Multi-layered Acoustic Damping Panel with Reinforcement Layer
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Solution Overview
Problem
Existing acoustic damping panels face challenges such as high weight due to wood fiber boards, cumbersome installation processes, difficulties in achieving smooth groove edges during milling, and susceptibility to warping when exposed to moisture.
Innovation Solution
A multi-layered acoustic damping panel comprising a décor layer, a porous three-dimensional acoustic damping back layer, and a reinforcement layer that stabilizes the décor layer and allows for easier cutting with a saw instead of milling, reducing weight and installation complexity while preventing warping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a wood fiber board is used in the acoustic damping panel, then the panel has high structural stability, but the weight increases significantly making installation difficult
Solution Approach 1:
The patent removes the wood fiber board from the panel structure entirely, extracting only the essential acoustic damping function through a lighter alternative construction that achieves the same structural stability without the heavy wood fiber component
Solution Approach 2:
The patent uses a composite structure combining a rigid decorative layer, a lightweight acoustic damping layer, and a reinforcement layer, creating a multi-material construction that provides structural stability equivalent to wood fiber board but with significantly reduced weight
2Manufacturing precision
If milling is used to cut grooves into the acoustic damping panel, then grooves can be created for sound wave absorption, but the process is slow and produces rough edges
Solution Approach 1:
The patent replaces the milling process with a sawing process, substituting a rotary cutting mechanism with a linear saw blade that cuts through all layers simultaneously, achieving both higher speed and smoother edges in the decorative and reinforcement layers
Solution Approach 2:
The patent segments the cutting function across multiple layers, where the saw blade cuts the decorative layer, reinforcement layer, and acoustic damping layer in one operation, with the acoustic damping layer's porous structure providing the necessary groove formation without requiring precision milling
3Shape
If a wood-based decorative layer is used, then aesthetic appearance is achieved, but the layer is prone to warping when exposed to moisture
Solution Approach 1:
The patent introduces a reinforcement layer as an intermediary between the wood-based decorative layer and the acoustic damping layer, acting as a moisture barrier that prevents water from reaching the wood, thereby eliminating warping while preserving the aesthetic appearance of the wooden decorative surface
Solution Approach 2:
The patent extracts the moisture barrier function from the wood-based decorative layer itself and places it in the reinforcement layer, allowing the decorative layer to focus solely on aesthetic appearance without the compromising effect of moisture exposure
4Strength
If the acoustic damping panel includes a wood fiber board, then structural integrity is maintained, but the installation process becomes cumbersome requiring dismantling of electrical installations and skirting boards
Solution Approach 1:
The patent extracts the wood fiber board from the structure, reducing panel weight significantly, which transforms the installation process from one requiring dismantling of electrical installations and skirting boards to a simpler process using only adhesive or mechanical fasteners
Solution Approach 2:
The patent changes the weight parameter of the panel by removing the heavy wood fiber board, which directly affects the installation process by eliminating the need for complex preparation steps and allowing direct adhesion or fastening to the substrate
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a significantly lighter panel (79% weight reduction), simplifying installation, reducing transport costs and volume, and preventing warping when exposed to moisture, while maintaining effective acoustic damping properties.
Implementation Method 1
a reinforcement layer in the form of a two-dimensional sheet, film or web... The reinforcement layer stabilizes the décor layer
Implementation Method 2
a back layer formed of a porous three-dimensional acoustic damping material... the back layer provides most of the acoustic damping function of the panel
Implementation Method 3
The décor layer is bonded to the first surface of the reinforcement layer, and the back layer is bonded to the second surface of the reinforcement layer
Data Source
Figure 1~2d
Figure 3~4b
Figure 5~6
AI summary
A multi-layered acoustic damping panel (1) comprises a décor layer (100), defining a principal plane (XZ), a back layer (11) formed of a porous three-dimensional acoustic damping material, and a reinforcement layer (101) in the form of a two-dimensional sheet, film or web, the reinforcement layer (101) having: a first surface (1010) and a second surface (1011), opposite the first surface (1010). The décor layer (100) is bonded to the first surface (1010) of the reinforcement layer (101), and the back layer (11) is bonded to the second surface (1011) of the reinforcement layer (101). A method of manufacturing a multi-layered acoustic damping panel is also disclosed.