Perforated Polymer Foam Panels for Flexible Acoustic Assembly
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Solution Overview
Problem
Existing sound absorbing panels are unnecessarily complex in construction, limiting their ease of assembly and increasing manufacturing costs, and lack flexibility in shape and on-site installation.
Innovation Solution
A sound absorbing panel assembly comprising two sheets made of polymer foam material with backside-to-front side perforations and frame structures, allowing for a simple and cost-effective construction that can be assembled on-site in various shapes, using shredded polymer foam for the frames and sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If prior art acoustic absorbers use parallel absorption layers connected by integral edges or insulating material, then sound absorption function is achieved, but construction complexity increases and assembly simplicity deteriorates
Solution Approach 1:
The acoustic absorber is divided into independent modular units, each comprising a single sheet with frame structures at its edges. These modular units can be independently manufactured and then assembled together to form the complete acoustic absorption system, eliminating the need for complex integral connections between layers.
Solution Approach 2:
The frame structures are extracted as separate components that attach to the edges of the sheets rather than being integrally formed with the absorption material. This separation allows for simpler manufacturing of individual components and more flexible assembly of the complete structure.
2Reliability
If prior art acoustic absorbers use complex construction with multiple layers and connections, then sound absorption coverage is improved, but manufacturing cost increases
Solution Approach 1:
By segmenting the acoustic absorber into simple modular units with sheets and separate frame structures, the manufacturing process is simplified. Each module can be produced using straightforward techniques, and the overall sound absorption coverage is achieved through the assembly of multiple such simple units rather than through complex integrated structures.
3Reliability
If acoustic absorbers are manufactured with fixed complex structures, then acoustic performance is optimized, but adaptability to different shapes and on-site assembly flexibility deteriorates
Solution Approach 1:
The acoustic absorber is segmented into modular units that can be independently manufactured in standard configurations and then assembled on-site to create custom shapes and sizes. This modularity provides flexibility for adapting to different architectural requirements while maintaining effective acoustic performance through proper arrangement of the modular units.
Solution Approach 2:
The design allows for dynamic adaptation to different configurations through simple assembly and disassembly of modular units. The frame structures enable easy connection and reconfiguration of the acoustic absorber modules to suit various shapes and installation locations without requiring complex custom manufacturing for each application.
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 provides cost-effective, flexible, and easy-to-assemble sound absorbing panels with improved sound absorption properties across a wide frequency range, reducing waste and manufacturing costs while adhering to building standards.
Implementation Method 1
Each sheet comprises a polymer foam material and each sheet is provided with a plurality of backside-to-front side through-going perforations
Implementation Method 2
sound absorbing panel assembly that comprises a first sheet, a second sheet, a first frame structure and a second frame structure
Implementation Method 3
an air gap is present between the sheets
Data Source
Figure 1a
Figure 1b
Figure 1c~1f
AI summary
A sound absorbing panel assembly (10) comprises a first sheet (11), a second sheet (12), a first frame structure (21) and a second frame structure (22). Each sheet (11, 12) comprises a polymer foam material and each sheet (11, 12) is provided with a plurality of backside-to-front side through-going perforations (31) that are arranged in a pattern covering at least a major part of the area of the backside and front side of each sheet(11, 12). The first frame structure (21) is arranged on the backside of the first sheet (11) and the second frame structure (22) is arranged on the backside of the second sheet (12). Furthermore, the first sheet (11) and the second sheet (11) are arranged in a sandwich arrangement in relation to each other such that the first frame structure (21) is attached to the front side of the second sheet (12) and an air gap (13) is present between the sheets (11, 12).