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Advances in the design and manufacturing of Expandable Epoxy Foam Inserts have resulted in a dramatic rise in the use of these technologies for the treatment of structureborne noise and vibration control. The evolution of these technologies has resulted in light weight and cost competitive solutions when compared to changes in primary body structure and surrounding sheet metal. These advances are discussed in detail. A structured, methodical approach to the identification of requirements for vehicle treatments is discussed. Based on these requirements, a process for the evaluation of application designs and the design optimization process are discussed. Validation of both the material technology and the engineering approach are presented through demonstration on actual vehicle applications.

Maintaining or improving acoustic and vibration quality of vehicles, the automotive industry continually faces design goals to reduce weight and manufacturing cost. In light of these objectives, advanced material design techniques facilitate the development of a high performance bulk applied constrained layer vibration damper aimed at improved automotive acoustics. The overall vehicle acoustic and vibration quality relies heavily on floor pan vibration dampers. A review of current industry damping technologies is addressed. Industry migration to bulk applied extensional dampers from the once ubiquitous asphalt sheet damper is discussed. Furthermore, this paper addresses the development of a new bulk applied constrained layer damper technology that delivers superior acoustical performance. The paper presents the chemistry formulation, the prediction of analytical results, and experimental validation.