Recycled Polyurethane Foam Soundproofing Board with Checkered Back Surface
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Solution Overview
Problem
Current methods for manufacturing soundproofing board parts from recycled materials, such as polyurethane foam, are inefficient and costly due to the need for additional sound absorption non-woven fabrics, which complicate the process and increase costs, while also providing insufficient sound absorption performance.
Innovation Solution
A method involving the use of recycled polyurethane foam materials, molded in a preheating die and a molding die with a checkered structure to form a sound absorption part on the back surface of the board, eliminating the need for additional non-woven fabrics and enhancing sound absorption performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional sound absorption non-woven fabric is adhered to the back surface of the board part, then sound absorption performance is improved, but the manufacturing process becomes complicated and manufacturing cost increases
Solution Approach 1:
The patent combines the sound absorption function and the board part structure into a single integrated component. The soundproofing board part itself is designed with sound absorption capabilities through its material composition and internal structure, eliminating the need for separate non-woven fabric layers. This merging of functions reduces manufacturing process complexity while maintaining sound absorption performance.
Solution Approach 2:
The board part is designed to serve multiple functions simultaneously: structural support and sound absorption. By incorporating sound absorption properties directly into the board part material and structure, the component becomes multi-functional, eliminating the need for additional dedicated sound absorption layers and simplifying the overall manufacturing process.
2Reliability
If additional sound absorption non-woven fabric is adhered to the back surface of the board part, then sound absorption performance is improved, but manufacturing cost increases
Solution Approach 1:
The patent combines the sound absorption function and the board part structure into a single integrated component. The soundproofing board part itself is designed with sound absorption capabilities through its material composition and internal structure, eliminating the need for separate non-woven fabric layers. This merging of functions reduces manufacturing process complexity while maintaining sound absorption performance.
Solution Approach 2:
The patent extracts the sound absorption function from the separate non-woven fabric layer and integrates it directly into the board part material and structure. This extraction eliminates the need for additional expensive sound absorption materials and their associated adhesion processes, thereby reducing manufacturing costs while maintaining effectiveness.
3Ease of manufacture
If waste sheets are processed by incineration and landfill, then recycling rate is reduced, but processing simplicity is maintained
Solution Approach 1:
The patent implements a waste recovery system by collecting and recycling waste sheets from scrapped vehicles. Instead of incineration or landfill, the waste sheets are ground into particles and reused as raw material for manufacturing new soundproofing board parts. This closed-loop approach increases recycling rates while maintaining processing efficiency through established material recovery workflows.
Solution Approach 2:
The patent transforms waste sheets from a disposal problem into a valuable resource by changing their physical state and application. Waste sheets are ground into particles, changing their form from large sheets to fine material that can be uniformly distributed and bonded within the board part structure, enabling effective reuse in a different form and 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
This approach simplifies the manufacturing process, reduces costs, and significantly improves sound absorption performance by up to 20% compared to conventional methods, while maintaining or improving the rigidity of the soundproofing board parts.
Implementation Method 1
molding the recycled soundproofing material in a preheating die and a molding die
Implementation Method 2
a sound absorption part is formed on the back surface of the soundproofing board part with a checkered pattern figure including a volume part that has a thickness of about 3 to 5 mm
Data Source
AI summary
Disclosed is a method for manufacturing a soundproofing board part having improved sound absorption performance. The soundproofing board part is manufactured by using, as a material, a recycled soundproofing material which contains a polyurethane foam having excellent sound absorption performance and impact resilience during the press molding; and by producing a sound absorption part on the back surface of the soundproofing board part through a remolding processing method. Also disclosed is a soundproofing board part manufactured by the method.Accordingly, sound absorption performance of the soundproofing board part is improved by about 20% or greater, manufacturing cost thereof may be reduced by recycled resources utilizing waste sheets, and manufacturing process may be simplified compared the related art.