Perforated Backing for Broadband Sound Absorption

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Solution Overview

Problem

Conventional tufted articles, such as carpets, fail to provide sufficient sound absorption across the audible spectrum, particularly at frequencies around 1 kHz and 2 kHz, forcing acoustic designers to choose between tile options that absorb little sound or carpet options that offer higher absorption but only across an insufficient frequency range.

Innovation Solution

A sound-absorbing article with a backing that features perforations extending through its thickness, arranged in specific patterns to enhance acoustic properties, where sequential perforations are spaced between 5 mm and 100 mm center-to-center, improving sound absorption coefficients across various frequencies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional tufted carpet is used, then higher sound absorption is achieved, but the frequency spectrum coverage is insufficient

Engineering Contradiction:

Improvesound absorptionVSAvoidfrequency spectrum coverage

Core Design Contradiction:

Loss of energyVSAdaptability or versatility

Solution Approach 1:

The backing is divided into multiple zones with different perforation patterns, where each zone is optimized for specific frequency ranges. This creates local variations in acoustic properties that collectively provide broad-spectrum sound absorption while maintaining high absorption at particular frequencies.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The sound-absorbing article combines a tufted carpet layer with a perforated backing layer, creating a composite structure that integrates the sound absorption benefits of both components. The perforated backing acts as a resonant structure that complements the fibrous absorption of the carpet.

Inventive Principle:

Principle #40Composite materials

2Adaptability or versatility

If tile flooring is used, then broader frequency absorption is achieved, but overall sound absorption capability is low

Engineering Contradiction:

Improvefrequency spectrum coverageVSAvoidsound absorption

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The backing incorporates a porous structure with controlled perforations that allow sound waves to penetrate and be absorbed. The porous geometry creates resonant cavities that enhance absorption across different frequencies while maintaining the structural integrity needed for flooring applications.

Inventive Principle:

Principle #31Porous materials

3Loss of energy

If perforations are added to the backing, then sound absorption across frequencies is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvesound absorptionVSAvoidbacking structure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The backing structure is segmented into standardized zones with repeating perforation patterns. This modular approach simplifies manufacturing by allowing the use of standardized tools and processes for creating the perforations, while still achieving complex acoustic performance through the arrangement of these segments.

Inventive Principle:

Principle #1Segmentation

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 described solution significantly enhances sound absorption capabilities, providing balanced spectral absorption and allowing for the creation of surface coverings that effectively manage sound across a broader frequency range, addressing the limitations of conventional tufted articles.

Implementation Method 1

sound-absorbing article comprising a backing having a thickness and a plurality of face fibers associated with the backing, wherein the backing defines a plurality of perforations that fully extend through the thickness of the backing and are provided in a pattern to determine an acoustic property of the sound-absorbing article

Methodology Applied

Scientific EffectAcoustic absorption: Acoustic Absorption

Data Source

PatentUS12187018B2Sound-absorbing article with perforations in backing, surface coverings comprising same, and systems and methods of making and using same

Publication Date: 2025.01.07 COLUMBIA INSURANCE CO

AI summary

A sound-absorbing article (e.g., a tufted sound-absorbing article) can comprise a backing having a thickness and a plurality of face fibers associated with the backing. Optionally, the face fibers can comprise a plurality of tufts extending through the backing. The backing can define a plurality of perforations that fully extend through the thickness of the backing and are provided in a pattern to determine an acoustic property of the sound-absorbing article. Within at least a portion of the backing, sequential perforations within the pattern of the plurality of perforations can be spaced center-to-center by between 5 mm and 100 mm.