Porous Foam Structural Component for Vehicle Acoustic Sealing
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Solution Overview
Problem
Conventional structural components used for acoustic sealing and reinforcement in vehicle bodies face challenges such as high manufacturing effort due to undercuts and insufficient damping of acoustic sound waves, particularly in the direction of the structural component's longitudinal axis.
Innovation Solution
A structural component with at least two support levels and interconnected surface elements, where structural material fills the gaps between the support levels, forming corridors and extending through passages, providing a continuous layer for sealing, reinforcement, and damping, and using expandable material to secure the component in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional bulkhead parts with plastic carriers and edge areas are used, then the structural component provides basic sealing, but manufacturing effort increases due to required undercuts and damping of acoustic sound waves is insufficient
Solution Approach 1:
The patent uses a porous foam material that is injected into the carrier structure. The foam material fills the interior space and peripheral area of the carrier, creating a porous structure that effectively dampens acoustic sound waves while eliminating the need for complex undercut designs in the carrier itself.
Solution Approach 2:
The patent combines a plastic carrier with a foam material to create a composite structural component. The carrier provides the structural framework while the foam material provides acoustic damping, achieving both structural integrity and noise reduction without requiring undercuts.
2Reliability
If flat inserts with thermally expandable strands are used, then acoustic sealing is provided, but manufacturing complexity increases due to multiple undercuts and insufficient attenuation of sound waves moving in the longitudinal direction
Solution Approach 1:
The foam material is injected into the carrier and expands to fill all interior spaces and peripheral areas. This porous foam structure provides effective acoustic sealing and attenuation of sound waves in all directions, including the longitudinal direction, while requiring no undercuts for material retention.
Solution Approach 2:
The foam material is applied in a liquid or semi-liquid state and then expands automatically to fill the carrier interior and peripheral areas. This self-expanding property eliminates the need for complex molding features like undercuts, as the foam naturally fills and secures itself within the carrier structure.
3Reliability
If two plate elements connected via hinge with foam material are used, then sealing capability is improved, but assembly effort increases due to required pivoting operation
Solution Approach 1:
The structural component is divided into a carrier structure and an separately applicable foam material. The carrier is pre-formed without undercuts, and the foam material is injected separately, allowing for simplified manufacturing and assembly without requiring pivoting operations or complex pre-assembly steps.
Solution Approach 2:
The foam material is injected into the carrier in a fluid state and then expands to fill the interior space and peripheral areas automatically. This self-expanding process eliminates the need for manual assembly operations such as pivoting plate elements, reducing assembly effort while maintaining effective sealing capability.
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
This design results in a strong, torsion-resistant component with enhanced damping, insulation, and reinforcement capabilities, ensuring effective sealing and noise reduction while simplifying production by eliminating undercuts and ensuring positional fixation of the structural material.
Implementation Method 1
acoustic sound waves that move in the direction of the longitudinal axis of the structural component
Implementation Method 2
the process heat from the ovens is then used to harden the cathodic dip coating (KTL or E-coat), for example to trigger an expansion of an expandable part of the structural component
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The invention relates to a structural component (1), comprising a support (2) made of at least two support layers (100, 200), which are arranged spaced apart from each other in such a manner that an intermediate space (3) is formed between a first support layer (100) and a second support layer (200) located opposite the first support layer (100), wherein the support layers (100, 200) have a plurality of surface elements (101, 201) which are connected to each other and are separated from each other at least in some regions by respective free spaces (102, 202), wherein the surface elements (101) of the first support layer (100) are connected to surface elements (201) of the second support layer (200) via webs (10) in such a manner that passages (11) are formed in each case between adjacent webs (10), and wherein a structural material (6) is provided at least in some regions in the intermediate space (3) between the support layers (100, 200), which material extends through the passages (11) between the webs (10) in the intermediate space (3), and wherein the structural material (6) forms at least in some regions the outer surface (4, 5) of the structural component (1).