阅读说明：本技术 具有结构针刺地毯表面的机动车地板覆盖物、行李舱覆盖物或装载地板覆盖物 (Motor vehicle floor covering, luggage compartment covering or loading floor covering with structured needled carpet surface ) 是由 F·法尔克 V·舒尔策 M·迪克特 R·辛格 于 2020-01-09 设计创作，主要内容包括：本发明公开了一种用于机动车地板覆盖物、行李舱覆盖物或装载地板覆盖物的三维可成型丝绒地毯,所述的地毯在可见面具有通过刷子带中的结构化刷子产生的针刺结构。(A three-dimensional formable velour carpet for motor vehicle floor coverings, luggage compartment coverings or load floor coverings, said carpet having a needling structure on the visible side produced by structured brushes in a brush belt.)

1. A process for the production of a three-dimensional formable velour carpet having a structural needled, deformation-resistant surface for motor vehicle floor coverings, trunk coverings or load floor coverings, the carpet having a grammage of 180g/m²To 700g/m²Is characterized in that

Producing a structured velvet carpet from a starting nonwoven at a defined penetration depth setting, wherein

Brush belts are used which have different brushes and/or segments or partial regions of the brush arrangement and are provided with and profiled to a velour carpet with one or more sub-layers.

2. Method according to claim 1, characterized in that the structuring of the bristles is achieved by arranging the bristle segments, by different brush heights and/or by determined brush positions in the strip and/or the separation grid and/or the removal of the bristles.

3. A three-dimensionally shaped velour carpet for motor vehicle floor coverings, luggage compartment coverings or load floor coverings having a structured needled, deformation-resistant surface, the carpet having a grammage of 180g/m²To 700g/m²Further comprising one or more sub-layers, wherein the visible side of the carpet has an optional three-dimensional structured needled, abrasion resistant surface.

Technical Field

The invention relates to a method for producing a three-dimensionally shaped floor covering, luggage compartment covering or loading floor covering for a motor vehicle, the carpet surface having a needle-punched structure on the visible side, and the covering itself.

Background

The surface material of the motor vehicle itself is a velour carpet, which may have multiple sub-layers and may have foam or fibrous/non-woven insulation facing the vehicle body.

In particular, due to the development of electric vehicles, designs/styling have sought alternative solutions to the surface of formable carpets compared to plain, smooth flat needle-punched carpets, velour carpets and tufted carpets.

This configuration is also particularly suitable for use in luggage and loading floors for motor vehicles having a rear door (station wagon) and a folding rear seat back, since the exposed interior of the motor vehicle is visible from behind when the rear door is opened and the rear seat back is folded. As such, both the luggage compartment and the passenger compartment must exhibit a uniform, coordinated style.

In the prior art, various designs of carpet tiles for automotive floor coverings, luggage compartment coverings and load floor coverings are known, namely especially tufted carpets, velour carpets and flat needle carpets.

For tufted carpets, PA6.6, PA6, PP, rPA and PET, rPET and the corresponding biobased polyamides (PA 5.10; PA6.10) are used in particular; for velour carpets and flat needle-punched carpets, PET/PP, PA/PET and rPET are mainly used as yarn/fiber materials.

In the prior art, methods for producing velour carpets are known, see in particular DE 4409771 a1, DE 2900935C 2 and DE 102008026968 a 1.

Velour nonwovens are a fine needle-punched nonwoven, the production of fibre fleece in a prefabricated nonwoven material by needle-punching on a running, homogeneous brush belt. A velour nonwoven is called cut velour if it is cut to a defined fluff height in a further processing step.

Velour carpets differ from needle punched carpets in that they have a higher quality look and feel, as well as improved abrasion resistance.

Special methods for the homogenization of the stitch pattern in needle-punched nonwovens are described in US 9567698B 2, US 2016/0069006 a1, US 9260806B 2, US 2015/0259836 a1 and EP 2918719 a 1. In the production of flat needle-punched non-woven fabrics, short fibers are solidified between two metal plates by means of multiple needle punching in a carding and cross-lapping mode after the non-woven fabric is formed. In a further working step, a velour needle-punched nonwoven can be produced from a flat needle-punched nonwoven by repeated needle-punching in a brush belt. For both variants, it is necessary to thermally or chemically bond the staple fibers after needling in order to achieve good final strength.

The bonding of the fibers is mainly performed by means of foamed latex or acrylates. The use of latex or acrylate in combination with BiCo fibres (coPET/PET bicomponent fibres) is also common in practice. Furthermore, bonding is also achieved exclusively by BiCo fibers.

WO 2017/061970 a1 relates in particular to the bonding of carpet by bicomponent (BiCo) fibres. The optimization of the fiber fixation in the drying oven by the use of special slot nozzles (BiCo) is described here. Furthermore, it is known that: dispersed PE, EVA/PE blends, extruded PE, films, hot glue, thermoplastic dispersions and thermal bonding (EP 1598476B 1).

DE 2008439C [ US 3755055 ] describes a process in which a single-or mixed-color nonwoven fabric and a nonwoven fabric printed on one side with a pigment having a decorative pattern of one or more colors are laid one on top of the other, with the printed side of the nonwoven fabric facing away from the other unprinted nonwoven fabric, and then both nonwoven fabrics are needled one on top of the other, so that the unprinted nonwoven fibers are mixed with the printed nonwoven fibers to form a pile on the printed surface thereof, the printed decorative pattern of which becomes a flexible three-dimensional pattern.

DE 3904526 a1 discloses a floor covering and a method for its manufacture. In order to produce a floor covering consisting of two layers of needled nonwoven, wherein the upper layer is structured on its upper side and the lower layer is needled into the structured upper layer from the underside of the structured upper layer. The depth of the needling is significantly less than the thickness of the upper layer. By needling both layers together from the back of the upper layer, the structure of the upper layer is not destroyed. After needling, the two layers are additionally bonded by impregnating with adhesive through the upper layer.

In EP 0888743 a1[ US 2002/0029445 a1, US 6287407B 1, US 6398895B 1], a structured textile material for the cleaning textile sector made of at least two different base nonwovens is described. The technical teaching relates to a structured textile material made of at least two different needled base nonwoven fabrics, the base nonwoven fabrics having a structure obtained from at least one side needling, the needles used for the structured needling being fork needles or crown needles, the depth of the fork needles or crown needles being selected such that, upon needling, they are completely filled with fibers facing the needled base nonwoven fabric, the textile material having unmixed pure fibers in a pattern, on the base and on the reverse side. In the method for producing a structured textile material, on the one hand, a needled base nonwoven fabric comprising two melt fibers is laminated without activating the melt fibers, and then single-or double-sided structured needling is carried out, the melt fibers of the base nonwoven fabric being activated after the structured needling; on the other hand, before entering the structural needling machine, an intermediate layer made of a material capable of bonding two base nonwoven fabrics, in particular a tacky nonwoven fabric, is introduced between the two needled base nonwoven fabrics with melt fibers, the two base nonwoven fabrics and the intermediate layer being needled in one or both sides structurally to each other, and then the bonding between the two base nonwoven fabrics and the intermediate layer is produced by activating the melt fibers and the intermediate layer.

A graphic velour carpet and its production are described in WO 2011/045691 a 1. Two structured machines were used, each equipped with 2 needle plates; and a base nonwoven fabric and a top nonwoven fabric. The base nonwoven is transferred between two structuring machines onto the top nonwoven and needled on a second structuring machine to form the nonwoven. The needles on the needle board are arranged in a predetermined pattern. The adhesive is applied to the base nonwoven and the fibers of the nonwoven layer are then fixed/bonded.

Furthermore, it is also known to produce patterns on needle felts by means of various components, fibrous layers and various needling processes, see for example DE 10346473 a1 and WO 2011/065851 Al1 and the like.

DE 202009000775U 1 discloses a fibrous surface structure consisting of a visible-side needled nonwoven or fiber fleece (surface layer) and a fibrous fleece or fiber nonwoven (pattern layer), which are bonded to one another by needling with different needle types/needle types and/or needle arrangements and/or puncture directions and/or puncture depths. The pattern layer is pretreated, and the coloring of the pattern layer on the fiber and the coloring of the fiber are different from that of the surface layer; the pattern layer is also punched and/or cut out with the surface layer before needling; and is dyed and/or printed. In addition, a plurality of different pattern velours or pattern non-woven fabrics are used as the pattern layer. The surface layer is subjected to back needling and surface treatment.

All "structural needle-punching" applications, methods and devices and material structures described in the prior art relate to (non-single-layer) flat needle-punched non-woven carpets for motor vehicles, whose three-dimensional shaping is used for motor vehicle floor coverings, luggage compartment coverings or load floor coverings. Furthermore, no structuring of the velvet surface by the brush geometry and/or structuring of the brush was found to be achieved. There is no report on a non-destructive structure that retains its surface structure in a permanent manner during three-dimensional molding in contact with a heating field (tablet press), a radiation heating field, and the molding die itself.

Disclosure of Invention

In contrast to the prior art described above, the object of the present invention is therefore to provide a formable, structural needle-punched carpet which is able to lift the passenger compartment and/or the luggage compartment and/or the goods compartment of a motor vehicle with a "living room/pleasant atmosphere". In particular, the object of the invention is to introduce a permanent, wear-resistant surface pattern with a selectable three-dimensional structure, which is differently structured in the width and length of the carpet surface and which can withstand three-dimensional shaping into a motor vehicle floor covering or luggage compartment covering, in the course of the manufacture of velour carpets and/or needle-punched non-woven carpets.

In a first embodiment, the present invention relates to a method of producing a three-dimensional formable velour carpet having a structural needled, deformation-resistant surface for an automotive floor covering, trunk covering, or cargo floor covering, the carpet having a grammage of 180g/m²To 700g/m²Is characterized in that

Producing a structured velvet carpet from a starting nonwoven at a defined penetration depth setting, wherein

Brush belts are used which have different brushes and/or sections or partial regions of the brush arrangement and are provided with one or more sub-layers of velour carpet and are shaped.

The core of the invention is therefore the use of a velour carpet produced in a conventional standard process for the production of a floor covering, a luggage compartment covering or a loading floor covering for a motor vehicle, with structural needling, profiled suitable viewing surfaces, for needling or felting of the floor covering, the luggage compartment covering or the loading floor covering for a motor vehicle, solely by the arrangement of different brush/brush fibre heights and brush/brush fibre structures.

The width and length of the brush strip are set with a predetermined brush/brush fibre height and/or brush/brush fibre structure and needle type and/or geometry, so that a predetermined velvet surface structure is formed.

An advantage of the present invention is to provide a structural needle punched carpet that resists deformation properly/stably for the production of automotive floor coverings and luggage compartment coverings or load floor coverings without the need for additional production work steps in its production compared to standard needle punched carpet production.

The method of the invention-without additional non-woven layers, needling sections, needling machines or needle boards-can be realized in a "standard" arrangement only by the brush/brush fiber height and the brush/brush fiber structure, the finished brush tape mounting in width and length, and the needle geometry/type of needles.

Another embodiment of the present invention is a floor covering for a motor vehicle having a structural, stab-resistant, deformation-resistant surfaceThree-dimensionally shaped velour carpet for coverings, luggage compartment coverings or load floor coverings, the grammes per square metre of carpet being 180g/m²To 700g/m²And one or more sub-layers, wherein the visible side of the carpet has an optional three-dimensional structured needled, abrasion resistant surface.

Preferably, this should be done on the one hand on a single-layer needle-punched non-woven carpet and, secondly, on a double-layer velour carpet. In the case of the two-layer embodiment, additional color effects of different structures can also be needled.

Detailed Description

To produce a suitably shaped/stabilized structural needled floor covering, a pre-nonwoven of 80% commercially available 13dtex fibers having a fiber length of 60mm, PET fibers and 20% commercially available 6.7dtex fibers having a fiber length of 64mm, PET fibers was used as the starting nonwoven. The surface weight is 480g/m²。

The needle board is equipped with fork needles of the company Groz-Beckert, as follows:

in the penetration direction

1. Plate-type fork needle: 15X 17X 32X 40X 63.5V G9077

2. Plate-type fork needle: 15X 17X 32X 40X 63.5D G9077 DUR

In the velvet carpet shown in FIG. 1, the piercing depth was 6mm and the piercing density was 550 needles/cm²。

The brushes of the brush strip had a width of 4.5mm and a depth of 2mm, a reduced height, transverse to the direction of passage.

The structure of the surface is clearly visible.

FIG. 2 shows a portion of a partially constructed needled diamond surfaced velour carpet; the puncture depth here was 4mm, and the puncture density was 550 needles/cm²。