KR100741377B1 - A manufacturing method of inner ceiling material using vehicles - Google Patents

A manufacturing method of inner ceiling material using vehicles Download PDF

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KR100741377B1
KR100741377B1 KR1020060031441A KR20060031441A KR100741377B1 KR 100741377 B1 KR100741377 B1 KR 100741377B1 KR 1020060031441 A KR1020060031441 A KR 1020060031441A KR 20060031441 A KR20060031441 A KR 20060031441A KR 100741377 B1 KR100741377 B1 KR 100741377B1
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South Korea
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layer
ceiling material
fiber
needle punching
lower fiber
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KR1020060031441A
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Korean (ko)
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손만호
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주식회사 만호
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/04—Punching, slitting or perforating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/04—Punching, slitting or perforating
    • B32B2038/042—Punching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00—Polyalkenes
    • B32B2323/04—Polyethylene
    • B32B2323/043—HDPE, i.e. high density polyethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/003—Interior finishings

Abstract

Provided is a recyclable inner ceiling material for automobiles, which prevents damages caused by glass type matters and adhesives, is manufactured at high productivity and at low cost, and exhibits superior cushioning properties and sound absorption. The inner ceiling material for automobiles is comprised of: upper and lower fiber layers(11,12) made out of a mixture of natural fiber and synthetic fiber in a form of sheet or plate with a web structure where inner fibers are physically connected by needle punching; a foam layer(13) interposed between the upper and the lower fiber layer(11,12), being impregnated to the bottom and the top of the upper and lower fiber layers(11,12) through needle punching; and an outer layer(14) bonded to at least one of the top surface of the upper fiber layer(11) and the bottom of the lower fiber layer(12).

Description

자동차 실내 천장재와 그 제조 방법{A manufacturing method of inner ceiling material using vehicles}Interior lighting material for automobiles and its manufacturing method

도 1은 본 발명 일실시예 천장재의 단면 구조도.1 is a cross-sectional structural view of an embodiment of the present invention ceiling material.

도 2는 본 발명 일실시예 제조 방법의 블록도.Figure 2 is a block diagram of a method of manufacturing an embodiment of the present invention.

((도면의 주요 부분에 대한 부호의 설명))            ((Explanation of symbols for main part of drawing))

11. 상부 섬유층 12. 하부 섬유층             11. Upper Fibrous Layer 12. Lower Fibrous Layer

13. 발포층 14. 표피층             13. Foam layer 14. Skin layer

본 발명은, 천연섬유와 합성섬유가 혼합된 상·하부 섬유층 사이에 발포층을 개재시킨 상태에서, 접착제가 아닌, 니들 펀칭 방법으로 상·하부 섬유층과 발포층을 물리적으로 결합시키고, 필요에 따라, 상부 섬유층 상면 또는 상·하부 섬유층의 각 상면과 저면에 고밀도 폴리에틸렌을 융착시킴으로써, 제조시 또는 사용시 접 착제에 의한 유해 성분 발생을 방지하면서 제조 비용을 절감하고, 고밀도 폴리에틸렌 표피층에 의해 적절한 강성을 가질 수 있도록 한, 자동차 실내 천장재와 그 제조 방법에 관한 것이다.The present invention is to physically combine the upper and lower fiber layer and the foam layer by needle punching method, not an adhesive, in the state of interposing the foam layer between the upper and lower fiber layer mixed with natural fibers and synthetic fibers, if necessary, By fusing high density polyethylene to the upper surface of the upper fiber layer or to the upper and lower surfaces of the upper and lower fiber layers, it is possible to reduce the manufacturing cost while preventing the generation of harmful components by the adhesive during manufacture or use, and to have adequate rigidity by the high density polyethylene skin layer. The present invention relates to a car interior ceiling material and a method of manufacturing the same.

산업 혁명 이후 만들어진 자동차는, 과학 기술의 발전과 함께 눈부실 만큼 발전해 왔으며, 오늘날 없어서는 안 될 현대 산업 사회의 가장 기본적인 운송수단으로서, 승용차의 경우에는 국내에서도 이미 생활 필수품들 중의 하나로 자리를 잡은 실정이다.Cars made after the Industrial Revolution have developed remarkably with the development of science and technology, and as the most basic means of transportation in the modern industrial society today, passenger cars have already established themselves as one of the necessities of life in Korea.

자동차는 사람이나 재화의 운송을 위한 목적으로 개발되었는 바, 초기 자동차의 경우에는 주행 기능만이 중요하였으나, 특히, 승용차의 경우, 생활 수준의 향상과 함께 단지 "탈것" 이상의 수준이 요구되고 있으며, 그에 따라, 단순 주행 기능 이외에 탑승자의 안전을 비롯한 편의성, 쾌적성 등을 위한 각종 부가 기능을 구비하게 되었다.Cars were developed for the purpose of transporting people or goods. In the case of early cars, only driving functions were important, but in the case of passenger cars, more than just a "mount ride" is required along with the improvement of living standards. Accordingly, in addition to the simple driving function, various additional functions for convenience, comfort, and the like of the occupant's safety are provided.

더욱이, 자동차가 필수품화되면서 자동차를 타면서 보내는 시간이 증가하게 됨은 물론, 자동차를 이용한 가족 단위의 여행이 증가하면서 자동차 실내에 사용되는 내장재에 대하여 요구되는 품질 수준이 높아지고 있는바, 종래의 자동차 실내에 사용되고 있는 내장재 중 특히, 직물류 내장재에 대하여 살펴보면 다음과 같다.In addition, as the automobile becomes a necessity, the time spent in riding a car increases, and as the travel of the family unit using the car increases, the level of quality required for the interior materials used in the car interior is increasing. Among the interior materials used in the fabric, in particular, look at the fabric interior materials as follows.

자동차에 사용되는 직물류 내장재는, 시트(seat), 헤드 레스트(head rest), 도어 트림(door trim), 리어 쉘프(rear shelf), 트렁크 트림(trunk trim), 실내 바닥, 천장 등에 주로 사용되는데, 시트, 헤드 레스트, 도어 트림, 리어 쉘프 등의 내장재는, 자동차의 고급화 및 먼지 축적 방지의 측면에서 근래에는 합성 가죽이나 천연 가죽 등으로 대체되고 있다.Textile interior materials used in automobiles are mainly used for seats, head rests, door trims, rear shelves, trunk trims, interior trims, ceilings, etc. Interior materials such as seats, head rests, door trims and rear shelves are being replaced by synthetic leather and natural leather in recent years in terms of high-quality automobiles and dust accumulation.

그리고, 각종 물건을 싣는 화물 적재함인 트렁크 트림용 내장재의 경우에는 적당한 강성과 적당한 미관 상태만 가져도 되는바, 그 종류에는 큰 문제가 없으며, 실내 바닥용 내장재의 경우에는 특히, 흡음성과 밟았을 때의 접촉감이 중요하기 때문에, 여전히 직물류가 적합하나, 차체 바닥에 깔린 상태이기 때문에 강성을 가질 필요는 없다.In addition, in the case of the trunk trim interior material, which is a cargo box for loading various things, it may have only moderate rigidity and a moderate aesthetic state, and there is no big problem in the type thereof, and in the case of interior floor interior material, especially when absorbing and stepping on Because the contact feeling is important, textiles are still suitable, but they do not have to be rigid because they are laid on the floor of the body.

그러나, 천장에 사용되는 천장재는, 자동차의 루프 패널 저면에 그 상면이 결합되어 저면이 외부로 하향 노출된 상태로 사용되는바, 천장면 즉, 천장재의 저면이, 자중에 의해, 바닥을 향하여 늘어지지 않을 정도의 강성을 가져야 함은 물론, 외부 소음 유입이 최소화되도록 적절한 흡음성과 함께 단열성을 가져야만 한다.However, the ceiling material used for the ceiling is used in a state where the upper surface is coupled to the bottom of the roof panel of the car and the bottom surface is exposed downward, so that the ceiling surface, that is, the bottom surface of the ceiling material, does not fall toward the floor by its own weight. Not only should it be rigid, but it must also have insulation with adequate sound absorption to minimize the ingress of external noise.

따라서, 종래의 자동차 천장재의 경우에는, 강성을 가진 지지층과 흡음단열층이 적층된 다층 구조의 내장재가 사용되었는 바, 합성수지판에 페놀 등의 열경화성 수지를 함침 또는 도포한 후 고온 고압 하에서 열간 성형한 레진 펠트나, 고온 고압으로 열간 성형한 열경화성 합성수지판의 양 표면에 부직포 등으로 이루어진 표피층을 적층 형성시킨 천장재를 예로 들 수가 있다.Therefore, in the case of a conventional car ceiling material, since a multi-layered interior material in which a rigid support layer and a sound absorbing heat insulating layer are laminated is used, a resin hot formed under high temperature and high pressure after impregnating or applying a thermosetting resin such as phenol to a synthetic resin board The ceiling material which laminated | stacked and formed the skin layer which consists of a nonwoven fabric etc. on both surfaces of the felt and the thermosetting synthetic resin board hot-molded by high temperature and high pressure is mentioned.

그러나, 상기와 같은 천장재는 열경화성 수지가 사용되기 때문에, 필요 이상으로 무거워지게 되고, 그에 따라 자동차 루프 패널의 강성을 높여 주어야 하는 등의 문제를 발생시키게 되거나, 자동차의 경량화에도 역행하게 될 뿐 아니라, 제조 과정이 복잡하며, 그 재질이 딱딱하여 탑승자의 안전과 승차감에 좋지 않은 영향을 미치는 문제가 초래될 수 있다.However, the ceiling material as described above is used because the thermosetting resin, it becomes heavier than necessary, thereby causing problems such as increasing the stiffness of the car roof panel, or not only against the weight reduction of the car, The manufacturing process is complicated, and the material is hard, which may cause problems that adversely affect the occupant's safety and ride comfort.

따라서, 상기와 같은 문제점을 해결하기 위하여 폴리우레탄 수지를 발포 성형한 폴리우레탄 폼의 양 표면에, 글라스 파이버 또는 글라스 촙(glass chop) 등을 접착한 후 그 표면에 부직포 등으로 이루어진 표피층을 다시 적층 접착한 다층 구조의 복합 글라스 폴리우레탄 천장재가 개발되었다.Therefore, in order to solve the above problems, after adhering a glass fiber or glass chop, etc., to both surfaces of the polyurethane foam foamed with a polyurethane resin, a skin layer made of a nonwoven fabric or the like is laminated again on the surface. An adhesive multi-layered composite glass polyurethane ceiling has been developed.

그러나, 복합 글라스 폴리우레탄 천장재는, 각 층과 층이 접착제와 핫 멜트 필름 등에 의해 접착 결합될 뿐만 아니라, 다수의 가열 공정을 필요로 하기 때문에 제조 과정이 길어짐은 물론, 제조원가가 상승하게 되며, 재활용도 어렵다.However, the composite glass polyurethane ceiling material is not only adhesively bonded to each layer and layers by an adhesive and a hot melt film, but also requires a large number of heating processes, resulting in a long manufacturing process and an increase in manufacturing cost. Is also difficult.

또한, 제조시 글라스 파이버나 글라스 촙 분진 및 접착제로부터 발생되는 휘발성 유기 물질이 작업자에게 해로울 뿐만 아니라, 천장재로 사용된 후에도 그러한 현상이 어느 정도 지속될 수 있기 때문에, 탑승자에게도 악영향을 미칠 수가 있다.In addition, volatile organic substances generated from glass fibers or glass wool dust and adhesives in manufacturing are not only harmful to the worker, but may also adversely affect the occupant because such phenomena may persist even after being used as ceiling materials.

본 발명은, 종래의 자동차 실내 천장재와 그 제조 방법이 가지고 있는 제반 문제점들을 해결하기 위하여 창안된 것으로, 글라스류 물질과 접착제로부터 초래되는 해를 방지하고, 생산성을 높여 제조 비용을 절감할 수 있을 뿐 아니라, 적절한 강성과 함께 우수한 흡음성 및 쿠션성을 동시에 가지고 있음은 물론, 분리 재활용할 수 있는 천장재와 그 제조 방법을 제공함에 본 발명의 목적이 있다.The present invention was devised to solve various problems of the conventional automotive interior ceiling material and its manufacturing method, and can only prevent the damage caused by glass materials and adhesives, and increase productivity, thereby reducing manufacturing costs. In addition, it is an object of the present invention to provide a ceiling material and a method of manufacturing the same, as well as having excellent sound absorption and cushioning properties as well as appropriate rigidity at the same time.

본 발명의 상기 목적은, 천연섬유와 합성섬유가 혼합된 상·하부 섬유층과, 두 섬유층 사이에 개재된 발포층의 니들 펀칭 결합 구조에 의하여 달성된다.The above object of the present invention is achieved by the needle punching bonding structure of the upper and lower fiber layers mixed with natural fibers and synthetic fibers, and the foam layer interposed between the two fiber layers.

본 발명의 자동차 실내 천장재는, 상부 섬유층, 발포층, 하부 섬유층이 순차적으로 적층된 상태에서, 접착제나 핫멜트 등의 접착력이 아닌, 니들 펀칭에 의해 일측 섬유가 타측 내부로 함침되면서 상호 물리적으로 결합시키되, 필요에 따라, 최상층인 상부 섬유층의 상면 또는 상부 섬유층의 상면과 하부 섬유층의 저면에 고강성 표피층을 융착 결합시킨 구조를 갖는 내장재로서, 각각을 살펴보면 다음과 같다.Car interior ceiling material of the present invention, in the state in which the upper fiber layer, foam layer, lower fiber layer is sequentially laminated, the one fiber is impregnated into the other side by needle punching, but not physically bonded to each other by the adhesive punch or hot melt, etc. , If necessary, as the interior material having a structure in which a high rigid skin layer is fusion-bonded to the upper surface of the upper fibrous layer or the upper surface of the upper fibrous layer and the lower surface of the lower fibrous layer, as follows.

상·하부 섬유층은, 각각, 마, 케나프(kenaf), 바나나, 코코넛 등으로부터 얻어지는 천연섬유 20∼60wt%와, 저융점 합성섬유 40∼80wt%를 혼합한 웹(web) 구조의 부직포로서, 발포층을 보호하면서 보강하여 주는 역할을 한다. 상기 저융점 합성섬유로는, 저융점 폴리에스터, 저융점 폴리에틸렌, 폴리프로필렌 등을 예로 들 수 있다.The upper and lower fiber layers are a web structure nonwoven fabric in which 20 to 60 wt% of natural fibers obtained from hemp, kenaf, banana, coconut, etc. and 40 to 80 wt% of low melting point synthetic fibers are mixed. It serves to reinforce and protect the foam layer. Examples of the low melting point synthetic fibers include low melting point polyester, low melting point polyethylene, and polypropylene.

이때, 상기와 같이 섬유의 혼합 비율을 한정한 것은, 천연섬유의 함량이 20wt%에 미치지 못하면 제조 비용이 필요 이상으로 상승하는 동시에, 표피층의 융착을 위한 가열시 부피 수축률이 커져 두께 관리가 어려워지나, 60wt% 를 초과하면 자체 결합력이 떨어지게 되기 때문이다.At this time, limiting the mixing ratio of the fiber as described above, if the content of the natural fiber is less than 20wt%, the manufacturing cost increases more than necessary, and the volume shrinkage during heating for fusion of the epidermal layer becomes difficult to manage the thickness If it exceeds 60wt%, the self-bonding force is lowered.

그리고, 각종 천연섬유 중에서는 케나프가 가장 바람직하데, 이는, 강성, 내열성, 방취(防臭)성, 방진(防塵)성 등의 측면에서 타 천연섬유보다 유리하기 때문이다.Among various natural fibers, kenaf is the most preferable because it is advantageous over other natural fibers in terms of rigidity, heat resistance, deodorization resistance, and dust resistance.

발포층은, 단열성, 흡음성 및 쿠션성 등의 기능을 갖도록 상기 상·하부 섬유층 사이에 개재된 중간층으로서, 폴리우레탄, 폴리에틸렌, 폴리프로플렌, 폴리에스터 등으로 이루어진 발포체이다.A foam layer is an intermediate | middle layer interposed between the said upper and lower fiber layers so that it may have functions, such as heat insulation, sound absorption, and cushioning, and is a foam which consists of a polyurethane, polyethylene, polypropylene, polyester, etc.

표피층은, 고밀도 폴리에틸렌으로 이루어지며, 상부 섬유층의 상면 또는 상부 섬유층의 상면과 하부 섬유층의 저면 모두에 융착 결합됨으로써, 본 발명의 천장재에 적절한 강성을 부여하기 위한 역할을 하게 되는데, 표면 조도를 향상시키기 위하여, 상부 섬유층의 상면 또는 상부 섬유층의 상면과 하부 섬유층의 저면에 분말상 또는 액상의 고밀도 폴리에틸렌을 도포한 후 가열 융착시켜 적층 형성되도록 하는바, 적절한 강성을 얻기 위하여서는 도포량을 50∼200g/m2 범위로 하는 것이 바람직하다.The skin layer is made of high density polyethylene and is fusion bonded to both the upper surface of the upper fiber layer or the upper surface of the upper fiber layer and the lower surface of the lower fiber layer, thereby acting to impart proper rigidity to the ceiling material of the present invention. In order to apply a powdery or liquid high density polyethylene to the upper surface of the upper fiber layer or the upper surface of the upper fiber layer and the lower surface of the lower fiber layer, and heat-fusion bonding to form a lamination, in order to obtain an appropriate rigidity, the coating amount is 50 ~ 200g / m 2 It is preferable to set it as the range.

이때, 상기와 같이 고밀도 폴리에틸렌의 도포량을 조절하는 것은, 도포량이 50g/m2 에 미치지 못하면, 강성이 부족하여 자동차의 루프 패널 저면에 결합된 천장재가 바닥측으로 쳐질 수도 있으나, 200g/m2 을 초과하게 되면, 자체 중량이 필요 이상 증가하는 동시에 제조 비용을 상승시키게 되기 때문이다.At this time, to adjust the coating amount of the high-density polyethylene as described above, if the coating amount is less than 50g / m 2 , the ceiling material coupled to the bottom of the roof panel of the car may be struck to the floor side if the rigidity is insufficient, but exceeds 200g / m 2 This is because the weight increases more than necessary and increases the manufacturing cost.

그리고, 분말상 고밀도 폴리에틸렌을 사용할 경우에는, 분말의 입경이 1㎛ 이하인 것을 사용하는 것이 바람직한바, 입경이 1㎛보다 큰 분말을 사용하는 경우에는, 융착 속도가 늦어져 생산성이 저하되는 것은 물론, 융착 후의 표면 상태가 거칠게 되거나 굴곡이 발생하는 등 표면 품질이 떨어지게 된다.And when using a powdery high density polyethylene, it is preferable to use the thing whose particle diameter of a powder is 1 micrometer or less. When using the powder whose particle size is larger than 1 micrometer, a fusion rate becomes slow and productivity falls, of course, fusion | melting is carried out. The surface quality is degraded, such as a rough surface condition or bending occurs.

또한, 본 발명의 천장재를 구성하는 섬유층 또는 표피층에, 항균 기능, 탈취 기능, 음이온 발생 기능 등을 부수적으로 부여할 수도 있는바, 일라이트 파이버 등을 섬유층에 혼합하거나, 분말상 또는 액상의 고밀도 폴리에틸렌에, 참숯 분말, 황토 분말, 옥 분말, 토르말린 분말, 게르마늄 분말 등의 기능성 분말을 혼합하여 사용할 수도 있다.Further, the antimicrobial function, the deodorizing function, the anion generating function and the like may be additionally imparted to the fiber layer or the skin layer constituting the ceiling material of the present invention. And functional powders such as charcoal powder, ocher powder, jade powder, tourmaline powder and germanium powder.

상기 본 발명의 목적과 기술적 구성을 비롯한 그에 따른 작용 효과에 관한 자세한 사항은 본 발명의 바람직한 실시예를 도시하고 있는 도면을 참조한 아래의 설명에 의해 명확하게 이해될 것이다.Details of the effects and the resulting effects, including the object and technical configuration of the present invention will be clearly understood by the following description with reference to the drawings showing a preferred embodiment of the present invention.

도 1에 본 발명 천장재의 단면 구조도를, 도 2에 본 발명 제조 방법의 블록도를 도시하였다.The cross-sectional structural diagram of the ceiling material of this invention is shown in FIG. 1, and the block diagram of the manufacturing method of this invention is shown in FIG.

본 발명의 천장재는, 천연섬유와 합성섬유가 일정 비율로 혼합되며, 니들 펀칭에 의해 내부 섬유끼리 물리적으로 결합되어 웹 구조를 갖는 쉬트상 또는 판체상의 상·하부 섬유층(11)(12)과;The ceiling material of the present invention includes a sheet or plate-like upper and lower fiber layers 11 and 12 in which natural fibers and synthetic fibers are mixed at a predetermined ratio, and the inner fibers are physically bonded by needle punching;

상기 상·하부 섬유층(11)(12) 사이에 개재되며, 니들 펀칭에 의해 그 상면과 저면이 상·하부 섬유층(11)(12)의 각 저면 및 상면과 상호 함침 결합된 발포층(13)과;The foam layer 13 interposed between the upper and lower fibrous layers 11 and 12, and the upper and lower surfaces thereof are impregnated with each of the lower and upper surfaces of the upper and lower fibrous layers 11 and 12 by needle punching. and;

상기 상·하부 섬유층(11)의 각 상면과 저면 중의 적어도 어느 한면에 융착 결합된 표피층(14) 등으로 구성된다.It consists of the skin layer 14 etc. which were fusion-bonded to at least one of each upper surface and the bottom surface of the said upper and lower fiber layers 11, and the like.

이때, 상기 표피층(14)은, 필요에 따라, 생략될 수도 있다.At this time, the skin layer 14 may be omitted, if necessary.

그리고, 상기와 같이 상·하부 섬유층(11)(12)과 발포층(13)이 순차적으로 적층된 상태에서, 니들 펀칭에 의해 상호 물리적으로 결합된 후 상부 섬유층(11)의 상면에 표피층(14)이 융착 결합되어 4층의 적층 구조를 갖는 본 발명의 천장재는,Then, in the state in which the upper and lower fiber layers 11 and 12 and the foam layer 13 are sequentially stacked as described above, they are physically bonded to each other by needle punching, and then the epidermal layer 14 is formed on the upper surface of the upper fiber layer 11. ), The ceiling material of the present invention having a laminated structure of four layers by fusion bonding,

천연섬유와 합성섬유를 혼합 비율로 혼합, 타면 및 카딩(carding) 및 성형하여 웹 구조를 갖는 쉬트상 또는 판체상의 상·하부 섬유층(11)(12)을 각각 만드는 단계(100)와;Mixing (100) the natural fiber and the synthetic fiber at a mixing ratio, the other surface and carding and forming the sheet or plate-like upper and lower fiber layers 11 and 12 having a web structure, respectively;

상·하부 섬유층(11)(12) 각각을 니들 펀칭하여 자체 섬유 조직이 치밀해지면서 균일하게 혼합되도록 하는 단계(200)와;Needle punching each of the upper and lower fiber layers 11 and 12 so as to uniformly mix their own fiber tissues (200);

상·하부 섬유층(11)(12) 사이에 발포층(13)을 개재시킨 후, 상부 섬유층(11)과 발포층(13) 및 발포층(13)과 하부 섬유층(12)을 각각 니들 펀칭하여 상부 섬유층(11)-발포층(13)-하부 섬유층(12)의 순으로 적층 결합시키는 단계(300)와;After interposing the foam layer 13 between the upper and lower fiber layers 11 and 12, needle punching is performed on the upper fiber layer 11 and the foam layer 13 and the foam layer 13 and the lower fiber layer 12, respectively. Laminating and bonding (300) the upper fibrous layer (11) -foaming layer (13) -the lower fibrous layer (12) in this order;

상부 섬유층(11)의 상면에 고밀도 폴리에틸렌을 도포한 후 가열하여 융착시키는 단계(400) 등의 순차적인 공정들에 의해 제조된다.After the high-density polyethylene is applied to the upper surface of the upper fibrous layer 11, it is manufactured by sequential processes, such as the step (400) of heating and fusion.

이때, 하부 섬유층(12)의 저면에도 고밀도 폴리에틸렌을 도포한 후 가열하여 융착시키는 단계가 부가적으로 포함될 수 있는바, 이러한 경우, 상부 섬유층(11)의 상면에 표피층(14)이 형성된 본 발명의 천장재를 뒤집음으로써, 하부 섬유층(12)의 저면을 천장재의 상면이 되도록 한 상태에서 표피층을 추가적으로 하부 섬유층(12)의 저면에 형성시키게 된다.In this case, the step of applying the high density polyethylene to the bottom surface of the lower fiber layer 12 may be additionally included in the heating and fusion step, in this case, the skin layer 14 is formed on the upper surface of the upper fiber layer 11 of the present invention By inverting the ceiling material, the skin layer is additionally formed on the bottom surface of the lower fiber layer 12 in a state where the bottom surface of the lower fiber layer 12 is to be the upper surface of the ceiling material.

상기와 같은 제조 단계들 중 적층 결합시키는 단계(300)에서, 상부 섬유층(11)과 발포층(13) 및 하부 섬유층(12)과 발포층(13)의 각 니들 펀칭은, 각 섬유층(11)(12)이 발포층(13) 위에 위치하도록 한 후 각 섬유층(11)(12)으로부터 발포층(13)을 향하여 이루어진다.In the step of laminating 300 of the above manufacturing steps, each needle punching of the upper fibrous layer 11 and the foam layer 13 and the lower fibrous layer 12 and the foam layer 13, each fibrous layer 11 (12) is placed on the foam layer (13) and then made from the respective fiber layers (11) (12) toward the foam layer (13).

상기와 같은 일련의 단계들에 의해 제조되는 본 발명의 천장재에서, 각 섬유층(11)(12)을 구성하는 합성섬유는, 융점이 110∼160℃ 정도인 저융점 합성섬유를 사용하는 것이 바람직한데, 필요에 따라, 고융점 합성섬유를 혼합 사용할 수도 있다.In the ceiling material of the present invention produced by the above series of steps, the synthetic fibers constituting each of the fiber layers 11, 12, it is preferable to use a low melting point synthetic fibers having a melting point of about 110 ~ 160 ℃ If necessary, high melting point synthetic fibers may be mixed and used.

그리고, 표피층(14)을 이루는 고밀도 폴리에틸렌은, 분자들이 100% 무정형 상태를 이루게 되는 융점이 132℃∼190℃ 정도로서, 이를 상부 섬유층(11)의 상면에 융착시키기 위하여서는, 생산 속도에 따라, 140∼200℃ 범위로 가열하게 되는 바, 상·하부 섬유층(11)(12)에 함유된 저융점 합성섬유도 함께 부분적으로 용융되도록 함으로써, 표피층(14) 및 발포층(13)에 각각 융착 결합되도록 하는 동시에, 각 섬유층(11)(12) 내부에서도 융착 결합이 이루어질 수 있도록 할 수 있기 때문이다.The high-density polyethylene constituting the skin layer 14 has a melting point of about 132 ° C to 190 ° C in which the molecules form a 100% amorphous state. In order to fuse it to the upper surface of the upper fiber layer 11, 140, depending on the production rate, The low melting point synthetic fibers contained in the upper and lower fiber layers 11 and 12 are also partially melted together to be fused and bonded to the skin layer 14 and the foam layer 13, respectively. At the same time, it is because the fusion bonding can be made even inside each fiber layer (11, 12).

이상에서 살펴본 바와 같이, 본 발명의 자동차 실내 천장재는, 글래스류 물질과 접착제류 등이 전혀 사용되지 않기 때문에 생산자는 물론, 차량에 장착한 후에도 탑승자에게 해로운 물질을 전혀 배출하지 않으며, 제조 공정이 간단해지면서 생산성이 향상되어 제조 비용 절감이 가능하고, 니들 펀칭에 의해 결합되기 때문에 섬유층과 발포층의 분리는 물론, 섬유층에서의 천연 섬유 분리가 쉬워 재활용이 가능할 뿐 아니라, 표피층에 의해 외부 소음이 반사되기 때문에 차음 성능이 우수한 장점이 있다.As described above, the vehicle interior ceiling material of the present invention does not emit any harmful substances to the occupants as well as to the passengers even after the vehicle is mounted on the vehicle because glass materials and adhesives are not used at all, and the manufacturing process is simple. As the productivity increases, the manufacturing cost can be reduced, and the combination of needle punching allows the separation of the fiber layer and the foam layer, as well as the separation of natural fibers from the fiber layer, making it easy to recycle and reflecting external noises by the skin layer. Since the sound insulation performance is excellent.

Claims (9)

삭제delete 삭제delete 합성섬유를 포함하며, 다층 구조로 제조된 자동차 실내 천장재에 있어서,In a car interior ceiling material comprising a synthetic fiber, made of a multi-layer structure, 천연섬유와 합성섬유가 혼합된 상·하부 섬유층(11)(12)과;Upper and lower fiber layers 11 and 12 mixed with natural fibers and synthetic fibers; 상기 상·하부 섬유층(11)(12) 사이에 개재된 상태에서 니들 펀칭에 의해 상·하부 섬유층(11)(12)과 결합된 발포층(13)을 포함하여 구성되며,It comprises a foam layer 13 bonded to the upper and lower fibrous layer (11, 12) by needle punching in the state interposed between the upper and lower fibrous layer (11, 12), 이때, 상기 상·하부 섬유층(11)(12)은 각각, 니들 펀칭에 의해 내부 섬유끼리 물리적으로 결합된 것을 특징으로 하는 자동차 실내 천장재.At this time, the upper and lower fiber layer (11) (12), the interior of the car interior, characterized in that the inner fibers are physically coupled to each other by needle punching. 삭제delete 삭제delete 합성섬유를 포함하며, 다층 구조로 제조된 자동차 실내 천장재에 있어서,In a car interior ceiling material comprising a synthetic fiber, made of a multi-layer structure, 천연섬유와 합성섬유가 혼합된 상·하부 섬유층(11)(12)과;Upper and lower fiber layers 11 and 12 mixed with natural fibers and synthetic fibers; 상기 상·하부 섬유층(11)(12) 사이에 개재된 상태에서 니들 펀칭에 의해 상·하부 섬유층(11)(12)과 결합된 발포층(13)을 포함하여 구성되며,It comprises a foam layer 13 bonded to the upper and lower fibrous layer (11, 12) by needle punching in the state interposed between the upper and lower fibrous layer (11, 12), 이때, 상기 상·하부 섬유층(11)(12)의 각 상면과 저면 중 적어도 어느 한 면에는, 고밀도 폴리에틸렌을 융착시킨 표피층(14)이 부가적으로 적층 형성된 것을 특징으로 하는 자동차 실내 천장재.At this time, at least one of the upper surface and the lower surface of each of the upper and lower fiber layers (11) (12), the interior of the car interior ceiling material, characterized in that the additional laminated layer formed by fusing high-density polyethylene. 천연섬유와 합성섬유를 혼합, 타면, 카딩 및 성형하여 웹 구조를 갖는 쉬트상 또는 판체상의 상·하부 섬유층을 각각 만드는 단계와;Mixing, zipping, carding, and molding natural fibers and synthetic fibers to form sheet- or plate-shaped upper and lower fiber layers, respectively, having a web structure; 상·하부 섬유층 각각을 니들 펀칭하는 단계와;Needle punching each of the upper and lower fiber layers; 상·하부 섬유층 사이에 발포층을 개재시킨 후 상부 섬유층과 발포층 및 발포층과 하부 섬유층을 각각 니들 펀칭하는 단계를 포함하여 이루어짐을 특징으로 하는 자동차 실내 천장재의 제조 방법.Method of manufacturing a vehicle interior ceiling material comprising the step of punching the upper fiber layer and the foam layer and the foam layer and the lower fiber layer after interposing the foam layer between the upper and lower fiber layers. 제 7항에 있어서, 상기 상부 섬유층과 발포층 및 발포층과 하부 섬유층을 니들 펀칭하는 단계 후, 상부 섬유층의 상면과 하부 섬유층의 저면 중 적어도 어느 한 면에 고밀도 폴리에틸렌을 도포하여 가열 융착시키는 단계가 부가적으로 실시됨을 특징으로 하는 자동차 실내 천장재의 제조 방법.The method of claim 7, wherein after the needle punching of the upper fibrous layer, the foam layer, the foam layer and the lower fibrous layer, the step of applying heat-fusing high density polyethylene to at least one of the upper surface of the upper fibrous layer and the bottom of the lower fibrous layer A method of manufacturing a vehicle interior ceiling material, characterized in that additionally carried out. 제 7항에 있어서, 상기 고밀도 폴리에틸렌은, 1㎛ 이하의 입경을 갖는 분말상 고밀도 폴리에틸렌 또는 액상의 고밀도 폴리에틸렌 중의 어느 하나가 50∼200g/m2 양으로 도포됨을 특징으로 하는 자동차 실내 천장재.The vehicle interior ceiling material according to claim 7, wherein the high density polyethylene is coated with either a powdery high density polyethylene having a particle diameter of 1 µm or less or a liquid high density polyethylene in an amount of 50 to 200 g / m 2 .
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KR100989171B1 (en) * 2008-06-24 2010-10-22 김현영 Vibration and sound proof material for vehicles
KR101029842B1 (en) 2009-08-14 2011-04-15 (주) 금토일산업 Manufacturing method of head lining skin for vehicle
KR101034641B1 (en) 2009-08-14 2011-05-16 (주) 금토일산업 Manufacturing apparatus of head lining skin for vehicle
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Publication number Priority date Publication date Assignee Title
KR100989171B1 (en) * 2008-06-24 2010-10-22 김현영 Vibration and sound proof material for vehicles
KR101037092B1 (en) 2009-06-29 2011-05-26 코오롱글로텍주식회사 Needle punch carpet and manufacturing method thereof
KR101029842B1 (en) 2009-08-14 2011-04-15 (주) 금토일산업 Manufacturing method of head lining skin for vehicle
KR101034641B1 (en) 2009-08-14 2011-05-16 (주) 금토일산업 Manufacturing apparatus of head lining skin for vehicle
KR101840731B1 (en) * 2017-06-21 2018-03-22 (주)아코플레닝 Manufacturing method of breathable hybrid-leather
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