EP1809510A1 - Moulded carpet part with an acoustic function for motor vehicles and method for producing the same - Google Patents

Moulded carpet part with an acoustic function for motor vehicles and method for producing the same

Info

Publication number
EP1809510A1
EP1809510A1 EP05808195A EP05808195A EP1809510A1 EP 1809510 A1 EP1809510 A1 EP 1809510A1 EP 05808195 A EP05808195 A EP 05808195A EP 05808195 A EP05808195 A EP 05808195A EP 1809510 A1 EP1809510 A1 EP 1809510A1
Authority
EP
European Patent Office
Prior art keywords
carpet
needle felt
molding according
fibers
carpet molding
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.)
Withdrawn
Application number
EP05808195A
Other languages
German (de)
French (fr)
Inventor
Herbert Vollmert
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.)
Carcoustics Techconsult GmbH
Original Assignee
Carcoustics Tech Center GmbH
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Carcoustics Tech Center GmbH filed Critical Carcoustics Tech Center GmbH
Publication of EP1809510A1 publication Critical patent/EP1809510A1/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N3/00—Arrangements or adaptations of other passenger fittings, not otherwise provided for
    • B60N3/04—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets
    • B60N3/048—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets characterised by their structure
    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/485—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with weld-bonding
    • 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
    • D04H1/54—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 welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
    • 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
    • D04H1/54—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 welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/542—Adhesive fibres
    • D04H1/55—Polyesters
    • 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
    • D04H1/54—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 welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—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 welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • 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
    • D04H13/00—Other non-woven fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/05—5 or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/12—Conjugate fibres, e.g. core/sheath or side-by-side
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B32B2307/734—Dimensional stability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/738—Thermoformability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B32B2471/02—Carpets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23979—Particular backing structure or composition

Definitions

  • the invention relates to an acoustically effective carpet molding for motor vehicles, in particular as a floor covering a passenger compartment, with a textile upper material which is connected via a multilayer material composite with a backing carpet, and a method for producing such a carpet molding.
  • this object is achieved by a carpet molding with the material structure specified in claim 1 or by the method defined in claim 11.
  • the carpet molding according to the invention has a textile upper material which is connected to a backing by a multi-layered composite material, wherein the material composite arranged between the upper material and the backing consists of a first needled nonwoven made of bicomponent melt fibers bonded to the outer material, a second needle felting thereafter is formed from Einkomponentenfasern and a subsequent third needled nonwoven bicomponent melt fibers.
  • the two needled nonwoven webs formed from bicomponent fibers should each consist of at least 85% by volume bicomponent melt adhesive fibers.
  • these needled webs are as complete as possible, i. as far as possible 100% of bicomponent melt-adhesive fibers.
  • bicomponent fibers are used in an advantageous embodiment of the carpet molding according to the invention, the core of polyester and the sheath of polyester are formed with a melting point below the melting point of the core.
  • Fig. 1 shows a preferred material structure of a carpet molding according to the invention
  • FIGS. 2A and 2B process steps for producing a carpet molding according to the invention.
  • Figures 3A, 3B and 3C process steps for producing a carpet molding according to the invention according to a variant.
  • the carpet molding according to the invention can be used in particular as an acoustically effective floor covering in the passenger compartment of a motor vehicle. Other uses are the covering of the floor and the side panels of a trunk of a motor vehicle.
  • the size of the carpet molding according to the invention preferably corresponds to the size of a vehicle floor to be covered, so that the vehicle floor can be completely covered with the one-piece carpet molding.
  • the carpet molding can thus be relatively large, being adapted to all troughs and tunnel-like elevations of the vehicle floor.
  • the carpet molding according to the invention consists of a textile upper 1, a first needle felt 2 of bicomponent melt adhesive fibers, a second needle felt 3 of monocomponent fibers, a third needle felt 4 of bicomponent Schmelzklebefasern- and optionally a back of carpet 5 (second back ) educated.
  • the textile upper 1 preferably consists of a tufted product, wherein as a tuft carrier in particular a nonwoven of polyester and / or polypropylene fibers can be used.
  • the pile material (pile material) of the textile upper 1 may be, for example, fibers, yarns or threads of polyamide, polyester or polypropylene and mixtures thereof, wherein the pile material may additionally also contain bicomponent fibers.
  • the proportion of bicomponent fibers in the Optionally, the pile-forming fiber mixture is about 10% by volume.
  • Tuftingware can be used as a textile upper material 1 if necessary, a dilute, a Malimoware, a Maliwattware, a knitted fabric or a nonwoven fabric.
  • the first needle felt 2 immediately following the textile upper 1 is preferably made from 100% bicomponent fibers.
  • the basis weight of the needle felt 2 is less than 200 g / m 2 ; for example, it is about 100 g / m 2 .
  • the bicomponent fibers each have a sheath which has a much lower melting point than its core.
  • the jacket material may for example consist of polypropylene and the core material of polyester.
  • bicomponent fibers are used for the production of the erfindungs ⁇ contemporary carpet molding whose core material is made of polyester and the shell material of a modified, having a lower melting point polyester.
  • the needle fleece 3 follows from Einkomponentenmaschinen.
  • the monocomponent fibers may be man-made fibers and / or natural fibers. In turn, polyester fibers are preferred. But it can also be used as cotton fibers.
  • the thickness and the weight per unit area of the needle-punched nonwoven 3 are considerably greater than in the case of the needle-punched nonwoven 2 made of bicomponent fibers.
  • the needled nonwoven 3 has a basis weight in the range of 300 to 700 g / m 2 at a fiber fineness in the range of 3 to 7 dtex.
  • the fiber length of the chemical or natural fibers of the needle felt 3 is in the range of, for example, 50 to 80 mm.
  • carpet back (secondary backing) 5 a further needle felt or a heavy layer is finally arranged below the needle felt 4 of bicomponent fibers.
  • the carpet backing 5 is comparatively thick or heavy. It has a basis weight in the range of 300 to 800 g / m 2 .
  • the back of the carpet 5 is a heavy layer, for example of filler-containing elastomer, then this is not hot-stamped together with the other layers of material 1 to 4, but adapted in another way to the contour of the vehicle surface to be covered or the carpet molding and with the latter connected.
  • the textile upper 1 is moistened with a suitable fluid, for example with water, before it with the other Material layers 2 to 4 or 2 to 5 is introduced as a loose stack in a device for hot stamping.
  • a suitable fluid for example with water
  • the moistening of the circuit board 1 can take place, for example, by means of a device 6 having a plurality of spray nozzles.
  • a device 6 having a plurality of spray nozzles.
  • By moistening excessive heating of the textile upper 1 is prevented during hot stamping. Excessive heating of the textile upper 1 may cause gloss effects that affect the appearance of the finished carpet molding.
  • the moistening causes a steam effect, which protects the textile upper 1 during hot stamping from excessive heating. Due to the humidification, a reduction in the process time required for hot stamping (cycle time) is possible.
  • the forming device has heatable forming tools 7, 8, the heating temperature of which is adjustable independently of one another.
  • heating channels 9 for a heating fluid may be formed in the upper tool 7 and the lower tool 8.
  • electrical heating resistors or the like can also be integrated in the molds 7, 8.
  • the heating temperatures of the raised and lowered molds 7, 8 are depending on the nature of the textile upper 1 used, the melting temperature of the jacket material of the bicomponent fibers and the desired cycle time for the hot stamping in the range of 50 to 160 0 C.
  • the molding tool 7 or 8 which faces the textile upper 1 is operated at a temperature which is at least 10 ° C. lower than the molding tool which forms the carpet back (needle felt) 5 or the needle felt 4 of the multilayer composite material (without heavy layer).
  • the textile upper 1 facing mold is operated for example at a temperature below 100 0 C, while the temperature of the other mold is set to a temperature in the range of 110 to 160 0 C.
  • the upper tool of the H discloses the upper tool of the H andmboge ⁇ device facing the textile upper 1.
  • the production of the inventive carpet molding takes place in such a way that the lower tool of the hot stamping device faces the textile upper 1.
  • infiltration of water or another moistening fluid from the moistened upper material 1 into the material layers 2 to 4 or 2 to 5 arranged thereunder can be prevented.
  • the upper tool 7 and the lower tool 8 exchanged with each other or the figures 2B and 3C can be rotated in each case by 180 °, so that the molding material associated with the textile upper 1 is then the lower tool.

Abstract

The invention relates to a moulded carpet part for motor vehicles with an acoustic function, in particular for use as the floor covering of a vehicle interior. Said part comprises an upper fabric material (1), which is connected to a carpet backing (5) by means of a multi-layer material composite (2 - 4). The invention also relates to a method for producing a moulded carpet part of this type. The moulded carpet part can be produced to a great extent without shrinkage and with a high fitting accuracy. To achieve this, the material composite that is located between the upper material (1) and the carpet backing (5) is configured from a first needle nonwoven (2) consisting of bi-component fused fibres, which is bonded to the upper material, a subsequent second needle nonwoven (3) consisting of single component fibres and a third needle nonwoven (4) consisting of bi-component fused fibres. To produce the moulded carpet part, the upper fabric material (1) is moistened prior to the hot embossing process.

Description

Akustisch wirksames Teppichformteil für Kraftfahrzeuge und Verfahren zu dessen Herstellung Acoustically effective carpet molding for motor vehicles and method for its production
Die Erfindung betrifft ein akustisch wirksames Teppichformteil für Kraftfahrzeuge, insbesondere als Bodenverkleidung eines Fahrgastraumes, mit einem textilen Obermaterial, das über einen mehrschichtigen Materialverbund mit einem Teppichrücken verbunden ist, sowie ein Verfahren zur Herstellung eines solchen Teppichformteils .The invention relates to an acoustically effective carpet molding for motor vehicles, in particular as a floor covering a passenger compartment, with a textile upper material which is connected via a multilayer material composite with a backing carpet, and a method for producing such a carpet molding.
Es ist bekannt, Teppichboden für den Fahrgastraum eines Kraftfahrzeuges durch Wärmeumformung (Heißprägen) mittels eines beheizten Formwerkzeuges oder in erwärmtem Zustand durch Kaltumformung mittels eines unbeheizten Formwerk¬ zeuges an die Kontur des Fahrzeugbodens anzupassen. Beim Einsatz herkömmlicher Teppichverbundmaterialien tritt während der Wärmeumformung regelmäßig eine Schrumpfung im Formteil auf. Diese Schrumpfung ist problematisch, wenn das fertige Teppichformteil infolge der Schrumpfung nicht die geforderte Passgenauigkeit aufweist.It is known to adapt carpet for the passenger compartment of a motor vehicle by heat deformation (hot stamping) by means of a heated molding tool or in the heated state by cold forming by means of an unheated mold tool to the contour of the vehicle floor. When using conventional carpet composite materials occurs during the heat deformation regularly shrinkage in the molding. This shrinkage is problematic if the finished carpet molding due to the shrinkage does not have the required fit.
Der vorliegenden Erfindung liegt die Aufgabe zugrunde, einen Materialaufbau anzugeben, mit dem sich ein weitest- gehend schrumpfungsfreies, eine hohe Passgenauigkeit aufweisendes Teppichformteil herstellen lässt. Insbesondere soll ein Teppichformteil bereitgestellt werden, das selbst bei einem größeren Klimawechsel im Wesentlichen schrumpffrei bleibt. Ferner soll ein kostengünstiges Verfahren zur Herstellung eines solchen Teppichformteils angegeben werden.The present invention has for its object to provide a material structure with which a largely shrinkage-free, a high fitting accuracy exhibiting carpet molding can be produced. In particular, a carpet molding is to be provided, which remains substantially shrink-free even with a larger climate change. Furthermore, a cost-effective method for producing such a carpet molding can be specified.
Erfindungsgemäß wird diese Aufgabe durch ein Teppichformteil mit dem im Anspruch 1 angegebenen Materialaufbau bzw. durch das in Anspruch 11 definierte Verfahren gelöst .According to the invention this object is achieved by a carpet molding with the material structure specified in claim 1 or by the method defined in claim 11.
Das erfindungsgemäße Teppichformteil weist ein textiles Obermaterial auf, das über einen mehrschichtigen Materialverbund mit einem Teppichrücken verbunden ist, wobei der zwischen Obermaterial und Teppichrücken ange¬ ordnete Materialverbund aus einem mit dem Obermaterial verbundenen ersten Nadelvlies aus Bikomponenten-Schmelz- fasern, einem darauf folgenden zweiten Nadelvlies aus Einkomponentenfasern und einem darauf folgenden dritten Nadelvlies aus Bikomponenten-Schmelzfasern gebildet ist.The carpet molding according to the invention has a textile upper material which is connected to a backing by a multi-layered composite material, wherein the material composite arranged between the upper material and the backing consists of a first needled nonwoven made of bicomponent melt fibers bonded to the outer material, a second needle felting thereafter is formed from Einkomponentenfasern and a subsequent third needled nonwoven bicomponent melt fibers.
Es wurde gefunden, dass der vorgenannte Materialverbund einer Schrumpfung des Teppichbodenmaterialaufbaus während des Heißprägens wirksam entgegenwirkt, so dass sich im Wesentlichen schrumpfungsfreie Teppichformteile mit hoher Passgenauigkeit erzielen lassen.It has been found that the aforementioned composite material effectively counteracts shrinkage of the carpeting structure during hot stamping so that substantially shrink-free carpet moldings with high accuracy of fit can be achieved.
Bikomponenten-Schmelzfasern sind vergleichsweise teuer. Für die Erzielung von im Wesentlichen schrumpffreien Teppichformteilen genügt es jedoch, wenn die beiden aus Bikomponentenfasern gebildeten Nadelvliese relativ dünn sind bzw. ein relativ geringes Flächengewicht aufweisen. Die Materialkosten bleiben somit in einem akzeptablen Rahmen. Gemäß einer bevorzugten Ausgestaltung ist vorgesehen, dass die beiden aus Bikomponentenfasern gebildeten Nadelvliese jeweils ein Flächengewicht von weniger als 200 g/m2, insbesondere weniger als 150 g/m2, beispielsweise etwa 100 g/m2 aufweisen.Bicomponent melt fibers are comparatively expensive. However, for the achievement of substantially shrink-free carpet moldings, it is sufficient if the two needled nonwovens formed from bicomponent fibers are relatively thin or have a relatively low weight per unit area. The material costs thus remain within an acceptable range. According to a preferred embodiment, it is provided that the two needle fleeces formed from bicomponent fibers each have a basis weight of less than 200 g / m 2 , in particular less than 150 g / m 2 , for example about 100 g / m 2 .
Für die erwünschte Schrumpffreiheit des Teppichformteils sollten die beiden aus Bikomponentenfasern gebildeten Nadelvliese jeweils aus mindestens 85 Vol.-% Bikomponenten-Schmelzklebefasern bestehen. Vorzugsweise bestehen diese Nadelvliese jedoch möglichst vollständig, d.h. möglichst zu 100% aus Bikomponenten-Schmelzklebe- fasern.For the desired shrinkage freedom of the carpet molding, the two needled nonwoven webs formed from bicomponent fibers should each consist of at least 85% by volume bicomponent melt adhesive fibers. Preferably, however, these needled webs are as complete as possible, i. as far as possible 100% of bicomponent melt-adhesive fibers.
Hinsichtlich eines sortenreinen Recyclings ist es vorteilhaft, wenn die verschiedenen Materiallagen des Teppichformteils aus nur einer Kunststoffsorte bestehen. Vorzugsweise sind die einzelnen Materiallagen des erfindungsgemäßen Teppichformteils jeweils aus Polyester hergestellt. Polyesterfasern verleihen dem fertigen Teppichformteil eine hohe Abriebfestigkeit und sind geruchsfrei sowie fäulnisresistent . Aufgrund der Polyesterfasern bzw. der verwendeten Bikomponentenfasern gehen von dem erfindungsgemäßen Teppichformteil im Wesentlichen keine Ausdünstungen aus, die sich als Verschmutzung auf der Innenseite der Fahrzeugscheiben niederschlagen würden (sogenanntes Fogging) .With regard to a sorted recycling, it is advantageous if the different material layers of the carpet molding consist of only one type of plastic. Preferably, the individual layers of material of the carpet molding according to the invention are each made of polyester. Polyester fibers give the finished carpet molding a high abrasion resistance and are odorless and rot-resistant. Because of the polyester fibers or the bicomponent fibers used, substantially no perspiration originates from the carpet molding according to the invention, which would be deposited as soiling on the inside of the vehicle windows (so-called fogging).
Dementsprechend werden in einer vorteilhaften Ausgestaltung des erfindungsgemäßen Teppichformteils Bikomponentenfasern verwendet, deren Kern aus Polyester und deren Mantel aus Polyester mit einem Schmelzpunkt unterhalb des Schmelzpunktes des Kerns gebildet sind.Accordingly, bicomponent fibers are used in an advantageous embodiment of the carpet molding according to the invention, the core of polyester and the sheath of polyester are formed with a melting point below the melting point of the core.
Das erfindungsgemäße Verfahren zur Herstellung des erfindungsgemäßen Teppichformteils ist im Wesentlichen dadurch gekennzeichnet, dass das textile Obermaterial und der mehrschichtige Materialverbund aus den aus Bikomponentenfasern bzw. Einkomponentenfasern gebildeten Nadelvliesen mit dem oder ohne den Teppichrücken in einer beheizten Umformungsvorrichtung heißgeprägt werden, wobei das textile Obermaterial vor dem Heißprägen mit Wasser befeuchtet wird.The inventive method for producing the carpet molding according to the invention is essentially characterized in that the textile upper material and the multilayer material composite from the needled nonwovens formed from bicomponent fibers or monocomponent fibers with or without the back of the carpet are heat-embossed in a heated forming device, wherein the textile outer material is moistened with water prior to hot embossing.
Eine übermäßige Erwärmung kann zu einer unerwünschten Glanzwirkung an dem textilen Obermaterial führen. Durch die Befeuchtung des textilen Obermaterials wird während des Heißprägens eine übermäßige Erwärmung des textilen Obermaterials verhindert. Mit der Verdampfung der •Feuchtigkeit ist eine örtliche Temperaturbegrenzung im Bereich des textilen Obermaterials verbunden. Der mit dem textilen Obermaterial zu verbindende Materialverbund kann somit schneller auf die erforderliche Temperatur zum Anschmelzen der Bikomponentenfasern, das heißt zum Erweichen bzw. Schmelzen des Mantelmaterials der Bikomponentenfasern erhitzt werden. Das erfindungsgemäße Verfahren ermöglicht daher eine Reduzierung der Taktzeiten, was eine höhere Produktivität bzw. geringere Herstellungskosten bedeutet.Excessive heating can lead to an undesirable gloss effect on the textile upper. By moistening the textile upper material excessive heating of the textile upper material is prevented during hot stamping. With the evaporation of moisture • a local temperature limitation in the area of the textile upper material is connected. The composite material to be connected to the textile upper material can thus be heated more quickly to the required temperature for melting the bicomponent fibers, that is to say for softening or melting the jacket material of the bicomponent fibers. The method according to the invention therefore makes it possible to reduce the cycle times, which means higher productivity or lower production costs.
Bei der Herstellung des erfindungsgemäßen Teppichformteils kommt kein zusätzlicher Kleber in Pulverform oder in Form einer Klebefolie zum Einsatz. Auch entfällt bei dem erfindungsgemäßen Verfahren der Einsatz einer der Umformungsvorrichtung vorgeschalteten Heizvorrichtung, denn die Formwerkzeuge der verwendeten Umformungsvorrichtung sind beheizbar ausgeführt. Durch den Wegfall einer vorgeschalteten Heizvorrichtung können die erforderlichen Maschineninvestitionskosten reduziert werden. Hinsichtlich der Vermeidung eines unerwünschten Glanzeffektes am textilen Obermaterial ist es auch vorteilhaft, wenn gemäß einer bevorzugten Ausgestaltung zum Heißprägen eine Umformungsvorrichtung verwendet wird, die beheizbare Formwerkzeuge aufweist, deren Temperatur unabhängig voneinander einstellbar ist, wobei das Formwerkzeug, welches dem textilen Obermaterial zugewandt ist, mit einer um mindestens 100C geringeren Temperatur betrieben wird als das Formwerkzeug, welches dem mehrschichtigen Materialverbünd oder dem Teppichrücken zugewandt ist.In the preparation of the carpet molding according to the invention no additional adhesive in powder form or in the form of an adhesive film is used. Also omitted in the method according to the invention, the use of a heating device upstream of the forming device, because the forming tools of the forming device used are designed to be heated. By eliminating an upstream heater, the required machine investment costs can be reduced. With regard to the avoidance of an undesirable gloss effect on the textile upper material, it is also advantageous if, according to a preferred embodiment for hot stamping, a forming device is used which has heatable forming tools whose temperature can be set independently of each other, wherein the forming tool which faces the textile upper carries operated at a temperature at least 10 0 C lower than the mold, which faces the multilayer material composite or the back of the carpet.
Weitere Merkmale des erfindungsgemäßen Teppichformteils und des Verfahrens zu seiner Herstellung sind in den Unteransprüchen angegeben.Further features of the carpet molding according to the invention and the method for its preparation are specified in the subclaims.
Nachfolgend wird die Erfindung anhand einer mehrere Ausführungsbeispiele darstellenden Zeichnung näher erläutert. Es zeigen schematisch:The invention will be explained in more detail with reference to a drawing illustrating several embodiments. They show schematically:
Fig. 1 einen bevorzugten Materialaufbau eines erfindungsgemäßen Teppichformteils;Fig. 1 shows a preferred material structure of a carpet molding according to the invention;
Figuren 2A und 2B Verfahrenschritte zur Herstellung eines erfindungsgemäßen Teppichformteils; undFIGS. 2A and 2B process steps for producing a carpet molding according to the invention; and
Figuren 3A, 3B und 3C Verfahrenschritten zur Herstellung eines erfindungsgemäßen Teppichformteils nach einer Variante. Das erfindungsgemäße Teppichformteil kann insbesondere als akustisch wirksame Bodenverkleidung im Fahrgasträum eines Kraftfahrzeuges zum Einsatz kommen. Weitere Einsatzmöglichkeiten sind die Verkleidung des Bodens und der Seitenteile eines Kofferraums eines Kraftfahrzeuges.Figures 3A, 3B and 3C process steps for producing a carpet molding according to the invention according to a variant. The carpet molding according to the invention can be used in particular as an acoustically effective floor covering in the passenger compartment of a motor vehicle. Other uses are the covering of the floor and the side panels of a trunk of a motor vehicle.
Die Größe des erfindungsgemäßen Teppichformteils entspricht vorzugsweise der Größe eines zu verkleidenden Fahrzeugbodens, so dass der Fahrzeugboden mit dem einstückigen Teppichformteil vollständig verkleidet werden kann. Das Teppichformteil kann somit relativ groß sein, wobei es allen Mulden und tunnelartigen Erhebungen des Fahrzeugbodens angepasst ist.The size of the carpet molding according to the invention preferably corresponds to the size of a vehicle floor to be covered, so that the vehicle floor can be completely covered with the one-piece carpet molding. The carpet molding can thus be relatively large, being adapted to all troughs and tunnel-like elevations of the vehicle floor.
Wie in Fig. 1 schematisch dargestellt, ist das erfindungsgemäße Teppichformteil aus einem textilen Obermaterial 1, einem ersten Nadelvlies 2 aus Bikomponenten-Schmelzklebefasern, einem zweiten Nadelvlies 3 aus Einkomponentenfasern, einem dritten Nadelvlies 4 aus Bikomponenten-Schmelzklebefasern- und gegebenenfalls einem Teppichrücken 5 (Zweitrücken) gebildet.As schematically illustrated in FIG. 1, the carpet molding according to the invention consists of a textile upper 1, a first needle felt 2 of bicomponent melt adhesive fibers, a second needle felt 3 of monocomponent fibers, a third needle felt 4 of bicomponent Schmelzklebefasern- and optionally a back of carpet 5 (second back ) educated.
Das textile Obermaterial 1 besteht vorzugsweise aus einer Tuftingware, wobei als Tuftträger insbesondere ein Vlies aus Polyester- und/oder Polypropylenfasern Verwendung finden kann. Bei dem Flormaterial (Polmaterial) des textilen Obermaterials 1 kann es sich beispielsweise um Fasern, Garne oder Zwirne aus Polyamid, Polyester oder Polypropylen sowie Mischungen hieraus handeln, wobei das Flormaterial zusätzlich auch Bikomponentenfasern enthalten kann. Der Anteil der Bikomponentenfasern in der den Flor bildenden Fasermischung liegt gegebenenfalls bei ca. 10 Vol.-%.The textile upper 1 preferably consists of a tufted product, wherein as a tuft carrier in particular a nonwoven of polyester and / or polypropylene fibers can be used. The pile material (pile material) of the textile upper 1 may be, for example, fibers, yarns or threads of polyamide, polyester or polypropylene and mixtures thereof, wherein the pile material may additionally also contain bicomponent fibers. The proportion of bicomponent fibers in the Optionally, the pile-forming fiber mixture is about 10% by volume.
Anstelle einer Tuftingware kann bei Bedarf auch eine Dilourware, eine Malimoware, eine Maliwattware, eine Wirkware oder ein Vliesstoff als textiles Obermaterial 1 verwendet werden.Instead of a Tuftingware can be used as a textile upper material 1 if necessary, a dilute, a Malimoware, a Maliwattware, a knitted fabric or a nonwoven fabric.
Das unmittelbar auf das textile Obermaterial 1 folgende erste Nadelvlies 2 ist vorzugsweise zu 100% aus Bikomponentenfasern hergestellt. Das Flächengewicht des Nadelvlieses 2 beträgt weniger als 200 g/m2 ; es liegt beispielsweise bei etwa 100 g/m2.The first needle felt 2 immediately following the textile upper 1 is preferably made from 100% bicomponent fibers. The basis weight of the needle felt 2 is less than 200 g / m 2 ; for example, it is about 100 g / m 2 .
Die Bikomponentenfasern besitzen jeweils einen Mantel, der einen deutlich geringeren Schmelzpunkt aufweist als ihr Kern. Das Mantelmaterial kann beispielsweise aus Polypropylen und das Kernmaterial aus Polyester bestehen. Vorzugsweise werden für die Herstellung des erfindungs¬ gemäßen Teppichformteils Bikomponentenfasern verwendet, deren Kernmaterial aus Polyester und deren Mantelmaterial aus einem modifizierten, einen geringeren Schmelzpunkt aufweisenden Polyester bestehen.The bicomponent fibers each have a sheath which has a much lower melting point than its core. The jacket material may for example consist of polypropylene and the core material of polyester. Preferably, bicomponent fibers are used for the production of the erfindungs¬ contemporary carpet molding whose core material is made of polyester and the shell material of a modified, having a lower melting point polyester.
Auf das aus Bikomponentenfasern gebildete Nadelvlies 2 folgt das Nadelvlies 3 aus Einkomponentenfasern. Bei den Einkomponentenfasern kann es sich um Chemiefasern und/oder Naturfasern handeln. Bevorzugt sind wiederum Polyesterfasern. Es können aber auch z.B. BaumwolIfasern verwendet werden. Die Dicke und das Flächengewicht des Nadelvlieses 3 sind erheblich größer als bei dem Nadelvlies 2 aus Bikomponentenfasern. Das Nadelvlies 3 weist bei einer Faserfeinheit im Bereich von 3 bis 7 dtex ein Flächengewicht im Bereich von 300 bis 700 g/m2 auf. Die Faserlänge der Chemie- bzw. Naturfasern des Nadelvlieses 3 liegt im Bereich von beispielsweise 50 bis 80 mm.On the needle fleece 2 formed from bicomponent fibers, the needle fleece 3 follows from Einkomponentenfasern. The monocomponent fibers may be man-made fibers and / or natural fibers. In turn, polyester fibers are preferred. But it can also be used as cotton fibers. The thickness and the weight per unit area of the needle-punched nonwoven 3 are considerably greater than in the case of the needle-punched nonwoven 2 made of bicomponent fibers. The needled nonwoven 3 has a basis weight in the range of 300 to 700 g / m 2 at a fiber fineness in the range of 3 to 7 dtex. The fiber length of the chemical or natural fibers of the needle felt 3 is in the range of, for example, 50 to 80 mm.
Auf das Nadelvlies 3 aus Chemie- und/oder Naturfasern folgt unmittelbar ein weiteres Nadelvlies 4 aus Bikomponentenfasern, das vorzugsweise hinsichtlich seines Flächengewichtes entsprechend dem anderen Bikomponenten- faser-Nadelvlies 2 ausgebildet ist. Es liegt jedoch auch im Rahmen der Erfindung, unterschiedlich schwere bzw. dicke Nadelvliese 2, 4 aus Bikomponentenfasern zu verwenden. Die Faserlänge der Bikomponentenfasern liegt vorzugsweise im Bereich von 30 bis 90 mm.The needle-punched nonwoven fabric 3 made of chemical and / or natural fibers is immediately followed by another needle-punched nonwoven fabric 4 made of bicomponent fibers, which is preferably formed with respect to its basis weight in accordance with the other bicomponent fiber needle-punched nonwoven fabric 2. However, it is also within the scope of the invention to use differently heavy or thick needle fleeces 2, 4 of bicomponent fibers. The fiber length of the bicomponent fibers is preferably in the range of 30 to 90 mm.
Als Teppichrücken (Zweitrücken) 5 wird schließlich ein weiteres Nadelvlies oder eine Schwerschicht unterhalb des Nadelvlieses 4 aus Bikomponentenfasern angeordnet. Der Teppichrücken 5 ist vergleichsweise dick bzw. schwer. Er weist ein Flächengewicht im Bereich von 300 bis 800 g/m2 auf.As carpet back (secondary backing) 5, a further needle felt or a heavy layer is finally arranged below the needle felt 4 of bicomponent fibers. The carpet backing 5 is comparatively thick or heavy. It has a basis weight in the range of 300 to 800 g / m 2 .
Handelt es sich bei dem Teppichrücken 5 um eine Schwerschicht, zum Beispiel aus Füllstoff enthaltendem Elastomer, so wird diese nicht zusammen mit den anderen Materiallagen 1 bis 4 heißgeprägt, sondern in anderer Weise an die Kontur der zu verkleidenden Fahrzeugfläche bzw. des Teppichformteils angepasst und mit letzterer verbunden.If the back of the carpet 5 is a heavy layer, for example of filler-containing elastomer, then this is not hot-stamped together with the other layers of material 1 to 4, but adapted in another way to the contour of the vehicle surface to be covered or the carpet molding and with the latter connected.
Die Herstellung eines erfindungsgemäßen Teppichformteils wird nun weiter mit Bezug auf die Figuren 2A und 2B erläutert. Wie in Fig. 2A gezeigt, wird das textile Obermaterial 1 mit einem geeigneten Fluid, beispielsweise mit Wasser befeuchtet, bevor es mit den anderen Materiallagen 2 bis 4 bzw. 2 bis 5 als loser Stapel in eine Vorrichtung zum Heißprägen eingebracht wird.The production of a carpet molding according to the invention will now be further explained with reference to Figures 2A and 2B. As shown in Fig. 2A, the textile upper 1 is moistened with a suitable fluid, for example with water, before it with the other Material layers 2 to 4 or 2 to 5 is introduced as a loose stack in a device for hot stamping.
Die Befeuchtung der Platine 1 kann beispielsweise mittels einer mehrere Sprühdüsen aufweisen Vorrichtung 6 erfolgen. Durch die Befeuchtung wird während des Heißprägens eine übermäßige Erwärmung des textilen Obermaterials 1 verhindert. Eine übermäßige Erwärmung des textilen Obermaterials 1 kann Glanzeffekte verursachen, die das Erscheinungsbild des fertigen Teppichformteils beeinträchtigen. Die Befeuchtung bewirkt einen Dampfeffekt, der das textile Obermaterial 1 während des Heißprägens vor einer zu starken Erhitzung schützt. Aufgrund der Befeuchtung ist eine Reduzierung der für das Heißprägen erforderlichen Prozesszeit (Taktzeit) möglich.The moistening of the circuit board 1 can take place, for example, by means of a device 6 having a plurality of spray nozzles. By moistening excessive heating of the textile upper 1 is prevented during hot stamping. Excessive heating of the textile upper 1 may cause gloss effects that affect the appearance of the finished carpet molding. The moistening causes a steam effect, which protects the textile upper 1 during hot stamping from excessive heating. Due to the humidification, a reduction in the process time required for hot stamping (cycle time) is possible.
Die Umformungsvorrichtung weist beheizbare Formwerkzeuge 7, 8 auf, deren Heiztemperatur unabhängig voneinander einstellbar ist. Zu diesem Zweck können in dem Oberwerkzeug 7 und dem Unterwerkzeug 8 Heizkanäle 9 für ein Heizfluid ausgebildet sein. Alternativ können in den Formwerkzeugen 7, 8 auch elektrische Heizwiderstände oder dergleichen integriert sein.The forming device has heatable forming tools 7, 8, the heating temperature of which is adjustable independently of one another. For this purpose, heating channels 9 for a heating fluid may be formed in the upper tool 7 and the lower tool 8. Alternatively, electrical heating resistors or the like can also be integrated in the molds 7, 8.
Die Heiztemperaturen der heb- und senkbaren Formwerkzeuge 7, 8 liegen je nach der Beschaffenheit des verwendeten textilen Obermaterials 1, der Schmelztemperatur des Mantelmaterials der Bikomponetenfasern und der für das Heißprägen gewünschten Taktzeit im Bereich von 50 bis 1600C.The heating temperatures of the raised and lowered molds 7, 8 are depending on the nature of the textile upper 1 used, the melting temperature of the jacket material of the bicomponent fibers and the desired cycle time for the hot stamping in the range of 50 to 160 0 C.
Zur Erzielung kurzer Taktzeiten beim Warmumformen des Materialaufbaus bedarf es grundsätzlich einer relativ hohen Heißprägetemperatur. Um das textile Obermaterial 1 dennoch zu schonen, wird das Formwerkzeug 7 bzw. 8, welches dem textilen Obermaterial 1 zugewandt ist, mit einer um mindestens 100C geringeren Temperatur betrieben als das Formwerkzeug, welches dem Teppichrücken (Nadelvlies) 5 bzw. dem Nadelvlies 4 des mehrschichtigen Materialverbundes (ohne Schwerschicht) zugewandt ist.In order to achieve short cycle times during hot forming of the material structure, it generally requires a relatively high hot stamping temperature. To the textile upper 1 nonetheless, the molding tool 7 or 8, which faces the textile upper 1, is operated at a temperature which is at least 10 ° C. lower than the molding tool which forms the carpet back (needle felt) 5 or the needle felt 4 of the multilayer composite material ( without heavy layer).
Das dem textilen Obermaterial 1 zugewandte Formwerkzeug wird beispielsweise mit einer Temperatur unterhalb von 1000C betrieben, während die Temperatur des anderen Formwerkzeuges auf eine Temperatur im Bereich von 110 bis 1600C eingestellt wird.The textile upper 1 facing mold is operated for example at a temperature below 100 0 C, while the temperature of the other mold is set to a temperature in the range of 110 to 160 0 C.
Die Figuren 3A bis 3C zeigen eine Variante der Herstel¬ lung eines erfindungsgemäßen Teppichformteils, bei der Materiallagen gemäß Fig. 1 vor dem Heißprägen miteinander vernadelt werden. Die Bezugszeichen 10, 11 bezeichnen heb- und senkbare Nadelbalken einer Vernadelungs- vorrichtung. Eine Vernadelung der Materiallagen 1 bis 5 kann allerdings auch entfallen, wie im Ausführungs¬ beispiel gemäß den Figuren 2A und 2B gezeigt ist.FIGS. 3A to 3C show a variant of the production of a carpet molding according to the invention, in which material layers according to FIG. 1 are needled together prior to hot embossing. Reference numerals 10, 11 designate raised and lowered needle bars of a needling device. However, a needling of the material layers 1 to 5 can also be dispensed with, as shown in the embodiment according to FIGS. 2A and 2B.
In der Zeichnung ist das Oberwerkzeug der Heißpräge¬ vorrichtung dem textilen Obermaterial 1 zugewandt. Vorzugsweise erfolgt die Herstellung des erfindungs¬ gemäßen Teppichformteils aber in der Weise, dass das Unterwerkzeug der Heißprägevorrichtung dem textilen Obermaterial 1 zugewandt ist. Hierdurch kann ein Einsickern von Wasser oder einem anderen Befeuchtungs- fluid aus dem befeuchteten Obermaterial 1 in die darunter angeordneten Materiallagen 2 bis 4 bzw. 2 bis 5 verhindert werden. In diesem Zusammenhang versteht sich, dass in den Figuren 2B und 3C das Oberwerkzeug 7 und das Unterwerkzeug 8 gegeneinander getauscht bzw. die Figuren 2B und 3C jeweils um 180° gedreht werden können, damit das dem textilen Obermaterial 1 zugeordnete Formwerkzeug dann das Unterwerkzeug ist.In the drawing, the upper tool of the Heißpräge¬ device facing the textile upper 1. Preferably, however, the production of the inventive carpet molding takes place in such a way that the lower tool of the hot stamping device faces the textile upper 1. In this way, infiltration of water or another moistening fluid from the moistened upper material 1 into the material layers 2 to 4 or 2 to 5 arranged thereunder can be prevented. In this context, it is understood that in the figures 2B and 3C, the upper tool 7 and the lower tool 8 exchanged with each other or the figures 2B and 3C can be rotated in each case by 180 °, so that the molding material associated with the textile upper 1 is then the lower tool.
Im Gegensatz zu herkömmlichen Teppichformteilen wird bei der Herstellung des erfindungsgemäßen Teppichformteils kein zusätzlicher Kleber in Pulverform oder in Form einer Klebefolie verwendet. Die Einbindung des Flors des texti¬ len Obermaterials 1 und dessen Verbindung mit dem Nadel- vlies 3 aus Chemie- und/oder Naturfasern erfolgt aus¬ schließlich durch das beim Heißprägen geschmolzene Man¬ telmaterial der Bikomponentenfasern des Nadelvlieses 2. In contrast to conventional carpet shaped parts, no additional adhesive in powder form or in the form of an adhesive film is used in the production of the carpet molding according to the invention. The incorporation of the pile of the textile upper 1 and its connection with the needle fleece 3 made of chemical and / or natural fibers takes place exclusively by the mantle material of the bicomponent fibers of the needle felt 2, which is melted during hot stamping.

Claims

P A T E N T A N S P R Ü C H E PATENT APPLICATIONS
1. Akustisch wirksames Teppichformteil für Kraftfahrzeuge, insbesondere als einstückige Bodenverkleidung eines Fahrgastraumes, mit einem textilen Obermaterial (1) , das über einen mehrschichtigen Materialverbund (2 - 4) mit einem Teppichrücken (5) verbunden ist, d a d u r c h g e k e n n z e i c h n e t, dass der zwischen Obermaterial und Teppichrücken angeordnete Materialverbund aus einem mit dem Obermaterial verbundenen ersten Nadelvlies (2) aus Bikomponenten-Schmelzklebefasern, einem darauf folgenden zweiten Nadelvlies (3) aus Einkomponentenfasern und einem darauf folgenden dritten Nadelvlies (4) aus Bikomponenten-Schmelz¬ klebefasern gebildet ist.1. Acoustically effective carpet molding for motor vehicles, in particular as a one-piece floor covering a passenger compartment, with a textile upper (1), which is connected via a multilayer composite material (2-4) with a carpet back (5), characterized in that between the upper and carpet back arranged composite material of a connected to the upper first needle felt (2) of bicomponent melt adhesive fibers, a subsequent second needle felt (3) consists of Einkomponentenfasern and a subsequent third needle felt (4) of bicomponent Schmelz¬ adhesive fibers is formed.
2. Teppichformteil nach Anspruch 1, d a d u r c h g e k e n n z e i c h n e t, dass das erste Nadelvlies (2) und das dritte Nadelvlies2. Carpet molding according to claim 1, d a d e r c h e c e n e s in that the first needle felt (2) and the third needle felt
(4) jeweils aus mindestens 85 Vol.-% Bikomponenten- Schmelzklebefasern gebildet sind.(4) are each formed from at least 85 vol .-% bicomponent melt adhesive fibers.
3. Teppichformteil nach Anspruch 1 oder 2, d a d u r c h g e k e n n z e i c h n e t, dass das erste Nadelvlies (2) und das dritte Nadelvlies (4) jeweils ein Flächengewicht von weniger als 200 g/m2, insbesondere weniger als 150 g/m2 aufweisen. 3. carpet molding according to claim 1 or 2, characterized in that the first needle felt (2) and the third needle felt (4) each have a basis weight of less than 200 g / m 2 , in particular less than 150 g / m 2 .
4. Teppichformteil nach einem der Ansprüche 1 bis 3, d a d u r c h g e k e n n z e i c h n e t, dass die Bikomponenten-Schmelzklebefasern vom Typ Kern- Mantelfasern sind, wobei der Kern aus Polyester und der Mantel aus Polyester mit einem Schmelzpunkt unterhalb des Schmelzpunktes des Kerns gebildet sind.4. A carpet molding according to any one of claims 1 to 3, wherein the bicomponent melt adhesive fibers are of the type core sheath fibers, the core being polyester and the sheath being polyester having a melting point below the melting point of the core.
5. Teppichformteil nach einem der Ansprüche 1 bis 4, d a d u r c h g e k e n n z e i c h n e t, dass die Bikomponenten-Schmelzklebefasern eine Länge im Bereich von 30 bis 90 mm aufweisen.5. Carpet molding according to one of claims 1 to 4, d a d e r c h e c e n e s in that the bicomponent melt adhesive fibers have a length in the range of 30 to 90 mm.
6. Teppichformteil nach einem der Ansprüche 1 bis 5, d a d u r c h g e k e n n z e i c h n e t, dass das zweite Nadelvlies (3) bei einer Faserfeinheit im Bereich von 3 bis 7 dtex ein Flächengewicht im Bereich von 300 bis 700 g/m2 aufweist.6. carpet molding according to one of claims 1 to 5, characterized in that the second needle felt (3) at a fiber fineness in the range of 3 to 7 dtex has a basis weight in the range of 300 to 700 g / m 2 .
7. Teppichformteil nach einem der Ansprüche 1 bis 6, d a d u r c h g e k e n n z e i c h n e t, dass das zweite Nadelvlies (3) aus Polyesterfasern gebildet ist.7. Carpet molding according to any one of claims 1 to 6, d a d e r c h e c e n e s in that the second needle felt (3) is formed from polyester fibers.
8. Teppichformteil nach einem der Ansprüche 1 bis 7, d a d u r c h g e k e n n z e i c h n e t, dass der Teppichrücken (5) aus einem Nadelvlies oder einer Schwerschicht gebildet ist. 8. carpet molding according to one of claims 1 to 7, characterized in that the carpet backing (5) is formed of a needle felt or a heavy layer.
9. Teppichformteil nach einem der Ansprüche 1 bis 8, d a d u r c h g e k e n n z e i c h n e t, dass der Teppichrücken (5) ein Flächengewicht von 300 bis 800 g/m2 aufweist.9. Carpet molding according to one of claims 1 to 8, characterized in that the backing (5) has a basis weight of 300 to 800 g / m 2 .
10. Teppichformteil nach einem der Ansprüche 1 bis 9, d a d u r c h g e k e n n z e i c h n e t, dass das textile Obermaterial (1) aus einer Tuftingware besteht .10. Carpet molding according to one of claims 1 to 9, d a d e r c h e c e n e s in that the textile upper material (1) consists of a tufted goods.
11. Verfahren zur Herstellung eines Teppichformteils gemäß Anspruch 1, bei dem das textile Obermaterial11. A method for producing a carpet molding according to claim 1, wherein the textile upper material
(1) und der mehrschichtige Materialverbund (2 - 4) mit dem oder ohne den Teppichrücken (5) in einer beheizten Umformungsvorrichtung heißgeprägt werden, d a d u r c h g e k e n n z e i c h n e t, dass das textile Obermaterial (1) vor dem Heißprägen befeuchtet wird.(1) and the multilayer composite material (2-4) are hot-stamped with or without the backing (5) in a heated forming apparatus, that the textile upper (1) is moistened prior to hot stamping.
12. Verfahren nach Anspruch 11, d a d u r c h g e k e n n z e i c h n e t, dass zum Heißprägen eine Umformungsvorrichtung verwendet wird, die beheizbare Formwerkzeuge (7, 8) aufweist, deren Temperatur unabhängig voneinander einstellbar ist, und dass das Formwerkzeug, welches dem textilen Obermaterial (1) zugewandt ist, mit einer um mindestens 100C geringeren Temperatur betrieben wird als das Formwerkzeug, welches dem mehrschichtigen Materialverbund (2 - 4) oder dem Teppichrücken (5) zugewandt ist. 12. The method according to claim 11, characterized in that for hot stamping a forming device is used, the heatable molding tools (7, 8), whose temperature is independently adjustable, and that the mold, which is the textile upper material (1) facing, with a temperature is operated by at least 10 0 C lower than the mold, which faces the multilayer composite material (2-4) or the back of the carpet (5).
13. Verfahren nach Anspruch 11 oder 12, d a d u r c h g e k e n n z e i c h n e t, dass der mehrschichtige Materialverbund (2 - 4) vor dem Heißprägen mit dem textilen Obermaterial (1) vernadelt wird.13. Method according to claim 11 or 12, characterized in that the multilayer material composite (2 - 4) is needled with the textile outer material (1) before the hot embossing.
14. Verfahren nach Anspruch 11 oder 12, d a d u r c h g e k e n n z e i c h n e t, dass das textile Obermaterial (1) und der mehrschichtige Materialverbund (2 - 4) als loser Stapel in die Umformungsvorrichtung eingebracht werden. 14. Method according to claim 11 or 12, characterized in that the textile upper material (1) and the multilayer material composite (2-4) are introduced as a loose stack into the conversion device.
EP05808195A 2004-11-09 2005-11-08 Moulded carpet part with an acoustic function for motor vehicles and method for producing the same Withdrawn EP1809510A1 (en)

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DE200410054299 DE102004054299A1 (en) 2004-11-09 2004-11-09 Acoustically effective carpet molding for motor vehicles and method for its production
PCT/EP2005/011901 WO2006050893A1 (en) 2004-11-09 2005-11-08 Moulded carpet part with an acoustic function for motor vehicles and method for producing the same

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