Reusable Vehicle Sound Absorbing Mat Without Adhesives
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Solution Overview
Problem
Current sound deadening products require removal and disassembly of vehicle interiors and use adhesives for bonding, making them labor-intensive and limited to one-time use.
Innovation Solution
A sound absorbing mat composed of multiple layers, including a thick polyurethane open cell polyester layer, a polyvinyl chloride layer, and a urethane layer, which are fused together without adhesives, allowing for easy installation and removal, and can be reused across different vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sound deadening products are bonded to vehicle surfaces using adhesives, then the sound absorption effectiveness is improved, but the installation complexity and labor time increase
Solution Approach 1:
The sound deadening system is divided into modular panels that can be independently installed on different vehicle surfaces. Each panel is self-contained with adhesive backing, allowing separate installation without requiring removal of interior components. This segmentation enables straightforward installation while maintaining effective sound absorption coverage.
Solution Approach 2:
The adhesive material is pre-applied to the back of each sound deadening panel during manufacturing. This preliminary action eliminates the need for workers to apply adhesives during installation, reducing installation complexity and labor time while ensuring consistent adhesive application for reliable sound absorption.
2Reliability
If interior components are removed and disassembled to install sound deadening products, then the sound absorption coverage is improved, but the installation time and labor requirements increase
Solution Approach 1:
The sound deadening solution is divided into multiple removable panels that can be installed without removing interior components. Each panel targets specific areas where sound absorption is needed, providing comprehensive coverage while allowing installation over existing interior surfaces rather than requiring disassembly.
Solution Approach 2:
The sound deadening panels serve as an intermediary layer installed over existing vehicle interior surfaces. This intermediary approach allows sound absorption coverage without direct contact with or removal of interior components, eliminating the time-consuming disassembly and reassembly process while maintaining effective coverage.
3Strength
If adhesives are used to bond sound deadening products to vehicle surfaces, then the bonding strength is improved, but the reusability and ease of removal decrease
Solution Approach 1:
The adhesive material is formulated with specific temperature-dependent properties. At normal temperatures, the adhesive provides sufficient bonding strength to hold the panels in place. When heated during removal, the adhesive's bonding strength decreases, allowing easy removal and reuse of the panels on different vehicles or locations.
Solution Approach 2:
The adhesive undergoes a phase transition when heated, changing from a strong bonding state at room temperature to a more pliable, easily removable state. This phase transition enables the panel to be firmly bonded during use but easily removed and reused when needed, providing both strong bonding and reusability.
4Stability of the object's composition
If sound deadening products are permanently bonded to vehicle surfaces, then the sound absorption stability is improved, but the ease of installation and removal decreases
Solution Approach 1:
The adhesive's bonding parameters are designed to be temperature-sensitive. During normal operation, the adhesive maintains stable bonding to ensure consistent sound absorption. During installation and removal, temperature changes modify the adhesive's properties, enabling easy application and removal without compromising sound absorption stability during use.
Solution Approach 2:
The bonding characteristics of the sound deadening panel are made dynamic rather than static. The adhesive provides stable bonding under normal conditions but allows for easy attachment and detachment when temperature or other parameters are changed. This dynamic behavior enables both stable sound absorption during use and ease of installation/removal when needed.
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
Enables efficient noise reduction without altering the vehicle's interior, allowing for easy installation and removal, and can be reused multiple times, reducing weight and damage from wear and tear.
Implementation Method 1
inserting the mat in an oven at a predetermined temperature for a predetermined timeframe, wherein the quantity of liquid polyvinyl chloride becomes a solid and fuses with the first polyurethane open cell polyester layer and the second polyurethane open cell polyester layer
Implementation Method 2
rolling the mat with the urethane layer through a roller at a predetermined temperature, wherein the urethane layer is heated to a temperature that allows the urethane layer to fuse with the mat
Implementation Method 3
a first polyurethane open cell polyester layer, wherein the first polyurethane open cell polyester layer is at least one quarter of an inch thick
Data Source
AI summary
A sound absorbing mat comprising a first polyurethane open cell polyester layer, wherein the first polyurethane open cell polyester layer is at least one quarter of an inch thick, a polyvinyl chloride layer having a top surface and a bottom surface, wherein the polyvinyl chloride layer is at least a quarter inch thick and the bottom surface is fused to the first polyurethane open cell polyester, a second polyurethane open cell polyester layer having a top surface and a bottom surface, wherein the second polyurethane open cell polyester layer is at least three quarters of an inch and the bottom surface of the second polyurethane open cell polyester layer is fused with the top surface of the polyvinyl chloride layer, and a urethane layer, wherein the urethane layer is at least a quarter inch thick and is mated to the top surface of the second polyurethane open cell polyester layer.