Heavy Porous Soundproofing Layer for Vehicle Acoustic Insulation
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Solution Overview
Problem
Current soundproofing complexes in vehicles are inadequate due to difficulties in recycling, high material costs, and a compromise between acoustic performance and vehicle mass, as well as lengthy manufacturing times, while also lacking mechanical strength and localized acoustic and mechanical performance.
Innovation Solution
A heavy porous soundproofing layer composed of entangled fibers and polymeric particles with a hot-melt binder, allowing for adjustable density and flexibility, combined with a fibrous spring layer, which can be parameterized for localized noise treatment and mechanical performance, enabling effective insulation and absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional heavy mass layers (impermeable polymer with mineral fillers) are used for acoustic insulation, then insulation performance is improved, but sound absorption capability deteriorates due to sealing
Solution Approach 1:
The patent uses a porous foam material (polyurethane or polyester) as the heavy mass layer instead of traditional impermeable polymers. This porous structure allows air to pass through while maintaining mass effect for insulation, and simultaneously enables sound absorption through the void spaces that dissipate acoustic energy.
2Reliability
If multi-material soundproofing complexes are used to achieve both insulation and absorption, then acoustic performance is improved, but recyclability deteriorates due to material separation difficulty
Solution Approach 1:
The patent combines the insulation function and absorption function into a single integrated porous foam layer. This single-material approach eliminates the need to separate multiple materials for recycling, while still achieving both insulation (through mass effect) and absorption (through porous structure) simultaneously.
Solution Approach 2:
The porous foam layer serves multiple functions: it provides acoustic insulation through its mass effect, sound absorption through its porous structure, and mechanical properties through its foam composition. This multi-functional single material replaces traditional multi-material complexes.
3Reliability
If density and thickness of spring-forming layer are increased to improve insulation, then acoustic insulation is improved, but vehicle mass increases
Solution Approach 1:
The porous foam material provides insulation through its cellular structure which traps air and reduces sound transmission, while being inherently lightweight. The foam's low density compared to solid materials allows achieving insulation performance without proportionally increasing mass.
Solution Approach 2:
The patent uses composite foam structures combining polymeric matrix with air voids, creating a material that has both the mass effect needed for insulation and the low density required for weight reduction. The cellular architecture provides insulation performance per unit mass.
4Object-generated harmful factors
If porous fibrous layers with low air resistance are used for absorption, then sound absorption is improved, but acoustic insulation deteriorates due to reduced density
Solution Approach 1:
The patent uses porous foam material that maintains high density while having controlled porosity for absorption. The foam structure provides both the mass effect for insulation and the void spaces for absorption, unlike low-density fibrous materials that sacrifice insulation for absorption.
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 solution provides enhanced acoustic insulation and absorption performance while maintaining flexibility and mechanical strength, allowing for localized adjustments to meet specific noise and mechanical demands, and is recyclable, reducing material costs and environmental impact.
Implementation Method 1
hot-melt binder fibers amalgamating the polymeric particles and the fibers
Implementation Method 2
act by acoustic absorption, that is to say by absorption and dissipation of sounds
Implementation Method 3
provide the 'mass' effect necessary for insulation. acoustic
Data Source
Figure 1~3
Figure 4~5
Figure 6~9
AI summary
The invention relates to a heavy porous soundproofing layer (2) comprising fibres which are entangled with polymer particles and thermofusible binding fibres amalgamating the polymer particles and the fibres. The invention also relates to a complex consisting of a heavy porous layer to which a springy fibrous layer (3) is applied.