Compressible Urethane Foam Dash Insulator for Panel Vibration Noise
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Solution Overview
Problem
Conventional soundproofing materials for automotive dash insulators fail to effectively prevent noise from penetrating into the vehicle cabin, particularly noise arising from vibrations of panels and automotive components, due to complex production methods and inadequate consideration of vibration prevention.
Innovation Solution
A single-layer urethane foam material with adjustable thickness, compressible to improve sound insulation and absorption, is used to create a simple structure that can be easily installed around automotive components, reducing elastic modulus and enhancing soundproofing performance by compressing the foam to specific ratios and densities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a three-layer soundproofing material structure is used, then sound insulation performance is improved, but production complexity increases
Solution Approach 1:
The patent merges the sound absorption function and vibration damping function into a single integrated layer structure. By combining urethane foam with vinyl chloride or acrylic resin in one cohesive material system, the patent achieves complex sound insulation performance without requiring multiple separate layers, thereby simplifying production.
Solution Approach 2:
The soundproofing material is designed to perform multiple functions simultaneously: sound absorption, vibration damping, and sound insulation. This multi-functional design eliminates the need for separate specialized layers, reducing production complexity while maintaining high sound insulation performance.
2Object-affected harmful factors
If felt material is thickened to enhance soundproofing performance, then sound absorption improves, but attachment of automotive components becomes difficult
Solution Approach 1:
The patent optimizes the elastic modulus and density parameters of the urethane foam material to achieve an optimal balance. By controlling these parameters, the material provides sufficient thickness for sound absorption while maintaining appropriate softness and compressibility for easy attachment of automotive components, avoiding the problems associated with thick felt material.
3Strength
If felt material is compressed to improve sound insulation, then elastic modulus increases, but sound insulation performance deteriorates
Solution Approach 1:
The patent uses a composite material system where the vinyl chloride resin or acrylic resin layer provides structural support and maintains sound insulation performance even when compressed. The urethane foam layer can be compressed for attachment without significantly degrading overall sound insulation, as the composite structure compensates for compression effects.
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 superior soundproofing performance against noise from vibrations and components, improving sound absorption and insulation while simplifying the installation process and reducing reaction forces, thus effectively blocking radiated sound and enhancing attachment of automotive components.
Implementation Method 1
a fiber structure or a foam that has flexibility capable of following fine unevenness of a vehicle body panel and contains many voids is suitable. This type of soundproofing material exhibits a sound absorbing effect of capturing sound waves in the voids and damping the sound waves
Implementation Method 2
exhibits a sound insulating effect of preventing sound waves from penetrating into the vehicle cabin by reflecting the sound waves
Implementation Method 3
by compressing the urethane foam material, an elastic modulus of the urethane foam material is reduced and sound insulation performance is improved
Implementation Method 4
the urethane foam material is configured to have either a uniform thickness or an increased thickness only in a region where it is needed, and an automotive component can be installed while compressing the urethane foam material
Data Source
AI summary
[Problem] To realize, by means of a simple structure, a soundproofing material having a soundproofing property equal or superior to that of a conventional one against sound including noise arising from vibration generated by a panel (dash panel) that separates the inside and outside of a vehicle cabin or an automotive component and penetrating into the vehicle cabin, and further to realize an excellent soundproofing property in a method for attaching an automotive component using the soundproofing material.[Solution] An automotive soundproofing material made of a urethane foam material, characterized in that the urethane foam material has a single-layer structure, the urethane foam material is configured to have either a uniform thickness or an increased thickness only in a region where it is needed, and an automotive component can be installed while compressing the urethane foam material.