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Soundproof material using polyurethane foam from car seat and fabrication process thereof

A polyurethane foam and sound-insulating material technology, applied in chemical instruments and methods, vehicle parts, non-woven fabrics, etc., can solve problems such as fiber dust, poor sound-absorbing properties, and poor sound-insulating properties

Inactive Publication Date: 2014-01-15
HYUNDAI MOTOR CO LTD +1
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

However, although PP fiberboard is cheap, its sound absorption characteristics are poor
Moreover, PET felt is heavy, generates fiber dust, and has poor sound insulation properties

Method used

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  • Soundproof material using polyurethane foam from car seat and fabrication process thereof
  • Soundproof material using polyurethane foam from car seat and fabrication process thereof
  • Soundproof material using polyurethane foam from car seat and fabrication process thereof

Examples

Experimental program
Comparison scheme
Effect test

Embodiment approach

[0077] According to another embodiment of the present invention, there is provided a method of manufacturing a sound-insulating material, the method comprising the steps of:

[0078] (a) breaking the PU foam, preferably polyurethane foam from vehicle waste seats, into fine particles;

[0079] (b) by mixing the crushed PU foam obtained in step (a) with polyester-based fibers and low-melting-point polyester-based fibers to produce a sound-absorbing material;

[0080] (c) carding sound-absorbing materials;

[0081] (d) needle-punched sound-absorbing materials;

[0082] (e) thermoforming and cooling the sound-absorbing material, in particular to provide a felt shape;

[0083] (f) To manufacture sound-insulating materials by mixing polyester fibers, low-melting polyester fibers, and PP fibers;

[0084] (g) combing sound-proofing materials;

[0085] (h) needle-punched sound-insulating materials;

[0086] (i) thermoforming and cooling the sound insulation material, in particular...

Embodiment 1

[0100] 10wt% of PET fiber, 10wt% of LM (low melting point) PET fiber, 10wt% of PP fiber, and 20wt% of thermoplastic resin were introduced into 50wt% of Obtained thermosetting polyurethane foam. As a result of this process, at least some thermoplastic resin is injected instead of fibers, which increases the mechanical strength of the product, but results in the mixture being partially coated with molten thermoplastic resin, which reduces the sound-absorbing properties and dimensional stability of the product.

Embodiment 2

[0102] 10wt% PET fiber, 10wt% LM PET fiber, 20wt% PP fiber, and 50g / m 2 The thermoplastic film of ® was incorporated into 50 wt% of thermoset polyurethane foam obtained by crushing PU foam from scrapped vehicle seats into fine particles. The products manufactured by laminating thermoplastic films thereon had better sound insulation properties and higher mechanical strength than those manufactured according to Comparative Examples 1 and 2.

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Abstract

Disclosed is a soundproof material fabricated using recycled polyurethane foam from waste seats and a process of fabricating the same, and more particularly, a soundproof material fabricated by stacking a thermoplastic polymer on a sound absorbing material including recycled polyurethane foam from seats from end-of-life vehicles and a process of fabricating the same. Use of recycled resources provides an eco-friendly impact, reduces manufacturing costs for parts, and allows for improved mechanical rigidity and sound insulating properties. The soundproof material may be applied to various automobile parts such as package trays, luggage coverings, covering shelves and isolation pads.

Description

technical field [0001] The present disclosure relates to a soundproofing material manufactured using recycled polyurethane foam, in particular polyurethane foam recycled from vehicle seats, and a manufacturing method thereof. Background technique [0002] Typically, car seats are made of polyurethane foam, and the weight of the polyurethane foam in each vehicle amounts to about 10kg. Currently, car seats are discarded along with other components of end-of-life vehicles. Although there has been intensive research into recycling technologies for automotive components made of thermoplastic materials, most seat foams, thermoset materials that are difficult to recycle, are sent to landfill or disposed of by burning. This leads to soil pollution and environmental pollution. Furthermore, according to Directive 2000 / 53 / EC of the European Parliament and of the Council on end-of-life vehicles, reuse and recycling of all end-of-life vehicles will be increased to at least 85% and heat...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): B32B27/04B32B27/08B32B38/04
CPCB32B27/40C08K7/02B32B2305/022C08G2350/00B32B2307/102C08J9/0085B32B5/18C08J2467/02B32B2375/00B32B2305/20C08J2400/22B32B38/08B32B27/36C08L67/00B32B2305/70B32B27/08C08J2300/30C08J9/33C08J2375/04C08L75/04C08G2101/00B32B27/02B32B27/04B32B5/06B32B27/065B32B27/12B32B27/281B32B27/286B32B27/30B32B27/306B32B27/308B32B27/34B32B2260/021B32B2260/046B32B2262/0253B32B2262/0276B32B2262/0284B32B2266/0278B32B2272/00B32B2605/00C08J2323/12B60R13/08C08J5/04D04H1/413D04H1/485
Inventor 具洪谟张宰银梁埈滈李东俊
Owner HYUNDAI MOTOR CO LTD
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