Application of Novel Viscoelastic Microcellular Foams for Passive Noise Control in Automotive Body Structures

This paper discusses the development of lighter weight, superior acoustic performance and cost effective viscoelastic microcellular foams for the use in automotive passive noise control panels. The study incorporates the control of the foaming process for production of variable microcellular structures and morphologies for the novel foams under investigation. For that purpose, the foaming process was controlled for production of foam samples with various microcellular structures. Cross linked LDPE was used as a base material for the produced foams. Very high open-cell content (ranging between 43 - 95%), high microcellular cell densities (9E10⁸ - 1.6E10⁹ cells/cm³) and desired expansion ratios (3 - 9 folds) were successfully obtained. While the material is overly porous, it is noted that the unfoamed skins on the outer surfaces of the samples have prevented sound waves from penetrating the samples. Manual skin removal resulted in slight improvement in sound absorption testing. However, in order to get more reliable data, skinless samples need to be produced.