AU680301B2 - A sandwich, a method for its production, and the use of said sandwich - Google Patents

A sandwich, a method for its production, and the use of said sandwich Download PDF

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Publication number
AU680301B2
AU680301B2 AU77583/94A AU7758394A AU680301B2 AU 680301 B2 AU680301 B2 AU 680301B2 AU 77583/94 A AU77583/94 A AU 77583/94A AU 7758394 A AU7758394 A AU 7758394A AU 680301 B2 AU680301 B2 AU 680301B2
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AU
Australia
Prior art keywords
sandwich
base web
fibres
outer layer
intermediate layer
Prior art date
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Ceased
Application number
AU77583/94A
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AU7758394A (en
Inventor
Gunther Feist
Rainer Dr Gardill
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Megatech Industries Deutschland GmbH
Original Assignee
Empe-Werke Ernst Pelz GmbH and Co KG
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Application filed by Empe-Werke Ernst Pelz GmbH and Co KG filed Critical Empe-Werke Ernst Pelz GmbH and Co KG
Publication of AU7758394A publication Critical patent/AU7758394A/en
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Publication of AU680301B2 publication Critical patent/AU680301B2/en
Assigned to EMPE FINDLAY INDUSTRIES GMBH reassignment EMPE FINDLAY INDUSTRIES GMBH Alteration of Name(s) in Register under S187 Assignors: EMPE-WERKE ERNST PELZ GMBH & CO. KG
Anticipated expiration legal-status Critical
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02—Physical, chemical or physicochemical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B32B2262/065—Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/08—Animal fibres, e.g. hair, wool, silk
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/04—Time
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/12—Pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/10—Natural fibres, e.g. wool, cotton
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2479/00—Furniture
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Laminated Bodies (AREA)
  • Battery Mounting, Suspending (AREA)

Abstract

A laminated body having a sheet-like supporting part made of a consolidated base nonwoven (coating substrate) with a content of thermoplastic fibres, which is provided at least on one side with a plastic-containing outer layer, is characterised in that the base nonwoven is bonded to the outer layer by the application of pressure and heat via an intermediate layer which has a thermoplastic content, is of a different or the same material as that of the synthetic fibres of the base nonwoven and the softening temperature of which lies above that of the synthetic fibres of the base nonwoven. Also disclosed are methods of production and use thereof. <IMAGE>

Description

rr 44672 GEH:HB 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 nventors: "Actual Inventors: .4* a *eaba
B
DR RAINER GARDILL GUNTHER FEIST Address for Service: COLLISON CO.,117 King William Street, Adelaide, S.A. 5000 Invention Title: A SANDWICH, A METHOD FOR ITS PRODUCTION, AND THE USE OF SAID SANDWICH The following statement is a full description of this invention, including the best method of performing it known to us: 2 The invention relates to a sandwich with a sheetlike support part consisting of a base web which is bonded, has a thermoplastic synthetic fibres content, and is provided with a plastic-containing outer layer on at least one side; also, a method of producing such a sandwich, and the use of such a sandwich.
I Sandwiches of the type described above, e.g. formed parts made of webs consisting of polyester fibres, as described in DE-A 40 41 934, are produced as follows: they are first 0o heated to a temperature above the softening point of the synthetic fibres, whereupon they are shaped in a cold or hot mould under pressure, and are then cooled, thus producing stiff moulded parts which can be used as e.g.
lining parts for motor vehicles.
S s1 It is also known in the art how to produce such sandwiches not from pure synthetic fibres, e.g. polyester fibres, but from mixed webs made from e.g. jute plus polyester fibres, as described in GB-A 2,090,849 or from flax fibres plus thermoplastic polymers or polypropylenes, as disclosed in 20 US-A 4,323,625, or from flax or other lignocellulosic fibres plus polypropylene glycol or polyester polyols, as disclosed in US-A 4,546,039. Also known in the art is the use of flax fibres plus bicomponent fibres, with e.g. 30 to polypropylene/polyethylene bicomponent fibres by za weight.
If sandwiches of the above-mentioned general type are produced using such bonded webs, to which an outer layer is attached, e.g. either a decorative layer on the front of the sandwich and/or a barrier sheet or a crash-pad on the back of the sandwich, generally consisting of temperaturesensitive material such as foam sheets (especially PVC), plastic compact sheets (especially PVC), temperaturesensitive fabric decorative layers or polyurethane flexible i -I I~IIIC 3 foam, then it is generally necessary to adhesively attach the outer layer to the already-bonded base web after the pressing operation, because, due to the high nonthermoplastic fibres content of the base web, particularly with the use of mixed-fibre webs, no adequate adhesion to the outer layer can be achieved not even when a cotton fabric or suchlike is applied to the side of the outer layer facing the base web in an attempt to improve the adhesion of the outer layer to the base web. The reason for this is as follows: There is fundamentally only a small degree of adhesiveness between the thermoplastic content of the base material and the material of the outer layer, especially if the outer .i1. is layer is not heated to a temperature above its softening point. Due to the proportion of non-thermoplastic fibres in the base web, the number of points of contact oi adhesioncapable thermoplastic fibres of the base web with the outer layer is reduced, with the result that even with the use of 20 cotton fabrics and suchlike as bonding intermediaries, adequate connection cannot be achieved. The heating of temperature-sensitive outer layers to softening temperature is not possible, because then e.g. patterned decorative surfaces would be damaged during pressing. On the other hand, due to the loose structure of the base web, if the latter is heated sufficiently then so much heat energy is stored that unacceptable heating of the decorative layer is caused thereby.
Thermal impairment, particularly of a decorative layer, cannot be prevented by the use of sufficiently highlycooled compression moulding tools, because with too low a surface temperature e.g. on a plastic outer sheet of the outer layer adjacent to the base web, a "white break" fault will occur in the shaped regions if the interface temperature is too low. In addition, with the use of foam 4 sheets instead of compact sheets for the outer layer and in the case of outer layers with flexible foam underlayers, the amount of heat eduction is too low, even with highlycooled tools, with the result that generally the foam structure is partially destroyed.
The aim of the invention is: to create a sandwich, of the type mentioned initially, in which the bonding of the base web by the application of pressure and heat and the secure attachment thereof even to Jo temperature-sensitive outer layers can be performed simultaneously in a single pressing and laminating operation; and also to provide a method of producing such a sandwich; and to indicate the use of such a sandwich.
In terms of the invention, this aim is achieved with a sandwich of the type mentioned initially in that the base o* *web is attached to the outer layer through the application of pressure and heat, by way of an intermediate layer with a thermoplastic content, the material of which can be the 20 same as or different from that of the synthetic fibres of the base web and whose softening temperature is higher than that of the synthetic fibres of the base web.
0 It can be specified that the base web has polyethylene fibres, 2" 5 It can also be specified that the base web has polypropylene fibres.
The invention also provides that the base web can be a mixed web of thermoplastic synthetic fibres and natural fibres.
In this regard, it can be specified that the base web has jute fibres.
It can also be specified that the base web has flax fibres.
It can also be specified that the base web has sisal fibres.
It can also be specified that the base web has cotton fibres.
S It can also be specified that the base web has wool fibres.
In addition, it can be specified that the base web has a weight per unit area of 500 to 3000 g/m 2 Finally, the invention proposes that the base web have a weight per unit area of 1500 to 2500 g/m 2 In addition, it can be specified that the base web has a f weight per unit area of approximately 2000 g/m 2 °The invention also provides that the base web consists of to 80% synthetic fibres and 80 to 20% natural fibres by weight.
a.
is In this regard, it is preferable for the base web to contain equal proportions of synthetic and natural fibres by weight.
The invention also proposes that the intermediate layer be a web.
2( This web can be a polyester web.
A foam sheet can also be used as the intermediate layer.
The intermediate layer can have a weight per unit area of from 100 to 500 g/m 2 It can also have a weight per unit area of approximately 2s 300 g/m 2 The outer layer can be attached to the base web by way of the intermediate layer. I 11 6 The outer layer can be a barrier sheet, a crash pad, or even a decorative layer.
The outer layer can also be made of polyvinyl chloride.
If appropriate, particularly when a decorative layer is s used, the outer layer can be made of cloth material.
In addition, there can be a foam layer interposed between the outer layer and the intermediate layer and attached to the outer layer.
In a preferred design, the base web has a density gradient with respect to the synthetic fibre material. In this regard, for example, the side facing the outer layer or plastic intermediate layer contains a higher proportion of plastic than the side facing the rear. This change in density can be either continuous, e.g. produced by 15 aerodynamic web laying, or discontinuous, e.g. produced by multilayer formation of the base web.
The method of producing sheetlike sandwiches according to the invention, in which a base web with a thermoplastic Ssynthetic-fibres content is bonded by the application of .o pressure and heat and is attached on at least one side to a plastic-containing outer layer, is distinctive in that: the base web is first heated to a temperature greater than the softening temperature of the synthetic fibres of the base web; and then the heated base web, a non-preheated intermediate layer adjacent thereto with a thermoplastic content, the material of which is either the same as or different from that of the synthetic fibres of the base web, and whose softening temperature is greater than that of the synthetic fibres of the base web, and the likewise-nonpreheated outer layer, are all subjected together to one and the same compression
"SJ
7 moulding operation, in which both the bonding of the base web and the attachiment of the outer layer thereto take place.
In this regard, the heating of the base web can be performed by means of a hot air flow.
In addition, according to the invention, after the base web has been preheated it can first be precompressed, e~g. to a thickness of 1 mm more than the desired final thickness.
This is advantageous in that a lower pressure can be used io for the final production of the sandwich, and thus e.g. any decorative layer will be treated gently. A further benefit of this precompacting is that the base web will already have a smooth surface before it is brought into contact with the outer layer and the intermediate layer.
The invention also proposes that the intermediate layer be attached to the outer layer before being united with the base web.
The invention also proposes that the intermediate layer be adhesively bonded to the outer layer.
2a According to the invention it can also be specified that in addition to the base web, the outer layer is also preheated, to a temperature above ambient temperature but below that to which the base web is preheated.
In this regard, the temperature to which the outer layer is preheated is preferably between 80 and 1209 C.
it is also proposed that the base web be heated to approximately 200* C before the sandwich consisting of the preheated web, non-preheated intermediate layer, and nonpreheated or only slightly preheated decorative layer is 3o put together.
i II 8 It can also be specified that the pressing operation is performed at a temperature of approximately 60* C.
The invention also proposes that the pressing time be 30 to 140 seconds.
It is advantageous if the prering time is approximately seconds.
The invention also teaches the use of the sandwich according to the invention for the lining of motor vehicles, as a packing material, and/or as a component part for furniture.
The invention is based on the surprising finding that in cases where the base web contains a high proportion of nonthermoplastic fibres (particularly natural fibres), Sreliable uniting of the layers, together with the bonding 15 of the base web, can be successfully achieved in a single pressing or laminating operation without danger of damaging the material of the outer layer, even with the use of temperature-sensitive outer materials by arranging a thin, firm intermediate layer, preferably a polyester layer, between the base web and the outer layer. On the one hand the intermediate layer protects the outer layer sufficiently against an unsuitably high degree of heattransfer, and on the other hand good adhesion to the base web is achieved by means of the intermediate layer, even m" 2 though the softening temperature of the intermediate layer is only reached to the extent that superficial softening of X_ the fibres of the intermediate layer occurs.
By means of the method according to the invention, decorative-layer materials made of plastic or textile materials and provided with a temperature-sensitive flexible foam on their back can also be back-pressed in a single stage. An outer layer applied to the back of the sandwich can be a sheet, e.g. a barrier sheet, but also a V crash-pad or suchi like, or even facing-sheets. All such parts, which can also be preheated if required, can be Further features and benefits of the invention will emerge s from the following description, where examples of embodiments will be explained in detail with reference to th~t diagrammatic drawing, in which: FIG. 1 shows one example of a sandwich according to the invention, in a sectional view perpendicular to the plane of the sandwich; FIG. 2 is a view, corresponding to that in FIG. 1, but showing a second example of a sandwich according to the invention; and FIG. 3 shows a third example of a sandwich according to the If, invention.
As can be seen in the example shown in FIG. 1, the sandwich according to the invention has a base web 10. This is a mixed web consisting of 50% flax fibres by weight and polyethylene/polypropylene bicomponent fibres by weight and having a weight per unit area of 2000 g/M 2 Next to the base web 10, there is an intermediate layer 12, this being a polyester web with a weight per unit area of 300 g/m', such as that available commercially under the trade name 0.0 "$Roy Polo Ell, for example. Next to the intermediate layer 26 12 there is a decorative sheet 14 in FIG. 1 (PVC decorative sheet available commercially, e.g. from the firm Beneke).
in the example shown in FIG. 2, there is a foam layer 18 consisting of polyurethane flexible foam ("Molto-schaum") arranged next to the intermediate layer 12 already described in relation to FIR. 1; and again this is followed by the decorative layer 14.
In the example shown in FIG. 3, the sandwich again consists of the base web 10, the intermediate layer, 12, and the decorative layer 14, as described above. In addition, however, a further intermediate layer 12 is provided on the back of the base web 10. This intermediate layer 12 again consists either of the above-mentioned polyester web or of a foam material, on which are arranged a crash pad 20 (only diagrammatically indicated) and a sheet (possibly in the form of a barrier sheet).
The sandwich is produced according to the method of the invention as follows: Firstly, the base web 10 is heated to a temperature of 200°C. Then the base web thus preheated, the intermediate layer(s) 12 (FIGS. 1 and and the decorative layer 14, S 15 possibly with the foam layer 18 interposed as shown in FIG.
2, and also the crash-pad 20 with the barrier sheet (FIG.
3) are placed in a compression moulding die at a temperature of 60°C, whereupon the pressing operation takes place with a press-locking time of 90 seconds.
20 If reinforcing elements are to be introduced into the sandwich, e.g. metal or plastic clip-holders to take plastic clips, these can all be put into the compression moulding die at the same time and pressed-in in the pressing operation mentioned above.
Sandwiches are obtained in which reliable attachment of the base web 10 to the covering material is achieved, without impairment of the covering material by thermal overload.
The features of the invention disclosed in the description above, in the drawing, and in the clairs, can be significant, both individually and in any combination, for the implementation of the invention in its various forms of embodiment.

Claims (29)

1. A sandwich, with a sheetlike support part consisting of a bonded base web having a thermoplastic synthetic- fibres content, and with a plastic-containing outer layer provided on at least one side of said sandwich, characterized in that the base web (10) is attached to the outer layer (14, 18) by the application of pressure and heat, by way of an intermediate layer (12) with a ~0 thermoplastic content, and the material of the intermediate layer is the same as or different from that of the synthetic fibres of the base web, and the softening temperature of the intermediate layer is above that of the synthetic fibres of the base web 1m5 2. A sandwich as claimed in claim 1, characterized in that the base web (10) has polyethylene fibres.
3. A sandwich as claimed in claim 1 or 2, characterized in that the base web (10) has polypropylene fibres.
4. A sandwich as claimed in any of claims 1 to 3, 20 characterized in that the base web (10) is a mixed-fibre web consisting of thermoplastic synthetic fibres and natural fibres. A sandwich as claimed in claim 4, characterized in that the base web (10) has jute fibres.
6. A sandwich as claimed in claim 4 or 5, characterized Sin that the base web (10) has flax fibres. i 7. A sandwich as claimed in any of claims 4 to 6, characterized in that the base web (10) has sisal fibres.
8. A sandwich as claimed in any of claims 4 to 7, characterized in that the base web (10) has cotton fibres. 12
9. A sandwich as claimed in any of claims 4 to 8, characterized in that the base web (10) has wool fibres. A sandwich as claimed in any of claims 1 to 9, characterized in that the base web (10) has a weight per unit area of 500 to 3000 g/m 2
11. A sandwich as claimed in claim 10, characterized in that the base web (10) has a weight per unit area of 1500 to 2500 gfM 2
12. A sandwich as claimed in claim 1, characterized in io that the base web (10) has a weight per unit area of approximately 2000 g/M 2
13. A sandwich as claimed in any of claims 4 to 12, *.characterized in that the base web (10) consists of 20 to 80% synthetic fibres by weight and 80 to 20% natural fibres by weight.
14. A sandwich as claimed in c)iim 13, characterized in that the base web (10) contains synthetic fibres and a::.natural fibres in approximately equal proportions by weight.
15. A sandwich as claimed in claim 1, characterized in a that the intermediate layer (12) is a web with a thermoplastic content.
16. A sandwich as claimed in claim 15, cha~racterized in that the intermediate layer (12) is a polyester web.
17. A sandwich as claimed in claim 1, characterized ift that the intermediate layer (12) with a thermoplastic content is a foam sheet.
18. A sandwich as claimed in any of the above claims, characterized 'in that the intermediate layer (12) has a weight per unit area of 100 to 500 g/M 2 *i I 13
19. A sandwich as claimed in claim 18, characterized in that the intermediate layer (12) has a weight per unit area of approximately 300 g/m 2 A sandwich as claimed in any of the above claims, s characterized in that the outer layer (14) is attached to the base web (10) by way of the intermediate layer (12).
21. A sandwich as claimed in claim 20, characterized in that the outer layer (14) is a barrier sheet.
22. A sandwich as claimed in any of the above claims, characterized in that the outer layer (14) consists of polyvinyl chloride.
23. A sandwich as claimed in any of the above claims, characterized in that the outer layer (14) consists of fabric. 5 24. A sandwich as claimed in any of the above claims, characterized in that there is a foam layer (18) between the outer layer (14) and the intermediate layer and said foam layer (14) is attached to the covering layer (14). 20 25. A sandwich as claimed in claim 1, characterized in that there is a gradient in the density of the synthetic material in the base web in a direction perpendicular to the plane of the surface thereof.
26. A sandwich as claimed in claim 25, characterized in that the change in density is continuous.
27. A sandwich as claimed in claim 25, characterized in that the change in density is discontinuous.
28. A method of producing a sheetlike sandwich as claimed in any of the above claims, in which a base web with a thermoplastic synthetic-fibres content is bonded by means 14 of the application of pressure and heat, and is attached on at least one of its sides to an outer layer, characterized in thatt the base web is first heated to a temperature greater h than the softening temperature of the synthetic fibres of the base web; and then the heated base web, a non-preheated intermediate layer attached thereto lo with a thermoplastic content the material of which is either the same as or different from that of the synthetic fibres of the base web and whose softening temperature is greater than that of the synthetic fibres of the base web, and 15 the likewise-nonpreheated outer layer, 4 are all subjected together to one and the same compression moulding operation, in which both the bonding of the base web and also the attachment of the outer layer thereto take place. 20 29. A method as claimed in claim 28, characterized in that the base web is preheated by a hot air flow. A method as claimed in claim 28 or 29, characterized in that the base web, after preheating, is firstly S precompressed. :25 31. A method as claimed in claim 28, characterized in that the intermediate layer is attached to the outer layer before being united with the base web.
32. A method as claimed in claim 28, characterized in that the intermediate layer is adhesively bonded to the outer lyar.
33. A method as claimed in claim 28, characterized in that the outer layer as well as the base layer is preheated, to a temperature above ambient temperature but below that to which the base web is preheated.
34. A method as claimed in any of claims 28 to 33, characterized in that the temperature to which the outer layer is preheated is between 80 and 120*C. A method as claimed in any of claims 28 to 34, characterized in that before the sandwich consisting of the preheated base web, the non-preheated or only-slightly- preheated intermediate layer, and the non-preheated outer layer are put together, the base web is heated to approximately 200 0 C.
36. A method as claimed in claim 35, characterized in that the compression moulding operation is performed at a temperature of approximately S 15 37. A method as claimed in any of claims 28 to 36, characterized in that the pressing time is 30 to 140 seconds.
38. A method as claimed in claim 37, characterized in that c* the pressing time is approximately 90 seconds. .20 39. The use of the sandwich as claimed in any of claims 1 to 27 for the lining of motor vehicles. The use of the sandwich as claimed in any of claims 1 to 27 as a packing material.
41. The use of the sandwich as claimed in any of claims 1 to 27 as a component part for furniture.
42. A sandwich substantially as hereinbefore described with reference to and as illustrated by the accompanying drawings. 16
43. A method of producing a sandwich as defined in Claim 1 substantially as hereinbefore described with reference to and as illustrated by the accompanying drawings. Dated this 2nd day of November 1994 EMPE-WERKE ERNST PELZ GmbH &CO. KG By their Patent Attorneys COLLISON CO. V, *J Abstract A sandwich with a sheetlike support part made of a bonded base web with a thermoplastic synthetic-fibres content and s provided with a plastic-containing outer layer on one side, characterized in that the base web is attached to the outer layer, through the application of pressure and heat, by way of an intermediate layer with a thermoplastic content, the material of which is either the same as or different from 0 that of the synthetic fibres of the base web, and whose softening temperature is higher than that of the synthetic fibres of the base web. Also disclosed are a method for .0 producing said sandwich, and the use of said sandwich. 0 0 o 0• .5,5 O*
AU77583/94A 1993-11-02 1994-11-02 A sandwich, a method for its production, and the use of said sandwich Ceased AU680301B2 (en)

Applications Claiming Priority (2)

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DE4337352 1993-11-02
DE4337352 1993-11-02

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CN (1) CN1110223A (en)
AT (1) ATE179114T1 (en)
AU (1) AU680301B2 (en)
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DE20020712U1 (en) * 2000-12-07 2002-04-18 Hp Chem Pelzer Res & Dev Ltd Layer molded article
DE10319967A1 (en) * 2003-05-05 2004-11-25 Quadrant Plastic Composites Ag Nonwoven composite element
DE10356665A1 (en) 2003-12-04 2005-07-07 Benecke-Kaliko Ag Process for the production of grained shaped articles and the molded articles produced therefrom
DE102004042405A1 (en) 2004-09-02 2006-03-30 Rkw Ag Rheinische Kunststoffwerke Non-woven sheet laminates
DE102005005576A1 (en) 2005-02-07 2006-08-17 Benecke-Kaliko Ag Process for producing a grained film and its use
JP4558091B1 (en) * 2009-10-29 2010-10-06 株式会社イノアックコーポレーション Fiber-reinforced molded body and method for producing the same
CN103112234A (en) * 2013-03-04 2013-05-22 苏州裕克施乐塑料制品有限公司 Composite material sheet production method and dual-tensioning device of composite material sheet
DE102013007283A1 (en) 2013-04-27 2014-03-06 Volkswagen Ag Interior trim component useful for motor vehicles, comprises a carrier part , carrier part, which is a composite material comprising natural fibers and plastic fibers, and a top layer
CN105235314B (en) * 2015-09-23 2017-07-18 常州市泛亚汽车饰件有限公司 Resistant to elevated temperatures automotive light weight technology polyester non-woven fabric and preparation method thereof

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KR950013705A (en) 1995-06-15
DE59408134D1 (en) 1999-05-27
CN1110223A (en) 1995-10-18
ES2130330T3 (en) 1999-07-01
EP0650828A1 (en) 1995-05-03
ATE179114T1 (en) 1999-05-15
JP2632297B2 (en) 1997-07-23
CZ268594A3 (en) 1996-03-13
AU7758394A (en) 1995-05-18
JPH07195601A (en) 1995-08-01
SI0650828T1 (en) 1999-06-30

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