DE102021111788A1 - Sound Insulation Construction - Google Patents

Abstract

Carpet, in particular tufted carpet (1) or velor carpet (9), for a motor vehicle, with a pile (2), an integrated adhesive layer (4) and with a further adhesive layer (5), characterized in that the pile ( 2) the carpet (1,9) contains yarns and/or fiber loops and/or filament loops and/or fibers consisting of polyamide (PA), the binding adhesive layer used to bind the yarns, fiber loops, filament - loops and/or fibers, consists of a polyamide or co-polyamide-based adhesive and that the further adhesive layer consists of a polyamide or co-polyamide-based adhesive.

Description

The invention relates to a material structure for motor vehicle sound insulation, in particular for the motor vehicle interior and motor vehicle luggage compartment; especially for floor mats, seat back panels, side panels, floor panels and luggage compartment panels. The material structure includes a "mono-construction", i.e. a one-material system, so this structure can be efficiently remanufactured and the soundproofing is fully recyclable.

The focus here is on the wear layer of floor and luggage compartment linings in particular, consisting of the surface/visible surface layer with adhesive layers underneath, acoustic/reinforcing nonwovens, sealing and heavy foils as well as contact/foil nonwovens.

Various designs of floor covering wear layers are known in practice; Tufted, velor and flat-needle carpets are commonly found here as the surface/visible surface layer.

The floor coverings used in motor vehicles today generally have material structures that have a wear layer - consisting of the surface/visible surface layer with adhesive layers underneath, acoustic/reinforcing nonwovens, sealing and heavy foils as well as contact/foil nonwovens - and the insulation include.

Various designs of floor covering wear layers are known in the prior art; Tufted, velor and flat-needle carpets are widely used as the surface/face layer. In the case of VANs, SUVs, pickups and light commercial vehicles in particular, rubber, PUR-RIM, PVC and increasingly TPO (surface-structured/with graining) are also used as the surface/visible surface layer of the wear layer in the prior art.

In the case of tufted carpets, preference is given in particular to using PA6.6, PA6, PP, rPA and PET, rPET and the bio-based polyamides (PA 5.10; PA 6.10) or wool as the yarn/filament material. In the field of velor and flat-needle fleece carpets, PET, PET/PP, PP, PA/PET and rPET are primarily used as fiber materials. The tufting backing for the tufting qualities mostly consists of PET/PP, PET/coPET or PET/PA as well as PET/PA+PP.

The filament/yarn (yarn nubs) or fiber connections used here preferably include EVA and PE in the case of tufted carpets and SBR latex or acrylate in the case of velor and flat needle fleece carpets. Furthermore, in the case of velor and flat needle fleece carpets, foils, fleeces, adhesives (hot melts), thermoplastics (mainly PE) and the in EP 1 598 476 B1 described thermal bonding method used. Furthermore, binding fibers, EVA or thermoplastic dispersions are increasingly being used.

The coatings, mostly as an adhesive layer for sub-fleeces, but also for stiffening, mainly comprise PE or PP. Adhesives (hot melts), thermoplastic dispersions and PE as well as EVA/PE powder are used to ensure integration and coating in one if possible.

The lower layers, such as acoustic and/or stiffening nonwovens, preferably consist of PET and/or mixed fiber nonwovens, often with a BiCo fiber content. Furthermore, three-layer recycled sandwich nonwovens ( DE 10 2016 203 348 A1 ) Application. PE/PA and PE/PA/PE films as well as PE/PA/PE+PET film fleece are used as sealing or insulating films. Depending on the acoustic requirements, so-called heavy foils based on EVA, PE, PP and EPDM are also used partially and/or over the entire surface as insulating foils.

Between the wear layer (often generally also referred to as the upper fabric) and the body floor, there is advantageously an insulation layer, which can be formed in particular from PUR foam or fleece structures (fleeces or fiber flock (HMP) composites). If a foam is used, it is preferably firmly connected (and in particular foamed) to the wear layer. Fleece/fiber flock structures can also be firmly connected to the wear layer, in which case they are then usually glued or also fused. However, there is also pure superimposition without a fixed connection.

The properties of the foam insulation differ significantly in the specifications of the automobile manufacturers with regard to density, modulus of elasticity and loss factor; the fleece or fiber flock (HMP) composites of an insulation in terms of density and compressive strength.

Such floor covering systems are described, for example, in DE 10 2004 046 201 A1 , DE 103 60 427 A1 , DE 199 60 945 A1 and DE 10 2007 036 952 A1 .

The reprocessing of such heterogeneous sound insulation structures, the most diverse, mostly inextricably linked Materials with different basis weights is extremely problematic.

DE 20 2012 004 594 U1 discloses a PET-based sound insulation. The structures presented therein, in particular the PET carpet layer, largely do not meet the requirements of the automobile manufacturers; in particular with regard to the utility properties (including the wear behavior). The look and feel also do not meet the specified requirements, primarily when used in the premium segment of motor vehicles.

In addition, PET recycling, reuse/refurbishment, is not always guaranteed in comparison to PA recycling.

The material structures for motor vehicle sound insulation known in the prior art, in particular for the motor vehicle interior and motor vehicle luggage compartment, are not “single-material systems”; these composites contain a wide variety of plastics/types with different basis weights. This means that optimal reprocessing and economic recycling are not possible.

The object of the present invention compared to the aforementioned prior art is therefore to provide a material structure for motor vehicle sound insulation, in particular for the motor vehicle interior and motor vehicle luggage compartment, which represents a one-material system, is relatively easy to recycle, and in particular the mechanical-physical and acoustic requirements the car manufacturer guarantees; and also has high utility properties over the life of a motor vehicle.

According to the invention, these objects are achieved by the subject matter of the independent claims. Advantageous embodiments and developments are the subject of the dependent claims.

A carpet according to the invention, in particular a tufted carpet or velor carpet or flat-needle fleece carpet for a motor vehicle has a pile, a bonded adhesive layer and a further adhesive layer; the tufted carpet also has a backing layer. According to the invention, the pile of the carpet contains or has polyamide yarns and/or fiber loops and/or filament loops and/or fibers. Furthermore, there is a binding adhesive layer, which serves in particular to bind the yarns, fiber loops, filament loops and/or fibers, from an adhesive based on polyamide or co-polyamide. Furthermore, the further adhesive layer also consists of a polyamide or co-polyamide-based adhesive or adhesive (or has such an adhesive). The pile of the carpet preferably consists exclusively of the yarns and/or fiber loops and/or filament loops and/or fibers mentioned consisting of polyamide.

In a further preferred embodiment, the binding adhesive layer and the further adhesive layer are arranged on one another and in particular arranged directly on one another and in particular arranged flat on one another.

In a further preferred embodiment, the carpet (a tufted carpet) has a backing layer which preferably consists of polyamide fibers and/or copolymeric polyamide fibers. This carrier layer, also known as the primary backing, serves to fix the pile yarn, which is repeatedly inserted with needles during the tufting process, in a planar arrangement.

In a further preferred embodiment, the carrier layer has a polyamide, co-polyamide or a fleece consisting of (a composition of) polyamide and co-polyamide and in particular staple fiber fleece or spun fleece.

In a further preferred embodiment, the carrier layer is an absorptive PA, coPA or PA/coPA staple fiber fleece, which is preferably calendered on at least one side, optionally also on both sides.

In a further preferred embodiment, the velor or flat-needle fleece carpet, the polyamide fibers of the pile have a predetermined proportion of coPA (particularly BiCo) fibers. This proportion is particularly preferably greater than 5%, preferably greater than 10%. In a further embodiment, said proportion is less than 50%, preferably less than 40%, preferably less than 30% and preferably less than 25%.

In a further preferred embodiment, the carpet has a wear layer, the surface and/or visible surface layer of which is preferably a tufted, velor (dilour) or flat-needle fleece carpet.

In a further preferred embodiment, at least one component of the carpet and in particular a filament, yarn or yarn nub or fiber binding and/or at least one adhesive layer and in particular the further adhesive layer has a PA or coPA dispersion. In addition, sprinkled or sprayed PA or coPA powders can also be found here Application; extrusion on is less common.

In a further preferred embodiment, at least one element of the carpet consists of a recycled material. The polyamide yarns and/or fiber and/or filament loops and/or fibers of the pile can preferably consist of new material or recycled polyamide or bio-based polyamide or a mixture of these materials.

In a further preferred embodiment, the filament and/or yarn (yarn tufts) or fiber bindings and/or the adhesive layers have a PA and/or coPA powder-water dispersion or powder, with these mixtures preferably comprising melting points that can be set differently .

In a further preferred embodiment, a film and in particular a PA film and/or a coPA/PA/coPA film is arranged between the acoustic and/or stiffening layer and/or the insulation.

The present invention is also directed to a motor vehicle with a carpet of the type described above and/or a floor covering of the type described above.

In a preferred embodiment, the components of the carpet and the floor covering each have predetermined basis weights, which are preferably in the ranges mentioned below.

When designed as a tufted carpet, the pile preferably has a weight per unit area which is greater than 200 g/m ² , preferably greater than 250 g/m ² and particularly preferably greater than 260 g/m ² and preferably greater than 300 g/m 2 . ^m2 . In a further preferred embodiment, when configured as a tufted carpet, the pile has a basis weight which is less than 1000 g/m ² , preferably less than 800 g/m ² , preferably less than 700 g/m ² and preferably less than 650 ^gsm .

In the configuration as a tufted carpet, a backing preferably has a weight per unit area which is greater than 50 g/m ² , preferably greater than 60 g/m ² and particularly preferably greater than 70 g/m ² and preferably greater than 80 g/m 2 . ^m2 . In a further preferred embodiment, when configured as a tufted carpet, the backing has a weight per unit area which is less than 300 g/m ² , preferably less than 200 g/m ² , preferably less than 150 g/m ² and preferably less than 140 ^gsm .

In the configuration as a tufted carpet, the binding or the binding layer preferably has a weight per unit area which is greater than 20 g/m ² , preferably greater than 30 g/m ² and particularly preferably greater than 40 g/m ² and preferably greater than 50 g/m ² .

In a further preferred embodiment, the binding or binding layer in the configuration as a tufted carpet has a basis weight which is less than 300 g/m ² , preferably less than 250 g/m ² , preferably less than 200 g/m ² and preferably less than 150 g/m ² .

When configured as a velor (Dilour) carpet, the pile and/or the fibers preferably have a weight per unit area which is greater than 200 g/m ² , preferably greater than 250 g/m ² and particularly preferably greater than 280 g/m 2 . m ² and preferably greater than 300 g/m ² . In a further preferred embodiment, the pile and/or the fibers in the configuration as a velor (Dilour) carpet have a weight per unit area which is less than 1000 g/m ² , preferably less than 800 g/m ² , preferably less than 700 g/m ² and preferably less than 650 g/m ² .

When configured as a velor (dilour) carpet, the binding or the binding layer preferably has a weight per unit area which is greater than 20 g/m ² , preferably greater than 30 g/m ² and particularly preferably greater than 40 g/m ² and preferably greater than 50 g/m ² . In a further preferred embodiment, the binding or binding layer in the configuration as a velor (dilour) carpet has a weight per unit area which is less than 300 g/m ² , preferably less than 250 g/m ² , preferably less than 200 g/m 2 . m ² and preferably less than 160 g/m ² .

A BiCo fiber content in the configuration as velor (or dilour) is preferably between 0% and 25%, preferably between 5% and 25% and preferably between 10% and 25%.

The tufted or velor carpet preferably has a coating. A basis weight of this coating is preferably between 80 g/m ² and 2000 g/m ² ; preferably between 85 g/m ² and 350 g/m ² .

The acoustic and/or stiffening fleece preferably has a weight per unit area between 250 g/m ² and 1200 g/m ² ; preferably between 300 g/m ² and 900 g/m ² .

As mentioned above, a heavy foil can also be used in the composite. This preferably has a basis weight between between 500 g/m ² and 8000 g/m ² ; preferably between 1200 g/m ² and 6000 g/m ² .

In addition, as mentioned above, further sealing foils and/or contact foils-fleeces can be provided. These preferably have a weight per unit area of between 40 g/m ² and 260 g/m ² ; preferably between 60 and 130 g/m ² .

Furthermore, when using a tufted carpet, a polyamide fiber and/or copolymeric polyamide fiber carrier is used, which has a high level of intrinsic absorption.

1. (a) der Flor 2 des Teppichs 1 aus Polyamid (PA)-Garnen und/oder -Faser-/Filament-Schlingen besteht,
2. (b) eine Trägerschicht 3 aus Polyamidfasern und/oder copolymeren Polyamidfasern besteht,
3. (c) eine erste Klebeschicht (Filament-/Garn-(Garnnoppen-) Einbindung) 4 aus einem Polyamid- oder co-Polyamid-basierenden Kleber besteht und
4. (d) die Klebeschicht 5, Beschichtung, aus einem Polyamid oder co-Polyamid-basierenden Kleber besteht.

In a particularly preferred embodiment, a tufted carpet 1 according to the invention for a motor vehicle is characterized in that:

1. (a) the pile 2 of the carpet 1 consists of polyamide (PA) yarns and/or fiber/filament loops,
2. (b) a carrier layer 3 consists of polyamide fibers and/or copolymeric polyamide fibers,
3. (c) a first adhesive layer (filament/yarn (yarn nub) binding) 4 consists of a polyamide or co-polyamide-based adhesive and
4. (d) the adhesive layer 5, coating, consists of a polyamide or co-polyamide-based adhesive.

In a preferred embodiment, the tufting carrier 3 is an acoustically absorptive PA, coPA or PA/coPA staple fiber fleece that is calendered on one or both sides.

1. (a) der Flor 2 des Teppichs 9 aus Polyamid (PA)-Fasern ggf. mit einem %-ualen Anteil an coPA (BiCo-) Fasern besteht,
2. (b) eine erste Klebeschicht (Faser-Einbindung) 4 aus einem Polyamid- oder co-Polyamid-basierenden Kleber besteht und
3. (c) die Klebeschicht 5, Beschichtung, aus einem Polyamid oder co-Polyamid-basierenden Kleber besteht.

In a particularly preferred embodiment, a velor carpet according to the invention or a flat-needle fleece carpet 9 for a motor vehicle is characterized in that

1. (a) the pile 2 of the carpet 9 consists of polyamide (PA) fibers, possibly with a percentage of coPA (BiCo) fibers,
2. (b) a first adhesive layer (fiber binding) 4 consists of a polyamide or co-polyamide-based adhesive and
3. (c) the adhesive layer 5, coating, consists of a polyamide or co-polyamide-based adhesive.

It should be pointed out that velor (Dilour) carpets are not always referred to as pile, but rather as needle felt with the corresponding fiber weight (area weight or mass per unit area). One also often speaks here of decorative fleece.

1. (a) der Flor 2 der Nutzschicht 2, 3, 4, 5, 7 aus Polyamid (PA)-Garnen und/oder - Faser/Filamenten ggf. mit einem %-ualen Anteil an coPA (BiCo-) Fasern besteht,
2. (b) eine bei Tufting-Teppichen 1 vorhandene Trägerschicht 3 aus Polyamidfasern und/oder copolymeren Polyamidfasern besteht,
3. (c) eine erste Klebeschicht (Filament-/Garn-(Garnnoppen-) oder Faser-Einbindung) 4 aus einem Polyamid oder co-Polyamid-basierenden Kleber besteht,
4. (d) die Klebeschicht (Beschichtung) 5 aus einem Polyamid oder co-Polyamid-basierenden Kleber besteht,
5. (e) die angrenzende Akustik-/Versteifungsvlies-Schicht 7 aus einem auf Polyamid basierenden Faservlies oder Gewebe besteht und
6. (f) die Faser-basierende Isolationsschicht 8 aus Polyamid Fasern besteht, oder
7. (g) eine anstatt der Faser-basierende Isolationsschicht 8 eingesetzte Schaum-Isolation aus Polyamidschaum besteht.

In a further particularly preferred embodiment, a floor covering 6 for a motor vehicle is characterized in that

1. (a) the pile 2 of the wear layer 2, 3, 4, 5, 7 consists of polyamide (PA) yarns and/or fibers/filaments, possibly with a percentage of coPA (BiCo) fibers,
2. (b) a backing layer 3 present in tufted carpets 1 consists of polyamide fibers and/or copolymeric polyamide fibers,
3. (c) a first adhesive layer (filament/yarn (yarn nubs) or fiber binding) 4 consists of a polyamide or co-polyamide-based adhesive,
4. (d) the adhesive layer (coating) 5 consists of a polyamide or co-polyamide-based adhesive,
5. (e) the adjacent acoustic/stiffening nonwoven layer 7 consists of a polyamide-based nonwoven or woven fabric and
6. (f) the fiber-based insulation layer 8 consists of polyamide fibers, or
7. (g) a foam insulation used instead of the fiber-based insulation layer 8 consists of polyamide foam.

Further advantageous embodiments and developments result from the following figures.

• 1 eine Materialstruktur Tufting-Teppich 1
• 2 eine Materialstruktur Velour-Teppich 9
• 3 Bodenverkleidung 6
• 4 akustische Wirksamkeit des Trägers 3 eines Tufting-Teppichs 1

The figures show:

• 1 a material structure tufted carpet 1
• 2 a material structure velor carpet 9
• 3 floor covering 6
• 4 acoustic effectiveness of the carrier 3 of a tufted carpet 1

1 shows an embodiment of a tufted carpet 1 with the pile 2 and the tufted backing 3, the filament/yarn (yarn tuft) binding 4 and the adhesive layer 5. 2 shows an embodiment of a velor (Dilour) carpet 9 with the velorized pile 2, the fiber binding 4 and the adhesive layer 5.

Instead of a napped pile 2, the pile 2 can also be a flat-needle fleece. Both variants of pile 2 can be found in practice.

In 3 an embodiment of a floor covering 6 is shown with a wear layer, consisting of a tufted carpet 2 with the other layers of carrier 3, binding 4 and coating 5 and an acoustic/Verfestungsv Read 7 and an insulation layer 8, which can be a non-woven insulation and a (PA) foam insulation on the one hand.

4 shows a diagram to illustrate the (acoustic) effectiveness of the tufted backing layer 3, which is here a (PA fiber) fleece (250 g/m ² ) calendered on both sides; compared to standard carriers in use today. The degree of absorption a0 (absorption with vertical sound incidence) was determined. In particular, an impedance tube measurement was performed according to ISO 10534-2 and ASTM E1050-98.

The sound insulation structure according to the invention comprises a “mono system”, a so-called one-material system that can be completely reprocessed and recycled; and thus meets the demand for sustainability.

The high-quality PA fibers can be recovered by using the tearing systems available on the market today; and used again in sound insulation, for example. The material structure of the wear layer and the fleece or fiber flock (HMP) composite insulation is thermoformable and the formed component is dimensionally stable; with high utility properties. In particular, the PA-based material structure of the surface/visible surface layer guarantees very good wear behavior and is graceful in terms of haptics and optics.

The applicant reserves the right to claim all features disclosed in the application documents as essential to the invention, provided they are new compared to the prior art, either individually or in combination. It is also pointed out that the individual figures also describe features which can be advantageous in and of themselves. The person skilled in the art recognizes immediately that a specific feature described in a figure can also be advantageous without adopting further features from this figure. Furthermore, the person skilled in the art recognizes that advantages can also result from a combination of several features shown in individual figures or in different figures.

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• EP 1598476 B1 [0007]
• DE 102016203348 A1 [0009]
• DE 102004046201 A1 [0012]
• DE 10360427 A1 [0012]
• DE 19960945 A1 [0012]
• DE 102007036952 A1 [0012]
• DE 202012004594 U1 [0014]

Claims (14)

Carpet (1,9), in particular tufted carpet (1) or velor carpet (9), for a motor vehicle, with a pile (2), a binding adhesive layer (4) and with a further adhesive layer (5), characterized that the pile (2) of the carpet (1, 9) made of polyamide (PA) contains yarns and/or fiber loops and/or filament loops and/or fibers, the binding adhesive layer, which is used to bind the yarns, Fiber loops, filament loops and/or fibers is used, consists of a polyamide or co-polyamide-based adhesive and that the further adhesive layer consists of a polyamide or co-polyamide-based adhesive. carpet after claim 1 , characterized in that the carpet (1) has a backing layer (3) which preferably consists of polyamide fibers and/or copolymeric polyamide fibers. Carpet (1) according to the preceding claim, characterized in that the carrier layer (3) comprises a PA, coPA or PA/coPA staple fiber fleece or spunbonded fleece or that the carrier layer comprises an absorptive PA, coPA or PA/coPA staple fiber Fleece is, which is preferably calendered on one or both sides. Carpet (9) according to at least one of the preceding claims, characterized in that the polyamide fibers of the pile (2) have a predetermined proportion of coPa (BiCo) fibers. Carpet (1, 9) or floor covering (6) according to at least one of the preceding claims, comprising a wear layer (2, 3, 4, 5, 7) whose surface and/or visible surface layer (2) is a tufted, velour -(Dilour) or flat needle punched carpet. Carpet (1, 9) according to at least one of the preceding claims, characterized in that the filament/yarn (yarn tufts) or fiber binding (4) and the adhesive layer (coating) (5) have a PA or coPA Dispersion or PA or coPA powder include. Carpet (1,9) according to at least one of the preceding claims, characterized in that the polyamide (PA) yarns and/or fiber/filament loops or fibers of the pile (2) are made from new material or recycled PA or organic based PA or a mixture thereof. Carpet (1, 9) according to at least one of the preceding claims, characterized in that the filament/yarn (yarn tufts) or fiber binding (4) and the adhesive layers (coatings) (5) have a PA or coPA Powder-water dispersion or PA or coPA powder, preferably with a different adjustable melting point. Floor covering (6) for a motor vehicle with a carpet (1,9) according to at least one of the preceding claims and with an acoustic and/or stiffening layer (7) and/or an insulation (8). Floor covering (6) after claim 9 , characterized in that the acoustic and / or stiffening layer (7) consists of a polyamide-based fiber fleece or a polyamide-based fabric. Floor covering (6) according to at least one of the preceding claims, characterized in that the insulation (8) is a fiber-based insulation layer made of polyamide fibers, preferably with a predetermined proportion of coPA (BiCo) fibers, or foam insulation made of polyamide foam . Floor covering (6) for a motor vehicle according to one of the preceding claims, characterized in that the sound insulation floor covering (6) is (acoustically) flow-open or (acoustically) flow-closed. Floor covering (6) for a motor vehicle according to one of the preceding claims, characterized in that a PA film and/or a coPA/PA/coPA film is arranged between the acoustic and/or stiffening fleece layer (7) and the insulation (8). is. Motor vehicle with a carpet (1, 9) according to at least one of the preceding ones Claims 1 - 8th and/or with a floor covering (6) according to at least one of the preceding ones claims 9 - 13 .

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