Multi-layer brick with acoustically decoupled shells
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Solution Overview
Problem
Existing multi-layer bricks for double-shell masonry struggle to achieve both improved sound insulation and thermal insulation without compromising one for the other, as increasing hole proportion for sound insulation reduces thermal insulation, and vice versa.
Innovation Solution
A monolithic multi-layer brick design featuring a rigid supporting shell and a lighter sound-insulating facing shell, acoustically decoupled by soft, resilient connecting means such as PUR foam or form-fitting connecting elements, maintains thermal insulation while enhancing sound insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the proportion of holes in the brick is increased to improve sound insulation, then sound insulation properties are improved, but thermal insulation properties deteriorate
Solution Approach 1:
The brick is divided into multiple functional layers: a facing shell with high hole proportion for sound insulation, a core shell with optimized hole structure for thermal insulation, and connecting elements for structural integrity. This segmentation allows each layer to specialize in its primary function without compromising the others.
Solution Approach 2:
Different regions of the brick are assigned different hole proportions and structures tailored to their specific functions. The facing shell has a higher proportion of holes optimized for sound absorption, while the core shell maintains a balanced hole structure that preserves both thermal and structural properties.
2Temperature
If the raw weight of the brick is reduced to improve thermal insulation, then thermal insulation is improved, but sound insulation properties deteriorate
Solution Approach 1:
The brick weight is optimized by segmenting the mass distribution: the facing shell uses lighter materials with higher porosity for sound insulation, while the core shell maintains sufficient density for thermal performance, achieving overall weight reduction without sacrificing either function.
Solution Approach 2:
The brick employs composite material construction combining different ceramic compositions and pore structures in each shell, allowing lightweight sound-absorbing materials in the facing shell while maintaining thermal insulation through the core shell's optimized composition.
3Object-affected harmful factors
If the brick design uses a monolithic multi-layer structure with acoustically decoupled shells, then sound insulation is significantly improved, but manufacturing complexity increases
Solution Approach 1:
The monolithic brick is manufactured by segmenting the forming process into sequential steps: first forming the facing shell with its high-hole structure, then adding the core shell with optimized thermal properties, and finally integrating connecting elements. This segmented manufacturing approach simplifies production while achieving the complex multi-layer acoustic decoupling.
Solution Approach 2:
Multiple functional components (facing shell, core shell, connecting elements) are merged into a single monolithic structure through integrated forming processes, eliminating the need for separate assembly steps and reducing manufacturing complexity despite the sophisticated multi-layer design.
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 design achieves significant sound insulation improvements (up to 63 dB) without affecting thermal insulation properties, with the supporting shell having a higher surface mass and the facing shell optimized for sound absorption, allowing for flexible decoupling between the two shells.
Implementation Method 1
both of which are acoustically decoupled from one another via the soft-spring connecting means
Implementation Method 2
soft, resilient connecting means, preferably soft-elastic PUR foam with a dynamic modulus of elasticity between 0.1 and 6 N/mm 2
Implementation Method 3
heat-insulating supporting shell
Implementation Method 4
sound-insulating facing shell
Data Source
Figure 1~3
Figure 4
Figure 5~8
AI summary
The bricks has a brick main portion (10) that is provided with a tray (12) that is provided with a facing layer (14). The hollow brick elements (16,18) are connected through connecting unit, and are acoustically isolated from one another. The weight of the facing layer of the hollow brick element is lower than the tray of another hollow brick element, and modulus elasticity of the connecting unit is less than 20 N/mm2. An independent claim is included for method for manufacturing multilayer bricks.