NON-FLAMMABLE THERMAL INSULATING COMPOSITE SUBSTRATE FOR MOTOR VEHICLES AND PRODUCTION METHOD

Abstract

Disclosed is a non-flammable thermal insulating composite substrate for motor vehicles including: a textile component constituted by a layer of needle-sewn non-woven fabric composed of a percentage of pre-oxidized polyacrylonitrile fiber included between 40% and 70%, preferably 58% and of the remaining percentage of polyethylene glycol-terephthalate fiber, the textile component having weight preferably 400 gr/m.sup.2; and a barrier fixed to the textile component using a spreading process, constituted by a thermoplastic resin based on low density polyethylene added with non-halogen flame retardants, the barrier having weight preferably 100 gr/m.sup.2. The composite substrate has the following features: a thickness included between 2 mm and 5 mm, preferably 3.8 mm; a weight included between 300 gr/m.sup.2 and 700 gr/m.sup.2, preferably 500 gr/m.sup.2; odorless; no emission of fumes; dimensionally stable, even at heatstroke, with a maximum variation of 1%; and non-flammability.

Claims

1. Non-flammable thermal insulating composite substrate for motor vehicles, comprising a textile component and a barrier; said textile component consisting of a layer of needle-sewn non-woven fabric composed of a percentage of pre-oxidized polyacrylonitrile fiber ranging from 40% to 70%, and of the remaining percentage of polyethylene glycol-terephthalate fiber, said textile component having a weight of between 200 g/m.sup.2 and 600 g/m.sup.2; said barrier being irreversibly fixed to a surface of said textile component through a spreading process; said barrier consisting of a thermoplastic resin based on low density polyethylene added with non-halogen flame retardants, said barrier having a weight of between 30 g/m.sup.2 and 150 g/m.sup.2; said composite substrate having the following features: thickness of between 2 mm and 5 mm; weight of between 300 g/m.sup.2 and 700 g/m.sup.2; odorless; no emission of fumes when exposed to the flame at said textile component; dimensionally stable, even at heatstroke, with a maximum variation of 1%; non-flammability when exposed to the flame at said textile component.

2. The non-flammable thermal insulating composite substrate for motor vehicles, according to claim 1, wherein said barrier is made of polyethylene and is provided with reliefs and recesses which increase the adhesion thereof.

3. The non-flammable thermal insulating composite substrate for motor vehicles, according to claim 1, wherein said barrier is made of polyamide and is provided with reliefs and recesses which increase the adhesion thereof.

4. The non-flammable thermal insulating composite substrate for motor vehicles, according to claim 1, wherein said barrier is made of ethylene vinyl acetate and is provided with reliefs and recesses which increase the adhesion thereof.

5. The non-flammable thermally insulating composite substrate for motor vehicles, according to claim 1, wherein by impregnating said textile component in a bath, said textile component becomes a water-oil repellent barrier.

6. The non-flammable thermal insulating composite substrate for motor vehicles, according to claim 1, further comprising a layer made of any plastic polymer, engaged externally to said barrier.

7. A method for producing a motor vehicle component, comprising: inserting a non-flammable thermal insulating composite substrate for motor vehicles comprising a textile component and a barrier into an injection mold; and co-molding the composite substrate with a predetermined plastic polymer, such that said composite substrate adheres to the plastic polymer at an outer surface of said barrier.

8. Method for producing a non-flammable thermal insulating composite substrate for motor vehicles, comprising: unrolling a roll of textile component according to claim 1, by means of an unrolling roller; tensioning and aligning said textile component through a plurality of first tensioning rollers; heating a predetermined amount of barrier-forming agent at a temperature ranging from 50° C. to 350° C.; said heating taking place in a special oven); spreading said barrier on one face of said textile component through a dispenser; rolling said barrier onto said textile component through a plurality of rolling rolls; cooling said barrier-forming agent by means of a cooling device and irreversible adhesion between said textile component and said barrier-forming agent, generating said composite substrate; tensioning and aligning said composite substrate through a plurality of second tensioning rollers; rolling said composite substrate by means of a rolling roller.

9. The method for producing a non-flammable thermal insulating composite substrate for motor vehicles, according to claim 8, further comprising a step for storing said barrier-forming material in a special tank in which said barrier-forming material is stored in powder; said tank being connected to said oven in turn upstream of said dispenser.

10. The non-flammable thermal insulating composite substrate for motor vehicles of claim 1, wherein the layer of needle-sewn non-woven fabric is composed of 58% pre-oxidized polyacrylonitrile fiber, said textile component has a weight of 400 g/m.sup.2, said barrier has a weight of 100 g/m.sup.2, and said composite substrate has a thickness of 3.8 mm and a weight of 500 g/m.sup.2.

11. The non-flammable thermally insulating composite substrate for motor vehicles, according to claim 2, wherein by impregnating said textile component in a bath, said textile component becomes a water-oil repellent barrier.

12. The non-flammable thermally insulating composite substrate for motor vehicles, according to claim 3, wherein by impregnating said textile component in a bath, said textile component becomes a water-oil repellent barrier.

13. The non-flammable thermally insulating composite substrate for motor vehicles, according to claim 4, wherein by impregnating said textile component in a bath, said textile component becomes a water-oil repellent barrier.

14. The non-flammable thermal insulating composite substrate for motor vehicles, according to claim 2, further comprising a layer made of any plastic polymer, engaged externally to said barrier.

15. The non-flammable thermal insulating composite substrate for motor vehicles, according to claim 3, further comprising a layer made of any plastic polymer, engaged externally to said barrier.

16. The non-flammable thermal insulating composite substrate for motor vehicles, according to claim 4, further comprising a layer made of any plastic polymer, engaged externally to said barrier.

17. The non-flammable thermal insulating composite substrate for motor vehicles, according to claim 5, further comprising a layer made of any plastic polymer, engaged externally to said barrier.

18. The non-flammable thermal insulating composite substrate for motor vehicles, according to claim 11, further comprising a layer made of any plastic polymer, engaged externally to said barrier.

19. The non-flammable thermal insulating composite substrate for motor vehicles, according to claim 12, further comprising a layer made of any plastic polymer, engaged externally to said barrier.

20. The non-flammable thermal insulating composite substrate for motor vehicles, according to claim 13, further comprising a layer made of any plastic polymer, engaged externally to said barrier.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The invention will be described hereinbelow in at least one preferred embodiment by way of a non-limiting example with the aid of the enclosed figures, in which:

[0031] FIG. 1 shows a schematic section of the composite material that forms the substrate 10, object of the present invention.

[0032] FIG. 2 illustrates the scheme of the production plant for making the claimed composite substrate 10.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] The present invention will now be illustrated as a merely exemplifying but non-limiting or non-binding example, with reference to the figures which illustrate several embodiments relative to the present inventive concept.

[0034] With reference to FIG. 2, the production plant adapted to make the composite substrate 10, object of the present invention, is shown.

[0035] This consists of an unrolling roller 100, a plurality of first tensioning rollers 110-110′, a tank 120 of barrier-forming agent 12, an oven 122 and a dispenser device 124, a plurality of rolling rolls 130-130′, a cooling device 140, a plurality of second tensioning rollers 150-150′ and a rolling roller 160.

[0036] The attainment method then provides for: [0037] A first step of unrolling a roll of textile component 11, by means of said unrolling roller 100. The textile component 11 is constituted by a layer of needle-sewn non-woven fabric composed of pre-oxidized polyacrylonitrile fiber in a percentage that varies from 40% to 70% preferably 58% and by the remaining percentage of polyethylene glycol-terephthalate fiber; [0038] A second step of tensioning and aligning said textile component 11 by means of the first tensioning rollers 110-110′; [0039] A third step of heating a predetermined quantity of barrier-forming agent 12 at a temperature comprised between 50° C. and 350° C. The barrier-forming agent 12 is constituted by a low density polyethylene powder added with non-halogen flame retardants and it is stored in a tank 120 connected to the oven 122 where the heating occurs; [0040] A fourth step of spreading the barrier-forming agent 12 on one face of the textile component 11 by means of a dispenser 124; [0041] A fifth step of rolling the barrier-forming agent 12 on the textile component 11 by means of the rolling rolls 130-130′; [0042] A sixth step of cooling the barrier-forming agent 12 by means of a cooling device 140. The cooling of the barrier-forming agent 12 on the textile component 11 determines the irreversible adhesion and hence generates the desired composite substrate 10; [0043] A seventh step of tensioning and aligning the composite substrate 10 just produced, by means of the second tensioning rollers 150-150′; [0044] An eighth step of rolling the composite substrate 10 by means of a rolling roller 160.

[0045] Finally, it is clear that modifications, additions or variations that are obvious for the man skilled in the art can be made to the invention described up to now, without departing from the protective scope provided by the enclosed claims.