Molding may be a nonwoven composite

Abstract

The moldable nonwoven composite comprises a nonwoven surface layer, an adhesive layer, a sound-absorbing nonwoven layer, and a backing layer. The upper surface of the nonwoven surface layer forms the first surface of the moldable nonwoven composite. The nonwoven surface layer contains about 80–95% by weight of a first polyester terephthalate fiber and about 5–20% by weight of a first low-melting-point polyester fiber. The adhesive layer contains a first low-melting-point polyester adhesive. The sound-absorbing nonwoven layer contains about 40–90% by weight of a second polyester terephthalate fiber and about 10–60% by weight of a second low-melting-point polyester fiber. The lower surface of the polymer backing layer forms the second surface of the moldable nonwoven composite. The polymer backing layer contains a second low-melting-point polyester adhesive. The entire moldable nonwoven composite is essentially made of polyester, which is defined as at least 95% by weight of polyester.

Description

Technical field of inventions

[0001]

[0001] The present invention provides a moldable nonwoven fabric composite having good physical properties. Background

[0002]

[0002] In various industries, including automotive, office and home furniture, construction, and others, there are several products that require materials having thickness in the z direction that provide both structural strength and thermal insulation, sound insulation, aesthetics, and / or other performance characteristics. In many of these applications, it is also required that the material be thermoformable to a specific shape and rigidity. In the automotive industry, these products are often used in shielding applications, such as noise and thermal barriers in car hood liners, underbody shields, firewalls, floor liners, carpets, and trunk liners.

[0003]

[0003] Composite materials used in automotive applications, such as package shelves, door panels, or headliners, are often manufactured by heating a structural nonwoven composite layer bonded with thermoplastic binder fibers, and then cold-pressing it into a decorative layer.

[0004]

[0004] It would be preferable to be able to create a composite that is easy to manufacture and use, using thermoplastic materials and which would be more recyclable than other products currently on the market. Brief Summary of the Invention

[0005]

[0005] The present invention relates to a moldable nonwoven composite comprising a nonwoven surface layer, an adhesive layer, a sound-absorbing nonwoven layer, and a backing layer. The upper surface of the nonwoven surface layer forms the first surface of the moldable nonwoven composite. The nonwoven surface layer comprises about 80-95% by weight of first polyester terephthalate fibers and about 5-20% by weight of first low-melting-point polyester fibers, with a weight of about 150-750 g / m². 2 The adhesive layer contains a first low-melting-point polyester adhesive, weighing approximately 80-400 g / m². 2It is. The sound-absorbing non-woven fabric layer contains about 40 to 90% by weight of a second polyester terephthalate fiber and about 10 to 60% by weight of a second low-melting-point polyester fiber, and the weight is about 150 to 1,500 g / m 2 It is. The lower surface of the polymer backing layer forms the second surface of the formable non-woven fabric composite. The polymer backing layer contains a second low-melting-point polyester adhesive, and the weight is about 80 to 1,000 g / m 2 It is. The entire formable non-woven fabric composite is essentially made of polyester, which is defined as at least 95% by weight of polyester.

[0006]

[0006] In another aspect, the formable non-woven fabric composite includes a non-woven fabric surface layer, a sound-absorbing non-woven fabric layer, and a backing layer. The upper surface of the non-woven fabric surface layer forms the first surface of the formable non-woven fabric composite. The non-woven fabric surface layer contains about 80 to 95% by weight of a first polyester terephthalate fiber and about 5 to 20% by weight of a first low-melting-point polyester fiber, and the weight is about 150 to 750 g / m 2 It is. The sound-absorbing non-woven fabric layer contains about 40 to 90% by weight of a second polyester terephthalate fiber and about 10 to 60% by weight of a second low-melting-point polyester fiber, and the weight is about 150 to 1,500 g / m 2 It is. The lower surface of the polymer backing layer forms the second surface of the formable non-woven fabric composite. The polymer backing layer contains a second low-melting-point polyester adhesive, and the weight is about 80 to 1,000 g / m 2 It is. The entire formable non-woven fabric composite is essentially made of polyester, which is defined as at least 95% by weight of polyester.

[0007]

[0007] In another aspect, the formable non-woven fabric composite includes a non-woven fabric surface layer, an adhesive layer, and a sound-absorbing non-woven fabric layer. The upper surface of the non-woven fabric surface layer forms the first surface of the formable non-woven fabric composite. The non-woven fabric surface layer contains about 80 to 95% by weight of a first polyester terephthalate fiber and about 5 to 20% by weight of a first low-melting-point polyester fiber, and the weight is about 150 to 750 g / m 2 It is. The adhesive layer contains a first low-melting-point polyester adhesive, and the weight is about 80 to 400 g / m 2The sound-absorbing nonwoven fabric layer contains approximately 40-90% by weight of secondary polyester terephthalate fibers and approximately 10-60% by weight of secondary low-melting point polyester fibers, with a weight of approximately 150-1,500 g / m². 2 The lower surface of the sound-absorbing nonwoven fabric layer forms the second surface of the moldable nonwoven fabric composite. The entire moldable nonwoven fabric composite is essentially made of polyester, which is defined as at least 95% by weight of polyester.

[0008]

[0008] Hereinafter, one embodiment of the present invention will be described illustratively with reference to the attached drawings. [Brief explanation of the drawing]

[0009] [Figure 1]

[0009] Figure 1 schematically shows a cross-section of one embodiment of a moldable nonwoven composite having a nonwoven surface layer, an adhesive layer, a sound-absorbing layer, and a polymer backing layer. [Figure 2]

[0010] Figure 2 schematically shows a cross-section of one embodiment of a moldable nonwoven composite having a nonwoven surface layer, a sound-absorbing layer, and a polymer backing layer. [Figure 3]

[0011] Figure 3 schematically shows a cross-section of one embodiment of a moldable nonwoven composite having a nonwoven surface layer, an adhesive layer, and a sound-absorbing layer. Detailed description of the invention

[0010]

[0012] Referring to Figure 1, one embodiment of a moldable nonwoven composite 10 having a first surface 10a and a second surface 10b is shown. The moldable nonwoven composite 10 includes a nonwoven surface layer 100, an adhesive layer 200, a sound-absorbing layer 300, and a polymer backing layer 400. The nonwoven surface layer 100 includes an upper surface 100a and a lower surface 100b. The upper surface 100a of the nonwoven surface layer 100 forms the first surface 10a of the moldable nonwoven composite 10. The adhesive layer 200 includes an upper surface 200a and a lower surface 200b. The upper surface 200a of the adhesive layer 200 faces, is adjacent to, preferably in contact with, and continuous with the lower surface 100b of the nonwoven surface layer 100. The sound-absorbing nonwoven layer 300 includes an upper surface 300a and a lower surface 300b. The upper surface 300a of the sound-absorbing nonwoven fabric layer 300 faces, is adjacent to, preferably in contact with, and continuous with the lower surface 200b of the adhesive layer 200. The polymer backing layer 400 includes an upper surface 400a and a lower surface 400b. The upper surface 400a of the polymer backing layer 400 faces, is adjacent to, preferably in contact with, and continuous with the lower surface 300b of the sound-absorbing nonwoven fabric layer 300. The lower surface 400b of the polymer backing layer 400 forms the second surface 10b of the moldable nonwoven composite 10. When the moldable nonwoven composite 10 is molded under heat and pressure, it becomes a molded composite.

[0011]

[0013] The entire moldable nonwoven composite is essentially made of polyester. "Essentially" is defined as being at least 95% by weight. Single-material compositions (materials containing the same polymer species) tend to eliminate chemical compatibility / bonding problems. In addition, structures using the same material species can be more easily recycled and reused at the end of their lifespan, and scrap generated during manufacturing can also be more easily recycled. Polyester is preferred because of its high melting point and durability. Furthermore, recycled polymer materials may be used in some of the final products to help make the product more environmentally friendly.

[0012]

[0014] In one embodiment, the area weight of the moldable nonwoven composite 10 is approximately 460-3650 g / m². 2 More preferably, approximately 550-1800 g / m² 2 That is the case.

[0013]

[0015] The nonwoven fabric layer 100 preferably forms a surface that is expected to be touched by the user, which may be referred to as "A" or the surface. In some embodiments, the upper surface 100a of the nonwoven fabric layer 100 has a carpet-like appearance, with fibers from the nonwoven fabric layer 100 extending outward to give the layer a pile-like appearance. This may be preferred in embodiments where the moldable nonwoven composite is used in the floor upholstery area of ​​a vehicle to give the floor upholstery a more traditional carpet-like appearance. In other embodiments, the upper surface 100a of the nonwoven surface layer has a smoother appearance. This may be preferred in applications such as trunk liners, where the presence of pile can make cleaning more difficult.

[0014]

[0016] In one embodiment, the average thickness of the nonwoven surface layer 100 is approximately 1 mm to 10 mm, more preferably approximately 2 mm to 7 mm. The thickness is defined as the distance between the first surface 100a and the second surface 100b of the nonwoven surface layer 100, measured and averaged at 5 to 10 locations. The weight of the nonwoven surface layer 100 is approximately 150 to 750 g / m². 2 More preferably, approximately 250-550 g / m² 2 That is the case.

[0015]

[0017] The nonwoven surface layer 100 comprises about 80-95% by weight of a first polyester terephthalate fiber and about 5-20% by weight of a first low-melting-point polyester fiber. In a more preferred embodiment, the nonwoven layer 100 comprises about 85-92% by weight of a first polyester terephthalate (PET) fiber and about 8-15% by weight of a first low-melting-point polyester fiber. Preferably, essentially all of the fibers in the nonwoven surface layer 100 are polyester (essentially all means at least about 95% by weight). The fibers of the nonwoven surface layer 100 are preferably staple fibers. Preferably, the denier of the first PET fiber is about 3-15, and the denier of the first low-melting-point polyester fiber is preferably about 1.5-4. In this application, “low-melting-point” is defined as a melting point below about 200°C. In another embodiment, the melting point of the low-melting-point fibers and / or adhesive may be below about 140°C or below 130°C. In one embodiment, the melting point of the first PET fiber is at least twice that of the first low-melting-point polyester fiber. This difference in melting points allows for good moldability and adhesion (due to the low-melting-point fiber) while maintaining the strength of the nonwoven fabric layer (due to the PET fiber).

[0016]

[0018] The sound-absorbing nonwoven fabric layer 300 has an upper surface 300a and a lower surface 300b. In one embodiment, the average thickness of the nonwoven surface layer 300 is approximately 1 mm to 15 mm, more preferably approximately 2 mm to 10 mm. The thickness is defined as the distance between the first surface 300a and the second surface 300b of the sound-absorbing nonwoven fabric layer 300, measured and averaged at 5 to 10 locations. The weight of the sound-absorbing nonwoven fabric layer 300 is approximately 150 to 1,500 g / m². 2 Comfortably approximately 300-1,000 g / m² 2 In one embodiment, the density of the sound-absorbing nonwoven fabric layer 300 is higher than that of the nonwoven fabric surface layer 100. In one embodiment, the average thickness of the sound-absorbing nonwoven fabric layer 300 is greater than that of the nonwoven fabric surface layer 100. In another embodiment, the average thickness of the nonwoven fabric surface layer 100 is greater than that of the sound-absorbing nonwoven fabric layer 300.

[0017]

[0019] The sound-absorbing nonwoven fabric layer 300 comprises about 40-90% by weight of a second polyester terephthalate fiber and about 10-60% by weight of a second low-melting-point polyester fiber. In a more preferred embodiment, the sound-absorbing nonwoven fabric layer 300 comprises about 60-80% by weight of a second polyester terephthalate (PET) fiber and about 20-40% by weight of a second low-melting-point polyester fiber. Preferably, essentially all of the fibers in the sound-absorbing nonwoven fabric layer 300 are polyester (essentially all means at least about 95% by weight). The fibers of the sound-absorbing nonwoven fabric layer 300 are preferably staple fibers. Preferably, the denier of the second PET fiber is about 3-15, and the denier of the second low-melting-point polyester fiber is preferably about 1.5-4. In one embodiment, the melting point of the second PET fiber is at least twice that of the melting point of the second low-melting-point polyester fiber.

[0018]

[0020] In composite 10, using these two nonwoven fabric layers 100 and 300 instead of a single nonwoven fabric layer may offer several advantages in the finished product. For example, the combination of the two nonwoven fabric layers may result in superior sound absorption. Sound absorption can be adjusted by selecting different fiber sizes and densities for the two layers 100 and 300.

[0019]

[0021] Returning to Figure 1, the adhesive layer 200 has an upper surface 200a and a lower surface 200b, and is located on the lower surface 100b of the nonwoven fabric surface layer 100a. The adhesive layer 200 contains a first low-melting-point polyester adhesive and weighs approximately 80-400 g / m². 2The adhesive layer may be incorporated into the moldable nonwoven composite in any suitable manner. The adhesive layer 200 may be applied to the nonwoven surface layer 100 or the sound-absorbing nonwoven layer 400 as a liquid or melt coating, or introduced as a self-supporting film. Some examples of coating techniques include, but are not limited to, extrusion coating, solvent coating, gravure coating, knife coating, curtain coating, and dip coating. Preferably, the adhesive layer 200 is extruded onto the nonwoven layer 100 and / or the sound-absorbing nonwoven layer 300. Preferably, after the adhesive layer is added, the sandwich structure of the nonwoven surface layer 100, the adhesive layer 200, and the sound-absorbing nonwoven layer 300 is passed through a hot and / or pressured nip to bond the layers together. Preferably, after bonding, the low-melting-point polyester adhesive of the adhesive layer spreads (or migrates) at least partially within the nonwoven surface layer 100 and / or the sound-absorbing nonwoven layer 300. This contributes to ensuring good bonding between the two nonwoven fabric layers 100 and 300.

[0020]

[0022] The polymer backing layer 400 has an upper surface 400a and a lower surface 400b, with the lower surface 400b of the polymer backing layer 400 forming the second surface of the composite 10. The polymer backing layer 400 contains a second low-melting-point polyester adhesive and weighs approximately 80-1,000 g / m². 2It is so. This second low-melting-point polyester adhesive may be the same as the first low-melting-point polyester adhesive or may be a different polyester. The polymer backing layer 400 may be incorporated into the formable nonwoven composite by any suitable method. The adhesive layer 200 may be applied to the sound-absorbing nonwoven layer 300 as a liquid or melt coating or may be introduced as a self-supporting film. Some examples of coating techniques are, but are not limited to, extrusion coating, solvent coating, gravure coating, knife coating, curtain coating, dip coating. Preferably, the polymer backing layer 400 is extrusion-coated onto the sound-absorbing nonwoven layer 300 by extrusion coating. Preferably, once the polymer backing layer 400 is added, the entire sandwich structure of the composite is passed through a nip with heat and / or pressure applied to bond the layers together. Preferably, once bonded, the low-melting-point polyester adhesive of the adhesive layer spreads (or migrates) at least partially into the sound-absorbing nonwoven layer 300. This contributes to ensuring a good bond between the nonwoven layer 300 and the polymer backing layer 400.

[0021]

[0023] Referring to Figure 2, another embodiment of the present invention similar to the embodiment shown in Figure 1 is shown, which does not include an adhesive layer. In this embodiment, the moldable nonwoven composite 10 has a first surface 10a and a second surface 10b. The moldable nonwoven composite 10 includes a nonwoven surface layer 100, a sound-absorbing layer 300, and a polymer backing layer 400. The nonwoven surface layer 100 includes an upper surface 100a and a lower surface 100b. The upper surface 100a of the nonwoven surface layer 100 forms the first surface 10a of the moldable nonwoven composite 10. The sound-absorbing nonwoven layer 300 includes an upper surface 300a and a lower surface 300b. The upper surface 300a of the sound-absorbing nonwoven layer 300 faces, is adjacent to, preferably in contact with, and continuous with the lower surface 100b of the nonwoven surface layer 100. The polymer backing layer 400 includes an upper surface 400a and a lower surface 400b. The upper surface 400a of the polymer backing layer 400 faces, is adjacent to, preferably in contact with, and continuous with the lower surface 300b of the sound-absorbing nonwoven fabric layer 300. The lower surface 400b of the polymer backing layer 400 forms the second surface 10b of the moldable nonwoven composite 10. When the moldable nonwoven composite 10 is molded under heat and pressure, it becomes a molded composite. In this embodiment, since there is no adhesive between the nonwoven surface layer 100 and the sound-absorbing nonwoven fabric layer 300, the first and second low-melting-point polyester fibers contribute to bonding the two nonwoven layers 100, 300 together.

[0022]

[0024] Referring to FIG. 3, another embodiment of the present invention similar to the embodiment shown in FIG. 1 without a polymer backing layer is shown. In this embodiment, the formable nonwoven composite 10 has a first surface 10a and a second surface 10b. The formable nonwoven composite 10 includes a nonwoven surface layer 100, an adhesive layer 200, and a sound-absorbing layer 300. The nonwoven surface layer 100 includes an upper surface 100a and a lower surface 100b. The upper surface 100a of the nonwoven surface layer 100 forms the first surface 10a of the formable nonwoven composite 10. The adhesive layer 200 includes an upper surface 200a and a lower surface 200b. The upper surface 200a of the adhesive layer 200 faces, is adjacent to, preferably contacts, and is continuous with the lower surface 100b of the nonwoven surface layer 100. The sound-absorbing nonwoven layer 300 includes an upper surface 300a and a lower surface 300b. The upper surface 300a of the sound-absorbing nonwoven layer 300 faces, is adjacent to, preferably contacts, and is continuous with the lower surface 200b of the adhesive layer 200. The lower surface 300b of the sound-absorbing nonwoven layer 300 forms the second surface 10b of the formable nonwoven composite 10. When the formable nonwoven composite 10 is formed under heat and pressure, it becomes a formed composite.

[0023]

[0025] The formable nonwoven composite 10 is preferably still flexible. This means that the formable nonwoven composite 10 can be completely folded (180-degree fold) onto itself and then unfolded without any permanent change in appearance or physical properties. This flexibility is important for composites used in certain applications, such as automotive formed parts.

[0024]

[0026] The formable nonwoven composite 10 may be used as is or further formed into a three-dimensional shape using heat and / or pressure. In one embodiment, the formable nonwoven composite 10 is cut and formed into a desired shape and size. To form the formable nonwoven composite 10 into a formed composite, heat and optionally pressure are applied to the formable nonwoven composite 10, and the composite is heated to a temperature of at least about 150°C, which contributes to the melting of the low-melting-point polyester of the different layers.

[0025]

[0027] In the molded composite, at least some of the binder fibers may still retain a fibrous shape, while the other fibers melt into the binder material (the binder material typically coats the PET fibers or forms an adhesive mass).

[0026]

[0028] The molded nonwoven composite is preferably more rigid (or less flexible) than the moldable nonwoven composite 10. Preferably, the molded nonwoven composite is rigid enough to support its own weight and maintain its own shape, and may even be rigid enough to support additional weight without changing its shape.

[0027]

[0029] The composite 10 may include any additional layers for physical or aesthetic purposes. Suitable additional layers include, but are not limited to, nonwoven fabrics, woven fabrics, knitted fabrics, foam layers, films, paper layers, adhesive backing layers, foils, meshes, elastic fabrics (i.e., any of the above woven, knitted, or nonwoven fabrics having elastic properties), perforated webs, adhesive backing layers, or any combination thereof. Other suitable additional layers include, but are not limited to, color-containing layers (e.g., printed layers); one or more additional submicron fiber layers having distinct average fiber diameters and / or physical compositions; one or more secondary fine fiber layers for additional thermal insulation performance (e.g., meltblown webs or glass fiber fabrics); foams; particle layers; foil layers; films; decorative fabric layers; membranes (i.e., films with controlled permeability, e.g., dialysis membranes, reverse osmosis membranes, etc.); nets; meshes; wiring and piping networks (i.e., electrical conductive wires, or groups of tubes / pipes for various fluid transport, e.g., wiring networks for electrical blankets, and piping networks for coolant flows through cooling blankets); or combinations thereof. The additional layer may be on one or both sides of the nonwoven composite. For example, a fabric may be attached to one side of the nonwoven composite using an optional adhesive layer to form an aesthetic surface for the final use, e.g., a particular automotive application. In a preferred embodiment, any additional layer or material added to the composite is also essentially all polyester to aid in the recyclability of the composite.

[0028]

[0030] The composite may further include one or more mounting devices for enabling the composite to be attached to a substrate or other surface. In addition to adhesives, other mounting devices, such as mechanical fasteners, such as screws, nails, clips, staples, stitching, thread, hook-and-loop fasteners, etc., may be used.

[0029]

[0031] The composite may be mounted to various substrates using one or more mounting devices. Examples of substrates include, but are not limited to, vehicle parts; vehicle interiors (i.e., passenger compartments, motor rooms, trunks, etc.); building walls (i.e., interior or exterior wall surfaces); building ceilings (i.e., interior or exterior ceiling surfaces); building materials forming the walls or ceilings of buildings (e.g., ceiling tiles, wood components, gypsum board, etc.); partition walls; metal sheets; glass substrates; doors; windows; machine parts; home appliance parts (i.e., interior or exterior surfaces of home appliances); pipe or hose surfaces; computer or electronic components; recording or playback devices; and housings or cases for home appliances, computers, etc. In another embodiment, the first surface of the molded composite has a lower surface roughness than the second surface of the molded composite.

[0030]

[0032] All references cited herein, including publications, patent applications, and patents, are incorporated herein by reference to the same extent as they are presented herein, with each reference specifically incorporated by reference.

[0031]

[0033] With regard to the description of the subject matter of this application (in particular with regard to the claims below), the use of the terms “a,” “an,” and “the,” and similar references, should be interpreted as encompassing both singular and plural forms, unless otherwise specified or unless clearly inconsistent with the context. The terms “comprising,” “having,” “including,” and “containing” should be interpreted as non-restrictive terms (i.e., “including, but not limited to”), unless otherwise specified. The descriptions of ranges of values ​​herein are merely intended to serve as a concise way of referring individually to each distinct value within the range, unless otherwise specified, and each distinct value is incorporated herein as individually described. All methods described herein may be carried out in any preferred order, unless otherwise specified or unless clearly inconsistent with the context. Any examples or illustrative language provided herein (e.g., "such as") are intended solely to clarify the subject matter of this application and, unless otherwise requested, not to limit the scope of the subject matter. Nothing in this specification should be construed as indicating that any non-claimed element is essential to the implementation of the subject matter described herein.

[0032]

[0034] Preferred embodiments of the subject matter of this application, including the best mode for performing the claimed subject matter as known to the inventors, are described herein. Modifications of these preferred embodiments may become apparent to those skilled in the art by reading the preceding description. The inventors anticipate that those skilled in the art will use such modifications as needed, and the inventors intend that the subject matter described herein may be performed in ways other than those specifically described herein. Accordingly, this disclosure includes all modifications and equivalents of the subject matter described herein in the attached claims, as permitted by applicable law. Furthermore, any combination of the above elements in all possible modifications of the above elements is incorporated herein unless otherwise specified herein or unless it is clearly inconsistent with the context.

Claims

1. A moldable nonwoven fabric composite having a first surface and a second surface, A nonwoven surface layer having an upper surface and a lower surface, wherein the upper surface of the nonwoven surface layer forms the first surface of the moldable nonwoven composite, the nonwoven surface layer contains about 80 to 95% by weight of first polyester terephthalate fibers and about 5 to 20% by weight of first low-melting-point polyester fibers, and the weight of the nonwoven surface layer is about 150 to 750 g / m² ２ The nonwoven surface layer; The adhesive layer has an upper surface and a lower surface, wherein the adhesive layer is positioned on the lower surface of the nonwoven fabric surface layer, and the upper surface of the adhesive layer is adjacent to the nonwoven fabric surface layer, the adhesive layer contains a first low-melting-point polyester adhesive, and the weight of the adhesive layer is approximately 80 to 400 g / m². ２ The adhesive layer; The sound-absorbing nonwoven fabric layer has an upper surface and a lower surface, wherein the sound-absorbing layer is positioned adjacent to the lower surface of the adhesive layer, and the upper surface of the sound-absorbing layer is adjacent to the lower surface of the adhesive layer, and the sound-absorbing nonwoven fabric layer contains about 40 to 90% by weight of a second polyester terephthalate fiber and about 10 to 60% by weight of a second low-melting-point polyester fiber, and the weight of the nonwoven fabric surface layer is about 150 to 1,500 g / m². ２ This is a sound-absorbing nonwoven fabric layer; A polymer backing layer having an upper surface and a lower surface, wherein the polymer backing layer is positioned adjacent to the lower surface of the sound-absorbing nonwoven fabric layer, the upper surface of the polymer backing layer is adjacent to the lower surface of the sound-absorbing layer, the lower surface of the polymer backing layer forms the second surface of the moldable nonwoven fabric composite, the polymer backing layer contains a second low-melting-point polyester adhesive, and the weight of the polymer backing layer is approximately 80 to 1,000 g / m². ２ a polymer backing layer; Includes, A moldable nonwoven composite in which the entire moldable nonwoven composite is essentially made of polyester, and is defined as being at least 95% by weight of polyester.

2. The moldable nonwoven composite according to claim 1, wherein the nonwoven surface layer comprises about 85 to 92% by weight of first polyester terephthalate fibers and about 8 to 15% by weight of first low-melting-point polyester fibers.

3. The moldable nonwoven composite according to claim 1, wherein the denier of the first and second polyester terephthalate fibers is about 3 to 15.

4. The moldable nonwoven composite according to claim 1, wherein the melting points of the first and second low-melting-point polyester adhesives are less than about 140°C.

5. The moldable nonwoven composite according to claim 1, wherein the melting points of the first and second polyester terephthalate fibers are at least twice the melting points of the first and second low-melting-point polyester fibers.

6. The moldable nonwoven composite according to claim 1, wherein the adhesive layer is at least partially spread within the lower surface of the nonwoven surface layer and the upper surface of the sound-absorbing nonwoven layer.

7. The moldable nonwoven composite according to claim 1, wherein the sound-absorbing nonwoven layer comprises about 60 to 80% by weight of first polyester terephthalate fibers and about 20 to 40% by weight of first low-melting-point polyester fibers.

8. The moldable nonwoven composite according to claim 1, wherein the average thickness of the sound-absorbing nonwoven layer is approximately 2 to 10 mm.

9. The moldable nonwoven composite according to claim 1, wherein the density of the sound-absorbing nonwoven layer is higher than that of the nonwoven surface layer.

10. A moldable nonwoven fabric composite having a first surface and a second surface, A nonwoven surface layer having an upper surface and a lower surface, wherein the upper surface of the nonwoven surface layer forms the first surface of the moldable nonwoven composite, the nonwoven surface layer contains about 80 to 95% by weight of first polyester terephthalate fibers and about 5 to 20% by weight of first low-melting-point polyester fibers, and the weight of the nonwoven surface layer is about 150 to 750 g / m² ２ The nonwoven surface layer; The sound-absorbing nonwoven fabric layer has an upper surface and a lower surface, wherein the sound-absorbing layer is positioned on the lower surface of the nonwoven fabric surface layer, and the upper surface of the sound-absorbing layer is adjacent to the lower surface of the nonwoven fabric surface layer, the sound-absorbing nonwoven fabric layer contains about 40 to 90% by weight of a second polyester terephthalate fiber and about 10 to 60% by weight of a second low-melting-point polyester fiber, and the weight of the nonwoven fabric surface layer is about 150 to 1,500 g / m². ２ This is a sound-absorbing nonwoven fabric layer; A polymer backing layer having an upper surface and a lower surface, wherein the polymer backing layer is positioned adjacent to the lower surface of the sound-absorbing nonwoven fabric layer, the upper surface of the polymer backing layer is adjacent to the lower surface of the sound-absorbing layer, the lower surface of the polymer backing layer forms the second surface of the moldable nonwoven fabric composite, the polymer backing layer contains a second low-melting-point polyester adhesive, and the weight of the polymer backing layer is approximately 80 to 1,000 g / m². ２ a polymer backing layer; Includes, A moldable nonwoven composite in which the entire moldable nonwoven composite is essentially made of polyester, and is defined as being at least 95% by weight of polyester.

11. The moldable nonwoven composite according to claim 10, wherein the nonwoven surface layer comprises about 85 to 92% by weight of first polyester terephthalate fibers and about 8 to 15% by weight of first low-melting-point polyester fibers.

12. The moldable nonwoven composite according to claim 10, wherein the melting points of the first and second low-melting-point polyester fibers are less than about 200°C.

13. The moldable nonwoven composite according to claim 10, wherein the melting points of the first and second polyester terephthalate fibers are at least twice the melting points of the first and second low-melting-point polyester fibers.

14. The moldable nonwoven composite according to claim 10, wherein the sound-absorbing nonwoven layer comprises about 60 to 80% by weight of first polyester terephthalate fibers and about 20 to 40% by weight of first low-melting-point polyester fibers.

15. A moldable nonwoven fabric composite having a first surface and a second surface, A nonwoven surface layer having an upper surface and a lower surface, wherein the upper surface of the nonwoven surface layer forms the first surface of the moldable nonwoven composite, the nonwoven surface layer contains about 80 to 95% by weight of first polyester terephthalate fibers and about 5 to 20% by weight of first low-melting-point polyester fibers, and the weight of the nonwoven surface layer is about 150 to 750 g / m² ２ The nonwoven surface layer; An adhesive layer having an upper surface and a lower surface, the adhesive layer being positioned such that the lower surface of the adhesive layer is on the lower surface of the non-woven fabric surface layer and the upper surface of the adhesive layer is adjacent to the non-woven fabric surface layer, the adhesive layer containing a first low melting point polyester adhesive, and the weight of the adhesive layer being about 80 to 400 g / m ２ which is an adhesive layer; The sound-absorbing nonwoven fabric layer has an upper surface and a lower surface, wherein the sound-absorbing layer is positioned adjacent to the lower surface of the adhesive layer, the upper surface of the sound-absorbing layer is adjacent to the lower surface of the adhesive layer, the lower surface of the sound-absorbing nonwoven fabric layer forms the second surface of the moldable nonwoven fabric composite, the sound-absorbing nonwoven fabric layer contains about 40 to 90% by weight of second polyester terephthalate fibers and about 10 to 60% by weight of second low-melting-point polyester fibers, and the weight of the nonwoven fabric surface layer is about 150 to 1,500 g / m² ２ This is a sound-absorbing nonwoven fabric layer; Includes, A moldable nonwoven composite in which the entire moldable nonwoven composite is essentially made of polyester, and is defined as being at least 95% by weight of polyester.

16. The moldable nonwoven composite according to claim 15, wherein the nonwoven surface layer comprises about 85 to 92% by weight of first polyester terephthalate fibers and about 8 to 15% by weight of first low-melting-point polyester fibers.

17. The moldable nonwoven composite according to claim 15, wherein the melting points of the first and second low-melting-point polyester adhesives are less than about 130°C.

18. The moldable nonwoven composite according to claim 15, wherein the melting points of the first and second polyester terephthalate fibers are at least twice the melting points of the first and second low-melting-point polyester fibers.

19. The moldable nonwoven composite according to claim 15, wherein the adhesive layer is at least partially spread within the lower surface of the nonwoven surface layer and the upper surface of the sound-absorbing nonwoven layer.

20. The moldable nonwoven composite according to claim 15, wherein the sound-absorbing nonwoven layer comprises about 60 to 80% by weight of first polyester terephthalate fibers and about 20 to 40% by weight of first low-melting-point polyester fibers.

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