Fiber-based compositions for noise reduction and pressure resistance

Abstract

The present invention relates to a noise reducing and compression resistant fiber composition for vehicle applications. More particularly, the fiber composition is suitable for replacing expanded polypropylene foam pads used in vehicle carpet applications.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This PCT application claims the benefit of U.S. Provisional Application Serial No. 63 / 049,427, filed on July 8, 2020, the entire disclosure of which is incorporated herein by reference.

[0003] field

[0004] The present invention relates to a noise reducing and compression resistant fiber composition for vehicle applications. More particularly, the fiber composition is suitable for replacing expanded polypropylene foam pads used in vehicle carpet applications.

[0005] background

[0006] It is generally recognized that there is a need to reduce noise levels within the passenger compartment of a vehicle. Exterior noise, such as road noise, engine noise, vibrations, etc., as well as noise emanating from within the passenger compartment, can be attenuated through the use of various acoustic materials. Consequently, sound attenuating materials for vehicles (e.g., automobiles) are conventionally used in the instrument panel, along with carpet for the floor, in the wheel wells, in the trunk, under the hood, and as part of the headliner.

[0007] Another consideration regarding vehicle carpet construction is ensuring that any such construction also provides the necessary resistance required by OEM compression testing. That is, in addition to noise reduction considerations, vehicle carpet construction must typically meet certain constraints in terms of compression and recovery for various specific loading protocols.

[0008] To date, the automotive industry has widely used expanded polypropylene (EPP) foam reinforcements in various carpet lay-ups to provide the desired acoustic and compression performance characteristics for a given carpet structure. Improving these acoustic and compression characteristics through the use of alternative materials remains an ongoing goal, while also potentially reducing costs.

[0009] Summarize

[0010] A fiber composition comprising 30 to 75 weight percent binder fiber, 25 to 70 weight percent vehicle carpet waste regrind, wherein the fiber composition has a thickness in the range of 3.0 mm to 100.0 mm and a mass of 20.0 kg / m 3 Up to 200.0Kg / m 3 The fiber composition is particularly suitable for replacing EPP mats used in vehicle carpet applications.

[0011] A vehicle carpet structure comprising a first nonwoven surface layer, a second nonwoven layer having a higher density than the first nonwoven surface layer, a film layer, a shoddy fiber layer, and a backing layer of a fiber composition, wherein the fiber composition comprises 25% to 70% by weight of recycled material from waste vehicle carpets and 30% to 75% by weight of binder fibers, wherein the fiber composition has a thickness in the range of 3.0 mm to 100.0 mm and a density of 20.0 kg / m 3 Up to 200.0Kg / m 3 within the range.

[0012] A vehicle carpet structure comprising a first nonwoven surface layer, a long elastic fiber layer, and a backing layer of a fiber composition, wherein the fiber composition comprises 25% to 70% by weight of a recycled material from vehicle carpet waste and 30% to 75% by weight of a binder fiber, wherein the fiber composition has a thickness in the range of 3.0 mm to 100.0 mm and a density of 20.0 kg / m 3 Up to 200.0Kg / m 3 within the range.

[0013] A vehicle carpet structure comprising a first nonwoven face layer, a polyurethane foam layer, and a backing layer of a fiber composition comprising 25 to 70 weight percent of vehicle carpet waste recycled material and 30 to 75 weight percent of binder fiber, wherein the fiber composition has a thickness in the range of 3.0 mm to 100.0 mm and has a weight of 20.0 kg / m 3 Up to 200.0Kg / m 3 Density within the range.

[0014] A vehicle carpet structure comprising a first nonwoven face layer, a second nonwoven layer having a higher density than the first nonwoven face layer, a long elastic fiber layer, and a backing layer of a fiber composition, the fiber composition comprising 25% to 70% by weight of a recycled material from waste vehicle carpet and 30% to 75% by weight of a binder fiber, wherein the fiber composition has a thickness in the range of 3.0 mm to 100.0 mm and a density of 20.0 kg / m 3 Up to 200.0Kg / m 3 within the range.

[0015] A vehicle carpet structure comprising a first nonwoven face layer, a second nonwoven layer having a higher density than the first nonwoven face layer, a mass layer, a long elastic fiber layer, and a backing layer of a fiber composition, wherein the fiber composition comprises 25% to 70% by weight of a recycled material from waste vehicle carpet and 30% to 75% by weight of a binder fiber, wherein the fiber composition has a thickness in the range of 3.0 mm to 100.0 mm and a density of 20.0 kg / m 3 Up to 200.0Kg / m 3 within the range.

[0016] A vehicle carpet structure comprising a first nonwoven face layer, a mass layer, a polyurethane foam layer, and a backing layer of a fiber composition comprising 25 to 70 weight percent of vehicle carpet waste recycled material and 30 to 75 weight percent of binder fiber, wherein the fiber composition has a thickness in the range of 3.0 mm to 100.0 mm and a density of 20.0 kg / m 3 Up to 200.0Kg / m 3 within the range.

[0017] A vehicle carpet structure comprising

[0018] A first nonwoven facing layer, a second nonwoven layer, a film layer, a long spandex fiber layer, and a backing layer comprising a fiber composition of automotive carpet waste recycled material and binder fiber, wherein the carpet structure is indicative of one or more of the following:

[0019] (a) a sound transmission loss of 20-68 dB in the frequency range of 200-2000 Hz (1 / 3 octave); or

[0020] (b) An insertion loss within the range of 5.0 dB at 400 Hz (1 / 3 octave) to 25.0 dB at 5000 Hz (1 / 3 octave); or

[0021] (c) The sound absorption coefficient is greater than 0.7 within the frequency range of 400 Hz to 1000 Hz (1 / 3 octave). BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1A The use of the fiber compositions herein as a base or backing layer in a representative five (5) layer type carpet construction is shown.

[0024] Figure 1B The use of the fiber composition herein as a bottom or backing layer in a representative three (3) layer type structure is shown.

[0025] Figure 1CThe use of the fiber composition herein as a bottom or backing layer in another representative three (3) layer type structure is shown.

[0026] Figure 1D The fiber compositions herein are shown for use as a bottom or backing layer in a representative four (4) layer type structure.

[0027] Figure 1E The use of the fiber composition herein as a bottom or backing layer in another representative five (5) layer type structure is shown.

[0028] Figure 1F Illustrated is the use of the fiber composition herein as a bottom or backing layer in another representative four (4) layer type structure.

[0029] Figure 2 is the SAE J1400 test (July 1, 2017) and provides a graph of sound transmission loss (dB) versus frequency (Hz) (1 / 3 octave bands) for the fiber composition used herein as the underlayer or backing layer in the carpet construction of FIG. 1 .

[0030] Figure 3 The results of the APAMAT insertion loss test are provided as a plot of insertion loss (dB) versus frequency (Hz) (1 / 3 octave) for the identified samples.

[0031] Figure 4 A plot of the sound absorption coefficient (α) versus frequency (Hz) (1 / 3 octave) for the identified samples is provided.

[0032] Detailed Description of the Preferred Embodiments

[0033] The present disclosure relates to a fiber composition for noise reduction and compression resistance for automotive applications. The fiber composition includes a binder fiber and a recycled automotive carpet waste material. The binder fiber is preferably present in an amount of 30% to 75% by weight, and the recycled automotive carpet waste material is present in an amount of 25% to 70% by weight.

[0034] Binder fibers refer to fibers having a relatively lower melting point than the nylon or polyamide fibers, polyester fibers, or polypropylene fibers present in the automotive carpet waste recyclate, and when heated, are used to bind the existing automotive carpet waste recyclate. The binder fibers may preferably include polyethylene terephthalate (PET) bicomponent fibers, which contain two polymers with different chemical and physical properties (e.g., melting points). Therefore, binder fibers may preferably be used, which include a sheath-core structure, wherein the sheath is a relatively low-melting polyester made from a copolymer of PET and the core is PET-based. The melting point of the relatively low-melting polyester may preferably be 100°C to 200°C. More preferably, the melting point of the relatively low-melting polyester is 150°C to 200°C, or in the range of 175°C to 185°C. Therefore, it should be understood that within the broad context of the present invention, the binder fibers are not limited to bicomponent fibers and may include any fiber having a melting point in the range of 100°C to 200°C. The binder fiber also preferably has a denier (D) value of 2-6 and a length ranging from 20.0 mm to 80.0 mm, more preferably from 40.0 mm to 60.0 mm.

[0035] The automotive carpet waste recycled material herein comprises one or more of nylon (polyamide), polyester or polypropylene fibers as the primary fiber component, which may include a polymeric coating resin, such as a polymer latex coating. Such a coating is preferably derived from a polyolefin (e.g., polyethylene or polypropylene). The automotive carpet waste recycled material herein itself preferably contains a certain amount of polymer having a melting point in the range of 80°C to 180°C, even more preferably 100°C to 120°C. The preferred content of such polymer having the above-mentioned melting behavior is in the range of 5% to 40% by weight, more preferably 10% to 30% by weight. The automotive carpet waste is then preferably ground or shredded to provide a source of automotive carpet waste recycled material material herein. Such automotive carpet recycled material waste can be sourced from vehicle production facilities, where it can be readily obtained at a relatively low cost compared to EPP.

[0036] like Figure 1A As shown, the fiber composition (binder and automotive carpet waste recycled material) can be used in a representative carpet construction layer 10. However, it should be understood that within the broad context of the present invention, this fiber composition can now be used in any carpet construction layer to replace the use of EPP padding material.

[0037] Figure 1A The representative carpet structure in the embodiment includes a top layer 12, which is preferably a nonwoven layer with a thickness ranging from 1.0 mm to 3.0 mm, derived from PET. Such nonwovens may preferably have a thickness of 300 g / m 2 Up to 1200g / m 2This is followed by a nonwoven layer 14, also preferably derived from PET, with a thickness of 3.0 mm to 5.0 mm and a basis weight of greater than 450 g / m 2 Up to 1200g / m 2 The nonwoven layer 14 preferably has a higher relative density than the nonwoven face layer 12. The polymer film layer 16 is preferably present in a thickness of 0.01 mm to 0.25 mm, wherein such a film is preferably selected from a polyolefin polymer, such as polyethylene or polypropylene. The long elastic fiber insulation layer then appears at 18, wherein the reference to long elastic is generally understood to be recycled textile fibers. The long elastic insulation layer preferably has a thickness of 3.0 mm to 50.0 mm, at 500 g / m 2 Up to 2000g / m 2 Under the basis weight.

[0038] The fiber composition at 20 herein is preferably used as a base or backing layer of a given carpet layer. This fiber composition is now preferably used to replace the use of EPP mat as a base or backing layer of a given vehicle carpet structure. The fiber composition at 20 is preferably used in a layer thickness of 3.0 mm to 100.0 mm and a weight of 20.0 kg / m 3 Up to 200.0Kg / m 3 Other preferred thickness values ​​include 10.0 mm to 100.0 mm, or 10.0 mm to 50.0 mm, or 25.0 mm to 50.0 mm. Other preferred densities of the fiber composition 20 include 50.0 to 150.0 kg / m 3 or 100Kg / m 3 Up to 150.0Kg / m 3 Therefore, it can be seen that Figure 1A The vehicle carpet construction shown avoids the need for expanded polypropylene mats.

[0039] As mentioned above, the fiber composition 20 herein can be used as a backing layer in other representative carpet layers, which similarly can avoid the need to use expanded polypropylene. Figure 1B A representative carpet structure 22 is shown, which also includes a top layer 12, a long elastic pile layer 18 and a fiber composition 20 as a backing layer. The top layer 12 is again preferably a nonwoven layer with a thickness ranging from 1.0 mm to 3.0 mm, which is derived from PET. Such nonwovens may preferably have a thickness of 300 g / m 2 Up to 450g / m 2 The long elastic layer 18 is again a recycled textile fiber, which preferably has a thickness of 3.0 mm to 50.0 mm, at 500 g / m 2 Up to 2000g / m 2 Under the basis weight.

[0040] Figure 1C A representative carpet structure 24 is shown. Again, there is a top layer 12 which is preferably a nonwoven layer having a thickness in the range of 1.0 mm to 3.0 mm, derived from PET, and having a basis weight of 300 g / m 2 Up to 450g / m 2 This is followed by a polyurethane foam layer 26 having a thickness in the range of 3.0 mm to 50.0 mm and a density of 30 kg / m 3 Up to 100kg / m 3 The fiber composite backing layer is again shown at 20. Again the need to use expanded polypropylene is avoided.

[0041] Figure 1D A representative carpet structure 28 is shown. This is similar to Figure 1A , but without the membrane layer 16. The fiber composition backing layer is again shown at 20. Again, the need to use expanded polypropylene is avoided.

[0042] Figure 1E A representative carpet structure 30 is shown. This structure is similar to Figure 1A The representative carpet structure 10 in FIG. 1 is shown in FIG. 1 , wherein the membrane layer 16 is replaced by a mass layer 32 designed to act as a barrier to sound transmission. The mass layer 32 may preferably comprise a filled (i.e., calcium carbonate) polyethylene-co-vinyl acetate sheet and preferably has a thickness in the range of 0.5 mm to 3.0 mm and a sound insulation rating of 800 g / m². 2 Up to 4000g / m 2 This again avoids the need to use expanded polypropylene.

[0043] Figure 1F A representative structure 32 is shown. The structure includes a facing layer 12 as described herein, a mass layer 32 as described herein, a polyurethane foam layer 26 as described herein, and a fiber composition 20 as a backing layer. Again, the need to use expanded polypropylene is avoided.

[0044] As described above, the fiber composition 20 herein can completely replace the use of EPP mats in vehicle carpet construction while providing improved noise reduction and necessary compression properties. Turning first to noise reduction considerations, the fiber composition herein exhibits improved sound transmission loss, insertion loss, and absorption coefficient within key frequency ranges, as detailed below.

[0045] Figure 2 A graph of sound transmission loss (dB) versus frequency (Hz) (1 / 3 octave bands) according to the general procedure in SAE J1400 testing (July 1, 2017) is provided for the sound transmission loss (dB) used in this article as Figure 1AThe fiber composition of the bottom layer or backing layer 20 in the carpet structure of the present invention, wherein the thickness of the surface layer, nonwoven layer, film layer and insulation layer is 10.0mm. Figure 2 The fiber composition herein (binder fiber and vehicle carpet waste recycled material) identified by the trademark ECOBLEND™ exhibits a thickness of about 40.0 mm and a density of 98 kg / m 3 , thus providing a total carpet thickness of approximately 50.0 mm. This is comparable to using a 40.0 mm thick carpet with a density of approximately 59 kg / m2 on the back of the same 10.0 mm carpet structure (top layer, hard layer, film and insulation layer). 3 The results were compared with expanded polypropylene mats of the present invention. It can be seen that within the frequency range of 200-2000 (Hz) (1 / 3 octave band), the carpet structures based on the fiber composition provided sound transmission losses (dB) ranging from 20-68, which were consistently better than carpet structures using EPP. On average, within the frequency range of 200-2000 (Hz) (1 / 3 octave band), the carpet structures using the fiber composition herein achieved approximately 10 dB better sound transmission losses.

[0046] Figure 3 The results of the APAMAT-II (Autoneum) insertion loss test are provided as a graph of insertion loss (dB) versus frequency (Hz) (1 / 3 octave bands) for an identification sample of the fiber composition herein or EPP as the backing layer 20, as applied to a 10.0 mm thick carpet construction laminate (see Figure 1A ). Therefore, the following materials are used as the base layer of this carpet structure: (1) EPP, which has a thickness of about 30.0 mm and a density of 45 Kg / m 3 , thereby providing a total thickness of about 40.0 mm; (2) the density of the fiber composition herein is 132 Kg / m 3 , with a thickness of about 30.0 mm, thereby providing a total thickness of about 40.0 mm; (3) the density of the fiber composition herein is 98 Kg / m 3 , with a thickness of about 40.0 mm, thereby providing a total thickness of about 50.0 mm; (4) the thickness of EPP is about 40.0 mm and the density is about 59 kg / m 3 , thereby providing a total thickness of about 50.0 mm. As can be observed, when applied to the back side of a carpet structure, the fiber composition herein provides an insertion loss of about 5.0 dB at 400 Hz (1 / 3 octave) to 25.0 dB at 5000 Hz (1 / 3 octave). Furthermore, it can again be observed that when applied to the back side of a given carpet structure, the fiber composition herein is superior to the use of EPP.

[0047] Next follow Figure 4 , Figure 4Identified samples of the fiber composition or EPP described herein, applied as a backing layer 20 to a 10.0 mm thick carpet construction laminate (see Figure 1A )) versus frequency (Hz (1 / 3 octave). The sound absorption coefficient is determined according to the general procedure of ASTM C423-17 "Standard Test Method for Sound Absorption Coefficients by the Reverberation Room Method". Therefore, again, the following materials are applied as the backing layer 20 of this carpet structure: (1) EPP, thickness of about 30.0 mm, density of 45 kg / m 3 , thereby providing a total thickness of about 40.0 mm; (2) the density of the fiber composition herein is 132 Kg / m 3 , with a thickness of about 30.0 mm, thereby providing a total thickness of about 40.0 mm; (3) the density of the fiber composition herein is 98 Kg / m 3 , with a thickness of about 40.0 mm, thereby providing a total thickness of about 50.0 mm; (4) EPP, with a thickness of about 40.0 mm and a density of about 59 kg / m 3 , thereby providing a total thickness of about 50.0 mm. Figure 4 It was observed that in the frequency range of 400 Hz to 1000 Hz (1 / 3 octave), as shown in FIG. 1 , the fiber composition herein applied as the backing of a carpet structure indicates that its sound absorption coefficient (α) is greater than 0.70, or more preferably, in the range of greater than 0.70 to 1.2, and is significantly better than EPP in the critical region of the frequency range of 1000 Hz or less.

[0048] It should be noted that although the above sound test utilizes Figure 1A However, it is expected that similar results will apply to the carpet structure in Figures 1B-1F A carpet structure. Furthermore, as will now be appreciated, such a carpet structure avoids the use of an expanded polypropylene foam pad. Thus, the present invention provides a carpet structure indicating one or more of the following: (a) a sound transmission loss of 20-68 dB within a frequency range of 200-2000 Hz (1 / 3 octave); or (b) an insertion loss in the range of 5.0 dB at 400 Hz (1 / 3 octave) to 25.0 dB at 5000 Hz (1 / 3); or (c) a sound absorption coefficient greater than 0.70 within a frequency range of 400 Hz to 1000 Hz (1 / 3 octave).

[0049] The fiber compositions herein are also such that, when used in a given carpet construction, they match or exceed the compression performance exhibited by EPP. For comparative evaluation, the fiber compositions herein were evaluated according to an OEM compression test protocol (Honda Floor Carpet Specification, PC Spec 6-20, pp. 18-20), wherein various compressive forces in Newtons (N) are applied to the sample being evaluated, along with identification of the weight used to achieve the identified force on the sample, as shown in Table 1 below:

[0050] Table 1

[0051] Displacement code for the identified compressive force

[0052]

[0053]

[0054] Table 2 below provides the performance requirements for test specimens, with respect to whether they receive a Class A or Class B designation. As shown, the Class B designation identifies a relatively lower deflection requirement for the designated load increment, thereby identifying a relatively stiff specimen compared to the Class A designation.

[0055] Table 2

[0056] Compression performance requirements / codes

[0057]

[0058] Table 3 below provides comparative test results for the fiber compositions herein and EPP mats, either alone or in the representative carpet ply structure shown in FIG1 . It is important to note that in Table 3, due to the reference frame in which the measurements are recorded, any increase in the values ​​determined for D1, D2, D3, and D4, compared to the initial height D0, actually represents the amount of compression (in mm) achieved by the sample after 1.0 minute from the indicated applied force (or weight applied to the sample). For example, for the initial EPP mat entry, at a force of 200 N, the EPP mat experienced a compression of 98.5 - 98 = 0.5 mm.

[0059] Table 3

[0060] Comparative compression test

[0061]

[0062]

[0063] Table 4 analyzes the data in Table 3 to determine the compression performance and determines the Class A or Class B designation shown in Table 2:

[0064] Table 4

[0065] Compression performance

[0066]

[0067]

[0068] As can be seen in Table 4, the fiber compositions herein, when applied to a representative carpet layer, provide comparable compression performance and recovery compared to EPP mats, and a Class B designation (see Table 2). In addition, "total recovery" in Table 4 refers to the degree to which a test sample does not rebound to its original size (unit: mm).

[0069] Thus, it can now be appreciated that the present invention provides a noise reducing and compression resistant fiber composition for use in vehicle applications. The fiber composition is suitable for replacing and avoiding the use of expanded polypropylene foam pads currently used in vehicle carpet applications.

Claims

1. A vehicle carpet structure comprising A first nonwoven facing layer, a second nonwoven layer, a film layer, a layer of long spandex fibers of recycled textile fibers, and a backing layer of a fiber composition comprising automotive carpet waste reclaimed material and binder fibers, wherein the carpet structure indicates a sound absorption coefficient greater than 0.70 within a 1 / 3 octave frequency range of 400 Hz to 1000 Hz, and optionally One or more of the following: (a) a sound transmission loss of 20 to 68 dB in the one-third octave frequency range of 200 to 2000 Hz; or (b) the insertion loss is within the range of 5.0 dB at 400 Hz in the 1 / 3 octave band to 25.0 dB at 5000 Hz in the 1 / 3 octave band, The fiber composition of the backing layer comprises 30% to 75% by weight of binder fiber, 25% to 70% by weight of vehicle carpet waste recycled material, and wherein the fiber composition has a thickness in the range of 10.0 mm to 50.0 mm and a density of 20.0 Kg / m 3 Up to 200.0Kg / m 3 within the range.

2. The vehicle carpet structure according to claim 1, wherein: The nonwoven surface layer is present in a thickness of 1.0 mm to 3.0 mm and has a 300 g / m 2 Up to 1200g / m 2 Basis weight; The second nonwoven layer is present in a thickness of 3.0 mm to 5.0 mm and has a 2 Up to 1200g / m 2 Basis weight; The film layer exists in a thickness of 0.01 mm to 0.25 mm; The long elastic fiber layer is 500g / m 2 Up to 2000g / m 2 The present invention is provided with a thickness of 3.0 mm to 50.0 mm at a basis weight of 1.5477 mm.

3. The vehicle carpet structure of claim 1, wherein the vehicle carpet waste recycled material comprises one or more of polyamide, polyester, or polypropylene.

4. The vehicle carpet structure of claim 1, wherein the vehicle carpet waste recycled material contains 5 to 40 wt% of a polymer having a melting point in the range of 80°C to 180°C.

5. The vehicle carpet structure of claim 1, wherein the binder fiber has a melting point in the range of 100°C to 200°C.

6. The vehicle carpet structure of claim 5, wherein the binder fiber has a denier of 2-6 and a length in the range of 20.0 mm to 80.0 mm.

7. The vehicle carpet structure of claim 1 in combination with a vehicle carpet, wherein the fiber composition forms a backing layer of the vehicle carpet.

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