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KR-20260067497-A - NOISE ABSORBENT FABRIC FOR E-GMP DRIVE MODULE AND MANUFACTURING METHOD FOR THE SAME

KR20260067497AKR 20260067497 AKR20260067497 AKR 20260067497AKR-20260067497-A

Abstract

The present invention comprises a process for manufacturing a first felt having a uniform thickness by mixing polyester staple fibers and low-melting point fibers in a certain ratio in a mixer and then needle punching; a process for manufacturing a second felt having a uniform thickness by mixing polyester staple fibers and low-melting point fibers in a certain ratio in a mixer and then needle punching; a process for preheating by laminating a polypropylene film between the first felt and the second felt, placing it between the upper and lower molds of a flat plate press mold, and applying pressure within the range of 70 to 80 Kgf/㎠ at a temperature within the range of 180 to 220°C for 90 to 110 seconds; a process for molding a sound-absorbing material by mounting the preheated first felt, the second felt, and the polypropylene film into a mold of a compression molding machine, laminating them by applying pressure within the range of 70 to 90 Kgf/㎠ at a temperature within the range of 10 to 20°C for 60 to 90 seconds, and then cooling the laminated material; and a process for molding a sound-absorbing material. Disclosed is a sound-absorbing material for a drive module of an electric vehicle E-GMP, comprising a process of placing the material on a mold of a trimming machine and applying pressure within the range of 80 to 120 Kgf/㎠ for 30 to 40 seconds to cut off unnecessary edge portions.

Inventors

  • 김정수
  • 황경식
  • 김덕한
  • 정복기

Assignees

  • 화인솔루션 주식회사

Dates

Publication Date
20260513
Application Date
20241105

Claims (6)

  1. A method for manufacturing a sound-absorbing and sound-insulating material for a drive module of an electric vehicle E-GMP, comprising each of the following processes. (a) A process of manufacturing a first felt having a uniform thickness by mixing polyester staple fibers and low-melting fibers in a specific ratio in a mixer and then needle punching. (b) A process of manufacturing a second felt having a thinner thickness than the first felt by putting polyester staple fibers and low-melting fibers into a mixer in a certain ratio, blending them, and then needle punching. (c) A process of preheating by laminating a polypropylene film (PP Film) between the first felt and the second felt, placing it between the upper and lower molds of a flat plate press mold, and applying pressure at a temperature of 180 to 220°C and a pressure of 70 to 80 Kgf/㎠ for 90 to 110 seconds. (d) A process of forming a sound-absorbing material by mounting the preheated first felt, the second felt, and the polypropylene film into a compression molding machine mold at 10 to 20°C, applying pressure of 70 to 90 Kgf/㎠ for 60 to 90 seconds to laminate them, and then cooling. (e) A process of placing the molded sound-absorbing material onto the mold of a trimming machine and applying pressure of 80–120 Kgf/㎠ for 30–40 seconds to cut off unnecessary edge portions.
  2. In paragraph 1, The first felt above is a blend of 65-70 weight% of the polyester staple fibers and 30-35 weight% of the low-melting point fibers, with a total weight of 1,400-1,700g per square meter (㎡), and The second felt is a blend of 65-70 weight% of the polyester staple fibers and 30-35 weight% of the low-melting point fibers, with a total weight of 200±1g per square meter (㎡). The above polypropylene film is a method for manufacturing a sound-absorbing and sound-insulating material for a drive module of an electric vehicle E-GMP, having a total weight of 100±1g per square meter (㎡).
  3. A method for manufacturing a sound-absorbing and sound-insulating material for a drive module of an electric vehicle E-GMP, comprising each of the following processes. (a) A process of manufacturing a first felt having a uniform thickness by mixing polyester staple fibers and low-melting fibers in a specific ratio in a mixer and then needle punching. (b) A process of manufacturing a second felt having a thinner thickness than the first felt by putting polyester staple fibers and low-melting fibers into a mixer in a certain ratio, blending them, and then needle punching. (c) A process of preheating by sequentially laminating a low-melting point film and polyurethane foam between the first felt and the second felt, placing them between the upper and lower molds of a flat plate press mold, and applying pressure at a temperature of 180 to 220°C and a pressure of 70 to 80 Kgf/㎠ for 90 to 110 seconds. (d) A process of forming a sound-absorbing material by mounting the preheated first felt, the second felt, the low-melting point film, and the polyurethane foam into the mold of a compression molding machine, laminating them by applying pressure of 70 to 90 Kgf/㎠ at a temperature of 10 to 20°C for 60 to 90 seconds, and then cooling. (e) A process of placing the molded sound-absorbing material onto the mold of a trimming machine and applying pressure of 80–120 Kgf/㎠ for 30–40 seconds to cut off unnecessary edge portions.
  4. In paragraph 3, The first felt is a blend of 65-70 weight% of the polyester staple fibers and 30-35 weight% of the low-melting point fibers, with a total weight of 1,400 ± 1g per square meter (㎡) and a thickness of 2mm. The second felt is a blend of 65-70 weight% of the polyester staple fibers and 30-35 weight% of the low-melting point fibers, with a total weight of 100±1g per square meter (㎡). The above low-melting point film has a total weight of 100±1g per square meter (㎡), and A method for manufacturing a sound-absorbing and sound-insulating material for a drive module of an electric vehicle E-GMP, wherein the above-mentioned polyurethane foam has a total weight of 200 to 220 g per square meter (㎡) and a thickness of 11 to 12 mm.
  5. In paragraph 1 or 3, (f) A process of removing burrs from the edges of the molded sound-absorbing material and trimming the rough edges; A method for manufacturing a sound-absorbing and sound-insulating material for a drive module of an electric vehicle E-GMP, comprising further including
  6. A sound-absorbing and sound-insulating material for a drive module of an electric vehicle E-GMP, manufactured by the manufacturing method of any one of claims 1 to 4.

Description

Noise Absorbent Fabric for E-GMP Drive Module and Manufacturing Method for the Same The present invention relates to a sound-absorbing and sound-insulating material for a drive module of an electric vehicle E-GMP and a method for manufacturing the same. More specifically, the invention relates to a sound-absorbing and sound-insulating material for a drive module of an electric vehicle E-GMP and a method for manufacturing the same, which not only secures lightweighting and rigidity simultaneously but also enhances sound absorption and sound insulation performance to block high-frequency noise generated from the electric vehicle's drive motor, etc., from entering the interior. E-GMP (Electric-Global Modular Platform) is Hyundai Motor Group's dedicated electric vehicle platform that includes drive modules such as batteries and motors, as well as shock absorbers. These E-GMPs are equipped with a third-generation PE (Power Electric) system that integrates a drive motor required for driving an electric vehicle, a reduction gear that converts and transmits power to the torque and speed required for the vehicle, and an inverter that converts power to control motor torque. In addition, the E-GMP is equipped with a V2L function that supplies power to the outside of the vehicle without the need for separate additional devices through the Integrated Charging Control Unit (ICCU) and Vehicle Charging Management System (VCMS), allowing it to be used for using electronic devices outdoors or charging other electric vehicles. Meanwhile, sound-absorbing and sound-insulating materials with excellent sound absorption and sound insulation performance are being applied to prevent external noise, such as high-frequency noise generated while driving, friction noise between tires and the road surface, and wind noise, from entering the vehicle cabin and interfering with driving. In particular, the drive motor cover, inverter pad, and ICCU pad of the electric vehicle are equipped as standard to minimize high-frequency noise entering the cabin while driving. Recently, as regulations in various countries regarding eco-friendliness and recyclability have been gradually strengthened, fiber felts based on thermoplastic resins such as polypropylene (PP), and polyethylene terephthalate (PET) felts are being widely used as sound-absorbing and sound-insulating materials to improve sound absorption and thermal insulation performance. As an example of prior art related to this, Patent Document 1 discloses a polyurethane sheet formed by compression molding a waste polyurethane foam scrap with an adhesive, and a sound-absorbing/sound-insulating automotive interior material formed by laminating a PET sheet on the outer side of the polyurethane sheet and bonding it by heat fusion. However, since this structure uses a one-component adhesive to fill the pores of waste polyurethane foam, it has the limitation that sound absorption is inevitably poor. As another example, Patent Document 2 discloses an automotive sound-absorbing material produced by attaching olefin-based powder or ethylene vinyl acetate to the surface of waste polyurethane foam scraps, distributing it between PET fibers, laminating it, heating and cooling to produce a cotton PET fabric, and then compressing it using a mold after preheating. However, this has the problem that sound absorption is significantly reduced as the pores become clogged because olefin-based powder or water-soluble EVA is coated on the surface of the polyurethane foam. The background technology or prior art described above is information possessed by the inventor or acquired in the process of deriving and completing the present invention, and is specified as it helps in understanding the technical significance of the present invention and is useful for prior art search and examination. FIG. 1 is a flowchart schematically illustrating a method for manufacturing a sound-absorbing and sound-insulating material for a drive module of an electric vehicle E-GMP according to an embodiment of the present invention. FIG. 2 is a schematic cross-sectional view of a sound-absorbing and sound-insulating material for a drive module of an electric vehicle E-GMP according to an embodiment of the present invention. FIG. 3 is a schematic cross-sectional view of a sound-absorbing and sound-insulating material for a drive module of an electric vehicle E-GMP according to another embodiment of the present invention. Hereinafter, embodiments according to the present invention will be described in more detail with reference to the attached drawings. Prior to this, it is specified that the terms described below are defined in consideration of their functions in the present invention, and should be interpreted in accordance with the concept consistent with the technical spirit of the present invention and the meaning commonly accepted or recognized in the relevant technical field. In addition, if it is determined that a detailed description