CN1110223A - 层体、其制造方法及其应用 - Google Patents

层体、其制造方法及其应用 Download PDF

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CN1110223A
CN1110223A CN94120070A CN94120070A CN1110223A CN 1110223 A CN1110223 A CN 1110223A CN 94120070 A CN94120070 A CN 94120070A CN 94120070 A CN94120070 A CN 94120070A CN 1110223 A CN1110223 A CN 1110223A
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fiber net
layer body
matrix fiber
sheath
layer
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R·嘎迪尔
G·菲斯特
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Empe-Werke Ernst Pelz GmbH and Co KG
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Abstract

具有由含有热塑性塑料纤维的增强基质纤维网 形成的平面支撑部件的层体，该纤维网的至少一侧有 塑料护层，其特征在于，基质纤维网与护层通过使用 压力和热经含热塑性成分的中间层相结合，中间层的 材料是与基质纤维网的塑料纤维的材料不同或相同 并且其软化温度高于基质纤维网的塑料纤维。此外 本发明还公开了该层体的制造方法及其应用。

Description

本发明涉及一种层体，该层体具有由含热塑性塑料纤维的增强的基质纤维网形成的平面支撑部件，该纤维网的至少一侧有塑料护层，本发明还涉及该层体的制造方法及应用。
上述类型的层体，例如由聚酯纤维构成的纤维网的模制件（如在DE-A 4041394中所述），是将它先加热到塑料纤维的软化温度以上，然后在冷的或再在热的设备中于压力下成形并接着冷却而制成的。由此制成不易弯曲的模制件，它以后例如可用作机动车辆的衬里部件。
还已知，这类层体不是由纯塑料纤维如聚酯纤维制造的，而是由混合纤维网例如由黄麻和聚酯纤维制造的，如在GB-A2090849中所述，或是由亚麻纤维和热塑性聚合物如聚丙烯制成的，如在US-A4323625所公开的，以及由亚麻或其它木质纤维素纤维和聚丙二醇或聚酯多元醇制成的，如US-A4546039所公开的。还已知含双组分纤维（例如30-50%重量聚丙烯/聚乙烯双组分纤维）的亚麻纤维的应用。
如应用这类增强纤维网制造这种类型的层体，通常必要的是，按压力工序将护层贴到已经增强的基质纤维网上，护层的例子有或是层体前侧装饰层和/或保护薄片或是层体后侧的保护衬垫，该护层一般由温度敏感材料构成，例如（尤其聚氯乙烯）泡沫薄片，塑料、尤其聚氯乙烯密实薄片，温感装饰材料或聚氨酯软泡沫，因为尤其在使用混合纤维的纤维网时由于基质纤维网的高非热塑性纤维部分不能充分粘贴到护层上，即使试图用下述方式改进护层对基质纤维网的粘贴，即将棉织物或类似物贴到相邻于基质纤维网的护层上也不行。对此原因如下：
首先，如果未将护层加热到其软化点以上的温度，那么基质材料的热塑性部分和护层材料之间只有少量的粘合力。由于基质纤维网中非热塑性纤维部分，降低了基质纤维网中能粘合的热塑性纤维对护层的接触点数目，所以用棉织物或类似物作为粘合剂不能产生足够的粘合。将温感护层加热到其软化温度是不可能的，因为在加压时例如装饰的结构化表面将受到损坏。另一方面，由于基质纤维网的松软结构在足够的加热时将贮存很多的热能，因此不能进行装饰层的加热。
通过使用强冷压工具不会防止尤其是装饰层的热损害，因为如果界面温度太低，在例如于邻接基质纤维网的护层的塑料保护薄片具有太低表面温度时，在变形区域将出现白色破裂作为缺陷。还是在强冷压工具情况下，在使用泡沫薄片代替密实薄片做护层时及在具有软泡沫底层的护层时，附加散热太少，因此一般将部分地破坏泡沫结构。
因此本发明的任务是，制造一种上述类型的层体，其中在唯一的压合或包覆工序中通过使用压力和热能同时增强基质纤维网并使其与温感护层可靠地结合。此外还提供制造这种层体的方法及其应用。
根据本发明，在所述类型层体的情况下由此完成该任务，即通过使用压力和热经含热塑性部分的中间层来粘合基质纤维网和护层，中间层材料可以不同或相同于基质纤维网的塑料纤维，并且其软化温度高于基质纤维网的塑料纤维的转化温度。
这里可以预先规定，基质纤维网含有聚乙烯纤维。
此外可以预先规定，基质纤维网含有聚丙烯纤维。
本发明还可以预先规定，其质纤维网是热塑性塑料纤维和天然纤维的混合纤维纤维网。
此外本发明建议，基质纤维网含黄麻纤维。
还可预先规定，基质纤维网含亚麻纤维。
本发明还预先规定，基质纤维网还含有西沙尔麻纤维。
此外本发明还建议，基质纤维网含有棉纤维。
还可预先规定，基质纤维网含有羊毛纤维。
此外本发明预先规定，基质纤维网的面积比重为500至3000g/m2。
最后本发明建议，基质纤维网的面积比重为1500至2500g/m2。
此外还预先规定，基质纤维网的面积比重为大约2000g/m2。
本发明还预先规定，基质纤维网由20-80%（重量）塑料纤维和80-20%（重量）天然纤维构成。
此外优选的是，基质纤维网含有大约相等重量份的塑料纤维和天然纤维。
本发明还建议，中间层是纤维网。
此外该纤维网可以是聚酯纤维网。
同样本发明建议，用泡沫薄片作中间层。
进一步可以预先规定，中间层的面积比重为100至500g/m2。
本发明还预先规定，中间层的面积比重为大约300g/m2。
可以预先规定，护层经中间层与基质纤维网相结合。
此外护层可以是保护薄片、保护衬垫或装饰层。
此外本发明预先规定，护层由聚氯乙烯构成。
需要时可预先规定，护层、尤其在用作装饰层时，由装饰材料构成。
此外优选的是，在护层与中间层之间是与护层结合的发泡层。
根据本发明的一个优选实施方案，基质纤维网具有关于塑料纤维材料的密度梯度，其中例如面向护层或塑料中间层一侧具有比相邻位置的背侧高的塑料含量。于此同时，相应密度变化或者是连续的，例如通过气体动力学的纤维网铺设产生，或者是不连续的，例如通过形成多层使基质纤维网产生非连续性。
本发明涉及本发明类型的平面层体的制造方法，其中含有热塑性塑料纤维的基质纤维网通过使用压力和热增强并且在其至少一侧与含塑料的护层相结合，该方法的特征在于，首先将基质纤维网加热到比基质纤维网中塑料纤维的软化温度高的温度;接着使已加热的基质纤维网、与其相邻的含热塑性部分的中间层以及未预热的护层经受一共同的压力工序，由此不仅增强了基质纤维网，而且也使其与护层相结合。其中中间层的热塑性部分可以与基质纤维网的塑料纤维的材料不同或相同和它的软化温度高于基质纤维网的塑料纤维以及它是未预热的。
与此同时可预先规定，借助热空气流进行基质纤维网的加热。
此外可预先规定，预热后先预压缩基质纤维网，例如压至比所需最终厚度高1mm的厚度。对此有利的是，在最后制造层体时可使用低一些的压力，其中尤其不损坏装饰层。预压缩的另一个优点在于，在与护层和中间层合在一起之前基质纤维网就已经具有了平滑的表面。
本发明还建议，在与基质纤维网合在一起之前将中间层与护层结合在一起。
此外本发明还预先规定，中间层与护层粘合在一起。
根据本发明，还预先规定，用于基质纤维网的护层也要预加热，虽然加热的温度高于室温，但低于基质纤维网的预热温度。
对此护层的预热温度优选在80和120℃之间。
此外建议，在由预热的基质纤维网、未预热的中间层和未预热或只低温预热的装饰层构成的板叠合在一起之前，将基质纤维网加热到大约200℃。
还可预先规定，在温度为大约60℃进行压合工序。
此外本发明建议，压合时间为30到140秒。
有利的是压合时间为大约90秒。
此外本发明表明，本发明的层体可用于机动车辆的衬里饰面，包装材料和/或家俱的构件。
令人惊奇的知识作为本发明的基础，成功之处在于，在一个唯一的压合或包覆工序中实现温感保护材料与基质纤维网的有效结合与基质纤维网的增强，且不存在损害护层材料的危险，如果基质纤维网含有高含量非热塑纤维、尤其天然纤维时，在基质纤维网和护层之间设置一薄中间层，优选聚酯层。一方面，中间层充分保护了护层不受热基质纤维网的不适宜的高热传递的影响，另一方面，即使中间层的软化温度可能使中间层的纤维产生表面软化，也能通过中间层实现对基质纤维网的很好的粘合。
根据本发明的方法，还可以使用塑料或假定背侧带有温感软泡沫的织物材料构成的装饰层材料一步压合成型。层体背侧的护层可以是薄片，例如保护薄片，还可以是保护衬垫或类似物，或是保护薄膜。所有这些构件（需要时它们可预热）可以用一步法压合工序成型。
由下文给出本发明的其它特征和优点，其中借助附图所示的实施例详细说明。其中表示：
图1：以对层体平面垂直剖面表示的本发明层体的第一实施例;
图2：相应于图1描绘的本发明层体的另一实施例;
图3：本发明层体的第三实施例。
如图1所示，在所示实施例中本发明的层体具有一基质纤维网10，它涉及一混合纤维网，由50%（重量）亚麻纤维和50%（重量）聚乙烯/聚丙烯双组分纤维构成并且具有平面比重2000g/m2。与基质纤维网10连接的是中间层12，它是平面比重为300g/m2的聚酯纤维网，例如可以Roy PoloE商品名称由市场购得。由图1可以看出，与中间层12连接的是装饰层14（PVC装饰层，例如Beneke公司的市售产品）。
在图2的实施例中，与已在图1中描述过的中间层12连接放置的是纯软泡沫（“Molto-Schaum”）的泡沫层18，其上又是装饰层14。
按照图3说明的实施形式，层体又是由基质纤维网10、中间层12和装饰层14构成，如上所述，但基质纤维网10背侧还设有另一中间层12，它或又是由上述聚酯纤维网或由一种泡沫材料构成，其上装置一这里只图示说明的保护衬垫20及一薄膜，需要时薄膜形成保护薄膜。
按照本发明的方法，以下述方法进行层体的制造。
首先将基质纤维网加热到温度为200℃。接着将如此预热的基质纤维网、中间层12（图1和3）和装饰层14，需要时在中间放入的泡沫层18（如图2所示），以及有保护薄膜的保护衬垫20在压制设备中以温度60℃合在一起，对此以压力保持时间为90秒进行该压合工序。
如果应在层体中嵌入连接件，例如金属或塑料夹子支持物以接纳塑料夹，可将它们与层体一起放入到压制设备中并在共同的压制工序中压紧。
如此得到层体，其中基质纤维网10与保护材料得到有效结合，未观察到过热负载对保护材料的损害。
上述说明书，附图及权利要求中所公开的本发明的特征不仅单独而且以任意组合来以不同实施方式实现本发明时都可能是必要的。
符号
10  基质纤维网
12  中间层
14  装饰层
18  发泡薄片
20  含保护薄片的保护衬垫

Claims (41)

1、层体，该层体具有由含热塑性塑料纤维的增强基质纤维网形成的平面支撑部件，该纤维网的至少一侧有塑料护层，其特征在于，通过使用压力和热经含热塑性成分的中间层(12)将基质纤维网(10)和护层(14、18)结合在一起，其中中间层(12)的材料与基质纤维网的塑料纤维的材料不同或相同并且其软化温度高于基质纤维网的塑料纤维。
2、按照权利要求1的层体，其特征在于，基质纤维网（10）含有聚乙烯纤维。
3、按照权利要求1或2的层体，其特征在于，基质纤维网（10）含有聚丙烯纤维。
4、按照权利要求1至3之一的层体，其特征在于，基质纤维网（10）是热塑性塑料纤维和天然纤维的混合纤维纤维网。
5、按照权利要求4的层体，其特征在于，基质纤维网（10）含有黄麻纤维。
6、按照权利要求4或5的层体，其特征是，基质纤维网含有亚麻纤维。
7、按照权利要求4至6之一的层体，其特征在于，基质纤维网（10）含有西沙尔麻纤维。
8、按照权利要求4至7之一的层体，其特征在于，基质纤维网（10）含有棉纤维。
9、按照权利要求4至8之一的层体，其特征在于，基质纤维网（10）含有羊毛纤维。
10、按照权利要求1至9之一的层体，其特征在于，基质纤维网（10）的平面比重为500至3000g/m2。
11、按照权利要求10的层体，其特征在于，基质纤维网（10）的平面比重为1500至2500g/m2。
12、按照权利要求1的层体，其特征在于，基质纤维网（10）的平面比重为2000g/m2。
13、按照权利要求4至12之一的层体，其特征在于，基质纤维网（10）由20-80%（重量）塑料纤维和80-20%（重量）天然纤维构成。
14、按照权利要求13的层体，其特征在于，基质纤维网（10）含有大约等重量份的塑料纤维和天然纤维。
15、按照权利要求1的层体，其特征在于，含有热塑性成分的中间层（12）是一种纤维网。
16、按照权利要求15的层体，其特征在于，中间层（12）是一种聚酯纤维网。
17、按照权利要求1的层体，其特征在于，含热塑性成分的中间层是一种发泡薄片。
18、按照上述权利要求之一的层体，其特征在于，中间层（12）的平面比重为100至500g/m2。
19、按照权利要求18的层体，其特征在于，中间层（12）的平面比重为约300g/m2。
20、按照上述权利要求之一的层体，其特征在于，护层（14）经中间层（12）与基质纤维网相结合。
21、按照权利要求20的层体，其特征在于，护层（14）是一种保护薄片。
22、按照上述权利要求之一的层体，其特征在于，护层（14）由聚氯乙烯构成。
23、按照上述权利要求之一的层体，其特征在于，护层（14）由织物构成。
24、按照上述权利要求之一的层体，其特征在于，在护层（14）和中间层（12）之间有与护层（14）相结合的发泡层（18）。
25、按照权利要求1的层体，其特征在于，在朝平面的法向上基质纤维网（10）有一塑料材料的密度梯度。
26、按照权利要求25的层体，其特征在于，密度变化是连续的。
27、按照权利要求25的层体，其特征在于，密度变化是不连续的。
28、上述权利要求之一所述平面层体的制造方法，其中含有热塑性纤维的基质纤维网通过使用压力和热增强并且在其至少一侧与护层相结合，该方法的特征在于，首先将基质纤维网加热到比基质中塑料纤维的软化温度高的温度，接着使已加热的基质纤维网、与其相邻的含热塑性成分的中间层以及未预热的护层经受一共同的压合工序，由此不仅增强了基质纤维网，而且也使其与护层相结合，其中中间层的材料与基质纤维网的塑料纤维相同或不同，其软化温度高于基质纤维网的塑料纤维并且不预热。
29、按照权利要求28的方法，其特征在于，基质纤维网通过热空气流加热。
30、按照权利要求28或29的方法，其特征是，预热后的基质纤维网要先进行预压缩。
31、按照权利要求28的方法，其特征在于，在与基质纤维网合在一起前中间层与护层结合。
32、按照权利要求28的方法，其特征在于，中间层与护层粘合在一起。
33、按照权利要求28的方法，其特征在于，用于基质纤维网的护层也要预加热，虽然加热的温度高于室温，但低于基质纤维网的预热温度。
34、按照权利要求28至33之一的方法，其特征在于，护层的预热温度在80至120℃之间。
35、按照权利要求28至34之一的方法，其特征在于，在由预热基质纤维网、未预热或只低温预热的中间层以及未预热的护层构成的板叠合在一起之前，将基质纤维网加热到约200℃。
36、按照权利要求35的方法，其特征在于，在温度为大约60℃进行压合工序。
37、按照权利要求28至36之一的方法，其特征在于，加压时间为30至140秒。
38、按照权利要求37的方法，其特征在于，加压时间为大约90秒。
39、权利要求1至27之一的层体用于机动车辆的衬里。
40、权利要求1至27之一的层体用作包装材料。
41、权利要求1至27之一的层体用作家俱的构件。
CN94120070A 1993-11-02 1994-11-02 层体、其制造方法及其应用 Pending CN1110223A (zh)

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CN103112234A (zh) * 2013-03-04 2013-05-22 苏州裕克施乐塑料制品有限公司 复合材料薄板生产方法及其双张紧装置
CN105235314A (zh) * 2015-09-23 2016-01-13 常州市泛亚汽车饰件有限公司 耐高温的汽车轻量化用聚酯无纺布及其制备方法

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CN102574358B (zh) * 2009-10-29 2015-04-22 井上株式会社 纤维增强成型体及其制造方法
CN103112234A (zh) * 2013-03-04 2013-05-22 苏州裕克施乐塑料制品有限公司 复合材料薄板生产方法及其双张紧装置
CN105235314A (zh) * 2015-09-23 2016-01-13 常州市泛亚汽车饰件有限公司 耐高温的汽车轻量化用聚酯无纺布及其制备方法

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