Single-Layer Polyurethane Mat for Vehicle Noise Damping
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Solution Overview
Problem
Current solutions for reducing structural/airborne noise and vibrational noise in vehicles often require multiple layers or heavy materials, which increase complexity and fuel/energy consumption, necessitating a single-layer polyurethane mat with enhanced acoustic insulation properties.
Innovation Solution
A polyurethane elastomer with a specific composition, including a first polyol component, a second ethylene oxide capped polyoxypropylene-polyoxyethylene polyol, and a third polyoxypropylene polyol, exhibiting viscoelastic properties and high Shore A hardness, is used in a single layer to provide effective noise and vibration damping without additional layers or heavy materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multilayer solutions or high mass materials are used to reduce structural/airborne noise and vibrational noise, then acoustic insulation performance is improved, but device complexity and fuel/energy consumption increase
Solution Approach 1:
The patent combines multiple polyol components (polyether polyol, ethylene oxide capped polyoxypropylene-polyoxyethylene polyol, and polyoxypropylene polyol) into a single polyurethane elastomer formulation. This merging of multiple material functions into one composite material eliminates the need for multilayer structures while maintaining effective noise and vibration damping performance.
Solution Approach 2:
The invention creates a composite polyurethane elastomer by combining different polyol components with specific molecular weights and functionalities. This composite material integrates the beneficial properties of each polyol type to achieve both noise reduction and vibration damping in a single layer, avoiding the complexity of multiple separate layers.
2Reliability
If multilayer solutions or high mass materials are used to reduce structural/airborne noise and vibrational noise, then acoustic insulation performance is improved, but fuel/energy consumption increases
Solution Approach 1:
The patent combines multiple polyol components (polyether polyol, ethylene oxide capped polyoxypropylene-polyoxyethylene polyol, and polyoxypropylene polyol) into a single polyurethane elastomer formulation. This merging of multiple material functions into one composite material eliminates the need for multilayer structures while maintaining effective noise and vibration damping performance.
Solution Approach 2:
The invention optimizes specific parameters of the polyol components including molecular weight ranges (300-1,500 g/mol for first and third polyols, 4,000-6,000 g/mol for second polyol), hydroxyl functionality (>2.5 for first polyol, >1.5 and <4.0 for second and third polyols), and composition ratios (40-90 wt% first polyol, 2-20 wt% second polyol, 1-20 wt% third polyol). These parameter changes enable effective acoustic performance in a single layer, reducing the need for heavy multilayer structures and associated energy consumption.
3Device complexity
If a single layer polyurethane mat is used to reduce noise and vibrations, then device complexity is reduced, but acoustic insulation performance may be compromised
Solution Approach 1:
The invention creates a composite polyurethane elastomer by combining different polyol components with specific molecular weights and functionalities. This composite material integrates the beneficial properties of each polyol type to achieve both noise reduction and vibration damping in a single layer, avoiding the complexity of multiple separate layers.
Solution Approach 2:
The invention optimizes specific parameters of the polyol components including molecular weight ranges (300-1,500 g/mol for first and third polyols, 4,000-6,000 g/mol for second polyol), hydroxyl functionality (>2.5 for first polyol, >1.5 and <4.0 for second and third polyols), and composition ratios (40-90 wt% first polyol, 2-20 wt% second polyol, 1-20 wt% third polyol). These parameter changes enable effective acoustic performance in a single layer, reducing the need for heavy multilayer structures and associated energy consumption.
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 polyurethane mat effectively absorbs noise and vibrations within the temperature range of vehicle cabins, demonstrating high damping properties and reduced noise transmission with improved energy dissipation, thus addressing the need for a single-layer solution that maintains performance without increasing fuel/energy consumption.
Implementation Method 1
A polyurethane mat, e.g., a sound insulation interior cabin polyurethane mat, with a single layer of polyurethane elastomer may exhibit viscoelastic properties
Implementation Method 2
exhibiting a combined acoustic barrier effect of a high density material with an improved vibration energy dissipation
Implementation Method 3
The polyurethane mat effectively absorbs noise and vibrations within the temperature range of vehicle cabins
Data Source
Figure 1
AI summary
A polyurethane elastomer, e.g., for use in polyurethane mats, includes the reaction product of an isocyanate component that includes at least one isocyanate and an isocyanate-reactive component that includes (a) a first polyol component including from 40 wt% to 90 wt% of at least one polyether polyol having an average hydroxyl functionality that is greater than 2.5 and a number average molecular weight from 300 g/mol to 1,500 g/mol; (b) a second polyol component including from 2 wt% to 20 wt% of at least one ethylene oxide capped polyoxypropylene-polyoxyethylene polyol having an average hydroxyl functionality greater than 1.5 and less than 4.0, a number average molecular weight from 4,000 g/mol to 6,000 g/mol, and from 60 % to 85 % of a primary hydroxyl group content; and (c) a third polyol component including from 1 wt% to 20 wt% of at least one polyoxypropylene polyol having an average hydroxyl functionality greater than 1.5 and less than 4.0 and a number average molecular weight from 300 g/mol to 1,500 g/mol.