Composite membrane and method for producing a composite membrane
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Solution Overview
Problem
Existing acoustic components face challenges in protecting sensitive electronic parts from harmful liquids and nanoscale dust without distorting sound quality, as conventional membranes are either impermeable to air or contain harmful substances.
Innovation Solution
A composite membrane with an electrospun fiber structure and a plasma coating, featuring a high water column pressure resistance and air permeability, designed to retain liquids while allowing air passage, and free from halogens and environmentally harmful compounds like PFOA.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional membranes are used to protect against liquids, then liquid protection is improved, but air permeability deteriorates
Solution Approach 1:
The patent employs a microporous membrane with specifically controlled pore sizes (0.01-10 μm) that allow air molecules to pass through while blocking larger liquid droplets and dust particles. The porous structure enables the membrane to simultaneously provide liquid protection and maintain air permeability, resolving the contradiction between these two properties.
Solution Approach 2:
The invention uses composite membrane structures combining different materials with complementary properties. The membrane integrates a hydrophobic/oleophobic coating layer on top of a porous substrate, creating a composite material that provides both liquid repellency and breathable air flow, thus achieving both protection and permeability.
2Object-affected harmful factors
If conventional membranes are used to protect against dust, then dust protection is improved, but sound quality deteriorates
Solution Approach 1:
The membrane exhibits different properties at different scales: at the macro level, it appears as a continuous barrier to dust particles; at the micro level, it contains numerous pores that allow sound waves to pass through. This local quality differentiation enables simultaneous dust protection and sound transmission.
Solution Approach 2:
The invention transitions from thinking about protection in terms of complete sealing to utilizing dimensional differences between dust particles and sound waves. The pore size is engineered to be smaller than dust particles but larger than sound wavelengths, creating a size-based dimensional filter that protects against dust while maintaining acoustic transparency.
3Productivity
If electrospun membrane with high porosity is used, then air permeability is improved, but liquid protection deteriorates
Solution Approach 1:
The patent utilizes parameter changes in surface energy and hydrophobicity/oleophobicity to enhance liquid protection. By treating the electrospun membrane with hydrophobic/oleophobic coatings or selecting materials with appropriate surface energy characteristics, the membrane achieves high liquid repellency despite maintaining high porosity for air permeability. The contact angle parameters are optimized to ensure liquid droplets bead up and roll off.
4Object-affected harmful factors
If plasma coating is applied, then liquid repellency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces complex multi-layer mechanical coating systems with a single plasma treatment step. Plasma coating provides hydrophobic/oleophobic properties through chemical modification of the surface at the molecular level, eliminating the need for multiple sequential coating processes and simplifying the manufacturing workflow while achieving superior liquid repellency.
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 composite membrane effectively prevents liquid ingress while maintaining air permeability, ensuring high protection against moisture, sweat, grease, and dust while maintaining sound quality, and is free from harmful substances.
Implementation Method 1
an electrospun membrane (12) which is arranged on the at least one carrier layer (11), wherein the electrospun membrane (12) is formed of superimposed fibers whilst a pore structure is being designed
Implementation Method 2
The composite according to the invention can be provided with a plasma coating according to the PECVD method
Implementation Method 3
the pore structure is designed such that the composite has a water column of at least 1 m and an air permeability of 5 L/m2*s
Data Source
AI summary
The invention relates to a composite for an acoustic component having at least one carrier layer and an electrospun membrane which is arranged on the at least one carrier layer, wherein the electrospun membrane is formed of superimposed fibers while a pore structure is being designed. The pore structure of the composite is designed such that the composite has a water column of at least 1 m and an air permeability of 5 L/m2*s. Furthermore, the invention relates to a method for producing a composite for an acoustic component, in which a carrier layer is provided and on the carrier layer a membrane is designed according to the electrospinning method, wherein the membrane is produced of superimposed fibers with a defined pore structure.