KR20170028282A - Under Cover For Automobile And The Process Of Producing Thereof - Google Patents

Abstract

The present invention relates to an under cover for automobiles in which a resin impregnated grid layer is interposed between an upper felt layer and a lower felt layer. According to the present invention, problems of deterioration of workability and human health due to scattering of glass fiber when mounting a vehicle part on a lower part of an automobile, and a problem of exposure of glass fiber due to peeling and breakage of a nonwoven fabric part due to collision of a road foreign matter during driving are solved. Meanwhile, tensile strength, bending strength, and stability of the under cover are improved to prevent durability degradation due to weakness of a mounting part when testing a water pipe line and also the under cover can be recycled.

Description

BACKGROUND OF THE INVENTION Field of the Invention [0001] The present invention relates to an under cover for an automobile,

The present invention relates to an automotive undercover in which a resin impregnated grid layer is interposed between an upper felt layer and a lower felt layer.

An under cover for an automobile protects various components mounted on the lower part of the vehicle body, reduces the resistance to air when the vehicle is running, and blocks the non-product from the road surface. These under covers are normally mounted on the front bumper lower crossmember, floor, and under the fuel tank to protect the interior parts of the engine compartment and protect engine parts and chassis parts from other foreign matter or ground protrusions At the same time, the air flow of the vehicle bottom is smooth.

Conventional undercovers for automobiles can be manufactured by a resin compounding process, a resin injection molding process, a foam molding process of a sound absorbing material, a process of adhering an injection molded base and a sound absorbing structure as foams, and various post- . However, this method is inefficient in terms of the process configuration because it requires an adhesive process in which a base portion and a sound-absorbing structure portion are separately manufactured and adhered with an adhesive.

In addition, although the base and the sound absorbing structure are conventionally adhered with an adhesive, the structure of the under cover becomes complicated, and the process using the adhesive gradually becomes difficult. Further, the adhesive has disadvantages in terms of physical performance of the under cover.

 In order to solve the inconvenience of the manufacturing process due to the installation of a separate sound absorbing material and to achieve weight reduction, Korean Patent Laid-Open Publication No. 10-2013-0107627 discloses a method of mixing polypropylene with polypropylene by mixing or kneading glass fiber and polypropylene, And a cover body made of a composite material in which glass fibers are reinforced while the glass fiber is being reinforced. However, there is a problem in that workability is deteriorated due to scattering of glass fibers during component mounting and human health hazards, There is a problem that exposure to the glass fiber due to peeling and breakage of the nonwoven fabric portion due to the collision of the nonwoven fabric portion, durability due to weakness of the mounting portion during testing with watering, and recycling are impossible.

Korean Patent Publication No. 10-2013-0107627

Disclosure of Invention Problem to be Solved by the Invention The present invention solves the problem of deterioration of workability and human health due to scattering of glass fiber when mounted on the lower part of an automobile, exposure of glass fiber due to peeling and breakage of a nonwoven fabric part due to collision of road foreign matter during driving, , The tensile strength, the bending strength, and the resilience, thereby preventing the degradation of the durability due to the weakness of the mounting portion when testing with irrigation water, as well as providing an undercover which can be recycled.

According to the present invention, there is provided a thermoplastic resin composition comprising a top felt layer containing polyethylene terephthalate fibers and low melting point polyethylene terephthalate fibers and having a surface flame treated to be cured, a bottom felt layer, and a resin impregnated grid layer interposed between the top felt layer and the bottom felt layer An under cover for an automobile is provided.

The upper felt layer and the lower felt layer are preferably needle punching felt composed of 30 to 60 parts by weight of polyethylene terephthalate fibers and 40 to 70 parts by weight of low melting point polyethylene terephthalate fibers.

The polyethylene terephthalate fiber has a single fiber fineness of 3 to 20 d and a tensile strength of 4.5 to 5.0 g / d. The low melting point polyethylene terephthalate fiber has a single fiber fineness of 1 to 10 d, a tensile strength of 1.0 to 2.0 g / .

It is preferable that the polyethylene terephthalate fiber has a monofilament fineness of 3 to 10 d and a monofilament fineness of 10 to 20 d in a weight ratio of 3: 7 to 7: 3.

The upper felt layer and the lower felt layer preferably have a basis weight of 300 to 700 g / m < 2 >.

The resin impregnated grid layer has a tensile strength in an oblique direction of 1000 to 1300 N / 5, which is woven in a leno structure with an air-warp yarn density of 4T to 30T using air texture yarn of 250D to 2500D / 96 to 192 filaments, nylon or polyethylene terephthalate filament as a yarn Tensile strength in the direction of warp 1500 ~ 2000 N / 5 ㎝, tensile elongation in oblique direction 16 ~ 18%, tensile elongation in weft direction 16 ~ 18%, tear strength 1100 ~ 1300 N, tear strength 90 ~ 95 N, Direction tear strength 170 ~ 200 N It is preferable that the phosphor grid is impregnated with any one of acryl and PVA to dry it.

The resin impregnated grid layer preferably has a resin coating layer having a thickness of 1 to 5 mm formed on the surface of the grid.

The automotive undercover has a tensile strength in the longitudinal direction of 23 to 30 MPa, a tensile strength in the transverse direction of 23 to 30 MPa, a flexural strength in the longitudinal direction of 22 to 27 N, a flexural strength in the transverse direction of 22 to 27 N, a flexural modulus in the longitudinal direction of 90 to 125 MPa, 100 to 116 Mpa.

According to another aspect of the present invention, there is provided a method for fabricating a semiconductor device, comprising: forming a top felt layer by carding and needle punching a polyethylene terephthalate fiber and a low melting point polyethylene terephthalate fiber;

Forming a lower felt layer by carding and needle punching the polyethylene terephthalate fibers and the low melting point polyethylene terephthalate fibers;

Impregnating a resin-impregnated grid layer by impregnating a grid made of nylon or polyethylene terephthalate filaments with an air texture yarn as a yarn and having a leno weave density of 4T to 30T and acrylic or PVA,

Laminating the upper felt layer, the resin impregnated grid layer and the lower felt layer in this order and needle punching;

And flame treating the surface of the upper felt layer and the lower felt layer.

In the forming of the upper felt layer and the lower felt layer, the RPM is preferably 500 to 1200 RPM when the needle is punched.

According to the present invention, it is possible to solve the problems of deterioration in workability and human health due to scattering of glass fiber when mounted on the lower part of an automobile, and exposure problems of glass fiber due to peeling and breakage of nonwoven fabric part due to collision of road foreign matter On the other hand, it is possible to provide an under cover which can improve tensile strength, bending strength and stability and can be recycled as well as preventing durability deterioration due to weakness of the mounting portion when tested with irrigation water.

1 is a perspective view showing a structure of an under cover for an automobile according to an embodiment of the present invention.
2 is a cross-sectional view showing a structure of an under cover for an automobile according to an embodiment of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS The present invention is capable of various modifications and various embodiments, and specific embodiments are illustrated in the drawings and described in detail in the detailed description. It is to be understood, however, that the invention is not to be limited to the specific embodiments, but includes all modifications, equivalents, and alternatives falling within the spirit and scope of the invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.

The present invention relates to a thermoplastic resin composition comprising a top felt layer containing a polyethylene terephthalate fiber and a low melting point polyethylene terephthalate fiber and having a surface flame treated and cured, a bottom felt layer and a resin impregnated grid layer interposed between the top felt layer and the bottom felt layer And an under cover for an automobile.

That is, as shown in FIG. 1, the automotive under cover of the present invention has a three-layer structure of an upper felt layer, a resin impregnated grid layer, and a lower felt layer.

The upper felt layer and the lower felt layer are needle punching felt composed of 30 to 60 parts by weight of polyethylene terephthalate fibers and 40 to 70 parts by weight of low melting point polyethylene terephthalate fibers and the surface is flame treated to harden the dust, It can be solved, and the appearance is good, which is preferable. However, in order to exhibit excellent tensile strength, flexural strength, and flexural modulus as an under cover for automobiles, the resin impregnated grid layer is interposed between the upper felt layer and the lower felt layer to reinforce the tensile strength, flexural strength and flexural modulus do.

The polyethylene terephthalate fibers of the upper felt layer and the lower felt layer have a single yarn fineness of 3 to 20 d and a tensile strength of 4.5 to 5.0 g / d, and the low melting point polyethylene terephthalate fibers have a single yarn fineness of 1 To 10 d, a tensile strength of 1.0 to 2.0 g / d, and a melting point of 110 to 200 is preferably used because of excellent rigidity and NVH property during molding.

Particularly, when the polyethylene terephthalate fiber has a single fiber fineness of 3 to 10 d and a single fiber fineness of 10 to 20 d in a weight ratio of 3: 7 to 7: 3, the stiffness and sound absorption of the felt layer are preferably improved.

The low melting point polyethylene terephthalate fiber is easy to bend compared to the regular polyethylene terephthalate fiber, so that the workability and durability of the undercover can be improved. Also, the low melting point terephthalate is manufactured so as to reduce the crystallizing power during polymerization and has a low melting point, and can replace glass fibers harmful to the human body and the environment.

When the low melting point polyethylene terephthalate fiber is less than 40 parts by weight, the fluidity is increased and it is difficult to bind to the felt layer, the workability at the time of molding is lowered and the rigidity of the final product is lowered. There is a problem that it is difficult to reduce the weight of the vehicle and the workability is deteriorated.

Preferably, the upper and lower felt layers have a basis weight of 300 to 700 g / m < 2 >. When the basis weight is more than 700 g / m < 2 >, the rigidity is improved, When the basis weight is less than 300 g / m < 2 >, the rigidity and sound absorption performance may be deteriorated.

The resin impregnated grid layer has a tensile strength in an oblique direction of 1000 to 1300 N / 5, which is woven in a leno structure with an air-warp yarn density of 4T to 30T using air texture yarn of 250D to 2500D / 96 to 192 filaments, nylon or polyethylene terephthalate filament as a yarn Tensile strength in the direction of warp 1500 ~ 2000 N / 5 ㎝, tensile elongation in oblique direction 16 ~ 18%, tensile elongation in weft direction 16 ~ 18%, tear strength 1100 ~ 1300 N, tear strength 90 ~ 95 N, Direction tear strength 170 ~ 200 N It is preferable that the grid is dried by impregnating any one of acryl and PVA in the grid. The grid is made of 250D to 2500D / 96 to 192 filaments, air-textured yarn of nylon or polyethylene terephthalate filament as a yarn, It is preferable that the fabric is wefted at 4T to 30T because of excellent tensile strength, burst strength and tear strength. In particular, when the yarn is used as an air-texturing yarn, the woven fabric is prevented from being shrunk on the Leno structure, the shape of the fabric can be uniformly woven, and a large amount of resin can be impregnated when the resin is impregnated. It is possible to improve the thickness and strength.

Particularly, when the above-described grid is used as the middle layer of the undercover of the present invention, the grid is bent and the stability is poor, so that any resin such as acryl or PVA is impregnated and dried to complement the bendability, The total tensile strength, flexural strength and flexural modulus of the acrylic resin can be improved. It is preferable to use acrylic resin having a melting point of 160 and a PVA resin having a melting point of 200 because it can improve the heat resistance due to the increase in vehicle temperature.

Particularly, it is preferable that the resin impregnated grid layer has a resin coating layer having a thickness of 1 to 5 mm formed on the surface of the grid, because it can improve the tensile strength of the final undercover.

The automobile undercover thus formed has a longitudinal tensile strength of 23 to 30 MPa, a lateral tensile strength of 23 to 30 MPa, a longitudinal direction flexural strength of 22 to 27 N, a lateral direction flexural strength of 22 to 27 N, a longitudinal direction flexural modulus of 90 to 125 MPa, The flexural modulus in the transverse direction of 100 to 116 Mpa is superior to that of the undercoat made of only polyethylene terephthalate fibers, in terms of tensile strength, flexural strength and flexural modulus.

Hereinafter, an embodiment of a method of manufacturing an under cover for an automobile according to the present invention will be described.

 Forming a top felt layer by carding and needle punching the polyethylene terephthalate fibers and the low melting point polyethylene terephthalate fibers;

Forming a lower felt layer by carding and needle punching the polyethylene terephthalate fibers and the low melting point polyethylene terephthalate fibers;

Impregnating a resin-impregnated grid layer by impregnating a grid made of nylon or polyethylene terephthalate filaments with an air texture yarn as a yarn and having a leno weave density of 4T to 30T and acrylic or PVA,

Laminating the upper felt layer, the resin impregnated grid layer and the lower felt layer in this order, and needle punching;

And flaming the surface of the upper felt layer and the lower felt layer.

First, polyethylene terephthalate fibers and low melting point polyethylene terephthalate fibers are carded and needle-punched to form an upper felt layer and a lower felt layer. The polyethylene terephthalate fiber and the low melting point polyethylene terephthalate fiber are carded in a raw material step The webs after carding may be laminated to each other and mixed together, but the raw material mixture is excellent in exhibiting excellent formability and sound absorption performance.

The RPM is 500 to 1200 RPM when the needle is punched in the upper and lower felt layers, and peeling problems occur between the felt layers when the RPM is lower than 500 RPM. When the RPM is higher than 1200 RPM, A problem arises, so that the felt layer is formed by binding the constituent fibers by needle punching under the RPM conditions as described above.

Thereafter, in order to produce a resin-impregnated grid layer, the grid was weighed with a leno structure with a density of 4T to 30T using an air-textured yarn of nylon or polyethylene terephthalate filament as a yarn, and then one of acryl and PVA The resin is impregnated and dried to produce a resin impregnated grid layer.

The upper felt layer, the resin impregnated grid layer and the lower felt layer are laminated in order, needle punched and lapped, and the surface of the upper felt layer and the lower felt layer is flame treated to complete the automotive under cover of the present invention do.

When the undercover is molded for each vehicle model, the compression pressure is preferably 90 to 110 kgf / cm 2. When the undercoat is less than 90 kgf / cm 2, the appearance is poor and a burr is generated. / Cm < 2 >, the durability of the mold is lowered. Therefore, it can be applied as an under cover suitable for each automobile model by pressing under the above-mentioned pressing pressure condition.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. It should be understood, however, that these examples are for illustrative purpose only and are not to be construed as limiting the scope of the present invention

Example  One

(5 dpf, tensile strength: 1.4 g / d < 4 > and melting point: 180) were mixed with polyethylene terephthalate fibers (20 dpf 50 wt%, mixed density of 8 dpf 50 wt%, tensile strength 4.5 g / And an upper felt layer and a lower felt layer were formed by needle punching at 680RPM, and then air-textured yarn of polyethylene terephthalate filament (2500d / 384fila, tensile strength 4g / d) Impregnated grid layer was prepared by impregnating a PVA resin having a viscosity of 500 CPS on one grid and dried to form a resin impregnated grid layer. The upper impregnated layer, the resin impregnated grid layer and the lower felt layer were laminated in this order, and they were bonded by needle punching at 780RPM, The surface of the upper felt layer and the surface of the lower felt layer were flame treated to complete an automobile under cover.

Example  2

In the same manner as in Example 1 except that a resin-impregnated grid layer was formed by forming a resin coating layer 2 mm on the surface of the grid layer when the PVA resin was impregnated and dried in Example 1, an automotive under cover was completed.

Comparative Example  One

Except that the upper felt layer and the lower felt layer were laminated in this order without laying the resin impregnated grid layer in Example 1 and lapped by needle punching and then the surfaces of the upper felt layer and the lower felt layer were flame treated The under cover of the automobile was completed.

The physical properties and sound absorption ratios of the above Examples and Comparative Examples 1 were measured and compared and shown in Table 1 below.

Properties division Example 1 Example 2 Comparative Example 1 The tensile strength
(MPa) Vertical 25 27 14 horizontal 25 28 12 Flexural strength
(N) Heat resistance Vertical 26 25 14 horizontal 26 25 11 inroad Vertical 27 27 13 horizontal 27 27 12 Flexural modulus
(MPa) Heat resistance Vertical 116 117 42 horizontal 101 105 25 inroad Vertical 125 120 42 horizontal 116 115 37 Absorption rate - 0.35 0.32 0.24

As shown in Table 1, the properties of tensile strength, flexural strength, and flexural modulus of the examples are superior to those of the comparative example, and the sound absorption rate is also superior to the comparative example.

While the present invention has been particularly shown and described with reference to specific embodiments thereof, those skilled in the art will appreciate that such specific embodiments are merely preferred embodiments and that the scope of the present invention is not limited thereby. something to do. It is therefore intended that the scope of the invention be defined by the claims appended hereto and their equivalents.

10: upper felt layer 20: lower felt layer
30: Resin impregnated grid layer 100: Automobile under cover

Claims (10)

A top felt layer comprising a polyethylene terephthalate fiber and a low melting point polyethylene terephthalate fiber and having a surface flame treated to form a cured top felt layer,
Wherein a resin impregnated grid layer is interposed between the upper felt layer and the lower felt layer. The method according to claim 1,
Wherein the upper felt layer and the lower felt layer are needle punching felt composed of 30 to 60 parts by weight of polyethylene terephthalate fibers and 40 to 70 parts by weight of low melting point polyethylene terephthalate fibers. The method according to claim 1,
The polyethylene terephthalate fiber has a single fiber fineness of 3 to 20 d and a tensile strength of 4.5 to 5.0 g / d. The low melting point polyethylene terephthalate fiber has a single fiber fineness of 1 to 10 d, a tensile strength of 1.0 to 2.0 g / Wherein the under cover is made of a synthetic resin. The method of claim 3,
Wherein the polyethylene terephthalate fiber has a monofilament fineness of 3 to 10 d and a monofilament fineness of 10 to 20 d in a weight ratio of 3: 7 to 7: 3. The method according to claim 1,
Wherein the upper felt layer and the lower felt layer have a basis weight of 300 to 700 g / m < 2 >. The method according to claim 1,
The resin impregnated grid layer has a tensile strength in an oblique direction of 1000 to 1300 N / 5, which is woven in a leno structure with an air-warp yarn density of 4T to 30T using air texture yarn of 250D to 2500D / 96 to 192 filaments, nylon or polyethylene terephthalate filament as a yarn Tensile strength in the direction of warp 1500 ~ 2000 N / 5 ㎝, tensile elongation in oblique direction 16 ~ 18%, tensile elongation in weft direction 16 ~ 18%, tear strength 1100 ~ 1300 N, tear strength 90 ~ 95 N, Direction tear strength 170 ~ 200 N Wherein an acrylic resin or PVA resin is impregnated into the inner grid and dried. The method according to claim 6,
Wherein the resin impregnated grid layer has a resin coating layer having a thickness of 1 to 5 mm formed on the surface of the grid. The method according to claim 1,
The automotive undercover has a tensile strength in the longitudinal direction of 23 to 30 MPa, a tensile strength in the transverse direction of 23 to 30 MPa, a flexural strength in the longitudinal direction of 22 to 27 N, a flexural strength in the transverse direction of 22 to 27 N, a flexural modulus in the longitudinal direction of 90 to 125 MPa, 100 to 116 Mpa. Forming a top felt layer by carding and needle punching the polyethylene terephthalate fibers and the low melting point polyethylene terephthalate fibers;
Forming a lower felt layer by carding and needle punching the polyethylene terephthalate fibers and the low melting point polyethylene terephthalate fibers;
Impregnating a resin-impregnated grid layer by impregnating a grid made of nylon or polyethylene terephthalate filaments with an air texture yarn as a yarn and having a leno weave density of 4T to 30T and acrylic or PVA,
Laminating the upper felt layer, the resin impregnated grid layer and the lower felt layer in this order and needle punching;
And flame treating the surface of the upper felt layer and the lower felt layer. 10. The method of claim 9,
Wherein the RPM of the needle punching step is 500 to 1200 RPM in the step of forming the upper felt layer and the lower felt layer.

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