US 12,319,045 B2
Nonwoven composite for air flow applications
Christophe Chaut, Molsheim (FR); Greg Thompson, Simpsonville, SC (US); and Marc Engel, Lingolsheim (FR)
Assigned to Zephyros, Inc., Romeo, MI (US)
Appl. No. 17/265,846
Filed by Zephyros, Inc., Romeo, MI (US)
PCT Filed Aug. 6, 2019, PCT No. PCT/US2019/045191
§ 371(c)(1), (2) Date Feb. 4, 2021,
PCT Pub. No. WO2020/033339, PCT Pub. Date Feb. 13, 2020.
Claims priority of provisional application 62/714,981, filed on Aug. 6, 2018.
Prior Publication US 2021/0162702 A1, Jun. 3, 2021
Int. Cl. B32B 5/02 (2006.01); B32B 1/08 (2006.01); B32B 5/22 (2006.01); B32B 7/12 (2006.01); B32B 27/12 (2006.01); B32B 27/32 (2006.01); B32B 27/36 (2006.01); F24F 13/02 (2006.01); F24F 13/24 (2006.01)
CPC B32B 5/022 (2013.01) [B32B 1/08 (2013.01); B32B 5/22 (2013.01); B32B 7/12 (2013.01); B32B 27/12 (2013.01); B32B 27/32 (2013.01); B32B 27/36 (2013.01); F24F 13/02 (2013.01); F24F 13/0245 (2013.01); F24F 13/24 (2013.01); B32B 2262/0253 (2013.01); B32B 2262/0284 (2013.01); B32B 2262/101 (2013.01); B32B 2262/105 (2013.01); B32B 2262/144 (2021.05); B32B 2307/102 (2013.01); B32B 2307/304 (2013.01); B32B 2307/50 (2013.01); B32B 2605/00 (2013.01); F24F 2013/242 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A composite material comprising:
one or more fibrous sheets formed by a plurality of discrete layers layered on top of each other, the one or more fibrous sheets consisting of:
a) two nonwoven layers, wherein at least one of the nonwoven layers is a needlepunched layer; and
b) a core material comprising a fibrous material layer, wherein the fibrous material layer comprises short fibers having an average fiber length of less than 10 mm;
wherein the core material is sandwiched between the two nonwoven layers;
wherein each of the nonwoven layers has a weight of 100 grams per square meter or greater to 195 grams per square meter or less;
wherein each layer of the one or more fibrous sheets is permeable;
wherein each layer of the one or more fibrous sheets comprises polyethylene terephthalate;
wherein the composite material includes one or more localized overmolded features over a portion of the composite material from an injection molding process of overmolding material;
wherein the composite material includes one or more locally compressed areas to inhibit the overmolding material from reaching the fibrous material layer; and
wherein the composite material is shaped to form an air duct defining one or more channels through which air is permitted to travel.