DE10025482B9 - Continuous sound-absorbing additional mat for motor vehicles - Google Patents

Abstract

Textile auxiliary mat for motor vehicles with a textile top layer and an associated textile underlayer for laying on a bottom lining of the motor vehicle, wherein a polyurethane prepolymer layer is provided,
characterized,
in that the upper layer (1) is joined to the lower layer (4) by means of an open-pore air-permeable, polyurethane thermosetting prepolymer intermediate layer (6), wherein textile fibers (2, 5) of the upper layer (1) and the lower layer (4) in the intermediate layer (6) are bonded wear and abrasion resistant, and
the composite of upper layer (1), intermediate layer (6) and lower layer (4) is permeable to air permeable to the floor lining throughout.

Description

The The invention relates to a textile additional mat for motor vehicles with a textile upper layer and a textile underlayer connected to this Laying on a floor lining of a motor vehicle, wherein a Polyurethane prepolymer layer is provided.

multilayer Additional mats with different textile top layers (decorative layers) Flat needle fleeces, pile fleeces or tufting materials are manifold in use. To achieve optimum abrasion resistance, takes place the fiber bond mostly based on chemical binders Styrene-budadiene, latices or acrylate dispersions. The lower class is often a plastic coating, textile lamination or rubber lamination.

A vehicle floor covering, in which a polyurethane prepolymer layer for the integration of a textile layer is described, is known from DE 35 10 722 C2 known.

The DE 35 34 690 C2 teaches that continuous air permeability for a soundproofing panel is advantageous.

In the JP 08058454 For example, the fibers of a topsheet and a backsheet are bonded in an intermediate layer.

In DE-GM 93 09 926 such a mat is described as a doormat. At the textile upper layer is as slip-resistant lower layer a needled staple fiber fleece by gluing, laminating or needling attached. The doormat should due to their suppleness to the particular shape of the bottom lining to adjust.

In DE-GM 92 17 511 is a floor mat for motor vehicles described in which to improve the recyclability of the textile Cover layer and the non-textile carrier layer of non-crosslinking Polypropylene exist. The cover layer and the carrier layer can solventless thermally connected to each other.

In DE-GM 87 10 779 is a doormat for motor vehicles with a carrier described on the underside of an open-cell elastic foam sheet is applied as anti-slip. The carrier should be made of rubber, latex or Fabric consist.

Out DE-GM 94 15 231 is a doormat for motor vehicles known, which consists of an elastic plate of a rubbery Material with trough-like depressions to wear and wetting to avoid the bottom lining.

In the DE 296 22 755 U1 a protective mat for motor vehicles is described in which an anti-slip layer is applied to a roll material and the protective mat is cut out of the roll material. The underside of the protective mat is formed by a fleece or textile material, which is connected to the overlying mat material by gluing or heating.

From the EP 0 466 308 B1 is a doormat with a batt and a rubber reinforcement known.

In WO 86/06 691 describes a further insertable mat which for covering and protecting floor carpets in motor vehicles. Again, the problem of slipping in the foreground.

The known suggestions to deal with the design of additional mats of the type mentioned do not deal with the problem of sound insulation. The known additional mats also have the disadvantage that they are unpleasant for the vehicle occupants in many cases smells, especially if they are new, submit.

task The invention is an additional mat of the type mentioned suggest their sound absorption properties, in particular in the frequency range from 1250 Hz, the maximum are improved little unpleasant odors widespread, a vehicle weight reduction yields and yet has a sufficient abrasion resistance and dimensional stability.

According to the invention is the above Task solved by that the upper layer with the lower layer by means of an open pore air-permeable, thermosetting polyurethane prepolymer interlayer connected is, wherein textile fibers of the upper layer and the lower layer in the intermediate layer are bound, and that of the upper class, Intermediate layer and lower layer existing composite to the bottom lining permeable to air throughout is.

The Sound absorption properties of a textile layer depend on the sound-absorbing thickness of the textile material. The air permeability of the entire composite improves the sound absorption, because of the sound absorption the entire thickness of the additional mat is available and no air-impermeable layer the sound absorption interrupts.

If the interlayer were an air impermeable layer, then only the upper layer would be sound-absorbing effect.

For a high Sound absorption would have they are correspondingly thick. Your weight would be correspondingly larger.

Especially high is the total sound absorption when the additional mat on one floor covering consisting of a fleece, velor or tufting material is hung up. Because here the sound absorption values add up the floor lining and the additional mat. Due to the improved sound absorption The interior of the vehicle will be much quieter.

The Additional mat does not develop significant odor emissions, because the polyurethane prepolymer does not smell unpleasant and no further Binders and adhesives necessary are the odor-intensive solvents contain.

Preferably the upper layer and / or the lower layer consists of a fiber material whose Fibers essentially only mechanical, binder-free and adhesive-free are bound. It is therefore largely odorless. The polyurethane prepolymer interlayer create the for the necessary abrasion resistance necessary Fiber bonding.

by virtue of the thermoset property of the intermediate layer are the Auflegefähigkeit the contour accuracy and dimensional stability of the additional mat also at ensures high temperatures.

The Undercoat ensured the necessary slip resistance the additional mat on the bottom lining.

The described additional mat is inexpensive to produce, because for the upper class and the lower layer no additional Binding fibers such as bicomponent and / or melt fibers required are. For bicomponent fibers the fiber core consists of a plastic with a higher melting point and the Fiber cladding made of a plastic with a lower melting point. Such Bicomponent fibers are expensive and disadvantageous in recycling. melt fibers are fibers that have a lower melting point than that other fibers and having a lower melting point than serve those and their connection.

The Abrasion resistance of the underlayer can be increased thereby that the lower layer thermally partially solidified on the underside is. In this case, individual zones or communicate with each other fused at the bottom of the lower layer fused zones or embossed, wherein the local fibers connect with each other. If necessary Can also be the top of the top layer to improve the abrasion resistance be partially solidified in this way. Through the partial consolidation should be the air permeability not significantly reduce.

The lower abrasion resistance leaves also improve by the fact that the lower layer underneath another textile layer, in particular a nonwoven wears, the more resistant to abrasion than the lower layer and the lower layer by means of another open-pore air-permeable polyurethane prepolymer layer is attached. The further polyurethane prepolymer layer is preferably thinner than the polyurethane prepolymer interlayer.

Further advantageous embodiments of the invention will become apparent from the dependent claims and the following description of an embodiment. In the drawing demonstrate:

1 a partial cross section of an additional mat,

2 a 1 corresponding view of another embodiment and

• a) die Schallabsorptionskurve der beschriebenen Zusatzmatte und
• b) eine Schallabsorptionskurve einer Zusatzmatte nach dem Stand der Technik ist.

3 Sound absorption curves, where

• a) the sound absorption curve of the described additional mat and
• b) is a sound absorption curve of an additional mat according to the prior art.

The additional mat has a visible upper layer 1 of a textile material of synthetic fibers, for example thermoplastic synthetic fibers of polypropylene or polyester or polyamide. The fibers are one-component fibers or fiber mixtures. Its core is made of the same material as its coat. The textile material preferably contains no fused fiber portions.

In the textile base material for the upper class 1 are the fibers 2 essentially only mechanically, free of chemical binders and adhesives bound. The starting material for the upper class 1 is in the direction S perpendicular to a non-illustrated, in particular textile, floor lining of a motor vehicle on which the additional mat is to be placed as a mat, permeable to air permeability.

To 1 is the upper class 1 formed by a tufting material in which the fibers 2 by means of a perforated carrier fleece 3 mechanically bound. The upper class 1 a tufted cut fiber material (cf. 1 ) or a tufted loop fiber material.

According to the embodiment 2 is the upper class 1 gebil of a needled pile fleece det.

The additional mat has a textile lower layer 4 on, which is intended for slip-resistant support on the floor lining, in particular textile floor lining of a nonwoven, velor or tufted material. The lower class 4 consists of a fleece made of thermoplastic synthetic fibers 5 , in particular of polypropylene or polyester. In the fleece 4 are the fibers 5 only mechanical, solvent-free binders and adhesives, bound. The fleece 4 is permeable to air in the direction of S.

To 1 exists the lower class 4 from a random fiber fleece. To 2 is the lower class 4 formed by a needled and / or sheared pile fleece. The lower class 4 can be like the upper class 1 also consist of a tufting material.

Between the upper class 1 and the lower class 4 is a foamed polyurethane prepolymer interlayer 6 intended. This is open-pored and thus like the upper class 1 and the lower class 4 permeable to air.

The intermediate layer 6 is thermosetting, so keeps its shape even at higher temperatures.

Into the intermediate layer 6 are upper side substantial proportions of the fibers 2 the upper class 1 and optionally the carrier fleece 3 and underside substantial proportions of the fibers 5 the lower class 4 mechanically cohesive, what the mechanical abrasion resistance of the upper layer 1 on the one hand and the mechanical abrasion resistance of the lower layer 4 on the other hand increased.

In addition, the intermediate layer connects 6 the upper class 1 and the lower class 4 to a dimensionally stable additional mat, even in the case of high temperatures to be expected in a motor vehicle, without the tendency of the upper class to tend 1 and the lower class 4 by shear and Walk forces from each other.

The entire dimensionally stable upper layer composite 1 , Intermediate layer 6 and lower class 4 is permeable to air in the direction of S. Thus, the entire thickness D of the additional mat contributes to the sound absorption. The total thickness D of the structure is a maximum of 10 mm.

In 3 Sound absorption curves are shown with the sound absorption coefficient over the frequency f. The comparison of the sound absorption curve after 3a (described additional mat) with the sound absorption curve after 3b (Prior art) shows that in the described additional mat, the sound absorption coefficient in the entire frequency range is significantly higher than in a supplementary mat according to the prior art. The absorption coefficient measured according to DIN EN 20354 is in the range of 1250 to 8000 Hz at least 1.2.

The Sound absorption continues to improve when the extra mat on a textile floor lining is applied. Because then add the sound-absorbing values of the textile floor lining with the continuous sound-absorbing additional mat.

The Air permeability The additional mat also has the advantage of providing a water vapor permeability given is. So it can be between the bottom lining and The additional mat hardly ever damp or damming moisture.

The Additional mat is easily removed from the vehicle user by the floor liner removable and separate from this cleanable.

The Additional mat can be adapted to the floor lining flat contour or a three-dimensional shape adapted to the floor lining exhibit.

For the back and, if necessary, for the upper side attachment, the thermoplastic fibers of the lower layer 4 and / or the upper class 1 Partially or zonally embossed or bonded together by the effect of temperature, without thereby the air permeability and thus the sound absorption capacity is substantially reduced.

Claims (14)

Textile auxiliary mat for motor vehicles with a textile upper layer and a textile underlayer connected thereto for laying on a floor lining of the motor vehicle, wherein a polyurethane prepolymer layer is provided, characterized in that the upper layer ( 1 ) with the lower layer ( 4 ) by means of an open-pore air-permeable, polyurethane thermosetting prepolymer intermediate layer ( 6 ), whereby textile fibers ( 2 . 5 ) the upper class ( 1 ) and the lower class ( 4 ) in the intermediate layer ( 6 ) are bonded wear and abrasion resistant, and that the upper layer ( 1 ), Intermediate layer ( 6 ) and sublayer ( 4 ) existing composite perpendicular to the floor lining is continuously permeable to air. Additional mat according to claim 1, characterized in that the textile upper layer ( 1 ) and / or the textile lower layer ( 4 ) from an air permeable flat or fleece, woven, knitted or tufted. Additional mat according to claim 1 or 2, characterized in that the textile upper layer ( 1 ) and / or the textile lower layer ( 4 ) consist of a material whose fibers ( 2 . 5 ) are bonded only mechanically, binder-free and adhesive-free. Additional mat according to one of the preceding claims, characterized in that the fibers ( 2 . 5 ) Are single-component fibers or mixed fiber components. Additive according to one of the preceding claims, characterized in that the textile upper layer ( 1 ) in particular of an air-permeable tufting material with cut fibers or continuous fibers with perforated carrier fleece ( 3 ) or in particular a needled pile fleece is formed. Additional mat according to one of the preceding claims, characterized in that the textile lower layer ( 4 ) is formed by an air-permeable non-woven, in particular needled or shaved pile fleece. Additional mat according to one of the preceding claims, characterized in that the upper layer ( 1 ) and / or the lower layer ( 4 ) is made of thermoplastic synthetic fibers, in particular of polypropylene or polyester. Additional mat according to one of the preceding claims, characterized in that in the upper class ( 1 ) and / or the lower class ( 4 ) Melt fibers are not included. Additional mat according to one of the preceding claims, characterized in that the lower layer ( 4 ) is thermally partially solidified or embossed on the underside. Additional mat according to one of the preceding claims, characterized in that the lower layer ( 4 ) on the underside another textile layer, in particular a nonwoven, carries, which is more resistant to abrasion than the lower layer and which is attached to the lower layer by means of another open-pore air-permeable polyurethane prepolymer layer. Additional mat according to claim 10, characterized that the further polyurethane prepolymer layer thinner than the polyurethane prepolymer interlayer is. Additional mat according to one of the preceding claims, characterized characterized in that the additional mat cut in a contour and / or spatially is shaped. Additional mat according to one of the preceding claims, characterized characterized in that the absorption coefficient measured according to DIN EN 20354 is in the range of 1250 to 8000 Hz at least 1.2. Additional mat according to one of the preceding claims, characterized characterized in that the total thickness (D) of the structure is a maximum of 10 mm is.