MULTI-LAYER NONWOVEN COMPOSITE MATERIAL AND METHOD OF MANUFACTURE
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United States of America Patent
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Issued Date -
Jul 10, 2008
app pub date -
Nov 16, 2007
filing date -
Nov 16, 2006
priority date (Note) -
Abandoned
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Abstract
A multi-layer nonwoven composite material includes base layers which impart desired properties. The number of base layers can vary as desired for desired properties in order to tune the resulting multi-layer composite material. In a preferred composite material, three base layers are provided to impart sound deadening, sound dispersion, sound absorption, and sound durability. The base layers are first produced from constituent fibers to form constituent webs. These webs are then combined into a multi-layer substrate. A barrier layer may be applied to the multi-layer substrate to impart additional properties. A face layer may be adhered to form a multi-layer nonwoven composite material. The barrier material imparts fire retardancy water resistance while the face carpet imparts cosmetic and/or tactile qualities. Other materials, such as chemical additives, can be applied to the composite material to achieve desired characteristics.
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