Wear-resistant pads for automotive flooring systems

Abstract

Provided is an abrasion-resistant pad for automobile floor coverings, characterized in that the pad includes at least one layer containing a thermoplastic polyester elastomer (TPEE) material containing a crystalline polyester and an amorphous polyether.

Description

[Technical Field]

[0001] FIELD OF THE INVENTION The present invention relates to automotive flooring systems and flooring mats incorporating wear-resistant strips. [Background technology]

[0002] Automotive flooring systems and car mats are particularly susceptible to wear in areas of moving parts, especially in areas where the passenger's or driver's heels come into contact with the carpeted surface, and therefore it is common to include wear-resistant strips in affected areas.

[0003] For flooring systems and / or floor mats, additional pads or inlays can be inserted or applied locally to areas subject to high wear to provide reinforced areas. An example of such a patch or inlay is a heel pad. These are traditionally made of polyvinyl chloride (PVC).

[0004] These localized pads not only serve the purpose of reducing wear and tear, but also provide a non-slip surface to prevent your feet from slipping off the pedals while riding.

[0005] Automotive flooring components and floor mats are intricately manufactured trim components with multiple layers and attachments to comply with all necessary requirements for such components. These trim components may be molded in 3D shapes to conform to the surfaces underneath.

[0006] Trim pieces that cover the primary flooring of a vehicle or floor mats that are tossed into the vehicle may have a tufted or nonwoven carpet system surface. The industry is working to replace these multi-layer systems based on mixed plastic materials with substantially single-material layered ones based on polyester, preferably terephthalate-based polyester.

[0007] This has the advantage that production-related waste, such as cut-off and defective parts, and end-of-life waste of such flooring components or mats, can be recycled without the need for material separation. Thus, contamination caused by materials that do not belong to the polyester family is avoided during the recycling process. Such contamination can lead to a deterioration in the quality of the recycled material. This can result in a material mixture that is unacceptable for established recycling processes and may end up being incinerated or landfilled.

[0008] Wear-resistant or protective strips or pads appear to be neglected in the overall recycling concept of the automotive trim parts that contain them. Current wear-resistant or protective strips or pads are still made from polyvinyl chloride (PVC). While PVC can be recycled by itself or can retain recycled materials, when combined or mixed with polyester-based materials, it reduces the overall quality, processability, or value of the waste material, as well as manufacturing-related waste and end-of-life parts.

[0009] The main problem with recycling PVC is the high chlorine content in raw PVC (approximately 56 percent of the polymer's weight) and the high levels of harmful additives added to the polymer to achieve the desired material quality. As a result, PVC requires separation from other plastics even before mechanical recycling. These pads, such as heel pads, are firmly welded or glued to the carpet surface of flooring components or mats, making separation nearly impossible without contaminating that or other material layers.

[0010] Thus, although the main flooring systems are moving towards a single polyester-based material to allow efficient recycling, the accessories used do not follow this overall direction.

[0011] To date, the industry has struggled to find alternatives that meet the necessary requirements and can be included in the overall recycling of flooring systems, thereby eliminating the need to remove or disassemble them from their components, and / or preventing any contamination from reducing the value of the recycled material. Summary of the Invention [Problem to be solved by the invention]

[0012] It is an object to provide an alternative solution for wear-resistant pads in order to increase the recyclability of trim parts containing such pads, in particular to reduce separation steps and waste streams. [Means for solving the problem]

[0013] The present invention provides an anti-wear pad according to claim 1 and a trim part comprising such a pad, as well as the use of such a pad.

[0014] That is, there is provided an abrasion-resistant pad for automobile floor coverings, characterized in that the pad comprises at least one layer containing a thermoplastic polyester elastomer (TPEE) material containing a crystalline polyester and an amorphous polyether.

[0015] The polyester elastomer is preferably terephthalate-based, and is preferably either poly(butylene terephthalate) (PBT) or poly(ethylene terephthalate) (PET).

[0016] Preferably, the amorphous polyether is either poly(tetramethylene ether glycol terephthalate) or a poly(alkylene glycol). [Brief explanation of the drawings]

[0017] [Figure 1]1 is a schematic diagram of a flooring system with a heel pad according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0018] Heel pads can be extruded or injection molded. Their surfaces can be embossed or grained, which increases surface roughness and improves anti-slip properties, as well as preventing water or dirt from reducing their effectiveness. Additionally, the pads can be formed to conform to recesses in the underlying flooring or matting, or to follow curved or 3D shapes.

[0019] The pads according to the present invention can be used as a loose, single-layer replacement for classic PVC mats for floor protection, or as localized pads or strips on vehicle floor mats or integrated flooring systems. In both cases, the pads can be attached to the surface of the component by mechanical or chemical means, which may be a polyester nonwoven or tufted carpet layer containing polyester-based fibers or yarns. Preferably, the pads are thermally welded to the surface of the flooring system or pad.

[0020] Alternatively, strips of wear pads are placed in the border areas of the mat or flooring where the legs or feet rub or rest, and in the areas where the heels of the driver and / or passenger contact the mat.

[0021] The pad comprises a thermoplastic polyester elastomer (TPEE) comprising a hard segment comprising a crystalline polyester, preferably poly(butylene terephthalate) (PBT) or poly(ethylene terephthalate) (PET), and a soft segment comprising an amorphous polyether, e.g., poly(tetramethylene ether glycol terephthalate) or poly(alkylene glycol).

[0022] Preferably, the properties can be further improved by blending with crystalline and / or amorphous polyesters. For example, it can be blended with PBT to optimize thermal and mechanical properties. Commercially available examples that can be used in accordance with the present invention include DuPont® Hytrel® TPC-ET or DuPont® Crastin® PBT, or DSM Arnitel or Keyflex, which are combinations of crystalline PBT and PTMEG amorphous polyether.

[0023] Preferred materials may contain small amounts of fillers, up to 10%, to optimize properties and / or reduce the overall cost of the part. The filler may be at least one of an inert particulate or fibrous filler, for example, CaCO3, mica, clay, or any natural, synthetic, or mineral fiber may be used.

[0024] Preferred materials for the pad may further include any additives that may improve the quality appearance or aid in the manufacturing process, for example, UV blocking additives and / or coloring dyes such as carbon black.

[0025] Preferably, the TPEE-based material of the pad has a hardness of 65 to 90 Shore A, preferably 70 to 80 Shore A, measured to DIN 53 505 10".

[0026] Preferably, the TPEE-based material of the pad has a compressive strength of at least 10 N / mm 2 It has a tensile strength of

[0027] The crystalline polyester and / or amorphous polyether may be derived from bio-based or recycled sources, or from mixed sources where petroleum-based products are partially replaced with either bio-based or recycled content to further optimize the environmental footprint.

[0028] Pads based on TPEE materials according to the present invention can be used as floor mats, trunk mats, or front trunk mats in vehicles. These are mats that are loosely placed on top of the flooring system or floor mat. These mats can be locally attached by mechanical attachments such as clips, male-female means for attachments that can be pressed together, or similar attachments known in the art.

[0029] The present invention provides an automotive flooring system or floor mat having at least a nonwoven or tufted carpet layer comprising at least one pad based on a TPEE material according to the present invention.

[0030] An automotive flooring system is defined as an automobile trim piece that is molded to fit the interior of a passenger compartment, for example, by molding it to cover at least a portion of the primary floor area. This can extend to include at least a portion of the inner dash and / or adjacent vertical side areas of the passenger compartment. Preferably, pads or strips of TPEE material according to the present invention can be used, particularly in the footwell area where the driver's or passenger's feet or heels may come into contact with the flooring system. This can also be pads or strips along the sidewalls where the sides of shoes rub against them. In general, it can be used on all surfaces that are subject to more intensive wear.

[0031] At least one pad can be attached to the carpet or floor mat surface of the flooring system. The pad can be attached by any known mechanical, chemical, or thermal method typically used to attach, for example, heel pads to carpet surfaces. Attachment can be mechanical, such as by clips, stitching, or staples; thermally attached to the carpet surface, such as by a welding operation or during molding of the part; or materially attached to the carpet surface, such as by adhesive or chemical welding. The pad can be either point-bonded, partially bonded, or bonded across the entire surface of the pad. Preferably, the pad is attached after molding of the automotive flooring system or floor mat and is thermally welded to the surface facing the passenger compartment in a dot or stripe pattern.

[0032] The automotive flooring system or floor mat may further comprise a surface based on a nonwoven or tufted carpet comprising polyester, polyamide or polyolefin. Preferably, the carpet layer comprises a terephthalate-based polyester such as PET and / or PBT, which is compatible with the base material of the heel mat, making recycling easier and improving the quality of the resulting waste.

[0033] The automotive flooring system or floor mat may further comprise at least a fibrous backing layer comprising polyester fibers, and it is preferred to use terephthalate-based fibers, preferably PET or PBT, for the backing layer, preferably made of polyester fibers.

[0034] Automotive flooring systems or floor mats having a carpet surface layer at least partially covered with pads or strips based on TPEE materials according to the present invention may further comprise at least one additional layer, preferably at least one of a highly filled thermoplastic elastomer layer, a foil layer, a foam layer, a nonwoven or scrim layer, or a textile layer such as a woven or knitted layer.

[0035] Generally, in all cases, polyester is used in either the carpet surface or initial layer, and this polyester is preferably from up to 100% recycled and / or bio-based sources.

[0036] Surprisingly, TPEE material based pads can withstand wear, while rejects of polyester, preferably terephthalate based flooring pieces, floor mats or cut-offs, or combinations thereof, can be recycled without the need for separation of the different layers, i.e., separation of the padding strips from the flooring pieces or other layers.

[0037] FIG. 1 is a schematic diagram of a flooring system with a heel pad according to the present invention.

[0038] Flooring system 1 includes a nonwoven or tufted terephthalate-based polyester surface and a polyester-based backing layer (not shown) laminated together, and further includes a heel pad 2 including a thermoplastic polyester elastomer (TPEE) material including crystalline polyester and amorphous polyether. The heel pad is positioned so that the driver's foot 5 can remain in contact with the heel pad and act as a pedal 4, thereby eliminating scraping of the primary floor components and preventing foot slippage during interaction.

[0039] The surface of the insert or pad can be molded and can include a surface embossment or grain. The underside of the insert or pad can be embossed with pin-type shapes to provide better grip to the carpet surface underneath.

Claims

1. 1. A wear-resistant pad for automotive floor coverings, comprising:

1. A wear-resistant pad for automotive floor coverings, characterized in that the pad comprises at least one layer comprising a thermoplastic polyester elastomer (TPEE) material comprising a crystalline polyester and an amorphous polyether.

2. 2. A pad according to claim 1, wherein the crystalline polyester is a terephthalate-based polyester, preferably one of poly(butylene terephthalate) (PBT) or poly(ethylene terephthalate) (PET).

3. 3. The pad of claim 1 or 2, wherein the amorphous polyether is one of poly(tetramethylene ether glycol terephthalate) or poly(alkylene glycol).

4. 4. The pad according to claim 1, wherein the surface comprises an embossed or grained pattern.

5. The thermoplastic polyester elastomer material is CaCO ３ A pad according to any one of claims 1 to 4, further comprising fillers such as mica or fibres, and / or additives such as UV blocking additives, and / or colouring dyes such as carbon black.

6. 6. Pad according to any one of claims 1 to 5, wherein said layer based on a thermoplastic polyester elastomer has a Shore A of 65 to 90, preferably a Shore A of 70 to 80, measured according to DIN 53 505 10".

7. Pad according to any one of claims 1 to 6, wherein the crystalline polyester and / or amorphous polyether used is at least partly bio-based or derived from recycled resources.

8. Use of the pad according to any one of claims 1 to 7 as a floor mat, trunk mat or front trunk mat in a vehicle.

9. An automotive flooring system or automotive floor mat having at least a nonwoven or tufted carpet layer comprising at least one pad according to any one of claims 1 to 7.

10. 10. The automotive flooring system or automotive floor mat of any one of claims 1 to 9, wherein the at least one pad is mechanically attached to the carpet surface, such as by clips, stitching or staples, thermally attached to the carpet surface, such as by welding or during molding of the part, or physically attached to the carpet surface, such as by adhesive or chemical welding.

11. 11. The automotive flooring system or automotive floor mat of claim 10, wherein the at least one pad is point bonded, partially bonded, or bonded over the entire surface of the pad.

12. 12. The automotive flooring system or automotive floor mat of any one of claims 9 to 11, wherein the nonwoven or tufted carpet layer comprises polyester, preferably polyester including PET and / or PBT, polyamide, or polyolefin such as polypropylene.

13. 13. The automotive flooring system or automotive floor mat according to any one of claims 9 to 12, further comprising at least a fibrous backing layer comprising polyester fibres, preferably PET or PBT, preferably consisting of polyester fibres.

14. 14. The automotive flooring system or automotive floor mat of any one of claims 9 to 13, further comprising at least an additional layer, preferably a textile layer such as a highly filled thermoplastic elastomer layer, a foil layer, a foam layer, a nonwoven fiber layer or a scrim layer, or a woven or knitted layer.

15. 15. The automotive flooring system or automotive floor mat of any one of claims 9 to 14, wherein the polyester for the carpet surface and / or backing layer is from up to 100% recycled sources.

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