CN110878476A

CN110878476A - Method for manufacturing textile components for devices and related components

Info

Publication number: CN110878476A
Application number: CN201910838081.5A
Authority: CN
Inventors: 瓦莱丽·博丹
Original assignee: Faurecia Automotive Industrie SAS
Current assignee: Adler Pelzer France Grand Est SAS
Priority date: 2018-09-05
Filing date: 2019-09-05
Publication date: 2020-03-13
Also published as: FR3085390B1; FR3085390A1

Abstract

The invention relates to a method for manufacturing a textile component for an apparatus and a related component, comprising the following steps: providing a velvet sheet comprising a base fibre (20) and at least partially fusible binder fibres (22); then carrying out needling flocking on the sheet, and then heating; so as to form a velour sheet (12) comprising a front layer (24) and a back layer (26); the binder fibers (22) of the back layer (26) partially melt and form holes (32) at the back layer; the method further comprises the steps of: ejecting a solution comprising an active compound (18) and a solvent, the active compound being capable of binding with a volatile organic compound; and evaporating the solvent so that the active compound is impregnated in the pores of the first face of the back layer.

Description

Method for manufacturing textile components for devices and related components

Technical Field

The invention relates to a method for producing a textile component for an apparatus, comprising the following steps: providing a substrate comprising base fibers and a non-zero amount and less than 15% by weight of at least partially fusible binder fibers; the substrate is then needle flocked to stretch the loops on the face of the sheet; then heating; thereby forming a velvet sheet including a front layer and a back layer; the binder fibers of the back layer partially melt and form apertures at the base of the front layer at the first side of the back layer.

The invention is particularly suitable for interior equipment components of motor vehicles.

Background

The interior of motor vehicles must meet increasingly stringent air composition standards, particularly volatile organic compounds or VOCs.

However, various components equipped with the vehicle interior are generally made of recycled materials and involve processes such as thermoforming, which generate VOCs, particularly aldehydes.

Such materials or processes can be avoided, but the production cost is significantly increased.

Disclosure of Invention

The object of the present invention is to provide a component for an installation that facilitates the removal of air pollution, in particular by capturing VOC.

For this purpose, the subject of the invention is a manufacturing process of the above-mentioned type, which then comprises the following steps: spraying a solution comprising an active compound and a solvent onto the front layer, the active compound being capable of binding with the volatile organic compound; the solvent is then evaporated so as to impregnate the active compound in the pores of the first face of the back layer.

According to other advantageous aspects of the invention, the manufacturing method comprises one or more of the following features, alone or in any technically possible combination:

-the active compound is capable of binding to at least one aldehyde;

-the active compound is selected from hydrazine-formamidine amide phosphate, hydrazine-formamidine amide sulphate or a mixture comprising several phosphates and/or hydrazine-formamidine amide sulphates;

-before the spraying step, the method comprises a step of introducing a reinforcing component on a second face of the back layer of the velvet sheet, said second face being opposite to the front layer;

-the reinforcing component introduced onto the back layer of the velour sheet comprises a thermoplastic polymer, the step of introducing comprising heating the back layer to bring the reinforcing component into contact at the second face of the back layer;

-the step of introducing a reinforcing component comprises thermoforming a velvet sheet together with the reinforcing component;

-the binder fiber comprises a bicomponent fiber comprising a core and a sheath surrounding the core, the sheath having a melting temperature lower than the melting temperature of the core;

velvet density in the front layer of velvet sheet from 0.015g/cm³To 0.030g/cm³；

The method comprises feeding the substrate onto a conveyor belt provided with brushes and then needle-flocking the substrate opposite the brushes.

The invention also relates to a textile element for the interior equipment of a motor vehicle, comprising: a velvet sheet comprising a base fiber and a non-zero amount and less than 15% by weight of at least partially fusible binder fiber; the fibers form a front layer and a back layer; the binder fibers of the back layer partially melt and form holes at the bottom of the front layer at the first side of the back layer; an active compound impregnated in at least a portion of the pores, the active compound being capable of binding to a volatile organic compound, preferably an aldehyde; and a reinforcing component disposed in the back-side layer at the second side of the back-side layer.

According to an advantageous aspect of the invention, the textile element is derived from the method as described above.

The invention also relates to a motor vehicle comprising a textile element for interior equipment as described above.

Drawings

The invention will be better understood from reading the following description, given purely by way of non-limiting example and made with reference to the accompanying drawings, in which:

figure 1 is a schematic cross-sectional view of a textile element for an apparatus according to a first embodiment of the invention;

figure 2 is a schematic cross-sectional view of a textile element for an apparatus according to a second embodiment of the invention;

figure 3 is a sectional detail view of the piece of figure 1 or 2;

FIG. 4 is a schematic cross-sectional view of a velvet sheet for making the piece of FIGS. 1 and 2;

fig. 5 is a schematic view of an apparatus for manufacturing the velvet sheet of fig. 4;

FIG. 6 is a schematic view of an apparatus for manufacturing the textile element of FIG. 1 from the velvet sheet of FIG. 4; and

figure 7 is a logic diagram illustrating successive steps of the manufacturing method of the piece of figures 1 and 2.

Detailed Description

Fig. 1 and 2 show a textile element 10 and a textile element 110 according to a first and a second embodiment of the invention, respectively. The

textile elements

10 and 110 will be described simultaneously below, with common elements being indicated by the same reference numerals.

The

textile element

10, 110 is preferably an interior equipment element of a motor vehicle, such as a carpet or a cabin trim, or a floor or a luggage rack.

The

textile element

10, 110 comprises, inter alia, a velvet sheet 12 and a reinforcing

component

14, 114. The textile element 110 according to the second embodiment of the invention further comprises a support 116.

As will be detailed later,

textile components

10, 110 also contain active compound 18 impregnated in velvet sheet 12 (fig. 3).

In a step of the method of manufacturing the

textile element

10 or 110, the velvet sheet 12 is shown separately in fig. 4. This method will be described later.

Velvet sheet 12 is formed from base fibers 20 and binder fibers 22. Preferably, velvet sheet 12 has a weight per unit area of more than 300g/m²In particular 400g/m²To 1000g/m²。

The base fibers 20 and the binder fibers 22 are randomly distributed throughout the velvet sheet 12.

The base fiber 20 is for example made based on a thermoplastic polymer, such as polypropylene, polyethylene terephthalate, polyamide, polylactic acid, mixtures or copolymers thereof.

The base fiber 20 is typically between 40mm and 100mm in length. Their titer is advantageously from 3.3dtex to 25 dtex.

The binder fibers 22 are at least partially meltable. It typically comprises bicomponent fibers comprising, for example, a core and a sheath surrounding the core. The outer jacket has a melting temperature lower than the melting temperature of the core. For example, the core is made of polyethylene terephthalate and the jacket is made of copolymerized polyethylene terephthalate.

As a variation, the binder fibers 22 are composed of a single polymer having a melting temperature that is lower than the melting temperature of the base fibers 20, advantageously about 50 ℃ less than the melting temperature of the base fibers 20.

In the case where the base fiber 20 is based on polyethylene terephthalate, the binder fiber 22 is formed, for example, based on polypropylene, polyethylene, or co-polyethylene terephthalate, mixtures thereof, or copolymers thereof.

The binder fibers 22 are present in an amount different from zero and less than 15%, preferably less than 13%, by weight relative to the total weight of the

fibers

20, 22 in the velvet sheet 12. In some cases, the weight content is less than 10%.

The

fibers

20, 22 of the velvet sheet 12 are needle-punched and flocked to form a front layer 24 and a back layer or backing layer 26. Such a velour sheet of needle-punched flocked fibers is described in particular in document FR 3018287.

The front layer 24 has a velvet appearance. The velvet is comprised of

fibers

20, 22 randomly distributed in the form of loops 28 or individual strands 30. In particular, in the

textile components

10, 110 shown in fig. 1 and 2, the loops 28 of the velvet sheet 12 of fig. 4 have been trimmed to form individual strands 30.

The velvet density in the front layer 24 is preferably 0.015g/cm³And 0.030g/cm³In the meantime. This density is measured, for example, by determining the ratio between the weight of the material obtained by trimming the front layer 24 through to the entirety of the back layer 26 and the initial volume of the layer being trimmed.

This relatively low density is particularly suitable for implementing the manufacturing method described below for the

component

10, 110.

The back layer 26 formed by the interlocking of the

fibers

20, 22 advantageously has a thickness e that is less than the thickness of the front layer 24₁(FIG. 1). Preferably, the weight per unit area of the back layer 26 is greater than 200g/m²And more preferably 200g/m²To 800g/m²。

The binder fibers 22 of the back layer 26 partially melt to adhere to each other and to adjacent base fibers. The

adhesive fibers

20, 22 form apertures 32 in the back layer 26 at the bottom of the front layer 24, particularly at the first face 34 of the back layer. At least some of the holes 32 are in fluid communication with each other and with the outside air.

Fig. 3 shows a detailed view of the velvet sheet 12 of a

component

10, 110 at the first face 34 of the backsheet 26. Particles 36 of active compound 18 are impregnated in first face 34 of velvet sheet 12, particularly in pores 32 of first face 34.

The active compound 18 is capable of binding volatile organic compounds, in particular aldehydes. Thus, active compound 18 is capable of trapping the volatile organic compounds in pores 32 of velvet sheet 12.

Preferably, the active compound 18 is selected from hydrazine-formamidine amide phosphate (or carbazole amidine phosphate), hydrazine-formamidine amide sulfate or a mixture comprising several phosphates and/or hydrazine-formamidine amide sulfate. In particular, the active compound is chosen according to the type of aldehyde to be captured (for example formaldehyde, acetaldehyde or acrolein).

The mass per unit area of the active compound 18 in the

component

10, 110 is preferably from 50g/m²To 200g/m²The stated weight per unit area corresponds to the total weight of the active compound 18 impregnated in the

component

10, 110 adhering to the respective surface of the velour sheet 12.

The reinforcing

component

14, 114 of the

component

10, 110 is incorporated into the back layer 26 of the velour sheet 12 at the second face 40 or outer surface opposite the face layer 24. More specifically, at the second face 40, the reinforcing

component

14, 114 impregnates the

fibers

20, 22 of the back layer 26 and is particularly disposed in the pores 32 proximate the second face 40.

The

reinforcement component

14, 114 impregnates the back layer 26 from the second side 40 at a thickness e2 (fig. 1) that is less than e1 so as to leave a hole 32 in fluid communication at the first side 34.

Preferably, the reinforcing

component

14, 114 comprises a thermoplastic polymer, such as a polymer or copolymer of the same kind as the base fiber 20. Preferably, however, the melting point of the reinforcing

component

14, 114 is less than the melting point of the base fiber 20, and more preferably less than the melting temperature of the binder fiber 22.

In the embodiment of fig. 1, the second side 40 of the back layer 26 forms an exterior surface of the component 10. Preferably, the reinforcing component 14 is flexible at room temperature, which provides softness to the component 10, which is a carpet, for example.

In the embodiment of fig. 2, the second side 40 of the back layer 26 is in contact with the support 116. Preferably, the support 116 is rigid at room temperature. Thus, the component 110 (e.g., a vehicle rear luggage rack) has a certain rigidity and mechanical strength.

The support 116 is formed, for example, from one or more layers of composite material, including structural elements incorporated in a plastic matrix 142. The structural elements are for example reinforcing fibres of the glass fibre or carbon type. The plastic matrix 142 preferably comprises a thermoplastic polymer. Preferably, the plastic matrix 142 has a melting point that is lower than the melting point of the binder fibers 22.

Preferably, support 116 of member 110 is thermoformed from velour sheet 12. The reinforcing component 114 is formed by the plastic matrix layer 142 of the support 116, which layer enters the velvet sheet 12 during thermoforming. The corresponding method will be described later.

Fig. 5 shows a first device 200 for producing the velvet sheet 12 shown in fig. 4.

The first apparatus 200 includes: a supply roll 202 for supplying a substrate 204 formed of base fibers 20 and binder fibers 22; the conveyor 206 comprises an endless belt provided with brushes 208, a needling device 210, a thermal bonding device 212 and a winder 214. A similar device is described in document FR 3018287.

The bristles of the brush 208 of the conveyor 206 define an upper surface 216 on which the substrate 204 is carried. The conveyor 206 is capable of rolling the upper surface along a horizontal axis a-a'.

The needle-punched flocking device 210 is disposed facing the upper surface 216. It comprises a needle board 218 which can be deployed perpendicularly towards the surface 216 for piercing the substrate 204 and drawing the

fibres

20, 22 in the bristles of the brush 208 to form a loop 28 as described in FR 3018287.

The thermal bonding apparatus 212 is, for example, a ventilation oven or an infrared oven. The device 212 is adapted to heat the sheet of fibers after needle flocking to at least partially melt the bonding fibers 22. The temperature inside the thermobonding means 212 is for example greater than 90 ℃ and in particular from 120 ℃ to 200 ℃.

A winder 214 is placed at the exit of the thermal bonding device 212 to receive the velour sheet 12 formed thereby.

Fig. 6 shows a second apparatus 250 for manufacturing the textile element 10 of fig. 1 from the velvet sheet 12 of fig. 4.

The second device 250 includes: a roller 252 for feeding the velvet sheet 12; means 254 for applying the enhancing component 14; a first heater 256; a shearing device 258; a device 260 for applying active compound 18; a second heater 262; and a winder 264.

In the illustrated embodiment, the reinforcing component 14 is applied to the second side 40 of the back layer 26 of the velour sheet 12 in the form of a film or nonwoven 266. As a variant not shown, the reinforcing component 14 is applied in powder form or in the form of a plastisol or organosol, as described in document FR 3018287.

The cutting device 258 is capable of cutting one end of the loops 28 of the face layer 24 of the velvet sheet 12 to form individual strands 30, as shown in fig. 1.

The apparatus 260 for applying the active compound 18 is capable of spraying a solution 268 containing the active compound 18 and a solvent (preferably water) onto the front layer 24.

The surface tension of solution 268 is preferably selected to facilitate its impregnation in interstices 32 of velour sheet 12. Optionally, additives are incorporated into the solution 268 for this purpose.

Like the thermal bonding apparatus 212 of the first apparatus 200, the first heater 256 and the second heater 262 are, for example, a vented oven or an infrared oven.

A winder 264 is placed at the outlet of the second heater 262 to receive the textile element 10 thus formed, in the form of a continuous strip ready to be cut.

Referring now to fig. 7, a method 300 of manufacturing a

component

10, 110 according to one embodiment of the invention will be described.

The method 300 comprises a first stage 302 for manufacturing the velvet sheet 12, with a feeding step 304 for feeding the substrate 204 onto the upper surface 216 of the conveyor 206; a needle-punching flocking step 306 of needle-punching flocking the substrate by the needle-punching flocking device 210 to form a loop 28 outside the substrate 204; a heating step 308 of heating is then performed by the thermal bonding apparatus 212. The heating step 308 is performed at a temperature above the melting temperature of the binder fibers 22, particularly greater than 90 ℃, particularly from 110 ℃ to 190 ℃. The binder fibers 22 at least partially melt and bind to the base fibers 20 to form openings 32 in the back layer 26.

After cooling, the velvet sheet 12 thus formed is wound on the winder 214 of the first apparatus 200 (step 310).

According to a first variant, the method 300 comprises a second stage 320 for manufacturing the textile element 10 of fig. 1 from the velvet sheet 12.

The second stage 320 of the first variation includes: a feeding step 322 for feeding the velvet sheet 12 at the application device 254 by means of a roller 252; followed by an application step for applying a film 266 on the second face 40 of the back layer 26 by means of said application device 254; followed by a first heating step 326 by a first heater 256. During the first heating step 326, the reinforcement component 14 forming the film 266 melts and impregnates the back side layer 26 from the second side 40. Thickness of impregnation e₂Leaving the aperture 32 near the first side 34 of the back layer 26.

The second stage 320 of the first variation then includes a trimming step 328 that trims the loops 28 of the front layer 24 to form the individual strands 30. According to an alternative, the trimming step 328 occurs before the time step 324 for applying the film 266. According to another alternative, the trimming step 328 is omitted in order to form the component 10 whose deposited layer 24 comprises the ring 28.

The second stage 320 of the first variation then includes a spraying step 330 of spraying the solution 268 onto the front layer 24. The solution is impregnated in the velvet sheet 12. In particular, the low velvet density of the front layer 24 allows the solution 268 to enter the free holes 32 of the first side 34 of the back layer 26. The second heating step 332 is then performed by the second heater 262 at a temperature suitable for evaporating the solvent from the solution 268. Particles 36 of active compound 18 are formed in open pores 32.

After cooling, the textile element 10 thus formed is wound on a winder 264 of the second device 250 (step 334). The textile element 10 may then be cut into a suitable shape, for example to form a motor vehicle carpet.

According to a second variant, method 300 comprises a second stage 340 for manufacturing textile element 110 of fig. 2 from velvet sheet 12.

The second stage 340 of the second variation includes a step 342 of thermoforming the plush sheet 12 with the support 116. Generally, the thermoforming step 342 includes: superimposing the velvet sheet 12 with at least one composite precursor element of the support 116 with which the second face 40 of the back layer is in contact; the composition thus formed is then hot pressed in a hot forming die.

The pressing is performed at a temperature above the melting temperature of the plastic matrix 142, but preferably below the melting point of the binder fibers 22 of the velvet sheet 12. Thus, the fibers of the face layer 24 are not bonded together by pressing.

The thermoforming step 342 also includes cutting the velvet sheet 12 and support 116 before or after hot pressing.

Optionally, the second stage 320 of the second variation further includes a trimming step 328 of trimming the loops 28 of the front layer 24 to form individual strands 30. The trimming step 328 is preferably performed prior to the thermoforming step 342.

The second stage 320 of the second variation also includes a spraying step 344 of a spray solution 268 on the front layer 24, followed by a heating step 346. Preferably, the injecting 344 and heating 346 steps are performed after the thermoforming 342 step.

The injecting step 344 is similar to the injecting step 330 described above; the thermoformed parts in step 342 are, for example, placed on a conveyor belt (not shown) and passed one after the other through the aforementioned applicator 260. Similarly, the heating step 346 is similar to the second heating step 332 of the first variation: the solvent of solution 268 evaporates and particles 36 of active compound 18 form in open pores 32 of velvet sheet 12.

The textile element 110 thus formed is then recovered at the output of the conveyor belt (step 348).

The method of using the

textile element

10, 110 is described below: the

textile part

10, 110 is arranged in a motor vehicle, in particular as a carpet, a cab decoration, a floor, a rear luggage shelf or a luggage board.

Air within the motor vehicle passes through the apertures 32 of the back layer 26 of the velvet sheet 12 of the

textile element

10, 110. Due to the active compound 18 present in the pores 32, volatile organic compounds present in the air are trapped in the pores by the active compound. Thus, the

textile element

10, 110 helps to decontaminate the air inside the motor vehicle.

In particular, the above-described fabrication process of

components

10 and 110 allows active compound 18 to remain impregnated in pores 32 of velvet sheet 12 without losing its effectiveness for volatile organic compounds (e.g., aldehydes).

According to a variant of the manufacturing method described above, solution 268 is sprayed on front layer 24 of velvet sheet 12 before reinforcing elements 14 are introduced or before thermoforming with supports 116. However, such an embodiment is less effective.

Claims

1. A method (300) for manufacturing a textile component (10, 110) for an apparatus, comprising the steps of:

-providing a substrate (204) comprising base fibres (20) and a non-zero amount and less than 15% by weight of at least partially fusible bonding fibres (22); then the

-needle flocking (306) a substrate to stretch loops (28) on a face of the substrate; then heating (308);

so as to form a velour sheet (12) comprising a front layer (24) and a back layer (26); the binder fibers (22) of the back layer partially melt and form holes (32) at a first face (34) of the back layer at the bottom of the front layer;

said method is characterized in that it further comprises the steps of:

-spraying (330, 344) a solution (268) comprising an active compound (18) and a solvent on the front layer (24), the active compound being capable of binding with a volatile organic compound; and

-evaporating the solvent (332, 346) so that the active compound is impregnated in the pores (32) of the first side of the back layer.

2. The method according to claim 1, wherein the active compound (18) is capable of binding to at least one aldehyde.

3. The method according to claim 1 or claim 2, wherein the active compound (18) is selected from hydrazine-formamidinephosphate, hydrazine-formamidinesulfate or a mixture comprising several phosphates and/or hydrazine-formamidinesulfate.

4. The method according to any of the preceding claims, comprising, before the step of spraying (330, 344), a step of introducing (324, 326, 342) a reinforcing component (14, 114) onto a second face (40) of a back layer (26) of the velvet sheet, the second face being opposite to the front layer.

5. The method of claim 4, wherein the reinforcing component (14, 114) introduced onto the back layer (26) of the velvet sheet comprises a thermoplastic polymer, the introducing step comprising heating (326, 342) the back layer to cause the reinforcing component to enter at the second face (40) of the back layer.

6. A method for manufacturing a textile element (110) for equipment according to claim 4 or claim 5, wherein the step of introducing a reinforcing composition (114) comprises thermoforming (324) the velvet sheet (12) together with the reinforcing composition.

7. The method according to any one of the preceding claims, wherein the binder fibers (22) comprise bicomponent fibers comprising a core and a sheath surrounding the core, the sheath having a melting temperature lower than the melting temperature of the core.

8. Method according to any one of the preceding claims, wherein the density of velvet in the front layer (24) of the velvet sheet (12) is from 0.015g/cm³To 0.030g/cm³。

9. The method according to any of the preceding claims, comprising feeding (304) the substrate (204) onto a conveyor belt (206) equipped with brushes (208), and then needle-flocking (306) the substrate opposite the brushes.

10. A textile element (10, 110) for the interior equipment of a motor vehicle, comprising:

-a velvet sheet (12) comprising a base fiber (20) and a non-zero amount and less than 15% by weight of at least partially fusible binder fibers (22); the fibers forming a front layer (24) and a back layer (26); the binder fibers (22) of the back layer partially melt and form holes (32) at a first face (34) of the back layer at the bottom of the front layer;

-an active compound (18) impregnated in at least a portion of the pores, the active compound being capable of binding to a volatile organic compound, preferably to an aldehyde; and

-a reinforcing component (14, 114) provided in the back-side layer (26) at its second face (40).

11. The textile component of claim 10 from the method of any of claims 4-9.

12. A motor vehicle comprising a textile component (10, 110) for interior equipment according to claim 10 or 11.