Variable Thickness Polyurethane Sound Insulation Panel
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Solution Overview
Problem
Existing sound-proofing and sound-insulating insulation panels are heavy, large, expensive, and have poor mechanical resistance, with performance deteriorating over time and under temperature variations, and they waste material by maintaining uniform thickness across surfaces with varying sound intensity peaks.
Innovation Solution
A differential mass insulation panel with a first layer of compact polyurethane resin and a second layer of expanded viscoelastic polyurethane resin, where the thickness and density of the first layer are varied based on sound intensity peaks, allowing for optimized sound absorption and reduced material usage, manufactured through controlled spraying and injection processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a uniform thickness first layer is used across the entire panel, then the highest intensity sound wave peaks are absorbed, but material is wasted in areas where less absorption is needed, increasing cost and weight
Solution Approach 1:
The first layer is designed with variable thickness, having greater thickness in areas corresponding to high intensity sound wave peaks and lesser thickness in areas with lower intensity peaks. This local differentiation optimizes sound absorption performance while reducing material usage and cost.
2Reliability
If high density materials are used to reduce panel thickness, then sound insulation performance improves, but panel weight increases
Solution Approach 1:
Instead of using high density materials uniformly, the invention uses variable thickness of the first layer combined with the second layer to achieve sound insulation performance. This approach maintains effectiveness while avoiding the weight penalty of high density materials throughout the entire panel.
3Weight of moving object
If the first layer thickness is reduced to decrease weight, then material cost decreases, but sound absorption performance deteriorates
Solution Approach 1:
The first layer thickness is optimized locally based on sound intensity distribution. In areas with high intensity peaks, greater thickness provides adequate absorption, while in areas with lower intensity, reduced thickness suffices. This maintains overall sound absorption performance while minimizing weight.
4Ease of manufacture
If uniform thickness panels are manufactured, then production is simplified, but material cost increases due to excessive material usage
Solution Approach 1:
The variable thickness first layer is formed by controlling the foaming process to create different thicknesses in different areas. This can be achieved through controlled spraying or injection of the foaming composition, which expands to different heights in different zones, thereby creating the differential thickness pattern.
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 better sound-proofing and sound-insulating performance with reduced weight and size, maintaining effectiveness across temperature variations and being completely recyclable, while simplifying the manufacturing process and reducing costs.
Implementation Method 1
a second layer made of a second expanded material... an second layer made of an expanded viscoelastic polyurethane resin
Implementation Method 2
a first layer in the direction of thickness made of a first non-expanded compact material... capable of absorbing even the highest intensity peaks of the sound waves
Data Source
Figure 1~2
AI summary
A sound-insulating and sound-proofing insulation panel, formed by two different layers: a first layer made of non-expanded compact polyurethane material, named "mass", and a second layer made of expanded polyurethane material, named "foam". Specifically, compared with an equal weight of other similar products, the panel of the invention diminishes noise considerably better or, performance being equal, the panel exhibits a lighter weight. This is allowed by means of a differential distribution of the thickness and/or density of the "mass" of the panel in particular areas, thus determining saving in terms of materials. The process relative to the manufacturing of such a panel also results being particularly advantageous.