Fiber-based compositions for noise reduction and crush resistance

Abstract

The present invention is directed to a fibrous composition for noise attenuation and crush resistance for vehicle applications. More particularly, the fibrous composition is suitable for replacing expanded polypropylene foam padding utilized in vehicle carpet applications.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application No. 63 / 049,427, filed July 8, 2020, the entire disclosure of which is incorporated herein by reference.

[0002] Field The present invention is directed to a fibrous composition for noise attenuation and crush resistance for vehicle applications. More particularly, the fibrous composition is suitable for replacing expanded polypropylene foam padding utilized in vehicle carpet applications. [Background technology]

[0003] background It is generally considered desirable to reduce noise levels within the passenger compartment of a vehicle. Exterior noises, such as road noise, engine noise, vibrations, etc., as well as noises emanating from within the passenger compartment, can be attenuated through the use of various acoustic materials. Accordingly, sound-absorbing materials for vehicles, such as automobiles, are conventionally used in the dashboard, in conjunction with carpeting for floor panels, in wheel wells, in the trunk, under the hood, and as part of the headliner.

[0004] Another consideration, particularly with respect to vehicle carpet constructions, is ensuring that such constructions also provide the necessary resistance to OEM compression test requirements, i.e., in addition to noise abatement considerations, vehicle carpet constructions generally must meet specific limits regarding compression and recovery for various prescribed loading protocols. Summary of the Invention [Problem to be solved by the invention]

[0005] For a given carpet construction, the bicycle industry has historically made extensive use of expanded polypropylene (EPP) foam reinforcing padding in various carpet lay-ups to provide corresponding acoustic and compression performance characteristics. Improvement of such acoustic and compression properties through the use of alternative materials, along with potential cost savings, remains a continuing goal. [Means for solving the problem]

[0006] summary A fiber composition comprising 30% (by weight) to 75% (by weight) of binder fiber, 25% (by weight) to 70% (by weight) of vehicle carpet waste regrind, said fiber composition having a thickness ranging from 3.0 mm to 100.0 mm and a density of 20.0 Kg / m 3 to 200.0 kg / m 3 The fibrous composition has a density in the range of 100 to 1500. The fibrous composition is particularly suitable for replacing EPP padding utilized in vehicle carpet applications.

[0007] 1. A vehicle carpet construction comprising a first nonwoven facing layer, a second nonwoven layer having a density higher than that of the first nonwoven facing layer, a membrane layer, a shoddy fiber layer, and a backing layer of a fiber composition comprising 25% (by weight) to 70% (by weight) vehicle carpet waste regrind and 30% (by weight) to 75% (by weight) binder fibers, the fiber composition having a thickness in the range of 3.0 mm to 100.0 mm and a density of 20.0 Kg / m 3 to 200.0 kg / m 3 A vehicle carpet construction having a density in the range of

[0008] 1. A vehicle carpet construction comprising a first nonwoven facing layer, a shoddy fiber layer, and a backing layer of a fiber composition comprising 25% (by weight) to 70% (by weight) vehicle carpet waste regrind and 30% (by weight) to 75% (by weight) binder fiber, said fiber composition having a thickness in the range of 3.0 mm to 100.0 mm and a fiber density of 20.0 Kg / m 3 to 200.0 kg / m 3 A vehicle carpet construction having a density in the range of

[0009] 1. A vehicle carpet construction comprising a first nonwoven facing layer, a polyurethane foam layer, and a backing layer of a fiber composition comprising 25% (by weight) to 70% (by weight) vehicle carpet waste regrind and 30% (by weight) to 75% (by weight) binder fibers, said fiber composition having a thickness in the range of 3.0 mm to 100.0 mm and a fiber density of 20.0 Kg / m 3 to 200.0 kg / m 3 A vehicle carpet construction having a density in the range of

[0010] 1. A vehicle carpet construction comprising a first nonwoven facing layer, a second nonwoven layer having a density higher than that of the first nonwoven facing layer, a shoddy fiber layer, and a backing layer of a fiber composition comprising 25% (by weight) to 70% (by weight) vehicle carpet waste regrind and 30% (by weight) to 75% (by weight) binder fiber, the fiber composition having a thickness in the range of 3.0 mm to 100.0 mm and a density of 20.0 Kg / m 3 to 200.0 kg / m 3 A vehicle carpet construction having a density in the range of

[0011] 1. A vehicle carpet construction comprising a first nonwoven facing layer, a second nonwoven layer having a density higher than that of the first nonwoven facing layer, a mass layer, a shoddy fiber layer, and a backing layer of a fiber composition comprising 25% (by weight) to 70% (by weight) vehicle carpet waste regrind and 30% (by weight) to 75% (by weight) binder fibers, the fiber composition having a thickness in the range of 3.0 mm to 100.0 mm and a density of 20.0 Kg / m 3 to 200.0 kg / m 3 A vehicle carpet construction having a density in the range of

[0012] 1. A vehicle carpet construction comprising a first nonwoven facing layer, a mass layer, a polyurethane foam layer, and a backing layer of a fiber composition comprising 25% (by weight) to 70% (by weight) vehicle carpet waste regrind and 30% (by weight) to 75% (by weight) binder fibers, said fiber composition having a thickness in the range of 3.0 mm to 100.0 mm and a fiber density of 20.0 Kg / m3 to 200.0 kg / m 3 A vehicle carpet construction having a density in the range of

[0013] 1. A vehicle carpet construction comprising a first nonwoven facing layer, a second nonwoven layer, a membrane layer, a shoddy fiber layer and a backing layer of a fibrous composition comprising vehicle carpet waste regrind and binder fibers, said carpet construction comprising: (a) a sound transmission loss of 20 to 68 dB over the frequency range of 200 to 2000 Hz (one-third octave); or (b) an insertion loss ranging from 5.0 dB at 400 Hz (1 / 3 octave) to 25.0 dB at 5000 Hz (1 / 3 octave); or (c) a sound absorption coefficient greater than 0.7 over the frequency range of 400 Hz to 1000 Hz (one-third octave); 1. A vehicle carpet construction showing one or more of: [Brief explanation of the drawings]

[0014] [Figure 1A] FIG. 1A illustrates the use of the fibrous composition herein as a bottom or backing layer in a typical five (5) layer type carpet construction. [Figure 1B] FIG. 1B illustrates the use of the fibrous compositions herein as a bottom or backing layer in a representative three (3) layer type construction. [Figure 1C] FIG. 1C illustrates the use of the fiber compositions herein as a bottom or backing layer in another exemplary three (3) layer type construction. [Figure 1D] FIG. 1D illustrates the use of the fiber compositions herein as a lower or backing layer in a representative four (4) layer type construction. [Figure 1E] FIG. 1E illustrates the use of the fiber compositions herein as a bottom or backing layer in another exemplary five (5) layer type construction. [Figure 1F]FIG. 1F illustrates the use of the fiber compositions herein as a bottom or backing layer in another exemplary four (4) layer type construction. [Figure 2] FIG. 2 is an SAE J1400 test (July 1, 2017) providing a plot of sound transmission loss (dB) versus frequency (Hz) (1 / 3 octave) for the fiber composition herein used as the base or backing layer in the carpet construction of FIG. [Figure 3] FIG. 3 provides the results of the APAMAT insertion loss test, i.e., a plot of insertion loss (dB) versus frequency (Hz) (1 / 3 octave) for a particular sample. [Figure 4] FIG. 4 provides a plot of sound absorption coefficient (α) versus frequency (Hz) (1 / 3 octave) for a particular sample. DETAILED DESCRIPTION OF THE INVENTION

[0015] The present disclosure is directed to a fiber composition for noise reduction and crush resistance for vehicle applications. The fiber composition includes binder fiber and vehicle carpet waste regrind. The binder fiber level is preferably 30% to 75% by weight, and the vehicle carpet waste regrind level is 25% to 70% by weight.

[0016] Binder fibers refer to fibers that have a relatively lower melting point than the nylon or polyamide fibers, polyester fibers, or polypropylene fibers present in vehicle carpet waste regrind, and when heated, serve to bind the existing vehicle carpet waste regrind. The binder fibers may preferably include polyethylene terephthalate (PET) bicomponent fibers composed of two polymers with different chemical and physical properties (e.g., melting points). Therefore, binder fibers having a sheath-core structure, in which the sheath is a relatively low-melting polyester made from a PET copolymer and the core is PET-based, may be utilized. The relatively low-melting polyester may preferably have a melting point in the range of 100°C to 200°C. More preferably, the relatively low-melting polyester has a melting point in the range of 150°C to 200°C or 175°C to 185°C. Therefore, in the broad context of the present invention, binder fibers are not limited to bicomponent fibers, but may include any fiber that provides a melting point in the range of 100°C to 200°C. The binder fibers also preferably have a denier (D) value of 2 to 6 and a length ranging from 20.0 mm to 80.0 mm, more preferably from 40.0 mm to 60.0 mm.

[0017] The vehicle carpet waste regrind herein comprises, as a first fiber component, one or more nylon (polyamide), polyester, or polypropylene fibers, which may include a polymer-type coating resin, such as a polymer latex coating. Such coatings are preferably provided from polyolefins (e.g., polyethylene or polypropylene). The vehicle carpet waste regrind herein itself preferably includes some polymer having a melting point in the range of 80°C to 180°C, or even more preferably, in the range of 100°C to 120°C. Preferred levels of such polymers with the aforementioned melting behavior are in the range of 5% to 40% by weight, more preferably 10% to 30% by weight. The vehicle carpet waste is then preferably ground or shredded to provide a source of vehicle carpet waste regrind material herein. Such vehicle carpet waste regrind may be sourced from vehicle manufacturing facilities, where vehicle carpet waste regrind is conveniently available at a relatively lower cost than EPP.

[0018] The fibrous composition (binder and vehicle carpet waste regrind) may be utilized in a representative carpet construction layup 10 as shown in Figure 1A. However, within the broad context of the present invention, it should be understood herein that such a fibrous composition may be utilized in any carpet construction layup to replace the use of EPP padding material.

[0019] The representative carpet construction in Figure 1A includes a surface layer 12, which is preferably a nonwoven layer provided from PET and having a thickness in the range of 1.0 mm to 3.0 mm. Such nonwovens preferably have a thickness of 300 g / m 2 from 1200g / m 2 This may include a thickness of 3.0 mm to 5.0 mm and a basis weight of 450 g / m 2 Over 1200g / m 2This is followed by a nonwoven layer 14, which is also preferably sourced from PET, and has a relative density of 500 g / m². Preferably, the nonwoven layer 14 has a higher relative density than the nonwoven facing layer 12. A polymeric film layer 16 is preferably present at a thickness of 0.01 mm to 0.25 mm, such film preferably being selected from polyolefin polymers such as polyethylene or polypropylene. A shoddy fiber insulation layer is then present at 18, reference to shoddy being generally understood as recycled textile fibers. The shoddy insulation layer preferably has a density of 500 g / m². 2 to 2000g / m 2 It has a basis weight of 3.0 mm to 50.0 mm in thickness.

[0020] The fiber composition of 20 herein preferably serves as the bottom or backing layer of certain carpet layups. Such fiber composition is preferably utilized herein to replace the use of EPP padding as such bottom or backing layer in certain vehicle carpet constructions. The fiber composition of 20 preferably has a layer thickness of 3.0 mm to 100.0 mm and a density of 20.0 Kg / m 3 to 200.0 kg / 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 for the fiber composition 20 include 50.0 to 150.0 Kg / m 3 or 100 kg / m 3 to 150.0 kg / m 3 Thus, as can be seen, a vehicle carpet construction such as that shown in FIG. 1A can avoid the use of a foamed polypropylene pad.

[0021] As alluded to above, the fibrous composition 20 herein may be used as a backing layer in other exemplary carpet layups, which may similarly avoid the need to utilize expanded polypropylene. FIG. 1B shows an exemplary carpet construction 22, again including a face layer 12, a shoddy layer 18, and the fibrous composition 20 as a backing layer. The face layer 12 is again preferably a nonwoven layer having a thickness ranging from 1.0 mm to 3.0 mm, preferably sourced from PET. Such nonwovens are preferably 300 g / m 2 from 450 g / m 2 Again, the shoddy layer 18 may have a basis weight in the range of 500 g / m 2 to 2000g / m 2 It is a recycled textile fiber having a basis weight of 3.0 mm to 50.0 mm in thickness.

[0022] Figure 1C shows a typical carpet construction 24. Again, there is a surface layer 12, which is preferably provided from PET and has a weight of 300 g / m 2 from 450 g / m 2 A nonwoven layer having a basis weight in the range of 1.0 mm to 3.0 mm and a thickness in the range of 1.0 mm to 3.0 mm is then added to the nonwoven layer. 3 to 100.0 kg / m 3 This is followed by a polyurethane foam layer 26 having a density in the range of 1000 psi. The fibrous composition backing layer is again designated 20. The need to utilize expanded polypropylene is again avoided.

[0023] Figure ID shows an exemplary carpet construction 28, which is similar to the exemplary carpet construction 10 in Figure IA, but does not include the film layer 16. The fibrous composition backing layer is again indicated at 20. The need to utilize expanded polypropylene is again avoided.

[0024] Figure 1E shows a representative carpet structure 30. The structure is similar to the representative carpet structure 10 in Figure 1A, with the film layer 16 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, preferably in a thickness range of 0.5 mm to 3.0 mm and 800 g / m 2 to 4000g / m 2 The need to utilize expanded polypropylene is again avoided.

[0025] 1F shows an exemplary structure 32. This structure includes a surface layer 12 as described herein, a mass layer 32 as described herein, a polyurethane foam layer 26 as described herein, and a fibrous composition 20 as a backing layer. The need to utilize expanded polypropylene is again avoided.

[0026] As noted above, the fiber compositions 20 herein can completely replace the use of EPP padding in vehicle carpet construction while providing improved noise attenuation and the requisite compression performance. Turning first to a consideration of noise attenuation, the fiber compositions herein demonstrate improved sound transmission loss, insertion loss, and sound absorption coefficient in important frequency ranges, as detailed below.

[0027] 2 provides a plot of sound transmission loss (dB) versus frequency (Hz) (1 / 3 octave) according to the general procedure in SAE J1400 testing (July 1, 2017) for the fiber composition herein as used as the bottom or backing layer 20 in the carpet construction of FIG. 1A , where the facing, nonwoven, film, and insulating layers have a thickness of 10.0 mm. The fiber composition herein (binder fiber and vehicle carpet waste regrind) identified in FIG. 2 by the trademark ECOBLEND™ has a sound transmission loss of approximately 40.0 mm, a density of 98 Kg / m 3, thus providing a total carpet thickness of approximately 50.0 mm. This means that the same 10.0 mm carpet structure (surface layer, hard layer, thin film and insulating layer) would have a thickness of 40.0 mm on the backside, with a density of approximately 59 Kg / m 3 The results were compared to those using an expanded polypropylene pad having a density of 1000 Hz. As can be seen, the fiber composition-based carpet constructions provided sound transmission losses (dB) ranging from 20 to 68, consistently superior to carpet constructions utilizing EPP, across frequencies from 200 to 2000 Hz (1 / 3 octave). On average, the improvement in sound transmission loss for carpet constructions utilizing the fiber composition herein was approximately 10 dB better across frequencies from 200 to 2000 Hz (1 / 3 octave).

[0028] 3 provides the results of the APAMAT-II (Autoneum) insertion loss test, i.e., a plot of insertion loss (dB) versus frequency (Hz) (1 / 3 octave) for identified samples of either the fiber compositions herein or EPP as the bottom layer 20, as applied to a 10.0 mm thick layup (see FIG. 1A) of a carpet construction. Accordingly, the following were applied as the bottom layer of such a carpet construction: (1) 45 Kg / m 3 (2) 132 kg / m2, with a thickness of approximately 30.0 mm of EPP, providing a total thickness of approximately 40.0 mm. 3 (3) a density of 98 Kg / m 2 and a thickness of about 30.0 mm of the fiber composition herein provides a total thickness of about 40.0 mm; 3 (4) a fiber composition herein having a thickness of about 40.0 mm at a density of about 59 Kg / m 3A thickness of about 40.0 mm of EPP at a density of 1000 Hz provides a total thickness of about 50.0 mm. As can be observed, the fiber compositions herein, when applied to the backside of a carpet construction, provide insertion losses ranging from about 5.0 dB at 400 Hz (1 / 3 octave) to 25.0 dB at 5000 Hz (1 / 3 octave). It can again be observed that the fiber compositions herein, when applied to the backside of a given carpet construction, outperform the use of EPP.

[0029] Attention is now directed to Figure 4, which provides a plot of sound absorption coefficient (α) versus frequency (Hz) (1 / 3 octave) for identified samples of either the fiber composition herein or EPP as bottom layer 20, as applied to a 10.0 mm thick layup (see Figure 1A) of a carpet construction. The sound absorption coefficient is determined in accordance with the general procedure of ASTM C423-17, "Standard Test Method for Sound Absorption Coefficient by Reverberation Chamber Method." Accordingly, again, the following were applied as bottom layer 20 of such carpet construction: (1) 45 Kg / m 3 (2) 132 kg / m2, with a thickness of approximately 30.0 mm of EPP, providing a total thickness of approximately 40.0 mm. 3 (3) a density of 98 Kg / m 2 and a thickness of about 30.0 mm of the fiber composition herein provides a total thickness of about 40.0 mm; 3 (4) a fiber composition herein having a thickness of about 40.0 mm at a density of about 59 Kg / m 3 A thickness of about 40.0 mm of EPP at a density of 1000 Hz provides a total thickness of about 50.0 mm. Thus, as can be observed in Figure 4, over the frequency range of 400 Hz to 1000 Hz (1 / 3 octave), the fiber compositions herein applied as the bottom layer of a carpet construction such as that shown in Figure 1 exhibit sound absorption coefficients (α) greater than 0.70, or more preferably having values ​​ranging from greater than 0.70 to 1.2, significantly outperforming EPP in what may be considered the Key Area of ​​the frequency range below 1000 Hz.

[0030] It should be noted that while the above acoustic testing utilized the carpet structure of Figure 1A, similar results are believed to apply to the carpet structures of Figures 1B-1F. Also, as can be appreciated, such carpet structures avoid the use of expanded polypropylene foam padding. Accordingly, the present invention provides carpet structures that exhibit one or more of the following: (a) a sound transmission loss of 20-68 dB over the frequency range of 200-2000 Hz (1 / 3 octave); or (b) an insertion loss ranging from 5.0 dB at 400 Hz (1 / 3 octave) to 25.0 dB at 5000 Hz (1 / 3 octave); or (c) a sound absorption coefficient of greater than 0.70 over the frequency range of 400 Hz to 1000 Hz (1 / 3 octave). [Example]

[0031] The fiber compositions herein are also such that when utilized in a given carpet construction, they will equal or exceed the compression performance exhibited by EPP. For comparative evaluation, the fiber compositions herein are evaluated according to the OEM compression test protocol (Honda Floor Carpet Specifications, PC Specs 6-20, pages 18-20) as shown in Table 1 below, in which various compression forces (Newtons (N)) are applied to the sample being evaluated, while simultaneously identifying the weight applied to the sample to achieve the specified force.

[0032] [Table 1]

[0033] Table 2 below then provides the performance requirements for the samples tested to receive a Class A or Class B designation. As can be seen, a Class B designation specifies a relatively low deflection requirement for a specified load increment, thereby specifying a relatively stiffer sample compared to a Class A designation.

[0034] [Table 2]

[0035] Table 3 below provides the results of the comparative testing of fiber compositions versus EPP pads herein, both by themselves and in the representative carpet layup construction shown in Figure 1. In Table 3, for the frame of reference for the recorded measurements, it should be noted that the specified increases in values ​​for D1, D2, D3, and D4, as compared to the initial height D0, actually represent the amount of compression in mm that the sample achieved from the indicated applied force (or weight applied to the sample) after 1.0 minute. For example, for the first EPP pad entry, at a force of 200 N, the EPP pad underwent a compression of 98.5 - 98 = 0.5 mm.

[0036] [Table 3]

[0037] Table 4 provides an analysis of the data in Table 3 and identifies the compression performance and the decision for either Class A or Class B designation as shown in Table 2.

[0038] [Table 4]

[0039] As can be seen from Table 4, the fiber compositions herein, either by themselves or when applied to a typical carpet layup, provide comparable compression performance and recovery compared to EPP padding and are designated Class B (see Table 2). Also, "Full Recovery" in Table 4 indicates how much of the tested sample did not return to its original size in mm.

[0040] Thus, it can now be seen that the present invention provides a fibrous composition for noise attenuation and compression resistance for vehicle applications, which is suitable for replacing and avoiding the use of expanded polypropylene foam padding currently utilized in vehicle carpet applications.

Claims

1. 30% (by weight) to 75% (by weight) of binder fibers; 25% (by mass) to 70% (by mass) vehicle carpet waste regrind; A fiber composition comprising: The fiber composition has a thickness ranging from 3.0 mm to 100.0 mm and a density of 20.0 kg / m ３ to 200.0 kg / m ３ The fiber composition has a density in the range of

2. 10. The fibrous composition of claim 1, wherein the vehicle carpet waste regrind comprises one or more of polyamide, polyester, or polypropylene.

3. 10. The fiber composition of claim 1, wherein the vehicle carpet waste regrind comprises 5% to 40% by weight of a polymer having a melting point in the range of 80°C to 180°C.

4. The fiber composition of claim 2 , wherein the binder fiber has a melting point in the range of 100° C. to 200° C.

5. 5. The fiber composition of claim 4, wherein the binder fibers have a denier of 2 to 6 and a length ranging from 20.0 mm to 80.0 mm.

6. 10. The fiber composition of claim 1 in combination with a vehicle carpet, said fiber composition forming a backing layer of said vehicle carpet.

7. 1. A vehicle carpet construction comprising a first nonwoven facing layer, a second nonwoven layer, a membrane layer, a shoddy fiber layer, and a backing layer of a fibrous composition comprising vehicle carpet waste regrind and binder fibers, The fiber composition of the backing layer comprises 30% (by weight) to 75% (by weight) of binder fiber, 25% (by weight) to 70% (by weight) of vehicle carpet waste regrind, the backing layer having a thickness in the range of 3.0 mm to 100.0 mm, and a fiber density of 20.0 Kg / m ３ to 200.0 kg / m ３ and having a density in the range of The carpet structure comprises: (a) a sound transmission loss of 20 to 68 dB over the frequency range of 200 to 2000 Hz (one-third 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 octave); or (c) a sound absorption coefficient greater than 0.70 over the frequency range of 400 Hz to 1000 Hz (1 / 3 octave); 1. A vehicle carpet construction showing one or more of:

8. The first nonwoven facing layer is present at a thickness of 1.0 mm to 3.0 mm and has a density of 300 g / m ２ to 1200 g / m ２ having a basis weight of The second nonwoven layer is present at a thickness of 3.0 mm to 5.0 mm and has a density of 450 g / m ２ to 1200 g / m ２ having a basis weight of the membrane layer is present at a thickness of 0.01 mm to 0.25 mm; The shoddy fiber layer has a density of 500 g / m ２ to 2000 g / m ２ and a thickness of 3.0 mm to 50.0 mm.

8. The vehicle carpet construction of claim 7.

9. 8. The vehicle carpet construction of claim 7, wherein the vehicle carpet waste regrind comprises one or more of polyamide, polyester, or polypropylene.

10. 8. The vehicle carpet construction of claim 7, wherein the vehicle carpet waste regrind comprises 5% to 40% by weight of polymers having a melting point in the range of 80°C to 180°C.

11. 1. A vehicle carpet construction comprising a first nonwoven facing layer, a second nonwoven layer having a density higher than that of the first nonwoven facing layer, a membrane layer, a shoddy fiber layer, and a backing layer of a fibrous composition comprising 25% (by weight) to 70% (by weight) vehicle carpet waste regrind and 30% (by weight) to 75% (by weight) binder fibers, the fibrous composition having a thickness in the range of 3.0 mm to 100.0 mm and a density of 20.0 Kg / m ３ to 200.0 kg / m ３ A vehicle carpet construction having a density in the range of

12. 1. A vehicle carpet construction comprising a first nonwoven facing layer, a shoddy fiber layer, and a backing layer of a fiber composition comprising 25% (by weight) to 70% (by weight) vehicle carpet waste regrind and 30% (by weight) to 75% (by weight) binder fiber, said fiber composition having a thickness in the range of 3.0 mm to 100.0 mm and a fiber density of 20.0 Kg / m ３ to 200.0 kg / m ３ A vehicle carpet construction having a density in the range of

13. 1. A vehicle carpet construction comprising a first nonwoven facing layer, a polyurethane foam layer, and a backing layer of a fibrous composition comprising 25% (by weight) to 70% (by weight) vehicle carpet waste regrind and 30% (by weight) to 75% (by weight) binder fibers, said fibrous composition having a thickness in the range of 3.0 mm to 100.0 mm and a saturation of 20.0 Kg / m ３ to 200.0 kg / m ３ A vehicle carpet construction having a density in the range of

14. 1. A vehicle carpet construction comprising a first nonwoven facing layer, a second nonwoven layer, a shoddy fiber layer, and a backing layer of a fiber composition comprising 25% (by weight) to 70% (by weight) vehicle carpet waste regrind and 30% (by weight) to 75% (by weight) binder fiber, said fiber composition having a thickness in the range of 3.0 mm to 100.0 mm and a fiber density of 20.0 Kg / m ３ to 200.0 kg / m ３ A vehicle carpet construction having a density in the range of

15. 1. A vehicle carpet construction comprising a first nonwoven facing layer, a second nonwoven layer, a mass layer, a shoddy fiber layer, and a backing layer of a fiber composition comprising 25% (by weight) to 70% (by weight) vehicle carpet waste regrind and 30% (by weight) to 75% (by weight) binder fiber, said fiber composition having a thickness in the range of 3.0 mm to 100.0 mm and a density of 20.0 Kg / m ３ to 200.0 kg / m ３ A vehicle carpet construction having a density in the range of

16. 1. A vehicle carpet construction comprising a first nonwoven facing layer, a mass layer, a polyurethane foam layer, and a backing layer of a fiber composition comprising 25% (by weight) to 70% (by weight) vehicle carpet waste regrind and 30% (by weight) to 75% (by weight) binder fibers, said fiber composition having a thickness in the range of 3.0 mm to 100.0 mm and a density of 20.0 Kg / m ３ to 200.0 kg / m ３ A vehicle carpet construction having a density in the range of

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