Resonant Sound-Blocking Sheet Structure for Lightweight Noise Isolation
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Solution Overview
Problem
Existing sound-blocking materials face limitations in design freedom, manufacturing complexity, and durability due to the use of rigid substrates and adhesive installation methods, leading to poor productivity and economic efficiency, while methods to increase mass for noise reduction are restricted by weight constraints.
Innovation Solution
A sound-blocking sheet member with rubber elasticity and resonance portions, featuring weight portions supported by base portions with penetration features, allowing for resin filling and even positioning, thereby enhancing manufacturability and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If stump-shaped protrusions (resonators) are installed on a substrate using adhesive, then sound-blocking performance is improved, but manufacturing steps become complicated and productivity decreases
Solution Approach 1:
The patent merges the substrate and resonators into a single integral structure by molding the resonators directly from the substrate material (e.g., foam material), eliminating the need for separate adhesive installation steps. This combining approach maintains sound-blocking performance while dramatically simplifying manufacturing.
Solution Approach 2:
The substrate material serves multiple functions: it provides the base structure, acts as the molding medium for resonators, and eliminates the need for separate adhesive materials. This multi-functionality reduces the number of components and manufacturing steps.
2Object-affected harmful factors
If rigid substrates like aluminum or epoxy are used for sound-blocking plates, then sound-blocking performance is improved, but the plates cannot be easily deformed to fit non-flat surfaces
Solution Approach 1:
The patent uses flexible foam material as the substrate, which can be easily deformed and conform to non-flat surfaces while maintaining sound-blocking performance. This replaces rigid substrates with flexible ones, enabling adaptation to curved or irregular surfaces.
Solution Approach 2:
The patent changes the physical state and properties of the substrate material from rigid (aluminum, epoxy) to flexible foam, allowing the material to be molded into various shapes and conform to different surface geometries while retaining acoustic performance.
3Object-affected harmful factors
If adhesive is used to install resonators on curved surfaces, then sound-blocking performance is maintained, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the substrate formation and resonator creation into a single molding process, eliminating the need for separate adhesive application steps. The resonators are formed integrally with the substrate, simplifying manufacturing even for curved surfaces.
4Ease of manufacture
If resin is poured into cavities with weight portions, then manufacturing is simplified, but air bubbles remain and resin does not reach portions below weight portions
Solution Approach 1:
The patent performs preliminary action by creating through-holes in the weight portions before molding, which allows resin to flow through and escape air bubbles during the molding process. This preliminary structural modification prevents filling defects.
Solution Approach 2:
The patent uses porous or permeable weight portions with through-holes that allow resin penetration and air bubble escape during molding, ensuring complete and uniform resin filling without trapping air pockets.
5Ease of manufacture
If weight portions are placed in cavities without position regulation, then manufacturing is simpler, but weight portions become unevenly positioned
Solution Approach 1:
The patent performs preliminary action by providing positioning protrusions on the weight portions that engage with corresponding recesses in the mold cavities before resin pouring. This preliminary positioning ensures accurate placement without requiring complex positioning mechanisms during molding.
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 lightweight sound-blocking performance exceeding the mass action law, with improved manufacturability and durability, and prevents uneven positioning of weight portions, ensuring effective sound isolation.
Implementation Method 1
a sheet having rubber elasticity
Implementation Method 2
resonance portions are provided in contact with a sheet surface of the sheet
Data Source
AI summary
An object of the present invention is to provide a resonator that is relatively lightweight, has high sound-blocking performance overwhelming the law of mass action, and is excellent in terms of manufacturability and durability. The resonator includes at least a sheet and at least one resonance portion. The resonance portion is provided in contact with a sheet surface of the sheet, and the resonance portion includes a weight portion and a base portion. The weight portion is supported by the base portion and has a larger mass than the base portion, and the weight portion has a penetration portion. The base portion is in contact with a surface on a resonance portion front end side of the weight portion and covers the weight portion.