Light-weight, multi-layered composite substrate and method of making the same

Abstract

A lightweight, multi-layered composite substrate for a vehicle interior material and a method for manufacturing the same are disclosed. A method for manufacturing a lightweight, multi-layered composite substrate including a core layer being a foam sheet and reinforcement layers stacked on both surfaces of the core layer includes preparing the foam sheet, forming each of the reinforcement layers by forming a low-density reinforcement sheet by mixing a natural fiber with a synthetic fiber by carding, subjecting the mixed natural fiber and synthetic fiber to cross wrapping and needle punching, coating polyolefin-based powder to a weight per unit area of 10 g/m.sup.2 to 100 g/m.sup.2 on the low-density reinforcement sheet, and pressing the low-density reinforcement sheet by a heat roller set to 150 to 230 C., and obtaining a multi-layered composite substrate by stacking the reinforcement layers on both surfaces of the foam sheet by heat.

Claims

1. A method for manufacturing a lightweight, multi-layered composite substrate including a core layer being a foam sheet and reinforcement layers stacked on both surfaces of the core layer, the method comprising: preparing the foam sheet; forming each of the reinforcement layers by forming a low-density reinforcement sheet by mixing a natural fiber with a synthetic fiber by carding, subjecting the mixed natural fiber and synthetic fiber to cross wrapping and needle punching, coating polyolefin-based powder to a weight per unit area of 10 g/m.sup.2 to 100 g/m.sup.2 on the low-density reinforcement sheet, and pressing the low-density reinforcement sheet by a heat roller set to 150 to 230 C.; and obtaining a multi-layered composite substrate by stacking the reinforcement layers on both surfaces of the foam sheet by heat.

2. The method according to claim 1, wherein the low-density reinforcement sheet has a thickness of 4.0 to 6.0 mm and a weight per unit area of 50 g/m.sup.2 to 450 g/m.sup.2, and each of the reinforcement layers has a thickness of 0.5 to 1 mm and a weight per unit area of 150 g/m.sup.2 to 450 g/m.sup.2.

3. The method according to claim 2, wherein each of the reinforcement layers has a thickness of 0.7 to 0.8 mm and a weight per unit area of 150 g/m.sup.2 to 300 g/m.sup.2.

4. The method according to claim 1, wherein the natural fiber includes a vegetable fiber.

5. The method according to claim 4, wherein the vegetable fiber includes one of yellow hemp, kenaf, sisal hemp, linen, and bamboo.

6. The method according to claim 1, wherein the synthetic fiber is a mixture of one or more of a low-melting point polyester fiber, a PolyEthylene Terephthalate (PET) fiber, a nylon fiber, a polypropylene fiber, an acrylic fiber, and a biodegradable resin fiber.

7. The method according to claim 1, wherein the foam sheet is a polypropylene-based continuous sheet foam that has a foaming ratio of 3 to 40 times and a thickness of 1 to 15 mm and is windable into a roll.

8. A method for manufacturing a lightweight, multi-layered composite substrate including a core layer being a foam sheet and reinforcement layers stacked on both surfaces of the core layer, the method comprising: preparing the foam sheet; forming each of the reinforcement layers by forming a low-density reinforcement sheet by mixing a natural fiber with a synthetic fiber by carding, cross-wrapping the mixed natural fiber and synthetic fiber on a polyester-based felt, and combining the natural fiber and the synthetic fiber with the polyester-based felt by needle punching, coating polyolefin-based powder to a weight per unit area of 10 g/m.sup.2 to 100 g/m.sup.2 on a surface of the polyester-based felt of the low-density reinforcement sheet, and pressing the low-density reinforcement sheet by a heat roller set to 150 to 230 C.; and obtaining a multi-layered composite substrate by stacking the reinforcement layers on both surfaces of the foam sheet.

9. The method according to claim 8, wherein the polyester-based felt has a weight per unit area of 5 g/m.sup.2 to 30 g/m.sup.2, and each of the reinforcement layers has a thickness of 0.5 to 1 mm and a weight per unit area of 150 g/m.sup.2 to 450 g/m.sup.2.

10. The method according to claim 9, wherein each of the reinforcement layers has a thickness of 0.7 to 0.8 mm and a weight per unit area of 150 g/m.sup.2 to 300 g/m.sup.2.

11. The method according to claim 8, wherein the foam sheet is a polypropylene-based continuous sheet foam that has a foaming ratio of 3 to 40 times and a thickness of 1 to 15 mm and is windable into a roll.

12. A method for manufacturing a lightweight, multi-layered composite substrate including a core layer being a foam sheet and reinforcement layers stacked on both surfaces of the core layer, the method comprising: preparing the foam sheet; forming each of the reinforcement layers by forming a low-density reinforcement sheet by mixing a natural fiber with a synthetic fiber by carding, cross-wrapping the mixed natural fiber and synthetic fiber, and combining the natural fiber and the synthetic fiber by needle punching, combining a polyolefin-based film with the low-density reinforcement sheet before or after the needle punching, and pressing the low-density reinforcement sheet by a heat roller set to 150 to 230 C.; and obtaining a multi-layered composite substrate by stacking the reinforcement layers on both surfaces of the foam sheet.

13. The method according to claim 12, wherein the polyolefin-based film has a weight per unit area of 50 g/m.sup.2 to 130 g/m.sup.2, and each of the reinforcement layers has a thickness of 0.5 to 1 mm and a weight per unit area of 150 g/m.sup.2 to 450 g/m.sup.2.

14. The method according to claim 13, wherein each of the reinforcement layers has a thickness of 0.7 to 0.8 mm and a weight per unit area of 150 g/m.sup.2 to 300 g/m.sup.2.

15. The method according to claim 14, wherein the foam sheet is a polypropylene-based continuous sheet foam that has a foaming ratio of 3 to 40 times and a thickness of 1 to 15 mm and is windable into a roll.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings:

(2) FIG. 1 is a schematic view of a conventional natural fiber-reinforced substrate structure;

(3) FIG. 2 is a sectional view of a lightweight, multi-layered composite substrate according to the present invention; and

(4) FIGS. 3 and 4 are schematic enlarged views of the lightweight, multi-layered composite substrate illustrated in FIG. 2.

DETAILED DESCRIPTION OF THE INVENTION

(5) The present invention will be described below with reference to the attached drawings.

(6) FIG. 2 is a sectional view of a lightweight, multi-layered composite substrate according to the present invention, and FIGS. 3 and 4 are schematic enlarged views of the lightweight, multi-layered composite substrate illustrated in FIG. 2.

(7) The lightweight, multi-layered composite substrate of the present invention includes a core layer 100 being a polypropylene foam sheet and reinforcement layers 200.

(8) The reinforcement layers 200 are stacked on both surfaces of the polypropylene foam sheet 100, thereby increasing density uniformness, strength, humidity-resistance, and shape stability of the lightweight, multi-layered composite layer.

(9) In the process of stacking the reinforcement layers 200 on both surfaces of the core layer 100, if the core layer 100 and the reinforcement layers 200 are combined and molded by directly heating the core layer 100 and the reinforcement layers 200 in a mold, much time is taken for the combining. As a result, a natural fiber is carbonized, a synthetic fiber is shrunken, and the thickness of the foam layer is decreased excessively. In this regard, the direct heating is not effective.

(10) According to the present invention, the light, multi-layered composite substrate is manufactured by forming continuous thin sheets 201 having density increased by means of a heat roller, as the reinforcement layers 200 and then simultaneously laminating the continuous thin sheets 201 to the polypropylene foam layer 100. Since this method increases the strength reinforcement effect of the reinforcement layers 200, a strong vehicle interior material may be achieved.

(11) Particularly, the present invention characteristically provides a technical method for manufacturing the lightweight reinforcement layers 200 to a weight per unit area of 300 g/m.sup.2 or below. As the weight of the reinforcement layers 200 decreases, a density deviation and a thickness deviation increase. The resulting degradation of properties of the composite substrate leads to a decrease in the shape stability and heat-resistant stability of the molded product. In order to maintain the properties of the composite substrate by minimizing the density deviation, a natural fiber is combined with a synthetic fiber by needle punching and then polypropylene powder 203 is coated on the combined natural and synthetic fibers and pressed by means of a heat roller. Thus the properties of the composite substrate including a flexural strength may be maintained and shrinkage of the composite substrate may be prevented during heating.

(12) A polyester-based felt 205 or a polyolefin-based film 204, which has a weight per unit area of 5 g/m.sup.2 to 30 g/m.sup.2, may be combined simultaneously with the natural fiber and the synthetic fiber by needling punching and heat rolling. In general, the thermal shrinkage of a polypropylene fiber or a low-melting point polyester fiber is controlled using excellent heat-resistance of the polyester-based felt 205 having a melting point of 250 C. or above. The use of the polyolefin-based film 204 may increase density uniformness and may minimize the effects of moisture and improve sagging by increasing surface tension. Therefore, the shape stability and strength of the lightweight, multi-layered composite substrate may further be increased.

(13) According to the present invention, the reinforcement layers 200 are formed by mixing a natural fiber with a synthetic fiber. Since the moisture absorption of the natural fiber may affect the shape stability of the composite substrate in a high-temperature, high-humidity environment, formation of a shielding film for shielding moisture is crucial to minimization of the moisture absorption of the natural fiber contained to a certain extent in the reinforcement layers 200. Thus, the present invention minimizes the effects of moisture from the natural fiber by forming a coating surface on each of the reinforcement layers 200 using the polyolefin-based powder 203 or the polyolefin-based film 204.

(14) For each of the reinforcement layer 200, a thin sheet 201 is formed by mixing the natural fiber with the synthetic fiber and subjecting the mixed fibers to needle punching and heat rolling. As the thin sheet 201 gets thinner, the strength and flexural properties of the completed lightweight, multi-layered composite substrate become more excellent. Therefore, it is important to increase density and decrease a thickness deviation by heat rolling.

(15) To readily impregnate the natural fiber and the synthetic fiber, a temperature and heating interval of the heat roller should be controlled appropriately. Accordingly, it is significant to select a synthetic fiber that melts at the temperature of the heat roller.

(16) Specifically, the natural fiber and the synthetic fiber are mixed at a weight ratio of 1:9 to 9:1 in each of reinforcement sheets 202 in the fabrication process of the reinforcement layers 200 according to the present invention. The natural fiber is made from kenaf, yellow hemp, sisal hemp, cotton, etc. While the natural fiber may be 40 m to 120 m thick and 40 mm to 80 mm long, the type, length, and thickness of the natural fiber are not limited to any specific type, length, and thickness. The synthetic fiber may be made by mixing one or more of a low-melting point polyester, PolyEthylene Terephthalate (PET), polypropylene, acryl, a biodegradable resin fiber, etc. so that the synthetic fiber may have durability, water-resistance, corrosion-resistance, and high strength.

(17) Further, the reinforcement layers 200 are formed by forming a coating surface using the polyolefin-based powder 203 or the polyolefin-based film 204 and increasing the impregnability of the natural fiber, so that the reinforcement layers 200 may have an increased strength and humidity-resistance.

(18) When the lightweight, multi-layered composite substrate is used as a vehicle interior material, an outer surface layer 300 is additionally stacked on one or both surfaces of a reinforcement layer 200. The outer surface layer 300 is formed of a polyolefin-based felt or a polyester-based felt. The outer surface layer 300 may be attached to the polyolefin-based powder 203 or the polyolefin-based film 204 coated on the reinforcement layer 200 by thermal melting without a solvent adhesive or a hot-melt adhesive because the polyolefin-based powder 203 or the polyolefin-based film 204 is tacky. Therefore, the process may be simplified and an odor problem encountered with use of a conventional adhesive may be overcome.

(19) FIGS. 3 and 4 are enlarged views of the lightweight, multi-layered composite substrate according to the present invention. The core layer 100 being a 2-layer continuous polypropylene foam sheet, the reinforcement layers 200, and the outer surface layer 300 are stacked in FIGS. 3 and 4.

(20) While the polypropylene foam sheet being the core layer 100, the reinforcement layers 200, and the outer surface layer 300 may be stacked sequentially by heat or an adhesive, it is preferred that the reinforcement layers 200 are disposed on and under the polypropylene foam sheet and stacked by heat and pressure because the polypropylene foam sheet as the core layer 100 and the reinforcement layers 200 are formed of the same type material in the present invention.

(21) According to the present invention, the two reinforcement layers 200 and the polypropylene foam sheet being the core layer 100 are laminated successively by heat. A laminated product experiences creases and overlapping. To avert this problem, the polypropylene foam sheet 100 and the reinforcement layers 200 are pre-heated at different temperatures, to thereby prevent creases in the present invention.

(22) The lightweight, multi-layered composite substrate of the present invention is useful in applications of building interior materials or vehicle interior materials, in that it has an excellent flexural strength and a small sagging variation in various environments. Specifically, the flexural strength (kgf/5 cm) of the lightweight, multi-layered composite substrate (a flexural strength test is performed in conformance to ASTM D 790, the dimensions of a specimen are 50 mm150 mmthickness, a span length is 100 mm, and a test speed is 5 mm/min) is equal to or larger than 1.70 and 1.51 in width and length under a state condition of 23 C.50% R.H, 1.5 and 1.29 in width and length under a heat-resistant condition that the specimen is left at 80 C. for 24 hours and then stabilized for 1 hour in the state condition, and 1.11 and 1.31 in width and length under a humidity-resistant condition that the specimen is left at 50 C.90% R.H for 24 hours and then stabilized for 1 hour under the state condition). A sag change rate ((%)=(L1K)/L100 where L(mm) is a height before exposure and L1 (mm) is a height after exposure) of the lightweight, multi-layered composite layer is equal to or less than 5.5. With one end of a specimen with dimensions of 500 mm200 mmthickness fixed by a jig having an area of 70 mm and the other end of the specimen fixed by attaching a 30 mm40 mm jig having a weight of 29 g, the sag change rate is measured by measuring an initial height L above a floor surface, leaving the specimen at a condition of 5090 R.H for 7 hours, and measuring a height L1 above the floor surface.

(23) The foregoing and following descriptions are given to help understanding of the present invention. Thus, embodiments of the present invention may be modified to other forms and the scope of the present invention should not be interpreted as limited by the embodiments as set forth below.

Embodiment 1

(24) Each of the thin sheets 201 are formed by mixing a natural fiber and a synthetic fiber at a weight ratio of 6:4 to 180 g/m.sup.2 by carding, subjecting the mixed natural fiber and synthetic fiber to cross wrapping and needle punching, coating the polyolefin-based powder 203 of 50 g/m.sup.2 on the natural fiber and the synthetic fiber, and heat-rolling the resulting structure by means of a heat roller set to 210 C. Then, the lightweight, multi-layered composite substrate is manufactured by stacking the thin sheets 201 on both surfaces of the polypropylene foam sheet being the core layer 100 and thermally pressing the thin sheets 201.

Embodiment 2

(25) Each of the thin sheets 201 are formed by mixing a natural fiber and a synthetic fiber at a weight ratio of 6:4 with the polyester-based felt 205 of 30 g/m.sup.2 to 150 g/m.sup.2 by carding, subjecting the mixed natural fiber, synthetic fiber, and polyester-based felt 205 to cross wrapping and needle punching, coating the polyolefin-based powder 203 of 50 g/m.sup.2 on the natural fiber, the synthetic fiber, and the polyester-based felt 205, and heat-rolling the resulting structure by means of a heat roller set to 210 C. Then, the lightweight, multi-layered composite substrate is manufactured by stacking the thin sheets 201 on both surfaces of the polypropylene foam sheet being the core layer 100 by heat.

Embodiment 3

(26) Each of the thin sheets 201 are formed by mixing a natural fiber and a synthetic fiber at a weight ratio of 6:4 with the polyolefin-based film 204 of 100 g/m.sup.2 to 130 g/m.sup.2 by carding, subjecting the mixed natural fiber, synthetic fiber, and polyolefin-based film 204 to cross wrapping and needle punching, and heat-rolling the resulting structure by means of a heat roller set to 220 C. Then, the lightweight, multi-layered composite substrate is manufactured by stacking the thin sheets 201 on both surfaces of the polypropylene foam sheet being the core layer 100 by heat.

Comparison Example 1

(27) The reinforcement sheets are stacked on both surfaces of the core layer 100 being the polypropylene foam sheet by heat in the same manner as Embodiment 1, Embodiment 2, and Embodiment 3, except that none of the polyester-based felt 205, the polyolefin-based film 204, and the polyolefin-based powder 203 are used.

(28) [Table 1] below lists flexural strengths measured from specimens formed according to Embodiment 1, Embodiment 2, Embodiment 3, and Comparison Example 1 under a state condition, a heat-resistant condition, and an humidity-resistant condition, and sag change rates measured from the specimens under the humidity-resistant condition.

(29) A comparison between Embodiment 1, Embodiment 2, and Embodiment 3, and Comparison Example 1 reveals that the lightweight, multi-layered composite substrate of the present invention has an increased flexural strength, strength, and humidity-resistance under the state condition, the heat-resistant condition, and the humidity-resistant condition. Due to the use of the polyolefin-based powder 203 or the polyolefin-based film 204, the coating effect and surface tension of the natural fiber are increased. The resulting improvement of the humidity-resistance leads to a remarkable improvement in sagging in a sagging test after a humidity-resistance test.

(30) A flexural strength test is performed in conformance to ASTM D 790, the dimensions of a specimen are 50 mm150 mmthickness, a span length is 100 mm, and a test speed is 5 mm/min. The state condition is 23 C.50% R.H, the heat-resistant condition is that the specimen is left at 80 C. for hours and then stabilized for 1 hour in the state condition, and the humidity-resistant condition is that the specimen is left at 50 C.90% R.H for 24 hours and then stabilized for 1 hour under the state condition).

(31) In a sagging test, with one end of a specimen with dimensions of 500 mm200 mmthickness fixed by a jig having an area of 70 mm and the other end of the specimen fixed by attaching a 30 mm40 mm jig having a weight of 29 g, a sag change rate is measured by measuring an initial height L above a floor surface, leaving the specimen at a condition of 5090 R.H for 7 hours, and measuring a height L1 above the floor surface.

(32) TABLE-US-00001 TABLE 1 Embodiment Embodiment Embodiment Comparison 1 2 3 Example 1 PP FOAM 25 times/ 25 times/ 25 times/ 25 times/ 4.5 mm, 4.5 mm, 4.5 mm, 4.5 mm, 180 g/m.sup.2 180 g/m.sup.2 180 g/m.sup.2 180 g/m.sup.2 Natural fiber and synthetic fiber (4:6) 180 g/m.sup.2 150 g/m.sup.2 130 g/m.sup.2 230 g/m.sup.2 Polyester-based felt 30 g/m.sup.2 Polyolefin-based powder 50 g/m.sup.2 50 g/m.sup.2 Polyolefin-based film 100 g/m.sup.2 Net weight (g/m.sup.2) 658 655 651 652 thickness (mm) 5.9 6.1 6.2 5.8 Flexural state length 1.70 1.83 1.90 1.60 strength Width 1.51 1.58 1.51 1.26 (kgf/5 cm) Heat- Length 1.58 1.70 1.78 1.42 resistance Width 1.29 1.41 1.41 1.24 Humidity- Length 1.31 1.48 1.54 1.12 resistance Width 1.11 1.32 1.42 1.06 Sagging change rate (%) 5.5 3.5 3.5 11.5

(33) As is apparent from the above description of the present invention, since a polypropylene foam sheet is used as a core layer and reinforcement layers are stacked on both surfaces of the polypropylene foam sheet, a lightweight, multi-layered composite substrate can be manufactured in a simplified process, compared to a conventional manufacturing process using a polyolefin-based foam, a polyurethane-based foam, or an Expanded PolyPropylene (EPP) foam. Consequently, manufacture cost can be reduced. Further, as an adhesive is not used for the lightweight, multi-layered composite substrate, the lightweight, multi-layered composite substrate is not harmful to the human body.

(34) The density uniformness of the lightweight, multi-layered composite substrate is increased by subjecting a synthetic fiber with high durability, water-proofness, and strength and an ecofriendly natural fiber, both or in combination with a polyester-based felt, to needle punching and heat rolling. In addition, polyolefin-based powder or a polyolefin-based film is used for the reinforcement layers to increase surface tension and improve sagging. Therefore, the lightweight, multi-layered composite substrate has a high flexural strength, is robust against external impacts and changes in temperature and humidity, and is ecofriendly.

(35) Since a process of pre-heating the polypropylene foam sheet being the core layer and the reinforcement layers at different temperatures is added, creasing and overlapping can be reduced during thermal lamination.

(36) Those skilled in the art will appreciate that the present invention may be carried out in other specific ways than those set forth herein without departing from the spirit and essential characteristics of the present invention. The above embodiments are therefore to be construed in all aspects as illustrative and not restrictive. The scope of the invention should be determined by the appended claims and their legal equivalents, not by the above description, and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein.