KR20220056268A - Composite material for vehicle interior - Google Patents

Abstract

The present invention relates to a composite material for a vehicle. The composite material for a vehicle includes: a core layer which is made of a honeycomb board; and a reinforcing layer which is made by mixing glass fiber and polyolefin-based resin, and stacked on both sides of the core layer. With the configuration, it is possible to reduce exhaust gas through improved fuel efficiency by achieving weight reduction, to have excellent rigidity, to increase recyclability at the time of disposal, and to obtain an effect of providing a composite material harmless to a human body.

Description

Composite materials for vehicles {COMPOSITE MATERIAL FOR VEHICLE INTERIOR}

The present invention relates to a composite material for a vehicle, and more particularly, to a composite material for a vehicle that not only has excellent rigidity while achieving weight reduction, but also can increase recyclability during disposal, and is harmless to the human body.

Conventionally, resin felt, wood flour reinforced board, paper board, etc. have been used as a material of a self-structured covering for automobile interior materials.

The resin felt and paper board are manufactured by impregnating with phenol resin. Phenolic resin, a curing agent, is a type of thermosetting resin produced by the condensation reaction of phenols and aldehydes. Phenol and aldehydes released due to unreacted or incomplete combustion during incineration of phenolic resins are It acts as a pollutant of

In addition, it is necessary to use an adhesive containing a volatile organic solvent for bonding the above material, in which case there is a problem harmful to the working environment and the human body.

On the other hand, the conventional material of the covering self-structure for the interior of a vehicle does not have excellent soundproofing and thermal insulation properties, a high unit price, a relatively high weight, easy to deform during long-term use, harmful to the human body, and difficult to recycle.

The present invention has been devised to solve the above problems, and it is an object of the present invention to provide a composite material for vehicles that not only has excellent rigidity while achieving light weight, but also can increase recyclability during disposal, and is harmless to the human body. .

In order to achieve the above object, a composite material for a vehicle according to a preferred embodiment of the present invention includes a core layer made of a honeycomb board; and a reinforcing layer manufactured by mixing glass fiber and polyolefin-based resin and laminated on both sides of the core layer.

Here, the reinforcing layer may be manufactured by mixing the glass fiber and the polyolefin-based resin in a weight % ratio of 60:40 to 80:20.

The reinforcing layer may further include a foaming agent.

Here, while foam molding by the foaming agent, at least a portion may penetrate and adhere to the core layer.

As an example, the foaming agent may be formed by mixing 0.5 to 1.5% by weight of the thermally expandable microcapsules, which expand by heat, based on the total weight.

Alternatively, the blowing agent is azodicarbonamide (ADCA), para-toluenesulfonyl semicarbazide (TSSC), dinitrosopentamethylenetetramine (DPT), oxydibenzenesulfonylhydrazide (OBSH), 5- Including at least one selected from the group of organic blowing agents consisting of phenyltetrazole (5-PT), DPT/ADCA, ADCA/OBSH, or inorganic blowing agents consisting of soda, sodium hydrogen carbonate, and citric acid, 0.1 to 5 phr relative to the total weight can be mixed.

The composite material for a vehicle according to an embodiment of the present invention is manufactured by coating a polyolefin-based resin on a glass fiber mat, and an auxiliary reinforcing layer laminated on the reinforcing layer may be further included.

Here, the auxiliary reinforcing layer may be prepared by mixing the glass fiber mat and the polyolefin-based resin in a weight % ratio of 50:50 to 70:30.

The glass fiber mat may be made of glass fibers having a weight range of 20 to 1,000 g/m 2 and a length of 10 to 100 mm per unit area.

And, the polyolefin-based resin, polypropylene resin, polyethylene resin, low-density polyethylene resin, at least any one of ABS resin, or a combination thereof may be provided.

The core layer may have a weight range of 500 to 1,000 g/m ² per unit area.

In addition, the reinforcing layer may have a weight range of 800 to 1,500 g/m ² per unit area.

Also, the auxiliary reinforcing layer may have a weight range of 100 to 400 g/m ² per unit area.

According to the composite material for a vehicle according to the present invention, it is possible to achieve weight reduction and reduce exhaust gas through improved fuel efficiency, and to provide a composite material that is not only excellent in rigidity, but also recyclable when discarded, and is harmless to the human body. effect can be obtained.

1 is a view schematically showing a composite material for a vehicle according to a first embodiment of the present invention;
2 is a view schematically showing a composite material for a vehicle according to a second embodiment of the present invention;
3 is a view schematically showing a composite material for a vehicle according to a third embodiment of the present invention;
4 is a view schematically showing a composite material for a vehicle according to a fourth embodiment of the present invention.

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

Since the present invention can have various changes and can have various embodiments, specific embodiments are illustrated in the drawings and will be described in detail in the detailed description. This is not intended to limit the present invention to specific embodiments, and should be construed to include all modifications, equivalents, and substitutes included in the spirit and scope of the present invention.

In describing the present invention, terms such as first, second, etc. may be used to describe various components, but the components may not be limited by the terms. The above terms are only for the purpose of distinguishing one component from another. For example, without departing from the scope of the present invention, a first component may be referred to as a second component, and similarly, a second component may also be referred to as a first component.

The term “and/or” may include a combination of a plurality of related listed items or any of a plurality of related listed items.

When a component is referred to as being “connected” or “connected” to another component, it may be directly connected or connected to the other component, but other components may exist in between. can be understood On the other hand, when an element is referred to as being “directly connected” or “directly connected” to another element, it may be understood that the other element does not exist in the middle.

The terms used in the present application are only used to describe specific embodiments, and are not intended to limit the present invention. The singular expression may include the plural expression unless the context clearly dictates otherwise.

In the present application, terms such as “comprise” or “have” are intended to designate that a feature, number, step, operation, component, part, or combination thereof described in the specification exists, and one or more other features It may be understood that the existence or addition of numbers, steps, operations, components, parts, or combinations thereof is not precluded in advance.

Unless defined otherwise, all terms used herein, including technical or scientific terms, may have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Terms such as those defined in a commonly used dictionary may be interpreted as having a meaning consistent with the meaning in the context of the related art, and unless explicitly defined in the present application, it is interpreted in an ideal or excessively formal meaning. it may not be

In addition, the following embodiments are provided to more completely explain to those with average knowledge in the art, and the shapes and sizes of elements in the drawings may be exaggerated for more clear explanation.

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

1 and 2 are views schematically showing a composite material for a vehicle according to a first embodiment and a second embodiment of the present invention.

1, the composite material 101 for a vehicle according to the first embodiment of the present invention is manufactured by mixing a core layer 110 made of a honeycomb board, glass fiber and a polyolefin-based resin, and the core layer 110 It may include a reinforcing layer 120 laminated on both surfaces of the.

The core layer 110 is made of a paper material such as corrugated cardboard and has a honeycomb structure.

For example, the honeycomb board applied as the core layer 110 has a structure in which hollow hexagonal pillars with both sides open are continuously formed. Such a structure can be expected to not only increase the structural rigidity of itself, but also reduce noise for sound passing through both open surfaces.

In particular, by manufacturing the honeycomb board in the form of a sheet using 　 paper, it is possible to reduce the overall weight of the composite material for vehicles according to the present invention as well as the structural rigidity reinforcement and sound absorption effect. Furthermore, this weight reduction can be expected to have a significant weight reduction effect compared to when the vehicle composite material is made of a conventional polypropylene resin.

The core layer 110 may be made of a paper-made honeycomb board to have a weight range of 500 to 1,000 g/m ² per unit area.

The reinforcing layer 120 is made by mixing glass fiber and polyolefin-based resin, and is laminated on both surfaces of the core layer 110 .

Here, the reinforcing layer 120 preferably has a weight range of 800 to 1,500 g/m ² per unit area.

In addition, the reinforcing layer 120 may be manufactured by mixing the glass fiber and the polyolefin-based resin in a weight % ratio of 60:40 to 80:20.

Here, when the weight ratio of the glass fiber is less than 60%, there is a problem in that strength and formability are deteriorated because lofting is not achieved by more than twice the thickness compared to the manufacturing thickness in the part molding process through a preheating oven. And, when the weight ratio of the glass fiber exceeds 80%, there is a problem in that the adhesive component is lowered during preheating, so that the product formability is lowered and the surface quality is lowered.

And, the glass fiber is provided with at least one selected from the group consisting of short fibers, long fibers and glassol.

It is preferable that the glass fiber is provided with a thickness of 20 to 120 μm and a length of 40 to 80 mm. That is, when the thickness of the glass fiber is 20 μm and the length is less than 40 mm, aggregation between fibers occurs, and thus there is a problem in that the strength is lowered during the manufacturing of the felt layer. In addition, when the thickness of the glass fibers exceeds 120 μm and the length exceeds 80 mm, there is a problem in that the kneading property between the fibers is insufficient in processes such as mixing, opening, carding, and web formation.

The polyolefin-based resin is impregnated into the glass fiber mat to improve the mechanical properties of the auxiliary reinforcing layer 130 .

Here, the polyolefin-based resin is at least one of polypropylene (polypropylene; PP) resin, polyethylene (PE) resin, low density polyethylene (Low 　Density 　Polyethylene; LDPE) resin, ABS (acrylonitrile-butadiene-styrene) resin or at least one of these It may be provided in combination.

The stacking method of the core layer 110 and the reinforcing layer 120 may be stacked by a heat lamination molding method. That is, the reinforcing layer 120 may be laminated on the core layer 110 by the thermal bonding method, rather than using an additional adhesive layer having adhesive strength such as an adhesive or hot melt.

Through this, since melt bonding only by heat is possible without using an adhesive, the operation is very simple, and problems such as odor generated when using a conventional adhesive can be solved.

2, the composite material for a vehicle 102 according to the second embodiment of the present invention further includes an auxiliary reinforcing layer 130 in the composite material 101 for a vehicle according to the first embodiment of the present invention described above. characterized in that

More specifically, the vehicle composite material 102 according to the second embodiment is manufactured by mixing a core layer 110 made of a honeycomb board, glass fiber and a polyolefin-based resin, and laminated on both sides of the core layer 110 . A reinforcing layer 120 and an auxiliary reinforcing layer 130 manufactured by coating a polyolefin-based resin on a glass fiber mat and laminated on the reinforcing layer 120 is included.

Here, since the core layer 110 and the reinforcing layer 120 are the same as the core layer 110 and the reinforcing layer 120 described in the vehicle composite material 101 according to the first embodiment, a detailed description thereof will be omitted. .

The auxiliary reinforcing layer 130 may be manufactured by impregnating a glass fiber mat with a polyolefin-based resin and coating the glass fiber mat with a polyolefin-based resin.

Here, the auxiliary reinforcing layer 130 preferably has a weight range of 100 to 400 g/m ² per unit area.

In addition, the glass fiber mat preferably has a weight per unit area of 20 g/m 2 to 1,000 g/m 2 . That is, when the weight per unit area of the glass fiber mat is less than 20 g/m 2 , the pores of the mat are large, so it is difficult to impregnate the polyolefin-based resin, and when the weight per unit area exceeds 1,000 g/m 2, the polyolefin-based resin in the molten state is inside the glass fiber mat It is difficult to permeate into the material, so peeling may occur.

In addition, in order to improve the mechanical properties of the auxiliary reinforcing layer 130, the length of the glass fibers constituting the glass fiber mat is preferably 10 mm to 100 mm.

The polyolefin-based resin is impregnated into the glass fiber mat to improve the mechanical properties of the auxiliary reinforcing layer 130 .

Here, the polyolefin-based resin is at least one of polypropylene (polypropylene; PP) resin, polyethylene (PE) resin, low density polyethylene (Low 　Density 　Polyethylene; LDPE) resin, ABS (acrylonitrile-butadiene-styrene) resin or at least one of these It may be provided in combination.

The stacking method of the core layer 110 , the reinforcing layer 120 , and the auxiliary reinforcing layer 130 may be stacked by a heat lamination molding method. That is, the reinforcing layer 120 and the auxiliary reinforcing layer 130 may be laminated on the core layer 110 by the thermal bonding method, rather than using an additional adhesive layer having adhesive strength such as an adhesive or hot melt.

Through this, since melt bonding only by heat is possible without using an adhesive, the operation is very simple, and problems such as odor generated when using a conventional adhesive can be solved.

3 and 4 are views schematically showing a composite material for a vehicle according to a third embodiment and a fourth embodiment of the present invention.

The vehicle composite material 103 according to the third embodiment of the present invention is characterized in that the reinforcing layer 120 in the vehicle composite material 101 according to the first embodiment of the present invention described above further contains a foaming agent.

And, the vehicle composite material 104 according to the fourth embodiment of the present invention is characterized in that it further contains a foaming agent in the reinforcing layer 120 in the vehicle composite material 102 according to the second embodiment of the present invention described above. .

More specifically, referring to FIG. 3 , the composite material 103 for a vehicle according to the third embodiment of the present invention is manufactured by mixing a core layer 110 made of a honeycomb board, glass fiber, and a polyolefin-based resin, and the core A reinforcing layer 120 laminated on both surfaces of the layer 110 is included, and the reinforcing layer 120 further includes a foaming agent.

4, the composite material 104 for a vehicle according to the fourth embodiment of the present invention is manufactured by mixing a core layer 110 made of a honeycomb board, glass fiber and a polyolefin-based resin, and the core layer ( 110) including a reinforcing layer 120 laminated on both sides, and an auxiliary reinforcing layer 130 manufactured by coating a polyolefin-based resin on a glass fiber mat and laminated on the reinforcing layer 120, wherein the reinforcing layer 120 includes a foaming agent further including

That is, the vehicle composite material 103 according to the third embodiment and the vehicle composite material 104 according to the fourth embodiment of the present invention further include a foaming agent in the reinforcing layer 120 .

Through this, while the reinforcing layer 120 is foam-molded by the foaming agent in the process of thermally bonding the core layer 110 and the reinforcing layer 120, at least a portion penetrates into the core layer 110 to improve adhesion. do.

To this end, the foaming agent may be provided as thermally expandable microcapsules that expand by heat.

The thermally expandable microcapsule may have a structure in which a core is present in an ethylene vinyl acetate copolymer (EVA) or a cell having elasticity.

As the core, isobutane, propane, pentane, etc., which are materials that easily gasify and expand by heating, may be used.

The cell may be a molten material or a material that is destroyed by thermal expansion. For example, the cell may include vinylidene chloride-acrylonitrile copolymer, polyvinyl alcohol, polyvinyl butyral, polymethyl methacrylate, polyacrylonitrile, polyvinylidene chloride, polysulfone, and the like.

The thermally expandable microcapsules can be manufactured by a core cell vation method or an interfacial polymerization method, and have an average diameter of about 10 μm and an average diameter of 40 μm to 180 μm by thermal expansion.

When the foaming agent is provided as thermally expandable microcapsules, the foaming agent may be mixed in an amount of 0.5 to 1.5% by weight based on the total weight of the reinforcing layer 120 . Here, when the thermally expandable microcapsule is contained in an amount of less than 0.5% by weight, the amount of expansion is insufficient, and thus there is no effect of weight reduction and weight reduction, and when it is contained in an amount exceeding 1.5% by weight, extrusion moldability is deteriorated as well as the thermally expandable microcapsule is destroyed Therefore, there is no lightening effect, the rigidity of the substrate is lowered, and the product durability may be deteriorated.

Alternatively, the foaming agent may include any one or more selected from the group of organic foaming agents and the group of inorganic foaming agents.

As the organic foaming agent group, azodicarbonamide (ADCA), para-toluenesulfonyl semicarbazide (TSSC), dinitrosopentamethylenetetramine (DPT), oxydibenzenesulfonyl hydrazide (OBSH), 5-phenyl It may be made of tetrazole (5-PT), DPT/ADCA-based, ADCA/OBSH-based, and the like.

The inorganic foaming agent group may include soda, sodium hydrogen carbonate, citric acid, and the like.

The foaming agent is thermally decomposable, and a foamable product may be selected according to the foaming temperature.

It is characterized in that the foaming agent is added to the foaming layer in an amount of 0.1 to 5 phr with respect to the foaming layer.

When the foaming agent is added in an amount of less than 0.1 phr to the reinforcing layer 120, the foaming rate between the glass fibers is low, so that a sufficient foaming effect cannot be expressed. And by suppressing the orientation of the glass fiber may cause a problem that the strength is lowered.

Example

Hereinafter, an experimental example in which the conventional interior material for a vehicle and the composite material for a vehicle according to the first to fourth embodiments of the present invention are compared will be described.

In Table 1 below, Comparative Example 1 is a conventional interior material for a vehicle manufactured as a single extruded sheet by mixing wood powder with polypropylene resin.

And, Examples 1 to 6 are composite materials for vehicles according to the first to fourth embodiments of the present invention.

Here, as the composite material for vehicles according to the embodiment of the present invention, a honeycomb board made of paper was used as the core layer, and the reinforcing layer was produced as an extruded sheet by mixing polypropylene resin and glass fiber at 70:30 wt%, and auxiliary The reinforcing layer was prepared by coating the glass fiber mat with the polypropylene resin in a ratio of 60:40 wt % of the glass fiber mat and the polypropylene resin.

And, as the foaming agent, thermally expandable microcapsules were used, and 0.5 to 1.5% by weight of the total weight of the reinforcing layer was mixed. Specific mixing ratios are shown in Table 1 below.

division Configuration Comparative Example 1 50% PP + 50% wood flour, 4,025g/m ² Example 1 Reinforcing layer (PP + fiberglass, 1,300 g/m ² )Core layer (paper honeycomb board, 850 g/m ² )
Reinforcing layer (PP + fiberglass, 1,300 g/m ² ) Example 2 Auxiliary reinforcing layer (PP + fiberglass mat, 250 g/m ² ) Reinforcing layer (PP + fiberglass, 1,050 g/m ² )
Core layer (paper honeycomb board, 825 g/m ² )
Reinforcing layer (PP + fiberglass, 1,050 g/m ² )
Auxiliary reinforcing layer (PP + fiberglass mat, 250 g/m ² ) Example 3 Reinforcing layer (PP + glass fiber + foaming agent 1.0%, 1,300 g/m ² ) Core layer (paper honeycomb board, 850 g/m ² )
Reinforcing layer (PP + glass fiber + foaming agent 1.0%, 1,300g/m ² ) Example 4 Auxiliary reinforcing layer (PP + fiberglass mat, 250g/m ² ) Reinforcing layer (PP + fiberglass + foaming agent 0.5%, 1,050 g/m ² )
Core layer (paper honeycomb board, 825 g/m ² )
Reinforcing layer (PP + glass fiber + foaming agent 0.5%, 1,050g/m ² )
Auxiliary reinforcing layer (PP + fiberglass mat, 250 g/m ² ) Example 5 Auxiliary reinforcing layer (PP + fiberglass mat, 250g/m ² ) Reinforcing layer (PP + fiberglass + foaming agent 1.0%, 1,050 g/m ² )
Core layer (paper honeycomb board, 825 g/m ² )
Reinforcing layer (PP + glass fiber + foaming agent 1.0%, 1,050g/m ² )
Auxiliary reinforcing layer (PP + fiberglass mat, 250 g/m ² ) Example 6 Auxiliary reinforcing layer (PP + fiberglass mat, 250g/m ² ) Reinforcing layer (PP + fiberglass + foaming agent 1.5%, 1,050 g/m ² )
Core layer (paper honeycomb board, 825 g/m ² )
Reinforcing layer (PP + glass fiber + foaming agent 1.5%, 1,050g/m ² )
Auxiliary reinforcing layer (PP + fiberglass mat, 250 g/m ² )

The composite material for vehicles manufactured at the weight ratio disclosed in Table 1 was prepared as a specimen having a size of 150x50mm, the test speed was 5mm/min, and the flexural strength was measured with the span length of 100mm, and it is described in Table 2 below.

Comparative Example 1 Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Gross weight [g/m ² ] 4,025 3,450 3,450 3,450 3,450 3,450 3,450 Flexural strength [kgf] 15.3 27.8 35.1 30.1 36.2 37.4 34.1

As disclosed in Table 2, the composite material for vehicles according to the embodiment of the present invention (Examples 1 to 6) exhibits strong flexural strength at a lighter weight compared to the conventional interior material for vehicles (Comparative Example 1). Able to know.

More specifically, Comparative Example 1 has a weight of 4,025 g/m ² , and Examples 1 to 6 have a weight of 3,450 g/m ² , so it can have a higher flexural strength even when weight reduction of about 15% is achieved. .

That is, in Examples 1 to 6, it can be seen that the flexural strength is increased by about 80 to 145% in a state of about 15% light compared to Comparative Example 1.

Therefore, the composite material for a vehicle according to an embodiment of the present invention can achieve high strength and weight reduction compared to a conventional material currently used as an interior material for a vehicle.

Although the present invention has been described in detail through specific examples, it is intended to describe the present invention in detail, and the present invention is not limited thereto. It is clear that the transformation or improvement is possible by the person.

All simple modifications or changes of the present invention fall within the scope of the present invention, and the specific scope of protection of the present invention will be made clear by the appended claims.

100: composite material for vehicles
110: core layer
120: reinforcing layer
130: auxiliary reinforcement layer

Claims (12)

a core layer made of a honeycomb board; and
a reinforcing layer made by mixing glass fiber and a polyolefin-based resin and laminated on both sides of the core layer;
Composite material for vehicles containing.
According to claim 1,
The reinforcing layer is
A composite material for a vehicle, characterized in that it is produced by mixing the glass fiber and the polyolefin-based resin in a weight % ratio of 60:40 to 80:20.
According to claim 1,
The reinforcing layer is
It further comprises a foaming agent;
A composite material for a vehicle, characterized in that at least a portion penetrates and adheres to the core layer while being foamed by the foaming agent.
4. The method of claim 3,
The foaming agent,
A composite material for a vehicle, characterized in that 0.5 to 1.5% by weight of the thermal expansion microcapsule expanded by heat is mixed with respect to the total weight.
4. The method of claim 3,
The foaming agent,
Azodicarbonamide (ADCA), paratoluenesulfonylsemicarbazide (TSSC), dinitrosopentamethylenetetramine (DPT), oxydibenzenesulfonylhydrazide (OBSH), 5-phenyltetrazole (5- PT), DPT/ADCA-based, ADCA/OBSH-based organic foaming agent group, or inorganic foaming agent group consisting of soda, sodium hydrogen carbonate, and citric acid, characterized in that it is mixed at 0.1-5 phr relative to the total weight Composite materials for vehicles.
According to claim 1,
an auxiliary reinforcing layer manufactured by coating a polyolefin-based resin on a glass fiber mat and laminated on the reinforcing layer;
Composite material for vehicles, characterized in that it further comprises.
7. The method of claim 6,
The auxiliary reinforcing layer,
A composite material for a vehicle, characterized in that it is produced by mixing the glass fiber mat and the polyolefin-based resin in a weight % ratio of 50:50 to 70:30.
7. The method of claim 6,
The glass fiber mat,
A composite material for a vehicle, characterized in that it is made of glass fibers having a weight range of 20 to 1,000 g/m 2 and a length of 10 to 100 mm per unit area.
According to claim 1,
The polyolefin-based resin is
A composite material for a vehicle, characterized in that it is prepared by at least one of polypropylene resin, polyethylene resin, low-density polyethylene resin, ABS resin, or a combination thereof.
The method of claim 1,
The core layer is
A composite material for a vehicle, characterized in that the weight range per unit area is 500 to 1,000 g/m ² .
According to claim 1,
The reinforcing layer is
A composite material for a vehicle, characterized in that the weight range per unit area is 800 to 1,500 g/m ² .
7. The method of claim 6,
The auxiliary reinforcing layer,
A composite material for a vehicle, characterized in that the weight range per unit area is 100 to 400 g/m ² .

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