Nonwoven fabric for a vehicle interior material, manufacturing method thereof, and trunk cover for a vehicle using the nonwoven fabric for a vehicle interior material

Abstract

Manufacturing method for a nonwoven fabric (100) for a vehicle interior material, comprising: Forming a felt (110) by mixing low-melting PET (low-melting polyethylene terephthalate) staple fibers having a melting point in a range of 120 to 140°C and 150 to 170°C and PET staple fibers (410), and performing thermocompression molding of the felt (420), wherein the formation of the felt (110) comprises: Forming the felt by mixing the low-melting PET staple fibers in an amount of 15 to 25 wt.% based on a total fiber weight and PET staple fibers in an amount of 75 to 85 wt.% based on a total fiber weight, and wherein the low-melting PET staple fibers and the PET staple fibers have a thickness in the range of 1 to 6 denier.

Description

The present invention relates to a nonwoven fabric for a vehicle interior material, a manufacturing method for the nonwoven fabric, and a trunk lid for a vehicle using the nonwoven fabric for a vehicle interior material.Nonwoven fabrics are fabrics manufactured in such a manner that various fibers including natural fibers, chemical fibers, glass fibers, and metal fibers form fabric sheets, and the fabric sheets are joined together by physical or chemical methods. Nonwoven fabrics are used in a variety of applications at low cost due to recent developments in the chemical industry and mass production of high performance products.The fields where nonwoven fabrics are used include the field concerning vehicle interior materials (door panels, headliners, seats, etc.), and here, interior materials of polyvinyl chloride (PVC) having a low-grade shape and texture are steadily replaced with interior materials having various functionalities.In addition, research and development is constantly being carried out in the field of nonwoven fabrics in order to obtain a soft and luxurious finish, as in leather.The above description of the related art is intended merely to aid in understanding the general background of the present invention and is not to be taken as the prior art well known to those skilled in the art.KR 10 1999 0 039 952 A discloses a method for producing a needle punched non-woven carpeting.KR 10 0 939 960 B1 discloses a production method for a patterned fibre board.KR 20 0 370 190 Y1 discloses a cargo cover device for vehicles.JP 2010-128 005 A discloses a sound-absorbing composite material.JP 2006-88 504 A discloses an integrally molded skin material.The invention provides a manufacturing method of a non-woven fabric for a vehicle interior material according to claim 1, a non-woven fabric for a vehicle interior material according to claim 6, and a trunk lid for a motor vehicle according to claim 10. Further embodiments are defined in the dependent claims.Various aspects of the present disclosure are directed to providing a nonwoven fabric for an in-vehicle material, which is manufactured by needle punching a fabric web manufactured by mixing polyethylene terephthalate (PET) staple fibers and low-melting PET staple fibers, a manufacturing method for the nonwoven fabric, and a trunk lid using the nonwoven fabric for an in-vehicle material.Various aspects of the present disclosure are directed to providing a non-woven fabric for a vehicle interior material, which is manufactured by performing a thermoplastically compression molding process to improve a thickness deviation caused by a needle punching process and performing an embossed pattern molding process on one side of the non-woven fabric to improve the quality of the appearance of the non-woven fabric, a manufacturing process for the non-woven fabric, and a trunk lid using the non-woven fabric for a vehicle interior material.The present invention provides a manufacturing method of a nonwoven fabric for a vehicle interior material. The method includes forming a felt by mixing low melting point PET (low melting point polyethylene terephthalate) staple fibers having a melting point in the range of 120 to 140 and 150 to 170° C. and PET staple fibers, and performing thermo-compression molding of the felt. Forming the felt includes forming the felt by mixing the low melting point PET staple fibers in an amount of 15 to 25 wt % based on the total fiber weight and PET staple fibers in an amount of 75 to 85 wt % based on the total fiber weight.According to another aspect of the present invention, forming the felt comprises forming a web by mixing the low melting point PET staple fibers and the PET staple fibers, and forming the felt by needling the web.According to another aspect of the present invention, the method further comprises forming an embossed pattern on one side of the felt.According to one aspect of the present invention, the method further comprises performing a binder coating step by impregnating one side of the felt with a phosphorus-containing flame retardant and an acrylic binder.In accordance with one aspect of the present invention, the method further comprises coating one side of the felt with an acrylic polymer.The present invention further provides a nonwoven fabric for a vehicle interior material, which is manufactured by thermoplastically forming a felt, the felt being formed by mixing polyethylene terephthalate (PET) staple fibers and low-melting PET (low-melting polyethylene terephthalate) staple fibers having a melting point in the range of 120 to 140° C. and 150 to 170° C. The felt is formed by mixing low melting point PET staple fibers in an amount of 15 to 25 wt % based on the total fiber weight and PET staple fibers in an amount of 75 to 85 wt % based on the total fiber weight.According to another aspect of the present invention, the felt has an embossed pattern on one side of the felt.According to one aspect of the present invention, the felt has a binder coating layer formed of a phosphorus-containing flame retardant and an acrylic binder on one side of the felt.According to another aspect of the present invention, the felt has a printing layer formed of an acrylic polymer on one side of the felt.The present invention further provides a trunk cover for an automobile. The trunk cover includes a housing having both end portions supported by the vehicle body and having an opening slot formed on one side of the housing, a winding roll rotatably provided in the housing and elastically supported to rotate in a direction opposite to the opening slot, and a non-woven fabric wound around the winding roll to be pulled out to the outside by an external force, the non-woven fabric being manufactured by thermoplastically molding a felt formed by mixing polyethylene terephthalate (PET) staple fibers and low melting point PET staple fibers having a melting point in the range of 120 to 140° C. and 150 to 170° C. The nonwoven fabric is formed by mixing low melting point PET staple fibers in an amount of 15 to 25 wt % based on the total fiber weight and PET staple fibers in an amount of 75 to 85 wt % based on the total fiber weight.According to another aspect of the present invention, the nonwoven fabric has an embossed pattern on one side of the nonwoven fabric.According to another aspect of the present invention, the non-woven fabric has a binder coating layer formed of a phosphorus-containing flame retardant and an acrylic binder on one side of the non-woven fabric.According to one aspect of the present invention, the nonwoven fabric has a print layer formed of an acrylic polymer on one side of the nonwoven fabric.The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.In the drawings, there are shown: FIG. 1 is a diagram showing a structure of a nonwoven fabric for a vehicle interior material according to an exemplary embodiment of the present invention, FIG. 2 is a view showing a state in which a trunk cover for an automobile according to an exemplary embodiment of the present invention is disposed inside a vehicle, FIG. 3 is a view showing a structure of a trunk cover for a vehicle according to an exemplary embodiment of the present invention, FIG. 4 is a flowchart illustrating a manufacturing method of a nonwoven fabric for a vehicle interior material according to an exemplary embodiment of the present invention, FIG. 5 is a flowchart illustrating a manufacturing method of a nonwoven fabric for a vehicle interior material according to another exemplary embodiment of the present invention, FIG. 6 is a flowchart illustrating a manufacturing method of a nonwoven fabric for a vehicle interior material according to another exemplary embodiment of the present invention; and FIG. 7 is a view showing a device for measuring flexibility.It is to be understood that the appended drawings are not necessarily to scale, presenting a somewhat simplified representation of various features illustrative of the basic principles of the present invention. The specific design features of the present invention as disclosed herein, including, for example, particular dimensions, orientations, locations, and shapes will be determined in part by the particular intended application and use environment.Reference numerals in the figures refer to the same or equivalent parts of the present invention.Reference will now be made in detail to various embodiments of the present invention, examples of which are illustrated in the accompanying drawings and described below. Although the invention has been described in connection with exemplary embodiments, it is to be noted that the invention is not limited to these embodiments by the present description. On the contrary, the invention is intended to embrace not only the exemplary embodiments but also numerous alternatives, modifications, equivalents and other embodiments which may be included within the spirit and scope of the invention as defined by the appended claims.The following detailed description is provided to aid the reader in understanding the methods, apparatus, and / or systems described herein. Accordingly, those skilled in the art will recognize various changes, modifications, and equivalents to the methods, apparatus, and / or systems described herein.The flow of processing processes described herein is exemplary. However, the sequence of operations is not limited to the disclosure illustrated herein and may be changed as known in the art, except for operations necessarily proceeding in a particular order. Moreover, respective descriptions of known functions and constructions are omitted for improved clarity and accuracy.Moreover, exemplary embodiments will be described in detail below with reference to the attached drawings. However, the exemplary embodiments may be embodied in different forms and should not be considered limited to the embodiments illustrated herein. These embodiments are provided so that the present disclosure will be thorough and complete, and will fully convey the exemplary embodiments to those skilled in the art. Like reference numerals refer to like elements throughout the document.Note that when the terms first, second, etc. are used to describe various elements, these elements are not limited by these terms. These terms are used only to distinguish one element from another. As used herein, the term "and / or" includes any combination of one or more of the listed items.It is noted that when an element is referred to as being "connected" to another element, it may be directly connected to the other element, or intervening elements may also be present. On the other hand, when an element is referred to as being "directly" "connected" to another element, there are no intervening elements.Terms used herein are used merely to describe particular embodiments and are not intended to limit the present invention. Terms in the singular include plural referents unless the context expressly indicates otherwise.Reference will now be made in detail to the exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout the document.FIG. 1 is a diagram showing a structure of a nonwoven fabric 100 for a vehicle interior material according to an embodiment of the invention.As shown in FIG. 1, a nonwoven fabric 100 for a vehicle interior material according to the embodiment is provided with a felt 110 formed by mixing PET (polyethylene terephthalate) staple fibers and low-melting PET (low-melting polyethylene terephthalate) staple fibers having a melting point in the range of 120 to 140° C. and 150 to 170° C.The felt 110 formed by mixing low-melting PET staple fibers and PET staple fibers is manufactured by forming a web by mixing the low-melting PET staple fibers and the PET staple fibers and needling the web.The PET staple fibers may comprise PET staple fibers having a melting point in the range of about 250-270°C, preferably a melting point of about 260°C.The low melting point PET staple fiber is a low melting point PET staple fiber having a melting point lower than the melting point of a general staple fiber. The low melting point PET staple fiber may include a PET staple fiber having a melting point in the range of 120-140° C. and a PET staple fiber having a melting point in the range of 150-170° C. For example, low melting point PET staple fibers having a melting point of 130° C. may be used, low melting point PET staple fibers having a melting point of 160° C. may be used, or low melting point PET staple fibers may be used mixed therewith.The low melting point PET staple fibers contained in the fiber may be present in an amount of 15-25 wt % based on the total fiber weight. When the proportion of the low-melting PET staple fibers is less than 15 wt %, the proportion of the PET staple fibers becomes relatively high, whereby the quality of appearance may deteriorate, involving deterioration of the sharpness and formability of the embossed pattern, and only the flexibility and heat resistance of the nonwoven fabric 100 are excellent. Moreover, this non-woven fabric 100 as the vehicle interior material may have problems in durability.On the other hand, when the content of low-melting PET staple fibers is more than 25 wt %, the content of low-melting PET staple fibers becomes relatively high, and thus the properties in terms of heat aging resistance and moisture aging resistance are weak. For this reason, this fiber is not suitable as a vehicle interior material. Moreover, in the hot pressing method, curing due to melting of low-melting PET staple fibers is diffused and thus flexibility of the nonwoven fabric 100 is deteriorated, which may cause wrinkles to remarkably deteriorate appearance quality.Next, the PET staple fibers included in the fiber may be present in an amount of from 75 wt % to 85 wt % based on the total weight of the fiber. When the proportion of the PET staple fibers is less than 75 wt %, the proportion of the low-melting PET staple fibers is increased, and as described above, these are not suitable for use as a vehicle interior material due to their poor heat aging resistance and moisture aging resistance.On the other hand, when the proportion of the PET staple fibers is more than 85 wt %, the proportion of the PET staple fibers becomes relatively high, and thus the quality of appearance including deterioration of sharpness and formability of the embossed pattern deteriorates, while only the flexibility and heat resistance of the nonwoven fabric 100 are excellent. Moreover, in this non-woven fabric 100 as the vehicle interior material, there may be problems in durability.Accordingly, it is necessary to appropriately adjust the content ratio of the low melting point PET staple fibers and the PET staple fibers according to the physical properties of the product to be implemented.The thickness of the low melting point PET staple fiber and the PET staple fiber can be appropriately selected in consideration of the processability and the quality of appearance. The low melting point PET staple fiber and the PET staple fiber may preferably have a thickness in the range of 1 to 6 denier. If the thickness of the fiber is less than 1 denier, the processability in the production of the nonwoven fabric may be lowered because the thickness of the fiber is too small. On the other hand, if the thickness of the fiber is larger than 6 denier, the haptics and quality of the appearance of the nonwoven fabric 100 may be deteriorated because the thickness of the fiber is too thick. For this reason, a corresponding adaptation of the thickness of the fibers is preferred.An embossing pattern P may be formed on a surface of the felt 110. The embossing pattern P may be formed by pressing the flat felt 110 with an embossing die, and the embossing pattern P may be formed along the shape of the embossing die. Here, the die may be formed on a surface of a nip roller provided in a nonwoven fabric manufacturing apparatus. Moreover, the embossed pattern P is formed in a regular or irregular shape, and may be formed in a regular pattern or an irregular pattern according to the embodiment.The emboss pattern P formed on one side of the felt 110 gives the non-woven fabric 100 an emboss effect, and thus the quality of the appearance of the felt 110 can be improved. Moreover, when the non-woven fabric 100 is used in a trunk cover of an automobile, an effect of reducing noises generated by friction between edge portions of an opening slot of a trunk cover case and the non-woven fabric 100 occurs due to the emboss pattern P.A binder coating layer 120 may be formed on a surface of the felt 110 to impart flame retardancy and dimensional stability to the felt 110. The binder coating layer 120 may be formed by impregnating a phosphorus-based flame retardant and an acrylic binder by a foam coating method, but the constituents and the forming method of the binder coating layer 120 are not limited to the examples described above.The embossing pattern P may be formed on one side of the binder coating layer 120, and the embossing pattern P may have the same shape as the embossing pattern P formed on one side of the felt 110.A print layer 130 may be formed on the other surface of the felt 110 to improve wear resistance of the felt 110 and ensure a function of preventing contamination. The printing layer 130 may include an acrylic-based polymer component, but the constituent elements of the printing layer 130 are not limited to the examples described above.The nonwoven fabric 100 described above can be used for parts of vehicle interior materials including door panels and seats. As an example, the non-woven fabric 100 may be used for a trunk cover for an automobile. For convenience of explanation, an example in which the above-described nonwoven fabric 100 is used in a trunk lid of an automobile will be described, and a method of manufacturing the nonwoven fabric 100 for a vehicle interior material according to an exemplary embodiment of the present invention will be described in detail.FIG. 2 is a view showing a state in which a trunk cover 200 for an automobile according to an exemplary embodiment of the present invention is disposed inside a vehicle, and FIG. 3 is a view showing a structure of the trunk cover 200 for a vehicle according to an embodiment.As shown in FIG. 2 and FIG. 3, the trunk cover 200 is disposed in a cover guide groove formed in a trunk side liner of the vehicle, and the trunk cover 200 is configured to open or close a trunk 301 to cover various items stored in the trunk 301.The trunk cover 200 includes a housing 204 having opposite end portions supported by the vehicle body and having an opening slot 202 formed at one side of the housing 204, a winding roll 206 rotatably provided in the housing 204 and elastically supported to rotate in a direction opposite to the opening slot 202, and a non-woven fabric 100 wound around the winding roll 206 to be pulled out to the outside by an external force. As the nonwoven fabric 100, the nonwoven fabric 100 having the structure as described with reference to FIG. 1 can be used, and thus description of the same parts as those in the above description is omitted.Moreover, the trunk cover 200 may include a bracket 208 provided at an end portion of the non-woven fabric 100 to facilitate gripping of the non-woven fabric 100 and to prevent the non-woven fabric 100 from being pulled into the housing 204.On the other hand, a noise reduction device 210 for reducing friction noise generated when the nonwoven fabric 100 is pulled out may be formed at the upper and lower end portions of the opening slot 202. The noise reduction device 210 may be made of a soft brush member or PTFE (polytetrafluoroethylene) based on fluororesin. The noise reduction device 210 may be provided with a sliding member having a round processed surface formed on a surface of the sliding member to reduce noise generated when the noise reduction device 210 is in contact with the non-woven fabric 100.The structure of the nonwoven fabric 100 for a vehicle and the trunk cover 100 formed of the nonwoven fabric 100 for a vehicle according to an exemplary embodiment of the present invention has been described above. The technical idea of the present invention is not limited to the above-described embodiment, and the nonwoven fabric 100 for a vehicle may be applied to vehicle interior parts other than a trunk cover 200 for a vehicle.Next, a method of manufacturing such a non-woven fabric 100 for a vehicle will be described in detail.FIG. 4 is a flowchart of a manufacturing method of a nonwoven fabric 100 for a vehicle interior material according to an embodiment.As shown in FIG. 4, a manufacturing method of a nonwoven fabric for a vehicle interior material may include forming a felt by mixing low-melting PET staple fibers and PET staple fibers 410 and thermo-compression molding the felt 420.Forming a felt by mixing the low melting PET staple fibers and the PET staple fibers comprises forming a web by mixing the low melting PET staple fibers having a melting point in the range of 120-140 and 150-170°C and the PET staple fibers 412, and forming the felt by needling the web 414. The needle punching process is a process of forming an irregular warp in a fabric structure in which the low-melting PET staple fibers and the PET staple fibers are transversely laminated.The low melting PET staple fibers and the PET staple fibers may be blended such that 15-25 wt % of the low melting PET staple fibers based on the total fiber weight and 75-85 wt % of the PET staple fibers based on the total fiber weight are blended. The description of the same parts as those shown in the above description with reference to numerical limitations is omitted here, and the experimental example concerning the basis of the numerical limitation will be described in detail in the description of the experimental example described later.Subsequently, a step of thermo-compression molding the felt may be performed. When the web is formed by needling, the thickness of the felt may vary due to needling. The step of thermo-compression forming the felt may be performed to reduce the thickness variations of the felt. The nonwoven fabric according to an exemplary embodiment of the present invention is manufactured by a nonwoven fabric manufacturing apparatus. The nonwoven fabric manufacturing apparatus may include a heating roller and a rubber roller for the thermoplastically forming the nonwoven fabric. Accordingly, the felt is thermoplastically formed by the heating roller and the rubber roller of the nonwoven fabric manufacturing apparatus, resulting in a uniform thickness.The step of thermo-compression molding the felt may include a step of forming an embossed pattern on a surface of the felt. When the felt is thermo-compression molded, the felt is passed between the heating roller and the rubber roller as described above. At this time, an embossed pattern to be formed in the felt may be formed on a surface of the rubber roller. In the present case, the emboss patterns are formed on a surface of the felt while the felt passes between the heating roller and the rubber roller (420).The method for manufacturing the nonwoven fabric for vehicle interior materials may include additional methods for complementing the physical properties of the felt according to the embodiment. Additional processes that can be selectively performed will be described below.FIG. 5 is a flowchart for a manufacturing method of a nonwoven fabric for a vehicle interior material according to another exemplary embodiment, and FIG. 6 is a flowchart for a manufacturing method of a nonwoven fabric for a vehicle interior material according to another exemplary embodiment.As shown in FIG. 5, the manufacturing method of a nonwoven fabric for a vehicle interior material according to another exemplary embodiment may further include a step of forming a binder coating layer on a side of the felt 430.The step of forming the binder coating layer 430 may be performed between the step of forming the felt 410 and the step of thermo-compression molding the felt 420.The step of forming the binder coating layer may include a step of impregnating one side of the felt with a phosphorus-containing flame retardant and an acrylic binder in a foam coating process. Such a binder coating layer can impart flame retardancy and dimensional stability to the felt.As shown in FIG. 6, the manufacturing method of the nonwoven fabric for a vehicle interior material according to another exemplary embodiment may further include a step of forming a print layer by coating the other surface of the felt with an acrylic polymer ( 440). Here, the other surface of the felt refers to a surface of the felt opposite to a surface of the felt having the binder coating layer described above with reference to FIG. 5.The step of coating the acrylic polymer 440 may be performed between the step of forming the felt 410 and the step of thermo-compression forming the felt 420.The step of forming the printing layer may include a step of coating the other side of the felt with an acrylic polymer, and the printing layer may impart abrasion resistance and an antifouling function to the felt.The manufacturing method of a nonwoven fabric for a vehicle interior material has been described above. The manufacturing method of the nonwoven fabric for a vehicle interior material may include the step of forming the binder coating layer and the step of forming the print layer as described above, and both operations may be included according to the embodiment.Next, in order to facilitate understanding, the melting point and the limitation of the weight ratio of the low-melting PET staple fibers and the PET staple fibers used in the manufacturing method of the nonwoven fabric for a vehicle interior material according to an exemplary embodiment of the present invention will be described in detail with reference to experimental data.In order to conduct the physical property measurement test, webs were formed by mixing the low-melting PET staple fibers and the PET staple fibers having the melting points and content ratios shown in [Table1] and [Table2] for each of Examples and Comparative Examples, the web was needled to form felt, and the felt was thermo-compression molded to produce a physical sample. In the present case, the felt is thermo-compression formed by the heating roller and the rubber roller, and an amorphous emboss pattern is formed on one side of the felt to improve the quality of the appearance of the felt and reduce generation of noises upon friction.The melting point and the content ratio of the components of the physical samples according to [Example 1] to [Example 6] and [Comparative Example 1] to [Comparative Example 9] are as follows:[Example 1]Felt was formed by mixing 85 wt % of PET staple fibers having a melting point of 260 °C based on the total fiber weight and 15 wt % of low melting point PET staple fibers having a melting point of 130 °C based on the total fiber weight, and the felt was subjected to thermo-compression molding to produce physical samples. Here, the PET staple fiber and the low melting point PET staple fiber each have a fiber having a 3d thickness.[Example 2]Except that 80 wt % of PET staple fibers based on the total fiber weight and 20 wt % of low melting point PET staple fibers based on the total fiber weight were mixed together to form a felt, this example corresponds to the physical sample manufacturing method according to [Example 1].[Example 3]Except that 75 wt % of PET staple fibers based on the total fiber weight and 25 wt % of low melting point PET staple fibers based on the total fiber weight were mixed together to form a felt, this example corresponds to the physical sample manufacturing method according to [Example 1].[Example 4]Except that the felt was formed using PET staple fibers and low-melting PET staple fibers having a melting point of 160° C., this example corresponds to the production method for the physical sample according to [Example 1].[Example 5]Except that 80 wt % of PET staple fibers based on the total fiber weight and 20 wt % of low melting point PET staple fibers having a melting point of 160° C. based on the total fiber weight were mixed together to form a felt, this example corresponds to the physical sample manufacturing method according to [Example 1].[Example 6]Except that 75 wt % of PET staple fibers based on the total fiber weight and 25 wt % of low melting point PET staple fibers having a melting point of 160° C. based on the total fiber weight were mixed together to form a felt, this example corresponds to the physical sample manufacturing method according to [Example 1].[Comparative Example 1]Felt was formed by mixing 90 wt % of PET staple fibers having a melting point of 260 °C based on the total fiber weight and 10 wt % of low melting point PET staple fibers having a melting point of 110 °C based on the total fiber weight, and the felt was subjected to thermo-compression molding to produce physical samples. Here, the PET staple fiber and the low melting point PET staple fiber each have a fiber having a 3d thickness.[Comparative Example 2]Except that 85 wt % of PET staple fibers based on the total fiber weight and 15 wt % of low melting point PET staple fibers based on the total fiber weight were mixed together to form a felt, this example corresponds to the physical sample manufacturing method according to [Comparative Example 1].[Comparative Example 3]Except that 80 wt % of PET staple fibers based on the total fiber weight and 20 wt % of low melting point PET staple fibers based on the total fiber weight were mixed together to form a felt, this example corresponds to the physical sample manufacturing method according to [Comparative Example 1].[Comparative Example 4]Except that 75 wt % of PET staple fibers based on the total fiber weight and 25 wt % of low melting point PET staple fibers based on the total fiber weight were mixed together to form a felt, this example corresponds to the physical sample manufacturing method according to [Comparative Example 1].[Comparative Example 5]Except that 70 wt % of PET staple fibers based on the total fiber weight and 30 wt % of low melting point PET staple fibers based on the total fiber weight were mixed together to form a felt, this example corresponds to the physical sample manufacturing method according to [Comparative Example 1].[Comparative Example 6]Except that 90 wt % of PET staple fibers based on the total fiber weight and 10 wt % of low melting point PET staple fibers having a melting point of 150° C. based on the total fiber weight were mixed together to form a felt, this example corresponds to the production method for the physical sample according to [Comparative Example 1].[Comparative Example 7]Except that 70 wt % of PET staple fibers based on the total fiber weight and 30 wt % of low-melting PET staple fibers having a melting point of 150° C. based on the total fiber weight were mixed together to form a felt, this example corresponds to the production method for the physical sample according to [Comparative Example 1].[Comparative Example 8]Except that the felt was formed using PET staple fibers and low-melting PET staple fibers having a melting point of 160° C., this example corresponds to the production method for the physical sample according to [Comparative Example 1].[Comparative Example 9]Except that 70 wt % of PET staple fibers based on the total fiber weight and 30 wt % of low-melting PET staple fibers having a melting point of 160° C. based on the total fiber weight were mixed together to form a felt, this example corresponds to the production method for the physical sample according to [Comparative Example 1].The melting points and content ratios of the components of the physical sample according to [Example 1] to [Example 6] and [Comparative Example 1] to [Comparative Example 9] are summarized in the following [Table 1] and [Table 2]. [Table 1] Table 1] [Table 1] Table 1]Example 12601308515Example 22601308020Example 32601307525Example 42601608515Example 52601608020Example 62601607525[Table 2][Table 2]Comparative Example 12601109010Comparative Example 22601108515Comparative Example 32601108020Comparative Example 42601107525Comparative Example 52601107030Comparative Example 62601509010Comparative Example 72601507030Comparative Example 82601609010Comparative Example 92601607030The physical properties of the physical samples according to [Example 1] to [Example 6] and [Comparative Example 1] to [Comparative Example 9] were evaluated by the following methods.Sharpness of the Embossed PatternThe sharpness of the embossed pattern was visually determined in consideration of the embossing depth, the blurring of the surface, and the like.Wear resistanceA test piece having a diameter of about 150 mm was taken, and a hole having a diameter of about 6 mm was drilled at the center of the test piece. The test piece as such was mounted on a TABER type abrasion tester specified by JIS L 1096 (general cloth test method), and the wear resistance was measured according to the conditions of [Table 3]. The wear of the test piece surface after the measurement is shown in Table 4. [Table 3] [Table 3]SheetsSevere wearCS-104,9 (500)1000Trim TypeLower wearCS-104,9 (500)500In Table 3, the load refers to the weight applied to one side, and the test was performed by increasing the weight on both sides of the physical sample. [Table 4] [Table 4]5No signs of wear could be observed.4The surface is slightly dull or there is evidence of wear.3Lint can be seen on the wear part or the surface is lint-free and the interior is free of lint.2In the wear part, there is thread breakage and the formation of lint is clear.1The back side is visible because the surface is severely worn out.FlexibilityFIG. 7 is a view showing a device for measuring flexibility. For measurement of flexibility, five test pieces having a width of 25 mm and a length of 200 mm were used. Subsequently, as shown in FIG. 7, the test piece was placed on a horizontal track having a smooth surface with an inclination of 45° at one end, and the test piece was pressed with a pressing plate having the same size as the test piece, so that the test piece was moved toward the inclination at a speed of about 10 mm / s. The strength is indicated by the movement distance scale (point B scale) (mm) of the pressure plate when one end of the test piece contacts the slope, and is expressed as the average value of the measurement values for five test pieces.Heat resistanceThe procedure of subjecting the test piece to a condition of -110°C for 2 hours, a condition of -40°C for 2 hours and a room temperature for 2 hours is repeated over three cycles. After the test, the test piece is evaluated for appearance deviations including wrinkles.Deformation StateAfter preparing the trunk cover with the test pieces according to [Example 1] to [Example 6] and [Comparative Example 1] to [Comparative Example 9], the degree of deformation of the fabric at both end portions of the trunk cover was measured with respect to the horizontal line of the fabric.The results of measuring the physical properties of the test pieces measured in the above manner are shown below in [Table 5] to [Table 10]. In [Table 5] to [Table 10], the results are shown as being excellent (⊚), excellent (◯), normal (△) and poor (×) according to the order of superiority of physical properties.First, in [Table 5] to [Table 7], the results of physical properties of the test piece according to the weight ratio of low-melting PET staple fibers based on the melting point of low-melting PET staple fibers are shown. [Table 5] [Table 5]Comparative Example 1 (10 wt %)◯◯ (Step 4)◯△△Comparative Example 2 (15 wt %))⊚⊚ (Step 5)◯×◯Comparative Example 3 (20 wt %))⊚⊚ (Step 5)△×⊚Comparative Example 4 (25 wt %))⊚⊚ (Step 5)××⊚Comparative Example 5 (30 wt %))⊚⊚ (Step 5)××⊚[Table 6][Table 6]Weight Ratio of Low Melting PETSharpness of the Embossed PatternWear resistanceFlexibilityHeat resistanceDeformation StateComparative Example 6 (10 wt %)△△ (Step 3)⊚⊚△Example 1 (15 wt%)◯o (Step 4)◯◯◯Example 2 (20 wt%)⊚⊚ (Step 5)◯◯◯Example 3 (25 wt%)⊚⊚ (Step 5)△△⊚Comparative Example 7 (30 wt %)⊚⊚ (Step 5)××⊚[Table 7][Table 7]Weight Ratio of Low Melting PETSharpness of the Embossed PatternWear resistanceFlexibilityHeat resistanceDeformation StateComparative Example 8 (10 wt %)△× (Step 2)⊚⊚△Example 4 (15 wt%)◯△ (Step 3)⊚⊚◯Example 5 (20 wt%)⊚o (Step 4)◯⊚◯Example 6 (25 wt%)⊚⊚ (Step 5)◯◯◯Comparative Example 9 (30 wt %)⊚⊚ (Step 5)△△⊚In the evaluation of the test for the physical properties, when the conditions of wear resistance of the test pieces satisfy the condition of the step 3, the test piece is evaluated as being suitable for use as a vehicle interior material. Moreover, the test piece is evaluated as being suitable for use as the vehicle interior material when the condition of heat resistance of the test pieces satisfies the condition very excellent (⊚) as the most important physical condition.With reference to [Table 5], it was confirmed that when low-melting PET staple fibers having a melting point of 110° C. were used, the heat resistance was inferior regardless of the weight ratio of the low-melting PET. Moreover, as in the case of [Comparative Example 4] and [Comparative Example 5], it was confirmed that flexibility was also decreased as the weight ratio of the low-melting PET staple fibers was increased.With reference to [Table 6], when low-melting PET staple fibers having a melting point of 130° C. were used, sharpness of the embossed pattern formed on the nonwoven fabric was deteriorated and deformation phenomena occurred when low-melting PET staple fibers were added in an amount of 10% by weight, as shown in [Comparative Example 6]. On the other hand, when low-melting PET staple fibers were added in an amount of 30 wt %, as shown in [Comparative Example 7], the flexibility and the heat resistance of the nonwoven fabric were deteriorated. When the low-melting PET staple fibers were added in an amount of 15 wt %, 20 wt %, and 25 wt %, respectively, as shown in [Example 1] to [Example 3], it was confirmed that a nonwoven fabric having excellent physical properties can be provided.Referring to [Table 7], when the low-melting PET staple fibers having a melting point of 160° C. were used, the sharpness of the embossed pattern formed on the nonwoven fabric was deteriorated and deformation phenomena occurred when low-melting PET staple fibers were added in an amount of 10% by weight as shown in [Comparative Example 8]. On the other hand, when the low-melting PET staple fibers were added in an amount of 30 wt % as in [Comparative Example 9], it was confirmed that the flexibility and the heat resistance of the nonwoven fabric were relatively deteriorated as compared with [Example 4] to [Example 6]. On the other hand, when low-melting PET staple fibers were added in an amount of 15 wt %, 20 wt %, and 25 wt %, respectively, as in [Example 4] to [Example 6], it was confirmed that a nonwoven fabric having excellent physical properties can be provided.In the following Tables 8-10, the results of physical properties of the examples and comparative examples shown in [Table 5] to [Table 7] were compared with those of low melting PET staple fiber melting point based on the weight ratio of low melting PET staple fibers, and the description of properties of the test results of the same parts shown in the test results of [Table 5] to [Table 7] is omitted here. [Table 8] [Table 8]Comparative Example 2 (110°C)△⊚ (Step 5)◯×◯Example 1 (130°C)⊚o (Step 4)◯◯◯Example 4 (160°C)◯△ (Step 3)⊚⊚◯[Table 9][Table 9]Comparative Example 3 (110°C)⊚⊚ (Step 5)△×⊚Example 2 (130°C)⊚⊚ (Step 5)◯◯◯Example 5 (160°C)◯o (Step 4)◯⊚◯[Table 10][Table 10]Comparative Example 5 (110°C)⊚⊚ (Step 5)××⊚Comparative Example 7 (130°C)⊚⊚ (Step 5)××⊚Comparative Example 9 (160° C.)⊚⊚ (Step 5)△△◯As a result of the experiment, it was found that a nonwoven fabric for vehicle interior materials having excellent physical properties can be produced when the felt is formed by mixing the low melting point PET staple fibers having a melting point in the range of 120-140 and 150-170° C. with PET staple fibers when a felt is formed by mixing 15-25 wt % low melting point PET staple fibers based on the total fiber weight with 75-85 wt % PET staple fibers based on the total fiber weight.The nonwoven fabric manufactured by the method for manufacturing the nonwoven fabric for vehicle interior materials as described above has excellent physical properties and can contribute to weight reduction as the vehicle interior material. The nonwoven fabric according to an exemplary embodiment of the present invention has improved emboss pattern sharpness, wear resistance, flexibility, heat resistance, antistatic function, flame resistance, antifouling function, and the function of suppressing the formation of volatile organic compounds (VOCs), and thus the nonwoven fabric can be usefully used as a vehicle interior material.Moreover, by using the heating roller and the rubber roller in the embossing step, the thickness deviation of the felt itself can be smoothed and the occurrence of gloss can be prevented. Moreover, since an irregular embossed pattern is formed on a surface of the nonwoven fabric, the quality of appearance can be improved.As is apparent from the above description, according to the provided nonwoven fabric for a vehicle interior material, a method for manufacturing the nonwoven fabric and a trunk lid using the nonwoven fabric for a vehicle interior material, it is possible to realize a three-dimensional and luxurious appearance while satisfying requirements for a vehicle interior material in terms of physical properties such as wear resistance, flexibility, heat resistance, flame retardancy, antistatic function, antifouling function, and suppression of formation of volatile organic compounds (VOCs).For purposes of simplified explanation and accurate definition in the appended claims, the terms "upper", "lower", "inner", "outer", "front", "rear", etc. are used to describe features of the exemplary embodiments with reference to the positions of such features as may be seen from the figures.

Claims

A manufacturing method of a nonwoven fabric (100) for a vehicle interior material, comprising: forming a felt (110) by mixing low-melting-point PET (low-melting-point polyethylene terephthalate) staple fibers having a melting point in a range of 120 to 140°C and 150 to 170°C and PET staple fibers (410); and performing thermo-compression molding of the felt (420), wherein the forming of the felt (110) comprises: forming the felt by mixing the low-melting-point PET staple fibers in an amount of 15 to 25 wt% based on a total fiber weight and PET staple fibers in an amount of 75 to 85 wt% based on a total fiber weight, and wherein the low melting point PET staple fibers and the PET staple fibers have a thickness in the range of 1 to 6 denier.The method of claim 1, wherein forming the felt (110) comprises: forming a web by mixing the low melting PET staple fibers and the PET staple fibers (412); and forming the felt by needling the web (414).The method of any of claims 1 to 2, further comprising forming an embossing pattern (P) on one side of the felt (110).The method of any of claims 1 to 3, further comprising performing a binder coating (120) by impregnating a side of the felt (110) with a phosphorus-containing flame retardant and an acrylic binder (430).The method of any of claims 1 to 4, further comprising coating a side of the felt (110) with an acrylic polymer.A nonwoven fabric (100) for a vehicle interior material, which is produced by thermoplastically forming a felt (110), wherein the felt (110) is formed by mixing polyethylene terephthalate (PET) staple fibers and low-melting PET (low-melting polyethylene terephthalate) staple fibers having a melting point in a range of 120 to 140°C and 150 to 170°C, wherein the felt (110) is formed by mixing the low-melting PET staple fibers in an amount of 15 to 25 wt% based on a total fiber weight and the PET staple fibers in an amount of 75 to 85 wt% based on a total fiber weight, and wherein the low-melting PET staple fibers and the PET staple fibers have a thickness in the range of 1 to 6 denier.The nonwoven fabric (100) of claim 6, wherein the felt (110) has an embossed pattern (P) on one side of the felt.The nonwoven fabric (100) according to any one of claims 6 to 7, wherein the felt (110) has a binder coating layer (120) of a phosphorus-containing flame retardant and an acrylic binder on one side of the felt (110).The nonwoven fabric (100) according to any one of claims 6 to 8, wherein the felt (110) has a print layer (130) formed of an acrylic polymer on one side of the felt (110).A trunk cover (200) for an automobile, comprising: a housing (204) having first and second end portions supported by the vehicle body and having an opening slot (202) formed at one side of the housing (204); a winding roll (206) rotatably provided in the housing (204) and elastically supported to rotate in a direction opposite to the opening slot (202); and a non-woven fabric (100) wound around the winding roll (206) to be pulled out to the outside by an external force, wherein the non-woven fabric (100) is manufactured by thermoplastically forming a felt (110), the low melting point PET (low melting point polyethylene terephthalate) staple fibers and the low melting point PET (low melting point polyethylene terephthalate) staple fibers having a melting point in the range of 120 to 140°C and 150 to 170°C, wherein the nonwoven fabric (100) is formed by mixing the low melting point PET staple fibers in an amount of 15 to 25 wt% based on a total fiber weight and the PET staple fibers in an amount of 75 to 85 wt% based on a total fiber weight, and wherein the low melting point PET staple fibers and the PET staple fibers have a thickness in the range of 1 to 6 denier.The trunk lid (200) for an automobile according to claim 10, wherein the non-woven fabric (100) has an embossed pattern (P) on one side of the non-woven fabric (100).The trunk lid (200) for an automobile according to any one of claims 10 to 11, wherein the non-woven fabric (100) has a binder coating layer (120) formed of a phosphorus-containing flame retardant and an acrylic binder on one side of the non-woven fabric (100).The trunk lid (200) for an automobile according to any one of claims 10 to 12, wherein the non-woven fabric (100) has a printing layer (130) formed of an acrylic polymer on one side of the non-woven fabric.

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