KR20040088434A - Manufacturing method of headliner for automobils - Google Patents
Manufacturing method of headliner for automobils Download PDFInfo
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- KR20040088434A KR20040088434A KR1020040074428A KR20040074428A KR20040088434A KR 20040088434 A KR20040088434 A KR 20040088434A KR 1020040074428 A KR1020040074428 A KR 1020040074428A KR 20040074428 A KR20040074428 A KR 20040074428A KR 20040088434 A KR20040088434 A KR 20040088434A
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- 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
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/0036—Heat treatment
- B32B38/004—Heat treatment by physically contacting the layers, e.g. by the use of heated platens or rollers
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- 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
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- 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
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- 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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- 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
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0276—Polyester fibres
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- 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
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0278—Polyurethane
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- 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
- B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
- B32B2309/02—Temperature
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- 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
- B32B2605/00—Vehicles
- B32B2605/003—Interior finishings
Landscapes
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
Abstract
Description
본 발명은 자동차용 천장재의 제조방법에 관한 것이다. 자동차 실내의 천장이나 도어 내측면, 바닥면 앞 뒤좌석의 선반 등 자동차 실내의 여러부위에는 다양한 내장재가 사용되고 있다. 자동차용 내장재는 사용자에게 미려함과 안락감을 주므로서 고급스러움과 편안함을 제공하고 외부소음으로 부터의 방음, 외부열로 부터의 단열 및 흡음성을 구비하면서 무게가 가볍고 성형이 용이하며 신차(新車)에서 나타나는 나쁜냄새(異臭)의 발산이 없는 것이 요구된다. 특히 천장재는 장시간 사용하더라도 밑으로 늘어지는 변형이 일어나지 않을 정도의 강도가 요구된다.The present invention relates to a method of manufacturing a ceiling material for automobiles. Various interior materials are used in various parts of the car interior, such as the ceiling of the car interior, the inner surface of the door, and the shelves of the front and rear seats. Automotive interior materials provide luxury and comfort by giving the user a beautiful and comfortable, soundproof from external noise, heat insulation and sound absorption from external heat, light weight, easy to mold and appear in new cars. It is required that there is no emission of bad smell. In particular, the ceiling material is required to the strength that the deformation does not occur down even if used for a long time.
종래 자동차용 내장재로 다양한 종류의 판재들이 이미 사용되고 있다.Various kinds of plate materials are already used as interior materials for automobiles.
예를들면 합성섬유, 마섬유 및 면섬유 등 혼합섬유로 된 판재에 분말상의 페놀수지를 분사 도포한 후 가열 압착시켜 판재로 형성시킨 것이 있으나 이는 페놀수지를 사용하므로서 페놀수지 특유의 이취가 발산된다는 문제가 있다.For example, powdered phenolic resin was spray-coated to a plate made of mixed fiber such as synthetic fiber, hemp fiber and cotton fiber, and then pressed to form a plate by heat compression. However, phenolic resin gives off odors peculiar to phenolic resin. There is.
또한 펄프(pulp)에 액상의 합성수지를 침지시키고 그 양면에 판지(板紙)나 골판지를 붙인 판재가 있으나 이는 복원력(復原力)이 약하고 수분을 쉽게 흡수하여 변형되기 쉽고 자동차 소음에 대한 흡음성이 떨어진다는 문제가 있다.In addition, there is a plate material in which pulp is immersed in a liquid synthetic resin, and cardboard or corrugated paper is attached to both sides thereof, but it has a weak restoring force, absorbs moisture easily, deforms easily, and absorbs sound from cars. there is a problem.
그밖에도 탈취 및 항균 합성 섬유사 40~60중량%와 저융점 화학섬유사 40~60중량%를 혼합하여 이루어진 경질(硬質)의 혼성부직포를 폴리우레탄폼(polyurethane foam) 양면에 접착제로 접착, 적층시키거나, 탈취 및 항균합성 섬유사 40~60중량%와 저융점 합성섬유사 40~60중량%를 혼합하여 이루어진 혼성부직포를 판상으로 성형하여서된 것이 있다.(대한민국 등록실용신안공보 등록번호 20-0266929호)In addition, the adhesive is laminated and bonded on both sides of polyurethane foam with a hard mixed nonwoven fabric made by mixing 40 to 60% by weight of deodorizing and antibacterial synthetic fiber yarn and 40 to 60% by weight of low melting point chemical fiber yarn. Or by forming a hybrid nonwoven fabric formed by mixing 40 ~ 60% by weight of deodorizing and antimicrobial synthetic fiber yarn and 40 ~ 60% by weight of low melting point synthetic fiber yarn. (Korea Registered Utility Model Publication No. 20- 0266929)
폴리우레탄폼 양면에 각각 유리섬유 직포와 부직포를 접착제로 접착, 다층으로 적층시켜서 된 것도 있다.In some cases, a glass fiber woven fabric and a nonwoven fabric are bonded to both sides of a polyurethane foam with an adhesive and laminated in multiple layers.
폴리우레탄폼을 기본소재로하는 것은 경량성은 확보되나 강도와 성형성이 미흡하기 때문에 여기에 합성섬유나 유리섬유로 된 직포나 부직포를 접착제로 접착시켜 강도와 성형성을 유지하고 있다.Polyurethane foam as a base material is secured, but the strength and formability is insufficient, and the woven or nonwoven fabric made of synthetic fibers or glass fibers is bonded to the adhesive to maintain the strength and formability.
폴리우레탄폼을 사용하지 않고 합성섬유만으로 된 부직포로 제조된 것은 경량성과 단열 및 방음성은 확보할 수 있으나 내열성이 약하고 중량이 무겁다는 문제가 있고 폴리우레탄폼에 유리섬유나 부직포를 접착제로 접착, 적층시켜서 된 내장재는 제조공정이 복잡하고 제조비용이 높아질 뿐아니라 액상의 합성수지제 접착제를 사용하기 때문에 내장재의 무게증가와 함께 상기 접착제가 완전히 건조될 때 까지 지속적으로 나쁜냄새를 발산한다는 문제가 따른다.The non-woven fabric made of synthetic fibers without using polyurethane foam can secure light weight, insulation and sound insulation, but has a problem of weak heat resistance and heavy weight.Adhesion and lamination of glass fiber or nonwoven fabric with adhesive to polyurethane foam The interior material made of the complex is not only complicated manufacturing process and high manufacturing cost, but also because of the use of liquid synthetic resin adhesive, the weight of the interior material is accompanied with the problem that the bad smell is continuously released until the adhesive is completely dried.
특히 최근에는 환경보호의 입장에서 세계적으로 산업폐기물의 재활용(Recycling)이 강력하게 요구되고 있으며 유럽 등 일부국가에서는 이미 재활용이 불가능한 소재의 사용이 엄격하게 규제되고 있다.In particular, from the standpoint of environmental protection, recycling of industrial waste is strongly demanded worldwide, and in some countries, such as Europe, the use of non-recyclable materials is strictly regulated.
이러한 상황에서 유리섬유를 사용한 자동차용 내장재나 접착제로 여러종류의 소재를 접착, 적층시켜서 제조되는 내장재는 재활용이 어렵다는 문제를 수반한다. 따라서 이 분야에서는 자동차용 내장재로서 요구되는 경량성, 방음성, 단열성, 흡음성 및 강도 등을 충족시키면서 재활용이 가능하고 이취를 발산시키지 않는 자동차용 내장재의 개발이 요구되고 있는 실정에 있다.Under these circumstances, interior materials manufactured by bonding and laminating various kinds of materials with automotive interior materials or adhesives using glass fibers have a problem that it is difficult to recycle. Therefore, in this field, there is a demand for the development of automotive interior materials that can be recycled and do not emit odor while satisfying light weight, sound insulation, heat insulation, sound absorption and strength required for automotive interior materials.
본 발명의 목적은 가볍고, 단열, 방음, 흡음성이 우수하고 장시간 천장재로 사용 후에도 늘어지는 등의 변형을 일으키지 않으며 이취 발산이 없고 사용 후 재활용이 가능한 자동차용 천장재의 제조방법을 제공하는데 있다.An object of the present invention is to provide a method for manufacturing a vehicle ceiling material which is light, excellent in heat insulation, sound insulation, sound absorption, does not cause deformation such as sagging even after use as a ceiling material for a long time, there is no off-odor emission and can be recycled after use.
본 발명자는 판상의 폴리우레탄폼 양면에 마섬유(麻纖維)와 저융점 폴리에스텔사 및 고융점 폴리에스텔사를 일정비율로 혼합하여서 얻어지는 혼합 폴리에스텔사로 이루어진 부직포를 합착(合着)시켜서 얻어진 시트를 천공법(針穿孔法)으로 천공하고 가열성형한 후 정형기(Trimmer)에서 정형하여 폴리우레탄폼과 마섬유와 폴리에스텔섬유로 이루어진 판재를 제조하므로서 접착제를 사용하지 않고 우수한 경량성, 단열성, 방음성, 흡음성 및 성형성을 유지하면서 이취발산이 없고 사용 후 재생시켜 재활용이 가능한 자동차용 천장재를 얻을 수 있는 것을 확인하고 본발명을 완성하게 되었다.MEANS TO SOLVE THE PROBLEM This inventor obtained the sheet | seat obtained by bonding the nonwoven fabric which consists of mixed polyester yarn obtained by mixing a hemp fiber, low melting polyester yarn, and high melting polyester yarn in fixed ratio on both sides of plate-shaped polyurethane foam. Is punched out by punching method, heated and then molded in a trimmer to manufacture a plate made of polyurethane foam, hemp fiber and polyester fiber. The present invention was completed by confirming that a ceiling material for automobiles, which can be recycled after use, is free from odor emission while maintaining sound absorption and formability, and is recyclable.
도 1a 및 1b는 발명의 제조공정을 나타태는 개략도이다.1A and 1B are schematic diagrams illustrating the manufacturing process of the invention.
* 도면의 주요부분에 대한 부호의 설명 *Explanation of symbols on the main parts of the drawings
1, 1′: 부직포 시트 4 : 미세기공1, 1 ': nonwoven fabric sheet 4: fine pores
2 : 폴리우레탄폼 5, 5′ : 가열기2: Polyurethane foam 5, 5 ′: Heater
3, 3′: 침천공기 6, 6′ : 압착 로울러3, 3 ′: 6, 6 ′: compressed roller
7 : 성형기 8 : 정형기7: molding machine 8: molding machine
9 : 자동차용 천장재9: car ceiling materials
본 발명은 경량성, 단열성, 방음성, 흡음성 및 성형성이 우수하면서 장시간 천장재로 사용시에도 변형을 일으키지 않으며 이취발산이 없고 사용 후 재활용이 가능한 자동차용 천장재의 제조방법에 관한 것이다.The present invention relates to a method for manufacturing a vehicle ceiling material which is excellent in light weight, heat insulation, sound insulation, sound absorption, and moldability, does not cause deformation even when used as a ceiling material for a long time, does not cause off-flavor, and is recycled after use.
구체적으로는 판상의 폴리우레탄폼 양면에 저융점 폴리에스텔사 25~75중량%와 고융점 폴리에스텔사 25~75중량%를 혼합하여서된 혼합 폴리에스텔사 25~75중량%와 여기에 마섬유 25~75중량%를 혼합하여서된 부직포 시트를 합착시키고 이를 침천공기로 천공하여 폴리우레탄폼 내부에 부직포시트와 연통하는 다수의 미세기공을 형성시키고 이를 가열연화 시킨 후 압착로울러로 압착하여 판재로 얻고 이를 성형기(成形機)로 성형후 정형기(trimmer)에서 정형하여 자동차용 내장재를 제조하는방법에 관한 것이다.Specifically, 25 to 75% by weight of mixed polyester yarn 25 to 75% by weight of low melting point polyester yarn and 25 to 75% by weight of high melting point polyester yarn are mixed on both sides of plate-shaped polyurethane foam, and hemp fiber 25 ~ 75% by weight of the non-woven fabric sheet is bonded together and punched with a perforated air to form a plurality of micropores in communication with the non-woven fabric sheet inside the polyurethane foam, heat-softened it, and then compressed with a roller to obtain a sheet material The present invention relates to a method for manufacturing automotive interior materials by shaping in a trimmer after molding with a molding machine.
이하 실시예를 들어 본 발명을 구체적으로 설명한다.The present invention will be described in detail with reference to the following Examples.
도 1은 본발명의 제조공정을 개략적으로 나태낸 공정흐름도이다.1 is a process flow diagram schematically showing the manufacturing process of the present invention.
도 1에 도시한 바와 같이 두께 6㎜인 판상의 폴리우레탄폼(2)과 저융점 폴리에스텔사 5㎏과 고융점 폴리에스텔사 5㎏을 혼합하여 얻어지는 혼합 폴리에스텔사 10㎏과 황마섬유 10㎏을 혼합하고 이를 시트상으로 만들어 중량 500g/㎡이고 두께 약 3㎜인 부직포 시트(1)(1′)를 준비한다. 폴리우레탄폼(2) 양면에 부직포시트(1)(1′)를 합착시킨 후 침천공기(3)(3′)(이하 니들펀치라 한다)로 천공하여 폴리우레탄폼과 부직포 시트가 일체로 합착된 판재에 미세기공(4)이 관통되도록 형성시킨다. 니들펀치는 인치당 약 600개의 바늘침이 형성된 것을 사용하였다. 폴리우레탄폼은 두께 5~8㎜의 것이 적당하고 중량 300~600g/㎡이고 두께 3~5㎜인 것이 적당하다.As shown in FIG. 1, 10 kg of mixed polyester yarn and 10 kg of jute fiber obtained by mixing a plate-shaped polyurethane foam 2 having a thickness of 6 mm, 5 kg of low melting point polyester yarn and 5 kg of high melting point polyester yarn And mixed into sheets to prepare a nonwoven fabric sheet 1 (1 ') having a weight of 500 g / m 2 and a thickness of about 3 mm. The non-woven fabric sheet (1) (1 ') is bonded to both sides of the polyurethane foam (2), and then perforated with a punching air (3) (3') (hereinafter referred to as a needle punch). The micropores 4 are formed to penetrate through the plate. Needle punches were used in which about 600 needle needles were formed per inch. Polyurethane foam having a thickness of 5 to 8 mm is appropriate, a weight of 300 to 600 g / ㎡ and a thickness of 3 to 5 mm is appropriate.
여기에서 얻어진 판재를 260~280℃로 유지되는 가열기(oven)(5)(5′)를 통과시킨 후 온도 230~250℃로 유지되는 압착로울러(6)(6′)에 통과시켜 압착시킨 후 성형기(7)에서 성형하고 정형기(8)에서 정형하여 본 발명의 자동차용 천장재(9)를 제조하였다. 여기에서 가열기에 통과시키는 것은 폴리우레탄폼을 포함하는 판재를 가공이 용이하도록 연화(軟化) 시켜주기위한 것이다.After passing the plate obtained here through a heater (5) (5 ') maintained at 260 ~ 280 ℃ and passed through a pressing roller (6) (6') maintained at a temperature of 230 ~ 250 ℃ and pressed The automobile ceiling material 9 of the present invention was manufactured by molding in the molding machine 7 and shaping in the molding machine 8. In this case, the heater is made to soften the plate member including the polyurethane foam to be easily processed.
본 실시예에서는 부직포시트(1)(1′)는 마섬유 50중량%와 고융점 폴리에스텔사 25중량% 및 저융점 폴리에스텔사 25중량%를 혼합하여서 된 부직포 상태로 구성시켜준 것을 사용하였다.In this embodiment, the nonwoven fabric sheet (1) (1 ') was composed of 50% by weight of hemp fiber, 25% by weight of the high melting point polyester yarn, and 25% by weight of the low melting point polyester yarn. .
폴리에스텔사는 종류에 따라 융점이 110~190℃의 것이 있으며 융점이 120℃이하의 것을 저융점 폴리에스텔사라하고 융점 170℃ 이상의 것을 고융점 폴리에스텔사라고 하는데 마섬유와 저융점 폴리에스텔사로만 부직포를 구성시켜 줄 수도 있고 마섬유와 고융점 폴리에스텔사로만 부직포를 구성시켜줄 수도 있으나 저융점 폴리에스텔사만으로 부직포를 구성시켜 주게되면 폴리우레탄폼과의 결착력은 높아지나 강도가 저하될 우려가 있고 고융점 폴리에스텔사로만 부직포를 구성시켜 주게되면 가공온도가 높아지게되어 폴리우레탄폼을 용융시킬 우려가 있고 폴리우레탄폼과의 결착력도 떨어지게된다.The polyester has a melting point of 110 ~ 190 ℃ and the melting point of 120 ℃ or less is called low melting point polyester yarn and the melting point of 170 ℃ or higher is called high melting point polyester yarn. Only non-woven fabric is made of hemp fiber and low melting point polyester yarn. The nonwoven fabric can be composed only of hemp fiber and high melting point polyester yarn.However, if the nonwoven fabric is composed of only low melting point polyester yarn, the binding strength with the polyurethane foam may be increased but the strength may be lowered. If the nonwoven fabric is composed only of polyester yarns, the processing temperature becomes high, which may melt the polyurethane foam, and the binding strength with the polyurethane foam is also reduced.
이런점들을 고려할 때 저융점 폴리에스텔사 25~75중량%와 고융점 폴리에스텔사 25~75중량%로된 혼합 폴리에스텔사로 부직포를 형성시켜주는 것이 적당하다.Considering these points, it is appropriate to form a nonwoven fabric with a mixed polyester yarn composed of 25 to 75 wt% of low melting polyester yarn and 25 to 75 wt% of high melting polyester yarn.
또한 마섬유는 혼합 폴리에스텔사에 25~75중량%정도 사용하는 것이 적당하다.It is also suitable to use about 25 to 75% by weight of hemp fiber mixed polyester yarn.
마섬유로는 황마(黃麻)섬유, 아마(亞麻)섬유, 야자섬유(coir yarn) 중에서 선택 사용할 수 있다. 마섬유는 표면이 거칠고 질긴 성질이 있어 포장용 끈, 와이어 로프(wire rope) 범포 등의 제조에 주로 사용되는 것이다.Hemp fibers may be selected from jute fibers, flax fibers, and palm fibers. Hemp fibers have a rough surface and are tough, and thus are mainly used in the manufacture of packaging strings, wire rope canvases, and the like.
니들펀치로 합착된 시트에 니들 펀치로 다수의 바늘구멍을 형성시키는 과정에서 마섬유 및 폴리에스텔섬유의 일부가 바늘침에 의해서 폴리우레탄폼(2) 내부로 밀려드러가게되며 또한 폴리우레탄폼(2) 내부에 다수의 미세기공(4)이 형성되게 된다.In the process of forming a plurality of needle holes with a needle punch on the sheet bonded with the needle punch, a part of the hemp fiber and polyester fiber is pushed into the polyurethane foam (2) by the needle needle, and the polyurethane foam (2 ) A plurality of micropores (4) is formed inside.
여기에서 얻어진 합착된 시트를 260~280℃로 유지되는 가열기(5)(5′)에 통과시킨 후 230~250℃로 유지되는 압착로울러(6)(6′)로 압착하여 두께를 조절한다.The laminated sheet thus obtained is passed through a heater (5) (5 ') maintained at 260 ~ 280 ℃ and then pressed by a compression roller (6) (6') maintained at 230 ~ 250 ℃ to adjust the thickness.
여기에서 얻어진 판재를 성형기(7)에서 일정형태로 성형하고 정형기(8)에서 정형하여 제품을 완성시킨다.The sheet material obtained here is shape | molded by the shaping | molding machine 7 to a fixed form, and shaping | molding in the shaping | molding machine 8 is completed a product.
상기 가열기(5)와 압착로울러(6)를 통과하는 과정에서 폴리우레탄폼 내부로 밀려드러간 저융점폴리에스텔사가 용융되게되며 용융된 저융점폴리에스터사가 폴리우레탄폼 내부로 밀려드러간 마섬유와 결착되게 되고 이를 냉각시켜주면 폴리우레탄폼(2)과 부직포시트(1)(1′)는 접착제를 사용하지 않고도 강력하게 결착되게된다. 마섬유는 가볍고 질긴 성질이 있고 용융된 저융점 폴리에스텔사와의 결착력도 우수하다.In the course of passing through the heater (5) and the pressing roller (6), the low-melting-point polyester yarn pushed into the polyurethane foam is melted, and the low-melting-polyester polyester yarn melted into the polyurethane foam and When the binder is cooled and cooled, the polyurethane foam 2 and the nonwoven fabric sheet 1, 1 'are strongly bound without using an adhesive. Hemp fiber has light and tough properties and excellent binding ability with molten low melting polyester yarn.
성형기는 천장재를 자동차 천장의 내부형상과 일치되도록 성형시키주는 장치이다.The molding machine is a device for molding the ceiling material to match the internal shape of the car ceiling.
일반적으로 성형공법에는 열간성형공법과 냉간성형공법이 있다.In general, there are hot forming methods and cold forming methods.
냉간성형공법은 성형하고자 하는 소재를 열변형 온도까지 예열하여 형태를 유지 시켜준 후 냉각시키면서 성형하는 방법이다.Cold forming method is a method of pre-heating the material to be molded to heat deformation temperature to maintain the shape and then cooling while molding.
본 발명에서는 저융점폴리에스텔사를 용융시켜 마섬유와 폴리우레탄폼을 결착시켜주기 위한 것이기 때문에 성형기를 230~250℃ 가열한 후 4~5분정도 압착시키는 가열압착성형법으로 성형한다.In the present invention, since the low melting point polyester yarn is melted to bind the hemp fiber and the polyurethane foam, the molding machine is heated by a thermocompression molding method after heating the molding machine at 230 to 250 ° C. for 4 to 5 minutes.
성형기에서 일정한 형태를 유지되게한 후 정형기(trimmer)에서 원하는 크기와 형태로 절단, 정형(整形)하면 두께 8㎜의 자동차용 천장재가 얻어진다.After maintaining a constant shape in the molding machine, when cut and shaped to a desired size and shape in a trimmer, a car ceiling material having a thickness of 8 mm is obtained.
폴리우레탄폼(2)은 두께 5~8㎜정도의 부직포시트(1)(1′)는 중량300~600g/㎡의 것이 적당하다.As for the polyurethane foam 2, the nonwoven fabric sheet 1 (1 ') whose thickness is about 5-8 mm is suitable for the weight of 300-600 g / m <2>.
본 발명에서 마섬유를 사용하는 이유는 마섬유는 조직이 치밀하지 않아 가벼우며 표면이 거칠고 질긴 성질이 있고 표면이 거칠기 때문에 니들펀칭 공정에서 바늘침에 의해서 폴리우레탄폼(2) 내부로 잘 밀려드러가게 되며 용융폴리에스텔사와의 결착력도 우수하며 질긴성질 때문에 높은 결착강도를 유지할 수 있고 경량성도 확보할 수 있기 때문이다. 그러나 고강도의 자동차용 천장재가 요구되는 경우에는 마섬유에 탄소섬유를 혼합하여 사용할 수도 있다.The reason why the hemp fiber is used in the present invention is that the hemp fiber is light due to its compact structure, and the surface is rough and tough, and because the surface is rough, the hemp fiber is pushed well into the polyurethane foam 2 by the needle needle in the needle punching process. This is because it has excellent binding strength with molten polyester yarn, and because of its toughness, it can maintain high binding strength and secure lightweight. However, when high-strength automotive ceiling materials are required, carbon fibers may be mixed with hemp fibers.
본 발명의 방법으로 제조된 자동차용 천장재는 폴리우레탄폼을 기본소재로하고 접착제를 사용하지 않아 경량성과 함께 단열성 및 방음성 확보가 가능하고 접착제는 사용하지 않아 이취발산이 없으며 원료들이 모두 열가소성 물질들이기 때문에 사용 후 재활용이 가능하며 니들펀치 공정에서 내부에 다수의 미세기공(4)이 형성되어 있어 흡음성도 우수하게 된다. 또한 가벼우면서 강도가 높아 장시간 사용하여도 변형을 일으키지 않는다. 본 발명의 방법으로 제조된 자동차용 천장재는 천장재로서 적합한 것이기는 하나 천장재 이외에 자동차용 내장재로도 사용될 수 있다.Automotive ceiling materials manufactured by the method of the present invention is a polyurethane material as a base material and does not use an adhesive, it is possible to secure heat insulation and sound insulation with light weight, and no adhesive is used because there is no odor emission and the raw materials are all thermoplastic materials After use, it is possible to recycle and a plurality of fine pores (4) is formed inside the needle punch process is excellent sound absorption. In addition, it is light and high in strength and does not cause deformation even after long use. Although the ceiling material for automobiles manufactured by the method of the present invention is suitable as a ceiling material, it may be used as a vehicle interior material in addition to the ceiling material.
본 발명의 방법으로 제조된 자동차용 천장재는 이취발산이 없으면서 경량성과 강도 및 흡음성을 유지할 수 있고 사용 후 재활용이 가능한 효과를 갖는다.The ceiling material for automobiles manufactured by the method of the present invention can maintain light weight, strength and sound absorption without deodorization and have an effect of recycling after use.
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Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2006083144A1 (en) * | 2005-02-07 | 2006-08-10 | Karam Tech Co., Ltd. | The member for headliner on motor vehicles |
| WO2006091031A1 (en) * | 2005-02-23 | 2006-08-31 | Karam Tech Co., Ltd | The member for headliner on motor vehicles of multilayer structure |
| KR100893690B1 (en) * | 2008-07-03 | 2009-04-17 | 엔피에프(주) | Noise prevention material using waste polyurethane scrap |
| KR101371811B1 (en) * | 2012-06-25 | 2014-03-07 | 기아자동차주식회사 | Soundproofing material using polyurethane from car seat foam and a fabrication process thereof |
| CN112537106A (en) * | 2020-12-02 | 2021-03-23 | 宁波耀众模塑科技有限公司 | Polyurethane board and processing technology and application thereof |
| CN114537295A (en) * | 2022-02-17 | 2022-05-27 | 湖北南泽汽车复合材料有限公司 | Environment-friendly automotive interior structure with sound absorption function |
| CN115246261A (en) * | 2021-12-31 | 2022-10-28 | 齐齐哈尔大学 | China-hemp-fiber-reinforced organic composite material automotive interior panel and preparation method thereof |
| US11613604B2 (en) | 2021-06-28 | 2023-03-28 | Covestro Llc | Isocyanate-reactive compositions, polyurethane foams formed therefrom, multi-layer composite articles that include such foams, and methods for their preparation |
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2004
- 2004-09-17 KR KR1020040074428A patent/KR20040088434A/en not_active Application Discontinuation
Cited By (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2006083144A1 (en) * | 2005-02-07 | 2006-08-10 | Karam Tech Co., Ltd. | The member for headliner on motor vehicles |
| KR100849507B1 (en) * | 2005-02-07 | 2008-07-31 | (주)리앤에스 | The member for headliner on motor vehicles |
| WO2006091031A1 (en) * | 2005-02-23 | 2006-08-31 | Karam Tech Co., Ltd | The member for headliner on motor vehicles of multilayer structure |
| JP2008531361A (en) * | 2005-02-23 | 2008-08-14 | リ アンド エス カンパニー リミテッド | Multi-layer automotive ceiling material |
| KR100916213B1 (en) * | 2005-02-23 | 2009-09-08 | (주)리앤에스 | The member for headliner on motor vehicles of multilayer structure |
| KR100893690B1 (en) * | 2008-07-03 | 2009-04-17 | 엔피에프(주) | Noise prevention material using waste polyurethane scrap |
| KR101371811B1 (en) * | 2012-06-25 | 2014-03-07 | 기아자동차주식회사 | Soundproofing material using polyurethane from car seat foam and a fabrication process thereof |
| CN112537106A (en) * | 2020-12-02 | 2021-03-23 | 宁波耀众模塑科技有限公司 | Polyurethane board and processing technology and application thereof |
| US11613604B2 (en) | 2021-06-28 | 2023-03-28 | Covestro Llc | Isocyanate-reactive compositions, polyurethane foams formed therefrom, multi-layer composite articles that include such foams, and methods for their preparation |
| CN115246261A (en) * | 2021-12-31 | 2022-10-28 | 齐齐哈尔大学 | China-hemp-fiber-reinforced organic composite material automotive interior panel and preparation method thereof |
| CN114537295A (en) * | 2022-02-17 | 2022-05-27 | 湖北南泽汽车复合材料有限公司 | Environment-friendly automotive interior structure with sound absorption function |
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