KR101619977B1 - Eco-friendly lightweight base material for automotive interior with improved resistance to humidity - Google Patents
Eco-friendly lightweight base material for automotive interior with improved resistance to humidity Download PDFInfo
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- KR101619977B1 KR101619977B1 KR1020140103366A KR20140103366A KR101619977B1 KR 101619977 B1 KR101619977 B1 KR 101619977B1 KR 1020140103366 A KR1020140103366 A KR 1020140103366A KR 20140103366 A KR20140103366 A KR 20140103366A KR 101619977 B1 KR101619977 B1 KR 101619977B1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/28—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer impregnated with or embedded in a plastic substance
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—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
- B32B5/024—Woven fabric
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/32—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed at least two layers being foamed and next to each other
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
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Abstract
본 발명은 자동차용 내장재용 친환경 경량기재에 관한 것으로서, 고온다습한 환경에 취약한 천연섬유를 포함하는 샌드위치 구조의 자동차 내장재용 기재의 성능 보완을 위해 수분경화형 이소시아네이트 또는 에폭시를 첨가하여, 천연섬유의 수분침투에 의한 물성저하를 보완하여 천연섬유 보강층의 내습성과 강도를 개선하고, 열가소성 발포시트 심재층에 열라미네이션을 이용하여 연속적으로 기재가 제조되는 것을 특징으로 한다. 본 발명에 의해 제조된 기재는 친환경 소재이며, 중량절감에 의한 경량화가 가능하면서 내습성과 강도가 우수하여 자동차 내장재 뿐만 아니라 철도, 항공기 및 건축용 내장재 같은 다양한 산업분야에 응용될 수 있다.The present invention relates to an environmentally friendly lightweight substrate for an automobile interior material, and in order to supplement the performance of a substrate for a car interior material having a sandwich structure containing natural fibers susceptible to high temperature and high humidity environment, a moisture curing type isocyanate or epoxy is added, It is possible to improve the moisture resistance and strength of the natural fiber reinforcing layer by complementing the lowering of physical properties due to penetration and to continuously produce the base material by using thermal lamination on the thermoplastic foam sheet core layer. The base material produced by the present invention is an eco-friendly material and can be reduced in weight by weight reduction, and is excellent in moisture resistance and strength, and can be applied not only to automobile interior materials but also to various industrial fields such as railroad, aircraft, and architectural interior materials.
Description
본 발명은 자동차용 친환경 경량기재에 관한 것으로서, 더욱 상세하게는 고온다습한 환경에 취약한 천연섬유를 포함하는 샌드위치 구조의 자동차 내장재용 기재의 내습성 및 강도 향상을 위해, 수분경화형 이소시아네이트를 천연섬유 보강층에 첨가하여 경화반응을 진행하고, 시트형태로 제조한 후 열가소성 발포시트에 열라미네이션공정을 통해 연속적으로 제조한, 내습성이 강화된 자동차 내장재용 친환경 경량기재 및 그 제조방법에 관한 것이다.The present invention relates to an environmentally friendly light weight base material for automobiles, and more particularly, to a base material for automobile interior materials having a sandwich structure containing natural fibers susceptible to high temperature and high humidity environment, To an environmentally lightweight automotive interior material reinforced with moisture resistance, which is produced continuously in a sheet form and then continuously formed on a thermoplastic foam sheet through a thermal lamination process, and a production method thereof.
자동차 내장용 기재는 승객과 직접 부딪히는 자동차 부품으로서, 수많은 부품들이 조립되어 형태를 유지하며 승객을 외부환경으로부터 보호하는 역할을 수행하고 있기 때문에 다양한 온도 및 습도의 외부환경에서 치수안정성과 물성이 유지 되어야 한다. 또한 최근에는 환경오염과 지구온난화 같은 문제로 인해서 친환경 소재의 사용과 연비 향상을 위한 경량화도 추가적으로 요구되고 있다.The automotive interior base material is an automobile part that directly hits the passenger, and since many parts are assembled to maintain the shape and protect the passenger from the external environment, dimensional stability and physical properties should be maintained in various environments of various temperature and humidity do. In addition, recently, due to problems such as environmental pollution and global warming, the use of environmentally friendly materials and weight reduction for improving the fuel efficiency are additionally required.
일반적으로 자동차 내장재용 기재는 주로 형태안정성을 부여하는 보강층(10)이 흡음성을 부여하는 심재층(20)의 일면 또는 양면에 적층된 샌드위치 구조로 되는 기재(30)으로 되어 있는데, 종래에는 유리섬유펠트에 열경화성 페놀수지를 함침된 보강층과 폴리우레탄 발포시트를 심재층으로 주로 사용하여 왔다. Generally, the base material for the automobile interior material is a base material 30 having a sandwich structure in which the reinforcing layer 10 imparting shape stability is laminated on one surface or both surfaces of the core material layer 20 that imparts sound- A reinforcing layer impregnated with a thermosetting phenolic resin and a polyurethane foam sheet have been mainly used as a core layer.
하지만 보강층에 사용되는 유리섬유 펠트는 제조시 발생하는 분진이 작업자의 인체에 유해하고, 자연환경에서 거의 분해가 되지 않아 폐기물이 환경오염을 초래하는 문제점을 가지고 있으며, 바인더로 사용되는 페놀수지 또한 자연환경에서 분해가 거의 되지 않고 재활용도 어렵기 때문에 친환경적이지 못하다. 뿐만 아니라 이들 소재의 밀도가 높기 때문에 자동차 부품에 적용시 중량이 증가하여 연비가 감소할 수 있는 단점도 가지고 있다. 또한 심재층에 사용되는 폴리우레탄 발포시트는 열에 녹지 않기 때문에 보강층 적층시 접착제를 도포하거나 핫멜트 필름을 적용하는 추가공정이 필요하기 때문에 공정이 복잡하고 비용이 증가하는 문제를 가지고 있다.However, the glass fiber felt used in the reinforcing layer has a problem that the dust generated in the manufacturing process is harmful to the human body of the operator and is hardly decomposed in the natural environment, causing the waste to pollute the environment, and the phenol resin used as the binder is also natural It is not environmentally friendly because it is hardly decomposed and recycled in the environment. In addition, since the density of these materials is high, there is a disadvantage in that the weight is increased when applied to an automobile part, resulting in a decrease in fuel consumption. In addition, since the polyurethane foam sheet used for the core layer does not dissolve in heat, an additional step of applying an adhesive or applying a hot-melt film to the laminate of the reinforcing layer is required, which complicates the process and increases the cost.
최근에는 상기 기술한 문제를 해결하기 위해서 천연섬유를 보강층으로 사용하고 열가소성 발포시트를 심재층으로 사용하여 상온에서 사용시 기재의 경량화와 친환경화인 부분에서 우수함을 나타냈으나, 수분에 취약한 천연섬유의 단점으로 인해서 고온 다습한 환경에서 기재가 뒤틀리거나 처짐현상이 발생하여 형태안정성에 대한 문제점이 발생하였다. In recent years, in order to solve the above-mentioned problems, it has been shown that natural fiber is used as a reinforcing layer and thermoplastic foam sheet is used as a core layer, which is excellent in light weight and environment friendly part when used at room temperature. However, , The substrate was warped or sagged in a high temperature and high humidity environment, resulting in a problem of the morphological stability.
따라서 이러한 문제를 해결하고자 전자빔 조사, 플라즈마 조사, 알칼리처리 및 실란처리 같은 다양한 물리화학적 방법으로 천연섬유의 수분에 대한 저항성을 높이기 위한 많은 전처리 방법에 대한 연구가 진행되어 왔지만 전처리를 위한 공정설치비용이 고가이며 추가적인 가공시간이 요구되어 산업적인 부분에 응용이 제한되고 있다.Therefore, in order to solve this problem, many pretreatment methods have been studied to increase the moisture resistance of natural fibers by various physicochemical methods such as electron beam irradiation, plasma irradiation, alkali treatment and silane treatment. However, It is expensive and requires additional processing time, which limits its application to industrial parts.
한편, 메틸렌 디페닐 디이소시아네이트(Methylenediphenyl diisocyanate) (MDI) 또는 톨루엔 디이소시아네이트(toluene diisocyanate)(TDI)는 하이드록실(hydroxyl) 그룹 또는 카르복실(carboxyl) 그룹과의 반응성이 우수하여 우레탄 결합을 쉽게 형성할 수 있는 커플링제(coupling agent)로 알려져 있다. 이들은 액상접착물질로 건축 내장재 등의 제조시 재료들과 처음부터 혼합된 것을 가열가압하여 판재화하는 식으로 사용되거나, 폴리올과 혼합하고 아민으로 중화하여 최종적으로 폴리우레탄 코팅을 형성하기 위해 사용되는 것이 알려져 있다. 그러나 이들 기술은 공정이 번거럽고 연속작업이 불가능하며, 추가적인 설비가 많이 필요하기 때문에 공정비용이 증가하는 단점을 가지고 있다.On the other hand, methylene diphenyl diisocyanate (Methylenediphenyl diisocyanate) (MDI) or toluene diisocyanate (toluene diisocyanate) (TDI) are hydroxyl (hydroxyl) group or a carboxylic acid (carboxyl) and the reactivity of the group excellent easy a urethane bond formed Which is known as a coupling agent. These are liquid adhesive materials which are used to form a polyurethane coating by mixing with a polyol and neutralizing with an amine to form a polyurethane coating. It is known. However, these techniques have disadvantages in that the process cost is increased because the process is troublesome and the continuous operation is impossible, and the additional equipment is required.
본 발명은 상술한 바와 같이 기존의 천연섬유를 포함하는 샌드위치 구조의 자동차 내장재용 기재가 가지는 고온다습한 환경에서의 처짐현상 및 물성저하를 해결하기 위한 것으로서, 이소시아네이트 또는 에폭시를 사용하여 천연섬유 보강층의 내습성과 강도를 개선하며, 이를 통해 기재의 처짐 및 물성의 저하를 개선하고, 경량성이 우수한 자동차 내장재용 기재의 제조방법을 제공하는 것을 목적으로 한다.As described above, the present invention is to solve the sagging phenomenon and the deterioration of physical properties in a high temperature and high humidity environment of a base material for automobile interior materials having a sandwich structure including existing natural fibers, and it is an object of the present invention to provide a natural fiber- It is an object of the present invention to provide a method for manufacturing a base material for an automobile interior material which is improved in moisture resistance and strength, thereby improving deflection and physical properties of the base material, and having excellent lightweight properties.
본 발명은 천연섬유와 합성섬유로 구성된 펠트에 이소시아네이트를 도포하여 내습성이 개선된 박막 보강층을 제조하고, 열가소성 발포시트에 연속적으로 열라미네이션하여, 친환경재료를 사용하면서 내습성과 경량성이 우수한 자동차 내장재용 기재 제조방법을 제공하는데 목적이 있다.The present invention relates to a method for producing a thin film reinforcing layer having improved moisture resistance by applying isocyanate to a felt composed of natural fibers and synthetic fibers and continuously laminating the laminate to a thermoplastic foam sheet to form an automobile interior material The present invention provides a method for manufacturing a substrate for a substrate.
상기 과제를 달성하기 위해서, 본 발명은 천연섬유와 합성섬유로 펠트를 제조하는 제 1단계; 상기 펠트에 액상 이소시아네이트 또는 에폭시를 도포 후 열간 압착롤러를 통해 반경화반응을 진행하여 시트를 제조하는 제 2단계; 상기 시트에 열가소성 고분자 파우더를 도포한 후 열간오븐을 통과하여 열가소성 고분자 파우더 층 형성 및 경화반응을 완료하고 압착롤러를 통해 박막 보강층을 제조하는 제 3단계; 상기 제작된 박막 보강층이 열가소성 발포시트로 이루어진 심재층의 일면 혹은 양면에 열라미네이션 공정을 통해 연속적으로 적층되어 기재가 제작되는 4단계를 포함하는 것을 특징으로 하는 내습성이 강화된 자동차 내장재용 친환경 경량기재를 제조하는 방법을 제공한다. In order to accomplish the above object, the present invention provides a method for producing a felt, comprising: a first step of producing a felt from natural fibers and synthetic fibers; A second step of applying a liquid isocyanate or epoxy to the felt and then performing a semi-curing reaction through a hot press roller to produce a sheet; A third step of applying a thermoplastic polymer powder to the sheet, passing the thermoplastic polymer powder through a hot oven to complete a thermoplastic polymer powder layer formation and curing reaction, and manufacturing a thin film reinforcing layer through a pressing roller; Wherein the thin film reinforcing layer is continuously laminated on one side or both sides of a core layer made of a thermoplastic foam sheet through a thermal lamination process to produce a substrate. A method for producing a substrate is provided.
또한, 본 발명은 천연섬유와 합성섬유를 카딩을 통해 혼합하고, 웹포밍과 니들펀칭 공정을 통해 펠트를 제작하는 제 1단계; 상기 펠트에 이소시아네이트 또는 에폭시를 도포 또는 함침하여 150℃ 내지 250℃의 열간 압착롤러를 통해 반경화상태로 성형 후 압착하여 시트로 제조하는 제 2단계; 및 상기 시트에 10g/㎡ 내지 100g/㎡의 열가소성 파우더를 도포하고 150℃ 내지 250℃의 열간오븐을 통과시킨 후, 열간 롤에서 압착하여 박막 보강층을 준비하는 제 3단계; 상기 제작된 박막 보강층이 열가소성 발포시트에 열라미네이션 공정을 통해 연속적으로 적층되어 기재가 제작되는 4단계를 포함하는, 내습성이 강화된 자동차 내장재용 친환경 경량기재의 제조방법을 제공한다. The present invention also relates to a method for manufacturing a felt, comprising: a first step of mixing natural fibers and synthetic fibers through carding, and fabricating the felt through web forming and needle punching; A second step of applying or impregnating the felt with isocyanate or epoxy, molding the felt in a semi-hardened state through a hot pressing roller at 150 to 250 ° C, and pressing the felt into a sheet; And a third step of applying a thermoplastic powder of 10 g / m 2 to 100 g / m 2 to the sheet, passing the sheet through a hot oven at 150 ° C to 250 ° C, and pressing the sheet in a hot roll to prepare a thin film reinforcing layer; Wherein the thin film reinforcing layer is continuously laminated to a thermoplastic foam sheet through a thermal lamination process to produce a substrate. The present invention also provides a method for manufacturing an environmentally lightweight automotive interior material with improved moisture resistance.
본 발명에서 상기 열가소성 발포시트는 폴리프로필렌, 폴리에틸렌 또는 폴리에스터로 이루어지고, 발포배율은 5배 내지 40배이며, 두께는 2mm 내지 10mm인 것이 바람직하다. In the present invention, the thermoplastic foam sheet is made of polypropylene, polyethylene or polyester, the expansion ratio is 5 to 40 times, and the thickness is preferably 2 to 10 mm.
본 발명에서 상기 이소시아네이트는 메틸렌 디페닐 디이소시아네이트(MDI) 또는 톨루엔 디이소시아네이트(TDI)인 것이 바람직하다. In the present invention, the isocyanate is preferably methylene diphenyl diisocyanate (MDI) or toluene diisocyanate (TDI).
본 발명에서 상기 천연섬유 박막 보강층에 도포 또는 함침되는 이소시아네이트의 중량은 5g/㎡ 내지 100g/㎡인 것이 바람직하다. In the present invention, the weight of the isocyanate applied or impregnated in the natural fiber thin film reinforcing layer is preferably 5 g / m 2 to 100 g / m 2.
본 발명에서 상기 박막 보강층에 포함되는 에폭시 또는 이소시아네이트는 스프레이 공정 또는 롤에 함침하여 첨가되는 것을 바람직하다. In the present invention, the epoxy or isocyanate contained in the thin film reinforcing layer is preferably added by spraying or impregnating the roll.
본 발명에서 상기 박막 보강층의 두께는 0.5mm 내지 2mm이며, 중량은 120g/㎡ 내지 700g/㎡인 것이 바람직하다.In the present invention, the thickness of the thin film reinforcing layer is preferably 0.5 mm to 2 mm, and the weight is preferably 120 g / m 2 to 700 g / m 2.
본 발명에서, 상기 박막 보강층에 사용되는 합성섬유는 길이가 30mm 내지 100mm인 폴리프로필렌 섬유, 심초형 저융점 폴리에스터 섬유, 폴리에스터섬유, 폴리에틸렌 섬유, 아크릴섬유 또는 생분해성 섬유 중에서 선택된 1종 이상을 사용하는 것이 바람직하다. In the present invention, the synthetic fibers used for the thin-film reinforcing layer may be at least one selected from polypropylene fibers having a length of from 30 mm to 100 mm, core-sheath type low melting point polyester fibers, polyester fibers, polyethylene fibers, acrylic fibers or biodegradable fibers Is preferably used.
또한, 상기 박막 보강층에 사용되는 합성섬유의 함량은 30중량% 내지 70중량%이 바람직하다. The content of the synthetic fibers used in the thin film reinforcing layer is preferably 30% by weight to 70% by weight.
또한, 상기 박막 보강층에 사용되는 천연섬유는 길이가 30mm 내지 100mm인 양마, 황마, 아마, 대마, 대나무 또는 사이잘 중에서 1종 이상 선택되는 것이 바람직하다. The natural fibers used for the thin-film reinforcing layer may be at least one selected from among cotton, jute, flax, hemp, bamboo, or sisal having a length of 30 mm to 100 mm.
또한, 상기 박막 보강층에 사용되는 천연섬유의 함량은 30중량% 내지 70중량%이 바람직하다. The content of the natural fiber used in the thin film reinforcing layer is preferably 30 wt% to 70 wt%.
상기 열가소성 파우더는 저밀도 폴리에틸렌, 고밀도 폴리에틸렌 또는 폴리프로필렌 중에서 선택된 1종 또는 그 이상을 사용하는 것이 바람직하다. The thermoplastic powder is preferably one or more selected from low-density polyethylene, high-density polyethylene or polypropylene.
또한, 본 발명의 내습성이 우수한 친환경 경량기재의 중량은 300g/㎡ 내지 1500g/m2인 것이 바람직하다. The weight of the environmentally friendly lightweight substrate having excellent moisture resistance of the present invention is preferably 300 g / m 2 to 1500 g / m 2 .
본 발명은 또한, 상기 제조방법들 중 하나에 의해 제조되고, 열가소성 발포시트로 이루어진 심재층의 일면 또는 양면에 박막 보강층이 열라미네이션된 것으로서, 상기 박막 보강층은, 천연섬유와 합성섬유 펠트층 표면에 액상 이소시아네이트가 도포 또는 함침된 후 열간 압착롤러를 통해 반경화되고, 여기에 열가소성 파우더 도포 후 열간오븐을 통과하여 열가소성 파우더층 형성 및 이소시아네이트나 에폭시의 경화반응이 완료된 것을 특징으로 하는, 내습성이 강화된 자동차 내장재용 친환경 경량기재를 제공한다.The present invention also relates to a laminate comprising a core layer formed by one of the above-described manufacturing methods and thermally laminated on one side or both sides of a core layer made of a thermoplastic foam sheet, wherein the thin film reinforcing layer is formed on the surface of the natural fiber and the synthetic fiber felt layer The liquid isocyanate is applied or impregnated and then semi-cured through a hot press roller, and after the application of the thermoplastic powder, the thermoplastic powder layer is formed and the thermosetting powder layer is formed and the curing reaction of the isocyanate or epoxy is completed. Friendly lightweight substrate for automobile interior materials.
본 발명은 또한, 아래 기준에 의한 내습굴곡강도가 1.0 kgf/5cm 초과, 내습처짐량(L)이 2.0 이하인 것을 특징으로 하는, 내습성이 강화된 자동차 내장재용 친환경 경량기재를 더욱 제공한다. The present invention further provides an environmentally friendly lightweight substrate for automotive interior materials having enhanced moisture resistance, characterized in that the moisture resistance bending strength according to the following standard is 1.0 kgf / 5 cm or more and the moisture absorption amount (L) is 2.0 or less.
(이 때, 내습굴곡강도(kgf/5cm)는"50mm x 150mm x 두께" 및 "660g/㎡" 중량의 시편에 대하여, 시험속도 5mm/min, 스판 넓이(span width) 100mm로 하고, 50℃, 95RH% 습도에서 24시간 방치 후, 23℃, 95RH%에서 1시간 안정화한 다음, ASTM D790에 의거 측정한 값이고,(At this time, the specimens having a weight of 50 mm x 150 mm x thickness and 660 g / m < 2 > were subjected to a test speed of 5 mm / min and a span width of 100 mm, , After standing for 24 hours at 95 RH% humidity, stabilized at 23 DEG C and 95% RH for 1 hour, then measured according to ASTM D790,
내습 처짐량(L)은 "50mm x 200mm x 두께" 및 "660g/㎡" 중량의 시편을, 끝부분 70mm를 고정시키고, 반대 쪽 부분에 40mm x 60mm의 34.2g의 추를 올려두고, 바닥면에서 시편 아래까지 측정한 초기 높이(L1)와, 50℃, 95RH% 습도에서 7시간 방치 후 다시 측정한 후기높이(L2)의 차이 L = L1 -L2 로 측정됨).The specimens with a weight of 50mm x 200mm x thickness and 660g / m < 2 > were fixed to the end portion of 70mm, and 34.2g of 40mm x 60mm weight was placed on the opposite side, The difference between the initial height (L1) measured to the bottom of the specimen and the later height (L2) measured again after leaving for 7 hours at 50 ° C and 95% RH was measured as L = L1-L2.
상기한 바와 같이, 본 발명에 의한 내습성이 강화된 자동차 내장재용 친환경 경량기재는 종래에 자동차 산업분야에 사용되는 유리섬유를 천연섬유로 대체한 것에 의해, 인체에 유해하지 않은 친환경소재의 장점과, 발포시트와 보강층을 접착하기 위해 사용하던 접착제나 핫멜트 필름을 사용하지 않고 열라미네이션 공정을 적용함으로써 공정이 단순하고, 가격이 저렴하며, 작업자의 인체에 무해한 작업환경의 장점을 가지고 있다. 또한 가격이 저렴하고 단순한 공정으로 이소시아네이트(또는 에폭시)를 천연섬유 보강층에 적용함으로써 기존의 천연섬유를 포함하는 샌드위치 구조의 자동차 내장재용 기재가 가지던 고온다습한 환경에서의 처짐현상, 뒤틀림 현상 및 물성저하를 상당수준 개선할 수 있는 효과를 가지고 있어, 자동차 내장재 뿐만 아니라, 철도내장재, 항공내장재 및 건축 내장재 같은 다양한 산업분야에도 응용할 수 있는 장점이 있다. As described above, the eco-friendly lightweight substrate for automotive interior materials with improved moisture resistance according to the present invention has the advantage of eco-friendly materials which are not harmful to the human body by replacing the glass fiber used in the automobile industry field with natural fibers , The application of heat lamination process without using the adhesive or hot melt film used for bonding the foam sheet and the reinforcing layer is advantageous in that the process is simple, the price is low, and the work environment is harmless to the human body. In addition, by applying isocyanate (or epoxy) to natural fiber reinforcing layer at a low cost and simple process, it is possible to prevent sagging phenomenon, warping phenomenon, and physical properties in a high temperature and high humidity environment, It can be applied not only to automobile interior materials, but also to various industrial fields such as railway interior materials, airborne interior materials and architectural interior materials.
또한, 본 발명의 제조방법은 이러한 경량기재를 제조함에 있어서, 기존의 생산 공정에 간단한 공정만을 추가하여, 추가 설비 등에 대한 비용 부담을 최소로 하여 저비용으로 제조할 수 있는 효과가 있다. In addition, the manufacturing method of the present invention is advantageous in manufacturing a lightweight substrate by adding only a simple process to an existing production process, thereby making it possible to manufacture the lightweight substrate at a low cost by minimizing the cost burden on additional equipment and the like.
도 1은 본 발명에 의한 기재의 층구조를 보인 설명도이다.1 is an explanatory view showing a layer structure of a substrate according to the present invention.
상기한 바와 같이, 본 발명의 내습성이 강화된 자동차 내장재용 친환경 경량기재는 심재층 발포시트와 보강층으로 천연섬유 박막 시트를 포함한다. 종래의 천연섬유 적용 자동차 내장재용 기재는 천연섬유의 수분에 취약한 특성으로 인해 고온다습의 환경에서 처짐 및 뒤틀림 같은 현상이 발생하여 형태 안정성에 대한 문제점이 지적되었다. As described above, the eco-friendly lightweight substrate for an automobile interior material with improved moisture resistance of the present invention comprises a core layer foam sheet and a natural fiber thin sheet sheet as a reinforcing layer. Conventional base materials for automobile interior materials using natural fibers have been pointed out to be problematic in terms of form stability due to the phenomenon such as sagging and twisting in a high temperature and high humidity environment due to the nature of the natural fibers being vulnerable to moisture.
따라서, 본 발명에서는 발포시트에 박막 보강층으로 이소시아네이트가 적용된 천연섬유시트를 열라미네이션 공정을 통해 연속적으로 적층하여 내습성 및 굴곡강도를 향상시킬 수 있었다. Accordingly, in the present invention, the natural fiber sheet to which the isocyanate is applied as the thin film reinforcing layer to the foam sheet can be continuously laminated through the thermal lamination process to improve the moisture resistance and the bending strength.
본 발명의 효과를 상세하게 설명하고자 아래에 실시예를 나타내었지만, 이는 단지 예시를 위한 것이기에 다양한 형태로 변형될 수 있으며, 본 발명의 범위를 제한하는 것은 아니다. In order to illustrate the effect of the present invention in detail, the following embodiments are shown. However, the present invention is not limited to the above-described embodiments, and various modifications may be made without departing from the scope of the present invention.
본 발명에 의한 내습성이 강화된 자동차 내장재용 친환경 경량기재의 제조는 하기 공정순서에 의거하여 진행하였다.The production of an environmentally friendly lightweight substrate for automotive interior materials with enhanced moisture resistance according to the present invention was carried out in accordance with the following process sequence.
ⅰ) 천연섬유와 합성섬유를 4 : 6의 중량비로 믹싱공정, 카딩공정, 웹포밍공정, 니들펀칭 공정을 통해서 천연섬유 펠트를 제조한다. I) Natural fiber felts are produced through mixing, carding, web forming and needle punching processes of natural fibers and synthetic fibers at a weight ratio of 4: 6.
ⅱ) 상기 펠트에 스프레이 공정을 통해 이소시아네이트를 도포/함침한 후 열간 압착롤러를 통해 이소시아네이트를 반경화 상태로 성형한다 Ii) The felt is coated / impregnated with isocyanate through a spray process, and the isocyanate is molded into a semi-cured state through a hot press roller
ⅲ) 그 위에 고밀도 폴리에틸렌 파우더를 도포하고 열간오븐을 통과하여 고밀도 폴리에틸렌 파우더층 형성 및 이소시아네이트의 경화반응을 완료하고 압착롤러를 이용하여 천연섬유 박막 보강시트의 보강층(10)를 제조한다. (Iii) A high-density polyethylene powder is applied thereon, and a high-density polyethylene powder layer and a curing reaction of isocyanate are completed through a hot oven, and a reinforcing layer 10 of a natural fiber thin film reinforcing sheet is produced by using a pressing roller.
ⅳ) 심재층(20)인 폴리프로필렌 발포시트에 상기 천연섬유 박막 보강시트를 열라미네이션을 통해 양면에 연속적으로 적층하여 친환경 경량기재(30)를 제조한다.Iv) The natural fiber thin film reinforcing sheet is continuously laminated on both sides of the polypropylene foam sheet as the core layer 20 through thermal lamination to produce an environmentally friendly lightweight substrate 30. [
표 1은 본 발명에 의해 제조된 시편의 상온, 내습 굴곡강도 및 내습 처짐량을 종래의 시편과 비교하여 나타내고 있다. 표 1을 통해 비교해보면 동일한 중량에서 이소시아네이트가 12g/m2, 24g/m2 각각 첨가되었을 때 굴곡강도 상태가 60%, 85%, 내습굴곡강도가 약 90%, 110%씩 증가하였고, 내습 처짐량 또한 50%, 80% 감소하여 내습성과 기계적특성이 현저히 개선되었다. Table 1 shows the room temperature, the moisture resistance bending strength and the moisture absorption amount of the specimens produced by the present invention in comparison with the conventional specimens. In comparison with the Table 1, the flexural strength conditions of 60% As the isocyanate is added to 12g / m 2, 24g / m 2 respectively, at the same weight of 85%, the moisture resistance flexural strength of about 90% was increased by 110%, invasions deflection In addition, 50% and 80% reduction in moisture resistance and mechanical properties were significantly improved.
종래의 고중량 기재와 비교하였을 경우에는 중량이 약 20% 낮음에도 불구하고 이소시아네이트가 12g/m2 첨가되었을 경우에 내습성이 우수하며, 24g/m2 첨가되었을 때에는 굴곡강도와 내습성이 현저히 개선되어 본 발명에 의한 친환경 기재의 경량화가 실현 가능함을 알 수 있다. Compared with the conventional heavy-weight substrate, the moisture resistance is excellent when 12 g / m 2 of isocyanate is added, and the flexural strength and moisture resistance are remarkably improved when 24 g / m 2 is added It can be understood that the weight reduction of the environmentally friendly substrate according to the present invention can be realized.
굴곡강도 측정은 ASTM D790에 의거하여 진행하였으며, 시편크기는 50mm x 150mm x 두께, 시험속도 5mm/min, span width는 100mm로 진행하였고, 내습 굴곡강도 조건은 50℃, 95RH% 습도에서 24시간 방치 후 23℃, 95RH%에서 1시간 안정화한 다음 위와 같은 조건으로 시험을 진행하였다.The bending strength was measured in accordance with ASTM D790. The specimen size was 50 mm x 150 mm x thickness, the test speed was 5 mm / min, and the span width was 100 mm. The humidity bending strength condition was set at 50 ° C and 95 RH% After stabilization at 23 ° C and 95% RH for 1 hour, the test was carried out under the above conditions.
내습처짐량은 50mm x 200mm x 두께의 시편을 끝부분 70mm를 고정시킨 후 반대 쪽 부분에 40mm x 60mm의 34.2g의 추를 올려두고 바닥면에서 시편 아래까지 초기 높이(L1)를 측정한 뒤에 50℃, 95RH% 습도에서 7시간 방치 후 다시 높이를 측정(L2)하여 습도부여 전 후 높이의 변화량을 내습 처짐량(L)로 하였다.
The thickness of the specimen was 50mm x 200mm x thickness, and 70mm of the end was fixed. 34.2g of 40mm x 60mm weight was placed on the opposite side, and the initial height (L1) was measured from the bottom to the bottom of the specimen. , And the height was measured again (L2) after leaving at a humidity of 95% RH for 7 hours, and the amount of change in the height before and after the application of humidity was defined as an invasion deflection amount (L).
내습처짐량(L) = 초기높이(L1)-후기높이(L2)(L) = Initial height (L1) - Later height (L2)
200g/m2 25 times / 4.5 mm
200 g / m 2
180 g/m2 25 times / 5.0mm
180 g / m 2
180g/m2 25 times / 4.5 mm
180 g / m 2
180g/m2 25 times / 4.5 mm
180 g / m 2
(kgf/5cm)Flexural strength
(kgf / 5 cm)
10 : 보강층 20 : 심재층 30 : 기재10: reinforcing layer 20: core layer 30: substrate
Claims (15)
상기 펠트에 이소시아네이트 또는 에폭시를 도포 후 열간 압착롤러를 통해 이소시아네이트를 반경화 상태로 성형하여 시트를 제조하되, 상기 펠트에 이소시아네이트를 도포 또는 함침하여 150℃ 내지 250℃의 열간 압착롤러를 통해 반경화 상태로 성형 후 압착하여 시트로 제조하는 제 2단계;
상기 시트에 10g/m2 내지 100g/m2의 열가소성 고분자 파우더를 도포한 후 150℃ 내지 250℃의 열간오븐을 통과시킨 후, 열가소성 파우더 층 형성 및 이소시아네이트 경화반응을 완료하고 압착롤러를 통해 압착하여 박막 보강층을 제조하는 제 3단계;
상기 제조된 박막 보강층이 열가소성 발포시트로 이루어진 심재층의 일면 혹은 양면에 열라미네이션 공정을 통해 연속적으로 적층되어 기재가 제작되는 제4단계를 포함하는 것을 특징으로 하는, 내습성이 강화된 자동차 내장재용 친환경 경량기재의 제조방법.A first step of mixing the natural fibers and the synthetic fibers through carding, and fabricating the felt through web forming and needle punching processes;
After the isocyanate or epoxy is applied to the felt, the isocyanate is molded into a semi-cured state through a hot press roller to form a sheet. The felt is coated or impregnated with isocyanate and heated to a semi-cured state A second step of forming the sheet into a sheet by pressing;
The thermoplastic polymer powder of 10 g / m 2 to 100 g / m 2 was applied to the sheet and then passed through a hot oven at 150 ° C to 250 ° C. Then, thermoplastic powder layer formation and isocyanate curing reaction were completed and pressed through a compression roller A third step of preparing a thin film reinforcing layer;
And a fourth step in which the thin film reinforcing layer is continuously laminated on one side or both sides of a core layer made of a thermoplastic foam sheet through a thermal lamination process to form a base material. A method for manufacturing an environmentally friendly lightweight substrate.
(이 때, 내습굴곡강도(kgf/5cm)는"50mm x 150mm x 두께" 및 "660g/㎡" 중량의 시편에 대하여, 시험속도 5mm/min, 스판 넓이(span width) 100mm로 하고, 50℃, 95RH% 습도에서 24시간 방치 후, 23℃, 95RH%에서 1시간 안정화한 다음, ASTM D790에 의거 측정한 값이고,
내습 처짐량(L)은 "50mm x 200mm x 두께" 및 "660g/㎡"중량의 시편을, 끝부분 70mm를 고정시키고, 반대 쪽 부분에 40mm x 60mm의 34.2g의 추를 올려두고, 바닥면에서 시편 아래까지 측정한 초기 높이(L1)와, 50℃, 95RH% 습도에서 7시간 방치 후 다시 측정한 후기높이(L2)의 차이 L = L1 -L2 로 측정됨).The eco-friendly lightweight substrate for an automobile interior material having moisture resistance enhanced according to claim 14, wherein the moisture-proof flexural strength according to the following criteria is 1.0 kgf / 5 cm or more and the moisture-proof deflection amount (L) is 2.0 or less.
(At this time, the specimens having a weight of 50 mm x 150 mm x thickness and 660 g / m < 2 > were subjected to a test speed of 5 mm / min and a span width of 100 mm, , After standing for 24 hours at 95 RH% humidity, stabilized at 23 DEG C and 95% RH for 1 hour, then measured according to ASTM D790,
The specimens with a weight of 50mm x 200mm x thickness and 660g / m < 2 > were fixed to the end portion of 70mm, and 34.2g of 40mm x 60mm weight was placed on the opposite side, The difference between the initial height (L1) measured to the bottom of the specimen and the later height (L2) measured again after leaving for 7 hours at 50 ° C and 95% RH was measured as L = L1-L2.
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| JP2014242098A JP5992982B2 (en) | 2013-12-05 | 2014-11-28 | Eco-friendly lightweight substrate for natural fiber polymer composites and automotive interior materials |
| CN201410710332.9A CN104691074B (en) | 2013-12-05 | 2014-11-28 | Natural fiber polymer composite and eco-friendly lightweight base material for automotive interior |
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