# US 11,999,142 B2 · Light and thin sound-absorbing material and method of manufacturing same

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- Number: US 11,999,142 B2
- Document ID: US11999142B2
- Status: Granted
- Kind: B2
- Application number: 17/503,795
- Filed: 2021-10-18
- Published: 2022-05-12
- Granted: 2024-06-04
- Earliest claimed: 2020-11-06
- Assignees: Hyundai Motor Company; Kia Corporation
- Applicants: Hyundai Motor Company; Kia Corporation
- Inventors: Seong Je Kim
- Web page: https://patentgrep.com/patent/US11999142B2

## CPC

- B32B 27/12: next to a fibrous or filamentary layer
- D01D 5/0985: {by means of a flowing gas (e.g. melt-blowing)}
- B32B 5/022: {Non-woven fabric}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/265: {characterised by one fibrous or filamentary layer being a non-woven fabric layer}
- B32B 27/065: {of foam}
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/306: {comprising vinyl acetate or vinyl alcohol (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/34: comprising polyamides
- B32B 27/36: comprising polyesters
- B32B 27/365: {comprising polycarbonates}
- B32B 27/40: comprising polyurethanes
- B32B 37/182: {one or more of the layers being plastic}
- D01F 6/06: from polypropylene
- D01F 6/62: from polyesters
- G10K 11/168: Plural layers of different materials, e.g. sandwiches
- B32B 37/24: with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate (B32B37/15 takes precedence)
- B32B 2262/0253: Polyolefin fibres
- B32B 2262/0276: Polyester fibres
- B32B 2262/0284: Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
- B32B 2262/16: Structural features of fibres, filaments or yarns e.g. wrapped, coiled, crimped or covered
- B32B 2266/0278: Polyurethane
- B32B 2270/00: Resin or rubber layer containing a blend of at least two different polymers
- B32B 2274/00: Thermoplastic elastomer material
- B32B 2307/102: Insulating
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/732: Dimensional properties
- B32B 2605/003: Interior finishings
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- D01D: MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01F: CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- G10K: SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR

## Abstract

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.

## Claims

### Claim 1

A sound-absorbing material comprising:
a surface layer comprising low-melting (LM) fibers and melt-blown (MB) fibers; and
a sound-absorbing layer disposed on at least one side of the surface layer;
wherein the low-melting (LM) fibers and melt-blown (MB) fibers are mixed in the surface layer; and
wherein the surface layer comprises, based on a total of 100 wt % of the surface layer, 10 to 50 wt % of the low-melting (LM) fibers and 50 to 90 wt % of the melt-blown (MB) fibers.

### Claim 2 (depends on 1)

The sound-absorbing material of claim 1, wherein the low-melting (LM) fibers have a fineness of 3 to 5 denier and a length of 40 to 60 mm.

### Claim 3 (depends on 1)

The sound-absorbing material of claim 1, wherein the melt-blown (MB) fibers have an average diameter of 0.3 to 10 μm.

### Claim 4 (depends on 1)

The sound-absorbing material of claim 1, wherein a weight of the surface layer is 30 to 300 gsm.

### Claim 5 (depends on 1)

The sound-absorbing material of claim 1, wherein a thickness of the surface layer is 0.1 to 2 mm.

### Claim 6 (depends on 1)

The sound-absorbing material of claim 1, wherein the sound-absorbing layer comprises at least one material selected from the group consisting of polyethylene terephthalate (PET), polyurethane, and mixtures thereof.

### Claim 7 (depends on 1)

The sound-absorbing material of claim 1, further comprising a sound-insulating layer interposed between the surface layer and the sound-absorbing layer, the sound-insulating layer comprising at least one material selected from the group consisting of polypropylene (PP), polycarbonate (PC), polyamide 6 (PA6), polyamide 66 (PA66), polyvinyl chloride (PVC), thermoplastic olefin (TPO), thermoplastic elastomer (TPE), ethylene vinyl acetate (EVA), and mixtures thereof.

### Claim 8 (depends on 1)

The sound-absorbing material of claim 1, further comprising a skin layer formed on the surface layer, the skin layer comprising at least one material selected from the group consisting of polyester fiber and polypropylene fiber.

### Claim 9

A method of manufacturing a sound-absorbing material, the method comprising:
spinning melt-blown (MB) fibers;
manufacturing a surface layer by mixing the melt-blown (MB) fibers with low-melting (LM) fibers, wherein the surface layer comprises, based on a total of 100 wt % of the surface layer, 10 to 50 wt % of the low-melting (LM) fibers and 50 to 90 wt % of the melt-blown (MB) fiber;
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.

### Claim 10 (depends on 9)

The method of claim 9, wherein spinning the melt-blown (MB) fibers is performed at a spinning temperature of 230 to 300° C. and a spinning pressure of 4 to 8 psi.

### Claim 11 (depends on 9)

The method of claim 9, wherein manufacturing the surface layer comprises:
hot-pressing fibers obtained by mixing the melt-blown (MB) fibers with the low-melting (LM) fibers; and
cutting the hot-pressed fibers.

### Claim 12

A method of manufacturing a sound-absorbing material, the method comprising:
forming a surface layer comprising low-melting (LM) fibers and melt-blown (MB) fibers; and
forming a sound-absorbing layer on at least one side of the surface layer;
wherein the low-melting (LM) fibers and melt-blown (MB) fibers are mixed in the surface layer; and
wherein the surface layer comprises, based on a total of 100 wt % of the surface layer, 10 to 50 wt % of the low-melting (LM) fibers and 50 to 90 wt % of the melt-blown (MB) fibers.

### Claim 13 (depends on 12)

The method of claim 12, wherein forming the surface layer comprises spinning the melt-blown (MB) fibers and mixing the melt-blown (MB) fibers with the low-melting (LM) fibers.

### Claim 14 (depends on 12)

The method of claim 12, wherein forming the sound-absorbing layer comprises laminating the sound-absorbing layer on the surface layer.

### Claim 15 (depends on 12)

The method of claim 12, wherein the low-melting (LM) fibers have a fineness of 3 to 5 denier and a length of 40 to 60 mm.

### Claim 16 (depends on 12)

The method of claim 12, wherein the melt-blown (MB) fibers have an average diameter of 0.3 to 10 μm.

### Claim 17 (depends on 12)

The method of claim 12, wherein a weight of the surface layer is 30 to 300 gsm.

### Claim 18 (depends on 12)

The method of claim 12, wherein a thickness of the surface layer is 0.1 to 2 mm.

### Claim 19 (depends on 12)

The method of claim 12, wherein the sound-absorbing layer comprises at least one material selected from the group consisting of polyethylene terephthalate (PET), polyurethane, and mixtures thereof.

### Claim 20 (depends on 12)

The method of claim 12, further comprising forming a skin layer formed on the surface layer, the skin layer comprising at least one material selected from the group consisting of polyester fiber and polypropylene fiber.