Integrally Molded Soundproof Structure with Through Holes
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Solution Overview
Problem
Conventional soundproof structures are heavy and large due to the mass law, and they struggle to effectively shield low-frequency sounds, with issues in manufacturing such as peeling of materials and non-uniform adhesion due to differences in thermal expansion coefficients and stiffness between the frame and film.
Innovation Solution
A soundproof structure with soundproof cells formed by a frame and film made of the same material, where the film is integrally molded with through holes and a weight, arranged in a two-dimensional manner, providing improved resistance to environmental changes and manufacturing challenges, and allowing for air and heat permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sound insulation materials use mass law for sound shielding, then sound insulation effect is improved, but the structure becomes large and heavy
Solution Approach 1:
The patent changes the fundamental parameter from mass-based sound insulation (mass law) to stiffness-based sound insulation (stiffness law). By using a membrane structure with specific tension and stiffness characteristics, the invention achieves effective sound insulation without requiring large mass, thereby resolving the contradiction between sound insulation effect and weight.
Solution Approach 2:
The patent employs a thin film membrane structure that can vibrate and respond to sound waves. This flexible thin film approach replaces traditional heavy mass-based soundproofing materials, achieving sound insulation through the membrane's stiffness and tension characteristics rather than its mass, thus significantly reducing weight while maintaining effectiveness.
2Reliability
If conventional sound insulation materials use mass law for sound shielding, then sound insulation effect is improved, but the structure becomes large
Solution Approach 1:
The patent transitions from mass-based sound insulation to stiffness-based sound insulation, changing the fundamental physical parameter. This allows the soundproof structure to achieve effective sound shielding with a much smaller size, as the stiffness law enables higher sound insulation per unit area compared to mass law.
Solution Approach 2:
By using a thin film membrane structure with controlled tension and stiffness, the invention achieves sound insulation in a compact form. The membrane's ability to vibrate and its stiffness characteristics enable effective sound blocking without requiring large structural dimensions.
3Ease of manufacture
If frame and film are made of different materials and bonded together, then soundproof structure is formed, but peeling occurs due to differences in thermal expansion coefficients and stiffness
Solution Approach 1:
The patent uses the same material for both the frame and the membrane (both made of resin), ensuring homogeneous material properties throughout the structure. This eliminates differences in thermal expansion coefficients and stiffness between dissimilar materials, preventing peeling and bonding failures while maintaining manufacturing ease.
Solution Approach 2:
The patent employs a composite resin structure where the frame and membrane are integrally formed from the same resin material. This composite approach with uniform material composition ensures consistent thermal and mechanical properties, preventing the peeling issues that arise from bonding dissimilar materials with different expansion coefficients and stiffness.
4Reliability
If soundproof structure uses stiffness law with thin structure, then low frequency sound shielding is improved, but manufacturing precision is required
Solution Approach 1:
The patent merges the frame and membrane into an integrally formed single structure made of the same resin material. This integration eliminates the need for precise bonding between separate components, reducing manufacturing precision requirements while maintaining the stiffness law benefits for low frequency sound shielding.
Solution Approach 2:
By using homogeneous resin material for both frame and membrane with integral formation, the patent simplifies manufacturing processes. The uniform material properties and integrated structure reduce the precision requirements compared to assembling different materials, while still achieving effective low frequency sound shielding through stiffness law.
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 results in a lightweight, thin, and robust soundproof structure that effectively shields sound across various frequencies without relying on the position or shape of through holes, offering improved manufacturability and stability, while maintaining air permeability and reducing heat retention.
Implementation Method 1
the principle of sound insulation is a stiffness law different from the mass law described above. Accordingly, low frequency components can be shielded even with a thin structure. This region is called a stiffness law, and sound insulation is performed by fixing film vibration at a frame portion.
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3B
AI summary
A soundproof structure includes one or more soundproof cells. Each of the one or more soundproof cells includes a frame having a hole portion, a vibratable film fixed to the frame so as to cover the hole portion, and one or more through holes drilled in the film. Both end portions of the hole portion of the frame are not closed, and the frame and the film are formed of the same material and are integrally formed. Therefore, it is possible to provide a soundproof structure and a soundproof structure manufacturing method capable of not only stably insulating sound due to increased resistance to environmental change or aging but also avoiding problems in manufacturing, such as uniform adhesion or bonding of a film to a frame.