KR102227943B1 - Lightweight suit insulator having high heat resistant and stiffness and manufacturing method therefor - Google Patents

Abstract

The present invention is a high heat-resistant and rigid lightweight fibrous insulation material, polyamide fiber yarn (PA) and glass fiber yarn (GF) are cut and mixed, but the polyamide fiber yarn and glass fiber yarn are 65 to 40% by weight vs. 35 to 60 High heat-resistant and stiff lightweight fiber-type insulation material characterized by forming a high-heat-resistant lightweight fiber felt member by combining the web at a blending ratio of weight percent and binding the web to enable thermal molding. Vibration and 150℃ generated in the engine room of automobiles It can withstand a high heat environment continuously, can secure dimensional stability (no shape unfolding or shape distortion), has excellent rigidity, and has a light fiber felt-type fiber-type insulation material, which is relative to existing synthetic resin injection products. As it is light (20~30%), it is possible to improve fuel efficiency or reduce weight. When applied to the inside of the engine cover of a car, it helps to promote collision safety with pedestrians, and can also be used as an engine room bulkhead.

Description

High heat resistance and rigidity, lightweight fibrous insulation and its manufacturing method {LIGHTWEIGHT SUIT INSULATOR HAVING HIGH HEAT RESISTANT AND STIFFNESS AND MANUFACTURING METHOD THEREFOR}

The present invention relates to a fibrous insulating material, in particular, can withstand vibration and high heat generated in an engine room of an automobile, can be thermoformed, has excellent stiffness, and has light properties, and a high heat-resistant and rigid lightweight fibrous insulating material and a manufacturing method thereof It is about.

In the automotive field these days, interest in vehicle collision laws and regulations is on the rise and regulations are gradually strengthening. Therefore, it is essential to develop new products through the use of eco-friendly materials that can be recycled and increased fuel economy due to weight reduction of products.

Engine covers for automobiles are generally made of heat-resistant plastic, and a sound absorbing and insulating material that can reduce noise and vibration must be installed to prevent noise and vibration from being generated by vibration during engine operation.

Existing products of automobile engine covers are reinforced plastics, which are generally molded products, which are heavy and do not correspond to the recent situation where improvement of fuel economy, weight reduction, safety of pedestrian collisions, and protection of the inside of the engine are important.

Therefore, not only the product is lightened, but also it can withstand high temperature heat of 150℃, such as in an automobile engine, without deformation, and minimizes the heat energy generated from the engine is discarded into the atmosphere after the engine start is stopped, and the coolant or oil of the engine It is possible to improve fuel economy by allowing it to be stored on the back, and it is possible to prevent noise and vibration caused by vibration when the engine is operated, and related to the engine cover or engine room that can buffer as much as possible to prevent pedestrians from getting injured even in the event of a vehicle collision. If a product is developed and a fibrous insulation material is implemented for it, it will get great response from people involved in the technology.

Registered Patent No. 10-1304879 "Method of manufacturing floor undercover composite material for vehicles"

Accordingly, an object of the present invention is to provide a high heat-resistant and rigid lightweight fiber insulation material that can withstand vibration and high heat generated in the engine room of automobiles, has dimensional stability, can be thermoformed, has excellent rigidity, and has light properties, and a manufacturing method thereof. Is in.

Another object of the present invention is to provide a high heat-resistant and rigid lightweight fiber insulation material and a method of manufacturing the same for the sound absorbing and insulating material inside the engine cover or for the partition wall in the engine room.

The present invention according to the above object is to mix the polyamide fiber yarn (PA) and glass fiber yarn (GF) after cutting, but the blending ratio of the polyamide fiber yarn and the glass fiber yarn is 65 to 40% by weight versus 35 to 60% by weight It is a high heat-resistant and stiff, lightweight fiber-type insulation material, characterized by forming a high-heat-resistant lightweight fiber felt member by web binding after web lamination and heat-forming.

In addition, as another aspect of the present invention, in the method of manufacturing a high heat-resistant and rigid lightweight fiber-type insulation material, polyamide fiber yarn (PA) and glass fiber yarn (GF) are cut and then mixed, but polyamide fiber yarn: glass fiber yarn = 65-40% by weight: The process of providing a composite fiber mixture by mixing at a blending ratio of 35-60% by weight, the process of laminating the composite fiber mixture into a plurality of webs on a conveying conveyor, and the process of stacking the laminated webs. It is characterized by the process of obtaining high heat-resistant lightweight fiber felt that can be thermally formed in the future by binding the web by needle punching.

The present invention can withstand vibrations generated in the engine room of automobiles and a high heat environment of about 150°C continuously, and dimensional stability can be secured (no shape expansion or shape distortion) while thermoforming is possible, and excellent rigidity is achieved. The weight is relatively light (20~30%) compared to the synthetic resin injection material by implementing a light fiber felt type fiber-type insulation material, so it is possible to improve fuel efficiency or reduce weight, and when applied to the inside of the engine cover of a car, collision with pedestrians is safe. It helps in design and can also be used as an engine room bulkhead.

1 is a schematic procedure for manufacturing a high heat-resistant and rigid lightweight fiber-type insulation according to an embodiment of the present invention,
2 is an exemplary view of the process photo of FIG. 1,
3 is an exemplary photograph of a high heat-resistant and rigid lightweight fibrous insulation material of the present invention,
Figure 4 is a photographic view showing the use of the high heat resistance and rigid lightweight fiber-type insulation of the present invention is used.

Hereinafter, exemplary 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 fibrous insulation material according to an embodiment of the present invention, FIG. 2 is an exemplary process photograph of FIG. 1, and FIG. 3 is a high heat-resistant and rigid lightweight fiber-type of the present invention. This is an exemplary picture of an insulation material. And, Figure 4 is a photographic view showing the use of the high heat-resistant and rigid lightweight fiber-type insulation of the present invention is used.

The highly heat-resistant and rigid lightweight fiber-type insulation material of the present invention can be used as a cylinder block cover as shown in FIG. 4 covered on the upper end of a cylinder head of an automobile engine, or applied to a sound absorbing and insulating material inside the engine cover or a partition wall of an engine room.

As an example of the development of materials including engine covers these days, there is an attempt to use fiber composite materials with light weight and shock-absorbing properties, mainly by applying polypropylene or polyester-based fiber composite materials. However, attempts to develop such fiber composite materials are difficult to commercialize because they cannot withstand the high heat (150℃ or higher) generated in the engine room, or cause a lack of dimensional stability such as shape unfolding or shape distortion of the engine cover. .

In addition, a composite material reinforced with aramid fiber or the like using plastic as a matrix is used, but since aramid fiber is very expensive, there is a lack of economic feasibility for product production.

Accordingly, in the present invention, it is possible to continuously withstand vibrations generated in the engine room of a vehicle and a high heat environment of about 150°C or higher, and also secure dimensional stability (no shape expansion or shape distortion), while thermoforming is possible. , It has the advantage of excellent stiffness and implements a fiber-type insulation material with a light fiber felt type. In addition, it implements a high heat-resistant and rigid lightweight fiber-type insulation material that is much more economical than expensive aramid fibers and is compatible with product applications.

The high heat resistance and stiffness lightweight fibrous insulation material of the present invention is made of polyamide fiber (PA) (2) and glass fiber yarn (GF: Glass Fiber yarn) (4). It is provided with a heat-resistant lightweight fiber felt member (10).

High heat resistance and rigidity of the present invention, as shown in Figure 1 (a), polyamide fiber yarn (PA: Polyamide) (2) and glass fiber yarn (GF: Glass Fiber yarn) (4) first After cutting into a length of approximately 50 mm, the mixture is evenly mixed to obtain a composite fiber mixture to be a high heat-resistant lightweight fiber felt member (10 in FIG. 1).

In the present invention, in constructing the high heat-resistant lightweight fiber felt member 10, the glass fiber yarn 4 serving as a refractory material and a sound-absorbing material is evenly selected for a polyamide-based material having elasticity, high heat resistance, and light weight, that is, polyamide fiber yarn. It is made into felt by mixing and becomes a composite fiber yarn, so it is lightweight and has good shock absorption compared to the injection resin.

In particular, the high heat-resistant lightweight fiber felt member 10 of the present invention is a fibrous composite material, polyamide fiber yarn 2 having good heat resistance and stiffness and crimp property, and good heat resistance, sound absorbing and insulating properties, and thermal insulation properties. Since glass fiber yarn (4), which is an excellent inorganic fiber material, is mixed and used, dimensional stability is ensured when compressed during thermoforming, and high heat resistance in environments around 150°C through the range of types and blending ratios of the composite fiber yarn as well as the present invention It is also possible to implement the appropriate strength required by the fibrous insulation material of.

In the present invention, the blending ratio of the composite fiber mixture is composed of polyamide fiber yarn (2): glass fiber yarn (4) = 65 to 40% by weight: 35 to 60% by weight.

The selected raw material mixture composition and fiber mixture mixing ratio of these composite fiber mixtures are the high heat resistance and stiffness to be realized in the present invention, ensuring product moldability, dimensional stability, light weight, high heat resistance, and stiffness. (Tensile strength and bone curve strength) It is the critical significance of the selection configuration and range because it is optimal for securing. In particular, in the present invention, the blending ratio of the components of the polyamide fiber yarn (2) is important to maintain the product molding shape without deformation and to secure rigidity (tensile strength and flexural strength), and the molded product is agglomerated by fusion. It is meaningful to keep the fibrous form without damaging the fibrous form.

In the material composition of the composite fiber mixture, the polyamide fiber yarn (2) is light (specific gravity: 1.14), has high strength, has excellent abrasion resistance, and has good elasticity and bending resistance. In addition, since the polyamide fiber yarn (2) has a melting point of about 220 to 250°C, it has excellent high heat resistance, that is, thermal stability, has excellent dimensional stability, and is light and soft, and exhibits crimp properties due to elasticity and bending resistance. It has vibration absorption and shock absorption. Furthermore, the polaramide fiber yarn 2 of the present invention also serves as a binder for bonding the glass fiber yarn 4 while maintaining the fiber shape during thermoforming.

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 mixed with the polyamide fiber yarn 2 and used in the present invention, can be mass-produced compared to other inorganic fibers such as basalt fiber or silica fiber, and has excellent quality uniformity and usability. Since it has an advantage, it is suitable as one material to be used in the present invention. The glass fiber yarn of the present invention is preferable to select a glass fiber yarn because the thinner the glass fiber diameter, the better the handling properties and acoustic properties.

The glass fiber yarn 4 of the present invention has a higher specific gravity (specific gravity 2.54 g/cm2) than the polyamide fiber yarn 2, so some care should be taken when mixing properly, but it improves thermoformability and improves the polyamide fiber. Compared to yarn (2), it is a raw material that is relatively inexpensive and is advantageous in maintaining a sturdy frame and also improving sound absorption and insulation performance. However, in the case of a glass fiber yarn material, the higher the content of the glass fiber, the more severe the exposure of the glass fiber is. Therefore, it may cause difficulties in manufacturing and use due to itching during handling, so care should be taken in handling it.

So, 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 that becomes the high heat-resistant and rigid lightweight fiber-type insulation material according to the present invention is 65 to 40% by weight vs. 35 It is ~60% by weight, preferably, it is advantageous that the proportion of the polyamide fiber yarn (2) is the same (50:50% by weight) or relatively higher than that of the glass fiber yarn (4).

As raw materials for the composite fiber mixture according to the present invention, both of the polyamide fiber yarn 2 and the glass fiber yarn 4 have a fine thickness of 4 to 20 denier, and are suitable for sound absorption and weight reduction.

In the present invention, the polyamide fiber yarn 2 and the glass fiber yarn 4 as raw materials for the composite fiber mixture are cut into units of several millimeters and then uniformly mixed to obtain a composite fiber mixture.

In mixing so as to be a composite fiber mixture in the present invention, thermoplastic fibers with low specific gravity [in the case of polyamide fiber yarn 2, the specific gravity is 1.14 g/㎠] and glass fiber yarn 4 with a high specific gravity (specific gravity 2.54 g /㎠) should be effectively dispersed/blended for fiber yarns with different specific gravity so that they are evenly mixed. To this end, in the present invention, the homogeneity of fiber blending is improved by performing a carding process using a plurality of hoppers and a plurality of cards.

In the present invention, the composite fiber mixture provided in this way is introduced as a raw material to form a web as shown in Fig. 2 (a) photographic diagram on a transfer conveyor, but a plurality of webs are laminated and formed, and then Fig. 1 (b) And a high heat-resistant lightweight fiber felt member 10 capable of subsequent product thermoforming by performing needle punching using a needle-type pin 8 on a plurality of webs stacked as shown in (b) of FIG. 2 Get

In performing the needle punching process for web binding, the inventors of the present invention pre-punching and hook-punching the multi-layered portion of the web in which the glass fiber yarn and the polyamide fiber yarn, which is a thermoplastic fiber yarn, are mixed. The web was bound by two types of punching method. When hook punching was applied, there was a drawback that yarns such as glass fiber yarns came out to the outside.

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

FIG. 3 shows a photograph of a high heat-resistant lightweight fiber felt member 10 formed by mixing a polyamide fiber yarn 2 and a glass fiber yarn 4 to form a web lamination.

The high heat-resistant lightweight fiber felt member 10 of the present invention is reinforced in strength by inputting the glass fiber yarn 4 and the polyamide fiber yarn 2, and by defining the area density range, it is possible to obtain the appropriate strength desired by the manufacturer. . The surface density (weight) of the high heat-resistant lightweight fiber felt member 10 in the present invention has 700 to 1200 g/m 2.

The inventor of the present invention conducted two types of heat resistance tests for the high heat resistant lightweight fiber felt member 10 as shown in the photograph of FIG. 3 as the high heat resistance and rigid fibrous insulation material of the present invention.

The first was a heat aging test under the condition of 150℃/200 hours required by the automobile industry, and the second was a heat resistance test under the condition of 180℃/30 hours as a more severe high temperature environment than the first 150℃/200 hours condition. Was performed.

As a result, in the two types of heat resistance tests, the high heat-resistant lightweight fiber felt member 10 of the present invention satisfies thermal aging properties and heat resistance without deformation.

In addition, a heat shrinkage test was performed under the condition of 150°C/200 hours, and it was confirmed that dimensional stability was also guaranteed as both width and length satisfies the allowable range within 0.5% required by the automobile industry.

In the present invention, a high heat-resistant and stiff lightweight fiber-type insulating material made of a high-heat-resistant lightweight fiber felt member 10 is oven-heated to form a molding base material in the shape of a molding frame, and the atmosphere temperature in the molding frame during oven thermoforming is 220 to 250°C. It is inside and outside.

The thermoforming of the high heat-resistant and rigid lightweight fibrous insulation material of the present invention must be thermoformed under pressure in an oven molding mold to maintain the fiber yarn shape, unlike the conventional injection molding after melting resin.

After thermoforming, a fiber skin material or the like may be attached to the surface of the molding base material taken out of the molding mold through a polyurethane binder.

The engine cover 20 including the high heat-resistant and rigid lightweight fiber-type insulation material of the present invention as described above has an effect of reducing weight by 20 to 30% compared to conventional plastic injection products, and dimensional stability and molding despite the use of a composite fiber material. It has high heat resistance that can be used for bulkheads or engine cover sound absorbing and insulating materials in the engine room, as well as the required rigidity (tensile strength, flexural strength, etc.) related to the engine cover or engine room. There is an effect of preventing or reducing injuries in the event of a collision.

An example of a test result for stiffness (tensile strength, flexural strength) when the high heat-resistant and rigid lightweight fiber-type insulation material of the present invention is composed of a high-heat-resistant lightweight fiber felt member (polyamide fiber yarn and glass fiber yarn) (unit weight 1000~ 1100 g/m2), the tensile strength is 300 to 900 N in the longitudinal direction and 100 to 500 N in the width direction, and the flexural strength is 3 to 10 N in the longitudinal direction and 7 to 15 N in the width direction.

In the above description of the present invention, specific embodiments have been described, but various modifications may 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 determined by the claims and equivalents to the claims.

(2)-- Polyamide fiber yarn (4)-- Glass fiber yarn
(8)-- Needle type pin (10)-- High heat-resistant lightweight fiber felt member

Claims (2)

Polyamide fiber yarn (PA) and glass fiber yarn (GF) having a thickness of 4 to 20 denier are cut and mixed, but the polyamide fiber yarn and glass fiber yarn are mixed at a blending ratio of 65 to 40% by weight versus 35 to 60% by weight. After the web is laminated, it is possible to form a high heat-resistant lightweight fiber felt member with an area density of 700 to 1200 g/m2 by web binding. Among the stiffnesses of tensile strength and flexural strength, the tensile strength is 300 to 900 N in the length direction and 100 to in the width direction. 500N, high heat resistance and rigidity, lightweight fiber-type insulation, characterized in that the flexural strength is 3-10N in the longitudinal direction and 7-15N in the width direction among the stiffness.
In the method of manufacturing a high heat-resistant and rigid lightweight fibrous insulation material,
Polyamide fiber yarn (PA) and glass fiber yarn (GF) having a thickness of 4 to 20 denier are cut and mixed, but polyamide fiber yarn: glass fiber yarn = 65 to 40% by weight: mixed at a blending ratio of 35 to 60% by weight And the process of providing a composite fiber mixture,
The process of laminating the composite fiber mixture into a plurality of webs on a transfer conveyor,
A high heat-resistant lightweight fiber felt with an area density of 700 to 1200 g/m2, which can be thermally formed in the future, is obtained by binding a number of stacked webs to the web by needle punching. A method of manufacturing a high heat-resistant and rigid lightweight fiber-type insulation material, characterized in that it consists of a process of obtaining a high heat-resistant lightweight fiber felt with a width direction of 100 to 500 N and a flexural strength of 3 to 10 N in the longitudinal direction and 7 to 15 N in the width direction. .

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