Motor vehicle floor covering, boot or trunk covering or load compartment covering having a structurally needle-punched carpet surface

Abstract

The object of the invention is a method of manufacturing a three-dimensionally shaped floor paneling, luggage compartment paneling or load floor paneling for motor vehicles, the carpet surface of which has a needled structure on the visible side, as well as the panellings themselves.

Claims

1. A method for the production of a three-dimensionally shaped needled non-woven carpet for a floor paneling, luggage compartment paneling or load floor paneling of a motor vehicle with a structurally needled, deformation-resistant surface having a grammage of the paneling in the range from 180 g/m.sup.2 to 700 g/m.sup.2, characterized in that two or more needle are arranged in segments across the width of a needle board, wherein with a defined setting of the feed/stroke of the initial non-woven material as well as a defined setting of the penetration depth, the structured paneling surface from the initial non-woven material is produced, the paneling is provided with one or more underlayers and is deformed; the needle board is divided into different segments in a transverse direction, wherein alternating a first needle type and a second needle type is arranged in segments; and the first needle type is a needle type 1518433, R222 G 2017 and the second needle type is a needle type 1518363, R333.

2. The method according to claim 1, characterized in that needles are used which differ in fineness, notch spacing, notch size, working part geometry, and distance from tip to first notch.

3. The method according to claim 1, characterized in that the needle board is divided into four different segments, needle type 1 fine, needle type 2 coarse, needle type 1 fine, needle type 2 coarse, in a transverse direction.

Description

EXAMPLE OF EXECUTION

(1) For the production of a deformation-resistant/stable, structure-needled floor paneling, a pre-non-woven material made of 7 dtex 100% PES fibres with a length of 64 mm was used as the initial non-woven material; the grammage was 400 g/m2.

(2) The needle board was divided into four different segments in the transverse direction:

(3) Needle type Mine)Needle type 2 (coarse)Needle type 1 (fine)Needle type 2 (coarse)

(4) Commercially available needles from Groz-Beckert KG, Albstadt, Germany were used: Needle type 1: 1518433 R222 G 2017 Needle type 2: 1518363 R333 G 2007

(5) These needles differ in fineness, number of notches, notch size and distance from tip to first notch.

(6) During production, it was necessary to find the optimum penetration depth and the optimum feed/stroke by trial and error. For the needled non-woven carpet shown in FIG. 1, the feed/stroke was 1.55 mm/stroke and the penetration depth 12 mm.

(7) The structurally needled non-woven carpet floor produced in this way was then bound with 80 g/m2 of commercial latex and coated with 80 g/m2 of commercial PE.

(8) Subsequently, the needled non-woven carpet floor with the underlayers (a) heavy foil 2.5 kg/m2 and (b) a non-woven foil 150 g/m2 was formed into a floor paneling upper product of a mid-range vehicle at the process parameters contact heating field 185 C./180 C., 58 sec; radiant heating field 150 C. and a tool closing time of 68 sec at the mould surface temperature of 5 C.

(9) FIG. 2 shows a section of the formed floor paneling upper product. The structuring, fine needle=fluffy, coarse needle=stripy, is clearly visible. The strip in between was only pre-needled.

(10) Specifically in FIG. 2, it can be seen that the structural needling of the carpet is deformation-appropriate and deformation-stable.

(11) By choosing the needle combinations, one could combine the carpet texturing in different ways.

(12) FIG. 3 shows another example of this: Needle type 1: 1525323.sub.1/2 R333 G3012 Needle type 2: 15203.sub.1/2 C333 G3012 Feed/stroke: 7.99 mm/stroke Penetration depth: 12 mm