WO2002032639A2 - Materials which have sound absorbing properties - Google Patents

Materials which have sound absorbing properties Download PDF

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Publication number
WO2002032639A2
WO2002032639A2 PCT/ZA2001/000073 ZA0100073W WO0232639A2 WO 2002032639 A2 WO2002032639 A2 WO 2002032639A2 ZA 0100073 W ZA0100073 W ZA 0100073W WO 0232639 A2 WO0232639 A2 WO 0232639A2
Authority
WO
WIPO (PCT)
Prior art keywords
fibres
melting point
acoustically
anechoic
mould
Prior art date
Application number
PCT/ZA2001/000073
Other languages
French (fr)
Other versions
WO2002032639A3 (en
Inventor
Dunstan Walter Runciman
Original Assignee
Dunstan Walter Runciman
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 Dunstan Walter Runciman filed Critical Dunstan Walter Runciman
Priority to AU2002232966A priority Critical patent/AU2002232966A1/en
Publication of WO2002032639A2 publication Critical patent/WO2002032639A2/en
Publication of WO2002032639A3 publication Critical patent/WO2002032639A3/en

Links

Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/542—Adhesive fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/002—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor characterised by the choice of material
    • B29C51/004—Textile or other fibrous material made from plastics fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4242—Carbon fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/542—Adhesive fibres
    • D04H1/55—Polyesters
    • 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
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/82—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to sound only
    • E04B1/84—Sound-absorbing elements
    • E04B2001/8414—Sound-absorbing elements with non-planar face, e.g. curved, egg-crate shaped
    • E04B2001/8419—Acoustical cones or the like, e.g. for anechoic chambers

Definitions

  • THIS INVENTION relates to materials which have sound absorbing
  • Open-cell foamed synthetic plastics material is possibly the most
  • the elements are shaped, and/or their density varies, so as
  • Carbon or another electrically conductive material excludes emissions of a background nature. Carbon or another electrically conductive material
  • the cage is lined with of this material.
  • the conductive material creates the multiplicity of electrical flow paths that are required to absorb radio frequency signals Such a material
  • the main object of the present invention is to provide a new acoustically
  • a subsidiary object is to provide a new acoustically anechoic material
  • the method can include the step of dispersing electrically conductive fibres in
  • Said fibres are preferably carbon fibres, and can be carbon fibres with a metallic coating
  • Bonding can be achieved by means of an adhesive
  • acoustically anechoic element which comprises a compressed mass of fibres of a synthetic
  • At least the surfaces of the fibres are of heat weldable material
  • the mass includes fibres of a higher melting point mixed with fibres of a lower melting point, the lower melting point fibres bonding the higher melting point fibres together.
  • fibres are bonded to one another by an adhesive.
  • Electrically conductive fibres can be dispersed in the synthetic plastic material
  • fibres to obtain an element which absorbs RF signals.
  • said fibres are carbon
  • fibres which can have a metallic coating.
  • Said metallic coating can be of nickel.
  • the conductive fibres are evenly dispersed in the plastics fibres but
  • Fibres of materials such as polyester are widely available commercially.
  • Solid fibres are available as also are hollow fibres. This latter form of fibre is often referred to
  • monofilament or coarse spun referred to as monofilament or coarse spun.
  • Coarse spun fibres are of composite construction and have a core and a
  • the coating melts at
  • a monofilament is of unitary construction and is
  • thermally insulating sheets form thermally insulating sheets, padding for upholstered furniture etc can be used.
  • moulds can be used. These can be heated in an electrical oven at a temperature such that
  • the moulds are not damaged but adequate fibre bonding is achieved.
  • the mould can be shaped to produce cones, wedges, blocks or panels
  • a product comprising a carbon fibre core with a nickel coating which is
  • nickel coated carbon fibre has the further
  • polyester is available in grades which will melt at temperatures of 130°C
  • low melting point fibres can be softened and whilst the high melting point fibres remain
  • the adhesive can be heat activated after being sprayed on the fibres.
  • the adhesive can be solvent based, the solvent being driven off, or allowed to

Abstract

The invention provides an anechoic material which comprises a compressed mass of synthetic plastic material fibres. At least the surfaces of the fibres are of weldable synthetic plastics material. The fibres are welded together where they touch by the application of heat to a mould in which they are compressed. The material may comprise electrically conductive fibres to absorb radio frequency (RF) emissions or signals. The conductive fibres are carbon fibres with a metallic coating of nickel.

Description

MATERIALS WHICH HAVE SOUND ABSORBING PROPERTIES
FIELD OF THE INVENTION
THIS INVENTION relates to materials which have sound absorbing
properties. It also relates to materials which additionally block RF emissions.
BACKGROUND TO THE INVENTION
Many forms of equipment need to be tested in acoustically anechoic
chambers. The conventional way of creating such a chamber is to line all the bounding
walls of a room with cone shaped or wedge shaped elements. A variety of materials are
used for this purpose. Open-cell foamed synthetic plastics material is possibly the most
widely used material. The elements are shaped, and/or their density varies, so as
progressively to change the impedance from that of air to that of the walls without creating reflections.
It is also desirable to be able to test some equipment in an environment
which is free of radio frequency (RF) emissions and reflections. This is conventionally
achieved by lining a room with sheet metal panels thereby to create a Faraday cage which
excludes emissions of a background nature. Carbon or another electrically conductive
material usually in powdered form is mixed into foamed synthetic plastics material and the
cage is lined with of this material. The conductive material creates the multiplicity of electrical flow paths that are required to absorb radio frequency signals Such a material,
however, has two major problems Firstly, the open-cell foam required is expensive and
secondly the quantity of carbon or other conductive powder that must be used to be
effective in absorbing RF emissions is such that the mechanical strength of the foam is
impaired
The main object of the present invention is to provide a new acoustically
anechoic material A subsidiary object is to provide a new acoustically anechoic material
which also absorbs RF signals
BRIEF DESCRIPTION OF THE INVENTION
According to a first aspect of the present invention there is provided a method
of manufacturing an acoustically anechoic material which comprises compressing a mass
of synthetic plastics material fibres into a mould, and bonding the fibres to one another
where they are touching
According to a second aspect of the present invention there is provided a
method of manufacturing an acoustically anechoic material which comprises compressing
a mass of synthetic plastics material fibres into a mould, at least the surfaces of the fibres
being of a material which welds to itself when heated, and heating the mould to a
temperature at which the surfaces of the fibres soften and fibres are welded together
where they are touching According to a third aspect of the present invention there is provided a
method of manufacturing an acoustically anechoic material which comprises compressing
a mass of synthetic plastics material fibres into a mould, the fibres being a mixture of
higher melting point fibres and lower melting point fibres and heating the mass of fibres to a
temperature between said melting points so as to cause the lower melting point fibres to
melt and bond the higher melting point fibres together
The method can include the step of dispersing electrically conductive fibres in
the synthetic plastics material fibres before the mixed fibres are compressed into the mould
thereby to provide an acoustically anechoic material which also absorbs RF signals
Said fibres are preferably carbon fibres, and can be carbon fibres with a metallic coating
Bonding can be achieved by means of an adhesive
According to a fourth aspect of the present invention there is provided an
acoustically anechoic element which comprises a compressed mass of fibres of a synthetic
plastics material, the fibres being bonded to one another where they touch
In one form at least the surfaces of the fibres are of heat weldable material,
the fibres in the mass being heat welded to one another where they touch In another form
the mass includes fibres of a higher melting point mixed with fibres of a lower melting point, the lower melting point fibres bonding the higher melting point fibres together. In yet
another form said fibres are bonded to one another by an adhesive.
Electrically conductive fibres can be dispersed in the synthetic plastic material
fibres to obtain an element which absorbs RF signals. Preferably said fibres are carbon
fibres which can have a metallic coating. Said metallic coating can be of nickel.
Preferably the conductive fibres are evenly dispersed in the plastics fibres but
there can be circumstances where distribution of the conductive fibres in strata is desirable to create zones of varying conductive fibre concentration.
DETAILED DESCRIPTION OF THE INVENTION
Fibres of materials such as polyester are widely available commercially.
Solid fibres are available as also are hollow fibres. This latter form of fibre is often referred
to as "Hollowfil" and is used in pillows, duvets etc. The solid fibres available are usually
referred to as monofilament or coarse spun.
Coarse spun fibres are of composite construction and have a core and a
coating on the core, the core and coating being of different materials. The coating melts at
a lower temperature than the core. A monofilament is of unitary construction and is
composed of a single material. To achieve the requisite bonding the nature of the fibre
must be such that its surface softens when heated and will then weld to another fibre at a zone where the two fibres are touching. The types of fibre which are packed in layers to
form thermally insulating sheets, padding for upholstered furniture etc can be used.
A mould is filled with fibres having the described characteristics and the fibres
are compressed into the mould until the desired density is achieved. The mould is then
heated. In Applicant's experimental work it has been found that the temperatures which
must be achieved to bond the fibres into the form of a block are such that simple wooden
moulds can be used. These can be heated in an electrical oven at a temperature such that
the moulds are not damaged but adequate fibre bonding is achieved.
The mould can be shaped to produce cones, wedges, blocks or panels
depending on the intended use of the final product.
The product resulting from the method of production described has sound
absorbing qualities which suit it for Use in acoustical anechoic chambers and other places
where sound absorption is required. However, it has no ability to absorb RF signals. By
mixing electrically conductive fibres such as stainless steel or carbon into the synthetic
plastics material fibres before moulding, RF absorbing properties are achieved.
A product comprising a carbon fibre core with a nickel coating which is
applied by chemical vapour deposition is available commercially. Such fibres have
properties which suit them for use mixed with synthetic plastics materials to produce RF emission absorbing material. The use of nickel coated carbon fibre has the further
advantage that it also has magnetic properties not displayed by uncoated carbon fibres.
It is also possible to mix fibres which have different melting points, and then
compress the mixed fibres into a mould. A mixture of 60% by mass high melting point
fibres and 40% by mass of low melting point fibres has been found to be suitable. As a
specific example, polyester is available in grades which will melt at temperatures of 130°C
and 160°C. By heating the mould to a temperature between these two temperatures the
low melting point fibres can be softened and whilst the high melting point fibres remain
unaffected. It is the low melting point fibres which bond the high melting point fibres together to give the block its structural integrity.
It is also possible to use adhesives to bond the compressed fibres into the
form of a block. The adhesive can be heat activated after being sprayed on the fibres.
Alternatively the adhesive can be solvent based, the solvent being driven off, or allowed to
evaporate off, so as to bond the fibres. Adhesives that cure as a result of catalytic action
can also be used. These are applied before the fibres are compressed into the mould, and
then set as the components in the adhesive react.

Claims

CLAIMS:
1 . A method of manufacturing an acoustically anechoic material which
comprises compressing a mass of synthetic plastics material fibres into a mould, and
bonding the fibres to one another where they are touching.
2. A method of manufacturing an acoustically anechoic material which
comprises compressing a mass of synthetic plastics material fibres into a mould, at least
the surfaces of the fibres being of a material which welds to itself when heated, and
heating the mould to a temperature at which the surfaces of the fibres soften and fibres are
welded together where they are touching.
3. A method of manufacturing an acoustically anechoic material which
comprises compressing a mass of synthetic plastics material fibres into a mould, the fibres
being a mixture of higher melting point fibres and lower melting point fibres and heating the
mass of fibres to a temperature between said melting points so as to cause the lower
melting point fibres to melt and bond the higher melting point fibres together.
4. A method as claimed in claim 1 , 2 or 3 and including dispersing electrically
conductive fibres in the synthetic plastics material fibres before the mixed fibres are
compressed into the mould thereby to provide an acoustically anechoic material which also
absorbs RF signals.
5. A method as claimed in claim 4, wherein said fibres are carbon fibres.
6. A method as claimed in claim 5, wherein said carbon fibres have a metallic
coating.
7. A method as claimed in claim 1 , wherein said fibres are bonded to one
another by an adhesive.
8. An acoustically anechoic element which comprises a compressed mass of
fibres of a synthetic plastics material, the fibres being bonded to one another where they touch.
9. An element as claimed in claim 8, in which at least the surfaces of the fibres
are of heat weldable material, the fibres in the mass being heat welded to one another where they touch.
10. An element as claimed in claim 8, and including fibres of a higher melting
point mixed with fibres of a lower melting point, the lower melting point fibres bonding the
higher melting point fibres together.
1 1. An element as claimed in claim 8, wherein said fibres are bonded to one
another by an adhesive.
12. An element as claimed in claim 8, 9, 10 or 1 1 and including electrically
conductive fibres dispersed in the synthetic plastic material fibres.
13. An element as claimed in claim 12, wherein said fibres are carbon fibres.
14. An element as claimed in claim 13, wherein said carbon fibres have a metallic
coating.
15. An element as claimed in claim 14, wherein said metallic coating is of nickel.
16. A method of manufacturing an acoustically anechoic material substantially as hereinbefore described.
17. An acoustically anechoic material substantially as hereinbefore described.
PCT/ZA2001/000073 2000-06-05 2001-06-05 Materials which have sound absorbing properties WO2002032639A2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2002232966A AU2002232966A1 (en) 2000-06-05 2001-06-05 Materials which have sound absorbing properties

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ZA2000/2785 2000-06-05
ZA200002785 2000-06-05

Publications (2)

Publication Number Publication Date
WO2002032639A2 true WO2002032639A2 (en) 2002-04-25
WO2002032639A3 WO2002032639A3 (en) 2003-04-03

Family

ID=25588775

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/ZA2001/000073 WO2002032639A2 (en) 2000-06-05 2001-06-05 Materials which have sound absorbing properties

Country Status (2)

Country Link
AU (1) AU2002232966A1 (en)
WO (1) WO2002032639A2 (en)

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB871117A (en) * 1957-10-12 1961-06-21 Carl Freudenberg Kommandit Ges Improvements in or relating to the production of mouldings containing synthetic materials
US4420526A (en) * 1980-10-21 1983-12-13 Firma Carl Freudenberg Sound absorbing irregularly shaped panel
EP0323826A1 (en) * 1988-01-05 1989-07-12 Nec Corporation Electromagnetic wave absorber
US5047453A (en) * 1984-05-04 1991-09-10 Hoechst Aktiengesellschaft Process for preparing moldings by compacting and simultaneously bonding fibrous material
WO1997000989A1 (en) * 1995-06-23 1997-01-09 Minnesota Mining And Manufacturing Company Method of attenuating sound, and acoustical insulation therefor
US5657386A (en) * 1995-09-06 1997-08-12 Schwanke; Jurgen H. Electromagnetic shield for cellular telephone
US5677027A (en) * 1995-01-13 1997-10-14 Nissan Motor Co., Ltd. Sound insulating structure
EP0963964A1 (en) * 1997-02-27 1999-12-15 Osaka Gas Company Limited Sound absorbing and heat insulating material, and method of manufacturing same
WO2001031131A1 (en) * 1999-10-29 2001-05-03 Owens Corning Fibrous acoustical insulation product

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB871117A (en) * 1957-10-12 1961-06-21 Carl Freudenberg Kommandit Ges Improvements in or relating to the production of mouldings containing synthetic materials
US4420526A (en) * 1980-10-21 1983-12-13 Firma Carl Freudenberg Sound absorbing irregularly shaped panel
US5047453A (en) * 1984-05-04 1991-09-10 Hoechst Aktiengesellschaft Process for preparing moldings by compacting and simultaneously bonding fibrous material
EP0323826A1 (en) * 1988-01-05 1989-07-12 Nec Corporation Electromagnetic wave absorber
US5677027A (en) * 1995-01-13 1997-10-14 Nissan Motor Co., Ltd. Sound insulating structure
WO1997000989A1 (en) * 1995-06-23 1997-01-09 Minnesota Mining And Manufacturing Company Method of attenuating sound, and acoustical insulation therefor
US5657386A (en) * 1995-09-06 1997-08-12 Schwanke; Jurgen H. Electromagnetic shield for cellular telephone
EP0963964A1 (en) * 1997-02-27 1999-12-15 Osaka Gas Company Limited Sound absorbing and heat insulating material, and method of manufacturing same
WO2001031131A1 (en) * 1999-10-29 2001-05-03 Owens Corning Fibrous acoustical insulation product

Also Published As

Publication number Publication date
WO2002032639A3 (en) 2003-04-03
AU2002232966A1 (en) 2002-04-29

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