Porous Fibrous Frunk Structure for Vehicle Noise Absorption

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Solution Overview

Problem

The existing molded front storage compartments in vehicles, particularly electric cars, face challenges in noise reduction and acoustic performance due to the use of heavy, non-porous solid plastic materials that lack sufficient stiffness and noise absorption.

Innovation Solution

A molded front storage compartment utilizing a structural layer composed of a porous fibrous layer made of thermoplastic core-sheath bicomponent endless filaments, which provides the necessary strength, stiffness, and noise absorption by distributing the binder polymer evenly and enhancing bonding between filaments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If solid plastic materials are used for the front storage compartment, then the compartment can be formed with sufficient structural integrity, but the compartment becomes heavy and lacks noise absorption capability

Engineering Contradiction:

Improvestructural integrityVSAvoidcompartment weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies porous materials by using a non-woven fabric made of thermoplastic filaments as the structural layer of the front storage compartment. This fabric structure inherently provides porosity, allowing the material to be lighter while maintaining structural integrity through the interwoven filament network. The porous structure reduces density and weight compared to solid plastic materials.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent uses composite materials by combining thermoplastic filaments with a specific bicomponent structure (core-sheath configuration). The composite nature of these filaments, with different polymer components providing different properties, creates a material that achieves both structural strength and reduced weight, resolving the contradiction between structural integrity and weight.

Inventive Principle:

Principle #40Composite materials

2Strength

If solid plastic materials are used for the front storage compartment, then the compartment can be formed with sufficient structural integrity, but the compartment does not provide noise absorption

Engineering Contradiction:

Improvestructural integrityVSAvoidnoise

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The porous structure of the non-woven fabric created by thermoplastic filaments provides noise absorption capability. The porous network allows sound waves to penetrate and dissipate energy through friction and vibration of the filament structure, converting acoustic energy to thermal energy. This resolves the contradiction by providing noise absorption while maintaining structural integrity through the fabric's mechanical properties.

Inventive Principle:

Principle #31Porous materials

3Object-affected harmful factors

If the structural layer is made porous to improve noise absorption, then acoustic performance is enhanced, but the stiffness and strength may be reduced

Engineering Contradiction:

Improvenoise absorptionVSAvoidstiffness

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent applies parameter changes by controlling the physical and chemical parameters of the thermoplastic filaments, including filament diameter, length distribution, crimp, and packing density. By optimizing these parameters, the non-woven fabric achieves a balance where the porous structure provides noise absorption while the filament network maintains sufficient stiffness and strength for structural support.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The use of composite thermoplastic filaments with bicomponent structure allows the material to exhibit both porous characteristics for noise absorption and sufficient mechanical properties for stiffness. The composite nature enables tailored properties where one component provides structural strength while the other enhances porosity and acoustic performance.

Inventive Principle:

Principle #40Composite materials

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 porous fibrous layer achieves sufficient strength and stiffness to maintain its shape under load and withstand various environmental conditions, while also significantly reducing noise through enhanced acoustic performance.

Implementation Method 1

the at least one porous fibrous layer is consisting essentially of thermoplastic core-sheath bicomponent endless filaments wherein the core consists of a first polymer and the sheath consists of a second polymer

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

enhancing bonding between filaments

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 3

significantly reducing noise through enhanced acoustic performance

Methodology Applied

Scientific EffectAcoustic absorption: Acoustic Absorption

Data Source

PatentUS20250033567A1Acoustic front storage compartment for a vehicle

Publication Date: 2025.01.30 AUTONEUM MANAGEMENT AG

AI summary

A molded front storage compartment for a vehicle, comprising a structural layer wherein the structural layer is shaped as a three-dimensional storage cavity for holding luggage or goods wherein the structural layer comprises at least one porous fibrous layer and wherein the at least one porous fibrous layer is consisting essentially of thermoplastic core-sheath bicomponent endless filaments wherein the core consists of a first polymer and the sheath consists of a second polymer.