KR101892645B1 - Composite panel for loading structure - Google Patents

Abstract

Disclosed is a composite panel for a load structure having enhanced water resistance, durability and airtightness. In the composite panel according to embodiments of the present invention, the gas (bubble) generated in a curing process of a thermosetting adhesive resin is discharged to the outside through voids formed in a short fiber assembly, so that the composite panel is not peeled off even after frequent vibration or time. The short fiber assembly includes polyester short fibers, glass fiber short fibers, and carbon fiber short fibers to enhance the durability of the composite panel. Further, joints of a plurality of foaming foams forming an inner layer of the composite panel are not formed in a straight line in the vertical direction but formed in a combined form in the horizontal direction and the vertical direction (forming a combining part or bridging layer) to enhance the airtightness to reduce cold air leakage or inflow of outside air, thereby enhancing insulation efficiency.

Description

[0001] COMPOSITE PANEL FOR LOADING STRUCTURE [0002] The present invention relates to a composite panel for a building structure having improved invasiveness, durability and airtightness.

The present invention relates to a composite panel, and more particularly, to a composite panel for a load structure having a low damage rate (high resistance to intrusion) and improved durability and airtightness even when invasive.

The logistics industry market is growing day by day. As demand-driven markets have grown significantly, suppliers have been supplying goods through a wider variety of channels, and logistics competitiveness has become an important competitive element. As a result, the demand for special vehicles with stacked structures is also increasing, and research and development for improving the functions of these vehicles is actively being carried out.

For special vehicles equipped with loading structures for courier or cargo transport, the function and performance of the loading structure is crucial to the operators operating these vehicles. In addition, the durability and light weight of the load structure directly connected to the service unit price is also important for stable profitability. Therefore, the research and development on the load structure is progressing not only to improve the function and performance of the load structure, but also to improve durability and light weight.

Generally, the stacking structure is formed by assembling the composite panel into a box shape. At this time, the composite panel is manufactured by attaching core materials such as paper or foam plastic, wood plywood (mainly plywood) to both sides of the core material, and attaching a finishing material to the outer side of the wood plywood . The core material, the wood plywood, and the finishing material are attached using an adhesive.

However, there are some problems in the case of a composite panel manufactured in this manner.

First, moisture penetrates into the wood plywood. There is a temperature difference between inside and outside of the stacked structure. If the loaded cargo is food, etc., the internal temperature of the cargo structure should be kept low. The temperature difference between the inside and outside of the load structure causes condensation. Since the stacked structure has a plurality of composite panels assembled, moisture is likely to penetrate into the wood plywood by condensation. Wood plywood is vulnerable to moisture. Over time, there is mold, wood, or wood that is twisted by moisture. Therefore, timber plywood should be periodically replaced. Maintenance costs or replacement costs are excessive.

Second, the durability is weak. The adhesive that bonds the core, the wood plywood, and the finish material together is a thermosetting adhesive. These adhesives are generally heated while bubbles are generated. However, it is difficult to discharge these bubbles to the outside in the stacked structure formed by mutually joining the core material, the wood plywood, and the finishing material. This is why bubbles are present in the adhesive in the form of pores. The pores repeat shrinkage and expansion as the temperature changes are repeated. Repeated shrinkage and expansion are factors that decrease the adhesive strength and adhesive strength. As a result, vibration often occurs due to local factors (unpacked roads, mountainous areas, etc.), and the core material, wood plywood and finishing material are peeled off due to deterioration of adhesiveness (so-called mooring phenomenon). In addition, since the wood plywood is hard and its vibration absorbing ability is relatively low, problems such as loosening of fastening parts (bolts, rivets, etc.) occur due to frequent vibration. Similarly, maintenance costs or replacement costs are excessive.

Third, it is a problem that cool air leaks from the joint part of a plurality of core materials or the outside air flows in, resulting in low insulation efficiency. In order to form a relatively large-sized load structure, a plurality of core materials are disposed so as to be in contact with each other. At this time, since the joint between the core and the core is not completely airtight, cold air may leak through the joint, or outside air may be introduced, which may lead to deterioration of heat insulation efficiency.

The above-mentioned problems are the main factors that increase the cost of vehicle operators. That's why we need to improve.

Patent Document 1: Korean Utility Model Registration No. 20-0264919 (published on Feb. 21, 2002)

The present invention is to provide a composite panel for a load structure that has low damage rate and does not cause faulty mending, thereby improving life and durability as well as having excellent heat insulation and light weight in comparison with a wood lumber reinforcement.

According to an aspect of the present invention, there is provided a laminated sheet comprising: an inner layer comprising a first inner layer and a second inner layer bonded to both sides of the first inner layer respectively and formed of foamed polyethylene foam, foamed polyurethane foam, expanded polystyrene foam or compressed styrofoam; And the first inner layer and the second inner layer each have a first protruding portion extending in a direction from one side to the other and protruding downwardly, and a second protruding portion formed between the first protruding portion and the one side surface A first engaging portion including a first accommodating portion; And a second engaging portion extending from the lower portion to the other portion and having a shape protruding upward and a second accommodating portion formed between the second projecting portion and the other side of the first engaging portion, One side of the first inner layer and the other side of the second inner layer are bonded to each other in such a manner that the protrusions are received in the second accommodating portion of the second inner layer and the first accommodating portion of the first inner layer accommodates the second protrusions of the second inner layer, The second protrusions of the inner layer are accommodated in the first accommodating portion of the second inner layer and the second accommodating portion of the first inner layer accommodates the first protrusions of the second inner layer so that one side of the first inner layer and one side of the second inner layer are bonded Wherein the outer layer comprises a first sheet bonded to one side of the inner layer and a second sheet laminated to the first sheet and formed of glass fiber reinforced plastic or aluminum, Bonded short-fiber bonded body is thermosetting Wherein the short fiber bonded body has a web formed of a first staple fiber which is a polyester fiber, a web formed by a second staple fiber which is a glass fiber, and a third staple fiber which is a carbon fiber Wherein the web comprises a formed web and the content of the second staple fibers is less than the content of the first staple fibers and the content of the third staple fibers is less than the content of the second staple fibers, Can be provided.

According to another aspect of the present invention, there is provided a method of manufacturing a semiconductor device comprising a first inner layer, a second inner layer, and a bridge layer interconnecting the first inner layer and the second inner layer and comprising a foamed polyethylene foam, a foamed polyurethane foam, a foamed polystyrene foam, A first inner groove formed on a side of the first inner layer, a second insertion groove formed on a side of the second inner layer, and a bridge layer having a cross section The first and second inner layers are connected to each other by a first end inserted into the first insertion groove and a second end inserted into the second insertion groove to connect the first inner layer and the second inner layer, And a second sheet laminated on the first sheet and formed of glass fiber reinforced plastic or aluminum, wherein the first sheet is a laminate in which the short-fiber bonded body in which the webs formed by the short fibers are mutually bonded is thermosetting adhesive And the short fiber bonded body is formed by a web formed of a first staple fiber which is a polyester fiber, a web formed by a second staple fiber which is a glass fiber, and a web formed by a third staple fiber which is a carbon fiber Wherein the content of the second staple fibers is less than the content of the first staple fibers and the content of the third staple fibers is less than the content of the second staple fibers based on the total weight of the staple fibers, A composite panel can be provided.

In the composite panel according to embodiments of the present invention, the gas (bubbles) generated in the curing process of the thermosetting adhesive resin is discharged to the outside through the pores formed in the short fiber assembly, so that the composite panel is not peeled off even after frequent vibration or time. The durability of the bar composite panel formed by including the short staple fiber of polyester, the short fiber of glass fiber, and the short fiber of carbon fiber can be improved.

In addition, since the first sheet constituting the outer layer of the composite panel does not cause mold generation or distortion even when moisture penetrates, the life of the product can be greatly improved compared to the case of using conventional wood plywood. Further, It is possible to lower the tolerance weight at the time of forming the structure, thereby increasing the fuel efficiency of the vehicle on which the load structure is mounted.

Further, the joints of a plurality of foamed foams constituting the inner layer of the composite panel are not formed in a straight line in the vertical direction but are formed in a combination of a horizontal direction and a vertical direction (forming a joining portion or bridging layer) The cold air leakage or the inflow of outside air can be reduced, and the insulation efficiency can be further improved.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic cross-sectional view of a composite panel for a building according to an embodiment of the present invention; FIG.
2 is a schematic cross-sectional view of a composite panel for a stacked structure according to another embodiment of the present invention.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings. It is to be understood that the following description is illustrative of the present invention, and the technical spirit of the present invention is not limited to the following description. BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. In addition, thickness, size, etc. of each member in the drawings may be exaggerated, omitted, or schematically shown for convenience of explanation.

In the description of the structure of the present invention described herein, the positional relationship or direction is based on the drawings attached hereto unless otherwise stated.

In the description of the structure of the present invention described in the present specification, the description of the space and the description of the positional relationship mean the relative positions between the elements constituting the present invention. Also, unless otherwise stated, there may be other components in the space between one component and another. For example, when reference is made herein to the presence of "on top" or "on top" of one component, it is to be understood that not only is there a case where another component is located directly on top of one component, Until the element and another element are located between the other elements.

1 is a view schematically showing a cross section of a composite panel 100 for a stacked structure according to an embodiment of the present invention.

Referring to FIG. 1, a composite panel 100 includes an inner layer 110 and an outer layer 120 that is bonded to both surfaces of the inner layer 110, respectively.

The inner layer 110 may be selected from expanded polyethylene foam, foamed polyurethane foam, expanded polystyrene foam, or compressed styrofoam having a certain standard. The inner layer 110 functions and functions as heat insulation, sound insulation, sound insulation, and insulation. In one embodiment, the inner layer 110 may have the shape of an extruded board. In one embodiment, the density of the inner layer 110 is 30-60 kg / m < ³ >, and the compressive strength may be greater than 10 N / cm < ² >. The thickness of the inner layer 110 may be about 3 cm to 5 cm.

A plurality of slots a may be formed on a surface of the inner layer 110 in the direction of the outer side 120 (i.e., upper and lower surfaces of the inner layer 110 in Fig. 1). In one embodiment, the slot a may be formed in a V-shaped groove. For example, the slot (a) may be a 'V-shaped groove' shape having a width of 1 mm and a depth of about 2 to 3 mm. The spacing between slots a is not specified, and may be, for example, 5-10 cm. In the slot (a), gas (bubbles) generated in the curing process of the thermosetting adhesive resin applied to both surfaces of the inner layer 110 are discharged to the outside in joining the outer layer 120 to the inner layer 110. In addition, since the thermosetting adhesive resin is applied to both surfaces of the inner layer 110, a part of the inner surface of the inner layer 110 is filled with the slots a, so that the bonding strength between the inner layer 110 and the outer layer 120 can be increased.

The inner layer 110 includes a first inner layer 111 and a second inner layer 112. The first inner layer 111 and the second inner layer 112 are bonded in the longitudinal direction. Specifically, the other side of the second inner layer 112 abuts against one side of the first inner layer 111. The shapes of the first inner layer 111 and the second inner layer 112 are the same or similar as shown in Fig.

The first inner layer 111 and the second inner layer 112 include a first coupling portion 113 and a second coupling portion 115. The first engaging portion 113 is formed on one side of the first inner layer 111 and the second inner layer 112, respectively. The second coupling portion 115 is formed on the other side of the first inner layer 111 and the second inner layer 112, respectively. The first inner layer 111 and the second inner layer 112 are joined through the first and second coupling portions 113 and 115. Here, "one side" means the left side with reference to Fig. The "other side " means the right side with reference to Fig. The same applies to the following unless otherwise stated.

Since the first engaging portion 113 and the second engaging portion 115 formed on the first inner layer 111 and the second inner layer 112 have the same shape and the first engaging portion 113 formed on the first inner layer 111 113 and the second coupling portion 115 will be mainly described.

The first engaging portion 113 includes a first protruding portion 113a and a first accommodating portion 113b. The first protrusion 113a extends from the upper portion of the first inner layer 111 in one direction and protrudes downward. That is, as shown in Fig. 1, the first protrusion 113a has a shape in which the "a" is 180 degrees symmetrical. The first receiving portion 113b has a shape of being drawn upward between the first protrusion 113a and one side of the first inner layer 111. [

The second engaging portion 115 includes a second protrusion 115b and a second accommodating portion 115a. The second protrusion 115b extends from the bottom of the first inner layer 111 to the other side and protrudes upward. That is, as shown in Fig. 1, the second protrusion 115b has a shape in which "b" is 180 degrees symmetrical. The second accommodating portion 115a is drawn downward between the second protrusion 115b and the other side of the first inner layer 111. [

The coupling of the first and second inner layers 111 and 112 through the first and second coupling portions 113 and 115 will be described.

The first protrusion 113a of the first inner layer 111 is accommodated in the second accommodating portion of the second inner layer 112 and the first accommodating portion 113b of the first inner layer 111 is accommodated in the second inner layer 112, One side of the first inner layer 111 and the other side of the second inner layer 112 are bonded to each other. The second protrusions 115b of the first inner layer 111 are accommodated in the first accommodating portion of the second inner layer 112 and the second accommodating portion 115a of the first inner layer 111 is accommodated in the second inner layer 112 The other side of the first inner layer 111 and one side of the second inner layer 112 are bonded to each other. In other words, the first engaging portion 113 of the first inner layer 111 and the second engaging portion of the second inner layer 112 are engaged with each other to form one side of the first inner layer 111 and the second inner layer 112, And the second engaging portion 115 of the first inner layer 111 and the first engaging portion of the second inner layer 112 are engaged with each other so that the other side of the first inner layer 111 and the second engaging portion of the second inner layer 112 are engaged with each other. One side of the inner layer 112 is bonded. The joining portions of the first inner layer 111 and the second inner layer 112 are formed by merely engaging the serpentine first engaging portion 113 and the second engaging portion 115 with each other, And the horizontal direction and the vertical direction are combined. Accordingly, the airtightness of these joints is strengthened, thereby reducing the possibility that cool air leaks through the joints or outside air is introduced. Therefore, the heat insulating efficiency can be further improved. In addition, since the side bonding properties of the first and second inner layers 111 and 112 are structurally improved, the first and second inner layers 111 and 112 can be more firmly bonded even if a smaller amount of adhesive is used.

The outer layer 120 includes a first sheet 121 and a second sheet 122 laminated to the first sheet 121.

The first sheet 121 is bonded to one surface of the inner layer 110. The first sheet 121 includes a short fiber assembly 121a and a sheet body 122b. The thickness of the first sheet 121 may be about 1.5 mm to 3.0 mm, and the thickness of the short fiber aggregate 121a and the sheet body 121b may also be within the above range.

The short fiber assembly 121a is formed on a surface where a web formed of a first staple fiber, a web formed of a second staple fiber, and a web formed of a third staple fiber are mutually coupled. The first staple fiber, the second staple fiber and the third staple fiber are different staple fibers.

The first staple fiber can be obtained by spinning and stretching a polymer obtained by a polymerization reaction of terephthalic acid and ethylene glycol. In one embodiment, the first staple fibers may be short fibers having a fiber length in the range of about 1-8 micrometers in fiber diameter and 20-120 mm in fiber length. In one embodiment, the web formed of the first staple fibers has a weight of 200 - 500 g / m ² , a melting point of 254 - 284 ° C, a breaking elongation of 200 - 500%, a dry heat shrinkage at 160 ° C of 20 - 60% , And the fiber thickness may be 2 - 10 denier. In one embodiment, the first staple fiber may be a polyester fiber.

The second staple fiber may be a glass fiber. The second staple fibers reinforce the strength of the single-stitched fibers 121. In one embodiment, the length of the second staple fiber can have a length of 10 mm to 100 mm, more specifically 10 mm to 90 mm, and more specifically 10 mm to 80 mm. In particular, when the length of the second staple fibers is less than 10 mm, there may arise a problem in bonding with the first staple fibers.

The third staple fiber may be carbon fiber. The third staple fiber reinforces the durability of the short fiber aggregate 121.

In one embodiment, the first staple fibers comprise 50-70 wt%, the second staple fibers 10-20 wt%, and the third staple fibers 10-40 wt%, based on the total weight of the monofilament assembly 121a The content of the second staple fibers may be smaller than the content of the first staple fibers, and the content of the third staple fibers may be smaller than the content of the second staple fibers.

In one embodiment, the web is formed by ejecting the staple fibers together with hot air on a continuously circulating perforated belt, and air sucking at the bottom of the perforated belt to cause the staple fibers to stick onto the perforated belt .

The short fiber bundle 121a is formed by mutually combining the webs formed of the three short fibers, and has a void. At this time, the average pore size of the voids formed in the short fiber aggregate 121a may be 1 to 6 micrometers. When the pore size is less than 1 micrometer, the thermosetting adhesive resin constituting the sheet body 121b hardly penetrates through the pores. On the contrary, when the pore size exceeds 6 micrometers, the short- It is difficult to secure the strength of the first and second guide portions 121a. On the other hand, the voids formed in the short fiber aggregate 121a have a random shape. The porosity may be between 25% and 60%.

The sheet body 121b can be formed by curing the thermosetting adhesive resin. The thermosetting adhesive resin may be selected from a polyurethane resin, an epoxy resin, and an acrylic resin.

In one embodiment, the thermosetting adhesive resin may be a liquid polyurethane resin which is cured by a thermal reaction at 60-80 占 폚. Specifically, the liquid type polyurethane resin may include a polyether polyol, which is a subject, and a diphenylmethane diisocyanate curing agent containing methylenebisphenyl in a molecular weight of about 350-400. The polyether polyol and the curing agent may be mixed in a weight ratio of 100: 23. The liquid polyurethane resin has a viscosity of about 4,000 mPa.s, a specific gravity (g / cm ³ ) of about 1.5-1.7, a tensile strength of 12 MPa or more as measured by ASTM-D297, a shear strength measured by ASTM-D1002 Can be about 10 MPa.

The first sheet 121 has a shape in which the short fiber aggregate 121a is integrated with the sheet body 121b. Concretely, the thermosetting adhesive resin constituting the sheet body 121b may penetrate through the pores and be cured after the voids formed in the short-fiber binding body 121a. That is, the first sheet 121 may have a shape in which the short fiber assembly 121a is embedded in the sheet body 121b.

In forming the first sheet 121 by curing the sheet body 121b, the gas (bubbles) generated from the thermosetting adhesive resin in the curing process is discharged to the outside through the gap formed in the short-fiber body 121a . Therefore, no pores are formed in the sheet body 121b of the first sheet 121 because the gas can not be discharged. Therefore, the first sheet 121 and the second sheet 122 are not peeled off even after frequent vibration or time, thereby improving durability. In other words, the mooring phenomenon does not occur and the quality of the product can be improved.

The first sheet 121 may have a thermal resistance measured according to ASTM-D5470 of 0.085 m ² K / W or higher. That is, the first sheet 121 has a thermal resistance five times or more higher than the average thermal resistance of the wood plywood of 0.01-0.02 m ² K / W. Therefore, heat insulation can be greatly improved compared to wood plywood.

Also, since the first sheet 121 is formed of the short fiber assembly 121a and the sheet body 121b, it is resistant to invasion as compared with the wood plywood. This is because even if water penetrates, molds do not occur or are not distorted. Therefore, the life span of the composite panel 100 is greatly increased.

Further, since the first sheet 121 is formed of the short-fiber-bonded body 121a and the sheet body 121b, the first sheet 121 is lighter than the wood-based plywood. Accordingly, when the cargo structure is formed in the composite panel 100 and installed in the vehicle, the weight of the cargo can be greatly reduced, thereby increasing the fuel efficiency of the vehicle.

On the other hand, the second sheet 122 can be selected from glass fiber reinforced plastic or aluminum materials. As the material of the second sheet 122, a glass fiber reinforced plastic is more preferable. The glass fiber reinforced plastic may comprise polypropylene, fibrous glass and additives. In one embodiment, the glass fiber reinforced plastic may comprise 25-75 wt% polypropylene, 25-75 wt% fibrous glass, and 0-5 wt% additive. The thickness of the second sheet 122 may be about 0.8 mm to 1.6 mm.

2 is a view schematically showing a cross section of a composite panel 200 for a stacked structure according to another embodiment of the present invention.

Referring to FIG. 2, the composite panel 200 includes an inner layer 210 and an outer layer 220 that is bonded to both surfaces of the inner layer 210, respectively.

The inner layer 210 can be selected from foamed polyethylene foam, foamed polyurethane foam, expanded polystyrene foam, or compressed styrofoam having a certain standard. The inner layer 210 functions and functions as thermal insulation, sound insulation, sound insulation, and insulation. In one embodiment, the inner layer 210 may have the shape of an extruded board. In one embodiment, the density of the inner layer 210 is 30-60 kg / m ³ and the compressive strength may be 10 N / cm ^{2 or} higher. The thickness of the inner layer 210 may be about 3 cm to 5 cm.

A plurality of slots a may be formed on a surface of the inner layer 210 in the direction of the outer side 220 (i.e., upper and lower surfaces of the inner layer 210 in Fig. 2). In one embodiment, the slot a may be formed in a V-shaped groove. For example, the slot (a) may be a 'V-shaped groove' shape having a width of 1 mm and a depth of about 2 to 3 mm. The spacing between slots a is not specified, and may be, for example, 5-10 cm. The slot a discharges gas (bubbles) generated in the curing process of the thermosetting adhesive resin applied on both surfaces of the inner layer 210 to the outside in joining the outer layer 220 to the inner layer 210. In addition, since the thermosetting adhesive resin is applied to both surfaces of the inner layer 210, a part of the inner surfaces of the inner layer 210 and the outer layer 220 can fill the slot a.

The inner layer 210 includes a first inner layer 211, a second inner layer 213, and a bridge layer 212. The first inner layer 211 and the second inner layer 213 are joined in the longitudinal direction via the bridge layer 212. The bridge layer 212 is positioned between the first inner layer 211 and the second inner layer 213 to interconnect the first inner layer 211 and the second inner layer 213.

A first insertion groove 211a is formed on the side of the first inner layer 211. [ Specifically, the first insertion grooves 211a are formed at both central portions of the first inner layer 211, and have a shape drawn inwardly of the first inner layer 211 to a predetermined extent.

And a second insertion groove 213a is formed on the side of the second inner layer 213. [ Specifically, the second insertion groove 213a is formed at both central portions of the second inner layer 213, and has a shape drawn into the second inner layer 213 to a predetermined extent.

The bridge layer 212 is formed in cross-section as a whole. Specifically, both side central portions of the bridge layer 212 protrude outward by a predetermined degree. At this time, the shape and size of the protruded portion of the bridge layer 212 correspond to the lead-in space formed by the first insertion groove 211a and the second insertion groove 213a. The protruding one side of the bridge layer 212 is inserted into the first insertion groove 211a of the first inner layer 211 and the other side of the bridge layer 212 protruding is inserted into the second insertion groove 211b of the second inner layer 211, (213a). The upper and lower portions of the bridge layer 212 are disposed so as to fill the spacing spaces of the first inner layer 211 and the second inner layer 213.

That is, the first inner layer 211 and the second inner layer 213 are coupled to each other in the horizontal direction through the bridge layer 212, and the joints of the first inner layer 211 and the bridge layer 212, 2 inner layer 213 and the bridge layer 212 are tightened. This is because the joint portion is not a straight line in the vertical direction but a composite of the horizontal direction and the vertical direction along the contour (outline contour) of the bridge layer 212. Accordingly, the airtightness of these joints is strengthened, thereby reducing the possibility that cool air leaks through the joints or outside air is introduced. Therefore, the heat insulating efficiency can be further improved. In addition, since the side bonding properties of the first and second inner layers 211 and 213 are structurally improved, the first and second inner layers 211 and 213 can be more firmly bonded even if a smaller amount of adhesive is used.

The outer layer 220 includes a first sheet 221 and a second sheet 222 laminated to the first sheet 221.

The first sheet 221 is bonded to one surface of the inner layer 210. The first sheet 221 includes a short fiber bundle 221a and a sheet body 222b. The thickness of the first sheet 221 may be about 1.5 mm to 3.0 mm, and the thickness of the short fiber coupling body 221a and the sheet body 221b may also be within the above range.

The short fiber assembly 221a is formed on a surface where a web formed of a first staple fiber, a web formed of a second staple fiber, and a web formed of a third staple fiber are mutually coupled. The first staple fiber, the second staple fiber and the third staple fiber are different staple fibers.

The first staple fiber can be obtained by spinning and stretching a polymer obtained by a polymerization reaction of terephthalic acid and ethylene glycol. In one embodiment, the first staple fibers may be short fibers having a fiber length in the range of about 1-8 micrometers in fiber diameter and 20-120 mm in fiber length. In one embodiment, the web formed of the first staple fibers has a weight of 200 - 500 g / m ² , a melting point of 254 - 284 ° C, a breaking elongation of 200 - 500%, a dry heat shrinkage at 160 ° C of 20 - 60% , And the fiber thickness may be 2 - 10 denier. In one embodiment, the first staple fiber may be a polyester fiber.

The second staple fiber may be a glass fiber. The second staple fibers reinforce the strength of the short fiber joined body 221. In one embodiment, the length of the second staple fiber can have a length of 10 mm to 100 mm, more specifically 10 mm to 90 mm, and more specifically 10 mm to 80 mm. In particular, when the length of the second staple fibers is less than 10 mm, there may arise a problem in bonding with the first staple fibers.

The third staple fiber may be carbon fiber. The third staple fiber reinforces the durability of the staple fiber composite 221.

In one embodiment, the first staple fibers comprise 50-70 wt%, the second staple fibers 10-20 wt%, and the third staple fibers 10-40 wt% based on the total weight of the monofilament assemblies 221a The content of the second staple fibers may be smaller than the content of the first staple fibers, and the content of the third staple fibers may be smaller than the content of the second staple fibers.

In one embodiment, the web is formed by ejecting the staple fibers together with hot air on a continuously circulating perforated belt, and air sucking at the bottom of the perforated belt to cause the staple fibers to stick onto the perforated belt .

The short fiber assemblies 221a are formed by mutually joining the webs formed of the three short fibers, and have voids. At this time, the average pore size of the voids formed in the short fiber bundle 221a may be 1 to 6 micrometers. When the pore size is less than 1 micrometer, the thermosetting adhesive resin constituting the sheet body 221b hardly penetrates through the pores. On the other hand, when the pore size exceeds 6 micrometers, 221a. On the other hand, the voids formed in the short fiber composite body 221a have a random shape. The porosity may be between 25% and 60%.

The sheet body 221b can be formed by curing the thermosetting adhesive resin. The thermosetting adhesive resin may be selected from a polyurethane resin, an epoxy resin, and an acrylic resin.

In one embodiment, the thermosetting adhesive resin may be a liquid polyurethane resin which is cured by a thermal reaction at 60-80 占 폚. Specifically, the liquid type polyurethane resin may include a polyether polyol, which is a subject, and a diphenylmethane diisocyanate curing agent containing methylenebisphenyl in a molecular weight of about 350-400. The polyether polyol and the curing agent may be mixed in a weight ratio of 100: 23. The liquid polyurethane resin has a viscosity of about 4,000 mPa.s, a specific gravity (g / cm ³ ) of about 1.5-1.7, a tensile strength of 12 MPa or more as measured by ASTM-D297, a shear strength measured by ASTM-D1002 Can be about 10 MPa.

The first sheet 221 has a shape in which the short fiber composite body 221a is integrated with the sheet body 221b. Concretely, the thermosetting adhesive resin constituting the sheet body 221b may penetrate through the pores and may be cured after the voids formed in the short fiber composite body 221a. That is, the first sheet 221 may have a shape in which the short fiber bundle 221a is buried in the sheet body 221b.

In forming the first sheet 221 by curing the sheet body 221b, the gas (bubbles) generated from the thermosetting adhesive resin during the curing process is discharged to the outside through the voids formed in the short fiber composite body 221a . Therefore, no pores are generated in the sheet body 221b of the first sheet 221 because the gas can not be discharged. Therefore, the first sheet 221 and the second sheet 222 are not peeled off even after frequent vibration or time, thereby improving durability. In other words, the mooring phenomenon does not occur and the quality of the product can be improved.

The first sheet 221 may have a thermal resistance measured according to ASTM-D5470 of 0.085 m ² K / W or higher. That is, the first sheet 221 has a thermal resistance five times or more higher than the average thermal resistance of the wood plywood of 0.01-0.02 m ² K / W. Therefore, heat insulation can be greatly improved compared to wood plywood.

Further, since the first sheet 221 is formed of the short fiber composite body 221a and the sheet body 221b, it is resistant to invasion as compared with the wood plywood. This is because even if water penetrates, molds do not occur or are not distorted. Therefore, the life span of the composite panel 200 is greatly increased.

Further, since the first sheet 221 is formed of the short fiber composite body 221a and the sheet body 221b, the first sheet 221 is lighter than the wood plywood. Accordingly, when the cargo structure is formed in the composite panel 100 and installed in the vehicle, the weight of the cargo can be greatly reduced, thereby increasing the fuel efficiency of the vehicle.

On the other hand, the second sheet 222 can be selected from glass fiber reinforced plastic or aluminum materials. As the material of the second sheet 222, a glass fiber reinforced plastic is more preferable. The glass fiber reinforced plastic may comprise polypropylene, fibrous glass and additives. In one embodiment, the glass fiber reinforced plastic may comprise 25-75 wt% polypropylene, 25-75 wt% fibrous glass, and 0-5 wt% additive. The thickness of the second sheet 222 may be about 0.8 mm to 1.6 mm.

Hereinafter, a composite panel manufacturing method according to the present invention will be described.

A manufacturing method of the composite panel 100 shown in Fig. 1 will be described. First, the outer layer 120 is first fabricated. A first thermosetting adhesive resin in liquid phase is applied to one surface of a second sheet (122) selected from glass fiber reinforced plastic or aluminum. Next, the short-fiber assemblies 121a in which the webs formed of the three types of short fibers are mutually bonded are disposed on the above-mentioned one surface of the second sheet 122. The first thermosetting adhesive resin is permeated into the voids formed in the short-fiber binding body 121a after the short-fiber binding body 121a is disposed. As a result, the short-fiber-bonded body 121a is buried in the first thermosetting adhesive resin. Next, the first thermosetting adhesive resin is cured. Specifically, the first thermosetting adhesive resin can be cured by hot pressing at 60 - 80 占 폚. When the first thermosetting adhesive resin is cured, the sheet body 121b is formed. The short fiber aggregate 121a and the sheet body 121b have an integrated form and are referred to as a first sheet 121. [

On the other hand, a method for producing the short fiber aggregate 121a will be described. The short fiber bundle 121a forms a web by blowing short fibers together with hot air on a continuously circulating perforated belt and by air sucking at the bottom of the perforated belt so that the short fibers adhere to the perforated belt step; Mechanically interconnecting the webs via needle punching to form a planar assembly; And elevating the smoothness of the joined body by subjecting the joined body to heat treatment.

In this case, it is important to add not only the planar bonded body through the needle punching but also a step of further increasing the smoothness of the bonded body by further subjecting it to a hot-pressing treatment. Needle punching is a process of mechanically interconnecting the webs by moving needles up and down in both directions relative to the surface of the fiber web. Through needle punching, the web can be a planar assembly. However, the smoothness of the planar assemblies formed only by needle punching is very low. The upward and downward movement of the needle increases the degree of bending on the surface of the bonded body. In the case where such a bonded body is used as it is, the thermosetting adhesive resin can permeate nonuniformly into the single-fiber bonded body. Therefore, different physical properties (for example, thermal resistance) may appear depending on the portion of the first sheet 121. However, as in the present specific example, in the case of performing additional pressure treatment after forming a planar bonded body through needle punching, the smoothness of the planar bonded body is increased, so that penetration of the thermosetting adhesive resin can be made uniform. Therefore, there is an effect that the difference in physical properties depending on the region of the first sheet 121 is greatly reduced.

The staple fiber includes a first staple fiber which is a polyester fiber, a second staple fiber which is a glass fiber, and a third staple fiber which is a carbon fiber. The detailed contents of the first staple fiber, the second staple fiber and the third staple fiber have been described above, and a duplicate description will be omitted. In one embodiment, the first staple fibers comprise 50-70 wt%, the second staple fibers 10-20 wt%, and the third staple fibers 10-40 wt%, based on the total weight of the monofilament assembly 121a The content of the second staple fibers may be smaller than the content of the first staple fibers, and the content of the third staple fibers may be smaller than the content of the second staple fibers.

The first thermosetting adhesive resin is a liquid polyurethane resin, and the resin may be prepared by including a polyether polyol as a main component and a diphenylmethane diisocyanate curing agent containing methylenebisphenyl in a molecular weight of about 350-400. In some cases, a certain amount of a filler such as calcium carbonate may be added. The polyether polyol and the curing agent may be mixed in a weight ratio of 100: 23. The liquid polyurethane resin has a viscosity of about 4,000 mPa.s, a specific gravity (g / cm ³ ) of about 1.5-1.7, a tensile strength of 12 MPa or more as measured by ASTM-D297, a shear strength measured by ASTM-D1002 Can be about 10 MPa.

Next, an inner layer 110 is provided. The inner layer 110 can be selected from foamed polyethylene foam, foamed polyurethane foam, foamed polystyrene foam, or compressed styrofoam. The inner layer 110 may be made of a material having a density of 30-60 kg / m ³ and a compressive strength of 10 N / cm ² or more among the materials listed above and their modifications. After a plurality of inner layers 110 having a predetermined standard are prepared, a first engaging portion 113 is formed on one side of each of the inner layers 110, and a second engaging portion 115 is formed on the other side. Since the first engaging portion 113 and the second engaging portion 115 have been described above, a detailed description thereof will be omitted. For example, the inner layer 110 is disposed on a workbench of a CNC machining apparatus, and a first engaging portion 113 is formed on one side of the inner layer 110. The dimensions and the like of each part for forming the first engaging part 113 are inputted to the control part of the CNC machining device and are driven in accordance with the input contents of the CNC machining device so that the inner layer 110 scrapes one side 1 engaging portion 113 can be machined. When the first engaging portion 113 is formed, the inner layer 110 is relocated to the work table in the opposite direction and the second engaging portion 115 is formed in the same manner on the other side of the inner layer 110.

On the other hand, a plurality of slots a are formed at predetermined intervals on both sides of the inner layer 110. The slot (a) can be formed using equipment such as a V-cutter.

When a plurality of inner layers 110 formed with the first engaging portion 113 and the second engaging portion 115 are provided, the second thermosetting adhesive resin is applied along the outer surface of the inner layer 110 and the adjacent first inner layer 111 The first engaging portion 113 of the first inner layer 111 is engaged with the second engaging portion 115 of the second inner layer 112 and the second engaging portion 115 of the first inner layer 111 is engaged with the second engaging portion 115 of the second inner layer 112, The plurality of inner layers 110 are bonded in a horizontal direction in a manner to fit into the first engagement portion 113. [ On the other hand, the second thermosetting adhesive resin may be the same as the above-mentioned first thermosetting adhesive resin.

Next, the outer layer 120 is placed on both sides of the inner layer 110. The outer layer 120 may be positioned such that the first sheet 121 of the outer layer 120 contacts both surfaces of the inner layer 110. Next, the inner panel 110 and the outer panel 120 are heated and pressed to cure the first thermosetting adhesive resin and the second thermosetting adhesive resin to produce the composite panel 100. [ Since the first and second thermosetting adhesive resins are the same, the composite panel 100 has an integrated form.

According to the present manufacturing method, the outer layer 120 is formed separately and the outer layer 120 is bonded to both surfaces of the inner layer 110, which reduces the process time and simplifies the process. . Generally, when a composite panel is manufactured, a method of sequentially laminating different layers on both sides of a core layer with reference to the core layer is used. In this case, the process becomes complicated and the process time becomes longer.

A manufacturing method of the composite panel 200 shown in Fig. 2 will be described. First, the outer layer 220 is first prepared. The outer layer 220 can be manufactured in the same or similar manner as the outer layer 120 of the composite panel 100 shown in FIG. 1, and redundant description is omitted.

Next, an inner layer 210 is provided. The inner layer 210 can be selected from foamed polyethylene foam, foamed polyurethane foam, foamed polystyrene foam, or compressed styrofoam. The inner layer 210 may be made of a material having a density of 30-60 kg / m ³ and a compressive strength of 10 N / cm ² or more among the materials listed above and their modifications. A plurality of inner layers 210 having a predetermined standard are prepared and then the inner layer 210 is processed to form the first inner layer 211, the bridge layer 212 and the second inner layer 213. The first inner layer 211 and the second inner layer 213 have insertion grooves formed on both sides thereof and the bridge layer 212 is processed into a cross shape. For example, the inner layer 210 is disposed on a workbench of a CNC machining apparatus and an insert groove is formed on both sides of the inner layer 210, respectively. This can be done in such a way that a part of both sides of the inner layer 210 is shaved. The bridge layer 212 is also formed by scraping the inner layer 210. The dimensions and the like of each part for the machining can be inputted to the control unit of the CNC machining apparatus, and the machining can be performed by driving the CNC machining apparatus in accordance with the input contents to cut the inner layer 210. When the first inner layer 211, the bridge layer 212 and the second inner layer 213 are formed, a thermosetting adhesive resin is applied along the outer surface of the inner layer 210, The second inner layer, the second inner layer, and the second inner layer in such a manner that the side projected portions of the layer 212 are inserted and fitted.

Next, the outer layer 220 is placed on both sides of the inner layer 210. [ The outer layer 220 can be positioned such that the first sheet 221 of the outer layer 220 contacts both surfaces of the inner layer 210. Next, the composite panel 200 can be manufactured by hot-pressing the inner layer 210 and the outer layer 220.

Embodiments of the present invention have been described above. However, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the appended claims. It will be understood that various modifications may be made in the invention, and that such modifications are also included within the scope of the present invention.

100: composite panel 110: inner layer
111: first inner layer 112: second inner layer
113: first coupling portion 115: second coupling portion
120: outer layer 121: first sheet
121a: Short fiber bonded body 121b: Sheet body
122: second sheet 200: composite panel
210: inner layer 211: first inner layer
212: bridging layer 213: second inner layer
220: outer layer 221: first sheet
221a: short fiber bonded body 221b: sheet body

Claims (4)

An inner layer formed of a foamed polyethylene foam, a foamed polyurethane foam, a foamed polystyrene foam or a compressed styrofoam, and an outer layer bonded to both surfaces of the inner layer, each of which includes a first inner layer and a second inner layer bonded to both sides of the first inner layer, Including,
The first inner layer and the second inner layer may include a first protrusion part extending from the upper part to one side and protruding downwardly and a first coupling part including a first receiving part formed between the first protrusion part and one side surface; And a second engaging portion including a second protrusion extending from the lower portion to the other and protruding upward and a second accommodating portion formed between the second protrusion and the other side,
The first protruding portion of the first inner layer is accommodated in the second accommodating portion of the second inner layer and the first accommodating portion of the first inner layer accommodates the second protruding portion of the second inner layer, And the second protrusion of the first inner layer is accommodated in the first accommodating portion of the second inner layer and the second accommodating portion of the first inner layer receives the first protrusion of the second inner layer, 2 inner layer are bonded to each other,
Wherein the outer layer comprises a first sheet bonded to one surface of the inner layer and a second sheet laminated to the first sheet and formed of glass fiber reinforced plastic or aluminum,
The first sheet has a form in which a sheet-shaped short-fiber bonded body, in which webs formed of short fibers are mutually bonded, is integrated with a sheet body formed of a thermosetting adhesive resin, and the short-fiber bonded body is formed of a web A web formed of a second staple fiber which is a glass fiber and a web formed of a third staple fiber which is carbon fiber, wherein the content of the second staple fiber, based on the total weight of the staple fiber composite, And the content of the third staple fiber is smaller than the content of the second staple fiber. The method according to claim 1,
The web formed of the first staple fibers has a weight of 200 to 500 g / m ² , a melting point of 254 to 284 ° C, a breaking elongation of 200 to 500%, a dry shrinkage at 160 ° C of 20 to 60% 10 denier, and the second staple fiber has a fiber length of 10 mm to 80 mm. An inner layer comprising a first inner layer, a second inner layer, and a bridge layer interconnecting the first inner layer and the second inner layer and formed of foamed polyethylene foam, foamed polyurethane foam, expanded polystyrene foam or compressed styrofoam, Respectively,
A first insertion groove is formed on the side of the first inner layer, a second insertion groove is formed on the side of the second inner layer, and the bridge layer is formed in a cross shape in cross section so that one end is inserted into the first insertion groove, Is inserted into the second insertion groove to interconnect the first inner layer and the second inner layer,
Wherein the outer layer comprises a first sheet bonded to one surface of the inner layer and a second sheet laminated to the first sheet and formed of glass fiber reinforced plastic or aluminum,
The first sheet has a form in which a sheet-shaped short-fiber bonded body, in which webs formed of short fibers are mutually bonded, is integrated with a sheet body formed of a thermosetting adhesive resin, and the short-fiber bonded body is a web formed of a first staple fiber A web formed of a second staple fiber which is a glass fiber and a web formed of a third staple fiber which is carbon fiber, wherein the content of the second staple fiber, based on the total weight of the staple fiber composite, And the content of the third staple fiber is smaller than the content of the second staple fiber. The method of claim 3,
The web formed of the first staple fibers has a weight of 200 to 500 g / m ² , a melting point of 254 to 284 ° C, a breaking elongation of 200 to 500%, a dry shrinkage at 160 ° C of 20 to 60% 10 denier, and the second staple fiber has a fiber length of 10 mm to 80 mm.

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