High performance moldable composite
First Claim
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1. A formable automotive structural non-woven composite comprising:
- a blend of fibers having a plurality of high melt fibers and a plurality of low melt fibers to form a first nonwoven composite layer;
the blend of fibers further including a high melt carrier fiber of polyethylene terephthalate (PET) or polybutylene terephthalate (PBT), and a low melt binder fiber made of polyethylene glycol (PETG), Polylactic acid (PLA), Isophthallic modified PET, polyethylene, or polypropylene;
at least one of the high melt carrier fiber or the low melt fiber is a non-flame retardant fiber containing an internal flame retardant selected from the group consisting of polyphosphonates, organophosphates, phosphonates, antimony trioxide and any combination thereof;
the high melt carrier fiber and low melt binder fiber having at least a 10°
C. (19°
F.) difference in melt temperatures to allow the low melt fiber to melt during processing and stick to the high melt fibers;
a meniscus formed between bond points of the high melt carrier fiber and low melt binder fiber when the low melt binder fiber is melted and flows into interstitial spaces between the high melt carrier fiber and low melt binder fiber;
the first nonwoven composite layer having improved acoustic impedance due to a decreased nonwoven web pore sizes created by the low melt fibers when amorphous portions of the low melt binder fiber are melted during bonding wherein air flow resistance through the formable automotive structural non-woven composite is decreased due to the decreased web pore sizes and attributable to increased acoustic properties of the formable automotive structural non-woven composite;
a blown film layer disposed onto the first nonwoven composition layer as a second nonwoven composite layer and forms a multi-layer nonwoven composite, the blown film layer having controlled micro-porosity of the film for restricting air flow and furthering acoustic impedance properties of the formable automotive structural non-woven composite;
and wherein the blend of fibers further having a physical properties including a flexural modulus sufficient for automotive structural use, and heat resistance to withstand automotive engine compartment conditions and the formable composite is used as an automotive structural component for use in areas around the engine compartment or under the vehicle.
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Abstract
A moldable composite with high heat resistance and noise absorption properties utilizes nonwoven fabrics and a heat resistance additive. The composition that provides both superior acoustic performance and excellent flex modulus that may be utilized in automotive products and applications in interior and exterior structures. A blowing agent may be utilized to create micro porous cells in a polymer non-woven structure. The cells or voids make the material lighter and allow the material to have superior acoustic properties that are useful in automotive applications.
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Citations
27 Claims
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1. A formable automotive structural non-woven composite comprising:
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a blend of fibers having a plurality of high melt fibers and a plurality of low melt fibers to form a first nonwoven composite layer; the blend of fibers further including a high melt carrier fiber of polyethylene terephthalate (PET) or polybutylene terephthalate (PBT), and a low melt binder fiber made of polyethylene glycol (PETG), Polylactic acid (PLA), Isophthallic modified PET, polyethylene, or polypropylene; at least one of the high melt carrier fiber or the low melt fiber is a non-flame retardant fiber containing an internal flame retardant selected from the group consisting of polyphosphonates, organophosphates, phosphonates, antimony trioxide and any combination thereof;
the high melt carrier fiber and low melt binder fiber having at least a 10°
C. (19°
F.) difference in melt temperatures to allow the low melt fiber to melt during processing and stick to the high melt fibers;a meniscus formed between bond points of the high melt carrier fiber and low melt binder fiber when the low melt binder fiber is melted and flows into interstitial spaces between the high melt carrier fiber and low melt binder fiber; the first nonwoven composite layer having improved acoustic impedance due to a decreased nonwoven web pore sizes created by the low melt fibers when amorphous portions of the low melt binder fiber are melted during bonding wherein air flow resistance through the formable automotive structural non-woven composite is decreased due to the decreased web pore sizes and attributable to increased acoustic properties of the formable automotive structural non-woven composite; a blown film layer disposed onto the first nonwoven composition layer as a second nonwoven composite layer and forms a multi-layer nonwoven composite, the blown film layer having controlled micro-porosity of the film for restricting air flow and furthering acoustic impedance properties of the formable automotive structural non-woven composite; and wherein the blend of fibers further having a physical properties including a flexural modulus sufficient for automotive structural use, and heat resistance to withstand automotive engine compartment conditions and the formable composite is used as an automotive structural component for use in areas around the engine compartment or under the vehicle. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21)
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22. A method of making a formable automotive structural non-woven composite, comprising:
extruding a high melt and a low melt nonwoven polymeric fibers and incorporating a flame resistant additive into the low melt fiber having at least one region defining holes to create a microporous open cell structure for acoustic impedance, and heat and flame resistance. - View Dependent Claims (23, 24)
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25. A method of making a formable automotive structural non-woven composite, comprising:
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compounding a flame retardant into a carrier fiber, wherein the flame retardant is supportive to provide heat resistance to withstand automotive engine compartment conditions and the flame retardant is selected from a group consisting of polyphosphonate, organophosphates, phosphonates, antimony trioxide, halogens and any combination thereof; and
wherein the carrier fiber is selected from a group consisting of polyethylene glycol (PETG) cyclohexanedimethanol (CHDM), polyester, nylon, acrylic, polypropylene, polylactic acid, fiberglass, and any combination thereof;
said compounding done below 290°
C. with no heat history;drawing the carrier fiber at a low draw ratio of approximately 2-2.5 to prevent crystallinity from occurring thereby creating an amorphous carrier fiber; and creating a nonwoven web material having pores by combining the carrier fiber with a blend of fibers having physical properties that includes a flexural modulus sufficient for automotive structural use, wherein amorphous fibers will melt at a lower temperature filling the pores within the nonwoven material to block air and create resistance for sound. - View Dependent Claims (26, 27)
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Specification