DE29619592U1 - Recyclable molded carpet part - Google Patents

Description

RECYCLABLE
CARPET MOULDING

The invention relates to recyclable carpet moldings for motor vehicles with a multi-layer structure.

Carpet floor moldings in motor vehicles are well known. They are usually manufactured by first molding a textile floor covering in a matrix mold of the floor panel of the motor vehicle. Due to the transmission tunnel or elevations or depressions on the floor panels, height differences of a few millimeters to several centimeters occur.

Back-coated, velour or needle felt floor coverings are usually used. To improve sound insulation, the floor coverings in high-quality vehicles are provided with a so-called heavy layer. This is, for example, an EPDM film containing up to 70% filler by weight.

The resulting laminate of backed carpet and heavy layer is usually subjected to deformation.

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To compensate for the unevenness of the floor panel and to absorb sound, an absorption foam backing is applied to the above-mentioned laminate using the back-injection process. In particular, the use of a filled two-component polyurethane foam (heavy foam) that is injected into the tool is preferred in the state of the art. This polyurethane foam is acoustically effective in combination with the heavy layer.

WO 93/00216 relates to a method for producing multilayer molded articles by back-injection molding of a laminate (16) consisting of a substantially flexible, film-like surface material (19) such as leather or textile materials and a foam layer (22) laminated to the back of the laminate. Before the laminate is molded into the injection mold, a separating layer (18) is applied to the foam surface. The separating layer consists of a separating agent that contains a mixture of an aqueous rubber dispersion and an aqueous silicone emulsion.

From WO 94/01278 and the state of the art cited therein, a process is known for the production of textile top floors in motor vehicles by

(a) doctoring a mixture of foam flakes and a self-hardening binder (absorption foam) 2 into a matrix mold of the floor panel of the motor vehicle 1 in a desired layer thickness profile,

(b) applying by pressing the optionally preformed textile floor covering 4 provided with a heavy layer 3 onto the mixture of foam flakes and self-hardening binder 2 while adjusting the desired foam flake density,

(c) Activating the binder and

(d) Bonding the mixture of foam flakes and self-hardening binder 2 to the heavy layer 3 of the textile floor covering. With the help of this publication, a uniform density distribution over the entire volume of the rear absorption foam 2 can be achieved.

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However, when recycling such textile floor coverings, a serious problem arises in that the layers used are inseparably connected to one another and therefore only multi-component mixtures are available for reuse. In principle, however, the textile floor coverings connected to the heavy layer on the one hand and the foam backing on the other hand could be used for excellent reuse after separation.

DE 295 08 807 U1 describes a recyclable carpet molding for automobiles made from a carpet based on polypropylene fibers and a damping element containing fusible fibers. This recyclable carpet molding represents a step towards the recycling of carpet moldings for automobiles, but the acoustic properties of this carpet molding are unsatisfactory.

Accordingly, the object of the present invention is to provide a recyclable carpet molding for automobiles consisting of a carpet top and a carrier layer, in which an economically viable separation of the individual construction layers can be carried out after use of the motor vehicle. Furthermore, the object of the present invention is to give the carpet parts designed in this way improved acoustics with low weight.

The above-mentioned object is achieved by a recyclable carpet molding part for motor vehicles consisting of a carpet upper part and a carrier layer, which is characterized in that the carrier layer comprises a heavy layer integrated in a sandwich-like manner in two fleece layers.

With the help of the present invention, a recyclable carpet molding with excellent acoustic properties could be provided. The double spring mass system provided hereby consists of a first spring mass system through damping from the fleece facing the floor panel and the heavy foil covering as well as a second spring mass system of the

Carpet with hard-pressed fleece, heavy foil and carpet. Surprisingly, the building acoustics ceiling test bench produced very good results, with the insulation level from 1250 Hz being significantly higher than that of a heavier carpet that was based on the state of the art. A construction fleece and heavy foil were used with a carpet built on top, where the heavy foil had a surface weight of 2 kg/m ^2. This spring-mass system was extremely heavy due to the double layer of heavy foil and had an inadequate appearance and feel.

In contrast, the carpet molding according to the invention was 0.6 kg/m ² lighter. The acoustic results are shown in Fig. 1.

Even in the Apamat, in which the improvement in airborne sound radiation compared to the body sheet was measured, an excellent airborne sound radiation behavior was measured for the carpet molding according to the invention (solid line in Fig. 2) with a surface weight of 6.5 kg/m ² and a thickness of 21.7 mm, which was clearly superior to a carpet of the reference example as described above (dashed line in Fig. 2} with a thickness of 17.5 mm and a surface weight of 6.6 kg/m ² and a carpet molding made of a carpet and a rear damping element made of natural fibers (state of the art).

The advantages of the invention were particularly evident when the body sheet was covered with a heavy foil.

While the combination of two spring-mass systems in the Apamat showed advantages, good results were already achieved in the ceiling test bench when a light carpet (fleece, 1.5 kg/m ² , heavy foil, carpet) was attached to dampers without heavy foil.

The floor insulation according to the invention shows a partially considerably higher level of insulation both on damping with heavy foil (double spring mass system) and without heavy foil than heavy floor insulation or equally heavy

Floor insulation.

In a particular embodiment of the present invention, the carpet top is made from polyester and/or polypropylene fibers, these fibers being used in particular in a weight ratio of 70:30 to 60:40. In this sense, it is particularly preferred to provide the aforementioned fibers as needle-punched nonwovens without special reinforcement (latex) but with either a binding fiber component (PE/PP) or additionally with a needled-on PE nonwoven binding layer. This results in a particularly low weight of the carpet top of less than 0.5 kg/m ² .

Various materials are available to the person skilled in the art for the carrier layer. Needle-punched nonwovens with a basis weight of 0.2 to 1.2 kg/m ² are particularly preferred, with the following compositions being particularly preferred:

a) polypropylene (PP)/polyester (PES)/cotton (BW), in particular in the weight ratio 50/25/25;

b) Polypropylene (PP)/polyacrylonitrile (PAN), particularly in a weight ratio of 50/50, but 30/70 to 70/30 wt.% are also possible, whereby, depending on the weight setting, a softer or harder needle fleece is obtained and the acoustic transparency is changed;

c) Polypropylene (PP)/polyacrylonitrile (PAN)/polyester (PES) in a weight ratio of 50/30/20, but, as mentioned above, different mixtures are also possible, depending on the desired hardness and acoustic transparency;

d) Polypropylene (PP)/Polyester (PES), especially 50/50, but also in the weight ranges mentioned above. These materials are generally harder than the polyacrylonitrile-containing ones mentioned above.

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Needle fleece.

The heavy layer in the sense of the present invention comprises a commercially available EPDM film filled with up to 80 wt. %, in particular 70 wt. %, of filler, in particular with a basis weight of 0.9 kg/m ² to 2 kg/m ² .

Claims (5)

— 7 — Protection claims 1. Recyclable carpet molding for motor vehicles made of a carpet top layer and a carrier layer, characterized in that the carrier layer comprises a heavy layer integrated in a sandwich-like manner in two fleece layers of the carrier layer. 2. Moulded part according to claim 1, characterized in that the carpet upper part is constructed on the basis of polyester and/or polypropylene fibres, in particular in a weight ratio of 70:30 to 60:40. 3. Moulded part according to claim 1 or 2, characterized in that the carpet top part consists of a needle-punched fleece without consolidation, but with a binding fibre edge! or additionally needled fleece binding shaft. 4. Moulded part according to claim 1, characterized in that the fleece layer of the support layer contains fibres from a) polypropylene/polyester/cotton, b) Polypropylene/polyacrylonitrile, c) polypropylene/polyacrylonitrile/polyester or d) Polypropylene/Polyester
includes. 5. Moulded part according to claim 1, characterised in that the heavy layer is a highly filled EPDM layer, in particular with a basis weight of 0.9 to 2 kg/m ² .