Corrugated Cardboard Ceiling Panels for Acoustic Absorption
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Solution Overview
Problem
Current acoustical ceiling panels face challenges in achieving high Noise Reduction Coefficient (NRC) values, resisting sagging, being lightweight, and economically produced with high post-consumer recycle content while maintaining good acoustical performance at target frequencies.
Innovation Solution
A ceiling panel constructed with a core made of corrugated fiberboard, where the corrugated layers are laminated perpendicular to each other, covered with an acoustically transparent face sheet and optionally a backing sheet for improved air flow resistance, allowing for efficient sound absorption and sag resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional materials and surface treatments are used to achieve high NRC values, then acoustical performance is improved, but cost increases and recycle content decreases
Solution Approach 1:
The invention changes the fundamental parameter of the ceiling panel material from conventional dense materials to corrugated cardboard with air spaces. This parameter change achieves high NRC values through the air spaces and corrugated structure while using low-cost, highly recyclable materials, directly resolving the contradiction between acoustical performance and production cost
Solution Approach 2:
The invention uses composite construction combining corrugated cardboard layers with acoustically transparent fabric and optional acoustical foam or mineral wool. This composite approach achieves superior acoustical performance through the combination of materials while maintaining low cost and high recyclability, resolving the contradiction between performance and cost
2Reliability
If dense materials are used to achieve high NRC values, then acoustical absorption is improved, but weight increases
Solution Approach 1:
The invention uses porous corrugated cardboard with air spaces as the core material, which provides high acoustical absorption through the porous structure and air cavities. This achieves good NRC values while maintaining lightweight properties, directly resolving the contradiction between acoustical absorption and weight
Solution Approach 2:
The invention changes the material density parameter from conventional dense ceiling tiles to lightweight corrugated cardboard with air spaces, achieving the desired acoustical absorption through the porous structure rather than material density, thus resolving the contradiction between absorption performance and weight
3Ease of manufacture
If horizontal orientation of corrugated layers is used, then production is simplified, but panel sags over time
Solution Approach 1:
The invention changes the orientation of the corrugated layers from horizontal to vertical, standing the flutes on end rather than lying flat. This dimensional change in orientation provides structural rigidity to prevent sagging while maintaining the acoustic benefits, resolving the contradiction between production simplicity and panel stability
4Stability of the object's composition
If uniform flute size and alignment are required, then structural consistency is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The invention achieves structural consistency through the repetitive corrugated pattern and lamination process, where the uniform structure is created by the manufacturing process itself rather than requiring uniformity in the source cardboard material. This allows use of reclaimed materials with varying flute characteristics while maintaining consistent panel performance, resolving the contradiction between structural consistency and manufacturing complexity
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 high acoustical absorption with an NRC of approximately 0.70, is lightweight due to its air-space design, and can be produced using reclaimed materials, making it economically viable and sag-resistant for large grid modules.
Implementation Method 1
The ability of a panel to absorb sound is conventionally reported as its Noise Reduction Coefficient or NRC... the inventive panel has high acoustical absorption properties... achieves high acoustical absorption with an NRC of approximately 0.70
Data Source
Figure 1~2
Figure 3
AI summary
An acoustical ceiling panel comprising a flat core and an acoustically transparent face sheet adhesively attached to one of two oppositely facing major sides of the core, the core comprising a multitude of layers of corrugated fiberboard laminated together, the corrugated fiberboard layers each having a corrugated medium adhesively attached to a flat liner board, the corrugated medium forming regularly spaced flutes of curvilinear cross-section, the flutes of the layers of fiberboard being arranged in parallel directions extending perpendicularly to the major faces of the core.