Multilayer Felt Manufacturing Using Vacuum Adsorption and Segmentation
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Solution Overview
Problem
Existing single-layer felt manufacturing processes generate excessive fine dust, affecting worker health and increasing costs due to the need for additional dust protection measures, while also not effectively improving NVH performance in vehicles.
Innovation Solution
A multilayer felt manufacturing apparatus and method using a low-cost inner layer and a dust-preventing PET outer layer, where the inner layer is formed with a low-cost chip felt and the outer layer is made of PET material to minimize dust generation and enhance NVH performance by applying vacuum pressure and press molding techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If single-layer felt is manufactured using chip felt material, then manufacturing cost is reduced, but excessive fine dust is generated affecting worker health and working environment
Solution Approach 1:
The felt product is divided into multiple layers with different functions: an inner layer made of chip felt for cost-effectiveness and NVH performance, and an outer layer made of PET material for dust prevention. This segmentation allows each layer to perform its specific function optimally without compromising the others.
Solution Approach 2:
The invention uses a composite structure combining chip felt and PET materials in a multilayer configuration. The chip felt provides cost benefits and sound absorption properties, while the PET material provides dust resistance, creating a composite material system that achieves multiple objectives simultaneously.
2Device complexity
If single-layer felt is manufactured, then manufacturing process is simple, but NVH performance improvement is insufficient
Solution Approach 1:
The felt structure is segmented into multiple layers, each contributing to NVH performance in different ways. The inner chip felt layer provides sound absorption, while the outer PET layer provides dust protection, achieving superior overall NVH performance compared to single-layer structures.
Solution Approach 2:
The composite multilayer structure combines materials with different properties to achieve enhanced NVH performance. The combination of chip felt and PET creates a material system that simultaneously provides sound insulation and dust protection, improving overall product reliability.
3Object-generated harmful factors
If protective film is attached to single-layer felt surface, then dust generation is prevented, but manufacturing cost increases
Solution Approach 1:
Instead of adding a separate protective film as an additional component, the dust protection function is merged into the felt structure itself by making the outer layer of PET material. This integration eliminates the need for separate protective films while maintaining dust prevention capabilities.
Solution Approach 2:
The PET material in the outer layer serves as an intrinsic protective barrier against dust, eliminating the need for additional protective films. This composite structure incorporates protection within the material itself rather than adding separate protective components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The multilayer felt product reduces manufacturing costs and minimizes dust generation while maintaining or improving NVH performance by using a low-cost inner layer and a dust-preventing PET outer layer, effectively addressing the issues of dust and cost associated with single-layer felt production.
Implementation Method 1
vacuum pressure is applied to the vacuum suction gates 12 of the upper mold 10 as the vacuum source is operated, and in this case, the chip felt 33, which is supplied between the upper mold 10 and the lower mold 20, is adsorbed and fixed on a bottom surface of the upper mold 10 by vacuum pressure
Implementation Method 2
a blower fan 36, which serves to allow the chip felt to flow toward the mold, is disposed at a rear end portion of the chip felt supply line 34. Therefore, the chip felt discharged from the chip felt supply gate 35 is supplied between the upper mold 10 and the lower mold 20 in the hermetic molding box 30 along the chip felt supply line 34 by blowing force that is generated by operating the blower fan 36
Implementation Method 3
the upper mold 10 is moved downward toward the lower mold 20, and simultaneously, a pressing process of thermally compressing the chip felt 33 is performed, such that a single-layer molded felt product 38 is completely manufactured
Data Source
AI summary
An apparatus and a method for manufacturing multilayer felt to improve NVH (noise, vibration, and harshness) of a vehicle may include supplying first chip felt between an upper mold and a lower mold, and simultaneously, firstly adsorbing the first chip felt on a bottom surface of the upper mold by vacuum pressure applied to vacuum suction gates of the upper mold, supplying second chip felt between the upper mold and the lower mold, and simultaneously, secondly adsorbing the second chip felt on a surface of the first chip felt by vacuum pressure applied to the vacuum suction gates of the upper mold, to stack the second chip felt on the first chip felt, pressing the first chip felt and the second chip felt, which are stacked on each other, using a press molding operation of the upper mold and the lower mold, and forming a multilayer felt product.