Porous composite material for sound absorption and method of producing same

Patent metadata

Field	Value
Publication number	US-12570817-B2
Application number	US-202017622358-A
Country	US
Kind code	B2
Filing date	Aug 4, 2020
Priority date	Aug 5, 2019
Publication date	Mar 10, 2026
Grant date	Mar 10, 2026

Abstract

A porous composite material ( 50 ) for sound absorption and a method ( 10 ) of producing the porous composite material ( 50 ) are provided. The method ( 10 ) includes preparing ( 12 ) a mixture of mechano-electrical conversion elements ( 56 ) and electro-thermal conversion elements ( 58 ) in an organic solvent. The mixture of the mechano-electrical conversion elements ( 56 ) and the electro-thermal conversion elements ( 58 ) in the organic solvent is mixed ( 14 ) with an aqueous solvent to precipitate a piezoelectric hybrid filler material ( 54 ). The piezoelectric hybrid filler material ( 54 ) is mixed ( 16 ) with a precursor. A foaming operation is performed ( 18 ) with the precursor to produce the porous composite material ( 50 ).

First claim

The invention claimed is:

1 . A method of producing a porous composite material for sound absorption, comprising:
preparing a mixture of mechano-electrical conversion elements and electro-thermal conversion elements in an organic solvent; mixing the mixture of the mechano-electrical conversion elements and the electro-thermal conversion elements in the organic solvent with an aqueous solvent to precipitate a piezoelectric hybrid filler material; mixing 1 to 10 wt. % of the piezoelectric hybrid filler material based upon the total weight of the porous composite material with a precursor; and performing a foaming operation with the precursor to produce the porous composite material.

2 . The method of claim 1 , wherein the step of preparing the mixture of the mechano-electrical conversion elements and the electro-thermal conversion elements in the organic solvent comprises:
dissolving the mechano-electrical conversion elements in the organic solvent; and dispersing the electro-thermal conversion elements in the organic solvent.

3 . The method of claim 1 , wherein the mechano-electrical conversion elements comprise one of a piezoelectric polymer and a polymeric electret.

4 . The method of claim 3 , wherein the piezoelectric polymer is selected from a group consisting of polyvinylidene fluoride (PVDF), poly (vinylidene fluoride-trifluoroethylene) (PVDF-TrFE) and poly (vinylidene fluoride-hexafluoropropylene) (PVDF-HFP).

5 . The method of claim 3 , wherein the polymeric electret is selected from a group consisting of polyimide, polypropylene, polyethylene terephthalate (PET), polytetrafluoroethylene, polymethylmethacrylate, and ethylene vinyl acetate cyclic olefin copolymers.

6 . The method of claim 1 , wherein the electro-thermal conversion elements comprise one of electrically conductive elements and dielectric lossy elements.

7 . The method of claim 6 , wherein the electrically conductive elements are selected from a group consisting of single-walled carbon nanotubes (SWCNT), multi-walled carbon nanotubes (MWCNT), graphene and carbon black.

8 . The method of claim 6 , wherein the dielectric lossy elements are selected from a group consisting of aluminium nitrate nonahydrate, aluminium chloride hexahydrate (AlCl 3 .6H 2 O), tetra-n-butylammonium chloride and ammonium acetate.

9 . The method of claim 8 , wherein the piezoelectric hybrid filler material comprises between about 10 percent by mass (wt %) and about 50 wt. % of the dielectric lossy elements.

10 . The method of claim 1 , wherein the foaming operation comprises one of a physical foam extrusion process, a chemical foam extrusion process and a chemical foam expanding process.

11 . The method of claim 1 , wherein the step of mixing the piezoelectric hybrid filler material with the precursor comprises:
mixing between about 1 wt. % and about 10 wt. % of the piezoelectric hybrid filler material and between about 90 wt. % and about 98 wt. % of the precursor, based upon the total weight of the porous composite material wherein the precursor is a thermoplastic polymer.

12 . The method of claim 11 , further comprising mixing between about 1% by mass and about 10% by mass of a foaming agent with the piezoelectric hybrid filler material and the precursor.

13 . The method of claim 11 , wherein the thermoplastic polymer is selected from a group consisting of poly (methyl methacrylate) (PMMA), polyamide (PA), polycarbonate (PC), polyester (PES), polyethylene (PE), polyethylene terephthalate (PET), polypropylene (PP), polystyrene (PS), polyurethane (PU), polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), poly (lactic acid) (PLA), polybenzimidazole (PBI), polyoxymethylene (POM), polyether ether ketone (PEEK), polyetherimide (PEI), polyphenylene oxide (PPO), polyphenylene sulfide (PPS), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE) and acrylonitrile butadiene styrene (ABS).

14 . The method of claim 1 , wherein the step of mixing the piezoelectric hybrid filler material with the precursor comprises:
mixing between about 1 part and about 10 parts by weight of the piezoelectric hybrid filler material with between about 50 parts and about 100 parts by weight of the precursor and between about 1 part and about 2.5 parts by weight of fire-retardant agent to form a set of reagents.

15 . The method of claim 14 , wherein the step of performing the foaming operation comprises:
reacting the set of reagents with about 25 parts of the precursor.

16 . The method of claim 14 , wherein the precursor comprises one of polyurethane (PU), silicone and latex.

17 . A porous composite material for sound absorption, comprising:
a porous polymer matrix; and a piezoelectric hybrid filler dispersed in the porous polymer matrix, wherein the piezoelectric hybrid filler comprises a homogenous mixture of mechano-electrical conversion elements and electro-thermal conversion elements; wherein the porous composite material comprises 1-10 wt. % of the piezoelectric hybrid filler based on the total weight of the composite material.

18 . The porous composite material of claim 17 , wherein the porous polymer matrix comprises at least one of the group consisting of polyurethane (PU), silicone, latex, and a thermoplastic polymer.

19 . The porous composite material of claim 18 , wherein the thermoplastic polymer is selected from the group consisting of poly (methyl methacrylate) (PMMA), polyamide (PA), polycarbonate (PC), polyester (PES), polyethylene (PE), polyethylene terephthalate (PET), polypropylene (PP), polystyrene (PS), polyurethane (PU), polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), poly (lactic acid) (PLA), polybenzimidazole (PBI), polyoxymethylene (POM), polyether ether ketone (PEEK), polyetherimide (PEI), polyphenylene oxide (PPO), polyphenylene sulfide (PPS), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE) and acrylonitrile butadiene styrene (ABS).

20 . The porous composite material of claim 17 , wherein the mechano-electrical conversion elements comprise one of a piezoelectric polymer and a polymeric electret.

21 . The porous composite material of claim 20 , wherein the piezoelectric polymer is selected from the group consisting of polyvinylidene fluoride (PVDF), poly (vinylidene fluoride-trifluoroethylene) (PVDF-TrFE) and poly (vinylidene fluoride-hexafluoropropylene) (PVDF-HFP).

22 . The porous composite material of claim 20 , wherein the polymeric electret is selected from the group consisting of polyimide, polypropylene, polyethylene terephthalate (PET), polytetrafluoroethylene, polymethylmethacrylate, and ethylene vinyl acetate cyclic olefin copolymers.

23 . The porous composite material of claim 17 , wherein the electro-thermal conversion elements comprise one of electrically conductive elements and dielectric lossy elements.

24 . The porous composite material of claim 23 , wherein the electrically conductive elements are selected from the group consisting of single-walled carbon nanotubes (SWCNT), multi-walled carbon nanotubes (MWCNT), graphene and carbon black.

25 . The porous composite material of claim 23 , wherein the dielectric lossy elements are selected from the group consisting of aluminium nitrate nonahydrate, aluminium chloride hexahydrate (AlCl 3 .6H 2 O), tetra-n-butylammonium chloride and ammonium acetate.

26 . The porous composite material of claim 25 , where

Assignees

• Agency Science Tech & Res

Inventors

• Yan Hong
• Yao Kui
• Chen Shuting
• Lim Poh Chong

Classifications

• C08L75/04

  Polyurethanes · CPC title

• G10K11/165

  Particles in a matrix · CPC title

• C08L83/04

  Polysiloxanes · CPC title

• C08J2479/08

  Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors · CPC title

• C08J2427/16

  Homopolymers or copolymers of vinylidene fluoride · CPC title