ESI PAM-COMPOSITES Helps Kotobukiya Fronte Manufacture High-Quality Sound Absorbing Automotive Carpets
Kompozitní materiályAutomobilový průmysl & Doprava 
ESI PAM-COMPOSITES is equipped with the features and parameters necessary for carpet analysis. The analysis accuracy and the usability are excellent, and graphical display of analysis results is easy to understand, which is why we rate it highly. We consult with ESI daily about various matters such as how to reduce calculation time or what kind of modeling is necessary. ESI Japan is also actively and frequently providing information. We recognize that the early practical application of simulation of sound absorption type carpet is largely owed to support from ESI Japan.
Challenge
In the last decade, major material changes occurred in floor carpets as a shift was made from using rubber to synthetic materials. This increased the manufacturing difficulty and made existing knowledge obsolete. As Kotobukiya Fronte produces roughly 30 kinds of complex synthetic floor carpets, in the thousands every month, they need to be able to adopt new floor designs quickly and insure a high production rate. Additionally, it is imperative for them to validate and integrate new materials quickly.
Story
Around 2010, the main function of floor carpets for automobiles changed from sound insulation to sound absorption. This evolution was made possible by using synthetic fiber materials in place of high-density rubber based materials. Because of the positive environmental impact of synthetic fiber material (lightweight, hence less fuel consumption) and its dual function (sound absorption + insulation), sound absorptive floor carpeting has become the new standard in cars. Their only downfall is that they are difficult to form and require new manufacturing processes. Read the complete story.
Benefits
ESI PAM-COMPOSITES allowed Kotobukiya Fronte to adapt to innovations smoothly and quickly as they switched from sound insulating to sound absorptive floor carpeting. The simulation software enabled them to establish and improve their manufacturing methods quickly, inexpensively and as early as possible in their product development process.
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