KR100883033B1 - The base material for vehicle head liner - Google Patents

Abstract

A base material for a vehicle head liner is provided to reduce thermal contraction and secure dimensional stability by making core with polyolefin-group foamed sheet and improve sound absorptivity /sound insulation capacity of impact energy with foam formed inside polyolefin-group foamed sheet. A base material for a vehicle head liner comprises a core(11) formed with a crosslinked polyolefin foamed sheet and a reinforcement(12) equipped in one side or both sides of the core. The reinforcement is formed with the combination of PET(Polyethylene Terephtalate) fiber and polyolefine fiber at 30:70~70:30wt.%.

Description

Ceiling material base material for automobile interior {TH BASE MATERIAL FOR VEHICLE HEAD LINER}

The present invention relates to a vehicle interior ceiling material substrate, and more particularly made of an eco-friendly material that can be recycled, and relates to a vehicle interior ceiling material substrate which is excellent in weight and stiffness, sound absorption and sound insulation, and heat insulation.

Recently, as the automobile industry develops rapidly, there is a demand for the development of recyclable materials that reduce environmental pollution caused by waste of automobile interior materials.

Conventionally, as a base material of a ceiling material for automobile interior, there are resin felt, natural fiber reinforced board, paper board, wood fiber, hard polyurethane, and the like.

Here, resin felt and paper board are manufactured by impregnating phenolic resin, etc., phenolic resin, which is a curing agent, is a kind of thermosetting resin produced by condensation reaction between phenols and aldehydes. Phenol and aldehyde released due to act as a pollutant in the living environment, including the working environment, there is a problem of toxic gas emissions.

In the case of a ceiling material for automobile interior containing conventional glass fiber or glass chop, not only the harmful effects on the workers are caused by the glass dust which may be generated during the manufacturing and transportation process. When using an adhesive containing a volatile organic solvent to adhere these materials, there is a disadvantage that is harmful to the working environment and human body.

In addition, the polyurethane rigid foam is excellent in heat insulation and light weight, but the recyclability is low and the impact resistance is weak, brittle fracture is likely to occur in the molding process for producing the substrate.

On the other hand, the above-described ceiling materials for automobile interiors are not excellent in sound insulation and heat insulation, and the unit price is high, relatively high weight, easy to be deformed when used for a long time, harmful to the human body and difficult to recycle.

The present invention is to solve the problems described above, an embodiment of the present invention comprises a core material consisting of a cross-linked polyolefin-based foam sheet, and a reinforcement provided on one side or both sides of the core material, the reinforcement is polyethylene tere It is composed of phthalate (polyethylene terephtalate (PET)) fibers and polyolefin-based fibers, and is related to a vehicle interior ceiling material substrate that is lightweight and excellent in recyclability, rigidity, sound absorbing and insulating properties.

According to an embodiment of the present invention, the core material comprising a cross-linked polyolefin-based foam sheet and a reinforcing material provided on one side or both sides of the core material, wherein the reinforcing material is polyethylene terephtalate (PET) fiber and polyolefin-based fiber Provided is a vehicle interior ceiling material substrate, characterized in that consisting of.

According to a preferred embodiment of the present invention, the crosslinked polyolefin-based foam sheet is polypropylene, linear low density polyethylene, low density polyethylene, high density polyethylene, ethylene propylene nonconjugated diene copolymer rubber (EPDM), and ethylene propylene copolymer rubber (EPM And one or more components selected from the group consisting of

According to a preferred embodiment of the present invention, the crosslinked polyolefin-based foam sheet is characterized in that it has a product width of 700mm to 1600mm.

According to a preferred embodiment of the present invention, the foaming ratio of the crosslinked polyolefin foam sheet is 5 to 30 times, and the thickness is characterized in that 3mm to 8mm.

According to a preferred embodiment of the present invention, the core material is characterized by having a thickness of 6mm to 8mm by laminating the crosslinked polyolefin-based foam sheet having a thickness of 3mm to 4mm in two layers.

According to a preferred embodiment of the present invention, the mixing ratio of the PET fiber and the polyolefin fiber of the reinforcing material is 30:70 to 70:30 by weight ratio, characterized in that the thickness of the reinforcing material is 0.7mm to 3mm.

According to a preferred embodiment of the present invention, the reinforcing material is characterized in that it is cured by heating and pressing after fiber mixing by needle punching.

According to a preferred embodiment of the present invention, the reinforcing material is characterized in that attached to the core material by adhesive, heat fusion or needle punching.

According to a preferred embodiment of the present invention, one side of the reinforcing material may further include a skin material attached by adhesive, heat fusion or needle punching.

According to a preferred embodiment of the present invention, the skin material is characterized in that the polyolefin nonwoven fabric or polyester nonwoven fabric.

Car interior ceiling material substrate according to an embodiment of the present invention has the advantage of being lightweight and excellent in rigidity, and can be produced in a simple process compared to the conventional heating oven manufacturing process, thereby reducing the manufacturing cost.

In addition, by using the polyolefin-based foam sheet as a core material, the heat shrink is less, thereby ensuring the dimensional stability as well as bubbles are formed inside the polyolefin-based foam sheet is improved impact energy absorption and sound absorbing and insulating performance.

In addition, according to an embodiment of the present invention, when the ceiling material base is composed of only polyolefin-based materials, defective products may be generated or very simply recycled when the vehicle is abandoned.

Hereinafter, the present invention will be described in detail with reference to preferred embodiments of the accompanying drawings. 1 is a schematic diagram of a conventional car interior ceiling material substrate, Figure 2 is a schematic view of a vehicle interior ceiling material substrate according to an embodiment of the present invention, Figure 3 is a car with a skin material according to an embodiment of the present invention It is sectional drawing of the interior ceiling material base material.

1 is a schematic view of a vehicle interior ceiling material substrate 1 used as a conventional vehicle headliner, and is composed of a core material 2 and a skin material 3.

2 is a schematic view of a vehicle interior ceiling material substrate 10 according to an embodiment of the present invention, a core material 11 composed of a crosslinked polyolefin-based foam sheet and a reinforcement material provided on both sides of the core material 11. It consists of 12 pieces. At this time, it is of course possible that the reinforcing material 12 is provided only on any one of the upper side or the lower side of the core material (11).

Here, the crosslinked polyolefin-based foam sheet applied to the core material 11 according to an embodiment of the present invention is formed by foaming the crosslinked polyolefin-based foam in a sheet shape.

The crosslinked polyolefin-based foam can be classified into chemical crosslinking and physical crosslinking. The crosslinked polyolefin-based foam according to an embodiment of the present invention is not limited by the crosslinking method, but is preferably manufactured by a physical crosslinking method.

In addition, the resin for producing the crosslinked polyolefin-based foam is most preferably a mixed form of polyolefin-based and linear low density polyethylene.

On the other hand, in the case of using polypropylene alone, when irradiating an electron beam which is a physical crosslinking method for crosslinking, a certain amount of linear low density polyethylene (LLDPE) is added because polyolefin chains are easily cut and crosslinking efficiency is not so high.

When the linear low density polyethylene is used, the elongation of the final product is sharply improved, so the moldability is excellent.

In addition to linear low density polyethylene, low density polyethylene (LDPE), high density polyethylene (HDPE), ethylene propylene nonconjugated diene copolymer rubber (EPDM), ethylene propylene copolymer rubber (EPM) and the like may be used instead.

In order to crosslink the polyolefin system, a crosslinking aid must be added, and these crosslinking aids are divinylbenzene, triallyl cyanurate, trimethylolpropane, nitrosobenzene, diphenylguanidine and ethylene glycol dimethylacrylate and thirimethyl. Polyfunctional vinyl monomers such as allpropane trimethacrylate are suitable.

The addition amount of a crosslinking adjuvant is 0.1-2.0 weight part, More preferably, it is 0.3-1.5 weight part. In addition, one or more crosslinking aids may be mixed and added within the above weight part range.

The gel content of the polyolefin-based sheet crosslinked through the electron beam irradiation process as described above is 30% to 60% is appropriate, the crosslinking degree can be measured by ATSM D-2765.

As a blowing agent for producing a crosslinked polyolefin-based foam sheet according to an embodiment of the present invention, a thermally decomposable blowing agent is generally used, and azodicarbonamida (ADCA) is useful.

At this time, the addition amount of ADCA is different depending on the expansion ratio, but 5 to 20 phr addition is appropriate, if necessary, in addition to the above additives, inorganic fillers, antioxidants, weathering agents, antistatic agents, colorants can be added.

Method for producing a crosslinked polyolefin foam sheet according to an embodiment of the present invention is as follows.

First, the resins and additives of the kind described above are mixed in a half-barrier mixer, and then extruded into a sheet of a predetermined thickness through an extrusion apparatus, and subjected to electron beam irradiation.

The irradiated sheet is passed through a heat oven to prepare a continuous foam sheet.

The prepared crosslinked polyolefin foam sheet has a thickness of 3 to 8 mm and a product width of 100 to 1600 mm.

According to a preferred embodiment of the present invention, the foaming ratio of the crosslinked polyolefin foam sheet is preferably 5 times to 30 times.

That is, if the foaming ratio is less than 5 times, the weight is relatively high without affecting the sound absorption improvement, and if the foaming ratio is more than 30 times, the sound absorption and light weight are improved, but strength and shape stability are deteriorated. .

In order to use this crosslinked polyolefin-based foam sheet as a base material for automobile interior, it needs to be formed to a certain dimension. That is, the thickness is preferably 3 mm to 8 mm, more preferably 3 mm to 6 mm.

At this time, the core 11 is preferably laminated with a laminated polyolefin foam sheet having a thickness of 3mm to 4mm in two layers to have a thickness of 6mm to 8mm.

According to one embodiment of the invention, the reinforcing material 12 is composed of polyethylene terephthalate (PET) fibers and polyolefin-based fibers.

Here, it is preferable that the mixing ratio of PET fiber and polyolefin fiber constituting the reinforcing material 12 is 30:70 to 70:30 by weight ratio, and the thickness of the reinforcing material 12 is preferably 0.7mm to 3mm.

In this case, the two fibers are mixed by needle punching to produce a felt (felt) state, and then hardened by thermocompression, which is mainly related to the internal shape of the material and sound insulation performance of the material This is because it is closely related to density and structure.

That is, in order to satisfy the sound absorption performance, many fine open cell particles, such as urethane foam, must be present, and in the case of felt, it is known that the rigidity is increased and the sound insulation and sound insulation performance is increased compared to other materials using the same weight. have.

In addition, when the difference between the density of the surface and the sound absorbing material in the sound absorbing material, by using the principle that the energy loss is increased according to the different surface density of the sound absorbing material can exhibit more improved performance than the same surface density.

In addition, when the reinforcing member 12 composed of PET fibers and polyolefin-based fibers is molded in the mold in a state in which the reinforcing member 12 is attached to the core member 11, the releasability with the mold is improved, thereby improving workability.

At this time, the reinforcing material 12 may be attached to the core material 11 using a solvent-type adhesive or a hot melt type adhesive, and needle punching or heat fusion for simplification of work and prevention of odor caused by the adhesive. It is preferable to attach by the method.

According to one embodiment of the present invention, as shown in FIG. 3, the skin 13 may be further attached to one surface of the aforementioned reinforcement 12 as needed, and the skin 13 may be polyolefin-based. It is preferred that a nonwoven or polyester based nonwoven is used.

At this time, the skin material 13 may be attached to the reinforcing material 12 using a solvent type adhesive or a hot melt type adhesive, and the needle punching or It is preferable to attach by a thermal fusion method.

In other words, the vehicle interior ceiling material substrate 10 according to an embodiment of the present invention, as shown in Figure 3, each cross-linked as a core material 11 between the reinforcing material 12 is provided spaced apart from the top and bottom, respectively. The polyolefin-based foam sheet was inserted, and these were combined by needle punching method. The reinforcement 12 was laminated and bonded to the upper and lower portions of the crosslinked polyolefin-based foam sheet, respectively, and a high rigid skin was applied to the lower reinforcement 12 as necessary. The ash 13 is laminated and bonded.

At this time, the reinforcing material 12 is formed by mixing PET fibers and polyolefin-based fibers, and inserted the cross-linked polyolefin foam sheet of the core material 11 between the reinforcing material 12, the upper reinforcing material 12 and the core material 11 And needle punching the core 11 and the lower reinforcement 12, respectively, and is manufactured in a sequential step of laminating and bonding the skin 13 to the lower reinforcement 12 by needle punching.

Thus, the base material for automobile interiors is processed by processing the base material manufactured by laminating | stacking the reinforcement material 12 and the skin material 13 one by one using the crosslinked polyolefin foam seat | seet as the core material 11 in the required shape using a metal mold | die. Fabrication of the (10) is completed, and thus the built-in ceiling material substrate 10 for automobile interior has an advantage of high dimensional stability and rigidity.

In addition, when a crosslinked polyolefin foam sheet is applied as the core material 11 and a polyolefin nonwoven fabric is used as the skin material 13, a defect occurs during manufacture or the skin material 13 and the core material 11 when the vehicle is abandoned. Since it can be crushed and recycled as it is without separation, there is an advantage that it is resource-saving and environmentally friendly.

It is apparent to those skilled in the art that the present invention is not limited to the described embodiments, and that various modifications and changes can be made without departing from the spirit and scope of the present invention. That is, such modifications or variations will have to belong to the claims of the present invention.

1 is a schematic diagram of a conventional car interior ceiling material substrate.

Figure 2 is a schematic diagram of a vehicle interior ceiling material substrate according to an embodiment of the present invention.

Figure 3 is a cross-sectional view of the ceiling material for automobile interior with a skin material in accordance with an embodiment of the present invention.

Explanation of symbols on the main parts of the drawings

10: car interior ceiling material

11: heartwood

12: reinforcement

13: skin material

Claims (10)

And a core 11 formed of a crosslinked polyolefin-based foam sheet and a reinforcement 12 provided on one side or both sides of the core 11, wherein the reinforcement 12 includes polyethylene terephtalate (PET) fibers and A vehicle interior ceiling material substrate, wherein the polyolefin-based fibers are mixed at a weight ratio of 30:70 to 70:30. The method according to claim 1, The crosslinked polyolefin foam sheet comprises at least one component selected from the group consisting of polypropylene, linear low density polyethylene, low density polyethylene, high density polyethylene, ethylene propylene nonconjugated diene copolymer rubber (EPDM), and ethylene propylene copolymer rubber (EPM). Car interior ceiling material substrate comprising a. The method according to claim 1, The crosslinked polyolefin-based foam sheet is a vehicle interior ceiling material substrate, characterized in that having a product width of 700mm to 1600mm. The method according to claim 1, The foaming ratio of the crosslinked polyolefin-based foam sheet is 5 to 30 times, the thickness is 3mm to 8mm vehicle interior ceiling material substrate. The method according to claim 1, The core material 11 is a vehicle interior ceiling material substrate, characterized in that having a thickness of 6mm to 8mm by laminating the cross-linked polyolefin-based foam sheet having a thickness of 3mm to 4mm in two layers. The method according to claim 1, The thickness of the reinforcing member 12 is a vehicle interior ceiling material substrate, characterized in that 0.7mm to 3mm. The method according to claim 1, The reinforcing material 12 is a vehicle interior ceiling material base material, characterized in that the hardening by heating and pressing after mixing the fibers by needle punching. The method according to claim 1, The reinforcing member 12 is a vehicle interior ceiling material substrate, characterized in that attached to the core material 11 by adhesive, heat fusion or needle punching. The method according to claim 1, The interior of the ceiling material for automobile interior, characterized in that it further comprises a skin material (13) attached to one surface of the reinforcing material (12) by adhesive, heat welding or needle punching. The method according to claim 9, The skin material 13 is a vehicle interior ceiling material substrate, characterized in that the polyolefin nonwoven fabric or polyester-based nonwoven fabric.

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