Expandable Dishwasher Insulation Element for Gap-Borne Noise Control
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Solution Overview
Problem
Existing noise suppression methods for dishwashers, such as using mass dampener materials like mastic, result in acoustic variations between units, fail to effectively reduce pump motor noise and can become less effective over time, while also affecting energy efficiency.
Innovation Solution
An insulation element made from an expandable material that swells to bridge gaps between the dishwasher tub and cabinet, providing a specific spring rate to suppress noise and improve energy efficiency, potentially reducing or eliminating the need for mass dampener materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If mass dampener materials like mastic are applied to the tub, then wash noise in the 35-60 Hz range is reduced, but acoustic variation between units increases and pump motor noise at 125-400 Hz is not effectively suppressed
Solution Approach 1:
The patent changes the physical state of the insulation material from a fixed mass dampener (mastic) to an expandable foam that transitions from compressed state to expanded state. This parameter change allows the material to adapt to different gap sizes and tub configurations, reducing acoustic variation between units while maintaining noise suppression effectiveness across different frequency ranges.
Solution Approach 2:
The patent applies different materials with different properties to different locations: expandable foam insulation is applied to the tub exterior for broad-spectrum noise suppression, while mass dampener materials are selectively applied only to specific areas where structural noise transmission occurs. This local differentiation optimizes both acoustic consistency and manufacturing precision.
2Object-affected harmful factors
If mass dampener materials are applied to the tub, then wash noise is suppressed, but the tub begins to ring at motor frequency accentuating pump motor noise
Solution Approach 1:
The patent uses expandable foam insulation that changes density and stiffness as it expands, creating a gradient structure that dampens low-frequency wash noise while maintaining flexibility to avoid resonating at higher motor frequencies. The material's expanding nature allows it to conform to the tub shape without creating rigid coupling that would cause ringing.
Solution Approach 2:
The patent employs composite insulation structures combining expandable foam with other materials having different acoustic properties. This composite approach allows the system to suppress wash noise through the foam's cellular structure while the additional materials provide damping characteristics that prevent motor frequency resonance.
3Object-affected harmful factors
If mass dampener materials like mastic are used, then noise suppression is achieved, but the materials harden over time reducing effectiveness
Solution Approach 1:
The patent uses expandable foam insulation that undergoes a one-time expansion process to achieve its final density and acoustic properties. Unlike mass dampeners that harden and become brittle over time, the expanded foam maintains its cellular structure and damping characteristics throughout the appliance's lifetime, ensuring consistent noise suppression performance.
Solution Approach 2:
The patent replaces permanent mass dampener materials that degrade over time with expandable foam that is designed to maintain its properties throughout the appliance's service life. The foam's structure is inherently resistant to the hardening and cracking that plagues traditional mastic materials, providing reliable long-term noise control.
4Object-affected harmful factors
If mass dampener materials are applied to the tub, then noise suppression is achieved, but energy efficiency decreases
Solution Approach 1:
The patent uses expandable foam insulation that provides both acoustic damping and thermal insulation properties. The foam's cellular structure traps air pockets that resist heat transfer, reducing the energy required for heating and cooling the appliance interior while simultaneously suppressing noise transmission to the cabinet.
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 effectively reduces noise across all units with reduced acoustic variation, enhances energy efficiency by up to 28%, and maintains performance over time without the drawbacks of traditional mass dampener materials.
Implementation Method 1
Upon heating, that body swells to a thickness T2 where T2 is equal to or greater than G so that the insulation element bridges the gap, engages the two objects
Implementation Method 2
provides a spring rate of about 4.0 to about 275.0 grams per square inch
Data Source
AI summary
An insulation element is provided for installation in a gap of thickness G provided between two objects. The insulation element includes a body made from a thermoplastic polymer material. The body has a first face, a second face and a thickness defined between the first and second faces. The body is characterized by a semi permanently pre-installation thickness T1 where T1 is less than G. The body swells upon heating to a thickness T2 where T2 is greater than or equal to G so that the insulation element bridges the gap, engages the two objects and provides a spring rate of between 4.0 and 275.0 grams per square inch.