Foam Sound-Absorbing Material With Open-Pore Particle Fixing

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Solution Overview

Problem

The size limitation of the back cavity in small audio devices compromises sound quality at low frequencies, and existing sound-absorbing materials occlude pores of sound-absorbing particles, compromising the performance of electronic devices.

Innovation Solution

A sound-absorbing material is developed with sound-absorbing particles fixed directly to the surfaces of foam cell walls using minimal or no binder or adhesive, utilizing a solvent carrier to disperse the particles and swell the cell walls for improved adhesion, maintaining an open architecture and enhancing low-frequency performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of stationary object

If sound-absorbing particles are fixed to cavity surfaces using binders and/or adhesives, then the apparent volume of the cavity is effectively increased and low frequency performance is improved, but the pores of the sound-absorbing particles are occluded and the performance of the electronic device is compromised

Engineering Contradiction:

Improveapparent volume of cavityVSAvoidperformance of electronic device

Core Design Contradiction:

Volume of stationary objectVSReliability

Solution Approach 1:

The patent removes the binder/adhesive layer from the sound-absorbing material structure, extracting the harmful element that causes pore occlusion while retaining the essential function of volume enhancement through the foam framework itself

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs a foam-based sound-absorbing material with inherently porous structure that does not require additional binders or adhesives, maintaining open pores for sound absorption while providing the necessary structural framework for volume enhancement

Inventive Principle:

Principle #31Porous materials

2Volume of moving object

If the size of the back cavity is limited in small audio devices, then the device becomes more portable and compact, but the sound quality at low frequencies is compromised

Engineering Contradiction:

Improvesize of back cavityVSAvoidsound quality at low frequencies

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent changes the physical parameters of the sound-absorbing material by using a foam structure with controlled cell size and porosity, enabling effective low-frequency sound absorption in a compact cavity volume without requiring increased physical size

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite sound-absorbing material combining foam framework with sound-absorbing particles, achieving enhanced low-frequency performance in a compact configuration through the synergistic properties of the composite structure

Inventive Principle:

Principle #40Composite materials

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 increases the effective volume of the cavity, lowers the resonant frequency, and preserves porosity, thereby improving the low-frequency sound quality in small electronic devices without compromising their performance.

Implementation Method 1

utilizing a solvent carrier to disperse the particles and swell the cell walls for improved adhesion

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 2

maintaining an open architecture and enhancing low-frequency performance

Methodology Applied

Scientific EffectPorosity: Porosity

Data Source

PatentUS20250358566A1Sound-absorbing material

Publication Date: 2025.11.20 ROGERS CORP

AI summary

A sound-absorbing material including a foam; and sound-absorbing particles fixed directly to surfaces of cells walls in the foam.