Design and Fabrication of Polyurethane Foams Modified with Rock Wool Fiber: The Effect of Reinforcement Amount on Acoustical and Mechanical Properties

Document Type : Research Paper

Authors

1 Department of Occupational Health Engineering, School of Public Health, Tabriz University of Medical Sciences, P.O. Box 5166614711, Tabriz, Iran

2 Department of Color and Surface Coatings, Faculty of Polymer Processing, Iran Polymer and Petrochemical Institute, P.O. Box 14975-112, Tehran, Iran

3 Department of Biostatistics and Epidemiology, Faculty of Health, Tabriz University of Medical Sciences, P.O. Box 5166614711, Tabriz, Iran

4 Department of Occupational Health Engineering, School of Public Health, Tabriz University of Medical Sciences, P.O. Box 5166614711, Tabriz, Ira

Abstract

Hypothesis: The goal of the study was to focus on improving the acoustic and mechanical properties of polyurethane foams doped with rock wool fibers, at different percentages (rock wool fiber) (0-1.2% by wt), that were synthesized using the polymerization process.
Methods: In order to fabricate acoustic composites, the relationship between non-acoustical parameters (airflow resistivity, porosity, density, and percentage of reinforcing fibers) and microstructure with sound absorption coefficient (SAC) was investigated. SAC was measured using a two-microphone impedance tube in the frequency range of 63-6400 Hz according to the ISIRI 9803 standard without an air gap behind the sample. Physical structure morphology and tensile strength were investigated using field emission scanning electron microscopy (FE-SEM) and tensile strength test, respectively. Non-acoustic measurements including porosity and air flow resistance (AFR) were performed using porosimetry test (BET) test, and Archimedes method. 
Findings: The results showed that increasing the RF amount in the polyurethane foam increased the hardness of the foam surface, and the SAC increased in all frequency range on all the studied samples. The highest SAC was shown by fiber-polyurethane composite foam (2% by wt) sample in the frequency range of 2000-4000 Hz. This increase in the sound absorption coefficient is probably related to the reduction in pore size with the increase in the amount of fibers in polyurethane foam, as shown by the morphological results. The mechanical properties (tensile strength) of foams were investigated by changing the amount of reinforcing fibers. The results showed that the tensile strength of composite foams significantly improved by adding fibers. Eventually, regression analysis was performed to investigate the relationship between non-acoustic parameters (airflow resistivity, porosity, density, and percentage of reinforcing fibers) and SAC. A relatively good fit between the experimental and statistical data was obtained. The data and results of this study showed that composite foams can be used to reduce noise.

Keywords

References

  1. Belojevic G., Noise and Performance: Research in Central, Eastern and South-Eastern Europe and Newly Independent States, Noise and Health, 15, 32-41, 2013.
  2. Geravandi S., Takdastan A., Zallaghi E., Niri M.V., Mohammadi M.J., and Saki H., Noise Pollution and Health Effects, Jundishapur J. Health Sci., 7, 2015.
  3. Ghotbi M.R., Monazzam M.R., Baneshi M.R., Asadi M., and Fard S.M.B., Noise Pollution Survey of a Two-Storey Intersection Station in Tehran Metropolitan Subway System, Monit. Assess., 184,1097-1106, 2012.
  4. Sadr M.K., Nassiri P., Hosseini M., Monavari M., and Gharagozlou A., Assessment of Land Use Compatibility and Noise Pollution at Imam Khomeini International Airport, Air Trans. Manag., 34, 49-56, 2014.
  5. Moradi G., Omidi L., Vosoughi S., Ebrahimi H., Alizadeh A., and Alimohammadi I., Effects of Noise on Selective Attention: The Role of Introversion and Extraversion, Acoust., 146, 213-217, 2019.
  6. Cao L., Fu Q., Si Y., Ding B., and Yu J., Porous Materials for Sound Absorption, Commun., 10, 25-35, 2018.
  7. Chu R.K., Naguib H.E., and Atalla N., Synthesis and Characterization of Open-Cell Foams for Sound Absorption with Rotational Molding Method, Eng. Sci., 49, 1744-1754, 2009.
  8. Chen S., Jiang Y., Chen J., and Wang D., The Effects of Various Additive Components on the Sound Absorption Performances of Polyurethane Foams, Mater. Sci. Eng., 2015, 2015.
  9. Jahani D., Injection-Molded Thermoplastic Foams for Sound Insulation, ProQuest Dissertations, University of Toronto, Canada, 2015.
  10. Alexandre M. and Dubois P., Polymer-Layered Silicate Nanocomposites: Preparation, Properties and Uses of a New Class of Materials, Sci. Eng. R: Reports, 28,1-63, 2000.
  11. Moradi G., Nassiri P., Ershad-Langroudi A., and Monazzam M.R., Acoustical, Damping and Thermal Properties of Polyurethane/Poly(methyl methacrylate)-Based Semi-Interpenetrating Polymer Network Foams, Rubber Compos., 47, 221-231, 2018.
  12. Gibson L.J. and Ashby M.F., Cellular Solids: Structure and Properties, Acta Materialia, 10, 2853-2863, 1999.
  13. Ugarte L., Saralegi A., Fernández R., Martín L., Corcuera M., and Eceiza A., Flexible Polyurethane Foams Based on 100% Renewably Sourced Polyols, Crops Prod., 62, 545-551, 2014.
  14. Han X., Zeng C., Lee L.J., Koelling K.W., and Tomasko D.L., Extrusion of Polystyrene Nanocomposite Foams with Supercritical CO2, Eng. Sci., 43, 1261-1275, 2003.
  15. Daemi H., Barikani M., and Barmar M., Highly Stretchable Nanoalginate Based Polyurethane Elastomers, Polym., 95, 630-636, 2013.
  16. Moradi G., Monazzam M., Ershad-Langroudi A., Parsimehr H., and Keshavarz S.T., Organoclay Nanoparticles Interaction in PU: PMMA IPN Foams: Relationship Between the Cellular Structure and Damping-Acoustical Properties, Acoust., 164,107295, 2020.
  17. Sung G., Kim J.W., and Kim J.H., Fabrication of Polyurethane Composite Foams with Magnesium Hydroxide Filler for Improved Sound Absorption, Ind. Eng. Chem., 44, 99-104, 2016.
  18. Yuvaraj L., Jeyanthi S., and Babu M.C.L., Sound Absorption Analysis of Castor Oil Based Polyurethane Foam with Natural Fiber, Today: Proc., 5, 23534-23540, 2018.
  19. Lee L.J., Zeng C., Cao X., Han X., Shen J., and Xu G., Polymer Nanocomposite Foams, Sci. Technol., 65, 2344-2363, 2005.
  20. Siligardi C., Miselli P., Francia E., and Gualtieri M.L., Temperature-Induced Microstructural Changes of Fiber-Reinforced Silica Aerogel (FRAB) and Rock Wool Thermal Insulation Materials: A Comparative Study, Energy Build., 138, 80-87, 2017.
  21. Chuang Y.C., Li T.T., Huang C.H., Huang C.L., Lou C.W., Chen Y.S., and Lin J.H., Protective Rigid Fiber-Reinforced Polyurethane Foam Composite Boards: Sound Absorption, Drop-Weight Impact and Mechanical Properties, Fibers Polym., 17, 2116-2123, 2016.
  22. Olcay H. and Kocak E.D., Rice Plant Waste Reinforced Polyurethane Composites for Use as the Acoustic Absorption Material, Acoust., 173, 107733, 2021.
  23. Pirani M., Monazzam M.R., and Pourjandaghi S.Q., Correlation Between the Acoustic and Cell Morphology of Polyurethane/Silica Nanocomposite Foams: Effect of Various Proportions of Silica at Low Frequency Region,Health Saf. Work, 11,1-12, 2021.
  24. Mohammadi B., Safaiyan A., Habibi P., and Moradi G., Evaluation of the Acoustic Performance of Polyurethane Foams Embedded with Rock Wool Fibers at low-Frequency Range, Design and Construction, Acoust., 182, 108223, 2021.
  25. Mohammadi B., Ershad-Langroudi A., Moradi G., Safaiyan A., and Habibi P., Mechanical and Sound Absorption Properties of Open-Cell Polyurethane Foams Modified with Rock Wool Fiber, Build. Eng., 48,103872, 2022.
  26. Kim J.M., Kim D.H., Kim J., Lee J.W., and Kim W.N., Effect of Graphene on the Sound Damping Properties of Flexible Polyurethane Foams, Res., 25, 190-196, 2017.
  27. Lu T.J., Hess A., and Ashby M., Sound Absorption in Metallic Foams, Appl. Phys., 85, 7528-7539, 1999.
  28. Seddeq H.S., Factors Influencing Acoustic Performance of Sound Absorptive Materials, J. Basic Appl. Sci., 3, 4610-4617, 2009.
  29. Najib N., Ariff Z., Bakar A., and Sipaut C., Correlation Between the Acoustic and Dynamic Mechanical Properties of Natural Rubber Foam: Effect of Foaming Temperature, Des., 32, 505-511, 2011.
  30. Choe H., Sung G., and Kim J.H., Chemical Treatment of Wood Fibers to Enhance the Sound Absorption Coefficient of Flexible Polyurethane Composite Foams, Sci. Technol., 156, 19-27, 2018.
  31. Baferani A.H., Keshavarz R., Asadi M., and Ohadi A., Effects of Silicone Surfactant on the Properties of Open-Cell Flexible Polyurethane Foams, Polym. Technol., 37, 71-83, 2018.
  32. Van Krevelen D. and Te Nijenhuis K., Polymer Properties, Properties of Polymers, Elsevier, Amsterdam, Chapt. 1, 2009.
  33. Lu M., Hopkins C., Zhao Y., and Seiffert G., Sound Absorption Characteristics of Porous Steel Manufactured by Lost Carbonate Sintering, MRS Online Proceedings Library, 1188, 2009.
  34. Xie Z.K., Ikeda T., Okuda Y., and Nakajima H., Characteristics of Sound Absorption in Lotus-Type Porous Magnesium, J. Appl. Phys., 43, 7315, 2004.
  35. Zhang C., Li J., Hu Z., Zhu F., and Huang Y., Correlation Between the Aoustic and Porous Cell Morphology of Polyurethane Foam: Effect of Interconnected Porosity, Des., 41, 319-325. 2012.
  36. Pinto S.C., Marques P.A.A.P., Vicente R., Godinho L., and Duarte I., Hybrid Structures Made of Polyurethane/Graphene Nanocomposite Foams Embedded within Aluminum Open-Cell Foam, Metals, 10, 768, 2020.
  37. Gwon J.G., Kim S.K., and Kim J.H., Sound Absorption Behavior of Flexible Polyurethane Foams with Distinct Cellular Structures, Des., 89, 448-454, 2016.
  38. Haghgou M., Mohammadi N., Ahmadi M., Faghihi F., and Pazouki M., Damping of Mechanical Waves with Styrene/Butadiene Rubber Filled with Polystyrene Particles: Effects of Particle Size and Wave Frequency, Polym. Sci. Part B: Polym. Phys., 48, 82-88, 2010.
  39. Lee J., Kim G.H., and Ha C.S., Sound Absorption Properties of Polyurethane/Nano-Silica Nanocomposite Foams, Appl. Polym. Sci., 123, 2384-2390, 2012.
  40. Sung G. and Kim J.H., Effect of High Molecular Weight Isocyanate Contents on Manufacturing Polyurethane Foams for Improved Sound Absorption Coefficient, Korean J. Chem. Eng., 34, 1222-1228,
  41. Doutres O., Atalla N., and Dong K., Effect of the Microstructure Closed Pore Content on the Acoustic Behavior of Polyurethane Foams, Appl. Phys., 110, 064901, 2011.
  42. Corredor-Bedoya A., Acuña B., Serpa A., and Masiero B., Effect of the Excitation Signal Type on the Absorption Coefficient Measurement Using the Impedance Tube, Acoust., 171, 107659, 2021.
  43. Li Y., Zou J., Zhou S., Chen Y., Zou H., Liang M., and Lu W., Effect of Expandable Graphite Particle Size on the Flame Retardant, Mechanical, and Thermal Properties of Water-Blown Semi-Rigid Polyurethane Foam, Appl. Polym. Sci., 131, 2014.
  44. Gholampour M., Aghvami-Panah M.A., and Anbaran S.R.G., Mechanical Properties and Electromagnetic Interference (EMI) Shielding Performance of PP/CNT/Glass Fiber Microcellular Foam, J. Polym. Sci. Technol. (Persian), 34, 373-385, 2021.
  45. Saha M., Kabir M.E., and Jeelani S., Enhancement in Thermal and Mechanical Properties of Polyurethane Foam Infused with Nanoparticles, Sci. Eng. A, 479, 213-222, 2008.

 

Iranian Journal of Polymer Science and Technology
Volume 35, Issue 2 - Serial Number 178
July and August 2022
Pages 97-109

Files

Cited by

Share

How to cite

Statistics