KR102410154B1 - Mqanufacturing method of insert injection molding vehicle wheel guard using composite material - Google Patents

Abstract

The present invention relates to a method for manufacturing a wheel guard for a lightweight and high-strength 1-piece type insert injection molding vehicle, and a sound-absorbing composite fiber nonwoven fabric obtained by laminating a skin layer and a back layer made of double fibers of PET fiber, LM fiber and hollow fiber as an insert member Thus, while injecting the PP resin by insert injection molding, the 1-piece type insert injection molding vehicle wheel guard is manufactured by integrating it with the PP resin so that a part of the composite fiber nonwoven fabric is exposed to the outer surface.
The insert injection molding vehicle wheel guard of the present invention is lightweight and high-strength. In particular, it is molded in a 1-piece type, so it has excellent durability, and the effect of absorbing sand noise caused by the collision of zeolite on the road surface is improved. have.

Description

Method of manufacturing insert injection molding vehicle wheel guard using composite material and wheel guard for vehicle manufactured therefrom

The present invention relates to a method of manufacturing a wheel guard for an insert injection molding vehicle using a composite material, and more particularly, to a method for manufacturing a wheel guard for an insert injection molding vehicle using a light weight and high strength composite material, and a wheel guard for a vehicle manufactured therefrom.

In general, a vehicle wheel guard (wheel guard) prevents foreign substances such as soil and rainwater on the tire from entering the body panel or the lower part of the vehicle body while the vehicle is driving, thereby preventing damage or corrosion of the vehicle body and preventing air from around the vehicle body and tires. is installed on the vehicle body around the tire to prevent a significant amount of running noise caused by the turbulence and turbulence of air generated around the tire.

Since such vehicle wheel guards are usually made of synthetic resin panels, the scattering of pollutants can be effectively prevented, but they are not suitable for reducing the weight of the vehicle and the effect of reducing the noise transmitted into the vehicle, especially the sand noise, is insufficient. In order to reduce the weight, development is underway in the direction of weight reduction and durability improvement using an injection method using a nonwoven fabric material and polypropylene resin.

As a manufacturing method related to vehicle wheel guards for weight reduction and noise reduction, they are manufactured by injection molding with synthetic resin such as polypropylene, and then attaching a separate sound absorbing material to the back of the whiguard. For example, the step of forming a felt layer by carding the fibers in Patent Document 1 to form a fiber sheet or web, then bonding the fibers; Heating the surface of the felt layer to melt the fiber ol located on the surface of the felt layer; Forming a felt board by using a pressing roller, pressing the felt layer in which the fiber ol on the surface is melted; and compression-molding the felt board using a mold, wherein heating the surface of the felt layer removes the fibers present on the surface of the felt layer, and at the same time, the fibers present in the felt layer are removed from the felt layer. Disclosed is a method for manufacturing a wheel guard for a vehicle in which the surface of the felt layer is melted or adhered to form a surface heat treatment layer on the surface of the felt layer to prevent migration to the surface, and in Patent Document 2, polypropylene and glass fiber are mixed a core layer formed by being; a film layer integrally provided on the upper surface of the core layer and made of polyurethane; Includes; a scrim layer integrally provided on the lower surface of the core layer, wherein the core layer is a mixture of polypropylene and glass fiber, and the scrim layer is integrated by combining microfibers of polypropylene and PET by a spunbond type method, The thickness of the wheel guard discloses a wheel guard for a vehicle, characterized in that 3 ~ 4.5mm.

In addition, the step of injecting the adhesive layer to Patent Document 3; bonding the nonwoven-based skin layer and the thermoplastic resin-based sound-absorbing layer to each other around the adhesive layer; and molding the skin layer and the sound-absorbing layer into a preset wheel guard shape in a state in which the skin layer and the sound-absorbing layer are joined by the adhesive layer.

The inventor of the present invention completed the present invention by confirming the effect of reducing the weight, moldability and durability of a wheel guard molded into a sound absorbing and insulating integrated 1-piece type by injection molding of a synthetic resin and a nonwoven material.

Patent Document 1: Korean Patent Laid-Open Publication No. 10-2015-0070877 Patent Document 2: Republic of Korea Patent Publication No. 10-1615167 Patent Document 3: Republic of Korea Patent Publication No. 10-1629736

The problem to be solved by the present invention relates to the provision of a method for manufacturing a wheel guard for an insert injection molding vehicle using a lightweight high-strength composite material, and more particularly, it is lighter than the conventional wheel guard for a vehicle, and has improved moldability and durability. An object of the present invention is to provide a method for manufacturing an insert injection molding vehicle wheel guard using a composite material molded into an integrated 1-piece type, and a vehicle wheel guard manufactured therefrom.

As a solution to the problem according to the present invention, a method for manufacturing a wheel guard for an insert injection molding vehicle using a composite material is a sound-absorbing property consisting of an outer layer made of PET fiber, LM fiber, and hollow fiber, and a back layer made of PET fiber, LM fiber and hollow fiber. In insert injection molding the composite fiber nonwoven material to be integrated with the PP resin, the sound-absorbing composite fiber nonwoven material is disposed in the insertion cavity of the insert member in the insert injection mold, and then injection molding is performed so that a part of the skin layer is exposed to the external surface. .

An embodiment according to a method of manufacturing a wheel guard for an insert injection molding vehicle using the composite material of the present invention is a). The weight per unit area of the skin layer 1 is the first sound-absorbing layer comprising 20-40 parts by weight of polyethylene terephthalate (PET) fiber, 30-40 parts by weight of LM fiber (Low Melting fiber), and 30-40 parts by weight of hollow fiber 300 A first step of producing a nonwoven fabric of ~350 g/m2, b). 20 to 40 parts by weight of polyethylene terephthalate (PET) fiber 30 to 40 parts by weight of LM fiber (Low Melting fiber) and 30 to 40 parts by weight of hollow fiber 2The second step of producing a nonwoven fabric having a mass per unit area of 500 to 550 g/m 2 using the sound absorbing layer as the back layer (2), c) laminating the surface layer (1) nonwoven fabric and the back layer (2) nonwoven fabric by needle punching A third step and d) to produce a sound-absorbing composite fiber nonwoven material (3). After placing the composite fiber nonwoven material 3 in the insert cavity of the insert member in the insert injection molding mold, injection molding so that a part of the skin layer 1 is exposed to the outer surface while injecting polypropylene resin, the composite fiber It consists of including the fourth step of molding the 1-piece type wheel guard in which the nonwoven material 3 and the polypropylene resin are integrated.

Another embodiment according to the manufacturing method of the insert injection molding vehicle wheel guard using the composite material of the present invention is a). 10 to 12 denier polyethylene terephthalate (PET) fiber 20 to 40 parts by weight, 7 denier LM fiber (Low Melting fiber) 30 to 40 parts by weight and hollow fiber 30 to 40 parts by weight of the first sound-absorbing layer consisting of an epidermis layer (1 ) of the first step of producing a nonwoven fabric having a mass per unit area of 300 to 350 g/m 2 , b). A second sound-absorbing layer consisting of 20 to 40 parts by weight of polyethylene terephthalate (PET) fiber of 10 to 12 denier, 30 to 40 parts by weight of LM fiber (Low Melting fiber) of 7 denier and 30 to 40 parts by weight of hollow fiber is applied as a back layer ( The second step of producing a nonwoven fabric having a mass per unit area of 500 to 550 g/m 2 as 2), c) laminating the surface layer (1) nonwoven fabric and the back surface layer (2) nonwoven fabric by needle punching to form a sound-absorbing composite fiber nonwoven fabric ( A third step of preparing 3) and d). After placing the composite fiber nonwoven material 3 in the insert cavity of the insert member in the insert injection molding mold, injection molding so that a part of the skin layer 1 is exposed to the outer surface while injecting polypropylene resin, the composite fiber It consists of including the fourth step of molding the 1-piece type wheel guard in which the nonwoven material 3 and the polypropylene resin are integrated.

The polyethylene terephthalate (PET) fiber according to the present invention is made of a PET fiber having a polygonal cross-sectional shape, and the hollow fiber is made of a hollow fiber having a polygonal shape such as a circle or a triangle.

The insert injection molding vehicle wheel guard using the composite material according to the present invention is lightweight and high strength, and is particularly molded in a 1-piece type to prevent separation of the joint surface compared to the existing 2-piece type product, thereby improving durability. In addition, the effect of absorbing the sand noise caused by the collision of the gravestone is improved as well as the prevention of damage to the vehicle body due to the gravestone generated on the road surface.

1 is a view schematically showing a manufacturing process of an insert injection molding vehicle wheel guard of the present invention;
1 is a view schematically showing a wheel guard for an insert injection molding vehicle of the present invention;

Hereinafter, the present invention will be described in more detail with reference to specific contents and <Examples> and <Test Examples> for carrying out the present invention, but the present invention is not limited by the contents and Examples described below.

The manufacturing method of the insert injection molding vehicle wheel guard using the composite material of the present invention is a). The weight per unit area of the skin layer 1 is the first sound-absorbing layer comprising 20-40 parts by weight of polyethylene terephthalate (PET) fiber, 30-40 parts by weight of LM fiber (Low Melting fiber), and 30-40 parts by weight of hollow fiber 300 A first step of producing a nonwoven fabric of ~350 g/m2, b). 20 to 40 parts by weight of polyethylene terephthalate (PET) fiber 30 to 40 parts by weight of LM fiber (Low Melting fiber) and 30 to 40 parts by weight of hollow fiber 2The second step of producing a nonwoven fabric having a mass per unit area of 500 to 550 g/m 2 using the sound absorbing layer as the back layer (2), c) laminating the surface layer (1) nonwoven fabric and the back layer (2) nonwoven fabric by needle punching A third step and d) to produce a sound-absorbing composite fiber nonwoven material (3). The composite fiber nonwoven material 3 is placed in the insert cavity of the insert member in the insert injection molding mold, and injection molded so that a part of the epidermis layer 1 is exposed to the outer surface while injecting polypropylene (pp) resin. It consists of including the fourth step of molding the 1-piece type wheel guard in which the composite fiber nonwoven material 3 and the polypropylene resin are integrated.

The first step according to the present invention is a process for manufacturing a nonwoven fabric of the epidermis layer (1), which is the first sound-absorbing layer, and 20 to 40 parts by weight of polyethylene terephthalate (PET) fiber, 30 to 40 parts by weight of LM fiber (Low Melting fiber) A composite fiber composed of parts and hollow fibers of 30 to 40 parts by weight is manufactured according to a conventional nonwoven fabric manufacturing process, and a nonwoven fabric having a mass per unit area of 300 to 350 g/m 2 is manufactured.

The second step according to the present invention is a process of manufacturing the nonwoven fabric of the back layer 2, which is the second sound-absorbing layer, and 20 to 40 parts by weight of polyethylene terephthalate (PET) fiber, 30 to 40 parts by weight of LM fiber (Low Melting fiber) A nonwoven fabric is manufactured by using a composite fiber composed of 30 to 40 parts by weight and 30 to 40 parts by weight of the hollow fiber according to a conventional nonwoven fabric manufacturing process, and a nonwoven fabric having a mass per unit area of 500 to 550 g/m 2 is prepared.

For the polyethylene terephthalate (PET) fibers of the first and second steps, PET fibers of 10 to 12 denier having a polygonal cross-sectional shape are selected, and as the LM fibers, PET fibers of 7 denier are selected, and the hollow fiber is hollow. The shape is made of PET hollow fibers made of polygons such as circles or triangles.

It is possible to select a recycled PET fiber for the PET fiber and the hollow fiber having a polygonal cross-sectional shape, and the cross-sectional shape consists of various shapes such as a triangle, a square, a polygon, and a star shape.

In the third step according to the present invention, the nonwoven fabric of the outer layer 1 and the nonwoven fabric of the back layer 2 prepared in the first and second steps are laminated by needle punching to obtain a sound-absorbing composite fiber nonwoven material (3). It is a manufacturing process, and the needle punching process for laminating the nonwoven fabric is needle punching about 4 times including preliminary punching, and the conditions of the needle punching process according to the present invention are shown in [Table 1] below.

Needle room Pre-Punching (1st) 2nd Punching 3rd Punching 4th Punching Depth of Penetration (mm) 12 12 12 12 Penetration depth (mm) 5 5 5 5 In-let(m/min) 2.6 2.6 2.6 2.6 stroke(rpm) 600 700 850 1100 Out-let(m/min) 2.8 2.8 2.8 2.8 Needle density (#/m ² ) 5000 pieces/m 8000 sheets/m 8000 sheets/m 8000 sheets/m Advance/stroke (mm) 13 15 15 17 Drft rate (%) 5 3 3 4

The fourth step according to the present invention integrates the composite fiber nonwoven material 3 and the polypropylene resin by insert injection molding the composite fiber nonwoven material 3 prepared in the third step together with a polypropylene resin. It consists of a process of remanufacturing a 1-piece type wheel guard by injection molding while

The insert injection molding is performed by placing the composite fiber nonwoven material 3 as an insert member in a cavity in the insert injection molding mold, and then injecting the molten polypropylene resin while part of the outer surface of the skin layer 1 of the composite fiber nonwoven material 3 It consists of injection molding to expose the

Insert injection molding according to the present invention consists of an insert injection mold manufactured to be molded according to the shape of the wheel guard of the present invention, and the cavity into which the insert member is inserted in the insert injection mold is also manufactured in a predetermined shape, and the composite fiber The nonwoven material 3 is cut in advance to have the same shape as the cavity shape so that it can be inserted into the cavity in the insert injection mold.

In the insert injection molding of the present invention, the composite fiber nonwoven fabric is injection molded while injecting the molten polypropylene resin after placing the pre-cut composite fiber nonwoven material 3 in a cavity into which the insert member is inserted in a pre-fabricated insert injection mold. It consists of manufacturing a wheel guard in which a part of the skin layer 1 of the material 3 is exposed to the outer surface.

As shown in FIG. 2, in the insert injection molding wheel guard (W) according to the present invention, the sound-absorbing composite fiber nonwoven material 3 is partially exposed to the surface of the wheel guard W, and the composite fiber nonwoven material 3 and The integrated polyethylene resin (P) is positioned outside the wheel guard (W) to maintain the shape of the wheel guard (W).

The insert injection molding wheel guard (W) according to the present invention is a 1-piece type in which the composite fiber nonwoven material (3) and the polyethylene resin (P) are integrated. It has the advantage of improving durability by preventing have.

Insert injection molding according to the present invention as described above generally employs well-known insert injection molding means, so those skilled in the art to which the present invention pertains can easily employ it, so a detailed description will be omitted.

Hereinafter, through <Example> and <Test Example>, a method of manufacturing an insert injection molding vehicle wheel guard using a composite material according to the present invention will be described in more detail.

<Example> Manufacturing of non-woven composite fiber material

A first sound-absorbing layer having a composition of 20 parts by weight of PET fiber, 30 parts by weight of LM fiber, and 30 parts by weight of hollow fiber having an approximately triangular hollow shape, and having a mass per unit area of 300 g/m2, is applied to the skin layer (1) by a well-known non-woven fabric manufacturing method A second sound-absorbing layer having a composition of a nonwoven fabric comprising: Each nonwoven fabric is prepared.

The nonwoven fabric having the prepared skin layer (1) and the second sound-absorbing layer as the back layer (2) were laminated by needle punching under the conditions shown in [Table 1], and then cut into an insert member of a certain shape. Prepare the fibrous non-woven fabric (3).

Using the insert injection mold of the wheel guard of the present invention prepared in advance, the composite fiber nonwoven material (3) cut with an insert member is placed in a cavity in the insert injection mold, and the molten PP resin is injected while the composite fiber nonwoven material (3) and A 1-piece type wheel guard was manufactured by integrating PP resin, and as the PP resin was molded into the outer layer, a part of the composite fiber nonwoven material (3) was exposed to the outer surface of the wheel guard. .

<Test Example>

After preparing a specimen from the wheel guard prepared in <Example>, mechanical strength and the like were tested on the specimens (5 pieces), and the results (average values) are shown in [Table 2] below.

Evaluation items
(Main performance) unit world-class
(Germany/Freundberg) domestic level test example Test Methods weight g/m ² 1250 1500 1100 - The tensile strength MPa 0.05 0.01 0.05 MS341-17] (PAD-built-in for sound absorption) shrinkage % 5 10 5 absorption rate % 10 20 10 MS-341-19 compressive modulus % 70 100 70 MS-341-18 impact resistance - no deformation no deformation no deformation MS 34-20 sound absorption rate 1,000 Hz 0.10 0.05 0.10 MS200-39 (Standard Test Method Sound Insulation Material Evaluation) 2,000 Hz 0.20 0.10 0.20 3,150Hz 0.30 0.20 0.30

As shown in [Table 2], it can be seen that the mechanical strength of the insert injection molding vehicle wheel guard using the composite material in the present invention is equal to the world's highest level, and it is superior to the existing domestic products in terms of sound quality.

In particular, the unit weight of the wheel guard for insert injection molding vehicles using the composite material according to the present invention is 1100 g/m ² , which is 25% lighter than the existing domestic product (1,500 g/m ² ), and is the world’s highest level (1,250). g/m ² ), it can be confirmed that it is lightweight, and these physical properties can improve the fuel efficiency of 0.7% when the vehicle body weight is reduced by 1%, so the composite material according to the present invention in terms of vehicle fuel efficiency It can be seen that the insert injection molding vehicle wheel guard using

Claims (4)

a). A nonwoven fabric having a mass per unit area of 300 to 350 g/m 2 is manufactured using the skin layer 1 as the first sound-absorbing layer consisting of 20 to 40 parts by weight of polyethylene terephthalate fiber, 30 to 40 parts by weight of LM fiber, and 30 to 40 parts by weight of hollow fiber the first step to
b). 20 to 40 parts by weight of polyethylene terephthalate fiber 30 to 40 parts by weight of LM fiber and 30 to 40 parts by weight of hollow fiber The second sound-absorbing layer as the back layer (2) having a mass per unit area of 500 to 550 g/m a second step of producing a nonwoven fabric;
c) a third step of manufacturing a sound-absorbing composite fiber nonwoven material (3) by laminating the skin layer (1) nonwoven fabric and the back surface layer (2) nonwoven fabric by needle punching; and
d). The composite fiber nonwoven material (3) is placed in the insert cavity of the insert member in the insert injection molding mold, and injection molded so that a part of the skin layer (1) is exposed to the outer surface while injecting polypropylene resin, and the composite fiber nonwoven material ( 3) and a polypropylene resin integrated 1-piece type wheel guard manufacturing method, characterized in that it comprises a fourth step of molding insert injection molding vehicle wheel guard. The method according to claim 1, wherein the polyethylene terephthalate fibers of the first and second steps are 10 to 12 denier fibers having a polygonal cross-sectional shape, the LM fibers are 7 denier low-melting polyethylene terephthalate fibers, and the hollow fibers are hollow. A method of manufacturing a wheel guard for an insert injection molding vehicle, characterized in that the shape is a round or polygonal PET hollow fiber. The method for manufacturing a wheel guard for insert injection molding vehicle according to claim 2, wherein the hollow fiber is a PET hollow fiber having a hollow shape. A wheel guard for a 1-piece type insert injection molding vehicle, characterized in that it is manufactured by the manufacturing method according to any one of claims 1 to 3.

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