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Method for forming a sound attenuation composite
| Details |
Inventors: Veiga, Manuel J.; Satin, Richard J.;
Assignee: Bradford Industries, Inc. (Lowell, MA)
Primary Examiner: Kuhns; Allan R.
Assistant Examiner:
Attorney, Agent or Firm: Dilworth & Barrese
The present invention relates to a sound attenuation composite and a method for making the composite. The sound attenuation composite includes a barrier layer and an open cell foam layer loaded with a sound blocking filler. In one embodiment, the foam layer is filled with a barium sulfate filler. In another embodiment, a solid polyvinyl chloride barrier layer is loaded with barium sulfate, wherein 60 parts of barium sulfate is present in each 100 parts of polyvinyl chloride. |
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DETAILED DESCRIPTION The present invention relates to a sound attenuation composite which includes a barrier layer and an open cell foam layer.
Due to the unique chemistry and processing of the composite, the fractured irregular open cell structure absorbs, traps, blocks and dissipates sound energy.
In the preferred embodiment the barrier layer includes a solid polyvinyl chloride (PVC) polymer layer loaded with barium sulfate, wherein 60 parts of barium sulfate is present in each 100 parts of PVC polymer.
The open cell foam layer is loaded with barium sulfate and glass microsphere filler as well as other additives that work together to improve sound attenuation and flammability performance.
Alternatively, the barrier layer may be constructed from a polymer selected from the group consisting of polyesters, polyethers, polyurethane, polyamides and polyethylene and the open cell foam layer may be constructed from a polymer selected from the group consisting of polyurethane, silicone, nitrile, polyesters, polyethers, polyamides and polyethylene.
To provide a distinctive appearance both of the layers of the sound attenuation composite may be formulated with pigment.
The sound attenuation composite of the present invention may include a decoupling layer affixed to the open cell foam layer.
The decoupling layer separates vibration energy from sound energy so that the sound energy passes therethrough and enters the open cells of the open cell foam layer.
Generally, the decoupling layer reduces the sound energy by at least 1 db.
In an alternative embodiment, the sound attenuation composite of the present invention may include a reinforcing layer positioned adjacent the open cell foam layer.
The reinforcement is provided to strengthen the open cell foam layer and preferably includes a woven fabric bonded to the open cell foam layer.
The reinforcing layer may be a woven, non-woven or knitted textile made out of various fibers such as cotton, fiberglass, polyester, acrylic, nylon and other hybrid fibers
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