KR20210129859A - Automobile floor carpet using low weight thermoplastic polyethylene sound insulation coating and method for manufacturing the same - Google Patents
Automobile floor carpet using low weight thermoplastic polyethylene sound insulation coating and method for manufacturing the same Download PDFInfo
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- KR20210129859A KR20210129859A KR1020200047908A KR20200047908A KR20210129859A KR 20210129859 A KR20210129859 A KR 20210129859A KR 1020200047908 A KR1020200047908 A KR 1020200047908A KR 20200047908 A KR20200047908 A KR 20200047908A KR 20210129859 A KR20210129859 A KR 20210129859A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- B60N3/00—Arrangements or adaptations of other passenger fittings, not otherwise provided for
- B60N3/04—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets
- B60N3/042—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets of carpets
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4326—Condensation or reaction polymers
- D04H1/435—Polyesters
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
- D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- D06M15/693—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with natural or synthetic rubber, or derivatives thereof
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Abstract
Description
본 발명은 경량성의 차량용 플로어 카펫에 관한 것이며, 상세하게는 저중량 열가소성 폴리에틸렌 차음코팅을 이용한 경량성의 자동차용 플로어 카펫 및 그 제조방법에 관한 것이다.The present invention relates to a lightweight vehicle floor carpet, and more particularly, to a lightweight vehicle floor carpet using a low-weight thermoplastic polyethylene sound insulating coating and a method for manufacturing the same.
일반적으로 자동차의 내부에는 다양한 기능을 갖는 내장재를 적용하여 차량의 주행 시에 엔진소음, 타이어의 마찰음 등 각종 소음이 실내로 유입되는 것을 차단하여 운전자 및 탑승자에게 안락한 운행을 제공한다.In general, interior materials having various functions are applied to the interior of a vehicle to prevent various noises such as engine noise and tire friction noise from entering the interior when the vehicle is driving, thereby providing a comfortable driving experience for the driver and passengers.
자동차용 플로어 카펫은 자동차의 실내 바닥에 설치되어 실내 인테리어 및 운전자나 탑승자의 미끄럼 등의 방지의 목적도 있지만, 자동차 바닥으로부터 유입되는 진동 및 각종 소음을 차단하는 것이 보다 중요한 기능이라 하겠다.The floor carpet for automobiles is installed on the indoor floor of a car and has the purpose of preventing slippage of the interior and the driver or passengers, but it is a more important function to block vibration and various noises flowing from the floor of the car.
이에 따라 자동차용 플로어 카펫은 자동차 외부로부터 실내로 유입되는 진동 및 소음을 차단하기 위하여 흡,차음성 및 물리적 특성 등에 대한 적절한 기능을 가진 다양한 재질의 흡차음소재가 사용되고 있으며, 선행기술로 예를 들면, 특허문헌1에 카펫(1)과, 카펫(1) 저면에 도포되어 융착되며, HDPE 파우더, P.E., PP, ABC, 나이론 재질의 파우더 중 어느 하나를 포함하여 이루어지는 접착성 파우더(3)와, 접착성 파우더(3) 저면에 일체로 부착되며, 폴리프로필렌이나 또는 폴리에틸렌테레프탈레이트 재질 중 어느 하나로 이루어지고 통공(50)을 형성하는 장섬유로 이루어지는 케미컬부직포(4)와, 케미컬부직포(4) 저면에 일체로 형성되고, P.E.T. 50 ~ 95 중량%와, 저융점(L.M)화이버 5 ~ 50중량% 를 혼합한 재료의 것으로 이루어지고, 니들펀칭된 부직포(2)를 포함하되, 상기 부직포(2)와 케미컬부직포(4) 사이는 열압착으로 부착하는 것을 특징으로 하는 자동차용 바닥재를 개시하고 있으며, 또 특허문헌2에는 내환경성 및 성형성이 우수한 자동차 플로어 카페트에 있어서, 플로어 필름층 및 평균직경 0.1 ∼10㎛의 극세사로 이루어지는 멜트블로운 부직포층인 흡음층이 차례로 적층되되, 상기 멜트블로운 부직포층은 양 표면에 각각 장섬유 스판본드 부직포가 추가 형성되고, 110∼150 ℃의 온도, 15 ∼ 25N/㎜의 압력으로 열융착되어 표면이 필름화된 특징이 있으며, 상기 플로어 필름층은 탄성을 발현하는 공중합 폴리에스테르계 탄성수지로 구성된 내열층 및 폴리 올레핀(PolyOlefin) 수지로 구성된 접착층을 포함하며, 상기 접착층은 상기 내열층과의 계면접착성을 향상시키기 위하여 말레익안하이드라이드(Maleic Anhydride)가 그래프팅(Grafting)된 내환경성 및 성형성이 우수한 자동차 플로어 카페트를 개시하고 있으나, 상기한 선행기술은 흡차음성 및 친환경성 등을 위한 흡차음재 등 소재와 관련한 기술이다.Accordingly, as for floor carpets for automobiles, various sound absorbing and insulating materials with appropriate functions for absorbing and insulating properties and physical properties are used in order to block vibration and noise flowing into the interior from the outside of the vehicle. , The carpet (1) in Patent Document 1, and the adhesive powder (3) which is applied to the bottom surface of the carpet (1) and fused, and includes any one of HDPE powder, PE, PP, ABC, and nylon powder; The chemical non-woven fabric 4 and the chemical non-woven fabric 4, which are integrally attached to the bottom surface of the adhesive powder 3, and made of either polypropylene or polyethylene terephthalate material and formed of long fibers forming the through hole 50, and the chemical non-woven fabric 4 bottom surface Formed integrally with PET 50 to 95% by weight and 5 to 50% by weight of low-melting point (LM) fiber, including a needle-punched nonwoven fabric (2), between the nonwoven fabric (2) and the chemical nonwoven fabric (4) discloses a flooring material for automobiles, characterized in that it is attached by thermocompression bonding, and Patent Document 2 discloses a floor film layer and microfibers having an average diameter of 0.1 to 10 μm in an automobile floor carpet having excellent environmental resistance and moldability. A sound-absorbing layer as a melt-blown non-woven fabric layer is sequentially stacked, and the melt-blown non-woven fabric layer is further formed with a long fiber spunbond non-woven fabric on both surfaces, and heated at a temperature of 110 to 150 ℃ and a pressure of 15 to 25 N/mm. It has a feature that the surface is filmed by fusion, and the floor film layer includes a heat-resistant layer made of a co-polyester-based elastic resin that expresses elasticity, and an adhesive layer made of a polyolefin (PolyOlefin) resin, wherein the adhesive layer is the heat-resistant layer In order to improve the interfacial adhesiveness with a maleic anhydride grafted (Maleic Anhydride) is disclosed a car floor carpet excellent in environmental resistance and moldability, but the prior art described above, such as sound absorption and insulation properties and eco-friendliness It is a technology related to materials such as sound absorbing and insulating materials for
근래에는 이산화탄소 저감을 위하여 차량의 연비 규제도 점차 심화되고 있는 추세에 따라 흡차음의 성능 향상과 함께 연비 향상을 위하여 경량화된 흡음재의 개발이 요구되고 있으나 기존의 자동차용 플로어 카펫으로 고무계 차음재층, 합성수지 코팅층 등으로 이루어진 구조는 경량성 측면에서는 부족한 측면이 있다. In recent years, as fuel efficiency regulations of vehicles are becoming increasingly stricter to reduce carbon dioxide, the development of lightweight sound absorbing materials is required to improve fuel efficiency as well as performance of sound absorbing and insulating materials. A structure made of a coating layer or the like is insufficient in terms of lightness.
자동차용 플러어 카펫의 경량화와 관련한 선행기술로는 특허문헌3에 발포 배율이 10 내지 30인 PET(polyethylene terephthalate) 발포 시트로 이루어지며, 두께가 2 mm 내지 8 mm인 코어층과, 발포 배율이 2 내지 10 인 PET 발포 시트로 이루어지며, 두께가 1 mm 내지 5 mm이며, 상기 코어층의 상면 및 하면에 열접착(Heat Lamination)에 의해 결합되는 한 쌍의 보강층과, 상기 보강층의 일면에 결합되는 폴리에스테르계 부직포를 포함하는 것을 특징으로 하는 경량성 및 성형성이 우수한 차량 내장재용 기재를 개시하고 있고, 특허문헌4에는 폴리에틸렌테레프탈레이트(PET) 부직포 웹 또는 PET 입모 원사로 이루어진 스킨층; 상기 스킨층에 40 내지 1000㎛ 평균입자크기를 가지는 PET 분말이 산포되어, 상기 PET 분말의 일부가 용융되어 내부에 충진되는 동시에 층상으로 경화된 PET 소재의 기포층; 및 상기 PET 소재의 기포층 상에 PET 소재로 코팅된 배면층으로 이루어진, 리사이클성과 경량성이 우수한 자동차용 플로우 카페트 복합 기재를 개시하고 있다.As a prior art related to weight reduction of floor carpets for automobiles, Patent Document 3 includes a PET (polyethylene terephthalate) foam sheet having a foaming ratio of 10 to 30, a core layer having a thickness of 2 mm to 8 mm, and a foaming ratio A pair of reinforcing layers made of a PET foam sheet of 2 to 10, having a thickness of 1 mm to 5 mm, and bonding to the upper and lower surfaces of the core layer by heat lamination, and bonding to one surface of the reinforcing layer Disclosed is a substrate for a vehicle interior material having excellent lightness and moldability, characterized in that it contains a polyester-based nonwoven fabric, and Patent Document 4 discloses a skin layer made of polyethylene terephthalate (PET) nonwoven web or PET napped yarn; PET powder having an average particle size of 40 to 1000 μm is dispersed on the skin layer, a portion of the PET powder is melted to fill the inside, and at the same time, a foam layer of PET material cured in layers; and a back layer coated with a PET material on the foam layer of the PET material, and a flow carpet composite substrate for automobiles having excellent recyclability and lightness is disclosed.
본 발명에서 해결하고자 하는 과제는 저중량 열가소성 폴리에틸렌 차음코팅를 이용하여 흡·차음성능이 기존 플로어 카펫과 동등 이상 수준인 동시에 보다 경량성인 자동차용 플로어 카펫 및 그 제조방법을 제공하는 것이다.The problem to be solved by the present invention is to provide a floor carpet for automobiles and a method for manufacturing the same, which are at the same or higher level of sound absorption and insulation performance than that of the existing floor carpet by using a low-weight thermoplastic polyethylene sound insulation coating and are lighter.
구체적으로는 기존의 자동차용 플로어 카펫에서 무거운 소재로 이루어진 고무계 차음재층과 합성수지 코팅층을 저중량 열가소성 폴리에틸렌의 차음코팅층으로 대체하여 보다 경량성의 자동차용 플로어 카펫과 그 제조방법의 제공을 목적으로 하는 것이다.Specifically, by replacing the rubber-based sound insulating material layer and the synthetic resin coating layer made of a heavy material in the existing floor carpet for automobiles with a sound insulating coating layer of low-weight thermoplastic polyethylene, the purpose is to provide a lighter automobile floor carpet and a method for manufacturing the same.
본 발명에 따른 과제의 해결수단으로 저중량 열가소성 폴리에틸렌(Low Weight Thermo Polyethylene, 이하에서는 ‘LWTPE’로 정의합니다) 차음코팅을 이용한 자동차용 플로어 카펫은 LM섬유 및 PET섬유로 조성된 부직포 또는 LM섬유, PET섬유 및 중공사로 조성된 부직로 이루어진 표면부직포층(1), 아크릴 라텍스층(2) 및 LWTPE 차음코팅층(3)으로 이루어진다.As a means of solving the problem according to the present invention, the floor carpet for automobiles using the sound insulation coating of Low Weight Thermo Polyethylene (hereinafter referred to as 'LWTPE') is a non-woven fabric made of LM fibers and PET fibers, or LM fibers, PET. It consists of a surface nonwoven fabric layer (1), an acrylic latex layer (2), and an LWTPE sound insulating coating layer (3) made of a nonwoven fabric composed of fibers and hollow fibers.
본 발명의 일 실시형태에 따른 저중량 LWTPE 차음코팅을 이용한 자동차용 플로어 카펫은 6데니어의 LM섬유 10중량%, 6데니어의 PET섬유 40중량% 및 10데니어의 PET섬유 50중량%로 조성된 부직포로 이루어진 표면부직포층(1), 아크릴 라텍스층(2) 및 EVA 고무 10 ~ 20중량%와 LLDPE칩 80 ~ 90중량%로 조성된 LWTPE 차음코팅층(3)으로 이루어진다.The floor carpet for automobiles using the low-weight LWTPE sound insulation coating according to an embodiment of the present invention is a nonwoven fabric composed of 10% by weight of 6 denier LM fibers, 40% by weight of 6 denier PET fibers, and 50% by weight of 10 denier PET fibers. It consists of a surface nonwoven fabric layer (1), an acrylic latex layer (2), and an LWTPE sound insulation coating layer (3) composed of 10 to 20 wt% of EVA rubber and 80 to 90 wt% of LLDPE chips.
본 발명의 또 다른 실시형태에 따른 저중량 LWTPE 차음코팅을 이용한 자동차용 플로어 카펫은 6데니어의 LM섬유 30중량%, 6데니어의 PET섬유 40중량% 및 10데니어의 PET섬유 30중량%로 조성된 표면부직포로 이루어진 표면부직포층(1), 아크릴 라텍스층(2) 및 EVA 고무 10 ~ 20중량%와 LLDPE칩 80 ~ 90중량%로 조성된 LWTPE 차음코팅층(4)으로 이루어진다.A floor carpet for automobiles using a low-weight LWTPE sound insulation coating according to another embodiment of the present invention is a surface composed of 30% by weight of 6 denier LM fibers, 40% by weight of 6 denier PET fibers, and 30% by weight of 10 denier PET fibers It consists of a surface nonwoven fabric layer (1) made of a nonwoven fabric, an acrylic latex layer (2), and an LWTPE sound insulation coating layer (4) composed of 10 to 20 wt% of EVA rubber and 80 to 90 wt% of LLDPE chips.
본 발명의 또 다른 실시형태에 따른 저중량 LWTPE 차음코팅을 이용한 자동차용 플로어 카펫은 6데니어의 LM섬유 30중량%, 6데니어의 PET섬유 40중량% 및 중공사 30중량%로 조성된 부직포로 이루어진 표면부직포층(1), 아크릴 라텍스층(2) 및 EVA 고무 10 ~ 20중량%와 LLDPE칩 80 ~ 90중량%로 조성된 LWTPE 차음코팅층(4)로 이루어진다.A floor carpet for automobiles using a low-weight LWTPE sound insulation coating according to another embodiment of the present invention has a surface made of a nonwoven fabric composed of 30% by weight of 6 denier LM fibers, 40% by weight of 6 denier PET fibers and 30% by weight of hollow fibers It consists of a nonwoven fabric layer (1), an acrylic latex layer (2), and an LWTPE sound insulation coating layer (4) composed of 10 to 20 wt% of EVA rubber and 80 to 90 wt% of LLDPE chips.
본 발명의 상기 LM섬유는 용융점이 140℃인 PET 소재의 저융점 섬유(Low melting fiber)이고, PET섬유는 폴리에틸렌테레프탈레이트(PET) 섬유이며 또 중공사는 폴리에틸렌테레프탈레이트(PET)의 중공섬유(Hollow fiber)이다.The LM fiber of the present invention is a low melting fiber of a PET material having a melting point of 140° C., the PET fiber is a polyethylene terephthalate (PET) fiber, and the hollow fiber is a hollow fiber of polyethylene terephthalate (PET). fiber).
본 발명의 표면부직포층(1)은 300 ~ 450g/㎡이고, 아크릴 라텍스층(2)은 45 ~ 100g/㎡이고, LWTPE 차음코팅층(3)은 450 ~ 600g/㎡인 것을 특징으로 한다.The surface nonwoven fabric layer (1) of the present invention is 300 to 450 g/m2, the acrylic latex layer (2) is 45 to 100 g/m2, and the LWTPE sound insulation coating layer (3) is 450 to 600 g/m2.
또 상기 EVA 고무는 에틸렌비닐아세테이트 공중합체(Ethylene Vinyl Acetate Copolymer)이며, LLDPE는 선형저밀도폴리에틸렌(Linear Low Density Polyethylene)이다.In addition, the EVA rubber is ethylene vinyl acetate copolymer (Ethylene Vinyl Acetate Copolymer), and LLDPE is linear low density polyethylene.
그리고 본 발명의 또 다른 과제의 해결수단으로 저중량 LWTPE 차음코팅을 이용한 자동차용 플로어 카펫의 제조방법은 a). LM섬유 및 PET섬유로 조성된 부직포 또는 LM섬유, PET섬유 및 중공사로 조성된 부직포로 표면부직포층(1)을 형성하는 제1공정, b). 상기 제1 공정의 표면부직포층(1)의 표면으로 아크릴 라텍스 용액을 저압 발포와 고압 발포 순으로 발포시킨 라텍스 발포액으로 코팅하여 아크릴 라텍스층(2)을 형성하는 제2 공정, c).상기 제2 공정의 아크릴 라텍스층(2)의 표면으로 EVA 고무 10 ~ 20중량%와 LLDPE칩 80 ~ 90중량%로 배합한 배합물을 압출에 의해 LWTPE 차음코팅층(3)을 형성하여 표면부직포층(1), 아크릴 라텍스층(2) 및 LWTPE 차음코팅층(3)의 구조를 갖는 소재(A)를 얻는 제3 공정 및 d) 상기 제3 공정의 소재(A)를 성형하여 저중량 LWTPE 차음코팅을 이용한 자동차용 플로어 카펫 성형품을 제작하는 제4 공정으로 이루어진다.And as a means of solving another problem of the present invention, a method of manufacturing a floor carpet for automobiles using a low-weight LWTPE sound insulation coating is a). A first step of forming a surface nonwoven fabric layer (1) with a nonwoven fabric composed of LM fibers and PET fibers or a nonwoven fabric composed of LM fibers, PET fibers and hollow fibers, b). A second step of forming the acrylic latex layer (2) by coating the surface of the surface nonwoven fabric layer (1) in the first step with the latex foam solution obtained by foaming the acrylic latex solution in the order of low pressure foaming and high pressure foaming, c). As the surface of the acrylic latex layer (2) in the second process, the LWTPE sound insulating coating layer (3) is formed by extrusion of a mixture of 10 to 20 wt% of EVA rubber and 80 to 90 wt% of LLDPE chips, and the surface nonwoven layer (1) ), the third process of obtaining the material (A) having the structure of the acrylic latex layer (2) and the LWTPE sound insulating coating layer (3), and d) the low-weight LWTPE sound insulating coating by molding the material (A) of the third process It consists of a 4th process of manufacturing a floor carpet molded article for use.
상기 저중량 LWTPE 차음코팅을 이용한 자동차용 플로어 카펫의 제조방법의 일 실시형태로 상기 제1 공정의 표면부직포층(1)이 6데니어의 LM섬유 10중량%, 6데니어의 PET섬유 40중량% 및 10데니어의 PET섬유 50중량%로 조성된 부직포로 이루어진다.In an embodiment of the method for manufacturing a floor carpet for automobiles using the low-weight LWTPE sound insulation coating, the surface nonwoven fabric layer 1 of the first process comprises 10% by weight of 6 denier LM fibers, 40% by weight of 6 denier PET fibers, and 10 It consists of a nonwoven fabric composed of 50% by weight of denier PET fibers.
상기 저중량 LWTPE 차음코팅을 이용한 자동차용 플로어 카펫의 제조방법의 또 다른 실시형태로 상기 제1 공정의 표면부직포층(1)이 6데니어의 LM섬유 30중량%, 6데니어의 PET섬유 40중량% 및 10데니어의 PET섬유 30중량%로 조성된 표면부직포로 이루어진다.In another embodiment of the method for manufacturing a floor carpet for automobiles using the low-weight LWTPE sound insulation coating, the surface nonwoven fabric layer 1 of the first process contains 30% by weight of 6 denier LM fibers, 40% by weight of 6 denier PET fibers and It consists of a surface nonwoven fabric composed of 10 denier PET fiber 30% by weight.
상기 저중량 LWTPE 차음코팅을 이용한 자동차용 플로어 카펫의 제조방법의 또 다른 실시형태로 상기 제1 공정의 표면부직포층(1)이 6데니어의 LM섬유 30중량%, 6데니어의 PET섬유 40중량% 및 중공사 30중량%로 조성된 부직포로 이루어진다. In another embodiment of the method for manufacturing a floor carpet for automobiles using the low-weight LWTPE sound insulation coating, the surface nonwoven fabric layer 1 of the first process contains 30% by weight of 6 denier LM fibers, 40% by weight of 6 denier PET fibers and It consists of a nonwoven fabric composed of 30% by weight of hollow fibers.
상기 제4 공정은 소재(A)를 성형압력 10Kgf/㎠, 가열조건 230℃로 40초 가열 가압하여 성형하고, 80℃이하로 냉각한 후에 제품을 취출한다.In the fourth step, the material (A) is heat-pressed for 40 seconds under a molding pressure of 10Kgf/cm 2 and a heating condition of 230°C, and the product is taken out after cooling to 80°C or less.
본 발명에 따른 저중량 LWTPE 차음코팅을 이용한 자동차용 플로어 카펫은 기존의 자동차용 플로어 카펫에서 PE 코팅 및 고무계 코팅으로 이루어진 무거운 차음층을 저중량 열가소성 폴리에틸렌의 차음코팅층으로 대체하여 자동차용 플로어 카페트를 보다 경량화한 개선된 효과를 나타냄과 동시에 흡·차음 성능도 기존의 플로어 카펫과 동등 이상 수준을 갖는 특징이 있다.The floor carpet for automobiles using the low-weight LWTPE sound insulation coating according to the present invention replaces the heavy sound insulation layer made of PE coating and rubber coating in the existing floor carpet for automobiles with a sound insulation coating layer of low-weight thermoplastic polyethylene to make the floor carpet for automobiles lighter. It exhibits an improved effect and at the same time has the characteristics of having the same or higher level of sound absorption and insulation performance than that of the existing floor carpet.
도 1은 본 발명의 저중량 LWTPE 차음코팅을 이용한 자동차용 플로어 카펫의 단면도를 나타내는 사진
도 2는 본 발명의 저중량 LWTPE 차음코팅을 이용한 자동차용 플로어 카펫의 성형품을 나타낸 사진1 is a photograph showing a cross-sectional view of a floor carpet for automobiles using a low-weight LWTPE sound insulation coating of the present invention;
Figure 2 is a photograph showing a molded article of the floor carpet for automobiles using the low-weight LWTPE sound insulation coating of the present invention;
이하에서는 실시예 및 시험예 등에 의해 본 발명을 더욱 구체적으로 설명하겠으며, 아래 기재에 의해 본 발명이 한정되는 것은 아니다.Hereinafter, the present invention will be described in more detail by way of Examples and Test Examples, and the present invention is not limited by the description below.
본 발명에 따른 저중량 LWTPE 차음코팅을 이용한 자동차용 플로어 카펫은 6데니어의 LM섬유, 6데니어의 PET섬유 및 10데니어의 PET섬유로 조성된 표면부직포층(1), 아크릴 라텍스층(2) 및 EVA 고무 10 ~ 20중량%와 LLDPE칩 80 ~ 90중량%로 조성된 LWTPE 차음코팅층(3)로 이루어진다.The floor carpet for automobiles using the low-weight LWTPE sound insulation coating according to the present invention is composed of 6 denier LM fibers, 6 denier PET fibers, and 10 denier PET fibers. It consists of a LWTPE sound insulation coating layer (3) composed of 10 to 20% by weight of rubber and 80 to 90% by weight of LLDPE chips.
본 발명에 따른 상기 표면부직포층(1)은 6데니어의 LM섬유, 6데니어의 PET섬유 및 10데니어의 PET섬유로 조성된 부직포로 이루어지며, 차음효과를 증대시키기 위해 밀도 제어를 통한 고밀도와 저밀도의 2-way 방식을 결합한 velour punching 결합기술을 적용하여 표면부직포층(1)을 형성하는 것을 포함한다.The surface nonwoven fabric layer (1) according to the present invention is made of a nonwoven fabric composed of 6 denier LM fibers, 6 denier PET fibers, and 10 denier PET fibers. It includes forming the surface non-woven fabric layer (1) by applying the velour punching bonding technique combined with the 2-way method of
상기 표면부직포층(1)에 따른 LM섬유와 PET섬유의 조성비율은 6데니어의 LM섬유 30중량%, 6데니어의 PET섬유 40중량% 및 10데니어의 PET섬유 30중량%로 조성되며 또 다른 조성비율은 6데니어의 LM섬유 10중량%, 6데니어의 PET섬유 40중량% 및 10데니어의 PET섬유 50중량%로 조성된다.The composition ratio of LM fibers and PET fibers according to the surface nonwoven fabric layer (1) is 30% by weight of LM fibers of 6 denier, 40% by weight of PET fibers of 6 denier, and 30% by weight of PET fibers of 10 denier. The ratio is composed of 10 wt% of 6 denier LM fiber, 40 wt% of 6 denier PET fiber, and 50 wt% of 10 denier PET fiber.
또한 상기 표면부직포층(1)은 상기 6데니어의 LM섬유 30중량%, 6데니어의 PET섬유 40중량% 및 PET 섬유소재의 중공사 30중량%로 조성되는 것도 가능하며, 상기 표면부직포층(1)은 300 ~ 450g/㎡의 면밀도로 제작된다.In addition, the surface nonwoven fabric layer (1) may be composed of 30 wt% of the 6 denier LM fiber, 40 wt% of the 6 denier PET fiber, and 30 wt% of the hollow fiber of the PET fiber material, and the surface nonwoven fabric layer (1) ) is manufactured with an areal density of 300 to 450 g/m2.
본 발명의 상기 아크릴 라텍스층(2)은 흡음기능 및 차음기능 확대를 위하여 고형분 40중량%의 아크릴 라텍스 액을 발포시킨 발포용액을 Back-Knife-Coating 기술을 이용하여 표면부직포층(1)의 표면으로 코팅하여 45 ~ 100g/㎡의 아크릴 라텍스층(2)을 형성한다. The acrylic latex layer (2) of the present invention is a foaming solution in which an acrylic latex solution having a solid content of 40% by weight is foamed in order to expand the sound absorption and sound insulation functions by using the Back-Knife-Coating technology on the surface of the nonwoven fabric layer (1) to form an acrylic latex layer (2) of 45 to 100 g/m 2 by coating with .
상기 아크릴 라텍스층(2)은 흡음기능, 차음기능의 확대 및 중량과 관련하여 아크릴 라텍스 용액을 고배율발포와 저배율발포의 조화가 필수적이며, 본 발명에서는 저압발포와 고압발포 순으로 2회 발포시켜 작은 크기의 기포 약 50%, 큰 크기의 기포 약 50%의 량으로 제어한 아크릴 라텍스 발포액으로 아크릴 라텍스층(2)을 형성한다.The acrylic latex layer (2) is essential in terms of the expansion and weight of the sound absorbing function and the sound insulation function, in which the acrylic latex solution must be in harmony with the high magnification foaming and the low magnification foaming. The acrylic latex layer 2 is formed with the acrylic latex foaming liquid controlled in an amount of about 50% of the size of the bubble and about 50% of the large size of the bubble.
본 발명의 상기 LWTPE 차음코팅층(3)은 EVA rubber 칩 10중량%, PE 칩 90중량% 혼합한 배합물을 압출에 의해 LWTPE 차음코팅층(3)을 형성하여 상기한 표면부직포층(1), 아크릴 라텍스층(2) 및 LWTPE 차음코팅층(3)의 적층구조를 갖는 저중량 LWTPE 차음코팅을 이용한 자동차용 플로어 카펫(소재)을 얻는다.The LWTPE sound insulating coating layer (3) of the present invention forms the LWTPE sound insulating coating layer (3) by extruding a mixture of 10 wt% of EVA rubber chips and 90 wt% of PE chips, and the surface nonwoven fabric layer (1), acrylic latex A floor carpet (material) for automobiles using a low-weight LWTPE sound insulating coating having a laminate structure of the layer (2) and the LWTPE sound insulating coating layer (3) is obtained.
그리고 본 발명에 따른 저중량 LWTPE 차음코팅을 이용한 자동차용 플로어 카펫의 제조방법은 a). LM섬유 및 PET섬유로 조성된 부직포(1a) 또는 LM섬유, PET섬유 및 중공사로 조성된 부직포(1b)로 표면부직포층(1)을 형성하는 제1 공정, b). 상기 제1 공정의 표면부직포층(1)의 표면으로 아크릴 라텍스 용액을 저압발포와 고압발포 순으로 발포시킨 라텍스 발포액으로 코팅하여 아크릴 라텍스층(2)을 형성하는 제2 공정, c).상기 제2 공정의 아크릴 라텍스층(2)의 표면으로 EVA rubber 칩 10 ~ 20중량%와 LLDPE 칩 80 ~ 90중량%로 배합한 배합물을 압출에 의해 LWTPE 차음코팅층(3)을 형성하여 표면부직포층(1), 아크릴 라텍스층(2) 및 LWTPE 차음코팅층(3)의 구조를 갖는 소재(A)를 얻는 제3 공정 및 d) 상기 제3 공정의 소재(A)를 성형하여 저중량 LWTPE 차음코팅을 이용한 자동차용 플로어 카펫 성형품을 제작하는 제4 공정으로 이루어진다.And the manufacturing method of the floor carpet for automobiles using the low-weight LWTPE sound insulation coating according to the present invention is a). A first step of forming a surface nonwoven fabric layer (1) with a nonwoven fabric (1a) composed of LM fibers and PET fibers or a nonwoven fabric (1b) composed of LM fibers, PET fibers and hollow fibers, b). A second step of forming the acrylic latex layer (2) by coating the acrylic latex solution on the surface of the surface nonwoven fabric layer (1) in the first step with the latex foaming solution in the order of low-pressure foaming and high-pressure foaming, c). As the surface of the acrylic latex layer (2) in the second process, the LWTPE sound insulating coating layer (3) is formed by extruding a mixture of 10 to 20% by weight of EVA rubber chips and 80 to 90% by weight of LLDPE chips to form a surface nonwoven layer ( 1), a third process of obtaining a material (A) having the structure of an acrylic latex layer (2) and an LWTPE sound insulating coating layer (3), and d) molding the material (A) of the third process using a low-weight LWTPE sound insulating coating It consists of a 4th process of manufacturing the floor carpet molded article for an automobile.
본 발명에 따른 상기 제1 공정은 상기 부직포(1a) 또는 상기 부직포(1b)로 표면부직포층(1)을 형성하는 공정이다.The first step according to the present invention is a step of forming the surface nonwoven fabric layer 1 from the nonwoven fabric 1a or the nonwoven fabric 1b.
상기 부직포(1a)는 6데니어의 LM섬유 30중량%, 6데니어의 PET섬유 40중량% 및 10데니어의 PET섬유 30중량%로 조성되는 부직포 또는 6데니어의 LM섬유 10중량%, 6데니어의 PET섬유 40중량% 및 10데니어의 PET섬유 50중량%로 조성되는 부직포로 이루어진다.The nonwoven fabric (1a) is a nonwoven fabric composed of 30% by weight of 6 denier LM fibers, 40% by weight of 6 denier PET fibers, and 30% by weight of 10 denier PET fibers or 10% by weight of 6 denier LM fibers, 6 denier PET. It consists of a nonwoven fabric composed of 40% by weight of fibers and 50% by weight of 10 denier PET fibers.
또 상기 부직포(1b)는 6데니어의 LM섬유 30중량%, 6데니어의 PET섬유 40중량% 및 PET 섬유소재의 중공사 30중량%로 조성된 부직포로 이루어지며, 상기 표면부직포층(1)은 300 ~ 450g/㎡의 면밀도로 제작된다.In addition, the nonwoven fabric 1b is composed of a nonwoven fabric composed of 30% by weight of 6 denier LM fibers, 40% by weight of 6 denier PET fibers, and 30% by weight of hollow fibers of PET fiber material, and the surface nonwoven fabric layer 1 is It is manufactured with an areal density of 300 ~ 450g/m2.
본 발명에 따른 상기 제2 공정은 아크릴 라텍스 용액을 저압발포와 고압발포 순으로 발포시켜 기포크기와 기포량을 제어한 아크릴 라텍스 발포액으로 코팅하여 아크릴 라텍스층(2)을 형성하는 공정이다.The second process according to the present invention is a process of forming the acrylic latex layer 2 by foaming the acrylic latex solution in the order of low pressure foaming and high pressure foaming, and coating it with the acrylic latex foaming solution in which the bubble size and the amount of bubbles are controlled.
상기 아크릴 라텍스 발포액은 저압발포 또는 고압발포의 발포조건에 따라 기포크기, 기포량에 차이가 있으며 또한 저압발포 또는 고압발포의 조합 및 순서에 의해서도 차이가 있다. 이러한 발포조건은 아크릴 라텍스층(2)의 폼형성에 의해 흡음기능, 차음기능의 확대 및 중량에 상당한 영향을 미친다.The acrylic latex foaming liquid has a difference in bubble size and bubble amount depending on the foaming conditions of low-pressure foaming or high-pressure foaming, and there is also a difference in the combination and sequence of low-pressure foaming or high-pressure foaming. These foaming conditions have a significant effect on the expansion and weight of the sound absorption function and sound insulation function by the foam formation of the acrylic latex layer (2).
본 발명에서의 상기 아크릴 라텍스 발포액은 고형분 40중량%의 아크릴 라텍스 액을 저압발포와 고압발포 순으로 발포시켜 2 ~ 4㎜ 크기의 작은 기포 50%와 8 ~ 12㎜ 크기의 큰 기포 50%로 제어한 발포액으로 이루어지며, 상기 발포액으로 45 ~ 100g/㎡의 아크릴 라텍스층(2)을 형성한다..The acrylic latex foaming liquid in the present invention is made by foaming the acrylic latex liquid having a solid content of 40% by weight in the order of low-pressure foaming and high-pressure foaming to 50% of small cells of 2 to 4 mm and 50% of large cells of 8 to 12 mm. It consists of a controlled foaming liquid, and the acrylic latex layer 2 of 45 ~ 100g/m 2 is formed with the foaming liquid.
상기한 발포조건에서 고압발포와 저압발포 순으로 발포시키면, 작은 크기의 폼의 량은 상대적으로 작고(약 10%), 큰 크기의 폼의 량은 상대적으로 많은(약 90%) 발포액이 얻어지므로 본 발명의 조건을 만족시킬 수가 없으며, 발포액의 제어는 본 발명이 속한 기술분야에서 통상 사용하는 발포기의 조작 및 변형 등에 의해 가능하다.When foaming in the order of high-pressure foaming and low-pressure foaming under the above foaming conditions, the amount of small-sized foam is relatively small (about 10%), and the amount of large-sized foam is relatively large (about 90%). Therefore, the conditions of the present invention cannot be satisfied, and the control of the foaming liquid is possible by operation and modification of the foaming machine commonly used in the technical field to which the present invention belongs.
본 발명에 따른 상기 제3 공정은 상기 아크릴 라텍스층(2)의 표면으로 LWTPE 차음코팅층(3)을 형성하여 표면부직포층(1), 아크릴 라텍스층(2) 및 LWTPE 차음코팅층(3)의 구조를 갖는 소재(A)를 얻는 공정이다.In the third process according to the present invention, the LWTPE sound insulating coating layer 3 is formed on the surface of the acrylic latex layer 2, so that the surface nonwoven fabric layer 1, the acrylic latex layer 2 and the LWTPE sound insulating coating layer 3 are structured It is a process of obtaining a material (A) having
상기 제3 공정은 EVA 고무 칩 10 ~ 20중량% 및 LLDPE 칩 80 ~ 90중량%로 조성된 배합물을 압출에 의해 450 ~ 600g/㎡의 LWTPE 차음코팅층(3)을 형성하는 것으로 이루어지며, 상기 EVA 고무는 에틸렌비닐아세테이트공중합체이고, LLDPE는 선형저밀도폴리에틸렌이다.The third process consists of forming the LWTPE sound insulation coating layer 3 of 450 to 600 g/m 2 by extruding a mixture composed of 10 to 20 wt % of EVA rubber chips and 80 to 90 wt % of LLDPE chips, and the EVA The rubber is an ethylene vinyl acetate copolymer, and LLDPE is a linear low-density polyethylene.
본 발명에 따른 상기 제4 공정은 제3 공정에서 얻은 소재(A)를 통상의 플로어 카펫 성형수단에 의해 성형하여 저중량 LWTPE 차음코팅을 이용한 자동차용 플로어 카펫 성형품을 제조하는 공정이다.The fourth process according to the present invention is a process of manufacturing a floor carpet molded article for automobiles using a low-weight LWTPE sound insulation coating by molding the material (A) obtained in the third process by a conventional floor carpet molding means.
상기 제4 공정은 성형압력 10Kgf/㎠, 가열조건 230℃로 40초 가열가압하는 성형조건으로 성형한 다음 80℃이하로 냉각한 후에 제품을 취출하는 것으로 이루어진다.The fourth step consists in taking out the product after molding under the molding conditions of heating and pressing for 40 seconds at a molding pressure of 10Kgf/cm 2 and heating conditions of 230°C, and then cooled to 80°C or less.
<실시예 1> 자동차용 플로어 카펫 소재 제조<Example 1> Manufacturing of floor carpet material for automobiles
미리 준비한 6D LM섬유 10%, 6D PET섬유40%, 10D PET섬유 50%로 조성된 400g/㎡의 부직포을 표면부직포층으로 하고, 표면부직포층 표면으로 고형분 40중량%의 아크릴 라텍스 액을 저압발포와 고압발포 순으로 발포시켜 기포크기 3㎜(평균) 50%와 기포크기 10㎜(평균) 50%로 제어한 발포액으로 50g/㎡의 아크릴 라텍스층을 형성한다.A nonwoven fabric of 400 g/m2 composed of 10% of 6D LM fiber, 40% of 6D PET fiber, and 50% of 10D PET fiber prepared in advance was used as the surface non-woven fabric layer, and an acrylic latex solution having a solid content of 40 wt% was applied to the surface of the non-woven fabric layer by low pressure foaming and An acrylic latex layer of 50 g/m 2 is formed by foaming in the order of high-pressure foaming with a foaming liquid controlled to a cell size of 3 mm (average) of 50% and a cell size of 10 mm (average) of 50%.
이후, EVA고무 칩10%, LLDPE 칩 90%을 배합한 배합물을 준비한 다음 압출기를 이용하여 상기한 아크릴 라텍스층의 표면으로 배합물을 압출하여 500g/㎡의 LWTPE 차음코팅층을 형성하여 표면부직포층(1), 아크릴 라텍스층(2) 및 LWTPE 차음코팅층(3)의 구조를 갖는 소재(A)를 제조하였다.After that, a formulation containing 10% EVA rubber chips and 90% LLDPE chips was prepared, and then the formulation was extruded onto the surface of the acrylic latex layer using an extruder to form a 500 g/m2 LWTPE sound insulation coating layer, and a surface nonwoven fabric layer (1 ), an acrylic latex layer (2) and a material (A) having the structure of the LWTPE sound insulation coating layer (3) was prepared.
<실시예 2> 자동차용 플로어 카펫 성형<Example 2> Molding of floor carpet for automobile
상기 <실시예 1>에서 제조한 자동차용 플로어 카펫의 소재(A)를 이용하여 아래 [표 1]에 나타낸 성형조건으로 성형하여 자동차용 플로어 카펫 성형품을 제조하였다.Using the material (A) of the floor carpet for automobiles manufactured in <Example 1>, it was molded under the molding conditions shown in [Table 1] below to manufacture a floor carpet for automobiles.
<시험예><Test Example>
상기 <실시예 1>에서 제조한 자동차용 플로어 카펫의 소재 및 <실시예 2>에서 성형한 성형품의 시편을 제작한 다음 시편에 대하여 물리적 특성를 시험하고 그 결과아래 [표 2]에 나타내었다.The material of the floor carpet for automobiles manufactured in <Example 1> and the specimen of the molded article molded in <Example 2> were prepared, and the physical properties of the specimen were tested, and the results are shown in [Table 2] below.
(20%이상)950 or less
(20% or more)
가로방향 38.7Portrait 45.2
Horizontal 38.7
가로방향 39.1Portrait 44.5
Landscape 39.1
가로방향 +0.3Vertical +0.2
Horizontal +0.3
Claims (4)
표면부직포층(1)이 6데니어의 LM섬유 30중량%, 6데니어의 PET섬유 40중량% 및 10데니어의 PET섬유 30중량%로 조성되거나 또는 6데니어의 LM섬유 10중량%, 6데니어의 PET섬유 40중량% 및 10데니어의 PET섬유 50중량%로 조성되는 것을 특징으로 하는 저중량 열가소성 폴리에틸렌 차음코팅을 이용한 자동차용 플로어 카펫.The method according to claim 1,
The surface nonwoven fabric layer (1) is composed of 6 denier LM fibers 30% by weight, 6 denier PET fibers 40% by weight, and 10 denier PET fibers 30% by weight, or 6 denier LM fibers 10% by weight, 6 denier PET fibers A floor carpet for automobiles using a low-weight thermoplastic polyethylene sound insulation coating, characterized in that it is composed of 40% by weight of fibers and 50% by weight of 10 denier PET fibers.
표면부직포층(1)이 6데니어의 LM섬유 30중량%, 6데니어의 PET섬유 40중량% 및 중공사 30중량%로 조성되는 것을 특징으로 하는 저중량 열가소성 폴리에틸렌 차음코팅을 이용한 자동차용 플로어 카펫.The method according to claim 1,
A floor carpet for automobiles using a low-weight thermoplastic polyethylene sound insulation coating, characterized in that the surface nonwoven fabric layer (1) is composed of 30% by weight of 6 denier LM fibers, 40% by weight of 6 denier PET fibers, and 30% by weight of hollow fibers.
b). 상기 제1 공정의 표면부직포층(1)의 표면으로 아크릴 라텍스 용액을 저압발포와 고압발포 순으로 발포시켜 2 ~ 4㎜ 크기의 작은 기포, 50%와 8 ~ 12㎜ 크기의 큰 기포 50%로 이루어지도록 제어한 발포액으로 코팅하여 아크릴 라텍스층(2)을 형성하는 제2 공정,
c).상기 제2 공정의 아크릴 라텍스층(2)의 표면으로 EVA 고무 10 ~ 20중량%와 LLDPE 80 ~ 90중량%로 배합한 배합물을 압출에 의해 LWTPE 차음코팅층(3)을 형성하여 표면부직포층(1), 아크릴 라텍스층(2) 및 LWTPE 차음코팅층(3)의 구조를 갖는 소재(A)를 얻는 제3 공정 및
d). 상기 제3 공정의 소재(A)를 성형하여 저중량 LWTPE 차음코팅을 이용한 자동차용 플로어 카펫 성형품을 제작하는 제4 공정을 포함하는 것을 특징으로하는 저중량 열가소성 폴리에틸렌 차음코팅을 이용한 자동차용 플로어 카펫의 제조방법.a). A nonwoven fabric (1a) composed of 6 denier LM fibers, 6 denier PET fibers, and 10 denier PET fibers or a nonwoven fabric (1b) composed of 6 denier LM fibers, 6 denier PET fibers and hollow fibers. 1) forming a first process,
b). The acrylic latex solution is foamed in the order of low-pressure foaming and high-pressure foaming on the surface of the surface nonwoven fabric layer 1 of the first process, and 50% of small bubbles of size 2 to 4 mm, and 50% of large bubbles of size 8 to 12 mm. A second process of forming an acrylic latex layer (2) by coating with a foaming solution controlled to be made;
c). As the surface of the acrylic latex layer (2) in the second step, the LWTPE sound insulation coating layer (3) is formed by extrusion of a mixture of 10 to 20 wt% of EVA rubber and 80 to 90 wt% of LLDPE, and a surface nonwoven fabric A third step of obtaining a material (A) having the structure of a layer (1), an acrylic latex layer (2) and an LWTPE sound insulating coating layer (3);
d). Method for manufacturing a floor carpet for automobiles using a low-weight thermoplastic polyethylene sound-insulating coating, comprising a fourth step of molding the material (A) of the third step to produce a molded product for a floor carpet for automobiles using a low-weight LWTPE sound-insulating coating .
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