AU675143B2 - A lining part for motor vehicles and a method for its production - Google Patents

Description

44336 GEH:KLS P/00/011 Regulation 3.2

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

Name of Applicant: EMPE-WERKE ERNST PELZ GmbH CO. KG Actual Inventors: SVEN WELICH GUNTHER FEIST DR RAINER GARDILL Address for Service: COLLISON CO.,117 King William Street, Adelaide, S.A. 5000 Invention Title: A LINING PART FOR MOTOR VEHICLES AND A METHOD FOR ITS PRODUCTION .The following statement is a full description of this invention, including the best method of performing it known to us: 2 This invention relates to a sheetlike lining part for motor vehicles, e.g. an interior roof lining or suchlike, consisting of a single- or multi-ply core layer covered by two outer layers of non-woven natural-fibre web, one on either side, each being attached to the core layer by an adhesive layer; the invention also relates to a method of producing a sheetlike lining part for motor vehicles, e.g.

an interior roof lining or suchlike, in which an adhesive layer is provided on either side of a core layer, with an outer layer of non-woven natural-fibre web being attached to each adhesive layer, and with the entire laminated structure being bonded together by the application of pressure and heat in a heated forming-mould or suchlike.

*There are prior-art lining parts of this type, in the form is. 15 of roof linings, in which the core layer consists of polyurethane foam while the outer layers consist of glass fibres or webs (also known as batts). These glass fibre layers are bonded to the outer surfaces of the core layer by means of polyurethane adhesives or thermal adhesives.

The facing-layers used consist of polyester web or paper web; they prevent the outer layers from sticking to the forming-mould and constitute a protective covering for the glass fibre webs used as the outer layers.

There are disposal problems with these prior-art lining parts, because glass fibre webs are either non-recyclable or else can only be recycled after undergoing expensive material-separation processing.

There are also prior-art lining parts of the general type outlined above in which the outer layers consist of mechanically bonded, needled jute fibre webs. In this case a decorative layer can be provided; this is bonded on in a separate operation, or can also be applied in a single step instead of the outer web at the time of the production of the core layer. These jute webs are mechanically bonded, and in the prior-art lining part they are bonded onto the core layer by means of the adhesive layers consisting of polyurethane adhesive.

It has been found that this design does not provide adequate strength under conditions of climatic stress.

Moreover, in hot humid climates the lining part sags unacceptably under climatic stress, particularly when designed as a cantilevered internal roof lining.

The aim of the invention is to create a lining part of the general type mentioned above which will retain its shape adequately under the climatic conditions to which a vehicle roof lining may be subjected and will also be fully recyclable.

*0o This aim is achieved by the invention in that the layers of 15 adhesive consist of epoxy resin foam, and the outer layers consist exclusively of loosely needled material.

In addition, it can be specified that at least one of the outer layers is to consist of a non-woven natural fibre web.

20 It can also be specified that at least one of the outer layers is to consist of non-woven jute fibre web.

*It can also be specified that at least one of the outer layers consists of non-woven sisal fibre web.

The invention also proposes that at least one of the outer layers is covered with a facing-layer on the side facing away from the core layer.

It can also be specified according to the invention that at least one of the facing-layers consists of non-woven polyester web.

I I- I In this regard it can be specified that at least one of the facing-layers consists of paper web.

The invention also provides that the facing-layer or layers are bonded to the respective outer layer by means of an epoxy resin foam.

Another form of embodiment of the invention is characterised by an outer decorative layer facing outwards on the visible side of the lining part.

It can also be specified according to the invention that the core layer consists of polyurethane foam.

In this regard, it can be specified that the core layer consists of corrugated cardboard.

The method according to the invention is characterised by the fact that the adhesive layers are formed by the spraying-on of a foaming epoxy resin, which expands in the mould and impregnates the outer layers.

In this regard, it can be specified that the epoxy resin is sprayed onto the core layer.

The invention also proposes that the epoxy resin be sprayed onto the side of the outer layers facing towards the core layer.

0o99 In a further form of embodiment of the invention, the facing-layers are also impregnated with the epoxy resin.

The invention is based on the surprising finding that by producing the adhesive layers from foaming epoxy resin, which is preferably sprayed onto the natucal fibre web on the side thereof facing the core layer, it is possible to create a lining part made of completely recyclable material that will retain its shape even under climatic stress. When this adhesive bond is cured in a heated mould, good I I I II -1.

impregnation of the outer layers occurs as well as adhesion of the outer layers to the core layer. Such impregnation, with concomitant avoidance of chemical or thermal bonding of the outer layers, is vital for resistance to adverse climatic conditions.

Surprisingly, it is possible to achieve outstanding resistance to climatic stress not only when the core layer is made of polyurethane foam but even when a simple corrugated cardboard is used. The corrugated cardboard remains sufficiently strong even in damp climates, and the amount of epoxy resin used can be reduced to the extent that it is in fact possible to talk of a "fully recyclable lining part".

SS°

**To improve ejectability from the mould, it is possible to 15 lay thin polyester webs or paper webs as facing-layers on the natural fibre web of the outer layers. These facinglayers are also bonded-on by the foaming epoxy resin constituting the adhesive layers. The facing-layers also increase the stiffness of the sandwich, although this is not absolutely necessary. The paper webs used can be laminated or unlaminated.

Further features and benefits of the invention will emerge from the following description, in which examples of embodiments will be explained with reference to the diagrammatic drawing, in which: FIG. 1 shows one example of a lining part according to the invention, in a sectional view perpendicular to the longitudinal surface of the lining part; FIG. 2 is a view, corresponding to that in FIG. i, but showing a second example of a lining part according to the invention; and -1 FIG. 3 is a view corresponding to those in FIGS. 1 and 2 but showing a third example of a lining part according to the invention.

In the example shown in FIG. 1, a core layer 10 consisting of polyurethane foam (medium-hard foam, obtainable from the firm of Reissgiess, density 33 kg/m 3 is bonded on both sides to outer layers 12, 14, by means of adhesive layers 16, 18. The outer layers 12, 14 consist of flax fibre web with a weight when dry of 150 g/m 2 while the adhesive layers 16, 18 consist of foaming epoxy resin with a dry weight of 160 g/m 2 available from Ciba-Geigy, using resin 9: type LMW 1135 and hardener type HY 5003.

.9 The example in FIG. 2 corresponds to that shown in FIG. 1, except that the outer layers 12, 14 are covered with 15 facing-layers of chemically-bonded polyester web with a dry weight of 50 g/m 2 obtainable from the firm "Textilgruppe Hof". The facing-layers 20, 22 of polyester web make it easier to eject the entire sandwich-product from the forming-mould.

99 9 In the example shown in FIG. 3, the core layer 10 consists of corrugated cardboard with a wave height of 5 to 7 rmi and a weight per unit area of 425 g/m 2 The adhesive layers 16, 18 consist of 100 g/m 2 of epoxy resin available from Ciba- Geigy, using the same resin and hardener types as in the examples shown in FIGS. 1 and 2. The other sandwich construction features are the same as in FIG. 2.

When the examples described above and illustrated in FIGS.

1 to 3 are being produced, the epoxy resin is sprayed in each case onto the side of the outer layers 12, 14 facing towards the core layer 10. It is, however, also possible to spray both surfaces of the core layer 10 itself with the epoxy resin.

I I a a The amounts preferably used are as follows: for the facinglayers 20, 22 polyester web with a weight per unit area of 30 to 150 g/m 2 or preferably 50 to 70 g/m 2 and for the outer layers 12, 14 flax or jute fibre web with a weight when dry of 100 to 300 g/m 2 or preferably 100 to 200 g/m 2 If r--rugated cardboard is not used for the core layer, the. is preferable to use polyurethane foam with a density of 20 to 60 kg/m 3 but preferably 25 to 35 kg/m 3 The epoxy foam for the adhesive layers 16, 18 is preferably applied at a rate of 60 to 300 g/m 2 and more particularly at a rate of 120 to 180 g/m 2 if the core layer 10 is made of polyurethane foam or 80 to 150 g/m 2 if it is made of corrugated cardboard or paperboard.

o If paper webs are used instead of polyester webs for the 1is facing-layers 20, 22, a weight per unit area of 90 g/m 2 in particular has proved successful.

The features disclosed in the above description, the Sdrawing and the claims, can be fundamental both individually or in any desired combination to the implementation of the invention in its various forms of embodiment.

*o* e o cole°

Claims (15)

1. A sheetlike lining part for motor vehicles, such as an interior roof lining, with a one-ply or multi-ply core layer, covered by two outer layers of nonwoven natural-fibre web, each attached to the core layer by an adhesive layer, characterised in that the adhesive layers consist of epoxy resin foam, and the outer layers consist of material that is neither mechanically nor chemically/thermally bonded.

2. A lining part as claimed in claim 1, characterised in that at least one of the outer layers consists of nonwoven natural-fibre web.

3. A lining part as claimed in claim 1 or 2, characterised in that at least to.o: one of the outer layers consists of nonwoven flax-fibre web.

4. A lining part as claimed in any of the above claims, characterised in :0 that at least one of the outer layers consists of nonwoven jute fibre web. 0 6 A lining part as claimed in any of the above claims, characterised in 1 5 that at least one of the outer layers consists of nonwoven sisal fibre web. to*

6. A lining part as claimed in any of the above claims, characterised in that at least one of the outer layers is covered with a facing layer on the side thereof facing away from the core layer.

7. A lining part as claimed in claim 6, characterised in that at least one of the facing-layers consists of nonwoven polyester web.

8. A lining part as claimed in claim 6 or 7, characterised in that at least one of the facing-layers consists of a paper web.

9. A lining part as claimed in any of claims 6 to 8, characterised in that the facing-layer(s) is/are bonded to the (respective) outer layer by means of an epoxy resin foam.

10. A lining part as claimed in any of the above claims, characterised by C ^,an external decorative layer on the visible side of the lining part,. L_ 9

11. A lining part as claimed in any of the above claims, characterised in that the core layer consists of polyurethane foam.

12. A lining part as claimed in any of claims 1 to 11, characterised in that the core layer consists of corrugated cardboard.

13. A method of producing a sheetlike lining part for motor vehicles, such as an interior roof lining, in which an adhesive layer is applied to either side of a core layer and an outer layer is provided on each adhesive layer, and the entire sandwich construction Is bonded together by the application of pressure and heat in a heated forming-mould, characterised in that the adhesive layers ";are formed by spraying-on a foaming epoxy resin which expands in the ;..forming-mould and impregnates the outer layers. ft

14. A method of producing a sheetlike lining part for motor vehicles, such as an interior roof lining, in which an adhesive layer Is applied to either side of a core layer and an outer layer is provided on each adhesive layer and the entire sandwich construction is bonded together by the application of heat and pressure in a heat forming mould for the production of a lining part so claimed in any one of claims 1 to 12, characterised in that the adhesive layers are formed by spraying on a foaming epoxy resin which expands in the foaming 20 mould and impregnates the outer layers.

15. A method as claimed in claim 13 or 14, characterised in that the epoxy resin is sprayed onto the core layer.

16. A method as claimed in any one of claims 13, 14 or 15 characterised In that the epoxy resin is sprayed onto the side of the outer layers facing the core layer. I I LI Abstract A sheetlike lining part for motor vehicles, e.g. interior roof linings or suchlike, with a single-ply or multi-ply core layer covered by two outer layers made of nonwoven natural-fibre web attached to either side of the core layer by an adhesive layer, characterised in that the adhesive layers consist of epoxy resin foam, and the outer layers consist solely of loosely-needled material; and also, a method of producing such a lining part. **0 a t**o 0@* s 9o