Sound Absorption Structure Manufacturing with Anchored Acoustic Elements
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Solution Overview
Problem
The existing method for manufacturing sound absorption structures with honeycomb cellular panels is inadequate as acoustic elements can shift during the curing process, leading to marks on the porous layer and indentations on the reflective layer, compromising cohesion and structural integrity.
Innovation Solution
A modified manufacturing method involving two distinct curing or polymerization steps with different pressures to securely anchor acoustic elements within the cellular panel, using an anchoring layer and intumescent adhesive films to prevent element displacement and ensure cohesion between layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If acoustic elements are inserted into recesses and pressed during curing, then sound absorption performance is improved, but acoustic elements shift during the process causing marks and indentations
Solution Approach 1:
The recesses are pre-formed in the cellular panel with precise dimensions and positioning before the acoustic elements are inserted. The recesses are designed to accommodate the acoustic elements with appropriate clearance, allowing for controlled movement during curing while maintaining final positioning accuracy. This preliminary preparation of the structural framework enables subsequent assembly without compromising precision.
Solution Approach 2:
An adhesive layer is introduced as an intermediary substance between the acoustic elements and the cellular panel recesses. This adhesive mediator allows the acoustic elements to be positioned and held securely during the curing process, preventing unwanted shifting while still enabling the necessary pressing action to ensure proper contact and bonding. The adhesive acts as a buffer that maintains positioning accuracy throughout the manufacturing process.
2Strength
If high pressure is applied during curing to ensure layer cohesion, then structural integrity is improved, but acoustic elements displace and create defects
Solution Approach 1:
The acoustic elements are pre-positioned in their recesses and temporarily secured with adhesive before the high-pressure curing process begins. This preliminary securing action ensures that when high pressure is applied to achieve layer cohesion, the acoustic elements remain fixed in their correct positions and do not displace to create defects in the final structure.
Solution Approach 2:
The adhesive layer serves as a cushioning mechanism that protects the acoustic elements from displacement during the high-pressure curing process. This beforehand cushioning allows the necessary pressure to be applied for achieving strong layer cohesion while preventing the harmful effect of acoustic element displacement and the resulting marks or indentations.
3Manufacturing precision
If acoustic elements are pressed into recesses to ensure proper positioning, then assembly accuracy is improved, but elements shift during curing causing defects
Solution Approach 1:
The acoustic elements are preliminarily positioned in the recesses with adequate clearance to allow for pressing and adjustment. This preliminary positioning with built-in tolerance ensures that the elements can be pressed into proper contact with the cellular panel structure while maintaining their correct final positions, preventing both displacement and structural defects.
Solution Approach 2:
The adhesive layer acts as an intermediary that maintains the positioning accuracy of acoustic elements throughout the curing process. It allows the elements to be securely held in their pressed positions without shifting, ensuring both manufacturing precision and the reliability of the final assembled structure.
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 enhances the cohesion between the porous, reflective, and cellular layers, preventing telegraphing phenomena and maintaining the structural integrity of the sound absorption structure, particularly effective in attenuating low-frequency sound waves.
Implementation Method 1
using an anchoring layer and intumescent adhesive films to prevent element displacement and ensure cohesion between layers
Implementation Method 2
using an anchoring layer and intumescent adhesive films to prevent element displacement and ensure cohesion between layers
Data Source
AI summary
A method for manufacturing a sound absorption structure comprising a cellular panel, a porous layer positioned on a cellular panel first face, a reflective layer positioned on a cellular panel second face and a plurality of acoustic elements positioned in the cellular panel. The method comprises the steps of producing, for each acoustic element, a recess in the cellular panel opening out onto the first and second faces of the cellular panel, inserting the acoustic elements into their recesses, laying an anchoring layer on the second cellular panel face, curing or polymerization at a first pressure to connect each acoustic element to the cellular panel and/or to the anchoring layer, putting in place the porous layer and the reflective layer, and curing or polymerization at a second pressure to connect the porous layer and the reflective layer to the cellular panel.