Polyurethane Foam Sound Insulation for Vehicle Roof Noise Reduction
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Solution Overview
Problem
Existing soundproofing devices for vehicle roofs, typically tar-based plates glued to sheet metal panels, pose health risks to workers, are costly, and require constrained bonding processes, often necessitating awkward working conditions or expensive robotic assistance.
Innovation Solution
A soundproofing device comprising a polymer-based foam plate impregnated with a mixture of mineral filler and organic binder, specifically polyurethane-based foam with an acrylic binder and alumina silicate or chalk filler, is interposed between the sheet metal and interior trim panels, providing intimate contact and improved ergonomics by being glued before assembly, reducing deformation and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a polymer-based foam plate impregnated with a mixture of mineral filler and organic binder is used, then noise reduction and deformation reduction are improved, but manufacturing complexity increases due to the impregnation process
Solution Approach 1:
The patent applies composite materials by combining polymer-based foam with a mixture of mineral filler and organic binder. This composite structure provides both noise reduction and deformation reduction properties while maintaining ease of manufacture through the integration of multiple functions into a single material system.
Solution Approach 2:
The patent utilizes parameter changes by controlling the density of the foam plate within a specific range (15-20 kg/m³) and adjusting the composition ratios of mineral filler and organic binder. These parameter optimizations ensure effective noise and deformation reduction while simplifying the manufacturing process through standardized material specifications.
2Ease of operation
If the foam plate is glued to the interior trim panel before assembly, then ease of operation is improved, but bonding process constraints increase
Solution Approach 1:
The patent applies preliminary action by gluing the foam plate to the interior trim panel before final assembly. This advance preparation allows operators to perform the bonding operation in a convenient position, improving ergonomics while the pre-assembly approach actually simplifies the overall manufacturing process by reducing the complexity of working in confined spaces during final installation.
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 effectively reduces noise and deformation of the roof, enhancing ergonomics and manufacturing efficiency while being more economical and lighter, avoiding health risks and application challenges of traditional tar-based solutions.
Implementation Method 1
a soundproofing device for the passenger compartment of a vehicle... intended to be interposed between a sheet metal panel of the vehicle bodywork and an interior trim panel
Implementation Method 2
impregnated with a mixture of mineral filler and organic binder
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to a soundproofing device for the passenger compartment of a vehicle (10), to be positioned between a sheet metal panel of the vehicle bodywork (12) and an inner trimming panel (14). The device comprises a polymer foam plate (20) impregnated with a mixture of an inorganic filler and an organic binder, the foam plate (20) being shaped so as to be in close contact with the sheet metal panel of the bodywork (12) and with the inner trimming panel (14). The invention further relates to an inner trimming system for the passenger compartment of a vehicle, comprising an inner trimming panel (14) for covering a sheet metal panel of the vehicle bodywork (12) and such a device. The invention further relates to a vehicle provided with such a system. The invention can be used in automobiles.