KR101143514B1 - Manufacturing method of composite panel for automobile interior - Google Patents

Abstract

The present invention relates to a method for manufacturing a composite panel for automobile interiors, comprising: a blending step of intermixing polypropylene fibers and E-GLASS fibers, and a felt layer by carding and needle punching the fibers manufactured in the aforementioned blending step Felt layer forming step, horn sum surface step of blending synthetic fibers, second felt layer forming step of carding and needle punching the fibers prepared in the horn sum surface step described above, the first felt layer forming step described above Laminating a second felt layer formed in the above-described second felt layer forming step and needle punching on both sides of the first felt layer formed in the laminated non-woven fabric on both sides of the laminate formed through the above-described lamination step It comprises a non-woven layer forming step of thermal compression.

Automotive, Interior, Panel, Polypropylene, E-GLASS, Polyester, Non-woven

Description

Manufacturing method of composite panel for automobile interior {MANUFACTURING METHOD OF COMPOSITE PANEL FOR AUTOMOBILE INTERIOR}

The present invention relates to a method for manufacturing a composite panel for automobile interiors, comprising a blending step, a first felt layer forming step, a blending surface, a second felt layer forming step, a lamination step and a nonwoven fabric layer forming step.

The present invention relates to a method for manufacturing a composite panel for automobile interiors, comprising a blending step, a first felt layer forming step, a blending surface, a second felt layer forming step, a lamination step and a nonwoven fabric layer forming step.

Conventionally used composite panels for automobile interiors are made of resin felt mixed with thermosetting phenolic resin with fibers mixed with hemp fiber, cotton fiber and chemical fiber, and wood fibers mixed with phenolic resin with wood powder or wood fiber. Alternatively, hemp fiber composite felt in which polypropylene fiber and hemp fiber were mixed in a proportion was used.

However, in the case of resin felt or woodfiber, a hardening agent called hexamine is added to promote thermal curing of phenol, and hexamine generates decomposition by-products of amines and ammonia during the decomposition reaction. In terms of environmental hygiene, it is mainly suitable, there was a harmful problem to the human body.

In addition, phenol resin dust is generated in the process of handling phenolic resin for application to interior parts, which adversely affects working environment pollution and worker's health, and in the process of forming phenolic resin into a certain form, formaldehyde harmful to human body And volatile organic compounds (VOCs).

In addition, in the case of the composite felt using hemp fiber, it is weak in heat resistance and moisture resistance, so in order to obtain suitable properties for use as a composite panel for automobile interior, a heavy weight felt containing a large amount of hemp fiber should be used. Due to the increase in the weight of the composite felt for the interior of the car, there was a problem that odor occurs due to carbonization of hemp fiber.

It is an object of the present invention to provide a method for manufacturing a composite panel for automobile interiors which is light in weight and excellent in dimensional stability against heat and moisture.

Another object of the present invention is to provide a composite panel for automobile interiors in which no formaldehyde and volatile organic compounds are harmful to a human body.

Still another object of the present invention is to provide a method for manufacturing a composite panel for automobile interior having a smooth surface by forming a second felt layer while having excellent mechanical properties using E-GLASS fibers.

An object of the present invention is to blend the polypropylene fiber and E-GLASS fiber mixed step, the first felt layer forming step of forming a felt layer by carding and needle punching the fiber prepared in the blending step, to blend the synthetic fiber The second felt layer forming step of carding and pulverizing the fibers prepared in the horn sum surface, forming a felt layer by needle punching, the second felt on both sides of the first felt layer formed in the first felt layer forming step A laminating step of laminating and needle punching the second felt layer formed in the layer forming step and a nonwoven fabric layer forming step of laminating and thermocompressing a polyester nonwoven fabric on both sides of the laminate formed through the laminating step.

According to a preferred feature of the invention, the mixing step is to be made by mixing 40 to 60 parts by weight of polypropylene fiber and 40 to 60 parts by weight of E-GLASS fiber.

According to a more preferred feature of the invention, the blending cotton surface step is made by blending 70 to 99 parts by weight of polypropylene fiber and 1 to 30 parts by weight of polyester fiber, or by taking 100 parts by weight of polypropylene fiber.

According to a more preferred feature of the present invention, the E-GLASS fiber is to comprise at least one selected from the group consisting of yarns formed of E-GLASS filament yarns and monospun yarns formed of E-GLASS filament yarns.

According to an even more preferred feature of the present invention, the E-GLASS fibers are 5 to 33 ㎛ in diameter, 50 to 80mm in length.

According to an even more preferable feature of the present invention, the surface density of the first felt layer is 400 to 1200g / m ² , the surface density of the second felt layer is 100 to 400g / m ² .

According to a further preferred feature of the present invention, the surface density of the polyester nonwoven layer is 20 to 100g / m ² .

According to a further preferred feature of the invention, the thermocompression uses a roller preheated to a temperature of 200 to 230 ° C.

The manufacturing method of the composite panel for automobile interiors according to the present invention exhibits an excellent effect of providing a composite panel for automobile interiors which is light in weight and excellent in dimensional stability against heat and moisture.

In addition, it exhibits an excellent effect of providing a composite panel for automobile interior which does not generate formaldehyde and volatile organic compounds harmful to the human body.

In addition, while using E-GLASS fiber has excellent mechanical properties, the second felt layer is formed to provide an excellent effect of providing a smooth interior surface composite panel.

In the following, preferred embodiments of the present invention and the physical properties of each component will be described in detail, which is intended to explain in detail enough to be able to easily carry out the invention by one of ordinary skill in the art, This does not mean that the technical spirit and scope of the present invention is limited.

In the manufacturing method of the composite panel for automobile interior according to the present invention, a blending step (S101) of mixing polypropylene fibers and E-GLASS fibers, carding and needle punching the fibers manufactured in the aforementioned blending step (S101), and forming a felt layer The first felt layer forming step (S103) to form, the horn sum surface step (S015) to blend the synthetic fibers, carding and needle punching the fibers prepared in the horn sum surface step (S105) described above to form a felt layer The second felt layer 20 formed in the above-described second felt layer forming step S107 on both sides of the felt layer forming step S107 and the first felt layer forming step S103 described above. ) Laminating and needle punching (S109) and the nonwoven fabric layer forming step (S111) of laminating and thermocompression bonding the polyester nonwoven fabric 30 on both sides of the laminate formed through the above-described lamination step (S109) Is done.

The above-mentioned mixing step (S101) is a step of mixing the polypropylene fiber and the E-GLASS fiber, and is made by mixing 40 to 60 parts by weight of polypropylene fiber and 40 to 60 parts by weight of the E-GLASS fiber, to blend the fibers evenly This is done by applying the air blowing method.

The aforementioned E-GLASS fibers comprise at least one selected from the group consisting of yarns formed from E-GLASS filament yarns and single-spun spun yarn fibers formed from E-GLASS filament yarns, wherein the yarns formed from E-GLASS filament yarns are twisted and flexible Single yarn (SINGLE YARN) is used, the single-spun yarn made of E-GLASS fiber is used single spinning yarn (SINGLE ROVING) fiber with excellent mechanical strength.

The aforementioned E-GLASS fibers have a diameter of 5 to 33 µm and a length of 50 to 80 mm.

The above-mentioned E-GLASS fiber serves to increase the dimensional stability against heat and moisture resistance of the composite panel for automobile interior, and the above-mentioned polypropylene fiber is melted during molding and soaked between the aforementioned E-GLASS fiber and cured. It acts as a binder that binds E-GLASS fibers and improves the moldability of composite panels for automobile interiors.

The first felt layer forming step (S103) described above is a step of forming a felt layer by carding and needle punching the fibers blended in the blending step (S101) described above, and the fibers blended through the blending step (S101) described above. Carding to have a uniform shape and to form a uniform shape to form a web having a surface density of 400 to 1200g / m ² , and then to punch the needle to increase the binding force of the web to form a first felt layer (10).

The binding force of the webs is increased by the aforementioned needle punching, and the mechanical properties of the composite panel for automobile interiors manufactured using the web with the increased binding force are improved.

The above-mentioned blending surface step (S105) is a step of blending the polypropylene fiber and the polyester fiber, 70 to 100 parts by weight of polypropylene fiber and 1 to 30 parts by weight of the polyester fiber by applying an air blowing (Air Blowing) method It is made by interweaving fibers or other fibers made of 100 parts by weight of polypropylene fibers.

The above-described second felt layer forming step (S107) is a step of forming a felt layer by carding and needle punching the blended fiber in the blending batting surface step (S105) described above. Carded fibers are evenly arranged so as to have a uniform shape and manufactured in the shape of a web having a surface density of 100 to 400 g / m ² , and then needle punched to increase the binding force of the web to form a second felt layer 20. It's a step.

The above-described lamination step (S109) is the second felt layer 20 formed in the above-described second felt layer forming step (S107) on both sides of the first felt layer forming step (S103). ) Is laminated and needle punched, since the E-GLASS fibers intermixed with the first felt layer 10 protrude to the surface of the first felt layer 10 to roughen the surface. ) Is laminated on both sides of the first felt layer 10 to prevent the E-GLASS fibers from protruding, and serves to complement the mechanical properties of the first felt layer (10).

The above-described nonwoven fabric layer forming step (S111) is a step of laminating and thermocompression bonding the polyester nonwoven fabric 30 on both sides of the laminate formed through the above-described lamination step (S109), and having a surface density of 20 to 100 g / m ² . The polyester nonwoven fabric 30 is laminated on both sides of the laminate and thermally compressed using a thermocompression roller. The composite panel for automobile interior manufactured through the formation of the polyester nonwoven fabric 30 has a smooth surface and an appearance quality. Is improved.

At this time, the thermocompression uses a roller preheated to a temperature of 200 to 230 ℃, the roller preheated to this temperature is most suitable for the melt-bonding of the laminate and the polyester nonwoven fabric 30 with a surface temperature of 180 to 200 ℃ Indicates the temperature.

Hereinafter, the production method and the property test results of the composite vehicle interior panel according to the present invention will be described with reference to Examples.

≪ Example 1 >

50 parts by weight of E-GLASS fiber and 50 parts by weight of polypropylene fiber in the form of single-spun spun fiber having a diameter of 12 μm and a length of 80 mm are mixed by air blowing, and then carded and needle punched to obtain a surface density of 700 g / m ^2. Phosphorous first felt layer 10 was prepared, and 80 parts by weight of polypropylene fiber and 20 parts by weight of polyester fiber were mixed with air blowing, followed by carding and needle punching to form a second felt layer having a surface density of 200 g / m ² . (20), and after laminating the second felt layer 20 on both sides of the first felt layer 10, needle punching to form a laminate, the surface density of 50g / m ² on both sides of the laminate The ester nonwoven fabric 30 was laminated and thermocompressed with a roller at 200 ° C. to manufacture a composite panel for automobile interior.

Comparative Example 1

A web having a surface density of 1000 g / m ² was prepared by mixing 50 parts by weight of E-GLASS fiber and 50 parts by weight of polypropylene fiber in the form of a single-spun fiber having a diameter of 12 μm and a length of 80 mm by air blowing. the area density on both sides, and then combined by needle punching and then laminated paper polypropylene foam of 50g / m ² to produce a layered product, and the area density is laminated to 50g / m ² of spun-bonded polyester non-woven fabric to laminate on both sides 200 of the Thermocompression bonding was carried out with a roller at 0 ° C. to manufacture a composite panel for automobile interiors.

Comparative Example 2

In the same manner as in Comparative Example 1, 50 parts by weight of jute fiber and 50 parts by weight of polypropylene fiber were mixed to prepare a composite panel for automobile interior using a felt having a surface density of 1200 g / m ² .

Car interior composite panel prepared in Example 1, Comparative Example 1 and Comparative Example 2 using a hot press having a surface temperature of 220 ℃ preheat pressed at 60kgf / cm ² for 60 seconds using a cold press By cold pressing for 45 seconds at a pressure of 80kgf / cm ² to prepare a board having a thickness of 3.5mm.

The tensile strength, flexural strength, flexural modulus, and initial slope of the board were measured using INSTRON's UTM (Universal Test Machine), and the results are shown in Table 1 below.

(However, the tensile strength of each of the five boards of 50 × 150mm in size, measured by MD (Machine Direction) and AMD (Across Machine Direction) based on the tensile speed of 50mm / min and showed the average value .

The flexural strength of each of the five boards 50 × 150mm in size, measured by the MD (Machine Direction) and AMD (Across Machine Direction) based on the compression rate of 5mm / min, respectively, the average value was shown.

The flexural modulus was prepared on each of five boards of 50 × 150 mm in size, and the average values were measured after measuring the compression speeds of 5 mm / min in MD (Machine Direction) and AMD (Across Machine Direction).

The initial tilt was made on each board of 50 × 150mm size, and measured on the basis of the compression speed of 5mm / min by MD (Machine Direction) and AMD (Across Machine Direction).

TABLE 1

As shown in Table 1 above, the composite panel according to the present invention has a superior physical property in tensile strength, flexural strength, flexural modulus and initial slope as compared to the conventional composite panel for automobile interior.

The composite panel for automobile interior manufactured in Example 1 was preheated and pressed for 60 seconds using a hot press having a surface temperature of 220 ° C. at a pressure of 60 kgf / cm ² , and then using a click covering self mold (Hyundai Motor) A covering self-prepared product was prepared by cold pressing at a pressure of 80 kgf / cm ² for 45 seconds.

The rate of dimensional change in the heat, cold and moisture conditions of the covering self product was measured and shown in Table 2 below.

(However, the rate of dimensional change was measured using a constant temp & humid chamber of KOREA KUMS Co., Ltd.

The rate of dimensional change was heated from 23 ° C. to 120 ° C. for 1 hour, maintained at 120 ° C. for 3 hours, cooled from 120 ° C. to 23 ° C. for 1 hour, and maintained at 23 ° C. for 1 hour, 1 Cool to minus 40 ° C. at 23 ° C. for hours, maintain minus 40 ° C. for 3 hours, heat from minus 40 ° C. to 23 ° C. for 1 hour, maintain 23 ° C. for 1 hour, and 23 ° C. at 1 hour Relative humidity is raised to 90% RH while heating to 50 ° C, maintaining 50 ° C and 90% RH for 7 hours, cooling from 50 ° C to 23 ° C and lowering 90% RH to 50% for 1 hour Was repeated once, and a total of three repetitions were performed to measure the presence or absence of deformation of the covering self product.)

TABLE 2

As shown in Table 2 above, the automobile interior composite panel manufactured by the manufacturing method of the automobile interior composite panel according to the present invention exhibits excellent dimensional stability.

1 is a flow chart showing a manufacturing method of a composite panel for interior of the vehicle according to the present invention.

2 is a cross-sectional view showing a composite vehicle interior panel manufactured by the method for manufacturing a composite vehicle interior panel according to the present invention.

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

10; First felt layer

20; 2nd felt layer

30; Polyester nonwoven fabric

Claims (8)

A blending step of blending polypropylene fibers and E-GLASS fibers; A first felt layer forming step of forming a felt layer by carding and needle punching the fibers prepared in the blending step; A horn sum surface step of blending synthetic fibers; A second felt layer forming step of forming a felt layer by carding and needle punching the fibers prepared in the blending surface; A lamination step of laminating and needle punching the second felt layer formed in the second felt layer forming step on both surfaces of the first felt layer formed in the first felt layer forming step; And And a nonwoven fabric layer forming step of laminating and thermocompressing a polyester nonwoven fabric on both sides of the laminate formed through the lamination step. The method according to claim 1, The mixing step is a manufacturing method of a composite panel for automobile interiors, characterized in that the mixed polypropylene fiber 40 to 60 parts by weight and E-GLASS fiber 40 to 60 parts by weight. The method according to claim 1, Wherein the blending cotton surface step is made by blending 70 to 99 parts by weight of polypropylene fiber and 1 to 30 parts by weight of polyester fiber, or 100 parts by weight of polypropylene fiber manufacturing method of a composite panel for automobile interiors. The method according to claim 1, The E-GLASS fiber is a method of manufacturing a composite panel for automobile interiors, characterized in that it comprises one or more selected from the group consisting of yarns formed of E-GLASS filament yarn and single-spun spun yarn formed of E-GLASS filament yarn. The method of claim 4, The E-GLASS fiber has a diameter of 5 to 33㎛, the length of the manufacturing method of the composite panel for interior of the car, characterized in that 50 to 80mm. The method according to claim 1, The surface density of the first felt layer is 400 to 1200g / m ² , the surface density of the second felt layer is 100 to 400g / m ² The manufacturing method of the composite panel for automobile interiors. The method according to claim 1, The polyester nonwoven fabric layer has a surface density of 20 to 100g / m ² The manufacturing method of the composite panel for automobile interiors. The method according to claim 1, The thermocompression manufacturing method of a composite panel for automobile interiors, characterized in that using a roller preheated to a temperature of 200 to 230 ℃.

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