KR101309130B1 - Method for manufacturing foam including volatile organic compounds reduction material and headliner skin fabric manufactured by the same - Google Patents

Abstract

The present invention provides a foam manufacturing method comprising a COC reducing material capable of deodorizing the COC to purify the air quality inside the vehicle by adding and reducing foam to the foam of the headliner skin layer installed inside the vehicle, and the headliner manufactured thereby. Provide an epidermal layer.
In addition, the present invention in the foam manufacturing process of the headliner skin layer by adding the foaming liquid and powder reducing agent in the mixing ratio of 1 to 10% or by adding the liquid reducing agent in the mixing ratio of 1 to 5% Provided are a method for producing a foam comprising a COC reducing material capable of increasing the COC reduction efficiency, and a headliner skin layer produced thereby.

Description

Method for manufacturing foam including volatile organic compounds reduction material and headliner skin fabric manufactured by the same

The present invention relates to a foam manufacturing method including a COC reducing material and a headliner skin layer produced by the same, and more specifically, to the foam of the headliner skin layer installed inside the vehicle, after adding the reducing material to the foam to deodorize the COC. And a COC reducing material capable of purifying the air quality inside the vehicle by reducing and a method for producing a foam, and a headliner skin layer produced thereby.

Modern people live more than 90% of their daily lives indoors, which are often contaminated by various pollutants such as particulate pollutants, chemical pollutants, biological pollutants, heavy metals and radioactive materials. Since indoor air pollution can seriously threaten the health of residents, indoor air quality control is a very important environmental problem.

In recent years, many studies have shown that new buildings are contaminated with volatile organic compounds (VOCs) and formaldehyde. Sustained exposure to COC and formaldehyde released from new building interior materials can cause sick building syndrome (SBS), which includes respiratory and eye irritation, breathing problems, nose and throat diseases, skin diseases, headaches, It can cause memory loss.

In addition, COC from carpets can lead to neuropathy in rats, severe breathing difficulties, and even death in the worst case. Accordingly, there is a great deal of interest in the control of COC concentration in an indoor space, such as active research on a method of reducing COC.

In recent years, research has been actively conducted on the inside of a vehicle because various types of COC may be emitted from interior materials even in a vehicle.

According to the demands of the times as described above, the current vehicle manufacturer has plans to establish and establish regulations for each manufacturer to improve indoor air quality, and the overall air condition for the vehicle and the BOC standard for each corresponding part are established.

Due to the increase in the supply of vehicles, modern people have increased their staying time in the vehicle, and the interior space of the vehicle has become a part of the living space. In response, the Ministry of Land, Transport and Maritime Affairs announced management standards aimed at promoting safe driving and protecting health by ensuring proper management of "human hazardous substances emitted from indoor interior parts of new vehicles produced in 2007". It was. In addition, since July 1, 2009, the new car interior air quality management standards have been announced, and new cars are recommended to keep OCC (benzene, toluene, xylene, styrene, and formaldehyde) below the regulation level. Is setting and applying the standards for VOC (Volatile Organic Compounds).

As described above, there is an urgent need for measures to reduce the COC emitted from the internal parts of the vehicle to cope with environmental regulations at home and abroad, and there is a need to improve the indoor air quality of the vehicle.

As described above, there is an urgent need for measures to reduce the COC emitted from the internal parts of the vehicle to cope with environmental regulations at home and abroad, and there is a need to improve the indoor air quality of the vehicle.

In addition, since the COC effect varies depending on the COC foaming amount control and the dilution ratio, there is an urgent need for a technology that can increase the COC reduction efficiency more effectively.

In addition, when a problem occurs, it is necessary to secure an optimal foaming amount by varying the foaming amount of polypropylene (PP) powder and to secure price competitiveness through cost reduction.

An object of the present invention for solving the above problems includes a COC reducing material that can purify the air quality inside the vehicle by deodorizing and reducing the COC by foaming the reducing material on the foam of the headliner skin layer installed inside the vehicle. It is to provide a headliner skin layer.

In addition, an object of the present invention is to add a foaming liquid and powder reducing agent in the range of 1 to 10% compounding ratio in the foam manufacturing process of the headliner epidermal layer or to reduce the mixing ratio of 1 to 5% in the liquid state The present invention provides a headliner skin layer and a headliner including a reducing material capable of reducing the COC and formaldehyde in an automobile interior by adding a foam to produce a foam.

Foam manufacturing method comprising a COC reducing material according to the present invention for solving the above problems comprises the steps of (a) preparing a reducing material in a powder state or a liquid state; And (b) blending the prepared reducing material and the foamed foam.

Preferably, in the step (a), the reducing material is characterized by consisting of any one or more of Graf (Graf), Bactoster Alexin (Bactoster Alexin) and mixtures thereof.

Preferably, the bactoster alexin is characterized in that the natural sterilized material extracted from propolis.

Preferably, the reducing material is 1 to 10% of the foaming material and the reducing material in the powder state in the foam manufacturing process of the headliner skin layer, or the reducing material in the liquid state is 1 to 5 It is characterized in that the foam is prepared by adding the compounding ratio of%.

Preferably, in the step (b), the foam is characterized in that any one or more of low-density foam, such as thermoplastic, polyurethane (polyurethane) and polyethylene (Polyethylene).

Preferably, the thermoplastic foam has a density of 15 to 90 kg / m ³ and a foaming ratio of 15 to 60 times.

Foam containing the reducing material manufactured by the foam manufacturing method containing the above-mentioned COC reducing material; And a skin positioned below the foam including the reducing material.

Preferably, the thermoplastic foam has a density of 15 to 90 kg / m ³ , and a foaming ratio is characterized by having a range of 15 to 60 times.

Preferably, the powder reducing agent has a blending ratio range of 1 to 10%.

Preferably, the reducing material in the liquid state is characterized by having a blending ratio range of 1 to 5%.

According to the present invention as described above, by adding foaming material to the foam of the headliner skin layer installed inside the vehicle, foaming deodorizes and reduces the COC to purify the air quality inside the vehicle.

In addition, the present invention by adding a reducing agent in the powder state in the blending ratio range of 1 to 10% or by adding a liquid reducing agent in the blending ratio of 1 to 5% to produce a foam containing the reducing material in the vehicle interior The effect of raising the COC reduction efficiency of the cell occurs.

1 is a perspective view of a headliner foamed by blending a reducing material into a foam of a headliner skin layer including a reducing material according to an embodiment of the present invention;
2 is a manufacturing process diagram for explaining a step (b) of adding and reducing the foam to the foam of the headliner skin layer including the reducing material according to an embodiment of the present invention,
3 is a process diagram showing the process of manufacturing the headliner base layer and the skin layer of FIGS. 1 to 2 in the order of (a), (b), (c) and (d),
(A), (b) is a sectional view and a perspective view showing the base layer and the skin layer of the headliner of Figure 1, and
5 is a comparison table of the results of the JOC test of the headliner skin layer.

A preferred embodiment of the foam manufacturing method including the COC reducing material according to the present invention and the headliner skin layer 100 produced thereby will be described with reference to FIGS. 1 to 5. In this process, the thicknesses of the lines and the sizes of the components shown in the drawings may be exaggerated for clarity and convenience of explanation. In addition, terms to be described below are terms defined in consideration of functions in the present invention, which may vary according to the intention or convention of a user or an operator. Therefore, the definitions of these terms should be described based on the contents throughout this specification.

In the present invention, the term "reducer" refers to a compound capable of deodorizing COC existing in the atmosphere or inside a vehicle throughout the specification. Note that the reducing material foams on the foam during the foaming process of the headliner skin layer. More specifically, the reducing material means adding 1 to 10% by weight in a powder state or 1 to 5% by weight in a liquid state to prepare a foam.

In order to facilitate understanding of the headliner skin layer 100 including the reducing material of the present invention, the base material layer 1 of the headliner will be described first.

The base layer 1 is a sheet layer 2 composed of natural fibers, polypropylene and polyethylene terephthalate, and a foam 11a positioned between the sheet layer 2 and the sheet layer 2. Is done. Here, the natural fiber may be used, such as hemp, hemp, jute, ramie fiber.

Sheet layer 2 is a rectangular plate material, it may be preferably made of a combination of natural fibers, polypropylene and polyethylene terephthalate. In the technical performance index of the sheet layer 2, the weight is 0.6 to 1.4 kg / m ² , the thickness is 2 to 10 mm, and the flame retardancy is 100 mm / min. It may be desirable to be within.

The foam 11a may be preferably applied as a thermoplastic foam or a polyurethane foam, and for details, refer to the foam 11b described later.

Hereinafter, the headliner skin layer 100 including the reducing material according to the embodiment of the present invention will be described in detail with reference to the above-described base layer 1 and FIGS. 1 to 2 as follows.

The headliner skin layer 100 including the reducing material according to an embodiment of the present invention is located below the base layer 1 and includes the skin layer 10 and the foam 30 including the reducing material.

The foam 30 including the reducing material is composed of the foam 11b and the reducing material 20.

The foam 11b may be generally applied as a thermoplastic foam or a polyurethane foam.

Polyurethane foam is composed of polyurethane obtained by the reaction of isocyanate compound and glycol as a constituent material, and a volatile solvent such as carbon dioxide and freon produced by reaction of constituent isocyanate with water used as a crosslinking agent is foamed. Refers to foamed products made by mixing. The bulk density of the foam can be freely controlled in an open / close cell fashion and foamed anywhere. Therefore, the foam made in this way has various rigidities, such as soft, semi-hard, and hard. Generally, 0.032 g / cc or less is called soft, 0.08 g / cc is called semi-hard and 0.144 g / cc or more is called hard. Here it is characterized by having a density range of 15 ~ 90kg / m ³ , the foaming ratio is characterized by having a range of 15 ~ 60 magnification.

Preferably, low-density foam such as polyethylene is to be similarly applied to the properties of the polyurethane foam in consideration of material-specific properties as described above. By having the above-mentioned performance indicators, the weight and thickness can be minimized to increase the strength, thereby reducing the production cost and achieving effective COC deodorization. In general, the foam 11b may be any one or more of low density foams such as polyurethane and polyethylene.

The skin 10 is located under the foam 11b.

The reducing material 20 is an additive which mixes and foams in the process of foaming and shape | molding the foam 11b. More specifically, the reducing agent 20 is a product in which Graf and Bactoster Alexin are mixed at an appropriate ratio, and the bacterium Alexin, which is a natural bactericidal material extracted from propolis and patented Graf ingredients in Japan, is specially produced. It is a sterilized deodorant for removing formaldehyde and various volatile compounds made from porous carrier by processing. Such a reducing material 20 removes more than 98% of formaldehyde within 2 hours with a strong deodorizing effect. In addition, by killing various bacteria and viruses contained in the adsorbed air, and supported on a porous carrier, the effect can be sustained for a long time (at least 6 months, up to 5 years).

As described above, the epidermal layer is generally composed of polyurethane foam and skin 10, and in some cases may be composed of skin 10 alone. Therefore, the COC reduction technique can be applied to the foam of the headliner skin layer and applied by incorporating the foaming technique. At this time, the mixing ratio of the foamed liquid and the reducing material of the foam applied to the headliner skin layer is in the range of 1 to 10% by weight to apply a powder reducing agent or a liquid reducing agent in the mixing ratio of 1 to 5% by weight. It may be desirable to add and foam. Here, the headliner skin layer 100 including the reducing material according to an embodiment of the present invention may be foamed by including the reducing material 20 in the foam 30 including the reducing material as shown in FIG.

Hereinafter, referring to FIGS. 2A to 2D, manufacturing process diagrams of the headliner skin layer including the reducing material will be described.

First, in the step (a), the raw material is transferred and blended in a mixed storage tank. The main items to be checked in step (a) include the prevention of foreign substance penetration, the temperature control of the liquid, and the compliance of the mixing ratio.

Next, in step (b), the foam 11b is foamed, and more specifically, the foam 11b and the reducing material 20 are mixed and foamed in the foaming machine, and the BOC reduction of the present invention is reduced during the entire manufacturing process. This is where the ash 20 is applied. Here, the reducing material 20 is added to the foamed liquid and powder state of the foam in the range of 1 to 10% by weight, or in the liquid phase in the blending ratio of 1 to 5% by weight to prepare the foam 30. . The steps to be checked in step (b) are to comply with the mixing head RPM, set the pressure of the chamber, set the pump discharge amount, and set the conveyor speed.

The foamed foam 30 is transferred to step (c) via a transfer conveyor. In the step (c), the foam 30 including the reducing material is cut into an appropriate size through a cutter. At this point, it is important to check the cutting length and synchronize the first and second conveyors.

Next, in step (d), the cut foam 11b is aged in the block warehouse. Here, check that the ripening time is properly set.

There are manufacturing processes such as post-treatment, cutting, packaging, and loading after step (d), but the description thereof will be omitted since it is a part that is not significantly related to the technical contents of the present invention.

Hereinafter, referring to (a), (b), (c) and (d) of FIG. 3, the manufacturing process of the headliner base layer and the skin layer for clarity of the headliner skin layer including the reducing material will be described in order. Is the same as

First, the headliner base layer 1 and the skin layer 10 are transferred in the order of (a), (b), (c) and (d) of FIG. 3 and the head is heated at a temperature of about 190 degrees for about 40 to 120 seconds. The liner base layer 1 and the skin layer 10 are preheated to make the material flexible. After that, the mold is formed in the mold for about 40 to 90 seconds, and the mold used for the mold is a cold mold. The trimming method after molding may be applied by trimming using a press, trimming using a waterjet, trimming using an ultrasonic cutter, and the like. Here, it is noted that the above-described methods can be selected according to the quantity and requirements of the demanding company.

4A is a cross-sectional view of the headliner base layer and the skin layer, and FIG. 4B is a perspective view of the headliner base layer and the skin layer.

Referring to FIG. 4, the type of the headliner epidermal layer 100 as shown is typically polyurethane (PU), polypropylene (PP: polypropylene) and polyethylene terephthalate (PET: polyethyleneterephthalate) and natural fibers (Natural). fiber), F10 and polypropylene (PP: polypropylene), and the method also varies depending on the material. Polyurethane and polypropylene base layer manufacturing method is a foaming method, a mixture of polypropylene (PP: polypropylene), polyethylene terephthalate (PET: polyethylene fiber) and natural fiber is a non-woven fabric manufacturing process, F10 is an extrusion process It can be produced as.

FIG. 5 is a JOC result comparison table showing the COC effect of the headliner epidermal layer, and the change of the JOC result can be seen when comparing before and after deodorization.

More specifically, it compares the change of the BOC item before the deodorization of the COC when the headliner skin layer 100 is not provided inside the vehicle and after the deodorization of the COC when the headliner skin layer 100 is installed inside the vehicle.

When compared with before and after deodorization, the COC result showed a 40% decrease from 155.2 to 94.2, followed by mp-xylene (89%), styrene (87%), and toluene (60%). It can be seen that the decrease. As a result, when the headliner including the headliner skin layer 100 including the reducing material manufactured by the above-described process is installed inside the vehicle, the COC reduction effect can be seen.

It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the invention as defined in the appended claims. It will be understood that the present invention can be changed.

1: substrate layer
2: sheet layer
10: skin
11a: foam
11b: foam
20: reducing material
30: foam containing a reducing material
100: headliner skin layer containing a reducing material

Claims (10)

(a) preparing a reducing agent in a powder state or a liquid state; And
(b) compounding and foaming the prepared reducing material and foam;
The reducing material is characterized in that consisting of Bactoster Alexin (Bactoster Alexin),
Foam manufacturing method containing a reducing material.
delete The method of claim 1,
The bactoster alexin is characterized in that the natural sterilized material extracted from propolis,
Foam manufacturing method containing a reducing material.
The method of claim 1,
Reducing material ratio of the foam containing the reducing material is 1 to 10% by weight when the reducing material is in a powder state, characterized in that 1 to 5% by weight when the reducing material is in a liquid state,
Foam manufacturing method containing a reducing material.
The method of claim 1,
In the step (b), characterized in that any one or more of the thermoplastic foam, polyurethane (Polyurethane) foam and polyethylene (Polyethylene) foam,
Foam manufacturing method containing a reducing material.
The method of claim 5, wherein
The thermoplastic foam has a density of 15 to 90 kg / m ³ and a foaming ratio of 15 to 60 times.
Foam manufacturing method containing a reducing material. Foam comprising a reducing material produced by the manufacturing method according to any one of claims 1, 3, 4, 5 and 6; And
Characterized in that it comprises a; skin located in the lower portion of the foam including the reducing material
Headliner epidermal layer. delete delete delete

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