WO2014082145A1 - Revêtement de tapis isolant à propriétés acoustiques et thermiques, fabriqué en plusieurs couches au moyen d'un procédé unique - Google Patents

Revêtement de tapis isolant à propriétés acoustiques et thermiques, fabriqué en plusieurs couches au moyen d'un procédé unique Download PDF

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Publication number
WO2014082145A1
WO2014082145A1 PCT/BR2012/000536 BR2012000536W WO2014082145A1 WO 2014082145 A1 WO2014082145 A1 WO 2014082145A1 BR 2012000536 W BR2012000536 W BR 2012000536W WO 2014082145 A1 WO2014082145 A1 WO 2014082145A1
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WO
WIPO (PCT)
Prior art keywords
layer
carpet
acoustic
thickness
blankets
Prior art date
Application number
PCT/BR2012/000536
Other languages
English (en)
Portuguese (pt)
Inventor
Sales Vanderlei Rezende Da Costa
Original Assignee
Sales Vanderlei Rezende Da Costa
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 Sales Vanderlei Rezende Da Costa filed Critical Sales Vanderlei Rezende Da Costa
Publication of WO2014082145A1 publication Critical patent/WO2014082145A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0076—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being a thermoplastic material applied by, e.g. extrusion coating, powder coating or laminating a thermoplastic film
    • 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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • B32B5/06—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 structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N3/00—Arrangements or adaptations of other passenger fittings, not otherwise provided for
    • B60N3/04—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0068—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the primary backing or the fibrous top layer
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0081—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing with at least one extra fibrous layer at the backing, e.g. stabilizing fibrous layer, fibrous secondary backing
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • 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
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0254—Polyolefin fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/02—Properties of the materials having acoustical properties
    • D06N2209/025—Insulating, sound absorber
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/06—Properties of the materials having thermal properties
    • D06N2209/065—Insulating

Definitions

  • the present application relates to an "ISOLATOR CARPET COATING WITH ACOUSTIC AND THERMAL PROPERTIES MADE IN MULTIPLE LAYERS IN A SINGLE PROCESS", which relates to an acoustic floor covering, particularly for cars, with a layer of carpet having on the back a mounting base and a thermal and acoustic insulation lower layer which are joined by hot pressing, producing an acoustic and thermal insulator and absorber with great efficiency.
  • the blankets used for this purpose consist of two layers, one of fiber and other heavy mass composed of elastomers, asphalt and mineral fillers, or two layers felt, these blankets do not fully develop their functions, because they can not fully absorb the noise.
  • floor liners have a very small sound absorption capacity.
  • floor liners with satisfactory sound absorption capacity, although these floor linings generally exhibit a relatively high surface weight, a fact which is disadvantageous in regard to the tendency to reduce the fuel consumption by reducing vehicle weight.
  • dispersive glues or acrylates are employed for fixing the warp of hairs.
  • these glues do not produce sufficient stiffness.
  • thermoplastic glues can, in fact, produce a high stiffness; but they have high coefficients of contraction, which causes an unsatisfactory flat position of a carpeting so fabricated.
  • DE 39 05 607 A 1 discloses an acoustic insulation floor lining for motor vehicles with a carpet layer and an acoustically acting layer which is comprised of a thermally absorbable, thermoformable synthetic material which can be processed to render foam and a layer of carded wool.
  • the carpet layer of this floor lining consists of a support layer, into which the carded fleece, the filament, through the application of tufts.
  • the filament For fixing the filament apply a coat of hotmelt or latex.
  • sintering of polyethylene powder is achieved over the filament attachment.
  • a foamed backing After the acoustically active layer is followed a foamed backing. Alternatively, between the acoustically active layer and the foamed backing, a cardboard cardboard wool or a heavy layer may still be placed. The fabrication of this known floor covering is relatively expensive.
  • Patent 0312296-4 The floor covering according to the invention consists essentially of a carpet layer having a base and a bottom layer which is bonded to the back side of the carpet layer through of fusible glue that is applied in several steps, being directly on the base of the carpet layer
  • melt adhesive which is applied in a subsequent step and which has an average melt flow rate in the range of from 140 to 160 g / 10min, preferably from about 150 g / 10 min.
  • the floor covering according to the invention is characterized by a good connection between the fiber material of the carpet layer and the acoustically active underlayer, which is preferably formed of light absorbent material.
  • a floor liner is obtained with a particularly light backing which exhibits no bending or contraction such that the carpet has a good flat position.
  • the floor lining according to the invention has a good rigidity, respectively good shape stability.
  • meltable glue is used as melt adhesive, for example melt adhesive EVA or LD-PE. Due to the comparatively high melt flow rate and the comparatively low melting point of the first applied melt glue, an excellent wear resistance is obtained at the base of the carpet layer.
  • the base of the carpet layer is a carded fabric, a knit or wool, the melt adhesive being applied immediately on the base and the melt adhesive applied in one step forming a layer of glue which exhibits a series of gaps defining passages for fluid.
  • the sound absorbing capacity of the floor liner according to the invention is improved.
  • the lower acoustic insulation layer of the liner according to the invention preferably consists of a carded wool layer, in particular a PET7 PP / PET mixed carded wool; and / or a heavy layer, in particular a foamed heavy layer.
  • Another advantageous configuration of the flooring liner according to the invention is that, in the second fusible glue, there are contained mineral micro-bodies and / or hollow mineral micro-bodies, such as hollow glass pellets or hollow ceramic pellets. These hollow bodies have a reduced weight and increase the stiffness, respectively, of the floor lining. Hollow micro-bodies are preferred because they are particularly light and act as thermal and acoustic insulation.
  • the shape stability, respectively the stiffness of the floor covering according to the invention, can be further increased by crosslinking additives, which are preferably added to the melt adhesive which is applied in the next step. In the case of such additives, it may be melamine resin powder, preferably. Melamine resin is distinguished by good resistance to temperatures and, in addition, has a certain flame protection effect.
  • the flame protection agent is contained in the melt adhesive applied in the next step.
  • the flame protection agent is preferably aluminum hydroxide powder and / or magnesium hydroxide powder.
  • the present invention relates to a layer of carpet (1) formed of synthetic fibers of PET or PP with a finish obtained by the interlacing of fibers by which determines the thickness and hardness of the layer by determining an acoustic barrier, said carpet (1) may have a Tok, Dilour and Velor surface finish, while the second layer is of thermoplastic molding (2). ) and the third layer is obtained by intertwining of natural and synthetic fibers by the process of forming a web through aiv-lay and determining the thickness and density.
  • the first carpet layer (1) is composed of:
  • the second thermoplastic molding layer 2 is composed of:
  • the third layer felt soft thermoplastic layer is composed of:
  • the first carpet layer 1 is a higher density layer whose function is to create an acoustic insulation barrier because its pores are more closed which does not prevent the passage of air between them in order to absorb the sound
  • the third thermoplastic or soft felt layer which has the function of acoustic and thermal absorption, because its pores are more open, the acoustic insulation capacity will vary according to the weight of the layer .
  • the blankets are formed by a suitable heating process and then subjected to a pressing, calendering or extrusion step so that said blankets can assume the shape of sheets of desired thicknesses.
  • PLATFORM OR BLANCK CONFORMATION the shaped sheets are joined by a suitable heating process and then subjected to a pressing, calendering or extrusion step that said blankets can assume the shape of sheets with desired thicknesses.
  • Figure 1 shows a schematic view of the layers.
  • Figure 2 shows a schematic view of the pressing of the layers.
  • Figure 3 shows a schematic view of the tool pressing or cold-cooled mold.
  • Figure 4 shows a schematic view of the finished part.
  • the first carpet layer (1) is composed of:
  • the second thermoplastic molding layer 2 is composed of:
  • the third layer felt soft thermoplastic layer is composed of:
  • the first layer of carpet (1) is a higher density layer, whose function is to create an acoustic ionization barrier, because its pores are more closed which does not impede the passage of air between them, in order to absorb the sound that the second thermoplastic felt layer (3), which has the acoustic and thermal absorption function, because its pores are more open, the acoustic isoiation capacity will vary according to the second molding layer (2). weight of the layer.
  • the blankets are formed by a suitable heating process and then subjected to a pressing, calendering or extrusion step so that said blankets can assume the shape of sheets of desired thicknesses.
  • PLATFORM OR BLANCK CONFORMATION the shaped sheets are joined by a suitable heating process and then subjected to a pressing, calendering or extrusion step so that said blankets can assume the shape of sheets of desired thicknesses.
  • CONFORMATION AND CLOSURE After the first completed step, the still heated blanket is placed in a cold-cooled tool or mold of desired shape, compressed and shaped into the final piece.
  • the first and second layers after pressing maintains a constant thickness
  • the third layer has its thickness varied according to the use of the product and the profile to be molded, that coating provides a better acoustic efficiency and lower weight by to the final product, the product being still ecologically correct, since in its manufacture recycled materials can be used, and it can be recycled either in the leftover material after cutting or even after being used, thus taking one of the few products that after use can give rise to the same product, which allows a reduction in the final cost.

Abstract

L'invention concerne un revêtement de tapis isolant à propriétés acoustiques et thermiques, fabriqué en plusieurs couches et au moyen d'un procédé unique, utilisé pour le revêtement d'automobiles. Ledit revêtement comprend une couche de tapis (1) constituée de fibres synthétiques de polyester ou de polypropylène avec finition obtenue par entrelacement de fibres synthétiques au moyen d'un procédé de cardage, ces fibres étant ancrées par aiguilletage, ce qui permet de déterminer l'épaisseur et la dureté de la couche, d'où la formation d'une barrière acoustique. Ledit tapis peut présenter une finition superficielle classique, la deuxième couche étant obtenue par moulage thermoplastique (2) et la troisième couche par entrelacement de fibres naturelles et synthétiques au moyen d'un procédé de formation de couverture. La première couche de tapis (1) présente un grammage de 150 à 700 g/m2; la deuxième couche de moulage thermoplastique (2) présente un grammage de 200 à 400 g/m2; la troisième couche (3) de feutre thermoplastique présente un grammage de 500 à 1000 g/m2, son épaisseur pouvant varier selon l'utilisation du produit final.
PCT/BR2012/000536 2012-11-30 2012-12-20 Revêtement de tapis isolant à propriétés acoustiques et thermiques, fabriqué en plusieurs couches au moyen d'un procédé unique WO2014082145A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
BRBR102012030529-1A BR102012030529A2 (pt) 2012-11-30 2012-11-30 Revestimento de carpete isolador com propriedades acústicas e térmicas confeccionada em múltiplas camadas em processo único
BRBR102012030529-1 2012-11-30

Publications (1)

Publication Number Publication Date
WO2014082145A1 true WO2014082145A1 (fr) 2014-06-05

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/BR2012/000536 WO2014082145A1 (fr) 2012-11-30 2012-12-20 Revêtement de tapis isolant à propriétés acoustiques et thermiques, fabriqué en plusieurs couches au moyen d'un procédé unique

Country Status (2)

Country Link
BR (1) BR102012030529A2 (fr)
WO (1) WO2014082145A1 (fr)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0384420B1 (fr) * 1989-02-23 1993-06-16 Bayerische Motoren Werke Aktiengesellschaft, Patentabteilung AJ-3 Revêtement de sol pour les véhicules et une méthode pour la fabrication du revêtement de sol
EP1517812B1 (fr) * 2002-07-01 2006-09-20 Carcoustics Tech Center GmbH Revetement de sol insonorisant et son procede de production
EP1948431A1 (fr) * 2005-11-03 2008-07-30 Racemark International, Lp Revetements de sols et procedes de fabrication et d'utilisation de ceux-ci

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0384420B1 (fr) * 1989-02-23 1993-06-16 Bayerische Motoren Werke Aktiengesellschaft, Patentabteilung AJ-3 Revêtement de sol pour les véhicules et une méthode pour la fabrication du revêtement de sol
EP1517812B1 (fr) * 2002-07-01 2006-09-20 Carcoustics Tech Center GmbH Revetement de sol insonorisant et son procede de production
EP1948431A1 (fr) * 2005-11-03 2008-07-30 Racemark International, Lp Revetements de sols et procedes de fabrication et d'utilisation de ceux-ci

Also Published As

Publication number Publication date
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