3D printing porous hollow sound-absorbing material

Abstract

This invention relates to the field of architectural acoustics and discloses a 3D-printed porous, hollowed-out sound-absorbing material, including extruded materials, linear materials, granular materials, powder-layer nozzle 3D-printed materials, laminated materials, and photopolymerized materials. Extruded materials mainly include thermoplastics, eutectic metals, and edible materials; linear materials include stainless steel and aluminum alloys; powder-layer nozzle 3D-printed materials include gypsum; laminated materials include paper, metal films, and plastic films; and photopolymerized materials include photocurable resins. This invention allows for the selection of different materials and processing models according to customer needs and acoustic design schemes, producing sound-absorbing materials with different properties and acoustic parameters, thereby meeting various acoustic requirements and solving various acoustic problems.

Description

Technical Field

[0001] This invention relates to the field of architectural acoustics, and more particularly to a 3D-printed porous hollow sound-absorbing material. Background Technology

[0002] Sound-absorbing materials on the market include: fiberglass boards (bonded with resin adhesive, not environmentally friendly, and prone to dust pollution during processing and use); mineral wool sound-absorbing boards and rock wool sound-absorbing boards (using adhesives, not environmentally friendly, and prone to dust pollution during processing and use); wood sound-absorbing boards (using MDF, plywood, and other wood, and also using glue in the veneer process, not environmentally friendly and not fireproof); upholstered fabric boards (using sponge and fabric, not fireproof); aluminum perforated honeycomb panels (aluminum honeycomb panels also use glue bonding, not environmentally friendly, with a simple perforated and honeycomb core structure, low and limited sound absorption parameters and data, and a limited range of applications); and sandstone sound-absorbing boards (made from sand and gravel, bonded and extruded with glue, heavy and not environmentally friendly).

[0003] Current drawbacks in the industry: 1. The materials are bulky, making them prone to overloading when hoisted in large public places; 2. Some fabric and wood sound-absorbing materials are not fireproof; 3. Most current acoustic materials are difficult to modify by changing their own structure to change their acoustic parameters, leading to numerous difficulties in application; 4. Most acoustic materials can only be used indoors, and there are no suitable acoustic materials for outdoor or special harsh environments; 5. All acoustic materials have a single method of use and cannot be adapted to different usage environments; 6. All of the above acoustic materials require multiple processes during processing, and even a large amount of adhesives are used, resulting in a decline in environmental performance. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of existing technologies and propose a 3D printed porous hollow sound-absorbing material.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a 3D-printed porous hollow sound-absorbing material, comprising extruded materials, linear materials, granular materials, powder-layer nozzle 3D-printed materials, laminated materials, and photopolymerized materials. The extruded materials mainly include thermoplastics, eutectic system metals, and edible materials; the linear materials include stainless steel and aluminum alloys; the powder-layer nozzle 3D-printed materials include gypsum; the laminated materials include paper, metal films, and plastic films; and the photopolymerized materials include photocurable resins.

[0006] As a further description of the above technical solution:

[0007] The extrusion-type material is 3D printed using fused deposition modeling.

[0008] As a further description of the above technical solution:

[0009] The linear material is manufactured using electron beam freeform 3D printing.

[0010] As a further description of the above technical solution:

[0011] The granular material is used in 3D printing via one of the following methods: direct metal laser sintering, electron beam melting, selective laser melting, selective thermal sintering, and selective laser sintering. Direct metal laser sintering uses alloy materials for granular 3D printing; electron beam melting uses titanium alloys; selective laser melting uses one of titanium alloys, cobalt-chromium alloys, stainless steel, and aluminum; selective thermal sintering uses thermoplastic powders; and selective laser sintering uses one of thermoplastic plastics, metal powders, and ceramic powders.

[0012] As a further description of the above technical solution:

[0013] The powder layer nozzle 3D printing type material uses plaster 3D printing for 3D printing.

[0014] As a further description of the above technical solution:

[0015] The laminated material is manufactured using a layered solid structure in 3D printing.

[0016] As a further description of the above technical solution:

[0017] The photopolymer material is one of the three methods used in 3D printing: stereolithography and digital light processing.

[0018] A modeling method for 3D printed porous sound absorbers includes the following steps:

[0019] B1: Determine the sound absorption parameters and appearance based on the architectural acoustic drawings;

[0020] B2: Input the sound absorption parameters into the acoustic calculation software, and use the acoustic calculation software for building materials to determine the pore spacing, structural diameter, pore ratio, material thickness, size, and structural shape of the sound absorption material;

[0021] B3: Based on the desired appearance, use professional 3D software to design and model the product, and determine the product manufacturing plan.

[0022] A method for preparing a 3D-printed porous hollow sound-absorbing material includes the following steps:

[0023] S1: Take out the required raw materials in a certain proportion for later use;

[0024] S2: Add the removed raw materials to the mixer and mix them together for 45-60 minutes.

[0025] S3: Load the mixed raw materials into the storage tank.

[0026] A method for printing a porous, hollowed-out sound-absorbing material using 3D printing includes the following steps:

[0027] A1: Choose different 3D printing materials based on the application environment;

[0028] A2: Prepare by mixing the selected materials;

[0029] A3: Then, depending on the type of 3D printing, different accumulation techniques should be selected;

[0030] A4: Place the embedded parts on the worktable before 3D printing;

[0031] A5: Select different 3D printing equipment based on different accumulation technologies, and use the 3D printing equipment to print the required sound-absorbing materials;

[0032] A6: The printed sound-absorbing material then undergoes surface treatment: such as mechanical treatment, chemical treatment, electrochemical treatment, hardening treatment and other surface treatment methods. The appropriate surface treatment method is selected according to different materials and design requirements.

[0033] The present invention has the following beneficial effects:

[0034] Compared to existing technologies, this 3D-printed porous sound-absorbing material allows for arbitrary changes in pore spacing, structural diameter, pore ratio, material thickness, size, and structural shape to achieve different sound absorption effects through 3D printing equipment. It is not limited by the application environment; for example, the addition of stainless steel and titanium alloys allows it to be used in various harsh environments, such as swimming pools, outdoor and semi-outdoor environments. The 3D-printed sound absorber is semi-transparent due to its porous structure, allowing it to be combined with lighting to create an integrated sound and light environment. The use of a single environmentally friendly material, combined with environmentally friendly 3D printing technology, makes the product more environmentally friendly. There is no material waste during processing, thus increasing material utilization and reducing costs. Installation accessories can be printed integrally with the acoustic material, saving on installation and assembly labor costs. Detailed Implementation

[0035] This invention provides a 3D-printed porous sound-absorbing material, comprising extruded materials, linear materials, granular materials, powder-layer nozzle 3D-printed materials, laminated materials, and photopolymerized materials. Extruded materials mainly include thermoplastics, eutectic system metals, and edible materials; linear materials include stainless steel and aluminum alloys; powder-layer nozzle 3D-printed materials include gypsum; laminated materials include paper, metal films, and plastic films; and photopolymerized materials include photocurable resins.

[0036] As a further implementation of the above technical solution:

[0037] Extrusion-type materials are 3D printed using fused deposition modeling.

[0038] As a further implementation of the above technical solution:

[0039] Linear materials are manufactured using electron beam freeform forming in 3D printing.

[0040] As a further implementation of the above technical solution:

[0041] The granular materials used in 3D printing are selected from one of the following methods: direct metal laser sintering, electron beam melting, selective laser melting, selective thermal sintering, and selective laser sintering. Direct metal laser sintering uses alloy materials for granular 3D printing; electron beam melting uses titanium alloys; selective laser melting uses one of titanium alloys, cobalt-chromium alloys, stainless steel, and aluminum; selective thermal sintering uses thermoplastic powders; and selective laser sintering uses one of thermoplastic plastics, metal powders, and ceramic powders.

[0042] As a further implementation of the above technical solution:

[0043] Powder layer nozzle 3D printing type material uses plaster 3D printing.

[0044] As a further implementation of the above technical solution:

[0045] Laminated materials are manufactured using a layered solid structure in 3D printing.

[0046] As a further implementation of the above technical solution:

[0047] Photopolymer materials are one type of material used in 3D printing, which employs stereolithography and digital light processing.

[0048] A modeling method for 3D printed porous sound absorbers includes the following steps:

[0049] B1: Determine the sound absorption parameters and appearance based on the architectural acoustic drawings;

[0050] B2: Input the sound absorption parameters into the acoustic calculation software, and use the acoustic calculation software for building materials to determine the internal structure, pore spacing, and structural diameter of the sound absorption material;

[0051] B3: Based on the desired appearance, use professional 3D software to design and model the product, and determine the product manufacturing plan.

[0052] A method for preparing a 3D-printed porous hollow sound-absorbing material includes the following steps:

[0053] S1: Take out the required raw materials in a certain proportion for later use;

[0054] S2: Add the removed raw materials to the mixer and mix them together for 45-60 minutes.

[0055] S3: Load the mixed raw materials into the storage tank.

[0056] A method for printing a porous, hollowed-out sound-absorbing material using 3D printing includes the following steps:

[0057] A1: Choose different 3D printing materials based on the application environment;

[0058] A2: Prepare by mixing the selected materials;

[0059] A3: Then, depending on the type of 3D printing, different accumulation techniques should be selected;

[0060] A4: Place the embedded parts on the worktable before 3D printing;

[0061] A5: Select different 3D printing equipment based on different accumulation technologies, and use the 3D printing equipment to print the required sound-absorbing materials;

[0062] A6: Spray or electroplate the printed sound-absorbing material surface.

[0063] Working principle:

[0064] When manufacturing sound absorbers, materials are selected based on customer needs, including stainless steel, aluminum alloy, cobalt-chromium alloy, titanium alloy, thermoplastic, eutectic system metals, aluminothermic plastics, metal powder, ceramic powder paper, metal film, plastic film, photocurable resin, and gypsum. After selecting the materials, finished products with ideal sound absorption effects are printed according to acoustic principles, allowing for application in environments with different requirements. Specifically, different sound absorption effects can be achieved by arbitrarily changing the channel spacing, structural diameter, channel ratio, material thickness, size, and structural shape. For example, the addition of stainless steel and titanium alloys allows for application in various harsh environments, such as swimming pools, outdoor and semi-outdoor environments; the perforated structure allows light to pass through, enabling integration with lighting to create a sound and light integrated environment; and the use of a single environmentally friendly material, combined with 3D environmentally friendly printing technology, makes the product even more environmentally friendly.

[0065] In 3D printing, the initial design process involves creating a 3D model using computer modeling software. This model is then divided into layers, or slices, to guide the printer in printing layer by layer. The standard file format for collaboration between the design software and the printer is the STL file format. An STL file uses triangular faces to approximate the surface of an object. The smaller the triangular faces, the higher the surface resolution. PLY is a scanner that generates 3D files through scanning; its generated VRML or WRL files are frequently used as input files for full-color printing.

[0066] Next comes the slicing process. The printer reads the cross-sectional information from the file and prints these sections layer by layer using liquid, powder, or sheet materials. The layers are then glued together in various ways to create a solid object. The characteristic of this technology is that it can create objects of almost any shape.

[0067] Finally, after printing, the embedded parts are added during the printing process, so that the embedded parts and the sound-absorbing material can be integrated, which makes it easier for workers to install later.

[0068] The specific implementation method is as follows:

[0069] For example: A certain stadium is designed and measured according to the "Acoustic Design and Measurement Code for Stadiums".

[0070] According to the JGJ / T 131-2012 standard, the appropriate mid-frequency (500Hz, 1000Hz) reverberation time and volume relationship for a full-field stadium are required. Based on the stadium's architectural conditions and usage requirements, the full-field reverberation time is selected as 1.8s ± 0.2s. However, the actual reverberation time inside the stadium is 6s, and the area of ​​sound-absorbing material that can be installed inside the stadium is only 5000㎡. Considering the space limitations and overall design requirements of the stadium, in order to reduce the reverberation time inside the stadium from 6s to 1.8s, it is necessary to calculate the NRC noise reduction coefficient range of the 5000 square meters of sound-absorbing material and the corresponding sound absorption coefficient range of each frequency (125hz, 250hz, 500hz, 1000hz, 2000hz). Then, based on these acoustic parameters, the pore spacing, structural diameter, pore ratio, material thickness, size, structure, and shape of the sound-absorbing material are determined, and a processing plan is formulated to finally produce an ideal product that achieves the acoustic design and overall design effect of the stadium. Traditional acoustic design works in the opposite way. Once an acoustic material is manufactured, its NRC noise reduction coefficient and the corresponding sound absorption coefficients at various frequencies (125Hz, 250Hz, 500Hz, 1000Hz, 2000Hz) are fixed. This makes it difficult to apply the material to the desired environment and often fails to achieve the expected results. However, by using this invention, the sound absorption parameters of the material itself can be changed by altering the spacing between pores, the diameter of the structure, the ratio of pores, the material thickness, the size, and the shape of the structure. This allows for acoustic effects that are currently unattainable with other acoustic materials.

[0071] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for modeling a 3D printed porous open-cell sound absorbing material, characterized in that: The method comprises the following steps: B1: determining sound absorption parameters and appearance effects according to architectural acoustics drawings; B2: inputting the sound absorption parameters into acoustic calculation software to determine the internal structure, pore spacing and structure diameter of the sound absorption material by using acoustic calculation software of building materials; The sound absorption material comprises extrusion type material, wire type material, granular type material, powder layer nozzle 3D printing type material, laminated type material and photopolymerization type material, the extrusion type material mainly comprises thermoplastic, eutectic system metal and edible material; the wire type material comprises stainless steel and aluminum alloy, the powder layer nozzle 3D printing type material comprises gypsum; the laminated type material comprises paper, metal film and plastic film, and the photopolymerization type material comprises light-hardening resin; B3: designing modeling by using professional three-dimensional software according to the appearance effects and determining a product manufacturing scheme.

2. The modeling method of 3D printing porous and hollow sound-absorbing material according to claim 1, characterized in that: The extrusion type material adopts a fused deposition type in 3D printing.

3. The modeling method of 3D printing porous and hollow sound-absorbing material according to claim 1, characterized in that: The wire type material adopts electron beam free-form fabrication in 3D printing.

4. The modeling method of 3D printing porous and hollow sound-absorbing material according to claim 1, characterized in that: The granular type material adopts one of direct metal laser sintering, electron beam melting forming, selective laser melting forming, selective heat sintering and selective laser sintering in 3D printing, the direct metal laser sintering uses alloy material in granular type 3D printing; the electron beam melting forming uses titanium alloy material in granular type 3D printing; the selective laser melting forming uses one of titanium alloy, cobalt-chromium alloy, stainless steel and aluminum in granular type 3D printing; the selective heat sintering uses thermoplastic powder in granular type 3D printing; the selective laser sintering uses one of thermoplastic, metal powder and ceramic powder in granular type 3D printing.

5. The modeling method of 3D printing porous and hollow sound-absorbing material according to claim 1, characterized in that: The powder layer nozzle 3D printing type material adopts gypsum 3D printing in 3D printing.

6. The modeling method of 3D printing porous and hollow sound-absorbing material according to claim 1, characterized in that: The laminated type material adopts layered solid manufacturing in 3D printing.

7. The modeling method of 3D printing porous and hollow sound-absorbing material according to claim 1, characterized in that: The photopolymerization type material adopts one of stereolithography and digital light processing in 3D printing.