High NVH (Noise, Vibration, Hardness) Performance Vehicle Floor Mat

Abstract

The invention relates to a low-cost, customizable, and high NVH (noise, vibration, and harshness) vehicle floor mat developed for use in the automotive industry, and its production. Specifically, the invention relates to the production of a thermoformable, PE film-reinforced nonwoven composite vehicle floor mat with NVH characteristics, developed for use in the interior floor coverings (floor mats) of electric vehicles.

Description

1 TARIFF High NVH (Noise, Vibration, Hardness) Performance Vehicle Floor Mat Technical Area The invention is a low-cost, customizable 5-in-1 system developed for use in the automotive industry. and it is related to high NVH performance vehicle floor carpets and their production. The invention is particularly relevant for interior floor coverings (floor carpets) in electric vehicles. Developed for use in thermoforming, it is PE film reinforced. NVH (noise, vibration, and harshness) resistant vehicle floor mat made of nonwoven composite material. It is related to production. 10 State of the Art Current vehicle floor mats are generally produced using the thermocompression method. This The method involves high mold costs (around €150,000), which affects production. This makes the processes expensive. Thermocompression processing, especially large-scale 15 Although it provides advantages in production, it is also suitable for low-volume production and start-up manufacturers. It is inefficient for their needs. High mold costs in carpet production make it difficult for manufacturers to compete. This reduces its power and contradicts the cost optimization goals in the sector. Conventional car carpets are not adequately adapted to the specific requirements of electric vehicles (EVs). This is not possible. In particular, electric vehicles have low NVH (noise, vibration, and harshness). It struggles to meet the requirements. Conventional carpets have high NVH It does not offer sufficient insulation to ensure performance, and as a result, additional insulation is needed. Additional layers are needed. This increases production costs, thereby reducing efficiency and It has negative effects in terms of performance. 25 More advanced cutting methods, such as the use of water jet or punch, are an advantage in carpet production. They stand out as alternatives. However, these methods are also expensive, especially. It is inefficient in low-volume production. Such methods have high initial costs. These solutions may not be compatible with manufacturers' limited budgets, so they are generally more suitable for 30-year-olds. It is preferred in large production volumes. 2 With the electric vehicle market growing rapidly, especially start-up manufacturers are facing lower costs. There are high-volume production requirements. These manufacturers offer low-cost, customizable, and They are looking for solutions that provide high NVH performance. However, existing vehicle carpets The available materials do not possess the necessary properties to meet these requirements. The materials are not suitable for thermoforming. These materials will not take shape. 5 They stretch and cannot maintain their shape, which negatively affects production efficiency and product quality. It has an effect in that direction. Current production methods and materials are not efficient enough to meet the requirements. It is not affordable. Therefore, in the current state of technology, especially in electric vehicles, 10 low-cost, customizable, and high NVH performance vehicle carpets for various uses. A solution is needed. In the literature review, TR 2021 / 014515 is given as an example of the known state of the technique. Application number [number] can be shown. A recyclable floor mat for a relevant vehicle with 15 It is related. The floor mat in question consists of an outer layer, a molded felt layer, and a sound layer. Upholstery for a vehicle that includes an absorbent felt layer but does not include a sound-insulating layer. It is a floor mat, where each layer that makes up the floor mat is the same olefin-based material. It includes. However, the application specifically mentions vibration and stiffness characteristics. 20 NVH (noise, vibration, and stiffness) resistant nonwoven composite structure made of PE film. The production of vehicle floor carpets is not mentioned. In conclusion, due to the negative aspects described above and the current solutions, the subject matter... Due to its shortcomings, an improvement is needed in the relevant technical field. It has been made. 25 Purpose of the Invention The present invention meets the aforementioned requirements while eliminating all disadvantages. NVH (noise, vibration, and harshness) performance that eliminates and offers some additional advantages. This relates to high-quality vehicle floor mats and their production method. 30 The primary aim of the invention is to reduce NVH (noise, vibration, and vibration) in vehicle floor mats manufactured for electric vehicles. aiming to reduce production costs while improving performance (vibration, stiffness). The goal is to develop an innovative production method and material structure. To this end, 3 Carpets produced using the thermoforming method do not require additional NVH insulation layers. The aim is to achieve high sound absorption performance. The aim of the invention is to create a composite material consisting of 600 g / m² PES fiber + 250 g / m² PE film + 100 g / m² latex layers. The goal is to create a three-layered nonwoven structure. 5 One aim of the invention is to create carpets using a PE (Polyethylene) layer that provides special formability. to ensure smooth surfaces are formed during the molding process and that the form lasts for a long time The aim is to enable its protection. Another aim of the invention is to produce carpets that are 18% more durable compared to those produced by the thermocompression process. The goal is to develop a method that enables production at a low unit cost. In this way, This will offer significant cost advantages to manufacturers. Another aim of the invention is to create a mold design that is quite simple, single-sided, and easily revisable. The advantage is that it is suitable for low production volumes. Thus, small-scale producers Economical and flexible production solutions are offered for start-up companies. Another aim of the invention is to develop low-cost solutions for cutting operations. Thanks to this invention, edge cleaning with a soldering iron, manual scissors, or guided edge cleaning with a fixture is no longer possible. Carpets can be cut using simple methods such as cutting. This is especially useful for low-volume carpets. It increases efficiency by further reducing costs in production. To fulfill the purposes described above, the invention applies NVH (noise, vibration, harshness) To obtain a high-performance, optimized nonwoven vehicle floor mat, a 25 It is a production method that includes the following steps: i. Thermoforming mold of nonwoven material laminated with PE film layer placement, ii. nonwoven carpet material in thermoforming mold, subjected to thermoforming process heating to be held, 30 iii. The heated PE layer on the material surface takes shape and adheres perfectly to the mold surface of the carpet. Shaping the carpet by ensuring it sits properly, iv. Cleaning the edges of the carpet after it has been removed from the mold following the thermoforming process, and cutting 35 4 To fulfill the purposes described above, the invention applies NVH (noise, vibration, harshness) It is a high-performance, optimized nonwoven vehicle floor mat. The structural and characteristic features and all the advantages of the invention are given in the figures below. Thanks to the detailed explanation written with references to the figures, 5 is clearer. This will be understood, and therefore the evaluation should also take these figures and detailed explanations into account. It must be done by taking it. Figures that will help understand the invention. Figure 1. Representative illustration of the process flow of the method described in the invention. 10 Detailed Description of the Invention This detailed explanation describes the product and method of invention only to provide a better understanding of the subject. 15 for the purpose of understanding and without imposing any limiting effect It is explained. The invention demonstrates sound absorption in NVH acoustic performance tests, in the frequency range of 50–6400 Hz. The coefficient α values ​​vary between 0.00 and 0.68, averaging in the 500–4000 Hz range. α ≈ 0.36 and optimized to achieve maximum performance with 0.68 at 6400 Hz. The production of a high-quality, nonwoven vehicle floor mat is related to a manufacturing method. The subject of the invention is a high-performance device with optimized NVH (noise, vibration, harshness) rating. The method for obtaining nonwoven vehicle floor mats basically involves the following process: It includes the following steps; 25 i. Thermoforming mold of nonwoven material laminated with PE film layer placement, ii. nonwoven carpet material in thermoforming mold, subjected to thermoforming process heating in order to be kept warm, iii. The heated PE layer on the material surface takes shape and adheres precisely to the mold surface of the carpet by 30 degrees. Shaping the carpet by ensuring it sits properly, iv. Cleaning the edges of the carpet after it has been removed from the mold following the thermoforming process, and cutting. The subject of the invention is the method i. Preferably using PES with a surface density of 600 g / m² in the process step, 250 Made from PE film with a surface area density of g / m² and latex material with a surface area density of 100 g / m². This involves placing laminated nonwoven carpet material into a thermoforming mold. The invention concerns the following method: ii. Process step: nonwoven carpet in thermoforming mold. The material must be subjected to thermoforming at 170–220 °C, preferably 180–210 °C, 5 Preferably a foil heater temperature of 190–200 °C, and a lower oven temperature of 0–25 °C, preferably 5–20 °C. and under a top furnace temperature of 25–55 °C, preferably 30–45 °C, even more preferably 35–40 °C. It involves heating. These intervals cause the PE layer to soften / flow, and the PES felt and By striking a balance between the dimensional stability of the latex binder and layer separation, It prevents excessive flow. 10 In a nominal sample application of the invention, the foil heater reached approximately 197 °C, the lower furnace 10 °C, and the upper furnace... The oven temperature was set at 38 °C. Due to line and material tolerances, the values ​​are ±5 °C. (foil) and ±3 °C (top / bottom oven) deviation may occur. The stated ranges are for the PE layer carpet molding. ensuring a perfect fit to the surface, preventing layer separation, and maintaining shape stability after thermoforming. It provides. 15 The subject of the invention is the method in step 4 of the process: After the thermoforming process, the edges of the carpet... This involves making a clean cut using manual scissors, a soldering iron, or a fixture. Low-cost, manual edge cutting is achieved using a soldering iron and support fixture. The subject of this invention... Carpets can be easily cut even with a utility knife. The invention involves applying NHV (noise, vibration, 20) to the carpet produced after the fourth processing step of the method. This includes applying tests such as hardness, fogging, flammability, abrasion, and cleanliness. The carpet subject to the invention has properties related to NHV (noise, vibration, stiffness), fogging, flame resistance, abrasion and cleaning. He / She passed the tests successfully. The floor mat produced with this invention is NVH acoustic tested according to the TS EN ISO 10534-2 standard. In performance tests, the sound absorption coefficient α values ​​were in the 50–6400 Hz frequency range. It varies between 0.00 and 0.68, the average α ≈ 0.36 in the 500–4000 Hz range, and 6400 It has been determined that the product reaches its maximum performance at 0.68 Hz. Therefore, the product is suitable for electric vehicles. indoor noise levels at mid-to-high frequencies, which are sensitive to the human ear. effectively reduces it in that range. The thermoforming mold described in the invention is a low-cost, single-surface Sikablok mold, made of PE. It is used to shape the backing carpet. 6 Invention of a high-performance nonwoven vehicle with optimized NVH (noise, vibration, harshness) performance. It relates to floor carpeting. The subject of the invention is a nonwoven vehicle floor mat, preferably with a 600 g / m² PES (polyester) fiber layer. It contains a 250 g / m² PE film layer and a 100 g / m² latex binder material. The PE (Polyethylene) Film Layer in the invention shall preferably have an area density of 250 g / m² and 5 It provides moldability, maintains surface smoothness, and improves sound absorption performance. It increases. The PES fiber layer within the invention preferably has an area density of 600 g / m²; the carpet It provides durability and absorbs sound and vibration energy. The latex binder in the invention preferably has a surface density of 100 g / m² and consists of 10 layers. It connects and provides structural stability. The process flow of the method described in the invention, the representative process flow of which is given in Figure 1, is as follows: It can be summarized as follows:  Supply of laminated nonwoven carpet (600 g / m² PES + 250 g / m² PE + 100 g / m² latex) 15  Adjustment of process parameters (Foil: 197°C, Bottom: 10°C, Top: 38°C)  Forming in thermoforming mold (Sikablok mold, PE layer above)  Trimming the edges (using manual scissors, soldering iron, or fixture)  Product tests (NHV, Fogging, Flammability, Abrasion, Cleaning) One application of the invention is as follows: PE film-backed nonwoven carpet. It is placed in a thermoforming mold to take shape. The PE layer on the back surface of the carpet, When heated, it takes on a molded shape, allowing the carpet to fit perfectly onto the molded surface. This ensures both... A structure with high performance in terms of both aesthetics and sound absorption is obtained. Thermoforming The parameters have been optimized (e.g., foil temperature 197°C, bottom oven temperature 10°C, top 25°C). (oven temperature 38°C). The shaped carpet, removed from the mold, is smoothed with the help of a soldering iron. It is cut in this way. The product is tested for NVH performance, cleanability, odor, abrasion and fogging. He / She has successfully passed the tests. The invention is located within the floor covering system of electric vehicles and has a cabin passenger capacity of 30. It is one of the main interior trim components that provides comfort. It can be applied independently, is modular, and It is customizable according to the vehicle platform.

Claims

8 SUMMARY High NVH (Noise, Vibration, Hardness) Performance Vehicle Floor Mat The invention is a low-cost, customizable solution developed for use in the automotive industry. The invention relates to vehicle floor carpets with high NVH performance and their production. especially for use in the interior floor coverings (floor carpet) of electric vehicles – 5 Developed for this purpose, thermoformable, PE film reinforced nonwoven Production of composite structure NVH (noise, vibration and harshness) resistant vehicle floor carpets. It is related.

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