Sound insulation property of recycled high-density polyethylene/waste jute fabric composites Jonty Mago 1 Automotive Health Monitoring Laboratory, Centre for Automotive Research & Tribology, Indian Institute of Technology Delhi, Hauz Khas, New Delhi-110016, India Sunali 2 Automotive Health Monitoring Laboratory, Centre for Automotive Research & Tribology, Indian Institute of Technology Delhi, Hauz Khas, New Delhi-110016, India Ashutosh Negi 3 School of Interdisciplinary Research, Indian Institute of Technology Delhi, Hauz Khas, New Delhi- 110016, India Automotive Health Monitoring Laboratory, Centre for Automotive Research & Tribology, Indian Institute of Technology Delhi, Hauz Khas, New Delhi-110016, India Renewable Energy and Chemicals Laboratory, Department of Chemical Engineering, Indian Institute of Technology Delhi, New Delhi-110016, India S. Fatima 4 Automotive Health Monitoring Laboratory, Centre for Automotive Research & Tribology, Indian Institute of Technology Delhi, Hauz Khas, New Delhi-110016, India

ABSTRACT

The present research aims to develop sound-insulating materials by utilizing recycled plastic (recycled high-density polyethene-rHDPE) and waste jute fabric (WJF) through the compression molding technique. Two configurations (Neat rHDPE and rHDPE+WJF composite) of sheets were developed. The effect of the sandwiched WJF (10% by wt.) layer in the rHDPE matrix on sound insulation property was studied. The prepared sheets were thoroughly characterized for their properties related to sound insulation, i.e., density (ASTM D792-20), tensile strength, and modulus (ASTM D638-14). The sound transmission loss (STL) of the developed sheets was measured as per ASTM-E2611-17 using a four-microphone impedance tube setup. The developed sheets of neat rHDPE and rHDPE+WJF composite sheets exhibited a density of 974 and 998 kg/m 3 , respectively. However, the rHDPE+WJF composite sheet possesses  18.24 and  46.52% higher tensile strength and modulus than the neat rHDPE sheet. Moreover, both developed sheets demonstrated excellent sound insulation properties (average STL of  49.01 (rHDPE) and  50.07 dB (rHDPE+WJF composite)).

1 jontymago@gmail.com 2 Sunali013@gmail.com 3 negi.ashutosh90@gmail.com 4 fatima@iitd.ac.in

Jai. inter noise 21-24 AUGUST SCOTTISH EVENT CAMPUS ? O ? . GLASGOW

1. INTRODUCTION

Noise pollution is a potential threat to human health and the environment. Using acoustic materials (barriers/insulators and absorbers) in the noise path is a customarily approach for noise control [1]. Nowadays, compared to traditional sound insulating materials (metals, gypsum, and concrete), polymers (plastics) have gained more interest among researchers because of their unique features like lightweight, ease of design, low cost, and available state-of-the-art technologies for mass production. However, most polymer materials need to improve their sound insulation properties to meet practical application requirements because their density and modulus are relatively low [2]. An appropriate way to improve the sound insulation performance of polymer materials is to add inorganic fillers or fiber to the polymer matrix to improve its modulus and density.

Therefore, different particle reinforcements/fillers (alumina nanoparticles, CaCO 3 , carbon black, carbon nanotubes, carbon fiber, clay, hollow glass bead, hollow glass mesosphere, mica, nano clay, and exfoliated graphite nanoplatelet) and polymer matrixes (acrylonitrile butadiene styrene, high- density polyethylene, low-density polyethylene, polypropylene, polyvinyl acetate, thermoplastic elastomer, and thermoplastic rubber) have been used to develop numerous particle reinforced polymer composites through solution blending, compression molding, casting and injection molding for improving sound insulation performance of the polymer materials [2-14]. Significant improvement in STL has been observed in the stiffness control region, which is attributed to the increased stiffness of the composite upon loading of fillers.

Moreover, many fiber-reinforced polymer composites have been developed using different manufacturing methods (vacuum bagging, carding, needle punching, and compression molding) to increase STL. The fibers utilized in the studies are carbon, jute, kenaf, bio luffa, linen, glass, flax, hemp, sisal, banana, coir, whereas the polymer matrixes used in the studies are epoxy bio epoxy, natural rubber, polypropylene, and urea-formaldehyde [15-28]. Higher STL has been successfully achieved in both lower (stiffness control region) and higher (mass control region) frequencies.

Concurrently, the massive amounts of solid waste such as plastic, e-waste, garment waste (textile), and agro residue end up in landfills or are incinerated [29-32]. Disposal of these solid wastes through landfilling or burning in the air deteriorates the environment. In the context of these problems, waste obtained from various sources such as used tires, blast furnace slag, printed circuit board, Washingtonia palm tree pruning, automotive parts, cotton fiber, denim, leather cutting, rice husk, etc., has been effectively used to develop the composite sound insulating materials [31,33-39]. Moreover, this research area (utilization of waste for developing sound insulating materials) requires further exploration.

Therefore, the proposed work aims to utilize rHDPE and WJF to develop sound-insulating materials through the compression molding technique. Two sheets (Neat rHDPE and rHDPE+WJF composite) have been developed and characterized using a four-microphone impedance tube, a universal testing machine, and analytical balance for STL, tensile strength, and density, respectively.

2. MATERIALS & METHODS

2.1. Raw Materials

The present study utilizes recycled high-density polyethylene (rHDPE) and waste jute fiber as a matrix and reinforcement material. rHDPE flakes obtained from discarded shampoo bottle (Figure 1(a)) was procured from Saurabh Plastic, Nangloi, Delhi. Further, with the help of a 50 HP disc shape pulverizer (Facility at the N.S. Fabricator Works, Bawana, Delhi), the rHDPE flakes were converted into a powder (Figure 1(b)) of particle size  500  30  m. The pulverized rHDPE powder was utilized for the development of sound-insulating materials. However, waste textile jute fiber (average fiber

diameter- 49.6  9.2  m) in the form of needle punched nonwoven fabric, i.e., waste jute fabric (WJF) of 600  25 GSM (Figure 1 (c)), was supplied by Eskay International, Kolkata, West Bengal.

Figure 1: (a) rHDPE flakes (b) rHDPE powder (c) waste jute fabric

2.2. Compression Molding

In the current work, two configurations of sound-insulating material were developed to study the effect of WJF reinforcement in the rHDPE matrix. The first configuration was made with only rHDPE powder, whereas the second configuration consists of one layer of WJF (10% by wt.) sandwiched between the two layers of the rHDPE powder, as illustrated in Figures 2 (a) and (b). Notations for the configuration first and second are neat rHDPE and rHDPE+WJF composite, respectively.

Figure 2: (a) Configuration 1-neat rHDPE (b) configuration 2-rHDPE+WJF composite

For both configurations, the sheets of length-28 mm, width-18 mm, and thickness-5 mm dimensions were developed through the compression molding technique. The parameters used during compression molding are given in Table 1.

Table 1: Compression molding parameters for the development of neat rHDPE and rHDPE+WJF

composite sheets Parameter Description Machine Model: Hydraulic; Make: Kalson Hydromantic, Ghaziabad, India Compression Pressure 5  0.2 MPa Temperature 120  5  C (Heating rate- 1  C/min) Breathing Cycles Three (to remove entrapped gasses and reduce voids)

Holding Time Fifteen minutes after applying pressure. After that, the material was slowly cooled to ambient temperature while still under pressure

2.3. Sample Preparation & Characterization

The specimens of four different dimensions as per ASTM D638-14 (Type I dumbbell-shaped), ASTM E2611-17 (29 mm diameter and 100 mm diameter), and ASTM D792-20 (10 mm  10 mm  5 mm)

were cut from the developed neat rHDPE and rHDPE+WJF composite sheets using water jet cutting machine (Model: Protomax; Make: Omax, USA) for the characterization of physical, mechanical, and acoustical properties. 2.3.1. Physical Property

The density of neat rHDPE and rHDPE+WJF composite sheets were measured on an analytical balance (Model: ME155DU; Make: Mettler Toledo, Switzerland), having the least count of 0.01 mg as per ASTM D792-20 (Test method B for testing solid plastics in liquids other than water) following Archimedes principle. The density was calculated using Equation 1 [40].

஡ ౢ౟౧౫౟ౚ ×୛ ౗౟౨ ୛ ౗౟౨ ି୛ ౢ౟౧౫౟ౚ (1)

ρ ୫ୟ୲ୣ୰୧ୟ୪ =

Where  material (in kg/m 3 ) is the density of material (rHDPE and rHDPE+WJF composite),  liquid is the density of the liquid (ethanol was used in the present work,  ethanol = 789 kg/m 3 ), W air is the weight of material in the air, and W liquid is the weight of material fully submerged in the liquid, i.e., ethanol.

2.3.2. Mechanical Property

Tensile tests of neat rHDPE and rHDPE+WJF composite sheets were carried out as per ASTM D638- 14 on the universal testing machine (Model: Z010; Make: Zwick/Roell, Germany). Type I dumbbell- shaped specimens were tested at a 50 mm/min crosshead speed. The test data were obtained in terms of load and deformation. The tensile stress (  ) in MPa, strain (ϵ) in mm/mm, and modulus (E) in GPa were computed with Equations 2, 3, and 4 [41]. The average tensile strength, modulus, and elongation at the break of three measurements were reported.

୊

ୠୢ (2)

σ =

∆୐

୐ ో (3)

ϵ =

஢

஫ (4)

E =

Where F is the tensile load in N, b is the width of the narrow section of the specimen in mm (13 mm), d is the thickness of the specimen in mm (5 mm), L o is the gage length of the specimen in mm (50 mm) and  L in the change in length upon loading in mm.

2.3.3. Acoustical Property

Sound transmission loss (STL) is the quantitative metric for the sound insulation performance of the material. Theoretically, it is defined as ten times the common logarithmic ratio of incident sound power to transmitted sound power (Equation 5 [2]). However, practical STL calculation utilizes the transfer matrix method, which involves STL measurement with two different terminations (hard- backed and anechoic). Sound transmission loss (STL) of the neat rHDPE and rHDPE+WJF composite sheets were characterized as per ASTM E2611-17 using a four-microphone impedance tube setup (Model: Type 4206-T; Make: Bruel & Kjaer, Denmark). The schematic of four microphone impedance tube is shown in Figure 3. Specimen of 100 mm diameter were tested for the low- frequency range (63 Hz to 1.6 kHz) and whereas the specimen of 29 mm diameter was tested in the medium to high-frequency range (500 Hz to 6.4 kHz) at 24  C and 50% RH. The rHDPE mounted specimens in 100 mm and 29 mm diameter impedance tubes with the help of sample holders are shown in Figures 3 (a) and (b), respectively.

୛ ౟ ୛ ౪ ቁ = 10 log ଵ଴ ቀ

ଵ

த ቁ (5)

STL = 10 log ଵ଴ ቀ

where STL = Sound transmission loss in dB, W i = Incident sound power in W, W t = Transmitted sound power in W, τ =

ௐ ೟ ௐ ೔ = Sound transmission coefficient.

Figure 3: Schematic of four microphone impedance tube setup for STL measurement

put & 2 Channel Generator ion System (Type 3160-A-042) Front End (Type UA-2102-042) Display Power Amplifier (Type 2735) Preamplifier (Type 2670) Mic-4 (Type 4187) cS D <——— Test Material Speaker Anechoic Termination

Figure 4: (a) Neat rHDPE sheet 100 mm diameter specimen; (b) neat rHDPE sheet 29 mm diameter

specimen mounted in impedance tube

3. RESULTS & DISCUSSION 3.1. Density

Table 2 contains the values of rHDPE flakes, WJF, neat rHDPE sheets, and rHDPE+WJF composite sheets densities. It was observed that  2.10% increase in the density of rHDPE on its conversion into sheets from flakes/powder through compression molding. The improved density of the neat rHDPE sheets can be attributed to the reduction in void content because of high compression pressure in compression molding, and slow cooling after molding might have improved the degree of crystallinity hence the density [42]. However, the results indicate that the density of the rHDPE+WJF composite sheets was  4.6% higher than the neat rHDPE sheets as the density of sandwiched WJF (1323 kg/m 3 ) was higher than that of rHDPE.

Table 2: Density values of rHDPE flakes, WJF, neat rHDPE sheet, and rHDPE+WJF composite

sheet Material Composition Density (kg/m 3 ) rHDPE Flakes 954 WJF 1323 Neat rHDPE Sheet 974 rHDPE+WJF Composite Sheet 998

3.2. Tensile Strength

Figure 5 shows the typical stress-strain curve of the neat rHDPE and rHDPE+WJF composite sheets. Also, the calculated results of tensile properties (tensile strength, tensile modulus, and elongation at break are summarized in Table 3. The tensile strength indicates the interfacial bonding between matrix and fiber, whereas the tensile modulus depends on the fiber concentration, fiber aspect ratio, and wettability of fiber in the matrix [41]. The steep rise in the slope of the curve was observed for the rHDPE+WJF composite sheet, indicating higher tensile strength. The tensile strength was enhanced from 27.28  0.11 MPa to 32.25  0.53 MPa (  18.24%) with the addition of the WJF layer in the rHDPE matrix, it can be understood from the fact that fiber in the polymer matrix improves the load-bearing capacity of the composite [43]. Moreover, the rHDPE+ WJF composite sheets depicted  46.52% higher tensile modulus (stiffness) than the neat rHDPE sheet. Further, from Figure 5, it can be seen that the ductility of the rHDPE matrix has decreased (58.27% decrease in elongation at the break was recorded) with the addition of the WJF layer. The results presented in the present work are close to the results obtained using virgin HDPE and jute fabric composites [41].

Neat rHDPE rHDPE+WJF Composite

Figure 5: Typical stress vs. strain curve for neat rHDPE and rHDPE+WJF composite sheets

T able 3: Tensile test results for neat rHDPE and rHDPE+WJF composite shee ts

Neat rHDPE

rHDPE+WJF Composite Sheets

Percentage Change (%) Tensile Strength (MPa) 27.28  0.11 32.25  0.53 18.24 Tensile Modulus (GPa) 0.15  0.01 0.22  0.02 46.52 Elongation at Break (mm) 34.22  1.43 14.28  0 . 86 -58.27

Sheets

3.3. Sound Transmission Loss

Figure 6 illustrates the normal incidence STL vs. frequency curves for the neat rHDPE and rHDPE+WJF composite sheets. Both STL curves show a similar trend. STL is a frequency-dependent

00 O1 02 03 04 O05 06 07 O08 Strain (mm/mm)

phenomenon; based on the frequency; the STL curve is divided into four main regions: (1) At lower frequencies, the stiffness-controlled region (STL depends on materials and mounting stiffness), (2) At lower-medium frequencies, the resonance-controlled region (STL depends on materials damping), (3) At medium-higher frequencies the mass-controlled region (STL depends on materials surface density), and (4) At higher frequencies the coincidence-controlled region (STL depends on materials bending stiffness) [44,45]. In the present work, the frequency range of different frequency regions was identified for both sheets as follows: 63-100 Hz (stiffness-controlled region), 125-500 Hz (resonance-controlled region), 630-3150 Hz (mass-controlled region), and above 4 kHz (coincidence-controlled region). The developed rHDPE+WJF composite sheets demonstrated higher STL than the neat rHDPE sheets at all frequencies. Both sheets showed the highest STL (98 and 100.82 dB) in the 3150 Hz octave frequency band. The average STL of neat rHDPE was 49.01 dB, whereas the sound insulation property was slightly improved by  2.16% (50.07 dB) with the addition of WJF in the rHDPE matrix. However, both developed sheets exhibited exceptional STL compared to 6 mm steel plate (37.83 dB) [46]. The higher surface density (neat rHDPE- 4.87 kg/m 2 and HDPE+WJF composite- 4.99 kg/m 2 ) and modulus (Table 3) of the HDPE+WJF composite sheet can be held responsible for better sound insulation property than neat rHDPE sheet.

j=—=2— Neat rHDPE = rHDPE+WJF Composite!

Se >- Oo oO & oe) D> ~~ oOo LLS a0uapio

Figure 6: Normal incidence STL vs. frequency curve for neat rHDPE and rHDPE+WJF composite

sheets

4. CONCLUSIONS

The present study focuses on utilizing rHDPE and WJF to develop sound-insulating materials through the compression molding technique. Based on the physical, mechanical, and acoustical investigations, the following major conclusions are drawn: a. Neat rHDPE and rHDPE+WJF composite sheets exhibited  2.10 and  4.6% higher density than

the rHDPE flasks, respectively. b.  18.24 and  46.52% enhancement in tensile strength and modulus of composite has been

Uy [VULION

observed, respectively, with sandwiched WJF layer in the rHDPE matrix. c. Neat rHDPE and rHDPE+WJF composite sheets showed an average STL of 49.01 dB and 50.07

dB, respectively. The appropriate physical, mechanical, and acoustical properties of the developed sheets suggest their suitability for sound insulation applications.

0 1000 2000 3000 4000 5000 Frequency (Hz)

5. ACKNOWLEDGEMENTS

The authors would like to acknowledge the Central Research Facility (CRF) and Friction Wear Laboratory, Center for Automotive Research and Tribology (CART), at the Indian Institute of Technology Delhi for providing tensile testing and density measurement facilities.

6. FUNDINGS

This study is financially supported by the Department of Science and Technology (DST), India, under the project titled, ‘Sustainable Processing of Agro-residual Waste to Produce Acoustic Materials and Bio-renewable Chemicals using Green Solvents’ [Grant No.: RP03946] and foundation for Innovation and Technology Transfer (FITT) of the Indian Institute of Technology Delhi, under the project titled, ‘Development of Vibration and Sound Dampening Materials from Biochar Obtained from Waste Lignocellulosic Biomass’ [Grant No.: MI02077].

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