CN104302830B - 机动车部件 - Google Patents

机动车部件 Download PDF

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CN104302830B
CN104302830B CN201380024871.0A CN201380024871A CN104302830B CN 104302830 B CN104302830 B CN 104302830B CN 201380024871 A CN201380024871 A CN 201380024871A CN 104302830 B CN104302830 B CN 104302830B
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pet
floor covering
standby
copet
fiber
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CN104302830A (zh
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福尔克马尔·舒尔茨
诺贝特·尼科莱
安德烈·费尤勒
法布里奇奥·佛娜森
费德里卡·费拉图
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Adler Per Ze Holdings Ltd
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HP Pelzer Holding GmbH
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/08—Insulating elements, e.g. for sound insulation
    • B60R13/0815—Acoustic or thermal insulation of passenger compartments
    • B60R13/083—Acoustic or thermal insulation of passenger compartments for fire walls or floors
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
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    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0068—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the primary backing or the fibrous top layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • 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
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N3/00—Arrangements or adaptations of other passenger fittings, not otherwise provided for
    • B60N3/04—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets
    • B60N3/042—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets of carpets
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
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    • B60N3/044—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets of removable mats
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    • B60N3/00—Arrangements or adaptations of other passenger fittings, not otherwise provided for
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    • B60N3/048—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets characterised by their structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
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    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
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    • B32B2255/00—Coating on the layer surface
    • B32B2255/02—Coating on the layer surface on 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
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    • B32B2262/0276—Polyester fibres
    • B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
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    • 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
    • B32B2471/00—Floor coverings
    • 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
    • B32B2471/00—Floor coverings
    • B32B2471/02—Carpets
    • 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
    • B32B2471/00—Floor coverings
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2605/00—Vehicles
    • B32B2605/003—Interior finishings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • D06N2209/00—Properties of the materials
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Abstract

本发明涉及一种隔音的机动车部件材料结构，用于机动车内部与机动车后备箱，即地板垫，地板覆盖物，以及后备箱衬板，这能够在工业上实现整个复合材料的完全再处理，特别是纤维材料。机动车部件具有PIT纤维层，由PET和/或coPET制成的任选的基材层，任选的PET粘结层，PET粘结层，由PET纤维无纺布或机织织物制成的一层，以及由PET/ coPET制成的绝缘层。

Description

机动车部件
技术领域
本发明涉及一种隔音的机动车部件材料结构，用于机动车内部与机动车后备箱，即地板垫，地板覆盖物，以及后备箱衬板，这能够在工业上实现整个复合材料的完全再处理，特别是纤维材料。
本发明所指的机动车部件包括，尤其是嵌合地毯。这些是一个机动车的固有部分。它们的结构通常包括三层不同的“层”。
由纱线或纤维和任选的支撑组成的摩损表面是朝向乘客的。纤维通常可以是天然的（动物：新的羊毛，植物：棉或麻）或合成的（聚酰胺，聚酯，聚丙烯等）。混合纱线也是可能的，诸如聚酰胺和新的羊毛。另外，“重型”磨损表面主要是由非交联和交联型TPO组成，具有和没有表面“颗粒”，都被采用。
“中间层”主要是由一种或多种粘合剂组合物组成，其通过纤维结构被固定在支撑织物上。大多是，合成橡胶（SBR胶乳）用作粘合剂。然而，天然胶乳也可以用作粘合剂。通常，第二粘合剂层用以结合/粘合背衬材料，其主要也是由合成或天然胶乳组成。另外，聚氯乙烯也可以与磨损表面和背衬层粘合在一起; PE，EVA和PP被进一步使用。
背衬层通常也是由发泡SBR胶乳制成。然而，有时也用非发泡的合成和天然胶乳的混合物。天然纤维的织物背衬，例如黄麻，和混合纤维也被利用。另外，密封薄膜和重型板以及接触层被发现。
这种异质的机动车部件的再处理是有问题的，特别是嵌合地毯，它们是由各种各样的材料制成的。
在目前市场上的机动车，发现嵌合地毯的不同表现形式，尤其是簇绒地毯，dilour地毯和平针刺地毯。对于簇绒地毯，主要是采用PA6.6，PA6，PP，rPA和rPET;而对于dilour地毯和平针刺地毯，主要采用PET，PET/ PP，PP和rPET。
在簇绒等级里，簇绒支撑是由PET/ PP，PET/ COPET或PET/ PA制成的。在簇绒地毯里，主要是EVA，而在dilour地毯和平针刺地毯里，主要是SBR乳胶或丙烯酸酯被用于纱线/纤维结合。该涂层，主要是作为粘结层用于底层织物，而且还用于加固，主要包括PE或PP;任选还包括基于EVA，PE，PP，EPDM的重层。底层织物主要包括PET或棉混纺纤维织物。
绝缘层，尤其是在地板覆盖系统，一面可以是泡沫，另一面是纤维网。对于泡沫材料，粘弹性或高弹性，并且还轻的泡沫在单一的情况下被采用。当泡沫被使用时，密封薄膜，非织造/薄膜或所谓的接触织物被用在顶部织物和泡沫绝缘层之间。在无纺布绝缘层中，在纤维植绒过程中产生的非变形（平面），预变形的瓦片以及绝缘层被发现。
例如，在DE10 2004046201 A，DE 10360427 A，DE 19960945 A，和DE102007036952A 描述了这样的地板覆盖系统。
US 2008/0220200 A，US2008/0223654 A和US2008/0292831A 描述了地毯/地板覆盖系统，其中簇绒顶级织物和绝缘层是基于PET。簇绒支撑优选由聚酯，聚烯烃纤维（PE），或其它合适的合成纤维组成。纱线的接合是通过发泡乳胶或丙烯酸酯以及聚乙烯的方式实现的。聚乙烯或EVA / PE混合物在网络中被进一步用作涂覆材料。在采用PE挤出（直接挤出的聚乙烯片/层）的接合方法中，纤维被部分熔融，从而形成一个“刚性地”缠结绒头/纤维底面。另外，接合材料（PE）仅在有条件下能够部分地渗透到纤维网。当地毯变形时，断裂可能会出现在“刚性地”缠结绒头/纤维底面，从而大大恶化了磨损性能，当然，还有外观。地板覆盖物和后备箱衬板因此而无法使用。尤其是在US 2008/0223654 A，重型板，PVC/ EVA/ PE被应用于复合材料中;进一步，PA，PE和/或PET的多孔和非多孔片层被使用。
现有技术中公知的技术方案不是“一种材料体系”;这些复合材料包括多种不同的聚合物。特别是，除了PE和EVA，SBR胶乳和丙烯酸酯被用于纤维粘合，这实际上避免了复合材料的再处理。因此，纤维材料的最佳再处理无法实现。
另外，在簇绒地毯里，纱线通过片材或挤出片材接合具有以下缺点：为了实现PET纤维或纱线绒头之间在地毯的底面的结合，在实践中后者必须被部分熔化。然而，其结果是，纱线绒头不仅以塑性化的方式接合，而且在其下部以“玻璃样”的方式部分熔化。这也解释了耐磨损值的下降，并且因此更高的磨损。单根纤维在短但重要的间距上失去其良好的工艺性能（伸长率，撕裂脱力等）；在负载条件下这可能会越来越多地导致断裂的纤维。在成型部件中，刚性挤塑板（刚性固定）趋向于“双金属效应”;在温度变化下低的尺寸稳定性;而且具有纤维/长丝断裂的风险。
当然，这也可适用于针刺地毯，然而，其中存在单根纤维而不是纱线绒头。
本发明的目的是实现一种用于隔音的地毯材料结构，可以以相对简单的方式100%再处理（再生）;涉及到总织物重量的降低及声学（吸收）优势的实现。
根据本发明，该目的，特别是，通过地毯材料结构由具有高含量的再生材料的PET纤维材料组成，以及尤其是，通过该纤维粘接剂是一种PET分散体的事实而实现。发泡纤维粘接剂的应用既允许实现最佳粘合（柔性），又允许使用蒸汽/热过程使纱线完全收缩，以及允许实现纤维的最佳堆积。
本发明的第一实施例包括一种用于机动车的嵌合地毯，其特征在于：
（a）磨损表面由聚对苯二甲酸乙酯（PET）纱线和/或纤维组成;
（b）任选的支撑层，如果存在的话，是由聚对苯二甲酸乙二醇酯和/或聚对苯二甲酸乙酯共聚物制成;
（c）任选的第一粘结层，如果存在的话，是由聚对苯二甲酸乙二醇酯系粘接剂制成;
（d）粘结层（中间层）是由聚对苯二甲酸乙二醇酯系粘合剂制成;
（e）背衬层是由聚对苯二甲酸乙二醇酯系纤维网或织物制成;和
（f）所述绝缘层是由PET/ coPET纤维制成。
根据本发明，特别优选的是在PET系分散体被用于粘接PET纱线（簇绒）/ PET纤维（dilour，平针刺地毯），以及进一步用于任选的粘结层。因此，简单操作在生产中是可能的，以及复合材料，特别是原材料，可以100％被最佳回收利用。所述纤维粘合是柔性的，并且单根纤维被结合在点而不是（刚性）熔合在一起。此外，该复合材料是100％的纯（PET）；等等，纤维材料和粘接剂和胶粘剂都是用这种材料制成的。特别地，这也适用于簇绒，因为所述支撑是由PET / coPET制成的。
PET分散体作为粘接剂可以实现良好的绒头固定以及在相对低的（处理）温度下胶嵌在纤维网中。因此，基本上保持了地毯/复合地毯的柔韧性; 达到最佳磨损值。
当应用粘接剂（PET分散体）时，将水相蒸发，因此纱线/纤维的完全收缩达到（自然而然）最佳的表面效果。
PET分散体涂层具有选择性地调节熔点范围，即，低温的一个优点是，没有纤维/纱的局部熔化。该纤维具有高柔韧性，和一个相对均匀的质量;因此，不存在“双金属效应”。
本发明的这种嵌合地毯结构可以根据各自的情况来确定。首先，根据本发明，嵌合地毯是由簇绒，dilour或平针刺顶部织物，以及一种或多种粘结层和无纺布层，并且一绝缘层，一无纺布绝缘层制备而成。因此，整个系统是基于PET的，并且特别地，簇绒支撑是一种PET/ coPET短纤维无纺布或纺粘纤维网。另外，纤维/纱线结合层和粘结层是基于PET分散体。为了保护物质资源， PET纤维可以由回收的PET组成。另外，当然也可以从纯PET或甚至原生和再生PET的混合物中生产PET纤维。
根据本发明，特别优选的，以PET粉/水分散体的形式分别制备纤维/纱线结合层和粘合层，具有可调节的熔点。
根据本发明，特别优选的是，如果下层织物是基于PET / rPET吸收/硬化的无纺布，任选地还含有回收的PET纤维。为了良好的吸声，在本发明的意义内特别优选的，如果隔音的整体系统（声学上）是不限流量的。
以相同的方式如上面所讨论的嵌合地毯，地板垫，座椅靠背，侧饰，内饰和后备箱衬板也可根据本发明而设计。
在下文中，本发明通过实施例进行说明。
实施例
实施例1：
一种簇绒地毯1，是用 1020dtex，127长丝和5/64"的针距的2尺寸的PET/rPET纱线，用带有绒头纱线最终重量（绒头2）为305 g/m2的120g/m2的PET/ coPET 支撑3制成的。所述接合是通过coPET分散体4以100g/m2的辊涂方法实现; 360 g/m2PET/ coPET无纺布5被层叠在其上，以提高吸收/硬挺性能。机动车地板覆盖物的复合材料成型是通过使用全自动热成型机在切割地毯和无纺布到长度的处理步骤中，在层叠热压机中层叠，接着通过在IR加热场所加热，然后成型来完成的。作为一种质量特性，磨损试验得到0.180克。
实施例2：
另一种簇绒地毯1，是用 1300dtex，127长丝和1/10"的针距的2尺寸的PET/rPET纱线，用带有绒头纱线最终重量（绒头2）为305 g/m2的120g/m2的PET/ coPET 支撑3制成的。所述接合通过coPET分散体4以100 g/m2的辊涂方法实现; 360 g/m2PET/ coPET无纺布5被层叠在其上，以提高吸收/硬挺性能。进行成型如实施例1。磨损试验得到0.210克。
实施例3：
通过纤维植绒工艺，相应的具有15％的PET/BiCo纤维比例的PET/rPET纤维绝缘6被生产。
因此，该地面覆盖物系统（顶部织物+绝缘）由PET一种材料体系组成。一个完全的再处理是可能的。因此，通过使用回收的PET（rPET）纤维，“可持续发展”和“绿色技术”的要求得到充分满足。
实施例4：
一种dilour地毯（未示出）用6.7/ 11 dtex的PET/rPET纤维2制成;且通过填充机施加100g/m2的coPET分散体4。在这种情况下，360 g/m2PET/ coPET无纺布5被层叠在其上，以提高吸收/硬挺性能。除了PET/rPET纤维混合物，PET/BiCo纤维也被用于该复合材料。
进行成型如第一个实施例。磨损试验得到0.260克。

Claims (5)

1.包括带有簇绒，dilour或平针刺顶部织物的磨损表面（2）的地板覆盖物（1），或后备箱衬板，其特征在于：
（a）磨损表面（2）由聚对苯二甲酸乙酯（PET）纱线/纤维和/或BiCoPET纤维组成;
（b）任选的支撑层（3），如果存在的话，是由聚对苯二甲酸乙二醇酯和/或聚对苯二甲酸乙酯共聚物制成;
(c) 第一粘结层（4），是由聚对苯二甲酸乙二醇酯系粘接剂制成，所述第一粘结层包含PET和/或coPET分散体;
(d) 进一步任选的粘合层，如果存在的话，是由聚对苯二甲酸乙二醇酯系粘合剂制成;
(e) 背衬层（5）是由聚对苯二甲酸乙二醇酯系和任选的BiCoPET纤维系，纤维网或织物制成;和
（f）绝缘层（6）是由PET/ coPET纤维以及BiCoPET纤维制成。
2.根据权利要求1所述的地板覆盖物或后备箱衬板，其特征在于，所述地板覆盖物为嵌合地毯。
3.根据权利要求1所述的地板覆盖物或后备箱衬板，其特征在于，簇绒支撑包括PET/coPET短纤维无纺布或纺粘纤维网。
4.根据权利要求1所述的地板覆盖物或后备箱衬板，其特征在于，所述聚对苯二甲酸乙酯PET纤维是由，原生或再生PET或它们的混合物，以及BiCoPET组成。
5.根据权利要求1所述的地板覆盖物或后备箱衬板，其特征在于，所述地板覆盖物或后备箱衬板包括纤维/纱线粘接剂，和所述粘结层包括可调节熔点的PET和/或coPET粉末/水分散体。
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