Note: Descriptions are shown in the official language in which they were submitted.
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NON-COMBUSTIBLE SOU N D-ABSORBING FACING
Field of Invention
The present invention relates to a non-combustible, sound-absorbing facing and
to a
laminate comprising the facing.
Background
Sound-absorbing materials are typically made of inefficient and/or hazardous
materials, in
particular, materials that can be readily combustible such as paper,
cellulose, viscose,
foam, cotton wool, polyester and the like. Other materials used which may not
bc as
readily combustible, still have low thermostability where the degree of
thermostability is
governed not by the environment in which the laminate is to be used but rather
by the
temperature involved in the moulding process for producing the sound-absorbing
laminate.
ln spite of these failings, sound-absorbing materials are often employed in
situations where
the reduction of noise pollution is considered of greater importance than the
potential for
thc material to become or to he rendered as a fire hazard. As a result of such
short
comings, sometimes a decision has to be made, when selecting a sound-absorbing
material
to be positioned in a fire hazard situation, as to whether the need for
reduced noise
pollution outweighs the potential for it to catch on fire or, if the reverse
is more important.
For example, when shielding noisy machinery or selecting a noise insulator to
surround an
automotive engine, the machine or engine oil can be sprayed onto and bc
absorbed by the
surrounding sound-absorbing material. The resultant effect being that not only
does the
sound-absorbing material start to lose its soUnd-absorption capacity, but it
becomes prone
to catching alight. Should a spark hit the oil-soaked sound-absorbing
material, the oil held
by the material will feed/exacerbate its flammability.
Summary of the Invention
According to the present invention there is provided a non-combustible sound-
absorbing
facing, wherein the facing has an air-flow resistance of between 80 to 3,000
RayIs and a
weight per unit area of between 20 to 1,000 g/m2.
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The invention is also directed to a non-combustible sound-absorbing laminate
which
comprises the facing of the invention and a substrate upon which the facing is
superimposed.
Detailed Description
Preferably, the facing is a fabric or textile (hereinafter referred to as a
"fabric"). More
preferably the fabric is a knitted or woven fabric. The fabric is made up of a
non-
combustible material, the preferred non-combustible material being selected
from glass,
ceramic and/or rock wool, fibre, yarn; or mixtures thereof. The non-
combustible material
may also be treated such as by coating to increase its fire resistance.
Crossing various
yarns generally known as warp and weft yarn preferably forms the fabric. Such
yarn can
be made according to suitable processing techniques as known in the art to
provide the
finished product having the required air-flow resistance values. The yarn from
which the
fabric is manufactured can be treated to provide the additional fire rating
coating prior to
the manufacture of the fabric or subsequent thereto.
The thickness of the resultant facing is preferably between 0.1 and 3.0 mm and
more
preferably between 0.12 and 1.5mm.
The yarn can be formed from several filaments. The weight of the yarns can
vary between
20 and 120 Tcx. However, the more preferred yam weight is between 34 and 68
Tex, with
a most preferred Tex of around 68, Typically, for a glass yarn, each filament
has a
diameter of between 6 and 9 microns, with the yam having a diameter ranging
between 3
and 500 mm. The preferred yarn diameter being between 6 and 150 mrn.
While the weight of the facing can vary between 20 to 1,000 g/m2, it is
preferred that the
facing is light-weight, having a wcight of less than 300 g/m2 and more
preferably around
200 g/m2. A light-weight facing is preferred in that it is more flexible and
enables it to be
moulded/shaped to a required shape or to be applied to a non-planar surface,
such as the
underside of automotive engine hoods i.e. to be a hood liner. When used as
part of a
laminate and when the laminate is applied to the surface of the lining of an
air duct, vehicle
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head-liner, in the vicinity of vehicle exhaust system and the like, the light-
weight facing
maintains its contact with the undulating surface a the substrate.
Thc selection of the facing weight is therefore dependent upon its end use.
For example, a
more rigid Lacing may be required where it will act as the exposed face of a
sound-
adsorbing wall upon which a picture, photograph and the like may be hung for
display.
Similarly, where the facing is exposed to people traffic, it may need to be
tougher i.e. have
increased rigidity to minimize tearing when bumped or contacted by the passing
people
traffic. Accordingly, the facing can be mechanically tough and also act as a
durable
protective layer. The facing is preferably also easy to clean, handle and cut.
If required, the facing can be partially or totally covered or overlaid by a
suitably selected
screen fabric or the like. It might also be coloured or an image applied
directly thereto,
provided such enhancements do not jeopardise the necessary air-flow
resistivity of the
facing to enable it to maintain its sound-absorbing properties and function.
it is also possible that the facing can be exposed to the outside environment
without
suffering undue degradation in its physical and sound-absorbing properties.
Preferably, the
facing will not, when subjected to hot and humid conditions, rot or powderize.
The facing
can be stretched over structures, such as metal or timber frames to make
panels, banners or
over cables to form, for example, sails and the like.
The facing can be affixed to a substrate thereby providing a non-combustible
sound-
absorbing laminate or composite. The substrate is preferably also one having
sound-
absorbing characteristics; however, it does not necessarily have to have such
characteristics. The substrate material can therefore have little or no
acoustic absorbing
performance and because of the presence of the facing of the present
invention, the
laminate is still effective. Thus, where the substrate is more susceptible to
damage or
tearing through being inadvertently knocked, the presence of the tough,
durable facing
provides a protective and non-combustible layer to traditional acoustic
materials,
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Brief Description of Drawines
Other features and advantages of one or more of the preferred embodiments of
the present
invention will be readily apparent to those skilled in the art from the
following written
description with reference to and used in conjunction with the accompanying
drawings in
which:
Figure 1 is a cross-sectional view of a non-combustible sound-absorbing
laminate or
composite comprising the facing of the present invention and a substrate.
Figure 2.1 to 2.4 are graphs of sound-absorption coefficient vs frequency for
various
combinations of thickness and materials of standard substrates with or without
the facing
of the present invention bonded to it as described in Examples 1 to 4,
Figure 3 is a cross-sectional view of an alternative non-combustible sound-
absorbing
laminate, wherein a bonding layer is located between the substrate and the
facing.
Description of the Prcferred Embodiments
In Figure 1, the laminate 10 is comprised of a substrate 20 with a facing 30
of the present
invention superimposed over it. The substrate 20 may be an acoustic foam or
air-
permeable material, which exhibits sound-absorbing properties. Suitable
examples arc
open-cell foams like polyurethanes. Other air-permeable materials can be
polyester fibres,
glass wool or fibre, rock wool or fibre, cellulose, paper pulp, wool, cotton
wool or felt,
viscose and polyfelt. All these materials allow a degree of trapping of the
sound waves
that pass into them and they are able to dissipate some of the energy of the
sound waves as
heat caused by the wave travelling through the substrate material as heat
given off.
Substrate 20 is not required to have the same air-flow resistivity as the
facing 30 covering
it. As a result of the facing 30, appropriate sound-absorbency is obtained,
which is not
dictated by or dependent on the substratc 20 thcrcunder.
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Substrate 20 is preferably formed as a foam or pad having a thickness which
may range
from between about 1 to 200 nun. The facing 30 is applied to the upper face 22
of the
substrate and it is the facing which is exposed towards the source of the
noise and/or in the
direction in which any flame or fire would be expected to come. Thc facing 30
docs not
normally enclose the substrate 20 within it. Normally, the facing is only
applied to the one
surface of the substrate 20.
The facing 30 is preferably affixed to the entire upper face 22 of the
substrate 20. That
fixing can be by mechanical rnearis and/or thermal and/or adhesive bonding.
Therefore,
the facing 30 can be releasably fixed by for example, the use of appropriate
attachment
means to the substrate 20. Such attachment means can include the use of pins,
clips,
staples and/or sewing.
The facing 30 can be adhered by using compression moulding or flame lamination
and the
method or composition of choice may be determined by the composition of the
substrate
20. For example, if the substrate 20 is made up of polyester wool, whereby the
upper
surface of the polyester, which is to be covered by the facing 30, is heated
sufficiently to
cause a partial melt of at least some of the exposed polyester fibres, whereby
they become
sufficiently tacky or sticky to then hold the facing 30 when applied thereon.
in Figure 3, the laminate 10 is comprised of a substrate 20 with an adhesive
layer 40
holding facing 30 in contact therewith.
When using an adhesive bonding, a variety of thermoplastic adhesives as are
known in the
art may be employed. The preferred adhesives would include co-polyesters,
polyarnides
and the like. These may be in the form of powder or web adhesives. More
preferably, the
adhesive selection is one that has a sufficient thermal stability in order to
maintain the
integrity of the bond between the facing 30 and the substrate 20 in the event
of facing 30 of
the laminate being exposed to a flame.
In relation to both the thermal and adhesive bonding, the degree of bonding
between the
facing 30 and the substrate 20 should be such that it is sufficient to hold
the facing 30 in
contact with the substrate 20, while not compromising the required air-fiow
resistivity
value of the facing 30. Accordingly, it is preferred that when an adhesive it
used, that it is
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one that is sufficiently air-permeable. A typical preferred adhesive is either
powder
adhesive or web adhesive, such as PA121 from Bostik. Further, adhesive layer
40
preferably has a negligible thickness.
The substrate 20 provides thc predominate amount of the thickness of the
laminate.
The thickness of the facing 30 may lie in the range from 0.1 to 3,0 mm, The
facing is
preferably of a 1 xl plain weave. The yarns making up such a weave may have a
spacing
of yarns/5cm of typically 60 x 57.5 or 87 x 61. The facing can substantially
prevent the
substrate from soaking up fluid when splashed onto it from the facing side.
The length and width of the facing 30 will vary with the dimensions of the
surface of the
substrate to be covered. The facing and/or laminate are usually available in
rolls of
indefinite length and widths. However, it is preferred that the rolls are
about 1.40m wide
and in lengths of 15, 30 or 60 metres.
The facing provides a low cost insulation material.
As with the facing, the laminate can also be handled easily and is simple to
cut.
When the substrate 30 is an open cell foam, it preferably has a density of
from 8 to 120
kg/m3, with a preferred range frotn 8 to 32kg/m3.
The facing can withstand temperatures up to 750 C. Even after being exposed
to such
temperatures or flames, the facing material maintains its integrity. Fire test
resul.ts using
the AS/NZS 3837 procedure have been performed on the facing of the present
invention
and the facing is classified as Group 1 or better.
The adhesion between the facing and substrate is dependent on thc
composition/materials
of the substrate 20 used where the substrate can be fused to the facing and/or
there is an
adhesive layer 40 therebetween, Accordingly the integrity of the bond when
using an
adhesive layer is dependent upon the melting temperature of the adhesive used.
When the
adhesion is via a polyester web adhesive like PA121 by Bostik, the laminate
can withstand
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a maintained temperature of 120 C, such that the adhesion between the facing
and the
substrate is maintained.
The thickness of the substrate 20 need not be consistent along its length or
width, which
variation in thickness might arise for example when the underside 21 of the
substrate 20 is
sculptured and then applied to an uneven surface such as the underside of an
cngine hood.
In such a situation, and it is preferred that the upper face 22 of the
substrate 20 maintains a
substantially flat exposed face 22 to which facing 30 is to be applied, it is
found that the
variation in the thickness of the substrate 20 is not substantially
detrimental to the sound
absorbency of the laminate, i.e. the integrity of the sound absorbency of the
laminate in its
thinner depths is substantially the same as at its thicker depths.
Therefore, the success of the sound absorbency of the facing 30 results in the
ability to use
thinner substrates while maintaining the required absorption coefficient, the
overall effect
:15 of which is that the laminate 10 can have a low weight per unit area.
Another advantage
achieved is that the laminate can occupy less spatial area. That is, it can
take up less
amount of space when placed, for example within a wall cavity, whereby thinner
walls can
be achieved.
To the underside 21 of the substrate 20, a self-adhesive backing 23 can be
applied to
permit fixing of the substrate 20 onto the wall, hood, lining of the area from
within which
the noise pollution is being emitted.
The hacking 23 is preferably a double-sided tape or sheet where that side of
the tape/sheet
which contacts the underside 21 of the substrate 20 is adhesively bonded
thereto. The
other or exposed side of the tape/sheet maintains its covering film or paper
contact with the
tape/sheet until it has to he removed to affix the laminate 10 to the wall,
lining, hood etc.
Those double-sided tapes/sheets as are used in the art can still be employed
with the
present invention.
As the facing can be used and is efficient by itself in reducing noise
pollution, when
affixed to the substrate, the thickness of the substrate is adjustable
according to the
requirements of the end user without any appreciable drop in the sound-
absorbency of the
laminate,
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Through using the facing of the present invention, it has been found that it
can bc applied
to traditional sound insulation materials and that the facing makes it
possible to provide
sound-absorption laminates with constant performance by removing the acoustic
variation
within the substrate.
Typical applications for using the facing and laminate of the present
invention include
acoustic wall treatments; commercial buildings, concert halls, auditoriums;
recording
studios; cinemas; classrooms and lecture theatres; restaurants; hotels; cafes;
bars; clubs;
power stations; linings for air ducts, compressorsõ generators, machinery,
equipment,
electronic, plant and electrical enclosures, wall and ceiling linings, hood
and head liners for
automotive vehicles; marine, aviation and transportation; banners and flags.
Specific embodiments and applications of the present invention will now be
discussed in
detail by reference to the accompanying example. This discussion is in no way
intended to
limit the scope of the invention.
,Example 1
A sound absorption test was performed on two samples of 25min thick acoustic
foam, one
with 0.18 mtn facing of the invention and one without any facing. To determine
the sound
absorption coefficient of the samples, the procedure was performed using the
AS ISO 354-
2006 "Acoustics: Measurement of sound absorption in a reverberation room"
test,
The frequency range measured using this procedure was from 100Hz to 5000Hz in
1/3
Octave increments.
Sample A comprised a 25mm thick acoustic hydrolysis resistant polyurethane
foam with a
OA S mm thick non-conbustible sound absorbing facing. Sample A had a nominal
density
of 28kg/m3 and a nominal thickness of 25mm.
Sample B comprised a 25nim thick acoustic hydrolysis resistant polyurethane
foam.
Sample B had a nominal density of 28kg/m3 and a nominal thickness of 25mm.
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The results arc shown in Table L
Tabk 1
Results of sound absorption tests and Noise Reduction Coefficient (NRC) for
Sample A
and Sample B.
Frequency Sound Absorption Sound Absorption
(I-1z) Sample A: Sample B:
100 0.01 0.02
125 =0.11 0.10
160 0.15 = 0.12
200 =0,18 0.14
250 0.28 0.20
315 0.35 0.25
400 0.49 = 0.34
500 0.63 0.43
630 0.74 0.45
800 0.81 0,50
1000 0.94 0.55
1250 1.01 0.57
1600 1.05 0.61
2000 1.05 0.65
2500 0.98 0.71
3150 0.90 0.70
4006 0.80 0.74
5000 0.76 0.76
NRC
_______________________________ J. 0.72 0.45
The NRC of the samples was calculated in accordance with ASTM C423-90A.
1 o
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The individual weighted sound absorption coefficient aw of each sample was
determined in
accordance with AS ISO 1.1654-1997 "Acoustics: Sound Absorbers for Use in
Buildings -
Rating of sound absorption" for
Sample A: ct, r- 0.55 (M, H)
Sample B: = 0.45 (14)
The Practical Sound Absorption Coefficients are shown in Table 2. These values
were
also determined i.n accordance with AS ISO 11654-1997.
Table 2
Practical Sound Absorption Coefficients for Sample A and Sample B.
Frequency Practical Sound Absorption Practical Sound
Absorption
(Hz) Coefficients Sample A Coefficients
Sample B
125 0.10 0.10
250 0.25 0.20
500 0.60 0.40
1000 0.90 0.55
2000 1.00 = 0.65
4000 0.80 0.75
Thc results of the absorption tests of Sample A and B are shown in Figure 2.1.
Example 2
A sound absorption test was performed on two samples of 25mm thick acoustic
polyester,
one with 0.18 mm facing of the present invention and one without any facing.
The sound
absorption coefficient of each sample was determined using the AS ISO 354-2006
"Acoustics: Measurement of sound absorption in a reverberation room" test,
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The frequency range measured using this procedure was from 100Hz to 5000H in
1/3
octave increments.
Sample C comprised a 25mm thick 100% thermally bonded acoustic polyester fibre
blend
with a 0.18 nim thick non-combustible suund-absorbing facing. Sample C had a
nominal
density of 32kg/m3 and a nominal thickness of 25mm.
Sample D comprised a 25mm thick 100% thermally bonded acoustic polyester fibre
blend.
Sample D had a nominal density of 32kg/m3 and a nominal thickness of 25mm.
The results are shown in Table 3,
Table 3
Results of sound absorption tests and (NRC) values in Sample C and Sample D.
Frequency Sound Absorption Sound Absorption
(Hz) Sample C Sample D
100 0.12 0.09
125 0.14 0.1.3
160 0.19 0.1.8
200 0.22 0.19
250 = 0.28 0.24
315 0.31 0.27
400 0.43 0.35
500 0.53 0.36
630 0.59 0.43
800 0.67 0.45
1000 0.79 0.46
1250 0.87 0.49
1600 0.98 0,55
2000 1.02 0,58
2500 1.00 0.59
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Frequency Sound Absorption Sound Absorption
(Hz) Sample C Sample
D
3150 0.99 0.59
4000 0.90 0:62
5000 0.81 0.62
NRC
0.65 0.40
The NRC of the samples was calculated in accordance with ASTM C423-90A.
The individual weighted sound absorption coefficient ay, of each sample was
again
determined in accordance with AS ISO 11654-1997.
Sample C: as, z 0.50 (M, H)
Sample D: ct, = 0.45 (H)
The Practical Sound Absorption Coefficients are shown in Table 4. These values
were
again determined in accordance with AS ISO 11654-1997.
Table 4
Practical. Sound Absorption Coefficients for Sample C and Sample D
¨ ____________________________________________________________________________
Frequency Practical Sound Absorption Practical Sound
Absorption
(Hz) Coefficients Sample C Coefficients
Sample D
.125 0.15 0.1.5
250 0.25 0.25
.,õ.. ___________________________
500 0.50 0.40
1000 0.80 0.45
2000 1.00 0.55
4000 0.90 0.65
The results of the absorption tests of Sample C and D are shown itt Figurc
2.2.
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Example 3
A sound absorption test was performed On two sarnples of 5Ornm thick acoustic
polyester,
one with 0.18 mm facing of the present invention and one without any facing.
The sound
absorption coefficient of each sample was determined using the AS ISO 354-2006
test.
The frequency range measured using this procedure was from 100Hz to 5000Hz in
1/3
octave increments.
Sample E comprised a 50rnm thick 100% thermally bonded acoustic polyester
fibre blend
with a 0.18 mm thick non-combustible sound-absorbing facing. Sample E had a
nominal
density of 32kg,1m3 and a nominal thickness of 50inm.
Sample F was the same as Sample E except that it did not contain the facing.
The results are shown in Table 5.
Table 5
Results of sound absorption tests and (NRC) values in Sample E and Sample F.
Frequency Sound Absorption Sound Absorption
(Hz) Sample E Sample F
100 0.25 0.20
125 0.30 0.22
160 0.45 0.33
200 0,47 0.37
250 0.69 0.54
315 0.83 0.62
400 1.03 0.77
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--
Frequency Sound Absorption Sound Absorption
=
(I-17) Sample E.' Sample F
500 1.14 0.85
630 =I.=17 0.88
800 1.17 0.85
1000 = 1.15 0.83
1250 1.12 0.85
'1600 1.07 0.86
2000 '1.00 0.86
2500 0.88 0,84
3150 0.85 0.85
4000 0.87 0.87
5000 0.89 0.89
=
NRC 1.00 0.77
The NRC of the samples was calculated in accordance with ASTM C423-90A.
The individual weighted sound absorption coefficient a. of each sample was
again
determined in accordance with AS ISO 11654-1997.
Sample E: = 0.95 (M, H)
Sample 1.): a.w= 0.80 (TI)
.10 The Practical Sound Absorption Coefficients are shown in Table 6. These
values were
again determined in accordance with AS ISO 11654-1997.
Table 6
Practical Sound Absorption Coefficients for Sample E and Sample F
Frequency
Practical Sound Absorption Practical Sound Absorption
(Hz) Coefficients Sample E Coefficients
Sample F
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Frequency Practical Sound Absorption Practical Sound
Absorption
(Hz) Coefficients Sample E Coefficients
Sample F
1.25 0.35 0.25
250 0.65 0.50
500 - 1..15 0.85
1000 1.15 0.85
2000 1.00 0.85
3150 = 0.85 0.85
The results of the absorption tests of Sample E and F are shown in Figure.
2.3.
Exam* 4
A sound absorption test was performed on two samples of 100mm thick acoustic
polyester,
one with 0.18 mm facing of the present invention and one without any facing.
The sound
absorption coefficient of each sample was cletertnined using the AS ISO 354-
2006 test.
The frequency range measured using this procedure was from 1.00Hz to 5000Hz in
1/3
octave increments.
Sample G comprised a 100mm thick 100% thermally bonded acoustic polyester
fibre blend
with a 0.18 mm thick non-combustible sound-absorbing facing. Sample G had a
nominal
density of 32.kg/m3 and a nominal thickness of 100mm.
Sample H comprised a 100mm thick thermally bonded acoustic polyester fibre and
its
nominal density and thickness were the same as Sample G.
The results are shown in Table 7.
Table 7
Results of sound absorption tests and (NRC) values in Sample G and Sample H.
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- ____________________
Frequency Sound Absorption Sound Absorption
(1-Iz) Sample G Sample 14
100 0.60 0.4
1-25 = 0.57 0.50
160 0.93 0,70
200 1.00 0.80
250 1.20 = 1.00
315 1,1.5 = 1.05
400 1.24 1.10
300 1.19 1.10
630 1 .10 1.10
800 1.6 1.10
1000 0.99 = 0.99
1250 0.92 0.92
1600 0.92 0.92
2000 = 0.99 0.99
2500 = 0.95 0.95
3150 0.96 0.96
-4000 = 0.90 0.90
5000 0.89 0.89
N1 _____________________________ L __________ 1,1.0 1,09
The NRC of the samples was calculated in accordance with ASTM C423-90A.
The individual weighted sound absorption coefficient aw of each sample was
again
determined in accordance with AS ISO 11654-1997,
Sample G: = 1.0 (M, H)
Sample H: ay, = 1.00 (H)
The Practical Sound Absorption Coefficients are shown in Table 6. These values
were
again determined in accordance with AS ISO 11654-1997.
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Table 8
Practical Sound Absorption Coefficients for Sample G and Sample H
Frequency Practical Sound Absorption Practical Sound
Absorption
(Hz) Coefficients Sample G
Coefficients Sample H
125 0.57 0.55
250 1.20 1.00
500 1.20 1.10
630 = 1.10 1.10
The results of the absorption tests of Sample G and H are shown in Figure 2.4.
Example 5
A Fire test was performed on Samples A and 13 of Example 1. The flammability
test was
conducted according to AS1530.3 -1.999: While this test can produce results on
Ignitability, Flame Propagation, Heat Release and Smoke Release, it is the
ignitablity or
combustibility value of each Sample which is of importance in the present
invention,
Ignitablity is determined using a scale of from 0 to 20 where 0 is read as the
tested material
will not ignite.
The results are shown in Table 9.
Table 9
Sample = Ignitability
Sample A = 0
Sample B 17 = _____
Accordingly, the presence of the facing has rendered a substrate that
previously had an
ignitablity of 17 down to zero.
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Example 0,
The same Fire test as employed in Example 5 was conducted on Samples C and D
of
Example 2.
Sample D gave an ignitablity value of 8 while Sample C which contained the
0,18mm
facing on the 25 mm thick acoustic polyester had a value of zero and would not
ignite.
Thus again the presence of the facing of the present invention enhanced the
ability of a
standard substrate material (25mm polyester) to withstand combustibility.
The Examples and Figures 2.1 to 2.4 demonstrate that a substantial sound
absorption
improvement is achieved by adding the facing of the present invention to a
conventional
sound absorbing substrate.
Further, since the facing is non-combustible a safer sound-absorbing noise
insulator can
surround potentially hazardous equipment. The facing of the present invention
has
successfully transformed earlier flammable sound absorbing materials into non-
combustible and thus safer acoustic systems.
Where the tenns "comprise", "comprises", "coinprised" or "comprising" are used
in this
specification, they are to be interpreted as specifying the presence of the
stated features,
integers, steps or components referred to, but not to preclude the presence or
addition of
onc.or more other feature, integer, step, component or group thereof.
While embodiments of the invention have been described in the detailed
description, the
scope of the claims should not be limited by the preferred embodiments set
forth in the
examples, but should be given the broadest interpretation consistent with the
description as
a whole.
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