KR100824695B1 - Multi-layer sheet and manufacturing method thereof - Google Patents

Abstract

A light multi-layer sheet and a manufacturing method for the same are provided to reduce the weight of the sheet and to secure high sound absorption and heat insulation properties by forming voids among fibers by using the fibers of specific thickness within a predetermined range. A light multi-layer sheet is produced by making a mat(70) and stacking the mats more than two layers by using a stampable sheet manufacturing device. The mat is produced by mixing and carding at least one kind of thermoplastic resin fiber or wadding conjugate fiber of 40~70wt.%, at least one kind of thermoplastic resin hollow fiber or polyester interlaced yarn of 20~40wt.%, and natural fiber of 5~20wt.%. The mat contains fiber with 10~20 deniers of 20~95wt.% and fiber with 2~7 deniers of 5~80wt.%.

Description

Lightweight laminated sheet and manufacturing method thereof Multi-layer Sheet and Manufacturing Method

1 is a flow chart for manufacturing a laminated sheet according to the present invention.

Figure 2 shows the perforated plate of the stamper sheet manufacturing apparatus used in the present invention.

Figure 3 shows a cross section of the heating portion of the stampable sheet manufacturing apparatus used in the present invention.

Explanation of the main parts of the drawings

31-Upper frame

32-lower frame

34-Conveyor Belt

35-Perforated Plate

36-Hot Air Spray Nozzles

70-Laminated Mat

The present invention relates to a laminated sheet to be used as a vehicle interior material, and to a laminate sheet for interior materials that can be applied to the ceiling material of the vehicle to reduce the weight of the vehicle.

Recently, the development of lightening the interior and exterior materials of the car for the purpose of lightening the car is in progress, and accordingly, research on the polymer composite material, which is a material that replaces the metal, is being actively conducted.

Conventional composite materials for automobile interior materials include high heat / high rigidity composite materials (FRP) or unsaturated polyester resins and thermoplastics reinforced with talc, glass fiber, carbon fiber, etc. as reinforcement materials for polymer materials such as polypropylene or thermoplastic olefins. Materials such as thermosetting composite materials through rubberization of polymers have been used.

However, such FRP did not produce satisfactory results such as impact resistance and fracture toughness, and it was impossible to recycle.

Therefore, interest in the material to replace the FRP is rapidly increasing, and to satisfy the requirements of light weight, but also to provide excellent strength, as well as sound-absorbing and thermal insulation in order to apply automotive interior materials.

The present invention has been made in order to solve the above problems, by using a mixture of a thermoplastic resin fiber or a sheath-type composite fiber and a thermoplastic resin hollow fiber or polyester composite air entangled yarn and natural fibers to form an air layer during sheet production Not only can it achieve sufficient weight reduction, but also to develop a light weight laminated sheet which can satisfy the outstanding strength and sound absorption / insulation performance, and completed this invention.

That is, the present invention is not only possible to recycle and lighten by using a thermoplastic resin fiber or a sheath type composite fiber and a thermoplastic resin hollow fiber or a polyester composite air entangled yarn and natural fiber, but also by using the thickness of the fibers in a specific range That is, by mixing 10 to 20 denia fibers 20 to 95% by weight, 2 to 7 denia fibers 5 to 80% by weight by the difference in the thickness of the fibers due to the greater the amount of empty space when producing the laminated sheet It is an object of the present invention to provide a laminated sheet suitable for automobile interior materials by improving sound absorption and thermal insulation performance.

The present invention relates to a lightweight laminated sheet used as an automotive interior material, and more particularly, the present invention relates to 40 to 70% by weight of at least one thermoplastic resin fiber or a sheath type composite fiber and at least one thermoplastic resin hollow fiber or polyester composite. As a laminated sheet manufactured by mixing 20 to 40% by weight of air entangled yarn and 5 to 20% by weight of natural fibers to prepare a mat, and then laminated the mat in one or more layers using a stampable sheet manufacturing apparatus, The mat relates to a lightweight laminated sheet in which 20 to 95% by weight of 10 to 20 denier fibers and 5 to 80% by weight of 2 to 7 denier fibers are mixed.

As described above, the bulky multi-dimensional three-dimensional network is formed by using fibers of a special structure that can contain air, such as a deep sheath type fiber, hollow fiber and composite air entangled yarn, to have a fine pore layer. In addition to being able to produce lightweight laminated sheets, it has been found that the use of two different types of fiber thicknesses allows the formation of voids between the fibers, resulting in lighter weight and better sound absorption and thermal insulation with superior strength. This completes the present invention.

In addition, the present invention is 40 to 70% by weight of the at least one thermoplastic resin or sheath type composite fiber and at least one thermoplastic resin hollow fiber or polyester composite air interlocking yarn 30 to 60 on one side or both sides of the laminated sheet as necessary. It is also possible to further laminate the sheet by weight. The present invention smoothly and uniformly prepares the surface of the surface layer by using only a thermoplastic resin or a sheath type composite fiber and a thermoplastic resin hollow fiber or a polyester composite air entangled yarn without using natural fibers on one or both outermost surfaces as described above. In this case, the resistance to water absorption, heat insulation and sound absorption effect can be further improved, and the adhesion of the finishing nonwoven fabric can be improved.

Hereinafter, the present invention will be described in more detail.

The thermoplastic resin in the present invention is not limited as long as it is commonly used in the art, more preferably polyethylene, polypropylene, polyvinyl chloride, polyester, polyethylene-polyester copolymer, nylon 6, nylon 66, nylon It is recommended to use at least one selected from ten.

In addition, the core sheath-type composite fiber is a thermoplastic polyester resin fiber copolymerized isophthalic acid component containing a metal sulfonate group, the core component uses a polyester composite fiber made of a thermoplastic polyethylene terephthalate resin fiber, More preferably, the polyester composite yarn disclosed in Korean Patent Publication No. 195-0005433 may be used. In the case of using the above-mentioned sheath type composite fiber, there is an advantage that can be dyed due to excellent dyeability, there is a feature that can produce a lightweight sheet with excellent strength.

In the present invention, the thermoplastic resin fiber or the herbicidal composite fiber may be selectively used, but it is also possible to use a mixture thereof, and the content thereof is preferably 40 to 70% by weight, and less than 40% by weight. When used, the desired light weight, heat insulation and sound absorption can not be satisfied, and when it exceeds 70% by weight, the strength reinforcement by natural fibers is reduced, and thus satisfactory strength cannot be exhibited.

In the present invention, the thermoplastic resin hollow fiber means that the inside of the fiber is formed into an empty space, and the heat resistance of the hollow fiber may be higher than 5 ° C. or higher than the remaining fibers. The heat resistance means a glass transition temperature or a melting temperature, and when using the hollow fiber, the cavity formed inside the hollow fiber is 5 ° C. or more higher than other fibers even when passing through the stampable sheet manufacturing apparatus. By having heat resistance, the shape can be better maintained in part to increase the sound absorption or thermal insulation of the final sheet. However, even when using a hollow fiber that is not increased heat resistance of 5 ℃ or more as described above is excellent in performance compared to not using it is not excluded from the present invention, but preferably 5 It is better to use higher than ℃.

As the hollow fiber, for example, a thermoplastic resin hollow fiber such as polyester, polyethylene, nylon, heat-melting fluorine resin, etc. may be used, and the cavity may have any shape such as a circle or a triangle. It is not limited to these. The heat-soluble fluororesin includes tetra fluoro ethylene-hexafluoro propylene copolymer (FEP), tetra fluoro ethylene-fel fluoro alkyl vinyl ether copolymer (PFA), tetra fluoro ethylene-hexafluoro propylene- phenyl fluoro alkyl vinyl ether Copolymer (EPA), tetrafluoro ethylene-ethylene copolymer (ETFE) and the like can be used. In the case of using such hollow fibers, the sound absorbing and insulating effect is further improved by the empty space inside the fiber.

In addition, the polyester composite air interlocking yarn is a raw fiber to mean a blended yarn in a state in which the two yarns are concentrated by forming a knot by air dispersed at the interlace nozzle by simultaneously supplying the polyester hollow fiber and the high shrink polyester fiber Phosphorous polyester hollow fiber may be a fully stretched or semi-stretched one, but it is preferable to use a semi-stretched one to express a bulky structure with a large difference in shrinkage force from a high shrink polyester fiber. In the present invention, it can be produced by the manufacturing method described in Korean Patent Publication No. 10-2004-0049035 as an example of such a polyester composite air interlocking yarn. The present invention has completed the present invention by discovering that a lighter weight sheet can be produced by a bulky structure containing air by using the polyester composite air entangled yarn. In addition, the composite air entangled yarn in the present invention is also good to use the heat resistance higher than 5 ℃ higher than the remaining fibers.

The thermoplastic hollow fiber or polyester composite air interlocking yarn can be used selectively or mixed, the content is preferably used 20 to 40% by weight, when used in less than 20% by weight Insulation and sound absorption performance can not be achieved, the manufacturing cost will rise if it exceeds 40% by weight.

In the present invention, the natural fiber is preferably any one or more selected from hemp, jute, hemp, flax, abaca any one or more selected from hemp fibers, cotton fibers, coir, wool fibers, cashmere or silk fibers. More preferably, the hemp fibers are used for reasons of low cost, good reinforcing ability, and easy purchase. The content of the natural fiber is preferably used 5 to 20% by weight, when using less than 5% by weight may be weakened, when the content exceeds 20% by weight can not produce a lightweight sheet.

In addition, the present invention can control the physical properties of the laminated sheet produced by selectively using the thickness of the fibers used in the manufacture of the laminated sheet. Particularly, the sheet fiber is preferably used by mixing 20 to 95% by weight of the fibers of 10 to 20 denier and 5 to 80% by weight of the 2 to 7 denier fibers.

The 10 to 20 denier fibers may serve to reinforce strength, such as the role of reinforcing steel when placing concrete, and the 2 to 7 denier fibers may form a space part to achieve excellent sound absorption / insulation effect and strength. have.

The reason of the present invention is limited to the 10 to 20 denier fibers and 2 to 7 denier fibers in the present invention was able to achieve an excellent sound absorption / insulation effect with sufficient strength for the purpose of the present invention when used in a mixture of the fibers Because. In addition, the reason for limiting the range of these contents is also intended to be used within the range that satisfies the strength and sound absorption / insulation of the range intended in the present invention.

Hereinafter, the method of manufacturing the laminated sheet for automobile interior of the present invention will be described in detail. Referring to the simplified diagram described in FIG. 1,

a) 40 to 70% by weight of one or more thermoplastic resin fibers or heart sheath composite fibers, 20 to 40% by weight of one or more thermoplastic resin hollow fibers or polyester composite air entangled yarn, and 5 to 20% by weight of natural fibers And each of the fibers is mixed with 20 to 95% by weight of 10 to 20 denia fibers, 5 to 80% by weight of 2 to 7 denier fibers, and then opened.

b) passing the mixed / opened fibers through a carding machine to form a mat;

c) stacking the mat into one or more layers;

d) fixing the mat laminated in one or more layers by needle punching;

e) preheating the laminated mat to a stampable sheet manufacturing apparatus having a plate-shaped conveyor belt having a plurality of perforations to be transmitted to the inside of the laminated mat through the perforations, and then to the inside of the mat. A process step of thermally fusion, pressing, cooling, and cutting the laminated mat in a molten state by transferring heat;

The light weight laminated sheet made into the objective by this invention can be manufactured.

In addition, the present invention is 40 to 70% by weight and at least one thermoplastic resin hollow fiber and at least one thermoplastic resin or sheath type composite fiber on one side or both sides of the outermost when laminating the mat in one or more layers as needed in step c) Or it is also possible to further add a sheet prepared using 30 to 60% by weight polyester composite air entangled yarn.

40 to 70% by weight of at least one thermoplastic resin fiber or a sheath-type composite fiber and at least one thermoplastic resin hollow fiber or polyester composite air entangled yarn at 20 to 40% by weight and natural fiber After mixing / opening uniformly to the content of ˜20% by weight to form a mat, then passing through a cylindrical cylindrical carding machine to form a fibrous thin web, and laminating different kinds of mats mixed by various mixing methods or Alternatively, the same type of mats are laminated in more than one layer, and the laminated mats are fixed by needle punching to prevent the mats from being pushed, and then supplied to the stampable sheet manufacturing apparatus for preheating, heat welding, pressing, cooling, and cutting. A plate-like sheet can be manufactured by a step. More specifically, the laminated nonwoven fabric is penetrated between the reinforcing fibers in which thermoplastic fibers are entangled by being divided and melted through the preheating zone of the stampable sheet manufacturing apparatus, and the molten laminated nonwoven fabric is pressurized through the pressure rollers in the pressing zone to have a constant thickness. It is made of laminated sheet. At this time, the stampable sheet manufacturing apparatus can be used by changing, so the steps of preheating, heat fusion, pressurization, cooling, and cutting may be changed according to the combination of the apparatus, and elements such as specific temperature and pressure are also changed. Since this is possible, it does not limit in this invention.

Hereinafter, a stampable manufacturing apparatus used in the present invention will be briefly described, and will be described with reference to FIGS. 2 and 3.

Figure 2 is an example showing a conveyor belt provided in the stampable sheet manufacturing apparatus used in the present invention, the conveyor belt 34 is a plurality of perforated plate 35 so that hot air can be directly supplied to the laminated mat in the heating process Is made of. By using the conveyor belt 34 made of the perforated plate 35 as described above, hot air injected from the hot air injection nozzle is directly supplied to the lamination mat to improve thermal efficiency and hot air to the surface of the lamination mat as well as to the deeper portion. By supplying the internal and external parts are uniform, the quality is improved and the process time is shortened.

3 is a cross-sectional view of the heating unit, in which hot air injected from the hot air injection nozzle 36 passes through a conveyor belt 34 formed of a perforated plate 35 to supply the surface of the laminated mat 70 as well as the deeper portion. do. As such, the hot air is directly supplied to the lamination mat 70, so that the hot air is excellent and the inner and outer parts of the lamination mat 70 are uniformly heated.

The hot air jet nozzle 36 may be provided in both the upper and lower frames 31 and 32, as shown in the figure, may be provided only at any one selected from the upper frame 31 or the lower frame 32, The upper and lower frames 31 and 32 may cross each other so as not to face each other.

It is obvious to those skilled in the art that the heating device 30 is provided with a control device for adjusting the pressure of the pressure control or the volume of the composite mat (70).

Hereinafter, the present invention will be described with reference to Examples for the specific description of the present invention. However, the present invention is not limited to the following Examples.

The sheath type polyester fiber and polyester composite air entangled yarn used in the following examples were prepared by the following physical properties.

Core type polyester fiber: The core component is made of thermoplastic polyester resin copolymerized with 2.7 mol% of isophthalic acid component containing metal sulfonate group, and the component is made of thermoplastic polyethylene terephthalate resin. A polyester composite yarn of 32% by weight was used.

* Polyester composite air entangled yarn: Composite air entangled yarn prepared by interlacing polyester semi-stretched hollow filament and high shrink polyester filament with 30% specific shrinkage rate by interlacing speed 400m / min and air pressure 3 bar Used. The melting temperature of the fiber produced is 245 ℃.

Example 1

With one kind of mat Stacked  Preparation of 3-layer laminated sheet

15% by weight of Denia's core sheath-type polyester fiber, 35% by weight of 5 Denia's polyester composite air entangled yarn, and 15% by weight of 7 Denia's natural horse (Kenaf) Pass through to prepare a mat.

The prepared mat was laminated in three layers, and then fixed by needle punching to laminate a 20 mm thick layer. The sheet was supplied to a stampable sheet manufacturing apparatus and passed through rollers preheated at a temperature of 170 ° C., 200 ° C., and 240 ° C. at a rate of 8 M / min to prepare a sheet having a thickness of 10 mm. 7 mm thick sheet was produced by passing through a rate of / min, and passed through a water cool zone of 50 ℃ at a rate of 8 M / min, and passed through a water cool zone of 30 ℃ at a rate of 8 M / min, finally 7 mm thick The laminated sheet of was prepared.

The physical properties of the prepared laminate sheet were measured and shown in Table 1 below.

Example 2

With two kinds of mats Stacked  Preparation of 3-layer laminated sheet

(Manufacture of mat 1)

A mat was prepared by mixing and opening 55 weight percent of Denia's core sheath-type polyester fiber and 45 weight percent of 5 Denia's polyester composite air entangled yarn and passing through a cylindrical cylindrical carding machine.

(Manufacture of mat 2)

15 weight percent of Denia's core sheath-type polyester fiber, 35 weight percent of Denia's polyester composite air entangled yarn, and 15 weight percent of 10 Denia's Kenaf, then opened and passed through a cylindrical cylindrical carding machine To prepare a mat.

The laminated mat 1 / mat 2 / mat 1 was laminated so as to overlap, fixed by needle punching and laminated to a thickness of 20 mm. It was supplied to the stampable sheet manufacturing apparatus and passed through the rollers preheated at 150 ° C, 180 ° C, and 220 ° C, respectively, at a speed of 9M / min to prepare a sheet having a thickness of 10 mm, and 9M in an air cool zone of 90 ° C. 7 mm thick sheet was produced by passing through a speed of / min, and passed through a water cool zone at 50 ° C. at a rate of 9 M / min, and passed through a water cool zone at 30 ° C. at a rate of 9 M / min. The laminated sheet of was prepared.

The physical properties of the prepared laminate sheet were measured and shown in Table 1 below.

Example 3

With two kinds of mats Stacked  Preparation of 3-layer laminated sheet

(Manufacture of mat 1)

The mat was manufactured by mixing and opening 45 weight percent of 15 denia sheath-type polyester fibers and 55 weight percent of 5 denier polyester composite air entangled yarns and passing them through a cylindrical cylindrical carding machine.

(Manufacture of mat 2)

45% by weight of 5 Denia polypropylene (PP) fibers, 40% by weight of 10 Denia polyester composite air entangled yarn, and 15% by weight of 15 Denia natural Kenaf (Kenaf) Pass through to prepare a mat.

Laminated to overlap in the order of mat 1 / mat 2 / mat 1 prepared above, and fixed by needle punching was laminated to a thickness of 20mm. The sheet was supplied to a stampable sheet manufacturing apparatus and passed through at a rate of 10 M / min in a roller preheated at a temperature of 140 ° C., 170 ° C., and 190 ° C., respectively, to prepare a sheet having a thickness of 10 mm, and 10 M in a 90 ° C. air cool zone. 6 mm thick sheet was made by passing through a speed of / min, and passed through a water cool zone of 50 ° C. at a rate of 10 M / min, and passed through a water cool zone of 30 ° C. at a rate of 10 M / min. A laminated sheet of thickness was prepared.

The physical properties of the prepared laminate sheet were measured and shown in Table 1 below.

TABLE 1

As shown in Table 1, it can be seen that the weight of the conventional sheet was reduced to 1300g / ㎡ compared to the weight of 1800g / ㎡ or more, and also showed satisfactory results of strength, sound absorption, heat insulation test.

As described above, the present invention is to produce a mat by mixing / improving a thermoplastic resin fiber or a sheath-type composite fiber and at least one thermoplastic resin hollow fiber or polyester composite air entangled yarn and natural fibers to a specific range, Laminated sheet manufactured by laminating one or more layers of mats, which is light in weight and has a specific sound absorption and thermal insulation effect due to voids between fibers by using fibers having a specific thickness in a specific range. It works.

Laminated sheet according to the present invention is suitable for use for automotive interior materials, in particular, is suitable for application to the headliner, there is an advantage that can be applied to construction, industrial materials such as partitions, furniture, plywood.

Claims (13)

40 to 70% by weight of one or more thermoplastic resin fibers or heart sheath composite fibers and 20 to 40% by weight of one or more thermoplastic resin hollow fibers or polyester composite air entangled yarns and 5 to 20% by weight of natural fibers After manufacturing, the laminated sheet manufactured by laminating the mat in two or more layers using a stampable sheet manufacturing apparatus, the mat is 10 to 20 denier fibers 20 to 95% by weight, 2 to 7 denier fibers Lightweight laminated sheet mixed with 5 to 80% by weight. The method of claim 1, On one or both sides of the laminated sheet, the sheet using 40 to 70% by weight of the at least one thermoplastic resin or a sheath type composite fiber and at least 30 to 60% by weight of the at least one thermoplastic resin hollow fiber or polyester composite air entangled yarn is further laminated. Lightweight laminated sheet characterized in that. The method of claim 1, The thermoplastic resin fiber is a lightweight laminated sheet using any one or more selected from polyethylene, polypropylene, polyvinyl chloride, polyester, polyethylene-polyester copolymer, nylon 6, nylon 66, nylon 10. The method of claim 1, The core sheath type composite fiber is a thermoplastic polyester resin fiber copolymerized with an isophthalic acid component containing a metal sulfonate group, and a polyester composite fiber made of a thermoplastic polyethylene terephthalate resin fiber having an initial component. Lightweight laminated sheet to say. The method of claim 1, The thermoplastic resin hollow fiber is any one or more selected from polyester-based, polyethylene-based, nylon-based, heat-soluble fluorine resin, and has a heat resistance of 5 ° C. or more higher than the fibers forming the mat. Lightweight laminated sheet characterized by using. delete The method of claim 1, The natural fiber is light lamination, characterized in that using any one or more selected from hemp, jute, hemp, flax, abaca, at least one selected from hemp fibers, cotton fibers, coir, wool fibers, cashmere or silk fibers Sheet. The method according to any one of claims 1 to 5 or 7, wherein The laminated sheet is preheated to be supplied to a stampable sheet manufacturing apparatus having a plate-shaped conveyor belt having a plurality of perforations to be transmitted to the inside of the mat in which hot air is laminated through the perforations, and then heat is transferred to the inside. Light lamination sheet, characterized in that the processing by heat-sealing, pressing, cooling and cutting the laminated mat in the molten state. An automotive interior using the laminated sheet according to any one of claims 1 to 5 or 7. a) 40 to 70% by weight of one or more thermoplastic resin fibers or heart sheath composite fibers, 20 to 40% by weight of one or more thermoplastic resin hollow fibers or polyester composite air entangled yarn, and 5 to 20% by weight of natural fibers The fibers may be mixed with 20 to 95% by weight of 10 to 20 denia fibers and 5 to 80% by weight of 2 to 7 denia fibers, followed by opening. b) passing the mixed / opened fibers through a carding machine to form a mat; c) laminating the mat in two or more layers; d) fixing the mat laminated in two or more layers by needle punching; e) preheating the laminated mat to a stampable sheet manufacturing apparatus having a plate-shaped conveyor belt having a plurality of perforations to be transmitted to the inside of the laminated mat through the perforations, and then to the inside of the mat. A process step of thermally fusion, pressing, cooling, and cutting the laminated mat in a molten state by transferring heat; Light weight laminated sheet manufacturing method characterized in that it has a. The method of claim 10, 40 to 70% by weight of the one or more thermoplastic resins or sheath type composite fibers and one or more thermoplastic resin hollow fibers or polyester composite air interlocking yarns on one or both outermost surfaces when laminating the mat in one or more layers in step c). Lightweight laminated sheet manufacturing method characterized in that further laminated by the sheet manufactured using 30 to 60% by weight. delete delete

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