• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    This method comprises: feeding a sheet of fibers (12) onto a conveyor (42), - needling the sheet of fibers (12) to form a soleplate in contact with the conveyor (42), and - introduction of a bonding component on the sole. The binding component introduced on the sole is a thermoplastic polymer in solid form. The method comprises a step of heating the soleplate to penetrate the thermoplastic polymer constituting the connecting component in the soleplate to a thickness less than the thickness of the soleplate.
    公开号:FR3018287A1
    申请号:FR1451788
    申请日:2014-03-05
    公开日:2015-09-11
    发明作者:Mathieu Jouve
    申请人:Faurecia Automotive Industrie SAS；
    IPC主号:
    专利说明:

    [0001] The present invention relates to a method for manufacturing an interior piece of equipment for a motor vehicle, comprising the following steps: feeding a sheet of fibers onto a conveyor equipped with brushes, the sheet of fibers comprising base fibers; - Needling the fiber web facing the brushes to form a sole in contact with the conveyor and a velvet pile layer opposite the conveyor; - thermoling the fiber web; - introduction of a connecting component on the sole. Such a piece is intended for example to form a floor covering carpet in a motor vehicle. The carpets used in the automobile as floor covering are essentially needled carpets of the type "needled flat" or needled "Dilour e". These carpets belong to the family of nonwovens. They are preferred over traditional woven coatings because they are deformable and can conform to the shapes of vehicle floors. This "shaping" of the floor mats to match the configuration of the floors of the vehicles takes place during the thermoforming operation. Since these carpets are generally associated with sub-layers (heavy masses or felts) to create an acoustic complex for insulation or sound absorption, the thermoforming takes place at the softening temperature of these sub-layers (for example, from 110 ° C in the case where the sub-rauche is a heavy mass based on polyolefin). Needles "Dilour®" are also called "velvet needles" because their surface appearance is similar to that of a velvet. This "velvet" is constituted in this case randomly distributed fibers. These fibers may be in the form of loops or individual fibers (curled loops).
    [0002] These mats are made from a layer of fibers (called the precursor sheet having undergone a first needling called pre-needling), for example on a machine "Dilour®" consisting of a conveyor equipped with a set of brushes and d a needling head equipped with needle boards (also called combs) type "crown" possibly supplemented with "fork" needles.
    [0003] The crown type needles, generally of triangular section, have a single barb per edge disposed just before the tip of the needle at the same distance from the tip. These barbs are positioned thus to entrain the fibers by forming loops of equal lengths. Moreover, their barbs being located on the side, they can seize fibers throughout the thickness of the precursor web. This type of needle therefore allows a maximum velvet yield.
    [0004] Nevertheless, because the barbs are located on edges, they have little depth and the number of fibers trained per shot is low. To constitute velvet, therefore, a large number of penetrations, that is to say a high needling density, which penalizes productivity. The fork needles are circular and have no point but a fork-shaped end (U inverted). They can only lead to fibers located essentially on the reverse of the precursor layer (where they penetrate) but in larger numbers than the crown needles, because the dimensions of the fork are much greater than those of a beard. Nevertheless, these needles are much more aggressive (they break some of the fibers they encounter). It is therefore considered that their use in large numbers is detrimental to the planar cohesion of the needled "Dilour®" and therefore its ability to deform without tearing during thermoforming. This is the reason why it is preferred to combine these two types of needles to obtain both velvet yields and acceptable productivity, without this being too detrimental to the plane cohesion. Thus, we can find combs for example consisting of half crown needles and half fork needles. These needles cause a portion of the fibers of the web to the inside of the conveyor brushes, to a depth that will correspond to the velvet height of the finished product.
    [0005] Simultaneously with the constitution of the pile, needling densifies the sheet by helping to entangle the fibers in the part of the sheet remaining on the surface of the brushes (called "sole"). That is, the thickness of the sole is reduced as the fibers intermingle. The height of the pile generally varies between 2 mm and 5 mm, the thickness of the soleplate varying from 1 mm to 3 mm, whereas the thickness of the precursor layer is of the order of 5 to 10 mm. When the velvet is shorn (in a step immediately after the "stretching", the top of the loops of the velvet being shaved), the constituent fibers of the velvet affect the shape of a U, the base of the U being in the sole. In the following, it will be considered that the velvet fibers are advantageously in this form.
    [0006] Then, the needled mats are consolidated by a resin that binds together the fibers in the sole. Indeed, the mechanical cohesion they receive because of the needling is insufficient to ensure good behavior in use, once installed in the vehicle (in particular, abrasion resistance, defibering ..).
    [0007] These resins are usually SBR (Styrene Butadiene Rubber) type latices and are applied on the back of the carpet in the form of an aqueous dispersion by known coating means, followed by squeezing to penetrate the dispersion into the sole. The carpets are then dried in ovens to evacuate the water. The density of the latex solids remaining in the sole after drying represents between 15 to 30% of the web mass of the web. The use of latex has disadvantages because the penetration of the dispersion inside the sole is difficult to control (it should not under any circumstances cross the sole, which pollutes the fibers in the velvet), partly to causes capillary phenomena due to the fibrous network by random nature. In addition, latexes are thermoset (or cross-linked) polymers that are difficult to recycle, and latex residues must be stored because they are potentially dangerous for the environment. To overcome these problems, it is known to use, in place of latex, hot melt fibers which are dispersed in the fiber web and which are melted after needling. These fibers may be mono-constituent fibers (based on the same polymer) or bi-constituent fibers (for example of the body and core type whose body is made of a polymer having a melting temperature lower than that of the polymer constituting the soul). The most commonly used low melting point polymer is polyethylene PE, which has a melting point of 90 ° C to 120 ° C.
    [0008] To obtain a binding similar to that of the latex, it is necessary to introduce a large amount of hot melt fibers into the web as described in EP 518 690. This increases the cost of the product (fusible fibers are generally more expensive than standard fibers ). This introduction also affects its surface appearance, given the appearance of moiré on the velvet layer after thermoforming.
    [0009] In fact, the needling in the Dilour® machine induces indifferently the base fibers and the binding fibers which are therefore found with the same proportion in the pile as in the precursor layer. However, the thermoforming is carried out at a temperature close to the melting temperature of the binder fibers, so that the binder fibers present in the velvet can stick together the base fibers of the velvet and prevent them from recovering from the crushing due to the closing of the thermoforming mold.
    [0010] To overcome this problem, EP 2,286,012 describes a method in which a first sheet comprising hot-melt fibers is used to form the sole and a second sheet without hot-melt fibers is used to form the appearance layer, the layers being assembled between they during the needling of the second layer. The implementation of such a method requires a machine having two needling heads positioned on the same conveyor, which requires a significant investment, and complicates the implementation of the method. EP 2664702 discloses a method in which a carpet is obtained by needling and then consolidated with a latex layer. The carpet comprises binder fibers with a high weight percentage, as indicated in EP 518 690. A layer of adhesive, for example made of thermoplastic polymer is glued to the back of the carpet, to allow a connection with a substrate (generally at acoustic function) or to allow improved rigidity of the carpet essential for mounting the carpet in the vehicle. This layer does not penetrate the needled fiber web. An object of the invention is to obtain, at lower cost, and with simple equipment, interior equipment parts having a layer of very satisfactory velvet appearance, and adequate mechanical strength, without the use of latex. For this purpose, the subject of the invention is a process of the aforementioned type, characterized in that the layer of fibers comprises a non-zero quantity and less than 15% by weight of at least partially fusible binder fibers, the binding component introduced on the sole being a thermoplastic polymer in solid form, the method comprising a step of heating the sole after application of the thermoplastic polymer constituting the binding component for penetrating the thermoplastic polymer constituting the binding component in the soleplate to a thickness less than thickness of the sole. The process according to the invention may comprise one or more of the following characteristics, taken alone or in any combination: the binder fibers comprise bi-component fibers comprising a core and a shell surrounding the core, the melting point of the envelope being less than that of the core, or fibers having a melting point lower than the melting point of the base fibers of the fiber web; the thermoplastic polymer constituting the binding component is introduced in pulverulent form, in the form of a film, in the form of a nonwoven, in the form of a plastisol and / or in the form of an organosol; the base fibers are formed on the basis of a thermoplastic polymer of the same nature as the thermoplastic polymer constituting the binding component, the heating step comprising the partial melting of the thermoplastic polymer of the base fibers in the soleplate, without significant melting thermoplastic polymer of the base fibers on the location layer; the base fibers are formed based on a polymer, the thermoplastic polymer constituting the binding component having a melting point lower than the melting point of the polymer of the base fibers; the creep index of the thermoplastic polymer constituting the binding component is between 50 g / 10 nm and 70 g / 10 nm; the thermolysis of the ply of fibers takes place before the introduction of the thermoplastic polymer constituting the connecting component on the soleplate; - The maximum penetration thickness of the thermoplastic polymer constituting the connecting component in the sole after at least partial melting is less than 30% of the thickness of the sole and is preferably greater than 10% of the thickness of the sole; - Needling comprises drilling the fiber web by needles mainly forked, preferably with a comb equipped with at least 80% of forked needles. The invention also relates to an interior piece of equipment for a motor vehicle, comprising: - a sheet of needled fibers comprising base fibers forming a velvet pile layer and a sole, - a binding component disposed in the soleplate ; characterized in that the fiber web comprises a non-zero and less than 15% by weight of at least partially fusible binder fibers, the bonding component disposed in the sole being a molten thermoplastic polymer in solid form having penetrated into the sole on a thickness less than the thickness of the sole. The part according to the invention may comprise one or more of the following characteristics, taken separately or in any technically possible combination: the binder fibers comprise bicomponent fibers comprising a core and an envelope surrounding the core, the melting point of the envelope being lower than that of the core, or fibers having a melting point lower than the melting point of the base fibers of the fiber web; - The maximum penetration thickness of the thermoplastic polymer constituting the connecting component in the sole after at least partial melting is less than 30% of the thickness of the sole and is preferably greater than 10% of the thickness of the sole; the creep index of the thermoplastic polymer constituting the binding component is between 50 g / 10 nm and 70 g / 10 nm; the base fibers are formed on the basis of a thermoplastic polymer of the same nature as the thermoplastic polymer constituting the binding component, the thermoplastic polymer of the base fibers in the sole being at least partially melted, without significant melting of the thermoplastic polymer of the base fibers on the place layer; the base fibers are formed based on a polymer, the thermoplastic polymer constituting the binding component having a melting point lower than the melting point of the polymer of the base fibers. The invention will be better understood on reading the description which will follow, given solely by way of example, and with reference to the appended drawings, in which: FIG. 1 is a partial sectional view of a first piece of interior equipment of a motor vehicle according to the invention; FIG. 2 is a logic diagram illustrating the successive steps of implementing a first method of manufacturing the part of FIG. 1; FIG. 3 is a schematic view, taken in partial section, of a needling station of an installation for implementing the manufacturing method of FIG. 2; FIG. 4 is a view of the free end of FIG. a needle used in the needling station of Figure 3; - Figure 5 is a schematic view, taken in partial section, of a depositing station and melting of a powdery thermoplastic polymer in the installation for implementing the manufacturing method according to the invention; - Figure 6 is a view similar to Figure 5, wherein the thermoplastic polymer is deposited in the form of a film or a nonwoven. In what follows, the terms "upstream" and "downstream" refer to the normal direction of movement in the manufacturing process according to the invention.
    [0011] A first part 10 of interior equipment of a motor vehicle according to the invention is illustrated in FIG. 1. The first part 10 is for example a carpet of interior equipment of a motor vehicle, intended to be placed on the ground or on a wall of the vehicle.
    [0012] The thickness of the first piece 10 is greater than 1 mm and is for example between 3 mm and 8 mm. The basis weight of the first piece 10 is less than 2000 g / m2 and in particular between 400 g / m2 and 1000 g / m2. The first piece 10 comprises a ply 12 of needled fibers 14, 16, at least partially bonded together, delimiting a pile layer 18 and a backing layer forming a sole 20. According to the invention, the first piece 10 comprises a connecting component 22 formed by a molten thermoplastic polymer penetrating part of the thickness and the sole 20.
    [0013] The part 10 is completely free of latex in the thickness of the ply 12. According to the invention, the ply 12 comprises base fibers 14 and binder fibers 16. The ply 12 has a basis weight greater than 300 g / m 2 and in particular between 400 g / m2 and 1000 g / m2.
    [0014] The base fibers 14 are distributed randomly. They are in the form of loops or individual fibers, such as shorn loops. The base fibers 14 are for example made of thermoplastic polymer, such as polypropylene, polyethylene terephthalate, polyamide, polylactic acid, mixtures or copolymers thereof.
    [0015] The length of the base fibers 14 is generally between 40 mm and 100 mm. Their title is advantageously between 3.3 dtex and 25 dtex. The binder fibers 16 are at least partially fusible. They generally comprise bi-component fibers comprising for example a core and an outer sheath surrounding the core. The outer sheath has a melting temperature lower than the melting temperature of the core. For example, the core is made of polyethylene terephthalate and the sheath made of polyethylene terephthalate. Alternatively, the binder fibers 16 consist of a single polymer, having a melting point below the melting point of the base fibers 14, advantageously less than about 50 ° C. at the melting point of the base fibers 14. .
    [0016] In the case where the base fibers 14 are based on polyethylene terephthalate, the binder fibers 16 are for example formed based on polypropylene, polyethylene, or co-polyethylene terephthalate, their mixtures, or their copolymers. According to the invention, the mass content of binder fibers 16, based on the total mass of the fibers 14, 16 in the ply 12, is non-zero and is less than 15%, in particular less than 13% by weight. In some cases, this mass content is less than 10%. The binder fibers 16 are dispersed throughout the web 12 and are present both in the location layer 18 and in the sole 20 homogeneously.
    [0017] The place layer 18 has a velvet outer appearance. This pile consists of fibers 14, 16 randomly distributed in the form of loops or individual fibers (curled loops). The thickness of the location layer 18 is advantageously greater than that of the sole 20. The location layer 18 advantageously has a thickness of between 2 mm and 5 mm. The velvet density in the place layer 18 is preferably between 0.01 g / cm3 and 0.06 g / cm3. Such density provides a good appearance and good resistance to abrasion. This density is measured, for example, by determining the ratio between the weight of the material obtained by mowing the entire area layer 18 to the sole 20, based on the initial volume of the sheared layer. The velvet yield, consisting of the ratio of the weight of the velvet after shearing with respect to the total weight of the part 10 before shearing is for example between 15% and 40%.
    [0018] The sole 20 is in the form of a flat needle. Its thickness is advantageously lower than that of the location layer 18. The basis weight of the soleplate 20 is greater than 200 g / m 2, and is in particular between 200 g / m 2 and 800 g / m 2. The sole 20 advantageously comprises the base of the U-forming fibers whose ends are located in the location layer 18. The thermoplastic polymer constituting the connecting component 22 is disposed in the soleplate 20 to a thickness e2 less than that el of the sole 20, taken from the outer surface of the sole 20. This thermoplastic polymer is for example formed of a polymer or a copolymer (then having a melting temperature lower than that of the base fibers 14), of the same nature as the constituent polymer of the base fibers 14.
    [0019] Alternatively, the thermoplastic polymer has a melting point lower than that of base fibers 14. For example, if the base fibers 14 are made of polyethylene terephthalate, the thermoplastic polymer is for example constituted by an olefin thermoplastic such as polypropylene, polyethylene, or with polylactic acid, polyamide, or polyurethane, their mixtures, or their copolymers. The weight percentage of bonding component 22, based on the total mass of the ply 12 is less than 25%, and is in particular between 10% and 20%. As will be seen below, the thermoplastic polymer constituting the binding component 22 is advantageously supplied in powder form, in the form of a film, in the form of a nonwoven, or in the form of plastisol or in the form of an organosol. In a particular variant, the hot-melt polymer is based on two-component fibers, as described above. The fusible portion of the fibers constitutes a binder that penetrates into the sole 20, while the remaining fibrous portion is bonded to the underside of the sole 20 to contribute to its planar cohesion. In this case, the weight of the web 12 is lowered. The connecting component 22 penetrates into the sole 20 to a thickness e2 less than 50% of the thickness e of the soleplate 20, and advantageously to a thickness e2 greater than 10% of the thickness e of the soleplate 20.
    [0020] The penetration thickness e2 of the connecting component 22 in the soleplate 20 is, for example, between 10% and 30% of the thickness and of the soleplate 20. The penetration thickness e2 in the soleplate 20 is controlled by virtue of the viscosity of the thermoplastic polymer forming the connecting component 22, measured by its creep index, and the temperature chosen for its melting. This thickness is not controlled by physical means such as calendering (which could deteriorate the velvet crushing). In fact, the penetration thickness advantageously depends on the deposited mass, the intrinsic viscosity of the polymer and the temperature chosen for its activation, in fact the viscosity decreases with the rise in temperature. For example, when the bonding component is based on polyolefin (polypropylene or polyethylene) the melt flow index (Melt Flow Index) measured by IS01133: 2005 Method A with a nominal load of 0.325 kg at 190 ° C is included between 50 g / 10 min and 70 g / 10 min. This MFI value range, reflecting the viscosity of the polymer in the molten state, is the range suitable for the invention. That is, depending on the polymer chosen, the melting temperature will be adapted to allow the polymer to reach this viscosity range.
    [0021] Thus, in the case of polyolefins, the temperature chosen for the melting is, for example, between 110 ° C. and 190 ° C. A polymer that is suitable for the invention is Licocene® from Clariant. The penetration thickness remaining limited, the density of thermoplastic polymer to be introduced into the sheet 12 is also relatively low. Despite this low penetration, the cohesion of the sole 20 remains very satisfactory. The weight per unit area of the thermoplastic polymer is generally between 80 g / m 2 and 200 g / m 2. Without being bound by any theory, the molten thermoplastic polymer constituting the connecting component 22 is added to the binder fibers 16 to bind the base of the fibers 14 forming the velvet of the location layer 18, ensuring a good mechanical strength. It has indeed been noted that the penetration thickness of the connecting component 22 required for good behavior was lower as the percentage of forked needles was high on the needling boards. This can be explained by the fact that, as seen above, this type of needling leads to having the base of the velvet fibers (U base) essentially on the back of the sole because it is at this point the fork needles grip the fibers they cause to constitute velvet.
    [0022] Nevertheless, 100% use of the needles can be detrimental to the useful velvet yield. The low percentage of binder fibers 16 in the remainder of the sole 20 lacking connecting component 22 provides, surprisingly, a sufficient planar cohesion of the sole 20, despite the low mechanical cohesion provided by the needling. A plant for manufacturing the workpiece 10 is illustrated in FIGS. 3 to 5. This installation advantageously comprises a pre-needling station (not shown) for a base ply to form the ply 12, a training station 30 for forming the ply. sole 20 and the pile layer 18 from the web 12, the station 30 being visible in Figure 3 and, according to the invention, a station 32 for applying the connecting component 22, visible in the figure 5. The pre-needling station is able to provide the precursor web a maximum of planar cohesion, while allowing the formation of velvet later. It comprises a conventional felting needle board bringing the web a needling density greater than 100 cps / cm 2 and in particular between 100 cps / cm 2 and 300 cps / cm 2.
    [0023] The training station 30 is illustrated in Figure 3. It is for example formed by a single "Dilour®" station that is to say having only one needling head. It comprises a roll unwinder 40, a conveyor 42 comprising a band provided with brushes, a needling apparatus 43, a thermal binding apparatus 44 and a winder 46. The conveyor 42 comprises an endless belt wound around minus two end rollers 48. The band is provided with a plurality of brushes 50 delimiting an upper surface 52, on which the sheet 12 bears. The belt of the conveyor 42 is adapted to be driven by at least one roller 48 to scroll its upper surface 52 in translation along an axis AA 'driving the web 12. The needling apparatus 43 is disposed facing the upper surface 52. It comprises a single needle board 54 deployable vertically towards the surface 52 to pierce the sheet 12.
    [0024] The board 54 carries a plurality of needles 56, allowing a needling density advantageously greater than 200 cps / cm 2 and in particular between 300 cps / cm 2 and 800 cps / cm 2. The majority, and advantageously all, of the needles 56 carried by the board 54 are fork-type needles, as illustrated in FIG. 6.
    [0025] These needles 56 comprise, at their free piercing end 58, two opposite piercing fingers 60 delimiting an intermediate slot 62, and a bearing heel 64 arranged in the slot 62 to partially seal part of the length of the slot 62. The needle 56 essentially drives the fibers present at the place of the web that it penetrates, unlike the crown or felting needles that drive the fibers present anywhere in the thickness of the web 12. Surprisingly, the use of these forked needles 56 does not penalize the overall cohesion of the ply 12. In fact, the consolidation treatments according to the invention surprisingly compensate for the flat fragility of the flange 20 inherent to this type of yarn. needling.
    [0026] The thermal binding apparatus 44 is for example a through air oven, an infrared oven. It is suitable for heating the sheet 12, after needling, to at least partially melt the binder fibers 16. The temperature within the thermal binding apparatus 44 is for example greater than 90 ° C and is in particular between 120 ° C and 200 ° C.
    [0027] The thermal binding apparatus 44 is placed between the band 42 and the reel 46 to receive the sheet 12 at the outlet of the apparatus 43.
    [0028] In the case where the thermoplastic polymer constituting the connecting component 22 is applied in pulverulent form or in the form of a plastisol or an organosol, the application station 32 is illustrated in FIG. unwinder 68, a tank 70 of thermoplastic polymer, a distributor 72, a heater 74, and a reel 76. The distributor 72 is placed opposite the sole 20 between the unwinder 68 and the heater 74. It is adapted to distribute by gravity the thermoplastic polymer contained in the tank 70 on the sole 20. The heater 74 is for example a through air oven, an infrared oven. It is able to melt the thermoplastic polymer to allow partial penetration of the thermoplastic polymer into the sole 20. In the variant illustrated in FIG. 6, when the thermoplastic polymer is supplied in the form of a film or a nonwoven , it is wound on a secondary winder 78 and is unwound with an application roller 80 on the sole 20, upstream of the heater 74. A manufacturing method 10 according to the invention This process advantageously comprises a step 100 of pre-needling on the pre-needling station.
    [0029] It further comprises, on the station 30, a step 102 for feeding a ply of fibers 12 onto the conveyor 42 equipped with the brushes 50, a step 104 of needling of the ply of fibers 12 facing the brushes 50 for forming the sole 20 in contact with the conveyor 42 and the velvet location layer 18 opposite the conveyor 42, and a step 106 of thermobinding the web 12.
    [0030] The method then comprises, on the station 32, a step 108 introduction of the binding component 22 on the sole 20, and a step 110 of heating the connecting component 22 to partially penetrate the sole 20. In step 100, a precursor sheet comprising base fibers 14 and binder fibers 16, with a binder fiber mass content of less than 15% 16, is introduced into the pre-needling station to undergo a needling with a needling density greater than 100 cps / cm2 and especially between 100 cps / cm2 and 300 cps / cm2. A ply of fibers 12 is thus obtained and wound. In the feeding step 102, the wound sheet 12 is placed on the unwinder 40 of the station 30 and is unrolled opposite the upper surface 52 of the conveyor 42, then through the apparatus 44 to the winder 46 In step 104, as it passes over the upper surface 52, opposite the brushes 50, the ply 12 is pierced by the needles 56 of the plank 54 to form the pile velor layer 18 in the zone pierced by the needles 56, and the sole 20 facing the brushes 50.
    [0031] These needles 56 are mainly forked needles, as described above. The needles 56 essentially cause the fibers present at the location of the sheet 12 to penetrate, by configuring the U-shaped deformed fibers, with the base of the U in the thickness of the sole 20.
    [0032] A sole 20 having a basis weight of between 200 g / m 2 and 500 g / m 2 is thus obtained. An area layer 18 of density between 0.01 g / cm3 and 0.060 g / cm3 is formed. Then, in step 106, the needled ply 12 is introduced into the binding apparatus 44 to be heated to a temperature above the melting temperature of the binder fibers 16, in particular greater than 90 ° C., and especially including between 110 ° C and 190 ° C. The binder fibers 16 melt at least partially and bind to the base fibers 14. The bonded web 12 is then wound on the reel 46. The rolled web 12 is then transported to the station 32, and is placed on the unwinder 68 The sheet 12 is unrolled facing the dispenser 72 and the heater 74 to the reel 76. In step 108, the connecting component 22 is deposited on the web 12 in the form of a polymer thermoplastic solid, for example in the form of a powder, a nonwoven, a film, a plastisol or an organosol. The connecting component 22 is just applied on the outer surface of the sole 20. In step 110, the ply 12, having the connecting component 22 on the outer surface of the sole 20, is placed opposite the apparatus heating element 74 to allow fusion and partial penetration of the thermoplastic polymer constituting the connecting component 22 in the soleplate 20.
    [0033] The penetration thickness e2 of the connecting component 22 in the soleplate 20 is less than the thickness e1 of the soleplate 20, and is in particular between 20% and 30% of the thickness of the soleplate 20. Advantageously, the bases U-shaped fibers of the location layer 18 are then bonded together and with the connecting fibers 16 via the connecting component 22.
    [0034] It is thus possible to obtain a piece 10 without latex in the thickness of the sheet 12, with a low content of binder fibers 16, and nevertheless having a very satisfactory mechanical strength and abrasion resistance. The low mass percentage of binder fibers 16 in the ply 12, is therefore consequently in the velvet 18, allows forming of the workpiece 10 without appearance defects. Despite the low content of binder fibers 16, the bonding component 22 made of thermoplastic polymer provides an effective mechanical strength, especially in terms of grinding and wear. Furthermore, the overall cost of material required for the manufacture of the part 10 is comparable, or even lower than the cost of a part 10 which would be manufactured based on latex, and the manufacturing process is simpler, which overall reduces the cost. The bonding obtained by the process according to the invention is at least as effective as that resulting from the use of latex, while reducing the weight of the web 12. The consolidated carpet according to the invention consists entirely of thermoplastic polymers, optionally a polymer and its co-polymers, which greatly facilitates its recycling.
    权利要求:
    Claims (15)
    [0001]
    1. A method of manufacturing a piece (10) of interior equipment of a motor vehicle, comprising the following steps: - feeding a fiber web (12) on a conveyor (42) equipped with brushes (50), the fiber web (12) having base fibers (14); - needling the fiber web (12) facing the brushes (50) to form a sole (20) in contact with the conveyor (42) and a velvet location layer (18) opposite the conveyor (42) ; - Thermoling the fiber web (12); - introducing a connecting component (22) on the sole (20); characterized in that the fiber web (12) comprises a non-zero and less than 15% by weight of at least partially fusible binder fibers (16), the connecting component (22) introduced on the sole (20) being a thermoplastic polymer in solid form, the method comprising a step of heating the sole (20) after application of the thermoplastic polymer constituting the connecting component (22) to penetrate the thermoplastic polymer constituting the connecting component (22) in the sole ( 20) on a thickness less than the thickness of the sole (20).
    [0002]
    2. - Method according to claim 1, characterized in that the binder fibers (16) comprise bicomponent fibers comprising a core and an envelope surrounding the core, the melting point of the envelope being lower than that of the core, or fibers having a melting point below the melting point of the base fibers (14) of the fiber web (12).
    [0003]
    3. - Process according to any one of the preceding claims, characterized in that the thermoplastic polymer constituting the binding component (22) is introduced in powder form, in the form of a film, in the form of a nonwoven, in the form of a plastisol and / or in the form of an organosol.
    [0004]
    4. - Process according to any one of the preceding claims, characterized in that the base fibers (14) are formed based on a thermoplastic polymer of the same nature as the thermoplastic polymer constituting the connecting component (22), heating step comprising partially melting the thermoplastic polymer of the base fibers (14) in the soleplate (20), without significant melting of the thermoplastic polymer of the base fibers (14) on the location layer (18).
    [0005]
    5. - Process according to any one of claims 1 to 3, characterized in that the base fibers (14) are formed based on a polymer, the thermoplastic polymer constituting the connecting component (22) having a melting point less than the melting point of the polymer of the base fibers (14).
    [0006]
    6. - Process according to any one of the preceding claims, characterized in that the creep index of the thermoplastic polymer constituting the connecting component (22) is between 50g / 1 Omn and 70g / 1 Omn.
    [0007]
    7. - Process according to any one of the preceding claims, characterized in that the heat-sealing of the sheet of fibers (12) takes place before the introduction of the thermoplastic polymer constituting the connecting component (22) on the sole (20). ).
    [0008]
    8. - Method according to claim 7, characterized in that the maximum penetration thickness of the thermoplastic polymer constituting the connecting component (22) in the sole (20) after at least partial melting is less than 30% of the thickness the sole (20) and is preferably greater than 10% of the thickness of the sole (20).
    [0009]
    9. - Method according to any one of the preceding claims, characterized in that the needling comprises the piercing of the fiber web (12) by needles (56) mainly forked, preferably with the aid of a comb equipped with at least 80% of forked needles.
    [0010]
    10. Part (10) of interior equipment of a motor vehicle, comprising: - a sheet of needled fibers (12) comprising base fibers (14) forming a velor layer (18) and a sole (20) ; - a connecting component (22) disposed in the sole (20); characterized in that the fiber web (12) has a non-zero and less than 15 mass% of at least partially fusible binder fibers (16), the connecting component (22) disposed in the sole (20) being a molten thermoplastic polymer in solid form having penetrated into the sole (20) to a thickness less than the thickness of the sole (20).
    [0011]
    11. Part (10) according to claim 10, characterized in that the binder fibers (16) comprise bicomponent fibers comprising a core and an envelope surrounding the core, the melting point of the envelope being less than that of the core, or fibers having a melting point below the melting point of the base fibers (14) of the fiber web (12).
    [0012]
    12.- part (10) according to any one of claims 10 or 11, characterized in that the maximum penetration thickness of the thermoplastic polymer constituting the connecting component (22) in the sole (20) after at least partial fusion is less than 30% of the thickness of the sole (20) and is advantageously greater (3/0 of the thickness of the sole (20).
    [0013]
    13. - Part (10) according to any one of claims 10 to 12, characterized in that the creep of the thermoplastic polymer constituting the connecting component (22) is between 50g / 1 Omn and 70g / 1 Omn .
    [0014]
    14. - Part (10) according to any one of claims 10 to 13, characterized in that the base fibers (14) are formed based on a thermoplastic polymer of the same nature as the thermoplastic polymer constituting the connecting component (22), the thermoplastic polymer of the base fibers (14) in the soleplate (20) being at least partially melted, without significant melting of the thermoplastic polymer of the base fibers (14) on the location layer (18).
    [0015]
    15. - Part (10) according to any one of claims 10 to 13, characterized in that the base fibers (14) are formed based on a polymer, the thermoplastic polymer constituting the connecting component (22) having a melting point below the melting point of the polymer of the base fibers (14).
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    US9796312B2|2017-10-24|
    US20150251581A1|2015-09-10|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    EP0518690A1|1991-06-13|1992-12-16|Chisso Corporation|Needle punched carpet|
    EP1251199A1|2001-04-19|2002-10-23|Magna Emfisint Automotive S.A.|Needlepunched und thermal bonded nonwoven fabric, process and use|
    US20060257616A1|2005-05-12|2006-11-16|Stowe-Pharr Mills, Inc. |Renewable nonwoven carpet|
    WO2009039914A1|2007-09-20|2009-04-02|Carl Freudenberg Kg|Needle-punched nonwoven velour, and use thereof|
    WO2009147051A1|2008-06-05|2009-12-10|Entwicklungsgesellschaft für Akustik mit beschränkter Haftung|Velour rug with tufting-like surface|FR3085390A1|2018-09-05|2020-03-06|Faurecia Automotive Industrie|METHOD OF MANUFACTURING A TEXTILE PIECE OF EQUIPMENT CAPABLE OF TRAPPING VOLATILE ORGANIC COMPOUNDS, AND ASSOCIATED PIECE|US2543101A|1944-07-20|1951-02-27|American Viscose Corp|Composite fibrous products and method of making them|
    SI2664702T1|2012-05-15|2014-09-30|Autoneum Management Ag|Needle punched carpet|DE102015108928A1|2015-06-05|2016-12-08|Johann Borgers GmbH|Automotive interior paneling material and automotive interior panel component|
    DE102017208200A1|2017-05-16|2018-11-22|Adler Pelzer Holding Gmbh|carpet|
    FR3078664B1|2018-03-12|2020-02-14|Psa Automobiles Sa|SOUNDPROOFING ELEMENT FOR A VEHICLE.|
    法律状态:
    2015-03-19| PLFP| Fee payment|Year of fee payment: 2 |
    2016-02-19| PLFP| Fee payment|Year of fee payment: 3 |
    2017-02-21| PLFP| Fee payment|Year of fee payment: 4 |
    2018-02-20| PLFP| Fee payment|Year of fee payment: 5 |
    2020-02-20| PLFP| Fee payment|Year of fee payment: 7 |
    2021-02-18| PLFP| Fee payment|Year of fee payment: 8 |
    2022-02-21| PLFP| Fee payment|Year of fee payment: 9 |
    优先权:
    申请号 | 申请日 | 专利标题
    FR1451788A|FR3018287B1|2014-03-05|2014-03-05|METHOD FOR MANUFACTURING AN AUTOMOTIVE VEHICLE INTERIOR EQUIPMENT COMPONENT COMPRISING A VELVET PLACE LAYER AND ASSOCIATED PIECE|FR1451788A| FR3018287B1|2014-03-05|2014-03-05|METHOD FOR MANUFACTURING AN AUTOMOTIVE VEHICLE INTERIOR EQUIPMENT COMPONENT COMPRISING A VELVET PLACE LAYER AND ASSOCIATED PIECE|
    US14/634,748| US9796312B2|2014-03-05|2015-02-28|Method for manufacturing an interior trim part of an automotive vehicle comprising a velvet font layer and associated part|
    DE102015103116.7A| DE102015103116A1|2014-03-05|2015-03-04|A method of manufacturing an interior trim part of a motor vehicle having a suede upper layer and a connected part|
    US15/711,500| US20180009357A1|2014-03-05|2017-09-21|Interior trim part of an automotive vehicle comprising a velvet font layer|
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