Automotive Dash Silencer Multi-Layer Soundproof Sheet
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Solution Overview
Problem
Conventional soundproofing materials for vehicles, such as dash insulators, have insufficient sound absorption and insulation performance due to their single-layer or simple lamination structures, which fail to effectively absorb and insulate a wide range of noise frequencies from the engine room.
Innovation Solution
A soundproof sheet with a lamination structure comprising a first outer layer made of porous material, an intermediate film lamination body, and a second outer layer with one-side porous and the other-side sound insulation materials, where the intermediate layer is layered on both outer layers and the second outer layer is further layered on the intermediate layer, enhancing sound absorption and insulation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-layer sound absorbing material is used, then the structure is simple, but the sound absorption performance is insufficient
Solution Approach 1:
The patent applies composite materials by creating a multi-layer soundproof sheet combining different materials with distinct acoustic properties. The first outer layer uses porous material for high-frequency absorption, the intermediate layer uses film lamination for mid-frequency absorption, and the second outer layer combines porous and sound insulation materials for low-frequency absorption and insulation, achieving comprehensive soundproofing across all frequency ranges
Solution Approach 2:
The patent segments the soundproofing function into three distinct layers, each targeting specific frequency ranges. The first outer layer handles high frequencies, the intermediate layer handles mid frequencies, and the second outer layer handles low frequencies, allowing each segment to optimize its performance for its designated frequency range
2Ease of manufacture
If a simple lamination structure of base sound absorbing layer and foamed resin sheet is used, then the manufacturing is easy, but the sound absorption and insulation performance are still insufficient
Solution Approach 1:
The patent enhances the simple lamination structure by incorporating three different material types with complementary acoustic properties. The porous material in the first outer layer provides high-frequency absorption, the film lamination in the intermediate layer provides mid-frequency absorption, and the combination of porous and sound insulation materials in the second outer layer provides low-frequency absorption and insulation, creating a composite structure that maintains manufacturing simplicity while achieving superior performance
Solution Approach 2:
The patent applies local quality by assigning different material properties to different layers based on their specific acoustic functions. Each layer is optimized with materials having appropriate porosity, density, and acoustic impedance for its designated frequency range, allowing each local region of the soundproof sheet to excel at its specific task
3Object-affected harmful factors
If sound insulation material is installed to not oppose the inner portion of the instrument panel, then reflected noises are reduced, but the sound insulation performance is insufficient
Solution Approach 1:
The patent resolves this contradiction by creating a composite second outer layer that combines porous material and sound insulation material. The porous material portion absorbs reflected high-frequency noises, while the sound insulation material portion provides low-frequency insulation, allowing the structure to handle both reflected noises and maintain strong sound insulation performance simultaneously
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 proposed soundproof sheet effectively absorbs and insulates noise frequencies across a wide range, improving soundproofing by utilizing the porous material for high-frequency absorption and sound insulation material for low-frequency insulation, thereby reducing noise transmission into the vehicle compartment.
Implementation Method 1
the sound absorbing material absorbs mainly noises of a high frequency range
Implementation Method 2
the sound insulation material insulates mainly noises of a low frequency range
Data Source
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AI summary
A dash silencer is constructed by layering a front side layer formed from a porous material, an intermediate layer constructed by a film structure body and a rear side layer. The rear side layer has upper and lower side layer portions which are formed from porous and sound insulation materials respectively and layered on upper and lower side layer portions of the intermediate layer.