KR101992116B1 - Vehicle interior material of multi-layer having Perforated film and synthetic resin powder and manufacturing method thereof - Google Patents

Abstract

The present invention relates to a vehicle interior material having a multi-layer structure having a perforated film and a synthetic resin powder, and a method of manufacturing the same.
The vehicle interior material having a multilayer structure manufactured according to the present invention has the effect of having improved sound absorbing and soundproofing by sound absorbing property of the nonwoven fabric layer and the felt layer and the sound insulating property of the film layer, and by selecting a synthetic resin powder for bonding between layers. Compared with the coating, the process is simpler, and the overall weight of the interior material is maintained in light weight.

Description

Vehicle interior material of multi-layer having perforated film and synthetic resin powder and manufacturing method

The present invention relates to a vehicle interior material and a method for manufacturing the same, and more particularly, to a vehicle interior material having a multi-layer structure having a perforated film and synthetic resin powder with improved sound absorption and sound insulation.

In general, the vehicle has various functions inside the vehicle to provide comfortable driving to the driver and the occupant by blocking the incoming noise since various noises such as engine noise and tire friction noise enter the interior while driving. Interior material is applied.

Typically, the vehicle interior material is composed of a base layer bonded to the vehicle body and the outer skin layer exposed to the outside, a laminated structure consisting of intermediate layers having a variety of functions between the base layer and the skin layer, the parts to which the interior material for applying the toothpaste is applied to the floor carpet, There are many parts such as drunk mat, side trim, rear seat back, and self-bag, and the base layer, skin layer, and middle layer that make up the interior materials for vehicles are selected from materials with appropriate functions for sound absorption, sound insulation, and physical properties However, it is not satisfactory in terms of performance and there is a complicated problem in the manufacturing process.

Taking the prior art as an example with respect to the interior material of the multilayer structure having sound absorption and sound insulation for the interior materials of the vehicle, Patent Document 1 in the upper structure of the cut pile method (needle punch) method and the upper structure In the lower portion of the sound absorbing layer is made of a layer comprising a stacked structure, one surface of the sound absorbing layer is equipped with a first hot melt film and a second hot melt film stacked layer of the hot melt film, the first hot melt film and the second hot melt film Disclosed is a vehicle carpet capable of sound absorbing and insulating, characterized in that a plurality of perforations comprising a carpet structure formed at a predetermined interval, at least one side of the carpet structure has an airlaid felt layer In Patent Document 2, a natural fiber woven reinforcement layer comprising at least one natural fiber, the natural fiber woven reinforcement layer on both sides It discloses a natural fiber woven multilayer structure, characterized in that it comprises a thermoplastic resin layer laminated on the thermosetting resin reinforcement layer and the thermosetting resin reinforcement layer laminated 20% to 60% by weight of the natural fiber woven fabric, but the prior art Due to the sound absorbing layer and the plurality of hot melt layer, the synthetic resin layer of the plurality of layers there is a problem that increases the weight of the overall interior material adversely affects the fuel efficiency of the vehicle.

In addition, Patent Document 3 consists of a PET foam sheet having a foaming ratio of 10 to 30, a core layer and a PET foam sheet having a foaming ratio of 2 to 10, a thickness of 1mm to 5mm, the upper surface of the core layer and Disclosed is a vehicle interior material having excellent light weight and formability, characterized in that it comprises a pair of reinforcing layers on the lower surface and a polyester-based nonwoven fabric bonded to one surface of the reinforcing layer, and the prior art is due to the foam layer. There is a problem that the strength of the interior material is weakened.

Applicant has completed the present invention by developing a material that is applied to the interior of the mobile device having a multi-layer structure, light weight, improved strength, sound absorption and sound insulation.

Patent Document 1: Republic of Korea Patent Registration No. 10-1447626 Patent Document 2: Republic of Korea Patent Publication No. 10-1543598 Patent Document 3: Republic of Korea Patent Registration No. 10-1567777

An object of the present invention is to provide a vehicle interior material and a manufacturing method for improving sound absorption and sound insulation which are applied to a floor carpet, a drake mat of a vehicle, and more specifically, a perforated film and a synthetic resin powder having improved sound absorption and sound insulation. An object of the present invention is to provide a vehicle interior having a multilayer structure and a method of manufacturing the same.

As a solution of a vehicle interior material having a multilayer structure, which is an object of the present invention, the skin layer 1 is formed of polyethylene terephthalate (PET) fibers or polyethylene terephthalate (PET) fibers, flame retardant polyethylene terephthalate (PET) fibers, and low melting point fibers. (Low Melting Fiber; LMF) formed of a non-woven fabric layer, the lower portion of the skin layer (1) polyethylene terephthalate (PET) powder layer (2), polyethylene terephthalate (PET) or a film layer of polyethylene (PE) material (3), a felt layer 4 composed of polyethylene terephthalate (PET) fibers and Low Melting Fibers (LMF) is formed, and the lowermost layer 5 is a polyethylene terephthalate (PET) or polyethylene It consists of forming the perforated film of (PE) material.

The epidermal layer 1 according to the present invention is made of a nonwoven fabric of polyethylene terephthalate (PET) fibers as the surface layer of the interior material or 30 to 85 parts by weight of polyethylene terephthalate (PET) fibers, flame retardant polyethylene terephthalate (PET) fibers 10 ~ It consists of a nonwoven fabric composed of 40 parts by weight and 5 to 30 parts by weight of Low Melting Fiber (LMF), and low melting point fiber (LMF) is preferably 130 ~ 180 ℃ polyethylene terephthalate (PET) fiber.

The nonwoven fabric forming the skin layer 1 is a fiber having a fineness of 3 to 10 denier and a length of 51 to 64 mm, and is manufactured by carding, web formation, and web bonding according to a known nonwoven fabric manufacturing method. Web bonding is preferred, and the skin layer 1 is preferably a velour-type nonwoven fabric whose surface has a smooth texture.

The polyethylene terephthalate (PET) powder layer 2 formed on the bottom of the skin layer 1 is dispersed on the surface of the skin layer 1 and then melted into the nonwoven fabric forming the skin layer 1 when heated, soaked into the nonwoven fabric. In combination with, some unmelted powder acts to block the voids of the nonwoven to improve sound insulation.

The film layer 3 of the polyethylene terephthalate (PET) or polyethylene (PE) material is a layer placed on the powder layer 2 and the felt layer 4 and has a sound insulation function, and a felt under the film layer 3 The layer 4 is formed, the felt layer 4 is composed of 60 to 90 parts by weight of polyethylene terephthalate (PET) fiber and 10 to 40 parts by weight of Low Melting Fiber (LMF), 3 to 10 denier, It is produced according to the felt manufacturing method from a fiber of 51 ~ 64㎜ in length.

The back layer 5 according to the present invention is a layer formed on the lowermost part of the interior material, and is formed by combining a film made of polyethylene terephthalate (PET) or polyethylene (PE) with the felt layer 4 and then perforated the back layer 5 Perforations are formed on the surface.

And the method of manufacturing a vehicle interior of a multi-layered structure according to the present invention is a). Dispersion of polyethylene terephthalate (PET) powder uniformly on the surface of the nonwoven fabric of the epidermal layer (1), and then heated to a part of the powder to melt and penetrate into the epidermal layer (1) agent having a powder layer (2) 1st process of obtaining 1 laminated body, and b). The backing layer 5 formed of the felt layer 4 and the backing layer 5 made of polyethylene terephthalate (PET) or polyethylene (PE) film are bonded to each other, and the surface of the backing layer 5 is perforated to form the felt layer 4 and the perforations. 2nd process of obtaining 2nd laminated body which has (5), and c). The first laminate of the first step and the second laminate of the second step are laminated via a polyethylene terephthalate (PET) film or polyethylene (PE) film (3), and the powder layer (2) Multi-layer laminated in order from the top to the felt layer (4) facing each other, the skin layer (1) / PET powder layer (2) / PET film layer (3) / felt layer (4) / perforated back layer (5) It consists of including the 3rd process of obtaining the laminated body S of a structure.

The skin layer 1 of the first step according to the present invention is a nonwoven fabric made of fibers having a fineness of 3 to 10 denier and a length of 51 to 64 mm, and a surface of the velor-type nonwoven fabric having a smooth texture is preferable. Do.

In addition, the powder layer 2 bonded to the epidermal layer 1 is partially melted by heating, soaks into the nonwoven fabric of the epidermal layer 1 and binds with the nonwoven fabric, and some unmelted powder improves sound insulation by blocking the voids of the nonwoven fabric. It has the function, there is an advantage that the process is simple and reduce the weight of the interior material as a whole compared to the conventional technology for coating and bonding the latex.

The felt layer 4 of the second process according to the present invention has a sound absorbing function, and the perforated polyethylene terephthalate (PET) or polyethylene (PE) film of the back layer 5 also has a sound absorbing function so that it is in direct contact with the vehicle body. The interior material according to the present invention by the action of the back layer 5 and the felt layer 4 on the upper side has an effect of improving sound absorption, the polyethylene terephthalate (PET) film or polyethylene (PE) of the third step ) The film has a role of bonding the first laminate and the second laminate and a sound insulation function by the film layer at the same time.

The laminate of the multilayer structure sequentially stacked from the above prepared according to the present invention into the skin layer (1) / PET powder layer (2) / PET film layer (3) / felt layer (4) / perforated back layer (5) The fabric may be manufactured by cold press compression molding into a mold of a desired interior material, and the interior material may be applied to a floor carpet, a trunk mat, or the like of a vehicle.

In the multi-layered vehicle interior material having the perforated film and the synthetic resin powder of the present invention, while the synthetic resin powder penetrates into the nonwoven fabric of the epidermal layer and combines with the nonwoven fabric, some unmelted powders have a function of blocking the voids of the nonwoven fabric to improve sound insulation, and coating a conventional latex. Compared to the bonding technology, the process is simpler, and the weight of the interior material is reduced as a whole. Also, the back layer has improved sound absorption by the formed perforated film, which is excellent in sound insulation and sound absorption as a vehicle interior material. It is applied to a mat and the like and produces a very desirable effect.

1 is a diagram schematically showing a process for manufacturing a vehicle interior material having a multilayer structure having a perforated film and a synthetic resin powder of the present invention.
Figure 2 is a view showing roughly the cross section and the perforated surface of the back layer of the vehicle interior of a multi-layered structure according to the invention

Hereinafter, the present invention will be described in more detail with reference to Examples and Test Examples, and the present invention is not limited by the following description.

Vehicle interior materials of the multi-layered structure of the present invention is the skin layer (1) is formed of polyethylene terephthalate (PET) fiber or polyethylene terephthalate (PET) fiber, flame retardant polyethylene terephthalate (PET) fiber and low melting fiber (Low Melting Fiber); LMF) is formed of a non-woven fabric layer, the lower portion of the skin layer (1) polyethylene terephthalate (PET) powder layer (2), polyethylene terephthalate (PET) or polyethylene (PE) film layer (3), polyethylene A felt layer 4 composed of terephthalate (PET) fibers and low melting fibers (LMF) is formed, and at the bottom, the back layer 5 is made of polyethylene terephthalate (PET) or polyethylene (PE). Perforated film is formed.

The skin layer (1) is made of a nonwoven fabric of polyethylene terephthalate (PET) fibers or the surface layer of the interior material 30 to 85 parts by weight of polyethylene terephthalate (PET) fibers, flame retardant polyethylene terephthalate (PET) fibers 10 to 40 parts by weight and Low Melting Fiber (LMF) is composed of a nonwoven fabric composed of 5 to 30 parts by weight, low melting point fiber (LMF) is preferably 130 ~ 180 ℃ polyethylene terephthalate (PET) fiber.

The nonwoven fabric forming the skin layer 1 is a fiber having a fineness of 3 to 10 denier and a length of 51 to 64 mm, and is manufactured by carding, web formation, and web bonding according to a known nonwoven fabric manufacturing method. Web bonding is preferred, and the skin layer 1 is preferably a velour-type nonwoven fabric whose surface has a smooth texture.

The polyethylene terephthalate (PET) powder layer 2 formed on the bottom of the skin layer 1 is dispersed on the surface of the skin layer 1 and then melted into the nonwoven fabric forming the skin layer 1 when heated, soaked into the nonwoven fabric. In combination with, some unmelted powder acts to block the voids of the nonwoven to improve sound insulation.

The film layer 3 of the polyethylene terephthalate (PET) or polyethylene (PE) material is a layer placed on the powder layer 2 and the felt layer 4 and has a sound insulation function, and a felt under the film layer 3 The layer 4 is formed, the felt layer 4 is composed of 60 to 90 parts by weight of polyethylene terephthalate (PET) fiber and 10 to 40 parts by weight of Low Melting Fiber (LMF), 3 to 10 denier, It is produced according to the felt manufacturing method from a fiber of 51 ~ 64㎜ in length.

The back layer 5 according to the present invention is a layer formed on the lowermost part of the interior material, and is formed by combining a film made of polyethylene terephthalate (PET) or polyethylene (PE) with the felt layer 4 and then perforated the back layer 5 Perforations are formed on the surface.

1 is a view schematically showing a process for manufacturing a vehicle interior material having a multi-layer structure having a perforated film and a synthetic resin powder of the present invention, Figure 2 is a cross-sectional and back layer of the vehicle interior material having a multilayer structure manufactured according to the manufacturing method of the present invention Referring to the perforated surface roughly, with reference to Figure 1 describes a method for manufacturing a vehicle interior material having a multilayer structure having a perforated film and a synthetic resin powder according to the present invention,

As shown in FIG. 1, the polyethylene terephthalate (PET) powder is uniform from the powder feeder 2a to the surface of the nonwoven fabric forming the skin layer 1 while the nonwoven fabric of the skin layer 1 is supplied from the supply roller by the first process. It is dispersed, and guided to the heater (H) by the guide roller while the polyethylene terephthalate (PET) powder is partially melted to combine with the nonwoven fabric of the skin layer 1 to produce a first laminate.

The second process is a separate process from the first process, while the felt forming the felt layer 4 is supplied from the supply roller, and at the same time the polyethylene terephthalate (PET) film of the back layer 5 is supplied from the supply roller. The guide roller is guided to the heater H to combine the felt and the film, and then guided to the perforator to form perforations on the surface of the film to produce a second laminate.

The third process is also a separate process, in which the first laminate produced in the first process and the second laminate produced in the second process are supplied from respective supply rollers, and at the same time, the polyethylene is interposed between the first laminate and the second laminate. The terephthalate (PET) film is supplied and coalesced by a thermal roller, and the method of laminating and bonding in the third process is performed through the polyethylene terephthalate (PET) film via the powder layer 2 and the second layer of the first laminate. The multilayer structure according to the invention, namely the skin layer (1) / PET powder layer (2) / PET film layer (3) / felt layer (4) / The laminated body S laminated one by one by the perforated back layer 5 is manufactured.

Figure 2 shows a cross section of a laminate of a multi-layered structure produced in accordance with the invention, wherein the skin layer (1) / PET powder layer (2) / PET film layer (3) / felt layer (4) / perforated back surface from above The laminated body laminated | stacked sequentially by the layer 5 is comprised, and the surface of the back layer 5 has been punched out.

And the laminate (S) fabric having a multi-layered structure according to the present invention prepared in the above is a mold after preheating compression by putting the fabric into a thermocompression apparatus by a method commonly known in the art according to the present invention according to the purpose of use It is put into the apparatus and molded by a cold press crimping method, etc. to manufacture the interior material.

<Example 1>

According to the composition and the ratio shown in the following [Table 1], the material according to each layer is prepared, and the skin layer (1) / PET powder layer (2) / PET film layer ( 3) / Felt layer 4 / The laminated body S of the multilayered structure sequentially laminated by the perforated back layer 5 was manufactured.

division Ingredient ratio  Remarks
Epidermal layer (1) PET Fiber 55 parts by weight
3-10 denier, 51-64 mm in length
Velor-type nonwovens made of fiber Flame Retardant PET Fiber 20 parts by weight LMF Fiber 25 parts by weight PET Powder Layer (2) PET powder - Film layer (3) PET film -
Felt Layer (4) PET Fiber 80 parts by weight 3-10 denier, 51-64 mm in length
Felt made of fiber LMF Fiber 20 parts by weight Back layer (5) PET film - Perforation after joining with the filter layer

<Example 2>

After heating the fabric of the multi-layered laminate (S) fabricated in Example 1 above at 230 ° C., it was placed in a lower mold cooled to a temperature of −10 ° C., and pressed at 7 Kgf / cm 2 for 2 minutes and 30 seconds. And then the molded trunk mat for the automotive interior was extracted from the mold.

 <Test Example>

Specimens were prepared from the trunk mats for vehicle interiors prepared from Examples 1 and 2, and mechanical strength, sound insulation (measurement of transmission loss with Apamat-II), and sound absorption rate (according to KS F2805DP) were evaluated for the specimens. Average values at 500, 1000, and 2000 Hz), and the results are shown in the following [Table 2] and [Table 3].

Test Items unit Test result Test Methods weight g / ㎡ 1190

MS 341-09 Tensile strength (horizontal / vertical) Kgf / 5cm 27.5 / 26.7
Heat resistance Tensile strength (horizontal / vertical) Kgf / 5cm 24.1 / 22.9 Export Rate (Landscape) % + 0.43 / 0.15 Compressive modulus % 92

Test Items Test result Remarks

Sound insulation 1,000 Hz 32
Transmission loss measurement with Apamat-II [dB] 2,000 Hz 35 3,150 Hz 45 5,000 Hz 48 Sound absorption Average value at 500, 1000, 2000 Hz 0.81 Noise Reduction Factor (NRC)

As shown in [Table 2] and [Table 3], the vehicle trunk mat according to the present invention has a relatively small deviation between the horizontal direction and the vertical direction, and the sound insulation is high in proportion to the frequency. In addition, the sound absorption rate is excellent because the higher the average value at 500, 1000, 2000Hz, it can be confirmed that the sound absorption and sound insulation of the vehicle trunk mat according to the invention.

1: epidermal layer
2, 2a: PET powder
3: PET film
4: felt layer
5: back layer
C: Cutting Machine
H, HR: Heaters and Heating Rollers
S: multilayer structure laminate

Claims (5)

Skin layer 1 formed of a nonwoven fabric consisting of 30 to 85 parts by weight of polyethylene terephthalate (PET) fiber, 10 to 40 parts by weight of flame retardant polyethylene terephthalate (PET) fiber and 5 to 30 parts by weight of low melting point fiber (LMF);
The polyethylene terephthalate (PET) powder is uniformly dispersed in the epidermal layer (1), and then partially melted by heating, partially melted into the epidermal layer (1), infiltrate with the epidermal layer (1), and some unmelted powder is the epidermal layer ( Polyethylene terephthalate (PET) powder layer (2) which has a sound insulation function by preventing the space | gap of 1),
A film layer 3 formed of a polyethylene terephthalate (PET) film or a polyethylene (PE) film,
Felt layer 4 composed of 60 to 90 parts by weight of polyethylene terephthalate (PET) fiber and 10 to 40 parts by weight of low melting point fiber (LMF), and
A multi-layered vehicle interior material having a perforated film and a synthetic resin powder, which is formed of a polyethylene terephthalate (PET) film or polyethylene (PE) and has a plurality of perforations formed on its surface. delete The vehicle interior material having a multilayer structure according to claim 1, wherein the interior material for vehicles is a floor carpet or a trunk mat. a). Polyethylene on the surface of the skin layer 1, which is a nonwoven fabric composed of 30 to 85 parts by weight of polyethylene terephthalate (PET) fiber, 10 to 40 parts by weight of flame retardant polyethylene terephthalate (PET) fiber and 5 to 30 parts by weight of low melting point fiber (LMF). After uniformly dispersing terephthalate (PET) powder, a part of the melt melts by heating and partially melts into the epidermal layer 1, soaks into the epidermal layer 1, and some unmelted powder blocks the pores of the epidermal layer 1 A first step of obtaining a first laminate having a powder layer 2 having a sound insulation function,
b). Backing layer consisting of a felt layer 4 composed of 60 to 90 parts by weight of polyethylene terephthalate (PET) fiber and 10 to 40 parts by weight of low melting point fiber (LMF) and a polyethylene terephthalate (PET) film or polyethylene (PE) film ( 2) a second process of joining 5) and perforating the surface of the back layer 5 to obtain a second laminate having a felt layer 4 and a back layer 5 formed with perforations;
C). The first laminate of the first step and the second laminate of the second step are laminated via a polyethylene terephthalate (PET) film or polyethylene (PE) film (3), and the powder layer (2) The felt layer 4 is bonded to face each other so that the epidermal layer 1 / polyethylene terephthalate (PET) powder layer (2) / polyethylene terephthalate (PET) film layer (3) / felt layer (4) / perforated from above And a third step of obtaining a laminate (S) having a multilayer structure sequentially stacked on the back layer (5). A method of manufacturing a vehicle interior material having a multilayer structure having a perforated film and a synthetic resin powder. delete

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