KR101987037B1 - Multi-layered composites for car interior base material and method for manufacturing the same - Google Patents

Abstract

The present invention relates to a skin layer comprising thermoplastic polyurethane (TPU); And a cushion layer formed on a lower surface of the skin layer, wherein the cushion layer is a double knit mesh structure.
The present invention relates to a rubber composition which is excellent in flexibility, elasticity, mechanical properties, durability, and abrasion resistance and which can provide a smooth texture to a user, High molding processability, improved productivity, and can be recycled in the future.
In addition, the present invention can improve the elongation of a multi-layer composite material including a cushion layer having a double knit mesh structure to improve the appearance quality deterioration problem such as occurrence of folding or wrinkling on the surface of the material, It is possible to improve the quality of the product by realizing soft touch.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a multi-layer composite material for an automobile interior base material,

The present invention relates to a multi-layer composite material for an automobile interior substrate and a method for manufacturing the multi-layer composite material, and more particularly to a multi-layer composite material for an automobile interior base material, And to a method for producing the same.

The automotive interior material product to be developed in the present invention is a skin material of automotive interior finishing trim, which is a portion where the passenger touches and touches directly to the skin of a passenger, and is required to have a soft and cushioning sensibility for the comfort and high quality of the interior.

Conventionally, a cushion layer such as a flexible polyurethane foam is laminated on the back of a polyurethane synthetic leather. In order to stabilize the physical properties of such a polyurethane synthetic leather, a continuous two-ply or three-ply polyurethane coating is applied. The bonding layer is applied as a continuous process to laminate the cloth. Further, a separate bonding agent layer is required to provide a cushion layer on the back surface of the thus-produced skin layer. Therefore, due to such a multi-layer structure, the thickness and hardness of the skin material are increased, so that the cushioning property due to the lack of restoring elasticity is lowered, and a lot of processing time and costs are required for manufacturing the multi-layered fabric.

In addition, the polyurethane foam used as a cushioning material has a problem of shape deformation and yellowing phenomenon due to hydrolysis over a long period of time, and problems such as wrinkle generation and cushioning restorability are caused by the change of physical properties.

In recent years, double lacquer mesh fabric has been increasingly used as a cushioning material as a substitute for polyurethane foam mainly in high-end vehicles. By combining various types of lacquer processing methods using such double lacquer mesh fabrics, The development of alternative technologies is actively under way.

The automobile interiors fabrics with the double cushion layer with the double lacquer mesh fabric have the advantage that the touch feeling is smooth compared to the existing polyurethane foam cushion layer and the restoration elasticity is superior to improve the quality feeling. However, due to the directionality and mesh structure characteristics of the double lacquer mesh fabric, there is still a problem of bending and wrinkling of the fabric surface, which is difficult to apply in mass production.

Korea Public Utility Model No. 20-2011-0001360

The present invention relates to a multilayer composite material for an automotive interior substrate and a method of manufacturing the same.

An object of the present invention is to provide a multilayer composite material for an automobile interior base material having excellent flexibility, elasticity, mechanical properties, durability and abrasion resistance, as well as a method for manufacturing the same, by including a TPU as an environmentally friendly plastic having elasticity similar to rubber.

INDUSTRIAL APPLICABILITY The present invention can provide a soft texture to a user when used as an automobile built-in substrate by applying a skin layer containing a TPU, and it is possible to improve the productivity, Another object of the present invention is to provide a multilayer composite material for an automobile interior base material and a method of manufacturing the same.

The present invention can improve the elongation of a multilayer composite material including a cushion layer having a double knit mesh structure to improve a problem of deterioration in appearance quality such as occurrence of folding or wrinkling on the surface of a material, The present invention also provides a multi-layer composite material for an automobile interior base material and a method of manufacturing the same.

In order to accomplish the above object, in one embodiment of the present invention, the present invention provides a skin layer comprising thermoplastic polyurethane (TPU); And a cushion layer formed on a lower surface of the skin layer, wherein the cushion layer is a double knit mesh structure.

In one embodiment of the present invention, the double knit mesh structure of the cushion layer of the present invention can be produced by forming yarns in a loop shape and connecting the loop shapes in the longitudinal direction.

In one embodiment of the present invention, the cushion layer of the present invention may comprise a polyester yarn and a polyurethane yarn.

In one embodiment of the present invention, the skin layer of the present invention can be formed by a calendering method in which a TPU is put between two or more rolls rotating in opposite directions and rolled.

In one embodiment of the present invention, the skin layer of the present invention is composed of a single layer or a multi-layer structure, and when the skin layer has a multilayer structure, the skin layer comprises a first skin layer and a second skin layer, A plurality of concavities and convexities can be formed on the surface of the silver.

In one embodiment of the present invention, when the skin layer of the present invention is a single layer, the thickness may be 0.25 to 3.0 mm.

In one embodiment of the present invention, when the skin layer of the present invention is multi-layered, the thickness of the first skin layer may be 0.25 to 3.0 mm, and the thickness of the second skin layer may be 0.25 to 3.0 mm.

In one embodiment of the present invention, the present invention provides a method for producing a cushion layer, comprising: 1) weaving a polyester yarn and a polyurethane yarn into a double knit mesh structure to produce a cushion layer; 2) preparing a skin layer by putting the TPU between two or more rolls rotating in mutually opposite directions and rolling it in a calendering manner; And 3) bonding the cushion layer of step 1) to the skin layer of step 2).

In one embodiment of the present invention, the cushion layer may be bonded by the latent heat present in the skin layer produced in the calendering process of step 2) in the step 3) of the present invention.

In one embodiment of the present invention, the double knit mesh structure of step 1) of the present invention can be produced by forming polyester yarns and polyurethane yarns in a loop shape and connecting the loop shapes in the longitudinal direction.

In one embodiment of the present invention, the cushion layer of the step 1) of the present invention may contain a polyester yarn and a polyurethane yarn in a weight ratio of 8: 2 to 9.5: 0.5.

In one embodiment of the present invention, the skin layer in step 2) of the present invention is prepared as a single layer or a multilayer structure. When the skin layer has a multi-layer structure, the first skin layer and the second skin layer And a plurality of concavities and convexities may be formed on the surface of the first skin layer.

The present invention relates to a rubber composition which is excellent in flexibility, elasticity, mechanical properties, durability, and abrasion resistance and which can provide a smooth texture to a user, High molding processability, improved productivity, and can be recycled in the future.

In addition, the present invention can improve the elongation of a multi-layer composite material including a cushion layer having a double knit mesh structure to improve the appearance quality deterioration problem such as occurrence of folding or wrinkling on the surface of the material, It is possible to improve the quality of the product by realizing soft touch.

BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is a view of a multilayer structure for an automotive interior substrate according to an embodiment of the present invention; FIG.
2 is a view of a multi-layer structure for an automotive interior substrate according to an embodiment of the present invention.
3 is a view of a double lacquer mesh structure.
4 is a view of a double knit mesh structure.
100: Cushion layer
200: Skin layer
10: Double Knitted Mesh Fabric
20: second skin layer
30: First skin layer

Hereinafter, the present invention will be described.

Referring to FIG. 1, a multi-layer composite material for an automobile interior substrate according to the present invention includes a cushion layer 100 and a skin layer 200 formed on one surface of the cushion layer 100.

The cushion layer (100) comprises a double knit mesh fabric (10). The double knit mesh fabric is manufactured by weaving a yarn in a double knit manner. More specifically, the yarn is provided in the width direction of the fabric, the provided yarn is formed in a loop shape, and the formed loop shape is sequentially connected in the longitudinal direction of the fabric. 4 is a view of the double knit method of the present invention. The cushion layer 100, which was conventionally used in a multilayer composite material for an automotive interior embedded substrate, was manufactured using the double lacelle method shown in Fig. That is, a plurality of yarns arranged in the longitudinal direction of the fabric are respectively formed in loops, and these loops are formed by weaving in the width direction of the fabric.

Compared with the double lacquered fabric of Fig. 3, the fabric of the double knit fabric of Fig. 4 has a difference in the effect of excellent elongation due to the difference in the shape of the fabric. That is, the difference in fabric properties such as elongation occurs depending on whether the yarn is formed in a loop shape and the formed loop shape is connected in the longitudinal direction of the fabric or in the width direction.

The present invention can provide the cushion layer 100 having excellent elongation by using the double knit method instead of the double lacelle method shown in Fig. Since the elongation of the cushion layer 100 is superior to that of conventional fabrics, the problem of deterioration of appearance quality when used as an automotive interior substrate can be improved. That is, since the cushion layer 100 in the multi-layer composite material is excellent in elongation, when used as an automobile built-in substrate, it does not easily bend or wrinkle to an external force generated by contact with a user.

It has been attempted to prevent deterioration in appearance of the skin layer 200 formed on one side of the cushion layer 100 rather than the cushion layer 100. The skin layer 200 has mechanical properties, Durability and abrasion resistance are poor, and a problem that a smooth texture can not be provided to a user has arisen. Therefore, in the present invention, the cushion layer 100 including the double knit mesh structure is manufactured by applying the double knit method instead of the conventional double lacel method to the cushion layer 100 instead of the skin layer 200 on the surface , Thereby improving the elongation and preventing the deterioration of appearance quality when applied to an automotive interior substrate.

In addition to the double knit method, the cushion layer 100 of the present invention maximizes the effect of improving the elongation by mixing and kneading yarn with polyester yarn and polyurethane yarn. More specifically, the fabric can be produced by mixing polyester yarn and polyurethane yarn in a weight ratio of 8: 2 to 9.5: 0.5, preferably 9: 1.

The skin layer 200 of FIG. 1 is characterized in that it includes a thermoplastic polyurethane (TPU). More specifically, the TPU may be formed into a film form, and the cushion layer 100 may be bonded to one side of the TPU in the form of a film to produce a multilayer composite material for an automotive interior embedded material of the present invention.

Unlike the conventional multi-layer composite material for an automobile interior base material, the skin layer 200 and the cushion layer 100 can be bonded without requiring a separate bonding layer. That is, when manufacturing the skin layer 200, the cushion layer 200 can be bonded using the latent heat present in the skin layer.

Conventional skin layers were made using soft PVC. Soft PVC can be freely changed in hardness and properties and used as an automotive interior material. However, due to the addition of plasticizer and stabilizer added to the soft layer of PVC to cause the dioxin, a unique odor may occur There was a problem because it was uncomfortable. That is, in the case of soft PVC, about 30 to 50% by weight of plasticizer is composed of a plasticizer. As time passes, a problem of VOC that plasticizer in PVC is released into the air has occurred, There is a problem in that the tactile sensation deteriorates and deforms when used as an automobile built-in substrate.

As another use example, when polyurethane is used as the skin layer 200, an adhesive layer is formed by using an adhesive for bonding with the cushion layer 100, or a skin layer or the like that can replace the adhesive layer must be formed, The process is complicated and the productivity is low.

On the other hand, since the multilayer composite material for an automotive interior embedded material of the present invention does not include a separate adhesive layer, the manufacturing process can be simplified, and excellent productivity can be exhibited. That is, the present invention can be applied to the cushion layer 100 by using the latent heat generated at the time of manufacturing the skin layer 200.

This is because there is a latent heat in the TPU film because the TPU is produced in the form of a film using the calendering method using the TPU to produce the skin layer 200 and the latent heat is generated in the TPU film and the cushion layer 100) can be bonded.

More specifically, in the calendar process, the TPU is put between two or more rolls rotating in mutually opposite directions, and rolled into a film or a sheet. By using the calendering method, when the skin layer 200 is produced, it can be produced in the form of a single layer film or in the form of a multilayer film.

The multi-layer composite material for an automotive interior embedded material of the present invention may be manufactured by preparing the skin layer 200 in the form of a single layer and bonding it with the cushion layer 100 by using the latent heat of the skin layer 200, Similarly, a skin layer 200 having a multi-layer structure can be manufactured and bonded to the cushion layer 100 using the latent heat of the skin layer 200 having a multi-layer structure.

The cushion layer 100 may be bonded to one surface of the second skin layer 20 after the first and second skin layers 30 and 20 are manufactured. . When the skin layer 200 having a multi-layer structure is manufactured, the first skin layer 30 may be formed with a plurality of concavities and convexities on the surface directly contacting the user.

The thickness of the first skin layer 30 may be in the range of 0.25 to 3.0 mm even when the skin layer 200 is formed in a multilayer structure. And the second skin layer 20 may also be formed to a thickness of 0.25 to 3.0 mm.

Manufacturing example  One

Manufacture of multi-layered structures for automotive interior materials

Polyester yarn and polyurethane yarn at a weight ratio of 9: 1, and a fabric including a double knit mesh structure was woven using a double knit method to produce a cushion layer. The yarn having a thickness of 150D was used.

The TPU was placed between two rolls rotating in opposite directions and rolled to produce a TPU film.

A cushion layer was bonded to one surface of the TPU film to prepare a multi-layer structure for an automotive interior substrate.

Manufacturing example  2

The same procedure as in Production Example 1 was carried out except that the thickness of the yarn was changed to 50D.

Manufacturing example  3

The same procedure as in Production Example 1 was carried out except that the thickness of the yarn was changed to 75D.

Comparative Example  One

Polyester yarn and polyurethane yarn at a weight ratio of 9: 1, and a cushion layer was produced using a double lacquer method.

Example  One

Evaluation of properties of multi-layer composites for automotive interior materials

The elongation was measured by the test method of MS300-31 4.6 for the multi-layered composite material prepared in Production Example and the multi-layered composite material of Comparative Example 1, and the results are shown in Table 1 below.

Test Items TEST MESHOD
MS321-07
Test Specification
TEST RESULT
MS321-07: 2015
(TYPE-E) Comparative Example 1
(150D) Production Example 1
(150D) Production Example 2
(50D) Production Example 3
(75D) Elongation
(%) horizontal MS 300-31 4.6 MIN 30 69.4 130 181 192.6 Vertical MIN60 54.9 177 176 190.8

According to the above Table 1, it can be confirmed that the elongation of the multilayer composite material for automotive interior trim substrates of Production Examples 1 to 3 is superior to that of Comparative Example 1. That is, the elongation ratios of Comparative Example 1 and Production Example 1, which were different from each other in the double lacquer or double knit method only in the weaving method of the cushion layer under the condition that the thickness of the yarn was the same, Which is more than 2 times.

As shown in Table 1, it was confirmed that the difference in the elongation was remarkable as the weaving method of the cushion layer was changed, and due to the difference in elongation, it was possible to provide a smooth texture to the user And the problem of deterioration of appearance quality such as occurrence of folding or wrinkling on the surface of the material can be improved.

Claims (12)

A skin layer comprising thermoplastic polyurethane (TPU); And
And a cushion layer formed on a lower surface of the skin layer,
The cushion layer has a double knit mesh structure,
The double knit mesh structure of the cushion layer is formed by forming a yarn in a loop shape,
And the loop shape is connected in the longitudinal direction. delete The method according to claim 1,
Wherein the cushion layer comprises a polyester yarn and a polyurethane yarn. The method according to claim 1,
Wherein the skin layer is formed by a calendering method in which a TPU is put between two or more rolls rotating in opposite directions to each other and rolled. The method according to claim 1,
The skin layer may have a single layer or a multi-layer structure,
When the skin layer has a multi-layer structure, it comprises a first skin layer and a second skin layer,
Wherein the first skin layer has a plurality of concavo-convex portions formed on the surface thereof. 6. The method of claim 5,
Wherein when the skin layer is a single layer, the thickness is 0.25 to 3.0 mm. 6. The method of claim 5,
Wherein the thickness of the first skin layer is 0.25 to 3.0 mm and the thickness of the second skin layer is 0.25 to 3.0 mm when the skin layer is a multilayer.
1) fabricating a cushion layer by weaving in a double knit mesh structure with a polyester yarn and a polyurethane yarn;
2) preparing a skin layer by putting the TPU between two or more rolls rotating in mutually opposite directions and rolling it in a calendering manner; And
3) bonding the cushion layer of step 1) to the skin layer of step 2)
The double knit mesh structure in the step 1) may be formed by forming a polyester yarn and a polyurethane yarn in a loop shape,
And the loop shape is connected in the longitudinal direction. 9. The method of claim 8,
Wherein the cushion layer is bonded to the skin layer by latent heat present in the skin layer produced by the calendering method of step 2). delete 9. The method of claim 8,
Wherein the cushion layer in the step 1) comprises a polyester yarn and a polyurethane yarn in a weight ratio of 8: 2 to 9.5: 0.5. 9. The method of claim 8,
In the step 2), the skin layer is formed into a single layer or a multi-layer structure,
When the skin layer has a multi-layer structure, it is rolled into a first skin layer and a second skin layer in a calendering manner,
Wherein the first skin layer is formed by forming a plurality of recesses and protrusions on a surface thereof.

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