Vehicle Interior Trim Decoupler Layer with Variable Density

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Solution Overview

Problem

Vehicle manufacturers face challenges in reducing noise within passenger compartments while minimizing the weight and cost of interior trim components, as conventional decouplers require complex shapes and multiple layers, leading to increased manufacturing costs and inefficiencies.

Innovation Solution

A method of manufacturing interior trim components with a decoupler layer that involves ascertaining sound attenuation needs, forming a preform with controlled density using a perforated enclosure, and bonding it with the trim component in a mold to create a lightweight, efficient sound attenuator with variable thickness and acoustical profiles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If conventional decouplers with complex shapes and multiple layers are used, then sound attenuation is improved, but weight and manufacturing cost increase

Engineering Contradiction:

Improvesound attenuationVSAvoidweight of trim component

Core Design Contradiction:

Object-affected harmful factorsVSWeight of moving object

Solution Approach 1:

The patent applies local quality by creating a decoupler layer with spatially varying density - higher density in regions requiring greater sound attenuation and lower density in less critical areas. This is achieved through the preform formation process where material distribution is controlled to match specific acoustical requirements of different dashboard regions, thereby reducing overall weight while maintaining effective noise reduction.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent utilizes parameter changes by varying the density parameter of the decoupler layer throughout its structure. The preform is formed with controlled density variations that are then bonded to the dashboard trim component, allowing optimization of sound attenuation performance without uniformly increasing weight across the entire component.

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If conventional decouplers with complex shapes and multiple layers are used, then sound attenuation is improved, but manufacturing cost increases

Engineering Contradiction:

Improvesound attenuationVSAvoidmanufacturing cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent merges the decoupler layer formation with the dashboard trim component manufacturing process. The preform is formed and then bonded directly to the trim component in a single manufacturing step, eliminating the need for separate production and assembly of multiple layers. This integration reduces manufacturing complexity and cost while achieving the required sound attenuation performance.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs composite materials by combining the preform material with the dashboard trim component material to create a unified structure with optimized acoustical properties. This composite approach allows the decoupler layer to be manufactured as part of the trim component itself, reducing the number of manufacturing steps and associated costs.

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If multiple layers are used to achieve sound attenuation, then acoustic performance is improved, but device complexity increases

Engineering Contradiction:

Improvesound attenuationVSAvoidstructure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent applies segmentation by dividing the decoupler layer into regions of different density within a single continuous layer. This segmented density distribution within one layer achieves the acoustic performance previously requiring multiple separate layers, thereby simplifying the overall structure while maintaining effective sound attenuation.

Inventive Principle:

Principle #1Segmentation

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 results in lighter, cost-effective interior trim components with enhanced sound attenuation capabilities, reducing material usage and eliminating the need for multiple layers, thereby improving noise reduction in vehicles while simplifying the manufacturing process.

Implementation Method 1

heating the preform to a temperature such that upon cooling adjacent materials may bond to one another; heating an interior trim component to a second temperature

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS7698817B2Methods of forming vehicle interior components which include a decoupler layer

Publication Date: 2010.04.20 AURIA SOLUTIONS UK I LTD

AI summary

A method of manufacturing an article such as vehicle interior trim component including a decoupler layer is disclosed. The method comprises the conveying of materials into an enclosure to form a preform having a shape of the enclosure, heating the preform to a temperature such that adjacent materials may bond to one another upon cooling and forming the heated preform into a predetermined three-dimensional decoupler configuration via a mold. The enclosure has a perforated portion and at least one panel movable relative to the enclosure so as to selectively expose portions of the perforated portion. The density of the preform may be varied as the at least one panel is moved to expose the perforated portion of the enclosure. A system for manufacturing articles such as a vehicle interior trim component including a decoupler layer is also disclosed.