Nonpermeable Composite Material for Vehicle Air Ducts

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Solution Overview

Problem

Current materials for air ducts in vehicles fail to effectively absorb sound and reduce noise, while also experiencing air leakage, which is undesirable for maintaining air flow and reducing rattling or squeaking noises.

Innovation Solution

A multi-layer non-permeable composite material is developed, comprising a thermoformable foil or film layer, a core material layer, and a nonwoven material layer, where the nonwoven layer is air permeable and the thermoformable layer is substantially non-permeable, significantly reducing air leakage and enhancing sound absorption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If molded parts are used for air ducts, then structural strength is improved, but weight increases and sound absorption characteristics are insufficient

Engineering Contradiction:

Improvestructural strengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent employs a composite material structure consisting of multiple layers including a nonwoven fabric layer, a porous core layer, and a molded outer layer. This composite structure combines the strength of molded parts with the sound absorption properties of nonwoven materials, while the porous core layer provides acoustic attenuation. The layered composite approach allows optimization of each layer for specific functions, achieving both structural integrity and weight reduction compared to solid molded parts.

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If textile materials are used for air ducts, then weight is reduced, but air leakage occurs

Engineering Contradiction:

ImproveweightVSAvoidair leakage

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent uses a multi-layer composite where a nonwoven fabric layer serves as the outer textile component providing lightweight properties, while a molded outer layer or barrier layer is incorporated to prevent air leakage. This composite structure maintains the weight advantages of textile materials while adding a sealing function through the molded layer, thus resolving the contradiction between lightweight construction and air tightness.

Inventive Principle:

Principle #40Composite materials

3Strength

If rigid parts are connected with fasteners, then structural strength is improved, but rattling or squeaking noises occur

Engineering Contradiction:

Improvestructural strengthVSAvoidrattling or squeaking noises

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent incorporates a nonwoven fabric layer and porous core layer that act as flexible, damping elements between rigid components. These soft layers absorb vibrations and prevent direct contact between rigid parts, thereby eliminating rattling and squeaking noises while maintaining structural strength through the molded outer layer and fastener connections.

Inventive Principle:

Principle #30Flexible shells and thin films

4Object-affected harmful factors

If sound absorption materials are used, then noise reduction is improved, but air permeability may increase causing air leakage

Engineering Contradiction:

Improvenoise reductionVSAvoidair leakage

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent applies different material properties to different layers: the nonwoven fabric layer and porous core layer provide sound absorption and acoustic attenuation, while a molded outer layer or barrier layer provides air tightness. Each layer is optimized for its specific function, allowing the system to achieve both noise reduction and air leakage prevention without compromising either performance.

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 composite material achieves 90% to 100% less air leakage and improved sound absorption, reducing noise levels and weight, making it suitable for air ducts and various applications requiring sound attenuation and lightweight acoustic materials.

Implementation Method 1

The nonwoven material layer may be an air permeable layer, which may allow for air to travel through the layer and into the core material layer

Methodology Applied

Scientific EffectAir permeability: Permeation

Implementation Method 2

The thermoformable foil or film layer may be substantially non-permeable by air

Methodology Applied

Scientific EffectNon-permeability: Permeation

Implementation Method 3

The present teachings provide improved sound absorption by creating a multi-layer, non-permeable composite material that allows for reduction of weight; reduction of undesirable noises

Methodology Applied

Scientific EffectAcoustic absorption: Acoustic Absorption

Implementation Method 4

The sheet may be formed by thermally activating the layers in an air-circulating oven, or by another heating system, and compressing to a desired thickness

Methodology Applied

Scientific EffectThermal bonding: Heating

Data Source

PatentUS11820102B2Nonpermeable composite material

Publication Date: 2023.11.21 ZEPHYROS INC

AI summary

A composite material having a plurality of discrete layers layered on top of each other including a thermoformable foil or film layer; a core material layer; and a nonwoven material layer. The nonwoven material layer is adapted to face a stream of air and the core material layer is sandwiched between the nonwoven material layer and the thermoformable foil or film layer. The composite material may be used to form an air duct.