CS206391A3 - Fibrous structure and shaped products made of it. - Google Patents

Abstract

The invention concerns a fibrous structure based on polyester, polyamide or polyolefin fibres which contains essentially (A) polyester, polyamide or polyolefin fibres from 3 to 1000 dtex having a staple fibre length of from 20 to endless and B) multicomponent fibres of identical composition to the first fibre, i.e. containing polyester, polyamide or polyolefin, from 3 to 1000 dtex and 20 to endless, or instead of the multicomponent fibre B a thermoplastic polymer powder of the particular polymer type. The invention also concerns a process predominantly for producing mats from these fibrous structures and the use for producing moulded articles. Because the production process involves force and energy only and no solvent-containing binders whatsoever, it does not produce any waste, it facilitates recycling during production and from disassembly, and by including the surface finishing step in one operation it is highly automated.

Description

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Technical field

BACKGROUND OF THE INVENTION 1. Field of the Invention The invention relates to a fiber structure obtained from clay and to its manufacture.

Background Art 2 GM 88 0? Is known for upholstery for seating, lying and the like, which is provided as a removable abutment or rigid piece with a fleece pad, which is formed of bonding fibers of thermoplastic material, in particular of so-called coated fibers. This bonding fiber web is molded. Also a mixture of bonding fibers which are bonded to each other by thermal non-melting may be used as the web material. They may be polyester fibers or sheathed fibers with a polyester core and a copolyester sheath.

SUMMARY OF THE INVENTION It is an object of the present invention to provide starting materials with the same or at least similar properties as are simultaneously tolerated by surface materials used in the automotive industry, so that other objects of the invention are still satisfactory and to provide a fabric made of fibers which, by choice of starting materials, fiber structure, The thickness of the fibers, the lengths of the main layers and the length of the shearing, the ratios of the components in the mixture could be formed into self-supporting welded parts without the use of any other binders, which would not change their shape after assembly by their own weight. As far as possible, the parts should have at least their own weight compared to the parts, they should be less expensive to produce and, on the basis of their material, they should allow for more cost-effective and therefore less expensive, more cost-effective machine arrangements. In this connection, it is particularly contemplated to re-utilize the raw materials used, also in the case of surface-laminated parts in O-waste production and to relieve the working space, as well as in the area of use in the presence of volatile, partly toxic substances such as e.g. isocyanate, formaldehyde, styrene and FCKW. Further, surface enrichment should also be included in the forming process, for example by forming a shaped slip of one material with different densities. With these fiber structures, the requirements for sound absorption, vibration and heat have been achieved, for example, by a layered structure. Furthermore, it was important to apply the time-consuming materials to the surface of the article such that when similar surfaces are no longer needed for fashion or technical reasons, the bulk of the weight remains, the greater the proportion of material remaining, the recovery of possibly separated decorative material. The aim was to take a view on the future demands of the waste industry, which the legislators submitted according to the responsibility of the responsibility.

These issues and tasks will be addressed in the following minutes. With the materials presented here, these tasks can already be accomplished in many industries, other than other moldings, which have hitherto been made from a wide variety of materials through a real material re-route. From the starting material in this case, the fiber is prevented from being recycled by energy burns and still unsolvable problems, or by the loading of the storage space.

The fiber A may be a full fiber or with a cavity or a fiber with particular properties, e.g. Trevira CS, a hardly flammable, colorless fiber in which a fibrous structure can be used without an additional decorative layer as a visible layer. Multicomponent thread 3 consists of t.zv. a multilayer fiber, e.g., a "side byside type" or a sheath fiber - a core or fibril type, usually as a core and sheath fiber, the core melting point typically being the melting temperature of the sheath material. A feature of the molded fiber component according to the invention is that it must consist of fibers of one chemical type, but of different properties, that is to say not. from fibers with a cavity for enlargement, and then for multi-component fibers, for example, a polyester fiber consisting of a polyester sheath and a polyester core.

As the polyester fiber A, for example, the Trevira Spinnfaser fiber UGCK 035 / X, such as a multi-component polyester fiber such as Trevira type 252, can be considered. As polyamide fiber A, for example, PA 6 Grilon can be used, as multi-component polyamide fibers 3 can for example, PA6, O Dipolyn.

For example, polyolefins A come in the form of fibers of the types HDFE and LDPE and PP, Danaklon EA or Danaklon Soft, Dana-clone ES as multicomponent fibers B.

For example, Dupont-Poly-ester Fiberfill type D202 can be used as fibers with a cavity.

The single fibers A have a thickness of 3 to 1000 dtex, in particular 3 to 170, in particular 3 to 30 dtex, and have a cutting length of 20 mm, in particular 30 to 80 mm, in particular 40 to 65 mm. The multi-component fiber B has a thickness of from 3 to 1000 dtex and a length of 20 mm, preferably from 30 to 80 mm, in particular from 40 to 65 mm.

As an alternative to the multi-component fiber that is to be used, the thermoplastic powder polymer may also be admixed to the fiber structure.

The powdered polymer is added in an amount of from 10 to 60% by weight, preferably from 20 to 50%, in particular from 30 to 40% by weight.

The fiber structure according to the invention can only occupy one main layer, but it should have two or more main fiber layers, which are homogeneous with respect to the fiber mixture, for better sound attenuation, vibration and heat. The mixture ratios in the main layer may vary. That is, the main layers are of the same material, i.e. either polyester or polyamide or polyolefin. The advantage of damping is, for example, the thermally reinforced fiber body, whose upper main layer contains 40% of the multicomponent fibers, the residual fiber A, for example the type of filled fiber and the lower layer of 20 to 50% multicomponent fibers, the residual fiber A, the fiber mixtures are homogeneously mixed within the corresponding main layer. The fiber lengths lie in the lower region. The mat is unilaterally mechanically reinforced. The thickness of the main layers is not critical and is chosen as needed. Longer need to increase economy by reducing the weight of the parts with respect to the use of these fiber structures. This is achieved by assembling the so-called. sandwich boards. In this case, the fiber fleece is introduced as a first step between the two tool halves in the manner described. The upper half of the tool generally consists of a perforated plate or also of a negative of the lower half.

The lower half of the tool is from the corresponding counterpart, for example, in the form of regular cylindrical shapes such as cones, loafs, waves, honeycombs, etc. at the desired thickness of the sandwich plate to be obtained. The fibers preheated by the emitter, the contact heat or the hot air are compressed to the desired geometries in these refrigerable formulations and can be removed from the mold in the shortest time possible, and it is possible to arrange the production on a running bar clock.

In addition to this production between the tool parts for the layer, it is also possible to produce on the calender rollers the corresponding diameters and structured surfaces, and according to the shape configuration, it is also possible to work with two roller surfaces or counter-shaped straight or one-cylinder-shaped passage.

The preformed mat is then generally introduced between two smooth pre-heated fiber structures or also the same polymeric materials as the film or, for example, the spunbond and between the rollers of the cauldron or, for example, the flat laminating apparatus under vacuum and under a variable temperature and laminated on both sides. This makes it possible to insert fibers of different thermal resistance between the formed fiber structures of different distances and the surface materials of the polymer. Laminating these smooth surface materials with a thermoplastic adhesive is also feasible.

The properties of the sandwich panels are versatile and can always be adapted by choosing different geometrical shapes, their adjustable softness and a variety of fiber blends as well as fiber density. The strength and stiffness depend on the geometry, its angle of inclination, the use of bonding material, the bulk density and can be adapted to the target values. of these material combinations. Further, we achieve a low weight in a large volume and thus an increased bending strength, wherein the forming tool is dimensioned for predetermined distances for the desired resultant parts, and a new thickness is also obtained in the areas of the desired greater densification. In this case, the stability of the molded parts can be achieved by subsequent girdling and sewing.

The fiber structures of the invention are versatile and can be processed into molded parts. In this case, it is possible for the first time to re-prepare by recycling the selected fiber mixture a limitation of one material by including predominantly used polyester, polyamide and polypropylene molded parts.

Furthermore, it is remarkable that no vapors or gases are present in the treatment of the fiber bodies according to the invention, as well as in their molded parts, because they do not use solvents containing solvents.

By constructing the fibers and using solely the force and energy (predominantly thermal), the fiber structure receives its final shape, with regions of very different densities being formed in one working cycle. The body does not change for a longer period of time as the load-bearing part is self-weighted, unless supported by the molding agent additive.

Important functions can be fulfilled by the proportion and placement of component fibers, as well as the length of their shearing, in terms of strength and densification, by applying different temperatures to surfaces, in one work step, such as sound insulation, vibration damping.

Another possibility is to preheat the fiber material in the blowing channel and suck it into a closed, cold but air-permeable tool, where the fibers are joined and solidified, with the shape of the tool. Here, too, densification can be created by regulating air suction. It is also possible to combine multiple fixtures as well as airflow throughputs to allow the overall shape of the part. b) The fiber structure is first formed as a blank in the form of a mat. This may additionally be one or two-sided mechanically strengthened and passed through the furnace. Hot gases, predominantly air, are blown through the fibrous structure, eventually sucked and subsequently thickened through the calender rolls. The product thus obtained can then be placed in a hot tool, compressed and formed, placed in a cooling tool, or removed after final densification and further processed if necessary. c) The process is shaken as described in b), but after pre-thickening, the perforated or sieve halves of the tool are reinserted, for example by sucking hot air. Next, it is cooled with a cold air and the finished product is removed. (6) The process is continued as described in (b), but after the pre-densification is followed by further cooling and the blank is removed. This mat can now be brought to the surface of the skin in the next operating cycle between the plates or cadders to achieve a sapon effect. in the following, it is again heated by means of hot air, steam, optionally via a radiator or a contact heating and inserted between the cooled preparations. The part which is dimensionally stable is subsequently compressed, eventually laminated and then removed and further applied as necessary. EXAMPLES Example 1 (Procedure a) A hand support part in a passenger car should be made. The product will not be surface-laminated, but should have a strong return on shape and strength as given by the high density 7-weight polyurethane foam.As a base fiber, the polyester hollow fiber of the Bscron Fiberfill type 13 dtex is mixed homogeneously, the length of the cut 63 mm and the Trevira fusion fiber 4.4 dtex, 51 mm The mixture is 50/50% · This mixture is deposited from the reservoir by the air flow through the perforated bottom jig and after reaching the desired weight on the platform, the top, also the perforated portion, is closed while the contents of the part are compressed. the tool is exposed to a stream of hot air, with the temperature, the amount of airflow and the flow time dependent on the volume of the component, and then cooled to about 30 kg / m @ 2 by supplying cold air while fixing the fibers. Example 2 (Process b) In this example, a so-called C-column is to be produced (cf. 1 between the rear window and the rear door of the car), using polyamide fibers type PA6 Grilon 7 dtex with a cutting length of 60 mm and jacketed fibers type PA 6.6 Dipolyn 4.4 dtex and fiber length of 50 mm. The mat is laminated with a polyamide knit of 170 g / m, 1 mm thick. This knit is pre-coated on the back with a layer of copolyamide adhesive film of 50 g / m. Activation temperature between 120 and 130 ° C, softening temperature at 100 ° C. The mat emerges at a temperature of 60 ° C from the preliminary mechanical and thermal densification and is placed in a hot preforming tool. Here the partopithe reaches its required temperature of about 160 ° C and is further transferred to an o-coolant.

Here, the fabric is now conveyed as an endless belt between the half-tools, pressed and laminated with the fiber body. A temperature of 130-140 C in conjunction with the pressure is sufficient to activate the copolyamide film and to form a bond. The molded and surface-treated part may be removed from the cooling tool for further processing. Example 3 (Procedure c)

The 17 dtex, 60 mm polypropylene fiber mat and the 3.3 dtex 60 mm bicomponent fiber are mixed homogeneously. Multicomponent Linkage Ratio: The single strand lies at 30:70, at the top main layer at a total thickness of 25mm and at 15: 85% at the longer layered layer at a total thickness of 25mm. This is pre-thickened with 1500 g and 50 mm thick mats, where polyethylene film is embedded and sandwiched between the layers. This mat is then introduced into the air-permeable intermediate space of the tool, subjected to a metering stream of hot air, whereby the material is compressed by a region of highly variable densification to conform to the carcass shape. Again, the temperature, flow rate and time depend on the desired surface of the part. The molded mat is subsequently pressed directly onto the molded carpet using a heavy EPEP film. (The bonding of the polypropylene fiber structure, the heavy EPDM layer and the polypropylene fiber mat can be recalculated as a polyolefin bond.) Therefore, the cooling phase will be short and the residual heat of the part is used to bond the fiber structure to the preformed carpet. Example 4 (Procedure d) A storage compartment for vehicles with a top section 2 such as scouring 340 g / m and bottom as a glazing of 100 g / m both of polyester should be made. It is a polyester fiber blend with a 60: 40 polyester fiber to multi-constituent fiber ratio. The polyester fiber has a thickness of 12 dtex and a shear of 50 mm, and the multi-component fiber of the sheath type has a thickness of 4.4 dtex and a shearing length of 50 mm. A fiber mat in the form of a mat of 2000 g / m is made from both of these fiber portions and heat treated. The mat, which is originally many times thicker, is pre-dried to 40 mm and unilaterally strengthened mechanically. The semi-finished product is fed into the thermal cabinet and heated to 180 ° with hot air or radiant heat. It is important that this temperature is achieved throughout the fiber body. Flow velocity, radiator temperature, force and time are again dependent on shape. Thereafter, the pre-processed mat is moved to the forming apparatus. The added co-polyester powder was pre-sintered, 50 g on top and 30 g on bottom. The decorative material for laminating the polyester fleece with a surface weight of 340 g / m and a thickness of 4 mm is also brought forward as a 100 g bottom as an endless belt between the top and bottom of the tool, both materials being pre-heated to about 90 ° C. The upper and lower parts of the tool are cooled. During compression and molding, the fiber mat transfers its own heat to the thermoplastic adhesive layer and a rigid connection occurs. The shock solidification fixes and solidifies the fibers so that the part can be stamped, removed from the tool and processed further.

Industrial_usability

The molded parts according to the invention can be used in particular in the automotive, aerospace and railway industries to produce upholstery of all kinds.

They are also suitable, for example, for the finishing of passenger car covers, sun visors, engine compartment insulation and suitcase, armrest and insulation insulation behind molded carpets and the like.

This also applies in conjunction with the volume and weight of larger-sized surface materials such as carpets, when they use fiber structures as alternative molding and fixing media in the same assortment and with thermoplastic films, powders, fibers, fleece or mixtures of these as substitutes for previously used plastics or non-homogeneous thermoplastics.

As mentioned above, the final wastes of the molded parts according to the invention can be re-used again after the crushing in the event of production errors in embossing or car assembly. In this case, a granulate or agglomerate can be obtained from the comminuted material by densification or build-up. The granulate is extruded into a foil, plate, or shaped-hour plastic mold in a furnace, or as a chemical material identical to the molded part, then a fiber with the same chemical structure can be obtained.

The same method of operation can be used when extraneous surfaces are used and if they can be removed by thermal activation of the thermoplastic main layer. The method and degree of surface treatment of the materials depends on their composition.

Claims (6)

PATENT NAROK o <xCD x XH - <mN s ° 1 <uD cn C / l [C CjC Fiber structure based on polyester, polyamide or polyolefin fibers, characterized in that it comprises, as A fibers, polyester, polyamide or polyolefin fibers of 3 to 1000 dtex and a length of 20 mm, as fiber-filled, with a cavity or a mixture thereof, as well as multi-component B fibers of the same composition, i.e. polyester, polyamide or polyolefin of 3 to 1000 dtex and 20 mm and longer as full, with a cavity or a mixture thereof or a multi-component fiber containing a thermoplastic polymer powder. 2. The fibrous structure according to claim 1, characterized in that one or more stabilizing or functional materials and / or thermoplastic adhesives and / or thermoplastic adhesives and / or thermoplastic adhesives are additionally or more or less stabilizing or functional between the main fiber layers and / or the surfaces of the same type. the decorative layer, wherein the decorative layers have a bulk density than the fiber structure. 3. A fiber structure according to any one of claims 1 or 2, characterized in that the fiber structure consists of two or more main layers, wherein the main fiber layer facing one surface comprises a proportion of 40 to 100% of the multicomponent fibers, the remainder A of the fibers and the second side and possible the interlayers have a proportion of from 0 to 100% of the multi-component B fiber inside, the existing layers being homogeneously mixed and the thicknesses of the existing layers being dependent on the shaped part. 4. A method according to any one of claims 1 to 3, characterized in that a mat of fibers A and B, or of a polymer powder consisting of one or more main fiber layers, which is always homogeneous or mixed with these types of fibers, is produced. the mat is thermally or mechanically or by a combination of the two techniques being formed, and the surfaces can then be smoothed with a calender, radiator or heating plates and additionally fixed in size. 5. A method according to claim 4, wherein the fiber structures take on the dimensioning contour of the calender rolls, or the materials of the same polymer are coated on one or both sides by flat-forming tools to achieve smooth surfaces. 6. A method according to any one of claims 1 to 3, characterized in that the fiber structures are pressed into molded parts also with areas of different densities exclusively by the action of forces and energy, predominantly thermal, which moldings do not change their own weight after installation.