Sound-absorbing and sound-insulating module for vehicle

Abstract

A sound-absorbing and sound-insulating module for a vehicle includes a perforated plate defining a plurality of apertures, a sound-absorbing material that is porous and disposed on the perforated plate, and a sound-insulating material disposed on the sound-absorbing material. The perforated plate, the sound absorbing material and the sound insulating material are sequentially combined. The diameter of the apertures, the number of apertures, and the distance between the apertures are determined based on the noise frequency band, thereby efficiently responding to various frequency bands of noise generated by one or more portions of a particular component of the vehicle.

Description

Technical Field

[0001] The present invention relates to a sound absorbing and insulating module for a vehicle, and more particularly, to a technology related to a sound absorbing and insulating module for a vehicle capable of effectively responding to noise of various frequency bands in each portion of a specific component. Background Art

[0002] Vehicles have various noise sources such as tires, engine, transmission, motor, inverter, road noise, and wind noise.

[0003] In order to effectively absorb and isolate these noises, various sound absorption and sound insulation systems are applied throughout the vehicle, such as partition walls, wheel arches, body insulators, interior vibration isolation pads and active noise control.

[0004] For example, the sound absorption and sound insulation system may include a combination of porous sound absorption materials and sound insulation materials, and in order to respond to a frequency component that causes noise in a specific part (a motor sequence component, an inverter specific component, a resonant frequency component of a specific part, etc.), inefficient countermeasures such as adding a sound absorption material to a part or increasing the thickness of the overall sound absorption and sound insulation material have been applied.

[0005] In some cases, conventional sound absorbing and sound insulating systems may have the disadvantages of increased assembly costs due to additional sound absorbing materials, and increased weight and cost due to increased thickness of the overall sound absorbing and sound insulating materials, and particularly have the disadvantage of not being able to effectively respond to noises of various frequency bands in each portion of a specific component. Summary of the invention

[0006] The present invention is directed to providing a sound absorbing and insulating module for a vehicle including a perforated plate formed with a plurality of holes, which can effectively respond to noise of various frequency bands in each portion of a specific component, and in particular, make the entire sound absorbing and insulating system thinner, thereby reducing its weight and cost.

[0007] According to one aspect of the subject matter described herein, a sound absorbing and insulating module for a vehicle includes a perforated plate defining a plurality of holes, a sound absorbing material that is porous and disposed on the perforated plate, and a sound insulating material disposed on the sound absorbing material.

[0008] One surface of the sound absorbing material may be laminated to one surface of the perforated plate by adhesive bonding, and one surface of the sound insulating material may be laminated to the other surface of the sound absorbing material by adhesive bonding.

[0009] The holes formed in the perforated plate may be formed so that the diameter size of the holes, the number of holes, and the distance between the holes are different in one target part as a noise removal object.

[0010] The noise frequency of the sound absorbed while passing through the holes formed in the perforated plate may be determined by the diameter size of the holes, the distance between the holes, and the cross-sectional thickness of the perforated plate.

[0011] The holes of the perforated plate can be formed by the following operations: a first operation of checking the frequency components and sound pressure intensity of the noise source of each part in a target component that becomes the object of noise removal, a second operation of classifying the frequency components of each part in the target component using the result value obtained by the first operation, a third operation of selecting the layout of the holes suitable for the frequency components of each part classified in the second operation, and a fourth operation of performing perforation on each part of the target component after reflecting the result of the third operation.

[0012] The perforated plate may be manufactured by compression molding a perforated plate formed by perforating a metal plate, the sound absorbing material may be manufactured by molding glass fiber, the sound insulating material may be manufactured by injection molding polypropylene, and the perforated plate, the sound absorbing material, and the sound insulating material may be sequentially combined.

[0013] Under the conditions that the cross-sectional thickness is in the range of 0.5 to 3 mm, the distance between the holes is in the range of 3 to 8 mm, and the diameter of the holes is in the range of 0.5 to 1 mm, the perforated plate may have a porosity of 0.5% to 3%, and may be sequentially formed together with a sound absorbing material and a sound insulating material to eliminate noise of a specific frequency in the range of 1 to 3 kHz.

[0014] Under the conditions that the cross-sectional thickness is in the range of 0.5 to 3 mm, the distance between the holes is in the range of 1.5 to 4 mm, and the diameter of the holes is in the range of 0.5 to 2 mm, the perforated plate may have a porosity of 2% to 11%, and may be sequentially formed together with a sound absorbing material and a sound insulating material to eliminate noise of a specific frequency in the range of 3 to 7 kHz.

[0015] Under the conditions that the cross-sectional thickness is in the range of 0.5 to 3 mm, the distance between the holes is in the range of 0.5 to 4 mm, and the diameter of the holes is in the range of 0.2 to 2 mm, the perforated plate may have a porosity of more than 10%, and may be sequentially formed together with the sound absorbing material and the sound insulating material to eliminate noise of a specific frequency in the range of 7 to 10 kHz.

[0016] The module in which the perforated plate, the sound absorbing material, and the sound insulating material are integrally combined may be applied to at least one of an insulator, a partition wall or an enclosure, a carpet and a vibration insulating pad, and a wheel cover of a vehicle.

[0017] The perforated plate may be made of a material other than metal having a greater hardness than the sound absorbing material and the sound insulating material.

[0018] The sound absorbing and insulating module for a vehicle may have a perforated plate formed with a plurality of holes, a sound absorbing material and a sound insulating material sequentially integrated, and the holes of the perforated plate are formed in a configuration such that the diameter size of the holes, the number of holes, and the distance between the holes are different for each part having noises of different frequency bands, and effectively respond to all noises of different frequency bands of each part in a specific component, and particularly make the entire sound absorbing and insulating system thinner, thereby reducing its weight and cost.

[0019] In some embodiments, the impedance characteristics of the perforated plate that are different for each portion can be used to target the sound absorption rate of a specific portion and a specific frequency, thereby constituting an optimal sound absorption and sound insulation system suitable for the sound characteristics of the target noise source.

[0020] In some embodiments, it is advantageous to reduce noise by reducing the weight of the sound absorbing material and the sound insulating material to the same extent as the weight of the perforated plate newly added to the conventional structure, and when the noise source changes, by keeping the sound absorbing material and the sound insulating material unchanged, it is possible to ensure a countermeasure to suppress noise and vibration by only changing the layout of the holes of the perforated plate.

[0021] In some embodiments, due to the increased sound absorption rate caused by the use of the perforated plate, the content of glass fiber can be reduced compared to traditional sound absorbing and sound insulating structures, thereby reducing harm to the human body and achieving excellent environmental performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description when considered in conjunction with the accompanying drawings.

[0023] Figure 1 is a view showing an example of a sound absorbing and insulating module for a vehicle.

[0024] Figures 2 to 6 is a view for explaining an example of a process of forming holes in a perforated plate.

[0025] Figures 7 to 13 is a view for explaining an example of a process of manufacturing a sound absorbing and sound insulating module.

[0026] Figures 14 to 17 is a view for explaining an example portion of a vehicle including a sound absorbing and insulating module. DETAILED DESCRIPTION

[0027] Hereinafter, the embodiments disclosed in the present specification will be described in detail with reference to the accompanying drawings, and the same or similar components are denoted by the same reference numerals regardless of the drawing numerals, and repeated description thereof will be omitted.

[0028] In the present disclosure, a unit or control unit included in the names of a motor control unit (MCU), a hybrid control unit (HCU), etc. is a term widely used to name a controller that controls specific functions of a vehicle and does not mean a general functional unit.

[0029] The controller may include a communication device for communicating with another controller or sensor for controlling the functions it undertakes, a memory for storing an operating system or logic commands and input and output information, and one or more processors for performing judgments, calculations, decisions, etc. for controlling the functions it undertakes.

[0030] Hereinafter, a sound absorbing and insulating module for a vehicle according to an exemplary embodiment of the present invention will be described with reference to the accompanying drawings.

[0031] like Figures 1 to 17 As shown, the sound absorbing and insulating module 1 for a vehicle includes a perforated plate 10 formed with a plurality of holes 11 , a porous sound absorbing material 20 laminated on the perforated plate 10 , and a sound insulating material 30 laminated on the sound absorbing material 20 .

[0032] In some embodiments, the perforated plate 10 may be formed of a metal plate having a predetermined cross-sectional thickness, the porous sound absorbing material 20 may be made of polyurethane (PU) foam and glass fiber (or glass wool), and the sound insulating material 30 may be made of polypropylene (PP).

[0033] The present invention has a configuration capable of maximizing the sound absorption and sound insulation performance of only the target frequency component by filtering the specific frequency component of the noise passing through the micropores 11 of the perforated plate 10, and can provide various types of sound absorption and sound insulation performance characteristics that are different for each part in one component by changing the porosity for each part where the frequency band of the noise is different.

[0034] In other words, by changing the perforation layout for each portion in one target component that becomes a noise removal object, it is possible to individually respond to the sound absorption and sound insulation of the frequency component of each portion.

[0035] The sound absorbing and insulating module 1 is configured as a combination of a metal perforated plate 10 formed with a plurality of holes 11, a sound absorbing material 20 made of polyurethane foam and glass fiber, and a sound insulating material 30 made of a polypropylene material, and noise is absorbed by resonance generated at a specific frequency while passing through the holes 11 of the perforated plate 10, the noise is absorbed by the porous sound absorbing material 20 in the form of heat energy and kinetic energy, and the noise of the remaining frequency components passing through the sound absorbing material 20 is finally isolated by the sound insulating material 30.

[0036] The sound absorbing and insulating module 1 has the advantages of absorbing noise of a specific frequency band by the perforated plate 10 , absorbing noise of a wide frequency band by the sound absorbing material 20 , and isolating noise of remaining frequency components by the sound insulating material 30 , thereby achieving further improved sound absorbing and insulating performance.

[0037] The sound absorbing and insulating module 1 may have a structure in which one surface of the sound absorbing material 20 is laminated to one surface of the perforated plate 10 by adhesive bonding, and one surface of the sound insulating material 30 is laminated to the other surface of the sound absorbing material 20 by adhesive bonding, and may be installed on a plurality of portions in a vehicle requiring noise insulation by integrating the sound absorbing and insulating module 1, the sound absorbing material 20, and the sound insulating material 30 which are sequentially bonded.

[0038] In some embodiments, since the holes 11 formed in the perforated plate 10 can be formed so that for each portion of a target component that is a noise removal object and in which the frequency band of noise is different, the size of the diameter D1 of the hole 11, the number of holes 11, and the distance L1 between adjacent holes 11 can be different, it is possible to meet the characteristics of all sound absorption and sound insulation performances of each portion in a target component.

[0039] The frequency of noise absorbed while passing through the holes 11 formed in the perforated plate 10 may be determined by the size of the diameter D1 of the holes 11 , the distance L1 between the holes 11 , and the cross-sectional thickness t1 of the perforated plate 10 .

[0040] In other words, as the diameter D1 of the hole 11 increases, the cross-sectional thickness t1 of the perforated plate 10 decreases, the distance L1 between adjacent holes 11 decreases, and the cross-sectional thickness of the sound absorbing layer decreases, the sound absorption frequency of the noise absorbed by the perforated plate 10 further increases.

[0041] As a result, the acoustic impedance of the perforated plate 10 is inversely proportional to the opening ratio of the holes 11, and as the opening ratio becomes larger, the sound absorption and sound insulation frequencies may increase.

[0042] Figures 2 to 5 A process of forming the holes 11 in the perforated plate 10 is shown.

[0043] First, execute Figure 2 As shown in FIG. 1 , a target component 40 to be removed from the noise is determined, and then Figure 3 As shown in FIG. 1 , a first operation of checking the frequency component and the sound pressure intensity 41 of the noise source for each portion in a target component 40 is performed, and a result value obtained by the first operation is used as shown in FIG. Figure 4 A second operation of classifying the frequency components 42 of each portion in the target component 40 is shown.

[0044] In addition, by executing Figure 5The third operation of selecting the layout of the holes 11 suitable for the frequency component 42 of each part classified in the second operation is shown, and performing the operation as follows after reflecting the result of the third operation. Figure 6 The fourth operation of performing the perforation on each portion of the target component 40 may ultimately form a plurality of holes 11 having different layouts for each portion of the perforated plate 10 .

[0045] The first operation may be performed by sound intensity evaluation.

[0046] In the third operation, the layout of the holes 11 may be selected by using a pre-calculated data map (library) 43 , and may include the size of the diameter D1 of the holes 11 , the number of the holes 11 , and the distance L1 between the holes 11 .

[0047] An appropriate perforation layout may be selected from the pre-calculated data map 43 in consideration of the sound absorption frequency of each part of the sound absorption and insulation system confirmed by the sound intensity evaluation in the first operation and the layout, material, thickness, etc. of the sound absorption and insulation system.

[0048] After the metal plate performs the fourth operation, the perforated plate 10 in which the plurality of holes 11 having different layouts for each portion are formed is finally formed, and the perforated plate 10 can satisfy the characteristics of all sound absorption and sound insulation performances for each portion within one target component.

[0049] like Figure 6 As shown, since the perforated plate 10 whose shape has been completed by the fourth operation has a different perforation layout for each portion, the sound absorption and sound insulation frequencies and the sound absorption rate for each portion may be different due to the change in porosity.

[0050] As described above, when the sound absorbing and insulating module 1 is constituted by applying the perforated plate 10 in which the size of the diameter D1 of the hole 11, the number of the holes, and the distance L1 between the holes 11 are different for each portion, noise of various frequency bands can be locally responded to one by one in one target component that becomes the object of noise removal, thereby achieving the best sound absorbing and insulating performance while minimizing the increase in its weight and cost.

[0051] Figures 7 to 13 A process of manufacturing the sound absorbing and insulating module 1 is shown.

[0052] Through Figure 7 As shown in the figure, a metal plate 51 with a predetermined cross-sectional thickness is first prepared, as shown in the figure. Figure 8 As shown, a needle or laser is used to perforate the metal plate 51, as shown in FIG. Fig. 9 A perforated plate 52 is formed in which a plurality of holes having different layouts for each portion is formed as shown, and as Fig.10 The perforated plate 52 is shown being compression molded to produce the perforated plate 10 having a predetermined shape.

[0053] Next, you can Fig.11 As shown, a sound absorbing material 20 having the same or similar shape as the perforated plate 10 is manufactured by molding glass fiber. Fig.12 As shown, the sound insulating material 30 having the same or similar shape as the perforated plate 10 is manufactured by injection molding polypropylene, and the perforated plate 10, the sound absorbing material 20 and the sound insulating material 30 are sequentially combined to finally complete the manufacture of the sound absorbing and sound insulating module 1, and the sound absorbing and sound insulating module 1 manufactured as described above can be applied to multiple parts of a vehicle that require noise isolation.

[0054] The perforated plate 10 according to the first embodiment of the present invention may be formed to have a porosity of 0.5% to 3% under the conditions where the cross-sectional thickness t1 is in the range of 0.5 to 3 mm, the distance L1 between the holes 11 is in the range of 3 to 8 mm, and the diameter D1 of the holes 11 is in the range of 0.5 to 1 mm, and the perforated plate 10 formed as described above may be sequentially formed together with the sound absorbing material 20 and the sound insulating material 30, thereby more effectively eliminating noise of a specific frequency in the range of 1 to 3 kHz.

[0055] The perforated plate 10 according to the second embodiment of the present invention may be formed to have a porosity of 2% to 11% under the conditions where the cross-sectional thickness t1 is in the range of 0.5 to 3 mm, the distance L1 between the holes 11 is in the range of 1.5 to 4 mm, and the diameter D1 of the holes 11 is in the range of 0.5 to 2 mm, and the perforated plate 10 formed as described above may be sequentially formed together with the sound absorbing material 20 and the sound insulating material 30, thereby more effectively eliminating noise of a specific frequency in the range of 3 to 7 kHz.

[0056] The perforated plate 10 according to the third embodiment of the present invention may be formed to have a porosity of 10% or more under the conditions where the cross-sectional thickness t1 is in the range of 0.5 to 3 mm, the distance L1 between the holes 11 is in the range of 0.5 to 4 mm, and the diameter D1 of the holes 11 is in the range of 0.2 to 2 mm, and the perforated plate 10 formed as described above may be sequentially formed together with the sound absorbing material 20 and the sound insulating material 30, thereby more effectively eliminating noise of a specific frequency in the range of 7 to 10 kHz.

[0057] The perforated plate 10 may be made of a material other than metal having a relatively greater hardness than the sound absorbing material 20 and the sound insulating material 30, and in this case, the process of manufacturing the perforated plate by perforating a metal plate and press-molding the perforated plate to finally manufacture the perforated plate 10 may be applied in the same manner.

[0058] Figures 14 to 17 An example of a portion in a vehicle to which the sound absorbing and sound insulating module 1 is applied is shown.

[0059] As shown in the figure, the sound absorbing and insulating module 1 may be applied to at least one of an insulator 61 , a partition wall or an enclosure 62 , a carpet and a vibration-isolating pad 63 , and a wheel cover 64 .

[0060] In other words, if Fig.14 As shown, the sound absorbing and insulating module 1 can be applied to an insulator 61, which is a sound absorbing and insulating system using a motor and an inverter located in a power electronics (PE) room as noise sources.

[0061] In addition, if Fig.15 As shown, the sound absorption and insulation module 1 may be applied to a partition wall or enclosure 62, which is a sound absorption and insulation system using a motor, inverter, or heating, ventilation, and air conditioning (HVAC) blower motor located in a PE room as a noise source.

[0062] In addition, if Fig.16 As shown, the sound absorbing and insulating module 1 may be applied to a carpet or a vibration insulating pad 63, which is a sound absorbing and insulating system using road noise transmitted from the ground to the tire as a noise source.

[0063] In addition, if Fig.17 As shown, the sound absorbing and insulating module 1 can be applied to wheel covers 64 of front and rear wheels, which is a sound absorbing and insulating system using the resonance sound of the tire as a noise source.

[0064] As described above, the sound absorbing and insulating module 1 for a vehicle may have a perforated plate 10 formed with a plurality of holes 11, a sound absorbing material 20, and a sound insulating material 30 sequentially integrated, and the holes 11 of the perforated plate 10 are formed to have different sizes of diameters D1 of the holes 11, the number of the holes 11, and the distances L1 between the holes 11 for each portion having noises of different frequency bands, and may effectively respond to all noises of various frequency bands of each portion in a specific component, and in particular, may make the entire sound absorbing and insulating system thinner and lighter, thereby reducing its weight and cost.

[0065] Furthermore, according to the sound absorbing and insulating module 1 for a vehicle, it is possible to target the sound absorption rate of a specific portion and a specific frequency using the impedance characteristics of the perforated plate 10 that differ for each portion, thereby constituting an optimal sound absorbing and insulating system suitable for the sound characteristics of the target noise source.

[0066] Furthermore, according to the sound absorbing and sound insulating module 1 for a vehicle, it is advantageous to reduce noise by reducing the weight of the sound absorbing material 20 and the sound insulating material 30 to the same extent as the weight of the perforated plate 10 newly added to the conventional structure, and when the noise source changes, it is possible to ensure a countermeasure to suppress noise and vibration by changing only the layout of the holes 11 of the perforated plate 10 while keeping the sound absorbing material 20 and the sound insulating material 30 unchanged.

[0067] Furthermore, according to the sound absorbing and insulating module 1 for a vehicle, due to the increase in sound absorption rate caused by applying the perforated plate 10, the content of glass fiber can be reduced compared with the conventional sound absorbing and insulating structure, thereby reducing human body harmfulness and achieving excellent environmental performance.

[0068] While particular embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that various modifications and changes may be made to the present invention without departing from the technical concept of the invention as provided by the appended claims.

Claims

1. A sound absorption and sound insulation module for a vehicle, comprising: a perforated plate defining a plurality of holes; A porous sound absorbing material disposed on the perforated plate; as well as A sound insulating material is disposed on the sound absorbing material.

2. The sound absorption and sound insulation module according to claim 1, wherein: The sound absorbing material has: a first surface bonded to the first surface of the perforated plate; and A second surface is bonded to the first surface of the sound insulating material.

3. The sound absorption and sound insulation module according to claim 1, wherein: One or more diameters of the plurality of holes are determined based on a target component of the vehicle to remove noise generated by the target component.

4. The sound absorption and sound insulation module according to claim 1, wherein: The number of the plurality of holes is determined based on a target component of the vehicle, thereby removing noise generated by the target component.

5. The sound absorption and sound insulation module according to claim 1, wherein: One or more distances between the plurality of holes are determined based on a target component of the vehicle to remove noise generated by the target component of the vehicle.

6. The sound absorption and sound insulation module according to claim 1, wherein: Each of (i) one or more diameters of the plurality of holes, (ii) a number of the plurality of holes, and (iii) one or more distances between the plurality of holes is determined based on the target component of the vehicle to remove noise generated by the target component.

7. The sound absorption and sound insulation module according to claim 1, wherein: The perforated plate is configured to absorb sound whose noise frequency corresponds to the size of the plurality of holes, the distance between the plurality of holes, and the cross-sectional thickness of the perforated plate, the sound being absorbed while passing through the plurality of holes in the perforated plate.

8. The sound absorbing and insulating module according to claim 1, wherein: The plurality of holes of the perforated plate are arranged in a layout determined by: a first operation of checking the frequency components and sound pressure intensity of a noise source of one or more portions of a target component of the vehicle from which noise is to be removed, a second operation of classifying the frequency components based on the result values ​​obtained by the first operation, a third operation of selecting a layout for the frequency components classified in the second operation, and A fourth operation of perforating is performed corresponding to the one or more portions of the target component based on the layout selected in the third operation.

9. The sound absorption and sound insulation module according to claim 1, wherein: The perforated plate comprises a metal plate perforated by die-forming, wherein the sound absorbing material comprises molded glass fiber, wherein the sound insulation material comprises injection molded polypropylene, and Wherein, the perforated plate, the sound absorbing material and the sound insulating material are combined sequentially.

10. The sound absorption and sound insulation module according to claim 1, wherein: The porosity of the perforated plate is 0.5% to 3%, Wherein, the cross-sectional thickness of the perforated plate is 0.5 to 3 mm, Wherein, the distance between the plurality of holes is 3 to 8 mm, wherein the diameter of the plurality of holes is 0.5 to 1 mm, and The perforated plate, the sound absorbing material and the sound insulating material are combined with each other and configured to eliminate noise with a frequency in the range of 1 to 3 kHz.

11. The sound absorbing and insulating module according to claim 1, wherein: The porosity of the perforated plate is 2% to 11%, Wherein, the cross-sectional thickness of the perforated plate is 0.5 to 3 mm, The distance between the plurality of holes is 1.5 to 4 mm. wherein the diameter of the plurality of holes is 0.5 to 2 mm, and The perforated plate, the sound absorbing material and the sound insulating material are combined with each other and configured to eliminate noise with a frequency in the range of 3 to 7 kHz.

12. The sound absorbing and insulating module according to claim 1, wherein: The porosity of the perforated plate is above 10%, Wherein, the cross-sectional thickness of the perforated plate is 0.5 to 3 mm, The distance between the plurality of holes is 0.5 to 4 mm. wherein the diameter of the plurality of holes is 0.2 to 2 mm, and The perforated plate, the sound absorbing material and the sound insulating material are combined with each other and configured to eliminate noise of a specific frequency within a range of 7 to 10 kHz.

13. The sound absorption and sound insulation module according to claim 1, wherein: The sound absorbing and insulating module is configured to be applied to at least one of an insulator, a partition wall, an enclosure, a carpet, a vibration insulating pad, and a wheel cover of the vehicle.

14. The sound absorption and sound insulation module according to claim 1, wherein: The perforated plate is made of a material other than metal, the material having a greater hardness than the sound absorbing material and the sound insulating material.

15. The sound absorption and sound insulation module according to claim 1, wherein: The perforated plate has a hardness smaller than that of each of the sound absorbing material and the sound insulating material.

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