Recycled Polyurethane Foam Soundproofing Material
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Solution Overview
Problem
There is a lack of effective methods for recycling thermosetting polyurethane foam from discarded car seats to produce high-quality soundproofing materials for automotive applications, as existing methods result in low-grade products with inferior soundproofing performance and environmental pollution.
Innovation Solution
A method involving the crushing, mixing, carding, needle punching, thermoforming, and heating rolling of polyurethane foam from discarded car seats with added polyester fibers, low-melting polyester fibers, polypropylene fibers, and hemp to create a soundproofing material with improved dispersibility, soundproofing performance, and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If polyurethane foam from discarded car seats is recycled using existing methods, then environmental pollution is reduced, but the soundproofing performance and quality of the recycled material deteriorates
Solution Approach 1:
The patent creates a composite material by combining crushed polyurethane foam with natural fibers (jute, hemp, coconut coir) and bonding agents. This composite structure allows the recycled foam to achieve satisfactory soundproofing performance while maintaining environmental benefits, resolving the contradiction between recycling and performance quality.
Solution Approach 2:
The patent modifies physical parameters including crushing the foam to specific size ranges (1-10mm, preferably 2-5mm), controlling fiber content (10-50 wt%), and adjusting bonding agent proportions. These parameter optimizations ensure the recycled material meets soundproofing requirements while maintaining environmental sustainability.
2Stability of the object's composition
If polyurethane foam is crushed into fine particles for recycling, then dispersibility in the soundproofing material improves, but the mechanical strength and structural integrity deteriorate
Solution Approach 1:
The patent reinforces the crushed foam particles with natural fiber networks and bonding agents, creating a composite structure where fine foam particles maintain dispersibility while the fiber-bonded matrix restores mechanical strength. The fiber reinforcement compensates for the structural weakness introduced by fine crushing.
Solution Approach 2:
The patent uses bonding agents as intermediaries to connect and reinforce the fine foam particles with natural fibers. This intermediary material bridges the gap between dispersed foam particles, maintaining both dispersibility and mechanical integrity in the final soundproofing product.
3Ease of manufacture
If thermosetting polyurethane foam is discarded without recycling, then the manufacturing process remains simple, but environmental pollution and resource waste increase
Solution Approach 1:
The patent implements a recovery system for discarded car seat foam, transforming waste material into valuable soundproofing products. The process collects used foam, crushes it to appropriate sizes, and incorporates it with natural fibers to create new soundproofing materials, thereby reducing environmental pollution while maintaining reasonable manufacturing simplicity.
Solution Approach 2:
The patent optimizes physical parameters such as foam particle size (1-10mm), fiber content (10-50 wt%), and processing temperatures to balance manufacturing simplicity with environmental sustainability. These controlled parameter changes enable effective recycling without overly complicating the manufacturing process.
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 method produces a soundproofing material with superior soundproofing performance and mechanical properties, reducing environmental impact by recycling discarded car seats and offering cost savings compared to traditional materials.
Implementation Method 1
low-melting polyester fiber (e.g., LM PET fiber)
Implementation Method 2
binding the crushed PU foam particles together
Implementation Method 3
needle punching, thermoforming
Data Source
AI summary
Disclosed is a method for manufacturing a soundproofing material by finely crushing a discarded car seat, mixing the crushed car seat with polyester fiber, low-melting polyester fiber such as LM PET, polypropylene fiber and hemp, and carding the resulting mixture, and a soundproofing material composition prepared thereby. The disclosed method allows recycling of polyurethane foam of the discarded car seat into a soundproofing material composition having superior appearance quality and soundproofing performance. The disclosed method also prevents generation of excessive static electricity and allows preparation of a soundproofing material with smooth surface.