KR102129992B1 - Lightweight suit material having high heat resistant and stiffness and manufacturing method therefor - Google Patents

Abstract

The present invention relates to a high heat-resistant and rigid lightweight protective material capable of cutting and mixing polyamide fiber yarn (PA) (2), glass fiber yarn (GF) (4), and high heat-resistant low melting point yarn (LMF) (6) with a melting point of 170 to 220°C; blending the polyamide fiber yarn, the glass fiber yarn, and the high heat-resistant low melting point yarn at a blending ratio of 40-65 wt%: 10-35 wt%: 10-35 wt%; and facilitating thermoforming by including a high heat-resistant lightweight fiber felt member (10) after laminating a web and binding the web. The present invention is used to manufacture an engine cover (20); continuously endures vibration generated in an engine room of a vehicle and a high heat environment of about 150°C; secures size stability (no shape expansion or shape distortion); provides excellent rigidity; facilitates fuel efficiency and a reduced weight by implementing a protective material of a light fiber felt-type and providing a relative weight (20-30%) in comparison to an injection product of a conventional synthetic resin material; and facilitates collision safety with a pedestrian and protection of an engine inside when being applied as the engine cover of the vehicle.

Description

LIGHTWEIGHT SUIT MATERIAL HAVING HIGH HEAT RESISTANT AND STIFFNESS AND MANUFACTURING METHOD THEREFOR

The present invention relates to a protective material, in particular, to withstand the vibration and high heat generated in the engine room of the vehicle, and is capable of thermoforming, excellent rigidity and relates to a protective material having light properties and a method for manufacturing the same.

In the automotive field these days, interest in vehicle collision laws is rising worldwide and regulations are gradually being strengthened, so it is essential to develop new products through increased fuel efficiency and the use of recyclable eco-friendly materials.

Automotive engine covers are generally made of heat-resistant plastic materials, and sound absorbing and insulating materials capable of reducing noise and vibration are necessarily installed to prevent noise and vibration caused by vibration when the engine is operated.

Existing products of engine covers for automobiles are reinforced plastic materials, and injection materials are common, which is heavy and does not meet the recent situation in which fuel efficiency, weight reduction, pedestrian collision safety, and engine interior protection are important.

Therefore, it is able to withstand the high temperature heat of 150℃, such as a car engine, as well as lightening the product without shape deformation, and minimizes the heat energy generated by the engine being discarded into the atmosphere after engine start is stopped, and coolant or oil in the engine It is possible to improve fuel efficiency by allowing it to be stored on the back, it is possible to prevent noise and vibration caused by vibration when the engine is operating, and an engine cover is developed to cushion the pedestrian so as not to hurt as much as possible in the event of a vehicle collision. If a protective material for the environment is implemented, it will be able to obtain great response from people related to the technology.

Patent Registration No. 10-1304879 "Manufacturing method of vehicle floor undercover composite material"

Accordingly, an object of the present invention is to provide a protective material having a light property and a method for manufacturing the same that can withstand vibration and high heat generated in an engine room of a vehicle, has dimensional stability, is capable of thermoforming, has excellent rigidity, and has light properties.

Another object of the present invention is to provide a high heat-resistant and rigid lightweight protective material made of a lightweight fiber-type composite material for improving the collision safety with a pedestrian for an engine cover and a method for manufacturing the same.

The present invention according to the above object, polyamide fiber yarn (PA) and glass fiber yarn (GF) and sheath (sheath) melting point of 170 ~ 220 ℃ high heat resistant low melting point (LMF) after cutting and mixed but poly Amide fiber yarn: Glass fiber yarn: High heat-resistant low-melting yarn = 40-65 wt%: 10-35 wt%: 10-35 wt% compounded in a blending ratio, and after web lamination, high heat-resistance lightweight fiber felt members are constructed. Therefore, it is a high heat-resistant and rigid lightweight protective material characterized by enabling thermoforming.

In the high heat-resistant and rigid lightweight protective material, a high-heat-resistant lightweight fiber felt member is further provided with an inner shell material for sealing the glass fiber yarn component and enhancing the rigidity of the protective material, and the high-heat-resistant lightweight fiber felt member. The other side of the characterized in that it further comprises a fiber skin material bonded via an adhesive layer.

In addition, as another aspect of the present invention, in the method of manufacturing a high heat resistance and rigid lightweight protective material, polyamide fiber yarn (PA), glass fiber yarn (GF) and sheath (sheath) melting point of 170 ~ 220 ℃ high heat resistance After cutting the low-melting yarn (LMF) and mixing, polyamide fiber yarn: glass fiber yarn: high heat-resistant low-melting yarn = 40-65 wt%: 10-35 wt%: 10-35 wt% and mixed in a compounding ratio A high heat-resistant lightweight fiber felt capable of subsequent product thermoforming by providing a fiber mixture, a process of causing the composite material fiber mixture to be laminated into a plurality of webs on a transport conveyor, and binding the multiple webs by needle punching the web. Characterized in that it consists of a process of obtaining.

In the method of manufacturing a high heat-resistant and rigid lightweight protective material of the present invention, the high-heat-resistant lightweight fiber felt member may further have a process of sealing the glass fiber yarn component and fusing the inner material for enhancing the rigidity of the protective material. And

In addition, it may further have a process of obtaining a molding base material by thermally forming a high heat-resistant lightweight fiber felt member to which the inner skin material is combined, and a process of bonding and forming a fiber skin material on the outer surface of the molding base material.

The present invention can continuously withstand vibrations generated in an engine room of a vehicle, etc., and a high temperature environment of about 150°C, and can secure dimensional stability (no shape spreading or shape distortion) while being thermoformable and having excellent rigidity. In addition, by implementing a lightweight fiber felt type protective material, the weight is relatively light (20~30%) compared to the synthetic resin injection material to improve fuel efficiency or reduce weight. This has the advantage of enabling protection inside the engine.

Figure 1 is a schematic diagram of the manufacturing process of the high heat resistance and rigid lightweight protective material according to an embodiment of the present invention,
Figure 2 is an exemplary view of the process picture of Figure 1,
Figure 3 is a photo illustration of a high heat resistance and rigid lightweight protective material of the present invention,
Figure 4 is a schematic configuration diagram of the engine cover containing the high heat resistance and rigid lightweight protective material of the present invention,
Figure 5 is an exemplary illustration of an engine cover containing a high heat resistance and rigid lightweight protective material of the present invention,
Figure 6 is a schematic process diagram of manufacturing a high heat resistance and rigid lightweight protective material according to another embodiment of the present invention.

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

1 is a schematic process diagram of manufacturing a high heat-resistant and rigid lightweight protective material according to an embodiment of the present invention, FIG. 2 is an exemplary view of the process picture of FIG. 1, and FIG. 3 is a photo of the high heat-resistant and rigid lightweight protective material of the present invention. It is an example. And, Figure 4 is a schematic configuration diagram of an engine cover 20 containing the high heat resistance and rigid lightweight protective material of the present invention, Figure 5 is an engine cover 20 containing the high heat resistance and rigid lightweight protective material of the present invention It is a picture example.

The high heat-resistant and rigid lightweight protective material of the present invention can be applied as the main material of the engine cover 20 as shown in FIGS. 4 and 5, which is covered with the upper end of the automobile engine cylinder head, below the existing synthetic resin injection-type engine cover. It is a material that can solve disadvantages or problems.

Existing synthetic resin injection-type engine cover has a large weight and relatively low fuel efficiency, and the cover is hard, so it is possible to reduce the impact on the human body when the engine cover is located where the head is mostly contacted when a vehicle crashes by a pedestrian. There were no shortcomings.

In addition, there is an attempt to use a fiber composite material having light weight and shock-absorbing property as an example of a material development that includes an engine cover these days, mainly by applying a polypropylene or polyester-based fiber composite material. However, attempts to develop such a fiber composite material are difficult to commercialize because they cannot withstand the high temperature (over 150°C) generated in the engine room or cause dimensional stability such as shape spreading or shape distortion of the engine cover. .

In addition, a composite material reinforced with aramid fiber or the like is used as a plastic matrix, and aramid fiber is very expensive, and thus, the economical efficiency of product production is lacking.

Accordingly, in the present invention, it is possible to continuously withstand vibrations generated in an engine room of a vehicle, etc., and a high temperature environment of about 150°C or more, and also secure dimensional stability (no shape spreading or shape distortion), but also thermoforming. , It has the advantage of excellent rigidity and realizes a protective material having a light fiber felt type. In addition, it is much more economical than expensive aramid fibers, etc., and realizes high-temperature and rigid lightweight protective materials that are compatible with product applications.

The high heat-resistant and rigid lightweight protective material of the present invention is a high-heat-resistant and rigid lightweight protective material, polyamide fiber yarn (PA: Polyamide) (2) and glass fiber yarn (GF) (4) and sheath (sheath) ) It has a high heat-resistant lightweight fiber felt member 10 made of high-melting low-melting fiber (LMF) (6) having a melting point of 170 ~ 220 ℃.

High heat-resistant and rigid lightweight protective material of the present invention, as shown in Figure 1 (a), polyamide fiber yarns (PA: Polyamide) (2) and glass fiber yarn (GF: Glass Fiber yarn) (4) and the sheath portion (sheath) High-melting low-melting fiber (LMF) having a melting point of 170 to 220°C (6) is first cut to a length of approximately 50 mm, and then evenly mixed to form a high heat-resistant lightweight fiber felt member (10 in FIG. 1). A composite material fiber mixture to be obtained is obtained.

In the present invention, in constructing the high heat-resistant lightweight fiber felt member 10, the elastic and high heat-resistant and lightweight polyamide-based materials, that is, the polyamide fiber yarn 2 and the glass fiber yarn 4 together with the binder role and stiffness reinforcement role The high heat-resistant low-melting yarn (6) is evenly mixed and felt to form a composite fiber yarn, so it is lighter than the injection resin and has good shock absorption.

In particular, the high heat-resistant lightweight fiber felt member 10 of the present invention is a fibrous composite material, and has a high heat resistance and rigidity, and a polyamide fiber yarn 2 having a crimp property, and heat resistance, sound absorption, sound insulation, and heat insulating properties. Glass fiber yarn (4), which is an excellent inorganic fiber material, and high heat-resistant low-melting yarn (6), which has excellent shape-retaining ability after adhesion with other materials, are used, so crimping during thermoforming ensures dimensional stability and composite fiber yarn Through the range of the type and the blending ratio, it is possible to realize high heat resistance in an environment of 150° C. and outside, as well as to implement an appropriate strength required by the protective material of the present invention.

In the present invention, the compounding ratio of the composite material fiber mixture is polyamide fiber yarn (2): glass fiber yarn (4): high heat-resistant low-melting yarn (6) = 40-65 wt%: 10-35 wt%: 10-35 wt %.

The selected raw material mixing composition of the composite material fiber mixture and the fiber mixture blending ratio are optimal for securing product formability, dimensional stability, light weight, high heat resistance, rigidity, and bufferability to be implemented in the present invention. That is, there is a critical significance of the selection structure and scope.

In the material composition of the composite material fiber mixture, the polyamide fiber yarn 2 is light (specific gravity 1.14), has high strength, excellent abrasion resistance, and has good elasticity and bending resistance. In addition, the polyamide fiber yarn (2) has a melting point of about 220 to 250°C, so it has high heat resistance, that is, excellent thermal stability, excellent dimensional stability, light and soft, and exhibits crimp properties due to elasticity and bending resistance. It has vibration absorption and shock absorption properties. In the present invention, the polyamide fiber yarn 2 may be nylon 6 or nylon 66.

The glass fiber yarn 4, which is an inorganic fiber material used in the present invention mixed with the polyamide fiber yarn 2, can be mass-produced compared to other inorganic fibers such as basalt fiber or silica fiber, and has excellent quality uniformity and usability. As it has advantages, it is suitable as one material to be used in the present invention. It is preferable to select the glass fiber yarn because the glass fiber yarn of the present invention has better handleability and acoustic characteristics as the glass fiber diameter is smaller.

The glass fiber yarn (4) of the present invention has a specific gravity (specific gravity 2.54 g/cm 2) that is higher than that of polyamide fiber yarn (2) or high heat-resistant low-melting yarn (6), so it is necessary to pay attention to proper mixing. However, it is a raw material that has good thermoforming properties, has good rigidity for maintaining a solid skeleton, and is also advantageous for improving sound absorption and heat insulation performance. However, in the case of the glass fiber yarn material, the higher the content of the glass fiber, the greater the exposure of the glass fiber, which causes difficulties in manufacturing and use due to itching during handling, so that the function of the glass fiber yarn can be sufficiently exhibited. It is good to use at the lowest mixing ratio as possible.

Therefore, the blending ratio of the polyamide fiber yarn (2) and the glass fiber yarn (4) of the high heat-resistant lightweight fiber felt member (10), which is a high-heat-resistant and rigid lightweight protective material according to the present invention, ranges from 40 to 65% by weight. It is 35% by weight, and the proportion of polyamide fiber yarns 2 is relatively high, on average, 2.5 times that of glass fiber yarns 4.

The high heat-resistant low-melting yarn 6 used in the formation of the high heat-resistant lightweight fiber felt member 10 of the present invention together with the polyamide fiber yarn 2 and the glass fiber yarn 4 is made of polyester material. It is a kind of low melting point yarn that can be melt-bonded from low temperature (about 110℃).

General low-melting fiber (LMF) is a material that is a composite spinning material of a modified low-melting polyester and a general polyester, and it can be used for adhesion by using a property in which low-melting components are melt-bonded by heat treatment. That is, the low melting point yarn is formed of a structure having a core part melting at a high temperature of 250 to 260°C, and a sheath part melting at a relatively low temperature having a melting point of 120 to 200°C, which is much lower than that of ordinary polyester yarn. At the temperature, only the outer part (sheath part) is melted to be combined with other materials.

As one of the raw materials according to the present invention, the high heat-resistant low-melting yarn (6) is a low-melting yarn having a melting point of 170 to 220°C in the sheath portion, so it has a low specific gravity (polyester specific gravity 1.31 g/cm2) and is light and heat resistant. It is also very good.

The high heat-resistant low-melting yarn (6) is a polyamide fiber yarn (2) or glass fiber yarn (4) by melting the sheath portion in the oven thermoforming of the high-heat-resistant lightweight fiber felt member (about 240°C at ambient temperature) and It is bonded together with other high heat-resistant low-melting yarns 6 and its core portion retains its shape so that it acts as a binder together with stiffness reinforcement.

High heat-resistant low-melting yarn (6), one of the raw materials of the present invention, properly strengthens stiffness and acts as a binder and forms heat when it occupies 10 to 35% by weight of the composition ratio of the high-heat-resistant lightweight fiber felt member (10). It helps to be good.

As a raw material of the composite material fiber mixture according to the present invention, the polyamide fiber yarn (2), the glass fiber yarn (4), and the high heat-resistant low-melting yarn (6) all have a thin thickness of 4 to 20 denier. , It is suitable for sound absorption and light weight.

In the present invention, the polyamide fiber yarn (2), the glass fiber yarn (4) and the high heat-resistant low-melting yarn (6) are cut in several millimeters as a raw material for the composite fiber mixture, and then uniformly mixed to form a composite fiber mixture. Get

In mixing to be a composite material fiber mixture in the present invention, the thermoplastic fiber having a low specific gravity [specific gravity of about 1, in the case of polyamide fiber yarn (2) has a specific gravity of 1.14 g/cm 2 and 1.31 g of a low melting point yarn made of polyester material. /Cm2] and high-specificity glass fiber yarns 4 (specific gravity 2.54 g/cm2) should be effectively dispersed/mixed with different specific gravity fiber fibers. To this end, in the present invention, the homogeneity of the fiber composition is improved by performing a carding process using a plurality of hoppers and a plurality of cards.

In the present invention, the composite material fiber mixture thus provided is introduced as a raw material to form a web on the transport conveyor as shown in the photo of FIG. 2(a), but a plurality of webs are stacked, and thereafter, FIG. 1(b). And (b) a high heat-resistant lightweight fiber felt member 10 capable of thermally forming a product by performing a needle punching using a needle-type pin 8 on multiple stacked webs as shown in the photo of FIG. 2(b). Get

In performing the needle punching process for web binding, the present inventors pre-punched a portion in which a web in which a glass fiber yarn and a thermoplastic fiber yarn (polyamide fiber yarn and high heat-resistant low-melt yarn) are mixed is formed in multiple layers. There have been two types of punching method and hook-punching method, and the web has been bound, and when hook punching is applied, there is a disadvantage in that yarns such as glass fiber yarns come out to the outside.

Accordingly, in the present invention, the web binding was performed by pre-punching using a needle-type pin (8). As a result, the high heat-resistant lightweight fiber felt member (10) as shown in FIG. I could get it.

Figure 3 (a) shows a high heat resistant lightweight fiber felt member 10, a photograph taken of the intercept, Figure 3 (b) is a web-bound high heat resistant lightweight fiber felt member 10 is wound on a roll It shows a picture of the real thing.

The high heat-resistant lightweight fiber felt member 10 of the present invention is a high-heat-resistant low-melting yarn (6) is introduced into the glass fiber yarn (4) and the polyamide fiber yarn (2) to strengthen the strength and to define the surface density range Appropriate strengths desired by the manufacturer can be obtained. The surface density (weight) of the high heat-resistant lightweight fiber felt member 10 in the present invention has 700 to 1600 g/m 2.

The inventors of the present invention have tried two types of heat resistance tests for the high heat resistance lightweight fiber felt member 10 as shown in the photo of FIG. 3 as a high heat resistance and rigid protection material of the present invention.

The first was a long-term heat resistance test under the conditions of 150°C/330 hours required by the automobile industry, and the second was a more severe high-temperature environment than the condition of the first 150°C/330 hours, and the heat resistance test under the conditions of 165°C/72 hours. Was performed.

As a result, it was confirmed that in the two types of heat resistance tests, the high heat-resistant lightweight fiber felt member 10 of the present invention satisfies the heat resistance, and the dimensional stability is also guaranteed because there is no displacement of the material.

In addition, the engine cover 20 shown in FIGS. 4 and 5 including the high heat-resistant and rigid protective material of the present invention, which is a high-heat-resistant lightweight fiber felt member 10, is changed by accelerating vibration and temperature to be similar to a real environment. It was also confirmed that it was suitable for the durability test of environmental vibration.

4 is a schematic configuration diagram of the engine cover 20 including the high heat resistance and rigid lightweight protective material of the present invention, and FIG. 5 is a photograph of the engine cover 20 including the high heat resistant and rigid lightweight protective material of the present invention It is an example. 5(a) is the outer surface of the engine cover 20, and FIG. 5(b) is the inner surface of the engine cover 20.

The high heat-resistant and rigid lightweight protective material of the present invention provides additional rigidity, and the inner and outer surfaces of the high-heat-resistant lightweight fiber felt member 10 as shown in FIG. , A skin material and an inner skin material may be further provided.

That is, the high heat-resistant and rigid lightweight protective material of the present invention, as shown as an example of the engine cover 20 in FIG. 4, one surface of the high-heat-resistant lightweight fiber felt member 10 is sealed and protective material of a glass fiber yarn component An inner shell material 14 for enhancing the rigidity may be further provided, and the other surface of the high heat resistant lightweight fiber felt member 10 may be formed with a fiber skin layer 12 as an adhesive layer.

The fiber skin material 12 provided as the outer surface of the engine cover 20 is preferably a non-woven fabric or a knit fabric, and the adhesive layer interposed between the fiber skin material 12 and the high heat-resistant lightweight fiber felt member 10 is made of polyurethane binder. It is preferred to be used.

The inner shell material 14 is made of a polyester fiber yarn or a polyamide fiber yarn material, and may have a slight shrinkage during thermoforming using the polyester, so that the sheath melting point is 170 to 220°C to prevent shape deformation of the protective material. It is preferable to mix and use the high heat-resistant low-melting yarn of long fiber.

In order to bond the inner shell of the high heat-resistant lightweight fiber felt member 10, after thermal molding, a polyurethane binder is coated on the outer surface of the high-heat-resistant lightweight fiber felt member 10 to adhere the fiber skin material 12, and the heat resistance is high. On the inner surface of the lightweight fiber felt member 10, a polyester material inner material 14 is placed and fixed and fixed by an ultrasonic fusion machine to prevent curling of the inner material 14 during preheating in a subsequent thermoforming machine.

In the present invention, the high heat-resistant and rigid lightweight protective material in which the inner shell 14 is coupled to the inner surface of the high-heat-resistant lightweight fiber felt member 10 is thermoformed in an oven to produce a molding material in the shape of a molding frame, and in the molding frame during oven thermoforming The ambient temperature is around 220~250℃.

The thermoforming of the high heat-resistant and rigid lightweight protective material of the present invention must be pressure-molded in an oven forming frame to maintain the shape of the fiber yarn, unlike injection molding after melting the existing resin.

After the thermoforming, a fiber skin material 12 is attached to the surface of the molding base material taken out of the molding frame via a polyurethane binder.

The engine cover 20 shown as an example of Figure 4 is provided with a high heat-resistant and rigid lightweight protective material that combines the fiber skin material 12 and the inner skin material 14 on both sides of the high heat-resistant lightweight fiber felt member 10, On the inner skin material 14, a foamable sound absorbing member 16 for fixing an engine and performing sound absorption function and a rubber material cap mount 18 for holding the cylinder head are provided.

The engine cover 20 including the high heat resistance and rigid lightweight protective material of the present invention as described above has a light weight effect of 20 to 30% compared to a conventional plastic injection material, and despite the use of a composite fiber material, dimensional stability and formability This ensures the rigidity (tensile strength, tensile load, flexural strength, etc.) required by the engine cover 20 along with high heat resistance, which can be used even for engines, etc., and also provides cushioning to prevent injuries when pedestrians collide with vehicles. It has the effect of reducing.

Test results for the stiffness (tensile strength, tensile load, flexural strength) of the engine cover 20 containing the high heat resistance and rigid lightweight protective material of the present invention (= high heat resistance lightweight fiber felt member + fiber skin material + inner skin material) As an example (unit weight 1800 ~ 2200g / ㎡), the tensile strength is 1800 ~ 3000N in the longitudinal direction, 2000 ~ 3000N in the width direction, the flexural strength is 17 ~ 60N in the longitudinal direction, 19 ~ 60N in the width direction, the flexural modulus (flexural modulus) ) Is 600 to 1100 Mpa in the longitudinal direction and 700 to 1400 Mpa in the width direction.

One example of test results for stiffness (tensile strength, tensile load, flexural strength) when the high heat-resistant and rigid lightweight protective material of the present invention is composed of a high-heat-resistant lightweight fiber felt member and an inner shell material (unit weight 1400-1800 g/㎡) The furnace has a tensile strength of 1600 to 2500 N in the longitudinal direction, 600 to 1300 N in the width direction, a flexural strength of 20 to 70 N in the longitudinal direction, 10 to 45 N in the width direction, and a flexural modulus of 800 to 1800 Mpa in the longitudinal direction and 500 in the width direction. It is ~1300Mpa.

In addition, when the high heat resistance and rigid lightweight protective material of the present invention is composed of high heat resistance lightweight fiber felt members (polyamide fiber yarns and glass fiber yarns and high heat resistance low melting point yarns), tests for rigidity (tensile strength, tensile load, flexural strength) As an example of the result (unit weight 1000 to 1400 g/m 2 ), the tensile strength is 700 to 1600 N in the longitudinal direction, 300 to 1200 N in the width direction, the flexural strength is 6 to 30 N in the longitudinal direction, 4 to 25 N in the width direction, and the flexural modulus (flexural) modulus) is 700~1600Mpa in the longitudinal direction and 100~1000Mpa in the width direction.

The high heat-resistant and rigid lightweight protective material of the present invention is a component exemplified in the engine cover 20 and can be implemented without the foamable sound absorbing member 16 or the cap mount 18, and is similar to the foamable sound absorbing member 16 instead. It should also be understood that a functional sound absorbing material such as an ultrafine fiber sound absorbing member can be used.

On the other hand, as another embodiment of the high heat resistant and rigid lightweight protective material of the present invention, the high heat resistant yeongyeong fiber felt member described above in the embodiment of the present invention is configured by omitting glass fiber yarns and further stacking a reinforcing material for strengthening the rigidity. It can be implemented to be molded.

That is, as another embodiment of the high heat-resistant and rigid lightweight protective material of the present invention, as shown in Figure 6, polyamide fiber yarn (PA) (2) and sheath (sheath) melting point of 170 ~ 220 ℃ high heat resistance Low-melting yarn (LMF) (6) is cut and mixed, but polyamide fiber yarn (2): high heat-resistant low-melting yarn (6) = 70 to 45% by weight: 30 to 55% by weight of polyamide fiber yarn ( 2) is blended to have a higher weight ratio than the high heat-resistant low-melting yarn (6) [Fig. 6 (a)], and the web-laminated web to form a high heat-resistant lightweight fiber felt member 10 (Fig. 6 ( b), (c)], the high heat-resistant lightweight fiber felt member 10 is configured to be laminated so that the reinforcing material (14a) for enhancing the rigidity on the surface (Fig. 6 (d)), the reinforcing material (14a) is high The heat-resistant lightweight fiber felt member 10 together with the thermoforming is possible. At this time, the reinforcing material 14a is preferably a polyamide fiber yarn (PA).

Moreover, in constructing a high heat-resistant and rigid lightweight protective material according to another embodiment of the present invention, the surface density (weight) of the high-heat-resistant lightweight fiber felt member 10 is relatively the same or higher than the surface density (weight) of the reinforcing material It is constructed so that there is no change in shape distortion or twist during thermoforming.

As described above, the high heat-resistant and rigid lightweight protective material according to another embodiment of the present invention in which the glass fiber yarn, which is a refractory material, is omitted, is a fiber material and can be used in parts requiring high levels of strength and heat resistance, such as interior materials or automobile bodies of automobiles. In addition, there is an advantage that recyclability is possible because there is no glass fiber yarn.

As another embodiment of the present invention, a polyamide fiber yarn (PA) and a sheath melting point of 170 to 220° C. are mixed with a high heat resistance low melting point yarn (LMF) and cut and mixed to form a web, and then heat the web to obtain high heat resistance and light weight. By constructing a fiber felt member, and constructing a reinforcing material made of polyamide fiber yarn (PA) to increase heat resistance and rigidity on the surface of the high heat-resistant light-weight fiber felt member, thermal molding together with the high heat-resistant light-weight fiber felt member It is possible to implement a high heat-resistant and rigid lightweight protective material characterized by this enablement.

As another embodiment of the high heat-resistant and rigid lightweight protective material of the present invention, the high-heat-resistant lightweight fiber felt member (polyamide fiber yarn and high heat-resistant low-melting yarn) and the rigidity when it is composed of a reinforcing material (tensile strength, tensile load, flexural strength) As an example of the test results for (unit weight 1400 to 1800 g/m 2 ), tensile strength is 1400 to 2300N in the longitudinal direction, 400 to 1300N in the width direction, flexural strength is 15 to 40N in the longitudinal direction, and 10 to 50N in the width direction, and bending The elastic modulus is 700 to 1600 Mpa in the longitudinal direction and 300 to 1400 Mpa in the width direction.

In addition, as an example of implementing the high heat-resistant and rigid lightweight protective material of the present invention, polyamide fiber yarn (PA), glass fiber yarn (GF), and sheath melting point of 170-220° C., high heat-resistant low-melting yarn (LMF) ) And then mix and cut the web to form a high heat-resistant lightweight fiber felt member by web binding, and a high-heat-resistant lightweight fiber felt member is constructed so that a reinforcement material made of polyamide fiber yarn (PA) is laminated on the surface to enhance rigidity. Thus, it is possible to configure the high heat-resistant lightweight fiber felt member together with a thermoforming function.

In the above description of the present invention, specific embodiments have been described, but various modifications can be made without departing from the scope of the present invention. Therefore, the scope of the present invention should not be determined by the described embodiments, but should be defined by the claims and the equivalents of the claims.

(2)-- Polyamide fiber yarn (4)-- Glass fiber yarn
(6)-- High heat resistance, low melting point (8)-- Needle type pin
(10)-- High heat-resistant lightweight fiber felt member (12)-- Fiber skin material
(14)-- Inner material (16)-- Foaming sound absorbing member
(18)-- Cap mount (20)-- Engine cover

Claims (11)

Polyamide fiber (PA), glass fiber (GF) and sheath (sheath) melting point 170 ~ 220 ℃ high heat resistant low melting point (LMF) is cut and mixed but polyamide fiber yarn: glass fiber yarn: high Heat-resistant, low-melting yarn = 40-65% by weight: 10-35% by weight: 10-35% by weight, and it is possible to perform thermal molding by forming a high-heat-resistant lightweight fiber felt member by web binding after web lamination. High heat resistance and rigid lightweight protective material.
The high heat-resistant and rigid lightweight protective material according to claim 1, further comprising an inner shell for sealing the glass fiber yarn component and enhancing the rigidity of the protective material on one surface of the high-heat-resistant lightweight fiber felt member.
[3] The high heat-resistant and rigid lightweight protective material according to claim 2, wherein the inner cover material is composed of one of polyester fiber yarns and polyamide fiber yarns.
The high heat-resistant and rigid lightweight protective material according to claim 1 or 2, further comprising a fiber skin material adhered via an adhesive layer on the other surface of the high-heat-resistant lightweight fiber felt member.
Polyamide fiber yarn (PA) and sheath have a melting point of 170-220° C. and then mixed with high heat-resistant low-melting yarn (LMF), but polyamide fiber yarn: high heat-resistant low-melting yarn = 70-45% by weight: As a blending ratio of 30 to 55% by weight, polyamide fiber yarns are blended to have a higher weight ratio than high heat-resistant low-melting yarns, and web-laminated webs form high heat-resistant lightweight fiber felt members.
A high heat-resistant and rigid lightweight protective material characterized in that a reinforcing material for enhancing rigidity is laminated on the surface of the high-heat-resistant lightweight fiber felt member to enable thermal molding together with the high-heat-resistant lightweight fiber felt member.
[6] The high heat-resistant and rigid lightweight protective material according to claim 5, wherein the high-heat-resistant lightweight fiber felt member has a relatively same or higher surface density (weight) than that of the reinforcing material.
Polyamide fiber (PA), glass fiber (GF) and sheath (sheath) melting point 170-220℃ high heat resistance low melting point (LMF) is cut and mixed, and then web laminated and high heat resistance lightweight fiber by web binding Constituting a felt member, the high heat-resistant lightweight fiber felt member is constructed to be laminated with a reinforcing material made of polyamide fiber yarn (PA) for stiffness enhancement and heat resistance on the surface, so that the thermoforming is performed together with the high heat-resistant lightweight fiber felt member. High heat-resistant and rigid lightweight protective material characterized by enabling.
The polyamide fiber yarn (PA) and the sheath melting point (LMF) having a melting point of 170 to 220° C. are cut and mixed to form a high heat resistant lightweight fiber felt member by web bonding after web lamination, and The high heat-resistant lightweight fiber felt member is constructed to be laminated with a reinforcing material made of polyamide fiber yarn (PA) for enhanced rigidity and heat resistance, and is characterized in that it can be thermoformed together with the high-heat-resistant lightweight fiber felt member. Heat-resistant and rigid lightweight protective material.
In the manufacturing method of high heat resistance and rigid lightweight protective material,
Polyamide fiber (PA), glass fiber (GF) and sheath (sheath) melting point 170 ~ 220 ℃ high heat resistant low melting point (LMF) is cut and mixed but polyamide fiber yarn: glass fiber yarn: high Heat-resistant low-melting yarn = 40 to 65% by weight: 10 to 35% by weight: a process of providing a composite material fiber mixture by mixing at a mixing ratio of 10 to 35% by weight,
The process of causing the composite material fiber mixture to be laminated into a plurality of webs on a transport conveyor,
A method of manufacturing a high heat-resistant and stiff lightweight protective material, characterized in that it consists of a process of obtaining a high-heat-resistant lightweight fiber felt that can be thermally molded in a subsequent product by bundling multiple stacked webs by needle punching.
The method of claim 9,
Method of manufacturing a high heat-resistant and rigid lightweight protective material, characterized in that it further has a process of fusing the inner material for sealing the glass fiber yarn component and enhancing the rigidity of the protective material on one surface of the high-heat-resistant lightweight fiber felt member.
The method of claim 10,
A process of obtaining a molding base material by thermally forming a high heat resistant lightweight fiber felt member in which the inner skin material is combined in a molding frame;
Method of manufacturing a high heat-resistant and rigid lightweight protective material characterized in that it further has a process of forming and forming a fiber skin material on the outer surface of the molding base material.

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