Elastomeric-resin hybrid composite with elastomeric layers

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Solution Overview

Problem

Existing materials fail to effectively mitigate noise, vibration, and harshness (NVH) while providing structural integrity and flexibility for complex shapes in various industries, including automotive, aerospace, and construction.

Innovation Solution

Development of elastomeric-resin hybrid composites with elastomeric layers, featuring a flexible woven non-metallic substrate reinforced with resin impregnation, fillers, and viscoelastic coatings, applied through continuous or semi-continuous processes to enhance mechanical and acoustic properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional materials are used for sealing and noise reduction, then manufacturing simplicity is maintained, but NVH mitigation performance and structural integrity are insufficient

Engineering Contradiction:

ImproveNVH mitigation performanceVSAvoidcomposite structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies composite materials by combining a non-metallic woven fabric substrate with resin impregnation and elastomeric coatings to create a multi-functional material that simultaneously provides structural integrity, flexibility, and superior NVH mitigation performance, resolving the contradiction between performance and complexity through integrated material design

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent merges multiple functions into a single composite structure by integrating the substrate, resin reinforcement, and elastomeric coating layers into one unified material system that delivers both structural support and noise/vibration reduction capabilities, eliminating the need for separate components

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If rigid structural materials are used, then structural support is provided, but flexibility for complex shapes and NVH mitigation are reduced

Engineering Contradiction:

Improvestructural integrityVSAvoidflexibility for complex shapes

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent changes the material parameters by using a non-metallic woven fabric substrate with resin impregnation that provides structural strength while maintaining flexibility, allowing the material to adapt to complex shapes and provide superior NVH mitigation compared to traditional rigid materials

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs flexible shells and thin films through the elastomeric coating layer applied over the resin-impregnated substrate, creating a flexible yet structurally sound composite that can conform to complex geometries while maintaining structural integrity and providing noise/vibration reduction

Inventive Principle:

Principle #30Flexible shells and thin films

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 composites provide enhanced NVH mitigation, structural support, and flexibility, with improved adhesion and thermal stability, suitable for diverse applications requiring noise reduction and sealing.

Implementation Method 1

a woven fiber material that is reinforced with resin impregnation

Methodology Applied

Scientific EffectResin impregnation: Composite Materials

Implementation Method 2

have a viscoelastic coating applied

Methodology Applied

Scientific EffectViscoelasticity: Viscoelasticity

Implementation Method 3

acoustic damping adhesive layers applied

Methodology Applied

Scientific EffectVibration damping: Damping

Implementation Method 4

elastomeric-resin hybrid composites with elastomeric layers

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 5

The resin may also contain fillers to enhance structural and mechanical properties (e.g., sound and/or thermal insulation)

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20250290248A1Elastomeric-resin hybrid composite with elastomeric layers

Publication Date: 2025.09.18 WOLVERINE ADVANCED MATERIALS LLC

AI summary

A noise, vibration, harshness (NVH) mitigation material comprising a non-metallic woven fabric substrate impregnated with a resin and one or more elastomeric layers applied to at least one surface of the non-metallic woven fabric substrate is disclosed herein. A method to fabricate a noise, vibration, harshness (NVH) mitigation material comprising preparing an impregnating resin comprising a resin and one or more of a filler and a toughening agent; impregnating a non-metallic woven fabric substrate with the impregnating resin by soaking the non-metallic woven fabric substrate with the impregnating resin, drying the impregnated non- metallic woven fabric substrate, and curing the impregnated non-metallic woven fabric substrate; and applying one or more elastomeric coatings onto the impregnated non-metallic woven fabric substrate is also disclosed herein.