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CN1768178A - 用于汽车衬里的吸声效果的非织造材料 - Google Patents

用于汽车衬里的吸声效果的非织造材料 Download PDF

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CN1768178A
CN1768178A CNA2004800087156A CN200480008715A CN1768178A CN 1768178 A CN1768178 A CN 1768178A CN A2004800087156 A CNA2004800087156 A CN A2004800087156A CN 200480008715 A CN200480008715 A CN 200480008715A CN 1768178 A CN1768178 A CN 1768178A
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P·安德里格
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Autoneum Technologies AG
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Rieter Technologies AG
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Abstract

用于汽车衬里的吸声效果的非织造物(1)，包括由粗纤维(8)制成的多孔纤维骨架(2)，特别包括短纤维或者纺粘纤维，所述纤维骨架(2)熔化的微纤维材料在前表面区域和/或者后表面区域(4，10)中的连续改变的重量份额，所述熔化微纤维材料(7)连接到该粗纤维(8)上并且将这些粗纤维粘合使得所述非织造物(1)具有预定的气流阻力并且至少在其表面区域(4，10)中以预定的弯曲硬度被硬化。气流阻力为200－60000Nsm－3，特别是在800－35000Nsm－3，最好在1000－20000Nsm－3，主要约为1400Nsm－3，弯曲硬度(8)为0.005－10Nm，特别是在0.025－6.0Nm之间。

Description

用于汽车衬里的吸声效果的非织造材料
本发明涉及一种根据权利要求1序言部分的吸声效果的非织造材料。
非织造物正逐渐被汽车工业广泛应用，因为它们具有的吸声性能的优点，特别是，这样的性能是使用衬里的汽车工业的主要目的，根据衬里的应用，所述衬里具有不同的吸声性能，重量轻，较薄并且易于成形，但是还稳定，另外还便于循环利用。因此希望使用实现了多个技术功能同时降低了材料成本从而获得利益的所述衬里。
已知的衬里部件例如在US-2001/0036788出版物中或者在EP-0939007出版物中被公开，所有的衬里部件都是复合结构，具有多个独立的层，每个独立的层实现了不同的技术功能。
已经证明生产这样的复合结构是相对复杂的，因为不同的材料层必须被预先生产并且随后彼此粘合。此外，这些复合结构倾向于随着时间的推移而分层。需要通过粘合薄片和/或点来抵销这种分层的努力非常大并且使得生产过程更加昂贵。
因此本发明的目标是提供一种用于为汽车作衬里的具有吸声效果的非织造物，该衬里不具有已知部件的缺点。特别是，本发明的目标在于提供一种多孔非织造物，该非织造物具有增强的并且易于调整的声音吸收性能和形状稳定的性能。同时，这种非织造物应该是重量轻而且薄，应该是耐用和便于循环利用。
通过提供一种具有权利要求1的特征的非织造物，特别是，提供一种吸声效果的非织造物，本发明实现了上述目标，所述非织造物具有预定的气流阻力和形状稳定性，含有纤维骨架，该纤维骨架包括支架或者粗纤维，将微纤维加入到所述骨架中，从而至少部分微纤维被完全熔化。这确保了该非织造物在其表面区域是硬的，所述表面区域为在非织造物的厚度的一半上最好在厚度的三分之一上延伸并且确保该非织造物具有预定的气流阻力。因此，本发明的非织造物的不同需要的技术性能通过在预定的纤维骨架的表面区域中引入同类型或者不同类型的微纤维而实现。因此，本发明的衬里并不含有独立的层而是具有连续改变的被引入到该纤维骨架中的微纤维材料的重量份额。
本发明使用了已知的生产方法，例如在DE-10044694中所描述的。这个出版物披露了诸如用于柔软的并且抗拉的擦拭毛巾的非织造物的生产。这种生产方法要求通过液力缠结方法将一层纺粘纤维加入到另一层熔吹纤维中。
另外，EP-0418493披露了一种用作裤子衬里或者一次性餐巾的两层非织造物，它们的单个层通过引导细的水射流到特定层中而彼此连接，使得将纤维部分地从这个直接撞击层进入到其他层中，从而产生了在所述两个层之间的抗撕扯连接。
这样生产的非织造织物通常用在个人或者家庭卫生用品中，一般不特别适合于稳定的即自我支撑(self supporting)的汽车衬里或者吸声效果的汽车部件。特别地，在这些已知的非织造物中，细纤维非常均匀地在整个纤维骨架(抹布)中分布或者在该独立层(清洁毛巾)的相互表面处几乎捻在一起。
与上述不同，根据本发明，所有的微纤维被完全输送到该表面区域中，即含有粗纤维的纤维骨架的厚度的不到一半中。这个表面区域的深度由微纤维的穿入深度决定，在下面通过统计出的平均穿入深度定义该表面区域的深度。从统计学上看，在该表面区域中的微纤维材料的重量份额随着深度连续改变，例如不断减小。
因此，通过在由骨架纤维制成的非织造物的顶部设置含有微纤维(即具有0.01-1.0dtex支数，最好0.1-0.6dtex支数的纤维)的非织造物进行这种非织造物的生产，后面将所述骨架纤维也称为纤维骨架。所述纤维材料的选择应使该骨架纤维的熔化温度高于所述微纤维。随后，许多微小的水射流在高压力下指向微纤维使得微纤维非织造物的纤维围绕纤维骨架的粗纤维扭转。在随后的干燥阶段，富含微纤维的非织造物通过热源例如指向该非织造物的热气流而受到一定温度的作用，在该温度下，该微纤维非织造物的纤维至少在表面上被熔化-但最好完全被熔化-在所述热处理之后，该骨架纤维在该非织造物的表面区域中被连接和硬化。
所述生产方法可以被改进，使得所述微纤维被其他热源熔化，例如来自微波炉的辐射热，接触加热或者由热蒸汽或者其他热流体加热。这些热源在所述非织造物上的持续时间和温度由技术人员决定。
这种方法生产的产品因此特征在于，纤维骨架，该纤维骨架的前面和/或后部表面区域包括熔化的微纤维材料的不断改变的重量份额。在后面称为粗纤维的骨架纤维具有大于1dtex，最好在6-7dtex的细度。合适的骨架纤维是无端的纺粘纤维以及短纤维。这些纤维可以有合适的聚合物制成或者包括矿物纤维，特别是玻璃纤维，金属纤维或者天然纤维。在优选实施例中，这种纤维骨架具有的面积重量为20-150g/m2。该面积重量由技术人员根据要求决定并且还可以具有大约800g/m2的面积重量。由聚对苯二甲酸乙二醇酯(PET)制成的粗纤维用在这种纤维骨架的优选实施例中。
通过加入熔化的微纤维材料特别是平均直径为2-8微米纤维、长度为2-80毫米的熔吹纤维材料，所要求的非织造物在其表面区域中被加料。根据纤维的长度，已经表明在运输之前将所述微纤维缩短为纤维骨架(通过液力缠结的方法进行)是有利的，这些熔化的微纤维的材料主要在该粗纤维的连接点处，或者还位于单个粗纤维长丝处。根据本发明，这些堆积物在该非织造物的表面区域根据统计呈连续改变的份额并且在深度方向减少。在所述优选实施例中，这种熔化纤维总面积重量大约为5-50g/m2(大约该纤维骨架的面积重量的10-30％)，该材料是共聚PET Co-PET。富含熔化的微纤维材料的表面区域(本发明的非织造物的总厚度的大约5-35％，最大为50％)还是多孔的并且基本上决定了该整个非织造物的气流阻力。本发明的非织造物是这样建立的：在成形挤压步骤之后，气流阻力为200Nsm-3＜Rt＜60000Nsm-3，特别是在800-35000Nsm-3，最好在1000-20000Nsm-3，主要为约1400Nsm-3。
此外，在该粗纤维上的微纤维材料的堆积导致该纤维骨架在其表面区域中的大致硬化，使得本发明的非织造物是自我支撑的。特别是通过具有大于1dtex的骨架纤维，下面称为粗纤维，的非织造物，并且使用上述的结合熔化方法的液力缠结方法，可以获得增强的稳定性和形状强度，因为一方面该粗纤维很少的扭转导致在表面区域中一定的加强，另一方面滴状熔化的纤维材料粘合到该粗纤维上并且从而在其固化时将这些粗纤维硬化，特别是强化了连接点。这些硬化的机制的组合导致本发明的非织造物的期望的弯曲硬度，即导致能够被汽车工业使用的形状加强和自我支撑的非织造物。
在该非织造物内部粗纤维的显著的弹性和柔韧性结合在表面区域中不断改变硬度导致高的吸声效果部件。这个部件起到吸声弹簧-质量力学系统，该系统的质量由表面区域中的多孔的硬化材料代替。通过这样的吸声系统，常规弹簧-质量力学系统的不可避免的共振特征可以被弥补或者避免。
然而应该理解本发明的非织造物的特别的设计取决于其预计的应用。因此，本发明的非织造物的前部侧面可以是有开孔的，同时该非织造物的后部侧面是可透气的。
还可以使用一种微纤维非织造材料，该微纤维非织造材料由具有可变细度，不同熔点的熔吹纤维或者它们的组合的熔吹纤维制成。此外可以调整传递给微纤维的水的微射流的撞击，即调整压力和持续时间，使得该一种或者其他类型的微纤维的穿入深度是可控的。这样可以提供一种非织造物：它在进行热处理之后具有粘的非织造物表面，该粘的非织造物表面包含部分熔化的微纤维，该非织造物允许另一个标准非织造物或者本发明的非织造物与之粘合。应该理解到合适的微纤维混合物的使用允许在表面区域中的气流阻力被容易地调整。
本发明的优点在下面将对于本领域技术人员来说是清楚的。特别是，用在其他领域中的已知生产方法的组合允许生产适合于为汽车作衬里的非织造物，该非织造物具有预定的气流阻力和需要的弯曲硬度但是不具有独立的层。获得适合用作汽车衬里的非织造物的可能性是令人惊讶的，该非织造物具有硬的表面区域和集成到这个表面区域中的用于产生预定气流阻力的区域。根据本发明生产的非织造物特别薄，即也是重量轻的并且能够易于被调整，即能够被设计为使得其具有预定的硬度和可选择的吸声效率。已经证明本发明的非织造物具有甚至在长时间大量使用之后不会分层的特别的优点。去除分层危险导致本发明的非织造物的增加的耐用性。此外，本发明的非织造物能够由仅仅一种材料制成并且还具有所有的用于现代汽车衬里的性能。因此，本发明的非织造物可以作成一体的材料部件，允许廉价地抛弃或者循环利用。
为了清楚，下面没有区分具有一定长度的无端长丝或者纤维，术语“纤维”包括以上两者。对于技术人员来说，该术语“微纤维”一般表示具有0.01-1.0tex，最好0.1-0.6dtex，通常是0.2dtex的熔吹纤维。本文中的粗纤维应该具有大于1.0dtex和/或者还包括诸如剑麻，椰纤维，树皮，或者玻璃纤维，金属纤维或者矿物纤维。
本发明的非织造物的其他优选实施例具有从属权利要求的特征。
下面，通过示范的实施例和附图更详细描述本发明。
图1示出了生产本发明的非织造物的方法；
图2示出了图1的区域A的放大图；
图3a-3d示出了本发明的非织造物的物理性能；
图4示出了本发明的非织造物的放大部分；和
图5示出了本发明的非织造物的进一步的改进的生产方法。
为了生产根据本发明的非织造物1，如图1所示，粗纤维非织造物2覆盖有微纤维层。这个粗非织造物2最好包括有聚对苯二甲酸乙二醇酯(PET)制成的纺粘纤维，具有大于1.0dtex。这个粗纤维非织造物用作纤维骨架并且具有吸声弹簧质量系统的软弹簧性能并且具有良好的恢复能力。这个纤维骨架可以具有20-800g/m2的面积重量并且最好用PET材料制成。可以理解到这个骨架还可以包括天然纤维，玻璃纤维，金属纤维和矿物纤维。在本实施例中，该被覆盖的非织造物受到了所谓的液力缠结方法的作用，该方法将沉积的微纤维层通过水的微射流5输送到表面区域4。这里使用的术语“表面区域”定义了包含微纤维材料并且在该整个非织造物的三分之一厚度和二分之一厚度间延伸的非织造物的区域。在这个过程中，该微纤维沿该骨架纤维滑动并且围绕这些骨架纤维把自己包裹起来，或者最好围绕该纤维骨架的接点扭转。这些微纤维具有0.01-1.0dtex，最好0.1-0.6dtex，通常为0.2dtex，最好还由PET或者Co-PET制成。这个方法允许该微纤维的穿入深度受控制并且确保了这些引入的微纤维的重量份额可选择地连续分布在该纤维骨架的表面区域中，特别是以连续可改变的方式；这意味着所述被引入的微纤维材料的重量份额的梯度可以被选择调整。这样处理的纤维骨架2随后受到干燥和加热处理，特别是通过处理工位被输送，在该处理工位，引入到该纤维骨架2的表面区域4中的微纤维材料通过热空气或者一些其他的加热机构6被熔化。在穿过这个处理工位之后，该微纤维3的形状被改变为水滴状，从而将粗纤维一起连接到特别是连接点或者交叉点的区域中，从而增强在这些区域中的纤维骨架。这样生产出多孔的形状稳定的非织造物，即可以生产出吸声效果的自我支撑的形状部件，例如用于现代汽车工业中。应该理解到该非织造物的吸声性能和硬度可以被纤维材料的变化和分布和/或者纤维的细度和/所选纤维的份额所决定。
图1的部分A在图2中示出。从该图，很明显看到该滴状熔化的材料7如何沉积在该纤维骨架2的粗纤维8上，导致在区域4中非织造物的硬化。
图3a示出本发明的非织造物1的不同性能之间的关系。简示出的非织造物1具有3个区域：微孔表面区域4；弹性中心区域19；和透气的底部区域10。该底部区域10和表面区域4以类似方式生产但是它们的熔化微纤维材料可以具有不同的重量份额和不同的穿入深度。
图3b示出了取决于本发明的非织造物的深度d的气流强度Rt值的曲线图。在表面区域4中的气流强度的特征值在500-5000Nsm-3，在中心区域19中，这些值大约为200Nsm-3，在底部区域10中为200-10000Nsm-3之间或者更高。
图3c的曲线图示出该弯曲硬度B与深度d的关系。这个弯曲硬度大致取决于熔化的微纤维材料的重量份额和在该表面区域中纤维的密度。在该例子中，在微孔表面区域4的斜率小于在透气的底部区域10的斜率。在本发明的非织造物中，用于弯曲硬度的值可以在0.0005-10.5Nm之间变化；特别是这些值在0.025-6.0Nm之间。
图3d示出了不同纤维和熔化纤维材料的密度指数K。曲线a示出用于纺粘或者粗纤维的密度值，因为该液力缠结工艺的作用，这些纤维以较高的密度存在于该表面区域中。曲线b示出熔化微纤维材料的密度分布并且示出其重量份额具有连续改变的曲线。这个纤维材料的斜率取决于该液力缠结工艺的持续时间和水压。粗纤维和微纤维的比率在3∶1范围内。曲线c示出了已经被引入到该非织造物的表面区域中的熔吹纤维的份额但是该熔吹纤维并没有被熔化。通过这些熔吹纤维可以特别地调节该气流阻力。这些未熔化的纤维是具有0.01-1.0dtex特别是包含聚酯，聚酯共聚物，聚酰胺，聚丙烯或者类似的合成材料，最好是PET或者Co-PET的熔吹纤维。
图4简示出本发明的非织造物的微观视图。这个图清楚示出了有粗纤维8制成的多孔纤维骨架如何充有熔化微纤维材料7和未熔化微纤维材料9。直接在该表面下面的该熔化纤维的重量份额显著高于该表面区域4的内部中的熔化纤维的重量份额。该非熔化微纤维在这个区域中的分布也被清楚地示出。微孔硬化层在该纤维骨架的表面区域中的形成对于本发明的非织造物是重要的。
应该理解到本发明的非织造物1可以与其他的同类型的非织造物组合以便获得具有特定使用性能的部件。这样的生产工艺在图5中被简示出。在这个工艺中，不同设计的非织造物11，12受到了已知的液力缠结工艺的作用(工位13)以便获得不同的中间产品14，15，16，17，它们以合适的方式被叠置并且被已知的热处理工艺18连接在一起。
对于本领域技术人员来说很清楚本发明的非织造物能够设有透气装饰层或者设有透气和/或透水薄片。特别适于装饰层的是织造层，针织物，织物，装饰非织造物和/或泡沫层。

Claims (12)

1.用于汽车衬里的吸声效果的非织造物(1)，包括由粗纤维(8)制成的多孔纤维骨架(2)，特别包括短纤维或者纺粘纤维，所述纤维骨架(2)具有熔化的微纤维材料在前表面区域和/或者后表面区域(4，10)中的连续改变的重量份额，所述熔化微纤维材料(7)连接到该粗纤维(8)上并且将这些粗纤维连接使得所述非织造物(1)具有预定的气流阻力并且至少在其表面区域(4，10)中以预定的弯曲硬度被硬化，使得这个非织造物自我支撑。
2.根据权利要求1所述的非织造物，其特征在于，该粗纤维(8)具有大于1dtex的支数，特别是在1-35dtex，最好为6-17dtex的支数。
3.根据权利要求1或者2所述的非织造物，其特征在于，该粗纤维(8)为纺粘纤维并且由聚酯，聚丙烯或者聚酰胺制成，最好由聚对苯二甲酸乙二醇酯制成。
4.根据权利要求1-3中任一项所述的非织造物，其特征在于，所述非织造物(1)包括未熔化的微纤维(9)。
5.根据权利要求4所述的非织造物，其特征在于，所述熔化的微纤维(9)具有0.01-1.0dtex的支数，最好0.1-0.8dtex的支数，一般为大约0.2dtex的支数。
6.根据权利要求1-5中任一项所述的非织造物，其特征在于，该微纤维材料(7)是熔吹纤维材料，特别是由聚酯，共聚-聚酯，聚酰胺，共聚-聚酰胺，聚丙烯，共聚-聚丙烯等制成，最好由聚对苯二甲酸乙二醇酯或者共聚-聚对苯二甲酸乙二醇酯制成。
7.根据权利要求1-6中任一项所述的非织造物，其特征在于，所述粗纤维(8)具有的熔点高于该微纤维材料(7)的熔点。
8.根据权利要求1-7中任一项所述的非织造物，其特征在于，在该纤维非织造物(1)的表面区域(4)中的气流阻力为200-60000Nsm-3，特别是在800-35000Nsm-3，最好在1000-20000Nsm-3，主要约为1400Nsm-3。
9.根据权利要求1-8中任一项所述的非织造物，其特征在于，该纤维非织造物(1)的弯曲硬度(B)为0.005-10Nm，特别是在0.025-6.0Nm之间。
10.根据权利要求1-9中任一项所述的非织造物，其特征在于，所述非织造物与至少另外一种非织造物组合。
11.根据权利要求1-10中任一项所述的非织造物，其特征在于，所述非织造物设有透气层。
12.根据权利要求1-11中任一项所述的非织造物，其特征在于，所述非织造物设有装饰层。
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