Facing Product for Vehicular Trim

Abstract

A composite facing material is disclosed that may be used in combination with, e.g. foam, fibers and/or shoddy in a vehicular application. The composite may provide heat insulation and/or sound attenuation in a vehicular trim panel. The facing material may include a layer of staple fibers with a spunbonded continuous filament web layer. The layers may be intermittently thermally bonded in a desired pattern.

1 . An automotive trim panel comprising;
 a non-woven composite facing material and one or more backing layers, wherein the facing material comprises at least one layer of a non-continuous thermoplastic staple fiber and at least one spunbonded web layer comprising continuous thermoplastic filaments;   wherein bonds between said layers of said facing material are formed as thermal bonds with said thermoplastic fibers over at least a portion of confronting surfaces between said layers, said thermal bonds being point-bonded.   
     
     
         2 . The automotive trim panel of  claim 1  wherein said layer of a non-continuous thermoplastic staple fiber may comprise one or a plurality of polymers. 
     
     
         3 . The automotive trim panel of  claim 1  wherein said spun bonded web layer may comprise one or a plurality of polymers. 
     
     
         4 . The automotive trim panel of  claim 3  wherein said spun bonded layer comprises at least two polymers, each of said polymers having different melting points. 
     
     
         5 . The automotive trim panel of  claim 1  wherein said layer of staple fiber comprises at least 15% thermoplastic fiber. 
     
     
         6 . The automotive trim panel of  claim 1  wherein said composite facing material has a surface area said thermal bonds being point bonded to cover about 5-40% of said surface area of the composite material. 
     
     
         7 . The automotive trim panel of  claim 1  wherein said composite facing material has a surface area and said thermal bonds being point bonded are intermittent over about 5-40% of the surface area of the composite material. 
     
     
         8 . The automotive trim panel of  claim 1  comprising two layers of spun bonded fibers and a layer of staple fibers between said two layers of spun bonded fibers. 
     
     
         9 . The automotive trim panel of  claim 1  comprising two layers of staple fibers and a layer of spun bonded fibers between said two layers of staple fibers. 
     
     
         10 . The automotive trim panel of  claim 1  wherein said one or more backing layers is comprised of one or a combination of a foam, natural fibers, synthetic fibers, and shoddy. 
     
     
         11 . The automotive trim panel of  claim 1  wherein said trim panel comprises a first backing layer, a second layer of non-continuous thermoplastic staple fibers, and a third outer spunbonded web layer. 
     
     
         12 . The automotive trim panel of  claim 1  wherein said panel is employed as a headliner, a hood liner or engine cover, or a dash insulator for a vehicle. 
     
     
         13 . A non-woven composite facing material, comprising;
 a layer of non-continuous, thermoplastic staple fiber having a first melting point Tm 1 , opposed to a layer of spunbonded web comprising continuous thermoplastic filaments having a second melting point Tm 2  wherein Tm 1 <Tm 2      thermal bonds between said layers formed from heat softened portions of said thermoplastic fibers, said thermal bonds being point bonds; and   wherein said staple fiber layer acts as an adhesive layer when the facing material is combined with one or more backing layers.   
     
     
         14 . The facing material of  claim 13  wherein said staple fiber comprises one or a plurality of polymers, at least one of said polymers having said first melting point Tm 1 . 
     
     
         15 . The facing material of  claim 13  wherein said composite facing material has a surface area, said thermal bonds being point bonded to cover about 5-40% of said surface area of the composite material. 
     
     
         16 . The facing material of  claim 13  wherein said composite facing material has a surface area and said thermal bonds being point bonded are intermittent over about 5-40% of the surface area of the composite material. 
     
     
         17 . The facing material of  claim 13  wherein said one or more backing layers is comprised of one or a combination of a foam, natural fibers, synthetic fibers, and shoddy. 
     
     
         18 . A non-woven composite facing material, comprising;
 a layer of non-continuous, thermoplastic staple fiber having a first melting point Tm 1 , opposed to a layer of spunbonded web comprising continuous thermoplastic filaments having a second melting point Tm 2  and a third melting point Tm 3  wherein Tm 1 <Tm 2  and/or Tm 1 <Tm 3 ;   thermal bonds between said layers formed from heat softened portions of said thermoplastic fibers, said thermal bonds being point bonds; and   wherein said staple fiber layer acts as an adhesive layer when the facing material is combined with one or more backing layers.   
     
     
         19 . The non-woven composite facing material of  claim 18  wherein said staple fiber comprises one or a plurality of polymers, at least one of said polymers having said first melting point Tm 1 .