EP4221973A1 - Vernadelte sandwich-vliesstruktur und verfahren zu dessen herstellung - Google Patents

Vernadelte sandwich-vliesstruktur und verfahren zu dessen herstellung

Info

Publication number
EP4221973A1
EP4221973A1 EP21773705.5A EP21773705A EP4221973A1 EP 4221973 A1 EP4221973 A1 EP 4221973A1 EP 21773705 A EP21773705 A EP 21773705A EP 4221973 A1 EP4221973 A1 EP 4221973A1
Authority
EP
European Patent Office
Prior art keywords
fibers
fleece
core
needled
sandwich
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.)
Pending
Application number
EP21773705.5A
Other languages
English (en)
French (fr)
Inventor
Siegfried Bernhardt
Volkmar Schulze
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.)
Adler Pelzer Holding GmbH
Original Assignee
Adler Pelzer Holding 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 Adler Pelzer Holding GmbH filed Critical Adler Pelzer Holding GmbH
Publication of EP4221973A1 publication Critical patent/EP4221973A1/de
Pending legal-status Critical Current

Links

Classifications

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    • 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 shape; Layered products comprising a layer 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 shape; Layered products comprising a layer 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
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer 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 an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
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    • 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
    • D04H1/498—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 entanglement of layered webs
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    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
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    • 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
    • B32B5/265—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 characterised by one fibrous or filamentary layer being a non-woven fabric layer
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    • B32B7/04—Interconnection of layers
    • B32B7/08—Interconnection of layers by mechanical means
    • B32B7/09—Interconnection of layers by mechanical means by stitching, needling or sewing
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    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
    • G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
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    • 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
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/582—Tearability
    • B32B2307/5825—Tear resistant
    • 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
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
    • D10B2321/022—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins polypropylene
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]

Definitions

  • the invention relates to needled sandwich material structures in which a nonwoven core with vertically oriented fibers is used; and a method of making these sandwiched material structures.
  • DE 10 2016 203 348 A1 reports on multi-layer acoustic and/or stiffening nonwovens. Also in the still unpublished DE 10 2019 104 847 A1 there is information on needling grit into needle fleece structures. The as yet unpublished DE 10 2019 104 851 A1 discloses devices for sprinkling grit into needle fleece structures.
  • the fiber layer material which can be used in particular as artificial leather and is formed from two types of fiber layers arranged one on top of the other, which differ in terms of the arrangement of the fibers that make them up.
  • the fiber layer material is made up of a first layer made up of fibers (short fiber layer), the fibers of which predominantly run in the direction of the layer thickness, and one or more second fiber layers, the fibers of which predominantly run in the surface direction. Both fiber layers are placed on top of one another in the manner of a laminate and connected to one another, with the fibers located in the surface area of the first fiber layer penetrating into the fiber structure of the second fiber layer.
  • the fibrous sheet material may preferably contain a high polymer elastic substance.
  • the short-fiber layer the fibers of which are mainly in the direction of the layer thickness is produced by cutting a sliver produced in the Rando-Webbers or a cross-laying machine into successive fiber pieces in the thickness direction in a cutting station; and the fiber pieces are then rotated through 90° in a rotating station. After that, slivers are fed in on both sides, and the layer structure is pressed and needled. Furthermore, the composite is cut in the middle of the short-fiber layer and then impregnated with a high-polymer elastic material and subjected to a buffing process. The fibers used have an island-like structure. After impregnation, the layered composite is treated with a solvent to remove the embedding component and dried. Thus, an artificial leather-like fiber layer material is finally obtained.
  • WO 02/20889 A2 WO 2005/081226 A1, WO 2009/140713 A1 and WO 2010/042993 A1 generally describe absorber material structures with vertical fiber orientation and their production. Vertical fiber orientations are also used as inserts, in particular for seats/seat cushions, see for example WO 2012/019752 A1 and WO 2020/072412 A1.
  • the object of the present invention compared to the aforementioned prior art is therefore to provide microperforated needled sandwich nonwoven structures made of a core nonwoven with vertical fiber orientation, in which grit is applied between the vertically oriented fibers due to the application and/or properties and this core nonwoven is integrated or is needled on both sides with fleece, woven fabrics, knitted fabrics, paper or foil.
  • the object of the invention is to provide a method for the in-line production of such nonwoven structures.
  • a microperforated needled sandwich fleece structure 1 with a core fleece 2 with vertical fiber orientation, comprising PET and/or PET/PP fibers and binding fibers made of PE, PP and/or BiCo fibers (coPET) , wherein the core fleece 2 is provided with cover materials 3a, 3b on one or both sides, characterized in that the area between the vertically oriented fibers of the core fleece 2 contains interspersed identical or different filling materials 4 made of ground material, fibers, flakes and/or powder, with the cover materials 3a, 3b being identical or different and each independently of one another being a fleece, woven fabric or knitted fabric , paper or foil.
  • a mechanically or aerodynamically produced fleece 6 is fed to the vertical layer 7 and the fibers are straightened at an angle of about 90° to 45°.
  • the thus “vertical” fibers are fed in-line to a scattering device 8 which adds to the fibers filler materials 4 held between the aforesaid fibers.
  • the preform thus obtained is then fed to an oven 9 in which the structure is thermoconsolidated.
  • the composite thus obtained is then provided with a cover material 3a, 3b on one or both sides.In the subsequent needling unit 10, the overall composite is then needled to form the finished end product 1.
  • FIG. 1 A variant of the device according to FIG. 1 is shown in FIG.
  • the web obtained from the vertical layer 7 is fed to a pair of rollers 11 after passing through the spreading device 8 and is correspondingly compressed and spread.
  • FIG. 3 a variant of the method is described in FIG. 3, which comprises two pairs of rollers 12, 13, the pair of rollers 12 being arranged upstream of the spreading device 8 and the pair of rollers 13 being arranged downstream of the spreading device.
  • nonwoven structures are known from the prior art which, based on mechanical or aerodynamic nonwoven formation, have a vertical fiber orientation with needled cover nonwovens, foils or papers on one or both sides. Furthermore, there are no explanations for sprinkling different grit between the vertical fiber orientations. Methods and plants for the production of such fleece structures are also not known.
  • cover materials 3a, 3b mentioned above are also preferred. These can be the same or different, have different materials, different thicknesses, different densities, different flow resistances (air permeability), etc.
  • Materials of the film(s) include, in particular, PE/PA/PE and PA/PE. Pure PE films are also used.
  • the films 5 essentially have a thickness in the range from 40 ⁇ m to 180 ⁇ m. If only a nonwoven film (PE/PA/PE+PET) is used as cover material (3a, b), thicknesses of up to 450 ⁇ m are preferred.
  • the basis weight of the fleeces 3a, 3b is preferably in the range from 60 to 450 g/m 2 .
  • a method according to the invention for producing the microperforated needled sandwich fleece structures 1 which makes it possible to feed a core fleece 2 with vertical fiber orientation in-line at least on one side with a cover material 3a, 3b and to needle the overall composite, is characterized that the fibers of a mechanically or aerodynamically formed fleece 6 are oriented in a vertical layer 7 in the range of predominantly 90° and 45°, the oriented fibres/fiber layers are spread apart, filling materials 4 are interspersed between the vertically oriented fibers by means of a scattering device 8, the resulting structure in thermosolidified in an oven 9, after solidification cover materials 3a, 3b are supplied on one or both sides and the composite obtained is needled in a needling unit 10.
  • the furnace 9 is equipped with two conveyor belts and two separate drives.
  • the density of the oriented fibers/fiber layers can be adjusted independently of one another by varying the speeds of the upper and lower belts. It is also advantageous if different temperatures (top and bottom) in the range of preferably 120 to 180° C. can be set in the oven, for example by means of special hot-air slot nozzles transverse to the flow direction, which can optionally be controlled separately. In particular, it is advantageous that the properties of the fiber/grid composite can be influenced via the thickness.
  • the focus here is mainly on the cross-linking of the materials, namely the influence on the mechanical properties of rigidity, strength and processing behavior in subsequent processes.
  • the fibers/fiber layers oriented perpendicularly (90°) to 45° are spread, for example, by arranging a pair of rollers 11 in the throughput direction behind the scattering device 8, ie between the scattering device 8 and the oven 9 (see FIG. 2).
  • the speed of the pair of rollers 11 can be variably adjusted and is greater than the working speed of the vertical layer 7.
  • a pair of rollers 12 is arranged in the direction of passage in front of the scattering device 8 and a pair of rollers 13 after the scattering device (in front of the oven 9) (see FIG. 3). Both pairs of rollers 12 and 13 can be controlled separately.
  • Essential elements of the present invention are a microperforated needled sandwich nonwoven structure, in which acoustic, mechanical and processing properties on the one hand through the Scattering of property-influencing grit into vertically oriented fibers and, on the other hand, the process of needling this structure on one or both sides with nonwovens, woven fabrics, knitted fabrics, paper or foil.
  • the in-line process for the production of such sandwich fleece structures in particular by means of the integrated scattering system, and the sprinkling of grit in vertical fiber orientations, represents a novelty in the system sector.
  • the advantage of the present invention consists in particular in the in-line production of microperforated needled sandwich nonwoven structures with (in the core) vertical fiber orientation; on the one hand by the fiber orientation, the fiber mix, the fineness of the fibers of the core fleece and the grit contained therein, the acoustic, mechanical and processing-technical fleece properties (and thus ultimately the component properties) and on the other hand by the one- or two-sided needling of this, grit-filled with Vertically oriented fibers formed core fleece with fleece, woven fabrics, knitted fabrics, paper or film can influence / adjust (tune) in a targeted manner and thus provides new, property-optimized sandwich fleece structures.
  • GF/BiCo/PET ground/fiber material foam flakes
  • Water absorption hydrophobic fibers (including H-PET), GF/PP/BiCo regrind/fibers;
  • Stone chips PP/PE regrind/fiber material
  • hydrophobic fibers e.g. H-PET
  • PP/PET regrind hydrophobic fibers
  • Stiffness carbon fibers, natural fibers
  • Combustion behavior GF/Panox/PET/BiCo ground/fiber material, flame retardants, fibers with flame retardant finish, mineral fibers, glass fibers;
  • the sandwich fleece structures according to the invention are microperforated according to the invention by needling. Microperforation within the meaning of the present invention is defined by hole diameters in the range from 0.05 to 2.4 mm.
  • Example 1 According to the method according to the invention, a commercially available 500 g/m 2 fleece 2 with vertically oriented fibers (65% PET/35% coPET), 50 g/m 2 75% PP/25% PE ground/fibrous material 4 was scattered on both sides needled with an 80 g/m 2 needle fleece (75%PET/25%PP) 3 .

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Multimedia (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)

Abstract

Gegenstand der Erfindung sind vernadelte Sandwich-Materialstrukturen in denen ein Kernvlies mit vertikal orientierten Fasern zum Einsatz kommt; und ein Verfahren zur Herstellung dieser Sandwich-Materialstrukturen.

Description

VERNADELTE SANDWICH-VLIESSTRUKTUR UND VERFAHREN ZU DESSEN HERSTELLUNG
Gegenstand der Erfindung sind vernadelte Sandwich-Materialstrukturen, in denen ein Kernvlies mit vertikal orientierten Fasern zum Einsatz kommt; und ein Verfahren zur Herstellung dieser Sandwich-Materialstrukturen.
Im Stand der Technik wird in der DE 10 2016 203 348 Al über mehrlagige Akustik- und/oder Versteifungsvliesstoffe berichtet. Auch findet man in der noch unveröffentlichten DE 10 2019 104 847 Al Angaben zum Einnadeln von Streugut in Nadelvliesstrukturen. Die noch unveröffentlichte DE 10 2019 104 851 Al offenbart Vorrichtungen zum Einstreuen von Streugut in Nadelvliesstrukturen.
Ein Faserschichtmaterial, welches sich insbesondere als Kunstleder verwenden lässt, und aus zwei Arten übereinander angeordneter Faserschichten gebildet ist, die sich hinsichtlich der Anordnung der sie aufbauenden Fasern unterscheiden, wird in DE 2 032 624 A beschrieben. Das Faserschichtmaterial ist aus einer ersten aus Fasern aufgebauten Schicht (Kurzfaserschicht), deren Fasern zu einem überwiegenden Anteil im Wesentlichen in Richtung der Schichtdicke verlaufen, und aus einer oder mehreren zweiten Faserschichten, deren Fasern zu einem überwiegenden Anteil in Oberflächenrichtung verlaufen, aufgebaut. Beide Faserschichten sind laminatartig übereinander gebracht und miteinander verbunden, wobei die im Oberflächenbereich der ersten Faserschicht befindlichen Fasern in den Faseraufbau der zweiten Faserschicht eindringen. Das Faserschichtmaterial kann vorzugsweise eine hochpolymere elastische Substanz enthalten. Die Kurzfaserschicht, deren Fasern zu einem überwiegenden Anteil im Wesentlichen in Richtung der Schichtdicke verlaufen, wird erzeugt, indem ein im Rando-Webbers oder einer Kreuzlegemaschine erzeugtes Faserband, in Dickenrichtung in einer Schneidstation in aufeinanderfolgende Faserstücke zerschnitten wird; und die Faserstücke werden anschließend in einer Drehstation um 90° gedreht. Danach werden beidseitig Faserbänder zugeführt, der Schichtaufbau verpresst und vernadelt. Des Weiteren wird der Verbund in der Mitte der Kurzfaserschicht durchgeschnitten und nachfolgend mit einem hochpolymeren elastischen Material imprägniert sowie einem Schwabbelvorgang unterzogen. Die verwendeten Fasern haben einen inselartigen Aufbau. Nach dem Imprägnieren wird der Schichtverbund mit einem Lösungsmittel für die Entfernung der Einbettkomponente behandelt und getrocknet. Somit erhält man letztlich ein kunstlederartiges Faserschichtmaterial.
Mit der DE 298 12 401 Ul wird ein Faserverbundwerkstoff für selbsttragende Formteile mit hoher Flächenstabilität offenbart, in dem ein Struto-Vlies beidseitig mit einem weiteren Vlies kaschiert wird. Tao Yang et al., Investigation on Acoustic Behaviour and Air Permeability of Struto Nonwovens; Fibers and Polymers 2016, Vol. 17, No.12, 2078- 2084 beschreiben die akustische Leistung von Struto-Vliesen und ihre Luftdurchlässigkeit.
In den WO 02/20889 A2, WO 2005/081226 Al, WO 2009/140713 Al und WO 2010/042993 Al werden allgemein Absorber-Materialstrukturen mit senkrechter Faserorientierung und deren Herstellung beschrieben. Auch finden vertikale Faserorientierungen als Einleger, insbesondere bei Sitzen / Sitzkissen Anwendung, siehe zum Beispiel WO 2012/019752 Al und WO 2020/072412 Al.
Die DE 11 2012 005 205 T5 (siehe auch WO 2013/088828 Al, US 2014/0302285 Al, US 9 321 412 B2) offenbart die Anwendung vertikaler Faserorientierungen bei Isolationen von Bodenverkleidungen in der Automobilindustrie; die US 2017/0008462 Al beschreibt in diesem Zusammenhang insbesondere die Anwendung als partielles Dämpfungselement.
Die Aufgabe der vorliegenden Erfindung gegenüber dem vorgenannten Stand der Technik ist somit die Bereitstellung von mikroperforierten vernadelten Sandwich-Vliesstrukturen aus einem Kernvlies mit senkrechter Faserorientierung, bei dem zwischen die senkrecht orientierten Fasern anwendungs- und/oder eigenschaftsbedingt Streugut appliziert ist und dieses Kernvlies ein- oder beidseitig mit Vliesen, Geweben, Gewirken, Papier oder Folie vernadelt wird. Darüber hinaus ist es Aufgabe der Erfindung, ein Verfahren zur in-line Herstellung derartiger Vliesstrukturen bereitzustellen.
Gegenstand der vorliegenden Erfindung ist in einer ersten Ausführungsform eine mikroperforierte vernadelte Sandwich-Vliesstruktur 1, mit einem Kernvlies 2 mit senkrechter Faserorientierung, umfassend PET und/oder PET/PP - Fasern und Bindefasern aus PE, PP und/oder BiCo-Faser (coPET), wobei das Kernvlies 2 ein- oder beidseitig mit Deck-Materialien 3a, 3b versehen ist dadurch gekennzeichnet ist, dass der Bereich zwischen den senkrecht orientierten Fasern des Kernvlieses 2 eingestreute gleiche oder verschiedene Füllmaterialien 4 aus Mahlgut, Fasern, Flocken und/oder Pulver enthält, wobei die Deck-Materialien 3a, 3b gleich oder verschieden sind und jeweils unabhängig voneinander ein Vlies, Gewebe, Gewirke, Papier oder Folie umfassen.
In der Fig. 1 wird eine Vorrichtung zur Herstellung der erfindungsgemäßen mikroperforierten vernadelten Sandwich-Vliesstrukturen 1 und deren prinzipielles Herstellungsverfahren dargestellt. Ein mechanisch oder aerodynamisch hergestelltes Vlies 6 wird dem Senkrechtleger 7 zugeführt und dabei die Fasern in einem Winkel von etwa 90° bis 45° aufgerichtet. Die somit „senkrechtgelegten" Fasern werden Inline einer Streueinrichtung 8 zugeführt, die den Fasern Füllmaterialien 4 hinzufügt, die zwischen den vorgenannten Fasern gehalten werden. Der so erhaltene Vorformling wird anschließend einem Ofen 9 zugeführt, in dem die Struktur thermoverfestigt werden. Der so erhaltene Verbund wird anschließend einseitig-und oder beidseitig mit einem Deck-Material 3a, 3b versehen. In der sich daran anschließenden Vernadelungseinheit 10 wird dann der Gesamtverbund zu dem fertigen Endprodukt 1 vernadelt. In der Fig. 1 wird auch die bevorzugte Ausführungsform dargestellt, bei der zusätzlich zu den Deck-Materialien 3a, 3b hier einseitig eine weitere Folie 5 zwischen den Kernvlies 2 und den Deck-Materialien 3a, 3b zugeführt wird. Die Folie 5 wird zusätzlich -zwischen Deck-Material 3a, 3b und Kernvlies (2)- zugefahren, wenn akustische oder mechanische Eigenschaften beeinflusst werden sollen. Umfasst das Deckmaterial 3a, 3b eine Folie, dann entfällt die zusätzliche Folie 5. In der Fig. 2 wird eine Variante der Vorrichtung gemäß der Fig. 1 dargestellt. Das aus dem Senkrechtleger 7 erhaltene Vlies wird im Anschluss an den Durchlauf durch die Streueinrichtung 8 einem Walzenpaar 11 zugeführt und entsprechend komprimiert sowie gespreizt. Alternativ hierzu wird in der Fig.3 eine Verfahrensvariante beschrieben, die zwei Walzenpaare 12,13 umfasst, wobei das Walzenpaar 12 stromaufwärts der Streueinrichtung 8 und das Walzenpaar 13 stromabwärts der Streueinrichtung angeordnet ist.
Aus dem Stand der Technik sind keine Vliesstrukturen bekannt, die basierend auf einer mechanischen oder aerodynamischen Vliesbildung eine senkrechte Faserorientierung mit vernadelten ein- oder beidseitigen Deckvliesen, Folien oder Papieren aufweisen. Des Weiteren findet man keine Darlegungen zum Einstreuen von unterschiedlichen Streugut zwischen die senkrechten Faserorientierungen. Verfahren und Anlagen zur Herstellung derartiger Vliesstrukturen sind ebenfalls nicht bekannt.
Neben der einseitigen Bedeckung des Kernvlieses 2 ist auch eine beidseitige Bedeckung desselben mit den oben genannten Deck-Materialen 3a, 3b bevorzugt. Diese können dabei gleich oder verschieden sein, unterschiedliche Materialien, unterschiedliche Dicken, unterschiedliche Dichten, unterschiedliche Strömungswiderstände (Luftdurchlässigkeit) etc. aufweisen.
In einer weiteren Ausführungsform befindet sich ein- oder beidseitig zwischen dem Kernvlies 2 mit senkrechter Faserorientierung und den Deck-Materialien 3a, 3b weiterhin eine Folie 5; die ebenfalls durch die Vernadelung des Gesamtverbundes mikroperforiert ist. Materialien der Folie(n) umfassen insbesondere PE/PA/PE und PA/PE. Auch finden reine PE-Folien Anwendung. Die Folien 5 weisen im Wesentlichen eine Dicke im Bereich von 40 pm bis 180 pm auf. Sollte nur ein Folienvlies (PE/PA/PE + PET) als Deck-Material (3a, b) Anwendung finden, dann sind Dicken bis 450 pm bevorzugt. Das Flächengewicht der Vliese 3a, 3b liegt vorzugsweise im Bereich von 60 bis 450 g/m2.
Ein erfindungsgemäßes Verfahren zur Herstellung der mikroperforierten vernadelten Sandwich-Vliesstrukturen 1 (siehe Fig. 1), das es ermöglicht in-line einem Kernvlies 2 mit senkrechter Faserorientierung wenigstens einseitig ein Deck-Materialien 3a, 3b zuzuführen und den Gesamtverbund zu vernadeln, ist dadurch gekennzeichnet, dass man die Fasern eines mechanisch oder aerodynamisch gebildeten Vlieses 6 in einem Senkrechtleger 7 im Bereich von vorwiegend 90° und 45° orientiert, die orientierten Fasern/Faserlagen spreizt, mittels Streueinrichtung 8 Füllmaterialien 4 zwischen die senkrecht orientierten Fasern einstreut, die erhaltene Struktur in einem Ofen 9 thermoverfestigt, nach der Verfestigung ein- oder beidseitig Deck-Materialien 3a, 3b zuführt und den erhaltenen Verbund in einer Vernadelungseinheit 10 vernadelt.
Vorteilhaft ist, wenn der Ofen 9 mit zwei Transportbändern und zwei getrennten Antrieben ausgerüstet ist. Durch unterschiedliche Geschwindigkeiten des oberen und unteren Bandes kann die Dichtheit der orientierten Fasern/Faserlagen unabhängig voneinander eingestellt werden. Des Weiteren ist von Vorteil, wenn im Ofen unterschiedliche Temperaturen (oben und unten) im Bereich von vorzugsweise 120 bis 180 °C einstellbar sind, beispielsweise durch spezielle Heißluftschlitzdüsen quer zur Durchlaufrichtung, die gegebenenfalls separat steuerbar sind. Insbesondere ist es von Vorteil, dass man somit die Eigenschaften des Fa- ser-/Streugut-Verbunds über die Dicke beeinflussen kann.
Im Fokus ist hier hauptsächlich die Vernetzung der Materialien, nämlich die Beeinflussung der mechanischen Eigenschaften Steifigkeit, Festigkeit und das Verarbeitungsverhalten in Folgeprozessen.
Die Spreizung der senkrecht (90°) bis 45° orientierten Fasern/Faserla- gen erfolgt beispielsweise durch Anordnung eines Walzenpaares 11 in Durchlaufrichtung hinter der Streueinrichtung 8, also zwischen der Streueinrichtung 8 und dem Ofen 9 (siehe Fig. 2). Die Geschwindigkeit des Walzenpaares 11 kann variabel einstellbar und größer als die Arbeitsgeschwindigkeit des Senkrechtlegers 7.
Auch ist es möglich, mit zwei Walzenpaaren 12,13 zu arbeiten. Ein Walzenpaar 12 ist dabei in Durchlaufrichtung vor der Streueinrichtung 8 und ein Walzenpaar 13 nach der Streueinrichtung (vor dem Ofen 9) angeordnet (siehe Fig. 3). Beide Walzenpaare 12 und 13 können separat steuerbar sein.
Wesentliche Elemente der vorliegenden Erfindung sind eine mikroperforierte vernadelte Sandwich-Vliesstruktur, bei der akustische, mechanische und verarbeitungstechnische Eigenschaften zum einen durch das Einstreuen von eigenschaftsbeeinflussendem Streugut in senkrecht orientierte Fasern und zum anderen das Verfahren der einseitigen oder beidseitigen Vernadelung dieser Struktur mit Vliesen, Geweben, Gewirken, Papier oder Folie. Darüber hinaus stellt das in-line Verfahren zur Herstellung derartiger Sandwich-Vliesstrukturen, insbesondere durch die integrierte Streu-Anlage, und eben das Einstreuen von Streugut in vertikale Faserorientierungen eine Neuheit im Anlagensektor dar.
Der Vorteil der vorliegenden Erfindung besteht insbesondere in der inline Herstellung von mikroperforierten vernadelten Sandwich-Vliesstrukturen mit (im Kern) senkrechter Faserorientierung; indem man zum einen durch die Faserorientierung, den Faser-Mix, die Faserfeinheit des Kernvlieses und des darin befindlichen Streugutes die akustischen, mechanischen und verarbeitungstechnischen Vlieseigenschaften (und damit letztlich der Bauteileigenschaften) und zum anderen durch das ein- oder beidseitige Vernadeln dieses, streugutgefüllten mit senkrecht orientierten Fasern gebildeten, Kernvlieses mit Vliesen, Geweben, Gewirken, Papier oder Folie zielgerichtet beeinflussen/einstellen (tunen) kann und damit neue, eigenschaftsoptimierte Sandwich-Vliesstrukturen bereitstellt.
Als Streugut zwischen den senkrecht orientierten Fasern des Kernvlieses mit senkrechter Faserorientierung finden unter anderem folgende Materialien Anwendung, die die folgenden Eigenschaften beeinflussen:
Akustik: Hohlfasern mit unterschiedlicher Querschnittsgeometrie,
GF/BiCo/PET-Mahl-/Fasergut, Schaumflocken; Wasseraufnahme: hydrophobierte Fasern (u.a. H-PET), GF/PP/BiCo- Mahl-/Fasergut;
Steinschlag : PP/PE-Mahl-/Fasergut;
Eisansammlung/-anhaftung: hydrophobierte Fasern (u.a. H-PET), PP/PET-Mahlgut;
Steifigkeit: Kohlenstofffasern, Naturfasern;
Temperaturbeständigkeit: PP/GF-Mahl-/Fasergut, Mineralfasern, Glasfasern (GF);
Brennverhalten: GF/Panox/PET/BiCo-Mahl-/Fasergut, Flammschutzmittel, flammschutzausgerüstete Faser, Mineralfasern, Glasfasern;
Reißfestigkeit: Aramidfasern.
Die erfindungsgemäßen Sandwich-Vliesstrukturen werden erfindungsgemäß durch Vernadelung mikroperforiert. Mikroperforation im Sinne der vorliegenden Erfindung wird definiert durch Lochdurchmesser im Bereich von 0,05 bis 2,4 mm.
Ausführungsbeispiel :
Beispiel 1 : Entsprechend dem erfindungsgemäßem Verfahren wurde einem handelsüblichen 500 g/m2 Vlies 2 mit senkrecht orientierten Fasern (65%PET/35%coPET), 50 g/m2 75%PP/25%PE-Mahl-/Fasergut 4 eingestreut, dieses beidseitig mit einem 80 g/m2 Nadelvlies (75%PET/25%PP) 3 vernadelt.
Nach der Verformung zu einer Radlaufschale wurden vergleichende Untersuchungen zu einer üblichen Radlaufschale, hergestellt mit herkömmlichem Vlies (800 g/m2 40%PP/30%PET/30%BiCo), gemacht. Es wurden deutliche Unterschiede hinsichtlich Biegesteifigkeit (10% Erhöhung), Steinschlagfestigkeit (in Durchschuss und Gewichtsverlust) sowie im Verformungsverhalten festgestellt.
Beispiel 2:
Entsprechend dem erfindungsgemäßem Verfahren, wurde einem 1300 g/m2 Vlies mit senkrecht orientierten Fasern (70%PET/30%coPET) 2, 100 g/m2 40%PP/30%PET/30%BiCo-Mahlgut 4 eingestreut und anschließend beidseitig mit 150 g/m2 Nadelvlies (75%PET/25%PP) 3 vernadelt. Auch hier zeigte sich nach der Verformung zu einem Unterbodenschild, im Vergleich zur herkömmlichen Unterbodenschild-Materialstrukturen, eine deutliche Verbesserung der mechanischen Eigenschaften.
Bezugszeichenliste:
1 - Sandwich-Vliesstruktur
2 - Kernvlies
3a, 3b - Deck-Material - Füllmaterial
- Folie
- Vlies
- Senkrechtleger
- Streueinrichtung
- Ofen
- Vernadelungseinheit
- Walzenpaar
- Walzenpaar
- Walzenpaar

Claims

Patentansprüche
1. Mikroperforierte vernadelte Sandwich-Vliesstruktur (1), mit einem Kernvlies (2) mit senkrechter Faserorientierung, umfassend PET und/oder PET/PP - Fasern und Bindefasern aus PE, PP und/oder BiCo-Faser (coPET), wobei das Kernvlies (2) ein- oder beidseitig mit Deck-Materialien (3a, 3b) versehen ist dadurch gekennzeichnet ist, dass der Bereich zwischen den senkrecht orientierten Fasern des Kernvlieses (2) eingestreute gleiche oder verschiedene Füllmaterialien (4) aus Mahlgut, Fasern, Flocken und/oder Pulver enthält, wobei die Deck-Materialien (3a, 3b) gleich oder verschieden sind und jeweils unabhängig voneinander ein Vlies, Gewebe, Gewirke, Papier oder Folie umfassen.
2. Sandwich-Vliesstruktur (1) nach Anspruch 1, umfassend eine Folie (5) zwischen dem Kernvlies (2) und den Deck-Materialien (3a, 3b).
3. Verfahren zur Herstellung von Sandwich-Vliesstrukturen (1) nach Anspruch 1 oder 2, wobei man in-line die Fasern eines mechanisch oder aerodynamisch gebildeten Vlieses (6) in einem Senkrechtleger (7) im Bereich von vorwiegend 90° und 45° orientiert, die orientierten Fasern/Faserlagen spreizt, mittels Streueinrichtung (8) Füllmaterialien (4) zwischen die senkrecht orientierten Fasern einstreut, die erhaltene Struktur in einem Ofen (9) thermoverfestigt, nach der Verfestigung ein- oder beidseitig Deck-Materialien (3a,
3b) zuführt und den erhaltenen Verbund in einer Vernadelungseinheit (10) ver- nadelt.
4. Verfahren nach Anspruch 3, dadurch gekennzeichnet, dass man die senkrecht orientierten Fasern des Kernvlieses (2) durch
Walzenpaare (11, 12, 13) spreizt, die
(a) vor (12) und nach (13) der Streueinrichtung (8) oder
(b) nach der Streueinrichtung (8) durch ein Walzenpaar (11) angeordnet sind, wobei die Walzenpaare (11, 12, 13) gegebenenfalls separat steuerbar sind.
EP21773705.5A 2020-09-30 2021-09-02 Vernadelte sandwich-vliesstruktur und verfahren zu dessen herstellung Pending EP4221973A1 (de)

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PCT/EP2021/074312 WO2022069148A1 (de) 2020-09-30 2021-09-02 Vernadelte sandwich-vliesstruktur und verfahren zu dessen herstellung

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US20230374710A1 (en) 2023-11-23

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