EP0696962A1

EP0696962A1 - Molded composite body, particularly interior trim for motor vehicles, as well as process and device for its manufacture

Info

Publication number: EP0696962A1
Application number: EP94916167A
Authority: EP
Inventors: Dieter W. Hess; Klaus Stricker; Rolf Maysenhölder
Original assignee: Individual
Current assignee: Individual
Priority date: 1993-04-28
Filing date: 1994-04-28
Publication date: 1996-02-21
Also published as: WO1994025265A1; US5670235A; ES2117734T3; EP0622176A1; DE4313911A1; DE59406349D1; EP0622176B1

Abstract

The invention pertains to a molded composite body, particularly an interior trim for motor vehicles. The composite body (1) has an essentially rigid base foil (2) made of thermoplastic material. This foil is coated on at least one side, preferably both sides, with a surface coating (3, 4) in the form of nonwoven fabric. The nonwoven fabric and the plastic foil are bonded using thermally-activated adhesives. To form the bond the nonwoven fabric consists at least in part, preferably entirely, of the same kind of plastic as the foil. The invention also pertains to a process and device for manufacturing the composite body. To effect the adhesive bond the foil is heated on at least one side to a temperature in the adhesion range of the thermoplastic plastic, the interior of the foil being kept at a low temperature. This method preserves the structure of the nonwoven fabric during the bonding and molding. The invention provides a simple means of manufacturing homogeneous composite bodies such that they can be readily recycled as whole units, as can the wasters generated in their manufacture.

Description

description

Shaped laminate. in particular

Interior lining part for motor vehicles, as well

Method and device for its production

The invention relates to a shaped laminated body, in particular an interior lining part for motor vehicles, with a carrier layer made of a rigid film made of a thermoplastic and at least one surface covering made of a flat textile structure, and a method and a device for its production.

Interior lining parts for motor vehicles often consist of a laminate which is shaped according to the walls of the interior and has a textile covering, in particular in the form of a needle felt, on its side facing the interior. In order to produce such inner lining parts, thermoplastic materials, in particular polypropylene, are extruded into films, with the hot film the textile covering is immediately laminated on, the fibers of the needle punch being pressed into the still soft mass of the film and embedded therein. It is customary here that the needle fleece serving as the surface covering consists of a material which does not melt at the extrusion temperature, which in the case of polypropylene is approximately 240 ° C., since this would otherwise result in the destruction of the structure of the needle fleece .

Attempts have also already been made to laminate needlepunched nonwovens made of polypropylene onto extruded polypropylene foils, as a result of which a welded connection between the foil and the nonwoven is obtained, which, however, leads to a major structural change in the nonwoven because the fibers melt strongly and lose strength.

The invention has for its object to improve a shaped laminate and its production, in particular to enable an environmentally friendly structure of a high quality laminate and to expand the design options in its manufacture.

The invention is characterized in that fibers of at least one surface covering consist at least partially of an essentially identical thermoplastic material as the film and the surface covering is connected to the film by thermal bonding of these fibers.

In contrast to the mere embedding of fibers made of infusible material or thermoplastic materials, the softening range of which lies above the extrus temperature of the film, the invention provides for the connection between the textile surface covering and the film to be formed as an adhesive bond in the fiber material of the textile surface covering with the thermoplastic plastic - 3 -

Film is adhesively bonded across common interfaces. This provides a good bond without the need for any additional adhesives.

While the phase boundaries between the film material and covering material dissolve and the fibers of the textile covering in the area of the covering close to the film melt during melting in the above-mentioned welded joint, the phase boundaries between the film material and fiber material are largely retained in the adhesive bonding according to the invention. The fibers are deformed in the area close to the film and sintered together. The fiber structure is compressed in the sintered area, a fiber composite being formed which is glued to the film surface, possibly with the formation of indentations or depressions in the film surface. The fiber cross section and the interfaces of the fibers are largely preserved even in the area close to the film. Immediately next to it, the structure of the textile covering is unchanged, i.e. remained in the original form.

The thickness of the compressed or sintered area of the fibers corresponds to approximately 1 to 10 times, in particular approximately 1 to 5 times, the fiber thickness. There are free surface areas of the film between the individual bonding points.

Thermoplastic plastics of the same type are understood to mean those plastics which are the same or essentially the same as the plastics of the film or different, but in which the softening and tackiness range is at approximately the same temperature level, so that it is thermal can be glued together and can form a common melt during recycling. The textile surface covering is, in a manner known per se, preferably a nonwoven fabric, in particular a nonwoven, preference being given to nonwovens which are free of a textile backing are. The layered body is generally a three-dimensionally shaped layered body which has obtained its three-dimensional structure from the original plane of the film by reshaping it. The laminate is preferably a trunk interior lining. The surface covering is expediently designed as a surface decor. According to a preferred embodiment of the invention, the laminate has surface coverings on both sides, ie two, one of which can serve as a decorative layer and one as a backing coating. A surface covering can be designed as a back coating, which is used for sound absorption. The second surface covering or the back coating is preferably likewise formed from a non-woven fabric, in particular a needle-punched nonwoven.

The thermoplastic material of the film is known per se, preferably a polyolefin, in particular polypropylene. Polypropylene has satisfactory mechanical properties and is suitable for recycling. Preferably, at least one surface covering, in particular the decorative layer, consists entirely of essentially the same material as the film, in particular polypropylene. According to the invention, it is preferred to construct the laminate according to type or at least to assemble it from materials which can be recycled together. A carrier film made of polypropylene and at least one surface covering made of polypropylene fibers represent such a single-variety structure.

If desired, it is also possible for at least one surface covering, in particular a backing layer, to consist in part, in particular in large part, of fibers which cannot be bonded to the material of the film, the covering forming a portion of the adhesive connection Has fibers which are suitable for fusing with the thermoplastic plastic of the film. Such a supervisor - 5 -

The surface covering can be, for example, a needle punch that is made from waste from the textile industry, in particular using cotton and / or acrylic fibers. A minimum proportion of fibers made of a plastic is provided in the fiber fleece, which can be thermally bonded to the material of the film, the bond between the fiber fleece and the film being obtained by gluing these fibers to the film. The content of fibers from a material that can be thermally bonded to the material of the film is generally at least 10% by weight, preferably approximately 20% by weight or more. The proportion of these fibers is preferably evenly distributed in the nonwoven fabric. It is also possible to use the share of. the fibers that can be glued to the film are enriched on the side of the nonwoven fabric facing the film. In such cases, parts by weight of fibers made of the material that can be glued to the film in the range of approximately 5% are sufficient.

In particular when the laminated bodies are designed as a trunk interior lining, their production is associated with a high proportion of waste which is caused by the respective cut. The proportion of waste can be of the order of 50 -. According to the invention, it is envisaged to recycle this waste already during the production of the laminate. It is therefore particularly preferred that the layered body is constructed unmixed or at least consists of such materials which may form a common melt ver ^*, as it is particularly easy to shred the waste and return it to the extruder to prepare the film. Surprisingly, it has been found that a limited proportion of foreign fibers, which are not in the molten state at the melting temperature of the film material, do not interfere. With a corresponding fine comminution of this fiber portion while shredding the waste, this fiber portion can be processed in the extruder and acts as a fiber reinforcement for the Foil. Larger amounts of foreign fibers are preferably removed from the film before recycling.

In a preferred embodiment of the invention, at least one side of the film is covered over the entire surface with an open-pore layer made of a thin web material which is shaped corresponding to the film and the at least one surface covering. The pores of the web material are preferably so wide and the layer thickness of the web material is so thin that the adhesive connection between the film and the surface covering penetrates the pores. It is thereby achieved that the web material, the importance of which will be discussed later, does not impair the bond between the surface covering and the film if the layer of the web material is between the surface covering and the film. The web material is preferably in the form of a very thin non-woven fabric in the form of a fiber fabric, in which the fibers lie in the plane of the web material. The web material is preferably a spunbond. The layer weight of the web material is very low. It is generally between 10 and 50 g / m ^{2, in} particular approximately 30 g / m ² . According to one embodiment of the invention, the web material is formed by a lost carrier web which remains in the laminate.

In a preferred embodiment of the invention, the carrier film is provided with perforations at least in some areas. These perforations are preferably used for sound absorption and can also be provided for ventilation purposes. At least one surface covering, in particular a visible decorative layer, is advantageously free of perforations, ie it covers the perforations of the film so that they are not visible from the outside. If surface coverings are provided on both sides of the film, then both surface coverings are preferably free of such perforations. At least some of the perforations can be deformed depending on the deformation of the film his. This is the case when the surface areas in which the perforations are located are provided at locations which have been stretched during the shaping of the film, in particular by a deep-drawing process which will be described later. The perforated surface areas are advantageously limited to those locations on the laminate which are used to cover low-noise areas of a motor vehicle. In this way it is achieved that the sound to be destroyed penetrates through the perforations into the low-noise rooms behind it and is thereby absorbed. The perforations can have a cross-sectional area of 0.5-5 mm ² . The perforation percentage of the perforations, based on the area of the perforated areas, can be of the order of 0.3-8%, in particular 1-6 k. The individual per orations can have any shape, but are preferably circular. Their inside diameter can be in the range of 1-3 mm, preferably about 1.5 mm. The hole spacing of the perforations can be adapted to the acoustic conditions and is generally in the range between 0.5 and 3 cm, in particular between 0.7 and 1.5 cm (hole center to hole center).

As already mentioned above, the surface covering provided as a back coating can advantageously be designed as sound absorption or insulation. For this reason, the back coating advantageously has a greater material thickness than the decorative layer. The back coating is generally formed over the entire surface. In places where special sound absorption is important, it can be reinforced by separate requirements. This is advantageously the case where larger openings are provided in the exterior of the bodywork, which serve to forcefully vent the interior of a motor vehicle through the trunk area. The invention also relates to a method for producing a shaped laminate with a carrier layer made of a substantially rigid film made of a thermoplastic and at least one textile surface covering by joining and molding at elevated temperature. This method is characterized in that a film made of thermoplastic material, which has a temperature in the melting range on at least one surface and a lower temperature in the range of plastic deformability on the inside, is bonded to at least one textile surface covering by thermal bonding, the temperature level inside is used to deform the film.

It has been found that an adhesive bond that is particularly gentle and compatible with the material for the textile surface covering is obtained if not the entire film but only its surface areas to be bonded to the textile surface covering lie at a suitable teroperative level, whereas the film core and possibly a surface that is not to be coated is preferably at a lower temperature level. In this way, overheating of the surface covering and thus undesired damage to the covering can be avoided. At the same time, it is achieved that there is no undesired reheating from the inside and the cooling time of the laminate in the shaping device is relatively short. In addition, the film is still relatively stable due to the lower temperature level in the film core, so that unwanted deformations can be prevented by technically simple means before the actual molding process.

The interior of the film or the film core is preferably at a teraperature level during the bonding of the surface to the surface covering, which corresponds to the forming temperature of the thermoplastic material. In particular in the case of thermoplastics with a crystalline fraction, the ambient temperature is at the transition from the crystalline to the amorphous region.

The temperature gradation can be achieved in that at least one surface of a solid film, in particular film web made of a thermoplastic, is brought to a surface temperature in the stickiness range of the thermoplastic by surface heating in such a way that the temperature inside the film is sufficient for the plastic deformation of the Foil does not exceed the required temperature. The surface heating is advantageously carried out by the infrared radiation. If only one side of the film is to be connected to the surface covering, then there is only one-sided heating. This one-sided heating can preferably be combined with simultaneous cooling of the other side, cooling with cold gases, in particular cold air, being preferred. The thermoplastic plastic of the film can contain conventional fillers.

According to the invention, it is also possible to subsequently connect a film which has already been provided with a surface layer on the other side to a second surface layer by heating the side of the coated film provided for the adhesive connection and preferably cooling the coated side at the same time.

The surface coverings to be joined are particularly advantageously at room temperature, ie they are applied to the film to be coated without prior heating. This is particularly advantageous if the surface layer consists entirely of the same material as the film. The structure of this surface layer is retained by the cold supply of the surface layer, for example in the form of a needle fleece. The connection between the at least one surface covering and the film can be made before, during or after the shaping of the film and is expediently carried out at the latest during the shaping of the laminate. An at least partial or complete implementation of the adhesive bond is preferred, as long as the individual layers of the laminated body have not yet been subjected to the shaping. The connection is preferably carried out after the heating of the film, in that the individual layers are brought together under moderate pressure, for example carried out together by a pair of rollers or by clamping beams. Carrying out the adhesive connection separately from the actual molding process also permits control of the contact pressure, which is separate from the molding process, and direct utilization of the temperature level of the surface layer of the heated film for the adhesive bond, so that precautionary heating to a higher temperature than necessary can be avoided.

The actual shaping into the three-dimensional body is advantageously carried out in a manner known per se using a drawing press with a die and a patrix, the entire shaping process being carried out in one step. The shapes of the press are expediently tempered to a temperature below the solidification range of the thermoplastic plastic of the film. The shaped laminated body is held between the molds until the plastic of the film solidifies to such an extent that undesired subsequent deformation of the laminated body is avoided after it has been removed. Preferably, the molds are heated by means of a brine to a temperature of minus 3 C ^β, and the surface temperature of the molds can advantageously be in the range of + 5 ° C. The molding process between the dies is carried out discontinuously, ie step by step. The individual layers, which are brought together and formed together to form the laminate, can be withdrawn from supply rolls in a corresponding manner step by step, especially since the heating of the carrier film is advantageously carried out step by step. However, it is also possible to continuously mold the plastic film from a slot die of an extruder, to allow it to cool, and then to guide the film web as an endless web to the molding press, with a queue or the like preferably being located between the extruder and the heating zone. is inserted in order to balance the continuous extrusion and the step-by-step molding process.

The film is preferably held on a carrier web during the heating process, which prevents an undesired deformation of the carrier web in the heated state. It has proven to be particularly advantageous to design this carrier web as a so-called lost carrier, which remains as an additional layer in the shaped laminate. For this purpose, the carrier web is preferably designed in such a way that it has the required tensile strength, which is required to prevent unwanted deformation of the softened film due to its own weight, the tensile strength of the carrier web, on the other hand, being so limited that the three-dimensional deformation is not hindered in drawing pressing, ie the structure of the carrier web yields during drawing pressing and follows the drawing path of the film during pressing without cutting into it. The carrier web is laminated onto the film as long as it is still hot enough after leaving the extruder's wide slots to enable the carrier web to be anchored to the film. It has proven to be advantageous here to form the carrier web from a material which is stable at the temperature level at which the film material is after leaving the extruder. In the case of a polypropylene film material, the outlet temperature is approximately 240 ° C., with rapid cooling taking place. A carrier web made of textile fibers is particularly suitable, with polyester fibers being preferred. These are sufficiently stable at softening temperatures of polypropylene.

The carrier web preferably has an open structure. This is particularly advantageous if the side of the film covered with the carrier web is to be provided with a surface covering. The pore size or the open structure is advantageously dimensioned such that the formation of the adhesive connection between the fibers of the surface material and the thermoplastic plastic of the film is possible without hindrance through the pores of the carrier web. Furthermore, the carrier web is preferably kept very thin in material thickness, which in turn has a positive effect on the good connection between the surface covering and the film. A spunbonded fabric, ie a nonwoven fabric in which the fibers lie in the plane of the scrim, has proven to be particularly suitable for the carrier web. Backing webs with a layer weight of 10-50 g / m ² , in particular 20-40 g / m ^2, are particularly preferred. The thickness of the carrier web is preferably on the order of 1 to 5 times the fiber thickness.

During the heating process, the film is preferably guided or held at its longitudinal edges. This can take place, for example, in such a way that the longitudinal edges are clamped in or are hung in needle chains. The carrier web is included in each case. In contrast, the surface coverings which are supplied to the hot film are preferably kept narrower so that they do not cover the edge region of the film which is trimmed anyway.

If the film is to have perforations, the corresponding perforations are preferably made while the film is in a solid state, ie after it has been solidified by extrusion after its production and before the heating has taken place. The perforation can be done with Perforation or spiked rollers are made. The perforation can be carried out over the entire surface area of the film or, if desired, restricted to, for example, acoustically preferred areas. If the holes are located in areas which are drawn during the deep-drawing process, then holes are deformed accordingly, ie as a rule enlarged in at least one direction. This is taken into account when dimensioning the hole size when attaching the hole to the cold foil.

In the unshaped state, the plastic film advantageously has a basis weight or layer weight in the range from 500 to 3000 g / m ² , in particular in the range from 900 to 1600 g / m ² . A textile surface layer that is used as a decorative layer generally has a basis weight in the range from 100 to 600 g / m ² , in particular 200 to 350 g / m ² . A surface layer which is used as sound insulation on the back preferably has a higher weight per unit area depending on the desired sound damping, wherein the weight per unit area can be up to 1500 g / m ² or more.

For sound absorption, textile needle fleeces are advantageously used which are made from waste fibers from the clothing industry, with a minimum proportion of fibers fusible with the film material being provided in the damping layer for the preferred formation of the adhesive connection.

If the film consists of polypropylene, the heating of the film is preferably controlled so that the film surface reaches a surface temperature of approximately 180 ° C., this temperature being measured with a radiation pyrometer. At this surface temperature, the polypropylene is sufficiently sticky to form a thermoplastic bond with the fibers of the surface covering, which consist of the same or the same material. The core temperature of the In contrast, film is preferably kept in the range of 140-160 ° C. This temperature range corresponds to the deformation range of the polypropylene with plastic deformability, a minimum level of strength still being retained. Is characterized in that according to the method according to the invention chentemperatur a core temperature in the deformation region and a Oberflä¬ provided in Klebrigkeitsbereich, a g ^* ute bonding between the film and the textile surface layer can be obtained, wherein the bonding process because of the limitation of the Wäremenergie of the film does not adversely affects the structure of the surface covering and, on the other hand, the thermal energy present in the film is sufficient to simultaneously use it to produce the layered body by deformation.

The device according to the invention for producing the laminate has a heating device for the film, a merging device for merging at least one surface covering and film and a shaping device. These devices are preferably arranged essentially one behind the other along the transport path of the film. If only one side of the film is to be welded to a surface covering, the heating device preferably has a cooling device for cooling the other side of the film.

Further features of the invention result from the following description of preferred embodiments in conjunction with the drawing and the subclaims. The individual features can be implemented individually or in combination with one another in one embodiment of the invention.

The drawing shows: 1 shows a partial cross section through a laminated body according to the invention.

Fig. 2. is a schematic representation of the procedure and the device for producing the layer body and pers

3 shows another embodiment of the procedure

Device for producing the laminated body.

In the embodiment of the invention shown in FIG. 1, a trunk interior lining designed as a laminated body 1 is provided, which is composed of three layers. A carrier layer 2 made of a polypropylene film is shaped by thermal deformation from a flat material and adapted to existing shapes of a trunk, whereby a three-dimensional laminate is formed. The carrier layer 2 is coated on both sides with a textile needle fleece as a surface covering. A surface covering 3 is designed as a decorative layer, whereas a surface covering provided on the invisible side of the trunk interior lining is designed as a backing layer 4, which serves for sound absorption. Between the decorative layer 3 and the carrier layer 2 there is still a very thin, interleaved layer 5 which is formed by a lost carrier web. Both the decorative layer 3 and the back layer 4 consist of a needle fleece made of polypropylene fibers. The layer weight of the needle punch fleece of the decorative layer is approximately 350 g / m ² , whereas the layer weight of the back fleece is approximately twice as high. The two needle fleeces are connected to the polypropylene film by thermal gluing. This means that individual fibers or fiber conglomerates, which lie on the side of the needle fleece facing the film, are sintered with the film surface. This creates a good connection between the three layers without using additional glue. The intermediate layer 5 consists of a polyester fleece in the form of a very thin and light fiber fabric with a layer weight of 30 g / m ² . This fiber fabric is very thin and, apart from its relatively large openings, has a material thickness of 1 to approx. 5 times the fiber thickness. The percentage of holes or pores in the fiber scrim is approximately 90% and more. The polypropylene film itself has a layer weight of approximately 1600 g / m ² in non-deformed areas. It is correspondingly lower at those points that are drawn during the deformation.

The laminated body shown is thus essentially sorted by type. The small proportion of polyester fibers that is introduced through the carrier web 5 plays no role in the reprocessing of the laminate and is negligible, especially since the polyester fibers are very thin and are shredded in the event of any pelletization of the laminate during recycling.

The sorted construction is particularly advantageous if there is a lot of waste during the production of the laminated body, as is the case with a trunk interior lining. Because of the complicated shapes of such trunk linings, the waste can be up to 50 k. The waste can be used to produce carrier film without any problems.

The carrier layer 2 has perforations 7 in the side wall region 6 of the trunk interior lining. The holes in the perforations have a diameter of approximately 1-2 mm and are located at intervals of 0.5-2 cm from one another, the holes in the regions, in which the polypropylene film is drawn, in contrast to the original circular shape, are deformed and enlarged accordingly. The intermediate layer 5 is in the drawn areas of the film disintegrated. This means that the fiber composite is partially or completely dissolved in these areas. The needle fleece of the decorative layer 3 and the back layer 4 have fully undergone the deformation of the carrier film and are correspondingly stretched at the points at which the film is drawn or stretched, without this being visible on the surface. The perforations provided in the carrier layer are covered by the decorative layer and are not visible. Airborne sound that has penetrated into the trunk can penetrate through the holes in the perforations 7 into the covered areas of the trunk lying behind and runs dead in these rooms. This results in effective sound absorption. Accordingly, the back layer 4 is mainly used for sound absorption. The carrier layer at the imperforate points prevents sound that penetrates into the vehicle interior from the outside through openings in the body, for example at points of the forced ventilation, from entering the interior of the trunk through the trunk interior lining.

It is also possible to provide only a portion of fiber material that can be glued to the film material in individual surface layers or to connect only one surface layer to the carrier film by thermal gluing. However, the proportion of foreign fibers is preferably kept so low that recycling of the entire laminate by thermoplastic processing remains possible.

Fig. 2 shows a schematic representation of a device for producing the laminated body according to the invention and the associated mode of operation. The carrier layer 2 is extruded from an extruder 11 as an endless web and emerges from a slot die, not shown, of the extruder as a plastic, easily deformable polypropylene endless web. A web-shaped fiber fabric is fed to this web from below by a supply roll 12 which the intermediate layer 5 forms. When the carrier web is brought together with the still hot polypropylene web, the polyester fibers of the carrier web with the soft polypropylene are partially embedded in the latter. This provides a good connection between the carrier web and the polypropylene film, the fibers of the carrier web not being changed as a result of the temperature stability of the polyester fibers. The polypropylene film 2 thus produced, which is connected to the carrier web 5, can be rolled up and temporarily stored after cooling and solidifying. The roll can then serve as a supply roll during further processing. However, it is also possible to feed the carrier web directly to the processing, as shown in FIG. 2. There, the cooled carrier web is first provided with a perforation with the aid of a perforation roller 13, which at the same time can comprise peripheral perforations for holding the web in a subsequent heating device 14. In front of the heating device 14, the web of the carrier layer is expediently placed in a compensating loop 15, which offers to compensate for the transition from continuous extrusion to discontinuous heating and shaping.

The heating device 14 works with infrared radiators and, in the embodiment shown, is equipped for surface heating on both sides. In the heating device, a web section is heated which essentially corresponds to the size of a section used for the production of a trunk interior lining. The surface coverings, namely the decorative layer 3 and the back layer 4, are pulled off from supply rolls 17 and 16 and at the same time are combined on both sides with the heated carrier layer. The union and the connection is preferably carried out via deflection rollers 18, which also serve as pressure rollers. For this purpose, additional clamping jaws 19 can also be provided. As a result of the heating, the surfaces of the carrier layer 2 are heated up more than the inside of the film. To The end of the heating process has softened the film surface to such an extent that it is capable of thermal bonding with the polypropylene fibers of the decorative layer 3 and the back layer 4. The film core is still so firm that it can withstand the extrusion pressure provided to connect the three layers. At the same time, however, the film core is heated to such an extent that its temperature is in the forming range of polypropylene, so that the shaping of the still flat layer body can take place immediately after the three layers have been combined in a drawing press 20. This has a male part 21 and a female part 22, which are constantly tempered, in particular cooled. The cooling causes protection of the needle fleece of the surface layers and, at the same time, a consolidation of the carrier layer after the flat layer body has been formed into a three-dimensional layer body. Edge trimming of the finished laminate can be carried out simultaneously with the drawing press or afterwards.

In the embodiment shown in FIG. 3, a supply roll 31 is provided, on which there is a supply of polypropylene film which is already connected to a surface covering 3 made of a decorative fleece and a carrier web, which later forms the intermediate layer 5. This carrier web is located between the web of the carrier layer 2 and the web of the decorative layer 3. This pre-formed layer body 32 is fed step by step to a heating / cooling device 33 which has an infrared heating device 34 on its upper side for heating the exposed surface of the carrier layer and on its underside there is a cooling device 35 for simultaneous cooling of the decorative layer 3 located on the other side. The heating is again carried out in such a way that the surface of the carrier layer provided for the adhesive connection is brought to a temperature in the range of approximately 180 ° C. , whereas the film core and the other side of the carrier layer one in the temperature range of 140 - 160 ^β C does not exceed. A backing layer 4 'is drawn off as a web material from a supply roll 36, and this backing layer is a needle fleece which consists entirely of polypropylene fibers or of foreign fibers and a minimum proportion of polypropylene fibers which is sufficient to form the adhesive bond. The connection of the back layer 4 to the pre-formed layer body 32 is carried out similarly to the embodiment according to FIG. 2 via a pair of rollers 37. The still flat composite body is also shaped into a three-dimensional layer body by means of a drawing press 20 with a male part 21 and a female part 22.

Claims

Expectations

Shaped laminated body, in particular interior lining part for motor vehicles, and method and device for its production

Shaped laminate (1), in particular interior part for motor vehicles, with a carrier layer (2) made of an essentially rigid film made of a thermoplastic and at least one surface covering (3, 4) made of a textile sheet material, characterized in that fibers of at least one surface covering (3, 4) consist at least partially of a thermoplastic of essentially the same type as the film (2) and the surface covering (3, 4) is connected to the film (2) by thermal bonding of these fibers .

2. Laminate according to claim l, characterized in that two textile surface coverings (3 and 4) are provided, which are preferably both connected by thermal bonding to the film.

3. Laminated body according to claim 1 or 2, characterized gekenn¬ characterized in that at least one surface covering (3, 4), in particular a decorative layer (3), consists of essentially the same material as the film, in particular of polypropylene.

4. Laminated body according to one of the preceding claims, characterized in that it consists of materials which are compatible with one another in relation to recycling.

5. Laminated body according to one of the preceding claims, characterized in that the film (2) and at least one surface covering (3, 4) consists of thermoplastic polymers which, when the film is melted, in particular during reprocessing, a common melt able to form.

6. Laminated body according to one of the preceding claims, characterized in that it is constructed essentially pure sorten¬.

7. Laminated body according to one of claims 1 to 5, characterized in that at least one surface covering (4 "), in particular a backing layer, consists at least in part, preferably for the most part, of fibers which do not match the material of the film (2) are fusible, the surface covering (4 ') having a sufficient proportion for thermal bonding Fibers made of the same material as the film.

8. Laminated body according to claim 7, characterized in that the fibers suitable for thermal bonding to the film (2) are enriched in the surface of the surface covering facing the film.

9. Laminated body according to one of the preceding claims, characterized in that the film (2) is connected on at least one side with an open-pore layer (5), in particular an intermediate layer, made of a web material which is shaped in accordance with the film.

10. Laminated body according to claim 9, characterized in that the layer (5) made of the web material between the surface covering (3), preferably a back layer, and the film (2) is arranged.

11. Laminated body according to claim 9 or 10, characterized gekennz¬ eichnet that the layer (5) of the sheet material is so thin and the pore size is so large that the adhesive bond between the film (2) and surface covering (3) the pores penetrates the layer (5).

12. Laminated body according to one of claims 9 to 11, characterized in that the web material (5) is formed by a lost carrier web, which remains in the laminated body (1).

13. Laminated body according to one of the preceding claims, characterized in that the film (2) has perforations (7) at least on surface areas.

14. Laminated body according to claim 13, characterized in that at least one surface covering (3, 4) is free of perforations and covers the perforations (7) of the film (2).

15. Laminated body according to claim 13 or 14, characterized gekenn¬ characterized in that the perforations (7) are deformed as a function of the deformation of the film (2).

16. 'Laminated body according to one of claims 13 to 15, characterized in that the perforations (7) are provided on those areas of the film (2) which cover cavities suitable for sound absorption.

17. A method for producing a shaped laminate with a carrier layer made of a substantially rigid film made of a thermoplastic and at least one surface covering made of a textile fabric by connecting and molding at elevated temperature, in particular according to one of the preceding claims, characterized in that a film web of thermoplastic material, which has a temperature in the stickiness range on at least one surface and a lower temperature in the area of the plastic deformability of the thermoplastic material, is bonded to at least one textile surface covering, the temperature level inside is used to deform the film.

18. The method according to claim 17, characterized in that at least one surface of a solid film, in particular film web, made of a thermoplastic material by surface heating in such a way on a surface D

temperature in the stickiness range of the thermoplastic material is brought about so that the temperature inside the film does not substantially exceed the temperature required for the plastic deformation of the film.

19. The method according to claim 17 or 18, characterized gekennzeich¬ net that a textile fabric, in particular a needle fleece, is used as the surface covering, the fibers of which at least partly consist of a plastic of the same type as the film, the melting range being Plastics is essentially the same.

20. The method according to any one of claims 17 to 20, characterized in that a film made of polypropylene is used and the film is heated on at least one side to a surface temperature of approximately 180 ° C.

21. The method according to claim 20, characterized in that the heating of the film surface is controlled such that the film core does not exceed a temperature in the range of 140-160 ° C.

22. The method according to any one of claims 17 to 21, characterized in that the film web is heated only on one side, preferably the unheated other side is cooled at the same time.

23. The method according to any one of claims 17 to 22, characterized in that the at least one surface covering is supplied without preheating, in particular essentially at ambient temperature, of the heated top of the film.

24. The method according to any one of claims 17 to 23, characterized in that the film is perforated, in particular perforated, at least in some areas before heating.

25. The method according to any one of claims 17 to 24, characterized in that the perforations are changed in shape depending on the material flow of the film during molding, in particular widened and this is preferably taken into account in the perforation.

26. Device for performing the method according to one of claims 17 to 25, characterized by a heating device (14, 34) for heating at least one surface of a film, a merging device (18, 19; 37) for merging the heated film with at least one textile Surface covering and a shaping device (19, 20) for shaping the coated film into a three-dimensional body.