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KR-20260063859-A - Method for producing headliner parts using high heat resistance, high strength and lightweight composite

KR20260063859AKR 20260063859 AKR20260063859 AKR 20260063859AKR-20260063859-A

Abstract

The present invention relates to a method for manufacturing an automotive interior part using a high-heat-resistant, high-rigidity, lightweight composite material, comprising: a step of forming a foamed sheet using a polyester resin composition; a step of forming a composite material by laminating the foamed sheet and the nonwoven fabric while simultaneously manufacturing a nonwoven fabric containing natural fibers and low-melting point fibers through needle punching; and a step of molding the composite material.

Inventors

  • 허미
  • 이광희
  • 서영훈
  • 김동원
  • 류지원

Assignees

  • 주식회사 휴비스
  • 주식회사 서연이화

Dates

Publication Date
20260507
Application Date
20241031

Claims (16)

  1. A step of preparing a foamed sheet comprising a polyester resin composition; A step of manufacturing a nonwoven fabric comprising natural fibers and low-melting point fibers through needle punching, while simultaneously combining a foamed sheet and a nonwoven fabric to form a composite material; and A method for manufacturing automotive interior parts comprising the step of molding a composite material.
  2. In paragraph 1, A method for manufacturing automotive interior parts in which non-woven fabric is bonded to both sides of a foam sheet.
  3. In paragraph 1, A method for manufacturing automotive interior parts in which the weight of the nonwoven fabric is 200 to 500 g/m².
  4. In paragraph 1, A method for manufacturing automotive interior parts comprising a nonwoven fabric comprising 10 to 90 weight% of natural fibers and 10 to 90 weight% of low melting point fibers.
  5. In paragraph 1, A method for manufacturing automotive interior parts, wherein the nonwoven fabric further comprises 0 to 50 weight percent of polypropylene fibers.
  6. In paragraph 1, A method for manufacturing automotive interior parts by destroying closed cells of a foam sheet to form open cells through needle punching.
  7. In paragraph 1, A method for manufacturing automotive interior parts in which the natural fiber is hemp fiber and the low-melting point fiber is low-melting point polyester fiber.
  8. In paragraph 1, A method for manufacturing automotive interior parts comprising a polyester resin composition of a foamed sheet, a polyester resin, a thickener, a nucleating agent, and a foaming agent.
  9. In paragraph 8, A method for manufacturing automotive interior parts, wherein the intrinsic viscosity of the polyester resin is 0.65 to 1 dL/g, and the molecular ratio of the polyester resin having a molecular weight of 10,000 or more is 60 weight% or more based on the total weight of the polyester resin.
  10. In paragraph 1, A method for manufacturing an automotive interior part, wherein the weight of the foam sheet is 200 to 500 g/m², the density of the foam sheet is 80 to 400 kg/m³, the thickness of the foam sheet is 1 to 3.5 mm, or the cell size of the foam sheet is 100 to 700 μm.
  11. In paragraph 1, A method for manufacturing automotive interior parts in which the weight of the composite material is 600 to 1500 g/m².
  12. In paragraph 1, A method for manufacturing automotive interior parts, wherein in the molding step, the composite material is preheated using a heater and then molded using a press.
  13. In paragraph 1, A method for manufacturing automotive interior parts in which the peel strength between the foam sheet and the non-woven fabric is 5 N/25 mm or more.
  14. In paragraph 1, A method for manufacturing an automotive interior part having a flexural strength of 29 N or more as a maximum load.
  15. In paragraph 1, A method for manufacturing automotive interior parts that pass through a 90℃ heat-resistant cycle.
  16. In paragraph 1, A method for manufacturing automotive interior parts having a volatile organic compound content of 11,000 μg/m³ or less.

Description

Method for producing headliner parts using high heat resistance, high strength and lightweight composite The present invention relates to a method for manufacturing an automotive interior part using a high-heat-resistant, high-rigidity, lightweight composite material. Automotive interior materials use PP (Polypropylene) boards, natural fiber reinforced boards (HS Felt), glass fiber PP boards, PU (Polyurethane) foam, etc. as base materials, and PET nonwoven fabrics, etc. as surface and backing materials. Automotive parts are manufactured through a molding process using composite materials formed by combining the base material and the surface material. Recently, due to eco-friendly trends, there is an increasing need for lightweight materials that can reduce fuel consumption, recyclable materials that can comply with European ELV regulations, and single materials that can be recycled after scrapping the vehicle. Automotive interior materials utilize a foamed layer as a substrate for lightweighting, and a single material can be manufactured by combining a PET foamed layer substrate with a PET nonwoven fabric. The molding process in the domestic automotive industry primarily uses cold forming, and single-material composites combining a PET foamed layer substrate and a PET nonwoven fabric exhibit heat resistance performance of approximately 80°C when this conventional molding method is applied. To achieve high heat resistance of over 90°C using a single PET material, the molding process must be changed to a hot forming process; however, due to the high equipment investment costs involved, commercialization in Korea is currently difficult. In domestic molding processes, a PET foam substrate can be utilized to manufacture a composite material with a reinforcing nonwoven fabric to complement high rigidity and heat resistance. Required performance characteristics for application as automotive interior materials include, for example, physical properties such as moldability, peel strength, flexural strength, and heat resistance. Figure 1 is a schematic diagram of a composite material according to the present invention. FIG. 2 is a schematic diagram of a needle punching process according to the present invention. The present invention will be described in detail below. The present invention relates to a method for manufacturing an automotive interior part using a high-heat-resistant, high-rigidity lightweight composite material, and may include a foam sheet forming step, a composite material forming step, and a composite material molding step. First, a foamed sheet is formed using a polyester resin composition. The foamed sheet may be formed from a polyester resin composition as a core substrate layer having a plurality of cells and a predetermined thickness, having a first surface (e.g., an upper surface) and a second surface (e.g., a lower surface). The polyester resin composition may include a polyester resin, a thickener, a nucleating agent, and a foaming agent. The polyester resin may be a polyethylene terephthalate (PET) resin as the main component, preferably. By using PET resin, it can be environmentally friendly and easy to reuse. Virgin PET resin and/or recycled PET resin may be used as the PET resin. To improve physical properties, the PET resin used in the foamed sheet may be a PET resin having a specific range for intrinsic viscosity, molecular weight, molecular weight distribution and/or melting point, etc. The intrinsic viscosity (IV) of the PET resin may be, for example, 0.65 dL/g or more, 0.7 dL/g or more, 0.72 dL/g or more, 0.74 dL/g or more, or 0.76 dL/g or more; it may also be 1.0 dL/g or less, 0.95 dL/g or less, 0.9 dL/g or less, 0.85 dL/g or less, or 0.82 dL/g or less, for example, 0.65 to 1 dL/g, 0.7 to 0.95 dL/g, 0.72 to 0.9 dL/g, 0.74 to 0.85 dL/g, or 0.76 to 0.82 dL/g. If the intrinsic viscosity (IV) of the PET resin is too low, the cell size of the foamed sheet increases, and the moldability and rigidity may decrease. The weight-average molecular weight (Mw) of the PET resin may be 20,000 to 200,000, 50,000 to 150,000, or 60,000 to 100,000. The weight-average molecular weight can be measured by gel permeation chromatography (GPC, analytical instrument HLC-8320), and polymethyl methacrylate (PMMA) may be used as a standard sample. The unit of molecular weight may be g/mol or Da. In particular, the PET resin may be a PET resin in which the proportion of molecules with a molecular weight of 10,000 or more, indicated by the fine molecular weight distribution, accounts for 60% or more of the total weight of the PET resin. That is, the proportion of molecules with a molecular weight of 10,000 or more in the PET resin may be 60% or more of the total weight of the PET resin, and the proportion of molecules with a molecular weight of less than 10,000 may be less than 40% of the total weight. The proportion of molecules with a molecular weight of 10,000 or more may be 60% or more, 65% or more of the mo