EP0392983A1 - Process for manufacture of a moulded building material - Google Patents

Process for manufacture of a moulded building material Download PDF

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Publication number
EP0392983A1
EP0392983A1 EP90810292A EP90810292A EP0392983A1 EP 0392983 A1 EP0392983 A1 EP 0392983A1 EP 90810292 A EP90810292 A EP 90810292A EP 90810292 A EP90810292 A EP 90810292A EP 0392983 A1 EP0392983 A1 EP 0392983A1
Authority
EP
European Patent Office
Prior art keywords
synthetic resin
die
resin binder
nonwoven
tower
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP90810292A
Other languages
German (de)
French (fr)
Other versions
EP0392983B1 (en
Inventor
Eusebio C/O Soc. Az. Italiana Keller Lucca
Paul Henri Gillard
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.)
Matec Holding AG
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Matec Holding AG
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Filing date
Publication date
Application filed by Matec Holding AG filed Critical Matec Holding AG
Priority to AT90810292T priority Critical patent/ATE101665T1/en
Publication of EP0392983A1 publication Critical patent/EP0392983A1/en
Application granted granted Critical
Publication of EP0392983B1 publication Critical patent/EP0392983B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • 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
    • 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
    • D04H1/58—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 by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64—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 by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • 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
    • 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
    • D04H1/4266—Natural fibres not provided for in group D04H1/425
    • 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
    • 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
    • D04H1/58—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 by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/60—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 by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S83/00—Cutting
    • Y10S83/913—Filament to staple fiber cutting
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/1062—Prior to assembly

Definitions

  • the present invention relates to a method for producing a shaped component from synthetic resin-bonded fiber material, a fine-grained or free-flowing synthetic resin binder being sprinkled or sprayed onto a nonwoven made of pure or predominantly natural fibers, and the nonwoven mixed with the synthetic resin binder being divided, after which the parts are combined in one
  • the tower is deposited on a perforated die belonging to a molding press and pre-compressed on the die by means of an air stream drawn through the perforations and to form dimensionally stable shaped components of the synthetic resin binder after the attachment and pressing on of a likewise perforated die by means of one through the perforations in the die and the Die-guided hot air flow is cured, and a device for performing this method.
  • a method of the type described is known for example from FR patent specification 76-20950 (publication No. 2,357,675). This method enables the production of components which have good cushioning properties, sound absorption and heat insulation and are therefore preferably used for the interior lining of vehicle cabins. The method also makes it possible to produce components with a predetermined outline and in this way to avoid material losses due to cutting, which experience has shown to average about 30% in the use mentioned.
  • a disadvantage of this known method is seen in the fact that the sound absorption, which is particularly important for the use described for the interior lining of vehicle cabins, cannot be optimized in practice. It is possible that the fleece parts or fibers and a fine-grained synthetic resin binder separate when deposited in the tower, so that the deposited non-woven parts or fibers contain different amounts of synthetic resin binders in some areas, which results in areas with different bonding between the non-woven parts and fibers and when the synthetic resin binder hardens resulting in different areas of elasticity and dependent sound absorption. If, in the known methods, a deposit that is practically constant in thickness over its entire surface is used to produce relief-shaped components with different thicknesses in some areas, then the deposit must be densified in different areas accordingly. This different degree of compression creates areas with different material density, which in turn leads to areas with different modulus of elasticity and therefore also different sound absorption.
  • the present invention was therefore based on the object to provide a method for producing a shaped component in which a separation of fiber parts or fibers and synthetic resin binders is practically not possible and which also enables a relief-shaped component with regions of different thickness, but practically in to produce all areas of uniform material density.
  • this object is achieved with a method of The type mentioned at the outset, which is characterized in that the synthetic resin binder is pre-hardened after sprinkling on or spraying on and before the fiber fleece is cut and the fiber non-woven bonded with the pre-hardened synthetic resin binder is divided into fiber bundles or flakes before being introduced into the tower.
  • the method according to the invention enables the large-area deposition of fiber material with a practically uniform thickness and the same distribution of the synthetic resin binder.
  • the flakes of the divided nonwoven are deposited to form a deposit with areas of different thickness.
  • This preferred embodiment of the method makes it possible to use a suitably designed die and / or patrix to produce relief-shaped components with different thicknesses and practically the same material density in all areas. Because in the case of a component made of synthetic resin-bonded fiber material, the material density influences the flow resistance for air and the coefficient of elasticity, on which the sound absorption or sound insulation depends, this embodiment of the method also enables components with different thicknesses and practically the same optimized sound absorption in all areas and insulation.
  • a preferred device for performing the fiction a fiber magazine and a loading device, which loads the fibers to form a fleece on a conveyor belt, a scattering or spraying device, which sprinkles or sprays a suitably prepared synthetic resin binder on the nonwoven, a transport device, which converts the nonwoven material with the synthetic resin binder into one Rice drum leads, the output of which is connected to the inlet opening of a tower for depositing the parts of the torn nonwoven fabric, and with a die, which is arranged for depositing the parts below or at the lower end of the tower, and with one for placing on the with the parts
  • the male die provided, the male die and the male die which have perforations, of which the perforations of the female die are provided during the placement of the parts with a vacuum source and the perforations of the male die are placed on the die for the introduction of a hot air flow and are characterized in that between the A device for sprinkling or spraying the synthetic resin binder and the rice drum is arranged a device for pre
  • FIGS. 1 and 2 A device suitable for carrying out the method according to the invention is shown schematically in FIGS. 1 and 2.
  • This device contains a magazine 10 for the fibers to be processed.
  • the magazine is assigned a loading device 11, which contains a plurality of conveyor belts, and an impeller, which deposits the fibers fed through a shaft onto the feed belt 12 of a card 13.
  • an allocation device 14 is provided with a storage container for fine-grained, thermosetting material that is suitable as a synthetic resin binder and with a transport screw for the metered feeding of this material into the area of a carding machine inlet.
  • the card 13 is enclosed in a housing 16 and a first blower 17 is provided which draws air from the area of the card spout and is connected via a pipe to a cyclone 18, the outlet of which leads to the card inlet.
  • a further conveyor belt 19 is arranged in the card outlet, which transports the fiber fleece removed from the card and interspersed with the fine-grained, thermosetting material to a continuous furnace 21.
  • the conveyor belt runs past a supply roll 20, which carries a roll of a non-woven textile composite (non-woven), which is used to cover the conveyor belt as it passes.
  • a magazine 22 with deflecting rollers which can be displaced in the vertical direction is set up adjacent to the exit of the continuous furnace.
  • a shredder 24 At the exit of the magazine are two frictionally rotating trans Port tapes 23 arranged between which the nonwoven fabric is captured and passed to the inlet of a shredder 24.
  • the shredder is arranged above a trickle tower 26, under the lower end of which a support 28 suitable for placing a die 27 is fastened.
  • the upper side of the carrier provided for fitting the die has bores which lead into a cavity which is connected to a second blower 29 via a pipeline.
  • the fiber magazine 10 is filled with textile fibers and preferably with rice wool, which was obtained by shredding textile waste from spinning mills, weaving mills, knitting mills, tailoring shops and from households.
  • the fibers are scattered by the loading device 11 from the magazine via the impeller and the sink shaft onto the feed belt 12 and from there to the card 13.
  • the outlet of the metering device 14 for the fine-grained, thermosetting material which is sprinkled into the nonwoven fabric to be formed on the card ends adjacent to the card inlet. After removal from the card, the nonwoven fabric is transferred to the further conveyor belt 19 covered with the textile composite material, which leads the nonwoven fabric to the inlet of the furnace 21.
  • the blower 17 sucks air into its suction opening from the area surrounding the card, and with it also the part of the fine-grained material that was not embedded in the nonwoven fabric or during the rotation of the card or during the transfer of the nonwoven from the card onto the transport path from the Fleece falls out.
  • the fan transports the sucked air and the fine-grained material to the cyclone 18, where the material is separated from the air and is returned to the outlet of the metering device for new use.
  • Fleece with the embedded material is heated to a medium temperature at which the thermosetting material softens and the fibers of the fleece stick to one another and to the textile composite without it polymerizing or hardening.
  • the fleece with the bonded fibers is then drawn into the magazine 22, where it cools and the fine-grained material previously softened in the oven is solidified again, and at the same time differences in the pulling speed of the fleece are compensated for.
  • the fleece together with the textile composite is reopened, for which purpose the shredder is set in such a way that it does not produce individual fibers, but rather fiber bundles or flakes consisting of a few fibers that are glued together.
  • the fiber bundles fall into the tower 26, where they sink under the effect of their own weight and the weak air flow generated by the fan 29, in order to form a homogeneous deposit on the die 27, which is caused by the air sucked through the holes in the matrix is slightly compressed.
  • the die is lifted off the support structure or swung out to the side.
  • a preforming tool 31 is preferably used, which presses the fiber bundles deposited on the projecting inner edge laterally against the edge and pre-compresses them, so that the deposit tion when fitting the male 32 can no longer be pushed down.
  • a patrix is then placed on the die, which compresses the deposit to the desired final thickness and shape.
  • the female mold, male mold and the enclosed fiber deposit are then heated in a heatable press (not shown) under suitable pressure and at a suitable temperature until the plastic material is polymerized to form a thermoset.
  • a tower 40 which has a plurality of guide surfaces (41, 42; 43, 44, 45) distributed at different heights and over the circumference, as is shown schematically in FIG. 3.
  • These guide surfaces enable the fiber bundles sinking in the tower to be directed in certain directions and in this way to produce deposits with regions of different thickness.
  • the guide surfaces for the production of simple components in large numbers are simply permanently installed and are preferably arranged movably for the production of components with a very strong relief-like shape in order to enable the direction of the surfaces to be readjusted and thus the correction of manufacturing parameters .
  • the fiber bundles do not sink freely onto the die in the entire cross section of the tower, but are introduced into a flexible tube 50 with a relatively narrow cross section, as is shown schematically in FIG. 4.
  • the outlet opening 51 of the tube is connected in motion to a guide device 52 which moves the outlet opening at different speeds leads over the surface of the die provided for depositing fiber bundles.
  • the guide device can be controlled by a mechanical control device 53, which is equipped, for example, with cam disks, or else by an electronic-numerical working device.
  • a die with bores of different diameters can simply be used. Through these holes, different amounts of air corresponding to the diameter are then sucked in, which results in the deposition of different amounts of fiber bundles.
  • textile fibers obtained from textile waste are preferably used in the shredder, to which no or no more than 50% synthetic fibers are added.
  • Proven fine-grained materials that can be used for thermosetting hardening are, for example, phenolic resins.
  • the weight ratio of fiber material to fine-grained material is approximately 2: 1.
  • the thickness of a middle deposit on the die is, for example, between 50-100 mm before the patrix is placed, which deposit results in components with thicknesses between 5 to 50 mm and an elastic modulus between 1 to 10 N / cm2 after pressing and curing the synthetic resin binder.
  • thermosetting the plastic binder depends on the thickness of the deposit and the type of synthetic resin binder used. Their correct selection lies in the area of professional skill, which is why this is not far here ter are explained.
  • the new method and the device used for its implementation enable a previously unattainable uniformity of the mixture of fiber material and plastic adhesive.
  • the use of a fine-grained and prepolymerized binder has the advantage over a liquid binder that neither the adhesive nor fibers or fiber bundles "wetted" by the adhesive get caught on the inner walls or edges of any device of the device and in particular the holes in the die with their relatively small diameter clog. It has already been mentioned that the prepolymerization of the powdery synthetic resin binder can prevent losses of binder, in particular in the tower and during thermosetting in a hot air stream.
  • the conveyor belt 19, which guides the nonwoven fabric from the card to the continuous furnace 21, is covered with a thin, non-woven, textile composite (non-woven).
  • This composite material is introduced into the continuous furnace with the nonwoven on top and glued to the nonwoven.
  • the composite is then opened together with the fleece lying on top in the shredder so that parts of the composite are also deposited on the die with the fiber bundles and finally form part of the component to be produced.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Dispersion Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Nonwoven Fabrics (AREA)
  • Reinforced Plastic Materials (AREA)
  • Transition And Organic Metals Composition Catalysts For Addition Polymerization (AREA)
  • Compositions Of Oxide Ceramics (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

The deposition of fibre material over a large area with virtually uniform thickness and with a uniform distribution of the synthetic-resin binder is achieved in that the web, to which the synthetic-resin binder has been added, before being torn apart again into tufts of fibre by a breaking drum, is guided through a device in which the synthetic-resin binder is precured. <IMAGE>

Description

Die vorliegende Erfindung betrifft ein Verfahren zum Her­stellen eines geformten Bauelements aus kunstharzgebundenem Fasermaterial, wobei auf ein Vlies aus reinen oder zum über­wiegenden Teil Naturfasern ein feinkörniger oder fliessfähi­ger Kunstharzbinder aufgestreut bzw. aufgesprüht und das mit dem Kunstharzbinder versetzte Vlies zerteilt wird, wonach die Teile in einem Turm auf eine zu einer Formpresse gehö­renden perforierten Matrize abgelagert und mittels eines durch die Perforierungen gesaugten Luftstroms auf der Matri­ze vorverdichtet werden und zur Bildung formbeständiger ge­formter Bauelemente der Kunstharzbinder nach dem Aufsetzen und Anpressen einer gleichfalls perforierten Patrize mittels eines durch die Perforierungen in der Patrize und der Matri­ze geleiteten Heissluftstroms ausgehärtet wird, sowie eine Vorrichtung zur Ausführung dieses Verfahrens.The present invention relates to a method for producing a shaped component from synthetic resin-bonded fiber material, a fine-grained or free-flowing synthetic resin binder being sprinkled or sprayed onto a nonwoven made of pure or predominantly natural fibers, and the nonwoven mixed with the synthetic resin binder being divided, after which the parts are combined in one The tower is deposited on a perforated die belonging to a molding press and pre-compressed on the die by means of an air stream drawn through the perforations and to form dimensionally stable shaped components of the synthetic resin binder after the attachment and pressing on of a likewise perforated die by means of one through the perforations in the die and the Die-guided hot air flow is cured, and a device for performing this method.

Ein Verfahren der beschriebenen Art ist beispielsweise aus der FR-Patentschrift 76-20950 (Publikation Nr. 2 357 675) bekannt. Dieses Verfahren ermöglicht die Herstellung von Bauelementen, die gute Polsterwirkung, Schallabsorption und Wärmeisolation aufweisen und darum vorzugsweise für die In­nenverkleidung von Fahrzeugkabinen verwendet werden. Das Verfahren ermöglicht auch, Bauelemente mit einem vorgegebe­nen Umriss herzustellen und auf diese Weise durch Zuschnei­den bedingte Materialverluste, die bei der genannten Verwen­dung erfahrungsgemäss im Mittel etwa 30% betragen, zu ver­meiden.A method of the type described is known for example from FR patent specification 76-20950 (publication No. 2,357,675). This method enables the production of components which have good cushioning properties, sound absorption and heat insulation and are therefore preferably used for the interior lining of vehicle cabins. The method also makes it possible to produce components with a predetermined outline and in this way to avoid material losses due to cutting, which experience has shown to average about 30% in the use mentioned.

Ein Nachteil dieses bekannten Verfahrens wird darin gesehen, dass die insbesondere für die beschriebene Verwendung zur Innenauskleidung von Fahrzeugkabinen wichtige Schallabsorp­tion praktisch nicht optimiert werden kann. Es ist möglich, dass sich die Vliesteile oder Fasern und ein feinkörniger Kunstharzbinder beim Ablagern im Turm entmischen, so dass die abgelagerten Vliesteile oder Fasern bereichsweise unter­schiedliche Mengen an Kunstharzbinder enthalten, was beim Aushärten des Kunstharzbinders zu Bereichen mit unterschied­licher Bindung zwischen den Vliesteilen und Fasern und da­durch bedingter, bereichsweise unterschiedlicher Elastizität und davon abhängiger Schallabsorption führt. Wenn aus einer Ablagerung, die bei den bekannten Verfahren notwendigerweise eine über ihrer gesamten Fläche praktisch konstante Dicke aufweist, relieftartig ausgeformte Bauelemente mit bereichs­weise unterschiedlicher Dicke hergestellt werden, dann muss die Ablagerung entsprechend bereichsweise unterschiedlich stark verdichtet werden. Diese unterschiedlich starke Ver­dichtung erzeugt Bereiche mit unterschiedlicher Material­dichte, was wieder zu Bereichen mit unterschiedlichem Ela­stizitätsmodul und darum auch unterschiedlicher Schallab­sorption führt.A disadvantage of this known method is seen in the fact that the sound absorption, which is particularly important for the use described for the interior lining of vehicle cabins, cannot be optimized in practice. It is possible that the fleece parts or fibers and a fine-grained synthetic resin binder separate when deposited in the tower, so that the deposited non-woven parts or fibers contain different amounts of synthetic resin binders in some areas, which results in areas with different bonding between the non-woven parts and fibers and when the synthetic resin binder hardens resulting in different areas of elasticity and dependent sound absorption. If, in the known methods, a deposit that is practically constant in thickness over its entire surface is used to produce relief-shaped components with different thicknesses in some areas, then the deposit must be densified in different areas accordingly. This different degree of compression creates areas with different material density, which in turn leads to areas with different modulus of elasticity and therefore also different sound absorption.

Der vorliegenden Erfindung lag darum die Aufgabe zugrunde, ein Verfahren zum Herstellen eines geformten Bauelements zu schaffen, bei dem eine Entmischung von Faserteilen oder Fa­sern und Kunstharzbinder praktisch nicht möglich ist und das auch ermöglicht, ein reliefartig geformtes Bauelement mit bereichsweise unterschiedlicher Dicke, aber praktisch in al­len Bereichen gleichmässiger Materialdichte herzustellen.The present invention was therefore based on the object to provide a method for producing a shaped component in which a separation of fiber parts or fibers and synthetic resin binders is practically not possible and which also enables a relief-shaped component with regions of different thickness, but practically in to produce all areas of uniform material density.

Erfindungsgemäss wird diese Aufgabe mit einem Verfahren der eingangs genannten Art gelöst, das dadurch gekennzeichnet ist, dass der Kunstharzbinder nach dem Aufstreuen bzw. Auf­sprühen und vor dem Zerteilen des Faservlieses vorgehärtet und das mit dem vorgehärteten Kunstharzbinder gebundene Fa­servlies vor dem Einführen in den Turm in Faserbündel oder Flocken zerteilt wird.According to the invention, this object is achieved with a method of The type mentioned at the outset, which is characterized in that the synthetic resin binder is pre-hardened after sprinkling on or spraying on and before the fiber fleece is cut and the fiber non-woven bonded with the pre-hardened synthetic resin binder is divided into fiber bundles or flakes before being introduced into the tower.

Das erfindungsgemässe Verfahren ermöglicht das grossflächige Ablegen von Fasermaterial mit praktisch gleichmässiger Dicke und ebensolcher Verteilung des Kunstharzbinders.The method according to the invention enables the large-area deposition of fiber material with a practically uniform thickness and the same distribution of the synthetic resin binder.

Bei einer bevorzugten Ausführungsform des Verfahrens werden zum Herstellen von Bauelementen mit Bereichen unterschiedli­cher Dicke und in allen Bereichen gleichmässiger Material­dichte die Flocken des zerteilten Faservlieses zu einer Ab­lagerung mit bereichsweise unterschiedlicher Dicke abgelegt.In a preferred embodiment of the method, in order to produce components with areas of different thickness and in all areas of uniform material density, the flakes of the divided nonwoven are deposited to form a deposit with areas of different thickness.

Diese bevorzugte Ausführungsform des Verfahrens ermöglicht, mit einer entsprechend ausgebildeten Matrize und/oder Patri­ze reliefartig geformte Bauelemente mit unterschiedlicher Dicke und praktisch in allen Bereichen gleicher Material­dichte herzustellen. Weil bei einem Bauelement aus kunst­harzgebundenem Fasermaterial die Materialdichte den Durch­strömwiderstand für Luft und den Elastizitätskoeffizienten beeinflusst, von denen wiederum die Schallabsorption bzw. die Schalldämmung abhängig ist, ermöglicht diese Ausfüh­rungsform des Verfahrens auch, Bauelemente mit bereichsweise unterschiedlicher Dicke und praktisch in allen Bereichen gleicher optimierter Schallabsorption und -dämmung herzu­stellen.This preferred embodiment of the method makes it possible to use a suitably designed die and / or patrix to produce relief-shaped components with different thicknesses and practically the same material density in all areas. Because in the case of a component made of synthetic resin-bonded fiber material, the material density influences the flow resistance for air and the coefficient of elasticity, on which the sound absorption or sound insulation depends, this embodiment of the method also enables components with different thicknesses and practically the same optimized sound absorption in all areas and insulation.

Eine bevorzugte Vorrichtung zur Ausführung des erfindungsge­ mässen Verfahrens enthält ein Fasermagazin und eine Ladeein­richtung, die die Fasern zur Vliesbildung auf ein Transport­band ladet, eine Streu- oder Sprüheinrichtung, die einen entsprechend aufbereiteten Kunstharzbinder auf das Vlies streut bzw. sprüht, eine Transporteinrichtung, die das mit dem Kunstharzbinder versetzte Vlies zu einer Reisstrommel führt, deren Ausgang mit der Einlassöffnung eines Turms zum Ablegen der Teile des zerrissenen Faservlieses verbunden ist, und mit einer Matrize, die zum Ablegen der Teile unter­halb oder am unteren Ende des Turms angeordnet ist, sowie mit einer zum Aufsetzen auf die mit den Teilen belegte Ma­trize vorgesehene Patrize, welche Matrize und welche Patrize Perforierungen aufweisen, wovon die Perforierungen der Ma­trize während des Ablegens der Teile mit einer Unterdruck­quelle und die Perforierungen der Patrize nach dem Aufsetzen auf die Matrize zum Einleiten eines Heissluftstroms vorgese­hen sind und ist dadurch gekennzeichnet, dass zwischen der Einrichtung zum Aufstreuen oder Aufsprühen des Kunstharzbin­ders und der Reisstrommel eine Einrichtung zum Vorhärten des Kunstharzbinders angeordnet und die Reisstrommel zum Zer­reissen des mit dem vorgehärteten Kunstharzbinders gebunde­nen Faservlieses in Faserbündel oder Flocken eingestellt ist.A preferred device for performing the fiction According to the method, a fiber magazine and a loading device, which loads the fibers to form a fleece on a conveyor belt, a scattering or spraying device, which sprinkles or sprays a suitably prepared synthetic resin binder on the nonwoven, a transport device, which converts the nonwoven material with the synthetic resin binder into one Rice drum leads, the output of which is connected to the inlet opening of a tower for depositing the parts of the torn nonwoven fabric, and with a die, which is arranged for depositing the parts below or at the lower end of the tower, and with one for placing on the with the parts The male die provided, the male die and the male die which have perforations, of which the perforations of the female die are provided during the placement of the parts with a vacuum source and the perforations of the male die are placed on the die for the introduction of a hot air flow and are characterized in that between the A device for sprinkling or spraying the synthetic resin binder and the rice drum is arranged a device for pre-curing the synthetic resin binder and the rice drum is set for tearing the nonwoven fabric bonded with the pre-hardened synthetic resin binder into fiber bundles or flakes.

Nachfolgend werden das erfindungsgemässe Verfahren und eine zu dessen Ausführung geeignete Vorrichtung mit Hilfe der Fi­guren beschrieben. Es zeigen:

  • Fig. 1 und 2 das Prinzipschema einer Vorrichtung zur Ausfüh­rung des erfindungsgemässen Verfahrens,
  • Fig. 3 die Prinzipskizze einer ersten Ausführungsform des Turms zum Ablegen von mit einem Kunstharzbinder ge­bundenen Faserflocken und
  • Fig. 4 die Prinzipskizze einer zweiten Ausführungsform die­ses Turms.
The method according to the invention and a device suitable for carrying it out are described below with the aid of the figures. Show it:
  • 1 and 2 the basic diagram of a device for performing the method according to the invention,
  • Fig. 3 shows the schematic diagram of a first embodiment of the Towers for depositing fiber flakes and bound with a synthetic resin binder
  • Fig. 4 shows the schematic diagram of a second embodiment of this tower.

Eine zur Ausführung des erfindungsgemässen Verfahrens geeig­nete Vorrichtung ist schematisch in den Fig. 1 und 2 ge­zeigt. Diese Vorrichtung enthält ein Magazin 10 für die zu verarbeitenden Fasern. Dem Magazin ist eine Ladeeinrichtung 11 zugeordnet, die mehrere Transportbänder enthält, und ein Flügelrad, das die zugeführten Fasern durch einen Schacht auf das Speiseband 12 einer Karde 13 ablegt. Weiter ist eine Zuteileinrichtung 14 vorgesehen mit einem Vorratsbehälter für feinkörniges, duroplastisch härtbares, als Kunstharzbin­der geeignetes Material und mit einer Transportschnecke zur dosierten Zuführung dieses Materials in den Bereich eines Kardeneinlaufs. Die Karde 13 ist in einem Gehäuse 16 einge­schlossen, und es ist ein erstes Gebläse 17 vorgesehen, das Luft aus dem Bereich des Kardenauslaufs absaugt und über ei­ne Rohrleitung mit einem Zyklon 18 verbunden ist, dessen Ausgang an den Kardeneinlauf führt. Im Kardenauslauf ist ein weiteres Transportband 19 angeordnet, dass das von der Karde abgenommene und mit dem feinkörnigen, duroplastisch härtba­ren Material durchsetzte Faservlies zu einem Durchlaufofen 21 transportiert. Das Transportband läuft an einer Vorrats­rolle 20 vorbei, die einen Wickel aus einem nichtgewebten textilen Verbundstoff (non-woven) trägt, mit dem das Trans­portband beim Vorbeilauf belegt wird. Dem Ausgang des Durch­laufofens benachbart ist ein Magazin 22 mit in senkrechter Richtung verschiebbaren Umlenkwalzen aufgestellt. Am Ausgang des Magazins sind zwei reibungsschlüssig umlaufende Trans­ portbänder 23 angeordnet, zwischen denen das Faservlies er­fasst und an den Einlauf eines Reisswolfs 24 weitergeleitet wird. Der Reisswolf ist über einem Rieselturm 26 angeordnet, unter dessen unterem Ende ein zum Aufsetzen einer Matrize 27 geeigneter Träger 28 befestigt ist. Die zum Aufsetzen der Matrize vorgesehene Oberseite des Trägers weist Bohrungen auf, die in einen Hohlraum führen, der über eine Rohrleitung mit einem zweiten Gebläse 29 verbunden ist.A device suitable for carrying out the method according to the invention is shown schematically in FIGS. 1 and 2. This device contains a magazine 10 for the fibers to be processed. The magazine is assigned a loading device 11, which contains a plurality of conveyor belts, and an impeller, which deposits the fibers fed through a shaft onto the feed belt 12 of a card 13. Furthermore, an allocation device 14 is provided with a storage container for fine-grained, thermosetting material that is suitable as a synthetic resin binder and with a transport screw for the metered feeding of this material into the area of a carding machine inlet. The card 13 is enclosed in a housing 16 and a first blower 17 is provided which draws air from the area of the card spout and is connected via a pipe to a cyclone 18, the outlet of which leads to the card inlet. A further conveyor belt 19 is arranged in the card outlet, which transports the fiber fleece removed from the card and interspersed with the fine-grained, thermosetting material to a continuous furnace 21. The conveyor belt runs past a supply roll 20, which carries a roll of a non-woven textile composite (non-woven), which is used to cover the conveyor belt as it passes. A magazine 22 with deflecting rollers which can be displaced in the vertical direction is set up adjacent to the exit of the continuous furnace. At the exit of the magazine are two frictionally rotating trans Port tapes 23 arranged between which the nonwoven fabric is captured and passed to the inlet of a shredder 24. The shredder is arranged above a trickle tower 26, under the lower end of which a support 28 suitable for placing a die 27 is fastened. The upper side of the carrier provided for fitting the die has bores which lead into a cavity which is connected to a second blower 29 via a pipeline.

Beim Betrieb der beschriebenen Vorrichtung wird das Faserma­gazin 10 mit textilen Fasern und vorzugsweise mit Reisswolle gefüllt, die durch Zerfasern von Textilabfällen aus Spinne­reien, Webereien, Wirkereien, Schneidereien und aus Haushal­ten gewonnen wurde. Die Fasern werden von der Ladeeinrich­tung 11 aus dem Magazin über das Flügelrad und den Sink­schacht auf das Speiseband 12 gestreut und von diesem zur Karde 13 geführt. Dem Kardeneinlauf benachbart endet der Auslass der Zuteileinrichtung 14 für das feinkörnige, duro­plastisch härtbare Material, das in das auf der Karde zu bildende Faservlies eingestreut wird. Das Faservlies wird nach der Abnahme von der Karde an das weitere mit dem texti­len Verbundstoff belegte Transportband 19 übergeben, das das Vlies zum Einlauf des Ofens 21 führt. Das Gebläse 17 saugt in seine Ansaugöffnung Luft aus der Umgebung der Karde und mit dieser auch den Teil des feinkörnigen Materials, der nicht in das Faservlies eingelagert wurde oder während der Drehung der Karde oder bei der Uebergabe des Vlieses von der Karde auf die Transportbahn aus dem Vlies herausfällt. Das Gebläse transportiert die angesaugte Luft und das feinkörni­ge Material zum Zyklon 18, wo das Material von der Luft ge­trennt und zur neueren Verwendung wieder an den Auslass der Zuteileinrichtung geführt wird. Im Durchlaufofen 21 wird das Vlies mit dem eingelagerten Material auf eine mittlere Tem­peratur erwärmt, bei der das duroplastisch härtbare Material erweicht und die Fasern des Vlieses miteinander und mit dem textilen Verbundstoff verklebt, ohne dass es polymerisiert oder aushärtet.In the operation of the device described, the fiber magazine 10 is filled with textile fibers and preferably with rice wool, which was obtained by shredding textile waste from spinning mills, weaving mills, knitting mills, tailoring shops and from households. The fibers are scattered by the loading device 11 from the magazine via the impeller and the sink shaft onto the feed belt 12 and from there to the card 13. The outlet of the metering device 14 for the fine-grained, thermosetting material which is sprinkled into the nonwoven fabric to be formed on the card ends adjacent to the card inlet. After removal from the card, the nonwoven fabric is transferred to the further conveyor belt 19 covered with the textile composite material, which leads the nonwoven fabric to the inlet of the furnace 21. The blower 17 sucks air into its suction opening from the area surrounding the card, and with it also the part of the fine-grained material that was not embedded in the nonwoven fabric or during the rotation of the card or during the transfer of the nonwoven from the card onto the transport path from the Fleece falls out. The fan transports the sucked air and the fine-grained material to the cyclone 18, where the material is separated from the air and is returned to the outlet of the metering device for new use. In the continuous furnace 21 Fleece with the embedded material is heated to a medium temperature at which the thermosetting material softens and the fibers of the fleece stick to one another and to the textile composite without it polymerizing or hardening.

Das Vlies mit den verklebten Fasern wird dann in das Magazin 22 gezogen, wobei es abkühlt und das vorgängig im Ofen er­weichte feinkörnige Material wieder verfestigt wird und in dem zugleich Unterschiede in der Durchzuggeschwindigkeit des Vlieses ausgeglichen werden. Im Reisswolf wird das Vlies mitsamt dem textilen Verbundstoff erneut geöffnet, wozu der Reisswolf derart eingestellt ist, dass keine einzelnen Fa­sern, sondern aus wenigen miteinander verklebten Fasern be­stehende Faserbündel oder Flocken entstehen. Die Faserbündel fallen in den Turm 26, wo sie unter der Wirkung des eigenen Gewichts und der vom Lüfter 29 erzeugten schwachen Luftströ­mung nach unten sinken, um auf der Matrize 27 eine homogene Ablagerung zu bilden, die von der durch die Bohrungen in der Matrix gesaugten Luft geringfügig verdichtet wird.The fleece with the bonded fibers is then drawn into the magazine 22, where it cools and the fine-grained material previously softened in the oven is solidified again, and at the same time differences in the pulling speed of the fleece are compensated for. In the shredder the fleece together with the textile composite is reopened, for which purpose the shredder is set in such a way that it does not produce individual fibers, but rather fiber bundles or flakes consisting of a few fibers that are glued together. The fiber bundles fall into the tower 26, where they sink under the effect of their own weight and the weak air flow generated by the fan 29, in order to form a homogeneous deposit on the die 27, which is caused by the air sucked through the holes in the matrix is slightly compressed.

Sobald eine ausreichend dicke Ablagerung erzeugt ist, wird die Matrize von der Trägerkonstruktion abgehoben oder seit­lich ausgeschwenkt. Bei der Herstellung von Bauelementen mit einem steil aufragenden seitlichen Bord ist es möglich, dass die auf dem entsprechenden Innenrand der Matrize abgelager­ten Faserbündel beim Einführen der Patrize nach unten zusam­mengeschoben werden und dadurch die angestrebte Verteilung der Faserbündel gestört wird. Um letzteres zu vermeiden, wird vorzugsweise ein Vorformwerkzeug 31 verwendet, das die am aufragenden Innenrand abgelagerten Faserbündel seitlich gegen den Rand drückt und vorverdichtet, so dass die Ablage­ rung beim Aufsetzen der Patrize 32 nicht mehr nach unten zu­sammengeschoben werden kann. Auf die Matrize wird sodann ei­ne Patrize aufgesetzt, die die Ablagerung auf die gewünschte Enddicke und mit der gewünschten Form verdichtet. Matrize, Patrize und die eingeschlossene Faserablagerung werden dann in einer (nicht gezeigten) heizbaren Presse unter geeignetem Druck und bei geeigneter Temperatur erwärmt, bis das Kunst­stoffmaterial zu einem Duroplast polymerisiert ist.As soon as a sufficiently thick deposit is created, the die is lifted off the support structure or swung out to the side. In the production of components with a steeply projecting lateral rim, it is possible for the fiber bundles deposited on the corresponding inner edge of the die to be pushed together when the patrix is inserted, thereby disrupting the desired distribution of the fiber bundles. In order to avoid the latter, a preforming tool 31 is preferably used, which presses the fiber bundles deposited on the projecting inner edge laterally against the edge and pre-compresses them, so that the deposit tion when fitting the male 32 can no longer be pushed down. A patrix is then placed on the die, which compresses the deposit to the desired final thickness and shape. The female mold, male mold and the enclosed fiber deposit are then heated in a heatable press (not shown) under suitable pressure and at a suitable temperature until the plastic material is polymerized to form a thermoset.

Bei einer bevorzugten Ausführungsform des Verfahrens wird ein Turm 40 verwendet, der eine Mehrzahl in unterschiedli­cher Höhe und über dem Umfang verteilter Leitflächen (41, 42; 43, 44, 45) aufweist, wie es schematisch in Fig. 3 ge­zeigt ist. Diese Leitflächen ermöglichen, die im Turm absin­kenden Faserbündel in bestimmte Richtungen zu lenken und auf diese Weise Ablagerungen mit bereichsweise unterschiedlicher Dicke zu erzeugen. Dabei versteht sich, dass die Leitflächen für die Herstellung von einfachen Bauelementen in grossen Stückzahlen einfacherweise fest eingebaut und für die Her­stellung von Bauelementen mit sehr starker reliefartiger Ausformung vorzugsweise beweglich angeordnet sind, um das Nachstellen der Richtung der Flächen zu ermöglichen und da­mit das Korrigieren von Fabrikationsparametern.In a preferred embodiment of the method, a tower 40 is used which has a plurality of guide surfaces (41, 42; 43, 44, 45) distributed at different heights and over the circumference, as is shown schematically in FIG. 3. These guide surfaces enable the fiber bundles sinking in the tower to be directed in certain directions and in this way to produce deposits with regions of different thickness. It goes without saying that the guide surfaces for the production of simple components in large numbers are simply permanently installed and are preferably arranged movably for the production of components with a very strong relief-like shape in order to enable the direction of the surfaces to be readjusted and thus the correction of manufacturing parameters .

Bei einer weiteren Ausführungsform des Verfahrens sinken die Faserbündel nicht frei im gesamten Querschnitt des Turms auf die Matrize ab, sondern werden in ein flexibles Rohr 50 mit relativ engem Querschnitt eingeleitet, wie es schematisch in Fig. 4 gezeigt ist. Zum Erzeugen von Ablagerungen mit unter­schiedlicher Schichtdicke ist die Auslassöffnung 51 des Rohrs mit einer Führungseinrichtung 52 bewegungsverbunden, die die Auslassöffnung mit unterschiedlicher Geschwindigkeit über die zum Ablagern von Faserbündeln vorgesehene Fläche der Matrize führt. Die Führungseinrichtung kann dazu von ei­ner mechanischen und beispielsweise mit Nockenscheiben aus­gerüsteten oder auch von einer elektronisch-numerisch arbei­tenden Steuereinrichtung 53 gesteuert werden.In a further embodiment of the method, the fiber bundles do not sink freely onto the die in the entire cross section of the tower, but are introduced into a flexible tube 50 with a relatively narrow cross section, as is shown schematically in FIG. 4. To produce deposits with different layer thicknesses, the outlet opening 51 of the tube is connected in motion to a guide device 52 which moves the outlet opening at different speeds leads over the surface of the die provided for depositing fiber bundles. For this purpose, the guide device can be controlled by a mechanical control device 53, which is equipped, for example, with cam disks, or else by an electronic-numerical working device.

Um mit einem Turm der beschriebenen Art Ablagerungen mit un­terschiedlicher Dicke zu erzeugen, kann einfacherweise eine Matrize mit Bohrungen unterschiedlichen Durchmessers verwen­det werden. Durch diese Bohrungen werden dann dem Durchmes­ser entsprechende unterschiedliche Luftmengen eingesaugt, was die Ablagerung unterschiedlicher Mengen an Faserbündeln zur Folge hat.In order to produce deposits of different thicknesses with a tower of the type described, a die with bores of different diameters can simply be used. Through these holes, different amounts of air corresponding to the diameter are then sucked in, which results in the deposition of different amounts of fiber bundles.

Zur Herstellung von Bauelementen für die Innenverkleidung von Automobilen werden vorzugsweise im Reisswolf aus texti­len Abfällen gewonnene textile Fasern verwendet, denen keine oder nicht mehr als 50% synthetische Fasern zugesetzt sind. Bewährte feinkörnige und zum duroplastischen Härten brauch­bare Materialien sind beispielsweise phenolhaltige Harze. Das Gewichtsverhältnis von Faserwerkstoff zu feinkörnigem Material beträgt etwa 2:1. Die Dicke einer mittleren Ablage­rung auf der Matrize beträgt vor dem Aufsetzen der Patrize beispielsweise zwischen 50-100 mm, welche Ablagerung nach dem Pressen und Aushärten des Kunstharzbinders Bauelemente mit Dicken zwischen 5 bis 50 mm und einem Elastizitätsmodul zwischen 1 bis 10 N/cm² ergibt.For the production of components for the interior lining of automobiles, textile fibers obtained from textile waste are preferably used in the shredder, to which no or no more than 50% synthetic fibers are added. Proven fine-grained materials that can be used for thermosetting hardening are, for example, phenolic resins. The weight ratio of fiber material to fine-grained material is approximately 2: 1. The thickness of a middle deposit on the die is, for example, between 50-100 mm before the patrix is placed, which deposit results in components with thicknesses between 5 to 50 mm and an elastic modulus between 1 to 10 N / cm² after pressing and curing the synthetic resin binder.

Der Pressdruck sowie die zum duroplastischen Aushärten des Kunststoffbinders erforderliche Temperatur und Zeit sind von der Dicke der Ablagerung und der Art des verwendeten Kunst­harzbinders abhängig. Deren richtige Auswahl liegt im Be­reich fachmännischen Könnens, weshalb diese hier nicht weit­ ter erläutert werden.The pressing pressure and the temperature and time required for thermosetting the plastic binder depend on the thickness of the deposit and the type of synthetic resin binder used. Their correct selection lies in the area of professional skill, which is why this is not far here ter are explained.

Das neue Verfahren und die zu dessen Ausführung verwendete Vorrichtung ermöglichen eine bisher nicht erreichbare Gleichmässigkeit der Mischung von Fasermaterial und Kunst­stoffkleber. Die Verwendung eines feinkörnigen und vorpoly­merisierten Binders hat gegenüber einem flüssigen Bindemit­tel den Vorteil, dass weder der Kleber noch vom Kleber "be­netzte" Fasern oder Faserbündel an den Innenwänden oder Rän­dern irgendeiner Einrichtung der Vorrichtung hängenbleiben und insbesondere die Bohrungen in der Matrize mit ihrem re­lativ kleinen Durchmesser verstopfen. Es wurde bereits er­wähnt, dass durch das Vorpolymerisieren des pulverförmigen Kunstharzbinders Verluste an Bindemittel insbesondere im Turm und beim duroplastischen Härten in einem Heissluftstrom vermieden werden können.The new method and the device used for its implementation enable a previously unattainable uniformity of the mixture of fiber material and plastic adhesive. The use of a fine-grained and prepolymerized binder has the advantage over a liquid binder that neither the adhesive nor fibers or fiber bundles "wetted" by the adhesive get caught on the inner walls or edges of any device of the device and in particular the holes in the die with their relatively small diameter clog. It has already been mentioned that the prepolymerization of the powdery synthetic resin binder can prevent losses of binder, in particular in the tower and during thermosetting in a hot air stream.

Bei noch einer weiteren Ausführungsform des beschriebenen Verfahrens wird das Transportband 19, das das Faservlies von der Karde zum Durchlaufofen 21 führt, mit einem dünnen, nichtgewebten, textilen Verbundstoff (non-woven) belegt. Dieser Verbundstoff wird mit dem aufliegenden Vlies in den Durchlaufofen eingeführt und dabei mit dem Vlies verklebt. Der Verbundstoff wird dann mitsamt dem aufliegenden Vlies im Reisswolf geöffnet, so dass mit den Fasernbündeln auch Teile des Verbundstoffs auf der Matrize abgelagert werden und schliesslich einen Teil des herzustellenden Bauelements bil­den.In yet another embodiment of the method described, the conveyor belt 19, which guides the nonwoven fabric from the card to the continuous furnace 21, is covered with a thin, non-woven, textile composite (non-woven). This composite material is introduced into the continuous furnace with the nonwoven on top and glued to the nonwoven. The composite is then opened together with the fleece lying on top in the shredder so that parts of the composite are also deposited on the die with the fiber bundles and finally form part of the component to be produced.

Claims (13)

1. Verfahren zum Herstellen eines geformten Bauelements aus kunstharzgebundenem Fasermaterial, wobei auf ein Vlies aus reinen oder zum überwiegenden Teil Naturfasern ein feinkörniger oder fliessfähiger Kunstharzbinder aufge­streut bzw. aufgesprüht und das mit dem Kunstharzbinder versetzte Vlies zerteilt wird, wonach die Teile in einem Turm auf eine zu einer Formpresse gehörenden perforierten Matrize abgelagert und mittels eines durch die Perforie­rungen gesaugten Luftstroms auf der Matrize vorverdichtet werden und zur Bildung formbeständiger geformter Bauele­mente der Kunstharzbinder nach dem Aufsetzen und Anpres­sen einer gleichfalls perforierten Patrize mittels eines durch die Perforierungen in der Patrize und der Matrize geleiteten Heissluftstroms ausgehärtet wird,
dadurch gekennzeichnet, dass der Kunstharzbinder nach dem Aufstreuen bzw. Aufsprühen und vor dem Zerteilen des Fa­servlieses vorgehärtet
und das mit dem vorgehärteten Kunstharzbinder gebundene Faservlies vor dem Einführen in den Turm in Faserbündel oder Flocken zerteilt wird.1. A method for producing a shaped component made of synthetic resin-bonded fiber material, a fine-grained or free-flowing synthetic resin binder being sprinkled or sprayed onto a nonwoven made of pure or predominantly natural fibers and the nonwoven mixed with the synthetic resin binder being divided, after which the parts are placed in a tower on a Perforated die belonging to a molding press is deposited and pre-compressed on the die by means of an air stream sucked through the perforations, and to form dimensionally stable shaped components of the synthetic resin binder after the attachment and pressing on of a likewise perforated die by means of a hot air stream guided through the perforations in the die and the die is cured,
characterized in that the synthetic resin binder is pre-hardened after sprinkling on or spraying on and before dividing the nonwoven fabric
and the nonwoven bonded with the pre-hardened synthetic resin binder is divided into fiber bundles or flakes before being introduced into the tower. 2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass das Faservlies vor dem Aufstreuen oder Aufsprühen des Kunstharzbinders auf einen aus einem nichtgewebten texti­len Verbundstoff gebildeten bahnförmigen Träger aufge­bracht wird,
welcher Träger beim Vorhärten des Kunstharzbinders mit dem Vlies verbunden und mit diesem in Flocken zerteilt und auf der Matrize abgelegt wird, um einen integralen Teil des Bauelements zu bilden.2. The method according to claim 1, characterized in that the nonwoven fabric is applied to a web-shaped carrier formed from a nonwoven textile composite before the sprinkling or spraying on of the synthetic resin binder,
which carrier is connected to the fleece during pre-hardening of the synthetic resin binder and divided into flakes with it and placed on the die to form an integral part of the device. 3. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass zum Herstellen von Bauelementen mit Bereichen unter­schiedlicher Dicke und in allen Bereichen gleichmässiger Materialdichte die Flocken des zerteilten Faservlieses mit bereichsweise unterschiedlicher Dicke auf der Matrize abgelegt werden.3. The method according to claim 1, characterized in that for the production of components with areas of different thickness and in all areas of uniform material density, the flakes of the divided nonwoven fabric are deposited with different thicknesses on the matrix. 4. Verfahren nach Anspruch 3, dadurch gekennzeichnet, dass zum Herstellen von Bauelementen mit optimaler Schallab­sorption und -dämmung die unterschiedliche Dicke der Ab­legebereiche entsprechend dem angestrebten Durchströmwi­derstand für Luft und Elastizitätsmodul gesteuert wird.4. The method according to claim 3, characterized in that for the production of components with optimal sound absorption and insulation, the different thickness of the storage areas is controlled according to the desired flow resistance for air and elastic modulus. 5. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass bei der Verwendung einer Matrize mit stark geneigter Um­randung auf dieser Umrandung abgelagerte Flocken an die Umrandung angedrückt werden, bevor die Patrize aufgesetzt wird.5. The method according to claim 1, characterized in that when using a die with a strongly inclined border, flakes deposited on this border are pressed against the border before the male is put on. 6. Vorrichtung zum Ausführung des Verfahrens nach Anspruch 1 mit einem Fasermagazin (10) und einer Ladeeinrichtung (11), die die Fasern zur Vliesbildung auf ein Transport­band (12) ladet, einer Streu- oder Sprüheinrichtung (14), die einen entsprechend aufbereiteten Kunstharzbinder auf das Vlies streut bzw. sprüht, eine Transporteinrichtung (19), die das mit dem Kunstharzbinder versetzte Vlies zu einer Reisstrommel (24) führt, deren Ausgang mit der Ein­lassöffnung eines Turms (26) zum Ablegen der Teile des zerrissenen Faservlieses verbunden ist, und mit einer Ma­ trize (27), die zum Ablegen der Teile unterhalb oder am unteren Ende des Turms angeordnet ist, sowie mit einer zum Aufsetzen auf die mit den Teilen belegte Matrize vor­gesehene Patrize (32), welche Matrize und welche Patrize Perforierungen aufweisen, wovon die Perforierungen der Matrize während des Ablegens der Teile mit einer Unter­druckquelle (29) und die Perforierungen der Patrize nach dem Aufsetzen auf die Matrize zum Einleiten eines Heiss­luftstroms vorgesehen sind,
dadurch gekennzeichnet, dass zwischen der Einrichtung (14) zum Aufstreuen oder Aufsprühen des Kunstharzbinders und der Reisstrommel (24) eine Einrichtung (21, 22) zum Vorhärten des Kunstharzbinders angeordnet und die Reiss­trommel (24) zum Zerreissen des mit dem vorgehärteten Kunstharzbinders gebundenen Faservlieses in Faserbündel oder Flocken eingestellt ist.6. Apparatus for carrying out the method according to claim 1 with a fiber magazine (10) and a loading device (11) which loads the fibers for nonwoven formation on a conveyor belt (12), a scattering or spraying device (14) which has a correspondingly prepared synthetic resin binder sprinkles or sprays onto the nonwoven, a transport device (19) which leads the nonwoven with the synthetic resin binder to a rice drum (24), the outlet of which is connected to the inlet opening of a tower (26) for depositing the parts of the torn nonwoven, and with a ma trize (27), which is arranged for depositing the parts below or at the lower end of the tower, and with a patrix (32) provided for placement on the die with the parts, which die and which patrix have perforations, of which the perforations of the The die is provided during the placement of the parts with a vacuum source (29) and the perforations of the die are placed on the die to initiate a hot air flow,
characterized in that between the device (14) for sprinkling or spraying the synthetic resin binder and the rice drum (24) a device (21, 22) for pre-curing the synthetic resin binder is arranged and the rice drum (24) for tearing the non-woven fabric bound with the pre-hardened synthetic resin binder in Fiber bundles or flakes is set. 7. Vorrichtung nach Anspruch 6, dadurch gekennzeichnet, dass zum Ablegen der den vorgehärteten Kunstharzbinder enthal­tenden Flocken in Bereichen mit unterschiedlicher Dicke im Turm (40) entsprechend angeordnete Leitflächen (41, 42, 43, 44, 45) vorgesehen sind.7. The device according to claim 6, characterized in that for depositing the flakes containing the pre-hardened synthetic resin binder in areas with different thicknesses in the tower (40) correspondingly arranged guide surfaces (41, 42, 43, 44, 45) are provided. 8. Vorrichtung nach Anspruch 6, dadurch gekennzeichnet, dass zum Ablegen der den vorgehärteten Kunstharzbinder enthal­tenden Flocken in Bereichen mit unterschiedlicher Dicke im Turm (40) bewegbare Leitflächen (43, 44, 45) angeord­net sind.8. The device according to claim 6, characterized in that for depositing the flakes containing the pre-hardened synthetic resin binder in regions with different thickness in the tower (40) movable guide surfaces (43, 44, 45) are arranged. 9. Vorrichtung nach Anspruch 6, dadurch gekennzeichnet, dass zum Ablegen der den vorgehärteten Kunstharzbinder enthal­tenden Flocken in Bereichen mit unterschiedlicher Dicke der Turm als Führungsrohr (50) ausgebildet ist, dessen Auslassöffnung (51) über der Matrize seitlich verschwenkbar ist.9. The device according to claim 6, characterized in that for depositing the flakes containing the pre-hardened synthetic resin binder in areas of different thickness the tower is designed as a guide tube (50), the outlet opening (51) of which can be pivoted laterally above the die. 10. Vorrichtung nach Anspruch 8 oder 9, dadurch gekennzeich­net, dass die Bewegung der Leitflächen (43, 44, 45) bzw. die Verschiebung der Auslassöffnung (51) des Führungs­rohrs (50) programmgesteuert ist.10. The device according to claim 8 or 9, characterized in that the movement of the guide surfaces (43, 44, 45) or the displacement of the outlet opening (51) of the guide tube (50) is program-controlled. 11. Vorrichtung nach Anspruch 6, dadurch gekennzeichnet, dass zum Ablegen der den vorgehärteten Kunstharzbinder enthaltenden Flocken in Bereichen mit unterschiedlicher Dicke der Saugluftstrom durch die Perforierungen der Ma­trize (27) bereichsweise auf unterschiedliche Werte ein­stellbar ist.11. The device according to claim 6, characterized in that for depositing the flakes containing the pre-hardened synthetic resin binder in areas with different thicknesses, the suction air flow through the perforations of the die (27) can be adjusted to different values in certain areas. 12. Vorrichtung nach Anspruch 11, dadurch gekennzeichnet, dass zum Einstellen unterschiedlicher Werte des Saug­luftstroms durch die Perforierungen der Matrize (27) diese Perforierungen unterschiedlich grosse Querschnitte aufweisen.,12. The device according to claim 11, characterized in that for setting different values of the suction air flow through the perforations of the die (27), these perforations have cross sections of different sizes. 13. Vorrichtung nach Anspruch 6, dadurch gekennzeichnet, dass der Transporteinrichtung (19) benachbart eine Vor­ratsrolle (20) mit einem zum Belegen der Transportein­richtung vorgesehenen, nicht gewebten textilen Verbund­stoff angeordnet ist.13. The apparatus according to claim 6, characterized in that the transport device (19) adjacent to a supply roll (20) is arranged with a non-woven textile composite provided for covering the transport device.
EP90810292A 1989-04-14 1990-04-11 Process for manufacture of a moulded building material Expired - Lifetime EP0392983B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AT90810292T ATE101665T1 (en) 1989-04-14 1990-04-11 METHOD OF MAKING A MOLDED COMPONENT.

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CH1425/89 1989-04-14
CH1425/89A CH681990A5 (en) 1989-04-14 1989-04-14

Publications (2)

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EP0392983A1 true EP0392983A1 (en) 1990-10-17
EP0392983B1 EP0392983B1 (en) 1994-02-16

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ID=4210163

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EP90810292A Expired - Lifetime EP0392983B1 (en) 1989-04-14 1990-04-11 Process for manufacture of a moulded building material

Country Status (7)

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US (1) US5160406A (en)
EP (1) EP0392983B1 (en)
JP (1) JPH0347712A (en)
AT (1) ATE101665T1 (en)
CH (1) CH681990A5 (en)
DE (1) DE59004576D1 (en)
ES (1) ES2049453T3 (en)

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JPH0667010U (en) * 1993-03-10 1994-09-20 日本特殊塗料株式会社 Resin recovery device
WO2005039415A1 (en) 2003-10-23 2005-05-06 Delta Tooling Co., Ltd. Fatigue degree measuring device, fatigue detection device, and computer program
CN102776717B (en) * 2012-07-11 2014-05-14 常熟市飞龙无纺机械有限公司 Automotive upholstery pre-shaping machine adopting air filling method
CN102776719B (en) * 2012-07-11 2014-04-16 常熟市飞龙无纺机械有限公司 Preforming box structure for automotive interior preforming machine through air filling method
CN102776718B (en) * 2012-07-11 2014-05-07 常熟市飞龙无纺机械有限公司 Automotive upholstery pre-shaping machine

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Also Published As

Publication number Publication date
US5160406A (en) 1992-11-03
DE59004576D1 (en) 1994-03-24
ES2049453T3 (en) 1994-04-16
CH681990A5 (en) 1993-06-30
ATE101665T1 (en) 1994-03-15
JPH0347712A (en) 1991-02-28
EP0392983B1 (en) 1994-02-16

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