JPS5828111B2 - Self-supporting molded lining - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION For the lining of automobiles, containers, etc., there is a need for insulating, lightweight materials that can be assembled in a minimum amount of time.

Above all, roof linings of motor vehicles, so-called "autohirrmel", require mounting elements of this nature which are at the same time dimensionally stable and as self-supporting as possible.

In contrast, traditionally used systems such as polyurethane flexible foams, synthetic leathers, phenolic resin-impregnated fiber fleeces and needled fleeces serve only as simple upholstery or coverings for automobile roofs and It is neither self-supportingly configurable nor particularly lightweight.

The disadvantages of the conventional systems have been overcome according to the invention in lining materials for automobiles, containers, etc., in which foam sheets of cross-linked polyethylene of the same or different densities have reinforcing layers bonded on both sides. The molded liner is a self-supporting structure characterized in that the foam sheet is frame-laminated to a reinforcing layer, such as kamphu fiber or kraft paper, and is formed into the liner by applying pressure and heat.

The multilayer body can be formed as a single plate by compression molding or as a flat extrusion body (Flach S) constructed from the aforementioned layers in succession.
trang).

The respective layers are preferably used as sheets.

Despite the bending strength obtained, these layers or the boards cut from the extrudates or sheets can be deformed within certain limits, so that they can be adapted, for example, to the shape of a car roof or a container.

Above all, for use as automobile roofs, multilayer self-supporting structures are very advantageous.

In this case, the support only takes place on the side parts of the motor vehicle or on one frame or on a few struts or a few supporting elements mounted from the outside.

The underside of the vehicle ceiling can be provided with a decorative layer or an airborne sound absorbing layer during manufacture or afterwards.

With the advantageous use as linings of motor vehicles and containers, in particular as car ceilings for roof coverings, the multilayers are generally used as impact-resistant, elastic and at the same time bend-resistant structures, for example for the covering of containers. It can be used as a board, as a side wall member of a vehicle, as a cushion board and as a self-supporting structural soundproofing cladding.

Although non-crosslinked polyethylene foam can be used as the polyethylene foam sheet, it is especially advantageous to use a crosslinked polyethylene foam.

As reinforcing materials thermoplastics or thermosetting plastics, in particular polyethylene, polypropylene, ethylene-
Preference is given to boards made of propylene copolymers, and also parcan fiber boards, such as boards made of kraft paper or other cellulosic materials impregnated with phenolic or melamine resins, but also polyvinyl chloride, stretched metal, metal knits. Alternatively, plates made of resin-impregnated glass fiber fleece or fabric are also possible.

As reinforcing layer it is possible to use a continuous flat, perforated or mesh plate.

On the closed side, surfaces with knots, mesh or webs are advantageous;

It is also possible to design it as a grid-like or optionally perforated plate or as a plate with flat or convex webs or honeycombs.

In order to achieve the desired weight reduction, it is advantageous for the plate to be sufficiently perforated.

It is also possible to reinforce the plastic used, for example with glass fibers.

Another advantageous and advantageous embodiment of the reinforcing layer is obtained if it is constructed as a reinforcing profile that tensions the multilayer body longitudinally and/or transversely.

A structure consisting of another intermediate layer of the multilayer, for example two reinforcing plates, is also possible, in which case the intermediate foam sheet preferably has a higher density than the outer foam material layer.

The layer of foam material forming the back surface in the mounting state may also have a high density.

The multilayer body can be manufactured by any suitable method that achieves a permanently strong bond.

For example, a sheet of foam material that has been preheated by direct or indirect heating can be bonded to a reinforcing plate in a laminating device under the application of a slight pressure.

Heating can then take place by direct flame application, with hot air, with a radiator or resistance heating, or in a heating tunnel.

Furthermore, it is possible to bond with or without adhesive media such as melt adhesives or two-component adhesives.

Finally, it is also possible to bond the foam sheets during the production of the multilayer by foaming them, so that the foam sheet that forms may pass into the perforations of the reinforcing plate or on the other side of the reinforcing plate. As a result of this penetration, a direct bonding of both foam sheets occurs.

The multilayer body produced and constructed in this way is sufficiently stable to solvents, in particular sufficiently resistant to benzine, is resistant to corrosion and non-water-absorbing.

Bonding and laminating properties to other materials are excellent.

A particular advantage lies in the good shock absorption combined with high stiffness at a relatively small thickness and low weight of the plate.

This combination of properties is not present in the respective components of the multilayer, the foam material sheet and the reinforcement.

The corresponding measured values are much greater than the sum of the individual measured values of the components, thus resulting in a surprising effect of the selection of materials and the construction of the multilayer.

The E-modulus, measured as a measure of stiffness, is high compared to known multilayer bodies made of inter alia plastics.

This makes possible a very advantageous construction as a self-supporting plate, to which the crosslinked polyethylene of the foam sheet which is advantageously used contributes effectively.

If a reinforcing profile is used, this is preferably provided on the back side of the lining, that is to say, for example, on the side facing the roof of the vehicle body.
It is glued to the lining material or firmly bonded to the foam material of the lining material by the action of heat.

The use of reinforced profiles which are specially shaped in cross-section and, for example, corrugated, meet the mechanical requirements to a particularly high degree (therefore only a relatively small number of reinforcing profiles have to be used in the lining material). has proven to be particularly effective.

In addition to sheet metal strips, plastics, in particular thermosetting plastics, are also suitable as processing materials for the reinforcing profiles.

In one embodiment of a lining material for a car ceiling constructed according to the invention, a sheet metal strip, for example corrugated, is assembled on the back side of a canopy made of polyethylene (PE) foam, for example compressed. A reinforcing grid with wide openings is provided, which tensions the vehicle ceiling longitudinally and/or laterally.

The reinforcing grid is connected to the polyethylene foam ceiling, for example by gluing or simply under the action of heat.

In addition to serving as a support for the polyethylene foam ceiling, the webs of the reinforcing grid simultaneously serve as fixing elements for the entire ceiling within the vehicle body.

Next, the present invention will be described in detail with reference to embodiments shown in the drawings.

The drawing shows a self-supporting motor vehicle roof in an implied cross-section when installed inside the vehicle body.

A car body roof 1 is rigidly connected to a reinforced arcuate frame 2.

The actual automobile ceiling consists of a lining 3 which is manufactured, for example, as a polyethylene foam molding with a reinforcing profile 4 .

The reinforcing profile 4 is firmly connected to the back side of the foam molded part 3.

The reinforcing profile covers the vehicle cabin longitudinally and/or laterally.

In that case, it is also conceivable to provide the longitudinal reinforcing profile only in the peripheral region.

The overall arrangement of the reinforcing profiles may be grid-like.

The spacing of the reinforcing profiles depends on the stiffness and coefficient of thermal expansion of the foam material used to form the lining 3.

The air gap 5 between the lining 3 and the vehicle roof 1, which is shown in the drawing but is not absolutely necessary, further increases the thermal insulation effect of the ceiling.

It is also quite possible to use the reinforcing profiles in multilayer motor vehicle ceilings that already have a reinforcing layer.

Preferably, however, the lining 3 is constructed as a multi-layered body consisting of a continuous flat reinforcing layer with polyethylene foam sheets on both sides, in which case a number of polyethylene foam sheets of equal or different density are provided, depending on the thickness of the lining. They can also be continued sequentially.

Next, examples of various multilayer bodies will be shown.

Example, 1 Cross-linked polyethylene foam (volume weight 30 kg/m3)
5mm thick sheet, a) 5mm thick polypropylene web board or b) polyethylene honeycomb structure board and 5mm thick polyethylene foam sheet (density 30k)
g/m3) by direct gas flame lamination (F l
ammk a sc h i e r e n )
heated to a surface temperature of 230°C and heated to 1.5°C between rolls.
They are firmly bonded by applying pressure at a low pressure.

Honeycomb structural plates and webs made of polyethylene or polypropylene offer the advantages of stiffness, thermal insulation through voids, and light weight, as well as strong bonding through lamination with polyethylene foam.

Example 2 A 5 mm thick sheet of cross-linked polyethylene foam (density 30 kg/m3) and a) a 0.8 mm thick Palcan fiber sheet or b) a 0.3 to 0.3 mm thick Palcan fiber sheet, A 5 mm thick sheet of polyethylene foam (density 60 kg/m3), then a) a 0.8 mm thick Palcan fiber sheet or b) a 0.3 mm thick Palcan fiber sheet and newly crosslinked Polyethylene foam (density 30kg/
5 mm thick sheets of m3) are joined together by frame bonding.

In this case, no film or adhesive is required as adhesive medium.

Example 3 Sheet approximately 5 mm thick made of cross-linked polyethylene foam (density 30 kg/m3), honeycomb structural board 5-7 mm thick cut from resin-treated soda kraft paper, 5 m thick.
m of polyethylene foam (density 30 kg/m3),
Continuous interconnection using a) reactive adhesives based on polyurethane or b) hot-melt adhesives based on polyester.

Example 4 The material described in Example 1 is preheated to 150-170° C. and is pressure-molded in a press mold under a pressure lower than 2 ata to form a laminated molded member.

A strong bond is created.

In this case, it is also possible to simultaneously press-form, for example, the final shape of the vehicle roof, using a corresponding mold of the press.

Example 5 A heat-set elongated lattice with a thickness of 1.0 mm made of a) polypropylene or b) polyvinyl chloride (impact resistant) having a hot shape stability of 76 4mm cross-linked polyethylene foam (density 30k)
g/m3) and a thickness of 8 mm.
It is used as a bonding band between two sheets consisting of a material with a density of 40 kg/m3) and bonded together at 1600C to firmly bond them.

[Brief explanation of the drawing]

The drawing is a sectional view showing one embodiment of the lining material of the present invention. 1... Vehicle roof, 2... Reinforcement frame, 3... Lining material, 4... Reinforcement profile material,
5...Gap.

Claims (1)

[Claims] 1 Foam sheets made of crosslinked polyethylene of the same or different densities have reinforcing layers bonded on both sides,
A lining material for automobiles, containers, etc., characterized by a foam sheet laminated to a reinforcing layer made of cellulose material, parcant fiber, or kraft paper, and formed into a lining material by applying pressure and heat. Molded lining material with self-supporting structure.