Acoustic articles and methods thereof

Patent metadata

Field	Value
Publication number	US-12198667-B2
Application number	US-202017602649-A
Country	US
Kind code	B2
Filing date	Apr 13, 2020
Priority date	Apr 25, 2019
Publication date	Jan 14, 2025
Grant date	Jan 14, 2025

Abstract

Provided are acoustic articles, and related methods, that include a porous layer and heterogeneous filler received in the porous layer. The heterogeneous filler can include clay, diatomaceous earth, graphite, glass bubbles, polymeric filler, non-layered silicate, plant-based filler, or a combination thereof, and can have a median particle size of from 1 micrometer to 1000 micrometers and a specific surface area of from 0.1 m 2 /g to 800 m 2 /g. The acoustic article can have an overall flow resistance of from 100 MKS Rayls to 8000 MKS Rayls. The acoustic articles can serve as acoustic absorbers, vibration dampers, and/or acoustic and thermal insulators.

First claim

What is claimed is:

1. An acoustic article comprising:
a porous layer that is a melt-blown non-woven fibrous layer having a plurality of fibers having a median fiber diameter of from 0.1 micrometers to 10 micrometers, wherein the porous article has an overall thickness of from 1 millimeter to 100 millimeters; and
heterogeneous filler received in the porous layer, wherein the heterogeneous filler has a median particle size of from 1 micrometer to 100 micrometers and a specific surface area of from 0.1 m 2 /g to 100 m 2 /g,
wherein the heterogeneous filler comprises particles dispersed within the fibers of the non-woven fibrous layer and substantially decoupled from each other within the fibers of the non-woven fibrous layer, and
wherein the acoustic article has a flow resistance of from 100 MKS Rayls to 8000 MKS Rayls.

2. An acoustic article comprising:
a porous layer that is a melt-blown non-woven fibrous layer having a plurality of fibers having a median fiber diameter of from 0.1 micrometers to 10 micrometers, wherein the porous article has an overall thickness of from 1 millimeter to 100 millimeters; and
heterogeneous filler received in the porous layer, wherein the heterogeneous filler has a median particle size of from 100 micrometers to 800 micrometers and a specific surface area of from 100 m 2 /g to 800 m 2 /g,
wherein the heterogeneous filler comprises particles dispersed within the fibers of the non-woven fibrous layer and substantially decoupled from each other within the fibers of the non-woven fibrous layer, and
wherein the acoustic article has a flow resistance of from 100 MKS Rayls to 8000 MKS Rayls.

3. An acoustic article comprising:
a porous layer that is a melt-blown non-woven fibrous layer having a plurality of fibers having a median fiber diameter of from 0.1 micrometers to 10 micrometers, wherein the porous article has an overall thickness of from 1 millimeter to 100 millimeters; and
heterogeneous filler received in the porous layer, wherein the heterogeneous filler has a median particle size of from 100 micrometers to 1000 micrometers and a specific surface area of from 1 m 2 /g to 100 m 2 /g,
wherein the heterogeneous filler comprises particles dispersed within the fibers of the non-woven fibrous layer and substantially decoupled from each other within the fibers of the non-woven fibrous layer, and
wherein the acoustic article has a flow resistance of from 100 MKS Rayls to 8000 MKS Rayls.

4. The acoustic article of claim 1 , wherein the heterogeneous filler comprises a non-layered silicate, and wherein the non-layered silicate is an alkali silicate, alkaline earth silicate, non-zeolitic aluminosilicate, or geopolymer.

5. The acoustic article of claim 1 , wherein the heterogeneous filler comprises graphite, and wherein the graphite is unexpanded graphite.

6. The acoustic article of claim 1 , wherein the heterogeneous filler comprises a porous polymer filler, and wherein the porous polymer filler comprises a polyolefin foam, polyvinylpyrrolidone, divinylbenzene, divinylbenzene-maleic anhydride, styrene-divinylbenzene or polyacrylate.

7. The acoustic article of claim 1 , wherein the heterogeneous filler is agglomerated.

8. The acoustic article of claim 1 , wherein the heterogeneous filler has a Dv50/Dv90 particle size ratio of from 0.25 to 1.

9. The acoustic article of claim 2 , wherein the heterogeneous filler comprises a non-layered silicate, and wherein the non-layered silicate is an alkali silicate, alkaline earth silicate, non-zeolitic aluminosilicate, or geopolymer.

10. The acoustic article of claim 3 , wherein the heterogeneous filler comprises a non-layered silicate, and wherein the non-layered silicate is an alkali silicate, alkaline earth silicate, non-zeolitic aluminosilicate, or geopolymer.

11. The acoustic article of claim 1 , wherein the heterogeneous filler has an average interparticle spacing of from 100 micrometers to 1000 micrometers.

12. The acoustic article of claim 1 , wherein the porous layer filled with the heterogeneous has a solidity of from 10 percent to 30 percent.

13. The acoustic article of claim 1 , wherein the heterogeneous filler has an open-cell structure.

14. The acoustic article of claim 2 , wherein the heterogeneous filler has an average interparticle spacing of from 100 micrometers to 1000 micrometers.

15. The acoustic article of claim 2 , wherein the porous layer filled with the heterogeneous has a solidity of from 10 percent to 30 percent.

16. The acoustic article of claim 2 , wherein the heterogeneous filler has an open-cell structure.

17. The acoustic article of claim 3 , wherein the heterogeneous filler has an average interparticle spacing of from 100 micrometers to 1000 micrometers.

18. The acoustic article of claim 3 , wherein the porous layer filled with the heterogeneous has a solidity of from 10 percent to 30 percent.

19. The acoustic article of claim 3 , wherein the heterogeneous filler has an open-cell structure.

Assignees

• 3M Innovative Properties Company
• 3M Innovative Properties Compnay

Inventors

• Mok Michelle M
• Berrigan Michael R
• Petkovich Nicole D
• Alexander Jonathan H
• Wendland Michael S
• Lee Seungkyu
• Sahouani Hassan

Classifications

• G10K11/168

  Plural layers of different materials, e.g. sandwiches · CPC title

• D06M23/08

  Processes in which the treating agent is applied in powder or granular form (adhesives for multi-layer textile fabrics D06M17/00) · CPC title

• D06M15/227

  of hydrocarbons, or reaction products thereof, e.g. afterhalogenated or sulfochlorinated · CPC title

• D06M15/01

  with natural macromolecular compounds or derivatives thereof (with natural rubber or derivatives thereof D06M15/693) · CPC title

• D06M11/77 Primary

  with silicon or compounds thereof (with silanes or disilanes D06M11/01) · CPC title