DE102021106621A1 - Absorbent backing fleece for tufted carpet - Google Patents

Abstract

Backing fleece (2) for a tufted carpet for use in motor vehicles, consisting of one or more fleeces, characterized in that a spunbonded fleece (24) is connected to a carded needle felt (22) or airlay fleece or the backing fleece (2) has a one-sided or has both sides calendered carded needle fleece or airlay fleece.

Description

The invention relates to a base fleece (primary backing) for a tufted carpet for use in motor vehicles, which consists of one or more fleeces.

Various designs of usable surfaces of motor vehicle interior lining parts are known in the prior art. A motor vehicle interior lining part is understood here in particular as a motor vehicle floor lining, a luggage compartment lining or a loading floor. Carpet face fabrics are widespread as a usable area, namely in particular tufted, velor and flat-needle carpets.

Especially in VANs, SUVs, pickups and light commercial vehicles, rubber, PUR-RIM, PVC and increasingly TPO are also used as usable surfaces in the prior art.

In the case of tufted carpets, the prior art uses in particular PA6.6, PA6, PP, rPA and PET, rPET and the bio-based polyamides (PA 5.10; PA 6.10) or wool as yarn/filament material. In the field of velor and flat needle fleece carpets, PET, PET/PP, PP, PA/PET and rPET are mainly used as fiber material.

The tufted backing (primary backing) for the tufted qualities mostly consists of PET/PP, PET/coPET or PET/PA (bico) as well as PET/PA+PP.

The fiber bindings used here primarily include EVA and PE for tufted carpets and SBR latex or acrylate for velor and flat needle fleece carpets.

Furthermore, in the case of velor and flat needle fleece carpets, foils, fleeces, adhesives (hot melts), thermoplastics (mainly PE) and the in EP 1 598 476 B1 described thermal bonding method used. Furthermore, binding fibers, EVA or thermoplastic dispersions are increasingly being used.

Adhesive layers, acoustic/reinforcing nonwovens, sealing and heavy foils as well as contact/foil nonwovens are located under the usable surface.

The coating, mostly as an adhesive layer for sub-fleeces, but also for stiffening, mainly consists of PE or PP.

Adhesives (hot melts), thermoplastic dispersions and PE as well as EVA/PE powder are used to ensure integration and coating in one if possible.

The lower layers, such as acoustic and/or stiffening fleece, usually consist of PET and mixed fiber fleece, often with a BiCo fiber content. Furthermore, three-layer recycled sandwich nonwovens ( DE 10 2016 203 348 A1 ) Application.

PE/PA and PE/PA/PE films as well as PE/PA/PE+PET film fleece are used as sealing or insulating films. Depending on the acoustic requirements, so-called heavy foils are also used partially or over the entire surface as insulating foils.

There is usually an insulation layer between the top fabric (wear layer plus underlayers) and the body floor, which can be formed in particular from PUR foam or fleece structures (fleeces or fiber flock (HMP) composites). If a foam is used, it is firmly connected (foamed) to the outer fabric. Fleece/fiber flock structures can also be firmly connected to the outer fabric, which are then usually glued. However, there is also pure superimposition without a fixed connection.

In the case of acoustically open, highly absorptive floor covering systems in particular, the focus is on the acoustic and/or stiffening nonwovens; which are glued (laminated) to the carpet (wearing layer) so that they are open to the flow.

These are usually polyethylene terephthalate (PET) or mixed fiber fleeces - often with a percentage of BiCo fibers - in a grammage range of 250 to 1800 g/m ² . Recycled sandwich nonwovens are also increasingly being used here.

The general requirements for a tufted backing are given in H. Fuchs; W. Albrecht (editor), Nonwovens, 2nd completely revised edition, 2012 Wiley-VCH Verlag & Co. KGaA, Weinheim described.

The tufted backings used in practice today in tufted carpets for the automotive industry are on the one hand spunbond nonwoven 100% polyester and on the other nonwoven based on thermally bonded continuous bicomponent filaments (nonwoven based on thermally bonded continuous bicomponent filaments) [core-sheath fibers, PET core and PP coat]; in the grammage range from 80 to 140 g/m ² . See also DE 28 34 438 C3 , DE 196 09 586 C1 and DE 101 08 092 A1 .

The present invention also relates to carpet and more particularly to tufted carpet for motor vehicles. In the prior art there are various designs of usable surfaces of motor vehicle interior lining parts known. A motor vehicle interior lining part is understood here in particular as a motor vehicle floor lining, a luggage compartment lining or a loading floor. Carpet face fabrics are widespread as a usable area, namely in particular tufted, velor and flat-needle carpets.

From the point of view of the tufting process and later (thermo-)forming, the essential properties of the tufting backing are the tuftability itself, the required inherent rigidity with a given ability to be penetrated by the tufting needles, high tensile strength and tear strength, isotropic property distributions, high elongation, dimensional stability and thermal properties Stability (low shrinkage behavior), the high affinity to coatings (EVA, SBR latex, acrylate, LDPE powder and various (thermoplastic) dispersions and their mixtures) and the thermoformability. Also, the carrier should withstand the demands of washing, dyeing and steaming.

In order to influence the mechanical and acoustic properties of the component (e.g. a floor panel or a luggage compartment side panel) through the tufted carrier of the wear layer (in particular its contribution to stability and sound absorption), especially in correlation with the sub-layers of the component, an increase in efficiency in the acoustic effectiveness can be achieved one to be scored; and the optimization of set-up times during forming on the other hand, which ultimately leads to a reduction in cycle times and the associated cost savings.

the DE 10 2009 010 919 A1 discloses an interior trim part that has at least a first flat layer made of a needle felt and a tufted layer tufted into it, and optionally a pile connection on the opposite side of the opened tufted pile loops. It is stated that the needle fleece is made using the needling and water jet techniques.

the DE 20 2005 013 023 U1 describes a textile covering with a backing layer and pile yarn nubs incorporated therein by means of a tufting machine and forming a velor pile, the backing layer being formed from a needle felt containing melting fibers, the top side of which faces the velor pile has velor-like protruding fibers, the pile yarn -Nubs in the carrier layer are fixed by the melting fibers. It is pointed out that the needle felt is a dilute needle felt.

the DE 10 2004 046 201 A1 and the DE 10 2004 054 299 A1 disclose a non-woven backing layer made from polyester and/or polypropylene fibers, also in combination with bi-component hot-melt adhesive fibers.

the DE 10 2007 020 818 B3 describes a method of making a deformable tufted product wherein a meltblown nonwoven fabric is laid upon a deformable polyester tufted backing and the meltblown nonwoven fabric and polyester tufted backing are tufted together.

In the state of the art (the cited patent, disclosure or utility model documents) no information is given on the requirements for tufted backings in terms of the production process and the end product.

In practice, no needle fleece or velorised (dilorised) needle fleece backings are found.

Furthermore, in practice there are no 2-layer carriers, as in U.S. 6,808,786 B2 ( CA 2 514 119 A1 , U.S. 2004/0151870 A1 , EP 1 590 170 B1 ) described.

Here, in particular, the improvement of the acoustic properties is achieved through the combination of a first backing, formed from woven nonwoven or spunbond material, a second backing, formed from hydroentangled microfilament material and an adhesive textile arranged between the first backing and the second backing for the thermal connection of the first and second backing , outlined. The manufacturing process is complicated and prone to failure; and the process costs and carrier costs themselves are uneconomically high.

U.S. 7,700,176 B2 deals with a porous tufted carpet and its manufacture. The pile yarn is brought into a tufted backing and fixed and laminated over the entire surface on the back with a thermoplastic material. In a subsequent process step, air flows through the heated and almost molten, compact thermoplastic layer perpendicular to the carpet surface by applying a pressure difference (vacuum and overpressure on opposite sides) and is thus provided with air ducts. The tufted backing itself does not have an absorptive effect here; rather, the introduced flow channels enable the acoustic connection of another absorptive layer located under the tufted backing.

The object of the present invention compared to the aforementioned prior art is to provide a one- or at least two-layer non-woven backing for tufted carpets in the automotive sector, which compared to those currently in use tion located carrier fleece has a high absorptive acoustic effectiveness; and guarantees process-capable and economical series production.

This object is achieved by the subject matter of the independent patent claims. Advantageous embodiments and developments are the subject of the dependent claims.

A carrier fleece according to the invention, in particular for a tufted carpet and in particular for use in motor vehicles, has at least one and preferably several fleeces.

According to the invention, a spunbonded nonwoven is connected to a—particularly carded—needled nonwoven or airlay nonwoven and/or the carrier nonwoven has a needled nonwoven or airlay nonwoven that is calendered and/or carded on one or both sides.

A carrier fleece of a tufted carpet for use in motor vehicles is thus preferably made available, which has a high absorptive effect; and which also has mechanical-physical properties which, on the one hand, enable a process-capable tufting process; and on the other hand deliver a dimensionally stable component in a thermoforming process.

In a further advantageous embodiment, the spunbonded nonwoven on the one hand and the needled nonwoven or airlay nonwoven on the other hand are connected to one another over a large area. In a further preferred embodiment, the spunbonded nonwoven is needled to the needled nonwoven (or the airlay nonwoven). In this way, tufting is also made easier during manufacture.

However, it is also conceivable that the spunbonded nonwoven or the airlay nonwoven is composed of at least two components or layers.

The spunbonded nonwoven is preferably in a basis weight range of 50 to 140 g/m ² ; and the needle fleeces and airlay fleeces in the range from 80 to 250 g/m ² .

In a further advantageous embodiment, the spunbonded nonwoven has a basis weight which is greater than 30 g/m ² , preferably greater than 40 g/m ² and particularly preferably greater than 50 g/m ² .

In a further embodiment, the spunbonded nonwoven has a basis weight which is less than 200 g/m ² , preferably less than 180 g/m ² , preferably less than 160 g/m ² and particularly preferably less than 140 g/m ² .

In a further advantageous embodiment, the needle fleece or the airlay fleece has a basis weight which is greater than 40 g/m ² , preferably greater than 60 g/m ² and particularly preferably greater than 80 g/m ² .

In a further advantageous embodiment, the needle felt has a weight per unit area which is less than 350 g/m ² , preferably less than 320 g/m ² , preferably less than 280 g/m ² and particularly preferably less than 250 g/m ² .

In a further preferred embodiment, the needle fleece or the airlay fleece has a single-layer or multi-layer structure.

In a further advantageous embodiment, the spunbonded nonwoven is laminated with the needled nonwoven (22) or airlay nonwoven.

In a further advantageous embodiment, the needle fleece or airlay fleece or the needle fleece backing or airlay backing is calendered on one side or two sides. In a further preferred embodiment, the needle fleece or airlay fleece has one or more layers, at least two layers and particularly preferably exactly two layers.

The basis weights of the calendered carrier nonwovens are preferably in the range from 80 to 350 g/m ² .

In a further preferred embodiment, the spunbonded nonwoven, the needled nonwoven or the airlay nonwoven is made from a material or contains a material which is selected from a group of materials which PET, PBT, PTT, PA, PP, PE, PLA or viscose, their Co -Contains polymers or mixtures thereof.

It is possible for the spunbonded nonwoven, the needled nonwoven and/or the airlay nonwoven to consist of the same or different materials.

In a preferred embodiment, the needle fleece or the airlay fleece has a multi-layer structure. The individual layers of a multi-layered needle fleece or airlay fleece can consist of the same or different materials or have such materials.

A carpet device is thus made available which is characterized in that the tufted carpet itself already has a high absorptive effect; and thus the lamination process of the wear layer (tufting), which is complex in the deformation processes for a floor paneling or luggage compartment side paneling in particular carpet) with an acoustic underlay, including most of the required adhesive layers, can be omitted; or the basis weights of sub-layers, in particular of acoustic/stiffening nonwovens, can be reduced.

The carpet is preferably designed without additional sound-absorbing further layers.

As a result of the integration of the acoustic underlay into the tufted backing, there are further advantages. In addition to the absorption by the pile itself [area weight, fiber cross section, hollow or solid core fiber, fiber thickness (single fiber/yarn dtex)], the carpet device receives an increased acoustically absorptive effectiveness through the absorptive carrier.

The general wear behavior of the wear layer is advantageously also positively influenced, since even after use-related wear and tear of the pile yarn, the fiber character of the wear layer is still given by the needle fleece layer of the tufting carrier material.

In a particularly preferred embodiment, a spunbonded fabric with a basis weight of (approximately) 100 g/m ² is needled with a (approximately) 100 g/m ² PET needle mat.

In a further preferred embodiment, an (approximately) 100 g/m ² spunbonded nonwoven is needled with an (approximately) 140 g/m ² PET needled nonwoven.

The approximate specification is understood to mean that the basis weights deviate by no more than 10%, preferably by no more than 5%, from the stated values.

These needled carrier fleeces were measured acoustically in comparison to a carrier fleece in use today (absorption degree a0 (absorption with vertical sound incidence), impedance tube measurement according to ISO 10534-2 and ASTM E1050-98). In the one below 3 the absorptive effectiveness of the needled nonwovens can be clearly seen in comparison to the spunbonded nonwoven backing (the sound was incident on the needled nonwoven side).

The present invention is also directed to a motor vehicle and in particular a road motor vehicle and in particular a passenger car with a carpet of the type described above with a carrier fleece of the type described above.

Further advantages and embodiments result from the attached drawings:

• 1 eine Darstellung eines erfindungsgemäßen Trägervlieses
• 2 eine Darstellung eines Tufting-Teppichs mit dem erfindungsgemäßen Trägervlies
• 3 eine Darstellung des akustischen Verhaltens für erfindungsgemäße Teppich-Trägervliese im Vergleich zu einem herkömmlichen Spinnvlies-Träger

Show in it:

• 1 a representation of a carrier fleece according to the invention
• 2 a representation of a tufted carpet with the carrier fleece according to the invention
• 3 a representation of the acoustic behavior for carpet backings according to the invention compared to a conventional spunbonded backing

1 shows a backing fleece 2 of a carpet backing fleece structure according to the invention. This carrier fleece 2 has in 1 shown embodiment, a needle mat 22 and a spunbonded fabric 24, which lie flat against each other. The reference character L refers to the longitudinal direction of the carrier element, the reference character B to the width direction and the reference character D to the thickness direction.

The spunbonded nonwoven 24 is at the in 1 embodiment shown needled with the needle mat 22.

2 shows a schematic representation of a carpet structure 1. This consists of the in 1 shown carrier fleece 2 (22, 24) and other possible materials / layers 4 together. This carpet structure 1 shown here has a binding layer 42 which is arranged on the underside of the spunbonded fabric 24 . In addition, the carpet structure 1 has yarn 44 which is tufted through or into the backing fleece 2 and forms the pile.

In addition, the in 2 The carpet structure 1 shown has further layers (not shown).

3 shows a diagram to illustrate the (acoustic) effectiveness of the carpet fleece according to the invention. The degree of absorption a0 (absorption with vertical sound incidence) was determined. In particular, a raw impedance measurement was carried out in accordance with ISO 10534-2 and ASTM E1050-98.

It can be seen that the carrier fleece composed of a 245 g/cm ² carrier and needle fleece (curve K1) and the carrier fleece composed of a 192 g/cm ² carrier and a needle fleece (curve K2) have a significantly higher sound absorption than the previously used 100 g/cm ² carrier (curve K3).

The applicant reserves the right to claim all features disclosed in the application documents as essential to the invention, provided they are new compared to the prior art, either individually or in combination. It will continue to point pointed out that the individual figures also describe features which can be advantageous in and of themselves. The person skilled in the art recognizes immediately that a specific feature described in a figure can also be advantageous without adopting further features from this figure. Furthermore, the person skilled in the art recognizes that advantages can also result from a combination of several features shown in individual figures or in different figures.

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• EP 1598476 B1 [0007]
• DE 102016203348 A1 [0011]
• DE 2834438 C3 [0017]
• DE 19609586 C1 [0017]
• DE 10108092 A1 [0017]
• DE 102009010919 A1 [0021]
• DE 202005013023 U1 [0022]
• DE 102004046201 A1 [0023]
• DE 102004054299 A1 [0023]
• DE 102007020818 B3 [0024]
• US 6808786 B2 [0027]
• CA 2514119 A1 [0027]
• US 2004/0151870 A1 [0027]
• EP 1590170 B1 [0027]
• US 7700176 B2 [0029]

Claims (11)

Backing fleece (2) for a tufted carpet for use in motor vehicles, which has one or more fleeces, characterized in that a spunbonded nonwoven (24) is connected to a carded needled nonwoven (22) or airlay nonwoven or the carrier fleece (2) has a carded needle fleece or airlay fleece that is calendered on one side or on both sides. Carrier fleece (2) after claim 1 , characterized in that the spunbonded nonwoven (24) is needled to the needled nonwoven (22) or airlay nonwoven. Carrier fleece (2) according to at least one of the preceding claims, characterized in that the spunbonded fleece (24) is laminated with the needle fleece (22) or airlay fleece. Carrier fleece (2) according to at least one of the preceding claims, characterized in that the spunbonded fleece (24) has a weight per unit area which is greater than 30 g/m ² , preferably greater than 40 g/m ² and particularly preferably greater than 50 g/m 2 m ² and/or that the spunbonded nonwoven (24) has a basis weight which is less than 200 g/m ² , preferably less than 180 g/m ² , preferably less than 160 g/m ² and particularly preferably less than 140 g/m 2 ² . Carrier fleece (2) according to at least one of the preceding claims, characterized in that the needle fleece (22) or airlay fleece has a basis weight which is greater than 40 g/m ² , preferably greater than 60 g/m ² and particularly preferably greater than 80 g / m ² and / or that the needle fleece (22) or Airlay fleece has a basis weight which is less than 350 g / m ² , preferably less than 320 g / m ² , preferably less than 280 g / m ² and particularly preferably less than ^250gsm . Carrier fleece (2) according to at least one of the preceding claims, characterized in that the needle fleece (22) or airlay fleece has a single-layer or multi-layer structure. Carrier fleece (2) according to at least one of the preceding claims, characterized in that the spunbonded fleece (24), needled fleece (22) or airlay fleece made of PET, PBT, PTT, PA, PP, PE, PLA or viscose, their copolymers or mixtures consist of. Carrier fleece (2) according to at least one of the preceding claims, characterized in that the spunbonded fleece (24), needled fleece (22) or airlay fleece consist of the same or different materials. Carrier fleece (2) according to at least one of the preceding claims, characterized in that the individual layers of a multi-layer needle fleece (22) or airlay fleece can consist of the same or different materials. Carpet, in particular tufted carpet with a carrier fleece according to at least one of the preceding claims. Motor vehicle with a carpet according to the preceding claim and/or with a carrier fleece according to at least one of the preceding claims Claims 1 - 10 .

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