PU foaming material with unique cavity structure
By setting a regular array of cavity structure on the surface of the PU foamed material, the weight reduction and acoustic performance improvement of noise isolation materials in automobiles is solved, and the lightweight and acoustic performance optimization of the material are achieved.
Patent Information
- Application Number
- CN202510714445.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-05-30
- Publication Date
- 2025-08-15
AI Technical Summary
In the prior art, it is difficult to effectively reduce weight and improve acoustic performance in the noise insulation materials in automobiles.
The regular array distribution of cavity structures with specific shapes and sizes in the PU foamed material body surface, including bevel and chamfered designs, optimize material thickness and cavity depth to improve acoustic performance.
The weight reduction of PU foamed materials is achieved by 10% to 30%, cost reduction of 10% to 30%, and acoustic performance improvement of 2~3dB.
Smart Images
Figure CN120496481A_ABST
Abstract
Description
Technical Field
[0001] The present invention belongs to the field of acoustic metamaterials, and in particular relates to a PU foam material with a unique cavity structure. Background Art
[0002] Noise inside a car is primarily generated by the powertrain, tires / road surface, and airflow acting on the vehicle body, then transmitted through the vehicle body system to the human body and ears. The vehicle body system, including the body, acoustic packaging, and interior and exterior panels, is the key transmission path for isolating the source and external noise. The design and technical solutions employed within these systems (including material composition, structural dimensions, layout, assembly relationships, and detailed processing) are crucial to path sound insulation design.
[0003] Therefore, as the automotive industry pays more and more attention to lightweighting and in-vehicle noise, a PU foam material with a unique cavity structure that can improve acoustic performance is urgently needed. Summary of the Invention
[0004] In order to solve the defects of the prior art, the present invention provides a PU foam material with a unique cavity structure.
[0005] In order to solve the above technical problems, the present invention provides the following technical solutions: The present invention provides a PU foam material with a unique cavity structure, comprising a PU foam material body, wherein a plurality of cavity structures distributed in a regular array are provided on the outer surface of the PU foam material body, wherein the bottom and top of the cavity structure are respectively square structures with a lower side length and an upper side length, wherein the upper side length S is greater than the lower side length, and an oblique angle α is provided between the side surface of the cavity structure and the direction perpendicular to the bottom of the cavity structure.
[0006] Preferably, when the thickness T of the PU foam material body is between 5 and 10 mm, the depth D of the cavity structure is D=T-5 mm; when the thickness T of the PU foam material body is between 10 and 15 mm, the depth D of the cavity structure is 5 mm; when the thickness T of the PU foam material body is greater than 15 mm, the depth D of the cavity structure is 60% to 75% of the foaming thickness T.
[0007] Preferably, the distance L between the upper sides of any two adjacent cavity structure tops is 7 mm.
[0008] Preferably, the upper side length S of the top of the cavity structure is 50 to 65 mm.
[0009] Preferably, the bevel angle α is 15 to 22°.
[0010] Preferably, each edge of the cavity structure is provided with a chamfer, and the chamfer radius is 8 to 12 mm.
[0011] Compared with the prior art, the present invention has the following beneficial effects: The present invention provides a plurality of cavity structures in a regular array on the outer surface of the PU foam material body, which reduces the weight of the PU foam material by 10% to 30%, reduces the cost by 10% to 30%, and improves the acoustic performance by 2 to 3dB. BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Figure 1 This is a structural schematic diagram of a PU foam material with a unique cavity structure according to the present invention; Figure 2 This is a side view of a PU foam material with a unique cavity structure according to the present invention; Figure 3 This is a partial cross-sectional view of a PU foam material having a unique cavity structure according to the present invention; Figure 4 is an enlarged schematic diagram of the cavity structure of the present invention; Figure 5 Schematic diagram of acoustic performance of the cavity structure of different depths D in the present invention; Figure 6 It is a schematic diagram of the acoustic performance of the cavity structure with different upper side lengths in the present invention. DETAILED DESCRIPTION
[0013] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are only used to illustrate and explain the present invention, and are not used to limit the present invention.
[0014] like Figures 1 to 4 As shown, this embodiment provides a PU foam material with a unique cavity structure, including a PU foam material body 1, wherein a plurality of cavity structures distributed in a rectangular array are provided on the outer surface of the PU foam material body 1, and the bottom and top of the cavity structure 2 are respectively rectangular structures with a lower side length and an upper side length, wherein the upper side length dimension S is larger than the lower side length dimension, and an oblique angle α is provided between the side surface of the cavity structure 2 and the direction perpendicular to the bottom of the cavity structure. In this embodiment, the oblique angle α can be selected from 15°, 18°, or 22° according to actual conditions. The spacing between the upper side lengths of any two adjacent cavity structures 2 is 7 mm. The upper side length of the top of the cavity structure 2 can be selected from 50 mm, 55 mm, or 65 mm according to actual conditions. Each edge of the cavity structure 2 is provided with a chamfer, and the chamfer radius can be selected from 8 mm, 10 mm, or 12 mm according to actual conditions.
[0015] When the thickness T of the PU foam material body 1 is between 5 and 10 mm, the depth D of the cavity structure 2 is D=T-5 mm; when the thickness T of the PU foam material body 1 is between 10 and 15 mm, the depth D of the cavity structure 2 is 5 mm; when the thickness T of the PU foam material body 1 is greater than 15 mm, the depth D of the cavity structure 2 is 60% to 75% of the foaming thickness T.
[0016] In order to test the influence of the depth D of the cavity structure on the acoustic properties of the material, the depth D of the cavity structure is designed to be 0, 19%, 38%, 60%, 75%, and 100% of the foaming thickness T, respectively. Figure 5 As shown in the figure, when the depth D of the cavity structure is 0, its acoustic performance is the worst. As the depth D of the cavity structure continues to increase, until it reaches the range of 60% to 75%, its acoustic performance reaches the optimal level, and then gradually deteriorates.
[0017] In order to test the effect of the upper side length of the cavity structure on the acoustic performance of the material, the upper side lengths of the cavity structure are designed to be 0mm, 19mm, 35mm, 44mm, 50mm, and 65mm respectively in this embodiment. Figure 6 As shown in the figure, when the upper side length of the cavity structure is 0, its acoustic performance is the worst. As the upper side length of the cavity structure increases, its acoustic performance also increases. Finally, it is found that when the upper side length of the cavity structure is 50mm and 65mm, its acoustic performance is the best.
[0018] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art will be able to modify the technical solutions described in the aforementioned embodiments or substitute equivalents for some of the technical features. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.
Claims
1. A PU foam material with a unique cavity structure, characterized in that: The invention comprises a PU foam material body (1), wherein a plurality of cavity structures (2) are provided on the outer surface of the PU foam material body (1) and are regularly arrayed. The bottom and top of the cavity structure (2) are respectively rectangular structures with a lower side length and an upper side length. The upper side length S is greater than the lower side length. An oblique angle α is provided between the side surface of the cavity structure and a direction perpendicular to the bottom of the cavity structure.
2. The PU foam material with a unique cavity structure according to claim 1, characterized in that: When the thickness T of the PU foam material body (1) is between 5 and 10 mm, the depth D of the cavity structure (2) is D=T-5 mm; when the thickness T of the PU foam material body (1) is between 10 and 15 mm, the depth D of the cavity structure (2) is 5 mm; when the thickness T of the PU foam material body (1) is greater than 15 mm, the depth D of the cavity structure (2) is 60% to 75% of the foaming thickness T.
3. The PU foam material with a unique cavity structure according to claim 1, characterized in that: The distance L between the upper sides of any two adjacent cavity structures (2) is 7 mm.
4. The PU foam material with a unique cavity structure according to claim 1, characterized in that: The upper side length S of the top of the cavity structure (2) is 50 to 65 mm.
5. The PU foam material with a unique cavity structure according to claim 1, characterized in that: The bevel angle α is 15 to 22 degrees.
6. The PU foam material with a unique cavity structure according to claim 1, characterized in that: Each edge of the cavity structure (2) is provided with a chamfer, and the chamfer radius is 8 to 12 mm.