WO2006066601A1 - Piece support thermoformable - Google Patents

Piece support thermoformable Download PDF

Info

Publication number
WO2006066601A1
WO2006066601A1 PCT/EP2004/014251 EP2004014251W WO2006066601A1 WO 2006066601 A1 WO2006066601 A1 WO 2006066601A1 EP 2004014251 W EP2004014251 W EP 2004014251W WO 2006066601 A1 WO2006066601 A1 WO 2006066601A1
Authority
WO
WIPO (PCT)
Prior art keywords
fibers
thermoformable
carrier part
part according
nonwoven fabric
Prior art date
Application number
PCT/EP2004/014251
Other languages
German (de)
English (en)
Inventor
Volker Wilhelm
Detlef Barbier
Norbert Goffing
Steve Lew
Walter Tseng
Original Assignee
Carl Freudenberg Kg
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 Carl Freudenberg Kg filed Critical Carl Freudenberg Kg
Priority to PCT/EP2004/014251 priority Critical patent/WO2006066601A1/fr
Publication of WO2006066601A1 publication Critical patent/WO2006066601A1/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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/02—Layered products comprising a layer of synthetic resin in the form of fibres or filaments
    • 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
    • B32B5/00—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
    • 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

Definitions

  • thermoformable carrier part comprising at least one layer of a spunbonded nonwoven, which preferably consists at least partially of contoured fibers, of hollow fibers or mixtures thereof, wherein the layer has a basis weight dry of 100-1500 g / m 2 at a thickness of 1-100 mm, as well as thermoformed carrier therefrom, in particular for molded parts of a vehicle.
  • thermoformed carrier parts such as.
  • headliner in vehicles thermoset composite materials are preferably used from several materials. It forms the core of such
  • Composite is a saturated or coated with liquid isocyanates polyurethane foam, which is solidified by crosslinking during deformation.
  • the isocyanate-impregnated or coated polyurethane foam is used before the Thermoforming, inter alia, covered on both sides with glass fibers. Nonwovens and / or films and decorative layers are applied over the glass fibers.
  • Such thermoformed carrier such as. As headliner, prepare because of the glass fibers contained therein problems in the disposal and show only a limited acoustic effectiveness, which is not sufficient for vehicles.
  • Corresponding constructions are known, for example, from DE-A-1 974 468 2, DE-A-1 975 710 2 or DE-A-1 981 315 2.
  • Carrier parts in which this problem is largely avoided, are known from DE-U-2 990 409 1. These carrier parts are made of staple fiber nonwovens based on thermoplastic polyester fibers, which have a high proportion of so-called bicomponent binder fibers in the nonwoven fabric to achieve the necessary mechanical properties, in particular a high stiffness and thermal resistance. To achieve the necessary stiffness basis weights of more than 1500 g / m 2 to 1800 g / m 2 are necessary, which is not acceptable in view of the desired weight reduction of vehicles and the associated lower fuel consumption.
  • thermoformable support member comprising a carrier formed therefrom, preferably a molding for vehicles, excellent acoustic effectiveness, easy disposal and excellent mechanical properties, in particular excellent rigidity, at a relatively low basis weight guaranteed.
  • thermoformable support part according to the invention comprising at least one layer of a spunbonded nonwoven fabric, wherein the layer has a basis weight dry of 100-1500 g / m 2 at a thickness of 1-100 mm.
  • the layer of spunbonded nonwoven fabric of the thermoformable carrier part has a weight per unit area of 300 to 1200 g / m 2 at a thickness of 2 to 30 mm, particularly preferably a basis weight of 400 to 1000 g / m 2 at a thickness of 3 to 15 mm.
  • thermoformable carrier part according to the invention preferably has no glass fibers.
  • the spunbonded fabrics used are preferably obtained from the corresponding polymer melt in line by spinning, drawing, laying and solidification.
  • solidification of the spunbonded nonwovens the well-known in the art methods such as thermofusion and possibly needling come into question.
  • the fibers of the spunbonded fabric are at least partially solid or hollow fibers. At least part of the fibers may have a round or contoured cross-section.
  • all the fibers of the spunbond fabric are solid, but preferably at least a portion of the fibers is hollow. It is also preferred that at least a part of the fibers has a contoured cross-section.
  • the contoured fibers preferably have a multilobal, polygonal, preferably triangular, star-shaped, flat, oval, T-shaped, Y-shaped shaped or H-shaped cross-section.
  • the hollow fibers Preferably, have a round cross-section.
  • the fibers of the spunbonded nonwoven fabric are preferably made of synthetic, particularly preferably thermoplastic polymers selected from the
  • the fibers of the spunbonded nonwoven fabric are made of polyester.
  • the spunbonded fabric also includes binder fibers.
  • binder fibers mono- and / or bicomponent binder fibers can be used.
  • the bicomponent binder fibers may preferably have a core / sheath or side by side construction.
  • the layer or layers of spunbonded nonwoven fabric are preferably solidified by thermofusion with the aid of mono- or bicomponent binder fibers and optionally by needle punching.
  • the needling of the spunbond fabric is carried out by known methods.
  • the binding fibers mentioned can, like the other fibers of the spunbonded fabric, have a round or contoured cross section, be solid or hollow, but a round cross section is preferred.
  • the contoured cross sections correspond to the cross sections given for the remaining fibers of the spunbonded fabric.
  • the monocomponent binder fibers have a contoured cross-section.
  • they are hollow.
  • the bicomponent binder fibers are preferably solid.
  • they have a contoured cross-section.
  • the binder fibers consist of at least one synthetic thermoplastic polymer selected from the group comprising polyesters, polyamides, viscose, polyolefins and polyacrylonitriles, wherein the bicomponent binder fibers are composed of two thermoplastic polymers with different melting points. At least one outboard part of a binder fiber is composed of a thermoplastic polymer which melts more deeply by at least 15 0 C as the polymers from which the fibers of the spunbonded nonwoven fabric are constructed.
  • these fibers are entirely composed of the aforementioned lower melting thermoplastic polymers, while when using bicomponent binder fibers, the outer-member polymer, preferably the sheath, of the bicomponent binder fibers has a melting point which is around at least 15 0 C is lower than the melting point of the polymer of the remaining part, preferably of the core, the
  • Bicomponent binding fibers or the remaining fibers of the spunbonded nonwoven fabric Preferably, one part, preferably the core, of the bicomponent binder fiber consists of the same polymer as the other fibers of the spunbonded nonwoven, more preferably the same polyester.
  • the monocomponent binder fiber or an outer part, preferably the sheath, the bicomponent binder fiber preferably consists of the same type of polymer of the thermoplastic polymer from which the remaining fibers of the spunbonded fabric have been produced, wherein, as already stated, such a polymer or Copolymer has a melting point at least 15 0 C lower than the melting point of the polymer were made from the fibers of the spunbonded nonwoven fabric.
  • the monocomponent binder fibers or an outer part, preferably the sheath, the bicomponent binder fiber of a further polyester or copolyester, if the fibers of the spunbonded fabric or the remaining part, preferably the core, the bicomponent Bindefasem consist of preferably identical polyesters.
  • the layer or layers of the spunbonded fabric can consist of up to 100% by weight of bicomponent binder fibers.
  • the layer or layers of the spunbonded fabric preferably have 20 to 80% by weight, particularly preferably 40 to 60% by weight, based on the total weight of the respective spunbonded nonwoven layer, bicomponent binder fibers or preferably 1-50% by weight, preferably 1 to 25% by weight, particularly preferably 5 to 20% by weight, based on the total weight of the spun-bonded nonwoven layer of the monocomponent binder fiber.
  • the fibers of the spunbonded fabric including the monocomponent binder fibers or the bicomponent binder fibers have a titer in the range of 2 to 20 dtex, preferably 5 to 15 dtex.
  • the layer or layers of spunbonded nonwoven fabric of the thermoformable carrier part according to the invention may also be constructed in multiple layers to adjust the mechanical properties of the carrier formed therefrom.
  • the individual layers of this layer preferably consist of identical spunbonded nonwovens. But it is also possible to use for each layer a spunbonded fabric of identical staple fibers and different binder fibers, provided that the above-mentioned conditions for the binder fibers are met. This also applies to a multi-layered build that out
  • the individual layers of the layer of spunbonded nonwoven fabric using an adhesive based on a polyolefin, a polyamide, copolyamide, a polyester, a copolyester, an optionally crosslinkable polyurethane and / or a crosslinkable epoxy resin, or by hydroentanglement and optionally by needling to connect with each other.
  • the adhesive can be used as a powder, adhesive fleece (M-Webs), spray adhesive, individual adhesive dots or in the form of an adhesive film.
  • thermoformable carrier part according to the invention also has a multi-layered construction beyond.
  • layer of spunbonded nonwoven fabric which may optionally be constructed in multiple layers, at least one surface of the support part may be covered with a textile covering layer.
  • the textile cover layer consists of a nonwoven fabric.
  • a nonwoven fabric a spunbonded fabric, a wet nonwoven fabric or a dry laid nonwoven fabric based on the above-mentioned fibers, preferably polyester fibers, may be used.
  • Nonwovens with a low intrinsic weight and with a low extensibility are preferably used.
  • cover layers of nonwoven fabric layers preferably have a thickness between 0.05 and 1 mm and have a weight per unit area of 20 to 250, preferably between 50 and 200 and very particularly preferably between 50 and 150 g / m 2 .
  • the nonwoven fabrics used can be solidified by any known consolidation methods such as needling, thermofusion, calendering, chemical bonding or hydroentanglement or a combination of these methods. Very particular preference is given to a spun-bonded nonwoven fabric or a dry-laid nonwoven fabric, if appropriate may contain up to 50-80 wt .-% of natural fibers and is solidified by water jet used.
  • natural fibers are z.
  • wood fibers flax, hemp, kenaf, jute or sisal fibers.
  • the concomitant use of natural fibers makes it possible to further increase the stiffness of the carriers formed from the carrier parts according to the invention. This is necessary if the thermoformed carrier as a molded part such.
  • the complete attachments such as sun visors, mirrors, lighting systems and cable strands must carry freely.
  • the second, opposite surface of the layer of spunbonded nonwoven fabric of the thermoformable support part according to the invention may also be covered with a further textile layer, which is preferably identical to the first cover layer described above.
  • the basis weight dry of the preferably used nonwoven fabric preferably corresponds to the values given above.
  • the total weight per unit area dry of the thermoformable carrier part according to the invention is 100-1500, preferably 300-1200, particularly preferably 400-1000 g / m 2 .
  • thermoformable carrier part preferably a molded part of a vehicle.
  • a visible decorative material can still be applied on the visible side of the above-described overall construction of the thermoformable carrier part according to the invention, so that after thermoforming of the carrier part the desired finished molded part, preferably a molded part of a vehicle, is obtained.
  • the bonding of the individual layers can be carried out with the aid of the abovementioned adhesives, after the layers have been preceded if necessary have already been loosely connected by a needling together.
  • these adhesives can be used as a powder, adhesive fleece (M-Webs), spray adhesive, individual adhesive dots or in the form of an adhesive film.
  • the permanent connection of the individual layers is preferably achieved by the subsequent thermoforming of the carrier part according to the invention, which is covered with the covering layers and optionally the decorative layer, in particular by the thermofusion of the binding fibers.
  • a further subject of the present invention is therefore also a process for the preparation of a thermoformable support member by in line, solid and / or hollow fibers with a round or contoured cross-section and corresponding mono- or bicomponent binder fibers according to a corresponding melt spinning process using suitable nozzle devices prepares, deposits to a spunbonded fabric and solidified by thermofusion using the existing mono- or bicomponent binder fibers and optionally needlepunching, optionally with the above-mentioned other textile layers, and optionally decorated and singulated into a carrier part.
  • thermoforming process for producing a thermoformed carrier from the thermoformable carrier part according to the invention can take place with the aid of a so-called cold or hot pressing process.
  • the thermoformable carrier part according to the invention which is optionally provided with the cover layers and the decorative layer, placed in a preheated press and deformed under pressure to the desired shape.
  • a corresponding thermoformable support member is heated prior to pressing by means of IR-beam, hot air or contact heating to the temperature necessary for the deformation and deformed in a cold press under pressure to the desired shape.
  • Another object of the present invention are therefore also a thermoformed carrier with a dry area of 100-1500 g / m 2 and with a flexural strength of> 1000 N mm.
  • These carriers are obtained by thermoforming from the thermoformable carrier part according to the invention. Preferably, they are used as a molded part of a vehicle.
  • thermoformed support is a molded part of a vehicle, preferably in the form of a vehicle headliner, a pillar and / or door panel, a floor panel, a parcel shelf, a trunk lining, at least part of an engine compartment lining, such as a Bonnetliner, an insert mat and / or a front wall insulation.
  • Fiber deposit slightly vorvernadelt and was thermally prefixed at 200 0 C is with a second layer of identical spunbonded nonwoven fabric having a basis weight of 250 g / m 2 using a propylene copolymer spunbonded with a basis weight of 30 g / m 2 at a temperature of 130 0 C laminated.
  • the total basis weight of the carrier part is 780 g / m 2 .
  • the support member is heated by means of flow heating so that the temperature is 200 0 C and pressed in a cold press at 80 0 C to a headliner. Obtained is a molding, which in the three-point bending test as indicated above, according to EN 310 has a maximum bending force of 35.9 N at a flexural strength of 1100 Nmm.
  • the acoustic behavior was determined in the impedance tube according to DIN EN ISO 105341-1 and compared with a headliner made of PU / glass fibers (prior art) in Tab.
  • the total basis weight of the carrier part is 1030 g / m 2 .
  • the support member is heated by means of flow heating so that the temperature is 200 0 C and pressed in a cold press at 80 0 C to a headliner. Obtained is a molding that in the three-point bending test as indicated above, according to EN 310 a maximum Bending force of 67.4 N with a bending stiffness of 1236 Nmm.
  • the acoustic behavior was determined in the impedance tube according to DIN EN ISO 105341-1 and compared with a headliner made of PU / glass fibers (prior art) in Tab.

Abstract

L'invention concerne une pièce support thermoformable comprenant au moins une couche constituée d'une matière filée-liée d'un poids surfacique sec de 100 - 1500 g/m2. L'invention concerne également des supports ainsi façonnés, de préférence, comme des pièces poulées destinées à des véhicules automobiles.
PCT/EP2004/014251 2004-12-15 2004-12-15 Piece support thermoformable WO2006066601A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/EP2004/014251 WO2006066601A1 (fr) 2004-12-15 2004-12-15 Piece support thermoformable

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/EP2004/014251 WO2006066601A1 (fr) 2004-12-15 2004-12-15 Piece support thermoformable

Publications (1)

Publication Number Publication Date
WO2006066601A1 true WO2006066601A1 (fr) 2006-06-29

Family

ID=34960047

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2004/014251 WO2006066601A1 (fr) 2004-12-15 2004-12-15 Piece support thermoformable

Country Status (1)

Country Link
WO (1) WO2006066601A1 (fr)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010108562A1 (fr) * 2009-03-25 2010-09-30 Carl Freudenberg Kg Triplure en non-tissé thermofixable, son procédé de fabrication et son utilisation
EP2366821A1 (fr) * 2010-03-19 2011-09-21 Carl Freudenberg KG Tissu non tissé en fibres naturelles fibrillées
WO2013014364A1 (fr) * 2011-07-28 2013-01-31 Saint-Gobain Adfors Revêtement mural absorbant acoustique renfermant une couche de fibres multilobees
FR2978459A1 (fr) * 2011-07-28 2013-02-01 Saint Gobain Adfors Revetement mural absorbant acoustique renfermant une couche de fibres multilobees
WO2013120885A1 (fr) * 2012-02-14 2013-08-22 Groz-Beckert Kg Pièce en matériau fibreux et son procédé de fabrication
EP2873768A1 (fr) * 2013-11-19 2015-05-20 Autoneum Management AG Tapis à double couche
WO2016166322A1 (fr) * 2015-04-16 2016-10-20 J.H. Ziegler Gmbh Matière textile composite
US10465320B2 (en) 2012-05-12 2019-11-05 Autoneum Management Ag Needle punched carpet

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2937399A1 (de) * 1979-09-15 1981-04-02 Empe-Werke Ernst Pelz Gmbh & Co Kg, 8192 Geretsried Ausstattungsteil fuer fahrzeuge und verfahren zu seiner herstellung
DE19757102A1 (de) * 1997-12-20 1999-06-24 Hp Chemie Pelzer Res & Dev Selbsttragendes Automobilformteil
WO2001090464A2 (fr) * 2000-05-24 2001-11-29 Kimberly-Clark Worldwide, Inc. Milieu de filtration presentant des caracteristiques ameliorees de retention particulaire
US20030119403A1 (en) * 2001-11-30 2003-06-26 Reemay, Inc. Spunbond nonwoven fabric

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2937399A1 (de) * 1979-09-15 1981-04-02 Empe-Werke Ernst Pelz Gmbh & Co Kg, 8192 Geretsried Ausstattungsteil fuer fahrzeuge und verfahren zu seiner herstellung
DE19757102A1 (de) * 1997-12-20 1999-06-24 Hp Chemie Pelzer Res & Dev Selbsttragendes Automobilformteil
WO2001090464A2 (fr) * 2000-05-24 2001-11-29 Kimberly-Clark Worldwide, Inc. Milieu de filtration presentant des caracteristiques ameliorees de retention particulaire
US20030119403A1 (en) * 2001-11-30 2003-06-26 Reemay, Inc. Spunbond nonwoven fabric

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
TWI395850B (zh) * 2009-03-25 2013-05-11 Freudenberg Carl Kg 可熱固定的內襯不織布、其製造方法及應用
KR101406150B1 (ko) * 2009-03-25 2014-06-12 칼 프로이덴베르크 카게 열고정성 인터라이닝 부직포, 인터라이닝 부직포의 제조 방법, 및 인터라이닝 부직포의 용도
WO2010108562A1 (fr) * 2009-03-25 2010-09-30 Carl Freudenberg Kg Triplure en non-tissé thermofixable, son procédé de fabrication et son utilisation
EP2366821A1 (fr) * 2010-03-19 2011-09-21 Carl Freudenberg KG Tissu non tissé en fibres naturelles fibrillées
FR2978459A1 (fr) * 2011-07-28 2013-02-01 Saint Gobain Adfors Revetement mural absorbant acoustique renfermant une couche de fibres multilobees
WO2013014364A1 (fr) * 2011-07-28 2013-01-31 Saint-Gobain Adfors Revêtement mural absorbant acoustique renfermant une couche de fibres multilobees
AU2012288730B2 (en) * 2011-07-28 2015-10-29 Saint-Gobain Adfors Acoustic absorbent wall coating
US9186865B2 (en) 2011-07-28 2015-11-17 Saint-Gobain Adfors Acoustic absorbent wall coating
WO2013120885A1 (fr) * 2012-02-14 2013-08-22 Groz-Beckert Kg Pièce en matériau fibreux et son procédé de fabrication
US10465320B2 (en) 2012-05-12 2019-11-05 Autoneum Management Ag Needle punched carpet
US11313063B2 (en) 2012-05-12 2022-04-26 Autoneum Management Ag Needle punched carpet
EP2873768A1 (fr) * 2013-11-19 2015-05-20 Autoneum Management AG Tapis à double couche
WO2015074870A1 (fr) * 2013-11-19 2015-05-28 Autoneum Management Ag Tapis double couche
CN105874119A (zh) * 2013-11-19 2016-08-17 欧拓管理公司 双层地毯
WO2016166322A1 (fr) * 2015-04-16 2016-10-20 J.H. Ziegler Gmbh Matière textile composite

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