FR2475460A1 - Pre-fabricated moulded construction - of synthetic continuous filament non-woven fabric, needled and singed, then pressed with plastic support in mould - Google Patents

Abstract

A prefabricated construction material comprises at least one non-woven textile material of synthetic continuous filaments, which may be needled and singed, and a plastic support material, which may be loaded. The plastic support material may be injection moulded in a mould where at least one of the internal surfaces is covered with one or more layers of the non-woven textile. Non-woven fabrics of melt-spun fibres when used for mouldings of this kind provide an isotropy, deforming well in stress zones, with no thin places. Folds do not occur in the moulding, nor bursting in the relief zones. Such fabrics have good resistance to abrasion, light, ageing, heat and cleaning. The pre-fabricated construction element is obtained in a single operation. The pre-fabricated construction elements are used for building, domestic appliances and for furniture, etc.

Description

 The present application relates to prefabricated dressed construction elements and their manufacturing processes.

 Prefabricated construction elements such as those used for example in the construction of means of transport, in building, household appliances, furniture, sometimes require a covering of a textile coating on at least one of their faces to reasons of comfort, aesthetics and integration of the production process to simplify it.

 Thus, for the interior lining of means of transport by water, air, land, such as cars, railroad cars, boats, coaches, canyons, planes, whether these means of transport are used for personnel or merchants. is known to use an interior covering in textile, leather or imitation posed according to long and expensive upholstery methods. Recently, it has been proposed to combine knitting with molded parts during the molding of the latter. However, knitting is generally only stretchable in one direction and the deformations due to molding in particular in highly stressed areas such as corners, Hollow, etc., cause weak points, fragile at bursting, and folds detrimental to the appearance of the finished product. Consideration has also been given to using non-woven textiles produced from fibers by the dry or wet method. However, these non-wovens have a low deforability and a relative breaking strength which do not give good results. the production of prefabricated partitions facilitates construction, but a coating must then be added thereto, which requires other operations.

 The present application proposes to avoid the drawbacks of the textile covers previously proposed.

 The subject of the present invention is dressed prefabricated construction elements, characterized in that they comprise on the surface, at least on the visible side, at least one nonwoven fabric of synthetic continuous filaments secured to the support of said elements.

 The present application also relates to a process for the production by molding of the above elements, characterized in that one associates with the support and on at least one face of the latter at least one nonwoven of synthetic continuous filaments then that the assembly is subjected to a forming operation in a press.

 The present application relates to a method for producing by injection of the elements described above, characterized in that a plastic material, possibly loaded, is injected into a cold mold, said mold being covered on at least one of its internal faces. '' at least one nonwoven textile of synthetic continuous filatents.

For molding, the raw materials of the supports are of known type, such as corrugated cardboard, waste of textile fibers or glass fiber, of cellulose fibers, coated with thermoformable resins, rigid foam, pitre, cement, plastics possibly loaded with products such as talc, etc.
The synthetic continuous filament nonwoven used is preferably needled on at least one face with a number of perforations greater than 50 perforations per square centimeter.

This nonwoven can be of ecru color, dyed, colored in the mass, it can be printed with the frame, with the rollers, or by thermal transfer. The nonwoven is preferably flamed on at least one side to improve its resistance to friction. A nonwoven of weight between 50 and 300 g / m2 is used, preferably between 90 and 200 g / m2. These nonwovens are obtained by extrusion according to known methods, from melts of synthetic polymers such as those based on polyamide1 polyester, polyolefin, used alone, as a mixture or giving rise, during their extrusion, to bicomposite or mixed products , preferably a polyester-based nonwoven such as polyethylene terephta late extruded alone or in combination with poly butylene terephthalate glycol is used to give continuous six-ply yarns.
The molding can be carried out hot at a temperature between 100 and 2200C and at a pressure between 0.5 and 100 bars / cm2 or cold with an appropriate glue on the support already formed by assembly using '' a two-part mold using a pressure of between 0.5 and 100 bars. it is also possible to combine the nonwoven and a plastic material with a cellular structure and then use the interlayer. The interlayer can also be a fusible beam. During the injection, the injected support is generally k resin base
ABS or loaded polyolefins. The injection and the relief are carried out according to known methods and on known equipment.

For forcing-molding, temperatures and pressures compatible with the raw material of the nonwoven fabric and the supports used are used, for example when a dyed or printed nonwoven is used, the temperature must not cause degradation. donation of the colonist sought.

 The nonwovens of continuous filaments obtained by the melt process, unlike the nonwovens obtained by the dry or wet route exhibit isotropy, good deformability in the highly stressed areas, there is no thinning in the areas of strong deformation because the cohesion of these nonwovens of continuous filaments allows a solicitation of the material on a larger surface, there are no folds in the molding, no bursting on the raised parts the nonwoven is opaque, it has good resistance to abrasion, to light, to aging, good thermal resistance, fastness to cleaning; in this way a support / textile complex is obtained in a single piece, which is important from an economic point of view. Regardless of the use of nonwovens with a flat surface, it is possible to use embossed nonwovens between etched and heated metal cylinders for example for polyethylene terephthalate glycol at a temperature of 220 / 2300C. With these elements, it is thus possible, for example, to produce any interior covering for any means of transport such as pavilions, door panels, rear seats, dashboards, it is also possible to obtain plastic furniture with textile surface in furniture. a single operation, in the building of apartment partitions with textile covering incorporated during the production of the prefabricated partitions, the interior and exterior cladding of household appliances such as washing machine, refrigerator.

 The following examples illustrate the present application without limiting it.

Example 1-
For the production of pavilions for motor vehicles, on the one hand, a nonwoven of continuous filaments of polyethylene terephthalate, blue in color, needled at 170 strokes per square centimeter, weighing 110 g / m2, title to the strand 3,5 dtex, of Bidim registered trademark of the Company RHoNE-POULÈNC-
TEXTILE, flamed on the tex faces on a gas ramp at a speed of 100 m / min, and on the other hand, a flat panel made of polypropylene resin and sawdust brand WOODSTOOK from the company GRIFFINE MARECBAL , thickness 2 millimeters, weight 1.8 kg / m2. The panel is placed on one of the two parts of a mold heated to 160 C, maintained at this temperature for 2 minutes, then covered with non-woven fabric and the other part of the mold is lowered by pressing stepwise, pressure used 5 bars / cm2 We thus obtain, economically, in a single operation, a non-woven support complex having an excellent textile appearance on the visible face of the pavilion without folds or defects.

Example 2
For the production of elements for the interior trim of motor vehicles, one uses, on the one hand, a nonwoven of continuous filaments of polyethylene terephthalate registered trademark Bidim of the company RHQNE-POU'LENC- TEXTILE, weight 170 g / m2, stranded 5.6 dtex, three-lobed section, flamed on both sides, needled front / back of 150 strokes / cm2, the ecru surface is printed with a beige chevron design, on the other hand, a support is used consisting of a sheet of thickness 3 centimeters in weight 2 kilos / m2> consisting of waste textile fibers agglomerated with a phenolic resin, one also uses an interlayer constituted by a polyethylene fila d '' thickness 60 microns. We heat the mold to 190OC for the realization of a pavilion of automobiles, we preheat the support for two minutes then we cover the file and the nonwoven and we practice a direct pressing in a single operation and not in steps using a pressure of 4 bars / cm2.

Claim 3
For the production of elements such as crosspieces, front and rear stretchers, front legs and middle of motor vehicles, the nonwoven of Example 2 dyed in the mass with blue colon is used on the one hand and on the other hand hand, a polypropylene resin loaded with talc.

 The parts are produced by injection while keeping the cold vertical mold covered with the nonwoven on the face of the mold opposite to that of the injection; the injection of the loaded polypropylene is carried out at 18O / 1900C under a pressure of 500 bars per square centimeter. Unmolding is carried out after 2.5 minutes. The use of textiles when making the piece is practical and economical.

Example 4
For the production of an automobile pavilion, a nonwoven of continuous polypropylene filaments weighing 120 g / m2, strand count 3 dtex, needled recto / verso with 10 perforations per square centimeter is used. This nonwoven is printed on the rotary frame with a houndstooth pattern on the needle exit face of the second needling. Then proceed to the assembly on the back of a flexible polyurethane foam 1.5 mm thick by the flame process of the foam.

 The non-woven-foam complex is applied to a triple-thickness cellulosic cardboard with a 2 mm thick corrugated interlayer coated with EVA (Ethylene Vinyl Acetate) glue at a rate of 50 g / m2 of dry product by depositing a spraying of an aqueous dispersion with 30 μl of dry extract.

 The assembly is placed on the part of a metal ioule heated to 1200C. The female part of the mold is immediately lowered under a pressure of 3 barsjcm2, it is then removed from the mold after 1 minute 30.

Claims (16)

 1, - Dressed prefabricated construction elements, characterized in that they comprise on the surface, at least on the visible side, at least one nonwoven fabric of synthetic continuous filaments secured to the support of said elements.  2! - elements, objects of claim 1, characterized in that the nonwoven is needled on at least one face with a number of perforations greater than 50. per square centimeter.  3 / - Elements, objects of claims 1 and 2, characterized in that this nonwoven is flamed on at least one side.  4 / - Elements, objects of claims I k 3, characterized in that the nonwoven is of a weight between 50 and 300 g / m2> preferably between 90 and 200 g / m.  5 / - Elements according to claims 1 to 4, characterized in that the nonwoven is a nonwoven based on polyethylene terephthalate glycol.  6 / - elements according to claims 1 k 4, characterized in that the nonwoven is a polyamide nonwoven.  7 / - Elements according to claims 1 to 4, characterized in that the nonwoven is made of polyolefin.  8 / - Process for the production by molding of prefabricated dressed construction elements, objects of claims 1 k 7, characterized in that one associates with a known support and on care one side of the latter, at least one no -woven of synthetic continuous filaments then the whole is knitted for a forming operation  9 / - Method according to claim 8, characterized in that the molding is carried out using a pressure between 0.5 and 100 bars / cm.  10 / - Method according to claims 8 and 9, characterized in that the molding is carried out k hot at a temperature between 100 and 2200C.  11 / - Method according to claims 8 and 9, characterized in that the molding is carried out cold with an appropriate adhesive.  12 / - Method according to claims 8 to 10, characterized in that between the nonwoven and the support, there is an interlayer.  13 / - Method according to claim 12, characterized in that the interlayer is a tbermocollant film.  14 / - Method according to claim 12, characterized in that the interlayer is a fusible powder sprayed on the support.  15 / - Process for the production, by injection, of the prefabricated dressed construction winds, objects of claims 1 to 7, characterized in that one injects, into a cold mold, a plastic dobby, possibly loaded, said mold being covered on sheep with one of its internal faces with at least one nonwoven of continuous synthetic filaments.  16 / - Prefabricated cladding elements for construction, objects of claims 1 to 7, characterized in that they are used for the interior cladding of means of transport by land, water, air, in the building, in furniture, l 'home appliance.