Coated Core Composite Materials for Lightweight Sound Attenuation

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Solution Overview

Problem

Existing sound attenuation materials are expensive, heavy, and fail to provide adequate sound reduction, necessitating the development of more effective and lightweight solutions.

Innovation Solution

A sound attenuation material comprising particles with a dense core and an elastic or compliant coating, where the core is denser than the matrix and coating, combined with a method of manufacturing that involves coating the particles and incorporating them into a matrix material to create a composite with enhanced sound absorption properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If existing sound attenuation materials are used, then sound reduction is achieved, but the materials are expensive and heavy

Engineering Contradiction:

Improvesound transmissionVSAvoidmaterial weight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of stationary object

Solution Approach 1:

The patent uses composite particles consisting of a dense core material (metal, mineral, or ceramic) coated with an elastic or compliant material. This composite structure combines the high density of the core for sound attenuation with the elasticity of the coating for mechanical strength, achieving effective sound reduction without requiring heavy monolithic materials. The composite nature allows optimization of both acoustic performance and weight.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies different materials with specific properties to different parts of the particle structure. The core uses high-density material for maximum sound attenuation, while the coating uses elastic material for structural integrity. This local differentiation of material properties allows each component to contribute its optimal characteristics, reducing overall material weight while maintaining effectiveness.

Inventive Principle:

Principle #3Local quality

2Object-affected harmful factors

If existing sound attenuation materials are used, then sound reduction is achieved, but manufacturing and installation costs are high

Engineering Contradiction:

Improvesound transmissionVSAvoidmanufacturing cost

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent varies parameters such as core density, coating thickness, and particle size to optimize sound attenuation at different frequencies. By adjusting these parameters, the material can be tailored for specific applications, reducing the need for expensive custom-designed heavy materials while achieving the required sound reduction performance through parameter optimization rather than material quantity.

Inventive Principle:

Principle #35Parameter changes

3Object-affected harmful factors

If high mass materials are used for sound attenuation, then sound reduction is improved, but the materials fail to provide adequate attenuation in some cases

Engineering Contradiction:

Improvesound attenuationVSAvoidmaterial mass

Core Design Contradiction:

Object-affected harmful factorsVSWeight of stationary object

Solution Approach 1:

The patent utilizes the resonant vibration of dense core particles when exposed to sound waves. The elastic coating allows the core to vibrate at specific frequencies, absorbing sound energy through this mechanical resonance. This mechanism is more efficient than simple mass blocking, achieving better sound attenuation per unit of material mass by actively engaging the material in vibrational energy absorption.

Inventive Principle:

Principle #18Mechanical vibration

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 achieves significant sound attenuation with reduced weight and cost, demonstrating increased sound absorption across various frequency ranges, including low frequencies, while maintaining mechanical strength and durability.

Implementation Method 1

an elastic or compliant coating around the core

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

allowing for controlled sound absorption by varying the core and coating densities and sizes to target specific resonant frequencies

Methodology Applied

Scientific EffectVibration: Vibration

Implementation Method 3

the core is denser than the matrix. The core may also be denser than the elastic or compliant coating

Methodology Applied

Scientific EffectDensity contrast: Density Gradient

Data Source

PatentUS11885120B2Construction materials with engineered sound attenuating properties and methods therefor

Publication Date: 2024.01.30 OCEANIT LABORATORIES INC

AI summary

A sound attenuation material includes a plurality of particles, each having a core and an elastic or compliant coating around the core, and a matrix surrounding the plurality of particles, the matrix being less dense than the core. A method of manufacturing sound attenuating materials includes adding an elastic or compliant coating to core particles and drying and/or curing the coating, mixing the coated core particles into a matrix material, and pouring the mixture into a mold. The core particles are denser than the matrix material.