Manville Corporation

Johns Manville

Schuller International, Inc.

Indiana Acoustical Components

David W Bainbridge

Mario P Tocci

Larry Maxwell Bauman

William H Olbert

James W Stacy

A molded, self-supporting, composite part or panel for automotive and similar applications comprises a vapor impervious wood fiber filled polymeric (preferably polypropylene) sheet adhered to one major face of a corrugated paperboard medium and a layer of fibrous insulation (preferably glass fiber) or a second wood fiber filled polymeric sheet adhered to a second major face of the corrugated paperboard medium. The sheet and corrugated medium provide the structural strength for the composite and the fibrous insulation, when used, provides the composite with good sound absorption properties. The wood fiber filled polymeric sheet is formed during the molding process from a wood and polymeric fiber sheet. The heat and pressure of the molding process cause the polymeric fibers to melt and flow about the wood fibers to form the wood fiber filled sheet and bond the sheet securely to the corrugated medium. A thermoset binder can be used in the sheet to strengthen the composite and help the composite retain its molded shape prior to cooling. Uncured binder in the fibrous insulation is cured during the molding process to bond the fibrous insulation to the corrugated medium.

Method of making self-supporting composite structures

Described is an aqueous sprayable glass fiber binding composition comprising: a) an aqueous compatible formaldehyde thermosetting coating composition; and b) a compatible aqueous latex elastomeric composition. Also described are binder compositions that decrease fallout of glass fiber and binder from the coated glass fiber. Also disclosed is a glass fiber binder composition having low odor content.

Glass fiber binding composition containing latex elastomer and method of

A self-supporting headliner panel for lining the interior surface of an automotive roof comprises a front sheet, a back sheet and an intermediate corrugated sheet adhered to the front and back sheets. The front sheet and the back sheet each comprise wood fibers and polypropylene. To form the panel, a laminate of the front sheet, the back sheet and the intermediate corrugated sheet is molded in a heated mold which melts polypropylene fibers in the front and back sheet causing the laminate to conform to the shape of the mold and adhering the three sheets together.

Automotive headliner panel and method of making same

A flexible coupling for connecting an engine manifold to an exhaust pipe to relieve torque. Concentrically spaced flexible tubes, which have insulation filling the annular space between them, are connected to inlet and outlet tubes having interior ends located between the ends of the flexible tubes. The inlet and outlet tubes have enlarged upstream ends and smaller downstream ends. By overlapping the ends of the inlet and outlet tubes, the tubes are able to have relative angular movement when the flexible tubes bend due to engine torque. One or more separate tubes which also have enlarged and smaller upstream and downstream ends may be provided to overlap with the inlet and outlet tubes to allow bending of longer couplings.

Automotive exhaust system decoupler with resilient sleeve

An automotive exhaust system incorporating an insulated exhaust pipe. The insulation is selected so that it is very efficient at relatively low temperatures, thereby allowing the exhaust gases to reach the light-off temperature of the catalytic converter in a short time, and less efficient at high temperatures, thereby maintaining the temperature of the exhaust gases below the level at which aging of the catalytic converter increases.

Automotive exhaust system

Insulating the exhaust pipe of an internal combustion exhaust system by sliding a flexible insulated tube over the exhaust pipe. The tube comprises concentrically arranged inner and outer corrugated stainless steel tubes, with the annulus between the corrugated tubes filled with refractory fiber insulation. The wall thickness of the corrugated tubes is in the range of 0.002 inch and 0.004 inch, which provides the insulated tube with sufficient flexibility to be trained over the angled portions of the exhaust pipe. The contact between the corrugations and the pipe assists in holding the insulated tube in place. The inner tube may extend beyond the outer tube and be flared back to the outer tube to enclose the insulation and facilitate movement of the insulated tube over the exhaust pipe. Alternatively, the insulation may also be sealed by end caps.

Means and method for insulating automotive exhaust pipe

An insulated exhaust pipe comprising inner and outer spaced corrugated metallic tubes separated by refractory fiber isulation. Strips of higher density refractory fiber insulation hold the low density insulation in place during operation and prevent degradation of the fiber by vibration. The pipe is made by rolling the inner tube over a layer of insulation, including strips, to which adhesive has been applied. The insulated tube is then inserted into the outer tube, rotating the insulated tube so that the corrugations of the outer tube do not damage the insulation. Specific structure for carrying out these method steps is disclosed.

Insulated exhaust pipe and manufacture thereof

Attachment means for connecting an insulated pipe to an element, such as the manifold, in the exhaust system of a vehicle. The attachment means includes a conduit which extends into the end of the insulated pipe. A transverse lug or a helical flange on the conduit engages the spiral corrugations of the inner diameter of the pipe to allow the conduit to be threaded into the pipe. The end of the pipe is received in an end cap slidably mounted on the conduit. When the cap hits a stop on the conduit during threading of the conduit into the pipe the lug or helical flange pulls the pipe against the cap, tightening the connection to the pipe.

Insulated exhaust pipe attachment means

A process for making a fibrous mat includes the steps of (a) combining (i) glass fibers, (ii) polyolefine fibers, (iii) fibers selected from the group consisting of polyamide fibers, polyester fibers, and mixtures thereof, and (iv) a cross-linked latex binder, (b) consolidating the fibers and binder into a loosely packed mat, (c) curing the consolidated mat at a temperature in the range of about 250-400 F., and (d) molding the cured mat into a desired shape at ambient temperature.

Process for making a moldable fibrous mat

An automotive headliner comprised of a laminate of double corrugated paperboard. Perforations in all the sheets of the laminate except the back paperboard sheet improve the acoustical performance of the liner. A vapor barrier on the back sheet prevents entry of moisture into the laminate from the roof, and a layer of sound dampening material on the front face of the laminate improves the sound absorption of the laminate. The front corrugation is larger than the back corrugation. When molding the laminate it is first moisturized, then heat molded. Heat is applied until the laminate has regained its rigidity.

Corrugated paperboard automotive liner

A thermoformable fibrous mat which has good strength and temperature resistance and which combines balanced properties of flexibility and rigidity. The novel, inventive mat comprises glass fibers; polyolefin fibers; polyamide and/or polyester fibers; and a cross-linked latex binder. Preferably, the latex binder is a combination of styrene-butadiene and carboxylated styrene-butadiene. A process for forming the inventive mat is also disclosed.

Growing community of inventors

Littleton, CO, United States of America

David W Bainbridge