WO2017032419A1 - Deep drawn part and method for producing a deep drawn part - Google Patents

Abstract

The invention relates to a deep drawn part with a flexible textile layer (2) made from threads, with a support layer (3') which is rigid with respect to the flexible textile layer (2) and which is formed by at least partially melting a second textile layer, also comprising spacer threads (4) between the flexible textile layer (2) and the carrier layer (3'), said spacer threads (4) being bonded to the flexible textile layer, in particular techinically bonded in the carrier layer (3'). The invention also relates to a method for producing a deep drawn part.

Description

 Deep-drawn part and method for producing a deep-drawn part

Description:

The invention relates to a deep-drawn part and a method for producing a deep-drawn part.

Deep-drawn parts are known from practice and are used inter alia as a housing, trim parts of all kinds, packaging and other layered functional elements.

In many applications, the deep-drawn part itself should not form the visible surface, for which purpose subsequently a cover layer or initially only an intermediate layer is laminated on. So it is common, for example, in the interior trim of motor vehicles, that deep-drawn parts on the headliner, the panels of the doors, on the dashboard or on the pillars of the vehicle with a high-quality cover layer, such as a textile material or leather is provided. In order to produce a particularly pleasant and high-quality feel, a soft, flexible intermediate layer is frequently also provided, for which purpose, for example, a spacer valve, in particular a spacer fabric or a foam layer, can be used. The lamination of several different materials turns out to be expensive in practice, so that there is a corresponding need for a simplification of the manufacturing process and a reduction in costs.

EP 0 103 129 B1 discloses a flexible spacer fabric which is adapted to a certain extent in its shape. In order to form a corsetry part, in particular the shell of a brassiere, a spacer knit fabric in a corresponding shape under the action of temperature is made cupped.

Although the material has a predetermined structure, but overall remains relatively soft and elastic, so that there is a high wearing comfort for a user. Such a deformed spacer fabric for garments is also known from DD 129 155.

In order to form a carrier-free Interieurteil, according to DE 10 201 1 075 720 A1 a haptic layer of textile, in particular a spacer fabric provided with an additional stiffening material, which is introduced in a separate process step in the textile. Also, this results in a relatively complicated procedure. A similar approach is also pursued according to DE 10 2013 213 681 A1, according to which a plastic foam is introduced as additional material.

A stiffening of a spacer knitted fabric by curing by means of resin is known from DE 3 813 741 C1, wherein the entire spacer knitted fabric is given high rigidity and dimensional stability. The soft, elastic properties of the spacer knit are completely lost.

EP 1 910 597 B1 discloses a method for producing a form-fitted spacer knitted fabric, in which the knitted spacer fabric is heated in a region to be deformed and cooled in a region which is not to be deformed. By heating and cooling, the boundaries of the deformed portions relative to the area of the spacer knit can be clearly separated from each other. In the regions to be deformed, the spacer knitted fabric is deformed as a whole, as is already known from the production of clothing parts and in particular corsetry articles from the abovementioned EP 0 103 129 B1 or DD 129 155.

The present invention is based on the object to provide a deep-drawn part, which is characterized by good mechanical properties and can be easily manufactured against this background. In particular, the deep-drawn part should be equipped in a particularly simple manner with a soft haptic layer. Furthermore, a method for producing such a deep-drawn part is to be specified.

The object of the invention and solution of the problem are a deep-drawn part according to claim 1 and a method for producing a deep-drawn part according to claim 8.

Thus, the object of the invention is therefore first a deep-drawn part, which is preferably formed entirely from a spacer textile, in particular a spacer fabric. The deep-drawn part comprises a flexible textile layer formed from threads, in particular a knitted fabric as a soft haptic layer, a stiff compared to the flexible textile layer carrier layer, which is formed by an at least partial melting of a second textile layer, in particular knitted fabric, and spacer threads between the textile layer and the carrier layer , wherein the spacer threads are preferably technically connected to the flexible textile layer and integrally bonded in the carrier layer.

According to the invention, the deep-drawn part can be formed entirely from a suitably adapted spacer textile, wherein the deep-drawing process is carried out in such a way and the spacer textile is designed so that the rigid carrier layer is produced on one side to form a strongly asymmetric structure, while on the other side there arranged first textile layer retains its soft and flexible properties. Through the carrier layer, the deep-drawn part keeps its three-dimensional shape, while the

Spacer threads and the flexible textile layer form a particularly pleasant soft and resilient, the support layer opposite surface. When used as a cowling so laminating with an elastic, resilient intermediate layer is no longer necessary.

In the case of the deep-drawn part, it is readily apparent that the rigid carrier layer is formed by an at least partial melting of a second textile layer, in particular a knitted fabric layer. The course of the spacer threads also corresponds to the carrier layer of the usual structure in a conventional spacer fabric, but the original existing thread structure of the threads initially forming the corresponding textile layer is at least partially canceled, so that the spacer threads without the addition of another resin or an additional stiffening material materially are attached.

In a sense, during the production of the deep-drawn part, the initially soft and flexible second textile layer is converted by the at least partial melting into a stiff layer which is capable of permanently giving the deep-drawn part a three-dimensional shape.

The present invention is based in this context on the knowledge that between the first textile layer and the second textile layer, from which the carrier layer is formed during deep drawing, there may be an asymmetry with regard to the materials and / or the effect of pressure and temperature during deep drawing got to.

In principle, it is conceivable that for the same or comparable materials of the first textile layer and the second textile layer by a corresponding contact in a thermoforming mold, the second textile layer for forming the backing layer

heated up and thereby at least partially melted, while the first textile layer remains soft and flexible.

According to a preferred embodiment of the invention, however, it is provided that the carrier layer is formed from a polymer or at least contains a polymer which has a lower melting point than the threads of the flexible textile layer. A different temperature of mold halves of a thermoforming mold is then not absolutely necessary, but can also be optionally provided in the context of such a configuration.

In order to form the backing layer during deep drawing, the corresponding textile layer can be formed, for example, from a melted thread or, at least in the case of a multi-thread system, have a melted thread which then at least partially melts when subjected to a corresponding temperature.

Preferably, the carrier layer is at least partially formed of multi-component fibers and / or multifilament yarn with different filaments. Multicomponent fibers can have two different sections or even more sections. Two different sections result in bicomponent fibers, with the sections arranged side by side. Particularly preferred is a core-shell structure, wherein the sheath is formed of low-melting polymer and the core has a higher melting temperature.

A similar concept may be provided for a multifilament yarn with different filaments. Part of the filaments is then low melting while other filaments have a higher melting temperature.

As a result of the measures described, it is possible to ensure that the textile layer, which forms the carrier layer as a result of at least partial melting, does not completely melt and there is thus the risk that the spacer threads may detach from the melt. The constituents of the multicomponent fibers or of the multifilament yarn, which melt only at a high temperature, then remain in the originally provided structure (in the case of a fabric of the laying structure) of the textile layer, while the at least one further low-melting component can be distributed to form a uniform layer.

In the context of the invention, a deep-drawn part is to be formed, which is characterized on the support layer by a high strength and stability, so that this example, for interior trim, housing, panels of the A-, B- or C-pillar of a motor vehicle or to form a Seat shell is suitable. Other conceivable applications include furniture, in particular garden furniture, protectors for motorcycle clothing, workwear or sportswear, wall elements of functional parts such as strollers, child seats or the like.

A corresponding stability can be achieved on the one hand by a corresponding basis weight of the carrier layer. For example, the carrier layer may have a weight per unit area of between 10 g / m ² and 1 000 g / m ² .

In addition or alternatively, in addition to low-melting filaments, particularly stable filaments may also be provided which effect stiffening or reinforcement.

If, as described above, multicomponent fibers and / or multifilament yarns with different filaments are used, filaments may also be provided in the multicomponent fibers or in the multifilament yarn with different filaments filaments which are selected from a material selected from the group aramid fiber, carbon fiber , Basalt fiber and fiberglass. In addition, other reinforcing fibers are suitable. In a multi-thread system described above for the textile layer forming the carrier layer during thermoforming, corresponding fiber types can also be used. In a melting of the low-melting component then these additional threads, strands or filaments form a particularly stable, solid grid, whereby the deep-drawn part on the one hand heavy-duty and resistant and on the other hand, with a high dimensional stability maintains the predetermined by deep drawing form.

In order to increase the proportion of the low-melting component, other threads can be incorporated, for example, as standing or weft threads, which may also be below the corresponding surface before melting.

The total thickness of the deep-drawn part or of the spacer textile used for it is typically between 1 mm and 60 mm, preferably between 1.5 mm and 30 mm and in particular between 2 mm and 15 mm. According to a preferred embodiment of the invention, the carrier layer with an area fraction of at least 50%, more preferably 70% and particularly preferably completely closed. The carrier layer formed by the melting of the corresponding textile layer then has a particularly dense, film-like structure, but the spacer threads are secure

are involved. In an alternative embodiment of the invention, however, a hole structure may also be provided for the carrier layer if the corresponding textile layer is previously provided with a corresponding hole structure.

The opposite, even in the deep-drawn part still flexible and the haptic layer forming textile layer is not limited in terms of their design and can either have a substantially closed mesh structure or a mesh structure with openings extending in the direction of production and across the production direction over several stitches.

The invention also provides a method for producing the deep-drawn part described above. The method comprises the steps of forming, in particular, working a spacer textile with a first textile layer, a second textile layer and spacer threads between the textile layers, introducing the spacer textile into a thermoforming mold, deep-drawing the spacer textile in the thermoforming mold in such a way that only the second textile layer is at least partially melted and forms a carrier layer.

Optionally, the spacer fabric can be heat-set on a tenter frame prior to insertion into the thermoforming mold. However, care must be taken to ensure that the first and second textile layers are not melted, so that deep drawing into the desired shape can take place after that and the spacer textile can still be easily handled. In heat setting, the spacer fabric is heated so that the plastic of the threads is only soft without becoming molten. By the knitting process and the Anwinkein the threads resulting stresses on the

Kinking of the threads are eliminated by such a Thernnofixieren, because the polymer chains can flow through a degree of mobility under heating tough to compensate for the externally applied voltages. A melting or merging of the individual threads is to be avoided by a suitable temperature control.

Alternatively, the spacer fabric can be processed without heat setting, the fixation of the article then takes place only during deep drawing. For this purpose, it may be expedient to heat a thermoforming mold also on its flexible side facing the textile layer forming the haptic layer, so that the heat setting described can take place without a melting of this textile layer.

In the context of the invention, it is also possible to preheat the spacer textile before thermoforming, so that the heat input necessary for the forming process and the formation of the carrier layer is reduced.

The spacer textile is preferably deep-drawn in a thermoforming mold with two mold halves, wherein a gap remaining in the closed position between the mold halves is expediently greater than the thickness of the spacer fabric in the compressed state. This avoids that, in the case of a melting of one of the textile layers to form the carrier layer, the other textile layer provided as a haptic layer is also glued or wetted by the molten plastic. Usually, the gap remaining between the mold halves is at least 1 mm, more preferably at least 2 mm larger than the thickness of the spacer knit in a fully compressed state.

Inn within the scope of the invention, therefore, solid, stable deep-drawn parts can be formed, which have as an integral part of a soft, supported by spacer threads haptic. A complex, subsequent laminating is not necessary, but the haptic layer can of course also be provided with a further covering layer, for example leather, artificial leather, fabric or the like.

At least with regard to the carrier layer and the textile layer, which is fabricated integrally therewith and supported by the spacer threads, as a haptic layer, there is also no danger of delamination-unlike laminating.

The invention will be explained in the following with reference to a drawing showing only one exemplary embodiment. 1 shows a spacer knitted fabric to form a deep-drawn part,

FIG. 2 shows a deep-drawn part formed from the spacer fabric according to FIG. 1, FIG. 3 a shows a schematic side view of that shown in FIG. 1

 spacer knit,

3b is a schematic side view of the thermoformed part formed therefrom according to FIG. 2.

FIG. 1 shows a spacer fabric designed as a spacer fabric 1, which according to the usual structure has a first knitted fabric 2, a second knitted fabric 3 and spacer yarns 4 between the two knitted fabrics 2, 3. The fabric layers 2, 3 are indicated only schematically

Maschen formed, wherein in the context of the invention a variety of laying patterns for the two fabric layers 2, 3 come into consideration.

The first knitted fabric layer 2 and the second knitted fabric layer 3 are formed of different polymeric materials for the respective yarns. The second knitted fabric layer 3 is designed so that it melts at least partially at a temperature at a lower temperature.

In particular, the second knitted fabric layer 3 may be partially formed of multi-component fibers and / or multifilament yarns with different filaments, wherein multi-component fibers strands or in multifilament yarns with different filaments filaments are provided, which are selected from a material selected from the group aramid fiber, carbon fiber, basalt fiber and Fiberglass exist.

Alternatively, at least two different thread systems can be used for the second knitted fabric.

It is essential in the context of the invention, however, that in a deep-drawing in a thermoforming mold, only the second knitted fabric layer 3 is at least partially melted and then forms a comparatively stiff, film-like support layer 3 '. The basis weight of the carrier layer 3 'can be, for example, between 10 g / m ² and 1 000 g / m ² without the spacer threads 4 incorporated therein.

A corresponding deep-drawn part is shown by way of example in FIG. 2. According to the invention, the carrier layer 3 'is responsible for the dimensional stability and stability of the deep-drawn part, while the first, via the spacer threads 4 supported on the carrier layer 3' knitted fabric 2 a soft haptic

forms. It is therefore formed from a single spacer knitted fabric 1 without the addition of other materials, a rigid, stable deep-drawn part, which is, however, at the same time provided integrally with a cushioning effect by the first knitted fabric layer 2 as a haptic.

In contrast to embodiments according to the prior art, therefore, a lamination of a deep-drawn part with an additional elastic layer in the form of a spacer fabric or a foam material is no longer necessary, resulting in considerable procedural simplifications and lower costs.

In the illustrated embodiment, the carrier layer 3 'is completely closed and forms a flat film structure, but the spacer threads 4 are securely anchored in the carrier layer 3'.

The structure of the spacer fabric before deep drawing is shown by way of example in FIG. 3a, while FIG. 3b shows the carrier layer 3 'formed by the melting of the second knitted fabric layer 3. Alternatively, however, the carrier layer 3 'may also have pores or larger openings.

The total thickness of the deep-drawn part according to FIG. 2 or the spacer fabric 1 according to FIG. 1 is typically between 1 mm and 60 mm.

The deep-drawn part is suitable for a wide variety of applications. For example, this can be used to make cost-effective trim parts, seat shells, wall elements, protectors, reinforcement elements or the like.

Claims

claims: 1 . Deep-drawn part with a flexible textile layer formed from threads, with a support layer (3 ') stiff relative to the flexible textile layer, which is formed by an at least partial melting of a second textile layer, and with spacer threads (4) between the flexible textile layer and the backing layer (3 '), wherein the spacer threads (4) with the flexible textile layer in particular connected technically and in the carrier layer (3') are integrally bonded. 2. Deep-drawn part according to claim 1, wherein the carrier layer (3 ') is formed from a polymer or at least contains a polymer which has a lower Melting point than the threads of the flexible textile layer has. 3. deep-drawn part according to claim 1 or 2, wherein the carrier layer (3 ') is at least partially formed of multi-component fibers and / or multifilament yarn with different filaments. 4. Deep-drawn part according to claim 3, wherein in multicomponent fibers strands or in multifilament yarns with different filaments filaments are provided, which consist of a material selected from the group aramid fiber, carbon fiber, basalt fiber and glass fiber. 5. Deep-drawn part according to one of claims 1 to 4, wherein the carrier layer (3 ') with an area ratio of at least 50%, preferably 70% and particularly preferably completely closed. 6. deep-drawn part according to one of claims 1 to 5, wherein the carrier layer (3 ') without the incorporated spacer threads (4) has a basis weight between 10 g / m ² and 1, 000 g / m ² . 7. Deep-drawn part according to one of claims 1 to 6, wherein the total thickness is between 1 mm and 60 mm. 8. A process for producing a deep-drawn part, in particular a deep-drawn part according to one of claims 1 to 7, comprising the steps: Forming, in particular, working a spacer textile with a first textile layer, a second textile layer and spacer threads (4) between the textile layers; Introducing the spacer fabric into a thermoforming mold; Deep drawing of the spacer fabric in the thermoforming mold under the effect of temperature such that only the second textile layer is at least partially melted and forms a carrier layer (3 '). 9. The method of claim 8, wherein the spacer fabric is thermoset before being introduced into the thermoforming mold on a clamping frame, without the first or second textile layer are melted. 10. The method of claim 8 or 9, wherein the spacer fabric is preheated prior to deep drawing. 1 1. A method according to any one of claims 8 to 10, wherein the spacer fabric is deep drawn in a thermoforming mold with two mold halves, one in one Closed position remaining gap between the mold halves is greater than the thickness of the spacer fabric in a compressed state.