Vehicular Carpet Fiber Composition for Noise and Compression Resistance
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Solution Overview
Problem
Current vehicular carpet constructions using expanded polypropylene foam pads face limitations in effectively addressing noise abatement and compression resistance while also being costly, necessitating the development of alternative materials that can improve acoustic and compression performance.
Innovation Solution
A fiber composition comprising 30% to 75% binder fiber and 25% to 70% vehicular carpet waste regrind, with specific thickness and density ranges, is used to create a multi-layer vehicular carpet construction that replaces EPP pads, enhancing sound transmission loss, insertion loss, and sound absorption coefficients, while maintaining compression resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If expanded polypropylene foam pads are used in vehicular carpet constructions, then compression resistance is maintained, but noise abatement performance is insufficient and cost is high
Solution Approach 1:
The patent uses a composite material system consisting of recycled carpet fibers (nylon, polyester, or polypropylene) bonded with adhesive to create a carpet reinforcement layer. This composite structure replaces traditional EPP foam pads and achieves both superior noise abatement through fiber composition and adequate compression resistance through adhesive bonding and layer construction, while reducing costs via material recycling.
2Ease of manufacture
If expanded polypropylene foam pads are used in vehicular carpet constructions, then compression resistance is maintained, but manufacturing cost is high
Solution Approach 1:
The patent recycles discarded carpet materials (nylon, polyester, or polypropylene fibers) from vehicular interiors, grinding them into reusable fibers. This recovery process transforms waste materials into a cost-effective replacement for virgin EPP foam, reducing raw material costs while maintaining functional performance through proper fiber selection and adhesive bonding.
3Ease of manufacture
If alternative materials are used to replace EPP pads, then cost is reduced, but compression resistance may be compromised
Solution Approach 1:
The patent optimizes several parameters to achieve both cost reduction and compression resistance: selecting fibers with appropriate material properties (nylon, polyester, or polypropylene), controlling fiber length and diameter, adjusting adhesive formulation and application rate, and specifying layer thickness (0.5-2.0 mm). These parameter changes enable the recycled fiber composite to match or exceed EPP foam compression performance at lower cost.
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 fiber composition significantly improves sound abatement and compression resistance, outperforming EPP pads in sound transmission loss, insertion loss, and sound absorption, while achieving comparable or better compression performance and cost-effectiveness.
Implementation Method 1
A fiber composition comprising 30% (wt.) to 75% (wt.) binder fiber, 25% (wt.) to 70% (wt.) vehicular carpet waste regrind
Implementation Method 2
sound attenuating materials for vehicles... may be attenuated through the use of various acoustical materials
Data Source
AI summary
The present invention is directed at fiber compositions for noise abatement and compression resistance for vehicular applications. More particularly, the fiber compositions are suitable to replace expanded polypropylene foam pads utilized in vehicular carpet applications.