Modular Vehicle Carpet with Removable Acoustic Modules
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Solution Overview
Problem
Conventional vehicle carpet systems are costly due to the use of expensive, high-wearing materials across the entire surface, are heavy due to uniform noise attenuation requirements, and lack recyclability, leading to increased vehicle mass and decreased performance.
Innovation Solution
A modular carpet system with a molded continuous carpet base and removable acoustic modules, allowing for customizable materials and layer configurations for noise attenuation, weight optimization, and recyclability, featuring a dovetail recess design and retaining mechanisms for secure module placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expensive high-wearing materials are used across the entire carpet surface, then durability in high-wear areas is improved, but total cost increases significantly
Solution Approach 1:
The patent applies local quality by using expensive high-wearing materials only in specific high-wear areas (footwells, driver and passenger areas) rather than uniformly across the entire carpet. The carpet is divided into zones with different material properties matched to local wear requirements, reducing total material cost while maintaining durability where needed.
Solution Approach 2:
The carpet system is segmented into multiple sections with different material compositions. High-wear areas use durable materials while low-wear areas use cheaper materials. This segmentation allows optimization of cost versus durability by matching material performance to actual usage patterns in different carpet zones.
2Object-affected harmful factors
If uniform noise attenuation material is added across the entire carpet, then acoustic performance is improved, but vehicle weight increases significantly
Solution Approach 1:
The patent applies local quality by providing noise attenuation only in specific areas where acoustic performance is required, rather than uniformly across the entire carpet. Different carpet zones have different noise attenuation properties matched to local acoustic requirements, reducing total material weight while maintaining necessary noise control.
Solution Approach 2:
The carpet is segmented into zones with varying noise attenuation capabilities. Areas requiring noise control incorporate attenuating materials while other areas use lighter materials. This segmentation optimizes the balance between acoustic performance and vehicle weight by matching noise control to actual acoustic requirements in different vehicle zones.
3Object-affected harmful factors
If multi-layered composite materials are used throughout the carpet, then noise attenuation is improved, but recyclability deteriorates
Solution Approach 1:
The carpet system is segmented into separate sections that can be removed and recycled independently. Acoustic modules are separable from the main carpet base, allowing different materials to be processed through appropriate recycling streams. This segmentation improves overall recyclability while maintaining noise attenuation performance where required.
Solution Approach 2:
The patent enables discarding and recovering of acoustic modules separately from the carpet base. Used acoustic modules can be removed and sent to specialized recycling facilities while the carpet base continues to serve its function. This approach improves material recovery rates and reduces waste by enabling selective recycling of different carpet components.
4Object-affected harmful factors
If heavy noise attenuation materials are used across the entire carpet, then acoustic performance is improved, but fuel economy deteriorates
Solution Approach 1:
The patent applies local quality by providing heavy noise attenuation materials only in specific areas where acoustic performance is critical, rather than uniformly across the entire carpet. This localized approach reduces total vehicle weight while maintaining necessary noise control, thereby improving fuel economy without sacrificing acoustic performance in key areas.
Solution Approach 2:
The carpet is segmented into zones with different noise attenuation densities. Areas requiring superior noise control use heavier materials while other areas use lighter materials. This segmentation reduces overall vehicle mass while maintaining acoustic performance where needed, leading to improved fuel economy.
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 modular system reduces costs, weight, and environmental impact by using high-wearing materials only where needed, improving fuel efficiency and meeting specific acoustic requirements while enabling recyclability and easy module replacement.
Implementation Method 1
The acoustic layer forms an acoustic layer designed to absorb noise from the vehicle
Implementation Method 2
The carpet base including at least one layer of a molded noise-attenuating material
Data Source
AI summary
A vehicle carpet system has a continuous carpet base molded to the shape of the vehicle floor in which it is to be installed. The carpet base includes at least one layer of a molded noise-attenuating material, at least one molded recess formed therein. A removable acoustic carpet module fitted into the at least one recess and held in place by a releasable retainer.