KR20090092437A - Fiber Material Having Acoustic Absorbent Bounded With Scarfskin and Manufacturing Method Thereof - Google Patents

Abstract

A fiber member and a manufacturing method of the same are provided to improve the quality by preventing the flatness from degrading. A fiber member comprises a surface material(110) combined in a sound-absorbing material(120). The sound-absorbing material is made by pressing the complex yarn. The sound-absorbing material is manufactured to be a plate shape. The sound-absorbing material includes regular PET fiber of 60~70 weight%, and low melting PET fiber or polypropylene of 30~40 weight%. The sound-absorbing material and the surface material are integrally combined by the melt in which the low melting point polyester fiber or the polypropylene fiber is fused. The sound-absorbing material is heat-treated at 250~300°C for 30~50 seconds.

Description

Fiber Material Having Acoustic Absorbent Bounded With Scarfskin and Manufacturing Method Thereof}

The present invention relates to a molding substrate that can be molded to be used as a building material for automobile interior materials or for noise prevention, and more particularly, to a fiber substrate having a sound absorbing material and a skin material combined and a method of manufacturing the same. More specifically, the raw material of the sound absorbing material is characterized by including a low melting polyester fiber or a polypropylene fiber together with the regular polyester fiber, and bonding the skin material to the melt thereof.

Conventionally, for example, glass fiber, gypsum board, felt, poly for sound insulation or sound absorption to prevent noise of a building, or sound absorption in a tunnel of a highway or subway or railway where noise of automobile driving is high. Urethane foam products, styropol, asbestos, etc. have been used, and sound absorbing materials have been combined with various skin materials according to the noise level of the construction site, the importance of sound absorbing and soundproofing, and the construction specifications of the client.

In addition, automotive interior materials are typically a base layer fixed to a vehicle body with a predetermined strength and shape, a surface layer having an exterior beauty to create an atmosphere of an interior of an automobile, and a buffer layer interposed between the base layer and the surface layer to have a soft touch. In general, the buffer layer and the surface layer are collectively referred to as a skin material, but a single skin material having only a high-density nonwoven fabric may be used.

In general, in order to obtain the interior material of the laminated structure as described above, first, the waste fiber composed of hemp, cotton, and chemical fiber is put into the hopper of the grinder, pulverized and kneaded to a certain size, and then air is injected and vortexed. After mixing phenolic resin, which is a thermosetting bonding medium, and passing it through a heater (oven) having an ambient temperature of 170 to 270 ° C. to improve workability (semi-cure), a felt for forming a base material (material) was prepared as described above. The thermosetting resin felt obtained in the step is molded in a hot pressing mold to release the substrate from the mold, and the substrate is trimmed (trimmed) to prepare the substrate. Then, after coating the solvent-type adhesive on the upper surface of the substrate separately, it is compression molded by a separately prepared skin material and vacuum molding method. Afterwards, the interior parts of the interior parts are combined, and then automobile parts are manufactured by combining the necessary attachment parts.

However, such a conventional method has a problem in that after forming the substrate and the skin material in a desired shape by separate processes, and then going through a complicated manufacturing process in which the substrate and the skin material are additionally bonded by a separate adhesive. In addition, as described above, when the substrate is first formed into a desired shape, trimmed, and bonded to the skin material, as shown in FIG. 1, a separate adhesive 3 must be used, and only a partial area of the skin material 2 is partially used. Since the substrate 4 can only be attached, the attached substrate 2 has a serious problem that the attached substrate 2 is lifted or fluttered, and the flatness is lowered, thereby lowering the performance of the interior material 1 such as sound absorption or sound insulation. To this end, there is an attempt to match the other additional parts and to improve the performance of the product by combining a separate additional substrate 5 on the upper surface of the base material 4 attached to the skin material 2, but also described above The problem cannot be solved in near term.

Accordingly, the present invention can manufacture a fiber base material is integrally bonded to the base material and the skin material without a separate adhesive layer in a single continuous process, thereby providing a fiber base material is a sound absorbing material integrally coupled to the entire surface of the skin material as in the prior art It is an object of the present invention to provide a molding material for automobile or building interior materials having excellent performance without deterioration of quality (wobble, lifting, flatness) that occurs when the base material is partially formed on the skin material.

Hereinafter, in describing the fibrous substrate according to the present invention in which the base material and the skin material are integrally combined, the sound absorbing material used for automobile interior as an example of the base material will be described as an example. However, the present invention is not limited thereto and is used in various ways in building materials for automobile interior materials or for noise prevention, and includes all types of substrates that are generally known or can be easily modified therefrom.

To achieve the above object, the sound absorbing material and the fiber material combined with the skin material according to the present invention are 60 to 70 wt% of regular polyester fiber and low melting PET fiber or polypropylene. (Polypropylene) The skin material is bonded to a sound absorbing material containing 40 to 30% by weight of the fiber as a main raw material, the sound absorbing material and the skin material is integrally bonded by a melted melt of the low melting point polyester fiber or polypropylene fiber It is characterized by.

In another embodiment of the present invention, the sound absorbing material and the manufacturing method of the fiber base material combined with the skin material, 60 to 70% by weight of regular polyester fiber and 40-30% by weight of low melting polyester fiber or polypropylene fiber Pressing down to prepare a plate-shaped sound absorbing material; Heat-treating the sound absorbing material in an oven having an internal temperature within a range of 250 ° C. to 300 ° C. for 30 seconds to 50 seconds to melt the low melting polyester fiber or the polypropylene fiber included in the sound absorbing material; And continuously supplying the skin material to the heat-treated sound absorbing material with a press roll, thereby combining the sound absorbing material and the skin material by the pressure of the press roll and a melt of the low melting point polyester fiber or polypropylene fiber. It is characterized by.

Here, the plate-shaped sound absorbing material may be characterized in that the fiber is a nonwoven fabric oriented in the vertical direction.

Specific details of other embodiments are included in the detailed description and the drawings.

The present invention as described above can provide a fiber base and a method for manufacturing the same, the sound absorbing material and the skin material integrally bonded by the melt of low-melting point polyester fiber or polypropylene fiber, in the case of the present invention is one continuous The process can produce a fiber substrate in which the sound absorbing material and the skin material are integrally bonded without a separate adhesive layer, and the fiber material thus produced is a case in which the sound absorbing material is integrally bonded to the entire surface of the skin material, thereby partially forming the sound absorbing material on the skin material. It is possible to provide a molding material for automobile or building interior materials having excellent performance by solving the problem of quality deterioration (wobble, lifting, flatness decrease).

1 is a cross-sectional view showing the interior material in which the substrate is bonded to a part of the skin material with a separate adhesive after separately molding the substrate and the skin material according to the prior art,

2 is a schematic diagram showing an example of a process for preparing a sound absorbing material in the method for producing a fiber base material is a sound absorbing material and a skin material in accordance with the present invention,

Figure 3 is a schematic diagram showing an example of a process of bonding the sound absorbing material and the skin material by melting the low melting point polyester fiber or polypropylene fiber according to the present invention,

4 is a cross-sectional view showing an example of an interior material manufactured by molding a fiber base material in which a sound absorbing material and a skin material are integrally bonded without a separate adhesive layer into a desired shape,

5 is a schematic view for explaining the form (a) in which the fibers contained in the sound absorbing material according to the present invention are oriented in the horizontal direction and the form (b) in the vertical direction.

Hereinafter, one preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings. The invention may be better understood by the following examples, which are intended for purposes of illustration of the invention and are not intended to limit the scope of protection defined by the appended claims.

The present invention relates to an interior material used as a building article for automobiles or noise prevention, for example, to a molding substrate including a sound absorbing material as a substrate and used to manufacture interior materials in which various skin materials are bonded thereto. The molding substrate according to the present invention can be manufactured with a interior material having a specific shape by various molding methods according to the user's desired purpose.

The present invention is to manufacture the interior materials for automobiles or construction by a complex manufacturing process of combining the substrate and the skin material by a separate adhesive after molding the substrate and the skin material in a desired shape in a separate process as in the prior art. Rather, in preparing a molding material for producing such a lining agent, a low melting polyester fiber or a polypropylene fiber together with regular polyester fibers as a raw material of the substrate (absorbing material), the low melting polyester fiber or polypropylene An object of the present invention is to provide a fibrous base material in which a sound absorbing material and a skin material are integrally bonded by a melt of fiber, and a method of manufacturing the same.

In other words, the sound absorbing material according to the present invention and the skin base material is combined, the first skin material is bonded to the sound absorbing material, the sound absorbing material basically comprises regular polyester fibers (regular PET fiber), low melting point polyester fiber (low melting PET fiber) or fibers containing polypropylene (polypropylene) fiber is the main raw material. In particular, the regular polyester fiber is preferably 60 to 70% by weight, and the low-melting polyester fiber or polypropylene fiber is preferably contained in 40 to 30% by weight, through which the low-melting polyester fiber or polypropylene fiber Is characterized in that the sound absorbing material and the skin material is integrally bonded by the melted melt.

The low melting polyester fiber or polypropylene fiber has a lower melting point than ordinary regular polyester fiber, and thus the low melting polyester fiber or polypropylene fiber at a temperature lower than the melting point of the regular polyester fiber. Only the melt can be selectively melted, thereby maintaining the crystallization and structural stiffness of the sound absorbing material by the regular polyester fiber while physically or chemically separating the separate skin material by the melt in which the low melting point polyester fiber or polypropylene fiber is melted. It is possible to bond by bonding.

To this end, as the raw material of the sound absorbing material, the regular polyester fiber is preferably 60 to 70% by weight, and the low melting point polyester fiber or polypropylene fiber is preferably contained at 40 to 30% by weight. If the content of the low-melting polyester fiber or polypropylene fiber exceeds 40% by weight, the shrinkage of the low-melting-point fiber fabric (fabric width) increases the size of the material and increases the cost, and the melt melts when it is less than 30% by weight. The amount of is not small enough to bond the skin material firmly. And, if the content of the regular polyester fiber is less than 60% by weight and more than 70% by weight, the content of the low-melting polyester fiber or polypropylene fiber exceeds 40% by weight and 30%, respectively The same phenomenon occurs when less than%.

Figure 2 is a schematic diagram showing an example of a process for preparing the sound absorbing material in the method for producing a sound absorbing material and the skin material in accordance with the present invention, Figure 3 is a low melting point polyester fiber or polypropylene fiber according to the present invention It is a schematic diagram which shows an example of the process of combining a sound absorption material and a skin material.

As shown here, the method for producing a fiber base material is a sound absorbing material and a skin material combined according to the present invention, largely prepare a plate-shaped sound absorbing material (S100), and heat-treated in an oven (S200), and the sound absorbing material and Through a series of processes to combine the separate skin material (S300).

First, S100 step of preparing a plate-shaped sound absorbing material, by pressing the compounding yarn containing a low melting point polyester fiber or 40-30% by weight of polypropylene fiber with 60 to 70% by weight of regular polyester fiber by pressing a roller Is to prepare the sound absorbing material. For example, when the blended yarn is opened in the bal opening apparatus, the fibers are aggregated in a lump form through a fine opening apparatus, and supplied to the fiber mixing apparatus 10 along the feed pipe, and the fiber mixing apparatus 10 is provided. Distributes the transferred fibers evenly and then supplies the evenly distributed fibers to the carding machine 20. The carding machine 20 forms a fiber layer having a horizontal structure by making the aggregated fibers into a thin sheet form (web). Thereafter, the sound absorbing material 120 which is subjected to a selective lapping process and then heated in a conventional heating device 30 and extruded and molded into a plate by a pressing roller 40 and cut into a predetermined length by the cutter 50 is It is made.

Here, the regular polyester fibers may be used in all kinds of polyester fibers known in the art, and have a melting point within the range of 250 ℃ to 270 ℃ so that not all melt in the subsequent heat treatment process (S200) in the oven. desirable. The low melting point polyester fiber or polypropylene (PP) fiber may be a bicomponent or bi-type PP or bi-type PP such as Cisco-type PET / PE, PET / PP, PET / PA, PET / modified PET. Or a polypropylene homopolymer (homo copolymer) or a copolymer containing polypropylene as a main component, wherein the copolymer is an α-olefin copolymer (random or block copolymer) containing 85% or more of polypropylene. ) Or a terpolymer (terpolymer) in which two kinds of α-olefins are copolymerized. The low melting polyester fibers or polypropylene (PP) fibers preferably have a melting point within the range of 150 ℃ to 200 ℃ to be sufficiently melted in the heat treatment process (S200) in the oven.

Next, the present invention by heat-treating the sound absorbing material 120 prepared as described above in the oven 60 having an internal temperature within the range of 250 ℃ ~ 300 ℃ 30 seconds to 50 seconds, low melting point poly contained in the sound absorbing material 60 The step of melting the ester fiber or polypropylene fiber (S200). The oven 60 used in this melting step can be used without limitation as long as it can heat-treat the sound absorbing material 120, for example, as shown in Figure 3, the inside of the heat chamber (heat chamber) It is possible to include a conveyor belt 61 for moving the sound absorbing material 120, a heater 63 for supplying hot hot air thereon, and a blower 62 for circulating hot air inside the oven 60.

The inside of the oven 60 is preheated as the sound absorbing material 120 is moved by providing a conveyor belt 61 therein as shown in FIG. It has a furnace atmosphere temperature of about 250 to 300 ° C. for about 30 to 60 seconds, and in particular, in consideration of the safety of polyester material, when preheated at about 260 to 290 ° C. for about 40 to 50 seconds, the polyester (PET) blended yarn is used. The sound absorbing material 120 has a surface temperature of less than about 200 ° C., so that the sound absorbing material 120 containing the low melting polyester fiber or polypropylene fiber starts to melt from the surface in the oven 60. Then, a melt in which the low melting fiber yarn is melted is formed on the surface of each part of the regular polyester fiber.

In this case, when the sound absorbing material 120 is placed in the oven 60 for 50 seconds or more, the surface of the sound absorbs more than 200 ° C., in particular, when the local overheating exceeds 250 ° C., there is a risk that the regular polyester fiber also melts. It is preferable to preheat 50 seconds as an upper limit and to let it preheat for 30 second or more in order to fully melt a low melting yarn.

Subsequently, the present invention continuously supplies a separate skin material 110 to the heat-absorbing sound absorbing material 120 to the press roll 70, and thus the pressure of the press roll 70 and the low melting point polyester fiber or polypropylene. By the melt of the fiber, the step of combining the sound absorbing material 120 and the skin material 110 (S300). Here, the skin material 110 is preferably prepared separately in advance, and more preferably, the low melting point fiber yarn is combined with the heat absorbing sound absorbing material 120 before the molten melt is cooled. To this end, the step (S300) of combining the sound absorbing material 120 and the skin material 110 is preferably performed at the same time or immediately after the molten melt of the low melting fiber fibers are produced. In FIG. 3, the sound absorbing material 120 and the skin material 110 are shown to be coupled to the outside of the oven 60, but in addition, the sound absorbing material 120 and the skin material 110 may be combined within the oven 60.

According to the present invention, as shown in Figure 4, it is possible to manufacture a fiber base in which the sound absorbing material 120 and the skin material 110 are integrally combined without a separate adhesive layer in one continuous process, The molding material may be manufactured from the interior material 100 having a specific shape by a variety of molding methods according to the user's desired purpose, and the quality deterioration occurring in the interior material that partially bonded the sound absorbing material to the skin material as in the prior art It is possible to provide a vehicle or building interior material 100 having excellent performance by solving the problem of flattening).

On the other hand, Figure 5 is a schematic diagram for explaining the form (a) and the vertically oriented form (a) of the fibers included in the sound absorbing material 120 according to the present invention in the horizontal direction, the other features of the present invention is It is also possible that the fibers included in the sound absorbing material 120 is a nonwoven fabric oriented in the vertical direction.

That is, in the step S100 of preparing the plate-shaped sound absorbing material 120, after supplying a blended yarn containing a low melting point polyester fiber or a polypropylene fiber with regular polyester fiber to the fiber mixing device 10, When the carding machine 20 is supplied to the carding machine 20, the carding machine 20 is formed into a thin sheet form (web) to form a horizontal fiber layer. In this case, the carded fiber 20 instead of the carding machine 20 has a vertical structure. By using a vertical machine that can be formed into a fibrous layer, as shown in Fig. 5B, a nonwoven fabric in which fibers are oriented in the vertical direction can be made. The nonwoven fabric in which the fibers are oriented in the vertical direction can be manufactured by a nonwoven fabric manufacturing facility called "V-Lap" of a company called Teijin Fiber.

Conventional polyester nonwoven fabrics have low repulsion properties because the rows of fibers are transverse, and there is a weak problem in the pressure from the top and bottom, but as described above, the nonwoven fabrics in which the fibers are oriented in the vertical direction are high performance nonwoven fabrics having high elasticity and light weight characteristics. to be.

In the present invention, paying attention to the characteristics of the high-performance nonwoven fabric, as the sound absorbing material 120, a non-woven fabric in which fibers are oriented in the vertical direction is used. By doing so, it is possible to realize a fiber base material and interior material having high resilience, strong pressure from up and down, low density and high breathability.

Furthermore, in the present invention, in the bonding and bonding of the sound absorbing material and the skin material by the melt of the low-melting point polyester fiber or polypropylene fiber, when the adhesive effect by the melt is insufficient, a separate adhesive (powder component or PP, PE) Or components). The present invention will be able to provide a more excellent fiber substrate and interior material by increasing the adhesive strength by a separate adhesive in addition to the adhesive strength by the melt.

On the other hand, while the present invention has been shown and described with respect to certain preferred embodiments, the invention is variously modified and modified without departing from the technical features or fields of the invention provided by the claims below It will be apparent to those skilled in the art that such changes can be made.

According to the present invention described above, the skin material and the sound absorbing material are manufactured and attached separately as in the prior art, and the sound absorbing material is not attached locally to the skin material (partially), but the skin material and the sound absorbing material are integrally combined in the entire area (the same area). By providing the fiber base, it is possible to improve the performance (absorption, sound insulation) and quality (wobble, lifting, flatness reduction) of parts for automobiles (industrial), as well as post-attachment of sound absorbing materials and adhesives, It is possible to reduce the attachment process of other substrates added separately, thereby reducing the price (manufacturing cost).

In addition, the manufacturing process according to the separate molding, which is a disadvantage of the conventional sound absorbing material for molding, can be reduced, thereby reducing the investment cost and manufacturing parts for competitive automobiles (industrial). The sound absorbing material, which has been added on the whole, can be replaced with only the sound absorbing material according to the present invention on the basis of the above-described performance improvement, thereby reducing manufacturing costs and thus reducing fuel consumption with a vehicle having reduced weight. In addition, it is also environmentally friendly by recycling by-products generated after molding.

Claims (3)

The skin material is a sound absorbing material mainly composed of a fiber containing 60 to 70% by weight of regular PET fiber and 40 to 30% by weight of low melting PET fiber or polypropylene fiber. Combined, And a sound absorbing material and a skin material, wherein the sound absorbing material and the skin material are integrally bonded by a melt in which the low melting point polyester fiber or the polypropylene fiber is melted. Preparing a plate-shaped sound absorbing material by pressing a blended yarn including 60 to 70 wt% of regular polyester fiber and 40 to 30 wt% of low melting polyester fiber or polypropylene fiber; Heat-treating the sound absorbing material in an oven having an internal temperature within a range of 250 ° C. to 300 ° C. for 30 seconds to 50 seconds to melt the low melting polyester fiber or the polypropylene fiber included in the sound absorbing material; And, Continuously supplying the skin material to the heat-treated sound absorbing material with a press roll, and combining the sound absorbing material and the skin material by the pressure of the press roll and the melt of the low melting point polyester fiber or polypropylene fiber. And a method of manufacturing a fibrous base material in which the skin material is bonded. The method of claim 2, wherein the plate-shaped sound absorbing material is a non-woven fabric in which the fibers are oriented in the vertical direction.