EPDM Rubber Granule Sound Insulation Layer

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Solution Overview

Problem

Existing sound insulation products in the building industry face challenges such as air pocket formation, low elasticity, and poor stability due to their materials, leading to inefficient sound insulation, especially when applied over irregular surfaces or around obstacles like pipes.

Innovation Solution

A multi-layer sound insulation product using a layer of EPDM or EPDM/SBR rubber granules with synthetic latex as a binder, combined with a non-woven fabric support and an additional acrylic-based binder for enhanced gripping and rigidity, allowing for improved sound insulation and mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If polyethylene insulating layers are used, then lightness and deformability under pressure are achieved, but air pockets form easily during laying, resulting in less efficient sound insulation

Engineering Contradiction:

Improvedeformability under pressureVSAvoidsound insulation efficiency

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent changes the material parameters by using rubber granules (EPDM and/or SBR) with specific elasticity and density characteristics instead of polyethylene. This allows the material to deform under pressure without forming permanent air pockets, while maintaining continuous contact with the substrate for reliable sound insulation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite structure by combining rubber granules with binding materials to form a cohesive insulating layer. This composite approach allows the material to兼具 deformability and structural integrity, preventing air pocket formation while maintaining sound insulation efficiency.

Inventive Principle:

Principle #40Composite materials

2Reliability

If cork insulating layers are used, then sound insulation properties are improved, but layer elasticity decreases, facilitating breakage during laying

Engineering Contradiction:

Improvesound insulation propertiesVSAvoidlayer elasticity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent changes the material composition from cork to rubber granules (EPDM and/or SBR), which have superior elasticity properties. This parameter change maintains high sound insulation performance while providing the necessary flexibility and resistance to breakage during installation.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If fibrous material such as glass wool is used, then sound insulation can be achieved, but compression strength and stability with time are poor

Engineering Contradiction:

Improvesound insulationVSAvoidcompression strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The invention uses a composite system of rubber granules bound together with binding materials, creating a structurally sound insulating layer. This composite structure provides both effective sound insulation and adequate compression strength and long-term stability.

Inventive Principle:

Principle #40Composite materials

4Quantity of substance

If compacted recycled rubber is used, then material availability is improved, but density increases, resulting in laying difficulty and lower sound insulation performance

Engineering Contradiction:

Improvematerial availabilityVSAvoidsound insulation performance

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The patent specifies using rubber granules with controlled density and size distribution (EPDM and/or SBR) rather than compacted recycled rubber. This parameter control ensures optimal sound insulation performance while maintaining ease of laying, even when using recycled materials.

Inventive Principle:

Principle #35Parameter changes

5Ease of operation

If non-woven fabric support layer is used, then flexibility and handleability are improved, but surface roughness and porosity increase, requiring better gripping mechanisms

Engineering Contradiction:

Improveflexibility and handleabilityVSAvoidgripping between layers

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The patent uses binding materials with specific adhesive properties that are optimized for bonding to the rough, porous surface of non-woven fabric. This ensures adequate gripping strength between layers while maintaining the flexibility and handleability benefits of the non-woven support structure.

Inventive Principle:

Principle #35Parameter changes

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 product significantly enhances sound insulation and mechanical performance, offering better elasticity, resistance to tearing, and improved electrical insulation, with increased durability and ease of handling and installation.

Implementation Method 1

a layer of EPDM or EPDM/SBR rubber granules with synthetic latex as a binder

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

a layer of EPDM or EPDM/SBR rubber granules

Methodology Applied

Scientific EffectViscoelastic damping: Viscoelasticity

Implementation Method 3

a non-woven fabric support

Methodology Applied

Scientific EffectPorosity: Porosity

Data Source

PatentEP1871959B1Multi-layer sound insulation product for the building industry, method for its production and plant for implementing the method

Publication Date: 2011.06.29 ISOLGOMMA

Figure 1~2

AI summary

A multi-layer sound insulation product for the building industry, characterised by comprising a layer of granules (1) at least partly of EPDM rubber, a support layer (3) and at least one binder (2) which glues the rubber granules together and to the support.