Granulate-Filled Soundproofing Device to Reduce Assembly Costs
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Solution Overview
Problem
Existing soundproofing devices with multiple flexible layers are costly to assemble and produce, prone to manufacturing errors, and difficult to recycle, while also requiring complex material management for effective sound insulation.
Innovation Solution
A soundproofing device comprising two limp layers connected by elements that maintain a predetermined distance, with the space between filled with pourable granulate, ensuring even distribution and preventing sedimentation, and featuring a closed textile surface to prevent granule penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If multiple layers of different materials are used to achieve high soundproofing, then sound insulation performance is improved, but assembly and production costs increase
Solution Approach 1:
The patent combines multiple sound-absorbing layers into a single composite material layer, eliminating the need to assemble multiple separate layers. This merging approach maintains the sound absorption functionality while significantly reducing assembly complexity and production costs.
Solution Approach 2:
The patent uses a composite material consisting of a base fabric and attached sound-absorbing particles (such as rubber granules or plastic granules). This composite structure provides effective sound absorption in a single layer, replacing the need for multiple separate material layers.
2Object-affected harmful factors
If multiple layers of different materials are used to achieve high soundproofing, then sound insulation performance is improved, but production errors increase
Solution Approach 1:
By merging multiple functional layers into a single composite material, the patent eliminates the cumulative errors that occur during multiple assembly steps. The single-layer composite structure ensures consistent sound absorption performance without the variability introduced by assembling multiple separate components.
3Object-affected harmful factors
If multiple layers of different materials are used to achieve high soundproofing, then sound insulation performance is improved, but recycling difficulty increases
Solution Approach 1:
The sound-absorbing particles are attached to the base fabric in a way that allows them to be easily separated and removed. This extraction capability enables the base fabric to be reused and the particles to be recycled, significantly improving the recyclability of the soundproofing material.
Solution Approach 2:
The patent design allows for the recovery and reuse of both the base fabric and the sound-absorbing particles. The particles can be detached and reused in new composite materials, while the fabric can be recycled, thereby reducing waste and improving sustainability.
4Ease of manufacture
If a single layer with sound-absorbing particles is used, then production costs are reduced, but granulate distribution uniformity may be compromised
Solution Approach 1:
The sound-absorbing particles are attached to the fabric in a controlled manufacturing process that ensures uniform distribution before the material is put into service. This preliminary action of proper attachment prevents clustering or uneven distribution, maintaining consistent sound absorption performance across the entire material surface.
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
This configuration achieves high sound insulation with reduced production costs, minimized errors, and facilitates recycling, while maintaining flexibility and acoustic effectiveness through the use of granulate distribution and specific material properties.
Implementation Method 1
The effect of soundproofing devices with several flexible layers is based to a large extent on sound absorption
Implementation Method 2
friction processes and friction losses at the interfaces between the granules increase the sound insulation
Implementation Method 3
The connecting elements prevent the pourable granules from following the force of weight, sagging downwards and collecting at the lowest point
Data Source
Figure 1
AI summary
A soundproofing device is proposed comprising a flexible first layer (2), a flexible second layer (3), and connecting elements (4) which connect the first layer (2) and the second layer (3) and hold the first layer (2) at a predetermined distance to the second layer (3), wherein the space between the first and second layers (2, 3) is at least partially filled with a pourable granulate.