CN117863678A - Nonwoven laminate - Google Patents

Abstract

The subject of the present invention is a nonwoven laminate comprising, in order: -a spunbond nonwoven layer (a) comprising fibers comprising polyethylene terephthalate (PET) and copolyester; -a needled staple fiber nonwoven layer (C) comprising: an o-monocomponent PET staple fiber (c 1), and an o-multicomponent staple fiber (c 2) comprising at least a PET component and a copolyester component; -a spunbond nonwoven layer (E) comprising fibers comprising PET and copolyester; -a nonwoven layer (F) comprising monocomponent PET fibers and/or multicomponent fibers comprising at least a PET component and a copolyester component, wherein all layers are melt bonded to each other. The invention also relates to molded articles and interior products comprising the nonwoven laminate; to the use of nonwoven laminates and molded articles and to a process for producing said nonwoven laminates.

Description

Nonwoven laminate

The present invention relates to nonwoven laminates and articles, molded articles, uses, and methods comprising such nonwoven laminates.

Prior Art

Nonwoven laminates are used in a variety of applications. Nonwoven laminates are used, for example, as interior components for automotive applications, for example as doors, seats, roof or trunk panels and shells. Interior materials for automotive applications are typically heated and shaped to provide the desired interior components for placement within a given vehicle.

The vehicle interior is an important aesthetic aspect of the vehicle for passenger satisfaction. The interior must be aesthetically pleasing, but must be safe, easy to maintain, durable, and resistant to the mess often encountered during passenger transport, among other things. It is also desirable that such materials provide sound shielding. To meet such specifications, various materials have been proposed in the art.

For example, DE 102 08 524 B4 describes a method for manufacturing a nonwoven molded part. The molded part comprises a nonwoven provided with a thermoplastic binder and is thermally or mechanically pre-compacted to form a product precursor. The product precursor is heated until the binder melts and is pressed in a molding tool. After the binder between the fibers of the nonwoven has cooled and solidified, a compacted molded part having the desired structure is obtained.

EP3769954 discloses nonwoven laminates with layers (a) to (E) which can be molded into molded articles which can be used as underbody shields for automobiles. The underbody shield must resist moisture and high mechanical stresses and strains.

Improvements in nonwoven laminates and molded parts known in the art, particularly for interior applications, are generally desired.

Potential problems of the invention

It is an object of the present invention to provide a nonwoven laminate which at least partly overcomes the disadvantages encountered in the prior art.

It is another object of the present invention to provide a nonwoven laminate that can be easily heated and formed to provide a desired configuration, particularly a dimensionally stable nonwoven laminate when heated and formed.

It is another object of the present invention to provide a nonwoven laminate that can contribute to a reduction in the cost of an article comprising the nonwoven laminate.

It is a further object of the present invention to provide a nonwoven laminate having improved recyclability, improved heat resistance and incombustibility properties and/or advantageously being light weight.

It is a further object of the present invention to provide nonwoven laminates having uniform mechanical properties, particularly uniform elongation, tensile strength and/or heat shrinkage.

It is a particular object of the present invention to provide nonwoven laminates which can produce molded articles exhibiting reduced creasing effects.

It is a particular object of the present invention to provide nonwoven laminates which can produce molded articles exhibiting enhanced sound absorption.

It is a further object of the present invention to provide molded articles comprising nonwoven laminates that are suitable for interior applications, such as panels and housings, particularly for vehicular applications.

Disclosure of the invention

Surprisingly, it was found that the underlying problem of the invention is solved by a nonwoven laminate and a molded article according to the claims. Further embodiments of the invention are summarized throughout the specification.

The subject of the present invention is a nonwoven laminate comprising in order (a) to (F):

-a spunbond nonwoven layer (a) comprising fibers comprising polyethylene terephthalate (PET) and copolyester;

-an optional spunbond nonwoven layer (B) comprising fibers comprising polyethylene terephthalate (PET) and a copolyester, said nonwoven layer (B) having a higher copolyester content than the nonwoven layer (a);

-a needled staple fiber nonwoven layer (C) comprising:

first monocomponent polyethylene terephthalate (PET) staple fiber (c 1), and

an omicron multicomponent staple fiber (c 2) comprising at least a polyethylene terephthalate (PET) component and a copolyester component;

-an optional spunbond nonwoven layer (D) comprising fibers comprising polyethylene terephthalate (PET) and a copolyester, said nonwoven layer (D) having a higher copolyester content than the nonwoven layer (E);

a spunbond nonwoven layer (E) comprising fibers comprising polyethylene terephthalate (PET) and a copolyester,

A nonwoven layer (F) comprising monocomponent polyethylene terephthalate (PET) fibers and/or multicomponent fibers comprising at least a polyethylene terephthalate (PET) component and a copolyester component,

wherein all layers are fusion bonded to each other.

Nonwoven materials are conventional in the art. The nonwoven is neither woven nor knitted. Typically, the nonwoven is a woven fabric as defined in DIN EN ISO 9092:2018.

Spunbond refers generally to fabrics which theoretically contain long fibers drawn from a molten fibrous raw material. Preferably, the spunbond nonwoven layers (a), (B), (D) and (E) are each made of continuous filaments that are calendered together in sheet form.

Staple fibers generally refer to fibers of discrete length. A group of staple fibers has an average length of the fibers in the group, which is referred to as the staple length.

Needled nonwoven layer generally refers to a layer comprising a plurality of fibers that have been mixed using needles.

Polyethylene terephthalate is a copolymer of terephthalic acid and ethane-1, 2-diol (also known as ethylene glycol).

The copolyester is a copolymer of a first diacid monomer and a first diol monomer, and one or both of at least one different second diacid monomer and at least one different second diol monomer. In this context, diacid monomer preferably means dicarboxylic acid monomer.

Fusion bonding is conventional in the art. Fusion bonding generally refers to a technique of joining at least two polymeric (typically thermoplastic) materials by applying energy to at least one of the at least two materials and by bringing the at least two materials into intimate contact simultaneously, followed by cooling. Fusion bonding may also be referred to as thermal bonding or chemical bonding.

In the nonwoven laminate of the present invention, layers (a) through (F) are melt bonded in a given order. This can be achieved by forming a stack of layers and fusion bonding the stack.

Fusion bonding of the layers to each other can result in a high degree of uniformity in the heat shrink properties of the nonwoven laminate. The high uniformity of the heat shrink properties can reduce the formation of wrinkles during the molding process. The nonwoven laminates of the present invention can have attractive aesthetics and higher flexural strength after molding due to reduced formation of wrinkles.

Fusion bonding of the layers to each other may also impart high dimensional stability to the nonwoven laminate when heated and formed.

All layers (A), (B), (C), (D), (E) and (F) comprise polyethylene terephthalate. Polyethylene terephthalate is also referred to herein as "PET". The polyethylene terephthalate may be virgin polyethylene terephthalate (which is not recycled), recycled polyethylene terephthalate (also known as "r-PET"), or a mixture of virgin and recycled polyethylene terephthalate. The virgin polyethylene terephthalate may allow for a more accurate setting of the mechanical properties of the nonwoven laminate of the present invention. Recycled polyethylene terephthalate may allow for reduced cost nonwoven laminates of the present invention.

The polyethylene terephthalate comprised by all layers can impart high uniformity of mechanical properties to the nonwoven laminates of the present invention. In particular, the uniformity of elongation and tensile strength of the nonwoven laminate of the present invention may be enhanced thereby. The nonwoven laminates of the present invention can thus be readily heated and formed to provide the desired configuration. Thus, the nonwoven laminates of the present invention may be dimensionally stable when heated and formed.

The polyethylene terephthalate comprised by all layers can provide a relatively low basis weight for the layers and the overall laminate, respectively.

All layers comprise polyethylene terephthalate having a relatively high melting point of about 260 ℃. Thus, the nonwoven laminate of the present invention may have high heat resistance and incombustibility characteristics. The melting point is preferably a melting point determined in accordance with DIN ISO 11357-3:2013.

All layers comprise polyethylene terephthalate which is relatively inexpensive. The nonwoven laminate of the present invention may thus contribute to a reduction in the cost of an article comprising the nonwoven laminate of the present invention.

All layers (A), (B), (C), (D), (E) and preferably (F) comprise copolyesters. The copolyester may be an amorphous copolyester, a crystalline copolyester, or a mixture of amorphous and crystalline copolyesters. The optional layer (B), if present, has a higher copolyester content than layer (a), and the optional layer (D) has a higher copolyester content than layer (E). Higher copolyester content, respectively, may strengthen the bonding of layer (a) and/or layer (E) to layer (C). Higher copolyester contents respectively can thus increase the peel strength of the layer (a) and/or the layer (E).

The nonwoven laminate of the present invention may comprise, in a given order

Layers (A), (B), (C), (D), (E) and (F),

layers (A), (C), (D), (E) and (F),

-layers (A), (B), (C), (E) and (F), or

Layers (A), (C), (E) and (F), which are particularly preferred.

In such nonwoven laminates, layers (B) and (D) act as tie layers. The layers (B) and (D) may increase the bond between the outer layers (a) and (E) and the core layer (C). In such laminates, delamination of layer (a) and/or layer (E) may advantageously be reduced. From the viewpoint of increased peel strength, nonwoven laminates comprising layers (a), (B), (C), (D), (E), and (F) in that order are preferred.

From the viewpoint of simplifying productivity, nonwoven laminates comprising layers (a), (C), (E) and (F) are preferred. No additional feeding means for layers (B) and (D) are required for producing such a laminate. The production of such nonwoven laminates can thus be simplified. From a cost-effective point of view, the production of nonwoven laminates having only layers (a), (C), (E) and (F), i.e. without layers (B) and (D), is even more particularly preferred.

According to one particular definition of all the layers (a), (B), (C), (D), (E) and (F) melt-bonded to each other, in the nonwoven laminate of the present invention, none of the layers (a), (B), (C), (D), (E) and (F) is mechanically bonded to any other of the layers (a), (B), (C), (D), (E) and (F). In other words, there is no entanglement between any two of the layers (a), (B), (C), (D), (E) and (F). In particular, the needled staple fiber nonwoven layer (C) contains fibers that do not extend into any of layers (a), (B), (D), (E), and (F), especially into layer (a) and/or layer (E). More particularly, the needled staple fiber nonwoven layer (C) contains no fibers that pass through any of the layers (A), (B), (D), (E) and (F), and in particular do not pass through the layers (A) and/or (E). The absence of mechanical bonding may minimize the formation of undesired wrinkles when the layer is heated, so that an appealing aesthetic may be achieved. Further, the molded product produced from the nonwoven laminate without mechanical bonding may advantageously be flat, particularly without wrinkles, wavy structures, or the like. Further, the bending strength thereof can be increased.

It is preferred that in the nonwoven laminate of the present invention, none of the layers (a), (B), (C), (D), (E) and (F) are needled to any other of the layers (a), (B), (C), (D), (E) and (F). Such undesirable needling includes mechanical needling and water jet needling (which is also known as hydroentanglement). This can prevent the formation of undesired wrinkles when the layer is heated. Furthermore, a appealing aesthetic can be achieved. Molded products produced from preferred nonwoven laminates are generally flat and free of wrinkles and the like, typically increasing their flexural strength.

The nonwoven laminate of the present invention comprises an additional nonwoven layer (F). The layer (F) may impart at least one desired property to the composite. According to the present invention, it was found that the properties of the composite can be improved if a further nonwoven layer (F) is added. Thus, the additional nonwoven layer is also denoted herein as "functional layer (F)". For example, layer (F) may improve the cushioning effect, acoustic properties, optical properties, and/or mechanical properties of the composite.

At the same time, the functional layer (F) may be fully integrated into the laminate structure. Thus, layer (F) comprises and more preferably consists of monocomponent polyethylene terephthalate (PET) fibers and multicomponent fibers comprising at least a polyethylene terephthalate (PET) component and a copolyester component. If layer (F) comprises or consists of these polyester materials, it is applicable to layers (A) to (E) in terms of structure. Thus, the layer (F) may be provided from the same material and may be fully integrated into the production process of the laminate. All layers (a) to (F) can be conveniently melt-bonded to each other so that a stable and uniform nonwoven laminate is obtained. Thus, the nonwoven laminate may be moldable and also recyclable. Furthermore, the functional layer (F) may be at least partially provided by recycled material.

In a preferred embodiment, the nonwoven layer (F) consists of monocomponent polyethylene terephthalate (PET) fibers and multicomponent fibers comprising at least a polyethylene terephthalate (PET) component and a copolyester component. Preferably, layer (F) consists of 50 to 95% PET fibers and 5 to 50% bicomponent fibers from PET and copolyester. Preferably, the spunbond layers (a) and (E) consist of bicomponent fibers from PET and copolyester. When the nonwoven layer (F) and nonwoven laminate are composed of such materials, it can be conveniently produced and laminated, providing a highly uniform, recyclable and mechanically stable product that is entirely based on PET and copolyester, and that can be easily molded into molded parts (molded articles).

In a preferred embodiment, the nonwoven layer (F) consists of staple fibers. Preferably, the nonwoven layer (F) is needled. Such nonwoven layers may provide particular mechanical stability and other desirable properties to the nonwoven laminate.

The nonwoven layer (F) is advantageous because it can be fully integrated into the production process and provides a uniform structure while imparting advantageous properties to the nonwoven laminate or molded part. For example, the nonwoven layer (F) may improve the acoustic properties of the laminate and molded part. Since layer (F) can be applied to the outer surface, it can also improve the optical properties of the nonwoven laminate or molded part. For example, it may provide a smooth surface structure and/or may be embossed with a pattern. In addition, if layer (F) has high mechanical stability, it can improve mechanical properties of the nonwoven laminate or molded part, such as tensile strength and tear strength. Thus, layer (F) may protect the nonwoven laminate or molded part from mechanical stresses and strains. If the nonwoven layer is relatively stiff, it can increase the flexural strength of the nonwoven laminate or molded part.

In a preferred embodiment, the nonwoven laminate comprises a further nonwoven layer (F1) attached to the spunbond nonwoven layer (a). In this embodiment, a further layer (F1) is attached to the outer surface of layer (a). Thus, the outer layers of the nonwoven laminate are layer (F) on one side and layer (F1) on the other side. The composition and structure of layer (F1) may be adjusted as outlined above for layer (F). In a preferred embodiment, layers (F) and (F1) are identical. In another embodiment, at least one further layer may be provided on the outer surface, i.e. on top of the layers (F) and/or (F1). So that additional properties can be imparted to the nonwoven laminate.

In a preferred embodiment, the nonwoven laminate comprises a further spunbond nonwoven layer (G) located between layer (E) and layer (F), wherein the spunbond nonwoven layer (G) comprises fibers comprising polyethylene terephthalate (PET) and a copolyester, the nonwoven layer (G) having a higher copolyester content than the nonwoven layer (E). Such further nonwoven layers (G) having a relatively high copolyester content are suitable for bonding the adjacent layers (E) and (F) to each other more firmly. Preferably, the nonwoven layer (G) has the same structure, composition and properties as outlined herein for layers (B) and (D).

Preferably, in the nonwoven laminate of the present invention, the needled staple fiber nonwoven layer (C) is heat-shrinkable. Preferably, the needled fibers are heat shrunk in both the machine direction (machine direction) and the cross direction. The heat-shrinkable needled staple fiber nonwoven layer can avoid undesirable further shrinkage. This may avoid the formation of undesired wrinkles during the subsequent molding process.

Preferably, in the nonwoven laminate of the present invention, the nonwoven laminate contains less than 20%, more preferably less than 10% of all the fibers that are PET-free and copolyester-free. Most preferably, all the fibers contained in the nonwoven laminate are made from PET, copolyester, or mixtures thereof. Where all of the fibers contained in the nonwoven laminate are made primarily and preferably only of PET, copolyester, or mixtures thereof, the nonwoven laminate may have relatively low cost, relatively low weight, and relatively high peel strength.

Preferably, the nonwoven laminate of the present invention is free of polyolefin, in particular polypropylene. So that the nonwoven laminate can be recycled much more easily. Whereby the heat resistance and incombustibility properties of the nonwoven laminate can be increased. Thereby increasing the uniformity of the mechanical properties of the nonwoven laminate, particularly its elongation and tensile strength. This may allow for easier tuning of the properties of the product comprising the nonwoven laminate.

Preferably, the nonwoven laminate of the present invention is free of inorganic reinforcements, in particular glass fibers. The absence of inorganic reinforcements, particularly glass fibers, can simplify the processability of the nonwoven laminate. The absence of inorganic reinforcements, particularly glass fibers, can reduce the cost of articles comprising the nonwoven laminate.

Preferably, the nonwoven laminate of the present invention does not contain any accelerator (bulking agent). The absence of any promoter may increase the dimensional stability of the nonwoven laminate when the nonwoven laminate is heated and formed. The absence of any accelerators can reduce the cost of the article comprising the nonwoven laminate.

Preferably, the nonwoven laminate of the present invention has at least one of the following characteristics:

-a flexural strength of ≡330MPa according to ISO 178:2019-04;

-tensile strength of ≡780N according to ASTM 5034:2009; and/or

Tear strength of ≡110N according to DIN EN 29073-3:1992-08.

Flexural strength of ≡330MPa, > 780N tensile strength and/or ≡110N tear strength can lead to high abrasion resistance of the nonwoven laminate. Flexural strength of ≡330MPa, tensile strength of ≡780N, and/or tear strength of ≡110N can increase the sound absorption of the nonwoven laminate.

From the standpoint of even higher abrasion resistance and increased sound absorption of the nonwoven laminate, it is particularly preferred that the nonwoven laminate of the present invention has a flexural strength of ≡330MPa and a tensile strength of ≡780N; or bending strength of more than or equal to 330MPa and tearing strength of more than or equal to 110N; or a tensile strength of 780N or more and a tear strength of 110N or more. Most preferably, the nonwoven laminate of the present invention has a flexural strength of ≡330MPa, ≡780N tensile strength and ≡110N tear strength.

More preferably, the nonwoven laminates of the present invention have flexural strength of ≡370MPa, even more preferably ≡400MPa, and still more preferably ≡430MPa. The abrasion resistance and acoustic absorption of the nonwoven laminate may be further increased with increasing bond strength, respectively.

More preferably, the nonwoven laminates of the present invention have a tensile strength of greater than or equal to 850N, even more preferably greater than or equal to 900N, and still more preferably greater than or equal to 950N. The abrasion resistance and acoustic absorption of the nonwoven laminate may further increase with increasing tensile strength, respectively.

More preferably, the nonwoven laminates of the present invention have a tear strength of 125N or greater, even more preferably 145N or greater, and still more preferably 165N or greater. The abrasion resistance and acoustic absorption of the nonwoven laminate may be further increased with increasing tear strength, respectively.

Preferably, in the nonwoven laminate of the present invention, the copolyester in layers (a), (B), (C), (D), (E) and (F) is a copolymer of polyethylene terephthalate. The copolymer of polyethylene terephthalate comprises the monomers terephthalic acid, ethane-1, 2-diol and at least one further different dicarboxylic acid monomer and/or at least one further different diol monomer. A preferred additional dicarboxylic acid monomer is adipic acid. Another preferred additional dicarboxylic acid monomer is isophthalic acid. A preferred additional diol monomer is cyclohexanedimethanol. Copolymers of polyethylene terephthalate can simplify the recyclability of the nonwoven laminate. Copolymers of polyethylene terephthalate can increase peel strength in nonwoven laminates. Copolymers of polyethylene terephthalate can reduce the cost of raw materials for nonwoven laminates.

Preferably, in the nonwoven laminate of the present invention, the copolyesters in layers (A), (B), (C), (D), (E) and (F) have a melting point of 240 ℃. More preferably, the copolyester, in particular the copolyester in layers (B), (C) and (D), has a melting point of 220 ℃ or less, even more preferably 210 ℃ or less, even more preferably 200 ℃ or less, and still more preferably 190 ℃ or less, in particular = 180 ℃. Copolyesters having melting points of 240 ℃ or less can reduce the energy required to melt bond the layers to each other. Copolyesters having a melting point of 240 ℃ or less can reduce the energy required to produce spunbond layers (a), (B), (D) and (E). The energy reduction may continue to increase when lower melting points of 220 ℃ -210 ℃, -200 ℃, -190 ℃ and = 180 ℃ are reached, respectively.

Preferably, in the nonwoven laminate of the present invention, the copolyesters in layers (A) and (E) have a melting point that is higher than the melting point of the copolyester in layer (C), more preferably not less than 20 ℃, still more preferably not less than 30 ℃, and even more preferably not less than 35 ℃. In this way, after melt bonding, a stronger bond between the layers of the nonwoven laminate may be achieved.

This is particularly preferred for the absence of layers (B) and (D), more preferably the copolyesters in layers (a) and (E) have a melting point of 205 to 240 ℃, even more preferably 210 to 230 ℃ and still more preferably 210 to 225 ℃. In this case, the copolyester in layer (C) preferably has a melting point of 160 to 200 ℃, even more preferably 170 to 190 ℃, and still more preferably 175 to 185 ℃. This can avoid delamination of layers (a) and (E) from layer (C).

Preferably, in the nonwoven laminate of the present invention, the copolyesters in layers (A), (B), (C), (D), (E) and (F) have a melting point of ≡100 ℃. More preferably, the copolyester has a melting point of ≡110 ℃, even more preferably ≡140 ℃ and still more preferably ≡160 ℃. The copolyester with melting point not less than 100 ℃ can increase the bonding strength between layers after melt bonding.

Preferably, in the nonwoven laminate of the present invention, the copolyesters in layers (a), (B), (C), (D), (E) and (F) have a melting point in the range of 100 to 240 ℃, more preferably in the range of 110 to 240 ℃, even more preferably in the range of 140 to 230 ℃ and still more preferably in the range of 160 to 225 ℃. Copolyesters having melting points in these ranges can reduce the energy required to melt bond the layers to each other, can reduce the energy required to produce spunbond layers (a), (B), (D), and (E), and can increase the bond strength between the layers after melt bonding.

Preferably, in the nonwoven laminate of the present invention, the copolyesters in layers (a), (B), (D) and (E), and in particular the copolyesters in layers (a) and (E), are substantially neutral, i.e. have a pH of 6.5 to 7.5, more preferably 6.8 to 7.2, and still more preferably 7.0. This may avoid undesirable chemical interactions of the surface of the nonwoven laminate with the environment.

Preferably, in the nonwoven laminate of the present invention, the copolyesters in layers (A), (B), (D) and (E), in particular the copolyesters in layers (A) and (E), have a weight of from 1.1 to 1.6g/cm ³ More preferably 1.2 to 1.5g/cm ³ And still more preferably 1.3 to 1.4g/cm ³ . The density is determined in accordance with DIN EN ISO 1183-1:2019-09. Such densities can result in laminates of adequate strength while avoiding excessive costs.

More preferably, in the nonwoven laminate of the present invention, the copolyesters in layers (A), (B), (C), (D), (E) and (F) are copolymers of polyethylene terephthalate and the copolymers also have a melting point of 240 ℃. This can result in an increase in simultaneous peel strength, a reduction in cost, and a reduction in the energy required for melting the tie layer and producing the spunbond layer.

When layers (B) and (D) are present in the nonwoven laminate of the present invention, it is preferred that layers (a) and (E) comprise 2% to 30% copolyester, more preferably 5% to 25% copolyester. When layers (B) and (D) are not present in the nonwoven laminate of the present invention, it is preferred that layers (a) and (E) comprise at least 30% copolyester, more preferably 30 to 70% copolyester, particularly preferably at least 40% copolyester, at least 50% copolyester, at least 60% copolyester or at least 70% copolyester. Such copolyester content may avoid the wavy structure of the laminate. Such copolyester content may further achieve increased flexural strength of the laminate. Herein, "%" always refers to% by weight.

When layers (B) and (D) are present and layers (a) and (E) comprise 2% to 30% of the copolyester, it may be easier to melt bond layer (a) to layer (B) or layer (C), and likewise it may be easier to melt bond layer (E) to layer (D) or layer (C). When layers (a) and (E) comprise 2% to 30% of the copolyester, the peel strength of layers (a) and (E) may be increased. When layers (a) and (E) comprise 5% to 25% of the copolyester, the ease of fusion bonding and peel strength of layers (a) and (E) may be even further increased.

Laminates without layers (B) and (D) may have increased peel strength when layers (a) and (E) comprise at least 30%, more preferably at least 40%, at least 50%, at least 60% or at least 70% of the copolyester. That is, neither layer (B) nor layer (D) may then be required for increased peel strength. Whereby the cost of the laminate can be reduced. The production of the laminate can thereby be simplified. In such a case, where layers (B) and (D) are preferably absent, it is particularly preferred that the copolyester in layers (a) and (E) have a melting point of 205 to 240 ℃, even more preferably 210 to 230 ℃, and still more preferably 210 to 225 ℃. In this case, the copolyester in layer (C) preferably has a melting point of 160 to 200 ℃, even more preferably 170 to 190 ℃, and still more preferably 175 to 185 ℃. This makes it possible in particular to avoid delamination of layers (a) and (E) from layer (C).

Preferably, the nonwoven laminate of the invention comprises a spunbond nonwoven layer (B) and/or a spunbond nonwoven layer (D), the fibers of which consist of a copolyester. The presence of the spunbond nonwoven layer (B) and/or the spunbond nonwoven layer (D) may increase the peel strength of the layer (a) and/or the layer (E). When the fibers of the spunbond nonwoven layer (B) and/or the spunbond nonwoven layer (D) are composed of copolyesters, all layers of the nonwoven laminate may be more easily melt bonded to one another.

Preferably, the nonwoven laminate of the invention comprises a spunbond nonwoven layer (B) and/or a spunbond nonwoven layer (D) having a weight of 1 to 100g/m in accordance with DIN EN 29073-1:1992-08 ² Preferably 5 to 50g/m ² More preferably 10 to 20g/m ² Is based on the weight of the substrate. The presence of the spunbond nonwoven layer (B) and/or the spunbond nonwoven layer (D) may increase the peel strength of the layer (a) and/or the layer (E). When the nonwoven layer (B) and/or the spunbonded nonwoven layer (D) has a weight of 1 to 100g/m ² Preferably 5 to 50g/m ² More preferably 10 to 20g/m ² A good balance between the light weight of the laminate and the good wear resistance of the laminate can be achieved.

More preferably, the nonwoven laminate of the invention comprises a spunbond nonwoven layer (B) and/or a spunbond nonwoven layer (D), the fibers of which consist of a copolyester and which at the same time have a weight of 1 to 100g/m according to DIN EN 29073-1:1992-08 ² Preferably 5 to 50g/m ² More preferably 10 to 20g/m ² Is based on the weight of the substrate. The presence of the spunbond nonwoven layer (B) and/or the spunbond nonwoven layer (D) may increase the peel strength of the layer (a) and/or the layer (E). Because the fibers of the spunbond nonwoven layer (B) and/or the spunbond nonwoven layer (D) are composed of copolyesters, all layers of the nonwoven laminate may be more easily melt bonded to one another. At the same time, since the nonwoven layer (B) and/or the spunbonded nonwoven layer (D) has a weight of 1 to 100g/m ² Preferably 5 to 50g/m ² More preferably 10 to 20g/m ² Thus, a light weight of the laminate and a laminate can be achievedIs well balanced between good wear resistance.

Preferably, in the nonwoven laminate of the present invention, the needled staple fiber nonwoven layer (C) is composed of 10 to 90% of monocomponent staple fibers (C1) and 10 to 90% of multicomponent staple fibers (C2). More preferably, in the nonwoven laminate of the present invention, the needled staple fiber nonwoven layer (C) consists of 20 to 80% monocomponent staple fibers (C1) and 20 to 80% multicomponent staple fibers (C2), even more preferably 30 to 70% monocomponent staple fibers (C1) and 30 to 70% multicomponent staple fibers (C2), still more preferably 40 to 60% monocomponent staple fibers (C1) and 40 to 60% multicomponent staple fibers (C2), and most preferably 50% monocomponent staple fibers (C1) and 50% multicomponent staple fibers (C2).

When the needled staple fiber nonwoven layer (C) is composed of 10 to 90% of the monocomponent staple fibers (C1) and 10 to 90% of the multicomponent staple fibers (C2), the staple fiber nonwoven layer (C) can be produced much more easily as a needled layer. When the needled staple fiber nonwoven layer (C) is composed of 10 to 90% of the monocomponent staple fibers (C1) and 10 to 90% of the multicomponent staple fibers (C2), the needled staple fiber nonwoven layer (C) is mainly made of polyethylene terephthalate. This may reduce the weight of the nonwoven laminate, may result in high heat resistance and incombustibility characteristics of the nonwoven laminate, and may reduce nonwoven laminate costs. These effects increase as the ratio of (c 1)/(c 2) approaches 1, i.e., these effects are 20-80% (c 1)/20-80% (c 2); 30-70% (c 1)/30-70% (c 2); 40-60% (c 1)/40-60% (c 2); the order of 50% (c 1)/50% (c 2) increases.

The staple fibers (c 1) are monocomponent fibers, i.e. they consist of polyethylene terephthalate. Staple fibers (c 2) are multicomponent fibers, i.e. they consist of two or more components. The first component of the staple fiber (c 2) is polyethylene terephthalate. The second component of the staple fiber (c 2) is a copolyester. One or more additional components of the staple fibers (c 2) may be present. Preferably, the staple fibers (c 2) are bicomponent fibers, i.e. they consist of polyethylene terephthalate and copolyesters. Preferably, the bicomponent fiber has a islands-in-the-sea filament configuration, a segmented-segment filament configuration, a sheath-core filament configuration, or a side-by-side filament configuration, more preferably a sheath-core filament configuration. The copolyester component is typically present on the surface of such bicomponent fibers. Preferably, the staple fibers (c 2) have at least one, more preferably two or more and most preferably all of the following properties:

-fineness of 2 to 7 dtex, more preferably 3 to 6 dtex, still more preferably 4 to 6 dtex, determined according to DIN EN ISO 1973:2020-05;

-a fiber length of 30 to 70 mm, more preferably 40 to 60 mm, still more preferably 45 to 55 mm;

a strength of 1 to 6g/de, more preferably 2 to 5g/de, still more preferably 3 to 4g/de, determined according to DIN EN 13844:2003-04;

-an elongation of 20 to 60%, more preferably 30 to 50%, still more preferably 35 to 55%, determined according to DIN EN ISO 5079:2020-01;

-a curl of 4 to 10 EA/inch, more preferably 5 to 9 EA/inch, still more preferably 6 to 8 EA/inch, determined according to JIS L-1074;

-a heat shrinkage of 3 to 7%, more preferably 4 to 6%, still more preferably 3.5 to 4.5% at 75 ℃ x 15 minutes, determined according to DIN EN 13844:2003-04; and

-a melting point of 160 to 200 ℃, more preferably 170 to 190 ℃, still more preferably 175 to 185 ℃.

When the staple fibers (C2) have at least one, more preferably two or more and most preferably all of the above-described properties, the needled staple fiber nonwoven layer (C) can impart strength, flexibility and moldability to the nonwoven laminate at the same time.

Preferably, in the nonwoven laminate of the invention, the needled staple fiber nonwoven layer (C) has a weight of ∈2900g/m in accordance with DIN EN 29073-1:1992-08 ² More preferably 1500 to 2900g/m ² . For use in standard passenger cars, it is preferred that the needled staple fiber nonwoven layer (C) has a weight of 1600 to 2700g/m ² More preferably 1700 to 2500g/m ² And most preferably 2000g/m ² Is based on the weight of the substrate.

More preferably, in the nonwoven laminate of the present invention, the needled staple fiber nonwoven layer (C) is composed of 10 to 90% of monocomponent staple fibers (C1) and 10 to 90% of multicomponent staple fibersDimensional (c 2) and at the same time has a composition of ∈2900g/m in accordance with DIN EN 29073-1:1992-08 ² More preferably 1500 to 2900g/m ² Is based on the weight of the substrate. In this way, the staple fiber nonwoven layer (C) can be produced much more easily as a needled layer, and the nonwoven laminate can be versatile for interior applications, particularly for vehicles, such as panels and housings.

Preferably, the nonwoven laminates of the invention have a weight of 1000 to 3000g/m in accordance with DIN EN 29073-1:1992-08 ² Is based on the weight of the substrate. Preferably, the nonwoven laminate of the present invention has a thickness of 5 to 20 mm.

For the nonwoven laminates of the present invention, it is preferred that

The copolyester in layers (a), (B), (C), (D), (E) and (F) is a copolymer of polyethylene terephthalate, said copolymer having a melting point of 160 to 240 ℃;

It comprises a spunbond nonwoven layer (B) and a spunbond nonwoven layer (D), both composed of a copolyester and each having 10 to 20g/m according to DIN EN 29073-1:1992-08 ² Is a base weight of (2); and

-the needled staple fiber nonwoven layer (C) consists of 40 to 60% of monocomponent staple fibers (C1) and 40 to 60% of multicomponent staple fibers (C2).

Such preferred nonwoven laminates can be readily heated and formed to provide the desired configuration. Such preferred nonwoven laminates may be dimensionally stable as they are heated and formed. Such preferred nonwoven laminates may be particularly useful for interior applications, particularly for vehicles such as panels and housings. The peel strength may be high due to the presence of layers (B) and (D). The heat resistance may be high due to the presence of layers (B) and (D).

For the nonwoven laminates of the present invention, it is preferred that

It comprises neither a spunbond nonwoven layer (B) nor a spunbond nonwoven layer (D);

the copolyester in layers (a), (C) and (E) is a copolymer of polyethylene terephthalate, said copolymer having a melting point of 160 to 240 ℃; and

-the needled staple fiber nonwoven layer (C) consists of 40 to 60% of monocomponent staple fibers (C1) and 40 to 60% of multicomponent staple fibers (C2).

Such preferred nonwoven laminates can be readily heated and formed to provide the desired configuration. Such preferred nonwoven laminates may be dimensionally stable as they are heated and formed. Such preferred nonwoven laminates may be particularly useful for interior applications, particularly for vehicles such as panels and housings. Due to the absence of layers (B) and (D), the cost for the nonwoven laminate may be reduced. Due to the absence of layers (B) and (D), the production of the nonwoven laminate may be simplified.

The subject of the invention is also a molded article comprising the nonwoven laminate of the invention. The molded articles of the present invention benefit from the advantages of the nonwoven laminates of the present invention described herein. Particularly evident is the effect of reduced crease formation during the moulding process and the advantages associated therewith.

The nonwoven laminates of the present invention or the molded articles of the present invention are particularly suitable for interior applications, preferably for use in vehicles. Preferred applications are panels, housings, cladding, reinforcements or partitions, for example for doors, roofs, luggage or seats. The interior applications may be used in the automotive industry as well as in the production of vehicles in general, i.e. ground, marine or aerospace vehicles. For interior applications benefits from the advantages of the nonwoven laminates of the present invention and/or the molded articles of the present invention described herein. Particularly evident are the enhanced abrasion resistance, high heat resistance, incombustibility characteristics and the effect of sound absorption and the advantages associated therewith.

The subject of the invention is also an interior product, preferably for a vehicle, comprising the molded article of the invention. The subject of the invention is also the use of the nonwoven laminate or molded article of the invention for interior products, preferably for vehicles. The interior product is preferably a panel, a shell, a cladding, a reinforcement or a partition. The interior product is preferably used for doors, roofs, luggage cases or seats.

The subject of the invention is also a process for producing the nonwoven laminate of the invention comprising:

-preparing a needled staple fiber nonwoven layer (C) by needling;

-providing layers (a) to (F) in order; wherein layers (B) and (D) are optional, and

-fusion bonding of layers (a) to (F) to each other.

The subject of the invention is also a process for producing the molded article of the invention, comprising:

providing a nonwoven laminate of the invention

-moulding the nonwoven laminate, thereby obtaining the moulded article.

The process for producing the nonwoven laminate of the present invention benefits from the advantages of the nonwoven laminate of the present invention. Particularly evident is the easy-to-attach effect of the layers by fusion bonding, which can lead to increased peel strength, and the advantages associated therewith.

Brief description of the drawings

Exemplary aspects of the invention are illustrated in the accompanying drawings.

Fig. 1 shows schematically and in an exemplary form the layers of a preferred five-layer nonwoven laminate. An additional nonwoven layer (F) may be attached to the outside.

Fig. 2 shows schematically and in an exemplary form the individual layers of a preferred three-layer nonwoven laminate according to the invention.

Fig. 3 shows schematically and in an exemplary form a segmented yarn configuration which may be particularly useful in a spunbond nonwoven layer according to the present invention.

Fig. 4 shows schematically and in an exemplary form a sheath-core filament construction which may be particularly useful in a spunbond nonwoven layer according to the present invention.

Fig. 5 shows schematically and in an exemplary form a side-by-side filament configuration which may be particularly useful in a spunbond nonwoven layer according to the present invention.

Fig. 6 shows acoustic measurements of a nonwoven laminate according to the present invention.

Fig. 7a to 7c are microscopic images of mechanically bonded (needled) nonwovens produced according to US2016/0288451 A1.

General construction and production of nonwoven laminates

In fig. 1, a preferred five-layer nonwoven laminate 1 is shown. The five-layer nonwoven laminate 1 comprises a first outer layer 2 (corresponding to layer (a)), a first tie layer 3 (corresponding to layer (B)), a core layer 4 (corresponding to layer (C)), a second tie layer 5 (corresponding to layer (D)) and a second outer layer 6 (corresponding to layer (E)). The layers of the laminate are not mechanically bonded to each other. Instead, the layers of the laminate are only fusion bonded to each other. In all embodiments, a further nonwoven layer (F) (not shown) is provided on top of the outer layer 6.

In one embodiment, the advantageous fiber preparation is carried out before the staple fibers (c 1) and (c 2) are needled into the core layer 4. More specifically, fibers (c 1) and (c 2) are opened from the bag, mixed and carded prior to the needling process. Thereafter, fibers (c 1) and (c 2) are cross-overlapped and transferred to a needling machine. Alternative fiber preparation methods are to use air lay (air) or lay air (air-lay) processes, where open fibers are collected on a suction belt and needled. The core 4 is pre-shrunk by the application of heat to avoid shrinkage during the subsequent molding process. The staple fibers (c 1) and/or (c 2) have a staple fiber length preferably in the range of 10mm to 150mm, more preferably 40mm to 100 mm. The core layer 4 preferably has a weight of 1400g/m ² And 2900g/m ² Basis weight therebetween.

In one embodiment, the core layer 4 comprises a mixture of 10 to 70% virgin or recycled PET staple fibers (c 1) in combination with 30 to 90% bicomponent fibers (c 2). The bicomponent fiber has a sheath-core configuration in which the sheath has a melting point less than that of the core. The bicomponent fibers preferably exhibit various geometries, such as side-by-side, sheath-core, scalloped, or islands-in-the-sea structures.

In one embodiment, the binder polymer in the bicomponent fiber (c 2) is selected based on its melting point. In a preferred shell core configuration as shown in fig. 4, the core 11 is preferably composed of PET and the shell 10 is preferably composed of a copolyester having a melting point of < 200 ℃. One particularly preferred binder fiber has a sheath-core filament configuration. The core 11 is composed of PET having a melting point of >250 ℃ (i.e., about 260 ℃) and the shell 10 comprises a copolyester having a lower melting point in the range between 110 ℃ and 180 ℃.

In one embodiment, the core layer 4 is pre-shrunk to avoid further shrinkage during the subsequent molding process. The pre-shrinking is performed after the needling process. The needled staple fibers are processed through a furnace that is typically set above the melting point of the low melting copolymer. For example, for bicomponent fibers having a sheath polymer (which has a melting point of 180 ℃), the oven set temperature may exceed 180 ℃.

In one embodiment, the outer layers 2 and 6 are of a weight of between 10 and 500g/m ² A coarse denier spunbond nonwoven layer therebetween. The spunbond is a PET-based yarn having a round configuration with an amount of 1 to 50% copolyester. The copolyester melts during the molding process and aids in adhesion to the adjacent layers. Furthermore, the basis weight of layers 2 and 6 is significantly lower than the weight of layer 4. This may be desirable where a light overall weight of the final part is desired and cost is reduced.

The layers between core layer 4 and outer layers 2 and 6 (i.e., layer 3 and/or layer 5) are spun-bonded nonwoven layers based on copolyesters. Such a copolyester-based spunbond nonwoven layer is used to enhance the bonding of the outer layer to the core layer, i.e. it is a tie layer. The tie layers 3, 5 comprise a low melting point copolyester. Its weight is preferably 1g/m ² To 50g/m ² Within a range of (2).

In fig. 2, a preferred three layer nonwoven laminate 7 is shown. The layers of the laminate are not mechanically bonded to each other. Instead, the layers of the laminate are only fusion bonded to each other.

In one embodiment, the core layer 4 is pre-shrunk to avoid shrinkage during the subsequent molding process. The core layer 4 has a density of 1500g/m ² And 2900g/m ² Basis weight therebetween.

In one embodiment, the outer layers 2 and 6 are of a weight of between 10 and 500g/m ² A coarse denier spunbond nonwoven layer therebetween. The spunbond is a PET-based yarn having a round configuration with an amount of copolyester of 1 to 50%. The copolyester in all of the present layers 2 to 6 melts during the molding process and contributes to adhesion to the adjacent layers. Nonwoven layerThe fibers of the laminate, in particular the fibers comprising the copolyester, may thus partially or completely lose their fibrous structure in the laminate after melt bonding. The resulting structure is included in the nonwoven laminate of the present invention.

The difference between the configurations of fig. 1 and 2 is that no adhesive layers 3 and 5 are used in fig. 2. In contrast, the amount of copolyester in outer layers 2 and 6 generally increases. This may be achieved by taking one of the configurations described in figures 3 to 5.

After forming the preferred five-layer construction 1 or the preferred three-layer construction 7 as illustrated in fig. 1 and 2, i.e. by establishing a fusion bond between the individual layers rather than a mechanical bond, it is subjected to conditions of molding into the desired shape for the particular internal application. The layered construction may preferably be molded in two different ways: either in a cold molding process or in a hot molding process.

In fig. 3, a segmented pie configuration is shown. This configuration is used for spunbond nonwoven layers 2, 3, 5 and/or 6 and for multicomponent staple fibers (c 2). The illustrated segmented pie yarn construction has eight segments consisting of alternating PET segments 8 and copolyester segments 9. It may alternatively have a filament construction with 16, 32 or 64 segments consisting of alternating PET segments 8 and copolyester segments 9. During the molding process, the low melting point copolyester melts and provides rigidity to the material.

In fig. 4, a sheath-core wire configuration is shown. This configuration can be used for spunbond nonwoven layers 2, 3, 5 and/or 6 and for multicomponent staple fibers (c 2). The bicomponent filament construction shown consists of a sheath 10 (composed of a low melting copolymer) and a core (composed of PET11 having a higher melting point). During the molding process, the low melting point copolyester melts and provides rigidity to the material.

In fig. 5, a side-by-side wire configuration is shown. This configuration is used for spunbond nonwoven layers 2, 3, 5 and/or 6 and for multicomponent staple fibers (c 2). The side-by-side filament configuration shown consists of one side 13 (composed of a low melting point copolymer) and the other side 12 (composed of PET with a higher melting point). During the molding process, the low melting point copolyester melts and provides rigidity to the material.

Examples

Example 1 Cold Molding Process

Materials for construction of nonwoven laminates and for interior applications comprising nonwoven laminates:

staple fiber (for core layer 4):

50% monocomponent staple fiber (c 1):

materials: r-PET

Short fiber length: 64mm of

Fineness: 6.7dTex

50% bicomponent staple fiber (c 2):

configuration: shell core

Materials: a PET shell; copolyester core with 180 ℃ melting point

Short fiber length: 51mm

Fineness: 5dTex

Spunbond (for outer layers 2 and 6):

materials: 90% pet;10% PET copolyester (CoPET)

Basis weight: 90g/m ²

Thickness: 0.33 to 0.59mm

Wire diameter: 25-60 mu m

CoPET spunbond (for tie layers 3 and 5):

100% PET copolyester (CoPET)

Basis weight: 16g/m ²

Thickness: 0.15 to 0.45mm

Wire diameter: 25-60 mu m

Staple fibers were combined in 50%:50% of the components are mixed. The staple fibers are then carded, cross-lapped, and needled. The needle used was Groz-Beckert 36gg fine needle with 350 needles/cm ² Is used for the total needling strength of the fabric. The needling depth on both sides was set to 10mm. The needled material was then passed through a ventilation oven which was heated to 200 ℃ at a rate of 10 ℃/min. This heating of the needled material activates the bicomponent fibers. This makes the material exiting the furnace rigid. Thereby producing the core layer 4. The core layer 4 is then passed through a set of calender rolls in which the CoPET tie layers 3 and 5 and the outer layers 2 and 6 are introduced on both sides. The calendering pressure on both sides was set at 25 barAnd at a temperature of 200 ℃ to produce a nonwoven laminate. In this nonwoven laminate, all layers 2 to 6 are melt bonded to each other. None of layers 2 to 6 is mechanically bonded to any other layer. The laminate produced is then subjected to sheet cutting.

Molding and shaping:

the sheet cut material was introduced into a furnace heated to 210 ℃ for 3 minutes (in the case of a through air furnace) or 1 minute (in the case of an infrared furnace). This material softens due to heat. It is then immediately transferred to a cold press where the material is molded under high pressure (50 tons or more).

Acoustic measurement:

the acoustic properties of the produced molded part samples were tested in an instrument named Alpha-Cabin. In Alpha-Cabin, the sample tested is placed near a wall or floor with an air gap of 2 mm. The absorption coefficient of the sample is then measured by a series of sensors in the cabin. The Alpha-Cabin test results for the 3mm, 4mm and 5mm molded thickness samples are shown in Table 1 below.

TABLE 1

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In FIG. 6, the results of flat molded samples having thicknesses of 3mm, 4mm and 5mm are shown by the applied sound frequency (abscissa) and absorption coefficient alpha _s The (ordinate) diagram shows. Sound absorption coefficient alpha _s The higher the acoustic performance of the test sample, the better. It can be seen that the sound absorption coefficient increases with increasing thickness of the test sample.

Example 2 Cold Molding Process

In the cold molding process, the nonwoven laminate is preheated for 1 to 5 minutes at a temperature ranging between 180 ℃ and 220 ℃ depending on the basis weight. This is to activate the low melting point copolyester as a binder. By activating the binder, it melts and forms a glue between the virgin or recycled PET fibers. It also acts as a glue between the staple fiber nonwoven layer and the spunbond nonwoven layer. After activation, the nonwoven laminate is placed in a compression mold. The compression mold may then compress all or a portion of the nonwoven laminate at a tonnage of 50 tons to 200 tons. The nonwoven laminate was allowed to dwell in the mold for up to 60 seconds. The compressed nonwoven laminate is cooled either inside or outside the mold to cool the copolyester fibers in the staple fiber and spunbond construction below their melting points. Thereafter, the nonwoven laminate is converted into its final shape. The final thickness of the material is between 2mm and 6mm, depending on the requirements of the intended application. The nonwoven laminate is then trimmed as needed, which can be accomplished by mechanical, thermal, or water jet cutting.

TABLE 2

In Table 2, the "staple only" sample is a 2mm thick single layer needled PET web, consisting of 50% recycled polyester staple fibers and the remaining 50% PET bicomponent fibers. The bicomponent fiber has a PET core and a PET copolymer sheath, having a melting point in the range of 75 ℃ to 230 ℃.

"SF with needle punched spunbond" refers to a layered structure according to the disclosure in US2016/0288451 A1. The layered structure has a weight of 90g/m ² Is used for the production of a polyethylene terephthalate (PET) spun-bonded layer and 800g/m ² An intermediate layer of needled short PET staple of basis weight. The two outer PET spunbond layers were needled into the middle layer of needled short PET staple. The two outer PET spunbond layers were thereby mechanically bonded to the middle layer of needled short PET staple. No fusion bonding of these layers to each other occurs. The layered structure had an initial total thickness of 7.0 mm. The layered structure was then compression molded to a final thickness of 2 mm.

"nonwoven laminate" means a nonwoven laminate corresponding to the present invention but without layer (F).The nonwoven laminate had a 90g/m ² Is used for the production of a polyethylene terephthalate (PET) spun-bonded layer and 800g/m ² An intermediate layer of heat-set needled PET staple fibers of the basis weight. Two outer PET spunbond layers were melt bonded to the middle layer of heat set needled PET staple fibers. No mechanical bonding of the layers to each other occurs. The nonwoven laminate had an initial overall thickness of 7.0 mm. The nonwoven laminate was then compression molded to a final thickness of 2 mm. Will have a particle size of 650g/m ² The density of the needled staple fibers is fed into a furnace for heat setting. Heat setting causes shrinkage. After shrinkage, 800g/m was obtained ² Is added to the weight of the product. The spunbond was not needled onto the core, but rather was melt bonded. The spunbond used had a higher amount of copolyester, which ensured better bonding between the layers.

As can be seen from table 2, the results of the mechanical property test confirm that the nonwoven laminate samples significantly increased the flexural, tear and tensile strength. Without being bound by theory, it is believed that the reason for the increased flexural strength is the presence of a high amount of adhesive material that keeps the spunbond straight enough to produce a flat surface. Inclusion of the spunbond itself helps to increase tear strength due to the infinite (endless) calendered filaments in the spunbond.

Example 3 thermal molding Process

In a thermal molding process, a nonwoven laminate is placed between a pair of thermal compression molded panels. The plate is then brought to approximately the desired thickness, which is less than the thickness of the material. For example, if the nonwoven laminate is 6mm thick, the thickness between the plates is between 2mm and 5 mm. The molded plate is heated to a temperature in the range of 180 ℃ to 220 ℃. The nonwoven laminate is then compressed for 1 to 3 minutes based on basis weight in order to activate the low melting point copolyester (or adhesive). By activating the binder, it melts and forms glue between the original or recycled PET fibers. At the same time, it also acts as a glue between the staple fibers and the spunbond. Compression of all or a portion of the nonwoven laminate may be performed at tonnage of 50 tons to 200 tons. The compressed nonwoven laminate is cooled either inside or outside the mold to allow the staple fibers and binder fibers in the spunbond construction to cool below their melting points. Thereafter, the nonwoven laminate is converted into its final shape. The final thickness of the material is between 2mm and 6mm, depending on the requirements of the intended application. The nonwoven laminate is then trimmed as needed, which can be accomplished by mechanical, thermal, or water jet cutting.

TABLE 3 Table 3

"staple only", "SF with needle-punched spunbond" and "nonwoven laminate" are the same as described in example 2. As can be seen from table 3, a similar trend was noted as in table 2, which demonstrates the significant enhancement in bending, tearing and tensile strength of the nonwoven laminate samples. The values of flexural and tensile strength are higher for the hot molded samples compared to the cold molded samples. Without being bound by theory, it is believed that this is because the hot surface of the plate is in direct contact with the sample, melting the fibers and forming thin plastic sheets on both sides of the needled web.

EXAMPLE 4 weight Change

Also tested at 1000, 1200 and 1400g/m ² Mechanical properties of molded nonwoven laminate samples having a thickness of 2mm at different weights. The test results are shown in Table 4.

TABLE 4 Table 4

As can be seen from table 4, a linear increase in mechanical properties with respect to basis weight is observed. Higher weight means higher staple fiber content because the weight of the spunbond remains the same. A higher amount of staple fibers results in a higher percentage of bicomponent fibers and thus more binder material, which in turn results in greater stiffness and enhanced mechanical property values.

Example 5 (comparative) -mechanically bonded nonwoven laminate

Figures 7a, 7b and 7c are microscopic images of needled nonwoven produced according to US2016/0288451 A1. The fibre layers thereof are mechanically connected by needling, i.e. they are mechanically bonded to each other. Reference numeral 14 denotes a region of lower fiber density due to needling. It can be seen that some of the fibers of one layer (the core layer) extend and penetrate the adjacent layer (the spunbond outer layer). Whereby a mutual mixing of the respective fibres is formed, which results in a mechanical bond between the two layers. This bonding can cause the layered structure to deform upon further compression and molding, resulting in a non-uniform product having a wavy appearance (wrinkles).

The nonwoven laminate of the present invention can avoid this disadvantage by merely melt bonding the layers of the laminate to one another. Thus, there is no mechanical bond in the laminate of the present invention, and only a melt-bonded layer.

Example 6: nonwoven laminate with functional layer (F)

A nonwoven laminate having a functional layer (F) on one side was prepared. The following layers were melt bonded to each other:

layer (A) spunbond (PET/CoPET) 100% BiCo

Layer (C) needle-punched (needle punched) material (r-PET 50% + PET/CoPET BiCo 50%)

Layer (E) spunbond (PET/CoPET) 100% BiCo

Layer (F): PET nonwoven-80% PET and 20% BiCo PET/CoPET, needle penetration and embossing have different designs.

First, the needled material of layer (C) was heat-set at 210 ℃ to become a sheet, and then spunbond materials (a) and (E) on both sides were laminated together with a PET nonwoven layer (F) on top of side (E). The presence of CoPET in the spunbond layer (E) aids in bonding the PET nonwoven to the PET nonwoven of the core layer (C) and/or low melting CoPET nonwoven (B) and (D) may be incorporated to bond the two layers.

Overall, the nonwoven laminates with layer (F) can be produced and molded as outlined in examples 1 to 5 above for the corresponding nonwoven laminates without additional layer (F).

Example 7: molding of structural components for automotive interior applications

The nonwoven laminate according to example 6 with the functional layer (F) on one side was converted into a molded part.

Cold molding

The sheet cut nonwoven laminate part was placed in a 190 ℃ oven for 3 minutes and then immediately transferred to a cold molding tool and pressed at 100 tons for 1 minute. The molded part is then removed from the tool and the edges are trimmed to obtain the final product.

Thermal molding

The sheet cut nonwoven laminate part was placed in a hot molding tool at 190 ℃ for 90s and pressed with 100 tons. The molded part is then removed from the tool and the edges are trimmed to obtain the final product.

Properties of molded parts

Layer (F) may improve the properties of the nonwoven laminate and molded part. In particular, it was found that the further layer (F) may improve the cushioning effect, the acoustic properties, the personalized optical properties and the mechanical properties. The nonwoven laminate is moldable and 100% recyclable. The layer (F) may be at least partially provided by recycled material.

Claims (22)

1. Nonwoven laminate comprising in order (A) to (F)

-a spunbond nonwoven layer (a) comprising fibers comprising polyethylene terephthalate (PET) and copolyester;

-an optional spunbond nonwoven layer (B) comprising fibers comprising polyethylene terephthalate (PET) and a copolyester, said nonwoven layer (B) having a higher copolyester content than the nonwoven layer (a);

-a needled staple fiber nonwoven layer (C) comprising:

o monocomponent polyethylene terephthalate (PET) staple fiber (c 1), and

an o-multicomponent staple fiber (c 2) comprising at least a polyethylene terephthalate (PET) component and a copolyester component;

-an optional spunbond nonwoven layer (D) comprising fibers comprising polyethylene terephthalate (PET) and a copolyester, said nonwoven layer (D) having a higher copolyester content than the nonwoven layer (E);

-a spunbond nonwoven layer (E) comprising fibers comprising polyethylene terephthalate (PET) and copolyester;

a nonwoven layer (F) comprising monocomponent polyethylene terephthalate (PET) fibers and/or multicomponent fibers comprising at least a polyethylene terephthalate (PET) component and a copolyester component,

wherein all layers are fusion bonded to each other.

2. The nonwoven laminate of claim 1 wherein none of layers (a), (B), (C), (D), (E) and (F) are mechanically bonded to any other layer of layers (a), (B), (C), (D), (E) and (F).

3. The nonwoven laminate of at least one of the preceding claims wherein layer (F) consists of monocomponent polyethylene terephthalate (PET) fibers and multicomponent fibers comprising at least a polyethylene terephthalate (PET) component and a copolyester component.

4. The nonwoven laminate of at least one of the preceding claims wherein layer (F) consists of staple fibers.

5. The nonwoven laminate of at least one of the preceding claims wherein layer (F) is needled.

6. The nonwoven laminate according to at least one of the preceding claims, comprising a further nonwoven layer (F1) on the outer surface of the spunbond nonwoven layer (a).

7. The nonwoven laminate of at least one of the preceding claims comprising a further spunbond nonwoven layer (G) between layer (E) and layer (F), wherein the spunbond nonwoven layer (G) comprises fibers comprising polyethylene terephthalate (PET) and a copolyester, the nonwoven layer (G) having a higher copolyester content than the nonwoven layer (E).

8. The nonwoven laminate of at least one of the preceding claims wherein the needled staple fiber nonwoven layer (C) is heat-shrunk.

9. The nonwoven laminate of at least one of the preceding claims, which is free of polyolefin, in particular polypropylene.

10. The nonwoven laminate of at least one of the preceding claims, which is free of inorganic reinforcements, in particular free of glass fibers.

11. The nonwoven laminate of at least one of the preceding claims having at least one of the following characteristics:

-a flexural strength of ≡330MPa according to ISO 178:2019-04;

-tensile strength of ≡780N according to ASTM 5034:2009; and/or

Tear strength of ≡110N according to DIN EN 29073-3:1992-08.

12. The nonwoven laminate of at least one of the preceding claims wherein the copolyester of layers (a), (B), (C), (D) and (E) is a copolymer of polyethylene terephthalate having a melting point of 240 ℃.

13. The nonwoven laminate of at least one of the preceding claims, wherein layers (a) and (E) comprise from 10% to 70% of the copolyester, in particular at least 30% of the copolyester.

14. The nonwoven laminate of at least one of the preceding claims comprising a spunbond nonwoven layer (B) and/or a spunbond nonwoven layer (D), wherein

-the fibres of the spunbond nonwoven layer (B) and/or of the spunbond nonwoven layer (D) consist of copolyesters; and/or

The spunbond nonwoven layer (B) and/or the spunbond nonwoven layer (D) has a weight of 1 to 100g/m according to DIN EN 29073-1:1992-08 ² Is based on the weight of the substrate.

15. The nonwoven laminate of at least one of the preceding claims wherein a staple fiber nonwoven layer (C) is needled

-consisting of 10 to 90% of monocomponent staple fibers (c 1) and 10 to 90% of multicomponent staple fibers (c 2), and/or

Having a value of ∈2900g/m according to DIN EN 29073-1:1992-08 ² Is based on the weight of the substrate.

16. The nonwoven laminate of at least one of claims 1 to 13 wherein:

the copolyester in layers (a), (B), (C), (D) and (E) is a copolymer of polyethylene terephthalate, said copolymer having a melting point of 160 to 240 ℃;

-comprising 10 to 20g/m each consisting of a copolyester and each having a composition according to DIN EN 29073-1:1992-08 ² A spunbond nonwoven layer (B) and a spunbond nonwoven layer (C) of basis weight; and

-the needled staple fiber nonwoven layer (C) consists of 40 to 60% of monocomponent staple fibers (C1) and 40 to 60% of multicomponent staple fibers (C2).

17. The nonwoven laminate of at least one of claims 1 to 13 wherein:

-the nonwoven laminate comprises neither a spunbond nonwoven layer (B) nor a spunbond nonwoven layer (D);

the copolyester in layers (a), (C) and (E) is a copolymer of polyethylene terephthalate, said copolymer having a melting point of 160 to 240 ℃; and

-the needled staple fiber nonwoven layer (C) consists of 40 to 60% of monocomponent staple fibers (C1) and 40 to 60% of multicomponent staple fibers (C2).

18. Molded article comprising a nonwoven laminate according to at least one of claims 1 to 17.

19. An interior product comprising the molded article of claim 18, preferably for a vehicle, which is preferably a panel, a shell, a cladding, a reinforcement or a partition, preferably for a door, a roof, a trunk or a seat.

20. Use of the nonwoven laminate or molded article according to at least one of claims 1 to 18 for interior products, preferably for vehicles.

21. Process for producing a nonwoven laminate according to at least one of claims 1 to 17, comprising:

-preparing said needled staple fiber nonwoven layer (C) by needling;

-providing layers (a) to (F) in order; wherein layers (B) and (D) are optional, and

-the layers (a) to (F) are fusion bonded to each other.

22. A process for producing a molded article according to claim 18, comprising:

providing a nonwoven laminate and a nonwoven laminate according to the invention

-moulding the nonwoven laminate, thereby obtaining the moulded article.