WO2004037535A1 - Stratifies plats et procede de production de ces stratifies - Google Patents

Stratifies plats et procede de production de ces stratifies Download PDF

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Publication number
WO2004037535A1
WO2004037535A1 PCT/EP2003/011984 EP0311984W WO2004037535A1 WO 2004037535 A1 WO2004037535 A1 WO 2004037535A1 EP 0311984 W EP0311984 W EP 0311984W WO 2004037535 A1 WO2004037535 A1 WO 2004037535A1
Authority
WO
WIPO (PCT)
Prior art keywords
laminated body
carrier fleece
press
fleece
carrier
Prior art date
Application number
PCT/EP2003/011984
Other languages
German (de)
English (en)
Inventor
Jochen Gassan
Kathrin Reichel
Original Assignee
Faurecia Innenraum Systeme 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 Faurecia Innenraum Systeme Gmbh filed Critical Faurecia Innenraum Systeme Gmbh
Priority to AU2003276202A priority Critical patent/AU2003276202A1/en
Publication of WO2004037535A1 publication Critical patent/WO2004037535A1/fr

Links

Classifications

    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/26—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • B32B2037/243—Coating
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
    • 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
    • B32B2605/003—Interior finishings
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/06—Embossing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners

Definitions

  • Flat laminates are e.g. already known in principle as trim parts in the interior of motor vehicles.
  • Such a laminated body has, for example, a carrier fleece onto which a decorative layer facing the later motor vehicle interior is applied, which is intended to meet certain requirements regarding UV resistance, scratch resistance and visual appearance.
  • This decorative layer which is, for example, thermoplastic and can have a grain, is connected to the carrier fleece, for example, via a thermoplastic intermediate layer.
  • FIGS. 2a and 2b show process sequences for the production of known laminates.
  • thermosetting bonded nonwovens shows a known method which is used for thermosetting bonded nonwovens.
  • a fiber mat impregnated with a thermosetting system in the “pressing” process according to FIG. 2a is finally compressed in a press under high pressure.
  • the resulting carrier is then applied in the "adhesive application” step with e.g. Provide spray adhesive.
  • This spray adhesive is then e.g. in the step “Activate” made adhesive by heat, finally a e.g. grained decorative layer in the step “pressure or vacuum lamination” firmly connected to the carrier part.
  • Toxic spray glue should be criticized for the loss of glue during the spraying process.
  • thermoplastic bonded carrier materials for example, a natural fiber mat with thermoplastic fibers contained therein is first heated and compressed (for example to 200 ° C.). Then, in the “lamination” step, a decorative film is applied, finally in the “Forming + Consolidating” step, the decorative layer is connected to the carrier fleece in a press, so that a finished carrier part is available after cooling (this process is also called a "one-shot""Method referred to).
  • Both of the methods described above also have the disadvantage that, in addition to the time-consuming production method, the later laminate is cost-intensive and also weight-intensive due to the necessary decorative layer.
  • the present invention is based on the object of providing a laminated body or a method for its production, the laminated body being quick and inexpensive and environmentally friendly to produce and also having a low weight with a satisfactory surface quality.
  • thermosetting bonded fiber fleece onto which a barrier layer for preventing the passage of liquid, in particular liquid plastic, on which a thermosetting film is arranged, can be made more economical and lighter in weight
  • Laminates are produced, which does not require costly decorative film.
  • thermoset-bonded fiber fleece can be used to produce an inexpensive carrier part.
  • the barrier layer is used, for example, for coloring, and this barrier layer also ensures that, for example during the manufacturing process at high temperatures, the thermosetting film penetrates into the carrier fleece and an optically unsatisfactory later laminate surface on the inside. generated space of a motor vehicle.
  • the color of the layered body surface can be designed practically as desired by the thermosetting film. This also ensures UV resistance, and scratch resistance of the component surface is also ensured.
  • the manufacturing method according to the invention is particularly suitable.
  • This relates to a layered body with at least one thermosetting carrier fleece and at least one further layer connected to the carrier fleece (e.g. the barrier layer).
  • the carrier fleece is firmly connected to the at least one further layer by hot deformation in a press.
  • this method can be carried out quickly, since the nonwoven does not have to be finally compacted in a previous pressing process and later cooled, but the at least one further layer is joined directly during the final compression. It is particularly important here that in the “half-shot” method according to the invention the carrier fleece is finally compacted and on the other hand a further layer which has another function (namely that of a later cover layer or optically perfect surface layer) is joined together. It is essential here that the barrier layer sags
  • inventive layer body or Corresponding manufacturing processes it is thus possible to design novel and inexpensive surfaces, or a simplified process for applying new surfaces to wood fiber molding materials is provided.
  • shorter cycles are achieved when applying new surfaces; Existing energies can even be used here (the existing press heat becomes the final compaction of the carrier fleece (in order to achieve the adhesion of the at least one further layer).
  • the carrier fleece consists of natural fibers such as wood, flax, hemp or the like. This makes it possible to produce a lightweight carrier fleece using environmentally friendly fibers that are available everywhere.
  • These natural fibers can be bound by a system crosslinking as a polymer matrix based on phenolic resin, acrylate, epoxy resin, PUR or the like. These are also inexpensive and easily available materials that allow a lightweight carrier fleece.
  • the natural fibers in the carrier fleece can be homogeneously or integrally wetted with the crosslinking system before consolidation.
  • additional thermoplastic fibers it is also possible to incorporate additional thermoplastic fibers in order to influence the binding effect between the natural fibers and the adjacent layers in a targeted manner.
  • the barrier layer is particularly important in the invention. laminate according to the invention. Depending on its coloring, the subsequent surface coloring (which is also influenced by a partially transparent, thermosetting film) can be influenced.
  • This barrier layer can preferably be made of polyester. If possible, the barrier layer should have a basis weight between 100 and 300 g / m 2 ; It is important to make sure that there is compatibility or the best possible liability for the carrier to be connected; the processing temperature must be selected so that the joining of the barrier layer takes place melting or non-melting (both or mixed forms thereof are possible). In principle, any polar low-melting plastics for the production of the barrier layer are possible for the barrier layer. Polypropylene or polyamide can also be used for the barrier layer.
  • the barrier layer can also consist of cellulose. With this non-melting material, the textile character of the later surface is achieved. A desired structure can therefore also be specified (for example using a "crepe paper" layer as a barrier layer). This provides good structural effects in a cost effective manner; the advantage here is that optical defects (for example due to a damaged press) can be easily concealed. All in all, a wide variety of materials can be used for the barrier layer, but it is important that they can prevent the thermosetting film attached to the barrier layer from passing through to the carrier fleece. It should also be noted that the barrier layer can only consist "predominantly" of cellulose, polyester, polypropylene, polyamide, in the present context that these materials have a total weight of over 50%. the barrier layer should make up.
  • thermosetting film consists of a material based on acrylate, phenolic resin, PU or epoxy resin. Properties such as coloring, UV resistance or resistance to force are achieved in this way; a non-changing layer thickness, even during hot forming, is achieved in that the barrier layer is not permeable to liquids.
  • a particularly advantageous development of the method according to the invention provides that the press, with which the carrier fleece is compressed and firmly connected to the at least one further layer, has a scar structure on its inside for impressing an essentially complementary scar structure on an outer surface of the laminated body ,
  • the at least one further layer enables the at least one further layer to be easily structured, even if it does not have structural effects inherently (as with crepe paper etc.). To achieve the grained effect, by means of which surface defects can be easily concealed, it is therefore not necessary to provide a heavy film which is grained in itself.
  • the process according to the invention is also simpler to carry out than in the case of thermoplastic (injection molding) processes with a grained press, because there is no sticking of the thermoplastic layer to the press or no environmentally harmful release agent is necessary or expensive Teflon surfaces are required in the press.
  • a further advantageous development of the method provides that the at least one further layer consists of polyester, cellulose, polypropylene or polyamide at least 50 percent by weight.
  • the at least one further layer can be designed in different ways, in particular, however, in that a layering of a barrier layer described above with a thermosetting film applied there is given.
  • a further advantageous development of the method according to the invention provides that the press with which the hot forming described above is carried out is heated. Alternatively, however, it is also possible for the at least one further
  • Layer or also the pre-compressed carrier fleece are heated before insertion into the press and the residual heat or press heat is used to accomplish the hot deformation.
  • a semi-finished product of the carrier fleece is first pressed to form a carrier part (in a "press program 1"); afterwards the support part remains in the press; at least one further layer is then placed on the support part, the press heat of the support part is then used to achieve adhesion of the at least one further layer to the decor to the support part; The support part and the at least one additional layer are pressed into one component when another press program ("Press program 2") is set.
  • Press program 2 another press program
  • the temperature of the press on its inner side facing the laminate during the final compression is 70 ° C.
  • the pressing time until the final compaction or final joining of the layered body 20 seconds to 10 minutes, preferably 30 seconds to 3 minutes; the pressure is between 0.5 and 6 MPa.
  • FIGS. la-lc laminate according to the invention FIGS. 2a and 2b: manufacturing processes according to the prior art
  • Fig. La shows a flat laminate according to the invention. This is part of a trim part in the interior of a motor vehicle, e.g. an instrument panel.
  • the layered body 1 has a carrier fleece 2.
  • This is a thermosetting fiber fleece made of natural fibers such as wood, flax, hemp or the like. Of course, other fiber materials are also possible. Of course, other fiber materials are also possible, for example all polymer fibers. as well as glass fibers.
  • the carrier fleece 2 is bound by a system crosslinking as a polymer matrix based on phenolic resin, acrylate, epoxy resin or PUR.
  • a barrier layer 3 for preventing the passage of liquid, in particular liquid plastic, is firmly attached to the top of the carrier fleece 2. This barrier layer can either consist entirely or more than 50 percent by weight of polyester, cellulose, polypropylene or polyamide or mixtures of these substances.
  • a thermosetting film 4 is applied from a material based on acrylate, phenolic resin, PU or epoxy resin, which has already hardened and is therefore scratch-resistant and UV-resistant. The color of the thermoset also determines
  • FIGS. 1b and 1c show further embodiments of laminated bodies which can be produced using the method according to the invention shown in FIG. 2c.
  • a natural fiber mat 2 ' is shown, on which a textile carrier 3' is applied, which consists of cellulose, polyester, polypropylene, polyamide or the like, which carrier in addition to the barrier function also the coloring, UV resistance and strength resistance the later instrument panel surface guaranteed.
  • thermosetting film is applied directly to a (though liquid) carrier 2 11.
  • mats or comparable other semi-finished products are to be used, which are Process are consolidated into a high density material or prevent the penetration of the surface material into the carrier material due to a suitable mat formulation.
  • sandwich mats with an increased supply of binders on the mat surfaces should preferably be provided with a blowing agent or appropriate mats with an increased synthetic fiber content on the fiber surface should be used.
  • fibers with a low melting point ie a melting temperature well below the curing temperature of the mat and surface, which must continue to be "compatible" with the thermoset film.
  • a carrier fleece is produced from natural fibers such as wood, flax, hemp or the like. This fleece is then impregnated homogeneously or integrally by a system which crosslinks later as a polymer matrix and is based on phenolic resin, acrylate resin, epoxy resin, PUR or the like (homogeneous or integral). After possible pre-compression steps of this carrier fleece to be thermosetly bonded, at least one further layer (a later surface layer of the vehicle instrument panel to be produced, for example) is then placed on this mat.
  • the (pre-compressed) carrier fleece and the applied, at least one further layer during the final compression of the carrier fleece by hot forming in a press firmly connected to each other see Fig. 2c, process "pressing”
  • the press for hot forming the carrier fleece 2 and the at least one further layer (barrier layer 3, thermosetting film 4) has a scar structure on its inside facing the surface 5 (see FIG. 1 a) for applying an essentially complementary scar structure of the laminated body 1.
  • the production which essentially takes place in only a single step, takes place in the press at a temperature of the press on its inner side facing the laminate with the final compression of 70 ° C.-250 ° C., preferably 100 ° C.-200 ° C instead.
  • the pressing time is 20 sec. - 10 min., Preferably 30 sec. - 3 min.,
  • the pressing pressure is between 0.5 and 6 MPa.
  • the laminate which can be used as part of a trim part for motor vehicle interiors.
  • the laminate here has at least one thermoset-bonded carrier fleece and a further layer connected to the carrier fleece, the carrier fleece being firmly connected to the at least one further layer during final compression of the carrier fleece by hot forming in a press.
  • the further layer is designed as a barrier layer with a thermosetting film applied to the side of the barrier layer facing away from the carrier fleece, the barrier layer being designed in such a way that during the pressing process it prevents the thermosetting film from passing through the barrier layer to the carrier fleece. In this way, a high-quality part of a motor vehicle interior trim can be produced in a single production step (and thus quickly and very inexpensively).
  • the thermosetting film arranged above serves only to protect this barrier layer and can also have a grain, for example. It is important, however, that the provision of the barrier layer, which prevents the thermoset film from passing through, does not cause any "spots" to appear, so that the thermoset film has a cross-section that is constant over the surface of the carrier part.
  • the present process can also be carried out at relatively high temperatures, for this purpose the temperature of the press on its inner side facing the laminate in the final compression is particularly preferably 140 ° C. to 200 ° C., very particularly preferably 160 ° C. to 180 ° C. so that the final compression of the laminate takes place at these temperatures.
  • thermosetting film selected on the barrier layer is one that is highly stretchable or deformable (up to 70% based on the undeformed state of the barrier layer). This ensures that there are no cracks in the thermoset film during the strong 3D deformation during the pressing process.
  • the present method is also distinguished by a particular environmental friendliness, which is expressed, for example, by the fact that a natural fiber fleece is used. It should also be emphasized here that preference is given to using single-layer fleece structures (that is to say no paper layers, etc.), which further improves the 3D deformability.
  • the thickness of these preferably single-layer natural fiber fleece layers is 1.2 mm to 2.5 mm, preferably 1.7 mm to 2.2 mm (in the final compressed state).
  • the density of the carrier fleece in the final compressed state is 0.6 g / cm 3 to 0.7 g / cm 3 .
  • the carrier fleece preferably has a thickness of 2 mm in the final compressed state, a weight per unit area of 1,400 g / m 3 , and the density is 0.7 g / cm 3 . It should be emphasized here that despite the lightweight construction and the low thickness of the carrier fleece, no “backing” of the rear side of the carrier fleece is necessary.

Abstract

La présente invention concerne un stratifié plat, ainsi qu'un procédé de production de ce stratifié. Selon l'invention, ce stratifié (1) comprend un support non-tissé (2) qui se présente sous la forme d'un non-tissé lié par thermodurcissement. Sur ce non-tissé est appliquée une couche barrière (3) destinée à empêcher le passage de liquide, notamment de plastique liquide, cette couche barrière (3) étant elle-même recouverte d'un film thermodurcissable (4).
PCT/EP2003/011984 2002-10-28 2003-10-28 Stratifies plats et procede de production de ces stratifies WO2004037535A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2003276202A AU2003276202A1 (en) 2002-10-28 2003-10-28 Laminated materials and method for the production thereof

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE2002150989 DE10250989A1 (de) 2002-10-28 2002-10-28 Flächige Schichtkörper und Verfahren zu deren Herstellung
DE10250989.1 2002-10-28

Publications (1)

Publication Number Publication Date
WO2004037535A1 true WO2004037535A1 (fr) 2004-05-06

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2003/011984 WO2004037535A1 (fr) 2002-10-28 2003-10-28 Stratifies plats et procede de production de ces stratifies

Country Status (3)

Country Link
AU (1) AU2003276202A1 (fr)
DE (1) DE10250989A1 (fr)
WO (1) WO2004037535A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1851091A1 (fr) * 2005-02-21 2007-11-07 Karam Tech Co., Ltd. Element pour produits interieurs de vehicules a moteur presentant une structure multicouche
EP1972503A3 (fr) * 2007-03-21 2009-01-14 Johnson Controls Interiors GmbH & Co. KG Pièce d'équipement intérieur pour véhicule et procédé de fabrication
DE102013202461A1 (de) 2013-02-15 2014-08-21 Bayerische Motoren Werke Aktiengesellschaft Innenverkleidungsteil sowie Verfahren zu dessen Herstellung

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102013001144A1 (de) * 2013-01-23 2014-07-24 Thomas Hausmann Heftnadel aus faserverstärktem Kunststoff für eine Verbindungsvorrichtung zum temporären Verbinden von wenigstens zwei vorzugsweise plattenartigen Teilen sowie Verfahren zur Herstellung der Heftnadel
DE102022115270A1 (de) 2022-06-20 2023-12-21 Lisa Dräxlmaier GmbH Verfahren zur herstellung einer verbundmatte für ein dekorbauteil eines fahrzeugs

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EP0288107A2 (fr) * 1987-04-20 1988-10-26 The Boeing Company Laminés décoratifs avec une couche protectrice réduisant le dégagement de chaleur et empêchant la décoloration de l'encre
US5368916A (en) * 1991-04-08 1994-11-29 Nec Corporation Laminated vibration-damping material
EP0671259A1 (fr) * 1994-02-09 1995-09-13 R + S STANZTECHNIK GmbH Panneau composite multicouche ou corps avec une âme contenant des fibres naturelles ainsi que procédé pour sa fabrication
WO2001003927A1 (fr) * 1999-07-07 2001-01-18 Magna Eybl Ges.M B H Structure decorative a plusieurs couches, destinee a une partie d'equipement interieur d'un vehicule et partie d'equipement interieur d'un vehicule

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CH547076A (fr) * 1972-01-19 1974-03-29 Wernli Pierre Procede de fabrication d'un plateau de service et plateau obtenu par ce procede.
DE3147989A1 (de) * 1981-12-04 1983-06-16 Hoechst Ag, 6230 Frankfurt Dekoratives, insbesondere plattenfoermiges formteil, verfahren zu seiner herstellung und seine verwendung
DE3220768C2 (de) * 1982-06-02 1986-10-16 ERPE - Ernst Pelz - Vertriebs GmbH + Co - Verwaltungs KG, 8581 Vorbach Verfahren zum Herstellen von mit einer strukturierten Dekorschicht versehenen Formteilen aus Faservliesen
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Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0288107A2 (fr) * 1987-04-20 1988-10-26 The Boeing Company Laminés décoratifs avec une couche protectrice réduisant le dégagement de chaleur et empêchant la décoloration de l'encre
US5368916A (en) * 1991-04-08 1994-11-29 Nec Corporation Laminated vibration-damping material
EP0671259A1 (fr) * 1994-02-09 1995-09-13 R + S STANZTECHNIK GmbH Panneau composite multicouche ou corps avec une âme contenant des fibres naturelles ainsi que procédé pour sa fabrication
WO2001003927A1 (fr) * 1999-07-07 2001-01-18 Magna Eybl Ges.M B H Structure decorative a plusieurs couches, destinee a une partie d'equipement interieur d'un vehicule et partie d'equipement interieur d'un vehicule

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1851091A1 (fr) * 2005-02-21 2007-11-07 Karam Tech Co., Ltd. Element pour produits interieurs de vehicules a moteur presentant une structure multicouche
EP1851091A4 (fr) * 2005-02-21 2008-04-09 Karam Tech Co Ltd Element pour produits interieurs de vehicules a moteur presentant une structure multicouche
CN100591549C (zh) * 2005-02-21 2010-02-24 Li&S株式会社 具有多层结构的机动车内饰产品用部件
EP1972503A3 (fr) * 2007-03-21 2009-01-14 Johnson Controls Interiors GmbH & Co. KG Pièce d'équipement intérieur pour véhicule et procédé de fabrication
DE102013202461A1 (de) 2013-02-15 2014-08-21 Bayerische Motoren Werke Aktiengesellschaft Innenverkleidungsteil sowie Verfahren zu dessen Herstellung

Also Published As

Publication number Publication date
DE10250989A1 (de) 2004-05-13
AU2003276202A1 (en) 2004-05-13

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