Acoustic Felt Ceiling Tile with Embossed Rigidity
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Solution Overview
Problem
Tile systems used in ceilings and walls, especially in institutional facilities, face structural integrity issues and compromised sound absorption properties due to impacts, such as from balls in gymnasiums.
Innovation Solution
A tile system comprising a main body made of at least one layer of acoustic felt with tongue-and-groove arrangements and embossed portions, providing structural rigidity and sound absorption, where the acoustic felt has varying densities and is combined with a decorative liner and adhesive film, allowing for interlocking tiles that maintain sound absorption and decorative functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If tile systems are made from conventional materials for ceiling and wall coverage, then aesthetic and decorative functions are provided, but structural integrity and sound absorption properties are compromised under impact loads
Solution Approach 1:
The patent applies composite materials by combining acoustic felt (providing sound absorption) with thermoplastic material (providing structural integrity and impact resistance). This creates a hybrid structure where the acoustic felt layer maintains acoustic properties while the thermoplastic framework provides mechanical strength and durability under impact loads, resolving the contradiction between strength and reliability.
Solution Approach 2:
The patent implements local quality by creating regions of different material properties within the tile structure. The acoustic felt is positioned in specific zones to maximize sound absorption, while thermoplastic reinforcement is concentrated in areas requiring structural strength and impact resistance. This localized distribution of material properties allows simultaneous optimization of both sound absorption and structural integrity.
2Ease of manufacture
If tile systems use single-layer construction for simplicity, then manufacturing is easier, but structural rigidity and impact resistance are insufficient
Solution Approach 1:
The patent applies segmentation by dividing the tile into distinct functional layers: an acoustic felt layer for sound absorption and a thermoplastic layer for structural support. These segmented layers are bonded together through lamination or adhesive application, maintaining manufacturing simplicity while achieving enhanced structural rigidity and impact resistance that neither layer could provide alone.
3Reliability
If tile systems are designed with interlocking mechanisms for durability, then structural integrity is improved, but device complexity increases
Solution Approach 1:
The patent merges the interlocking mechanism with the tile's structural layers by integrating tongue-and-groove features directly into the thermoplastic framework. This integration allows the interlocking function to be achieved through the existing structural material rather than adding separate complex fastening systems, thereby improving functional durability while minimizing increases in device complexity.
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 tile system enhances structural integrity and sound absorption while maintaining aesthetic appeal, effectively addressing impact-related issues and ensuring functional durability.
Implementation Method 1
the at least one layer of acoustic felt defining at least one of the exposed side or the concealed side
Data Source
AI summary
A tile comprises a main body having an exposed side and a concealed side. The exposed side defines a main surface and the concealed side defines a rear plane. Side surfaces between the exposed side and the concealed side of the main body have tongue-and-groove arrangements in the rear plane. The main body is made of at least one layer of acoustic felt defining at least one of the exposed side or the concealed side. The at least one layer of acoustic felt has a main plane of at least one compressed portion, with at least one embossed portion projecting from the main plane of the at least one compressed portion.