Sound insulation constructions and methods of using the same

Abstract

Sound insulation constructions, multilayer constructions for acoustically insulating a source of sound from a receiver that include one or more sound insulation constructions, structures comprising one or more sound insulation constructions and/or multilayer constructions, and a method for acoustically insulating a source of sound from a receiver. In some embodiments, the sound insulation construction includes a first layer and a second layer. The first layer can include a bonded fiber nonwoven web exhibiting a work of compression of at least about 0.7 kJ/m 3 and an airflow resistance of no greater than 10,000 Rayls/m. The second layer can exhibit an airflow resistance of greater than 10,000 Rayls/m. In some embodiments, the method includes coupling the first layer to a surface of a vehicle to attenuate sound in at least a portion of the vehicle.

What is claimed is: 
     
         1 . A sound insulation construction comprising:
 a first layer comprising a bonded fiber nonwoven web exhibiting a work of compression of at least about 0.7 kJ/m 3  and an airflow resistance of no greater than 10,000 Rayls/m,   wherein individual fibers of the bonded fiber nonwoven web of the first layer are bonded to each other at fiber-bonding points by melt bonding or by a binder that extends between the individual fibers, the fiber-bonding points being distributed throughout the entire thickness of the bonded fiber nonwoven web.   
     
     
         2 . The sound insulation construction of  claim 1 , wherein the first layer exhibits a maximum acceleration of no greater than about 10 g. 
     
     
         3 . The sound insulation construction of  claim 1 , wherein the sound insulation construction exhibits at least about 60% absorption at a frequency of 1500 hertz. 
     
     
         4 . The sound insulation construction of  claim 1 , further comprising a second layer coupled to the first layer, with the second layer comprising at least one of headliner facing, carpeting, trunk liner facing, side panel facing, dash facing, hood liner facing, an outwardly facing layer of a wheel well liner, and an outwardly facing layer of an engine cover. 
     
     
         5 . The sound insulation construction of  claim 1 , further comprising a second layer coupled to the first layer, with the second layer comprising a nonwoven web. 
     
     
         6 . The sound insulation construction of  claim 1 , wherein the bonded fiber nonwoven web comprises at least one of inter-engaged continuous crinkled coarse filaments of resilient thermoplastic polymer and a sponge-like, compressible nonwoven web comprising randomly intermingled and randomly bonded hydrophobic fibers. 
     
     
         7 . The sound insulation construction of  claim 1 , wherein the bonded fiber nonwoven web exhibits an airflow resistance no greater than about 2000 Rayls/m. 
     
     
         8 . The sound insulation construction of  claim 7 , wherein the bonded fiber nonwoven web exhibits a work of compression of at least 1 kJ/m 3 . 
     
     
         9 . The sound insulation construction of  claim 8 , wherein the bonded fiber nonwoven web has an acoustic performance parameter of no greater than about 10,000 g-Rayls/m. 
     
     
         10 . The sound insulation construction of  claim 1 , wherein the sound insulation construction further comprises a second layer coupled to the first layer, with the second layer being air permeable. 
     
     
         11 . The sound insulation construction of  claim 10 , wherein the sound insulation construction further comprises a second layer coupled to the first layer, with the second layer having an airflow resistance greater than 10,000 Rayls/m. 
     
     
         12 . A multilayer construction coupled to a surface of a structure and adapted to acoustically insulate a source of sound from a receiver, the multilayer construction comprising the sound insulation construction of  claim 1 . 
     
     
         13 . The multilayer construction of  claim 12 , wherein the structure is selected from the group consisting of machines, appliances, laboratory equipment, medical equipment, power tools, and architectural structures. 
     
     
         14 . The multilayer construction of  claim 12 , wherein the structure forms at least a portion of a motor vehicle and is selected from the group consisting of a wheel well, a trunk, a ceiling, a side panel, a rear gate, a floor panel, a dash panel, a hood, an engine cover, and combinations thereof. 
     
     
         15 . The multilayer construction of  claim 12 , wherein the sound insulation construction is further coupled to a barrier layer, a decoupler layer, and an optional mastic layer, and wherein the multilayer construction forms a carpet laminate. 
     
     
         16 . The multilayer construction of  claim 12 , wherein the sound insulation construction is further coupled to at least one of shoddy, needle punched shoddy, foam, plastic, woven web, nonwoven web, film, and perforated film, and combinations thereof. 
     
     
         17 . An assembly comprising:
 a sound insulation construction of  claim 1 , wherein the first layer of the sound insulation construction is coupled to an additional layer.   
     
     
         18 . The assembly of  claim 17 , wherein the additional layer comprises an element selected from the group consisting of metal, mastics, foam, chopped fiberglass, fabric, film, and combinations thereof. 
     
     
         19 . A method of insulating sound, the method comprising:
 providing a sound insulation construction of  claim 1 ; and   coupling the first layer of the sound insulation construction to an additional layer   
     
     
         20 . The method of  claim 19 , wherein the sound insulation construction further comprises a second layer coupled to the first layer, with the second layer being air permeable. 
     
     
         21 . The method of  claim 20 , wherein the sound insulation construction further comprises a second layer coupled to the first layer, with the second layer having an airflow resistance greater than 10,000 Rayls/m. 
     
     
         22 . The method of  claim 19 , wherein the additional layer is selected from the group consisting of metal, mastics, foam, chopped fiberglass, fabric, film, and combinations thereof. 
     
     
         23 . A method of insulating sound in at least a portion of a vehicle, the method comprising:
 coupling a first layer comprising a bonded fiber nonwoven web to a surface of the vehicle,   the bonded fiber nonwoven web exhibiting a work of compression of at least about 0.7 kJ/m 3  and an airflow resistance of no greater than 10,000 Rayls/m, and individual fibers of the bonded fiber nonwoven web of the first layer being bonded to each other at fiber-bonding points by melt bonding or by a binder that extends between the individual fibers, with the fiber-bonding points being distributed throughout the entire thickness of the bonded fiber nonwoven web.