Integrally Molded Vehicular Undercover with Air Permeable Synthetic Resin Layer

Solution Overview

Problem

Vehicular undercovers face challenges in achieving durability against foreign matters while maintaining sound absorption properties and lightness, as integrating synthetic resin fibers with both surfaces increases weight and compromises sound absorption.

Innovation Solution

An integrally molded vehicular undercover design featuring a base material layer with inorganic fibers and a solidified thermoplastic binder, an outer layer with synthetic resin fibers and a second solidified thermoplastic binder, and a synthetic resin layer with air permeability, integrated with the vehicle body side surface to reduce weight and enhance sound absorption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If skin layers containing synthetic resin fibers are integrated with both surfaces of the vehicular undercover, then durability against foreign matters is improved, but weight of the vehicular undercover increases

Engineering Contradiction:

Improvedurability against foreign mattersVSAvoidweight of vehicular undercover

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent applies local quality by providing the outer layer containing synthetic resin fibers only on the road side surface where durability is most needed for protection against stones and foreign matters, while the vehicle body side surface uses a lighter synthetic resin layer, thus achieving differential protection based on local requirements

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The vehicular undercover is segmented into three distinct layers: a base material layer with inorganic fibers, an outer layer with synthetic resin fibers on the road side, and a synthetic resin layer on the vehicle body side. This segmentation allows each layer to fulfill specific functions while optimizing the overall weight-durability balance

Inventive Principle:

Principle #1Segmentation

2Reliability

If skin layers containing synthetic resin fibers are integrated with both surfaces of the vehicular undercover, then durability against foreign matters is improved, but sound absorption property deteriorates

Engineering Contradiction:

Improvedurability against foreign mattersVSAvoidsound absorption property

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by providing the outer layer containing synthetic resin fibers only on the road side surface where durability is most needed for protection against stones and foreign matters, while the vehicle body side surface uses a lighter synthetic resin layer, thus achieving differential protection based on local requirements

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The base material layer contains inorganic fibers with air permeability, creating a porous structure that maintains sound absorption properties while providing the necessary durability through the outer layer configuration

Inventive Principle:

Principle #31Porous materials

3Reliability

If a base material layer with inorganic fibers and outer layer with synthetic resin fibers are integrated, then durability against foreign matters is improved, but weight increases

Engineering Contradiction:

Improvedurability against foreign mattersVSAvoidweight of vehicular undercover

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent applies local quality by providing the outer layer containing synthetic resin fibers only on the road side surface where durability is most needed for protection against stones and foreign matters, while the vehicle body side surface uses a lighter synthetic resin layer, thus achieving differential protection based on local requirements

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses composite materials by combining inorganic fibers in the base material layer with synthetic resin fibers in the outer layer, creating a composite structure that optimizes both durability and weight characteristics through material synergy

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 solution provides a vehicular undercover with improved durability against foreign matters, reduced weight, and excellent sound absorption properties within the frequency range of 500 to 2000 Hz, balancing durability and lightness.

Implementation Method 1

a base material layer containing inorganic fibers and a first solidified thermoplastic binder

Methodology Applied

Scientific EffectThermoplastic binder solidification: Phase Change

Implementation Method 2

an outer layer containing synthetic resin fibers and a second solidified thermoplastic binder

Methodology Applied

Scientific EffectThermoplastic binder solidification: Phase Change

Implementation Method 3

a synthetic resin layer having air permeability

Methodology Applied

Scientific EffectAir permeability: Porosity

Implementation Method 4

excellent sound absorption properties within the frequency range of 500 to 2000 Hz

Methodology Applied

Scientific EffectSound absorption: Acoustic Absorption

Data Source

PatentUS10960652B2Vehicular undercover

Publication Date: 2021.03.30 HAYASHI TELEMPU CO LTD

AI summary

The present invention discloses an integrally molded vehicular undercover having air permeability includes a base material layer containing inorganic fibers and a first solidified thermoplastic binder, the base material layer having a road side surface and a vehicle body side surface, an outer layer containing synthetic resin fibers and a second solidified thermoplastic binder, the outer layer being integrated with the road side surface of the base material layer, and a synthetic resin layer having air permeability, the synthetic resin layer being integrated with the vehicle body side surface of the base material layer.