Method for manufacturing eco-friendly fabric for automobile harnesses using natural ink

Abstract

The present invention relates to a method for developing a high-strength, eco-friendly fabric applicable to automotive harnesses and a natural pigment-based ink. In particular, it relates to the development of a high-strength fabric utilizing recycled PET composite flammable yarn, and a manufacturing technology for natural pigment-based DTP (Digital Textile Printing) ink using TiO2 (titanium dioxide) and charcoal (Carbon Black). Through this, the invention provides a technology capable of simultaneously achieving eco-friendliness and high quality for automotive harness tapes.

Description

Technology Field

[0001] The present invention relates to a method for developing a high-strength, eco-friendly fabric and a natural pigment-based ink applicable to future automotive harnesses. In particular, it relates to the development of a high-strength fabric utilizing recycled PET composite twisted yarn and a manufacturing technology for natural pigment-based DTP (Digital Textile Printing) ink using TiO2 (titanium dioxide) and charcoal (Carbon Black). Through this, the invention provides a technology capable of simultaneously achieving eco-friendliness and high quality for automotive harness tapes. Background Technology

[0002] Conventional automotive harness tapes use PVC (polyvinyl chloride) as the main material.

[0003] PVC releases large amounts of hazardous substances, such as POSs, phthalates, and VCMs, during production and disposal, causing environmental pollution and harm to the human body. In particular, plasticizers volatilize or decompose in high-temperature environments, generating toxic gases that can have adverse effects on human health.

[0004] To address this, a method using recycled PET dope-dyed yarn is employed; however, recycled PET dope-dyed yarn has low strength and poor durability, which limits its use in producing high-strength fabrics, and there were difficulties in manufacturing high-strength fabrics due to insufficient composite twisting process technology.

[0005] Meanwhile, DTP (Digital Textile Printing) inks are primarily produced using synthetic chemical pigments. These synthetic pigments contain hazardous chemicals during the production process and cause wastewater and air pollution problems. In addition, conventional DTP inks have limitations in printfastness (light, friction, sublimation) and durability, and reduced productivity occurs due to print head clogging.

[0006] In addition, conventional inks using chemical pigments frequently cause print head clogging, which negatively affects print quality and productivity. Due to issues with ink viscosity and surface tension, print fastness is low, resulting in poor color reproduction when printing brand emblems and patterns. Prior art literature

[0007] Republic of Korea Published Patent No. 10-2018-0100250 (Method for manufacturing a fabric for automotive harness tape) Republic of Korea Published Patent No. 10-2010-0101374 (Method for manufacturing nano-grade natural ink for DTP (Digital Textile Printing) using natural pigments and digital printing method) The problem to be solved

[0008] The present invention aims to solve the aforementioned problems by addressing the emission of harmful substances from existing PCV materials, replacing them with eco-friendly fabrics, and developing a DTP ink using natural pigments to solve environmental pollution issues, and to provide an ink and a method for manufacturing fabric for automotive harnesses using the same.

[0009] Furthermore, the present invention provides a method for manufacturing a fabric for automotive harnesses by developing a high-strength fabric by compensating for the low strength of recycled PET original dyed yarn, and improving tensile strength and durability through a composite twisting process. means of solving the problem

[0010] According to one embodiment of the present invention for achieving the above objective, a method for manufacturing ink for DTP comprises: a step of dispersing and grinding a natural pigment containing TiO2 or charcoal to a particle size of 1 µm or less; a step of extracting a natural pigment from the natural pigment through a low-temperature vacuum; a step of separating the natural pigment and a precipitate by enzymatically hydrolyzing the extracted natural pigment; a step of separating the natural pigment from which the precipitate has been separated into layers using a solvent or a coagulant; and a step of capturing a specific pigment from the separated natural pigment and then stabilizing it.

[0011] According to one embodiment of the present invention, a method for manufacturing a fabric for a harness comprises: a step of dispersing and grinding a natural pigment containing TiO2 or charcoal to a particle size of 1 µm or less; a step of extracting a natural pigment from the natural pigment through a low-temperature vacuum; a step of separating the natural pigment and a precipitate by enzymatically hydrolyzing the extracted natural pigment; a step of separating the natural pigment from which the precipitate has been separated into layers using a solvent or a coagulant; a step of collecting a specific pigment from the separated natural pigment and stabilizing it to manufacture an ink for DTP; a step of preparing a recycled PET original dyed yarn; a step of manufacturing a composite twisted yarn with improved strength through a composite twisting process with a high-strength fiber using the original dyed yarn; a step of weaving a fabric for a tape using the composite twisted yarn; a step of printing the DTP ink onto the fabric for a tape using a DTP method; and a step of completing the fabric for a harness with the printed fabric. Effects of the invention

[0012] According to the method for manufacturing DTP ink and the method for manufacturing fabric for automobile harnesses using the same according to the present invention, it is possible to resolve the emission of harmful substances from existing PVC materials, replace them with eco-friendly fabrics, and develop DTP ink using natural pigments, thereby having the effect of solving environmental pollution problems.

[0013] In addition, according to the method for manufacturing DTP ink and the method for manufacturing fabric for automotive harnesses using the same according to the present invention, a high-strength fabric can be developed by compensating for the low strength of recycled PET original dyed yarn, and a fabric for automotive harnesses can be manufactured by improving tensile strength and durability through a composite twisting process. Brief explanation of the drawing

[0014] FIG. 1 is a flowchart illustrating a method for manufacturing a fabric for an automobile harness according to one embodiment of the present invention. Figure 2 schematically illustrates the process for manufacturing eco-friendly DTP ink according to the present invention. Figure 3 schematically illustrates the process for manufacturing recycled PET yarn. Specific details for implementing the invention

[0015] The present invention will be described in more detail below with reference to the attached drawings. However, the following drawings are provided merely to aid in understanding the present invention, and the present invention is not limited by the drawings. Furthermore, the shapes, sizes, ratios, angles, numbers, etc. disclosed in the drawings are exemplary, and the present invention is not limited to the depicted details.

[0016] Throughout the specification, the same reference numerals refer to the same components. Additionally, in describing the present invention, detailed descriptions of related prior art are omitted if it is determined that such detailed descriptions would unnecessarily obscure the essence of the invention.

[0017] Where terms such as 'includes,' 'have,' and 'consists of' are used in this specification, other parts may be added unless 'only' is used. Where a component is expressed in the singular, it includes cases where it is in the plural unless specifically stated otherwise.

[0018] In interpreting the components, they are interpreted to include a margin of error even in the absence of a separate explicit statement.

[0019] When the positional relationship between two parts is described using expressions such as 'on', 'on the upper', 'on the lower', or 'next to', one or more other parts may be located between the two parts unless 'immediately' or 'directly' is used.

[0020] Positional relationships such as 'upper,' 'upper surface,' 'lower,' and 'lower surface' are described based solely on the drawing and do not represent absolute positional relationships. In other words, depending on the observation location, the positions of 'upper' and 'lower,' or 'upper surface' and 'lower surface,' may be interchanged.

[0021] In this specification, "a to b" indicating a numerical range is defined as "≥a and ≤b".

[0022] Various environmental and safety regulations, including carbon neutrality and the Green New Deal, the eco-friendliness of parts due to the rapid shift toward greenness in the automotive market, and material differentiation for premium brands by automotive companies are taking place.

[0023] Given the demand for the development of eco-friendly materials to replace PVC, this invention aims to provide a high-strength, eco-friendly fabric for use in harnesses of future automobiles, replacing PVC. Additionally, to enhance the quality of the material, the invention seeks to differentiate the fabric from existing products by printing a brand emblem on it. To achieve this, the invention develops white DTP ink using TiO2 and gray DTP ink using TiO2 and charcoal, and aims to provide inks that satisfy physical and chemical properties, such as high colorfastness and head clogging, starting from the ink manufacturing process.

[0024] In addition, the present invention provides a high-strength, eco-friendly fabric for future automobile harnesses with stabilized functionality and durability, and smart manufacturing technology based on the standardization and automation of natural dyeing in conjunction with DTP technology, through the development of technology to manufacture nano-sized, eco-friendly inks for natural DTP using TiO2 and charcoal.

[0025] With the growth of the future automotive market, automakers are developing future vehicles centered on product premiumization, such as high-end design and materials, to differentiate themselves from competitors. For example, the market is shifting toward the establishment of their own luxury brands, similar to Hyundai Motor's 'Genesis,' Toyota's 'Lexus,' and Mercedes-Benz's 'Mercedes.' As a result of this premium branding, automakers are conducting differentiated market promotion and marketing by employing methods such as printing their brand emblems on automotive parts.

[0026] In line with these market trends, automobile manufacturers are seeking to promote and differentiate their products by placing brand emblems on parts of the interior and exterior. Consequently, they are also seeking to display brand marks on the tapes required for wiring connections during internal body assembly.

[0027] Meanwhile, the methods for applying brand emblems to current products can be broadly narrowed down to three: dyeing, embossing, and embroidery, due to the characteristics of eco-friendly textile materials.

[0028] First, dyeing methods include the copper plate method, the transfer method, and the DTP method. Among these, the copper plate method involves printing onto the cut fabric after it has been cut; the transfer method involves laser-cutting transfer paper into the desired shape and then applying it to the fabric using a press and heat; and the DTP method is a direct digital dyeing method that applies digital prints directly to the fabric. This dyeing method has the advantage of enabling multi-variety, small-batch or large-batch production, as well as allowing for the application of various patterns and colors. Additionally, it offers advantages such as reduced labor, production time, and wastewater volume, the ability to database colors and conditions, and the possibility of automated production. However, the dyeing method has drawbacks, including the fact that ink application varies by print head, requiring equipment experts, and that the safety of DTP inks is low. Furthermore, there is a need to secure physical properties for core DTP ink technology that are compatible with the print head to resolve issues such as clogging and aggregation.

[0029] Furthermore, the embossing method involves placing a pattern on an embossing roll and pressing it onto the fabric as it is fed to create an intaglio design. While this method has the advantages of being inexpensive and fast, it presents several drawbacks: the production of embossing rolls takes a long time, existing embossing rolls cannot be reused for different patterns, and quality variations occur because the physical properties of the embossed fabric differ slightly from those of the unembossed areas.

[0030] The embroidery method involves inputting a pattern to be embroidered into a machine, feeding the fabric, and processing the pattern using thread. While this method has the advantages of clear visibility and a low defect rate, it is expensive, places a burden on inventory management due to the use of various yarns, and has the problem that the embroidered fabric becomes thicker, potentially exceeding the final thickness specifications of the product.

[0031] In this invention, considering the advantages and disadvantages of printing processing methods, it was determined that dyeing is the final printing method to be applied to the fabric for eco-friendly tapes. Among these methods, the fabric was developed using a DTP process that allows for the rapid and efficient modification of various emblems and patterns while also providing clear print quality.

[0032] However, currently, for wiring connection tapes and tapes applied inside vehicles, black is used as the base color globally, with the exception of some hybrid products. This creates a problem where any color does not show up well when dyed against black. Generally, the base color is white, and a method of adding a white base is used when dyeing black-based products, but white ink has not yet been developed.

[0033] Therefore, through this invention, we have developed eco-friendly high-end tape fabric utilizing recycled composite flammable yarn, gray and white inks utilizing natural materials, and an optimal DTP system, thereby enabling the development of market-competitive products with applied brand image in the increasingly premium automotive market.

[0034] FIG. 1 is a flowchart illustrating a method for manufacturing a fabric for an automobile harness according to one embodiment of the present invention.

[0035] Referring to FIG. 1, a method for manufacturing a fabric for an automobile harness according to one embodiment of the present invention includes a natural pigment dispersion and grinding step (S110), a natural pigment extraction step (S120), a precipitate separation step (S130), a pigment layer separation step (S140), a DTP ink manufacturing step (S150), a dope-dyed yarn preparation step (S160), a composite twisted yarn manufacturing step (S170), a fabric weaving step (S180), a printing step (S190), and a harness fabric manufacturing step (S200).

[0036] Figure 2 schematically illustrates the process for manufacturing eco-friendly DTP ink according to the present invention.

[0037] Referring to FIGS. 1 and 2, first, in the natural pigment dispersion and grinding step (S110), the particle size of the natural pigment containing TiO2 or charcoal is dispersed and ground to 1 µm or less. Dispersion research was required to develop eco-friendly DTP inks of gray and white colors using TiO2 or charcoal. In the present invention, a process was adopted in which the particle size of the charcoal pigment is dispersed and ground to 1 µm or less in the step of dispersing and grinding the TiO2 / charcoal pigment aggregate into nano-size and uniform particle sizes. Furthermore, research was conducted on the optimization conditions of the dispersion process of the TiO2 / charcoal pigment according to the optimal concentrations of distilled water, iron remover, acidity regulator, dispersant, defoamer, dye, etc., and content conditions according to the following Table 1 were obtained.

[0038] Content substance water 20~30% water surfactants 4~10% J690 additives Antifoamer 1~4% S-104 emulsifier 2~7% EG moisturizer 3~7% Glycerin Thickener 4~11% - bookbinder 3~12% Acrylic antiseptic 2~5% Ascorbic acid pH regulator 2~5% Sodium hydroxide dyes 10~30% Charcoal / TiO2

[0039] And, in the natural pigment extraction step (S120), the natural pigment is extracted through a low-temperature vacuum.

[0040] Subsequently, in the precipitate separation step (S130), the extracted natural pigment is hydrolyzed by enzymatic hydrolyzing to separate the natural pigment and the precipitate.

[0041] In the pigment layer separation step (S140), the natural pigment from which the precipitate has been separated is separated into layers using a solvent or a coagulant.

[0042] Then, in the DTP ink manufacturing step (S150), a specific pigment is captured from the layer-separated natural pigment and stabilized to manufacture DTP ink.

[0043] Thus, the manufacturing of the DTP ink according to the present invention is completed through steps S110 to S150. This DTP ink is used when applying the DTP printing method to the manufacture of fabric for automobile harnesses, which is the final goal of the present invention.

[0044] Referring again to FIG. 1, in the pre-dyed yarn preparation step (S160), recycled PET pre-dyed yarn is prepared.

[0045] Figure 3 schematically illustrates the process for manufacturing recycled PET yarn.

[0046] In this invention, as the demand for recycled PET yarn increases to address environmental pollution issues, recycled PET yarn was utilized for the purpose of developing an eco-friendly product.

[0047] Referring to Fig. 3, recycled yarn is produced by turning PET bottles into PET flakes, which are then manufactured into PET chips. This is then made into fiber yarn, and a method for making fiber products is used.

[0048] Meanwhile, since recycled PET yarn is generally weaker than PET yarn and is used only in clothing rather than industrial applications, we pursued strength improvement through the PET dope yarn and composite twisted yarn processes to enhance the strength of recycled PET yarn.

[0049] Accordingly, in the composite twisted yarn manufacturing step (S170), the original dyed yarn is combined with a high-strength fiber through a composite twisting process to manufacture a composite twisted yarn with enhanced strength.

[0050] Meanwhile, recycled composite twisted yarn, after the composite twisting process is completed, may undergo a sizing process to improve weaving performance.

[0051] In the fabric weaving step (S180), a tape fabric is woven using a composite twisted yarn.

[0052] Fabric structures are typically classified into plain weave, twill weave, and satin weave. In the case of twill and satin weaves, the arrangement of warp and weft threads differs, and due to the nature of tapes that are cut to a uniform size after production, partial changes in physical properties may occur due to these differences in arrangement. In contrast, plain weave is a structure in which the warp and weft threads intersect in a single manner; it is the simplest of the three structures and is a fabric with high strength. Accordingly, considering strength, the present invention adopts plain weave to weave composite twisted yarn into a fabric for tape.

[0053] Meanwhile, the fabric from which the weaving process is completed undergoes a washing process to remove foreign substances that were attached during the sizing and weaving processes, and the fabric made using recycled composite twisted yarn is thicker and has a rougher texture than ordinary fabric, so a pre-setting process is also carried out to take this into account.

[0054] In addition, since fabrics made using recycled composite yarns are thicker and have a rougher texture than ordinary yarns, there is a problem with reduced tape usability compared to conventional PVC (vinyl) fabrics. Accordingly, in the present invention, an additional setting process is performed to set the touch, flexibility, and final thickness of the fabric so that it can be used as a fabric for automobile harnesses.

[0055] In the printing step (S190), the above DTP ink is printed on the tape material using a DTP printing method, that is, a direct dyeing digital method, which is a spraying method that prints digitally directly onto the material.

[0056] In the manufacturing step for the harness fabric (S200), the automobile harness fabric is completed using the printed fabric.

[0057] This invention aims to develop an eco-friendly fabric for future automobile harnesses using recycled PET yarn, in response to the growing trend of stricter environmental regulations and increasing interest in eco-friendly products as environmental pollution becomes more severe. Furthermore, it was developed to enhance the strength of recycled PET yarn through a composite twisting process, in conjunction with the custom production of recycled PET yarn.

[0058] In the case of fabrics using recycled composite twisted yarns, the strength and touch sensation differ from existing products, requiring the setting of optimal fabric weaving and processing conditions tailored to this. Through this invention, optimal conditions could be verified.

[0059] In this invention, the goal was to develop eco-friendly, high-end products through brand emblem printing by developing gray and white inks using natural pigments and developing an optimized DTP process. Additionally, natural charcoal and TiO2 inks are considered to have high utility as eco-friendly inks because they remove harmful chemicals that cause air pollution and do not cause skin irritation. Furthermore, since they are highly biodegradable when disposed of, it was determined that using them as DTP inks would minimize human health risks caused by exposure to endocrine disruptors. Consequently, the development of gray and white inks using natural pigments on high-end tape fabrics utilizing these materials was pursued. Finally, the development of gray and white inks using natural pigments on high-end tape fabrics utilizing recycled composite twisted yarns, along with brand emblem dyeing through the optimization of the DTP process, resulted in the development of products that are differentiated from existing ones.

[0060] As such, according to the method for manufacturing DTP ink and the method for manufacturing fabric for automobile harnesses using the same according to the present invention, it is possible to resolve the emission of harmful substances from existing PVC materials, replace them with eco-friendly fabrics, and develop DTP ink using natural pigments, thereby having the effect of solving environmental pollution problems.

[0061] In addition, according to the method for manufacturing DTP ink and the method for manufacturing fabric for automotive harnesses using the same according to the present invention, a high-strength fabric can be developed by compensating for the low strength of recycled PET original dyed yarn, and a fabric for automotive harnesses can be manufactured by improving tensile strength and durability through a composite twisting process.

[0062] The present invention has been described above with reference to embodiments. Those skilled in the art will understand that the present invention may be embodied in modified forms without departing from the essential characteristics of the invention. Therefore, the disclosed embodiments should be considered in an illustrative rather than a restrictive sense. The scope of the invention is defined by the claims, not by the foregoing description, and all variations within the scope of equivalents should be interpreted as being included in the invention.

Claims

Claim 1 A method for manufacturing DTP ink comprising: a step of dispersing and grinding a natural pigment containing TiO2 or charcoal to a particle size of 1 µm or less; a step of extracting a natural pigment from the natural pigment through a low-temperature vacuum; a step of separating the natural pigment and a precipitate by enzymatically hydrolyzing the extracted natural pigment; a step of separating the natural pigment from which the precipitate has been separated into layers using a solvent or a coagulant; and a step of capturing a specific pigment from the separated natural pigment and then stabilizing it. Claim 2 A method for manufacturing a fabric characterized by comprising: a step of dispersing and grinding a natural pigment containing TiO2 or charcoal to a particle size of 1 µm or less; a step of extracting a natural pigment from the natural pigment through a low-temperature vacuum; a step of separating the natural pigment and a precipitate by enzymatically hydrolyzing the extracted natural pigment; a step of separating the natural pigment from which the precipitate has been separated into layers using a solvent or a coagulant; a step of collecting a specific pigment from the separated natural pigment and stabilizing it to manufacture an ink for DTP; a step of preparing a recycled PET original dyed yarn; a step of manufacturing a composite twisted yarn with enhanced strength through a composite twisting process with a high-strength fiber using the original dyed yarn; a step of weaving a fabric for tape using the composite twisted yarn; a step of printing the DTP ink onto the fabric for tape using a DTP method; and a step of completing a fabric for a harness using the printed fabric.

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