Thin Sound-Absorbing Material with Layered Fiber Structure
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Solution Overview
Problem
Conventional sound-absorbing materials for vehicles face challenges in achieving a balance between rigidity, weight reduction, and sound absorption performance, with nonwoven PET fabrics being heavy and rigid but lacking in sound absorption, and sound-absorbing microfiber materials being lightweight but expensive and limited in application.
Innovation Solution
A thin-film-type sound-absorbing material comprising a surface layer with low-melting fibers and melt-blown fibers, along with a sound-absorbing layer, which includes specific weight and thickness ratios and optional sound-insulating and skin layers, manufactured through spinning, mixing, laminating, and hot-pressing processes to enhance rigidity and sound absorption while reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If nonwoven PET fabric is used for sound-absorbing material, then rigidity is maintained, but sound absorption performance deteriorates due to thinning
Solution Approach 1:
The sound-absorbing material is divided into distinct functional layers: a surface layer containing low-melting fibers and melt-blown fibers for structural integrity, and a sound-absorbing layer for acoustic performance. This segmentation allows each layer to optimize its specific function independently.
Solution Approach 2:
The invention uses composite materials by combining low-melting fibers (for rigidity) with melt-blown fibers (for sound absorption) in the surface layer, and integrating these with a dedicated sound-absorbing layer. This composite structure achieves both rigidity and sound absorption performance simultaneously.
2Reliability
If sound-absorbing microfiber material is used, then sound absorption performance is improved, but weight and thickness increase
Solution Approach 1:
Different regions of the material have different properties: the surface layer uses low-melting fibers for local rigidity and structural support, while the sound-absorbing layer uses appropriate materials for acoustic performance. This local differentiation optimizes both weight and performance.
Solution Approach 2:
The invention optimizes parameters such as fiber diameter (0.3 to 10 μm for melt-blown fibers), fiber length (40 to 60 mm for low-melting fibers), and layer thickness to achieve superior sound absorption with reduced weight and thickness compared to conventional materials.
3Reliability
If sound-absorbing microfiber material is used, then sound absorption performance is improved, but application flexibility deteriorates due to thickness requirements
Solution Approach 1:
The invention transitions from a single thick layer approach to a multi-layer structure with different functional dimensions. The surface layer provides structural dimension while the sound-absorbing layer provides acoustic absorption dimension, enabling application in space-constrained vehicle interior parts.
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 resulting material is lightweight, thin, and exhibits superior rigidity and sound absorption performance, enabling its wide application in vehicle interiors while reducing part weight and thickness, thereby improving noise, vibration, and harshness (NVH) performance.
Implementation Method 1
a sound-absorbing material including a surface layer including low-melting (LM) fibers and melt-blown (MB) fibers and a sound-absorbing layer disposed on at least one side of the surface layer
Implementation Method 2
hot-pressing a surface layer/sound-absorbing layer configured such that the sound-absorbing layer is laminated on the surface layer
Data Source
AI summary
An embodiment sound-absorbing material including a surface layer including low-melting (LM) fibers and melt-blown (MB) fibers and a sound-absorbing layer disposed on at least one side of the surface layer. An embodiment method of manufacturing a sound-absorbing material includes spinning melt-blown (MB) fibers, manufacturing a surface layer by mixing the melt-blown (MB) fibers with low-melting (LM) fibers, laminating a sound-absorbing layer on the surface layer, and hot-pressing a surface layer/sound-absorbing layer in which the sound-absorbing layer is laminated on the surface layer.