Acoustic Ceiling Panel with Segmented Bonding
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Solution Overview
Problem
Previous laminate acoustic ceiling panels fail to effectively address the interface between layers, impacting noise blocking and sound dampening characteristics, leading to suboptimal acoustical performance.
Innovation Solution
A method involving a sound absorbing ceiling panel with an NRC value of at least 0.9, combined with a sound attenuation layer having a CAC value of at least 37, positioned in a free-floating relationship to form a multi-component panel with enhanced acoustical properties, achieving a CAC value of at least 40 and an NRC value of at least 0.95.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If layers are bonded together across substantially the entire interface, then structural integrity is improved, but noise blocking and sound dampening characteristics deteriorate
Solution Approach 1:
The interface between layers is segmented into bonded regions and unbonded regions. The bonded regions provide structural integrity at specific locations, while the unbonded regions allow for acoustic performance by enabling air movement and reducing sound transmission. This segmentation resolves the contradiction by distributing bonding functions across different zones rather than applying uniform bonding across the entire interface.
Solution Approach 2:
Different regions of the layer interface have different bonding characteristics. Some areas are bonded to provide structural support, while other areas remain unbonded to optimize acoustic performance. This local differentiation allows the structure to simultaneously achieve both structural integrity and superior noise blocking/sound dampening properties.
2Device complexity
If a single layered structure is used, then device complexity is reduced, but acoustical performance (noise blocking and sound dampening) deteriorates
Solution Approach 1:
The acoustic ceiling panel uses a laminate structure combining multiple layers with different properties (sound absorbing layer, sound attenuating layer, and interface structures). This composite approach enables the panel to achieve superior simultaneous noise blocking and sound dampening performance that cannot be realized with a single homogeneous material, while maintaining reasonable structural complexity through integrated design.
3Manufacturing precision
If laminate structures with fully bonded layers are used, then manufacturing precision is improved, but acoustical performance deteriorates
Solution Approach 1:
The interface bonding is segmented into discrete bonded and unbonded regions rather than applying continuous bonding. This segmentation allows manufacturing processes to achieve precise control over where bonding occurs, maintaining manufacturing precision while preserving acoustic performance through the intentional unbonded regions that facilitate sound attenuation mechanisms.
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 significantly improves soundproofing between adjacent rooms while maintaining excellent sound absorption within a single room, avoiding the degradation in NRC performance seen in previous designs, and allows for a thinner ceiling panel structure with improved CAC performance.
Implementation Method 1
mounting a first ceiling panel to a support grid, the first ceiling panel formed of a sound absorbing material
Implementation Method 2
positioning a first sound attenuation layer in a free-floating relationship atop the upper major surface of the first ceiling panel, wherein the first sound attenuation layer has a CAC value of at least 37
Data Source
AI summary
Described herein is a multi-component panel comprising a ceiling panel and a sound attenuation layer, as well as a ceiling system that includes the multi-component panel.