KR100418438B1 - Moldable Substrate for Automotive Top Ceiling and Method of Processing the Same - Google Patents

Abstract

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molding material for automobile interiors, and more particularly, to a method for manufacturing a substrate such as a car ceiling, a bonnet hood, a door trim, a trunk, and the like. This molding material for automobile interior materials is a material that can be recycled and used to reduce fuel consumption of automobiles by lowering the weight, and to simplify the existing complicated molding process, and to give price competitiveness, and form stability required for automobile molding materials. It can contribute to the improvement of domestic automobile quality by manufacturing molding materials for automobiles that satisfy the requirements such as heat stability, flame retardancy, antibacterial, mass productivity and dimensional stability. Will be provided.

Description

Manufacturing method of molding base material for automobile interior {Moldable Substrate for Automotive Top Ceiling and Method of Processing the Same}

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing interior molding materials for automobiles, and more particularly, to form a car ceiling, a bonnet hood, a door trim, a trunk, etc. by applying a recyclable material. The present invention relates to a molding material for automobile interiors and a method of manufacturing the same, thereby achieving fuel economy reduction of automobiles, simplifying the molding process, and improving the quality of automobile interior materials.

In general, in the interior materials for automobiles, the ceiling substrate has a wide application area and forms a three-dimensional structure, various various properties are required. Recently, in Japan, Europe, and North America, the movement to prevent environmental pollution by using materials that can be recycled (Re-Cycle) as automobile parts is actively underway.

Therefore, the development of recyclable materials for automobile interior materials is progressing variously, and the substrate using 100% of polypropylene and polyester materials is being developed. In the case of polypropylene, sheet and foam layers were sandwiched in Japan and commercialized on the ceiling of automobiles.However, in the case of polyester, since the workability, such as adhesiveness, is worse than that of polypropylene, development is proceeded to a nonwoven fabric shape. It is becoming.

Molding materials using 100% polyester non-woven fabric can be recycled and have excellent sound absorption, but various developments are underway. However, the strength of molding materials is relatively low, so that the thickness of nonwoven fabric becomes thicker and the weight increases to compensate for the strength. There is a disadvantage that the manufacturing speed is low, the price is high, the product is thick, the transportation is difficult and the transportation cost is high.

In addition, the existing polyester interior materials are manufactured in a high-loft method, but these methods are very expensive and have a problem in mass supply.

Recently, as the environmental pollution problem has emerged as a serious problem, fuel economy reduction has become an important point in the development of automobiles for the recyclability of the material to reduce the environmental pollution by waste, and the air pollution by the smoke of the vehicle.

In order to reduce such environmental pollution, the recent development direction of automobile parts is recycling materials and weight reduction for fuel efficiency.

Considering this point, the problems of the 100% polyester nonwoven fabrics being produced are as follows.

first; The production process of nonwoven fabric is high-loft type, so the production speed is low, so the price is high and supply is not desired.

second; High-Loft type makes the non-woven fabric thick. Therefore, handling is difficult and transportation costs are high.

third; In the molding process, the preheating time of the product is long and the shrinkage rate of the product is high.

fourth; Since the molding process is performed separately from the substrate molding and the skin material forming, the molding process is complicated, the mold manufacturing cost is high, and the processing cost is high. This related technology is Japanese Patent Laid-Open No. 11-268596, but this is the production of the base layer and the skin material. Is a technology for advancing the smoothing operation using a separate metal plate or a thermal roller and adhering it, or adhering it in the ceiling material forming process, and requires an extra cost because the skin material layer and the base material layer are bonded in a separate process. There is a problem that the productivity is lowered. Therefore, as a technology that does not improve the manufacturing cost, which is the biggest problem of 100% polyester ceiling material, the present invention is to provide a technology that can produce a 100% polyester ceiling material at a low cost. Although the technique of needling is introduced in Korean Patent Application Publication No. 2001-8119 filed by the applicant of the present application, the technique has been introduced as a technique related to the process by needle punching. It is a relatively simple technology that requires a function of continuously adhering a hot melt film of polyester material and a skin material of polyester material to a substrate and bonding them collectively by press roll pressure and latent heat of interior materials.

The present invention has been made in order to solve such a conventional problem, the substrate layer nonwoven fabric obtained by the needle punching process is subjected to a heat treatment using a special hot air dryer, and the skin material and the hot melt film collectively using the heat applied during the heat treatment By integrating without additional smoothing process and bonding process, we want to obtain the ceiling material with the skin material and the substrate integrated at low cost. By minimizing thermal shrinkage after molding, we want to obtain interior materials with excellent heat stability and to minimize wrinkles of the skin material due to shrinkage of the substrate during molding.The interior materials are made of 100% polyester and can be recycled. Therefore, eco-friendly recycling is possible. To provide dimensional stability, heat stability, flame retardance, large quantities for mass production, the molding base material for automobile interior to meet the requirements of properties such as dimensional stability and a production method by which it is an object in the substrate.

The purpose is to produce a nonwoven fabric for automotive interior molding materials, 100% polyester fiber needle punched to produce a needle felt to an appropriate thickness and through the hot air circulation dryer to set the product thermal settings to minimize shrinkage, Hot melt film (Poly Melt P (F) ilm) made of polyester (PET) and the skin material of polyester (PET) are continuously supplied on the molding material obtained continuously, and the pressure of the press roll and latent heat of the interior material It is achieved by gluing in batches and then cutting them to a constant length.

1 is a cross-sectional view of a molding substrate according to the present invention,

2 is a cross-sectional view of the manufacturing process of the molding substrate according to the present invention.

<Explanation of symbols for main parts of drawing>

10; Molding substrate 12; Bale opening

13; Fiber mixing apparatus 14; Carding machine

15; Crosapepe 16; Needle punching device

17; Hot air circulation dryer 20; Hot Melt Film

30; Skin 100; Integral Formation Materials

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

Fig. 1 shows in cross section a molding substrate completed by the molding process of the present invention, and Fig. 2 shows in cross section a process for producing a molding substrate according to the present invention.

As shown in Figure 1 and 2, the manufacturing method of the molding material for automobile interior of the present invention by supplying polyester (PET) fiber after the carding process (carding) needle punching and homogeneous hot melt film and skin material Is continuously supplied and adhered in a batch process by the pressure of the press roll and the latent heat of the base material layer, and cut into a predetermined size to complete the skin material integral molding material.

Molding base material and hot melt film layer and the skin used in the present invention 100% polyester material is used and may contain organic fibers as necessary.

For example, the molding material may be 100% polyester by opening the fiber in the bal opening device (12) to agglomerate the fibers in the form of a mass through a fine opening device, etc. Supply.

The fiber mixing apparatus 13 distributes the fibers evenly and then supplies the evenly distributed fibers to a carding machine 14.

The carding machine 14 forms the aggregated fibers into a thin sheet form (web) and sends them to a cross-lapper (cross wrapper) 15 to be laminated in multiple layers to form a predetermined fiber layer.

Next, the fiber layer is needled in the needle punching device 16 to form a bond to each other, and at the same time, needle felt is manufactured to a proper thickness by needle punching.

The needle felt completed by needle punching is passed through a hot air circulation dryer 17 to thermally set the product to obtain a molding base 10 continuously.

Here, the needle punching device (16; needle machine) for coupling the needle felt is made of 2 to 8, the punching density of the needle is 300 ~ 800st / ㎠ and the needle depth (Needle Depth) is suitable 3 ~ 12㎜ .

And the hot air circulation dryer 17 is composed of two conveyor belts made of mesh (Mesh) in the heat chamber (Hesh Chamber) is supplied with hot hot air on the mesh belt, the hot air is sucked under the mesh belt to circulate, It is preferable that the hot air is forced through the nonwoven needle felt to allow thermal setting of the nonwoven needle felt in a short time.

The hot melt film (PET) material and the skin material (PET) material of the polyester (PET) material (30) on the molding material (10) continuously obtained through thermal setting of the product through the hot air circulation dryer ) Is continuously supplied and adhered by the pressure of the press roll and latent heat of the built-in base material, and then cut into a predetermined length to complete the skin material-integrated molding base material 100.

Here, the polyester fiber is mixed with a low melt polyester and a general polyester in a predetermined ratio, and in the case of a low melt polyester, one component, or two components in which the low melt polyester and the general polyester are spun simultaneously It is appropriate that one of each of the low melt is used, or two kinds are used by mixing a predetermined amount.

As shown in FIG. 1, the completed molding material for automobiles is formed by laminating the molding material layer 10, the hot melt film layer 20, and the skin material 30, and all of them are made of 100% polyester. It is possible.

The molding substrate layer has a needle felt thickness of 2 to 20 mm, and the skin material 30 of the polyester (PET) material is preferably made of any one of a nonwoven fabric and a cloth.

A cushioning property of the skin material 30 may be provided by attaching one of polyurethane and polyethylene foam to an appropriate thickness on the surface of the skin material 30 support layer side of the polyester material.

As described above, the manufacturing method of the automotive interior molding material according to the present invention can prevent the environmental pollution because it can be recycled using 100% polyester fiber, and because of the low weight compared to the existing molding materials, It enhances the competitiveness by reducing fuel efficiency and has excellent moldability of the product, so that no wrinkles occur in the molding process, which can drastically reduce product defects.

In addition, the automobile molding material according to the present invention can greatly simplify the molding method, it can significantly reduce the development cost and molding cost of the vehicle.

Therefore, it is possible to realize high speed production speed by using needle punching process when manufacturing non-woven molding materials, and to minimize the shrinkage in the molding process by setting the product thermally stable by using hot air circulation type dryer and heat stability of the molded product. This excellent product can be obtained, and because the adhesive is applied in a batch process using the latent heat applied during the heat setting of the skin material layer and the base material layer, a separate bonding process is not required, and wrinkles can be minimized when the skin material is bonded. In addition, the molding substrate obtained in the present invention is provided with the effect that the skin material and the substrate layer are integrated, thereby greatly simplifying the molding process.

Claims (8)

In the manufacture of a nonwoven fabric for automobile interior molding materials using a support layer made of needle felt needled with polyester fiber to enable regeneration. 100% polyester fiber is needled to become a needle felt and passed through a hot air circulation dryer to provide a support layer composed of a thermal setting, a 100% polyester hot melt film layer and a skin material are sequentially supplied to the support layer, and a press roll A method of manufacturing a molding machine interior material for automobiles, which is bonded in a batch process by the pressure of the substrate and the latent heat of the base material layer, and cut into a predetermined length. The method of claim 1, The needle felt has a thickness of 5 ~ 20㎜ manufacturing method of the automotive interior molding material. (delete) (delete) (delete) (Correction) According to claim 1, The polyester fiber is mixed with a low melt polyester and a general polyester in a predetermined ratio, and in the case of a low melt polyester, one component or a two-component low in which the low melt polyester and the general polyester are spun at the same time. A method of manufacturing a molding material for automobile interiors in which one kind of melt is used or two kinds are mixed in a predetermined amount. (delete) (Correction) According to claim 1, The hot air circulation dryer consists of two conveyor belts made of mesh in a heat chamber, hot hot air is supplied on the mesh belt, and hot air is sucked under the mesh belt to circulate by sucking the hot air. A method of manufacturing a molding material for automobile interiors characterized in that the heat setting of the nonwoven needle felt is made in a short time by forcibly passing hot air therebetween.