KR20170003750A - Natural fiber composite substrate and headlining for vehicle using the same - Google Patents

Abstract

An objective of the present invention is to provide a natural fiber composite substrate and a method for manufacturing a vehicle headlining using the same that are configured such that an insulation effect can be achieved from a layer containing a natural fiber and heat coming to the inside through a roof panel can be blocked by an attached material between layers of a multilayer structure being coated with a heat blocking material so that heat blocking effects can be enhanced without a heat blocking layer and the heat blocking effects can be maximized with an increase in weight limited to the minimum. Another objective of the present invention is to provide a natural fiber composite substrate and a method for manufacturing a vehicle headlining using the same in which a carbon nano tube is added to a heat blocking material applied to a hot melt film for heat blocking effects for the manufacturing and thus the heat blocking effects can be maximized by means of the carbon nano tube and vehicle fuel efficiency can be improved by means of the minimization of an increase in its weight. Yet another objective of the present invention is to provide a natural fiber composite substrate and a method for manufacturing a vehicle headlining using the same in which the heat blocking material is applied to layers of hot melt films used for inter-layer coupling in the case of a multilayer structure and thus the layers of the hot melt films can be selectively coated with the heat blocking material so that heat coming through a roof panel can be sufficiently blocked depending on the types of vehicles.

Description

TECHNICAL FIELD [0001] The present invention relates to a natural fiber composite material, and a method of manufacturing a headliner for an automobile using the same. BACKGROUND OF THE INVENTION [0002]

The present invention relates to a natural fiber composite substrate and a method of manufacturing a headliner for an automobile using the same. More particularly, the present invention relates to a natural fiber composite substrate, So that the room temperature can be prevented from rising and the energy efficiency can be increased.

Generally, automobiles are surrounded by glass everywhere, so that the heat flows into the room in summer and the cold air flows into the room in winter. Especially in summer, because of the theft prevention, most of the automobile which is in the airtight condition is made of metal sheet, so the inside temperature of the automobile is increased by external influence.

To prevent this problem, the glass is coated or coated with a film to prevent glare and prevent external heat from entering the room. However, external heat is not only absorbed by glass, but also through steel plates, especially roof panels. Accordingly, as in Patent Documents 1 to 3, various technologies are being developed to obtain a thermal insulation effect on the head lining.

Patent Document 1 is a multi-layered structure design which is composed of a core layer and a skin layer of a microporous structure using natural fibers and thermoplastic organic fibers, and does not use materials harmful to humans and the environment, Sound absorbing property, heat insulating property, and the like, and also relates to a method for manufacturing a lightweight natural fiber reinforced composite board which is human and environmentally friendly, and a vehicle interior material thereof.

Patent document 2 relates to a high sound-absorbing ceiling panel for a vehicle, which comprises a polyurethane foam layer, a reinforcing layer formed on both sides of the polyurethane foam layer, a felt layer formed on the upper surface of the polyurethane foam layer on which the reinforcing layer is formed, A film layer formed on the lower surface of the urethane foam layer, and a nonwoven fabric layer formed on the lower surface of the film layer. Thus, it is attached to the ceiling of the vehicle to block noise from the outside and improve the heat insulation of the vehicle.

Patent Document 3 not only improves the heat insulating performance by applying heat to the roof panel of a vehicle by blocking the heat flowing from the outside of the vehicle, but also adhering the laminated bodies in such a manner that they are melted and bonded using an adhesive film or an adhesive layer The present invention provides a ceiling material for a vehicle and a method of molding the same using a vacuum insulating material which can reduce the amount of process water and manufacturing cost and reduce the amount of volatile organic compounds emitted since no adhesive is used.

However, existing interior materials and ceiling materials (head lining) have the following problems.

(1) Since any one of the layers constituting the headlining is made of a material having a thermal insulation effect, a thermal insulation effect can be obtained as compared with the conventional headlining. However, since the entire heatlength of the headlining becomes thick There is a concern.

(2) As the thickness becomes thicker, the space occupied by the head lining becomes larger in the interior space of the limited automobile, which causes a decrease in space utilization.

(3) Addition of a separate insulating layer increases the manufacturing cost.

(4) In particular, since the total weight of the head lining is increased by addition of the heat insulating layer, the total weight of the automobile also increases, thereby contributing to a decrease in fuel consumption.

(5) Adhesive or the like is used to adhere the layer having the heat insulating function to the head lining, which may cause harm to the health of the driver as well as the operator.

Korean Registered Patent No. 1279522 (Registered on June 23, 2013) Korean Registered Patent No. 1302220 (Registered: 2013.08.26) Korean Registered Patent No. 1394746 (Registered on May 31, 2014)

The present invention has been made in view of this point and it is an object of the present invention to provide a heat insulating material which can prevent the heat coming into the room through the roof panel by coating a heat insulating material on the adhesion material between the multi- The present invention provides a natural fiber composite material capable of enhancing heat blocking effect while minimizing weight increase while maximizing heat blocking effect without forming a separate heat barrier layer and manufacturing a head lining using the same And the like.

In particular, since the present invention is manufactured by adding carbon nanotubes to a heat shielding material applied to a hot melt film for heat shielding effect, the heat shielding effect can be maximized through the carbon nanotubes, And a method of manufacturing a head lining for an automobile using the same.

In addition, the present invention applies such a heat shielding material to a plurality of layers of hot melt films used for interlayer bonding in the case of a multi-layer structure. Therefore, in order to sufficiently block the heat coming through the roof panel depending on the type of vehicle, Another object of the present invention is to provide a natural fiber composite material which can be used by coating a hot melt material on a hot melt film and a manufacturing method of head lining for an automobile using the same.

A first hot melt film 30, a second layer 40 containing natural fibers, a second hot melt film 50, and a second hot melt film 50. The first layer 20, The first and second hot melt films 30 and 50 are made of at least one of polyolefin, TPE, EVA, PET, and polyamide having a thickness of 30 to 50 탆, respectively, And at least one of the first and second hot melt films (30, 50) is coated with a heat shielding material on at least one surface thereof in a thickness of 1 to 10 mu m.

Particularly, the first layer 20 and the third layer 60 are made of PP, PET, rubber plywood, soft plate sound insulation sheet, thermoplastic elastomer (TPE), ethylene propylene rubber (EPDM), ethylene vinyl acetate (EVA) CaCo3 · Stearic Acid · LLDPE · Elastomer · PP · Nonwovens · Glass wool · Cork · Foam resin · Felt · Microfiber · PET and polyurethane foam At least one monolayer or at least two multi-layer structures, and the second layer 40 is at least one of a PP, a nonwoven fabric, a glass wool, a cork, a foamed resin, a felt, a microfiber, a PET and a polyurethane foam And has at least two multilayer structures.

In addition, the first layer 20 is a PP containing natural fibers, has a weight of 1,000 to 1,100 g / m 2, and a thickness of 4 to 10 mm.

The heat shielding material is composed of 5.0 to 10.0% by weight of modified polyacrylic resin, 9.9 to 20.0% by weight of carbon nanotubes, 65.0 to 85.0% by weight of alcohol, and 0.1 to 5.0% by weight of additives. The carbon nanotubes are multi-wall carbon nanotubes having a diameter of 10 to 30 nm and a length of 20 to 40 μm.

Of the first and second hot-melt films 30 and 50, the hot-melt film coated with the heat-shielding material is characterized in that it exhibits a heat-shielding rate of 50 to 90% in the infrared region (800 to 2,200 nm) of sunlight .

The present invention also relates to a method of manufacturing a headlining for an automobile using the above-mentioned natural fiber composite substrate. This method is characterized in that the surface layer 10 is put in contact with the first layer 20 of the above- And then heated in an oven at a temperature of 200 to 210 DEG C for 80 to 100 seconds, followed by cooling molding at a pressure of 70 to 90 bar for 20 to 40 seconds.

Lastly, the surface layer 10 is characterized in that it is made of at least one of artificial leather, urethane, fabric and vinyl including nonwoven fabric, suede, cloth, natural leather, PVC leather.

The natural fiber composite material according to the present invention and the method for manufacturing a headliner for an automobile using the natural fiber composite material have the following effects.

(1) Since the hot melt film used for adhesive bonding is applied to the heat shielding material to block external heat flowing into the room from the roof panel, it is not necessary to separately form a layer for heat shielding.

(2) This makes it possible to obtain a heat shielding effect without increasing the thickness of the headlining, thereby making it possible to increase the space utilization of the car interior space of a limited size.

(3) Especially, since the hot-melt film has adhesiveness and is usually used for various layers of head lining having a multi-layered structure, it is possible to selectively apply a heat shielding material to these hot- Head lining having different heat shielding effect can be manufactured depending on the type of vehicle.

(4) In addition, since the heat shielding material is formed by adding carbon nanotubes, the heat shielding ability of the carbon nanotubes improves the effect of blocking external heat, and in particular, the carbon nanotubes have a superior heat shielding effect It is possible to increase the heat shielding effect while minimizing the weight.

(5) Since natural fiber is added, natural fibers can form an air layer to increase the heat insulation effect, but also lighten the heat insulation effect, thereby lowering the fuel consumption rate.

1 is a partial cross-sectional view cut to show a layer structure of a natural fiber composite material according to the present invention;
FIG. 2 is a graph comparing the heat blocking performance of a hot melt film (example) applied with a heat shielding material according to the present invention and an improper hot melt film (comparative example).
3 is a partial cross-sectional view cut to show the layer structure of a head lining according to the present invention.
4 is a graph comparing the heat shielding performance of the head lining (embodiment) using the hot melt film applied with the heat shielding material according to the present invention and the comparative example not applied.
FIG. 5 is a graph showing the internal temperature of an automobile mounted on a vehicle without a head lining (embodiment) in which a hot melt film applied with a heat shielding material according to the present invention is applied (a non-applied example).

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. Prior to this, terms and words used in the present specification and claims should not be construed as limited to ordinary or dictionary terms, and the inventor should properly define the concept of the term to describe its invention in the best possible way The present invention should be construed in accordance with the spirit and scope of the present invention.

Therefore, the embodiments described in the present specification and the configurations shown in the drawings are merely the most preferred embodiments of the present invention and are not intended to represent all of the technical ideas of the present invention. Thus, various equivalents And variations may be present.

(Natural fiber composite substrate)

1, the first layer 20, the first hot melt film 30, the second layer 40 containing natural fibers, and the second hot melt film 50 And the third layer 60 are sequentially stacked and melt-pressed.

Particularly, the present invention is characterized in that at least one of the hot-melt films used for attaching the multi-layer structure is coated with a thermal barrier material on at least one surface thereof to obtain a heat shielding effect without forming a separate thermal barrier layer In addition, it is possible to increase the energy efficiency of the automobile and increase the heat shielding effect by minimizing the weight increase of the structure for the heat shielding.

Hereinafter, this configuration will be described in more detail.

The first layer 20, the second layer 40 and the third layer 60 are sequentially stacked to form a multi-layer structure as shown in FIG. 1, and in particular, And is made of a sound absorbing material or a sound insulating material well known in the art.

For example, the first layer 20 and the third layer 60 may be made of PP, PET, rubber plywood, sound insulating sheet, thermoplastic elastomer (TPE), EPDM ethylene propylene rubber EVA (Ethylene Vinyl Acetate) Calcium Carbonate (CaCo3) Stearic Acid LLDPE (Elastomer) Elastomer PP Nonwoven fabric Glass wool Cork foam A single layer made of at least one of resin, felt, microfiber, PET and polyurethane foam, or at least two multi-layered structures.

The second layer 40 is a sound-absorbing layer and is formed of at least one single layer of PP, nonwoven fabric, glass wool, cork, foamed resin, felt, microfiber, PET and polyurethane foam, Layer structure.

Of course, the first layer 20, the second layer 40, and the third layer 60 may be formed of a sound-absorbing layer or a sound-insulating layer, and the first layer 20 and the third layer 60 60 may be constituted by a sound-absorbing layer and the second layer 40 may be constituted by a sound-insulating layer.

In a preferred embodiment of the present invention, it is preferable that the second layer 40 uses PP containing natural fibers so that the sound absorbing performance and the heat insulating performance can be combined. It is preferable that the weight of the second layer 40 at this time is about 1,000 to 1,100 g / m 2 so that the weight increase of the composite substrate can be reduced as much as possible. The second layer 40 may be formed to have a thickness of 4 to 10 mm so as not to increase the thickness of the composite substrate so as to increase the space utilization of the automobile interior.

The first and second hot melt films 30 and 50 are inserted between the first to third layers 20, 40 and 60 as shown in Fig. 1, and are adhered to each other as they are melt- .

Since such a hot melt film does not use a solvent, it is environmentally friendly, and it is made of an ordinary technique which is not only quick in drying time but also easily adhered to various materials and used. For example, the hot melt film may be made of at least one of polyolefin, TPE, EVA, PET and polyamide. The thickness at this time is set to a thickness capable of attaching the above-described layers to each other, for example, 30 to 50 mu m.

Meanwhile, in a preferred embodiment of the present invention, the first and second hot melt films 30 and 50 are coated with a heat shielding material. At this time, the heat shielding material is coated on at least one side of both sides of the hot melt film. Since the natural fiber composite substrate has a multilayered structure, the hot-melt film needs a plurality of layers. In order to control the heat-shielding effect, at least one of the hot- Coating is used.

The heat shielding material used herein may be any material that can block the heat transmitted through the roof panel. Illustratively, in a preferred embodiment of the present invention, the thermal barrier material comprises 5.0 to 10.0% by weight of modified polyacrylic resin, 9.9 to 20.0% by weight of carbon nanotubes, 65.0 to 85.0% by weight of alcohol, 0.1 to 5.0% May be used. Further, the heat shielding material can be coated to a thickness of 1 to 10 mu m to minimize the weight increase. At this time, the carbon nanotubes are preferably multi-wall carbon nanotubes having a diameter of 10 to 30 nm and a length of 20 to 40 μm.

The heat shielding performance of the heat shielding material according to the present invention is as shown in the following FIG. FIG. 2 shows the results of measurement of the transmittance in the infrared region for the hot-melt film coated with the heat-shielding material of the present invention (Examples) and the hot-melt film (Comparative Example) not coated. At this time, the transmittance (%) was measured with a measuring instrument "Jasco V-670 " at a wavelength of 200 to 2,700 nm.

As a result, as shown in FIG. 2, it can be seen that the transmittance increases as the wavelength increases, whereas the comparative example shown as yellow appears almost constant irrespective of the wavelength, as the wavelength increases. In particular, it can be seen that the embodiment blocks heat by about 50 to 90% in the infrared region (800 to 2,200 nm) of sunlight.

As described above, according to the present invention, the first layer 20, the first hot-melt film 30, the second layer 40 containing natural fibers, the second hot-melt film 50, and the third layer 60, And these are melt-pressed to obtain a natural fiber composite substrate. In this case, the melt-pressing is carried out within a range of melting the hot-melt film and attaching each layer to each other.

Therefore, the natural fiber composite material according to the present invention can obtain the heat insulation performance through heat shielding, and in particular, the heat shielding material can be adjusted to have different heat insulation performance depending on the coating location, The insulation performance can be improved.

(Manufacturing method of head lining)

The head lining manufacturing method according to the present invention is manufactured by using the above-mentioned natural fiber composite substrate (B) as shown in Fig. Here, the constitution of the above-mentioned natural fiber composite substrate and its detailed description are omitted and the same reference numerals are used for the same constitution.

That is, the head lining according to the present invention is manufactured by needle punching the surface layer 10 on the outer surface of the first layer 20 as described above with reference to FIG. 3, followed by heating and cooling molding.

Here, needle punching refers to a conventional technique in which fibers are drawn on a substrate with a needle or the fibers are wound together, which may weaken the adhesion between the natural fiber composite substrate (B) and the surface layer (10).

In the present invention, after the needle punching, heating and cooling molding are performed. At this time, heating is performed in an oven at a temperature of 200 to 210 DEG C for 80 to 100 seconds, and cooling molding is performed at a pressure of 70 to 90 bar for 20 to 40 seconds.

On the other hand, the surface layer 10 is a portion exposed to the indoor side when the headlining is mounted on the ceiling of the room, and any material can be used as long as it can be closed. Such material may be at least one of artificial leather, urethane, fabric and vinyl including nonwoven fabric, suede, cloth, natural leather, and PVC leather.

4) and the result of measuring the indoor temperature of the actual vehicle (refer to FIG. 5) are as follows.

FIG. 4 is a graph showing the results obtained by cutting a head lining (embodiment) according to the present invention and a conventional head lining (comparative example) into a 250 × 250 mm wide area and irradiating a light source with a wavelength of 0.75-3 μm at a temperature of 24 ° C. And the temperature was measured according to the time change (unit of 5 minutes) when irradiated at a temperature of 80 ° C.

As a result, as shown in FIG. 4, it can be seen that the temperature is lower over the entire time than the comparative example in which the blue is displayed in yellow, and the temperature difference is more increased with time . This means that the temperature rise relative to the external temperature is not so large because the embodiment has an adiabatic effect as compared with the comparative example. In FIG. 4, the horizontal axis represents time and the vertical axis represents temperature change, respectively.

[Fig. 5] is a graph showing the internal temperature of the automobile interior in the middle portion of the roof panel measured in units of 30 minutes, with the embodiment and the comparative example mounted on the actual vehicle.

As a result, as shown in FIG. 5, it can be seen that the temperature of the embodiment shown in yellow is lower than that of the comparative example shown in blue, and the temperature becomes larger as time passes. Thus, it can be seen that the maximum temperature difference differs by about 3 ° C. In Fig. 5, the horizontal axis represents the time change from 10:00 am to 2:30 pm, and the vertical axis represents the temperature change of the room.

As described above, the heat shielding effect of the present invention is higher than that of the conventional head lining.

10: Surface layer
20: First layer
30: first hot melt film
40: Second layer
50: second hot melt film
60: Third floor

Claims (8)

The first layer 20, the first hot-melt film 30, the second layer 40 containing the natural fibers, the second hot-melt film 50, and the third layer 60 are successively stacked and melt-
The first and second hot melt films 30 and 50 are each formed of at least one of polyolefin, TPE, EVA, PET, and polyamide having a thickness of 30 to 50 탆. The first and second hot melt films 30 and 50, Wherein at least one of the hot melt films is coated with a heat shielding material on at least one side to a thickness of 1 to 10 mu m.
The method according to claim 1,
The first layer 20 and the third layer 60 may be formed of at least one selected from the group consisting of PP, PET, rubber plywood, sound insulating sheet, thermoplastic elastomer (TPE), ethylene propylene rubber (EPDM), ethylene vinyl acetate (EVA) (CaCo3), Stearic Acid, LLDPE (Elastomer), Elastomer, PP, Nonwoven fabric, Glass wool, Cork, Foam resin, Felt, Microfiber, PET and Polyurethane foam Or at least two multi-layered structures,
Wherein the second layer (40) comprises at least one single layer or at least two multi-layer structures of PP, nonwoven fabric, glass wool, cork, foamed resin, felt, microfiber, PET and polyurethane foam. .
The method according to claim 1,
The first layer 20 is a PP containing natural fibers,
A weight of 1,000 to 1,100 g / m 2, and a thickness of 4 to 10 mm.
The method according to claim 1,
The heat-
Modified polyacrylic resin 5.0 to 10.0 wt%
9.9 to 20.0 wt% of carbon nanotubes
Alcohol 65.0 ~ 85.0 wt%
Additive 0.1-5.0 wt%
Wherein the natural fiber composite substrate is a fiber-reinforced composite fiber.
5. The method of claim 4,
Wherein the carbon nanotube is a multi-wall carbon nanotube having a diameter of 10 to 30 nm and a length of 20 to 40 μm.
The method according to claim 1,
Among the first and second hot melt films 30 and 50,
Wherein the hot melt film coated with the heat shielding material exhibits a thermal cutoff ratio of 50 to 90% in the infrared region (800 to 2,200 nm) of sunlight.
A method for manufacturing an automotive head lining using a natural fiber composite material according to any one of claims 1 to 6,
The surface layer 10 is sandwiched between the first layer 20 of the natural fiber composite material and the second layer 20,
Characterized in that it is heated in an oven at a temperature of 200 to 210 占 폚 for 80 to 100 seconds and then cooled at a pressure of 70 to 90 bar for 20 to 40 seconds to form the natural fiber composite material.
8. The method of claim 7,
The surface layer (10)
Wherein the natural fiber composite material is made of at least one of artificial leather, urethane, fabric, and vinyl including nonwoven fabric, suede, cloth, natural leather, and PVC leather.

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