Design and Validation of a PU–Six-Cavity Helmholtz Metamaterial Composite Acoustic Package for Broadband Noise Reduction in Commercial Vehicle Cabs

To address the broadband noise distribution, complex excitation sources, and insufficient low-frequency attenuation of conventional porous acoustic packages in commercial vehicle cabs, this study proposes a PU–six-cavity Helmholtz metamaterial composite acoustic package for broadband noise reduction. The proposed structure consists of a 30 mm PU porous layer for mid-to-high-frequency dissipation and a 30 mm six-cavity Helmholtz metamaterial layer for low-frequency absorption, forming a 60 mm composite acoustic package. A full-vehicle acoustic model of a commercial vehicle cab was established in VA One to identify the A-weighted sound pressure level (SPL) spectrum at the driver position. The results show that the PU porous acoustic package improves the mid- and high-frequency noise response, whereas pronounced peaks remain in the low- and low-to-mid-frequency ranges. To enhance these bands, the six sub-cavities of the Helmholtz metamaterial were tuned to 200, 250, 315, 400, 500, and 630 Hz through spatial partitioning and cavity grouping. COMSOL (version 6.1) simulations and particle velocity distributions confirmed the multi-peak absorption mechanism and the selective excitation of the corresponding sub-cavities. The composite structure was further validated through impedance-tube measurements, full-vehicle acoustic simulations, and in-vehicle tests. The VA One simulation shows that the total A-weighted SPL at the driver position decreases from 68.25 dB for the PU porous package to 66.01 dB after introducing the six-cavity Helmholtz metamaterial, corresponding to an additional reduction of 2.24 dB. A preliminary in-vehicle test under a stationary idling condition shows that the total A-weighted SPL near the driver’s ear decreases from 55.83 dB(A) to 54.56 dB(A). These results demonstrate that the proposed PU–six-cavity Helmholtz metamaterial composite acoustic package combines broadband porous dissipation with low-frequency resonant absorption, providing a feasible solution for broadband noise control in commercial vehicle cabs.