Air-Permeable Tufted Insert Mat for Vehicle Floor Carpets
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Solution Overview
Problem
Existing floor mats for motor vehicles compromise the sound absorption capacity of vehicle carpets due to lack of air permeability and adhesion, and are not sufficiently tread-resistant or moisture-proof, making them unsuitable for use as inlay mats.
Innovation Solution
A three-layer insert mat structure featuring a decorative tuft layer, a fleece carrier layer, and a tuft adhesive layer, with a high air-permeable fleece middle layer and reduced adhesive weight, allowing for deformability and moisture resistance while maintaining sound absorption and non-slip properties without additional fastening means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thick layer of adhesive is used to fix the floor mat to the vehicle floor, then adhesion is improved, but air permeability deteriorates and sound absorption capacity is impaired
Solution Approach 1:
The adhesive layer is designed as a porous structure with air channels that extend through the entire thickness of the adhesive layer. This allows air to pass through the adhesive layer, maintaining air permeability and sound absorption capacity while still providing sufficient adhesion to secure the floor mat to the vehicle floor structure.
2Reliability
If an air-permeable structure is used to maintain sound absorption, then sound absorption capacity is improved, but adhesion deteriorates and the mat slips on the carpet
Solution Approach 1:
The adhesive layer exhibits spatially varying properties: it has porous regions with air channels for sound absorption and adhesion-promoting regions with higher adhesive content for securing the mat. This local differentiation allows the same layer to simultaneously provide both sound absorption and adhesion functions.
3Reliability
If a complex manufacturing process with vacuum application is used to create air ducts, then air permeability is improved, but device complexity increases and manufacturing precision deteriorates
Solution Approach 1:
Air channels are incorporated into the adhesive layer during the adhesive formulation and application process, before the final assembly is complete. This preliminary incorporation of air channels eliminates the need for subsequent vacuum application steps to create the porous structure, simplifying the manufacturing process while ensuring consistent air permeability.
4Reliability
If reduced adhesive weight is used to improve air permeability, then sound absorption is improved, but adhesion deteriorates
Solution Approach 1:
The adhesive layer functions as a composite material combining adhesive substances with air channels. This composite structure provides both bonding functionality (from the adhesive components) and air permeability (from the channel structure), allowing reduced overall adhesive weight while maintaining sufficient adhesion strength.
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 insert mat maintains sound absorption and is impermeable to water while being highly air-permeable, allowing it to be used without impairing the vehicle's sound absorption capacity and providing effective non-slip properties on existing vehicle carpets.
Implementation Method 1
the adhesive layer is designed as an air-permeable adhesive layer
Implementation Method 2
The carrier layer (3) has a hydrophobic finish
Implementation Method 3
a tufted decorative layer (2) which, when the insert mat (1) is used as intended, faces a vehicle interior
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to an insert mat (1) for motor vehicles for laying on a sound-absorbing floor carpet structure of the motor vehicle, having an at least three-layer construction, wherein the construction has a decorative layer (2), which faces a vehicle interior when the insert mat (1) is used as intended and which is connected to a top face (3a) of a carrier layer (3) that faces the vehicle interior during use as intended, and an adhering layer (4), which is connected to a bottom face (3b) of the carrier layer (3) when the insert mat (1) is used as intended and which is designed to interact with a floor carpet of a vehicle in a gripping manner, wherein the entire construction is air-permeable, wherein the decorative layer (2) is a tuft, the carrier layer (3) is a nonwoven fabric, and the adhering layer (4) is a tuft.