Acoustical polymer foam and methods for preparation thereof

C - Chemistry – Metallurgy – 08 – J

Patent

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C08J 9/00 (2006.01) B29C 44/56 (2006.01) C08J 9/38 (2006.01)

Patent

CA 2340217

Thermoplastic polymer foams having sound deadening properties satisfactory for demanding applications are provided which have mechanical strength, which are economical to manufacture, and which are hydrolytically stable. Methods of preparing these foams are also provided. The foams are useful in sound management, cushion packaging, filtering, and fluid absorption and exhibit one or more of the following proprties: 1) average cell size greater than about 2 mm, 2) substantially open-cell structure and 3) relatively large pores connecting the cells. In order that the foam be acoustically active, the foam should possess a substiantially open-cell structure and a relatively low airflow resistivity. Foams with substantially open-cell structure and relatively low airflow resistivity are prepared by mechanically opening a foam having an average cell size greater than about 2 mm. In most cases, such mechanical opening creates relatively large pores connecting the cells.

Mousses polymères thermoplastiques ayant des propriétés d'insonorisation satisfaisantes pour des applications exigeantes, qui possèdent une résistance mécanique, qui sont économiques à fabriquer et qui sont hydrolytiquement stables, ainsi que procédés de préparation de ces mousses. Lesdites mousses sont utiles pour l'insonorisation, en tant que matière de rembourrage pour emballages, pour le filtrage et l'absorption de fluides, et présentent une ou plusieurs des propriétés suivantes: (1) taille moyenne des cellule supérieure à environ 2 mm, (2) structure cellulaire ouverte, et (3) connexion entre les cellules par des pores relativement grands. Pour que cette mousse ait un effet acoustique, elle doit posséder une structure cellulaire ouverte et une résistance relativement faible aux flux d'air. Des mousses ayant une structure cellulaire ouverte et une résistance relativement faible au flux d'air sont préparées par ouverture mécanique d'une mousse dont la taille moyenne des cellules est supérieure à environ 2 mm. Dans la plupart des cas, ces ouvertures mécaniques créent des pores relativement grands connectant les cellules.

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