Lightweight syntactic foams for blast mitigation in thermal/acoustic flooring
View Patent ↗A flooring system for use in thermal and/or acoustic floor systems is provided where the flooring system mitigates external forces from a shock/blast wave. The flooring system includes a foam layer and filler material that includes micro and/or nano structures strategically dispersed in the foam layer. The micro and/or nano structures mitigate a magnitude of the external forces propagating through the foam layer.
1. A thermal/acoustic flooring system comprising:
a plurality of foam layers; and
a filler material comprising a plurality of microparticles or nanoparticles randomly dispersed and completely separated from each other in each foam layer,
wherein the filler material mitigates a magnitude of the external forces propagating through the plurality of foam layers,
wherein the plurality of foam layers are placed on top of one another to form a multi-layered flooring system, and
wherein the filler material has a particle size gradient throughout a thickness of the thermal/acoustic flooring system such that the filler material in a foam layer closest to an entry of the external forces into the flooring system has a particle size greater than that of the filler material in a foam layer furthest away from the external forces into the flooring system.
2. The flooring system of claim 1 , wherein the plurality of foam layers includes a first foam layer, a second foam layer placed on a top of the first foam layer, and a third foam layer placed on top of the second foam layer.
3. The flooring system of claim 2 , wherein the first foam layer comprises a first filler material with a first particle size, the second foam layer comprising a second filler material with a second particle size, the third foam layer comprising a third filler material with a third particle size, wherein the first particle size is greater than the second particle size, and wherein the second particle size is greater than the third particle size.
4. The flooring system of claim 2 , wherein the first filler material, the second filler material, and the third filler material is introduced into each respective foam layer via a spray device.
5. The flooring system of claim 1 , wherein the microparticles or nanoparticles are strategically placed in the foam layer and having the appearance of a random dispersion.
6. A method of manufacturing a multi-layered thermal/acoustic flooring system comprising:
providing a plurality of foam layers;
dispersing a filler material comprising a plurality of microparticles or nanoparticles randomly dispersed and completely separated from each other in each foam layer;
wherein the filler material mitigates a magnitude of external forces propagating through the foam layer,
wherein the plurality of foam layers are placed on top of one another to form a multi-layered flooring system,
wherein the filler material has a particle size gradient throughout a thickness of the thermal/acoustic flooring system such that the filler material in a foam layer closest to an entry of the external forces into the flooring system has a particle size greater than that of the filler material in a foam layer furthest away from the external forces into the flooring system.
7. The method of claim 6 , wherein the plurality of foam layers include a first foam layer having a first filler material, a second foam layer having a second filler material, and a third foam layer having a third filler material.
8. The method of claim 7 , wherein the first filler material has a first particle size, the second filler material having a second particle size, the third filler material having a third particle size, wherein the first particle size is greater than the second particle size, and wherein the second particle size is greater than the third particle size.
9. The method of claim 7 , wherein the first filler material, the second filler material, and the third filler material is introduced into each respective foam layer via a spray device.