Flexible Noise Reduction Sheet with Honeycomb Grooves

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Solution Overview

Problem

Existing noise reduction sheets have limited degree of freedom in deformation, making them inflexible when attached to objects.

Innovation Solution

A noise reduction sheet with a flexible sheet containing a soft magnetic material, featuring a honeycomb structure on its surface with grooves extending in three directions, allowing for increased deformation flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a square sintered ferrite plate structure is used, then the noise reduction function is provided, but the degree of freedom in deformation is limited to two orthogonal directions

Engineering Contradiction:

Improvedegree of freedom in deformationVSAvoidstructural complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The ferrite plate is divided into multiple small ferrite granules (0.1-5mm in size) that are dispersed and embedded within a flexible resin matrix. This segmentation allows the noise reduction sheet to deform in multiple directions while maintaining the noise reduction function of the ferrite particles.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention creates a composite material structure where ferrite granules are embedded in a flexible resin. This composite structure combines the noise reduction properties of ferrite with the deformation flexibility of the resin matrix, enabling the sheet to adapt to various shapes and directions.

Inventive Principle:

Principle #40Composite materials

2Reliability

If a protective layer with adhesive and ink is formed on sintered ferrite plates, then small pieces are prevented from falling off, but the deformation flexibility is reduced

Engineering Contradiction:

Improvestability of ferrite particlesVSAvoiddeformation flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

Instead of using rigid protective layers on sintered plates, the invention embeds small ferrite granules within a flexible resin matrix. This flexible encapsulation maintains particle stability while allowing the overall structure to deform freely in multiple directions.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The ferrite granules are distributed throughout the flexible resin matrix, with each granule providing localized noise reduction function while the surrounding flexible resin provides deformation capability. This local distribution maintains both stability and flexibility.

Inventive Principle:

Principle #3Local quality

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 sheet's enhanced deformation flexibility allows it to effectively follow the shape of objects and reduce noise emission, while also being cost-effective and lightweight.

Implementation Method 1

a flexible sheet containing a soft magnetic material

Methodology Applied

Scientific EffectMagnetic hysteresis: Magnetic Hysteresis

Implementation Method 2

soft magnetic material

Methodology Applied

Scientific EffectEddy current damping: Eddy Current Damping

Data Source

PatentUS20250069779A1Noise reduction sheet and wire harness

Publication Date: 2025.02.27 YAZAKI CORP

AI summary

A noise reduction sheet includes a flexible sheet containing a soft magnetic material, in which a plurality of first grooves extending in a first direction, a plurality of second grooves extending in a second direction, and a plurality of third grooves extending in a third direction are provided on a first surface of the sheet, the first surface is divided into a plurality of regular triangular regions by the first grooves, the second grooves, and the third grooves, and each of the first grooves, the second grooves, and the third grooves has a cross-sectional shape in which a groove width increases toward an opening along a depth direction of the groove.