EP1171291A1 - Article composite moulable et son procede de fabrication - Google Patents

Article composite moulable et son procede de fabrication

Info

Publication number
EP1171291A1
EP1171291A1 EP00913664A EP00913664A EP1171291A1 EP 1171291 A1 EP1171291 A1 EP 1171291A1 EP 00913664 A EP00913664 A EP 00913664A EP 00913664 A EP00913664 A EP 00913664A EP 1171291 A1 EP1171291 A1 EP 1171291A1
Authority
EP
European Patent Office
Prior art keywords
fabric
layer
formable
article
variable compression
Prior art date
Legal status (The legal status 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 status listed.)
Withdrawn
Application number
EP00913664A
Other languages
German (de)
English (en)
Other versions
EP1171291A4 (fr
Inventor
Stephen D. Copperwheat
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Knowlton Nonwovens Inc
Original Assignee
Knowlton Nonwovens Inc
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
Priority claimed from US09/286,916 external-priority patent/US6008149A/en
Application filed by Knowlton Nonwovens Inc filed Critical Knowlton Nonwovens Inc
Publication of EP1171291A1 publication Critical patent/EP1171291A1/fr
Publication of EP1171291A4 publication Critical patent/EP1171291A4/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • 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
    • 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
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
    • B60R13/0212—Roof or head liners
    • 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
    • B32B2307/70—Other properties
    • B32B2307/738—Thermoformability
    • 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
    • B32B2605/003—Interior finishings

Definitions

  • the present invention relates in general to a composite article and more specifically to a moldable nonwoven fibrous composite article.
  • the inner surfaces of the two outer non-woven fabric layers adhere to the surfaces of extruded polypropylene by the heat generated in the extrusion process and the consequent molten state of adjacent surfaces that melt during the process. With all three layers containing the same polymer, namely polypropylene, eventual recycling of the articles is facilitated.
  • the present invention as embodied and broadly described herein provides for a moldable non-woven fibrous composite material and method of manufacture.
  • the non- woven fibrous composite in accordance with the present invention possesses at least two functional layers, all of which are made of the same non-woven thermoformable polymeric chemical substance or material.
  • Suitable polymeric materials include polypropylene, polyvinyl chloride, polyvinyl acetate, polyamide, polyvinyl alcohol, polyethylene, polyurethane and polyester.
  • the layers are made of a polyester. These composites may typically be used for but not limited to the manufacture of automobile headliners, trunk liners, passenger compartment components, luggage, furniture, sporting goods, and filtration products.
  • the polymeric chemical substance selected is fabricated into two different fabrics having different mechanical and/or other physical properties.
  • At least one fabric is a formable fabric, which upon final molding under heat and/or pressure, possesses a relatively high degree of strength and stiffness.
  • the other fabric is a variable compression fabric (also described as a variable thickness fabric) which is capable of assuming variable thickness and density when subjected to molding under heat and/or pressure. In certain applications where the final article requires a uniform thickness and density, the variable compression fabric may also be used.
  • variable compression fabric is the subject of U.S. Patent No. 5,532,050 which is incorporated herein by reference.
  • another layer constituting a facing fabric can be applied to the outer surface of either of the layers for the purpose of enhancing the appearance of articles molded from the composite.
  • the functional layers and the layer of facing fabric may be assembled into a composite capable of shipment to fabricators of finished, formable articles.
  • the composite may be assembled by stacking the layers one upon the other and combining them together.
  • composite includes any stack of successive layers whether or not cohesion between or among such layers has been enhanced by chemical and/or physical means.
  • Cohesion of adjacent layers of the composite can be enhanced by such techniques as spray powder bonding, use of liquid dispersion/solutions, stitch bonding, flame lamination, use of an intermediate adhesive fabric between functional layers, and mechanical needlepunching, all of which are well known to those versed in the art.
  • blends of selected fibers having predetermined melting temperature ranges are contained within either or both layers which effects the adhesion between the layers of the composite and stiffness of the final molded article.
  • This mechanism of adhesion which takes place can be described as a "thermoplastic bonding" and is more fully described in U.S. Patent 5,456,976; col. 3, lines 36-50 which is incorporated herein by reference.
  • a sheet of the composite is then set into a mold, formed with heat and/or pressure to take the shape of the mold cavity, and thereby forming the final article shape.
  • Fig. 1 is an isometric view of the moldable fibrous composite according to an embodiment of the present invention showing its layered configuration.
  • Fig. 2 is a schematic representation of a system for producing molded articles according to another embodiment of the present invention.
  • articles are molded from separate rolls or sheets of variable compression and formable fabric layers, respectively.
  • formable fabric (25 and 26) is dispensed from rolls (29 and 32, respectively)
  • variable compression fabric (28) is dispensed from roll (31) and, optionally, facing fabric (27) from roll (30).
  • These fabric layers are simultaneously fed from their respective rolls in a molding means having top (33) and bottom (34) portions, as depicted in Fig. 2.
  • Automobile headliners are formed by passing the separate layers of variable compression and formable fabric, which contain binder fibers, through a compression mold having a cavity whose shape is the form of the headliner as a roll of the composite material is unrolled. To effect molding, the composite material is subjected to an elevated temperature for a predetermined time and then cooled in the mold.
  • the binder fibers in the separate layers soften and/or melt and intermingle under heat and/or pressure and upon mold release the fibers will cool and harden and bond the layers together.
  • layers of formable and variable compression fabric and, optionally a layer of facing fabric are formed into a composite prior to fabrication in an article.
  • Fig. 1 illustrates the various layers which comprise a composite article according to the present invention.
  • a composite article (1) comprising a layer of variable compression fabric (2) is sandwiched between formable fabric layer (5), having upper surface (6) and lower surface (7), and formable fabric layer (8), having upper surface (9) and lower surface (10), upper (14) and lower (11) adhesive layers are interposed between variable compression fabric layer (2) and formable fabric layers (5) and (8), respectively, such that the upper surface (3) of variable compression layer (2) abuts the lower surface (16) of adhesive layer (14) and the upper surface (15) of adhesive layer (14) abuts the lower surface (7) of formable fabric layer (5) and the upper surface (12) of adhesive layer (11) abuts the lower surface (4) of variable compression layer (2) and the lower surface (13)of adhesive layer (11) abuts the upper surface (9) of formable fabric layer (8), thereby enhancing contact and cohesion between formable
  • the foregoing embodiment may be modified by applying the lower surface (19) of facing fabric layer (17) to the upper surface (6) of formable fabric layer (5) by means of adhesive layer (20) such that the lower surface (19) of facing fabric (17) abuts the upper surface (21) of adhesive layer (20) and the lower surface (22) of adhesive layer (20) abuts the upper surface (6) of formable fabric layer (5), thereby enhancing the appearance of the outer surface of the composite material and of articles molded therefrom.
  • Automobile headliners or trunk liners can then be formed by passing the composite material through compression molding means, subjecting the composite material to elevated temperature and/or pressure for a time sufficient to have the composite material assume the shape of the mold's cavity.
  • the basis weight for the formable or stiffening fabric should be from about 4 to 18 oz/yd 2 .
  • a preferred range is from about 6 to 12 oz/yd 2 .
  • a sheet of polyester variable compression fabric is sandwiched between two sheets of formable polyester in the form of a needlepunch felt, thereby forming a composite article.
  • the needlepunch felt is produced by Knowlton Nonwovens, Inc. of Utica, New York. Cohesion between adjacent sheets is enhanced by mechanical needlepunching.
  • the composite material is then rolled into storage rolls.
  • a layer of decorative fabric, such as HOF AHMV8 printed stitchbond polyester or Foss needlepunch polyester, may be applied to an outer surface of one of the layers of the formable polyester fabric.
  • enhanced cohesion between the facing fabric layer and a formable fabric layer may be effected by the interposition there between of an adhesive layer, while enhanced cohesion between a formable fabric layer and the variable thickness fabric layer may be effected by needlepunching.
  • the composite material suitable for molding may be fabricated from a single layer of formable fabric and a layer of variable compression fabric.
  • a facing fabric layer may be applied to the outer surface of either the formable fabric layer or the variable compression fabric layer.
  • Cohesion between functional fabric layers may be enhanced by such mechanical means as needlepunching and/or by adhesive means such as spray power bonding, the use of liquid dispersion/solutions, flame lamination, and/or the interposition of an adhesive layer and combinations thereof.
  • first and second stiffener layers are produced by the needlepunch process by first blending the selected fibers on standard textile blending equipment following by carding the fibers into a nonwoven web which is then cross-lapped to build a high loft multilayered batt which is subsequently needlepunched with about 1,000 pin needle penetrations.
  • Example A moldable composite structure in which a layer of variable compression fabric is sandwiched between two layers or sheets of a formable (stiffener) fabric is made by the following technique.
  • the layers of the three materials are as follows: First Stiffener 50% Fiber Innovation Technologies 3.5 denier X 2
  • Second Stiffener same fibers, blend, and construction as above
  • the vertical lap product variable compression fabric is produced on a Strudo machine produced by:
  • the three polyester fibers including the one binder fiber, are blended together on standard textile fiber blending equipment and carded into a nonwoven web.
  • the carded web is fed to the vertical lap Strudo machine to be folded back onto itself or pleated to produce a vertically folded product of given thickness.
  • the thick product is passed through an oven which heats the product to at least about 150°C which softens or melts the binder fiber to allow it to thermally bond to the other fibers in the blend, thereby producing a lofty, thick 3-dimensional product.
  • the process includes layering the fabrics into a composite, preheating the composite to about 400 °F for about 8 minutes, placing the composite into the mold, closing the mold to a 16mm gap for about 4 minutes, and opening and removing the molded article.
  • the mold warm tool was preheated to about 300 °F.
  • the operative range which provides for a suitable stiffness for the molded composite of the present invention is about 13 to 26 Newtons for the Offset Yield Load.
  • the Yield Load at 1" for the present invention ranges from about 90 to 140%, and the Slope should be in the range of about 2.5 to 7.0 N/mm.
  • the product of the present invention in a preferred embodiment, requires a high degree of stiffness to be suitable for use as an automotive headliner, with the term "high degree of stiffness" being defined by the flex test results disclosed in Table 1 and discussed above.
  • a molded headliner requires a high degree of stiffness in order to support its own weight over its span, which can be up to 8 feet in a minivan, and the additional weight of the interior dome lights and sun visors, without bending and cracking over a broad range of temperatures from -40° to 185°F when exposed for up to three days as evaluated in a standard environmental resistance test for headliners.
  • the product must not flex or bend to a failure point where it will crack the headliner, making it unable to bear the weight of the added headliner components.
  • a failure crack in the headliner will show through the decorative fabric layer in the headliner, giving it an aesthetically unacceptable appearance for installation into an automobile.
  • the product of the present invention will bend and then crack upon failure, making it unsuitable for use as an automotive headliner for the reasons stated.
  • Low modulus products do not crack upon failure, and do not exhibit the stiffness required to bear the added component weight while in use, particularly in the environmental resistance test described above. Therefore, low modulus products are inherently unsuitable for use as automobile headliner.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Manufacture Of Macromolecular Shaped Articles (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

L'invention concerne un article (1) qui comporte une couche de tissu formable (5) qui, lorsqu'il subit un moulage sous l'effet de la chaleur et/ou d'une pression, présente un degré de rigidité élevé. Une couche de tissu à compression variable (2) présentant une épaisseur variable lorsqu'elle subit un moulage sous l'effet de la chaleur et/ou de la pression, est liée à la surface du tissu formable (5), les couches étant constituées de la même substance chimique polymère thermoformable.
EP00913664A 1999-04-06 2000-02-29 Article composite moulable et son procede de fabrication Withdrawn EP1171291A4 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US286916 1981-07-27
US09/286,916 US6008149A (en) 1997-04-23 1999-04-06 Moldable composite article and method of manufacture
PCT/US2000/005151 WO2000059716A1 (fr) 1999-04-06 2000-02-29 Article composite moulable et son procede de fabrication

Publications (2)

Publication Number Publication Date
EP1171291A1 true EP1171291A1 (fr) 2002-01-16
EP1171291A4 EP1171291A4 (fr) 2002-09-11

Family

ID=23100709

Family Applications (1)

Application Number Title Priority Date Filing Date
EP00913664A Withdrawn EP1171291A4 (fr) 1999-04-06 2000-02-29 Article composite moulable et son procede de fabrication

Country Status (9)

Country Link
EP (1) EP1171291A4 (fr)
JP (1) JP2002540981A (fr)
KR (1) KR20010108459A (fr)
CN (1) CN1159150C (fr)
BR (1) BR0009554A (fr)
CA (1) CA2368738A1 (fr)
MX (1) MXPA01010157A (fr)
TW (1) TW500665B (fr)
WO (1) WO2000059716A1 (fr)

Families Citing this family (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ITSV20020063A1 (it) * 2002-12-30 2004-06-30 Compass Sa Pannello sagomato in materiale termoplastico, lastra intermedia per la fabbricazione di detto pannello e procedimento per la fabbricazione del detto pannello e della detta lastra intermedia
BR112014010217B1 (pt) * 2011-10-31 2021-01-05 Industrialesud S.P.A. artigo feito de um material composto de múltiplas camadas, componente para automóveis e processo para sua preparação
RU2619711C2 (ru) * 2012-06-26 2017-05-17 Сан Шян Текнолоджи Ко., Лтд. Способ производства нетканого композиционного слоистого продукта с разной степенью твердости
DE102019100919A1 (de) * 2019-01-15 2020-07-16 Adler Pelzer Holding Gmbh Kraftfahrzeug-Bodenverkleidung, Gepäckraumverkleidung oder Ladebodenverkleidung mit strukturgenadelter Teppich-Oberfläche (II)
DE202021103471U1 (de) 2021-06-29 2021-07-07 Tenowo GmbH Verbundmaterial auf Vliesstoffbasis
EP4241979A1 (fr) * 2022-03-10 2023-09-13 Carl Freudenberg KG Stratifié non tissé durable pour des applications de pièce structurale

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS60196332A (ja) * 1984-03-17 1985-10-04 Ikeda Bussan Co Ltd 車両用内装材の製造方法
US5532050A (en) * 1986-06-30 1996-07-02 Wm. T. Burnett & Co., Inc. Densified thermo-bonded synthetic fiber batting
ATE89461T1 (de) * 1987-08-28 1993-06-15 Gates Formed Fibre Products Halbsteife gepaeckschale und verfahren zu ihrer herstellung.
JP3351475B2 (ja) * 1992-10-03 2002-11-25 ユニチカ株式会社 積層板及びその製造方法
JPH06199182A (ja) * 1993-01-06 1994-07-19 Dainippon Ink & Chem Inc 自動車のトランクサイドトリムの製造方法
US5591289A (en) * 1995-06-29 1997-01-07 Davidson Textron Inc. Method of making a fibrous headliner by compression molding
WO1998030375A1 (fr) * 1997-01-08 1998-07-16 Owens Corning Matiere de moulage et procede de fabrication associe
US6096669A (en) * 1997-10-28 2000-08-01 Gkn Westland Aerospace Inc. Unidirectional fiber-random mat preform

Also Published As

Publication number Publication date
WO2000059716A1 (fr) 2000-10-12
EP1171291A4 (fr) 2002-09-11
CA2368738A1 (fr) 2000-10-12
TW500665B (en) 2002-09-01
MXPA01010157A (es) 2003-07-14
KR20010108459A (ko) 2001-12-07
CN1159150C (zh) 2004-07-28
JP2002540981A (ja) 2002-12-03
CN1346308A (zh) 2002-04-24
BR0009554A (pt) 2002-01-29

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