KR20180113004A - A floor carpet for automobile having excellent sound-absorbing and sound-blocking properties - Google Patents
A floor carpet for automobile having excellent sound-absorbing and sound-blocking properties Download PDFInfo
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- KR20180113004A KR20180113004A KR1020170044129A KR20170044129A KR20180113004A KR 20180113004 A KR20180113004 A KR 20180113004A KR 1020170044129 A KR1020170044129 A KR 1020170044129A KR 20170044129 A KR20170044129 A KR 20170044129A KR 20180113004 A KR20180113004 A KR 20180113004A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- B60N3/00—Arrangements or adaptations of other passenger fittings, not otherwise provided for
- B60N3/04—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets
- B60N3/042—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets of carpets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/02—Physical, chemical or physicochemical properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- B60N3/00—Arrangements or adaptations of other passenger fittings, not otherwise provided for
- B60N3/04—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets
- B60N3/048—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets characterised by their structure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0261—Polyamide fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0278—Polyurethane
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/10—Properties of the layers or laminate having particular acoustical properties
- B32B2307/102—Insulating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2471/00—Floor coverings
- B32B2471/02—Carpets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/08—Cars
Landscapes
- Engineering & Computer Science (AREA)
- Transportation (AREA)
- Mechanical Engineering (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
- Passenger Equipment (AREA)
- Soundproofing, Sound Blocking, And Sound Damping (AREA)
Abstract
Description
본 발명은 자동차용 플로어 카페트에 관한 것으로, 보다 상세하게는 흡음재부에 저밀도의 폴리우레탄 폼을 적용하고, 차음재부에 면밀도가 낮은 열가소성 탄성체를 적용함으로써 경량화하여 차량 연비를 개선시키고, 물성 특성은 동등 이상을 유지하는 동시에 흡음 및 차음 성능이 우수한 자동차용 플로어 카페트에 관한 것이다.
The present invention relates to a floor carpet for automobiles, and more particularly to a floor carpet for automobiles, in which a low density polyurethane foam is applied to a sound absorbing material portion and a thermoplastic elastic material having a low density is applied to a sound insulating material portion, Which is excellent in sound absorption and sound insulation performance.
차량의 주행소음을 저감하기 위하여 차량 하부에 적용하는 플로어 카페트는 고객에게 편안함을 제공할 수 있는 원단부, 소음진동을 차단하는 차음재부와 차체 하부의 빈공간을 채우고 디딤성을 확보하고 고주파를 흡수하는 흡음재부로 구성되어 있다. The floor carpet applied to the lower part of the vehicle to reduce the traveling noise of the vehicle has a fabric part for providing comfort to the customer, a sound insulating material for blocking noise vibration and a hollow space at the lower part of the vehicle, As shown in FIG.
차음부는 두꺼울수록 로드 노이즈를 저감시키는 효과가 있어 차음재부를 계속 두껍게 만드는데, 이는 차량의 무게와 가격을 증가시키는 원인이 되어왔다. 또한 흡음재부는 펠트류를 주로 사용하고 있으나, 펠트류는 높은 고밀도를 가져 부품의 무게를 증가시키는 문제가 있다. The thicker the sound insulation part, the less the load noise is, the thicker the sound insulating part, which has caused the increase of the weight and the price of the vehicle. In addition, although the sound absorbing material portion mainly uses the felt, the felt has a high density to increase the weight of the parts.
또한 흡음재부는 별도로 분리 발포한 후 원단부 및 차음재부와 부착하여 카페트 모양을 성형하고 후속작업으로 부착하는 방법으로 제조되어 공정이 복잡하고 시간이 오래 걸리는 문제들이 있었다.In addition, the sound absorbing material part is manufactured by separately foaming and then attaching the raw material part and the sound insulating material part to form a carpet shape and then attaching it as a subsequent operation, which complicates the process and takes a long time.
종래 한국등록특허 제10-1317819호에서는 흡음층으로 저융점 폴리에스터 섬유와 폴리에스터 중공사를 혼합한 흡음층을 카페트 원단, 기포지 및 부직포 중에 적용한 플로어 카페트에 대해 개시되어 있으나, 차음 및 흡음 성능 향상을 모두 고려하고 있지 않으며, 펠트류로 이루어져 있어 경량화하는데 한계가 있다.Korean Patent No. 10-1317819 discloses a floor carpet in which a sound-absorbing layer obtained by mixing low-melting-point polyester fibers and polyester hollow fibers as a sound-absorbing layer into a carpet fabric, a base paper and a nonwoven fabric, Improvement is not considered at all, and it is made up of felt and has a limitation in weight reduction.
따라서, 이러한 기존의 플로어 카페트가 가진 문제들을 개선하기 위해 경량화하면서도 향상된 흡음 및 차음 성능을 동시에 구현할 수 있는 새로운 소재의 플로어 카페트에 대한 연구개발이 필요하다.
Therefore, it is necessary to research and develop a new floor carpet which can realize improved sound absorption and sound insulation performance at the same time, while improving the weight of the conventional floor carpet.
상기와 같은 문제 해결을 위하여, 본 발명의 목적은 흡음재부에 저밀도의 폴리우레탄 폼을 적용하고, 차음재부에 면밀도가 낮은 열가소성 탄성체를 적용함으로써 NVH(Noise, Vibration, Hardness) 성능을 향상시키고, 경량화하여 차량 연비를 개선시키고, 물성 특성은 동등 이상을 유지하는 동시에 흡음 및 차음 성능이 우수하여 차량 운전 시 정숙함을 제공할 수 있는 자동차용 플로어 카페트를 제공하는데 있다.
In order to solve the above-mentioned problems, an object of the present invention is to improve the performance of NVH (Noise, Vibration, Hardness) by applying a low density polyurethane foam to a sound absorbing material portion and applying a thermoplastic elastic material having a low density to a sound insulating material portion, And to provide a floor carpet for automobiles which can provide a quietness when the vehicle is operated because of excellent sound absorption and sound insulation performance while maintaining equal or better physical properties.
본 발명은 카페트 원단부, 차음재부 및 흡음재부를 포함하는 자동차용 플로어 카페트에 있어서, 상기 흡음재부는 중량평균분자량이 7000~8000 g/mol인 폴리올, 중량평균분자량이 5500~6500 g/mol인 폴리올, 중량평균분자량이 4500~5500 g/mol인 아크릴-스티렌 공중합체 및 발포제를 포함하는 폴리올 혼합물 100 중량부에 이소시아네이트 45~55 중량부가 혼합된 원료 조성물을 상기 차음재부 상에 직발포하여 제조된 폴리우레탄 폼으로 이루어지고, 상기 차음재부는 면밀도가 500~1200 g/m2인 열가소성 탄성체(thermoplastic elastomer, TPE)로 이루어지고, 상기 카페트 원단부는 나일론 필름으로 이루어진 것을 특징으로 하는 자동차용 플로어 카페트를 제공한다.
The present invention relates to a floor carpet for a car comprising a carpet fabric part, a sound insulating material part and a sound absorbing material part, wherein the sound absorbing material part comprises a polyol having a weight average molecular weight of 7000 to 8000 g / mol, a polyol having a weight average molecular weight of 5500 to 6500 g / mol, Styrene copolymer having a weight average molecular weight of 4500 to 5500 g / mol and a foaming agent is mixed with 45 to 55 parts by weight of isocyanate in 100 parts by weight of a polyol mixture prepared by directly foaming a polyurethane Wherein the sound insulating material portion is made of a thermoplastic elastomer (TPE) having a surface density of 500 to 1200 g / m 2 , and the carpet front end portion is made of a nylon film.
본 발명에 따른 자동차용 플로어 카페트는 흡음재부에 저밀도의 폴리우레탄 폼을 적용하고, 차음재부에 면밀도가 낮은 열가소성 탄성체를 적용함으로써 NVH(Noise, Vibration, Hardness) 성능을 향상시키고, 경량화하여 차량 연비를 개선시킬 수 있다.The floor carpet for automobiles according to the present invention is characterized in that a low density polyurethane foam is applied to a sound absorbing material portion and a thermoplastic elastic material having a low density is applied to a sound insulating material portion to improve NVH (Noise, Vibration, Hardness) Can be improved.
또한, 본 발명의 자동차용 플로어 카페트는 전체적으로 부품의 무게는 감소하였으나, 경도, 영구압축줄음률 평균 흡음율 등의 물성특성은 동등이상을 유지하는 동시에 흡음 및 차음 성능이 우수하여 차량 운전 시 정숙함을 제공할 수 있다.
In addition, the weight of the parts of the automobile floor carpet of the present invention as a whole is reduced, but the physical properties such as hardness, permanent compression ratio and average sound absorption ratio are maintained equal to each other and sound absorption and sound insulation performance are excellent, can do.
도 1은 본 발명에 따른 자동차용 플로어 카페트의 후면도이다.
도 2는 본 발명에 따른 자동차용 플로어 카페트의 측면도이다.
도 3은 본 발명의 실시예 및 비교예에서 제조된 자동차용 플로어 카페트의 차음률을 관내법을 이용하여 측정한 결과를 나타낸 그래프이다.
도 4는 본 발명의 실시예 및 비교예에서 제조된 자동차용 플로어 카페트의 흡음률을 관내법을 이용하여 측정한 결과를 나타낸 그래프이다.
도 5는 본 발명의 실시예 및 비교예에서 제조된 자동차용 플로어 카페트의 경도를 측정한 결과를 나타낸 그래프이다.
도 6은 본 발명의 실시예 및 비교예에서 제조된 자동차용 플로어 카페트의 영구압축줄음률을 측정한 결과를 나타낸 그래프이다.
도 7은 본 발명의 실시예 및 비교예에서 제조된 자동차용 플로어 카페트의 평균흡음률를 측정한 결과를 나타낸 그래프이다.1 is a rear view of an automotive floor carpet according to the present invention.
2 is a side view of an automotive floor carpet according to the present invention.
FIG. 3 is a graph showing the results of measurement of the differential tone of a floor carpet for automobiles manufactured in Examples and Comparative Examples of the present invention, using the in-pipe method.
4 is a graph showing the results of measurement of sound absorption ratios of automobile floor carpets manufactured by the examples and comparative examples of the present invention using the in-pipe method.
5 is a graph showing the results of measuring the hardness of floor carpets for automobiles manufactured in Examples and Comparative Examples of the present invention.
6 is a graph showing the results of measurement of permanent compression toughness of a floor carpet for an automobile manufactured in Examples and Comparative Examples of the present invention.
7 is a graph showing the results of measuring the average sound absorption rate of floor carpets for automobiles manufactured in Examples and Comparative Examples of the present invention.
이하에서는 본 발명을 하나의 실시예로 더욱 상세하게 설명한다.Hereinafter, the present invention will be described in more detail with reference to one embodiment.
본 발명은 주행소음 저감 및 중량 저감을 중심으로 한 카페트 원단부, 차음재부 및 흡음재부를 포함하는 자동차용 플로어 카페트에 관한 것이다. The present invention relates to a floor carpet for a vehicle including a carpet end portion, a sound insulating material portion, and a sound absorbing material portion centering on reduction of running noise and weight reduction.
보다 상세하게는 본 발명의 자동차용 플로어 카페트의 흡음재부는 중량평균분자량이 7000~8000 g/mol인 폴리올, 중량평균분자량이 5500~6500 g/mol인 폴리올, 중량평균분자량이 4500~5500 g/mol인 아크릴-스티렌 공중합체 및 발포제를 포함하는 폴리올 혼합물 100 중량부에 이소시아네이트 45~55 중량부가 혼합된 원료 조성물을 상기 차음재부 상에 직발포하여 제조된 폴리우레탄 폼으로 이루어지고, 상기 차음재부는 면밀도가 500~1200 g/m2인 열가소성 탄성체(thermoplastic elastomer, TPE)로 이루어지고, 상기 카페트 원단부는 나일론 필름으로 이루어진 것을 특징으로 한다.More specifically, the sound absorbing material portion of the automotive floor carpet of the present invention comprises a polyol having a weight average molecular weight of 7000 to 8000 g / mol, a polyol having a weight average molecular weight of 5500 to 6500 g / mol, a weight average molecular weight of 4500 to 5500 g / mol A polyurethane foam prepared by directly foaming a raw material composition in which 45 to 55 parts by weight of an isocyanate is mixed with 100 parts by weight of a polyol mixture comprising an acryl-styrene copolymer and a foaming agent, wherein the sound- And a thermoplastic elastomer (TPE) having a weight of 500 to 1200 g / m 2 , wherein the carpet is made of a nylon film.
상기 흡음재부의 폴리올 혼합물은 중량평균분자량이 7000~8000 g/mol인 폴리올 37~54 중량%, 중량평균분자량이 5500~6500 g/mol인 폴리올 10~17 중량%, 중량평균분자량이 4500~5500 g/mol인 아크릴-스티렌 공중합체 35~40 중량% 및 발포제 1~6 중량%를 포함할 수 있다.Wherein the polyol mixture in the sound absorbing material portion comprises 37 to 54% by weight of a polyol having a weight average molecular weight of 7000 to 8000 g / mol, 10 to 17% by weight of a polyol having a weight average molecular weight of 5500 to 6500 g / mol, a weight average molecular weight of 4500 to 5500 g / mol of acryl-styrene copolymer and 1 to 6% by weight of a foaming agent.
상기 폴리올 혼합물에서 상기 폴리올은 중량평균분자량이 서로 다른 폴리올 혼합물을 혼합 사용할 수 있으며, 이때 상기 폴리올은 그 종류로 폴리에스테르계인 것을 사용할 수 있다.In the polyol mixture, the polyol may be mixed with a polyol mixture having a different weight average molecular weight, and the polyol may be polyester-based.
구체적으로 상기 폴리올은 폴리우레탄 폼의 회복력 보강을 위해 중량평균분자량이 7000~8000 g/mol인 폴리올 37~54 중량%과 중량평균분자량이 5500~6500 g/mol인 폴리올 10~17 중량%를 혼합 사용할 때, 고탄성을 유지하는 이점이 있다. Specifically, the polyol is prepared by mixing 37 to 54% by weight of a polyol having a weight average molecular weight of 7000 to 8000 g / mol and 10 to 17% by weight of a polyol having a weight average molecular weight of 5500 to 6500 g / mol for reinforcing the recovery of polyurethane foam When used, there is an advantage of maintaining high elasticity.
이때, 상기 중량평균분자량이 7000~8000 g/mol인 폴리올의 사용량이 37 중량% 미만이면 탄성이 저하될 수 있고, 54 중량% 초과이면 폼이 너무 단단해질 수 있다.If the amount of the polyol having a weight average molecular weight of 7000 to 8000 g / mol is less than 37 wt%, the elasticity may deteriorate. If the amount of the polyol is more than 54 wt%, the foam may become too hard.
상기 중량평균분자량이 7000~8000 g/mol인 폴리올은 중량평균분자량이 7000 g/mol 미만이면 경도가 약화될 수 있고, 8000 g/mol 초과이면 혼합이 어려워질 수 있다. 바람직하게는 중량평균분자량이 7200~7800 g/mol이고, 더욱 바람직하게는 7500 g/mol인 폴리올을 사용할 수 있다.If the weight average molecular weight of the polyol having a weight average molecular weight of 7000 to 8000 g / mol is less than 7000 g / mol, the hardness of the polyol may be lowered. If the weight average molecular weight is more than 8000 g / mol, mixing may be difficult. Preferably, a polyol having a weight average molecular weight of 7200 to 7800 g / mol, more preferably 7500 g / mol, can be used.
또한 상기 중량평균분자량이 5500~6500 g/mol인 폴리올은 중량평균분자량이 5500 g/mol 미만이면 탄성이 약화될 수 있고, 6500 g/mol 초과이면 고점도의 혼합물이 형성되어 제대로 교반되지 않을 수 있다. 바람직하게는 중량평균분자량이 5700~6200 g/mol이고, 더욱 바람직하게는 6000 g/mol인 폴리올을 사용할 수 있다.If the weight average molecular weight of the polyol having a weight average molecular weight of 5500 to 6500 g / mol is less than 5500 g / mol, the elasticity may be weakened. If the weight average molecular weight is more than 6500 g / mol, a highly viscous mixture may be formed, . Preferably, a polyol having a weight average molecular weight of 5700 to 6200 g / mol, more preferably 6000 g / mol, can be used.
상기 중량평균분자량이 4500~5500 g/mol인 아크릴-스티렌 공중합체는 폴리우레탄 폼의 저밀도화로 경도 약화를 방지하기 위해 첨가되는 것으로 스티렌에 포함된 벤젠 구조의 하드세그먼트(hard segment) 증가에 의한 경도 보강 특성이 있어 폴리우레탄 폼의 경도를 향상시킬 수 있다. 상기 아크릴-스티렌 공중합체는 아크릴 10~90 중량% 및 스티렌 90~10 중량%가 공중합된 것일 수 있다. 상기 아크릴-스티렌 공중합체는 그 사용량이 전체 폴리올 혼합물을 기준으로 35~40 중량%를 사용할 수 있는데, 그 함량이 35 중량% 미만이면 경도가 약화되는 문제가 있고, 40 중량% 초과이면 목표이상으로 경화될 수 있다.The acryl-styrene copolymer having a weight average molecular weight of 4500 to 5500 g / mol is added to prevent the hardness from lowering due to the low density of the polyurethane foam. The acryl-styrene copolymer has a hardness It is possible to improve the hardness of the polyurethane foam. The acryl-styrene copolymer may be a copolymer of 10 to 90% by weight of acrylic and 90 to 10% by weight of styrene. The acryl-styrene copolymer may be used in an amount of 35 to 40% by weight based on the total polyol mixture. If the content of the acrylic-styrene copolymer is less than 35% by weight, the hardness may be weakened. Can be hardened.
또한 상기 아크릴-스티렌 공중합체의 중량평균분자량이 4500 g/mol 미만이면 경도가 낮아지는 문제가 있고, 5500 g/mol 초과이면 점도가 높아져 교반이 어려울 수 있다. 바람직하게는 중량평균분자량이 4700~5300 g/mol이고, 더욱 바람직하게는 5000 g/mol인 아크릴-스티렌 공중합체를 사용할 수 있다.When the weight-average molecular weight of the acryl-styrene copolymer is less than 4500 g / mol, there is a problem that the hardness is lowered. When the weight-average molecular weight is more than 5500 g / mol, the viscosity may be increased and stirring may be difficult. Preferably, an acryl-styrene copolymer having a weight average molecular weight of 4700 to 5300 g / mol, more preferably 5000 g / mol, can be used.
이러한 상기 흡음재부는 중량평균분자량이 서로 다른 폴리올에 아크릴-스티렌 공중합체를 혼합하여 저밀도의 폴리우레탄 폼을 제조함으로써 기존의 고밀도 펠트류에 비해 카페트의 무게를 크게 저감시키고, 흡음 성능을 향상시키는 효과가 있다. 또한 기존의 흡음재용 원료 조성물을 분리발포 후 차음재부에 부착하는 대신 상기 원료 조성물을 상기 차음재부 상에 직발포하여 공정단계를 축소할 수 있으며, 제조비용을 절감할 수 있는 이점이 있다. Such a sound-absorbing material part can reduce the weight of the carpet and significantly improve the sound-absorbing performance by producing a low-density polyurethane foam by mixing an acryl-styrene copolymer with a polyol having a different weight average molecular weight have. Further, instead of adhering the existing raw material composition for sound-absorbing material to the sound insulating material portion after the separate foaming, the raw material composition can be directly foamed on the sound insulating material portion so that the process steps can be reduced and the manufacturing cost can be reduced.
본 발명의 바람직한 구현예에 의하면, 상기 차음재부는 기존의 두꺼운 차음재층을 형성하는 대신 면밀도가 500~1200 g/m2인 열가소성 탄성체(thermoplastic elastomer, TPE)로 이루어진 소재를 사용할 수 있다. 상기 열가소성 탄성체는 Closed cell로 구성되어 소리를 차단하는 특성이 있어 차음 성능이 우수한 이점이 있다. 특히, 상기 열가소성 탄성체는 면밀도가 500~1200 g/m2인 것을 사용하는데, 상기 면밀도가 500 g/m2 미만이면 원단부 합지 시 얇게 형성되어 차음 역할을 수행할 수 없고, 1200 g/m2 초과이면 두껍게 형성되어 차량 무게 증가의 원인이 될 수 있다. 상기 열가소성 탄성체는 폴리올레핀계 엘라스토머, 에틸렌 옥테인-부테인 중합체 또는 이들의 혼합물과 수산화마그네슘이 혼합된 것을 사용할 수 있다.According to a preferred embodiment of the present invention, the sound insulating material portion may be made of a thermoplastic elastomer (TPE) having a surface density of 500 to 1200 g / m 2 instead of a conventional thick sound insulating material layer. The thermoplastic elastomer is composed of a closed cell and has a sound blocking property, which is advantageous in that the sound insulating performance is excellent. In particular, the thermoplastic elastomer surface density is 500 ~ 1200 g / m in using the two, the area density that is 500 g / m is less than 2 are formed to be thinner when the distal end lamination can not perform the sound insulating role, 1200 g / m 2 If it is more than the thickness, it may be formed thick and cause the increase of the vehicle weight. The thermoplastic elastomer may be a mixture of a polyolefin elastomer, an ethylene-octene-butene polymer, or a mixture thereof and magnesium hydroxide.
상기 차음재부는 면밀도가 500~1200 g/m2인 열가소성 탄성체를 적용하고, 여기에 상기한 저밀도의 폴리우레탄 폼을 흡음재부로 적용하여 경량화하면서도 흡음 및 차음 성능을 동시에 향상시킬 수 있다.The sound insulating material portion may be applied with a thermoplastic elastomer having a surface density of 500 to 1200 g / m < 2 >, and the low density polyurethane foam may be applied to the sound absorbing material portion to lighten the sound absorbing and sound insulating performance simultaneously.
본 발명의 바람직한 구현예에 의하면, 상기 카페트 원단부는 나일론 필름으로 이루어진 것일 수 있다. 상기 폴레우레탄 폼의 전면 발포 시 발생하는 금형 내 발포압으로 인해 상기 차음재부가 약한 원단에서는 폴리우레탄 폼이 새는 문제가 발생할 수 있다. 본 발명에서는 이러한 폴리우레탄 폼이 상기 카페트 원단부 방향으로 새는 문제를 해결하기 위해 상기 카페트 원단부로 기포지 대신 나일론 필름을 사용할 수 있다. 상기 나일론 필름은 기존 원단하부 마감재로 사용되는 기포지 대신 가볍고 밀폐성이 우수하여 폴리우레탄폼액을 발포할 때 원단으로 폴리우레탄 폼액이 새는 것을 방지할 수 있다. According to a preferred embodiment of the present invention, the carpet end portion may be formed of a nylon film. The polyurethane foam may leak at the weak fabric due to the foaming pressure in the mold caused by the foaming of the polyurethane foam. In the present invention, a nylon film may be used as the carpet raw material in place of the prepreg in order to solve the problem that the polyurethane foam leaks toward the carpet original portion. The nylon film is light and hermetic in place of the base fabric used as a conventional underfill material, so that the polyurethane foam solution can be prevented from leaking to the fabric when the polyurethane foam solution is foamed.
본 발명의 바람직한 구현예에 의하면, 상기 발포제는 증류수인 것일 수 있다.According to a preferred embodiment of the present invention, the foaming agent may be distilled water.
본 발명의 바람직한 구현예에 의하면, 상기 이소시아네이트는 메틸렌 디페닐 디이소시아네이트(methylene diphenyl diisocyanate, MDI), 톨루엔 디이소시아네이트(toluene diisocyanate, TDI) 또는 이들의 혼합물인 것일 수 있다. 상기 흡음재부는 상기 폴리올 혼합물 100 중량부에 이소시아네이트 45~55 중량부가 혼합된 것일 수 있다. 이때, 상기 이소시아네이트의 함량이 45 중량부 미만이면, 가교반응으로 인한 겔화가 원활히 일어나지 않아 폼형성이 안될 수 있고, 55 중량부 초과이면 가교도 과량 증가되어 흡음재의 갈라짐이 형성될 수 있다.According to a preferred embodiment of the present invention, the isocyanate may be methylene diphenyl diisocyanate (MDI), toluene diisocyanate (TDI) or a mixture thereof. The sound absorbing material part may be a mixture of 100 parts by weight of the polyol mixture and 45 to 55 parts by weight of isocyanate. If the amount of the isocyanate is less than 45 parts by weight, gelation due to the cross-linking reaction may not occur smoothly and foam may not be formed. If the amount of the isocyanate is more than 55 parts by weight, excessive crosslinking may be caused to cause cracking of the sound absorbing material.
본 발명의 바람직한 구현예에 의하면, 상기 흡음재부의 폴리우레탄 폼은 겉보기 밀도가 70~80 kg/m3로 저밀도의 폴리우레탄 폼을 구현할 수 있다.According to a preferred embodiment of the present invention, the polyurethane foam of the sound absorbing material part can realize a low density polyurethane foam with an apparent density of 70 to 80 kg / m 3 .
본 발명의 바람직한 구현예에 의하면, 상기 자동차용 플로어 카페트에서 콘솔이 장착되는 터널부위는 상기 흡음재부로 흡음 처리된 것일 수 있다. 기존 카페트의 터널부는 조립성을 고려하여 차음 소재만으로 마감되어 있으므로 흡음 성능에 취약한 문제가 있었다. 본 발명에서는 이러한 문제를 보완하기 위해 상기 플로어 카페트에서 콘솔이 장착되는 부위인 터널부를 흡음재부로 흡음 처리함으로써 흡음성능을 향상시킬 수 있다.According to a preferred embodiment of the present invention, a portion of the tunnel where the console is mounted in the automotive floor carpet may be a sound absorbing material treated with the sound absorbing material portion. The tunnels of the existing carpets are poor in sound absorption performance because they are closed only by the sound insulating material in consideration of the assembling property. In order to solve this problem, in the present invention, the sound absorbing performance can be improved by sound-absorbing the tunnel portion, which is a portion where the console is mounted on the floor carpet, with the sound absorbing material portion.
본 발명의 바람직한 구현예에 의하면, 상기 차음재부는 열가소성 탄성체(thermoplastic elastomer, TPE)로 이루어지고, 상기 카페트 원단부는 나일론 필름으로 이루어진 것을 특징으로 한다.According to a preferred embodiment of the present invention, the sound insulating material part is made of a thermoplastic elastomer (TPE), and the carpet raw part is made of a nylon film.
도 1은 본 발명에 따른 자동차용 플로어 카페트의 후면도이고, 도 2는 본 발명에 따른 자동차용 플로어 카페트의 측면도이다.FIG. 1 is a rear view of a floor carpet for a vehicle according to the present invention, and FIG. 2 is a side view of a floor carpet for a car according to the present invention.
따라서, 본 발명에 따른 자동차용 플로어 카페트는 흡음재부에 저밀도의 폴리우레탄 폼을 적용하고, 차음재부에 면밀도가 낮은 열가소성 탄성체를 적용함으로써 NVH(Noise, Vibration, Hardness) 성능을 향상시키고, 경량화하여 차량 연비를 개선시킬 수 있다.Therefore, the floor carpet for automobiles according to the present invention can improve the NVH (Noise, Vibration, Hardness) performance by applying a low density polyurethane foam to the sound absorbing material portion and applying the thermoplastic elastic material having a low density to the sound insulating material portion, Fuel economy can be improved.
또한, 본 발명의 자동차용 플로어 카페트는 전체적으로 부품의 무게는 감소하였으나, 경도, 영구압축줄음률 평균 흡음율 등의 물성특성은 동등 이상을 유지하는 동시에 흡음 및 차음 성능이 우수하여 차량 운전 시 정숙함을 제공할 수 있다.
In addition, the weight of the parts of the automobile floor carpet of the present invention as a whole is reduced, but the physical properties such as hardness, permanent compression ratio and average sound absorption ratio are maintained equal to each other and sound absorption and sound insulation performance are excellent, can do.
이하 본 발명을 실시예에 의거하여 더욱 구체적으로 설명하겠는 바, 본 발명이 다음 실시예에 의해 한정되는 것은 아니다.
Hereinafter, the present invention will be described in more detail with reference to Examples, but the present invention is not limited by the following Examples.
실시예 및 비교예Examples and Comparative Examples
하기 표 1에 나타낸 구성성분 및 조성비로 폴리우레탄 폼을 제조하였다. 제조된 폴리우레탄 폼의 밀도는 표 1에 나타내었다. 그 밖에 차음재부로는 면밀도가 500 g/m2인 열가소성 탄성체(에틸렌 중합체 40% 및 수산화마그네슘 60%의 혼합물)를 준비하였으며, 카페트 원단부는 나일론 필름을 준비하였다. Polyurethane foams were prepared with the constituents and composition ratios shown in Table 1 below. The density of the prepared polyurethane foam is shown in Table 1. In addition, a thermoplastic elastomer (mixture of ethylene polymer 40% and magnesium hydroxide 60%) having a surface density of 500 g / m 2 was prepared as a sound insulating material, and a nylon film was prepared as a raw material of the carpet.
구체적으로 카페트 원단부에 열가소성 탄성체를 열 압착하여 차음재부를 형성하였다. 그 다음 차음재부 상에 하기 표 1의 구성 성분들을 혼합한 원료 조성물을 상온 조건에서 직발포하여 흡음재부가 형성된 자동차용 플로어 카페트를 제조하였다.Specifically, the thermoplastic elastic body was thermally bonded to the carpet distal end portion to form a sound insulating material portion. Next, a raw material composition prepared by mixing the components shown in Table 1 below on a sound insulating material was directly foamed at room temperature to prepare a floor carpet for a vehicle having a sound absorbing material portion.
발포 시 조건은 이소시아네이트 화합물을 제외한 모든 첨가물을 모두 배합하여 1500 g 기준 20 분간 5000 rpm의 기계식 교반기를 이용한 믹싱 작업 후, 이소시아네이트 화합물을 첨가하여 8000 rpm에서 최종 혼합시켜 제조된 반응물을 플로어 카페트 원단이 셋팅된 약 50~70 ℃의 온도가 설정되어 있는 플로어 카페트 형태의 금속 몰드에 부어 밀봉을 한 후 약 10 분간 반응을 시킨 후 반응 완료 후 탈형하였다. All the additives except for the isocyanate compound were mixed in the foaming condition, mixing was performed by using a mechanical stirrer at 5000 rpm for 20 minutes on the basis of 1500 g, followed by final mixing at 8000 rpm by adding an isocyanate compound, and then the floor carpet fabric was set And the mixture was poured into a mold of a floor carpet mold having a temperature of about 50 to 70 ° C, sealed and reacted for about 10 minutes, and then demolded after completion of the reaction.
[구성성분][Components]
(a) 폴리올-1: 중량평균분자량이 7500 g/mol인 폴리에스테르계 폴리올(a) Polyol-1: Polyester-based polyol having a weight average molecular weight of 7500 g / mol
(b) 폴리올-2: 중량평균분자량이 6000 g/mol인 폴리에스테르계 폴리올(b) Polyol-2: Polyester-based polyol having a weight average molecular weight of 6000 g / mol
(c) 아크릴-스티렌 공중합체: 중량평균분자량이 5000 g/mol이고, 아크릴 (c) Acryl-styrene copolymer: a copolymer having a weight average molecular weight of 5000 g / mol,
40 중량% 및 스티렌 60 중량%가 공중합된 아크릴-스티렌 공중합체40% by weight of styrene and 60% by weight of styrene were copolymerized with an acryl-styrene copolymer
(d) 발포제: 물(DI-water)(d) Foaming agent: water (DI-water)
(e) 이소시아네이트: KW5029, BASF사(e) Isocyanate: KW5029, BASF
(단위: g)Polyol mixture
(Unit: g)
(중량부)Polyol mixture: isocyanate
(Parts by weight)
(kg/m3) Apparent density
(kg / m 3 )
(kg/m3) Actual density
(kg / m 3 )
상기 표 1에서 확인할 수 있듯이, 상기 비교예에 비해 상기 실시예의 경우 겉보기 밀도가 75 kg/m3로 저감된 것으로 보아 폴리우레탄 폼이 경량화 되었음을 확인하였다.
As can be seen from Table 1, the apparent density was reduced to 75 kg / m < 3 > in the case of the comparative example, and thus it was confirmed that the polyurethane foam was lightened.
실험예 1Experimental Example 1
상기 실시예 및 비교예에서 제조된 자동차용 플로어 카페트에 대해 차음율 및 흡음율을 관내법을 이용하여 측정하였다. 그 결과는 도 3, 4에 나타내었다.For the floor carpets for automobiles manufactured in the examples and comparative examples, the difference in tone and the sound absorption ratio were measured by the in-pipe method. The results are shown in Figs.
도 3, 4는 본 발명의 실시예 및 비교예에서 제조된 자동차용 플로어 카페트의 차음률 및 흡음률을 관내법을 이용하여 측정한 결과를 나타낸 그래프들이다. 상기 도 3, 4를 살펴보면, 상기 비교예(SKC PU foam 85K 양산)에 비해 상기 실시예(SKC PU 75K 개발)의 경우 차음률 및 흡음률에서 모두 향상된 수치를 보임을 확인하였다.
FIGS. 3 and 4 are graphs showing the results of measurement of the difference in sound absorption ratio and the sound absorption ratio of a floor carpet for a vehicle manufactured in Examples and Comparative Examples of the present invention. Referring to FIGS. 3 and 4, it was confirmed that the difference between the tone and sound absorption rate of the embodiment (SKC PU 75K developed) is improved compared to the comparative example (SKC PU foam 85K mass production).
실험예 2Experimental Example 2
상기 실시예 및 비교예에서 제조된 자동차용 플로어 카페트에 대해 경도, 영구압축줄음률 및 평균흡음률을 관내법을 이용하여 측정하였다. 그 결과는 도 5-7에 나타내었다.The hardness, the permanent compression toughness and the average sound absorption rate of the floor carpet for automobiles manufactured in the Examples and Comparative Examples were measured by the in-pipe method. The results are shown in Figs. 5-7.
도 5~7은 본 발명의 실시예 및 비교예에서 제조된 자동차용 플로어 카페트의 경도, 영구압축줄음률 및 평균흡음률을 측정한 결과를 나타낸 그래프들이다. 상기 도 5-7를 살펴보면, 경도(지지력) 및 평균흡음률 특성이 모두 향상되었으며, 영구압축줄음률이 낮아진 것으로 보아 폴리우레탄 폼의 회복력이 보강되었음을 알 수 있었다. FIGS. 5 to 7 are graphs showing the results of measuring the hardness, the permanent compression toughness and the average sound absorption rate of the floor carpet for automobiles manufactured in Examples and Comparative Examples of the present invention. 5-7, the hardness (supporting force) and the average sound absorption rate characteristics are improved, and the permanent compression stiffness is lowered, indicating that the recovery force of the polyurethane foam is reinforced.
이를 통해, 저밀도의 폴리우레탄 폼을 흡음재부에 적용하고, 면밀도가 낮은 열가소성 탄성체를 적용함으로써 기존 플로어 카페트와 동등 또는 향상된 물성 수준을 유지하는 동시에 차음 및 흡음 성능이 향상된 것을 확인하였다.
Through the application of low density polyurethane foam to the sound absorbing material part and application of thermoplastic elastic material with low density, it was confirmed that sound insulation and sound absorption performance were improved while maintaining the same or improved physical property level as existing floor carpet.
Claims (6)
상기 흡음재부는 중량평균분자량이 7000~8000 g/mol인 폴리올, 중량평균분자량이 5500~6500 g/mol인 폴리올, 중량평균분자량이 4500~5500 g/mol인 아크릴-스티렌 공중합체 및 발포제를 포함하는 폴리올 혼합물 100 중량부에 이소시아네이트 45~55 중량부가 혼합된 원료 조성물을 상기 차음재부 상에 직발포하여 제조된 폴리우레탄 폼으로 이루어지고,
상기 차음재부는 면밀도가 500~1200 g/m2인 열가소성 탄성체(thermoplastic elastomer, TPE)로 이루어지고,
상기 카페트 원단부는 나일론 필름으로 이루어진 것을 특징으로 하는 흡음 및 차음 성능이 우수한 자동차용 플로어 카페트.
Claims [1] A floor carpet for a vehicle comprising a carpet end portion, a sound insulating material portion, and a sound absorbing material portion,
Wherein the sound absorbing material portion comprises a polyol having a weight average molecular weight of 7000 to 8000 g / mol, a polyol having a weight average molecular weight of 5500 to 6500 g / mol, an acryl-styrene copolymer having a weight average molecular weight of 4500 to 5500 g / mol, A polyurethane foam prepared by directly foaming a raw material composition in which 45 to 55 parts by weight of isocyanate is mixed with 100 parts by weight of a polyol mixture,
The sound insulating material part is made of a thermoplastic elastomer (TPE) having a surface density of 500 to 1200 g / m 2 ,
Wherein the carpet is made of a nylon film.
상기 흡음재부의 폴리올 혼합물은 중량평균분자량이 7000~8000 g/mol인 폴리올 37~54 중량%, 중량평균분자량이 5500~6500 g/mol인 폴리올 10~17 중량%, 중량평균분자량이 4500~5500 g/mol인 아크릴-스티렌 공중합체 35~40 중량% 및 발포제 1~6 중량%를 포함하는 것을 특징으로 하는 자동차용 플로어 카페트.
The method according to claim 1,
Wherein the polyol mixture in the sound absorbing material portion comprises 37 to 54% by weight of a polyol having a weight average molecular weight of 7000 to 8000 g / mol, 10 to 17% by weight of a polyol having a weight average molecular weight of 5500 to 6500 g / mol, a weight average molecular weight of 4500 to 5500 g / mol and 35 to 40% by weight of an acryl-styrene copolymer and 1 to 6% by weight of a foaming agent.
상기 발포제는 증류수인 것을 특징으로 하는 자동차용 플로어 카페트.
The method according to claim 1,
Wherein the foaming agent is distilled water.
상기 이소시아네이트는 메틸렌 디페닐 디이소시아네이트(methylene diphenyl diisocyanate, MDI), 톨루엔 디이소시아네이트(toluene diisocyanate, TDI) 또는 이들의 혼합물인 것을 특징으로 하는 자동차용 플로어 카페트.
The method according to claim 1,
Wherein the isocyanate is methylene diphenyl diisocyanate (MDI), toluene diisocyanate (TDI), or a mixture thereof.
상기 흡음재부의 폴리우레탄 폼은 겉보기 밀도가 70~80 kg/m3인 것을 특징으로 하는 자동차용 플로어 카페트.
The method according to claim 1,
Wherein the polyurethane foam of the sound absorbing material part has an apparent density of 70 to 80 kg / m 3 .
상기 자동차용 플로어 카페트에서 콘솔이 장착되는 터널부위는 상기 흡음재부로 흡음 처리된 것을 특징으로 하는 자동차용 플로어 카페트.The method according to claim 1,
Wherein a portion of the tunnel where the console is mounted on the automotive floor carpet is sound-absorbed by the sound-absorbing material portion.
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| KR20200125368A (en) | 2019-04-25 | 2020-11-04 | 원풍물산주식회사 | Method for Manufacturing Floor Carpet Having Sound Insulation Layer Integrated with Sound Absorption Using the Sound Insulation Material Having Low Weight Thermoplastic Polyethylene |
| KR20220055239A (en) | 2020-10-26 | 2022-05-03 | 주식회사 서연이화 | Floor carpet for vehicle |
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| KR102632167B1 (en) | 2023-03-13 | 2024-02-01 | 주식회사 익성 | Carbon fiber impregnation complex material and manufacturing method thereof |
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