MXPA04008914A

MXPA04008914A - Insulating material.

Info

Publication number: MXPA04008914A
Application number: MXPA04008914A
Authority: MX
Inventors: A Tilton Jeffrey
Original assignee: Owens Corning Fiberglass Corp
Priority date: 2002-03-15
Filing date: 2003-02-28
Publication date: 2004-11-26
Also published as: EP1485528A2; JP2005520941A; KR20040094804A; AU2003216453A8; CA2478568A1; AU2003216453A1; WO2003078714A2; US20030176131A1; WO2003078714A3; BR0308064A

Abstract

An insulating material is constructed in weight percent from about 20-60% low melt bicomponent fiber, 10-40% high melt bicomponent fiber and 20-60% staple fiber. The material provides a unique combination of strength, acoustical insulating and even thermal insulating properties heretofore unavailable in the art.

Description

INSULATING MATERIAL TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION The present invention relates generally to the field of acoustic and thermal insulation and more particularly to a new and unique insulating material of bicomponent fibers with low melting point and high melting point, which exhibits the unique mix of acoustic and structural insulation properties. BACKGROUND OF THE INVENTION Acoustic and thermal liners for application in vehicles are well known in the art. These liners typically rely on both sound absorption, ie the ability to absorb incident sound waves and transmission losses, that is, the ability to reflect the incident sound waves in order to provide sound attenuation. They are also based on thermal shielding properties to prevent or reduce the heat transfer from various heat sources (for example the engine, transmission and exhaust system), to the passenger compartment of the vehicle. This insulation is commonly used as a chest liner, board lining and fire wall lining. More recently, these linings have been used in engine covers, to attenuate the sound of the engine closer to its source. Examples of acoustic and thermal insulation in the liner form are described in a number of patents of the prior art including U.S. Pat. No. 4,851,283 granted to Holtrop et al. And No. 6,008,149 granted to Copperwheat. As should be apparent from a review of these two patents, engineers have found it necessary in general to construct these linings from laminate incorporating a) one or more layers to provide the desired acoustic and thermal insulating properties, and b) one or more layers additional, to provide the desired mechanical strength properties that allow simple and convenient installation as well as adequate functional performance during a long service life. While over the years a number of adhesives, adhesive webs and binder fibers have been developed specifically to secure the various layers of laminates as a whole, laminated linings and insulators have an inherent risk of delamination and failure. The potential in fact is significant, primarily due to the rigorous operating environment to which these linings and insulators are subjected. Many liners and insulators are located nearby and / or designed to protect high heat sources such as the engine, transmission and exhaust system components. As a result, linings and insulation are often subjected to temperatures exceeding 93.3 degrees C (200 degrees F) which tend to degrade adhesives or binders over time. Additionally, many linings and insulators are subjected to water from the surface of the roads, which tends to be directed by capillary action to the interface between the liner layers or insulators. This water can have a deleterious effect on the integrity of the adhesive layer over time. This is particularly true when that water includes in solution, salt or other road chemicals that are corrosive and destructive. Therefore a need is identified for a casing cover for hood, board, fire wall or engine, which incorporates an insulating layer of non-laminated acoustic and thermal polymer fibers which avoids any inherent delamination potential. This liner is suitable for use in the high temperature operating environment of the engine compartment and capable of providing the desired mechanical strength and rigidity, for ease of installation as well as the desired thermal and acoustic insulating properties. SUMMARY OF THE INVENTION Accordingly, the present invention relates to an insulating material that exhibits a unique combination of structural / strength and sound insulation properties. The insulating material comprises in percent by weight of about 20 to 60 weight percent of bicomponent fibers of low melting point, 10 to 40 percent of bicomponent fibers of high melting point and 20 to 60 percent of short fibers. The melt includes an average fiber diameter between about 10 to 30 microns, more typically 16 to 24 microns and in particular 18 to 22 microns. The material has a density of between about 16.02 to 160.2 kg / m3 (1.0 to 10.0 pcf) and a flexural strength between about 275.79 to 8273.71 kPa (40 to 1200 psi). Still more specifically describing the invention, the insulating material has the acoustic absorption coefficients as follows: 0.17 to 0.24 at a frequency of 500 Hz, 0.29 to 0.63 at a frequency of 1000 Hz, 0.50 to 0.94 at a frequency of 2000 Hz and 0.71. at 0.99 at a frequency of 4000 Hz, all at a density of 32.04 kg / m3 (2 pcf). Still further describing the invention, the insulating material has a thermal conductivity value between about 0.20 and 0.30 to 32.04 kg / m3 (2 pcf) of density. The short or body fibers are chosen from a group of materials consisting of polyester fibers, polyethylene fibers, propylene fibers, nylon fibers, rayon fibers, glass fibers, natural fibers and mixtures thereof. The low melting bicomponent fibers are chosen from a group of materials consisting of copolyester / polyethylene terephthalate (CoPET / PET), poly 1,4-cyclohexanedimethyl terephthalate / polyethylene terephthalate (PCT / PET), poly 1,4-cyclohexanedimethyl terephthalate / polypropylene (PCT / PP), glycol-modified polyethylene terephthalate / polyethylene terephthalate (PETG / PET), propylene / polyethylene terephthalate (PP / PET), nylon 6 / nylon 66r polyethylene / glass, or other polymer combination including polymers / glass and polymers / natural fibers that produce differential melt flow temperatures. The bicomponent fibers can be any of a variety of configurations that produce acceptable fiber bonding such as core / liner, side-by-side, segmented pie, etc. The low melting bicomponent fibers are described as having a melt flow temperature of about 100 ° C to 130 ° C (212 ° F to 266 ° F). High-melting bicomponent fibers are chosen from a group of materials consisting of copolyester / polyethylene terephthalate (CoPET / PET), poly 1,4-cyclohexanedimethyl terephthalate / polyethylene terephthalate (PCT / PET), poly 1,4-cyclohexanedimethyl terephthalate / polypropylene (PCT / PP), polyethylene terephthalate modified with glycol / polyethylene terephthalate (PETG / PET), propylene / polyethylene terephthalate (PP / PET), nylon 6 / nylon 66, or other combinations of polymers that produce melt flow temperatures differentials. The bicomponent fibers may be any of a variety of configurations that produce acceptable fiber bonding such as core-liners, side-by-side, segmented segmented pie, etc. The high melting point bicomponent is described as having a melt flow temperature of about 170 to 200 degrees C. Bicomponent fibers described as crystalline or semicrystalline having a melt flow temperature in general of about 150 ° to 180 ° C. (302 ° to 356 ° F) can be replaced in part or totally by the bicomponent fiber of high melting point. BRIEF DESCRIPTION OF THE DRAWING The accompanying drawing incorporated in and forming a part of the specification, illustrates various aspects of the present invention and together with the description, serves to explain the principles of the invention. In the drawing: Figure 1 is a schematic side elevational view of a possible embodiment of the present invention; Figures 2-4 are illustrations in schematic side elevation of other possible alternative embodiments of the present invention; Figure 5 is a graphic illustration comparing the flexural strength in the machine direction of the structural / acoustic insulating material of the present invention with a standard state of the polymer formulation of the art; and Figure 6 is a graphic illustration comparing the flexural strength in the transverse direction of the machine of the structural / acoustic insulating material of the present invention with a polymer formulation of the standard prior art. Reference will now be made in detail to the present preferred embodiment of the invention, an example of which is illustrated in the accompanying drawing. DETAILED DESCRIPTION OF THE INVENTION The present invention relates to an insulating material that is particularly notable for its combination of structural and acoustic properties. Specifically, as described below the insulating material produces at least 100% improvement in the elastic modulus over a standard polymer formulation, while (1) it maintains acoustics equivalent to the standard formulation, (2) they produce high performance. temperature and (3) has a minimal increase in cost compared to standard formulations. While in the past it has generally been found necessary to provide a significant level of acoustic performance or use fibers of much higher price or both to achieve improvement in structural properties, the present invention achieves the dramatic increase in elastic modulus without compromising acoustic properties or low costs. of production and as such, represents a significant advance in the technique.

The insulating material in the present invention comprises in percent by weight of approximately 20-60% low-melting bicomponent fibers, 10-40% high-melting bicomponent fibers and 20-60% short fibers. The melt includes an average fiber diameter of between about 10-30 microns, or typically 16-24 microns and more typically 18-22 microns. The material has a density between approximately 16.02-160.2 kg / m3 (1.0-10.0 pcf) and a flexural strength between approximately 275.79-8273.71 kPa (40-1200 psi). For clarity purposes, the bicomponent fibers are comprised of a main polymer component and a binder polymer component. The bicomponent fibers can be formed as core-liner fibers, with the main polymer component forming the core material and the binder polymer component forming the liner around the core. It should be understood however that other assemblies may be used such as a side-by-side assembly. In any such assembly, the binder polymer complement binds the bicomponent fibers and the short fibers to themselves and to each other.

The binder polymer component of the bicomponent fibers has a softening point lower than the softening point of the main polymer component, so that the two materials respond differently when heating. When heated to a temperature above the softening point of the binder polymer component but below the softening point of the main polymer component, the binder component softens and becomes sticky, thereby bonding the various bicomponent fibers when they are in contact. contact with each other and short fibers. As long as the temperature is not increased to a value as high as the softening point of the main polymer component, that component remains in the form of fibers. The bicomponent fibers of low melting point are chosen from a group of materials consisting of copolyester / polyethylene terephthalate (CoPET / PET), poly 1,4-cyclohexanedimethyl terephthalate / polyethylene terephthalate (PCT / PET), poly 1,4-cyclohexanedimethyl terephthalate / polypropylene (PCT / PP), glycol-modified polyethylene terephthalate / polyethylene terephthalate (PETG / PET), polyethylene propylene terephthalate / polyethylene terephthalate (PP / PET), nylon 6 / nylon 66, polyethylene / glass, or other polymer combinations including polymer / glass and polymer / natural fibers that produce a flow temperature of differential fusion. The bicomponent fibers may be any of a variety of configurations that produce acceptable fiber bonding such as core-liners, side-by-side, segmented pie, etc. The low melting segment bicomponent fibers are described as having a melt flow temperature of about 100 ° to 130 ° C (212 ° to 266 ° F). High-melting bicomponent fibers are chosen from a group of materials consisting of copolyester / polyethylene terephthalate (CoPET / PET), poly 1,4-cyclohexanedimethyl terephthalate / polyethylene terephthalate (PCT / PET), poly 1,4-cyclohexanedimethyl terephthalate / polypropylene (PCT / PP), polyethylene terephthalate modified with glycol / polyethylene terephthalate / polyethylene terephthalate (PETG / PET), propylene / polyethylene terephthalate (PP / PET), nylon 6 / nylon 66, or other combinations of polymers that produce flow temperatures differential melting. The bicomponent fibers may be any of a variety of configurations that produce acceptable fiber bonding such as core-liners, side-by-side, separable segmented pie, etc. The high melting component b.i is described as having a melt flow temperature of about 170 ° to 200 ° C (338 ° to 392 ° F). Bicomponent fibers described as crystalline or semicrystalline having a melt flow temperature of about 150 ° to 180 ° C (302 ° to 356 ° F) may be replaced in part or totally by the bicomponent fiber of high melting point. The insulating material provides unique acoustic insulating properties in combination with flexural strength of between approximately 275.79-8273.71 kPa (40-1200 psi). Specifically, the insulating material is characterized by acoustic absorption coefficients of 0.17-0.24 at a frequency of 500 Hz, 0.29-0.63 at a frequency of 1000 Hz, 0.50-0.94 at a frequency of 2000 Hz and 0.71-0.99 at a frequency of 4000 Hz all at a density of 32.04 km / g3 (2 pcf). The insulating material also has a thermal conductivity value within about 0.20 and 0.30 to 32.04 kg / m3 (2 pcf) density. Accordingly, it should be appreciated that the insulating material also provides good thermal insulating properties in conjunction with good structural properties and acoustic insulators.

The short or bulking fibers used in the insulating material are chosen from a group of materials consisting of polyester fibers, polyethylene fibers, polypropylene fibers, nylon fibers, rayon fibers, glass fibers, natural fibers and their fibers. mixtures The insulating material of the present invention can be used for a number of applications requiring the unique structural and acoustic insulation and when appropriate for certain applications, thermal insulation properties of the present invention. For example, the insulating material of the present invention can be used in the construction of hood, board, fire wall or engine hood linings, as illustrated in Figures 1 to 4 of the present invention. The liner 10 shown in Figure 1 comprises an acoustic and thermal insulating layer 12 of the insulating material of the present invention. More specifically, a single non-laminated layer 12 is provided with the necessary mechanical strength and stiffness, to allow for easy installation and the desired thermal and acoustic insulation properties. By sale, all these benefits are achieved in a lightweight lining that can even be used in compact vehicles, where considerations of fuel economy lead manufacturers to seek savings in weight, whenever possible. In a first alternative embodiment shown in Figure 2, the liner 10 also comprises a single unlaminated thermal and acoustic insulation layer 12 of the insulating material of the present invention. The layer 12 includes a relatively high density, non-laminated or unitary density surface layer 14 of that insulating material together with at least one face thereof. Advantageously, the high density surface layer 14 will not delaminate from the layer 12 under the environmental conditions that exist in the engine compartment and will also contribute structural integrity and resistance to the liner 10 which significantly helps to handle and adjust the part during installation. The high density surface layer 14 is also more aesthetically pleasing. Furthermore, for many applications, the high density surface layer 14 eliminates the need to provide an additional face face of another type of fabric material. This serves to eliminate virtually any potential due to failure of the lining due to delamination.

It also results from a liner 10 made exclusively of a material, this is therefore fully recyclable. In addition, since the surface layer can be formed with a hot platen during the molding of the liner 10 to its desired shape, an additional processing step is not required. This reduces production costs with respect to a liner with a cloth and another front, since this front must adhere to the thermal and acoustic insulating layer in a separate processing step. In yet another embodiment shown in Figure 3, the liner 10 includes a single non-laminated thermal and acoustic insulating layer 12 of the insulating material of the present invention, in combination with the front face 16 on a first face 18 of the insulating layer , thermal and acoustic. The front layer 16 can be constructed from a polymeric material selected from the group consisting of polyester, rayon, polyethylene, polypropylene, ethylene vinyl acetate, polyvinyl chloride and mixtures thereof. In yet another alternate embodiment shown in Figure 4, the liner 10 comprises a single non-laminated acoustic and thermal insulation layer 12 of the insulating material of the present invention as described above, in combination with a first front face 16 covering a first face 18 thereof and a second front face 20 having a second opposite face 22 thereof. The second facing face 20 can be constructed from the same or different material as the first facing layer 16. Preferably, the first and second facing layers have a weight between about 16.95-101.72 g / m2 (0.50-3.00 oz / sq and d). According to some other aspect of the present invention, the insulating, acoustic and thermal layer 12 can be in natural white or even suitable in coloration or pigment in order to provide a gray or black color. Alternatively, the thermal and acoustic insulating layer may incorporate any suitable pigment or color to substantially approximate the color of the first and second facing faces 16, 20 and / or the paint color of the vehicle. This provides significant aesthetic benefits. Specifically, when the liner 10 is molded under heat and pressure in order to fit into the hood, fire wall and other appropriate body panel or superstructure of the engine compartment, the liner 10 is often deep-drawn into one or more points. This deep sausage has a tendency to disperse the weft of the fabric front 16, 20 in that manner by exposing a portion of the underlying face 18, 20 of the thermal and acoustic insulation layer to the light. If the thermal and acoustic insulation layer 12 does not substantially correspond to the color of the facing layer 16, 20, this creates an undesirable color variation in these deep drawing areas. In contrast, by coupling the color of the layer 12 with the fronts 16, 20, this color variation can be substantially eliminated. Furthermore, it will be appreciated that during use of the facing faces 16, 20 may become entangled or subject to partial tearing by exposing some of the face of the underlying thermal and acoustic insulating layer 12. Again, by adjusting the color of the layer 12 with the front 16, 20, any color variation is substantially eliminated and attention is not easily directed to the damaged area. Accordingly, a total improved aesthetic appearance is maintained over the service life of the liner 10. The insulating material of the present invention is produced in accordance with the processing steps generally known in the art. The fibers require to be mixed in the given proportions and thermally bonded to form a semi-rigid layer. The fibers are generally packed in packs of 226.79-317.51 kg (500-700 Ib.). Each of the three fibers in general is packaged separately although it is possible to obtain the fiber supplier fibers mixed in the proper proportion and packaged together. For purposes of this description, it is considered that the fibers are packaged separately. In general, each packaged fiber needs to be "opened" by a bale opening system common in the industry. The opening system pulls the fibers and removes the proper amount of fiber and sends the appropriate amount of fibers by weight to a mixing area. This impregnation serves to detach the swarmed fibrous masses and improves fiber-to-fiber contact. The mixing area evenly distributes the different fibers according to the desired fiber proportions. Once mixed, the fibers are uniformly distributed in the transport system that forms a "sheet" or "layer" of uniformly distributed fibers. Thermally activated powder binders or other supplemental bonding or bonding methods may be added during the transport or fiber mixing stages before the sheet enters the thermal bonding furnace.

The furnace is constructed to allow hot air to penetrate the fibrous package and bring the fibers to a temperature sufficient to activate the binding fibers and / or other binding materials or binders. If the layer material is produced for post-molding applications, the furnace temperature only needs to be high enough to activate at least some of the low melting point link fibers. The operation of a post-molding only requires reaching temperatures high enough to activate the fibers of higher melting point. If post-molding operation is not going to occur, then the furnace requires adjusting to a temperature high enough to activate both the low melting and high melting point fibers - in this case the required temperature would be at least 180 degrees C ( 356 degrees F). Once the fibers have reached the appropriate temperature, the kiln area or later, the kiln should be able to reduce the temperature below the trigger point of the binder materials in this case approximately less than 100 degrees C (212 degrees F) ). The desired thickness of the layer is usually established in the kiln process. After leaving the furnace, additional binder materials such as powders may be added to the fibrous layer or other treatments may occur, such as densifying one or both surfaces of the layer. The layer can now be handled and used "as is" for structural-acoustic applications or it can be post-molded to produce parts of simple or highly complex shapes. Molding methods can vary between those typically used in the industry for molding thermoplastic materials. One such method is to preheat the layer material to a temperature sufficient to (re) activate all the binder materials and then quickly transfer the heated layer to a cold molding tool and pressure mold the part until the temperature of the fibers is below the activation point of the binding fibers or low melting point binders. In the case of the samples used for structural testing in the following example, no post-molding operation is used to achieve the desired test thickness. The following examples are presented to further illustrate the invention, but shall not be considered as a limit to it. EXAMPLE The structural / acoustic formulation for the insulating material of the present invention was tested and compared to a standard formulation of 40% bicomponent of low melting point having an average fiber diameter of 14.3 microns, 30% of short fibers (from bulge) having an average fiber diameter of 12.4 microns and 30% short fibers (bulking) having an average fiber diameter of 50.0 microns. Altogether, the standard formulation had an average fiber diameter of 30.0 micras. Flexural strength test of the structural / acoustic formulation of the insulating material of the present invention and the standard formulation, then run in accordance with the static three-point bending of ASTM D1037. The results of this test are clearly illustrated in Figures 5 and 6. Figure 5 shows the flexural strength of the two formulations in the machine direction and Figure 6 shows the flexural strength of the two formulations in the direction transverse to the machine. In both cases, it will be appreciated that the structural / acoustic formulation of the insulating material of the present invention provides at least 100 percent improvement in the elastic modulus over the standard formulation tested.

The structural / acoustic formulation of the insulating material of the present invention also provides somewhat better acoustic absorption coefficients than those provided by the standard formulation and as such, provides significant gains in strength and improved acoustic insulation performance. As such, the present invention represents a significant advance in the art. In summary, numerous benefits result from employing the concepts of the present invention. An insulating material provides a unique combination of structural strength, acoustic insulation and even thermal properties are provided. The insulating material is particularly suitable for use as a hood cover, board, fire wall or engine. Provides mechanical strength and rigidity to allow ease of handling and installation, while also providing acoustic and thermal insulation properties that are consistently and reliably maintained over a long service life even in the operating environment of high temperature and high humidity compartment the motor. These performance characteristics, to date have not been available in a lining that incorporates a single non-laminated layer of acoustic and thermal insulation material. The above description of a preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described. The modality was selected and described to provide the best illustration of the principles of the invention and its practical application in order to allow a person with ordinary skill in the art to use the invention in various modalities and when these modifications are suitable for the particular use contemplated. For example, bi-crystalline / emicrystalline fibers having a melt flow temperature of about 150 degrees C to about 180 degrees C may be replaced, wholly or partially, by the high melting, bicomponent fibers. All these modifications and variations are within the scope of the invention as determined by the appended claims, when interpreted in accordance with the scope to which one is entitled in a fair, legal and equitable manner.

Claims

CLAIMS 1. An insulating material, characterized in that it comprises in weight percent approximately 20-60% bicomponent fibers of low melting point, 10-40% of bicomponent fibers of high melting point and 20-60% of short fibers . 2. A material in accordance with claim 1, characterized in that it includes an average fiber diameter between about 10-30 microns. 3. A material in accordance with claim 1, characterized in that it includes an average fiber diameter between about 16-24 microns. 4. A material according to claim 1, characterized in that it includes an average fiber diameter between about 18-22 microns. 5. A; material according to claim 1 characterized in that the material has a density between approximately 16.02-160.2 kg / m3 (1.0-10.0 pcf) and a flexural strength of between approximately 275.79-8273.71 kPa (40-1200 psi). 6. A material in accordance with claim 5, characterized in that the material has acoustic absorption coefficients as follows: frec (Hz) @ Density 32.04 kg / m3 (2 pcf) 500 0.17-0.24 1000 0.29-0.63 2000 0.50-0.94 4000 0.71-0.99 7. A material in accordance with claim 6, characterized in that it has a thermal conductivity value between about 0.20 and 0.30 at a density of 32.04 kg / m3 (2 pcf). 8. A material according to claim 1, characterized in that the bicomponent fibers of low melting point and high melting point are a concentric CoPET / PET liner / core. . A material according to claim 8, characterized in that the short fibers are chosen from a group of materials consisting of polyester fibers, polyethylene fibers, polypropylene fibers, nylon fibers, rayon fibers, glass fibers, natural fibers and its mixtures 10. A material in accordance with claim 1, characterized in that the material has acoustic absorption coefficients as follows: frec < Hz) @ density 32.04kg / m3 (2 pcf) 500 0.17-0.24 1000 0.29-0.63 2000 0.50-0.94 4000 0.71-0.99 11. A material in accordance with claim 10, characterized in that the material has a thermal conductivity value between about 0.20 and 0.30 at a density of 32.04 kg / m3 (2 pcf). 12. A material according to claim 11, characterized in that the short fibers are chosen from a group of materials consisting of polyester fibers, polyethylene fibers, propylene fibers, nylon fibers, rayon fibers, glass fibers, fibers natural and their mixtures. 13. A material according to claim 1, characterized in that the short fibers are selected from the group of materials consisting of polyester fibers, polyethylene fibers, propylene fibers, nylon fibers, rayon fibers, glass fibers, natural fibers and their mixtures. A material according to claim 13, characterized in that the bicomponent fibers of low melting point are chosen from a group of materials consisting of copolyester / polyethylene terephthalate (CoPET / PET), poly 1,4-cyclohexanedimethyl terephthalate / polyethylene terephthalate (PCT / PET), poly 1,4-cyclohexanedimethyl terephthalate / polypropylene (PCT / PP), glycol-modified polyethylene or terephthalate / polyethylene terephthalate (PETG / PET), propylene / polyethylene terephthalate (PP / PET), nylon 6 / nylon 66, polyethylene / glass, or other combination of polymers including polymers / glass and polymers / natural fibers and their blends that produce differential melt flow temperatures. 15. A material in accordance with claim 14, characterized in that the bicomponent fibers are in a configuration selected from the group consisting of side-by-side, segmented core-liner and mixtures thereof. 16. A material according to claim 14, characterized in that the high-melting bicomponent fibers have a melt flow temperature between about 100 degrees C (212 degrees F) to about 130 degrees C (266 degrees F). 17. A material in accordance with claim 13, characterized in that the bicomponent fibers of high melting point are chosen from the group of materials consisting of copolyester / polyethylene terephthalate, poly 1,4-cycle exandimethyl terephthalate / polyethylene terephthalate, poly 1,4-cyclohexanedimethyl terephthalate / polypropylene, polyethylene terephthalate modified with glycol / polyethylene terephthalate, propylene / polyethylene terephthalate, nylon 6 / nylon 66, and mixtures thereof that produce differential melt flow temperatures. 18. A material according to claim 17, characterized in that the bicomponent fibers of high melting point are in a configuration selected from a group consisting of side-shell, side-by-side, segme segme pie and their mixtures. 19. A material according to claim 17, characterized in that the high melting point bicomponent fibers have a melt flow temperature of about 170 degrees C (338 degrees F) to about 200 degrees' (392 degrees F).