Moulded Soundproofing Component with Simultaneous Layer Formation
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Solution Overview
Problem
Existing soundproofing components with an airtight intermediate layer are costly to produce due to the need for multiple manufacturing steps, and they often compromise on acoustic properties.
Innovation Solution
Producing the air-impermeable intermediate layer and one porous soundproofing layer simultaneously in a single injection step, where the injected polymer composition penetrates into the porous structure of the first layer, forming a densified intermediate layer, thereby reducing production costs and maintaining soundproofing effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an airtight intermediate layer is added between two porous layers to improve soundproofing, then acoustic performance is improved, but manufacturing cost and process complexity increase due to multiple separate operations
Solution Approach 1:
The patent combines the formation of the airtight intermediate layer and the second porous layer into a single injection molding operation. The injection mold simultaneously forms both layers from a single molded piece, eliminating the need for separate operations to lay out and attach the intermediate layer. This merging of operations reduces manufacturing complexity while maintaining the three-layer structure with improved soundproofing performance.
Solution Approach 2:
The injection molding process serves multiple functions: it forms the second porous layer with soundproofing properties, creates the airtight intermediate layer, and bonds both layers together in a single operation. This multi-functional approach replaces multiple specialized operations (laying out intermediate layer, injecting foam, bonding layers) with a single universal molding process.
2Strength
If traditional multi-step manufacturing is used to produce soundproofing components with airtight intermediate layers, then structural integrity is maintained, but production cost increases
Solution Approach 1:
The patent merges multiple manufacturing steps (forming intermediate layer, forming second porous layer, bonding layers) into a single injection molding operation that produces all components as one integrated piece. This eliminates the need for separate bonding operations and reduces the number of manufacturing steps, thereby lowering production costs while maintaining structural integrity through the monolithic construction.
Solution Approach 2:
The injection molding process automatically creates the airtight intermediate layer and bonds it to the first porous layer during the same operation that forms the second porous layer. The process self-services by integrating multiple functions (layer formation, bonding, and sealing) into one automated molding cycle, eliminating the need for additional manual or mechanical bonding steps.
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 method significantly reduces production costs and enhances sound insulation and absorption capabilities compared to traditional multi-step processes, achieving superior acoustic performance with a broad range of material applications.
Implementation Method 1
part of the fluid composition injected penetrates into the porous structure of the first layer to a certain depth
Implementation Method 2
a first porous layer has open porosity... for the formation of the second porous layer with open cells
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
This method comprises the placing of the first porous layer (1) onto one part of a wall of a mould cavity having the shape desired by the soundproofing component, the first layer (1) not occupying the entire cavity, and the injection of a foaming polymer composition into the cavity of the mould to form the second open-cell porous layer (3). The two steps of placing the practically airtight intermediate layer (2) onto the first porous layer (1) and of injecting a polymer composition in order to form the second porous layer (3) are carried out simultaneously in a single step of injecting the foaming polymer composition.