Vehicle Floor Cladding with Foamed Carrier Layer for Load Resistance
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Solution Overview
Problem
Conventional cladding elements for vehicle luggage compartments lack sufficient compressive strength to withstand heavy loads, leading to surface dents and reduced durability, while harder foams compromise acoustic damping.
Innovation Solution
A cladding element with a cover layer of olefin-based thermoplastic elastomer, a mineral-containing thermoplastic elastomer heavy layer, and a foamed thermoplastic elastomer carrier layer between the acoustic foam layer and heavy layer, providing enhanced compressive strength and acoustic damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soft foam material is used for acoustic damping, then acoustic effectiveness is improved, but compressive strength deteriorates
Solution Approach 1:
The patent employs a composite structure consisting of multiple layers: a soft acoustic foam layer (polyurethane or polyethylene foam) for acoustic damping, a heavy layer (mineral-containing thermoplastic elastomer) for compressive strength, and a carrier layer (foamed thermoplastic elastomer) bonding the two. This composite material system allows each layer to fulfill its specific function, resolving the contradiction between softness for acoustics and hardness for load-bearing capacity.
Solution Approach 2:
The cladding element is divided into functionally distinct segments: the acoustic foam layer dedicated to sound insulation, the heavy layer dedicated to mechanical strength and load distribution, and the carrier layer dedicated to bonding. This segmentation allows optimization of each layer for its specific purpose without compromise.
2Strength
If heavy layer is added to improve compressive strength, then load resistance is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into an integrated multi-layer structure where the carrier layer serves both as a bonding medium and as a structural element that distributes loads. The heavy layer is integrated with the acoustic foam layer through the carrier layer, creating a unified component that provides both acoustic damping and mechanical strength without requiring separate assembly steps.
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 ensures no visible imprints from heavy loads, increased durability, improved surefootedness, and maintained acoustic effectiveness with high crush resistance and extended service life.
Implementation Method 1
an acoustic foam layer facing the vehicle body
Implementation Method 2
a carrier layer made out of a foamed thermoplastic elastomer arranged between the acoustic foam layer and heavy layer
Data Source
Figure 1
AI summary
The disclosure relates to a cladding element (1) consisting of several layers for the floor area of the luggage compartment in a vehicle, with a cover layer (2) facing the luggage compartment, an acoustic foam layer (4) facing the vehicle body, and a heavy layer (3) arranged between the cover layer (2) and acoustic foam layer (4), which further exhibits a carrier layer (5) consisting of a foamed thermoplastic material, which is arranged between the acoustic foam layer (4) and heavy layer (3), as well as to a method for manufacturing the cladding element (1), and wherein the foamed thermoplastic material of the carrier layer is preferably polypropylene.