KR100348783B1 - Moldable Substrate for Automotive Top Ceiling and Method of Processing - Google Patents

Abstract

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to molding materials for automobile interiors, and more particularly, to molding materials for use in automobile ceilings, bonnet hoods, door trims, trunks, and the like and methods of manufacturing the same. .

This molding material for automobile interior is special fiber, flame retardant fiber, antibacterial fiber obtained by spinning the low melting point resin and the high melting point resin at the same time to manufacture the molding material of the sandwich structure in which the nonwoven fabric reinforcement is bonded to both sides of the thermoplastic foam by the adhesive resin. The nonwoven fabric reinforcement is manufactured by using a nonwoven fabric reinforcement, and when manufacturing the nonwoven fabric reinforcement, a nonwoven fabric reinforcement layer in which a reinforcement layer is inserted by continuously supplying a separate reinforcement layer between the nonwoven fabric reinforcement is combined by one of needle punching or point sealing, Laminating adhesive resin on one side of non-woven fabric reinforcement in batch process, greatly simplifying the manufacturing process of molding material of sandwich structure, and morphological stability, heat stability, flame retardancy, antibacterial property, mass productivity, dimension required for molding material for automobile at low cost Satisfying the requirements such as stability and weight reduction Preparing a copper substrate by forming the borrower can contribute to improving the quality of domestic cars, thereby providing the effect of strengthening the international competitiveness due to the fuel efficiency of cars.

Description

Molded Substrate for Automotive Interior and Manufacturing Method {Moldable Substrate for Automotive Top Ceiling and Method of Processing}

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molding material for automobile interiors and a method for manufacturing the same. The present invention relates to a molding material for automotive interiors, which is used in automotive ceiling molding materials, bonnet hoods, door trims, trunks, and the like. will be. In the interior materials for automobiles, the ceiling substrate has a wide application area and forms a three-dimensional structure, and various various properties are required.

Recently, the automobile industry has been rapidly developed and mass-produced, which makes it impossible to mass-produce automotive interior materials by molding. Therefore, the molding workability is excellent, there is no damage and contamination during transportation of the molded product, and the worker should be easy to handle the assembly work.

In addition, as the environmental pollution problem has emerged as a serious problem, fuel economy reduction is an important point in the development of automobiles for the recyclability of materials that reduce environmental pollution by waste and the reduction of air pollution by the smoke of automobiles. In order to reduce such environmental pollution, the recent development direction of automobile parts is recycling materials and weight reduction for fuel efficiency.

Automobile ceiling materials have a wide application area and form a complex structure of three-dimensional structure, so shape stability is essential, and weather resistance that satisfies climatic conditions in various regions is required. Weather resistance is free from morphological deformation of the ceiling substrate shrinking and expanding during long-term operation under high temperature and high humidity in the tropical region, low temperature drying in the polar region, and high rainfall regions, and no exfoliation between layers by long-term exposure to high temperature. Should not.

Currently used ceiling materials include paper as a base material, a paper board reinforced with polyethylene sheet (PE sheet), aluminum foil, etc., and thermosetting resins such as phenolic resin (Phenol Resin) in the mixed yarn felt. Resin felt, glass wool impregnated with glass thermosetting resin (Glass Felt) is used.

Each of these substrates has excellent advantages, but also has a considerable disadvantage, which is a problem.

The paper board is lighter than other materials and is made of paper, so it is easy to dispose of waste paper. However, wrinkles occur during molding due to low elongation, and there is a weak problem in moisture.

Resin felt is used as a ceiling material of a large car because of its strength, but heavy weight is a problem against the fuel economy of the car, and waste treatment is a problem because it uses a phenol resin, a thermosetting resin.

Glass felt has the advantage of excellent sound absorption and strong strength, but the workability which is a typical problem of glass fiber is very bad and the disposal is also a problem.

Therefore, in developed countries such as Europe, USA, and Japan, automobile interior materials based on light and sound-absorbing polyurethane foam and polystyrene foam have been developed since the late 1980s. In 1987, BASF of Germany can maintain shape by heat. Development was actively carried out with the release of Thermo Formable polyurethane foam.

In the early 1990s, Mercedes-Benz, Germany, developed a thermoplastic composite foam based on Thermo Formable polyurethane foam and bonded the reinforcement layer to the front and back of the foam material. In recent years, about 70-80% of European automobiles are using a composite ceiling substrate having a sandwich structure, which is based on thermoplastic polyurethane foam and has a reinforcing layer bonded to the front and rear surfaces thereof.

The composite ceiling material of the sandwich structure is composed of two parts, a foam material and a reinforcement material.

In the case of foam materials, rigid and semi-rigid foams have been used recently by chemical companies such as BASF and BAYER.

In the case of nonwoven fabric reinforcement, various kinds of materials have been developed and patented, but recently, they are used in two ways.

1 is a cross-sectional view of a molding material for automobile interiors in which a conventional reinforcing layer is formed, and FIG. 2 is a cross-sectional view of a molding material for automobile interiors in which a glass layer and a glass reinforcing layer are formed in the related art.

The first is to have a structure of Figure 1 that has been used since the beginning of development steadily until recently, the base layer 1 is formed on the upper and lower surfaces of the polyurethane foam (2) by forming adhesive resin layers (3a, 3b) to the glass layer (4a, 4b) is bonded, and adhesive resin layers 5a and 5b are formed on one surface of the upper and lower glass layers 4a and 4b to form the glass blocking layers 6a and 6b in combination, and the glass blocking layer 6a is formed. ), The adhesive resin layer 7 was formed, and the skin material layer 10 was bonded to the skin material 8.

Although there is a composite substrate composed of the glass layers 4a and 4b and the glass blocking layers 6a and 6b as described above, such a method is excellent in strength, heat stability and sound absorption performance, but it is necessary to adhere several layers with an adhesive layer such as hot melt. Therefore, the manufacturing cost is high, there is a problem that the workability by the glass (Glass) is bad.

In addition, the base layer 11 having the structure of FIG. 2 forms adhesive resin layers 13a and 13b on the upper and lower surfaces of the polyurethane foam 12 to bond the reinforcing layers 14a and 14b, and the reinforcing layer 14a. An adhesive resin layer 15a was formed on one surface of the c) to bond the skin material 18 to form the skin material layer 20.

As described above, a three-layered composite substrate with a simple reinforcement layer except for a glass layer was developed and used. As the reinforcement layer, a synthetic fiber nonwoven fabric, a natural fiber reinforcement layer, a film layer, and a fabric layer were developed. There are a number of problems in recent years, a small amount of the situation remains.

In particular, when using a synthetic fiber nonwoven fabric, the manufacturing cost is low, but heat resistance and morphological stability are a problem, and when the natural fiber layer is bonded with a hot melt fiber and used as a reinforcing layer (patent EP-0832787 A1), in terms of heat resistance, Advantageous to the fiber, but weak in moisture, odor due to decay, there is a problem that the stable supply of natural fibers is difficult. In the case of the film layer, there is a problem of lack of sound absorbing performance, and in the case of the fabric layer, the price is high, and the elongation is insufficient, resulting in poor moldability.

The present invention has been made to solve the above problems, using a special fiber, flame retardant fiber, antibacterial fiber obtained by spinning a low melting point resin and a high melting point resin on both sides of the thermoplastic foam at the time of manufacturing the molding material for automobile interior The nonwoven fabric reinforcement is manufactured, and in the manufacture of the nonwoven fabric reinforcement, a separate reinforcement layer is continuously supplied between the nonwoven fabric reinforcements, and the fiber layer of the nonwoven fabric reinforcement into which the reinforcement layer is inserted is combined by one of needle punching or point sealing, and the nonwoven fabric Laminating adhesive resin on one side of reinforcement in a batch process, greatly simplifying the manufacturing process of the molding material of sandwich structure, and morphological stability, heat resistance, flame resistance, antibacterial property, mass productivity, dimensional stability required for automobile molding materials at low cost Automotive molding that satisfies requirements such as weight reduction and weight reduction To prepare a material.

A fiber supply step of supplying fibers from the bale opening device to the fine opening device, and a fiber agglomeration step of agglomerating the fibers in the form of agglomerates in the fine opening device and transferring the fibers to the fiber mixing device along a feed pipe; A fiber mixing step of evenly distributing the fibers and transferring them to the carding machine, a sheet (web) forming step of forming a sheet (web) of a predetermined size in the carding machine, and a sheet stacking step of laminating the sheet in two to three layers. A reinforcing layer supplying step of continuously supplying the reinforcing layer to the upper surface of the sheet, a sheet supplying step of laminating the sheet on the upper surface of the reinforcing layer, and a needle punching step of passing the needle punching machine to make the thickness of the sheet and the reinforcing layer thin; , Fusion step of fusion of sheet and reinforcement layer while passing through high temperature and high pressure heat press, adhesive resin supply step of adhering resin to reinforcement, and nonwoven reinforcement It comprises a step of winding.

1 is a cross-sectional view of a molding material for automobile interior in which a conventional reinforcing layer is formed,

2 is a cross-sectional view of a molding material for automobile interior in which a glass layer and a glass reinforcement layer are formed in the related art.

3 is a flow chart showing a manufacturing process of the present invention,

Figure 4 is a perspective view showing the manufacturing process of the molding material for automobile interior of the present invention,

5 is a cross-sectional view showing the manufacturing process of the molding material for automobile interior of the present invention,

6 is a cross-sectional view showing a needle punching process of the present invention,

7 is a cross-sectional view showing a pointing sealing process of the present invention,

8 is a spinning principle diagram of a special fiber used in the nonwoven fabric reinforcement layer of the molding substrate of the present invention,

9 is a cross-sectional view of the fiber of the reinforcing layer according to the present invention,

10 is a cross-sectional view of the molding material for automobile interior of the present invention,

11 is a cross-sectional view of the nonwoven fabric reinforcement of the present invention,

12 is an electron micrograph at a magnification of 100 times the surface of the molding substrate reinforcement layer of the present invention,

13 is an electron micrograph at 350 times the magnification of the molding material reinforcement layer surface of the present invention.

Figure 14 is an electron micrograph enlarged 500 times the surface of the molding substrate reinforcement layer of the present invention.

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

101: bale opening device 102: fine opening device

121: first fiber mixing device 122: second fiber mixing device

131: first carding machine 132: second carding machine

135a and 135b: fiber reinforcing layer 141: first fiber layer molding machine

142: second fiber layer molding machine 151: reinforcing layer

171: needle punching machine 182: heat press roll device

175: needle 176: guide roll

177: embossing roll 182: heat press roll apparatus

191: non-woven fabric reinforcement 300: special fiber molding apparatus

302: inner nozzle 304: outer nozzle

DETAILED DESCRIPTION Hereinafter, the most preferred embodiments will be described with reference to the accompanying drawings so as to be easily implemented by those skilled in the art.

Figure 3 is a flow chart showing a manufacturing process of the present invention, Figure 4 is a perspective view showing a manufacturing process of the automotive interior molding material of the present invention, Figure 5 is a cross-sectional view showing a manufacturing process of the automotive interior molding material of the present invention. .

The present invention provides a fiber supply step of supplying fibers, a fiber agglomeration step of agglomerating the supplied fibers in a lump form, a fiber mixing step of evenly distributing the agglomerated fibers and transferring them to a carding machine; A sheet forming step of forming a web), a sheet laminating step of laminating sheets in a first fiber layer molding machine, a reinforcing layer supplying step of supplying a reinforcing layer to the upper surface of the sheet, and laminating a sheet on the upper surface of the reinforcing layer A sheet feeding step, a needle punching step of needle punching the sheet and the reinforcing layer, a fusion step of thermally fusion of the sheet and the reinforcing layer, an adhesive resin supplying step of forming the adhesive resin layer, and a nonwoven fabric reinforcement having the adhesive resin layer formed thereon. It is made up of a winding stage.

The fiber supply step 100 opens the fiber in the bal opening device 101 and supplies the fiber to the fine opening device 102.

The fiber agglomeration step 110 aggregates the fibers in a lump form in the fine opening device 102 and transfers the fibers to the fiber mixing apparatuses 121 and 122 along the feed pipe 103.

In the fiber mixing step 120, the fibers are evenly distributed in the first fiber mixing device 121 and the second fiber mixing device 122 so as to distribute the fibers evenly, and then transferred to the carding machines 131 and 132.

The sheet (web) forming step 130 forms the fibers evenly distributed through the fiber mixing apparatuses 121 and 122 in the form of a thin sheet (web) in the first carding machine 131 and the second carding machine 132.

In the sheet stacking step 140, the sheet supplied through the first carding machine 131 is stacked in two to three layers of sheet-shaped fiber layers in the first fiber layer forming machine 141 to form a fiber reinforcement layer 135a.

The reinforcing layer supplying step 150 continuously supplies the reinforcing layer 151 wound on the upper surface of the fiber reinforcing layer 135a transferred from the first fiber layer molding machine 141.

The sheet supplying step 160 includes a sheet formed in the second carding machine 132 and a fiber reinforcing layer 135b in which two to three layers of sheet-like fiber layers are stacked in the second fiber layer molding machine 142. Lay on the upper surface of.

Needle punching step 170 is passed through a plurality of needle punching machine 171 to combine the fiber reinforcement layer (135a, 135b) and the reinforcing layer 151, the fiber reinforcing layer (135a, 135b) and the reinforcing layer (151) ) Thinner.

The fusion step 180 heat-bonds the fiber reinforcement layer 181 and the reinforcement layer 151 while passing the reinforcement layer 151 combined with the fiber reinforcement layers 135a and 135b through the high temperature and high pressure heat press roll device 182. do.

The heat-sealed fiber reinforcement layers 135a and 135b and the reinforcement layer 151 through the above steps are referred to as nonwoven fabric reinforcement 191.

The adhesive resin supplying step 190 bonds the adhesive resin layer 401 wound on the upper surface of the heat-sealed nonwoven fabric reinforcement 191.

In this case, the adhesive resin may be supplied in the form of a film as shown in the drawing, or may be uniformly scattered in a certain amount in a powder state.

The winding step 200 winds up the nonwoven fabric reinforcing material 191 to which the adhesive resin layer 401 is attached.

6 is a cross-sectional view showing a needle punching process of the present invention, Figure 7 is a cross-sectional view showing a pointing sealing process of the present invention.

The needle punching process is coupled to the needle board 174 which vertically reciprocates the fiber reinforcement layers 135a and 135b and the reinforcement layer 151 transferred by the conveyor 172 as shown in FIG. The fiber reinforcement layers 135a and 135b and the reinforcement layer 151 are combined by the needle 175.

In the point sealing process, the fiber reinforcing layers 135a and 135b and the reinforcing layer 151 are passed between the guide rolls 176 and the embossing rolls 177 as shown in FIG. 7 and the fiber reinforcing layers 135a and 135b as in the needle process. And the reinforcement layer 151.

Therefore, in the present invention, between the nonwoven fabric reinforcing layer is softened at a temperature of 150 ° C. or more, and stretches to a desired shape during molding, and at 150 ° C. or less, a thermally stable reinforcing layer 151 having non-extension characteristics is provided with a fibrous layer 135a of the nonwoven fabric reinforcing material 191. Continuously supplying the reinforcing layer 151 between the (135b) and combined by a high temperature, high pressure point sealing process or needle punching process to provide a good shape stability and thermally stable nonwoven fabric reinforcement ( 191).

Since the nonwoven fabric reinforcement 191 thus manufactured is combined by any one of a facility for manufacturing a reinforcement or point sealing, a reinforcement layer having excellent shape stability and heat resistance at the same time can be manufactured at low cost.

In the present invention, the material used as the reinforcing layer 151 is defined as three types, such as spunbond non-woven fabric, hemp, glass mat, these materials have different characteristics, but must be non-extensible at 130 ℃ or less.

At this time, if it is not softened at a temperature of 130 ℃ or more, wrinkles are generated during the molding operation has no value as a product, and if the increase is not inextensible at a temperature of 130 ℃ or less, the problem arises that the ceiling is sagging after being mounted on the car.

Therefore, the reinforcement layer 151 should be made of a material that can maintain the same shape even when exposed to high temperature for a long time.

The spunbond nonwoven fabric used as the reinforcing layer 151 may be formed of one or two or more copolymers of polyester, polypropylene, and nylon fibers.

The spunbond nonwoven fabric used as the reinforcing layer 151 has a high strength and very low extensibility compared to a short fiber nonwoven fabric because it is directly spun onto a conveyor under a desired weight to form a sheet, and has a low melt component. The bonding force with the fiber layer is excellent, and the price is low, so that it can be appropriately used as the reinforcing layer 151.

The filament used as the reinforcing layer 151 is filamentized with polyester, polypropylene, and nylon polymer, and the fabric is woven into a mesh shape using the filaments as warp and weft yarns. As a scrim), it has high strength and very low extensibility, can be combined with a fiber layer by needle punching or point sealing, and is widely used in rice sack, etc. in everyday life, and is very inexpensive and can be suitably used as a reinforcing layer.

In this invention, the glass mat layer used by the existing base material can also be used as a reinforcement layer. Conventional glass mat layer is conventionally bonded with other material layer by hot melt, but in the present invention it is possible to reduce the cost of hot melt because it is continuously supplied between the fiber layer and bonded by high temperature, high pressure point sealing process or needle punching process. And, it is possible to prevent the peeling by hot melt after being mounted on the vehicle, there is an advantage that can prevent allergies or stinging during work because the glass mat is inserted between the nonwoven fabric reinforcement.

Reinforcement layer 151 composed of such a material exhibits a large physical property by the conditions of the bonding process.

In the present invention, the punching density is suitably about 200 to 400 st / cm 2, and the penetrating depth of the needle 175 is 3 to 12 mm under the condition of needle punching for bonding the fiber reinforcing layers 135a and 135b and the reinforcing layer 151. proper. If the punching density is 200 st / cm 2 or less, the bonding strength is lowered. If the punching density is 400 st / cm 2 or more, partial breakage of the fiber reinforcement layers 135a and 135b occurs, resulting in a decrease in strength.

When the penetration depth of the needle 175 is 3 mm or less, the bonding strength of the fiber reinforcement layers 135a and 135b is lowered. When the needle depth is 7 mm or more, the fiber reinforcement layers 135a and 135b are partially destroyed to penetrate the fiber reinforcement layers 135a and 135b. do. Needle punching conditions are defined as described above, but more suitable conditions are punching densities of 280 to 350 st / cm 2, and 4 to 7 mm is appropriate as the penetration depth of the needle 175.

In addition, as the point sealing conditions used in the present invention, the press roll temperature is appropriately 150 to 280 ° C, the roll pressure (linear pressure) is appropriately 30 to 100 kN / cm 2, and the sealing area is 10 to 35%. Do. If the press roll temperature is 150 ° C. or lower, the bonding strength is lowered. If the press roll temperature is 280 ° C. or higher, the fiber reinforcement layers 135a and 135b are excessively melted, the air permeability is lowered, and the sound absorption performance is lowered.

If the press roll pressure is 30 kN / cm 2 or less, the bonding strength of the fiber reinforcement layers 135a and 135b is lowered. If the press roll pressure is 100 kN / cm 2 or more, the fiber reinforcement layers 135a and 135b are partially destroyed. If the sealing area is 10% or less, the bonding strength of the fiber reinforcement layers 135a and 135b is lowered. If the sealing area is 35% or more, the air permeability is lowered and the sound absorption performance is lowered.

Although the conditions of a point seal are prescribed | regulated as mentioned above, more suitable conditions are press roll temperature of 180-230 degreeC, roll pressure (linear pressure) of 50-80 kN / cm <2>, and 10-35% of sealing area is suitable.

In this case, the number of press rolls is defined as two to three stages, but more appropriately, a two-stage press roll is appropriate.

FIG. 8 is a spinning principle diagram of special fibers used in the nonwoven fabric reinforcement layer of the molding substrate of the present invention, and FIG.

The special fiber forming apparatus 300 forms the spinning fiber 310 by forming an outer nozzle 304 for supplying the low melting point resin 303 outside the inner nozzle 302 for supplying the high melting point resin 301. .

In the present invention, in the production of nonwoven fabric reinforcement, the two parts are spun at the same time through a specially shaped nozzle so that the middle part of the fiber section is a conventional polyester, and the outer part is a low melting temperature at a relatively low degree of polymerization compared to a conventional polyester. Low-melt polymer is melted to prepare a fiber reinforcement layer having excellent shape stability.

The fiber made by spinning the low-melt polyester and general polyester at the same time is mass-produced at Samyang Corp. in Korea, and cooperated with our company to produce low-melt polyester. The present invention is completed by developing a fiber having an appropriate temperature condition.

The flame retardant fiber is composed of one or two or more fibers of polyester, polypropylene, viscose rayon, polycral, polyamide, polyvinylchloride mixed with organic and inorganic flame retardants. It is preferred that the mixing ratio of the flame retardant fibers is 5 to 25%.

Antibacterial fiber is composed of one or two or more fibers of polyester, polypropylene, viscose rayon, acetate, polyamide, polyvinylchloride mixed with organic and inorganic antibacterial agents. It is preferable that the mixing ratio is produced at 1 to 5%.

In the present invention, the appropriate melting point (melting point) of the low-melt polymer is defined as 80 to 200 ° C, more preferably 100 to 160 ° C. When the melting point is 100 ° C. or lower, the heat resistance after molding is poor, and when the melting point is 160 ° C. or higher, the fusion between the fibers is difficult to be achieved, so that the strength and elasticity of the molding material are lowered.

The nonwoven fabric reinforcement 191 combined with the reinforcement layer 151 through this process continuously passes through a high temperature and high pressure heat press roll, and the two components constituting the nonwoven fabric reinforcement 191 are radiated simultaneously. The low-melt portion of the adhesive fiber is heat-sealed to obtain a nonwoven fabric reinforcement 191 into which a reinforcing layer 151 having excellent strength and elasticity is inserted.

At this time, the heat press conditions are the press roll (Pres Roll) is 2 stages-3 stages, the roll temperature is 120-200 degreeC, and the roll pressures are 1-3 kg / cm <2> conditions.

When the number of press rolls is appropriate, two to three stages are suitable, and when the temperature of the roll is 120 ° C. or lower, the fusion between fibers is not well performed. When the temperature of the roll is 200 ° C. or higher, the low melt portion of the fiber is excessively fused to form a molding material. Reduces the sound absorption performance.

When the roll pressure is 1 kg / cm 2 or less, the fusion between fibers is not performed well, and when the thickness is 3 kg / cm 2 or more, the thickness of the nonwoven fabric reinforcement becomes thin and the low melt portion of the fiber is excessively fused to improve the sound absorption performance of the molding material. Lowers.

Although heat press conditions are prescribed | regulated as mentioned above, the conditions with more suitable conditions of a press roll are three steps, the roll temperature is 140-180 degreeC, and a roll pressure of 2 kg / cm <2> is appropriate.

The nonwoven fabric reinforcement 191 into which the reinforcement layer 151 is inserted proceeds continuously and is finally wound by adhering the adhesive resin layer 401 to one side of the nonwoven fabric reinforcement 191 by a separate adhesive resin supply device. do.

10 is a cross-sectional view of the molding material for automobile interior of the present invention, Figure 11 is a cross-sectional view of the nonwoven fabric reinforcement of the present invention.

Molding material for automobile interior according to the present invention is a fiber reinforcement layer (135a, 135b) and the reinforcing layer 151, the adhesive resin layer 401 is formed on the upper and lower surfaces of the polyurethane foam 400, as shown in FIG. The nonwoven fabric reinforcing material 191 is bonded, and an adhesive resin layer 402 is formed on the upper surface of the nonwoven fabric reinforcing material 191 to bond the skin material 403.

The nonwoven fabric reinforcement 191 into which the reinforcing layer 151 obtained by the above process is inserted is adhered to both surfaces of the thermoplastic foam 350 by a conventional bonding process. At this time, since the nonwoven fabric reinforcement 191 obtained by the present invention is treated with adhesive resin on one side, a separate adhesive resin supply device is not needed in the bonding process, and thus, the adhesive resin does not have to be incurred by supplying and replacing the adhesive resin. There is no defect caused by the supply and replacement of.

FIG. 12 is an enlarged photograph of an electron microscope of the surface of the nonwoven fabric reinforcement 191 according to the present invention, showing the fiber reinforcing layers 135a and 135b and the reinforcing layer 151 in which the fibers are combined in multiple layers. FIG. 12 is an enlarged photograph of 350 times to show a fusion state of the fibers of the fiber reinforcement layers 135a and 135b and the low-melt fibers of the reinforcement layer 151.

Fig. 14 shows a cross section of the fiber used as the reinforcing layer 151, which is a 500 times magnification of the electron microscope, and the inside of each fiber is a high melting point resin and the outside is a low melting point resin.

The automotive ceiling substrate manufactured by the present invention compensates for the disadvantages of the existing molding substrate, and uses the unique and creative manufacturing method, which is required at low cost in terms of form stability, heat resistance, flame retardancy, and mass production. It can satisfy the required properties, such as dimensional stability, weight reduction, and can provide a comfortable interior of the car by maintaining a permanent antibacterial performance by mixing antibacterial fibers.

The effect of the present invention is to supply a separate reinforcement layer continuously during the manufacture of the nonwoven fabric reinforcement to combine by any one of needle punching or point sealing process to adhere the nonwoven fabric reinforcement and the reinforcing layer (for example, glass layer) existing Since it does not use a separate adhesive resin layer as in the product, it can reduce the cost, there is no layer separation caused by the adhesive resin after molding, and in the case of the reinforced layer such as glass that is harmful to the human body, it is inserted between the nonwoven reinforcement materials. There is no fear of exposure.

In addition, the nonwoven fabric reinforcement obtained by inserting the reinforcing layer obtained in the present invention does not incur additional costs because the adhesive resin is processed in one step, and a separate adhesive resin is supplied in the process of bonding the nonwoven fabric reinforcement on both sides of the thermoplastic foam. There is no need to supply and replace the adhesive resin because it does not need to be done, and no defects are caused by the supply and replacement of the adhesive resin.

In addition, the fibers used in the nonwoven fabric reinforcement of the present invention is a low-melt polymer (two components are spun at the same time so that the middle portion of the fiber cross-section is a conventional polyester and the outer portion of the fiber cross-section melts at a relatively low temperature) It consists of a high-temperature, high-pressure heat press roll when the contact between all the fibers are melted and adhered to each other, the strength and elasticity is very excellent. On the contrary, the fibers used in the existing nonwoven fabric reinforcement materials are relatively low in strength and elasticity because the low melting point fibers and the high melting point fibers are mixed at a constant ratio, so that the contact areas between the high melting point fibers are not fused during high temperature and high pressure heat treatment.

Therefore, the nonwoven fabric reinforcement obtained in the present invention has various advantages, thereby obtaining a molding material for automobile interior having excellent physical properties, low cost, and flame retardant performance and antibacterial performance.

Claims (15)

In the molding material for automobile interior, By supplying a non-extension reinforcement layer continuously between the fiber reinforcement layer composed of special fiber, flame retardant fiber and antibacterial fiber, combine the fiber reinforcement layer and the fiber layer by any one of needle punching or point sealing, and heat press of high temperature and high pressure Heat-bonding between the rolls, and forming an adhesive resin layer on one side of the nonwoven fabric reinforcement layer, characterized in that the automotive interior molding material. The method according to claim 1, The special fiber constituting the reinforcing layer is the inner nozzle for supplying the low melting point resin and the outer nozzle for supplying the high melting point resin at the same time. The two parts are made of polyester and the middle part of the fiber section is low melt. Molding materials for automobile interiors, characterized in that the bonding portion between the fibers are fused with each other to form a high-strength fiber layer made of a polymer. The method according to claim 1, The reinforcing layer is softened at a temperature of 130 ° C. or higher and stretched to a desired shape during molding, and at 130 ° C. or lower, a filament is formed into a polymer having non-extension characteristics, and the fabric is woven into a mesh shape using the filaments as warp and weft yarns. Automotive interior molding material, characterized in that consisting of a reinforcing layer. The method according to claim 1, Molding for automobile interiors, wherein spunbond nonwoven fabrics in which sheets of one, two or more copolymers of polyester, polypropylene, and nylon fibers are spun into sheets and bonded with a high-temperature, high-pressure press roll as a reinforcing layer materials. The method according to claim 1, The reinforcing layer is an automobile interior molding material, characterized in that consisting of a glass mat. The method according to claim 1, The flame retardant fiber is composed of one or two or more fibers of polyester, polypropylene, viscose rayon, polycral, polyamide, polyvinylchloride mixed with organic and inorganic flame retardants. Automobile interior molding material, characterized in that The method according to claim 1, An automotive interior molding material comprising a nonwoven fabric reinforcing material having a mixing ratio of flame retardant fibers of 5 to 25%. The method according to claim 1, Antimicrobial fiber is composed of one or two or more fibers of polyester, polypropylene, viscose rayon, acetate, polyamide, polyvinylchloride mixed with organic and inorganic antimicrobial agents. An automotive interior molding material. The method according to claim 1, Molding material for automobile interior characterized in that the nonwoven fabric reinforcing material is made of 1 to 5% of the antimicrobial fiber mixing. The fiber feeding step of feeding the fiber from the bale opening device to the fine opening and the fiber aggregating step of agglomerating the fibers in the form of agglomerates in the fine opening device and transferring them to the fiber mixing device. The fiber mixing step of distributing and transferring to the carding machine, the sheet (web) forming step of forming the fiber through the fiber mixing device in the form of a sheet (web) in the carding machine and the sheet stacking step of laminating the sheet supplied through the carding machine In the manufacturing method of the molding material for automobile interior, The reinforcing layer supplying step of continuously supplying the reinforcing layer wound on the upper surface of the fiber reinforcing layer conveyed from the first fiber layer molding machine, and transferring the fiber reinforcing layer formed by the second carding machine to the second fiber layer molding machine to laminate the fiber reinforcing layer on the upper surface of the reinforcing layer. Sheet feeding step, needle punching step of needle punching to combine the fiber reinforcing layer and reinforcing layer, and fusion of the fiber reinforcing layer and reinforcing layer while passing the needle punched fiber reinforcing layer and reinforcing layer through a high temperature and high pressure heat press roll apparatus. Method for manufacturing a molded vehicle interior material, characterized in that consisting of a fusion step. The method according to claim 10, The middle fiber of the fiber cross-section is a polyester, the manufacturing method of the automotive interior molding material, characterized in that the melting point is manufactured at 250 ℃ or more. The method according to claim 10, Needle machine for joining the reinforcing layer inserted between the fiber reinforcement layer is made of 2 to 8, the punching density of the needle is 200 ~ 400st / ㎠, needle penetration depth is characterized in that 3-12mm The manufacturing method of a base material. The method according to claim 10, The press roll temperature of the point seal for bonding the reinforcing layers inserted between the fiber reinforcing layers is 150 to 280 ° C, the roll pressure (linear pressure) is 30 to 100 kN / cm 2, and the sealing area is bonded to the conditions of 10 to 35%. A method of manufacturing a molding material for automobile interior, characterized in that. The method according to claim 10, Under the heat press conditions, the press roll is two to three stages, the roll temperature is 120 to 200 ° C, and the automobile reinforcing layer is characterized in that the fiber reinforcing layer and the reinforcing layer are thermally bonded under the conditions of the roll pressure of 1 to 3 kg / cm 2. Manufacturing method of interior molding material. The method according to claim 10, For the interior of the automobile, the fiber of the outer portion of the reinforcing layer fiber section is one of polyester, polypropylene, polyethylene, nylon, or two or more copolymers, and the melting point is manufactured at 80 to 200 ° C. or more. Manufacturing method of molding base material.