Composite Foam Sound Absorber for Ship Bulkheads
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Solution Overview
Problem
Conventional elastomeric foams fail to pass the non-combustibility test required for shipping materials, and existing sound-absorbing materials do not effectively absorb low-frequency noise in ship engines.
Innovation Solution
A composite foam sound-absorbing molded body is created using elastomeric foam flakes, non-combustible fillers, and a binder, with the fillers' mass fraction optimized to ensure the molded body meets the IMO 2010 FTP Code non-combustibility test, and melamine resin foam flakes are used to enhance sound absorption and fire resistance, along with hot-melt adhesives for bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional elastomeric foams are used for sound absorption, then good sound-absorbing properties are achieved, but the non-combustibility test requirement is not met
Solution Approach 1:
The patent creates a composite foam material combining elastomeric foam flakes (for sound absorption) with flame-retardant polyurethane foam flakes and non-combustible fillers (for fire resistance). This composite structure allows the material to simultaneously achieve both sound-absorbing properties and pass the non-combustibility test, resolving the contradiction between acoustic performance and fire safety requirements in shipping applications.
2Reliability
If the mass fraction of non-combustible fillers is increased to pass the non-combustibility test, then fire resistance is improved, but sound absorption effectiveness may be reduced
Solution Approach 1:
The patent optimizes the mass fraction of non-combustible fillers to a specific range (5-50 wt.%) to balance fire resistance and sound absorption. By carefully controlling this parameter, the composite foam achieves compliance with the non-combustibility test while maintaining effective sound-absorbing properties, including low-frequency noise absorption in ship engines.
Solution Approach 2:
The composite foam combines multiple materials with complementary properties: elastomeric foam for sound absorption, flame-retardant polyurethane foam for fire resistance, and non-combustible fillers for structural stability and fire safety. This multi-material composition allows simultaneous optimization of both fire resistance and sound absorption without significant compromise.
3Reliability
If heavy non-combustible fillers are added to achieve fire resistance, then the non-combustibility test is passed, but the volume of the sound-absorbing material increases
Solution Approach 1:
The patent controls the mass fraction of non-combustible fillers within the range of 5-50 wt.% to achieve the necessary fire resistance while minimizing volume increase. By optimizing this parameter, the composite foam passes the non-combustibility test with acceptable mass loss (<50%) while maintaining a compact size suitable for ship bulkhead applications.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively absorbs low-frequency noise and meets maritime non-combustibility standards, utilizing recycled materials and ensuring the molded body's longevity and high strength, making it suitable for ship bulkheads.
Implementation Method 1
the molded body effectively absorbs sound, especially the low frequencies that occur during ship operation
Implementation Method 2
a binder, pressing the components to form the molded body
Data Source
AI summary
The invention relates to a sound-absorbing molded body designed for attachment to ship surfaces, as well as a method for its production. In order to create a molded body that can be produced inexpensively, passes the non-combustibility test for shipping and also has good sound absorption properties, it is proposed that the molded body comprise the following components pressed together: - flakes of elastomeric foam, - a binder, and - non-combustible fillers in accordance with the non-combustibility test IMO 2010 FTP Code Part 1 [Resolution MSC.307(88)], wherein the mass fraction of the fillers in the composite foam molded body is determined such that the average mass loss of the molded body after conducting the non-combustibility test IMO 2010 FTP Code Part 1 [Resolution MSC.307(88)] does not exceed 50%. A method for producing the molded body is also specified.