Acoustic insulator and method of manufacturing same

Abstract

An acoustic insulator includes a first layer having an outer surface and an inner surface and a second layer having an outer surface and an inner surface. The outer layer of the second layer is disposed adjacent to and engaging the inner surface of the first layer. The first layer and the second layer form at least one protrusion extending outwardly from the acoustic insulator.

1 . An acoustic insulator comprising:
 a first layer having an outer surface and an inner surface; and   a second layer having an outer surface and an inner surface, said outer layer of said second layer disposed adjacent to and engaging said inner surface of said first layer, said first layer and said second layer having a protrusion extending outwardly from said acoustic insulator.   
     
     
         2 . The acoustic insulator according to  claim 1 , wherein said first layer and said second layer have a plurality of protrusions extending outwardly from said acoustic insulator. 
     
     
         3 . The acoustic insulator according to  claim 2 , wherein said protrusions are spaced evenly apart from one another throughout the extent of said acoustic insulator. 
     
     
         4 . The acoustic insulator according to  claim 1 , wherein said protrusion is shaped generally in the shape of an inverted bell. 
     
     
         5 . The acoustic insulator according to  claim 1 , wherein said first layer is a needled non-woven fiber pad. 
     
     
         6 . The acoustic insulator according to  claim 1 , wherein said first layer is formed from at least one of cotton, hemp, wool, silk, jute, polyester, polypropylene, nylon, glass, ceramic, and polyethylene terephthalate. 
     
     
         7 . The acoustic insulator according to  claim 1 , wherein said first layer is formed of a combination of polyethylene and polyethylene terephthalate fibers 
     
     
         8 . The acoustic insulator according to  claim 1 , wherein said second layer is generally air impermeable. 
     
     
         9 . A combined acoustic insulator and supporting component including:
 a supporting component having a surface; and   an acoustic insulator including a first layer having an outer surface and an inner surface and a second layer having an outer surface and an inner surface, said outer layer of said second layer being disposed adjacent to and engaging said inner surface of said first layer, said first layer and said second layer having a protrusion extending outwardly from said acoustic insulator into engagement with said surface of said supporting component.   
     
     
         10 . The acoustic insulator according to  claim 9 , wherein said supporting component is a vehicle dash panel. 
     
     
         11 . The acoustic insulator according to  claim 9 , wherein said supporting component is a vehicle wheel well. 
     
     
         12 . The acoustic insulator according to  claim 9 , wherein said first layer and said second layer have a plurality of protrusions extending from said acoustic insulation panel into engagement with said surface of said supporting component. 
     
     
         13 . The acoustic insulator according to  claim 12 , wherein the size, shape and quantity of said plurality of protrusions is selected so as to cancel specific frequencies of noises and vibrations generated by said supporting component. 
     
     
         14 . The acoustic insulator according to  claim 12 , wherein said protrusions are spaced evenly apart from one another throughout the extent of said acoustic insulation panel. 
     
     
         15 . The acoustic insulator according to  claim 9 , wherein said protrusion is shaped generally in the shape of an inverted bell. 
     
     
         16 . The acoustic insulator according to  claim 9 , wherein said first layer is a needled non-woven fiber pad. 
     
     
         17 . The acoustic insulator according to  claim 9 , wherein said first layer is formed from at least one of cotton, hemp, wool, silk, jute, ramie, sisal, polyester, polypropylene, nylon, glass, and polyethylene terephthalate. 
     
     
         18 . The acoustic insulator according to  claim 9 , wherein said first layer is formed of a combination of polyethylene and polyethylene terephthalate fibers 
     
     
         19 . The acoustic insulator according to  claim 9 , wherein said second layer is generally air impermeable. 
     
     
         20 . A method of manufacturing an acoustic insulator-comprising the steps of:
 (a) providing a fiber layer;   (b) extruding a film layer onto the fiber layer; and   (c) molding the fiber layer and film layer to form an acoustic insulator having at least one protrusion extending outwardly therefrom.