# US 9,005,498 B2 · Method for manufacturing soundproofing material using polyurethane foam from car seat foam and composition thereof prepared thereby

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 9,005,498 B2
- Document ID: US9005498B2
- Status: Granted
- Kind: B2
- Application number: 13/270,718
- Filed: 2011-10-11
- Published: 2013-01-10
- Granted: 2015-04-14
- Earliest claimed: 2011-07-06
- Assignees: Hyundai Motor Company; Kia Motors Corporation
- Applicants: Hong Mo Koo; Kyungnam Kim; June Ho Yang; Young-Tae Kim
- Inventors: Hong Mo Koo; Kyungnam Kim; June Ho Yang; Young-Tae Kim
- Web page: https://patentgrep.com/patent/US9005498B2

## CPC

- B29B 17/0042: {for shaping parts, e.g. multilayered parts with at least one layer containing regenerated plastic}
- D04H 1/413: containing granules other than absorbent substances
- D04H 1/4266: Natural fibres not provided for in group D04H1/425
- D04H 1/485: in combination with weld-bonding
- D04H 1/544: Olefin series
- B29K 2075/00: Use of {PU, i.e.} polyureas or polyurethanes {or derivatives thereof}, as moulding material
- B29K 2105/04: cellular or porous
- Y02W 30/62: Plastics recycling; Rubber recycling
- B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT

## Abstract

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.

## Claims

### Claim 1

A method for preparing a soundproofing material, comprising:
crushing a discarded car seat comprised of polyurethane (PU) foam finely into a size of about 2-3 mm;
mixing the resulting crushed polyurethane (PU) foam with polyester fiber, low-melting temperature polyester fiber as a binder, polypropylene (PP) fiber, thermoplastic fiber and hemp;
carding the resulting mixture;
needle punching the carded material;
thermoforming and cooling the needle punched material into a felt; and
hot rolling and cutting the felt,
wherein the low-melting temperature polyester fiber as a binder has a melting temperature of 130-180° C. and is included in an amount of 2-50 wt %, the polypropylene (PP) fiber is included in an amount of 20-25 wt%, and the hemp is included in an amount of 10-15 wt %.

### Claim 2 (depends on 1)

The method according to claim 1, wherein the polyester fiber is selected from the group consisting of polyglycolic acid (PGA), polylactic acid (PLA), polyethylene adipate (PEA), polyhydroxyalkanoate (PHA), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT) and polyethylene naphthalate (PEN).

### Claim 3 (depends on 1)

The method according to claim 1, wherein the thermoplastic fiber is selected from the group consisting of acrylonitrile butadiene styrene (ABS), celluloid, cellulose acetate, ethylene vinyl acetate, ethylene vinyl alcohol, polyoxymethylene, polyacrylate, polyamide, polyamide-imide, polyaryletherketone, polybutadiene, polybutylene, polybutylene terephthalate, polycaprolactone, polyethylene terephthalate, polycyclohexylenedimethylene terephthalate, polycarbonate, polyethylene, polyetherimide, polyimide, polylactic acid, polymethylpentene, polyphenylene oxide, polyphenylene sulfide, polyphthalamide, polystyrene, polysulfone, polyurethane, polyvinyl acetate, polyvinyl chloride and styrene acrylonitrile.

### Claim 4 (depends on 1)

The method according to claim 1, wherein the mixture comprises 10-80 wt % of crushed seat foam and 10-80 wt % of the polyester fiber.

### Claim 5 (depends on 1)

The method according to claim 1, wherein the polyurethane foam is thermoset polyurethane foam.