Novel Sound Absorbing Materials Made From Elastomeric Waste: Compounding And Structuring Of Elastomeric Waste Crumb And Fibers With Binders Into Innovative Noise Insulation Materials

Abstract

Elastomeric wastes plague our time, polluting our environment and requiring urgent upcycling solutions. This research contributes to this agenda using an important source of waste, car tyre shred fibre residue (TSFR). It is demonstrated how using binders, non-foaming (SBR) and foaming (PU), we can transform these TSFR into structured porous acoustic-thermal insulation materials, suitable as underlay, cavity wall and pipe insulation. These structures were fabricated in purpose designed moulds and characterised for their porosity, tortuosity, flow resistivity and density. Their acoustic absorption performance was measured using industrial standards and the measurement underpinned with the Johnson-Champoux-Allard (JCA) model. With the under-layer materials, thermal insulation was also measured. The results were as follows: (i) 40%/60% SBR/TSFR was an optimal composition for the underlay with the addition of 15% w/w bumper crumb of size > 1mm enhancing both impact sound and thermal insulation, (ii) PU was found to produce well performing wall cavity insulation, particularly when vacuum pressure was applied, allowing micro and macro pores to be formed; (iii) PU applied with controlled amount of water to control foaming CO2 formation produced super-performing (compared with Armacell System B) stratified pipe cladding insulation, optimal at porosity stratification of 90%, 83%, and 70%; (iv) Very good agreement was observed with predictions using JCA model, allowing further research to be carried out with these now well characterised sound insulations. In addition to the developing materials, a novel technique for measuring sound absorption of pipe cladding was developed that could replace the expensive standard using a reverberation chamber.