KR102661761B1 - High-strength luggage board for vehicle and its manufacturing method - Google Patents

Abstract

The disclosed content relates to a high-strength luggage board for a vehicle capable of reducing weight and increasing rigidity by forming a lightweight core layer with a lightweight material and applying urethane prepolymer instead of semi-rigid urethane foam, which was conventionally used as a foam adhesive layer, and a method of manufacturing the same.
This high-strength luggage board for vehicles includes a lightweight core layer, first and second glass mat layers laminated on the upper and lower surfaces of the lightweight core layer, and foam provided between the lightweight core layer and the first and second glass mat layers, respectively. It includes an adhesive layer, and the foam adhesive layer is formed by a roll coater.

Description

High-strength luggage board for vehicles and manufacturing method thereof {HIGH-STRENGTH LUGGAGE BOARD FOR VEHICLE AND ITS MANUFACTURING METHOD}

The content disclosed in this specification relates to a high-strength luggage board for a vehicle with increased rigidity and a method of manufacturing the same.

Unless otherwise indicated herein, the material described in this section is not prior art to the claims of this application, and is not admitted to be prior art by inclusion in this section.

Generally, a storage space and an auxiliary space of a certain size are provided in the trunk room of a vehicle, and the storage space and the auxiliary space are separated by a luggage board. These luggage boards must be manufactured with parts that can withstand strong loads to enable loading of heavy loads in the trunk room of a vehicle.

Recently, due to the demand for lightweight and rigidity of vehicle luggage boards, paper honeycomb material made of paper that is lighter than metal or synthetic resin has been used as an intermediate substrate. The paper honeycomb material and the glass mat layer can be bonded by foaming and curing urethane, but when spraying urethane solution over a large area, there is a problem in that the rigidity is reduced due to partial application of urethane reactivity and deviation.

Republic of Korea Patent No. 10-1988340 (2019.06.05)

The aim is to provide a high-strength luggage board for vehicles that can increase rigidity while reducing weight, and a manufacturing method thereof.

In addition, it is not limited to the technical challenges described above, and it is obvious that other technical challenges may be derived from the description below.

According to one embodiment of the disclosed content, a high-strength luggage board for a vehicle includes a lightweight core layer, first and second glass mat layers laminated on the upper and lower surfaces of the lightweight core layer, the lightweight core layer, and the first and second glass mat layers. It includes a foam adhesive layer provided between each glass mat layer, and the foam adhesive layer is formed by a roll coater.

Additionally, the lightweight core layer may include one or more selected from paper honeycomb, expanded polypropylene, and expanded polystyrene.

Additionally, the weight of the first and second glass mat layers may be 100 to 900 g/m2.

In addition, the foam adhesive layer contains 10 to 30% by weight of at least one polyol selected from polypropylene glycol, polytetramethylene glycol, polycarbonate polyol, polybutadiene polyol, and acrylic polyol, and one selected from toluene diisocyanate and methylene diphenyl diisocyanate. It may consist of 70 to 90% by weight of isocyanate.

In addition, the foam adhesive layer may have a viscosity of 1500 to 2800 cps at room temperature, a curing time of 30 to 60 seconds, and a solid content of 95% by weight or more.

In addition, it may further include a surface layer provided on the upper surface of the first glass mat layer.

According to another embodiment of the disclosed content, a method of manufacturing a high-strength luggage board for a vehicle includes (a) preparing a lightweight core layer made of at least one selected from paper honeycomb, expanded polypropylene, and expanded polystyrene, (b) the lightweight core layer forming a foamed adhesive layer by applying a urethane prepolymer to the upper and lower surfaces of the core layer using a roll coater and then spraying water, and (c) applying first and second layers to the upper and lower parts of the lightweight core layer on which the foamed adhesive layer is formed, respectively. It includes the step of laminating two glass mat layers and then hot forming them.

According to another embodiment of the disclosed content, a method of manufacturing a high-strength luggage board for a vehicle includes the steps of (a) preparing a lightweight core layer made of at least one selected from paper honeycomb, expanded polypropylene, and expanded polystyrene, (b) the above Positioning the first and second glass mat layers on the upper and lower surfaces of the lightweight core layer, (c) applying urethane prepolymer to both sides of the lightweight core layer or the first and second glass mat layers using a roll coater. It includes the step of forming a foam adhesive layer by spraying water, and (d) hot forming the first and second glass mat layers by pressing them.

According to an embodiment disclosed in the present specification, a high-strength luggage board for a vehicle and a method of manufacturing the same form a lightweight core layer with a lightweight material and apply urethane prepolymer instead of semi-rigid urethane foam, which was conventionally used as a foam adhesive layer, to achieve weight reduction and rigidity. There is an effect that can be increased.

In addition, by forming a foam adhesive layer using a roll coater, the urethane prepolymer can be applied more uniformly, thereby improving partial density and weight variation and improving load-bearing rigidity.

1 and 2 are cross-sectional views showing a high-strength luggage board for a vehicle according to an embodiment of the content disclosed in this specification.
3 and 4 are schematic diagrams for explaining a method of manufacturing a high-strength luggage board for a vehicle according to another embodiment of the disclosure disclosed herein.
Figure 5 is a process diagram for explaining a method of manufacturing a high-strength luggage board for a vehicle according to another embodiment of the content disclosed in this specification.
Figure 6 is a process diagram for explaining a method of manufacturing a high-strength luggage board for a vehicle according to another embodiment of the content disclosed in this specification.

Hereinafter, the configuration and operational effects of preferred embodiments of the disclosed content will be examined with reference to the attached drawings. For reference, in the drawings below, each component is omitted or schematically shown for convenience and clarity, and the size of each component does not reflect the actual size. In addition, the same reference numerals refer to the same components throughout the specification, and reference numerals for the same components in individual drawings will be omitted.

The high-strength luggage board for vehicles and its manufacturing method disclosed in this specification apply a prepolymer one-component solution using a roll coater method instead of the existing method of spraying a two-component solution of polyol and isocyanate as a urethane foaming material, resulting in a time difference during the application process. The problem of reactivity deviation that occurred has been resolved. Therefore, uniform application of the urethane prepolymer is possible, thereby further increasing the load-bearing rigidity.

Hereinafter, the high-strength luggage board for vehicles disclosed in this specification will be described in detail with reference to the drawings.

1 and 2 are cross-sectional views showing a high-strength luggage board for a vehicle according to an embodiment of the content disclosed in this specification.

Referring to Figures 1 and 2, the high-strength luggage board 100 for a vehicle includes a lightweight core layer 10, first and second glass mat layers 31 and 32, and a foam adhesive layer 20. In addition, it further includes a surface layer 40 provided on the upper surface of the first glass mat layer 31.

The lightweight core layer 10 includes at least one selected from paper honeycomb, expanded polypropylene, and expanded polystyrene, preferably paper honeycomb, has a weight of 400 to 2000 g/m2, and may be formed to a thickness of 10 to 30 mm. It is not limited. If the thickness is less than 10 mm, the load-bearing rigidity may be weak, and if it exceeds 30 mm, the thickness of the final product may be thicker than necessary and the weight may increase, which is undesirable.

Meanwhile, the cell size of the paper honeycomb may be 8 to 12 mm, and the expansion ratio of the expanded polypropylene and the expanded polystyrene may be 15 to 45 times. Therefore, it can contribute to reducing the weight of the final product.

The first and second glass mat layers 31 and 32 are laminated on the upper and lower surfaces of the lightweight core layer 10, and the weights of the first and second glass mat layers 31 and 32 are the same or different from each other. can be formed. Meanwhile, the first and second glass mat layers 31 and 32 may be formed of a plurality of layers, and the weight of the first and second glass mat layers 31 and 32 may be 100 to 900 g/m2.

The foam adhesive layer 20 is provided between the lightweight core layer 10 and the first and second glass mat layers 31 and 32, respectively, and may be formed using a roll coater. The foam adhesive layer 20 is made of urethane prepolymer material, and specifically, polypropylene glycol, polytetramethylene glycol, polycarbonate polyol, polybutadiene polyol, and acrylic polyol ( It may be composed of 10 to 30% by weight of one or more polyols selected from acryl polyol and 70 to 90% by weight of one or more isocyanates selected from toluene diisocyanate and methylene diphenyl diisocyanate. This foam adhesive layer 20 can satisfy a viscosity of 1500 to 2800 cps, a curing time of 30 to 60 seconds, and a solid content of 95% by weight or more under room temperature (25°C) conditions.

The surface layer 40 is provided on the upper surface of the first glass mat layer 31 to protect the first glass mat layer 31 and simultaneously perform an interior function inside the vehicle. It may be formed of felt, but may be made of felt. There are no significant restrictions on its use.

Hereinafter, the manufacturing method of the high-strength luggage board for vehicles disclosed in this specification will be described in detail according to the drawings.

Figures 3 and 4 are schematic diagrams for explaining a method of manufacturing a high-strength luggage board for a vehicle according to another embodiment of the content disclosed herein, and Figure 5 is a high-strength luggage board for a vehicle according to another embodiment of the content disclosed herein. This is a process chart to explain the board manufacturing method.

Referring to Figures 3 to 5, first, prepare a lightweight core layer (S10).

As the lightweight core layer 10, one or more materials selected from paper honeycomb, expanded polypropylene, and expanded polystyrene may be used. Since the paper honeycomb, expanded polypropylene, and expanded polystyrene have been described in detail above, they will be omitted.

After applying urethane prepolymer to the upper and lower surfaces of the lightweight core layer 10 using a roll coater (100, 100'), water is sprayed to form a foamed adhesive layer (20) (S20).

After applying urethane prepolymer to the upper and lower surfaces of the lightweight core layer 10 prepared in step S10 using a roll coater (100, 100') consisting of two or more rolls, water is sprayed to cure the urethane prepolymer, forming a foam adhesive layer (20). ) can be formed, and it is best to perform this in a clean room (200) to prevent foreign substances from adhering to the surface of the wet urethane prepolymer. For example, it is preferable to apply water by spraying, but if other methods are used, it may be difficult to precisely control the amount of water, making it difficult for the urethane prepolymer to cure evenly.

Meanwhile, it is preferable that the amount of water sprayed is 5 to 100 g/m2. This means that if the amount of water sprayed is less than 5 g/m2, not only will it be difficult for the urethane prepolymer to cure evenly, but the time it takes for it to cure may be long. If it exceeds ㎡, the effect of using it more than necessary may not be that great.

In this embodiment, by applying the roll coater (100, 100') method, uniform application of urethane prepolymer is possible and partial reaction deviation does not occur, which can contribute to increasing rigidity. These roll coaters (100, 100') are composed of two or more rolls, and the lightweight core layer 10 passes between two of the rolls, so that urethane prepolymer can be applied on the lightweight core layer 10.

For example, referring to FIG. 3, the roll coater 100 rotates in the same direction and includes a coating roll 110 and a backup roll 120 that transfer the urethane prepolymer to the upper and lower surfaces of the lightweight core layer 10, the coating It consists of a metalling roll 130 provided at a predetermined distance from the roll 110, and a liquid tank 140 provided with a urethane prepolymer on which the coating roll 110 and the metalling roll 130 are supported, and the coating roll The thickness of the urethane prepolymer may be determined by the interval or speed between (110) and the metalling roll (130). Of course, the distance or speed between the coating roll 110 and the metalling roll 130 can be adjusted as needed.

As another example, referring to FIG. 4, the roll coater 100' rotates in different directions and includes a coating roll 110' and a backup roll 120' that transfer urethane prepolymer to the upper and lower surfaces of the lightweight core layer 10. ) and a chamber 140' for supplying the urethane prepolymer to the coating roll 110'. By supplying the urethane prepolymer from the chamber 140', urethane prepolymer odor emission or viscosity change can be reduced.

In this embodiment, any one of the above-mentioned roll coaters (100, 100') can be adopted and applied depending on the viscosity or desired thickness of the urethane prepolymer.

The first and second glass mat layers 31 and 32 are laminated on the upper and lower parts of the lightweight core layer 10 on which the foam adhesive layer 20 is formed, respectively, and then hot formed (S30).

In this embodiment, hot forming is performed in a hot press forming mold 300, and can be performed at a pressure of 2 to 4 bar at a temperature of 100 to 200 ℃. This means that if the temperature is less than 100 ℃, spraying at the previous stage Not only does the water remain on the foam adhesive layer, it may be difficult for adhesion and molding to occur properly. If the temperature exceeds 200°C, the viscosity of the foam adhesive layer decreases, resulting in an unclean finish at the ends and changes in the physical properties of the substrate, which is not desirable. .

Figure 6 is a process diagram for explaining a method of manufacturing a high-strength luggage board for a vehicle according to another embodiment of the content disclosed in this specification.

Referring to FIG. 6, preparing a lightweight core layer 10 made of one or more selected from paper honeycomb, expanded polypropylene, and expanded polystyrene (S110), a first layer is applied to the upper and lower surfaces of the lightweight core layer 10. and positioning the second glass mat layers 31 and 32 (S120), using roll coaters 100 and 100' on both sides of the lightweight core layer 10 or the first and second glass mat layers 31 and 32. A step of applying a urethane prepolymer and then spraying water to form a foamed adhesive layer 20 (S130) and a step of hot forming by pressing the first and second glass mat layers 31 and 32 (S140). It can be implemented.

In this embodiment, the roll of the roll coater passes between the lightweight core layer 10 and the first or second glass mat layers 31 and 32, so that the urethane prepolymer is applied to the lightweight core layer 10 as well as the first or second glass mat layer. It can also be applied to the mat layers 31 and 32 simultaneously.

<Examples 1 to 2, Comparative Example 1>

It was prepared using the ingredients and weights listed in Table 1 below. First, a lightweight core layer was prepared, and a foam adhesive layer was formed on the lightweight core layer using a roll coater. Then, the first and second glass mat layers were laminated and hot formed at 150 to 160° C. to manufacture a luggage board having the structure of Figure 1.

division Example 1 Example 2 Comparative Example 1 Luggage board material (g/m ² ) 1st glass mat layer 600 600 600 foam adhesive layer 600 765 900 Lightweight core layer 900 900 900 foam adhesive layer 600 765 900 Second glass mat layer 450 600 450 Weight (g/m ² ) 3,150 3,630 3,750 Thickness (mm) 18 18 18

Experimental Example 1. Stiffness evaluation

In order to confirm the rigidity of the luggage board according to the examples, the load bearing rigidity was measured as follows.

First, a specimen was prepared with a size of 1000

division Example 1 Example 2 Comparative Example 1 Maximum load (mm) 17.2 14.6 18.2 1 hour after load removal (mm) 1.8 1.4 3.8

Referring to Table 2, it was confirmed that Examples 1 and 2 had significantly higher load-bearing rigidity compared to Comparative Example 1.

The disclosed content is merely an example, and may be modified and implemented in various ways by those skilled in the art without departing from the gist of the claims, so the scope of protection of the disclosed content is limited to the specific scope described above. It is not limited to the examples.

1: High-strength luggage board for vehicles 10: Lightweight core layer
20: Foam adhesive layer 31, 32: First and second glass mat layers
40: Surface layer 100, 100': Roll coater
100, 100': Coating roll 120, 120': Backup roll
130: metal ring roll 140: liquid tank
140': Chamber 200: Clean room
300: Hot press forming mold machine

Claims (8)

A lightweight core layer made of paper honeycomb with a weight of 400 to 2,000 g/m2 and a thickness of 10 to 30 mm;
First and second glass mat layers laminated on the upper and lower surfaces of the lightweight core layer; and
It includes a foam adhesive layer provided between the lightweight core layer and the first and second glass mat layers, respectively,
The foam adhesive layer is formed by a roll coater,
The foam adhesive layer has a viscosity of 1500 to 2800 cps at room temperature, a curing time of 30 to 60 seconds, and a solid content of 95% by weight or more,
The foam adhesive layer is,
Consisting of 10 to 30% by weight of at least one polyol selected from polycarbonate polyol or acrylic polyol and 70 to 90% by weight of methylene diphenyl diisocyanate,
High-strength luggage board for vehicles.
delete According to paragraph 1,
A high-strength luggage board for vehicles in which the first and second glass mat layers have a weight of 100 to 900 g/m2.
delete delete According to paragraph 1,
A high-strength luggage board for a vehicle further comprising a surface layer provided on an upper surface of the first glass mat layer.
(a) preparing a lightweight core layer made of paper honeycomb with a weight of 400 to 2,000 g/m2 and a thickness of 10 to 30 mm;
(b) applying urethane prepolymer to the upper and lower surfaces of the lightweight core layer using a roll coater and then spraying water to form a foam adhesive layer; and
(c) laminating first and second glass mat layers on the upper and lower parts of the lightweight core layer on which the foam adhesive layer is formed, and then hot forming them,
The foam adhesive layer has a viscosity of 1500 to 2800 cps at room temperature, a curing time of 30 to 60 seconds, and a solid content of 95% by weight or more,
The foam adhesive layer is,
Consisting of 10 to 30% by weight of at least one polyol selected from polycarbonate polyol or acrylic polyol and 70 to 90% by weight of methylene diphenyl diisocyanate,
Manufacturing method of high-strength luggage board for vehicles.
(a) preparing a lightweight core layer made of paper honeycomb with a weight of 400 to 2,000 g/m2 and a thickness of 10 to 30 mm;
(b) positioning first and second glass mat layers on the upper and lower surfaces of the lightweight core layer;
(c) applying urethane prepolymer to both sides of the lightweight core layer or the first and second glass mat layers using a roll coater and then spraying water to form a foam adhesive layer; and
(d) hot forming the first and second glass mat layers by pressing them,
The foam adhesive layer has a viscosity of 1500 to 2800 cps at room temperature, a curing time of 30 to 60 seconds, and a solid content of 95% by weight or more,
The foam adhesive layer is,
Consisting of 10 to 30% by weight of at least one polyol selected from polycarbonate polyol or acrylic polyol and 70 to 90% by weight of methylene diphenyl diisocyanate,
Manufacturing method of high-strength luggage board for vehicles.