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EP3959073A1 - Absorbent needle-punched layered composite - Google Patents

Absorbent needle-punched layered composite

Info

Publication number
EP3959073A1
EP3959073A1 EP20721494.1A EP20721494A EP3959073A1 EP 3959073 A1 EP3959073 A1 EP 3959073A1 EP 20721494 A EP20721494 A EP 20721494A EP 3959073 A1 EP3959073 A1 EP 3959073A1
Authority
EP
European Patent Office
Prior art keywords
needled
foam
fleece
absorptive
layer composite
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.)
Pending
Application number
EP20721494.1A
Other languages
German (de)
French (fr)
Inventor
Volkmar Schulze
Ray SINGH
Volker Kursch
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.)
Adler Pelzer Holding GmbH
Original Assignee
Adler Pelzer Holding GmbH
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
Application filed by Adler Pelzer Holding GmbH filed Critical Adler Pelzer Holding GmbH
Publication of EP3959073A1 publication Critical patent/EP3959073A1/en
Pending 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
    • B32B5/245—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 being a foam layer
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0076—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised in that the layers are not bonded on the totality of their surfaces
    • 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
    • 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
    • B32B5/06—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 characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • 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
    • B32B5/08—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 the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different 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
    • 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
    • B32B5/18—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 features of a layer of foamed material
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/08—Interconnection of layers by mechanical means
    • B32B7/09—Interconnection of layers by mechanical means by stitching, needling or sewing
    • 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
    • B60R13/08—Insulating elements, e.g. for sound insulation
    • G—PHYSICS
    • G10—MUSICAL INSTRUMENTS; ACOUSTICS
    • G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
    • G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
    • G10K11/162—Selection of materials
    • G10K11/168—Plural layers of different materials, e.g. sandwiches
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/02—2 layers
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • 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
    • B32B2262/0253—Polyolefin 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
    • 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
    • B32B2262/0261—Polyamide 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
    • 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
    • B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
    • 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
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • 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
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • 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
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • 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
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/56—Damping, energy absorption
    • 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
    • B32B2307/718—Weight, e.g. weight per square meter
    • 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
    • B32B2307/72—Density
    • 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
    • B32B2307/732—Dimensional properties
    • 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
    • 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
    • B32B2605/08—Cars
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/435—Polyesters
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres

Definitions

  • the invention relates to a layer composite, a sandwich structure, in which a PUR foam layer is needled with at least one fleece.
  • thermoformable acoustic and / or stiffening nonwovens are used, especially in the passenger compartment and luggage compartment. Most of these are loosely pressed thermosetting or thermoplastic bonded textile fiber nonwovens and combinations of foam and / or nonwoven layers with the same or different flow resistances. In addition, so-called flow nonwovens are also used to specifically tune the acoustics.
  • porous, air- and therefore sound-open layers are inserted between the actual outer fabric and the process-related sealing and heavy layers or the insulation in floor coverings.
  • Polyester and mixed fiber fleeces as well as micro-perforated foils are used as porous, air-tight and therefore sound-open layers.
  • the crush resistance is also influenced by the proportion of bicomponent fibers (BiCo) in the nonwovens.
  • BiCo bicomponent fibers
  • TR 200803410 relates to a process for the reuse of relatively coarse waste materials, for example textile waste from the manufacture of automobile parts and products made from them.
  • the method is characterized in that the waste materials are broken into relatively small pieces. This grist is then placed on a base. A top layer of another raw material is then applied to the surface of the waste material and the layers are bonded together.
  • TR 200906997 an analogous process is described in which a further hard layer is also introduced using the effect of heat.
  • US 2018/0251924 A1 proposes a nonwoven composite system in which, on the one hand, two nonwovens and, on the other hand, two nonwovens with an intermediate film. Specially modified fibers are used in the nonwovens.
  • WO 2012/052535 A1 relates to a method for making a composite fleece in a continuous process sequence and a device for carrying out the method.
  • FH ierbei a fiber web is formed from a fiber stream by a carding device, on the surface of which a fleece layer made of synthetic fibers is then placed.
  • the fiber web is guided within a suction zone on a storage belt to a meltblowing device in which the Synthetikfa fibers are placed on the surface of the fiber web by meltblowing.
  • the fibrous web covered with the nonwoven system is then laid in several layers to form the composite nonwoven by a nonwoven laying device.
  • multi-layer needled acoustic and / or stiffening nonwoven with two outer cover nonwovens described with a) a first cover nonwoven consisting of a PE adhesive nonwoven with a weight per unit area of 30 g / m 2 to 200 g / m 2 , preferably from 50 g / m 2 to 150 g / m 2 , and a second cover nonwoven consisting of a PP / PET fleece with a weight per unit area of 50 g / m 2 to 250 g / m 2 , preferably 80 g / m 2 to 200 g / m 2 or
  • both cover nonwovens are each a PP / PET cover nonwoven with a weight per unit area of 200 g / m 2 to 800 g / m 2 , preferably 300 g / m 2 to 600 g / m 2 ,
  • the regrind contains 5% by weight to 50% by weight, preferably 10% by weight to 40% by weight, based on the regrind, dust waste from recycled cotton, PET and two-component fibers.
  • a needled fleece for the setting of textile wheel arch shells in particular is described, which comprises 5 to 14 individual pile layers with a grammage of the fleece in the range from 650 g / m 2 to 1900 g / m 2 , wherein the base fleece made of PP / PET, PP / BiCo / PET, PP / BiCo or PET / BiCo fibers summarizes, described, which is characterized in that
  • the individual layers - according to the acoustic and mechanical requirements in particular for a textile wheel arch liner - each include the same or different materials made of regrind and / or fibers and / or flakes and / or powder in the same or different amounts in layers.
  • the layer composites “fleece / foam” are glued or foamed together.
  • the object of the present invention in relation to the aforementioned prior art is thus to provide an absorptive layer composite, a sandwich structure in which a foam layer is needled with a nonwoven layer arranged thereon and, if appropriate, underneath.
  • the focus here is on the one hand on the significantly improved acoustic effectiveness with approximately the same weight per unit area and on the other hand on the improved acoustic effectiveness and the weight advantage.
  • a fleece / PUR foam layer composite comprising at least one PET fleece with a grammage of 80 g / m 2 to 300 g / m 2 , preferably in the range of 100 g / m 2 to 200 g / m 2 , arranged on the top and / or bottom side of a PUR foam, the PUR foam having a density in the range from 45 g / l to 120 g / l, in particular in the range from 60 g / l to 85 g / l and a thickness in the range from 4 mm to 20 mm, preferably in the range from 8 mm to 15 mm, which is characterized in that the layer composite is needled.
  • acoustically effective components or individual components are known from the prior art in which a foam, a foam layer, is needled with one or more fleece layers / fleece layers (cover fleece).
  • so-called lightweight foams in the density range from 9 g / l to 40 g / l are used instead of the PUR foam in the density range from 45 g / l to 120 g / l.
  • the nonwovens (at least one nonwoven) arranged in particular on the upper and / or lower side of the foam can consist of PET or PA fibers, as well as a fiber mix (mixed fibers); here in particular made of PET / PP and PP / PET / cotton fibers.
  • Fig. 2 is a photo of a needled composite nonwoven / foam / nonwoven is shown.
  • FIG. 3 illustrates in particular the weight and acoustic advantages of the inventive solution when using lightweight foams (LeveCell® and LeveSoft®) compared to a mixed fiber fleece currently in use.
  • FIG. 4 an inventive composite with needled cold foam is shown in comparison with a conventional recycling sandwich fleece; the enormous acoustic advantage of the composite according to the invention can be seen with approximately the same weight per unit area.
  • a further embodiment of the present invention consists in a method for producing the aforementioned layer composite, which is characterized in that the foam is fed or placed onto the first (lower) cover fleece from a roll or as a blank; and then the second (upper) cover fleece runs over it, compacts and needles the entire composite. If necessary, the second (upper) cover fleece is left out.
  • the needling takes place with fork / fork needles, crown / crown needles, fork / crown needles or felting needles.
  • the core of the present invention is thus the provision of a layer composite comprising a needled fleece / foam composite, which improves the acoustic effectiveness of this sandwich structure.
  • the foam cells are pierced during the needling.
  • individual fibers are drawn from the nonwovens that surround it into the foam structure during needling.
  • the foam itself also becomes softer.
  • the advantage of the present invention lies in the fact that the needling of a foam with fleeces arranged on both sides or on one side significantly improves the acoustic effectiveness of the composite and reduces the weight compared to conventional composites or fleeces.
  • the mechanical behavior of the composite needled with fleece is also improved compared to a pure foam.
  • a PUR lightweight foam (LeveSoft®, 24 g / l, thickness 10 mm) was needled on both sides with a 100 g / m 2 and 150 g / m 2 PET fleece.
  • the needling was carried out on a commercially available Fehrer system, the needling density was 20 stitches / cm 2 , the penetration depth 14 mm and the speed 4 m / min.
  • Commercially available felt needles were used as needles.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Multimedia (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)

Abstract

The invention relates to a layered composite, a sandwich structure, wherein a PUR foam layer is needle-punched with two nonwovens.

Description

Absorptiver vernadelter Schichtverbund Absorptive needled layer composite

Gegenstand der Erfindung ist ein Schichtverbund, eine Sandwich- Struktur, bei dem eine PUR-Schaumstoffschicht mit wenigstens einem Vlies vernadelt sind. The invention relates to a layer composite, a sandwich structure, in which a PUR foam layer is needled with at least one fleece.

In Kraftfahrzeugen werden insbesondere im Fahrgastraum und Gepäck raum thermoformbare Akustik- und/oder Versteifungsvliesstoffe einge setzt. Meist sind dies locker verpresste duroplastisch oder thermoplas tisch gebundene Textilfaservliesstoffe sowie Kombinationen von Schaumstoff- und / oder Vliesstoffschichten mit gleichen oder verschie denen Strömungswiderständen. Darüber hinaus finden auch sogenannte Strömungsvliesstoffe Anwendung, um zielgerichtet die Akustik zu tunen. In motor vehicles, thermoformable acoustic and / or stiffening nonwovens are used, especially in the passenger compartment and luggage compartment. Most of these are loosely pressed thermosetting or thermoplastic bonded textile fiber nonwovens and combinations of foam and / or nonwoven layers with the same or different flow resistances. In addition, so-called flow nonwovens are also used to specifically tune the acoustics.

Zur Beeinflussung des Schallschluckvermögens in Korrelation mit der Trittsteifigkeit werden bei Bodenverkleidungen poröse, luft- und damit schalloffene Schichten zwischen der eigentlichen Oberware und den prozessbedingten Dicht- und Schwerschichten beziehungsweise der Iso lation eingefügt. Als poröse, luft- und damit schalloffene Schichten fin den hier Polyester- und Mischfaservliese, sowie mikro-perforierte Folien, Anwendung. Die Trittfestigkeit wird auch durch den Anteil an Bikompo nentenfasern (BiCo) in den Vliesstoffen beeinflusst. Bei Stirnwand-Materialstrukturen finden häufig einlagige Vliesstoffe, mehrschichtige Vliesstoffe und hinterschäumte Vliesstoffe Anwendung. Vorwiegend bei Seitenverkleidungen, Heckklappenverkleidungen und Reserveradmulden finden auch Vliesstoffe und/oder Vliesstoffkombinati onen im Gepäckraum ihre Anwendung. In order to influence the sound absorption capacity in correlation with the step stiffness, porous, air- and therefore sound-open layers are inserted between the actual outer fabric and the process-related sealing and heavy layers or the insulation in floor coverings. Polyester and mixed fiber fleeces as well as micro-perforated foils are used as porous, air-tight and therefore sound-open layers. The crush resistance is also influenced by the proportion of bicomponent fibers (BiCo) in the nonwovens. Single-layer nonwovens, multi-layer nonwovens and foam-backed nonwovens are often used for end wall material structures. Primarily for side panels, tailgate panels and spare wheel wells, nonwovens and / or nonwoven combinations are also used in the luggage compartment.

Akustisch wirksame Kraftfahrzeug-Komponenten, Bauteile, haben stets eine der in Fig. 1 dargestellte Materialstruktur. Acoustically effective motor vehicle components, parts, always have the material structure shown in FIG. 1.

TR 200803410 betrifft ein Verfahren zur Wiederverwendung von relativ groben Abfallmaterialien, beispielsweise von Textilabfällen aus der Her stellung von Automobilteilen sowie Produkte, die daraus hergestellt werden. Das Verfahren ist dadurch gekennzeichnet, dass man die Ab fallmaterialien in relativ kleine Stücke bricht. Dieses Mahlgut wird dann auf eine Unterlage aufgebracht. Anschließend wird eine obere Lage ei nes weiteren Rohmaterials auf die Oberfläche des Abfallmaterials aufge bracht und die Schichten miteinander verbunden. In TR 200906997 wird ein analoges Verfahren beschrieben, bei dem zusätzlich noch eine wei tere Hartschicht, unter Nutzung von Wärmeeinwirkung, eingebracht wird. TR 200803410 relates to a process for the reuse of relatively coarse waste materials, for example textile waste from the manufacture of automobile parts and products made from them. The method is characterized in that the waste materials are broken into relatively small pieces. This grist is then placed on a base. A top layer of another raw material is then applied to the surface of the waste material and the layers are bonded together. In TR 200906997, an analogous process is described in which a further hard layer is also introduced using the effect of heat.

DE 10 2015 115 458 Al [WO 2017/046164 Al] offenbart ein Struktur bauteil eines Kraftfahrzeuges, insbesondere eine Radlaufschale oder ei ne Motorraumabschirmung, wobei das Strukturbauteil mindestens teil weise aus einem Verbundmaterial besteht, das aus mindestens zwei übereinanderliegenden Vliesschichten verpresst ist. Es wird hier vorge schlagen, dass auf mindestens einer der Vliesschichten eine Verstär- kungsschicht aus mindestens einem gelegten Verstärkungsfilament zur Verstärkung des Verbundmaterials angeordnet ist. DE 10 2015 115 458 A1 [WO 2017/046164 A1] discloses a structural component of a motor vehicle, in particular a wheel arch liner or an engine compartment shield, the structural component at least partially consisting of a composite material that is pressed from at least two superimposed nonwoven layers. It is proposed here that at least one of the fleece layers be reinforced Kungsschicht is arranged from at least one laid reinforcement filament to reinforce the composite material.

In US 2018/0251924 Al wird ein Vliesverbundsystem vorgeschlagen, bei dem einerseits zwei Vliese und andererseits zwei Vliese mit einer zwischenliegenden Folie angeordnet sind. Anwendung in den Vliesen finden speziell modifizierte Fasern. US 2018/0251924 A1 proposes a nonwoven composite system in which, on the one hand, two nonwovens and, on the other hand, two nonwovens with an intermediate film. Specially modified fibers are used in the nonwovens.

Darüber hinaus sind Verfahren zur Fierstellung von sogenannten Recyc- ling-Sandwich-Vliesen beziehungsweise Bauteilen im Stand der Technik beschrieben, bei denen zum einen die Press-Technologie (DE 10 2016 202 290 Al) und zum anderen das Vernadeln (DE 10 2013 222 403 Al, DE 10 2016 203 348 Al) angewendet werden. In addition, methods for making so-called recycling sandwich fleeces or components are described in the prior art, in which, on the one hand, press technology (DE 10 2016 202 290 A1) and, on the other hand, needling (DE 10 2013 222 403 Al, DE 10 2016 203 348 Al) can be used.

WO 2012/052535 Al betrifft ein Verfahren zur Fierstellung eines Ver bundvlieses in einer kontinuierlichen Prozessfolge sowie eine Vorrich tung zur Durchführung des Verfahrens. FH ierbei wird aus einem Faser strom durch eine Kardiereinrichtung ein Faserflor gebildet, an dessen Oberfläche anschließend eine Vlieslage aus Synthetikfasern gelegt wird. Hierzu wird der Faserflor innerhalb einer Saugzone an einem Ablage band zu einer Schmelzblaseinrichtung geführt, in der die Synthetikfa sern durch Schmelzblasen an der Oberfläche des Faserflors gelegt wer den. Der mit der Vliesanlage belegte Faserflor wird anschließend durch eine Vliesverlegeeinrichtung in mehrere Schichten zu dem Verbundvlies verlegt. WO 2012/052535 A1 relates to a method for making a composite fleece in a continuous process sequence and a device for carrying out the method. FH ierbei a fiber web is formed from a fiber stream by a carding device, on the surface of which a fleece layer made of synthetic fibers is then placed. For this purpose, the fiber web is guided within a suction zone on a storage belt to a meltblowing device in which the Synthetikfa fibers are placed on the surface of the fiber web by meltblowing. The fibrous web covered with the nonwoven system is then laid in several layers to form the composite nonwoven by a nonwoven laying device.

In der DE 10 2016 203 348 Al wird ein In DE 10 2016 203 348 A1, a

mehrlagiger vernadelter Akustik- und/oder Versteifungsvliesstoff mit zwei äußeren Deckvliesstoffen beschrieben mit a) einem ersten Deckvliesstoff bestehend aus einem PE-Klebevlies mit einem Flächengewicht von 30 g/m2 bis 200 g/m2, vorzugsweise von 50 g/m2 bis 150 g/m2, und einem zweiten Deckvliesstoff bestehend aus einem PP/PET-Vlies mit einem Flächengewicht von 50 g/m2 bis 250 g/m2, vorzugsweise von 80 g/m2 bis 200g/m2 oder multi-layer needled acoustic and / or stiffening nonwoven with two outer cover nonwovens described with a) a first cover nonwoven consisting of a PE adhesive nonwoven with a weight per unit area of 30 g / m 2 to 200 g / m 2 , preferably from 50 g / m 2 to 150 g / m 2 , and a second cover nonwoven consisting of a PP / PET fleece with a weight per unit area of 50 g / m 2 to 250 g / m 2 , preferably 80 g / m 2 to 200 g / m 2 or

b) wobei beide Deckvliesstoffe jeweils ein PP/PET-Deckvlies mit ei nem Flächengewicht von 200 g/m2 bis 800 g/m2, vorzugsweise 300 g/m2 bis 600 g/m2 sind, b) where both cover nonwovens are each a PP / PET cover nonwoven with a weight per unit area of 200 g / m 2 to 800 g / m 2 , preferably 300 g / m 2 to 600 g / m 2 ,

mit einer jeweils zwischen den Deckvliesstoffen liegenden Schicht aus Mahlgut mit einem Flächengewicht von 250 g/m2 bis 700 g/m2 aus PE, PET, PP, Zweikomponenten-Fasern und Mehrkomponentenfasermaterial, der dadurch gekennzeichnet, dass with a layer of regrind between the cover nonwovens with a weight per unit area of 250 g / m 2 to 700 g / m 2 made of PE, PET, PP, two-component fibers and multi-component fiber material, which is characterized in that

das Mahlgut 5 Gew. % bis 50 Gew. %, vorzugsweise 10 Gew. % bis 40 Gew. %, bezogen auf das Mahlgut, Staubabfälle aus Reißbaumwolle, PET und Zweikomponenten-Fasern enthält. the regrind contains 5% by weight to 50% by weight, preferably 10% by weight to 40% by weight, based on the regrind, dust waste from recycled cotton, PET and two-component fibers.

In der noch unveröffentlichten DE 10 2019 104 847 ist ein vernadeltes Vlies zur Fierstellung von insbesondere textilen Radlaufschalen be schrieben, das 5 bis 14 Flor-Einzellagen mit einer Grammatur des Vlie ses im Bereich von 650 g/m2 bis 1900 g/m2 umfasst, wobei das Basis vlies aus PP/PET-, PP/BiCo/PET-, PP/BiCo- oder PET/BiCo-Fasern um fasst, beschrieben, das dadurch gekennzeichnet ist, dass In the as yet unpublished DE 10 2019 104 847, a needled fleece for the setting of textile wheel arch shells in particular is described, which comprises 5 to 14 individual pile layers with a grammage of the fleece in the range from 650 g / m 2 to 1900 g / m 2 , wherein the base fleece made of PP / PET, PP / BiCo / PET, PP / BiCo or PET / BiCo fibers summarizes, described, which is characterized in that

die Einzellagen -entsprechend den insbesondere akustischen und me chanischen Anforderungen an eine textile Radlaufschale- jeweils gleiche oder unterschiedliche Materialien aus Mahlgut und/oder Fasern und/oder Flocken und/oder Pulver in lagenweise gleichen oder unter schiedlichen Mengen eingestreut umfassen. Bei den im Stand der Technik zu findenden akustisch wirksamen Bautei len sowie Einzelkomponenten sind die Schichtverbunde „Vlies / Schaumstoff' miteinander verklebt oder angeschäumt. the individual layers - according to the acoustic and mechanical requirements in particular for a textile wheel arch liner - each include the same or different materials made of regrind and / or fibers and / or flakes and / or powder in the same or different amounts in layers. In the acoustically effective components and individual components to be found in the prior art, the layer composites “fleece / foam” are glued or foamed together.

Die Aufgabe der vorliegenden Erfindung gegenüber dem vorgenannten Stand der Technik besteht somit in der Bereitstellung eines absorptiven Schichtverbundes, einer Sandwichstruktur, bei der eine Schaumstoff schicht mit darauf und gegebenenfalls darunter angeordneter Vlies schicht vernadelt ist. Im Fokus ist dabei zum einen die deutlich verbes serte akustische Wirksamkeit bei annähernd gleichem Flächengewicht und zum anderen die verbesserte akustische Wirksamkeit sowie der Gewichtsvorteil. The object of the present invention in relation to the aforementioned prior art is thus to provide an absorptive layer composite, a sandwich structure in which a foam layer is needled with a nonwoven layer arranged thereon and, if appropriate, underneath. The focus here is on the one hand on the significantly improved acoustic effectiveness with approximately the same weight per unit area and on the other hand on the improved acoustic effectiveness and the weight advantage.

Die vorgenannte Aufgabe der vorliegenden Erfindung wird in einer ers ten Ausführungsform gelöst durch ein Vlies / PUR-Schaumstoff- Schichtverbund, umfassend wenigstens ein PET-Vlies mit einer Grammatur von 80 g/m2 bis 300 g/m2, vorzugsweise im Bereich von 100 g/m2 bis 200 g/m2, angeordnet auf der Ober- und/oder Unterseite eines PUR-Schaumstoffes, wobei der PUR-Schaumstoff eine Dichte im Bereich von 45 g/l bis 120 g/l, insbesondere im Bereich von 60 g/l bis 85 g/l und eine Dicke im Bereich von 4 mm bis 20 mm, vorzugsweise im Bereich von 8 mm bis 15 mm aufweist, der dadurch gekennzeichnet ist, dass der Schichtverbund vernadelt ist. The above-mentioned object of the present invention is achieved in a first embodiment by a fleece / PUR foam layer composite comprising at least one PET fleece with a grammage of 80 g / m 2 to 300 g / m 2 , preferably in the range of 100 g / m 2 to 200 g / m 2 , arranged on the top and / or bottom side of a PUR foam, the PUR foam having a density in the range from 45 g / l to 120 g / l, in particular in the range from 60 g / l to 85 g / l and a thickness in the range from 4 mm to 20 mm, preferably in the range from 8 mm to 15 mm, which is characterized in that the layer composite is needled.

Aus dem Stand der Technik sind keine akustisch wirksamen Bauteile sowie Einzelkomponenten bekannt, bei denen ein Schaumstoff, eine Schaumstoffschicht, mit einer oder mehreren Vliesschichten / Vlieslagen (Deckvliese) vernadelt ist. In einer weiteren alternativen Ausführungsform finden anstatt des PUR- Schaumstoffes im Dichtebereich von 45 g/l bis 120 g/l sogenannte Leichtschaumstoffe im Dichtebereich von 9 g/l bis 40 g/l Anwendung. No acoustically effective components or individual components are known from the prior art in which a foam, a foam layer, is needled with one or more fleece layers / fleece layers (cover fleece). In a further alternative embodiment, so-called lightweight foams in the density range from 9 g / l to 40 g / l are used instead of the PUR foam in the density range from 45 g / l to 120 g / l.

Die insbesondere auf der Ober- und/oder Unterseite des Schaumstoffes angeordneten Vliese (wenigstens ein Vlies) können aus PET- oder PA Fasern, sowie aus einem Faser-Mix (Mischfasern) bestehen; hier insbe sondere aus PET/PP- und PP/PET/Baumwoll-Fasern. The nonwovens (at least one nonwoven) arranged in particular on the upper and / or lower side of the foam can consist of PET or PA fibers, as well as a fiber mix (mixed fibers); here in particular made of PET / PP and PP / PET / cotton fibers.

In Fig. 2 ist ein Foto eines vernadelten Verbundes -Vlies / Schaumstoff / Vlies- abgebildet. In Fig. 2 is a photo of a needled composite nonwoven / foam / nonwoven is shown.

In den Fig. 3 und 4 ist die akustische Leistungsfähigkeit der erfindungs gemäßen Materialstrukturen im Vergleich mit Strukturen aus dem Stand der Technik dargestellt. 3 and 4, the acoustic performance of the fiction, contemporary material structures is shown in comparison with structures from the prior art.

Fig. 3 verdeutlicht insbesondere die Gewichts- und Akustik-Vorteile der erfinderischen Lösung bei Anwendung von Leichtschaumstoffen (Leve- Cell® und LeveSoft®) gegenüber einem derzeit im Einsatz befindlichen Mischfaservlies. 3 illustrates in particular the weight and acoustic advantages of the inventive solution when using lightweight foams (LeveCell® and LeveSoft®) compared to a mixed fiber fleece currently in use.

In Fig. 4 ist ein erfindungsgemäßer Verbund mit vernadeltem Kalt schaumstoff im Vergleich zu einem üblichen Recycling-Sandwich-Vlies dargestellt; bei etwa gleichem Flächengewicht ist der enorme Akustik vorteil des erfindungsgemäßen Verbundes zu sehen. Eine weitere Ausführungsform der vorliegenden Erfindung besteht in einem Verfahren zur Herstellung des vorgenannten Schichtverbundes, das dadurch gekennzeichnet ist, dass man den Schaumstoff von einer Rolle oder als Platine auf das erste (untere) Deckvlies zufährt bzw. auf legt; und anschließend das zweite (obere) Deckvlies darüberfährt, den Gesamtverbund verdichtet und vernadelt. Gegebenenfalls wird das zweite (obere) Deckvlies wegelassen. In Fig. 4, an inventive composite with needled cold foam is shown in comparison with a conventional recycling sandwich fleece; the enormous acoustic advantage of the composite according to the invention can be seen with approximately the same weight per unit area. A further embodiment of the present invention consists in a method for producing the aforementioned layer composite, which is characterized in that the foam is fed or placed onto the first (lower) cover fleece from a roll or as a blank; and then the second (upper) cover fleece runs over it, compacts and needles the entire composite. If necessary, the second (upper) cover fleece is left out.

Besonders bevorzugt im Sinne der vorliegenden Erfindung erfolgt die Vernadelung mit Gabel-/Gabelnadeln, Kranz-/Kranznadeln, Gabel- /Kranznadeln oder Filznadeln. Particularly preferably in the context of the present invention, the needling takes place with fork / fork needles, crown / crown needles, fork / crown needles or felting needles.

Kern der vorliegenden Erfindung ist somit die Bereitstellung eines Schichtverbundes, umfassend eines vernadelten Vlies / Schaumstoff - Verbundes, wodurch die akustische Wirksamkeit dieser Sandwichstruk tur verbessert ist. The core of the present invention is thus the provision of a layer composite comprising a needled fleece / foam composite, which improves the acoustic effectiveness of this sandwich structure.

Die Schaumstoffzellen werden bei der Vernadelung durchstochen. Dar über hinaus werden bei der Vernadelung einzelne Fasern aus den um mantelnden Vliesen in die Schaumstoffstruktur gezogen. Auch wird der Schaumstoff in sich weicher. The foam cells are pierced during the needling. In addition, individual fibers are drawn from the nonwovens that surround it into the foam structure during needling. The foam itself also becomes softer.

Der Vorteil der vorliegenden Erfindung besteht eben darin, dass durch das Vernadeln eines Schaumstoffes mit beidseitig oder einseitig ange ordneten Vliesen die akustische Wirksamkeit des Verbundes deutlich verbessert und das Gewicht gegenüber herkömmlichen Verbunden bzw. Vliesen reduziert wird. Auch verbessert sich das mechanische Verhalten des mit Vlies vernadel- ten Verbundes gegenüber einem reinen Schaumstoff. The advantage of the present invention lies in the fact that the needling of a foam with fleeces arranged on both sides or on one side significantly improves the acoustic effectiveness of the composite and reduces the weight compared to conventional composites or fleeces. The mechanical behavior of the composite needled with fleece is also improved compared to a pure foam.

Ausführungsbeispiel: Embodiment:

(a) In einem ersten Beispiel wurde ein PUR-Leichtschaumstoff (Le- veSoft®, 24 g/l, Dicke 10 mm) mit einem 100 g/m2 und 150 g/m2 PET- Vlies beidseitig vernadelt. (a) In a first example, a PUR lightweight foam (LeveSoft®, 24 g / l, thickness 10 mm) was needled on both sides with a 100 g / m 2 and 150 g / m 2 PET fleece.

(b) In einem zweiten Beispiel wurde ein PUR-Leichtschaumstoff (Le- veCell®, 12 g/l, Dicke 8 mm) jeweils mit einem 100 g/m2 und 150 g/m2 handelsüblichem PET-Vlies beidseitig vernadelt. (b) In a second example, a PUR lightweight foam (LeveCell®, 12 g / l, thickness 8 mm) was needled on both sides with a 100 g / m 2 and 150 g / m 2 commercially available PET fleece.

(c) In einem dritten Beispiel wurde ein handelsüblicher PUR- Kaltschaumstoff (65 g/l, Dicke 10 mm) mit einem 100 g/m2 und 150 g/m2 handelsüblichen PET-Vlies beidseitig vernadelt. (c) In a third example, a commercial PUR cold foam (65 g / l, thickness 10 mm) was needled on both sides with a 100 g / m 2 and 150 g / m 2 commercial PET fleece.

Die Vernadelung erfolgte auf einer handelsüblichen Fehrer-Anlage, die Vernadelungsdichte betrug 20 Stiche/cm2, die Einstichtiefe 14 mm und die Geschwindigkeit 4 m/min. Als Nadeln kamen handelsübliche Filzna deln zum Einsatz. The needling was carried out on a commercially available Fehrer system, the needling density was 20 stitches / cm 2 , the penetration depth 14 mm and the speed 4 m / min. Commercially available felt needles were used as needles.

Die akustische Leistungsfähigkeit der vernadelten Schaumstoffe ist in den Fig. 3 und 4 dargestellt. The acoustic performance of the needled foams is shown in FIGS. 3 and 4.

Claims

Patentanspüche: Patent claims: 1. Absorptiver Vlies / PUR-Schaumstoff-Schichtverbund, umfassend wenigstens ein PET-Vlies mit einer Grammatur von 80 g/m2 bis 300 g/m2, angeordnet auf der Ober- und/oder Unterseite eines PUR- Schaumstoffes, wobei der PUR-Schaumstoff 1. Absorptive fleece / PUR foam layer composite, comprising at least one PET fleece with a grammage of 80 g / m 2 to 300 g / m 2 , arranged on the top and / or bottom of a PUR foam, the PUR - foam (a) eine Dichte im Bereich von 45 g/l bis 120 g/l, oder (a) a density in the range of 45 g / l to 120 g / l, or (b) eine Dichte von im Bereich von 9 g/l bis 40 g/l, und (b) a density ranging from 9 g / l to 40 g / l, and jeweils eine Dicke im Bereich von 4 mm bis 20 mm aufweist, each has a thickness in the range from 4 mm to 20 mm, dadurch gekennzeichnet, dass der Schichtverbund vernadelt ist. characterized in that the layer composite is needled. 2. Absorptiver vernadelter Schichtverbund nach Anspruch 1, gekennzeichnet dadurch, dass 2. Absorptive needled composite according to claim 1, characterized in that die auf der Ober- und/oder Unterseite des Schaumstoffes angeordneten Vliese aus PET- oder PA Fasern, sowie aus einem Faser-Mix (Mischfa sern) bestehen; hier insbesondere aus PET/PP- und PP/PET/Baumwoll- Fasern. the fleeces arranged on the top and / or bottom of the foam are made of PET or PA fibers and a fiber mix (mixed fibers); here in particular made of PET / PP and PP / PET / cotton fibers. 3. Absorptiver vernadelter Schichtverbund nach Anspruch 1 oder 2, gekennzeichnet dadurch, dass 3. Absorptive needled layer composite according to claim 1 or 2, characterized in that der Schaumstoff nur einseitig mit einem Vlies vernadelt ist. the foam is only needled with a fleece on one side. 4. Absorptiver vernadelter Schichtverbund nach einem der Ansprü che 1 bis 3, dadurch gekennzeichnet, dass das PET-Vlies eine Gramma tur von 100 g/m2 bis 200 g/m2 aufweist. 4. Absorptive needled layer composite according to one of claims 1 to 3, characterized in that the PET fleece has a gramma of 100 g / m 2 to 200 g / m 2 . 5. Absorptiver vernadelter Schichtverbund nach einem der Ansprü che 1 bis 4, dadurch gekennzeichnet, dass der PUR-Schaumstoff eine Dichte im Bereich von 60 g/l bis 85 g/l aufweist. i o 5. Absorptive needled layer composite according to one of claims 1 to 4, characterized in that the PUR foam has a density in the range from 60 g / l to 85 g / l. ok 6. Absorptiver vernadelter Schichtverbund nach einem der Ansprü che 1 bis 4, dadurch gekennzeichnet, dass der PUR-Schaumstoff eine Dichte im Bereich von 12 g/l bis 32 g/l aufweist. 6. Absorptive needled layer composite according to one of claims 1 to 4, characterized in that the PUR foam has a density in the range from 12 g / l to 32 g / l. 7. Absorptiver vernadelter Schichtverbund nach einem der Ansprü che 1 bis 6, dadurch gekennzeichnet, dass der PUR-Schaumstoff eine Dicke im Bereich von 8 mm bis 15 mm aufweist. 7. Absorptive needled layer composite according to one of claims 1 to 6, characterized in that the PUR foam has a thickness in the range from 8 mm to 15 mm. 8. Absorptiver vernadelter Schichtverbund nach einem der Ansprü che 1 bis 7, dadurch gekennzeichnet, dass der Schichtverbund zwei PET-Vliese aufweist. 8. Absorptive needled layer composite according to one of claims 1 to 7, characterized in that the layer composite has two PET nonwovens. 9. Verfahren zur Herstellung eines absorptiven vernadelten9. Process for making an absorptive needled Schichtverbundes nach einem der Ansprüche 1 bis 8, dadurch gekenn zeichnet, dass der Schaumstoff von einer Rolle oder als Platine auf ein erstes (untere) Deckvlies zugefahren oder aufgelegt und anschließend ein zweites (obere) Deckvlies darübergefahren, der Gesamtverbund verdichtet und vernadelt wird. Layer composite according to one of Claims 1 to 8, characterized in that the foam is fed or placed onto a first (lower) cover fleece from a roll or as a plate and then a second (upper) cover fleece is passed over it, the overall composite is compressed and needled. 10. Verfahren zur Herstellung eines absorptiven vernadelten10. Process for making an absorptive needled Schichtverbundes nach einem der Ansprüche 1 bis 9, dadurch gekenn zeichnet, dass der Schaumstoff von einer Rolle oder als Platine auf ein (unteres) Deckvlies zugefahren oder aufgelegt, der Gesamtverbund verdichtet und vernadelt wird. Layer composite according to one of Claims 1 to 9, characterized in that the foam is fed or placed onto a (lower) cover fleece from a roll or as a blank, and the overall composite is compressed and needled. 11. Verfahren nach Anspruch 9 oder 10, dadurch gekennzeichnet, dass die Vernadelung mit Gabel-/Gabelnadeln, Kranz-/Kranznadeln, Ga- bel-/Kranznadeln oder Filznadeln erfolgt. 11. The method according to claim 9 or 10, characterized in that the needling takes place with fork / fork needles, crown / crown needles, fork / crown needles or felting needles.
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WO2020216745A1 (en) 2020-10-29
CN114007855A (en) 2022-02-01

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