KR101082129B1 - Noise absortion material for vehicle by recycling poly urethane foam and Manufacturing method thereof - Google Patents

Abstract

The present invention relates to a sound absorbing and insulating material for automobiles that recycled waste polyurethane foam, and to a method of manufacturing the same. More specifically, the waste polyurethane foam scrap, which is a porous material, is adhered to an olefinic powder or water-soluble EVA on its surface, and then polyethylene. Waste Polyurethane Foam Formed to Desired Product Shape by Dispersing Between Terephthalate Fibers, Laminating and Heating to Prepare Plush Polyethylene Terephthalate Fabric, Preheating the Prepared Plush Polyethylene Terephthalate Fabric, and Compressing with Mold It relates to a sound absorbing and insulating material for automobiles and a method of manufacturing the same.
According to the present invention, it is possible to recycle the waste urethane foam generated as industrial waste, it is possible to reduce the production cost of the sound absorbing and insulating material for automobiles, as well as to improve the environment.

Description

Noise absortion material for vehicle by recycling polyurethane foam and Manufacturing method

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sound absorbing and insulating material for automobiles that recycles waste polyurethane foam, and to a method for manufacturing the same. More specifically, waste polyurethane foam scrap, which is a porous material, is disposed in the pores of the surface thereof with olefinic powder or ethylene vinyl acetate. (Ethylenen Vinyle Acetate) (hereinafter referred to as “water-soluble EVA”) is then distributed between polyethylene terephthalate fibers, laminated and heated to fabricate a sound absorbing and insulating material for automobiles, and then fabricating the sound absorbing and insulating material for the automobile. The present invention relates to a sound absorbing and insulating material for automobiles that recycle waste polyurethane foam formed into a desired shape by heat compression using the same, and a method of manufacturing the same.

Generally, in the automobile field, sound absorbing and insulating materials are used to prevent noise generated from the outside of a vehicle from entering a vehicle interior, and as such sound absorbing and insulating material, polyethylene terephthalate (hereinafter referred to as “PET”). ) Regular resin having high melting point property and PET having low melting point (hereinafter referred to as "LM PET") are mixed and spun at a certain ratio to produce a plush PET fabric, and the plush PET fabric is made into a constant shape. A molded polyurethane-based sound absorbing material (hereinafter referred to as " PET-based sound absorbing material ") and a polyurethane foam molded into a predetermined shape by foaming polyurethane were used.

However, in general, the PET-based sound absorbing material requires a certain ratio of LM PET, which serves as a binder in the process of forming into a required shape. Since the LM PET is expensive compared to regular PET, its manufacturing cost is high. there was.

In addition, the polyurethane foam sound absorbing material remains a residue, which is a residue generated in the process of manufacturing a certain shape as an automotive part, and such polyurethane foam residue is incinerated as industrial waste because there is no proper recycling method, and thus the treatment accordingly In addition to the cost, there was a problem of causing air pollution by exhaust gas emission due to incineration.

In order to solve the above-mentioned problems, a sound absorbing material for automobiles is formed by compression molding the waste polyurethane foam pieces surface-treated with a mixture of polyol and methylene chloride between layers and layers of regular PET fibers in a homogeneously distributed state. It was.

The prior art uses a waste polyurethane foam piece surface-treated with a mixture of polyol and methylene chloride instead of LM PET, which acts as a binder, but this technology uses a mixture of solvents in the manufacturing process to volatilize a safe environment. There is a problem that the shape is deformed after the automobile sound absorbing material is molded due to a decrease in the adhesive force of the polyol at a high temperature.

The present invention is a problem of the conventional PET-based sound absorbing material, which is a problem of the prior art, and the polyurethane foam residue is incinerated as industrial waste because there is no suitable recycling method is not only a treatment cost, but also according to the incineration exhaust gas It is an object of the present invention to provide a sound absorbing and insulating material for automobiles that recycled waste polyurethane foam, and a method of manufacturing the same.

The sound absorbing and insulating material for automobiles recycling the waste polyurethane foam according to the present invention for achieving the above object is a waste polyurethane foam scrap, which is a porous material, is attached to the surface of the olefin powder or water-soluble EVA and then between the PET fibers After distribution and lamination, it is heated to produce a plush PET fabric, and after preheating the produced plush PET fabric, it is formed into a desired product shape by compression using a mold.

In particular, the waste polyurethane foam scrap has a diameter of 3 to 8 mm, and the weight% may be 5 to 50% of the total weight of the sound absorbing and insulating material.

In addition, a sound insulation layer formed of hard PET or heavy layer (water-soluble EVA, PVC, TPE, etc.) material may be further formed on one or both sides of the sound absorbing and insulating material for automobiles recycled waste polyurethane foam.

On the other hand, a method for producing a sound absorbing and insulating material for automobiles recycled waste polyurethane foam according to the present invention a first step of attaching the olefin-based powder or water-soluble EVA to the surface of the waste polyurethane foam scrap; A second step of fabricating a plush PET fabric by uniformly dispersing a predetermined amount of waste polyurethane foam scrap attached to the surface of the olefin-based powder or water-soluble EVA and laminating it between PET fibers and heating it to a predetermined temperature in an oven; And a third step of pre-heating the plush PET fabric to a predetermined temperature and compressing it into a mold to manufacture a sound absorbing and insulating material for automobiles.

According to the present invention has the following effects.

First, while lowering the LM PET weight ratio, which is a high-priced component of PET-based sound absorbing materials, to less than half (less than 12%) from the existing (30-40%), instead, recycled waste urethane foam, which is to be disposed of, is absorbed for automobiles. Since the manufacturing cost of the sound absorbing and insulating material for automobiles, there is an effect that can be much lower than the manufacturing cost of the normal PET-based sound absorbing material.

Second, in the case of disposal, it is possible to recycle waste polyurethane foam that causes treatment costs and environmental pollution as a material of sound absorbing and insulating material for automobiles, thereby preventing environmental pollution and reducing waste disposal costs.

1 is a flow chart for explaining a method for manufacturing a sound absorbing and insulating material for automobiles according to the present invention.
Figure 2 is a cross-sectional view showing a cross-section of the plush PET fabric of an embodiment manufactured in the second step (S200) of the method for manufacturing a sound absorbing and insulating material for automobiles according to the present invention.
3 is a perspective view showing a dash insulator which is a sound absorbing and insulating material for an automobile as an embodiment manufactured by the method for manufacturing a sound absorbing and insulating material for a vehicle according to the present invention.
Figure 4 is a cross-sectional view showing a cross-sectional view of a vehicle sound absorbing and insulating material is further formed with a sound insulation layer made of a heavy layer material on the upper surface of the cotton wool PET fabric as an embodiment manufactured by the method for manufacturing a vehicle sound absorbing and insulating material according to the present invention.
Figure 5 is a graph showing the sound insulation performance results measured for each of Examples 1, 2, 3 and Comparative Examples according to the present invention.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. Prior to this, terms or words used in the present specification and claims should not be construed as being limited to the common or dictionary meanings, and the inventors should properly explain the concept of terms in order to best explain their own invention. Based on the principle that can be defined, it should be interpreted as meaning and concept corresponding to the technical idea of the present invention.

Therefore, the embodiments described in the specification and the drawings shown in the drawings are only the most preferred embodiments of the present invention and do not represent all of the technical idea of the present invention, various equivalents that may be substituted for them at the time of the present application It should be understood that there may be water and variations.

The sound absorbing and insulating material for automobiles that recycled waste polyurethane foam according to the present invention is a waste polyurethane foam scrap, which is a porous material, is adhered to an olipine-based powder or water-soluble EVA and then distributed between PET fibers and laminated By producing a plush PET fabric, it is characterized in that it is formed in the desired product shape by compressing using a mold after preheating the produced plush PET fabric.

The sound absorbing and insulating material for automobiles according to the present invention will be described in more detail together with the manufacturing method thereof. 1 is a flowchart for explaining a method for manufacturing a sound absorbing and insulating material for a vehicle according to the present invention, as shown in FIG. 1, a method for manufacturing a sound absorbing and insulating material for a vehicle according to the present invention is performed in three steps as follows.

A first step of attaching the olefin-based powder or water-soluble EVA to the surface of the waste polyurethane foam scrap; A second step of fabricating a plush PET fabric by uniformly dispersing a predetermined amount of waste polyurethane foam scrap attached to the surface of the olefin-based powder or water-soluble EVA and laminating it between PET fibers and heating it to a predetermined temperature in an oven; And a third step of pre-heating the plush PET fabric to a predetermined temperature and compressing it into a mold to manufacture a sound absorbing and insulating material for automobiles.

The first step (S100) is a step of attaching the olefin-based powder or water-soluble EVA to the surface of the waste polyurethane foam scrap. Here, the waste polyurethane foam scrap is formed by grinding waste urethane having a density of 50 to 130 kg / m 3 to have a diameter of 3 to 8 mm for sound absorbing and insulating performance. The waste polyurethane foam scrap and the olefin-based powder thus formed are stirred and mixed at 160 to 170 ° C. for 20 to 30 minutes at a ratio of 7: 3 to 8: 2, and then cooled, or the water-soluble EVA is diluted with water to waste polyurethane. The waste polyurethane foam scrap is sprayed so that the ratio of foam scrap and water-soluble EVA is 7: 3-8: 2, and then dried for water evaporation. At this time, the olefin-based powder or water-soluble EVA is easily attached to the surface of the polyurethane foam, which is a porous material, and thus the polyurethane foam scrap having the olefin-based powder or water-soluble EVA attached to the surface is formed in the third step described later. Even after being molded into a predetermined shape through the step, the PET fiber functions as a binder to prevent the PET fiber from being restored to its original shape again. That is, the olefin-based powder or the water-soluble EVA attached to the surface of the polyurethane foam scrap combines the PET fiber and the polyurethane foam scrap with adhesive force to prevent the PET fiber from being restored after compression molding to a certain shape. And since the polyurethane foam is a porous material can easily adsorb fine particles such as powder or water-soluble EVA to the pores formed on the surface has a condition that the olefin-based powder or water-soluble EVA can be easily attached to the surface.

In the second step (S200), in the first step (S100), the waste polyurethane foam scrap having the olefin-based powder or the water-soluble EVA adhered to the surface is uniformly dispersed and laminated between PET fibers, and then heated to a predetermined temperature in an oven. It is a step of producing a cotton PET fabric.

At this stage, PET fiber and waste poly are uniformly distributed in a state in which a predetermined amount of olefin-based powder or water-soluble EVA is attached to the surface of the spun PET fiber by spinning the PET with a card machine. Urethane foam scraps are laminated to a thickness of 350 to 500 mm. Next, the laminated PET fiber and the waste polyurethane foam scrap are heated in an oven at 150 to 170 ° C. for 30 seconds to 3 minutes, and then cooled to prepare a plush PET fabric. In this case, the plush PET fabric is a sound absorbing and insulating material for automobiles, and is formed in the range of 20 to 30 mm in consideration of performance and weight requirements, and the size of the waste polyurethane foam scrap is difficult to be laminated with PET fibers when the diameter is larger than 8 mm. If it is less than 3 mm, it is difficult to produce a scrap, so the size of the waste polyurethane foam scrap is preferably 3 to 8 mm in diameter. And if the weight ratio of the waste polyurethane foam scrap is less than 5% of the total weight of the plush PET fabric, the binder function is not sufficient, if greater than 50% the product is returned to its original shape after molding in the next step (S300) to be described later Since the weight ratio of the waste polyurethane foam scrap is appropriate, 5 to 50% of the total weight of the silk PET fabric is appropriate, and thus, the olefinic powder or the water-soluble EVA is 2 to 30% of the total weight of the silk PET fabric. And PET fibers account for 20 to 93% of the total weight of the plush PET fabric. Figure 2 is a cross-sectional view showing a cross-sectional view of the plush PET fabric of an embodiment manufactured in the second step (S200), the plush PET fabric 10 is laminated PET fibers 11 and the waste polyurethane homogeneously distributed therebetween. It is formed of foam scrap 12.

The third step (S300) is a step of forming and manufacturing a sound absorbing and insulating material for automobiles by pre-heating the plush PET fabric manufactured in the second step (S200) to a predetermined temperature and then compressing it into a mold. At this stage, pre-warp the plush PET fabric at 220 ~ 280 ℃ for 30 seconds to 3 minutes, and press and place the upper and lower molds of the mold formed in the shape corresponding to the upper and lower surfaces of the desired product, respectively, and pressurize the sound absorbing and insulating material for automobiles. Manufacture. 3 is a perspective view of a vehicle sound insulation material of an embodiment manufactured in the third step (S300), where the vehicle sound insulation material 20 is in a dash panel that separates the interior of the car from the engine room which is the space where the engine of the vehicle is installed The thing manufactured with the dash insulator which is a sound absorbing and insulating material adhered is shown.

Meanwhile, in order to further improve sound insulation performance, a sound insulation layer formed of a heavy layer material may be further formed on one or both sides of the upper and lower sides of the plush PET fabric. Here, after laminating the plush PET fabric and the heavy layer, preheat it for 30 seconds to 3 minutes at 220 ~ 280 ℃, and then press and place between the upper and lower molds of the mold where the shape corresponding to the upper and lower surfaces of the desired product is intaglio. A sound absorbing and insulating material is manufactured. The heavy layer is made of hard PET, poly vinyl chloride, ethylene vinyl acetate, etc., and has a high soundproofing performance. Figure 4 is a cross-sectional view showing a cross-sectional view of the sound absorbing and insulating material for automobiles further formed with a sound insulation layer made of heavy layer material on the upper surface of the plush PET fabric as an embodiment manufactured in this step, wherein the sound absorbing and insulating material 30 for automobiles It is formed of a PET material layer 31 and a sound insulation layer 32 made of a heavy layer material.

Embodiment of the Invention

EMBODIMENT OF THE INVENTION Hereinafter, embodiment of the sound absorbing and insulating material for automobiles of this invention is described with reference to an Example and a comparative example.

Example 1

In Example 1 of the sound absorbing and insulating material for automobiles of the present invention, the waste polyurethane foam was pulverized to have a diameter of 3 to 8 mm to make a scrap, and the waste polyurethane foam scrap and the olefin powder were 160 to 77:23 weight ratio. After stirring for 30 minutes at room temperature, the mixture was cooled and then cooled. Then, the ratio of the weight of PET fiber and the mixed weight of waste polyurethane foam scrap and olefin powder in a card machine was 61:39 (at this time, regular PET fiber). And LM PET fiber weight ratio is 49:12) After laminating PET fiber and waste polyurethane foam scrap, it was heated in an oven at 160 ° C. for 1 minute and then cooled to prepare a plush PET fabric. Further, the water-soluble EVA was sprayed on the waste polyurethane foam scrap so that the ratio of the waste polyurethane foam scrap and the water-soluble EVA was 77:23 weight ratio, and then cooled by drying at 160 ° C for 10 minutes. Next, the ratio of the weight of PET fiber to the mixed weight of waste polyurethane foam scrap and water-soluble EVA in a card machine is 61:39 (when the ratio of regular PET fiber and LM PET fiber is 49:12. ) PET fiber and waste polyurethane foam scraps were laminated and heated in an oven at 160 ° C. for 1 minute and then cooled to prepare a plush PET fabric. A test specimen was prepared at 0.84 m, wherein the thickness of the test specimen was 25 mm and a unit weight was 1200 g / m 2.

Example 2

In Example 2 of the sound absorbing and insulating material for automobiles of the present invention, the waste polyurethane foam was pulverized to have a diameter of 3 to 8 mm to make a scrap. Next, the waste polyurethane foam scrap and the olefin powder were 160 to 77:23 weight ratio. After stirring for 30 minutes at room temperature, the mixture was cooled and then cooled. Then, the ratio of the weight of PET fiber and the mixed weight of waste polyurethane foam scrap and olefin powder in a card machine was 48:52 (at this time, regular PET fiber). And LM PET fiber weight ratio is 38:10) After laminating PET fiber and waste polyurethane foam scrap, it was heated at 160 ° C for 1 minute in an oven and cooled to prepare a silk PET fabric. Further, the water-soluble EVA was sprayed on the waste polyurethane foam scrap so that the ratio of the waste polyurethane foam scrap and the water-soluble EVA was 77:23 weight ratio, and then cooled by drying at 160 ° C for 10 minutes. Next, the ratio of the weight of PET fiber and the mixed weight of waste polyurethane foam scrap and water-soluble EVA in a card machine is 48:52 (when the ratio of regular PET fiber and LM PET fiber is 38:10. ) PET fiber and waste polyurethane foam scraps were laminated and then heated in an oven at 160 ° C. for 1 minute and then cooled to prepare a plush PET fabric. Next, for the sound absorbing and insulating performance test, the plush PET fabric was prepared with test specimens each having a width and width of 0.84 m, wherein the thickness of the test specimen was 25 mm and the unit weight was 1200 g / m 2.

≪ Example 3 >

In Example 3 of the sound absorbing and insulating material for automobiles of the present invention, the waste polyurethane foam was pulverized to have a diameter of 3 to 8 mm to make a scrap. Next, the waste polyurethane foam scrap and the olefin powder were 160 to 77:23 weight ratio. After stirring for 30 minutes at room temperature, the mixture was cooled and then cooled. Then, the ratio of the weight of the PET fiber and the mixed weight of the waste polyurethane foam scrap and the olefin powder in the card machine was 35:65 (at this time, the regular PET fiber) And LM PET fiber weight ratio is 28: 7) After laminating PET fiber and waste polyurethane foam scrap, it was heated at 160 ° C. in an oven for 1 minute and then cooled to prepare a plush PET fabric. Further, the water-soluble EVA was sprayed on the waste polyurethane foam scrap so that the ratio of the waste polyurethane foam scrap and the water-soluble EVA was 77:23 weight ratio, and then cooled by drying at 160 ° C for 10 minutes. Next, the ratio of the weight of PET fiber to the mixed weight of waste polyurethane foam scrap and water-soluble EVA in a card machine is 35:65 (the weight ratio of regular PET fiber and LM PET fiber is 28: 7). ) PET fiber and waste polyurethane foam scraps were laminated and then heated in an oven at 160 ° C. for 1 minute and then cooled to prepare a plush PET fabric. Next, for the sound absorbing and insulating performance test, the plush PET fabric was prepared with test specimens each having a width and width of 0.84 m, wherein the thickness of the test specimen was 25 mm and the unit weight was 1200 g / m 2.

Comparative Example

The comparative example is a known method by weight ratio of regular PET fiber and LM PET fiber 60 ~ 70: 30 ~ 40%, thickness of 25mm and weight of 1200g / ㎡ test dog PET with a vertical length of 0.84m each It was prepared by.

A summary of the above is shown in Table 1 below. And Examples 1, 2, 3 and Comparative Examples were prepared in the state of plush PET fabric which is a state that is taken as a sample of a normal test in the sound insulation performance test described below.

division First embodiment Second Embodiment Third embodiment Comparative example
Furtherance
Regular PET Fiber (wt%) 49 38 28 60-70 LM PET Fiber (wt%) 12 10 7 30 to 40 Waste Polyurethane Foam (wt%) 30 40 50 Binder (Olefin Powder, Water Soluble EVA) (wt%) 9 12 15
Properties Thickness (mm) 25 25 25 25 Unit weight (g / ㎡) 1200 1200 1200 1200

<Sound insulation performance test>

The sound insulation performance test was measured for the above Examples 1, 2, and 3 and Comparative Examples using APAMAT II (product of RIETER, a Swiss company), which is an automobile sound-absorbing and insulating material NVH (Noise and Vibration and Harshness) performance test equipment. . Here, the test frequency range was 100 kHz ~ 10 kHz range, and the sound insulation performance test result was compared with calculating the TL (Transmission Loss) value, and the larger the TL (Transmission Loss) value, the better the sound insulation performance.

<Sound insulation performance test result>

Figure 5 is a graph showing the sound insulation performance results measured for each of Examples 1, 2, 3 and Comparative Examples according to the present invention. Referring to FIG. 5, sound insulation performances of Examples 1, 2, and 3 and Comparative Examples are generally equivalent in the frequency range 100 Hz to 10 Hz.

In the low frequency section, 100 kHz to 500 kHz, noise is reduced by structure-borne noise such as booming noise generated by engine vibration, intake and exhaust vibration resonating with the vehicle body. Since attaching does not contribute to the body stiffness reinforcement, the effect of improving the sound insulation performance is minimal.

However, if the frequency range is 500 kHz or more, the noise is air-borne noise such as engine noise introduced into the cabin from a noise source such as an engine, and the sound-absorbing sound absorbing material effectively blocks air-borne noise transmitted by the air. When the sound insulation material is attached, the improvement effect of sound insulation is shown as the test result.

<Evaluation of sound insulation test result>

The sound insulation performance test results can be evaluated as follows.

The comparative example shows that the sound insulation performance is excellent mainly in the high frequency region of 2.5 kHz or more in the frequency range.

In Examples 1, 2 and 3, since the polyurethane foam scrap having excellent sound insulation performance in the low frequency region is included in the frequency range of 2.5 Hz or less, the sound insulation performance in the low frequency region of 2.5 Hz or less is compared with that of the comparative example. At the same level, but in the high frequency region of 2.5 kHz or more, the voids are generated in the PET fiber and the polyurethane foam scrap and the interface, and the sound insulation performance is slightly lowered in comparison with the comparative example.

However, in Examples 1, 2, and 3, the TL (Transmission Loss) value is 8 to 10 dB even in the high frequency range of 2.5 dB or more. In general, when the TL (Transmission Loss) value is 5 dB or more, it functions as a sound absorbing and insulating material for automobiles. Considering that it can be seen that Examples 1, 2, and 3 have sufficient effects in terms of sound insulation performance so that they can be used as sound absorbing and insulating materials for automobiles not only in the region of 500 Hz to 2.5 Hz but also in the high frequency region of 2.5 Hz or more.

10, 30; Sound absorbing and insulating material for automobile that recycled waste polyurethane foam
11; PET fiber
12; Waste Polyurethane Foam Scrap
20; Dash insulator made of sound absorbing and insulating material for automobile that recycled waste polyurethane foam
31; Plush PET Fabric
32; Sound insulation layer made of heavy layer material

Claims (5)

delete The waste polyurethane foam scrap, which is a porous material, is attached to the surface of olefinic powder or water-soluble EVA, then distributed between PET fibers, laminated, and then heated and cooled to produce a plush PET fabric. In the sound absorbing and insulating material for automobiles in which waste polyurethane foam formed into a desired product shape by recycling using a mold after preheating is recycled,
The waste polyurethane foam scrap has a diameter of 3 to 8 mm, the weight percent of the waste polyurethane foam scrap is 5 to 50% of the total weight of the sound absorbing and insulating material for automobiles in which the waste polyurethane foam is recycled, and the olefin powder Alternatively, the weight percent of the water-soluble EVA is 2 to 15% of the total weight of the vehicle sound absorbing and insulating material in which the waste polyurethane foam is recycled, and the weight percent of the PET fiber is 35 to the total weight of the sound absorbing and insulating material for the car in which the waste polyurethane foam is recycled. Sound absorbing and insulating material for automobile which recycled 93% of waste polyurethane foam. delete delete Attaching an olefinic powder or water-soluble EVA to the surface of the waste polyurethane foam scrap; Manufacturing a plush PET fabric by uniformly dispersing the waste polyurethane foam scrap attached to the surface of the olefinic powder or water-soluble EVA uniformly between PET fibers, and then heating them at a predetermined temperature in an oven; And pre-heating the plush PET fabric to a predetermined temperature and compressing the mold with a mold to form a sound absorbing and insulating material for automobiles, wherein the weight ratio of the olefin-based powder or the water-soluble EVA attached to the waste polyurethane foam scrap is 7: 3 to 8: The method for producing a sound absorbing and insulating material for a vehicle recycled waste polyurethane foam, characterized in that 2.

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