A system for forming fabricated polymer panels for sound absorption

Abstract

The present subject matter discloses a system (102) for forming a plurality of fabricated polymer panels (802). The system (102) includes a container (104) with at least one pair of walls enclosing a vacant space. The system (102) includes a heating unit (106) with at least one hot wire (108) placed beneath the container (104), configured to move in a relative motion in an upward direction and a downward direction with respect to the container (104), inside the container (104) through the vacant space. The system (102) further includes a plurality of tubes (110) stacked with one another inside the container (104) in the vacant space, wherein the plurality of tubes (110) endures, a cutting in a transverse direction when the heating unit (106) moves in the upward direction and the downward direction to form a plurality of panels, and a melting of a surface of at least two tubes placed adjacent with one another, that forms a fuse weld at a contact region between at least two tubes forming the plurality of fabricated polymer panels (802). {To be published with figure 1}

Description

Description:A SYSTEM FOR FORMING FABRICATED POLYMER PANELS FOR SOUND ABSORPTION

[0001] The present disclosure relates to a system for manufacturing polymer panels, particularly, the present subject matter relates to the system for manufacturing polymer panels for sound absorption. BACKGROUND OF THE INVENTION

[0002] Background description includes information that may be useful in understanding the present invention.

[0003] In the passive noise control methods, absorption coefficient and transmission loss are the important acoustic material properties. In traditional acoustic material, absorption coefficient depends on material porosity, flow resistance and thickness. This absorption occurs by dissipating the acoustic energy in the form of thermal energy while propagating through material. As a rule of thumb, to get maximum absorption coefficients at frequency, thickness of absorptive material should be more than one-fourth of wavelength.

[0004] The Polypropylene tubes have been utilized as the working material in fabricating the periodic cell polymer tube acoustic absorber sheet in the current study. Polypropylene is a versatile thermoplastic polymer with a wide range of applications. It ranks as the second most widely produced polymer (after polyethylene) and finds extensive use in packaging and labelling purposes. Its suitability for manufacturing lies in its durability and chemical resistance.

[0005] However, bonding polypropylenes poses challenges due to their low surface energy and hydrophobic nature. These characteristics hinder adhesive penetration and result in poor bonding, with adhesive beading up on the surface instead.

[0006] Therefore, there is a need for a solution to overcome the above-mentioned drawbacks. SUMMARY OF THE INVENTION

[0007] This summary is provided to introduce concepts related to a system for forming a plurality of fabricated polymer panels. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

[0008] The present subject matter discloses a system for forming a plurality of fabricated polymer panels. The system includes a container with at least one pair of walls enclosing a vacant space. The system includes a heating unit with at least one hot wire placed beneath the container, configured to move in a relative motion in an upward direction and a downward direction with respect to the container, inside the container through the vacant space. The system includes a plurality of tubes stacked with one another inside the container in the vacant space. The plurality of tubes endures a cutting by the at least one hot wire in a transverse direction when the heating unit moves in the upward direction and the downward direction to form a plurality of panels, and a melting of a surface of at least two tubes amongst the plurality of tubes of the plurality of panels placed adjacent with one another, that forms a fuse weld at a contact region between at least two tubes from of the plurality of adjacent surfaces forming the plurality of fabricated polymer panels.

[0009] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

[0010] The illustrated embodiments of the subject matter will be understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:

[0011] Fig. 1 illustrates a diagram depicting a system for forming a number of fabricated polymer panels, in accordance with an embodiment of the present subject matter;

[0012] Fig. 2 illustrates a diagram depicting a movement of the at least one hot wire through a vacant space of the container of the system, in accordance with an embodiment of the present subject matter;

[0013] Fig. 3 illustrates a diagram depicting the container of the system, in accordance with an embodiment of the present subject matter;

[0014] Fig. 4a-4c illustrate images depicting a wire feed mechanism of the system, in accordance with an embodiment of the present subject matter;

[0015] Fig. 5 illustrates an image depicting a method to mount at least one hot wire on the container of the system, in accordance with an embodiment of the present subject matter;

[0016] Fig. 6a illustrates an image depicting a wire holder guide with the lead screw, in accordance with an embodiment of the present subject matter. The wire holder guide may be configured to hold at least one hot wire.

[0017] Fig. 6b illustrates an image depicting the lead screw and the smooth rod, in accordance with an embodiment of the present subject matter; and

[0018] Fig. 6c illustrates an image depicting a stepper motor support powering at least one hot wire and raising a temperature of the at least one hot wire, in accordance with an embodiment of the present subject matter;

[0019] Fig. 7 illustrates a graphical representation depicting an average absorption coefficient of a polymer tube, in accordance with an embodiment of the present subject matter;

[0020] Fig. 8 illustrates an image depicting the number of fabricated polymer panels 802, in accordance with an embodiment of the present subject matter; and

[0021] Fig. 9 illustrates a diagram depicting another embodiment of the system 102, in accordance with an embodiment of the present subject matter.

[0022] The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein. DETAILED DESCRIPTION

[0023] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.

[0024] Fig. 1 illustrates a diagram 100 depicting a system 102 for forming a number of fabricated polymer panels, in accordance with an embodiment of the present subject matter. The number of fabricated polymer panels may be formed for a purpose of sound absorption. The number of fabricated polymer panels may be made up of a number of tubes 110 of polymer. The number of tubes 110 may specifically be made up of polypropylene polymer. The system 102 may be configured to fabricate a periodic cell sheet absorber with polymer material that may be used in acoustic applications. Fabrication of the period cell sheet absorber with the number of tubes 110 may be required for forming the number of fabricated polymer panels. The system 102 may be housed within a structural frame. The structural frame the system 102 may be made using an aluminium extrusion profile measuring 20 x 20 mm². The structural frame may occupy a space of (400 x 400 x 1000) mm³.

[0025] Continuing with the above embodiment, the system 102 may include a container 104, a heating unit 106 with at least one hot wire 108, the number of tubes 110, a power source 112, a lead screw, and a motor. The container 104 may be a 4-sided structure in a shape of a square having a roof. The container 104 may be made up of a number of panels. The container 104 may include at least one pair of walls that may further be configured to enclose a vacant space. To that understanding, in an embodiment, the at least one pair of walls may include a first pair of opposite walls and a second pair of opposite walls. The first pair of opposite walls may have at least one vertical slot. The at least one vertical slot may be configured to allow a movement of the at least one hot wire 108 in an upward direction and a downward direction. Moving forward, the second pair of opposite walls may be configured to be removed from the container 104. The second pair of opposite walls may be removable and may further be removed based on a size of the number of tubes 110 being placed inside the container 104.

[0026] Subsequently, the heating unit 106 with the at least one hot wire 108 may be placed beneath the container 104. The heating unit 106 may be attached to the structural frame and the power source 112 that may be an electrical source. The at least one hot wire 108 may be made up of an alloy and may be under tension. The heating unit 106 with the at least one hot wire 108 may be configured to move in a relative motion in the upward direction and the downward direction with respect to the container 104. Precisely, the heating unit 106 with the at least one hot wire 108 may move inside the container 104 through the vacant space and the second pair of opposite walls may be removed so as to assure that the second pair of opposite walls is not creating a hinderance in a movement of the at least one hot wire 108 within the container 104, based on the size of the number of tubes 110. The number of tubes 110 may be stacked with one another inside the container 104 in the vacant space. The number of tubes 110 may be stacked inside the container 104 at an adjustable distance between one another.

[0027] To that understanding, the relative motion may include the heating unit 106 with the at least one hot wire 108 moving in the upward direction and the downward direction while the container 104 stays in a stationary position, the container 104 moving in the upward direction and the downward direction and the heating unit 106 while the at least one hot wire 108 stays in the stationary position, the heating unit 106 with the at least one hot wire 108 moving in the upward direction while the container 104 moves in the downward direction, and the container 104 moving in the upward direction and the heating unit 106 while the at least one hot wire 108 moves in the downward direction. Any of the above-mentioned relative motions may take place.

[0028] Moving forward, during the relative motion of the heating unit 106 with the at least one wire and the container 104, the number of tubes 110 may be configured to endure a number of effects. The number of effects may include a cutting by the at least one hot wire 108, and a melting of a surface of at least two tubes amongst the number of tubes 110 of the number of panels placed adjacent with one another. The cutting may take place in a transverse direction when the heating unit 106 moves in the upward direction and the downward direction to form a number of panels. The melting of the surface may form a fuse weld at a contact region between at least two tubes from of the number of adjacent surfaces further forming the number of fabricated polymer panels that may be used for the sound absorption. The relative velocity maintained based on a melting temperature of the number of tubes 110. The at least one hot wire 108 may be employed to melt and cut the number of tubes 110. The melted polypropylene from the number of tubes 110 ahead of the at least one wire may serve as an adhesive, facilitating a strong bond between each tube. The same manufacturing may be used for other polymer materials as well.

[0029] Subsequently, each fabricated polymer panel that may be formed from the number of polymer fabricated panel may correspond to a thickness based on a distance between at least two hot wires attached to the heating unit 106. The number of fabricated polymer panels may further be separated from one another. The separation may be performed via a paper membrane. The paper membrane may be placed between each fabricated polymer panel from the number of fabricated polymer panels.

[0030] To that understanding, the power source 112 may be configured to power the heating unit 106 and increase a temperature of the at least one hot wire 108. The at least one hot wire 108 may be configured to melt the number of tubes 110 at a predetermined temperature.

[0031] Fig. 2 illustrates a diagram 200 depicting a movement of the at least one hot wire 108 through a vacant space of the container 104 of the system 102, in accordance with an embodiment of the present subject matter. The at least one hot wire 108 may be heated to a predetermined temperature prior to running through the container 104. The container 104 may be having the number of tubes 110 stacked inside the vacant space and the at least one hot wire 108 may be running through the number of tubes 110. Fig. 2 depicts a movement of the at least one hot wire 108 in a downward direction while the container 104 stays in a stationary position. The number of tubes 110 may be configured to endure a number of effects. The number of effects may include a cutting by the at least one hot wire 108, and a melting of a surface of at least two tubes amongst the number of tubes 110 of the number of panels placed adjacent with one another. The cutting may take place in a transverse direction when the heating unit 106 moves in the upward direction and the downward direction to form a number of panels. The melting of the surface may form a fuse weld at a contact region between at least two tubes from of the number of adjacent surfaces further forming the number of fabricated polymer panels that may be used for the sound absorption.

[0032] Fig. 2 depicts the at least one hot wire 108 above the number of tubes 110, moving downwards while cutting through the number of tubes 110 and then beneath the number of tubes 110. When the heating element passes through the number of tubes 110 arranged in the container 104, the heating element cuts the number of tubes 110 by localized melting in a transverse direction. In an embodiment where the number of tubes 110 includes adjacent / meeting surfaces, the heating element may melt the adjacent surfaces, and form a fuse weld at the contact region to form a number of fabricated polymer panels.

[0033] The at least one hot wire 108 may be of a high specific resistance, a high temperature strength, and a creep resistance. The high resistance may enable a rapid response to changes in an electrical power. The at least one hot wire 108 may be made up of Nickel alloy that provides the high specific resistance and the high-temperature strength at a reduced cost.

[0034] Fig. 3 illustrates a diagram 300 depicting the container 104 of the system 102, in accordance with an embodiment of the present subject matter. The container 104 may be a 4-sided structure in a shape of a square having a roof. The container 104 may be made up of a number of panels. Further, each panel may be made up of acrylic sheet. The container 104 may include at least one pair of walls that may further be configured to enclose a vacant space. To that understanding, the at least one pair of walls may include the first pair of opposite walls 302a, 302b and a second pair of opposite walls 302c, 302d. The first pair of opposite walls 302a, 302b may have at least one vertical slot 304. The at least one vertical slot 304 may be configured to allow a movement of the at least one hot wire 108 in an upward direction and a downward direction. Moving forward, the second pair of opposite walls 302c, 302d may be configured to be removed from the container 104. The second pair of opposite walls 302c, 302d may be removed based on a size of the number of tubes 110 being placed inside the container 104. The vertical slot may be of 17 mm through which the at least one hot wire 108 passes while moving in a downward direction.

[0035] Fig. 4a-4c illustrate images 400a-400c depicting a wire feed mechanism of the system 102, in accordance with an embodiment of the present subject matter. The wire feed mechanism may include a lead screw 402, a wire holder 404, a smooth rod 406,. The lead screw 402 may be attached to a heating unit to allow the movement of a frame holding at least one hot wire in the upward direction and the downward direction via a motor. The lead screw 402 may be utilized to provide a linear movement in an upward direction and a downward direction to the wire holder 404. The lead screw 402 may be a 500 mm long trapezoidal single start lead screw 402 with an 8 mm thread and 2 mm pitch, along with a copper nut. The smooth rod may be measuring 8 mm in diameter and 500 mm in length. The smooth rod may be configured to support the lead screw 402. Additionally, the smooth rod 406 of the same dimensions as the smooth rod 406 may be employed to support the lead screw 402, preventing the lead screw 402 from rotating.

[0036] Fig. 5 illustrates an image depicting a method 500 to mount at least one hot wire on the container 104 of the system 102, in accordance with an embodiment of the present subject matter. A wire feed mechanism may be utilised in mounting the at least one hot wire.

[0037] Fig. 6a illustrates an image 600a depicting a wire holder guide 602 with the lead screw 402, in accordance with an embodiment of the present subject matter. The wire holder guide 602 may be configured to hold at least one hot wire.

[0038] Fig. 6b illustrates an image 600b depicting the lead screw 402 and the smooth rod 406, in accordance with an embodiment of the present subject matter. The smooth rod 406 may be measuring 8 mm in diameter and 500 mm in length.

[0039] Fig. 6c illustrates an image 600c depicting a stepper motor support 604 powering at least one hot wire and raising a temperature of the at least one hot wire, in accordance with an embodiment of the present subject matter.

[0040] Fig. 7 illustrates a graphical representation 700 depicting an average absorption coefficient of a polymer tube, in accordance with an embodiment of the present subject matter.

[0041] Fig. 8 illustrates an image 800 depicting the number of fabricated polymer panels 802, in accordance with an embodiment of the present subject matter.

[0042] Fig. 9 illustrates a diagram 900 depicting another embodiment of the system 102, in accordance with an embodiment of the present subject matter.

[0043] While the embodiments of the disclosure are subject to various modifications and alternative forms, specific embodiment thereof have been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the scope of the disclosure.

[0044] The terms “comprises”, “comprising”, or any other variations thereof used in the disclosure, are intended to cover a non-exclusive inclusion, such that a device, system 102, assembly that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such system 102, or assembly, or device. In other words, one or more elements in a system 102 or device proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system 102 or device.

[0045] It will be further appreciated that functions or structures of a number of components or steps may be combined into a single component or step, or the functions or structures of one-step or component may be split among plural steps or components. The present invention contemplates all of these combinations. Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention. The present invention also encompasses intermediate and end products resulting from the practice of the methods herein. The use of “comprising” or “including” also contemplates embodiments that “consist essentially of” or “consist of” the recited feature.

Claims

, Claims:We claim:

1. A system (102) for forming a plurality of fabricated polymer panels (802), comprising:a container (104) with at least one pair of walls enclosing a vacant space;a heating unit (106) with at least one hot wire (108) placed beneath the container (104), configured to move in a relative motion in an upward direction and a downward direction with respect to the container (104), inside the container (104) through the vacant space; anda plurality of tubes (110) stacked with one another inside the container (104) in the vacant space, wherein the plurality of tubes (110) endures:a cutting by the at least one hot wire (108) in a transverse direction when the heating unit (106) moves in the upward direction and the downward direction to form a plurality of panels; anda melting of a surface of at least two tubes amongst the plurality of tubes (110) of the plurality of panels placed adjacent with one another, that forms a fuse weld at a contact region between at least two tubes from of the plurality of adjacent surfaces forming the plurality of fabricated polymer panels (802).

2. The system (102) as claimed in claim 1, further comprising:a power source (112) configured to power the heating unit (106) and increase a temperature of the at least one hot wire (108), wherein the hot wire melts the plurality of tubes (110) at a predetermined temperature; anda lead screw (402) attached to the heating unit (106) to allow the movement of a frame holding the at least one hot wire (108) in the upward direction and the downward direction via a motor (604).

3. The system (102) as claimed in claim 1, wherein the relative motion comprises:a. The heating unit (106) with the at least one hot wire (108) moving in the upward direction and the downward direction and the container (104) staying in a stationary position;b. The container (104) moving in the upward direction and the downward direction and the heating unit (106) with the at least one hot wire (108) staying in the stationary position;c. The heating unit (106) with the at least one hot wire (108) moving in the upward direction and the container (104) moving in the downward direction; andd. The container (104) moving in the upward direction and the heating unit (106) with the at least one hot wire (108) moving in the downward direction.

4. The system (102) as claimed in claim 1, wherein the plurality of tubes (110) is stacked inside the container (104) at an adjustable distance between one another.

5. The system (102) as claimed in claim 1, wherein each polymer fabricated panel corresponds to a thickness based on a distance between at least two hot wires.

6. The system (102) as claimed in claim 1, wherein the at least one hot wire (108) is made up of an alloy.

7. The system (102) as claimed in claim 1, wherein the at least one pair of walls comprises:a first pair of opposite walls (302a, 302b) having At least one vertical slot (304) to allow a movement of the at least one hot wire (108) in the upward directions and the downward direction; anda second pair of opposite walls (302c, 302d) configured to be removed based on a size of the plurality of tubes (110) being placed inside the container (104).

8. The system (102) as claimed in claim 1, wherein the plurality of fabricated polymer panels (802) is separated from one another via a paper membrane placed between each fabricated polymer panel amongst the plurality of fabricated polymer panels (802).

9. The system (102) as claimed in claim 1, wherein the system (102) is housed within a structural frame.

10. The system (102) as claimed in claim 1, wherein the container (104) is made up of a plurality of panels and the plurality of tubes (110) is made up of a polymer.