DE10052693A1 - Laminate for vehicle interiors, combines a thermoplastic layer with a natural cellulose fiber reinforced thermoplastic plastic layer - Google Patents

Abstract

Laminate construction comprises a film of thermoplastic resin (3) combined with a layer of a thermoplastic resin reinforced with 50-90 wt.% of natural plant cellulose fibers. Independent claims are made for: (a) a thermoplastic resin layer used in the laminate comprising a thermoplastic resin and natural cellulose fibers; (b) a fiber fleece laminate comprising a thermoplastic resin layer and a composite fiber fleece layer based on thermoplastic resin fibers and natural cellulose fibers; (c) a fiber fleece composite comprising thermoplastic resin fibers and natural cellulose fibers; (d) uses of the laminate, thermoplastic resin film, fiber fleece laminate and fiber fleece composite in the production of internal parts for vehicles; (e) a process for producing the thermoplastic resin film in which the layers of a) are pressed between heated rolls; (f) a process for producing a laminate in which the fiber-containing thermoplastic resin layer in a) is heated and pressed between heated rolls with a preheated thermoplastic resin film; (g) a process for producing a fiber fleece laminate in which a fiber fleece composite layer (1a) according to (c) is preheated (2) and pressed between heated rolls (5a,5b) onto one or both sides of a thermoplastic film (3).

Description

The present invention relates to

• 1. a laminate that is used as a material for interior structural parts of vehicles is suitable, and in particular a laminate for internal structural parts of properties required by vehicles, being as a stock part of an inner structural part ver a thermoplastic resin layer is used, which contains fibers based on natural vegetable cellulose;
• 2. a thermoplastic resin film used as a material (processed material) for inner structural parts of vehicles is suitable;
• 3. a nonwoven laminate that is used as a material (another processed material) is suitable for internal structural parts of vehicles, in particular a Nonwoven laminate that has properties that have not been preserved so far were, using a nonwoven fabric, the fibers from different Contains materials;
• 4. a nonwoven composite material which is used as material (material for processing) is suitable for internal structural parts of vehicles, in particular a Nonwoven composite that has properties that have not yet been were obtained using fibers from different materia lien; and the same.

As inner structural parts of vehicles such. B. as a ceiling material for a Vehicle, thermoplastic resin ones have been widely used. To the quality of the design, the handle and the impression of high quality such internal Improving structural parts of vehicles are sometimes different Types of surface layer materials as a layer on surfaces of inner Construction parts laminated from a thermoplastic resin. As materials for such surface layers are known different materials, such as. B. Textile woven or knitted fabrics, such as B. Mokett and jersey, non-woven fabric, metal foils and one  Foil or a film made of a thermoplastic resin or a thermoplastic Elastomer.

It is often required that internal structural parts be made of a thermoplastic Resin including interior construction parts for vehicles properties like (1) have a high stiffness, (2) a small linear expansion coefficient and (3) light weight.

The inner construction parts made of a thermoplastic resin can Properties (1) and (3) easily achieve, but what the reduction in linear out strain coefficient, no desired value has been reached so far.

The temperature inside a vehicle varies greatly when the Season changes. The temperature change can be up to 100 ° C. The inner ones Structural parts of the vehicle must have properties such that the parts do not bend even if such a temperature change occurs. To a Meeting such a requirement is an important factor for internal structural parts of vehicles that they have a low coefficient of linear expansion, in fact, however, an internal structural part of a vehicle cannot consist of only one thermoplastic resin exists, meet this requirement satisfactorily.

In these circumstances, many technologies have been proposed to one low coefficient of linear expansion for internal structural parts from one thermoplastic resin, especially for vehicles. The most typical so far well-known technology is a laminate in which a mat made of glass fibers on the upper surface of a layer is laminated comprising a thermoplastic resin. Such one thermoplastic resin laminate has a relatively low linear out expansion coefficients of the glass fibers have a relatively low linear expansion coefficients.  

However, glass fiber mats have a poor grip and are as inner Construction parts not suitable for vehicles. In addition, they are heavy and can prevent the above property (3). Also affect Glass fibers are and are not the working environment in the manufacture of laminates easily recyclable, causing a disposal problem. In addition is point out that glass fibers are relatively expensive, and the above Laminate therefore causes relatively high costs.

On this basis, the present invention has been made and its object The position is an inner construction part made of a thermoplastic resin and to provide its materials, with the inner structural part Problems to be solved with internal construction parts from a thermo plastic resin bonded using a conventional glass fiber mat and with which a low linear expansion coefficient can be achieved which is the most important property for internal structural parts of vehicles, which have high rigidity and light weight.

In order to achieve the above task, the inventors have sub searches from different directions and their attention too next in particular on fibers based on natural vegetable cellulose as an end Material for the laminate, the thermoplastic resin film, the nonwoven laminate and the nonwoven fabric composite of the present invention having the foregoing named properties directed. They also turned their attention to special on hemp fibers, which have an excellent natural feel, a high Young modulus, and have a low coefficient of linear expansion.

As a result, the present invention has been accomplished by finding that to get the desired laminates, especially for internal structural parts from Vehicles to achieve, using the properties of such fibers on the Base of natural vegetable cellulose laminates that of the above Task can be obtained by using at least one  thermoplastic resin layer containing 50 to 10% by weight of a thermoplastic resin and 50 to 90% by weight of fibers based on natural vegetable cellulose contains and laminates at least one layer comprising a thermoplastic resin.

The invention relates to a laminate according to claim 1, a thermoplastic A resin sheet according to claim 9, a nonwoven fabric laminate according to claim 14 and a Nonwoven composite according to claim 18.

Preferred embodiments thereof are the subject of claims 2 to 8, 10 to 13, 15 to 17, or 19 to 22.

Another object of the invention is the use of a laminate according to Claim 1 as an inner structural part of vehicles and a thermoplastic Resin sheet according to claim 9, a nonwoven fabric laminate according to claim 14 and one Nonwoven composite material according to claim 18 as a material for internal structural parts of vehicles.

Another object of the invention is a method according to claim 27 for Production of a thermoplastic resin film according to the invention, a method according to Claim 28 for producing a laminate according to the invention, and a method according to claim 29 for the production of a nonwoven fabric laminate according to the invention.

The broader scope of applicability of the present invention will become apparent from the detailed description given below. The detailed description spelling and the specific examples, the preferred Aus according to the invention Show leadership forms, but are given for illustration only and for it will be apparent to those skilled in the art from this detailed description that various changes and modifications within the nature and framework of the Invention are possible.  

In this description and the appended claims, when the con text does not indicate anything else, the word "comprise" and variations of how "includes" and "comprising" that a whole or step, or groups of whole units or steps are included, but any other wholes or Steps or groups of wholes or steps are not excluded.

FIG. 1 is a schematic illustration to illustrate a method for producing the nonwoven fiber laminate according to the invention.

With the present invention, a laminate is first provided, which around summarizes (a) at least one fiber based on natural vegetable cellulose holding thermoplastic resin layer comprising (a-i) a thermoplastic resin and (a-ii) Fibers based on natural vegetable cellulose, and (b) at least a layer comprising a thermoplastic resin, the content of the fibers being the base of natural vegetable cellulose (a-ii) in the at least one fiber on the Basis of natural vegetable cellulose-containing thermoplastic resin layer (a) Is 50 to 90 wt .-%.

As described above, fibers are based on natural vegetable Cellulose, especially hemp fibers, have properties such as (a) excellent natural grip, (b) a high Young's modulus, (c) a low linear out elongation coefficients, (d) light weight, (e) water absorbability and (f) an antistatic effect. A laminate in which (a) a thermoplastic resin film that (a-i) a thermoplastic resin and (a-ii) fibers based on natural vegetable Comprises cellulose, and (b) a layered structural material comprising a thermoplastic resin includes, are laminated, the properties of the fibers based on natural plants Licher cellulose reflect, and fulfills the properties (1) to (3), which Eigen the inner structural parts of vehicles. On such laminate also has a surface with a good grip. Because fibers on the The basis of natural vegetable cellulose is a natural material, it also causes it  no recycling problems and is relatively cheap, making it relatively low Cost of the laminate can be achieved.

Although the internal structural parts for vehicles ver can be used by the above-mentioned laminate in a certain Shapes can be a surface layer material (as a layer) before or after the Form the laminate as required on one or both sides of the laminate bound or welded.

Containing the fibers based on natural vegetable cellulose Thermoplastic resin film in the laminate according to the invention can, for. B. manufactured by using a nonwoven composite using thermo plastic resin fibers together with fibers based on natural vegetable Cellulose used and the nonwoven composite with rollers under a be matched pressure hot-pressed to form a film. As already be the nonwoven composite used here comprises thermoplastic resin fibers and fibers based on natural vegetable cellulose, and the content of Fibers based on natural vegetable cellulose in the nonwoven composite preferably set to 50 to 90 wt .-%. If the fiber content on the The basis of natural vegetable cellulose is less than 50 wt .-%, are laminates that the properties (a) to (f) by the fibers based on natural vegetable Cellulose can be caused to reflect, or nonwoven composites that are Properties (a), (e) and (f) reflect not easy to obtain. If the salary on fibers based on natural vegetable cellulose in nonwoven composite 90 Exceeds wt .-%, the proportion of thermoplastic resin becomes relatively low (less than 10% by weight). As a result, the fibers will soon come loose and it will difficult for the fibers to maintain a certain shape and formed into a film can be.

The thermoplastic resin film can preferably be used as a material for inner cones structural parts of vehicles are used and can preferably also be used as the  Expansion-inhibiting material of a thermoplastic resin foam as the core containing synthetic "tatami" can be used.

The above-mentioned layer comprising a thermoplastic resin can either a non-foamed layer or a foamed layer.

Generally, a non-foamed layer is preferred for applications where rigidity and strength are required, and a foamed layer is placed before moves when weight reduction is required. If a foamed polyolefin is used, its expansion ratio is in view of a reduction in the Weight between approximately three times or more and approximately twenty times or less, because too high an expansion ratio leads to a reduction in strength leads.

The laminate according to the invention can be produced in the following manner be performed. First, a surface of a thermoplastic resin film that is on was prepared in the manner described above, heated with a heater to melt the thermoplastic resin in the film. At the same time, a waiter area of the layered material comprising a thermoplastic resin heats to melt the surface. Then both materials between heating Rolled out and pressed under heating. This will melt the upper surfaces (heated surfaces) welded to form a laminate in which the thermoplastic resin layer and the layered material laminated together are. Using such a method, laminates that have at least one thermoplastic resin layer and at least one a thermoplastic resin have comprehensive layer, are produced.

When the thermoplastic resin film and / or the one is a thermoplastic resin comprehensive layer of polyolefin, the application of a halogenated poly olefins on a surface of the thermoplastic resin film and / or a thermo plastic resin layer ver the adhesive strength between the layers ver  improve. The halogenated polyolefin may depend on the the thermoplastic resin film and / or the materials forming a layer comprising a thermoplastic resin to get voted. For example, chlorinated polypropylene and chlorinated poly ethylene can be used.

The process for producing the laminate according to the invention is not based on that limited above. The laminate can e.g. B. also be made by using at least one thermoplastic resin film and at least one layer comprising thermoplastic resin in an appropriate order puts one another and connects them with an adhesive. The glue to be used here can be an adhesive based on an epoxy resin or an adhesive based on an Be polyester resin.

By finally shaping the laminate into a certain shape, such as. B. in a Blanket material, using a die-cutting machine or the like, can be invented inner construction part for vehicles are manufactured. If required, a connection or welding of a surface layer Material (as a layer), which can be selected from different types, with a or both sides of the laminate before or after its formation to improve the Quality of design, grip and high quality expression can be useful. The Joining or welding can be done in the same way as they are have been described above for the manufacture of the laminate. The surface layer material (as a layer) is preferably with one or both surfaces of the Laminates connected or welded, the surface or each of the surfaces a surface of a fiber based on natural vegetable cellulose ent holding thermoplastic resin film.

The vehicle inner structural member of the present invention obtained in the above-described manner has excellent properties that the inner vehicle structural parts are supposed to have, such as (1) rigidity, (2) a low coefficient of linear expansion, and (3) light weight. The desired values of these properties required for internal structural parts are as follows:

• 1. Stiffness: 30 N / 50 mm or more, expressed as the maximum bending load, and 80 N / 50 mm / cm or more, printed out as a bending module
• 2. coefficient of linear expansion: 3 × 10-5 / ° C or less
• 3. Light weight: 700 g / m ² or less, expressed as a weight per unit area

Examples of the used in the thermoplastic resin sheet of the present invention thermoplastic resin or its fibers include various resins or theirs Fibers, e.g. B. including conventional thermoplastic resins or their fibers Polyolefins, e.g. B. polypropylene and polyethylene, acrylonitrile / styrene / butadiene Block copolymer, polystyrene, polyamides such as B. nylon, polyester, polyvinyl chloride, Polycarbonate, acrylic resins and styrene / butadiene copolymer, thermoplastic elastomers or their fibers, e.g. B. EPM (ethylene / propylene copolymer) and EPDM (ethylene / - Propylene / diene copolymer), mixtures of these resins or their fibers, and polymer alloys or their fibers using these resins. Among them are in the way view of the processability to films polyolefins and thermoplastic elastomers, such as B. polypropylene, polyethylene, EPM and EPDM or their fibers preferred. Ins particularly preferred is polypropylene or its fibers, which have good heat resistance possess.

To make the polyolefins or their fibers based on natural fibers It is good to bind vegetable cellulose to achieve greater strength preferred that the polyolefins or their fibers are polyolefins which are unsaturated Acids or unsaturated acid anhydrides are modified, d. H. modified poly olefins or their fibers. Usual unsaturated acids and unsaturated anhydrides include unsaturated carboxylic acids and unsaturated carboxylic anhydrides. Examples therefor include acrylic acid, methacrylic acid, maleic acid, maleic anhydride, fumar acid, itaconic acid, itaconic anhydride, mesaconic acid, citraconic acid, crotonic acid,  Isocrotonic acid and angelic acid. Preferred modified polyolefins or their Fibers include maleic anhydride modified polypropylene or its fibers.

Examples of used in the thermoplastic resin sheet of the present invention Fibers based on natural vegetable cellulose include cotton fibers, Hemp fibers, palm fibers and bamboo fibers. Although any of these fibers are used can be hemp fibers as the material of the nonwoven composite according to the invention most appropriate. Among the above-mentioned fibers based Natural vegetable cellulose has the best moisture absorption properties and moisture-desorbing property. Also are Hemp fibers are stronger than other fibers based on natural vegetable cellulose. In addition, they have a fresh, cool feel and a fresh feel feel an excellent grip.

Among those used in the thermoplastic resin sheet of the present invention The flax hemp fiber is able to produce fibers based on natural plant cellulose (Linen), ramie, jute, Manila hemp (Abaca), sisal, kenaf and the like. Any of these hemp fibers can be used. Among them, it is preferred Use jute, kenaf or flax as they are annual and relatively easy to obtain are.

The diameter (i.e. the thickness) and length of the fibers based on natural Vegetable cellulose which are used according to the invention can, depending on the Type of fibers vary and is not limited as long as the fibers are nonwoven can form, but standards for some fibers are the following.

With regard to the diameter of the fibers based on natural vegetable A suitable diameter of cellulose varies depending on the type of fiber being but a diameter of about 1 to 50 denier is preferably used. A fiber with A desired diameter can therefore depend on the type of fiber be chosen and used. In the case of a cotton fiber z. B. preferred  as used with a diameter of about 1 to 4 denier. In case of a Hemp fibers are preferably those with a diameter of approximately 5 to 40 deniers used. Those with a diameter of approximately 5 to are particularly expedient 20 denier.

With regard to the length of the fibers based on natural vegetable cellu when cotton fibers are used, their length is preferably approx. 10 to 45 mm. If hemp fibers are used, their length is more normal about 10 to about 60 mm, and preferably about 20 to about 60 mm, and in particular approx. 40 to approx. 60 mm.

The thermoplastic resin sheet can be made by using one such nonwoven composite described below with rollers under a be agreed pressure hot-pressed to form a film.

The present invention provides a nonwoven composite that (i) thermoplastic resin fibers and (ii) fibers based on natural vegetable cellu loosely embraced.

Various methods of manufacturing the nonwoven composite are Methods known, including a wet method, a dry method and one Spinning method. The drying method includes (1) a needle-bond method, (2) sewing mode of action and (3) adhesion method. Although all of these methods are used as a method for Production of the nonwoven fiber composite according to the invention can be used can is the use of the needle-punch method, which is a type of drying method is from the standpoint of obtaining a nonwoven composite in which the properties of the natural fibers used as the starting material Licher vegetable cellulose reflect, and because of the convenient production prefers. The needle bond method is a method in which the fibers are wrapped in a film like tissue by means of a card for spinning or the like in a film-like Tissues are formed and the fabric with many needles goes through several times  is pricked, which entangles the fibers in the tissue up and down. This method hardly destroys the fibers used as the starting material on the Base of natural vegetable cellulose and can have the soft feel and feel of Fibers based on natural vegetable cellulose after the formation of the thermo plastic resin film or nonwoven laminate obtained.

Examples of those used in the nonwoven composite of the present invention thermoplastic resin fibers include various resin fibers, e.g. B. fibers from con conventional thermoplastic resins, including polyolefins such as e.g. B. Poly propylene and polyethylene, acrylonitrile / styrene / butadiene block copolymers, polystyrene, Polyamides such as B. nylon, polyesters, polyvinyl chloride, polycarbonate, acrylic resins and styrene / butadiene copolymer, thermoplastic elastomers or their fibers, such as e.g. B. EPM (ethylene / propylene copolymer) and EPDM (ethylene / propylene / diene co polymer), mixtures of these resins and polymer alloys. Among them are poly olefin fibers and thermoplastic elastomer fibers, such as. B. polypropylene, polyethylene, EPM and EPDM fibers preferred in terms of processability into films. Ins polypropylene fibers which have good heat resistance are particularly preferred sit.

To the polyolefin fibers to the fibers based on natural vegetable To bind cellulose well in order to achieve greater strength, it is preferred that the polyolefin fibers are polyolefin fibers containing unsaturated acids or un saturated acid anhydrides are modified, d. H. are modified polyolefin fibers. Common unsaturated acids and unsaturated acid anhydrides include unsaturated ones Carboxylic acids and unsaturated carboxylic anhydrides. Examples include acrylic acid, methacrylic acid, maleic acid, maleic anhydride, fumaric acid, itaconic acid, Itaconic anhydride, mesaconic acid, citraconic acid, crotonic acid, isocrotonic acid and Angelica acid. Preferred modified polyolefin fibers include maleic acid anhydride modified polypropylene fibers.  

Examples of those used in the nonwoven composite of the present invention Fibers based on natural vegetable cellulose include cotton fibers, hemp fibers, palm fibers and bamboo fibers. Although any of these fibers are used hemp fibers are the material for the nonwoven fabric according to the invention. Most useful composite. Among the fibers listed above on the Hemp fibers are the basis of natural vegetable cellulose with regard to their moisture moisture-absorbing properties and moisture-absorbing properties best. Hemp fibers are also stronger than other natural fibers vegetable cellulose. In addition, they have a fresh, cool feel and the fresh grip feel an excellent grip.

Among those used in the nonwoven fabric composite of the present invention The flax hemp fibers can be used to make fibers based on natural vegetable cellulose (Linen), ramie fibers, jute, Manila hemp (Abaca), sisal, kenaf and the like. The use of jute, kenaf or flax is preferred, since these are annual and relative are easy to obtain.

The diameter (i.e. the thickness) of the fibers used in the invention The base of natural vegetable cellulose can vary depending on the type of fiber vary and is not limited as long as the fibers can form a nonwoven but Standards for some fibers are as follows.

With regard to the diameter of fibers based on natural plants A suitable diameter varies depending on the type of fiber, but those with a diameter of about 1 to 50 denier are preferably used become. Depending on the type of fiber, a fiber can therefore be used with one purpose moderate diameter can be selected. In the case of cotton fibers, e.g. B. those with a diameter of about 1 to 4 denier are preferably used. In the event of Hemp fibers are preferred to those with a diameter of approximately 5 to 40 deniers trains used. Those with a diameter of approximately 5 to 20 deniers are special expedient.  

As for the length of the fibers based on natural vegetable cellulose, when cotton fibers are used, their preferred length is about 10 to 45 mm. If hemp fibers are used, their length is usually approx. 10 to approx. 60 mm, preferably approx. 20 to approx. 60 mm and in particular approx. 40 to approx. 60 mm.

The present invention provides a nonwoven laminate comprising (a) one A layer comprising a thermoplastic resin and (b) a layer containing a Nonwoven composite comprising one or both sides of a thermo plastic resin layer (a) is laminated, wherein the nonwoven composite Fabric includes (b-i) thermoplastic resin fibers and (b-ii) fibers based on natural Licher vegetable cellulose, the content of the fibers (b-ii) based on natural Vegetable cellulose in the layer comprising the nonwoven composite (b) is 50 to 90% by weight.

With reference to the drawing, a method for producing the described nonwoven laminate according to the invention.

Fig. 1 is a schematic diagram for illustrating a method for producing a non-woven fabric laminate of the invention. The reference numerals 1 , 1 a, 2 , 3 , 4 and 5 a and 5 b denote a roll of a film-shaped nonwoven composite, the film-shaped nonwoven composite, a preheater, a thermoplastic resin film (or web), a heating device and a Heating roller pair.

In the production of the nonwoven laminate according to the invention, the film-like nonwoven composite 1 a, which is rolled up in the form of a roll 1, is heated with a preheater 2 in order to melt the thermoplastic resin fibers in the nonwoven composite 1 a. At the same time, a surface of the thermoplastic resin sheet 3 (the layer (a) comprising a thermoplastic resin) is heated with a heater 4 to melt the surface. Then both materials between the heating rollers 5 a and 5b introduced and pressed under heating to be welded. This forms a nonwoven laminate in which a nonwoven composite is laminated on one side of the thermoplastic resin sheet 3 (the layer (a) which comprises a thermoplastic resin). In addition, using such a method, a nonwoven fabric laminate can be formed in which the nonwoven fabric composite is laminated on both sides of a layer comprising a thermoplastic resin.

Although a case is shown in Fig. 1 in which both the nonwoven composite fabric 1a and the thermoplastic resin sheet 3 (the layer (a) comprising a thermoplastic resin) are heated, it is also possible to either the above heater 2 or to omit the heater 4 and to heat either the nonwoven composite 1 a or the thermoplastic resin film 3 (the layer (a), which comprises a thermoplastic resin), and then to guide them between the heating rollers 5 a and 5 b to compress them under heating. To weld the nonwoven composite 1 a and the thermoplastic resin film 3 (the layer (a) comprising a thermoplastic resin) even when such a case is used, and only the nonwoven composite 1 is heated, it is necessary to set the content of the thermoplastic resin fibers in the nonwoven composite to 10% by weight or more.

The method for producing the nonwoven fabric laminate of the present invention is not limited to that illustrated in Fig. 1, and other methods can be used. For example, a nonwoven laminate in which a nonwoven composite is laminated to both sides of a layer comprising a thermoplastic resin can be made by inserting a nonwoven composite between a pair of dies and die, a layer which a thermoplastic resin, the surfaces of which are in a molten state, inserted between the nonwoven composite and one of the mold members, and firmly clamping the mold members to press the nonwoven composite and the layer comprising the thermoplastic resin.

Alternatively, a nonwoven laminate can be made in which two nonwoven composites are applied both sides of a layer comprising a thermoplastic resin are laminated on, be obtained by using two nonwoven composites, one layer, the comprises a thermoplastic resin whose surfaces are in a molten state are inserted between the two non-woven fabrics and the shaped elements clamped to the two nonwoven composites and the one comprising the thermoplastic resin Press layer. However, if this method is used, it is necessary the weight of the nonwoven composite correctly set so that the thermo Plastic resin layer in the molten state is not completely through penetrates the nonwoven composite.

In the case where the thermoplastic resin in the nonwoven composite and / or the thermoplastic resin in which comprises a thermoplastic resin Layer is polyolefin, the application of halogenated polyolefin on a Surface of the nonwoven composite and / or a thermoplastic resin comprehensive layer improve the adhesive strength between the layers. The Halogenated polyolefin can depend on the materials of the nonwoven composite Fabric and / or the layer comprising a thermoplastic resin selected and chlorinated polyolefin, chlorinated polyethylene and the like can be used be applied.

In addition, the connection of a nonwoven composite and a Layer comprising thermoplastic resin to form an inventive Nonwoven laminates are made by an adhesive. The adhesive used for this can an adhesive based on an epoxy resin, an adhesive based on a polyester resin and the like.

The above-mentioned layer comprising a thermoplastic resin can either a non-foamed layer or a foamed layer.  

In general, a non-foamed layer is preferred for applications where rigidity and strength are required, and a foamed layer is for Appli cations preferred where weight reduction is desired. If a ge foamed polyolefin is used, its expansion ratio is in terms of the weight reduction is preferably between three times or more, and about that Twenty times or less because the expansion ratio is too high to reduce strength.

Examples of the used in the nonwoven fabric laminate according to the invention thermoplastic resin or its fibers include various resins or their fibers, e.g. B. conventional thermoplastic resins or their fibers, including poly olefins such as B. polypropylene and polyethylene, an acrylonitrile / styrene / butadiene block Copolymer, polystyrene, polyamides such. B. nylon, polyester, polyvinyl chloride, poly carbonate, acrylic resins and styrene / butadiene copolymer, thermoplastic elastomers or their fibers, e.g. B. EPM (ethylene / propylene copolymer) and EPDM (ethylene / - Propylene / diene copolymer), mixtures of these resins or their fibers and polymer alloys or their fibers using these resins. Among them are poly olefins and thermoplastic elastomers, such as. B. polypropylene, polyethylene, EPM and EPDM or its fibers are preferred in terms of processability into films. Polypropylene or its fibers are particularly preferred because they have good heat possess stability.

To make the polyolefins or their fibers based on natural fibers It is good to bind vegetable cellulose to achieve greater strength preferred that the polyolefins or their fibers are polyolefins which are unsaturated Acids or unsaturated acid anhydrides are modified, d. H. modified poly olefins or their fibers. Usual unsaturated acids and unsaturated acid anhydrides include unsaturated carboxylic acids and unsaturated carboxylic anhydrides. Examples therefor include acrylic acid, methacrylic acid, maleic acid, maleic anhydride, fumar acid, itaconic acid, itaconic anhydride, mesaconic acid, citraconic acid, crotonic acid,  Isocrotonic acid and angelic acid. Preferred modified polyolefins and their fibers include maleic anhydride modified polypropylene or its fibers.

Examples of those used in the nonwoven fabric laminate according to the invention Fibers based on natural vegetable cellulose include cotton fibers, hemp fibers, palm fibers and bamboo fibers. Although any of these fibers are used hemp fibers are the material for the nonwoven fabric according to the invention. Most useful composite. Among the above fibers on the Hemp fibers are the basis of natural vegetable cellulose in terms of moisture moisture-absorbing properties and moisture-desorbing properties best. Hemp fibers are also stronger than other natural fibers vegetable cellulose. They also have a fresh, cool feel and their fresh grip feel an excellent grip.

Among the fibers used in the nonwoven laminate according to the invention The hemp fibers flax (linen) and ramie are the basis of natural plant cellulose fiber, jute, Manila hemp (Abaca), sisal, Kenaf or the like. Any of these hemp fibers can be used. Among them, it is preferred to use jute, kenaf or flax too use because they are relatively easy to obtain annually.

The diameter (i.e. thickness) and length of those used in the present invention Fibers based on natural vegetable cellulose can vary depending on the type of Fibers vary and are not limited as long as the fibers form a nonwoven fabric can, but standards for some fibers are as follows.

As for the diameter of the fibers based on natural vegetable cellulose concerns, a suitable diameter varies depending on the type of fiber, preferably however, one with a diameter of approximately 1 to 50 denier is used. Depending on the type of fiber, a fiber with the appropriate diameter can therefore be used knives can be selected and used. In the case of cotton fibers, e.g. B. those with a diameter of about 1 to 4 denier are preferably used. In the event of  Hemp fibers are those with a diameter of approx. 5 to 40 deniers preferably used. Those with a diameter of about 5 to 20 deniers are particularly useful.

As for the length of the fibers based on natural vegetable cellulose If cotton fibers are used, the length is preferably approx. 10 to 45 mm. If hemp fibers are used, their length is more common about 10 to 60 mm, preferably about 20 to about 60 mm, and in particular about 40 to approx. 60 mm.

The present invention will now become concrete by means of the following examples described without restricting the scope of the invention thereto. Modifications with regard to the tasks described above and below and Solutions are included within the technical scope of the present invention.

EXAMPLES example 1 Manufacture of nonwoven composite, thermoplastic resin film and Laminate

A fabric with a weight per unit area of 150 g / cm ² was prepared by uniformly mixing jute fibers (diameter: 16 to 21 denier; length: 30 to 50 mm) and propylene fiber (diameter: 5 denier; length: 51 mm) in one ge weight ratio (jute fibers: propylene fibers) made from 80 to 20. This fabric was subjected to a needle-punch method with a density of 200 needles / m ² and gave a needle-punched non-woven fabric with a thickness of 3 mm. The nonwoven fabric was pressed between heating rollers at 180 ° C. which defined an intermediate gap of 0.3 mm to produce a thermoplastic resin film with a thickness of 0.3 mm.

On the surfaces of two thermo made in the above way Plastic resin films became a solution of chlorinated polypropylene in toluene applied, and then heated with hot air at 250 ° C. On the other hand, both waiters surfaces of a polypropylene film with an expansion ratio of 8 (linear out expansion coefficient: 1 × 10-4 / ° C; Bending modulus: 118 MPa; maximum bending load: 7.8 N / 50 mm) a solution of chlorinated polypropylene in toluene and applied Hot air heated at 250 ° C. The polypropylene film was between the two thermo plastic resin films introduced so that their treated with chlorinated polypropylene Surfaces faced each other and the films were laminated. The laminated Films were placed between heating rolls at 120 ° C with one in between Gap of 3 mm pressed, and a two-type three-layer laminate was obtained.

The laminate obtained had a linear expansion coefficient of 3 × 10 ^-5 / ° C, a flexural modulus of 1079 MPa and a maximum bending load of 19.6 N / 50 mm. The values of the linear expansion coefficient, the bending modulus and the maximum bending load were determined using the following measurement methods.

Linear expansion coefficient

Three 150 mm x 20 mm samples were made from one product in length direction taken. Three other samples were also taken from the product in cross direction taken. These samples were in a thermostatic oven at 85 ± 2 ° C Leave for 24 hours and then removed and cooled spontaneously. The Samples were marked with 130 mm and their size measured.

Next, the samples were placed in a thermostatic oven at 80 ± 2 ° C Leave for 6 hours, then removed and their size measured immediately. In addition, the samples were cooled spontaneously and placed in a thermostatic oven Leave at 0 ± 2 ° C for 6 hours. They were taken out of the oven and theirs Size measured immediately.  

The coefficient of linear expansion of each sample was as follows Equation calculated. From the mean of the linear expansion coefficient of the Samples in the longitudinal direction and that of the linear expansion coefficient of the samples in The transverse direction became the greater than the linear expansion coefficient of the product considered.

Linear expansion coefficient (1 / ° C = [standard length at 80 ° C (mm) - Standard length at 0 ° C (mm)] / [Standard length at 0 ° C (mm) × temperature difference to Standard Length Measurement Time]

Bending module and maximum bending load

A 50 mm x 150 mm sample was placed at two points at a distance of 100 mm supported and with a load in the center between the support points applied at a rate of 50 mm / min. From the relationship between the deplacement and the load, the bending modulus and the maximum bending load were determined.

Example 2 Production of a nonwoven laminate

A fabric with a weight per unit area of 100 g / m ² was produced by uniformly mixing 60% by weight of jute fibers (diameter: 16 to 21 denier; length: 30 to 50 mm) and 40% by weight of polypropylene fibers (diameter : 5 denier; length: 51 mm). The fabric was subjected to a needle-punch method at a density of 200 needles / m ² and gave a 1.5 mm-thick needle-punched nonwoven fabric. The nonwoven fabric was heated from one side by means of an infrared heating device in such a way that the temperature of the heated surface reached approximately 150.degree. The heated surface was then brought into contact with a 180 ° C bar heater, causing the polypropylene fibers to melt in the vicinity of the heated surface. On the other hand, a 3 mm thick polypropylene film was heated from one side by means of an infrared heating device so that the temperature of the heated surface reached approximately 140 ° C.

The nonwoven composite and the polypropylene film were laminated by their heated surfaces were facing each other and then between heating rollers were pressed at 160 ° C and a pressure of 0.29 MPa. This resulted in a Nonwoven laminate in which the nonwoven composite is applied to a surface of the poly propylene film was laminated.

The essence of the present invention has been described above. By Forming internal structural parts from a thermoplastic resin, ins special of internal structural parts for vehicles, from a laminate in which a thermoplastic resin film that has a thermoplastic resin and fibers on it Basis of natural vegetable cellulose comprises, and a layer that a thermo plastic resin, laminated, can be problems with internal construction tion parts made of a thermoplastic resin, especially with internal construction Share vehicles made from conventional laminates using glass fiber mats exist, occur, be solved. At the same time, a reduction in linear expansion coefficients can be achieved, which is the most important for internal con Structural parts of vehicles is required property, and it can inner Kon structural parts made of thermoplastic resin, in particular internal structural parts for Vehicles with high rigidity and light weight can be obtained.

In addition, the thermoplastic resin sheet / fiber of the present invention fleece laminate and the nonwoven composite material by using fibers different materials have properties that have not yet been obtained and are therefore suitable as materials for internal structural parts of Vehicles.

Claims (29)

1. Laminate comprising (a) at least one fiber based on natural plants Licher cellulose-containing thermoplastic resin layer, which (a-i) a thermo plastic resin and (a-ii) fibers based on natural vegetable cellulose and (b) at least one layer comprising a thermoplastic resin, the content of fibers based on natural vegetable cellulose (a-ii) in ent of at least one fiber based on natural vegetable cellulose holding thermoplastic resin layer (a) is 50 to 90 wt .-%. 2. Laminate according to claim 1, characterized in that the thermoplastic Resin (a-i) in the at least one fiber based on natural vegetable Cellulose-containing thermoplastic resin layer (a) is polyolefin. 3. Laminate according to claim 1, characterized in that the thermoplastic Resin (a-i) in the fibers based on natural vegetable cellulose holding thermoplastic resin layer (a) is polypropylene. 4. Laminate according to claim 1, characterized in that the fibers on the basis natural vegetable cellulose (a-ii) are hemp fibers. 5. Laminate according to claim 4, characterized in that the hemp fibers jute, Are flax or kenaf. 6. Laminate according to claim 1, characterized in that the at least one layer (b) a thermoplastic resin comprising a foamed polyolefin layer is. 7. Laminate according to claim 6, characterized in that the foamed poly olefin layer has an expansion ratio of 3 or more.   8. Laminate comprising the laminate of claim 1 and a surface Layer of material bound or ge on one or both sides of the laminate is welded. 9. A thermoplastic resin sheet comprising (i) a thermoplastic resin and (ii) Fibers based on natural plant cellulose, the content of Fibers based on natural vegetable cellulose (ii) in the thermoplastic Resin film is 50 to 90 wt .-%. 10. A thermoplastic resin film comprising (i) a thermoplastic resin and (ii) Hemp fibers, the content of hemp fibers (ii) in the thermoplastic resin film is 50 to 90 wt .-%. 11. Thermoplastic resin film according to claim 9, characterized in that the thermoplastic resin (i) is polyolefin. 12. Thermoplastic resin film according to claim 9, characterized in that the thermoplastic resin (i) is polypropylene. 13. Thermoplastic resin film according to claim 10, characterized in that the Hemp fibers are jute, flax or kenaf. 14. A nonwoven laminate comprising (a) a thermoplastic resin Layer (a) and (b) a layer comprising a nonwoven composite, the one or both sides of the layer (a) comprising a thermoplastic resin is laminated on, the nonwoven composite comprising (b-i) thermoplastic Resin fibers and (b-ii) fibers based on natural vegetable cellulose, where the content of the fibers is based on natural vegetable cellulose (b-ii) in the layer (b) comprising the nonwoven composite, 50 to 90% by weight is.   15. Nonwoven laminate according to claim 14, characterized in that the fibers based on natural vegetable cellulose (b-ii) are hemp fibers. 16. Nonwoven laminate according to claim 14, characterized in that the thermo plastic resin fibers (b-i) are polyolefin fibers. 17. Nonwoven laminate according to claim 14, characterized in that the layer consists of a thermoplastic resin (a) made of polyolefin. 18. A nonwoven composite comprising (i) thermoplastic resin fibers and (ii) Fibers based on natural plant cellulose. 19. Nonwoven composite material according to claim 18, characterized in that the Content of fibers based on natural vegetable cellulose (ii) in the fiber nonwoven composite is 50 to 90 wt .-%. 20. Nonwoven composite material according to claim 18 or 19, characterized in that the diameter of the fibers based on natural vegetable cellulose (ii) 1 is up to 50 denier. 21. Nonwoven composite material according to claim 18, characterized in that the Fibers based on natural vegetable cellulose (ii) are hemp fibers. 22. Nonwoven composite material according to claim 18, characterized in that the thermoplastic resin fibers (i) are polyolefin fibers. 23. Use of the laminate according to claim 1 as an inner structural part of Vehicles.   24. Use of the thermoplastic resin film according to claim 9 as a material for interior structural parts of vehicles. 25. Use of the nonwoven laminate according to claim 14 as a material for interior Structural parts of vehicles. 26. Use of the nonwoven composite material according to claim 18 as a material for interior structural parts of vehicles. 27. A method for producing a thermoplastic resin sheet comprising (i) a thermoplastic resin and (ii) fibers based on natural vegetable Cellulose, the method comprising the steps of: forming the nonwoven fabric Composite according to claim 18 and hot pressing this nonwoven composite fabric with rollers under a certain pressure to form it into a film. 28. A method of making a laminate comprising (a) at least one fiber based on thermoplastic containing natural vegetable cellulose A resin layer comprising (a-i) a thermoplastic resin and (a-ii) fibers on the Based on natural vegetable cellulose, and (b) at least one thermo layer comprising plastic resin, the content of the fibers being based natural vegetable cellulose (a-ii) in the at least one fiber on the Basis of natural vegetable cellulose-containing thermoplastic resin layer (a) is 50 to 90% by weight, the process comprising the steps: Heating a surface of the thermoplastic resin sheet according to claim 9 with a heater to the thermoplastic resin in the thermoplastic Melting resin sheet, heating a surface of a layered Material comprising a thermoplastic resin with a heater to melt the surface and insert the thermoplastic resin sheet and of the layered material between heating rollers to heat them up press to weld their molten surfaces.   29. A method of making a nonwoven laminate comprising (a) one thermoplastic resin layer and (b) a nonwoven fabric Composite layer comprising on one or both sides of layer (a), which comprises a thermoplastic resin is laminated on, the nonwoven fabric Composite thermoplastic resin fibers (b-i) and fibers based on natural Licher vegetable cellulose (b-ii), and the content of fibers on the Basis of natural vegetable cellulose (b-ii) in the nonwoven composite comprising layer (b) is 50 to 90 wt .-%, wherein the process Stages comprising: forming the nonwoven composite of claim 18, Heating a surface of the nonwoven composite material with a heating device, to melt the thermoplastic resin in the nonwoven composite, Heating a surface of a layered thermoplastic resin with a heater to melt the surface and insert the layer-structured material and the nonwoven composite body between Heating rollers to press them under heat to their molten top to weld surfaces.