Facing for acoustic batts that contain Melt-Film Fibrillation

Melt-Film Fibrillation (MFF) technology produces a facing for acoustic batts for vehicle sound insulation that offers equivalent or superior sound-deadening performance at reduced weight and cost. Equivalent weights of MFF fibers produce substantially enhanced sound insulation over conventional batts incorporating meltblown, polypropylene fibers. Comparable acoustic performance has been demonstrated with MFF fibers at half the weight of traditional meltblown fiber. 90% submicron fibers can be achieved via the MFF process versus the 2–6 micron meltblown fibers when produced at traditional throughputs. The submicron fibers of MFF increase sound impedance, with significant performance improvements realized in the frequencies between 3000 Hz and 5000 Hz. Estimated cost savings over conventional acoustic facing is estimated to be 20%, and may be even greater depending on final construct.

Melt-Film Fibrillation (MFF) technology delivers consistent sub-micron fibers at higher throughput rates than other submicron technology.

The submicron fibers produced by MFF technology provide many more fibers per unit mass and several times greater surface area per unit mass than traditional melt-blown fibers (which typically measure 2–6 microns in size). This directly affects and improves air flow resistance and sound absorption, as shown by the impedance tube, air resistivity, and RAYLs charts, below. The performance of MFF fibers is indicated by SNS and SNNS in the charts. Conventional products are indicated by SMMS.

The extreme thinness and high aspect ratio of sub-micron fibers translates to higher surface area per given weight of fiber than can be achieved with larger fibers like those produced through traditional meltblowing. In general, it is anticipated that fine fiber-containing materials may achieve equivalent product performance with less fiber mass, significantly reducing material cost, weight, size, shipping costs, and so forth; or using equivalent fiber mass, performance in many applications could be significantly enhanced.

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