Incombustible Sound Absorption Panel Using Foam Chips
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Solution Overview
Problem
Existing sound absorption panels fail to achieve incombustibility while maintaining heat-insulating and sound absorption/insulation functions, particularly when using combustible materials, and often rely on combustible adhesives that increase costs and pose fire safety risks.
Innovation Solution
The solution involves limiting airflow paths using chips from foam material cutting, diluting combustible gases with inert gases, and using materials that undergo endothermic reactions to inhibit combustion, along with a sintered adhesive to retain panel shape and reduce combustible organic matter content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a combustible foam material is used for sound absorption, then sound absorption properties are improved, but incombustibility deteriorates
Solution Approach 1:
The patent uses a composite structure combining incombustible honeycomb material (magnesium silicate or aluminum hydroxide) with foam material filling. The inorganic honeycomb material provides fire resistance while the foam filling maintains sound absorption properties, creating a composite panel that achieves both requirements simultaneously.
Solution Approach 2:
The patent utilizes the chemical properties of magnesium silicate and aluminum hydroxide which release water vapor when heated, creating an inert atmosphere that suppresses combustion. This endothermic reaction absorbs heat and releases non-combustible gases, effectively protecting the combustible foam material from burning.
2Strength
If adhesive is used to fix honeycomb material and surface materials, then structural integrity is improved, but incombustibility deteriorates due to combustible adhesive
Solution Approach 1:
The patent accepts that adhesive will combust but designs the system so that the adhesive layer is thin and its combustion does not propagate to the main structure. The incombustible honeycomb material and surface materials act as barriers that contain the adhesive fire, allowing the use of conventional adhesive without compromising overall fire safety.
3Reliability
If honeycomb material is sandwiched between incombustible materials without air permeability, then incombustibility is improved, but sound absorption properties deteriorate
Solution Approach 1:
The patent fills the honeycomb cells with foam material that has controlled porosity. This foam filling provides sound absorption through acoustic energy dissipation in the porous structure while the outer incombustible honeycomb material and surface materials maintain fire resistance. The porous foam interior allows sound absorption without compromising the incombustible exterior barrier.
4Reliability
If plaster board is used as incombustible sound insulation material, then incombustibility is improved, but weight and brittleness increase causing ceiling falling risk
Solution Approach 1:
The patent creates a lightweight composite panel using thin incombustible honeycomb material (magnesium silicate or aluminum hydroxide) combined with foam filling and surface materials. This composite structure achieves fire resistance comparable to plaster board but with significantly reduced weight and improved flexibility, eliminating the ceiling falling risk associated with heavy brittle 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 resulting incombustible sound absorption panel meets Building Standards Act criteria by limiting heat release, preventing through cracks, and ensuring mouse survival times exceed 6.8 minutes in gas toxicity tests, demonstrating effective fire protection and safety.
Implementation Method 1
limiting airflow paths using chips from foam material cutting
Implementation Method 2
diluting combustible gases with inert gases
Implementation Method 3
using materials that undergo endothermic reactions to inhibit combustion
Implementation Method 4
using a sintered adhesive to retain panel shape
Data Source
AI summary
[Problem to be Solved ] To attain an incombustible sound absorption panel by providing incombustibility to a sound absorption/insulation sandwich panel containing a combustible material as a constituting material.[Solution to Problem] Fine powder of chips generated during cutting of a foam material to fill in a honeycomb material is located in a gap between the foam material and a sound absorption surface material. A gap between fibers of the sound absorption surface material is blocked by the chips having been moved by a flow such as a water vapor flow generated from hydrate of the honeycomb material heated on the occurrence of a fire. As a result, an air flow path is limited. Further, carbon dioxide gas generated from the foam material is trapped to reduce an oxygen amount, thereby inhibiting combustion. Usage of an adhesive as a combustible material is reduced.