KR101054752B1 - Composite panel for automobile interior and its manufacturing method - Google Patents

Abstract

The present invention relates to a composite panel for automobile interior materials and a method for manufacturing the same, the composite panel of the present invention is a felt comprising a natural fiber and a thermoplastic fiber; And a continuous thermoplastic fiber woven body comprising a continuous inorganic long fiber and a polyolefin resin. The manufacturing method includes: a first step of preparing a felt from natural fibers and thermoplastic fibers; A second step of preparing a thermoplastic continuous fiber by impregnating a continuous inorganic long fiber in a polyolefin resin; A third step of weaving the thermoplastic continuous fibers to produce a thermoplastic continuous fiber woven body (WCFT); And a fourth step of laminating the woven body on one or both sides of the felt. The present invention is excellent in mechanical properties such as tensile strength, flexural strength, heat resistance, impact resistance, and very light, and thus is suitable for use as automotive interior materials such as headlining, door trim, package tray, covering self, and seat back panel.

Automotive interior materials, natural fiber, inorganic long fiber, felt, thermoplastic continuous fiber weave

Description

Composite panel for interior materials of Vehicle and Preparing method

The present invention is a felt comprising a natural fiber and a thermoplastic fiber; And a continuous thermoplastic fiber woven body comprising a continuous inorganic inorganic fiber and a polyolefin resin. The present invention relates to a composite panel for automobile interior materials and a method of manufacturing the same.

The structure of a conventional automobile interior material is Resin Felt mixed with thermosetting phenolic resin to fibers mixed with hemp fiber, cotton fiber, chemical fiber, etc., and wood fiber mixed with phenolic resin with wood flour or wood fiber ( Or a three-layer felt structure in which an intermediate layer is laminated on both sides of a felt in which a polypropylene fiber and a hemp fiber are mixed at a predetermined ratio, and a felt in which a polypropylene fiber and a polyester fiber are mixed. Alternatively, a four-layered composite structure in which two sheets of composite felt (HS Felt) in which polypropylene foam paper is laminated on one side of a felt in which polypropylene (PP) fibers and hemp fibers are mixed at a predetermined mixing ratio, is laminated on a felt side. Generally used.

However, in the case of the resin felt and the wood fiber, a hardening agent called hexamine is added to promote the thermal curing of phenol, and the decomposition product of amine and ammonia is generated during the decomposition reaction of the hexamine, which is a odor generating factor. In terms of environmental hygiene, there is a problem that the working environment is poor due to dust generated by the powder phenol resin falls during the material handling process.

In another conventional technology of the three-layer felt structure, after forming the web (Web) through the carding (Carding), the web is laminated by combining the laminated webs in the needle-punching process by the needle-punching process To prepare, each of the intermediate layer felt and the felt layer is laminated on both sides of the intermediate layer felt to be laminated in three layers and then to combine the respective felt in the needle punching process.

In the conventional technique, in the case of the four-layered composite structure in which two composite felts in which PP bubble paper is laminated on one surface of the felt are laminated with the felt surface, the composite felt is manufactured in the same way as the three-layered felt structure described above. After lamination to each other, the needle punching process is to combine the respective felt. Therefore, the three-layer felt structure requires a total of four needle punching processes and the four-layer composite structure requires three needle punching processes, which not only reduces the production speed but also produces felts with a surface density of more than 1,800 g / m ^2. In this case, the needle punching stroke (Stroke) also has to be long and the capacity of the needle punching should be increased, so that the equipment is unreasonable or the process is not balanced, the needle is broken and the felt remains in the felt. Therefore, in the automotive industry, there is an increasing demand for new automotive interior materials that solve such problems.

Accordingly, the present inventors endeavor to solve the problems and industry demands of the existing automotive interior materials described above, using a thermoplastic continuous fiber woven fabric containing a continuous inorganic fiber and polyolefin resin, it is lighter than conventional automotive interior materials The present invention was completed by finding that it is possible to manufacture a composite panel having excellent mechanical properties.

Composite panel for automobile interior of the present invention for solving the above problems

Felts, including natural fibers and thermoplastic fibers; And a thermoplastic continuous fiber woven body comprising a continuous inorganic long fiber and a polyolefin resin.

In addition, the manufacturing method of the composite panel of the present invention

A first step of making felt from natural fibers and thermoplastic fibers; A second step of preparing a thermoplastic continuous fiber by impregnating a continuous inorganic long fiber in a polyolefin resin; A third step of weaving the thermoplastic continuous fibers to produce a thermoplastic continuous fiber woven body (WCFT); And a fourth step of laminating the woven body on one or both sides of the felt.

The present invention is excellent in mechanical properties such as tensile strength, flexural strength, heat resistance, impact resistance, while improving productivity and weight can be obtained, and thus, additional effects of improving engine fuel efficiency and reducing exhaust gas can be obtained.

The present invention described above will be described in detail below.

Composite panel for automobile interior of the present invention

Felts, including natural fibers and thermoplastic fibers; And

It comprises a; continuous continuous fiber woven fabric comprising inorganic long fibers and polyolefin resin.

In the structural description of the present invention, the composite panel for automobile interior of the present invention has a structure in which the thermoplastic continuous fiber woven body is laminated on one side or both sides of the felt, the exploded perspective view of the present invention as shown in Figs. 2 is shown.

And the present invention

Felt comprising 40 to 60% by weight of natural fibers and 40 to 60% by weight of thermoplastic fibers; And

Weaving continuous fiber reinforced thermoplastics (WCFT) comprising 30 to 50% by weight of continuous inorganic inorganic fibers and 50 to 70% by weight of polyolefin resin, characterized in that it comprises the following, The compositions will be described in more detail.

felt

In the present invention, the felt which is responsible for the strength and impact resistance of the composite panel comprises 40 to 60% by weight of natural fibers and 40 to 60% by weight of thermoplastic fibers, wherein the natural fibers to increase the strength of the composite panel When the natural fiber is less than 40% by weight relative to the total weight of the felt, the strength may be reduced due to the lack of the reinforcing fiber of the composite panel, and when more than 60% by weight, the natural fiber acts as a binder to bind the natural fibers. When the composite panel is formed due to the lack of thermoplastic fibers, the strength of the composite panel may be lowered due to the lack of bonding strength between the natural fibers. Such, the felt has an average surface density of 600 g / m ² ~ 1,400 g / m ² Characterized in that, if the average surface density of the felt is less than 600 g / m ^{2 It} is difficult to implement a felt having a predetermined thickness or more, 1,400 g / m ² In addition to the use of the excess, the weight of the composite panel, which is reinforced with the thermoplastic continuous fiber weave on one or both sides of the felt, increases the weight of the thermoplastic continuous fiber weave to reduce the weight of the composite panel, and also the reinforcing effect It is preferable to use felt having a surface density within the above range since it is reduced.

The natural fiber may be selected from the group consisting of Flax, Ramie, Hemp, Jute, and Kenaf, or two or more kinds of vegetable bast fibers (Bast Fiber); And single or two or more vegetable leaf vein fibers selected from Acaca, Sisal, Henkenn and the like; It is preferable to use single or 2 or more types of natural fibers selected from among them. And the natural fiber is good to use a fineness of 20 ~ 80 ㎛, 50 ~ 80 ㎜ length, where the fineness of the natural fiber is less than 20 ㎛ advantage that the strength to increase the bonding strength with the thermoplastic fiber increases However, due to the additional work of separating the natural fibers by physical methods or modifying the surface by chemical methods to produce the natural fibers to less than 20 ㎛, there may be a problem that leads to a decrease in productivity and an increase in price, 80 ㎛ If the excess is used, the natural fiber may be embedded in the cylinder in the carding process for producing the felt, and the productivity may be reduced, or the needle may be broken in the needle punching process. If the length of the natural fiber is less than 50 mm, the felt may be manufactured. Dust may be generated in the carding process, resulting in a poor working environment, exceeding 80 mm When a good idea to use natural fibers having a fineness and a length in the bar which can cause problems with the cylinder in the carding process for producing a felt of natural fibers which is wound decreases the productivity, the scope used.

The thermoplastic fibers are mixed with the natural fibers and melted during the preheating of the composite panel of the present invention, and the molten thermoplastic fibers are sintered between the natural fibers and cured between the natural fibers when the cooling process is performed. It serves to bind the binder and gives the moldability of the composite panel. Such thermoplastic fibers may have a fineness of 3 to 15 de, a length of 50 to 80 mm, and a crimp. In addition, the thermoplastic fiber is preferably a polypropylene fiber, a polyethylene fiber and a low melting point polyester fiber having a low melting point of 170 ° C to 200 ° C. Here, since the fineness of the thermoplastic fiber is less than 3 de, the fineness of the thermoplastic fiber is thin, and thus, in the carding process for producing the felt, the dispersion of the thermoplastic fiber may not be performed smoothly, and agglomeration may occur. In the carding process to produce a natural fiber is embedded in the cylinder or the weight of the web produced is reduced, there may be a problem that the productivity is lowered. If the length of the thermoplastic fiber is used less than 50 mm dust in the carding process for producing the felt This may result in a poor working environment, and the use of more than 80 mm may cause natural fibers to be wound around the cylinder in the carding process for producing felt, which may cause a problem of reduced productivity. It is preferable to use thermoplastic resin fibers having In addition, when the heat transmitted from the hot press to the composite panel when forming the composite panel exceeds 220 ℃, there is a problem that carbonization of natural fibers easily occurs, since the melting point is 240 ℃ ~ 260 ℃ when using general polyester fibers There is a problem to use to prepare a composite panel, the polyester fiber is preferably used a low melting point polyester having a low melting point.

Thermoplastic Continuous Fiber Weave

The thermoplastic continuous fiber woven body, which is one of the components of the present invention, includes 30 to 50% by weight of continuous long inorganic fiber and 50 to 70% by weight of polyolefin resin, where the inorganic long fiber is less than 30% by weight Problems may occur that the physical reinforcing effect is lowered, and when more than 50% by weight, it may be difficult to completely impregnate the polyolefin resin, the amount of the polyolefin resin is relatively determined by the amount of inorganic long fibers. The thermoplastic continuous fiber woven body is characterized in that the average surface density of 200 ~ 1,000 g / m ² , where the average surface density of 200 Using less than g / m ² may cause a problem that the reinforcing effect of the thermoplastic continuous fiber weave is reduced, 1,000 If the g / m ² or more is used, the surface density increases the weight of the composite panel as well as reduces the weight of the felt to reduce the weight of the composite panel. It is better to use one having a surface density.

The inorganic long fiber serves to increase the physical properties of the thermoplastic continuous fiber woven body, and may use a single type or two or more types of high strength fibers selected from glass fibers, Basalt fibers, carbon fibers, and metal fibers. The inorganic long fiber is a continuous fiber having a fineness of 8 to 20 μm, and when the fineness of the inorganic long fiber is less than 8 μm, there is a possibility that a price increase may be caused due to a decrease in productivity of the inorganic long fiber. In the manufacture of fibers, the broken inorganic fiber is likely to penetrate through the skin or respiratory organs, which may result in a poor working environment. It is preferable to use what has a fineness in the said range.

The polyolefin resin serves to bond the thermoplastic continuous fiber woven body and the felt and the moldability of the composite panel when forming the composite panel of the present invention. Here, since the heat transmitted to the composite panel in the hot press during the molding of the composite panel is generally 180 ° C. to 220 ° C., the polyolefin resin is selected from a polyethylene resin having a melting temperature of about 130 ° C. and a polypropylene resin of about 165 ° C. It is good to use.

Method for producing a composite panel of the present invention

A first step of making felt from natural fibers and thermoplastic fibers; A second step of preparing a thermoplastic continuous fiber by impregnating a continuous inorganic long fiber in a polyolefin resin; A third step of weaving the thermoplastic continuous fibers to produce a thermoplastic continuous fiber woven body (WCFT); And a fourth step of laminating the woven body on one or both sides of the felt.

Hereinafter, the present invention will be described in more detail with reference to Examples. However, the scope of the present invention is not limited by the following examples.

Manufacture of composite panel for automobile interior

Example 1

50% by weight of wool fibers having a fineness of 20 to 30 μm and a length of 80 mm and 50% by weight of a crimped polypropylene fiber having a fineness of 6 de and a length of 64 mm were formed to form a web through a carding process, and then formed a web. Was laminated to produce a felt having an average surface density of 1100 g / m ² through a needle punching process.

A glass continuous fiber (40 wt%) having a fineness of 12 μm was impregnated into a polypropylene resin (60 wt%) to prepare a thermoplastic continuous fiber woven fabric having a surface density of 550 g / m ² .

After laminating and stretching the thermoplastic continuous fiber woven body on the cross section of the felt, pressurized heating was performed for 90 seconds in a hot press adjusted to 240 ° C., and pressurized cooling for 60 seconds in a cold press to produce a composite panel having a thickness of 2.5 mm. It was.

Examples 2-6

Example 2 was carried out in the same manner as in Example 1, but a composite panel having a surface density of 1,000 g / m ² was laminated on the cross section of the felt to prepare a composite panel having a thickness of 2.5 mm, and Example 2 was carried out.

Example 3 was carried out in the same manner as in Example 1, wherein the thermoplastic continuous fibers were laminated on both sides of the felt to prepare a composite panel having a thickness of 2.5 mm.

And, Example 4 was carried out in the same manner as in Example 1, a composite panel having a thickness of 3.5 mm was prepared.

Example 5 was carried out in the same manner as in Example 2 and Example 6 in the same manner as in Example 3 to produce a composite panel having a thickness of 3.5 mm.

Manufacturing of composite panel for automobile interior

Comparative Example 1 to Comparative Example 2

50% by weight of Kenaf fibers with a fineness of 20 to 30 μm and 80 mm in length and 50% by weight of polypropylene (PP) fibers impregnated with a crimp of 6 de and 64 mm in length, through the carding process After forming the formed web was laminated on top of a polypropylene bubble paper having a surface density of 50 g / m ² to prepare ^two composite felt (HS Felt) with a surface density of 1150 g / m ² through a needle punching process. Then, the two composite felt sheets were laminated to each other with a felt surface, and the two composite felts were bound by a needle punching process, and heated under pressure in a hot press adjusted to 240 ° C. for 90 seconds, and then pressure-cooled in a cold press for 60 seconds. 2.5 mm and 3.5 mm composite panels were produced, respectively, and Comparative Example 1 and Comparative Example 2 were carried out.

Experimental Example

Property evaluation experiment

The composite panels prepared in Examples 1 to 7 and Comparative Examples 1 to 2 were measured in the tensile strength, flexural strength, flexural modulus and initial slope by the method shown in Table 1 below, the results are shown in Table 2 below.

Looking at the experimental results of Table 2, it can be confirmed that the composite panel for automobile interior of the present invention is very excellent mechanical properties, such as tensile strength, flexural strength than the conventional automotive interior composite panel. The composite panel of the present invention having such an effect is very suitable for use as automotive interior materials such as headlining, door trim, package tray, covering self, seat back panel and the like.

1 is an exploded perspective view of a composite panel for automobile interiors in which a thermoplastic continuous fiber woven body is formed in a cross section according to the present invention.

Figure 2 is an exploded perspective view of a composite panel for automobile interiors formed with thermoplastic continuous fiber woven body on both sides according to the present invention.

3 is a felt picture made by mixing a natural fiber and a thermoplastic fiber according to the present invention.

Figure 4 is a photograph of a thermoplastic continuous fiber woven body according to the present invention.

*** Description of the main parts of the drawings ***

10; felt

20; Thermoplastic Continuous Fiber Weave

Claims (9)

Contains natural and thermoplastic fibers with an average surface density of 600 g / m ² to 1,400 g / m ² In felt; And Thermoplastic continuous fiber weave comprising continuous long inorganic fiber and polyolefin resin and having an average surface density of 200 g / m ² to 1,000 g / m ² ; Composite panel for automobile interior, characterized in that it comprises a. delete The method of claim 1, wherein the natural fiber Flax, hemp, jute, jute, hemp, abaca, sisal and heneken selected from the group consisting of two or more of the composite material for automobile interiors. The method of claim 1, wherein the thermoplastic fiber A composite panel for automobile interiors comprising at least one selected from polypropylene fibers, polyethylene fibers and low melting point polyester fibers having a melting point of 170 ° C. to 220 ° C. The method of claim 1, wherein the inorganic long fiber Fineness is 8 μm to 20 μm, A composite panel for automobile interior materials comprising at least one selected from glass fibers, basalt fibers, carbon fibers and metal fibers, or two or more thereof. The method of claim 1, wherein the polyolefin resin A composite panel for automobile interiors, characterized in that it is one or two selected from polypropylene resin and polyethylene resin. According to any one of claims 1 and 3 to 6, wherein the composite panel Felt comprising 40 to 60% by weight of natural fibers and 40 to 60% by weight of thermoplastic fibers; And Composite continuous fiber woven fabric comprising a continuous continuous inorganic fiber 30 to 50% by weight and 50 to 70% by weight of a polyolefin resin; composite panel for an automotive interior. The method of claim 7, wherein the automotive interior material A composite panel for automobile interiors, characterized in that the headlining, door trim, package tray, covering self, or seat back panel. Natural and thermoplastic fibers with an average surface density of 600 g / m ² ~ 1,400 g / m ² A first step of preparing the phosphate; A second step of preparing a thermoplastic continuous fiber having an average surface density of 200 g / m ² to 1,000 g / m ² by impregnating a continuous inorganic long fiber in a polyolefin resin; A third step of weaving the thermoplastic continuous fibers to produce a thermoplastic continuous fiber woven body; And A fourth step of laminating the woven body on one side or both sides of the felt; Method of manufacturing a composite panel for automotive interiors comprising a.

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