KR101279522B1 - Natural fiber reinforced composite board for vehicle headliner of multi-layers structure using thermoplastic matrix fibers of high crystalline and bonding to improve heat resistance and strength, and method for preparing the board - Google Patents

Abstract

PURPOSE: A natural fiber reinforced composite board for a vehicle headliner using thermoplastic matrix fibers having excellent heat resistance and adhesive properties and a manufacturing method thereof are provided to have stable heat resistance property and to increase flexural rigidity and elasticity. CONSTITUTION: A natural fiber reinforced composite board for a vehicle headliner using thermoplastic matrix fibers having excellent heat resistance and adhesive properties is composed of a core layer and skin layers. The thermoplastic matrix fiber of the core layer is a thermoplastic polypropylene organic fiber, and a reinforced fiber is composed of a natural fiber. The thermoplastic matrix fiber of the skin layers is a low melting polyester composite fiber having high crystallizability and excellent adhesive strength to reinforce the rigidity of the core layer. The reinforced fiber is composed of a high melting polyester organic fiber. A manufacturing method of the natural fiber reinforced composite board is to attach the skin layers to both sides of the core layer.

Description

Natural Fiber reinforced composite board for vehicle headliner of multi-layers structure using thermoplastic matrix fibers of high crystalline and bonding to improve heat resistance and strength, and method for preparing the board}

The present invention relates to a method for manufacturing an interior material for a vehicle ceiling made of a lightweight thermoplastic natural fiber composite board having a microporous structure using thermoplastic organic fibers and natural fibers.

Polypropylene-based and polyester-based thermoplastic matrix fibers with excellent crystallinity and adhesion to improve the disadvantages of low heat resistance, stiffness and dimensional stability of thermoplastic organic fibers used as reinforcing fibers and used as base fibers Natural fiber reinforced composite board with excellent heat resistance and rigidity of multi-layered structure, natural fiber reinforced composite board attached with a film with excellent adhesion to fabric, nonwoven fabric, foam foam, etc. It is about a method.

More specifically, the core layer of the present invention is a multi-layered natural fiber reinforced composite board composed of a core layer and a skin layer to improve reinforcing fibers and heat resistance of natural fibers, high melting point polyester fibers, etc. Highly crystalline polypropylene fiber or polypropylene fiber containing maleic anhydride is composed of matrix fibers, and the skin layer is composed of a high melting point polyester composite fiber having excellent heat resistance and a reinforcing fiber and a high melting point polyester composite fiber. Together, the low melting point polyester-based composite fiber having excellent crystallinity is composed of matrix fibers.

The present invention also relates to a lightweight natural fiber reinforced composite material having a network structure of reinforcing fibers and matrix fibers.

As the industry develops, there is a growing demand for eco-friendly materials that can be recycled and biodegraded due to oil depletion and environmental pollution. In the automotive industry, the development of lightweight materials for improving fuel efficiency of automobiles and the development of materials for thermoplastic fiber composite materials that can be recycled using bio or natural materials to prevent environmental pollution are rapidly increasing.

Conventionally, it is a fiber-reinforced composite material, which is a base material having adhesiveness to reinforcing fibers such as natural fiber, glass fiber, carbon fiber, and arimid fiber having excellent heat resistance and rigidity, and crosslinking of epoxy resin, unsaturated ester resin, penol resin, and the like. Or the development of lightweight fiber-reinforced composites for the industrial use to replace the metal by impregnating or laminating the curable resin has become the mainstream. However, these materials are lighter than metals due to the high-density structure by impregnating base resin, using crosslinking and curable materials, but are difficult to apply to low-density lightweight products that require functionalities such as sound absorption, thermal insulation, and shock absorption. It contains problems such as environmental problems due to the difficulty of recycling due to the crosslinking and curing properties.

In addition, in the manufacture of thermoplastic fiber-reinforced composite materials for automobile interior materials for light weight and eco-friendliness, natural fibers, inorganic fibers, and high melting point thermoplastic fibers, which have excellent heat resistance and rigidity, are used as reinforcing fibers. Development has been made using thermoplastic organic fibers such as polyethylene, polypropylene, low melting point polyamide, low melting point polyester, etc., which have light weight and excellent processability, but due to the low rigidity and heat resistance of the thermoplastic matrix fibers, Due to the problem of not satisfying the reliability required by the material, it is limited to the application, and is mainly applied by a method of adding resins having a crosslinking and thermosetting reaction. These materials replace metals with high specific gravity for the purpose of weight reduction. They are satisfactory for mechanical properties but have a small range of deformation that can be allowed when transforming into various product types. Problems still exist.

The present inventors demanded as a material for automobile interior materials due to low stiffness and low heat resistance, although the polypropylene and low melting point polyester fiber used as the base material have advantages such as low specific gravity, excellent processability and recyclability. In order to overcome the limitations that do not satisfy the reliability, such as stiffness, heat resistance, dimensional stability, etc., the problems are improved by improving the crystallinity and adhesion of the thermoplastic matrix fibers, and by designing a multilayered structure to improve reliability as a vehicle interior material We developed eco-friendly and lightweight natural fiber reinforced composite materials. In addition, when thermoforming a ceiling product by attaching a polyamide-based and polyolefin-based adhesive film having excellent adhesion to a surface finishing material fabric, nonwoven fabric, foam foam, etc., on one surface of a natural fiber reinforced composite material developed as a base material for automotive ceiling materials It is characterized by having effects such as surface finish material and adhesive improvement, process simplification, and cost reduction.

The present invention, in order to solve the problems of the conventional vehicle ceiling material, that is, a lightweight natural fiber reinforced composite material of the network structure using fibers and fibers,

It is a base material and reinforcing fiber that improves crystallinity and adhesion of pure thermoplastic organic fibers without using cross-linking and curable adhesive resin harmful to human body and environment as a base material, and natural fiber and high melting point thermoplastic organic fiber and adhesive base material The fiber has a lower melting point than the reinforcing fiber and combines and integrates excellent crystalline and environmentally friendly polypropylene fiber and low melting point polyester composite fiber, and then the base fibers having low melting point and crystallinity are thermally fused to the surface of the reinforcing fiber. A lightweight natural fiber reinforced composite board for automobile ceilings having a multi-layered structure consisting of a core layer and a skin layer in which the internal and surface structures are formed in a shape that is thermally fused at cross and crosslinked portions. Thermoplasticity through crystallinity, fast crystallization rate and good adhesion Characterized in that the improved rigidity and heat resistance of the natural fiber-reinforced composite material.

In embodiments of the present invention, the core layer is composed of a fiber, such as natural fibers, high melting point polyester-based fibers as a reinforcing fiber and a thermoplastic polypropylene fiber having a relatively low melting point as the base fiber,

The skin layer is composed of reinforcing fibers, which are high melting point polyester composite fibers, and matrix fibers, which are low melting point polyester composite fibers. Multi-layered natural fiber reinforced composite board,

More specifically, in order to improve the problems due to the low heat resistance and rigidity of the thermoplastic matrix fibers, it is possible to improve the heat resistance through crystallization of the adhesive component of the low melting point polyester matrix fibers and to use a high crystalline polypropylene resin in the core layer. Automobile cloth characterized in that the polypropylene fiber or composite fiber developed by adding maleic anhydride as a base fiber to improve the adhesiveness with the polypropylene fiber or a natural fiber used as a reinforcing fiber with improved heat resistance The present invention relates to a light weight natural fiber reinforced composite board for refining materials and a method for manufacturing the same, wherein a composite nonwoven fabric is prepared by mixing a network structure using the fibers as described above, that is, reinforcing fibers and matrix fibers, and then By forming internal structures in the form of fusion at intersection and crosslinking points The present invention relates to the manufacture of a low-density lightweight natural fiber reinforced composite board having a large number of pore layers, and is characterized by providing a natural fiber reinforced composite board for automobile interiors having improved rigidity and heat resistance by improving crystallinity and adhesion of base fibers.

In addition, the present invention is pre-heated the substrate in the oven during product molding, such as automotive ceiling material is transferred to the press seated product mold, and a surface finishing material selected from non-woven fabric, fabric, foam foam, etc. attached to the surface of the preheated substrate The present invention relates to a natural fiber reinforced composite board for automobile interior having a specific shape by pressing after pressing.

Also, in the related art, a thermoplastic adhesive film is attached to one surface of the surface finish material to adhere between the substrate and the surface finish material. In this case, when the film is attached to the surface of the surface finish material, the adhesive film is not sufficiently melted due to the low amount of heat from the preheated base material, so that the adhesion between the substrate and the surface finish material may be insufficient after molding the product. To solve the problem, complicated process problems such as the need to use another oven to preheat the surface finish material.

In order to solve the above problems, the present invention attaches an adhesive film such as polyamide-based, polyester-based, and polyolefin-based excellent surface adhesives to one surface of a natural fiber reinforced composite board to preheat the substrate in an oven. Another feature is the development of natural fiber reinforced composite materials that can be preheated to improve surface finish and adhesion and simplify the process.

The present invention is a new thermoplastic base having excellent crystallinity and adhesiveness by modifying polypropylene fiber, low melting point polyester-based composite fiber, etc., which are environmentally-friendly materials but are poor in heat resistance and rigidity to be used as base fibers of fiber reinforced composite board for automobile interior materials. By developing the fiber, it is intended to be used as a base fiber of lightweight natural fiber reinforced composite board for automobile interior.

More specifically, both surfaces of the core layer of the microporous structure composed of reinforcing fibers such as natural fibers and high melting point polyester fibers, and thermoplastic polypropylene matrix fibers having high crystallinity and adhesiveness and excellent heat resistance and rigidity. It is a multi-layered structure designed to attach a skin layer composed of polyester-based reinforcing fiber with high melting point and heat-stable polyester and polyester-based fiber with low melting point and high crystallinity and adhesion. It is an object of manufacturing a natural fiber reinforced composite board having environmentally friendly and lightweight characteristics satisfying the reliability required as interior materials.

In addition, by attaching an adhesive film such as polyamide-based, polyester-based, or polyolefin-based adhesive having excellent adhesion to the surface finish material on one surface of the natural fiber reinforced composite board, the substrate is preheated together in the oven to pre-heat together with the surface finish material and adhesiveness. The purpose is to simplify the improvement and process.

The core layer of the present invention is made of a natural fiber, a high melting point polyester fiber, etc., which is stable to heat resistance, and a polypropylene fiber or a composite fiber having excellent heat resistance characteristics due to high crystallinity of 65 to 75%. It is characterized in that it is used as a fiber to produce a microporous structure.

In addition, the polypropylene-based fiber or composite fiber having adhesiveness after melting of the core layer is a polypropylene resin or the above high crystallinity in order to improve the wettability and affinity of the natural fiber and the like used as the reinforcing fiber due to the non-polar characteristics. It is characterized in that it further comprises a polypropylene fiber or a composite fiber prepared by adding maleic anhydride to the polypropylene resin.

The polypropylene fiber refers to the fiber containing 0.05% to 1.0% maleic anhydride in the total weight, the polypropylene-based composite fiber is made of polypropylene containing 0.05% to 1.0% maleic anhydride as a primary component and polypropylene, poly It refers to a composite fiber of a deep sheath type composed of a high melting point organic polymer resin such as amide and polyester as a core component.

The core sheath type composite fiber is a fiber prepared by mixing 40-60 wt% of the core component having a melting point of 160-270 ° C. and 40-60 wt% of the core component having a melting point of 100-180 ^° C., and having a thickness of 2-20 deniers. It is preferable that length is 30-100 mm.

The reinforcing fibers of the core layer are kenaf fibers, jute fibers, hemp fibers, flax fibers, abaca fibers, sisal fibers, coir ) Natural fibers selected from the group consisting of: fibers, banana fibers, cotton fibers, and the like; Or organic or inorganic fibers selected from the group consisting of polyester fibers, polyamide fibers, polyacrylic fibers, polyvinyl alcohol fibers, aramid fibers, glass fibers, carbon fibers, boron fibers, basalt fibers and the like.

The core layer is characterized in that consisting of 30 to 70% by weight of the base material fiber and 30 to 70% by weight of the reinforcing fiber.

The skin layer of the present invention is composed of high melting point and low melting point polyester composite fiber, the high melting point polyester fiber is a reinforcing fiber and low melting point polyester fiber is applied as a base material to heat-sealed in the composite board manufacturing process It forms the epidermal layer in the form of a three-dimensional network structure in the form of bonding at the point of crosslinking and cross each other.

The low-melting polyester fiber refers to a deep-core composite fiber obtained by composite spinning with a low-melting polyester component having excellent adhesion as a supercomponent and a high melting organic polymer resin such as polyamide and polyester as a core component.

In addition, the low melting point polyester polymer resin, which is a component of the polyester-based sheath type composite fiber, has a high crystallinity of 10 to 30% together with adhesive properties, and is stable to heat resistance.

The high-melting point polyester-based reinforcing fiber is characterized by using a conjugated polyester-based or hollow conjugated polyester-based composite fiber having excellent dimensional stability and elastic modulus against heat.

The skin layer may be a scrim or non-woven fabric composed of a mixture of polyester fibers or polyester fibers and polypropylene fibers having crystallinity and good dimensional stability against heat.

In addition, the present invention is a method of manufacturing a composite board for automobile interior material is attached to both sides of the core layer consisting of the base material fiber and the reinforcing fiber is made of a polyester-based non-woven fabric or a non-woven fabric integral polyester and polypropylene-based It is characterized by the interior materials for automobiles including the composite board.

In the embodiments of the present invention, a method for manufacturing a composite board, comprising: mixing the base material fiber and the reinforcing fiber which is the thermoplastic organic fiber; Carding the blended fibers to form a fibrous thin web; A cross lapping step of laminating the fibrous web to a constant weight; Manufacturing a core layer nonwoven fabric by binding the web laminated by a predetermined weight in the cross-lapping step by needle punching in a vertical direction; It provides a composite board manufacturing method comprising the step of laminating the skin layer on both sides of the core layer non-woven fabric and the skin layer is attached to both surfaces of the core layer through a preheating, heat fusion, pressure, cooling process.

In addition, by attaching a polyamide-based, polyester-based and polyolefin-based adhesive film excellent in adhesion to the fabric, non-woven fabric, foam foam and the like as a surface finishing material on one side of the microporous lightweight fiber composite board prepared above The present invention relates to an eco-friendly lightweight natural fiber reinforced composite board and its manufacturing method, which have advantages such as simplicity of process when forming a product into a ceiling material, increased adhesion to a surface finish material, and cost reduction.

Fiber reinforced composite board using general polypropylene fiber and low melting point polyester-based sheath-type composite fiber has the disadvantages of being vulnerable to heat resistance and bending strength, the present invention is a lightweight thermoplastic natural fiber of a multi-layer structure consisting of a core layer and a skin layer Stiffness and heat resistance through the improvement of the crystallinity of the polypropylene fiber applied as the core layer base fiber and the low melting polyester composite fiber applied to the skin layer by the reinforcement composite board, and the adhesion between the reinforcement fiber and the base fiber Automotive interior material, which is an excellent natural fiber reinforced composite board, not only exhibits a very stable value of heat resistance, but also increases flexural rigidity and elastic modulus and improves elongation.

1 is a cross-sectional schematic diagram of a natural fiber reinforced composite board for automobile interior materials having a three-layer structure according to an exemplary embodiment of the present invention.
Figure 2 is a schematic cross-sectional view of a natural fiber reinforced composite board for automobile interior material of the four-layer structure according to the adhesive film attached to one surface of the skin layer of the natural fiber reinforced composite board as an exemplary embodiment of the present invention.

The present invention is a multi-layered structure consisting of a core layer and a skin layer of a microporous structure using natural fibers and thermoplastic organic fibers, without using materials harmful to humans and the environment as automotive interior materials, rigidity, heat resistance, dimensional and shape stability, sound absorption It satisfies the reliability required as a vehicle interior material, such as heat insulation, and will be described in detail with respect to the human body and environmentally friendly lightweight natural fiber reinforced composite board manufacturing method and the automobile interior material.

Embodiments of the present invention is a multi-layered natural fiber reinforced composite board consisting of a core layer and a skin layer as a vehicle interior material such as a ceiling material, the core layer is heat-resistant and rigid, natural fiber, high melting point polyester fiber, reinforcement fiber, etc. In order to improve the heat resistance, and using a high-crystalline polypropylene fiber or a polypropylene fiber containing maleic anhydride as a base fiber, the skin layer is made of a high-melting polyester composite fiber having excellent heat resistance as a reinforcing fiber and high Lightweight natural due to multi-layer and internal structure of the skin layer attached to both surfaces of the core layer after the melting point polyester-based composite fiber and low melting point polyester-based composite fiber having excellent crystallinity and excellent crystallinity as a base fiber A fiber reinforced composite board was prepared.

In the present invention, by using the fibers developed by improving the crystallinity and adhesion of the thermoplastic matrix fibers having low strength and heat resistance as matrix fibers, it overcomes the low stiffness and heat resistance of the natural fiber reinforced composite board as a vehicle interior material Lightweight natural fiber composite board that can be applied,

More specifically, the general polypropylene fiber used as the core layer matrix fiber of the present invention is widely used as a matrix fiber of a composite material for various purposes with crystallinity, excellent processability and low specific gravity. However, despite having crystallinity, there is a problem in expanding application to various uses due to lack of heat resistance and rigidity to apply as a base fiber of automotive interior materials. In particular, the reliability test of automotive interior materials such as headliners should be performed at a temperature of about 80 to 100 ^o C, so that no deformation occurs. Among the thermoplastic fibers that can be used as base fibers, polypropylene fibers with good crystallinity are about 75 to 90 ^{o It} has a problem in that it is applied to automotive interior materials because it has a weak thermal deformation at C temperature. In addition, in the case of products using polypropylene chips or pellets instead of fibers as base materials, 20 to 50% of inorganic fillers such as talc, mica, calcium carbonate, and glass fibers are added or crystallinity is 65 to 75 to improve heat resistance. It is used to improve the low heat resistance of polypropylene by a method such as using a high crystalline chip or pellets of%. However, injection products using polypropylene chips or pellets are high-density products, and there are problems in that they are applied to products requiring lightness with a certain thickness of functionality in addition to sound absorption, shock absorption, and stability, such as headliners, which are automotive interior materials. In order to improve the heat resistance of the injection product, a resin in which an excessive amount of inorganic filler is added to a polypropylene chip or pellet, and a high crystalline resin having a crystallinity of 65 to 75% is impossible to be fiberized by melt spinning. There is a problem in manufacturing a lightweight and environmentally friendly natural fiber reinforced composite board using reinforcing fibers such as thermoplastic base material fibers and natural fibers, and applying them to materials for automobile interior materials. Therefore, in this development, rather than high-density injection products using thermoplastic polypropylene chips or pellets containing inorganic fillers for improving rigidity and heat resistance, highly crystalline polypropylene resins and maleic anhydride, which are difficult to fiberize, are added for improving crystallinity and adhesion. Microporosity and network using thermoplastic base fibers such as polypropylene-based fibers having high heat resistance and adhesion and reinforcement fibers such as natural fibers developed by improving spinning conditions, maleic anhydride content, etc. A natural fiber reinforced composite board composed of a low density core layer having a structure was applied to automobile interior materials.

In an exemplary embodiment, most thermoplastic polypropylene matrix fibers have an isotactic structure with a crystallinity of 50 to 65%, which is weak in terms of rigidity and heat resistance for use as matrix fibers in automotive interior materials. In the present invention, by using a fiber obtained by melt spinning a highly crystalline polypropylene resin having an isotactic structure and crystallinity of 65 to 75% for rigidity and heat resistance purposes as a base fiber, excellent stiffness and heat resistance characteristics due to high crystallinity are obtained. It characterized by manufacturing a composite board having.

More preferably, the polypropylene fiber has a disadvantage in that the affinity and adhesion of the natural fiber used as the reinforcing fiber are poor due to its non-polar characteristics, thereby lowering the heat resistance and rigidity of the final product. In order to improve such a problem, polypropylene-based fiber prepared by adding 0.05 ~ 1.0% of maleic anhydride having excellent wettability and affinity to natural fiber to polypropylene or high crystalline polypropylene resin for fiber is used as a base material. It further includes doing.

In another exemplary embodiment, more preferably the high crystalline polypropylene resin has a 50-65% crystallinity to improve characteristics of low elongation due to fast crystallization rate due to high crystallinity of 65-75%, too high hardness after solidification, and the like. The polypropylene-based fiber prepared by adding 0.05-1.0% maleic anhydride to the polypropylene resin in which 10-30% by weight of the polypropylene resin having a polypropylene resin is mixed with the highly crystalline polypropylene resin is used as a base material. Include.

In another exemplary embodiment, to reduce the weight of the core layer, the core component is preferably a polypropylene component including 0.05-1.0% maleic anhydride and the supercomponent is composed of a high melting point polyester or polyamide-based component. By using the composite fiber as a matrix fiber, the core layer may be manufactured in a structure having more pore layers, which may have more advantageous features for weight reduction.

In an embodiment of the present invention, the reinforcing fibers include, for example, natural fibers such as kenaf, jute, hemp, flax, sisal, coir, and the like. Melting points of polyester fibers, polyamide fibers, glass fibers, and the like may be organic or inorganic fibers having excellent rigidity and heat resistance at 200 ^° C. or higher. The length of the reinforcing fiber is 30-100 mm that can be produced nonwoven fabric on the web, such as carding, air raiding.

The core layer is composed of a one-piece by mixing 30 to 70% by weight of thermoplastic polypropylene-based fiber and 30 to 70% of natural fiber with reinforcing fiber as the base fiber. More preferably, 10 to 30% by weight of high melting point thermoplastic organic fibers such as polyester fibers and polyamide fibers as well as natural fibers may be mixed with reinforcing fibers for the purpose of enhancing the adhesion to the skin layer and improving the elongation of the composite board. In order to improve moldability, 10-30% by weight of polypropylene fiber and 30-50% by weight of polypropylene fiber containing maleic anhydride may be mixed with the known fiber.

In addition, the skin layer attached to both surfaces of the core layer made of natural fibers and thermoplastic matrix fibers is composed of a high melting point polyester composite fiber and a low melting point polyester composite fiber, and the final product thickness, surface appearance, structural The sandwich-type structure is used for the purpose of improving the rigidity of the final product, and besides such a purpose, it has to meet the purpose of weight reduction such as heat resistance, microporous and network structure like the core layer. In order to meet the above object, in the low melting polyester-based composite fiber which is applied as a matrix fiber, the core component is a low melting polyester-based component having adhesiveness, and the supercomponent is a vinegar composed of a high melting polyester-based component. It consists of a type of composite fiber and a low melting polyester composite at the cross-linking or intersecting part when a skin layer is formed by mixing a high melting point polyester fiber, a reinforcing fiber, and a low melting polyester fiber, a matrix fiber, at a predetermined ratio. The core components of the low melting point polyester-based composite fibers are melted and melted to form a network and a microporous structure by fusion of reinforcing fibers and fusion. By fusion and cooling, fast solidification and crystallization to form a hard skin layer It characterized by using the low-melting-point core-sheath type conjugated fiber having a high crystallinity can improve the heat resistance along with improved stiffness of the composite board.

Conventional low melting polyester-based sheath type composite fibers are composed of a polyester-based component having a high melting point and crystallinity, and the core component is 5% over an amorphous or wide temperature range in order to give high adhesion. Although there is a disadvantage in that it is susceptible to heat by using a polyester-based resin having a low crystallinity of the following, in the present invention, the core component of the low-melting polyester-based herbicidal composite fiber is quickly formed in a narrow region with 7 to 30% crystallinity. It has the characteristics of melting and solidification, and has excellent heat resistance and adhesion. Moreover, in order to improve adhesiveness with a core layer, the polypropylene resin containing maleic anhydride which has high crystallinity as a core component of a low melting-point polyester-based sheath type composite fiber can also be used as a core component.

The epidermal layer adhering to both surfaces of the core layer is a high melting point of 210 ^o C or more and a thin scrim type fabric having a weight of 50 to 200 g / m ² composed of crystalline polyester fibers or polyester fibers and polypropylene fibers. It may further include those which may use knitted fabrics, nonwovens, and the like.

Next, looking at the method of manufacturing a composite board using the prepared core layer and the skin layer,

Polypropylene fibers or polypropylene fibers or composite fibers containing maleic anhydride are used as matrix fibers, and natural fibers, high melting point organic fibers, and inorganic fibers are used as reinforcing fibers. The core layer is manufactured by needle punching and heat fusion of the nonwoven fabric on the web formed by the ding process. In addition, as in the skin layer embodiment, low melting point polyester-based composite fibers are used as base fibers, and high melting point polyester-based composite fibers are used as reinforcing fibers. The nonwoven fabric on the web is subjected to needle punching or heat fusion to produce a skin layer. The skin layers are laminated on both surfaces of the prepared core layer and integrated into one by needle punching to produce a composite nonwoven fabric having a multilayer structure. More preferably, a web-like skin layer formed by a carding process may be attached to both surfaces of the manufactured core layer to be integrated by needle punching.

Natural Fiber Reinforced Composite Board is manufactured by multi-layered composite nonwoven fabric with core layer and skin layer integrated into composite board manufacturing equipment adjusted to a certain temperature and thickness, and then undergoes preheating, melting, pressing, and cooling processes to achieve stiffness, elastic modulus, and heat resistance. It is possible to manufacture a porous lightweight fiber-reinforced composite board with improved physical properties, moldability, shape stability, etc., such as impact absorption and sound absorption.

1 is a schematic cross-sectional view of a composite board for automobile interiors having a multilayer structure according to an exemplary embodiment of the present invention.

As shown in Figure 1, in order to manufacture a lightweight fiber-reinforced composite board for automobile interior, the core layer (1) consisting of 30 to 70% by weight of the base material fiber and 30 to 70% by weight of the reinforcing fiber as an integral, Multi-layer lightweight fiber reinforced composite board by attaching the skin layer (2, 2-1) composed of 40 to 80% by weight of the melting point polyester matrix fiber and 20 to 60% by weight of the high melting point polyester fiber Can be prepared.

Figure 2 is a cross-sectional schematic diagram of a composite board for automobile interior materials having a multi-layer structure according to an exemplary embodiment of the present invention is to attach an adhesive film on one surface of the skin layer.

As shown in FIG. 2, the present invention relates to the manufacture of a lightweight natural fiber reinforced composite board for automobile interiors composed of the same core layer and skin layer as in FIG. 1, and fabrics, nonwoven fabrics, and foams that are applied as a finishing material on one side of the skin layer, unlike FIG. 1. It is possible to manufacture a lightweight natural fiber reinforced composite board having a multilayer structure made of a method of attaching the adhesive film (3) for adhesion when forming a product.

In addition, by using only thermoplastic organic fibers and natural fibers, it is advantageous to apply them as various environmentally friendly materials such as parts for automobile interior materials and industrial materials, which have excellent recyclability and the like. Non-limiting examples of its use include ceilings and the like.

Hereinafter, the present invention will be described in more detail with reference to Examples and Experiments, but the present invention is not limited to the contents described below.

Manufactured fiber reinforced composite board

≪ Comparative Example 1 &

In manufacturing a lightweight natural fiber reinforced composite board for automobile interior materials, the core layer used 60% by weight of polypropylene fiber having a 61% crystallinity as a base material, and 40% by weight of Kenyaf fiber, a natural fiber, as a reinforcing fiber. These fibers were opened and mixed, followed by a carding process to form a fibrous web, and a needle punching process to prepare a 700 g / m ² nonwoven fabric. The skin layer is made of 70% by weight of low melting polyester-based sheath type composite fiber as a base material, and 30% by weight of high melting point polyester-based composite fiber is used as reinforcing fiber. It was made and needle punched to produce a weight of 200 g / m ² nonwoven fabric. The prepared skin layer was attached to both surfaces of the core layer and then integrated through a needle punching process to prepare a composite nonwoven fabric having a multilayer structure.

The multi-layered composite nonwoven fabric is passed through 8m / min speed through pre-heating, heat fusion, pressurization, cooling, adhesive film laminating, cutting through continuous fiber reinforced composite board manufacturing apparatus, thickness 4.0mm, weight 1,100 g / A lightweight natural fiber-reinforced composite board of m ² melt pressed was prepared. At this time, the skin layer is injected into the top and bottom of the core layer nonwoven fabric to produce a composite board product by heat fusion to the core layer, and the composite board for adhesion to fabric, nonwoven fabric, foam foam, etc. used as a finishing material when forming a ceiling product. A 50 g / m ² adhesive film was attached to one side to produce a natural fiber reinforced composite board for ceiling materials, which is an automobile interior material.

≪ Example 1 >

Unlike Comparative Example 1, the core layer was opened by mixing 60% by weight of highly crystalline polypropylene fiber having a 71% crystallinity as the base material, and 40% by weight of Kenyaf fiber, which is a natural fiber, as a reinforcing fiber. A fibrous web was made through a carding process and a 700 g / m ² nonwoven fabric was produced by needle punching. The skin layer is made of 70% by weight of low melting point polyester-based sheath-type composite fiber which is crystalline and has excellent adhesive strength, and 30% by weight of high melting point polyester-based composite fiber as reinforcing fiber. The carding process made a fibrous web and needle punched to produce a weight of 200 g / m ² nonwoven fabric. The prepared skin layer was attached to both surfaces of the core layer and then integrated through a needle punching process to prepare a composite nonwoven fabric having a multilayer structure.

Fabric made of automobile interior materials by manufacturing a light weight composite board with a thickness of 4.0mm and a weight of 1100 g / m ^{2 by using} the same manufacturing method as Comparative Example 1 and attaching 50 g / m 2 of adhesive film continuously to one side of the manufactured composite board. Produced natural fiber reinforced composite board for refining.

<Example 2>

Unlike Comparative Example 1, the core layer uses 60% by weight of polypropylene fiber prepared by adding maleic anhydride resin to a highly crystalline polypropylene resin having a crystallinity of 71% as a base material, and Kenya, a natural fiber, as a reinforcing fiber. Each fiber was opened using 40% by weight of the fiber, mixed with carding process to form a fibrous web, and needle punching process to prepare a 700 g / m ² nonwoven fabric. The outer skin layer is 70% by weight of low melting point polyester-based sheath composite fiber which is crystalline and has excellent adhesive strength, and 30% by weight of high melting point polyester composite fiber is used as reinforcing fiber. The process made a fibrous web and needle punched to produce a weight of 200 g / m ² nonwoven fabric. The prepared skin layer was attached to both surfaces of the core layer and then integrated through a needle punching process to prepare a composite nonwoven fabric having a multilayer structure.

A light weight composite board having a thickness of 4.0 mm and a weight of 1100 g / m ² was manufactured by the same manufacturing method as that of Comparative Example 1, and the adhesive film having a weight of 50 g / m ² was continuously attached to one surface of the manufactured composite board. A natural fiber reinforced composite board for ceiling materials was prepared.

&Lt; Example 3 >

Unlike Comparative Example 1, the core layer uses 60% by weight of polypropylene fiber prepared by adding maleic anhydride resin to a polypropylene resin for general fibers having a crystallinity of 61% as a base material, and Kenya, a natural fiber, as a reinforcing fiber. Using 40% by weight of the fiber fibers, each of them were opened and mixed, followed by a carding process to form a fibrous web, and a needle punching process to prepare a 700 g / m ² nonwoven fabric by weight. The outer skin layer is 70% by weight of low melting point polyester-based sheath composite fiber which is crystalline and has excellent adhesive strength, and 30% by weight of high melting point polyester composite fiber is used as reinforcing fiber. The process made a fibrous web and needle punched to produce a weight of 200 g / m ² nonwoven fabric. The prepared skin layer was attached to both surfaces of the core layer and then integrated through a needle punching process to prepare a composite nonwoven fabric having a multilayer structure.

A light weight composite board having a thickness of 4.0 mm and a weight of 1100 g / m ² was manufactured by the same manufacturing method as that of Comparative Example 1, and the adhesive film having a weight of 50 g / m ² was continuously attached to one surface of the manufactured composite board. A natural fiber reinforced composite board for ceiling materials was prepared.

<Example 4>

Unlike Comparative Example 1, the core layer is 40% by weight of polypropylene fiber prepared by adding maleic anhydride resin to polypropylene resin for general fiber having a crystallinity of 61% as a base material and 20% by weight of polypropylene fiber having a 61% crystallinity. % Is mixed, and each of them is opened using 40% by weight of Kenyaf fiber, a natural fiber as reinforcing fiber, mixed, then carded to make a fibrous web, and needle punching to produce 700 g / m ² nonwoven fabric. It was. The outer skin layer is 70% by weight of low melting point polyester-based sheath composite fiber which is crystalline and has excellent adhesive strength, and 30% by weight of high melting point polyester composite fiber is used as reinforcing fiber. The process made a fibrous web and needle punched to produce a weight of 200 g / m ² nonwoven fabric. The prepared skin layer was attached to both surfaces of the core layer and then integrated through a needle punching process to prepare a composite nonwoven fabric having a multilayer structure.

A light weight composite board having a thickness of 4.0 mm and a weight of 1100 g / m ² was manufactured by the same manufacturing method as that of Comparative Example 1, and the adhesive film having a weight of 50 g / m ² was continuously attached to one surface of the manufactured composite board. The natural fiber reinforced composite board for the ceiling material was manufactured.

&Lt; Example 5 >

Unlike Comparative Example 1, the core layer is 40% by weight of polypropylene fiber prepared by adding maleic anhydride resin to a high crystalline polypropylene resin having a crystallinity of 71% as a matrix and 20% by weight of polypropylene fiber having a 61% crystallinity. % Is mixed, and each of them is opened using 40% by weight of Kenyaf fiber, a natural fiber as reinforcing fiber, mixed, then carded to make a fibrous web, and needle punching to produce 700 g / m ² nonwoven fabric. It was. The outer skin layer is 70% by weight of low melting point polyester-based sheath composite fiber which is crystalline and has excellent adhesive strength, and 30% by weight of high melting point polyester composite fiber is used as reinforcing fiber. The process made a fibrous web and needle punched to produce a weight of 200 g / m ² nonwoven fabric. The prepared skin layer was attached to both surfaces of the core layer and then integrated through a needle punching process to prepare a composite nonwoven fabric having a multilayer structure.

A light weight composite board having a thickness of 4.0 mm and a weight of 1100 g / m ² was manufactured by the same manufacturing method as that of Comparative Example 1, and the adhesive film having a weight of 50 g / m ² was continuously attached to one surface of the manufactured composite board. A natural fiber reinforced composite board for ceiling materials was prepared.

<Experiment>

The fiber composite board manufactured in the comparison and examples was compared and analyzed through the following performance test.

(1) The machine direction (MD) is the value of the mechanical direction in which the product emerges, and the cross-machine direction (AMD) is the direction perpendicular to the mechanical direction.

(2) The flexural strength was measured by setting the sample size 75x200 mm, span area 100 mm, and measuring speed 50 mm / min by the ISO 178 test standard method.

(3) The sagging test was performed using the GMW14838 test standard method. The sample size was 76x305mm, and the test results are shown in the following table.

division density
(g / cm ³⁾ Deflection
(mm) Flexural strength
(N) Flexural modulus
(N / mm) Elongation (%) MD AMD MD AMD MD AMD MD AMD Comparative Example 1 0.29 15 27 37.2 31.4 7.1 5.8 15.3 21.0 Example 1 0.29 10 18 40.4 34.2 8.5 7.2 9.4 13.2 Example 2 0.29 2 5 52.1 47.7 12.8 10.1 6.8 10.7 Example 3 0.29 5 8 45.3 41.3 10.2 9.1 9.5 12.3 Example 4 0.29 7 10 44.1 39.5 9.8 8.7 7.9 11.2 Example 5 0.29 4 6 49.0 45.4 11.7 9.8 8.2 11.4

The test results were obtained from Comparative Example 1 of the fiber-reinforced composite board obtained by applying a polypropylene fiber and a low-melting polyester-based sheath composite fiber applied as a general thermoplastic matrix fiber, and the crystalline and adhesion-improved thermoplastics developed in the present invention. It is the content which analyzed and compared the physical properties of Examples 1-5 using matrix fiber. As shown in the table, the fiber-reinforced composite board using general polypropylene fiber and low melting polyester-based core sheath-type composite fiber can be seen to exhibit vulnerable properties to heat resistance and flexural strength, and improved high crystallinity and adhesion developed in the present invention. When the thermoplastic matrix fiber is used, not only the heat resistance is very stable but also the flexural strength and elastic modulus are increased. In addition, in the case of products requiring high elongation, as shown in Examples 4 and 5, by adding some of the general thermoplastic matrix fibers to the crystalline and adhesion improving thermoplastic matrix fibers developed in the present invention, Elongation is improved.

Claims (14)

In the manufacturing method of a lightweight natural fiber reinforced composite board having a multi-layered structure composed of a reinforcing fiber composed of a low melting point thermoplastic matrix organic fiber having high crystallinity and adhesion and a natural fiber and a high melting point thermoplastic organic fiber,
The lightweight natural fiber reinforced composite board is composed of a multi-layer core layer and a skin layer, wherein the base fiber of the core layer is a thermoplastic polypropylene-based organic fiber, and the reinforcing fiber is made of natural fiber, and the base material of the skin layer Fiber is a low melting polyester-based composite fiber with high crystallinity and excellent adhesive strength for rigid reinforcement of the core layer, the reinforcing fiber is composed of a high melting point thermoplastic polyester-based organic fiber,
A method of manufacturing a lightweight natural fiber reinforced composite board having a multilayer structure applicable to a vehicle interior material, characterized in that the skin layer is attached to both surfaces of the core layer. The method of claim 1,
The base fiber of the core layer is a natural fiber-reinforced composite board manufacturing method, characterized in that the polypropylene fiber produced by melt spinning a high crystalline polypropylene resin having a crystallinity of 65 ~ 75%. 3. The method according to any one of claims 1 to 3,
The base fiber of the core layer is a fiber-reinforced composite board manufacturing method, characterized in that the fiber is added by adding 0.05 ~ 1.0% maleic anhydride to the polypropylene resin having a crystallinity of 50 to 65%. 3. The method according to any one of claims 1 to 3,
The base fiber of the core layer is a natural fiber reinforced composite board manufacturing method characterized in that the fiberized by adding 0.05 ~ 1.0% maleic anhydride to a polypropylene resin having a crystallinity of 65 to 75%. The method of claim 1,
Thermoplastic polypropylene-based matrix fibers of the core layer are manufactured by melt spinning, and have a thickness of 4 to 15 deniers, elongation of 100 to 350%, and length of 30 to 100 mm for carding or air blowing ( A method of manufacturing a natural fiber reinforced composite board comprising staple fibers having crimps suitable for forming a web of fibers by an air blowing process. The method of claim 1,
The thermoplastic matrix fiber of the epidermal layer has a melting point of 250 to 270 ^° C., a melting point of 140 to 180 ^° C. of a core component, and a natural fiber of a sheath type composite fiber having a crystallinity of 7 to 30%. Reinforced composite board manufacturing method. The method according to claim 1 or 6,
The base fiber of the skin layer is produced by melt spinning, the thickness is 2 to 15 denier (denier), carding or air to 30 ~ 100 mm thermoplastic polyester core sheath composite fiber having an elongation of 30 to 70% A method of manufacturing a natural fiber reinforced composite board, characterized in that it is a staple fiber crimped to be suitable for forming a fiber web by an air blowing process.
The method of claim 1,
The reinforcing fibers of the core layer are selected from the group consisting of kenaf fibers, jute fibers, hemp fibers, flax fibers, abaca fibers, cotton fibers. Natural fibers; Or a high melting point organic or inorganic fiber selected from the group consisting of polyester fiber, polyamide fiber, polyacrylic fiber, polyvinyl alcohol fiber, aramid fiber, glass fiber and basalt fiber. Composite board manufacturing method.
In the natural fiber reinforced composite board having a multi-porous structure having a microporous structure composed of a low melting point thermoplastic matrix organic fiber having high crystallinity and adhesion and a natural fiber and a high melting point thermoplastic organic fiber,
The natural fiber reinforced composite board is composed of a multi-layered core layer and a skin layer, the base fiber of the core layer is a thermoplastic polypropylene-based organic fiber, the reinforcing fiber is made of a natural fiber, the base fiber of the skin layer Is a low melting polyester-based composite fiber having high crystallinity and adhesive strength for reinforcing the core layer, and the reinforcing fiber is a high-melting thermoplastic organic material selected from conjugated polyester-based composite fiber and hollow conjugated polyester-based composite fiber. Natural fiber reinforced composite board, characterized in that the fiber. The method of claim 9,
The core layer is composed of 40 to 70% by weight of the base fiber and 30 to 60% by weight of the reinforcing fiber, and the skin layer is composed of 40 to 80% by weight of the base fiber and 20 to 60% by weight of the reinforcing fiber. Natural fiber reinforced composite walkway. delete The method of claim 9,
The skin layer is composed of a high melting point polyester fiber or mixed with a polypropylene fiber and polyester fiber, characterized in that it comprises a scrim, woven fabric, knitted fabric, nonwoven fabric of 50 ~ 200g / m ² integrated weight Compound Press. The method of claim 1,
The natural fiber reinforced composite board further comprises attaching an adhesive film having a weight of 30 ~ 60g / m ² on one side of the composite board for adhesion to the fabric, non-woven fabric, foam foam used as a finishing material when forming the product Manufacturing method. Mixing the matrix fiber and the reinforcing fiber, which is a thermoplastic organic fiber;
Carding the mixed fibers to form a fibrous web;
A cross lapping step of laminating the fibrous web to a predetermined weight;
Binding the web by needle punching the web laminated in the cross lapping step to produce a core layer nonwoven fabric;
Manufacturing a skin layer nonwoven fabric using the thermoplastic matrix fibers and reinforcing fibers in the same manner as the core layer manufacturing method;
Preparing a multi-layered natural fiber reinforced composite board having skin layers attached to both sides of the core layer by preheating, heat fusion, pressing, and cooling by simultaneously inserting the skin layer nonwoven fabric on both sides of the core layer nonwoven fabric;
Attaching an adhesive film to one surface of the manufactured natural fiber reinforced composite board by using a thermal roller; Method of manufacturing a fiber composite board for automobile interior material comprising a.

Images