WO2022161720A1 - Floor element and in particular loading floor for motor vehicles and method for producing same - Google Patents

Floor element and in particular loading floor for motor vehicles and method for producing same Download PDF

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Publication number
WO2022161720A1
WO2022161720A1 PCT/EP2021/087422 EP2021087422W WO2022161720A1 WO 2022161720 A1 WO2022161720 A1 WO 2022161720A1 EP 2021087422 W EP2021087422 W EP 2021087422W WO 2022161720 A1 WO2022161720 A1 WO 2022161720A1
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WO
WIPO (PCT)
Prior art keywords
layer
layers
materials
hemp
floor element
Prior art date
Application number
PCT/EP2021/087422
Other languages
German (de)
French (fr)
Inventor
Nour-Eddine BOUHOUCH
Volkmar Schulze
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 WO2022161720A1 publication Critical patent/WO2022161720A1/en

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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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • 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
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/02—Layered products comprising a layer of paper or cardboard next to a fibrous or filamentary 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
    • 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
    • B32B5/22—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
    • B32B5/26—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 also being fibrous or filamentary
    • B32B5/265—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 also being fibrous or filamentary characterised by one fibrous or filamentary layer being a non-woven fabric layer
    • B32B5/266—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 also being fibrous or filamentary characterised by one fibrous or filamentary layer being a non-woven fabric layer next to one or more non-woven fabric 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
    • 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
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding 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
    • B32B2250/00—Layers arrangement
    • B32B2250/04—4 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
    • B32B2250/05—5 or more 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
    • 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
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B32B2262/065—Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
    • 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
    • B32B2262/067—Wood 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/716—Degradable
    • 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
    • B32B2471/00—Floor coverings
    • 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

Definitions

  • Floor element and in particular loading floor for motor vehicles and method for the production thereof
  • the subject matter of the invention is a floor element and in particular a loading floor for motor vehicles; which has sustainable materials in its material structure and guarantees or improves the recyclability and compliance with the specifications of the OEMs, in particular mechanical properties.
  • upper and lower layers are provided, which serve to cover or laminate a core layer. These are made, for example, from material combinations such as PP and glass fibers or PA and glass fibers.
  • WO 2012/104318 A1 describes a structural component in which a spacer, on both sides with a mat consisting of wood fibers and a binding resin; whereby the mats can also consist of a mixture of wood fibers and synthetic fibers as well as natural fibers.
  • WO 2020/148152 A1 discloses a sandwich panel in which the core layer and a spacer panel are laminated on both sides with fiber mats; and these can consist of inorganic as well as synthetic fibers, organically regenerated fibers, natural fibers and animal fibers or a mixture of these. These fibers are embedded/impregnated with polyurethane.
  • the core layer has a honeycomb, corrugated or tubular construction or has a closed-cell foam structure.
  • the core material can be plastic, paper or cardboard, an inorganic material, a combination of natural fibers with resin or metal.
  • the loading floors known from the prior art therefore have the disadvantage that they are not or only partially recyclable and also that they are not made of sustainable materials.
  • the object of the present invention compared to the aforementioned prior art is therefore to provide a loading floor material structure for motor vehicles, which has sustainable and recyclable individual layers in its structure, advantageously up to the wear layer (decor), and preferably the overall structure the specifications of OEM's, especially in terms of mechanical properties - the focus here is on strength-to-weight ratio, dimensional stability - and emissions.
  • a floor element according to the invention and in particular a loading floor for motor vehicles has a layered composite of several layers or flat bodies, with an upper layer and a lower layer (i.e. in particular an uppermost layer and a lowermost layer, which are in particular outer layers with regard to the composite layers) is provided and at least two further layers arranged between this top layer and the bottom layer are provided.
  • these two further layers are made from recyclable and/or recycled materials and/or from sustainable materials or at least have one such material, these materials of the two layers differ.
  • these layers differ in at least one physical property (such as in particular a material used, a density or the like) and/or in terms of their chemical composition.
  • a recyclable material is a material that can be recycled and in this way can be fed back into a production cycle.
  • the materials are also biodegradable materials.
  • the proportion of recycled or recyclable material in at least one of the other layers, preferably in several of the other layers and particularly preferably in all other layers is at least 30% (mass fraction and/or volume fraction, preferably at least 40%.
  • said upper layer faces a vehicle interior, for example a trunk, and the lower layer faces in the opposite direction, for example downwards in a motor vehicle.
  • said layers d. H. in particular the upper layer, the lower layer and the intermediate layers are attached to one another and in particular glued/laminated to one another.
  • the composite of the layers can have a thermoplastic and/or duroplastic structure.
  • the floor element described here has the advantage of being easier to recycle or of being more sustainable in production. This means that recycled materials and sustainable materials are used a priori in the individual layers.
  • a third layer is arranged between the top layer and the bottom layer and preferably the third layer also consists of a recyclable material and/or a recycled material or has such a material; Furthermore, sustainable materials are preferably used.
  • the further layers have a core layer which is arranged between two further layers, the two further layers also preferably being arranged between the bottom and the top layer, ie between the bottom layer and the top layer.
  • the layered composite preferably has at least three layers, preferably at least five layers.
  • the layered composite preferably has at most 11, preferably at most 9 and preferably at most 7 layers.
  • the upper layer can in turn have several sub-layers.
  • At least one of the two further layers and preferably the two further layers are formed as fleece materials and/or fleece mats.
  • At least one of the two further layers is preferred and the two further layers are preferably made of a material which is selected from a group of materials which includes bamboo, in particular bamboo fibres, flax, in particular flax fibres, kenaf, in particular kenaf fibres, hemp, in particular hemp fibres, Contains cellulose, in particular cellulose fibers, wood, in particular wood fibers, mixtures of these materials and the like.
  • said layers are made of a material containing between 30% and 70%, preferably between 40% and 60% flax.
  • the layer is made of a material which contains between 30% and 70%, preferably between 40% and 60% kenaf.
  • the layer is made of a material mixture which is between 30% and 70%, preferably between 40% and 60% of a mixture of 25% flax and 15% kenaf and 10% hemp, preferably 25% kenaf and 25% hemp having.
  • these materials and in particular these fibers are bound and/or held by means of synthetic materials and in particular by means of synthetic fibers.
  • These synthetic fibers can be selected from a group of synthetic materials including recycled PP (rPP), recycled PET (rPET), PLA, coPET or BiCO).
  • the layers can also be impregnated, which serves in particular for lamination of the resulting mat.
  • the incorporation can also take place with resins, with impregnation preferably being provided here as well.
  • the core layer is made of a material selected from a group of materials including paper, cardboard, recycled paper and the like, or mixtures of these materials.
  • This core layer is preferably thicker in a thickness direction of the floor element than the two other layers (arranged between the top layer and the bottom layer).
  • the topsheet is also at least partially made of a recyclable or recycled material.
  • this upper layer can have several intermediate layers or partial layers.
  • a binding layer can be provided. This binding layer preferably consists of recycled PE (rPE) or EVA and/or recycled PE (rPE) or has these materials.
  • the binding layer can also consist, for example, of recycled PE (rPE) or of acrylate, ABS or SBR latex.
  • a carrier can be arranged on this binding layer, on which in turn a tufting material is arranged.
  • This carrier preferably consists of a mixture of PET and PP or of PET and PA or of PET and coPET.
  • the material particularly preferably consists of recycled PET and recycled PA or of recycled PET and coPET. In this way, too, the recyclability can be increased.
  • the tufting material can particularly preferably be a tufting yarn.
  • This can be made of materials selected from a group of materials including Econyl (rPA), rPET or bio-based PA (6.10; 5.10).
  • a material structure made of velor fibers can also be provided for the top layer. These can consist of rPET, rPET/rPA or rPET/rPP, for example.
  • the underlayer is a cover layer and in particular a cover fleece, which is preferably made of rPET or rPP.
  • this bottom layer can also be made from a mixture of these materials.
  • At least one layer and preferably multiple layers contain a binder in the form of a bio-based binder.
  • the following invention is further directed to a motor vehicle with a floor element of the type described above.
  • the present invention is also directed to a method for producing a floor element for a motor vehicle.
  • a composite of at least three layers is produced, with a core layer being arranged between two further layers and the composite being heated. This heating is preferably carried out in order to achieve curing of the composite.
  • an underlayer is activated and this underlayer is attached to a composite.
  • At least two layers of the composite are made from a recyclable and/or recycled material and/or sustainable material, and the materials of these at least three layers preferably differ from one another at least in part.
  • 1 shows a schematic view of a structure of a floor element according to the invention.
  • 1 shows a schematic view of a structure or a composite 1 of a floor element according to the invention.
  • an upper layer identified in its entirety as 12 is provided, which in turn can preferably have three sub-layers 12a, 12b and 12c. When using a velor carpet, for example, this preferably consists of two sub-layers.
  • the reference number 18 designates an underlayer which delimits the structure or composite 1 at the bottom.
  • Three further layers or intermediate layers are provided between the upper layer and the lower layer, the layer 15 being a core layer which is arranged between two further layers 14 and 16 . Together, these three layers 14, 15 and 16 form a carrier of the composite 1.
  • compositions are conceivable for the carrier, which can also differ in terms of whether the entire structure is a thermoplastic structure or a duroplastic structure.
  • the layer 14 may consist of a mixture of PP (polypropylene) and a mixture of kenaf and hemp.
  • This mixture of kenaf and hemp can preferably have between 40% and 60% and preferably 50% kenaf and between 40% and 60% hemp and preferably 50% hemp.
  • the proportion of the kenaf-hemp mixture can be between 30% and 50% and preferably 40%.
  • the proportion of polypropylene can be between 50% and 70% and preferably 60%.
  • the layer 16 can also consist of a mixture of PP (polypropylene) and a mixture of kenaf and hemp.
  • This mixture of kenaf and hemp can preferably have between 40% and 60% and preferably 50% kenaf and between 40% and 60% hemp and preferably 50% hemp.
  • the proportion of the kenaf-hemp mixture can be between 30% and 50% and preferably 40%.
  • the proportion of polypropylene can be between 50% and 70% and preferably 60%.
  • the entire structure preferably has a thickness of between 5 mm and 30 mm, preferably between 10 mm and 20 mm.
  • the core layer can be designed as a paper honeycomb.
  • the layers 14 and 16 can consist of a mixture of between 40% and 60% and preferably 50% flax and between 40% and 60% and preferably 50% PP.
  • the layer 16 can consist of a mixture of between 40% and 60% and preferably 50% flax and between 40% and 60% and preferably 50% PP.
  • the core layer can be designed as a paper honeycomb.
  • the layer 14 may consist of a mixture of PP (polypropylene) and a mixture of flax, kenaf and hemp.
  • This mixture of kenaf and hemp can preferably have between 20% and 30% and preferably 25% flax, between 20% and 30% and preferably 25% kenaf, and between 5% and 15% hemp.
  • the proportion of the flax-kenaf-hemp mixture can be between 50% and 70% and preferably 60%.
  • the proportion of polypropylene can be between 30% and 50% and is preferably 40%.
  • the layer 16 can also consist of a mixture of PP (polypropylene) and a mixture of flax, kenaf and hemp.
  • This mixture of kenaf and hemp can preferably have between 20% and 30% and preferably 25% flax, between 20% and 30% and preferably 25% kenaf, and between 5% and 15% hemp.
  • the proportion of the flax-kenaf-hemp mixture can be between 50% and 70% and preferably 60%.
  • the proportion of polypropylene can be between 30% and 50% and is preferably 40%.
  • the core layer can be designed as a paper honeycomb.
  • the layer 14 may consist of a mixture of binding matrix and a mixture of kenaf and hemp.
  • This mixture of kenaf and hemp can preferably have between 40% and 60% and preferably 50% kenaf and between 40% and 60% hemp and preferably 50% hemp.
  • the proportion of the kenaf-hemp mixture can be between 60% and 80% and preferably 72%.
  • the proportion of binding matrix can be between 20% and 40% and preferably 28%.
  • the layer 16 can also consist of a mixture of binding matrix and a mixture of kenaf and hemp.
  • This mixture of kenaf and hemp can preferably have between 40% and 60% and preferably 50% kenaf and between 40% and 60% hemp and preferably 50% hemp.
  • the proportion of the kenaf-hemp mixture can be between 60% and 80% and preferably 72%.
  • the proportion of binding matrix can be between 20% and 40% and preferably 28%.
  • the core layer can be designed as a paper honeycomb.
  • the layer 14 may consist of a mixture of binding matrix and a mixture of kenaf and hemp.
  • This mixture of kenaf and hemp can preferably have between 40% and 60% and preferably 50% kenaf and between 40% and 60% hemp and preferably 50% hemp.
  • the proportion of the kenaf-hemp mixture can be between 60% and 80% and preferably 70%.
  • the proportion of binding matrix can be between 20% and 40% and preferably 30%.
  • the layer 16 can also consist of a mixture of binding matrix and a mixture of kenaf and hemp.
  • This mixture of kenaf and hemp can preferably have between 40% and 60% and preferably 50% kenaf and between 40% and 60% hemp and preferably 50% hemp.
  • the proportion of the kenaf-hemp mixture can be between 60% and 80% and preferably 72%.
  • the proportion of binding matrix can be between 20% and 40% and preferably 28%.
  • the core layer can be designed as a paper honeycomb.
  • the layer 14 may consist of a mixture of binding matrix and a mixture of kenaf and hemp.
  • This mixture of kenaf and hemp can preferably have between 40% and 60% and preferably 50% kenaf and between 40% and 60% hemp and preferably 50% hemp.
  • the proportion of the kenaf-hemp mixture can be between 60% and 80% and preferably 66%.
  • the proportion of binding matrix can be between 20% and 40% and preferably 34%.
  • the layer 16 can also consist of a mixture of binding matrix and a mixture of kenaf and hemp.
  • This mixture of kenaf and hemp can preferably have between 40% and 60% and preferably 50% kenaf and between 40% and 60% hemp and preferably 50% hemp.
  • the proportion of the kenaf-hemp mixture can be between 60% and 80% and preferably 72%.
  • the proportion of binding matrix can be between 20% and 40% and preferably 28%.
  • the core layer can be designed as a paper honeycomb.

Abstract

The invention relates to a floor element (1) for motor vehicles, the floor element having a layered composite composed of a plurality of layers, wherein an upper layer (12) and a lower layer (18) are provided, and at least two further layers (14, 15, 16) arranged between the uppermost layer (12) and the lowermost layer (18) are provided. According to the invention, these at least two layers (14, 15, 16) are produced from recyclable and/or recycled materials, the materials of these at least three layers (14, 15, 16) differing from one another.

Description

Bodenelement und insbesondere Ladeboden für Kraftfahrzeuge und Verfahren zu dessen Herstellung Floor element and in particular loading floor for motor vehicles and method for the production thereof
Beschreibung description
Gegenstand der Erfindung ist ein Bodenelement und insbesondere ein Ladeboden für Kraftfahrzeuge; der in seiner Materialstruktur nachhaltige Materialien aufweist und die Recyclingfähigkeit sowie die Einhaltung der in den Spezifikationen der OEM's geforderten, insbesondere mechanischen Eigenschaften garantiert bzw. verbessert. The subject matter of the invention is a floor element and in particular a loading floor for motor vehicles; which has sustainable materials in its material structure and guarantees or improves the recyclability and compliance with the specifications of the OEMs, in particular mechanical properties.
Aus dem Stand der Technik sind diverse Materialstrukturen in Sandwich-Verbund Technologie bekannt, beispielsweise aus der WO 2016/196472 A1 , der WO 2018/053002 A1 und der WO 2019/221828 A1 . Various material structures in sandwich composite technology are known from the prior art, for example from WO 2016/196472 A1, WO 2018/053002 A1 and WO 2019/221828 A1.
Dabei ist es auch bekannt, dass Ober- und Unterschichten vorgesehen sind, welche zum Kaschieren oder Laminieren einer Kernschicht dienen. Diese sind beispielsweise aus Materialkombinationen wie PP und Glasfasern oder PA und Glasfasern hergestellt. It is also known that upper and lower layers are provided, which serve to cover or laminate a core layer. These are made, for example, from material combinations such as PP and glass fibers or PA and glass fibers.
In der WO 2012/104318 A1 wird eine Strukturkomponente beschrieben, bei der ein Abstandhalter, beidseitig mit einer Matte, bestehend aus Holzfasern und einem Bindeharz; wobei die Matten auch aus einem Gemisch von Holzfasern und synthetischen Fasern sowie auch Naturfasern bestehen können, versehen ist. Die WO 2020/148152 A1 offenbart eine Sandwich-Platte bei der die Kern-Schicht und eine Abstandsplatte, beidseitig mit Fasermatten laminiert ist; und diese aus anorganischen sowie synthetischen Fasern, organisch regenerierten Fasern, Naturfasern und tierischen Fasern oder einer Mischung dieser bestehen können. Eingebunden/imprägniert sind diese Fasern mit Polyurethan. Die Kern-Schicht hat eine Waben-, Well- oder Rohrkonstruktion bzw. hat eine geschlossenzellige Schaumstruktur. Das Kernmaterial kann aus Kunststoff, Papier oder Pappe, einem anorganischen Material, einer Kombination aus Naturfasern mit Harz oder Metall bestehen. WO 2012/104318 A1 describes a structural component in which a spacer, on both sides with a mat consisting of wood fibers and a binding resin; whereby the mats can also consist of a mixture of wood fibers and synthetic fibers as well as natural fibers. WO 2020/148152 A1 discloses a sandwich panel in which the core layer and a spacer panel are laminated on both sides with fiber mats; and these can consist of inorganic as well as synthetic fibers, organically regenerated fibers, natural fibers and animal fibers or a mixture of these. These fibers are embedded/impregnated with polyurethane. The core layer has a honeycomb, corrugated or tubular construction or has a closed-cell foam structure. The core material can be plastic, paper or cardboard, an inorganic material, a combination of natural fibers with resin or metal.
Die aus dem Stand der Technik bekannten Ladeböden weisen daher den Nachteil auf, dass sie nicht oder nur teilweise recyclingfähig sind und auch, dass sie nicht aus nachhaltigen Materialien hergestellt sind. The loading floors known from the prior art therefore have the disadvantage that they are not or only partially recyclable and also that they are not made of sustainable materials.
Die Aufgabe der vorliegenden Erfindung gegenüber dem vorgenannten Stand der Technik ist damit die Bereitstellung einer Ladeboden-Material-Struktur für Kraftfahrzeuge, die in ihrer Struktur nachhaltige und recycelbare Einzelschichten aufweist, vorteilhaft bis hin zur Nutzschicht (Dekor), und bevorzugt der Gesamtaufbau den Spezifikationen der OEM's, insbesondere hinsichtlich der mechanischen Eigenschaften -im Fokus sind hier Festigkeits-Gewichts- Koeffizient, Dimensionsstabilität- und den Emissionen entspricht. The object of the present invention compared to the aforementioned prior art is therefore to provide a loading floor material structure for motor vehicles, which has sustainable and recyclable individual layers in its structure, advantageously up to the wear layer (decor), and preferably the overall structure the specifications of OEM's, especially in terms of mechanical properties - the focus here is on strength-to-weight ratio, dimensional stability - and emissions.
Die vorbenannten Aufgaben werden erfindungsgemäß durch ein Bodenelement und insbesondere einen Ladeboden und ein Verfahren zu dessen Herstellung nach den unabhängigen Patentansprüchen gelöst. The aforementioned objects are achieved according to the invention by a floor element and in particular a loading floor and a method for its production according to the independent patent claims.
Ein erfindungsgemäßes Bodenelement und insbesondere ein Ladeboden für Kraftfahrzeuge weist einen Schichtverbund aus mehreren Schichten bzw. flächigen Körpern auf, wobei eine Oberschicht und eine Unterschicht (d. h. insbesondere eine oberste Schicht und eine unterste Schicht, bei denen es sich insbesondere um außen bezgl. des Verbundes liegende Schichten handelt) vorgesehen ist und wenigstens zwei zwischen dieser Oberschicht und der Unterschicht angeordnete weitere Schichten vorgesehen sind. A floor element according to the invention and in particular a loading floor for motor vehicles has a layered composite of several layers or flat bodies, with an upper layer and a lower layer (i.e. in particular an uppermost layer and a lowermost layer, which are in particular outer layers with regard to the composite layers) is provided and at least two further layers arranged between this top layer and the bottom layer are provided.
Erfindungsgemäß sind diese zwei weiteren Schichten aus recyclingfähigen und/oder recycelten Materialien, und/oder aus nachhaltigen Materialien hergestellt oder weisen zumindest ein solches Material auf, wobei sich diese Materialien der beiden Schichten unterscheiden. Insbesondere unterscheiden sich diese Schichten in wenigstens einer physikalischen Eigenschaft (wie insbesondere eines verwendeten Materials, eine Dichte oder dergleichen) und/oder hinsichtlich ihrer chemischen Zusammensetzung. Unter einem recyclingfähigen Material wird ein Material verstanden, welches recycelt werden kann und auf diese Weise erneut einem Produktionszyklus zugeführt werden kann. Insbesondere handelt es sich bei den Materialien auch um biologisch abbaubare Materialien. According to the invention, these two further layers are made from recyclable and/or recycled materials and/or from sustainable materials or at least have one such material, these materials of the two layers differ. In particular, these layers differ in at least one physical property (such as in particular a material used, a density or the like) and/or in terms of their chemical composition. A recyclable material is a material that can be recycled and in this way can be fed back into a production cycle. In particular, the materials are also biodegradable materials.
Bevorzugt liegt der Anteil an recyceltem oder recyclingfähigem Material in wenigstens einer der weiteren Schichten, bevorzugt in mehreren der weiteren Schichten und besonders bevorzugt in allen weiteren Schichten bei wenigstens 30 % (Masseanteil und/oder Volumenanteil, bevorzugt bei wenigstens 40 %. The proportion of recycled or recyclable material in at least one of the other layers, preferably in several of the other layers and particularly preferably in all other layers is at least 30% (mass fraction and/or volume fraction, preferably at least 40%.
Die genannte Oberschicht ist dabei in einem Einbauzustand einem Fahrzeuginnenraum, beispielsweise Kofferraum, zugewandt und die Unterschicht ist in die entgegengesetzte Richtung, beispielsweise in einem Kraftfahrzeug nach unten gewandt. In an installed state, said upper layer faces a vehicle interior, for example a trunk, and the lower layer faces in the opposite direction, for example downwards in a motor vehicle.
Bei einer weiteren Ausführungsform sind die genannten Schichten d. h. insbesondere die Oberschicht, die Unterschicht sowie die Zwischenschichten aneinander befestigt und insbesondere aneinander geklebt / kaschiert. In a further embodiment, said layers d. H. in particular the upper layer, the lower layer and the intermediate layers are attached to one another and in particular glued/laminated to one another.
Bei einer weiteren bevorzugten Ausführungsform kann der Verbund aus den Schichten thermoplastisch und/oder duroplastisch aufgebaut sein. In a further preferred embodiment, the composite of the layers can have a thermoplastic and/or duroplastic structure.
Das hier beschriebene Bodenelement weist den Vorteil auf, leichter recyclingfähig zu sein, oder auch in der Herstellung nachhaltiger zu sein. D. h., es werden Recycling-Materialien und nachhaltige Materialien a priori in den einzelnen Schichten eingesetzt. The floor element described here has the advantage of being easier to recycle or of being more sustainable in production. This means that recycled materials and sustainable materials are used a priori in the individual layers.
Bei einer bevorzugten Ausführungsform ist zwischen der Oberschicht und der Unterschicht eine dritte Schicht angeordnet und bevorzugt besteht auch die dritte Schicht aus einem recyclingfähigen Material und/oder einem recycelten Material oder weist ein solches Material auf; des Weiteren finden bevorzugt nachhaltige Materialien ihre Anwendung. Bei einer weiteren bevorzugten Ausführungsform weisen die weiteren Schichten eine Kernschicht auf, welche zwischen zwei weiteren Schichten angeordnet ist, wobei auch bevorzugt die beiden weiteren Schichten zwischen der untersten und der obersten Schicht, d. h. zwischen der Unterschicht und der Oberschicht angeordnet sind. Bevorzugt weist der Schichtverbund mindestens drei Schichten, bevorzugt wenigstens fünf Schichten auf. Bevorzugt weist der Schichtverbund höchstens 1 1 , bevorzugt höchstens 9 und bevorzugt höchstens 7 Schichten auf. Weiterhin kann die Oberschicht wiederum mehrere Teilschichten aufweisen. In a preferred embodiment, a third layer is arranged between the top layer and the bottom layer and preferably the third layer also consists of a recyclable material and/or a recycled material or has such a material; Furthermore, sustainable materials are preferably used. In a further preferred embodiment, the further layers have a core layer which is arranged between two further layers, the two further layers also preferably being arranged between the bottom and the top layer, ie between the bottom layer and the top layer. The layered composite preferably has at least three layers, preferably at least five layers. The layered composite preferably has at most 11, preferably at most 9 and preferably at most 7 layers. Furthermore, the upper layer can in turn have several sub-layers.
Bei einer weiteren bevorzugten Ausführungsform ist wenigstens eine der zwei weiteren Schichten und bevorzugt sind die beiden weiteren Schichten als Vliesmaterialien und/oder Vliesmatten ausgebildet. In a further preferred embodiment, at least one of the two further layers and preferably the two further layers are formed as fleece materials and/or fleece mats.
Bevorzugt ist wenigstens eine der zwei weiteren Schichten und bevorzugt sind die beiden weiteren Schichten aus einem Material hergestellt, welches aus einer Gruppe von Materialien ausgewählt ist, welche Bambus, insbesondere Bambusfasern, Flachs, insbesondere Flachsfasern, Kenaf, insbesondere Kenaffasern, Hanf, insbesondere Hanffasern, Zellulose, insbesondere Zellulosefasern, Holz, insbesondere Holzfasern, Mischungen aus diesen Materialien und dergleichen enthält. At least one of the two further layers is preferred and the two further layers are preferably made of a material which is selected from a group of materials which includes bamboo, in particular bamboo fibres, flax, in particular flax fibres, kenaf, in particular kenaf fibres, hemp, in particular hemp fibres, Contains cellulose, in particular cellulose fibers, wood, in particular wood fibers, mixtures of these materials and the like.
Bei einer bevorzugten Ausführungsform sind die genannten Schichten aus einem Material hergestellt, welches zwischen 30 % und 70 %, bevorzugt zwischen 40 % und 60 % Flachs enthält. Bei einer weiteren bevorzugten Ausführungsform ist die Schicht aus einem Material hergestellt, welches zwischen 30 % und 70 %, bevorzugt zwischen 40 % und 60 % Kenaf enthält. In a preferred embodiment, said layers are made of a material containing between 30% and 70%, preferably between 40% and 60% flax. In a further preferred embodiment, the layer is made of a material which contains between 30% and 70%, preferably between 40% and 60% kenaf.
Bei einer weiteren bevorzugten Ausführungsform ist die Schicht aus einer Materialmischung hergestellt, welche zwischen 30 % und 70 %, bevorzugt zwischen 40 % und 60 % einer Mischung 25 % Flachs und 15 % Kenaf und 10 % Hanf, bevorzugt 25 % Kenaf und 25 % Hanf aufweist. In a further preferred embodiment, the layer is made of a material mixture which is between 30% and 70%, preferably between 40% and 60% of a mixture of 25% flax and 15% kenaf and 10% hemp, preferably 25% kenaf and 25% hemp having.
Bei einer bevorzugten Ausführungsform sind diese Materialien und insbesondere diese Fasern mittels synthetischer Materialien und insbesondere mittels synthetischer Fasern eingebunden und/oder gehalten. Dabei können diese synthetischen Fasern aus einer Gruppe von synthetischen Materialien ausgewählt sein, welche recyceltes PP (rPP), recyceltes PET (rPET), PLA, coPET oder BiCO) enthält. Vorteilhaft können die Schichten auch noch imprägniert sein, was insbesondere für eine Kaschierung der entstehenden Matte dient. Daneben oder zusätzlich kann die Einbindung auch mit Harzen erfolgen, wobei auch hier bevorzugt eine Imprägnierung vorgesehen ist. In a preferred embodiment, these materials and in particular these fibers are bound and/or held by means of synthetic materials and in particular by means of synthetic fibers. These synthetic fibers can be selected from a group of synthetic materials including recycled PP (rPP), recycled PET (rPET), PLA, coPET or BiCO). Advantageously, the layers can also be impregnated, which serves in particular for lamination of the resulting mat. In addition or in addition, the incorporation can also take place with resins, with impregnation preferably being provided here as well.
Bei einer weiteren bevorzugten Ausführungsform ist die Kernschicht aus einem Material hergestellt, welches aus einer Gruppe von Materialien ausgewählt ist, welche Papier, Pappe, recyceltes Papier und dergleichen oder auch Mischungen aus diesen Materialien enthält. In another preferred embodiment, the core layer is made of a material selected from a group of materials including paper, cardboard, recycled paper and the like, or mixtures of these materials.
Bevorzugt ist diese Kernschicht in einer Dickenrichtung des Bodenelements dicker ausgebildet als die beiden weiteren (zwischen der Oberschicht und der Unterschicht angeordneten) Schichten. This core layer is preferably thicker in a thickness direction of the floor element than the two other layers (arranged between the top layer and the bottom layer).
Bei einer weiteren bevorzugten Ausführungsform ist die Oberschicht auch wenigstens teilweise aus einem recyclingfähigen oder einem recycelten Material hergestellt. Dabei kann diese Oberschicht mehrere Zwischenschichten bzw. Teilschichten aufweisen. So kann beispielsweise eine Einbindungsschicht vorgesehen sein. Diese Einbindungsschicht besteht bevorzugt aus recyceltem PE (rPE) oder aus EVA und/oder recyceltem PE (rPE) oder weist diese Materialien auf. In another preferred embodiment, the topsheet is also at least partially made of a recyclable or recycled material. In this case, this upper layer can have several intermediate layers or partial layers. For example, a binding layer can be provided. This binding layer preferably consists of recycled PE (rPE) or EVA and/or recycled PE (rPE) or has these materials.
Daneben kann die Einbindungsschicht auch beispielsweise aus recyceltem PE (rPE) oder aus Acrylat, ABS oder SBR-Latex bestehen. In addition, the binding layer can also consist, for example, of recycled PE (rPE) or of acrylate, ABS or SBR latex.
An dieser Einbindungsschicht kann ein Träger angeordnet sein, an dem wiederum ein Tufting- material angeordnet ist. Dabei besteht bevorzugt dieser Träger aus einer Mischung aus PET und PP oder aus PET und PA oder aus PET und coPET. Besonders bevorzugt besteht das Material jedoch aus recyceltem PET und recyceltem PA oder aus recyceltem PET und coPET. Auch auf diese Weise kann die Recycling-Fähigkeit erhöht werden. A carrier can be arranged on this binding layer, on which in turn a tufting material is arranged. This carrier preferably consists of a mixture of PET and PP or of PET and PA or of PET and coPET. However, the material particularly preferably consists of recycled PET and recycled PA or of recycled PET and coPET. In this way, too, the recyclability can be increased.
Das Tuftingmaterial kann besonders bevorzugt ein Tufting - Garn sein. Dieser kann aus Materialien bestehen, die aus einer Gruppe von Materialien ausgewählt ist, welche Econyl (rPA), rPET oder bio basierendes PA (6.10; 5.10) enthält. Daneben kann für die Oberschicht auch eine Materialstruktur aus Velourfasern vorgesehen sein. Diese können dabei beispielsweise aus rPET, rPET/rPA oder rPET/rPP bestehen. The tufting material can particularly preferably be a tufting yarn. This can be made of materials selected from a group of materials including Econyl (rPA), rPET or bio-based PA (6.10; 5.10). In addition, a material structure made of velor fibers can also be provided for the top layer. These can consist of rPET, rPET/rPA or rPET/rPP, for example.
Bei einer weiteren vorteilhaften Ausführungsform ist die Unterschicht eine Abdeckschicht und insbesondere ein Abdeckvlies, welches bevorzugt aus rPET oder rPP hergestellt ist. Daneben kann diese unterste Schicht auch aus einer Mischung dieser Materialien hergestellt sein. In a further advantageous embodiment, the underlayer is a cover layer and in particular a cover fleece, which is preferably made of rPET or rPP. In addition, this bottom layer can also be made from a mixture of these materials.
Bevorzugt enthält wenigstens eine Schicht und enthalten bevorzugt mehrere Schichten einen Binder in Form eines bio-basierenden Binders. Preferably, at least one layer and preferably multiple layers contain a binder in the form of a bio-based binder.
Die folgende Erfindung ist weiterhin auf ein Kraftfahrzeug mit einem Bodenelement der oben beschriebenen Art gerichtet. The following invention is further directed to a motor vehicle with a floor element of the type described above.
Die vorliegende Erfindung ist weiterhin auf ein Verfahren zur Herstellung eines Bodenelements für ein Kraftfahrzeug gerichtet. Dabei wird ein Verbund aus wenigstens drei Schichten hergestellt, wobei eine Kernschicht zwischen zwei weiteren Schichten angeordnet wird und der Verbund erwärmt wird. Dieses Erwärmen erfolgt bevorzugt, um ein Aushärten des Verbundes zu erreichen. The present invention is also directed to a method for producing a floor element for a motor vehicle. In this case, a composite of at least three layers is produced, with a core layer being arranged between two further layers and the composite being heated. This heating is preferably carried out in order to achieve curing of the composite.
In einem weiteren Verfahrensschritt wird eine Unterschicht aktiviert und es wird diese Unterschicht an einen Verbund angebracht. In a further process step, an underlayer is activated and this underlayer is attached to a composite.
Erfindungsgemäß sind wenigstens zwei Schichten des Verbundes aus einem recyclingfähigen und/oder aus einem recycelten Material und/oder nachhaltigem Material hergestellt und bevorzugt unterscheiden sich die Materialien dieser wenigstens drei Schichten zumindest teilweise voneinander. According to the invention, at least two layers of the composite are made from a recyclable and/or recycled material and/or sustainable material, and the materials of these at least three layers preferably differ from one another at least in part.
Weitere Vorteile und Ausführungsformen ergeben sich aus der beigefügten Zeichnung: Further advantages and embodiments result from the attached drawing:
Darin zeigt: It shows:
Fig. 1 eine schematische Ansicht eines Aufbaus eines erfindungsgemäßen Bodenelements. Fig. 1 zeigt eine schematische Ansicht eines Aufbaus bzw. eines Verbundes 1 eines erfindungsgemäßen Bodenelements. Dabei ist eine in ihrer Gesamtheit mit 12 gekennzeichnete Oberschicht vorgesehen, die wiederum bevorzugt drei Teilschichten 12a, 12b und 12c aufweisen kann. Bei Anwendung zum Beispiel eines Velour-Teppichs besteht diese bevorzugt aus zwei Teilschichten. 1 shows a schematic view of a structure of a floor element according to the invention. 1 shows a schematic view of a structure or a composite 1 of a floor element according to the invention. In this case, an upper layer identified in its entirety as 12 is provided, which in turn can preferably have three sub-layers 12a, 12b and 12c. When using a velor carpet, for example, this preferably consists of two sub-layers.
Das Bezugszeichen 18 kennzeichnet eine Unterschicht, welche den Aufbau bzw. Verbund 1 nach unten hin abgrenzt. Zwischen der Oberschicht und der Unterschicht sind drei weitere Schichten bzw. Zwischenschichten vorgesehen, wobei es sich bei der Schicht 15 um eine Kernschicht handelt, die zwischen zwei weiteren Schichten 14 und 16 angeordnet ist. Gemeinsam bilden diese drei Schichten 14, 15 und 16 einen Träger des Verbundes 1 aus. The reference number 18 designates an underlayer which delimits the structure or composite 1 at the bottom. Three further layers or intermediate layers are provided between the upper layer and the lower layer, the layer 15 being a core layer which is arranged between two further layers 14 and 16 . Together, these three layers 14, 15 and 16 form a carrier of the composite 1.
Für den Träger sind mehrere Zusammensetzungen denkbar, welche sich auch dahingehend unterscheiden können, ob der gesamte Aufbau ein thermoplastischer Aufbau oder ein duroplastischer Aufbau ist. Several compositions are conceivable for the carrier, which can also differ in terms of whether the entire structure is a thermoplastic structure or a duroplastic structure.
Erste Ausgestaltung First design
Bei einer ersten Ausgestaltung insbesondere für einen thermoplastischen Aufbau kann die Schicht 14 aus einer Mischung aus PP (Polypropylen) und einer Mischung aus Kenaf und Hanf bestehen. Dabei kann diese Mischung aus Kenaf und Hanf bevorzugt zwischen 40 % und 60 % und bevorzugt 50% Kenaf sowie zwischen 40 % und 60 % Hanf und bevorzugt 50 % Hanf aufweisen. Weiterhin kann der Anteil der Kenaf-Hanf-Mischung zwischen 30 % und 50 % und bevorzugt bei 40 % liegen. Der Anteil an Polypropylen kann zwischen 50 % und 70 % und bevorzugt bei 60 % liegen. In a first embodiment, particularly for a thermoplastic construction, the layer 14 may consist of a mixture of PP (polypropylene) and a mixture of kenaf and hemp. This mixture of kenaf and hemp can preferably have between 40% and 60% and preferably 50% kenaf and between 40% and 60% hemp and preferably 50% hemp. Furthermore, the proportion of the kenaf-hemp mixture can be between 30% and 50% and preferably 40%. The proportion of polypropylene can be between 50% and 70% and preferably 60%.
Bei dieser ersten Ausgestaltung insbesondere für einen thermoplastischen Aufbau kann weiterhin auch die Schicht 16 aus einer Mischung aus PP (Polypropylen) und einer Mischung aus Kenaf und Hanf bestehen. Dabei kann diese Mischung aus Kenaf und Hanf bevorzugt zwischen 40 % und 60 % und bevorzugt 50 % Kenaf sowie zwischen 40 % und 60 % Hanf und bevorzugt 50 % Hanf aufweisen. Weiterhin kann der Anteil der Kenaf-Hanf-Mischung zwischen 30 % und 50 % und bevorzugt bei 40 % liegen. Der Anteil an Polypropylen kann zwischen 50 % und 70 % und bevorzugt bei 60 % liegen. Der gesamte Aufbau weist bei allen hier diskutierten Ausführungsformen bevorzugt eine Dicke auf, die zwischen 5 mm und 30 mm, bevorzugt zwischen 10 mm und 20 mm liegt. In this first embodiment, in particular for a thermoplastic structure, the layer 16 can also consist of a mixture of PP (polypropylene) and a mixture of kenaf and hemp. This mixture of kenaf and hemp can preferably have between 40% and 60% and preferably 50% kenaf and between 40% and 60% hemp and preferably 50% hemp. Furthermore, the proportion of the kenaf-hemp mixture can be between 30% and 50% and preferably 40%. The proportion of polypropylene can be between 50% and 70% and preferably 60%. In all of the embodiments discussed here, the entire structure preferably has a thickness of between 5 mm and 30 mm, preferably between 10 mm and 20 mm.
Weiterhin kann bei dieser Ausgestaltung die Kernschicht als Papierwabe ausgebildet sein. Furthermore, in this configuration, the core layer can be designed as a paper honeycomb.
Zweite Ausgestaltung Second embodiment
Bei einer weiteren Ausgestaltung insbesondere für einen thermoplastischen Aufbau kann die Schicht 14 und 16 aus einer Mischung aus zwischen 40 % und 60 % und bevorzugt 50 % Flachs und zwischen 40 % und 60 % und bevorzugt 50 % PP bestehen. Bei dieser weiteren Ausgestaltung für einen thermoplastischen Aufbau kann die Schicht 16 aus einer Mischung aus zwischen 40 % und 60 % und bevorzugt 50 % Flachs und zwischen 40 % und 60 % und bevorzugt 50 % PP bestehen. In a further embodiment, particularly for a thermoplastic construction, the layers 14 and 16 can consist of a mixture of between 40% and 60% and preferably 50% flax and between 40% and 60% and preferably 50% PP. In this further embodiment for a thermoplastic construction, the layer 16 can consist of a mixture of between 40% and 60% and preferably 50% flax and between 40% and 60% and preferably 50% PP.
Weiterhin kann bei dieser Ausgestaltung die Kernschicht als Papierwabe ausgebildet sein. Furthermore, in this configuration, the core layer can be designed as a paper honeycomb.
Dritte Ausgestaltung Third embodiment
Bei einer dritten Ausgestaltung insbesondere für einen thermoplastischen Aufbau kann die Schicht 14 aus einer Mischung aus PP (Polypropylen) und einer Mischung aus Flachs, Kenaf und Hanf bestehen. Dabei kann diese Mischung aus Kenaf und Hanf bevorzugt zwischen 20 % und 30 % und bevorzugt 25 % Flachs, zwischen 20 % und 30 % und bevorzugt 25 % Kenaf, und zwischen 5 % und 15 % Hanf aufweisen. Weiterhin kann der Anteil der Flachs-Kenaf- Hanf-Mischung zwischen 50 % und 70 % und bevorzugt bei 60 % liegen. Der Anteil an Polypropylen kann zwischen 30 % und 50 % und bevorzugt bei 40 % liegen. In a third embodiment, particularly for a thermoplastic construction, the layer 14 may consist of a mixture of PP (polypropylene) and a mixture of flax, kenaf and hemp. This mixture of kenaf and hemp can preferably have between 20% and 30% and preferably 25% flax, between 20% and 30% and preferably 25% kenaf, and between 5% and 15% hemp. Furthermore, the proportion of the flax-kenaf-hemp mixture can be between 50% and 70% and preferably 60%. The proportion of polypropylene can be between 30% and 50% and is preferably 40%.
Bei dieser dritten Ausgestaltung für einen thermoplastischen Aufbau kann auch die Schicht 16 aus einer Mischung aus PP (Polypropylen) und einer Mischung aus Flachs, Kenaf und Hanf bestehen. Dabei kann diese Mischung aus Kenaf und Hanf bevorzugt zwischen 20 % und 30 % und bevorzugt 25 % Flachs, zwischen 20 % und 30 % und bevorzugt 25 % Kenaf, und zwischen 5 % und 15 % Hanf aufweisen. Weiterhin kann der Anteil der Flachs-Kenaf-Hanf- Mischung zwischen 50 % und 70 % und bevorzugt bei 60 % liegen. Der Anteil an Polypropylen kann zwischen 30 % und 50 % und bevorzugt bei 40 % liegen. In this third embodiment for a thermoplastic construction, the layer 16 can also consist of a mixture of PP (polypropylene) and a mixture of flax, kenaf and hemp. This mixture of kenaf and hemp can preferably have between 20% and 30% and preferably 25% flax, between 20% and 30% and preferably 25% kenaf, and between 5% and 15% hemp. Furthermore, the proportion of the flax-kenaf-hemp mixture can be between 50% and 70% and preferably 60%. The proportion of polypropylene can be between 30% and 50% and is preferably 40%.
Weiterhin kann bei dieser Ausgestaltung die Kernschicht als Papierwabe ausgebildet sein. Vierte Ausgestaltung Furthermore, in this configuration, the core layer can be designed as a paper honeycomb. Fourth embodiment
Bei einer vierten Ausgestaltung insbesondere für einen duroplastischen Aufbau kann die Schicht 14 aus einer Mischung aus Bindungsmatrix und einer Mischung aus Kenaf und Hanf bestehen. Dabei kann diese Mischung aus Kenaf und Hanf bevorzugt zwischen 40 % und 60 % und bevorzugt 50 % Kenaf sowie zwischen 40 % und 60 % Hanf und bevorzugt 50 % Hanf aufweisen. Weiterhin kann der Anteil der Kenaf-Hanf-Mischung zwischen 60 % und 80 % und bevorzugt bei 72 % liegen. Der Anteil an Bindungsmatrix kann zwischen 20 % und 40 % und bevorzugt bei 28 % liegen. In a fourth embodiment, particularly for a thermoset construction, the layer 14 may consist of a mixture of binding matrix and a mixture of kenaf and hemp. This mixture of kenaf and hemp can preferably have between 40% and 60% and preferably 50% kenaf and between 40% and 60% hemp and preferably 50% hemp. Furthermore, the proportion of the kenaf-hemp mixture can be between 60% and 80% and preferably 72%. The proportion of binding matrix can be between 20% and 40% and preferably 28%.
Bei dieser vierten Ausgestaltung insbesondere für einen duroplastischen Aufbau kann auch die Schicht 16 aus einer Mischung aus Bindungsmatrix und einer Mischung aus Kenaf und Hanf bestehen. Dabei kann diese Mischung aus Kenaf und Hanf bevorzugt zwischen 40 % und 60 % und bevorzugt 50 % Kenaf sowie zwischen 40 % und 60 % Hanf und bevorzugt 50 % Hanf aufweisen. Weiterhin kann der Anteil der Kenaf-Hanf-Mischung zwischen 60 % und 80 % und bevorzugt bei 72 % liegen. Der Anteil an Bindungsmatrix kann zwischen 20 % und 40 % und bevorzugt bei 28 % liegen. In this fourth embodiment, in particular for a duroplastic structure, the layer 16 can also consist of a mixture of binding matrix and a mixture of kenaf and hemp. This mixture of kenaf and hemp can preferably have between 40% and 60% and preferably 50% kenaf and between 40% and 60% hemp and preferably 50% hemp. Furthermore, the proportion of the kenaf-hemp mixture can be between 60% and 80% and preferably 72%. The proportion of binding matrix can be between 20% and 40% and preferably 28%.
Weiterhin kann bei dieser Ausgestaltung die Kernschicht als Papierwabe ausgebildet sein. Furthermore, in this configuration, the core layer can be designed as a paper honeycomb.
Fünfte Ausgestaltung Fifth Embodiment
Bei einer fünften Ausgestaltung insbesondere für einen duroplastischen Aufbau kann die Schicht 14 aus einer Mischung aus Bindungsmatrix und einer Mischung aus Kenaf und Hanf bestehen. Dabei kann diese Mischung aus Kenaf und Hanf bevorzugt zwischen 40 % und 60 % und bevorzugt 50 % Kenaf sowie zwischen 40 % und 60 % Hanf und bevorzugt 50 % Hanf aufweisen. Weiterhin kann der Anteil der Kenaf-Hanf-Mischung zwischen 60 % und 80 % und bevorzugt bei 70 % liegen. Der Anteil an Bindungsmatrix kann zwischen 20 % und 40 % und bevorzugt bei 30 % liegen. In a fifth embodiment, particularly for a thermoset construction, the layer 14 may consist of a mixture of binding matrix and a mixture of kenaf and hemp. This mixture of kenaf and hemp can preferably have between 40% and 60% and preferably 50% kenaf and between 40% and 60% hemp and preferably 50% hemp. Furthermore, the proportion of the kenaf-hemp mixture can be between 60% and 80% and preferably 70%. The proportion of binding matrix can be between 20% and 40% and preferably 30%.
Bei dieser fünften Ausgestaltung insbesondere für einen duroplastischen Aufbau kann auch die Schicht 16 aus einer Mischung aus Bindungsmatrix und einer Mischung aus Kenaf und Hanf bestehen. Dabei kann diese Mischung aus Kenaf und Hanf bevorzugt zwischen 40 % und 60 % und bevorzugt 50 % Kenaf sowie zwischen 40 % und 60 % Hanf und bevorzugt 50 % Hanf aufweisen. Weiterhin kann der Anteil der Kenaf-Hanf-Mischung zwischen 60 % und 80 % und bevorzugt bei 72 % liegen. Der Anteil an Bindungsmatrix kann zwischen 20 % und 40 % und bevorzugt bei 28 % liegen. In this fifth embodiment, in particular for a duroplastic structure, the layer 16 can also consist of a mixture of binding matrix and a mixture of kenaf and hemp. This mixture of kenaf and hemp can preferably have between 40% and 60% and preferably 50% kenaf and between 40% and 60% hemp and preferably 50% hemp. Furthermore, the proportion of the kenaf-hemp mixture can be between 60% and 80% and preferably 72%. The proportion of binding matrix can be between 20% and 40% and preferably 28%.
Weiterhin kann bei dieser Ausgestaltung die Kernschicht als Papierwabe ausgebildet sein. Furthermore, in this configuration, the core layer can be designed as a paper honeycomb.
Sechste Ausgestaltung Sixth aspect
Bei einer sechsten Ausgestaltung insbesondere für einen duroplastischen Aufbau kann die Schicht 14 aus einer Mischung aus Bindungsmatrix und einer Mischung aus Kenaf und Hanf bestehen. Dabei kann diese Mischung aus Kenaf und Hanf bevorzugt zwischen 40 % und 60 % und bevorzugt 50 % Kenaf sowie zwischen 40 % und 60 % Hanf und bevorzugt 50 % Hanf aufweisen. Weiterhin kann der Anteil der Kenaf-Hanf-Mischung zwischen 60 % und 80 % und bevorzugt bei 66 % liegen. Der Anteil an Bindungsmatrix kann zwischen 20 % und 40 % und bevorzugt bei 34 % liegen. In a sixth embodiment, particularly for a thermoset construction, the layer 14 may consist of a mixture of binding matrix and a mixture of kenaf and hemp. This mixture of kenaf and hemp can preferably have between 40% and 60% and preferably 50% kenaf and between 40% and 60% hemp and preferably 50% hemp. Furthermore, the proportion of the kenaf-hemp mixture can be between 60% and 80% and preferably 66%. The proportion of binding matrix can be between 20% and 40% and preferably 34%.
Bei dieser sechsten Ausgestaltung insbesondere für einen duroplastischen Aufbau kann auch die Schicht 16 aus einer Mischung aus Bindungsmatrix und einer Mischung aus Kenaf und Hanf bestehen. Dabei kann diese Mischung aus Kenaf und Hanf bevorzugt zwischen 40 % und 60 % und bevorzugt 50 % Kenaf sowie zwischen 40 % und 60 % Hanf und bevorzugt 50 % Hanf aufweisen. Weiterhin kann der Anteil der Kenaf-Hanf-Mischung zwischen 60 % und 80 % und bevorzugt bei 72 % liegen. Der Anteil an Bindungsmatrix kann zwischen 20 % und 40 % und bevorzugt bei 28 % liegen. In this sixth embodiment, in particular for a duroplastic structure, the layer 16 can also consist of a mixture of binding matrix and a mixture of kenaf and hemp. This mixture of kenaf and hemp can preferably have between 40% and 60% and preferably 50% kenaf and between 40% and 60% hemp and preferably 50% hemp. Furthermore, the proportion of the kenaf-hemp mixture can be between 60% and 80% and preferably 72%. The proportion of binding matrix can be between 20% and 40% and preferably 28%.
Weiterhin kann bei dieser Ausgestaltung die Kernschicht als Papierwabe ausgebildet sein. Furthermore, in this configuration, the core layer can be designed as a paper honeycomb.
Die Anmelderin behält sich vor, sämtliche in den Anmeldungsunterlagen offenbarten Merkmale als erfindungswesentlich zu beanspruchen, sofern sie einzeln oder in Kombination gegenüber dem Stand der Technik neu sind. Es wird weiterhin darauf hingewiesen, dass in den einzelnen Figuren auch Merkmale beschrieben wurden, welche für sich genommen vorteilhaft sein können. Der Fachmann erkennt unmittelbar, dass ein bestimmtes in einer Figur beschriebenes Merkmal auch ohne die Übernahme weiterer Merkmale aus dieser Figur vorteilhaft sein kann. Ferner erkennt der Fachmann, dass sich auch Vorteile durch eine Kombination mehrerer in einzelnen oder in unterschiedlichen Figuren gezeigter Merkmale ergeben können. Bezugszeichenliste The applicant reserves the right to claim all features disclosed in the application documents as essential to the invention, provided they are new compared to the prior art, either individually or in combination. It is also pointed out that the individual figures also describe features which can be advantageous in and of themselves. The person skilled in the art recognizes immediately that a specific feature described in a figure can also be advantageous without adopting further features from this figure. Furthermore, the person skilled in the art recognizes that advantages can also result from a combination of several features shown in individual figures or in different figures. reference list
1 Verbund, Bodenelement 1 compound, floor element
12 Oberschicht 12a - 12c Teilschichten der Oberschicht 12 Upper layer 12a - 12c sub-layers of the upper layer
14 Zwischenschicht, insbesondere Vlies - Matte14 intermediate layer, especially fleece - mat
15 Kernschicht 15 core layer
16 Zwischenschicht, insbesondere Vlies - Matte16 intermediate layer, especially fleece - mat
18 Unterschicht 18 underclass

Claims

Patentansprüche patent claims
1 . Bodenelement (1 ) für Kraftfahrzeuge, mit einem Schichtverbund aus mehreren Schichten, wobei eine Oberschicht (12) und eine Unterschicht (18) vorgesehen sind und wenigstens zwei zwischen der obersten Schicht (12) und der untersten Schicht (18) angeordnete weitere Schichten (14, 15, 16) vorgesehen sind, dadurch gekennzeichnet, dass diese wenigstens zwei Schichten (14, 15, 16) aus recyclingfähigen und/oder recycelten Materialien hergestellt sind oder solche aufweisen, und/oder aus nachhaltigen Materialien, wobei sich die Materialien dieser wenigstens drei Schichten (14, 15, 16) unterscheiden. 1 . Floor element (1) for motor vehicles, with a layered composite of several layers, an upper layer (12) and a lower layer (18) being provided and at least two further layers (14 , 15, 16) are provided, characterized in that these at least two layers (14, 15, 16) are made of recyclable and / or recycled materials or have such, and / or sustainable materials, the materials of these at least three Differentiate layers (14, 15, 16).
2. Bodenelement (1 ) nach Anspruch 1 , dadurch gekennzeichnet, dass zwischen der Oberschicht (12) und der Unterschicht (18) eine dritte Schicht angeordnet ist und bevorzugt die dritte Schicht (14, 15, 16) aus einem recyclingfähigen Material und/oder nachhaltigem Material besteht. 2. Floor element (1) according to claim 1, characterized in that between the top layer (12) and the bottom layer (18) a third layer is arranged and preferably the third layer (14, 15, 16) made of a recyclable material and / or sustainable material.
3. Bodenelement (1 ) nach wenigstens einem der vorangegangenen Ansprüche, dadurch gekennzeichnet, dass die weiteren Schichten (14, 15, 16) eine Kernschicht (15) aufweisen, welche zwischen zwei weiteren Schichten (14, 16) angeordnet ist, wobei auch die zwei weiteren Schichten (14, 16) zwischen der Unterschicht und der Oberschicht angeordnet sind. 3. Floor element (1) according to at least one of the preceding claims, characterized in that the further layers (14, 15, 16) have a core layer (15) which is arranged between two further layers (14, 16), the two further layers (14, 16) are arranged between the bottom layer and the top layer.
4. Bodenelement (1 ) nach dem vorangegangenen Ansprüche, dadurch gekennzeichnet, dass wenigstens eine der zwei weiteren Schichten und bevorzugt die beiden weiteren Schichten (14, 16) als Vlies - Matten ausgebildet sind. Bodenelement (1 ) nach wenigstens einem der vorangegangenen Ansprüche 1 - 4, dadurch gekennzeichnet, dass wenigstens eine der zwei weiteren Schichten und bevorzugt die beiden weiteren Schichten aus einem Material hergestellt sind, welches aus einer Gruppe von Materialien ausgewählt ist, welche Bambus, Flachs, Kenaf, Hanf, Zellulose, Holz, Mischungen aus diesen Materialen, oder dergleichen enthalten. Bodenelement (1 ) nach wenigstens einem der vorangegangenen Ansprüche 4 - 5, dadurch gekennzeichnet, dass die Kernschicht aus einem Material hergestellt ist, welche aus einer Gruppe von Materialien ausgewählt ist, welche Papier oder Pappe enthält. Bodenelement (1 ) nach wenigstens einem der vorangegangenen Ansprüche, dadurch gekennzeichnet, dass auch die Oberschicht wenigstens teilweise aus einem recyclingfähigen Material besteht. Bodenelement (1 ) nach wenigstens einem der vorangegangenen Ansprüche, dadurch gekennzeichnet, dass die Unterschicht ein Abdeckvlies ist, welches bevorzugt aus rPET und/oder rPP hergestellt ist. Kraftfahrzeug mit einem Bodenelement (1 ) nach wenigstens einem der vorangegangenen Ansprüche. Verfahren zur Herstellung eines Bodenelements für ein Kraftfahrzeug mit den Schritten 4. Floor element (1) according to the preceding claims, characterized in that at least one of the two further layers and preferably the two further layers (14, 16) are designed as fleece mats. Floor element (1) according to at least one of the preceding claims 1 - 4, characterized in that at least one of the two further layers and preferably the two further layers are made of a material which is selected from a group of materials which is bamboo, flax, Kenaf, hemp, cellulose, wood, mixtures of these materials, or the like. Floor element (1) according to at least one of the preceding claims 4-5, characterized in that the core layer is made of a material which is selected from a group of materials which includes paper or cardboard. Floor element (1) according to at least one of the preceding claims, characterized in that the top layer also consists at least partially of a recyclable material. Floor element (1) according to at least one of the preceding claims, characterized in that the underlayer is a cover fleece, which is preferably made of rPET and/or rPP. Motor vehicle with a floor element (1) according to at least one of the preceding claims. Method for producing a floor element for a motor vehicle with the steps
- Herstellen eines Verbundes aus wenigstens drei Schichten, wobei eine Kernschicht (15) zwischen zwei weiteren Schichten angeordnet wird und der Verbund erwärmt wird; - producing a composite of at least three layers, wherein a core layer (15) is arranged between two further layers and the composite is heated;
- Aktivierung einer Unterschicht und Anbringen der Unterschicht an den Verbund, dadurch gekennzeichnet, dass 14 diese wenigstens zwei Schichten (14, 15, 16) aus recyclingfähigen und/oder recycelten Materialien, und/oder nachhaltigen Materialien hergestellt sind, wobei sich die Materialien dieser wenigstens drei Schichten (14, 15, 16) unterscheiden. - activation of a sub-layer and attachment of the sub-layer to the composite, characterized in that 14 these at least two layers (14, 15, 16) are made of recyclable and/or recycled materials and/or sustainable materials, the materials of these at least three layers (14, 15, 16) being different.
PCT/EP2021/087422 2021-01-27 2021-12-22 Floor element and in particular loading floor for motor vehicles and method for producing same WO2022161720A1 (en)

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WO2020148152A1 (en) 2019-01-16 2020-07-23 Autoneum Management Ag Sandwich panel for a car able to carry a load

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Publication number Priority date Publication date Assignee Title
EP0671259A1 (en) * 1994-02-09 1995-09-13 R + S STANZTECHNIK GmbH Multilayer composite panel or article with a core comprising natural fibers and method for its manufacture
DE19719274A1 (en) * 1996-11-12 1998-05-20 Hp Chemie Pelzer Res & Dev Recyclable molded carpet part
WO2012104318A1 (en) 2011-02-04 2012-08-09 Faurecia Automotive Industrie Motor vehicle structural component and associated method of manufacture
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WO2018053002A1 (en) 2016-09-13 2018-03-22 Sabic Global Technologies B.V. A honeycomb system
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WO2020148152A1 (en) 2019-01-16 2020-07-23 Autoneum Management Ag Sandwich panel for a car able to carry a load

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