KR102249855B1 - Lightweight composite material for automotive interior - Google Patents

Abstract

The present invention relates to a lightweight composite material for vehicle interior materials and, more particularly, to a lightweight composite material for vehicle interior materials including a base sheet layer capable of being lightweight while having high strength. To this end, the lightweight composite material for vehicle interior materials comprises: a base sheet layer including an intermediate layer on which a plurality of protrusions are formed at regular intervals and a thermoplastic sheet layer laminated on upper and lower surfaces of the intermediate layer, respectively; and a molding layer laminated on the upper and lower surfaces of the base sheet layer, respectively. According to the present invention, moldability is improved, strength and weight reduction are excellent, and price competitiveness is excellent.

Description

Lightweight composite material for vehicle interior materials {LIGHTWEIGHT COMPOSITE MATERIAL FOR AUTOMOTIVE INTERIOR}

The present invention relates to a lightweight composite material for vehicle interior materials, and more particularly, to a lightweight composite material for vehicle interior materials including a base sheet layer capable of being lightweight while having high strength.

The composite material for vehicle interior materials is a composite material in which organic/inorganic fillers are added to a thermoplastic and thermosetting resin base, a fiber-reinforced composite material made of felt and board made of chemical fibers, natural fibers, and inorganic fibers, depending on the required characteristics of the applied parts, and strength. It is applied as a sandwich structure composite material in which upper/lower reinforcing layers are stacked on the core layer holding the core layer.

The _{requirements for the application of lightweight, high-rigidity, lightweight composite materials that are lighter and have excellent physical properties to suppress CO 2} emissions are constantly increasing, and at the same time, they also require price competitiveness to secure market competitiveness in the global era. It is urgent to develop new materials with excellent price competitiveness and improvement of problems in the market.

In fact, parts such as covering shelves and luggage boards that are already applied are high-weight materials to satisfy high-level requirements, and to improve the above problems, eco-friendly and lightweight materials have been developed. Various types of materials are being developed and applied, but it is difficult to develop materials that satisfy all of eco-friendly, lightweight, excellent physical properties and price competitiveness.

For example, GMT (Glass mat Thermoplastics) and GM-PUR (Glass-mat polyurethane composite) have high stiffness, but high cost, and natural fiber reinforced boards and woodstock have low cost and excellent physical properties. However, high weight is applied to satisfy high requirements. In addition, the application is limited due to VOC and odor problems.

In order to solve the existing problems, a hollow bubble sheet having excellent strength and light weight is applied to trunk coverings and boards as an eco-friendly material without problems of VOC and odor, due to the characteristics of being vulnerable to residual stress and heat in the manufacturing process. , Application is limited to products that can be formed only by the flat-type cold forming method.

Therefore, it is necessary to develop a lightweight composite material for vehicle interior materials that are light and excellent in physical properties.

Korean Patent Registration Publication No. 10-1856521 (Registration Date: 2018.05.03)

The present invention was created to improve the problems of conventional vehicle interior materials as described above, and has excellent weight reduction effect compared to existing applied materials, excellent strength, odor, VOC, etc., and lightweight composite for vehicle interior materials with excellent price competitiveness. Its purpose is to provide the material.

In order to achieve the above object, the lightweight composite material for vehicle interior according to the present invention includes an intermediate layer in which a plurality of protrusions are formed at regular intervals, and a base sheet layer including a thermoplastic sheet layer laminated on the upper and lower surfaces of the intermediate layer, respectively. ;And

It characterized in that it comprises a; molding layer laminated on each of the upper and lower surfaces of the base sheet layer.

The intermediate layer may be formed of the same thermoplastic resin as the thermoplastic sheet layer, and the base sheet layer may be integrally formed by extruding the intermediate layer and the thermoplastic sheet layer, respectively, and passing through a roll mold.

The thermoplastic resin may be polypropylene (PP), polyethylene (PE), polyamide (PA), or polyester (PET).

In addition, the base sheet layer may further include any one or more additives from the group consisting of glass fiber, natural fiber, glass wool, whisker, talc, clay, and calcium carbonate.

The molding layers formed on the upper and lower surfaces of the base sheet layer may be in the form of a felt-treated board formed by needle punching glass fibers, glass wool, whiskers, or glass bubbles with thermoplastic fibers.

Meanwhile, in order to mold the base sheet layer and the molding layer into a laminated component, the base sheet layer is trimmed using a water-jet without a preheating process, or preheated to a certain temperature and then pressed and trimmed. It may be molded.

In addition, the lightweight composite material for vehicle interior material according to the present invention can be cold-pressed simultaneously by inserting a lofted molding layer by preheating each of the upper and lower surfaces of the primary molded base sheet layer by an indirect heating method. have.

On the other hand, the weight ratio of the base sheet layer and the molding layer may be 1:0.1 to 1:1.

The lightweight composite material for vehicle interior materials according to the present invention has excellent strength and weight reduction performance, and has excellent effects on improving moldability, removing VOC, and odors.

In addition, since the existing manufacturing process can be used, the investment cost is low, and the cost of raw materials is low, so there is an effect of excellent cost competitiveness.

1 is a schematic cross-sectional view of an intermediate layer of a base sheet layer according to an embodiment of the present invention.
Figure 2 is a cross-sectional view showing a schematic laminated structure of a lightweight composite material for a vehicle interior according to an embodiment of the present invention,
3 is a process diagram showing a process of forming a component of a lightweight composite material for a vehicle interior according to an embodiment of the present invention.
4 is a schematic diagram showing a state in which a preheated molding layer is lofted when molding a component of a lightweight composite material for a vehicle interior according to an embodiment of the present invention.

In order to help understand the features of the present invention, the following will be described in more detail with respect to the lightweight composite material for vehicle interior material of the present invention.

In adding reference numerals to the components of the accompanying drawings to aid in understanding the embodiments described below, it should be noted that the same components are to have the same reference numerals as much as possible, even if they are indicated on different drawings. . In addition, in describing the present invention, when it is determined that a detailed description of a related known configuration or function may obscure the subject matter of the present invention, a detailed description thereof will be omitted.

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

1 is a schematic cross-sectional view of an intermediate layer 110 of a base sheet layer 100 according to an embodiment of the present invention. Referring to Figure 1, the lightweight composite material 10 for vehicle interiors according to an embodiment of the present invention, a plurality of protrusions 111 to be applied to a covering shelf and luggage board that require a high level of strength is constant. It consists of a structure formed at intervals. Since the plurality of protrusions 111 are formed, a certain weight reduction effect can be obtained. At this time, it is preferable that the interval between the protrusions 111 is formed within 5mm or more and 20mm or less. When the spacing of the protrusions 111 is 5 mm or less, the weight reduction effect may be significantly lowered because many materials are used in manufacturing the base sheet layer 100 due to an increase in the surface density, and when the spacing of the protrusions 111 is 20 mm or more, the protrusions ( 111) There may be an increase in air layer, which may lead to a turn-off part and a decrease in strength during molding.

In addition, a thermoplastic sheet layer 120 is laminated on the upper and lower surfaces of the intermediate layer 110, respectively.

Since only the intermediate layer 110 having a large number of protrusions formed thereon greatly deteriorates the moldability, it is possible to increase the moldability by further laminating the thermoplastic sheet layer 120 to improve surface smoothness.

For more efficient production of the base sheet layer 100, by simultaneously extruding the intermediate layer 110 and the thermoplastic sheet layer 120, the base sheet layer 100 having a sandwich structure can be integrally formed, and the intermediate layer ( 110) can maintain high strength due to the protrusion structure. For such integral molding, the same thermoplastic resin may be extruded and passed through a roll mold, respectively, and at this time, it is preferable that it is provided in an amount of 2,000g/m2 or more and less than 3,200g/m2.

In this case, the intermediate layer 110 and the thermoplastic sheet layer 120 may have different mixing ratios of the thermoplastic resin and the additive, and the intermediate layer 110 contains the thermoplastic resin and the additive in a weight% ratio of 97:3 to 80:20. The thermoplastic sheet layer 120 may be used by mixing a thermoplastic resin and an additive in a ratio of 90:10 to 60:40% by weight.

At this time, the thermoplastic resin included in the base sheet layer 100 may be polypropylene (PP), polyethylene (PE), polyamide (PA6, PA66), polyester (PET), or the like.

In addition, as an additive included in the base sheet layer 100, glass fiber, natural fiber, glass wool, whisker, talc, clay, calcium carbonate, etc. may be used, and at least one of them and the thermoplastic resin may be mixed and used. .

2 is a cross-sectional view showing a schematic laminated structure of a lightweight composite material 10 for a vehicle interior according to an embodiment of the present invention. Referring to FIG. 2, in order to maintain the shape of the base sheet layer 100 and improve part moldability, it is characterized in that it comprises a molding layer 200 formed on the upper and lower surfaces of the base sheet layer 100. .

At this time, the molding layer 200 laminated on the upper and lower surfaces of the base sheet layer 100 is made by needle punching at least one of the group consisting of glass fibers, glass wool, whiskers, and glass bubbles with thermoplastic fibers. After that, it may be formed in the form of a board.

At this time, the molding layer 200 may be used by mixing at least one of the group consisting of glass fibers, glass wool, whiskers, and glass bubbles and thermoplastic fibers in a weight% ratio of 20:80 to 60:40, The unit weight of the shaping layer 200 is preferably 200g/m2 to 1,000g/m2. At this time, if the unit weight of the shaping layer 200 is less than 200 g/m2, the shaping layer maintains shape and the effect of improving part moldability is significantly reduced, and if it exceeds 1,000 g/m2, due to the high weight, the deep- Draw and bend design values and tolerances may occur.

On the other hand, the molding layer 200 manufactured to improve formability is more preferably provided with a unit weight of 400g/m2 or more and less than 700g/m2 in consideration of the effect of lofting after preheating in the part molding process. It is effective.

The shaping layer 200 according to the present invention can be manufactured by an opening process of preferably mixing fiber materials, opening each fiber with a spike roll, and carding. . At this time, each fiber is mixed and arranged using a carding machine to form a web, stacked with a desired weight and width, and then cut into a desired length and width after needle punching. By (cutting) the molding layer in the form of a felt can be formed.

On the other hand, it is preferable that the weight% ratio of the base sheet layer 100 and the molding layer 200 is formed in a ratio of 1:0.1 to 1:1. When the weight ratio of the base sheet layer 100 and the shaping layer 200 is less than 1:0.1, the effect of improving moldability is insufficient, resulting in deep-draw and edge molding defects, and the base sheet layer 100 and When the weight ratio of the shaping layer 200 exceeds 1:1, the weight reduction effect and price competitiveness decrease.

3 is a process diagram showing a part molding process of the lightweight composite material 10 for vehicle interior according to an embodiment of the present invention. This is an example of molding the composite material 10 into a component (luggage board) by simultaneously molding the molding layer 200 and the base sheet layer 100. In order to form a component in which the base sheet layer 100 and the molding layer 200 are laminated, the base sheet layer 100 is trimmed using a water-jet without a preheating process, or preheated to a low temperature and then compressed. It can be manufactured as a semi-finished product first molded by a trimming process, and the shaping layer 200 is preheated by an indirect heating method and lofted, and the base sheet layer 100 in the form of a semi-finished product It can be inserted into the upper and lower surfaces and formed by cold forming at the same time.

Meanwhile, in order to simultaneously mold the first trimmed base sheet layer 100 and the shaping layer 200, the shaping layer 200 is preheated by an indirect heating method and formed on the top and bottom surfaces of the base sheet layer 100 At this time, the forming layer 200 formed on the upper and lower surfaces of the base sheet layer 100 is, first, the forming layer 200 to be seated on the lower surface, heated in a conveyor belt oven of an indirect heating method, and a cold forming mold ( 300), the first trimmed base sheet layer 100 is inserted, and then the top molding layer 200, which is sequentially heated in an indirect heating type conveyor belt oven, etc., is inserted into the base sheet layer 100 ) Simultaneous molding can be performed by placing it on the upper surface.

After indirect oven heating, the shaping layer 200 is lofted up to 2 to 10 times the production thickness, which can be adjusted according to the content of thermoplastic fibers and additives, and can also be adjusted according to the heating temperature and time. have. The lofting of the molding layer 200 is a phenomenon that occurs due to the oriented property of glass fibers, glass wool, etc., which are additives, and this is formed to the final thickness by adjusting the clearance of the molding mold 300 according to the detailed part specifications. Can be. At this time, lofting is performed at an optimal 4-7 magnification at a heating temperature of 180° or more and less than 250° and a heating time of 60 seconds or more and less than 90 seconds, and in order to increase the magnification, the heating temperature and heating time are adjusted. Although it can be formed by lengthening, if it is formed at too high a magnification, a problem of lowering the strength may occur.

Therefore, due to the lofting of the preheated molding layer 200, deep-draw molding of parts that the flat-type base sheet layer 100 cannot implement, and irregularities or criticism of the base sheet layer 100 in the edge area The shape of the part can be molded by wrapping the burnt surface area with the shaping layer 200.

As shown in FIG. 4, when forming the upper and lower surfaces of the shaping layer 200 seated on the base sheet layer 100, the shaping layer 200 on the lower surface is formed in a flat shape, and the shaping layer 200 on the upper surface has a sidewall portion. By designing the mold 300 in a structure that is wrapped and molded, the upper and lower surfaces of the molding layer 200 may be matched and formed at the lower end.

Example.

Hereinafter, a composite material according to an embodiment of the present invention will be described with a conventional material for vehicle interior materials. The interior materials prepared in Examples 1 to 6 were manufactured according to the composition and weight of the base sheet layer and the forming layer shown in Table 1, and formed by cold forming through a forming process as shown in FIG. 3. In this example, the base sheet layer was ^{manufactured with a total weight of 2,000-2,400 g/m 2} , of which the intermediate layer was manufactured so that the protrusion spacing was 10 mm, and the intermediate layer and the thermoplastic sheet layer were manufactured in a 50:50 weight ratio. At this time, the intermediate layer is prepared by mixing glass fiber and polypropylene resin in a weight% of 5:95, and then the thermoplastic sheet layer prepared by mixing talc and polypropylene resin in a weight% of 20:80 is simultaneously extruded up and down. Thus, it was manufactured in a three-layer structure.

On the other hand, the molding layer was mixed with glass fiber and polypropylene fiber in a weight% of 60:40 to 50:50 and manufactured by the carding process to 400 to 700 g/m2, and then heat-compressed to 1 mm to produce a boarded sheet. The parts were molded by heating and cold forming, which is the forming process shown in 3. The configuration of Examples 1 to 6 is shown in Table 1 below.

division Base sheet layer weight
(g/m ² ) Molding layer weight
(g/m ² ) Forming layer composition
(Additive: PP fiber) Example 1 2,000 400 50:50 Example 2 2,000 500 50:50 Example 3 2,000 700 50:50 Example 4 2,400 400 50:50 Example 5 2,400 400 60:40 Example 6 2,400 500 50:50

In addition, the following Comparative Example 1 is GMT (Glass mat thermoplastic + honeycomb + Glass mat thermoplastic), a material that is typically applied to the luggage board, the configuration is shown in Table 2 below.

division Applied material composition Weight (g/m ² ) Comparative Example 1 Glass mat thermoplastic + Honeycomb+Glass mat thermoplastic 3,500

The interior materials produced in the weight ratios disclosed in Tables 1 and 2 were prepared as specimens having a size of 150 x 50 mm and a thickness of 5 mm, and then the flexural load was measured, and the formability of the deep draw area was measured. Here, in the flexural load test, the test speed was 5 mm/min, and the formability was measured through an R gauge. The cost ratio was compared relative to the percentage by weight.

Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Comparative Example 1 Gross weight
[g/m ² ] 2,800 3,000 3,400 3,200 3,200 3,400 3,500 Bending load
[N] 350N 365N 396N 370N 380N 400N 320N Formability
[R] 3.0 3.0 3.0 3.0 2.5 2.5 2.5 Weight reduction rate [%] 28 22 12 17 17 12 8 Cost ratio
[Relative to] 50 55 60 57 57 60 95

As disclosed in Table 3 above, it can be seen that the vehicle interior material according to the present invention achieves weight reduction compared to the conventional interior material according to Comparative Example 1 and has excellent price competitiveness. In addition, it can be seen that the rigidity can be maintained compared to the existing material, and the formability is at the same level.

Although the present invention has been described in detail through specific examples, this is for explaining the present invention in detail, and the present invention is not limited thereto, and the present invention is not limited to those of ordinary skill in the art within the spirit of the present invention. It is clear that the transformation or improvement is possible by the ruler.

All simple modifications to changes of the present invention belong to the scope of the present invention, and the specific scope of protection of the present invention will be made clear by the appended claims.

10: Lightweight composite material for vehicle interior materials
100: base sheet layer
110: middle layer
120: thermoplastic sheet layer
200: forming layer
300: molding mold

Claims (10)

A base sheet layer including an intermediate layer in which a plurality of protrusions are formed at regular intervals and a thermoplastic sheet layer laminated on the upper and lower surfaces of the intermediate layer, respectively; And In the method of manufacturing a lightweight composite material for a vehicle interior comprising a; and molding layers laminated respectively on the upper and lower surfaces of the base sheet layer,
Extruding the intermediate layer and the thermoplastic sheet layer, respectively, passing through a roll mold to integrally form the base sheet layer;
Preheating the base sheet layer to a predetermined temperature or lower, followed by pressing and trimming for primary molding; And
Each of the upper and lower molding layers preheated by indirect heating and lofted is inserted into the upper and lower surfaces of the primary formed base sheet layer and cold pressed at the same time,
The lower surface forming layer is seated on a cold forming mold, and then the primary formed base sheet layer is inserted onto the lower surface forming layer, and the upper surface forming layer is seated on the upper surface of the base sheet layer, followed by simultaneous cold pressing,
Forming the bottom shaping layer to be flat, the top shaping layer to wrap around the sidewall of the base sheet layer, and forming the top shaping layer and the bottom shaping layer so that their ends match each other;
A method of manufacturing a lightweight composite material for vehicle interiors comprising a. The method of claim 1,
The intermediate layer is a method of manufacturing a lightweight composite material for vehicle interiors, characterized in that made of the same thermoplastic resin as the thermoplastic sheet layer. delete The method of claim 2,
The method of manufacturing a lightweight composite material for vehicle interiors, wherein the thermoplastic resin is polypropylene (PP), polyethylene (PE), polyamide (PA), or polyester (PET). The method of claim 1,
The base sheet layer is a method of manufacturing a lightweight composite material for vehicle interiors, characterized in that it contains any one or more additives from the group consisting of glass fiber, natural fiber, glass wool, whisker, talc, clay, and calcium carbonate. The method of claim 1,
The molding layer is a method of manufacturing a lightweight composite material for vehicle interiors, characterized in that the molding layer is in the form of a felt-treated board by needle punching at least one of the group consisting of glass fiber, glass wool, whisker and glass bubble with thermoplastic fiber. delete delete The method of claim 1,
The weight ratio of the base sheet layer and the molding layer is 1:0.1 to 1:1, the method of manufacturing a lightweight composite material for vehicle interior, characterized in that. The method of claim 1,
A method of manufacturing a lightweight composite material for vehicle interiors, characterized in that the unit weight of the molding layer is 200g/m2 to 1,000g/m2.

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