KR20060039037A - Method for processing of moldable substrate for automotive top ceiling - Google Patents

Abstract

The present invention relates to a method for manufacturing a vehicle interior material, in particular, the interior material used as a base material such as a car ceiling, a hood (Bonnet Hood), a door trim, a trunk (Trunk) is 100 Made of% polyester material, it is a recyclable material that reduces the weight to reduce the fuel efficiency of automobiles, and simplifies the existing complex molding process and gives price competitiveness, especially the form stability and heat stability required for such interior materials By satisfying requirements such as flame retardancy, antibacterial property, mass productivity, dimensional stability, etc., the present invention relates to a method for manufacturing interior materials for automobiles that can contribute to the improvement of automobile quality as well as enhance international competitiveness by reducing fuel efficiency.

Automotive, interior materials, recycling, polyester film, film reinforcement layer

Description

Method for manufacturing interior materials for automobiles {Method for Processing of Moldable Substrate for Automotive Top Ceiling}             

1 is a cross-sectional view showing a vehicle interior according to the invention,

2 is a process chart showing a manufacturing process of the interior material for automobiles according to the present invention.

<Explanation of symbols for the main parts of the drawings>

10: molding substrate layer 12: bale opening

13 fiber mixing device 14 carding machine

15: cross-referencer 16: needle punching device

17: hot air circulation dryer 18: press roll

20: hot melt film layer 30: skin material layer

40: film reinforcement layer 100: interior material

The present invention relates to a method for manufacturing a vehicle interior material, and more particularly, by applying a recyclable material to form a car ceiling, a hood (Bonnet Hood), a door trim (Tork), etc. By reducing fuel consumption, dramatically simplifying the existing complex molding process to give price competitiveness, and satisfying requirements such as shape stability, heat stability, flame retardancy, antibacterial property, mass productivity, dimensional stability, etc. The present invention relates to a method for manufacturing interior materials for automobiles that can contribute to improving the quality of automobiles, as well as enhancing international competitiveness by reducing fuel consumption.

In general, in the case of automotive interior materials made of 100% polyester that is developed and applied to interior materials for automobiles, the skin layer made of 100% polyester fiber and the molding substrate layer made of 100% polyester material are bonded to the two layers. It consists of a hot melt film layer.

As a related technology, there is a 'method of manufacturing a molding material for automobile interiors' disclosed in Korean Patent No. 0418438, and such interior materials cannot be used other than polyester, and particularly, a thermosetting resin is used. If used, it becomes impossible to recycle.

Accordingly, the automotive interior material made of polyester has a relatively weak flexural strength and good sound absorption performance compared to the interior material using a thermosetting resin, but has a problem in that sound insulation performance against noise introduced from the outside of the vehicle is inferior.

That is, the interior material made of polyester is simply composed of a skin material layer and a molding substrate layer, in particular, there is a problem that the strength is insufficient for use in interior materials used in a large area, such as a car ceiling, the molding substrate layer to compensate for this strength Since the weight of the rises considerably increases, there is a problem that goes against the fuel economy of the car.

In addition, the interior material for automobiles is made of a 100% fiber layer of the skin material layer and the molding base material is excellent sound absorption, but there is a problem that the sound insulation performance against noise introduced from the outside of the vehicle is inferior.

Therefore, in order to solve the above problems, by laminating the film layer of the same material made of 100% polyester on the back of the automotive interior made of 100% polyester fiber layer, to enable regeneration and at the same time to complement the strength To reduce the cost by lowering the weight of the molding substrate layer, the sound insulation performance by the film layer is improved.

However, since the molding base layer made of polyester has a melting point of 260 ° C. or more, and is not melted under the temperature conditions in the molding process of molding into a desired shape in a conventional laminating process, the polyester film is adhered to the back surface of the interior material. As it is not easy to have a problem to be adhered using a separate hot melt film layer.

In addition, after bonding the polyester film to the back surface of the interior material, it is necessary to preheat it to a high temperature above the melting point of the polyester film in order to mold it into a desired shape. There is a problem that is melted together and damaged.

Therefore, the present invention is invented to solve the above problems, and excludes a hot melt film layer for bonding the skin layer and the molding substrate layer, instead of a polyester film that can be adhered to the back of the polyester interior material at low temperatures By applying, it is possible to mold under normal preheating conditions to prevent damage to the skin material layer, and to prevent the noise flowing from the outside of the car by laminating a non-breathable polyester film on the back of the interior material SUMMARY OF THE INVENTION An object of the present invention is to provide a method for manufacturing the interior decoration material.

Hereinafter, the features of the present invention for achieving the above object are as follows.

In the manufacturing method of automotive interior according to the present invention, 100% of the polyester film (1) by opening the fibers in the bal opening (Bail Opening) device 12 by agglomerated the fibers in the form of agglomeration through a fine opening device, etc. Supplying the fiber mixing apparatus 13 along the pipe;

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) sends the cross-linker (Cross Lapper) (15) by making the aggregated fibers into a thin sheet, and stacking them in several layers to form a predetermined fiber layer;

Needle fabricating the fiber layer in a needle punching machine (Needle Machine) (16) to form a needle felt with an appropriate thickness at the same time by the needle punching;

Passing the needle felt through a hot air circulation dryer (17) to obtain a molding substrate layer (10) continuously through thermal setting of the product;

Continuously supplying a hot melt film layer (PET) hot melt film layer 20 and a skin layer 30 of polyester material on the molding substrate layer 10;

Continuously supplying a polyester film to the back surface of the skin material layer 30 to bond through the pressure of the press roll 18 and the latent heat of the molding material layer 10 to form a film reinforcement layer 40, cut to a constant length Characterized in that it comprises a step to complete.

In particular, the polyester film 1 is characterized in that the addition of 0.1 to 10% by weight of IPA (Iso Phthalic Acid) or CHDM (Cyclo Hexane Di-Methyl) to maintain the melting point at 120 ~ 180 ℃.

In addition, the film reinforcing layer 40 is characterized in that the breathable film layer.

The film reinforcement layer 40 is characterized in that the thickness of 10 to 200 microns.

Hereinafter, the configuration of the present invention with reference to the accompanying drawings in detail.

1 is a cross-sectional view showing a vehicle interior according to the present invention, Figure 2 is a process chart showing a manufacturing process of the vehicle interior according to the present invention.

Here, the interior material for automobiles shown in FIG. 1 is manufactured through the manufacturing method of FIG. 2, and first, a polyester (PET) fiber is supplied, after the carding process, needle punching is performed, and a hot air dryer is passed through. Heat setting is done.

The hot melt film layer and the skin material layer of the same material are attached to the surface of the molding material layer passing through the hot air dryer in a batch process through the latent heat of the molding material layer and the pressure of the press roll, and at the same time the polyester film on the back surface of the skin material layer Bonding using the latent heat of the molding substrate layer and the pressure of the press roll, and cut to a predetermined size to complete the skin material layer and the film reinforcement layer integrated interior material.

At this time, the hot melt film layer, the skin material layer and the film reinforcement layer including the molding substrate layer used in the present invention is 100% polyester material is used because the interior material for automobiles obtained in the present invention can be recycled (Recycle).

More specifically, the interior material is 100% polyester film to open the fiber in the bal opening (Bail Opening) device 12 to agglomerate the fibers in the form of agglomeration through a fine opening device, etc. 13), the fiber mixing device 13 evenly distributes the fibers, and then supplies the evenly distributed fibers to the carding machine 14.

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

Next, the fiber layer is needled in a needle punching machine (16) to achieve mutual coupling, and at the same time, needle felt is manufactured to an appropriate thickness by needle punching.

The needle felt, which is completed by needle punching, is passed through the hot air circulation dryer 17 to obtain the molding substrate layer 10 continuously through thermal setting of the product.

Here, the needle punching device 16 for coupling the needle felt is made as 2 to 8, as the preferred embodiment of the present invention, the punching density of the needle is 300 ~ 800st / ㎠ and the needle depth (Needle Depth) It is preferable that it is 3-12 mm.

In addition, the hot air circulation dryer 17 is composed of two conveyor belts made of mesh in a heat chamber, and hot hot air is supplied on the mesh belt, and the hot air is sucked under the mesh belt. By circulating, the hot air is forced through the needle felt so that the thermal setting of the needle felt is achieved in a short time.

Next, a hot melt film layer 20 of polyester (PET) material and a skin layer 30 of polyester material (PET) on the molding substrate layer 10 continuously obtained by thermal setting of the product. Continuously supplied, and the polyester film reinforcement layer 40 was continuously supplied to the opposite surface of the skin material layer 30 to be bonded through the pressure of the press roll 18 and the latent heat of the molding substrate layer, and then to a constant length. By cutting, the interior material 100 in which the skin material layer 30 and the film reinforcement layer 40 made of 100% polyester is integrated is completed.

Here, the polyester fiber is mixed with a low melt polyester and a general polyester in a predetermined ratio, in the case of low melt polyester, one component, or 2 in which the low melt polyester and the general polyester are spun at the same time Among the component low melts, one of them is preferably used, or two kinds thereof are appropriately mixed.

Automobile interior materials manufactured through the manufacturing method as described above, as shown in Figure 1, the molding material layer 10, the hot melt film layer 20, the skin material layer 30, the film reinforcement layer 40 is laminated, All are 100% polyester and can be recycled.

At this time, the thickness of the film reinforcement layer 40 is 10 ~ 200 microns, which is to lessen the effect of the strength reinforcement is less than 10 microns, if it exceeds 200 microns, to solve the problem of low price competitiveness.

On the other hand, during the manufacture of the polyester film, an appropriate amount of IPA (Iso Phthalic Acid) or CHDM (Cyclo Hexane Di-Methyl) is added by 0.1 to 10% by weight to prevent crystallization of the polyester film, thereby melting the polyester film. By lowering the point to 120 ~ 180 ℃ to enable adhesion with the molding substrate layer in the low temperature range, and exhibits sufficient elongation under the general molding conditions to prevent the occurrence of wrinkles of the molded product.

As described above, according to the manufacturing method of the automotive interior material according to the present invention, by bonding a polyester film having a lower melting point on the back surface of the existing 100% polyester interior material can significantly increase the strength of the molded article, the skin material layer , The hot melt film layer, the molding base layer, and the film reinforcement layer can be recycled by using the 100% polyester material, thereby preventing environmental pollution, and excellent product formability, so that no wrinkle occurs in the molding process As a result, product defects can be dramatically reduced.

In addition, it is possible to greatly simplify the molding method can significantly reduce the development cost and molding cost of the vehicle.

Finally, the skin layer of 100% polyester material is fixed to the surface of the molding substrate layer through the hot melt film layer, and the polyester film is bonded to the opposite side of the skin layer in a batch process, and the skin layer made of polyester fiber layer The molding base layer can effectively absorb the noise generated in the interior of the automobile, and effectively block the noise from the outside of the vehicle by using a non-breathable polyester film, thereby achieving sound absorption performance and sound insulation performance at the same time. There is.

Claims (4)

The 100% polyester film 1 is opened in a bal opening apparatus 12, the fibers are opened, the fibers are aggregated in a lump form through a fine opening apparatus, etc., and fed to the fiber mixing apparatus 13 along the feed pipe. Steps; 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) is a step of forming a bundle of fibers in the form of a thin sheet to the cross wrapper (Cross Lapper) (15), laminating them in multiple layers to form a predetermined fiber layer; Needle fabricating the fiber layer in a needle punching machine (Needle Machine) (16) to form a needle felt with an appropriate thickness at the same time by the needle punching; Passing the needle felt through a hot air circulation dryer (17) to obtain a molding substrate layer (10) continuously through thermal setting of the product; Continuously supplying a hot melt film layer (PET) hot melt film layer 20 and a skin layer 30 of polyester material on the molding substrate layer 10; Continuously supplying a polyester film to the back surface of the skin material layer 30 to bond through the pressure of the press roll 18 and the latent heat of the molding material layer 10 to form a film reinforcement layer 40, cut to a constant length Method for manufacturing the interior material for cars, characterized in that it comprises a step of completing. The method according to claim 1, The polyester film 1 is an automotive interior material characterized in that the addition of 0.1 to 10% by weight of IPA (Iso Phthalic Acid) or CHDM (Cyclo Hexane Di-Methyl) to maintain the melting point at 120 ~ 180 ℃ Manufacturing method. The method according to claim 1, The film reinforcing layer 40 is a method for manufacturing a car interior material, characterized in that the breathable film layer. The method according to claim 1 or 3, The film reinforcing layer 40 is a method of manufacturing a car interior material, characterized in that the thickness of 10 ~ 200 microns.

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