Acoustical Foam Case Study

This case study highlights Patvin Engineering’s ability to deliver innovative and effective solutions to complex engineering challenges.

Challenge

Vehicle interior noise, a significant factor in passenger comfort, comprises structure-borne and airborne components. One leading Indian automobile manufacturer grappled with reducing airborne noise, traditionally addressed using baffle technology. However, baffle placement inconsistencies and displacement posed significant challenges.

Solution

Recognizing the need for a more effective approach, the manufacturer partnered with Patvin Engineering to implement a groundbreaking solution. Patvin integrated Graco’s NVH system with their engineering expertise to replace baffles with a pumpable foam.

The Process

Patvin designed a comprehensive system, including a Graco HFR machine for precise foam dispensing and a GPS-coordinate-based vision system for sequencing and quality control. This innovative setup ensured accurate foam application in every cavity, eliminating the risk of missed or misplaced baffles.

Additionally, Patvin developed a robust process architecture to maintain foam quality and consistency throughout production. This included a material refresh system, heat conditioning, and storage solutions to prevent material degradation.

Overcoming Obstacles

Implementing this new technology demanded meticulous attention to detail. Patvin addressed challenges such as maintaining gun perpendicularity, ensuring accurate foam volume, and guaranteeing correct shot sequencing. Graco’s advanced gun technology, coupled with Patvin’s vision system, provided precise control and error prevention.

Furthermore, Patvin overcame the challenges of handling the sensitive foam material by developing a comprehensive material management system. This system included heat aging detection, a peggable system for material refresh, and a controlled storage environment to preserve foam integrity.

The Results

By successfully implementing the Graco NVH system and Patvin’s engineering solutions, the automobile manufacturer achieved a substantial reduction in interior noise levels. The elimination of baffles and the precise application of foam significantly enhanced vehicle comfort.

Moreover, Patvin’s process architecture ensured consistent foam quality and efficient production, leading to improved overall manufacturing efficiency.

Acoustic Baffles: A Comparative Analysis

While baffles offer low upfront costs and minimal space requirements, their drawbacks are significant. They require specific tooling for each part, suffer from unreliable expansion, and necessitate a multitude of part numbers, leading to high inventory and slow time-to-market. Moreover, their sealing performance can be inconsistent.

Injected Foams: The Future of NVH

In contrast, injected foams provide a 3D, robust seal, dramatically improving NVH performance. Their flexibility allows for application across multiple vehicle lines, and the potential for reduced or eliminated tooling costs makes them highly cost-effective.

Additionally, the ability to adjust foam volume and shot locations offers unparalleled customization. While the upfront capital costs and potential space requirements are considerations, the long-term benefits often outweigh these initial investments.

The Graco HFR Advantage

Graco’s HFR metering system is the cornerstone of this successful implementation. Its standard, modular design and precision dispensing capabilities make it both reliable and affordable. Compared to custom systems, the HFR offers advanced technology at a fraction of the cost, opening up new possibilities for acoustical foam applications.

By combining the innovative technology of Graco’s HFR system with Patvin Engineering’s deep industry knowledge, this partnership has redefined the standards for automotive noise control. The result is a quieter, more comfortable driving experience for consumers and a more efficient, cost-effective manufacturing process for automotive manufacturers.

Conclusion

Customer perception is clear: silence equates to quality. As the automotive industry increasingly prioritizes NVH solutions, the demand for quieter vehicles grows.

Graco’s HFR system, paired with Patvin Engineering’s expertise, offers a compelling solution. This technology is not only easy to use and maintain but also affordable, flexible, and precise, delivering a superior return on investment compared to traditional baffle methods.

FAQ’s

1. What are the applications of acoustical foam in vehicles?
   Car makers use acoustical foam to block noise from outside and reduce movement, improving the car’s NVH. Foam is used in door and floor areas to stop sound from entering and make the car feel calmer. By using foam instead of baffles, cars get better sealing and a nicer driving experience.
2. What challenge did the automobile manufacturer face in this case study?
   The manufacturer couldn’t control noise well because the baffles were placed unevenly in different cars. They wanted a clear and automatic method to apply foam correctly, reduce noise, and use less hand work.
3. What did we do to solve the issue?
   Our team set up a robot to spray foam the same way each time, making sure it was always done right. The use of automation improved their work and helped reduce the car’s noise and shaking.
4. Why is automotive NVH treatment so dependent on automation?
   Robots apply foam in the right way each time, helping cut down sound and vibration. It helps workers make fewer mistakes, builds cars quicker, and keeps the inside calm and quiet.