Method for manufacturing soundproofing board part having excellent sound absorption performance and soundproofing board part manufactured by the same

Patent metadata

Field	Value
Publication number	US-9805706-B2
Application number	US-201514689256-A
Country	US
Kind code	B2
Filing date	Apr 17, 2015
Priority date	Jul 30, 2014
Publication date	Oct 31, 2017
Grant date	Oct 31, 2017

Abstract

Disclosed is a method for manufacturing a soundproofing board part having improved sound absorption performance. The soundproofing board part is manufactured by using, as a material, a recycled soundproofing material which contains a polyurethane foam having excellent sound absorption performance and impact resilience during the press molding; and by producing a sound absorption part on the back surface of the soundproofing board part through a remolding processing method. Also disclosed is a soundproofing board part manufactured by the method.
Accordingly, sound absorption performance of the soundproofing board part is improved by about 20% or greater, manufacturing cost thereof may be reduced by recycled resources utilizing waste sheets, and manufacturing process may be simplified compared the related art.

First claim

What is claimed is:

1. A method for manufacturing a soundproofing board part having improved sound absorption performance, comprising:
preparing a recycled soundproofing material manufactured from a ground polyurethane (PU) foam product obtained by grinding waste sheets; and
molding the recycled soundproofing material in a preheating die and a molding die which are configured to include a sound absorption part shape with a checkered structure to form a sound absorption part on a back surface of the soundproofing board part,
wherein the molding die is a die in which a shape of the sound absorption part which is the same as that of the preheating die is introduced.

2. The method of claim 1 , wherein the sound absorption part shape is a concave shape and a convex shape of the checkered structure that is selected from a tetragonal shape, a pentagonal shape, a hexagonal shape, or a modified shape thereof, and
the soundproofing board part has a basic thickness of about 1.6 to 2 mm, and comprises the sound absorption part comprising a volume part having a thickness of about 3 to 5 mm.

3. The method of claim 2 , wherein the volume part is configured to absorb sound.

4. The method of claim 2 , wherein the volume part has a tetragonal shape, a pentagonal shape, a hexagonal shape, or a modified shape thereof.

5. The method of claim 2 , wherein the sound absorption part having the basic thickness part of 1.6 to 2 mm in the soundproofing board part has a tetragonal shape, a pentagonal shape, a hexagonal shape, or a modified shape thereof.

6. The method of claim 1 , comprising:
(i) preparing a soundproofing material as a two-layer structure by laminating a natural fiber-reinforced soundproofing material and the recycled soundproofing material;
(ii) preheating the laminated soundproofing material in a preheating mold;
(iii) laminating a finished non-woven on the laminated soundproofing material which is preheated in step (iii); and
(iv) forming, in the molding die, the sound absorption part on the soundproofing board part by performing cold molding on the soundproofing material of step (iii) including the natural fiber-reinforced soundproofing material, the recycled soundproofing material, and the finished non-woven fabric,
wherein the molding die in step (iv) is a die in which a shape of the sound absorption part which is the same as that of the preheating die in step (ii) is introduced.

7. The method of claim 1 , comprising:
(i) preparing the recycled soundproofing material;
(ii) preheating the recycled soundproofing material in a preheating mold;
(iii) laminating a finished non-woven fabric on the soundproofing material which is preheated in step (ii); and
(iv) forming, in the molding die, the sound absorption part on the part by performing cold molding on the soundproofing material of step (iii) including the recycled soundproofing material and the finished non-woven fabric,
wherein the molding die in step (iv) is a die in which a shape of the sound absorption part which is the same as that of the preheating die in step (ii) is introduced.

8. The method of claim 6 , wherein the natural fiber-reinforced soundproofing material in step (i) is manufactured by mixing an amount of about 40 to 50 wt % of polypropylene (PP); an amount of about 40 to 50 wt % of kenaf; and an amount of about 0 to 20 wt % of polyethylene terephthalate (PET), based on the total weight of the natural fiber-reinforced soundproofing material; and by a process comprising carding, lamination, needle punching, and thermal-roller processes.

9. The method of claim 6 , wherein the recycled soundproofing material is manufactured by mixing an amount of about 40 to 60 wt % of the ground polyurethane (PU) foam product; an amount of about 10 to 20 wt % of a low melting point polyester-based fiber; an amount of about 10 to 20 wt % of polypropylene (PP); and an amount of about 10 to 20 wt % of kenaf, based on the total weight of the recycled soundproofing material; and by a process comprising carding, lamination, needle punching, and thermal-roller processes.

10. The method of claim 7 , wherein the recycled soundproofing material is manufactured by mixing an amount of about 40 to 60 wt % of the ground polyurethane (PU) foam; an amount of about 10 to 20 wt % of a low melting point polyester-based fiber; an amount of about 10 to 20 wt % of polypropylene (PP); and an amount of about 10 to 20 wt % of kenaf, based on the total weight of the recycled soundproofing material; and by a process comprising carding, lamination, needle punching, and thermal-roller processes.

11. The method of claim 9 , wherein the recycled soundproofing material further comprises an amount of about 0 to 20 wt % of glass fiber, based on the total weight of the recycled soundproofing material.

12. The method of claim 9 , wherein the ground polyurethane (PU) foam product is ground to have a size of about 3 mm or less.

13. The method of claim 10 , wherein the recycled soundproofing material further comprises an amount of about 0 to 20 wt % of glass fiber, based on the total weight of the recycled soundproofing material.

14. The method of claim 10 , wherein the ground polyurethane (PU) foam product is ground to have a size of about 3 mm or less.

15. The method of claim 8 , wherein the kenaf is jute, flax (Lien), hemp, or ramie.

16. The method of claim 10 , wherein the kenaf is jute, flax (Lien), hemp, or ramie.

17. The method of claim 6 , wherein the preheating in step (ii) is performed at a temperature of about 190 to 220° C. for about 60 to 100 seconds in the preheating die.

18. The method of claim 7 , wherein the preheating in step (ii) is performed at a temperature of about 190 to 220° C. for about 60 to 100 seconds in the preheating die.

19. The method of claim 6 , wherein the sound absorption part shape of the preheating die is a concave shape and a convex shape of the checkered structure that is selected from a tetragonal shape, a pentagonal shape, a hexagonal shape, or a modified shape thereof.

20. The method of claim 7 , wherein the sound absorption part shape of the preheating die is a concave shape and a convex shape of the checkered structure that is selected from a tetragonal shape, a pentagonal shape, a hexagonal shape, or a modified shape thereof.

21. The method of claim 6 , wherein the sound absorption part shape is a concave shape and a convex shape of the checkered structure that is selected from a tetragonal shape, a pentagonal shape, a hexagonal shape, or a modified shape thereof.

22. The method of claim 7 , wherein the sound absorption part shape is a concave shape and a convex shape of the checkered structure that is selected from a tetragonal shape, a pentagonal shape, a hexagonal shape, or a modified shape thereof.

23. The method of claim 6 , wherein the sound absorption part formed on the back surface of the soundproofing board part in step (iv) has a basic thickness of about 1.6 to 2 mm through the molding process, and comprises a volume part having a thickness of about 3 to 5 mm.

24. The method of claim 7 , wherein the sound absorption part formed on the back surface of the soundproofing board part in step (iv) has a basic thickness of about 1.6 to 2 mm through the molding process, and comprises a volume part having a thickness of about 3 to 5 mm.

25. The method of claim 23 , wherein the volume part is configured to absorb sound using a tetragonal shape, a pentagonal shap

Assignees

• Hyundai Motor Co Ltd
• Kia Motors Corp

Inventors

• Koo Hong Mo
• Chang Jae Eun
• Lee Dong Jun
• Jeong Kie Youn
• Park Bong Hyun
• Joo Kil Bu
• An Boo Youn

Classifications

• B60R13/08

  Insulating elements, e.g. for sound insulation {(sound insulating linings for trains B61D17/185; drivers' cabs for load-carrying vehicles insulated against vibrations or noise B62D33/0604; thermal or acoustic insulation of engines F02B77/11; damping of sounds using compensation by electro-acoustic methods G10K11/178)} · CPC title

• B60R13/0268

  Rear parcel liners (used as luggage covering means B60R5/044) · CPC title

• B60R5/044

  luggage covering means, e.g. parcel shelves · CPC title

• B32B2605/003

  Interior finishings · CPC title

• B32B2605/00

  Vehicles · CPC title