KR100877365B1 - Plate made by combining short fiber and heterogeneous material and its manufacturing method - Google Patents

Plate made by combining short fiber and heterogeneous material and its manufacturing method Download PDF

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Publication number
KR100877365B1
KR100877365B1 KR1020070083863A KR20070083863A KR100877365B1 KR 100877365 B1 KR100877365 B1 KR 100877365B1 KR 1020070083863 A KR1020070083863 A KR 1020070083863A KR 20070083863 A KR20070083863 A KR 20070083863A KR 100877365 B1 KR100877365 B1 KR 100877365B1
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South Korea
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intermediate substrate
substrate layer
plate
sides
release material
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KR1020070083863A
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Korean (ko)
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서연권
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서연권
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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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
    • B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • 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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/008—Sewing, stitching
    • 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
    • B32B2262/0253—Polyolefin fibres
    • 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
    • B32B2262/0276—Polyester fibres
    • B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
    • 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
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B32B2262/065—Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
    • 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
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • 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
    • B32B7/04—Interconnection of layers
    • B32B7/08—Interconnection of layers by mechanical means
    • 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
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/047—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material made of fibres or filaments

Abstract

A method for preparing a panel material combined with monofilament is provided to reduce the harmfulness of a panel material due to the use of a chemical adhesive. A method for preparing a panel material combined with monofilament comprises the steps of molding honeycomb by using a releasing material to make a middle base layer; laminating the monofilament comprising any one chemical fiber selected from polyethylene, polypropylene and polyethylene terephthalate and any one natural fiber selected from hemp, bamboo and coconut fruit on the both sides of the middle base layer; adhering them by needle punching; hot wind drying it at 120-250 deg.C for 2-30 min and surface treating it with a heating roller; and pressing it.

Description

이형소재와 단섬유를 결합한 판재의 제조방법과 그 판재{Plate made by combining short fiber and heterogeneous material and its manufacturing method}Plate made by combining short fiber and heterogeneous material and its manufacturing method

본 발명은 폴리에틸렌(Polyethylene;PE), 폴리프로필렌(Polypropylene:PP), 폴리에틸렌테레프탈레이트(Polyethyleneterephthalate:PET) 중 어느 하나의 화학사와 마, 코코넛, 대나무 중 어느 하나에서 추출한 자연사를 일정비율로 혼합하여 이루어진 단섬유를 지류나 수지재로 성형된 하니콤 형상의 이형소재인 중간기재층의 양면에 적층시켜 단섬유층을 형성하고, 니들펀칭작업에 의해 중간기재층과 양면의 단섬유층을 가접합을 이루게 하여 히팅공정을 통해 일체를 이루게 함으로서, 판재의 중량을 절감하면서도 강도와 흡음성과 차음성 및 강연성등의 조정이 가능한 이형소재와 단섬유를 결합한 판재의 제조방법과 그 판재에 관한 것이다. The present invention is made by mixing a certain ratio of the chemical history of any one of polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET) and the natural history extracted from any one of hemp, coconut, bamboo The short fibers are laminated on both sides of the intermediate substrate layer, which is a honeycomb-shaped release material molded of paper or resin, to form a short fiber layer, and the intermediate substrate layer and both sides of the short fiber layer are temporarily bonded by needle punching. By forming a unit through the heating process, while reducing the weight of the plate and the strength and sound-absorbing, sound insulation and ductility, and the like and a plate manufacturing method of the plate combined with a short fiber combined with a short fiber.

일반적으로 하니콤 형상의 이형소재를 이용한 판재는 다양하게 개발되어 사용되고 있는 실정으로, 여기서 하니콤 형상에 대해 설명하면 벌집모양의 구조체를 지칭하는 것으로, 최근 들어서는 벌집모양의 육면체 기둥 외에도 사각형(다이아몬드형)기둥, 또는 삼각형 기둥(이하 "이형소재" 이라고 통칭한다)을 이루고 있으며, 이형소재의 재질은 대부분 지류로 이루어졌으나 최근 들어서는 수지재를 이용하여 사출 성형되면서 이형소재의 단면형상이 다양하게 개발되고 있다.Generally, a plate using a honeycomb-shaped release material has been developed and used in various ways. When the honeycomb shape is described here, it refers to a honeycomb-shaped structure, and recently, in addition to a honeycomb-shaped cube, a square (diamond type) ) Or triangular pillar (hereinafter referred to as "release material"), and the material of the release material is mostly made of tributary, but recently, the cross-sectional shape of the release material is variously developed by injection molding using resin material. have.

상기와 같은 이형소재을 이용한 판재의 구조는 이형소재의 양면에 목재인 합판 또는 금속재인 패널이 부착되어 하나의 판재를 이루고 있으며, 이러한 판재는 내부에 설치되어 있는 이형소재에 의해 외력에 의한 지지강성이 높을 뿐만 아니라, 이형소재에 의해 형성된 공간에 의해 열전도 차단율이 우수하여 단열성과 경량성이 뛰어나므로 건축자재를 비롯한 산업 전반에 걸쳐 다양한 용도로 사용되고 있다.The structure of the plate using the release material as described above is a panel of wood or plywood or metal material is attached to both sides of the release material to form a single plate, the plate material is supported by the external force by the release material installed inside In addition to the high heat shielding rate is excellent due to the space formed by the release material is excellent in heat insulation and light weight has been used in various applications throughout the industry, including building materials.

그러나, 상기 이형소재를 이용한 판재는 전술한 바와 같이 이형소재의 양면에 부착되는 재질이 목재이거나 금속재가 부착되어 하나의 판재를 이룸으로서, 건축용 내장재나 일정한 공간을 구분하기 위한 칸막이용 벽체로 사용하는데 적합하였으나, 이형소재의 양면에 목재나 금속재의 패널이 부착됨으로서 흡음성과 차음성이 떨어지는 문제점이 있었다.However, as described above, the plate using the release material is made of wood or metal attached to both surfaces of the release material to form a single plate, and used as a partition wall for partitioning a building interior material or a predetermined space. Although it is suitable, there is a problem in that sound absorption and sound insulation are inferior as the panel of wood or metal is attached to both sides of the release material.

또한, 이형소재의 양측면에 부착되는 목재나 금속재인 패널은 경질의 소재로서 형상변형이 곤란하여 곡면을 이루는 면에는 사용하지 못하는 문제점과 이형소재와 양측면에 부착되는 패널이 화학접착제 또는 밴딩공정에 의해 일체를 이룸으로서 화학접착제에 의해 발생되는 환경오염물질로 인해 생활환경을 해치는 문제점이 있었다.In addition, the panel, which is a wood or metal material attached to both sides of the release material, is a hard material, and it is difficult to change the shape and thus cannot be used on a curved surface, and the release material and the panel attached to both sides are chemically adhesive or banded. As a result, there was a problem of harming the living environment due to environmental pollutants generated by chemical adhesives.

이에 본 발명은 상기와 같이 이형소재를 이용한 판재의 문제점을 개선하기 위하여 발명한 것으로서, 폴리에틸렌(Polyethylene;PE), 폴리프로필렌(Polypropylene:PP), 폴리에틸렌테레프탈레이트(Polyethyleneterephthalate:PET) 중 어느 하나의 폴리계 화학사와 마, 코코넛열매, 대나무 중 어느 하나에서 추출한 자연사를 일정비율로 혼합하여 이루어진 단섬유를 지류나 수지재로 성형된 하니콤 형상의 이형소재인 중간기재층의 양면에 적층시켜 니들펀칭작업에 의해 가접합을 이루게 하고, 이어서 히팅공정을 통해 일체를 이루게 함으로서, 판재의 중량을 절감하면서도 강도와 흡음성과 차음성 및 강연성등의 조정이 가능한 이형소재와 단섬유를 결합한 판재의 제조방법과 그 판재를 제공하는데 목적이 있다.Therefore, the present invention is invented to improve the problems of the plate using the release material as described above, any one of polyethylene (Polyethylene; PE), polypropylene (Polypropylene: PP), polyethylene terephthalate (Polyethyleneterephthalate: PET) Needle punching work by laminating short fibers made by mixing natural yarns extracted from any one of system chemical yarns, hemp, coconut fruit and bamboo on both sides of an intermediate substrate layer of honeycomb-shaped release material molded from paper or resin By forming a temporary joint, and then forming a unit through a heating process to reduce the weight of the plate, and to control the strength, sound absorption, sound insulation and ductility, and the like, and a method of manufacturing a plate that combines short fibers The purpose is to provide the board.

상기와 같은 목적을 달성하기 위하여 본 발명은 평단면상 다각형을 이루고 있는 하니콤을 이형소재로 성형하여 이루어지는 중간기재층 성형공정과; 상기 중간기재층의 양면에 폴리에틸렌(Polyethylene;PE), 폴리프로필렌(Polypropylene:PP), 폴리에틸렌테레프탈레이트(Polyethyleneterephthalate:PET) 중 어느 하나의 폴리계의 화학사와 마, 대나무, 코코넛열매 중 어느 하나에서 추출된 천연사를 6:4~4:6으로 혼합한 단섬유를 적층시키는 단섬유층 적층공정과; 상기 적층공정을 거친 단섬유를 포함한 중간기재층을 니들펀칭작업에 의해 단섬유를 교락(트러스 형상으로 심는 상태)시켜 가접합을 이루게 하는 판재가접합공정과; 판재가접합공정을 거친 단섬유를 포함한 중간기재층에 120℃∼250℃로 2분내지 30분간 히팅가열하는 히팅공정을 거처 프레스가공에 의해 제조되는 이형소재의 양면에 단섬유를 결합한 판재의 제조방법을 특징으로 한다.In order to achieve the above object, the present invention is an intermediate substrate layer forming process formed by molding a honeycomb constituting a polygon on a planar cross-section with a release material; Extracted from any one of poly-based chemical yarns, hemp, bamboo and coconut fruit on both sides of the intermediate substrate layer of polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET) A short fiber layer lamination step of laminating the short fibers obtained by mixing the natural yarns 6: 4 to 4: 6; A plate joining step of forming an intermediate substrate layer including the short fibers having undergone the lamination process by needle punching to entangle the short fibers (planted in a truss shape) to form a temporary joint; Manufacture of sheet material in which short fibers are bonded to both sides of the release material produced by pressing through a heating process in which the heating is heated at 120 ° C to 250 ° C for 2 to 30 minutes in an intermediate substrate layer including the short fibers which have undergone the bonding process. Method.

상기와 같은 제조방법을 통해 평단면상 다각형을 이루고 있는 하니콤을 이형소재로 성형하여 이루어진 중간기재층의 양면에 폴리계의 화학섬유와 마, 대나무, 코코넛열매 중 어느 하나에서 추출된 천연섬유를 6:4∼4:6으로 혼합한 단섬유층을 형성하고, 중간기재층을 포함한 단섬유층을 니들펀칭에 의해 단섬유가 교락상태를 이루게 하며 120℃∼250℃로 2분내지 30분간 히팅가열하여 프레스가공에 의해 일체를 이루는 구조를 특징으로 한다.Through the manufacturing method as described above, the natural fibers extracted from any one of poly-based chemical fibers and hemp, bamboo and coconut fruit on both sides of the intermediate substrate layer formed by forming a honeycomb forming a polygon on a flat cross-section with a release material. Form a short fiber layer mixed with: 4 to 4: 6, and short fiber layer including the intermediate base layer to form a entangled state by needle punching, heating and heating for 2 minutes to 30 minutes at 120 ℃ to 250 ℃ press It is characterized by a structure that is integrated by processing.

상기와 같은 제조방법을 통해 이형소재인 중간기재층의 양면에 폴리에틸렌(Polyethylene;PE), 폴리프로필렌(Polypropylene:PP), 폴리에틸렌테레프탈레이트(Polyethyleneterephthalate:PET) 중 어느 하나의 폴리계의 화학사와 마, 대나무, 코코넛열매 중 어느 하나에서 추출된 천연사를 6:4~4:6으로 혼합한 단섬유를 적층시켜 단섬유층을 형성한 후, 니들펀칭에 의해 중간기재층에 단섬유를 교락(트러스형태로 단섬유를 심은 상태)시켜 열풍과 히팅로울러를 거쳐 프레스가공에 의해 일체를 이루는 판재를 제작함으로서, 종래와 같은 화학접착제에 의한 판재의 유해성을 해소하는 효과와, 이형소재의 양면에 부착된 단섬유에 의해 흡음성과 차음성을 확보할 수 있는 효과가 있다.E. The chemical company of any one of poly-based of polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET) on both sides of the intermediate material layer of the release material through the manufacturing method as described above, After stacking the short fibers in which the natural yarns extracted from any one of bamboo and coconut fruit are mixed at 6: 4 to 4: 6, to form a short fiber layer, intertwine the short fibers in the intermediate substrate layer by needle punching (truss type) The short fiber is planted) to produce a plate that is integrally formed by press processing through hot air and a heating roller, thereby eliminating the harmfulness of the plate material by a chemical adhesive as in the past, and attaching to both sides of the release material. The fiber has the effect of ensuring sound absorption and sound insulation.

또한, 단섬유의 구성요소인 화학사를 저융점사를 30%~40%를 혼합할 경우에는 판재의 강도를 임의적으로 조정할 수 있으며, 특히 완성된 판재의 양면에 일반직물이나 석고, 시멘트·세라믹 도료, 난연도료를 도포하여 차량용 또는 건축용 내장재로 사용할 수 있는 효과가 있다.In addition, when mixing 30% to 40% of low-melting point yarn and chemical yarn, which is a constituent of short fibers, the strength of the plate can be arbitrarily adjusted.In particular, general fabric, gypsum, cement and ceramic paints on both sides of the finished plate. , By applying flame retardant paints can be used as interior materials for vehicles or buildings.

이하 본 발명을 첨부된 예시도를 참고로 하여 보다 구체적으로 설명하면 다음과 같다.Hereinafter, the present invention will be described in more detail with reference to the accompanying drawings.

예시도 1은 본 발명에 따른 이형소재를 이용한 판재의 제조공정도이고, 예시도 2의 (a)(b)는 본 발명에 따른 제조방법에 의해 제작된 판재의 일예를 나타낸 사시도이며, 예시도 3의 (a)(b)는 본 발명에 따른 제조방법에 의해 제작된 판재의 단면도로서, (a)는 니들펀칭에 의해 가접합을 이루고 있는 상태에서 프레스 압력을 가하는 상태의 단면도, (b)는 프레스 압력에 의해 단섬유층이 압착된 상태의 단면도이다.Exemplary Figure 1 is a manufacturing process diagram of a plate using a release material according to the present invention, Exemplary Figure 2 (a) (b) is a perspective view showing an example of a plate produced by the manufacturing method according to the present invention, Exemplary Figure 3 (A) (b) is a cross-sectional view of the plate material produced by the manufacturing method according to the present invention, (a) is a cross-sectional view of a state in which the press pressure is applied in the temporary bonding state by the needle punching, (b) It is sectional drawing of the state which the short fiber layer was crimped by the press pressure.

상기 예시도에 표현된 바와 같이, 본 발명의 성형공정(1)은 평단면상 다각형을 이루고 있는 하니콤을 이형소재로 성형하여 이루어진 중간기재층(10)을 성형하고, 상기 적층공정(2)은 중간기재층(10)의 양면에 화학사와 천연사가 4:6~6:4로 혼합된 단섬유(14)로 이루어진 단섬유층(12)을 적층시키되, 상기 화학사는 폴리에틸렌 또는 폴리프로필렌 또는 폴리에틸렌테레프탈레이트 원사중 어느 하나의 원사이고, 천연사는 마 또는 코코넛열매 또는 대나무 중 어느 하나에서 추출한 섬유질의 원사이다.As shown in the exemplary diagram, the molding step (1) of the present invention is to form the intermediate substrate layer (10) formed by molding a honeycomb constituting a polygon on a planar cross-section with a release material, the lamination step (2) On both sides of the intermediate substrate layer 10 is laminated a short fiber layer 12 made of short fibers 14 mixed with chemical yarns and natural yarns 4: 6-6: 4, wherein the chemical yarns are polyethylene or polypropylene or polyethylene terephthalate The yarn of any one of the yarns, the natural yarn is a fibrous yarn extracted from either hemp or coconut fruit or bamboo.

상기와 같이 중간기재층(10)의 양면에 단섬유층(12)을 적층시킨 상태에서 가접합공정(3)을 거치게 되는데 이를 구체적으로 설명하면, 중간기재층(10)의 양면(도면상 상면과 하면)에 적층된 단섬유층(12)에 니들펀칭을 하게 되면, 중간기재층(10)의 양면에 적층되어 있는 단섬유층(12)의 단섬유(14)들이 트러스형태로 중간 기재층(10)의 공간을 통해 심어지게 되어 중간기재층(10)과 양면의 단섬유층(12)은 가접합을 이루게 된다.As described above, in the state in which the short fiber layer 12 is laminated on both sides of the intermediate substrate layer 10, the temporary bonding process 3 is carried out. Specifically, both surfaces of the intermediate substrate layer 10 (upper surface and When needle punching is performed on the short fiber layer 12 stacked on the lower surface), the short fibers 14 of the short fiber layer 12 stacked on both sides of the intermediate substrate layer 10 are in the form of trusses. It is planted through the space of the intermediate substrate layer 10 and the short-fiber layer 12 of both sides to form a temporary joint.

상기과 같이 가접합공정(3)을 거친 중간기재층(10)과 양면의 단섬유층(12)이 히팅공정(4)을 거치게 되는데, 상기 히팅공정(4)은 중간기재층(10)의 양면에 단섬유층(12)이 가접합을 이룬 상태에서 120℃∼250℃로 2분 내지 30분간 열풍건조를 시키면, 중간기재층(10)의 공간을 통해 심어진 단섬유(14)가 열에 의해 유용되어 주변의 단섬유(14)와 일체를 이루게 된다.As described above, the intermediate substrate layer 10 and the double-sided short fiber layer 12 that have undergone the temporary bonding process 3 are subjected to the heating process 4, and the heating process 4 is formed on both sides of the intermediate substrate layer 10. When hot-air drying is carried out at 120 ° C to 250 ° C for 2 to 30 minutes while the short fiber layer 12 is temporarily bonded, the short fiber 14 planted through the space of the intermediate base layer 10 is useful due to heat. It becomes integral with the short fiber 14 of.

여기서, 단섬유층(12)을 이루고 있는 화학사에 저융점원사를 혼합하게 되는데, 상기 저융점원사는 원사소재에 따라 용융점이 차이가 있으며, 이러한 용융점 차이를 이용하여 일정시간 열을 가하면 상대적으로 용융점이 낮은 원사가 용융되면서 주변의 원사와 결합을 이루게 되고, 이러한 상태에서 히팅로울러를 거치게 되면, 단섬유층(12)의 표면이 면처리 됨은 물론 내부의 원사들이 서로 엉키면서 일체를 이루게 되어 하나의 판재를 이루게 된다.Here, the low-melting point yarn is mixed with the chemical yarn forming the short fiber layer 12. The low-melting point yarn has a different melting point depending on the material of the yarn. When the low yarn is melted to form a bond with the surrounding yarn, and through the heating roller in this state, the surface of the short-fiber layer 12, as well as the surface of the yarn is tangled with each other to form a single plate Is achieved.

이와 같이 히팅공정(4)을 거친 판재는 프레스가공공정(5)을 거치게 되는데 상기 판재의 양면을 이루고 있는 단섬유층(12)이 열풍건조와 히팅로울러에 의해 유연성을 지닌 상태에서 냉각기능을 갖춘 판재형상의 금형에 넣어 압력을 가하게 되면 중간기재층(10)에는 변형이 없으나 중간기재층(10)의 양면을 이루고 있는 단섬유층(12)은 가해지는 압력에 의해 압축되면서 냉각되어 하나의 판재가 완성된다.As such, the plate that has undergone the heating process (4) is subjected to a press working process (5), and the sheet fiber having a cooling function in a state in which the short fiber layer 12 forming both sides of the plate has flexibility by hot air drying and a heating roller. When the pressure is applied to the mold, there is no deformation in the intermediate base layer 10, but the short fiber layer 12 forming both sides of the intermediate base layer 10 is compressed and cooled by the applied pressure to complete one plate. do.

상기와 같이 제조된 판재는 중간기재층(10)을 이루고 있는 이형소재의 두께에 따라 판재의 두께를 임의적으로 조정할 수 있어 판재의 성형성을 확보할 수 있 는데, 이를 보다 구체적으로 설명하면 현재 이형소재인 하니콤의 두께는 1㎜∼100㎜까지 다양하게 제조되어 유통되고 있으므로 중간기재층(10)을 이루는 이형소재의 두께가 얇으면 얇을수록 완성된 판재의 성형성이 확보된다.Plate manufactured as described above can be arbitrarily adjusted the thickness of the plate according to the thickness of the release material constituting the intermediate substrate layer 10 to ensure the formability of the plate, more specifically, the present release Since the thickness of the honeycomb, which is a raw material, is variously manufactured and distributed from 1 mm to 100 mm, the thinner the thickness of the release material constituting the intermediate substrate layer 10, the thinner the moldability of the finished plate is secured.

따라서 곡면에 본 발명에 따른 판재를 부착하고자 할 경우에는 중간기재층(10)의 두께를 얇은 것(10㎜이하)을 선택하여 프레스가공공정(5)을 거치게 되면 일정한 형상을 이루는 판재의 제작도 가능하다.Therefore, when the plate according to the present invention is to be attached to the curved surface, the thickness of the intermediate substrate 10 (10 mm or less) is selected to go through the press working process (5) to produce a plate of a certain shape It is possible.

상기와 같이 제작된 본 발명에 따른 판재는 중간기재층(10)의 양면에 단섬유층(12)을 이루고 있으므로 흡음성과 차음성이 뛰어나고, 특히 중간기재층(10)과 양면을 이루고 있는 단섬유층(12)이 화학접착제에 의한 결합이 아니라 단섬유간의 결합으로 일체를 이루고 있으므로 친환경적인 판재를 얻을 수 있고, 또한 기존의 하니콤을 이용한 판재보다 경량화를 이루면서도 강연성을 갖춤으로서 자동차내장재, 물품포장재, 건축내장재 등 산업전반에 걸쳐 보다 폭넓게 사용이 가능하다.The plate according to the present invention manufactured as described above has a single fiber layer 12 on both sides of the intermediate substrate layer 10, so it is excellent in sound absorption and sound insulation, in particular a single fiber layer forming both sides with the intermediate substrate layer 10 ( 12) Because it is integrated with short fibers instead of bonding with chemical adhesives, it is possible to obtain eco-friendly plates, and it is also lighter than conventional honeycomb plates, and has stiffness. It can be used more widely throughout the industry such as building interior materials.

특히, 상기 본 발명에 따른 판재를 제조하는데 있어, 히팅공정을 거친 판재의 표면에 일반직물을 덧씌우거나, 석고·시멘트·세라믹·난연도료 등을 도포하고, 프레스가공공정을 거쳐 완성된 판재의 사용 용도는 산업전반에 걸쳐 보다 폭넓게 사용할 수 있다.In particular, in the manufacture of the plate according to the present invention, the surface of the plate subjected to the heating process, the general fabric, or coated with gypsum, cement, ceramics, flame retardant paint, etc., the use of the plate finished through the press working process Applications can be used more widely throughout the industry.

도 1 은 본 발명에 따른 이형소재를 이용한 판재의 제조공정도이고, 1 is a manufacturing process of the plate using the release material according to the invention,

도 2의 (a)(b)는 본 발명에 따른 제조방법에 의해 제작된 판재의 일 예를 나 타낸 사시도이며, Figure 2 (a) (b) is a perspective view showing an example of a plate produced by the manufacturing method according to the present invention,

도 3의 (a)(b)는 본 발명에 따른 제조방법에 의해 제작된 판재의 단면도로 서, Figure 3 (a) (b) is a cross-sectional view of the plate produced by the manufacturing method according to the present invention,

(a)는 니들펀칭에 의해 가접합을 이루고 있는 상태에서 프레스 압력을 가하 는 상태의 단면도, (a) is a cross-sectional view of a state in which press pressure is applied in the temporary bonding state by needle punching,

(b)는 프레스 압력에 의해 단섬유층이 압착된 상태의 단면도이다.(b) is sectional drawing in which the short fiber layer was crimped | bonded by the press pressure.

<도면의 주요 부분에 대한 부호의 설명><Explanation of symbols for the main parts of the drawings>

1 - 성형공정, 2 - 적층공정,1-forming process, 2-lamination process,

3 - 가접합공정, 4 - 히팅공정,3-provisional bonding process, 4-heating process,

5 - 프레스가공공정,5-press processing process,

10 - 중간기재층, 12 - 단섬유층,10-intermediate layer, 12-short fiber layer,

14 - 단섬유.14-short fibers.

Claims (2)

평단면상 다각형을 이루고 있는 하니콤을 이형소재로 성형하여 이루어지는 중간기재층 성형공정(1)과; An intermediate substrate layer forming step (1) formed by molding a honeycomb constituting a polygon on a planar cross section with a release material; 상기 중간기재층의 양면에 폴리에틸렌(Polyethylene;PE), 폴리프로필렌(Polypropylene:PP), 폴리에틸렌테레프탈레이트(Polyethyleneterephthalate:PET) 중 어느 하나의 폴리계 화학섬유와 마, 대나무, 코코넛열매 중 어느 하나에서 추출된 천연섬유를 6:4~4:6으로 혼합한 단섬유를 적층시키는 적층공정(2)과; Extracted from any one of poly-based chemical fibers of any one of polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET) and hemp, bamboo, coconut fruit on both sides of the intermediate substrate layer A lamination step (2) of laminating the short fibers obtained by mixing the natural fibers in a ratio of 6: 4 to 4: 6; 상기 적층공정을 거친 단섬유를 포함한 중간기재층을 니들펀칭작업에 의해 단섬유를 교락(트러스 형상으로 심는 상태)시켜 가접합을 이루게 하는 판재 가접합공정(3)과;A plate preliminary joining step (3) of interlacing the short fibers (a state of being planted in a truss shape) by needle punching the intermediate substrate layer including the short fibers having undergone the lamination process to form a temporary joint; 상기 판재 가성형공정을 거친 단섬유를 포함한 중간기재층에 120℃∼250℃로 2분내지 30분간 열풍건조시키고 히팅로울러로 표면처리하는 히팅공정(4)과;A heating step (4) of performing hot-air drying at 120 ° C. to 250 ° C. for 2 to 30 minutes on the intermediate substrate layer including the short fiber which has undergone the sheet forming process and surface-treating with a heating roller; 상기 히팅공정을 거친 판재를 냉각기능을 갖춘 프레스금형에 넣어 일정압력을 가하는 프레스가공공정(5)을 포함하는 것을 특징으로 하는 이형소재의 양면에 단섬유를 결합한 판재의 제조방법. And a press working step (5) of applying a predetermined pressure to the plate which has been subjected to the heating process into a press mold having a cooling function, and combining short fibers on both sides of the release material. 삭제delete
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CN113059815A (en) * 2021-03-23 2021-07-02 南通大学 Preparation method of novel flame-retardant, heat-insulating and sound-absorbing composite material
CN113142894A (en) * 2021-05-14 2021-07-23 山西鑫隆植物纤维科技有限公司 Composite board honeycomb mattress and manufacturing method thereof

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JPH0664076A (en) * 1992-08-20 1994-03-08 Tonen Corp Composite plate material and its manufacture
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CN102644333A (en) * 2012-04-20 2012-08-22 上海捷成企业管理集团有限公司 Honeycomb material made of bamboos
CN113059815A (en) * 2021-03-23 2021-07-02 南通大学 Preparation method of novel flame-retardant, heat-insulating and sound-absorbing composite material
CN113142894A (en) * 2021-05-14 2021-07-23 山西鑫隆植物纤维科技有限公司 Composite board honeycomb mattress and manufacturing method thereof

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