Double-Wall Cargo Room Trim for Noise Absorption and Deep Drawing
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Solution Overview
Problem
Existing cargo room trims face challenges in molding the front and rear portions with different elongation rates, necessitating separate materials for sound absorption and structural integrity, which complicates manufacturing and increases costs.
Innovation Solution
A cargo room trim design featuring a first plate section with an elongation rate of 120% or higher, combined with a second plate section and a sound absorbing material, forms a double wall structure that absorbs high-frequency noise without material fracture, allowing both portions to be molded as a solid plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a fiber reinforced sheet is used for the front portion of the cargo room trim to achieve sound absorption, then high-frequency noise absorption is improved, but the elongation rate is insufficient for deep drawing of the rear portion
Solution Approach 1:
The cargo room trim is divided into a front portion and a rear portion that can be manufactured separately using different materials optimized for their specific functions, then assembled together. The front portion uses fiber reinforced sheet for sound absorption while the rear portion uses high elongation resin for deep drawing.
Solution Approach 2:
The invention uses composite material construction where the front portion employs fiber reinforced sheet containing glass fiber for sound absorption properties, while the rear portion uses resin with high elongation rate (120% or more) to enable deep drawing operations without fracture.
2Object-affected harmful factors
If separate materials are used for the front and rear portions of the cargo room trim, then sound absorption and deep drawing requirements are met, but manufacturing complexity and cost increase
Solution Approach 1:
The trim is segmented into front and rear portions that can be manufactured independently using different materials, allowing each segment to be optimized for its specific functional requirements while simplifying the overall manufacturing process.
Solution Approach 2:
The front portion (sound absorption section) and rear portion (deep drawing section) are merged into a single integrated cargo room trim assembly, combining the benefits of different materials while maintaining functional performance.
3Ease of manufacture
If a resin with high elongation rate is used for the rear portion to enable deep drawing, then moldability is improved, but the front portion cannot achieve adequate sound absorption
Solution Approach 1:
The cargo room trim is segmented into distinct front and rear portions, each using materials optimized for their specific requirements: high elongation resin for deep drawing in the rear, and fiber reinforced sheet for sound absorption in the front.
Solution Approach 2:
Different composite materials are used in different sections: the rear portion uses resin with elongation rate of 120% or more for deep drawing, while the front portion uses fiber reinforced sheet with glass fiber for sound absorption.
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 design ensures high-frequency noise absorption, reduces manufacturing costs, enhances moldability, and increases rigidity while eliminating the need for additional sound-insulating materials, thus improving overall performance and reducing weight.
Implementation Method 1
a sound absorbing material disposed between the first plate section and the second plate section
Implementation Method 2
a fiber reinforced sheet containing a glass fiber for a sound absorption effect is used as a wall material to face a cargo room. The fiber reinforced sheet mainly absorbs high-frequency tire pattern noise since the fiber reinforced sheet has sound absorption properties.
Data Source
AI summary
A cargo room trim is included in a side wall of a cargo room disposed horizontally next to and/or above a rear wheel of a vehicle. The cargo room trim includes: a first plate section that includes a resin having an elongation rate which is equal to or greater than 120%, and has: an outward recess recessed from an inner side of the cargo room to an outer side of the cargo room; and an inward recess that is continuous with the outward recess in a front-back direction of the cargo room, and is recessed from the outer side of the cargo room to the inner side of the cargo room; a second plate section disposed along the first plate section; and a sound absorbing material disposed between the first plate section and the second plate section.