Exterior trim part
In accordance with a first aspect of the invention, the exterior trim part for a vehicle comprises a fibrous porous structural layer. The exterior trim part further comprises at least one at least sectional perforated film layer, which is made of thermoplastic polyurethane with a melting temperature according to DSC of at least 140° C. The film layer is materially connected to the fibrous porous structural layer, at least in sections.
1. An exterior trim part for a vehicle, comprising:
a fibrous porous structural layer; and
at least one perforated film layer materially connected to said fibrous porous structural layer, said at least one perforated film layer being made of non-foamed thermoplastic polyurethane with a melting temperature according to DSC of at least 140° C.
2. The exterior trim part according claim 1 , wherein the fibrous porous structural layer consists of bicomponent filaments with a CoPET first polymer with a melting temperature of at least 150° C., preferably at least 190° C., and a PET second polymer with a melting temperature of at least 240° C.
3. The exterior trim part according claim 1 , wherein the fibrous porous structural layer consists of bicomponent staple fibres with a CoPET first polymer with a melting temperature of at least 150° C., preferably at least 190° C., and a PET second polymer with a melting temperature of at least 240° C.
4. The exterior trim part according claim 1 , wherein the fibrous porous structural layer comprises first bicomponent staple fibres with a CoPET first polymer with a melting temperature of at least 150° C., preferably at least 190° C., and a PET second polymer with a melting temperature of at least 240° C.
5. The exterior trim part according claim 4 , wherein the fibrous porous structural layer further comprises second bicomponent staple fibres with a CoPET first polymer with a melting temperature of at least 20° C. lower than the melting temperature of the first polymer of the first bicomponent staple fibres.
6. The exterior trim part according to claim 4 , wherein the fibrous porous structural layer further comprises PET staple fibres with a melting temperature of at least 240° C. or CoPET staple fibres.
7. The exterior trim part according claim 1 , wherein the fibrous porous structural layer comprises a mixture of CoPET staple fibres with a melting temperature of at least 150° C., preferably at least 190° C., and PET staple fibres with a melting temperature of at least 240° C.
8. The exterior trim part according to claim 2 , wherein the first polymer forms the sheath of a filament, wherein the PET second polymer forms the core of the filament.
9. The exterior trim part according to claim 1 , wherein the thermoplastic polyurethane film is based on polyether or polyester.
10. The exterior trim part according to claim 1 , wherein the exterior trim part has a total thickness between 1.5 and 10 mm and has an airflow resistance (AFR) in the direction of thickness between 1,000 to 4,500 N·s/m 3 .
11. The exterior trim part according to claim 1 , wherein the perforated film layer is only partially perforated.
12. The exterior trim part according to claim 1 , further comprising a scrim layer connected to the at least one perforated film layer.
13. A method of using an exterior trim part according to claim 1 as an engine bay covering panel, a top of an engine, a side of an engine, an undercover for an engine, an oil pan cover, an under engine shield, a fire wall, an at least partial outer dash panel covering, an air guiding panel located behind a cooler of the engine bay or a vehicle's underbody covering panel, an outer wheel arch liner, or as an automotive exterior trim part.
14. The exterior trim part according to claim 1 , wherein the non-foamed thermoplastic polyurethane is elastomeric.
15. The exterior trim part according to claim 3 , wherein the first polymer forms the sheath of a staple fibre, wherein the PET second polymer forms the core of the staple fibre.
16. An exterior trim part for a vehicle, comprising:
a fibrous porous structural layer; and
at least one air permeable film layer materially connected to said fibrous porous structural layer, said at least one air permeable film layer being made of non-foamed thermoplastic polyurethane with a melting temperature according to DSC of at least 140° C.
17. The exterior trim part according claim 16 , wherein the fibrous porous structural layer comprises first bicomponent staple fibres with a CoPET first polymer with a melting temperature of at least 150° C., preferably at least 190° C., and a PET second polymer with a melting temperature of at least 240° C.; and
wherein the fibrous porous structural layer further comprises second bicomponent staple fibres with a CoPET first polymer with a melting temperature of at least 20° C. lower than the melting temperature of the first polymer of the first bicomponent staple fibres.
18. The exterior trim part according claim 16 , wherein the fibrous porous structural layer comprises first bicomponent staple fibres with a CoPET first polymer with a melting temperature of at least 150° C., preferably at least 190° C., and a PET second polymer with a melting temperature of at least 240° C.; and
wherein the fibrous porous structural layer further comprises PET staple fibres with a melting temperature of at least 240° C. or CoPET staple fibres.
19. The exterior trim part according claim 16 , wherein the fibrous porous structural layer comprises a mixture of CoPET staple fibres with a melting temperature of at least 150° C., preferably at least 190° C., and PET staple fibres with a melting temperature of at least 240° C.
20. The exterior trim part according to claim 16 , wherein the air permeable film layer is only partially air permeable.