KR102513838B1 - Interior parts applying lightweight composite material and manufacturing method - Google Patents

Interior parts applying lightweight composite material and manufacturing method Download PDF

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KR102513838B1
KR102513838B1 KR1020210145111A KR20210145111A KR102513838B1 KR 102513838 B1 KR102513838 B1 KR 102513838B1 KR 1020210145111 A KR1020210145111 A KR 1020210145111A KR 20210145111 A KR20210145111 A KR 20210145111A KR 102513838 B1 KR102513838 B1 KR 102513838B1
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South Korea
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layer
molding
manufacturing step
intermediate layer
type
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KR1020210145111A
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Korean (ko)
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김동원
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주식회사 서연이화
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/20—Making multilayered or multicoloured articles
    • B29C43/203—Making multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/52—Heating or cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/3461—Making or treating expandable particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/3461—Making or treating expandable particles
    • B29C44/3465—Making or treating expandable particles by compressing particles in vacuum, followed by expansion in normal pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/02—Layered products essentially comprising sheet glass, or glass, slag, or like fibres in the form of fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

The present invention relates to an interior material using a lightweight composite material and a method for manufacturing the same. The method for manufacturing the interior material comprises: an intermediate layer manufacturing step; a molding layer manufacturing step; and a laminated and molded interior material manufacturing step. According to the present invention, an intermediate material is formed by mixing S+PP or PE, PET, and TPE through foam molding, and thus, excellent strength and lightweight performance are provided.

Description

경량 복합소재를 적용한 내장재 및 그 제작방법{Interior parts applying lightweight composite material and manufacturing method}Interior parts applying lightweight composite material and manufacturing method

본 발명은 차량 내장재용 경량 복합소재를 적용한 차량 내장재 및 차량 내장재 제작방법에 관한 것으로, 보다 상세하게는 고강도를 가지면서 경량인 샌드위치 구조의 차량 내장재용 경량 복합소재를 적용한 차량 내장재에 관한 것이다.The present invention relates to a vehicle interior material and a method for manufacturing a vehicle interior material using a lightweight composite material for vehicle interior materials, and more particularly, to a vehicle interior material having a high strength and lightweight sandwich structure using a lightweight composite material for vehicle interior materials.

차량 내장재용 복합소재는 적용 부품의 요구 특성에 따라, 열가소성 및 열경화성 수지 기반에 유/무기 필러가 첨가되는 복합소재, 화학섬유와 천연섬유 및 무기섬유 등을 펠트 및 보드화한 섬유보강 복합소재, 강도를 유지하는 코어층에 상/하 보강층을 적층한 샌드위치 구조 복합소재 등으로 적용되고 있다. Depending on the required characteristics of the applied parts, composite materials for vehicle interior materials include composite materials in which organic/inorganic fillers are added to thermoplastic and thermosetting resin bases, fiber-reinforced composite materials made of felt and board made of chemical fibers, natural fibers, and inorganic fibers, etc., and strength. It is applied as a sandwich structure composite material in which upper and lower reinforcing layers are laminated on a core layer that maintains a core layer.

상기 소재들은 CO2 배출 억제를 위해 더 가볍고 물성이 우수한 고강성 경량화 복합소재의 적용에 대한 요구사항이 지속적으로 높아지고 있으며, 동시에 글로벌 시대에 시장경쟁력을 확보하기 위한 가격경쟁력도 요구하고 있기에, 기존 소재의 문제점들을 개선하고 가격 경쟁력이 우수한 새로운 소재의 개발이 시급한 실정이다.For the above materials, the requirements for the application of lightweight, high-strength, lightweight composite materials with excellent physical properties are continuously increasing to suppress CO 2 emission, and at the same time, price competitiveness is required to secure market competitiveness in the global era. There is an urgent need to improve the problems and develop new materials with excellent price competitiveness.

실제로, 기존에 적용중인 커버링 셀프 및 러기지 보드 등의 내장부품은 높은 수준의 요구사항을 만족하기 위해 고중량의 소재가 적용되고 있으며, 상기의 문제점을 개선하기 위해, 친환경 및 경량화 소재의 개발이 진행되어 여러 타입의 소재가 개발 및 적용되고 있는데, 완성차 업체에서 요구하는 친환경, 경량화, 우수한 물성 및 가격경쟁력을 모두 만족하는 소재를 개발하기에 다소 난이성 있다.In fact, high-weight materials are applied to interior parts such as covering shelves and luggage boards that are currently being applied to meet high-level requirements, and in order to improve the above problems, development of eco-friendly and lightweight materials is in progress. Various types of materials are being developed and applied, but it is somewhat difficult to develop materials that satisfy all of the eco-friendly, lightweight, excellent physical properties and price competitiveness required by finished car manufacturers.

예를 들어, GMT(Glass mat Thermoplastics), GM-PUR (Glass-mat polyurethane composite) 은 강성이 우수하나, 원가가 높은 단점이 있고, 또한, 천연섬유 강화보드 및 우드스탁 등은 저렴한 원가 및 우수한 물성을 가지고 있지만, 높은 요구사항을 만족하기 위해서는 높은 중량이 적용되어야 하며, 그에 따른, VOC 및 냄새 문제로 인해 적용에 제한을 두고 있다.For example, GMT (Glass mat Thermoplastics) and GM-PUR (Glass-mat polyurethane composite) have excellent rigidity but high cost, and natural fiber reinforced boards and woodstock have low cost and excellent physical properties. However, in order to satisfy high requirements, high weight must be applied, and consequently, VOC and odor problems limit its application.

위와 같은 기존의 문제점들을 해결하기 위해, 최근에 EPP foam 소재를 코어로 구성한 복합소재 타입이 개발되어 자동차 러기지보드에 적용이 시도되었으나, 제조공정 및 성형 업체의 제조여건 한계로 인해 변형 및 공정문제를 개선하지 못하여 양산적용에 실패한 사례가 있다. EPP foam은 화학적 발포제를 사용하지 않고 물리적으로 발포한 무가교 폴리프로필렌을 입자 형태로 성형하는 발포체로써 Bumper core, Sun visor core 등에 범용적으로 사용되지만, 성형 후 공차가 ±6mm 수준으로 치수안정화에 어려움이 있어 복합재료 성형공정 적용에 어려움이 있다. In order to solve the above existing problems, a composite material type composed of EPP foam material as a core was recently developed and applied to an automobile luggage board, but due to limitations in the manufacturing process and manufacturing conditions of molding companies, deformation and process problems There is a case where mass production application failed due to failure to improve. EPP foam is a foam that molds non-crosslinked polypropylene physically expanded into particles without using chemical foaming agents. It is commonly used for bumper cores and sun visor cores, but it is difficult to stabilize dimensions as the tolerance after molding is ±6mm. This makes it difficult to apply the composite material molding process.

따라서, 기존의 요구사항을 만족하며, 연비향상, CO2 배출 규제 등에 대응 가능한 경쟁력을 확보하는 경량화가 가능한 차량 내장재용 경량 복합소재의 개발이 필요하다.Therefore, it is necessary to develop a lightweight composite material for vehicle interior materials that can be reduced in weight that satisfies the existing requirements and secures competitiveness capable of responding to fuel efficiency improvement and CO2 emission regulations.

본 발명은 상기한 바와 같은 종래 차량 내장재가 가지는 문제점들을 개선하기 위해 창출된 것으로, 기존 적용 소재 대비 경량화 효과가 우수하며, 강도 및 냄새, VOC 등이 우수하며, 가격경쟁력이 우수한 차량 내장재용 경량 복합소재를 제공하는 데에 그 목적이 있다.The present invention was created to improve the problems of the conventional vehicle interior materials as described above, and is superior in weight reduction effect compared to existing applied materials, excellent in strength, odor, VOC, etc., and lightweight composite for vehicle interior materials with excellent price competitiveness. Its purpose is to provide material.

본 발명의 일 측면에 따르면, Bead 발포제를 스팀성형기를 이용하여 시트인 중간층을 제작하는 중간층 제조단계; 펠트상태의 재료를 오븐 또는 히팅 프레스로 예열하여 제 1성형층 및 제 2성형층을 제조하는 성형층 제조단계; 상기 중간층 제조단계에서 제조된 중간층 과 상기 성형층 제조단계에서 제조된 제 1성형층 및 제 2성형층을 몰딩프레스에 투입하여 차량 내장재의 형태로 성형하는 적층성형 내장재 제조단계; 를 포함하고 상기 중간층(10)은 비드형태의 SAN(A type)과 비드형태의 PP, PE, PET, TPE(B type) 중 어느 한가지와 혼합되어 발포 foam타입으로 성형되어 오토클레이브, 압출법 중 어느 한가지의 방법을 이용하여 압출 비드의 형태로 형성되고 상기 제 1성형층은 상기 중간층의 상측에 배치되며 열가소성 섬유를 니들펀칭 또는 시트압출 방법으로 제조되고 상기 제 2성형층은 상기 중간층의 하측에 배치되며 열가소성 섬유를 니들펀칭 또는 시트압출 방법으로 제조되는 경량 복합소재 적용 내장재 제작방법이 제공될 수 있다.According to one aspect of the present invention, the intermediate layer manufacturing step of producing a sheet of intermediate layer using a bead foaming agent using a steam molding machine; A molding layer manufacturing step of preheating a felt material in an oven or a heating press to prepare a first molding layer and a second molding layer; Laminate molding interior material manufacturing step of putting the intermediate layer manufactured in the intermediate layer manufacturing step and the first molding layer and the second molding layer manufactured in the molding layer manufacturing step into a molding press and molding them in the form of a vehicle interior material; And the intermediate layer 10 is mixed with bead-type SAN (A type) and any one of bead-type PP, PE, PET, TPE (B type) and molded into an expanded foam type, and the autoclave or extrusion method It is formed in the form of an extrusion bead using any one method, the first molding layer is disposed on the upper side of the intermediate layer, and thermoplastic fibers are manufactured by needle punching or sheet extrusion method, and the second molding layer is disposed on the lower side of the intermediate layer. A method for manufacturing an interior material applied with a lightweight composite material, which is arranged and manufactured by needle punching or sheet extrusion of thermoplastic fibers, may be provided.

또한, 비트형태의 SAN(A type)과 비드형태의 PP, PE, PET, TPE(B type) 중 어느 한가지와 혼합되어 발포 foam타입으로 성형되어 오토클레이브, 압출법 중 어느 한가지의 방법을 이용하여 압출 비드의 형태로 형성되는 중간층; 상기 중간층의 상측에 배치되며 열가소성 섬유를 니들펀칭 또는 시트압출 방법으로 제조되는 제 1성형층; 및 상기 중간층의 하측에 배치되며 열가소성 섬유를 니들펀칭 또는 시트압출 방법으로 제조되는 제 2성형층; 을 포함하는 경량 복합소재 적용 내장재가 제공될 수 있다.In addition, it is mixed with bit-type SAN (A type) and bead-type PP, PE, PET, TPE (B type) and molded into a foam type, using either autoclave or extrusion method. an intermediate layer formed in the form of an extruded bead; a first molding layer disposed on the upper side of the intermediate layer and manufactured by needle punching or sheet extrusion of thermoplastic fibers; and a second shaping layer disposed below the intermediate layer and manufactured by needle punching or sheet extrusion of thermoplastic fibers. A lightweight composite material applied interior material including may be provided.

본 발명의 실시예에 따른 차량 내장재용 경량 복합소재 적용 내장재 및 내장재 제작방법은 발포성형을 통한 S+PP 또는 PE, PET, TPE를 혼합하여 중간재를 형성하여 강도 및 경량화 성능이 우수하고, 성형성 향상, VOC, 냄새제거 등에 우수한 효과가 있는 차량 내장재가 제작되는 활용될 수 있다.Interior materials applied with lightweight composite materials for vehicle interior materials and a method for manufacturing interior materials according to an embodiment of the present invention form an intermediate material by mixing S+PP or PE, PET, and TPE through foam molding to have excellent strength and lightweight performance, and excellent moldability. It can be used to manufacture vehicle interior materials with excellent effects such as improvement, VOC, and odor removal.

도 1은 본 발명의 일 실시예에 따른 복합소재를 적용한 차량 내장재 제작방법을 나타낸 순서도이다.
도 2는 중간층 제조단계를 개략적으로 나타낸 도면이다.
도 3은 성형층제조단계를 개략적으로 나타낸 도면이다.
도 4는 적층성형 내장재 제조단계를 개략적으로 나타낸 도면이다.
도 5는 적층성형 내장재 제조단계에서 원소재가 장입되는 순서를 나타낸 흐름도이다.1 is a flowchart illustrating a method of manufacturing a vehicle interior material using a composite material according to an embodiment of the present invention.
2 is a view schematically showing an intermediate layer manufacturing step.
3 is a view schematically showing a forming layer manufacturing step.
4 is a view schematically showing a manufacturing step of the laminated interior material.
5 is a flowchart showing the order in which raw materials are charged in the step of manufacturing interior materials for laminate molding.

이하, 본 발명의 실시예들을 첨부된 도면을 참조하여 설명하기로 한다. 다만, 이하의 실시예들은 본 발명의 이해를 돕기 위해 제공되는 것이며, 본 발명의 범위가 이하의 실시예들에 한정되는 것은 아님을 알려둔다. 이하의 실시예들은 해당 기술 분야에서 평균적인 지식을 가진 자에게 본 발명을 보다 완전하게 설명하기 위해서 제공되는 것으로, 불필요하게 본 발명의 기술적 요지를 흐릴 수 있다고 판단되는 공지의 구성에 대해서는 상세한 기술을 생략하기로 한다.Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. However, it should be noted that the following examples are provided to aid understanding of the present invention, and the scope of the present invention is not limited to the following examples. The following embodiments are provided to more completely explain the present invention to those with average knowledge in the relevant technical field, and detailed descriptions are given for well-known configurations that may unnecessarily obscure the technical gist of the present invention. to omit

도 1은 본 발명의 일 실시예에 따른 복합소재를 적용한 차량 내장재 제작방법을 나타낸 순서도이다.1 is a flowchart illustrating a method of manufacturing a vehicle interior material using a composite material according to an embodiment of the present invention.

도 1을 참조하면, 본 실시예의 차량 내장재 제작방법은 중간층 제조단계를 포함할 수 있다. 중간층 제조단계(S1)는 제품형태의 내장재의 내측에 배치되는 층이 될 수 있다. 중간층(10)은 내장재의 기계적성능이 보강되도록 완제품인 차량 내장재의 내측에 배치되는 층이 될 수 있다. 이때, 중간층(10)에 의해 보강되는 기계적성능은 차량 내장재의 길이방향 및 폭방향의 강도 및 강성이 될 수 있다.Referring to FIG. 1 , the method for manufacturing a vehicle interior material according to the present embodiment may include an intermediate layer manufacturing step. The intermediate layer manufacturing step (S1) may be a layer disposed inside the product-shaped interior material. The intermediate layer 10 may be a layer disposed inside the vehicle interior material, which is a finished product, to reinforce the mechanical performance of the interior material. At this time, the mechanical performance reinforced by the intermediate layer 10 may be the strength and rigidity of the vehicle interior material in the longitudinal and width directions.

도 2는 중간층 제조단계를 개략적으로 나타낸 도면이다.2 is a view schematically showing an intermediate layer manufacturing step.

도 2를 참조하면, 중간층 제조단계(S1)에서는 재료가 배합될 수 있다. 중간층 제조단계(S1)에서 중간층(10)으로 제조되는 재료는 Atype과 Btype 두가지 재료의 배합으로 형성될 수 있다. 일 예로, Atype재료는 비드형태로 형성된 SAN(Styrene AcryloNitrile)이 될 수 있다. 한편, Btype재료는 비드형태로 형성된 PP, PE, PET, TPE 중 어느 한종류의 재료가 될 수 있다. 이와 같은 Atype재료와 Btype재료의 비드 사이즈는 1mm ~ 5mm가 될 수 있다. 또한, Atype재료의 배합비율은 20% ~ 50%이고, Btype재료의 배합비율은 50% ~ 80%가 될 수 있다. 중간층 제조단계(S1)에서 Atype재료 및 Btype재료는 위와 같은 비율로 혼합되어 컴파운딩을 통해 1차 비드가 제작될 수 있다. 1차 비드의 형태는 발포성형기에서 성형되기 용이한 형태가 될 수 있다. 중간층 제조단계(S1)에서 1차 비드의 형태로 제작된 재료들은 발포성형기에 투입될 수 있다. 발포성형기는 스팀을 이용하여 내부의 투입된 재료를 발포시켜 Expanded 및 Expadable 타입의 상태로 발포성형하는 Autoclave 기계가 될 수 있다. 중간층제조단계(S1)에서 발포성형기에 투입된 Atype재료 및 Btype재료는 발포성형기의 내부로 주입되는 스팀에 의해 발포성형이 진행될 수 있다. 중간층제조단계(S1)에서 발포성형기의 내부로 주입되는 스팀은 100℃ ~ 200℃의 고온의 스팀증기가 될 수 있다. 중간층 제조단계(S1)은 이와 같은 조건에서 발포성형이 진행된 1차 비드 형태의 재료는 부피가 팽창되어, 도 2의 확대도와 같이 Expanded 및 Expandable 타입의 형태가 될 수 있다. 이때, 발포된 형태의 재료는 차량내장재의 외관형태로 형성된 중간층(10)이 될 수 있다. 중간층(10)은 블록시트 타입 및 성형가공된 부품의 형상이 될 수 있다. 또한, 중간층(10)은 전부 또는 일부가 열가소성 수지의 특성으로 형성된 발포폼이 될 수 있다. 또한, 중간층(10)은 10.0mm 내지 20.0mm의 두께로 형성될 수 있다. 또한, 중간층(10)은 600 kg/m3 내지 1200 kg/m3 의 밀도로 형성될 수 있다.Referring to FIG. 2 , materials may be mixed in the intermediate layer manufacturing step (S1). In the intermediate layer manufacturing step (S1), the material to be manufactured as the intermediate layer 10 may be formed by combining two types of materials, Atype and Btype. For example, the Atype material may be SAN (Styrene AcryloNitrile) formed in a bead form. Meanwhile, the B-type material may be any one kind of material among PP, PE, PET, and TPE formed in a bead form. The bead size of the Atype material and the Btype material may be 1mm to 5mm. In addition, the mixing ratio of the A type material is 20% to 50%, and the mixing ratio of the B type material may be 50% to 80%. In the intermediate layer manufacturing step (S1), the Atype material and the Btype material may be mixed in the same ratio as above, and the primary beads may be produced through compounding. The shape of the primary bead may be a shape that is easy to mold in a foam molding machine. Materials manufactured in the form of primary beads in the intermediate layer manufacturing step (S1) may be put into the foam molding machine. The foam molding machine can be an autoclave machine that foams the injected material using steam to form expanded and expadable types. In the intermediate layer manufacturing step (S1), the A type material and the B type material injected into the foam molding machine can be foamed and molded by steam injected into the foam molding machine. In the intermediate layer manufacturing step (S1), the steam injected into the foam molding machine may be high-temperature steam steam of 100 ° C to 200 ° C. In the intermediate layer manufacturing step (S1), the volume of the primary bead-shaped material subjected to foam molding under such conditions may be expanded, and may be expanded or expandable types as shown in the enlarged view of FIG. 2. At this time, the foamed material may be the intermediate layer 10 formed in the exterior shape of the vehicle interior material. The intermediate layer 10 can be of the block sheet type and the shape of a molded part. In addition, the intermediate layer 10 may be a foam formed in whole or in part with properties of a thermoplastic resin. In addition, the intermediate layer 10 may be formed to a thickness of 10.0 mm to 20.0 mm. In addition, the intermediate layer 10 may be formed with a density of 600 kg/m3 to 1200 kg/m3.

한편, 본 실시예의 차량 내장재 제작방법은 성형층 제조단계를 포함할 수 있다.On the other hand, the vehicle interior material manufacturing method of this embodiment may include a forming layer manufacturing step.

도 3은 성형층제조단계를 개략적으로 나타낸 도면이다.3 is a view schematically showing a forming layer manufacturing step.

도 3을 참조하면, 성형층제조단계(S2)에서는 열가소성 섬유를 니들펀칭 또는 시트압출방법으로 제 1성형층(20) 및 제 2성형층(30)이 제조될 수 있다. 이때, 제 1성형층(20) 및 제 2성형층(30)은 유리섬유, 유리울, 휘스커 또는 유리버블의 재질로 형성될 수 있다. 이와 같은 제 1성형층(20) 및 제 2성형층(30)은 성형층제조단계(S2)에서 오븐이나 히팅프레스에서 예열될 수 있다. 성형층제조단계(S2)에서 예열조건은 제 1성형층(20) 및 제 2성형층(30)에 열가소성섬유와 혼합되어있는 재료를 용융하도록 형성될 수 있다. 일 예로 성형층제조단계(S2)의 예열온도는 분위기 온도 180℃ ~ 230℃수준이 될 수 있다. 또한, 성형층제조단계(S2)의 예열시간 20초 ~ 80초가 될 수 있다. 이 때, 제 1성형층(20)은 중간층(10)의 상측에 배치됨에 따라 상측면이 예열될 수 있으나 이에 제한되지 않으며, 필요에 따라 제 1성형층(20)은 상하측면이 모두 예열될 수 있다. 이와 같이 예열되는 제 1성형층(20)은 예열전 펠트상태로 5mm ~10mm의 두께로 형성될 수 있다. 성형층제조단계(S2)에서 예열된 제 1성형층(20)은 압착되어 강성이 발현되며, 1mm ~ 3mm의 두께로 형성될 수 있다.Referring to FIG. 3 , in the shaping layer manufacturing step (S2), the first shaping layer 20 and the second shaping layer 30 may be manufactured by needle punching or sheet extrusion of thermoplastic fibers. At this time, the first shaping layer 20 and the second shaping layer 30 may be formed of glass fibers, glass wool, whiskers, or glass bubbles. The first shaping layer 20 and the second shaping layer 30 may be preheated in an oven or heating press in the shaping layer manufacturing step (S2). In the shaping layer manufacturing step (S2), preheating conditions may be formed to melt the material mixed with the thermoplastic fibers in the first shaping layer 20 and the second shaping layer 30. For example, the preheating temperature in the forming layer manufacturing step (S2) may be at the atmospheric temperature level of 180 ° C to 230 ° C. In addition, the preheating time of the forming layer manufacturing step (S2) may be 20 seconds to 80 seconds. At this time, the upper side of the first shaping layer 20 may be preheated as it is disposed above the middle layer 10, but is not limited thereto, and the first shaping layer 20 may be preheated on both the upper and lower sides as needed. can The first molding layer 20 preheated in this way may be formed to a thickness of 5 mm to 10 mm in a felt state before preheating. The first shaping layer 20 preheated in the shaping layer manufacturing step (S2) is compressed to develop rigidity, and may be formed to a thickness of 1 mm to 3 mm.

반면, 성형층제조단계(S2)에서 제 2성형층(30)은 중간층(10)의 하측에 배치됨에 따라 하측면이 예열될 수 있으나 이에 제한되는 것은 아니며, 제 2성형층(30)은 상하측면이 모두 예열될 수 있다. 제 2성형층(30)은 제 1성형층(20)과 동일한 조건으로 예열공정이 수행될 수 있다. 이와 같이 예열된 제 1성형층(20) 및 제 2성형층(30)은 몰딩프레스(M)로 이송될 수 있다. On the other hand, in the shaping layer manufacturing step (S2), the lower side of the second shaping layer 30 may be preheated as it is disposed below the middle layer 10, but is not limited thereto, and the second shaping layer 30 is top and bottom. Both sides can be preheated. The second shaping layer 30 may be preheated under the same conditions as the first shaping layer 20 . The first shaping layer 20 and the second shaping layer 30 preheated in this way may be transferred to the molding press M.

도 4는 적층성형 내장재 제조단계를 개략적으로 나타낸 도면이다.4 is a view schematically showing a manufacturing step of the laminated interior material.

도 4를 참조하면, 적층성형 내장재 제조단계(S3)에서는 중간층 제조단계(S1)에서 제조된 중간층(10)과 성형층 제조단계(S2)에서 제조된 제 1성형층(20) 및 제 2성형층(30)이 몰딩프레스(M)에 투입될 수 있다. 이때, 몰딩프레스(M)에는 원소재가 순차적으로 장입될 수 있다.Referring to FIG. 4, in the laminated interior material manufacturing step (S3), the intermediate layer 10 manufactured in the intermediate layer manufacturing step (S1), the first molding layer 20 manufactured in the molding layer manufacturing step (S2), and the second molding The layer 30 may be put into the molding press M. At this time, raw materials may be sequentially charged into the molding press M.

도 5는 적층성형 내장재 제조단계(S3)에서 원소재가 장입되는 순서를 나타낸 흐름도이다.5 is a flowchart showing the order in which raw materials are charged in the step of manufacturing interior materials for laminate molding (S3).

도 4 및 5를 참조하면, 적층성형 내장재 제조단계(S3)에서 몰딩프레스(M)에는 하측에 배치되는 W/paper(40)가 장입될 수 있다. W/paper(40)는 PET 섬유로 제조한 부직포 타입의 표면재가 될 수 있다. W/paper(40)는 적층성형 내장재의 성형시 외측에 배치되어 외곽표면을 형성하게 될 수 있다.Referring to FIGS. 4 and 5 , in the step of manufacturing the interior material for laminate molding (S3), the molding press M may be loaded with the W/paper 40 disposed on the lower side. W / paper 40 may be a non-woven fabric type surface material made of PET fibers. The W/paper 40 may be disposed on the outside during molding of the laminated interior material to form an outer surface.

다음으로, 적층성형 내장재 제조단계(S3)에서 몰딩프레스(M)에는 제 2성형층(30)이 장입될 수 있다. 제 2성형층(30)은 성형층제조단계(S2)를 통해 예열된 상태로 장입될 수 있다.Next, the second molding layer 30 may be loaded into the molding press M in the step of manufacturing the interior material for laminate molding (S3). The second shaping layer 30 may be loaded in a preheated state through the shaping layer manufacturing step (S2).

다음으로, 적층성형 내장재 제조단계(S3)에서 몰딩프레스(M)에는 중간층(10)이 장입될 수 있다. 이때, 중간층(10)은 별도의 예열되는 공정 없이 장입될 수 있다.Next, the intermediate layer 10 may be charged into the molding press M in the step of manufacturing the interior material for laminate molding (S3). At this time, the intermediate layer 10 may be charged without a separate preheating process.

다음으로, 적층성형 내장재 제조단계(S3)에서 몰딩프레스(M)에는 제 1성형층(20)이 장입될 수 있다. 제 1성형층(20)은 제 2성형층(30)과 마찬가지로 예열된 상태로 장입될 수 있다.Next, the first molding layer 20 may be loaded into the molding press M in the step of manufacturing the interior material for laminate molding (S3). Like the second shaping layer 30, the first shaping layer 20 may be loaded in a preheated state.

다음으로, 적층성형 내장재 제조단계(S3)에서 몰딩프레스(M)에는 W/paper(40)가 장입될 수 있다. W/paper(40)는 적층성형 내장재 제조단계(S3)에서 제일 처음 장입된 W/paper(40)와 같은 재료로 형성될 수 있다.Next, W/paper 40 may be charged into the molding press M in the laminated molding interior material manufacturing step (S3). The W/paper 40 may be formed of the same material as the W/paper 40 first charged in the laminated molding interior material manufacturing step (S3).

적층성형 내장재 제조단계(S3)에서 이와 같은 순서로 장입된 원소재들은 제 1성형층(20) 및 제 2성형층(30)에 의해 직/간접적으로 중간재(10)가 예열된 후 몰딩프레스(M)에 의해 Press 성형 공정이 진행될 수 있다. 몰딩프레스(M)는 냉간성형 몰딩프레스(M)가 될 수 있다. 몰딩프레스(M)는 100ton ~ 300ton의 압력으로 30초 ~ 60초 간 가압하는 조건으로 성형하게 될 수 있다. 이와 같은 성형과정이 완료된 내장재는 후가공과정을 거쳐 제품으로 완성될 수 있다.In the additive manufacturing interior material manufacturing step (S3), the raw materials charged in this order are directly/indirectly preheated by the first molding layer 20 and the second molding layer 30, and then the molding press ( Press molding process may proceed by M). The molding press (M) may be a cold forming molding press (M). The molding press (M) may be molded under conditions of pressing for 30 seconds to 60 seconds at a pressure of 100 ton to 300 ton. The interior material having completed the molding process may be completed into a product through a post-processing process.

이상 설명한 바, 본 발명의 실시예에 따른 차량 내장재용 경량 복합소재 적용 내장재 및 내장재 제작방법은 발포성형을 통한 S+PP 또는 PE, PET, TPE를 혼합하여 중간재를 형성하여 강도 및 경량화 성능이 우수하고, 성형성 향상, VOC, 냄새제거 등에 우수한 효과가 있는 차량 내장재가 제작되는 활용될 수 있다. As described above, the interior material applied with a lightweight composite material for vehicle interior materials and the method for manufacturing interior materials according to an embodiment of the present invention have excellent strength and lightweight performance by forming an intermediate material by mixing S+PP or PE, PET, and TPE through foam molding. In addition, it can be used to manufacture vehicle interior materials that have excellent effects on moldability improvement, VOC, odor removal, etc.

이상, 본 발명의 실시예들에 대하여 설명하였으나, 해당 기술 분야에서 통상의 지식을 가진 자라면 특허청구범위에 기재된 본 발명의 사상으로부터 벗어나지 않는 범위 내에서, 구성 요소의 부가, 변경, 삭제 또는 추가 등에 의해 본 발명을 다양하게 수정 및 변경시킬 수 있을 것이며, 이 또한 본 발명의 권리범위내에 포함된다고 할 것이다.Although the embodiments of the present invention have been described above, those skilled in the art can add, change, delete, or add components within the scope not departing from the spirit of the present invention described in the claims. The present invention can be variously modified and changed by the like, and this will also be said to be included within the scope of the present invention.

S1 : 중간층 제조단계 S2 : 성형층 제조단계
S3 : 적층성형 내장재 제조단계 10 : 중간층
20 : 제 1성형층 30 : 제 2성형층S1: Intermediate layer manufacturing step S2: Molding layer manufacturing step
S3: Laminate molding interior material manufacturing step 10: Intermediate layer
20: first shaping layer 30: second shaping layer

Claims (6)

Bead 발포제를 스팀성형기를 이용하여 시트인 중간층(10)을 제작하는 중간층 제조단계(S1);
펠트상태의 재료를 오븐 또는 히팅 프레스로 예열하여 제 1성형층(20) 및 제 2성형층(30)을 제조하는 성형층 제조단계(S2);
상기 중간층 제조단계(S1)에서 제조된 중간층(10) 과 상기 성형층 제조단계에서 제조된 제 1성형층(20) 및 제 2성형층(30)을 몰딩프레스(M)에 투입하여 차량 내장재의 형태로 성형하는 적층성형 내장재 제조단계(S3); 를 포함하고
상기 중간층(10)은
비드형태의 SAN(A type)과 비드형태의 PP, PE, PET, TPE(B type) 중 어느 한가지와 혼합되어 발포 foam타입으로 성형되어 오토클레이브, 압출법 중 어느 한가지의 방법을 이용하여 압출 비드의 형태로 형성되고
상기 제 1성형층(20)은
상기 중간층(10)의 상측에 배치되며 열가소성 섬유를 니들펀칭 또는 시트압출 방법으로 제조되고
상기 제 2성형층(30)은
상기 중간층(10)의 하측에 배치되며 열가소성 섬유를 니들펀칭 또는 시트압출 방법으로 제조되는 경량 복합소재 적용 내장재 제작방법.An intermediate layer manufacturing step (S1) of manufacturing an intermediate layer 10, which is a sheet, using a bead foaming agent using a steam molding machine;
A molding layer manufacturing step (S2) of preheating a material in a felt state with an oven or a heating press to manufacture a first molding layer 20 and a second molding layer 30;
The intermediate layer 10 manufactured in the intermediate layer manufacturing step (S1) and the first molding layer 20 and the second molding layer 30 manufactured in the molding layer manufacturing step are put into a molding press M to form a vehicle interior material. Laminate molding interior material manufacturing step (S3) to mold into a shape; and include
The intermediate layer 10 is
It is mixed with bead-type SAN (A type) and any one of bead-type PP, PE, PET, TPE (B type) and molded into a foam type, and extruded beads using either autoclave or extrusion method formed in the form of
The first shaping layer 20 is
It is disposed on the upper side of the intermediate layer 10 and is manufactured by needle punching or sheet extrusion of thermoplastic fibers.
The second shaping layer 30 is
A lightweight composite material applied interior material manufacturing method that is disposed on the lower side of the intermediate layer 10 and manufactured by needle punching or sheet extrusion method of thermoplastic fibers. 20% ~ 50%의 비율의 비트형태의 SAN(A type)과 50% ~ 80% 비율의 비드형태의 PP, PE, PET, TPE(B type) 중 어느 한가지가 혼합되어 컴파운딩된 후 발포성형되어 형성되는 중간층(10);
상기 중간층(10)의 상측에 배치되며 열가소성 섬유를 니들펀칭 또는 시트압출 방법으로 제조되는 제 1성형층(20); 및
상기 중간층(10)의 하측에 배치되며 열가소성 섬유를 니들펀칭 또는 시트압출 방법으로 제조되는 제 2성형층(30); 을 포함하는 경량 복합소재 적용 내장재.20% to 50% of bit-type SAN (A type) and 50% to 80% of bead-type PP, PE, PET, TPE (B type) are mixed and compounded, then foamed An intermediate layer 10 formed by being;
A first molding layer 20 disposed on the upper side of the intermediate layer 10 and manufactured by needle punching or sheet extrusion of thermoplastic fibers; and
a second molding layer 30 disposed below the intermediate layer 10 and manufactured by needle punching or sheet extrusion of thermoplastic fibers; Interior materials applied with lightweight composite materials including 청구항 1에 있어서
상기 성형층 제조단계(S2)는
오븐 또는 히팅프레스에서 상기 제 1성형층(20) 및 제 2성형층(30)의 열가소성섬유 및 혼합재료가 용융되도록 180℃ ~ 230℃의 분위기 온도와 20초 ~ 80초의 시간으로 예열되는 경량 복합소재 적용 내장재 제작방법.in claim 1
The molding layer manufacturing step (S2) is
A lightweight composite that is preheated at an ambient temperature of 180 ° C. to 230 ° C. and a time of 20 seconds to 80 seconds so that the thermoplastic fibers and mixed materials of the first molding layer 20 and the second molding layer 30 are melted in an oven or heating press. Material applied Interior material manufacturing method. 청구항 1에 있어서
상기 적층성형 내장재 제조단계(S3)는
PET 섬유로 제조한 부직포 재질로 형성되는 W/paper(40), 상기 성형층 제조단계(S2)에서 예열된 제2성형층(30), 상기 적층성형 내장재 제조단계(S3)에서 제조된 중간층(10), 상기 성형층 제조단계(S2)에서 예열된 제 1성형층(20), PET 섬유로 제조한 부직포 재질로 형성되는 W/paper(40)의 순서로 적층되어 몰딩프레스(M)로 프레스성형되는 경량 복합소재 적용 내장재 제작방법.in claim 1
The laminated molding interior material manufacturing step (S3)
W / paper 40 formed of a non-woven fabric material made of PET fiber, the second molding layer 30 preheated in the molding layer manufacturing step (S2), and an intermediate layer manufactured in the laminated molding interior material manufacturing step (S3) ( 10), the first shaping layer 20 preheated in the shaping layer manufacturing step (S2), and the W / paper 40 formed of a non-woven fabric material made of PET fiber are stacked in order and pressed with a molding press (M) Method of manufacturing interior materials applied with lightweight composite materials to be molded. 청구항 2에 있어서
상기 제 1성형층(20) 및 제 2성형층(30)은 유리섬유, 유리울, 휘스커 또는 유리버블의 재질로 형성되는 경량 복합소재 적용 내장재.in claim 2
The first shaping layer 20 and the second shaping layer 30 are made of a material of glass fiber, glass wool, whisker or glass bubble. 청구항 2에 있어서
상기 중간층(10)은
전부 또는 일부가 열가소성 수지의 특성으로 발포폼으로 형태로 형성되고 10.0mm 내지 20.0mm의 두께로 형성되며 600 kg/m3 내지 1200 kg/m3 의 밀도로 형성되는 경량 복합소재 적용 내장재.in claim 2
The intermediate layer 10 is
A lightweight composite material application interior material that is formed in whole or in part as a foam with the characteristics of a thermoplastic resin, is formed in a thickness of 10.0 mm to 20.0 mm, and is formed with a density of 600 kg/m 3 to 1200 kg/m 3 .
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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2001293741A (en) * 2000-04-13 2001-10-23 Kasai Kogyo Co Ltd Method for molding beads foamed molded object and mold for molding beads
KR20170014074A (en) * 2015-07-28 2017-02-08 주식회사 세운 Method for manufacturing under cover for vehicle using glass fibrous reinforcing sheet
JP2017056730A (en) * 2015-09-15 2017-03-23 現代自動車株式会社Ｈｙｕｎｄａｉ Ｍｏｔｏｒ Ｃｏｍｐａｎｙ Method for producing molding capable of density adjustment and molding produced by the production method
KR20180047882A (en) * 2016-11-01 2018-05-10 원풍물산주식회사 Single vehicle interior materials and methods for their preparation
KR102249855B1 (en) * 2019-10-29 2021-05-11 주식회사 서연이화 Lightweight composite material for automotive interior

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2001293741A (en) * 2000-04-13 2001-10-23 Kasai Kogyo Co Ltd Method for molding beads foamed molded object and mold for molding beads
KR20170014074A (en) * 2015-07-28 2017-02-08 주식회사 세운 Method for manufacturing under cover for vehicle using glass fibrous reinforcing sheet
JP2017056730A (en) * 2015-09-15 2017-03-23 現代自動車株式会社Ｈｙｕｎｄａｉ Ｍｏｔｏｒ Ｃｏｍｐａｎｙ Method for producing molding capable of density adjustment and molding produced by the production method
KR20180047882A (en) * 2016-11-01 2018-05-10 원풍물산주식회사 Single vehicle interior materials and methods for their preparation
KR102249855B1 (en) * 2019-10-29 2021-05-11 주식회사 서연이화 Lightweight composite material for automotive interior

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