KR101901235B1 - Lightweight and sound absorbing, interior materials for automobile containing waste fibers and their preparation - Google Patents

Lightweight and sound absorbing, interior materials for automobile containing waste fibers and their preparation Download PDF

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KR101901235B1
KR101901235B1 KR1020150132050A KR20150132050A KR101901235B1 KR 101901235 B1 KR101901235 B1 KR 101901235B1 KR 1020150132050 A KR1020150132050 A KR 1020150132050A KR 20150132050 A KR20150132050 A KR 20150132050A KR 101901235 B1 KR101901235 B1 KR 101901235B1
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fibers
layer
fiber
weight
base layer
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KR1020150132050A
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Korean (ko)
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KR20170034003A (en
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박성탁
박창석
김상윤
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원풍물산주식회사
재단법인 한국섬유기계융합연구원
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/06Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/12Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/36Layered products comprising a layer of synthetic resin comprising polyesters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00Polyalkenes
    • B32B2323/10Polypropylene
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00Vehicles
    • B32B2605/003Interior finishings

Abstract

More particularly, the present invention relates to an automobile interior material for a wheel guard comprising a skin layer, a base layer including waste fibers, and a polyethylene film, A skin layer, and a base layer containing waste fibers, and a method for manufacturing the same.
According to the present invention, it is possible to replace a conventional polypropylene plastic material with a waste fiber nonwoven fabric material, thereby making it lightweight, more economical and environmentally friendly, and simultaneously heating each side at different temperatures, The process can simplify the process and further increase the economic and productivity. Further, although the composite structure is a two-layer structure or a three-layer structure, it is possible to manufacture each layer integrally and to manufacture without attaching additional felt or attaching a sound absorbing material, thereby improving productivity and reducing production cost.

Description

TECHNICAL FIELD [0001] The present invention relates to a lightweight, sound-absorbing interior material for automobiles using waste fibers, and a method of manufacturing the same. BACKGROUND OF THE INVENTION 1. Field of the Invention [0002]

The present invention relates to an automotive interior material and a method of manufacturing the same, and more particularly, to a lightweight sound absorbent interior material for automobiles using waste fibers and a method of manufacturing the same.

Background Art [0002] Conventionally, automotive interior material sheets are made of a plurality of stacked bodies such as a surface layer, a base layer, and a backside layer. Conventional automotive interior material sheets have various noise (Engine: Road & Tire, Stone, Chipping, Water Slash Etc.), the sound absorbing material is attached to the back of the seat.

 After forming the sheet for automobile interior material, the sound absorbing material is adhered separately with double-sided tape, adhesive, ultrasonic welding, high frequency welding, etc. The cost is increased due to quality problems such as odor and weakening of adhesive force, When a press pressure is applied during the molding of a sheet for an interior material, the structure for buffering the pressure in the structure of the material is weak, so that the felt can not be restored in a pressed state, , And the visual and tactile quality is deteriorated (see Figs. 1A and 1B).

As another method for producing an automobile interior material sheet, a plurality of short fiber yarns obtained by cutting a polyester yarn such as polyester into a short length of 2 to 3 inches are squeezed into a needle needle so as to have a distribution of 800 to 1,500 g / a method in which an acrylic latex or a PE layer is coated on the back surface at a thickness of 300 to 600 g / m < 2 > is known. However, it is pointed out as a problem in manufacturing an automobile interior material because of reduced merchantability due to moisture absorption.

An extrusion processing method is known as the most effective method of producing a sheet for an automobile interior material. However, if a sound absorbing material does not adhere to the entire surface of an extruded sheet for an automobile interior material, a noise reduction effect is caused by a resonance phenomenon.

 In addition, when the sound absorbing material is attached to the back surface of the extruded sheet as the present technology, the base layer is excessively infiltrated into the back layer, which is a sound absorbing material, and the sound absorbing function is weakened due to high fluidity at the time of extrusion of the base layer at 200 to 240 캜 .

An extruded sheet used for manufacturing parts such as automobile trunks and seats is formed by extruding a natural fiber, a filler such as talc or calcium carbonate into a plastic raw material such as PP and PE, BACKGROUND ART [0002] Nonwoven fabrics are bonded to one side or both sides of a substrate layer. However, recycling of extrusion sheet scrap generated in an automobile part manufacturing process has been a problem in terms of environmental protection and resource recycling.

On the other hand, air flow around the vehicle body occurs when the vehicle is traveling, and the influence of air generated around the tire can not be ignored.

Due to the air flow generated around the tire, the air near the tire is entangled with turbulence and vortices to form a three-dimensional and complicated structure. As a countermeasure thereto, a wheel guard is installed to surround the tire.

Generally, the wheel guard is installed between the tire, the vehicle body panel and the bumper so as to divide the tire, the vehicle body panel and the bumper located outside the tire. The wheel guard is bent in a curved shape so as to surround the tire, .

Such a wheel guard is usually manufactured using a hard polypropylene (PP) resin or a soft polypropylene (PP) resin. As described above, the wheel guard is installed between a tire and a vehicle body panel, Or foreign matter such as soil is prevented from flowing into the body panel.

The wheel guard partitions between the tire and the vehicle body panel to prevent the soil adhered to the tire from flowing into the inside of the tire. When the vehicle travels at a high speed, air flowing toward the tire collides with the rotating tire It is also responsible for arranging complex turbulence and vortices in the tire section to make it smooth flow.

However, since the conventional wheel guard made of polypropylene (PP) resin is manufactured with an emphasis on the simple appearance of the wheel guard, there is a disadvantage in that it can not effectively remove the road noise generated during traveling. Therefore, the load noise caused by the friction between the tire and the road So that the vibration noise performance of the rear seat is deteriorated.

Accordingly, a separate sound absorbing material is adhered to the rear surface of the wheel guard by using a double-sided tape. However, there has been a problem in that inconvenience of the additional process and deterioration of the sound absorbing performance when the double-sided tape is dropped by water.

Conventional conventional two-layer nonwoven fabric manufacturing methods for manufacturing an automobile interior material for a wheelguard and a trunk cycle trim are performed in two steps as a method of laminating one layer on the back surface after producing one layer.

Then, it is carried out in three steps through a pin tenter.

In such an automobile interior material, it is preferable to use low-melting point fibers and polypropylene having a water-repellent effect to complement stiffness. The melting point (110 ° C) of the low melting point fiber and the melting point (140 ° C) of the polypropylene fiber The difference must be two heat treatments.

In Japan, these two different materials are often applied to fendliners, trunk liners, hearliners, and trunk mats, but in the case of domestic automotive materials There is a problem in that the process ratio is increased, and there is a demand for a heat treatment method and apparatus capable of simultaneously operating the same.

Generally, the conventional trunk side trim and wheel guard material for a general commercial vehicle are manufactured by molding a polypropylene plastic board and attaching a sound absorbing nonwoven fabric to the board.

Such a manufacturing method and a material produced by this method are complicated in process, and due to the characteristics of the polypropylene plastic board, corrosion is caused by calcium chloride for snow removal in the winter, deformation due to shrinkage occurs, (Refer to FIG. 2).

The following relates to the prior art for automotive interiors.

Korean Unexamined Patent Application Publication No. 10-2004-0096503 (filed on Nov. 6, 2004, filed on November 6, 2004) discloses an interlayer noise eliminator and a method for manufacturing the same, wherein a nonwoven fabric The present invention relates to an interlayer noise attenuating material capable of simultaneously exhibiting a sound absorption effect by sound absorption, a sound insulation effect by a sound insulation, and a heat insulation effect by adhering the foam sheet in the order of a foam sheet and a nonwoven fabric.

Although the present invention is characterized in that waste fiber is utilized, the present invention has a problem in that the process is complicated such as water glass treatment.

Korean Patent Laid-Open No. 10-2004-0002329 (filed on Jan. 8, 2014 by Winko Co., Ltd.) discloses a method for producing a composite nonwoven fabric having excellent lightness and rigidity, comprising 30 to 50% A first step of producing a needle punched composite nonwoven fabric comprising 50 to 70% by weight of polypropylene fibers and 0 to 10% by weight of meta-aramid fibers; A second step of heating the needle punching composite nonwoven fabric in a first heating mold having a temperature of 190 to 240 캜 for 30 to 120 seconds; A third step of pressing the needle punching composite nonwoven fabric to a thickness of 1 to 3 mm in a primary cooling mold having a temperature of 5 to 80 캜 to form a sheet; A fourth step of reheating the pressed sheet for 45 to 120 seconds in a secondary heating mold having a temperature of 190 to 230 DEG C; And a fifth step of cold-molding the compressed sheet in a second cooling mold having a temperature of 80 ° C or less for 30 to 120 seconds.

The present invention is different from the present invention in that glass fiber is used.

Korean Patent Registration No. 10-1181201 (filed on September 3, 2012; patent right holder for a new patent) discloses a method of manufacturing a wheel guard for a vehicle. To separate a tire and a body panel located outside the tire, 1. A method for manufacturing a vehicle wheel guard which is formed by bending a tire to cover a predetermined portion of the tire inside a vehicle body panel, the method comprising: a first felt layer forming step of forming a felt layer by carding and needle punching polyester fibers; A second felt layer forming step of carding and needle punching the polyester fibers to form a felt layer; And a lapping step of laminating the first felt layer and the second felt layer and needle punching.

The present invention has a problem in that a polyester film must be coated to prevent dust on the surface, the top and bottom fabrics must be lapped, and the surface must be treated with a heating roller by hot air drying in an oven.

Korean Patent Registration No. 10-1069903 (filed on September 27, 2011, Patentee Hanyang Materials Co., Ltd.) is a laminate for automobile interior material with improved sound absorption function and a method for producing the same, which comprises a surface nonwoven fabric layer, Absorbing nonwoven fabric layer and the sound absorbing force of the backing-and-sounding nonwoven fabric layer are at the same time, so that the melted portion of the base layer is infiltrated into the backing-sound absorbing nonwoven fabric layer A laminated body for an automobile interior material improved in sound absorption function is provided.

The above-described invention has a problem that the base layer, which is an extruded sheet of PP plastic, is formed between the nonwoven fabric on the front surface and the back surface, and the base layer is formed between the nonwoven fabric on the back surface and the backing layer by a heating roll, .

Disclosure of Invention Technical Problem [8] Accordingly, the present invention has been made to solve the above-mentioned problems, and it is an object of the present invention to provide an automotive interior material which is excellent in sound absorption performance, lighter in weight, more economical, environmentally friendly and highly productive.

In order to solve the above-mentioned problems, the present invention relates to a surface layer composed of 40 to 70% by weight of polypropylene fibers and 30 to 60% by weight of polyethylene terephthalate (PET) fibers; A base layer composed of 20 to 50% by weight of polypropylene fibers, 20 to 40% by weight of waste fibers made of polyethylene terephthalate (PET) fibers and low melting point fibers, 15 to 25% by weight of hollow fibers and 15 to 25% ; And 30 to 100% by weight of low density polyethylene (LLDPE), and 0 to 70% by weight of high density polyethylene (HDPE), wherein the surface layer and the base layer are laminated together, And simultaneously heating them to different temperatures. The present invention also provides an automobile interior material for a wheel guard and a method of manufacturing the same.

The present invention also relates to a skin layer composed of polyethylene terephthalate (PET) fibers; A base layer composed of 30 to 70% by weight of waste fibers consisting of polyethylene terephthalate (PET) fibers and low melting point fibers, 20 to 40% by weight of polypropylene, 10 to 30% by weight of low melting point fibers and 0 to 20% by weight of hollow fibers An automobile interior material for a trunk side trim composed of a laminate formed by laminating a skin layer and a base layer and simultaneously heating them to different temperatures, and a method for manufacturing the same.

According to the present invention, it is possible to replace a conventional polypropylene plastic material with a waste fiber nonwoven fabric material, thereby making it lighter, more economical and environmentally friendly, and simultaneously heating each side at different temperatures, The process can simplify the process and further increase the economic and productivity.

Further, although the composite structure is a two-layer or three-layer structure, it is possible to manufacture each layer integrally and to manufacture without additional felt attachment or adhering sound-absorbing material attachment process, thereby improving productivity and reducing production cost.

FIG. 1A is a photograph of a conventional trunk side trim of a sound absorbing material, and FIG. 1B is a photograph showing a conventional trunk side trim of a conventional sound trunk side trim according to positions where the sound absorbing material is attached.
2 is a photograph showing the problems of conventional polypropylene plastic materials or conventional nonwoven fabrics.
3 is a view showing an application example of the wheel guard according to the present invention.
4 is a view showing an example of a trunk side trim of the present invention.
FIG. 5A is a photograph of a base layer produced using the waste fiber of the present invention, and FIG. 5B is a photograph of a skin layer of the present invention. FIG.
6 is a photograph of the front wheel guard produced by the present invention.
7 is a photograph of a trunk side trim produced by the present invention.
Fig. 8 is a view showing a lay-out for needle punching after air-laid.

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

One aspect of the present invention relates to a skin layer; A base layer comprising waste fibers; And an automobile interior material for a wheel guard composed of a polyester film.

More specifically, a skin layer composed of polypropylene fibers and polyethylene terephthalate (PET) fibers; A base layer composed of polypropylene fibers, waste fibers, hollow fibers and low melting point fibers; And a polyethylene film laminated on one another, wherein the automobile interior material for a wheel guard is formed by laminating a skin layer and a base layer, followed by laminating a polyethylene film and simultaneously heating the polyethylene film to different temperatures.

First, the skin layer is composed of polypropylene fibers and polyethylene terephthalate (PET) fibers.

Polypropylene (PP) fiber as a first component of the skin layer is a component used for improving the moldability and water repellency of an automobile interior material and more specifically, it is melted in a heat treatment process to form a film to improve water repellency , But not all polypropylene fibers are melted in this process.

The fibers of the polypropylene used in the skin layer in the present invention may be fibers of various thicknesses, preferably fibers of 4 to 9 denier.

The content thereof is preferably 40 to 70% by weight based on the total weight of the skin layer.

If the content is less than the above range, moldability and water repellency are deteriorated. If it exceeds the above range, the nonwoven fabric may be torn at the time of molding or may be wrinkled at the time of molding, The formability of the nonwoven fabric may be different and the shape of the product may not be formed as desired due to the difference in thickness between the portion of the nonwoven fabric and the both edge portions.

Polyethylene terephthalate (PET) fibers as the second component of the skin layer include all types of polyethylene terephthalate (PET) fibers commonly used in automotive interiors.

The polyethylene terephthalate (PET) fiber is a component used for forming a substrate layer which is the body of an automobile interior material. The polyethylene terephthalate (PET) fiber used in the skin layer in the present invention may be fibers of various thicknesses, Fibers of 2 to 6 denier may be used.

The content thereof is preferably 30 to 60% by weight based on the total weight of the skin layer.

In the case of deviating from the above range, there is a problem that the absorptive sound data value does not constantly appear at the low frequency and high frequency values during the sound absorption test, and the product shape may not be constant when the nonwoven fabric is molded.

This skin layer is formed as a single nonwoven layer by mixing the components and sequentially treating the first carding, the first lamination, optionally the second carding, and then the first to fourth needle punching.

In the case of carding and lamination, it may be carried out more than once to better mix the components if necessary, and preferably the second carding and optionally the second lamination may be carried out.

Carding, lamination and needle punching can be performed using all conventional apparatuses and methods known in the art, and these are not particularly limited in the present invention (see FIG. 5B).

Further, the base layer is composed of polypropylene fiber, waste fiber, hollow fiber and low melting point fiber.

As the first component of the base layer, the polypropylene fiber may be a fiber having the same thickness as that used in the skin layer.

The content thereof is preferably 20 to 50% by weight based on the total weight of the base layer.

In the case of deviating from the above range, there is a problem that the absorptive sound data value does not constantly appear at the low frequency and high frequency values during the sound absorption test, and the product shape may not be constant when the nonwoven fabric is molded.

As a second component of the base layer, the waste fiber is a substitute for the conventional polyethylene terephthalate (PET) fiber and exhibits similar physical properties as polyethylene terephthalate (PET) fibers through its use, It is a substance that can be.

Such waste fiber is mainly composed of waste nonwoven fabric such as scrap generated in the manufacturing process of the applicant company, and polyethylene terephthalate (PET) fiber and low melting point fiber are the main components of the waste nonwoven fabric.

Other scrap scrap generated in the latex coating process or film coating process may also be used.

In the present invention, waste fibers made of polyethylene terephthalate (PET) fibers and low melting point fibers can be used.

The content thereof is preferably 20 to 40% by weight based on the total weight of the base layer.

The main material constituting the waste fiber is a polyethylene terephthalate (PET) fiber and a low melting point fiber, which is a component used for forming a substrate layer which is a body of an automobile interior material having the same function as a polyethylene terephthalate (PET) The stiffness value of the interior material does not come out constantly, and the product shape may not be uniform when the nonwoven fabric is molded.

As the third component of the base layer, a hollow fiber is used to improve the sound absorption property. The hollow fiber can be formed of a triangular hollow fiber or a circular hollow fiber according to its cross section. In the present invention, it is preferable to use a triangular hollow fiber.

The triangular hollow fiber has a triangular cross section and has a very stable structure. When the same mechanical force is applied at the time of spinning, the triangular hollow fiber has better resistance to deformation, and the ratio of hollow fiber to fiber after spinning can be maintained well.

In addition, the circular hollow fiber has low pressure resistance and large deformation due to mechanical force. As a result, the ratio of the hollow fiber to the total fiber fiber cross section is low, while the triangular hollow fiber fiber has high resistance to pressure, So that the ratio of the hollow portion to the total area of the fiber cross section can be maintained.

Overall, the triangular hollow fiber was superior to the circular hollow fiber in the overall fabric, knitted fabric and filler.

Also, the No. 21, it was found that the heat insulation was the most excellent. Especially, in the case of the fabric, the triangular hollow fiber fabric has a larger heat insulating property than the circular hollow fiber yarn, as the yarn becomes thinner.

When the content of polyethylene terephthalate (PET) and the content of polypropylene is relatively small, the rigidity value of the automobile interior material is made constant (for example, 15 to 25% by weight) And the shape of the product is not constant when the nonwoven fabric is molded.

As the fourth component of the base layer, the low-melting-point fibers are melted in the heating process and then melted in the secondary heating, which is a preheating process during molding, and the main function thereof is a process And to improve moldability which prevents the fabric from continuing during the press forming process.

The low melting point fibers used in the present invention are preferably low melting point fibers having a melting temperature of about 110 to 170 DEG C, particularly 140 DEG C.

The low melting point fiber used in the base layer of the present invention is a fiber having a denier of 3 to 8 denier, and its content is preferably 15 to 25% by weight.

When the content is out of the above range, the shape during molding is not uniform and not constant, and the waterproof effect may not be exhibited properly.

Such a base layer can be formed by mixing the respective components described above, and thereafter laminating using an air-laid process, followed by heating and drying.

If necessary, needle punching may be additionally performed between the lamination and the heat drying using the air-laid process (see Fig. 8).

It also includes a polyethylene film as a layer of automotive interiors for wheel guards.

Such a polyethylene film serves to enhance a sound insulation effect and a waterproof effect.

Any polyethylene film that can be used in this field can be used, and the present invention is not limited thereto.

After such a skin layer and base layer are laminated by a gas lamination process at 180 to 190 DEG C, a polyethylene laminate is laminated thereto and heated at different temperatures for each side at the same time only once to form an automobile interior material for a wheel guard Reference).

At this time, the heating temperature on the side of the skin layer is 100 to 120 占 폚, the heating temperature on the side of the polyethylene film is 120 to 140 占 폚, and the heating speed is 3.2 to 3.8 m / min.

The automobile interior material for a wheel guard according to the present invention has suitable tensile strength and tear strength for each automobile part and shows characteristics of elongation> tensile strength> tensile strength suitable for use as an automotive wheel guard.

Another aspect of the present invention provides a vehicle interior material for a trunk side trim comprising a skin layer composed of polyethylene terephthalate (PET) fibers and a base layer comprising waste fibers.

More specifically, a skin layer composed of polyethylene terephthalate (PET) fibers; And a base layer composed of waste fibers, polypropylene, low-melting-point fibers and hollow fibers. The trunk side trim is formed by laminating a skin layer and a base layer and simultaneously heating them to different temperatures. (See Fig. 4).

As the first layer, the skin layer is composed of polyethylene terephthalate (PET) fibers.

The polyethylene terephthalate (PET) fiber can be any type of polyethylene terephthalate (PET) fiber that can be used in automotive interiors and is not specifically limited in the art.

This skin layer is formed as a single nonwoven layer by mixing the components and sequentially treating the first carding, the first lamination, optionally the second carding, and then the first to fourth needle punching.

In the case of carding and lamination, it may be carried out more than once to better mix the components if necessary, and preferably the second carding and optionally the second lamination may be carried out.

The carding, lamination and needle punching can be carried out using any conventional apparatus and methods known in the art, and these are not particularly limited in the present invention (see FIG. 8).

Further, the base layer as the second layer is composed of waste fibers, polypropylene, low melting point fibers and hollow fibers.

As a first component of the base layer, the waste fiber is a substitute for conventional polypropylene fibers, which, through its use, exhibits physical properties similar to those of polypropylene fibers and is more economical than such an economical product.

In the present invention, waste fibers made of polyethylene terephthalate (PET) fibers and low melting point fibers can be used.

The content thereof is preferably 30 to 70% by weight based on the total weight of the base layer.

The main material constituting the waste fiber is a polyethylene terephthalate (PET) fiber and a low melting point fiber, which is a component used for forming a substrate layer which is a body of an automobile interior material having the same function as a polyethylene terephthalate (PET) The stiffness value of the interior material does not come out constantly, and the product shape may not be uniform when the nonwoven fabric is molded.

As a second component of the base layer, the polypropylene fiber is a component used for improving moldability and water repellency of an automobile interior material, and more specifically, it plays a role of improving water repellency by forming a film by melting in a heat treatment process after lapped, Not all polypropylene fibers are melted in this process.

The fibers of the polypropylene used in the base layer in the present invention may be fibers of various thicknesses, preferably fibers of 4 to 9 denier.

The content thereof is preferably 20 to 40% by weight based on the total weight of the base layer.

In the case of deviating from the above range, there is a problem that the absorptive sound data value does not constantly appear at the low frequency and high frequency values during the sound absorption test, and the product shape may not be constant when the nonwoven fabric is molded.

As the third component of the base layer, the low-melting-point fibers are melted in the heating process and then melted in the secondary heating, which is the preheating process during molding, and the main function thereof is a process And to improve moldability which prevents the fabric from continuing during the press forming process. The low melting point fibers used in the present invention are preferably low melting point fibers having a melting temperature of about 110 to 170 DEG C, particularly 140 DEG C. The low melting point fiber used in the base layer of the present invention is a fiber having a denier of 3 to 8 denier, and its content is preferably 15 to 25% by weight. When the content is out of the above range, the shape during molding is not uniform and not constant, and the waterproof effect may not be exhibited properly.

As the fourth component of the substrate layer, a hollow fiber is used to improve the sound absorption property. The hollow fiber may have a triangular hollow fiber or a circular hollow fiber according to its cross section. In the present invention, it is preferable to use a triangular hollow fiber.

The triangular hollow fiber has a triangular cross section and has a very stable structure. When the same mechanical force is applied at the time of spinning, the triangular hollow fiber has better resistance to deformation, and the ratio of hollow fiber to fiber after spinning can be maintained well.

In addition, the circular hollow fiber has low pressure resistance and large deformation due to mechanical force. As a result, the ratio of the hollow fiber to the total fiber fiber cross section is low, while the triangular hollow fiber fiber has high resistance to pressure, So that the ratio of the hollow fibers to the total area of the fiber cross-section can be maintained, and the heat insulating property is excellent.

Overall, the triangular hollow fiber was superior to the circular hollow fiber in the overall fabric, knitted fabric and filler.

Also, the No. 21, it was found that the heat insulation was the most excellent. Especially, in the case of the fabric, the triangular hollow fiber fabric has a larger heat insulating property than the circular hollow fiber yarn, as the yarn becomes thinner.

When the content of polyethylene terephthalate (PET) and polypropylene is relatively small, the rigidity value of the automobile interior material is not constant, and when the nonwoven fabric is molded, the product shape is constant Do not come out.

Such a base layer can be formed by mixing the respective components described above, and thereafter laminating using an air-laid process, followed by heating and drying.

If necessary, needle punching may be additionally performed between the lamination and the heat drying using the air-laid process (see Fig. 8).

After this skin layer and base layer are lapped, a car interior material for the trunk side trim is formed by simultaneously heating it to different temperatures for each side only once (see FIG. 7).

At this time, the heating temperature on the skin layer side is from 100 to 120 占 폚, the heating temperature on the substrate layer side is from 130 to 150 占 폚, and the heating passing speed is from 3.2 to 3.8 m / min.

The automobile interior trim for trunk side trim according to the present invention has appropriate tensile strength and tear strength for each automobile part and shows characteristics of tear strength of elongation > tensile strength >, and is suitable for use as trunk side trim for automobile .

Still another aspect of the present invention provides a method for providing an automotive interiors.

More specifically, each component of the skin layer is charged and mixed, and the first carding, the first lamination, optionally the second carding and optionally the second lamination are sequentially treated with the first through fourth needle punching to form the skin layer (Step 1);

(Step 2) of charging and mixing the respective components of the base layer, laminating them using an air-laid process, followed by heating and drying to form a base layer; And

The surface layer and the substrate layer are simultaneously heated at different temperatures to form an automobile interior material or the surface layer and the base layer are joined by a gas laminating process and then the polyethylene film is laminated and simultaneously heated to different temperatures for each side, And a step of forming an interior material (step 3).

Step 1 is for forming a skin layer.

First, the components constituting the skin layer for the wheel guards or trunk side trims described above are charged and mixed.

The content of these components and the thickness of the fibers are as described above.

The mixing apparatus may be any conventional mixing apparatus known in the art and is not particularly limited in the present invention.

Thereafter, the obtained mixture is subjected to the first carding, the first lamination, and optionally the second carding, and then sequentially treated with the first through fourth needle punching to form one layer of nonwoven fabric.

In the case of carding and lamination, it may be carried out more than once to better mix the components if necessary, and preferably the second carding and optionally the second lamination may be carried out.

The carding, lamination and needle punching can be performed using all conventional apparatuses and methods known in the art, and these are not particularly limited in the present invention.

The skin layer thus obtained is shown in Fig. 5B.

Step 2 is for forming a base layer.

First, the components constituting the base layer for the wheel guards or trunk side trims described above are charged and mixed.

The content of these components and the thickness of the fibers are as described above.

The mixing apparatus may be any conventional mixing apparatus known in the art and is not particularly limited in the present invention.

Thereafter, the resulting mixture is air-laid laminated and then heated and dried to form a base layer.

If necessary, needle punching may be additionally performed between the lamination and the heat drying using the air-laid process.

Apparatuses capable of carrying out such a process can use apparatus customary to those skilled in the art, or suitably modified ones, as shown in Fig. 8 as an example.

The substrate layer thus obtained is shown in Fig. 5A.

In step 3, the skin layer and the base layer are laminated, heated and pressed to form a car interior material for wheel guard or trunk side trim.

 First, in the case of an automobile interior material for a wheel guard, the prepared skin layer and base layer are joined by a gas laminating process.

At this time, the gas laminating temperature is preferably 180 to 190 DEG C, and the heating rate is preferably about 3.5 / min.

After joining the polyethylene film thereafter, each side is heated at a different temperature at the same time only once to form an automobile interior material for wheel guard.

At this time, the heating temperature on the skin layer side is preferably 100 to 120 占 폚, and the heating temperature on the polyethylene film side is preferably 120 to 140 占 폚.

Further, in the case of a trunk side trim automotive interior material, the prepared skin layer and the base layer are joined together, and then the respective side surfaces are simultaneously heated only once at different temperatures to form a trunk side trim automotive interior material.

At this time, the heating temperature on the skin layer side is preferably 100 to 120 ° C, and the heating temperature on the substrate layer side is preferably 130 to 150 ° C.

For this heating, an appropriate heater can be used, and it is preferable that the infrared heater is appropriately modified and used for this purpose. In particular, it is preferable to use a two-stage infrared heater.

Conventional conventional nonwoven fabric two-layer manufacturing method involves two steps of a one-layer lamination method on the back side of a first layer, and then three steps are performed through a pin tenter.

Such a conventional method is carried out in a hot air mode, and it is essential to perform the heat treatment two times in consideration of the difference between the melting point (110 캜) of the low-melting fiber and the melting point (140 캜) of the polypropylene fiber.

If the heat treatment is performed only once with such a hot air blowing method, the low melting point fiber having a lower melting point melts and the polypropylene fiber having a melting point higher than the melting point may not melt.

On the other hand, in the present invention, as described above, the heating process is processed by one step of heating both sides simultaneously at one time by using a two-stage infrared heater, so that the components having different melting points can be processed simultaneously, And the productivity can be improved.

Hereinafter, the present invention will be described in more detail with reference to Examples.

These examples are for further illustrating the present invention, and the scope of the present invention is not limited to these examples.

Example 1 Production of wheel guard of the present invention

The wheel guard of the present invention was produced according to the process described below.

Each component is as described in Tables 1 to 3 below.

(1) Manufacturing process of the skin layer

Raw material input - Raw material mixing - Carding 1 - Lamination 1 - Carding 2 - Lamination 2 - Needle punching 1 - Needle punching 2 - Needle punching 3 - Needle punching 4 -

Figure 112015090874749-pat00001

(2) Production process of base layer

Feeding of raw materials - Mixing of raw materials - Lamination by air-laid process - Needle punching - Heat drying (see FIG. 8)

(3) The surface layer and the substrate layer were laminated by a gas laminating process, followed by laminating a polyethylene film and heating each side by using a two-stage infrared heater under the conditions described below to prepare a wheel guard.

Temperature of gas laminating: 180 to 190 占 폚, heating rate of 3.5 m / min.

Heating temperature of the skin layer: 100 to 120 DEG C,

* Heating temperature of the polyethylene film: 120 to 140 ° C,

The heating rate during simultaneous heating is 44 to 52 seconds, or the heating rate is 3.2 to 3.8 m / min.

The substrate layer thus produced is as shown in Fig. 5A, and the skin layer is as shown in Fig. 5B.

The finally produced front wheel side wheel guard is as shown in Fig.

In the following table, PP is polypropylene, PET is polyethylene terephthalate (PET), LM is low melting point fiber, HDPE is high density polyethylene, LLDPE is low density polyethylene, 6D is 6 denier and 3D is 3 denier.

Example 2 Production of trunk side trim of the present invention

The trunk side trim of the present invention was produced according to the process described below.

Each component is as described in Tables 4 to 5 below.

(1) Manufacturing process of the skin layer

Raw material input - Raw material mixing - Carding 1 - Lamination 1 - Carding 2 - Lamination 2 - Needle punching 1 - Needle punching 2 - Needle punching 3 - Needle punching 4 -

Figure 112015090874749-pat00002

(2) Production process of base layer

Feeding of raw materials - Mixing of raw materials - Lamination by air-laid process - Needle punching - Heat drying (see FIG. 8)

(3) The skin layer and the base layer were simultaneously heated by using a two-stage infrared heater under the same conditions as described below to prepare a trunk side trim.

 Temperature of gas laminating: 180 to 190 占 폚, heating rate of 3.5 m / min.

 Heating temperature of the skin layer: 100 to 120 DEG C,

 * Heating temperature of the polyethylene film: 130 to 150 ° C,

The heating rate during simultaneous heating is 44 to 52 seconds, or the heating rate is 3.2 to 3.8 m / min.

The substrate layer thus produced is as shown in Fig. 5A, and the skin layer is as shown in Fig. 5B.

The trunk side trim produced finally is as shown in Fig.

Figure 112015090874749-pat00003

Figure 112015090874749-pat00004

Figure 112015090874749-pat00005

Claims (11)

A skin layer composed of 40 to 70% by weight of polypropylene fibers and 30 to 60% by weight of polyethylene terephthalate (PET) fibers;
A base layer composed of 20 to 50% by weight of polypropylene fibers, 20 to 40% by weight of waste fibers made of polyethylene terephthalate (PET) fibers and low melting point fibers, 15 to 25% by weight of hollow fibers and 15 to 25% ; And
A polyethylene film composed of 30 to 100% by weight of low-density polyethylene, and 0 to 70% by weight of high-density polyethylene,
The skin layer and the base layer are laminated by a gas laminating process at a heating temperature of 180 to 190 캜, the polyethylene layer is laminated on the base layer,
Characterized in that the heating temperature on the skin layer side is in the range of 100 to 120 占 폚 and the heating temperature on the polyethylene film side is formed by heating with a two-stage infrared heater at different temperatures in the range of 120 to 140 占 폚 at the same time.
delete The method according to claim 1,
Wherein the heating pass speed heated at the same time is 3.2 to 3.8 m / min, and the heating pass speed of the gas lamination is 3.2 to 3.8 m / min.
The method according to claim 1,
Wherein the polypropylene fiber in the skin layer and the base layer is a fiber having a denier thickness of 4 to 9 and the polyethylene terephthalate (PET) fiber is a fiber having a thickness of 2 to 6 denier.
A skin layer composed of polyethylene terephthalate (PET) fibers;
A base layer composed of 30 to 70% by weight of waste fibers consisting of polyethylene terephthalate (PET) fibers and low melting point fibers, 20 to 40% by weight of polypropylene, 10 to 30% by weight of low melting point fibers and 0 to 20% by weight of hollow fibers; Lt; / RTI >
Laminating the skin layer and the base layer and simultaneously heating them to different temperatures for each side,
Wherein the heating temperature on the skin layer side is 100 to 120 占 폚 and the heating temperature on the substrate layer side is 130 to 150 占 폚 by a two-stage infrared heater.
delete 6. The method of claim 5,
Wherein the heating and passing speed is from 3.2 to 3.8 m / min at the same time.
6. The method of claim 5,
The polyethylene terephthalate (PET) fiber in the skin layer is a fiber having a denier of 4 to 9,
Wherein the polypropylene in the base layer is 4 to 9 denier fibers, and the polyethylene terephthalate (PET) fibers are 2 to 6 denier fibers.
delete delete delete
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