KR101728063B1 - Noise-preventing material for automobile and method for manufacturing the same - Google Patents

Abstract

The present invention relates to a noise-preventing material for cars and a method for producing the same. More particularly, the present invention relates to a noise-preventing material obtained by supplying polyethylene (PE) powder and a noise-absorbing material to the lower art of a reinforced mixed felt comprising a PET felt to form an integral crude fabric, and molding a predetermined shape of a noise-preventing material by disposing the reinforced mixed felt in a lower mold and disposing the noise-absorbing material in an upper mold while heating the upper mold and cooling the lower mold. The method according to the present invention comprises the steps of: a PET pelt-producing step in which a reinforced mixed felt having a weight of 400-1,100g/m^2 and a thickness of 1-5 mm is supplied; a PE powder-supplying step in which PE powder is supplied to the upper part of the reinforced mixed felt; a noise-absorbing material supplying step in which a noise-absorbing material is supplied to the upper part of the PE powder; a crude fabric-lamination step in which the reinforced mixed felt, PE powder and noise-absorbing material are supplied to a pair of rollers and forming an integral crude fabric by pressurization; and a noise-preventing material molding step in which the laminated crude fabric is supplied to the upper molding space of the upper mold and the lower molding space of the lower mold and applying a pressure of 45-130 tons for 40-120 seconds, while heating the upper mold to 150-230C by supplying electric power to a heating rod and cooling the lower mold to 1-10C by supplying cooling water to a cooling pipe.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a noise-

More particularly, the present invention relates to a noise preventive material for automobiles, and more particularly, to a method of manufacturing a noise preventive material for automobiles, And forming a noise preventive material having a predetermined shape so that the pet felt is positioned in the lower mold while the sound absorbing material is positioned in the upper mold while cooling the lower mold, and a method for manufacturing the same.

Generally, outside noise is introduced into the vehicle interior through various routes to the vehicle in motion. The friction noise between the tire and the ground, the noise generated by the high-temperature and high-pressure combustion gas flow of the exhaust system, and the engine-transmitted noise generated by the engine or transmitted through the air are transmitted to the passenger's ears, .

In general, an engine cover or a hood insulator is used in order to suppress the engine transmission noise, but there is a limitation in removing the engine transmission noise to a desired level by itself.

Accordingly, a sound absorbing material is mounted on the front, the left side, and the floor of the vehicle. For example, a sound absorbing material is installed on a dash panel that separates the engine room from the vehicle room to block noise generated in the engine room. A sound absorbing material is attached to the side panel.

As a material using such a sound absorbing material, usually glass fiber, urethane foam, or felt felt is used. In the case of urethane foam, which is mainly used, the odor is toxic and toxic gas may be generated at the time of an accident due to flammability, and when the foamed material is made of a sound absorbing material, molding is difficult.

Recently, regulations on the environment-friendly factors and the possibility of recycling have been gradually strengthened. Therefore, fiber felt based on thermoplastic resin such as polypropylene (PP) rather than urethane foam and improvement of sound absorption and insulation performance Polyethylene terephthalate (PET) felt is widely used.

With respect to a sound absorbing material containing such a polyethylene terephthalate resin, Korean Patent No. 10-893690 discloses a polyurethane sheet produced by compression molding a waste polyurethane scrap and a PET sheet laminated outside the polyurethane sheet, And proposed a car interior material for ash / tea. However, it is somewhat insufficient to say that it is an environmentally friendly sound absorbing material which can recycle felt, recycle and the like based on a polyurethane sheet which is still difficult to use,

Compressing the waste polyurethane foam using a one-component adhesive to fill the pores can adversely affect the absorption rate and the regulation of volatile organic compounds (VOC).

On the other hand, in order to improve the NVH (Noise, Vibration, Harness) performance of the vehicle according to the acoustic characteristics, a heavy weight and a thick sound absorbing material are mainly used in medium and large luxury cars. In this case, the polyurethane foam reduces the noise the most and improves the quietness of the vehicle. However, as described above, since recycling is not possible, it is not an environmentally friendly material. .

Patent No. 1470478 discloses a Korean patent for preventing such drawbacks. It is proposed that a low-melting polyethylene terephthalate fiber and a regular polyethylene terephthalate fiber are carded and needle-punched to form a first felt layer (Felt layer) and a second felt layer;

Inserting the first felt layer into a lower jig and inserting the second felt layer into an upper jig located above the lower jig;

Inserting the lower jig and the hot plate located at one end of the upper jig into a space between the lower jig and the upper jig;

The lower jig and the upper jig are moved up and down to place the first felt layer and the second felt layer adjacent to each other on the heat plate so that the upper surface of the first felt layer and the lower surface of the second felt layer are brought into contact with the heat plate Indirectly melting by the temperature of < RTI ID = 0.0 >

Drawing the hot plate between the lower jig and the upper jig after indirect melting the first felt layer and the second felt layer; And

And drawing the hot plate and moving the lower jig and the upper jig up and down to press the first and second felted layers which are indirectly melted and to join them together.

However, this conventional technique has a lot of questions as to whether noise can be solved normally because the first and second felt layers are pressed and joined together.

Patent No. 1375442 discloses a laminate comprising a top felt layer and a bottom felt layer containing a low melting point polyethylene terephthalate fiber and a regular polyethylene terephthalate fiber; And

A technique comprising an airlight layer interposed between the upper felt layer and the lower felt layer and containing polypropylene has been proposed.

However, this conventional technique has to form the upper and lower felt layers, respectively, and since the air layer is included between the upper and lower felt layers, the cost increases greatly, .

Particularly, since the conventional sound absorbing material is composed of micro-fine fibers mainly composed of polypropylene, the heat-resistant portion is weak when exposed to the engine room temperature, so that it may be crumbled or crumbled due to severe hardness during long- The temperature of the engine room is 150 ~ 180 ℃, whereas the temperature of the existing micro-plastic is usually 100 ℃.

On the other hand, automobiles are used in various positions such as an engine cover, a hood cover, a dashboard, and a wheel cover for the purpose of noise prevention. However, since they have different structures and shapes, they are complicated in manufacturing process, It has a drawback that the effect on noise prevention is insufficient.

Literature 1. Patent Registration No. 1375442 (Registered on Mar. 11, 2014) Document 2. Patent Registration No. 1470478 (Registered on December 12, 2014) Literature 3. Patent Registration No. 0893690 (Registered on April 04, 2009) Literature 4. Patent Registration No. 1128199 (registered on Mar. 12, 2012)

SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a noise preventing material having a predetermined shape by supplying pe powder and sound absorbing material to a reinforced mixed felt made of pet felt.

Another object of the present invention is to provide a method of manufacturing a composite material having a predetermined shape by supplying a pe powder and a sound absorbing material to a reinforced blend felt made of pet felt to make an integral type of fabric and feeding the fabric between an upper mold for heating and a lower mold for cooling And to form a noise preventing member.

A further object of the present invention is to provide a method of manufacturing a metal mold, which comprises the steps of: feeding a reinforced composite felt made of pet felt to a lower mold for preheating through a preheater and then cooling the peel powder and a sound absorbing material; The object is to mold the ash.

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The present invention relates to a process for producing a reinforced composite felt, which is manufactured to have a weight of 400 to 1,100 g / m 2 and a thickness of 1 to 5 mm;

A pe powder supplying step of supplying pe powder to the upper side of the reinforcing mixing felt;

A sound absorbing material supplying step of supplying a sound absorbing material to an upper side of the pe powder;

A reinforcing mixed felt, a pe powder, and a sound absorbing material are supplied to a pair of rollers to be pressed into a single-piece fabric; And

After the joined fabric is supplied to the upper molding space of the upper mold and the lower molding space of the lower mold, the upper mold is heated to supply power to the heating rod at a temperature of 150 to 230 캜 and the lower mold is heated to 1 to 10 캜 A noise preventing material forming step of forming a noise preventing material by applying a pressure of 45 to 130 tons for 40 to 120 seconds while cooling water is supplied to the cooling pipe; .

In the present invention, the reinforcing mixed felt made of various materials is formed on the pet felt to provide a sufficient strength by reinforcing one reinforcing mixed felt to secure safety, and the pe powder and the sound absorbing material are supplied to the reinforcing mixed felt, The damping material having a predetermined shape is formed between the lower mold to be cooled and the upper mold to be cooled, thereby providing the sound absorbing property sufficiently in the engine cover for an automobile, the hood, the dashboard and the wheel cover have.

Brief Description of the Drawings Fig. 1 is a sectional view
FIG. 2 is a cross-sectional view of a bonded state of each layer showing another embodiment of the present invention
3 is a bottom view of the upper mold according to the present invention,
Fig. 4 is a plan view of the installation state of the lower mold of the present invention
5 is a cross-sectional view showing a state in which the noise preventing member is formed by combining the upper mold and the lower mold of the present invention
Figure 6 is a block diagram illustrating the most preferred embodiment of the present invention.
Figure 7 is a block diagram illustrating another embodiment of the present invention,
8 is a block diagram showing an embodiment in which the noise preventing member of the present invention is molded in a separable shape
9 is a graph for the sound absorption performance test of the present invention
Fig. 10 is a photograph of a sample for sound absorption performance test of the present invention

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

FIG. 1 is a cross-sectional view of a bonded state of each layer showing a preferred embodiment of the present invention, and FIG. 2 is a cross-sectional view of bonded state of each layer showing another embodiment of the present invention.

One of the thermoplastic general-purpose resins is made of PET (polyethylene terephthalate) felt having heat resistance and excellent chemical resistance, or made by needle-punching the PET felt, polypropylene (PP), and LM fiber The mixed felt 11 is molded to prepare a weight of 400 to 1,100 g / m 2.

A sound absorbing material 13 supplied with a PE (polyethylene) powder 12 is conveyed to a lower side of the reinforced mixing felt 11 through a pair of rotating rollers to form a monolithic fabric.

The fabric is made of PET felt, or needle punched with PET felt, PP, polypropylene, and LM fiber to form a reinforced blended felt 11 to prepare a weight of 400 to 1,100 g / m 2.

A sound absorbing material 13 supplied with a sheet layer 14 composed of any one of an aluminum sheet and an LDPE sheet is passed through a pair of rollers rotating on top of the reinforced mixing felt 11, It is molded into an integral type of fabric.

The fabric is supplied to the upper molding space 21 of the upper mold 20 and the lower molding space 31 of the lower mold 30 so that the upper mold 20 is heated and the lower mold 30 is cooled, (10).

The reinforced blended felt 11 is primarily made of polypropylene (PP) felt. The thickness of the reinforced blended felt 11 is 1 to 5 mm. The reinforced blended felt 11 is prepared by blending 40 to 55% of the total weight.

Secondary production of pet (polyethylene terephthalate) and LM fiber (fiber);

45 ~ 55% of the total felt weight, and 38 ~ 42% of the double LM fiber.

PET (polyethylene terephthalate) and LM fiber fabric, which are secondarily manufactured on the first-produced polypropylene (PP) felt, are needle-punched to be reinforced and mixed by binding, 400 to 1,100 g / m 2.

The noise preventing member 20 may be made of any one of 3M pet micro-yarn, pct microfiber and hobis nova-micro, and preferably has a weight of 180-350 g / m 2.

A reinforcing composite felt 11, a peel powder 12 and a sound absorbing material 13 formed by a pair of rollers that are rotated so as to be integrally formed,

A sheet layer 14 made of any one of the reinforced blended felt 11 and the pe powder 12 and an aluminum sheet and an LDPE film and a fabric made of a pair of rollers rotating the sound- And the noise preventing member 10 is formed by feeding the noise preventing member 10 to the outside.

A sheet layer 14 composed of any one of the reinforcing blended felt 11 supplied to the noise preventing member 10, the pe powder 12 or the reinforcing blended felt 11 and the pe powder 12 and the aluminum sheet and the LDPE film, Can be supplied to the lower mold 30 which is automatically put into the oven MC for 180 to 350 ° C for 40 to 90 seconds to cool the same.

FIG. 3 is a bottom plan view of the upper mold according to the present invention, FIG. 4 is a plan view of the lower mold according to the present invention, and FIG. 5 is a cross- To a cross-sectional view showing a state.

The fabric made up of the reinforced blended felt 11, the pe powder 12 and the sound absorbing material 13, the reinforced blended felt 11 and the pe powder 12, the sheet layer 14, and the sound absorbing material 13, (10), which is supplied between the lower mold (20) and the lower mold (30) and has a predetermined shape.

The upper mold 20 has an upper molding space 21 formed therein to have an upper shape of the noise preventing member 10 and a heating rod 22 for heating the entire surface to a uniform temperature at regular intervals And is heated to a temperature of 150 to 230 캜.

A heating rod 22 is provided on the upper side of the upper molding space 21 and an insulator 23 is provided on the upper side of the heating rod 22.

A lower molding space 31 formed to have a lower shape of the noise preventing member 10 is formed in the lower mold 30 and a cooling pipe 32 for cooling the entire surface at a uniform temperature is provided And cooling water is supplied at a temperature of ~ 10 ° C.

The most preferred embodiment of the present invention having such a configuration will be described in detail with reference to the block diagrams and the drawings of FIG. 6, FIG. 7 and FIG.

In the pet felt manufacturing step S10, the reinforcing mixed felt 11 produced so as to have a weight of 400 to 1,100 g / m < 2 > and a thickness of 1 to 5 mm is fed,

And polypropylene (FEP) felts are firstly produced by blending them so as to have a level of 40 to 55% of the total weight.

The poly (ethylene terephthalate) and the LM fiber are produced together after the polypropylene (PP) felt is produced, so that the PET is 45 to 55% of the total felt weight. The dual LM fiber is about 38 ~ 42%, and PET (polyethylene terephthalate) and LM fiber are needle-punched and reinforced by binding.

The pet and LM fiber bonded to the polypropylene (PP) felt are fed to bind the polypropylene felt, reinforced with PET felt and LM fiber bond, and bonded to be weighed to a weight of 400 to 1,100 g / Thereby forming the mixed felt 11.

The pet and the LM fiber are bonded together and the polypropylene felt is fed to the lower side to form the reinforced composite felt 11. [

The reinforced composite felt 11 is provided with a pe powder supplying step S20 and the pee polyethylene powder 12 is supplied to the upper side of the reinforced mixed pile 11 or to the lower side of the sound absorbing material 13 .

The sound absorbing material supplying step S30 is performed such that the pe powder 12 supplied to the upper side of the reinforced mixing felt 11 is located on the lower side and the sound absorbing material 13 is supplied so as to have the size of the reinforcing mixed felt 11 will be.

The sound absorbing material 13 is made of any one of 3M pet micro-fiber, pct micro-fiber and nova-micro fiber, and it is preferable that the sound absorbing material 13 is made of 180-350 g / m 2.

Next, in the tailoring step (S40), the reinforcing mixed felt 11, the pe powder 12 and the sound absorbing material 13 are fed to a pair of rollers, and are pressed together so as to be an integral type fabric.

Next, the joined fabric is supplied to the lower molding space 31 of the lower mold 30 and the upper molding space 21 of the upper mold 20 in the noise preventing molding step (S50), and then the upper mold 20 Is supplied to the heating rod 22 to be heated to 150 to 230 캜 and cooling water is supplied to the cooling pipe 32 so that the lower mold 30 is cooled to 1 to 10 캜, The noise preventing member 10 is molded by applying a pressure of 45 to 130 tons per second.

The pe powder supplying step S20 may be replaced with a pe powder supplying step of feeding the aluminum sheet or the LDPE sheet to the lower side of the pe powder 12 and a sheet layer supplying step S20 '.

The fabric lining step S40 is omitted and the reinforcing blended felt 11 formed in the reinforcing blend pellet manufacturing step S10 is heated to 180 to 350 캜 for 40 to 90 seconds in the oven MC The reinforcing mixed felt preheating step (S40 ') for automatically preheating the preform is performed to feed the lower mold 20.

The present invention is characterized in that an upper mold 20 for heating a noise preventing member 10 in which a sound absorbing material 13 is integrally formed by using a pe powder 12 on one side of a reinforced mixing felt 10 and a lower mold 20 30), it can be used for various noise prevention such as an engine cover, a hood, a dashboard, and a wheel cover by different sizes and shapes.

The noise preventing member 10 improves rigidity by forming the reinforced composite felt 11 into a triple structure such as a polypropylene (PP) felt and a pet and LM fiber so that it is not easily damaged or deformed after being installed, The sound absorbing material 13 installed as the engine is used as an engine cover through an integral structure welded to the reinforcing mixed felt 11 on the entire surface thereof. (180 DEG C or less) generated by the heat generated by the heat source, and various shapes and sizes for noise prevention are provided, thereby providing various applications.

Since the noise preventing member 10 is made of a doubly composed of the reinforced mixing felt 11 and the sound absorbing material 13, a very simple structure that can be easily manufactured through the upper mold 20 to be heated and the lower mold 30 to be cooled It is lighter and consumes less raw material, so it can supply very cheap price.

The results of testing the sound absorption performance by the simple reverberation method (Alpha Cabin) were shown in [Table 1] and [Table 2] below.

Test sample (specimen size 1.2m) part Time Actual weight (kg) One Engene Top Cover

1000g + PET320g 1.735 2 1400g + PET320g 2.385 3 1400g + PET320g 2.115

Test results (sound absorption rate α) 400 500 630 800 1k 1.25k 1.6k 2k 2.5k 3.15k 4k 5k 6.3k 8k 10k One 0.33 0.59 0.74 0.86 1.00 1.06 1.08 1.09 1.04 1.03 1.06 1.05 1.05 1.08 1.17 2 0.36 0.61 0.77 0.90 1.02 1.08 1.09 1.08 1.02 1.00 1.01 0.99 1.02 1.05 1.09 3 0.36 0.64 0.81 0.94 1.07 1.11 1.10 1.09 1.04 1.03 1.03 1.05 1.11 1.11 1.02

9 is a graph showing a sound absorption performance test according to the present invention. As shown through the test sample and test results, it can be confirmed that the sound absorption performance is excellent.

The present invention relates to a method for molding a sound absorbing material integrally with a reinforced compound felt bonded together by punching a polypropylene (PP) felt, a PET felt and an LM fiber by needle punching, and supplying an upper mold for heating and a lower mold for cooling, The present invention provides a very useful invention that reduces cost and eliminates noise generated during operation of the engine and the vehicle.

10: noise preventing member 11: reinforced mixed felt
12: pe powder 13: sound absorbing material
14: sheet layer 20: upper mold
21: upper molding space 22: heating rod
23: insulator 30: lower mold
31: Lower molding space 32: Cooling pipe

Claims (7)

delete delete A pet felt manufacturing step (S10) of supplying a reinforced mixed felt (11) produced so as to have a weight of 400 to 1,100 g / m < 2 > and a thickness of 1 to 5 mm;
A pe powder supplying step (S20) of supplying the pe powder (12) to the upper side of the reinforced mixing felt (11);
A sound absorbing material supplying step (S30) for supplying the sound absorbing material (13) to the upper side of the pe powder (12);
A fabric lapping step (S40) of feeding the reinforcing mixed felt (11), the pe powder (12), and the sound absorbing material (13) to a pair of rollers so as to be integrally formed by pressing; And
The sound absorbing material 13 is inserted into the upper molding space 21 of the upper mold 20 and the upper mold 20 after the reinforcing mixing felt 11 is supplied to the lower molding space 31 of the lower mold 30. [ The cooling water is supplied to the cooling pipe 32 so that the lower mold 30 is cooled to 1 to 10 占 폚 and cooled for 40 to 120 seconds Forming a noise preventing member 10 by applying a pressure of 45 to 130 ton to form a noise preventing member 10; Wherein the method comprises the steps of:
The method of claim 3,
In the pet felt manufacturing step S10, a polypropylene felt is firstly prepared by blending the PET felt to a level of 40 to 55% of the total weight, and 45 to 55% But; The double LM fiber is about 38 to 42%, and PET (polyethylene terephthalate) and LM fiber are needle-punched and the reinforcing blended felt 11 is weighed so as to have a weight of 400 to 1,100 g / And then molding the mixture.
The method of claim 3,
The sound-absorbing material 13 in the sound-absorbing material supply step S30 uses any one of 3M pet micro-fiber, pct micro-fiber, and post-nova-micro fibers and has a weight of 180-350 g / m 2 By weight based on the total weight of the composition.
The method of claim 3,
The pe powder supplying step (S20) is carried out by supplying a pe powder and a sheet layer supplying step (S20 ') for supplying either the aluminum sheet or the LDPE sheet to the upper side of the pe powder (12) A method for manufacturing a noise preventing material.
A pet felt manufacturing step (S10) of supplying a reinforced mixed felt (11) produced so as to have a weight of 400 to 1,100 g / m < 2 > and a thickness of 1 to 5 mm;
A reinforcing mixed felt preheating step (S40 ') for automatically preheating the reinforcing mixed felt (11) at 180 to 350 캜 for 40 to 90 seconds into the oven MC;
A pe powder supplying step (S20) of supplying the pe powder (12) to the upper side of the reinforced mixing felt (11);
A sound absorbing material supplying step (S30) for supplying the sound absorbing material (13) to the upper side of the pe powder (12);
The reinforcing compound felt 11, the pe powder 12 and the sound absorbing material 13 are supplied to the upper molding space 21 of the upper mold 20 and the lower molding space 31 of the lower mold 30, Is supplied to the heating rod 22 to be heated to 150 to 230 캜 and cooling water is supplied to the cooling pipe 32 so that the lower mold 30 is cooled to 1 to 10 캜, (S50) forming a noise preventing member (10) by applying a pressure of 45 to 130 tons per second; Wherein the method comprises the steps of:

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