Description:FIELD OF THE INVENTION

[0001] The present invention relates to an automated noise cancellation panel manufacturing device that is capable of allowing a user to define dimensions of a noise cancellation panel to be manufactured and accordingly dispenses various materials on the panel along with dispensing adhesive over the panel, enabling secure bonding of the noise-dampening materials, thus manufacturing noise cancellation panel in an automated manner.

BACKGROUND OF THE INVENTION

[0002] Noise pollution has become a significant concern in various environments, including residential, commercial, and industrial spaces. Excessive noise can lead to numerous health issues such as stress, impaired hearing, and reduced productivity. To address these concerns, noise-cancellation panels are commonly used to dampen and reduce the impact of ambient noise. Conventional methods for manufacturing noise-cancellation panels, however, are often labor-intensive and lack the flexibility to customize panel dimensions or material compositions based on specific noise-reduction requirements. This can result in a limited effectiveness of the panels for diverse applications and make production time-consuming and costly.

[0003] In response to these challenges, there is a need for a device that produces noise-cancellation panels as per the user's specifications in an efficient and consistent manner. Such a device would allow users to define the dimensions and thickness of the panels, facilitate the precise dispensing of noise-dampening materials and adhesives, and incorporate mechanisms to apply these materials onto the panel securely. Furthermore, the device incorporates built-in testing and quality control capabilities would enhance the overall effectiveness of noise-cancellation panels, meeting the growing demand for customizable and reliable soundproofing solutions across different environments. The present invention addresses these needs by providing an automated device that simplifies and improves the manufacturing process of noise-cancellation panels.

[0004] US6855398B1 discloses about a carbon fiber as its constituent material, to provide a thermal-acoustic insulation material having excellent properties in durability, compression resilience, lightness, fireproofness, and non-galvanic corrosiveness. The material of the present invention comprises a wool-like carbon fiber aggregate composed of carbon fibers having an average fiber diameter of 0.5 μm to 5 μm and an average fiber length of 1 mm to 15 mm and the contact points of the fibers are bonded together by a thermosetting resin. The galvanic current of the material is 10 μA or lower in a galvanic cell comprising an electrode composed of the thermal-acoustic insulation material, the other electrode composed of an aluminum plate, and an electrolytic solution composed of 0.45 wt. % sodium chloride aqueous solution.

[0005] US20150266203A1 discloses about an apparatus for manufacturing a thermal and/or acoustic insulation product based on mineral wool, including: a first line for production of first mineral fibers, including at least one fiberizing member; a second line for production of second mineral fibers, including at least one fiberizing member and a cross-lapping device; and a cross-lapping device configured to deposit the second mineral fibers onto the first mineral fibers by cross-lapping. The apparatus can manufacture a thermal and/or acoustic insulation product with improved thermal and/or acoustic properties.

[0006] Conventionally, many devices have been developed to manufacture noise-cancellation panels using manual or semi-automated processes. These devices require significant human intervention to measure and cut panels, apply materials, and ensure proper adhesive bonding. While these systems have been able to produce functional noise-cancellation panels, they often suffer from issues such as inconsistent panel dimensions, inefficient material usage, and labor-intensive operations. Furthermore, these conventional devices lack the capability to customize the manufacturing process to user-specific requirements, resulting in longer production times and higher costs.

[0007] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a device that requires to automate the entire process of noise-cancellation panel manufacturing, allowing for precise customization of panel dimensions and material composition. Additionally, the developed device also needs to be capable of efficiently dispensing materials, applying adhesive for secure bonding, and ensuring the correct thickness and performance of the panel.

OBJECTS OF THE INVENTION

[0008] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a device that allows a user to define dimensions of a noise cancellation panel to be manufactured and accordingly dispenses various materials on the panel along with dispensing adhesive over the panel, enabling secure bonding of the noise-dampening materials, thus manufacturing noise cancellation panel in an automated manner.

[0010] Another object of the present invention is to develop a device that applies consistent pressure on the noise-dampening materials, allowing for uniform thickness and effective fabrication of the soundproof layer as per user-defined specifications.

[0011] Yet another object of the present invention is to develop a device that provides a means to assess the panel’s noise-cancellation performance by measuring the decibel level reduction achieved, ensuring the final product meets desired soundproofing standards.

[0012] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0013] The present invention relates to an automated noise cancellation panel manufacturing device that enables a user to define specific panel dimensions and accordingly the device is equipped with a means for dispensing required materials and adhesive layers to securely bond the noise-dampening materials onto the panel for manufacturing of noise cancellation panels to meet various soundproofing needs.

[0014] According to an embodiment of the present invention, an automated noise cancellation panel manufacturing device, comprises of a housing developed to be installed on a fixed surface and arranged with a touch interactive display panel accessed by a user for providing input regarding thickness and dimensions of a noise cancellation panel to be manufactured, a multi-section box arranged inside the housing and integrated with a motorized lid to get open for dispensing a required dimensions of panel stored in the box over base of the housing, an artificial intelligence-based imaging unit installed inside the housing to determine positioning of the panel inside the housing, plurality of motorized clamps integrated at base of the housing to acquire a grip on the panel, a multi-sectioned chamber arranged inside the housing for storing different material utilized for preparing a noise cancellation layer, plurality of electronically controlled valve integrated underneath the chamber to get open for dispensing an optimum amount of the material from the chamber, a container arranged underneath the chamber for accommodating the dispensed material inside the chamber.

[0015] According to another embodiment of the present invention, the proposed device further comprises of a motorized blade integrated in the container to rotate which results in unweaving of and shredding of the material to form a wool like fabric, a motorized iris lid integrated underneath the container to get open for allowing dispensing of the wool fabric out of the container onto the accommodated panel, a motorized roller suspended from ceiling of the housing by means of a motorized two-axis lead screw to apply pressure on the dispensed wool fabric against the panel which results in fabrication of the wool fabric over the panel as per the user-specified thickness as monitored by an ultrasonic sensor integrated inside the housing, a storage vessel is arranged on the lead screw and integrated with an electronically controlled sprinkler to dispense an adhesive solution stored in the vessel over the panel for adhering the accommodated fabric on the panels, a robotic arm installed inside the housing to position the panel at a required distance from a speaker installed in the housing, followed by actuation of a microphone integrated on another side of the panel to determine decibel of sound restricted by the panel during actuation of the speaker.

[0016] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an isometric view of an automated noise cancellation panel manufacturing device.

DETAILED DESCRIPTION OF THE INVENTION

[0018] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0019] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0020] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0021] The present invention relates to an automated noise cancellation panel manufacturing device that is capable of allowing a user to define dimensions of a noise cancellation panel to be manufactured and accordingly dispenses various materials on the panel along with dispensing adhesive over the panel, enabling secure bonding of the noise-dampening materials, thus manufacturing noise cancellation panel in an automated manner.

[0022] Referring to Figure 1, an isometric view of an automated noise cancellation panel manufacturing device is illustrated, comprising a housing 101 developed to be installed on a fixed surface and arranged with a touch interactive display panel 102, a multi-section box 103 arranged inside the housing 101 and integrated with a motorized lid, an artificial intelligence-based imaging unit 104 installed inside the housing 101, plurality of motorized clamps 105 integrated at base of the housing 101, a multi-sectioned chamber 106 arranged inside the housing 101, plurality of electronically controlled valve integrated underneath the chamber 106.

[0023] Figure 1 further illustrates a container 107 arranged underneath the chamber 106, a motorized blade 108 integrated in the container 107, a motorized iris lid integrated underneath the container 107, a motorized roller 109 suspended from ceiling of the housing 101 by means of a motorized two-axis lead screw 110, a storage vessel 111 arranged on the lead screw 110 and integrated with an electronically controlled sprinkler, a robotic arm 112 installed inside the housing 101, a speaker 113 installed in the housing 101 and a microphone 114 integrated on another side of the panel.

[0024] The proposed device herein comprises of a housing 101 developed to be installed on a fixed surface, wherein the housing 101 is made from a durable material such as steel, aluminum, or high-strength polymer, chosen for its ability to provide structural integrity, corrosion resistance, and ease of maintenance.

[0025] The housing 101 is arranged with a touch interactive display panel 102 that is accessed by a user for providing input regarding thickness and dimensions of a noise cancellation panel to be manufactured. The display panel 102 consists of multiple layers, including a transparent conductive layer such as indium tin oxide (ITO) coated glass, which forms the surface that users directly touch. Beneath the layer lies a grid of electrodes, typically made of a conductive material like copper or silver, arranged in rows and columns. When the user touches the display panel 102, it creates a measurable change in capacitance at the point of contact, altering the electrical field between the electrodes. This change is detected by the controller circuitry embedded within the display panel 102, which interprets the position and intensity of the touch. The controller then converts this data into digital signals representing user inputs, which are further processed by an inbuilt microcontroller associated with the device.

[0026] A multi-section box 103 is arranged inside the housing 101 and integrated with a motorized lid that is actuated by the microcontroller to get open for dispensing a required dimensions of noise cancellation panel stored in the box 103. The motorized lid consists of a DC motor integrated with a linear actuator. The motor is controlled by the microcontroller, which receives signals from the microcontroller and activates the motor, causing the lid to open or close by moving along a predefined path. The motor’s movement is translated into mechanical motion through the drive components, enabling precise control over the lid’s positioning. This mechanism ensures that the lid opens at the right moment to dispense the required dimensions of the panel stored in the box 103 onto the base of the housing 101.

[0027] The microcontroller activates an artificial intelligence-based imaging unit 104 installed inside the housing 101 to determine positioning of the panel inside the housing 101. The imaging unit 104 comprises of an image capturing arrangement including a set of lenses that captures multiple images of the surroundings, and the captured images are stored within a memory of the imaging unit 104 in form of an optical data. The imaging unit 104 also comprises of a processor that is integrated with artificial intelligence protocols, such that the processor processes the optical data and extracts the required data from the captured images. The extracted data is further converted into digital pulses and bits and are further transmitted to the microcontroller. The microcontroller processes the received data and determines positioning of the panel inside the housing 101.

[0028] Plurality of motorized clamps 105 are integrated at base of the housing 101 that is actuated by the microcontroller to acquire a grip on the panel. A multi-sectioned chamber 106 is arranged inside the housing 101 for storing different material utilized for preparing a noise cancellation layer. The are powered by a DC (direct current) motor that is actuated by the microcontroller by providing required electric current to the motor. The motor comprises of a coil that converts the received electric current into mechanical force by generating magnetic field, thus the mechanical force provides the required power to the clamps 105 thus extending/retracting for gripping the panel.

[0029] Plurality of electronically controlled valve are integrated underneath the chamber 106 that is actuated by the microcontroller to get open for dispensing an optimum amount of the material from the chamber 106. The electronically controlled valve operates through precise control facilitated by a solenoid valve actuated by the microcontroller. When the microcontroller sends an electrical signal to the solenoid coil, it generates a magnetic field that moves the valve's armature, allowing the material from the connected chamber 106 to flow through the nozzle into a container 107 arranged underneath the chamber 106 for accommodating the dispensed material.

[0030] The microcontroller then actuates a motorized blade 108 integrated in the container 107 to rotate which results in unweaving of and shredding of the material to form a wool like fabric. The blade 108 is powered by a DC (direct current) motor that is capable of converting the electric current provided from an external force into mechanical force for providing the required power to the blade 108, thus unweaving of and shredding of the material to form a wool like fabric.

[0031] A motorized iris lid is integrated underneath the container 107 that is actuated by the microcontroller to get open for allowing dispensing of the wool fabric out of the container 107 onto the accommodated panel. The iris lid comprises of a ring and a blade with multiple protrusions. The ring is fabricated with multiple grooves. The protrusions on the blades engage with the grooves on the ring in order to link the movement of the ring and blades. As the ring rotates, the protrusions move within the grooves to open or close the lid according to the degree of rotation of the ring. The ring is installed with the motor that is actuated by the microcontroller for rotating the ring with a specified speed to regulate the opening and closing of the lid, thus dispensing the wool fabric out of the container 107 onto the accommodated panel.

[0032] A motorized roller 109 is suspended from ceiling of the housing 101 by means of a motorized two-axis lead screw 110 that is actuated by the microcontroller to apply pressure on the dispensed wool fabric against the panel. The motorized two-axis lead screw 110 comprises of a pair of the lead screw, i.e. one horizontal and one vertical, aligned perpendicular to each other. The lead screw is a type of mechanical power transmission that is used for high-precision actuation. The nut of the lead screw 110 remains stationary and a rotational motion is delivered to the shaft by employing a DC (Direct Current) motor. The lead screw 110 converts the rotational motion into linear motion. The vertical lead screw 110 delivers an upward and downward motion to the roller 109 and the horizontal lead screw provides horizontal movement to the roller 109 as per requirement. The roller 109 apply pressure on the dispensed wool fabric against the panel which results in fabrication of the wool fabric over the panel as per the user-specified thickness as monitored by an ultrasonic sensor integrated inside the housing 101.

[0033] The ultrasonic sensor works by emitting high-frequency sound waves from a transducer and measuring the time it takes for the sound waves to reflect back from the wool fabric layer on the panel. The ultrasonic sensor includes a transmitter, which emits the ultrasonic sound waves, and a receiver, which detects the waves after they bounce back. The microcontroller calculates the distance based on the time delay between emission and reception of the waves, using the known speed of sound and measures the thickness of the wool fabric layer by calculating the distance between the sensor and the fabric’s surface, comparing it to the user-specified thickness. If the layer is too thick or thin, the microcontroller adjusts the roller’s 109 pressure or fabric dispensing accordingly, ensuring precise fabrication of the wool layer on the panel.

[0034] A storage vessel 111 is arranged on the lead screw 110 and integrated with an electronically controlled sprinkler that is actuated by the microcontroller to dispense an adhesive solution stored in the vessel 111 over the panel. The sprinkler consists of a valve controlled by an electronic actuator linked with the microcontroller. Such that the microcontroller actuates the sprinklers by sending signal to the actuator which in turn opens the valve and allowing pressurized adhesive solution to flow though the sprinkler’s nozzle, thereby sprinkling adhesive solution stored in the vessel 111 over the panel prior accommodation of the wool fabric on the panel, in view of adhering the accommodated fabric on the panel.

[0035] After the manufacturing of the panel, the microcontroller actuates a robotic arm 112 installed inside the housing 101 to position the panel at a required distance from a speaker 113 installed in the housing 101. The robotic arm 112 is able to perform the designated task with high efficiency and accuracy, wherein the robotic arm 112 consists of mechanical joints and actuators, which are controlled by the microcontroller. The actuators allow various degrees of freedom and movement and the joints are actuated by a DC (Direct Current) motor, providing the necessary force and motion to position the panel at a required distance from the speaker 113.

[0036] The microcontroller then actuates a microphone 114 integrated on another side of the panel to determine decibel of sound restricted by the panel during actuation of the speaker 113. The microphone 114 operates by converting sound waves into electrical signals through its main components a diaphragm, a backplate and an electronic circuit. When sound waves, such as those from the speaker 113, reach the microphone 114, they cause the diaphragm, a thin and flexible membrane, to vibrate. These vibrations create changes in the spacing between the diaphragm and the backplate, generating a varying electrical signal that corresponds to the sound wave's intensity and frequency. This electrical signal is then processed by the microphone’s 114 internal circuit, amplifying and converting it into an output signal that the microcontroller interprets to analyze the microphone’s 114 output to measure the decibel level of the sound that the panel has blocked, providing an assessment of the panel's noise-cancellation effectiveness.

[0037] The device is associated with a battery for providing the required power to the electronically and electrically operated components including the microcontroller, electrically powered sensors, motorized components and alike of the device. The battery within the device is preferably a lithium-ion-battery which is a rechargeable battery and recharges by deriving the required power from an external power source. The derived power is further stored in form of chemical energy within the battery, which when required by the components of the device derive the required energy in the form of electric current for ensuring smooth and proper functioning of the device.

[0038] The present invention works best in the following manner, where the housing 101 as disclosed in the invention is arranged with the touch interactive display panel 102 that is accessed by a user for providing input regarding the noise cancellation panel dimensions and thickness and input information is sent to the microcontroller, which coordinates the device’s components to start manufacturing. Initially, the microcontroller activates the motorized lid on the multi-section box 103 to dispense the blank panel onto the housing 101 base. The imaging unit 104 captures images to confirm the panel’s alignment, allowing the microcontroller to make any necessary positional adjustments using motorized clamps 105 at the base, which secure the panel in place. The microcontroller opens electronically controlled valves, releasing material into the container 107 equipped with the motorized blade 108. The blade 108 shreds and unweaves the material to form a wool-like fabric suitable for sound absorption. Before placing this fabric, the adhesive solution stored in the vessel 111 is dispensed onto the panel using an electronically controlled sprinkler, ensuring strong adhesion. The motorized iris lid opens allowing the wool fabric to be spread onto the panel. The motorized roller 109 is suspended from the housing 101 ceiling on the two-axis lead screw 110 that applies consistent pressure across the wool layer. The thickness is monitored by the ultrasonic sensor to verify compliance with the user’s input. Finally, after assembly the microcontroller actuates the robotic arm 112 to position the panel near an inbuilt speaker 113, which emits sound to test the panel’s noise-blocking capacity. The microphone 114 on the opposite side measures sound levels, and the microcontroller assesses the panel’s effectiveness.

[0039] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) An automated noise cancellation panel manufacturing device, comprising:

i) a housing 101 developed to be installed on a fixed surface, wherein said housing 101 is arranged with a touch interactive display panel 102 that is accessed by a user for providing input regarding thickness and dimensions of a noise cancellation panel to be manufactured;
ii) a multi-section box 103 arranged inside said housing 101 and integrated with a motorized lid that is actuated by an inbuilt microcontroller to get open for dispensing a required dimensions of panel stored in said box 103 over base of said housing 101, wherein an artificial intelligence-based imaging unit 104 is installed inside said housing 101 and integrated with a processor for capturing and processing multiple images of internal portions of said housing 101, respectively to determine positioning of said panel inside said housing 101;
iii) plurality of motorized clamps 105 integrated at a base of said housing 101 that is actuated by said microcontroller to acquire a grip on said panel, wherein a multi-sectioned chamber 106 is arranged inside said housing 101 for storing different material utilized for preparing a noise cancellation layer;
iv) plurality of electronically controlled valve integrated underneath said chamber 106 that is actuated by said microcontroller to get open for dispensing an optimum amount of said material from said chamber 106, wherein a container 107 is arranged underneath said chamber 106 for accommodating said dispensed material inside said chamber 106, followed by actuation of a motorized blade 108 integrated in said container 107 to rotate which results in unweaving of and shredding of said material to form a wool like fabric; and
v) a motorized iris lid integrated underneath said container 107 that is actuated by said microcontroller to get open up for allowing dispensing of said wool fabric out of said container 107, onto said accommodated panel, wherein a motorized roller 109 is suspended from ceiling of said housing 101 by means of a motorized two-axis lead screw 110 that is actuated by said microcontroller to apply pressure on said dispensed wool fabric against said panel which results in fabrication of said wool fabric over said panel as per said user-specified thickness as monitored by an ultrasonic sensor integrated inside said housing 101.

2) The device as claimed in claim 1, wherein a storage vessel 111 is arranged on said lead screw 110 and integrated with an electronically controlled sprinkler that is actuated by said microcontroller to dispense an adhesive solution stored in said vessel 111 over said panel, prior accommodation of said wool fabric on said panel, in view of adhering said accommodated fabric on said panel.

3) The device as claimed in claim 1, wherein post manufacturing of said panel, said microcontroller actuates a robotic arm 112 installed inside said housing 101 to position said panel at a required distance from a speaker 113 installed in said housing 101, followed by actuation of a microphone 114 integrated on another side of said panel to determine decibel of sound restricted by said panel during actuation of said speaker 113.