DE102006001036A1 - Fibrous moldings comprise, for use in aircraft or vehicle production, comprise molded, compressed fiber layer which is bonded to carpet layer using jets of fluid - Google Patents

Abstract

Fibrous moldings comprise a molded, compressed fiber layer which is bonded to a carpet layer using jets of fluid. An independent claim is included for: (A) a method for making the moldings comprising (a) pressing and molding a first fiber layer; (b) depositing one or more additional layers of fiber; and (c) bonding the product to a carpet layer using jets of high pressure gas, high pressure liquid and/or steam; and (B) a molding machine for use in the method, in which the surface which faces the second fiber layer has bore which act as outlets for the gas,, liquid or steam.

Description

The The present invention relates to a fiber molding with integrated, carpet-like textile surface, especially for aircraft construction and vehicle manufacturing, a method of manufacture a fiber molding according to the invention and a mold for performing the method.

The separate deformation of plastic floor coverings and decorative carpet materials in needled and tufted quality, as Velours or Schlingenware, for the purpose of subsequent laying or joining on a separately formed insulating layer of optional fleece, or foam, with or without mass layer are known. As well is the common deformation of such materials in one process step known as multilayer structure.

Three-dimensional Fibrous molded parts obtained by the targeted filling of ventilated molding tools loose, sporadic fiber material and by energy be solidified directly in the same tool without first a sheet-like structure must be produced as semi-finished non-woven, are also known. at this process is a reduction of the production waste produced, usually as edge trim and in the form of punched out accrues, possible. Across from The deformed nonwoven fabric results in a higher contour accuracy, thickness variability and Dense consistency. Such fiber moldings can be found in the Vehicle industry as a sound and heat-insulating components Use. Such molded fiber parts are usually produced in ventilated Formpresswerkeugen, under the action of heat and pressure in the nonwoven fabric contained thermoplastic and / or thermoset materials deform and solidify.

at The production of fiber-molded parts can also be multi-layered structures be generated. In a multilayer or multi-layered Construction leaves known create a cover layer, the color due to their fiber mixture and haptically receives a decorative claim.

at However, the molding process shows that, as a rule, due to the In the fiber molding binder contained a smooth surface is produced. In particular, when the moldings have a higher content of thermoplastic or thermosetting binder, resulting in a plastic-like smooth surface. Always when sound and heat-insulating materials to be used in the field of vision in the interior of a vehicle, is the limitation unacceptable on such smooth plastic surfaces.

Reduced one the thermoplastic or thermosetting binder content in the cover layer of the molding, however, drastically, with the purpose of a surface with a fluffy character in the sense of a carpet-like decor too generate, or leave one The binder even completely eliminated, so is a sufficient connection to the insulating layer usually by conventional methods of the state the technology does not succeed. Likewise, the mechanical requirements to a carpet decor The mechanical abrasion can not be met, since a sufficient Solidification of the decorative top layer does not set.

The The invention therefore has the task of providing fiber molded parts, the sound and heat insulation Properties of moldings produced by in-mold process with the aesthetic pleasant and acoustic properties of unpressed textiles connect and at the same time a mechanical load capacity and strength of the compound they use for for example, as a floor covering in vehicle makes it practically usable.

The The object is achieved by a three-dimensional fiber molding containing a first deformed and solidified fiber layer, with a carpet-like textile, unpressed, fluid beam-strengthened second fiber layer connected in a planar manner is. Such a fleece arrangement is the first time after that below described inventive method available. It is essential that the unpressed second fiber layer fluid-jet needled and fluid beam solidified and thus carpet-like (fleece) structure having. Under fluid jets according to the invention are gas, Air, liquid and / or steam jets understood. The first fiber layer has prefers insulating properties on. It can therefore be called "insulating fiber layer" in contrast to second (carpet-like) fiber layer can be called.

Flat connection in the context of the invention is not limited to a full-surface connection and includes point or strip-shaped Compounds and other forms of connection, if substantially the complete area both fiber webs adheres to each other.

Prefers Both fiber webs are permanently connected to each other. As inseparably connected apply in the context of the invention arrangements of fiber webs, when the fiber webs not unbroken released from each other again can be. A (destructive) Separability of the layers for the purpose of recycling the raw materials (Recycling) is not excluded within the meaning of the invention, but on the contrary, especially preferred.

The fluid jet needling by turbulence of fibers by means of, for example, highly stressed water jets and the fluid jet hardening of fiber webs while maintaining a textile, carpet-like structure is known in principle (DE-A-1 635 577, US Pat. US 3,485,706 . US 3,494,821 ).

The Method of fluid jet needling, which also includes beam interlacing, Hydroentanglement, hydraulic interweaving, water jet sewing, winding compounding and spun-bonding is called, or comprises, runs off, that a fluid, for example a liquid, usually water, with high Pressure through nozzles or outlet openings is forced to fine columnar To form rays and a beam curtain on a fibrous web to judge. The fibrous web to be processed is placed on a support grid moved through the jet curtain, whereby the fibers are intertwined and a coherent one textile web without using binders or resins. Although the physical process of intertwining is not fully understood, It is believed that the turbulent breaking up of the fine fluid jets when striking and brushing the fibers in the web and at the Webs of the support grid the physical Causes entanglement of the fibers. The support grid can be equipped with a coordinated continuous area be equipped to its pattern on the intertwined product transferred to and this one textile-like To give appearance.

In a known manner, a nonwoven fabric produced by means of carding machines, carding machines or pneumatic devices can be presented to a hydrodynamic consolidation device. Likewise is from the DD 156 275 a solidification device with a nozzle beam is known from the fine water jets emerge at high pressure and high speed and impinge on a nonwoven fabric. In this case, the principally oriented in two directions fibers are taken and reoriented in the third direction. The water jet - and thus the entrained fibers - meet a resistance, a so-called baffle plate. There, the water jet is broken down into many sprayed in different directions parts that drag along the fibers and thus connect to a sheet.

According to DD 98 125 Nonwovens of thermoplastic fibers are entangled by means of heated gas jets and solidified by fusion of the fibers together.

Out DE-A-25 41 336 is further a method and a non-woven fabric known in which an air-conveyed Staple fiber stream against a net conveyor directed with strip-forming strips and stored on this becomes. It creates an aesthetic more appealing fleece with corresponding dense and less dense strip-shaped areas, in the presence of thermoplastic fibers by fusion, in the other case by conventional Method is solidified.

One A method for patterning a nonwoven fabric is also disclosed in DE-A-1 560,701. These are single fibers or fiber groups the nonwoven web by streams a liquid or gaseous Mediums pushed like a knob and thereby solidified the nonwoven web.

According to DD 141 041 For example, a fibrous web formed on a carding machine is solidified directly in the region of the decrease by fluid jets.

DE 694 12 106 T2 (corresponding EP 0 719 355 B1 ) describes a method of making a fabric from fibers having a fuser component by impinging a hot jet on the fiber structure.

Also US 3,353,225 describes a method of making a web by double-sided blast treatment with a fluid for entangling fibers in a fibrous sheet to form a patterned coherent nonwoven web. The patterned contiguous structures are prepared directly from loose fibrous layers without the use of binders or adhesives by treatment with high velocity streams of fluid such as air or steam. In this way, two or more textile nonwoven layers can also be needled and bonded together.

DE 31 32 792 C2 describes a process for producing a nonwoven fabric in which a nonwoven having a weight of 15 to 100 g / m ^{2 is} guided onto a water-impermeable support member and exposed to jets of water which are spaced apart, directed towards the surface of the nonwoven and across the Width of the web extending nozzles are sprayed to achieve a mechanical entanglement of the fibers of the nonwoven. In one embodiment, a parallel web having a weight of 20 g / m ² of rayon fibers is piled on a 1 mm thick layer of polyurethane foamed layer and implanted by water jet needling and felted.

DE 693 19 611 T2 ( EP 0 669 994 B1 U.S. Patent No. 4,839,830 discloses an unbonded or thermally bonded spunlaced nonwoven fabric comprising an unbonded flashblown web containing polyolefin polyethylene or polypropylene plexifilaments in which web staple fibers are embedded and entangled therewith, wherein the fabric has a Frazier porosity of at least 1.22 m ³ / m ² / min.

DD 207 227 describes a process for the production of fabrics from fibers which are intertwined or entangled, characterized in that a fiber-gas or fiber-liquid mixture is squeezed out of a pressure vessel through perforated or slot dies and the fibers are entangled upon impact with a baffle and the fiber-gas or fiber-liquid mixture is dissolved. It is proposed inter alia to shoot the fibers of the fiber-gas or fiber-liquid mixture on and in a prefabricated basic trajectory to unite in this way different materials to form a sheet.

The aforementioned method in which during the fluid needling a fleece made a connection to another layer The common feature is that this layer is thin, flexible and textile-like in itself.

On the other hand can the fiber moldings according to the invention with appropriate procedure be formed such that the adjacent layer is a compressed Represents nonwoven fabric. In this sense, in the Vliesanordung invention the first nonwoven fabric with the second nonwoven fabric through in the first Fiber fleece penetrating fluid jet needling be connected.

So is particularly preferred when the first fibrous layer with the second, carpet-like fiber layer connected by these penetrating fluid jets and solidified.

A Entanglement and entanglement the fibers of the second fibrous web with unmelted or merely partially molten fibers of the underlying pressed first nonwoven fabric causes in particular a close and permanent connection the layers formed from the respective fiber webs, so that the mechanical strength of the nonwoven carpet with the Inventive fleece arrangement extraordinarily elevated is. According to the invention, the Connection of layers with each other, however, or instead by partial or full-scale melting both fiber webs to be joined, for example by heated Fluids take place in the fluid jet needling of the second nonwoven fabric.

The The invention therefore also relates, in a further embodiment, to a fiber molding according to the invention, characterized in that the first fiber layer with the second carpet-like fiber layer by thermoplastic bonding is connected, wherein the bonding punctiform, planar and / or even partial area can.

In the fiber moldings according to the invention can the first and / or second fiber layer preferably thermoplastic Contain fibers. Are these contained in the second fiber layer, can by mechanical entanglement and / or by thermoplastic Fusion and / or by gluing or otherwise completely particularly preferably be connected to the first fiber layer. Preferred materials of the first and / or especially of the second Fiber layer are: PES, PA, PP, PE, acrylic fibers, bicomponent fibers, Secondary fibers. Preferred fiber lengths are: 15 mm to 100 mm Preferred free lengths (due to crimping and / or nonlinearity) are: 10-70 mm. Preferred fiber strengths are 0.8 to 135 dtex.

Furthermore or instead of that the first and / or the second fiber layer contain natural fibers. Particularly preferred here are cotton as a shredded fiber recyclate with synthetic parts, cotton as raw fiber, domestic bast fibers such as hemp, flax, other natural fibers such as coco, ramie, jute, sisal etc. Preferred fiber lengths are: 20 to 100 mm. Preferred free lengths (due to rippling and / or nonlinearity) are 10 to 80 mm.

Of the Term "fiber", as he means in the sense staple fibers, filaments, plexifilamentary filaments and like.

Built according to the invention Fiber moldings can be designed so that they are excellent thermal and / or have acoustically insulating properties. Among other things For this reason, they are particularly suitable in the Shape of a fiber-fleece carpet therefore in aviation and vehicle construction, in particular to find use in motor vehicle construction. This includes the term "non-woven carpet" flexible carpet-like qualities such as Webs or mats to rigid moldings or components of molded parts. Preferred uses include use as Roof lining, engine compartment cover, floor covering, interior door trim, Trunk cover and lining, hat rack, footwell trim, seat back panel in airplanes and / or vehicles, in particular motor vehicles, including passenger and commercial vehicles, but also rail vehicles and Ships.

in the The following should make the process closer be described, with the inventive fiber moldings for the first time can be produced and which is also the subject of the invention.

• a) Verpressen und gegebenenfalls dreidimensionales Verformen einer ersten textilen Faserschicht,
• b) Ablegen von Textilfasern auf der ersten Faserschicht in einer oder mehreren Lagen,
• c) Verfestigen der abgelegten Textilfasern zu einer zweiten, teppichartigen Faserschicht untereinander und Verbinden mit der ersten verpressten Faserschicht mittels Fluidstrahlvernadelung, insbesondere Druckgas-, Druckflüssigkeitsstrahl- und/oder Dampfstrahlvernadelung in situ.

The invention then relates to a method for producing a fiber molding according to the invention, comprising the steps

• a) pressing and optionally three-dimensional shaping of a first textile fiber layer,
• b) depositing textile fibers on the first fibrous layer in one or more layers,
• c) solidifying the deposited textile fibers to form a second, carpet-like fiber layer with one another and bonding to the first compressed fiber layer by means of fluid jet needling, in particular pressurized gas, pressurized liquid jet and / or steam jet needling in situ.

To the method according to the invention is ensured that the textile appearance, for example, the the visible side forming fiber layer of the fiber molding in relation appearance, feel, fluffiness and insulation properties wherein the underlying nonwoven (form) can be compressed and thus has corresponding acoustic and thermal insulation properties and Nevertheless, achieved an excellent connection between the layers becomes. This compound is probably based on cross-layer entanglements and / or fusions of the fibers of the carpet-like fiber layer with fibers or fiber parts of the compressed first fiber layer. The transfer of the known method of fluid beam solidification the consolidation of a carpet-like decorative fiber layer on a vorverpresste fiber layer of a fiber molding is in State of the art not described. By the method according to the invention are molded fiber parts with hitherto inaccessible properties, in particular in this combination for the first time inaccessible properties available. Besides this lies the method according to the invention based on the new knowledge that when needling on a pre-pressed first fiber layer these serve as baffles simultaneously can, which the swirling of the fluid flow and thus the fibers causes the textile second fiber layer to be consolidated and at the same time passive in the needling and / or merger itself is included.

Especially it is preferred that the pre-compressed and optionally three-dimensional deformed first fiber layer thermoplastic and / or thermosetting Binder and optionally natural fibers, their preferred composition, Length and Strength described above.

Especially for use of the resulting fiber molding as a non-woven carpet, or part of a larger molded part, is particularly preferred, a three-dimensionally deformed first nonwoven fabric to be used as the first fiber layer.

To This purpose is also served by the preferred embodiment of the method according to the invention, after the pre-compressed and possibly three-dimensionally deformed first fiber layer or nonwoven fabric is punched before step b), around a different contour of the compressed and the textile Layer obtained by the first and the second fiber layer To be defined.

The Depositing in step b) of the method according to the invention can be based on various Sages. In particular, it is preferable to have multiple layers, for example two three four five or more layers of the same or different fibers or fiber blends store. It can the layers each different, same or alternating orientation comprising the fibers. In particular, the layers are defined in Angles to each other in the range of 10 ° to 150 °, in particular 30 ° to 120 ° or at right angles be stored crossed.

Especially it is preferred that the textile second fiber layer forming Fibers thermoplastic and / or thermosetting plastic and optionally Contain natural fibers whose preferred composition, length, free Length and strength continue described above.

Of the actual step of Fluidstrahlvernadelung / -verfestigung or Compound, step c), according to the invention with a pressurized Fluid jet at different temperatures. Apparative on The simplest and most economical is a fluid jet at room temperature to create. Needed in step c) of the method according to the invention by means of a hot, pressurized gas, a hot liquid or steam, so can in addition to heat transfer on the fibers of the needled and the pre-compressed nonwoven whose at higher Temperature increased flexibility and flexibility and, where appropriate their thermoplasticity make use of. A warming the fibers can thus increase their tendency to become entangled and / or a melting and bonding with each other and between the Nonwovens effect. This effect is all the more productive if the Fluid jets have temperatures in the range or above the softening temperature of at least one fiber or fiber component of the needled nonwoven fabric lies.

For this is particularly preferred when the temperature of the fluid, in particular the gas, the liquid or the steam in the range of 90 ° C to 220 ° C, in particular 110 ° C to 160 ° C.

For the fluid jet to be used according to the invention, it is particularly preferable to use air, nitrogen, water or steam. Air, stick but also water have the advantage of being eco-friendly and economical. Water vapor, in particular superheated steam also has the advantage of excellent heat capacity and best heat transfer properties.

In a preferred embodiment you can the process of the invention modify so that you can steps b) and c) in one operation executing, by mixing a fiber-liquid mixture or fiber-gas mixture through nozzle openings on the first fiber layer, in particular a compressed fiber fleece Apply and needled in its own fluid jet and, if necessary in a further step c) solidified by fluid jet needling. This means, that first a fiber-liquid mixture or fiber-gas mixture by suspension and / or turbulence is formed and this mixture under high pressure on the pre-compressed first fiber fleece is brought up. It is doing it in its own fluid jet needled. To the strength of such fabricated nonwovens To further improve, this can be a further solidification step connect by fluid jet needling.

A special impact force and thus a particularly favorable entangling effect on the textile fibers has the fluid jet used in the invention, if he is at a distance of 5 to 30 mm, especially 10 to 20 mm, especially about 10 mm from the nozzle to the needled second Nonwoven meets. In this case, the inventive method in a manner accomplished be that at least step c) in a sealable mold from essentially two mold halves performs and while of the closing process the tool halves needled when the tool halves at a distance of 5 to 30 mm, in particular 10 to 20 mm from their final position.

optimal Needling is achieved when a needle during the needling Relative movement of the tool halves in a plane perpendicular to the closing direction. This is preferably such that the relative movement of the tool halves. 1 to 20 mm, in particular 2 to 10 mm in a plane perpendicular to closing direction is.

The tool halves of the method according to the invention used mold can forming surfaces have, wherein a modification of the method is that the forming surface, the forming of the second, textile nonwoven fabric associated surface opposite, whole or partial area Perforations, holes or openings through which one passes during the needling creates a negative pressure.

The described inventive method you lead preferably in such a way that at least step c) in one performs specially designed mold. Therefore, the invention relates also a lockable Mold for implementation of at least step c) of the method according to the invention, characterized that in the forming surface associated with the second fibrous layer, or part of the area Holes with nozzle openings comprising, by the pressurized gas, liquid and / or steam passed through the layer to be needled can be.

The Arrangement of the nozzle openings in the invention for use coming mold can different orientations, distances, arrangements, designs, Have shapes and materials. For example, the nozzle openings all or partially disposed perpendicular to the forming surface of the mold be.

All particularly preferred is a molding tool which is characterized that the nozzle openings a diameter in the range of 0.06 to 0.2 mm, in particular in Range from 0.8 to 0.13 mm, a distance in the range from 0.05 to 0.2 mm, in particular in the range of 0.08 to 0.13 mm have for the use of water jet for needling.

Becomes In contrast, water vapor jet used for needling, according to the invention is very special preferred that the nozzle openings a diameter in the range of 0.3 to 1.5 mm, in particular in Range from 0.5 to 0.9 mm, a distance in the range of 1 to 4 mm, in particular in the range of 1.5 to 2.5 mm.

Embodiment:

At first was a three-dimensional fiber fleece insulator produced as an insulating layer, deformed and punched, wherein the nonwoven insulator of 35 wt .-% PES s / c Bicomponentenfasern and 65% by weight of flax fibers. The nonwoven insulator was as "first Fiber layer "in spent the mold.

A Fiber blend of polyester carpet fibers and melt fibers was placed on the nonwoven insulator in several layers, the layers were offset in their orientation against each other.

The solidification of the textile useful surface ("second fiber layer") took place in the following manner:
The second fiber layer facing (upper) The mold half consisted of a pressure-resistant frame with a surface forming the contour of the finished part, covering the frame on one side, and a bottom covering the frame on the other side. The frame, bottom and forming surface formed a confined space as small as possible, into which pressurized gas or steam could be introduced at room temperature or heated. Perpendicular to the surface, bores with nozzle orifices of 0.6 mm diameter were randomly distributed at a distance of 2.5 mm into the forming surface.

The tool halves were in a closing device so led to each other, that while the closing process a back and forth movement the upper half of the mold against the lower half of the mold in a plane perpendicular to the closing device by about 5 to 6 mm.

During the Closing process, at a distance of the tool halves 15 mm from its final position, was with the introduction of heated water vapor started in a room behind the forming surface. Through the holes and the nozzle openings streamed the hot steam at high speed in the direction of the deposited for the textile surface Fibers out.

Under ongoing Back and forth movement, the mold was closed and then to cooling of needled fleece and fleece arrangement cold air (room temperature) passed through the mold at low pressure. After cooling down the mold was opened and the molding according to the invention taken.

in the molding according to the invention owned the fleece the textile wear layer with a uniformly solid surface bulky character. There were fibers through the hot steam jet to near the surface cavities of the underlying under the textile wear layer insulation (the insulating first fiber layer) entrained there and with fibers of the first Faservlieses engulfed and partially to thermoplastic fibers and thermoplastic material has been melted on and so on that sticking dots were created. The composite was within the meaning of the invention unsolvable and reliable connected.

Claims (18)

Three-dimensional fiber molding containing one first deformed and consolidated fiber layer, with a carpet-like textile, non-compressed, fluid beam-strengthened second fiber layer flat connected is. Fiber molding according to claim 1, characterized in that the first fiber layer with the second, carpet-like fiber layer through these penetrating fluid jets connected and solidified. Fiber molding according to claim 1 or 2, characterized in that the first fiber layer with the second carpet-like fiber layer by thermoplastic bonding connected is. Fiber molding according to a the claims 1 to 3, characterized in that the first and / or second Fiber layer contains thermoplastic fibers. Fiber molding according to a the claims 1 to 4, characterized in that the first and / or second Fiber layer thermoplastic and / or thermosetting plastic and optionally contains natural fibers. Fiber molding according to a the claims 1 to 5, in particular for the aircraft or vehicle construction. Process for producing a fiber molding according to the claims 1 to 5, containing the steps a) pressing and optionally three-dimensional shaping of a first textile fiber layer, b) Laying textile fibers on the first fiber layer in one or several layers, c) solidifying the second deposited textile fibers to a second, carpet-like fiber layer with each other and Bonding to the first compressed fiber layer by fluid jet needling, especially compressed gas, pressurized fluid jet and / or steam jet needling in situ. Method according to claim 7, characterized in that the first fiber layer before step b) punches to a different contour of the respective layers obtained by the first, compressed fiber layer and the second, carpet-like fiber layer can be defined. Method according to one the claims 7 or 8, characterized in that in step b) two, three or more layers of textile fibers at a defined angle to each other in the range of 10 ° to 150 °, in particular 30 ° to 120 ° or crossed at right angles. Method according to one the claims 7 to 9, characterized in that in step c) by means of a hot, pressurized gas, a hot liquid or steam solidifies and connects. A method according to claim 10, characterized ge indicates that the temperature of the gas, the liquid or the steam in the range of 90 ° C to 220 ° C, in particular 110 ° C to 160 ° C. Method according to one the claims 7 to 11, characterized in that one comprises air, nitrogen, water or steam. Method according to one the claims 7 to 12, characterized in that the steps b) and c) in one operation, by mixing a fiber-liquid mixture or fiber-gas mixture through nozzle openings on the first fiber layer and in its own fluid jet needled and optionally in a further step c) by Fluid jet bonding solidified. Method according to one the claims 7 to 13, characterized in that at least step c) in a lockable Mold from essentially two mold halves performs and while of the closing process the tool halves needled when the tool halves themselves at a distance of 5 to 30 mm, in particular 10 to 20 mm from their final position. Method according to claim 14, characterized in that the mold halves of the molding tool forming surfaces has and the forming surface, that of the second, textile fiber layer associated forming Surface opposite, whole or partial area Perforations, holes or openings through which one passes during the needling creates a negative pressure. lockable Mold for implementation at least step c) of the method according to one of claims 7 to 15, characterized in that it is in the second fiber layer associated forming surface whole or partial area Holes with nozzle openings comprising, by the pressurized gas, liquid and / or steam passed through the layer to be needled can be. Mold tool according to claim 16, characterized in that the nozzle openings have a diameter in the range of 0.06 to 0.2 mm, in particular in the range of 0.8 to 0.13 mm, a distance in the range of 0.05 to 0.2 mm, in particular in the range of 0.08 to 0.13 mm for use from water jet to needling. Mold tool according to claim 16, characterized in that the nozzle openings have a diameter in the range of 0.3 to 1.5 mm, in particular in the range of 0.5 to 0.9 mm, a distance in the range of 1 to 4 mm, in particular in the range of 1.5 to 2.5 mm for the use of water vapor jet for needling.