Variable Density Sound-Absorbing Panel Without Frames
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Solution Overview
Problem
Existing sound-absorbing panels are cumbersome due to frames or support surfaces, which increase weight and cost, and often detract from aesthetic harmony in environments, while also reducing effective sound absorption.
Innovation Solution
A sound-absorbing panel with a padding layer of variable density, where the density is higher near the outer layers and lower near the center, allowing for increased rigidity without additional frames, and featuring a dual shell shape with a reduced thickness edge for improved acoustic performance and ease of installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a frame or support surface is added to increase panel rigidity, then the panel structural strength is improved, but the panel weight and cost increase
Solution Approach 1:
The padding layer is designed with variable density distribution, where the outer layers have higher density to provide rigidity and the inner layer has lower density to reduce weight. This local quality variation allows the panel to achieve sufficient structural strength without requiring additional heavy frames or support surfaces.
Solution Approach 2:
The invention changes the density parameter of the padding layer material across different regions of the panel. By controlling the density gradient from outer to inner layers, the panel achieves optimal balance between rigidity and weight, eliminating the need for separate frame structures.
2Stability of the object's composition
If a frame is added to maintain panel shape, then the panel structural stability is improved, but the aesthetic appearance deteriorates due to visible frames and joints
Solution Approach 1:
The invention extracts and eliminates the separate frame structure from the panel design. The frameless construction removes visible metal frames, wooden borders, and stitching joints that normally define the panel boundaries, resulting in clean, seamless edges that blend harmoniously with the surrounding environment.
Solution Approach 2:
The invention merges the structural support function previously performed by separate frames into the padding layer itself. The variable density padding layer simultaneously provides both aesthetic coverage and structural shape stability, combining multiple functions into a single integrated component.
3Strength
If the padding layer density is increased throughout to improve rigidity, then the panel strength is improved, but the sound absorption performance deteriorates
Solution Approach 1:
The padding layer features localized density variations rather than uniform density throughout. The outer layers have higher density to provide rigidity and shape stability, while the inner layer maintains lower density to preserve sound absorption capabilities. This spatial differentiation of material properties resolves the contradiction between structural strength and acoustic performance.
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 achieves enhanced rigidity, eliminating the need for frames, maintaining a flat form, and providing effective sound absorption across various frequencies while blending aesthetically with its surroundings, and is lightweight and recyclable.
Implementation Method 1
Sound-absorbing materials have the property that they absorb at least part of the acoustic energy and reduce the amount of energy which is reflected
Data Source
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AI summary
A sound-absorbing panel comprising a padding layer with heat-bonded synthetic fibers, wherein the padding layer has a first outer surface, a second outer surface and a first thickness, wherein the panel is made of said padding layer with no further layers of a different material between the first outer surface and the second outer surface, wherein the padding layer in at least one portion of panel has a variable density in a direction transverse to the first and second outer surfaces, the density being higher in proximity of the first and second outer layers thereof and being lower in proximity of its inner layer.