Analysis of the effect of production parameters on sound absorption and abrasion resistance performance of needlepunched nonwovens for automotive carpet applications using Taguchi method

Abstract

In this study, sound absorption and abrasion resistance performance of needlepunched nonwovens produced from blend of round polyethylene terephthalate/hexaflower polyethylene terephthalate/low melt polyethylene terephthalate fibers with various weight ratios, i.e. 50/40/10, 40/40/20, 70/20/10, 50/30/20, were reported. The carded webs were bonded by needlepunching at two punch densities, i.e. 400–500 punches/cm2 and penetration depths, i.e. 11-6-6 and 13-8-8 mm, then passed through an through-air thermal bonding oven to melt low melt polyethylene terephthalate fibers within the samples. Design of experiments was planned according to Taguchi method, and an optimum sample, produced according to optimum production levels, was determined. In order to further improve the sound absorption and abrasion resistance performance, as a first approach, a low denier nonwoven top layer was combined with the optimum sample. As a second method, samples were back coated with a styrene butadiene resin and the changes in sound absorption were analyzed. The effect of production parameters on sound absorption and abrasion resistance was analyzed using a Minitab statistical software. As a result, fiber blend ratio, penetration depth, and areal density significantly affected sound absorption and abrasion resistance performance of nonwoven samples. On the other hand, punch density was found to be statistically insignificant over sound absorption and abrasion resistance. The optimum sample reached to a sound absorption coefficient value of 0.273 at 2000 Hz, and showed a fiber loss percentage of 1.55% and was found to be a suitable facing material for automotive carpet applications.

Application of Scirpus grossus fiber as a sound absorber

“…The values of SAC averaged 0.4 at 125 Hz decreased across the frequency range of 250–2000 Hz and then increased again, with the SAC value of 0.47 observed at 2000 Hz for SG specimen coated PAS with a hole diameter of 1.0 mm. The performance of SG coated with PAS reached to a SAC value of 0.47 at 2000 Hz could be a suitable adsorber material for office wall applications [ 34 ]. The SAC value of 0.56 at 2000 Hz for specimen of SG coated PAS with a hole diameter of 1.5 mm could be twice as big as that of 0.26 for SG specimen without coating.…”

Study on the Sound Absorption Properties of Recycled Polyester Nonwovens through Alkaline Treatment and Dimple Processing

“…Electric vehicles, lacking an internal combustion engine, eliminate engine and exhaust sounds, creating a serene driving environment [3]. However, friction between the tires and the road surface, collisions of foreign objects between the car's wheel guards and the road surface, and external sounds generate noise in the frequency range of 1 kHz and below, which distracts drivers from focusing on safe driving [4][5][6][7]. Consumers are increasingly seeking noise reduction for quiet driving, a notable advantage of electric vehicles.…”

Fabrication, sound absorption simulation and performance optimization of multi‐layer gradient fiber‐based composites

“…5 However, the poor sound absorption performance of these materials at low and medium frequencies limits their further application. To solve this problem, Kucuk et al 6 and Palak et al 7 improved the sound absorption of fiber-based materials by increasing the thickness or gram weight of the materials. Ramamoorthy et al 8 discussed the influence of fiber crosssectional morphology on improving the sound absorption of nonwovens.…”