KR101941211B1 - A method for manufacturing a trunk lining material for a vehicle and a truck lining material manufactured by the method - Google Patents

Abstract

The present invention relates to a method for manufacturing an interior material for a vehicle trunk, and an interior material manufactured thereby. The method of the present invention comprises the steps of: manufacturing a bubble sheet; seating the bubble sheet manufactured in the manufacturing step on a lower mold, and molding the same in a predetermined size by a descending upper mold; applying a hot melt on one surface of the bubble sheet molded in the molding step; combing a coated fabric on one surface of the bubble sheet applied with the hot melt in the applying step; and attaching a sound absorbing pad to the other surface of the bubble sheet combined with the coated fabric in the combining step. The bubble sheet is formed of a middle sheet having a plurality of spaces alternately opened upward and downward, separately, and top and bottom sheets combined in a form of covering upper and lower surfaces of the middle sheet, respectively. The bubble sheet includes: a base layer made of polypropylene (PP) and having the sound absorbing pad attached to a lower surface of the bubble sheet in an interior material manufactured by going through the steps; a sound absorbing layer attached to a lower surface of the base layer, and having a plurality of upwardly protruding portions having a concave groove which becomes narrow toward an upper portion from a lower portion thereof; and a cover layer attached to a lower surface of the sound absorbing layer. Accordingly, an interior material for a vehicle trunk is manufactured by using a bubble sheet manufactured by using a material of polypropylene and 20% of TD, and particularly, is manufactured by attaching a fabric such as non-woven fabric and the like by using a hot melt applied on a bubble sheet after completion of the manufacturing of the bubble sheet, thereby having less odor and remarkably reducing the weight.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a trunk lining material for an automobile and a lining material made by the method.

The present invention relates to a process for producing a bubble sheet by compression and trimming with a predetermined size using a bubble sheet made of polypropylene (PP), applying a hot melt to one surface of the bubble sheet, A method of manufacturing a trunk lining material for an automobile, which comprises attaching a sound absorbing pad to the trunk lining material by ultrasonic welding, and a lining material manufactured by the method.

BACKGROUND ART [0002] With respect to a manufacturing method for an interior material used in a trunk of an automobile and a technique related to the interior material produced by the method,

Korean Patent Registration No. 10-1137527 (Registered April 10, 2012, hereinafter referred to as "Document 1") discloses a method for producing an automotive interior material using compression molding,

Reference 1 discloses a process for producing a polyurethane foam composition by mixing a polyurethane raw material for foaming with a thermoplastic additive in powder or fiber form to prepare a polyurethane foam composition; Subjecting the polyurethane foam composition to sheet molding to produce a foam sheet; And the foam sheet is inserted into a mold and subjected to a compression molding and an aging process. By using the polyurethane foam material, excellent physical properties as an interior material can be obtained and compression molding, which was impossible with conventional polyurethane foam materials, The present invention relates to a method for manufacturing an automotive interior material using compression molding which enables the molding of an interior material in accordance with the shape of a desired part of an automobile using the same.

As another technique, "Korean Patent Registration No. 10-1898014 (Registered on 2018.09.06, hereinafter referred to as" Document 2 ")" Mold for Manufacturing Automotive Interior Materials and Manufacturing Method "is proposed,

Reference 2 discloses an image forming apparatus comprising a lower core on which a synthetic resin panel and a fabric are seated, an upper core installed on an upper portion of the lower core, and a bending jig provided on a side portion of the lower core, The present invention relates to a mold for manufacturing an automobile interior material and a manufacturing method for manufacturing an automobile interior material that can be used more safely by forming a curved portion by wrapping the end of the automobile interior material with a fabric.

Another technology is disclosed in Korean Patent Registration No. 10-1777781 (hereinafter referred to as Document 3), "Interior Lining for Automobile Trunk Including Polyester Foam Sheet"

Document 3 has a polyester foam sheet having an average basis weight in the range of 200 to 2,000 g / m, which improves moisture resistance and strength to provide excellent durability and can reduce the weight of the vehicle by reducing weight, The present invention relates to an interior material for a trunk of a vehicle,

The manufacturing method of the above documents 1 to 3 and the interior material by using the sheet of the natural fiber material have a problem that the smell unique to the natural fiber is large and the weight is excessively large. In particular, There is a problem that defective rate is high due to occurrence of deformation or whitening phenomenon due to compression production.

Literature 1. Korean Patent Registration No. 10-1137527 (April 10, 2012 registration) Literature 2. Korean Patent Registration No. 10-1898014 (Registered on 2018.09.06) Literature 3. Korean Patent Registration No. 10-1777781 (Registered on September 6, 2017)

The present invention relates to a bubble sheet having a predetermined size such as a square or the like and having a predetermined length of time at room temperature or the like, And to provide a method of manufacturing an interior material.

Further, the present invention provides a method for manufacturing a trunk lining material for an automobile and a lining material manufactured by the method, in which the sound absorption structure of the sound absorbing pad attached to the bubble sheet is diversified to prevent noise or the like from being transmitted to the vehicle as much as possible. There is a purpose.

According to another aspect of the present invention, there is provided a method for manufacturing a trunk lining material for a vehicle,

Bubble sheet manufacturing step;

Molding the bubble sheet produced in the manufacturing step on a lower mold and molding the lower mold by a lower mold to descend;

Applying a hot melt to one surface of the bubble sheet formed in the forming step;

Bonding the coated fabric to one side of the bubble sheet to which the hot melt is applied in the applying step; And

Attaching a sound absorbing pad to the other surface of the bubble sheet having the coated fabric laminated in the lapping step;

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Wherein the bubble sheet comprises a middle sheet having a plurality of openings alternately arranged in an upward and downward direction and a top sheet and a bottom sheet laminated in a shape covering the top and bottom surfaces of the middle sheet,

The bubble sheet is made of polypropylene (PP).

According to another aspect of the present invention, there is provided a trunk interior material for a vehicle,

In the interior material manufactured by the above-described manufacturing method,

A base layer attached to a lower surface of the bubble sheet;

A sound absorbing layer attached to a lower surface of the base layer and having a plurality of upward protruding portions formed with recesses of a shape narrowing from an upper portion to a lower portion;

And a cover layer attached to a lower surface of the sound-absorbing layer.

A method for manufacturing a trunk lining material for an automobile according to the present invention and an interior material produced thereby,

A trunk interior material of an automobile is manufactured using a bubble sheet produced using a polypropylene + TD 20% raw material. In particular, a raw material such as a nonwoven fabric is manufactured at the time of manufacturing by using a hot melt applied to a bubble sheet after the production of the bubble sheet is completed By weight and the like, it has the greatest effect of reducing the odor and significantly reducing the weight.

Further, the bubble sheet is subjected to compression and trimming molding while keeping the high temperature thermal oil at a predetermined temperature by using an oil heater. At this time, the non-squeezed area inside the blade for pressing and trimming and the non-squeezed The cooling water is circulated in each of the regions to lower the temperature of each heat conduction region due to the heat medium flow, thereby preventing deformation of the bubble sheet located in each region during the compression molding by the blade.

Further, the sound-absorbing structure of the sound-absorbing pad attached to the bubble sheet is variously improved, thereby preventing the noise transmitted to the vehicle to the utmost.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram showing a method for manufacturing a trunk lining material for an automobile according to the present invention;
FIG. 2 is a schematic view showing the lower and upper dies,
3 is a plan view and a partial cross-sectional view of the trunk lining of a vehicle,
4 is a perspective view and a partial cross-sectional view showing an example of a sound absorbing pad,
5 is a partial cross-sectional view showing another example of a sound absorbing pad,
6 is a perspective view and a partial cross-sectional view showing another example of a sound absorbing pad,
7 is a perspective view and a partial cross-sectional view showing another example of a sound absorbing pad,
8 is a perspective view and a partial cross-sectional view showing another example of a sound absorbing pad.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

Prior to this, terms and words used in the present specification and claims should not be construed as limited to ordinary or dictionary terms, and the inventor should appropriately interpret the concepts of the terms appropriately It should be interpreted in accordance with the meaning and concept consistent with the technical idea of the present invention based on the principle that it can be defined. Therefore, the embodiments described in the present specification and the configurations shown in the drawings are merely the most preferred embodiments of the present invention and are not intended to represent all of the technical ideas of the present invention. Therefore, various equivalents It should be understood that water and variations may be present.

2, the upper mold side is designated as the upper or upper side, and the lower mold side is designated as the lower or lower side.

1 to 3, a method for manufacturing a trunk lining material for an automobile according to the present invention includes:

(S1), a molding step (S2), a coating step (S3), a lapping step (S4), and an attaching step (S5).

Looking at each step,

The manufacturing step (S1)

As shown in Figs. 1 to 3,

As a step of producing the bubble sheet 10,

The bubble sheet 10 includes a middle sheet 11 having a plurality of openings alternately arranged upward and downward and a top sheet 11 covering the upper and lower surfaces of the middle sheet 11, (12) and a bottom sheet (13)

A resin liquid in which a chip made of polypropylene (PP) is melted is extruded by an extruder and is conveyed in a direction facing each other, so that the top sheet 12 and the middle sheet 11 are joined together, (11) is formed with a space having an opening in the upper and lower surfaces by the projections of the roller rotated by the extruding device upon extrusion.

The middle sheet 11 and the top sheet 12 are cooled naturally at room temperature or forcedly cooled using a separate cooling device such as an oven or the like and then reheated so as to heat the bottom sheet 11 13).

The finished bubble sheet 10 is cut into a predetermined size (for example, a quadrangle), and wound and stored.

The forming step S2

As shown in Figs. 1 to 3,

Molding the bubble sheet 10 manufactured in the manufacturing step S1 into the lower mold 100 and molding the lower mold 100 into a predetermined size by the lower mold 200,

The upper mold 200 includes a blade 201 formed on a lower surface thereof for cutting the bubble sheet 10 to a predetermined size and a flow passage 202 through which the heat medium oil flows in the blade 201 do.

As shown in FIG. 2, the blade 201 has two or more stepped portions 201a formed therein. The blades 201 are formed by press-molding to form one or more stepped portions along the rim of the bubble sheet 10 during molding. As a result, the edge of the bubble sheet 10 is flattened by pressure, and is cut to a predetermined size. At this time, the cut surface is fused so that the space formed in the middle sheet 11 of the bubble sheet 10 from the outside is exposed It is trimmed neatly.

The scrap of the bubble sheet 10 remaining after molding may be removed and then collected without being discarded and melted, and then recycled as a molten resin for producing the bubble sheet 10.

The 'predetermined size' means a size corresponding to the shape of the floor space of each vehicle trunk, and since the size is a size of each vehicle, the size of each trunk flooring material of the corresponding vehicle will be different.

2, cooling water flows in the upper non-compression region 203, which is an inner empty space formed by the blade 201 so as to be in contact with the upper surface of the bubble sheet 10, And the lower flow path 102 in which the cooling water flows is formed in the lower non-squeezed region 101 in contact with the lower surface of the bubble sheet 10 seated on the lower flow path.

The 'upper non-squeezed area' and the 'lower non-squeezed area' refer to the area of the corresponding mold where the bubble sheet 10 is not pressed and thus is not pressed. For example, in the upper mold 200, the blade 201 may be an empty space inside the shape. In the lower mold 100, an entire upper surface or an area where the bubble sheet 10 is seated on the upper surface It will mean.

At this time, the forming time of the bubble sheet 10 by the upper mold 200 in the forming step S2 is 25 to 35 seconds, and the press pressure is 120 kgf or more. Here, the press pressure is a force that the upper mold 200 located on the upper side of the stopped lower mold 100 is lowered by a separate elevating device to press the bubble sheet 10 seated on the lower mold 100 .

The heat medium oil supplied to the flow path 202 of the upper mold 200 is preheated by the boiler 300 and then supplied to the flow path of the upper mold 200 through the supply pipe 400 202, and is recovered through the recovery pipe 500 and then reheated by the boiler 300, so that the temperature of the heat medium oil in the flow path 202 is maintained at 180 to 200 degrees at all times .

As a feature of the present invention, the temperature of each of the upper non-squeezed region 203 and the lower non-squeezed region 101 in the forming step S2 is 80 to 100 degrees. This is a proper temperature lowered by the heat exchange between the lower flow path 102 and the cooling water flowing into the upper flow path 204. Due to such a lowered temperature, the corresponding region of the bubble sheet 10 abutted by the upper non-squeezed region 203 and the lower non-squeezed region 101 is not deformed because of the squeezing, and a high-temperature heat medium oil flows Only the blade 201, that is, only the region where the blade 201 is pressed, is pressed and trimmed to be formed.

In the application step S3,

As shown in Figures 1 and 3,

Applying the hot melt 14 to one surface of the bubble sheet 10 formed in the molding step S2,

The bubble sheet 10 passes through a pair of facing rollers and hot melt 14 is applied to one surface of the bubble sheet 10 through a separate roller directed to one roller or roller side of the pair of rollers, .

The lapping step S4

As shown in Figures 1 and 3,

(20) on one side of the bubble sheet (10) to which the hot melt (14) is applied in the applying step (S3)

The bubble sheet 10 on which the hot melt 14 is applied is placed on the table, and then the cloth 20 is pressed up by the pressing jig which is lowered by the elevating device.

At this time, the coated fabric 20 is preferably made of a nonwoven fabric.

The attachment step S5

As shown in Figures 1 and 3,

Attaching the absorbing pad 30 to the other surface of the bubble sheet 10 to which the coated fabric 20 is joined in the lapping step S4,

A bubble sheet 10 having a cloth 20 bonded to the top of the table is placed on the bubble sheet 10 so that the other surface of the bubble sheet 10 faces upward and then a sound absorbing pad 30 are fused and attached.

When the weight and the cost of the interior material according to the manufacturing method are compared with the conventional natural fiber interior material,

division Natural fiber reinforced board 1.9 Kg / m ² + PP Flim 100 g / m ^{2 with} both sides (a) When applying bubble sheet
bubble sheet 1,700 / m ² (b) Difference (a-b) weight 1,513 g 1,225 g -288 g cost $ 15,518 $ 15,318 -200 won

As can be seen from the above Table 1, it can be seen that the weight of the interior material using the existing natural fibers is 1,513 g and the weight of the interior material of the present invention is reduced by 288 g compared to the existing interior materials, It can be expected that the product price will be greatly reduced and the competitiveness of the market can be increased.

In the interior material manufactured by the above-described manufacturing method,

As shown in Figure 4,

A base layer 31 attached to the lower surface of the bubble sheet 10,

A sound absorbing layer 32 attached to a lower surface of the base layer 31 and having a plurality of upward protruding portions 322 formed with recesses 321 of a shape narrowing from the bottom to the top,

A cover layer 33 attached to the lower surface of the sound-absorbing layer 32,

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At this time, the sound-absorbing layer 32 is a feature of the present invention, and it is expected that the sound or the like generated in the lower portion of the vehicle is absorbed and canceled through the sound-absorbing layer 32.

The upward protruding portion 322 protrudes to the upper portion of the sound absorbing layer 32 as viewed in a vertical cross-sectional view of the sound absorbing layer 32. The upward protruding portion 322 is formed such that the upward protruding portion 322 The noise generated in the lower portion of the vehicle is canceled by colliding with the inner and outer walls of the groove 321. As a result,

5, a plurality of radial protruding protrusions 323 may be formed on a lower surface of the upward protruding portion 322, the protruding protruding protrusions 323 being formed at a lower portion of the protrusion 321 and having a height downward.

That is, since the radial protrusion 323 is formed at a lower portion of the upward protruding portion 322 to form a certain height, the noise can be absorbed and canceled more .

The radial protruding protrusion 323 having the above-described configuration is annular about the lower portion of the groove 321 and forms a plurality of radial layers on the lower surface of the upward protruding portion 322, so that any one of the radial protruding protrusions 323 Can be canceled again by another radial protruding jaw 323 adjacent to the lower portion of the groove 321.

6, the upper portion of the upward protrusion 322 is provided with a linear sound absorbing tube 324 having a flow path formed therein. The linear sound absorbing tube 324 is inserted into the base layer 31, .

That is, the linear sound-absorbing pipe 324 has a structure for preventing the noise absorbed by the sound-absorbing layer 32 from passing through the lower portion of the groove 321 as much as possible, and the lower end is connected to the upper portion of the groove 321 And the upper end is extended from the lower end to the upper end to form a predetermined length, and is inserted into the base layer 31.

In addition, the length of the linear sound-absorbing pipe 324 having the above-described configuration can be appropriately adjusted according to the judgment of a person skilled in the art, and more preferably, the upper end of the linear sound-absorbing pipe 324 is positioned in the middle- It is desirable to have a length that can be used.

7, the upper end of the linear sound-absorbing pipe 324 may be provided with a funnel 325 that widens from the lower part toward the upper part.

That is, the funnel 325 has a hollow having a narrow inner diameter and a large inner diameter connected to the upper end of the linear sound-absorbing pipe 324, So that noise or the like can be absorbed and canceled in the hollow of the funnel 325.

8, a curved sound absorbing tube 326 having a flow path is formed on the upper protruding portion 322, and the curved sound absorbing tube 326 is inserted into the base layer 31 .

As a result, the curved sound absorbing pipe 326 has a lower end connected to the upper portion of the groove 321, and an upper end extending horizontally from the lower end to a predetermined length and inserted into the base layer 31.

Like the linear sound-absorbing pipe 324, the curved sound-absorbing pipe 325 can absorb and cancel noise and the like, and particularly exhibits a higher sound absorption and cancellation performance than the linear sound-absorbing pipe 324.

That is, the noise introduced into the groove 321 flows into the hollow of the curved sound absorbing tube 325 through the lower portion of the groove 321, and then is sucked and canceled by coming out to the end of the curved sound absorbing tube 325.

In addition, the length of the curved sound absorbing tube 326 may be appropriately adjusted according to the judgment of a person skilled in the art. More preferably, the end of the curved sound absorbing tube 326 is positioned at a middle or more portion of the thickness of the cover layer 33 It is preferable that it has a length enough to be positioned in the "

While the present invention has been described with reference to the accompanying drawings, it is to be understood that the present invention has been fully described by way of examples with reference to the accompanying drawings, And such variations and modifications are to be construed as being within the scope of protection of the present invention.

10: Bubble sheet
11: Middle sheet
12: Topsheet
13: bottom sheet
14: Hot melt
20: Cloth fabric
30: Sound absorbing pad
31: base layer
32: sound-absorbing layer
321: groove
322: upward protrusion
323: Radial protruding chin
324: Linear sound absorbing tube
325: Funnel
326: Curved sound-absorbing tube
33: Cover layer
100: Lower mold
101: Lower non-squeezed area
102:
200: upper mold
201: Blade
201a:
202: Distribution channel
203: upper non-squeezed area
204:
300: Boiler
400: Supply piping
500: Return piping

Claims (9)

Bubble sheet 10 manufacturing step S1;
(S2) of placing the bubble sheet (10) manufactured in the manufacturing step (S1) on the lower mold (100) and molding the lower mold (100) into a predetermined size by the lower mold (200);
(S3) applying a hot melt 14 to one surface of the bubble sheet 10 formed in the molding step S2;
(S4) joining the coated fabric 20 to one side of the bubble sheet 10 to which the hot melt 14 is applied in the applying step S3; And
(S5) attaching the absorbing pad 30 to the other surface of the bubble sheet 10 to which the coated fabric 20 is laminated in the lining step S4;
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The bubble sheet 10 includes a middle sheet 11 having a plurality of openings alternately arranged in an upward and downward direction and a topsheet 12 which is laminated in a shape covering the upper and lower surfaces of the middle sheet 11, 12 and a bottom sheet 13,
The bubble sheet 10 is made of polypropylene (PP)
The upper mold 200 is provided with a blade 201 formed to cut the bubble sheet 10 to a predetermined size on the lower surface and a flow path 202 through which the heat medium oil flows in the blade 201 ,
Wherein the blade (201) has two or more stepped portions (201a) formed therein, and the edge of the bubble sheet (10) is trimmed by press molding to form at least one step.
delete The method according to claim 1,
An upper flow path 204 in which cooling water flows is formed in the upper non-pressurized area 203 which is an inner empty space formed by the blade 201 so as to contact the upper surface of the bubble sheet 10 in the upper mold 200 And,
Wherein a lower flow path (102) through which cooling water flows is formed in the lower non-pressurized region (101) contacting the lower surface of the bubble sheet (10) Way.
delete A sound absorbing pad (30) in an interior material manufactured by the manufacturing method according to claim 1 or 3,
A base layer 31 attached to the lower surface of the bubble sheet 10,
A sound absorbing layer 32 attached to a lower surface of the base layer 31 and having a plurality of upward protruding portions 322 formed with recesses 321 of a shape narrowing from the bottom to the top,
And a cover layer (33) attached to a lower surface of the sound - absorbing layer (32).
6. The method of claim 5,
A plurality of radially protruding protrusions 323 are formed on the lower surface of each upward protruding portion 322 of the sound-absorbing layer 32 with a downward center around the lower portion of the groove 321. [ Trunk lining.
6. The method of claim 5,
A sound absorbing tube 324 having a passage is formed on each of the upward protrusions 322 of the sound absorbing layer 32 and the sound absorbing tube 324 is inserted into the base layer 31 The trunk interior material of a car made with.
8. The method of claim 7,
Wherein a funnel (325) is formed at the upper end of the sound-absorbing pipe (324) so as to be wider from the lower part to the upper part.
6. The method of claim 5,
A curved sound absorbing tube 326 having a passage is formed on each of the upward protrusions 322 of the sound absorbing layer 32 and the sound absorbing tube 326 is inserted into the base layer 31 Interior lining for trunk of car to feature.

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