KR20010070896A - Nonwoven Composite for Automotive Top Ceiling - Google Patents

Abstract

PURPOSE: A process for preparing a base material for molding interior materials of an automobile by continuously supplying needled surface material to thermoplastic base material obtained through a needle process and physically binding the two material by a needle punching process is provided, which has an effect on reducing weight, production cost and molding defective. CONSTITUTION: In manufacturing an integrated base material(100) of an inner part of an automobile, a needled surface material(20) is continuously supplied to thermoplastic base material(10) obtained through a needle process and the two material is physically bound through a needle punching process and heat-set at 170 to 250deg.C.

Description

Manufacturing method of integral molding material for automobile interiors {Nonwoven Composite for Automotive Top Ceiling}

The present invention relates to a molding material for automobiles, and more particularly, to shorten the molding time by molding the skin and the base material of the molding material used for automotive ceilings, bonnet hoods, door trims, drunks, floor mats without adhesives at once. The present invention relates to a manufacturing method of an integrally molded molding material for automobile interior materials.

In general, a variety of materials are used as the automobile molding material.

For example, paper as a base material, paper board reinforced with polyethylene sheet, aluminum foil, resin felt impregnated with thermosetting resin such as phenol resin in sandpaper felt, glass felt impregnated with thermosetting resin in glass wool, polypropylene Glass composite felt mixed with Pelen fiber and glass fiber, Panel made of styrene resin, Felt mixed with natural materials such as polypropylene fiber and hemp, Polyester felt mixed with low melting point polyester and high melting point polyester, Glass mat And a panel obtained by joining a thermoplastic polyurethane resin are used.

Among the above types, paper board and resin felts are gradually decreasing in use due to workability and environmental problems. Instead, the use of glass composite felt and thermoplastic polyurethane resin panels is increasing.

Recently, new materials that can be recycled have been developed in relation to environmental regulations of developed countries, and are interested in polyester felt and styrene resin panels, and mixed felt of polypropylene fiber and hemp.

1 is a cross-sectional view of a conventional molding material widely used.

Conventionally used molding materials have a form in which the skin 3 is attached to the upper surface of various kinds of substrates 1 with an adhesive 2.

The conventional molding substrate is a variety of the skin material (3) with a variety of base material (1), polyvinyl chloride resin, woven fabric, knitted fabric, nonwoven fabric and the like are widely used. As for the skin material (3), the use of polyvinyl chloride resins has been reduced in connection with environmental regulations, and instead modified polyethylene materials have been developed, and the use of knitted fabrics and nonwoven fabrics is gradually increasing.

With the development of materials, the molding technology is also developing together. The hot forming method used for resin felt has a large heat loss, requires many workers, and requires a lot of equipment investment. Forming methods using the system are increasing. When using the preheating system and cold forming, the preheating system can be commonly used in a variety of products, the cold forming has the advantage of free replacement of the molding machine and no deformation of the molding after molding.

In addition, the preheating system and the molding operation can be automated, which reduces the number of workers.

Molding using self-heating curing systems also has similar advantages.

Simplification of these facilities can be expected to reduce molding manufacturing costs.

The weight of the automobile material has an important effect on the fuel efficiency of the vehicle, most of the materials currently used as molding materials have a weight of 800 ~ 2500g / ㎡.

In order to reduce the weight of the material, materials such as glass material and hemp having high strength are widely used, and the substrate using such material has a weight of 800 to 1300 g / m 2.

In this way, the molding material should be recyclable, the molding operation should be easy, simple and light.

Until recently, the automotive industry has grown very fast in terms of quantity. Given the global trend, development cost through mass production, cost reduction through modularization, and the like will play an important role in the future automobile industry.

In addition, environmental regulations are considered to be important. Recyclability and fuel economy are the most urgent issues.

The present invention has been made in order to solve such a conventional problem, the interior material by bonding the substrate and the skin material by physical bonding rather than the conventional thermal bonding method or chemical bonding method or giving the appearance of the skin material to the substrate at the same time The manufacturing method of the automobile interior material-integrated molding material that enables production in a batch process, thereby reducing raw materials and reducing weight, simplifying equipment during molding operation, and at the same time, recycling materials by unifying materials of base materials and skin materials. To provide.

The above object is achieved by continuously supplying a skin material needled to a thermoplastic material obtained through a needle punching process, and physically bonding the two materials through a needle punching process in manufacturing an automobile interior material. .

1 is a cross-sectional view of a conventional molding material,

2 is a cross-sectional view of a molding substrate according to the present invention;

(a) represents the physical bonding method,

(b) is the color binder to finish the appearance on the substrate,

(c) is a state in which the color fibers are mixed and completed in the production of the substrate,

3 is a cross-sectional view of the manufacturing process of the molding substrate according to the present invention.

<Explanation of symbols for main parts of drawing>

10; Base 20; Skin

30; Fibrous layer 40; Needle punching machine

50; Sheet 100; Integrated Type

110; Hot air circulation dryer 120; Molding Equipment

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

Figure 2 shows a molding substrate according to the present invention in a cross-sectional view, (a) shows a physical bonding method, (b) shows a form of completing the appearance on the substrate with a color binder, (c) is a color fiber Indicates a state of mixing to complete the substrate production. 3 is a cross-sectional view illustrating a manufacturing process of the molding substrate according to the present invention.

As shown in Figure 2 and 3, the manufacturing method of the automotive interior material-integrated molded substrate of the present invention is largely the process of physically bonding the base material 10 and the skin material 20 during the automobile interior material manufacturing, and the substrate 10 It imparts to the appearance of the skin material 20 to the.

The substrate 10 is mixed with 20 to 95% of a thermoplastic fiber material having a melting temperature of 80 to 180 ° C and 5 to 80% of a fiber material having a melting temperature of 200 ° C to 260 ° C to suit molding conditions.

The mixed fiber layer 30 is bound to each other through the needling process in the needle punching machine 40 to have a form on a sheet (50). Here, the needle punching condition has a very important influence on the strength of the substrate, and the needle punching process is essential to prevent the peeling of the laminated web. If the needle punching process is not performed, peeling may occur at a wide space between the edge of the substrate and the mold after molding.

In general, a suitable punching density is 100-1000 st / cm 2, and a penetration depth (needle) of the needle is appropriately 3-12 mm. 750-1350g / m <2> is suitable for the weight of a base material, and thickness is 5-15 mm.

The skin material 20 is manufactured using a colored fiber material and also has a sheet-like form by a needle punching process. The needle punching condition is suitable for 200 ~ 700st / ㎠, the penetration depth of the needle is suitable 3 ~ 12mm. As for the weight of the skin material 20, 130-350 g / m <2> is suitable and the thickness becomes 1-3.5 mm.

The bonding process of the base material 10 and the skin material 20 can be performed separately, but in the last needle punching step of the process of producing the base material 10 to simplify the process. At this time, the punching density is 20 ~ 200st / ㎠, the penetration depth of the needle is suitable 0.5 ~ 5mm in consideration of the thickness of the skin material. If the depth of penetration of the needle is deep, the appearance of the skin is worsened. If the depth of the needle is shallow, the bond between the substrate and the skin is weakened and peeling may occur after the molding process. And since the base material 10 and the skin material 20 are bonded by a physical method, there is no peeling phenomenon between the two materials due to poor adhesion during molding, and the weight is reduced by using a separate adhesive layer, and the cost is reduced. Can be.

In order to impart the appearance of the skin 20 to the substrate 10, there is a method of mixing and coating a pigment and a binder on the surface of the substrate 20 as shown in FIG. 2B. Acrylic binders may be mainly used, but in some cases, polyvinylacetate (EVA) and polyester (PET) -based binders may be added, and the coating amount of the binder is 5 to 50 g / m 2. .

Here, the coating method may be a coating method using a spray and a coating using a foam.

As another method of imparting the appearance of the skin material 20 to the base material 10, 10 to 80% of the colored fiber material may be mixed as shown in FIG. 2C. In this case, the fiber material may be mixed with the substrate 10 uniformly or non-uniformly to provide an effect of obtaining various appearances. For example, it is possible to increase the number of colored fibers on the surface of the entire substrate, or to use a mixture of evenly colored fibers as a whole.

It is also possible to distribute the fibers with different colors in several layers. This prevents uneven mixing of the fibers and gives a luxurious appearance.

The skin material integrated substrate 100 thus manufactured is subjected to a heat setting process in the hot air circulation dryer 110 in order to be easily handled in the molding process. Far infrared heaters, hot air circulators, and hot plate presses may be used for heat setting. 170-250 degreeC is suitable for temperature. The dual hot air circulator allows for continuous operation and reduces the time required for hot setting.

Since a simple preheating process and cold forming machine can be easily produced for the automotive molding material 120.

As described above, the skin material integrated substrate prepared in accordance with the present invention can produce the skin material and the substrate, which were previously produced and combined by hand during the molding process, at a time, thereby saving manpower and time required during the molding work. In addition, the adhesive is not used separately, thereby reducing the weight and cost. In addition, since the thermoplastic material is used as the material of the substrate, it shows excellent moldability and can significantly reduce molding defects that may occur in existing materials. In addition, the use of the same fibrous material between the skin and the substrate is provided with the effect that it is possible to recycle.

Claims (7)

In manufacturing automotive interior materials, A method of manufacturing an integrated interior molding material for automobiles, characterized in that the needle material is continuously supplied to the thermoplastic material obtained through the needle punching process, and the two materials are physically combined through the needle punching process. The method of claim 1, The thermoplastic base material is a method for manufacturing a vehicle interior molded molding material, characterized in that made of a uniform or non-uniform mixing of the colored fiber material. The method of claim 1, The method of manufacturing an interior molding material for automobile interior molding material, characterized in that the surface of the thermoplastic substrate obtained through the needle punching process is made by coating a colored binder. The method of claim 1, A method of manufacturing a vehicle interior integrally molded substrate further comprising the step of physically combining the two materials, the needled thermoplastic material and the needled skin material, through a needle punching process and heat setting at 170 to 250 ° C. The method according to claim 1, 20 to 95% of the thermoplastic fiber material having a melting temperature of 80 to 180 ℃ mixed with 5 to 80% of the fiber material having a melting temperature of 200 ~ 270 ℃ or more and characterized in that the needle punching process to combine with each other Manufacturing method of integral molding material for automobile interior. The method according to claim 1, The above-mentioned fiber material is applied to the base material and the skin material in the same way, the manufacturing method of the interior material-integrated molding material for automobiles, characterized in that recycling is possible. The method according to claim 2, In the process of uniformly mixing the fiber material, the manufacturing method of the automobile interior material-integrated molding material, characterized in that to obtain a uniform appearance by distributing fibers of different colors in multiple layers.