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    • 专利摘要:
    production method for a multilayer coating for thermal and sound insulation production method for a multilayer coating for thermal and sound insulation with the mixed fiber reinforcement steps and polyamide matrix material, in the form of fibers, flakes or powder, and forming a plot of said mixture; layering said merged web and at least one additional layer chosen from an open cell foam layer, a heat reflective layer, or another of said merged web within a mold; treating the stacked multilayer material with pressurized saturated steam, such that the polyamide matrix material in the merged web melts at a temperature under vapor pressure that is lower than the melting temperature of the polyamide matrix according to dsc, from this thus linking the reinforcement fibers together thus consolidating the merged weft forming a porous reinforcement layer, and all layers of the multilayer are laminated together.
    公开号:BR112013023257B1
    申请号:R112013023257-9
    申请日:2012-03-13
    公开日:2020-12-15
    发明作者:Thomas Bürgin；Pierre Daniere；Philippe Godano；Stefan Königbauer；Wenzel Krause
    申请人:Autoneum Management Ag；
    IPC主号:
    专利说明:

    The invention relates to a method of producing a multilayer coating molded by heat and sound insulation, in particular the vehicle engine compartment.
    <HEAD>> Fundamentals of technique
    Acoustic and thermal coatings for vehicle applications are well known in the art. These coatings typically depend on both sound absorption, that is, the ability to absorb incident sound waves, and loss of transmission, that is, the ability to reflect incident sound waves, in order to provide sound attenuation. They also depend on the thermal protection properties to prevent or reduce the transmission of heat from various heat sources (engine, transmission and exhaust system), to the passenger compartment of the vehicle. Such linings are in particular used in the area of the engine compartment of a vehicle, for example, employed as an engine cover in order to attenuate the sound of the engine closest to its source.
    In the engine compartment of vehicles, including passenger and commercial vehicles, soundproof parts in the form of absorbers are increasingly being used to reduce engine noise. In general, these pads are designed as molded articles to reduce vehicle interior and exterior noise. Molded articles can be made of wefts (for example, cotton) or polyurethane foam, and typically have thermal stability up to around 160 ° C.
    In certain areas, such as exhaust manifolds, hot air recirculation areas or around the engine itself, molded articles can be subjected to high thermal loads. Thus, these molded articles are often laminated, partially or completely, with aluminum foils to serve as heat reflectors in order to protect the underlying nonwoven. In general, the aluminum foil is thick enough to function as the carrier layer, activating the mechanical properties for the part to be self-supporting. The sound-absorbing material is kept as loose material and as thick as possible to optimize the acoustic properties of the piece. For example, DE 8700919 discloses such aluminum laminate with foam glued on the inside for insulation purposes. Other examples are made of interposing sheets of loose fibrous material between two layers of metal sheets with which the metal layers have structural carrier properties.
    Recently, composite thermal coatings are partially replacing the typical heat protection trim pieces. These composite coatings are generally formed as multilayer assemblies. These sets are constructed with a thermally exposed layer having reflective and waterproofing functions, and a composite layer having good thermal insulation, mechanical and structural properties and sometimes with an additional top layer for appearance and waterproof properties. These types of coatings are produced using injection molding or compression molding. The disadvantage of these composite thermal coatings is that they are waterproof and heavy structural parts. Although they have good thermal and structural properties, they lack acoustic and thermal attenuation properties in most cases.
    While a number of adhesives, adhesive wefts and bonding fibers have been specifically developed over the years to ensure that the various layers of laminates together, laminate and insulating coatings have an inherent risk of delamination and failure. This potential risk is significant mainly due to the harsh operating environment to which such coatings and insulators are subjected. Many coatings and insulators are located close to and / or designed to house sources of hot heat such as the engine, transmission and exhaust system components. As a result, coatings and insulators are often subjected to temperatures in excess of 180 ° C, where adhesives or binders show strong and rapid degradation over time.
    In addition, directly assembled parts adjacent to the engine tend to vibrate and cause noise due to vibrations transmitted from the engine. These vibrating parts can form additional unwanted noise. Another aspect is the fatigue property of the coating involved, the frequency of vibration can have a negative effect on the total life of the coating.
    An additional disadvantage of the prior art is the high temperature required to obtain the final composite. To reach the heating temperature there is a dependence on the matrix polymer. In general to form the composite, the matrix and reinforcement fibers are heated using dry heating methods such as hot air, contact heating or infrared heating. In order to compensate for the loss of temperature, for example, from the heating device to the molding device, the product is usually heated above the actual melting point of the matrix polymer or above the activation temperature of the bonding resin. Heating the polymer above the melting point accelerates degradation.
    Using a contact heater has the additional disadvantage that the product has to be compressed to obtain good heat transfer through the thickness of the product. Hot air is generally used at a temperature above the melting temperature of the binder polymer such that the polymer becomes damaged by heat, while the use of infrared heating is only possible with thin materials. In thicker materials the amount of energy needed to heat the inner material is detrimental to the outer surface polymers. This method is normally used only for a thickness of up to 4-5 mm.
    Using contact heaters in a multilayer coating including a layer of foam in an open cell plate will cause the foam to collapse, particularly in the skin of the plate foam making it impermeable to airborne sound waves, thereby deteriorating the total sound absorption of the piece.
    Another disadvantage is the fact that most of the thermoplastic polymers used as matrix fibers and the reinforcement fibers have their melting temperature close to each other, for example, the melting temperature as measured using Differential Scanning Calorimetry (DSC) according to ISO11357-3 of polyethylene terephthalate (PET) is in the range of 230-260 ° C, of polypropylene between MO-VO ° C, of Polyamide-6 (PA6.6) between 170-225 ° C and of Polyamide-6.6 between 220 -260 ° C. Using matrix fibers and reinforcement fibers both being thermoplastic polymers, for example, PA6.6 as matrix and PET as reinforcement, having to heat them above the melting temperature of the matrix fibers will also cause the reinforcement fibers to start melting or soften. This will lead to a collapse of the structure, forming a very compact composite.
    Felts are widely used particularly in the automotive industry for their thermal and acoustic insulation properties. The trend is towards recyclable materials; therefore, thermoplastic binders have taken a significant share in recent years. Fibers made from high performance polymers such as polyester, polyamide are highly interesting due to their mechanical and heat resistance properties. But the necessary bonding agent forms the limitation for its use in 3D molded parts.
    The bonding agents used until then always have a lower melting point than reinforcement fibers, yielding relatively poor performance behavior for the molded fiber web and limiting its use to soft areas in the vehicle. None of these types of molded fiber wefts are suitable for exposure to high temperature in the engine compartment or cab, particularly the contact areas of the engine. Some of these binders are modified polymers (Co-Polyester (CO-PET) as an example) with shear behaviors due to their modified structure being particularly sensitive to hydrolysis phenomena.
    The processes for molding such felts as known in the art are a "cold" molding process in which the felt is preheated by various means, and then transferred to a cold mold in which it is compressed in order to obtain the shape of the part or a “hot” molding process, in which the felt is introduced into a closed mold, in which a heat transfer medium, such as air, is introduced to bind the bonding agent to its melting point, and then The part is then cooled, inside or outside the instrument, with or without cooling aid. (See for example, EP 1656243 A, EP 1414440 A, and EP 590112 A) Only after complete cooling to a temperature at which the material is defined, the part can be removed from the mold and transported.
    Fibrous composites as disclosed are generally used in combination with additional layers, such as reflective layers as discussed or with foam. The foam can be applied to such fibrous composites by direct back foam defoaming (foam injection or foam molding). However, the foam is often first produced as foam board and cut to the desired thickness. For lamination of the foam from the adjacent fibrous layer, generally hot compression molding is used. The layer stack is placed between two hot plates to melt the material and obtain lamination of the layers. Compression is necessary to help heat transfer to the porous reinforcement of the layered material. A disadvantage of such a method, in particular in which foam layers are used, is that the foam collapses and forms a layer of skin over the open cell structure. This layer of skin deteriorates the total sound absorbing performance of open cell foam. Summary of the Invention
    Under these conditions, the objective of the invention is to provide a process for producing a molded multilayer coating, in particular for the vehicle engine compartment, having comparable heat insulating and soundproofing properties, but which are lighter and maintain the structure in long-term exposure to thermal load in the area of use.
    The objective is achieved by the production process for a steam-formed multilayer coating according to claim 1.
    In particular, by using the production method according to the invention comprising at least the steps of mixing reinforcement fibers and polyamide matrix material in the form of fibers, flakes or powder, and forming a weave of said mixture; - layering a first of said blended fabric and at least one additional layer chosen from an open cell foam layer, a heat reflective layer, or a second of said blended fabric within a mold; - treating the stacked multilayer material with pressurized saturated steam, such that the polyamide matrix material in the merged web is based on a temperature under vapor pressure that is lower than the melting temperature of the polyamide matrix according to DSC, in this way connecting the reinforcement fibers together thus consolidating the merged weft forming a porous reinforcement layer, and all layers of the multilayer are laminated together.
    It has been found that using a direct steam molding process on polyamide as a bonding material, the softening and melting point of the polyamide is shifted to a lower temperature under vapor pressure as the normal polyamide melting temperature measured according to DSC. By using this knowledge it is now possible to make parts that in use have a higher melting temperature and are able to be heat stable at temperatures much higher than those of prior art materials. In addition, it has been found that the polyamide material used in the reinforcement layer is sufficient to also laminate adjacent layers. Layers such as foam or heat reflective layer, without the need for additional corresponding glue layers. In particular, it was found that the use of direct steam molding on additional foam layers had no negative effect, for example, foam melting, on the acoustic properties of the foam layer. Therefore, maintaining the advantageous acoustic properties of skinless open cell foam as produced.
    The production process according to the invention can be used directly to steam mold the multilayer coating in a three-dimensional format, such as an engine span cover panel, an upper, side or bottom cover for an engine, a protective cover from oil pan, lower engine cover, fire wall, and external instrument panel with at least partial coverage, an air guide panel behind the engine compartment radiator, a rear shelf or a loading surface from the trunk, to serve as an automotive trim piece inside the car.
    In the following, the steam-molded multilayer coating according to the inventive process and the steam molding process will be explained in more detail and with examples of the use of such material. Production process
    In the method according to the invention, high modulus reinforcement fibers are mixed with matrix forming material in the form of polyamide fibers, flakes or powder to form a weave by any suitable method such as air laying, moisture laying, carding etc. . This web is then heated using saturated steam to melt the polyamide matrix material at a temperature that is lower than the polymer melting temperature as measured using Differential Scanning Calorimetry (DSC) according to ISO11357-3. For example, the melting temperature Tm of polyamide-6 (PA-6) is 2201C as measured using DSC. However, the melting temperature of the same PA-6 under vapor pressure according to the invention is, for example, 190 ° C.
    The weft is positioned in a pressure-resistant mold with at least one vapor-permeable surface. The mold is closed and stapled to withstand internal pressure. Saturated steam of at least 9 bar absolute pressure is applied to melt the binder. Saturated steam above 20 bar absolute pressure is no longer economical. Preferably a range of 11 to 15 bar absolute pressure is a good working range. The actual displacement of the polyamide melting temperature is dependent on the vapor pressure generated in the cavity that the product is molded by steam. The choice of pressure used is therefore also dependent on the melting temperature of the reinforcement fibers. For example, using PA-6 as binding fibers the preferred pressures are 11 to 15 bar absolute pressure.
    By using steam instead of the usual hot air, hot plates or IR wave it is possible to move the melting point of polyamide to a lower temperature using the effect of water molecules on steam. The effect of water on polyamide is known and is usually considered to be a disadvantage; many states of the art describe ways to avoid the effect or try to avoid it.
    It is simply this effect, which makes it possible to combine polyamide material applied in the form of powder, flakes or fibers with other thermoplastic fibers with similar melting points as measured with DSC, such as polyester (PET), using polyamide as the bonding material alone, maintaining the reinforcing fibers, such as PET, in their fibrous form. It is now possible to obtain a heat-stable product molded with a porous structure, thereby improving the acoustic properties, such as absorption and resistivity to airflow, as well as thermal conductivity.
    The steam effect is based on a reversible diffusion mechanism. Using polyamide, in the form of small or fine fiber diameter particles, melting and solidification is fast and provides short production cycles. Once steam is released from the polyamide mold it changes to a solid state and the part can be demoulded as a rigid part. This is an advantage compared to other thermoplastic binders that need to be cooled explicitly inside or outside the mold before obtaining a structural part that will be handled.
    Because of the total temperature used, it can now be kept much lower compared to steam-free heating methods, the resilience of PET fibers is to remain intact, leading to a more noble material. In addition, it was found that the PA bond was sufficient to obtain the necessary rigidity of the final product. Because the PET fibers maintain their resilience and the melted PA matrix material only bonds to the crossing points. The material maintains its noble appearance due to the void volume in the weave. Therefore, the final product will still be air permeable. Furthermore, it was found that using glass fibers as reinforcement fibers together with polyamide as the matrix, the use of steam is advantageous. Due to the precise regulation of the binding properties less energy is required for the process, both during heating and during cooling.
    In the heating process according to the state of the art the material is heated to the melting point of the thermoplastic matrix material. The cooling of the material is slow due to the slower convection of heat out of the product and because of the collapsed material, due to the lack of resilience of the reinforcement fibers and to have become more compact. Thus, the melting condition will continue for a longer period. As a result it is more difficult to regulate the amount of binding. In addition, during this cooling period the material remains soft because of the longer molten state of the bonding matrix and is therefore more difficult to handle. This is particularly the case for larger automotive trim parts, such as roof cladding or cargo surfaces for a large truck or vehicle.
    It was verified, that the use of the material and the process according to the invention, as soon as the steam was removed from the material the casting process stopped immediately and the obtained material is in solid state again. This is an advantage in the ability to reduce production cycle times because the material is immediately manageable. The fact that the melting process can be stopped immediately is also a very precise way of regulating the bonding properties and therefore, the porosity of the material. Which is important for the material's air permeability properties.
    The use of polyamide in a discrete form such as flakes, powder or fibers, is necessary to ensure a discreet bonding of the reinforcement fibers, to obtain a porous but consolidated structure. Due to the discreet but complete consolidation of the reinforcement fibers, flexural stiffness as well as dynamic stiffness can be achieved. As the materials chosen are preferably thermostable at least above 180 ° C, a material that maintains its structure is obtained, in particular it will not soften or deform upon long-term exposure to a high thermal load. As the consolidation of the polyamide and the reinforcement fibers is only based on the softening and melting of the polyamide under the influence of the direct treatment with saturated steam under pressure, it is not necessary to compress the reinforcement layer more than necessary to obtain the desired 3D format of the final product.
    It has been found that lamination of the additional layers to the porous reinforcement layer is possible in the same step of the steam molding process. It was even found that the PA matrix material was strong enough to be used as a laminating binder to bond additional layers, for example, in combination with an open cell foam layer and / or a reflective layer such as aluminum foil and / or a layer of fabric trellis.
    It was found that using steam molding in the temperature range according to the invention the foam material was not modified in acoustic performance. In normal hot molding methods according to the state of the art the foam is usually heated to a temperature at which the foam softens and forms a skin on the outer layer or even worse shrinks in volume or collapses. This has a deteriorating effect on foam quality after molding as well as on acoustic performance. An unwanted displacement can be seen in the sound absorption after molding, as compared to the original state. At worst, the displacement can be transformed into a total loss of sound absorption.
    Steam is known to regenerate the foam back to its original components and is therefore not normally used for molding parts where a degeneration of the material is undesirable. The process according to the invention does not show any measurable impact on the structural and acoustic properties of the treated foam. As the foam is not particularly melting during the vaporization process, the open cell structure originally obtained during foam production is maintained. The bonding of the porous reinforcement layer with the foam layer comes only from the melted droplets of the polyamide binder material. This is sufficient to obtain a stable laminated connection. This has the additional advantage that in thermally charged environments such as the engine compartment the temperature for delamination is much higher than with the material normally used. Furthermore, the thermally weak link is no longer the binder itself.
    It was even verified that reflective material could be laminated directly with the porous reinforcement layer according to the same principle. However, in the case of metal sheets, in particular aluminum sheets, the lamination surface in contact with the porous reinforcement layer could be pretreated to improve lamination.
    If necessary, an additional binder layer of polyamide, in the form of a film, powder, flakes or a layer of fabric trellis can be placed between the layers to improve the binding properties. The porous reinforcement layer
    The porous reinforcement layer is an air-permeable composite with increased rigidity of randomly arranged bonding material and reinforcement fibers held together at the fiber crossing sites by essentially discrete droplets of the thermoplastic bonding material.
    The material used as the thermoplastic bonding material is a polyamide matrix in the form of powder, flakes or fibers. The use of polyamide fibers in the porous reinforcement layer is the most preferred, the fibers generally mixed
    together they improve and remain that way during weft handling before consolidation. In particular flakes or dust may fall between the reinforcement fibers outside the web by handling without consolidation.
    As polyamide all types of polyamide mixtures are feasible, preferably at least one of CoPA (Co-polyamide), Polyamide-6 (PA-6) or Polyamide-6.6 (PA6.6). Normal additives used in the basic polyamide recipe are expected to be part of the basic polyamide material as claimed, for example, chemical compounds to obtain Ultra Violet Resistance or additional chemicals to increase heat stability.
    The use of polyamide polyamide binding fibers is the most preferred and used in the examples and preferred embodiments, however, the use of powder or flakes can be used as well as in the same examples with comparable results.
    Reinforcement fibers can be - mineral based fibers, such as glass fibers, basalt fibers or carbon fibers, and / or - man-made fibers having a melting temperature measured according to DSC, which is higher than the melting temperature of the polyamide under vapor pressure, such as polyester fibers, and / or - natural fibers, such as linen, coconut or quenafe fibers.
    In particular the reinforcement fibers can be any material based on thermoplastic polymer with a melting temperature according to DSC Measurement, which is higher than the melting temperature of the polyamide binder material in a steam environment. For example, man-made fibers like PET (polyester terephthalate) with a melting temperature of between 230-260 ° C can be used as a reinforcing fiber. The choice of material is based on the requirement for total heat stability of the final product and the price of individual materials.
    Mixtures of man-made fibers with mineral fibers can also be used as reinforcement fibers, for example, PET together with glass fibers (GF). Using such combinations will increase the nobility of the final layer and can be defined as an acoustic reinforcement layer, see separate description of this layer for more details. Reinforcement fibers can be cut fibers, endless filaments or wicks depending on the required material properties.
    The raw material for the reinforcement layer is a blanket of bonding material arranged at random and reinforcement fibers, which can be made according to methods known in the art, for example, using air-laid, or carding technology or by forming directly after extrusion of fiber materials. The produced mat can be pre-consolidated to allow easier handling, for example, by needling.
    The rate of polyamide material binding to the reinforcement fibers is such that after steam treatment the material remains porous. Preferably between 20 and 60% by weight of polyamide bonding material. Acoustic reinforcement layer
    The acoustic reinforcement layer is a noble version of the reinforcement layer with increased sound absorption properties.
    The bonding material is the same as disclosed for the porous reinforcement layer, however, the reinforcement fibers can be any combination or mixture of mineral-based fibers, such as glass fibers, basalt fibers or carbon fibers, and fibers made by man having a melting temperature measured in accordance with DSC, which is higher than the melting temperature of the polyamide under vapor pressure, such as polyester fibers, one / or natural fibers, such as linen, coconut or quenafe fibers. For example, a combination of PET (polyester terephthalate) with a melting temperature of between 230-260 ° C together with glass fibers would work as well as reinforcing fibers.
    It was found that by using such a combination of fibers the material maintains its nobility during the steam molding process. The material not only has increased stiffness, but also increased sound absorption.
    Mineral fibers like glass fibers are fine fibers and as such are preferred for sound absorption, however, through heat treatment they tend to lose their volume, and therefore the original sound absorbing properties. It has been found that man-made fibers or properly chosen natural fibers, such as polyester fibers or quenafe fibers, maintain their rigidity during steam molding of the coating material. Therefore, the volume of the material is maintained and the consolidated material remains porous, from which the original sound-absorbing properties are still given.
    Preferably a mixture of approximately 20-40% by weight of polyamide, approximately 20-50% by weight of glass fibers and 20-50% by weight of polyester fibers or natural fibers would work well.
    Reinforcement fibers can be cut fibers, endless filaments or wicks depending on the required material properties. Heat reflective layer
    Along with the fibrous layer of porous reinforcement at least one heat reflective layer can be used. The surface facing the heat source, usually the engine or parts of the power train or exhaust line or the surface exposed to sunlight, can be covered, either partially or completely, with a layer of heat reflective covering at least in the area of increased thermal load. The reflective covering layer should be heat-stable and capable of reflecting infrared radiation from either the heat source or the sun, to obtain a good insulation from the heat of the trim piece, preferably the reflective covering layer is one of a sheet layer. metal, preferably stainless steel or aluminum foil layer, or an aluminized or non-woven textile, or a textile made of aluminum fibers. The heat reflective layer must at least be able to withstand steam treatment without deterioration.
    The reflective covering layer is preferably between 20 and 150 μm, more preferably between 50 and 80 μm. The low thickness can be used as long as the reinforcement layer is carried out in the main static function, the function of the reflective layer is only, in principle, to reflect heat radiation.
    Although not necessary in all cases, the reflective covering layer can be at least partially microperforated. Microperforation can be done by technologies known as needling, splitting, micro cracking or puncture technologies. Through an optional perforation of the heat reflector, the heat reflection effect of the layer is maintained, however, the transmittance for acoustic waves is achieved in this area such that the aluminum-coated side of the multilayer coating facing the source of heat sound maintains its acoustic activity.
    Particularly in the case of the reflective covering layer the material of choice is non-porous or non-perforated, the heat input should preferably be on the side of the fibrous trim piece that is not covered with the reflective covering layer to optimize the penetration of vapor into the layer porous reinforcement.
    In the case of the use of reflective covering layers on both sides of the material, at least one of the layers used must be perforated and / or porous enough to allow a flow of steam in the fibrous layer.
    A layer of reflective material can also be used in between two layers of reinforcement according to the invention. This layer is preferably perforated or porous, however, the sheet being perforated or porous is not necessary if the flow of steam is entering the mold from both halves of the mold instead of through only one half of the mold. Foam layer
    As an additional layer, a layer of open cell foam can be used. The foam is preferably skinless foam. Foam board, produced continuously or discontinuously, is the most preferred, as this foam is cut into sheets after foaming and curing, so the open cell structure is directly accessible without any skin.
    Preferably the foam layer is at least thermally stable for a short time between 160 and 220 ° C, for example, it is made of open cell polyurethane foam (PUR), or a polyester foam (PET).
    Polyurethane foams are made by adding polyisocyanates and polyols. Additives are used as needed. Examples of PUR Foams that can be used in the coating according to the invention are for example, disclosed in EP 0937114 or EP 937109 A.
    In particular for use in the area of the engine compartment or in areas with an increased thermal load the use of a flame retardant for example, treatment with a liquid and / or solid retardant and or incorporating such retardant in the foam is favored. The use of foam with additional graphite for example, as disclosed in EP 1153067 or US 6552098 would be preferred.
    The full disclosure of these documents in particular regarding the production process and the composition of the foam board material is incorporated herein by reference.
    Industrially available foams, prepared as foam on slabs, which can be used with the coating according to the invention are, for example, ACOUSTIFLEX S15 (semi-rigid), or ACOUSTIFLEX F 25 (flexible) from Huntsmann, or Flexidur 15 FR + (semi rigid) or Rigidaur 10 (semi-rigid) by Foampartner or the range of semi-rigid Thermoflex foams in different grades and densities made by Eurofoam such as Thermoflex 15, Thermoflex 15 MDA, Thermoflex 15 MDA VW, Thermoflex 16, Thermoflex 16 22 and flexible Thermoflex foams such as T-flex 16 or T-flex 22.
    Preferably the density of the foam is between 8 and 40 kg / m3, more preferably between 12 and 30 kg / m3. As the open cell foam will add to the total noise attenuation of the coating according to the invention, resistance to air flow is preferred in the range of 100 to 5000 (Ns.m3) for a thickness of between approximately 6 and 45 ( mm) for the foam board before molding.
    It has been found that the foam layer does not change its acoustic properties during steam treatment, in particular the time and conditions are such that the foam is keeping the foam of open cell structure. In particular, the closure of the skin layer, as can be seen with laminated foam in a standard molding instrument, could not be observed with the method according to the invention. Therefore, the acoustic properties of the open cell foam are completely maintained in the coating according to the invention.
    If the coating is used for a structural part with a high mechanical load the foam layer used can be chosen to improve the total structural properties, for example, by choosing a more rigid foam layer, for example, made of polyurethane or polyester, or by adding reinforcing fibers to the foam layer. Additional layers
    Preferably additional layers can be used. For example, an aesthetic coating, or a non-stick layer, to prevent the laminate coating from sticking to the mold walls may be necessary. Preferably, a lattice layer of fabric made of thermoplastic fibrous material, heat resistant to the temperature range as given during steam molding is used.
    A fabric trellis is a thin non-woven fabric with a thickness between 0.1 and around 1 (mm), preferably between 0.25 and 0.5 (mm). Preferably they have an increased air flow resistance (AFR) of between 500 and 3000 (Nsrrf3), more preferably between 1000 and 1500 (Nsm 3).
    The weight / area ratio of the fabric trellis layer can be between 15 and 250 (g / m2), preferably between 50 and 150 (g / m2).
    The fabric lattice can be made of continuous or stapled fibers or mixtures of fibers. The fibers can be made by meltblown or spunbond technologies. They can also be mixed with natural fibers. Preferably, the material chosen is heat-stable on long-term exposure to thermal load. The fabric lattice can be made of fibers, for example, made of polyester, or polyamide, or oxidized, thermally stabilized polyacrylonitrile (PAN, also known as PANox) or a combination of fibers for example, polyester and cellulose, or polyamide and polyester. The layer
    can be treated with the usual treatment required for the application area, for example, oil repellent, water repellent, flammability treatment etc. A preferred example of a fabric lattice layer can be a nonwoven fabric lattice layer made of polyester and viscose fibers.
    When the covering according to the invention is used in the passenger area, alternative cover layers such as non-woven carpet or tufted carpet can also be used. These layers could also be added after the steam molding process step, using conventional methods known in the art.
    In the steam molding process, a lattice layer of polyamide fabric can be used in addition to laminate additional layers not directly adjacent to the reinforcement layer and / or to increase the amount of bonding material in the laminating zone. The polyamide can also be sprayed in the form of powder or flakes on / on the surface before adding additional layers, or applied as a thin adhesive sheet or reticular structure. Thus, other layers not directly adjacent to a reinforcement layer can also be laminated to the multilayer coating according to the invention, for example, aesthetically different covering layers, such as tufted or non-woven carpet layer, flake material wool or nonwoven cover materials. Multilayer coating
    The steam-formed multilayer coating produced in accordance with the invention comprises a porous reinforcement layer, and at least a second layer chosen from a foam layer, a reflective layer, or a second porous reinforcement layer.
    Additional layers can be used as well, such as additional foam layers or reinforcement layer or as aesthetic covering layers, or technical fabric lattice layer for further improving the properties of the multilayer coating according to the invention. The use of similar layers with different densities can also be envisaged. If, for example, two layers of foam are used in direct contact, also the use of a polyamide bonding layer, in the form of a fibrous polyamide fabric lattice, weft, perforated sheet, powder or flakes can be used. The use of polyamide as an additional bonding layer is advantageous, as it will react to steam in the same way as the material matrix in the reinforcement layer.
    The porous reinforcement layer is mainly forming the necessary structural rigidity. In most applications the coating is used as a self-supporting structure.
    In a preferred application, the multilayer coating comprises at least two layers chosen from a porous reinforcement layer and a porous acoustic reinforcement layer. Preferably, both layers are only connected to each other in the coating ring or by the use of separators, leaving an empty space between the main surfaces of the layers. The empty space acts as an additional acoustic absorption area and an acoustic and thermal decoupling zone. By using at least one layer of porous acoustic reinforcement, the total acoustic performance can be increased.
    In the area of the engine compartment, different types of trim parts are used, for example, engine encapsulation, upper engine covers as well as engine encapsulation that is mounted on the vehicle chassis. In addition, other components such as car hood lining, external roof lining as well as under engine cover and vertical elements along the front beams can be positioned in the engine compartment to optimize the heat management of the engine compartment . In particular, a hood, fire wall, or cover members adjacent to the automotive engine as the main engine cover, engine side panels, as well as other coatings used on a vehicle in thermally exposed areas such as a power train, including the box gearbox, exhaust line, in particular heat shields mounted on the body and power train and / or exhaust line. Also, all types of underbody panels used, in particular under the engine and the passenger compartment, fall within the scope of use for the inventive coating.
    This and other characteristics of the invention will be clarified from the following description in the preferred way, given as non-restrictive examples with reference to the attached illustrations.
    With the help of the figures, examples of advantageous combinations of layers for specific applications will be given, to further explain the invention. However, the invention should not be restricted to these examples, they are intended to show the possibilities of the coating according to the invention. Brief description of the illustrations
    Figure 1 is a schematic top view of the steam treatment according to the invention
    Figure 2 shows schematically the layering of the coating material according to the invention. Description of modalities
    The production process will be explained in more detail using figure 1 shown a steam mold comprising a lower mold half 2 and a higher upper mold half 1. These two mold halves together define a mold cavity in which the semi product -finished will be at least consolidated. The mold cavity can be formed in the desired three-dimensional shape of the final trim piece. As a semi-finished product, a nonwoven fiber mat with a mixture of bonding material and reinforcement fibers 10 together with, for example, foam layer 11. Preferably the two mold halves have inlets and outlets 7,8 through which the Saturated steam can flow into the mold cavity by coming into direct contact with the multilayer material to be consolidated and laminated. As saturated steam is used, it is preferable that the mold halves are kept warm to help intensify the pressure and prevent vapor condensation. As steam condensation would cause a loss of heat energy and immerse the product in water. In the figure this is shown with channels 3,4,5 and 6, showing a closed heating system for the mold halves. The heat of the mold halves is not important for molding the coating.
    The mold may have additional cutting and sealing elements 9 at its ends; these can be moved and pushed independently, and they make a perimeter pressure-proof seal of the mold, that is, through a labyrinth seal. After pressure-proof sealing of the mold, the semi-finished product is exposed to saturated steam. The steam is used as pressurized steam with a pressure in the mold cavity of approximately 2-20 (absolute bar), preferably a pressure of at least 9 (absolute bar), and remains under this pressure in the mold cavity during the period of entire consolidation.
    The tempo process is governed by rising steam pressure and released for consolidation. Preferably before opening the press mold, the pressurized steam is released. Although some water condenses during the steam treatment, and is left in the coating material according to the invention, it will dry out after opening the mold, mainly due to the residual thermal energy left in the core of the part. Thus, once the steam pressure is removed, the softening and casting of the polyamide is reversed and the part is solidified. The vaporization process is therefore not only advantageous due to the necessary short downtimes, it also eliminates any cooling time required with traditional compression molding with dry systems before the molded part can be removed from the mold cavity.
    An example of a production method for a multilayer coating according to the invention contains at least the steps of: - mixing 40 to 80% of reinforcement fibers and 20 to 60% of polyamide matrix material in the form of fibers, flakes or powder, and forming a weave of said mixture; - lay a first blended weave and at least one additional layer chosen from an open cell foam layer, a heat reflective layer, or a second blended weave of reinforcement fibers and polyamide matrix material, within a mold consisting of two mold halves; - treating the stacked multilayer material with saturated pressurized steam, such that the polyamide matrix material in the merged web melts at a temperature under vapor pressure that is lower than the melting temperature of the polyamide matrix according to DSC, thereby linking the reinforcement fibers together, thus consolidating the merged weft forming a porous reinforcement layer, and such that the stacked layers are laminated together.
    The mold halves can be completely closed at the beginning or they can be closed during steam treatment, allowing some of the steam to escape at the beginning and / or at the end of the steam process. The saturated vapor pressure is preferably used in a range of 9 to 20 (absolute bar).
    At least one additional fabric lattice layer can be used to prevent the layered material from sticking to the mold. For example, a lattice layer of non-woven polyester-cellulose. The stacked multilayer material can contain even more additional layers like an additional layer of a merged weave, a layer of foam. The polyamide matrix is preferably co-polyamide or polyamide-6 or polyamide-6.6 or a mixture of these polyamides.
    The molded saturated porous multilayer coating, produced according to the production process as disclosed can be directly molded in a 3-D format to serve as an automotive trim part, such as an engine span cover panel, a top cover, side or bottom for an engine, a protective oil pan cover, a lower engine cover, a fire wall, an external instrument panel with at least partial coverage, an air guide panel behind the span radiator of the engine, a rear shelf or a cargo surface of the trunk.
    The steam-molded multilayer coating may be the most advantageous used in areas of increased thermal load on a vehicle, such as in the vicinity of the engine, power train and exhaust, but also in the trunk area or as trim parts that are exposed to sunlight directly behind a car window, such as a rear shelf or sunscreens.
    Figure 2 shows examples of possible multilayer material coating. For the base of the coating according to the invention, a porous reinforcement layer or a porous acoustic reinforcement layer can be chosen. The difference is that the reinforcement layer is mainly made of the polyamide matrix and reinforcement fibers. While the acoustic reinforcement layer consists of the polyamide matrix and reinforcement fibers, however, the reinforcement fibers are a mixture of man-made fibers and mineral fibers, for example, a mixture of polyester and glass fibers, resulting in a layer nobler after consolidation using the steam process.
    Figure 2A shows an example with a porous reinforcement layer 10 and an open cell foam layer 11, preferably an infrared reflective layer 13 can at least partially cover at least one of the outer surfaces of the coating. While also a layer of fabric lattice 13 can be used to cover the outer surface of the lining. Instead of the porous reinforcement layer 10 an acoustic reinforcement layer can be used in the situation where a higher level of sound absorption is required.
    Generally, reinforcement layers can replace injection-molded plastic layers, normally used in automotive trim parts since it has comparable rigidity properties. However, due to its porosity, it shows sound absorbing properties, which is not the case for injection molded measurements. The use of additional absorption layers even increases the sound absorption.
    For automotive trim parts used in a hot environment, particularly in the engine compartment area, the combination of the porous reinforcement layer with a layer of open cell foam is a good choice since it is very light and will suit most acoustic requirements.
    For trim parts used in areas with an increased thermal load, such as parts mounted directly on the engine, the use of combining a porous reinforcement layer with the nobler porous acoustic reinforcement layer is a better option.
    The heat reflective layer can be used in particular on the surface or partially on the surface which is directed towards the heat source, and / or which obtains most of the direct heat energy.
    The porous reinforcement layer 10 can also be combined with the acoustic reinforcement layer 14 (Figure 2B)
    Figures 2C, and 2D show examples of at least three layers. In 2C a foam layer 11 is placed between two reinforcement layers 10, although here the standard reinforcement layers are used, also two layers of acoustic reinforcement or one of each type can be used, depending on the situation, the coating multilayer is used. In particular in areas of high thermal load of the car where the foam needs thermal protection, this is an option. Preferably also with at least partial coverage with a reflecting surface (not shown) and or a layer of fabric lattice.
    Figure 2 D shows an interposition with a reinforcement layer 10 as a core layer, interposed between two / two layers of foam 11. This arrangement is an advantage if used in areas where the passenger and / or personal service come into regular contact with the surfaces. If glass fibers detach from the coating surface, they have a detestable pungent effect, which is at least unpleasant. Foam would cover the fiberglass surfaces, preventing this effect on the spot. The reinforcement layer will bring the structural properties, and therefore the foam can be semi-rigid or even a softer type of open cell foam as would normally be used.
    权利要求:
    Claims (13)
    [0001]
    1. Production method for a multilayer coating for thermal and sound insulation, characterized by the fact that it is with the steps of mixing reinforcement fibers and polyamide matrix material, in the form of fibers, flakes or powder, and forming a weave of said mixture; layered additive blend and at least one additional layer chosen from a layer of open cell foam, or a heat reflective layer, or another of said blend fabric within a mold; treating the stacked multilayer material with pressurized saturated steam, such that the polyamide matrix material in the merged web melts at a temperature under vapor pressure that is lower than the melting temperature of the polyamide matrix according to the Calorimetry of Differential Scanning (DSC), thus linking the reinforcement fibers together, thus consolidating the mixed weave forming a porous reinforcement layer, and all layers of the multilayer are laminated together.
    [0002]
    2. Production method for a multilayer coating according to claim 1, characterized by the fact that the reinforcement fibers in said blended weave are between approximately 40 to 80% by weight and the polyamide matrix material is between 20 to 60% by weight.
    [0003]
    3. Production method for a multilayer coating, according to claim 1 or 2, characterized by the fact that the saturated steam in the mold is pressurized in the range of 9 to 20 (absolute bar).
    [0004]
    4. Production process method for a multilayer coating according to any one of the preceding claims 1 to 3, characterized by the fact that at least one additional fabric lattice layer is used.
    [0005]
    5. Production process for a multilayer coating according to any one of the preceding claims 1 to 4, characterized in that the additionally stacked multilayer comprises an additional layer of said merged web or a foam layer or a heat reflective layer.
    [0006]
    6. Production process method for a multilayer coating according to any one of the preceding claims1 to 5, characterized by the fact that the heat reflective layer is only partially covering the adjacent layer.
    [0007]
    7. Production process method for a multilayer coating according to any one of the preceding claims1 to 6, characterized in that the reinforcing fibers are mineral based fibers, such as glass fibers, basalt fibers or carbon fibers, and / or man-made fibers having a melting temperature, measured according to a_DSC, which is higher than the melting temperature of polyamide under vapor pressure, such as polyester fibers, and / or natural fibers, such as linen, coconut or quenafe fibers.
    [0008]
    8. MethodProduction process for a multilayer coating according to any one of the preceding claims1 to 7, characterized in that the reinforcing fibers are a mixture of mineral-based fibers, such as glass fibers, basalt fibers or carbon, and man-made fibers having a melting temperature, measured according to DSC, which is higher than the melting temperature of polyamide under vapor pressure, such as polyester fibers, or natural fibers, such as linen, coconut fibers or quenafe.
    [0009]
    9. MethodProduction process for a multilayer coating according to any one of the preceding claims1 to 8, characterized in that the reinforcement fibers forming the reinforcement layer is a mixture of approximately 20-40% by weight of polyamide, approximately 20-50% by weight of glass fibers, and 20-50% by weight of polyester and / or natural fibers.
    [0010]
    10. MethodProduction process for a multilayer coating according to any one of the preceding claims 1 to 9, characterized in that the polyamide matrix is polyamide-6 or polyamide-6.6 or co-polyamide or a mixture of different types of polyamide .
    [0011]
    11. MethodProduction process for a multilayer coating according to any one of the preceding claims 1 to 10, characterized in that the open cell foam is a skinless foam, preferably a foam board.
    [0012]
    12. MethodProduction process for a multilayer coating according to any one of the preceding claims1 to 11, characterized in that the foam is polyurethane foam (PUR) or polyester foam (PET) or foam filled with fiber.
    [0013]
    13. MethodProduction process for a multilayer coating according to any one of the preceding claims1 to 12, characterized by the fact that the porous vapor-molded multilayer coating is molded in a three-dimensional format to serve as an automotive trim part in areas with a increased thermal load, such as an engine compartment cover panel, an upper, side or bottom cover for an engine, an oil pan protective cover, a lower engine cover, a fire wall, an external instrument panel at least partial coverage, a targeting panel
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    同族专利:
    公开号 | 公开日
    WO2012126775A1|2012-09-27|
    MY168683A|2018-11-29|
    KR20140015484A|2014-02-06|
    US9505178B2|2016-11-29|
    KR101650343B1|2016-08-23|
    PL2502788T3|2014-08-29|
    JP2014516818A|2014-07-17|
    ZA201307114B|2014-05-28|
    BR112013023257B8|2021-06-15|
    EP2502788B1|2014-03-12|
    CN103459204B|2016-04-20|
    US20140124972A1|2014-05-08|
    RU2582503C2|2016-04-27|
    EP2688770A1|2014-01-29|
    AR085546A1|2013-10-09|
    EP2502788A1|2012-09-26|
    MX2013010782A|2014-01-16|
    ES2467933T3|2014-06-13|
    BR112013023257A2|2016-12-20|
    CN103459204A|2013-12-18|
    JP6001634B2|2016-10-05|
    CA2828677A1|2012-09-27|
    RU2013147152A|2015-04-27|
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    法律状态:
    2018-12-18| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-10-22| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-09-29| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2020-12-15| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 13/03/2012, OBSERVADAS AS CONDICOES LEGAIS. |
    2021-06-15| B16C| Correction of notification of the grant [chapter 16.3 patent gazette]|Free format text: REF. RPI 2606 DE 15/12/2020 QUANTO AO QUADRO REIVINDICATORIO. |
    优先权:
    申请号 | 申请日 | 专利标题
    GB11159402.4|2011-03-23|
    EP11159402.4A|EP2502788B1|2011-03-23|2011-03-23|Production process for a moulded multilayer lining|
    PCT/EP2012/054383|WO2012126775A1|2011-03-23|2012-03-13|Production process for a moulded multilayer lining|
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