Functional Laminate with Porous Intermediate Layer for Acoustic Damping

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Solution Overview

Problem

Existing sound-absorbing materials for engine powertrain members in vehicles fail to achieve sufficient sound absorbability and thermal insulation, despite attempts using foamed products with glass fiber nonwoven fabrics.

Innovation Solution

A functional laminate comprising a porous intermediate layer with air permeability, high affinity to the foaming resin, laminated between a porous surface layer and a resin foamed layer, which moderates the capillary phenomenon to enhance sound absorbability, thermal insulation, and damping properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a porous surface layer is directly combined with a resin foamed layer, then the structure is simple, but sound absorbability is insufficient

Engineering Contradiction:

Improvestructure simplicityVSAvoidsound absorbability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The laminate is divided into three distinct layers: a porous surface layer, a porous intermediate layer with affinity to foaming resin, and a resin foamed layer. This segmentation allows each layer to perform its specific function, with the intermediate layer moderating capillary phenomenon to optimize sound absorbability while maintaining structural organization.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The porous intermediate layer acts as an intermediary between the porous surface layer and the resin foamed layer. It has specific affinity to the foaming resin, which moderates the capillary phenomenon and prevents excessive resin penetration into the porous surface layer, thereby achieving optimal sound absorbability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If foaming resin is directly applied to porous surface layer, then manufacturing is simple, but thermal insulation is insufficient

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidthermal insulation

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The thermal insulation function is enhanced by segmenting the structure into three layers, where the porous intermediate layer with controlled resin affinity creates optimal conditions for thermal insulation by preventing excessive resin penetration while maintaining manufacturing feasibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The affinity parameter of the porous intermediate layer to the foaming resin is specifically controlled to moderate capillary phenomenon. This parameter change optimizes both thermal insulation performance and manufacturing simplicity by regulating resin distribution.

Inventive Principle:

Principle #35Parameter changes

3Strength

If glass fiber nonwoven fabric is used with foaming molding, then structural integrity is maintained, but sound absorbability remains insufficient

Engineering Contradiction:

Improvestructural integrityVSAvoidsound absorbability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The invention uses a composite laminate structure combining porous surface layer (which can be glass fiber nonwoven fabric), porous intermediate layer with affinity to foaming resin, and resin foamed layer. This composite structure maintains structural integrity while significantly enhancing sound absorbability through controlled capillary phenomenon.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The porous intermediate layer serves as a mediator that preserves the structural integrity of the glass fiber nonwoven fabric while optimizing sound absorbability by controlling resin distribution and preventing excessive penetration.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 laminate significantly improves sound absorbability, thermal insulation, and damping properties, making it suitable for use in engine-equipped machines like vehicles and agricultural machinery.

Implementation Method 1

the porous intermediate layer has an affinity to a foaming resin forming the resin foamed layer... which moderates the capillary phenomenon to enhance sound absorbability

Methodology Applied

Scientific EffectCapillary phenomenon: Capillary Action

Implementation Method 2

functional laminate including a porous intermediate layer having air permeability laminated between a porous surface layer and a resin foamed layer... more excellent in sound absorbability

Methodology Applied

Scientific EffectAcoustic absorption: Acoustic Absorption

Implementation Method 3

functional laminate... more excellent in thermal insulating properties

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11535005B2Functional laminate and production method therefor

Publication Date: 2022.12.27 MAZDA MOTOR CORP

AI summary

Provided is a functional laminate including a porous intermediate layer having air permeability laminated between a porous surface layer and a resin foamed layer, the porous intermediate layer having an affinity to a foaming resin forming the resin foamed layer.