Vehicle Load Floor Honeycomb Paper Polyurethane Noise Reduction

Solution Overview

Problem

Conventional load floors for vehicles are heavy, reducing fuel efficiency and failing to effectively absorb noise and vibrations, leading to a compromised indoor environment due to noise transfer from the trunk to the passenger compartment.

Innovation Solution

A load floor manufactured with a honeycomb structure made of paper, featuring polyurethane sheets on both sides and punched holes in at least one sheet, providing improved structural stiffness, sound absorption, and insulation, optimized for specific frequency bands to reduce noise and enhance indoor comfort.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional load floors are manufactured with reinforced natural fiber board or injection-molded polypropylene, then structural strength is achieved, but weight increases reducing fuel efficiency

Engineering Contradiction:

Improvestructural strengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies composite materials by combining a paper honeycomb core structure with polypropylene skin layers. This composite construction achieves the required structural strength while significantly reducing weight compared to conventional solid natural fiber boards or injection-molded polypropylene, as the honeycomb structure provides high strength-to-weight ratio through its geometric configuration rather than material density alone

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent utilizes porous materials by implementing a honeycomb structure with cellular voids. This porous configuration reduces the overall density and weight of the load floor while maintaining structural integrity through the distributed cellular framework. The hollow chambers within the honeycomb structure contribute to weight reduction without compromising the load-bearing capacity

Inventive Principle:

Principle #31Porous materials

2Stability of the object's composition

If conventional load floors are manufactured with solid materials, then structural stiffness is achieved, but sound absorption performance is lowered

Engineering Contradiction:

Improvestructural stiffnessVSAvoidsound absorption performance

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The patent employs composite materials consisting of a paper honeycomb core sandwiched between polypropylene skin layers. This composite structure achieves structural stiffness through the rigid skin layers and the geometric stability of the honeycomb core, while the porous nature of the honeycomb structure simultaneously provides sound absorption by trapping and dissipating acoustic energy within its cellular voids

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent utilizes porous materials by implementing a honeycomb structure with cellular voids. This porous configuration reduces the overall density and weight of the load floor while maintaining structural integrity through the distributed cellular framework. The hollow chambers within the honeycomb structure contribute to weight reduction without compromising the load-bearing capacity

Inventive Principle:

Principle #31Porous materials

3Ease of operation

If trunk and passenger compartment are opened to each other for loading equipment, then loading convenience is improved, but noise and vibration transfer to passenger compartment

Engineering Contradiction:

Improveloading convenienceVSAvoidnoise and vibration transfer

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent utilizes porous materials by implementing a honeycomb structure with cellular voids. This porous configuration reduces the overall density and weight of the load floor while maintaining structural integrity through the distributed cellular framework. The hollow chambers within the honeycomb structure contribute to weight reduction without compromising the load-bearing capacity

Inventive Principle:

Principle #31Porous materials

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 results in a lighter load floor with enhanced structural stiffness and noise reduction, improving fuel efficiency and maintaining a pleasant indoor environment by effectively absorbing and insulating noise, while allowing for optimal noise performance tailored to the vehicle model.

Implementation Method 1

a sound absorption effect may be obtained in addition to obtaining light and sufficient structural stiffness

Methodology Applied

Scientific EffectSound absorption: Acoustic Absorption

Implementation Method 2

as the polyurethane sheets are respectively provided on both surfaces of the honeycomb structure, sound absorption and insulation performances are obtained

Methodology Applied

Scientific EffectSound insulation: Acoustics

Data Source

PatentUS10166737B2Load floor having sound absorption and insulation performances for vehicle

Publication Date: 2019.01.01 DAESOL AUSYS CO LTD

AI summary

A load floor for a vehicle, by which, as the load floor is manufactured by including manufacturing a honeycomb structure with paper and adding polyurethane sheets to both side surfaces of the honeycomb structure, light and sufficient structural stiffness and a sound absorption effect are obtained through the honeycomb structure. As the polyurethane sheets are respectively provided on both surfaces of the honeycomb structure, sound absorption and insulation performances are obtained to further increase a sound absorption and insulation effect.