KR20130008101A - Felt material with recycled fiber for the vehicle interiors and method of the same - Google Patents

Abstract

PURPOSE: An interior base felt is provided to reduce a raw material cost by using a recycled fiber and to reduce the generation of harmful materials by reducing the content of a jute fiber. CONSTITUTION: An interior base felt(100) using a recycled fiber comprises felt layer(111), a foam sheet(112), and a nonwoven fabric(113). The felt layer comprises a felt layer(111), a foam sheet(112), and a PET nonwoven fabric(113). The felt layer is formed of the polypropylene fiber, jute fiber, and a recycled fiber. The foam sheet consists of a homo polypropylene and arranged on both sides of the felt layer. The PET nonwoven fabric is attached on the foam sheet attached on one side of the felt layer. A manufacturing method of the felt comprises: a step of mixing the jute fiber, polypropylene fiber, and recycled fiber. The mixing material is opened and carded. The carded mixed material is web-foamed on the foam sheet and forms two felt layers; a step of needle-punching the two felt layer; and a step of needling-punching the PET nonwoven fabric on the foam sheet.

Description

Felt material with recycled fiber for the vehicle interiors and method of the same}

The present invention relates to a vehicle interior material based felt and a method for manufacturing the same, and more particularly, to a vehicle interior material based felt using recycled fibers and a manufacturing method thereof.

In general, the rear shelf for automobiles requires light weight, high rigidity, and dimensional stability, and the position of lighter weight and recyclability of vehicle parts is more important due to the recent tightening of environmental regulations on automobiles and the depletion of oil resources. Occupies.

Generally, the material of the rear shelf for cars is woodstock or natural fiber reinforced board, and is manufactured by extrusion molding or carding / needle punching.

Mat 2 rolls prepared by mixing jute fibers and polypropylene fibers in a proper ratio among the base materials for this purpose, and then forming a web on a polypropylene bubble paper and needle punching. The four-layered thermoplastic felt for automobile interior materials which laminated | stacked the surface without bubble paper is used.

Thermoplastic felt according to the invention is excellent in rigidity and heat resistance can be reduced in weight and can improve the vehicle stability with excellent impact resistance and is characterized by a relatively low production cost. On the other hand, due to the use of jute fiber, the odor caused by jute fiber carbonization and the preservatives that are processed to suppress the decay or mold caused by the import of jute fiber are generated. To provide. In addition, when heat-forming in a hot mold, bubble paper adheres to the surface of the hot mold, and workability decreases. The process is complicated by applying an adhesive to a molded substrate and then attaching a skin material to the coated surface, thereby causing quality problems due to adhesive smell. This happens. In addition, due to rising import prices and unstable supply of jute fiber, the price competitiveness is lowered, resulting in a rise in production costs.

Accordingly, the present invention is to provide a vehicle interior material having a good workability by providing a comfort to consumers by reducing the harmful substances caused by a number of factors to compensate for the above disadvantages.

An object of the present invention is to provide a felt for a vehicle interior material using a recycled fiber and a method for manufacturing the same, by utilizing recycled fiber, which can be heated up without heating.

One aspect of the present invention, a polypropylene fiber, jute fiber, recycled fiber is made of a felt layer mixed with a certain ratio, and made of homo polyflopylene, disposed on both sides of the felt layer to improve the rigidity and surface strengthening effect Felt for vehicle interior material using a recycled fiber comprising a bubble paper to give and a PET non-woven fabric attached to the bubble paper attached to one surface of the felt layer to improve the workability during heating molding to enable simultaneous molding Can provide.

In addition, the thickness of the jute fiber may be 40 ㎛ or more and 120 ㎛ or less.

In addition, the length of the jute fiber may be 45mm or more and 80mm or less.

In addition, the recycled fiber may be made through at least one waste fiber of hemp, cotton, and chemical fibers that are by-products generated in at least one of the process of weaving, spinning and weaving through the horn and the other surface.

In addition, the recycled fiber may be 5mm or more and 80mm or less in length.

In addition, the polypropylene fibers, natural fibers and recycled fibers may each comprise a component ratio of 40 to 60: 20 to 30: 40 to 10% by weight.

In addition, the bubble paper may have a weight per unit area of 50 g / ㎡ or more and 150 g / ㎡ or less.

In addition, the PET nonwoven fabric may have a fiber thickness of 4 deniers or more and 15 deniers or less.

In addition, the PET nonwoven fabric may have a weight per unit area of 25 g / m 2 or more and 50 g / m 2 or less.

Another aspect of the invention, the first step of cutting the jute fibers, mixed with the polypropylene fibers, recycled fibers, mixing and opening the cart after opening; A second step of forming a felt layer by webforming the mixture material carded in the first step on a bubble paper; A third step of needle punching the felt layer formed in the second step against the bubble free surface; And a fourth step of needle punching the PET nonwoven fabric on the bubble paper formed on one surface of the felt layer.

In the embodiments according to the present invention, it is possible to reduce the cost by using recycled fiber, the content of jute fiber is low, the generation of harmful substances due to odor or preservative treatment due to the jute fiber carbonization is reduced, skin material And cohesion can be improved by improving the adhesiveness can be improved workability, such as less adhesive use.

1 is a cross-sectional view showing a felt for a vehicle interior material using recycled fibers according to an embodiment of the present invention.
2 is a manufacturing process diagram showing a manufacturing process of the felt for the vehicle interior material using the recycled fiber shown in FIG.

1 is a cross-sectional view showing a felt for a vehicle interior material using recycled fibers according to an embodiment of the present invention. 2 is a manufacturing process diagram showing a manufacturing process of the felt for the vehicle interior material using the recycled fiber shown in FIG.

Referring to FIGS. 1 and 2, a felt layer (111) in which a felt () for a vehicle interior material using recycled fibers, a polypropylene fiber, jute fibers, and recycled fibers are mixed at a predetermined ratio. )Wow; A bubble paper 112 made of Homo Polypropylene and positioned on both sides of the felt layer 111 to improve rigidity of the substrate and to impart a surface reinforcing effect; It is attached to the bubble paper 112 attached to one surface of the felt layer 111 is characterized in that the PET non-woven fabric 113 to improve the workability during the heating molding to enable simultaneous molding.

More detailed description of the present invention is as follows.

Polypropylene fiber used in the felt layer 111 is preferably 6 to 15 deniers (denier) and 45 to 80mm in length, and crimp (Crimp) for needle punching workability Staple fibers imparted. If 6 denier or less polypropylene (Polypropyelen) fiber is used, carding workability is not smooth, and when 15 denier or more coarse fiber is used, uniform dispersion mixing becomes difficult.

Jute fibers are preferably 40-120 μm thick and 45-80 mm long. In general, natural fibers are divided into jute, hemp, flax, and the like, jute is excellent in strength and durability, so it is suitable for the purpose of strength reinforcement.

Recycled fiber is made of waste fibers such as hemp, cotton, and chemical fibers, which are by-products generated in the weaving, spinning or weaving process, through the horn and the other surface, and is preferably 5 to 80 mm in length.

In the present invention, the felt layer 111 is composed of polypropylene fiber, jute fiber, recycled fiber, and the mixing ratio of each component is polypropylene fiber: jute fiber: recycled. It is preferable that the fiber (Recycled fiber) is composed of a weight percent of 40 ~ 60: 20 ~ 30: 40 ~ 10.

Polypropylene fiber is melted when forming the substrate, and serves to bind the jute fibers and the recycled fibers, and to provide the formability of the substrate, so the mixing ratio is preferably 40 to 60% by weight. When the polypropylene fiber is 40 wt% or less, the form stability of the felt decreases and the formability of the substrate is difficult, and when the polypropylene fiber is 60 wt% or more, the substrate forming preheating time becomes longer. Mass productivity falls.

Jute fiber reinforces the strength and stiffness of the molded substrate, but since it is a major cause of deterioration of moldability and odor problems, the mixing ratio is preferably 20 to 30% by weight. When the jute fiber is 20% by weight or less, the rigidity and heat resistance of the substrate Lower than 30% by weight is less than the odor improving effect and the cost savings are insignificant.

Since recycled fiber is used for the purpose of filling for odor improvement and cost reduction, a blending ratio of 40 to 10% by weight is preferable, and when the recycled fiber is 10% by weight or less, the effect of cost reduction and odor improvement is improved. If less than 40% by weight, the needle punching process (Needle punching) process workability is poor, making the felt (Felt) is difficult.

The bubble paper 112 is made of a homo polypropylene resin and has a weight of 50 to 150 g / m 2 per unit area. The bubble paper 112 is located on both surfaces of the felt 111 to be melted when forming a substrate. (Felt layer) 111 is absorbed by the surface to improve the surface strengthening effect of the substrate and the substrate rigidity, and also serves to improve the adhesive force when the melt-adhesives such as brackets and retainers to the substrate.

The PET nonwoven fabric 113 is made of PET fibers having a fiber thickness of 4 to 15 deniers (Denier) and has a weight per unit area of 25 to 50 g / m 2. It is attached to the side by needle punching method, and it has the effect of reinforcing strength and improving mold release property with hot mold when forming base material with wide cross-section, and improving skin and co-formability. If the area weight of the PET nonwoven fabric 113 is 25 g / m 2 or less, the releasability and co-moldability with the hot mold are lowered.

The manufacturing process of the felt (Felt) 1 according to the present invention is shown in Figure 2 and describes the process as follows.

First, the polypropylene fibers, jute fibers, and recycle fibers are weighed and mixed so that the mixing ratio is 40 to 60: 20 to 30: 40 to 10, and then each fiber is spiked ( Open the process by releasing with a spike roll and mixing again. Using a carding machine (Carding machine) to mix and arrange the fibers at the same time to perform a Web (Foaming), laminating the web (Web) with the desired weight and width on the bubble paper 112, Needle punching is used to increase the binding force of the laminated felt layer (Felt) 111 and to adjust to a desired thickness. Needle punching once again with two felt layers 111 fabricated in this way back to the surface without bubble paper 112 and then adding PET nonwoven fabric 113 to the surface to be attached to the skin material. Next, it is cut to a desired length and width to produce a felt (100) for vehicle interior materials (Felt) 100 using recycled fibers of a five-layer laminated structure.

Felt (100) manufactured according to the present invention is molded into a vehicle interior material substrate.

The felt 100 prepared according to the above process was charged to a heated plate mold, pressurized and melted to be about 1.2 to 1.8 times the thickness of the final substrate, and then the melted felt 100 was coated with the skin material. Injecting into a cold molding mold as described above provides a vehicle interior material base material in which the skin material is simultaneously molded.

Below is an experimental example comparing and analyzing the embodiment for the vehicle package tray (Package tray) according to the present invention.

In this case, the polypropylene fiber has a fineness of 6 deniers and a length of 65 mm, the jute fiber has an average thickness of 80 µm and a length of 60 mm, and the recycled fiber has an average length of 25 mm. Was used. The mixing ratio of polypropylene fiber, jute fiber, and recycled fiber was 40: 30: 30 wt%, and the bubble paper 112 was 100g / m2 attached on both sides, and the PET nonwoven fabric 113 was used. 50g / m <2> was used. Felt (1) was manufactured so that the unit area weight of the felt (1) was 1400, 1600 g / ㎡ through the process described in the configuration of the invention. The molding conditions of the test piece were made into the molding thickness of 1.8 mm, the molding temperature 200 ~ 210 ℃, preheating time 50 seconds, cooling molding pressure 15kgf / cm 2, cooling molding time 45 seconds. The test results for the specimen thus prepared were tested as described in the prior art, and are shown in Table 1.

Test Items unit Test Methods Example Prior art #One #2 Thermoplastic felt thickness mm MS361-15 1.8 1.8 1.8 weight g / m ² MS361-15 1400 1600 1400 density g / m ³ MS361-15 0.78 0.89 0.78 The tensile strength Vertical kgf / cm ² MS361-15 105 121 117 horizontal 189 215 210 Flexural strength Vertical kgf / cm ² MS361-15 172 204 198 horizontal 322 340 341 Flexural modulus Vertical kgf / cm ² MS361-15 12150 14250 13720 horizontal 29720 34320 34560 smell class MS300-34 Level 3 Level 3 Class 3.5 Peel strength kgf / 25cm MS320-11 Material destruction Material destruction 1.4

※ MS (Material Specification): Hyundai Motor Test Specification

As can be seen from the above experimental results, the embodiments according to the present invention can reduce the cost by using recycled fiber, and the content of the jute fiber is low, so that the harmful substances due to the odor or preservative treatment due to the jute fiber carbonization, etc. It is possible to reduce the occurrence, and to improve the adhesiveness and the skin material can be co-molded to improve the workability, such as reducing the use of the adhesive.

In addition, the embodiments according to the present invention have almost no change in tensile strength, flexural strength and flexural modulus as compared to the prior art, and thus can be sufficiently utilized as a description of a vehicle.

100: felt for vehicle interior material using recycled fiber
111: felt layer
112: bubble paper
113: PET nonwoven fabric

Claims (10)

A felt layer in which polypropylene fibers, jute fibers and recycled fibers are mixed in a proportion;
A bubble paper made of homo polyflopylene and disposed on both sides of the felt layer to improve rigidity and impart a surface strengthening effect,
Felt for a vehicle interior material using recycled fibers comprising a PET non-woven fabric is attached to the bubble paper attached to one side of the felt layer to improve the workability during heating molding to enable simultaneous molding. The method according to claim 1,
Felt for the vehicle interior material using recycled fibers of the thickness of the jute fiber 40 ㎛ to 120 ㎛. The method according to claim 1,
The length of the jute fiber is 45mm or more, 80mm or less felt for vehicle interior materials using recycled fibers. The method according to claim 1,
The recycled fiber is a felt for a vehicle interior material using recycled fiber made of at least one waste fiber of hemp, cotton, and chemical fibers, which are by-products generated in at least one of textile, spinning and weaving processes, through a mixed and other surfaces. The method of claim 4,
The recycled fiber is felt for vehicle interior materials using recycled fibers having a length of 5mm or more and 80mm or less. The method according to claim 1,
The polypropylene fibers, natural fibers and recycled fibers are felt for vehicle interior materials using recycled fibers containing each component ratio of 40 to 60: 20 to 30: 40 to 10% by weight. The method according to claim 1,
The bubble paper is a vehicle interior material felt using recycled fibers having a weight per unit area of more than 50 g / ㎡ 150g / ㎡. The method according to claim 1,
The PET nonwoven fabric is felt for vehicle interior material using recycled fibers having a fiber thickness of 4 denier (denier) or more than 15 denier (denier). The method according to claim 1,
The PET nonwoven fabric is felt for vehicle interior materials using recycled fibers having a weight per unit area of 25 g / ㎡ or more and 50 g / ㎡ or less. A first step of cutting the jute fibers, mixing and mixing with polypropylene fibers and recycled fibers, and then carding them after opening;
A second step of forming a felt layer by web foaming the mixture material carded in the first step on a bubble paper;
A third step of needle punching the felt layer formed in the second step against the bubble free surface;
And a fourth step of needle punching the PET nonwoven fabric on the bubble paper formed on one surface of the felt layer.

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