Assessing the Sound and Heat Insulation Characteristics of Layered Nonwoven Composite Structures Composed of Meltblown and Recycled Thermo-Bonded Layers

Sound and heat insulation are among the most important concerns in modern life and nonwoven composite structures are highly effective in noise reduction and heat insulation. In this study, three layered nonwoven composite structures composed of a recycled polyester (r-Pet)-based thermo-bonded nonwoven outer layer and meltblown nonwovens from Polypropylene (PP) and Polybutylene terephthalate (PBT) as inner layers were formed to provide heat and sound insulation. Fiber fineness and cross-section of the thermo-bonded outer layer, fiber type (PP/PBT), areal weight (100/200 g/m2) and process conditions (calendared/non-calendared) of the meltblown inner layer were changed systematically and the influence of these independent variables on thickness, bulk density, air permeability, sound absorption coefficient and thermal resistance of composite structures were analyzed statistically by using Design Expert 13 software. Additionally, the results were compared with composite structures including an electrospun nanofiber web inner layer and with structures without an inner layer. It was concluded that comparable or even better sound absorption values were achieved with the developed nonwoven composites containing meltblown layers compared to nanofiber-included composites and the materials in previous studies.