KR20230153637A - Headliner manufacturing method and the headliner thererof - Google Patents

Abstract

The present invention applies an amine-based reducing agent to both sides of the polyurethane foam used to manufacture the headliner, so that the amine-based reducing agent reacts with aldehyde VOCs (formaldehyde, acetaldehyde, acrolein, etc.) generated from the polyurethane foam. The purpose is to provide a headliner for automobiles and a manufacturing method thereof that can reduce harmful substances and easily remove aldehyde VOCs without a separate removal process. In particular, the present invention is an automobile head that minimizes weight increase and further enhances the reduction effect of aldehyde VOCs by applying the amine-based reducing agent to polyurethane foam at a thickness of 10 to 30 g/m2. There is another purpose in providing a liner and a method of manufacturing the same.

Description

Headliner for automobiles and manufacturing method thereof {HEADLINER MANUFACTURING METHOD AND THE HEADLINER THEREROF}

The present invention relates to a headliner for automobiles and a method of manufacturing the same. More specifically, the present invention relates to a headliner for automobiles and a method of manufacturing the same, and more specifically, by applying an amine-based reducing agent to both sides of the polyurethane foam used as a base material and using it to manufacture the headliner, thereby reducing the noise generated from the polyurethane foam. This allows to reduce aldehyde volatile organic compounds (VOCs) such as formaldehyde, acetaldehyde, and acrolein. At this time, the amine-based reducing agent is applied during the process of supplying polyurethane foam to manufacture the headliner, thereby minimizing additional components and minimizing the emission of VOCs.

In general, the headliner installed in the car interior to face the roof panel of the car is often made of polyurethane foam (1) for the purpose of formability and weight reduction, as shown in [Figure 1] and [Figure 2]. . Such headliners are manufactured in various ways for the purpose of improving shape stability and rigidity, as shown in (Patent Document 1) to (Patent Document 3) below.

(Patent Document 1) Korean Patent Publication No. 10-2021-0098569

By applying a silane coupling agent solution to any one of the multiple layers that make up the headliner to form a single piece, the added weight of the headliner is minimized while improving flexural properties such as flexural strength and flexural modulus of elasticity, thereby improving the head liner's flexural properties. The shape stability of the liner can be improved. In particular, by applying a silane coupling agent solution between the glass mat and the polymer film that constitutes the headliner to form a single piece, the silane coupling agent solution penetrates well into the glass mat and adheres firmly to the polymer film, thereby improving the shape stability of the headliner. can be further increased. In addition, by spraying a silane coupling agent solution to form a single piece, it is possible to easily and conveniently apply the desired thickness and form a single piece while increasing the shape stability of the headliner.

(Patent Document 2) Korean Patent Publication No. 10-2022-0001136

By applying a silane coupling agent solution to any one of the multiple layers that make up the headliner to form a single body, the added weight of the headliner is minimized while improving flexural properties such as flexural strength and flexural modulus of elasticity, thereby improving the shape stability of the headliner. It can be raised. In particular, by applying a silane coupling agent solution between the polyurethane that makes up the headliner and the glass mat to form a single piece, the silane coupling agent solution penetrates well into the glass mat and adheres firmly, further increasing the shape stability of the headliner. You can. In addition, by spraying the silane coupling agent solution onto the polyurethane surface and placing a glass mat on top of it to form a single piece, the shape stability of the headliner can be improved while easily and conveniently applied to the desired thickness and formed as a single piece. .

(Patent Document 3) Korean Patent Publication No. 10-2017-0026866

By constructing the headlining by using polyurethane foam with excellent noise performance as a base and reinforcing composite fabric reinforcement on at least one of both sides, the lightweight yet excellent noise performance characteristics of polyurethane foam and the rigidity of the composite fabric reinforcement are complemented. A method of manufacturing a high-rigidity, lightweight automobile headlining that is sturdy and lightweight while maintaining noise performance is provided, which reduces fuel consumption. In particular, a loose lattice-like Leno Plain is woven with fibers such as carbon fiber, glass fiber, silicon carbonized fiber, alumina fiber, and aramid fiber, and then coated with resin on at least one of both sides, or the fiber is coated with a thermosetting material. Composite fabric reinforcement is manufactured in the form of prepreg impregnated with resin or thermoplastic resin and attached to polyurethane foam, so it can be easily manufactured and used to the desired strength, and has excellent formability, making it easy to form complex three-dimensional shapes. A method of manufacturing a high-rigidity, lightweight automobile headlining that can be molded is provided. In addition, by further reinforcing the reinforcing layer made of non-woven fabric or glass fiber mat on both surfaces of the substrate reinforced with composite fabric reinforcing material, it is possible to easily manufacture and use it to fit the shape of a complex three-dimensional headlining in addition to being lightweight and rigid. A method of manufacturing a high-rigidity, lightweight automobile headlining is provided.

Korean Patent Publication No. 10-2021-0098569 (Publication Date: 2021.08.11) Korean Patent Publication No. 10-2022-0001136 (Publication Date: 2022.01.05) Korean Patent Publication No. 10-2017-0026866 (Publication date: 2017.03.09)

However, as shown in [FIGS. 1] and [FIG. 2], headliners using polyurethane foam (1) as a main material suffer from the following problems. In the drawings, the unillustrated reference numeral '2' represents a glass fiber mat, '3' represents a non-woven fabric, and '4' represents a skin.

(1) Even in the multi-layer structure that makes up the headliner, polyurethane foam emits the most aldehyde VOCs (formaldehyde, acetaldehyde, acrolein, etc.).

(2) These aldehyde VOCs can harm the health of drivers and passengers. Accordingly, the manufactured headliner must be manufactured to minimize the generation of aldehyde VOCs.

(3) Therefore, in order to reduce aldehyde VOCs in the headliner, the aldehyde VOCs must be removed through a separate process after manufacturing the headliner.

(4) Therefore, a process to remove aldehyde VOCs must be performed separately from the process of manufacturing the headliner, so not only does the manufacturing process increase, but the manufacturing time also increases, reducing productivity.

The present invention takes this into consideration, and by applying an amine-based reducing agent to both sides of the polyurethane foam used to manufacture the headliner, this amine-based reducing agent reduces aldehyde VOCs (formaldehyde, acetaldehyde, The purpose is to provide a headliner for automobiles that can easily remove aldehyde VOCs without a separate removal process by reducing harmful substances by reacting with acrolein, etc., and a manufacturing method thereof.

In particular, the present invention is an automobile head that minimizes weight increase and further enhances the reduction effect of aldehyde VOCs by applying the amine-based reducing agent to polyurethane foam at a thickness of 10 to 30 g/m2. There is another purpose in providing a liner and a method of manufacturing the same.

The method of manufacturing a headliner for an automobile according to the present invention to achieve this purpose is to form a glass fiber mat 20 and a non-woven fabric ( 30) are temporarily attached in order, and the skin 40 is laminated facing each other on one of the non-woven fabrics 30 exposed to the interior of the car, and then integrally molded into a headliner shape using a thermoforming mold. Do it as

At this time, a urethane adhesive 21 is applied and temporarily attached between the polyurethane foam 10 and the glass fiber mat 20, and a hot melt film 31 is applied between the glass fiber mat 20 and the non-woven fabric 30. It is characterized by being inserted and temporarily attached.

In addition, the amine-based reducing agent is characterized in that it is applied at a thickness of 10 to 30 g/m2.

Lastly, the present invention includes an automobile headliner manufactured by the automobile headliner manufacturing method described above.

The automobile headliner and its manufacturing method according to the present invention have the following effects.

(1) Aldehyde VOCs (formaldehyde, acetaldehyde, acrolein, etc.) generated during the polyurethane foam molding process can be removed through an amine-based reducing agent applied to the surface of polyurethane foam, thereby reducing the amount of harmful substances released.

(2) In particular, as the process of applying an amine-based reducing agent to polyurethane foam is added in the process of manufacturing the headliner, there is no need to add a separate process to reduce aldehyde VOCs in the finished headliner. In addition, loss or damage to the headliner can be prevented in the process of removing harmful substances.

(3) In addition, the amine-based reducing agent is not only easy to work with when applied, but can also be easily applied to a desired thickness and adjusted to an appropriate thickness according to the amount of harmful substances generated. In a preferred embodiment of the present invention, the amine-based reducing agent is used by applying it at a thickness of 10 to 30 g/m2.

(4) By minimizing the amount of added amine-based reducing agent, the increase in weight of the headliner can be minimized and the generation of aldehyde VOCs harmful to the human body can be reduced.

[Figure 1] is a plan view of a car showing the location where a conventional headliner is mounted on the car.
[Figure 2] is a diagram showing a conventional headliner, where (a) is a perspective view and (b) is a cross-sectional view showing the layer structure.
[Figure 3] is a block diagram explaining the manufacturing method of the headliner according to the present invention.
[Figure 4] is a conceptual diagram briefly showing the manufacturing equipment used in the manufacturing method of the headliner according to the present invention.
[Figure 5] is a cross-sectional view showing the layer structure of the headliner according to the present invention.

Hereinafter, preferred embodiments of the present invention will be described in more detail with reference to the attached drawings. Prior to this, the terms or words used in this specification and claims should not be construed as limited to their usual or dictionary meanings, and the inventor may appropriately define the concept of terms in order to explain his or her invention in the best way. It must be interpreted with meaning and concept consistent with the technical idea of the present invention according to the principle that it can be done.

Therefore, the embodiments described in this specification and the configurations shown in the drawings are only one of the most preferred embodiments of the present invention and do not represent the entire technical idea of the present invention, so various equivalents can be substituted for them at the time of filing the present application. It should be understood that there may be variations.

[Manufacturing method of headliner]

In the headliner manufacturing method according to the present invention, as shown in [FIG. 3] to [FIG. 5], the glass fiber mat 20 and the non-woven fabric 30 are temporarily attached to each side of the polyurethane foam 10 in turn, The skin 40 is placed face to face on one nonwoven fabric 30 facing the car interior, and then thermoformed into the shape of a headliner.

At this time, by applying an amine-based reducing agent to the polyurethane foam 10 before the glass fiber mat 20 and the non-woven fabric 30 are temporarily attached, formaldehyde, acetaldehyde, and acrolein generated during polyurethane molding are reduced. It neutralizes aldehyde VOCs so that they do not cause harm to the human body.

In addition, by applying the amine-based reducing agent at a thickness of 10 to 30 g/m2, not only can it be easily applied to the polyurethane foam 10 in the process of manufacturing the headliner, but it can also minimize additional weight while reducing aldehyde VOCs. By reducing this, it is possible to create a safe and comfortable car interior environment.

In addition, a urethane adhesive 21 is applied between the polyurethane foam 10 and the glass fiber mat 20 to temporarily attach it, and a hot melt film 31 is applied between the glass fiber mat 20 and the non-woven fabric 30. By constructing it so that it is inserted and temporarily attached, it can be molded as one piece through a thermoforming process.

Hereinafter, this configuration will be described in more detail with reference to the attached drawings.

go. polyurethane foam

Polyurethane foam 10 mainly plays a sound-absorbing function in automobile headliners, as shown in [FIGS. 3] to [FIG. 5]. This polyurethane foam 10 can be manufactured using conventional techniques used in the technical field to which the present invention pertains.

In particular, in a preferred embodiment of the present invention, the polyurethane foam 10 is used by applying an amine-based reducing agent to both sides of the polyurethane foam 10, as shown in [Figure 4]. At this time, the amine-based reducing agent is a compound with an amine group (amino group) that reacts with aldehydes such as formaldehyde, acetaldehyde, and acrolein, and is used to reduce these aldehyde VOCs among substances generated when molding polyurethane. It is a reducing agent. Examples of compounds having an amine group include amines, polyamines, aromatic amines, ethylenediamine, and monoamines. Among these, amines neutralize aldehyde VOCs through the reaction shown in [Chemical Formula 1] below.

At this time, in a preferred embodiment of the present invention, when applying the amine-based reducing agent to the polyurethane foam 10, it is preferable to apply it at a thickness of 10 to 30 g/m2. This is to reduce the increase in the overall weight of the headliner by minimizing the amount of application of the amine-based reducing agent, while also maximizing the reduction effect of aldehyde VOCs through this amine-based reducing agent.

In addition, in a preferred embodiment of the present invention, the amine-based reducing agent can be applied before or after applying the urethane adhesive 21 used to attach the glass fiber mat 20, which will be described later, to the polyurethane foam 10. However, as shown in [Figure 3], preferably, the adhesion between the polyurethane foam 10 and the glass fiber mat 20 can be prevented by applying the urethane adhesive 21 and then applying the amine-based reducing agent. It is desirable to have it.

To the polyurethane foam 10 formed in this way, glass fiber mats 20 are temporarily attached to both sides, as shown in [FIGS. 3] to [FIG. 5].

me. fiberglass mat

The glass fiber mat 20 is temporarily attached one by one to both sides of the polyurethane foam 10 described above, as shown in [FIGS. 3] to [FIG. 5]. Here, the glass fiber mat 20 may be used for sound absorption and rigidity reinforcement to maintain the overall shape of the headliner.

This glass fiber mat 20 can be temporarily attached using a urethane adhesive 21, as shown in [FIGS. 3] to [FIG. 5]. At this time, the urethane adhesive 21 is applied in advance to the surface of the polyurethane foam 10, and as the polyurethane foam 10 moves, the glass fiber mat 20 is supplied to each side in contact with it to achieve temporary attachment. It is desirable to configure it properly. In the drawing, the urethane adhesive 21 is shown to be applied to the polyurethane foam 10 in advance before applying the amine reducing agent described above.

all. Non-woven

The nonwoven fabric 30 is temporarily attached to the externally exposed surface of the above-described glass fiber mat 20, as shown in [FIGS. 3] to [FIG. 5]. Here, the non-woven fabric 30 can be used as a material manufactured using a conventional technology that reinforces the rigidity of the headliner to prevent it from being easily torn or damaged, maintains the shape of the headliner, and also provides moisture absorption.

Meanwhile, the nonwoven fabric 30 is temporarily attached to the above-described glass fiber mat 20 using a hot melt film 31, as shown in [FIGS. 4] and [FIG. 5]. At this time, the hot melt film 31 is supplied between the glass fiber mat 20 and the non-woven fabric 30 and is temporarily attached by applying a predetermined amount of heat or pressure, or left in a laminated state and then integrated into one body through thermoforming described later. It can also be configured to be attached.

la. skin

As shown in [FIG. 5], the skin 40 is disposed to face the side of the non-woven fabric 30 that is exposed to the interior of the automobile. At this time, the skin 40 can be made of fabric as is, or it can be configured as a multi-layer structure through various combinations of film, slab foam, fabric, and leather (Suedg). Since this skin 40 is the surface exposed to the interior of the car, it is decided in consideration of aesthetics and aesthetics.

mind. thermoforming

In thermoforming, as shown in [FIG. 3] and [FIG. 4], the glass fiber mat 20 and the non-woven fabric 30 are sequentially attached to both sides of the polyurethane 10 described above, and one of the non-woven fabrics 30 This is the process of putting the skin 40 into a thermoforming mold with it temporarily attached and forming it into the shape of the headliner. At this time, the thermoforming mold is molded into the shape of the headliner by applying a certain pressure and heat. The heat and pressure conditions at this time are determined by considering the fusion temperature of the polyurethane adhesive 21 and the hot melt film 31 used as a temporary adhesive. It is desirable to apply pressure and heat to mold the material into an appropriate shape in a sufficiently molten state.

In the present invention achieved in this way, the amine-based reducing agent is applied in advance to the polyurethane foam in the process of manufacturing the headliner, so the amine-based reducing agent reduces aldehyde VOCs such as formaldehyde, acetaldehyde, and acrolein, making it safe to use. .

In addition, the results of testing the headliner according to the present invention for VOCs content are shown in [Table 1] below. In [Table 1], the comparative example did not use an amine-based reducing agent, and the examples did not use an amine-based reducing agent, and the product name 'manufactured at Taesung Environmental Research Institute Co., Ltd. (Address: 623-6, Mugeo 2-dong, Nam-gu, Ulsan)' 'TS-NVS' was used. Comparative Examples and Examples were compared by quantitatively analyzing air collected after heating in a constant temperature and humidity chamber, respectively, by GC/MS and HPLC. The results are shown in [Table 1] below, and the unit here is [㎍/㎥].

division

benzene
toluene
ethylbenzene
xylene
styrene
formaldehyde
acetaldehyde
acrolein
Comparative example

5
108
37
51
15
237
105
58
Example

7
99
25
27
10
35
46
29

[Car Headliner]

The present invention includes a headliner manufactured by the method for manufacturing an automobile headliner described above.

10: Polyurethane foam
20: Fiberglass mat
21: Polyurethane adhesive
30: Non-woven fabric
31: hot melt film
40: skin

Claims (4)

Based on the polyurethane foam (10) coated with an amine-based reducing agent on both sides, a glass fiber mat (20) and a non-woven fabric (30) are temporarily attached to each side in turn,
The skin 40 is laminated facing one of the non-woven fabrics 30 that is exposed to the interior of the car,
A method of manufacturing a headliner for an automobile, characterized in that it is integrally molded into the shape of the headliner using a thermoforming mold.
In paragraph 1:
A urethane adhesive (21) is applied and temporarily attached between the polyurethane foam (10) and the glass fiber mat (20),
A method of manufacturing a headliner for an automobile, characterized in that a hot melt film (31) is inserted between the glass fiber mat (20) and the non-woven fabric (30) and temporarily attached.
In paragraph 1:
The amine-based reducing agent,
A method of manufacturing a headliner for an automobile, characterized in that it is applied at a thickness of 10 to 30 g/m2.
An automobile headliner manufactured by the automobile headliner manufacturing method according to any one of claims 1 to 3.

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