CN114096389A

CN114096389A - Lightweight reinforced thermoplastic composite article comprising bicomponent fibers

Info

Publication number: CN114096389A
Application number: CN202080027157.7A
Authority: CN
Inventors: R.王; H.陈
Original assignee: Hanwha Azdel Inc
Current assignee: Hanwha Azdel Inc
Priority date: 2019-02-01
Filing date: 2020-01-31
Publication date: 2022-02-25
Also published as: JP2022523732A; JP7554196B2; EP3917746A4; KR20220007847A; CA3128362A1; WO2020160362A1; EP3917746A1; AU2020214836A1

Abstract

Lightweight reinforced thermoplastic articles having a core layer including bicomponent fibers in the core layer are described. In some examples, the core layer includes a thermoplastic material, reinforcing fibers, bicomponent fibers, and a lofting agent. After molding of the composite article, an increase in one or more of a peak load value, a stiffness value, a bending strength value, and a bending modulus value can be achieved for a particular molded thickness.

Description

Lightweight reinforced thermoplastic composite article comprising bicomponent fibers

Priority application

The present application relates to and claims priority and benefit from U.S. provisional application No. 62/800,314 filed on 1/2019 and U.S. provisional application No. 62/874,036 filed on 15/2019, each of which is hereby incorporated by reference herein.

Technical Field

Certain embodiments relate to thermoplastic composite articles comprising bicomponent fibers. In some cases, the thermoplastic composite article with bicomponent fibers may provide improved performance over thermoplastic composite articles lacking bicomponent fibers.

Background

Certain automotive and construction applications typically use thermoplastic type materials in place of traditional steel or metal products. The use of thermoplastics type materials may create unique considerations not found in steel or metal products.

Disclosure of Invention

Certain aspects are described herein to illustrate some configurations of thermoplastic composite articles having bicomponent fibers. Other configurations for producing a thermoplastic composite article comprising bicomponent fibers will be within the ability of one of ordinary skill in the art, given the benefit of this disclosure.

In one aspect, a molded porous composite article comprises a lofty core layer comprising a web formed from reinforcing fibers, bicomponent fibers, lofting agent, and a thermoplastic material, wherein the porosity of the web is from about 20% to about 80%, and wherein the bicomponent fibers comprise a core-shell arrangement, wherein the melting point of the shell material of the shell of the core-shell arrangement is substantially similar to the melting point of the thermoplastic material, and wherein the melting point of the core material of the core-shell arrangement is at least twenty degrees celsius higher than the melting point of the thermoplastic material, and wherein the molded porous composite article comprises a peak load in the longitudinal direction of from 10N to about 40N and a peak load in the transverse direction of from about 6N to about 30N as tested by SAE J949 — 200904 at a molded thickness in the longitudinal and transverse directions of from about 2mm to about 4 mm.

In certain embodiments, the bicomponent fiber comprises: a shell comprising a polyolefin and a core comprising a polyester or a polyamide. In other examples, the bicomponent fiber comprises: a shell comprising a polyolefin and a core comprising a polyester. In some examples, the polyolefin comprises polyethylene. In other examples, the polyethylene is a linear low density polyethylene. In some embodiments, the polyester comprises polyethylene terephthalate. In other examples, the polyamide comprises nylon.

In some cases, the thermoplastic material is polypropylene, the polyolefin of the shell comprises linear low density polyethylene, the lofting agent comprises expandable microspheres, and the polyester of the core comprises polyethylene terephthalate.

In other cases, the thermoplastic material is polypropylene, the polyolefin of the shell comprises linear low density polyethylene, the lofting agent comprises expandable microspheres, and the polyamide of the core comprises nylon.

In certain examples, the thermoplastic material comprises polypropylene, the reinforcing fibers comprise glass fibers, the bicomponent fibers comprise linear low density polyethylene in the sheath and polyester or polyamide in the core, wherein the polyester or polyamide in the core has a melting point at least twenty degrees celsius greater than the melting point of the thermoplastic material, wherein the lofting agent comprises expandable microspheres.

In some examples, the molded composite article further comprises a stiffness in the machine direction of about 10N/cm to about 50N/cm and a stiffness in the cross direction of about 7N/cm to about 30N/cm as tested by SAE J949_ 200904.

In other examples, the molded composite article further comprises a flexural strength in the machine direction of about 6MPa to about 17MPa and a flexural strength in the transverse direction of about 4MPa to about 11MPa as tested by SAE J949 — 200904.

In further examples, the molded composite article further comprises a flexural modulus in the machine direction of about 800MPa to about 2000MPa and a flexural modulus in the transverse direction of about 500MPa to about 1300MPa as tested by SAE J949 — 200904.

In certain instances, the molded composite article further comprises a stiffness of from about 10N/cm to about 50N/cm in the machine direction and a stiffness of from about 7N/cm to about 30N/cm in the transverse direction as tested by SAE J949_200904, and a flexural strength of from about 6MPa to about 17MPa in the machine direction and a flexural strength of from about 4MPa to about 11MPa in the transverse direction as tested by SAE J949_ 200904.

In some embodiments, the molded composite article further comprises a stiffness of from about 10N/cm to about 50N/cm in the machine direction and a stiffness of from about 7N/cm to about 30N/cm in the cross direction as tested by SAE J949_200904, and a flexural modulus of from about 800MPa to about 2000MPa in the machine direction and a flexural modulus of from about 500MPa to about 1300MPa in the cross direction as tested by SAE J949_ 200904.

In certain examples, the molded composite article further comprises a flexural strength in the machine direction of from about 6MPa to about 17MPa and a flexural modulus in the machine direction of from about 800MPa to about 2000MPa and a flexural modulus in the transverse direction of from about 500MPa to about 1300MPa as tested by SAE J949 — 200904.

In some examples, the molded composite article further comprises a stiffness of from about 10N/cm to about 50N/cm in the machine direction and a stiffness of from about 7N/cm to about 30N/cm in the transverse direction as tested by SAE J949_200904, a flexural strength of from about 6MPa to about 17MPa in the machine direction and a flexural strength of from about 4MPa to about 11MPa in the transverse direction as tested by SAE J949_200904, and a flexural modulus of from about 800MPa to about 2000MPa in the machine direction and a flexural modulus of from about 500MPa to about 1300MPa in the transverse direction as tested by SAE J949_ 200904.

In certain embodiments, the article is configured as an automotive headliner, interior component, partition panel, or furniture panel.

In another aspect, a molded porous composite article comprises a lofty core layer comprising a web formed from reinforcing fibers, bicomponent fibers, lofting agent, and a thermoplastic material, wherein the porosity of the web is from about 20% to about 80%, and wherein the bicomponent fibers comprise a core-shell arrangement, wherein the melting point of the shell material of the shell of the core-shell arrangement is substantially similar to the melting point of the thermoplastic material, and wherein the melting point of the core material of the core-shell arrangement is at least twenty degrees celsius higher than the melting point of the thermoplastic material, and wherein the molded porous composite article comprises a stiffness of from about 10N/cm to about 50N/cm in the machine direction and a stiffness of from about 7N/cm to about 30N/cm in the cross direction as tested by SAE J949 — 200904.

In some examples, the molded composite article further comprises a flexural strength in the machine direction of about 6MPa to about 17MPa and a flexural strength in the transverse direction of about 4MPa to about 11MPa as tested by SAE J949 — 200904.

In other examples, the molded composite article further comprises a flexural modulus in the machine direction of about 800MPa to about 2000MPa and a flexural modulus in the transverse direction of about 500MPa to about 1300MPa as tested by SAE J949 — 200904.

In additional examples, the molded composite article further comprises a flexural strength of about 6MPa to about 17MPa in the machine direction and a flexural strength of about 4MPa to about 11MPa in the transverse direction as tested by SAE J949_200904, and a flexural modulus of about 800MPa to about 2000MPa in the machine direction and a flexural modulus of about 500MPa to about 1300MPa in the transverse direction as tested by SAE J949_ 200904.

In another aspect, a molded porous composite article comprises a lofty core layer comprising a web formed from reinforcing fibers, bicomponent fibers, lofting agent, and a thermoplastic material, wherein the porosity of the web is from about 20% to about 80%, and wherein the bicomponent fibers comprise a core-shell arrangement, wherein the melting point of the shell material of the shell of the core-shell arrangement is substantially similar to the melting point of the thermoplastic material, and wherein the melting point of the core material of the core-shell arrangement is at least twenty degrees celsius higher than the melting point of the thermoplastic material, and wherein the molded porous composite article comprises a flexural strength of from about 6MPa to about 17MPa in the machine direction and a flexural strength of from about 4MPa to about 11MPa in the transverse direction as tested by SAE J949 — 200904.

In certain examples, the molded composite article further comprises a flexural modulus in the machine direction of about 800MPa to about 2000MPa and a flexural modulus in the transverse direction of about 500MPa to about 1300MPa as tested by SAE J949 — 200904.

In an additional aspect, a molded porous composite article comprises a lofty core layer comprising a web formed from reinforcing fibers, bicomponent fibers, lofting agent, and a thermoplastic material, wherein the porosity of the web is from about 20% to about 80%, and wherein the bicomponent fibers comprise a core-shell arrangement, wherein the melting point of the shell material of the shell of the core-shell arrangement is substantially similar to the melting point of the thermoplastic material, and wherein the melting point of the core material of the core-shell arrangement is at least twenty degrees celsius higher than the melting point of the thermoplastic material, and wherein the molded porous composite article comprises a flexural modulus of from about 800MPa to about 2000MPa in the machine direction and a flexural modulus of from about 500MPa to about 1300MPa in the cross direction as tested by SAE J949 — 200904.

Additional aspects, examples, embodiments, and configurations are described in more detail below.

Drawings

Certain aspects, embodiments and examples are described with reference to the accompanying drawings, in which:

FIG. 1 is an illustration of a core-shell fiber arrangement according to some examples;

FIG. 2 is an illustration of a side-by-side fiber arrangement according to certain embodiments;

fig. 3A and 3B are each illustrations of a side-by-side fiber arrangement with a shell, according to some examples;

fig. 4 is an illustration of a core layer according to some examples;

fig. 5 illustrates a method that may be used to produce a core layer, according to some examples;

FIG. 6 illustrates another method that may be used to produce a core layer, according to certain examples;

fig. 7 is an illustration of an article including a core layer and an outer skin layer, according to some examples;

fig. 8 is an illustration of an article comprising a core layer and two skin layers, according to some examples;

fig. 9 is an illustration of an article comprising a core layer, an outer skin layer, and a decorative layer, according to some examples;

FIG. 10 is an illustration of an automotive headliner according to some examples;

FIG. 11 is an illustration of an automotive rear trim panel assembly according to some examples;

FIG. 12 is an illustration of an article of furniture according to some embodiments;

FIG. 13 is another illustration of an article of furniture according to some embodiments;

FIG. 14 is another illustration of an article of furniture according to some embodiments;

FIG. 15 is another illustration of an article of furniture according to some embodiments;

FIG. 16 shows a photograph of a molded part produced using a hybrid lightweight reinforced thermoplastic sheet;

FIG. 17 is a graph showing the tensile modulus measured in the Machine Direction (MD) and the Cross Direction (CD) for several samples;

FIG. 18 is a graph showing the tensile strength measured in the Machine Direction (MD) and Cross Direction (CD) for several samples;

FIG. 19A is a graph comparing peak loads in the machine direction for various samples; and

fig. 19B is a graph comparing peak loads in the lateral direction for various samples.

Those of ordinary skill in the art will recognize that the depictions and layers of the figures are provided for illustrative purposes only. No particular thickness, material dimensions, etc. are intended to be implied or required unless expressly described in the description herein in connection with a particular illustration.

Detailed Description

Certain examples of composite articles are described herein that include a combination of thermoplastic materials and different fibers to provide improved properties. In some examples, one or more of peak load, stiffness, flexural strength, and flexural modulus may be increased.

In certain embodiments, in certain instances, the articles produced herein are described as lightweight reinforced thermoplastic (LWRT) articles. In general, the article comprises: a core layer comprising a web formed of a thermoplastic material, reinforcing fiber bicomponent fibers, and optionally a lofting agent. The presence of the combined materials may help to enhance the properties.

In certain configurations, the bicomponent fibers of the core layer may comprise two or more different materials that may be arranged in a number of different ways. For example, the bicomponent fibers can be configured in a core-sheath arrangement, a side-by-side arrangement, or a combination of these arrangements, wherein the sheath surrounds the side-by-side arrangement of fibers. The different fibers may be extruded, coextruded, drawn or produced in a similar manner as used to produce the fibers. In some examples, the produced fiber may be coated with another material to provide a shell around the core fiber. Where there are more than a single fiber in the shell, the fibers may be coaxial, e.g., remain untwisted, or may be crossed or twisted as desired.

Referring to fig. 1, a diagram showing a cross-section of a bicomponent fiber through a core-sheath arrangement is shown. The bicomponent fiber 100 comprises a core material 110 surrounded by a sheath material 120. Each of the

components

110, 120 may not be a fiber in the true sense, but the materials of the core 110 and the shell 120 together form a fiber. Alternatively, each of the

materials

110, 120 may be considered a fiber. The shell material 120 need not completely surround the core material 110 or be symmetrical. Without wishing to be bound by any particular theory, shell material 120 is selected to be compatible with the thermoplastic material, e.g., thermoplastic resin, used to produce the core layer. For example, the melting point of the shell material 120 may be about the same or the same as the melting point of the thermoplastic material of the core layer. In some examples, the melting points of the shell material 120 and the thermoplastic material may differ by about one degree celsius to about ten degrees celsius and the materials may still be considered compatible.

In certain embodiments, the core material 110 generally has a higher melting point than the shell material 120 and the thermoplastic material. For example, in forming the core layer, the shell material 120 and the thermoplastic material may melt or soften to form a web of the core layer. The core material 110 generally remains solid and does not melt soften to any significant extent during processing of the material to form the core layer.

In certain examples, the melting point of the core material 110 is at least fifteen degrees celsius higher than the melting point of the shell material 120 or the melting point of the thermoplastic material. In some examples, the melting point of the core material 110 is at least twenty degrees celsius higher than the melting point of the shell material 120 or the melting point of the thermoplastic material. In other examples, the melting point of the core material 110 is at least twenty-five degrees celsius higher than the melting point of the shell material 120 or the melting point of the thermoplastic material. In other examples, the melting point of the core material 110 is at least thirty degrees celsius higher than the melting point of the shell material 120 or the melting point of the thermoplastic material. In certain examples, the melting point of the core material 110 is at least thirty-five degrees celsius higher than the melting point of the shell material 120 or the melting point of the thermoplastic material. In certain embodiments, the melting point of the core material 110 is at least forty degrees celsius greater than the melting point of the shell material 120 or the melting point of the thermoplastic material. In other embodiments, the melting point of the core material 110 is at least forty-five degrees celsius higher than the melting point of the shell material 120 or the melting point of the thermoplastic material. In other embodiments, the melting point of the core material 110 is at least fifty degrees celsius higher than the melting point of the shell material 120 or the melting point of the thermoplastic material.

In some configurations, the materials present in the shell 120 and the core 110 are not the same material. For example, the shell material 120 may comprise a polyolefin, and the core material 110 may comprise a material having a melting point higher than the melting point of the polyolefin of the shell material 120. In other cases, the core material 110 may comprise a polyester, polyamide, or copolyamide, and the shell material 120 may comprise a material having a melting point lower than the melting point of the polyester, polyamide, or copolyamide in the core material 110. In additional examples, the shell material 120 may comprise a polyolefin and the core material 110 may comprise a polyester, a polyamide, or a copolyamide. In some examples, the shell material 120 comprises a polyolefin and the core material 110 comprises a polyester. In other examples, the shell material 120 comprises a polyolefin and the core material 110 comprises a polyamide. In some examples, the shell material 120 comprises a polyolefin and the core material comprises a copolyamide.

In some examples, the polyolefin of shell material 120 may be polyethylene, polypropylene, or other olefin polymers and copolymers. In some embodiments, the polyolefin material of the shell 120 can be considered a linear low density polyolefin. For example, the polyolefin material of the shell 120 may be Linear Low Density Polyethylene (LLDPE) or Low Density Polyethylene (LDPE). Although the exact material properties may vary, the linear low density polyethylene may have a density of about 0.91g/cm3 to about 0.94g/cm 3. In some examples, the melting point of the LLDPE or LDPE may be at least fifteen degrees celsius below the melting point of the core material 110. In certain examples, the melting point of the LLDPE or LDPE may be at least twenty degrees celsius below the melting point of the core material 110. In other examples, the melting point of the LLDPE or LDPE may be at least twenty-five degrees celsius below the melting point of the core material 110. In certain examples, the melting point of the LLDPE or LDPE may be at least thirty degrees celsius below the melting point of the core material 110. In other examples, the melting point of the LLDPE or LDPE may be at least thirty five degrees celsius below the melting point of the core material 110. In certain examples, the melting point of the LLDPE or LDPE may be at least forty degrees celsius below the melting point of the core material 110. In other examples, the melting point of the LLDPE or LDPE may be at least forty-five degrees celsius below the melting point of the core material 110. In some examples, the melting point of the LLDPE or LDPE may be at least fifty degrees celsius below the melting point of the core material 110.

In other examples, the core material 110 may comprise: a polyester comprising terephthalate monomer units. For example, the polyester can be polyethylene terephthalate, polybutylene terephthalate, or polynaphthalene terephthalate. In certain examples, the melting point of the polyester comprising terephthalate monomer units in core material 110 can be at least fifteen degrees higher than the melting point of the material in shell material 120. In some examples, the melting point of the polyester comprising terephthalate monomer units in the core material 110 can be at least twenty degrees higher than the melting point of the material in the shell material 120. In certain examples, the melting point of the polyester comprising terephthalate monomer units in core material 110 can be at least twenty-five degrees higher than the melting point of the material in shell material 120. In other examples, the melting point of the polyester comprising terephthalate monomer units in the core material 110 can be at least thirty degrees higher than the melting point of the material in the shell material 120. In certain examples, the melting point of the polyester comprising terephthalate monomer units in core material 110 can be at least thirty-five degrees higher than the melting point of the material in shell material 120. In some examples, the melting point of the polyester comprising terephthalate monomer units in the core material 110 can be at least forty degrees higher than the melting point of the material in the shell material 120. In other examples, the melting point of the polyester comprising terephthalate monomer units in the core material 110 can be at least forty-five degrees higher than the melting point of the material in the shell material 120. In additional examples, the melting point of the polyester comprising terephthalate monomer units in the core material 110 can be at least fifty degrees higher than the melting point of the material in the shell material 120.

In some embodiments, the core material 110 may comprise a polyamide or copolyamide. For example, the core material 110 may comprise nylon, nylon 66, aramid, polyesteramide, polyetheramide, polyetheresteramide, or other polyamide-containing copolymers. In certain examples, the melting point of the polyamide or copolyamide in core material 110 may be at least fifteen degrees higher than the melting point of the material in shell material 120. In some examples, the melting point of the polyamide or copolyamide in the core material 110 may be at least twenty degrees higher than the melting point of the material in the shell material 120. In certain examples, the melting point of the polyamide or copolyamide in core material 110 may be at least twenty-five degrees higher than the melting point of the material in shell material 120. In other examples, the melting point of the polyamide or copolyamide in the core material 110 may be at least thirty degrees higher than the melting point of the material in the shell material 120. In certain examples, the melting point of the polyamide or copolyamide in core material 110 may be at least thirty-five degrees higher than the melting point of the material in shell material 120. In some examples, the melting point of the polyamide or copolyamide in the core material 110 may be at least forty degrees higher than the melting point of the material in the shell material 120. In other examples, the melting point of the polyamide or copolyamide in the core material 110 may be at least forty-five degrees higher than the melting point of the material in the shell material 120. In additional examples, the melting point of the polyamide or copolyamide in the core material 110 may be at least fifty degrees higher than the melting point of the material in the shell material 120.

In certain examples, the shell material 120 may comprise polyethylene, such as LLDPE, and the core material 110 may comprise polyester or polyamide. For example, the core material 110 may comprise nylon, polyethylene terephthalate, polybutylene terephthalate, polynaphthalene terephthalate, or a combination thereof. In certain examples, the melting point of the polyester or polyamide in core material 110 may be at least fifteen degrees higher than the melting point of the polyethylene material in shell material 120. In some examples, the melting point of the polyester or polyamide in the core material 110 may be at least twenty degrees higher than the melting point of the polyethylene material in the shell material 120. In certain examples, the melting point of the polyester or polyamide in core material 110 may be at least twenty-five degrees higher than the melting point of the polyethylene material in shell material 120. In other examples, the melting point of the polyester or polyamide in the core material 110 may be at least thirty degrees higher than the melting point of the polyethylene material in the shell material 120. In certain examples, the melting point of the polyester or polyamide in core material 110 may be at least thirty-five degrees higher than the melting point of the polyethylene material in shell material 120. In some examples, the melting point of the polyester or polyamide in the core material 110 may be at least forty degrees higher than the melting point of the polyethylene material in the shell material 120. In other examples, the melting point of the polyester or polyamide in the core material 110 may be at least forty-five degrees higher than the melting point of the polyethylene material in the shell material 120. In additional examples, the melting point of the polyester or polyamide in the core material 110 may be at least fifty degrees higher than the melting point of the polyethylene material in the shell material 120.

In other cases, the bicomponent fibers present in the LWRT article can comprise a side-fiber arrangement. Referring to fig. 2, a diagram showing a cross-section of bicomponent fibers arranged through side-by-side fibers is shown. The bicomponent fiber 200 comprises a first fiber 210 arranged on one side of a second fiber 220. The

fibers

210, 220 may or may not be wrapped around each other and extend substantially coaxially with each other throughout the fiber 200. Without wishing to be bound by any particular theory, the melting point of the material in one of the

fibers

210, 220 is typically about the same or the same as the melting point of the thermoplastic material of the core layer. In some examples, the melting points of one of the

fibers

210, 220 and the thermoplastic material may differ by about one degree celsius to about ten degrees celsius, and the materials may still be considered compatible.

In certain embodiments, the fibers 210 generally have a higher melting point than the other fibers 220 and the thermoplastic material. For example, in forming the core layer, the fibers 220 and thermoplastic material may melt or soften to form a web of the core layer. The fibers 210 generally remain solid and do not melt and soften to any significant degree during processing of the material to form the core layer. In certain examples, the melting point of the fibers 210 is at least fifteen degrees celsius higher than the melting point of the fibers 220 or the melting point of the thermoplastic material. In some examples, the melting point of the fibers 210 is at least twenty degrees celsius higher than the melting point of the fibers 220 or the melting point of the thermoplastic material. In other examples, the melting point of the fibers 210 is at least twenty-five degrees celsius higher than the melting point of the fibers 220 or the melting point of the thermoplastic material. In other examples, the melting point of the fibers 210 is at least thirty degrees celsius higher than the melting point of the fibers 220 or the melting point of the thermoplastic material. In certain examples, the melting point of the fibers 210 is at least thirty-five degrees celsius higher than the melting point of the fibers 220 or the melting point of the thermoplastic material. In certain embodiments, the melting point of the fibers 210 is at least forty degrees celsius greater than the melting point of the fibers 220 or the melting point of the thermoplastic material. In other embodiments, the melting point of the fibers 210 is at least forty-five degrees celsius greater than the melting point of the fibers 220 or the melting point of the thermoplastic material. In other embodiments, the melting point of the fibers 210 is at least fifty degrees celsius greater than the melting point of the fibers 220 or the melting point of the thermoplastic material.

In some configurations, the materials present in the

fibers

210, 220 are not the same material. For example, fibers 220 may comprise a polyolefin, and fibers 210 may comprise a material having a melting point higher than the melting point of the polyolefin of shell material 120. In other cases, the fibers 210 can comprise a polyester, polyamide, or copolyamide, and the fibers 220 can comprise a material having a melting point lower than the melting point of the polyester, polyamide, or copolyamide in the fibers 210. In additional examples, the fibers 220 may comprise a polyolefin and the fibers 210 may comprise a polyester, a polyamide, or a copolyamide. In some examples, fibers 220 comprise a polyolefin and fibers 210 comprise a polyester. In other examples, the fibers 220 comprise a polyolefin and the fibers 210 comprise a polyamide. In some examples, the fibers 220 comprise a polyolefin and the fibers 210 comprise a copolyamide.

In some examples, the polyolefin of the fibers 220 can be polyethylene, polypropylene, or other olefin polymers and copolymers. In some embodiments, the polyolefin material of the fibers 220 can be considered a linear low density polyolefin. For example, the polyolefin material of the fibers 220 may be Linear Low Density Polyethylene (LLDPE) or Low Density Polyethylene (LDPE). Although the exact material properties may vary, the linear low density polyethylene may have a density of about 0.91g/cm3 to about 0.94g/cm 3. In some examples, the melting point of the LLDPE or LDPE can be at least fifteen degrees celsius below the melting point of the fibers 210. In certain examples, the melting point of the LLDPE or LDPE can be at least twenty degrees celsius below the melting point of the fibers 210. In other examples, the melting point of the LLDPE or LDPE can be at least twenty-five degrees celsius below the melting point of the fibers 210. In certain examples, the melting point of the LLDPE or LDPE may be at least thirty degrees celsius below the melting point of the core material 110. In other examples, the melting point of the LLDPE or LDPE may be at least thirty-five degrees celsius below the melting point of the fibers 210. In certain examples, the melting point of the LLDPE or LDPE can be at least forty degrees celsius below the melting point of the fibers 210. In other examples, the melting point of the LLDPE or LDPE can be at least forty-five degrees celsius below the melting point of the fibers 210. In some examples, the melting point of the LLDPE or LDPE can be at least fifty degrees celsius below the melting point of the fibers 210.

In other examples, the fibers 210 may include: a polyester comprising terephthalate monomer units. For example, the polyester can be polyethylene terephthalate, polybutylene terephthalate, or polynaphthalene terephthalate. In certain examples, the melting point of the polyester comprising terephthalate monomer units in the fibers 210 can be at least fifteen degrees higher than the melting point of the material in the fibers 220. In some examples, the melting point of the polyester comprising terephthalate monomer units in the fibers 210 can be at least twenty degrees higher than the melting point of the material in the fibers 220. In certain examples, the melting point of the polyester comprising terephthalate monomer units in the fibers 210 can be at least twenty-five degrees higher than the melting point of the material in the fibers 220. In other examples, the melting point of the polyester comprising terephthalate monomer units in the fibers 210 can be at least thirty degrees higher than the melting point of the material in the fibers 220. In certain examples, the melting point of the polyester comprising terephthalate monomer units in the fibers 210 can be at least thirty-five degrees higher than the melting point of the material in the fibers 220. In some examples, the melting point of the polyester comprising terephthalate monomer units in the fibers 210 can be at least forty degrees higher than the melting point of the material in the fibers 220. In other examples, the melting point of the polyester comprising terephthalate monomer units in the fibers 210 can be at least forty-five degrees higher than the melting point of the material in the fibers 220. In additional examples, the melting point of the polyester comprising terephthalate monomer units in the fibers 210 can be at least fifty degrees higher than the melting point of the material in the fibers 220.

In some embodiments, the fibers 210 may comprise a polyamide or copolyamide. For example, the fibers 210 may comprise nylon, nylon 66, aramid, polyesteramide, polyetheramide, polyetheresteramide, or other polyamide-containing copolymers. In certain examples, the melting point of the polyamide or copolyamide in the fiber 210 can be at least fifteen degrees higher than the melting point of the material in the fiber 220. In some examples, the melting point of the polyamide or copolyamide in the fiber 210 can be at least twenty degrees higher than the melting point of the material in the fiber 220. In certain examples, the melting point of the polyamide or copolyamide in the fiber 210 can be at least twenty-five degrees higher than the melting point of the material in the fiber 220. In other examples, the melting point of the polyamide or copolyamide in the fiber 210 may be at least thirty degrees higher than the melting point of the material in the fiber 220. In certain examples, the melting point of the polyamide or copolyamide in the fiber 210 can be at least thirty-five degrees higher than the melting point of the material in the fiber 220. In some examples, the melting point of the polyamide or copolyamide in the fibers 210 can be at least forty degrees higher than the melting point of the material in the fibers 220. In other examples, the melting point of the polyamide or copolyamide in the fiber 210 can be at least forty-five degrees higher than the melting point of the material in the fiber 220. In an additional example, the melting point of the polyamide or copolyamide in the fiber 210 can be at least fifty degrees higher than the melting point of the material in the fiber 220.

In certain examples, the fibers 220 may comprise polyethylene, such as LLDPE, and the fibers 210 may comprise polyester or polyamide. For example, the fibers 210 may comprise nylon, polyethylene terephthalate, polybutylene terephthalate, polynaphthalene terephthalate, or a combination thereof. In certain examples, the melting point of the polyester or polyamide in the fibers 210 can be at least fifteen degrees higher than the melting point of the polyethylene material in the fibers 220. In some examples, the melting point of the polyester or polyamide in the core fiber 210 may be at least twenty degrees higher than the melting point of the polyethylene material in the fiber 220. In certain examples, the melting point of the polyester or polyamide in the fibers 210 can be at least twenty-five degrees higher than the melting point of the polyethylene material in the fibers 220. In other examples, the melting point of the polyester or polyamide in the fibers 210 may be at least thirty degrees higher than the melting point of the polyethylene material in the fibers 220. In certain examples, the melting point of the polyester or polyamide in the fibers 210 can be at least thirty-five degrees higher than the melting point of the polyethylene material in the fibers 220. In some examples, the melting point of the polyester or polyamide in the fibers 210 can be at least forty degrees above the melting point of the polyethylene material in the fibers 220. In other examples, the melting point of the polyester or polyamide in the fibers 210 may be at least forty-five degrees higher than the melting point of the polyethylene material in the fibers 220. In an additional example, the melting point of the polyester or polyamide in the fibers 210 may be at least fifty degrees higher than the melting point of the polyethylene material in the fibers 220.

Referring to fig. 3A, a diagram illustrating a cross-section through a side-by-side fiber arrangement is shown, wherein a sheath surrounds the bicomponent fibers of the side-by-side fiber arrangement. For example, the fiber 300 includes a shell 320 surrounding two

fibers

310, 315. In fig. 3A, the

fibers

310, 315 may comprise the same or similar composition. For example, each of

fibers

310, 315 may independently comprise the same materials as described in connection with core material 110 in fig. 1, e.g., each of

fibers

310, 315 may independently comprise polyamide, polyester, or other polymers.

In certain embodiments, the shell material 320 may comprise a polyolefin. In some examples, the polyolefin of shell material 320 may be polyethylene, polypropylene, or other olefin polymers and copolymers. In some embodiments, the polyolefin material of the shell 320 can be considered a linear low density polyolefin. For example, the polyolefin material of the shell 320 may be Linear Low Density Polyethylene (LLDPE) or Low Density Polyethylene (LDPE). Although the exact material properties may vary, the linear low density polyethylene may have a density of about 0.91g/cm3 to about 0.94g/cm 3. In some examples, the melting point of the LLDPE or LDPE may be at least fifteen degrees celsius below the melting point of the

fibers

310, 315. In certain examples, the melting point of the LLDPE or LDPE can be at least twenty degrees celsius lower than the melting point of the

fibers

310, 315. In other examples, the melting point of the LLDPE or LDPE may be at least twenty-five degrees celsius lower than the melting point of the

fibers

310, 315. In certain examples, the melting point of the LLDPE or LDPE can be at least thirty degrees celsius below the melting point of the

fibers

310, 315. In other examples, the melting point of the LLDPE or LDPE may be at least thirty-five degrees celsius lower than the melting point of the

fibers

310, 315. In certain examples, the melting point of the LLDPE or LDPE can be at least forty degrees celsius below the melting point of the

fibers

310, 315. In other examples, the melting point of the LLDPE or LDPE may be at least forty-five degrees celsius lower than the melting point of the

fibers

310, 315. In some examples, the melting point of the LLDPE or LDPE may be at least fifty degrees celsius below the melting point of the

fibers

310, 315.

In certain examples, the

fibers

310, 315 may independently comprise polyester or polyamide. In some cases, the

fibers

310, 315 independently can comprise nylon, polyethylene terephthalate, polybutylene terephthalate, polynaphthalene terephthalate, or a combination thereof. In certain examples, the melting point of the polyester or polyamide in

fibers

310, 315 can be at least fifteen degrees higher than the melting point of the polyethylene material in shell material 320. In some examples, the melting point of the polyester or polyamide in

fibers

310, 315 can be at least twenty degrees higher than the melting point of the polyethylene material in shell material 320. In certain examples, the melting point of the polyester or polyamide in

fibers

310, 315 can be at least twenty-five degrees higher than the melting point of the polyethylene material in shell material 320. In other examples, the melting point of the polyester or polyamide in

fibers

310, 315 may be at least thirty degrees higher than the melting point of the polyethylene material in shell material 320. In certain examples, the melting point of the polyester or polyamide in

fibers

310, 315 can be at least thirty-five degrees higher than the melting point of the polyethylene material in shell material 320. In some examples, the melting point of the polyester or polyamide in

fibers

310, 315 can be at least forty degrees higher than the melting point of the polyethylene material in shell material 320. In other examples, the melting point of the polyester or polyamide in

fibers

310, 315 can be at least forty-five degrees higher than the melting point of the polyethylene material in shell material 320. In an additional example, the melting point of the polyester or polyamide in

fibers

310, 315 can be at least fifty degrees higher than the melting point of the polyethylene material in shell material 320.

Although fig. 3A shows two side-by-side fibers that may contain the same composition, this configuration is not necessary. By way of example and with reference to fig. 3B, side-by-side arranged

fibers

360, 365 are shown surrounded by a shell 370. The

fibers

360, 365 need not have the same composition as one another, but the melting point of each of the

fibers

360, 365 is generally higher than the melting point of the shell 370 in the fiber arrangement 350. In one configuration, one of the

fibers

360, 365 is a reinforcing fiber, such as an inorganic fiber, e.g., a glass fiber, a graphite fiber, a carbon fiber, etc., as mentioned below, and the other of the

fibers

360, 365 is an organic fiber, e.g., containing one or more covalently bonded carbon-hydrogen groups. By packing the inorganic and organic fibers in the shell, the addition of fibers during processing of the material to form the core layer can be simplified. In other examples,

fibers

360, 365 may each be organic fibers having different compositions.

In certain embodiments, shell material 370 may comprise a polyolefin. In some examples, the polyolefin of shell material 370 may be polyethylene, polypropylene, or other olefin polymers and copolymers. In some embodiments, the polyolefin material of the shell 370 can be considered a linear low density polyolefin. For example, the polyolefin material of the shell 370 may be Linear Low Density Polyethylene (LLDPE) or Low Density Polyethylene (LDPE). Although the exact material properties may vary, the linear low density polyethylene may have a density of about 0.91g/cm3 to about 0.94g/cm 3. In some examples, the melting point of the LLDPE or LDPE can be at least fifteen degrees celsius below the melting point of the

fibers

360, 365. In certain examples, the melting point of the LLDPE or LDPE can be at least twenty degrees celsius lower than the melting point of the

fibers

360, 365. In other examples, the melting point of the LLDPE or LDPE can be at least twenty-five degrees celsius below the melting point of the

fibers

360, 365. In certain examples, the melting point of the LLDPE or LDPE can be at least thirty degrees celsius below the melting point of the

fibers

360, 365. In other examples, the melting point of the LLDPE or LDPE can be at least thirty-five degrees celsius lower than the melting point of the

fibers

360, 365. In certain examples, the melting point of the LLDPE or LDPE can be at least forty degrees celsius below the melting point of the

fibers

360, 365. In other examples, the melting point of the LLDPE or LDPE can be at least forty-five degrees celsius below the melting point of the

fibers

360, 365. In some examples, the melting point of the LLDPE or LDPE can be at least fifty degrees celsius below the melting point of the

fibers

360, 365.

In certain examples, the

fibers

360, 365 may independently comprise polyester or polyamide, or one of the

fibers

360, 365 may be an inorganic reinforcing fiber. In some cases, the

fibers

360, 365 independently can comprise nylon, polyethylene terephthalate, polybutylene terephthalate, polynaphthalene terephthalate, or a combination thereof. In some examples, the melting point of the material in

fibers

360, 365 may be at least fifteen degrees higher than the melting point of the polyethylene material in shell material 370. In some examples, the melting point of the material in

fibers

360, 365 may be at least twenty degrees higher than the melting point of the polyethylene material in shell material 370. In some examples, the melting point of the material in

fibers

360, 365 may be at least twenty-five degrees higher than the melting point of the polyethylene material in shell material 370. In other examples, the melting point of the material in

fibers

360, 365 may be at least thirty degrees higher than the melting point of the polyethylene material in shell material 370. In certain examples, the melting point of the material in

fibers

360, 365 may be at least thirty-five degrees higher than the melting point of the polyethylene material in shell material 320. In some examples, the melting point of the material in

fibers

360, 365 may be at least forty degrees higher than the melting point of the polyethylene material in shell material 370. In other examples, the melting point of the material in

fibers

360, 365 may be at least forty-five degrees higher than the melting point of the polyethylene material in shell material 370. In an additional example, the melting point of the material in

fibers

360, 365 may be at least fifty degrees higher than the melting point of the polyethylene material in shell material 370.

In certain embodiments and referring to fig. 4, core layer 410 is shown to comprise a thermoplastic material, reinforcing fibers, bicomponent fibers, and lofting agents. Combinations of these materials below may provide improved mechanical properties as discussed further below. Although not in all configurations, the lofting agent is typically trapped in the voids or pores of the core layer 410. Core layer 410 may be first formed into a prepreg, which is typically a precursor of core layer 410 and need not be completely formed. For ease of illustration, the core layer is described below, but the core layer may also have the same properties as the prepreg. The core layer 410 comprises a porous structure to allow gas flow through the core layer. For example, the void content or porosity of the core layer may be 0% -30%, 10% -40%, 20% -50%, 30% -60%, 40% -70%, 50% -80%, 60% -90%, 0% -40%, 0% -50%, 0% -60%, 0% -70%, 0% -80%, 0% -90%, 10% -50%, 10% -60%, 10% -70%, 10% -80%, 10% -90%, 10% -95%, 20% -60%, 20% -70%, 20% -80%, 20% -90%, 20% -95%, 30% -70%, 30% -80%, 30% -90%, 30% -95%, 40% -80%, 40% -90%, 40% -95%, 50% -90%, 50% -95%, 60% -95%, 70% -80%, 70% -90%, 70% -95%, 80% -90%, 80% -95%, or any illustrative value within these exemplary ranges. In some cases, the porosity or void content of the core layer 410 is greater than 0%, e.g., not fully consolidated, up to about 95%. Unless otherwise specified, reference to a core layer of a certain void content or porosity is based on the total volume of the core layer, and does not necessarily require the core layer plus the total volume of any other materials or layers coupled to the core layer.

In certain embodiments, improved mechanical properties may be achieved by including polymeric bicomponent fibers in the core layer 410. For example, increasing the amount of reinforcing fibers in the core layer 410 may generally reduce certain mechanical properties. The inclusion of bicomponent fibers in the core layer may, for example, increase one or more of the peak load value, stiffness value, flexural strength value, and flexural modulus value of a selected molded thickness. These values may be measured, for example, using SAEJ949 (also referred to as SAEJ949_200904) dated 4 months 2009. Briefly, the SAEJ949 protocol was used to perform a three point bend test on the samples and measure various performance values.

In certain embodiments, the thermoplastic material of the core layer 410 may at least partially comprise one or more of the following: polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene tetrachloride and polyvinyl chloride, both plasticized and unplasticized, and blends of these materials with each other or other polymeric materials. Other suitable thermoplastics include, but are not limited to, poly (arylene ether), polycarbonate, polyestercarbonate, thermoplastic polyester, polyimide, polyetherimide, polyamide, acrylonitrile-butyl acrylate-styrene polymer, amorphous nylon, polyarylene ether ketone, polyphenylene sulfide, polyarylsulfone, polyethersulfone, liquid crystal polymer, commercially known as

Poly (1, 4-phenylene) compounds of (a), e.g. Bayer (Bayer)

The high heat polycarbonate of PC, high temperature nylon and silicone, as well as alloys and blends of these materials with each other or other polymeric materials, can be used in powder form, resin form, rosin form, fiber form or other suitable forms of the original thermoplastic material used to form the core layer. Exemplary thermoplastic materials in various forms are described herein, and are also described, for example, in U.S. publication nos. 20130244528 and US 20120065283. The exact amount of thermoplastic material present in core layer 410 can vary, and illustrative amounts range from about 20 wt% to about 80 wt%. As mentioned herein, the material of the core layer 410 may be selected such that its melting point is about the same as one of the materials in the bicomponent fiber and lower than the melting point of the other material in the bicomponent fiber. Illustrative melting point ranges for thermoplastic materials include, but are not limited to, about 120 degrees celsius to about 260 degrees celsius. Thermoplastic materials that melt between 100 degrees celsius and 315 degrees celsius may also be used if desired.

In certain examples, the reinforcing fibers of the core layer described herein may comprise glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high modulus organic fibers, such as para-and meta-aramid fibers, nylon fibers, polyester fibers, or any high melt flow index resin suitable for use as fibers, natural fibers (such as hemp, sisal, jute, flax, coir, kenaf, and cellulose fibers), mineral fibers (such as basalt, mineral wool (e.g., rock or slag wool), wollastonite, alumina silica, and the like, or mixtures thereof), metal fibers, metallized natural and/or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In some cases, one type of reinforcing fiber may be used with the mineral fibers, for example, fibers formed by spinning or drawing a molten mineral. Illustrative mineral fibers include, but are not limited to, mineral wool fibers, glass wool fibers, asbestos fibers, and ceramic wool fibers. In some examples, the reinforcing fibers may be selected to be inorganic fibers, such as fibers that do not include covalently bonded carbon-hydrogen groups.

In some embodiments, any of the foregoing reinforcing fibers may be chemically treated prior to use to provide desired functional groups or to impart other physical properties to the fibers. The total fiber content (reinforcement fibers + bicomponent fibers) in the core layer may be from about 20% to about 90% by weight of the core layer, more specifically, from about 30% to about 70% by weight of the core layer. Typically, the total fiber content of the composite article comprising the core layer varies from about 20% to about 90%, more specifically from about 30% to about 80%, for example from about 40% to about 70% by weight of the composite. The particular size and/or orientation of the reinforcing fibers used may depend, at least in part, on the polymeric material used and/or the desired characteristics of the resulting core layer. Additional types of suitable fibers, fiber sizes, and numbers will be readily selected by those of ordinary skill in the art, given the benefit of this disclosure. In one non-limiting illustration, the reinforcing fibers dispersed in the thermoplastic material to provide the core layer are generally greater than about 5 microns in diameter, more specifically about 5 microns to about 22 microns, and about 5mm to about 200mm in length. More particularly, the reinforcing fibers may have a diameter of about 5 microns to about 22 microns and a fiber length of about 5mm to about 75 mm. In some configurations, the flame retardant material may be present in the form of fibers. For example, the core layer may comprise thermoplastic materials, reinforcing fibers, bicomponent fibers, and fibers comprising flame retardant materials.

In some configurations, the core layer 410 may be substantially halogen-free or halogen-free to meet the constraints of hazardous material requirements for certain applications. In other cases, core layer 410 may comprise a halogenated flame retardant (which may be present in the flame retardant material, or may be added in addition to the flame retardant material), for example, a halogenated flame retardant comprising one or more of F, Cl, Br, I, and At, or a compound comprising such a halogen, such as tetrabromobisphenol a polycarbonate or a monohalogenated, dihalogenated, trihalo, or tetrahalo polycarbonate. In some cases, the thermoplastic material used in core layer 410 may include one or more halogens to impart some flame retardancy without the addition of another flame retardant. For example, in addition to the presence of the flame retardant material, the thermoplastic material may be halogenated, or the original thermoplastic material may be halogenated and used alone. In the case of halogenated flame retardants, it is desirable that the flame retardant be present in a flame retardant amount, which can vary depending on the other components present. For example, the halogenated flame retardant present in addition to the flame retardant material may be present from about 0.1 wt% to about 40 wt% (based on the weight of the prepreg), more specifically from about 0.1 wt% to about 15 wt%, for example, from about 5 wt% to about 15 wt%. Two different halogenated flame retardants may be added to the core layer 410 if desired. In other cases, non-halogenated flame retardants may be added, such As, for example, flame retardants comprising one or more of N, P, As, Sb, Bi, S, Se, and Te. In some embodiments, the non-halogenated flame retardant may include a phosphated material, and thus the core layer 410 may be more environmentally friendly. In the presence of a non-halogenated or substantially halogen-free flame retardant, it is desirable that the flame retardant be present in a flame retardant amount, which can vary depending on the other components present. For example, the substantially halogen-free flame retardant may be present from about 0.1 wt% to about 40 wt% (based on the weight of the prepreg), more specifically from about 5 wt% to about 40 wt%, for example from about 5 wt% to about 15 wt%, based on the weight of the core layer. If desired, two different substantially halogen-free flame retardants may be added to the core layer 410. In certain instances, the core layer 410 described herein may comprise one or more halogenated flame retardants and one or more substantially halogen-free flame retardants. When two different flame retardants are present, the combination of the two flame retardants can be present in a flame retardant amount that can vary depending on the other components present. For example, the total weight of flame retardant present may be from about 0.1 wt% to about 40 wt% (based on the weight of the prepreg or core), more specifically from about 5 wt% to about 40 wt%, for example from about 2 wt% to about 14 wt%, based on the weight of the core layer. The flame retardants used in the core layer described herein may be added to the mixture comprising the thermoplastic material, bicomponent fibers, and reinforcing fibers (before the mixture is placed on a mesh screen or other processing component) or may be added after the core layer 410 is formed.

As referred to herein, the core layer 410 may comprise lofting agents present in the pores or voids of the core layer. The bulking agent may take the form of expandable microspheres, the volume of which may increase upon exposure to heat or other stimuli. For example, the thickness of the core layer 410 may be increased by expansion of the lofting agent. The exact amount of leavening agent present in core layer 410 may vary, but illustrative amounts include, but are not limited to, about 0.5 wt.% to about 30 wt.%.

In certain embodiments, the exact amount of bicomponent fibers in the core layer described herein can vary. In general, the weight percent of the bicomponent fibers in the core layer can vary from about 2 weight percent to about 30 weight percent. In some examples, there are approximately the same amount of bicomponent fibers and reinforcing fibers in the core layer. In some examples, the total basis weight of core layer 410 may vary from about 500gsm to about 3500 gsm. In some examples, a lighter core layer with suitable mechanical properties may be more desirable to reduce the total weight, for example the basis weight of core layer 410 may range from about 750gsm to about 1500gsm or from about 750gsm to about 1250 gsm.

In certain embodiments, the core layers and/or articles described herein may be prepared using reinforcing fibers, bicomponent fibers, lofting agents, and thermoplastic materials, as generally shown in fig. 5. To produce the core layer, the thermoplastic material, reinforcing fibers, bicomponent fibers, lofting agent, and optionally other materials may be added or metered to the dispersed foam in an open-top mixing tank equipped with an impeller to provide an aqueous dispersion of the materials at step 510. Without wishing to be bound by any particular theory, the presence of trapped air pockets of the foam may help disperse the reinforcing fibers, bicomponent fibers, thermoplastic materials, lofting agents, and any other materials. In some examples, the dispersed mixture of fibers, leavening agents, and thermoplastics may be pumped through a distribution manifold to a headbox located above the wire section of a paper machine. For example, at step 520, the aqueous mixture may be deposited on a moving mesh screen or other support element. The foam can then be removed without removing the fibers, lofting agent, or thermoplastic material, while the dispersed mixture is applied using pressure to a moving support, such as a mesh screen, to continuously produce a uniform wet web of fibers with lofting agent entrapped in the web. At step 530, the wet web may be passed through a dryer at a suitable temperature to reduce the moisture content and melt or soften at least one of the thermoplastic material and the bicomponent fibers to provide a core layer. As the heated web exits the dryer, an optional surface or skin layer, such as a textured film, may be laminated to the web by passing the web of reinforcing fibers, bicomponent fibers, thermoplastic material, lofting agent, and textured film through the nip of a set of heated rolls. Additional layers, such as another film layer, scrim layer, etc. may also be attached to one or both sides of the web along with the textured film, if desired, to facilitate easy handling of the produced composite. The composite may then be passed through tension rolls and continuously cut (slit) to the desired size for subsequent shaping into the final composite article. Further information on the preparation of such composites, including suitable materials and processing conditions used in forming such composites, is described, for example, in U.S. patents 6,923,494, 4,978,489, 4,944,843, 4,964,935, 4,734,321, 5,053,449, 4,925,615, 5,609,966 and U.S. patent application publications US 2005/0082881, US2005/0228108, US 2005/0217932, US 2005/0215698, US 2005/0164023, and US 2005/0161865.

In another configuration, the core layers and/or articles described herein may be prepared using reinforcing fibers, bicomponent fibers, and thermoplastic materials as generally shown in fig. 6. To produce the core layer, thermoplastic material, reinforcing fibers, bicomponent fibers, and optionally other materials may be added or metered into the dispersed foam in an open-top mixing tank equipped with an impeller to provide an aqueous dispersion at step 610. Without wishing to be bound by any particular theory, the presence of trapped air pockets of the foam may help disperse the reinforcing fibers, bicomponent fibers, thermoplastic materials, and any other materials. In some examples, the dispersed mixture of fibers and thermoplastic may be pumped via a distribution manifold to a headbox located above the wire section of a papermaking machine. For example, the aqueous mixture may be deposited 620 on a moving mesh screen or other support element to provide a wet web. The foam can then be removed without removing the fibers or thermoplastic material while pressure is used to provide the dispersed mixture to a moving support, such as a mesh screen, to continuously produce a uniform wet web of fibers. The leavening agent may then be deposited or sprayed onto the top of the wet web at step 625 to provide a wet web comprising the leavening agent. At step 630, the wet web containing the deposited lofting agent may be passed through a dryer, optionally under vacuum or by applying pressure, and heated at a suitable temperature to reduce the moisture content and melt or soften the thermoplastic material and at least one of the bicomponent fibers to provide the core layer. As the heated web exits the dryer, an optional surface or skin layer, such as a textured film, may be laminated to the web by passing the web of reinforcing fibers, bicomponent fibers, thermoplastic material, lofting agent, and textured film through the nip of a set of heated rolls. Additional layers, such as another film layer, scrim layer, etc. may also be attached to one or both sides of the web along with the textured film, if desired, to facilitate easy handling of the produced composite. The composite may then be passed through tension rolls and continuously cut (slit) to the desired size for subsequent shaping into the final composite article.

In certain embodiments, the core layer described herein may be used with an outer skin layer to provide a composite article. Referring to fig. 7, skin layer 720 is shown disposed on a first surface of core layer 410 to provide composite article 700. The skin layer 720 may comprise, for example, a film, a scrim (e.g., fiber-based scrim), inorganic fiberglass (inorganic fiberglass + scrim), a foil, a woven fabric, a nonwoven fabric, or be present as an inorganic coating, organic coating, or thermoset coating disposed on the core layer. In other cases, the layer 720 may include a limiting oxygen index of greater than about 22 as measured according to ISO 4589 dated 1996. Where a fibrous scrim is present as the outer skin layer 720 (or as part of the outer skin layer 720), the fibrous scrim can comprise at least one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, and metallized inorganic fibers. Where a thermoset coating is present as layer 720 (or as part of layer 720), the coating may comprise at least one of unsaturated polyurethanes, vinyl esters, phenols, and epoxies. Where the inorganic coating is present as layer 720 (or as part of layer 720), the inorganic coating can comprise a mineral comprising a cation selected from the group consisting of: ca. Mg, Ba, Si, Zn, Ti, and Al, or may comprise at least one of gypsum, calcium carbonate, and mortar. Where a nonwoven fabric is present as layer 720 (or as part of layer 720), the nonwoven fabric may comprise a thermoplastic material, a thermoset binder, inorganic fibers, metal fibers, metalized inorganic fibers, and metalized synthetic fibers. If desired, an intermediate layer (not shown) may be present between the core layer and the skin layer 720. For example, there may be a layer of adhesive or other material between the core layer 410 and the skin layer 720.

In some examples, the composite article may further comprise a second skin layer disposed on another surface of the core layer. Referring to fig. 8, a composite article 800 is shown comprising outer skin layers 720, 820 sandwiching a core layer 410. The layer 820 may be the same as layer 720 or may be different. In some cases, layer 820 may comprise, for example, a film, a scrim (e.g., a fiber-based scrim), inorganic fiberglass (inorganic fiberglass + scrim), a foil, a woven fabric, a nonwoven fabric, or be present as an inorganic coating, organic coating, or thermoset coating disposed on a core layer. In other cases, layer 820 may comprise a limiting oxygen index of greater than about 22 as measured according to ISO 4589 dated 1996. Where a fibrous scrim is present as layer 820 (or as part of layer 820), the fibrous scrim can comprise at least one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, and metallized inorganic fibers. Where a thermoset coating is present as layer 820 (or as part of layer 820), the coating may comprise at least one of unsaturated polyurethanes, vinyl esters, phenols, and epoxies. Where an inorganic coating is present as layer 820 (or as part of layer 820), the inorganic coating can comprise a mineral comprising a cation selected from the group consisting of: ca. Mg, Ba, Si, Zn, Ti, and Al, or may comprise at least one of gypsum, calcium carbonate, and mortar. Where a nonwoven fabric is present as layer 820 (or as part of layer 820), the nonwoven fabric may comprise a thermoplastic material, a thermosetting binder, inorganic fibers, metal fibers, metalized inorganic fibers, and metalized synthetic fibers. If desired, an intermediate layer (not shown) may be present between the core layer and the skin layer 820. For example, there may be a layer of adhesive or other material between the core layer 410 and the skin layer 820.

In certain configurations, the composite article may include a decorative layer disposed on a surface of the core layer or on the outer skin layer. Referring to fig. 9, an article 900 is shown comprising a decorative layer 830 disposed on an outer skin layer 720. Although not shown, a decorative layer may be disposed on the opposite surface of the core layer 410 or may be disposed on the outer skin layer 820 shown in fig. 8. In some examples, the decorative layer 930 can be configured as a decorative layer, a textured layer, a colored layer, and the like. For example, the decorative layer 930 may be formed from a thermoplastic film such as polyvinyl chloride, polyolefin, thermoplastic polyester, thermoplastic elastomer, and the like. The decorative layer 930 may also be a multi-layer structure that includes a foam core formed from, for example, polypropylene, polyethylene, polyvinyl chloride, polyurethane, or the like. The fabric may be bonded to the foam core, such as a woven fabric made of natural and synthetic fibers, a needled organic fiber woven fabric or the like, a pile fabric, knitwear, flocked fabric, or other such materials. The fabric may also be bonded to the foam core with thermoplastic adhesives, including pressure sensitive adhesives and hot melt adhesives, such as polyamides, modified polyolefins, polyurethanes and polyolefins. Decorative layer 930 can also be produced using spunbond, thermal bonding, spunlace, meltblown, wet-laid, and/or dry-laid processes. An insulating or sound absorbing layer can also be bonded to one or more surfaces of the articles described herein, and the insulating or sound absorbing layer can be open or closed, such as open cell foam or closed cell foam, as desired.

In certain embodiments, the LWRT articles described herein can be molded to a specific thickness. While not in all cases, the molding temperature can be selected to increase the total volume of the leavening agent, which can increase the thickness of the LWRT article. LWRT articles without a bulking agent may also be somewhat bulked during molding if compressed during the formation of the LWRT article. The exact mold thickness can vary as desired, and typical mold thicknesses range from about 1cm to about 10cm in the longitudinal and transverse directions, although other mold thicknesses can also be used.

In certain embodiments, as mentioned herein, the presence of bicomponent fibers, reinforcing fibers, lofting agents, and thermoplastic materials in the core layer of the LWRT article can provide improved mechanical properties for a selected molded thickness.

In certain embodiments, the LWRT article comprising a core layer and an outer skin layer can comprise a peak load value of from about 10N/cm to about 40N/cm in the machine direction and from about 5N/cm to about 30N/cm in the cross direction as measured by SAEJ949 — 200904 at a molded thickness of from 1.5cm to 4cm in the machine direction and the cross direction.

In certain embodiments, the LWRT article comprising a core layer and an outer skin layer can comprise a stiffness value of from about 6N/cm to about 50N/cm in the machine direction and from about 3N/cm to about 30N/cm in the cross direction as measured by SAEJ949 — 200904 at a molded thickness of from 1.5cm to 4cm in the machine direction and the cross direction.

In certain embodiments, the LWRT article comprising a core layer and an outer skin layer can comprise about 6N/m in the machine direction as measured by SAEJ949 — 200904 at a molded thickness of 1.5cm to 4cm in the machine direction and in the cross direction²To about 20N/m²And about 4N/m in the transverse direction²To about 12N/m²The bending strength value of (a).

In some examples, the LWRT article comprising a core layer and an outer skin layer can comprise about 800N/m in the machine direction as measured by SAEJ949 — 200904 at a molded thickness of 1.5cm to 4cm in the machine direction and in the cross direction²To about 1800N/m²And about 500N/m in the transverse direction²To about 1600N/m²The flexural modulus of (a).

In certain embodiments, the core layers and articles described herein may be used in architectural and automotive applications, such as headliners, rear window trim panels, trunk trim panels, office partitions, cabinet back panels, automotive trim panels, or other automotive interior articles.

In certain embodiments and with reference to fig. 10, the articles described herein may be present in a headliner of a vehicle. Illustrative vehicles include, but are not limited to, automobiles, trucks, trains, subways, recreational vehicles, airplanes, ships, submarines, spacecraft, and other vehicles that can transport personnel or cargo. In some cases, the headliner typically comprises at least one layer comprising bicomponent fibers, reinforcing fibers, a thermoplastic material, a lofting agent prepreg or core layer, one or more optional skin layers disposed on or over the core layer, and a decorative layer, such as a decorative fabric. The decorative layer may enhance sound absorption in addition to being aesthetically and/or visually pleasing and may optionally include foam, insulation, or other materials. Fig. 10 shows a top view of the roof. The canopy 1000 includes a body 1010 and an opening 1020, such as for a skylight, a roof window, and the like. The body of the ceiling 1010 may be produced using one or more of the core layers described herein, and using a molding machine, wherein a decorative fabric is placed onto a surface of the core layer and pressed with a desired mold to transform the article into a ceiling having a desired shape. Opening 1020 may then be provided by trimming canopy 1000. The non-visible surface of the headliner, such as the surface that rests on the vehicle roof, may include one or more additional layers or adhesives as desired. The overall shape and geometry of the roof may be selected based on the area of the vehicle to which the roof is to be coupled. For example, the length of the headliner may be sized and arranged to span from the front windshield to the rear windshield, and the width of the headliner may be sized and arranged to span from the left side of the vehicle to the right side of the vehicle. In some examples, the core layer of the headliner 1000 can include 20 wt% to 80 wt% of the reinforcing fibers and bicomponent fibers (in total) and 20 wt% to 80 wt% of the thermoplastic material. In other embodiments, the reinforcing fibers comprise glass fibers and the thermoplastic material comprises a polyolefin. The bicomponent fibers may comprise a core-sheath arrangement or other arrangements as described herein. In some examples, the automotive headliner can provide peak load values, stiffness values, bending strength values, and/or bending modulus values as discussed herein in connection with the core layer.

In some cases, the core layer may also be used to produce other automotive interior components, including panels, trim pieces, and the like. An illustration (top view) of a rear window trim panel 1100 is shown in fig. 11. The trim panel 1100 may comprise one or more of the core layers as described herein, optionally with an outer skin layer and/or a decorative layer. In some examples, the core layer of an automotive component, such as a plaque sheet, may comprise 20 to 80 weight percent reinforcing fibers and bicomponent fibers (in total) and 20 to 80 weight percent thermoplastic material. In other embodiments, the reinforcing fibers comprise glass fibers and the thermoplastic material comprises a polyolefin. The bicomponent fibers may comprise a core-sheath arrangement or other arrangements as described herein. In some examples, an automotive trim panel or interior component may provide peak load values, stiffness values, bending strength values, and/or bending modulus values as discussed herein in connection with the core layer.

In other configurations, the bicomponent fibers described herein can be used in non-automotive articles, such as furniture. For example and referring to fig. 12, a display case 1200 is shown that includes a top surface 1110,

side surfaces

1212, 1214 coupled to a front surface 1210, and a back surface 1220 coupled to the side surfaces 1212, 1214. Together, surfaces 1210, 1212, 1214, and 1220 form an internal storage area accessible to a user. Although not shown, the cabinet 1200 may include a front surface, such as a glass surface or other material to view the contents of the cabinet. Alternatively, a door or other device may be attached to the cabinet 1200 to obscure the contents within the cabinet 1200 from view. One or more surfaces of the cabinet 1200 may be configured as a LWRT article having a core layer comprising a TP material, reinforcing fibers, and bicomponent fibers. In some examples, the back surface 1220 can include a core layer comprising a web of reinforcing fibers and bicomponent fibers held together by a thermoplastic material. Where more than one of the surfaces of the article 1200 includes bicomponent fibers in one layer, the layers need not have the same composition, thickness, or number of layers. In some examples, the core layer of furniture article 1200 may comprise 20 to 80 wt.% reinforcing fiber bicomponent fibers (in total) and 20 to 80 wt.% thermoplastic material. In other embodiments, the reinforcing fibers comprise glass fibers and the thermoplastic material comprises a polyolefin. The bicomponent fibers may comprise a core-sheath arrangement or other arrangements. In some examples, furniture article 1200 or a panel thereof may provide peak load values, stiffness values, bending strength values, and/or bending modulus values as discussed herein in connection with the core layer.

In some configurations, an article of furniture may be configured to receive at least one drawer. By way of example and with reference to fig. 13, a cabinet 1300 is shown containing a drawer 1310 and a back surface 1320. For example, the back surface 1320 can include an LWRT article as described herein, such as an article having bicomponent fibers. Other surfaces of the cabinet 1300 may also include LWRT articles as described herein. In other configurations, furniture article 1300 may be configured to receive (or may include) at least one door. Referring to fig. 14, cabinet 1400 includes a door 1410 and a back surface 1420. For example, the back surface 1420 may include an LWRT article as described herein. Other surfaces of the cabinet 1400 may also include the LWRT articles described herein. If desired, the exterior surface of the door 1410 may comprise LWRT as described herein. Where the cabinet includes a door, the door need not be closable by means of

hinges

1412, 1414. Indeed, the door may be configured as a sliding door 1510 as shown in the cabinet 1500 of fig. 15.

Certain specific examples are described to illustrate additional aspects of the technology described herein.

Example 1

Several samples were prepared and tested to determine the characteristics of composite articles comprising bicomponent fibers. The materials used in the test samples and their numbers are shown in table 1 below. PP refers to polypropylene. The polymeric fibers tested were core-sheath bicomponent fibers with LLDPE in the sheath and polyethylene terephthalate in the core.

TABLE 1

Example 2

The composite article of example 1 was molded to different thicknesses. Table 2 below lists some of the different thicknesses of the different articles. MD refers to the longitudinal direction of the test specimen matching the longitudinal direction, and CD refers to the longitudinal direction of the test specimen matching the lateral direction.

TABLE 2

Example 3

Peak load values for the test samples were measured using SAEJ949 — 200904. In the three-point bending test, a three-point bending test is used, in which the membrane side of the test specimen faces the load. The measured peak load values for the test samples are shown in table 3 below.

TABLE 3

For all samples tested, the peak load values in the machine and transverse directions generally increased as the molded thickness increased. When comparing peak load values for samples with microspheres (ST-12244 and ST-12245) to those without microspheres (ST-12242 and ST-12243), peak loads for microsphere-based samples were generally higher at similar thicknesses. For example, at a thickness of 2.6cm, the 990gsm ST-12242b sample had peak load values in the machine direction and the cross direction of 25.2 and 17.0, respectively. At a thickness of 2.5cm, the 990gsm ST-12244a sample had peak load values in the machine direction and the cross direction of 32.2 and 21.1, respectively. Similar results were observed for the 790gsm sample, e.g., MD and CD peak load values for ST-12245a were greater than MD and CD peak load values for ST-12243 c. These results are consistent with the combination of thermoplastic materials, reinforcing fibers, polymeric fibers, and microspheres, providing increased peak loads at selected basis weights and molded thicknesses.

Example 4

The stiffness values of the test samples were measured using SAEJ949 — 200904. In the three-point bending test, a three-point bending test is used, in which the membrane side of the test specimen faces the load. The measured stiffness values of the test samples are shown in table 4 below.

TABLE 4

Lighter products comprising fewer fibers are generally less stiff. When comparing the stiffness values of the samples with microspheres (ST-12244 and ST-12245) with those without microspheres (ST-12242 and ST-12243), the stiffness of the microsphere-based samples was the same or higher at similar thicknesses. For example, at about 2.6cm molded thickness, the 990gsm ST-12242b sample had a stiffness value of 21.0 in the machine direction. The stiffness value of the 990gsm ST-12244a sample was 22.2 at a molded thickness of 2.5 cm. For these same samples, the stiffness in the transverse direction was reduced in the presence of microspheres. For the 790gsm sample, the MD and CD stiffness values of ST-12245a (10.1 and 7.6) were less than the MD and CD stiffness values of ST-12243c (15.1 and 12.7). These results are consistent with bicomponent fibers and microspheres, providing the same or more flexible articles than results without microspheres present.

Example 5

The bending strength values of the test samples were measured using SAEJ949 — 200904. In the three-point bending test, a three-point bending test is used, in which the membrane side of the test specimen faces the load. The measured bending strength values of the test samples are shown in table 5 below.

TABLE 5

The bending strength generally decreases with increasing molding thickness. Lighter products comprising fewer fibers also typically have lower flexural strength. When comparing the flexural strength of the samples with microspheres (ST-12244 and ST-12245) with those without microspheres (ST-12242 and ST-12243), the flexural strength of the microsphere-based samples was the same or higher at similar thicknesses. For example, at a molded thickness of about 2.6cm, the bending strength of the 990gsm ST-12242b sample in the machine direction was 11.3. The bending strength of the 990gsm ST-12244a sample was 15.1 at a molded thickness of 2.5 cm. For these same samples, the flexural strength in the transverse direction was slightly increased in the presence of microspheres.

For the 790gsm sample, the MD and CD bending strength values of ST-12245a (14.5 and 10.2) were much higher than those of ST-12243c (8.9 and 6.3). These results are consistent with bicomponent fibers and microspheres, providing equal or better flexural strength.

Example 6

Flexural modulus values of the test samples were measured using SAEJ949 — 200904. In the three-point bending test, a three-point bending test is used, in which the membrane side of the test specimen faces the load. The measured flexural modulus values of the test samples are shown in table 6 below.

TABLE 6

The flexural modulus generally decreases with increasing mold thickness. When comparing the flexural modulus of the samples with microspheres (ST-12244 and ST-12245) with those without microspheres (ST-12242 and ST-12243), the flexural modulus of the microsphere-based samples was the same or higher at similar thicknesses. For example, at a molded thickness of about 2.6cm, the 990gsm ST-12242b sample had a flexural modulus of 1389.6 in the machine direction. The flexural modulus of the 990gsm ST-12244a sample was 1582.8 at a molded thickness of 2.5 cm. For these same samples, the flexural strength in the transverse direction was increased in the presence of the microspheres. For the 790gsm sample, the MD and CD flexural modulus values (1546.7 and 1204.8) of ST-12245a were much higher than those of ST-12243c (1195.5 and 914.3). These results are consistent with bicomponent fibers and microspheres, providing the same or better flexural modulus.

Example 7

Glass/bicomponent polymeric fiber hybrid LWRT (H-LWRT) and standard glass fiber LWRT (S-LWRT) sheets were made by using the same wet-laid process. The polyolefin resin for H-LWRT, chopped glass fibers and bi-component polymeric fibers were dispersed in water. The aqueous suspension of well-dispersed resin and fiber is transferred to the wire-forming section and a bulking agent is added to the continuous wire. The resulting web was drained, heated, laminated with facing materials (scrim and film) and consolidated to produce a flat LWRT composite sheet. Materials having various basis weights (areal densities) can be produced by adjusting the manufacturing parameters. The basis weight of the control sample (S-LWRT) was 650g/m2, which was about 14.4% heavier than the basis weight 568g/m2 of HLWRT.

After being heated above the melting point of the resin, the material undergoes an increase in thickness due to bending of the fibers and relaxation of the residual stress by the expansion/bulking agent. Thus, all materials can be molded to a thickness of 3.5 to 7mm, which is thicker than the as-produced condition/thickness (table 1). FIG. 16 shows an example part molded from sample B (H-LWRT) sheet. The material shows good formability to fit the complex shape of the mold.

Analytical properties including basis weight (areal density), as-produced thickness and glass (ash) content were measured according to standard internal test procedures. Tensile properties of a sample having a thickness of 3mm were measured according to ASTM D790. Flexural properties of molded test specimens with thicknesses of 3.5, 4, 5.5 and 7mm were evaluated according to ASTM D638. Table 7 shows the physical properties of S-LWRT and H-LWRT.

TABLE 7

Sample (I)	Basis weight (g/m)²)	Thickness (mm)	Ash (%)
				Control (S-LWRT)	650	1.02	33.50
Sample A: (H-LWRT)	568	1.12	29.72
				Sample B (H-LWRT)	568	1.20	34.18

The control sample S-LWRT weighed 82g/m more than the two H-LWRT samples²(14.4%). S-LWRT showed a slightly lower thickness, indicating a slightly higher consolidation level. Samples A and B (H-LWRT) have different glass contents due to the different weight percentages of the bicomponent polymeric fibers.

Example 8

To evaluate the tensile properties of the samples shown in Table 7, a molded sheet having a thickness of 3.5mm was cut into dog bone tensile specimens by a punch press. Fig. 17 is a graph showing tensile moduli of sample a (H-LWRT), sample B (H-LWRT), and control (S-LWRT), and fig. 18 is a graph showing tensile strengths thereof. For tensile modulus and tensile strength, the results in the Machine Direction (MD) were significantly better than the results in the Cross Direction (CD) for all three samples. This may be due to fiber orientation bias in the machine direction, which occurs primarily in the headbox. The flow in the headbox is a combination of shear and tension. Complex flows may have shear near the wall and stretch longitudinally throughout the domain. As a result, the fibers can be strongly aligned towards the flow direction, resulting in better mechanical properties in the MD.

Sample B (H-LWRT) had the best average tensile modulus in the MD, while the control (SLWRT) showed an average modulus in the CD that was only slightly greater than that of the two samples a and B. For tensile strength, all three samples show very similar performance in the MD. On CD, sample a shows similar results to the control, and sample B is only slightly lower than the other two. It is noteworthy that the control (S-LWRT) weighed 82g/m compared to the two H-LWRT samples². This means that a total of up to 82g/m is achieved by shuffling the glass fibre bicomponent polymeric fibres²Weight reduction without sacrificing tensile properties. Particularly with respect to tensile properties, strength is highly dependent on the bond between the resin and the fiber. Bicomponent polymeric fibers have components with melting points lower than the matrix resin. During the heating and consolidation stages, the lower melting component of the polymeric fiber melts and bonds to the surface of the glass fiber, which is believed to help better saturate the resin around the glass fiber.

Example 9

Bending tests were performed on specimens molded to 3.5, 4, 5.5 and 7 mm. FIGS. 19A and 19B compare peak loads at MD and CD between sample A (H-LWRT), sample B (HLWRT), and control (S-LWRT). Like the tensile properties, the peak load results in MD are better than in CD. The peak load decreases with increasing thickness due to increasing porosity. All three samples showed very similar peak load results throughout the entire forming thickness range. This indicates that weight reduction of up to 82g/m2 was achieved by shuffling the glass fibers with the bicomponent polymeric fibers without sacrificing the peak bending load.

When introducing elements of the examples disclosed herein, the articles "a," "an," "the," and "said" are intended to mean that there are one or more of the elements. The terms "comprising," "including," and "having" are intended to be open-ended and mean that there may be additional elements other than the listed elements. It will be recognized by those of ordinary skill in the art, given the benefit of this disclosure, that various components in the examples can be interchanged or substituted with various components in other examples.

While certain aspects, examples, and embodiments have been described above, those of ordinary skill in the art, having the benefit of this disclosure, will appreciate that additions, substitutions, modifications, and variations to the disclosed illustrative aspects, examples, and embodiments are possible.

Claims

1. A molded porous composite article comprising a lofty core layer comprising a web formed of reinforcing fibers, bicomponent fibers, lofting agent, and thermoplastic material, wherein the web has a porosity of about 20% to about 80%, and wherein the bicomponent fibers comprise a core-sheath arrangement, wherein the melting point of the shell material of the shell of the core-shell arrangement is substantially similar to the melting point of the thermoplastic material, and wherein the core material of the core-shell arrangement has a melting point at least twenty degrees celsius higher than the melting point of the thermoplastic material, and wherein the molded porous composite article comprises a peak load in the machine direction of from 10N to about 40N and a peak load in the transverse direction of from about 6N to about 30N as tested by SAE J949_200904 at a molded thickness in the machine direction and the transverse direction of from about 2mm to about 4 mm.

2. The molded porous composite article of claim 1, in which the bicomponent fibers comprise: a shell comprising a polyolefin and a core comprising a polyester or a polyamide.

3. The molded porous composite article of claim 2, in which the bicomponent fibers comprise: a shell comprising a polyolefin and a core comprising a polyester.

4. The molded porous composite article of claim 3, in which the polyolefin comprises polyethylene.

5. The molded porous composite article of claim 4, in which the polyethylene is linear low density polyethylene.

6. The molded porous composite article of claim 5, in which the polyester comprises polyethylene terephthalate.

7. The molded porous composite article of claim 2, in which the polyamide comprises nylon.

8. The molded porous composite article of claim 2, in which the thermoplastic material is polypropylene, the polyolefin of the shell comprises linear low density polyethylene, the lofting agent comprises expandable microspheres, and the polyester of the core comprises polyethylene terephthalate.

9. The molded porous composite article of claim 2, in which the thermoplastic material is polypropylene, the polyolefin of the shell comprises linear low density polyethylene, the lofting agent comprises expandable microspheres, and the polyamide of the core comprises nylon.

10. The molded porous composite article of claim 1, in which the thermoplastic material comprises polypropylene, the reinforcing fibers comprise glass fibers, the bicomponent fibers comprise linear low density polyethylene in the shell and polyester or polyamide in the core, in which the polyester or polyamide in the core has a melting point at least twenty degrees celsius greater than the melting point of the thermoplastic material, in which the lofting agent comprises expandable microspheres.

11. The molded porous composite article of claim 10, wherein the molded composite article further comprises a stiffness in the machine direction of from about 10N/cm to about 50N/cm and a stiffness in the transverse direction of from about 7N/cm to about 30N/cm as tested by SAE J949_ 200904.

12. The molded porous composite article of claim 10, in which the molded composite article further comprises a flexural strength in the machine direction of from about 6MPa to about 17MPa and a flexural strength in the transverse direction of from about 4MPa to about 11MPa as tested by SAE J949_ 200904.

13. The molded porous composite article of claim 10, in which the molded composite article further comprises a flexural modulus in the machine direction of from about 800MPa to about 2000MPa and in the transverse direction of from about 500MPa to about 1300MPa as tested by SAE J949_ 200904.

14. The molded porous composite article of claim 10, wherein the molded composite article further comprises a stiffness in the machine direction of from about 10N/cm to about 50N/cm and a stiffness in the transverse direction of from about 7N/cm to about 30N/cm as tested by SAE J949_200904, and a flexural strength in the machine direction of from about 6MPa to about 17MPa and a flexural strength in the transverse direction of from about 4MPa to about 11MPa as tested by SAE J949_ 200904.

15. The molded porous composite article of claim 10, wherein the molded composite article further comprises a stiffness in the machine direction of from about 10N/cm to about 50N/cm and a stiffness in the transverse direction of from about 7N/cm to about 30N/cm as tested by SAE J949_200904, and a flexural modulus in the machine direction of from about 800MPa to about 2000MPa and a flexural modulus in the transverse direction of from about 500MPa to about 1300MPa as tested by SAE J949_ 200904.

16. The molded porous composite article of claim 10, wherein the molded composite article further comprises a flexural strength in the machine direction of from about 6MPa to about 17MPa and a flexural modulus in the machine direction of from about 800MPa to about 2000MPa and a flexural modulus in the transverse direction of from about 500MPa to about 1300MPa as tested by SAE J949_ 200904.

17. The molded porous composite article of claim 10, wherein the molded composite article further comprises a stiffness of about 10N/cm to about 50N/cm in the machine direction and a stiffness of about 7N/cm to about 30N/cm in the transverse direction as tested by SAE J949_200904, a flexural strength of about 6MPa to about 17MPa in the machine direction and a flexural strength of about 4MPa to about 11MPa in the transverse direction as tested by SAE J949_200904, and a flexural modulus of about 800MPa to about 2000MPa in the machine direction and a flexural modulus of about 500MPa to about 1300MPa in the transverse direction as tested by SAE J949_ 200904.

18. The molded porous composite article of any one of claims 1 to 17, wherein the article is configured as an automotive headliner.

19. The molded porous composite article of any one of claims 1 to 17, wherein the article is configured as an automotive interior component.

20. The molded porous composite article of any one of claims 1 to 17, wherein the article is configured as a compartment panel or a furniture panel.

21. A molded porous composite article comprising a lofty core layer comprising a web formed of reinforcing fibers, bicomponent fibers, lofting agent, and thermoplastic material, wherein the web has a porosity of about 20% to about 80%, and wherein the bicomponent fibers comprise a core-sheath arrangement, wherein the melting point of the shell material of the shell of the core-shell arrangement is substantially similar to the melting point of the thermoplastic material, and wherein the core material of the core-shell arrangement has a melting point at least twenty degrees celsius higher than the melting point of the thermoplastic material, and wherein the molded porous composite article comprises a stiffness in the machine direction of from about 10N/cm to about 50N/cm and a stiffness in the transverse direction of from about 7N/cm to about 30N/cm as tested by SAE J949_ 200904.

22. The molded porous composite article of claim 21, in which the bicomponent fibers comprise: a shell comprising a polyolefin and a core comprising a polyester or a polyamide.

23. The molded porous composite article of claim 22, in which the bicomponent fibers comprise: a shell comprising a polyolefin and a core comprising a polyester.

24. The molded porous composite article of claim 23, in which the polyolefin comprises polyethylene.

25. The molded porous composite article of claim 24, in which the polyethylene is linear low density polyethylene.

26. The molded porous composite article of claim 25, in which the polyester comprises polyethylene terephthalate.

27. The molded porous composite article of claim 22, in which the polyamide comprises nylon.

28. The molded porous composite article of claim 22, in which the thermoplastic material is polypropylene, the polyolefin of the shell comprises linear low density polyethylene, the lofting agent comprises expandable microspheres, and the polyester of the core comprises polyethylene terephthalate.

29. The molded porous composite article of claim 22, in which the thermoplastic material is polypropylene, the polyolefin of the shell comprises linear low density polyethylene, the lofting agent comprises expandable microspheres, and the polyamide of the core comprises nylon.

30. The molded porous composite article of claim 21, in which the thermoplastic material comprises polypropylene, the reinforcing fibers comprise glass fibers, the bicomponent fibers comprise linear low density polyethylene in the shell and polyester or polyamide in the core, in which the polyester or polyamide in the core has a melting point at least twenty degrees celsius greater than the melting point of the thermoplastic material, in which the lofting agent comprises expandable microspheres.

31. The molded porous composite article of claim 30, in which the molded composite article further comprises a flexural strength in the machine direction of from about 6MPa to about 17MPa and a flexural strength in the transverse direction of from about 4MPa to about 11MPa as tested by SAE J949_ 200904.

32. The molded porous composite article of claim 30, in which the molded composite article further comprises a flexural modulus in the machine direction of from about 800MPa to about 2000MPa and in the transverse direction of from about 500MPa to about 1300MPa as tested by SAE J949_ 200904.

33. The molded porous composite article of claim 30, wherein the molded composite article further comprises a flexural strength in the machine direction of from about 6MPa to about 17MPa and a flexural strength in the transverse direction of from about 4MPa to about 11MPa as tested by SAE J949_200904, and a flexural modulus in the machine direction of from about 800MPa to about 2000MPa and a flexural modulus in the transverse direction of from about 500MPa to about 1300MPa as tested by SAE J949_ 200904.

34. The molded porous composite article of any one of claims 21 to 33, wherein the article is configured as an automotive headliner or an automotive interior component.

35. The molded porous composite article of any of claims 21 to 33, wherein the article is configured as a compartment panel or a furniture panel.

36. A molded porous composite article comprising a lofty core layer comprising a web formed of reinforcing fibers, bicomponent fibers, lofting agent, and a thermoplastic material, wherein the porosity of the web is from about 20% to about 80%, and wherein the bicomponent fibers comprise a core-shell arrangement, wherein the melting point of the shell material of the shell of the core-shell arrangement is substantially similar to the melting point of the thermoplastic material, and wherein the melting point of the core material of the core-shell arrangement is at least twenty degrees celsius higher than the melting point of the thermoplastic material, and wherein the molded porous composite article comprises a flexural strength of from about 6MPa to about 17MPa in the machine direction and a flexural strength of from about 4MPa to about 11MPa in the transverse direction as tested by SAE J949 — 200904.

37. The molded porous composite article of claim 36, in which the bicomponent fibers comprise: a shell comprising a polyolefin and a core comprising a polyester or a polyamide.

38. The molded porous composite article of claim 37, in which the bicomponent fibers comprise: a shell comprising a polyolefin and a core comprising a polyester.

39. The molded porous composite article of claim 38, in which the polyolefin comprises polyethylene.

40. The molded porous composite article of claim 39, in which the polyethylene is linear low density polyethylene.

41. The molded porous composite article of claim 40, in which the polyester comprises polyethylene terephthalate.

42. The molded porous composite article of claim 37, in which the polyamide comprises nylon.

43. The molded porous composite article of claim 37, in which the thermoplastic material is polypropylene, the polyolefin of the shell comprises linear low density polyethylene, the lofting agent comprises expandable microspheres, and the polyester of the core comprises polyethylene terephthalate.

44. The molded porous composite article of claim 37, in which the thermoplastic material is polypropylene, the polyolefin of the shell comprises linear low density polyethylene, the lofting agent comprises expandable microspheres, and the polyamide of the core comprises nylon.

45. The molded porous composite article of claim 36, in which the thermoplastic material comprises polypropylene, the reinforcing fibers comprise glass fibers, the bicomponent fibers comprise linear low density polyethylene in the shell and polyester or polyamide in the core, in which the polyester or polyamide in the core has a melting point at least twenty degrees celsius greater than the melting point of the thermoplastic material, in which the lofting agent comprises expandable microspheres.

46. The molded porous composite article of claim 36, in which the molded composite article further comprises a flexural modulus in the machine direction of from about 800MPa to about 2000MPa and in the transverse direction of from about 500MPa to about 1300MPa as tested by SAE J949_ 200904.

47. The molded porous composite article of any one of claims 31 to 46, in which the article is configured as an automotive headliner.

48. The molded porous composite article of any of claims 31 to 46, in which the article is configured as an automotive interior component.

49. The molded porous composite article of any one of claims 31 to 46, wherein the article is configured as a compartment plate.

50. The molded porous composite article of any of claims 31 to 46, wherein the article is configured as a furniture panel.

51. A molded porous composite article comprising a lofty core layer comprising a web formed of reinforcing fibers, bicomponent fibers, lofting agent, and a thermoplastic material, wherein the porosity of the web is from about 20% to about 80%, and wherein the bicomponent fibers comprise a core-shell arrangement, wherein the melting point of the shell material of the shell of the core-shell arrangement is substantially similar to the melting point of the thermoplastic material, and wherein the melting point of the core material of the core-shell arrangement is at least twenty degrees celsius higher than the melting point of the thermoplastic material, and wherein the molded porous composite article comprises a flexural modulus of from about 800MPa to about 2000MPa in the machine direction and a flexural modulus of from about 500MPa to about 1300MPa in the transverse direction as tested by SAE J949_ 200904.

52. The molded porous composite article of claim 51, in which the bicomponent fibers comprise: a shell comprising a polyolefin and a core comprising a polyester or a polyamide.

53. The molded porous composite article of claim 52, in which the bicomponent fibers comprise: a shell comprising a polyolefin and a core comprising a polyester.

54. The molded porous composite article of claim 53, in which the polyolefin comprises polyethylene.

55. The molded porous composite article of claim 54, in which the polyethylene is linear low density polyethylene.

56. The molded porous composite article of claim 55, in which the polyester comprises polyethylene terephthalate.

57. The molded porous composite article of claim 52, in which the polyamide comprises nylon.

58. The molded porous composite article of claim 52, in which the thermoplastic material is polypropylene, the polyolefin of the shell comprises linear low density polyethylene, the lofting agent comprises expandable microspheres, and the polyester of the core comprises polyethylene terephthalate.

59. The molded porous composite article of claim 52, in which the thermoplastic material is polypropylene, the polyolefin of the shell comprises linear low density polyethylene, the lofting agent comprises expandable microspheres, and the polyamide of the core comprises nylon.

60. The molded porous composite article of claim 51, in which the thermoplastic material comprises polypropylene, the reinforcing fibers comprise glass fibers, the bicomponent fibers comprise linear low density polyethylene in the shell and polyester or polyamide in the core, in which the polyester or polyamide in the core has a melting point at least twenty degrees Celsius greater than the melting point of the thermoplastic material, in which the lofting agent comprises expandable microspheres.

61. The molded porous composite article of any one of claims 51 to 60, in which the article is configured as an automotive headliner.

62. The molded porous composite article of any one of claims 51 to 60, in which the article is configured as an automotive interior component.

63. The molded porous composite article of any one of claims 51 to 60, in which the article is configured as a compartment plate.

64. The molded porous composite article of any one of claims 51 to 60, in which the article is configured as a furniture panel.