Multidensity liner/ insulator formed from multidimensional pieces of polymer fiber blanket insulation

Abstract

In accordance with the purposes of the present invention as described herein, an improved acoustical, compressible, polymer fiber blanket ( 10 ) of enhanced performance characteristics is provided. The polymer fiber blanket of the present invention is constructed of a plurality of individual pieces of polymer fiber blanket ( 12 ) that have been bonded together via heat and pressure.

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       22 . A method of producing a compressible, flexible polymer fiber blanket ( 10 ) comprising the steps of: 
 a) providing a plurality of individual pieces of polymer fiber blanket ( 12 );    b) laying said plurality of pieces of polymer fiber blanket in a randomly oriented pattern;    c) applying sufficient heat and pressure to said plurality of individual pieces of polymer fiber blanket to form said compressible, flexible polymer fiber blanket.    
   
   
       23 . The method of  claim 22 , wherein said wherein said individual pieces of polymer fiber blanket are made of scrap polymer fiber blanket.  
   
   
       24 . The method of  claim 22 , wherein said individual pieces of polymer fiber blanket are geometric in shape.  
   
   
       25 . The method of  claim 22 , wherein said individual pieces of polymer fiber blanket comprise a lofty, acoustically insulating portion having a density of between substantially 8.0-80.0 kg/m 3  and a relatively higher density skin along at least one face thereof, said skin having a thickness of between substantially 0.25-10.0 mm and a density of between substantially 32.0-800.0 kg/m 3 .  
   
   
       26 . The method of  claim 22 , wherein said blanket is an automotive undercarpet.  
   
   
       27 . The method of  claim 22 , wherein said pad is a nonlaminate.  
   
   
       28 . The method of  claim 22 , wherein said polymer fiber blanket has a percent wet compression of between about 15 to about 18 percent.  
   
   
       29 . The method of  claim 22 , wherein said polymer fiber blanket has a percent dry compression of between about 16 to about 21 percent.  
   
   
       30 . The method of  claim 22 , wherein said polymer fiber blanket has a percent dry wet recovery of between about 85 to about 87.5 percent.  
   
   
       31 . The method of  claim 22 , wherein said polymer blanket is thermally bonded to at least one layer of flexible, polymeric fibrous material.  
   
   
       32 . The method of  claim 26 , wherein said polymeric fibrous material has a lofty, acoustically insulating portion having a density of between substantially 8.0-80.0 kg/m 3  and a relatively higher density skin along a first face thereof, said skin having a thickness of between substantially 0.25-10.0 mm and a density of between substantially 32.0-800.0 kg/m 3 , said fibrous material being selected from a group consisting of (a) thermoplastic polymer staple fibers and thermoplastic bicomponent fibers,(b) glass staple fibers and thermoplastic bicomponent fibers and (c) a combination of (a) and (b).  
   
   
       33 . The method of  claim 31 , wherein said fibrous material is selected from a group of materials consisting of polyester, polyethylene, polypropylene, nylon, glass fibers, natural fibers and any mixtures thereof.  
   
   
       34 . The method of  claim 31 , wherein said polymeric fibrous material includes said relatively higher density skin along a second face thereof.  
   
   
       35 . The method of  claim 22 , wherein said blanket further comprises at least one water barrier layer.  
   
   
       36 . A compressible, flexible, polymer fiber blanket comprising a plurality of individual pieces of polymer fiber blanket thermally bonded together wherein said individual pieces of polymer fiber blanket comprise fibrous material having a lofty, acoustically insulating portion having a density of between substantially 8.0-80.0 kg/m 3  and a relatively higher density skin along a first face thereof, said skin having a thickness of between substantially 0.25-10.0mm and a density of between substantially 32.0-800.0 kg/m 3 , said fibrous material being selected from a group consisting of (a) thermoplastic polymer staple fibers and thermoplastic bicomponent fibers,(b) glass staple fibers and thermoplastic bicomponent fibers and (c) a combination of (a) and (b).  
   
   
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