DE2454975A1 - METHOD AND APPARATUS FOR IMPROVING THE APPEARANCE OF A LAYER OF ELASTOMERIC MATERIAL, IN PARTICULAR FOR IMPROVING THE APPEARANCE OF A CARPETED FLOOR, AND A PRODUCT HAVING SUCH IMPROVED APPEARANCE - Google Patents

Description

S.A. AUTOMOBILES CITROEN

117 a 167, Quai Andre Citroen F-75747 - PARIS CEDEX 15

Method and apparatus for improving the appearance a layer of elastomeric material, in particular for Improvement of the appearance of a carpeted floor and product having such an improved appearance

The invention relates to a method for improving the appearance of a layer of elastomeric material, in particular Made of natural rubber or synthetic rubber, the layer being made from an unprocessed film which is a smoothing process and then a heat treatment is subject.

The invention also relates to an implementation device of the method as well as layers or foils made of ela-

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stomer material used as carpets, floor coverings, etc. Find use. The invention is also particularly directed to the production of coverings made of elastomeric material, which in motor vehicles as carpeting, door panels, Dashboard-egg, shelves, etc. are used.

Such carpeting or floor coverings that have layers made of elastomeric material are known per se and are widespread in the automotive industry. These slides or layers of elastomeric material generally have a smooth, matte or glossy appearance, causing the At first glance you can see which material is used for the production the layers was used. The appearance of these layers of elastomeric material is less appealing than the appearance of carpeting made from a fiber material whether the fibers are woven or non-woven. Nevertheless, the carpeting or paneling, the layers of elastomeric material are used because their cost price is relatively low in relation to the cost price of the better looking cladding is made of the aforementioned fiber materials are made.

It is an object of the invention to provide a method which enables such improvement in the appearance of the layer of elastomeric material enables this layer to better meet the requirements placed on it in practice and that the appearance of the layer of elastomeric material, in particular carpeting, resembles that of woven or not woven fibers are made.

The invention is characterized in that after the smooth

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Operation and prior to heat treatment on the surface of the layer of elastomeric material, the appearance of which is improved is to be, a layer of soft, cellular material is applied, and that then on the collapsed Layers of soft, cellular material and of elastomeric material have a suitable compressive force and the two layers are exposed to a certain temperature which is below the baking temperature of the layer is made of elastomeric material, the pressing force and the temperature are selected such that the surface of the layer Made of elastomeric material, the appearance of which is to be improved, after this treatment a satin-like, due to the roughness the layer has a conditioned appearance.

According to an advantageous feature of the invention, the layer consists of cellular, soft material made of polyether and has a layer thickness between 5 and 15 mm. These Layer of polyether is preferably formed by a layer of expanded polyurethane, the density of which is about 28 kg + 2 kg / m- *. The pores of this cellular material can be open or closed.

The pressing force exerted on the layer of elastomeric material and the layer of cellular, soft material is exerted, as well as the heating to which these layers are exposed, are advantageously carried out between the plates of a heating press.

In the case where the layer of elastomeric material is made up of a layer of natural rubber or synthetic If rubber is formed, the temperature of the press plates during the processing process is between 120 °

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and 130 ° C, while the pressing force of the plates of the press such it is chosen that a pressure of around 60 bar is exercised.

When the thickness of the layer of elastomeric material is around 1 mm, then corresponds to the time in which this layer is exposed to pressure between the plates of the press is about a few seconds, more precisely about 10 seconds for a layer of black natural rubber or black synthetic rubber, and about 15 seconds for a layer of colored natural rubber or colored synthetic rubber.

Essentially, the layer is made of elastomeric material glued to a carrier, in particular to a felt carrier, on the side opposite the side, whose appearance is to be improved. In this case, it is used after the smoothing process and before the heat treatment the layer of elastomeric material, the appearance of which is to be improved, has a role of a composite Manufactured tape, wherein the tape consists of several superimposed layers, namely a carrier layer, the is formed in particular by a felt layer, the layer of the already smoothed elastomeric material and of the ■ Layer of the cellular material, and wherein the layer of elastomeric material between the carrier layer and the Layer of cellular material is arranged, and this roll is then processed in another work station, by gradually introducing the rolled up band into a press that applies a certain pressure to the band Exerts pressing force and the tape at the same time on a certain

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Temperature warmed. The press is preferably designed in such a way that they perform a cutting operation at the same time can, through which a piece, in particular a piece of carpet is produced, which the desired Has dimensions.

According to a further advantageous feature of the invention it is provided that the sheet piece of cellular material, which is cut by closing the press is, after its separation from the layer of elastomeric material, reinserted with its support into the press and placed on the side of the beam in such a way that between the platens of the press there are four layers on top of each other are arranged, namely the layer piece of cellular material that has just been cut off, the carrier layer, the layer of elastomeric material and the uncut layer of cellular material.

The invention also relates to a device for carrying out the method, which is characterized in that ■ that a work station for the production of a supply roll a tape is provided which has at least one layer of elastomeric material on a Layer of cellular, soft material is arranged, in particular on the side of the layer elastomeric material which is opposite the side on which the layer of cellular, soft material is arranged, a third layer serving as a carrier layer is arranged, and that a second work station is provided is where the supply roll of composing tape

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is gradually rolled out and introduced into a press that loads the tape with a certain compressive force . and warms up to a certain temperature and which pieces, in particular pieces of carpeting, cut off.

Finally, the invention relates to an industrial product, in particular a carpet or surface cladding, which has the same characteristics as the product produced by the method according to the invention.

The invention also relates to an industrial product whose visible surface is formed by a layer of elastomeric material, in particular on a felt carrier layer is glued, this industrial product is characterized in that the visible Layer of elastomeric material is roughened and has a similar appearance to that of woven or carpets made of nonwoven fibers, this roughness in all directions of the surface of the Layer is even.

Further features, details and advantages of the invention emerge from the following description of exemplary embodiments based on the drawing. Show in it:

1 shows a schematic representation of one of a layer made of elastomeric material and a layer of cellular material joined together tape that is between the plates of a press is arranged, which is used to carry out the method according to the invention;

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2 also shows a schematic representation of a work station for producing a roll of the assembled , Tape;

3 is a schematic view of the work station at which separating the layer of cellular material from the layer of elastomeric material;

4 shows a partial sectional view through the layer of cellular soft material and

5 is a perspective view of a carpet which has a layer of elastomeric material and the visible surface of which has a better appearance.

In the figure! is a layer 1 of elastomeric material, in particular made of natural rubber or synthetic rubber, whose final appearance is improved target.

This layer or film 1 has previously been subjected to a smoothing process and, if necessary, repeated heating, as is known per se to achieve a desired thickness, in particular a thickness of about 1 mm +0.1 mm is.

This layer must normally be up to its final state later exposed to a firing process, which takes about 10 minutes for the various types of rubber takes place for a long time at 160 ° C.

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According to the method according to the invention, the surface is applied after the smoothing process and before the baking process 1a of the layer of elastomeric material, the appearance of which is to be improved, a layer 2 of soft, cellular Material is then applied to the folded layers of soft, cellular material and made of elastomeric material exerted a suitable compressive force F and exposed the two layers to a certain temperature, which is below the baking temperature of the layer 1, the pressing force and the temperature being selected such that the layer 1 has a satin-like or felt-like, roughened appearance after the treatment.

The layer 2 consists of cellular, soft material advantageously from a layer of polyether, whose Thickness is preferably between 5 mm and 15 mm. The layer 2 preferably consists of an expanded polyurethane layer , the density of which is about 28 kg + 2 kg / m ^. The cells or pores can be open or closed.

The expanded polyurethane layer used. owns in advantageous Make the properties listed below. The lowering of the layer, i.e. the reduction in thickness, is with a pressure load between 20 mb and 36 mb 25%. So if the thickness of the layer in the unloaded state e, then this strength is reduced to 0.75 · e in the case of a compressive stress present in the manner described above. • This lowering is 50% with a pressure load between 30 mb and 46 mb and increases to 65% with a pressure load between 65 mb and 85 mb.

One can define a stress index which is the same

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the ratio of the stress that results in a reduction of 65% causes, to the stress that causes a reduction of 25%. This stress index is for Layer of expanded polyurethane preferably at least 1/7.

Another interesting parameter for the expanded polyurethane can be a minimum tensile strength of 1.3 bar and a minimum elongation at break of 150% is given.

The layers 1 and 2 are pressed together between the plates 3 and 4 of a press 5, which is shown schematically in FIG is shown. These plates 3 and 4 are equipped with molds 6 and 7, the layer 1 the desired give geometric shape. The molds 6 and 7, which are respectively on the lower plate 3 and below the Upper plate 4 are arranged, are equipped with electrical heating resistors 8 and 9.

In addition, this upper tool 7 is by means of elastic spring devices 10 from the plate 4 at a distance j held. These elastic spring devices 10 give when the press 5 is closed in such a way that the tool 7 against the plate 4 comes to rest. On the edge of the tool 7 cutting tools 11 are provided, which by means of springs 12 for Plate 4 are kept at a distance. When the press is open and the tool 7 is at a distance from the plate 4, then the cutting edges 11a are slightly retracted upwards relative to the lower edge 7a of the tool 7, as shown in FIG Fig.1 can be seen. When the press is closed, as soon as layers 1 and 2 are between the tools 6 and 7 are located, then the spring 10 is compressed. The cutting

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tools 11 therefore grip with their cutting edges 11a over the Edge 7a out and cut off a part of the layers 1 and 2, which corresponds to a certain piece, in particular a carpeted floor.

For processing a layer 1 of synthetic or natural rubber with a thickness of approximately 1 mm

+ 1 o ° C a tool temperature of tools 6 and 7 of 120 ⁰ C _ Xop

Suitable, that is, that the temperature is between 120 ⁰ C and 130 ° C during use.

The compressive force of the plates 3 and 4 is such that a pressure of 60 bar + 5 bar is applied to the layers 1 and 2.

The temperature during which the press is closed and during which pressure is applied to layers 1 and 2 is about 10 seconds for a black layer 1 and about 15 seconds for a layer of colored elastomer Material, i.e. if colored batches are used.

The introduction of the layers 1 and 2 between the plates of the press 5 takes place by means of a material roll R, whose drive takes place step by step, each step corresponding to the length L required to achieve an element.

In general, the layer 1 made of elastomeric material is glued onto a carrier layer 13. This carrier layer 13 is formed in particular by a felt layer, the thickness of which is advantageously approximately 8 mm. The felt can be soft be or so impregnated with synthetic resin that it is semi-rigid or rigid. In addition, the felt in general fireproof.

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The role R is thus formed by a band b that consists of consists of three layers arranged one above the other, namely layers 2, 1 and 13.

The tape b is fed automatically by two Guide rollers 14 which are arranged at the entrance of the press 5 and between which the belt b passes.

The production of the role R takes place in a work station, which is shown schematically in Figure 2 and on Exit of the station for smoothing the elastomeric material layer 1 is arranged. The guide rollers 15, which are shown in Figure 2 and on horizontal, parallel, but axes offset from one another in the perpendicular direction are supported and between which the layer 1 runs, form the exit of the work station for smoothing. The layer 1 then runs over the carrier rolls 16 before entering a device 17 reached, which the surface 1a of the layer 1, the appearance of which is to be improved, with an anti-adhesive pollinated.

pie whole system is designed so that the surface 1a of the layer 1 in this work station is arranged on the top is. Downstream of the device 17, a drying device 19 is provided for the surface 1a.

To the right of the drying device 19 is located below the layer 1 has a guide roller 20. A carrier layer 13 formed in particular from felt comes from one on one Carrier 21 freely rotatably mounted roller B and runs around the roller 20, with a change of direction by about one half turn takes place, so that the carrier layer of

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at the bottom against layer 1, as shown in FIG is. The two layers 1 and 13 then run between two guide rollers 22, where the connection with the layer 2 of cellular material coming from a roll C. This layer 2 hits from above the layer 1 so that the composite tape b downstream of the guide rollers 22 in the upper part of the Layer 2, in the middle of the layer 1 and in the lower part of the carrier layer 13 is formed. This put together Tape is rolled up to form the R roll.

In order to reduce the time for changing the rolls B ^{and C, a device is provided which enables full rolls B 1} and C to be kept in stock, which are shown in dash-dotted lines in FIG.

Preferably the layers of rolls B and C are of equal layer length so that roll R is ready when a roll B and C is completely unwound. Then layer 1 is cut off. The role R then becomes the next one Work station transported, which is shown in Fig.1, so that the composite tape b between the Plates of the press can pass through. It should be noted that the roller R is arranged such that the layer 2 consisting of the cellular, soft material is on the underside of the belt b, like this is shown in Fig.1.

Closing the press cuts off an element, such as a piece of carpet, and takes place at the same time the gluing of the carrier layer 13 to the layer 1

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made of elastomeric material.

The cut element is then transported by a conveyor belt 23, shown schematically in FIG the cut part 2 ^{1 of} the layer 2 of cellular material is lifted off. A device, not shown, is provided which inverts the element cut by the press 5 so that the top becomes the underside before the element is gripped by the conveyor belt 23, so that the part of the cellular material layer which has just been cut and was located inside the press under the layer 1, is now on the conveyor belt 23 and on the table 24 above the cut off part 1 '.

According to an advantageous feature of the invention, the
Part 2 ", which has just been removed from the layer of cellular,
soft material was cut, inserted again between the plates of the press 5 before the subsequent one
Cutting process and pressing process are carried out. As can be seen from Figure ^{1, the part 2 1 is} on
the carrier layer 13 is arranged in such a way that the arrangement compressed between the plates consists of an overlay of four layers, namely seen from top to bottom of part 2 'of the layer consisting of cellular material which has just been cut from the. Backing layer 13, made from layer 1 made of elastomeric «! Material and from the layer 2 of cellular, soft material.

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After using the cut piece of layer again 2 'of cellular material (this previously has served as a stamp), this piece is removed from the work process.

The reintroduction of the part 2 ¹ into the press 5 in the aforementioned manner enables the production of a more uniform satin-like or felt-like appearance of the visible surface of the layer 1. The piece 2 'of the layer of cellular, soft I4material thus forms a cushion through which the Load and the profiling of layer 1 are balanced. It should be pointed out that the material layer 13, especially if it is a soft felt, plays a comparable role, and that the visible surface of the layer 1 after passage through the press 5 looks essentially more uniform than if none Carrier layer 13 is used. Satisfactory tests were carried out with a press 5, the opening and closing speed of which was 9 m / min with an opening width of 300 mm, because this enables increased cycle rates.

The pieces, in particular the carpet pieces, which have been cut off one after the other by the press 5 and from which the parts 2 ^{1 have been} peeled off the cellular layer, are then subjected to a heat treatment in a pressure vessel so that the elastomeric material acquires its final appearance. This heat treatment is carried out for 10 minutes at a temperature of 160 ° C.

The pieces or shapes are preferably placed on plates of five shapes and ten plates are made at a time

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introduced into the pressure vessel. The final gluing between parts 1 'and 13' takes place during this Burn-in process.

As can be seen from FIG. 5, the inventive Piece 1 'of the layer of elastomeric material has a visible surface, its satin-like or felt-like roughened appearance gives the impression that it is a fiber material. The roughened material of the visible surface of the layer 1 'has no preferred Running direction, but has a uniform appearance in all directions of this surface.

In addition, the piece 1 'can advantageously be provided beforehand or at the same time with ribs 25 (see Fig. 5), in particular with intersecting ribs, e.g. form rectangular patterns according to the embodiment according to FIG. These ribs allow between during the pressing process the plates of the press 5 a good hold of the layer 2 of soft, cellular material on the surface 1a.

The result is an improved homogeneity of the satin-like or felt-like appearance. These ribs 25 are advantageously produced during the closing of the press 5, placing appropriate patterns on the tools 6 and 7 are located. The production of the ribs and the felt-like or satin-like appearance is therefore carried out at the same time.

As an attachment, two samples of the carpet are handed over, which is produced by means of the "method according to the invention". There is a layer on the felt-like carrier layer Made of elastomeric material, the surface of which has a satin-like or felt-like appearance. The roughened structure does not have a preferred running direction, but gives the surface a uniform appearance in all directions.

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Claims (14)

Claims 1. Method of improving the appearance of a layer made of elastomeric material, in particular made of natural rubber or synthetic rubber, the layer of a unprocessed film is produced, which is subjected to a smoothing process and then a heat treatment is, characterized in that after the smoothing process and before the heat treatment on the surface (1a) the layer (1) made of elastomeric material, the appearance of which is to be improved, a layer (2) made of soft, cellular material is applied and that then on the folded layers of soft, cellular Material and made of elastomeric material exerted a suitable compressive force and the two layers of a certain Exposed to temperature below the stoving temperature of the layer (1) made of elastomeric material, wherein the pressing force and the temperature are chosen such that the surface (1a) of the layer of elastomeric material, whose appearance is to be improved, after this treatment a satin-like one caused by the roughness of the layer Has appearance. 2. The method according to claim 1, characterized in that the layer (2) made of cellular, soft Material consists of polyether and that the layer thickness is between 5 and 15 mm. 3. The method according to claim 1 or 2, characterized in that the layer (2) of cellular, soft material made of expanded polyurethane. 509821/0799 4. The method according to claim 1 or 3, characterized in that the layer of expanded polyurethane has a density of 28 kg + 2 kg / m ³ . 5. The method according to any one of claims 1 to 4, characterized in that the expanded polyurethane has a stress index of at least 1.7. 6. The method according to any one of claims 1 to 5, characterized in that the temperature of the press plates during the processing of those made of natural rubber or synthetic rubber and the appearance of which is to be improved, elastomeric layer between 120 ° and 130 ° C and that the pressing force of the plates is chosen such that a pressure of about 60 bar is exerted on the layer. 7. The method according to any one of claims 1 to 6, wherein a Layer of elastomeric material is glued to a carrier, in particular to a felt carrier, and wherein the side glued to the felt layer is opposite the side whose appearance is to be improved, characterized in that after the smoothing process and before the heat treatment of the layer (1) of elastomeric material, the appearance of which is to be improved, a roll (R) of a composite tape (b) is produced, wherein the tape consists of several superimposed layers, namely a carrier layer (13), which is formed in particular by a layer of felt, the layer (1) made of the already smoothed, elastomeric material and the layer (2) made of the cellular Material, and wherein the layer of elastomeric material 509821/079 9 is arranged between the support layer and the layer of cellular material, and that this role is subsequently is processed in another work station by gradually feeding the composite strip into a press is that exerts a certain pressing force on the tape and the tape is heated to a certain temperature at the same time. 8. The method according to claim 7, characterized in that that pieces of the desired dimensions are cut at the same time as the machining to improve the appearance of the layer (1) made of elastomeric material, the press being designed in this way is that it can perform these two operations at the same time. 9. The method according to any one of claims 1 to 7, characterized in that'das layer piece (2 ') of cellular material, which is cut by closing the press (5), after its separation from the layer piece of elastomeric material with its carrier is reinserted into the press and arranged on the side of the carrier (13) in such a way that four layers are arranged one above the other between the plates of the press, namely the layer ^{piece (2 1} ) just cut from cellular material, the carrier layer (13), the Layer (1) made of elastomeric material and the uncut layer made of cellular material. 10. The method according to any one of claims 1 to 9, characterized in that the layer (2) of cellular Material before the heat treatment of the layer (1) of elastomeric material is separated from this. 509821/0799 11 .. The method according to any one of claims 1 to 10, characterized in that ribs (25), in particular intersecting ribs, on the surface of the layer (1) of elastomeric material, their appearance is to be improved, and that the formation of the ribs before or at the same time done with editing to improve the appearance. 12. Device for 'carrying out the method according to a of claims 1 to 11, characterized in that that a work station for producing a supply roll (R) of a tape (b) is provided, which has at least one layer (1) of elastomeric material, which is on a layer (2) of cellular, soft material is arranged, in particular on the side of the layer of elastomeric material that the Side on which the layer of cellular, soft material is arranged, is opposite, a third as Carrier layer (13) serving layer is arranged, and that a second work station is provided, 'where the The supply roll of the composite tape is gradually rolled out and introduced into a press (5) which the tape is loaded with a certain compressive force and warms up to a certain temperature and which pieces, especially pieces of carpet. 13. Industrial product, in particular carpeting or surface cladding, which has a layer of elastomeric material, one surface of which is visible, characterized in that this visible 509821/0799 visible surface the features of the visible surface of the produced by the method according to any one of claims 1 to 11 Product. 14. Industrial product, in particular carpeting or surface cladding, which has a layer of elastomeric material, which is preferably made of Felt existing carrier layer is arranged and is particularly glued to this, marked thereby net that the visible surface of the layer of elastomeric Material is roughened and gives the product a felt-like or satin-like appearance. 509821/0799