CN102459737B - 用于汽车应用的簇绒地毯 - Google Patents
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Abstract
本发明提供了一种用于在汽车应用中的簇绒地毯。地毯由绒毛层和至少一主背衬层组成。绒毛层具有绒毛重量并包含有膨化长丝(BCF)纱线,膨化长丝(BCF)纱线包含具有预定直径的预定数量的细丝。地毯以预定的规格被簇饰。BCF纱线由在50%到70%的伸长率时具有在2.6cN/dtex(百分之一牛顿每分特)和3.2cN/dtex之间的韧性的聚丙烯(PP)纱线构成,或者由在20%到40%的伸长率时具有在2.6cN/dtex到3.4cN/dtex之间的韧性的聚对苯二甲酸乙二酯(PET)纱线构成。
Description
技术领域
本发明总地涉及簇绒地毯,更具体地涉及用于汽车应用的簇绒地毯。
背景技术
在汽车工业中,簇绒地毯用于多种目的并使用在各种各样的应用场合中。一个这样的目的是噪音衰减。另一个目的是增加驾驶环境的舒适度。这些目的是通过车辆底板***、主底板、行李箱中板侧装饰包括货箱地板和行李架来实现的。
那些应用可以在人类的运输车辆诸如汽车、货车或卡车中发现。车辆底板***包括几层:表面层或绒毛层、主背衬层、背涂层、衬底层以及减振层(decoupler)。该减振层是与白车身(Body-in-White,BIW)相接触的层,其作用在于减弱BIW中来自客舱的任何噪音或振动。该减振层大体上以泡沫和纤维材料为基础。衬底层可以是吸收层或阻挡层并可以基于纤维以及泡沫的材料组合用以形成受控的多孔衬底。背涂层用于将簇绒牢固地保持在主背衬层中。可选择地,通过熔融将簇绒和主背衬层牢固地粘合在一起的热过程可以替代背涂层。主背衬层由纺织物或无纺材料形成。绒毛层由簇绒形成。绒毛层和主背衬层构成地毯,其中背涂层构成到衬底的区际层(intersectionallayer)。大体上在车辆底板***中,绒毛层和主背衬层形成地毯。
板侧装饰也可以在人类的运输车辆诸如汽车、货车或在卡车中找到。板侧装饰包含地毯、背涂层或其替代物以及如果必要的话包括第二背衬层或更多背衬层。地毯由绒毛层和主背衬层形成。
簇绒地毯的其他汽车应用可以是可选择的底板垫或其他的内部装饰件。
根据它的应用,装饰构造或垫构造以其结构和和设计的不同来满足要求。所述构造包括簇绒地毯,该簇绒地毯包括绒毛层和主背衬层、背涂层以及与应用的特定要求相适应的附加层。绝大多数挑战性的要求与用在车辆底板***中的簇绒地毯有关。
由于有割绒层或绒圈层,故,独立于应用,具有其绒毛层的簇绒地毯主要具有两种不同类型的地毯表面构造。簇绒地毯大体上包括诸如将地毯纱线的簇绒引入到其中的主背衬层的复合结构。簇绒形成绒毛层。主背衬层典型地由聚酰胺、聚酯、聚烯烃、棉或前述聚合物的混合物的非纺织材料或纺织材料形成。典型地,非纺织的主背衬层通过纺粘(spunbonding)形成。
在簇绒处理后,然后背涂层可以被施加到地毯构造的下侧,以牢固地将簇绒材料保持在主背衬层中。为簇绒以及主背衬层选择相同类型的合成材料在回收方面是有利的。背涂层由例如乳胶组成。具有背涂层的相同目的,通过挤出来将除了乳胶外的其他合成材料施加到地毯构造的下侧也是已知的。对于背涂层,可选择地,将簇绒材料保持在主背衬层中能够通过热过程来完成;其中簇绒和主背衬层被熔融在一起。
在用于汽车应用的簇绒地毯中使用的地毯纱线通常是一种包含有聚酰胺、聚酯纤维或聚烯烃的人造纱线。这些纱线是一种由一定数量的单丝构成的BCF纱线(膨化长丝,Bulked Continuous Filament yarns)。BCF纱线为已经被熔融纺纱、牵伸和纹理处理的成卷细丝。在汽车应用中用作地毯纱线的大多数普通的BCF纱线为聚酰胺(PA)。在技术上的发展已经产生了相比于用在簇绒地毯构造中的PA纱线的替代纱线。那些替代纱线包括聚对苯二甲酸乙二酯(PET)纱线和聚丙烯(PP)纱线。
在车辆地毯中支配性因素是成本,进一步地,通过磨损、应力致白以及重量作为用在汽车应用中的地毯的最重要的特性来评估簇绒地毯,品质的其他方面为所用材料的可清洁性、美观度、触觉感以及可回收利用性。
提高地毯技术的希望已经在最大的磨损特性和最小的重量之间做出了妥协以使成本最优化。为了满足标准的磨损规格,构成簇绒地毯需要一定重量的材料。磨损能够根据DIN 53 754(德国工业标准,German IndustrialStandard)测试。这种程序是一种通过旋转的样品支撑平台以及双砂轮型机器来测定装饰材料的耐磨性的方法。当样品旋转时,轮子压到样品的绒毛层上。当样品在一定数量的旋转后,测量其重量损失并评估其视觉外观。重量损失表明耐磨性或者在泰伯工业(Taber Industries)的测试装置测试后的泰伯磨损(Taber abrasion)。另一种由泰伯测试导致的结果是应力致白。物理的或视觉的外观被改变了。这种影响由光反射的变化而导致,光反射的变化是因为细丝由于磨损而导致的小部分的机械损伤而产生的。
通过将PP纱线用作地毯纱线,材料的重量由于磨损规格必须相对于PA纱线增加。另一方面,PP纱线的簇绒地毯相比于PA纱线的簇绒地毯具有更高的耐沾污性;可清洁性是用在车辆中的地毯的重要特性。
使用PET纱线作为地毯纱线使其铺成的地毯不如PA纱线铺成的地毯耐磨,并且推荐仅仅用于轻度到中度的磨损条件。PET纱线也具有天然的耐沾污性的特性,其避免PA纱线由于其极易于着色而需要应用耐沾污性化学制品的问题。
发明内容
本发明的目的是提供一种具有高的耐沾污性的地毯,其由聚丙烯(PP)纱线或聚对苯二甲酸乙二酯(PET)纱线制成,这种地毯在未增加地毯的重量或制造成本的情况下表现出改进的耐磨性。
本发明的上述目的的方案由权利要求1的特征给出。该目的通过具有绒毛层和至少一主背衬层的簇绒地毯来解决,其中绒毛层具有绒毛重量并且包含有膨化长丝(BCF)纱线。BCF纱线包含有预定数目的具有预定直径的细丝。BCF纱线由在50%到70%的伸长率时具有在2.6克力/分特(cN/dtex,百分之一牛顿每分特)和3.2克力/分特之间的韧性的聚丙烯(PP)纱线构成,或者由在20%到40%的伸长率时具有在2.6克力/分特到3.4克力/分特之间的韧性的聚对苯二甲酸乙二酯(PET)纱线构成。
关于不同类型的地毯以及BCF纱线的广泛变化的研究已经显示出,用于汽车应用的地毯的耐磨性取决于所用的BCF纱线以及其材料的物理特性。韧性是那些物理特性的其中之一。为了达到预定的韧性,纱线在其生产过程中被拉伸到一定的程度。细丝越被拉伸,韧性就变得越高。由于有拉伸比的限制,故拉伸纱线在某一点后将导致细丝断裂。在强度方面过去的经验基本认为,对于提高耐磨性能而言不需要较高的韧性,并且此外在纱线生产过程中产生抽丝问题,因此,BCF PP纱线和BCF PET纱线在最适宜水平的韧性上被制造从而具有好的流动性能(没有断丝)。与目前的信念相反,看起来,韧性增强到一定程度,PP或PET纱线并未增加断丝(具有同样的流动性能),使得地毯的磨损性能增加。看起来,PP纱线或PET纱线当它们在高韧性区内生产时就抗磨性而言具有有益的性能。因此,通过增加韧性,可以结合PET纱线或PP纱线的优点在耐沾污性上超过PA纱线并具有改进的抗磨性。
关于簇绒地毯的磨损性能,通过使用在50%到70%的伸长率时具有2.6克力/分特(百分之一牛顿每分特)到3.2克力/分特之间的韧性的BCF PP纱线而得到最好的结果。较优地,所用的PP纱线的韧性在50%到65%的伸长率时处于2.8克力/分特(百分之一牛顿每分特)到3.1克力/分特的范围内。令人惊讶地,这种特性也适用于BCF PET纱线。关于簇绒地毯的磨损特性,通过使用在20%到40%的伸长率时具有2.6克力/分特(百分之一牛顿每分特)到3.4克力/分特的韧性的BCF PET纱线而得到最好的结果。较优地,所用的PET纱线的韧性在25%到35%的伸长率时处于2.8克力/分特(百分之一牛顿每分特)到3.2克力/分特的范围。
为了减少地毯的重量,单丝的直径被减少。无论是PP纱线还是PET纱线,细丝的直径处于5~20dpf(分特每丝,decitex per filament)。较优地,用来制造簇绒地毯的PP纱线具有6~12dpf的直径。对于结合有磨损性能和特定韧性的PP纱线最好的结果通过7dpf的直径给出。较优地,用于制造簇绒地毯的PET纱线具有10~20dpf的直径。对于结合有磨损性能和特定韧性的PET纱线最好的结果是通过15dpf的直径给出。改性率应当接近于一以在细丝直径上具有高的一致性。典型地,对于BCF纱线,改性率在0.9和1.1之间。
为了达到与通常使用的地毯纤维相当的磨损性能,诸如PA,通过制造具有纤细的分特每丝(dpf)的PP纱线的地毯而使用重量上较少的材料或者通过制造具有纤细的分特每丝(dpf)的PET纱线而相当于使用重量上较少的材料。PP纱线包括120到150根细丝,较优地包括130到140根细丝。重量相对性能的最佳比例可以以135根细丝的PP纱线来实现。PET纱线包括70到100根细丝,较优地为75到90根细丝。重量相对性能的最佳比例可以以80根细丝的PET纱线来实现。
每平方米细丝的数量也影响着簇绒地毯的触觉感或触摸感;通过更多数量的细丝来增强触觉感。
根据DIN 53754标准的磨损测试已经显示与PA纱线制造的已知地毯相当的耐磨性。根据本发明,由于韧性增加,绒毛层的耐磨性是优于本领域已知的PP纱线或PET纱线的簇绒地毯。
PP细丝以及PET细丝以不同的横截面形状制造,诸如圆形的、矩形的、多边形的或其他形式的横截面形状以及中空的或带芯的以及带壳的细丝。根据本发明,PP或PET的BCF纱线有利地由三叶形类型的细丝构成用以制造地毯。
根据本发明,簇绒地毯的绒毛重量是200gsm(克每平方米,grams persquare meter)到750gsm,其取决于在汽车地毯铺设的技术领域中的应用。例如,根据本发明具有PP纱线或PET纱线的地毯的绒毛重量处于250gsm到450gsm的范围中,其中所述地毯用在具有最高磨损标准的车辆底板***中。PP或PET相比于用在簇绒地毯中的其他人造纤维,考虑到增加簇绒地毯的汽车应用的环境证书的愿望,低重量同回收利用可能性一起越来越重要。根据本发明用在地毯中的BCF纱线以及主背衬层可以由20%到80%的回收的工业化后的废物制成。
在汽车应用中地毯的一种染色类型是匹染(piece dyeing)。在匹染中,地毯以白色生产并在簇绒处理后应用背涂层之前染色。另一种染色类型用于簇饰BCF纱线,其为纺前染色纱(solution dyed yarn)的类型。由于簇绒地毯准备在簇饰后使用,故纺前染色工艺在制造上具有优点。有利地,PP纱线是纺前染色纱,然而由PET纱线制成的地毯通常是匹染的地毯。
根据本发明的应用,为了达到视觉的和触觉的特性,在制造过程中,对于较纤细的PP纱线,簇饰的规格较优地选在5/64英寸。在PET纱线的情况下,5/64英寸、1/10英寸的规格是优选的。簇饰的规格的选择也影响应力致白,当地毯由于底板或装饰件的轮廓而产生形状时,其表现出,每平方米的细丝越多,应力致白就越少。也可以被用于两者之中任一种聚合物的通常的簇饰规格为1/8英寸、5/32英寸以及1/10英寸。
附图说明
根据附图从下面对优选的实施方式的详细说明,本发明的上面的以及其他的优点对于本领域的技术人员来说将是显而易见的,其中:
图1是车辆底板***的示意性的横截面图;
图2是根据本发明的簇绒的割绒地毯的示意性的横截面图。
具体实施方式
本发明大体上涉及车辆的底板***、行李箱板侧装饰、可选的垫子或其他的内部装饰件以及更具体地,涉及簇绒的PP地毯或簇绒的PET地毯以及其生产方法。
参考图1,示出了大体上根据已知的现有技术的底板***1的实施方式。车辆底板***1包括三个主要组成部分,第一个主要组成部分为具有装饰性的纤维顶层3的地毯2,第二个主要组成部分为衬底4和第三个主要组成部分为具有声音和振动衰减层的减振层5。减振层5是与车辆的白车身、车身6接触的层,该减振层大体上以泡沫和纤维材料作为基础。
衬底4可以是吸收体或阻隔层,并可以以纤维以及泡沫的组合材料作为基础用以形成被控的多孔衬底。
地毯2由绒毛层和主背衬层两层形成。装饰性的顶层3由成簇绒状的纱线形成并构成绒毛层。簇绒被缝合成主背衬层。该主背衬层由纺织材料或非纺织材料形成。绒毛层和主背衬层构成地毯,其中背涂层构成到衬底的区际层。大体上在车辆底板***内,绒毛层和主背衬层形成地毯。
参考图2,根据本发明以示意图示出了成簇绒状的割绒地毯2的实施方式。割绒以及圈绒地毯2的结构除簇绒7的特征外均是相同的。簇绒地毯包括引入到主背衬层8中的簇绒7。然后在地毯2的上侧将该簇绒割开。根据本发明,绒毛层7和主背衬层8形成簇绒地毯。为了将簇绒7在主背衬层8中锁定在它们的位置上,在本技术领域中有几种已知的可能性。例如为了将簇绒7保持在主背衬层8中,背涂层9相邻于主背衬层8而形成。或者,簇绒7和主背衬层在地毯的下侧上被熔融在一起。取决于底板***中的位置或其他汽车应用以及地毯2的所希望的功能,可以将第三或更多的背衬层附接成邻近于背涂层9。
簇绒7形成了被车辆的使用者看到并感觉到的绒毛层。该绒毛层由成簇绒状的PP或PET纱线构成,该PP或PET纱线包括预定数量的细丝。由于纤细的细丝,故根据本发明的地毯每平方米的重量不会超过如本领域中已知的所制造的地毯的重量。
Claims (14)
1.一种用于在汽车应用中的簇绒地毯,具有绒毛层和至少一主背衬层,其中,所述绒毛层具有绒毛重量并包含有膨化长丝(BCF)纱线,所述膨化长丝(BCF)纱线包含有预定数量的具有预定直径的细丝,其特征在于,所述膨化长丝纱线由在50%到70%的伸长率时具有在2.6cN/dtex(克力/分特)(百分之一牛顿每分特)和3.2cN/dtex(克力/分特)之间的韧性的聚丙烯(PP)纱线构成。
2.根据权利要求1所述的地毯,其特征在于,所述细丝的所述预定直径为5~20dpf(分特每丝)。
3.根据权利要求1或2所述的地毯,其特征在于,所述细丝的所述预定数量为所述膨化长丝纱线的70~150根细丝。
4.根据权利要求3所述的地毯,其特征在于,所述聚丙烯纱线包括120~150根细丝。
5.根据权利要求4所述的地毯,其特征在于,所述纱线包括三叶形类型的细丝。
6.根据权利要求5所述的地毯,其特征在于,所述绒毛重量为200gsm(克每平方米)到750gsm。
7.根据权利要求6所述的地毯,其特征在于,所述地毯在簇绒处理后被匹染。
8.根据权利要求6所述的地毯,其特征在于,所述纱线是纺前染色型纱线。
9.根据权利要求8所述的地毯,其特征在于,主背衬层和所述膨化长丝纱线为相同类型的聚丙烯合成材料。
10.根据权利要求9所述的地毯,其特征在于,一个或多个由与所述地毯相同类型的合成材料制成的附加层附接到所述地毯的下侧。
11.一种生产具有根据权利要求1至6中任一项所述的簇绒地毯的方法,其特征在于,将所述膨化长丝纱线以5/64英寸的规格簇饰到主背衬层上,其中簇绒是缝合的,并且通过挤出或乳胶应用或热过程将背涂层施加到所述簇绒上以将成簇绒状的纱线固定到所述主背衬层上。
12.根据权利要求11所述的方法,其特征在于,在施加所述背涂层之前,所述簇绒地毯被匹染。
13.根据权利要求11或12所述的方法,其特征在于,所述主背衬层包含有与所述簇绒相同类型的合成材料。
14.根据权利要求13所述的方法,其特征在于,所述纱线和所述主背衬层包含有20%-80%的再生的后工业废物。
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- 2010-05-17 ES ES10722331T patent/ES2467340T3/es active Active
- 2010-05-17 US US13/321,496 patent/US20120064281A1/en not_active Abandoned
- 2010-05-17 PL PL10722331T patent/PL2432925T3/pl unknown
- 2010-05-17 CA CA 2756922 patent/CA2756922C/en not_active Expired - Fee Related
- 2010-05-17 RU RU2011151639/12A patent/RU2541285C2/ru not_active IP Right Cessation
- 2010-05-17 CN CN201080022712.3A patent/CN102459737B/zh active Active
- 2010-05-17 MX MX2011012208A patent/MX2011012208A/es active IP Right Grant
- 2010-05-17 JP JP2012511245A patent/JP5619150B2/ja not_active Expired - Fee Related
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- 2010-05-17 EP EP20100722331 patent/EP2432925B1/en active Active
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Also Published As
Publication number | Publication date |
---|---|
WO2010133531A1 (en) | 2010-11-25 |
CN102459737A (zh) | 2012-05-16 |
CA2756922C (en) | 2015-02-10 |
RU2011151639A (ru) | 2013-06-27 |
MX2011012208A (es) | 2011-12-16 |
ES2467340T3 (es) | 2014-06-12 |
US20120064281A1 (en) | 2012-03-15 |
JP5619150B2 (ja) | 2014-11-05 |
CA2850822C (en) | 2015-08-25 |
JP2014240271A (ja) | 2014-12-25 |
PL2432925T3 (pl) | 2014-08-29 |
EP2432925A1 (en) | 2012-03-28 |
CA2756922A1 (en) | 2010-11-25 |
CA2850822A1 (en) | 2010-11-25 |
JP2012527370A (ja) | 2012-11-08 |
CN104074005A (zh) | 2014-10-01 |
EP2432925B1 (en) | 2014-03-12 |
RU2541285C2 (ru) | 2015-02-10 |
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