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<p>Noise pollution is a growing environmental concern that negatively affects human health, while the rapid expansion of textile production generates large amounts of waste, particularly polypropylene (PP) carpet residues and cotton yarn byproducts, that are difficult to recycle. This study addresses both challenges by developing eco-friendly, porous acoustic panels from recycled polypropylene (PP) carpet waste and cotton yarn waste. PP and cotton fibers were recovered through centrifugal and mechanical recycling, then blended and processed via carding and hot pressing to fabricate panels with varied thicknesses (15, 20, and 25&#xa0;mm), densities (20, 30, and 40&#xa0;kg/m<sup>3</sup>), and cotton/PP ratios (70/30, 60/40, and 50/50). Acoustic performance was evaluated using a two-microphone impedance tube in accordance with ISO 10534, and the effects of structural parameters were systematically analyzed through Response Surface Methodology (RSM) with a Central Composite Design (CCD). Results showed that greater thickness and density improved absorption, particularly at low frequencies, while higher PP content reduced performance due to pore blockage and increased rigidity. The statistical model identified an optimal configuration of 25&#xa0;mm thickness, 40&#xa0;kg/m<sup>3</sup> density, and a 70/30 cotton/PP ratio, yielding a Sound Absorption Average (SAA) of 0.39, which was confirmed experimentally and exceeds the commonly accepted threshold of NRC ≈ 0.30 (ASTM C423) for commercial acoustic materials. These findings demonstrate that binder-free panels made from textile waste can achieve competitive acoustic performance while offering practical benefits such as recyclability, reduced material use, and suitability for sustainable building insulation.</p> Graphical Abstract <p></p>

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Acoustic performance of sustainable lightweight panels made from recycled cotton yarn and carpet waste

  • 期刊论文

  • 发表日期：

    2025年12月27日

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  • Armin Davarpanah,
  • Hossein Hasani,
  • Parham Soltani,
  • Mohammad Ghane

摘要

Noise pollution is a growing environmental concern that negatively affects human health, while the rapid expansion of textile production generates large amounts of waste, particularly polypropylene (PP) carpet residues and cotton yarn byproducts, that are difficult to recycle. This study addresses both challenges by developing eco-friendly, porous acoustic panels from recycled polypropylene (PP) carpet waste and cotton yarn waste. PP and cotton fibers were recovered through centrifugal and mechanical recycling, then blended and processed via carding and hot pressing to fabricate panels with varied thicknesses (15, 20, and 25 mm), densities (20, 30, and 40 kg/m3), and cotton/PP ratios (70/30, 60/40, and 50/50). Acoustic performance was evaluated using a two-microphone impedance tube in accordance with ISO 10534, and the effects of structural parameters were systematically analyzed through Response Surface Methodology (RSM) with a Central Composite Design (CCD). Results showed that greater thickness and density improved absorption, particularly at low frequencies, while higher PP content reduced performance due to pore blockage and increased rigidity. The statistical model identified an optimal configuration of 25 mm thickness, 40 kg/m3 density, and a 70/30 cotton/PP ratio, yielding a Sound Absorption Average (SAA) of 0.39, which was confirmed experimentally and exceeds the commonly accepted threshold of NRC ≈ 0.30 (ASTM C423) for commercial acoustic materials. These findings demonstrate that binder-free panels made from textile waste can achieve competitive acoustic performance while offering practical benefits such as recyclability, reduced material use, and suitability for sustainable building insulation.

Graphical Abstract