic polymer staple fibers and thermoplastic bicomponent fibers.    
     
     
         2 . The liner/insulator of  claim 1 , further comprising a third layer of wet processed mat comprising thermoplastic polymer staple fibers and thermoplastic bicomponent fibers.  
     
     
         3 . The liner/insulator of  claim 2 , wherein said thermoplastic staple fibers and said thermoplastic bicomponent fibers are selected from a group of materials consisting of polyester, polyethylene, polypropylene, polyethylene terephthalate and any mixtures and/or copolymers thereof.  
     
     
         4 . The liner insulator of  claim 2 , wherein said first, second and third layers are bonded together.  
     
     
         5 . The liner/insulator of  claim 4 , wherein said layers are bonded together by heat and pressure.  
     
     
         6 . The liner/insulator of  claim 1 , wherein said first and said second layers are between about 0.05 to about 0.30 inches thick.  
     
     
         7 . The liner/insulator of  claim 2 , wherein said third layer is between about 0.05 to about 0.30 inches thick.  
     
     
         8 . The liner/insulator of  claim 7 , wherein said liner/insulator is between about 0.125 to about 1.5 inches thick.  
     
     
         9 . The liner/insulator of  claim 2 , wherein said first layer is hydrophilic.  
     
     
         10 . The liner/insulation of  claim 2 , wherein said first layer has a high heat resistance.  
     
     
         11 . The liner/insulator of  claim 2 , wherein said second layer is hydrophobic.  
     
     
         12 . The liner/insulator of  claim 2 , wherein said third layer is sound absorbent.  
     
     
         13 . A method of producing a wet processed liner/insulator comprising the steps of: 
 a) providing a first layer of wet processed mat;    b) providing a second layer of wet processed mat;    wherein said first and second layers comprise thermoplastic polymer staple fibers and thermoplastic bicomponent fibers.    c) applying sufficient heat and pressure to said first and second layers of mat to form said liner/insulator.    
     
     
         14 . The method of  claim 13 , further comprising the step of providing a third layer of wet processed mat comprising thermoplastic polymer staple fibers and thermoplastic bicomponent fibers.  
     
     
         15 . The method of  claim 14 , wherein said thermoplastic staple fibers and said thermoplastic bicomponent fibers are selected from a group of materials consisting of polyester, polyethylene, polypropylene, polyethylene terephthalate and any mixtures and/or copolymers thereof.  
     
     
         16 . The method of  claim 13 , wherein said first and said second layers are between about 0.05 to about 0.30 inches thick.  
     
     
         17 . The method of  claim 14 , wherein said third layer is between about 0.05 to about 0.30 inches thick.  
     
     
         18 . The method of  claim 13 , wherein said liner/insulator is between about 0.125 to about 1.5 inches thick.  
     
     
         19 . The method of  claim 14 , wherein said first layer is hydrophilic.  
     
     
         20 . The method liner/insulation of  claim 14 , wherein said first layer has a high heat resistance.  
     
     
         21 . The method of  claim 14 , wherein said second layer is hydrophobic.  
     
     
         22 . The method of  claim 14 , wherein said third layer is sound absorbent.  
     
     
         23 . The method of  claim 13 , wherein heat is applied to said first and said second layers at a temperature of about 250° F. to about 400° F.