Compressed Polyurethane Foam Sound Absorber for Compact Spaces
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Solution Overview
Problem
Conventional sound absorbing bodies, such as those made from fibrous substances and foam, require increased volume to achieve effective sound absorption, leading to space utilization issues and limited effectiveness in compact applications.
Innovation Solution
The use of hot compression molding of soft polyurethane foam to a volume ratio between 1/1.5 and 1/12, combined with surface treatments like film application or flocking, enhances sound absorption performance even with the same volume, allowing for more effective sound absorption in smaller spaces and enabling decorative designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the volume of sound absorbing body is increased to improve sound absorbing effect, then sound absorbing performance is improved, but space utilization deteriorates
Solution Approach 1:
The patent applies parameter changes by hot compression molding soft polyurethane foam at temperatures of 150-240°C to achieve volume ratios between 1/1.5 and 1/12. This thermal processing fundamentally alters the physical state and density of the foam, creating a compact structure that maintains superior sound absorbing performance while occupying minimal space, directly resolving the contradiction between sound absorbing effect and volume.
Solution Approach 2:
The patent uses composite material approach by combining soft polyurethane foam with surface treatments (film application, flocking, or painting). This creates a multi-functional composite structure where the compressed foam core provides sound absorption while the surface layer enhances both aesthetic appearance and acoustic performance, allowing effective sound absorption in compact forms suitable for interior applications.
2Reliability
If the volume of sound absorbing body is increased to improve sound absorbing effect, then sound absorbing performance is improved, but effective utilization of space deteriorates
Solution Approach 1:
Through hot compression molding at 150-240°C achieving volume ratios of 1/1.5 to 1/12, the patent transforms the foam's physical parameters to create a compact yet acoustically effective material. This enables adaptation to various space-constrained applications such as interior design elements, furniture, and architectural features where both aesthetic versatility and sound absorption are required.
Solution Approach 2:
The compressed polyurethane foam with surface treatments serves multiple functions simultaneously: sound absorption, aesthetic decoration, and space-saving design. The material can be applied in diverse locations including rooms visible to direct eyesight, combining functional and decorative roles that enhance its adaptability across different applications.
3Reliability
If surface treatment is applied to enhance sound absorbing effect and aesthetics, then sound absorbing performance and appearance are improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple manufacturing operations into a single integrated hot compression molding process. The foam is compressed and surface treatments (film application, flocking, or painting) are applied simultaneously during the same heating and pressing operation, eliminating the need for separate post-processing steps and reducing overall manufacturing complexity despite the enhanced functional and aesthetic outcomes.
Solution Approach 2:
The surface treatments are applied preliminarily during the hot compression molding process itself, before the final product is removed from the mold. This preliminary action allows the surface layer to be integrated with the compressed foam structure, simplifying subsequent handling and installation while achieving both enhanced sound absorption and aesthetic appearance.
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
This method provides improved sound absorption in both middle and low frequency ranges, enabling effective sound absorption in compact spaces while allowing for decorative designs, thus overcoming the limitations of conventional sound absorbing materials in terms of space and aesthetic appeal.
Implementation Method 1
hot compression molding of a raw material, made from soft polyurethane foam, to a volume ratio of between 1/1.5 and 1/12
Implementation Method 2
molding temperature is (preferably between 150 and 240° C.
Implementation Method 3
enabling diffusion of the incident sound by the raised and recessed portions of the surface
Implementation Method 4
enabling a further increase the sound absorbing effect in the middle and low range through the film on the surface
Data Source
AI summary
Sound-absorbing material is provided which is more effective for the same volume. A sound-absorbing body is formed characteristically by hot-compression molding of a raw material (C) comprises a flexible polyurethane foam to a volume ratio ranging from 1/1.5 to 1/12. In the molding, metal molds (A·B) are heated in an electric furnace up to a set temperature of 180° C.; the flexible polyurethane foam of the cell number of 50 is held between the metal molds (A·B), and compressed and heated in the electric furnace in this state at 180° C. for 60 minutes; the fixing clamp is removed; and the hot-compressed urethane foam is taken out to obtain the intended sound-absorbing body.