Wheel Guard Composite Layer Bonding for Noise Reduction
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Solution Overview
Problem
Conventional wheel guards manufactured from polypropylene resin are ineffective in reducing road noise and improving durability, as they do not adequately absorb sound or insulate against vibration noise, and they produce dust during the manufacturing process.
Innovation Solution
A method involving injection-molding of a wheel guard with a non-woven fabric outer layer, an adhesive layer, and a sound-absorbing thermoplastic resin layer, where a heat treatment layer with Low Melting Fiber, film, or sheet is applied to enhance sound absorption, insulation, and wear resistance, and the layers are bonded under pressure with thermal planarization to smooth the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-layer polypropylene resin structure is used for the wheel guard, then the manufacturing process is simple and cost is low, but sound absorption ability is insufficient and road noise cannot be effectively blocked
Solution Approach 1:
The wheel guard employs a composite structure consisting of an outer layer made of polypropylene resin and an inner layer made of acoustic absorbent material. This composite material approach allows the wheel guard to simultaneously achieve structural integrity from the outer layer and effective sound absorption from the inner layer, resolving the contradiction between manufacturing simplicity and sound absorption performance.
Solution Approach 2:
The wheel guard is divided into two distinct functional layers: an outer layer for structural protection and durability, and an inner layer for sound absorption. This segmentation allows each layer to be optimized for its specific function while maintaining overall manufacturing efficiency through a integrated molding process.
2Ease of manufacture
If a single-layer polypropylene resin structure is used for the wheel guard, then the manufacturing process is simple, but wear resistance and durability are insufficient
Solution Approach 1:
The composite structure with an outer polypropylene resin layer provides enhanced wear resistance and durability while maintaining manufacturing simplicity. The outer layer serves as a protective barrier that resists abrasion and environmental degradation, while the inner acoustic absorbent layer provides sound absorption functionality.
3Ease of manufacture
If the surface of the wheel guard is not smoothly coated, then the manufacturing process is simple, but dust is produced and overall durability is reduced
Solution Approach 1:
The outer polypropylene resin layer serves as a smooth coating that encapsulates the inner acoustic absorbent material. This composite structure prevents dust generation by sealing the surface while maintaining manufacturing simplicity through integrated molding, and enhances durability by providing a protective outer shell.
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 method improves sound absorption, sound insulation, wear resistance, and durability while reducing dust production, effectively blocking road noise and enhancing the overall manufacturing process efficiency.
Implementation Method 1
bonding an outer layer including a non-woven fabric and a sound-absorbing layer including thermoplastic resin with the adhesive layer therebetween
Implementation Method 2
The heat treatment layer may be heat-treated through a heating roller
Implementation Method 3
performing thermal planarizing, such that it is possible to reduce production of dust by the coating
Implementation Method 4
a sound-absorbing layer including thermoplastic resin... effectively blocking road noise generated between a tire and a road
Implementation Method 5
The outer layer and the sound-absorbing layer may be bonded under pressure by two rollers when being bonded through the adhesive layer
Data Source
AI summary
A method of manufacturing a wheel guard may include injection-molding an adhesive layer, bonding an outer layer including a non-woven fabric and a sound-absorbing layer including thermoplastic resin with the adhesive layer in between, and forming the layers into a predetermined shape of the wheel guard, with the outer layer and the sound-absorbing layer bonded by the adhesive layer. The thickness of the outer layer may be 2 to 10 mm, the thickness of the adhesive layer may be 0.1 to 2 mm, and the thickness of the sound-absorbing layer may be 2 to 10 mm, before the bonding. A specific heat treatment layer may be formed on a non-adhesive side of the outer layer and may have an LM FIBER, a film, or a sheet.