Molded Vibration Isolation Mat Using Polyurethane and Rubber Granules
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Solution Overview
Problem
Existing vibration isolation solutions for building services and machine foundations face challenges with insufficient elasticity and stiffness under high static forces, as they are not optimized for these specific applications.
Innovation Solution
A molded body composed of a cellular polyurethane elastomer with a density of at least 150 kg/m³ and foamed rubber elastomer grains, which provides a linear increase in rigidity with increasing load, combining the elastic properties of both materials to enhance vibration isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If flexible polyurethane foam flakes are used for vibration isolation, then good damping properties are achieved, but elasticity is insufficient under high static forces
Solution Approach 1:
The patent combines flexible polyurethane foam flakes with rubber granules to create a composite material that exhibits both damping properties and elasticity. The foam flakes provide vibration damping while the rubber granules contribute elasticity, allowing the composite to perform under high static forces typical in building services and machine foundation applications.
Solution Approach 2:
The patent specifies that the flexible polyurethane foam should have a density of at least 150 kg/m³. This parameter change from lower density foams increases the material's load-bearing capacity and elasticity while maintaining its damping properties, making it suitable for applications with high static forces.
2Adaptability or versatility
If rubber granules are added to improve elasticity, then elasticity increases, but the material becomes less suitable for high static force applications
Solution Approach 1:
The patent creates a composite where rubber granules (10-50 wt%) are combined with flexible polyurethane foam flakes. This composite structure allows the rubber to provide elasticity while the foam matrix maintains load-bearing capacity, resolving the contradiction between elasticity and strength under high static forces.
Solution Approach 2:
The patent specifies that the rubber granules should have a grain size of 0.5-5 mm, creating local elastic zones within the foam matrix. This local quality approach allows elasticity where needed (at the granule level) while maintaining overall structural integrity through the continuous foam matrix.
3Strength
If polyurethane composite flexible foam with specific weight of 200 kg/m³ is used, then load-bearing capacity increases, but elasticity decreases
Solution Approach 1:
The patent combines dense polyurethane foam (≥150 kg/m³) with rubber granules to create a composite that maintains the foam's load-bearing capacity while adding the rubber's elasticity. The composite structure allows both properties to coexist, resolving the contradiction between density-related strength and elasticity.
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 effectively addresses the need for improved stiffness and elasticity under high loads, providing effective vibration isolation and structure-borne noise reduction in building services and machine foundations.
Implementation Method 1
a molded body for vibration isolation with a cellular polyurethane elastomer and with a rubber granulate
Implementation Method 2
for vibration isolation, which is primarily used for structure-borne noise isolation and vibration decoupling or storage
Data Source
Figure 1~2
AI summary
The mat comprises a cellular polyurethane elastomer, which has a density of 150 kg/m 3>, and a rubber granulate consisting of grains (80 wt.%) made of foamed rubber elastomer (3). The polyurethane elastomer and the grains of the rubber granulate are arranged in the form of a heterogeneous mixture in the mat. The porosity of the polyurethane elastomer and/or the grains of the rubber elastomer is 10%. The grain size of the 90% of the grains is 5-10 mm. The polyurethane elastomer forms a matrix, in which the grains of granulate are embedded. The mat comprises a cellular polyurethane elastomer, which has a density of 150 kg/m 3>, and a rubber granulate consisting of grains (80 wt.%) made of foamed rubber elastomer (3). The polyurethane elastomer and the grains of the rubber granulate are arranged in the form of a heterogeneous mixture in the mat. The porosity of the polyurethane elastomer and/or the grains of the rubber elastomer is 10%. The grain size of the 90% of the grains is 5-10 mm. The polyurethane elastomer forms a matrix, in which the grains of granulate are embedded. The portion of the matrix is 50-80 wt.% in the mat. The polyurethane elastomer is present in the form of grains of granulate in the mat. The polyurethane elastomer and the grains of the foamed rubber elastomer are bonded with one another by a bonding agent (4), which consists of one-component polyurethane binder e.g. prepolymer isocyanate and/or two-component polyurethane binder. The portion of the grains of the polyurethane elastomer (2) is 15-25 wt.% and/or the portion of the grains of the foamed rubber elastomer is 35-85 wt.% in the mat. The portion of the bonding agent is 5-15 wt.% in the mat. An independent claim is included for a method for producing a mat for vibration insulation.