KR100356412B1 - Internal Sheet of Moter and Method For Manufacturing The Same - Google Patents

Abstract

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molding material for automobile interior and a method of manufacturing the same, which are applied to a ceiling and a bonnet hood of an automobile to have excellent sound absorption and sound insulation. This molding material uses urethane foam in the manufacture of molding materials for automobile interiors, and by adhering the foamed plastic layer to the surface where the urethane foam is in contact with the car body, and by adhering the porous nonwoven fabric to the opposite side (the surface in contact with the car interior), And sound insulation are achieved at the same time. The manufacturing method of the molding base material is coated with a polyurethane foam sheet (Poly-Urethane Foam Sheet) to the foamed plastic sheet extruded through the extrusion nozzle and passed between the upper and lower press rollers, and then the polymer powder is dispersed and a reinforcing agent (non-woven fabric) is added. It is pressed by a press roller and melted with a heat press roller by adding a skin agent, and then passes through a cooling roller to cut to a predetermined size. Accordingly, the molding material effectively absorbs and blocks the inflow of noise generated from the outside of the car, and effectively absorbs the noise generated from the inside of the car, exerts sound absorption and sound insulation at the same time, and improves the reliability of the product. By reducing the production process of integrated molding materials in one process, it is possible to improve productivity while providing the effect of use in various places such as bonnet cover and door trim as well as automotive ceiling materials.

Description

Molding material for automobile interior and its manufacturing method {Internal Sheet of Moter and Method For Manufacturing The Same}

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molding material for automobile interiors, and more particularly, to a molding material for automobile interiors and a method for manufacturing the same, which are applied to a ceiling and a bonnet hood of an automobile to have excellent sound absorption and sound insulation. will be.

In general, the configuration of the molding materials for automobile interiors includes a base part that maintains form, mounting property, and sound absorption and sound insulation, a skin part that provides design, sound absorption, and cushioning, and a base part and a skin part that adhere to each other. It consists of an adhesive layer.

Glass wool mat, resin felt, paper board, etc. are currently used as materials, and these materials have advantages and disadvantages, and despite of various advantages, And the molding of the skin part is made of two steps, there is a problem that takes a lot of process cost and process time.

In order to solve this problem, in Europe, such as Germany and the United Kingdom, the glass reinforcing layer and the nonwoven fabric are urged to be integrated with an adhesive polymer (hot-melt) layer, and then the skin is laminated. Laminated and integrated sheets have been developed many years ago and are widely used. PU foam integral sheets can be molded in the shape of molds in one step, which can significantly reduce process costs. have. However, the urethane foam-integrated sheet has the advantages of being light and sound-absorbing, while the sound insulation is inferior to other materials, and the price increases due to the use of multiple layers of adhesive polymer (hot-melt). On the other hand, a method for manufacturing automotive interior parts that can be manufactured at low cost in a single process without increasing the surface designability while increasing the cushioning of the portion by increasing the thickness of the desired part of the product is disclosed in Japan. Patent Document No. 61-245384. The above technique is a method for producing an interior component part for automobiles by laminating a pad material on a desired part of a composite resin core material and coating the surface of the core material and the pad material with a skin material. In the press lower shape having the required shape of the surface, the composite handmade core material which was softened by heat was placed, and preformed into the desired part of the core material. Laminated pad material made of thermoplastic resin foam in reinforcement resin foam or heat-softened state, the core material and pad material should be coated next to the upper surface, and the skin material is laminated and press-welded corresponding to the press shape. Core material, pad material and skin material are integrally molded to the required shape, but the adhesive polymer is used instead of the adhesive polymer, so the air permeability of the adhesive layer is lowered, so that the sound absorbing performance of the substrate is lowered and the noise generated in the car interior is effectively prevented. There is a problem that can not achieve the fuel economy improvement of the vehicle because it can not absorb, the weight of the seat is weighted.

The present invention has been made in order to solve such a conventional problem, the reinforcing layer is bonded to the upper and lower sides of the urethane foam, the foam plastic is bonded to the surface in contact with the car body, the non-woven fabric is bonded to the opposite surface is generated outside the car To effectively block the inflow of noise, and to effectively absorb the noise generated in the interior of the car to provide a molding material for the interior of the car to exhibit sound absorption and sound insulation at the same time on the substrate.

In addition, the present invention reduces the use of an adhesive polymer (Polymer; Hot-Melt) layer by directly adhering urethane foam in the process of making a foamed plastic sheet, manufacturing method for automobile interior molding materials for manufacturing a urethane foam integrated sheet at low cost To provide.

The above object is, according to the present invention, using a urethane foam in the manufacture of the molding material for automobile interior, the polyurethane foam adheres the foamed plastic layer on the surface in contact with the car body, and the porous non-woven fabric on the opposite surface (face in contact with the car interior) It is achieved by the molding material for automobile interior, characterized in that at the same time to achieve the sound absorption and sound insulation.

Here, the foamed plastic is preferably used to be lighter than the non-foamed plastic sheet of the same thickness by using a foam sheet foamed 2 to 80 times.

The foamed plastic is composed of polyethylene (Poly Ethylene (LDPE, HDPE, LLDPE)}, polyurethane (Poly Urethane), polyvinylacetate (Ethylene Vinyl Acetate), polypropylene (Poly Propylene), styrene block copolymer (Styrenic Block) Copolymer, Poly Amide, Ethylene Vinyl Chloride (Evcl), NBR-based, SBR-based polymer (polymer) or at least one CO-polymer (Polymer) is mixed in a certain ratio, wax, plasticizer It is preferable to use a modified polymer (Polymer) modified by using a filler or the like as an additive.

Here, the porous nonwoven fabric has a weight of 50 ~ 300g / ㎡, and as a kind of fibers constituting the nonwoven fabric, polyester (PET), flame retardant polyester, polypropylene (PP), viscose rayon (VR), nylon, carbon fiber, PVC fiber It is preferable to form a continuous sheet by mixing synthetic fibers such as and one or two or more fibers among natural fibers such as cotton, hemp, wool and silk at a constant ratio.

Here, the components of the particulate adhesive polymer (Polymer (Hot-Melt)) is polyethylene {Poly Ethylene (LDPE, HDPE, LLDPE)}, polyvinylacetate (Eyhylene Vinyl Acetate), polypropylene (Poly Prophylene), styrene block copolymer (Styrenic Block Copolymer), Nylon (Poly Amide), Polyurethane (Poly Urethane), ethylene vinyl chloride (Evcl), NBR, one of the polymer (Polymer) of the SBR polymer or two or more CO-polymer (Polymer) It is preferable to use it as an adhesive polymer (Polymer; Hot-Melt) layer in which a modified polymer modified by mixing at a predetermined ratio or modified with a wax, a plasticizer, a filler, a polar material, etc. as an additive.

In addition, the object is to apply a polyurethane foam sheet (Poly-Urethane Foam Sheet) to the foamed plastic sheet is extruded through the extrusion nozzle and passed between the upper and lower press rolls, the adhesive polymer powder is dispersed and a reinforcing agent (non-woven fabric) In addition, it is achieved by a method for manufacturing a molding machine for automobile interiors, which is pressed by a press roller, melted by a heat press roller by adding a skin material, and then cut into a predetermined size by passing through a cooling roller.

Here, the urethane foam and the foamed plastic can be directly bonded by using the residual heat of the extruded plastic sheet without using an adhesive polymer (hot-melt) layer when the plastic sheet is extruded. It is desirable to.

Here, when adhering urethane foam and porous nonwoven fabric and adhering porous nonwoven fabric and epidermal agent, do not use adhesive film but apply power (Polymer) polymer (Hot-Melt) power of 10 ~ per meter. Using 80 g, it is desirable to be able to minimize the reduction of the sound absorption effect.

1 is a cross-sectional view of a molding substrate according to the present invention,

2 is a manufacturing process diagram of a molding substrate according to the present invention.

Explanation of symbols on the main parts of the drawing

One; Extruder 2; Extrusion nozzle

3; Foamed plastic sheet 4; Polyurethane Foam Sheet

5,6,7,8,9,10; Press roller 12; Polymer Powder

13; Stiffeners 14; Cuticle

16,17; Heater press roller 21; Urethane Foam

22; Foamed plastic layer 23; Porous Nonwoven Layer

25; Cuticle

Hereinafter, the most preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those skilled in the art can easily practice the present invention.

1 is a cross-sectional view of a molding substrate according to the present invention, Figure 2 is a manufacturing process diagram of the molding substrate according to the present invention.

As shown in FIG. 1, the molding base material is a porous nonwoven fabric layer 23, a urethane foam 21, and a foamed plastic layer 22 stacked on the lower end of the foreskin material 25.

The foamed plastic layer 22 is bonded to the surface in which the urethane foam 21 is in contact with the vehicle body, and the porous nonwoven fabric 23 is bonded to the opposite surface, which is in contact with the vehicle interior, so that one side of the urethane foam 21 is in contact with the vehicle body. It effectively blocks the inflow of noise generated from the outside of the vehicle through the foamed plastic layer 22 attached to the surface), and the porous nonwoven fabric layer attached to the surface in contact with the interior of the car, which is the opposite side of the foamed plastic layer 22. Through the 23 and the skin 25, the noise generated in the vehicle interior is effectively absorbed, and the sound absorbing and sound insulating effects are exerted simultaneously on the substrate.

In the case of the foamed plastic used in the present invention, the sound insulation performance is high because of the relatively high density compared to the nonwoven fabric used on the opposite side. It is a natural principle that sound insulation performance is better with higher density. Such foamed plastic is mixed with a foaming agent in the manufacture of a plastic resin to be foamed and introduced into the extruder, and foamed by the heat applied during extrusion, and the control of the foaming ratio can be controlled by the amount of foaming agent.

The foamed plastic layer 22 is light weight compared to the non-foamed plastic sheet of the same thickness by using a foam sheet foamed 2 to 80 times, it is possible to improve the fuel economy of the vehicle.

Although the foaming ratio is suitably 2 to 80 times foaming, the foaming ratio which is more suitable for the objective of this invention is 4 to 20 times foaming. When the foaming ratio is 4 times or less, the weight of the plastic is increased, so that the weight of the molding material can not be reduced, and the material cost is also increased. In addition, when the foaming ratio is 20 times or more, the density is too low, the sound insulation performance is bad.

Components of the foamed plastic layer 22 include polyethylene (Poly Ethylene (LDPE, HDPE, LLDPE), Polyurethane (Poly Urethane), Polyvinylacetate (Ethylene Vinyl Acetate), Polypropylene (Poly Propylene), Styrene Block Copolymer ( Styrenic Block Copolymer), Nylon (Poly Amide), Ethylene Vinyl Chloride (Evcl), NBR-based, SBR-based Polymers (Polymers) or one or more CO-Polymers (Polymers) Modified polymer modified with additives, plasticizers, fillers, etc. is used.

The porous nonwoven fabric layer 23 has a weight of 50 to 300 g / m 2, and is a kind of fibers constituting the nonwoven fabric, such as polyester (PET), flame retardant polyester, polypropylene (PP), viscose rayon (VR), nylon, and carbon fiber. And continuous sheeting by mixing one or two or more kinds of synthetic fibers such as PVC fibers, and natural fibers such as cotton, hemp, wool, and silk at a constant ratio.

Part of the particulate adhesive polymer (Polymer (Hot-Melt)) is polyethylene {Poly Ethylene (LDPE, HDPE, LLDPE)}, polyvinylacetate (Ethylene Vinyl Acetate), polypropylene (Poly Propylene), styrene block copolymer (Styrenic) Block Copolymer), Nylon (Poly Amide), Polyurethane (Poly Urethane), Ethylene Vinyl Chloride (Evcl), NBR-based, SBR-based polymer (Polymer) of one polymer or two or more CO-polymer (Polymer) An adhesive polymer (Polymer (Hot-Melt)) layer 24a (24b) is used in which a modified polymer modified by mixing at a predetermined ratio or modified with a wax, a plasticizer, a filler, a polar material, etc. as an additive.

2 is a manufacturing process diagram of a molding substrate according to the present invention. The method of manufacturing the molding material is a polyurethane foam sheet (Poly-Urethane Foam Sheet) (4) to the foamed plastic sheet (3) which is extruded through the extrusion nozzle (2) of the extruder (1) as shown in FIG. After passing through between the upper and lower press rolls (5) and (6), the polymer powder 12 is dispersed and a reinforcing agent (nonwoven fabric) 13 is added and pressed with a press roller 7, and the skin agent 14 is again ) Is preheated with the heater 15, and then melted with the upper and lower heater press rollers 16 and 17, and then cut through the cooling rollers 18 and 19 to a predetermined size to obtain a molding material.

Here, the urethane foam layer 21 and the foamed plastic layer 22 are directly adhered by using the residual heat of the extruded plastic sheet without using an adhesive polymer (hot-melt) layer when the plastic sheet is extruded. In order to reduce the production cost, the adhesive polymer (Hot-Melt) during the adhesion of the urethane foam layer 21 and the porous nonwoven fabric layer 23 and the adhesion of the porous nonwoven fabric layer 23 and the skin 25. When the film is used, the film is not breathable and there is a problem of reducing the sound absorbing performance of the molding material, so in the present invention, without the use of an adhesive film, it is a powder of power (Polymer) (Hot-Melt) powder Use 10 to 80 grams per cubic meter of power to minimize the reduction of sound absorption.

In the present invention, it is possible to manufacture the substrate at a much lower cost than the molding substrate used in Europe, the United States, and the like. This is because the urethane foam, which is sliced to a certain thickness, is directly supplied onto the melted plastic during extrusion of the foamed plastic, thereby adhering without using a separate adhesive polymer (hot-melt) layer. At this time, the urethane foam supplied must blow out the fine urethane fragments broken by the high-pressure injector. The urethane microflakes crumble during slicing and transport and adhere to the urethane surface, which degrades the adhesion when adhering to the foamed plastic and the nonwoven fabric on the opposite side.

In addition, in the present invention, in order to maximize the sound absorbing performance of the noise generated in the interior of the vehicle, without using an adhesive film, the adhesive polymer (Polymer; Hot-Melt) is pulverized to a suitable size 20 ~ 80g / ㎡ Sprinkle evenly and use as an adhesive. The adhesive polymer powder (Polymer Powder) used in this way can maintain the air permeability of the adhesive layer to minimize the degradation of the sound absorption performance of the substrate, it is excellent in sound absorption performance compared to the substrate using the adhesive film.

As described above, the present invention effectively absorbs and blocks the inflow of noise generated from the outside of the vehicle by the molding material, effectively absorbs the noise generated from the interior of the car, and exhibits sound absorption and sound insulation at the same time, thereby improving product reliability. By reducing the use of adhesives, it is possible to produce integrated molding materials in one process, thereby improving productivity, and to use them in various places such as bonnet covers and door trims as well as automotive ceiling materials.

Claims (8)

In the molding material for automobile interior, Urethane foam is foamed 2 to 80 times on the surface in contact with the car body, and the components are polyethylene {Poly Ethylene (LDPE, HDPE, LLDPE)}, polyurethane (Poly Urethane), polyvinylacetate (Ethylene Vinyl Acetate), polypropylene (Poly Propylene) ), Styrenic Block Copolymer (Styrenic Block Copolymer), Nylon (Poly Amide), Ethylene Vinyl Chloride (Evcl), NBR-based, SBR-based polymer (Polymer), or at least one CO-polymer (Polymer) Is mixed at a certain ratio, or a foamed plastic layer made of a foamed sheet made of a modified polymer modified with wax, plasticizer, filler, etc. is added. 50 to 300 g / m2, which is a kind of nonwoven fabric, and includes synthetic fibers such as polyester (PET), flame retardant polyester, polypropylene (PP), viscose rayon (VR), nylon, carbon fiber, PVC fiber and cotton Natural islands such as horses, hemp, wool and silk An automobile characterized in that it is configured to impart sound absorption and sound insulation by adhering a porous nonwoven fabric which is continuously sheeted by mixing one or two or more kinds of fibers at a predetermined ratio by using a particulate adhesive polymer (hot melt). Molding materials for interiors. (delete) (delete) (delete) The method according to claim 1; The components of the particulate adhesive polymer (Polymer (Hot-Melt)) include polyethylene {Poly Ethylene (LDPE, HDPE, LLDPE)}, Polyurethane, Polyvinyl Acetate, Polypropylene, Styrene Block Copolymer (Styrenic Block Copolymer), Nylon (Poly Amide), Ethylene Vinyl Chloride (Evcl), NBR-based, SBR-based polymer (Polymer) of one kind or two or more kinds of CO-polymer (Polymer) A molding material for automobile interiors, characterized in that it is used as an adhesive polymer (Polymer; Hot-Melt) layer in which a modified polymer modified in proportion or modified with wax, plasticizer, filler, polar material, etc. as an additive. After supplying Polyurethane Foam Sheet (Poly-Urethane Foam Sheet) to the foamed plastic sheet extruded through the extruded nozzle, it passes through the upper and lower press rollers, and then spreads the adhesive polymer powder and adds a reinforcing agent (nonwoven fabric) to the press roller. A method of manufacturing a molding material for automobile interiors, which is pressed and melted with a heat press roller again by adding a skin agent, and then cutting through a cooling roller to a predetermined size. The method according to claim 6; In order to reduce the production cost by directly bonding the urethane foam and the foamed plastic sheet by using the residual heat of the extruded plastic sheet without using an adhesive polymer (hot-melt) layer when the plastic sheet is extruded Method for manufacturing a molded vehicle interior material, characterized in that. The method according to claim 6; When bonding urethane foam and porous nonwoven fabric and porous nonwoven fabric and epidermal agent, 10 ~ 80g of Power (Polymer) (Hot-Melt) powder (Power) is used without adhesive film. Method for manufacturing a molding machine interior material, characterized in that to minimize the reduction of the sound absorbing effect.