KR20160142427A - Interior materials for automobiles and method of manufacturing the same - Google Patents

Abstract

Disclosed are an interior material for an automobile and a method of manufacturing the same, which can be designed with few constraints. According to the present invention, the interior material for an automobile comprises: a substrate layer; and a finishing material layer having a strength reinforcing layer formed on the substrate layer, a surface material layer formed on the strength reinforcing layer, and a flexible layer interposed between the strength reinforcing layer and the surface material layer, wherein an adhesive is immersed in the flexible layer.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to an automotive interior material,

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an automotive interior material and a method of manufacturing the same, and more particularly, to an automotive interior material and a method of manufacturing the same.

In general, resin molded parts are used for interior parts of automobiles such as center fascias, instrument panel finishing materials, door garnishes, and console boxes, and resin molded articles are widely used as surface finishing materials for home appliances.

In particular, various control devices and convenience devices are installed in a dash board, an audio deck, a gear shift portion, an airbag, a door lock, and a window opening / closing portion mounted around a driver's seat and a passenger seat of a vehicle. An interior finishing panel is installed in the gap between the exterior of the apparatus and the interior material to finish the interior material, and this interior material is an important factor for determining the sensibility quality of the interior of the vehicle.

As described above, since the automotive interior material has a considerable influence on the aesthetics inside the automobile, there is a growing demand for aesthetic appearance in the trend of automobiles becoming more sophisticated and individualized.

Accordingly, in recent years, there has been a growing demand for automotive interior materials to which natural materials such as real wood are applied in order to obtain a sophisticated appearance and fine texture in appearance.

A related prior art is Korean Patent No. 10-0830882 (published on May 22, 2008), which discloses a reinforced laminated sheet and a method for producing the same.

An object of the present invention is to provide an automotive interior material and a method for manufacturing the same, which can improve the degree of freedom of design by securing excellent moldability through the improvement of the radius of curvature and the molding depth.

According to an aspect of the present invention, there is provided an automotive interior material comprising: a substrate layer; And a finishing material layer having a strength reinforcing layer formed on the base layer, a surface material layer formed on the strength reinforcing layer, and a softening layer impregnated with an adhesive interposed between the strength reinforcing layer and the surface material layer.

According to another aspect of the present invention, there is provided a method for manufacturing an automotive interior material, comprising: (a) forming a finishing material layer in which a strength reinforcing layer, a softening layer impregnated with an adhesive, and a surface material layer are sequentially stacked, Molding in a compression method; And (b) inserting an injection-molded base layer under the finishing material layer by insert injection.

The automotive interior material and the method of manufacturing the same according to the present invention include a method of inserting a softening layer impregnated with an adhesive in a space between a surface material layer and an intensifying stiffener layer to secure flexibility and buffering property by a softening layer It is possible to prevent cracks from being generated in the surface material layer at the edge bending portion and to prevent defects such as tearing.

In addition, since the flexible layer is formed as an integral structure in which the adhesive is impregnated on the both surfaces of the flexible substrate according to the present invention, there is no need to form a separate adhesive layer, There is a structural advantage in that the interlayer peeling failure can be prevented in advance.

Further, the automotive interior material and the manufacturing method thereof according to the present invention have a curvature radius (R) of <5 and a maximum molding depth (D) of 6 to 12 mm, So that the degree of freedom of design can be improved and various designs can be applied.

1 is an exploded perspective view showing an automotive interior material according to an embodiment of the present invention.
2 is an assembled cross-sectional view illustrating an automotive interior material according to an embodiment of the present invention.
3 to 5 are process sectional views illustrating a method of manufacturing an automotive interior material according to an embodiment of the present invention.
Fig. 6 shows the moldability evaluation results of the automotive interior material produced according to Example 1 and Comparative Example 1. Fig.
Fig. 7 shows the moldability evaluation results of the automotive interior material produced according to Examples 2 to 3 and Comparative Examples 2 to 3. Fig.

BRIEF DESCRIPTION OF THE DRAWINGS The advantages and features of the present invention, and the manner of achieving them, will be apparent from and elucidated with reference to the embodiments described hereinafter in conjunction with the accompanying drawings. It should be understood, however, that the invention is not limited to the disclosed embodiments, but is capable of many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, To fully disclose the scope of the invention to those skilled in the art, and the invention is only defined by the scope of the claims. Like reference numerals refer to like elements throughout the specification.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, an automotive interior material according to a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

FIG. 1 is an exploded perspective view showing an automotive interior material according to an embodiment of the present invention, and FIG. 2 is a sectional view showing an automotive interior material according to an embodiment of the present invention.

Referring to FIGS. 1 and 2, an automotive interior material 100 according to an embodiment of the present invention includes a base layer 120 and a finishing layer 140. In addition, the automotive interior material 100 according to the embodiment of the present invention may further include a surface coating layer 160.

The automotive interior material 100 according to the embodiment of the present invention can be easily attached and detached, which is a main function of the automotive interior material 100, by applying the injection-molded base material layer 120 in advance, Can be implemented.

That is, in the automotive interior material 100 according to the embodiment of the present invention, the base material layer 120 is disposed at the lowermost part of the automotive interior material 100, and the base material layer 120 is preliminarily It may be injection molded.

The substrate layer 120 may be formed of a material selected from the group consisting of polyamide, nylon, polycarbnate, acrylonitrile-butadiene-styrene, polyvinyl chloride, polystyrene, at least one material selected from the group consisting of polystyrene, polystyrene, polystyrene, carbon fiber, glass fiber, bakelite, polyphenylene sulfide, polypropylene, polyethylene, Can be used.

At this time, by using a non-foamed substrate which is not subjected to the foam molding process using the foaming agent as the base layer 120, it is possible to realize more excellent mechanical properties and primary dimensional stability effect.

The finishing layer 140 includes a strength reinforcing layer 142 formed on the base layer 120, a surface material layer 146 formed on the strength reinforcing layer 142 and a reinforcing layer 142 interposed between the strength reinforcing layer 142 and the surface material layer 146. [ And a softened layer 144 impregnated with the adhesive.

At this time, the strength reinforcing layer 142 is formed on the base layer 120, thereby realizing an additional dimensional stability effect that can stably maintain the different physical behavior inherent to the material of the different material lamination, And further enhances mechanical properties due to improvement in interlaminar peeling strength.

The strength reinforcing layer 142 preferably has a thickness of 0.4 to 0.6 mm. When the thickness of the strength of the reinforcing layer 142 is less than 0.4mm, there are difficulties to follow to properly demonstrate the effect that difficult to secure an appropriate strength prevents the deformation of the surface material layer 146. On the contrary, when the thickness of the strength reinforcing layer 142 exceeds 0.6 mm, it is advantageous in securing strength but the ductility is rapidly lowered, It may be difficult to secure moldability.

At this time, the strength reinforcing layer 142 may be made of polycarbonate, nylon, glass fiber, carbon fiber, nonwoven fabric, bakelite, polyphenylene sulfide It is preferable to use at least one material selected from the group consisting of metals, metals, fabrics, rubbers, and stones.

The surface material layer 146 is formed on the strength reinforcing layer 142, more specifically, on the flexible layer 144 impregnated with the adhesive, which will be described later, and plays a role of realizing the appearance of sophistication and high-quality texture.

The surface layer 146 preferably has a thickness of 0.3 to 0.7 mm. When the thickness of the surface layer 146 is less than 0.3 mm, there is a problem that it is difficult to secure an appropriate strength, so that there is a great possibility that the surface layer 146 is easily broken or damaged by an external impact, and sanding work before surface treatment such as painting is impossible. Conversely, if the thickness of the surface layer 146 exceeds 0.7 m, it may cause defects such as cracks during the curved surface molding due to excessive thickness design, which may cause the manufacturing cost to rise.

The surface layer 146 may be formed of wood and one or more metals selected from the group consisting of aluminum, stainless steel, zinc, copper, carbon steel, alloy steel, brass and bronze, carbon fiber, carbon prepreg, It is preferable to use at least one material selected from the group consisting of stone, leather, fabric, rubber and synthetic polymer film, and synthetic polymer sheet.

Natural wood or synthetic wood may be used when the natural material is used as the surface material layer 146. Specifically, the natural wood may be wood veneer (real wood), plywood, medium density fiber board (MDF), high density fiber board HDF), a particle board (PB), a laminate, and the like can be used.

Particularly, when real wood is applied to the surface layer 146 of the automotive interior material 100 as natural wood, there is an advantage in that it can obtain an appearance of sophistication and high-quality texture. In addition, Is high.

In the present invention, 'real wood' refers to a veneer obtained by thinning an ash, walnut or the like, and a veneer made by cutting and cutting natural wood have.

The automotive interior material 100 according to the embodiment of the present invention has an advantage of being able to easily apply such real wood to the surface material layer 146 because the dimensional stability effect and the mechanical properties are improved.

The real wood may be selected from natural wood species that can be expected to have an appearance effect as an automobile interior material 100, and may be used in an ash tree, a walnut tree, etc., but is not limited to a specific tree species.

That is, when a real wood product is used as the automotive interior material 100 according to the present invention, the interior design of the automobile can be enhanced, and the center facia, the door trim garnish, the gear box gear box, crash pad, and the like.

The softening layer 144 is inserted into the space between the strength reinforcing layer 142 and the surface material layer 146 to give flexibility and bufferability to the automotive interior material 100 to improve moldability and improve the degree of design freedom Reinforcing layer 142 and the surface material layer 146. In addition,

The flexible layer 144 preferably has a thickness of 0.05 to 0.5 mm. If the thickness of the softening layer 144 is less than 0.05 mm, it is advantageous in securing flexibility but it may be difficult to secure bufferability. On the other hand, when the thickness of the softening layer 144 exceeds 0.5 mm, there is a great possibility that the moldability is lowered due to the excessive thickness design.

For this, the flexible layer 144 includes a flexible substrate (not shown) having flexible properties and an adhesive (not shown) impregnated on both sides of the flexible substrate, though not shown in detail in the drawings.

At this time, it is preferable to use at least one material selected from nonwoven fabric, glass fiber paper, carbon fiber fabric, cellulose, pulp and the like as the flexible substrate.

Examples of the adhesive include polyurethane, polyamide, ethylene-vinyl acetate, polyvinyl acetate, phenol, melamine, urea, It is possible to use an epoxy resin such as epoxy, polyester, polyvinyl alcohol, acrylonitrile butadiene rubber (NBR), styrene butadiene rubber (SBR), alkyd, acetyl cellulose, nitrocellulose nitro cellulose, and hot melt thermoplastic polyurethane.

When the softening layer 144 impregnated with the adhesive is inserted into the space between the surface layer 146 and the reinforcing material layer 142 as in the present invention, It is possible to secure flexibility and buffering property, and thus it is possible to prevent defects such as cracks or tears in the surface material layer 146 at the edge bending portion.

Further, since the flexible layer 144 according to the present invention has an integral structure in which an adhesive is impregnated on both sides of the flexible substrate, there is no need to form a separate adhesive layer, There is a structural advantage that can be avoided.

As a result, the automotive interior material 100 according to the embodiment of the present invention has a radius of curvature R <5 and a maximum molding depth D of 6 to 12 mm, It is possible to improve the degree of design freedom and to apply various designs.

On the other hand, the surface coating layer 160 is formed on the surface material layer 146, and serves to express the appearance of the automotive interior material 100 with a high-quality texture.

It is preferable that the surface coating layer 160 has a thickness of 0.4 to 0.7 mm. If the thickness of the surface coating layer 160 is less than 0.4 mm, the thickness of the coating film may be too thin to represent the high-quality texture. On the contrary, when the thickness of the surface coating layer 160 exceeds 0.7 mm, it may be a factor for raising the thickness of the coating film without further increasing the effect, which is not economical.

The surface coating layer 160 may include at least one selected from the group consisting of an aqueous system coating, an oil based coating, a synthetic resin coating, a natural resin coating, a fibrous coating, a metal coating, and a metal oxide coating.

Specifically, the aqueous system paint may include at least one selected from the group consisting of a vinyl emulsion, a milk casein, a sodium silicate, and a metal as a solvent to be diluted with water as a solvent, and the oil based coating material may contain an organic solvent As the paint to be used by dilution, it may include at least one selected from the group consisting of boiling oil, linseed oil, resin varnish, oil varnish and oil enamel.

The synthetic resin coating material may be a coating material containing a synthetic resin as a coloring agent and may be at least one selected from the group consisting of polyurethane, (unsaturated) polyester, acrylic acid, acrylate, epoxy, phenol, melamine, urea, polyisocyanate, enamel and phthalic acid And the natural resin-based paint may include a lac varnish, a damer varnish, or a quick-drying varnish as a paint containing a natural resin as a coloring agent, and the fiber-based paint may contain fibrin as a coloring agent As the coating material, nitrocellulose, acetylcellulose, benzylcellulose or the like may be included.

The metal-based paint or the metal oxide-based paint is a paint containing a metal or a metal oxide as a coloring agent. Examples of the coating include germanium (Ge), hafnium oxide (HfO ₂ ), magnesium fluoride (MgF ₂ ), magnesium oxide (MgO ₂ ) ₂ ), titanium oxide (TiO ₂ ), titanium oxide (Ti ₂ O ₃ ), tantalum oxide (V) (Ta ₂ O ₅ ), yttrium oxide (Y ₂ O ₃ ) And may include at least one selected from the group consisting of zinc (ZnS) and zirconium dioxide (ZrO ₂ ), and nickel-chromium (50Ni-50Cr).

The automotive interior material according to the present invention may be formed by inserting a softening layer impregnated with an adhesive in a space between a surface layer and an intensifying stiffener layer so as to ensure flexibility and buffering property by a softening layer during curved surface molding of the finish material layer It is possible to prevent defects such as cracks or tears in the surface material layer at the edge bending portion.

Further, the automotive interior material according to the embodiment of the present invention does not need to form a separate adhesive layer because the flexible layer is formed as an integral structure in which the adhesive is impregnated on both sides of the flexible substrate, There is a structural advantage in that the peeling failure can be prevented in advance.

As a result, the automotive interior material according to the embodiment of the present invention has a curvature radius R of <5 and a maximum molding depth D of 6 to 12 mm, thereby achieving excellent moldability by improving the radius of curvature and the molding depth So that the degree of freedom of design can be improved and various designs can be applied.

Manufacturing method of automobile interior material

3 to 5 are process sectional views illustrating a method of manufacturing an automotive interior material according to an embodiment of the present invention.

3, after forming the finishing material layer 140 in which the strength reinforcing layer 142, the softening layer 144 impregnated with the adhesive, and the surface material layer 146 are stacked in order, the finishing material layer 140 is heated It is molded by compression method.

At this time, thermocompression by a hot press is performed by inserting the laminated structure of the strength reinforcing layer 142, the softening layer 144 impregnated with the adhesive, and the surface material layer 146 between the upper and lower thermocompression plates, By molding by applying heat and pressure, a uniform and high-density finishing material layer 140 can be formed through hot press molding.

Next, as shown in Fig. 4, a substrate layer 120, which has been injection-molded in advance, is attached to the bottom of the finishing material layer 140 by insert injection.

The base layer 120 may be adhered to the finish layer 140 by an insert injection method. In the insert injection molding method, the substrate layer 120 and the finishing material layer 140 are put into a mold, and heat and pressure are applied to the mold, thereby making it possible to produce various shapes by insert injection.

As described above, the substrate layer 120 has various shapes, thereby facilitating detachment and attachment as a main function as an automotive interior material.

Next, as shown in Fig. 5, a surface coating layer 160 is formed by applying a coating treatment to the surface material layer 146. Next, as shown in Fig.

The surface coating layer 160 may be applied by a stain coating method using at least one selected from the group consisting of an aqueous system coating, an oil based coating, a synthetic resin coating, a natural resin coating, a fibrous coating, a metal coating and a metal oxide coating Followed by drying and curing treatment.

Example

Hereinafter, the configuration and operation of the present invention will be described in more detail with reference to preferred embodiments of the present invention. It is to be understood, however, that the same is by way of illustration and example only and is not to be construed in a limiting sense.

The contents not described here are sufficiently technically inferior to those skilled in the art, and a description thereof will be omitted.

1. Manufacture of automotive interior materials

Example 1

A real wood surface layer having a thickness of 0.6 mm was prepared using a walnut seed. A 0.3 mm thick softened layer impregnated with a polyurethane adhesive was formed on the lower part of the real wood surface layer and a 0.5 mm thick nonwoven fabric made of a composite material was used as the strength reinforcing layer.

Next, the surface material layer, the softening layer and the strength reinforcing layer were thermocompression-bonded for 180 seconds at a temperature of 140 DEG C and a pressure of 30 kg / cm &lt; 2 &gt; using a hot press facility, : 7 mm to prepare a finishing material layer.

Subsequently, a base material layer previously injection-molded was placed in the lower part of the finishing material layer, followed by laminating by insert injection to prepare an automotive interior material.

Example 2

A car interior material was prepared in the same manner as in Example 1, except that the finishing material layer was formed by molding under conditions of radius of curvature (R) = 3 and maximum molding depth (D): 10 mm.

Example 3

A car interior material was prepared in the same manner as in Example 1, except that the finishing material layer was formed by molding under conditions of radius of curvature (R) = 2 and maximum molding depth (D): 10 mm.

Comparative Example 1

A real wood surface layer having a thickness of 0.6 mm was prepared using a walnut seed. A glue sheet having a thickness of 0.2 mm impregnated with a thermosetting adhesive agent was formed as an adhesive layer on the lower part of the real wood surface layer and then a nonwoven fabric having a thickness of 0.5 mm made of the composite material described in Example 1 was used as the strength reinforcing layer Respectively.

Next, the surface material layer, the adhesive layer and the strength reinforcing layer were thermocompression-bonded for 180 seconds at a temperature of 140 DEG C and a pressure of 30 kg / cm &lt; 2 &gt; using a hot press facility, To form a finishing material layer.

Subsequently, a base material layer previously injection-molded was placed in the lower part of the finishing material layer, followed by laminating by insert injection to prepare an automotive interior material.

Comparative Example 2

An automotive interior material was prepared in the same manner as in Comparative Example 1, except that the finishing material layer was formed by molding under conditions of a radius of curvature (R) = 3 and a maximum molding depth (D): 10 mm.

Comparative Example 3

An automotive interior material was prepared in the same manner as in Comparative Example 1, except that the finishing material layer was formed by molding under conditions of a radius of curvature (R) = 2 and a maximum molding depth (D): 10 mm.

2. Formability evaluation

Fig. 6 shows the results of evaluation of formability of an automotive interior material produced according to Example 1 and Comparative Example 1, and Fig. 7 shows the results of evaluation of moldability of an automotive interior material produced according to Examples 2 to 3 and Comparative Examples 2 to 3 The results of the evaluation are shown.

As shown in Fig. 6, in the case of Example 1, although the molding was performed under the condition of the curvature radius R = 2 and the maximum molding depth D: 7 mm, the edge portion of the finishing material layer was cracked and torn It can be confirmed that the smooth surface is maintained.

On the other hand, in the case of the comparative example 1, it can be confirmed that a crack is generated in a part of the edge part of the finishing material layer and is torn.

Particularly, as shown in Fig. 7, Example 2 molded with the radius of curvature R = 3 and the maximum molding depth D of 10 mm, the radius of curvature R = 2 and the maximum molding depth D: It can be confirmed that the edge portion of the finishing material layer retains a smooth surface without cracks or tears.

On the other hand, in Comparative Example 2 molded under the conditions of a radius of curvature R = 3 and a maximum molding depth D of 10 mm, and Comparative Example 3 molded under a condition of a radius of curvature R = 2 and a maximum molding depth D of 10 mm , It can be confirmed that a substantial part of the edge portion of the finishing material layer is torn.

As can be seen from the above experimental results, when the softening layer impregnated with the adhesive is inserted into the space between the surface material layer and the strength reinforcing material layer, flexibility and buffering property are ensured by the softening layer during the curved surface molding of the finishing material layer It is possible to prevent defects such as cracking or tearing of the surface layer in the edge bending portion.

Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. These changes and modifications may be made without departing from the scope of the present invention. Accordingly, the scope of the present invention should be determined by the following claims.

100: car interior material 120: substrate layer
140: Finishing material layer 142: Strengthening layer
144: softening layer 146: surface layer
160: Surface coating layer

Claims (17)

A base layer; And
A finishing material layer having a strength reinforcing layer formed on the base layer, a surface material layer formed on the strength reinforcing layer, and a softening layer impregnated with an adhesive interposed between the strength reinforcing layer and the surface material layer;
And an interior material for a vehicle.
The method according to claim 1,
The base layer
But are not limited to, polyamide, nylon, polycarbnate, acrylonitrile-butadiene-styrene, poluvinyl chloride, polystyrene, carbon fiber ), A glass fiber, a bakelite, a polyphenylene sulfide, a polypropylene, and a polyethylene.
The method according to claim 1,
The thickness of the strength-
0.4 ~ 0.6mm interior material for automobile.
The method of claim 3,
The strength-
It is also possible to use polycarbonate, nylon, glass fiber, carbon fiber, nonwoven fabric, bakelite, polyphenylene sulfide, metal, fabric, rubber, and stone. &lt; RTI ID = 0.0 &gt; 1. &lt; / RTI &gt;
The method according to claim 1,
The thickness of the softening layer
0.05 to 0.5 mm in interior material for automobiles.
6. The method of claim 5,
The softening layer
A flexible substrate,
Wherein the adhesive agent is impregnated on both sides of the flexible substrate.
The method according to claim 6,
The flexible substrate
An automotive interior material comprising at least one of nonwoven fabric, glass fiber paper, carbon fiber fabric, cellulose and pulp.
The method according to claim 6,
The adhesive
But are not limited to, polyurethane, polyamide, ethylene-vinyl acetate, polyvinyl acetate, phenol, melamine, urea, epoxy, But are not limited to, polyester, polyvinyl alcohol, acrylonitrile butadiene rubber (NBR), styrene butadiene rubber (SBR), alkid, acetyl cellulose, nitro cellulose, Wherein the adhesive comprises at least one adhesive selected from the group consisting of hot melt thermoplastic polyurethane.
The method according to claim 1,
The thickness of the surface material layer
0.3 ~ 0.7mm interior material for automobile.
10. The method of claim 9,
The surface material layer
The present invention relates to wood and at least one metal selected from the group consisting of aluminum, stainless steel, zinc, copper, carbon steel, alloy steel, brass and bronze, carbon fibers, carbon prepregs, An automotive interior material comprising at least one member selected from the group consisting of rubber, synthetic polymer film, and synthetic polymer sheet.
The method according to claim 1,
The automotive interior material
And a surface coating layer formed on the surface material layer.
12. The method of claim 11,
The thickness of the surface coating layer
0.4 ~ 0.7mm interior material for automobile.
12. The method of claim 11,
The surface coating layer
An automotive interior material comprising at least one selected from the group consisting of a synthetic resin coating material, an aqueous coating material, an oil based coating material, a fiber-based coating material, a natural resin coating material, a metal coating material, a metal coating material and a metal oxide coating material.
The method according to claim 1,
The finishing layer
An automotive interior material having a radius of curvature (R) < 5.
The method according to claim 1,
The finishing layer
Maximum molding depth (D): Automotive interior material with 6 to 12 mm.
(a) forming a finishing material layer in which a strength reinforcing layer, a softening layer impregnated with an adhesive, and a surface material layer are stacked in order, and then molding the finishing material layer by a thermal compression bonding method; And
(b) attaching an injection-molded base layer to the lower part of the finishing material layer by insert injection.
17. The method of claim 16,
After the step (b)
(c) forming a surface coating layer by applying a paint treatment on the surface material layer.

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