Composite Wall Beam with Detachable Panels for Acoustic Absorption

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Solution Overview

Problem

Current composite wall designs are limited to eight feet in height, are aesthetically unpleasing due to use of plastic-based materials like PVC and PP, and have poor sound-absorbing properties compared to traditional wood and brick walls.

Innovation Solution

A lightweight composite wall system featuring a sound-absorbing wall assembly with a hollow beam made of fiberglass or similar materials, detachable panels with grill openings, and insulation to achieve improved sound absorption and aesthetic appeal, allowing for heights greater than eight feet.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If plastic-based materials (PVC, PP) are used for composite wall panels, then the walls can be manufactured with lightweight properties and modular design, but the aesthetic appeal and sound-absorbing properties deteriorate

Engineering Contradiction:
Improvewall weightVSAvoidaesthetic appeal
Core Design Contradiction:
Weight of moving objectVSEase of manufacture

Solution Approach 1:

The patent applies composite materials by combining fiberglass-reinforced plastic for the beam structure with wood or wood-composite materials for the panel faces. This creates a hybrid construction that maintains the lightweight and modular advantages of plastic-based materials while achieving the aesthetic appeal and sound-absorbing properties of traditional wood and brick walls.

Inventive Principle:
Principle #40Composite materials

2Ease of manufacture

If plastic-based materials are used for composite wall panels, then modular and pre-fabricated construction is enabled, but sound-absorbing properties worsen

Engineering Contradiction:
Improvemodular constructionVSAvoidsound absorption
Core Design Contradiction:
Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent applies local quality by using different materials for different functional requirements: fiberglass-reinforced plastic for the structural beam portions that require strength and modularity, and wood or wood-composite materials for the panel faces where sound absorption and aesthetics are priorities. This localized material selection allows each component to optimize its specific function.

Inventive Principle:
Principle #3Local quality

3Ease of manufacture

If traditional composite wall designs are used, then manufacturing simplicity is maintained, but wall height is limited to eight feet

Engineering Contradiction:
Improvemanufacturing simplicityVSAvoidwall height
Core Design Contradiction:
Ease of manufactureVSLength of stationary object

Solution Approach 1:

The patent applies segmentation by dividing the wall into modular components (beams and detachable panels) that can be assembled in various configurations. The beam structure is designed with corrugated ribs and flanges that allow for standardized connection points, enabling walls to be extended beyond eight feet by stacking multiple modular sections while maintaining manufacturing simplicity through repeated use of standard components.

Inventive Principle:
Principle #1Segmentation

4Strength

If fiberglass-reinforced plastic is used for the beam structure, then structural strength and lightweight properties are improved, but aesthetic appeal deteriorates

Engineering Contradiction:
Improvebeam strengthVSAvoidaesthetic appeal
Core Design Contradiction:
StrengthVSEase of manufacture

Solution Approach 1:

The patent uses fiberglass-reinforced plastic for the beam portions where structural strength is critical, while covering the panel faces with wood or wood-composite materials that provide aesthetic appeal. This composite approach allows each material to be used where its properties are most beneficial, resolving the contradiction between strength and aesthetics.

Inventive Principle:
Principle #40Composite materials

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 system provides enhanced sound absorption with a Noise Rating Coefficient greater than 0.85 and Sound Transmission Class above 30, while offering aesthetic flexibility and extended height capabilities.

Implementation Method 1

insulation material which is enclosed between the wall beam and the face panel to absorb sound

Methodology Applied
Scientific EffectSound absorption: Acoustic Absorption

Implementation Method 2

securing the upper clip over the upper connecting flange to create a frictional fit

Methodology Applied
Scientific EffectFriction: Friction

Data Source

PatentUS11142914B1System, method and apparatus for providing a sound absorbing composite wall
Publication Date: 2021.10.12 VALMONT INDUSTRIES INC
  • US11142914B1 patent drawing
  • US11142914B1 patent drawing
  • US11142914B1 patent drawing

AI summary

The present invention provides a light weight, composite wall system. According to a preferred embodiment, the present invention includes a sound absorbing wall assembly system which includes a wall beam with detachably mounted wall panels. According to further aspects of the present invention, the wall beam preferably includes an upper surface, a lower surface and a back beam surface which is connected between the upper and lower surfaces. According to further aspects of the present invention, the upper surface of the wall beam includes a corrugated rib and an upper connecting flange, and the lower surface includes a lower corrugated rib and a lower connecting flange.