Needlefelt carpet layer with aesthetic surface

Abstract

Needlefelt for forming the surface layer of automotive parts comprising a carded fibrous mat, cross lapped and needled, whereby the fibrous mat comprises staple fibers. The fibrous mat may further comprise pieces of yarn in at least a color distinctive from the staple fibers, blended into the fibers forming the mat, and whereby the majority of the yarn pieces are only partially opened and forming color streaks throughout the needlefelt.

Description

[0001] Needlefelt carpet layer with aesthetic surface

[0002] Technical Field

[0003]

[0001] The present invention relates to a needlefelt carpet layer for automotive parts, a method of producing such a layer and the use of such a layer in automotive parts.

[0004] Background

[0005]

[0002] In the automotive industry, it is known to use needlefelt carpet constructions to cover the main flooring and other areas. In the majority of the cases a single colour, most of the time a version of black, is used for the overall optics of the carpet. In minor cases different coloured fibers or tones of one colour fibers may be blended to obtain a more blended colour.

[0006]

[0003] In all these cases the starting material is thermoplastic fibers of a certain length and defined colours. By mixing and blending fibers together a homogenous colour may be achieved in the final product.

[0007]

[0004] The mixing and blending of the starting fibers may be done on a mixing or blending unit combined with different openers and finalised on a card. The thus obtained felt comingfrom the card is than cross lapped and needled to form the final needlefelt carpet layer. This layer may be used alone or combined with other layers to form automotive parts. For this the needlefelt carpet and optional other layers may be moulded into a carpet construction or an automotive trim part to be used on a surface, for instance as a floor covering, a trunk carpet, trim parts, a seatback cover or door panels.

[0008]

[0005] There is since long a need for obtaining a more appealing surface, away from the standard black or homogenous blended fibers.

[0009]

[0006] However, by just adding coloured fibers to the basic stock of mainly black fibers, the fibers are blended in the main stock by the card and will disappear against the black main fibers or gives a very uniform homogenous melange effect. By blending in a high volume of a particular colour the overall colour may change, in the extreme of using equal black and white a “salt and pepper” effect may be achieved, but it is more difficult to get colour blocks or variation in the surface of the felt

[0010]

[0007] Another option would be adding colour fibers on top of the felt mat coming from the card before the cross lapping or later after the cross lapping before the needling, although this gives a certain appearance, it will interfere with the running processes and such fibers on top might not be enough visible, hidden during the cross lapping, or forming a more distinctive pattern more related to the application form. The forming of a distinctive repeating pattern has the disadvantage that the placement of the material in the car might start playing a role, or the moulding might distort the pattern initially obtained.

[0011]

[0008] It is therefore the goal to provide an alternative patterned needlefelt, with a random pattern over the surface of the needlefelt layer for aesthetic purposes and a method of creating such a layer, as well as the use of such a layer for automotive parts, like flooring and trim parts.

[0012] Summary

[0013]

[0009] The object is achieved by the needlefelt for forming the surface layer of automotive parts comprising a carded fibrous mat, cross lapped and needled, whereby the fibrous mat comprises staple fibers accordingto the main claim, the method of producing such a needlefelt accordingto claim, and the use of such a needlefelt in automotive parts.

[0014]

[0010] In particular, by the use of pieces of yarn in the fibrous mat in at least a colour distinctive from the staple fibers, whereby the pieces of yarn are blended into the fibers forming the mat, and whereby the majority of the yarn pieces are only partially opened and forming colour streaks, it is possible to obtain colour streaks throughout the needlefelt material.

[0015]

[0011] With colour streak a line or mark of a different colour from the ground in the final needlefelt is meant, whereby one colour streak according to the invention is formed from at least a small bundle of fibers originating from one single yarn piece. Streaks may be organised randomly over the surface as well as within the layer.

[0016]

[0012] With “a colour distinctive from the staple fibers” it is meant that there is a difference in colour, colour hue or tone, such that the yarn pieces form colour streaks that are visible for the user of the surface. This may be for instance a dark colour yarn pieces on a light version of the same colour, tone in tone, or a dark colour background with bright colour streaks as well as the other way round.

[0017]

[0013] Surprisingly, by usingyarn pieces in combination with carding, cross lapping and needling it is possible to create colour streaks throughout the needlefelt material, creating a pattern on the surface not possible before with standard fiber mixtures. Even more surprisingly adding the yarn pieces to the fiber blend before the carding, enables a random distribution, while the yarn pieces stay in bundles of filaments and / or fibers forming the colour streaks.

[0018]

[0014] Depending on the original material used for the yarn pieces, the streaks may differ in colour within the streak or between streaks and / or the streaks may vary in size and or direction within the needlefelt.

[0019]

[0015] As the colour streaks are formed throughout the needlefelt layer, the felt material may still be used on both sides, and any scuffing of the surface will not result in a disappearance of the colour streaks over time. Also any stretching during moulding will maintain an even random distribution of the colour streaks independent of the direction the felt is stretched or used in.

[0020]

[0016] As a source of yarn pieces, yarn may be cut in defined length pieces. Preferably endless spun filament yarn is used, preferably based on partially oriented yarns (POY) or yarns derived from POY, like for instance Drawn Texturized Yarn (DTY) .

[0021]

[0017] Alternatively yarn from textile or industrial waste may be used, for instance off- cut material of textile or industrial production waste. By combining yarn pieces derived from the cut-off waste of chair seat cover fabric in the needlefelt for the flooring and / or trim part visible surfaces, it is possible to colour match both in an aesthetic way that could not be achieved before, with colour streaks in the flooring and trim parts matching the seat cover fabric.

[0022]

[0018] But also yarn pieces from other sources both recycling and reclaimed may be used to obtain the needlefelt according to the invention. However, it is important to blend yarn pieces and not fabric or textile based on yarn into the fiber stock to obtain the needlefelt according to the invention. Hence pieces of woven fabric must be pulled into yarn pieces without substantially reducing the integrity of the yarn itself.

[0019] By varying the thickness of the yarn pieces used in the blend for the needlefelt according to the invention, for instance by increasing the yarn filament coarseness, and / or cross section and / or the number of filaments within a bundle, it is possible to create an even more varied pattern, whereby thicker yarn pieces may increase the width of the colour streak.

[0023]

[0020] The length of the streaks may be varied by the length of the yarn pieces used. The yarn pieces are at least 2.5 cm long, preferably between 3 and 10 cm long, preferably between 3 and 6cm long. The length is to be seen as on average. In case the yarn pieces are too short the openers and card might open them, and the yarn will blend into the fibers. A combination of different length of yarn pieces may be used to obtain a more varied pattern of colour streaks.

[0024]

[0021] The final length of the streaks is also dependent on the card used and the setting of the card as well as the garniture of the card. Preferably a nonwoven type of card is used with a garniture -the teeth on the main and additional card rollers as well as on the static carding tools around the roller, chosen such that the yarn pieces are not shredded by the action of the card. Hence a less aggressive overall setting must be chosen. The aim is to blend the yarn pieces and staple fibers into the fibrous felt layer coming of the card without fully disintegrating the yarn pieces into single individual filaments. .

[0025]

[0022]

[0026]

[0023] In the needle felt according to the invention yarn pieces are combined with staple fibers and optionally a binder.

[0027]

[0024] The staple fibers are forming the fiber stock and may be any thermoplastic manmade or natural fiber, preferably the fibers are of the same material basis as the yarn pieces. Preferably the staple fibers are polyester based, preferably predominantly terephthalate based. The staple fibers used may be recycled, reclaimed, or re-spun from recycled polyester.

[0028]

[0025] Alternatively, the fibers, binder and yarn pieces may be polyamide, for instance polyamide 6 or polyamide 66, or olefin, like polypropylene or polyethylene, based.

[0029]

[0026]

[0030]

[0027] Preferably the basic fibers used are made in a contrasting colour to the yarn pieces used, to obtain an optimal visual effect. Optionally the basic fibers may be a fiber blend of different tones or hues of a colour, to obtain a variegated effect of the background colour to add more interest.

[0031]

[0028] The staple fibers used for the basic fiber stock may be any of solid, hollow, or shaped fibers or a combination of those.

[0032]

[0029]

[0033]

[0030] Surprisingly already a low percentage of yarn pieces gives a visual impact on the surface. Preferably the yarn pieces are at least 3% by weight of the layer, preferably between 5 and 40% by weight of the layer, preferably between 5 and 20% by weight of the layer.

[0034]

[0031] Preferably not more than 40%, preferably not more than 30%, preferably not more than 20% of yarn pieces are used, too high volume of yarn pieces may interfere with the visual as well as the formatting of the needlefelt, in particular high levels of yarn may cause distortion of the colour streaks or overlapping of streaks forming more colour patches as discrete colour streaks. Surprisingly already with a percentage between 5 and 10% a good visual impact may be obtained without a crowded appearance. The final amount is also depending on the colours used, the thickness and or length of the yarn pieces and the visual appearance required by the designers.

[0035]

[0032]

[0036]

[0033] Optionally the needlefelt further comprises binder, preferably binder fibers, more preferably bicomponent binder fibers. As binder fibers preferably mono or bicomponent fibers are used, preferably core-sheath bicomponent fibers, whereby the sheath is made of a lower melting polyester than the core. Preferably a CoPET / PET bicomponent binder fiber or a polypropylene binder fiber is used, preferably from the same material type as the fibers and the yarn pieces. Preferably the fibrous mat further comprises at least 10 -30% by weight of the layer of binder fibers, preferably bicomponent fibers.

[0037]

[0034] Upon thermal moulding of at least the needlefelt into the required shape, the binder fiber or the sheath of the binder fibers is molten and forms droplets binding adjacent fibers together. Using a binder in addition to the needling to consolidate the needlefelt layer might increase the stiffness of the needlefelt, which is beneficial in certain applications in particular in those areas that are subject to compressional force. However, as the needling is already binding the fibers and yarn pieces together it is not necessary to use a binder for the needlefelt according to the invention.

[0038]

[0035]

[0039]

[0036] Preferably the components of the needlefelt, the staple fibers, the yarn pieces and the optional binder are polyester based, preferably a polymer or a copolymer of polyester or a combination of a polymer and a copolymer of polyester are used. Preferably one of a polyethylene terephthalate PET, polybutylene terephthalate PBT, or other terephthalate-based polyester,

[0040]

[0037]

[0041]

[0038] The needlefelt according to the invention may be used as visual surface layer of door panels, flooring part, floormats, parcel shelfs, lining for trunk or front storage compartments, trim parts, seat back covers. As a single layer, with or without binder and where necessary combined with one or more layers.

[0042]

[0039] At least one of the following layers or materials may be combined to form an automotive part, a foam or felt layer, a film layer, a thermoplastic barrier layer, stiff core material like cardstock, honeycomb plates.

[0043]

[0040] The needlefelt may be thermally moulded in a 3 D shape alone or in combination with additional layers. Combination of layers may be combined by thermal moulding optionally including adhesive layers to ensure surface to surface bonding or lamination of the layerto each other.

[0044]

[0041] Surprisingly the 3-D shaping and or moulding of the needlefelt with or without binder and with or without additional layers, does not have a negative effect on the colour streaks or their distribution.

[0045]

[0042]

[0046]

[0043] The method of making the needlefelt layer according to the invention with the steps of

[0047] - Forming a preblended fiber mixture including the yarn pieces by mixing and preblending of the basic fibers and the binder with yarn pieces in a standard fiber blending line. The line may include bale openers, mixing and blending units as well as dosage systems like weight units to obtain the right combination of fibers. Preferably at least 5% by weight of yarn pieces based on the final weight, are added. Preferably binder in the form of binder fibers or bicomponent fibers are used. Needlefelt according to one of the preceding claims whereby the fibrous mat further comprises at least 10 -30% by weight of the layer of binder fibers. Preferably between 10 and 30% of bicomponent binder fibers by weight of the layer are used as binder in the overall blend.

[0048] - carding the preblended mixture to form a fibrous mat. The thus obtained fibrous mat comingfrom the card, is subsequently cross lapped and needled to form the final needlefelt carpet layer.

[0049]

[0044] Surprisingly yarn pieces can be carded together with the stock fibers without provoking a fully disintegration into single filaments, but instead the yarn pieces are only partly frayed and are forming colour streaks throughout the felt layer. This has the advantage that the felt may be moulded, whereby the material is stretched and formed into a 3Dimensional shape without losing its appealing surface aesthetics formed by the random orientated and organised colour streaks formed by the yarn pieces.

[0050]

[0045] By the action of the card and the needlingthe yarn pieces are no longer just more or less straight pieces of yarn but are forming partly frayed colour streaks integrated within the basic fibers and bound by the action of the needles.

[0051]

[0046] The final length of the streaks is also dependent on the card used and the setting of the card as well as the garniture of the card. Preferably a nonwoven type of card is used with a garniture -the teeth on the main and additional card rollers as well as on the static carding tools around the roller- chosen, such that the yarn pieces are not shredded by the action of the card, hence a less aggressive overall setting must be chosen. The aim is to blend the yarn pieces into the fibrous felt layer coming of the card without fully disintegrating the yarn pieces into single filaments.

[0052]

[0047]

[0053]

[0048] This needlefelt may be used alone or combined with other layers to form automotive parts. For this the needlefelt and optional other layers may be moulded into a carpet construction or an automotive trim part to be used to cover the body in white surface of the car, for instance as a floor covering, a trunk carpet, trim parts, a chairback cover or door panels.

[0054]

[0049] The needlefelt according to the invention as disclosed has a pattern that is not directional, giving the freedom to produce the automotive parts or a set of automotive parts without constrains on how to place the parts on the needlefelt, as the pattern is random. This optimises the use of the needlefelt blanks and reduces waste cut-off. It is possible to choose the material for all components such that they are the same or compatible, which would enable a recycling back into fiber spinning processes for instance.

[0055] Drawings

[0056]

[0050] Figure 1 is a black and white photo of an example surface of a needlefelt accordingto the invention.

[0057]

[0051] Figure 2 Automotive flooring part with a needlefelt according to the invention

[0058]

[0052] Figure 3 is a schema of the method of producing needlefelt according to the invention.

[0059]

[0053] Figure 4 Selvedge waste from seat fabrics.

[0060]

[0054] Figure 1 is showing a black and white photo of a needlefelt surface 1 according to the invention. The original needlefelt was made with black staple fibers and 8% by weight of yarn pieces derived from car seat fabric cut-offs in 3 different colours, pink, yellow and blue, substantially cut the same length. The colour streaks 2 visible on the needlefelt surface 1 show different sizes and patterns but are clearly distinct from the black fiber background. Surprisingly the bundle of filaments forming the yarn pieces is partly frayed but staid substantially together forming the colour streaks.

[0061]

[0055] The example of figure 1 was subjected to an abrasion test and although it is not surprising that the abrasion overall is not influenced by the yarn pieces, it is surprising, that also the visual performance was not earlier impaired. The abrasion had no visible effect on the appearance of the yarn pieces they were not impaired or scraped off the surface.

[0062]

[0056] Figure 2 is showing an example of a possible use of the needlefelt 1 in an automotive flooring part 3, combined with a decoupler layer 5 and optionally an adhesive layer 4 to laminate both layers together. The flooring part 3 is moulded with all layers together in the typical shape needed to cover a floor in the car, in this case with a middle console or channel, whereby the left and right side of the channel are forming the left and right side of the passenger compartment in the length of the car.

[0063]

[0057] Figure 3 is showing the method of forming needlefelt according to the invention comprising the steps of

[0064] - mixing and blending the yarn pieces A with the basic fibers B and optionally binder C

[0200] ;

[0065] - carding the thus blended material to obtain a fibrous mat

[0300] ;

[0066] - cross lapping the fibrous mat

[0400] ;

[0067] - needling the fibrous mat to obtain a needlefelt with the yarn pieces forming colour streaks throughout the needlefelt

[0500] .

[0068]

[0058] The yarn pieces A may be derived from an additional step for instance of cutting textile waste D into small pieces of roughly equal size and pulling the pieces apart into loose yarn pieces A without substantially distorting the yarn

[0100] . Preferably textile waste from the car seat fabric may be used as shown in figure 4 . Showing photograph of a selvedge, a textile manufacturing waste strip cut from the sides of a cloth, which may be used to recover long, undamaged fibers.

[0069]

[0059] Alternatively yarn pieces may be salvaged from bobbins that are discarded at the end of the yarn or at yarn changes during production of fabrics or tufted carpets.

Claims

ClaimsClaim 1 . Needlefelt for forming the surface layer of automotive parts comprising a carded fibrous mat, cross lapped and needled, whereby the fibrous mat comprises staple fibers, characterized in that the fibrous mat further comprises pieces of yarn in at least one color distinctive from the staple fibers, blended into the fibers forming the mat, and whereby the majority of the yarn pieces are only partially opened and forming color streaks throughout the needlefelt.Claim 2. Needlefelt according to claim 1 , whereby the yarn pieces are at least 2.5 cm long, preferably between 3 and 10 cm long, preferably between 3 and 6cm long.Claim 3. Needlefelt according to one of the preceding claims whereby the fibrous mat further comprises binder, preferably binder fibers in the form of monocomponent or bicomponent fibers.Claim 4. Needlefelt accordingto the previous claims, whereby the yarn pieces and / or the staple fibers and / or the binder are based on polyester, preferably terephthalate-based polyester, or polyamide, preferably polyamide 6 or 6.6 or polyolefin, preferably polypropylene.Claim 5. Needlefelt accordingto one of the preceding claims, whereby the yarn pieces are at least 3% by weight of the layer, preferably between 5 and 40% by weight of the layer, preferably between 5 and 20% by weight of the layer.Claim 6. Needlefelt accordingto one of the preceding claims whereby the fibrous mat further comprises between 10 -30% by weight of the layer of binder fibers.Claim 7. Needlefelt accordingto claim 1 or 2, whereby the yarn pieces are obtained from fabric waste material, preferably from waste derived from automotive parts production, like seat fabric.Claim 8. Method of forming a needlefelt accordingto one of the previous claims comprising the steps of- mixing and blending yarn pieces with staple fibers and optionally a binder;- cardingthe thus blended material to obtain a fibrous mat;- cross lappingthe fibrous mat;- needlingthe fibrous mat to obtain a needlefelt with the yarn pieces forming colour streaks throughout the needlefelt.Claim 9. Method accordingto the previous claim, further comprisingthe step of cutting textile waste into small pieces of roughly equal size and pulling the pieces apart into loose yarn pieces without substantially distorting the yarn.Claim 10. Method accordingto one of the previous claims, whereby the textile waste is cut-off waste material from the automotive seat cover production.

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