Sound-absorbing wall elements with cast-in sealing profiles
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Solution Overview
Problem
Existing sound-absorbing components for noise protection walls face issues with seals detaching from panels, leading to reduced soundproofing and damage to double T-beams during dismantling, as well as a lack of protection for the I-beams from the hard surfaces of the panels.
Innovation Solution
The sound-absorbing components feature a support plate with cast-in sealing elements that protrude from the plane, ensuring a permanent seal and protection for the profile, with the sealing elements being band-shaped and optionally coated with polymer fleece or containing long loose fibers for improved retention and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealing elements are attached to support plates using conventional methods (screws, adhesives, mechanical retention), then the sealing function is provided, but the sealing elements become detached during dismantling, reducing soundproofing and damaging profiles
Solution Approach 1:
The sealing elements are cast integrally with the support plates, merging two previously separate components (sealing element and support plate) into a single monolithic structure. This integral construction eliminates the attachment interface that caused detachment, ensuring the sealing elements remain permanently fixed to the support plates throughout installation and dismantling cycles.
Solution Approach 2:
The support plates are made of concrete or glass fiber concrete, while the sealing elements are made of polymer materials. This composite material approach combines the structural strength of concrete with the sealing and protective properties of polymers, creating a durable assembly that resists detachment and profile damage.
2Strength
If sealing elements are made from hard materials to ensure durability, then structural strength is improved, but the hard surfaces damage the double T-beam profiles during installation and dismantling
Solution Approach 1:
The sealing elements exhibit local quality differentiation: the inwardly facing surface contacts the concrete support plate and requires high strength and friction for retention, while the outwardly facing surface contacts the aluminum profile and requires softness to prevent damage. This spatial variation in material properties resolves the contradiction between durability and profile protection.
Solution Approach 2:
The sealing elements are constructed from composite materials or coated with polymer fleece, combining the structural integrity needed for retention with the softness required for profile protection. The polymer material provides both mechanical strength for holding the seal in place and a compliant surface that protects the aluminum profile from damage.
3Ease of repair
If sealing elements are made detachable to simplify replacement, then maintenance becomes easier, but the seal becomes unreliable and soundproofing is compromised
Solution Approach 1:
By merging the sealing element with the support plate through integral casting, the invention creates a permanently reliable seal that cannot detach. The support plate itself becomes the carrier of the sealing function, eliminating the need for separate attachment mechanisms that could fail.
Solution Approach 2:
The support plates are designed for reuse after dismantling. The integral sealing elements remain attached to the support plates, allowing the entire assembly to be removed as one unit and reinstalled elsewhere, maintaining sealing reliability while enabling component recovery and reuse.
4Strength
If the support plates are made thick for structural stability, then load-bearing capacity is improved, but the weight of the components increases
Solution Approach 1:
The support plates utilize glass fiber concrete, a composite material that provides high structural strength and stability with reduced weight compared to traditional concrete. The glass fiber reinforcement allows for thinner plate designs while maintaining load-bearing capacity, thus reducing overall component weight without compromising structural integrity.
Data Source
Figure 1~3
AI summary
The sound-absorbing component (1) has a carrier plate (2), which is inserted at their end in a groove of a profile. The carrier plate has a cast in sealing element, which is protruded from a level of the ends of the carrier plate for installing in the groove. The sealing elements are formed at their outwardly turned surface with a polymer fleece coating. The carrier plate is casted as concrete support shell, glass fibre concrete or as plastic plate. Independent claims also included for the following: (1) a method for manufacturing a soundproof wall of sound-absorbing component (2) a device for manufacturing a soundproof wall of sound-absorbing component.