Polyester Felt Sound Absorption for Integral Vehicle Trim Molding
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Solution Overview
Problem
Conventional trunk trim parts for vehicles require a separate process to attach sound absorption materials, increasing processing costs and making recycling difficult due to the use of different materials for the skin member, substrate, and sound absorption pad.
Innovation Solution
A polyester sound absorption material comprising a felt with a base fiber, low-melting-point polyester adhesive fiber, and hollow fiber, which can be integrally molded with a skin member to reduce weight and processing costs, using a method that involves preheating and cold pressing to attach the sound absorption material directly to the skin member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate sound absorption pad is attached to the skin member, then sound absorption performance is improved, but processing costs and manufacturing complexity increase
Solution Approach 1:
The invention merges the sound absorption material and skin member into a single integral molded product. The felt material serves dual functions as both the skin member and sound absorption material, eliminating the need for separate attachment processes and reducing manufacturing complexity while maintaining sound absorption performance
2Reliability
If different materials are used for skin member, substrate, and sound absorption pad, then functional performance is improved, but recyclability deteriorates
Solution Approach 1:
The invention uses homogeneous polyester-based materials throughout the entire molded product, including the skin member and sound absorption portions. This uniform material composition maintains functional performance while enabling easy recycling and repurposing of the entire component at end-of-life
3Adaptability or versatility
If multiple components are assembled separately, then manufacturing flexibility is improved, but processing time and costs increase
Solution Approach 1:
The invention incorporates sound absorption functionality directly into the skin member during the initial molding process, rather than adding it as a separate subsequent step. This preliminary integration of functions reduces processing time and costs while maintaining manufacturing flexibility for different vehicle interior applications
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 solution maintains sound absorption performance while reducing the weight of vehicle parts and simplifying the manufacturing process, thereby lowering processing time and costs, and allows for easier recycling by using a single type of material for the skin member and sound absorption material.
Implementation Method 1
an adhesive fiber including a low-melting-point polyester resin
Implementation Method 2
the adhesive fiber including a low-melting-point polyester resin, and a hollow fiber including a polyester resin
Data Source
AI summary
The present invention relates to a polyester sound absorption material having improved moldability and decreased weight and a method of manufacturing a molded product using the same, and more particularly to a polyester sound absorption material, which is capable of integrally molding a skin member and a sound absorption material using a felt including a polyester base fiber, a low-melting-point polyester adhesive fiber and a polyester hollow fiber, without the need to attach an additional sound absorption pad onto a skin member.