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2005-01-2376

SAE TECHNICAL
PAPER SERIES

Design for Acoustics & Thermal Excellence:

Balanced With Sustainable Economic
Development
Hameed Khan and Steve Tessendorf
Rieter Automotive North America

James Fisher
Contract Engineer

SAE 2005 Noise and Vibration

Conference and Exhibition
Traverse City, Michigan
May 16-19, 2005

400 Commonwealth Drive, Warrendale, PA 15096-0001 U.S.A. Tel: (724) 776-4841 Fax: (724) 776-5760 Web: www.sae.org
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2005-01-2376

Design for Acoustics & Thermal Excellence: Balanced With

Sustainable Economic Development
Hameed Khan and Steve Tessendorf
Rieter Automotive North America

James Fisher
Contract Engineer

Copyright © 2005 SAE International

ABSTRACT individual program. Second, there are targets for

Acoustical and Thermal treatments for automotive
applications are constructed using a number of different
materials and composites. These range from the simple
needled felt absorber, to the sophisticated multi layer
composites to provide noise and thermal Improvements.
Since, in most cases a finish fabric or treatment typically
covers these materials, the actual color of these
substrates has not really been a key design criteria. This
has allowed the Acoustics Integrators, when the function
of the part is not compromised, to utilize recycled, and
byproduct materials. These materials often provide
Recyclability of the automobile. The target for
demonstrated recyclability in Europe is 95%. Finally, the
European ELV sets the actual recovery rate targets. The
recovery rate should be 85 % by 2006 and 95 % by 2015
(Toyota, 1995-2005). The following timeline illustrates
the various initiatives.
RECYCLING TIMELINE PER ELV LEGISLATION
2000

2005

2006

2010

2015
superior performance, lighter weight, and reduced cost
from the use of virgin materials. This model of Source
Reduction for Acoustical and Thermal Product
Design supports the environmentally sustainable
Eco system.
ELV Legislation

(ELV)
recoverability of 95%
Demonstrated

recovered (ELV)
85 % of vehicle

RECOVERED (ELV)
95% OF VEHICLE
The End of Life directive may open up more recycled
material streams by providing the necessary
infrastructure to recover and process the automotive
materials. The industry needs to be open to use these
materials, and consider review of material specs, and
design in order to achieve the End of Vehicle Life (ELV)
targets it has set for itself. (Wastewatch, 2004)

INTRODUCTION Obviously, if the automobile parts are to be recycled,

Even though the recycling initiatives have been
historically driven by economics. Green car initiatives,
both in Europe (ELV), and the United States are giving
added incentives to choose recycled materials in
developing an acoustical part. First, targets have been
set for the recycled content of the car. Chrysler
Corporation set a target of 30% recycled content by 2010
in their CS9003 E standard (DaimlerChrysler, 1999). In
later versions, these targets have been left to the
the best use of the resulting materials is to put them
back into automobile parts. Designers need to focus on
ease of recycling and recycled content of parts to meet
the ELV goals. Further environmental impact reduction
can be achieved by developing parts lighter, and
multifunctional as well. This results in a minimum
environmental impact over the life of the part.
This paper details the classical and advanced
acoustical treatments. The focus primarily will be on the
 Downloaded from SAE International by University of Edinburgh, Saturday, August 25, 2018
construction of treatments that utilize recycled or
byproduct materials, as part of Source Reduction
strategy. The sources and quantities of these materials
will also be discussed. Finally the impact of designing for
the environment will be discussed.
MAIN SECTION
Acoustical treatments address noise reduction via
damping the sheet metal vibrations, blocking the
transmission of noise, and finally absorption of noise in
the passenger compartment. These treatments include
dampers, dashes, carpet, floor systems, headliners,
package trays and absorbers. Heat management
involves thermal barriers and insulators. All of these
parts can utilize recycled materials or byproducts for raw
materials.
Recycling greatly decreases the life cycle cost of a part
through source reduction. The environmental impact of
obtaining the raw materials is greatly reduced when by-
products, and recycled materials are used. Recycling
also reduces the load on landfills and incinerators by
reusing materials that otherwise might be thrown away.
Thus, source reduction through recycling has a double
impact in reducing the start, and end, of life
environmental cost of a part as illustrated below. The
materials do not have to be mined or otherwise created
because they are recovered at the end of life of some
other manufactured object. The load on the landfill is
reduced because materials are used rather than
discarded.
ENVIORNMENTAL IMPACTS REDUCED BY
RECYCLING
Part in Use
Part
Manufacture
Disassembly
Processing RECYCLE
Landfill/
Raw Material Incineration
mining/manufacture
DAMPING COMPOSITES
The sound reduction package starts with the damping
material that is adhered to the sheet metal to reduce
resonance. This is the most economic and effective way
to reduce the noise levels in an automobile.
A number of exotic formulations are in use, including
spray on epoxies, but the most environmentally friendly
construction is the Asphaltic extensional sheet damper. It
can utilize cost effective, by-product and recycled raw
materials. This makes the product sustainable with
minimal impact on the environment. This material is
provided in die cut shapes to precisely fit the sheet
metal. Areas requiring additional treatment can have
heavier pieces applied. Damper is usually added to the
vehicle prior to the sealer and paint bake ovens so that
the damper conforms to the sheet metal contours. This
way the mass of material used can be optimized.
Damping material formulators are always looking for
cost effective and sustainable raw materials for both
economic and environmental reasons. The following is a
partial list.
Asphalts
The active ingredient in damping, asphalt, is a byproduct
of petroleum refining. This is the heavy oils and solids
that remain after all of the volatile fractions of crude oil
are fractionated off. This material is used for roads,
roofing and heavy industrial fuels in addition to the
damping of sheet metal. This is a very low cost
polymer/binder. When properly specified and processed,
asphalt will have inherent sound damping characteristics.
Due to asphalt’s broad molecular weight, and inherent
excellent viscoelastic characteristics, these properties
are prevalent across a range of temperatures.
Compared to epoxy, acrylic or PVC based systems, the
asphalt dampers are more cost effective. Further, since it
is a byproduct, asphalt manufacture is not as costly to
the environment as the production of pure polymers.
Fillers and Functional Additives
A number of different fillers and binders can be used in
damping formulations. Since we are focusing on
recycled and byproduct materials, this discussion is
limited to limestone fines, wood fibers and fly ash.
In the mining of limestone for construction and steel
production, fines are produced. These fines reduce the
value of the intended product. The use of limestone
fines in dampers provides an outlet for this low value
material.
Wood fiber from recycling newsprint can also be used
to produce dampers. This material effectively reinforces
and modifies the rheology of the damping material, and
helps to reduce specific gravity of the dampers.
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Approximately 8.8 million tons of this material is recycled
annually. (Re-sourcing Associates, 2000)
The industry is constantly challenged to reduce the part
weight. The goal of lighter weight damping treatments is
made possible through the use of certain fly ash fractions
from coal burning power plants. This material consists of
tiny hollow ceramic balls. Using the ceramic micro-
spheres allows the production of lighter damping
treatments that are just as effective as their heavier
counterparts.
SOUND ATTENUATING COMPOSITE PARTS
Floor systems, dash liners, wheelhouse liners and
other absorbers are further tools available to the
acoustical integrator. They improve passenger comfort
by reducing the amount of noise transmitted into the
passenger compartment, or by absorbing it from the
compartment. The ideal parts are designed to both
absorb ambient noise, and reduce the amount of noise
that is transmitted into the compartment.
As with dampers, a number of different constructions
are used for this type of part. The traditional construction
separates the function of transmission attenuation from
absorption. Transmission loss is achieved by laminating
a heavy top layer made from PVC, EPDM, or EVA to a
soft layer made from fiber or PUR foam. Dash liners and
floor systems are typically made this way. These parts
keep noise from entering the passenger compartment.
Absorption is typically achieved by applying absorptive
fiber mats strategically in the vehicle. This strategy
reduces noise levels by absorbing the noise that is
already in the passenger compartment.
Both transmission loss parts and absorption parts are
designed to fit the sheet metal precisely. At very least,
these parts are die cut to fit the car. Usually they are
molded and cut to fit using sophisticated 3 dimensional
cutting technologies.
A number of raw materials are used for these parts.
The most environmentally friendly raw materials are the
recycled fibers, foam and resins.
Post Industrial Fibers
The apparel and carpet industry produce webs of set
width and length. The fabrics are typically cut into the
required shapes prior to further processing. The
byproducts of the cutting operations are a valuable
source of acoustical material. This material is segregated
and blended to meet exact specifications necessary for
each application. The material is then processed under
proprietary conditions into individual fibers. These fibers
are laid into uniform mats and bound together using
thermosetting resins, binder fibers or needling.
The amount of post industrial fibers available in the
United States is estimated to exceed one billion pounds
per year. Since the fibers are obtained from relatively
stable industrial sources, and processed under uniform
conditions, they provide a consistent raw material that
allows the production of precisely tailored acoustical
parts.
Post Consumer Fiber
Post consumer recycled fiber comes from two sources.
Post consumer materials such as used clothing, white
goods, and carpets are another source of recyclable
fibers. These materials must be collected, classified,
sorted, and have the buttons and other trash removed
prior to being processed. Another post consumer source
of recycled fiber starts with soft drink bottles. The
Polyester (PET) bottles that are collected for recycle in
the United States and elsewhere are used by processors
who convert them to PET staple fibers. These can be
used in conjunction with the post industrial textile fibers,
binders, or binder fibers to make the automotive parts.
Currently only one fifth of the 4 billion pounds of PET
bottles used yearly in the US are recycled. (Container
Recycling Institute, 2003)
Paint Powder Resins
Powder coating operations produce waste paint
powder from overspray and color changes. This paint
powder retains its potential for cross-linking, and is very
finely divided. These properties make it appropriate to
use as a binder for fiber felts. Paint powder is used
extensively in Europe as a binding agent. With efforts to
reduce volatile organic emissions, the supply of the paint
powder suitable for use as a binder resin should
increase.
Chipped Foam
Polyurethane foam is available from die cutting
operations, including the production of acoustical parts.
This is cut into ½ inch chips in recovery operations.
These foam chips can be added to fiber parts or
rebonded and sliced for flat stock. In a fiber part the
foam improves the finished part flexibility and improves
the compression set.
ACOUSTICAL TRIM
Acoustical trim parts are visible to the customer.
Typically they consist of a surface fabric and a semi rigid
substrate. These parts include headliners, trunk
systems, closeout panels and rear shelves. Both
recycled and sustainable raw materials are also used in
these applications.
Recycled Fibers
Both post industrial fibers and post consumer PET
fibers are used in these applications. The post industrial
fibers are typically bonded together with a thermo setting
resin. When molded under heat and pressure a
lightweight, stable, rigid sound absorbing part is
 Downloaded from SAE International by University of Edinburgh, Saturday, August 25, 2018

achieved. Recycled PET bonded with a melt fiber can
also produce substrates for these applications.
Wood Products
The lumber industry produces a made from resins and
sawdust. This hardboard is often molded and used as a
substrate for rigid trim parts such as door liners, and rear
shelves. Since this material is a by product of producing
other higher valued products, and it is derived from a
sustainable resource, it can be very environmentally
friendly.
Natural Fibers
Increasingly, natural fibers such as Knauf, Sisal, Hemp
and Flax are finding there way into automotive parts.
Typically, these fibers are air laid or carded along with a
binder fiber such as polypropylene to produce a
moldable sheet. Again this makes a lightweight
substrate for trim parts. These fibers represent a
renewable resource. (Sherman, 1999)
MULTIFUNCTIONAL PARTS
The aluminum used in heat shields is primarily made
from recycled beverage containers, and other post
industrial streams.
Glass Fibers
Glass fibers are also used for insulation. Mostly this
material is used to reduce the temperatures of surfaces
that might be contacted by the customer.
The production of glass benefits from the use of up to
70% of recycle or cullet glass. This recycle stream can
come from post industrial and post consumer sources as
long as the impurities are minimized. (Re-sourcing
Associates, 2000)
END OF LIFE RECYCLING
The current use of recycled and byproduct materials in
vehicle acoustics is illustrated by the display pictured
below.
Recycled Materials Used in Acoustical and Thermal
Parts

Recent manufacturing advances have allowed

integrators to substitute highly compressed and tuned
layers of fiber for the traditional thermoplastic heavy layer
in transmission attenuation parts. This creates a lighter
multifunctional part that reduces noise levels by both
attenuating noise from the outside, and absorbing noise
from the inside. The addition of a face fabric, such as
carpeting, allows the part to also function esthetically. By
integrating esthetics with transmission loss and
absorption, there is a net reduction in vehicle weight and
complexity.

When these multifunctional parts are made with

recycled fibers they approach the environmental ideal.
They reduce the weight of the vehicle; they keep
materials out of the landfill, and do not require additional
raw materials to be mined, The 100 % fiber construction
can be very easily recycled. Since there is no heavy
layer to separate, the part can be fed directly into fiber
reclamation equipment. The resulting opened fiber is an
excellent feedstock for new parts.
HEAT SHIELDS
Aluminum
Thermal barriers and heat shields must be lightweight
and flame resistant. They are used to protect cooler
components from the effects of the heat radiated from
hotter components. The typical technology utilizes
multiple layers of aluminum or stainless steel with
spacers to allow air circulation. The layers block radiant
energy and reradiate it at a lower temperature. Each
layer reduces the total amount of energy that can be
absorbed by the cooler surface.
The success pictured above was achieved prior to the
ELV directives. The directives to increase the materials
recycled from cars at the end of their useful lives. It is
expected that these initiatives will provide more streams
of predictable quality and quantity. As these become
available, the industry will respond by finding appropriate
uses for them.
DESIGNING THE ENVIORNMENTALLY FRIENDLY
ACOUSTICAL PACKAGE
The most environmentally friendly parts will be the
lightest, simplest and contain the most recycled
materials, by-products, and renewable resources.
This means that there are strong environmental
reasons to design simple, multifunctional
lightweight, recyclable acoustical parts that contain
the maximum amount of recycled materials. Lighter
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parts are better environmentally for 2 reasons: First, Thermoplastic barrier can then be recycled into
fewer raw materials must be produced and processed in thermoplastic barrier. The foam cannot be directly
order to make the parts. In a life cycle analysis, this recycled into foam parts. It must be first re-bonded, then
results in a lower cost to the environment to produce the sliced to the appropriate thickness and used as flat
parts. Secondly, lighter cars use less fuel. So the lighter stock.
parts will have less of an environmental impact over the
vehicle’s life because less fuel must be pumped from the EVALUATING THE ENVIORNMENTALLY FRIENDLY
oil well, refined and burned. A 10% savings in the ACOUSTICAL PACKAGE
vehicle’s weight translates to a 7-8% fuel savings. (The
Aluminum Association, 2003) This means that for each Many of the design characteristics for low life cycle
10% reduction in the vehicle’s weight 7% less oil has to costs were incorporated into one vehicle. The dash
be pumped and refined, and 7 % less carbon dioxide and insulator and carpet systems were made of recycled fiber
other greenhouse gasses are released to the bonded with thermo setting resin. No barrier layers were
environment over the vehicle’s life. utilized. The recycled content of the dash insulators and
floor systems approach 75 %. Advanced manufacturing
The use of recycled materials, or byproducts as raw methods and design allow these parts to function as both
materials greatly reduces the environmental costs of absorbers and transmission inhibitors. Dampers were
producing a part. The environmental cost of mining and the standard asphaltic variety.
processing these materials is just not there. In fact,
materials are kept out of the landfills when they are This acoustical package was compared against a more
recycled into another product. standard package that utilizes foam and barrier
composites.
When parts are recovered at the end of their useful life,
and they are recycled into new parts the loop is closed. The environmentally friendly package saves between
Except for the processing costs, the environmental 20 lb and 40 lb per vehicle in weight.( Wentzel, 1999)
impact of producing the part is minimized. The ideal part Over the life of the car this should save 35 gallons in
has to be designed with the end of life in mind. The fuel, and produce 700 lb less CO2. 20 to 40 lb of raw
simpler parts will be easier to recycle. All fiber acoustical material did not have to be produced to make the parts.
parts will be much easier to recycle than those that utilize
incompatible materials. For example a dash insulator or The real story comes in evaluating the noise levels at
carpet system made of 100% fiber can be completely the driver’s ear. As shown on the following chart an
recovered into new dash insulators using existing fiber environmentally friendly sound package actually
opening and forming technologies. A cast foam dash improved the driver’s comfort over much of the audible
insulator made with barrier layer must first have the range, by improving the “articulation index.” (Magee
barrier separated from the foam. This will result in a 10 Rieter Automotive, 2004)
to 20 % loss of material. (Fisher, 1998)

G M T 8 0 0 R U L D a s h 1 s t D r iv e G e a r W O T 1 0 -85 m p h
Light Weight
G M T 8 0 0
Multifunctional Acoustical Part Performance
B a rrie r D a s h 1 s t D riv e G e a r W O T 1 0 -8 5 m p h
1 0 0 First Gear Run Up
H i g h e r i s B e t te r

9 0

8 0

Light weight
7 0
environmentally
Articulation Index (%)

friendly
6 0

5 0
Conventional
4 0

3 0

2 0
2 10 0 2 4 3 0 2 7 60 3 0 9 0 3 4 2 0 3 7 5 0 4 0 8 0 4 4 1 0 47 4 0 5 0 7 0 5 4 0 0
E n g in e S p ee d ( rpm )
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2/8/2005 from http://www.container-

recycling.org/documents/PET2003pressreleaseCRI-
CONCLUSIONS 091503.doc

Economics has driven the production of thermal and Daimler Chrysler Corporation, 1999 Characteristic
acoustical management materials to utilize recycled raw Standard No. CS9003 Change E. Downloaded on
materials and byproducts. This has helped reduce the 12/12/01 from http://www.autoweb.net
environmental impact of producing these parts for
decades. By evaluating systems based on their cost to Fisher, J. 1998 Recovery of Foam and Barrier from Trim
the environment to make, transport, and dismantle we Waste Lowell, Indiana Rieter Automotive internal
can develop even more environmentally friendly designs. document
To be environmentally friendly, the part should use
Magee-Rieter Automotive Inc., 2004 GMT 800 Internal
recycled, by-product or renewable raw materials. This
presentation.
reduces the impacts of producing the part. It should be
lightweight and multifunctional. This reduces the fuel
used and carbon dioxide produced over the life of the Re-Sourcing Associates, 2000 Glass Recycling
part. Finally it should be easy to recycle at the end of its downloaded on 2/8/2005 from
life. Multifunctional acoustical parts made from recycled http://www.rsrecycle.com/glass.html
fiber fit this definition very well.
Re-Sourcing Associates, 2000 Paper Recycling
With the End Of Life initiatives, more vehicles will be downloaded on 2/8/2005 from
dismantled, and more of each vehicle will become http://www.rsrecycle.com/paper.html
available for recycling. With proper design of the parts,
this recycling can be facilitated and maximized. The cost Sherman, 1999 Natural Fibers: The New Fashion In
to the customer in terms of the acoustical system Automotive Plastics “Plastics Technology” Gardner
performance can be minimized, at the same time the Publications Inc. Downloaded on 2/10/2005 from
environmental benefits can be maximized. http://www.plasticstechnology.com.articles/19910fa1.html

The acoustics integrators and vehicle engineers must Toyota, 1995-2005 Overview of the Automobile
do their part by insisting on the environmentally friendly Recycling Law in the European Union Downloaded on
multifunctional acoustical and thermal components. This 2/8/2005 from
will result in more comfortable more environmentally http://www.toyota.co.jp/en/environment/recycle/law/outlin
friendly automobiles. This effort along with the support e02.html
of the industry will help with achieving a sustainable
industry for the future.
Wastewatch, 2004 End of Life Vehicle and Tyre
Recycling Information Sheet. National Waste Awareness
Initiative Accessed on 2/7/2005 at
http://www.wasteonline.org.uk/resources/informationshe
CONTACTS
ets/vehicle.htm#law
Hameed Khan is the Vice President of R&D at Rieter
Wentzel, & VanBuskirk, 1999 A Dissipative Approach to
Automotive North America. He can be contacted at
hameed.khan@rieterauto.com Vehicle Sound Abatement “SAE Noise and Vibration
Conference Proceedings” #99NV-144
James Fisher is an independent engineering contractor.
He is available at jhfisher@engineer.com.
ADDITIONAL SOURCES

Bellman & Anshuman, 1999 European Response to

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