• 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:
    The invention relates to a method for manufacturing a piece of motor vehicle equipment (1), comprising the following steps: - providing a sheet comprising ceramic fibers (24) and hot-melt polymer fibers, the temperature melting point of the hot-melt polymer being greater than 200 ° C, - heating the web at a temperature above 200 ° C to melt the hot-melt polymer, - applying a fabric (12) to the web, the fabric ( 12) comprising yarns having a polymer core having a softening point greater than or equal to 200 ° C, thermoforming the fabric (12) and the web into a shaping mold.
    公开号:FR3029825A1
    申请号:FR1462332
    申请日:2014-12-12
    公开日:2016-06-17
    发明作者:Steve Jeunesse；Xavier Bathelier
    申请人:Faurecia Automotive Industrie SAS；
    IPC主号:
    专利说明:

    [0001] TECHNICAL FIELD The present invention relates to a method for manufacturing a motor vehicle equipment part.
    [0002] The motor vehicle part is intended to constitute a structuring part in a motor vehicle, such as a shelf, a false floor or trunk side trim. Current pavement, shelf or trunk side trim of motor vehicle, are often considered messy, not resistant to abrasion and difficult to clean. They require the addition of over-mats or plastic heels. Current coatings for motor vehicle equipment parts generally include needled or tufted carpets, warp knit fabrics as siding for shelves or pavilions, optionally grained TPO (Thermoplastic PolyOlefin) plastic sheets or flexibilised wood facing sheets. However, these coatings have either limited properties in terms of abrasion resistance or cleanability problems. There is a need for a cheap, thermoformable coating with controlled sound absorption.
    [0003] Yarn fabrics comprising a polyvinyl chloride (PVC) sheath and a semicrystalline polyethylene terephthalate (PET) core are known. Semi-crystalline PET is understood to mean PET having, for example, a degree of crystallinity greater than 20%. Such fabrics are solid and not very deformable. These fabrics are suitable for flooring in the field of housing and outdoor applications because of their water resistance and mechanical strength. In addition, the PET core has a rigidity facilitating the weaving of the yarn. However, such fabrics are not used for the manufacture of motor vehicle parts with irregular shapes because of their thermoforming constraints. Indeed, such fabrics are not deformable in the operating conditions of the forming lines and with the composite bodies generally associated with the coating. Indeed, when the vehicle part to be formed is an element of a soundproofing vehicle floor complex, it is necessary to have a coating capable of conforming to the shape of the complex. For example, floor coverings are associated with other products, such as heavy masses or felts for acoustical reasons and / or to give them sufficient stiffness that will allow it to be positioned in the vehicle quickly on assembly lines. The composite body covered by the coating comprises, for example, a ply of ceramic fibers, for example, glass fibers, the ceramic fibers being embedded in a polyolefin thermoplastic polymer matrix, such as polypropylene. This type of material is referred to as "Sommold". This material consisting of glass fibers and polypropylene degrades very rapidly above 200 ° C. However, the softening temperature of the PET is about 230 ° C. The semicrystalline PET is thermoformable only from 230 ° C. which makes it impossible to associate it with the Sommold and thus its shaping for use in the context of automobile coatings. At 160 ° C, the melting temperature of the polypropylene, and shaping Sommold, the PET is not thermoformable. At 230 ° C, the PET is thermoformable but the polypropylene degrades leading to poor mechanical properties of the part. In addition, the PVC which constitutes the sheath of the yarns of the fabric also degrades very rapidly above 200 ° C. The Sommold and the fabric of the type described above are therefore incompatible and are not associable in a composite part. An object of the invention is to provide a method of manufacturing a part 20 comprising such a fabric but which is compatible with forming processes dedicated to automotive floor coverings. For this purpose, the subject of the present invention is a process of the aforementioned type comprising the following steps: providing a sheet comprising ceramic fibers and hot-melt polymer fibers, the melting temperature of the hot-melt polymer being greater than 200; ° C; - heating the web, at a temperature above 200 ° C, to melt the hot melt polymer; - applying a fabric to the web, the fabric comprising yarns having a polymer core having a softening point greater than or equal to 200 ° C; thermoforming of the fabric and the ply in a conforming mold. The process according to the invention may comprise one or more of the following characteristics taken separately or in any technically possible combination: the process comprises a step of heat transfer between the web and the fabric after the heating of the web, the heat transfer for heating the fabric to a temperature greater than or equal to the softening temperature of the core, preferably greater than 200 ° C; the thermofusible polymer is polyethylene terephthalate; the threads of the fabric have a polyethylene terephthalate core; The yarns of the fabric have a sheath comprising polyvinyl chloride; the shaping mold is maintained at a temperature of between 100 ° C. and 200 ° C., advantageously at 140 ° C .; the fabric and the ply are held in the conforming mold for less than one minute; The method further comprises the following steps: applying a bonding film to the sheet, before applying the fabric, the fabric being applied to the bonding film, before thermoforming; the ply has an upper face and an opposite face, the fabric being fixed on the upper face of the ply, the method comprising the step of applying a nonwoven to the opposite face of the ply. The invention also relates to a piece of motor vehicle equipment comprising: - a composite body comprising a polymer matrix and ceramic fibers embedded in the matrix; A fabric, the fabric comprising an upper face intended to be oriented towards a passenger compartment of the vehicle and an opposite face fixed on the composite body, the fabric conforming to the shape of the composite body; characterized in that the fabric comprises yarns having a polymer core having a softening point greater than or equal to 200 ° C.
    [0004] The motor vehicle equipment part according to the invention may comprise one or more of the following characteristics taken individually or in any technically possible combination: the matrix of the composite body comprises polyethylene terephthalate; the fabric comprises yarns having a polyethylene terephthalate core and a sheath comprising polyvinyl chloride; the part comprises a bonding film between the composite body and the fabric, the bonding film preferably being made of polyamide; the fabric has a thickness of less than 2 mm; the composite body has an upper face and an opposite face, the fabric being fixed on the upper face of the composite body, the part comprising a nonwoven fixed on the opposite face of the composite body. The piece comprises at least one sheet attached to the composite body, the fabric being fixed on the sheet; The workpiece has a first composite body, a second composite body and an intermediate spacer, the fabric being attached to the first composite body.
    [0005] 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 sectional view, in a plane vertical, of an example of a false floor element and of a vehicle body part on which it is mounted, and FIG. 2 represents a thread of the fabric of the part according to the invention, FIG. is a view of a heating unit of a manufacturing assembly of a piece of equipment according to the invention during a manufacturing step. FIG. 4 is a sectional view of a thermoforming unit during a subsequent manufacturing step; FIG. 5 is a partial sectional view of a second part produced by a method according to the invention. - Figure 6 is a partial sectional view of a third part made by a method according to the invention. Figure 1 illustrates an example of a motor vehicle equipment part 1 20 according to the invention. The piece of equipment of a motor vehicle 1 is intended to be placed in a passenger compartment 2 of the vehicle. In the example described here, the piece of equipment of a motor vehicle 1 is a false floor element. Alternatively, the motor vehicle equipment part 1 25 is a dashboard element, a tunnel element, a tablet lining complex, the trunk, a soundproofing siding complex, or the like. The tunnel is the central part of the passenger compartment, generally raised from the floor, and separating the driver from the passenger. Figure 1 is oriented in the orthonormal frame X, Y, Z corresponding to the normal orientation of a vehicle. In this system of axes: - the X axis corresponds to the longitudinal axis of the vehicle, oriented in the direction of travel; the Z axis is the vertical axis oriented from bottom to top; and the Y axis is the transverse axis of the vehicle.
    [0006] In the remainder of the description, the terms of position and orientation refer to this system of axes. The piece of equipment of a motor vehicle 1 is disposed in the passenger compartment 2 of the vehicle.
    [0007] Part 1 has acoustic absorption or acoustic insulation characteristics so as to reduce noise pollution. For example, the part 1 is intended to acoustically isolate the interior passenger compartment of the engine compartment. In addition, the piece 1 has a stiffness and dimensional stability adapted to its use as a floor in the motor vehicle.
    [0008] In Figure 1, the motor vehicle equipment part 1 is shown in assembled configuration on a vehicle body. The vehicle body is schematically represented by a body floor portion 4, and vertical flanges 6, consisting of parts of cases integrally with the floor 4 or spars integral with the body.
    [0009] The piece of equipment of a motor vehicle 1 comprises a composite body 10 and a fabric 12, visible from the passenger compartment 2. The piece of equipment 1 further comprises a bonding film 14 placed between the fabric 12 and the 10. Advantageously, the piece further comprises a nonwoven 16 disposed opposite the fabric 12 on the composite body 10.
    [0010] The piece of equipment of a motor vehicle 1 has a thickness of between 3 mm and 8 mm. The composite body 10 has an upper face 18 intended to be oriented towards the passenger compartment 2 of the vehicle and an opposite face 20. The composite body 10 has, for example, advantageously a thickness of between 1 mm and 5 mm. The composite body 10 has a substantially flat shape, for example, with low reliefs when it is for example a floor or a form with very accentuated reliefs when it is a trunk shelf. The composite body 10 comprises a polymer matrix 22 and a plurality of ceramic fibers 24 embedded in the matrix. The polymer matrix 22 bonds the ceramic fibers 24 together. The matrix 22 is formed of a hot melt polymer as will be described later. The hot-melt polymer is advantageously based on a thermoplastic saturated polyester, different from an unsaturated thermoset polyester.
    [0011] For example, the hot melt polymer is polyethylene terephthalate (PET). For example, the hot melt polymer is a saturated polyethylene terephthalate (PET) 309 obtained by polycondensation of terephthalic acid with ethylene glycol. The thermofusible polymer advantageously has a glass transition temperature, measured by DSC ("Diffferential Scanning Calorimetry" or Differential Scanning Calorimetry) according to the ISO 11357-2 Standard, greater than 60 ° C., and in particular between 75 ° C. and 85 ° C. ° C. The hot-melt polymer has a melting temperature of in particular greater than 200 ° C., for example between 240 ° C. and 260 ° C. The thermofusible polymer is advantageously semi-crystalline. It has a degree of crystallinity greater than 10%, especially between 20% and 40%. The thermofusible polymer has a crystallization temperature, measured by the ISO 11357-1 standard advantageously greater than 100 ° C., and in particular between 140 ° C. and 160 ° C. Thus, the hot-melt polymer forming the matrix 22 has a creep index ( melt flow index or MFI) at 260 ° C. with a nominal load of 0.325 kg, as measured by the ISO 1133: 2005 Method A standard, greater than 20 g / 10 min, and in particular between 20 g / 10 nm and 60 g / 10 nm, advantageously between 30 g / 10 nm and 60 g / 10 nm. The softening point of the hot melt polymer is between 200 ° C and 250 ° C and preferably between 220 ° C and 240 ° C. The mass proportion of hot melt polymer in the composite body 10 is between 30% and 70% by weight and the mass proportion of the ceramic fibers 24 in the composite body 10 is between 70% and 30% by weight. These percentages are calculated with respect to the total mass of the ceramic fibers 24 and the matrix 22 of hot melt polymer. The ceramic fibers 24 are, for example, glass fibers.
    [0012] The ceramic fibers have an average length of less than 150 mm and a diameter of less than 50 micrometers. The composite body 10 is obtained from an initial web 26 comprising a mixture of ceramic fibers 24 and fibers 28 of hot melt polymer. The initial ply 26 is advantageously apt to be thermoformed at a temperature greater than or equal to 200 ° C, between 260 ° C and 300 ° C and preferably at a temperature between 250 ° C and 270 ° C. By material "capable of being thermoformed" is meant that the material at the thermoforming temperature is ductile and able to take the form of a mold. As the material cools, the material then retains the shape obtained.
    [0013] In the initial web 26 before melting of the polymer fibers, the ceramic fibers 24 are dispersed in the hot melt polymer fibers 28.
    [0014] In the initial ply 26, the mass proportion of thermofusible polymer fibers 28 is similar to that of the composite body 10. The initial ply 26 has a clean mechanical strength. It has a density, for example, between 80 kg / m3 and 150 kg / m3.
    [0015] The thickness of the initial ply 26 is greater than 5 mm, and is, for example, between 7 mm and 12 mm. The basis weight and the thickness of the initial ply 26 are adapted to facilitate the heat transfer which will be described later. The web 26 has for example a basis weight between 1500 g / m2 and 2000 g / m2.
    [0016] The thermofusible polymer fibers 28 have an average length of less than 150 mm and a titer of between 6.7 dTex and 17 dTex. The fabric 12 is visible from the passenger compartment 2 of the vehicle. The fabric 12 is disposed above the upper face 18 of the composite body 10. The fabric 12 is fixed on the upper face 18 of the composite body 10, advantageously by the adhesive film 14. The fabric 12 comprises an upper face 30 intended to be oriented towards the passenger compartment 2 of the vehicle and an opposite face 32 fixed on the composite body 10. In the assembled part, the fabric 12 matches the shape of the composite body 10. In addition, the fabric 12 has a thickness between 1 mm and 2 mm and a basis weight of less than 500 g / m 2. The basis weight and the thickness of the fabric 12 are adapted to facilitate the heat transfer which will be described later. Thus the weight of the fabric 12 is much lower than that of the web 26. The fabric 12 is able to be thermoformed at a temperature above 200 ° C between 220 ° C and 260 ° C and preferably at 2 ° C. In addition, the fabric 12 has a Young's modulus measured according to the NF EN ISO 527-3 standard at 20 ° C. greater than 2 Mega Pascal. The fabric 12 is made up of a plurality of threads 34. The fabric 12 advantageously comprises warp threads and weft threads woven between them.
    [0017] The softening temperature of the yarns 34 of the fabric 12 is greater than 220 ° C. A wire 34 is shown in FIG. 2. The wire 34 comprises a core 36 and a sheath 38 covering the core 36. The wire 34 is elongated along a main axis A. The length of the wire 34 along the main axis A is adapted to the fabric 12.
    [0018] In addition, the yarn 34 is resistant to weaving traction. In addition, the wire 34 has a Young's modulus measured according to the NF EN ISO 527-3 standard at 20 ° C higher than 2 Mega Pascal. The section of the wire 34 transversely to the main axis A is advantageously circular. The diameter D of the wire 34 is less than 1 mm and is advantageously between 0.4 mm and 0.6 mm. The section of the core 36 transversely to the main axis A is regular over the entire length of the wire 34. The section of the core 36 is substantially a disk. The diameter d of the core 36 is between 30% and 50% of the diameter D of the wire 34.
    [0019] The section of the sheath 38 transverse to the main axis A is regular over the entire length of the wire 34. The section of the sheath 38 is substantially a ring. The thickness e of the sheath 38 is between 25% and 35% of the diameter D of the wire 34. The core 36 is made of polymer. The sheath 38 is made of polymer. The softening point of the polymer of the core 36 is between 200 ° C and 250 ° C and preferably between 220 ° C and 240 ° C. For example, the core 36 comprises polyester terephthalate (PET). The core 36 advantageously comprises PET in the form of a continuous filament. Alternatively, the core 36 comprises PET fiber yarn. The softening point of the polymer of the sheath 38 is less than 200 ° C, especially less than 130 ° C. The polymer of sheath 38 degrades from 200 ° C. The sheath 38 comprises polyvinyl chloride (PVC). Alternatively, the sheath 38 further comprises plasticizers. The sheath 38 based on PVC begins to release its plasticizer to 180 ° C.
    [0020] PVC is degraded from 200 ° C. The sheath 38 is able to prevent the accumulation of dust. The sheath 38 is integral with the core 36. The sheath 38 is, for example, formed by extrusion around the core 36. The fabric 12 is both porous and resistant. The armor, the diameter and the tightening of the threads 34 of the fabric 12 is adapted to have the desired porosity and therefore a resistance to the passage of suitable air and the desired resistance to elongation. The number of 34 yarns of the fabric 12 in the warp and weft directions is between 5 and 15. The air flow resistance of the fabric 12 (RPA) measured according to ISO 9053 is included between 50 Nsrn-3 and 500 Nsrn-3.
    [0021] The porosity of the fabric 12 imparts to the piece of equipment of a motor vehicle 1 improved acoustic absorption properties. The fabric 12 has a particularly improved abrasion resistance compared to tufted or needled carpets, usually used in vehicles. In addition, the fabric 12 is provided with a complementary layer, conferring other properties such as, for example, a resistance to friction and abrasion. For example, the complementary layer of the fabric 12 is a polyurethane (PU) varnish, which makes it possible to limit the emanations of materials such as plasticizers, for example, the PVC-based sheath. Advantageously, the varnish is capable of being heated to 140 ° C. without undergoing degradation. The varnish is applied for example during the heat-setting step immediately following the weaving step. This heat-setting step makes it possible to lightly weld the wires together so as to avoid deformations of the fabric during winding in order to be packaged.
    [0022] The high resistance to friction that the polyurethane-based supplementary layer gives to the fabric 12 makes it possible to avoid the addition of heelpieces, for example, under the pedals of the vehicle. In the same way, the simplicity of care and cleaning of this fabric 12 renders the use of "on-carpet", that is to say removable carpet parts, which makes it possible to limit the fouling of the fabric, to be unnecessary. carpet and simplify the cleaning of the cabin. The fabric 12 is dust-proof, that is to say it is able to prevent the dust present in the passenger compartment 2 and regularly deposited on the floor to be retained on the fabric 12. In addition, the Tissue 12 is able to prevent the proliferation of mites responsible for allergens.
    [0023] The bonding film 14 is applied between the upper face of the composite body 10 and the opposite face 22 of the fabric 12. For example, the bonding film 14 is applied over the entire surface of the upper face 18 of the composite body 10. alternatively, the bonding film 14 is applied to some attachment areas only. The bonding film 14 is capable of allowing adhesion between the composite body 10 and the tissue 12. The bonding film 14 comprises, for example, polyamide (PA). The adhesive film 14 is, for example, a single layer of copolyamide. For example, the adhesive film 14 is the film referenced L202.89 of the company Proshimir. The bonding film 14 has a high affinity with the polymer of the sheath 32.
    [0024] For example, the adhesive film 14 is compatible with the PVC allowing strong adhesion between the composite body 10 and the fabric 12.
    [0025] The basis weight and thickness of the bonding film 26 are adapted to facilitate heat transfer which will be described later. Thus the film 26 has a much lower basis weight than the web 26 for example 100g / m2. The adhesive film 14 has a thickness less than or equal to 50 microns. The bonding film 14 has a melting temperature of between 120 ° C and 140 ° C. In FIG. 1, the nonwoven 16 is fixed on the opposite face 20 of the composite body 10.
    [0026] The nonwoven 16 is able to provide dimensional stability to the complex. In addition, the nonwoven 16 makes it possible to obtain a part 1 with a non-rough backside appearance and not having ceramic fibers 24 protruding from the composite body 10. The nonwoven 16 advantageously comprises non-woven PET fibers. The nonwoven 16 is deformable by sliding the PET fibers relative to each other under the effect of stretching. However, the PET fibers of the nonwoven 16, after heating to 140 ° C, retain the same rigidity properties. A manufacturing assembly 40 of the part 10, intended for the implementation of the method according to the invention is illustrated by FIGS. 3 and 4.
    [0027] The manufacturing assembly 40 comprises a heating unit 42 visible in FIG. 3, a thermoforming unit 44 visible in FIG. 4 and a gluing film application unit 45. The heating unit 42 comprises at least one plate 48 for supporting a sheet and at least one means 50 for heating the sheet.
    [0028] The heating unit 42 is adapted to heat the initial web 26 at a temperature above 200 ° C, preferably between 210 ° C and 300 ° C, preferably 270 ° C. In the example shown in FIG. 3, the heating unit 42 comprises a pair of plates 48 facing each other for preforming the ply 26.
    [0029] The pair comprises two facing plates 48 delimiting between them an intermediate space 52. Advantageously, a heating means 50 is disposed in each plate 48 to heat the initial web 26 directly by contact. Moreover, these heating means 50 are mounted on a low-power press but nevertheless capable of exerting a force of 10 tons to allow compression of the initial web 26.
    [0030] In the example shown in FIG. 4, the thermoforming unit 44 is formed of a mold 54 which comprises a first half-mold 56 and a second half-mold 58 delimiting between them a molding cavity 60. mold 54 has the final shape of part 1. The lower mold half is shown hollow in FIG.
    [0031] The thermoforming unit 44 further comprises means for regulating the temperature 62 of each half-mold 56, 58. The height of the mold cavity 60 corresponds to the thickness of the part 1. A method of manufacturing a piece of motor vehicle equipment 1 will now be described with reference to FIGS. 3 and 4.
    [0032] The method comprises a step of supplying the initial ply 26, a step of heating the initial ply 26, a step of applying the bonding film 14, a step of applying the fabric 12 and a step of thermoforming. Advantageously, the method further comprises a varnishing step. In the supplying step, an initial ply 26 formed of ceramic fibers 24 and 15 of fibers 28 of thermofusible polymer material is provided. This initial ply 26 is cut to present an outer contour corresponding to the dimensions of the part 1. The initial ply 26 has been advantageously made by an air dispersion or "airlay" process which makes it possible to easily treat the fiber blends 24 , 28 20 of all kinds. It can also be carried out by conventional dry process (carding followed by topping). After its constitution, the initial ply 26 is reinforced by needling for easier handling. Similarly, a fabric 12 is provided and is cut to present an outer contour corresponding to the dimensions of the part 1.
    [0033] Then, during the heating step, the initial ply 26 is introduced into the heating unit 42, as shown in FIG. 3. Then, the initial ply 26 is placed in abutment against the plates 48. In the heating step, the initial web 26 is heated to a heating temperature higher than the melting temperature of the hot-melt polymer constituting the polymer fibers 28. The heating temperature is greater than 200 ° C. For example, the trays are maintained at 270 ° C by the heating means 50. This heating is carried out for a residence time greater than 10 seconds, and in particular between 30 seconds and 45 seconds. This temperature is, for example, greater than 200 ° C, and especially between 250 ° C and 270 ° C.
    [0034] The heating step makes it possible to melt the fibers of thermofusible polymer material 28 and to adhere the melted hot-melt polymer to the ceramic fibers 24. During the step of heating the initial ply 26, the initial ply 26 is advantageously compressed. The pressure exerted in the heating unit 42 allows on the one hand, the transfer of calories, and on the other hand, the compression of the ply 26 to form a preformed web at the desired density. The initial web 26 is compressed to the required density, i.e. between 500 kg / m3 and 1500 kg / m3. Thus, when the composite body 10 is manufactured in the heating unit 42, compression is exerted on the initial web 26 between the plates 48 to reduce the thickness of the initial web 26. This decrease is, for example, the order of a ratio five, advantageously a ratio ten. Thus, when the initial ply 26 initially has a thickness of between 12 mm and 7 mm, it later comprises between the plates 48 of the heating unit 42 a thickness of between 2 mm and 0.5 mm, which corresponds approximately to the final density required for the composite body 10. The pressure exerted in the heating unit 42 is, for example, 6 bar which is likely to be produced by a 10-tonne press. The residence time in the heating unit 42 makes it possible to heat the fibers 20 of hot-melt polymer 28 to a temperature higher than their melting temperature. The thermofusible polymer of the fibers 28 is then at least partially in liquid form and impregnates the ceramic fibers 24. At the end of this heating step of the initial ply 26, we speak of the "preformed ply" 64. Indeed, the composite body 10 as such is not really constituted because the polymer which is still melting does not, strictly speaking, constitute the matrix 22 of a composite body 10. This intermediate product is nonetheless manipulable. The preformed web 64 is removed from the heating unit 42. It should be noted that once removed from the heating unit 42, because of the resilience of the ceramic fibers 24 and the fact that the matrix 22 n is not formed, the preformed web 64 can resume the thickness. The preformed ply 64 thus has a density approaching the final density of the composite body 10. The difference in density between the preformed ply 64 and the final composite body 10 is thus between 50% and 100%. after the exit of the heating unit 42, the adhesive film 14 is applied to the preformed web 64.
    [0035] The adhesive film 14 is for example derived from a reel. The bonding film 14 is previously cut to the dimensions of the part 1. The bonding film 14 is applied to the preformed sheet 64 by the application unit 45.
    [0036] Subsequently, the fabric 12 is applied to the preformed web 64 which is covered with the adhesive film 14. The walls of the conforming mold 54 are maintained, by the thermal control unit 62, advantageously at the desired desired constant temperature which corresponds to advantageously at the crystallization temperature of the thermofusible polymer present in the web. The shaping mold 54 is thus maintained at a temperature of between 100 ° C. and 200 ° C., advantageously at 140 ° C., which is the crystallization temperature of the PET used. Alternatively, the mold is regulated to be maintained at room temperature. The complex consisting of the composite body 10, the film 16 and the fabric 12 is introduced into the mold cavity 60 between two half-molds 56, 58, as shown in FIG. 4. The nonwoven 16 is, for example, placed in the bottom of the lower mold half 54 of thermoforming. The complex is introduced into the lower half mold 54 so that the opposite face 20 of the web is in contact with the nonwoven 16. Following the step of applying the fabric 12 to the preformed web 64 the process comprises a heat transfer step. The heat transfer time is the time between the start of the application of the fabric 12 to the preformed web 64 and the closure of the mold. During heat transfer, the calories of the preformed web 64 are rapidly transferred to the bonding film 16 and the fabric 12 due to their low basis weight. It should be that when the mold is closed the core 36 of the wires 34 reaches a temperature above 200 ° C so that it can be thermoformed. This transfer time must be as short as possible. The heat transfer time is conditioned by the thermal inertia of the composite web 64 and therefore by its basis weight. The heat transfer time is less than or equal to 10 s. It is advantageously between 5 and 10s.
    [0037] The heat transfer time is adapted to allow the heating of the fabric 12 to a temperature greater than or equal to the softening temperature of the fabric 3029825 14 12, preferably greater than 200 ° C. In addition, the heat transfer time is short enough to limit the degradation of the polymer of the sheath 38. In particular, the heat transfer time is adapted to limit the degradation of the sheath and the exudation of the plasticizers when the sheath is in contact with the sheath. PVC. Thus, this mode of thermal transfer by the composite ply 64 of high thermal inertia towards the low thermal inertia fabric makes it possible, surprisingly, to reach the softening temperature of the core 36 of the wires 34, but this during a sufficiently short window of time not to degrade the sheath 38 PVC. This window is used to thermoform the assembly and in particular the fabric 12. Following the heat transfer, the adhesive film 14 reaches its melting temperature. In addition, the nonwoven 16 adheres to the preformed web 64 through contact with the hot melt polymer melt. Due to the heat transfer at the time of closure of the mold 54, the temperature within the fabric 12 corresponds to the softening temperature of the fabric. For example, the temperature of the fabric at the time of closure of the mold is between 200 ° C and 240 ° C. When the mold 54 is closed, the preformed web 64 and the fabric 10 then adopt a form conjugate to that of the volume that receives it. The molding cavity 60 remaining between the walls of the mold 54 then corresponds to the desired thickness for the final piece 1. In the thermoforming step, the fabric 12 and the preformed web 54 conform to the shape of the mold 54 to form the composite body 10 provided with a fabric covering 12. The fabric 12 conforms to the shape of the composite body 10. during the thermoforming step, the fabric 12 is fixed to the composite body 10. The fabric 10 and the preformed web 64 are held in the mold 54 closed for a residence time greater than 10 seconds, and in particular between 30 seconds and 45 seconds this to ensure good crystallization of the polymer. The hardening polymer forms the matrix 22 of the composite body 10.
    [0038] Advantageously, at least partial recrystallization of the polymer occurs to generate better mechanical performance. The pressure exerted between the walls of the mold 54 promotes the bonding of the fabric 12 to the composite body 10. Then, the formed part 1 is extracted out of the mold 54.
    [0039] Alternatively, the nonwoven 16 is adhered to the composite body 10 prior to placement in the thermoforming mold 54. Alternatively, the nonwoven 16 is adhered to the composite body 10 after the exit of the thermoforming mold. The method advantageously comprises a varnishing step. For example, the coating is carried out before the thermoforming step. During the varnishing step, the complementary layer is added to the fabric 12, for example, by spraying and UV curing. Alternatively, the complementary layer is added on the finished part 1. Alternatively, a fabric 12 is applied to both sides of the composite body 1 of the equipment part 1. This is advantageous if the piece of equipment 1 is intended to be visible on both sides, for example, when the part 1 is a tablet.
    [0040] Advantageously, the fabric 12 contributes to the mechanical performance of the part 1. The invention which has just been described provides a part 1 which is resistant to abrasion and easily washable, which avoids the addition of carpet and of heelettes. In addition, the piece 1 is resistant to ultraviolet due to the presence of the fabric 12 on its face exposed to light.
    [0041] In addition, the fabric 12 has acoustic characteristics allowing good soundproofing. In addition, fabrics 12 from PVC-sheathed filaments have a decorative appearance and exist with different textures or colors. Part 1 is easy to manufacture with a single thermoforming step.
    [0042] In addition, the tissues 12 used have a substantial Young's modulus. The tissues 12 make it possible to participate in the mechanical strength of the part 1 to limit the deflection or creep. The capacities of the fabric 12 thus make it possible to reduce the weight of the composite body 10 used in the room 1. A second piece 70 of motor vehicle equipment according to the invention will now be described with reference to FIG. 70 differs from the first part 1 in that it comprises at least one sheet 72, 74 between the composite body 10 and the adhesive film 14. For example, the part comprises a first sheet 72 fixed on the upper face 18 of the body composite 10 and a second sheet 74 fixed on the opposite face 20 of the composite body 10. The sheets 72, 74 advantageously cover all of the faces 18, 20 of the composite body 10, in particular more than 95% of the extent of each face. 18, 20. The sheet 72, 74 has a thickness less than that of the composite body 10. Advantageously, the thickness of the sheet 72, 74 is much lower than that of the composite body 10 and is, for example, less than 5% of the maximum thickness of the composite body 10.
    [0043] Each sheet 72, 74 is fixed on a face 18, 20 of the composite body 10, advantageously by partial impregnation of the hot-melt polymer of the matrix 22 in the sheet 72, 74. For this purpose, the matrix 22 penetrates the sheet 72 , 74 to a thickness advantageously greater than 50% of the thickness of the sheet 72, 74 and in particular less than 80% of the thickness of the sheet 72, 74. The sheet 72, 74 has a basis weight less than 100 g / m 2, in particular less than 80 g / m 2, advantageously less than 60 g / m 2. The sheet 72, 74 is porous. It thus has a plurality of openings which determine its wettability by capillarity. The wettability of the sheet 72, 74 depends on the critical surface tension of the fibers that constitute it, the average pore size between these fibers and the pressure exerted between the hot trays 48 during the heating of the initial web. By adjusting these three parameters with respect to the creep index of the hot melt polymer and the surface tension of the melt polymer, the penetration of the polymer within the material constituting the sheets 72, 74 under controlled pressure is controlled. In the piece 70 according to the invention, the polymer forming the matrix 22 penetrates as much as possible, at least over half the thickness of the sheet, but without crossing them. Thus, the sheet 72, 74 provides continuity with the matrix 22 of the composite body 10 and has similar mechanical properties. The sheet 72, 74 is made of a porous material. For example, the sheet 72, 74 is made of paper. The paper has a basis weight of less than 80 g / m2. It is, for example, made of vegetable, mineral, animal or synthetic fibers manufactured or a mixture of these fibers by deposition and compression of fibers on a suitable training device. The method of manufacturing the second piece differs from the method of manufacturing the first piece in that the sheets 72, 74 are applied to the initial web 26. In the step of providing the sheets 72, 74 are provided. Then, the initial ply 26 is covered with at least one sheet 72, 74.
    [0044] Advantageously, the initial ply 26 is interposed between two sheets 72, 74. A first sheet 72 is disposed on a first face of the initial ply 26, and a second sheet 74 is disposed on a second face of the initial ply 26. Next during the heating step, the initial ply 26 provided with at least one sheet 72, 74 advantageously of two sheets 72, 74 on its opposite sides is introduced into the heating unit 42, resting against the trays 48. During the heating step, the force exerted by the heating means 42 allows the sheets to be wetted by the hot melt polymer. The sheet 72, 74 is integrated into the preformed web 64 during the heating step. The polymer of the matrix 22 bonding the ceramic fibers of the initial web 26 between them penetrates partially into each of the sheets 72, 74, while being confined between the sheets 72, 74 to improve the mechanical properties of the body 10 and promote the fixing the sheets 72, 74 on the sheet 64. In addition, the sheets 72, 74 remain porous because partially penetrated by the matrix, they are preferred sites for fixing other layers, such as the adhesive film 14 or the non The sheets 72, 74 are necessary when the fabric 12 is very decontextured, that is to say it has few threads per cm 2. The sheets limit the risk that the ceramic fibers 24 pass through the fabric 12. In addition, the sheets 72, 74 advantageously have a color adapted to the color of the fabric. At the end of the heating step, the handling of the preformed web is facilitated by the presence of the sheets 72, 74.
    [0045] Then, after the exit of the heating unit, the adhesive film is applied to the sheet 72 of the preformed web 64. A third piece of motor vehicle equipment 80 according to the invention is described in FIG. 6. The third piece 80 differs from the first piece 1 and the second piece 70 in that the third piece 80 comprises a first composite body 82, a second composite body 84 and an intermediate spacer 86. The composite bodies 82, 84 are fixed on opposite sides of the intermediate spacer 86. Advantageously, the spacer 86 is made based on a cellular or honeycomb structure.
    [0046] Thus, the spacer 86 has a plurality of walls 88 substantially perpendicular to an average plane of the part 1, the walls 88 defining central spaces 90 of closed contour forming the cells. Thus, each central space 90 or cell opens out facing a body 82, 84. The spacer 14 is advantageously made of a light material, such as paper or cardboard. The method of manufacturing the third piece 80 differs in that the mold 54 is advantageously adapted to perform the assembly of the bodies 82, 84 on the spacer 14. The spacer 14 previously cut to the required dimensions is covered with binder on its two faces by, for example, roller gluing machines.
    [0047] The method of manufacture differs in that the method comprises a step of heating each initial ply 26 intended to form a composite body 82, 84 and 3029825 18 a phase of assembly of each composite body 82, 84 on the spacer 14 The fabric 12 is applied to at least one of the preformed composite bodies 82, 84. The molding cavity is adapted to receive the preformed composite body, the spacer 84 and the fabric 12.
    [0048] The third piece 80 is, for example, a double-shell composite body panel covered with a fabric decoration 12 on an upper face and a nonwoven 16 on a lower face.
    权利要求:
    Claims (15)
    [0001]
    CLAIMS 1.- A method of manufacturing a motor vehicle equipment part (1, 70, 80), comprising the following steps: - providing a sheet (26) comprising ceramic fibers (24) and fibers of hot-melt polymer (28), the melting temperature of the hot melt polymer being greater than 200 ° C, - heating the web (26) at a temperature above 200 ° C to melt the hot-melt polymer, - application of a fabric (12) on the web (26), the fabric (12) comprising yarns (34) having a polymer core (36) having a softening point greater than or equal to 200 ° C, - thermoforming the fabric (12) and the web (26) in a shaping mold (54).
    [0002]
    2. A manufacturing method according to claim 1, comprising a thermal transfer step between the web (64) and the fabric (12) after heating the web (26), the heat transfer for heating the fabric (12). at a temperature greater than or equal to the softening temperature of the core (36), preferably greater than 200 ° C.
    [0003]
    3. A method of manufacture according to any one of claims 1 or 2, in the hot melt polymer is polyethylene terephthalate (PET).
    [0004]
    4. Manufacturing method according to any one of the preceding claims, wherein the son (34) of the fabric (12) have a core (36) of polyethylene terephthalate (PET).
    [0005]
    The manufacturing method according to any one of the preceding claims, wherein the yarns (34) of the fabric (12) have a sheath (38) comprising polyvinyl chloride (PVC).
    [0006]
    6. A manufacturing method according to any one of the preceding claims, wherein the forming mold (54) is maintained at a temperature between 100 ° C and 200 ° C, preferably 140 ° C.
    [0007]
    7. A manufacturing method according to any one of the preceding claims, wherein the fabric (12) and the web (64) are maintained in the mold (54) shaping less than one minute.
    [0008]
    8. A manufacturing method according to any one of the preceding claims, further comprising the following steps: - application of a bonding film (14) on the sheet (64), before the application of the fabric (12) The fabric (12) is applied to the bonding film (14) prior to thermoforming.
    [0009]
    9. A manufacturing method according to any preceding claim, wherein the web (26) has an upper face (18) and an opposite face (20), the fabric (12) being fixed on the upper face of the web (26), the method comprising the following step 5: - application of a nonwoven (16) on the opposite side of the web (26).
    [0010]
    10. A motor vehicle equipment part (1, 70, 80) comprising: a composite body (10) comprising a matrix (22) of polymer and ceramic fibers (24) embedded in the matrix (22), A fabric (12), the fabric (12) comprising an upper face (30) intended to be oriented towards a passenger compartment (2) of the vehicle and an opposite face (32) fixed on the composite body (10), the fabric (12) conforming to the shape of the composite body (10), characterized in that the fabric (12) comprises yarns (34) having a polymer core (36) having a softening point greater than or equal to 200 ° C. 15
    [0011]
    11. Part (1, 70, 80) according to claim 10, wherein the matrix (22) of the composite body (10) comprises polyethylene terephthalate (PET).
    [0012]
    12. Part according to any one of claims 10 or 11, wherein the fabric (12) comprises yarns (34) having a core (36) of polyethylene terephthalate (PET) and a sheath (38) comprising polyvinyl chloride. vinyl (PVC). 20
    [0013]
    13.- part (1, 70, 80) according to any one of claims 10 to 12, comprising a bonding film (14) between the composite body (10) and the fabric (12), the bonding film (14). ) being preferably of polyamide (PA).
    [0014]
    14.- Part (1, 70, 80) according to any one of claims 10 to 13, wherein the fabric (12) has a thickness of less than 2 mm. 25
    [0015]
    15.- part (1, 70, 80) according to any one of claims 10 to 14, wherein the composite body (10) has an upper face (18) and an opposite face (20), the fabric (12). being attached to the upper face (18) of the composite body (10), the part (1, 70, 80) comprising a nonwoven (16) fixed on the opposite face (20) of the composite body (10). 30
    类似技术:
    公开号 | 公开日 | 专利标题
    FR3029825A1|2016-06-17|METHOD FOR MANUFACTURING A MOTOR VEHICLE EQUIPMENT PIECE AND MOTOR VEHICLE PART COMPRISING A COMPOSITE BODY THEREFOR
    EP3448646B1|2021-03-17|Improved method for forming retaining elements
    EP1001875B1|2002-09-04|Method for making a sandwich-type reinforced composite structural panel with alveolate core and resulting panel
    EP2822746B1|2016-02-17|Method of manufacturing a piece of automotive vehicle equipment and associated piece of equipment
    KR101969340B1|2019-04-17|Motor vehicle parts
    EP1575759A1|2005-09-21|Method and device for making a composite plate
    FR3041299A1|2017-03-24|METHOD FOR MANUFACTURING A PIECE OF INTERIOR EQUIPMENT OF A MOTOR VEHICLE
    FR3018287A1|2015-09-11|METHOD FOR MANUFACTURING AN AUTOMOTIVE VEHICLE INTERIOR EQUIPMENT COMPONENT COMPRISING A VELVET PLACE LAYER AND ASSOCIATED PIECE
    EP3233444B1|2019-07-31|Method for manufacturing a composite component with impressions in relief and composite component derived from such a method
    FR3039566A1|2017-02-03|WIRE, VEHICLE EQUIPMENT PIECE, WIRE FORMATION METHOD, AND METHOD FOR MANUFACTURING A VEHICLE VEHICLE ASSEMBLY THEREOF
    FR3025740A1|2016-03-18|METHOD FOR MANUFACTURING A CARRIAGE PIECE OF A VEHICLE
    FR3065392A1|2018-10-26|METHOD FOR MANUFACTURING A STRUCTURAL PART FOR A MOTOR VEHICLE HAVING IMPROVED FINISHES
    FR3014731A1|2015-06-19|METHOD FOR MANUFACTURING AN ECONOMIC STRUCTURAL PART, IN PARTICULAR FOR A MOTOR VEHICLE
    FR3074458A1|2019-06-07|AUTOMOTIVE VEHICLE EQUIPMENT PANEL AND METHOD OF MANUFACTURING THE SAME
    FR2523607A3|1983-09-23|TEXTILE FLOOR COVERING WITH WEAR SHEET AND METHOD FOR FIXING THE SAME
    EP0986463B1|2004-02-04|Sheet complex useful for surface coating of moulded structures
    EP1872939A2|2008-01-02|Raised floor comprising a non-woven cloth and a decorative layer and manufacturing method of same
    EP2172363B1|2012-08-29|Carpet for shielding a first equipmement carpet in an automotive vehicle
    FR3018761A1|2015-09-25|MOTOR VEHICLE EQUIPMENT PIECE, VEHICLE AND MANUFACTURING METHOD THEREOF
    FR2854601A1|2004-11-12|Structural component e.g. of motor vehicle interior trim has woven or knitted covering layer with backing based on thermoplastic polymer
    FR3085390A1|2020-03-06|METHOD OF MANUFACTURING A TEXTILE PIECE OF EQUIPMENT CAPABLE OF TRAPPING VOLATILE ORGANIC COMPOUNDS, AND ASSOCIATED PIECE
    FR2458618A1|1981-01-02|Nonwoven fabric prepd. by needling coloured fibrous layer - through layer of thermoplastic fibres, shapable and retaining shape
    FR3093669A1|2020-09-18|A method of manufacturing a prepreg fiber reinforcement from a thermoplastic nonwoven and a reinforcement of natural fibers
    FR3079166A1|2019-09-27|LAMINATED ASSEMBLY, SLEEVE LAYER COMPRISING SUCH AN ASSEMBLY AND METHOD FOR MANUFACTURING SUCH ASSEMBLY
    EP1382483A1|2004-01-21|Thermoformable blank with square tufting
    同族专利:
    公开号 | 公开日
    US20160167597A1|2016-06-16|
    CN105690893B|2018-08-21|
    US9950679B2|2018-04-24|
    CN105690893A|2016-06-22|
    FR3029825B1|2017-01-13|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    US20060141260A1|2004-12-29|2006-06-29|Enamul Haque|Sandwich composite material using an air-laid process and wet glass|
    DE102005028627B3|2005-06-20|2006-12-21|Carcoustics Tech Center Gmbh|Thermoformed supporting component, e.g. automobile roof rack, comprises core layer of glass and thermoplastic fibers, covering non-woven layer containing melt adhesive fibers|
    FR2990896A1|2012-05-24|2013-11-29|Faurecia Automotive Ind|METHOD FOR MANUFACTURING A REINFORCED EQUIPMENT PIECE, IN PARTICULAR FOR A MOTOR VEHICLE|
    AT278544T|2001-02-06|2004-10-15|Fagerdala Deutschland Gmbh|COMPOSITE MATERIAL FROM A POLYPROPYLENE TOP LAYER AND A POLYPROPYLENE FOAM FILM|
    JP2005536646A|2001-10-11|2005-12-02|コルボントベスローテンフェンノートシャップ|Custom-made nonwoven sheeting with non-uniform properties|
    WO2010042334A1|2008-10-09|2010-04-15|Dow Global Technologies Inc.|Polyolefin film having an improved barrier layer for airbag applications|
    US7798549B2|2008-10-30|2010-09-21|Honda Motor Co., Ltd.|Trunk liner method and apparatus|
    FR2987777B1|2012-03-09|2014-05-02|Faurecia Automotive Ind|METHOD FOR MANUFACTURING A MOTOR VEHICLE EQUIPMENT PIECE AND PART OF EQUIPMENT THEREFOR|
    CN102896822B|2012-07-03|2015-06-17|滁州格美特科技有限公司|High performance lightweight composite sheet material, production method and application|
    CN103088557B|2013-01-29|2015-04-22|大连华阳化纤科技有限公司|Producing method of double-component spun-bonded hot wind concretion non woven|US10435822B2|2017-02-24|2019-10-08|Glen Raven, Inc.|Resilient yarn and fabric having the same|
    FR3070301B1|2017-08-22|2021-02-12|Hutchinson|3D THERMOFORM PACKAGE|
    FR3074458B1|2017-12-01|2020-11-20|Faurecia Automotive Ind|AUTOMOTIVE VEHICLE INTERIOR EQUIPMENT PANEL AND ASSOCIATED MANUFACTURING PROCESS|
    FR3075089B1|2017-12-20|2021-02-19|Faurecia Automotive Ind|PROCESS FOR MANUFACTURING A SOUNDPROOFING PART, IN PARTICULAR INTENDED TO EQUIP A MOTOR VEHICLE|
    FR3078915B1|2018-03-13|2021-04-23|Faurecia Automotive Composites|COMPOSITE MATERIAL PART INCLUDING A COMPOSITE MATERIAL BODY AND AT LEAST ONE INSULATION LAYER|
    法律状态:
    2015-11-23| PLFP| Fee payment|Year of fee payment: 2 |
    2016-06-17| PLSC| Publication of the preliminary search report|Effective date: 20160617 |
    2016-11-21| PLFP| Fee payment|Year of fee payment: 3 |
    2017-11-21| PLFP| Fee payment|Year of fee payment: 4 |
    2019-11-20| PLFP| Fee payment|Year of fee payment: 6 |
    2020-11-20| PLFP| Fee payment|Year of fee payment: 7 |
    2021-11-18| PLFP| Fee payment|Year of fee payment: 8 |
    优先权:
    申请号 | 申请日 | 专利标题
    FR1462332A|FR3029825B1|2014-12-12|2014-12-12|METHOD FOR MANUFACTURING A MOTOR VEHICLE EQUIPMENT PIECE AND MOTOR VEHICLE PART COMPRISING A COMPOSITE BODY THEREFOR|FR1462332A| FR3029825B1|2014-12-12|2014-12-12|METHOD FOR MANUFACTURING A MOTOR VEHICLE EQUIPMENT PIECE AND MOTOR VEHICLE PART COMPRISING A COMPOSITE BODY THEREFOR|
    US14/966,951| US9950679B2|2014-12-12|2015-12-11|Fabrication method for making an equipment device for an automotive vehicle and associated equipment device for an automotive vehicle comprising a composite body|
    CN201510927588.XA| CN105690893B|2014-12-12|2015-12-14|A kind of manufacturing method for manufacturing machine motor car equipment component and the relevant motor vehicle apparatus assembly including composite layer|
    [返回顶部]