Bi-component Fibre Sound Absorber Self-Lamination
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sound absorption materials face challenges in achieving effective noise reduction across a broad spectrum while maintaining mechanical integrity and reducing environmental impact, as they often require additional adhesives and are heavy and energy-intensive to produce.
Innovation Solution
A method of manufacturing a sound absorption material involving a low-density fibrous web with bi-component fibers, where a facing layer is adhered using a thin film compatible with the sheath material, eliminating the need for additional adhesives and allowing for self-lamination, thereby enhancing sound absorption and reducing material usage and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional sound absorption materials are used, then noise reduction is achieved, but the materials are heavy and require additional adhesives for assembly
Solution Approach 1:
The patent combines the sound absorption material and facing layer into a single integrated laminate structure. The bi-component fibres integrate the facing layer and sound absorption material during web formation, eliminating the need for separate adhesives and reducing overall weight while maintaining acoustic performance.
Solution Approach 2:
The invention uses bi-component fibres consisting of a core material (providing sound absorption) and a sheath material (providing facing layer functionality). This composite fibre structure allows both functions to be achieved simultaneously in a lightweight material that requires no additional adhesives.
2Loss of energy
If thicker sound absorption materials are used, then sound absorption performance improves, but the materials become heavier and more energy-intensive to produce
Solution Approach 1:
The patent optimizes the density and thickness parameters of the sound absorption material by using a low-density fibrous web (density between 10-100 kg/m³) combined with a thin facing layer (5-100 micrometers). This parameter optimization achieves effective sound absorption with reduced material thickness and weight, lowering energy consumption during production and transportation.
3Loss of substance
If additional adhesives are used to attach facing layers, then assembly is achieved, but environmental impact increases and material purity is reduced
Solution Approach 1:
The patent extracts and eliminates the adhesive component from the assembly process. The bi-component fibres are designed so that the sheath material acts as a self-adhesive layer during web formation, completely removing the need for separate adhesive materials and reducing environmental impact.
Solution Approach 2:
The sheath material of the bi-component fibres provides self-adhesive properties that enable the facing layer to be attached to the sound absorption material without external adhesives. This self-service mechanism reduces material usage and eliminates harmful substances from the assembly process.
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 method results in a lightweight, highly effective sound absorption material that provides equivalent performance to thicker, heavier materials with reduced environmental impact and improved acoustic weight efficiency, achieving superior sound absorption across a broad frequency range.
Implementation Method 1
The bi-component fibres each have a core material and a sheath material which adheres to the facing layer
Implementation Method 2
heating the fibrous web to a temperature sufficient to soften the sheath material of at least some of the bi-component fibres for adhesion to the thin facing layer
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Described embodiments relate to a method of manufacturing a sound absorption material. The method comprises: forming a low density fibrous web to act as a porous bulk absorber, the fibrous web containing a proportion of bi-component fibres, each bi-component fibre having a core material and a sheath material around the core material, the sheath material having a lower melting point than the core material; applying a thin facing layer to the low density fibrous web, wherein the facing layer is adhesively compatible with the sheath material; heating the fibrous web to a temperature sufficient to soften the sheath material of at least some of the bi-component fibres; and pressing the facing layer and fibrous web together under low pressure such that at least part of the facing layer contacts the softened sheath material of at least some of the bi-component fibres to form an adhesive bond between the facing layer and the fibrous web.