Material for molding applications

Abstract

A material for molding applications is provided comprising a nonwoven fabric comprising fibers, the nonwoven fabric (i) comprising first fibers comprising a polyethylene terephthalate polymer and second fibers comprising a polybutylene terephthalate copolymer, (ii) comprising bicomponent fibers comprising a first component comprising a polyethylene terephthalate polymer and a second component comprising a polybutylene terephthalate copolymer, or (iii) comprising first fibers comprising a polyethylene terephthalate polymer and bicomponent second fibers comprising a first component comprising a polyethylene terephthalate polymer and a second component comprising a polybutylene terephthalate copolymer, wherein the polybutylene terephthalate copolymer is copolymerized from a dicarboxylic acid compound and a diol compound comprising 1,4-butanediol and / or comprising 2-methyl-1,3-propanediol, wherein the diol compound does not comprise neopentyl glycol.

Description

[0001] Material for molding applications

[0002] Description:

[0003] The invention pertains to a material for molding applications or a three- dimensional material comprising a nonwoven fabric, in particular for molded articles, for example a material for a primary carpet backing, in particular for tufted carpets, to tufted carpet comprising the material for molding applications and to molded carpets comprising the tufted carpet comprising the material for molding applications, and to underbody shields comprising the material for molding applications.

[0004] Nonwoven fabric comprising filaments composed of a polyethylene terephthalate resin and filaments composed of a polybutylene terephthalate resin copolymerized from a dicarboxylic acid compound and a diol compound are known to be suitable for molding applications.

[0005] KR102677145A1 discloses a spunbond nonwoven fabric for use as a primary carpet backing comprising first filaments composed of a polyethylene terephthalate resin and second filaments composed of a polybutylene terephthalate resin copolymerized from a dicarboxylic acid compound and a diol compound comprising 40 to 70 mol% of 1 ,4-butanediol, 25 to 50 mol% of ethylene glycol, and 1 to 20 mol% of neopentyl glycol.

[0006] Although the polybutylene terephthalate resin copolymerized from a dicarboxylic acid compound and a diol compound comprising 40 to 70 mol% of 1 ,4-butanediol, 25 to 50 mol% of ethylene glycol, and 1 to 20 mol% of neopentyl glycol may facilitate to manufacture a spunbond nonwoven fabric comprising a fibrous web for providing molded articles and for use as a primary carpet backing, but experience shows that the manufacturing process utilizing such a polybutylene terephthalate resin lacks to provide consistent high quality nonwoven fabrics due to filament breakage during spinning and / or sticking of filaments to processing equipment, such as for example rollers, hot air drums, and conveyor belts.

[0007] There remains a need to improve the manufacturing process for nonwoven fabrics comprising a polybutylene terephthalate resin copolymerized from a dicarboxylic acid compound and a diol compound, and to provide consistent high quality nonwoven fabrics.

[0008] It is therefore an object of the invention to provide a material for molding applications which resolves, or at least reduces, the disadvantages of the prior art.

[0009] The object of the invention is achieved by the material for molding applications according to claim 1 . Advantageous further developments of the material are provided by the dependent claims.

[0010] The material for molding applications comprising a nonwoven fabric comprising fibers, the nonwoven fabric (i) comprising first fibers comprising a polyethylene terephthalate polymer and second fibers comprising a polybutylene terephthalate copolymer, (ii) comprising bicomponent fibers comprising a first component comprising a polyethylene terephthalate polymer and a second component comprising a polybutylene terephthalate copolymer, or (iii) comprising first fibers comprising a polyethylene terephthalate polymer and bicomponent second fibers comprising a first component comprising a polyethylene terephthalate polymer and a second component comprising a polybutylene terephthalate copolymer, wherein the polybutylene terephthalate copolymer is copolymerized from a dicarboxylic acid compound and a diol compound comprising 1 ,4-butanediol and / or comprising 2-methyl-1 ,3-propanediol, wherein the diol compound does not comprise neopentyl glycol, enables to provide a material for molding applications having consistent high quality. The material for molding applications exhibits no, or at least reduced, sticking of filaments to processing equipment, such as for example rollers, hot air drums, and / or conveyor belts, and / or no, or at least reduced, filament breakage during spinning.

[0011] Within the scope of the present invention, it is understood that the term fibers refers to both staple fibers and filaments. Staple fibers are fibers which have a specified, relatively short length in the range of 2 to 200 mm. Filaments are fibers having a length of more than 200 mm, preferably more than 500 mm, more preferably more than 1000 mm. Filaments may even be virtually endless, for example when formed by continuous extrusion and spinning of a filament through a spinning hole in a spinneret.

[0012] The nonwoven fabric comprised in the material for molding applications comprises a polyethylene terephthalate polymer. In an embodiment, the polyethylene terephthalate polymer is a dimethyl terephthalate-based polyethylene terephthalate polymer.

[0013] In another embodiment, the polyethylene terephthalate polymer is a terephthalic acid-based polyethylene terephthalate polymer, enabling to provide the material for molding applications in a more economical manner and / or with an improved reliability of supply due to increased market availability.

[0014] The material for molding applications comprises a polybutylene terephthalate copolymer copolymerized from a dicarboxylic acid compound and a diol compound, wherein the diol compound does not comprise neopentyl glycol. In an embodiment, the polybutylene terephthalate copolymer is copolymerized from a dicarboxylic acid compound and a diol compound, wherein the diol compound does not comprise neopentyl glycol and does not comprise ethylene glycol, enabling to further reduce sticking of filaments to processing equipment, such as for example rollers, hot air drums, and / or conveyor belts, and / or to further reduce filament breakage during spinning.

[0015] The material for molding applications comprises a polybutylene terephthalate copolymer copolymerized from a dicarboxylic acid compound and a diol compound, wherein the diol compound does not comprise neopentyl glycol, and preferably does not comprise ethylene glycol. A polybutylene terephthalate copolymer is understood to be a polymer which is polymerized from at least three different monomers, including at least one dicarboxylic acid monomer and at least one diol monomer. In an embodiment, the dicarboxylic acid compound comprises at least one of terephthalic acid, dimethyl terephthalate, isophthalic acid, and dimethyl isophthalate. However, the dicarboxylic acid compound may further comprise one or more of adipic acid, suberic acid, sebacic acid, 1 ,4- cyclohexanedicarboxylic acid, 2,6- naphthalenedicarboxylic acid, dimethyl 2,6- naphthalate, and 1 ,5-naphthalenedicarboxylic acid.

[0016] The material for molding applications comprises a polyethylene terephthalate polymer. The polyethylene terephthalate polymer may have a melting temperature in the range of 240°C to 265°C. The polyethylene terephthalate polymer may have a melting temperature of at least 242°C, preferably of at least 250°C, preferably of at least 255°C. The polyethylene terephthalate polymer may have a melting temperature of at most 265°C, or at most 260°C, or at most 255°C.

[0017] The material for molding applications comprises a polybutylene terephthalate copolymer copolymerized from a dicarboxylic acid compound and a diol compound, wherein the diol compound does not comprise neopentyl glycol, and preferably does not comprise ethylene glycol. The polybutylene terephthalate copolymer comprised in the nonwoven fabric may have a melting temperature which is at least 50°C lower than the melting temperature of the polyethylene terephthalate polymer. The polybutylene terephthalate copolymer comprised in the nonwoven fabric may have a melting temperature between 150°C and 215°C, preferably between 155°C and 200°C, preferably between 160°C and 190°C, more preferably between 165°C and 180°C.

[0018] The material for molding applications comprises a polybutylene terephthalate copolymer copolymerized from a dicarboxylic acid compound and a diol compound comprising 1 ,4-butanediol and / or comprising 2-methyl-1 ,3-propanediol, wherein the diol compound does not comprise neopentyl glycol, and preferably does not comprise ethylene glycol, wherein the diol compound is preferably composed for more than 50 mol% of 1 ,4-butanediol and / or 2-methyl-1 ,3-propanediol.

[0019] In an embodiment, the material for molding applications may comprise a polybutylene terephthalate copolymer copolymerized from a dicarboxylic acid compound and a diol compound, wherein the diol compound comprises 1 ,4- butanediol and / or 2-methyl-1 ,3-propanediol, and one or more further diol monomers selected from the group consisting of 1 ,2-propanediol, 1 ,3-propanediol, 1 ,2-butanediol, 1 ,5-pentanediol, cyclopentanediol, 1 ,6-hexanediol, 1 ,4- cyclohexanediol, 1 ,2-cyclohexanedimethanol, 1 ,3-cyclohexanedimethanol, 1 ,4- cyclohexanedimethanol, trimethylolpropane, diethylene glycol, polyethylene glycol and polytetramethylene glycol wherein the diol compound is preferably composed for more than 50 mol% of 1 ,4-butanediol and / or 2-methyl-1 ,3-propanediol.

[0020] The material for molding applications comprises a polyethylene terephthalate polymer and a polybutylene terephthalate copolymer, wherein the polybutylene terephthalate copolymer is preferably copolymerized from a dicarboxylic acid compound and a diol compound in molar ratio of 1 :1 , wherein the diol compound does not comprise neopentyl glycol, and preferably does not comprise ethylene glycol.

[0021] The material for molding applications comprises a polyethylene terephthalate polymer and a polybutylene terephthalate copolymer, wherein the polybutylene terephthalate copolymer is copolymerized from a dicarboxylic acid compound and a diol compound, wherein the diol compound does not comprise neopentyl glycol, and preferably does not comprise ethylene glycol. The material for molding applications may comprise a nonwoven fabric which is composed for 50 to 95 wt.% of the polyethylene terephthalate polymer and for 5 to 50 wt.% of the polybutylene terephthalate copolymer. In an embodiment, the material for molding applications comprises a nonwoven fabric which is composed for 60 to 95 wt.% of the polyethylene terephthalate polymer and for 5 to 40 wt.% of the polybutylene terephthalate copolymer.

[0022] In an embodiment, the material for molding applications comprises a nonwoven fabric which is composed for 70 to 93 wt.% of the polyethylene terephthalate polymer and for 7 to 30 wt.% of the polybutylene terephthalate copolymer.

[0023] In another embodiment, the material for molding applications comprises a nonwoven fabric which is composed for 80 to 90 wt.% of the polyethylene terephthalate polymer and for 10 to 20 wt.% of the polybutylene terephthalate copolymer.

[0024] The material for molding applications comprises a nonwoven fabric which may comprise up to 25 wt.%, preferably up to 20 wt.%, more preferably up to 15 wt.%, even more preferably up to 10 wt.%, most preferably up to 5 wt.% based on the total weight of the nonwoven fabric, of commonly used additives, such as for example spinning auxiliaries, fillers, flame retardant materials, UV inhibitors, crystallization retarders / accelerators, plasticizers, heat stabilizers, antimicrobial additives, antistatic agents, coloring agents or any combination thereof.

[0025] The material for molding applications comprises a polyethylene terephthalate polymer and a polybutylene terephthalate copolymer, wherein the polybutylene terephthalate copolymer is copolymerized from a dicarboxylic acid compound and a diol compound, wherein the diol compound does not comprise neopentyl glycol, and preferably does not comprise ethylene glycol. The material for molding applications may comprise a nonwoven fabric which comprises first fibers composed for at least 50 wt.% of the polyethylene terephthalate polymer and second fibers composed for at least 50 wt.% of the polybutylene terephthalate copolymer. The first fibers and / or the second fibers may each independently comprise up to 25 wt.%, preferably up to 20 wt.%, more preferably up to 15 wt.%, even more preferably up to 10 wt.%, most preferably up to 5 wt.% based on the total weight of the first fibers or second fibers respectively, of commonly used additives, such as for example spinning auxiliaries, fillers, flame retardant materials, UV inhibitors, crystallization retarders / accelerators, plasticizers, heat stabilizers, antimicrobial additives, antistatic agents, coloring agents or any combination thereof.

[0026] The material for molding applications may comprise a nonwoven fabric which comprises first fibers composed for at least 50 wt.% of the polyethylene terephthalate polymer and second fibers composed for at least 50 wt.% of the polybutylene terephthalate copolymer. In an embodiment, the material for molding applications comprises a nonwoven fabric which is composed for 50 to 95 wt.% of the first fibers and 5 to 50 wt.% of the second fibers.

[0027] In an embodiment, the material for molding applications comprises a nonwoven fabric which is composed for 60 to 95 wt.% of the first fibers and 5 to 40 wt.% of the second fibers.

[0028] In an embodiment, the material for molding applications comprises a nonwoven fabric which is composed for 70 to 93 wt.% of the first fibers and 7 to 30 wt.% of the second fibers.

[0029] In another embodiment, the material for molding applications comprises a nonwoven fabric which is composed for 80 to 90 wt.% of the first fibers and 10 to 20 wt.% of the second fibers.

[0030] In an embodiment, the material for molding applications comprises a nonwoven fabric which comprises first fibers composed for at least 75 wt.% of the polyethylene terephthalate polymer and second fibers composed for at least 75 wt.% of the polybutylene terephthalate copolymer.

[0031] In an embodiment, the material for molding applications comprises a nonwoven fabric which comprises first fibers composed for at least 90 wt.% of the polyethylene terephthalate polymer and second fibers composed for at least 90 wt.% of the polybutylene terephthalate copolymer. In another embodiment, the material for molding applications comprises a nonwoven fabric which comprises first fibers composed for at least 95 wt.% of the polyethylene terephthalate polymer and second fibers composed for at least 95 wt.% of the polybutylene terephthalate copolymer.

[0032] In another embodiment, the material for molding applications comprises a nonwoven fabric which comprises first fibers consisting of the polyethylene terephthalate polymer and second fibers consisting of the polybutylene terephthalate copolymer.

[0033] The material for molding applications may comprise a nonwoven fabric which comprises first fibers composed for at least 50 wt.% of the polyethylene terephthalate polymer and second fibers composed for at least 50 wt.% of the polybutylene terephthalate copolymer, wherein the first fibers have a linear density of 5 to 25 dtex, preferably the first fibers have a linear density of 7 to 20 dtex, more preferably the first fibers have a linear density of 7 to 15 dtex. The linear density of the fibers is expressed as dtex, which is the weight of a fiber in gram per 10,000 meter length.

[0034] The material for molding applications may comprise a nonwoven fabric which comprises first fibers composed for at least 50 wt.% of the polyethylene terephthalate polymer and second fibers composed for at least 50 wt.% of the polybutylene terephthalate copolymer, wherein the second fibers have a linear density of 1 to 10 dtex, preferably the second fibers have a linear density of 2 to 7 dtex, more preferably the second fibers have a linear density of 3 to 5 dtex.

[0035] The material for molding applications comprising first fibers and second fibers having these preferred linear density ranges enables to provide a minimum level of processing stability of the material for molding applications, and in particular to prevent, or at least reducing, pile drift in a molded carpet, and / or to provide a minimum stitch holding capacity, i.e. a capability to hold the tufts in place, during tufting of the primary carpet backing when the material for molding applications is used as a primary backing. Preferably, the first fibers comprised in the nonwoven fabric comprised in the material for molding applications and / or the second fibers comprised in the nonwoven fabric comprised in the material for molding applications are filaments to further improve the breaking strength and / or tear strength of the material for molding applications.

[0036] The material for molding applications may comprise a nonwoven fabric which comprises first fibers composed for at least 50 wt.% of the polyethylene terephthalate polymer and second fibers composed for at least 50 wt.% of the polybutylene terephthalate copolymer, wherein the first fibers and / or the second fibers may each independently exhibit any cross-sectional shape. Preferably, the cross-sectional shape of the first fibers and / or the second fibers is round or elliptical. However, the cross-sectional shape of the first fibers and / or the second fibers may also be triangular, rectangular or multilobal, like bilobal or trilobal. The first fibers and / or the second fibers may each independently comprise a hollow section within the fiber cross section, i.e. the first fibers and / or the second fibers may be hollow fibers.

[0037] Selection of a certain cross-sectional shape for the first fibers and / or the second fibers allows to fine-tune the bonding strength between the first fibers and / or the second fibers, and enables to improve friction between the material for molding applications and pile yams tufted into the primary backing when the material for molding applications is used as a primary carpet backing.

[0038] The polyethylene terephthalate polymer comprised in the first fibers comprised in the nonwoven fabric comprised in the material for molding applications may be a recycled polyethylene terephthalate polymer enabling to manufacture the material for molding applications in a more sustainable manner.

[0039] The material for molding applications comprises a polyethylene terephthalate polymer and a polybutylene terephthalate copolymer, wherein the polybutylene terephthalate copolymer is copolymerized from a dicarboxylic acid compound and a diol compound, wherein the diol compound does not comprise neopentyl glycol, and preferably does not comprise ethylene glycol. The material for molding applications may comprise a nonwoven fabric which comprises bicomponent fibers comprising a first component composed for at least 50 wt.% of the polyethylene terephthalate polymer and a second component composed for at least 50 wt.% of the polybutylene terephthalate copolymer.

[0040] The material for molding applications may comprise a nonwoven fabric which comprises bicomponent fibers comprising a first component composed for at least 50 wt.% of the polyethylene terephthalate polymer and a second component composed for at least 50 wt.% of the polybutylene terephthalate copolymer. The first component of the bicomponent fibers and / or the second component of the bicomponent fibers may each independently comprise up to 25 wt.%, preferably up to 20 wt.%, more preferably up to 15 wt.%, even more preferably up to 10 wt.%, most preferably up to 5 wt.% based on the total weight of the first component of the bicomponent fibers or second component of the bicomponent fibers respectively, of commonly used additives, such as for example spinning auxiliaries, fillers, flame retardant materials, UV inhibitors, crystallization retarders / accelerators, plasticizers, heat stabilizers, antimicrobial additives, antistatic agents, coloring agents or any combination thereof.

[0041] The material for molding applications may comprises a nonwoven fabric which is composed for at least 30 wt.% of the bicomponent fibers, preferably for at least 35 wt.% of the bicomponent fibers, preferably for at least 40 wt.% of the bicomponent fibers, preferably for at least 50 wt.% of the bicomponent fibers, preferably for at least 75 wt.% of the bicomponent fibers, preferably for at least 90 wt.% of the bicomponent fibers, preferably for at least 95 wt.% of the bicomponent fibers. In an embodiment, the material for molding applications comprises a nonwoven fabric which consists of the bicomponent fibers.

[0042] The material for molding applications may comprise a nonwoven fabric which comprises bicomponent fibers comprising a first component composed for at least 75 wt.% of the polyethylene terephthalate polymer, preferably for at least 90 wt.% of the polyethylene terephthalate polymer, preferably for at least 95 wt.% of the polyethylene terephthalate polymer. In an embodiment, the material for molding applications may comprise a nonwoven fabric which comprises bicomponent fibers comprising a first component consisting of the polyethylene terephthalate polymer.

[0043] The material for molding applications may comprise a nonwoven fabric which comprises bicomponent fibers comprising a second component composed for at least 75 wt.% of the polybutylene terephthalate copolymer, preferably for at least 90 wt.% of the polybutylene terephthalate copolymer preferably for at least 95 wt.% of the polybutylene terephthalate copolymer. In an embodiment, the material for molding applications may comprise a nonwoven fabric which comprises bicomponent fibers comprising a second component consisting of the polybutylene terephthalate copolymer.

[0044] The material for molding applications may comprise a nonwoven fabric which comprises bicomponent fibers comprising a first component composed for at least 50 wt.% of the polyethylene terephthalate polymer and a second component composed for at least 50 wt.% of the polybutylene terephthalate copolymer, wherein the bicomponent fibers are composed for 50 to 95 wt.% of the first component and 5 to 50 wt.% of the second component.

[0045] In an embodiment, the material for molding applications comprises a nonwoven fabric which comprises bicomponent fibers comprising a first component composed for at least 50 wt.% of the polyethylene terephthalate polymer and a second component composed for at least 50 wt.% of the polybutylene terephthalate copolymer, wherein the bicomponent fibers are composed for 60 to 95 wt.% of the first component and 5 to 40 wt.% of the second component.

[0046] In an embodiment, the material for molding applications comprises a nonwoven fabric which comprises bicomponent fibers comprising a first component composed for at least 50 wt.% of the polyethylene terephthalate polymer and a second component composed for at least 50 wt.% of the polybutylene terephthalate copolymer, wherein the bicomponent fibers are composed for 70 to 93 wt.% of the first component and 7 to 30 wt.% of the second component.

[0047] In an embodiment, the material for molding applications comprises a nonwoven fabric which comprises bicomponent fibers comprising a first component composed for at least 50 wt.% of the polyethylene terephthalate polymer and a second component composed for at least 50 wt.% of the polybutylene terephthalate copolymer, wherein the bicomponent fibers are composed for 80 to 90 wt.% of the first component and 10 to 20 wt.% of the second component.

[0048] The material for molding applications comprises a nonwoven fabric which may comprise bicomponent fibers comprising a first component composed for at least 50 wt.% of the polyethylene terephthalate polymer and a second component composed for at least 50 wt.% of the polybutylene terephthalate copolymer, wherein the bicomponent fibers are selected from side-by-side bicomponent fibers, islands-in-the-sea bicomponent fibers, segmented pie, or core-sheath bicomponent fibers. In an embodiment, the bicomponent fibers are core-sheath bicomponent fibers, wherein the core is composed of the first component and the sheath is composed of the second component.

[0049] The material for molding applications comprises a nonwoven fabric which may comprise bicomponent fibers comprising a first component composed for at least 50 wt.% of the polyethylene terephthalate polymer and a second component composed for at least 50 wt.% of the polybutylene terephthalate copolymer, wherein the bicomponent fibers have a linear density of 2 to 25 dtex, preferably the bicomponent fibers have a linear density of 5 to 20 dtex, more preferably the bicomponent fibers have a linear density of 7 to 15 dtex.

[0050] The material for molding applications comprising bicomponent having these preferred linear density ranges enables to provide a minimum level of processing stability of the material for molding applications, and in particular to prevent, or at least reducing, pile drift in a molded carpet, and / or to provide a minimum stitch holding capacity, i.e. a capability to hold the tufts in place, during tufting of the primary carpet backing when the material for molding applications is used as a primary backing.

[0051] Preferably, the bicomponent fibers comprised in the nonwoven fabric comprised in the material for molding applications are filaments to further improve the breaking strength and / or tear strength of the material for molding applications.

[0052] The material for molding applications comprises a nonwoven fabric which may comprise bicomponent fibers comprising a first component composed for at least 50 wt.% of the polyethylene terephthalate polymer and a second component composed for at least 50 wt.% of the polybutylene terephthalate copolymer, wherein the bicomponent fibers may exhibit any cross-sectional shape. Preferably, the cross-sectional shape of the bicomponent fibers, preferably core / sheath bicomponent fibers, is round or elliptical. However, the cross-sectional shape of the first bicomponent core / sheath fibers may also be triangular, rectangular or multilobal, like bilobal or trilobal. The bicomponent fibers may comprise a hollow section within the fiber cross section, i.e. the bicomponent fibers may be hollow bicomponent fibers.

[0053] Selection of a certain cross-sectional shape for bicomponent fibers allows to finetune the bonding strength between the bicomponent fibers, and enables to improve friction between the material for molding applications and pile yams tufted into the primary backing when the material for molding applications is used as a primary carpet backing.

[0054] The polyethylene terephthalate polymer comprised in the first component of the bicomponent fibers comprised in the nonwoven fabric comprised in the material for molding applications may be a recycled polyethylene terephthalate polymer enabling to manufacture the material for molding applications in a more sustainable manner.

[0055] The material for molding applications may comprise a nonwoven fabric which comprises first fibers composed for at least 50 wt.% of the polyethylene terephthalate polymer and bicomponent second fibers comprising a first component composed for at least 50 wt.% of the polyethylene terephthalate polymer and a second component composed for at least 50 wt.% of the polybutylene terephthalate copolymer.

[0056] The first fibers, the first component of the bicomponent second fibers and / or the second component of the bicomponent second fibers may each independently comprise up to 25 wt.%, preferably up to 20 wt.%, more preferably up to 15 wt.%, even more preferably up to 10 wt.%, most preferably up to 5 wt.% based on the total weight of the first fibers or second fibers respectively, of commonly used additives, such as for example spinning auxiliaries, fillers, flame retardant materials, UV inhibitors, crystallization retarders / accelerators, plasticizers, heat stabilizers, antimicrobial additives, antistatic agents, coloring agents or any combination thereof.

[0057] In an embodiment, the material for molding applications comprises a nonwoven fabric which comprises first fibers composed for at least 75 wt.% of the polyethylene terephthalate polymer, preferably for at least 90 wt.% of the polyethylene terephthalate polymer, preferably for at least 95 wt.% of the polyethylene terephthalate polymer, and bicomponent second fibers comprising a first component composed for at least 50 wt.% of the polyethylene terephthalate polymer and a second component composed for at least 50 wt.% of the polybutylene terephthalate copolymer.

[0058] In an embodiment, the material for molding applications comprises a nonwoven fabric which comprises first fibers composed for at least 50 wt.% of the polyethylene terephthalate polymer, and bicomponent second fibers comprising a first component composed for at least 75 wt.% of the polyethylene terephthalate polymer, preferably for at least 90 wt.% of the polyethylene terephthalate polymer, preferably for at least 95 wt.% of the polyethylene terephthalate polymer, and a second component composed for at least 50 wt.% of the polybutylene terephthalate copolymer. In an embodiment, the material for molding applications comprises a nonwoven fabric which comprises first fibers composed for at least 50 wt.% of the polyethylene terephthalate polymer, and bicomponent second fibers comprising a first component composed for at least 50 wt.% of the polyethylene terephthalate polymer, and a second component composed for at least 75 wt.% of the polybutylene terephthalate copolymer, preferably for at least 90 wt.% of the polybutylene terephthalate copolymer, preferably for at least 95 wt.% of the polybutylene terephthalate copolymer.

[0059] In an embodiment, the material for molding applications comprises a nonwoven fabric which comprises first fibers composed for at least 75 wt.% of the polyethylene terephthalate polymer, preferably for at least 90 wt.% of the polyethylene terephthalate polymer, preferably for at least 95 wt.% of the polyethylene terephthalate polymer, and bicomponent second fibers comprising a first component composed for at least 50 wt.% of the polyethylene terephthalate polymer, preferably for at least 90 wt.% of the polyethylene terephthalate polymer, preferably for at least 95 wt.% of the polyethylene terephthalate polymer, and a second component composed for at least 75 wt.% of the polybutylene terephthalate copolymer, preferably for at least 90 wt.% of the polybutylene terephthalate copolymer, preferably for at least 95 wt.% of the polybutylene terephthalate copolymer.

[0060] In an embodiment, the material for molding applications comprises a nonwoven fabric which comprises first fibers consisting of the polyethylene terephthalate polymer, and bicomponent second fibers comprising a first component consisting of the polyethylene terephthalate polymer, and a second component consisting of the polybutylene terephthalate copolymer.

[0061] The material for molding applications may comprise a nonwoven fabric which comprises first fibers composed for at least 50 wt.% of the polyethylene terephthalate polymer and bicomponent second fibers comprising a first component composed for at least 50 wt.% of the polyethylene terephthalate polymer and a second component composed for at least 50 wt.% of the polybutylene terephthalate copolymer, wherein the first fibers have a linear density of 2 to 25 dtex, preferably the first fibers have a linear density of 5 to 20 dtex, more preferably the first fibers have a linear density of 7 to 15 dtex, and / or wherein the bicomponent fibers have a linear density of 2 to 25 dtex, preferably the bicomponent fibers have a linear density of 5 to 20 dtex, more preferably the bicomponent fibers have a linear density of 7 to 15 dtex.

[0062] Preferably, the first fibers comprised in the nonwoven fabric comprised in the material for molding applications and / or the bicomponent second fibers comprised in the nonwoven fabric comprised in the material for molding applications are filaments to further improve the breaking strength and / or tear strength of the material for molding applications.

[0063] The material for molding applications comprises a nonwoven fabric which may comprise first fibres composed for at least 50 wt.% of the polyethylene terephthalate polymer and bicomponent second fibers comprising a first component composed for at least 50 wt.% of the polyethylene terephthalate polymer and a second component composed for at least 50 wt.% of the polybutylene terephthalate copolymer, wherein the bicomponent fibers may exhibit any cross-sectional shape. Preferably, the cross-sectional shape of the bicomponent fibers, preferably core / sheath bicomponent fibers, is round or elliptical. However, the cross-sectional shape of the bicomponent core / sheath fibers may also be triangular, rectangular or multilobal, like bilobal or trilobal. The bicomponent fibers may comprise a hollow section within the fiber cross section, i.e. the bicomponent fibers may be hollow bicomponent fibers.

[0064] Selection of a certain cross-sectional shape for the first fibers and / or the bicomponent second fibers allows to fine-tune the bonding strength between the first fibers and / or the bicomponent second fibers, and enables to improve friction between the material for molding applications and pile yarns tufted into the primary backing when the material for molding applications is used as a primary carpet backing.

[0065] The polyethylene terephthalate polymer comprised in the first fibers and / or comprised in the first component of the bicomponent fibers comprised in the nonwoven fabric comprised in the material for molding applications may be a recycled polyethylene terephthalate polymer enabling to manufacture the material for molding applications in a more sustainable manner.

[0066] The nonwoven fabric comprised in the material for molding applications preferably is a nonwoven fabric composed of filaments produced by known spunbonding processes wherein filaments are extruded from a spinneret and subsequently laid down on a conveyor belt as a web of filaments and subsequently consolidated, also known as bonding, the web to form a nonwoven fabric, or by a two-step process wherein filaments are spun and wound on bobbins, preferably in the form of multifilament yarns, followed by the step of unwinding the filaments or multifilament yarns and laying the filaments down on a conveyor belt as a web of filaments and consolidating the web to form a nonwoven fabric.

[0067] The nonwoven fabric comprised in the material for molding applications may be consolidated by mechanical consolidation, for example by stitching, mechanical needling and / or hydrodynamic consolidation by fluid jets, in particular by hydroentanglement, and subsequent thermal consolidation, for example by calendaring, ultrasonic bonding and / or hot air bonding, preferably by hot air bonding.

[0068] The nonwoven fabric comprised in the material for molding applications may advantageously be consolidated by thermal consolidation only, for example by calendaring, ultrasonic bonding and / or hot air bonding.

[0069] The nonwoven fabric comprised in the material for molding applications may have a weight of at least 20 g / m2, or at least 25 g / m2, or at least 30 g / m2The nonwoven fabric comprised in the material for molding applications may advantageously have a weight of at most 200 g / m2, or at most 180 g / m2, or at most 160 g / m2. The nonwoven fabric comprised in the material for molding applications may a weight of at most 350 g / m2, or at most 400 g / m2, or at most 600 g / m2, or at most 800 g / m2.

[0070] The nonwoven fabric comprised in the material for molding applications may have a weight between 50 and 200 g / m2, preferably between 65 and 180 g / m2, preferably between 70 and 160 g / m2, preferably between 80 and 140 g / m2, in particular when the material for molding applications is used as a primary backing for a tufted carpet.

[0071] The nonwoven fabric comprised in the material for molding applications may have a weight between 20 and 100 g / m2, preferably between 25 and 75 g / m2, preferably between 30 and 60 g / m2, in particular when the material for molding applications is used as a secondary backing for a tufted carpet.

[0072] The material for molding applications may comprise one or more further nonwoven fabrics, wherein each of the further nonwoven fabrics may be independently selected according to any embodiment of the nonwoven fabric disclosed herein above or any combination thereof.

[0073] The one or more further nonwoven fabrics may be located directly adjacent, and preferably plane parallel, to the nonwoven fabric comprised in the material for molding applications.

[0074] The one or more further nonwoven fabrics may be connected to the nonwoven fabric comprised in the material for molding applications by any suitable known technology, including mechanical connection technologies, for example by stitching, mechanical needling and / or hydrodynamic consolidation by fluid jets, in particular by hydroentanglement, by gluing, and / or by thermal bonding, for example by ultrasonic bonding and / or hot air bonding.

[0075] The material for molding applications comprising a nonwoven fabric comprising fibers, wherein the nonwoven fabric comprises a polyethylene terephthalate polymer and a polybutylene terephthalate copolymer, wherein the polybutylene terephthalate copolymer is copolymerized from a dicarboxylic acid compound and a diol compound, wherein the diol compound does not comprise neopentyl glycol can advantageously be utilized in molded articles enabling improved molding performance. Therefore, a molded article is provided comprising the material for molding applications as disclosed herein above.

[0076] The material for molding applications comprising a nonwoven fabric comprising fibers, wherein the nonwoven fabric comprises a polyethylene terephthalate polymer and a polybutylene terephthalate copolymer, wherein the polybutylene terephthalate copolymer is copolymerized from a dicarboxylic acid compound and a diol compound, wherein the diol compound does not comprise neopentyl glycol can advantageously be utilized in carpet constructions molded into a three- dimensional carpet. Therefore, a molded three-dimensional carpet is provided comprising pile yams the material for molding applications as disclosed herein above as a primary backing

[0077] The material for molding applications comprising a nonwoven fabric comprising fibers, wherein the nonwoven fabric comprises a polyethylene terephthalate polymer and a polybutylene terephthalate copolymer, wherein the polybutylene terephthalate copolymer is copolymerized from a dicarboxylic acid compound and a diol compound, wherein the diol compound does not comprise neopentyl glycol can advantageously be utilized as a primary backing in a tufted carpet. Therefore, a tufted carpet is provided comprising pile yams and the material for molding applications as disclosed herein above as a primary backing.

[0078] The material for molding applications comprising a nonwoven fabric comprising fibers, wherein the nonwoven fabric comprises a polyethylene terephthalate polymer and a polybutylene terephthalate copolymer, wherein the polybutylene terephthalate copolymer is copolymerized from a dicarboxylic acid compound and a diol compound, wherein the diol compound does not comprise neopentyl glycol can advantageously be utilized as a secondary backing in a tufted carpet. Therefore, a tufted carpet is provided comprising pile yams and the material for molding applications as disclosed herein above as a secondary backing.

[0079] The tufted carpet comprising the material for molding applications as disclosed herein above as a primary backing and / or as a secondary backing may be molded into a molded carpet. Therefore, a molded carpet is provided comprising pile yams and a material for molding applications as disclosed herein above as a primary backing and / or as a secondary backing.

[0080] The material for molding applications comprising a nonwoven fabric comprising fibers, wherein the nonwoven fabric comprises a polyethylene terephthalate polymer and a polybutylene terephthalate copolymer, wherein the polybutylene terephthalate copolymer is copolymerized from a dicarboxylic acid compound and a diol compound, wherein the diol compound does not comprise neopentyl glycol can advantageously be utilized in underbody shields in vehicle applications. Therefore, an underbody shield is provided comprising the material for molding applications as disclosed herein above.

[0081] The nonwoven fabric comprised in the material for molding applications in underbody shields may have a weight of at least 200 g / m2, or at least 300 g / m2, or at least 400 g / m2. The nonwoven fabric comprised in the material for molding applications may have a weight of at most 1600 g / m2, or at most 1200 g / m2, or at most 1000 g / m2, or at most 800 g / m2.

[0082] Example 1

[0083] A material for a molding applications was provided comprising first fibers composed of a dimethyl terephthalate-based polyethylene terephthalate polymer and second fibers composed of composed of a polybutylene terephthalate resin copolymerized from a dicarboxylic acid compound and a diol compound which does not comprise neopentyl glycol and does not comprise ethylene glycol, wherein the polybutylene terephthalate resin has a melting temperature of 170°C. Example 2

[0084] A material for a molding applications was provided comprising first fibers composed of a terephthalic acid-based polyethylene terephthalate polymer and second fibers composed of composed of a polybutylene terephthalate resin copolymerized from a dicarboxylic acid compound and a diol compound which does not comprise neopentyl glycol and does not comprise ethylene glycol, wherein the polybutylene terephthalate resin has a melting temperature of 170°C.

[0085] Comparative Example

[0086] A material for a molding applications was provided comprising first fibers composed of a dimethyl terephthalate-based polyethylene terephthalate polymer and second fibers composed of composed of a polybutylene terephthalate resin copolymerized from a dicarboxylic acid compound and a diol compound comprising 71 mol% of 1 ,4-butanediol, 5 mol% of ethylene glycol, and 24 mol% of neopentyl glycol. The material for a molding applications of the comparative example showed sticking of filaments to processing equipment, such as hot air drums, while the material for a molding applications of the examples did not show filament breakage or sticking of filaments to processing equipment.

Claims

AMENDED CLAIMS received by the International Bureau on 10 April 2026 (10.04.2026)1 . A material for molding applications comprising a nonwoven fabric comprising fibers, the nonwoven fabric (i) comprising first fibers comprising a polyethylene terephthalate polymer and second fibers comprising a polybutylene terephthalate copolymer, (ii) comprising bicomponent fibers comprising a first component comprising a polyethylene terephthalate polymer and a second component comprising a polybutylene terephthalate copolymer, or (iii) comprising first fibers comprising a polyethylene terephthalate polymer and bicomponent second fibers comprising a first component comprising a polyethylene terephthalate polymer and a second component comprising a polybutylene terephthalate copolymer, wherein the polybutylene terephthalate copolymer is copolymerized from a dicarboxylic acid compound and a diol compound comprising 2-methyl-1 ,3-propanediol, and preferably 1 ,4-butanediol, wherein the diol compound does not comprise neopentyl glycol.

2. The material for molding applications according to claim 1 , wherein the polyethylene terephthalate polymer is a dimethyl terephthalate-based polyethylene terephthalate polymer.

3. The material for molding applications according to claim 1 , wherein the polyethylene terephthalate polymer is a terephthalic acid-based polyethylene terephthalate polymer.

4. The material for molding applications according to any one or more of claims 1 to 3, wherein the polybutylene terephthalate copolymer is copolymerized from a dicarboxylic acid compound and a diol compound, wherein the diol compound does not comprise ethylene glycol.

5. The material for molding applications according to any one or more of claims 1 to 4, wherein the diol compound comprises 2-methyl-1 ,3-propanediol, and preferably 1 ,4-butanediol, and one or more further diol monomers selected from the group consisting of 1 ,2-propanediol, 1 ,3-propanediol, 1 ,2-butanediol, 1 ,5-pentanediol, cyclopentanediol, 1 ,6-hexanediol, 1 ,4-cyclohexanediol, 1 ,2- cyclohexanedimethanol, 1 ,3-cyclohexanedimethanol, 1 ,4- cyclohexanedimethanol, trimethylolpropane, diethylene glycol, polyethylene glycol and polytetramethylene glycol.

6. The material for molding applications according to any one or more of claims 1 to 5, wherein the polybutylene terephthalate copolymer has a melting temperature between 150°C and 200°C.

7. The material for molding applications according to any one or more of claims 1 to 6, wherein the dicarboxylic acid compound comprises at least one of terephthalic acid, dimethyl terephthalate, isophthalic acid, and dimethyl isophthalate, and wherein the dicarboxylic acid compound optionally comprises one or more of adipic acid, suberic acid, sebacic acid, 1 ,4- cyclohexanedicarboxylic acid, 2,6- naphthalenedicarboxylic acid, dimethyl 2,6- naphthalate, and 1 ,5-naphthalenedicarboxylic acid.

8. The material for molding applications according to any one or more of claims 1 to 7, wherein the nonwoven fabric is composed for 50 to 95 wt.% of the polyethylene terephthalate polymer and for 5 to 50 wt.% of the polybutylene terephthalate copolymer, preferably for 60 to 95 wt.% of the polyethyleneterephthalate polymer and for 5 to 40 wt.% of the polybutylene terephthalate copolymer, more preferably for 70 to 93 wt.% of the polyethylene terephthalate polymer and for 7 to 30 wt.% of the polybutylene terephthalate copolymer, more preferably for 80 to 90 wt.% of the polyethylene terephthalate polymer and for 10 to 20 wt.% of the polybutylene terephthalate copolymer.

9. The material for molding applications according to any one or more of claims 1 to 8, wherein the nonwoven fabric comprises first fibers composed for at least 50 wt.% of the polyethylene terephthalate polymer and second fibers composed for at least 50 wt.% of the polybutylene terephthalate copolymer.

10. The material for molding applications according to any one or more of claims 1 to 8, wherein the nonwoven fabric comprises bicomponent fibers comprising a first component composed for at least 50 wt.% of the polyethylene terephthalate polymer and a second component composed for at least 50 wt.% of the polybutylene terephthalate copolymer.11 . The material for molding applications according to any one or more of claims 1 to 8, wherein the nonwoven fabric comprises first fibers composed for at least 50 wt.% of the polyethylene terephthalate polymer and bicomponent second fibers comprising a first component composed for at least 50 wt.% of the polyethylene terephthalate polymer and a second component composed for at least 50 wt.% of the polybutylene terephthalate copolymer.

12. The material for molding applications according to any one or more of claims 8 to 11 , wherein the bicomponent fibers are bicomponent core / sheath fibers, wherein the core is the first component and the sheath is the second component.

13. A tufted carpet comprising pile yarns and the material for molding according to any one or more of claims 1 to 12 as a primary backing.

14. A tufted carpet comprising pile yarns and a primary backing, and comprising the material for molding applications according to any one or more of claims 1 to 12 as a secondary backing.

15. A molded carpet comprising the tufted carpet according to any one or more of claims 13 to 14.

16. A molded article comprising the material for molding applications according to any one or more of claims 1 to 12.

17. The molded article according to claim 16, wherein the molded article is an underbody shield.