CN114434906A - 可回收汽车专用地毡 - Google Patents

可回收汽车专用地毡 Download PDF

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CN114434906A
CN114434906A CN202110996415.9A CN202110996415A CN114434906A CN 114434906 A CN114434906 A CN 114434906A CN 202110996415 A CN202110996415 A CN 202110996415A CN 114434906 A CN114434906 A CN 114434906A
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fiber
carpet
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朴玄濬
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Seoyon E Hwa Co Ltd
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    • 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
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
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    • 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
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2262/0276—Polyester fibres
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    • 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
    • B32B2262/0276—Polyester fibres
    • B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
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    • 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
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B2307/00—Properties of the layers or laminate
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Abstract

本发明涉及一种可回收利用的汽车专用地毡，具体来说，由于构成多层的各种材质都是同一系列，因此成型后丢弃的废料和产品可以回收利用，不仅如此，还是一种轻量化、吸声和隔音性能良好的汽车专用地毡。

Description

可回收汽车专用地毡
技术领域
本发明涉及一种可回收汽车专用地毡，具体来说，由于构成多层的材质都是同一系列，所有成型后丢弃的废料和产品可以回收利用，不仅如此，还是一种轻量化、吸声和隔音性能良好的汽车专用地毡。
背景技术
汽车专用地毡安装在车底板等上，以阻隔从地板传来的噪音。
传统汽车专用地毡通常由蒙皮层、聚乙烯(PE)材质的第1涂覆层和乙烯醋酸乙烯(EVA)材质的第2涂覆层等三层组成。第1涂覆层是为了成型，第2涂覆层是为了隔音，通常通过增加重量来控制这种成型和隔音性能，因此为了提高性能而不得不增加重量，由此对车辆燃油费用和CO2排放产生不利影响。另外，由于各层使用不同的材质，不仅制造工艺复杂，而且无法回收利用。
现有技术文献
专利文献
大韩民国公开专利第10-2007-0118731号(公开日2017.12.18)，
大韩民国公开专利第10-2001-0066081号(公开日2001.07.11.)。
发明内容
待解决的课题
为了解决上述问题，本发明旨在提供一种汽车专用地毡，构成多层的材质都是同一系列，因此成型后丢弃的废料和产品可以回收利用，不仅如此，还是一种轻量化、吸声和隔音性能良好的汽车专用地毡。
课题的解决手段
为此，本发明涉及的汽车专用地毡的特征是，包括蒙皮层、成型毡层和吸声毡层，但不包括隔音层，构成所述地毡的各层由相同的聚烯烃类纤维组成，所述成型毡层的面密度为200～600g/m2，所述吸声毡层的面密度为250～1000g/m2，所述成型毡层或所述吸声毡层进一步包括直径在1～20μm以下的超细纤维，所述成型毡层的厚度为3㎜以下，所述吸声毡层的厚度为5～20㎜。
所述聚烯烃类纤维可以是PET纤维或PE纤维。
所述聚烯烃类纤维可以是低熔点纤维(Low Melting Fiber)或再生纤维。
所述成型毡层或所述吸声毡层中，可以是再生纤维为60重量％至70重量％的、低熔点纤维为30重量％至40重量％。
另外，所述成型毡层和所述吸声毡层可以用PE粉末进行层压。
发明的效果
本发明涉及的汽车专用地毡具有的效果是，构成多层的材质均由相同的聚烯烃类纤维组成，因此成型后丢弃的废料和产品可以回收用于成型毡或吸声毡等。
此外，本发明涉及的汽车专用地毡除却了传统用于隔音的涂覆层，从而具备轻量化的优良效果，即便如此，不仅吸声性能优良，而且在与车辆钢板接触时，隔音性能也十分优异。
附图说明
图1是本发明涉及的汽车专用地毡的简略剖面图。
图2是根据本发明制备的汽车专用地毡的真实照片。
图3是本发明涉及的毡层的重量和成分的物性曲线图。
图4是有或无超细纤维的情况下不同吸声性能的曲线图。
图5是本发明的实施例和比较例的吸声性能的曲线图。
图6是本发明的实施例和比较例的隔音性能的曲线图。
符号的说明
10:地毡
100:蒙皮层
200:成型毡层
300:吸声毡层
具体实施方式
以下，将参考附图对本发明的实施例进行详细阐述。
为了区分于传统技术、更明确地表达以及为了便于对技术的了解，本发明所附图上可使用了夸张的表达手法。此外，后文所用术语是考虑到本发明中的各项功能而定义的术语，可能会因使用者、操作者的主观意图或惯例而异，因此，对这些术语的定义应基于贯穿于本说明书的技术内容而进行。另一方面，实施例只是本发明的权利要求中公开的构成要素的例举项，并不限定本发明的权利要求，权利要求应基于贯穿于本发明说明书中的技术思想进行解释。
图1是本发明涉及的汽车专用地毡10的简略剖面图，可包括布料的蒙皮层100、成型毡层200和吸声毡层300而组成。
传统上，由于使用了不同材质的蒙皮层和涂覆层，因此不能回收利用，但本发明中构成所述地毡10的各层都是由相同的聚烯烃类纤维组成，因此成型后丢弃的废料和产品可回收后用于成型毡或吸声毡等。
此外，本发明所具备的特点是，除却了传统用于隔音的有一定重量的涂覆层(隔音层)，因此不仅能实现轻量化、简化制造工艺，同时还能保留其优异的吸声性能。
为此，本发明涉及的汽车专用地毡10，所述蒙皮层的面密度优选300～800g/m2，其厚度可以为0.1mm以上10mm以下。
所述成型毡层的面密度优选200～600g/m2，其厚度5mm以下，优选3mm以下，更有利于成型。
所述吸声毡层的面密度优选250～1000g/m2，其厚度为5～20mm，有利于吸音。
所述蒙皮层100可以是无纺布，构成所述蒙皮层100、成型毡层200和吸声毡层300的聚烯烃类纤维可以是PET纤维或PE纤维，优选PET纤维。
另外，所述聚烯烃类纤维可以是低熔点纤维(Low Melting Fiber)、再生纤维或它们的混合物。
下表1和图3所示的是由PET纤维构成的毡层的面密度和组成(rPET，LM)所对应的不同的物性(抗拉强度、延伸率)。
【表1】
Figure BDA0003234208540000041
Figure BDA0003234208540000051
通过上述表1和图3可以确认，延伸率在LM的为30重量％时显得十分优秀。
另外，抗拉强度随着LM含量的提高而增加，举例来说，当LM为40重量％时，和30重量％时相比提高了1～2MPa左右，当LM为60～70重量％时，和40重量％时相比只提高1MPa以下。特别是可以看出，当面密度为600g/m2、LM为30重量％时，延伸率明显增加。
结论是，在考虑经济可行性时，价格昂贵的LM的含量应该最少，但考虑到物性，那么LM为30％到40％时是最理想的。
所述成型毡层200或吸声毡层300可进一步包括聚烯烃类材质(优选PET材料)的直径在1～20μm以下的超细纤维，以进一步提高吸声性能。图4所示的是有或无超细纤维时不同的吸声性能。这种性能差异可以使超细纤维进一步提高空气流动阻力，从而进一步提高吸声性能。所述超细纤维是优选的利于高温成型的聚酯(PET)材料。
本发明涉及的地毡10，各层均由相同的聚烯烃类纤维形成，特别是蒙皮层100和成型毡层200可以同时针刺层压或火焰层压，从而提升加工工程的效率。
另外，所述成型毡层200和所述吸声毡层300可以使用PE粉末或PE薄膜进行层压，但考虑到透气性，优选PE粉末。
[实施例]
1.制备了本发明涉及的汽车专用地毡(实施例)，由具备下表2所示组成的蒙皮层、成型毡层和吸声毡层构成。
【表2】
Figure BDA0003234208540000052
Figure BDA0003234208540000061
2.为了进行比较评估，制备了传统的汽车专用地毡，由具有下表3中所列组成的蒙皮层、成型涂覆层和隔音涂覆层构成。
【表3】
分类 面密度 组成 厚度(T)
蒙皮层 600g/m<sup>2</sup> LM PET 30重量％,rPET 70％ 3
成型涂覆层 200g/m<sup>2</sup> PE 0.5
隔音涂覆层 1000g/m<sup>2</sup> EVA(乙烯-醋酸乙烯酯) 1.5
[实验例]
1.吸声性能评估
为了对所制备的实施例和比较例的吸声性能进行评估，在声压均匀分布的小型混响室内进行了满足ISO 354标准的随机事件方式评估。
所述吸声性能的评估结果如图5所示，可以确认本发明涉及的实施例与传统的比较例相比在整体频率范围内具有更加优秀的吸声性能。
2.隔音性能评估
所制备的实施例和比较例的隔音性能评估是分成自身隔音性能和附着在具有下表4中物性的钢板上的情况下的隔音性能而进行的。作为参考，所述钢板的物性如下。
【表4】
密度 厚度 面密度
7.85g/cm 0.0008mm 6.28g/m<sup>2</sup>
本隔音性能评估是在小型混响无味室内用满足SAE J1400标准的声强法进行隔音性能的测试。
所述隔音性能评估结果如图6所示，可以确认在只有本发明涉及的实施例其本身为单品的情况下，不存在与隔音层相对应的配置，因此性能与比较例相比并不太好，但在附着于钢板上的情况下，隔音性能则有了明显的改善，和比较例相比在特定频率范围内更为优秀。
如上所述，应该理解为本发明是以附图所示实施例作为参考进行说明，但只不过是举例说明，在相关技术所属的领域，可能有基于常规知识进行各种变形和均等的其他实施例。因此，本发明真正的技术保护范围应取决于以下所述的专利权利要求范围，并应根据上述发明的具体内容来确定。

Claims (5)

1.一种汽车专用地毡，包括蒙皮层、成型毡层和吸声毡层，但不包括隔音层，其特征在于，
构成所述地毡的各层由相同的聚烯烃类纤维组成，所述成型毡层的面密度为200～600g/㎡，所述吸声毡层的面密度为250～1000g/㎡，所述成型毡层或所述吸声毡层包括直径为1～20μm的超细纤维，所述成型毡层的厚度为3㎜以下，所述吸声毡层的厚度为5～20㎜。
2.根据权利要求1所述的汽车专用地毡，其特征在于；
所述聚烯烃类纤维是PET纤维或PE纤维。
3.根据权利要求1所述的汽车专用地毡，其特征在于；
所述聚烯烃类纤维是低熔点纤维或再生纤维。
4.根据权利要求3所述的汽车专用地毡，其特征在于；
所述成型毡层或所述吸声毡层中，再生纤维为60重量％至70重量％、低熔点纤维为30重量％至40重量％。
5.根据权利要求1所述的汽车专用地毡，其特征在于；
所述成型毡层和所述吸声毡层用PE粉末进行层压。
CN202110996415.9A 2020-10-19 2021-08-27 可回收汽车专用地毡 Pending CN114434906A (zh)

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