Polyesters having a controlled melting point and fibers formed therefrom

A bicomponent binder fiber comprising:

• about 25 to about 90% by weight of a polymeric core portion;
• about 10 to about 75% by weight of a sheath portion;
• wherein the sheath portion is a polyester formed from the reaction product of a dicarboxylic acid component and a glycol component;
• wherein the dicarboxylic acid component comprises at least one dicarboxylic acid selected from the group consisting of acids, esters, acid chlorides, anhydrides and mixtures thereof, of an aromatic dicarboxylic acid having from about 8 to about 14 carbon atoms, an aliphatic dicarboxylic acid containing about 4 to about 12 carbon atoms, a cycloaliphatic dicarboxylic acid having about 8 to about 12 carbon atoms or mixtures thereof;
• wherein the glycol component comprises less than about 20 mole % of ethylene glycol or diethylene glycol and more than about 50 mole % of a four carbon glycol, a six carbon glycol or mixtures thereof;
• wherein the dicarboxylic acid component contains up to about 45 mole % of an acid, ester, acid chloride or anhydride of an aliphatic acid;
• and
• wherein the polyester has a melting point in the range of from about 140 to about 185° C.

An automotive article prepared from a fiber blend comprising at least one polyester formed from the reaction product of:

• an acid component and a glycol component;
• wherein the dicarboxylic acid component comprises at least one dicarboxylic acid selected from the group consisting of acids, esters, acid chlorides and anhydrides of an aromatic dicarboxylic acid having from about 8 to about 14 carbon atoms, an aliphatic dicarboxylic acid containing about 4 to about 12 carbon atoms, a cycloaliphatic dicarboxylic acid having about 8 to about 12 carbon atoms or mixtures thereof;
• wherein the glycol component comprises less than about 20 mole % of ethylene glycol or diethylene glycol and more than about 50 mole % of 1,4-butanediol, 1,6-hexanediol or mixtures thereof;
• wherein the dicarboxylic acid component contains up to about 45 mole % of an acid, ester, acid chloride or anhydride of an aliphatic acid;
• and
• wherein the polyester has a melting point in the range of from about 140 to about 185° C.