EP3347515B1 - Verfahren zur herstellung einer innenverkleidung insbesondere als bodenbelag für ein fahrzeug - Google Patents

Verfahren zur herstellung einer innenverkleidung insbesondere als bodenbelag für ein fahrzeug Download PDF

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Publication number
EP3347515B1
EP3347515B1 EP16758186.7A EP16758186A EP3347515B1 EP 3347515 B1 EP3347515 B1 EP 3347515B1 EP 16758186 A EP16758186 A EP 16758186A EP 3347515 B1 EP3347515 B1 EP 3347515B1
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EP
European Patent Office
Prior art keywords
fibers
batt
manufacturing
brushes
undulations
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Application number
EP16758186.7A
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English (en)
French (fr)
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EP3347515A1 (de
Inventor
Xavier Bathelier
Daniel BAUDET
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Adler Pelzer France Grand Est SAS
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Faurecia Automotive Industrie SAS
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Priority to PL16758186T priority Critical patent/PL3347515T3/pl
Publication of EP3347515A1 publication Critical patent/EP3347515A1/de
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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—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
    • D04H1/44—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
    • 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
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/74—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel (anisotropic fleeces)
    • 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
    • D04H11/00—Non-woven pile fabrics
    • D04H11/08—Non-woven pile fabrics formed by creation of a pile on at least one surface of a non-woven fabric without addition of pile-forming material, e.g. by needling, by differential shrinking
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
    • D04H3/105—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by needling

Definitions

  • the present invention relates to a method for manufacturing an interior covering, in particular a floor covering for a motor vehicle, of the nonwoven type, that is to say in an integrated manner directly from fibers.
  • the present invention also relates to a device for manufacturing this coating, and to a coating produced by this method.
  • the special feature of such a needling machine is to include conveyors covered with brushes which are used to form a homogeneous pile. To this end, needles of the needling machine entrain fibers of a sheet deposited on the conveyor through the bristles of the brushes.
  • EP 2,050,850 describes the use of a Dilour® machine comprising two needling heads working on a common conveyor to produce a velvet-type covering thanks to the association of two plies.
  • This type of process even if it leads to an improvement in the appearance of the products compared to a process based on a Dilour® machine equipped with a single head, does not make it possible to obtain sufficiently dense pile which can compete with velvets produced by processes using threads such as, for example, tufted type velvets (better known under the English name of "tuft”) also used in the automotive field. It should however be noted that a tufted type velvet is much more expensive than a Dilour® needled type product, so that it is usually reserved for high-end vehicles.
  • Each fiber is oriented in a direction forming an angle ⁇ with the machine direction, this angle ⁇ being given by a relationship between the distance between disks and the height of the undulations desired. If this angular value is respected, the fibers will be perfectly parallelized in the undulations and the forces generated in the device which are low, which preserves the integrity of the fibers.
  • corrugations are then deposited on a substrate, for example a glass fiber mat previously coated with an adhesive, for example a plastisol. After passing through an oven, the plastisol gels and traps the fibers constituting the base of the corrugations.
  • a substrate for example a glass fiber mat previously coated with an adhesive, for example a plastisol.
  • This process which allows very high velvet densities comparable to or even greater than tufted velvet, is for example used to produce a velvet type covering for applications in the home essentially as a floor covering, in particular by subsequently performing a step mowing or "splitting" of the structure made up of wavy fibers.
  • the adhesive layer used must be thick to ensure the trapping of the base of the corrugations over its entire thickness, which strongly impacts the mass and the cost of the product.
  • This process also has the disadvantage of requiring the association on the same production line of purely textile equipment (carding line, coating) and coating devices, therefore the creation of a specific production line.
  • textile and chemical resources are usually separated to avoid any pollution problem.
  • the object of the invention is in particular to remedy the drawbacks of the methods previously described in the state of the art, by proposing an integrated method for manufacturing a velvet-type covering in particular for a motor vehicle, therefore perfectly formable, allowing achieve high velvet densities that can be part of an existing textile coverings production line.
  • the subject of the invention is in particular a method of manufacturing a coating, according to claim 1.
  • the invention provides for temporarily blocking the structure constituted by the ripples of densified fibers inside the brushes of the conveyor of a Dilour machine, that is to say say by a purely mechanical trapping and therefore without the need to use an adhesive.
  • the invention then allows the undulations to penetrate deeper inside the brushes to possibly the depth corresponding to the height of the velvet desired for the finished product.
  • a second nonwoven ply which may for example be a ply previously needled on a conventional needling group or of the “spunbond” type (based on continuous filaments), by needling on the same brushes of the conveyor, using the needling head of the Dilour® machine, it is then possible to produce a covering having a velvet (essentially constituted by the undulations coming from a device similar to that of EP 0 859 077 ) with a chosen density and a cohesive and formable backing essentially constituted by the second nonwoven web.
  • the velvet as such is generated by the subsequent mowing of the undulations.
  • the inventors have found that the orientation of the fibers of the sheet, prior to the passage of this sheet in the looping device, has an important role in the final appearance obtained for the coating.
  • the width and the height of the corrugations are predefined, the width depending on the interval between two adjacent rotating disks, and the height depending in particular on this interval and on the initial length of the fibers.
  • the optimal angle of orientation of the fibers is determined thanks to the relationship established by the inventors.
  • the fiber orientation step is therefore carried out to orient the fibers in accordance with this optimal angle.
  • the invention also relates to a manufacturing device according to claim 8.
  • the invention relates to a covering, in particular a floor covering for a motor vehicle, characterized in that it comprises a facing layer of fibers which are not linked and parallel to each other, and a backing layer forming a sole formed essentially of fibers. bonded together, the place layer having a velvet exterior appearance consisting of fibers in the form of loops or individual fibers, the density of velvet in the place layer being between 0.05 and 0.1 g / cm 3 .
  • the coating 12 is shown in more detail on the figure 2 .
  • This coating 12 forms, for example, an interior coating, and more particularly an interior coating of a motor vehicle, intended to be placed on the ground or on a wall of the vehicle.
  • the coating 12 can form any conceivable interior coating.
  • the covering 12 has a face layer 14 of fibers 15 which are not linked and parallel to each other, and a backing layer 16 forming a sole formed essentially of fibers 17 linked together.
  • the fibers 15 and 17 are for example made from a thermoplastic polymer, such as polypropylene, polyethylene terephthalate (PET), polyamide, polylactic acid, their mixtures or their copolymers.
  • a thermoplastic polymer such as polypropylene, polyethylene terephthalate (PET), polyamide, polylactic acid, their mixtures or their copolymers.
  • PET polyethylene terephthalate
  • the fibers 15 and 17 can be fibers of natural origin such as flax or hemp fibers used alone or in mixtures.
  • the fibers 15 and 17 can be of different natures.
  • the fibers 15 may be based on polyamide while the fibers 17 will be based on PET.
  • the layers 14 and 16 can be formed from a mixture comprising a percentage of binder fibers, that is to say for example two-component fibers, one of the components of which has a lower melting point than the other.
  • the face layer 14 has a velvet exterior appearance. This velvet consists of fibers 15 in the form of loops or individual fibers (mowed loops).
  • the thickness of the face layer 14 is generally greater than that of the sole 16.
  • the face layer 14 has for example a thickness of between 2 and 8 mm.
  • the density of pile in the place layer 14 is preferably between 0.05 and 0.1 g / cm 3 , for example between 0.07 and 0.08 g / cm 3 . Such a density ensures a good appearance, good resistance to abrasion and ease of cleaning.
  • This density is measured for example by determining the ratio between the mass of the material obtained by shaving the entire place layer 14 up to the sole 16, relative to the initial volume of the shaved layer.
  • the yield of the pile consisting of the ratio of the weight of pile after total shaving to the sole relative to the total weight of the piece 12, is for example between 50 and 80%
  • the length of the fibers used is generally between 40 to and 90 mm.
  • the titer of the fibers is preferably between 4 and 17 dtex.
  • the crimping of the fibers is preferably between 2.5 and 4 undulations per cm.
  • the manufacturing device 10 comprises a carding device followed by a coating device 18 (known by the name of spreader-lapper) with interlacing of fibers, suitable for producing a layer of fibers.
  • a coating device 18 known by the name of spreader-lapper
  • the carding operation is carried out in a conventional manner and makes it possible to obtain a veil with a surface mass of between 40 and 120 g / m 2 .
  • a veil is formed by individualized fibers mainly oriented in a longitudinal direction, corresponding to a production direction (machine direction).
  • machine direction a production direction
  • these fibers overlapping slightly due to their crimping, it is accepted that the average angle relative to the longitudinal direction of this type of veil is between 5 and 10 ° (We resonate here by positioning our in a half plane relative to to the axis of the longitudinal direction, because the fibers are positioned symmetrically with respect to this axis).
  • this value unless otherwise specified, is close to 0 °.
  • the lapping device 18 is of the conventional type, and will therefore not be described in more detail.
  • the particularity of the use of this device in the context of the invention is that only one fold is produced, so that the fibers 15 intersected by the spreader-lapper extend parallel to a direction forming an average angle ⁇ of about 60 ° with the longitudinal direction X, in the case obviously where the lapping width corresponds to the carding width.
  • the ply at this stage of the process therefore consists of two superimposed webs having their fibers mainly oriented with an average angle ⁇ of 60 ° symmetrically with respect to the longitudinal axis X materializing the machine direction.
  • the manufacturing device 10 comprises, following the lapping device 18, a device 22 for orienting the fibers 15 of the fiber sheet 20.
  • This orienting device 22 can be arranged at the outlet of the lapping device 18, or alternatively be placed at a distance, in which case the sheet of fibers 20 is moved from the covering device 18 to the orientation device 22.
  • the orientation device 22 is capable of modifying the orientation of the fibers, initially oriented with the mean entry angle ⁇ , in order to parallel them to a general direction A, B forming a predetermined mean angle ⁇ with the longitudinal direction X.
  • the fibers being intertwined, some are aligned parallel to a first general direction A forming an angle ⁇ with the longitudinal direction X in a clockwise direction, and others are aligned parallel to a second general direction B forming an angle ⁇ with the longitudinal direction X in a trigonometric direction.
  • the orientation device 22 shown in more detail on the figures 4 and 5 , is for example a device for drawing the sheet of fibers 20, the fibers of which are intertwined.
  • This drawing device 22 comprising a first set 24 of upstream drive cylinders, and a second set 26 of downstream drive cylinders.
  • Each set 24, 26 has two complementary cylinders between which passes the ply 20, in contact with these two cylinders. The driving in rotation of the cylinders of each assembly 24, 26 therefore allows the ply 20 to be driven along the longitudinal direction X.
  • This device 22 is strictly speaking an orientation device and not a drawing device, although the ply sees its surface mass reduce between the two sets of cylinders, because its role is to rotate the fibers one by one. relative to each other (their point of intersection serving as a pivot point) and not to stretch the web by sliding the fibers parallel to each other as in a conventional textile stretching device. Therefore we try to position the two sets of cylinders as close as possible.
  • L is the length of the fiber 15 the distance between the nip lines of the two sets of cylinders will be slightly greater than L.cos ⁇ .
  • the downstream drive rolls of the second set 26 are movable in rotation with a higher speed of rotation than that of the upstream drive rolls of the first set 24, so that the sheet of fibers 20 is not driven with the same speed over its entire length. This sheet of fibers 20, passing between the cylinders of each assembly 24, 26, is then stretched due to this difference in speed.
  • This stretching makes it possible to align the fibers 15 of the ply 20 parallel to the desired general directions A and B.
  • V e peripheral speed of the input cylinders and P e the surface mass of the ply engaging between the input cylinders
  • V s peripheral speed of the output cylinders
  • Ps surface mass of the ply s' engaging between the input cylinders.
  • the average angle of the fibers relative to the longitudinal direction X of the outlet ply will be noted ⁇ .
  • Lv Ln (for example in the case of a card 2.5m wide for a covering of 2.5m corresponding to the width of the finished product) which will generally be the case, ⁇ 60 °.
  • the manufacturing device 10 comprises, at the output of the orientation device 22, a known looping device 28, for example in part similar to that described in EP 0 859 077 .
  • a looping device 28 is intended to loop the fibers 15 of the ply 20 by verticalizing them, thus forming undulations.
  • This looping device 28 comprises a set of rotating discs 30 carried on a common transverse axis, driven in continuous rotation at a peripheral speed preferably equal to the speed of entry of the web 20 into this looping device 28.
  • the rotating disks 30 are preferably each provided with a toothing on its periphery enabling the web of fibers 20 to be driven.
  • the looping device 28 also includes looping fingers 32, each being disposed between two adjacent discs 30.
  • the looper fingers 32 extend to one end which is substantially tangentially relative to the discs 30.
  • each fiber 15 is found pre-looped by being driven at each end by a respective disc 30, overcoming the looper finger 32 correspondent disposed between these two discs 30.
  • the path of a fiber 15 between two adjacent discs 30 is shown schematically on the figure 6 .
  • the fiber 15 has an angle ⁇ with the longitudinal direction X, which is also the direction of advance of the web 20 in the looping device 28.
  • a front part of the fiber 15 is driven by one of the discs 30, and a rear part of this fiber 15 is driven by the other disc 30.
  • These two discs being integral with the same axis, their rotational speeds are identical.
  • the front part of the fiber 15 arrives first at the end of the travel, against a stop which will be described later. While the front part is in abutment, the rear part continues to advance until it also comes into abutment, thus bending the fiber 15 which then forms a loop.
  • the fibers 15 passing through the looping device 28 all have the same behavior as described above, so that all of the looped fibers 15 form undulations over the width of the ply 20, taken in a transverse direction perpendicular to the longitudinal direction X.
  • Each loop has a height H, taken in an elevation direction perpendicular to the longitudinal direction and to the transverse direction, and a width G taken in the transverse direction as shown in the figure 7 . It should be noted that the width G corresponds substantially to the interval between two adjacent discs 30.
  • the discs are positioned so that they penetrate a depth P ⁇ H inside the brushes of a band 33 of the same type as the brushes fitted to the conveyor of a Dilour® machine.
  • the bristles constituting the brushes are flexible enough to move apart and gather in the free space between the discs.
  • this penetration depth P can correspond exactly to H, looping height.
  • the abovementioned abutment is therefore formed of a band 33 of a conveyor 34.
  • the band 33 is an endless band, extending between two drive cylinders.
  • the strip 33 is provided with brushes.
  • the strip 33 is moved, in the longitudinal direction X, with a speed lower than the tangential speed of the rotating discs 30, so that they have the effect of a stop for the fibers 15 leaving these rotating discs 30.
  • the undulations then accumulate on the brushes of the strip 33, with a density depending on the speed difference between the rotating discs 30 and the strip 33.
  • a person skilled in the art will be able to determine this speed difference as a function of the density desired.
  • This device makes it possible to obtain a high density of velvet, which is generally not attainable by conventional methods.
  • the brushes also prevent the fibers 15 from being driven upwards by the discs 30, which would harm the formation of the corrugations.
  • the manufacturing device 10 then comprises a device 36 for depositing a reinforcing ply 38 on the corrugations accumulated on the brushes.
  • the reinforcement ply 38 is generally formed by fibers 17, for example of the same kind as those of the ply 20.
  • the structure formed by the stack of corrugated fibers 15 and of this reinforcing ply 38 is then intended to pass under a needling device 40 or needling head, comprising at least one board of needles 41.
  • the assembly formed by the conveyor 34 with brushes and the needle boards is known per se, and for example formed by a machine of the Dilour® type.
  • the needle board 41 is disposed opposite the band 33 of the conveyor 34, and it can be deployed vertically towards this band 33 to pierce said structure.
  • the needle board 41 carries a plurality of needles, allowing a needling density of the order of 200 to 400 cps / cm 2 .
  • This needle board 41 makes it possible to secure the reinforcing ply 38 to the structure formed by the corrugations, that is to say the ply 20 deposited totally or partially inside the brushes, by extracting fibers from the ply 38 and by making them penetrate the sheet 20.
  • the depth of penetration of the fibers of the ply 38 into the ply 20 allowing this assembly of the ply 38 on the ply 20 can be variable, starting from a low value of the order of 0.5 to 1 mm up to the penetration depth P, in which case the fibers of the ply 20 will also contribute to nourishing the pile of the ply 20.
  • This penetration depth which can therefore vary from 0.5 mm to H will be determined by the type of needles fitted to the head needling of the Dilour® machine, and the nature of the web 38.
  • the face layer 14 is formed, as well as the sole 16, by intermingling the fibers 15 with the fibers 17 of the reinforcing ply 38.
  • the device 10 then comprises a device for tying the fibers of the place layer 14 in the sole 16.
  • This tying device 42 is for example a heat-fixing device, in particular a through-air oven or an infrared oven.
  • the binding can be carried out in any conceivable way, for example by incorporating a latex in the reinforcement ply 38, or between the reinforcement ply 38 and the fiber ply 20, or by incorporating hot-melt binder fibers among the fibers of the ply of fibers 20 and / or in the reinforcing ply 38. Binder fibers are generally preferred to latex, for reasons of recyclability. This binding, necessary for all needle type constructions to ensure sufficient cohesion of the pile fibers with the sole and to avoid tearing or abrasion problems, is carried out in a conventional manner and will therefore not be described in more detail.
  • the device 10 then includes a device 44 for mowing the top of the accumulated undulations of the structure, thereby forming a pile of vertical fibers. Due to the verticalization of the undulations in the looping device 28 and the perfect parallelism of the fibers resulting therefrom, the shorn fibers all have the same height, so that the appearance of the pile is optimized. It should be noted that scraps of shorn fibers can be recycled later.
  • the device 10 comprises a device 46 for winding the covering 12 formed, for handling.
  • the orientation of the fibers along this angle ⁇ is implemented by the configuration of the orientation device 22.
  • ⁇ f (G, H), as a function of the width G and the height H of the undulations.
  • the device according to the invention makes it possible to carry out a method of manufacturing a needled coating which will now be described according to a first embodiment.
  • the manufacturing process comprises a step 100 of producing a veil and then a sheet of fibers 20 comprising only a single ply, by coating with interlacing of the fibers.
  • the manufacturing process then comprises a step 110 of orienting the fibers 15 parallel to the first A or the second B in the general direction, each forming an angle ⁇ (clockwise or counterclockwise respectively) with the longitudinal direction X.
  • the method then comprises a step 120 of passing the sheet of fibers 20, along the longitudinal direction X, through the looping device 28, so as to generate corrugations having a length G predefined in the transverse direction, and a predefined height H in the direction of elevation.
  • the manufacturing process then comprises a step 130 of supplying the sheet of fibers 20 to the conveyor 34 equipped with brushes, and of accumulating undulations in the brushes so as to reach a predetermined density.
  • the conveyor 34 is arranged at the outlet of the discs 30, so that this feeding step 130 is carried out by the discs 30.
  • the discs penetrate into the brushes with a depth P equal to the height H.
  • the density of ripples depends on the speed difference between the discs 30 and the strip 33.
  • corrugated fibers thus accumulated are perfectly parallel to each other, so that the appearance of the covering 12 produced is optimal.
  • the method then includes a step 140 of depositing the reinforcing ply 38, preferably pre-needled, on the accumulated corrugations.
  • This reinforcing ply 38 is intended to form at least partially the sole 16.
  • the method then comprises a step 150 of needling the layer of fibers 20 through the brushes of the strip 33, to form the structure comprising the place layer 14 and the sole 16, in accordance with a conventional needling process.
  • this needling is carried out by a single needling head.
  • the needling head is preferably provided with “crown” type needles, that is to say needles having only one beard per edge situated at the same distance from the point. This type of needle is compatible with the use of brushes and allows effective interpenetration of the fibers of the ply 38 in the ply 20.
  • the needling head is not used here for the purpose of extracting fibers from the ply 20 to constitute a pile, which would be the operating logic of a Dilour® machine, but indeed in the aim to combine two tablecloths like a traditional needle loom.
  • Such a needling step 150 is advantageous for producing said structure, in particular in relation to the method described in EP 0 859 077 , in which the place layer is chemically bonded, in particular by gluing, to the sole. Indeed, a coating obtained by the process of EP 0 859 077 is therefore not thermoformable due to the presence of the adhesive, and is therefore not suitable for the production of motor vehicle floor coverings, which conventionally require such thermoforming.
  • the coating produced by the method according to the invention is thermoformable, therefore entirely suitable for the production of motor vehicle floor coverings.
  • the method then includes a step 160 of removing the structure thus formed from the conveyor 34.
  • the method then comprises a step 170 of blocking or bonding the fibers of the place layer 14 in the sole 16.
  • This blocking step 170 is carried out in the blocking device 42, by any conceivable means.
  • the method then comprises a step 180 of mowing the top of the accumulated undulations of the structure.
  • This step is optional, but a mowed covering is easier to clean than an uncut covering whose loops retain dirt.
  • the method finally comprises a step 190 of winding the covering 12 thus formed, with a view to its handling.
  • This second embodiment is identical to the first embodiment up to the feeding step 130. At this stage the position of the discs is adjusted so that the penetration P is less than the desired height H, for example either of l 1 to 2 mm.
  • This operating mode is suitable when the desired density is relatively high, generally above 0.05 g / cm 3 and / or when the fibers have a titer of less than 11 dtex. Indeed, in this case, the bulk caused by the accumulation of fibers between the brush bristles is such that the friction between fibers and discs increases considerably, which causes the entrainment of fibers accumulated by the discs, the brushes no longer able to play their role of abutment and of maintaining undulations.
  • the fibers must be penetrated into the brushes up to the penetration value H by a second device corresponding to an additional step of “penetration complementary ".
  • This second device comprises, for example, a second set of discs without toothing distant by a distance G between them and positioned exactly in the same vertical planes as the looping discs 30 and rotating at a peripheral speed close to the speed of the conveyor, or in variant comprises a comb fitted with “teeth” also spaced apart by a distance G, positioned in the exact extension of the discs, the comb being driven by an alternating movement.
  • the penetration P produced by this second device may remain less than H by a low value, for example 1 mm.
  • the material corresponding to this millimeter remaining above the brushes will participate in the sole and will reinforce the inking of the ply 20 in the sole.
  • This third embodiment is substantially identical to the second embodiment, insofar as corrugations of a height H are produced during the feeding step 130 for additional penetration P during said complementary penetration step in the brushes but here with H »P.
  • the deposition step 140 may prove to be useless.
  • the sole can be made up of the material corresponding to the 5mm which remains above the brushes without the need for the addition of additional material through a second ply 38.
  • the needling in this case will not allow the assembly of two tablecloths but the constitution of the sole in itself.
  • This third embodiment is particularly advantageous because it greatly simplifies the process and minimizes the investments (the spreader-lapper is no longer necessary, any more than an auxiliary needling line for the manufacture of the ply 38), the more it guarantees a perfect anchoring of the hairs constituting the velvet in the sole since the same fiber will participate in its entirety both in the velvet and in the sole. The abrasion performance of the coating will thus be greatly improved.
  • the surface mass of the sole (from the ply 38 or from the structure of the ply 20 itself) can be adapted independently of the surface mass of the velvet, this is unlike the product conventionally manufactured on a Dilour®.
  • the surface mass of this sole will be chosen to allow the thermoforming of the coating as a function of the required elongations (that is to say according to the more or less complex shape of the part of the vehicle to be covered) or generally between 100 and 200 g / m 2 which will lead to velvet yields as previously defined easily greater than 60% when they do not exceed 30% for a product of the classic Dilour® type.
  • detachers as described in EP 0 859 077 could be useful in particular to secure the operation and avoid any rise of fibers in the discs in the event of accidental "jamming".
  • the applications of this type of coating can extend to sectors other than the automobile, for example housing or rail transport, even in cases where formability is not required.
  • the invention makes it possible to produce a velvet covering having characteristics similar to those of a tufted covering, in particular in terms of velvet density, the process according to the invention being more economical than a conventional tufting process .

Claims (11)

  1. Verfahren zur Herstellung einer Verkleidung (12), insbesondere einer Boden-Verkleidung für ein Kraftfahrzeug, aufweisend:
    - einen Schritt (100) des Realisierens eines Tuchs (20) aus Fasern (15), das in einer Längsrichtung (X) langgestreckt ist, durch Überziehen mit einem Gewirr aus Fasern (15),
    - einen Schritt (120) des Passierens des Tuchs (20) aus Fasern entlang der Längsrichtung (X) durch eine Vorrichtung zur Verschlingung (28), die eine Einrichtung aus Drehscheiben (30) und feststehende Elemente zur Verschlingung (32) aufweist, wobei die Vorrichtung zur Verschlingung (28) die Fasern (15) verschlingt, unter Aufrichten derselben, dadurch Wellen ausbildend, und,
    - folgend dem Schritt des Passierens (120), einen Schritt (130) des Bringens des Tuchs (20) aus Fasern auf eine Fördervorrichtung (34), die mit Bürsten ausgestattet ist, und des Akkumulierens der Wellen in den Bürsten, um eine vorbestimmte Dichte zu erreichen,
    dadurch gekennzeichnet, dass die Wellen durch Schlingen gebildet sind, die eine vordefinierte Höhe H haben in einer Höhenrichtung senkrecht zur Längsrichtung (X), wobei das Verfahren aufweist einen Vorab-Schritt des Positionierens der Drehscheiben (30) derart, dass diese um eine Tiefe P≤H in das Innere der Bürsten eindringen.
  2. Verfahren zur Herstellung gemäß Anspruch 1, wobei die Wellen von Schlingen gebildet sind, die jeweils eine vordefinierte Weite G in einer Querrichtung senkrecht zu der Längsrichtung und eine vordefinierte Höhe H in einer Höhenrichtung senkrecht zu der Längsrichtung (X) und der Querrichtung haben, aufweisend, wobei das Verfahren zur Herstellung aufweist, vor dem Schritt des Passierens (120), einen Schritt (110) des Ausrichtens der Fasern (15) parallel zu einer Hauptrichtung (A, B), die einen Winkel α mit der Längsrichtung (X) bildet, der gegeben ist durch die Beziehung sina=G/2H mit +/-5° Ungenauigkeit, wobei der Schritt des Ausrichtens (110) z.B. realisiert wird durch Strecken des Tuchs (20) aus Fasern, dessen Fasern (15) verschlungen sind.
  3. Verfahren zur Herstellung gemäß Anspruch 1 oder 2, aufweisend, folgend dem Schritt des Bringens (130):
    - einen Schritt (150) des Nadelns des Tuchs (20) aus Fasern durch die Bürsten hindurch zum Bilden einer Struktur, die eine Ansicht-Schicht (14) und eine Sohle (16) aufweist,
    - einen Schritt (160) des Wegnehmens der Struktur von den Borsten und
    - einen Schritt (170) des Arretierens der Fasern (15) der Ansicht-Schicht (14) in der Sohle (16).
  4. Verfahren zur Herstellung gemäß Anspruch 3, wobei der Schritt (170) des Arretierens der Fasern (15) in der Sohle (16) realisiert wird mittels eines Latex oder Bindefasern.
  5. Verfahren zur Herstellung gemäß Anspruch 3 oder 4, aufweisend, nach dem Schritt des Arretierens (170), einen Schritt (180) des Scherens des Scheitels der akkumulierten Wellen der Struktur zum dadurch Bilden eines Velours.
  6. Verfahren zur Herstellung gemäß irgendeinem der Ansprüche 2 bis 5, aufweisend, vor dem Schritt des Nadelns (150), einen Schritt (140) des Aufbringens eines Verstärkungstuchs (38), bevorzugt vorgenadelt, auf die akkumulierten Wellen, wobei das Nadeln (150) dieses Verstärkungstuchs (38) mit den akkumulierten Wellen zusammenfügt, wobei dieses Verstärkungstuch (38) bestimmt ist zum wenigstens teilweise Bilden der Zunge (16) während des Schritts des Nadelns (150).
  7. Verfahren zur Herstellung gemäß irgendeinem der Ansprüche 2 bis 5, wobei das Tuch aus Fasern (20), das die Wellen aufweist, eine Höhe hat, die ausreicht, damit, wenn dieses Tuch aus Fasern (20) in den Bürsten angeordnet ist, ein Teil der Fasern 1 bis 10 mm über die Bürsten hinausragt, wobei die Fasern dieses Teils sich einander durchdringen während des Schritts des Nadelns (150) zum Verstärken der Zunge (16) oder Bilden der Zunge (16).
  8. Vorrichtung (10) zur Herstellung einer Verkleidung (12), insbesondere einer Bodenverkleidung für ein Kraftfahrzeug, aufweisend:
    - eine Vorrichtung (18) zum Überziehen mit einem Gewirr aus Fasern, die imstande ist, ein Tuch (20) aus Fasern (15) zu realisieren, welches in einer Längsrichtung (X) langgestreckt ist,
    - eine Vorrichtung (28) zur Verschlingung, die eine Einrichtung aus Drehscheiben (30) und feststehenden Elementen zur Verschlingung (32) aufweist und die imstande ist, das Tuch (20) aus Fasern in der Längsrichtung (X) zu nadeln, und imstande ist, Wellen zu erzeugen, und,
    - am Ausgang der Vorrichtung zur Verschlingung (28), eine Fördervorrichtung (34), die mit Bürsten (33) ausgestattet ist, dadurch gekennzeichnet, dass die Vorrichtung zur Verschlingung konfiguriert ist zum Erzeugen von Wellen, die von Schlingen gebildet sind, die eine vordefinierte Höhe H in einer Höhenrichtung senkrecht zur der Längsrichtung (X) haben, wobei die Drehscheiben (30) derart angeordnet sind, dass sie um eine Tiefe P≤H in das Innere der Bürsten eindringen.
  9. Vorrichtung zur Herstellung gemäß Anspruch 8, wobei die Vorrichtung zur Verschlingung (28) imstande ist, Wellen zu erzeugen, die von Schlingen gebildet sind, die jeweils eine vordefinierte Weite G in einer Richtung senkrecht zu der Längsrichtung (X) und eine vordefinierte Höhe H in einer Höhenrichtung senkrecht zu der Längsrichtung (X) und der Querrichtung haben, wobei die Vorrichtung zur Herstellung ferner aufweist eine Vorrichtung (22) zur Ausrichtung der Fasern (15) parallel zu einer Hauptrichtung (A, B), die einen Winkel α mit der Längsrichtung (X) bildet, der gegeben ist durch die Beziehung sina=G/2H mit +/-5° Ungenauigkeit.
  10. Vorrichtung zur Herstellung (10) gemäß Anspruch 9, wobei die Vorrichtung zur Ausrichtung (22) eine Vorrichtung zum Strecken des Tuchs (20) aus Fasern ist, dessen Fasern (15) verschlungen sind, insbesondere aufweisend eine erste (24) und eine zweite (26) Einrichtung aus Zylindern zum Antreiben des Tuchs (20), wobei die Zylinder zum Antreiben der ersten Einrichtung (24) drehbewegbar sind mit einer Geschwindigkeit, die verschieden ist zu jener der Zylinder zum Antreiben der zweiten Einrichtung (26), insbesondere mit einer kleineren Geschwindigkeit.
  11. Vorrichtung zur Herstellung (10) gemäß irgendeinem der Ansprüche 7 bis 9, aufweisend eine Vorrichtung zum Nadeln (40), die imstande ist das Tuch aus Fasern (20) durch die Bürsten hindurch zu Nadeln zum Bilden einer Struktur, die eine Ansichts-Schicht (14) und eine Sohle (16) aufweist.
EP16758186.7A 2015-09-10 2016-08-31 Verfahren zur herstellung einer innenverkleidung insbesondere als bodenbelag für ein fahrzeug Active EP3347515B1 (de)

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PL16758186T PL3347515T3 (pl) 2015-09-10 2016-08-31 Sposób wytwarzania wykładziny wewnętrznej, zwłaszcza wykładziny podłogowej dla pojazdu silnikowego

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FR1558413A FR3041001B1 (fr) 2015-09-10 2015-09-10 Procede de fabrication d'un revetement interieur, notamment d'un revetement de sol pour un vehicule automobile
PCT/EP2016/070508 WO2017042076A1 (fr) 2015-09-10 2016-08-31 Procédé de fabrication d'un revêtement intérieur, notamment d'un revêtement de sol pour un véhicule automobile

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EP3347515B1 true EP3347515B1 (de) 2020-02-26

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EP (1) EP3347515B1 (de)
CN (1) CN108026681B (de)
ES (1) ES2776237T3 (de)
FR (1) FR3041001B1 (de)
PL (1) PL3347515T3 (de)
WO (1) WO2017042076A1 (de)

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DE102017208200A1 (de) * 2017-05-16 2018-11-22 Adler Pelzer Holding Gmbh Teppich
FR3066769B1 (fr) * 2017-05-24 2020-04-03 Faurecia Automotive Industrie Dispositif perfectionne de fabrication d'un revetement interieur, notamment d'un revetement de sol pour un vehicule automobile
FR3067365B1 (fr) * 2017-06-07 2020-08-28 Faurecia Automotive Ind Dispositif de fabrication d’un revetement interieur, notamment pour un vehicule automobile, a haute densite de velours
FR3073232B1 (fr) * 2017-11-09 2019-11-29 Faurecia Automotive Industrie Procede de fabrication d'un revetement, notamment d'un revetement de sol pour vehicule automobile
FR3073530B1 (fr) * 2017-11-16 2019-11-29 Faurecia Automotive Industrie Procede de conception d'une installation pour fabrication d'un revetement, installation et procede de fabrication associes
FR3081886B1 (fr) * 2018-06-01 2020-08-28 Faurecia Automotive Ind Outillage destine a etre monte sur un arbre rotatif, procede de fabrication, dispositif de bouclage et dispositif de fabrication d'un revetement textile pour vehicule associes
FR3091713B1 (fr) 2019-01-16 2021-01-22 Faurecia Automotive Ind Dispositif d’étirage d’une nappe pour la fabrication d’un revêtement, notamment d’un revêtement textile pour véhicule automobile, ensemble d’étirage et procédé de fabrication d’un revêtement associé
FR3099440B1 (fr) 2019-07-31 2021-09-24 Faurecia Automotive Ind Pièce de fixation comprenant une structure fibreuse de fixation, ensemble et procédé associés
FR3100546B1 (fr) 2019-09-10 2021-09-17 Faurecia Automotive Ind Dispositif de fabrication de revêtement intérieur à motif pour véhicule automobile
FR3101645B1 (fr) 2019-10-03 2021-10-15 Faurecia Automotive Ind Procédé de fabrication d’un revêtement intérieur bicolore pour véhicule automobile
FR3107285B1 (fr) 2020-02-18 2022-12-02 Faurecia Automotive Ind Procédé de fabrication d’un revêtement à aspect amélioré, notamment d’un revêtement de sol de véhicule automobile
FR3112350B1 (fr) 2020-07-10 2022-09-23 Faurecia Automotive Ind Procédé de fabrication d’un revêtement intérieur à motif, notamment d’un revêtement de sol pour un véhicule automobile
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Publication number Publication date
FR3041001B1 (fr) 2017-10-13
PL3347515T3 (pl) 2020-08-24
FR3041001A1 (fr) 2017-03-17
ES2776237T3 (es) 2020-07-29
WO2017042076A1 (fr) 2017-03-16
US11168418B2 (en) 2021-11-09
CN108026681B (zh) 2021-04-09
US20180282919A1 (en) 2018-10-04
CN108026681A (zh) 2018-05-11
EP3347515A1 (de) 2018-07-18

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