Sound absorption and insulation pad for vehicle and manufacturing method thereof

Patent metadata

Field	Value
Publication number	US-2021198822-A1
Application number	US-202016883521-A
Country	US
Kind code	A1
Filing date	May 26, 2020
Priority date	Dec 31, 2019
Publication date	Jul 1, 2021
Grant date	—

Abstract

Disclosed are, inter alia, a sound absorption and insulation material including a polyester hollow fiber, a polyester low-melting-point composite fiber and a polyester base fiber, a sound absorption and insulation pad for a floor including the same, and a manufacturing method thereof for improving the elasticity and sound absorption and insulation performance of the sound absorption and insulation material. The sound absorption and insulation material is an environmentally friendly material that can reduce discomfort due to the generation of volatile organic compounds (VOCs) and the emission of toxic gases during combustion. Also, the sound absorption and insulation pad including the sound absorption and insulation material can exhibit superior sound absorption performance, sound insulation performance and actual vehicle performance compared to a conventional sound absorption and insulation pad of the same thickness.

First claim

What is claimed is:

1 . A sound absorption and insulation material, comprising:
a hollow fiber; a low-melting-point composite fiber; and a base fiber.

2 . The sound absorption and insulation material of claim 1 , comprising:
an amount of 10 to 50 wt % of the hollow fiber; an amount of 20 to 40 wt % of the low-melting-point composite fiber; and an amount of 20 to 50 wt % of the base fiber, all wt % are based on the total weight of the sound absorption and insulation material.

3 . The sound absorption and insulation material of claim 1 , wherein the hollow fiber has a fineness of about 5 to 15 denier, a fiber length of 50 to 70 mm, a hollow core ratio of 25 to 29%, a bulkiness of 12,300 to 12,800 cm 3 /g and 4 to 10 crimps/inch.

4 . The sound absorption and insulation material of claim 1 , wherein the low-melting-point composite fiber has a fineness of 3 to 5 denier, a fiber length of 40 to 60 mm and a melting point of 100 to 200° C.

5 . The sound absorption and insulation material of claim 1 , wherein the base fiber has a fineness of 5 to 15 denier and a fiber length of 50 to 70 mm.

6 . The sound absorption and insulation material of claim 1 , wherein the hollow fiber or the base fiber is a polyester fiber.

7 . The sound absorption and insulation material of claim 1 , wherein the low-melting-point composite fiber comprises a low-melting-point polyester fiber as a sheath and a regular polyester fiber as a core.

8 . The sound absorption and insulation material of claim 6 , wherein the polyester fiber comprises one or more selected from the group consisting of polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and polytrimethylene terephthalate (PTT).

9 . The sound absorption and insulation material of claim 1 , wherein the hollow fiber, the low-melting-point composite fiber or the base fiber is arranged perpendicular to a planar direction of the sound absorption and insulation material.

10 . The sound absorption and insulation material of claim 1 , having a noise reduction coefficient (NRC) of 0.799 to 0.830, a sound insulation coefficient of 18 to 22%, and a power-based noise reduction (PBNR) of 43 to 44 dB.

11 . A sound absorption and insulation pad comprising a sound absorption and insulation material of claim 1 .

12 . The sound absorption and insulation pad of claim 11 , having a noise reduction coefficient (NRC) of 0.950 to 1.100.

13 . A vehicle comprising a sound absorption and insulation material of claim 1 .

14 . A vehicle comprising a sound absorption and insulation pad of claim 11 .

15 . A method of manufacturing a sound absorption and insulation material, comprising:
manufacturing a mixed fiber by mixing a hollow fiber, a low-melting-point composite fiber and a base fiber; scutching the mixed fiber using a scutching machine; carding the scutched mixed fiber using a carding machine; orienting the carded mixed fiber in a direction perpendicular to a planar direction; and thermally treating the perpendicularly oriented mixed fiber.

16 . The method of claim 15 , wherein the carding machine is maintained at a feed rate of 160 to 180 RPM (Revolutions Per Minute) and a doffer of 740 to 760 RPM.

17 . The method of claim 15 , wherein the thermally treating the mixed fiber is performed in a hot-air oven at a temperature of 140 to 160° C.

Assignees

• Hyundai Motor Co Ltd
• Kia Motors Corp
• Sam Won Co Ltd
• Toray Advanced Mat Korea Inc

Inventors

• Kim Ji Wan
• Kim Keun Young
• Lee Jung Wook
• Kim Tae Yoon
• Kim Seong Je
• Jo Yong Gu
• Kim Hwang Ki

Classifications

• D04H1/5412 Primary

  sheath-core · CPC title

• D01G13/00

  Mixing, e.g. blending, fibres; Mixing non-fibrous materials with fibres · CPC title

• D01G9/00

  Opening or cleaning fibres, e.g. scutching cotton (scutching flax or like fibres D01B; making cellulose wadding in papermaking machines D21F11/14) · CPC title

• B60R13/0861

  for covering undersurfaces of vehicles, e.g. wheel houses · CPC title

• D01G15/00

  Carding machines or accessories; Card clothing; Burr-crushing or removing arrangements associated with carding or other preliminary-treatment machines (de-burring apparatus or machines operating independently D01B) · CPC title