KR20200062487A - Automotive interior material using bubble sheet-composite - Google Patents

Abstract

The present invention relates to an automotive interior material, which comprises: a hollow bubble sheet layer composed of an intermediate layer formed of a plurality of bubbles at predetermined intervals and a thermoplastic sheet layer formed on upper and lower surfaces of the intermediate layer; and a reinforcing layer formed on upper and lower surfaces of the hollow bubble sheet layer to reinforce the hollow bubble sheet layer. The automotive interior material reinforces strength, improves moldability, has excellent post-processing properties such as fabric compression and bracket attachment, and has an effect of improving heat resistance.

Description

Vehicle interior material {AUTOMOTIVE INTERIOR MATERIAL USING BUBBLE SHEET-COMPOSITE}

The present invention relates to a vehicle interior material, and more particularly, to a vehicle interior material using a hollow bubble sheet composite material having excellent strength and light weight.

Composite materials for automobile interior materials are applied to various types of materials depending on the applied parts.Typically, natural fiber reinforced boards, glass fiber reinforced boards, PP boards, wood stock, bamboo stock, There are thermoset composite, PET felt, hard board, glass fiber/polyurethane foam, and hollow bubble sheet. Recently, PP foam and natural fiber reinforcement layer are used for eco-friendly and light weight. Multilayer structures are also used.

The above materials are made of composite materials according to the requirements and the shape of the applied parts. However, there are limitations in the application of existing materials according to environmental regulations such as enhanced odor and VOC.

In addition, the requirements for the application of a lighter, higher-rigidity lightweight composite material with superior properties to suppress CO2 emissions are constantly increasing, and at the same time, the price competitiveness to secure market competitiveness in the global era is also demanded, so there are problems with existing materials. It is urgent to improve them and develop new materials with excellent price competitiveness.

Indeed, in order to improve the above problems, development of eco-friendly and lightweight materials has progressed, and various types of materials have been developed and applied. However, it is difficult to develop materials that satisfy both eco-friendly, lightweight, excellent physical properties and price competitiveness. to be.

For example, the natural fiber-PP foam material is eco-friendly and lightweight, but it has limitations in application due to its poor cost competitiveness compared to existing materials. Also, the natural fiber-thermosetting composite material is eco-friendly, VOC free, and high physical properties. And an excellent light weighting effect, but is limited in application due to high process cost.

In addition, the hollow bubble sheet, which satisfies VOC and odor, and has excellent strength, is widely applied to trunk coverings and boards as an excellent lightweight effect and eco-friendly material. Due to its characteristics of being vulnerable to residual stress and heat in the manufacturing process, it is a flat type Its application is limited to products that can be molded only by cold forming method.

Therefore, there is a need to develop a high-strength, lightweight composite material that is lightweight and has excellent properties.

Korean Registered Patent No. 1601861 (2016.03.03)'Pallet laminate for vehicle interior materials and manufacturing method thereof'

The present invention was created to improve the problems of the interior vehicle interior materials as described above, and has an object to provide a vehicle interior interior material that is lightweight while having excellent strength and heat resistance.

In order to achieve the above object, the vehicle interior material according to the present invention, a hollow bubble sheet layer composed of an intermediate layer formed of a plurality of bubbles at predetermined intervals and a thermoplastic sheet layer formed on the upper and lower surfaces of the intermediate layer, and the hollow bubble It characterized in that it comprises a reinforcement layer formed on the upper and lower surfaces of the hollow bubble sheet layer to reinforce the sheet layer.

At this time, the reinforcing layer may be formed in a felt form by needle punching a thermoplastic fiber with at least one of natural fiber, glass fiber, glass wool, whisker, and barzalt.

In addition, the reinforcing layer may be a mixture of at least one of natural fiber, glass fiber, glass wool, whisker, and barzal and thermoplastic resin in a ratio of 30:70 or more and 60:40 or less.

On the other hand, the reinforcing layer, natural fibers, glass fibers, glass wool, at least one of fibers, mixed with a chemical resin fiber, after mixing with a thermoplastic resin powder, it is also possible to be produced by heat pressing with a heat roller Do.

At this time, the reinforcing layer is thermally laminated at the same time as the hollow bubble sheet layer through latent heat generated when the hollow bubble sheet layer is formed, and the substrate is melted using an indirect heating conveyor belt type oven and then melted into the hollow bubble sheet layer. Cold compression molding is also possible.

On the other hand, the intermediate layer is also possible to form the bubble by mixing the thermoplastic resin and the additive and then passing the extruded sheet through a vacuum roll mold.

On the other hand, the weight ratio range of the hollow bubble sheet layer and the reinforcing layer may be formed in a ratio of 1:0.05 or more and 1:1 or less.

In addition, the weight ratio range of the hollow bubble sheet layer and the reinforcing layer may be formed in a ratio of 1:0.05 or more and 1:0.5 or less.

As described above, according to the interior material for a vehicle according to the present invention, there is an effect of improving strength, improving moldability, and post-processing properties such as crimping fabrics and attaching brackets, and improving heat resistance.

In addition, after simultaneous thermal lamination of the non-woven fabric layer to the hollow bubble sheet layer, there is an effect that the interior material for the vehicle can be reduced in weight through a conveyor belt oven process and cold forming.

1 is a cross-sectional view showing a laminated structure of a composite material having a reinforcing layer in a vehicle interior material according to an embodiment of the present invention,
1 is a cross-sectional view showing a laminated structure of a composite material having a thin film reinforcement layer in a vehicle interior material according to an embodiment of the present invention,
3 is a process flow diagram for manufacturing a felt reinforcement layer and a non-woven fabric layer in a vehicle interior material according to an embodiment of the present invention,
Figure 4 is a process flow diagram of forming a composite material laminated with a felt reinforcement layer and a hollow bubble sheet layer in a vehicle interior material according to an embodiment of the present invention,
5 is a process schematic diagram of laminating a non-woven fabric layer on a hollow bubble sheet in a vehicle interior material according to an embodiment of the present invention,
6 is a flowchart schematically showing a molding process of a composite material to which a nonwoven fabric layer is applied in a vehicle interior material according to an embodiment of the present invention.

In order to help understand the features of the present invention, a composite material to which the method for manufacturing a vehicle interior material according to the present invention is applied will be described in detail below.

In addition, in order to help the understanding of the embodiments described below, in addition to the reference numerals to the components of each of the accompanying drawings, it is noted that the same components have the same reference numerals as possible even though they are displayed on different drawings. . In addition, in describing the present invention, when it is determined that detailed descriptions of related well-known structures or functions may obscure the subject matter of the present invention, detailed descriptions thereof will be omitted.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

1 and 2 schematically show a laminated structure of a vehicle interior material of the present invention. 1, the vehicle interior material according to an embodiment of the present invention includes a hollow bubble sheet layer 10 and a reinforcing layer 20, the hollow bubble sheet layer 10 is an intermediate layer 11 and a thermoplastic sheet layer (12).

At this time, the intermediate layer 11 is provided in the form of a bubble-formed sheet at predetermined intervals, and a thermoplastic sheet layer 12 is laminated on the upper and lower surfaces of the intermediate layer 11.

Here, the hollow bubble sheet layer 10 is produced by mixing a thermoplastic resin and an additive at a ratio of 95:5 or more and 60:40 or less by weight. At this time, the additive may be talc, calcium carbonate, whisker, short glass fiber, cellulose, UV UV stabilizer, antioxidant, and the like.

More specifically, the hollow bubble sheet is mixed with a thermoplastic resin and an additive at a ratio of 95:5 or more and 60:40 or less by weight, then extruded, and the extruded sheet is passed through a vacuum roll mold to form bubbles at predetermined intervals. The intermediate layer 11 is prepared.

In addition, the hollow sheet sheet 10 is manufactured by laminating the thermoplastic sheet layer 12 on the upper and lower surfaces of the intermediate layer 11 with bubbles simultaneously with extrusion. This, the hollow bubble sheet layer 10 has a basis weight is 500g / m ² or more, 3000g / m ² preferably below provided by the weight per unit is provided below 1000g / m ² or more, 3000g / m ² It is more preferable to be.

The reinforcing layer 20 is stacked on the upper and lower surfaces of the hollow bubble sheet layer 10. At this time, in this embodiment, the reinforcing layer 20 is formed in a felt form.

At this time, the reinforcing layer 20 in the form of felt is manufactured by needle punching thermoplastic fibers such as natural fibers, inorganic fibers, and the like. That is, it is produced by mixing at least one of natural fiber, glass fiber, glass wool, whisker, and barzal and a thermoplastic resin in a ratio of 30:70 or more and 60:40 or less by weight.

Also, it felt in the form of the reinforcing layer 20 is for reinforcement, improved moldability, 150g / m ² or more is more is preferably arranged to 1000g / m ^2, and provided with 500g / m ² more than 1000g / m ² desirable. That is, the reinforcing layer 20 may be made of a material having a similar property capable of thermal lamination by latent heat during compression lamination molding in consideration of compatibility with the intermediate layer 11.

Meanwhile, the weight ratio range of the hollow bubble sheet layer 10 and the reinforcing layer 20 is preferably formed in a ratio of 1:0.05 or more and 1:1 or less. When the weight ratio of the hollow bubble sheet layer 10 and the reinforcing layer 20 is less than 1:0.05, the effect of strength reinforcing is insufficient, so it is difficult to expect moldability and strength improvement due to the reinforcing layer, and the hollow bubble sheet layer 10 ) And when the weight ratio of the reinforcing layer 20 is greater than 1:1, the weight of the reinforcing layer is reduced, resulting in a reduction in weight reduction effect and an increase in cost, resulting in a decrease in price competitiveness.

In addition, polypropylene (PP) resin may be used as the thermoplastic resin used in the hollow bubble sheet layer 10 and the reinforcing layer 20. However, the present invention is not limited to a thermoplastic resin, and is provided with a mixture of any one or more selected from polyamide, polyethylene, polystyrene, polyalkylene terephthalate, polyacetal, polysulfone, polyimide, and polycarbonate. It may be.

In addition, the reinforcing layer 20 is manufactured through needle punching of inorganic fibers or natural fibers and thermoplastic fibers, and the reinforcing layers 20 are laminated on both sides of the hollow bubble sheet layer 10 to reinforce the strength of the composite material for automobile interior materials. And heat resistance and moldability. Typically, a felt type natural fiber reinforcement board and a thin film natural fiber reinforcement paper may be used in the reinforcing layer 20.

Referring to Figure 1, the hollow bubble sheet layer 10 is composed of a structure in which the reinforcing layer 20 is stacked on the upper and lower surfaces, which has excellent strength reinforcing effect, excellent heat resistance and moldability.

2, a structure of a vehicle interior material according to another embodiment of the present invention is illustrated. In this embodiment, the hollow bubble sheet layer 110 and the reinforcing layer 120 are included, and the hollow bubble sheet layer 110 includes an intermediate layer 111 and a thermoplastic sheet layer 112.

At this time, the reinforcing layer 120 may be manufactured in the form of a low weight non-woven fabric and the weight of the hollow bubble sheet layer 110 may be increased to improve the moldability of the composite material.

Through this, it is possible to manufacture a composite material that requires the application of the heavy-weight hollow bubble sheet layer 120. The reinforcing layer 120 may be used as manufactured at a low weight through a heat roller through mixing of one or more fibers of natural fiber, synthetic fiber, and glass fiber.

That is, the reinforcing layer 120 is made through mixing (mixing) of one or more fibers of natural fiber, synthetic fiber, and glass fiber, and primarily produces a low weight web produced through a needle punching process. After forming as, after applying the thermoplastic resin powder to improve the surface density and complementary bonding of the fibrous, it can be produced by heat pressing with a heat roller (heat rolling).

At this time, the thermoplastic resin powder may be applied, such as polypropylene, polyethylene. In addition, the manufactured reinforcing layer 120 may be manufactured with a weight of 100 g/m ² or more and 500 g/m ² or less, and may have a thickness of 0.5 mm or more and 3 mm or less.

Meanwhile, the weight ratio range of the hollow bubble sheet layer 110 and the reinforcing layer 120 is preferably 1:0.05 or more and 1:0.5 or less. When the weight ratio of the hollow bubble sheet layer 110 and the reinforcing layer 120 is less than 1:0.05, the effect of strength reinforcing is insufficient, so it is difficult to expect moldability and strength improvement due to the reinforcing layer, and the hollow bubble sheet layer 110 ) And when the weight ratio of the reinforcing layer 120 is greater than 1:0.5, the weight of the reinforcing layer is reduced, resulting in a reduction in weight reduction effect and a rise in cost, resulting in a decrease in price competitiveness.

Referring to FIG. 3, a method of manufacturing the reinforcing layers 20 and 120 of the present invention is disclosed. First, the fiber material is mixed (S110), each fiber is opened with a spike roll (spike roll) (opening) (S120), and the carding process is performed again (S130). Mixing each fiber using a carding machine and simultaneously arranging them to form a web (S140), stacking the web with a desired weight and width on the foam paper 112, and then needle punching ) (S150), then cut to the desired length and width (S160) to form the reinforcing layer 20 in the form of a felt.

On the other hand, the reinforcing layer 120 in the form of a non-woven fabric is formed with a low weight of a web manufactured through a needle punching process (S150), and then applied with a thermoplastic resin powder to improve the surface density and complement the fibrous bonding force. , It is formed by heat pressing (S170) by heat rolling (winding) and then winding (S180).

4 shows a schematic diagram of a process of forming a composite material into parts by laminating the hollow bubble sheet layer 10 and the reinforcing layer 20.

In order to laminate the reinforcing layer 20 with the hollow bubble sheet layer 10, after loading (S210) and conveying (S220) of the material, the reinforcing layer 10 to be laminated on the upper and lower surfaces is hot pressed with hot press. After (S230), the lower part is transferred to the mold of the molded part (S240) and seated (S250), and the hollow bubble sheet layer 10 aged in the oven at a temperature of 50°C or more and 100°C or less (S260) is placed in the mold. After being seated on the seated reinforcing layer (S270), another reinforcing layer hot-pressed with a hot press is seated on the upper surface (S280), and simultaneously formed into parts through cold forming (S290).

Due to the latent heat of the hot-pressed reinforcing layer 20 and the latent heat of the aged hollow bubble sheet layer 10, mutual adhesion is possible. Through this, there is no bubble bursting of the hollow bubble sheet layer 10, so strength It can be maintained, and can be made of a composite material structural layer having improved moldability, heat resistance, post-processability, etc. due to the reinforcement layer 20 formed on the upper and lower surfaces.

In addition, since the hollow bubble sheet layer 10 is aged at a temperature of 100 degrees or less (preferably 50 degrees or more and 80 degrees or less) without heating in the forming line oven, the hollow bubble sheet layer 10 Shapes such as strength reduction due to bubble bursting due to heat, deterioration of formability, etc., which are the biggest disadvantages of the product, can be suppressed, and since the reinforcing layer 20 having good formability is laminated on the upper and lower surfaces, the formability and post-processability Composite materials that can be improved can be manufactured.

That is, the vehicle interior material disclosed in FIG. 1 is prepared by laminating the reinforcing layer 20 on the upper and lower surfaces in a part molding process and molding the hollow bubble sheet layer 10 in one process. At this time, the reinforcing layer 20 is made of at least one of synthetic fiber, inorganic fiber, and natural fiber, the reinforcing layer 20 is directly laminated on the hollow bubble sheet layer 10 through molding of a composite material for a vehicle , Strength reinforcement, heat resistance improvement and moldability can be improved.

Meanwhile, FIG. 5 is a conceptual diagram illustrating a process of simultaneously laminating the nonwoven fabric layer 120 with the hollow bubble sheet layer 110 in another embodiment of the present invention. The latent non-woven fabric layer 120 is simultaneously laminated using the latent heat when manufacturing the hollow bubble sheet layer 110 to manufacture a sheet-type composite material.

The sheet-type composite material manufactured in this way can be manufactured by cold forming into a component for automobile interior materials using the oven process of FIG. 6, unlike the case where the felt type reinforcement layer 20 is applied. That is, referring to FIG. 6, after loading the material 310 and transporting (S320), after aging the reinforcing layer 120 by melting the substrate through an indirect heating conveyor belt type (conveyor) oven S330 After lamination on a mold (S340), lamination may be performed through cold forming (S350).

At this time, the reinforcing layer 120 in the form of a non-woven fabric is prepared by mixing one or more fibers of natural fibers, glass fibers, glass wool, barzalt, whiskers with chemical resin fibers, applying a thermoplastic resin powder, and heat-pressing with a heat roller. (See FIG. 3).

Chemical resin fibers that can be used for the non-woven fabric reinforcement layer 120 include polyolefin-based, thermoplastic acrylic resin, and thermoplastic epoxy resins, and thermosetting resins include thermosetting epoxy resins, urethane resins, and acrylate resins.

The hollow bubble city layer 110 may be aged in the oven before lamination with the reinforcing layer 120 to release residual stress at the time of manufacturing the hollow bubble sheet layer 120 to prevent post-deformation after molding. . At this time, the oven temperature is about 50 to 90°C, and the time is maintained at 30 to 60 seconds.

Example.

Hereinafter, a composite material to which a vehicle interior material manufacturing method according to an embodiment of the present invention is applied will be described in comparison with a composite material of a conventional vehicle interior material. The composite materials produced in Examples 1 to 6 were manufactured according to the type of the reinforced layer (20,120) laminated with the hollow bubble sheet layer (10,110), and the reinforced layer (20) in the form of felt was made of polypropylene resin and natural fiber 30: After mixing at 70% by weight, it was produced by cold forming through a process as shown in FIG. 4. In addition, the reinforcing layer 120 in the form of a non-woven fabric is prepared by mixing polypropylene resin, polyester resin, natural fiber, and thermoplastic powder at 40:15:40:5% by weight, followed by a process as shown in FIG. 6. When the hollow bubble sheet layer 110 was manufactured, the composite material was produced by thermal lamination and then molded by cold forming.

In addition, Comparative Example 1 is a configuration generally used as a composite material for a conventional vehicle interior material, and Comparative Example 2 is produced in the same structure as in Example 1, but does not mix natural fibers when producing the core layer and the reinforcing layer without mixing polypropylene (PP). It was produced only with.

The configuration of the vehicle interior materials of Examples 1 to 6 is shown in Table 1 below.

division Reinforcing layer type Reinforcement layer mass (g/m ² ) Hollow bubble sheet layer mass (g/m ² ) Manufacturing method Laminated structure Example 1 felt 600+600 1,200 Hot press Fig. 1 Example 2 felt 700+700 1,200 Hot press Fig. 1 Example 3 felt 600+600 1,400 Hot press Fig. 1 Example 4 felt 600+600 1,400 Oven Fig. 1 Example 5 Non-woven 250+250 1,900 Oven Figure 2 Example 6 Non-woven 350+250 1,900 Oven Figure 2

The structures of the vehicle interior materials of Comparative Examples 1 and 2 are shown in Table 2 below.

division First material First material mass
(g/m ² ) Second material Second material mass
(g/m ² ) Comparative Example 1 Wood powder 2000 PP powder 2000 Comparative Example 2 Felt PP 600+600 Hollow bubble seat 1200

After the interior materials made in the weight ratios disclosed in Tables 1 and 2 were prepared as specimens having a size of 150 x 50 mm and a thickness of 5 mm, flexural loads were measured, and deep draw part moldability was measured. In addition, it was manufactured to a size of 200 x 200mm and the shrinkage was measured, and the results are shown in Table 2 below.

Here, in the flexural strength test, the test speed was 5 mm/min, and the formability was measured through an R gauge. The shrinkage was aged for 169 hours at a temperature of 100±2°C, and then left for 1 hour to measure the rate of change.

Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Comparative Example 1 Comparative Example 2 Gross weight
[g/m ² ] 2,400 2,600 2,600 2,600 2,400 2,600 4,000 2,400 Flexural load
[N] 110 125 124 100 101 107 110 100 Formability
[R] 3.0 3.0 3.0 3.0 2.5 2.5 3.0 2.5 Shrinkage
[%] 1.5 1.4 1.5 3.3 2.2 2.8 2.0 3.8 Weight reduction rate
[%] 40 35 35 35 40 35 - 40 Parts phenomenon
[Visually] none none none back side
part none none none back side
part Heating process Separate reinforcement layer, Fig. 4 Separate reinforcement layer, Fig. 4 Separate reinforcement layer, Fig. 4 The same time
Heating, Fig. 5 The same time
Heating, Fig. 5 The same time
Heating, Fig. 5 - Figure 4

As disclosed in Table 3 above, it can be seen that the vehicle interior material according to the present invention can maintain stiffness while achieving weight reduction compared to the interior material according to the conventional comparative example, and the formability and shrinkage are equal to or higher.

Therefore, by applying the method for manufacturing a vehicle interior material according to the present invention, it is possible to achieve a weight reduction effect of 30% or more due to the bubble structure of the intermediate core layer compared to the existing mass-producing material.

Looking in more detail, Comparative Example 1 has the advantage of good moldability and shrinkage in the case of parts made of the existing woodstock material, while having disadvantages such as high weight, odor and VOC. In the case of Examples 1, 2, 3 and 5, 6, although there are some differences depending on the weight produced, the weight is reduced compared to the conventional woodstock and similar strength can be achieved. However, in the case of Example 4 in which the method shown in FIG. 4 applied to improve post-deformation and formability, which is a disadvantage of the hollow bubble sheet layer, is not applied, the component development and shrinkage rate due to post-deformation, which is a conventional problem, are applied. A problem occurred.

And, Comparative Example 2 was produced with the same structure and gross weight as in Example 1, but when producing the felt reinforcement layer, it was made of polypropylene (PP) without mixing natural fibers. That is, it was made of only a thermoplastic resin without mixing additives.

When comparing Example 1 and Comparative Example 2, it can be seen that although the total weight is the same, Example 1 shows a higher flexural load than Comparative Example 2, and shrinkage and moldability defects due to post-deformation occur.

Therefore, by mixing natural fibers in the thermoplastic resin, the shrinkage rate can be lowered while achieving high strength to weight ratio.

Although the present invention has been described in detail through specific examples, the present invention is intended to specifically describe the present invention, and the present invention is not limited thereto, and the present invention has ordinary knowledge in the field within the technical spirit of the present invention. It is clear that the modification and improvement are possible by the ruler.

All simple modifications or changes of the present invention belong to the scope of the present invention, and the specific protection scope of the present invention will be clarified by the appended claims.

10, 110: hollow bubble sheet layer
11, 111: Middle floor
12, 112: thermoplastic sheet layer
20, 120: reinforcement layer

Claims (8)

A hollow bubble sheet layer composed of an intermediate layer formed of a plurality of bubbles at predetermined intervals and a thermoplastic sheet layer formed on upper and lower surfaces of the intermediate layer; And
A reinforcement layer formed on upper and lower surfaces of the hollow bubble sheet layer to reinforce the hollow bubble sheet layer;
Vehicle interior material comprising a.
According to claim 1,
The reinforcing layer,
Interior material for a vehicle characterized in that it is formed in a felt form by needle punching at least one of natural fiber, glass fiber, glass wool, whisker, and barzal.
According to claim 1,
The reinforcing layer,
Interior material for a vehicle, characterized in that at least one of natural fiber, glass fiber, glass wool, whisker, and barzal and thermoplastic resin are mixed at a weight ratio of 30:70 or more and 60:40 or less.
According to claim 1,
The reinforcing layer,
Vehicle interior material, characterized in that at least one of the fibers of natural fiber, glass fiber, glass wool, barzalt, whisker is mixed with chemical resin fiber, coated with thermoplastic resin powder, and then heat-pressed with a heat roller.
The method of claim 4,
The reinforcing layer,
It is heat-laminated simultaneously with the hollow bubble sheet layer through latent heat generated during the formation of the hollow bubble sheet layer, and is cold pressed and molded into the hollow bubble sheet layer after melting the substrate using an indirect heating conveyor belt type oven. Vehicle interior material characterized by.
According to claim 1,
The intermediate layer,
After mixing the thermoplastic resin and the additive, the extruded sheet is passed through a vacuum roll mold to form the bubbles.
According to claim 1,
A vehicle interior material characterized in that the hollow bubble sheet layer and the reinforcing layer have a weight ratio range of 1:0.05 or more and 1:1 or less.
The method of claim 4,
19, wherein the hollow bubble sheet layer and the reinforcing layer have a weight ratio range of 1:0.05 or more and 1:0.5 or less.

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