Vertically Lapped Fiber Composite Flooring for Vehicle Acoustics
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Solution Overview
Problem
Traditional transportation vehicle flooring systems using expanded polypropylene or expanded polystyrene foams are ineffective for acoustic absorption and require complex, time-consuming installation, while lacking compression resistance and being prone to molding and breakage.
Innovation Solution
A vertically lapped fiber composite structure with multiple layers of varying air flow resistance, including scrim layers, is used to create a lightweight, molded flooring assembly that provides enhanced sound absorption, compression resistance, and simplified installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If expanded polypropylene or expanded polystyrene foam blocks are used to fill packaging space and add stiffness, then compression resistance and structural support are improved, but acoustic absorption performance deteriorates
Solution Approach 1:
The patent combines fibrous acoustic absorber material with foam blocks in a composite structure. The fibrous layer provides acoustic absorption while the foam blocks provide compression resistance and stiffness. This composite approach allows both acoustic and mechanical requirements to be met simultaneously, resolving the contradiction between acoustic absorption and compression resistance.
2Object-affected harmful factors
If traditional barrier/fiber or barrier/foam layers are used with separate foam block installation, then acoustic absorption is provided, but installation complexity and time increase
Solution Approach 1:
The patent merges the fibrous acoustic absorber layer and the foam blocks into a single integrated assembly. The foam blocks are positioned within recesses of the fibrous layer, creating a unified structure that is installed as one piece rather than separate components. This eliminates the need for separate installation steps, reducing installation time and complexity while maintaining acoustic absorption performance.
3Volume of moving object
If close cell foams are used to fill packaging space, then space utilization is improved, but acoustic absorption performance deteriorates
Solution Approach 1:
The patent applies different material properties to different regions: the fibrous acoustic absorber material is used in regions where acoustic absorption is prioritized, while the close-cell foam blocks are used in regions where compression resistance and space filling are prioritized. This local differentiation allows the packaging space to be fully utilized while maintaining acoustic absorption performance in appropriate areas.
4Ease of operation
If traditional flooring systems are used, then installation is straightforward, but the system is prone to molding, breakage, and requires higher mass
Solution Approach 1:
The integrated composite assembly combines the durability of foam blocks with the resistance properties of the fibrous acoustic absorber material. This composite structure provides resistance to molding and breakage while maintaining ease of installation as a single unit, resolving the contradiction between installation simplicity and reliability.
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 multi-impedance mismatched composite structure achieves improved noise reduction and sound absorption capabilities while reducing material mass and manufacturing costs, offering a durable, easy-to-install solution for vehicle flooring.
Implementation Method 1
a vertical lapped absorber layer for acoustic absorption
Implementation Method 2
a densified fibrous air-flow resistive layer
Implementation Method 3
compression resistance
Data Source
Figure 1
AI summary
A flooring assembly comprising at least one first lofted lapped or airiald bulk absorber layer 14 for acoustic absorption and compression resistance; at least one impedance layer 16 for one or more of acoustic impedance, compression resistance, and stiffness; at least one second lofted lapped airlaid bulk absorber layer 18 for acoustic absorption and compression resistance; and one or more optional densifled fibrous air-flow resistive layers 12, 20.