KR102214761B1 - Multi layer non-woven fabric for autumobile floor carpet - Google Patents

Abstract

The present invention relates to a multilayer non-woven fabric for an automobile floor carpet, and more specifically, to a multilayer non-woven fabric for an automobile floor carpet capable of improving sound absorbing and insulating properties by ensuring breathability with a powder material; lightening a weight due to use of eco-friendly cotton felt; and simplifying an overall manufacturing process by manufacturing the non-woven fabric used for forming the floor carpet by a one-step process. The present invention relates to the multilayer non-woven fabric for an automobile floor carpet, comprising a fabric unit and a sound absorbing and insulating unit, wherein the sound absorbing and insulating unit includes a cotton felt layer.

Description

Multi layer non-woven fabric for autumobile floor carpet}

The present invention relates to a multi-layer nonwoven fabric for automobile floor carpets, and more particularly, by using a powder material to ensure breathability, thereby improving sound absorbing and insulating properties, and due to the use of eco-friendly cotton felt The present invention relates to a multi-layer non-woven fabric for automobile floor carpets that can reduce weight and simplify the overall manufacturing process by allowing the non-woven fabric used for floor carpet molding to be manufactured by a one-step process.

The interior material of a car refers to almost all parts that make up the interior of the car. The headliner, floor carpet, etc., which greatly affect the quietness of the vehicle through the finishing materials of seats and doors, and instrument panels. carpet).

Among them, the floor carpet is a component installed for the purpose of providing a more comfortable ride to the driver and passengers by covering the body panel invisibly from the interior of the vehicle and preventing noise and vibration from the outside generated during driving. As a result of testing the contribution of each interior material component that affects the quietness of the driver's seat, it was confirmed that the floor carpet appeared the highest at about 27%.

These floor carpets occupy a large proportion of the total automotive interior materials, and most of the nonwoven fabrics are used to compensate for the shortcomings of low strength, loss of brushing, trimming, and thermoformability.

In other words, recent floor carpets are manufactured using a nonwoven fabric made of a multi-layered structure using felts, and such a multi-layered nonwoven fabric is usually formed in a distal part providing comfort to passengers and a lower part of the distal part to make noise. And a sound absorbing and insulating unit that absorbs and blocks vibration.

Among them, in the case of the sound absorbing and insulating part, the thicker the sound absorbing and insulating part, the better the sound absorbing or sound insulating performance, but there is a disadvantage that the weight of the floor carpet increases as the sound absorbing and insulating part thickens.

As shown in FIG. 1, the conventional sound absorbing and insulating part 10 is a felt layer 16 made of a polyethylene (PE) coating layer 12, an acryl polymer (AP) coating layer 14, and PET, or a PU foam (polyurethane foam). ) It is made of a layer 16, and the PE coating layer 12 and the AP coating layer 14 have disadvantages in that the breathability is insufficient, so that the absorption performance is poor and the weight is increased.

In addition, felts such as PET felt used for the felt layer 16 have a disadvantage of increasing the weight of nonwoven fabrics and floor carpets due to their high density.Polyurethane foam may cause discoloration and debris depending on the usage environment. There is a concern, and there is a problem that may generate toxic gas in the event of an accident.

In addition, the polyurethane foam has an advantage of being excellent in sound absorbing and insulating performance, but it is not eco-friendly and has a problem that it is not suitable for weight reduction of a floor carpet because it is not eco-friendly and has a large weight per unit area.

And, in the case of the conventional nonwoven fabric used in the floor carpet, as in the first process of manufacturing PET that forms a relatively hard layer by carding and punching, a relatively soft layer by carding and punching Since it is manufactured by the second process of manufacturing PET forming the (soft layer) and the third process of combining the hard PET and soft PET produced in the first and second processes, many manufacturing facilities are required due to the complex manufacturing process. , There is a disadvantage in that the nonwoven fabric manufacturing process takes a lot of time and cost.

1. Republic of Korea Patent Publication No. 10-2018-0130027 (published on Dec. 06, 2018) 2. Republic of Korea Patent Publication No. 10-1835442 (2018. 03. 09. Announcement)

The present invention was conceived to solve the problems of the prior art as described above, and an object of the present invention is to improve the sound absorbing and insulating properties by using a powder material for the sound absorbing and insulating part to ensure breathability, and to reduce the weight. It is to provide a multi-layer non-woven fabric for automobile floor carpets.

In addition, the present invention uses cotton felt as a substitute for polyurethane foam that is harmful to the human body, thereby making it possible to reduce overall weight and improve eco-friendliness and recyclability. Offering has a different purpose.

In addition, the present invention makes it possible to manufacture the nonwoven fabric used for floor carpet molding by a one-step process, thereby reducing the time required for manufacturing the nonwoven fabric and the equipment used for manufacturing the nonwoven fabric, thereby improving economic efficiency. Another object is to provide a multi-layer nonwoven fabric for carpet.

The present invention for achieving the above objects,

In the multi-layer nonwoven fabric for automobile floor carpet comprising a distal end portion and a sound absorbing and insulating portion, the sound absorbing and insulating portion is characterized in that it comprises a cotton felt layer.

In this case, the sound absorbing and insulating portion is characterized in that it is configured to further include a powder layer made of a powder material formed between the distal portion and the cotton felt layer.

Here, the material of the powder material is characterized in that any one of PET, Nylon, and PE.

In addition, the cotton felt layer is configured to be separated into first and second cotton felt layers, and a perforated film is inserted between the first and second cotton felt layers.

In addition, the cotton felt layer is characterized in that it is formed by a combination of 30 to 60% by weight of cotton fibers, 20 to 40% by weight of low-melt fiber, and 20 to 30% by weight of PET fibers.

In addition, the cotton felt layer is manufactured by a one-step process and is integrally incorporated with the distal end of a powder material.

At this time, in the one-step process, cotton felt forming two layers is simultaneously supplied by the airlay method to form a web, and a perforated film is placed between the two layers, and then the cotton felt layer is thermally compressed. It is characterized by forming.

According to the present invention, it is possible to secure breathability by using a powder material as the sound absorbing and insulating part of the floor carpet, and by using cotton felt as a substitute for polyurethane foam that is harmful to the human body, the sound absorbing and insulating properties are improved and the total weight is reduced. It has an excellent effect that can achieve weight reduction at the same time.

In addition, according to the present invention, the eco-friendliness and recyclability of the product can be improved by the use of eco-friendly cotton felt, and the weight of the floor carpet can be reduced by 10% or more compared to the existing one, thereby contributing to the improvement of fuel efficiency of the vehicle. It has an additional effect.

In addition, according to the present invention, it is possible to manufacture a nonwoven fabric by a one-step process, thereby reducing the time required for manufacturing the nonwoven fabric and equipment used for manufacturing the nonwoven fabric, thereby improving productivity and securing price competitiveness. It has an additional effect that can be done.

1 is a partial enlarged cross-sectional view of a conventional multi-layer nonwoven fabric for an automobile floor carpet.
Figure 2 is a partial enlarged cross-sectional view of a multi-layer nonwoven fabric for an automobile floor carpet according to the present invention.
3 is a view showing a state in which a powder material is applied to the sound absorbing and insulating part of the present invention shown in FIG. 2.

Hereinafter, preferred embodiments of the multi-layer nonwoven fabric for a car floor carpet according to the present invention will be described in detail with reference to the accompanying drawings.

FIG. 2 is a partially enlarged cross-sectional view showing a multi-layer nonwoven fabric for an automobile floor carpet according to the present invention, and FIG. 3 is a view showing a state in which a powder material is applied to the sound absorbing and insulating part of the present invention shown in FIG.

In the present invention, by using a powder material to ensure breathability, it is possible to improve sound absorbing and insulating properties, and to reduce weight due to the use of eco-friendly cotton felt, as well as a one-step nonwoven fabric used for floor carpet molding. It relates to a multi-layer non-woven fabric 100 (hereinafter referred to as'non-woven fabric 100') for an automobile floor carpet that simplifies the overall manufacturing process by allowing it to be manufactured by a process, and its configuration is a distal part ( 110) and a sound absorbing and insulating portion 120.

In more detail, the distal part 110 is located on the uppermost layer of the present invention made of a multi-layer, that is, a multi-layered structure, and serves to provide comfort to passengers, and the material is latex. The material of the distal part 110 used for the existing floor carpet, etc. may be used.

Next, the sound-absorbing and insulating part 120 is integrally formed under the distal part 110 to absorb and sound-absorb noise generated during driving of the vehicle, and the cotton felt layer 122 is formed. Including.

That is, in the case of polyurethane foam, which is mainly used as a material of the conventional sound absorbing and insulating part, it has excellent sound absorbing and insulating properties, but there is a risk of discoloration or debris depending on the use environment, and it is not only possible to recycle, as well as to increase the weight per unit area In order to improve this, eco-friendly, recyclable, and low weight per unit area are used as the material of the sound absorbing and insulating part 120, since there are problems such as the risk of generating toxic gases in the event of an accident. The sound absorbing and insulating part 120 which is not harmful to the human body and can be lightened can be formed.

In addition, since the cotton felt has a relatively low weight, it can contribute to weight reduction of the nonwoven fabric 100 and the floor carpet using the same, and further has the advantage of being able to contribute to the improvement of fuel economy of a vehicle.

On the other hand, the cotton felt layer 122 is made of cotton fibers, low melting fiber (low melting fiber) and PET fiber.First, cotton fibers are made of a material that has excellent sound absorbing and insulating properties and has a low weight per unit area. ) To reduce the weight of the fiber, and the low melting point fiber has a property of melting at a temperature of 100 to 200°C lower than that of ordinary fiber, and is intended to improve adhesion with the powder layer 126 to be described later. Is used as

Next, the PET fiber is one of the representative materials that have been conventionally used as sound-absorbing materials because of its excellent sound-absorbing performance, and when PET fiber and cotton fiber are mixed and used, the weight of the nonwoven fabric 100 can be reduced, as well as an air layer around the PET fiber. It is possible to significantly improve the sound absorbing and insulating performance.

In addition, the cotton fibers, low melting point fibers, and PET fibers are all recyclable and have an advantage in that they are environmentally friendly materials that are harmless to the human body.

At this time, the mixing ratio of the cotton fibers, the low melting point fibers and PET fibers forming the cotton felt layer 122 is 30 to 60% by weight of cotton fibers, 20 to 40% by weight of the low melting point fibers, and 20 to 30% by weight of PET fibers. It is preferable that the weight of the cotton felt layer 122, sound absorbing and insulating performance, and adhesiveness are considered.

That is, in the case of the cotton fiber, if the weight is less than 30% by weight, the sound absorbing and insulating performance and the weight reduction effect may be deteriorated, and if it exceeds 60% by weight, the content of other components decreases, resulting in decreased adhesion or The advantages you have may not appear well.

In addition, when the weight of the low-melting fiber is less than 20% by weight, there is a concern that adhesiveness may be deteriorated, and when it exceeds 40% by weight, the content of the remaining components decreases, thereby deteriorating the sound absorbing and insulating properties.

And, when the content of the PET fiber is less than 20% by weight, the advantages of the PET fiber, that is, the effect of increasing workability, heat insulation, and sound absorbing and insulating performance by mixing with cotton fiber may be reduced, and exceeding 30% by weight. In this case, there is a fear that the effect of reducing the weight is lowered.

Meanwhile, as shown in FIG. 2, the cotton felt layer 122 may be divided into first and second cotton felt layers 122a and 122b, and the first and second cotton felt layers 122a and 122b ) A perforated film 124 is inserted between them.

The perforated film 124 is used for the purpose of improving sound absorbing and insulating performance, and a plurality of holes formed in the perforated film 124 serves to reduce noise by ensuring air permeability.

That is, the noise primarily reduced through the second cotton felt layer 122b is further reduced while passing through the perforated film 124, and is reduced once more while passing through the first cotton felt layer 122a, thereby reducing the cotton felt layer. It was constructed to show the effect of reducing noise over a total of three times with only (122).

At this time, as the material of the perforated film 124, PE (polyethylene), Nylon (nylon), PET (polyethylene terephthalate), TPE (thermoplastic elastomer), TPO (thermoplastic olefin), etc. may be used, and the perforated film 124 ) Thickness and the diameter and arrangement of the holes to be drilled may vary depending on the frequency of the noise to be absorbed or blocked.

Next, as the sound absorbing and insulating part 120 of the nonwoven fabric 100 according to the present invention, a powder layer 126 may be further included, wherein the powder layer 126 is between the distal part 110 and the cotton felt layer 122 It is formed so that the distal part 110 and the cotton felt layer 122 can be bonded to each other, and at the same time, it serves to improve the sound absorbing and insulating performance.

That is, in the conventional case, the PE coating layer and the AP coating layer were mainly used for bonding between the distal portion 110 and the sound absorbing and insulating portion 120, but the PE coating layer and the AP coating layer lacked breathability, resulting in poor absorption performance and high weight. Since there is a drawback of going out, in order to improve this, the distal portion 110 and the cotton felt layer 122 are configured to be integrated using the powder layer 126 using a powder material.

In more detail, as the material of the powder material used for the formation of the powder layer 126, ingredients such as PET, Nylon, and PE that are light and have sound absorbing and insulating properties without harm to the human body may be used. When uniformly applied between the part 110 and the sound absorbing and insulating part 120 and then bonded by a hot-melt method, the powder materials are partially bonded as they melt, and the powder layer 126 serving as a coating material is formed.

At this time, as can be seen in FIG. 3, the applied powder materials are partially bonded between the distal part 110 and the sound absorbing and insulating part 120 to form a porous shape and secure breathability, and the air in the porous hole is Sound energy is converted into heat energy and absorbed by friction generated while vibrating by sound waves, so that sound absorption performance can be improved.

In addition, when the distal part 110 and the sound absorbing and insulating part 120 are combined using a powder material as described above, the thickness of the powder layer 126 becomes thinner than that of the conventional PE coating layer and the AP coating layer, so that the nonwoven fabric 100 It can also contribute to weight reduction.

On the other hand, the cotton felt layer 122 of the nonwoven fabric 100 according to the present invention configured as described above has another feature in that it is configured to be manufactured by a one-step process, and the one-step process means that it can be produced in one work line. It means the process made.

That is, as described above, in the related art, a process for forming a hard layer, a process for forming a soft layer, and a process for incorporating the same are performed in different production lines, and a total of three steps are required, and a perforated film ( In the case of inserting 124), the first and second cotton felt layers 122a and 122b corresponding to the hard layer and the soft layer, respectively, in the present invention, whereas the process of attaching the perforated film 124 had to be additionally performed. And the perforated film 124 inserted between the first and second cotton felt layers 122a, 122b is configured to be manufactured by a one-step process in one line, so that the manufacturing time can be shortened, as well as equipment It is designed to significantly reduce manufacturing costs including cost.

In more detail, the process of producing the nonwoven fabric 100 according to the present invention may be largely comprised of a fabric part manufacturing process, a cotton felt layer manufacturing process, and a blending process. First, the fabric part manufacturing process is latex. This is a process of manufacturing the distal part 110 by using a material such as the same as the existing distal part manufacturing process, so a detailed description thereof will be omitted.

Next, in the cotton felt layer manufacturing process, three layers, that is, a first cotton felt layer 122a, a perforated film 124, and a second cotton felt layer 122b, are sequentially formed using a cotton felt and a perforated film 124. This is a process for manufacturing the cotton felt layer 122 that is laminated with two layers using an air-laid technique, namely, a first cotton felt layer 122a and a second cotton felt layer 122b. Cotton felt to form a web (web) is formed at the same time in different directions, and pre-punching (pre-punching), and then heat in a state in which the perforated film 124 is placed between the two layers. It is configured to form the cotton felt layer 122 in a one-step process by applying and thermocompression bonding using a heater roller or the like.

Next, the combining process is a process for combining the distal part 110 and the cotton felt layer 122, and as described above, the distal part 110 and the cotton felt layer are performed by a thermal compression method such as hot melt using a powder material. (122) is incorporated.

At this time, equipment for manufacturing the distal part 110 using a material such as latex, and equipment for combining the distal part 110 and the cotton felt layer 122 using a powdered material are used as a cotton felt layer. It goes without saying that the entire process for manufacturing the nonwoven fabric 100 according to the present invention by connecting to the manufacturing line 122 may be configured to be performed in one step.

Therefore, according to the multi-layer nonwoven fabric 100 for an automobile floor carpet according to the present invention as described above, it is possible to secure breathability by using a powder material as the sound absorbing and insulating part 120 of the floor carpet, and is harmful to the human body. By using cotton felt as an alternative to foam, not only can the sound absorbing and insulating properties be improved and the overall weight can be reduced at the same time, but also the eco-friendliness and recyclability of the product can be improved by using eco-friendly cotton felt. In addition, it is possible to reduce the weight of the floor carpet by more than 10% compared to the previous one, thus contributing to the improvement of fuel economy of the vehicle, and the time required for manufacturing the nonwoven fabric 100 by allowing the nonwoven fabric 100 to be manufactured by a one-step process. And, since it is possible to reduce equipment used for manufacturing the nonwoven fabric 100, it has various advantages, such as improving productivity and securing price competitiveness.

Although the above-described embodiments have been described with respect to the most preferred examples of the present invention, it is obvious to those skilled in the art that various modifications are possible without departing from the technical spirit of the present invention, and are not limited to the above embodiments.

The present invention relates to a multi-layer nonwoven fabric for automobile floor carpets, and more particularly, by using a powder material to ensure breathability, thereby improving sound absorbing and insulating properties, and due to the use of eco-friendly cotton felt The present invention relates to a multi-layer non-woven fabric for automobile floor carpets that can reduce weight and simplify the overall manufacturing process by allowing the non-woven fabric used for floor carpet molding to be manufactured by a one-step process.

100: non-woven fabric 110: fabric portion
120: sound absorbing and insulating part 122: cotton felt layer
122a: first cotton felt layer 122b: second cotton felt layer
124: perforated film 126: powder layer

Claims (7)

In the multi-layer nonwoven fabric for automobile floor carpet comprising a distal end portion and a sound absorbing and insulating portion,
The sound absorbing and insulating part cotton felt layer (cotton felt layer) made of a combination of 30 to 60% by weight of cotton fiber, 20 to 40% by weight of low-melt fiber, and 20 to 30% by weight of PET fiber,
Consisting of including a powder layer made of a powder material formed between the distal portion and the cotton felt layer,
The cotton felt layer is composed of a first and second cotton felt layer, and a perforated film interposed between the first and second cotton felt layers,
Fabric part manufacturing process,
Using an air-laid technique, cotton felt for forming the first cotton felt layer and the second cotton felt layer was simultaneously injected in different directions to form a web and pre-punching (pre-punching). After punching), a cotton felt layer manufacturing process of forming a cotton felt layer by applying heat in a state in which a perforated film is placed between the two layers and thermocompression bonding using a heater roller, and
For automobile floor carpet, characterized in that the entire process for manufacturing a multi-layer nonwoven fabric including a fabrication process of combining the fabric part and the cotton felt layer by a thermocompression method using a powder layer made of powder material is performed by a one-step process Multi-layer non-woven fabric.
delete The method of claim 1,
The material of the powder material is a multi-layer nonwoven fabric for automobile floor carpet, characterized in that any one of PET, Nylon, and PE.


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