TEXTILE COMPOSITE MATERIAL

Abstract

A textile composite material for lamination comprises, at least one nonwoven material layer and at least one further nonwoven material layer connected to the at least one nonwoven material layer, wherein the at least one nonwoven material layer and the at least one further nonwoven material layer are mechanically connected to each other, wherein the at least one nonwoven material layer and the at least one further nonwoven material layer each comprise at least one binder fiber, wherein the at least one binder fiber of the at least one further nonwoven material layer has a melting temperature that is equivalent to a value range from 130 C. to 190 C., and the at least one binder fiber of the at least one further nonwoven material layer has a melting temperature that is higher than a melting temperature of the at least one binder fiber of the at least one nonwoven material layer.

Claims

1. A textile composite material, in particular a textile composite material for lamination, with at least one nonwoven material layer and with at least one further nonwoven material layer which is connected to the at least one nonwoven material layer , wherein the at least one nonwoven material layer and the at least one further nonwoven material layer are mechanically connected to each other, wherein the at least one nonwoven material layer comprises at least one binder fiber and wherein the at least one further nonwoven material layer comprises at least one binder fiber, wherein the at least one binder fiber of the at least one further nonwoven material layer has a melting temperature that is equivalent to a value of a value range from 130 C. to 190 C., and that the at least one binder fiber of the at least one further nonwoven material layer has a melting temperature that is higher than a melting temperature of the at least one binder fiber of the at least one nonwoven material layer, wherein individual fibers of the nonwoven material layer completely penetrate the further nonwoven material layer.

2. The textile composite material according to claim 1, wherein the at least one nonwoven material layer and the at least one further nonwoven material layer are needled with each other, wherein at least more than 5% of an entire connecting surface of the at least one further nonwoven material layer are pierced by fibers of the at least one nonwoven material layer.

3. The textile composite material according to claim 1, wherein the at least one nonwoven material layer and the at least one further nonwoven material layer are needled with each other, wherein per 1 cm.sup.2 of a connecting surface of the at least one further nonwoven material layer at least two fibers of the at least one nonwoven material layer enter into the at least one further nonwoven material layer.

4. The textile composite material according to claim 1, wherein the at least one nonwoven material layer and the at least one further nonwoven material layer are needled with each other, wherein at least a large portion of fibers of the at least one nonwoven material layer entering into the at least one further nonwoven material layer extend into the at least one further nonwoven material layer at least by up to 50% of a maximum nonwoven material layer thickness of the at least one further nonwoven material layer.

5. The textile composite material according to claim 1, comprising at least one adhesive layer, which is arranged on a side of the at least one further nonwoven material layer that faces away from the at least one nonwoven material layer.

6. The textile composite material according to claim 1, comprising at least one cover layer, which is arranged on a side of the at least one further nonwoven material layer that faces away from the at least one nonwoven material layer.

7. The textile composite material according to claim 6, wherein the at least one cover layer is mechanically connected to the at least one further nonwoven material layer.

8. The textile composite material according to claim 5, wherein the at least one cover layer is fixated to the at least one further nonwoven material layer via the at least one adhesive layer

9. The textile composite material according to claim 1, wherein the at least one nonwoven material layer comprises at least one functional fiber having a linear mass density value that is greater than 15 dtex, the at least one binder fiber of the at least one nonwoven material layer having a linear mass density value that is greater than 5 dtex; and/or the at least one further nonwoven material layer comprises at least one functional fiber having a linear mass density value that is greater than 15 dtex, the at least one binder fiber of the at least one further nonwoven material layer having a linear mass density value that is greater than 5 dtex.

10. The textile composite material according to claim 1, wherein the at least one nonwoven material layer comprises at least one functional fiber which is embodied as a hollow fiber.

11. The textile composite material according to claim 1 wherein the at least one nonwoven material layer comprises at least one functional fiber which has a star-shaped, a quadrangular, a trilobal, a horseshoe-shaped or a circle-shaped cross section.

12. The textile composite material at least according to claim 7, wherein the at least one cover layer is sewn to the at least one nonwoven material layer and/or to the at least one further nonwoven material layer.

13. The textile composite material according to claim 1, comprising at least one additional reinforcing layer.

14. The textile composite material at least according to claim 6, comprising at least one additional reinforcing layer which is arranged between the at least one cover layer and the at least one further nonwoven material layer.

15. A seat cover with at least one textile composite material according to claim 1.

Description

DRAWINGS

[0035] Further advantages may be gathered from the following description of the drawings. The drawings show exemplary embodiments of the invention. The drawings, the description and the claims contain a plurality of features in combination. Someone skilled in the art will purposefully also consider the features separately and will find further expedient combinations.

[0036] It is shown in:

[0037] FIG. 1 a sectional view of a textile composite material according to the invention, which comprises at least one nonwoven material layer and a further nonwoven material layer, in a schematic presentation,

[0038] FIG. 2 a sectional view of the textile composite material according to the invention, with a cover layer of the textile composite material according to the invention which is arranged at the further nonwoven material layer, in a schematic presentation,

[0039] FIG. 3 a sectional view of an alternative textile composite material according to the invention, with a reinforcing layer of the alternative textile composite material, which is arranged between a cover layer and a further nonwoven material layer of the alternative textile composite material according to the invention, in a schematic presentation, and

[0040] FIG. 4 a sectional view of a further alternative textile composite material according to the invention, with a cover layer of the alternative textile composite material according to the invention, which is sewn to a further nonwoven material layer of the alternative textile composite material according to the invention, in a schematic presentation.

DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

[0041] FIG. 1 shows a textile composite material 10a with at least one nonwoven material layer 12a and with at least one further nonwoven material layer 14a which is connected to the nonwoven material layer 12a. The textile composite material 10a is embodied as a seat cover textile composite material. The textile composite material 10a is in particular configured to at least partly implement a seat cover 30a, in particular a motor vehicle seat cover. It is however also conceivable that the textile composite material 10a is configured to implement a different textile object, e.g. to implement an inner door lining of a motor vehicle, to implement an armrest cover, or the like.

[0042] The nonwoven material layer 12a is in particular embodied as a finished textile product. The further nonwoven material layer 14a is preferably embodied as a finished textile product, which is in particular producible by a stitch-bonding process. The nonwoven material layer 12a and the further nonwoven material layer 14a are mechanically connected to each other, in particular for at least partly implementing the textile composite material 10a. The nonwoven material layer 12a and the further nonwoven material layer 14a are needled with each other, wherein at least more than 5% of an entire connecting surface 16a of the further nonwoven material layer 14a are pierced by fibers 18a, 20a of the nonwoven material layer 12a. Preferably the nonwoven material layer 12a and the further nonwoven material layer 14a are needled with each other in such a way that at least more than 15% of the entire connecting surface 16a of the further nonwoven material layer 14a are pierced by fibers 18a, 20a of the nonwoven material layer 12a. In particular, per 1 cm.sup.2 of the connecting surface 16a of the further nonwoven material layer 14a at least two fibers 18a, 20a of the nonwoven material layer 12a enter into the further nonwoven material layer 14a. Preferably per 1 cm.sup.2 of the connecting surface 16a of the further nonwoven material layer 14a at least ten, in particular between twenty and three hundred fibers 18a, 20a of the nonwoven material layer 12a enter into the further nonwoven material layer 14a. It is however also conceivable that per 1 cm.sup.2 of the connecting surface 16a of the further nonwoven material layer 14a more than ten, in particular more than three hundred fibers 18a, 20a of the nonwoven material layer 12a enter into the further nonwoven material layer 14a.

[0043] Of the fibers 18a, 20a of the nonwoven material layer 12a entering into the further nonwoven material layer 14a, at least a large portion extend into the further nonwoven material layer 14a at least by up to 50% of a maximum nonwoven material layer thickness 22a of the further nonwoven material layer 14a. It is however also conceivable that individual fibers 18a, 20a of the nonwoven material layer 12a or, alternatively, the large portion of the fibers 18a, 20a of the nonwoven material layer 12a, wholly penetrate the further nonwoven material layer 14a. Beyond this it is conceivable that individual fibers 18a, 20a of the nonwoven material layer 12a or, alternatively, the large portion of the fibers 18a, 20a of the nonwoven material layer 12a, extend into the further nonwoven material layer 14a farther than 50% of the maximum nonwoven material layer thickness 22a of the further nonwoven material layer 14a. It is furthermore conceivable that individual fibers 18a, 20a of the nonwoven material layer 12a or, alternatively, the large portion of the fibers 18a, 20a of the nonwoven material layer 12a, extend into the further nonwoven material layer 14a by less than 50% of the maximum nonwoven material layer thickness 22a of the further nonwoven material layer 14a. A ratio of the maximum nonwoven material layer thickness 22a of the further nonwoven material layer 14a to a maximum nonwoven material layer thickness 24a of the nonwoven material layer 12a is herein at least greater than or equal to 1. It is however also conceivable that the textile composite material 10a features a ratio of a maximum nonwoven material layer thickness 22a of the further nonwoven material layer 14a to a maximum nonwoven material layer thickness 24a of the nonwoven material layer 12a that is at least smaller than or equal to 1.

[0044] The nonwoven material layer 12a and the further nonwoven material layer 14a are needled with each other in such a way that a holding force between the nonwoven material layer 12a and the further nonwoven material layer 14a acting counter to a nonwoven-nonwoven separating force is greater than 1 N. A mechanical connection of the nonwoven material layer 12a and the further nonwoven material layer 14a is achieved by a needling process in which the fibers 18a, 20a of the nonwoven material layer 12a are needled into the further nonwoven material layer 14a by means of a needling machine (not shown here). As a result of needling the nonwoven material layer 12a and the further nonwoven material layer 14a with one another, the fibers 18a, 20a of the nonwoven material layer 12a establish a form-fit and/or force-fit connection with fibers of the further nonwoven material layer 14a. The nonwoven material layer 12a is in particular connected to the further nonwoven material layer 14a captively, i.e. permanently. The nonwoven material layer 12a and the further nonwoven material layer 14a each have a basis weight that is greater than 45 g/m.sup.2. It is however also conceivable that the nonwoven material layer 12a and the further nonwoven material layer 14a each have a basis weight that is smaller than or equal to 45 g/m.sup.2.

[0045] The nonwoven material layer 12a comprises at least one functional fiber 26a, which has a linear mass density value that is smaller than or equal to 50 dtex. The functional fiber 26a is in particular implemented by one of the fibers 18a, 20a of the nonwoven material layer 12a. The functional fiber 26a may be embodied as a hollow fiber. The functional fiber 26a may have any cross section that is deemed expedient by someone skilled in the art, e.g. a star-shaped cross section, a quadrangular cross section, a trilobal cross section, a horse-shoe-shaped cross section, an annulus-shaped cross section, or the like. All in all, the nonwoven material layer 12a comprises a plurality of functional fibers 26a which have a linear mass density value smaller than or equal to 50 dtex and which are in particular embodied as hollow fibers.

[0046] The nonwoven material layer 12a comprises at least one binder fiber 36a (melt fiber). The binder fiber 36a is implemented by one of the fibers 18a, 20a of the nonwoven material layer 12a. All in all, the nonwoven material layer 12a comprises a plurality of binder fibers 36a. Due to being mixed-up, the binder fibers 36a and/or the functional fibers 26a of the nonwoven material layer 12a are interconnected via a form-fit connection (by interlacing), via cohesion and/or via adhesion. For the purpose of forming the nonwoven material layer 12a, the binder fibers 36a and/or the functional fibers 26a may be arranged in an oriented or in a tangled manner.

[0047] The binder fiber 36a of the nonwoven material layer 12a in particular has a linear mass density value that is greater than 0.9 dtex, that is preferably greater than 5 dtex and is especially preferentially smaller than 15 dtex. Particularly preferably the binder fiber 36a of the nonwoven material layer 12a has a linear mass density value that is equivalent to a value between 1 dtex and 9 dtex. Preferably the binder fiber 36a of the nonwoven material layer 12a has a melting temperature that is equivalent to a value of a value range from 100 C. to 220 C. Especially preferentially the binder fiber 36a of the nonwoven material layer 12a has a melting temperature that is equivalent to a value of a value range from 130 C. to 180 C.

[0048] The functional fiber 26a of the nonwoven material layer 12a is preferably embodied as a polyester fiber, in particular as a polyethylene terephthalate fiber. It is however also conceivable that the functional fiber 26a of the nonwoven material layer 12a is implemented in a different manner that is deemed expedient by someone skilled in the art, eg. as a polyamide fiber, as a polyolefin fiber, as a polyacrylonitrile fiber, as a polyvinyl chloride fiber, as a polyvinyl alcohol fiber, as a polytetrafluoroethylene fiber, as a polyurethane fiber, or the like. The functional fiber 26a of the nonwoven material layer 12a in particular has a linear mass density value that is greater than 1 dtex, is preferentially greater than 15 dtex and is especially preferentially smaller than 30 dtex. Very particularly preferably the functional fiber 26a of the nonwoven material layer 12a has a linear mass density value that is equivalent to a value between 1.5 dtex and 24 dtex. Preferably the functional fiber 26a of the nonwoven material layer 12a has a high resiliency capability. In particular, the functional fiber 26a of the nonwoven material layer 12a is embodied in a spirally-crimped fashion. It is however also conceivable that the functional fiber 26a of the nonwoven material layer 12a has a different implementation, deemed expedient by someone skilled in the art, which allows an implementation of a fiber with a high resiliency capability.

[0049] The further nonwoven material layer 14a preferably comprises at least one binder fiber 38a (melt fiber) and at least one functional fiber 40a. Preferentially the further nonwoven material layer 14a comprises a plurality of binder fibers 38a and/or functional fibers 40a. The binder fiber 38a of the further nonwoven material layer 14a in particular has a linear mass density value that is greater than 0.9 dtex, is preferably greater than 5 dtex and is especially preferentially smaller than 15 dtex. Very particularly preferably the binder fiber 38a of the further nonwoven material layer 14a has a linear mass density value that is equivalent to a value between 1 dtex and 9 dtex. The binder fiber 38a of the further nonwoven material layer 14a preferably has a melting temperature that is equivalent to a value of a value range from 100 C. to 240 C. Especially preferentially the binder fiber 38a of the further nonwoven material layer 14a has a melting temperature that is equivalent to a value of a value range from 130 C. to 190 C. Preferably the binder fiber 38a of the further nonwoven material layer 14a has a melting temperature that is higher than a melting temperature of the binder fiber 36a of the nonwoven material layer 12a. Alternatively, the binder fiber 38a of the further nonwoven material layer 14a may be implemented in a manner that is analogous to the binder fiber 36a of the nonwoven material layer 12a.

[0050] The functional fiber 40a of the further nonwoven material layer 14a is preferably implemented as a polyester fiber, in particular as a polyethylene terephthalate fiber. It is however also conceivable that the functional fiber 40a of the further nonwoven material layer 14a is implemented in a different manner that is deemed expedient by someone skilled in the art, eg. as a polyamide fiber, as a polyolefin fiber, as a polyacrylonitrile fiber, as a polyvinyl chloride fiber, as a polyvinyl alcohol fiber, as a polytetrafluoroethylene fiber, as a polyurethane fiber, as wool, or the like, and in particular features a different fiber implementation, deemed expedient by someone skilled in the art, which has a textile character (soft-elastic, high rebound force, in particular due to a spirally-crimped implementation) and is capable of being processed in a stitch-bonding procedure. The binder fibers 38a and/or the functional fibers 40a of the further nonwoven material layer 14a are meshed with each other, and have in particular been meshed already before a connection of the further nonwoven material layer 14a and the nonwoven material layer 12a.

[0051] The textile composite material 10a comprises, in particular for partly implementing the seat cover 30a, at least a cover layer 32a which is, in particular in a state when the nonwoven material layer 12a and the further nonwoven material layer 14a are connected to each other, arranged on a side of the further nonwoven material layer 14a that faces away from the nonwoven material layer 12a (FIG. 2). The cover layer 32a is preferably embodied as a leather cover layer. It is however also conceivable that the cover layer 32a is implemented in a different manner deemed expedient by someone skilled in the art, e.g. as a textile cover layer, as a faux-leather cover layer, or the like. For the purpose of connecting the further nonwoven material layer 14a and the cover layer 32a, the textile composite material 10a comprises at least one adhesive layer 28a. In particular in a state when the nonwoven material layer 12a and the further nonwoven material layer 14a are connected to one another, the adhesive layer 28a is arranged on a side of the further nonwoven material layer 14a that faces away from the nonwoven material layer 12a. The adhesive layer 28a may be embodied as an adhesive nonwoven/adhesive web, as a self-adhesive glue, in particular as a self-adhesive, pressure-sensitive glue, or the like. In an implementation of the adhesive layer 28a as an adhesive nonwoven/adhesive web, the adhesive layer 28a preferably has a reticulate structure. The adhesive layer 28a is in particular embodied of a material that is similar or identical to the material of the binder fiber 38a of the further nonwoven material layer 14a. The adhesive layer 28a preferentially has a melting temperature that is equivalent to a value of a value range from 50 C. to 140 C., preferably of a value range from 90 C. to 100 C.

[0052] In an alternative implementation of the cover layer 32a as a textile cover layer or as a faux-leather cover layer, which is not shown here, the textile composite material 10a may comprise, as an alternative to the adhesive layer 28a, a connection component (not shown here) which is embodied as an additional foam material layer, wherein the connection component may be flame-laminated in both of the implementations mentioned. In an implementation of the connection component as an additional nonwoven material layer, a lost-foam process, which is already known to someone skilled in the art, may be advantageously applicable. Herein the connection component may be arranged on the further nonwoven material layer 14a via flame lamination, and the cover layer 32a, in particular the cover layer 32a implemented as a textile cover layer or as a faux-leather cover layer, may be arranged, via flame lamination, at the connection component, which has already been arranged at the further nonwoven material layer 14a. After the flame lamination, the connection component embodied as an additional nonwoven material layer would be present just as a thin coating. Furthermore it is also conceivable that, alternatively or additionally, glue points and/or glue powders, melt-print procedures, hot-melt glues, adhesive foils or other adhesive-bonding measures or adhesive-bonding procedures deemed expedient by someone skilled in the art, in particular hot-melt or cold-melt adhesive-bonding procedures, which in particular advantageously maintain a textile character of the textile composite material 10a, may be used for connecting the cover layer 32a to the further nonwoven material layer 14a.

[0053] The textile composite material 10a advantageously allows a smooth, wrinkle-free arrangement of the textile composite material 10a and/or of the seat cover 30a on difficult seat contours of a seat (not shown here), in particular of a motor vehicle seat, e.g. on a convexly implemented cushioning of a seat, e.g. a lateral wing of an access side of a seat, etc. Moreover, the textile composite material 10a is advantageously highly drapable in minute radii, e.g. in case the textile composite material 10a and/or the seat cover 30a is arranged on a seat in which the textile composite material 10a is formed convex in a partial region of the textile composite material 10a and is formed concave in a further partial region of the textile composite material 10a which directly abuts the partial region. Furthermore the textile composite material 10a is embodied in such a way that it is difficult to ignite in accordance with FMVSS 302, or ISO 3795 respectively. Furthermore, advantageously all relevant documents of the automobile industry should be taken into consideration, e.g. requirements regarding emission/fogging/smell, the end-of-life vehicle regulation, etc., etc.

[0054] Further exemplary embodiments of the invention are depicted in FIGS. 3 and 4. The following description and the drawings are limited substantially to the differences between the exemplary embodiments, wherein regarding structural components having the same denomination, in particular structural components having the same reference numerals, the drawings and/or the description of the other exemplary embodiments, in particular of FIGS. 1 and 2, may principally be referred to as well. For distinguishing the exemplary embodiments, the letter a has been added to the reference numerals of the exemplary embodiment of FIGS. 1 and 2. In the exemplary embodiments of FIGS. 3 and 4 the letter a has been replaced by the letters b, respectively c.

[0055] FIG. 3 shows a textile composite material 10b with at least one nonwoven material layer 12b and with at least one further nonwoven material layer 14b which is connected to the nonwoven material layer 14b. The textile composite material 10b shown in FIG. 3 is implemented in a manner that is at least substantially analogous to the textile composite material 10a depicted in FIGS. 1 and 2. As a difference from the textile composite material 10a shown in FIGS. 1 and 2, the textile composite material 10b shown in FIG. 3 additionally comprises at least one reinforcing layer 34b. The reinforcing layer 34b is configured to reinforce a cover layer 32b of the further nonwoven material layer 14b. In the exemplary embodiment of the textile composite material 10b shown in FIG. 3, the reinforcing layer 34b is embodied as a leather-reinforcing material. It is however also conceivable that the reinforcing layer 34b is embodied in a different manner deemed expedient by someone skilled in the art, in particular in a manner that depends on an implementation of the cover layer 32b. The reinforcing layer 34b is arranged on a side of the further nonwoven material layer 14b that faces away from the nonwoven material layer 12b. The reinforcing layer 34b is arranged between the further nonwoven material layer 14b and the cover layer 32b. In particular, the reinforcing layer 34b is arranged between the further nonwoven material layer 14b and an adhesive layer 28b of the textile composite material 10b. It is however also conceivable that the reinforcing layer 34b is implemented and/or arranged in a different manner deemed expedient by someone skilled in the art. The reinforcing layer 34b may be embodied as a textured material, as a warp-knitted material, as a knitted material, as a lattice, or the like, for cover-layer supporting, in particular for leather supporting. The reinforcing layer 34b is preferably fixatable to the further nonwoven material layer 14b by means of an adhesive web (not shown here). Thus stretching of the cover layer 32b, in particular leather stretching, in case of a load onto the textile composite material 10b may advantageously be at least substantially prevented or at least reduced. Moreover, specially stressed areas of a seat cover 30b comprising the textile composite material 10b, e.g. an outlet point of the seat cover 30b for a lateral airbag, may be provided with appropriate reinforcements. Furthermore, by way of appropriate choice of the reinforcing layer 34b, at least a stretching characteristic, a material characteristic, in particular a maximum tensile force to be endured, etc., of the textile composite material 10b are/is specifically modifiable. In an alternative implementation (not shown here) of the cover layer 32b as a textile cover layer or as a faux-leather cover layer it is moreover conceivable that, in addition to a connection component, a chemical binding agent (not shown here), e.g. a glue, is provided which is arrangeable on the cover layer 32b and/or on the textile composite material 10b. This binding agent may advantageously at least substantially avoid or at least reduce a fiber dust of fibers of the cover layer 32b and/or an adhesion of fiber material of the further nonwoven material layer 14b on the cover layer 32b, in particular subsequently to a curing process of the binding agent. Advantageously a fluff protection is achievable. Regarding further functions and characteristics of the textile composite material 10b shown in FIG. 3, the textile composite material 10a described in the description of FIGS. 1 and 2 may be referred to.

[0056] FIG. 4 shows a textile composite material 10c with at least one nonwoven material layer 12c and with at least one further nonwoven material layer 14c which is connected to the nonwoven material layer 12c. The textile composite material 10c depicted in FIG. 4 is implemented in a manner that is at least substantially analogous to the textile composite material 10a shown in FIGS. 1 and 2. As a difference to the textile composite material 10a shown in FIGS. 1 and 2, the textile composite material 10c depicted in FIG. 4 comprises at least one cover layer 32c, which is mechanically connected to the nonwoven material layer 12c and/or to the further nonwoven material layer 14c. The cover layer 32c is sewn to the nonwoven material layer 12c and/or to the further nonwoven material layer 14c. For the purpose of fixating the cover layer 32c to the nonwoven material layer 12c and/or to the further nonwoven material layer 14c, the textile composite material 10c comprises at least one seam connection element 42c. Regarding further functions and characteristics of the textile composite material 10c shown in FIG. 4, the textile composite material 10a described in the description of FIGS. 1 and 2 may be referred to.