WO2008044892A1 - Multi-layer sheet of motor vehicles interior products and manufacturing method thereof - Google Patents

Multi-layer sheet of motor vehicles interior products and manufacturing method thereof Download PDF

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Publication number
WO2008044892A1
WO2008044892A1 PCT/KR2007/005000 KR2007005000W WO2008044892A1 WO 2008044892 A1 WO2008044892 A1 WO 2008044892A1 KR 2007005000 W KR2007005000 W KR 2007005000W WO 2008044892 A1 WO2008044892 A1 WO 2008044892A1
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WO
WIPO (PCT)
Prior art keywords
mat
fibers
motor vehicles
layer sheet
interior materials
Prior art date
Application number
PCT/KR2007/005000
Other languages
French (fr)
Inventor
Duckcheol Seo
Original Assignee
Huneco Co., Ltd
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Filing date
Publication date
Application filed by Huneco Co., Ltd filed Critical Huneco Co., Ltd
Publication of WO2008044892A1 publication Critical patent/WO2008044892A1/en

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Classifications

    • 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
    • B32B5/26—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 another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/04—Punching, slitting or perforating
    • 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
    • B32B5/06—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 characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • 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
    • B32B5/08—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 the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • 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
    • D04H1/425—Cellulose series
    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/485—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with weld-bonding
    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
    • 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
    • D04H1/54—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 by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—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 by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • 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
    • D04H13/00—Other non-woven fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/04—Punching, slitting or perforating
    • B32B2038/042—Punching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/536—Hardness
    • 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
    • B32B2605/00—Vehicles
    • B32B2605/003—Interior finishings
    • 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
    • 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
    • B60R13/08—Insulating elements, e.g. for sound insulation
    • B60R13/0815—Acoustic or thermal insulation of passenger compartments

Definitions

  • the present invention relates to a multi-layer sheet for interior materials of motor vehicles. More specifically, the present invention relates to a multi-layer sheet for interior materials to make lightweighted motor vehicles, which can be applied to door trims, package trays, headliners, etc.
  • FRP thermoplastic olefin having high heat resistance and stiffness
  • polymers such as polypropylene or thermoplastic olefin that were reinforced by talc, glass fiber, carbon fiber, etc., or thermosetting composite materials by rubberization of unsaturated polyester type resins and thermoplastic polymers.
  • the present invention was designed to solve such problems, making them reusable by mixing thermoplastic resin fibers and natural fibers and developed automotive interior materials that have lightweightness and satisfy excellent strength and sound absorption/heat insulating capacity.
  • the object of the present invention is to provide a multi-layer sheet suitable for automotive interior materials that can be reusable and lightweighted by mixing thermoplastic resin fibers and natural fibers and by using a specific thickness range of the fibers, which are 20 ⁇ 95 weight % of 10-20 Denier fibers and 5-80 weight % of 2-7
  • Denier fibers resulting in empty spaces due to the thickness difference among the fibers to improve sound absorption and heat insulation and intensify the strength.
  • the present invention relates to a multi-layer sheet for interior materials of motor vehicles, which can be applied to door trims, package trays, headliners, etc., and the manufacturing method thereof .
  • the present invention relates to a multi-layer sheet for interior materials of motor vehicles with excellent strength and sound absorption/heat insulating capacity, obtained by fabricating a mat through mixing and opening more than one thermoplastic resin fibers and more than one natural fibers and laminating more than one layer using the stampable sheet machine for the mats, which are mixed with 20-95 weight % of 10-20 Denier fiber and 5-80 weight % of 2-7
  • the present invention was completed by finding that forming pores among fibers using a specific range of thickness of the fibers improved strength, sound absorption, and heat insulating capacity.
  • the manufacturing method of the multi-layer sheet according to the present invention includes the followings: a) a step where more than one thermoplastic resin fibers and more than one natural fibers, which are 20-95 weight % of 10-20 Denier fiber and 5-80 weight % of 2-7 Denier fiber, are mixed and opened; b) a step where the mixed and opened fibers pass through the carding machine to form a mat ; c) a step where the above mat is laminated with more than one layer ; d) a step where the above mat with more than one layer is fixed by needle punching; e) a step where the layered mat goes through preheating, thermal bonding, pressurizing, cooling and cutting by the stampable sheet fabrication machine.
  • thermoplastic resin fibers There is no restriction on the kind of thermoplastic resin fibers if they are the ones generally used in this field, but it is more desirable to use more than one selected from the group consisting of polyethylene; polypropylene; polyvinylchloride; polyester; polyethylene-polyester copolymer; nylon 6; nylon 66; and nylon 10, whose resins have the property of proper processing temperature and great process capacity. It is desirable to use 30-95 weight % of them. When less than 30 weight % is used, the amount that melts and goes inside natural fibers decreases when making a uniform thickness by thermocompression through the stampable sheet fabrication machine, thus the thickness of the sheet increases and so does its weight. When more than 95 weight % is used, the reinforcement of strength by natural fibers decreases, resulting in unsatisfying strength.
  • hemp which is selected from kenaf, jute, hemp, flax and abaka, cotton, coir, wool, cashmere or silk. It is more desirable to use hemp fibers since they are inexpensive, reinforcing, and easily available.
  • 5-70 weight % is desirable. When less than 5 weight % is used, the effect is too mere. When more than 70 weight % is used, there is a limitation on controlling the thickness of the sheet, resulting in less strength.
  • the mixing rate of the two fibers is within the range of 30-95 weight % of thermoplastic resin fibers and 5-70 weight % of natural fibers. The rate is subject to change if necessary.
  • the property of the multi- layer sheet to be manufactured can be controlled by selectively using the thickness of the fibers. Particularly, it is desirable to mix 10-20 Denier fibers to be 20-95 weight % and 2-7 Denier fibers to be 5-80 weight %.
  • the 10-20 Denier fibers play a role to reinforce the strength, just as the steel reinforcement does for concrete casting.
  • the 2-7 Denier fibers form some pores and reaches high degree of sound absorption/heat insulting effect and strength.
  • the present invention is confined to 10-20 Denier fibers and 2-7 Denier fibers, because when the above fibers were mixed and used, the object of the present invention could be accomplished, which is adequate strength and excellent sound absorption/heat insulating effect, Also, the range of their contents was confined to bring the satisfactory strength and sound absorption/heat insulting capacity.
  • the property of the present invention can be controlled by freely selecting the content and thickness of the natural fibers and thermoplastic resin fibers within the above range. The examples are as follows.
  • thermoplastic resin fibers become melted while fabricating the multi- layer sheet by the stampable sheet fabrication machine and penetrates into the natural fibers, which makes the thickness of the sheet decrease and their surface smooth and uniform.
  • the sheet is made in this manner, it obtains excellent resistance against moisture and improved strength, since its surface becomes fine and smooth.
  • thermoplastic resin fibers are 10-20 Denier and natural fibers 2-7 Denier, a sheet with smoother surface can be obtained.
  • thermoplastic resin fibers are 2-7 Denier and natural fibers 10-20 Denier, its smoothness drops a little, but its strength gets improved and sound absorption and heat insulating capacity increase due to the bulkiness.
  • thermoplastic resin fibers are 2-7 Denier and natural fibers 10-20 Denier, its smoothness drops a little, but its strength gets improved and sound absorption and heat insulating capacity increase due to the bulkiness.
  • thermoplastic resin fibers are 10-20 Denier and natural fibers 2-7 Denier, a sheet with smoother surface can be obtained.
  • thermoplastic resin fibers are 2-7 Denier and natural fibers 10-20 Denier, its sound absorption and heat insulating capacity increase due to the bulkiness.
  • the present invention can properly control the properties if necessary by manufacturing the mat from suitably controlled ratio of thermoplastic resin and natural fibers and laminating more than one layer of the mat.
  • the same mat with more than one layer can be laminated, or more than one mat with more than one layer can be laminated.
  • More than one mat means more than one selected from four kinds of mats suggested in the present invention are selected and layered with other kinds .
  • the four kinds of mats above are as follows: first, the mat having more quantities of thermoplastic resin fibers than natural fibers and using thick thermoplastic resin fibers; second, the mat having more quantities of thermoplastic resin fibers than natural fibers and using thick natural fibers; third, the mat having more quantities of natural fibers than thermoplastic resin fibers and using thick thermoplastic resin fibers; fourth, the mat having more quantities of natural fibers than thermoplastic resin fibers and using thick natural fibers.
  • the present invention can fabricate a multi-layer sheet with various combination of more than one mat selected from the above four mats, so a variety of multi-layer sheets can be made depending on the desired property.
  • thermoplastic resin fibers it is more desirable to put the mat having more quantities of thermoplastic resin fibers on the outermost layer in order to make the surface smooth and keep great resistance against moisture. It is also desirable to lay the mat containing big amount of natural fibers on the inner layer to improve sound absorption and heat insulating capacity.
  • the present invention shows satisfying sound absorption and heat insulating capacity due to pores among fibers by the thickness difference, but in order to reinforce it, it is desirable to use hollow fibers made of thermoplastic resins instead of the above thermoplastic resin fibers for at least one mat that completes the multi- layer sheet.
  • the above hollow fiber means the one containing empty- space inside the fiber, and it is desirable to use one whose heat resistance is at least 5 ° C higher than others.
  • the heat resistance indicates glass transition temperature or melting temperature.
  • these hollow fibers are hollow fibers made of thermoplastic resins such as polyester type, polyethylene type, nylon type, hot-melt fluororesin, etc.
  • the pores can have any forms such as round or triangle and they are not restricted.
  • the hot-melt fluororesins are tetrafluoroethylene- hexafluoropropylene copolymer (FEP) , tetrafluoroethylene- perfluoro alkyl vinyl ether copolymer (PFA) , tetrafluoroethylene-hexafluoropropylene-perfluoro alkyl vinyl ether copolymer (EPA) , tetrafluoroethylene-ethylene copolymer (ETFE), etc.
  • FEP tetrafluoroethylene- hexafluoropropylene copolymer
  • PFA tetrafluoroethylene- perfluoro alkyl vinyl ether copolymer
  • EPA tetrafluoroethylene-hex
  • the thickness of the mats for the present invention is not restricted, since a person skilled in the art can control it if necessary.
  • the 20-95 weight % of 10-20 Denier fibers and 5-80 weight % of 2-7 Denier fibers are mixed and opened; b) a step (S2) where a mat is fabricated after putting the above fibers through the carding machine; c) a step (S3) where the above mat is laminated with more than one layer; d) a step (S4) where the layered mat is fixed by needle punching; e) a step (S5) where the layered mat is put in the stampable sheet fabrication machine equipped with the conveyor belt composed of a number of punching plates, and is preheated so that the hot air can be transferred to the inside of the mat, followed by thermal bonding, pressurizing, cooling, and cutting process.
  • the multi-layer sheet for interior materials of motor vehicles with excellent strength and sound absorption and heat insulting capacity can be manufactured to meet the object of the present invention.
  • thermoplastic resin fibers and 5-70 weight % of natural fibers are uniformly mixed and opened to fabricate a mat. Then they are put through a cylinder type carding machine to form a thin web of a fiber. After laminating various kinds of mats or all the same type of mats and fixating them by needle punching to keep them from moving, they are putting through the stampable sheet fabrication machine equipped with the conveyor belt composed of a number of punching plates, followed by preheating, thermal bonding, pressurizing, cooling, and cutting process, to obtain the sheet of the plate.
  • the above layered mat goes through the preheating zone of the stampable sheet fabrication machine equipped with a heating part, it is fibrillated and melted, penetrating into the reinforced fibers where thermoplastic fibers are tangled.
  • the melted multi-layer non-woven fabrics are pressurized through the pressure rollers in the pressure zone and form a multi-layer sheet with uniform thickness.
  • Changes can be made in the stampable sheet fabrication machine for each use, so the above preheating, thermal bonding, pressurizing, cooling, and cutting process can be changed depending on the combination of the equipment. Their specific temperature, pressure, and other elements are also changeable, so the present invention puts no restriction on that.
  • FIG. 2 shows a conveyor belt for the stampable sheet fabrication machine.
  • the conveyor belt (34) is composed of a number of punching plates (35) to supply hot air to the mat during the heating process.
  • punching plates (35) has some advantages such as improved heating efficiency due to directly supplied hot air from the hot air spray nozzle, better quality due to uniformed interior and exterior parts since the hot air is transferred into the deep part, and shortened the processing time.
  • Figure 3 shows a cross section of the heating part.
  • the hot air from the hot air spray nozzle (36) goes through the conveyor belt (34) composed of punching plates (35) and is transferred to not only the surface of the multi- layer mat (70) but also the deep parts.
  • Supplying the hot air directly to the multi-layer mat (70) has some advantages such as excellent heating efficiency and uniformly heated interior and exterior of the multi-layer mat (70) .
  • the hot air spray nozzle (36) can be equipped in both upper and lower frame (31, 32) or either upper (31) or lower frame (32) . It can be also put opposite not to face each other.
  • the present invention provides a multi-layer sheet fabricated by laminating more than one mat, which is made by mixing/opening natural fibers and thermoplastic resin fibers in a specific range. It is lightweighted and has excellent sound absorption and heat insulting capacity due to the pores among fibers with specific thickness and range, and has a synergy effect that improves strength.
  • Figure 1 is a flow chart to fabricate the multi-layer sheet according to the present invention
  • Figure 2 shows punching plates in the stampable sheet fabrication machine used in the present invention.
  • Figure 3 shows a cross section of the heating part in the stampable sheet fabrication machine used in the present invention.
  • the above mat was laminated with two layers and fixed by needle punching.
  • the rollers preheated at 150 ° Q 180 ° Q and 210 "C respectively were passes through at the speed of 8M/min to obtain a 10 mm thick sheet.
  • Air Cool Zone at 80 " C was passed at the speed of 8M/min to obtain a 3.2 mm thick sheet.
  • Water Cool Zone at 50 ° Cand 8M/min and then Water Cool Zone at 30°Cand 8M/min were passed to obtain a 3.2 mm thick sheet at the end.
  • Table 1 shows the property of the fabricated multi-layer sheets.
  • the above mat was laminated with Mat 1 and Mat 2 layered together and fixed by needle punching.
  • the rollers preheated at 140 °Q 160 ° Q and 190 "C respectively were passes through at the speed of 10 M/min to obtain a 10 mm thick sheet.
  • Air Cool Zone at 80°C was passed at the speed of 10 M/min to obtain a 3 mm thick sheet.
  • Water Cool Zone at 50 ° Cand 10 M/min and then Water Cool Zone at 30 ° Cand 10 M/min were passed to obtain a 2 mm thick sheet at the end.
  • Table 1 shows the property of the fabricated multi-layer sheets.
  • the above mat was laminated on the order of Mat 1/ Mat 2/ Mat 1 layered together and fixed by needle punching.
  • the rollers preheated at 150 ° C 170 ° C and 200 ° C respectively were passes through at the speed of 7 M/min to obtain a 10 mm thick sheet.
  • Air Cool Zone at 80°C was passed at the speed of 7 M/min to obtain a 3 mm thick sheet.
  • Water Cool Zone at 50 ° Cand 7 M/min and then Water Cool Zone at 30 ° Cand 7 M/min were passed to obtain a 2.5 mm thick sheet at the end.
  • Table 1 shows the property of the fabricated multi-layer sheets .
  • Table 1 shows the property of the fabricated multi-layer sheets .
  • the above mat was doubled to have two layers and fixed by needle punching.
  • the rollers preheated at 150 " C 1 180 ° Q and 210 °C respectively were passes through at the speed of 8M/min to obtain a 10 mm thick sheet.
  • Air Cool Zone at 80 ° C was passed at the speed of 8M/min to obtain a 3.2 mm thick sheet.
  • Water Cool Zone at 50 ° Cand 8M/min and then Water Cool Zone at 30 ° Cand 8M/min were passed to obtain a 3.2 mm thick sheet at the end.
  • Table 1 shows the property of the fabricated multi- layer sheets .
  • Example 1 As shown in Table 1, they have excellent strength and flexural modulus. Also, in Example 1, it was found that the thickness of the fiber does not get thinner below than 3.2 mm as a result of using more amounts of natural fibers than thermoplastic resin fibers, probably because natural fiber is bulky. In Example 2, a mat containing more thermoplastic resin fibers and another mat containing more natural fibers were layered together, so that sheets with lightweight and strength that are equivalent to or less than those of Example 1 can be obtained. Also, as in Example 3, when mats with more content of thermoplastic resin fibers were used as outermost layers and other mats with more content of natural fibers as an inner layer, they had smooth surface and greater resistance against moisture. It was also found that their strength and flexibility were better than those of Example 1 and 2.
  • Example 4 it was found that sound absorption and heat insulating capacity improves remarkably when hollow fibers were mixed in the inner layer. When they were mixed and fabricated with the same content as Example 1 after the thickness was made uniformed as in Comparative Example, it was also found that sound absorption and heat insulating effect as well as strength decreased compared to Example 1.
  • the multi- layer sheet according to the present invention is suitable for interior materials of motor vehicles, especially for package trays, door trims, headliners, seat bags, etc.
  • the present invention can be applied to construction or industrial materials such as partition, furniture and plywood.

Abstract

The present invention relates to a multi-layer sheet for interior materials of motor vehicles with excellent strength and sound absorption/heat insulating capacity, obtained by fabricating a mat through mixing and opening more than one thermoplastic resin fibers and more than one natural fibers and laminating more than one layer using the stampable sheet machine for the mats, which are mixed with 20~95 weight % of 10-20 Denier fiber and 5-80 weight % of 2-7 Denier fiber.

Description

MULTI-LAYER SHEET OF MOTOR VEHICLES INTERIOR PRODUCTS AND MANUFACTURING METHOD THEREOF
[Technical Field]
The present invention relates to a multi-layer sheet for interior materials of motor vehicles. More specifically, the present invention relates to a multi-layer sheet for interior materials to make lightweighted motor vehicles, which can be applied to door trims, package trays, headliners, etc.
[Background Art]
The development for lightweighted interior/exterior materials of motor vehicles has been recently in progress. Accordingly, the research on polymer composite materials, alternative materials for metals, is actively underway, too.
The existing composites for interior materials of motor vehicles that have been used so far are composite materials
(FRP) having high heat resistance and stiffness, which were polymers such as polypropylene or thermoplastic olefin that were reinforced by talc, glass fiber, carbon fiber, etc., or thermosetting composite materials by rubberization of unsaturated polyester type resins and thermoplastic polymers.
Yet, such materials as FRP had some disadvantages that they did not show a satisfactory result in impact resistance and fracture toughness and cannot be reusable.
Thus, the interest in alternative materials to replace FRP is on the rise. To be used for interior materials of motor vehicles, they need sound absorption and heat insulating capacity as well as great strength along with lightweightness . [Disclosure] [Technical Problem]
The present invention was designed to solve such problems, making them reusable by mixing thermoplastic resin fibers and natural fibers and developed automotive interior materials that have lightweightness and satisfy excellent strength and sound absorption/heat insulating capacity.
That is, the object of the present invention is to provide a multi-layer sheet suitable for automotive interior materials that can be reusable and lightweighted by mixing thermoplastic resin fibers and natural fibers and by using a specific thickness range of the fibers, which are 20~95 weight % of 10-20 Denier fibers and 5-80 weight % of 2-7
Denier fibers, resulting in empty spaces due to the thickness difference among the fibers to improve sound absorption and heat insulation and intensify the strength.
[Technical Solution]
The present invention relates to a multi-layer sheet for interior materials of motor vehicles, which can be applied to door trims, package trays, headliners, etc., and the manufacturing method thereof .
More specifically, the present invention relates to a multi-layer sheet for interior materials of motor vehicles with excellent strength and sound absorption/heat insulating capacity, obtained by fabricating a mat through mixing and opening more than one thermoplastic resin fibers and more than one natural fibers and laminating more than one layer using the stampable sheet machine for the mats, which are mixed with 20-95 weight % of 10-20 Denier fiber and 5-80 weight % of 2-7
Denier fiber.
The present invention was completed by finding that forming pores among fibers using a specific range of thickness of the fibers improved strength, sound absorption, and heat insulating capacity.
The manufacturing method of the multi-layer sheet according to the present invention includes the followings: a) a step where more than one thermoplastic resin fibers and more than one natural fibers, which are 20-95 weight % of 10-20 Denier fiber and 5-80 weight % of 2-7 Denier fiber, are mixed and opened; b) a step where the mixed and opened fibers pass through the carding machine to form a mat ; c) a step where the above mat is laminated with more than one layer ; d) a step where the above mat with more than one layer is fixed by needle punching; e) a step where the layered mat goes through preheating, thermal bonding, pressurizing, cooling and cutting by the stampable sheet fabrication machine.
Hereinafter, the present invention is described in detail. There is no restriction on the kind of thermoplastic resin fibers if they are the ones generally used in this field, but it is more desirable to use more than one selected from the group consisting of polyethylene; polypropylene; polyvinylchloride; polyester; polyethylene-polyester copolymer; nylon 6; nylon 66; and nylon 10, whose resins have the property of proper processing temperature and great process capacity. It is desirable to use 30-95 weight % of them. When less than 30 weight % is used, the amount that melts and goes inside natural fibers decreases when making a uniform thickness by thermocompression through the stampable sheet fabrication machine, thus the thickness of the sheet increases and so does its weight. When more than 95 weight % is used, the reinforcement of strength by natural fibers decreases, resulting in unsatisfying strength.
Also, for the natural fibers above, it is desirable to use more than one selected from the group consisting of hemp, which is selected from kenaf, jute, hemp, flax and abaka, cotton, coir, wool, cashmere or silk. It is more desirable to use hemp fibers since they are inexpensive, reinforcing, and easily available. For the content of the natural fibers, 5-70 weight % is desirable. When less than 5 weight % is used, the effect is too mere. When more than 70 weight % is used, there is a limitation on controlling the thickness of the sheet, resulting in less strength.
For the fabrication of the mat in the present invention, the mixing rate of the two fibers is within the range of 30-95 weight % of thermoplastic resin fibers and 5-70 weight % of natural fibers. The rate is subject to change if necessary.
Also, the property of the multi- layer sheet to be manufactured can be controlled by selectively using the thickness of the fibers. Particularly, it is desirable to mix 10-20 Denier fibers to be 20-95 weight % and 2-7 Denier fibers to be 5-80 weight %. The 10-20 Denier fibers play a role to reinforce the strength, just as the steel reinforcement does for concrete casting. And, the 2-7 Denier fibers form some pores and reaches high degree of sound absorption/heat insulting effect and strength. The present invention is confined to 10-20 Denier fibers and 2-7 Denier fibers, because when the above fibers were mixed and used, the object of the present invention could be accomplished, which is adequate strength and excellent sound absorption/heat insulating effect, Also, the range of their contents was confined to bring the satisfactory strength and sound absorption/heat insulting capacity. The property of the present invention can be controlled by freely selecting the content and thickness of the natural fibers and thermoplastic resin fibers within the above range. The examples are as follows.
First, in case more quantities of thermoplastic resin fibers are used than natural fibers, the thermoplastic resin fibers become melted while fabricating the multi- layer sheet by the stampable sheet fabrication machine and penetrates into the natural fibers, which makes the thickness of the sheet decrease and their surface smooth and uniform. When the sheet is made in this manner, it obtains excellent resistance against moisture and improved strength, since its surface becomes fine and smooth.
As for the thickness of the fibers, if thermoplastic resin fibers are 10-20 Denier and natural fibers 2-7 Denier, a sheet with smoother surface can be obtained.
On the contrary, if thermoplastic resin fibers are 2-7 Denier and natural fibers 10-20 Denier, its smoothness drops a little, but its strength gets improved and sound absorption and heat insulating capacity increase due to the bulkiness. Next, in case fewer quantities of thermoplastic resin fibers are used than natural fibers, a sheet with excellent strength due to reinforcing characteristics of natural fibers can be obtained while manufacturing the multi-layer sheet by the stampable sheet fabrication machine. It also obtains stability in warming, insulating, and heat by forming fine pores due to the bulkiness and reaches excellent degree of sound and impact absorption.
As for the thickness of the fibers, if thermoplastic resin fibers are 10-20 Denier and natural fibers 2-7 Denier, a sheet with smoother surface can be obtained. On the contrary, if thermoplastic resin fibers are 2-7 Denier and natural fibers 10-20 Denier, its sound absorption and heat insulating capacity increase due to the bulkiness. Thus, the present invention can properly control the properties if necessary by manufacturing the mat from suitably controlled ratio of thermoplastic resin and natural fibers and laminating more than one layer of the mat.
The same mat with more than one layer can be laminated, or more than one mat with more than one layer can be laminated. More than one mat means more than one selected from four kinds of mats suggested in the present invention are selected and layered with other kinds . The four kinds of mats above are as follows: first, the mat having more quantities of thermoplastic resin fibers than natural fibers and using thick thermoplastic resin fibers; second, the mat having more quantities of thermoplastic resin fibers than natural fibers and using thick natural fibers; third, the mat having more quantities of natural fibers than thermoplastic resin fibers and using thick thermoplastic resin fibers; fourth, the mat having more quantities of natural fibers than thermoplastic resin fibers and using thick natural fibers. The present invention can fabricate a multi-layer sheet with various combination of more than one mat selected from the above four mats, so a variety of multi-layer sheets can be made depending on the desired property.
It is more desirable to put the mat having more quantities of thermoplastic resin fibers on the outermost layer in order to make the surface smooth and keep great resistance against moisture. It is also desirable to lay the mat containing big amount of natural fibers on the inner layer to improve sound absorption and heat insulating capacity.
Moreover, the present invention shows satisfying sound absorption and heat insulating capacity due to pores among fibers by the thickness difference, but in order to reinforce it, it is desirable to use hollow fibers made of thermoplastic resins instead of the above thermoplastic resin fibers for at least one mat that completes the multi- layer sheet. The above hollow fiber means the one containing empty- space inside the fiber, and it is desirable to use one whose heat resistance is at least 5 °C higher than others. The heat resistance indicates glass transition temperature or melting temperature. When these hollow fibers are used, since the pores formed inside the fibers have more than 5 °C higher heat resistance than others even when passing through the stampable sheet fabrication machine, it helps keep the form and improves sound absorption or heating insulating capacity. Even the one that does not have improved heat resistance by 5 °C its performance is still better, so it is not excluded in the present invention, but it is desirable to use the one with high heat resistance.
For example, these hollow fibers are hollow fibers made of thermoplastic resins such as polyester type, polyethylene type, nylon type, hot-melt fluororesin, etc. The pores can have any forms such as round or triangle and they are not restricted. The hot-melt fluororesins are tetrafluoroethylene- hexafluoropropylene copolymer (FEP) , tetrafluoroethylene- perfluoro alkyl vinyl ether copolymer (PFA) , tetrafluoroethylene-hexafluoropropylene-perfluoro alkyl vinyl ether copolymer (EPA) , tetrafluoroethylene-ethylene copolymer (ETFE), etc. When these hollow fibers are used, sound absorption and heat insulting effect improve a lot due to the empty space inside the fibers.
The thickness of the mats for the present invention is not restricted, since a person skilled in the art can control it if necessary.
Hereinafter, the manufacturing method of the multi-layer sheet for interior materials of motor vehicles of the present invention is described in detail. With the reference of the brief drawing in Figure 1, the description is as follows: a) a step (Sl) where more than one thermoplastic resin fibers and more than one natural fibers are mixed and used. The 20-95 weight % of 10-20 Denier fibers and 5-80 weight % of 2-7 Denier fibers are mixed and opened; b) a step (S2) where a mat is fabricated after putting the above fibers through the carding machine; c) a step (S3) where the above mat is laminated with more than one layer; d) a step (S4) where the layered mat is fixed by needle punching; e) a step (S5) where the layered mat is put in the stampable sheet fabrication machine equipped with the conveyor belt composed of a number of punching plates, and is preheated so that the hot air can be transferred to the inside of the mat, followed by thermal bonding, pressurizing, cooling, and cutting process.
By these steps, the multi-layer sheet for interior materials of motor vehicles with excellent strength and sound absorption and heat insulting capacity can be manufactured to meet the object of the present invention.
During the mixing/opening process, 30~95 weight % of thermoplastic resin fibers and 5-70 weight % of natural fibers are uniformly mixed and opened to fabricate a mat. Then they are put through a cylinder type carding machine to form a thin web of a fiber. After laminating various kinds of mats or all the same type of mats and fixating them by needle punching to keep them from moving, they are putting through the stampable sheet fabrication machine equipped with the conveyor belt composed of a number of punching plates, followed by preheating, thermal bonding, pressurizing, cooling, and cutting process, to obtain the sheet of the plate. More specifically, while the above layered mat goes through the preheating zone of the stampable sheet fabrication machine equipped with a heating part, it is fibrillated and melted, penetrating into the reinforced fibers where thermoplastic fibers are tangled. The melted multi-layer non-woven fabrics are pressurized through the pressure rollers in the pressure zone and form a multi-layer sheet with uniform thickness. Changes can be made in the stampable sheet fabrication machine for each use, so the above preheating, thermal bonding, pressurizing, cooling, and cutting process can be changed depending on the combination of the equipment. Their specific temperature, pressure, and other elements are also changeable, so the present invention puts no restriction on that.
Hereinafter, the stampable sheet fabrication machine used in the present invention is described briefly with Figure 2 and Figure 3.
Figure 2 shows a conveyor belt for the stampable sheet fabrication machine. The conveyor belt (34) is composed of a number of punching plates (35) to supply hot air to the mat during the heating process. Using the conveyor belt (34) having punching plates (35) has some advantages such as improved heating efficiency due to directly supplied hot air from the hot air spray nozzle, better quality due to uniformed interior and exterior parts since the hot air is transferred into the deep part, and shortened the processing time.
Figure 3 shows a cross section of the heating part. The hot air from the hot air spray nozzle (36) goes through the conveyor belt (34) composed of punching plates (35) and is transferred to not only the surface of the multi- layer mat (70) but also the deep parts. Supplying the hot air directly to the multi-layer mat (70) has some advantages such as excellent heating efficiency and uniformly heated interior and exterior of the multi-layer mat (70) .
The hot air spray nozzle (36) , as shown in the drawing, can be equipped in both upper and lower frame (31, 32) or either upper (31) or lower frame (32) . It can be also put opposite not to face each other.
It is obvious for a person skilled in the art that a controlling device for the volume or pressure of the composite mat (70) should be equipped for the heating device (30) .
[Advantageous Effects] As described above, the present invention provides a multi-layer sheet fabricated by laminating more than one mat, which is made by mixing/opening natural fibers and thermoplastic resin fibers in a specific range. It is lightweighted and has excellent sound absorption and heat insulting capacity due to the pores among fibers with specific thickness and range, and has a synergy effect that improves strength.
[Description of Drawings]
Figure 1 is a flow chart to fabricate the multi-layer sheet according to the present invention
Figure 2 shows punching plates in the stampable sheet fabrication machine used in the present invention.
Figure 3 shows a cross section of the heating part in the stampable sheet fabrication machine used in the present invention.
* Explanation of symbols for main part of the Figures 31 - upper frame 32 - lower frame 34 - conveyor belt 35 - punching plate 36 - hot air spray nozzle 70 - multi-layer mat [Best Mode]
Hereinafter, the present invention is described in more detail based on the following examples. But, these examples are not intended to limit the scope of the present invention.
[Example 1]
Fabrication of 2 -layer sheets with one kind of mat
45 weight % of 15 Denier polypropylene (PP) fiber and 55 weight % of 5 Denier kenaf fiber were mixed and opened and then passed through the cylinder carding machine to obtain a 20mm thick mat.
The above mat was laminated with two layers and fixed by needle punching. With the stampable sheet fabrication machine, the rollers preheated at 150 °Q 180 °Q and 210 "C respectively were passes through at the speed of 8M/min to obtain a 10 mm thick sheet. Then Air Cool Zone at 80 "C was passed at the speed of 8M/min to obtain a 3.2 mm thick sheet. Water Cool Zone at 50°Cand 8M/min and then Water Cool Zone at 30°Cand 8M/min were passed to obtain a 3.2 mm thick sheet at the end. Table 1 shows the property of the fabricated multi-layer sheets.
[Example 2]
Fabrication of 2 -layer sheets with two kinds of mats (Fabrication of Mat 1)
45 weight % of 5 Denier polypropylene (PP) fiber and 55 weight % of 15 Denier hemp fiber were mixed and opened and then passed through the cylinder carding machine to obtain a 20 mm thick fiber mat. (Fabrication of Mat 2)
80 weight % of 15 Denier polypropylene (PP) fiber, 15 weight % of polyethyleneterephthalate (PET) fiber and 5 weight % of 5 Denier kenaf fiber were mixed and opened and then passed through the cylinder carding machine to obtain a 10 mm thick fiber mat.
The above mat was laminated with Mat 1 and Mat 2 layered together and fixed by needle punching. With the stampable sheet fabrication machine, the rollers preheated at 140 °Q 160 °Q and 190 "C respectively were passes through at the speed of 10 M/min to obtain a 10 mm thick sheet. Then Air Cool Zone at 80°C was passed at the speed of 10 M/min to obtain a 3 mm thick sheet. Water Cool Zone at 50°Cand 10 M/min and then Water Cool Zone at 30°Cand 10 M/min were passed to obtain a 2 mm thick sheet at the end.
Table 1 shows the property of the fabricated multi-layer sheets.
[Example 3] Fabrication of 3 -layer sheets with two kinds of mats (Fabrication of Mat 1)
75 weight % of 15 Denier polypropylene (PP) fiber and 25 weight % of polyethyleneterephthalate (PET) fiber were mixed and opened and then passed through the cylinder carding machine to obtain a 10 mm thick fiber mat. (Fabrication of Mat 2)
45 weight % of 5 Denier polypropylene (PP) fiber and 55 weight % of 15 Denier jute fiber were mixed and opened and then passed through the cylinder carding machine to obtain a 10 mm thick fiber mat.
The above mat was laminated on the order of Mat 1/ Mat 2/ Mat 1 layered together and fixed by needle punching. With the stampable sheet fabrication machine, the rollers preheated at 150 °C 170 °C and 200 °C respectively were passes through at the speed of 7 M/min to obtain a 10 mm thick sheet. Then Air Cool Zone at 80°Cwas passed at the speed of 7 M/min to obtain a 3 mm thick sheet. Water Cool Zone at 50°Cand 7 M/min and then Water Cool Zone at 30°Cand 7 M/min were passed to obtain a 2.5 mm thick sheet at the end.
Table 1 shows the property of the fabricated multi-layer sheets .
[Example 4] Fabrication of 3 -layer sheets with two kinds of mats (using hollow fibers)
(Fabrication of Mat 1)
75 weight % of 15 Denier polypropylene (PP) fiber and 25 weight % of polyethyleneterephthalate (PET) fiber were mixed and opened and then passed through the cylinder carding machine to obtain a 10 mm thick fiber mat.
(Fabrication of Mat 2)
30 weight % of 5 Denier polypropylene (PP) fiber, 15 weight % of 10 Denier polyester hollow fiber (melting temperature 220 °C) and 55 weight % of 15 Denier jute fiber were mixed and opened and then passed through the cylinder carding machine to obtain a 10 mm thick fiber mat.
The above mat was laminated on the order of Mat 1/ Mat 2/
Mat 1 layered together and fixed by needle punching. With the stampable sheet fabrication machine, the rollers preheated at 150 °C 170 °C and 200 °C respectively were passes through at the speed of 7 M/min to obtain a 10 mm thick sheet. Then Air Cool Zone at 80°Cwas passed at the speed of 7 M/min to obtain a 3 mm thick sheet. Water Cool Zone at 50°Cand 7 M/min and then Water Cool Zone at 30°Cand 7 M/min were passed to obtain a 2.5 mm thick sheet at the end.
Table 1 shows the property of the fabricated multi-layer sheets .
[Comparative Example]
Fabrication of 2 -layer sheets with one kind of mat (when the thickness of the fibers is identical)
45 weight % of 10 Denier polypropylene (PP) fiber and 55 weight % of 10 Denier kenaf fiber were mixed and opened and then passed through the cylinder carding machine to obtain a 20mm thick fiber mat.
The above mat was doubled to have two layers and fixed by needle punching. With the stampable sheet fabrication machine, the rollers preheated at 150 "C1 180 °Q and 210 °C respectively were passes through at the speed of 8M/min to obtain a 10 mm thick sheet. Then Air Cool Zone at 80°Cwas passed at the speed of 8M/min to obtain a 3.2 mm thick sheet. Water Cool Zone at 50°Cand 8M/min and then Water Cool Zone at 30°Cand 8M/min were passed to obtain a 3.2 mm thick sheet at the end.
Table 1 shows the property of the fabricated multi- layer sheets . [Table 1]
Figure imgf000020_0001
As shown in Table 1, they have excellent strength and flexural modulus. Also, in Example 1, it was found that the thickness of the fiber does not get thinner below than 3.2 mm as a result of using more amounts of natural fibers than thermoplastic resin fibers, probably because natural fiber is bulky. In Example 2, a mat containing more thermoplastic resin fibers and another mat containing more natural fibers were layered together, so that sheets with lightweight and strength that are equivalent to or less than those of Example 1 can be obtained. Also, as in Example 3, when mats with more content of thermoplastic resin fibers were used as outermost layers and other mats with more content of natural fibers as an inner layer, they had smooth surface and greater resistance against moisture. It was also found that their strength and flexibility were better than those of Example 1 and 2. As in Example 4, it was found that sound absorption and heat insulating capacity improves remarkably when hollow fibers were mixed in the inner layer. When they were mixed and fabricated with the same content as Example 1 after the thickness was made uniformed as in Comparative Example, it was also found that sound absorption and heat insulating effect as well as strength decreased compared to Example 1.
Also, when natural fibers were thicker than thermoplastic resin fibers, the strength was more intensified.
[industrial Applicability] The multi- layer sheet according to the present invention is suitable for interior materials of motor vehicles, especially for package trays, door trims, headliners, seat bags, etc.
Also, the present invention can be applied to construction or industrial materials such as partition, furniture and plywood.

Claims

[CLAIMS] [Claim l]
Multi-layer sheet for interior materials of motor vehicles with excellent strength and sound absorption/heat insulating capacity, obtained by fabricating a mat through mixing and opening more than one thermoplastic resin fibers and more than one natural fibers and laminating more than two layer using the stampable sheet machine for the mats, which are mixed with 20-95 weight % of 10-20 Denier fiber and 5-80 weight % of 2-7 Denier fiber.
[Claim 2]
The multi-layer sheet for interior materials of motor vehicles of claim 1, wherein said thermoplastic resin fibers are more than one selected from the group consisting of polyethylene; polypropylene; polyvinylchloride; polyester; polyethylene- polyester copolymer; nylon 6; nylon 66; and nylon 10.
[Claim 3]
The multi-layer sheet for interior materials of motor vehicles of claim 1, wherein said natural fibers are more than one selected from the group consisting of hemp, which is selected from kenaf, jute, hemp, flax and abaka, cotton, coir, wool, cashmere or silk.
[Claim 4] The multi- layer sheet for interior materials of motor vehicles of claim 1, wherein said mat uses 30~95 weight % of thermoplastic resin fibers and 5-70 weight % of natural fibers.
[Claim 5]
The multi- layer sheet for interior materials of motor vehicles of claim 1, wherein said multi-layer sheet is obtained by laminating the same mat with more than two layer, or more than one mat with more than two layer.
[Claim 6]
The multi-layer sheet for interior materials of motor vehicles of any one of claims 1 to 5, wherein at least one said mat uses thermoplastic resin hollow fibers.
[Claim 7]
The multi-layer sheet for interior materials of motor vehicles of claim 6, wherein said hollow fibers whose heat resistance is at least 5 °C higher than other fibers that form said mat are used.
[Claim 8]
Manufacturing method of the multi-layer sheet for interior materials of motor vehicles with excellent strength and sound absorption/heat insulating capacity comprising the followings : a) a step where more than one thermoplastic resin fibers and more than one natural fibers are mixed and used. The 20~95 weight % of 10-20 Denier fibers and 5-80 weight % of 2-7 Denier fibers are mixed and opened; b) a step where a mat is fabricated after putting the above fibers through the carding machine; c) a step where the above mat is laminated with more than one layer; d) a step where the layered mat is fixed by needle punching; e) a step where the layered mat is put in the stampable sheet fabrication machine equipped with the conveyor belt composed of a number of punching plates, and is preheated so that the hot air can be transferred to the inside of the mat, followed by thermal bonding, pressurizing, cooling, and cutting process.
[Claim 9] The manufacturing method of the multi-layer sheet for interior materials of motor vehicles of claim 8, wherein said thermoplastic resin fibers are more than one selected from the group consisting of polyethylene; polypropylene; polyvinyl chloride; polyester; polyethylene-polyester copolymer; nylon 6; nylon 66; and nylon 10. [Claim lθ]
The manufacturing method of the multi-layer sheet for interior materials of motor vehicles of claim 8, wherein said natural fibers are more than one selected from the group consisting of hemp, which is selected from kenaf, jute, hemp, flax and abaka, cotton, coir, wool, cashmere or silk.
[Claim 11]
The manufacturing method of the multi-layer sheet for interior materials of motor vehicles of claim 8, wherein said multi- layer sheet is obtained by laminating the same mat with more than two layer, or more than one mat with more than two layer.
[Claim 12]
The manufacturing method of the multi-layer sheet for interior materials of motor vehicles of claim 8, wherein at least one said mat uses thermoplastic resin hollow fibers.
[Claim 13]
The manufacturing method of the multi-layer sheet for interior materials of motor vehicles of claim 12, wherein said hollow fibers whose heat resistance is at least 5 °C higher than other fibers that form said mat are used.
[Claim 14]
The manufacturing method of the multi-layer sheet for interior materials of motor vehicles of claim 8, wherein said mat uses 30~95 weight % of thermoplastic resin fibers and 5~70 weight % of natural fibers.
[Claim 15]
Interior materials of motor vehicles using the multi-layer sheet for interior materials of motor vehicles manufactured by the manufacturing method of any one of claims 8 to 14.
PCT/KR2007/005000 2006-10-13 2007-10-12 Multi-layer sheet of motor vehicles interior products and manufacturing method thereof WO2008044892A1 (en)

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