CN107313179A - 用于车辆外部的无纺织物板及其制造方法 - Google Patents

用于车辆外部的无纺织物板及其制造方法 Download PDF

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Publication number
CN107313179A
CN107313179A CN201611173928.5A CN201611173928A CN107313179A CN 107313179 A CN107313179 A CN 107313179A CN 201611173928 A CN201611173928 A CN 201611173928A CN 107313179 A CN107313179 A CN 107313179A
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China
Prior art keywords
fiber
adhesive
bonded fabric
fibre
fabric plate
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Pending
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CN201611173928.5A
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English (en)
Inventor
李廷勖
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.)
Hyundai Motor Co
Kia Corp
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Hyundai Motor Co
Kia Motors Corp
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Publication of CN107313179A publication Critical patent/CN107313179A/zh
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/018—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the shape
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics
    • D—TEXTILES; PAPER
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    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • 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
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/253—Formation of filaments, threads, or the like with a non-circular cross section; Spinnerette packs therefor
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30—Conjugate filaments; Spinnerette packs therefor
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    • D04H1/4258—Regenerated cellulose series
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Abstract

本发明提供一种用于车辆外部的无纺织物板及其制造方法。无纺织物板包括具有非圆形横截面的基质纤维和具有非圆形横截面的粘合纤维，并且基于无纺织物板的总重量，基质纤维的含量为50重量％或更大。基质纤维和粘合纤维分别具有约6至15旦的线密度和约1.3至3.0的非圆形度。用于车辆外部的无纺织物板通过使用非圆形横截面纤维具有显著增加的比表面积，提高纤维之间的粘合效率，并且显著提高机械性能。此外，其热成型性提高，其重量减轻，并且吸声性能显著提高。

Description

用于车辆外部的无纺织物板及其制造方法
技术领域
本发明涉及一种用于车辆外部的无纺织物板及其制造方法。该无纺织物板可以获得显著提高的刚性和吸声性能。
背景技术
在车辆行驶过程中，外部噪声通过各种路径进入车辆内部。特别地，由于轮胎和地面之间的摩擦引起的噪声，由从排气系统释放的高温高压燃烧气体的流动产生的噪声，由发动机系统的运行引起的机械噪声等，进入车辆内部并传递到乘客的耳朵，这些噪声抑制了车辆的舒适性和安静性。
为了车辆的舒适性和安静性，已经安装诸如底罩(under cover)和车轮护罩(wheel guards)等部件，以在驾驶时阻挡车辆底部中的路面噪声，并且保护车辆底部免受飞行碎片例如泥和石头的撞击。在相关技术中，部件通常由塑料材料制成，例如聚丙烯(PP)和玻璃纤维增强PP。然而，塑料材料导致问题。例如，塑料材料易受冲击，并且由于不透气材料而不具有吸声性能。
近来，为了确保耐冲击性和隔音性能，已经使用可热成型的压缩毡材料。然而，可热成型的压缩毡刚性不足，因此在应用于具有大面积的部件例如底罩中有限制。另外，当为了提高无纺织物的刚性而对毡进行压缩时，吸声性能效率降低。
同时，由压缩的无纺织物材料形成的部件已经通过以下方式制备：在烘箱中在预定温度下对由针刺工艺制造的毡布以预定时间进行预热，然后使用冷模具将毡布成型为部件；或者使用热模具在预定温度下对毡布以预定时间进行压制，并使毡布成型为部件，而不对毡布进行单独的预热。
常规的无纺织物由作为基质纤维的聚对苯二甲酸乙二醇酯(PET)纤维和作为用于在PET纤维之间进行粘合的粘合纤维的双组分PET纤维组成，或者仅由PET纤维构成。已经通过在预定厚度下增加面密度(每单位面积的重量)的系统、或相反地通过在预定面密度下进一步减小厚度的系统以增加纤维之间的粘结性，来提高现有技术中压缩无纺织物的机械性能。
然而，面密度的增加导致部件重量和材料成本的增加，并且厚度的减小导致压缩无纺织物吸声率的劣化。
此外，在现有技术中，由于纤维的横截面通常是圆形的，因此纤维之间的接触面积很小，使得在提高粘结性方面存在限制，并且在成型加热过程中，使得当在预定温度的条件下进行处理时，布织物的蓬松度很小。这样，仅网络表面熔融，由此中间层部分保持纤维状，结果强度劣化。
因此，需要研究可用于车辆外部的无纺织物板，其中在保持刚性的同时提高吸声性能。
在该背景技术部分中公开的上述信息仅用于增强对本发明的背景的理解，因此其可以包含不形成在本国对于本领域普通技术人员已知的现有技术的信息。
发明内容
在优选的方面，本发明提供一种用于车辆外部的无纺织物板，其中刚性得到提高并且吸声性能得到提高。
一方面，本发明提供一种用于车辆外部的无纺织物板。无纺织物板可以包括：具有非圆形横截面的基质纤维和具有非圆形横截面的粘合纤维。基于无纺织物板的总重量，基质纤维的含量可以为约50wt％或更大。基质纤维和粘合纤维可以具有约6至15旦的线密度和约1.3至3.0的非圆形度。
这里所用的术语“基质纤维”包括构成无纺织物或织物主要成分的纤维，例如，构成纤维的基质纤维的量大于约25重量％、30重量％、40重量％、50重量％、60重量％、70重量％、80重量％或90重量％。本发明中构成无纺织物的基质纤维的量优选为约50重量％或更多。
这里所用的术语“粘合纤维”包括用于粘合基质纤维或其他纤维的纤维。优选的粘合纤维包括双组分纤维。这里所用的优选的双组分纤维可以包括两种不同的聚合物，并且由两种聚合物通过单个喷丝头形成，由此两种聚合物可包含在同一细丝中。此外，优选的粘合纤维可以具有在使用双组分纤维制造时形成的鞘/芯结构，使得一种聚合物组分(芯)至少部分地被另一聚合物组分(鞘)包围。
非圆形度(α)可以通过以下等式1确定：
[等式1]
非圆形度
其中纤维横截面周长为P，纤维横截面面积为A。
优选地，基质纤维的横截面形状和粘合纤维的横截面形状可以选自八叶型、W型、中空型、扁平型、十字型、三角型和星型。
基质纤维适当地可以选自聚对苯二甲酸乙二醇酯、聚丙烯、尼龙、丙烯酸树脂、粘胶人造丝和芳族聚酰胺纤维。
粘合纤维可以适当地包括选自低熔点聚对苯二甲酸乙二醇酯纤维，聚丙烯纤维和聚乙烯中的一种或多种。优选地，粘合纤维可以具有鞘/芯结构。
在一个优选的方面，粘合纤维用材料可以具有比典型基质纤维用材料低的熔点，使得粘合纤维可以在热成型或热粘合过程中熔融并用作基质纤维之间的胶或粘合材料，而基质纤维材料保持其原始形状或形式。例如，粘合纤维或粘合纤维材料可以具有比基质纤维或基质纤维材料的熔点低约30℃、约40℃、约50℃、约60℃、约70℃、约80℃、约90℃、约100℃、150℃或约200℃的熔点。
优选地，基质纤维或粘合纤维的纤维横截面周长P可以在约140至180μm的范围内，并且基质纤维或粘合纤维的纤维横截面面积A可以在约280至1,500μm2的范围内。
还提供了用于车辆外部的底罩材料，其可以包括如本文所述的无纺织物板。
另一方面，本发明提供一种制造用于车辆外部的无纺织物板的方法。该方法可以包括以下步骤：使包括具有非圆形横截面的基质纤维和具有非圆形横截面的粘合纤维的纤维聚集体成型为无纺织物板。基于无纺织物板的总重量，基质纤维的含量可以为约50重量％或更大，并且基质纤维或粘合纤维可以具有6至15旦的线密度。另外，基质纤维或粘合纤维可具有1.3至3.0的非圆形度(α)(由等式1定义)。
优选地，无纺织物板可以通过针刺工艺或热粘合工艺来成型。
优选地，基质纤维的横截面形状和粘合纤维的横截面可以选自八叶型、W型、中空型、扁平型、十字型、三角型和星型。
基质纤维适当地可以选自聚对苯二甲酸乙二醇酯、聚丙烯、尼龙、丙烯酸树脂、粘胶人造丝和芳族聚酰胺纤维。
粘合纤维可以适当地包括选自低熔点聚对苯二甲酸乙二醇酯纤维，聚丙烯纤维和聚乙烯中的一种或多种，并且可以具有鞘/芯结构。
优选地，根据等式1，基质纤维或粘合纤维的纤维横截面周长(P)可以在约140至180μm的范围内，并且基质纤维或粘合纤维的纤维横截面面积(A)可以在约280至1,500μm2的范围内。
还提供了可以包括本文所述的无纺织物板的车辆。优选地，无纺织物板可以安装在车辆外部。
根据本发明的用于车辆外部的无纺织物板可以通过使用非圆形横截面纱线而具有较大的比表面积，以便提高纤维之间的粘合效率，并且可以显著提高机械性能。此外，因为在加热过程中由于纤维的体积和比面积较大而使热量良好地传递，因此可以提高热成型性。
由于刚性的提高，通过降低无纺织物的面密度，无纺织物板可以减轻其重量，并且可以显著提高吸声性能。
本发明的其它方面和优选实施方式在下文讨论。
附图说明
现在将参考在附图中示出的本发明的某些示例性实施方式详细描述本发明的上述和其它特征，其在下文中仅以说明的方式给出，因此不限制本发明，并且其中：
图1示出了根据本发明示例性实施方式的示例性基质纤维和粘合纤维的示例性八叶型、W型、中空型、扁平型和星型横截面形状。
应当理解，附图不一定是按比例的，而是呈现了说明本发明的基本原理的各种优选特征的稍微简化的表示。本文公开的本发明的具体设计特征，包括例如特定的尺寸，取向，位置和形状，将部分地由具体的预期应用和使用环境来确定。
在附图中，附图标记在贯穿附图的若干图中表示本发明的相同或等同的部件。
具体实施方式
本文所使用的术语仅用于描述特定示例性实施方式的目的，并且不旨在限制本发明。如本文所使用的，除非上下文另有明确说明，否则单数形式“一”，“一个”和“该”也旨在包括复数形式。还应当理解，当在本说明书中使用时，术语“包括”和/或“包含”说明了存在规定的特征，整数，步骤，操作，元素和/或部件，但不排除存在或添加一个或多个其它特征、整数、步骤、操作、元素、组件和/或其组合。如本文所使用的，术语“和/或”包括一个或多个相关所列项目的任何和所有组合。
除非特别说明或从上下文显而易见，如本文所使用的，术语“约”被理解为在本领域的正常公差范围内，例如在平均值的2个标准偏差内。“约”可以理解为在标准值的10％、9％、8％、7％、6％、5％、4％、3％、2％、1％、0.5％、0.1％、0.05％或0.01％之内。除非从上下文显而易见，本文提供的所有数值都用术语“约”修饰。
应当理解，本文所使用的术语“车辆”或“车辆的”或其他类似术语包括通用的机动车辆，例如包括运动型多用途车辆(SUV)、公共汽车、卡车、各种商用车辆的乘用车辆，包括各种船舶和小船的船只，飞机等，并包括混合动力车辆，电动车辆，插电式混合动力电动车辆，氢动力车辆和其他替代燃料车辆(例如，源自除石油以外的资源的燃料)。如本文所提及的，混合动力车辆是具有两个或更多动力源的车辆，例如汽油动力和电动力的车辆。
在下文中，将详细参考本发明的各种实施方式，其实例在附图中示出并在下面描述。虽然将结合示例性实施方式描述本发明，但是应当理解，本描述并不旨在将本发明限制于那些示例性实施方式。相反，本发明旨在不仅覆盖示例性实施方式，而且覆盖可以包括在由所附权利要求限定的本发明的精神和范围内的各种替代，修改，等价方式和其他实施方式。
由于本发明可以以各种形式修改并包括各种示例性实施方式，因此将在附图中示出并在具体说明中详细描述具体示例性实施方式。然而，该描述并不旨在将本发明限于具体的示例性实施方式，并且应当理解，属于本发明的精神和技术范围的所有改变，等同方式和替换均包括在本发明中。当确定在描述本发明时相关的公知技术的详细描述可能模糊本发明的要点时，将省略其详细描述。
本发明提供一种用于车辆外部的无纺织物板。该无纺织物板可以包括具有非圆形横截面的基质纤维和具有非圆形横截面的粘合纤维。基于无纺纤维板的总重量，基质纤维的量可以为50重量％或更大。非圆形横截面基质纤维或非圆形横截面粘合纤维可以具有约6至15旦的线密度和约1.3至3.0的非圆形度(α)。非圆形度(α)可以通过以下等式1来确定。
[等式1]
非圆形度
在等式1中，纤维横截面周长表示为P，纤维横截面面积表示为A。
在下文中，将更详细地描述根据本发明具体示例性实施方式的用于车辆外部的无纺织物板。
在现有技术中，存在的问题是，由于纤维的横截面是圆形的，纤维之间的接触面积不足以提高粘结性。此外，对于圆形织物，在成型加热过程中，布织物的蓬松度很小，使得当在预定温度的条件下进行处理时，仅有网络表面熔融，因此中间层部分保持纤维状，结果强度劣化。
因此，本发明人通过实验证实，当使用具有预定线密度范围和预定范围的非圆形度的非圆形横截面纤维作为用于无纺织物板的基质纤维和粘合纤维时，由于纤维的蓬松度和比表面积较大，在加热过程中热量可良好地传递，从而提高热成型性和机械性能，由于刚性的提高，通过降低无纺织物的面密度而降低重量，并且可以改善吸声性能。
在本发明的一个方面中，提供了一种用于车辆外部的无纺织物板。该无纺织物板可以包括非圆形横截面基质纤维和非圆形横截面粘合纤维。基于无纺织物板的总重量，非圆形横截面基质纤维的含量可以为50重量％或更大。
特别地，非圆形横截面基质纤维或非圆形横截面粘合纤维可以具有约6至15旦的线密度和约1.3至3.0的非圆形度。
在一个优选的方面中，非圆形横截面纤维可以具有比常规圆形横截面纤维大约2至5倍的表面积。
通常，当声波碰到特定材料有摩擦时，产生粘性损失，从而导致当声波的机械能转换为热能时，噪声最终降低。基于如上所述的物理现象，本发明中使用的非圆形横截面纤维可以形成不同于通常的圆形横截面纤维的具有不规则或规则形状的横截面结构，因此可以提供优点。例如，可以使产生声波的粘性损失的纤维的表面最大化，从而改善吸声性能。
常规的PET纤维具有圆形横截面，使得纤维之间的粘结性通过点接触实现，但是非圆形横截面纤维具有更大的比表面积，使得纤维之间的粘附效率可以提高，从而提高机械性能。此外，由于纤维较大的蓬松度和比表面积，在加热过程中可以良好地传递热，因此可以提高热成型性，从而提高机械性能。
在使用非圆形横截面纤维的本发明的无纺织物板中，通过如上所述的具有较大面积的表面，即使表面密度变得低于现有技术中的吸声材料的表面密度，也表现出等于或高于现有技术中吸声材料的噪声、振动和声振粗糙度性能(NVH)水平，从而实现车辆的轻量化，并具有以下优点，即使本发明的无纺织物板与具有相同面密度的普通圆形横截面纤维吸声材料相比，也具有更高的吸声性能。
普通合成纤维的横截面大部分是圆形的。然而，在本发明优选的方面，纤维可以形成为具有非圆形横截面纤维，例如，喷丝头可以制造成所需的形状，例如八叶型、W型、中空型、扁平型、十字型、三角型和星型。这样，纺丝线的横截面形状具有除了圆形以外的特定形状，其可以与喷丝头的形状相同。由于非圆形横截面纤维具有比常规圆形横截面纤维更大的表面积，所以可以使物体的表面最大化，并且可以在其表面上产生声音特性的最重要的因素之一、声波的粘性损失，从而产生提高吸声性能的效果。
非圆形横截面的具体形状可以不受特别限制，但优选可以是八叶型、W型、中空型、扁平型、十字型、三角型和星型，优选W型和八叶型，并且可以基于所需的机械性能和吸声性能的考虑进行选择。
图1示出了示例性非圆形横截面基质纤维和示例性非圆形横截面粘合纤维的示例性八叶型、W型、中空型、扁平型和星型横截面形状。
非圆形横截面基质纤维可以从熔融纺丝获得，并且非圆形横截面基质纤维可以选自聚对苯二甲酸乙二醇酯、聚丙烯、尼龙，丙烯酸树脂、粘胶人造丝和芳族聚酰胺纤维，以及聚对苯二甲酸乙二醇酯。对批量生产和热稳定性而言可能适合使用尼龙。
粘合纤维可以是可用于非圆形横截面基质纤维之间的粘合的纤维。粘合纤维可以适当地包括低熔点聚对苯二甲酸乙二醇酯纤维，聚丙烯纤维等。非圆形横截面粘合纤维可以包括选自低熔点聚对苯二甲酸乙二醇酯纤维，聚丙烯纤维和聚乙烯中的一种或多种。特别地，非圆形横截面粘合纤维可以具有鞘/芯结构。例如，低熔点聚对苯二甲酸乙二醇酯可以包括以鞘-芯结构被共轭纺丝的鞘部和芯部。鞘部可以包括选自熔融温度为约180℃或更低的非晶形态或结晶形式中的任何一种，并且芯部可以包括熔融温度为约250℃或更高的结晶形式。特别地，芯部可以在部件的成型过程中熔融，因此可以用于通过使纤维相互连接来保持无纺织物板的形状。
在本发明中，当非圆形横截面基质纤维的含量小于约50重量％时，机械性能可能劣化，由此，基于无纺织物板的总重量，非圆形横截面基质纤维的含量可以适当地为约50重量％或更大。
同时，非圆形横截面纤维和非圆形横截面粘合纤维可以适当地具有优选为6至15旦的线密度。当线密度小于约6旦时，单根纤维的拉伸模量可能降低，使得最终无纺织物的刚性可能降低。当线密度大于约15旦时，无纺织物中具有相同面密度的单根纤维的数量可能减少，使得无纺织物的机械性能可能劣化。
非圆形横截面纤维和非圆形横截面粘合纤维可以适当地具有约1.3至3.0的非圆形度。当非圆形度小于约1.3时，与圆形相比表面积增加的效果可能不足，使得机械特性可能不能充分地提高。当非圆形度大于约3.0时，卷曲的数量可能减少，使得纤维之间的接触点可能劣化，由此机械性能可能劣化。
非圆形度(α)可以由下面的等式1表示，并且适当地可以具有大约140至180μm的纤维横截面周长(P)和约280至1,500μm2的纤维横截面面积纤维横截面面积(A)。
[等式1]
非圆形度
因此，当纤维具有八叶型横截面时，八叶型横截面纤维适当地可以具有在约1.3至3.0的范围内的非圆形度(α)，横截面周长(P)的范围为约140至180μm，横截面积(A)的范围为约280至1,500μm2，当纤维横截面周长(P)小于约140μm时，纤维的比表面积减小，因此吸声性能的提高效果不充分，在加热成型时由于纤维厚度的减少而大幅产生收缩。当纤维横截面周长(P)大于约180μm时，纤维的线密度可能增加，这可能表明无纺织物中具有特定面密度的单根纤维的数量可能减少。另外，吸声性能可能不能充分提高，纤维之间的间隙可能变得过大，因此，在热成型后刚性可能劣化。优选地，八叶型横截面纤维可以具有在上述范围内的纤维横截面周长P。
当纤维横截面面积纤维横截面面积(A)小于约280μm2时，可能不能制造用于制造工艺的具有八叶型横截面形状的喷丝头，并且在喷丝头纺丝后可能无法充分地实现实际的纤维八叶型横截面结构。当纤维横截面面积(A)大于约1,500μm2时，由于纤维旦数的增加和纺丝速率的降低，经济效率可能降低。此外，毡中纤维之间的间隙可能显著增加，使得在热成型过程中可能大幅发生收缩并且刚性可能劣化。优选地，八叶型横截面纤维可以具有在上述范围内的纤维横截面面积A。
在本发明的另一方面，提供一种制造用于车辆外部的无纺织物板的方法。该方法可以包括：将包括具有非圆形横截面的基质纤维和具有非圆形横截面的粘合纤维的纤维聚集体成型为无纺织物形式。基于无纺织物的总重量，基质纤维的含量可以为约50重量％或更大，并且基质纤维或粘合纤维可以具有6至15旦的线密度，和1.3～3.0的非圆形度(α)。
优选地，无纺织物可以通过针刺工艺或热粘合工艺成型。
本发明的无纺织物板的制造工艺可以与无纺织物板部件的常规成形工艺相同，也可以与以往的成形工艺不同。无纺织物板可以通过在烘箱中预热针刺布织物并使用冷模具成型为部件，或者可以通过使用热模具直接成型。
在下文中，将参照附图详细描述本发明的优选实施例。然而，提供这些实施例仅用于举例说明本发明，不应解释为本发明的范围受这些实施例的限制。
实施例
以下实施例说明本发明，并不意图限制本发明。
实施例1
以6∶4的重量比使用作为非圆形横截面基质纤维的PET纤维和包括低熔点PET纤维的非圆形横截面粘合纤维，并且使用生产热粘合无纺织物的常规生产工艺制造无纺织物板。无纺织物板形成为厚度为2mm，面密度为1,200g/m2。
作为如上所述的非圆形横截面基质纤维和非圆形横截面粘合纤维，使用通过用W形喷丝头的熔融纺丝制造的具有W形横截面的纤维，并且使用卷曲数为9.8ea/英寸，非圆形度为2.6并且线密度7旦的纤维。
实施例2
以6∶4的重量比使用作为非圆形横截面基质纤维的PET纤维和包括低熔点PET纤维的非圆形横截面粘合纤维，并且使用生产热粘合无纺织物的常规生产工艺制造无纺织物板。无纺织物板形成为厚度为2mm，面密度为1,200g/m2。
作为如上所述的非圆形横截面基质纤维和非圆形横截面粘合纤维，使用通过用W形喷丝头的熔融纺丝制造的具有W形横截面的纤维，并使用卷曲数为9.8ea/英寸，非圆形度为2.6的纤维，并且使用线密度为14旦的纤维作为非圆形横截面基质纤维，以及使用线密度为7旦的纤维作为非圆形横截面粘合纤维。
实施例3
以6∶4的重量比使用作为非圆形横截面基质纤维的PET纤维和包括低熔点PET纤维的非圆形横截面粘合纤维，并且使用生产热粘合无纺织物的常规生产工艺制造无纺织物板。无纺织物板形成为厚度为2mm，面密度为1,200g/m2。
作为如上所述的非圆形横截面基质纤维和非圆形横截面粘合纤维，使用通过用W形喷丝头的熔融纺丝制造的具有W形横截面的纤维，并且使用卷曲数为9.8ea/英寸，非圆形度为2.0的纤维，并且作为非圆形横截面基质纤维，使用线密度为14旦的纤维作为非圆形横截面基质纤维，以及使用线密度为7旦的纤维作为非圆形横截面粘合纤维。
实施例4
以6∶4的重量比使用作为非圆形横截面基质纤维的PET纤维和包括低熔点PET纤维的非圆形横截面粘合纤维，并且使用生产热粘合无纺织物的常规生产工艺制造无纺织物板。无纺织物板形成为厚度为2mm，面密度为1,200g/m2。
作为如上所述的非圆形横截面基质纤维和非圆形横截面粘合纤维，使用通过用W形喷丝头的熔融纺丝制造的具有W形横截面的纤维，并且使用卷曲数为9.8ea/英寸、非圆形度为2.0的纤维，并且使用线密度为14旦的纤维作为非圆形横截面基质纤维，以及使用线密度为14旦的纤维作为非圆形横截面粘合纤维。
比较例1
使用圆形PET纤维通过使用生产热粘合无纺织物的常规生产工艺制造厚度为2mm，面密度为1,200g/m2的无纺织物板。
比较例2
以6∶4的重量比使用圆形PET纤维和包括低熔点PET纤维的圆形横截面粘合纤维，并且使用生产热粘合无纺织物的常规生产工艺制造无纺织物板。无纺织物板形成为厚度为2mm，面密度为1,200g/m2。纤维的卷曲数为9.8ea/英寸，并且使用线密度为7旦的纤维作为圆形PET纤维，以及使用线密度为4旦的纤维作为圆形横截面粘合纤维。
比较例3
使用W型PET纤维，通过使用生产热粘合无纺织物的常规生产工艺制造厚度为2mm，面密度为1,200g/m2的无纺织物板。
使用卷曲数为6.8ea/英寸，非圆形度为3.5，线密度为7旦的纤维作为如上所述的W型PET纤维。
比较例4
使用W型PET纤维，通过使用生产热粘合无纺织物的常规生产工艺制造厚度为2mm，面密度为1,200g/m2的无纺织物板。
使用卷曲数为10.3ea/英寸，非圆形度为1.2，线密度为7旦的纤维作为如上所述的W型PET纤维。
比较例5
使用W型PET纤维，通过使用生产热粘合无纺织物的常规生产工艺制造厚度为2mm，面密度为1,200g/m2的无纺织物板。
使用卷曲数为9.8ea/英寸，非圆形度为2.6，线密度为4旦的纤维作为如上所述的W型PET纤维。
比较例6
使用W型PET纤维，通过使用生产热粘合无纺织物的常规生产工艺制造厚度为2mm，面密度为1,200g/m2的无纺织物板。
使用卷曲数为9.8ea/英寸，非圆形度为2.6，线密度为15旦的纤维作为如上所述的W型PET纤维。
比较例7
以6∶4的重量比使用W型PET纤维和包括低熔点PET纤维的圆形横截面粘合纤维，并且使用生产热粘合无纺织物的常规生产工艺制造无纺织物板。无纺织物板形成为厚度为2mm，面密度为1,200g/m2。
使用卷曲数为9.8ea/英寸，非圆形度为2.6，线密度为7旦的纤维作为如上所述的W型PET纤维。
实验例
根据ISO 178方法A评价的弯曲模量，根据ISO 527-4类型2评价的拉伸强度，根据ISO 354评价的吸声率和根据ISO6603-2评价的冲击强度示于下表1中。
与比较例相比，根据本发明的示例性实施方式的实施例1至4获得了显著提高的机械性能，如弯曲模量，拉伸强度和冲击强度，平均吸声率也特别好。
根据本发明的用于车辆外部的无纺织物板通过使用非圆形横截面纱线具有较大的比表面积，使得纤维之间的粘合效率提高，并且具有较大的蓬松度和纤维比表面积，因此机械性能显著提高，另外，由于在加热过程中热量充分地传递，因此可提高热成型性。此外，由于刚性的提高，可以降低无纺织物的面密度，从而可以减轻其重量，并且可以显著地提高吸声性能。
[表1]
尽管详细描述了本发明的示例性实施方式，但是对于本领域技术人员显而易见的是，这样的具体描述仅仅是示例性实施方式，并且本发明的范围不限于此。因此，本发明的实质范围将由所附权利要求及其等同方式限定。
已经参考本发明的各种示例性实施方式详细描述了本发明。然而，本领域技术人员将理解，在不脱离本发明的原理和精神的情况下，可以对这些实施方式进行改变，本发明的范围由所附权利要求及其等同方式限定。

Claims (16)

1.一种用于车辆外部的无纺织物板，其包括：
具有非圆形横截面的基质纤维，和
具有非圆形横截面的粘合纤维，
其中基于所述无纺织物板的总重量，所述基质纤维的含量为50重量％或更大，并且
所述基质纤维和所述粘合纤维分别具有6至15旦的线密度和1.3至3.0的非圆形度(α)，
其中所述非圆形度(α)由下面的等式1表示，
[等式1]
非圆形度
其中P为纤维横截面周长，且A为纤维横截面面积。
2.根据权利要求1所述的无纺织物板，其中所述基质纤维的横截面形状和所述粘合纤维的横截面形状选自八叶型、W型、中空型、扁平型、十字型、三角型和星型。
3.根据权利要求1所述的无纺织物板，其中所述基质纤维选自聚对苯二甲酸乙二醇酯、聚丙烯、尼龙、丙烯酸树脂、粘胶人造丝和芳族聚酰胺纤维。
4.根据权利要求1所述的无纺织物板，其中所述粘合纤维包括选自低熔点聚对苯二甲酸乙二醇酯纤维、聚丙烯纤维和聚乙烯中的一种或多种。
5.根据权利要求1所述的无纺织物板，其中所述粘合纤维具有鞘/芯结构。
6.根据权利要求1所述的无纺织物板，
其中所述基质纤维或所述粘合纤维的纤维横截面周长P为140至180μm，并且所述基质纤维或所述粘合纤维的纤维横截面面积A为280至1,500μm2。
7.一种用于车辆外部的底罩材料，其包括权利要求1所述的无纺织物板。
8.一种制造用于车辆外部的无纺织物板的方法，所述方法包括以下步骤：
将包含具有非圆形横截面的基质纤维和具有非圆形横截面的粘合纤维的纤维聚集体成型为无纺织物板，
其中基于所述无纺织物板的总重量，所述基质纤维的含量为50重量％或更大，并且
所述基质纤维或所述粘合纤维具有6至15旦的线密度和1.3至3.0的非圆形度(α)，
其中所述非圆形度(α)由下面的等式1表示，
[等式1]
非圆形度
其中P为纤维横截面周长，A为纤维横截面面积。
9.根据权利要求8所述的方法，其中所述无纺织物板通过针刺工艺或热粘合工艺成型。
10.根据权利要求8所述的方法，其中所述基质纤维和所述粘合纤维的横截面形状选自八叶型、W型、中空型、十字型、三角型和星型。
11.根据权利要求8所述的方法，其中所述基质纤维选自聚对苯二甲酸乙二醇酯、聚丙烯、尼龙、丙烯酸树脂、粘胶人造丝和芳族聚酰胺纤维。
12.根据权利要求8所述的方法，其中所述粘合纤维包括选自低熔点聚对苯二甲酸乙二醇酯纤维、聚丙烯纤维和聚乙烯中的一种或多种。
13.根据权利要求8所述的方法，其中所述粘合纤维具有鞘/芯结构。
14.根据权利要求8所述的方法，其中所述基质纤维或所述粘合纤维的纤维横截面周长P为140至180μm，并且所述基质纤维或所述粘合纤维的纤维横截面面积A为280至1,500μm2。
15.一种车辆，其包括权利要求1所述的无纺织物板。
16.根据权利要求15所述的车辆，其中所述无纺织物板是车辆的底罩材料。
CN201611173928.5A 2016-04-26 2016-11-04 用于车辆外部的无纺织物板及其制造方法 Pending CN107313179A (zh)

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