Honeycomb Thermoplastic Sound Damping Panel
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Solution Overview
Problem
Current building panels, such as chain linked fencing and mass loaded vinyl, fail to effectively absorb sound and blend into environments, while also being unable to be recycled or easily adapted for graphic printing.
Innovation Solution
A panel assembly comprising a core with a hexagonal honeycomb configuration sandwiched between two thermoplastic sheets, which can be thermowelded to form a sound-damping panel board with a printable surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If chain linked fencing is used, then the structure is simple and inexpensive, but it does not absorb sound and cannot be recycled
Solution Approach 1:
The patent uses a composite structure combining a hollow core (insulating material) between two sheet panels to create sound absorption properties while maintaining structural integrity. This composite approach allows the panel to absorb sound waves through the hollow core while remaining manufacturable and recyclable.
Solution Approach 2:
The hollow core structure creates a porous-like configuration that allows sound waves to enter and be absorbed within the core, converting acoustic energy into thermal energy through friction of the air molecules against the core walls, thereby achieving sound absorption without complex materials.
2Object-affected harmful factors
If mass loaded vinyl is used, then sound absorption is improved, but the material cannot be recycled and is difficult to manufacture
Solution Approach 1:
The panel is segmented into distinct components: two sheet panels and a removable hollow core. This segmentation allows each component to be manufactured separately using standard processes and then assembled, improving manufacturability while maintaining sound absorption properties. The removable core also enhances recyclability.
Solution Approach 2:
The hollow core is designed to be removable and potentially replaceable, allowing the sheet panels to be recovered and reused. This design approach facilitates recycling by separating the core material from the panels, enabling the panels to be reused while the core can be disposed of or recycled independently.
3Object-affected harmful factors
If open cell foam panels are used, then sound absorption is achieved, but they absorb moisture and cannot be recycled
Solution Approach 1:
The hollow core provides a closed-cell-like porous structure that absorbs sound waves while preventing moisture absorption. The hollow configuration allows sound energy to be trapped and dissipated without providing capillary pathways for moisture, solving the dual problem of sound absorption and moisture resistance.
4Object-affected harmful factors
If panels are designed for sound absorption, then noise reduction is improved, but they cannot be graphic printed to blend into environments
Solution Approach 1:
The outer sheet panels provide a smooth, solid surface suitable for graphic printing, while the inner hollow core provides sound absorption. This local differentiation allows different parts of the panel to serve different functions: the exterior surfaces can be printed for environmental blending or advertising, while the interior core handles acoustic performance.
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 panel assembly achieves significant sound wave absorption, reducing reverberation and noise, while also allowing for graphic printing and potential recycling, thus addressing the limitations of existing panels.
Implementation Method 1
thermowelding a core portion between a first sheet and a second sheet to form a thermoplastic panel board
Implementation Method 2
The first panel portion can include at least one aperture configured to allow a sound waves from an exterior environment to into the one or more interior chambers through the one or more apertures of the panel assembly to dissipate the sound waves
Data Source
AI summary
A panel assembly having a core portion positioned or formed in between a first panel portion and a second panel portion. One or more chambers can be formed between the first panel portion and the second panel portion by one or more sidewalls of the core portion. One or both panel portions can include one or more apertures that can correspond to a respective interior chamber formed between the first panel portion and the second panel portion. The core portion, first panel portion, and second panel portion can be comprised of the same material. The core portion can take any suitable configuration, including but not limited to a hexagonal honeycomb configuration.