Sound insulation property of recycled high-density polyethylene/waste

jute fabric composites

Jonty Mago1
Automotive Health Monitoring Laboratory, Centre for Automotive Research & Tribology, Indian
Institute of Technology Delhi, Hauz Khas, New Delhi-110016, India

Sunali2
Automotive Health Monitoring Laboratory, Centre for Automotive Research & Tribology, Indian
Institute of Technology Delhi, Hauz Khas, New Delhi-110016, India

Ashutosh Negi3
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. Fatima4
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/m3, 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
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, CaCO3, 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)
Fifteen minutes after applying pressure. After that, the material
Holding Time
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].
×
ρ = (1)

Where material (in kg/m3) 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/m3), Wair is the weight
of material in the air, and Wliquid 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.

σ= (2)

∆
ϵ= (3)

E= (4)

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), Lo 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.
 STL = 10 log = 10 log (5)

where STL = Sound transmission loss in dB, Wi = Incident sound power in W, Wt = Transmitted
sound power in W, τ = = Sound transmission coefficient.

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

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/m3) 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/m3)
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].

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

Table 3: Tensile test results for neat rHDPE and rHDPE+WJF composite sheets
Neat rHDPE rHDPE+WJF Percentage
Sheets Composite Sheets 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
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
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/m2 and
HDPE+WJF composite- 4.99 kg/m2) and modulus (Table 3) of the HDPE+WJF composite sheet can
be held responsible for better sound insulation property than neat rHDPE sheet.

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
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.
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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