KR101472884B1 - Engine Under Cover Material and Engine Under Cover Produced with the Same - Google Patents

Abstract

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a material for engine undercover and an engine undercover manufactured therefrom, and more particularly, to a polypropylene (PP) based board; A hollow PET (polyethylene terephthalate) nonwoven fabric formed on the PP-based board; An m-aramid nonwoven fabric formed on the hollow PET nonwoven fabric; And a PP spunbond nonwoven fabric formed on the m-aramid nonwoven fabric, which can simultaneously exhibit absorption, sound insulation, heat insulation, and heat resistance characteristics, and which can produce an engine undercover in a single process And an engine undercover manufactured therefrom.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to an engine under-cover material,

The present invention can be used in the automobile, aviation, shipbuilding industry, and construction fields. In particular, the present invention can be applied to an engine under cover, an engine under cover material which can be applied to an engine room sound absorber and an engine under cover made therefrom, .

Domestic materials mainly used for engine cover parts are mainly made of materials reinforced with GMT (Glass Mat Thermoplastic Composite) or PP (Polypropylene) injection materials for sound absorbing materials such as glass wool and resin felt .

The engine cover material is used to protect the engine and cooling module from external impacts and to reduce road noise, friction noise, sand noise, reducing noise, and improving aerodynamics. In order to satisfy all of them, a heavy-weight injection molding is applied.

As the engine cover material, the dry type glass fiber reinforced mat produced in Korea has not secured the mechanical properties required by the automobile manufacturer, and the mechanical properties such as advanced glass fiber wet nonwoven fabric products in high temperature / There is a problem that the sound absorption characteristic is remarkably low.

In addition, the carbon fiber reinforced mat, which is also manufactured as an engine cover material in Korea, has excellent physical properties of the reinforcing fiber, but the material itself is expensive, and electromagnetic interference caused by the conductive material is generated. There is a problem that it is difficult to utilize it as a built-in component.

Meanwhile, the conventional engine cover material has a problem that the manufacturing process is also troublesome by using a binary method in which the sound absorbing material is attached again after manufacturing the injection molding material, thereby increasing the manufacturing cost (FIG. 1).

The present invention is to provide an engine undercover material having a sound absorption and sound insulation function for each section and excellent heat insulation, heat resistance and cold resistance, and an engine under cover made therefrom.

Accordingly, the present invention provides, as a first preferred embodiment, a polypropylene (PP) board; A hollow PET (polyethylene terephthalate) nonwoven fabric formed on the PP-based board; An m-aramid nonwoven fabric formed on the hollow PET nonwoven fabric; And a PP spunbond nonwoven fabric formed on the m-aramid nonwoven fabric.

The PP-based board according to the embodiment may be a PP / natural fiber board or a PP / EPDM (Ethylene Propylene Diene Monomer) board.

The PP / natural fiber board according to the embodiment may be a PP / bamboo fiber board.

The m-aramid nonwoven fabric according to this embodiment may be processed to have a velor pattern and a lamellar pattern.

The PP-based board, the hollow PET nonwoven fabric, the m-aramid nonwoven fabric, and the PP-spunbond nonwoven fabric according to the above embodiments may be bonded at their respective interfaces by needle punching or gas lamination.

The present invention also provides, as a second preferred embodiment, an engine under cover prepared using the material for engine under cover.

The material for the engine under cover of the present invention can exhibit the suction / sound insulation function, the heat insulation function and the heat resistance function at the same time. In addition, since the engine under cover made of the material for the engine under cover has a comparatively low weight and a comparable physical property and an inexpensive product cost as compared with the conventional injection molded article, it is particularly useful for automobile, aviation, shipbuilding industry, In particular, the product competitiveness of the auto parts market is excellent.

Fig. 1 shows a dual process in which a sound absorbing material is to be separately attached to an injection mold to manufacture a conventional automobile engine undercover.
2 is a cross-sectional view of a material for engine undercover according to an embodiment of the present invention.
Fig. 3 shows a m-aramid nonwoven fabric processed to exhibit a velor pattern and a lamellar pattern in a material for engine undercover according to the present invention.

Hereinafter, the present invention will be described in more detail.

The present invention relates to a polypropylene (PP) -based board; A hollow PET (polyethylene terephthalate) nonwoven fabric formed on the PP-based board; An m-aramid nonwoven fabric formed on the hollow PET nonwoven fabric; And a PP spunbond nonwoven fabric formed on the m-aramid nonwoven fabric.

The material for engine under cover according to the present invention is a nonwoven fabric material exhibiting absorption / sound insulation characteristics and heat resistance characteristics.

The PP-based board generally refers to a board manufactured using PP as a main material. The PP-based board used in the present invention may be a PP / natural fiber board or a PP / EPDM (Ethylene Propylene Diene Monomer) board.

The PP / natural fiber board refers to a board produced by mixing PP and natural fibers. The content of PP in the PP / natural fiber board may be 50 to 80% by weight, and the content of natural fibers may be 20 to 50% by weight. If the content of PP is more than 80% by weight or the content of natural fibers is less than 20% by weight, the chemical resistance is lowered. If the content of PP is less than 50% by weight or the content of natural fibers is more than 50% There is a problem that the durability is deteriorated. Here, the natural fiber may be bamboo fiber, and the PP / bamboo fiber board is advantageous in that it is easy to obtain and the price is low.

The PP / EPDM board refers to a board manufactured by mixing PP and EPDM. The content of PP in the PP / EPDM board may be 60 to 80% by weight, and the content of EPDM may be 20 to 40% by weight. If the content of PP is more than 80% by weight or the content of EPDM is less than 20% by weight, sound absorption properties, lightweight properties, shape retention properties, Or when the content of EPDM is more than 40% by weight, the durability is deteriorated.

[Hollow PET nonwoven fabric]

The hollow PET nonwoven fabric can be used without restriction as long as it is a commonly used hollow PET nonwoven fabric.

[m-aramid nonwoven fabric]

The m-aramid fiber may have a length of 30 mm or more, preferably 30 to 80 mm, whereby the m-aramid nonwoven fabric is composed of m-aramid fibers, It exhibits characteristics that can withstand high temperatures and is suitable for application to engine undercover.

On the other hand, the m-aramid nonwoven fabric may be processed so that the surface thereof has a velor pattern and a lamellar pattern.

The term "velor type" used in the present invention means a form in which a plurality of yarns are bristled on the surface of an m-aramid nonwoven fabric so as to form a ring, as shown in FIG. 3 (a) As shown in Fig. 3 (b), the "lamellar pattern" is a pattern in which a plurality of stitch-like patterns formed by laminating a plurality of yarns in a straight line on a surface of an m-aramid nonwoven fabric, it means.

The m-aramid nonwoven fabric according to the present invention is processed so that its surface simultaneously exhibits a velor pattern and a lamellar pattern as described above, whereby the bulky properties are enhanced, the elasticity is improved, and the appearance (surface) It is effective to look luxurious and improve sound absorption (Fig. 3 (c)).

[PP spunbond nonwoven fabric]

PP spunbond nonwoven fabric refers to a nonwoven fabric made from PP, which is a thermoplastic polymer, as a raw material. The PP spunbonded nonwoven fabric is a step of directly spinning the PP into continuous filaments, which can be produced by a process comprising a step of forming a web by arbitrarily arranging and laminating, and a bonding step of improving the bonding between the fibers and stabilizing the shape.

 In general, the PP spunbonded nonwoven fabric has excellent properties such as economic efficiency, lightweight property, formability, chemical resistance, and beautiful appearance, and is thus used in the engine undercover of the present invention, thereby exhibiting the above excellent characteristics.

Particularly, the PP spunbonded nonwoven fabric is the same nonwoven fabric as the PP-based board, and has the advantage of being easily recycled later by using the same series of materials.

In particular, the PP spunbonded nonwoven fabric may have a weight per unit area of 50 to 100 g / m < 2 > in view of economical efficiency and light weight of the engine undercover to be finally produced.

[Interlayer adhesion means]

In the material for an undercoat of an automobile engine of the present invention, the PP-based board, the hollow PET nonwoven fabric, the m-aramid nonwoven fabric and the PP-spunbonded nonwoven fabric each have an interface by needle punching or gas lamination, As shown in Fig.

Needle punching is basically a method in which a plurality of needles are repeatedly pushed up and down by using various kinds of needles on the front surface or back surface of a laminated fiber layer to mechanically tie them together to form a fiber layer having a constant thickness and fiber density. The interface between the PP-based board, the hollow PET nonwoven fabric, the m-aramid nonwoven fabric, and the PP-spunbonded nonwoven fabric is bonded by needle punching, thereby improving the adhesive strength as compared with the case of using a general adhesive.

Gas lamination is to melt nonwoven fabrics using a gas flame to bond the nonwoven fabrics together. The interface between the PP-based board, the hollow PET nonwoven fabric, the m-aramid nonwoven fabric, and the PP-spunbonded nonwoven fabric is adhered by gas lamination, whereby air permeability is improved due to generation of pores, and as a result, sound absorption properties are improved.

The present invention also relates to an engine under cover manufactured using the engine under cover material as described above, wherein the engine under cover is manufactured by manufacturing a mold of an engine under cover, and feeding the engine under cover material into the mold Then, the molding of the engine under cover is completed through the pressing process, and the molded engine under cover can be manufactured.

As described above, the engine under cover is manufactured so as to simultaneously exhibit the sound absorbing property, the sound insulation, the heat insulation and the heat resistance effect by a single molding process, as compared with the process of attaching the sound absorbing material again after manufacturing the conventional molded article, .

Particularly, the material for engine under cover of the present invention is suitable for application to automobiles.

Hereinafter, the present invention will be described in more detail with reference to the following examples, but the scope of the present invention is not limited to these examples.

Example 1

Aramid nonwoven fabric (Woongjin Chemical) was laminated on the hollow PET nonwoven fabric, and a PP sponge was formed on the m-aramid nonwoven fabric by laminating a hollow PET nonwoven fabric (Woongjin Chemical) on a PP / EPDM board The material for automobile engine cover was manufactured by laminating a bond nonwoven fabric (Toray Saehan), and the interface of each layer was adhered by needle punching to produce a material for an automobile engine cover.

An automobile engine under cover was manufactured using the above-mentioned automobile engine under cover material as a mold for an automobile engine under cover.

Example 2

A material for an undercoat of an automobile engine and an automobile engine undercover using the same were prepared in the same manner as in Example 1, except that a PP / bamboo fiber board (Hanyang material) was used instead of the PP / EPDM board (Hanyang material).

Example 3

A material for an undercoat of an automobile engine and an automobile engine undercover using the same were prepared in the same manner as in Example 1, except that the interface of each layer was bonded by gas lamination instead of needle punching.

Comparative Example 1

A sound absorbing material was prepared and attached to an injection molding for an automobile engine undercover to manufacture an automobile engine under cover.

The sound absorption rate and heat resistance of the automobile engine undercover manufactured in Examples and Comparative Examples were measured in the following manner, and the results are shown in Table 1.

(1) Absorption rate

According to KS F 2814-2, the sound absorption rates for 1 kHz, 2 kHz, 3.15 kHz and 5 kHz noise were measured.

(2) Heat resistance

The heat distortion temperature was measured according to MS 213-51. Here, the heat deformation temperature means a temperature at which deformation starts to occur due to heat, and the higher the heat deformation temperature, the better the heat resistance.

Absorption rate Heat deformation temperature (캜) 1 kHz 2kHz 3.15 kHz 5kHz Example 1 10% 14% 20% 27% 130 Example 2 9% 14% 19% 25% 125 Example 3 10% 12% 20% 27% 127 Comparative Example 1 7% 10% 15% 20% 120

As a result of the measurement of the sound absorption coefficient and the heat distortion temperature, as shown in Table 1, in Comparative Example 1, which is an automobile engine cover manufactured using a general sound absorbing material, both the sound absorption coefficient and the heat distortion temperature were higher than those of the automobile engine covers of Examples 1 to 3 It turned out to be bad.

10: PP board
20: hollow PET nonwoven fabric
30: m-aramid nonwoven fabric,
31: m-aramid nonwoven fabric processed in Velor form and lamellar pattern
40: PP spunbond nonwoven fabric

Claims (6)

PP (polypropylene) based board;
A hollow PET (polyethylene terephthalate) nonwoven fabric formed on the PP-based board;
An m-aramid nonwoven fabric formed on the hollow PET nonwoven fabric; And
And a PP spunbond nonwoven fabric formed on the m-aramid nonwoven fabric,
Characterized in that the m-aramid nonwoven fabric is processed so that the surface of the m-aramid nonwoven fabric has a velor shape and a lamellar pattern.
The method according to claim 1,
Wherein the PP-based board is a PP / natural fiber board or a PP / EPDM (Ethylene Propylene Rubber) board.

3. The method of claim 2,
Wherein the PP / natural fiber board is a PP / bamboo fiber board.
delete The method according to claim 1,
Wherein the PP-based board, the hollow PET nonwoven fabric, the m-aramid nonwoven fabric, and the PP-spunbond nonwoven fabric are adhered to each other by needle punching or gas lamination. For the material.
An automobile engine under cover manufactured using the material for an automobile engine under cover according to any one of claims 1 to 3 and 5.

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