MXPA01009525A - Vacuum formed coated fibrous mat - Google Patents

Abstract

A composite structure (10) having a fibrous mat (100) with perforated film coverings (200, 300) vacuumed formed on both sides (110, 120) of the fibrous mat (100). The composite structure is affixed between a structural foam and a soft foam to create a component part for use in applications such as automotive trim parts.

Description

FIBROSA CARPET, COVERED, FORMED TO THE VACUUM BACKGROUND The present invention relates, in general, to carpets or carpets of fibrous materials, and in particular to laminates of fibrous carpets with perforated film coatings. Fibrous carpets are used in various applications such as in the construction of interior parts of automobile bodies. Prior technology formed fibrous carpets for automotive interior components by spraying adhesives on fiberglass strings into pieces. The adhesive agglomerates the glass fibers together and to the substrates. Different layers of fiberglass, foams, adhesives and other materials were stacked together by hand to build a "sandwich", which then formed into a biscuit and was used for the production of the interior part of the finished bodywork. However, the use of the fibrous carpets of the prior art required multiple steps and excessive labor to produce the biscuit for use in the interior parts for the automobile body. Therefore, fibrous tapestries are needed that can be used for the formation of a multilayer structure with fewer steps and less labor. In addition, a fibrous carpet is needed for use in the formation of a multilayer structure that has less weight, good thermoforming capacity, good acoustic properties and better rigidity.

COMPENDIUM In one embodiment, the present invention is a composite structure that includes, in general, a fibrous felt, a first film coating and a second film coating. The fibrous felt has a first side of the felt and a second side of the felt, and is formed of a plurality of fibers so that a plurality of passages are formed therein. The first film coating is located on the first side of the felt of the fibrous felt, and has a plurality of first protuberances of the film with first openings of the film extending towards the plurality of passages in the fibrous felt. The second film coating is located on the second side of the felt of the fibrous felt and has a plurality of second protuberances of the film with second openings of the film extending to the plurality of passages in the fibrous felt. In another embodiment, the present invention is a composite structure that includes a fibrous felt with a first side of the felt and a second side of the felt, and a coating of adhesive film located on the first side of the felt of the fibrous felt. The fibrous felt is formed of a plurality of fibers so that a plurality of passages are formed therein. The adhesive film coating has a plurality of protrusions of the adhesive film with openings of the adhesive film that extend toward the plurality of passages in the fibrous felt. In still another embodiment, the present invention is a composite structure that includes a fibrous felt with a first side of the felt and a second side of the felt, and a multilayer film coating located on the first side of the felt of the fibrous felt. The fibrous felt is formed of a plurality of fibers so that a plurality of passages are formed therein. The multilayer film coating includes a plurality of protrusions of the multilayer film with openings of the multilayer film, the plurality of protrusions of the multilayer film extending towards the plurality of passages of the fibrous felt. In yet another embodiment, the present invention is a process for forming a composite structure including the steps of providing a fibrous felt with a first side of the felt and a second side of the felt; placing the second side of the felt of the fibrous felt on a first perforated screen; Place the material of a first film coating on the first side of the fibrous felt located on the first perforated screen; apply a vacuum towards the back side of the first screen perforated with the fibrous felt and the first film coating material located therein to form a first film coating on the first side of the fibrous felt, placing the fibrous felt on a second screen perforated with the first film coating next to the second perforated screen; and, placing a second film coating material on the second side of the fibrous felt located on the second perforated screen; applying a vacuum towards the back side of the second screen perforated with the first film coating, the fibrous felt, and the second film coating material located therein to form a second film coating on the second side of the fibrous felt. In yet another embodiment, the present invention is a process for forming a composite structure including the steps of: providing a fibrous felt with a first side of the felt and a second side of the felt; placing the second felt side of the fibrous felt on a first perforated screen; coextruding a material of the first multilayer film coating on the first side of the fibrous felt located on the first perforated screen; and, applying a vacuum towards the back side of the first screen perforated with the fibrous felt and the first film coating material located therein to form a first multilayer film coating on the first side of the fibrous felt. In still another embodiment, the present invention is a composite part that includes a composite felt structure and a foam layer. The composite felt structure includes a fibrous felt with a first side of the felt and a second side of the felt, a first skin coating located on the first side of the felt of the fibrous felt, a second skin coating located on the second side of the felt of the felt fibrous. The fibrous felt of the composite felt structure is formed of a plurality of fibers so that a plurality of passages are formed therein. The first film coating of the composite felt structure has a plurality of first protuberances of the film with first openings of the film, the plurality of the first protuberances of the film extending towards the plurality of passages in the fibrous felt. The second film coating of the composite film structure [sic] includes a plurality of second protuberances of the film with second openings of the film, the plurality of second protuberances of the film extending toward the plurality of passages in the fibrous felt. The foam layer adheres to the first film coating of the composite felt structure. In another embodiment of the present invention the first film coating is a multilayer film having a first external adhesive layer next to the first foam layer. In still another embodiment, the present invention includes a second foam layer adhered to the second film coating of the composite felt structure. In yet another embodiment, the second film coating is a multilayer film having a second external adhesive layer adjacent to the second foam layer.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is an enlarged partial section of a laminate exemplifying one embodiment of the present invention. Figure 2 is a partial, enlarged perspective view of the laminate of Figure 1. Another embodiment of the laminate of Figure 1 Figure 4 is an enlarged partial section of yet another embodiment of the laminate of Figure 1 Figure 5 is a schematic view of one embodiment of a process for forming the laminate of the present invention Figure 6 is a more detailed scheme of the forming station of the first film coating of the process of Figure 5; Figure 7 is a more detailed scheme of the forming station of the second film coating of the process of Figure 5; and Figure 8 is a partial perspective view of a component part manufactured in accordance with the present invention with the composite structure of Figure 4.

DETAILED DESCRIPTION Now with reference to the figures, and in particular Figures 1-4, an embodiment of the present invention exemplified as the composite structure 10 is described.

The composite structure 10 generally comprises a fibrous felt 100 with a first side of the felt 110 and a second side of the felt 120, a first skin covering 200 placed on the first side of the felt 110, and a second skin covering 300 placed on the second side. felt side 120. The first skin overlay 200 includes first protrusions of the film 210 extending towards the fibrous felt 100 and first skin protuberances 220. The second skin overlay 300 includes second protrusions of the film 310 extending towards the fibrous felt 100 and second protuberances. of the film 320. The fibrous felt 100 is formed of a plurality of synthetic or natural fibers 130 such as fiberglass, henequen, polymeric fibers, excelsior, combinations of these, or similar. The fibers 130 in the fibrous felt 100 are arranged so as to form holes / passages 140 of the felt in the fibrous felt 100. The holes / passages of the felt 140 in the fibrous felt 100 provide an open area in the fibrous felt 100 between the felt. first side of the felt 110 and second side of the felt 120. In one embodiment, the fibrous felt 100 includes a binder 150 which holds the fibers 130 together in the fibrous felt 100.The characteristics of the fibrous felt 100, such as stiffness, thickness and / or open area, are selected based on the contribution of the fibrous felt 100 to the criteria of the composite structure 10, such as stiffness and sound insulation. In another preferred embodiment, the fibrous felt 100 has a thickness from about 10 mils to about 25 mils and an open area from about 10% to about 50% open area. The parameters of the components of the fibrous felt 100, such as the fibers 130 and the binder 150, determine the characteristics of the fibrous felt 100. For example, the density, diameter, size and modulus of elasticity of the fibers 130 will contribute to the rigidity and properties of open area of the fibrous felt 100. The binder 150 will also contribute to the stiffness and open area of fibrous felt 100. The first skin coating 200 adheres to the fibers 130 exposed on the first side of the felt 110 of the fibrous felt 100. In a preferred embodiment, the first film coating 200 encapsulates some of the fibers 130 on the first side of the felt 110. The first protrusions of the film 210 extend through the first side of the felt 110 towards the holes / passages of the felt 140 of the felt fibrous 100. The first protuberances of the film 220 are formed at the end of the first protuberances of the film 210.

In the same way as the first film coating 200, the second film coating 300, the second film coating 300 adheres to the fibers 130 exposed on the second side of the felt 120 of the fibrous felt 100. In a preferred embodiment, the second film coating 300 it encapsulates some of the fibers 130 on the second side of the felt 120. The second protuberances of the film 310 extend toward the holes / passages 140 of the felt on the second side of the felt 120 of the fibrous felt. The second perforations of the film 320 are formed at the end of the second protuberances of the film 310 of the second film coating 300. The extension of the first protrusions of the film and the second protuberances of the film 310 in the fibrous felt 100, prevent that the individual fibers 130 escape through the first perforations of the film 220 and the second perforations of the film 320, if these individual fibers become detached from the fibrous felt 100. Furthermore, at different points of the fibrous felt 100, the first perforations of the film 220 can even be joined with the second perforations of the film 320 to form a passage from the first film coating 200 to the second film coating 300.

The material of the first film coating 200 and the second film coating 300 is selected based on the desired characteristics that the respective film coating will provide to the composite structure 10. In one embodiment, the first film coating 200 and / or the second film coating 300 they provide rigidity to the composite structure using a thermoplastic material. Examples of the thermoplastic materials that can be used in the present invention include: high density polyethylene (HDPE), nylon, polyester, polypropylene, polystyrene, polycarbonate, combinations thereof, or the like. In addition, the material of the first film coating 200 and / or the second film coating 300 can be filled to improve stiffness, with materials such as calcium carbonate, talc, clay or other common fillers. In another embodiment, the first film coating 200 and / or the second film coating 300 are formed of an adhesive material to facilitate adhesion of the composite structure 10 to other structures. Examples of adhesive materials that can be used in the present invention include ionomer copolymers, ethylene acrylic acid (EAA), ethylene methyl acrylic acid (EMAA), ethylene vinyl acetate (EVA), ultra low density polyethylene (ULDPE), ethyl methyl acrylate (EMA), combinations of these or similar. In still another embodiment, the first film coating 200 and / or the second film coating 300 is a co-extrusion of two or more layers of different materials, as shown in Figures 3 and 4. For example, as shown in Figure 3 , the second film coating 200 can be a co-extrusion having a first layer of high density polyethylene film 200a adjacent to the fibrous felt 100 to provide structural rigidity, and a first layer of film adhesive material 200b on the opposite side to facilitate bonding to the composite structure 10. The coextrusion of a material such as high density polyethylene between an adhesive layer and the fibrous felt 100 prevents the migration of the adhesive layer towards the fibrous material. In another example as shown in Figure 4, the second film coating 300 is also a coextrusion with a second layer of high density polyethylene film 300a adjacent to the fibrous felt 100 to provide structural rigidity, and a second layer of film adhesive material 300b on the opposite side to facilitate attachment to the composite structure 10. One part of the present invention is the unexpected additional stiffness of the composite structure 10. The entire composite structure has a stiffness greater than the stiffness of the fibrous felt 100, the first and second film coatings 200 and 300, or the expected rigidity of the combination of the fibrous felt 100, the first film 200 and the second film 300. Referring now to Figures 5-7, there is shown one embodiment of a process for forming the composite structure 10 from Figures 1-4 illustrated as the 600 training process. The 600 training process in general includes a supply of the fibrous felt 610, a forming station of the first film coating 620, a forming station of the second film coating 630, a corona treatment station 640 and a device for receiving the compound 650. The fibrous felt 100 proceeds from the feeding of the fibrous felt 610 to the forming station of the first film coating 620. In the forming station of the first film coating 620, the fibrous felt proceeds on a first screen with vacuum 621. The first vacuum screen 621 includes a plurality of first openings of the vacuum screen 622. A first extruder 623 extrudes a first film material 624 on the fibrous felt 100 located on the first vacuum screen 621. A first vacuum source 625 behind the first vacuum screen 621 sucks the first film materials 624 towards the fibrous felt 100 forming the first film coating 200 with the first protuberances of the film 210 and the first perforations of the film 220 extending towards the holes / passages of the felt 140. In one embodiment, the vacuum source 625 can provide a vacuum of approximately 20 inches of mercury or less, and preferably between about 10 to about 15 inches of mercury. The fibrous felt 100 with the first film coating 200 therein continues from the forming station of the first film coating 220 to the forming station of the second film coating 630. At the forming station of the second film coating 630, the fibrous felt 100 and the first coating film 200 are placed on a second vacuum screen 631 with the first film coating 200 clutching the second vacuum screen 631. The second vacuum screen 631 includes a plurality of second openings of the vacuum screen 632, so that at least one portion of the openings of the second vacuum screen align with the first perforations of the film 220 in the first film coating 200. A second extruder 633 extrudes a second film material 634 on the second side of the felt 120 of the fibrous felt 100. A second vacuum source 635 behind the second vacuum screen 621 sucks the second mate film layer 634 in clutch with the second side of the felt 120 of the fibrous felt 100 so that the second film material 634 encapsulates the fibers 130 on the second side of the felt 120 of the fibrous felt, and extends towards the holes / passages of the felt 140 on the second side of the felt 120 to form the second protuberances of the film 130 and the second perforations of the film 320 of the second film coating 300. In one embodiment, the vacuum source 635 can provide a vacuum of approximately 20 inches of mercury or less, and preferably between about 10 to about 15 inches of mercury. Although Figure 5 is exemplified as a single continuous process, the present invention can be practiced by applying the first film coating in a first process, and performing the remaining steps in a second separate process. After the second film coating is formed on the fibrous felt 100, the composite structure 10 advances to a corona treatment station 640, if corona treatment is desired in the final product. After the final processing, the composite structure 10 is collected on a device for collecting the compound 650. In addition to the criteria already mentioned for selecting the material of the fibrous felt 100, this is the material capacity of the fibrous felt 100 to be used in the forming process 600 of the composite structure 10. The fibrous felt 100 must be very flexible to pass over the first and second vacuum screens 621 and 631, as well as the other equipment in the forming process 600. Likewise, the open area of the fibrous felt 100 the viscosity of the first and second film materials 624 and 634 should be sufficient that the first and second film materials 624 and 634 are drawn into the material of the fibrous felt 100 for perforation. In a preferred embodiment, the first and second film materials 624 and 634 have a melt index of from about 10 to about 20, preferably about 18 [sic]. The open area of the first vacuum screen 621 is selected to provide the highest probability of opening the first vacuum screen 622 by aligning with the holes / passages of the felt 140 in the fibrous material 100, to facilitate securing the first film coating 200 on the fibrous felt 100. In one embodiment, the fibrous felt 100 had an open area of about 50%, the open area of the first vacuum screen 621 was from about 60% to about 70%, resulting in an open area of the combination of the fibrous felt 100 with the first film coating 200 of about 15%. The open area of the second vacuum screen 631 is selected to provide the highest possibility that the openings of the second vacuum screen 632 align with the first perforations of the film 222 in the first film coating. In one embodiment, the second vacuum screen 631 has an open area from about 60% to about 70%, and was used in the combination of a fibrous felt 100 with a first film overlay 200 with an open area of about 15%, which caused the combination of the fibrous felt 100 with the first film coating 200 and the second film coating 300 having an open area of about 1% to about 10%. The above method was used to produce the following examples of the present invention.

EXAMPLE 1 A fiberglass felt JOHNS MANVILLE 8440 was coated on each side with a mixed high density polyethylene (HDPE) film with a weight per area of forty (40) grams per square meter. The HDPE mixture includes seventy percent (70%) by weight of EQUISTOR H6018 (HDPE) and thirty percent (30%) by weight of DOW 2517 (LDPE) and has a thickness of approximately 1.5 mils.

EXAMPLE 2 A fiberglass felt JOHNS MANVILLE 8450 is covered on both sides with a laminated film. The laminated film has a first layer of the HDPE mixture placed next to the glass fiber felt, a second layer of the adhesive mixture placed on the side of the laminate opposite the glass fiber felt. The first layer is a layer of 0.25 mils of a HDPE mixture of seventy percent (70%) by weight of EQUISTOR H6018 and thirty percent (30%) by weight of DOW 2517. The second layer is a layer of 1.25 mils of a seventy-five percent (75%) by weight adhesive blend of DUPONT BYNEL 2022 (EMA copolymer) and twenty-five percent (25%) by weight of DUPONT SURLYN 1855 (zinc ionomer).

EXAMPLE 3 A fiberglass felt JOHNS MANVILLE 8440 is covered on a first side with a film of the mixture HDPE, and on a second side with a film of the adhesive mixture. The HDPE blend film is a 2.5 mil film of a mixture of seventy percent (70%) by weight of EQUISTOR H6018 and thirty percent (30%) by weight of DOW 2517. The film of the adhesive mixture is a 1.0 mil film of a mixture of fifty-two and a half percent (52.5%) by weight of DUPONT 2022 seventeen and one-half percent (17.5%) by weight of DUPONT 1855 and thirty percent (30%) by weight of DOW 2517.

EXAMPLE 4 A fiberglass felt JOHNS MANVILLE 8440 is covered on both sides with a polypropylene mix film of 1.5 mils. In this modality, the polypropylene mixture is a mixture of seventy percent (70%) by weight of FINA 6573 (PP), twenty-two and a half percent (22.5%) by weight of DUPONT 2022, and seven and a half percent ( 7.5%) of DUPONT 1855. Now with reference to Figure 8 there is shown an embodiment of an invention using the composite material of Figures 1-4, exemplified as the component structure 800. The component part 800 generally includes the composite structure 10, a structural foam 820 and a soft foam 830. The composite structure 10 is of the type having an adhesive layer 200b and 300b located outwardly of the fibrous felt 100, as shown in Figure 4. The component part 800 is formed by thermal activation of the adhesive layers 200b and 300b in the composite structure 10, and fixing the structural foam 820 and the soft foam 830 to the opposite sides of the composite structure 10. The component part 800 may be molded into a shape to accommodate the application of the component part 830 as for a top coating on a car. The use of the fibrous felt 10 with the adhesive layers 200b and 300b eliminates the need for an adhesive sheet between the fibrous felt and the structural foam 820 or the soft foam 800. Furthermore, a part of the present invention is the discovery that the use of the composite structure 10 with the protuberances 210 and 310 and the perforations 220 and 320 offer additional, unexpected acoustic attenuation properties in the component part 800.

Claims (29)

1. A composite structure comprising: a fibrous felt with a first side of the felt and a second side of the felt, the fibrous felt being formed of a plurality of fibers so as to form therein a plurality of passages a first film coating placed on the first side of the felt of the felt fibrous, the first film coating includes a plurality of first protuberances of the film with first openings of the film, the plurality of the first protuberances of the film extending towards the plurality of passages in the fibrous felt; and a second film coating placed on the second side of the felt of the fibrous felt, the second skin coating includes a plurality of second protrusions of the film with second openings of the film, the plurality of second protuberances of the film extending toward the plurality of passages. in the fibrous felt.

2. The composite structure according to claim 1, wherein the first film coating is a first adhesive film.

3. The composite structure according to claim 2, wherein the first adhesive film is treated in a crown.

4. The composite structure according to claim 2, wherein the second film coating is a second adhesive film.

5. The composite structure according to claim 4, wherein the second adhesive film receives corona treatment.

6. The composite structure according to claim 2, wherein the second film coating is a multilayer film.

7. The composite structure according to claim 6, wherein the multilayer film has an external adhesive layer.

8. The composite structure according to claim 7, wherein the outer adhesive layer receives corona treatment.

9. The composite structure according to claim 1, wherein the first film coating is a first multilayer film.

10. The composite structure according to claim 9, wherein the first multilayer film has a first external adhesive layer on the film.

11. The composite structure according to claim 10, wherein the first external adhesive layer of the film receives corona treatment.

12. The composite structure according to claim 11, wherein the second film coating is a second multilayer film.

13. The composite structure according to claim 12, wherein the second multilayer film has a second external adhesive layer of the film.

14. The composite structure according to claim 13, wherein the second external adhesive layer of the film receives corona treatment.

15. A composite structure comprising: a fibrous felt with a first side of the felt and a second side of the felt, the fibrous felt being formed from a plurality of fibers so that a plurality of passages are formed therein; and an adhesive film coating placed on the first side of the felt of the fibrous felt, the adhesive film coating includes a plurality of protrusions of the adhesive film with openings of the adhesive film, the plurality of protrusions of the adhesive film extending toward the plurality of the adhesive film. passages in the fibrous felt.

16. The composite structure according to claim 15, wherein the coating of the adhesive film receives corona treatment.

17. A composite structure comprising: a fibrous felt having a first side of the felt and a second side of the felt, the fibrous felt being formed from a plurality of fibers so that a plurality of passages are formed therein; and a multilayer film coating placed on the first side of the felt of the fibrous felt, the multilayer film coating includes a plurality of protrusions of the multilayer film with openings of the multilayer film, the plurality of protrusions of the multilayer film extending toward the plurality passages in the fibrous felt.

18. The composite structure according to claim 17, wherein the coating of the multilayer film has an outer adhesive layer.

19. The composite structure according to claim 18, wherein the outer adhesive layer of the multilayer film coating receives corona treatment.

20. A process to form a composite material, comprises the steps of: providing a fibrous felt with a first side of the felt and a second side of the felt placing the second side of the felt of the fibrous felt on a first perforated screen placing a material of the first skin over the first side of the fibrous felt placed over the first perforated screen applying a vacuum on the back side of the first screen perforated with the fibrous felt and the material of the first film coating located therein to form a first film coating on the first side of the fibrous felt placing the fibrous felt on the second screen perforated with the first film coating next to the second perforated screen place a material for the second film coating on the second side of the fibrous felt placed on the second perforated screen apply a vacuum to the back side of the second screen perforated with the first film coating, the fibrous felt , and the material for the The film coating is placed on it to form a second film coating on the second side of the fibrous felt.

21. The process according to claim 20, further includes the step of treating in corona the first film coating on the first side of the fibrous felt.

22. The process according to claim 21 further includes the step of treating the second film coating on the second side of the fibrous felt in a crown.

23. The process according to claim 20, wherein the step of placing the material of the first film coating on the first side of the fibrous felt includes the step of coextruding a multilayer material of the first film coating onto the first side of the fibrous felt.

24. The process according to claim 23, further includes the step of treating in corona the first film coating on the first side of the fibrous felt.

25. The process according to claim 23, wherein the step of placing a material for the second film coating on the second side of the fibrous felt includes the step of coextruding a material of the second multilayer film coating onto the second side of the fibrous felt.

26. The process according to claim 25, further includes the step of treating the second film coating on the second side of the fibrous felt in a crown.

27. A process for forming a composite material, comprising the steps of: providing a fibrous felt with a first side of the felt and a second side of the felt placing the second side of the felt of the fibrous felt on a first perforated screen coextruding a material of the first multilayer film coating on the first side of the fibrous felt placed on the first screen perforated; and applying a vacuum on the back side of the first perforated screen with the fibrous felt and the material of the first film coating placed thereon to form a first multilayer film coating on the first side of the fibrous felt

28. The process according to claim 27, further includes the step of treating the first multilayer film coating on the first side of the fibrous felt in a crown.

29. The composite structure according to claim 1, wherein the plurality of the first apertures of the film is connected to a plurality of the second apertures of the film to form a plurality of passages completely through the fibrous felt.