2-Part Reactive Urethane Resin Composition for Sound Absorption
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Solution Overview
Problem
Current sound-absorbing materials face challenges in achieving effective sound absorption and low density, particularly in vehicle cabins, where they often leak through small gaps during injection and fail to provide sufficient sound-insulation due to their rigid nature and high density.
Innovation Solution
A 2-part reactive urethane resin composition is developed, comprising a polyisocyanate component and a polyol-containing component with catalysts, foam stabilizers, amine compounds, and carbon dioxide, which forms an open-cell soft polyurethane foam with a high sound absorption coefficient and minimal liquid dripping, suitable for on-site application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If rigid foam-forming materials are used to improve sound insulation, then sound-insulating performance is improved, but density increases and the material becomes heavy
Solution Approach 1:
The patent employs soft polyurethane foam with open-cell porous structure as the sound-absorbing material. The porous structure allows sound waves to penetrate and be absorbed through friction and viscous losses within the cells, achieving effective sound absorption without requiring high density. The foam's cellular architecture provides acoustic performance while maintaining low weight.
Solution Approach 2:
The patent changes the physical parameters of the foam material by using soft polyurethane foam with specific density range (20-80 kg/m³) and open-cell structure instead of rigid foam. This parameter change enables the material to absorb sound effectively through its soft, porous nature rather than relying on high density for sound insulation.
2Object-affected harmful factors
If injection type resin foaming materials are used to improve sound absorption, then sound-absorbing performance is improved, but the material leaks through small gaps during injection
Solution Approach 1:
The patent incorporates a surfactant in the polyol component before injection to pre-condition the foam mixture. This preliminary action reduces surface tension and enables the foam to better seal against gaps during injection, preventing leakage while maintaining the desired sound-absorbing performance.
Solution Approach 2:
The surfactant acts as an intermediary substance that mediates between the foam mixture and the injection system/gaps. It reduces surface tension and improves wetting properties, allowing the foam to effectively seal and fill small gaps without leaking during the injection process.
3Strength
If thermoset type foam-forming material is used to improve stiffness, then stiffness is improved, but foaming magnification ratio fluctuates with temperature changes
Solution Approach 1:
The patent changes the material type from thermoset to thermoplastic polyurethane foam, fundamentally altering the material's thermal and foaming characteristics. This parameter change makes the foaming process less sensitive to temperature fluctuations, as thermoplastic materials have more stable foaming behavior across a wider temperature range, ensuring consistent foaming magnification ratio.
4Weight of moving object
If soft polyurethane foam is used to reduce density, then weight is reduced, but sound-absorbing performance may be insufficient
Solution Approach 1:
The patent utilizes the open-cell porous structure of soft polyurethane foam to achieve effective sound absorption at low density. The interconnected cells and high porosity allow sound waves to penetrate deeply and be absorbed through viscous friction, making density irrelevant to sound absorption performance. The porous architecture provides acoustic functionality without requiring heavy materials.
Solution Approach 2:
The patent employs a composite formulation including polyol, polyisocyanate, surfactant, and blowing agent that creates a synergistic soft polyurethane foam system. This composite material achieves both low density and high sound-absorbing performance through the combined effects of its components and the resulting cellular structure.
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 composition effectively prevents sound leakage and provides excellent sound-absorbing performance with low density, suitable for vehicle cabins and other applications, ensuring improved sound-insulation and weight savings.
Implementation Method 1
a mixed reaction solution of polyurethane materials proceeds foaming and reaction of urethane formation
Implementation Method 2
reaction of urethane formation and urea formation
Implementation Method 3
proceeds foaming and reaction of urethane formation and urea formation immediately at the location where it is discharged
Implementation Method 4
the formed foam has excellent sound-absorbing property
Implementation Method 5
said 2-part reactive urethane resin composition when cured being an open-cell soft polyurethane foam
Data Source
AI summary
Provided is a material having an excellent sound-absorbing performance which can be easily applied to the desired area at the operation site and which can effectively prevent sound leakage.The material includes an open-cell soft polyurethane foam prepared from a 2-part reactive urethane resin composition prepared from a polyisocyanate component and a polyol-containing component,wherein the polyol-containing component comprises a polyol component, catalysts, a foam stabilizer, an amine compound having primary or secondary amino groups, and carbon dioxide;wherein an average sound absorption coefficient of said polyurethane foam is 30% or more, measured in accordance with JIS A 1405-2:2007 for 63 hertz to 5000 hertz; andthe length of liquid-dripping is within 300 mm.