CN100532089C - 无纺布复合件 - Google Patents

无纺布复合件 Download PDF

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CN100532089C
CN100532089C CNB2004800122906A CN200480012290A CN100532089C CN 100532089 C CN100532089 C CN 100532089C CN B2004800122906 A CNB2004800122906 A CN B2004800122906A CN 200480012290 A CN200480012290 A CN 200480012290A CN 100532089 C CN100532089 C CN 100532089C
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nonwoven
fibre
composite members
compound foil
thermoplastic
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CN1784303A (zh
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沃尔特·梅尔
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Quadrant Plastic Composites AG
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    • B32—LAYERED PRODUCTS
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    • 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
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/504—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B32B2310/00—Treatment by energy or chemical effects
    • B32B2310/04—Treatment by energy or chemical effects using liquids, gas or steam
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    • B32B2310/00—Treatment by energy or chemical effects
    • B32B2310/08—Treatment by energy or chemical effects by wave energy or particle radiation
    • B32B2310/0806—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation
    • B32B2310/0825—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation using IR radiation
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/003—Interior finishings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract

本发明涉及无纺布复合件，在该复合件中混纺纤维无纺布在一侧或两侧连接至一个或两个结构为ba或bab的复合片中，其中a是具有高熔点的热塑材料而b是具有低熔点的热塑材料，且复合膜的层b面对混纺纤维无纺布，所述混纺纤维无纺布包括热塑纤维和具有高熔点的增强纤维。

Description

无纺布复合件
技术领域
本发明涉及含有混纺纤维无纺布的无纺布复合件(composite element)，该混纺纤维无纺布包括热塑纤维和增强纤维，所述无纺布复合件在其一侧或两侧连接至粘合薄片。
本发明的混纺纤维无纺布是由热塑纤维和增强纤维制成的非强化的(non-consolidated)半成品，其可以通过热塑成型转化成增强纤维成品，例如汽车内部部件。
背景技术
该混纺纤维无纺布在例如DE-A3614533中进行了描述，该专利涉及生产由纤维增强的热塑材料制备的压实的(compact)模塑制品的方法。原料是受针刺压实的混纺纤维无纺布，包括热塑纤维，优选聚丙烯纤维或聚酰胺纤维及无机增强纤维或天然纤维。直接压榨混纺无纺布以形成成品件而无需事先强化(consolidation)，并且可以共压其它基片例如塑料薄片。在DE-A10105813中同样描述了混纺纤维无纺布，该专利涉及制造可热塑成型的、纤维增强的半成品的方法。根据该方法，混合热塑纤维和增强纤维以获得混纺无纺布(其受针刺压实)，然后加热并(任选通过共压装饰层例如热塑薄片)压制为强化的薄的半成品。
对于许多使用用途，由聚丙烯/玻璃纤维混纺无纺布生产的成品件是不充分防水和耐温的，因此它们在强热加工时会变形；而且，由聚丙烯/天然纤维混纺无纺布制得的薄成品件容易发霉并常常倾向于发出臭味；由聚酰胺/玻璃纤维混纺无纺布生产的成品件常常抗弯性不足。因此，本发明的目的是改进混纺无纺布，使得由其制得的成品件没有上述缺点。
发明内容
根据本发明实现了这一目的，即由热塑纤维的和具有高熔点的增强纤维构成的混纺纤维无纺布在其一侧或两侧与具有ba或bab结构的复合薄片粘合连接，其中a是高熔点的热塑材料，b是低熔点的热塑材料，且其中复合薄片的层b面对混纺纤维无纺布。
包括热塑纤维和增强纤维的混纺纤维无纺布基本上是已知的，并且例如在引用的文献中进行了详细描述。热塑塑料可以是任何可纺的热塑材料，优选熔点低于240℃的那类。特别有用的是聚烯烃(尤其是聚丙烯)和聚酰胺6。所述增强纤维必须比所述热塑纤维的熔点高；对于聚酰胺6，例如玻璃纤维和聚酯纤维是有用的；对于聚丙烯，除了玻璃纤维以外，天然纤维例如亚麻、大麻、黄麻、剑麻或洋麻也是有用的。通常，纤维的长度为40-100mm，借助例如纺织工业中广为人知的卷曲或气流成网法以80:20至20:80，优选70:30至30:70的混合比混合热塑纤维和增强纤维。在该过程中，混纺纤维无纺布成形为环带，之后优选通过针刺压实。混纺纤维无纺布的厚度优选为4-30mm，特别是大于10mm但小于25mm。
根据应用目的，混纺纤维无纺布A可以在其一侧或两侧粘合连接至复合薄片B。后者可具有ba或bab结构，其中a是高熔点的热塑塑料，优选为聚酰胺、聚酯或聚氨酯，且b是低熔点的热塑塑料，优选为聚乙烯或聚丙烯。通常复合薄片的厚度为50-200μm，特别为60-150μm。合适的复合薄片为例如Wipak供应的COVEXX和COMBITHERM薄片。
连接混合的无纺布和复合薄片，使得复合薄片B的层b面对混纺无纺布A。这是通过连续供应混纺纤维无纺布和复合薄片以经过加热源(例如热空气或IR辐射)而优选获得的。热空气的温度可为300-400℃。然而，加热混纺纤维无纺布的热塑纤维和复合薄片的低熔点热塑塑料至它们的熔点以上仅仅很短的时间，即仅仅几分之一秒，从而它们只会软化而不会滴下；之后立即通过例如辊压将它们压制在一起。在EP-A1055759中详细描述了该方法，但是，其中混纺纤维无纺布不连接至复合薄片而是连接至另外的热塑无纺布。同时，将装饰层C共压制在一侧或两侧，该装饰层C也可以通过低熔点热塑塑料b来连接。合适的装饰层为，例如织物片、由聚烯烃或聚氨酯制成的泡沫薄片，且可以任选将热塑塑料薄片染色。
本发明的无纺布复合件可以使用与常规混纺无纺布相同的方式加工为成品件。为此，将它们加热至高于热塑纤维的软化温度以上，并在2-10kp/cm2的压力下在合适的模具中进行压制。
本发明的无纺布复合件的主要应用领域是汽车内部部件，例如内部门板(interior door panels)、衣帽架(hat racks)、行李箱(luggage trunk)的装载门(loading floor)和车顶蓬蒙板(headliner)。后者包括两层复合件，该复合件在其两侧设置有结构为bab的复合薄片，其中该两层仅在多个部分段(partialsegments)焊接在一起，且其中在各层之间存在非焊接段，所述非焊接段包括气垫(air pad)并具有凸起的上层(convex upper layer)。这些车顶蓬蒙板是通过DE-A 10160442中描述的方法制造的，尽管不透气的复合薄片防止了气体损耗，但闭孔的泡沫薄片不能防止气体损失。对于汽车外部部件，也可以使用所述复合件制造汽车发动机灌封(encapsulation)和车身底板滑板(underbody skidplate)。另外的应用领域是箱子和其它容器，例如用于计算机的那些。当存在成品件可能软化并在强加热下弯曲的危险时，使用基于聚酰胺6的混纺纤维无纺布是不利的。
实施例
通过应用根据EP-A 1055759的连续热结合法，将12mm厚度的针刺混纺纤维无纺布在其两侧和90μm厚的结构为bab的复合薄片层压在一起，该无纺布由60wt％聚丙烯纤维和40wt％亚麻、大麻和洋麻的天然纤维混合物(Quadrant Natural Fiber Composites供应的NAF-COFORM)制成，该复合薄片由聚乙烯和聚酰胺6，6(Wipak提供的COVEXX)制成。将所得的无纺布复合件切成尺寸为80×120的预切部分。将这些预切部分放入模具中并在3kp/cm2的压力下压制，从而形成内部门板。

Claims (13)

1.无纺布复合件，包括
A.包括热塑纤维和高熔点增强纤维的混纺纤维无纺布，该混纺纤维无纺布在其一侧或两侧粘合连接至
B.一个或两个热塑材料的复合薄片，
其特征在于：复合薄片B具有ba或bab结构，其中a是高熔点的热塑材料，选自聚酰胺、聚酯和聚氨酯，和b是低熔点的热塑材料，选自聚乙烯或聚丙烯，且其中复合薄片的层b面对混纺纤维无纺布，以及其中复合薄片的厚度为50-200μm。
2.权利要求1的复合件，其特征在于：混纺纤维无纺布A的热塑纤维是聚丙烯纤维，且增强纤维是玻璃纤维或天然纤维。
3.权利要求1的复合件，其特征在于：混纺纤维无纺布A的热塑纤维是聚酰胺6纤维，且增强纤维是玻璃纤维或聚酯纤维。
4.权利要求1的复合件，其特征在于：热塑纤维和增强纤维的重量比是80:20至20:80。
5.权利要求1的复合件，其特征在于：混纺纤维无纺布是针刺的。
6.权利要求1的复合件，其特征在于：混纺纤维无纺布A的厚度为4-30mm。
7.生产权利要求1的无纺布复合件的方法，其特征在于将混纺纤维无纺布A和复合薄片B一起连续供应至加热源，并在加热之后马上一起压制。
8.权利要求7的方法，其特征在于：在加热期间，材料的温度高于混纺纤维无纺布A的热塑纤维及复合薄片B的低熔点热塑材料的软化温度。
9.权利要求7的方法，其特征在于：共压装饰层C。
10.权利要求1的复合件用于制备汽车部件中的用途，其是通过加热复合件至高于热塑纤维的软化温度，并在2-10kp/cm2下压制进行制备的。
11.由权利要求1的复合件制备的汽车内部部件，其特征在于：复合薄片具有bab结构。
12.权利要求11的汽车内部部件，其为车顶蓬蒙板、衣帽架、内部门衬里和行李箱衬里。
13.由权利要求1的复合件制备的车身底板滑板和汽车发动机灌封，其特征在于：复合薄片具有ba结构。
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