DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] FIG. 1 illustrates a composite or laminate article 100 formed in accordance with a first embodiment of the present invention suitable for use as a sound-absorbing water shield or deflector. The composite 100 includes a porous, energy absorbing foam layer 110 which is protected from water penetration by a film layer 112 that allows acoustic energy to pass while repelling or otherwise blocking the passage of water therethrough.

[0026] The foam layer is preferably a urethane foam, most preferably an ether-type urethane foam. Preferably, the foam has a thickness of at least about 5 mm, preferably about 10 mm. Additionally, although many different types of open- or closed-cell urethane foam could be used, the subject preferred form has a pore size of from about 8-32 cells/cm, preferably about 16 cells/cm, and a density of from about 20 to about 35 kg/m ³ , preferably about 27 kg/m ³ . Other acoustic energy absorbing materials include, but are not limited to, other open- or closed-cell polymeric foam materials, shoddy or fibrous insulation materials such as cotton, fiberglass, nonwoven synthetic fibers, and the like.

[0027] The film layer 112 is a polymer film, such as a thermoplastic film, such as polyethylene, polypropylene, polyvinyl chloride, and copolymers thereof. The film material is preferably polyethylene, such as linear low density polyethylene film, and most preferably a high-strength octene-type linear low density polyethylene film. Preferably, the film layer has a thickness in the range of about 4 to 12 mils. Alternately, film layer 112 comprises a closed-cell foam material.

[0028] In use, the film 112 is disposed on a side 114 of the article 100 which is intended to face wet or moist conditions or other environmental contaminants. A plurality of projections 116 are formed on the surface of film 112 . The projections 116 are directional, extending from the side 114 toward the wet side environment and have a small pore or opening therein which extends through the film 112 . In this manner, when the projections 116 face a wet environment, they form a series of micro funnels or cones which allow air and acoustic energy to pass while repelling water and other contaminants.

[0029] The projections 116 may extend perpendicularly or, alternatively, at an angle with respect to the surface of the film 112 . In the illustrated embodiment, the projections 116 are shown in a downwardly angled orientation which increases resistance to water inclusion. The formations 116 cover all or part (e.g., areas where sound absorption is most desired) of the surface of film 112 . In one embodiment, the perforations 116 are arranged in a regular pattern and can be formed by a number of perforation techniques. In a preferred embodiment, vacuum perforation techniques are used which produce raised bosses having perforated tips, as are generally known in the art. Other methods include, for example, hot or cold needle perforation techniques, and the like. The size and spacing of the projections 116 are such that they lend a degree of acoustic transparency to the film layer 112 while maintaining water resistance.

[0030] The porous protective film 112 can be laminated to the foam layer 110 using an adhesive. The adhesive can be applied in a continuous layer or, more preferably, in a an adhesive pattern for increased acoustic absorption, such as around the perimeter of the finished article. Other bonding techniques are also contemplated so long as it does not result in debossing the projections 116 .

[0031] Referring now to FIG. 2 , there is shown a sound-absorbing water shield 200 formed in accordance with a second embodiment of the present invention wherein like reference numerals are as described above by way of reference to FIG. 1 , and further comprising a continuous, imperforate plastic film layer 210 disposed opposite the perforated film 112 on foam layer 110 . The film layer 210 , which may be formed of the same or a different material as the perforated film 112 , is laminated to foam layer 110 , e.g., using an adhesive. Layer 210 can be applied before layer 112 , and in such cases, other conventional techniques for bonding the imperforate layer 210 and foam layer 110 can be used, such as flame bonding, heat lamination, and the like. The embodiment of FIG. 2 is advantageous in that the imperforate layer 210 , which lacks the acoustic transparency of the perforate film layer 112 , further assists in trapping acoustic energy in the core foam material.

[0032] Referring now to FIG. 3 , there is shown a sound-absorbing water shield 300 formed in accordance with a third embodiment of the present invention wherein like reference numerals are as described above by way of reference to FIGS. 1 and 2 , and further including sealed encasing film layers 310 and 312 extending around the perimeter of the article 300 . Film layers 310 and 312 can comprise separately formed members or, alternatively, can be integrally formed with film layers 210 and 112 , respectively. In this manner, the foam layer 110 is sealed on all sides against water and other contaminants entering therein.

[0033] Referring now to FIGS. 4 - 6 , a sound-absorbing water deflector sheet 400 of the present invention is shown which is particularly intended for use in a vehicle door construction to protect the door trim panel from water, and to also cover and overlie certain door mounted components, such as speakers, window and door electric switch mechanisms, and the like. The peripheral shape of the protector in FIG. 4 is merely exemplary and this shape is selected and designed SO that it overlies and totally covers those portions of the inner door panel through which water might enter from within the door. The peripheral shape can vary significantly, but generally comprises an upper edge portion 412 , a lower edge portion 414 , and end edges 416 and 418 . Various openings for the passage of wires and the like are often formed through the water deflector sheet.

[0034] The particular structure of the deflector sheet 400 comprises a two-layer composite or laminate, substantially as described in FIG. 1 , including a foam layer 110 attached to a perforate film layer 112 , and further including regions having different thicknesses. As shown in FIGS. 4 and 5 , a region 420 of reduced foam thickness is advantageously formed around the periphery of the shield 400 while central region 422 retains increased foam thickness for increased sound absorption. Since wicking of water by the foam member 110 is most likely to occur at the peripheral edges, removal of the porous material from the periphery minimizes the uptake of water into the foam, thus reducing possible mildew and leakage problems. Foam is also advantageously removed at other possible wicking areas or areas of potential water entry, such as where wires, fasteners, hardware, and the like, pass through the deflector 400 .

[0035] Additional regions of thin foam can also be provided for ease of assembly and installation. Referring now to FIGS. 4 and 6 , it is often desirable to provide the deflector sheets with laterally deflectable pocket areas to allow the sheets to better conform to various structures and surfaces within the door, such as loud speakers, door handles, and the like. In the illustrated embodiment, region 424 of FIG. 4 comprises a laterally deflectable pocket formation. The deflectable pockets can be mechanically produced in the manner of commonly assigned U.S. Pat. Nos. 4,696,848, 4,865,791, and 5,560,967, the entire contents of which are incorporated herein by reference. Briefly, the deflectable pocket is produced by mechanically deforming the sheet using interengaging closely spaced blade-like members so as to stretch the areas between the edges of the inner penetrating tools to form a series of pleats.

[0036] Preferably, the stretching of the film layer 112 is sufficient to fracture or tear the foam 110 layer in the area between the highly stretched portions of the film, with the foam remaining attached to the pleats.

[0037] Depending on the desired configuration, other various openings can be formed through the water deflector sheet, such as various holes, slits, perforations, etc., provided for the passage of wires, screws or other fasteners, handles, and the like. Such regions and are advantageously regions having a thin foam layer 110 . The removal of foam in regions such as region 424 or other regions provides an additional advantage in that a thin foam layer formed by cutting or other means for material removal, unlike compressed foam, may be made sufficiently thin so as to allow the passage of light, thus making it easier to locate fasteners and the like during installation.

[0038] Regions of variable thickness in the foam layer can be formed using a compression cutting technique. In this manner, the foam thickness can be varied in any configuration from full thickness down to near zero. The sheet is compressed between a smooth roller and a profiled roller or plate to selectively compress the foam different amounts in different regions. A cutting blade is positioned to cut the foam just as it exits the nip. In this manner, the regions that are compressed are not cut or are minimally cut and the uncompressed areas are cut more deeply. If a transparent film is used, the thin foam areas produced are nearly transparent or otherwise allow sufficient passage of light to provide the attendant assembly advantages mentioned above. Since no heat is involved, the process is rapid and relatively inexpensive.

[0039] The pocket forming section 424 can be formed before or after the water deflector sheet 400 has been cut to its desired peripheral size and configuration, however, it is normally done prior to cutting the sheet to size because of the need for the edge portions of the sheet for gripping and holding during the pocket forming operation. Likewise, laminated blanks are preferably compression cut with peripheral waste areas left at full foam thickness. The sheets can then be die cut in the conventional fashion. The sheets can also be stacked into pads for processing before or after they are cut to shape. For mounting and installation, a bead-type adhesive, such as a pressure-sensitive adhesive, or sealer is applied to the door or, alternately, the adhesive is applied to the periphery or various other locations of the shield 400 , as desired.

[0040] Referring to FIGS. 4 and 5 , there is shown in phantom an optional adhesive bead 426 applied to the periphery prior to installation. In a preferred embodiment, a film release coating, such as a silicone-based release agent or the like, is applied to surface of film 112 to allow preapplication of adhesive 426 and subsequent stacking of the shields for processing. Preferably, the release coating is applied to the exposed film side prior to laminating the film and foam layers.

[0041] Referring now to FIG. 7, a further embodiment of the present invention is illustrated. A sound-absorbing water shield 700 comprises an open- or closed-cell foam layer 110 , preferably an open-cell foam layer, laminated to an imperforate film layer 210 . Exposed open-cell foam layer 110 is disposed on water-facing side 114 of the shield 700 . With exposed foam facing the outside of the vehicle, the effectiveness of the shield in absorbing sound may be further enhanced. In a preferred embodiment, the foam layer 110 comprises a hydrophobic foam which has a significantly reduced tendency to absorb water, thereby avoiding leakage and mildew problems.

[0042] The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon a reading and understanding of this specification. The forms hereinbefore described being merely explanatory and exemplary, it is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.