Self-Supporting Rockwool Acoustic Panel Design

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Solution Overview

Problem

Existing sound-absorbing panels for indoor spaces face challenges with installation difficulty, poor fireproof characteristics, susceptibility to physical damage, and inadequate aesthetic appearance, while also failing to effectively address sound transmission issues between rooms.

Innovation Solution

A self-supporting sound-absorbing panel with a Rockwool core, a specific core density and binder percentage, and a lightweight cover, designed to be mounted without a frame, providing improved durability, fire resistance, and enhanced sound absorption characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by stationary object

If fiberglass batting is used for sound-absorbing panels, then thermal insulation is improved, but acoustic absorption characteristics and aesthetic appearance deteriorate

Engineering Contradiction:

Improvethermal insulationVSAvoidacoustic absorption characteristics

Core Design Contradiction:

Use of energy by stationary objectVSReliability

Solution Approach 1:

The patent employs a composite structure combining rockwool batting with a fabric cover and frame assembly, creating a multi-material system that delivers both thermal insulation and superior acoustic absorption characteristics while improving aesthetic appearance

Inventive Principle:

Principle #40Composite materials

2Use of energy by stationary object

If fiberglass batting is used for sound-absorbing panels, then thermal insulation is improved, but resistance to physical damage deteriorates

Engineering Contradiction:

Improvethermal insulationVSAvoidresistance to physical damage

Core Design Contradiction:

Use of energy by stationary objectVSStrength

Solution Approach 1:

The composite construction with fabric cover and frame provides structural protection to the rockwool batting, significantly improving resistance to abrasion and impact damage while preserving thermal insulation properties

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The fabric cover and frame assembly serve as a protective layer that cushions the vulnerable rockwool batting against physical damage before impact occurs

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Stability of the object's composition

If rockwool batting is compacted to form self-supporting panels, then dimensional stability is improved, but fire-resistance deteriorates

Engineering Contradiction:

Improvedimensional stabilityVSAvoidfire-resistance

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The patent optimizes the compaction density parameter of rockwool batting to achieve the right balance between dimensional stability and fire-resistance, maintaining porosity sufficient for acoustic performance while providing structural integrity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The use of minimal binder material (1-3% by weight) reduces fire hazard while maintaining panel integrity, accepting that the binder is a sacrificial component with limited fire resistance

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Stability of the object's composition

If rockwool batting is compacted to form self-supporting panels, then dimensional stability is improved, but acoustic absorption characteristics deteriorate

Engineering Contradiction:

Improvedimensional stabilityVSAvoidacoustic absorption characteristics

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The patent carefully controls compaction parameters to achieve optimal density that provides dimensional stability while preserving the porous structure necessary for acoustic absorption

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The frame assembly provides structural stability at the edges and perimeter, allowing the central batting region to maintain lower density for optimal acoustic absorption

Inventive Principle:

Principle #3Local quality

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 panel effectively reduces reverberation time in rooms, improves aesthetic appeal, and addresses sound transmission issues between rooms, offering a cost-effective and easy-to-manufacture solution for indoor acoustic management.

Implementation Method 1

Methodology Applied

Scientific EffectPorous material absorption: Absorption (physical)

Data Source

PatentUS11468872B2Sound absorbing panel

Publication Date: 2022.10.11 PERDUE JOAB JAY

AI summary

A sound absorbing panel for managing acoustic environments with desired durability, stiffness and advantageous characteristics for self-supporting sound-absorbing panels intended to be attached to indoor walls and ceilings of buildings. The sound absorbing panel comprising a height, a width, a length and a cover. The sound absorbing panel comprising materials characterized by an inner core comprising a core density, a core binder and a thickness. The core density is between two and a half and four and a half pounds per cubic-foot. The core binder is between one and three-fourths and two and three fourths percent. The thickness comprises a thickness between 35-45 mm. The cover comprises a cover weight. The cover weight is between one quarter and one half ounces per foot.