KR102187819B1 - Composite materials having natural fibre for interior parts of vehicle, and method for manufacturing the same - Google Patents

Abstract

A composite material for interior parts of vehicle according to the present invention and a method for preparing the same form a felt layer with natural fibers and thermoplastic binder fibers and interpose a separate adhesive layer between a coating layer and the felt layer, so as to prevent defects caused by non-uniform melting and non-uniform impregnation as in the related art, and perform a direct injection and molding onto the back side of the felt layer so as to form a rear structure such as ribs, fusion bosses, brackets, etc., thereby providing an effect of simplifying a manufacturing process and reducing manufacturing costs.

Description

Composite material for vehicle interior materials containing natural fibers and its manufacturing method {COMPOSITE MATERIALS HAVING NATURAL FIBRE FOR INTERIOR PARTS OF VEHICLE, AND METHOD FOR MANUFACTURING THE SAME}

The present invention relates to a composite material for vehicle interior materials containing natural fibers and a manufacturing method thereof. More specifically, the texture of natural fibers is exposed on the surface to enhance aesthetics, and at the same time, a vehicle interior material capable of simplifying the manufacturing process. It relates to a composite material and a manufacturing method thereof.

Automobile interior materials have a relatively large area applied to automobiles, and have a complex structure such as assembly and attachment of various related parts according to the trend of component modularization, so that the shape stability or dimensional stability of the material is required.

In addition, in recent years, in accordance with environmentally friendly demands, lightweight materials have been developed that have excellent heat resistance and stiffness, increase energy efficiency, and enhance aesthetics through surface treatment.

In order to achieve such eco-friendly, lightweight, high stiffness and high aesthetics, a composite material produced by mixing natural fibers and synthetic fibers, forming a felt layer through needle punching and web forming processes, and laminating a coating layer on the felt layer. Was developed.

In this regard, U.S. Patent Publication No. 20120142242 is prepared by mixing natural fibers and synthetic fibers to form a core layer, and attaching a film-type coating layer to the upper and lower surfaces of the core layer, but the texture of natural fibers is obtained from the outside of the coating layer. A composite material is disclosed that can be expressed so as to enhance aesthetics.

However, according to the configuration disclosed in the above document, since a laminate is formed by impregnating the film into the core layer by attaching a film-type coating layer to the upper and lower surfaces of the core layer and heat-pressing it, There is a high possibility of defects due to partial agglomeration.

In addition, since the bracket for reinforcing the rigidity of the composite material and the boss for the bonding of the functional member are separately manufactured and attached to the back side of the composite material using an adhesive such as hot melt, the number of manufacturing processes increases and the manufacturing cost increases. Problems arise.

US Patent Publication No. 20120142242

The present invention was conceived to solve the problems of the prior art described above, forming a felt layer with natural fibers and thermoplastic binder fibers, and interposing a separate adhesive layer between the coating layer and the felt layer to provide non-uniform melting and non-uniform impregnation as in the prior art. For interior materials of vehicles that can simplify the manufacturing process and reduce manufacturing cost by forming rear structures such as ribs, fusion bosses, and brackets through injection molding directly on the back of the felt layer. It is an object to provide a composite material and its manufacturing method.

In order to achieve the above object, the composite material for interior materials of a vehicle according to the present invention includes a composite layer formed by mixing natural fibers and thermoplastic binder fibers; A coating layer formed on the upper side of the composite layer; An adhesive layer interposed between the composite layer and the coating layer; And a rear structure formed by direct injection of a thermoplastic injection resin onto the lower side of the composite layer, wherein the adhesive layer includes an adhesive powder mixed with a natural fiber and a powder-type resin on the upper side of the composite layer. It is formed by applying a thickness, the coating layer is formed by laminating a thermoplastic film having a predetermined thickness on the upper side of the adhesive layer, characterized in that the texture of the natural fiber is exposed to the outside of the coating layer.

Further, by hot pressing and cold pressing the laminate in which the adhesive layer and the coating layer are stacked on the composite layer, the adhesive layer and the coating layer are at least partially impregnated into the interior of the composite layer.

In addition, in the rear structure, the thermoplastic injection resin is directly injected toward the lower side of the composite layer, so that the thermoplastic injection resin is at least partially penetrated and bonded into the interior of the lower side of the composite layer, and the thermoplastic binder fiber The material of and the material of the thermoplastic injection resin are the same.

Further, before the thermoplastic injection resin is injected, the compressed laminate is molded into a predetermined shape.

In addition, the composite layer becomes a felt layer formed by mixing the natural fibers and the thermoplastic binder fibers.

In addition, the felt layer is formed through a needle punching method after mixing the natural fiber and the thermoplastic binder fiber.

In addition, the felt layer is formed by mixing 30 to 70% by weight of the natural fiber and 70 to 30% by weight of the thermoplastic binder fiber.

On the other hand, the manufacturing method of the composite material for vehicle interior according to the present invention comprises the step of forming a composite layer by mixing natural fibers and thermoplastic binder fibers to form a composite layer; Laminating a coating layer to form a coating layer on the upper side of the composite layer; And applying an adhesive layer to form an adhesive layer between the composite layer and the coating layer. Including; a rear injection step of directly injecting a thermoplastic injection resin onto the lower side of the composite layer to form a rear structure, wherein in the step of applying the adhesive layer, an adhesive powder in which a natural fiber and a powder-type resin are mixed is formed of the composite layer. The adhesive layer is formed by being applied to the upper side with a predetermined thickness, and in the step of laminating the coating layer, a thermoplastic film having a predetermined thickness is laminated on the upper side of the adhesive layer as the coating layer, and the texture of the natural fiber is It is characterized by being exposed to the outside.

In addition, further comprising a pressing step of hot pressing the laminate in which the adhesive layer and the coating layer are stacked on the composite layer, and cold pressing the hot-pressed laminate, wherein in the pressing step, the adhesive layer and The coating layer is at least partially impregnated into the interior of the composite layer.

In addition, in the rear injection step, the thermoplastic injection resin is directly injected toward the lower side of the composite layer, so that the thermoplastic injection resin at least partially penetrates and bonds to the inside of the lower side of the composite layer, so that the rear structure is Is formed, the material of the thermoplastic binder fiber and the material of the thermoplastic injection resin are the same.

Further, before the thermoplastic injection resin is injected, the compressed laminate is molded into a predetermined shape.

In addition, the composite layer becomes a felt layer formed by mixing the natural fibers and the thermoplastic binder fibers.

In addition, the felt layer is formed through a needle punching method after mixing the natural fiber and the thermoplastic binder fiber.

In addition, the felt layer is formed by mixing 30 to 70% by weight of the natural fiber and 70 to 30% by weight of the thermoplastic binder fiber.

The composite material for interior materials of a vehicle according to the present invention and a method for manufacturing the same, are formed by forming a felt layer with natural fibers and thermoplastic binder fibers, and interposing a separate adhesive layer between the coating layer and the felt layer to achieve non-uniform melting and non-uniform impregnation as in the prior art. It is possible to prevent the occurrence of defects due to the formation of a rear structure such as ribs, fusion bosses, brackets, etc. through direct injection molding on the back surface of the felt layer, thereby simplifying the manufacturing process and reducing manufacturing cost.

1 is a cross-sectional view of a composite material for interior materials of a vehicle according to the present invention.
2 is a schematic diagram illustrating a process of manufacturing a laminate according to an embodiment of the present invention.
FIG. 3 is a schematic diagram illustrating a process of manufacturing a composite material using a laminate manufactured according to the process shown in FIG. 2.
4 is a flow chart for explaining the process illustrated in FIG. 3.
5 is a flowchart illustrating detailed steps of the step of forming the composite layer of FIG. 4.
6 is a flow chart for explaining detailed steps of the forming step of FIG. 4.

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

In the present invention, various modifications may be made and various embodiments may be provided, and specific embodiments will be illustrated in the drawings and described in detail in the detailed description. This is not intended to limit the present invention to a specific embodiment, and should be construed as including all changes, equivalents, or substitutes included in the spirit and scope of the present invention.

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

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 is said that it is directly connected to or may be connected to the other component, but other components may exist in the middle. Can be understood. On the other hand, when a component is referred to as being "directly connected" or "directly connected" to another component, it may be understood that there is no other component 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. Singular expressions may include plural expressions unless the context clearly indicates otherwise.

In the present application, terms such as "comprise" or "have" are intended to designate the presence of features, numbers, steps, actions, components, parts, or a combination thereof described in the specification, and one or more other features It may be understood that the presence or addition of elements or numbers, steps, actions, components, parts, or combinations thereof, does not preclude in advance.

Unless otherwise defined, all terms, including technical or scientific terms, used herein may have the same meaning as commonly understood by one of ordinary skill in the art to which the present invention belongs. Terms as defined in a commonly used dictionary may be interpreted as having a meaning consistent with the meaning in the context of the related technology, and unless explicitly defined in this application, interpreted as an ideal or excessively formal meaning. 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 clearer explanation.

1 is a cross-sectional view of a composite material 1 for interior materials of a vehicle according to the present invention.

First, referring to FIG. 1, the composite material 1 for interior materials of a vehicle according to an embodiment of the present invention is a felt layer in the form of a composite layer formed by mixing natural fibers 11a and thermoplastic binder fibers 11b. (11), a coating layer 13 formed on the upper side of the felt layer 11, a laminate 10 including an adhesive layer 12 interposed between the felt layer 11 and the coating layer 13, and a felt layer ( 11) includes a rear structure 30 formed by direct injection of a thermoplastic injection resin on the lower side.

The felt layer 11 forming the lowermost layer of the laminate 10 based on FIG. 1 serves to maintain the overall rigidity of the composite material according to the present invention, and contains natural fibers 11a and thermoplastic binder fibers 11b. After mixing, it is prepared in the form of a sheet.

In this case, the felt layer 11 does not contain glass fibers, and only natural fibers 11a and thermoplastic binder fibers 11b are provided. By excluding the use of glass fibers as a common harmful substance, it is possible to implement an environmentally friendly interior material.

Meanwhile, the mixing ratio of the natural fibers 11a and the thermoplastic binder fibers 11b is preferably 30 to 70% by weight of the natural fibers 11a and 70 to 30% by weight of the binder fibers 11b. This is because if the content of the binder fiber (11b) is insufficient, the shape stability of the product after molding is lowered and the moldability is lowered.If the content of the binder fiber (11b) is too high, the preheating time for molding increases, resulting in a decrease in mass productivity. Or the strength and elastic modulus may decrease.

In addition, the weight per unit area of the felt layer 11 is preferably in the range of 600-2,500 g/m ² .

The natural fiber 11a may be formed by including any one or more selected from the group consisting of vegetable fibers such as jute fibers, flax fibers, hemp fibers, sisal fibers, flax fibers, or bamboo fibers. It is used after cutting to have a length.

The binder fibers 11b are mostly melted in the preheating step and molding step described later, and penetrate between the natural fibers 11a to form a resin layer. FIG. 1 shows a composite material 1 for interior materials of a vehicle in a state in which the binder fibers 11b are melted and solidified.

The binder fiber 11b may have at least one material selected from polypropylene (PP) and polyethylene (PE)-based resins, and is cut to have a length of about 2 cm or less.

The felt layer 11 is made of a felt-shaped sheet through needle punching and web forming processes by mixing natural fibers 11a and binder fibers 11b.

The coating layer 13 corresponds to the top layer of the laminate 10 of the composite material according to the present invention and corresponds to a surface layer exposed to the outside. The coating layer 13 serves to protect the felt layer 11 described above.

The adhesive layer 12 is interposed between the above-described felt layer 11 and the coating layer 13 and serves to attach the coating layer 13 to the felt layer 11.

FIG. 2 shows a process in which the adhesive layer 12 and the coating layer 13 are stacked on the felt layer 11 to form the laminate 10 according to an embodiment of the present invention.

Referring to FIG. 2, first, a mixture of thermoplastic resin powder 12d and cut natural fibers 12c on the upper side of the felt layer 11 is prescribed on the upper side of the felt layer 11 in order to form the adhesive layer 12. It is applied to the thickness of.

In more detail, the raw material natural fibers 12b are introduced into the hopper 5a in the form of long fibers and are cut with a cutter 5b provided inside the hopper 5a. Preferably, the raw natural fibers 12b are cut to have a length of 1 to 5 cm.

The cut natural fiber 12c is uniformly mixed with the thermoplastic resin powder 12d inside the hopper 5a.

In this case, the mixing ratio is preferably 60 to 80% by weight of the cut natural fiber 12c and 40 to 20% by weight of the thermoplastic resin powder 12d.

The cut natural fibers 12c and the thermoplastic resin powder 12d mixed in a predetermined ratio are applied in a manner that evenly fall on the upper side of the felt layer 11 through the nozzle of the dispenser 5, and the adhesive layer 12 Is formed.

The material of the thermoplastic resin powder 12d is linear polystyrene, ethylene-vinyl acetate, ethylene acrylic copolymer, polyolefin suitable for improving the adhesion of the coating layer 13 and exposing the texture of the cut natural fibers 12c applied together. , At least one selected from among polyester and polyamide resins is preferred.

When the cut natural fiber 12c and the thermoplastic resin powder 12d are applied and the adhesive layer 12 is laminated, the thermoplastic film 13b is laminated to form the coating layer 13 on the upper side of the adhesive layer 12.

As the coating layer 13, the thermoplastic film 13b is polypropylene (PP), polyethylene (PE), polyamide (PA), or polyethylene terephthalate (PET), polycarbonate, Any one selected from PC) series resins is preferred, and a small amount of UV additives, antioxidants, and pigments may be added to improve scratch resistance and light resistance, and to realize a predetermined surface color.

When the lamination of the thermoplastic film 13b as the coating layer 13 is completed, hot pressing is performed in a state in which the adhesive layer 12 and the coating layer 13 are stacked on the felt layer 11.

Hot pressing may be performed using the heat roller 6 as shown, but is not limited thereto, and any pressing means known in the art may be applied.

The thermal roller 6 heats and compresses the laminate 10 of the felt layer 11, the adhesive layer 12, and the coating layer 13 in a temperature range of 150 to 400°C, and is included in the laminate 10. Most of the thermoplastic materials are melted.

That is, the binder fibers 11b forming the felt layer 11, the thermoplastic resin powder 12d of the adhesive layer 12, and the thermoplastic film of the coating layer 13 are mostly melted, and the melted adhesive layer 12 is mostly a felt layer. The upper surface of (11) is impregnated, and the thermoplastic film of the coating layer (13) is at least partially impregnated into the upper surface of the felt layer (11).

However, the molten thermoplastic resin powder 12d of the coating layer 13 is partially impregnated into the felt layer 11, but due to the adhesive layer 12, the natural fibers 11a and the binder fibers 11b of the felt layer 11 No contact.

On the other hand, after hot pressing through the hot roller 6, the cold pressing through the cold roller 7 is then performed.

At this time, the temperature of the cold roller 7 is preferably 20 to 50°C. When the temperature of the cold roller 7 is less than 20°C, there is a possibility that defects may occur due to shrinkage, and when it exceeds 50°C, there is a possibility that non-uniformity may occur in the coating layer 13.

Through such cold pressing, the texture of the cut natural fibers 12c included in the adhesive layer 12 is solidified in a state exposed to the outside of the coating layer 13.

On the other hand, the rear structure 30 is a part formed by direct injection of a thermoplastic injection resin onto the lower side of the laminate 10, and is fused for assembly of parts related to the composite material 1 for interior materials of a vehicle according to the present invention. It includes a boss 32, a bracket 33, ribs 31a and 31b for reinforcing rigidity, and a bracket 33.

In more detail, the ribs 31a and 31b for reinforcing rigidity include a plurality of first ribs 31a arranged parallel to each other in a first direction on the flat plate 10a on the lower side of the laminate 10, Includes a plurality of second ribs 31b arranged parallel to each other along a second direction crossing the first direction, and the bracket 33 is arranged along the edge portion 10c on the lower side of the stacked body 10 do.

The rear structure 30 is formed by direct injection toward the lower side of the felt layer 11 without the use of an adhesive. Accordingly, a process of bonding the rear structure 30 manufactured by a separate injection process to the felt layer 11 as in the related art may be omitted, thereby simplifying the manufacturing process and significantly reducing manufacturing cost.

The material to be injected may have at least one material selected from polypropylene (PP) and polyethylene (PE)-based resins, similar to the above-described binder fiber 11b.

In addition, mineral fillers, glass fibers, talc, calcium carbonate, and the like may be added to the injected material in a predetermined ratio as an additive for reinforcing strength.

When the injection material has the same material as the binder fiber 11b of the felt layer 11, the binder fiber 11b on the surface of the felt layer 11 at least partially melts with the injection resin due to the heat and pressure of the injection resin. Because of the bonding, the rear structure 30 can be firmly attached to the felt layer 11 without the use of a separate adhesive.

Hereinafter, detailed steps of the manufacturing method of the composite material 1 for a vehicle interior according to the present invention will be described with reference to FIGS. 3 to 6.

First, referring to Figure 4, the manufacturing method of the composite material (1) for interior materials of a vehicle according to the present invention, a laminate forming step (S10), a preheating step (S20), a molding step (S30), a rear injection step (S40) ).

As shown in FIG. 5, the step of forming a layered body (S10) includes a step of forming a felt layer (S11), a step of applying an adhesive layer (S12), a step of forming a coating layer (S13), and a step of pressing (S14).

In the felt layer forming step (S11), the natural fibers 11a and the thermoplastic binder fibers 11b are mixed and then manufactured into a sheet in the form of felt as shown in 4(a) through needle punching and web forming processes.

The mixing ratio of the natural fibers 11a and the thermoplastic binder fibers 11b is preferably 30 to 70% by weight of the natural fibers 11a and 70 to 30% by weight of the binder fibers 11b. This is because if the content of the binder fiber (11b) is insufficient, the shape stability of the product after molding is lowered and the moldability is lowered.If the content of the binder fiber (11b) is too high, the preheating time for molding increases, resulting in a decrease in mass productivity. Or the strength and elastic modulus may decrease.

In addition, the weight per unit area of the felt layer 11 is preferably in the range of 600-2,500 g/m ² .

The natural fiber 11a may be formed by including any one or more selected from the group consisting of vegetable fibers such as jute fiber, flax fiber, hemp fiber sisal fiber, flax fiber, or bamboo fiber, and the raw material fiber has a length of about 2 cm. It is used by cutting to have it.

The binder fibers 11b are mostly melted and penetrated between the natural fibers 11a in a preheating step and a molding step to be described later to form a resin layer.

The binder fiber 11b may have at least one material selected from polypropylene (PP) and polyethylene (PE)-based resins, and is cut to have a length of about 2 cm or less.

The felt layer 11 is made of a felt-shaped sheet through needle punching and web forming processes by mixing natural fibers 11a and binder fibers 11b.

In the adhesive layer applying step (S12), a mixture of the thermoplastic resin powder 12d and the cut natural fibers 12c is applied to the upper surface of the felt layer 11 to a predetermined thickness as described above.

In the coating layer forming step S13, a thermoplastic film is laminated to form the coating layer 13 on the upper side of the adhesive layer 12 as described above.

In the pressing step (S14), hot pressing using a hot roller 6 and cold pressing using a cold roller 7 in a state in which the adhesive layer 12 and the coating layer 13 are stacked on the felt layer 11 as described above. This proceeds continuously.

When the pressing step (S14) is completed, the laminate 10 in which the adhesive layer 12 and the coating layer 13 are laminated on the felt layer 11 is completed.

Next, the preheating step (S20) is the molding of the laminate 10 before the laminate 10 is moved to the inside of the mold 20 and molded in the molding step S30 to be described later. This is a step of preheating to a predetermined temperature to increase the performance.

In more detail, heating the laminate 10 under a temperature condition in which melting may occur at least partially for the thermoplastic resin included in the felt layer 11, the adhesive layer 12 and the coating layer 13 of the laminate 10 Thus, the moldability of the laminate 10 and the bonding property with the injection resin described later can be improved.

As a means for heating the stacked body 10, a hot press 40 and a hot air generator (not shown) shown in FIG. 3(b) may be used.

The present invention is not limited thereto, but illustratively hereinafter will be described based on an embodiment in which the hot press 40 is applied as a means for preheating the laminate 10.

In the case of using the hot press 40, the heating temperature and the heating time may be selected according to the type of material and the thickness of the laminate 10.

, 예열 시간은 15 ~ 300 초가 바람직하다.However, carbonization of the thermoplastic resin included in the felt layer 11, the adhesive layer 12, and the coating layer 13 does not occur, but at least partially melting of the thermoplastic resin may occur, and the preheating temperature is 150 to 300

, The preheating time is preferably 15 to 300 seconds.

When the preheating step (S20) is completed, the molding step (S30) proceeds.

The forming step (S30) is a step for forming the preheated laminate 10 into the press mold 20-1 to form a predetermined shape as shown in FIG. 3(c).

In more detail, the forming step (S30) includes an arrangement step (S31), a pressing step (S32), a holding step (S33), and a trimming step (S34) as shown in FIG. 6.

In the arrangement step (S31), the laminate 10, which has been preheated in the preheating step (S20) described above, is moved to the inside of the open press mold 20-1, and when the moving arrangement of the laminate 10 is completed The upper mold 21-1 of the press mold 20-1 is moved to close the upper mold 21-1 and the lower mold 22-1.

As the press mold 20-1 is molded and closed, the laminate 10 is formed into a predetermined shape corresponding to the shape of the cavity inside the press mold 20-1.

In the pressing step (S32) and the holding step (S33), the stacked body 10 is cooled by maintaining the pressurization for a predetermined delay time while the forming of the stacked body 10 is completed.

In this case, the mold temperature is preferably in the range of 20 to 70°C, and the predetermined pressurization holding time is preferably 30 to 300 seconds.

This is because if the pressurization holding time is less than 30 seconds, the cooling time becomes too short and cooling of the laminate 10 becomes insufficient, so that the laminate 10 may be torn or wrinkled in the back injection step (S40) to be described later. .

In addition, when the holding time of the pressurization exceeds 300 seconds, the possibility of tearing or wrinkles occurring in the laminate 10 due to the back injection decreases, but it is not preferable because a delay in the entire manufacturing process time may occur.

In the trimming step (S34), the outer portion of the laminate 10 on which the forming has been completed is cut or a through hole is formed at a predetermined position.

The trimming step (S34) may be performed inside the press mold 20-1, if possible inside the press mold 20-1, and press when it is impossible to proceed inside the press mold 20-1 After taking out the laminated body 10 in which the forming has been completed from the mold 20-1, the process may be performed using a separate trimming mold (not shown).

On the other hand, the rear injection step (S40) is a step for forming the rear structure 30 by injecting a thermoplastic resin to the rear surface of the laminate 10 that has undergone the above-described molding step (S30).

In the rear injection step (S40), the laminate 10, which has been formed and trimmed, is moved to the inside of the open injection mold 20-2, and when the moving arrangement of the laminate 10 is completed, the injection mold 20- Move the upper mold (21-2) of 2) to close the upper mold (21-2) and the lower mold (22-2).

After the upper mold 21-2 and the lower mold 22-2 are mold-closed, the thermoplastic injection resin is directly back-injected toward the lower side of the felt layer 11 to form the rear structure 30.

A fusion boss 32 for assembly of parts related to the composite material 1 for interior materials of a vehicle according to the present invention through such a single back injection, and a bracket 33, ribs 31a, 31b for reinforcing rigidity And the bracket 33 are integrally formed through a single process.

The material injected through the injection port 23 of the injection mold 20-2 and injected may have at least one material selected from polypropylene (PP) and polyethylene (PE) resins. .

In addition, mineral fillers, glass fibers, talc, calcium carbonate, and the like may be added to the injected material in a predetermined ratio as an additive for reinforcing strength.

When the injection material has the same material as the binder fiber 11b of the felt layer 11, the binder fiber 11b on the surface of the felt layer 11 at least partially melts with the injection resin due to the heat and pressure of the injection resin. Because of the bonding, the rear structure 30 can be firmly attached to the felt layer 11 without the use of a separate adhesive.

In this way, the injection time is preferably adjusted in the range of 10 to 120 seconds so that the rear structure 30 can be firmly attached to the felt layer 11, and the injection pressure is the laminate 10 having undergone the molding step (S30). It is desirable to be adjusted to have a pressure range that is not damaged by the injection pressure.

When the injection of the injection material is completed, the mold 20 is opened at a predetermined cooling time, preferably 10 to 120 seconds after the injection is completed, thereby completing the rear injection step (S40).

When the rear injection step (S40) is completed, the process of attaching the rear structure 30 to the laminate 10 is omitted, as shown in FIG. 3(d), so that the composite material 1 for interior materials of a vehicle according to the present invention ) Is completed.

As described above, it will be understood that the technical configuration of the present invention described above can be implemented in other specific forms without changing the technical spirit or essential features of the present invention by those skilled in the art.

Therefore, the above-described embodiments are to be understood as illustrative and not limiting in all respects, and the scope of the present invention is indicated by the claims to be described later rather than the detailed description described above, and the meaning and scope of the claims And it should be construed that all changes or modified forms derived from the equivalent concept are included in the scope of the present invention.

As described above, it will be understood that the technical configuration of the present invention described above can be implemented in other specific forms without changing the technical spirit or essential features of the present invention by those skilled in the art.

Therefore, the above-described embodiments are to be understood as illustrative and not limiting in all respects, and the scope of the present invention is indicated by the claims to be described later rather than the detailed description described above, and the meaning and scope of the claims And it should be construed that all changes or modified forms derived from the equivalent concept are included in the scope of the present invention.

Composite material for vehicle interior materials (1) Laminate (10)
Felt layer (11) natural fiber (11a)
Binder fiber (11b) adhesive layer (12)
Coating layer (13) Back structure (30)
1st rib (31a) 2nd rib (31b)
Fusion Boss(32) Bracket(33)

Claims (14)

A composite layer formed by mixing natural fibers and thermoplastic binder fibers;
A coating layer formed on the upper side of the composite layer;
An adhesive layer interposed between the composite layer and the coating layer; And
A rear structure formed by direct injection of a thermoplastic injection resin onto the lower side of the composite layer;
Including,
The adhesive layer is formed by applying an adhesive powder in which a natural fiber and a powder-type resin are mixed with a predetermined thickness on the upper side of the composite layer,
The coating layer is formed by laminating a thermoplastic film having a predetermined thickness on the upper side of the adhesive layer,
The texture of the natural fiber is exposed to the outside of the coating layer,
The interior material of a vehicle, characterized in that the adhesive layer and the coating layer are hot-pressed and cold-pressed to the composite layer, and the adhesive layer and the coating layer are at least partially impregnated into the interior of the composite layer. Composite material.
delete In claim 1,
In the rear structure, the thermoplastic injection resin is injected directly toward the lower side of the composite layer, so that the thermoplastic injection resin is at least partially penetrated into the interior of the lower side of the composite layer and bonded,
The composite material for interior materials of a vehicle, characterized in that the material of the thermoplastic binder fiber and the material of the thermoplastic injection resin are the same.
In paragraph 3,
A composite material for interior materials of a vehicle, characterized in that before the thermoplastic injection resin is injected, the compressed laminate is molded into a predetermined shape.
In claim 1,
The composite layer is a composite material for interior materials of a vehicle, characterized in that the felt layer is formed by mixing the natural fiber and the thermoplastic binder fiber.
In clause 5,
The felt layer is a composite material for interior materials of a vehicle, characterized in that formed through a needle punching method after mixing the natural fibers and the thermoplastic binder fibers.
In clause 5,
The felt layer is a composite material for interior materials of a vehicle, characterized in that formed by mixing 30 to 70% by weight of the natural fiber and 70 to 30% by weight of the thermoplastic binder fiber.
A composite layer forming step of forming a composite layer by mixing natural fibers and thermoplastic binder fibers;
Laminating a coating layer to form a coating layer on the upper side of the composite layer;
An adhesive layer application step of forming an adhesive layer between the composite layer and the coating layer;
A pressing step of hot-pressing a laminate in which the adhesive layer and the coating layer are laminated on the composite layer to the composite layer, and cold-pressing the hot-pressed laminate; And
A rear injection step of directly injecting a thermoplastic injection resin onto the lower side of the composite layer to form a rear structure;
Including,
In the step of applying the adhesive layer, an adhesive powder obtained by mixing natural fibers and a resin in powder form is applied to the upper surface of the composite layer to a predetermined thickness to form the adhesive layer,
In the coating layer laminating step, a thermoplastic film having a predetermined thickness on the upper side of the adhesive layer is laminated as the coating layer,
The texture of the natural fiber is exposed to the outside of the coating layer,
In the pressing step, the method of manufacturing a composite material for interior materials of a vehicle, wherein the adhesive layer and the coating layer are at least partially impregnated into the interior of the composite layer.
delete In clause 8,
In the rear injection step, the thermoplastic injection resin is directly injected toward the lower side of the composite layer, so that the thermoplastic injection resin at least partially penetrates and bonds to the inside of the lower side of the composite layer to form the rear structure, ,
The method of manufacturing a composite material for interior materials of a vehicle, characterized in that the material of the thermoplastic binder fiber and the material of the thermoplastic injection resin are the same.
In claim 10,
Prior to the back injection step, the method of manufacturing a composite material for an interior material of a vehicle, further comprising a molding step of forming the compressed laminate into a predetermined shape.
In clause 8,
The composite layer is a method of manufacturing a composite material for a vehicle interior, characterized in that the felt layer is formed by mixing the natural fiber and the thermoplastic binder fiber.
In claim 12,
The felt layer is a method of manufacturing a composite material for an interior of a vehicle, wherein the felt layer is formed through a needle punching method after mixing the natural fiber and the thermoplastic binder fiber.
In claim 12,
The felt layer is a method of manufacturing a composite material for a vehicle interior, characterized in that formed by mixing 30 to 70% by weight of the natural fiber and 70 to 30% by weight of the thermoplastic binder fiber.

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