DE202018006365U1 - Nonwoven molded part - Google Patents

Abstract

Fibrous nonwoven molded part comprising at least one thermally deformed nonwoven formed from A) structuring polyethylene terephthalate fibers; B) matrix-forming polyethylene terephthalate-containing bicomponent binding fibers which have a semicrystalline shell material with a melting range of 90 to 175 ° C; C) optionally matrix-forming polyethylene terephthalate-containing bicomponent Binding fibers which have a semicrystalline covering material and are different from the bicomponent binding fibers B); D) optionally additives.

Description

The invention is directed to a nonwoven molded part, in particular for covering vehicle floor areas or for wheel arch linings of motor vehicles, comprising at least one thermally deformed nonwoven fabric formed from structuring polyethylene terephthalate fibers and matrix-forming polyethylene terephthalate-containing bicomponent binding fibers. The invention also relates to the use of such a nonwoven molded part.

Such fiber (nonwoven) molded parts which are used in the automotive industry in motor vehicles are composite materials which are / are formed from structuring fiber components and matrix-forming fiber components. As a rule, these fibers are laid in the form of a nonwoven and then brought into the desired shape, in particular pressed, in an optionally multi-step thermal shaping process.

Such nonwoven molded parts are used, for example, as wheel arch liners, underbody panels, trunk side walls and parcel shelves in motor vehicles.

1. A) strukturgebenden Polyethylenterephthalat-Fasern;
2. B) matrixbildenden Polyethylenterephthalat-haltigen Bikomponenten-Bindefasern, welche ein semikristallines Hüllmaterial mit einem Schmelzbereich von 90 bis 175 °C aufweisen;
3. C) gegebenenfalls matrixbildenden Polyethylenterephthalat-haltigen Bikomponenten-Bindefasern, welche ein semikristallines Hüllmaterial aufweisen und von den Bikomponenten-Bindefasern B) verschieden sind; und
4. D) gegebenenfalls Additiven; bereitgestellt wird.

Dieses erfindungsgemäße Faservliesformteil ist so beschaffen, dass es gemäß der vorliegenden Erfindung folgende Herstellungsschritte benötigt:

1. i) Legen mindestens eines Faservlieses mittels eines Krempel-Kreuzleger-Verfahrens oder eines aerodynamischen Vliesbildungsverfahrens,
2. ii) anschließendes Vernadeln des oder der derart gebildete Faservliese(s) sowie
3. iii) Zuschneiden,
4. iv) Erhitzen und
5. v) thermisches Verformen des oder der Faservliese(s) zu dem gewünschten Faservliesformteil.

Such wheel arch liners formed from fiber (fleece) molded parts are, for example, from the DE 20 2005 015 164 U1 known. However, the wheel arch liners described there have a low heat resistance of approx. 90 ° C, and they also have a relatively high water absorption and consequently have a delayed water release. They also have a relatively easy flammability.
The invention is therefore based on the object of providing a fiber (nonwoven) molded part which overcomes the disadvantages described above.
The inventors of the present invention have achieved this object by forming at least one thermally deformed nonwoven fabric

1. A) structuring polyethylene terephthalate fibers;
2. B) matrix-forming polyethylene terephthalate-containing bicomponent binding fibers which have a semicrystalline covering material with a melting range from 90 to 175 ° C .;
3. C) optionally matrix-forming polyethylene terephthalate-containing bicomponent binding fibers which have a semicrystalline covering material and are different from the bicomponent binding fibers B); and
4. D) optionally additives; provided.

This nonwoven molded article according to the invention is designed in such a way that it requires the following production steps according to the present invention:

1. i) laying at least one nonwoven fabric by means of a carding stacker or an aerodynamic nonwoven formation process,
2. ii) subsequent needling of the fiber fleece (s) thus formed and
3. iii) cropping,
4. iv) heating and
5. v) thermally deforming the nonwoven fabric (s) into the desired nonwoven molded part.

1. 1. Faservliesformteil, insbesondere zur Abdeckung von Fahrzeugbodenbereichen oder für Radlaufschalen von Kraftfahrzeugen, umfassend oder bestehend aus mindestens einem thermisch verformten Faservlies gebildet aus
   1. A) strukturgebenden Polyethylenterephthalat-Fasern;
   2. B) matrixbildenden Polyethylenterephthalat-haltigen Bikomponenten-Bindefasern, welche ein semikristallines Hüllmaterial mit einem Schmelzbereich von 90 bis 175 °C aufweisen;
   3. C) gegebenenfalls matrixbildenden Polyethylenterephthalat-haltigen Bikomponenten-Bindefasern, welche ein semikristallines Hüllmaterial aufweisen und von den Bikomponenten-Bindefasern B) verschieden sind;
   4. D) gegebenenfalls Additiven.
2. 2. Faservliesformteil nach Aspekt 1, dadurch gekennzeichnet, dass die Polyethylenterephthalat-Fasern A) einen Schmelzpunkt von 220 bis 265 °C, bevorzugt 240 bis 260 °C, stärker bevorzugt 242 bis 250 °C aufweisen und/oder eine Feinheit von 5,0 bis 9,50 dtex, bevorzugt 5,5 bis 9,0 dtex, besonders bevorzugt 5,5 bis 8,5 dtex, gemessen nach DIN EN ISO 1973:1995-12 aufweisen und/oder eine Faserlänge von 45 bis 75 mm, bevorzugt 50 bis 70 mm, besonders bevorzugt 52 bis 68 mm aufweisen und/oder eine Einkräuselung von 1,5 bis 10,0 Bögen/cm, bevorzugt eine Einkräuselung von 2,5 bis 5,5 Bögen/cm, besonders bevorzugt eine Einkräuselung von 2,7 bis 3,7 Bögen/cm aufweisen und/oder eine Reißfestigkeit von 2,0 bis 5,0 cN/dtex, bevorzugt eine Reißfestigkeit von 2,5 bis 4,7 cN/dtex, besonders bevorzugt eine Reißfestigkeit von 2,7 bis 4,0 cN/dtex, gemessen nach DIN EN ISO 5079:1996-02 aufweisen.
3. 3. Faservliesformteil nach Aspekt 1 oder 2, dadurch gekennzeichnet, dass die Polyethylenterephthalat-haltigen Bikomponenten-Bindefasern B) eine Feinheit von 4,0 bis 10,0 dtex, bevorzugt 5,2 bis 9,5 dtex, besonders bevorzugt 5,3 bis 8,5 dtex, gemessen nach DIN EN ISO 1973:1995-12 aufweisen und/oder eine Faserlänge von 45 bis 70 mm, bevorzugt 50 bis 60 mm, besonders bevorzugt 52 bis 55 mm, aufweisen und/oder eine Einkräuselung von 2,0 bis 10,0 Bögen/cm, bevorzugt eine Einkräuselung von 3,0 bis 5,0 Bögen/cm aufweisen und/oder eine Reißfestigkeit von 1,0 bis 4,0 cN/dtex, bevorzugt eine Reißfestigkeit von 1,5 bis 3,5 cN/dtex, besonders bevorzugt eine Reißfestigkeit von 1,8 bis 3,25 cN/dtex, gemessen nach DIN EN ISO 5079:1996-02 aufweisen.
4. 4. Faservliesformteil nach einem der vorhergehenden Aspekte, dadurch gekennzeichnet, dass die Polyethylenterephthalat-haltigen Bikomponenten-Bindefasern B) einen Kern aus Polyethylenterephthalat oder Polyester aufweisen, insbesondere mit einem Schmelzpunkt von 220 bis 265 °C, bevorzugt 240 bis 260 °C, stärker bevorzugt 250 bis 255 °C und/oder die Polyethylenterephthalat-haltigen Bikomponenten-Bindefasern B) ein Hüllmaterial mit einem Schmelzbereich von 90 bis 175 °C, bevorzugt 100 bis 160 °C, stärker bevorzugt 110 bis 155 °C aufweisen, insbesondere ist in dem Bereich mindestens ein Schmelzpeak, insbesondere bevorzugt zwei Schmelzpeaks, vorhanden; am stärksten bevorzugt befindet sich ein Schmelzpeak, der besonders bevorzugt ein Schmelzpunkt ist, bei 150 bis 160 °C, insbesondere 155°C.
5. 5. Faservliesformteil nach einem der vorhergehenden Aspekte, dadurch gekennzeichnet, dass der Anteil des Kerns in den Polyethylenterephthalat-haltigen Bikomponenten-Bindefasern B) und/oder C) jeweils 50 bis 70 Gew.- %, bevorzugt 60 Gew.-% und der Anteil des Mantels jeweils 30 bis 50 Gew.- %, bevorzugt 40 Gew.-%, bezogen auf das Gesamtgewicht der Faser beträgt.
6. 6. Faservliesformteil nach einem der vorhergehenden Aspekte, dadurch gekennzeichnet, dass das Faservliesformteil ferner mindestens eine polare Verbindung enthält die oleophob wirkt, insbesondere eine fluorierte oder perfluorierte Kohlenwasserstoffverbindung mit bevorzugt 3 bis 15 Kohlenstoffatomen, stärker bevorzugt 4 bis 14 Kohlenstoffatomen, wobei die polare Verbindung bevorzugt als Bestandteil der eingesetzten strukturbildenden Polyethylenterephthalat-Fasern A) und/oder der eingesetzten matrixbildenden, Polyethylenterephthalat-haltigen Bikomponenten-Bindefasern B) und/oder C) in das Faservliesformteil eingebracht werden kann, besonders bevorzugt durch die strukturbildenden Polyethylenterephthalat-Fasern A).
7. 7. Faservliesformteil nach einem der vorhergehenden Aspekte, dadurch gekennzeichnet, dass die Polyethylenterephthalat-haltigen Bikomponenten-Bindefasern C) einen Kern aus Polyethylenterephthalat oder Polyester aufweisen, insbesondere mit einem Schmelzpunkt von 220 bis 265 °C, bevorzugt 240 bis 260 °C, stärker bevorzugt 250 bis 255 °C, gemessen mittels DSC und/oder die Polyethylenterephthalat-haltigen Bikomponenten-Bindefasern C) ein Hüllmaterial mit einem Schmelzbereich von 95 bis 200 °C aufweisen, insbesondere ist in dem Bereich mindestens ein Schmelzpeak, insbesondere bevorzugt ist lediglich ein Schmelzpeak, vorhanden; am stärksten bevorzugt befindet sich ein Schmelzpeak bei 175 bis 200 °C, insbesondere 180°C bis 185 °C, insbesondere bevorzugt 180°C und/oder eine Feinheit von 4,0 bis 10,0 dtex, bevorzugt 4,2 bis 9,5 dtex, besonders bevorzugt 4,3 bis 8,5 dtex, gemessen nach DIN EN ISO 1973:1995-12 aufweisen.
8. 8. Faservliesformteil nach einem der vorhergehenden Aspekte, dadurch gekennzeichnet, dass die Fasern in folgenden Gewichtsanteilen vorliegen
   1. A) 50 bis 70 Gew.-%, insbesondere 60 Gew.-%;
   2. B) 10 bis 40 Gew.-%, insbesondere 20 Gew.-%;
   3. C) 0 bis 30 Gew.-%, insbesondere 20 Gew.-%;
   bezogen auf das Gesamtgewicht der Komponenten A) bis C).
9. 9. Faservliesformteil nach einem der vorhergehenden Aspekte, dadurch gekennzeichnet, dass mehrere Faservliese zur Ausbildung eines mehrschichtigen Faservliesformteils in Stapellage übereinanderliegend angeordnet sind.
10. 10. Faservliesformteil nach einem der vorhergehenden Aspekte, dadurch gekennzeichnet, dass es eine textile Radlaufschale ausbildet.
11. 11. Verfahren zur Herstellung eines Faservliesformteils nach einem der Aspekte 1 bis 10, umfassend die Schritte:
    1. i) Legen mindestens eines, vorzugsweise kreuzgelegten, Faservlieses mittels eines Krempel-Kreuzleger-Verfahrens oder eines aerodynamischen Vliesbildungsverfahrens,
    2. ii) anschließendes Vernadeln des oder der derart gebildete Faservliese(s) sowie
    3. iii) Zuschneiden,
    4. iv) Erhitzen und
    5. v) thermisches, insbesondere thermoplastisches, Verformen des oder der Faservliese(s) zu dem gewünschten Faservliesformteil.
12. 12. Verfahren nach Aspekt 11, dadurch gekennzeichnet, dass das mindestens eine, vorzugsweise kreuzgelegte, Faservlies aus 10 bis 45 Einzelflorlagen, die vorzugsweise jeweils ein Flächengewicht von 35 bis 60 g/m² aufweisen, besteht.
13. 13. Verfahren nach Aspekt 11 oder 12, dadurch gekennzeichnet, dass in Schritt iv) auf eine Temperatur von 200 bis 240 °C, bevorzugt 210 bis 230 °C, insbesondere 220 °C, erhitzt wird, besonders bevorzugt bei einer Aufheizzeit von 40 bis 80 Sekunden.
14. 14. Verfahren nach einem der Aspekte 11 bis 13, dadurch gekennzeichnet, dass das Verformen in Schritt v) bei einer Temperatur von 7 bis 15 °C und bevorzugt bei einer Aufheizzeit von 30 bis 70 Sekunden stattfindet.
15. 15. Verwendung des Faservliesformteils nach einem der Aspekte 1 bis 10 als Radlaufschale, Unterbodenverkleidung, Kofferraumseitenwand oder Hutablage.

The object is also achieved by using the nonwoven molded part according to the present invention as a wheel arch liner, underbody paneling, trunk side wall or parcel shelf.
In particular, the present invention relates to:

1. 1. Nonwoven molded part, in particular for covering vehicle floor areas or for wheel arch liners of motor vehicles, comprising or consisting of at least one thermally deformed nonwoven formed from
   1. A) structuring polyethylene terephthalate fibers;
   2. B) matrix-forming polyethylene terephthalate-containing bicomponent binding fibers which have a semicrystalline covering material with a melting range from 90 to 175 ° C .;
   3. C) optionally matrix-forming polyethylene terephthalate-containing bicomponent binding fibers which have a semicrystalline covering material and are different from the bicomponent binding fibers B);
   4. D) optionally additives.
2. 2. Nonwoven molded article according to aspect 1, characterized in that the polyethylene terephthalate fibers A) have a melting point of 220 to 265 ° C, preferably 240 to 260 ° C, more preferably 242 to 250 ° C and / or a fineness of 5.0 up to 9.50 dtex, preferably 5.5 to 9.0 dtex, particularly preferably 5.5 to 8.5 dtex, measured according to DIN EN ISO 1973: 1995-12 have and / or a fiber length of 45 to 75 mm, preferably 50 to 70 mm, particularly preferably 52 to 68 mm and / or a crimp of 1.5 to 10.0 sheets / cm, preferably a crimp of 2.5 to 5.5 sheets / cm, particularly preferably have a crimp of 2.7 to 3.7 sheets / cm and / or a tear strength of 2.0 to 5.0 cN / dtex, preferably a tear strength of 2.5 to 4, 7 cN / dtex, particularly preferably a tear strength of 2.7 to 4.0 cN / dtex, measured according to DIN EN ISO 5079: 1996-02 exhibit.
3. 3. Nonwoven molded article according to aspect 1 or 2, characterized in that the bicomponent binding fibers B) containing polyethylene terephthalate a fineness of 4.0 to 10.0 dtex, preferably 5.2 to 9.5 dtex, particularly preferably 5.3 to 8.5 dtex, measured according to DIN EN ISO 1973: 1995-12 have and / or a fiber length of 45 to 70 mm, preferably 50 to 60 mm, particularly preferably 52 to 55 mm, and / or a crimp of 2.0 to 10.0 sheets / cm, preferably a crimp of 3.0 have up to 5.0 sheets / cm and / or a tear strength of 1.0 to 4.0 cN / dtex, preferably a tear strength of 1.5 to 3.5 cN / dtex, particularly preferably a tear strength of 1.8 to 3 , 25 cN / dtex, measured according to DIN EN ISO 5079: 1996-02 exhibit.
4. 4. Nonwoven molded part according to one of the preceding aspects, characterized in that the polyethylene terephthalate-containing bicomponent binding fibers B) have a core of polyethylene terephthalate or polyester, in particular with a melting point of 220 to 265 ° C, preferably 240 to 260 ° C, more preferably 250 to 255 ° C and / or the polyethylene terephthalate-containing bicomponent binder fibers B) have a covering material with a melting range of 90 to 175 ° C, preferably 100 to 160 ° C, more preferably 110 to 155 ° C, in particular in the range at least one melting peak, particularly preferably two melting peaks, is present; most preferably a melting peak, which is particularly preferably a melting point, is at 150 to 160 ° C., in particular 155 ° C.
5. 5. Nonwoven molded article according to one of the preceding aspects, characterized in that the proportion of the core in the bicomponent binder fibers B) and / or C) containing polyethylene terephthalate in each case 50 to 70% by weight, preferably 60% by weight and the proportion of the jacket is 30 to 50% by weight, preferably 40% by weight, based on the total weight of the fiber.
6. 6. Nonwoven molded part according to one of the preceding aspects, characterized in that the nonwoven molded part further contains at least one polar compound which acts oleophobically, in particular a fluorinated or perfluorinated hydrocarbon compound having preferably 3 to 15 carbon atoms, more preferably 4 to 14 carbon atoms, the polar compound being preferred as part of the structure-forming polyethylene terephthalate fibers A) and / or the matrix-forming, polyethylene terephthalate-containing bicomponent binder fibers B) and / or C) used, can be introduced into the nonwoven molded part, particularly preferably through the structure-forming polyethylene terephthalate fibers A).
7. 7. Nonwoven molded article according to one of the preceding aspects, characterized in that the polyethylene terephthalate-containing bicomponent binding fibers C) have a core made of polyethylene terephthalate or polyester, in particular with a melting point of 220 to 265 ° C, preferably 240 to 260 ° C, more preferably 250 to 255 ° C, measured by means of DSC and / or the polyethylene terephthalate-containing bicomponent binding fibers C) have a covering material with a melting range of 95 to 200 ° C, in particular there is at least one melting peak in the range, particularly preferred is only one melting peak, available; most preferably there is a melting peak at 175 to 200 ° C., in particular 180 ° C. to 185 ° C., particularly preferably 180 ° C. and / or a fineness of 4.0 to 10.0 dtex, preferably 4.2 to 9, 5 dtex, particularly preferably 4.3 to 8.5 dtex, measured according to DIN EN ISO 1973: 1995-12 exhibit.
8. 8. Nonwoven molded part according to one of the preceding aspects, characterized in that the fibers are present in the following proportions by weight
   1. A) 50 to 70 wt .-%, in particular 60 wt .-%;
   2. B) 10 to 40% by weight, in particular 20% by weight;
   3. C) 0 to 30% by weight, in particular 20% by weight;
   based on the total weight of components A) to C).
9. 9. Nonwoven molded part according to one of the preceding aspects, characterized in that a plurality of nonwoven fabrics are arranged one above the other in a stacked position to form a multi-layered nonwoven molded article.
10. 10. Nonwoven molded part according to one of the preceding aspects, characterized in that it forms a textile wheel arch shell.
11. 11. A method for producing a nonwoven molded article according to one of aspects 1 to 10, comprising the steps:
    1. i) laying at least one, preferably cross-laid, nonwoven fabric by means of a carding and stapling process or an aerodynamic nonwoven formation process,
    2. ii) subsequent needling of the fiber fleece (s) thus formed and
    3. iii) cropping,
    4. iv) heating and
    5. v) thermal, in particular thermoplastic, shaping of the nonwoven fabric (s) into the desired nonwoven molded part.
12. 12. The method according to aspect 11, characterized in that the at least one, preferably cross-laid, nonwoven fabric consists of 10 to 45 individual pile layers, which preferably each have a basis weight of 35 to 60 g / m ² .
13. 13. The method according to aspect 11 or 12, characterized in that in step iv) is heated to a temperature of 200 to 240 ° C, preferably 210 to 230 ° C, in particular 220 ° C, particularly preferably with a heating time of 40 to 80 seconds.
14. 14. The method according to any one of aspects 11 to 13, characterized in that the shaping in step v) takes place at a temperature of 7 to 15 ° C and preferably with a heating up time of 30 to 70 seconds.
15. 15. Use of the nonwoven molded part according to one of the aspects 1 to 10 as a wheel arch shell, underbody paneling, trunk side wall or parcel shelf.

According to the present invention, an arc is defined as 1 sine wave = 360 °.

According to the present invention, melting and softening ranges, melting and softening points are determined by means of differential scanning calorimetry (DSC) DIN EN ISO 11357-3: 2013-04 certainly.

The term semicrystalline is known to the person skilled in the field of polymers and he can determine the semicrystallinity of polymers or mixtures thereof by means of DSC measurements. The materials of the wrapping material (also referred to in the present invention as a jacket) of the bicomponent binding fibers B) and C) of the present invention each have specific melting ranges. This is to be understood to mean that the maximum of the peaks of the respective melting and / or softening points (referred to as melting peaks in the context of the present invention) are in this region in the curve determined by means of DSC.

The structuring polyethylene terephthalate fibers A) can be both solid and hollow fibers. With the same diameter, the hollow fibers have a lower weight than solid fibers, but due to their design as hollow bodies they have sufficient, in particular rigidity relevant strength values. By using hollow fibers, lighter nonwoven molded parts can be produced with sufficient, in particular undiminished, inherent stiffness values.

The matrix-forming polyethylene terephthalate-containing bicomponent binding fibers B), which have a semicrystalline shell material, preferably have the properties mentioned above. Furthermore, the wrapping material is preferably a thermoplastic material, more preferably a hot melt adhesive.

All fibers A) to C) described here are commercially available.

In order to produce the sufficient bond between the fibers, the fibers A) and B) and optionally C) are in a respective fiber mixture. These fibers B) and C) have at least in their respective cladding areas a lower melting and / or softening areas than the fibers A), so that when they come into contact with other fibers they form bonding points or bonding areas on the contact surfaces with the other fibers.

The mixture of different types of fibers can be adapted to the respective application and the properties required for each fiber fleece. It is advantageous here if the proportion by weight of fibers A) is greater than or at least equal to the proportion by weight of fibers B) or fibers B) and C).

The special mixture of fibers A) and B) or A) to C) makes it possible to obtain a nonwoven molded part which is characterized by reduced water absorption, in particular water wicking <5mm, rapid water release, and a low component weight. In addition, the nonwoven molded part is dimensionally stable at about 120 ° C permanent heat exposure and weatherproof. Furthermore, the requirements for SE / NBR flame resistance for cars, trucks, buses, land vehicles and vehicles in general can be met.

If the nonwoven molded part contains at least one polar compound that has an oleophobic effect, the surface tension of the component is changed, so that an advantageous repellent effect is formed on the surface of the nonwoven fabric in relation to media such as water, dirt and ice.

It can also contain at least one additive. Additives selected from pigments, dyes, antioxidants, processing aids or antistatic agents are particularly preferred.

With the aid of a fiber mixture according to the invention, it is also possible to process a plurality of nonwoven fabrics in a stacked position. It is therefore advantageous according to a further embodiment of the invention that a plurality of non-woven fabrics are arranged one above the other in a stacked position to form a multilayer molded non-woven fabric part.

The nonwoven molded parts of the present invention preferably have a basis weight which is greatly reduced by stretching at the lowest spatial point of the deformation, for example in the longitudinal direction varying from 1310/530/1410 g / m ² and / or a basis weight varying in the transverse direction from 1440/480/1470 g / m ² . It is further preferred that they have a thickness in the longitudinal direction varying from 2.34 / 1.32 / 2.36 mm and / or a thickness in the transverse direction varying from 2.36 / 1.33 / 2, 35 mm. It is also preferred that the bulk density in the longitudinal direction is 559.8 / 401.5 / 597.5 kg / m ³ and / or the bulk density in the transverse direction is 610.2 / 360.9 / 625 kg / m ³ . The bulk density is calculated as the quotient of the basis weight / thickness.

The use of the fiber mixture according to the invention is particularly advantageous for the production of a textile wheel arch liner, which the invention also provides. The wheel arch shell can preferably as in the DE 20 2005 015 164 U1 be constructed described, wherein the nonwoven fabric of the present invention replaces the nonwoven fabric disclosed in this document.

Finally, a particularly advantageous method according to an embodiment of the invention consists in that the nonwoven molded part is made by laying at least one, preferably cross-laid, nonwoven by means of a carding machine or an aerodynamic nonwoven forming method, subsequent needling of the nonwoven fabric (s) formed in this way and cutting to size, Heating and thermal, in particular thermoplastic, shaping of the nonwoven fabric (s) into the desired nonwoven molded article is produced.

Fine felting needles are preferably used for needling, in particular felting needles of the 15x16x36 3.5 "M332 G 53 037 type.

Examples:

Flammability, water absorption and release tests

example 1

60% by weight PET PPS 0104079 wave from Wellman-Indorama is a PET fiber that contains fluorocarbon compounds (fiber A).
40% by weight PET-Bico M 1439-wellbond from Wellman-Indorama, which has a melting peak at approx. 110.6 ° C, a melting peak at approx. 154 ° C (both sheaths) and a further melting peak at approx. 251, 1 ° C (core) in the DSC and the core consists of polyethylene terephthalate (fiber B).

Example 2

Composition of the nonwoven molded part:

60% by weight PET PPS 0104079 wave from Wellman-Indorama is a PET fiber that contains fluorocarbon compounds (fiber A).
20% by weight PET-Bico M 1439-wellbond from Wellman-Indorama, which has a melting peak at approx. 110.6 ° C, a melting peak at approx. 154 ° C (both sheaths) and a further melting peak at approx. 251, 1 ° C (core) in the DSC and the core consists of polyethylene terephthalate (fiber B).
20% by weight PET-Bico HT PPS 0069718 from HUVIS, which has a melting peak at approx. 182.3 ° C (jacket) and a further melting peak at approx. 252.1 ° C (core) in the DSC (fiber C) .

PET is an abbreviation for polyethylene terephthalate.

Comparative Example 1

Composition of the nonwoven molded part:

60% by weight PET PPS 0104079 wave from Wellman-Indorama, a PET fiber containing fluorocarbon compounds.
20% by weight PP FR PPS 0103758 from Asota, a polypropylene fiber.
20% by weight PET-Bico HT PPS 0069718 from HUVIS, which has a melting peak at approx. 182.3 ° C and a further melting peak at approx. 252.1 ° C in the DSC (fiber C).

Comparative Example 2

Composition of the nonwoven molded part:

60% by weight PET PPS 0010053-2 from Elana, which contains no fluorocarbon compounds
20 wt% PP FR 0103758 from Asota, a polypropylene fiber
20% by weight PET-Bico HT PPS 0069718 from HUVIS, which has a melting peak at approx. 182.3 ° C and a further melting peak at approx. 252.1 ° C in the DSC (fiber C).

• Brennprüfung nach ISO 3795:1989-10 in Längsrichtung (24 h bei 23 °C und 50 R.F. Probenmaße 356 x 102 x 2,0 mm; Kategorie SE/NBR).

The following tests were carried out with the nonwoven molded parts mentioned above:

• Burning test according to ISO 3795: 1989-10 in the longitudinal direction (24 h at 23 ° C and 50 RF sample dimensions 356 x 102 x 2.0 mm; category SE / NBR).

The "Water Wicking" test is carried out as follows. According to the test specification SAE J913: MAR2010, assuming point 3.2 (a), strips with a dimension of 200 mm long and 51 mm wide are cut lengthways and crossways from the nonwoven molded part with a cutter. The strips are then conditioned at 23 ° C +/- 2 ° C and 50% +/- 5% relative humidity for 24 hours. Each strip is marked with a liquid-resistant pen with a line at a distance of 50mm from one of the two narrow ends and placed in a suitable beaker so that each strip with the marking facing down touches the ground. Then add as much liquid to each of the beakers. Point 3.2 (a) filled, that the liquid level forms a meniscus of 2 mm to the drawn line. This storage should last for 16 hours and take place in a controlled environment at 23 ° C +/- 2 ° C and 50% +/- 5% relative humidity. At the end of storage after 16 hours, the strips are removed from the beaker and examined under a UV lamp. The migration of the fluorescent liquid beyond the mark at 50 mm indicates the degree of wicking in mm.

The “water release” test is carried out as follows. The component weight is determined in accordance with specification WSS-M99P32-D2, and the component is then completely immersed in a water bath with 23 ° C warm water for 1 h. After 1 h in a water bath, the component is dried at room temperature and in the installation position for 24 h. The component weight is then determined again and the percentage weight increase compared to the initial state is calculated. The water release is calculated according to the following equation: Water release = 100 - weight gain [%]. Table 1: Results of the tests Example 1 Example 2 VBsp 1 VBsp 2 Burning test OK OK not ok not ok Water wicking 0 mm 0 mm nB nB Water release 100% 100% nB nB Explanation: nb = not determined OK = OK not ok = not OK

The nonwoven molded articles according to the present invention showed excellent results in the above tests. Since the comparative examples did not pass the burning test and are therefore not suitable for use as material for wheel arch linings in road traffic, no further tests were carried out.

QUOTES INCLUDE IN THE DESCRIPTION

This list of documents listed by the applicant has been generated automatically and is only included for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• DE 202005015164 U1 [0004, 0019]
• FR 0103758 [0026]

Non-patent literature cited

• DIN EN ISO 1973: 1995-12 [0005]
• DIN EN ISO 5079: 1996-02 [0005]
• DIN EN ISO 11357-3: 2013-04 [0007]

Claims (13)

Nonwoven molded part comprising at least one thermally deformed nonwoven formed from A) structuring polyethylene terephthalate fibers; B) matrix-forming polyethylene terephthalate-containing bicomponent binding fibers which have a semicrystalline covering material with a melting range from 90 to 175 ° C .; C) optionally matrix-forming polyethylene terephthalate-containing bicomponent binding fibers which have a semicrystalline covering material and are different from the bicomponent binding fibers B); D) optionally additives. Nonwoven molded part after Claim 1 , characterized in that the polyethylene terephthalate fibers A) have a melting point of 220 to 265 ° C and / or have a fineness of 5.0 to 9.50 dtex measured according to DIN EN ISO 1973: 1995-12 and / or have a fiber length have from 45 to 75 mm and / or have a crimp of 1.5 to 10.0 sheets / cm and / or have a tensile strength of 2.0 to 5.0 cN / dtex measured according to DIN EN ISO 1973: 1995-12 . Nonwoven molded part after Claim 1 or 2nd , characterized in that the polyethylene terephthalate-containing bicomponent binder fibers B) have a fineness of 4.0 to 10.0 dtex measured according to DIN EN ISO 1973: 1995-12 and / or a fiber length of 45 to 70 mm and / or have a crimp of 2.0 to 10.0 sheets / cm and / or a tear strength of 1.0 to 4.0 cN / dtex measured according to DIN EN ISO 5079: 1996-02. Fibrous nonwoven molded part according to one of the preceding claims, characterized in that the polyethylene terephthalate-containing bicomponent binding fibers B) have a core made of polyethylene terephthalate or polyester and / or the polyethylene terephthalate-containing bicomponent binding fibers B) have a covering material with a melting range of 100 to 160 ° C exhibit. Nonwoven molded part according to one of the preceding claims, characterized in that the proportion of the core in the bicomponent binder fibers B) and / or C) containing polyethylene terephthalate in each case 50 to 70 wt. % based on the total weight of the fiber. Nonwoven molded part according to one of the preceding claims, characterized in that the nonwoven molded part further contains at least one polar compound which acts oleophobically. Fibrous nonwoven molded part according to one of the preceding claims, characterized in that the polyethylene terephthalate-containing bicomponent binding fibers C) have a core made of polyethylene terephthalate or polyester and / or the polyethylene terephthalate-containing bicomponent binding fibers C) have a covering material with a melting range of 95 to 200 ° C and / or have a fineness of 4.0 to 10.0 dtex measured according to DIN EN ISO 1973: 1995-12. Nonwoven molded part according to one of the preceding claims, characterized in that the fibers are present in the following proportions by weight A) 50 to 70% by weight; B) 10 to 40% by weight; C) 0 to 30% by weight; based on the total weight of components A) to C). Nonwoven molded part according to one of the preceding claims, characterized in that a plurality of nonwoven fabrics are arranged one above the other to form a multilayered nonwoven molded article in a stacked position. Nonwoven molded part according to one of the preceding claims, characterized in that it forms a textile wheel arch shell. Nonwoven molded part according to one of the Claims 1 to 10th , obtained by the following production steps: i) laying at least one, preferably cross-laid, nonwoven fabric by means of a carding-crosslaid process or an aerodynamic nonwoven formation process, ii) subsequent needling of the nonwoven fabric (s) thus formed, and iii) cutting, iv) heating and v) thermal, in particular thermoplastic, shaping of the nonwoven fabric (s) into the desired nonwoven molded article. Nonwoven molded part after Claim 11 , characterized in that the at least one non-woven fabric consists of 10 to 45 individual pile layers. Nonwoven molded part according to one of the Claims 1 to 10th , characterized in that it is used as a wheel arch liner, underbody paneling, trunk side wall or parcel shelf.