Donghe
Chen
,
Shuo
Zheng
,
Mingyu
Jing
,
Zaiqian
Yu
,
Jiawei
Zhang
,
Longjiao
Yu
,
Shulin
Sun
and
Shiwei
Wang
*
School of Chemical Engineering, Advanced Institute of Materials Science, Changchun University of Technology, Changchun 130012, P. R. China. E-mail: wswjldx2004@163.com
First published on 4th May 2023
Traditional polyvinyl butyral (PVB)-laminated glass could not satisfy the rising requirements of sound insulation due to the mass law, especially in the low-frequency region. In this study, a new strategy that uses piezoelectric fibers to improve the sound insulation of materials is first proposed. Polyvinylidene fluoride (PVDF)/multi-walled carbon nanotube (MWCNT) membranes were prepared by electrospinning. Thereafter, laminated glass with glass/PVB/PVDF/PVB/glass structure was successfully constructed by the hot pressing process. 30 pC/N of the maximum piezoelectric coefficient (d33) and 2 V of the maximum output voltage for the PVDF/MWCNT membrane were achieved. The PVB/PVDF composite glass interlayer film could break the conventional mass law with a transmission loss of over 15 dB in the low-frequency region (200–500 Hz). On average, 48% passing through sound energy was reduced than that for the pure PVB film, which indicated the effective block out of human noise. The excellent transmittance and impact resistance of the composite laminated glass were also confirmed from the ultraviolet spectrum and falling ball impact test, respectively. It is of great significance to the research and development of sound insulation materials.
PVB laminated glass is constructed by sandwiching PVB film between two or more glass substrates by a hot pressing process.10 The common deficiency of traditional sound insulation materials, is the unsatisfactory sound insulation in the low-frequency region, especially for blocking human noise. Yet it is not a good solution to increase the thickness of glass because of weight limits. Therefore, it is a challenge to develop a light and simple sound-insulating laminated safety glass. Recently, a new strategy for converting sound energy into electric energy has been proposed.11,12 Sound energy is first transferred to the piezoelectric material and converted into electric potential energy through the piezoelectric effect. Then electric energy is further converted into heat energy through the conductive network. Piezoelectric polymer materials, such as polyvinylidene fluoride (PVDF), have been widely investigated owing to their high piezoelectric coefficient, lightweight, and strong mechanical properties that facilitate their application in complex structures.13–15
PVDF has five crystalline forms with three conformations: (1) all-trans (TTTT) planar zigzag for the β phase, (2) TG + TG- for the α and δ phases, and (3) T3G + T3G- for γ and ε phase.16–18 The β phase has the highest polarization per unit cell, which is decisive for the piezoelectricity of PVDF polymers.19 The nonpolar α phase that is formed spontaneously could be converted into β phase through various post-treatments, such as high electric field poling, mechanical stretching, and quenching at higher rates.20 Blending PVDF with conductive additives is also a common method to improve piezoelectricity.21 Multi-walled carbon nanotubes (MWCNTs) have been widely used owing to their high aspect ratios and electron-rich large surface areas.22–24 It is well-recognized that well-dispersed MWCNTs can significantly improve the piezoelectricity of PVDF.25,26 The piezoelectric PVDF/MWCNT composites have the potential to be applied in many fields owing to the excellent electrical properties of MWCNTs and the efficient α to β phase transformation during the electrospinning (ES) process.27 The ES/PVDF membrane has excellent piezoelectricity through electric field poling and stretching while retaining high porosity and specific surface area. Wu and Chou demonstrated that ES piezoelectric PVDF/CNT membrane is an efficient sound absorption material.28 However, the relationship between the piezoelectricity of fibers and sound insulation has not been reported. It is an effective solution to improve the low-frequency sound insulation of laminated glass by incorporating electrospun piezoelectric fibers with negligible mass into the damping material of PVB.
In this work, PVDF composite membranes were produced by ES technology. The piezoelectric coefficient and output voltage of the PVDF membranes were greatly improved by the introduced MWCNTs. Then, the composite membrane was incorporated into PVB films by the hot pressing process. The transmission loss of the PVB/PVDF composite film is significantly enhanced in the low-frequency region and the enhancement can be reached a maximum of 3.6 dB compared to that of pure PVB film. The average passing through sound energy is significantly reduced, which means that human noise can be effectively blocked out. The results show that the sound insulation performance of the composite films is related to the piezoelectricity of fibers and demonstrate the feasibility of employing piezoelectric fibers for sound insulation. Then, laminated glass based on PVB/PVDF composite film was also constructed by hot pressing. Its transmittance reaches nearly 80%, which is attributed to efficient energy conversion. The excellent impact resistance of the composite laminated glass was also confirmed by a breakage rate of less than 3.0%. This lightweight and solid laminated glass with good sound insulation can be widely used in many fields.
PVDF/MWCNTs membranes with 10 μm of thickness were produced by ES at a voltage of 15 kV, 1 mL h−1 of flowing rate, and 20 cm distance between needle tip (1.36 mm diameter) and collector. The PVB/PVDF composite based on PVB/PVDF/PVB structure was constructed by sandwiching the PVDF membrane between two PVB films (0.38 mm) with 3 mm glass on the outer side by hot pressing at 130 ± 1 °C and 1.5 ± 0.1 Mpa.
Type SW-422 Impedance tubes (BSWA Technology Co., Ltd) were used to characterize the transmission loss of the composite film in the range of 64–1600 Hz according to the transfer matrix method specified in ASTM E2611-19. The power amplifier was connected to the impedance tube to provide sound. Four fixed-position microphones measured the sound pressure level and transmitted the data to the data acquisition system, and the transmission loss was calculated by the noise and vibration testing system (Va-Lab). The composite film was cut to the required size (114 mm in diameter) by using an electric punching machine.
The electrical properties of electrospun PVDF/MWCNTs Membranes were characterized, and the data is shown in Fig. 2a. It shows that the conductivity of the composite membrane increases slightly when the loading of MWCNTs was below 0.3 wt%, which is attributed to the excellent conductivity of MWCNTs. As the loading of MWCNTs was increased to 0.5 wt%, an abrupt increase (about 10−8 to 10−3) in conductivity appeared, which is attributed to a typical percolation threshold.31 That means the conductive network was completely formed in the PVDF membrane. However, the decrease in conductivity can be observed when 1.0 wt% MWCNTs were added. This is consistent with the previous conclusion (Fig. 1) that excess MWCNTs will agglomerate and hinder the formation of a conductive network.
The dielectric constant of composite membranes in the frequency range of 102 to 106 Hz at room temperature are shown in Fig. 2b. At low frequencies, much higher dielectric constant can be obtained for the composite membranes. In addition, the dielectric constant of all composite membranes will decrease with the increase of the frequency. The law of dielectric constant is consistent with that of conductivity. The maximum dielectric constant for the composite membranes is about 120 when the loading of MWCNTs increases to 0.5 wt%, which is much higher than that of pure PVDF membrane with 11. To sum up, the addition of MWCNTs increases the conductivity of the composite membranes, and its uniform dispersion contributes to reinforcement of the dielectric property, which means higher polarization efficiency in the electric field.32
Fig. S2 (ESI†). shows the diffraction angle of electrospun pure PVDF and PVDF/MWCNTs membrane with different MWCNTs loads at 20 kV were characterized by X-ray diffraction (XRD) from a scan range of 5° to 50°. The samples showed an intense peak around 20.6° ((110) reflection)33 corresponding to β and a small hump at 18° indicating the existence of α phase in the electrospun fiber membrane. The XRD results are further supported by FTIR, as shown in Fig. 2c, intercepted from Fig. S3 (ESI†), and the crystalline phase of PVDF was quantitatively calculated. The bands observed at 976, 764, and 613 cm−1 can be attributed to the α phase of PVDF, whereas the bands at 840 and 1275 cm−1 can be attributed to the β phase.34 The relative β phase fraction of PVDF samples F(β) was calculated using eqn (1) derived from the Beer–Lambert law:
(1) |
Sample | F(β) (%) | d 33 (pC/N) |
---|---|---|
PVDF | 78 | 15 |
PVDF/MWCNTs (0.1 wt%) | 70 | 17 |
PVDF/MWCNTs (0.3 wt%) | 67 | 20 |
PVDF/MWCNTs (0.5 wt%) | 69 | 30 |
PVDF/MWCNTs (1.0 wt%) | 63 | 26 |
As shown in Fig. 3a, the composite films with PVB/PVDF/PVB structure were constructed by the hot pressing process, Fig. S5 (ESI†) presents the thermogram of the electrospun PVDF nanofiber membrane, the melting point of PVDF (about 168 °C) is higher than the hot pressing temperature (130 °C), so the electrospun PVDF membrane will not be affected. The transmission loss (TL) of the composite films in the low-frequency region was measured using an acoustical measurement system, as shown in Fig. S6a (ESI†). Fig. S6b (ESI†) is the image of the sample. TL curves of PVB/PVDF composite films shown in Fig. 3b could be divided into three regions: stiffness control region, damping control region, and mass control region. The stiffness control region from 64 Hz to 180 Hz is generally shown as a downward-sloping curve, in which the TL of the sample is related to the sample size, stiffness, and the connection state with the instrument. The damping control region from 180 Hz to 200 Hz is related to the damping characteristics of the sample. In this region, their TL reaches the minimum value. TL in both regions cannot reflect the real sound insulation performance of the sample. The mass control region from 200 Hz to 500 Hz is an oblique upward straight line, which is the most valuable reference region, in this region, the sample follows the mass law that the TL of each frequency point increases by 6 dB when the surface mass of the sample is doubled. However, the TL curve that fluctuates after 500 Hz is the first-order modal characteristic of the sample, which does not need to be analysed.
Because the stiffness of the glass is too high, it causes the range of the mass control region to be significantly reduced, and the sound insulation performance of the laminated glass was not measured. It can be seen in the figure that all the composite samples are superior to the single ones in the mass control region (200–500 Hz). Generally, the sound waves pass directly through the fibers because of their porous structure, but when electrospun fibers are incorporated into PVB, the sound waves will collide with the fibers many times (Fig. S4, ESI†), which is attributed to the blocking effect of PVB on the transmission of the sound waves. However, the trend of the TL curve is not consistent with the conclusions of the previous BET test (Table S1, ESI†), which is due to the further elimination of sound energy by piezoelectric fibers. It can be seen that the higher is the piezoelectricity of the electrospun PVDF membrane, the higher the TL value of the composite film. The lightweight PVB/PVDF composite glass interlayer film can break the conventional mass law with a transmission loss of over 15 dB in the low frequency region. The increasement can reach a maximum of 3.6 dB when the loading of MWCNTs is 0.5 wt%, although its specific surface area and porosity are lower than those of the sample without MWCNTs. TL of PVB composite film containing electrospun non-piezoelectric polyamide 6 (PA6) fiber has been reported in Fig. S8 (ESI†). It can be seen that the TL of the PVB/PA6 composite film is superior to that of the pure PVB film, due to the absorption of low-frequency sound energy by the electrospun PA6 fiber with nanoscale diameter, which is much smaller than the diameter of PVDF.37,38 However, the TL of the PVB/PVDF composite film is significantly higher than that of the PVB/PA6 composite film, indicating that the piezoelectric effect of electrospun nanofiber take the dominant part in the elimination of sound energy. The TL values of all samples at different frequencies in detail are listed in Table S2 (ESI†). The average sound insulation performance of the samples in the mass control region can be measured using the following eqn (2):
(2) |
The impact resistance of laminated glass depends on the adhesion of the intermediate layer in the glass. Therefore, the shear test was performed on a universal tensile strength tester (QT-6201S QianTong Instrument Machine Co. Ltd), where the composite PVB film with the dimensions of 12.5 mm (width) × 25 mm (length) was hot pressed to the corresponding position of the glass and then stretched (Fig. S9a, ESI†). As shown in Fig. S9b (ESI†), the adhesion to glass is not affected by the introduction of the PVDF fiber membrane to the PVB, and the shear strength of all samples exceeds 3 MPa, which fully meets the performance requirements of the interlayer film of the laminated glass. The toughness of the PVDF membrane after hot pressing was also tested. As shown in Fig. S10a and b (ESI†), bended it and then unfolded it, a complete and crease-free PVDF membrane can be observed. In addition, the length of the PVDF has been stretched from 35 mm to 55 mm with an elongation exceeding 55%, indicating that the PVDF membrane after hot pressing is not a brittle material (Fig. S10c and d, ESI†). Then, the sound insulation laminated glass based on the PVB/PVDF composite film was constructed by the hot pressing process. As shown in Fig. 4a, the impact resistances of which were detected by falling ball impact on the samples in 9 cm × 9 cm size according to AS NZS 2208-1996, a 300 g ball was dropped and the drop height was progressively increased to 45 cm, 60 cm, 75 cm, 90 cm, 120 cm, and 150 cm until the breakage occurred. After testing, all the samples broke at a height of 120 cm, for more accurate experimental results, the ball with the same mass was dropped 5 times from a height of 120 cm and the mass percentage of the broken glass slag was measured (breakage rate). The image of laminated glass after being impacted is shown in Fig. 4b, and the breakage rate is listed in Table S3 (ESI†). As shown in the figure, the breakage rate of all samples is within the range of 2.5% to 2.8%. The impact resistance of the laminated glass is not affected by the introduction of a thin electrospun piezoelectric fiber membrane and is sufficient for normal use.
Fig. 4 (a) Falling ball impact test and (b) image of laminated glass after being impacted. (c) The ultraviolet spectrum of all laminated glass with different interlayers. |
The ultraviolet spectrum of the laminated glass is shown in Fig. 4c. As shown in the figure, when an appropriate amount of MWCNTs are added, the transmittance of composite laminated glass is nearly 80%, which is close to that of the PVB laminated glass. Therefore, this kind of sound insulation laminated safety glass has great application potential, such as in an automobile or architectural glass.
Footnote |
† Electronic supplementary information (ESI) available. See DOI: https://doi.org/10.1039/d3ma00150d |
This journal is © The Royal Society of Chemistry 2023 |