KR102482719B1 - Non-woven fabric composite for interior matrial of automobile - Google Patents

Abstract

The present invention relates to a non-woven fabric composite for automobile interior materials that can be reduced in weight while achieving excellent mechanical properties and has improved sagging. The nonwoven fabric composite includes a nonwoven fabric layer laminated in two or more layers; and a reinforcing fabric layer formed between adjacent nonwoven fabric layers or inserted into a single nonwoven fabric layer, wherein the reinforcing fabric layer is a fabric layer formed by weaving yarns containing polyolefin fibers.

Description

Non-woven composite for automotive interior materials {NON-WOVEN FABRIC COMPOSITE FOR INTERIOR MATRIAL OF AUTOMOBILE}

The present invention relates to a non-woven fabric composite for automobile interior materials that can be reduced in weight while achieving excellent mechanical properties and has improved sagging.

In general, various nonwoven composites are applied to vehicle interior and exterior materials such as a headliner mounted on the inner surface of a roof panel of a vehicle, a package tray installed behind a rear seat, and an undercover mounted on the floor of a vehicle. Typically, a nonwoven fabric composite in which two or more nonwoven fabric layers made of polyester fibers such as polyethylene terephthalate (PET) are laminated is applied to automotive interior materials such as the headliner.

However, since these nonwoven composites are manufactured using short fibers, mechanical properties such as stiffness and flexural strength are insufficient. In order to reinforce these mechanical properties, in the past, a method of increasing the weight of the nonwoven fabric itself or inserting another reinforcing material between the nonwoven fabric layers has been applied in the nonwoven fabric composite.

However, among these conventional methods, when the weight of the nonwoven fabric itself is increased, a problem in that the nonwoven fabric composite sags with the passage of time when applied to an automobile interior material, resulting in a problem in that the nonwoven fabric composite is lightweight. It was required.

In addition, conventionally, a method of reinforcing the nonwoven fabric composite by using polyester fibers such as PET or polyamide fibers such as nylon as a reinforcing material has been considered. However, these industrial fibers have a disadvantage in that it is difficult to sufficiently improve mechanical properties such as strength of the nonwoven fabric composite due to insufficient bonding and adhesive strength with the nonwoven fabric layer.

In addition, methods of reinforcing the nonwoven fabric composite using various polymer particles or films are also being studied and considered, but so far, it is possible to effectively bond each nonwoven fabric layer while uniformly reinforcing mechanical properties such as overall flexural strength of the nonwoven fabric composite. Reinforcements have not been developed yet.

Due to the various disadvantages of the prior art described above, while achieving excellent mechanical properties of the nonwoven fabric composite applied to the interior material for automobiles, there is a continuous demand for the development of related technologies that enable weight reduction thereof.

Accordingly, the present invention is to provide a nonwoven fabric composite for automobile interior materials, which exhibits mechanical properties such as improved flexural strength as a whole, while reducing sagging and the like by enabling weight reduction.

Accordingly, the present invention is a nonwoven fabric layer laminated in two or more layers; and

Including a reinforcing fabric layer formed between adjacent nonwoven fabric layers or inserted into a single nonwoven fabric layer,

The reinforcing fabric layer provides a non-woven fabric composite for automobile interior materials, which is a fabric layer formed by weaving yarns containing polyolefin fibers.

The nonwoven fabric composite of the present invention includes a fabric layer formed by weaving polyolefin fibers as a reinforcing material. As the specific reinforcing material is included, each nonwoven fabric layer can be bonded to each other with excellent bonding/adhesive strength through the reinforcing material, and mechanical properties such as flexural strength of the nonwoven composite are improved to a higher level than other previously known reinforcing materials. It has been confirmed that this can be done.

In addition, since this reinforcing material itself can bond each nonwoven fabric layer with excellent bonding strength, a separate adhesive film, powder, and foaming agent are not required, and the overall manufacturing process can be simplified and the physical properties of the product can be uniform.

As a result, by using the specific reinforcing material in the form of a fabric, overall mechanical properties can be improved while reducing the weight of the entire composite. Therefore, it is also possible to solve the sagging phenomenon due to the weight reduction, and the nonwoven fabric composite of the present invention can be applied very preferably to automobile interior materials such as headliners.

Since the present invention can have various changes and various forms, specific embodiments will be exemplified and described in detail below. However, it should be understood that this is not intended to limit the present invention to the specific disclosed form, and includes all modifications, equivalents, and substitutes included in the spirit and scope of the present invention.

Hereinafter, a method for manufacturing a nonwoven fabric composite for automotive interior materials according to specific embodiments of the present invention will be described in more detail.

Prior to that, technical terms used herein are only for referring to specific embodiments and are not intended to limit the present invention. And, as used herein, the singular forms also include the plural forms unless the phrases clearly indicate the opposite.

According to one embodiment of the invention, a nonwoven fabric layer laminated in two or more layers; and

Including a reinforcing fabric layer formed between adjacent nonwoven fabric layers or inserted into a single nonwoven fabric layer,

The reinforcing fabric layer is a fabric layer formed by weaving yarns containing polyolefin fibers, and a nonwoven fabric composite for automobile interior materials is provided.

The nonwoven fabric composite of one embodiment includes a fabric layer formed by weaving polyolefin-based fibers, typically a reinforcing fabric layer formed by weaving high-density polyethylene fibers. At least a portion of the reinforcing material in the form of a fabric formed of polyolefin fibers may be melted under heat and/or pressure during the manufacturing process of the nonwoven fabric composite and inserted into one or more nonwoven fabric layers, and the reinforcing fabric layer not inserted into the nonwoven fabric layer may be formed. It may be formed between nonwoven fabric layers adjacent to each other.

Due to these morphological characteristics, the polyolefin-based reinforcing fabric layer can impart strong bonding/adhesion between each nonwoven fabric layer. In addition, it was confirmed that the polyolefin-based reinforcing fabric layer could uniformly improve mechanical properties such as overall flexural strength of the nonwoven fabric composite to a large extent by maintaining properties such as high-strength polyethylene fibers on its own.

In particular, as a result of the experiments of the present inventors, even when the polyolefin-based resin is prepared in a different form such as powder or film and applied as a reinforcing material, as it is applied in the form of a fabric, the adhesive strength between the nonwoven fabric layers and the mechanical properties of the overall composite are improved. It was confirmed that it can be improved more effectively.

Therefore, the nonwoven fabric composite of one embodiment including the specific reinforcing fabric layer may exhibit excellent mechanical properties such as flexural strength without increasing the overall weight and further enabling overall weight reduction. Therefore, the non-woven fabric composite can also solve the sagging phenomenon caused by weight when applied to automotive interior materials, and exhibits very excellent mechanical properties as a whole, so it can be preferably applied to automotive interior materials such as headliners.

On the other hand, in the nonwoven fabric composite of one embodiment, the nonwoven fabric layer may be laminated in a plurality of layers of 2 or more, or 3 to 5. In a more specific example, the plurality of nonwoven fabric layers include a first nonwoven fabric layer formed on both outermost surfaces of the composite; And it may include a second non-woven fabric layer formed between the first non-woven fabric layer. At this time, the first nonwoven fabric layer is a nonwoven fabric layer formed between the first nonwoven fabric layers on both sides to support the overall composite, and is physically separated from the first nonwoven fabric layer, and will be laminated between the first nonwoven fabric layers. can The second nonwoven fabric layer may include, for example, fibers of a material different from those of the first nonwoven fabric layer, or may have different physical properties, for example, different fiber areal density.

In this laminated structure of non-woven fabric layers, the material of the first and second non-woven fabric layers is not particularly limited, and may be (short) fibers of any material previously known to be applicable to non-woven fabrics for automobiles. For example, the first and second nonwoven fabric layers include polyolefin fibers such as polyethylene fibers or polypropylene fibers, polyester fibers such as polyethylene terephthalate (PET) fibers, polyamide fibers such as nylon fibers, aramid fibers, and glass fibers. , carbon fiber, metal fiber, LMF (Low Melting Fiber) and hemp fiber (kenaf) may include one or more types of fibers selected from the group consisting of.

In a preferred embodiment, the first nonwoven fabric layer disposed on both outermost surfaces of the composite may be formed of polyester-based short fibers so that the entire nonwoven fabric composite may exhibit improved mechanical properties, etc., and the second nonwoven fabric layer It may be formed by including polypropylene short fibers and hemp fibers.

Each nonwoven fabric layer, including the first and second nonwoven fabric layers, uses the above-mentioned short fibers according to a general nonwoven fabric manufacturing method such as needle punching, thermal bonding, melt blown spun lace or stitch bond. Bonding the short fibers can be manufactured by In addition, considering the physical properties required for each nonwoven fabric layer, it is of course possible to obtain and use nonwoven fabrics commercially.

Among the laminated structures of these nonwoven fabric layers, the first nonwoven fabric layer may have a fiber areal density of 50 to 500 gsm or 100 to 400 gsm. In addition, the second nonwoven fabric layer formed between the first nonwoven fabric layers may have a fiber areal density of 100 to 1300 gsm or 500 to 1000 gsm.

As a result, the composite may exhibit superior mechanical properties such as strength without significantly increasing the overall weight of the nonwoven fabric composite. Furthermore, each nonwoven fabric layer is effectively combined by a reinforcing fabric layer to be described later, so that the physical properties of the overall composite can be excellently expressed.

On the other hand, the nonwoven fabric composite of one embodiment described above includes a reinforcing fabric layer formed between adjacent nonwoven fabric layers or inserted into the nonwoven fabric layer. In particular, in the composite of one embodiment, the reinforcing fabric layer is a fabric layer formed by weaving a yarn containing polyolefin fibers, and as a result, the composite of one embodiment can exhibit excellent mechanical properties while being lightweight as a whole.

In this reinforcing fabric layer, the yarn may include only polyolefin fibers, but more suitably may further include polyamide fibers such as nylon fibers or polyester fibers such as PET fibers. That is, by forming the reinforcing fabric layer using a mixed fiber of polyolefin-based fibers and polyamide-based fibers or polyester-based fibers, the composite of one embodiment may exhibit further improved flexural strength and the like.

In this case, the yarn may include 5 to 100% by weight, or 50 to 99% by weight, or 60 to 90% by weight of polyolefin fibers and the remaining content of polyamide or polyester fibers, based on the total weight. there is.

In addition, the polyolefin-based fibers applied for the production of the reinforcing fabric layer may be general polyethylene fibers or polypropylene fibers, but in order to further improve the mechanical properties of the nonwoven fabric composite of one embodiment and achieve weight reduction, the polyolefin fibers It is more preferable to use a polyethylene fiber having a density of 0.91 g/cm ³ to 0.98 g/cm ³ as the system fiber.

The reinforcing fabric layer may be woven and manufactured according to conventional fabric manufacturing methods and processes using yarns including the above-described polyolefin-based fibers and optionally polyamide-based or polyester-based fibers.

The yarn of the reinforcing fabric layer may have a fineness of 50 to 1000 denier or 200 to 800 denier, and may have a tensile strength of 3 to 40 g/d or 7 to 20 g/d. In addition, the reinforcing fabric layer obtained from these yarns may independently have a weaving density of 10 to 50 yarns/inch in both directions of the warp and weft yarns, and may have a fiber area density of 50 to 300 gsm.

As the reinforcing fabric layer satisfies the various physical properties of the yarn and fabric layer described above, each nonwoven fabric layer can be bonded with better bonding strength, and the mechanical properties of the overall composite can be more effectively reinforced.

On the other hand, the nonwoven fabric composite of one embodiment is prepared by preparing nonwoven fabrics and fabrics corresponding to each of the above-described nonwoven fabric layers and reinforcing fabric layers, sequentially stacking them, and then bonding them under application of pressure and heat. Can be prepared. The specific manufacturing method and conditions of these composites are described in the Examples to be described later, and since they are in accordance with the manufacturing conditions and methods of conventional nonwoven fabric composites, further description thereof will be omitted.

The nonwoven fabric composite of one embodiment described above may have a relatively low fiber areal density of 200 to 1500 gsm, 500 to 1300 gsm, or 800 to 1100 gsm, as overall mechanical properties are reinforced with the reinforcing fabric layer.

In this way, even in a relatively lightweight state, the nonwoven fabric composite may have excellent mechanical properties defined by excellent flexural strength of 35 N or more, or 35 to 80 N.

Therefore, the nonwoven fabric composite of one embodiment can be very preferably applied to various automotive interior materials including headliners, and can exhibit excellent overall mechanical properties while solving problems such as sagging due to light weight.

Hereinafter, preferred embodiments are presented to aid understanding of the invention. However, the following examples are only for exemplifying the invention, and do not limit the invention only to these.

First, in Tables 1 and 2 below, the materials and areal densities of each layer included in the nonwoven fabric composites of Reference Examples, Examples and Comparative Examples are summarized in the order of stacking.

Reference example 1 Reference example 2 Example 1 Example 2 Produce
condition 1st nonwoven fabric layer Material PET scrim PET scrim PET scrim area density
(gsm) 150 150 150 layer of reinforcing fabric Material PE + Nylon6(#1) HDPE 800D weaving density
(pattern/inch) 25X25 25X25 area density
(gsm) 153 185 2nd nonwoven fabric layer Material P.P.: Kenaf P.P.: Kenaf P.P.: Kenaf area density
(gsm) 850 550 550 1st nonwoven fabric layer Material PET scrim PET scrim PET scrim area density
(gsm) 150 150 150 total areal density
(gsm) 1150 1150 1003 1035

Example 3 Example 4 Example 5 Comparative Example 1 Produce
condition 1st nonwoven fabric layer Material PET scrim PET scrim PET scrim PET scrim Areal Density (gsm) 150 150 150 150 layer of reinforcing fabric Material HDPE 400D HDPE+Nylon6(#2) PP PET Warp Knitting weaving density 30X30 25X25 30X30 15X15 Areal Density (gsm) 100 153 90 94 2nd nonwoven fabric layer Material P.P.: Kenaf P.P.: Kenaf P.P.: Kenaf P.P.: Kenaf Areal Density (gsm) 550 550 550 550 1st nonwoven fabric layer Material PET scrim PET scrim PET scrim PET scrim Areal Density (gsm) 150 150 150 150 Total Areal Density (gsm) 950 1003 940 944

Reference Example 1: Required properties of nonwoven fabric for automobile headliner (SPEC.)

First, Reference Example 1 shows standard physical properties required for a nonwoven fabric composite manufactured as a car headliner. For reference, in the case of the headliner, the bending test value, which is the main factor for the sagging of the outer part, is important.

Reference Example 2, Examples 1 to 5 and Comparative Example 1: Preparation of nonwoven fabric composites

The first nonwoven fabric layer, the reinforcing fabric layer, the second nonwoven fabric layer, and the first nonwoven fabric layer having the materials and areal densities described in Table 1 or 2 were sequentially laminated, attached under heating, and cooled to obtain reference example 2 and examples 1 to 2. 5 and the nonwoven fabric composites of Comparative Example 1 were prepared, respectively.

The heating and cooling conditions were as follows. For reference, Reference Example 2 is a nonwoven fabric composite that is currently commercially applied for automotive headliners, and Comparative Example 1 is prepared using a reinforcing fabric layer of a material different from that of Example.

Heating Zone: 230~275℃

Cooling Zone: 20~40℃

Speed: 5.0~7.0M/min

The physical properties (flexural strength, stiffness, and toughness) of the nonwoven fabric composites of Reference Examples, Examples, and Comparative Examples prepared by the above method were measured, and the measurement results are summarized in Tables 3 and 4 below.

Reference example 1 Reference Example 2 Example 1 Example 2 curve
exam flexural strength MD(N) 30 ↑ 32.76 36.8 66.1 AMD(N) 25 ↑ 32.76 45 79.7 stiffness MD(N/mm) 6 ↑ 6.0 6.4 7.8 AMD (N/mm) 5 ↑ 5.5 8 9.1 toughness MD(%) 80 ↑ 91.3 83.4 94.9 AMD (%) 80 ↑ 85.3 81.6 82.6

Example 3 Example 4 Example 5 Comparative Example 1 curve
exam flexural strength MD(N) 54.4 48.9 55.3 25.4 AMD(N) 64.6 52.1 76.9 29.7 stiffness MD(N/mm) 8.4 7 8.1 4.6 AMD (N/mm) 9.2 7.6 9.4 6.9 toughness MD(%) 86 73.9 87 86.2 AMD (%) 85.2 73.3 80.9 81.4

Referring to Tables 3 and 4, the overall weight (area density) of the nonwoven fabric composites of the examples is lighter than that of the industry-required standard (Reference Example 1) (see Tables 1 and 2), but is at the level required for nonwoven fabrics for automotive headliners. It was confirmed that the mechanical properties significantly exceeded that of

In addition, it was confirmed that the nonwoven fabric composite of the above example exhibits improved mechanical properties compared to Reference Example 2 or Comparative Example 1, which are conventional nonwoven fabric composites for automotive headliners.

Claims (14)

A nonwoven fabric layer laminated in two or more layers; and
Including a reinforcing fabric layer formed between adjacent nonwoven fabric layers or inserted into a single nonwoven fabric layer,
The reinforcing fabric layer is a fabric layer formed by weaving yarns containing polyolefin fibers,
At least a portion of the reinforcing fabric layer is melted and inserted into one or more nonwoven fabric layers, and the remaining reinforcing fabric layers are formed between adjacent nonwoven fabric layers.
Non-woven fabric composite for automotive interior materials.
According to claim 1, wherein the non-woven fabric layer is a first non-woven fabric layer formed on both outermost surfaces of the composite; and
A nonwoven fabric composite for automobile interior materials comprising a second nonwoven fabric layer formed between the first nonwoven fabric layers and containing fibers different from those of the first nonwoven fabric layer or having a different fiber areal density.
The method of claim 2, wherein the first and second nonwoven fabric layers are polyolefin-based fibers, polyester-based fibers, polyamide-based fibers, aramid fibers, glass fibers, carbon fibers, metal fibers, LMF (Low Melting Fiber) and hemp fibers A non-woven fabric composite for automotive interior materials comprising at least one fiber selected from the group consisting of (kenaf).
[Claim 3] The non-woven fabric composite according to claim 2, wherein the first non-woven fabric layer has a fiber areal density of 50 to 500 gsm.
[Claim 3] The non-woven fabric composite according to claim 2, wherein the second non-woven fabric layer has a fiber areal density of 100 to 1300 gsm.
The nonwoven fabric composite for automobile interior materials according to claim 1, wherein the yarns of the reinforcing fabric layer further include polyamide-based or polyester-based fibers.
The nonwoven fabric composite of claim 1, wherein the polyolefin fibers include polyethylene fibers having a density of 0.91 g/cm ³ to 0.98 g/cm ³ .
[Claim 4] The nonwoven fabric composite for interior materials of a vehicle according to claim 1, wherein the yarns of the reinforcing fabric layer have a fineness of 50 to 1000 denier and a tensile strength of 3 to 40 g/d.
[Claim 4] The nonwoven fabric composite for automobile interior materials according to claim 1, wherein the reinforcing fabric layer has a weaving density of 10 to 50 yarns/inch in both warp and weft directions.
The nonwoven fabric composite according to claim 1, wherein the reinforcing fabric layer has a fiber areal density of 50 to 300 gsm.
delete The nonwoven fabric composite for automobile interior materials according to claim 1, having a fiber areal density of 200 to 1500 gsm.
An interior material for automobiles comprising the nonwoven fabric composite of claim 1.
The interior material for automobiles according to claim 13, which is a headliner for automobiles.