DE102006058257A1 - Composite element for lining the inside of a motor vehicle comprises a covering layer and a core layer adhered together using a hot melt adhesive - Google Patents

Abstract

Composite element (10) comprises a covering layer (16) and a core layer (12) adhered together using a hot melt adhesive. An independent claim is also included for a method for producing a composite element.

Description

The The invention relates to a composite component, in particular for the automotive industry with a core layer and at least one connected to the core layer Top layer.

The The invention further relates to a method for producing a composite component.

such Composite components are already known from the prior art and especially for the interior trim used in the automotive industry.

EP 0 671 259 describes a multi-layer plastic and natural fiber body with a backsheet backing for an outer layer, the backsheet containing a natural fiber pulp and a thermoplastic binder. The bond is achieved by melting the thermoplastic material.

Out DE 37 22 873 is a multi-layer plate is known, which is also used for interior trim in the automotive industry. In this plate, a thermoplastic resin foam is applied to a carrier layer, which connects the carrier layer with a decorative layer. In order to activate the plastic foam, this is brought to the melting temperature and then pressed the support layer with the decorative layer and cooled. The material used for the carrier layer is either a metal sheet or a polypropylene containing nonwoven fabric.

In DE 44 00 894 a method for the production of interior components for motor vehicles is described, which consists of a cover layer of a decorative material and a lower layer of a non-woven fabric. The nonwoven fabric has a thermoplastic fibrous component which is heated until it melts. Subsequently, decorative material and nonwoven fabric are deformed under pressure application and bonded together during deformation by a thermoplastic bond of the thermoplastic fibrous component. Alternatively, the decorative layer may also have a thermoplastic surface film, which then adopts the bond.

A method for laminating a carrier containing a thermoplastic material is out DE 196 46 007 C1 known. The essence of this invention is to provide a temperature profile that allows sufficient plasticization of the thermoplastic material on the surface of the carrier without a harmful heating of the carrier interior occurs.

All the abovementioned inventions have in common that thermoplastic materials are used for bonding, either as a constituent of the core and / or cover layer itself or as a separate intermediate layer. In particular DE 196 46 007 C1 can be seen, occurs when using such materials, the problem that the melting temperature required for plasticizing the bond may not be too high to change the structure of the layers to be bonded only at the surface, but not inside. Such changes in the structure inside, in particular, the beams could lead to a reduction in the load capacity of the composite components, which is unacceptable for the use of the composite components. Furthermore, the in DE 196 46 007 C1 proposed temperature profiles for optimum production of the composite components in practice only consuming implement, which would be preferred alterna tive and easier to handle materials and manufacturing processes.

Out EP 1 359 005 B1 is a use of honeycomb structures for the core layer of composite components known.

adversely In such a construction, the tendency is that the outer layer detached from the core layer under load and therefore the composite component its actual purpose can no longer comply.

Of the Invention is based on the object, a composite component as well a method for its production under advantageous use of honeycomb structures indicate so that core and outer layer can be securely connected together and also under load not detach each other.

Is solved the task in that the cover layer and the core layer by means of a hot melt adhesive glued together. By using a hot melt adhesive is, this can be chosen be that he meets the requirements of each case of application in an optimal way. So a hot melt adhesive can be chosen which has a melting temperature which the layers to be bonded by the heat effect not changed in its structure or destroyed. So can a maximum integrity ensured the composite component become. Furthermore, possible This design offers maximum flexibility in terms of choice of Materials for the core layer and the cover layer.

The object can be achieved in an equivalent way that the cover layer and the core layer by means of a wärmeak tivierbaren films adhesives are glued. Again, the film adhesive can be chosen so that it can be adapted to the requirements of each application.

ever after which machines for the production of the composite components are present or used can be either using a hot melt adhesive or a heat-activatable one Foil adhesive be suitable.

Advantageous The invention is further developed by the core layer substantially consists of one of the following materials: paper honeycomb, plastic honeycomb, Metal honeycomb, plastic foam, polyurethane foam, polypropylene foam, Metal foam, aluminum foam. By the choice of material for the core layer the composite component can be used in different fields of application be adapted to, for example, strength, cost, Weight or environmental aspects. As advantageous, the use has of honeycomb structures for the core layer proved. The honeycomb structures can be either so-called Honeycomb or wave structures be executed. A special advantage This construction consists in its high bending strength at the same time low basis weight compared to solid components, as in the prior art according to the above be described documents. In this context puts the use of paper honeycombs in the light of increased oil prices an advantageous, cost-effective Alternative to plastic, which has very good recycling properties having. The use of plastic foam allows composite components be made weight saving. The use of metal foam, aluminum foam in particular offers the possibility of composite components produce, which have high bending strengths, but at the same time across from massive versions have a lower Ge weight and thus also a both economically as well as ecological make a positive contribution in the automotive industry.

In a preferred embodiment of the invention, the at least a cover layer of one of the following materials: fleece, natural fibers, flax fibers, Hemp fibers, jute fibers, sisal fibers, polypropylene fibers, glass fibers or from a mixture of two or more of the aforementioned materials. The cover layer can thus be made of different materials or combinations of materials exist so that they meet different requirements can. Here are z. B. cost or surface condition.

Further it is preferred that the hot melt adhesive from the group of the following substances: PE (polyethylene), APAO (amorphous polyalphaolefin) or PUR (polyurethane). The hot melt adhesive can apply to the materials used for the top and core layers selected so that they can be advantageously glued together.

In Another preferred embodiment is the composite component as a whole or the core layer or cover layer as a molded part educated. This configuration allows the composite component to produce in different ways that have a different number of steps. Is there for example a layer of the composite component from a material that can not be adequately molded, but can be brought in other ways in shape, it is possible according to this invention Apply layer to the already brought in another layer.

Further It is preferred that one or more impressed into the composite component depressions or Surveys are provided. Through these depressions or elevations For example, the composite component to the body contours of the automobile and / or, in the case of a loading floor, spare tire molds be adjusted. By appropriate shaping can on the one hand an extensive coverage of body parts can be achieved to others Depressions or elevations in complementary body depressions or Engage surveys, causing slippage of the composite component is prevented in the automobile.

In a preferred embodiment has the outer layer outside a decorative layer consisting essentially of one of the following Materials consists of: natural fibers, synthetic fibers, textile fabric or Fleece. By the choice of materials can the composite components on the interior design of the relevant Automotive adapted. Selection criteria for the material used could be optics, Haptic or durability be.

According to one Another aspect of the invention is the composite component as a loading floor, Interior trim panel, hat rack, roof, hood, door or Bottom plate module of an automobile formed. The variety of design options reflects the broad scope of the invention.

In a method according to the invention, the composite component, which has a core layer and at least one cover layer, which is connected to the core layer, produced by the steps: applying hot melt adhesive to the core layer and / or cover layer, compressing the core layer and the cover layer, so that they make a lasting connection.

In an alternative method according to the invention is the composite component, which is a core layer and at least a cover layer which is bonded to the core layer is made with the steps: applying a foil adhesive on the core layer and / or cover layer, compressing the core layer and the topcoat so that they make a lasting connection.

In In another aspect of the invention, the hot melt adhesive is applied to the core layer applied, the hot melt adhesive at least partially cooled and subsequently those with hot melt glue coated core layer with the cover layer pressed.

Prefers becomes the hot melt adhesive on the surface an at least partially open-pored paper honeycomb and applied subsequently the paper honeycomb under pressure with a natural fibers Covering layer pressed into a molding.

Advantageous the compression takes place at high pressure and at joint temperatures from 160 to 220 ° C.

According to one In another aspect of the invention, the core layer is pre-pressed and subsequently Hot melt adhesive applied to the core layer and then followed by a compression with one or more cover layers.

The invention is explained in more detail below with reference to the exemplary embodiments of a composite component shown in the drawings and to a plurality of methods for producing such composite components:
Show it:

1 a cross section through the composite component according to the invention;

2a a plan view of a paper honeycomb with wave structure;

2 B a perspective view of the paper honeycomb in wave structure;

3 a schematic representation of the order of a hot melt adhesive by means of a roller on the paper honeycomb in cross section;

4 a schematic representation of the order of the hot melt adhesive by means of a spray head on the paper honeycomb in cross section;

5 a schematic representation of the order of a heat-activated adhesive film by means of a roller on the paper honeycomb in cross section;

6 a schematic representation of the feeding of the coated paper honeycomb in a joining tool in cross section;

7 a schematic representation of the molding of the adhesive-coated paper honeycomb in the joining tool in cross section;

8th a schematic representation of the bringing together of a cover and decorative layer with the adhesive-coated and molded paper honeycomb and the feeding into the joining tool

9 a schematic representation of the bonding of the cover and decorative layer with the adhesive-coated paper honeycomb in the joining tool and subsequent removal of the finished composite component

10 a schematic representation of the bringing together of a cover and decorative layer with the adhesive-coated, non-formed paper honeycomb and the feeding into the joining tool

11 a schematic representation of the molding and simultaneous bonding of the cover and decorative layer with the adhesive-coated paper honeycomb in the joining tool and subsequent removal of the finished composite component

In 1 is a composite component according to the invention 10 shown in cross section. It is essentially made up of at least one core layer 12 , at least one binding layer 14 , at least one cover layer 16 and at least one decorative layer 18 built up.

In the 2a and 2 B is a commercial paper honeycomb 20 shown both in plan view and in perspective. The illustrated honeycomb 20 has a wave structure and is available in different weights. In the automotive industry, paper honeycombs made of paper of 115 g / m ² paper weight have been established. The amplitude of the waves of the paper honeycomb can also be selected. The choice of the amplitude depends essentially on the strength requirements of the composite component to be produced 10 , A paper honeycomb shown here can be used as a core layer 12 of the composite component 10 be used.

In 3 a possible application process according to the invention is shown schematically. On the core layer 12 becomes the binding layer 14 applied by rolling. In the example shown, the paper honeycomb 20 as a core layer 12 and a hot melt adhesive 22 as a binding layer 14 used. The hot melt adhesive 22 is by means of a roller 24 on the paper honeycomb 20 applied. The liquefied hot melt adhesive 22 is by means of an application system 26 the roller 24 fed and then in the contact process on the paper honeycomb 20 applied. The hot melt adhesive can partially into the near-surface, open-pore structure of the paper honeycomb 20 penetration. In the surface area, a continuous or discontinuous, fiber-bonded hot-melt adhesive layer can be formed, which can be used as a bonding layer 14 can denote.

In 4 an alternative application process according to the invention is shown. Again, in the example shown, the paper honeycomb 20 as a core layer 12 and the hot melt adhesive 22 for producing a binding layer 14 used. In this case, however, the hot melt adhesive becomes 22 sprayed onto the paper honeycomb 20 applied. To apply a spray head 28 used with a spray applicator system 30 which is the supply of hot melt adhesive 22 ensures.

In 5 an alternative order process is shown in which the binding layer 14 from a heat-activated film adhesive 32 consists. The heat-activated film adhesive 32 is by means of a foil roll 34 on the core layer 12 , again in the example shown as a paper honeycomb 20 executed, applied. The heat-activated film adhesive is in a holding device 36 kept wrapped up and the film roll 34 fed.

6 shows how the with the tie layer 14 applied core layer 12 a joining tool 38 is supplied. Again, the core layer 12 as a paper honeycomb 20 realized. The binding layer 14 can either from the hot melt adhesive 22 or the foil adhesive 32 consist. The hot melt adhesive 22 can either by rolling or by spraying on the paper honeycomb 20 be applied (see 3 - 5 ). The corresponding coated paper honeycomb 20 becomes the joining tool 38 supplied, the parts essential for the molding an upper joining part 40 and a lower joining part 42 turn off.

In 7 is shown as the coated paper honeycomb 20 is pressed into shape. After the paper honeycomb 20 the joining tool 38 was fed, the upper joining part 40 and the lower joining part 42 moved under high pressure towards each other, causing the paper honeycomb highly compressed and in the of the joining parts 40 and 42 predetermined shape is pressed. During the joining process the paper honeycomb becomes 20 insofar as heated by heat and / or the deformation energy that the hot melt adhesive 22 or the foil adhesive 32 reach its melting temperatures and be activated.

8th shows how the now in shape and now with activated hot melt adhesive 22 or foil adhesive 32 beauf hit paper honeycomb 20 with the topcoat 16 and the decorative layer 18 brought together and in turn the joining tool 38 with the upper joining part 40 and the lower joining part 42 be supplied.

Out 9 is evident, like the paper honeycomb 20 with the topcoat 16 and the decorative layer 18 is glued. Again, the upper joining part 40 and the lower joining part 42 moved towards each other, leaving the paper honeycomb 20 , the topcoat 16 and the decorative layer 18 be pressed on each other. The cover layer 16 and the decorative layer 18 adapt to the shape of the paper honeycomb 20 at. Due to the high pressure and the high temperature in the joining tool 38 be generated, the paper honeycomb 20 , the topcoat 16 and the decorative layer 18 glued together. After a certain time, the upper joining part will be 40 and the lower joining part 42 returned to their original position; After a certain cooling time, the composite component produced in this way is 10 finished.

In 10 an alternative production process is shown. In contrast to the method described above, here is the paper honeycomb 20 not pressed in a separate step. Here is the one with not yet activated hot melt adhesive 22 or foil adhesive 32 loaded paper honeycomb 20 before molding with the cover layer 16 and the decorative layer 18 brought together and the joining tool 38 fed.

In 11 is shown as the paper honeycomb 20 with the topcoat 16 and the decorative layer 18 glued and pressed into shape. For this purpose, the upper joining part 40 and the lower joining part 42 moved towards each other, leaving the paper honeycomb 20 , the topcoat 16 and the decorative layer 18 be pressed against each other. Due to the high pressure and the high temperature in the joining tool 38 be generated, the paper honeycomb 20 , the topcoat 16 and the decorative layer 18 pressed together in one step in form and glued. After a certain time, the upper joining part will be 40 and the lower joining part 42 returned to their original position; After a certain cooling time, the resulting composite component 10 ready for use.

Claims (15)

Composite component ( 10 ), in particular for the automotive industry, with a core layer ( 12 ) and at least one with the core layer ( 12 ) associated cover layer ( 16 ), characterized in that the cover layer ( 16 ) and core layer ( 12 ) by means of a hot melt adhesive ( 22 ) are glued together. Composite component, in particular for the automotive industry, having a core layer ( 12 ) and at least one with the core layer ( 12 ) associated cover layer ( 16 ), characterized in that the cover layer ( 16 ) and core layer ( 12 ) by means of a heat-activated film adhesive ( 32 ) are glued together. Composite component according to claim 1 or 2, characterized in that the core layer ( 12 ) consists essentially of one of the following materials: paper honeycomb, plastic honeycomb, metal honeycomb, plastic foam, polyurethane foam, polypropylene foam, metal foam, aluminum foam. Composite component according to one of the preceding claims, characterized in that the at least one cover layer ( 16 ) consists essentially of one of the following materials: natural fibers, flax fibers, hemp fibers, jute fibers, sisal fibers, polypropylene fibers, glass fibers or a mixture of two or more of the aforementioned materials. Composite component according to one of the preceding claims, characterized in that the hot-melt adhesive ( 22 ) consists of the group of the following substances: PE (polyethylene), APAO (amorphous polyalphaolefin) or PUR (polyurethane). Composite component according to one of the preceding claims, characterized in that the composite component ( 10 ) as a whole or the core layer ( 12 ) or cover layer ( 16 ) is designed as a molding press part / are. Composite component according to one of the preceding claims, characterized by one or more in the composite component ( 10 ) embossed depressions or elevations. Composite component according to one of the preceding claims, characterized in that the cover layer ( 16 ) outside a decorative layer ( 18 ), which consists essentially of one of the following materials: natural fibers, synthetic fibers or textile fabric PET or PP or PA flat needle felt, dilour or velor or tuft. Composite component according to one of the preceding claims, characterized characterized in that it as a loading floor, interior trim part, hat rack, roof, Bonnet, tailgate, door or bottom plate module of an automobile is formed. Method for producing a composite component ( 10 ), which is a core layer ( 12 ) and at least one cover layer ( 16 ), which with the core layer ( 12 ), comprising the steps of: applying hot melt adhesive ( 22 ) on the core layer ( 12 ) and / or cover layer ( 16 ); - compressing the core layer ( 12 ) and the cover layer ( 16 ), so that they enter into a permanent connection. Method for producing a composite component ( 10 ), which is a core layer ( 12 ) and at least one cover layer ( 16 ), which with the core layer ( 12 ), comprising the steps of: - applying a film adhesive to the core layer ( 12 ) and / or cover layer ( 16 ) - compressing the core layer ( 12 ) and the cover layer ( 16 ), so that they enter into a permanent connection. Method according to one of the preceding claims, characterized in that hot melt adhesive ( 22 ) on the core layer ( 12 ), the hot melt adhesive ( 22 ) at least partially cools and then with hot melt adhesive ( 22 ) coated core layer ( 12 ) with the cover layer ( 16 ) is pressed. Process according to claim 12, characterized in that the hot-melt adhesive ( 22 ) on the surface of an at least partially open-pored paper honeycomb ( 20 ) is applied and then the paper honeycomb ( 20 ) under pressure with a covering layer made of natural fibers ( 16 ) is pressed into a molded part. Method according to claim 13, characterized in that that the compression at high pressure and at temperatures of 160 ° C up to 220 ° C takes place. Method according to one of the preceding claims, characterized in that the core layer ( 12 ) and then hot melt adhesive ( 22 ) on the core layer ( 12 ) and then a compression with one or more outer layers ( 16 ) he follows.