Bicomponent Fiber in Sound Absorbent Production : Investigation of using bicomponent fiber as adhesive between woven and nonwoven textile and how it affects the sound absorption

Sammanfattning: A new way of adhering woven textile to a nonwoven backing was explored, the end product in mind being a sound absorbent panel. Today a hot melt adhesive is sprayed on the nonwoven with woven decorating textile put on top before compression molding. This method results in an uneven layer of adhesive with the consequence of decorating textile detaching from the nonwoven and thereby a high number of discarded products. The report investigates the possibility of using a bicomponent fiber as the adhesive. This would guarantee an even layer of adhesive and make the manufacturing process one step shorter. A bicomponent fiber of core/sheath construction with a low melting polymer in the sheath was incorporated in the nonwoven upon fabrication. In the main bulk of the nonwoven a smaller ratio of bicomponent to normal polyester fiber was used, enough to stabilize the nonwoven. For the top layer of the nonwoven a higher ratio was chosen. As the nonwoven is then compression molded under heat together with the decorating textile, the low melting sheath of the bicomponent fiber will melt and create bonds within the nonwoven as well as to the textile. The ratio in the top layer was varied as well as the pressure in compression molding. The adhesion strength between nonwoven and decorating textile was tested, and the sound absorbing properties of the different manufactured samples were compared. The sound absorbing parameter of air flow resistance was tested and sound absorption was tested using impedance tube with transfer function method. Further, a way of testing transmission loss was developed by the manufacturing of a custom built impedance tube, which was then compared to the transfer function method. The results showed that a higher bicomponent percentage gave higher sound absorption in lower frequencies, but a lower sound absorption in higher frequencies. The thickness of the samples gave a positive effect on the sound absorption in all frequencies. The conclusion is to recommend a thicker material, and choose bicomponent according to which frequencies that should be absorbed and what adhesion strength is needed for end product.