Method for producing a nonwoven fabric used as an engine hood insulator material

Solution Overview

Problem

Existing engine hood insulators in the automotive industry are heavy, costly, and contain high levels of carcinogenic substances, posing health and environmental risks.

Innovation Solution

A method involving partial vacuuming of thermoplastic or thermoset powder coating on a semi-finished nonwoven fabric, followed by infrared heating and cold calendering, to create a lighter, less hazardous, and cost-effective second layer for insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional multilayered insulator structure is used, then insulation performance is achieved, but weight increases and production cost increases

Engineering Contradiction:

Improveinsulation performanceVSAvoidmaterial weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent extracts and removes excess carcinogenic substances from the nonwoven fabric through a specific treatment process. The method involves coating the fabric with a composition containing silane-modified polyethylene and other agents, then heating to eliminate harmful substances while retaining the protective and insulating functions of the material structure.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the chemical and physical parameters of the nonwoven fabric through treatment with specific compositions and heating processes. This modifies the material properties to reduce carcinogenic content while maintaining or improving insulation performance, using controlled temperature and chemical composition parameters.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If traditional multilayered insulator structure is used, then insulation performance is achieved, but production cost increases

Engineering Contradiction:

Improveinsulation performanceVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent extracts and removes excess carcinogenic substances from the nonwoven fabric through a specific treatment process. The method involves coating the fabric with a composition containing silane-modified polyethylene and other agents, then heating to eliminate harmful substances while retaining the protective and insulating functions of the material structure.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the chemical and physical parameters of the nonwoven fabric through treatment with specific compositions and heating processes. This modifies the material properties to reduce carcinogenic content while maintaining or improving insulation performance, using controlled temperature and chemical composition parameters.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If traditional insulator materials are used, then protective function is achieved, but carcinogenic substance content increases

Engineering Contradiction:

Improveprotective functionVSAvoidcarcinogenic substance content

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent extracts and removes excess carcinogenic substances from the nonwoven fabric through a specific treatment process. The method involves coating the fabric with a composition containing silane-modified polyethylene and other agents, then heating to eliminate harmful substances while retaining the protective and insulating functions of the material structure.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the chemical and physical parameters of the nonwoven fabric through treatment with specific compositions and heating processes. This modifies the material properties to reduce carcinogenic content while maintaining or improving insulation performance, using controlled temperature and chemical composition parameters.

Inventive Principle:

Principle #35Parameter changes

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 method results in a lighter, less hazardous, and cost-effective insulator with reduced carcinogenic content while maintaining insulation efficiency.

Implementation Method 1

a) coating the nonwoven material in semi-finished form (the product obtained after completing stage 110) with the thermoplastic or thermoset material in powder form by a scattering method after the fixing procedure in stage 110, and obtaining a lighter, low-cost and less hazardous (to health) insulator by using less production material through vacuuming a specific part of the material

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

followed by infrared heating

Methodology Applied

Scientific EffectInfrared heating: Infrared Radiation

Implementation Method 3

cold calendering

Methodology Applied

Scientific EffectMechanical compression: Compression

Data Source

PatentUS12467173B2Method for producing a nonwoven fabric used as an engine hood insulator material

Publication Date: 2025.11.11 HASSAN TEKSTIL SANAYI VE TICARET

AI summary

A coated nonwoven product used to make engine hood insulation material is produced by a method which involves needle punching a carded, cross-lapped web, then calendering the resulting web and then applying a foam coating. Rotary screen printing is used to apply a dot pattern of an acrylic emulsion to the dried, foam-coated web. Thermoplastic and/or thermoset material is deposited onto the acrylic coating and excess material is removed by vacuum, leaving a corresponding dot coating pattern of said material. The coated web is heated using infrared energy before cooling, cold calendering and winding-up.