Thermoformable nonwoven composites

A thermoformable nonwoven composite with intertwined binder fibers and resin addresses the challenges of thermoformability, strength, and recyclability, enhancing its suitability for automotive applications.

JP7864831B2Active Publication Date: 2026-05-25MILLIKEN & CO
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Patent Information

Authority / Receiving Office
JP · JP
Patent Type
Patents
Current Assignee / Owner
MILLIKEN & CO
Filing Date
2022-10-28
Publication Date
2026-05-25

AI Technical Summary

Technical Problem

Existing composite materials used in automotive applications lack thermoformability, structural strength, heat and sound insulation, and recyclability, making them difficult to manufacture and reuse.

Method used

A thermoformable nonwoven composite comprising a nonwoven layer with intertwined first and second binder fibers of differing melting points and a first resin, formed by carding, cross-wrapping, and needle-punching, followed by aqueous coating and heat treatment to create a flexible, recyclable material.

Benefits of technology

The composite achieves thermoformability, structural rigidity, and improved recyclability while maintaining heat and sound insulation, suitable for automotive applications like noise and heat barriers.

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Abstract

A thermoformable nonwoven composite comprising a nonwoven layer containing a plurality of first staple fibers, a plurality of first binder fibers having a first melting point, and a plurality of second binder fibers having a second melting point, the first staple fibers, the first binder fibers, and the second binder fibers intertwining and intersecting at crossover points. The difference between the first melting point and the second melting point differs by at least about 15°C, and at least 95% by weight of all of the fibers in the nonwoven layer are polyester. The thermoformable nonwoven composite also contains a first resin formulation containing a first resin. The first resin is located within the nonwoven and at at least some of the crossover points. The first staple fibers, the first and second binder fibers, and the first resin all contain polymers from the same chemical class.
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