Concavo-Convex Sound Insulation Sheet for Low-Frequency Noise
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Solution Overview
Problem
Conventional sound insulation members face challenges in achieving high sound insulation performance in a low frequency band, particularly when attached to high-density materials like steel plates, and are difficult to mass-produce without molding defects.
Innovation Solution
A sound insulation sheet with a concavo-convex structure on a substrate, where convex portions are linearly arranged, and a sound insulation structure with a sealed space between the sheet and a plate material, using a retention unit to enhance sound insulation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sound insulation sheet is made entirely of resin foam material, then it has good sound insulation performance and ease of processing, but it lacks flame retardancy
Solution Approach 1:
The patent applies composite materials by combining resin foam (for sound insulation) with flame-retardant particles (for flame retardancy). The sound insulation sheet comprises a resin foam body embedded with flame-retardant particles, creating a composite material that simultaneously provides both sound insulation performance and flame retardancy, resolving the contradiction between these two properties.
2Object-affected harmful factors
If flame-retardant particles are simply mixed into the resin foam, then flame retardancy is achieved, but the particles aggregate and reduce sound insulation performance
Solution Approach 1:
The patent uses an intermediary substance (silane-modified polymer or silicone oil) to prevent aggregation of flame-retardant particles. This intermediary acts as a dispersing agent that maintains uniform distribution of particles within the resin foam matrix, ensuring both flame retardancy and sound insulation performance are maintained without particle aggregation.
Solution Approach 2:
The patent changes the surface properties of flame-retardant particles by silane modification. This parameter change (surface treatment) prevents particle aggregation by modifying the surface energy and interaction characteristics, allowing particles to remain uniformly dispersed while maintaining their flame-retardant function and not compromising sound insulation.
3Ease of manufacture
If conventional mixing methods are used to incorporate flame-retardant particles, then processing is simple, but particle aggregation occurs and uniform distribution is poor
Solution Approach 1:
The patent applies preliminary action by pre-modifying the flame-retardant particles with silane before incorporating them into the resin foam. This preliminary surface treatment ensures that particles are prepared in advance with improved dispersibility, allowing them to be uniformly distributed during the foam formation process without requiring complex additional processing steps.
Solution Approach 2:
The patent changes the physical and chemical parameters of the flame-retardant particles through silane modification. This parameter change (surface modification) improves particle dispersibility and prevents aggregation during mixing, achieving uniform distribution while maintaining processing simplicity through the modified particle properties.
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 provides a thin, lightweight sound insulation sheet and structure that effectively insulates against low-frequency sound, even on high-density materials, while avoiding molding defects and enhancing sound insulation strength.
Implementation Method 1
the flame-retardant particles have a specific heat value of 0.83 cal/g·°C or more, and a water vapor generation value of 30 mass% or more based on the total weight of the particles
Implementation Method 2
a water vapor generation value of 30 mass% or more based on the total weight of the particles
Implementation Method 3
a sound insulation sheet for a vehicle
Data Source
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Figure 5~6
AI summary
To provide a sound insulation sheet member which is excellent in sound insulation performance in a low frequency band and which has a compact configuration. A sound insulation sheet member 1 including a substrate 2 and a concavo-convex structure 3 placed on at least one surface of the substrate 2, in which the concavo-convex structure 3 is provided by repeatedly arranging a plurality of units each defined as a concavo-convex unit shape 4 including a linear convex portion 5, in one direction at substantially constant intervals on the surface of the substrate 2.