KR20240076070A - Vehicle Trunk Luggage Covering Mat Using A Single Material And Its Manufacturing Method - Google Patents

Abstract

The present invention relates to a trunk luggage covering mat for a vehicle using a single material and a method of manufacturing the same. Specifically, the PP single material is used, and a surface non-woven fabric layer, a PP extrusion coating layer, a back non-woven fabric layer, and a microfiber sound-absorbing layer are sequentially laminated. The present invention relates to a trunk luggage covering mat for a vehicle that is lightweight, has excellent strength, sound insulation, and sound absorption, and has excellent formability with little distortion after molding, and a method of manufacturing the same.

Description

Vehicle trunk luggage covering mat using a single material and its manufacturing method {Vehicle Trunk Luggage Covering Mat Using A Single Material And Its Manufacturing Method}

The present invention relates to a trunk luggage covering mat for a vehicle using a single material and a method of manufacturing the same. Specifically, a PP single material is used, and a surface non-woven fabric layer, a PP extrusion coating layer, a back non-woven fabric layer, and a microfiber sound-absorbing layer are sequentially laminated. The present invention relates to a trunk luggage covering mat for a vehicle that is lightweight, has excellent strength, sound insulation, and sound absorption, and has excellent formability with little distortion after molding, and a method of manufacturing the same.

Currently, the strengthening of automobile fuel efficiency regulations to prevent global warming caused by the use of fossil fuels and reduce greenhouse gases is a global trend and is becoming an economic law. Technology to increase fuel efficiency through car bodies using lightweight materials is emerging as an important factor, and automobiles around the world are becoming more and more popular. A lightweight trend is blowing in the industry.

With the advent of environmental regulations and the era of high oil prices, improving fuel efficiency has become a necessity, not an option, due to the contribution of lightweight materials to automobiles.

As such, automotive technology trends are developing materials and technologies in the direction of light weight, high quality, cost reduction, and eco-friendliness, and these technological requirements are gradually increasing for automobile manufacturers and interior materials companies.

LUGGAGE COVERING MAT refers to a mat located on the bottom of the trunk among automobile interior materials. The materials currently used are dissimilar materials that cause VOC, odor, and are not recycled.

Among automobile interior materials, the luggage covering mat is mounted on the lower part of the vehicle's luggage compartment to facilitate cargo storage and is an automobile part that enhances the appearance. Although it has a simple shape, it is the part that requires the most impact resistance, strength, and heat resistance among automobile interior materials. am.

Patent Document 1 includes an outer skin layer 100 including non-woven fabric; A reinforcing layer 200 selected from one or more of a glass board made of glass fiber, glass fiber tape, and carbon fiber; A sound-absorbing layer (300) selected from one or more of polyurethane (PU), recycled polyurethane, recycled polyurethane foam, and recycled felt; The mat is composed of a lower layer 400 selected from one or more of non-woven fabric and wood stock (polypropylene & wood flour), and the lower part of the mat has a structure in which a plurality of supports are arranged in a honeycomb shape, a grid shape, and arranged side by side. A mat for a car trunk is presented, which is formed of a strength-reinforced structure including and each layer is bonded to each other by heat fusion.

As shown in Patent Document 1, the materials for luggage covering mats previously used include natural fiber composites, inorganic fiber composites, RESIN FELT composites, and MDF composites, but it is difficult to achieve rigidity as a trunk luggage covering mat with plastic resin alone. Different types of composite materials are used.

The most commonly used plastics in automobiles are PP, a general-purpose plastic, and PA, an engineering plastic. Among these, PP (polypropylene) has an excellent balance between molding processability and light weight, so it is the most widely used among automotive plastics. It is mainly used in the interior of instrument panels, exterior and outer panels such as bumpers, fuel in the engine room, mechanical parts, and electrical components. It is widely used.

The trunk interior material is composed of upper, lower, trunk lid, side trim, partition, and rugged cubby ring mat. Except for the rugged cubby ring mat, most of the materials are PP, but different types of composite materials are used. After use, it is difficult to dismantle each part and recycle it.

In addition, the material of the luggage cubby ring mat must have high strength to maintain functionality and shape, and at the same time, it must have water resistance and excellent fatigue strength depending on its function, so 80% of PP material can be recycled. Luggage mat plastic parts material There is a high need to develop and apply it to crumbling cubby ring mats.

Republic of Korea Patent Publication No. 10-1020140 (registered on February 28, 2011)

The problem to be solved in the present invention relates to a trunk luggage covering mat for a vehicle using a single material and a method of manufacturing the same. Specifically, it uses a PP single material, and includes a surface non-woven fabric layer, a PP extrusion coating layer, a back non-woven fabric layer, and a microfiber sound-absorbing layer. The purpose is to provide a trunk luggage covering mat for vehicles that is sequentially laminated, is lightweight, has excellent strength, sound insulation, and sound absorption, and has excellent formability with little distortion after molding, and a method of manufacturing the same.

As a means of solving the problem according to the present invention, a vehicle trunk luggage covering mat using a single material is sequentially laminated with a surface non-woven fabric layer, a PP extrusion coating layer, a back non-woven fabric layer, and a microfiber sound-absorbing layer.

A surface nonwoven layer made of the PP nonwoven fabric of the present invention with a weight of 160 to 450 g/m2, a PP extrusion coating layer with a weight of 800 to 1400 g/m2, a back nonwoven layer made of a PP nonwoven fabric with a weight of 160 to 450 g/m2, and a weight of 130 g/m2. PP microfiber sound-absorbing layers of ~600g/㎡ are sequentially laminated.

The surface nonwoven layer of the present invention is made of 35 to 45 parts by weight of 6 denier PP fiber, 35 to 45 parts by weight of 10 denier PP fiber, and 15 to 25 parts by weight of 4 denier LM fiber, and the PP extrusion coating layer is made of 100 parts by weight of PP resin. , the back foam layer is made of 35 to 45 parts by weight of 1.5 denier PP fiber, 35 to 45 parts by weight of 10 denier PP fiber, and 15 to 25 parts by weight of 4 denier LM fiber, and the microfiber sound-absorbing layer is made of 100 parts by weight of 1.5 denier PP fiber.

As a solution to another problem of the present invention, a vehicle trunk luggage covering mat using a single material is a). Step of preparing a surface non-woven fabric layer made of PP non-woven fabric with a weight of 160 to 450 g/m2 and a back non-woven layer made of PP non-woven fabric with a weight of 160 to 450 g/m2, b). A step of manufacturing a sheet-shaped PP extrusion coating layer with a weight of 800 to 1400 g/m2 by extruding the melted resin by mixing a crosslinker, antioxidant and filler into the PP resin, c). Step of preparing a microfiber sound-absorbing layer made of 100 parts by weight of 1.5 denier PP fiber, d). A step of combining the surface non-woven fabric layer and the PP extrusion coating layer while passing between the upper and lower rollers while supplying flame between the prepared surface non-woven fabric layer and the PP extrusion coating layer, e). A flame is supplied between the PP extrusion coating layer and the back non-woven fabric side, which is the opposite side of the bonding of the surface non-woven fabric layer and the PP extrusion coating layer, and passes between the upper and lower rollers to bond the surface non-woven fabric layer, the PP extrusion coating layer, and the back non-woven fabric layer in that order. Step, f). A flame is supplied between the back non-woven fabric layer and the microfiber sound-absorbing layer of the laminate in which the surface non-woven fabric layer, the PP extrusion coating layer, and the back non-woven fabric layer are laminated in that order, passing between the upper roller and the lower roller to combine the back non-woven fabric layer and the microfiber sound-absorbing layer. It is manufactured by laminating and combining the surface non-woven fabric layer, the PP extrusion coating layer, the back non-woven fabric layer, and the microfiber sound-absorbing layer in that order.

The trunk luggage covering mat for a vehicle using a single material according to the present invention has a PP extrusion coating layer as a base material, which satisfies the impact resistance and strength required for a trunk luggage covering mat while being lightweight, and blocks noise transmitted from the underside of the vehicle. The sound insulation performance is very effective.

The vehicle trunk luggage covering mat using a single material according to the present invention is excellent at absorbing noise transmitted from the bottom of the vehicle by forming a microfiber sound-absorbing layer at the bottom.

The vehicle trunk luggage covering mat using a single material according to the present invention has the effect of improving the bonding strength between the PP extrusion coating layer and the microfiber sound-absorbing layer by lamination of a non-woven backing layer between the PP extrusion coating layer and the microfiber sound-absorbing layer.

The vehicle trunk luggage covering mat using a single material according to the present invention is easy to recycle because it uses a single material.

1 is a photograph of a vehicle showing the position in which the present invention is applied in the vehicle;
Figure 2 shows a laminated structure of a trunk luggage covering mat for a vehicle according to the prior art;
Figure 3 shows a laminated structure of a vehicle trunk luggage covering mat using a single material according to the present invention;
Figure 4 shows an example of the manufacturing process of a vehicle trunk luggage covering mat using a single material according to the present invention.

Hereinafter, embodiments of the present invention will be described in more detail. Additionally, in describing the present invention, detailed descriptions of related well-known general configurations or functions will be omitted.

1 is a schematic diagram of a vehicle showing a position in the vehicle where a trunk luggage covering mat for a vehicle according to the present invention is applied. Referring to Figure 1, it is an automobile part that is mounted on the lower part of the trunk luggage compartment of a vehicle to facilitate cargo storage and enhance the appearance. Although it has a simple shape, it is a component that requires the most impact resistance, strength, and heat resistance among automobile interior materials. am.

Existing materials for luggage covering mats include natural fiber composites, inorganic fiber composites, RESIN FELT composites, and MDF composites. It is difficult to achieve rigidity as a trunk luggage covering mat with plastic resin alone, so different types of composite materials are used. was using

However, there is a disadvantage in that dissimilar materials must be physically separated during recycling, which increases processing costs during recycling.

The trunk luggage covering mat for vehicles according to the present invention simplifies the manufacturing process by manufacturing a surface layer and a sound absorbing and insulating layer and then combining them with a PP extrusion coating layer, rather than manufacturing a plurality of layers separately and combining them again, which is a disadvantage of the prior art. It is lighter than before, the PP extrusion coating layer is replaced with an eco-friendly coating method that does not generate harmful substances, and a single material is used to meet recycling conditions that meet the recycling rate regulations under EU environmental regulations.

The vehicle trunk luggage covering mat of the present invention is sequentially laminated with a surface non-woven fabric layer, a PP extrusion coating layer, a back non-woven fabric layer, and a microfiber sound-absorbing layer that form the surface of the interior floor of a vehicle trunk.

A surface nonwoven layer made of the PP nonwoven fabric of the present invention with a weight of 160 to 450 g/m2, a PP extrusion coating layer with a weight of 800 to 1400 g/m2, a back nonwoven layer made of a PP nonwoven fabric with a weight of 160 to 450 g/m2, and a weight of 160 to 450 g/m2. PP microfiber sound-absorbing layers of 130 to 600 g/m2 are sequentially laminated.

The surface nonwoven layer of the present invention is made of 35 to 45 parts by weight of 6 denier PP fiber, 35 to 45 parts by weight of 10 denier PP fiber, and 15 to 25 parts by weight of 4 denier LM fiber, and the PP extrusion coating layer is made of 100 parts by weight of PP resin. , the back nonwoven layer is made of 35 to 45 parts by weight of 1.5 denier PP fiber, 35 to 45 parts by weight of 10 denier PP fiber, and 15 to 25 parts by weight of 4 denier LM fiber, and the microfiber sound-absorbing layer is made of 100 parts by weight of 1.5 denier PP fiber.

The surface non-woven fabric layer of the present invention is a visible surface when installed on the interior floor of the trunk of a vehicle, and should provide a cushioning feeling rather than a hard feeling to the driver, etc., and prevent collisions between items in the trunk or passing over speed bumps while driving the vehicle. It is also desirable to have elasticity in order to reduce the impact of the product.

As discussed above, in order to provide elasticity, it is desirable that the surface nonwoven layer maintains the gap between PP fibers and does not adhere closely.

The surface nonwoven layer consists of 35 to 45 parts by weight of 6 denier PP fiber, 35 to 45 parts by weight of 10 denier PP fiber, and 15 to 25 parts by weight of 4 denier LM fiber.

At this time, the PP fibers include 35 to 45 parts by weight of 6 denier fibers and 35 to 45 parts by weight of 10 denier fibers, which have relatively large diameters. When these fibers are combined with 15 to 25 parts by weight of 4 denier LM fibers, they are heated and melted by a flame to form 6 denier fibers. The gap between the and 10 denier fibers is maintained, and the pore size is relatively large without being closely adhered.

The weight per unit area of the surface nonwoven layer is preferably 160 to 450 g/m2.

The role of satisfying the rigidity and impact resistance required in the vehicle trunk luggage covering mat of the present invention is played by the PP extrusion coating layer. The PP extrusion coating layer accounts for approximately 50% of the total weight of the vehicle trunk luggage covering mat of the present invention, has a sheet form, and has a base material and sound insulation function. The weight of the PP extrusion coating layer is preferably in the range of 800 to 1400 g/m2.

The back nonwoven fabric layer consists of 35 to 45 parts by weight of 1.5 denier PP fiber, 35 to 45 parts by weight of 10 denier PP fiber, and 15 to 25 parts by weight of 4 denier LM fiber. At this time, the PP fibers include 35 to 45 parts by weight of 1.5 denier fibers with a relatively thin diameter and 35 to 45 parts by weight of 10 denier fibers with a relatively large diameter, and these fibers are combined with 15 to 25 parts by weight of 4 denier LM fibers by flame. It is heated and melted to bind 1.5 denier fibers and 10 denier fibers. Among these, 1.5 denier fibers are included to facilitate bonding with the 1.5 denier fibers that make up the microfiber sound-absorbing layer. It also plays a big role in increasing sound absorption.

The microfiber sound-absorbing layer is made of 100 parts by weight of 1.5 denier PP fiber. The 1.5 denier microfiber fiber has the same thickness as regular cotton and performs the function of absorbing noise.

A method of manufacturing the trunk luggage covering mat for a vehicle of the present invention will be described.

a). 35 to 45 parts by weight of 6 denier PP nonwoven fabric, 35 to 45 parts by weight of 10 denier fabric, and 15 to 25 parts by weight of 4 denier LM fiber are carded and blended, then laminated and needle punched to prepare a surface nonwoven fabric layer. Separately from the fabric non-woven layer, the back non-woven fabric layer is carded and blended with 35 to 45 parts by weight of 1.5 denier PP fiber, 35 to 45 parts by weight of 10 denier PP fiber, and 15 to 25 parts by weight of 4 denier LM fiber, respectively, and then laminated and needle-laid. Prepare the back nonwoven fabric layer by punching.

b). A PP sheet-like PP extrusion coating layer with a weight of 800 to 1400 g/m2 is prepared by extruding the melted resin by mixing a crosslinking agent, antioxidant, and filler into the PP resin.

c). Prepare a microfiber sound-absorbing layer by carding and laminating 100 parts by weight of 1.5 denier PP fiber and needle punching.

d). While supplying flame between the prepared surface non-woven fabric layer and the PP extrusion coating layer, the surface non-woven fabric layer and the PP extrusion coating layer are combined while passing between the upper roller and the lower roller.

e). Flame is supplied between the PP extrusion coating layer and the back nonwoven fabric side, which is the opposite side of the bonding of the surface nonwoven fabric layer and the PP extrusion coating layer, and passes between the upper and lower rollers to bond the surface nonwoven fabric layer, the PP extrusion coating layer, and the back nonwoven fabric layer in that order. .

The process of combining the surface non-woven fabric layer, the PP extrusion coating layer, and the back non-woven fabric layer in that order is performed continuously by the device shown in Figure 4, d). The lower roller in step e). This is the upper roller in the step.

f). A flame is supplied between the back non-woven fabric layer and the microfiber sound-absorbing layer of the laminate in which the surface non-woven fabric layer, the PP extrusion coating layer, and the back non-woven fabric layer are laminated in that order, passing between the upper and lower rollers to combine the back non-woven fabric layer and the microfiber sound-absorbing layer. It is manufactured by laminating and combining the surface non-woven fabric layer, the PP extrusion coating layer, the back non-woven fabric layer, and the microfiber sound-absorbing layer in that order.

<Example>

40 parts by weight of 6-denier PP fiber, 40 parts by weight of 10-denier PP fiber, and 20 parts by weight of 4-denier LM fiber, which are the materials of the surface non-woven layer, were carded, blended, laminated, and needle-punched (4 times) to create a surface non-woven layer of 300 g/㎡. Manufactured.

The back non-woven fabric layer's materials are 40 parts by weight of 1.5 denier PP fiber, 40 parts by weight of 10 denier PP fiber, and 40 parts by weight of 4 denier LM fiber, respectively, by carding, blending, lamination, and needle punching (4 times) to produce a 300 g/㎡ back non-woven fabric layer. was manufactured.

A sheet-shaped PP extrusion coating layer was manufactured by extrusion coating 1200 g/m2 of PP resin, which is the material of the PP extrusion coating layer.

A microfiber sound-absorbing layer of 300 g/m2 was manufactured by carding, lamination, and needle-punching (3 times) 100 parts by weight of 1.5 denier PP fiber, which is the material of the microfiber sound-absorbing layer.

A vehicle trunk luggage covering mat material was manufactured by laminating and combining the prepared surface non-woven fabric layer, PP extrusion coating layer, back non-woven fabric layer, and microfiber sound-absorbing layer.

density
250g/㎡ tensile strength Tear strength elongation M.D.
(N/5cm) CD
(N/5cm) M.D.
kgf CD
kgf MD(%) CD(%) Example 1 1403 1456 25.7 24.3 76.9 76.2 Example 2 1348 2453 24.1 27.9 96.8 74.2

* In tensile strength, MD: machine direction, CD: perpendicular to the machine direction.

The test values shown in [Table 1] are the results of testing the tensile strength, tear strength, and elongation of Examples 1 and 2, which were manufactured using the same nonwoven fabric layer and PP extrusion coating layer, respectively.

It was confirmed that the example satisfies the lower limit of tensile strength of 1300 N/5cm or more required by the demand side, satisfies the lower limit of tensile strength of 5kgf or more, and satisfies more than 50% in terms of elongation.

Although the embodiments of the present invention have been described with reference to the embodiments shown in the drawings, this is merely illustrative, and various modifications and equivalent other embodiments can be made by those skilled in the art. You will understand. Therefore, the true scope of technical protection of the present invention should be determined by the technical spirit of the attached patent claims.

Claims (3)

The surface non-woven layer is made of PP non-woven fabric with a weight of 160 to 450 g/m2, the PP extrusion coating layer is made of 800 to 1,400 g/m2, the back non-woven layer is made of PP non-woven fabric and weighs 160 to 450 g/m2, and the PP microfiber sound-absorbing layer is sequentially formed. Car trunk luggage covering mat using a single material characterized by being laminated and its manufacturing method. According to claim 1,
The surface non-woven layer is made of 35 to 45 parts by weight of 6 denier PP fiber, 35 to 45 parts by weight of 10 denier PP fiber, and 15 to 25 parts by weight of 4 denier LM fiber, and the PP extrusion coating layer is made of 100 parts by weight of PP resin, and the backing fabric The layer is made of 35 to 45 parts by weight of 1.5 denier PP fiber, 35 to 45 parts by weight of 10 denier PP fiber, and 15 to 25 parts by weight of 4 denier LM fiber, and the microfiber sound-absorbing layer is composed of 100 parts by weight of 1.5 denier PP fiber. Car trunk luggage covering mat using a single material and its manufacturing method. a). Preparing a surface nonwoven layer made of PP nonwoven fabric with a weight of 160 to 450 g/m2 and a back nonwoven layer made of PP nonwoven fabric with a weight of 160 to 450 g/m2, respectively,
b). Manufacturing a PP extrusion coating layer in the form of a PP sheet with a weight of 800 to 1400 g/m2 by extruding a resin melt obtained by mixing a crosslinker, antioxidant and filler into a PP resin,
c). Preparing a microfiber sound-absorbing layer with 1.5 denier PP fiber and a weight of 300 g/m2,
d). A step of combining the surface non-woven fabric layer and the PP extrusion coating layer while passing between the upper roller and the lower roller while supplying a flame between the prepared surface non-woven fabric layer and the PP extrusion coating layer,
e). Flame is supplied between the PP extrusion coating layer and the back non-woven fabric side, which is the opposite side of the bonding of the surface non-woven fabric layer and the PP extrusion coating layer, and passes between the upper and lower rollers to combine the surface non-woven fabric layer, the PP extrusion coating layer, and the back non-woven fabric layer in that order. step,
f). A flame is supplied between the back non-woven fabric layer and the microfiber sound-absorbing layer of the laminate in which the surface non-woven fabric layer, the PP extrusion coating layer, and the back non-woven fabric layer are laminated in that order, passing between the upper roller and the lower roller to combine the back non-woven fabric layer and the microfiber sound-absorbing layer. A method of manufacturing a trunk luggage covering mat for a vehicle using a single material, characterized in that it is manufactured in the following steps by laminating and combining the surface non-woven fabric layer, the PP extrusion coating layer, the back non-woven fabric layer, and the microfiber sound-absorbing layer.