KR20150083322A - Method for manufacturing high strength multilayered composites for car interior part using prepreg and the multilayered composites manufactured by the same - Google Patents
Method for manufacturing high strength multilayered composites for car interior part using prepreg and the multilayered composites manufactured by the same Download PDFInfo
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- KR20150083322A KR20150083322A KR1020140002935A KR20140002935A KR20150083322A KR 20150083322 A KR20150083322 A KR 20150083322A KR 1020140002935 A KR1020140002935 A KR 1020140002935A KR 20140002935 A KR20140002935 A KR 20140002935A KR 20150083322 A KR20150083322 A KR 20150083322A
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- South Korea
- Prior art keywords
- layer
- felt layer
- felt
- thermosetting resin
- reinforcing 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
- B32B27/12—Layered products comprising a layer of synthetic resin next to 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
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
-
- 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
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- Physics & Mathematics (AREA)
- Fluid Mechanics (AREA)
- Laminated Bodies (AREA)
Abstract
Description
BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a base structure for automobiles, and more particularly, to a base structure for automobiles, which comprises a natural fiber felt layer composed of at least one natural fiber or synthetic fiber, And to a prepreg and multilayer composite produced thereby.
Structures for automobile interior materials are made of materials to satisfy customers' stability, convenience, and functionality, and various materials and structures have been developed and applied accordingly. Conventional materials and structures focus on the functionality of automobiles. However, as the industry develops and the living standard of the customers improves, the environment has a great interest in environmental pollution and greenhouse gas generation. In order to improve this, an environmentally friendly and lightweight material is required. Accordingly, natural fibers, bioplastics, and lightweight materials have been researched and developed in many fields.
In general, automotive interior materials are composed of core layer, reinforcing layer, and skin layer. Typical multi-layer structures currently used include hand-felt, resin felt, natural fiber reinforced board, glass fiber / polyurethane foam, natural fiber sheet / polypropylene Foam and so on. Of these, multilayer structures such as natural fiber sheet / polypropylene foam are attracting attention as eco-friendly and lightweight materials that customers demand, and they are now being applied in mass production.
Of the factors determining the strength of the natural fiber sheet / polypropylene foam, the most important one is the strength of the natural fiber sheet used as the reinforcing layer. Accordingly, the natural fiber and the synthetic fiber are bound by needle punching, and then the fiber reinforcing effect is imparted through the application of the powder.
However, with respect to the reinforcing layer, when it is produced by the above-described method, a precise technical force is required and there is a problem that it is not sufficient to prevent the water absorption performance inherent in natural fibers.
Further, in order to effectively laminate the core layer and the reinforcing layer, a needle punching or heat lamination method should be used. A manufacturing method such as coating the reinforcing layer with an adhesive resin or performing lamination through a post-process is required. As a result, the manufacturing process is complicated and the unit price is increased.
Accordingly, the present applicant has proposed a method of providing an automobile interior material having excellent bending properties and a method of manufacturing the automobile interior material and manufacturing method using a thermosetting resin as a reinforcing layer in a felt layer composed of natural fibers, in order to solve the above- .
In order to achieve the above object,
A method for manufacturing a highly rigid multi-layer composite for automobiles, comprising a felt layer (100) composed of natural fibers or synthetic fibers and a reinforcing layer (200) composed of a thermosetting resin,
A felt layer forming step of forming a felt layer 100 from one or more natural fibers or a mixture of one or more natural fibers and synthetic fibers;
Impregnating the felt layer 100 with a thermosetting resin at an impregnation speed of 1 mm to 5 m / min, moving the impregnated felt layer through a conveyor belt to a hot air oven, And a reinforcing layer (200) laminated on the reinforcing layer (200).
Further, in the present invention, in the step of forming the felt layer, the felt layer (100) is formed by a sheet having a thickness of 0.5 mm to 2 mm through a thermal roller pressing process. The present invention further provides a method for producing a high rigidity multi-layer composite for use in the present invention.
Further, in the present invention, a method for manufacturing a high rigidity multi-layer composite for automobile interior using a prepreg, wherein at least one of the natural fibers is selected from jute, kenaf, sisalma, flax, or bamboo More.
Further, in the present invention, the synthetic fiber is at least one selected from a low-melting-point polyester, PET, polypropylene, or biodegradable resin fiber. More.
Further, the present invention further provides a method for manufacturing a high rigidity multi-layer composite for automobile interior using a prepreg, wherein the thermosetting resin applied to the reinforcing layer (200) is an epoxy resin composition.
The reinforcing layer is continuously laminated on both sides of the felt layer through a prepreg method by impregnating the conveyed felt layer through a resin solution tank through rotation of the conveyor belt at the top of the manufacturing process. The present invention further provides a method of manufacturing a high rigidity multi-layer composite for automobile interior using a prepreg.
In the present invention, after the reinforcing layer laminating step, a curing step of curing the semi-cured reinforcing layer in a mold of 100 to 200 DEG C to form a cured composite body, The present invention further provides a method for producing a high rigidity multi-layer composite for use in the present invention.
Further, in the present invention, the curing step may be performed by laminating the skin layer 300 on one side of the semi-cured reinforcing layer, and thereafter, working with a hot press mold. The present invention further provides a method for producing a multi-layer composite.
In addition, in the present invention, a felt layer 100 made of one of the above-described methods and formed from one or more natural fibers or a mixture of one or more natural fibers and synthetic fibers, and on both sides of the felt layer 100, And a reinforcing layer (200) laminated in a semi-cured state after being impregnated with a thermosetting resin. The multi-layer composite prepreg according to claim 1,
The present invention also relates to a felt layer 100 made of one of the above methods and formed from one or more natural fibers or a mixture of one or more natural fibers and synthetic fibers and a thermosetting resin 100 on both sides of the felt layer 100. [ Characterized in that the prepreg including the reinforcing layer (200) laminated in a semi-cured state is cured after being laminated alone or after further lamination of a skin layer made of a polyolefinic nonwoven fabric or a polyester nonwoven fabric. And further provides a multi-layer composite for automobile interior use.
As described above, according to the present invention, a felt layer made of natural fibers and a thermosetting resin having good rigidity and no warpage are laminated through a prepreg method using a reinforcing layer as a reinforcing layer, thereby improving bending properties and being environmentally friendly. Further, the thermosetting resin is continuously laminated on the surface of the felt layer formed by one or more natural fibers or synthetic fibers on both sides by the prepreg method to produce three layers, whereby the strength is improved and the effect is strong against temperature and humidity.
Fig. 1 is a schematic view of an example of a device used in the preparation of the prepreg of the present invention.
2 is a cross-sectional view of an automotive interior multi-layer composite made in accordance with an embodiment of the present invention.
Hereinafter, the present invention will be described with reference to the drawings.
Fig. 1 is a schematic view of an example of an apparatus used for manufacturing a prepreg in the production method of the present invention, showing an example using a horizontal type drying furnace.
The sheet-like felt layer (1) containing at least one natural fiber or synthetic fiber produced by a needle punching process is passed through a resin solution tank (4) containing a thermosetting resin (3) through a conveyor belt The
In this case, the felt layer 100 according to the present invention is formed to increase the rigidity between the thermosetting resin reinforcing layers, and is formed into a sheet through needle punching process using two or more kinds of natural fibers or synthetic fibers . If the density of the felt layer is low, the flexural rigidity of the embedded board may be deteriorated. Therefore, in order to have a light weight and a high rigidity, it is preferable to produce a sheet having a thickness of 0.1 mm to 5 mm. More preferably, it is formed to have a thickness of 0.5 mm to 2 mm to improve the density and further improve the rigidity and bending property of the lightweight multilayer structure.
The natural fibers of the felt layer preferably include kenaf (yam), jute, sisal, flax, bamboo, etc., and preferably have a thickness of 40 to 120 탆 and a length of 40 to 120 mm. When two or more kinds of natural fibers are mixed, it is preferable to compare the strength, the length and the thickness of the natural fibers to form a high-density felt layer by using different kinds.
Among them, one or more natural fibers may be used, or natural fibers and synthetic fibers may be mixed in an 8: 2 ratio. The synthetic fibers may include one or more components selected from low melting point polyesters, polyolefins and biodegradable resin fibers So as to have durability, water resistance, corrosion resistance and excellent strength.
Further, in order to reinforce the rigidity of the felt layer, it is preferable that after the needle punching operation, the sheet is formed through the heat roller.
On the other hand, the first-order felt layer has a strength lowered by absorption of moisture, which is a characteristic inherent in natural fibers, and thus, a sagging phenomenon of the laminated multi-layer composite may occur. Therefore, in order to improve the strength of the felt layer and to suppress the water absorption, a reinforcing layer is additionally required. In the present invention, the thermosetting resin reinforcing layer is continuously laminated on both sides of the felt layer. At this time, the thermosetting resin is preferably an epoxy resin, but is not limited thereto.
The thermosetting resin reinforcing layer is continuously laminated on both sides of the felt layer through a prepreg method. It is preferable that the transferred felt layer is impregnated with a thermosetting resin and the resin is kept in a semi-cured state at a low temperature through a hot air drying process. In the process of forming the reinforcing layer 200, the thermosetting resin laminated on the felt layer 100 must be uniformly formed in order to improve the strength. For this purpose, the impregnated felt layer is impregnated with the thermosetting resin at a rate of 1 mm to 5 m / min. After the impregnation, the felt is moved to a hot air oven through a conveyor belt, and then the resin is dried in a semi-cured state. At this time, it is preferable to store the reaction at a low temperature to delay the reaction so that no further curing occurs before the next step.
Further, it is preferable that the reinforcing layer is continuously laminated on both surfaces, and it is preferable that the reinforcing layer is laminated on one surface of the felt layer to form a three-layer structure.
A method of manufacturing a multilayer composite according to the present invention includes: a first step of forming a felt layer through a needle punching process of one or more natural fibers; A second step of impregnating the felt layer with a thermosetting resin; And a third step of laminating a continuous semi-cured thermosetting resin reinforcing layer on both sides through the hot air drying step of the felt layer. In addition, after the third step, a fourth step of laminating a nonwoven fabric-like skin layer formed of a polyolefin-based or polyester-based material on the outer surface of the reinforcing layer may be included. In the second, The fourth step may be performed through a continuous process.
A polyolefin-based nonwoven fabric or a polyester nonwoven fabric is used as the surface layer 300 to be laminated on one surface or both surfaces of the reinforcing layer 200. The developed product can be melt-adhered by the tacky and heat of the thermosetting resin of the reinforcing layer (200) without using a solvent type adhesive or a hot melt type adhesive, so that the work is simplified, and odor problems Can be solved.
A method for laminating the felt layer 100, the reinforcing layer 200, and the skin layer 300 will now be described. In one embodiment, the thermosetting resin is impregnated into the thermosetting resin at a speed of 1 mm to 5 m / min on both sides of the felt layer 100 having a width of 300 mm to 1000 mm and a thickness of 0.5 mm to 2 mm to form the reinforcing layer 200, And the skin layer 300 are successively laminated, and then processed by using a metal mold.
After the felt layer 100 is impregnated with a thermosetting resin in order to laminate the reinforcing layer 200 on both sides of the natural fiber felt layer 100, the thermosetting resin reinforcing layer 200 passes through the felt- It is preferable that the reinforcing layer 200 is formed on both surfaces of the laminate.
The above description relates to specific embodiments and various modifications and variations are possible without departing from the spirit and scope of the invention as defined by the appended claims.
[Example]
A felt layer having a thickness of 0.5 mm to 1 mm was used, and a reinforcing layer was laminated on both sides with a thermosetting resin. The felt layer was impregnated with an epoxy resin at a rate of 1 to 5 m / min, and then a semi-cured reinforcing layer was coated through hot air drying to form and cure the felt layer through a hot press mold to confirm the strength and light weight of the product Specific gravity and flexural strength were measured.
(Impregnation speed 1m / min)
(Impregnation speed 5m / min)
As shown in Table 1, the produced high-rigidity multi-layer composites were classified into three types. Comparative Example 1 is a commonly used plastic material structure, and Examples 1 and 2 are high-stiffness multilayer composites in which a reinforcing layer is laminated by impregnating a thermosetting resin at a speed of 1 m / min and 5 m / min, respectively. As a result of the tests of the comparative example and the examples 1 and 2, the high-rigidity multi-layer composite according to the present invention shows a weight reduction ratio of 30% or more of the existing material of the comparative example 1 and exhibits an excellent rigidity over the equivalent level.
1,100: felt layer 2: conveyor belt 3: thermosetting resin
4: solution tank 5: hot air drying oven
100: felt layer 200: reinforcing layer 300: skin layer
Claims (10)
A felt layer forming step of forming a felt layer 100 from one or more natural fibers or a mixture of one or more natural fibers and synthetic fibers;
After impregnating both surfaces of the felt layer 100 with a thermosetting resin at an impregnation speed of 1 to 5 m / min, the impregnated felt layer is moved to a hot air oven through a conveyor belt, and then the thermosetting resin is semi-cured A method for manufacturing a high rigidity multi-layer composite for automotive interior use using a prepreg, comprising: a step of laminating a reinforcing layer (200) to be laminated
Wherein the felt layer (100) is formed of a sheet having a thickness of 0.5 mm to 2 mm through a heat roller pressing step in the felt layer forming step. A method for manufacturing a rigid multilayer composite.
Wherein the natural fiber is at least one selected from the group consisting of jute, kenaf, sisal, flax, or bamboo.
Wherein the synthetic fibers are at least one selected from low-melting-point polyesters, PET, polypropylene, and biodegradable resin fibers.
Wherein the thermosetting resin applied to the reinforcing layer (200) is an epoxy resin composition.
Wherein the reinforcing layer is continuously laminated on both sides of the felt layer through a prepreg method by impregnating the conveyed felt layer through a resin solution tank through rotation of the conveyor belt at the top of the manufacturing process, A method for producing a high rigid multi-layer composite for use in the present invention.
And a curing step of curing the semi-cured reinforcing layer (200) in a mold of 100 to 200 DEG C to form a cured composite, following the step of laminating the reinforcing layer (200) A method for producing a high rigid multi-layer composite for use in the present invention.
Wherein the hardening step comprises laminating a skin layer (300) on one side of a semi-hardened reinforcing layer, and then processing the laminate with a hot press mold.
A felt layer 100 formed from one or more natural fibers or a mixture of one or more natural fibers and synthetic fibers,
And a reinforcing layer (200) laminated on both sides of the felt layer (100) with a thermosetting resin and then laminated in a semi-cured state.
A felt layer 100 formed from one or more natural fibers or a mixture of one or more natural fibers and synthetic fibers,
The prepreg including the reinforcing layer 200 laminated in a semi-cured state after being impregnated with the thermosetting resin on both sides of the felt layer 100 may be used either alone or in combination with a skin layer 300 made of a polyolefin-based nonwoven fabric or a polyester- Of the total thickness of the laminate.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| KR1020140002935A KR20150083322A (en) | 2014-01-09 | 2014-01-09 | Method for manufacturing high strength multilayered composites for car interior part using prepreg and the multilayered composites manufactured by the same |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| KR1020140002935A KR20150083322A (en) | 2014-01-09 | 2014-01-09 | Method for manufacturing high strength multilayered composites for car interior part using prepreg and the multilayered composites manufactured by the same |
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| KR20150083322A true KR20150083322A (en) | 2015-07-17 |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR101875579B1 (en) * | 2016-03-28 | 2018-07-09 | 주식회사 서연이화 | Manufacturing method for vehicle interior parts |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR101875579B1 (en) * | 2016-03-28 | 2018-07-09 | 주식회사 서연이화 | Manufacturing method for vehicle interior parts |
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