Nonwoven fabric/spacer fabric/polyurethane foam composites: Physical and mechanical evaluations

Abstract

In the first stage, polyethylene terephthalate (PET) fibers and Kevlar fibers are combined at a blending ratio of 80/ 20 wt% in order to form PET/Kevlar nonwoven fabrics. Two pieces of PET/Kevlar nonwoven fabrics that enclose a carbonfiber (CF) interlayer are then needle punched in order to form PET/Kevlar/CF (PKC) composites. In the second stage, the sandwiches compose PKC composites as the top and the bottom layers, as well as an interlayer that is composed of a spacer fabric and polyurethane (PU) foam. PU foams have different densities of 200, 210, 220, 230, and 240 kg/m3. These resulting nonwoven fabric/spacer fabric/PU foam sandwiches are then tested using a drop-weight impact test, a compression test, a bursting strength test, a sound absorption test, and a horizontal burning test. The test results indicate that the optimal properties of sandwiches occur with their corresponding PU foam density as follows: an optimal residual stress (240 kg/m3), an optimal compressive strength (240 kg/m3), and an optimal bursting strength (220 kg/m3). In addition, the sandwiches reach the HF1 level according to the horizontal burning test results. They also have an average electromagnetic interference shielding effectiveness of -48 dB, as well as a sound absorption coefficient of 0.5 in a frequency between 1500-2500 Hz, which indicates a satisfactory sound absorption effect. The nonwoven fabric/spacer fabric/PU foam sandwiches proposed in this study are mechanically strong, sound absorbent, and fire retardant, and can be used in construction material and electromagnetic shielding composites.