DE102006003220A1 - Production of laminated molding for use in vehicle interior e.g. as self-supporting roof lining involves pressing preform of isocyanate-filled flexible foam between glass fiber layers and barrier layers of nonwoven, adhesive and film - Google Patents

Production of laminated molding for use in vehicle interior e.g. as self-supporting roof lining involves pressing preform of isocyanate-filled flexible foam between glass fiber layers and barrier layers of nonwoven, adhesive and film Download PDF

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Publication number
DE102006003220A1
DE102006003220A1 DE200610003220 DE102006003220A DE102006003220A1 DE 102006003220 A1 DE102006003220 A1 DE 102006003220A1 DE 200610003220 DE200610003220 DE 200610003220 DE 102006003220 A DE102006003220 A DE 102006003220A DE 102006003220 A1 DE102006003220 A1 DE 102006003220A1
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Germany
Prior art keywords
adhesive
nonwoven
film
layer
isocyanate
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DE200610003220
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German (de)
Inventor
Ulrich Krause
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GERLINGER INDUSTRIES AG, CH
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HAENSEL VERBUNDTECHNIK GmbH
Hansel Verbundtechnik GmbH
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Priority to DE200610003220 priority Critical patent/DE102006003220A1/en
Publication of DE102006003220A1 publication Critical patent/DE102006003220A1/en
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/02Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
    • B32B17/04Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments bonded with or embedded in a plastic substance
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/12Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/32Layered products comprising a layer of synthetic resin comprising polyolefins
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered 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
    • B32B5/02Layered 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
    • B32B5/022Non-woven fabric
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered 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
    • B32B5/18Layered 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered 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
    • B32B5/22Layered 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
    • B32B5/24Layered 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
    • B32B5/245Layered 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
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered 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
    • B32B7/04Interconnection of layers
    • B32B7/12Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60RVEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
    • B60R13/0212Roof or head liners
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00Layers arrangement
    • B32B2250/40Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02Synthetic macromolecular fibres
    • B32B2262/0276Polyester fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10Inorganic fibres
    • B32B2262/101Glass fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00Composition of foam
    • B32B2266/02Organic
    • B32B2266/0214Materials belonging to B32B27/00
    • B32B2266/0278Polyurethane
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00Condition, form or state of the layers or laminate
    • B32B2305/02Cellular or porous
    • B32B2305/022Foam
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/30Properties of the layers or laminate having particular thermal properties
    • B32B2307/308Heat stability
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/72Density
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00Vehicles
    • B32B2605/003Interior finishings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00Ancillary operations in connection with laminating processes
    • B32B38/18Handling of layers or the laminate

Abstract

In the production of a laminated molding, in which (a) a middle layer (3) of isocyanate-filled flexible foam with glass fiber material (4) and barrier film cover (5) on both sides is pressed to a preform (1) and (b) made into a molding completely covered with decorative composite (2), the array of upper and lower barrier films, each layer (5) of nonwoven (6)/adhesive (7)/film (8), with the middle layer and glass fiber cover (4) between them, is placed in the press so that films (8) prevent isocyanate escaping and the upper film (8) acts as means of transporting the preform from the press. An independent claim is included for laminated molding in which the nonwoven (6) of layer (5) consists of specified polyester material.

Description

Die Erfindung betrifft ein Verfahren zur Herstellung eines mehrlagigen Formteiles aus mehreren funktionell für Verarbeitung und/oder Gebrauch optimal zu verwendenden Einzellagen. Dieses Formteil wird in der Fahrzeuginnenausstattung, insbesondere für Dachinnenverkleidungen eingesetzt.The The invention relates to a method for producing a multilayer Molding of several functional for processing and / or use optimally used individual layers. This molding is in the Vehicle interior equipment, used in particular for roof interior trim.

Solche selbsttragenden Dachinnenverkleidungen bestehen allgemein aus einer er Metalloberfläche des Fahrzeugdaches zugewandten Fläche mit der Aufgabe der schonenden Anpassung, einem dicken, steifen Mittelteil mit der Funktion des Selbsttragens über die gesamte Dachfläche und einer inneren Dekorschicht, wobei alle drei Schichten aus mehreren Einzelflächen bestehen können und das gesamte Formteil in einem oder mehreren Arbeitsgängen aus den Einzelkomponenten gefertigt wird.Such self-supporting roof linings generally consist of one he metal surface the vehicle roof facing surface with the task of gentle Adaptation, a thick, stiff middle section with the function of Self-carrying over the entire roof area and an inner decorative layer, wherein all three layers of several individual areas can exist and the entire molded part in one or more operations from the Individual components is manufactured.

Selbsttragende Dachinnenverkleidungen weisen eine Vielzahl von Funktionseigenschaften auf, wie die Eigenstabilität für den Selbsttrageeffekt ohne flächige Verklebung oder sonstige mechanische Befestigung mit der Innenseite des Fahrzeugdaches, die akustische Dämpfungswirkung zur Reduzierung der Innenfahrgeräusche und die optische Gestaltung der Formteilfläche in den Innenraum hinein. All diese Funktionseigenschaften sind gefragt bei vielfältigen statischen und dynamischen Fahrbeanspruchungen sowie in weiten Klimabereichen.self-supporting Headliners have a variety of functional properties, like the inherent stability for the Self-supporting effect without flat Gluing or other mechanical fastening with the inside of the vehicle roof, the acoustic damping effect for reduction the internal noise and the optical design of the molding surface into the interior. All these functional properties are required for a variety of static and dynamic driving conditions as well as in wide climates.

Diese Vielfalt an Eigenschaftsanforderungen kann hervorragend gelöst werden durch Verbundstoffe, also der flächige Zusammenschluss mehrerer Einzelflächen mit unterschiedlichsten Verarbeitungs- und/oder Gebrauchseigenschaften zu dem einzubauenden Formteil.These Variety of property requirements can be excellently solved by composites, so the area Combination of several individual areas with different ones Processing and / or performance characteristics to be incorporated Molding.

Dazu gibt es eine Vielzahl von innovativen Lösungen, wie die bindemittelgefüllte Glasfasermatte mit aufkaschiertem Innendekor nach DE 2700907 , die der Mehrschichtmaterialien nach DE 19956152 , bei der ein Schaumkunststoff mit Dekorflächen auf einer Bandpresse durch Klebefolien verbunden wird oder wie das mit Vliesstoff verstärkte Polyurethanformteil nach DE 3521828 , bei dem zwischen Glasfasermatten ein Sisalfaservlies eingelegt wird und in dessen Poren ein Reaktionsgemisch eingebracht wird, das dann den Polyurethanschaum bildet.There are a variety of innovative solutions, such as the binder-filled glass fiber mat with laminated interior decor DE 2700907 after the multi-layer materials DE 19956152 in which a foam plastic is bonded to decorative surfaces on a belt press by adhesive films or like the nonwoven reinforced polyurethane molded part after DE 3521828 in which a sisal fiber fleece is inserted between glass fiber mats and in whose pores a reaction mixture is introduced, which then forms the polyurethane foam.

EP 0248199 zeigt ein mehrschichtiges Formteil für Fahrzeuginnenausstattungen mit einem Kern aus Polyurethanschaum als mittlere Trägerschicht. Auf beiden Oberflächen dieser Trägerschicht befindet sich eine Auflage aus Acrylnitril-Butadien-Styrol-Folie. Hierbei ist die Trägerschicht aus Polyurethan an die Auflage angeschäumt. An der sichtbaren Seite des Innenraumverkleidungsteiles ist mit Hilfe einer thermoplastischen Klebefolie eine Dekorschicht angeklebt. Bei diesem mehrlagigen Formteil werden die bisher verwendeten Glasfasern durch Thermoplaste ersetzt. EP 0248199 shows a multilayer molding for vehicle interiors with a core of polyurethane foam as the middle carrier layer. On both surfaces of this support layer is a support made of acrylonitrile-butadiene-styrene film. Here, the carrier layer of polyurethane is foamed to the support. On the visible side of the interior trim part, a decorative layer is glued using a thermoplastic adhesive film. In this multilayer molded part, the glass fibers used hitherto are replaced by thermoplastics.

Diese und viele andere Lösungen führen oft zu Formteilen mit notwendigen Optimierungen hinsichtlich Gewicht und/oder Steifigkeit und/oder Elastizität und/oder Wärmestandfestigkeit und/oder Aussehen und erfordern meist komplizierte verfahrenstechnische Kompromisse und/oder hohe wirtschaftliche Aufwendungen.These and many other solutions to lead often to moldings with necessary optimizations in terms of weight and / or stiffness and / or elasticity and / or heat resistance and / or appearance and usually require complicated process engineering Compromises and / or high economic expenses.

Seit langem bewährt hat sich in der Fahrzeuginnenausstattung ein mehrschichtiges Formteil, gefertigt nach dem sogenannten Tramico-Verfahren nach DE 3213610 .Has proven itself for a long time in the vehicle interior a multilayer molding, made by the so-called Tramico method after DE 3213610 ,

Dabei wird ein poröser Polyurethan-Weichschaum mit Isocyanat getränkt und beidseitig mit Glasfaserrovings bedeckt. Auf eine Oberfläche dieser Schicht kommt ein Abdeckvlies, das gleichzeitig die Oberfläche des späteren Formteiles zum Innendach der Fahrzeugkarosserie bildet, versehen mit einer Klebefolie, die in der Presseinrichtung einmal als Barriere gegen das Austreten des Isocyanates wirkt und gleichzeitig die flächige Verbindung mit dem Abdeckvlies herstellt. Die andere Seite dieser mit Isocyanat getränkten und mit Glasfaserrovings abgedeckten Polyurethanweichschaumschicht bildet eine Polyurethanfolienabdeckung. Sie ist zu dem Glasfasermaterial mit einem Klebevlies versehen, um die Glasfaseranordnung verbindend zu fixieren. Die Polyurethanfolie hat neben der Abdichtungsfunktion gegen austretendes Isocyanat auch eine Transportfunktion. Ihre beiden überstehenden Ränder sind in einer Transportkette eingekluppt und führen nach der thermischen Reaktion in der Presseinrichtung die gesamte Schichtanordnung als Vorformteil heraus. Verfahrenstechnisch wird dann in einem zweiten Arbeitsvorgang in einem beheizten Werkzeug ein flammkaschierter Dekorverbund, wobei die Schaumschicht dieses Verbundes mit thermoplastischen Klebepunkten versehen ist, auf die Polyurethanfolie des Trägerteiles aufgebracht und mit diesem zum mehrschichtigen Formteil verbunden. Bei diesem Verfahren und bei dem damit entstehenden Produkt sind entsprechend den aktuellen Anforderungen hinsichtlich Qualität und Wirtschaftlichkeit folgende Nachteile zu nennen.

  • – Einsatz von zusätzlicher Schutzfolie zur Verhinderung von Verschmutzungen mit austretendem Isocyanat an den Arbeitsorganen der Presseinrichtung einschließlich damit verbundener zusätzlicher Entsorgungsaufgaben;
  • – Eine für die spätere Laminierung mit dem Dekorverbund geringe Oberflächenspannung der Polyurethanfolie;
  • – geringe Wärmestandfestigkeit an den Flächenverbundstellen zwischen Abdeckvlies und Sperrfolie;
  • – Hohe wirtschaftliche Anforderungen an einzelne Verbundkomponenten ein schließlich deren Vielfalt.
A porous polyurethane flexible foam is impregnated with isocyanate and covered on both sides with glass fiber rovings. On a surface of this layer is a cover fleece, which simultaneously forms the surface of the later molded part to the inner roof of the vehicle body, provided with an adhesive film, which acts as a barrier in the pressing device against the escape of isocyanate and simultaneously produces the surface connection with the Abdeckvlies. The other side of this isocyanate-impregnated and fiberglass-covered polyurethane flexible foam layer forms a polyurethane film cover. It is provided to the glass fiber material with an adhesive fleece to fix the fiberglass assembly connecting. In addition to the sealing function against escaping isocyanate, the polyurethane film also has a transport function. Your two protruding edges are caught in a transport chain and run after the thermal reaction in the pressing device, the entire layer arrangement as a preform. Processually, then in a second operation in a heated tool, a flame-laminated decorative composite, the foam layer of this composite is provided with thermoplastic adhesive dots, applied to the polyurethane film of the support member and connected thereto to the multilayer molding. In accordance with the current requirements with regard to quality and cost-effectiveness, the following disadvantages must be mentioned in this method and in the resulting product.
  • - Use of additional protective film to prevent contamination with exiting isocyanate on the working organs of the pressing device including related additional disposal tasks;
  • - A low surface tension of the polyurethane film for subsequent lamination with the decorative composite;
  • - Low heat resistance at the surface composite sites between cover fleece and barrier film;
  • - High economic demands on individual composite components, including their diversity.

Erfindungsgemäß besteht die Aufgabe der Erfindung darin, unter Beseitigung der vorgenannten Nachteile und unter Verwendung einer Mittelschicht auf Basis einer mit Isocyanat getränkten Weichschaumschicht aus Polyurethan mit beidseitiger Glasfaserabdeckung als Tragfähigkeit gebende Mittelschicht mit anderen Abdeckkomponenten verfahrenstechnisch zu einem wirtschaftlich und qualitativ guten mehrlagigen Formteil zu kommen.According to the invention the object of the invention therein, while eliminating the aforementioned disadvantages and using a middle layer based on one with isocyanate soaked Soft foam polyurethane layer with double-sided fiberglass cover as carrying capacity giving middle layer with other covering components procedurally to an economically and qualitatively good multilayer molding get.

Die Lösung der Aufgabenstellung erfordert erfindungsgemäß den Einsatz einer speziellen Vliesstoff/Klebstoff/Folie-Kombination, die beidseitig gleich eingesetzt werden soll, die verfahrenstechnisch den Wegfall der Schutzfolie an Arbeitsorganen der Presseinrichtung gestattet und die hohe Wärmestandsfestigkeiten und hohe akustische Wirksamkeit im mehrlagigen Formteil ergibt.The solution The task requires according to the invention the use of a special Nonwoven / adhesive / foil combination, used the same way on both sides is to be, the procedurally the elimination of the protective film allowed to work organs of the pressing device and the high thermal stability and gives high acoustic effectiveness in the multilayer molding.

Im folgenden wird die Erfindung anhand eines Ausführungsbeispieles in Zusammenhang mit einer Zeichnung näher beschrieben. Es zeigtin the The following is the invention with reference to an embodiment in connection closer with a drawing described. It shows

1 den schematischen Querschnitt eines mehrlagigen Formteiles. 1 the schematic cross section of a multilayer molded part.

Auf einem mit Isocyanat-Dispersion getränkten Polyurethan-Weichschaum als Mittelschicht 3 werden auf beiden Oberflächen Glasfaserrovings 4 aufgebracht und darauf auch beidseitig die erfindungsgemäße Vliesstoff/Klebstoff/Folie-Kombination 5 so angeordnet, dass jeweils die Folie 8 zur Glasfaserschicht 4 liegt, um einmal oben sowohl als Sperrschicht gegen einen Austritt der Isocyanat-Dispersion zu wirken als auch als Transportmedium für die gesamte Materialschichtung aus der Presseinrichtung heraus zu fungieren und in unterer Anordnung als Sperrschicht gegen den Austritt von Isocyanat zu wirken. Diese beiden Folien 8 der erfindungsgemäßen Vliesstoff/Klebstoff/Folie-Kombination 5 übernehmen auch die Aufgabe der Schutzfolie gegen Verschmutzungen der Arbeitsorgane der Presseinrichtung.On a wetted with isocyanate dispersion flexible polyurethane foam as the middle layer 3 become glass fiber rovings on both surfaces 4 applied and also on both sides of the nonwoven fabric / adhesive / film combination according to the invention 5 so arranged that in each case the foil 8th to the glass fiber layer 4 is once to act both above as a barrier against leakage of the isocyanate dispersion and to act as a transport medium for the entire material stratification from the pressing device out and to act in a lower arrangement as a barrier against the escape of isocyanate. These two slides 8th the nonwoven fabric / adhesive / film combination according to the invention 5 take over the task of protective film against contamination of the working organs of the pressing device.

Dabei besteht erfindungsgemäß die Vliesstoff/Klebstoff/Folie-Kombination 5 in ihrer Konstruktion und in ihrer verfahrenstechnischen Anwendung aus folgenden Komponenten:
Vliesstoff 6: Wasserstrahlverfestigtes Faser- oder Filamentvlies aus 100 % Polyester, Flächenmasse 30 bis 50 g/m2, ca. 80 bis 100 % Dehnung bei hoher Isotropie im Festigkeits/Dehnungsverhalten in Längs- und Querrichtung.
Klebstoff 7: Hochdruckpolyethylen-Pulver oder Polyolefin-Klebevlies, vorher auf die Vliesstoffoberfläche aufgebracht, Masse 20 bis 40 g/m2, Schmelzbereich 110 bis 140°C.
Folie 8: Polyolefinfolie im Massebereich von 30 bis 50 g/m2.
According to the invention, there is the nonwoven / adhesive / film combination 5 in their construction and in their process engineering application from the following components:
nonwoven 6 : Water-jet-strengthened fiber or filament fleece made of 100% polyester, basis weight 30 to 50 g / m 2 , about 80 to 100% elongation at high isotropy in the strength / elongation behavior in the longitudinal and transverse directions.
adhesive 7 High-pressure polyethylene powder or polyolefin adhesive nonwoven, previously applied to the nonwoven surface, mass 20 to 40 g / m 2 , melting range 110 to 140 ° C.
foil 8th : Polyolefin film in the mass range of 30 to 50 g / m 2 .

In der Presseinrichtung bei Einwirken von Hitze und Druck bildet das Isocyanat eine reaktive Bindung im Schaum der Mittelschicht 3, mit dem benetzten Glasfasermaterial 4 und mit der Folie 8 an deren Berührungsstellen. Außerdem entsteht jeweils in der Klebefuge zwischen Vliesstoff 6 und Folie 8 durch das Aufschmelzen des Klebstoffes 7 bei einer Temperatur von 110 bis 140°C zwischen den beiden thermoplastischen Klebesubstanzen eine Polymerverbindung mit einer späteren Wärmestandsfestigkeit von 110°C und höher. Die flächige Schichtung aller Einzellagen wird dazu in der Presseinrichtung zum Vorformteil 1 ausgeformt.In the pressing device on exposure to heat and pressure, the isocyanate forms a reactive bond in the foam of the middle layer 3 , with the wetted glass fiber material 4 and with the foil 8th at their points of contact. In addition, each arises in the glue joint between nonwoven fabric 6 and foil 8th by melting the adhesive 7 at a temperature of 110 to 140 ° C between the two thermoplastic adhesive substances, a polymer compound having a later thermal stability of 110 ° C and higher. The laminar layering of all individual layers is to preform in the pressing device 1 formed.

In einem nächsten Arbeitsgang erfolgt in einem Werkzeug das Aufkaschieren des Dekorverbundes 2, bestehend aus einem textilen Oberstoff 11, kaschiert mit einer Polyurethanschaumschicht 10 oder einem Vliesstoff 10, auf die untere Vliesstoffoberfläche 6 der Vliesstoff/Klebstoff/Folie-Kombination 5 durch den auf der Schaumstoffschicht 10 befindlichem Klebstoff 9 zum mehrlagigen Formteil.In a next step, the lamination of the decorative composite takes place in a tool 2 , consisting of a textile outer fabric 11 laminated with a polyurethane foam layer 10 or a nonwoven fabric 10 , on the lower nonwoven surface 6 the nonwoven / adhesive / film combination 5 through the on the foam layer 10 located adhesive 9 to the multilayer molding.

Das erfindungsgemäße mehrlagige Formteil besteht, wie 1 schematisch zeigt, von oben als die später am Fahrzeugdach anliegende Oberfläche des mehrlagigen Formteiles bis nach unten zur Fahrraumseite hin verfahrenstechnisch aus dem Vorformteil 1 und dem Dekorverbund 2 und materialtechnisch aus folgenden Komponenten:

  • – Vliesstoff 6 der Vliesstoff/Klebstoff/Folie-Kombination 5
  • – Klebstoff 7 der Vliesstoff/Klebstoff/Folie-Kombination 5
  • – Folie 8 der Vliesstoff/Klebstoff/Folie-Kombination 5
  • – Glasroving 4
  • – Mittelschicht 3
  • – Glasroving 4
  • – Folie 8 der Vliesstoff/Klebstoff/Folie-Kombination 5
  • – Klebstoff 7 der Vliesstoff/Klebstoff/Folie-Kombination 5
  • – Vliesstoff 6 der Vliesstoff/Klebstoff/Folie-Kombination 5
  • – Klebstoff 9 des Dekorverbundes 2
  • – Schaumstoffschicht 10 des Dekorverbundes 2
  • – Textiler Oberstoff 11 des Dekorverbundes 2.
The multilayer molding according to the invention consists, as 1 schematically shows, from the top than the later applied to the vehicle roof surface of the multilayer molded part down to the driving room side procedurally from the preform 1 and the decor composite 2 and material technology from the following components:
  • - Nonwoven fabric 6 the nonwoven / adhesive / film combination 5
  • - adhesive 7 the nonwoven / adhesive / film combination 5
  • - Foil 8th the nonwoven / adhesive / film combination 5
  • - Glass roving 4
  • - middle class 3
  • - Glass roving 4
  • - Foil 8th the nonwoven / adhesive / film combination 5
  • - adhesive 7 the nonwoven / adhesive / film combination 5
  • - Nonwoven fabric 6 the nonwoven / adhesive / film combination 5
  • - adhesive 9 of the decorative composite 2
  • - Foam layer 10 of the decorative composite 2
  • - Textile outer fabric 11 of the decorative composite 2 ,

Dieses mehrlagige Formteil erfüllt die modernen Funktionsansprüche an eine Fahrzeuginnenverkleidung, zum Beispiel an eine selbsttragende Dachhimmelverkleidung mit kostengünstiger Herstellung, hoher Wärmestandsfestigkeit von 110°C und mehr und hoher akustischer Wirksamkeit.This multilayer molding meets the modern functional requirements to a vehicle interior trim, for example to a self-supporting Headlining with cost-effective production, high Heat resistance of 110 ° C and more and high acoustic effectiveness.

Claims (7)

Verfahren zur Herstellung eines mehrlagigen Formteiles, bei dem eine Mittelschicht (3) aus mit Isocyanat gefülltem Weichschaum mit beidseitiger Glasfaseranordnung (4) und Sperrfolienabdeckung in einer Presseinrichtung zu einem Vorformteil (1) ausgeformt wird, das in einem zweiten Arbeitsgang ganzflächig mit einem Dekorverbund (2) zum mehrlagigen Formteil verbunden wird, gekennzeichnet dadurch, dass die obere und untere Sperrfolienabdeckung als Vliesstoff (6)/Klebstoff (7)/Folie (8)-Schicht (5) mit der dazwischen befindlichen Mittelschicht (3) und deren Glasfaserabdeckung (4) so in die Presseinrichtung eingefahren werden, dass die Folie (8) der Vliesstoff/Klebstoff/Folie-Schicht (5) oben und unten ein Durchdringen von beim Pressen austretenden Isocyanat verhindern und die Folie (8) oben als Transportmittel für das Ausfahren des Vorformteiles (1) aus der Pressvorrichtung fungiert.Process for producing a multilayer molded part, in which a middle layer ( 3 ) of isocyanate-filled flexible foam with double-sided fiberglass arrangement ( 4 ) and barrier film cover in a pressing device to a preform ( 1 ) is formed, which in a second operation over the entire surface with a decorative composite ( 2 ) is joined to the multilayer molding, characterized in that the upper and lower barrier film cover as a nonwoven fabric ( 6 ) / Adhesive ( 7 )/Foil ( 8th ) Layer ( 5 ) with the intermediate middle layer ( 3 ) and its glass fiber cover ( 4 ) are moved into the press device so that the film ( 8th ) the nonwoven / adhesive / foil layer ( 5 ) prevent the top and bottom from penetrating isocyanate exiting during pressing and the film ( 8th ) above as a means of transport for the extension of the preform ( 1 ) from the press device. Verfahren zur Herstellung eines mehrlagigen Formteiles nach Anspruch 1, gekennzeichnet dadurch, dass in der Presseinrichtung beim Einwirken einer Temperatur von 110 bis 140°C durch die Polymergleichheit von Klebstoff (7) und Folie (8) der Vliesstoff/Klebstoff/Folie-Schicht (5) zwischen Vliesstoff (6) und Folie (8) eine Polymerverbindung mit einer Wärmestandsfestigkeit von mindestens 110°C entsteht.Process for the production of a multilayer molded part according to claim 1, characterized in that in the pressing device when exposed to a temperature of 110 to 140 ° C by the polymer equality of adhesive ( 7 ) and foil ( 8th ) the nonwoven / adhesive / foil layer ( 5 ) between nonwoven fabric ( 6 ) and foil ( 8th ) a polymer compound with a thermal stability of at least 110 ° C is formed. Verfahren zur Herstellung eines mehrlagigen Formteiles nach Anspruch 1 und 2, gekennzeichnet dadurch, dass beim Aufkaschieren des Dekorverbundes (2), bestehend aus dem textilen Oberstoff (11) mit Flammkaschierung aufgebrachter Schaumstoffschicht (10) und darauf aufgesinterter Klebstoffpunkte (9), auf das Vorformteil (1) zwischen dem Vliesstoff (6) der Vliesstoff/Klebstoff/Folie-Schicht (5) und dem Dekorverbund (2) eine Wärmestandfestigkeit dieser Verklebung von mindestens 110°C entsteht.Method for producing a multilayer molded part according to claim 1 and 2, characterized in that when laminating the decorative composite ( 2 ), consisting of the textile outer material ( 11 ) with flame lamination applied foam layer ( 10 ) and on it glued adhesive dots ( 9 ), on the preform ( 1 ) between the nonwoven fabric ( 6 ) the nonwoven / adhesive / foil layer ( 5 ) and the decorative composite ( 2 ) a heat resistance of this bond of at least 110 ° C is formed. Verfahren zur Herstellung eines mehrlagigen Formteiles nach Anspruch 1 bis 3, gekennzeichnet dadurch, dass die Anordnung der Schichten in der Presseinrichtung des Vorformteiles (1) und in der Presse zum Aufkaschieren des Dekorverbundes (2) so ist, dass die Oberseite des mehrlagigen Formteils der Vliesstoff (6) der einen Vliesstoff/Klebstoff/Folie-Schicht (5) und die Unterseite des mehrlagigen Formteiles der textile Oberstoff (11) des Dekorverbundes (2) sind.Method for producing a multilayer molded part according to Claims 1 to 3, characterized in that the arrangement of the layers in the pressing device of the preform part ( 1 ) and in the press for laminating the decor composite ( 2 ) so that is the top of the multilayer molding of the nonwoven fabric ( 6 ) of a nonwoven / adhesive / foil layer ( 5 ) and the underside of the multilayer molded part of the textile outer fabric ( 11 ) of the decorative composite ( 2 ) are. Mehrlagiges Formteil, gekennzeichnet dadurch, dass der Vliesstoff (6) der Vliesstoff/Klebstoff/Folie-Schicht (5) ein wasserstrahlverfestigtes Faser- oder Filamentvlies aus 100 % Polyester mit einer Flächenmasse von 30 bis 50 g/m2 und einer Höchstzugkraftdehnung in Längs- und Querrichtung von 80 bis 100 % ist.Multilayer molding characterized in that the nonwoven fabric ( 6 ) the nonwoven / adhesive / foil layer ( 5 ) is a hydroentangled fiber or filament nonwoven made of 100% polyester with a basis weight of 30 to 50 g / m 2 and a maximum tensile elongation in the longitudinal and transverse direction of 80 to 100%. Mehrlagiges Formteil nach Anspruch 5, gekennzeichnet dadurch, dass der Klebstoff (7) der Vliesstoff/Klebstoff/Folie-Schicht (5) ein Hochdruckpolyethylen-Pulver oder Polyolefin-Klebevlies ist, eine Masse von 20 bis 40 g/m2 und einen Schmelzbereich von 110 bis 140°C aufweist.Multilayer molding according to claim 5, characterized in that the adhesive ( 7 ) the nonwoven / adhesive / foil layer ( 5 ) is a high density polyethylene powder or polyolefin adhesive nonwoven, has a mass of 20 to 40 g / m 2 and a melting range of 110 to 140 ° C. Mehrlagiges Formteil nach Anspruch 5 und 6, gekennzeichnet dadurch, dass die Folie (8) der Vliesstoff/Klebstoff/Folie-Schicht (5) aus Polyolefin besteht und eine Masse von 30 bis 50 g/m2 aufweist.Multilayer molding according to claims 5 and 6, characterized in that the film ( 8th ) the nonwoven / adhesive / foil layer ( 5 ) consists of polyolefin and has a mass of 30 to 50 g / m 2 .
DE200610003220 2006-01-24 2006-01-24 Production of laminated molding for use in vehicle interior e.g. as self-supporting roof lining involves pressing preform of isocyanate-filled flexible foam between glass fiber layers and barrier layers of nonwoven, adhesive and film Withdrawn DE102006003220A1 (en)

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Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3521828A1 (en) * 1985-06-19 1987-01-02 Pegulan Werke Ag Process for producing polyurethane foam mouldings reinforced with non-woven fabric mats
EP0248199A2 (en) * 1986-06-05 1987-12-09 J. H. Benecke AG Multilayer lining element
DE3213610C2 (en) * 1981-04-14 1990-08-09 Tramico Societe De Transformation Et D'applications Modernes A L'industrie Et Au Commerce, Puteaux, Hauts-De-Seine, Fr
US5725704A (en) * 1995-12-21 1998-03-10 Davidson Textron, Inc. Process for the production of a multi-layer composite article having fasteners affixed to a surface thereof and the article produced thereby
WO2000027671A1 (en) * 1998-11-11 2000-05-18 Rieter Automotive (International) Ag Vehicle rooflining and method for producing the same
DE19956152A1 (en) * 1999-11-23 2001-06-28 Schuller Gmbh Method of making a multi-layer material and multi-layer material
US20030087569A1 (en) * 2001-06-29 2003-05-08 Harris Philip Edward Ultraviolet resistant laminate and method of manufacture
DE102004029596A1 (en) * 2004-06-18 2005-12-29 Oertel Gmbh Compound nonwoven staple fiber fabric in one or more layers, as tarpaulins or packing materials, has a polymer coating or laminated film on one side to give strength without added weight

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3213610C2 (en) * 1981-04-14 1990-08-09 Tramico Societe De Transformation Et D'applications Modernes A L'industrie Et Au Commerce, Puteaux, Hauts-De-Seine, Fr
DE3521828A1 (en) * 1985-06-19 1987-01-02 Pegulan Werke Ag Process for producing polyurethane foam mouldings reinforced with non-woven fabric mats
EP0248199A2 (en) * 1986-06-05 1987-12-09 J. H. Benecke AG Multilayer lining element
US5725704A (en) * 1995-12-21 1998-03-10 Davidson Textron, Inc. Process for the production of a multi-layer composite article having fasteners affixed to a surface thereof and the article produced thereby
WO2000027671A1 (en) * 1998-11-11 2000-05-18 Rieter Automotive (International) Ag Vehicle rooflining and method for producing the same
DE19956152A1 (en) * 1999-11-23 2001-06-28 Schuller Gmbh Method of making a multi-layer material and multi-layer material
US20030087569A1 (en) * 2001-06-29 2003-05-08 Harris Philip Edward Ultraviolet resistant laminate and method of manufacture
DE102004029596A1 (en) * 2004-06-18 2005-12-29 Oertel Gmbh Compound nonwoven staple fiber fabric in one or more layers, as tarpaulins or packing materials, has a polymer coating or laminated film on one side to give strength without added weight

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