Multi-Zone Polyurethane Floor Covering for Vehicle Sound Insulation

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Solution Overview

Problem

Existing floor coverings in motor vehicles lack effective sound-insulating properties and require additional components or complex manufacturing processes to achieve desired acoustic performance, leading to increased weight and cost.

Innovation Solution

A motor vehicle floor covering made of foamed viscoelastic polyurethane foam is formulated to have varying properties zone-by-zone, integrated into the foam itself without additional components, using a multi-zone design and controlled foaming process to achieve enhanced insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If additional sound-absorbing components or films are integrated into the floor covering, then sound-insulating properties are improved, but device complexity and manufacturing complexity increase

Engineering Contradiction:

Improvesound insulationVSAvoidstructure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent combines multiple functions (sound insulation, thermal insulation, comfort, and structural support) into a single integrated foam insulation layer. This eliminates the need for separate sound-absorbing films or additional components, thereby improving sound insulation without increasing device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The foam insulation layer is designed to perform multiple functions simultaneously: sound absorption, thermal insulation, comfort provision, and structural support. This multi-functional approach allows a single component to address various requirements, reducing overall system complexity while improving acoustic performance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Object-affected harmful factors

If additional sound-absorbing components or films are integrated into the floor covering, then sound-insulating properties are improved, but manufacturing complexity increases

Engineering Contradiction:

Improvesound insulationVSAvoidmanufacturing complexity

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The foam insulation layer is pre-formed with the required density distribution and acoustic properties before installation. This preliminary preparation simplifies the manufacturing process by eliminating the need for complex assembly steps during final production, as the insulation layer is ready-to-use in its final configuration.

Inventive Principle:

Principle #10Preliminary action

3Object-affected harmful factors

If heavy layers are used in the material structure for damping purposes, then sound-insulating properties are improved, but weight increases

Engineering Contradiction:

Improvesound insulationVSAvoidfloor covering weight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of moving object

Solution Approach 1:

The patent changes the density parameter of the foam insulation layer, using a density range of 15-50 kg/m³ (with specific embodiments at 20-40 kg/m³ and 25-35 kg/m³). This optimized density provides effective sound insulation while maintaining lower weight compared to traditional heavy damping layers, achieving acoustic performance without excessive weight increase.

Inventive Principle:

Principle #35Parameter changes

4Object-affected harmful factors

If zone-by-zone different foam formulations are used, then sound-insulating properties are improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvesound insulationVSAvoidfoam density distribution precision

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The patent implements zone-by-zone different foam formulations with specific density ranges for different areas (e.g., 20-30 kg/m³ for first zones, 30-40 kg/m³ for second zones, 40-50 kg/m³ for third zones). This local quality approach optimizes sound insulation for specific acoustic requirements in different vehicle floor areas while maintaining manufacturability through defined density ranges rather than precise single values.

Inventive Principle:

Principle #3Local quality

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 integrates high sound-insulating properties into the foam, reducing the need for additional sound-absorbing components and simplifying manufacturing, while maintaining or reducing weight and cost.

Implementation Method 1

Viscoelastic foam, DE 39 05 607 A1, WO 2006/032433 A1

Methodology Applied

Scientific EffectSound absorption: Acoustic Absorption

Implementation Method 2

foamed viscoelastic polyurethane foam

Methodology Applied

Scientific EffectViscoelasticity: Viscoelasticity

Implementation Method 3

floor covering insulation for a motor vehicle made of one or more foamed viscoelastic polyurethane foam(s)

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentEP3752392B1Motor vehicle floor covering

Publication Date: 2025.07.09 HP PELZER HLDG GMBH

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AI summary

The invention relates to an underbody panel insulation for a motor vehicle made of one or more foamed viscoelastic polyurethane foam materials which can differ in zones (partially) over the surface and thickness of the insulation in its formulation and the physical and mechanical properties, and to a method for the production thereof.