WO2018098335A1

WO2018098335A1 - Hydrophobic, anti-wicking non-woven material for liner or shield

Info

Publication number: WO2018098335A1
Application number: PCT/US2017/063086
Authority: WO
Inventors: Brian E. SPARKS; Andreas LAKE
Original assignee: Thrace-Linq, Inc.
Priority date: 2016-11-22
Filing date: 2017-11-22
Publication date: 2018-05-31

Abstract

A hydrophobic, anti-wicking non-woven material including a plurality of hydrophobic PET fibers and a plurality of bonding fibers. The hydrophobic PET fibers and bonding fibers are blended together and needle punched to form a single layer non-woven material having a thickness generally between about 1.3 - 40 millimeters. Optionally, the material comprises one or more fire retardant materials.

Description

HYDROPHOBIC, ANTI-WICKING NON-WOVEN MATERIAL

FOR LINER OR SHIELD

Cross-Reference to Related Application

[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 62/425,517 filed November 22, 2016, the entirety of which is hereby incorporated herein by reference for all purposes.

Technical Field

[0002] The present invention relates generally to the field of non-woven materials, and more particularly to a hydrophobic, anti-wicking non-woven material for use in automotive applications.

Background

[0003] Non-woven materials are used for various purposes, including without limitation in automotive applications. Needs exist for improved non-woven materials suitable for use as thermal and acoustic insulators, weatherproof! ng barriers and underbody shields, and the like. Demands on non-woven fabrics for automotive continue to increase, as engines are running hotter and non-wovens are used in increasingly more exterior facing applications. Accordingly, it can be seen that needs exist for improved non-woven materials for use in automotive applications. It is to the provision of improved non-woven materials meeting these and other needs that the present invention is primarily directed.

Summary

[0004] In example embodiments, the present invention provides a hydrophobic, anti- wicking non-woven material. In example forms, the material generally includes a blend of hydrophobic PET fibers and bonding fibers, which are needle punched to form a single layer non-woven material. In example forms, the material is moldable and can be used as an automotive wheel house liner, outer wheel arch liner, an underbody shield or liner, engine compartment barriers, etc.

[0005] In one aspect, the invention relates to a hydrophobic, anti-wicking non-woven material including a plurality of hydrophobic polyethylene terephthalate fibers and a plurality of bonding fibers carded and needle punched together to form a single-layer matting. The matting defines a first side surface and a second side surface generally opposite the first side surface, end surfaces, and a thickness is defined between the first and second side surfaces. In example embodiments, the first and second side surfaces and end surfaces provide an impenetrable barrier to water, oil or any other liquids or other materials.

[0006] In another aspect, the invention relates to an automotive component formed from a single layer non-woven material including a plurality of hydrophobic polyethylene terephthalate fibers carded and needle punched together to form a single layer matting. The matting includes a first side surface and a second side surface, the second side surface generally opposite the first side surface, and a thickness defined between the first and second side surfaces. In example embodiments, the first and second side surfaces are hydrophobic and anti-wicking such that water, oil and/or other liquids or other materials are incapable of being absorbed in the single layer matting from either of the first or second side surfaces.

[0007] In yet another aspect, the invention relates to a method of making a hydrophobic and anti-wicking non-woven material. The method includes providing a plurality of fibers; blending the fibers; carding the fibers to produce a parallel fibrous web; and needle punching the parallel fibrous web.

[0008] According to example embodiments, the fibers comprise a mixture of binding fibers and hydrophobic PET fibers. According to example embodiments, at least the hydrophobic PET fibers are coated with a hydrophobic coating. According to some example embodiments, the fibers are optionally coated with a fluorocarbon chemical finish. Preferably, the needle punched material is hydrophobic, anti-wicking, oil repellent and flame retardant. According to some example embodiments, the method further includes molding the needle punched material, for example, to form a wheel house liner, underbody shield and/or engine compartment shield. In example embodiments, the single layer matting can be molded by pressure and heat-forming to form a component for attachment to a vehicle. Optionally, the needle punched material can be molded to form other desired components. According to some example embodiments, the method further includes coating the hydrophobic polyethylene terephthalate fibers with a flame retardant material.

[0009] These and other aspects, features and advantages of the invention will be understood with reference to the drawing figures and detailed description herein, and will be realized by means of the various elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following brief description of the drawings and detailed description of example embodiments are explanatory of example embodiments of the invention, and are not restrictive of the invention, as claimed.

Brief Description of the Drawings

[0010] Figure 1 is a cross section of a hydrophobic, anti-wicking non-woven material according to an example embodiment of the present invention.

[0011] Figure 2 shows the molded hydrophobic, anti-wicking non-woven material of Figure 1 , wherein the material is molded and being used as a wheel house liner according to an example embodiment of the present invention.

[0012] Figure 3 shows the molded hydrophobic, anti-wicking non-woven material of Figure 1 , wherein the material is molded and being used as an underbody shield according to an example embodiment of the present invention. [0013] Figure 4 shows the hydrophobic, anti-wicking non-woven material of Figure 1 , wherein the material is molded and being used as an engine compartment shield or barrier according to an example embodiment of the present invention.

Detailed Description of Example Embodiments

[0014] The present invention may be understood more readily by reference to the following detailed description of example embodiments taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this invention is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention. Any and all patents and other publications identified in this specification are incorporated by reference as though fully set forth herein.

[0015] Also, as used in the specification including the appended claims, the singular forms "a," "an," and "the" include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from "about" or "approximately" one particular value and/or to "about" or "approximately" another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another embodiment.

[0016] With reference now to the drawing figures, wherein like reference numbers represent corresponding parts throughout the several views, Figure 1 shows an anti- wicking, hydrophobic non-woven material 10 according to an example embodiment of the present invention. In example embodiments, the material 10 comprises a single layer of cross or inline laid fibers, which are bonded together with a needle punch process. In example embodiments, the fibers comprise a blend of bonding fibers and hydrophobic polyethylene terephthalate (PET) fibers. According to example embodiments, a single layer needle punched matting is formed by needle punching the fibers. According to some example embodiments, the single layer matting can be molded, for example, by pressure and heat-forming to form a desirable component, for example, an automotive component as will be described below.

[0017] In example embodiments, as depicted in Figure 1 , the material 10 comprises a single layer of needle punched fibers comprising a thickness T1 . In example embodiments, the thickness T1 is generally between about 50 - 1580 mils (e.g., about 1.3 - 40 millimeters). For example, according to one example embodiment, the material comprises a thickness T1 of about 7.62 millimeters. Optionally, other thicknesses, either less than 1.3 millimeters or more than 40 millimeters, are within the scope of the present invention.

[0018] In example embodiments, the material 10 generally comprises a first side surface 20, a second side surface 30 generally opposite the first side surface 20, and cutting ends 40. Preferably, the first and second side surfaces 20, 30 and ends 40 are configured such that a hydrophobic barrier is provided thereon, for example, such that water, oil, and/or other liquids or materials are incapable of adhering thereto and/or or being absorbed by the material 10. For example, as shown in Figure 1 , water droplets W are restricted from being absorbed by the surfaces 20, 30, for example, whereby they generally bead at the surfaces and are incapable of remaining engaged therewith. In a similar manner, water droplets W or other generally polar materials or substances are restricted from being absorbed by the ends 40. Preferably, the material 10 is configured such that the plurality of needle punched fibers define a single hydrophobic and anti-wicking layer (and comprising first and second side surfaces), for example, which is impenetrable by water, oil, and/or other liquids or materials. Preferably, both the first and second side surfaces 20, 30 (and ends 40) act as a barrier to prevent any such liquids, oils or other materials from being retained thereon (or for example, from being absorbed into the material 10). According to example embodiments, the first and second side surfaces 20, 30 and ends 40 each define nonpolar boundaries to prevent the absorption of one or more generally polar molecules including water, oil or other liquids or materials. Thus, according to example embodiments, the entirety of the material 10 (e.g., all sides and ends thereof) preferably comprise nonpolar boundaries or are at least substantially hydrophobic to prevent the absorption of one or more generally polar molecules including water, oil or other liquids or materials.

[0019] According to example embodiments, the material 10 comprises a mixture of bonding fibers and hydrophobic PET fibers, for example, wherein the bonding fibers make up between about 10-50% of the material 10. In example embodiments, the bonding fiber can be formed from polyethylene (PE), polypropylene (PP), 1 10° -210° Celsius Bico (bi- component) PE, PP or PET, modified PET, undrawn PET, or combinations thereof. Optionally, other materials can be provided for being utilized as the bonding fiber. For example, according to one example embodiment, the material mixture comprises between about 10-20% bonding fibers and between about 80-90% hydrophobic PET fibers. According to another example embodiment, the material mixture comprises between about 20-30% bonding fibers and between about 70-80% hydrophobic PET fibers. According to another example embodiment, the material mixture comprises between about 30-40% bonding fibers and between about 60-70% hydrophobic PET fibers. According to another example embodiment, the material mixture comprises between about 40-50% bonding fibers and between about 50-60% hydrophobic PET fibers. Optionally, the mixture of the fibers (e.g., bonding fibers and hydrophobic PET fibers) can be chosen as desired.

[0020] In example embodiments, the hydrophobic PET fiber comprises a hydrophobic finish thereon, for example, which prevents water or other substances from being absorbed within the PET fiber. In example embodiments, a fluorocarbon chemical finish can be applied to the hydrophobic PET fiber, for example, to provide a "water and oil" repellent. Optionally, according to one example embodiment, the fluorocarbon chemical finish can be applied to the material 10 once constructed, for example, rather than being applied to the hydrophobic PET fiber prior to being blended and needle punched with the bonding fibers. Optionally, the hydrophobic PET fibers comprise only the fluorocarbon chemical finish, which can be applied prior to blending and needle punching with the bonding fibers. Further optionally, the bonding fibers can comprise a hydrophobic finish, for example, to further ensure the material 10 exhibits anti-wicking and water resistant properties. In example embodiments, the material 10 generally comprises a weight range of between about 70 - 2000 GSM, and the hydrophobic PET fiber comprises a denier of between about 1.3 - 10 and a cutting length of between about 20 - 150 millimeters. Optionally, the weight range, denier and cutting length can be chosen as desired.

[0021] According to some example embodiments, the material 10 can further comprise a flame retardant (FR) function, for example, such that the material 10 is both hydrophobic and substantially resistant (if not entirely resistant) to absorption of generally polar substances (e.g., water, oil or other liquids or materials) and substantially resists burning and can withstand heat (e.g., withstanding high temperatures without burning or deforming). According to one example embodiment, a flame retardant solution can be mixed together in a masterbatch, for example, which is further combined with the hydrophobic PET fibers (and optional bonding fibers) prior to carding and needle punching. According to some example embodiments, the hydrophobic PET fibers can further comprise a flame retardant finish thereon, for example, such that the hydrophobic PET fibers (and optional bonding fibers) can be carded and needle punched, thereby resulting in a single layer matting that is hydrophobic, anti-wicking and flame retardant. According to yet another example embodiment, the material 10, after being carded and needle punched (including the hydrophobic PET fibers and optional bonding fibers), can be coated or saturated with a flame retardant material. In alternate example embodiments, the material 10 is otherwise processed or treated to be hydrophobic, anti-wicking and fire retardant.

[0022] In example embodiments, the present material 10 can be used for various purposes. According to one example embodiment, the material 10 is moldable and can be used as an automotive wheel house liner, outer wheel arch liner, an underbody shield or liner, engine compartment barriers, etc. In preferred example embodiments, the material 10 preferably resist water (e.g., water resistant) or other materials, liquids, etc. from being absorbed within the material 10. In example embodiments, the material 10 preferably comprises anti-wicking properties, for example, such that substantially all substances, liquids, etc. exposed to the material (or coming into contact with the material 10) are not absorbed within the material 10. Rather, due to the hydrophobic aspect of the material 10, generally all, if not substantially all substances, liquids, ice, oil, etc. that are exposed and in contact (at some point) with the material 10 do not get absorbed by the material 10. In some example embodiments, due to the anti-wicking and hydrophobic properties of the material 10, the material 10 does not sag or become heavily weighted as it does not absorb water or other substances, thereby preventing the material from deforming or otherwise changing shape due to excess weight caused by absorption. Preferably, the anti-wicking and water resistant properties prevent excess weight from being absorbed by the automotive components, thereby keeping the vehicle less weighted and more efficient.

[0023] As depicted in Figure 2, a wheel house liner 100 comprises a molded liner member 1 10 that is generally sized and shaped to line the wheel house or wheel well of the vehicle V. In example embodiments, the liner member 1 10 comprises a single layer of needle punched fibers, for example, which a preferably hydrophobic and anti-wicking. In example embodiments, the liner member 1 10 is generally molded to form the wheel well of the vehicle, for example, wherein both the first side surface 120 and the second side surface 130 are entirely hydrophobic and anti-wicking such that any water, oil and/or other liquids or other materials are incapable of penetrating or being absorbed into the material. For example, any water, oil, or other liquids are materials that are exposed to the front side surface 120 and/or the second side surface 130 are incapable of being absorbed thereby, thereby preventing the wheel house liner 100 from sagging or becoming heavily weighted, thereby preventing the material from deforming or otherwise changing shape due to excess weight caused by absorption. Furthermore, as similarly described with respect to the first and second side surfaces 120, 130, the cutting ends thereof (see 40 in Figure 1 ) are also entirely hydrophobic and anti-wicking such that any water, oil, or other liquids are materials prevented from being absorbed in the material or liner member 1 10. Preferably, the anti- wicking and water resistant properties prevent excess weight from being absorbed by the automotive components, thereby keeping the vehicle less weighted and more efficient.

[0024] According to additional example embodiments, for example, as depicted in Figures 3-4, the hydrophobic and anti-wicking material can optionally be used as an underbody shield or engine compartment shield or barrier. Figure 3 shows an underbody shield 200 and Figure 4 shows an engine compartment shield 300. The underbody shield 200 comprises a molded shield member 210, which is generally sized and shaped for mounting to an underside portion of a vehicle V. In example embodiments, the molded shield member 210 comprises the single layer of needle punched fibers, and is generally at least partially rigid. In example embodiments, the molded shield member 210 comprises a first side surface 220 and a second side surface 230. As similarly described above, preferably both the first and second side surfaces 220, 230 (and ends thereof) are entirely hydrophobic and anti-wicking such that water, oil, and/or other liquids or materials are incapable of being absorbed in the shield 210. According to some example embodiments, the underbody shield 200 is generally mounted to a portion of the underside of the vehicle's frame, for example, with one or more fasteners.

[0025] Figure 4 shows the engine compartment shield 300, for example, for attachment to the underside of a vehicle's V hood H such that a barrier is provided between the underside of the hood H and the vehicle's engine. In example embodiments, the shield 300 preferably comprises a molded shield member 310 comprising a single layer of the needle punched fibers. In example embodiments, the molded shield member 310 comprises a first side surface 320 and a second side surface 330 (and ends 40 - see Figure 1 ). As similarly described above, preferably both the first and second side surfaces 220, 230 (and ends thereof) are entirely hydrophobic and anti-wicking such that water, oil, and/or other liquids or materials are incapable of being absorbed in the shield 310, for example, from either side surface 320, 330. According to one example form, one or more fasteners, clips, couplings, or other interengagement members are provided for fastening the shield 300 to the hood H. According to one example embodiment, the shield 300 is heat resistant to at least 1 10° C, 180° C, or about 220° C. According to another example embodiment, the shield 300 can be configured for acting as a shield over one or more exhaust components of a vehicle.

[0026] According to another example embodiment, the present invention relates to a method of making a hydrophobic and anti-wicking non-woven material. According to example embodiments, the method includes providing a plurality of fibers; blending the fibers; carding the fibers to produce a parallel fibrous web; and needle punching the parallel fibrous web. According to example embodiments, the fibers comprise a mixture of binding fibers and hydrophobic PET fibers. According to example embodiments, at least the hydrophobic PET fibers are coated with a hydrophobic coating. According to some example embodiments, the fibers are optionally coated with a fluorocarbon chemical finish. According to yet another example embodiment, the fibers can be coated with one or more additives, chemicals, blends, or other powder or generally liquid substances such that the material becomes fire retardant after the application thereof. Further optional, the flame retardant material or substance is provided in the masterbatch, or can be applied to the carded and needle punched material after the manufacture thereof. In example embodiments, the needle punched material is hydrophobic, anti-wicking, oil repellent and flame retardant. According to some example embodiments, the method further includes molding the needle punched material, for example, to form a wheel house liner, underbody shield and/or engine compartment shield. Optionally, the needle punched material can be molded to form other desired components. [0027] While the invention has been described with reference to example embodiments, it will be understood by those skilled in the art that a variety of modifications, additions and deletions are within the scope of the invention, as defined by the following claims.

Claims

What is Claimed is:

1 . A hydrophobic, anti-wicking non-woven material comprising a plurality of hydrophobic polyethylene terephthalate fibers and a plurality of bonding fibers carded and needle punched together to form a single-layer matting, the matting comprising a first side surface and a second side surface generally opposite the first side surface, end surfaces, and a thickness defined between the first and second side surfaces, wherein the first and second side surfaces and end surfaces provide an impenetrable barrier to water, oil or any other liquids or other materials.

2. The hydrophobic, anti-wicking non-woven material of Claim 1 , wherein the thickness is between about 1 .3 - 40 millimeters.

3. The hydrophobic, anti-wicking non-woven material of Claim 2, wherein the thickness is about 7.62 millimeters.

4. The hydrophobic, anti-wicking non-woven material of Claim 1 , wherein the material comprises a weight range of between about 70 - 2000 grams per square meter.

5. The hydrophobic, anti-wicking non-woven material of Claim 1 , wherein the hydrophobic polyethylene terephthalate fiber comprises a denier of between about 1 .3 - 10 and a cutting length of between about 20 - 150 millimeters.

6. The hydrophobic, anti-wicking non-woven material of Claim 1 , further comprising a flame retardant material applied to the fibers.

7. The hydrophobic, anti-wicking non-woven material of Claim 1 , wherein the material can be molded to form a wheel house liner, underbody shield or engine compartment shield.

8. The hydrophobic, anti-wicking non-woven material of Claim 1 , wherein the bonding fiber can be formed from polyethylene, polypropylene, 1 10° -210° Celsius bi-component polyethylene, polypropylene or polyethylene terephthalate, modified polyethylene terephthalate, undrawn polyethylene terephthalate, or combinations thereof.

9. The hydrophobic, anti-wicking non-woven material of Claim 1 , wherein the first and second side surfaces and end surfaces define nonpolar boundaries to prevent absorption of one or more polar molecules including water, oil or other liquids or materials.

10. An automotive component formed from a single layer non-woven material comprising: a plurality of hydrophobic polyethylene terephthalate fibers carded and needle punched together to form a single layer matting, the matting comprising a first side surface and a second side surface, the second side surface generally opposite the first side surface, and a thickness defined between the first and second side surfaces, wherein the first and second side surfaces are hydrophobic and anti-wicking such that water, oil and/or other liquids or other materials are incapable of being absorbed in the single layer matting from either of the first or second side surfaces.

1 1. The automotive component of Claim 10, wherein the thickness is between about 1 .3 - 40 millimeters.

12. The automotive component of Claim 10, wherein the thickness is about 7.62 millimeters.

13. The automotive component of Claim 10, wherein the single layer non-woven material comprises a weight range of between about 70 - 2000 grams per square meter.

14. The automotive component of Claim 10, wherein the hydrophobic polyethylene terephthalate fibers comprise a denier of between about 1 .3 - 10 and a cutting length of between about 20 - 150 millimeters.

15. The automotive component of Claim 10, wherein the hydrophobic polyethylene terephthalate fibers further comprise a fluorocarbon chemical finish applied thereon.

16. The automotive component of Claim 10, wherein the single layer non-woven material can be molded by pressure and heat-forming to form a component for attachment to a vehicle.

17. The automotive component of Claim 16, wherein the component comprises a wheel house liner, an underbody shield, or an engine compartment or exhaust component heat shield.

18. The automotive component of Claim 16, wherein the molded component comprises fire-resistant properties, and wherein the first and second side surfaces provide an impenetrable barrier to water, oil or any other liquids or other materials.

19. The automotive component of Claim 10, further comprising one or more bonding fibers blended together with the hydrophobic polyethylene terephthalate fibers, wherein the bonding fiber can be formed from polyethylene, polypropylene, 1 10° -210° Celsius bi- component polyethylene, polypropylene or polyethylene terephthalate, modified polyethylene terephthalate, undrawn polyethylene terephthalate, or combinations thereof.

20. A method of making a hydrophobic and anti-wicking non-woven material comprising: providing a plurality of fibers; blending the fibers; carding the fibers to produce a parallel fibrous web; and needle punching the parallel fibrous web to form a single layer matting.

21 . The method of Claim 20, wherein the fibers comprise a mixture of binding fibers and hydrophobic polyethylene terephthalate fibers.

22. The method of Claim 21 , wherein at least the hydrophobic polyethylene terephthalate fibers are coated with a hydrophobic coating.

23. The method of Claim 22, further comprising coating the hydrophobic polyethylene terephthalate fibers with a fluorocarbon chemical finish.

24. The method of Claim 20, wherein the single layer matting can be molded by pressure and heat-forming to form a component for attachment to a vehicle.

25. The method of Claim 20, further comprising coating the hydrophobic polyethylene terephthalate fibers with a flame retardant material.