Multizone PU Floor Covering Insulation for Vehicle Sound Damping

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Solution Overview

Problem

Existing floor covering systems in motor vehicles lack effective sound insulation, leading to increased weight and complexity due to the use of additional antinoise coatings and complicated production methods.

Innovation Solution

A multizone design for polyurethane (PU) foam insulation in motor vehicle floor coverings, where the foam composition and properties vary over the surface and thickness, integrating sound-insulating properties directly into the foam formulation without additional components or preparation steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If additional antinoise coatings and separate components are used to improve sound insulation, then sound insulation effectiveness is improved, but device complexity and weight increase

Engineering Contradiction:

Improvesound insulationVSAvoiddevice complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent combines multiple functions (sound insulation, footstep resistance, structural support) into a single integrated foam insulation system. The foam contains embedded crash elements, fastening elements, and antinoise properties, eliminating the need for separate antinoise coatings and components that would otherwise be required to achieve the same sound insulation effectiveness.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention uses composite foam structures with varying density zones (different foam pieces with different densities are embedded in the foam insulation) to achieve superior sound insulation properties. This composite approach allows the foam itself to function as both structural support and sound insulation, replacing traditional separate antinoise coatings.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If heavy layers and separate antinoise coatings are applied to achieve sound insulation, then sound insulation effectiveness is improved, but weight of the floor covering increases

Engineering Contradiction:

Improvesound insulationVSAvoidweight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of moving object

Solution Approach 1:

The patent merges sound insulation functionality into the foam insulation itself through integrated antinoise films and composite foam structures. This eliminates the need for additional heavy antinoise coatings that would be applied separately, thereby reducing overall weight while maintaining sound insulation effectiveness.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention applies antinoise films only in specific locally limited regions where sound insulation is most needed, rather than covering the entire floor covering area. This localized approach reduces the total weight of antinoise materials while maintaining effective sound insulation in critical areas.

Inventive Principle:

Principle #3Local quality

3Object-affected harmful factors

If separate components are prepared and mounted in additional working steps to improve sound insulation, then sound insulation effectiveness is improved, but manufacturing complexity and production time increase

Engineering Contradiction:

Improvesound insulationVSAvoidease of manufacture

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent integrates sound insulation components (antinoise films, foam structures) directly into the foam insulation manufacturing process. The antinoise films are integrated into the foam pieces before or during the foaming process, eliminating separate preparation and mounting steps that would otherwise be required to assemble multiple components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The antinoise films are pre-integrated into the foam insulation structure during manufacturing, rather than being applied as separate post-processing steps. This preliminary integration simplifies the overall manufacturing process by combining multiple operations into a single streamlined production flow.

Inventive Principle:

Principle #10Preliminary action

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 significantly enhances sound insulation in motor vehicle floor coverings, reduces the weight and complexity of antinoise coatings, and simplifies production processes by integrating insulation properties into the PU foam itself.

Implementation Method 1

floor covering insulation (2) consisting of a foamed polyurethane foam with visco-elastic properties

Methodology Applied

Scientific EffectViscoelasticity: Viscoelasticity

Implementation Method 2

enhances sound insulation in motor vehicle floor coverings

Methodology Applied

Scientific EffectAcoustic absorption: Acoustic Absorption

Data Source

PatentUS12296761B2Motor vehicle floor covering

Publication Date: 2025.05.13 HP PELZER HLDG GMBH

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.