MOTOR VEHICLE FLOOR COVERING, BOOT OR TRUNK COVERING OR LOAD COMPARTMENT COVERING HAVING A STRUCTURALLY NEEDLE-PUNCHED CARPET SURFACE

Abstract

A subject matter of the invention is a three-dimensionally deformable velour carpet for a floor paneling, a luggage compartment paneling or a load floor paneling of a motor vehicle, which has a needled structure on the visible side produced by structured brushes in the brush belt.

Claims

1. Method for the production of a three-dimensionally deformable velour carpet for a floor paneling, a luggage compartment paneling or a load floor paneling of a motor vehicle with a structurally needled, deformation-resistant surface with a grammage of the carpet in the range from 180 g/m2 to 700 g/m2, which is characterised in that at a defined setting of the penetration depth, a structured velour carpet is produced from an initial nonwoven, wherein one uses a brush belt which has segmental or partial sections of different brushes and/or brush arrangements and provides and deforms this velour carpet with one or more sub-layers.

2. Method according to claim 1, characterized in that, the structuring of the bristles is carried out by arranging brush segments, by different brush heights and/or by defined placement and/or removal of bristles in the belt and/or dividing webs.

3. Three-dimensionally shaped velour carpet for a floor paneling, a luggage compartment paneling or a load floor paneling of a motor vehicle with a structurally needled, deformation-resistant surface with a grammage of the carpet in the range from 180 g/m2 to 700 g/m2, further comprising one or more sublayers, wherein the visible side of the carpet has an optionally three-dimensional structurally needled, hard-wearing surface.

Description

[0021] The object of the present invention in comparison with the aforementioned prior art is thus to provide a structurally needled carpet which is suitable for deformation and which upgrades the passenger compartment and/or luggage compartment and/or load compartment of motor vehicles to the effect that the latter has a “living room/well-being atmosphere”. In particular, it is an object of the invention, during the manufacture of velour carpet and/or the velourisation of needlepunched nonwoven carpet, to introduce a permanent, hard-wearing surface pattern with a possibly three-dimensional structure, which is structured differently over the width and length of the carpet surface and withstands three-dimensional deformation to form a motor vehicle floor or luggage compartment paneling.

[0022] In a first embodiment, the subject matter of the present invention is a method for producing a three-dimensionally deformable velour carpet for a floor paneling, a luggage compartment paneling or a load floor paneling of a motor vehicle with a structurally needled, deformation-resistant surface having a grammage of the carpet in the range from 180 g/m2 to 700 g/m2, which is characterized in that at a defined setting of the penetration depth, a structured velour carpet is produced from an initial nonwoven, wherein one uses a brush belt which has segmental or partial sections of different brushes and/or brush arrangements and provides and deforms this velour carpet with one or more sub-layers.

[0023] The core of the present invention is thus the provision of a velour carpet, produced in a conventional standard process, for the manufacture of a floor paneling, a luggage compartment paneling or a load floor paneling of a motor vehicle with a structurally needled, deformation-resistant visible surface solely by the arrangement of brushes of the brush belt with different brush/brush fibre height and brush/brush fibre structure when needling and/or velouring the floor paneling, the luggage compartment paneling or the load floor paneling of a motor vehicle.

[0024] The brush belt is equipped over the width and length with predefined brush/brush fibre heights and/or brush/brush fibre structures, as well as needle types and/or geometries, which thus create a predefined structure of the velour surface.

[0025] The advantage of the present invention is to provide a deformation-resistant/stable, structurally needled velour carpet for the production of motor vehicle floor and luggage compartment paneling or load floor paneling without an additional working step in its production compared to standard velour carpet production.

[0026] The method of the present invention can be implemented-without additional non-woven layers, needling stages, needling machines or needle boards-on “standard” machines solely by means of the brush/brush fibre heights and brush/brush fibre structures, the brush belt assembly over the width and length, and the needle geometry/needle type.

[0027] A further embodiment of the present invention consists in a three-dimensionally shaped velour carpet for a floor paneling, a luggage compartment paneling or a load floor paneling of a motor vehicle with a structurally needled, deformation-resistant surface with a grammage of the carpet in the range from 180 g/m2 to 700 g/m2, further comprising one or more sublayers, wherein the visible side of the carpet has an optionally three-dimensional structurally needled, hard-wearing surface.

[0028] The realisation should preferably take place on the one hand with a single-layer and on the other hand with a two-layer velour carpet. In the case of a two-layer design, additional colour effects with different structures can be needled in.

[0029] Example of Execution:

[0030] For the production of a deformation-resistant/stable, structure-needled floor paneling, a pre-nonwoven made of a fibre mix consisting of 80% commercially available 13 dtex fibres, fibre length 60 mm, PET fibre and 20% commercially available 6.7 dtex fibres, fibre length 64 mm, PET fibre was used as the initial nonwoven. The basis weight was 480 g/m2.

[0031] The needle boards were equipped with fork needles from Groz-Beckert as follows:

[0032] In throughput direction [0033] 1. Board Fork Needle 15×17×32×40×63.5 V G 9077 [0034] 2. Board Fork Needle 15×17×32×40×63.5 D G 9077 DUR

[0035] In the case of the velour carpet shown in FIG. 1, the penetration depth was 6 mm and the stitch density 550 stitches/cm.sup.2.

[0036] The brushes of the brush belt had a 4.5 mm width and 2 mm depth, shortened height, transverse to the direction of travel.

[0037] The structure of the surface is clearly visible.

[0038] FIG. 2 shows a section of a velour carpet with a partially structure-needled diamond surface; the penetration depth here was 4 mm and the stitch density 550 stitches/cm2.