KR20170026866A - Method for manufacturing lightweight and high stiffness headlining of vehicle - Google Patents

Method for manufacturing lightweight and high stiffness headlining of vehicle Download PDF

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Publication number
KR20170026866A
KR20170026866A KR1020150122503A KR20150122503A KR20170026866A KR 20170026866 A KR20170026866 A KR 20170026866A KR 1020150122503 A KR1020150122503 A KR 1020150122503A KR 20150122503 A KR20150122503 A KR 20150122503A KR 20170026866 A KR20170026866 A KR 20170026866A
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KR
South Korea
Prior art keywords
polyurethane foam
composite fabric
fiber
melt film
headlining
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KR1020150122503A
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Korean (ko)
Inventor
권충호
최경민
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(주)대한솔루션
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Priority to KR1020150122503A priority Critical patent/KR20170026866A/en
Publication of KR20170026866A publication Critical patent/KR20170026866A/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/12—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor of articles having inserts or reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
    • B60R13/0212—Roof or head liners
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/08—Insulating elements, e.g. for sound insulation

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Laminated Bodies (AREA)

Abstract

The present invention provides a method of manufacturing a light-weight high-stiffness automotive headlining, which uses polyurethane foam having an excellent noise function as a substrate and reinforces at least one side of the substrate with a composite fabric reinforcing member to form a headlining, so that the manufactured headlining possesses the light-weight and excellent noise function of the polyurethane foam and the stiffness supplemented by the composite fabric reinforcing member while maintaining the noise function, and being durable and light-weight, may improve the fuel efficiency of a vehicle. Specifically, the composite fiber reinforcing member may be produced by weaving a Leno plain in the shape of a coarse plaid with fibers such as carbon fiber, glass fiber, carbonized silicon, alumina fiber and aramid fiber, and coating at least one side thereof with a resin, or produced in the form of a prepreg in which fibers are impregnated with a heat-curing resin or thermoplastic resin, to be attached to the polyurethane foam. Accordingly, the method of the present invention can easily manufacture a headlining with a desired hardness and offers excellent moldability, allowing a complex three-dimensional structure to be easily molded. Also, both surfaces of the substrate reinforced with the composite fiber reinforcing member are further reinforced using a reinforcing layer made of non-woven fabric or glass fiber mat, and thus the substrate can be easily used to manufacture a light-weight, stiffness-reinforced headlining having a complex three-dimensional structure.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a high rigidity lightweight headlining for a vehicle,

The present invention relates to a method of manufacturing a high rigidity lightweight automotive headliner, and more particularly, to a method of manufacturing a headlining for automobiles, which comprises a polyurethane foam as a substrate, a composite fabric reinforcement made of fiber and resin, and a reinforcing layer using nonwoven fabric or glass fiber So that the overall weight of the head lining itself can be reduced through the composite fabric reinforcement and the reinforcing layer while maintaining almost no noise characteristics through the polyurethane foam, thereby improving the fuel efficiency.

Generally, a roof panel of a vehicle absorbs noise and vibration transmitted through a roof panel of an automobile and noise generated in a vehicle interior, as shown in Figs. 1 and 2, and provides appearance merchandise and convenience And a head lining (L) is mounted to prevent damage to the head of a passenger in the event of a collision. The head lining L is fixed to the roof rail and is made of various materials such as vinyl or cotton to serve as a heat insulating material against changes in temperature from the outside. The following Patent Documents 1 to 3 disclose a conventional head lining technique.

Patent Document 1 improves the adhesion of the acoustic head lining layer by improving the reliability of the product while simplifying the manufacturing process and prevents the polyurethane foam from being thermally deformed to have excellent sound absorbing performance.

Patent Document 2 discloses a laminate comprising a first layer comprising natural fibers, polypropylene and polyethylene terephthalate; A second layer comprising a thermoplastic blowing agent (TF foam); And a third layer comprising natural fibers, polypropylene and polyethylene terephthalate, and capable of realizing high sound absorption properties, environmental friendliness and light weight, and a method for manufacturing the head lining material.

Patent Document 3 uses an adhesive powder which is characterized by a graftomer and thus has excellent adhesive force. Since an adhesive film is not used, it can be produced by a simple process compared to a conventional adhesive film and a manufacturing process using adhesive powder, And the troublesome use of the adhesive film can be improved, and the air-permeable adhesive layer is formed.

The head lining has been replaced by lightweight materials due to the high weight characteristics of the products to ensure the environmentally friendly parts of the automobile interior and the formability of the fiber material, although various materials such as resin felt and natural fiber material have been mainstream. Accordingly, in recent years, foamed polyurethane foam having excellent NVH performance has become a mainstream as a lightweight material.

On the other hand, in addition to the light weight, head lining is also important for head lining including vehicle interior lighting and various convenience device module parts, in addition to NVH performance, securing product rigidity to prevent deformation due to load of module parts. For this purpose, glass wool or polymer binders reinforcing the rigidity of the foamed polyurethane foam were used, which made it lighter than resin felt and natural fibers, resulting in increased product weight.

Polypropylene / glass wool mixed materials having excellent rigidity have been developed and used as materials for solving such problems. However, rigidity is excellent due to stability problem after molding of polypropylene / glass wool mixed material. However, foamed polyurethane foam with reinforced layer is used more and more for reasons of NVH performance and moldability even at a slightly higher weight.

3 is a cross-sectional perspective view of a conventional polyurethane foam having excellent NVH performance, in which layers are separated to show the structure of a conventional head lining. In the conventional head lining, the glass fiber layer 2 is formed on at least one side of both sides of the polyurethane foam 1. In the figure, the glass fiber layer 2 is formed on both sides, and the reference numeral 3 denotes a binder such as an adhesive for attaching the polyurethane foam 1 and the glass fiber layer 2.

However, the polyurethane foam is somewhat efficient for the noise problem and light weight, but has a weak stiffness in itself. That is, since the head lining is a portion where a wire, an indoor lighting, and various kinds of convenience devices are mounted on a surface facing the roof panel, self rigidity is required to support such various devices.

Therefore, glass fiber and polymer binder were used for reinforcing the head lining made of a polyurethane foam having excellent noise performance and light weight. However, this is advantageous in strengthening the rigidity of the head lining, but it is heavy in weight, and as a result, it lowers the fuel efficiency of the automobile. In addition, the polypropylene / glass wool mixed material has excellent noise characteristics, but its weight is heavy, which lowers fuel efficiency.

Korean Registration Practice No. 0188709 (Registered on April 29, 2000) Korean Registered Patent No. 1192416 (Registered on October 11, 2012) Korean Registered Patent No. 1227628 (Registered on March 31, 2013)

The present invention takes this point into consideration and it is an object of the present invention to provide a polyurethane foam which is excellent in noise performance and has a structure in which a composite fabric reinforcement is reinforced on at least one side of both sides thereof to form a head lining, And to provide a method of manufacturing a high rigidity and lightweight automotive headlining that is robust, lightweight, and capable of reducing fuel consumption while maintaining noise performance by supplementing rigidity of the composite fabric reinforcement.

More particularly, the present invention relates to a method of woven Leno Plain which is a lattice-like lattice of a fiber such as carbon fiber, glass fiber, silicon carbide, alumina fiber and aramid fiber, then woven on at least one side of both sides thereof with resin, Since the composite fabric stiffener is fabricated in the form of a prepreg impregnated with a thermosetting resin or a thermoplastic resin and attached to a polyurethane foam, the fabric can be easily manufactured with desired strength, Another object of the present invention is to provide a method of manufacturing a high rigidity and lightweight headlining for an automobile which can be easily formed into a shape.

In addition, the present invention can be easily fabricated in accordance with the shape of a complicated three-dimensional head lining with lightness, stiffness complement, and by reinforcing a reinforcing layer made of a nonwoven fabric or a glass fiber mat on both surfaces of the base material reinforced with the composite fabric reinforcement. The present invention provides a method of manufacturing a high rigidity and lightweight headlining for an automobile.

In order to achieve the above object, a method of manufacturing a high rigidity lightweight car headliner according to a first embodiment of the present invention is characterized in that a polyurethane foam 10 and at least one of both surfaces of the polyurethane foam 10 are coated with a binder The hot melt film 31 and the nonwoven fabric 30 are sequentially laminated on both sides of the base material made of the composite fabric stiffener 20 attached to the base material B and then heated in the thermoforming mold at a temperature of 140 to 160 DEG C for 40 to 80 The composite fabric stiffener 20 is fabricated by pressing synthetic resin on at least one side of both sides of a fabric woven with Leno Plain so that the clearance between the fibers and the fiber has a predetermined gap And then coated.

A method of manufacturing a high rigidity lightweight car headliner according to a second embodiment of the present invention is a method of manufacturing a headlining for a vehicle having a polyurethane foam 10 and a method of attaching a polyurethane foam 10 on at least one surface of the polyurethane foam 10 with a binder B The hot melt film 31 and the nonwoven fabric 30 are laminated in order on both sides of the substrate made of the composite fabric stiffener 20 and then subjected to compression molding at a temperature of 140 to 160 DEG C for 40 to 80 seconds in a thermoforming mold The composite fabric stiffener 20 is characterized in that the fiber is a prepreg impregnated with a thermosetting resin or a thermoplastic resin.

A method of manufacturing a high rigidity and lightweight automotive headliner according to a third embodiment of the present invention is a method of manufacturing a headlining for a vehicle having a polyurethane foam 10 and a polyurethane foam 10, A hot melt film 31 and a nonwoven fabric 30 which are sequentially stacked on one side of the base material and a hot melt film 31 and a glass fiber mat 30 which are sequentially stacked on the other side of the base material, The composite fabric stiffener 20 is fabricated by laminating the composite fabric stiffener 20 in turn on a thermoforming mold at a temperature of 140 to 160 ° C. for 40 to 80 seconds; (Leno Plain) woven fabric is coated on at least one side of both sides with a synthetic resin.

A method of manufacturing a high rigidity lightweight car headliner according to a fourth embodiment of the present invention is a method of manufacturing a headlining for a vehicle having a polyurethane foam 10 and a method of manufacturing a headlining having a structure in which a polyurethane foam 10 is bonded to at least one surface of the polyurethane foam 10 with a binder B A hot melt film 31 and a nonwoven fabric 30 which are sequentially stacked on one side of the base material and a hot melt film 31 and a glass fiber mat 30 which are sequentially stacked on the other side of the base material, The composite fabric reinforcement 20 is produced by pressing a thermoplastic resin or a thermoplastic resin impregnated with a thermoplastic resin or a thermoplastic resin in a thermoforming mold at a temperature of 140 to 160 ° C for 40 to 80 seconds, And is a prepreg.

In particular, the fiber is at least one of carbon fiber, glass fiber, silicon carbide, alumina fiber and aramid fiber.

Also, the composite fabric reinforcement 20 has a surface density of 50 to 300 g / m 2.

The polyurethane foam 10 is formed by foam molding in the form of a block having a radius of 22 to 32 g / m < 3 >, aged for 7 to 10 days to remove heat inside the foam, .

The binder (B) is characterized by being an isocyanate-based glue 30 to 150 g / m 2 or a polyolefin-based film-type polymer 30 to 150 g / m 2 .

Also, the nonwoven fabric 30 is 30 to 100 g / m 2 , and the hot-melt film 31 is a polyolefin-based or polyamide-based polymer 30 to 150 g / m 2 .

Finally, the nonwoven fabric 30 is 30 to 100g / m 2, and the glass fiber mat 30 'is 50 ~ 350g / m 2, and wherein the hot-melt film (31) is a polyolefin-based or polyamide-based polymer 30 - 150 g / m < 2 >.

The method for manufacturing a high rigidity and lightweight automotive headlining according to the present invention has the following effects.

(1) The use of a composite fabric stiffener makes it possible to support a wide range of comfort devices mounted on the roof panel due to its own weight, A headlining having rigidity can be manufactured.

(2) In particular, the composite fabric stiffener is made of fibers, which is lighter in weight, but also has excellent noise performance in addition to polyurethane foam, and can be manufactured using resin to increase its own rigidity while being lightweight.

(3) At this time, the composite fabric stiffener is fabricated by impregnating resin into a resin, fabricating the fabric in a lattice form by leno plain weaving, and then coating the resin on the surface thereof to form a composite Fabric reinforcements can be easily manufactured and used.

(4) That is, the greater the amount of the resin impregnated into the fibers, the greater the rigidity. When the spacing between the grids is narrower, the stiffness becomes greater as the spacing between the grids becomes smaller. In this case, depending on the thickness of the fibers used, A reinforcing material can be produced.

(5) Since different rigidity is required depending on the type of vehicle and so on, composite fabric stiffeners can be manufactured and used in accordance with the different stiffness, so that optimization design is possible.

(6) As described above, the composite fabric stiffener is reinforced on the polyurethane foam, and a reinforcing layer such as a nonwoven fabric and a glass fiber mat is further formed on both sides thereof, so that the rigidity of the head lining can be further enhanced.

(7) Since a thermoforming mold is used in such a manner as to pad such a reinforcing layer, it can be easily and quickly manufactured in a desired shape.

(8) As compared with the comparative example in which the glass fiber mat is applied to both sides of the present invention, the present invention has a weight reduction effect of about 34% in the case of applying the composite fabric reinforcement on both sides, the composite fabric reinforcement on one side, In the case of the embodiment using the glass fiber mat, the weight is reduced by about 17% compared to the conventional comparative example.

FIG. 1 is a perspective view of a vehicle for showing a mounting position of a head lining. FIG.
FIG. 2 is a perspective view showing an example of a conventional head lining. FIG.
FIG. 3 is a cross-sectional perspective view of a conventional headlining to show a layer structure thereof. FIG.
4 is a sectional view showing a layer structure of a head lining according to Embodiment 1 of the present invention.
5 is a photograph showing a state in which fibers are woven in a Leno Plain for use in manufacturing a composite fabric stiffener according to Embodiment 1 of the present invention.
6 is a sectional view showing a layer structure of a head lining according to Embodiment 2 of the present invention.
7 is a sectional view showing a layer structure of a head lining according to Embodiment 3 of the present invention.
8 is a sectional view showing a layer structure of a head lining according to Embodiment 4 of the present invention.

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.

A method of manufacturing a high rigidity lightweight car headliner according to a first embodiment of the present invention is characterized in that a polyurethane foam 10 and a composite fabric 10 are formed on at least one of both surfaces of the polyurethane foam 10 as shown in Figs. A reinforcement layer composed of a hot melt film 31 and a nonwoven fabric 30 is laminated on both sides of a base material provided with a reinforcing material 20 and thermally molded.

Particularly, the composite fabric stiffener 20 is fabricated by leno plaining fabric so as to be lattice-like with the fibers while maintaining the noise performance and light weight by using the fibers, and by applying synthetic resin to the surface thereof, The lining can be reinforced with the overall rigidity and lightened.

Hereinafter, this configuration will be described in more detail. Here, the constitution of the head lining according to the present invention will be described first, and the thermoforming for integrating these constitutions together will be described.

The head lining according to the first embodiment of the present invention includes a polyurethane foam 10, a composite fabric reinforcement 20, and a nonwoven fabric 30 as shown in Fig.

The polyurethane foam 10 may be any of those having sound absorbing performance, but it is preferable that the polyurethane foam 10 is manufactured so as to minimize the increase in the weight of the head lining, and to eliminate the internal heat and prevent twisting after molding. The polyurethane foam 10 is formed by foam molding in the form of a block having a radius of 22 to 32 g / m < 3 > and aged for 7 to 10 days to remove heat inside the foam, .

The composite fabric stiffener 20 is formed by affixing a composite fabric stiffener 20 on at least one side of both sides of a polyurethane foam 10 by using a binder B. [ At this time, the composite fabric stiffener 20 is attached to the polyurethane foam 10 via the binder B. Such a binder may be of a film type such as hot melt, but may be made of a conventional technique such as an adhesive applied by spraying on the surface. Most preferably, the binder is an ISOCYANATE glue 30 to 150 g / m 2 or a polyolefin film type It is preferable to use 30 to 150 g / m 2 of the polymer.

In the meantime, the composite fabric reinforcement 20 is formed by leno plaiting fabric in the form of a lattice, and then at least one side of both sides thereof is coated with synthetic resin. Leno Plain Weave is a method of weaving two or more warp yarns together to form a single weft yarn so that there is a wide clearance between weft yarn and warp yarns and that the fabric with a small number of yarns is not pushed. That is, in the present invention, as shown in FIG. 5, a lattice is formed in a lattice form using fibers, and a lattice having a predetermined size of space is formed therein.

Here, the fiber can be used as long as it is used in the technical field of the present invention. Among them, carbon fiber, glass fiber, silicon carbide, alumina fiber and aramid fiber can be used. At this time, each of these fibers may be used singly, or at least one of them may be mixed and weaved.

The synthetic resin may be a thermosetting resin or a thermoplastic resin, and any synthetic resin used for the composite material may be used. It is most preferable to use an epoxy resin as the thermosetting resin among these synthetic resins.

In a preferred embodiment of the present invention, it is preferable that the composite fabric reinforcement 20 has a surface density of 50 to 300 g / m 2. This is because the composite fabric stiffener 20 is lightweight and has a certain degree of rigidity so that when the head lining is mounted on a vehicle, the composite fabric stiffener 20 has a surface density of not being sagged or warped due to its weight.

The reinforcing layer is composed of the hot melt film 31 and the nonwoven fabric 30 and is attached to both sides of the base material made of the polyurethane foam 10 having the composite fabric stiffener 20 attached on at least one side thereof.

The nonwoven fabric 30 is formed in a thin paper-like form and is convenient because it can be easily and quickly processed similarly to the shape of hygroscopic and complicated three-dimensional headlining. It is preferable that the nonwoven fabric 30 has a weight of 30 to 100 g / m 2 so as to minimize the increase in weight and to enhance the hygroscopicity, workability and rigidity reinforcement effect.

Here, a hot-melt film 31 is used to adhere the non-woven fabric 30 to a substrate. As the hot melt film that can be used at this time, any film may be used as long as it has adhesion ability, but it is preferable to use 30 to 150 g / m 2 of a polyolefin-based or polyamide-based polymer.

On the other hand, the constitution as described above is constituted by the hot melt film 31 and the hot melt film 31 on both sides of the base made of the composite woven fabric reinforcement 20 attached on at least one side of both sides of the polyurethane 10 with the binder B And the nonwoven fabric 30 are laminated in this order, followed by compression molding using a thermoforming mold to produce the head lining according to the first embodiment of the present invention.

In this case, the thermoforming mold is formed by pressing and molding the binder (B) and the hot-melt film (31) under the condition that the respective components can be integrally attached, for example, at a temperature of 140 to 160 DEG C for 40 to 80 seconds Compression molding.

The composite fabric stiffener 20 according to the present invention may have a light weight and a certain noise level due to the characteristics of the fiber. In particular, the synthetic resin may have a complicated shape of the head lining It is possible to easily mold and improve the moldability. In addition, the fabric of the weave fabric can increase the rigidity of the head lining through the structural rigidity and the moldability of the three dimensional shape of the complex head lining.

Therefore, the head lining according to the first embodiment of the present invention can reduce the weight of the head lining itself and maintain the noise characteristics to some extent, and can easily form a complicated three-dimensional shape of the head lining with high rigidity.

Further, by providing a reinforcing layer such as the nonwoven fabric 30 on both sides of the substrate, it is possible to expect effects such as the hygroscopic effect and the moldability of the nonwoven fabric in addition to the rigidity reinforcement of the headlining.

The head lining according to the second embodiment of the present invention is similar to the head lining according to the second embodiment except that the fibers and the synthetic resin used in the first embodiment are used as they are in the structure of the composite fabric stiffener 20 ' There is a difference. Here, the detailed description of the fibers and the synthetic resin will be omitted and only the constitution of the composite fabric stiffener 20 'will be described.

Preliminary materials are used as the composite fabric stiffener 20 'according to the second embodiment. A prepreg is a sheet made by impregnating a matrix into a reinforced fiber in advance. An epoxy resin, a polyester resin, and a thermoplastic resin can be used as the binder material. As the reinforcing fiber, carbon fiber, glass fiber, silicon carbide, alumina fiber and aramid fiber can be used. Composite fabric abdominal materials made in the form of prepreg can improve various characteristics such as strength, stiffness, corrosion resistance, fatigue life, abrasion resistance, impact resistance and light weight compared with other materials.

As described above, since the head lining mounted on the roof panel of an automobile can be manufactured with light weight and rigid head lining using fiber and synthetic resin, It is possible to secure a sufficient rigidity, and furthermore, it is lightweight, which can greatly contribute to improvement of fuel economy.

The head lining according to the third embodiment of the present invention differs from the first embodiment as shown in Fig. 7 in the structure of the reinforcing layer provided on both outer sides of the base material. Therefore, detailed description of the same structure as that of the first embodiment will be omitted and only the reinforcing layer will be described.

The third embodiment has the same structure as that of the first embodiment as shown in Fig. 7, but is replaced with a glass fiber mat 30 'in place of the nonwoven fabric provided on the outer surface of the substrate. That is, in Example 1, non-woven fabrics were fabricated as reinforcing layers on both sides of the substrate, while in Example 3, non-woven fabrics were reinforced on one side and glass fiber mats 30 'were reinforced on the other side.

Therefore, it is known that glass fiber is excellent in heat insulation and soundproofing property when it is manufactured in a mat form without being well-corroded and excellent in abrasion resistance. In the present invention, glass fibers having such characteristics are used, and in particular, the glass fiber mat 30 'having a surface density of 50 to 350 g / m 2 is used to minimize weight increase, desirable.

Therefore, the automotive head lining according to the third embodiment can be expected to improve not only the moisture absorption performance and the moldability using the nonwoven fabric but also the performance such as heat insulation and sound insulation through glass fiber.

The head lining according to the fourth embodiment of the present invention differs from that of the second embodiment as shown in Fig. 8 in the structure of the reinforcing layer provided on both outer sides. Therefore, detailed description of the same structure as that of the first embodiment will be omitted and only the reinforcing layer will be described.

In the fourth embodiment, as shown in Fig. 8, the structure is the same as that of the second embodiment, but the glass fiber mat 30 'is substituted for the nonwoven fabric provided on the outer surface of the substrate. That is, in Example 2, nonwoven fabrics were fabricated as reinforcing layers on both sides of the base material. In Example 4, nonwoven fabric was reinforced on one side and glass fiber mat 30 'was reinforced on the other side.

Accordingly, in Example 4, as in Example 3, not only the moisture absorption performance and the moldability using the nonwoven fabric but also the performance such as heat insulation and soundproofing can be expected to be improved through the glass fiber.

<Comparison of weight and stiffness improvement>

When the composite fabric reinforcement according to the present invention is applied to this embodiment, compared with the comparative example in which the conventional glass fiber mat is applied, in the case of applying the composite fabric reinforcement on both sides, the weight reduction effect is about 34% In the case of a composite fiber reinforcing material on one side and a glass fiber mat on the other side, the weight is reduced by about 17% compared with the conventional comparative example.

In addition, the present invention exhibited similar stiffness to that of the conventional comparative example in the case where the composite fabric reinforcement was applied to both sides in comparison with the conventional comparative example.

10: Polyurethane foam
20: Composite fabric reinforcement
30: Nonwoven fabric
30 ': Glass fiber mat
31: Hot melt film

Claims (10)

A hot melt film 31 and a hot melt film 31 are provided on both sides of a base made of a composite fabric stiffener 20 attached to at least one side of a polyurethane foam 10 and at least one side of the polyurethane foam 10 with a binder B, The nonwoven fabric 30 is laminated in this order, followed by compression molding at 140 to 160 DEG C for 40 to 80 seconds in a thermoforming mold,
Characterized in that the composite fabric stiffener (20) is formed by coating a synthetic resin on at least one side of both sides of a fabric woven with Leno Plain so that the clearance between the fibers and the fiber has a predetermined interval. A method of manufacturing a lightweight automotive headliner.
A hot melt film 31 and a hot melt film 31 are provided on both sides of a base made of a composite fabric stiffener 20 attached to at least one side of a polyurethane foam 10 and at least one side of the polyurethane foam 10 with a binder B, The nonwoven fabric 30 is laminated in this order, followed by compression molding at 140 to 160 DEG C for 40 to 80 seconds in a thermoforming mold,
Characterized in that the composite fabric reinforcement (20) is a prepreg in which fibers are impregnated with a thermosetting resin or a thermoplastic resin.
A base material composed of a polyurethane foam 10 and a composite fabric stiffener 20 adhered to at least one side of both sides of the polyurethane foam 10 with a binder (B), a hot melt film The hot melt film 31 and the glass fiber mat 30 'which are sequentially stacked on the other side of the substrate are laminated one by one and then heat-treated at a temperature of 140 to 160 ° C. in a thermo- Followed by compression molding for 80 seconds,
Characterized in that the composite fabric stiffener (20) is formed by coating a synthetic resin on at least one side of both sides of a fabric woven with Leno Plain so that the clearance between the fibers and the fiber has a predetermined interval. A method of manufacturing a lightweight automotive headliner.
A base material composed of a polyurethane foam 10 and a composite fabric stiffener 20 adhered to at least one side of both sides of the polyurethane foam 10 with a binder (B), a hot melt film The hot melt film 31 and the glass fiber mat 30 'which are sequentially stacked on the other side of the substrate are laminated one by one and then heat-treated at a temperature of 140 to 160 ° C. in a thermo- Followed by compression molding for 80 seconds,
Characterized in that the composite fabric reinforcement (20) is a prepreg in which fibers are impregnated with a thermosetting resin or a thermoplastic resin.
5. The method according to any one of claims 1 to 4,
Wherein the fiber is at least one of carbon fiber, glass fiber, silicon carbide, alumina fiber and aramid fiber.
5. The method according to any one of claims 1 to 4,
Wherein the composite fabric reinforcement (20) has a surface density of 50 to 300 g / m &lt; 2 &gt;.
5. The method according to any one of claims 1 to 4,
The polyurethane foam (10)
Molded in the form of a block having a radius of 22 to 32 g / m &lt; 3 &gt;
After aging for 7 to 10 days to remove the heat inside the foam,
Wherein the headlining is manufactured by cutting to a predetermined thickness.
5. The method according to any one of claims 1 to 4,
The binder (B)
Wherein the isocyanate-based glue of 30 to 150 g / m 2 or the polyolefin-based film-type polymer of 30 to 150 g / m 2 .
5. The method according to any one of claims 1 to 4,
The nonwoven fabric 30 has a weight of 30 to 100 g / m 2 ,
Wherein the hot-melt film (31) is a polyolefin-based or polyamide-based polymer in an amount of 30 to 150 g / m 2 .
The method according to claim 3 or 4,
The nonwoven fabric 30 has a weight of 30 to 100 g / m 2 ,
The glass fiber mat 30 'is 50 to 350 g / m 2 ,
Wherein the hot-melt film (31) is a polyolefin-based or polyamide-based polymer in an amount of 30 to 150 g / m 2 .
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Cited By (5)

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Publication number Priority date Publication date Assignee Title
KR20190059365A (en) 2017-11-23 2019-05-31 (주)대한솔루션 Light-weight headliner for vehicle
KR20190117938A (en) 2018-04-09 2019-10-17 (주)대한솔루션 Headliner for vehicle
CN111791544A (en) * 2020-08-03 2020-10-20 格林莱特实业（苏州）有限公司 Light bearing plate for vehicle and production method thereof
KR20220067745A (en) 2020-11-18 2022-05-25 (주)대한솔루션 Partial rigidity reinforcement apparatus of glass mats used for headliner of vehicles
KR20230153637A (en) 2022-04-29 2023-11-07 (주)대한솔루션 Headliner manufacturing method and the headliner thererof

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KR100188709B1 (en) 1996-03-30 1999-06-01 이종구 Dielectric ceramics
KR101192416B1 (en) 2010-07-29 2012-10-17 유승훈 Headliner material for use in automobile and method for manufacturing the same
KR101227628B1 (en) 2010-10-21 2013-01-30 주식회사 투에이취켐 Automobile headliner material having sound-absorbing improvement and method of manufacturing thereof

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KR100188709B1 (en) 1996-03-30 1999-06-01 이종구 Dielectric ceramics
KR101192416B1 (en) 2010-07-29 2012-10-17 유승훈 Headliner material for use in automobile and method for manufacturing the same
KR101227628B1 (en) 2010-10-21 2013-01-30 주식회사 투에이취켐 Automobile headliner material having sound-absorbing improvement and method of manufacturing thereof

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR20190059365A (en) 2017-11-23 2019-05-31 (주)대한솔루션 Light-weight headliner for vehicle
KR20190117938A (en) 2018-04-09 2019-10-17 (주)대한솔루션 Headliner for vehicle
CN111791544A (en) * 2020-08-03 2020-10-20 格林莱特实业（苏州）有限公司 Light bearing plate for vehicle and production method thereof
KR20220067745A (en) 2020-11-18 2022-05-25 (주)대한솔루션 Partial rigidity reinforcement apparatus of glass mats used for headliner of vehicles
KR20230153637A (en) 2022-04-29 2023-11-07 (주)대한솔루션 Headliner manufacturing method and the headliner thererof

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