Composite component containing a polychloroprene and/or polyurethane binder

Abstract

The invention relates to a method for producing a composite component, comprising the steps: i) applying an aqueous composition, which contains a polychloroprene dispersion and/or a polyurethane dispersion, to at least one nonwoven; ii) coagulating the aqueous composition on the nonwoven by bringing the aqueous composition into contact with a coagulant and/or heating to 80 to 220 C., in order to form a semifinished product; and iii) optionally attaching a decoration, which comprises an adhesive film; and iv) thereafter, shaping the semifinished product from step ii) or iii) by pressing and/or heating to 30 to 220 C., in order to obtain the composite component, characterized in that the aqueous composition contains at least one thickener. The invention further relates to the use of the composite component of the invention as part of an interior trim, of a sun visor, of a support part, of a 2- or 3-dimensional sound-proofing panel, of a 3D-printed component, of a padding material, of a collision protection means, of a seat shell and of an impact isolation means.

Claims

1. A composite component obtained by a process comprising the steps of: i) applying an aqueous composition comprising a polychloroprene dispersion and/or a polyurethane dispersion to at least one nonwoven web; ii) coagulating the aqueous composition on the nonwoven web by contacting with a coagulant and/or heating to 80 to 220 C. in order to form a semifinished product comprising a binder formed from the aqueous composition; iii) optionally applying a decoration including an adhesive film; iv) then shaping the semifinished product from step ii) or iii) by pressing and/or heating to 30 to 220 C., in order to obtain the composite component; and v) optionally applying a layer to a portion or the whole surface of the composite component and then optionally applying a decoration, wherein the aqueous composition comprises at least one thickener, wherein the aqueous composition further comprises an aqueous silicon dioxide dispersion in the amount of 9.9 to 90% by weight, based on the total weight of the nonvolatile components of the aqueous composition.

2. An article comprising the composite component as claimed in claim 1.

3. A method comprising utilizing the composite component as claimed in claim 1 as a constituent of an interior trim part, a sunvisor, a load-bearing part, a 2- or 3-dimensional soundproofing panel, a 3-dimensional printed component, a cushioning material, a collision protection barrier, a seat bucket or an impact insulation.

4. The composite component of claim 1, wherein the polychloroprene dispersion and/or the polyurethane dispersion has an average particle size of 60 to 300 nm.

5. The composite composition of claim 1, wherein the aqueous composition further comprises additives.

6. The composite component of claim 1, wherein the aqueous composition comprises: 9.9% to 90% by weight of the polychloroprene dispersion and/or the polyurethane dispersion; 0.01% to 15% by weight of the at least one thickener; 9.9% to 90% by weight of the aqueous silicon dioxide dispersion; and 0% to 50% by weight of additives; based in each case on the total weight of the nonvolatile components of the aqueous composition.

7. The composite component of claim 1, wherein the aqueous composition has a viscosity of 500 to 7000 mPa*s, determined according to DIN ISO 2555 by means of a Brookfield rotary viscometer with spindle #2 up to a viscosity of 2500 mPa*s, and above that with a spindle #3, at 12 rpm and 23 C.

8. The composite component of claim 1, wherein, after step ii), 20 to 600 g/m2 dry weight of binder is present on a nonwoven web.

9. The composite component of claim 1, wherein the at least one nonwoven web consists of polyolefin-, polyethylene terephthalate-, polyether sulfone-, glass-, mineral-, carbon-, or plant-based fibers, such as cotton fibers, coconut fibers, rice cotton fibers, or mixtures thereof; and/or in that a nonwoven web has a density of 300 to 1200 g/m2.

10. The composite component of claim 1, wherein at least two nonwoven webs are used, and the binder is between the nonwoven webs.

11. The composite component of claim 1, wherein a coagulant is used.

12. The composite component of claim 1, wherein the decoration, a textile fabric with foam backing, is wetted with binder on the foam side in step iii), but is not dried or not dried completely, so as to leave a moist adhesive film, and the binder-coated decoration is placed by the moist adhesive film side onto the binder-coated nonwoven web from step ii) or is run into a press by respective rolls and then pressed in step iv).

13. The composite component of claim 1, wherein the composite component is a constituent of an interior trim part, a sunvisor, a load-bearing part, a 2- or 3-dimensional soundproofing panel, a 3-dimensional printed component, a cushioning material, a collision protection barrier, a seat bucket or an impact insulation.

Description

EXAMPLES

(1) The present invention is elucidated in detail hereinafter with reference to working examples and FIGS. 1 to 3. These figures show:

(2) FIG. 1 a first production process for a composite component of the invention,

(3) FIG. 2 a second production process for a composite component of the invention and

(4) FIG. 3 a third process for production of a composite component of the invention.

(5) FIG. 1 shows a first continuous production process for creation of a composite component 9 of the invention. In this process, a nonwoven web 1 is fed from a roll 2 via two guide rolls 3 to a binder application device 4, a spraying device in the present context. The binder application device 4 applies the binder to both sides of the nonwoven web 1. The nonwoven web 1 thus coated is then fed to a reactant application device 5, where a coagulant is applied by spraying. Subsequently, the nonwoven web 1 is fed to a press 6 with hydraulically actuated and heated press tables 7. The coated nonwoven web 1 is pressed therein into the desired shape, heated and simultaneously cut to the desired size with a stamping device likewise disposed in the press 6. The cutting or punching of the composite component 9 is especially performed in a pinch edge mold. On attainment of the residence time, the composite component 9 of the invention is then ejected and the process is repeated.

(6) FIG. 2 shows an alternative continuous production process for creation of a composite component 9 according to the invention. This differs from the process shown in FIG. 1 essentially in that the binder application device is implemented in the form of a dip bath 10, through which the nonwoven web 1 is guided by means of a squeeze roll arrangement 11, in the course of which it is contacted with the binder. In the squeeze roll arrangement 11, the weight of the rolls generates pressure on the nonwoven web 1 conducted between the rolls and hence controls the amount of binder applied. When it leaves the dip bath 10, the coated nonwoven web 1 is guided through a gap between two stripping rolls 12, by means of which excess binder is removed and fed back to the dip bath 10. The rest of the process steps proceed in the manner described in FIG. 1.

(7) FIG. 3 shows a third variant of a continuous production process of the invention. This is based essentially on the procedure shown in FIG. 2, except that, in the embodiment shown in FIG. 3, the press 13 does not include a heated press table, but an unheated mold. The coated nonwoven web material is heated on one side or both sides directly upstream of the press 13 by a heating station 14, by means of a hotplate or infrared radiative heating. Typical heating temperatures here are about 220 C. Since this upstream heating station 14 already starts the curing reaction of the binder, it is possible here to dispense with any additional heating of the press mold or stamping tool in the pressing and stamping operation. The nonwoven web has a temperature of 30 C. to 220 C. on entry into the press 13, according to the transport speed and distance between the heating station 14 and the press 13.

Production of the Aqueous Binder Dispersion

Example of a Mixture Based on Polychloroprene

(8) Into an initial charge of 2690.8 g of Dispercoll C 2325 (polychloroprene dispersion, solids content 55%, Covestro Deutschland AG) are metered successively, while stirring, 64.69 g Rhenofit DDA-50 EM (aging stabilizer, solids content 50%, Lanxess AG), 64.69 g of Emulvin W (emulsifier, solids content 65%, Lanxess AG), 6278.54 g of Dispercoll S 4510 (silica sol dispersion, solids content 45%, Covestro Deutschland AG), 520.63 g of Martinal OI-104 (flame retardant based on aluminum hydroxide, Martinswerk GmbH) and 523.04 g of Borchigel A LA (thickener, solids content 10%, 1:1 diluted with water to solids content 5%, OMG Borchers GmbH), and the mixture is stirred for a further 30 min. Subsequently, the dispersion is left to stand at RT for 24 hours. The resultant aqueous binder dispersion has a solids content of 50%, a pH of 9.9 and a viscosity of 1240 mPas.

Example of a Mixture Based on Polyurethane

(9) Into an initial charge of 3218.1 g of Dispercoll U 53F (polyurethane dispersion, solids content 40%, Covestro Deutschland AG) are metered successively, while stirring, 33.9 g of Rhenofit DDA-50 EM (aging stabilizer, solids content 50%, Lanxess AG), 33.8 g of Emulvin W (emulsifier, solids content 65%, Lanxess AG), 2335.8 g of Dispercoll S 3030-1 (silica sol dispersion, solids content 30%, Covestro Deutschland AG), 271.51 g of Martinal OI-104 (flame retardant based on aluminum hydroxide, Martinswerk GmbH) and 382.5 g of Borchigel A LA (thickener, solids content 10%, 1:1 diluted with water to solids content 5%, OMG Borchers GmbH), and the mixture is stirred for a further 30 min. Subsequently, the dispersion is left to stand at RT for 24 hours. The resultant aqueous binder dispersion has a solids content of 37%, a pH of 10.2 and a viscosity of 1750 mPas.

Examples 1 and 2: Production of the Composite Components (Trim Parts)

(10) For the production of the composite components, configured as trim parts in the present case, a 1000 g/m.sup.2 PES nonwoven web composed of 60% by weight of black PES and 40% by weight of white PES bi-component fiber is used, giving rise to a gray nonwoven web. Such a nonwoven web was wetted in each case with one of the above-described compositions at 300 g/m.sup.2 dry weight and blown into the nonwoven web with the aid of compressed air. Subsequently, the material was heated at 200 to 220 C. for about 30 to 90 sec and then pressed in a mold at room temperature, giving the trim parts.