Patent Description:
With a <NUM>% weight reduction in the vehicle capable of providing about an <NUM>% increase in fuel efficiency, automotive and aerospace manufacturers have a great incentive to decrease vehicle weight while meeting existing performance targets. Yet, as vehicular structures become lighter, noise can become increasingly problematic. Some noise is borne from structural vibrations, which generate sound energy that propagates and transmits to the air, generating airborne noise. Structural vibration is conventionally controlled using damping materials made with heavy, viscous materials. Airborne noise is conventionally controlled using a soft, pliable material, such as a fiber or foam, capable of absorbing sound energy. <CIT> discloses an acoustic absorbing filler for a lining panel of an aircraft.

Thus, in one aspect, the present disclosure provides an acoustic absorbing filler, the acoustic absorbing filler comprising a core particle comprising a polymer; an outer layer coated on the core particle, wherein the outer layer comprise microporous particulates; and wherein the acoustic absorbing filler has a median particle size of from <NUM> micrometer to <NUM> micrometers and a specific surface area of from <NUM><NUM>/g to <NUM><NUM>/g; wherein a bed packed with acoustic absorbing fillers and having a bed thickness of <NUM> has a normal incidence acoustic absorption of no less than <NUM> at <NUM>.

In another aspect, the present disclosure provides an acoustic article comprising: a porous layer; and the acoustic absorbing filler of present discloure at least partially enmeshed in the porous layer, wherein the acoustic article has a flow resistance of from <NUM> MKS Rayls to <NUM>,<NUM> MKS Rayls In the following <NUM> Rayl = <NUM> Pa.

In another aspect, the present disclosure provides a method of making an acoustic article comprising: partially enmeshing acoustic absorbing filler of present discloure into a porous layer, the acoustic absorbing filler having a specific surface area of from <NUM><NUM>/g to <NUM><NUM>/g to increase acoustic absorption of the article for sound frequencies below <NUM>.

Various aspects and advantages of exemplary embodiments of the present disclosure have been summarized. The above Summary is not intended to describe each illustrated embodiment or every implementation of the present disclosure. Further features and advantages are disclosed in the embodiments that follow. The Drawings and the Detailed Description that follow more particularly exemplify certain embodiments using the principles disclosed herein.

For the following defined terms, these definitions shall be applied for the entire Specification, including the claims, unless a different definition is provided in the claims or elsewhere in the Specification based upon a specific reference to a modification of a term used in the following definitions:
The terms "about" or "approximately" with reference to a numerical value or a shape means +/- five percent of the numerical value or property or characteristic, but also expressly includes any narrow range within the +/- five percent of the numerical value or property or characteristic as well as the exact numerical value. For example, a temperature of "about" <NUM> refers to a temperature from <NUM> to <NUM>, but also expressly includes any narrower range of temperature or even a single temperature within that range, including, for example, a temperature of exactly <NUM>. For example, a viscosity of "about" <NUM> Pa-sec refers to a viscosity from <NUM> to <NUM> Pa-sec, but also expressly includes a viscosity of exactly <NUM> Pa-sec. Similarly, a perimeter that is "substantially square" is intended to describe a geometric shape having four lateral edges in which each lateral edge has a length which is from <NUM>% to <NUM>% of the length of any other lateral edge, but which also includes a geometric shape in which each lateral edge has exactly the same length.

The terms "a", "an", and "the" include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a material containing "a compound" includes a mixture of two or more compounds.

"Average" means number average, unless otherwise specified.

"Basis Weight" is calculated as the weight of a <NUM> x <NUM> web sample multiplied by <NUM>, and is expressed in grams per square meter (gsm).

"Copolymer" refers to polymers made from repeat units of two or more different polymers and includes random or statistical, gradient, alternating, block, graft, and star (e.g. dendritic) copolymers and combinations thereof.

"Dimensionally stable" refers to a structure that substantially holds its shape under gravity unassisted (i.e., not floppy).

"Die" means a processing assembly including at least one orifice for use in polymer melt processing and fiber extrusion processes, including but not limited to melt-blowing.

"Enmeshed" means that particles are dispersed and physically and/or adhesively held in the fibers or structure of the web.

"Glass transition temperature (or Tg)" of a polymer refers to a temperature at which there is a reversible transition in an amorphous polymer (or in an amorphous region within a semi crystalline polymer) from a hard and relatively brittle "glassy" state into a viscous, rubbery (elastic), or viscoelastic state as the temperature is increased.

"Median fiber diameter" of fibers in a non-woven fibrous layer is determined by producing one or more images of the fiber structure, such as by using a scanning electron microscope; measuring the transverse dimension of clearly visible fibers in the one or more images resulting in a total number of fiber diameters; and calculating the median fiber diameter based on that total number of fiber diameters.

"Non-woven fibrous layer" means a plurality of fibers characterized by entanglement or point bonding of the fibers to form a sheet or mat exhibiting a structure of individual fibers or filaments which are interlaid, but not in an identifiable manner as in a knitted or woven fabric.

"Oriented" when used with respect to a fiber means that at least portions of the polymer molecules within the fiber are aligned with the longitudinal axis of the fiber, for example, by use of a drawing (or stretching) process or attenuator upon a stream of fibers exiting from a die.

"Particle" or "particulate" refers to a small distinct piece or individual part of a material in finely divided form. A particle may also include a collection of individual particles associated or clustered together in finely divided form. Thus, individual particulates used in certain exemplary embodiments of the present disclosure may clump, physically intermesh, electrostatically associate, or otherwise associate to form clustered or agglomerated particulates. In certain instances, particulates in the form of agglomerates of individual particulates may be formed as described in <CIT>).

"Polymer" means a relatively high molecular weight material having a molecular weight of at least <NUM>,<NUM>/mol or more than <NUM> repeat units.

"Shrinkage" means reduction in the dimension of a fibrous non-woven layer after being heated to <NUM> for <NUM> days based on the test method described in <CIT>).

"Size" refers to the longest dimension of a given object or surface.

"Substantially" means a majority of, or mostly, as in an amount of at least <NUM>%, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>%, or <NUM>%.

"Surface area" refers to the specific surface area, unless noted otherwise. This quantity for a material is the surface area normalized by unit mass.

While the above-identified drawings, which may not be drawn to scale, set forth various embodiments of the present disclosure, other embodiments are also contemplated, as noted in the Detailed Description. In all cases, this disclosure describes the presently disclosed invention by way of representation of exemplary embodiments and not by express limitations.

Before any embodiments of the present disclosure are explained in detail, it is understood that the invention is not limited in its application to the details of use, construction, and the arrangement of components set forth in the following description. The invention is capable of other embodiments and of being practiced or of being carried out in various ways that will become apparent to a person of ordinary skill in the art upon reading the present disclosure. Also, it is understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. It is understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present disclosure.

As used in this Specification, the recitation of numerical ranges by endpoints includes all numbers subsumed within that range (e.g. <NUM> to <NUM> includes <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and <NUM>, and the like).

The present disclosure is directed to acoustic absorbing fillers, acoustic articles, assemblies, and methods thereof that function as acoustic absorbers, vibration dampeners, and/or acoustic and thermal insulators. The acoustic articles and assemblies generally include one or more porous layers and one or more acoustic absorbing fillers in contact with the one or more porous layers. Optionally, the provided acoustic articles and assemblies include one or more non-porous barrier layers and/or air gaps adjacent to the one or more porous layers. Structural and functional characteristics of each of these components are described in the subsections that follow.

The acoustic absorbing filler includes agglomerates comprising a core particle comprising a polymer and an outer layer coated on the core particle. The outer layer includes microporous particulates (having pores with a width less than <NUM> nanometers).

The coating layer may be held to the core particle through particle-to-particle interactions. Such interactions can be mediated by intermolecular forces such as dispersion forces or electrostatic forces or by intramolecular bonding with some degree of covalent character. In some embodiments, the coating layer is adhered to the core particle under slight pressure and/or heat to soften the core particle, allowing the coating layer particulates to fuse to the core particle upon cooling, forming a coated stucture. The heat may be provided using any known method, including steam, highfrequency radiation, infrared radiation, or heated air. In some embodiments, the coating layer may be held to the core particle through a binder or adhesive layer. In some embodiments, the core particle may have adhesive properties that can be activated by heat, light or ultraviolet electromagnetic radiation, or an induced chemical reaction.

The acoustic absorbing filler can be regularly or irregularly shaped. Preferably, aggregates stay together in intended use (are mechanically stable or robust), and the coating does not substantially delaminate from the core.

Porous particulates that have open pores with diameters on the nanoscale include zeolites, colloidal or molecular condensed sol-gel materials (e.g. xerogels or aerogels), aluminophosphates, porous alumina, mica, perlite, granulated polyurethane foam particles, soft and hard templated materials, polymers of intrinsic microporosity, ion exchange resins, layered compounds, dendrimers, metal organic frameworks (MOFs), layered silicates, layered double hydroxides, graphite oxide, inorganic nanotubes, porous divinylbenzene copolymers, etched block-co-polymers, many types of biomass, and porous carbon materials.

Activated carbon is a highly porous carbonaceous material having a complex structure composed primarily of carbon atoms. The activation process can be carried out using steam and/or CO<NUM> at high temperatures around <NUM> (a process called physical activation), or in some cases using phosphoric acid or other compounds like potassium hydroxide or zinc-based compounds at lower temperatures (a process called chemical activation). The network of pores in activated carbons are from pre-existing channels and new channels oxidized within a network of carbon with nanoscale (graphite-like) regions of SP2 bonding alongside disordered SP3 carbon. This creates a highly porous structure arising from a multiplicity of pits and fissures within the solid carbon framework network.

One remarkable feature of activated carbon is its ability to adsorb significant quantities of gas molecules. This arises, in large part, to the high surface area of the the pores within the material, which is typically on the order of the area of a football pitch (<NUM><NUM>) for less than ten grams of material. The behavior of porous carbon within enclosed spaces, such as cavities in loudspeakers, has been consistent with adsorption of ambient air molecules altering the overall acoustic response. When porous carbon adsorbs air molecules within a confined space, the effective air volume can be over two times the air volume in the same space without porous carbon. By expanding the effective air volume within an acoustic cavity, porous carbon tends to shift the acoustic resonance to lower frequecies (a phenomenon often call bass shifting). In the art, an analogous phenomenon involving the high adsorption capacity of activated carbon is thought to be operative in nonconfined acoustic absorbing articles (<NPL>)). This causes a frequency shift in the onset of absorption which can be interpreted as shortening of the quarter wavelength of the acoustic absorption (or slowing down of speed of sound in the acoustic medium), thus providing for enhanced low-frequency acoustic performance when compared to conventional absorbers.

The core particle can include a polymer composition selected from polypropylene, polyethylene, copolymers of polypropylene and polyethylene, halogenated polyolefins, polyurethane, ethylene-vinyl acetate, polystyrene, polyvinyl chloride, polycarbonates, polysulfones, polyesters, nylons, acrylates, ethylene acrylates, acrylics, epoxy, phenol-formaldehyde, melamine-formaldehyde, polybutylene elastomers, polyester elastomers, polyether block copolyamide elastomers, styrenic block copolymer elastomers, polybutylene, polyacrylonitrile, styrene-acrylonitrile, acrylonitrile butadiene styrene, ionomers, and combinations thereof. In some embodiments, the core particle does not include microporous materials. In some embodiments, the core particle has a specific surface area less than <NUM><NUM>/g.

The acoustic absorbing filler has a median sieved particle size of from <NUM> micrometer to 70C micrometers.

Owing to its porous nature, it is possible for the acoustic absorbing filler to have a high surface area, and consequently, adsorption capacity. Having a high surface area can reflect a high degree of complexity and tortuosity of the pore structure, leading to greater internal reflections and energy transfer to the solid structure through frictional losses. This is manifested as absorption of airborne noise. The specific surface area of the acoustic absorbing filler is from <NUM><NUM>/g to <NUM><NUM>/g.

Surface area can be measured based on the sorption of various pure gases (such as diatomic nitrogen gas or carbon dioxide) onto the surface of a given material. These measurements can be performed using an instrument known a gas sorption analyzer. In this measurement, one can generate an isotherm (volume of gas adsorbed at standard temperature and pressure per unit mass versus relative pressure) by dosing a sample with gas. By applying a modified form of the Langmuir equation known as the Brunauer-Emmett-Teller (BET) equation to the isotherm, it is possible to calculate the surface area. This value is known as the BET (specific) surface area, or the multi-point BET surface area (MBET surface area) if multiple points of the isotherm are used in the equation. In some embodiments, the surface area, as referred to herein, is the BET surface area.

Additionally, when the energetics of sorption are known, and general model of the pore structure exists, one can model the adsorption of a fluid on a solid phase for given equilibrium state (i.e. a global minimum) for the grand potential of the overall thermodynamic system. Density functional theory (DFT) is frequently employed to perform this analysis, which provides more accurate results than the simplified BET equation. Quenched state DFT (QSDFT) models are preferably employed when available, as they are two-component, accounting for the energetics of solid-solid interactions. These DFT models allow for analysis of the amount of surface area provided for a given range (or bin) of pore diameters. In some embodiments, the surface area, as referred to herein, is the QSDFT surface area for a specific range of pore diameters. From these analyses, one can also determine if a material contains primarily micropores, mesopores, macropores (pores with a diameter greater than <NUM>), or hierarchical porosity (smaller pores nested within larger pores).

The acoustic absorbing filler can have a total pore volume of from <NUM><NUM>/g to <NUM><NUM>/g. In some embodiments, the total pore volume can be less than, equal to, or greater than, <NUM><NUM>/g, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM><NUM>/g. This value can be determined using DFT analysis, or via analysis of the volume of gas adsorbed at a pressure (P) close to the saturation point (Po), typically at a relative pressure (P/Po) of <NUM>. Simlar to what is mentioned above, DFT can also be used to analyze the amount of specific pore volume provided for a given range (or bin) of pore sizes.

When tested as a packed bed with <NUM> thickness, the acoustic absorbing filler has a normal incidence acoustic absorption of <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM> alpha at <NUM> or more than <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> alpha at <NUM>, in some embodiments, for systems not exhibiting one or more resonance peak at low frequencies.

The acoustic absorbing filler may be present in various configurations relative to the porous layer. Where the porous layer is a non-woven fibrous layer, open-celled foam, or particulate bed, for example, the acoustic absorbing filler may be embedded in the non-woven fibrous layer, open-celled foam, or particulate bed. Where the porous layer includes a perforated film, the acoustic absorbing filler may reside, at least in part, within the plurality of apertures extending through the perforated film. In some embodiments, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, or at least <NUM>% of the acoustic absorbing filler contacting the porous layer resides within the plurality of apertures. Alternatively, the acoustic absorbing filler may be present as a discrete layer adjacent to the porous layer.

The acoustic absorbing filler of the present disclosure can have equivalent or improved acoustic performance in a packed bed configuration or when integrated into an acoustic article though it has a lower specific surface area and pore volume than the filler comprising only porous particulates, for example, pure, unmilled activated carbon. The acoustic absorbing filler of the present disclosure has a lower specific surface area because of its non-microporous core, yet can match the performance of particles with much higher surface area, contrary to what is known in the art.

The provided acoustic articles include one or more porous layers. Useful porous layers include, but are not limited to, non-woven fibrous layers, perforated films, particulate beds, open-celled foams, nets, woven fabrics, structured films, and combinations thereof.

Engineered non-woven fibrous layers containing fine fibers can be effective sound absorbers in aerospace, automotive, shipping, and building applications. Non-woven materials having a plurality of fine fibers can be especially effective at high sound frequencies, a regime in which the surface area of the structure promotes viscous dissipation of sound energy. Non-woven layers may be made from inorganic materials such as fiberglass, basalt, silicate compounds, alumina, and aluminosilicates. Polymeric non-woven layers can be made, for example, by melt blowing or melt spinning.

In melt-blowing, one or more thermoplastic polymer streams are extruded through a die containing closely arranged orifices and attenuated by convergent streams of hot air at high velocities to form fine fibers. These fine fibers can be collected on a surface to provide a melt-blown non-woven fibrous layer. Depending on the operating parameters chosen, e.g., degree of solidification from the molten state, the collected fibers may be semi-continuous or essentially discontinuous. In certain exemplary embodiments, the melt-blown fibers of the present disclosure may be oriented on a molecular level. The fibers can be interrupted by defects in the melt, crossing of formed filaments, excessive shear due to turbulent air used in attenuating the fibers or other events occurring in the formation process. They are generally understood to be as semi-continuous or having the length much longer than the distance between fiber entanglements so that individual fibers cannot be removed from the fiber mass intact end-to-end.

In melt spinning, the non-woven fibers are extruded as filaments out of a set of orifices and allowed to cool and solidify to form fibers. The filaments are passed through an air space, which may contain streams of moving air, to assist in cooling the filaments and passing through an attenuation (i.e., drawing) unit to at least partially draw the filaments. Fibers made through a melt spinning process can be "spunbonded," whereby a web comprising a set of melt spun fibers are collected as a fibrous web and optionally subjected to one or more bonding operations to fuse the fibers to each other. Melt-spun fibers are generally larger in diameter than melt-blown fibers.

The fibers can be made from a polymer selected from polyolefin, polypropylene, polyethylene, polyester, polyethylene terephthalate, polybutylene terephthalate, polyamide, polyurethane, polybutene, polylactic acid, polyphenylene sulfide, polysulfone, liquid crystalline polymer, polyethylene-co-vinylacetate, polyacrylonitrile, cyclic polyolefin, or copolymer or blend thereof in an amount of at least <NUM>% by weight, based on the overall weight of the plurality of fibers. Suitable fibers materials also include elastomeric polymers.

Non-woven layers based on aliphatic polyester fibers can be especially advantageous in resisting degradation or shrinkage at high temperature applications. Molecular weights for useful aliphatic polyesters can be in the range of from <NUM>,<NUM>/mol to <NUM>,<NUM>,<NUM>/mol, from <NUM>,<NUM>/mol to <NUM>,<NUM>,<NUM>/mol, from <NUM>,<NUM>/mol to <NUM>,<NUM>,<NUM>/mol, or in some embodiments, less than, equal to, or greater than <NUM>,<NUM>/mol; <NUM>,<NUM>; <NUM>,<NUM>; <NUM>,<NUM>; <NUM>,<NUM>; <NUM>,<NUM>; <NUM>,<NUM>; <NUM>,<NUM>; <NUM>,<NUM>; <NUM>,<NUM>; <NUM>,<NUM>; <NUM>,<NUM>; <NUM>,<NUM>; <NUM>,<NUM>; <NUM>,<NUM>; <NUM>,<NUM>; <NUM>,<NUM>,<NUM>; <NUM>,<NUM>,<NUM>; <NUM>,<NUM>,<NUM>; <NUM>,<NUM>,<NUM>; <NUM>,<NUM>,<NUM>; or <NUM>,<NUM>,<NUM>/mol.

The melt-blown or melt-spun fibers of the non-woven fibrous layer can have any suitable diameter. The fibers can have a median diameter of from <NUM> micrometers to <NUM> micrometers, from <NUM> micrometers to <NUM> micrometers, from <NUM> micrometers to <NUM> micrometers, or in some embodiments, less than, equal to, or greater than <NUM> micrometers, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> micrometers.

Optionally, at least some of the plurality of fibers in the non-woven fibrous layer are physically bonded to each other or to the acoustic absorbing filler. Conventional bonding techniques using heat and pressure applied in a point-bonding process or by smooth calendar rolls can be used, though such processes may cause undesired deformation of fibers or compaction of the web. Optionally, attachment between fibers or between fiber and the acoustic absorbing filler may be achieved by incorporating a binder into the non-woven fibrous layer. In some embodiments, the binder is provided by a liquid or a solid powder. In some embodiments, the binder is provided by staple binder fibers, which may be injected into the polymer stream during a melt blowing process. Binder fibers have a melting temperature significantly less than that of remaining structural fibers, and act to secure the fibers to each other. Other techniques for bonding the fibers are taught in, for example, <CIT>) and <CIT>). One technique involves subjecting the collected web of fibers to a controlled heating and quenching operation that includes forcefully passing through the web a gaseous stream heated to a temperature sufficient to soften the fibers sufficiently to cause the fibers to bond together at points of fiber intersection, where the heated stream is applied for a time period too short to wholly melt the fibers, and then immediately forcefully passing through the web a gaseous stream at a temperature at least <NUM> less than the heated stream to quench the fibers.

In some embodiments, two different kinds of molecular phases are present within the fibers. For example, a predominantly semi-crystalline phase may co-exist with a predominantly amorphous phase. As another example, a predominantly semi-crystalline phase may co-exist with a phase containing domains of lower crystalline order (e.g., one in which the polymers are not chain-extended) and domains that are amorphous, the overall degree of order being insufficient for crystallinity. Such fibers can also be processed under heat as above to form a non-woven fibrous layer.

In some embodiments, the fibers of the non-woven fibrous layer do not substantially melt or lose their fiber structure during the bonding operation, but remain as discrete fibers with their original fiber dimensions.

In some embodiments, the fiber polymers display high glass transition temperatures, which can be desirable for use in high temperature applications. Certain non-woven fibrous layers shrink significantly when heated to even moderate temperatures in subsequent processing or use, such as use as a thermal insulation material. Such shrinkage has been shown to be problematic when the melt-blown fibers include thermoplastic polyesters or copolymers thereof, and particularly those that are semi-crystalline in nature.

In some embodiments, the provided non-woven fibrous layers have at least one densified layer adjacent to a layer that is not densified. Either or both of the densified and non-densified layers may be loaded with acoustic absorbing filler. It can be cost effective for the densified layer and adjacent non-densified layer to be prepared from a unitary layer of non-woven fibrous layer having a uniform density.

The provided methods can, if desirable, provide a densified layer that has a uniform distribution of polymeric fibers throughout the layer. Alternatively, the distribution of polymeric fibers can be intentionally made non-uniform across a major surface of the non-woven fibrous layer, whereby the acoustic response can be tailored based on its location along the major surface.

In some embodiments, the median fiber diameters of the densified and non-densified portions of the non-woven fibrous layer are substantially the same. This can be realized, for example, by way of a process capable of fusing the fibers to each other in the densified region without significant melting of the fibers. Avoidance of melting the fibers can preserve the acoustic benefit that derives from the surface area produced within the densified layer of the non-woven fibrous layer.

Engineered non-woven fibrous layers can display numerous advantages, some of which are unexpected. These materials can be used in thermal and acoustic insulation applications at high temperatures where conventional insulation materials would thermally degrade or fail. Particularly demanding are automotive and aerospace vehicle applications, where insulation materials operate in environments that are not only noisy but can reach extreme temperatures.

The provided non-woven layers can resist shrinkage at temperatures as high as <NUM> or greater, as might be encountered in automotive and aerospace applications. Shrinkage can result from crystallization during heat exposure or processing, and is generally undesirable because it can degrade acoustic performance and impact the structural integrity of the product. The provided non-woven fibrous layers can exhibit a Shrinkage after being heated to <NUM> for <NUM> days, as measured using the Shrinkage test method described in <CIT>), of less than <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>% or <NUM>%. Such Shrinkage values can apply along both the machine and cross-web directions. In some embodiments, disposing acoustic absorbing filler into the interstices of non-woven layer can further reduce the degree of shrinkage at high temperatures.

As a further advantage, the densified layer can enable the non-woven fibrous layers to be thermally molded into three-dimensional structures that are dimensionally stable. Articles and assemblies based on such structures can be shaped to fit substrates having customized three-dimensional shapes. Customizing the shape of the article or assembly for a particular application optimizes use of space and simplifies attachment to, for example, an automotive or aerospace component. Because these shaped structures are dimensionally stable, these articles and assemblies also reduce the risk of de-lamination compared with conventional acoustic and thermal insulation products, which have the tendency to spring back to their original, planar configuration.

Yet another advantage relates to the ability to make non-woven fibrous layers that not only operate at high temperatures and are dimensionally stable, but also maintain their overall surface area within both densified and non-densified portions of the web. Retention of the surface area provided by the surface of the fibers (especially those with narrow diameters), in combination with acoustic absorbing filler, enables the material to not suffer from a degredation in performance due to heat-induced instability in the structure of the article. External surface area, i.e. not contained within internal porosity, is relevant because the ability of the non-woven fibrous layer to dissipate noise is based on viscous dissipation at the fiber surfaces, where kinetic energy of sound pressure waves is converted into heat.

When manufacturing non-woven fibrous webs from a single layer, fewer processing and web handling steps are necessary compared with processes used to manufacture articles containing multiple layers. Reducing the number of layers in the end product, while preserving its performance properties, simplifies manufacturing and reduces associated costs.

Other non-woven fibrous layers that may be used in the acoustic article include recycled textile fibers, sometimes referred to as shoddy. Recycled textile fibers, staple fibers, inorganic fibers and natural fibers can be formed into a non-woven structure using an air laid process, in which a wall of air blows fibers onto a perforated collection drum having negative pressure inside the drum. The air is pulled though the drum and the fibers are collected on the outside of the drum where they are removed as a web. Because of the air turbulence, the fibers are not in any ordered orientation and thus can display strength properties that are relatively uniform in all directions.

Other non-woven fibrous layers that may be used in the acoustic aricle include those made using a wet laid process. A wet laying or "wetlaid" process comprises (a) forming a dispersion comprising one or more types of fibers, optionally a polymeric binder, and optionally a particle filler(s) in at least one dispersing liquid (preferably water); and (b) removing the dispersing liquid from the dispersion.

In some embodiments, one or more additional fiber populations are incorporated into the non-woven fibrous layer. Differences between fiber populations can be based on, for example, composition, median fiber diameter, median fiber length, and/or fiber shape.

In some embodiments, a non-woven fibrous layer can include a plurality of first fibers having a median diameter of less than <NUM> micrometers and a plurality of second fibers having a median diameter of at least <NUM> micrometers. For various reasons, it can be advantageous to have fibers of different diameters. Inclusion of the thicker second fibers can improve the resiliency of the non-woven fibrous layer, crush resistance, and help preserve the overall loft of the web. The second fibers can be made from any of the polymeric materials previously described with respect to the first fibers and may be made from a melt blown or melt spun process.

The fibers of the non-woven layer can have any suitable fiber diameter to provide desirable mechanical, acoustic, and/or thermal properties. For example, either or both of the first and second fibers can have a median fiber diameter of at least <NUM> micrometers, from <NUM> micrometers to <NUM> micrometers, from <NUM> micrometers to <NUM> micrometers, or in some embodiments, less than, equal to, or greater than <NUM> micrometers, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> micrometers.

In some embodiments, the second fibers are staple fibers that are interspersed with the first plurality of the fibers. The staple fibers can include binder fibers and/or structural fibers. Binder fibers include, but are not limited to, any of the above-mentioned polymeric fibers. Suitable structural fibers can include, but are not limited to, any of the above-mentioned polymeric fibers, as well as inorganic fibers such as ceramic fibers, glass fibers, and metal fibers; and biologically-derived fibers such as cellulosic fibers. The blending of staple fibers into the non-woven layer is sometimes referred to as carding.

Additional options and advantages associated with combinations of the first and second fibers are described, for example, in <CIT>).

Porous layers need not be fibrous in nature. For instance, the one or more porous layers use a perforated film. Perforated films are comprised of a film or wall having a multiplicity of perforations, or through-holes, extending therethrough. The perforations allow for the propogation of pressure waves from one side of the film or wall to the opposing side.

Enclosed within the perforations are plugs of air that act as mass components within a resonant system. These mass components vibrate within the perforations and dissipate sound energy from friction between the plugs of air and the walls of the perforations. If the perforated film is disposed next to an air cavity, dissipation of sound energy may also occur through destructive interference at the entrance of the perforations from any sound waves reflected back towards the perforations from the opposite direction. Absorption of sound energy can take place with essentially zero net flow of fluid through the acoustic article.

The perforations can be provided with dimensions (e.g. perforation diameter, shape and length) suitable to obtain a desired acoustic performance over a given frequency range. Acoustic performance can be measured, for example, by reflecting sound off of the perforated film and characterizing the decrease in acoustic intensity as a result of near-field dampening as compared to the result from a control sample.

The perforations can be disposed along the entire surface of the perforated film. Alternatively, the wall could be only partially perforated-that is, perforated in some areas but not others. In certain instances, perforated areas of the wall can extend along longitudinal directions and be adjacent to one or more non-perforated areas-for example, the wall could have a rectangular cross-section tube with only one or two sides perforated.

The perforations can have a wide range of shapes and sizes and may be produced by any of a variety of molding, cutting or punching operations. The cross-section of the perforations can be, for example, circular, square, or hexagonal. In some embodiments, the perforations are represented by an array of elongated slits. While the perforations may have diameters that are uniform along their length, it is possible to use perforations that have the shape of a conical frustum or otherwise have side walls tapered along at least some their length. Tapering the side walls of the perforations can be advantageous, as described later, in enabling acoustic absorbing filler to be received within the perforations. Various perforation configurations and ways of making the same are described in <CIT>).

Optionally, the perforations have a generally uniform spacing with respect to each other. If so, the perforations may be arranged in a two-dimensional grid pattern or staggered pattern. The perforations could also be disposed on the wall in a randomized configuration where the exact spacing between neighboring perforations is non-uniform but the perforations are nonetheless evenly distributed across the wall on a macroscopic scale.

In some embodiments, the perforations are of essentially uniform diameter along the wall. Alternatively, the perforations could have some distribution of diameters. In either case, the average narrowest diameter of the perforations can be less than, equal to, or greater than <NUM> micrometers, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> micrometers. For clarity, the diameter of non-circular holes is defined herein as the diameter of a circle having the equivalent area as the non-circular hole in plan view.

Compared to other porous layers, perforated films can be made relatively thin while retaining their acoustic absorption properties. Perforated films can have an overall thickness of from <NUM> micrometer to <NUM> millimeters, from <NUM> micrometers to <NUM> millimeters, from <NUM> micrometers to <NUM> millimeter, or in some embodiments, less than, equal to, or greater than, <NUM> micrometer, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> micrometers, <NUM> millimeter, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> millimeters. In some embodiments, a perforated slab is used instead of a perforated film, where the perforated slab has a thickness of up to <NUM> millimeters, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or even <NUM> millimeters. The porosity of the perforated film is a dimensionless quantity representing the fraction of a given volume not occupied by the film. In a simplified representation, the perforations can be assumed to be cylindrical, in which case porosity is well approximated by the percentage of the surface area of the wall displaced by the perforations in plan view. In exemplary embodiments, the wall can have a porosity of <NUM>% to <NUM>%, <NUM>% to <NUM>%, or <NUM>% to <NUM>%. In some embodiments, the wall has a porosity less than, equal to, or greater than <NUM>%, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>%.

The film material can have a modulus (e.g., flexural modulus) suitably tuned to vibrate in response to incident sound waves having relevant frequencies. Along with the vibrations of the air plugs within the perforations, local vibrations of the wall itself can dissipate sound energy and enhance transmission loss through the acoustic article. The flexural modulus, reflecting the stiffness, of the wall also directly affects its acoustic transfer impedance.

In some embodiments, the film comprises a material having a flexural modulus of from <NUM> GPa to <NUM> GPa, <NUM> GPa to <NUM> GPa, <NUM> GPa to <NUM> GPa, or in some embodiments, less than, equal to, or greater than a flexural modulus of <NUM> GPa, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> GPa.

Suitable thermoplastic polymers typically have a flexural modulus in the range of from <NUM> GPa to <NUM> GPa. Addition of fibers or other fillers can, in some embodiments, increase the flexural modulus of these materials to <NUM> GPa. Thermoset polymers generally have a flexural modulus in the range of from <NUM> GPa to <NUM> GPa. Useful polymers include polyolefins, polyesters, fluoropolymers, polylactic acid, polyphenylene sulfide, polyacrylates, polyvinylchloride, polycarbonates, polyurethanes, and blends thereof.

Acoustic performance characteristics that can be ascribed to a plurality of perforations disposed in a flexible film are described in, for example, <CIT>), <CIT>), and <CIT>). Acoustic filler particles can be loaded into the perforations of the film to enhance the overall properties of the film, including acoustic absorption properties.

In some embodiments, the porous layer includes a particulate bed. The particle bed may contain non-porous materials, such as milled polymer granules, glass beads, or ceramic materials, or porous materials, such as clays, perlite, or granules of biomass. None, some, or all of the particles of the particulate bed may be acoustic absorbing filler that is acoustically active. The porosity of the particulate bed can be adjusted in part based on the size distribution of the particles. The particles may be in a range of from <NUM> micrometers to <NUM> micrometers, from <NUM> micrometers to <NUM> micrometers, from <NUM> micrometers to <NUM> micrometers, or in some embodiments, less than, equal to, or greater than, <NUM> micrometers, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> micrometers.

A porous layer can be generally characterized by its specific acoustic impedance, which is the ratio in frequency space of pressure differences across the layer and the effective velocity approaching the layer surface. In the theoretical model based on a rigid film with perforations, for example, the velocity derives from air moving into and out of the holes. If the film is flexible, motion of the wall can contribute to the acoustic impedance calculation. Specific acoustic impedance generally varies as a function of frequency and is a complex number, which reflects the fact that pressure and velocity waves can be out of phase with each other.

As used herein, specific acoustic impedance is measured in MKS Rayls, in which <NUM> MKS Rayl is equal to <NUM> pascal-second per meter (Pa·s·m-<NUM>), or equivalently, <NUM> newton-second per cubic meter (N·s·m-<NUM>), or alternatively, <NUM>·s-<NUM>·m-<NUM>.

A porous layer can also be characterized by its transfer impedance. For a perforated film, transfer impedance is the difference between the acoustic impedance on the incident side of the porous layer and the acoustic impedance one would observe if the perforated film were not present-that is, the acoustic impedance of the air cavity alone.

The flow resistance is the low frequency limit of the transfer impedance. Experimentally, this can be estimated by blowing a known, small velocity of air at the porous layer and measuring the pressure drop associated therewith. The flow resistance can be determined as the measured pressure drop divided by the velocity.

For embodiments that include a perforated film, the flow resistance through the perforated film alone (absent the acoustic absorbing filler) can be from <NUM> MKS Rayls to <NUM> MKS Rayls, <NUM> MKS Rayls to <NUM> MKS Rayls, or <NUM> MKS Rayls to <NUM> MKS Rayls. In some embodiments, the flow resistance through the perforated film can be less than, equal to, or greater than <NUM> MKS Rayls, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> MKS Rayls.

For embodiments that include a non-woven fibrous layer, the flow resistance through the non-woven fibrous layer alone (absent the acoustic absorbing filler) can be from <NUM> MKS Rayls to <NUM> MKS Rayls, <NUM> MKS Rayls to <NUM> MKS Rayls, or <NUM> MKS Rayls to <NUM> MKS Rayls. In some embodiments, the flow resistance through the non-woven fibrous layer can be less than, equal to, or greater than <NUM> MKS Rayls, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> MKS Rayls.

The flow resistance through the overall acoustic article can be from <NUM> MKS Rayls to <NUM>,<NUM> MKS Rayls, or <NUM> MKS Rayls to <NUM> MKS Rayls. In some embodiments, the flow resistance through the overall acoustic article is less than, equal to, or greater than <NUM> MKS Rayls, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>,<NUM> MKS Rayls.

Acoustic articles according to one exemplary embodiment are illustrated in <FIG> and hereinafter referred to by respective numeral <NUM>. In <FIG>, the direction of incident and reflected sound waves are represented by barred arrows, where applicable.

The article <NUM> is comprised of three primary layers. The layers include, in the following order, a first porous layer <NUM>, a second porous layer <NUM>, and a third porous layer <NUM>. Optionally and as shown, the porous layers <NUM>, <NUM> and porous layers <NUM>, <NUM> directly contact each other. In some embodiments, one or more additional layers can be disposed between these layers or extend along the exterior facing major surfaces of porous layers <NUM>, <NUM>. Alternatively, one or both of porous layers <NUM>, <NUM> could be omitted.

In the article <NUM>, the porous layers <NUM>, <NUM>, <NUM> are depicted as fibrous non-woven layers, but it is to be understood that other kinds of porous layers (e.g., open-celled foams, particulate beds, perforated films) may be used instead, as described in detail in the sub-section above entitled "Porous layers. " As indicated in <FIG>, the second porous layer <NUM> contains acoustic absorbing filler <NUM>, while the porous layers <NUM>, <NUM> are substantially devoid of acoustic absorbing filler.

Acoustic absorbing filler having desirable acoustic properties, such as porous particulates, is enmeshed in the plurality of fibers in the second porous layer <NUM>. The acoustic absorbing filler can be present in an amount of from <NUM>% to <NUM>%, <NUM>% to <NUM>%, <NUM>% to <NUM>%, <NUM>% to <NUM>%, or in some embodiments, less than, equal to, or greater than <NUM>%, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>% by weight relative to the overall weight of the second porous layer <NUM> and acoustic absorbing filler contacting the second porous layer <NUM>.

Optionally, but not shown, the acoustic absorbing filler may be only partially enmeshed in the second porous layer <NUM>, with some acoustic absorbing filler residing outside of the second porous layer <NUM>.

Advantageously, the addition of acoustic absorbing filler comprised of porous particulates can substantially increase acoustical absorption of the acoustic article at low sound frequencies, such as sound frequencies of from <NUM> to <NUM>. Additionally, the addition of acoustic absorbing filler comprised of activated carbon can increase acoustical absorption of the acoustic article at intermediate to high frequencies (<NUM> to <NUM>,<NUM>), such that alpha exceeds <NUM> in a random incident acoustic measurement (e.g., alpha cabin test) at frequencies from <NUM> to <NUM>. In some embodiments, the addition of acoustic absorbing filler can substantially increase acoustical absorption of the acoustic article over sound frequencies of less than, equal to, or greater than <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>,<NUM>.

In the depicted embodiment, the third porous layer <NUM> has a thickness significantly greater than that of the first porous layer <NUM>.

In these constructions, one porous layer may have a thickness that is less than, equal to, or greater than <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, or <NUM>% of the thickness of the other porous layer.

The provided acoustic articles preferably have an overall thickness that achieves the desired acoustic performance within the space constraints of the application at hand. An individual porous layer can have an overall thickness of from <NUM> micrometers to <NUM> centimeters, from <NUM> micrometers to <NUM> centimeter, from <NUM> micrometers to <NUM> millimeters, or in some embodiments, less than, equal to, or greater than, <NUM> micrometers, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> micrometers, <NUM> millimeter, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM> millimeters.

The porous layer <NUM> can serve as resistive materials that improve the low frequency performance of the total acoustic structure. The porous layer <NUM> can also reduce acoustic particle velocity (that is, of the air molecules in the fluid phase), which tends to induce reflection of the sound wave upon reaching the particle-filled porous layer <NUM>. Reflection tends to occur in this scenario because the acoustic impedance (pressure/velocity) becomes very high as velocity approaches zero. The presence of acoustic particles, however, can act as a pressure-reducing layer induced by reversible adsorption/desorption of air molecules as described previously, or by other mechanisms such as diffusive transport of air molecules into the pore network. Reducing pressure also lowers acoustic impedance, enabling some sound to penetrate and helping entrap more sound energy within the acoustic article <NUM>, thereby improving acoustic performance.

In this embodiment, the acoustic absorbing filler is substantially decoupled from each other and any porous layers; that is, the particles of the acoustic absorbing filler are not physically attached to each other and capable of at least limited movement or oscillation independently from the surrounding structure. In these instances, the enmeshed particles can move and vibrate within the fibers of the non-woven material largely independently of the fibers themselves.

Alternatively, at least some of the acoustic absorbing filler could be physically bonded to the porous layers in which it is disposed. In some embodiments, these physical bonds are created by incorporating binders (e.g., binder fibers) within the porous layer, which can become tacky and adhere to the filler particles upon application of heat. To preserve the acoustic properties of the acoustic absorbing filler, it is generally preferable that the binder does not significantly flow into the pores of the filler particles.

Substrates include structural components, such as components of an automobile or airplane and architectural substrates. Structural examples include molded panels (e.g., door panels), aircraft frames, in-wall insulation, and integral ductwork. Substrates can also include components next to these structural examples, such as carpets, trunk liners, fender liners, front of dash, floor systems, wall panels, and duct insulation. In some cases, a substrate can be spaced apart from the acoustic article, as might be the case with hood liners, headliners, aircraft panels, drapes, and ceiling tiles. Further applications for these materials include filtration media, surgical drapes, and wipes, liquid and gas filters, garments, blankets, furniture, transportation (e.g., for aircraft, rotorcraft, trains, and automotive vehicles), wheeled or tracked vehicles for agricultural applications (e.g. tractors, combines), wheeled or tracked vehicles for industrial applications (e.g. excavators, bulldozers, mobile drilling equipment), electronic equipment (e.g. for televisions, computers, servers, data storage devices, and power supplies), air handling systems, upholstery, and personal protection equipment.

The provided acoustic articles can be assembled using any of a number of suitable manufacturing methods.

Acoustic absorbing filler can be formed by various coating processes, for example, spray coating the porous particulates (and an optional binder) to the core polymer particle. In some of these embodiments, the core particle can be pre-coated with an adhesive to allow for attachment of absorbing filler. In other embodiments this is not necessary.

In some embodiments, core particles can be fluidized and sprayed with a mixture of a binder, solvent, and porous particulate. An example of this process would be fluidized bed coating. Coated particles can be optionally post-processed via heating or exposure to various forms of electromagnetic radiation.

In some embodiments, core particles can be agitated in a vessel, and a mixture of porous particle with fluid and/or a binder can be introduced. A low shear process such as drum coating can be utilized, or high shear methods can be employed. Coated particles can be further processed, once coating is complete.

In some embodiments, core particles can be placed into a bed of the porous particulates and heated either under applied pressure or absent applied pressure. These coated particles can then be recovered for further processing.

Acoustic absorbing filler can also be formed in equipment designed for high or low shear mixing by adjusting specific parameters. In this equipment, the core particles, porous particulates, and a binder solution can be mixed until a suitable coating is present on the core particles. These coated particles can be then post-pocessed.

For embodiments in which the porous layer is a non-woven fibrous web, acoustic absorbing filler can be incorporated into the constituent fibers either during or after the direct formation of the fibers. Where the non-woven fibrous web is made using a melt blowing process, for example, the acoustic absorbing filler may be conveyed and co-mingled with the streams of molten polymer as they are blown onto a rotating collector drum. The acoustic absorbing filler may be entrained within a flow of heated air that converges with the hot air used to attenuate the melt blown fibers. An exemplary process is described in <CIT>). In a similar fashion, particles of acoustic absorbing filler can be conveyed into an air laid process, such as the process use to manufacture porous layers made from recycled textile fibers (i.e., shoddy).

Acoustic absorbing filler can also be added after the non-woven fibrous layer has been made. For example, the porosity of the non-woven fibrous layer could enable the acoustic absorbing filler to infiltrate into its interstitial spaces by homogeneously dispersing the acoustic absorbing filler into a liquid medium such as water, followed by roll coating or slurry coating the particle-filled medium onto the non-woven porous layer. As an alternative to using a liquid medium, one can entrain the acoustic absorbing filler in a gaseous stream, such as an air stream, and then direct the stream toward the non-woven layer to fill it.

Alternatively, acoustic absorbing filler can also be enmeshed into the porous layer by agitation. In one embodiment of this method, a non-woven fibrous layer is placed over a flat surface and a cylindrical conduit placed over it to define a coating area. Particles of the acoustic absorbing filler can then be poured into the conduit and the assembly agitated until the particles are fully migrated into the non-woven structure through its open pores. A similar method may be used for porous layers comprised of open-celled foams.

Construction of multilayered acoustic articles and attachment to substrates can include one or more lamination steps. Lamination may be achieved using an adhesive bond. Preferably, any adhesive layers used do not interfere with sound penetration into the absorbing layer. Alternatively, or in combination, physical entanglement of fibers may be used to improve interlayer adhesion. Mechanical bonds, using fasteners for example, are also possible.

The acoustic articles can also be edge sealed to prevent particle egress. Such containment can be achieved by densifying the edges, filling edges with a resin, quilting the acoustic article, or fully encasing the acoustic article in a sleeve to prevent particle movement or egress. Edge sealing can be desirable to improve product lifetime, durability, and facilitate handling and mounting. Edge sealing can also be performed for aesthetic reasons.

In yet another embodiment, a non-woven fibrous layer can be sequentially sprayed with an adhesive and then with the filler particles. In some instances, the adhesive may be provided in the form of hot melt fibers.

The following working examples are intended to be illustrative of the present disclosure and not limiting.

Prior to imaging, samples were sputter coated with a thin palladium-gold alloy or gold layer. For imaging, one of two scanning electron microscopes (SEM) were used, interchangeably. The first SEM was obtained under the trade designation "TM-<NUM>" from Hitachi High-Technologies America, Inc. , Schaumburg, IL and was set to analytical mode for the probe current/accelerating voltage. The second SEM was an "FEI PHENOM" (a model believed to be equivalent is presently available under the trade designation "PHENOM G1" from NanoScience Instruments, Phoenix, AZ) and used at a 5kV accelerating voltage.

A kit (obtained under the trade designation "IMPEDANCE TUBE KIT (<NUM> - <NUM>) TYPE <NUM>" from Brüel & Kjær. Nærum, Denmark) was used. Normal incident acoustical absorption was tested according to ASTM E1050-<NUM>, "Standard Test Method for Impedance and Absorption of Acoustical Materials Using a Tube, Two Microphones and a Digital Frequency Analysis System," with the modifications specified below. The impedance tube was <NUM> millimeter (mm) in diameter and oriented vertically, with the microphones above the sample chamber. For particle samples, the particles were poured into the sample chamber in the tube and the thickness of the bed was <NUM>. For loaded nonwoven samples, discs were punched out using a <NUM>-mm punch and the sample chamber was set to a depth equivalent to the thickness of the media. For loaded film samples, the samples were tested as <NUM>-mm discs and placed directly over a <NUM>-mm metal screen resting on the lip of the sample chamber set to a <NUM>-mm gap height. The normal incident absorption coefficient was reported with respect to one third octave band frequency using the abbreviation "α".

Bulk densities were measured following ASTM D2854-<NUM>, except that the graduated cylinder was filled to <NUM> percent or greater of its capacity with the measured specimen.

Skeletal densities were measured by following ASTM D5550-<NUM>, with the following differences. The grinding step described in <NUM> was omitted since the particles were already similar in size to sand. For the pycnometry, a helium gas pycnometer (obtained under the trade designation "ACCUPYC II <NUM> TEC" from Micromeritics, Norcross, GA) was used. Prior to obtaining measurements, the instrument was calibrated for measured volume using a metal ball of a specified, traceable volume. A <NUM> cc cup was used for the measurements, and measurements were taken at ambient temperature.

Materials were analyzed using a two-station gas sorption analyzer (obtained under the trade designation "AUTOSORB IQ<NUM>-MP" from Anton Paar QuantaTec Inc. , Boynton Beach, FL). A Specimen was loaded into a <NUM> diameter sample tube and was outgassed to less than <NUM> mTorr (<NUM> Pa) for at least <NUM> hours at <NUM>. The KOWA and GW-H samples were outgassed at <NUM> for <NUM> hours. Helium was used for the void volume determination, which was performed periodically during the measurement. Isotherms were measured using nitrogen gas at <NUM>, and quenched-state density functional theory (QSDFT) analysis was performed using a kernel with carbon as the adsorbent, nitrogen at <NUM> as the adsorbate, and slit-like pore geometry. Application of the multi-point Brunauer-Emmett-Teller (MBET) equation was performed using points on the adsorption branch from <NUM> to <NUM> P/Po for carbon-containing samples and <NUM> to <NUM> P/Po for other samples. Total pore volume was calculated using a point on the adsorption branch taken at approximately <NUM> P/Po.

Thermogravimetric analysis (TGA) was performed using a TG/DTA Simultaneous Measuring Instrument (obtained under the trade designation "DTG-60AH" from Shimadzu Scientific, Kyoto, Japan). Aluminum oxide crucibles were used for both the reference and sample pans. Analyses were carried out a rate of <NUM>/min to <NUM> under a flow of air (<NUM>/min) with a hold time of one hour at temperature and an additional ramp at a rate of <NUM>/min to <NUM>.

Sample thickness of <NUM> in (<NUM>) diameter discs was measured using a thickness testing gauge having a tester foot with dimensions of <NUM> x <NUM> at an applied pressure of <NUM> Pa.

Air Flow Resistance (AFR) Test was conducted using a <NUM> disk in a <NUM> holder according to <NPL>" using a static airflow resistance meter (obtained under the trade designation "SIGMA" running "SIGMA-X" software, both from Mecanum, Sherbrooke, Canada). Results were recorded in MKS Rayls.

The term "effective fiber diameter" or "EFD" is the apparent diameter of the fibers in a fiber web based on an air permeation test in which air at <NUM> atmosphere (<NUM>. 1MPa) and room temperature is passed through a web sample at a specified thickness and face velocity (typically <NUM>/sec), and the corresponding pressure drop is measured. Based on the measured pressure drop, the Effective Fiber Diameter is calculated as set forth in <NPL>).

The Kowa AC was classified using a wire mesh screen having <NUM> micron openings in a <NUM> in (<NUM>) diameter round vibratory separator (obtained under the trade designation "SWECO HX" from SWECO, Florence, KY). The screening rate of the material in the separator was adjusted using eccentric weights on the motion generator shaft to <NUM> lb/min (<NUM>/min). The cut of particles under <NUM> microns was retained for use as a coating material. This is henceforth referred to as PE1.

The Accurel MP <NUM> was classified using <NUM> in (<NUM>) diameter round wire mesh screens (obtained from Retsch GmbH, Haan, Germany) having <NUM> micron and <NUM> micron openings, by placing the material and the screens into a vibratory sieve shaker (obtained under the trade designation "AS <NUM>" from Retsch GmbH, Haan, Germany), and they were agitated at an amplitude setting of <NUM> for <NUM> minutes. The <NUM>-<NUM> micron cut of particles was henceforth referred to as "Accurel <NUM>-<NUM> micron" and retained for use as Comparative Example C1.

PE1 (<NUM>) and Accurel <NUM>-<NUM> micron (<NUM>) materials were combined by manually mixing and shaking in a sealed plastic "ZIPLOCK" bag. The mixture was poured into an aluminum pan and the pan was heated for <NUM> at <NUM> at ambient pressure to bind PE1 to the Accurel <NUM>-<NUM> micron surface. The sample was cooled at ambient conditions and a wire mesh screen with <NUM> micron openings was used to remove any unbound PE1 using an "AS <NUM>" vibratory sieve shaker and the material of greater than <NUM> micron size was retained as Example <NUM>.

Examples <NUM> and C1 were imaged using a TM3000 SEM. The uncoated particles of Comp. C1 are shown in <FIG>. These particles appear as <NUM>-<NUM> macroporous sponge-like structures, with pores throughout the structure ranging from tens to hundreds of microns in size. The coated particles of Ex. <NUM>, after heating in the presence of PE1, are shown in <FIG>. In this image, the original macroporous structure of the particles is obscured or collapsed, while the particle has gained a coating layer of activated carbon fines where the fines appear <NUM>-<NUM> micron in size.

PE1 (<NUM>) and <NUM>-<NUM> or <NUM>-<NUM> UHMWPE particles (<NUM>) were combined by manually mixing and shaking in a sealed plastic "ZIPLOCK" bag. The mixture was poured into an aluminum pan and the pan was heated for <NUM> at <NUM> under vacuum to bind PE1 to the UHMWPE particle surface. The sample was cooled in the oven to room temperature under vacuum. A wire mesh screen with <NUM> micron openings was used to remove any unbound PE1 fines using an "AS <NUM>" vibratory sieve shaker. The material of greater than <NUM> micron size was retained as Example <NUM> for the <NUM>-<NUM> coated materials and as Example <NUM> for the <NUM>-<NUM> coated materials. Uncoated <NUM>-<NUM> or <NUM>-<NUM> UHMWPE particles served as Comparative Example C2 and Comparative Example C3.

The particles of Ex. <NUM> and Comp. C3 were imaged using either a "TM3000 SEM" or a "FEI PHENOM SEM". The uncoated particles, C3 are shown in <FIG>. The C3 particle appears as a <NUM> micron cluster of spheroids, with individual spheroids being tens of microns in diameter. The coated particles (Ex. <NUM>) after heating in the presence of PE1 are shown in <FIG> and <FIG>. In this image, the original spheroidal structure of the particles is lost, while the particles have gained a coating layer of activated carbon fines where the fines appear <NUM>-<NUM> micron in size.

NP1 (<NUM>) and <NUM>-<NUM> UHMWPE particles (<NUM>) were combined by manually mixing them. This mixture was poured into aluminum pans, and the pans were heated for <NUM> at <NUM> under vacuum. The pans were cooled in the oven to room temperature under vacuum. A wire mesh screen with <NUM> micron openings was used to remove any unbound NP1 using an "AS <NUM>" vibratory sieve shaker with <NUM>-<NUM> batches. The material greater than <NUM> microns in size was retained as Example <NUM>.

The bulk density and skeletal density of Comparative Examples C1-C4 (where Kowa activated carbon is Comparative Example C4) and Examples <NUM>-<NUM> were measured and are reported in Table <NUM>.

Gas sorption was used to analyze the particle samples and surface area, micropore surface area and total pore volume. Results are reported in Table <NUM>. Comparative Examples C2 and C3 have insufficient surface area to be accurately analyzed using nitrogen sorption, which suggests a specific surface area below <NUM><NUM>/g. Materials coated with activated carbon (AC) have much higher surface areas, mostly via microporosity, corresponding to the presence of the AC on the particle surface.

The estimated wt. % of activated carbon in the examples was calculated using the QSDFT surface area for the micropores (less than or equal to <NUM> in diameter) and determining the ratio between those values and that of the micropore surface area for the Kowa (C4). All the core particles (C1-C3) lack micropores and are assumed to have zero surface area for this calculation. Results are reported in Table <NUM>. Overall, the amount of AC is estimated at between <NUM> to <NUM>%.

TGA analysis was only carried out for Ex. <NUM> to determine the relative amounts of polypropylene and activated carbon by combustion, and the amount of AC in the particle was found to be <NUM> wt. This result gave reasonable correlation with the result calculated by sorption, with discrepancies likely due to overlap between carbon oxidation and polymer combustion events in the TGA. Due to the much greater overlap of oxidization events with regards to the UHMWPE and activated carbon, Examples <NUM>-<NUM> could not be analyzed in this fashion.

A nonwoven melt blown web was prepared by a process similar to that described in <NPL>), except that a drilled die was used to produce the fibers.

A polypropylene resin ("MF650Y") was extruded through the die into a high velocity stream of heated air which drew out and attenuated polypropylene blown microfibers (BMF) prior to their solidification and collection. Particles (Ex. <NUM>) were fed into the stream of polypropylene blown microfibers, according to the method of Examples <NUM>-<NUM> in <CIT>). The blend of polypropylene blown microfibers and particles was collected in a random fashion on a metal drum, affording a polypropylene BMF-web layer loaded with particles. The web was then removed from the drum to provide the final article. Sample constructions made are detailed in Table <NUM>. The base PP web without particles was also collected as Comp. C5 and Comp.

The basis weight, thickness and airflow resistance of the samples were measured and reported in Table <NUM>. For the base BMF, effective fiber diameter was also measured.

Microperforated films were prepared as described in <CIT>). For C7, a film-grade polypropylene resin PP-<NUM> was used in extrusion of a polypropylene film (<NUM> thickness) with a PP3019 masterbatch added at <NUM> wt. For C8, a film-grade polypropylene resin PP-<NUM> was used in extrusion of a polypropylene film (<NUM> thickness) with a S-<NUM> masterbatch added. The films were embossed, and heat treated so that the embossing created apertures with different-sized rectangular shaped openings as viewed from the top, where the two principal dimensions are designated Ht and Wt, and from the bottom, where the two principal dimensions are designated Hb and Wb. The cross section of the aperture as viewed from the both the long and short directions was trapezoidal. The dimensions of the apertures, recorded as average values in micrometers (µm), are listed in Table <NUM>.

Specific size cuts of Example <NUM> (<NUM>-<NUM> micron, <NUM>-<NUM> micron) were used to minimize oversized and undersized particles relative to the film perforation sizes. A portion of Example <NUM> (less than <NUM>) was classified using <NUM> in (<NUM>) diameter round wire mesh screens (obtained from Retsch GmbH, Haan, Germany) having either <NUM> micron and <NUM> micron openings or <NUM> micron and <NUM> micron openings, by placing the material and the screens into a vibratory sieve shaker (obtained under the trade designation "AS <NUM>" from Retsch GmbH, Haan, Germany), and they were agitated at an amplitude setting of <NUM> for <NUM> minutes. The desired fractions were kept for further use after the agitation.

Sample discs of C7 and C8 were punched out with a <NUM> diameter punch. For each disc, a specific size cut of particles was spread into the larger-aperture side by hand, attempting to fill the apertures. Sample constructions and the results of Air Flow Resistance (AFR) Test for the control samples are shown in Table <NUM>. AFR measurements were not performed with the Ex. <NUM> particles since their mass was low enough that they would be dislodged from the films, disrupting the measurement. AFR tests were instead conducted with similarly sized but higher density spherical TORAYCERAM zirconia beads, as noted in the table below.

Examples <NUM>-<NUM> and Comp. C1 to C4 were tested according for Normal Incident Acoustical Absorption performance as particle packed beds and the normal incident absorption coefficients as a function of frequency are reported in Table <NUM> and <FIG>. Absorption onset and slope were determined using a linear fit of the onset curve and extrapolated to an α of <NUM> and reported in Table <NUM>. After the coating process, the overall shape of the absorption curve was retained for all cases, but the slope of the rise increased, and the onset was shifted to lower frequencies. For two of the PE1-coated UHMWPE particle samples (Examples <NUM> and <NUM>), absorption at all frequencies was enhanced versus the uncoated cases (C2 and C3).

Examples <NUM>-<NUM> and Comparative Examples C5 and C6 underwent acoustic testing using Normal Incident Acoustical Absorption as applied to loaded nonwoven samples. Results are reported in Table <NUM>.

Examples <NUM> and <NUM> and Comparative Examples C7 and C8 underwent Normal Incident Acoustical Absorption as applied to loaded films. The results are reported in Table <NUM>.

Claim 1:
An acoustic absorbing filler, the acoustic absorbing filler comprising
a core particle comprising a polymer;
an outer layer coated on the core particle, wherein the outer layer comprises microporous particulates; and
wherein the acoustic absorbing filler has a median particle size of from <NUM> micrometer to <NUM> micrometers and a specific surface area of from <NUM><NUM>/g to <NUM><NUM>/g;
wherein a bed packed with acoustic absorbing fillers and having a bed thickness of <NUM> has a normal incidence acoustic absorption of no less than <NUM> at <NUM>.