Fabrication and optimization of polymeric accoustic foams with structural fonctionality (I2I Phase I)

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A novel acoustic foam was developed by Polytechnique Montreal in response to the needs of the aviationindustry. The thermoset polymeric open-cell foam shows excellent acoustic absorption coefficient in broadfrequency range, and particularly at low frequencies. Further, is light and mechanically strong. The foamsmechanical properties are attractive for applications in aircraft engines, flooring systems and fuselage. Thefabrication process is simple and reliable. Acoustic specialists in the aeronautics and the building constructionfields have recognized the potential of the proposed product and a provisional patent has been filed. Thecompanies approached are welcoming this unexampled multifunctional technology with high potential forcommercialization, and are calling for further testing and improvements.The purpose of this project is to respond to industry requirements prior to industrialization by validating thetechnology in relevant environment. The objective is to prove that the manufacturing process parameters arefully controlled, and that these thermoset foams respect acoustic, physical and mechanical specifications fromindustry. The project will show the benefits of making these low-cost acoustic foams with flight certifiedthermosetting resins. The fabrication process will be optimized. Large samples will be manufactured. Differentresin systems and foam structures will be tested. Acoustic performance, mechanical properties andairworthiness will be assessed experimentally. Effectiveness of acoustic prediction tools will be verified.Integration in representative aerospace sandwich structure will be tested.This new technology will contribute to the economic health and growth of the 211 000 jobs and 28 G$Canadian aerospace industry. It is providing a means of limiting the "adverse community reaction related to theoperation and expansion of airports" deplored by the International Civil Aviation Organisation. Mitigation ofaircraft noise is among manufacturers and airport managers' top priorities and key environmental goals.