WO2003069595A1 - Sound absorbing material including a plurality of pieces with pores - Google Patents

Sound absorbing material including a plurality of pieces with pores Download PDF

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Publication number
WO2003069595A1
WO2003069595A1 PCT/GB2003/000484 GB0300484W WO03069595A1 WO 2003069595 A1 WO2003069595 A1 WO 2003069595A1 GB 0300484 W GB0300484 W GB 0300484W WO 03069595 A1 WO03069595 A1 WO 03069595A1
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WIPO (PCT)
Prior art keywords
pieces
sound absorbing
less
pores
region
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Application number
PCT/GB2003/000484
Other languages
French (fr)
Other versions
WO2003069595A8 (en
Inventor
Edward French
Mark Johnathan Swift
Kirill Vjatcheslavovitch Horoshenkov
Original Assignee
Acoutechs Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Acoutechs Limited filed Critical Acoutechs Limited
Priority to AU2003208393A priority Critical patent/AU2003208393A1/en
Publication of WO2003069595A1 publication Critical patent/WO2003069595A1/en
Publication of WO2003069595A8 publication Critical patent/WO2003069595A8/en

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Classifications

    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
    • G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/162—Selection of materials
    • G10K11/165—Particles in a matrix

Definitions

  • the pieces may be connected together by adhesion, such as by a binder.
  • the binder may comprise less than 50% or less than 40% or more than 10% or more than 20% or in the region of 30 or 35% of the mass of the material.
  • the material prior to consolidation may have a flow resistivity of less than 300 or less than 150 or more than 20 or more than 40 or in the region of 80 kPascals x sec/m 2 .
  • the material may have a flow resistivity of more than 6 or less than 20 or in the region of 8,100 kPascals x sec/m 2 .
  • the present invention also includes a method of making sound absorbing material comprising connecting a plurality of pieces together with each piece including pores extending at least partially into the pieces and the pieces also including openings extending at least partially through the material between adjacent pieces.
  • the method may comprise cutting sections of sound absorbing material from a piece of ' sound absorbing material such as by cutting sheets from the piece.

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  • Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Acoustics & Sound (AREA)
  • Multimedia (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Building Environments (AREA)

Abstract

Sound absorbing board (10) is made from recycled high density foam granulate (12) that has been mixed with a binder (14) and consolidated under pressure. Pores (16) are present in spaces between the granules. Each granule includes small pores (18). Sound is absorbed by thermal diffusion and viscous friction.

Description

SOUND ABSORBING MATERIAL INCLUDING A PLURALITY OF PIECES WITH PORES
The present invention relates to sound absorbing material, to a method of using sound absorbing material and to a method of making sound absorbing material.
In a known sound absorbing material relatively soft, low density particles are glued together with the glue filling the spaces between the particles. The particles are approximately 5 to 20 mm in diameter. However such material is only able to absorb a relatively small amount of high frequency sound and a significant amount of medium and low frequency sound is reflected or transmitted through the material rather than being absorbed.
It is an object of the present invention to attempt to improve the acoustic performance of consolidated particulate material and to overcome a-t least some of the above described or other disadvantages.
According to one aspect of the present invention sound absorbing material includes a plurality of pieces connected together, each piece including pores extending at least partially into the pieces, the material also including openings extending at least partially through the material between adjacent pieces.
The pieces may comprise foam such as polyurethane foam. The foam may be recycled. The pieces of foam may include open cells. The foam may include closed cells. The pieces may have been taken off a closed cell structure with closed cells having been opened. The ratio of open cells to closed cells may be less than 10:1 or more than 1:1 or in the region of 1:3. The foam may be a high density foam or medium density foam, for instance having a density of more than 25 or less than 150 or preferably in the region of 100 to 120 kg/m3, before the pieces are connected together.
The pieces may be connected together by adhesion, such as by a binder. The binder may comprise less than 50% or less than 40% or more than 10% or more than 20% or in the region of 30 or 35% of the mass of the material.
The material may have been compressed down during manufacture by more than 25% or less than 75% or preferably in the region of 50%.
The porosity of the material may be less than 80% or more than 20% or more than 40% or in the region of 65%. Alternatively the porosity may be less than 95 or 85% or more than 70% or in the region of 84% after compression.
The material may have an initial porosity, before compression of more than 80% or in the region of 95%.
The material prior to consolidation may have a flow resistivity of less than 300 or less than 150 or more than 20 or more than 40 or in the region of 80 kPascals x sec/m2. Alternatively the material may have a flow resistivity of more than 6 or less than 20 or in the region of 8,100 kPascals x sec/m2.
The material may have a Youngs modulus of more than 105 or less than 109 or approximately 107 Pascals. The material may have a density of more than 25 or less than 150 kg/m3 before the pieces are connected.
The material may have a density of less than 800 or less than 600 or more than 100 or more than 200 or in the region of 400 kg/m3 after compression. Alternatively the material may have a density of more than 110 or less than 200 or in the region of 130kg/m3 after compression.
The ratio of the space provided by the pores to the total space in the material may be more than 60 or more than 70 or more than 80 or in the region of 85%. The ratio of the space provided by the openings to the total space in the material may be less than 40 or less than 30 or less than 20 or in the region of 15%.
The mean cross-sectional area of the pores may be less than 1.6mm2 or less than 0.25mm2 or more than 0.003mm2 or more than 0.012mm2 or in the region of 0.05mm2 or 0.5mm2 or less than 1.1mm2 or less than 2.0mm2. The standard deviation may be 0.61.
The mean cross-sectional area of the openings may be less tthhaann 22mmmm22 oorr lleessss tthhaann 11..55mmmm22 oorr mmoorree than 0.05mm2 or more than 0.1mm2 or in the region of 1.2mm2.
The material may comprise vehicle sound absorbing material or construction sound absorbing material.
The mean cross-sectional dimension of the pieces in the material may be less than 10 or more than 0.5 or in the region of 3 to 5 mm. At least one of the pores may be connected to at least one of the openings and preferably several pores are connected with several openings .
The material may be arranged to absorb more than 70 or more than 80 or more than 90% of the sound at at least one frequency. That frequency may be greater than 500 or greater than 600 or less than 6000 or less than 4000 or in the region of 800 Hz. Alternatively or additionally, that frequency may be more than 1100 or more than 1200 or less than 1600 or less than 1500 or in the region of 1300 Hz. The material may be arranged to absorb more than 70 or more than 80 or more than 90% of the sound at at least two spaced frequencies. The material may be arranged to absorb more than 30 or more than 40 or in the region of 50% or more of the sound at frequencies between the two spaced frequencies.
The material may comprise board material which may be less than 50 or less than 40 or more than 5 or in the region of 10 mm thick. The board material may be self supporting. The board material may be flexible.
The tortuosity of the material may be more than 1 or less than 1.5 or in the region of 1.2.
The present invention also includes a method of using sound absorbing material as herein referred to comprising attaching the sound absorbing material to a vehicle or attaching the sound absorbing material to a construction.
The present invention also includes a method of making sound absorbing material comprising connecting a plurality of pieces together with each piece including pores extending at least partially into the pieces and the pieces also including openings extending at least partially through the material between adjacent pieces.
The method may comprise adhering the pieces together.
The method may comprise compressing the pieces, for instance by more than 25% or less than 75% or in the region of 50%.
The method may comprise cutting sections of sound absorbing material from a piece of ' sound absorbing material such as by cutting sheets from the piece.
The present invention also includes a method of making sound absorbing material as herein referred to.
According to a further aspect of the present invention a method of absorbing sound comprises using sound absorbing material as herein referred to.
The method may comprise sound travelling along a pore and then an opening connected to that pore or, alternatively or additionally, along an opening and then along a pore connected to that opening.
The present invention includes any combination of the herein referred to features or limitations.
The present invention can be carried into practice in various ways but one embodiment will now be described, by way of example, and with reference to the accompanying drawings, in which:
Figure 1 is a perspective view of a finished sound absorber board 10;
Figure 2 is a detailed cross-sectional view of part of the board 10;
Figure 3 is a graph showing how sound is absorbed by this board at different frequencies, and
Figure 4 is a cross-section through a piece to be included into the board 10.
The board 10 is made from recycled high density (100 or 120 kg/m3) foam granulate 12 that has been mixed with a binder 14 and consolidated under pressure. (Each granule is approximately 3 to 6 mm wide) . In one embodiment the pressure reduces the volume of the board to approximately H its original thickness and the porosity is reduced from 95% to 65%. The flow resistivity of the board is approximately 80K Pascals x sec/m2" The board has a Youngs Modulus of 107 Pascals and a Density of 400 kg/m3. The relatively low amount of binder used represents around 35% by mass of the weight of the board. The board is able to support its own weight as a result of its relatively high Young's modulus and relatively low density. The board may be 10 mm thick.
The board includes large pores 16 comprising the spaces between the granules that comprise 15 to 20% of the volume of the board. Each granule includes small pores 18. Of the total pore volume, the large pores between the granules represents 10 to 15% of the pore volume and the small pores represent 85 to 90% of that total volume.
When sound energy enters the porous structure of the developed material part of it is absorbed as a result of the two physical processes: thermal diffusion and viscous friction. In the harmonic regime of an oscillating air flow in the material these processes are described by the thermal characteristic length
k pcpω and by the viscous characteristic length
Figure imgf000008_0001
where k is the thermal conductivity, p is the density, cp is the specific mass thermal capacity, η is the dynamic viscosity or air and ω = l7τf is the angular frequency. For typical audio frequencies of 50< f <20000 Hz these parameters are confined to ranges of 13 μm <δt<0.26 mm and 10 μm < δv < 2.2 mm. The absorption of the acoustic energy is particularly pronounced when the size of pores and openings (which may be the length or width of the pores or openings) is close to either of the above characteristic lengths.
In the low frequency range isothermal conditions are set up and the viscous forces are the predominant mechanism of acoustic absorption. Thermal exchanges become more pronounced in the transitional frequency range, between the isothermal and adiabatic regimes. As the frequency of sound increases further adiabatic perturbations in the pores and openings become predominant. In this case, thermal exchanges are reduced and the absorption of sound is primarily because of the inertial interaction of the viscous fluid and the twisted pore structure.
In a medium, in which small pores are connected to large openings the coupling of air flow between the pores and the openings is set up (see Figure 2) . In this case extra acoustic absorption is provided due to the additional viscous diffusion of the acoustic pressure in the pores and due to the additional thermal non-equilibrium in the dual porous system. Accordingly sound can enter the pores 14 and travel into the pores 18 or vice versa.
Accordingly, as the board includes both large and small pores sound is absorbed more effectively in a wide range of frequencies. Furthermore, the board may be relatively thin and yet still be able to absorb sound satisfactorily.
The tortuosity of the porous structure may be between 1 and 2.0 and is preferably in the region of 1.4 or 1.2.
The board has many uses including vehicle roofs, vehicle bumpers, vehicle seats or in insulating rooms such as by retrofitting rooms with the absorbing board. Clearly in these applications, the smaller the space that is occupied by the board the greater the remaining free space that is available. The board is able to be manufactured with various surface appearances including an apparent smooth surface to the eye. As shown in Figure 3, when the sound is incident upon the 10 mm thick board with a 40mm air spacing from a rigid layer behind the material, nearly all of the sound at 900 Hz is absorbed and nearly all of the sound at 1300 Hz is absorbed with the majority of sound between those frequencies also being absorbed. Sound of this frequency is most noticeable to the human ear.
Figure 4 is a cross-section through a piece 30 that may be included in the board. The piece has been formed from a recycled closed cell piece of foam. During the chopping of the foam into the pieces, some of the closed cells are rendered open to the exterior of the piece as shown by numeral 32. Others remain closed such as those shown at 34. It will be appreciated that Figure 4 is somewhat schematic. It does show though that there is a ratio of open cells 32 to closed cells 34 of 1:3. If the ratio were significantly greater such that there were many more open cells than closed cells the pieces would be extremely small and most of the sound would pass between adjacent pieces thereby reducing the frequency of sound absorbed by the pores. On the other hand if the pieces were much larger with many more closed cells, more sound would be absorbed by the pores with the frequency absorbed by the spaces between the pieces being adversely reduced.
A further embodiment will now be described. However, features of the first embodiment may be used with the second embodiment and vice versa where appropriate.
In the further embodiment, a large block of foam pieces such as shown in Figure 2 or 3 is formed in a press mould. The pieces are adhered together by a binder by an amount of 30% by weight compared to total weight of binder and pieces. The pieces are compressed by a suction mould without the addition of heat.
After removal from the mould the large block is sliced through to create several sheets of sound absorber board. The cutting of the large block achieves two advantages for the board. The first is that the exposed faces are flat and present a pleasing appearance. The second is that the cut faces are not over burdened with resin, which can be the case at the edges of the mould, and all cells that have a wall in the plane of the cut are opened up to ensure maximum penetration of sound into the board.
This embodiment is particularly concerned with situations where the thickness of the board is not crucial. Such applications include sound insulation 'on- false ceilings, for instance. Consequently the board can be of greater depth but less density. In the present embodiment the board has the following properties:
Flow Resistivity = 8123 Pa s m"2
Porosity = 84%
Mean Pore Radius = 4.02 x 10-m (with standard deviation) = 0.61)
Thickness = 10 mm
Tortuosity = 1.2
Density = 130 Kg/m3
The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.
All of the features disclosed in this specification (including any accompanying claims, abstract and drawings) , and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.
Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) , may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.
The invention is not restricted to the details of the foregoing embodiment (s) . The invention extend to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings) , or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

1. Sound absorbing material including a plurality of pieces connected together, each piece including pores extending at least partially into the pieces, the material also including openings extending at least partially through the material between adjacent pieces.
2. Material as claimed in Claim 1 in which the pieces comprise foam.
3. Material as claimed in Claim 2 in which the foam comprises recycled foam.
4. Material as claimed in Claim 2 or 3 in which the pieces of foam include open cells.
5. Material as claimed in any of Claims 2 to 4 in which the foam includes closed cells.
6. Material as claimed in any preceding claim in which the pieces have been taken off the closed cell-structure with closed cells having been opened.
7. Material as claimed in any of Claims 4 to 6 in which the ratio of open cells to closed cells is less than 10:1.
8. Material as claimed in any of Claims 4 to 7 in which the ratio of open cells to closed cells is more than 1:1.
9. Material as claimed in any of Claims 4 to 8 in which the ratio of open cells to closed cells is in the region of 1:3.
10. Material as claimed in any of Claims 2 to 9 in which the foam has a density of more than 25 kg/m3, before the pieces are connected together.
11. Material as claimed in any of Claims 2 to 10 in which the foam has a density of less than 150 kg/m3, before the pieces are connected together.
12. Material as claimed in Claims 10 or 11 in which the foam has a density in the region of 100 to 120 kg/m3, before the pieces are connected together.
13. Material as claimed in any preceding claim in which the pieces are connected together by adhesion.
14. Material as claimed in any preceding claim in which the material has been compressed down during manufacture by more than 25%.
15. Material as claimed in any preceding claim in which the material has been compressed down during manufacture by less than 75%.
16. Material as claimed in Claim 14 or 15 in which the material has been compressed down during manufacture by in the region of 50%.
17. Material as claimed in any preceding claim in which the porosity is less than 80%.
18. Material as claimed in any preceding claim in which the porosity is more than 20%.
19. Material as claimed in Claim 17 or 18 in which the porosity is in the region of 60%.
20. Material as claimed in any preceding claim in which, prior to consolidation, has a flow resistivity of less than 100 k Pascals x sec/m2-
21. Material as claimed in any preceding claim in which, prior to consolidation, has a flow resistivity of more than 6 k Pascals x sec/m2.
22. Material as claimed in any preceding claim having a Youngs Modulus of more than 105.
23. Material as claimed in any preceding claim having a Youngs Modulus of less than 109.
24. Material as claimed in any preceding claim in which the ratio of the space provided by the pores to the total space in the material is more than 60%.
25. Material as claimed in any preceding claim in which the ratio of the space provided by the pores to the total space in the material is in the region of 85%.
26. Material as claimed in any preceding claim in which the ratio of the space provided by the openings to the total space in the material is less than 40%.
27. Material as claimed in Claim 26 in which the ratio is in the region of 15%.
28. Material as claimed in any preceding claim in which at least one of the pores is connected to at least one of the openings .
29. Material as claimed in Claim 28 in which several pores are connected with several openings.
30. Material as claimed in any preceding claim comprising board material which is less than 50 mm thick.
31. Material as claimed in any preceding claim comprising board material that is in the region of 10 mm thick.
32. Material as claimed in Claim 30 or 31 in which the board material is self supporting.
33. Material as claimed in any preceding claim in which the tortuosity of the material is more than 1.
34. Material as claimed in any preceding claim comprising vehicle sound absorbing material.
35. Materials as claimed in any of Claims 1 to 33 comprising construction sound absorbing material.
36. A method of using sound absorbing material as claimed in any of Claims 1 to 35 comprising attaching the sound absorbing material to a vehicle.
37. A method of making sound absorbing material comprising connecting a plurality of pieces together with each piece including pores extending at least partly into the pieces, the pieces also including opening extending at least partially through the material between adjacent pieces.
38. A method as claimed in Claim 37 comprising adhering the pieces together.
39. A method as claimed in Claim 37 or 38 comprising compressing the pieces.
40. A method as claimed in any of Claims 36 to 38 comprising cutting sections of sound absorbing material from a piece of sound absorbing material such as by cutting sheets from the piece.
41. A method of absorbing sound when using sound absorbing material as herein referred to comprising sound travelling along a pore and then an opening connected to the pore.
42. A method of using sound absorbing material as herein referred to comprising sound travelling along an opening and then along a pore connected to that opening.
PCT/GB2003/000484 2002-02-14 2003-02-05 Sound absorbing material including a plurality of pieces with pores WO2003069595A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2003208393A AU2003208393A1 (en) 2002-02-14 2003-02-05 Sound absorbing material including a plurality of pieces with pores

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0203472A GB0203472D0 (en) 2002-02-14 2002-02-14 Sound absorbing material
GB0203472.6 2002-02-14

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WO2003069595A8 WO2003069595A8 (en) 2004-02-12

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Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2405818A1 (en) * 1977-10-14 1979-05-11 Sable Freres Int PVC coated polyurethane foam backed fabric for acoustic insulation - esp. for lining lorry or tractor cabs etc.
EP0588182A2 (en) * 1992-09-18 1994-03-23 M. Faist GmbH &amp; Co. KG Foam sound damping or insulating element manufacturing method thereof and its use
EP0657281A1 (en) * 1993-11-29 1995-06-14 C.A. Greiner & Söhne Gesellschaft M.B.H. Laminated building element
EP0664659A2 (en) * 1994-01-21 1995-07-26 Minnesota Mining And Manufacturing Company Perforated acoustical attenuators
EP0762382A1 (en) * 1994-05-23 1997-03-12 ZEON KASEI Co. Ltd. Panel for constituting sound insulating wall
US5744763A (en) * 1994-11-01 1998-04-28 Toyoda Gosei Co., Ltd. Soundproofing insulator
US6228478B1 (en) * 1994-05-03 2001-05-08 Stankiewicz Gmbh Method of manufacturing a composite foam from foam flakes, composite foam, and use of this composite foam
WO2002015168A1 (en) * 2000-08-15 2002-02-21 Ventures & Consultancy Bradford Limited Sound absorbing material

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2405818A1 (en) * 1977-10-14 1979-05-11 Sable Freres Int PVC coated polyurethane foam backed fabric for acoustic insulation - esp. for lining lorry or tractor cabs etc.
EP0588182A2 (en) * 1992-09-18 1994-03-23 M. Faist GmbH &amp; Co. KG Foam sound damping or insulating element manufacturing method thereof and its use
EP0657281A1 (en) * 1993-11-29 1995-06-14 C.A. Greiner & Söhne Gesellschaft M.B.H. Laminated building element
EP0664659A2 (en) * 1994-01-21 1995-07-26 Minnesota Mining And Manufacturing Company Perforated acoustical attenuators
US6228478B1 (en) * 1994-05-03 2001-05-08 Stankiewicz Gmbh Method of manufacturing a composite foam from foam flakes, composite foam, and use of this composite foam
EP0762382A1 (en) * 1994-05-23 1997-03-12 ZEON KASEI Co. Ltd. Panel for constituting sound insulating wall
US5744763A (en) * 1994-11-01 1998-04-28 Toyoda Gosei Co., Ltd. Soundproofing insulator
WO2002015168A1 (en) * 2000-08-15 2002-02-21 Ventures & Consultancy Bradford Limited Sound absorbing material

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WO2003069595A8 (en) 2004-02-12
GB0203472D0 (en) 2002-04-03
AU2003208393A1 (en) 2003-09-04

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