JPS5942937A - Manufacture of composite shape - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a plastic coating having a textile surface layer, for example a floor covering layer, and an insert or covering, which is fixed to one side of the surface layer and optionally consists of another material. A method for producing a composite molded body consisting of a foam, especially a composite molded body to be installed in an automobile as a heat insulating material/floor covering layer composite, in which the surface layer is first preformed and then molded in the form of an inner lining. Insert and then into the cavity of the mold a foamable plastic compound forming a specifically polyurethane flexible foam.
Regarding the type that supplies ξ land.

In a motor vehicle or machine, the insulation is first installed at the points where insulation and floor covering layers or wall linings located one above the other are required, and then only a possibly preformed floor covering layer or the like is installed. Until very recently, it was common practice to install When installing textile floor coverings in motor vehicles, a heavy layer, for example of bitumen, is first glued or sprayed onto the floorboard, and then a preformed insulation mat consisting of a foam material, knotite or fiber layer is applied. The preformed floor covering layer is then applied. In this case, it is also possible to glue the insulation mat to the floor covering layer and/or to the heavy layer before installing the preformed floor covering layer.

In the specification of the Federal Republic of Germany Patent No. 2323883,
The use of foam in place of the heavy layer is disclosed. In this case, the foam is finally produced by inserting an open-cell foam layer into a mold and foaming the foamable plastic Conn. ξlan P under superpressure.

In order to avoid layer-type installation, composite moldings are used, which can be manufactured using methods of the type mentioned at the outset.

In the first transition stage from layered mounting to composite molded mounting, the method disclosed, for example, in German Patent Application No. 4,396 and German Patent Application No. 2426793, As such, the floor covering layer is provided with a foamed back part or is combined over a large area with the essential insulation layer, which is a strip, and the layered combination is then formed into a composite molding suitable for installation in a motor vehicle. However, the disadvantages in this case include:
Despite the painstaking bonding of the materials together, considerable losses are caused by the debris produced during cutting, and considerable energy is still consumed during shredding. This is because the composite material, in particular the thermoplastic layer which is inserted in the center of the composite and which is essential for the shaping reservoir, has to be deformed through the layer located above it. Yet another drawback is that it is virtually impossible to produce shaped bodies with large wall thickness layers. Similarly, it is virtually impossible to insert a heavy layer into the mold part only in a specific area.

Owing to the above-mentioned drawbacks, methods of the type mentioned at the beginning are mainly used today for producing composite moldings. Such a method is known from DE 2930966 and DE 30 34 799. In these known methods, a preformed fibrous floor covering layer is first inserted into a mold, which mold is then closed compactly by a corresponding mold, after which the required amount of plastic condensation or o-land is added to the foam reservoir. The mold is loaded through one or several feed openings as quickly as possible under overpressure to ensure uniform distribution and uniform foam formation.

In this case, the foam reacts in the mold under overpressure. If necessary, the required heavy layer can be inserted into the mold before the injection of the plastic z/n ξ run 1, so that the heavy layer is encapsulated in the foam 1. Feeding the material under overpressure and the overpressure generated in the closed mold during foam formation can cause the foam to penetrate the porous fibrous floor covering layer, rendering it unusable. Sometimes it happens.

In order to avoid this foam penetration, it has hitherto been necessary to provide a barrier layer on the foam side of the textile floor covering layer. However, this barrier layer must be sufficiently adhered to the floor covering layer and the formed foam to ensure an essential bond between the floor covering layer and the foam. According to DE 30 34 799 A1, a layer made of polyethylene foam is used as a barrier layer, which is applied to the back side of the floor covering layer. The fixation of this layer is often carried out by deflagration and must therefore be carried out carefully. Still, the additional work steps during manufacture and the foam used for this barrier layer are more expensive than the plastic confections forming other foams.

Other attempts have been made to seal the back side of the textile floor covering layer with a plastic sheet to avoid ingress and penetration of the foam material. However, this approach presents significant problems in obtaining sufficient adhesion between the plastic sheet and the floor covering layer and between the plastic sheet and the plastic foam. We also attempted to install a plurality of corresponding ξ-formations in the plastic sheet, and to enable a slight amount of foam to penetrate into the floor covering layer through the perforation controller, thereby making it possible for the foam to adhere. However, ξ
If the foliation openings are too small, the adhesion will be insufficient; if the foliation openings are somewhat too large, the foam material will again penetrate to the front side. Even if the grooved plastic sheet is provided with slits, slit overlaps and the like, it is not possible to avoid the penetration of the foam material into the floor covering layer and its penetration to the front side.

It is therefore an object of the present invention to improve a method of the type mentioned at the outset in order to obtain a uniform foam formation which is simple to manufacture and has low material costs, and which can be applied to surfaces such as floor coverings, for example. It is an object of the present invention to provide a method by which a satisfactory combination can be made between a material and a form.

In order to solve this problem, the method according to the invention comprises, in a method of the type mentioned at the outset, applying a foamable plastic condenser to a surface layer without a barrier layer in a cavity maintained at least approximately at atmospheric pressure; A foam is then formed by further supplying plastic compound/e in the same manner at about atmospheric pressure, and the outer contour of the foam is overlaid onto the mold at a dimension of -i, leaving gaps, air flow openings or the like. It is designed to be molded using a compatible mold. In this case, it is advantageous if, before supplying the foamable plastic compound ξ land, the surface layer is heated above the plastic compound reaction temperature which causes foam formation.

The foam 14 penetrates only slightly into the surface layer, since the foamable plastic contour pad is applied to the surface layer only by adhesion without applying pressure, and foam formation is preferably introduced by the surface layer. However, the penetration of the foam material into the surface layer in this case is sufficient for satisfactory adhesion. Since the foam formation begins on the back side of the surface layer, the foam itself forms a barrier layer that prevents the flowable plastic con-q-land from further reaching and penetrating the surface layer.

Using the method according to the invention, the resulting foam forms an impermeable film on the inside of the surface layer and all over the outside, which film may optionally be added to the composite and inserted before closure of the mold. enveloping material. Additional materials encapsulated within the composite are, for example, insulating mats, sheets, heavy layer mats and prefabricated foams, which are often inserted only at predetermined locations. This avoids liquid ingress and accumulation in the composite molded body produced according to the method according to the invention.

It has already been mentioned that it is often desired to initiate the foam formation by the surface layer, and this is advantageously achieved by heating the surface layer. In this case, the plastic conomiland itself is supplied at a temperature below the reaction temperature of the plastic connomylan P. Foam formation is initiated by the heat in the heated surface layer, which first causes an exothermic reaction and then provides an initiation temperature to the supplied plastic condensate.

The invention will now be described in detail with reference to the drawings.

The drawings show two embodiments of the method according to the invention, in both methods the woven or knitted fiber floor covering layer is initially prepared in the customary form from Hg IJ ethylene. A heat-deformable layer consisting of a heat-deformable layer or, if appropriate, a corresponding dispersion which serves to fix the pole material or the base material is applied. The floor covering layer pretreated in this way is cut according to the predetermined dimensions of the molded body to be manufactured,
After being heat treated on the back side, it is deformed in a press. The method according to the invention relates to the further processing of the floor covering layer molded body produced in this way into a composite molded body.

In the method shown in FIGS. 1 and 2, a preformed floor covering layer 1 is placed on a holding mold 2 adapted to the outer contour of this floor covering layer. By means of this holding mold 2, the floor covering layer 1 is guided through a heating zone 3, in which the back side of the floor covering layer 1 is heated above the reaction temperature which causes foaming of the plastic compound, which will be discussed further below. The holding mold 2 and the floor covering layer I are then sent to the injection chamber 4. The spray chamber 4 is provided with a spray head 5 whose position is fixed and a spray belly F″7 which is movable back and forth on a lateral guide 6.The spray heads 5, 7 are capable of foaming the floor covering layer 1. Applying the plastic compound. By controlling the movement of the jetting head 7 and the feed rate of the individual jetting heads 5, 7-\, a possibly different amount of foamable plastic compound ξ land is applied to the floor covering layer 1. At the beginning of spraying, a foam-forming reaction begins immediately in the relatively small amount of applied plastic cone land, whereby the plastic cone land forms only a very small amount of the corresponding element. In particular, the foamable plastic compound penetrates the back side of the floor covering layer 1 at a depth defined by factors such as preheating temperature and viscosity to form a film, which is formed by further applying the foamable plastic compound to the fibrous floor covering layer 1. It acts as a barrier layer to prevent intrusion.

After applying the required amount of plastic compound, a corresponding mold is placed over the holding mold 2, leaving an air gap 9, up to the slit. This counterpart corresponds to counterpart 8 shown in FIG. 4, but unlike counterpart 8, it does not have an injection opening 12. The above operations are carried out in a press 10 located downstream of the injection chamber 4. In this press 10, the as-yet-uncompletely-reacted foam of plastic contour land is brought into a predetermined final shape.

In the corresponding mold, inserts such as insulation mats, heavy layer mats, seals or prefabricated foam products are inserted and pushed into the foam.

This allows the insert to absorb the forces created on the outside of the form.
It is connected to the foam body by a ζ-film. After the form formation is completed, the holding mold 2 and the corresponding mold are separated,
The produced composite body is optionally sent to a cutting station 11 or to another processing station or storage location.

In the method shown in FIGS. 3 and 4, the injection chamber 4 of FIG.
and at the press 10 is located an injection area in which a foamable plastic condenser ξ land is placed on the back side of the cut and preformed floor covering layer 1 through the injection opening 12 of the corresponding mold 8. applied. In this method as well, a void 9 is left in order to maintain the cavity at approximately atmospheric pressure during the feeding and reaction of the foamable plastic container. Depending on the number of injection openings 12, the type of arrangement and the supply amount of foamable plastic cone lands, the supply amount per unit area of plastic cone lands can be adapted to the different thicknesses required for the finished foam body. Can be done. Also in this case, a barrier layer is formed on the floor covering layer 1 to prevent the plastic compound from entering. Furthermore, it is also possible to insert additional material into the corresponding mold 8 which is ultimately connected to the foam 13. After the foaming reaction, the molded body is removed from the holding mold 2 and the corresponding mold 8, after which it is sent to a cutting station 11 or the like.

With the method according to the invention, it is possible to produce not only composite moldings for floors, but also other composite moldings made of fibers and foam, such as, for example, the linings of the sides and roof sumps of motor vehicle passenger compartments.

[Brief explanation of the drawing]

FIG. 1 schematically shows the working sequence according to an embodiment of the method according to the invention; FIG. 2 shows the foam and floor covering layer during the application of the plastic cone sander in the embodiment shown in FIG. 1; 3 is a diagram schematically illustrating the work progress according to another embodiment of the method according to the invention; FIG. It is a sectional view showing a mold. DESCRIPTION OF SYMBOLS 1... Floor covering layer, 2... Holding type, 3... Heating zone, 4... Injection chamber, 5, 7... Injection head, 6...
・Horizontal guide, 8... Compatible type, 9... Gap, 1o
...Press, 11...Cutting station,
12゛゛Note large opening, 13... Form FIG, I FIG, 2

Claims (1)

[Claims] A method for producing a composite molded body comprising a surface layer made of fibers and a plastic foam fixed to one side of the surface layer, the method comprising:
First, the surface layer is preformed and inserted into the mold in the form of an inner lining.
Then fill the cavity of the mold with a foamable plastic container.
ξ In the type of land supply, a foamable plastic compound is applied to the surface layer without barrier layer in a cavity maintained at least at approximately atmospheric pressure, and then a further plastic compound is also supplied at approximately atmospheric pressure. forming a form and leaving the outer contour of the form with gaps, air flow openings or the like;
1. A method for producing a composite molded article, characterized in that the molding is carried out using a corresponding mold placed over the mold.