Automotive floor, trunk, or luggage compartment cover having a structurally needle-punched carpet surface

Abstract

The present invention relates to a method for manufacturing a three-dimensional floor, trunk or luggage compartment cover for a motor vehicle, the carpet surface of which has a needle-punched structure on the visible side.

Description

[Technical Field]

[0001] The object of the present invention is a method for manufacturing a three-dimensionally shaped floor panel, luggage compartment panel or cargo floor panel for a motor vehicle, the carpet surface of which has a needled structure on the visible side, as well as the panel itself. [Background technology]

[0002] The automotive facing itself is a flat needled nonwoven carpet that may have some underlayer as well as foam or fibrous / nonwoven insulation on the chassis side.

[0003] Especially with the development of electric vehicles (e-vehicles), design / styling is looking for alternative solutions for deformable carpet surfaces compared to the mundane smooth and flat needled nonwoven materials, velour, and tufted carpet.

[0004] In the case of automobiles with rear doors (station wagons) and folding rear seat backs, this styling applies particularly to the luggage compartment and luggage floor, since when the rear doors are open and the rear seat backs are folded down, the thus opened interior of the automobile is visible from the rear. Therefore, both the luggage compartment and the passenger compartment must embody uniform and consistent styling.

[0005] In the state of the art, various designs are known for carpet top surfaces for automotive floor panels, luggage compartment panels and cargo floor panels, namely in particular tufted carpets, velour carpets and flat needled nonwoven carpets.

[0006] For tufted carpets, PA6.6, PA6, PP, rPA, and PET, rPET, as well as the corresponding bio-based polyamides (PA5.10; PA6.10), are particularly used, while for velour and flat needled nonwoven carpets, PET, PET / PP, PP, PA / PET, and rPET are mainly used as yarn / fiber materials.

[0007] In the prior art, processes for producing velour carpets are known, see inter alia DE 44 09 771 A1, DE 29 00 935 A2 and DE 10 2008 026 968 A1.

[0008] Nonwoven velour is a sophisticated needlework product in which the fibrous pile is created by needling a uniform brush belt running over a pre-made nonwoven material, which is then sheared to a defined pile height and is called sheared velour.

[0009] Velour carpet differs from needled nonwoven carpet in that it has a higher quality look and feel and improved wear behavior.

[0010] Special processes for achieving uniform stitch patterns in needled nonwoven materials are described in U.S. Pat. No. 9,567,698, U.S. Pat. App. Pub. No. 2016 / 0069006, U.S. Pat. No. 9,260,806, U.S. Pat. App. Pub. No. 2015 / 0259836, and European Pat. App. Pub. No. 2,918,719. In the production of flat needled nonwoven materials, the staple fibers are consolidated after the nonwoven material is formed by carding and multiple needling cross-wrapping between two metal plates. In a further process, velour needled fleece can be produced from this flat needled nonwoven material by repeated needling on a brush belt. In both variants, thermal or chemical bonding of the staple fibers after needling is necessary to achieve good final strength.

[0011] The fibers are mostly incorporated by foamed latex or acrylate. The use of a combination of latex or acrylate with BiCo fibers (coPET / PET bicomponent fibers) is also common. Furthermore, consolidation is also achieved exclusively with BiCo fibers.

[0012] WO 2017 / 061970 (Patent Document 9) deals specifically with the bonding of carpets using bicomponent (BiCo) fibers. Optimization of the fixation of the (BiCo) fibers by using special slot nozzles in the drying oven is described here. Furthermore, the following are known: extended PE, EVA / PE blends, extruded PE, films, thermal adhesives, thermoplastic dispersions, and thermal bonding (EP 1 598 476 (Patent Document 10)).

[0013] German Patent No. 2 008 439 (Patent Document 11) [U.S. Patent No. 3 755 055 (Patent Document 12)] describes a method in which a single-color or mixed nonwoven web and a nonwoven web printed on one side with a decorative pattern of one or more colors by means of colored dyes are superimposed on each other, with the printed side of one nonwoven web facing away from the unprinted nonwoven web, and then both nonwoven webs are needled from the unprinted surface to such an extent that the fibers of the unprinted nonwoven web intermix with the fibers of the printed nonwoven web, forming a pile on the printed surface and transforming the printed decorative pattern into a soft three-dimensional pattern.

[0014] German Patent Application Publication No. 39 04 526 (Patent Document 13) discloses a floor covering and a method for producing the same. To produce a floor covering consisting of two layers of needled nonwoven material, the upper layer of the two layers is structured on its upper surface, and the lower layer is needled from its lower surface onto the structured upper layer. The needling depth is much smaller than the thickness of the upper layer. By needling the two layers together from the back of the upper layer, the structure of this upper layer is not destroyed. After needling, the two layers are further bonded by impregnating a binder through the upper layer.

[0015] European Patent Application Publication No. 0 888 743 (Patent Document 14) [US Patent Application Publication No. 2002 / 0029445 (Patent Document 15), US Patent No. 6 287 407 (Patent Document 16), US Patent No. 6 398 895 (Patent Document 17)] describes a structured textile material made of at least two different nonwoven base materials in the field of cleaning textiles. The technical teaching relates to a structured textile material made of at least two different needled nonwoven base materials, where the nonwoven base material has a structure obtained by needling from at least one side, the needles used to needle the structure are forked or crowned needles, the depth of the forks or hooks is selected so that when the needles are pierced, they are completely filled with the fibers of the nonwoven base material facing the needles, and the textile material has a pattern of unmixed pure fibers on the base and back. It is stated that in a method for producing a structured textile material, on the one hand, two needled nonwoven base materials containing molten fibers are laminated without activating the molten fibers, and then structural needling is performed on one or both sides, and the molten fibers of the nonwoven base material are activated after structural needling; on the other hand, prior to entering the structural needling device, an intermediate layer of a material capable of bonding the two nonwoven base materials, in particular a nonwoven adhesive, is introduced between the two needled nonwoven base materials with molten fibers, and the two nonwoven base materials and the intermediate layer are subjected to structural needling on one or both sides, and then a bond between the two nonwoven base materials and the intermediate layer is created by activating the molten fibers and the intermediate layer.

[0016] WO 2011 / 045691 A1 describes a graphic velour carpet and its manufacture. Two structuring devices, each equipped with two needle boards, as well as a nonwoven base material and a nonwoven top material, are used. The nonwoven base material is fed onto the nonwoven top material between the two structuring devices and needled into a nonwoven material in the second structuring device. The needles in the needle boards are arranged according to a predetermined pattern. An adhesive is applied to the nonwoven base material, which then fixes / adheres the fibers of the nonwoven material layer.

[0017] Furthermore, it is known to produce patterns in needled nonwoven materials by means of several components, fiber layers and several needling processes, see inter alia DE 103 46 473 A1 and WO 2011 / 065851 A1.

[0018] German Utility Model No. 20 2009 000 775 (Patent Document 21) describes a fiber surface structure constructed by needling a visible needled nonwoven material or fiber pile (surface layer) with a fiber pile or fiber nonwoven material (pattern layer) using various needle types / needle arrangements, and / or penetration directions and / or penetration depths. The pattern layer is pre-treated and differs from the surface layer in the fibers themselves and the coloring of the fibers. Furthermore, the pattern layer is punched and / or cut out, dyed and / or printed prior to needling with the surface layer. Furthermore, several different sample piles or sample nonwoven materials are used as sample layers. The surface layer is needled on the back side and treated on the front side.

[0019] All "structural needling" applications, processes, and apparatus, as well as material structures, described in the prior art relate to non-(single layer) flat needled nonwoven carpets for automotive use and their three-dimensional transformation into automotive floor panels, luggage compartment panels, or cargo floor panels. There are no reports of non-destructive structures that retain the surface structure in a durable manner during three-dimensional transformation in a contact heating field (lamination press), a radiant heating field, and in the transformation tool itself. [Prior art documents] [Patent documents]

[0020] [Patent Document 1] DE 44 09 771 A1 [Patent Document 2] German Patent No. 29 00 935 [Patent Document 3] DE 10 2008 026 968 A1 [Patent Document 4] U.S. Patent No. 9,567,698 [Patent Document 5] US Patent Application Publication No. 2016 / 0069006 [Patent Document 6] U.S. Patent No. 9,260,806 [Patent Document 7] US Patent Application Publication No. 2015 / 0259836 [Patent Document 8] European Patent Application Publication No. 2 918 719 [Patent Document 9] International Publication No. 2017 / 061970 Brochure [Patent Document 10] European Patent No. 1 598 476 [Patent Document 11] German Patent No. 2 008 439 [Patent Document 12] U.S. Patent No. 3,755,055 [Patent Document 13] DE 39 04 526 A1 [Patent Document 14] European Patent Application Publication No. 0 888 743 [Patent Document 15] US Patent Application Publication No. 2002 / 0029445 [Patent Document 16] U.S. Patent No. 6,287,407 [Patent Document 17] U.S. Patent No. 6,398,895 [Patent Document 18] International Publication No. 2011 / 045691 Brochure [Patent Document 19] DE 103 46 473 A1 [Patent Document 20] International Publication No. 2011 / 065851 Brochure [Patent Document 21] German Utility Model No. 20 2009 000 775 Summary of the Invention [Problem to be solved by the invention]

[0021] It is therefore an object of the present invention over the prior art discussed above to provide a structurally needled carpet suitable for modification to upgrade the passenger compartment and / or luggage compartment of an automobile with the intent of creating a "living room / peaceful atmosphere." In particular, it is an object of the present invention to introduce a permanent, wear-resistant surface pattern, possibly with a three-dimensional structure, during manufacture / needling of a needled nonwoven carpet that is differentially structured across the width of the carpet surface and that will withstand three-dimensional deformation to form the panels of an automobile floor or luggage compartment. [Means for solving the problem]

[0022] In a first embodiment, the subject of the present invention is a 180 g / m 2 ~700g / m 21. A method for manufacturing a three-dimensionally deformable needled nonwoven carpet for an automotive floor panel, luggage compartment panel, or cargo floor panel having a structurally needled deformation-resistant surface having a panel basis weight within the range of two or more needle types arranged in segments across the width of the needle board; A structured panel surface is generated from the initial nonwoven material by needle processing, with a predetermined setting of feed / stroke of the initial nonwoven material and a predetermined setting of penetration depth; The method is characterized in that the panel comprises one or more sub-layers and is deformed.

[0023] Thus, the crux of the present invention is to provide a needled nonwoven carpet produced by conventional standard processes for the manufacture of automotive floor panels, luggage compartment panels, or cargo floor panels with a visible surface that structurally resists needled deformation simply by the arrangement of different needles / needle shapes across the width of one or more needle boards used to needle the automotive floor panels, luggage compartment panels, or cargo floor panels. The needle boards have predetermined needle types / shapes across their width, thus creating a predetermined, possibly three-dimensional structure in the needled nonwoven material surface. Preferably, needles of the same length but differing in fineness, notch spacing, notch size, working section shape, and tip-to-first notch distance are used.

[0024] An advantage of the present invention is that it provides a deformation-resistant / stable structural needled nonwoven carpet for producing automotive floor and luggage compartment panels or cargo floor panels without requiring additional manufacturing steps compared to standard needled nonwoven carpet manufacturing.

[0025] The roll or blank fabric as initially produced may have regions of different nap or stiffness in the machine direction, for example.

[0026] The method of the present invention can be performed on "standard" equipment without the need for additional nonwoven layers, needling stages, needling devices, or needle boards, simply by the needle shape / needle type of needles arranged across the width of the needle board.

[0027] A further embodiment of the present invention is 2 ~700g / m 2 and a three-dimensionally shaped needled nonwoven material for a floor panel, luggage compartment panel, or cargo floor panel of an automobile having a structurally needled deformation-resistant surface having a panel basis weight in the range of 1000 to 15000 mm, the nonwoven material further comprising one or more sub-layers, the visible side of the floor panel, luggage compartment panel, or cargo floor panel optionally having a three-dimensional structurally needled wear-resistant surface.

[0028] The implementation should preferably be carried out in a single layer on the one hand and a two-layer needled nonwoven carpet on the other hand. In the case of a two-layer design, additional color effects with different structures can be introduced in the needlework. [Example]

[0029] For the production of deformation-resistant / stable structural needled floor panels, a pre-woven material made of 100% PES fibres of 7 dtex with a length of 64 mm was used as the initial nonwoven material: basis weight 400 g / m 2 It was.

[0030] The needle board was divided laterally into four different segments:

[0031] Needle Type 1 (Fine) - Needle Type 2 (Coarse) - Needle Type 1 (Fine) - Needle Type 2 (Coarse)

[0032] Needles commercially available from Groz-Beckert KG, Albstadt, Germany were used: Needle Type 1: 15x18x43x3 R222 G 2017 Needle type 2: 15x18x36x3 R333 G 2007 These needles vary in fineness, number of notches, size of the notches, and distance from the tip to the first notch.

[0033] During production, it was necessary to find the optimum penetration depth and optimum feed / stroke by trial and error. For the needled nonwoven carpet shown in Figure 1, the feed / stroke was 1.55 mm / stroke and the penetration depth was 12 mm.

[0034] The structurally needled nonwoven carpet floor thus produced was then subjected to a 80 g / m 2 It was combined with commercially available latex and weighed 80g / m 2 It was coated with commercially available PE.

[0035] Next, (a) heavy foil 2.5 kg / m 2 and (b) nonwoven foil 150 g / m 2 The needled nonwoven carpet floor with an underlayer of was formed into a mid-range vehicle floor panel upper product using process parameters of 185°C / 180°C for 58 seconds in a contact heating field; 150°C and 5°C mold surface temperature in a radiant heating field with a tool closure time of 68 seconds.

[0036] Figure 2 shows a cross section of the formed floor panel top product. The structuring of the fine needles (fuzz) and the coarse needles (stripes) is clearly visible. The intervening stripes were only pre-needled.

[0037] Specifically, in Figure 2, it can be seen that the structural needling of the carpet is suitable for deformation and is deformation stable.

[0038] By selecting needle combinations, carpet textures can be combined in a variety of ways.

[0039] Figure 3 shows another example of this. Needle type 1: 15x25x32x3 1 / 2 R333 G3012 Needle type 2: 15x20x3 1 / 2 C333 G3012 Feed / stroke: 7.99mm / stroke Penetration depth: 12mm

Claims

1. 180 g / m ２ ~700g / m ２ 1. A method for manufacturing a three-dimensionally deformable needled nonwoven carpet for an automotive floor panel, luggage compartment panel, or cargo floor panel having a structurally needled deformation-resistant surface having a panel basis weight within the range of two or more needle types arranged in segments across the width of the needle board; A structured panel surface is generated from the initial nonwoven material by a predetermined setting of feed / stroke of the initial nonwoven material and a predetermined setting of penetration depth; The panel comprises one or more sub-layers and is deformed; the needle board is laterally divided into different segments; The segments are alternately arranged with first and second needle types, 10. The method of claim 9, wherein the first needle type is needle type 15x18x43x3 R222 G 2017 and the second needle type is needle type 15x18x36x3 R333 G 2007.

2. 2. The method according to claim 1, wherein needles are used that differ in fineness, notch spacing, notch size, working part shape, and tip-to-first notch distance.

3. A composition produced by the method of claim 1, having a viscosity of 180 g / m ２ ~700g / m ２ 1. A three-dimensionally shaped needled nonwoven material for an automotive floor panel, luggage compartment panel, or cargo floor panel, comprising a structurally needled deformation-resistant surface having a panel basis weight in the range of A nonwoven material, characterized in that the visible side of the floor panel, the luggage compartment panel, or the luggage floor panel has an abrasion-resistant surface that is optionally three-dimensionally needled.

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