Process for forming composite insulator

Abstract

A process for forming a multilayer composite insulator includes: (a) forming an insulator precursor by orienting an insulation insert in a desired location between a first facing layer of and a layer of a polymer based blanket material; (b) closing the insulator precursor in a molding press; (c) heating the insulator precursor in the molding press to a temperature sufficiently high to soften polymer binding fiber in the polymer based blanket material and cause reshaping; and (d) cooling the insulator precursor in the molding press so as to set the insulator precursor in its molded shape and complete formation of the insulator. Other relates processes are also disclosed.

Description

TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION [0001] The present invention relates generally to a process for manufacturing a multilayer composite acoustical and thermal insulator which may be utilized to insulate an environment such as a passenger compartment of a vehicle from the heat and sound generated by mechanical components of that vehicle during its operation. BACKGROUND OF THE INVENTION [0002] It is well known in the art to provide acoustical and thermal insulators on an automobile, truck or other vehicle in an effort to protect and insulate the operating or passenger compartment from the noise and heat generated by the mechanical equipment of the associated vehicle. Toward this end, mats of high temperature glass fibers have been utilized, eg. (a) on the fire wall between the dashboard and engine compartment and (b) along the floor pan of the vehicle between the passenger compartment and the drive line and exhaust system. These materials provide heat insula...

AI Technical Summary

Benefits of technology

"The present invention provides an improved process for forming a multilayer composite insulator that can be used in various applications such as vehicles, appliances, and building industry. The process involves heating an insulation insert in a polymer based blanket material and then shaping it by applying pressure in a molding press. The resulting insulator has improved mechanical, physical, and aesthetic properties. The process can be carried out as a continuous operation or by cutting and orienting the materials prior to molding. The heating and pressure application steps cause the polymer binding fiber to soften and reshap the insulator precursor, resulting in a molded shape and complete formation of the insulator. The process can also be used to form a four-layer composite insulator with a second facing layer added for desired properties."

Problems solved by technology

Thermoplastic resin-coated sheets of fibrous material are useful for certain applications but for most applications and particularly those relating to the insulation of automobiles, such sheets do not always provide the desired acoustical and thermal insulation properties.

The Hubert et al. patent, however, fails to indicate that the hot / cold mold technique may be utilized to manufacture such multilayer composite insulators.

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