Interior material and manufacturing method therefor

Abstract

According to the present invention, an interior material and a manufacturing method therefor may employ a protruding structure formed on the surface of a decorative layer and configured to provide a tactile feel, thereby improving a user's tactile experience when operating a button and enhancing the overall design quality of the exterior. The interior material comprises: a decorative layer; at least one shielding layer attached to the decorative layer; a through-portion formed through the shielding layer and the decorative layer and formed to correspond to a predetermined pattern; a light-transmitting layer formed by injecting an injection-molded product under the shielding layer; and a protruding pattern layer extending through the through-portion and formed on the light-transmitting layer to protrude above the surface of the decorative layer.

Description

Interior materials and methods for manufacturing the same

[0001] This application claims the benefit of priority based on Korean Patent Application No. 10-2024-0186318 dated December 13, 2024, and all contents disclosed in the document of said Korean Patent Application are incorporated as part of this specification.

[0002] The present invention relates to an interior material and a method for manufacturing the same, and more specifically, to an interior material and a method for manufacturing the same that can improve the user's button operation feel and enhance the design completeness of the exterior by applying a protruding structure capable of providing a tactile sensation to the surface of a decorative layer.

[0003] Generally, resin molded parts are used as interior and exterior materials for automobiles, such as console boxes and panels around instrument panels.

[0004] In particular, various control devices and convenience devices are installed in the dashboard, audio tech, gear shifting unit, airbag, door locking unit, and window opening / closing unit mounted around the driver and passenger seats inside the vehicle, and interior finishing panels are installed in the gaps between the outer edges of the various control devices and convenience devices and the interior materials to finish the interior materials, and these interior materials serve as an important factor in determining the appearance of the vehicle interior.

[0005] These automotive interior materials have a significant impact on the aesthetics of the car's interior, and as the trend toward individualizing and differentiating cars increases, consumers' aesthetic demands for the exterior are gradually growing.

[0006] Meanwhile, recently, there has been an increasing demand from consumers for automotive interior materials made of real materials in order to achieve sophistication and a high-end texture in the interior materials installed inside the car.

[0007] Accordingly, while it is possible to achieve a sophisticated appearance and high-quality texture by manufacturing the interior materials of the vehicle with real materials, there is no gap in the letters, characters, and shapes, so the driver is not provided with a tactile sensation, and there is a problem with reduced operability of the driver's buttons.

[0008] Meanwhile, recently, there has been an increasing demand for products made of various materials, such as real materials with unique surface textures, not only for automobiles but also for building materials including windows and doors, and electronic products, and there is a need for products to satisfy these consumer demands.

[0009] [Prior Art Literature]

[0010] [Patent Literature]

[0011] (Patent Document 1) Republic of Korea Published Patent No. 10-2022-0053395

[0012] Based on the technical background described above, the present invention aims to provide an interior material and a method for manufacturing the same, which can improve the user's button operation feel and enhance the design completeness of the exterior by applying a protruding structure capable of providing a tactile sensation to the surface of the decorative layer.

[0013] In addition, the present invention aims to provide an interior material and a method for manufacturing the same, which can be applied to various fields such as vehicle interiors, building materials, and electronic products, and can be easily used and identified at night by adding lighting to the decorative layer, thereby improving visibility and interior finish.

[0014] Furthermore, the technical problems that the present invention aims to solve are not limited to those mentioned above, and other unmentioned technical problems will be clearly understood by those skilled in the art to which the present invention belongs from the description below.

[0015] An interior material according to one embodiment of the present invention may include a decorative layer, at least one shielding layer attached to the decorative layer, a penetration portion formed by penetrating the shielding layer and the decorative layer and corresponding to a preset pattern, a light-transmitting layer formed by injecting an injection molded material into the lower part of the shielding layer, and a protruding pattern layer that passes through the penetration portion and is formed protruding higher than the surface of the decorative layer from the light-transmitting layer.

[0016] In an interior material according to one embodiment of the present invention, a light-transmitting layer can be formed in the penetration portion by injecting an injection molded material through an injection process.

[0017] In an interior material according to one embodiment of the present invention, a light-transmitting layer can be formed through an injection molding process.

[0018] In an interior material according to one embodiment of the present invention, the shielding layer may be a black material.

[0019] In an interior material according to one embodiment of the present invention, a penetration portion may be formed by laser processing.

[0020] In an interior material according to one embodiment of the present invention, the injection molded product may include a thermoplastic resin, a pigment, and a strength reinforcing material.

[0021] In an interior material according to one embodiment of the present invention, the ratio of the thermoplastic resin, pigment, and strength reinforcing material may be 70% to 80% by weight : 3% to 10% by weight : 10% to 25% by weight with respect to 100% by weight of the injection molded product.

[0022] In an interior material according to one embodiment of the present invention, the thermoplastic resin may include one or more selected from transparent PC resin, PCCD resin, or Co-Polyester resin.

[0023] In an interior material according to one embodiment of the present invention, the pigment may include one or more selected from CaCO3, TiO2, or Pigment.

[0024] In an interior material according to one embodiment of the present invention, the strength reinforcing material may include GF (Glass Fiber).

[0025] In an interior material according to one embodiment of the present invention, the decorative layer may be composed of at least one of Real Wood, Carbon, Stone, Fabric, Aluminum, Artificial Leather, or Glass Fiber Reinforced Plastic (GFRP).

[0026] A method for manufacturing an interior material according to one embodiment of the present invention may include a press forming step of press forming a decorative layer, a color coating step of color coating the decorative layer, a tape attachment step of attaching a tape to the decorative layer, a laser processing step of irradiating a laser onto the decorative layer to form a preset pattern, an injection step of injecting an injection molded product to form a light-transmitting layer on the decorative layer, and a protruding pattern layer forming step of removing the tape attached to the decorative layer to form a protruding pattern layer on the decorative layer.

[0027] A method for manufacturing an interior material according to one embodiment of the present invention may include a shielding layer forming step in which at least one shielding layer is formed on the back surface of a decorative layer during the press molding step.

[0028] A method for manufacturing an interior material according to one embodiment of the present invention may, in the color coating step, remove a release film attached to the front and back surfaces of a decorative layer and then color coat the front surface of the decorative layer.

[0029] A method for manufacturing an interior material according to one embodiment of the present invention may include a shielding coating step in which a shielding layer is shielded during the color coating step.

[0030] A method for manufacturing an interior material according to one embodiment of the present invention may, in the laser processing step, form a penetration portion to penetrate the shielding layer, the decorative layer, and the tape when forming a preset pattern.

[0031] A method for manufacturing an interior material according to one embodiment of the present invention can form a bridge portion between the inner portion of the closed curve and the island portion when a closed curve is included in a pre-set pattern.

[0032] In a method for manufacturing an interior material according to one embodiment of the present invention, during the laser processing step, a penetration portion is formed so that the shielding layer and the decorative layer penetrate when forming a preset pattern, and the tape may form a penetration portion only in a partial area.

[0033] In a method for manufacturing an interior material according to one embodiment of the present invention, in the laser processing step, if a closed curve is included in a preset pattern, an island portion disposed on the inner side of the closed curve can be attached to and fixed to the adhesive surface of the tape.

[0034] In a method for manufacturing an interior material according to one embodiment of the present invention, in the injection step, when a closed curve is included in a preset pattern, an island portion disposed on the inner side of the closed curve can be fixed to a light-transmitting layer formed by injecting into a through-hole processed only in a part of the tape.

[0035] Specific details of embodiments according to various aspects of the present invention are included in the following detailed description.

[0036] As described above, according to the present invention, by applying a protruding structure capable of providing a tactile sensation to the surface of a decorative layer, the user's button operation feel can be improved and the design completeness of the exterior can be enhanced, and it can be applied to various fields such as vehicle interior materials, building materials, and electronic products.

[0037] In addition, adding lighting to the decorative layer makes it easy to use and identify at night, and can improve visibility and the overall finish of the interior.

[0038] In addition, various materials with unique surface textures, such as Real Wood, Carbon, Stone, Fabric, Aluminum, Artificial Leather, or Glass Fiber Reinforced Plastic (GFRP), can be used as decorative layers to satisfy consumer needs.

[0039] In addition, forming protruding structures through an injection molding process allows for reduced production costs and simplified manufacturing processes in terms of mass production, compared to forming structures through other processes.

[0040] Furthermore, the effects obtainable from the present invention are not limited to those mentioned above, and other unmentioned effects will be clearly understood by those skilled in the art from the description below.

[0041] FIG. 1 is a perspective view showing an interior material manufactured by a method for manufacturing an interior material according to one embodiment of the present invention.

[0042] FIG. 2 is a cross-sectional view showing an interior material manufactured by a method for manufacturing an interior material according to one embodiment of the present invention.

[0043] FIG. 3 is a drawing showing a penetration formed by laser processing in a decorative layer by a method for manufacturing an interior material according to one embodiment of the present invention.

[0044] FIG. 4 is a drawing showing injection through an injection feeder in a method for manufacturing an interior material according to one embodiment of the present invention.

[0045] FIG. 5 is a flowchart illustrating a method for manufacturing an interior material according to one embodiment of the present invention.

[0046] FIGS. 6 to 12 are drawings showing the process of manufacturing an interior material according to a method for manufacturing an interior material according to an embodiment of the present invention.

[0047] FIGS. 13 to 15 are drawings showing part of the process of manufacturing an interior material according to a method for manufacturing an interior material according to another embodiment of the present invention.

[0048]

[0049] [Explanation of the symbol]

[0050] 1 : Interior materials

[0051] 10: Decorative layer

[0052] 10a : Front

[0053] 10b : Back side

[0054] 11 : Penetration

[0055] 13: Bridge section

[0056] 15 : Ireland

[0057] 20 : Shielding layer

[0058] 30a, 30b: Release film

[0059] 50 : Tape

[0060] 60a : Light-transmitting layer

[0061] 60b: Protruding pattern layer

[0062] 110, 120: Injection mold

[0063] 130 : Injection feeder

[0064] The present invention is capable of various modifications and may have various embodiments, and specific embodiments are illustrated and described in detail in the detailed description. However, this is not intended to limit the present invention to specific embodiments, and it should be understood that it includes all modifications, equivalents, and substitutions that fall within the spirit and scope of the invention.

[0065] The terms used in this invention are used merely to describe specific embodiments and are not intended to limit the invention. Singular expressions include plural expressions unless the context clearly indicates otherwise. In this invention, terms such as "comprising" or "having" are intended to indicate the existence of the features, numbers, steps, actions, components, parts, or combinations thereof described in the specification, and should be understood as not precluding the existence or addition of one or more other features, numbers, steps, actions, components, parts, or combinations thereof.

[0066] Preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Note that in the accompanying drawings, identical components are indicated by the same reference numerals whenever possible. Furthermore, detailed descriptions of known functions and configurations that may obscure the essence of the invention will be omitted. For the same reason, some components in the accompanying drawings may be exaggerated, omitted, or schematically depicted.

[0067] Hereinafter, an interior material and a method for manufacturing the same according to an embodiment of the present invention will be described.

[0068] FIG. 1 is a perspective view showing an interior material manufactured by a method for manufacturing an interior material according to an embodiment of the present invention. FIG. 2 is a cross-sectional view showing an interior material manufactured by a method for manufacturing an interior material according to an embodiment of the present invention. FIG. 3 is a drawing showing a penetration formed by laser processing in a decorative layer by a method for manufacturing an interior material according to an embodiment of the present invention. FIG. 4 is a drawing showing injection through an injection feeder in a method for manufacturing an interior material according to an embodiment of the present invention. FIG. 5 is a flowchart showing a method for manufacturing an interior material according to an embodiment of the present invention. FIG. 6 to 12 are drawings showing the process of manufacturing an interior material according to a method for manufacturing an interior material according to an embodiment of the present invention.

[0069] The interior material according to the present invention can be applied to various fields such as vehicle interior materials, building materials, and electronic products, but in this specification, it is described as being applied as an interior material for automobiles as one example.

[0070] As illustrated in FIGS. 1 and 2, an interior material (1) according to one embodiment of the present invention applies a protruding structure capable of providing a tactile sensation to the surface of a decorative layer (10) used as an interior material in the interior of a car, and transmits light through a protruding pattern layer (60b) to improve the driver's button operation sensation and visibility.

[0071] Here, the front (10a) of the decorative layer (10) is the side facing the driver after the decorative layer (10) is installed in the interior of the car, and the back (10b) of the decorative layer (10) is the side built into the interior device of the car.

[0072] Specifically, an interior material (1) according to one embodiment of the present invention may include a decorative layer (10), a shielding layer (20), a penetration portion (11), a light-transmitting layer (60a), and a protruding pattern layer (60b).

[0073] The decorative layer (10) may be made of a material having a unique surface texture, such as real wood, carbon, stone, fabric, aluminum, artificial leather, glass fiber reinforced plastic (GFRP) or carbon fiber reinforced plastic (CFRP), or steel.

[0074] In one embodiment of the present invention, the decorative layer (10) is described as being real wood as an example, but is not limited thereto.

[0075] The shielding layer (20) is attached to the back surface (10b) of the decorative layer (10), and at least one or more may be arranged.

[0076] Here, the shielding layer (20) is intended to shield light so that when light is shone on the decorative layer (10), the light irradiated through the light is irradiated only in a pre-set pattern such as a character, figure, or symbol, and may be a black material having a black color or a dark color.

[0077] At this time, the shielding layer (20) may be a layer comprising one or more selected from a non-woven fabric layer, a shielding coating layer, a film layer, and a coating layer, but is not limited thereto and can be modified in various ways.

[0078] If the shielding layer (20) is a bright color, the shielding layer (20) may be coated, applied, or painted with a black or dark color to perform the function of shielding light.

[0079] When multiple shielding layers (20) are arranged on the back surface (10b) of the decorative layer (10), it is possible for one or more of the multiple shielding layers (20) to be made of a black material, but is not limited thereto and can be modified in various ways.

[0080] The through-hole (11) can be formed to correspond to a pattern set in the decorative layer (10). Here, the through-hole (11) may be a laser-processed part formed by a laser.

[0081] The penetration portion (11) can be processed to be formed through the decorative layer (10) in the thickness direction.

[0082] Accordingly, the decorative layer (10) is cut and removed to correspond to the shape of a preset pattern, thereby forming a through-hole (11), and a protruding pattern layer (60b) that protrudes higher than the surface of the light-transmitting layer (60a) and the through-hole (11) can be formed in the through-hole (11) by injection.

[0083] The depth of the penetration (11) processed in the decorative layer (10) can be varied by controlling the output of the laser.

[0084] Meanwhile, when processing a penetration part (11) corresponding to a pattern set in the decorative layer (10), if the pattern includes a closed curve (or closed surface), an island part (15) formed on the inner side of the closed curve (or closed surface) can be separated and detached.

[0085] Therefore, a bridge can be formed when forming a through-hole (11) corresponding to a pre-set pattern in the decorative layer (10) through laser processing.

[0086] Referring to FIG. 3, for example, when forming patterns such as characters, shapes, and symbols for button operation by a user including a driver and a passenger seat, characters such as ‘HOME’, ‘POWER’, ‘NAVIGANTIN’, and ‘VOL’ can be laser-processed on the decorative layer (10).

[0087] In the following description, the characters 'POWER' among the pre-set patterns are used as an example. Of course, the technical concept of the present invention is not limited thereto.

[0088] Here, in the case of a character including a closed curve in which the inside and outside are separated, such as 'P, O, R', an island portion (15) may be formed inside when processing the through portion (11) corresponding to the pattern of the character, etc., and the island portion (15) may be separated and detached from the inner portion (not shown in the drawing) when laser processing.

[0089] Accordingly, when forming a penetration part (11) corresponding to a preset pattern by irradiating a laser onto a decorative layer (10), if the preset pattern includes a closed curve, the penetration part (11) must be processed so that a bridge part (13) is formed to connect the inner and outer parts of the closed curve, which are separated into inner and outer parts.

[0090] In this way, when processing a closed curve, a bridge section (13) is formed between the outer part (not shown in the drawing) of the penetration section (11) and the island section (15) placed on the inner part of the outer part, thereby preventing separation and detachment of the island section (15).

[0091] To this end, when processing the penetration part (11), a bridge part (13) of a predetermined width is formed by not processing a part of the closed curve, thereby preventing separation and detachment of the island part (15).

[0092] At this time, since the bridge part (13) is aesthetically advantageous as its width decreases, it is desirable to have a minimum width that prevents separation and detachment of the island part (15), but is not limited thereto.

[0093] Here, the bridge section (13) can be formed at least one or more times at a location to connect the inside and outside of the closed curve.

[0094] Preferably, the bridge portion (13) may be formed in two or more places at predetermined locations to connect the inside and outside of the closed curve.

[0095] Accordingly, as shown in FIG. 3(a), for characters such as 'P, O, R', two bridge sections (13) may be formed to connect the island section (15) and the outer section. Meanwhile, as shown in FIG. 3(b), for characters such as 'A', three bridge sections (13) may be formed, but this is not limited to this and various modifications are possible.

[0096] In this way, when a closed curve is included in a penetration part (11) corresponding to a pre-set pattern, when forming the penetration part (11), only the bridge part (13) is left, and the remaining part is processed to connect the inside and outside of the closed curve, thereby not only eliminating the need for a bridge injection part (not shown) or a rib injection part (not shown) through separate insert injection, but also eliminating the need for a separate insert injection process, thus enabling a reduction in manufacturing costs and a simplification of the manufacturing process.

[0097] The light-transmitting layer (60a) can be placed on the lower surface of the shielding layer (20) and inside the penetration portion (11).

[0098] At this time, the light-transmitting layer (60a) can be formed by injection molding to cover the entire back surface (10b) of the decorative layer (10), that is, the lower surface of the shielding layer (20). That is, the light-transmitting layer (60a) is formed by injection molding on the lower surface of the shielding layer (20), and at this time, the light-transmitting layer (60a) can be arranged to cover the entire lower surface of the shielding layer (20).

[0099] The light-transmitting layer (60a) is formed of a transparent or translucent material so that light passes through the light-transmitting layer (60a), and thus light can be transmitted to the front of the decorative layer (10) through the light-transmitting layer (60a).

[0100] Referring to FIG. 4, the light-transmitting layer (60a) can be formed by placing a decorative layer (10) in an injection mold (110, 120) and then injecting an injection product through an injection feeder (130) onto the back surface (10b) of the decorative layer (10).

[0101] Specifically, the injection molded product forming the light-transmitting layer (60a) may include a thermoplastic resin, a pigment, and a strength-reinforcing material.

[0102] As one embodiment, the thermoplastic resin may be a transparent PC resin (Polycarbonate, PC).

[0103] As another embodiment, the thermoplastic resin may comprise one or more resins selected from transparent PC (Polycarbonate) resin, PCCD (Polycyclohexylenedimethylene Cyclohexyl Dicarboxylate) resin, or Co-Polyester resin.

[0104] In one embodiment of the present invention, the injection molded product is described as being a thermoplastic resin as an example; however, depending on the case, a thermosetting resin may be used for the injection molded product, and the invention is not limited thereto and can be implemented in various ways.

[0105] The pigment may include one or more of CaCO3 (calcium carbonate), TiO2 (titanium dioxide), or Pigment.

[0106] TiO2, CaCO3, and Pigment are white pigments that have a high refractive index, precise particle size, and dispersibility, and are materials with excellent hiding power and coloring power, and are very chemically and physically stable.

[0107] Accordingly, light transmittance can be improved when illuminated by including TiO2, CaCO3, and Pigment in one or more resins selected from transparent PC (Polycarbonate) resin, PCCD (Polycyclohexylenedimethylene Cyclohexyl Dicarboxylate) resin, or Co-Polyester resin.

[0108] The strength reinforcing material may be GF (Glass Fiber).

[0109] Accordingly, structural stability and durability can be improved by including GF in one or more resins selected from transparent PC (Polycarbonate) resin, PCCD (Polycyclohexylenedimethylene cyclohexyl dicarboxylate) resin or Co-Polyester resin.

[0110] In one embodiment of the present invention, GF is described as being used as a strength reinforcing material, but depending on the case, fiber reinforced plastic (FRP) may also be used as the strength reinforcing material, and the invention is not limited thereto and various other modifications are possible.

[0111] Here, the ratio of the thermoplastic resin, pigment, and strength reinforcing material may be 70% to 80% by weight : 3% to 10% by weight : 10% to 25% by weight with respect to 100% by weight of the injection molded product.

[0112] When an injection part (60a) is injected into the back surface (10b) of the decorative layer (10), the protruding pattern layer (60b) can be formed as a protruding pattern layer (60b) on the front surface (10a) of the decorative layer (10) after the injection part (60a) is injected into the penetration part (11).

[0113] Examples, Comparative Examples, and Experimental Examples

[0114] The present invention will be described in detail below with reference to examples, comparative examples, and experimental examples. An average person skilled in the art to which the present invention pertains may modify the present invention in various forms other than the compositions described in the examples below. The following examples and experimental examples are merely illustrative of the present invention and should not be interpreted as intended to limit the scope of the technical concept of the present invention to the scope of the examples and experimental examples below.

[0115] Example 1

[0116] As shown in the composition in Table 1 below, PC resin and Co-Polyester resin were mixed and added at a rate of 100% by weight based on 100% by weight of the injection molded product, and then mixed to produce an injection molded product.

[0117] The manufactured injection molded product was injected into the back surface of the decorative layer installed in the injection mold through a post-injection feeder, injected into a penetration formed corresponding to a pre-set pattern in the decorative layer, and then cured.

[0118] Example 2

[0119] As shown in the composition in Table 1 below, PC resin and PCCD resin were mixed and added at a rate of 100% by weight based on 100% by weight of the injection molded product, and then mixed to produce an injection molded product. Subsequently, injection and curing were performed in the same manner as in Example 1.

[0120] Example 3

[0121] As shown in the composition in Table 1 below, based on 100% by weight of the injection molded product, 70% to 80% by weight of PC resin and Co-Polyester resin were mixed and added, and 10% to 25% by weight of GF was added, and then the mixture was mixed to produce an injection molded product. Subsequently, injection and curing were performed in the same manner as in Example 1.

[0122] Example 4

[0123] Based on 100% by weight of the injection molded product, 70% to 80% by weight of PC resin and PCCD resin were added by mixing, and 10% to 25% by weight of GF was added, and then the mixture was mixed to produce the injection molded product. Subsequently, injection and curing were performed in the same manner as in Example 1.

[0124] Example 5

[0125] Based on 100% by weight of the injection molded product, 70% to 80% by weight of a mixture of PC resin and Co-Polyester resin was added, 10% to 25% by weight of GF was added, and 3% to 10% by weight of a mixture of TiO2 and Pigment was added, and then the mixture was mixed to produce the injection molded product. Subsequently, injection and curing were performed in the same manner as in Example 1.

[0126] Example 6

[0127] Based on 100% by weight of the injection molded product, 70% to 80% by weight of a mixture of PC resin and Co-Polyester resin was added, 10% to 25% by weight of GF was added, and 3% to 10% by weight of a mixture of TiO2 and CaCO3 was added. Except for these factors, the injection molded product was manufactured using the same process as in Example 1. Subsequently, injection and curing were performed in the same manner as in Example 1.

[0128] Example 7

[0129] Based on 100% by weight of the injection molded product, 70% to 80% by weight of a mixture of PC resin and PCCD resin was added, 10% to 25% by weight of GF was added, and 3% to 10% by weight of a mixture of TiO2 and Pigment was added, and then the mixture was mixed to produce the injection molded product. Subsequently, injection and curing were performed in the same manner as in Example 1.

[0130] Example 8

[0131] Based on 100% by weight of the injection molded product, 70% to 80% by weight of a mixture of PC resin and PCCD resin was added, 10% to 25% by weight of GF was added, and 3% to 10% by weight of a mixture of TiO2 and CaCO3 was added. Except for these factors, the injection molded product was manufactured using the same process as in Example 1. Subsequently, injection and curing were performed in the same manner as in Example 1.

[0132] Example 9

[0133] Based on 100% by weight of the injection molded product, 70% to 80% by weight of a mixture of PCCD resin and Co-Polyester resin was added, 10% to 25% by weight of GF was added, and 3% to 10% by weight of a mixture of TiO2 and Pigment was added. Except for these factors, the injection molded product was manufactured using the same process as in Example 1. Subsequently, injection and curing were performed in the same manner as in Example 1.

[0134] Example 10

[0135] Based on 100% by weight of the injection molded product, 70% to 80% by weight of a mixture of PCCD resin and Co-Polyester resin was added, 10% to 25% by weight of GF was added, and 3% to 10% by weight of a mixture of TiO2 and CaCO3 was added. Except for these factors, the injection molded product was manufactured using the same process as in Example 1. Subsequently, injection and curing were performed in the same manner as in Example 1.

[0136] Comparative Example 1

[0137] Commercially available acrylic resin was injected into the back surface of the decorative layer installed in the injection mold through an injection feeder to form the decorative layer, and then cured after being injected into the penetration part corresponding to a pre-set pattern.

[0138] Classification Resin GF Additive Type Content (Weight%) Content (Weight%) Type Content (Weight%) Example 1 PC + Co-Polyester 100 --- Example 2 PC + PCCD 100 --- Example 3 PC + Co-Polyester 70~80 10~25 --- Example 4 PC + PCCD 70~80 10~25 --- Example 5 PC + Co-Polyester 70~80 10~25 TiO2 + pigment 3~10 Example 6 PC + Co-Polyester 70~80 10~25 TiO2 + CaCO3 3~10 Example 7 PC + PCCD 70~80 10~25 TiO2 + pigment 3~10 Example 8 PC + PCCD 70~80 10~25 TiO2 + CaCO3 3~10 Example 9 PCCD+Co-Polyester 70~80 10~25 TiO2+pigment 3~10 Example 10 PCCD+Co-Polyester 70~80 10~25 TiO2+CaCO3 3~10 Comparative Example 1 Acryl 100---

[0139] Experimental Example

[0140] As shown in [Table 1] above, an interior material was manufactured by injecting the injection molded product prepared according to Examples 1 to 10 and the injection molded product prepared according to Comparative Example 1 into the back surface of the decorative layer, injecting it into the laser-processed penetration part of the decorative layer, forming a light-transmitting layer, and then curing.

[0141] After transmitting light through the light-transmitting layer on the back of the interior material, the transmittance, tensile test, impact test, weather resistance, and discoloration resistance test on the protruding pattern layer formed on the front were tested and are shown in [Table 2] below.

[0142] transmittance

[0143] Transmittance was measured by irradiating a light source of constant output onto the back surface of an interior material with a thickness of 2 mm using test conditions specified in ISO 13468-2.

[0144] Tensile test

[0145] Tensile testing was performed on interior materials using a universal strength testing machine (UTM) according to the test conditions specified in ASTM D638.

[0146] Shock test

[0147] Impact testing was performed on interior materials using an Izod Impact Tester according to the test conditions specified in ASTM D256.

[0148] Weather resistance

[0149] Weather resistance was evaluated by exposing the interior material to low temperature (-40℃), room temperature (20℃), and high temperature (80℃) conditions for 4 hours each, and then evaluating the appearance of the interior material after 3 cycles. When visually inspecting the interior material, it was rated as strong if there was no change in appearance, medium if there was a slight change in appearance, and weak if there was a significant change in appearance such as discoloration and deformation.

[0150] Discoloration resistance

[0151] Discoloration resistance of the interior material was tested at a panel temperature of 89℃, irradiation humidity of 50%, and irradiation dose of 84 MJ / m² 2 After exposure to the condition for 4 hours, the color change before and after exposure was evaluated by measuring the color difference. A dE value of less than 3 was recorded as strong, a dE value between 3 and 5 as medium, and a dE value of 6 or higher as weak.

[0152] Classification Transmittance (%) Tensile Strength (MPa) Impact Strength (KJ / m² 2 Weather resistance and discoloration resistance Example 186% 4500MPa 38KJ / m 2 Weak Intermediate Example 284% 4200MPa 37KJ / m 2 Weak Intermediate Example 386% 5800MPa 45KJ / m 2 Medium Strength Example 485% 5800MPa 44KJ / m 2 Medium strength example 587% 5700MPa 50KJ / m 2 Strength Example 686% 5700MPa 48KJ / m 2Strength Example 786% 5500MPa 49KJ / m 2 Strength Example 886% 5700MPa 44KJ / m 2 Strength Example 986% 5750MPa 45KJ / m 2 Strength Example 1086% 5600MPa 42KJ / m 2 Intermediate Strength Comparison Example 185% 4000MPa 50KJ / m² 2 Weakness

[0153] As a result of the experiment, the light-transmitting layers prepared according to Examples 1 to 4 showed similar transmittance compared to the transmittance layer prepared according to Comparative Example 1, but had superior tensile strength and lower impact strength. The light-transmitting layers prepared according to Examples 5 to 7 showed superior transmittance and tensile strength compared to the transmittance layer prepared according to Comparative Example 1, but had similar impact strength. The light-transmitting layers prepared according to Examples 8 to 10 showed superior transmittance and tensile strength compared to the transmittance layer prepared according to Comparative Example 1, but lower impact strength.

[0154] This indicates that when PC resin and Co-Polyester resin are mixed, transparency is improved, structural stability and durability can be improved by including GF, and higher refractive index and transmittance are improved by mixing and adding TiO2 and Pigment among white pigments.

[0155] In addition, it can be seen that the addition of GF demonstrates excellent weather resistance and discoloration resistance.

[0156] Classification GF(10%) GF(20%) GF(30%) Tensile strength (kgf / cm²) 2 )9009201,130Impact strength(Izod impact strength, KJ / m 2 )101210

[0157] Meanwhile, as shown in [Table 3], when the GF content is 10%, the tensile strength is 900 kgf / cm² 2, impact strength is 10KJ / m 2 And when the GF content is 20%, the tensile strength is 920 kgf / cm 2 , impact strength is 12KJ / m 2 And when the GF content is 30%, the tensile strength is 1,130 kgf / cm 2 , impact strength is 10KJ / m 2 It appears as.

[0158] Here, tensile strength increases with higher GF content, but in the case of impact strength, it is 12 kJ / m² when the GF content is 20%. 2 It is the best.

[0159] Therefore, when the GF content as a strength reinforcing material is 20%, a light-transmitting layer with excellent tensile strength and impact strength can be obtained.

[0160] Hereinafter, a method and process for manufacturing an interior material according to the present invention will be explained with reference to FIGS. 5 to 15.

[0161] As illustrated in FIG. 5, a method for manufacturing an interior material according to one embodiment of the present invention may comprise a press molding step (S10), a color coating step (S20), a tape attachment step (S30), a laser processing step (S40), an injection step (S50), and a protruding pattern forming step (S60).

[0162] As shown in FIG. 6, the press forming step (S10) first manufactures a decorative layer (10) by pressing a material cut to a thin thickness.

[0163] At this time, the material of the interior material may be at least one of Real Wood, Carbon, Stone, Fabric, Aluminum, Artificial Leather, Glass Fiber Reinforced Plastic (GFRP) or Carbon Fiber Reinforced Plastic (CFRP), or Steel, which have a unique surface texture.

[0164] In the press molding step (S10), if the decorative layer (10) is real wood, the real wood may be a veneer made by thinning natural solid wood to a predetermined thickness. Accordingly, it can be applied as a decorative material for automobiles in a luxurious form due to the unique texture and pattern of the veneer.

[0165] Real wood is the outermost layer exposed to the driver in automotive interior materials, and can determine the overall shape, texture, and form of the real wood interior materials.

[0166] Here, a shielding layer (20) having a predetermined thickness is attached to the back surface (10b) of the decorative layer (10) for press molding.

[0167] That is, a shielding layer (20) for shielding light irradiated through the light when the decorative layer (10) is irradiated with light is attached to the back surface (10b) of the decorative layer (10).

[0168] Meanwhile, the shielding layer (20) may be a black material having a black or dark color to shield light so that light irradiated through lighting is irradiated only in a pre-set pattern such as characters, shapes, or symbols.

[0169] Here, the shielding layer (20) may be arranged in one or multiple layers. Accordingly, the shielding layer (20) may be arranged in one layer or multiple layers on the back surface (10b) of the decorative layer (10).

[0170] For example, if a shielding layer (20) is formed on the back surface (10b) of the decorative layer (10), the shielding layer (20) may be a black or dark-colored black material.

[0171] When two or more shielding layers (20) are formed on the back surface (10b) of the decorative layer (10), one of the shielding layers (20) may be a black or dark-colored black material.

[0172] Meanwhile, after forming at least one shielding layer (20) on the back surface (10b) of the decorative layer (10), release films (30a, 30b) can be attached to the front surface (10a) and back surface (10b) of the decorative layer (10). That is, to prevent damage to the decorative layer (10) during press molding, release films (30a, 30b) having a predetermined thickness are attached to the front surface (10a) and back surface (10b) of the decorative layer (10) before press molding.

[0173] As illustrated in FIG. 7, the color coating step (S20) color coats the front surface (10a) of the decorative layer (10) press-molded through the press-molding step (S10).

[0174] Specifically, after press-molding the decorative layer (10), the release film (30a, 30b) attached to the front (10a) and back (10b) of the decorative layer (10) is removed, and the front (10a) of the decorative layer (10) from which the release film (30a, 30b) has been removed is color-coated.

[0175] Meanwhile, the shielding layer (20) attached to the back surface (10b) of the decorative layer (10) may be a bright color rather than a black or dark color. To this end, after removing the release film (30a, 30b) from the decorative layer (10), the back surface (10b) of the decorative layer (10) on which the shielding layer (20) is placed may be shielded with a black or dark color, or coated or applied.

[0176] Thus, by attaching a shielding layer (20) having a black or dark color to the back surface (10b) of the decorative layer (10) before press molding, or by applying a shielding coating of the shielding layer (20) attached to the back surface (10b) of the decorative layer (10) with a black or dark color, it becomes easier to shield the light irradiated when illuminating the decorative layer (10).

[0177] As illustrated in FIG. 8, the tape attachment step (S30) attaches a tape (50) to the front surface (10a) of the decorative layer (10) that has been color-coated through the color coating step (S20). That is, after color-coating the front surface (10a) of the decorative layer (10), a tape (50) of a predetermined thickness is attached to the front surface (10a) of the decorative layer (10).

[0178] At this time, the tape (50) is formed with a predetermined thickness, and the thickness of the tape (50) may be formed to correspond to the height of the protruding pattern layer (60b) formed protruding from the decorative layer (10), or may be formed thicker than the height of the protruding pattern layer (60b).

[0179] That is, if the thickness of the tape (50) is thick, the height of the protruding pattern layer (60b) formed protruding from the front (10a) of the decorative layer (10) is increased, and if the thickness of the tape (50) is thin, the height of the protruding pattern layer (60b) formed protruding from the front (10a) of the decorative layer (10) can be decreased.

[0180] Therefore, since the thickness of the tape (50) corresponds to the height of the protruding pattern layer (60b), a tape (50) with a thickness corresponding to the required height of the protruding pattern layer (60b) must be attached to the front surface (10a) of the decorative layer (10).

[0181] At this time, the thickness of the tape (50) may be 0.5 mm or less, and the height of the protruding pattern layer (60b) may be 0.2 mm or less, but is not limited thereto and can be modified in various ways.

[0182] As illustrated in FIG. 9, the laser processing step (S40) processes a through-hole (11) corresponding to a pattern formed in the decorative layer (10), such as a character, figure, or symbol.

[0183] That is, after attaching a tape (50) to the front (10a) of the decorative layer (10), a pre-set pattern, such as a character, shape, or symbol for button operation, is laser-processed on the back (10b) of the decorative layer (10) to which the tape (50) is attached.

[0184] At this time, during the laser processing step (S40), a penetrating portion (11) is formed by penetrating the decorative layer (10) and the tape (50) during laser processing of the decorative layer (10).

[0185] Accordingly, when processing a penetration part (11) corresponding to a pattern set in the decorative layer (10), if the pattern includes a closed curve (or closed surface), a bridge may be formed when forming the penetration part (11) to prevent the island part (15) formed on the inner side of the closed curve (or closed surface) from being separated and detached.

[0186] To explain using the character 'POWER' as an example, in the case of a character that includes a closed curve with an internal and external separation, such as 'P, O, R', the island portion (15) formed inside can be separated and detached from the inner portion when processing the through portion (11) corresponding to the pattern of the character.

[0187] Accordingly, when a laser is irradiated onto a decorative layer (10) to form a penetration part (11) corresponding to a preset pattern, if the preset pattern includes a closed curve, the penetration part (11) is processed so that a bridge part (13) is formed to connect the inner and outer parts of the closed curve, which are separated into inner and outer parts.

[0188] As illustrated in FIG. 10, the injection step (S50) forms a light-transmitting layer (60a) by supplying an injection product to the back surface (10b) of the decorative layer (10) processed in the laser processing step (S40) using an injection feeder (130).

[0189] At this time, the injection step (S50) supplies an injection product to the back surface (10b) of the decorative layer (10) using an injection feeder (130), and forms a light-transmitting layer (60a) by injecting the injection product into the penetration part (11) of a preset pattern formed in the decorative layer (10).

[0190] Accordingly, the injection molded material supplied from the injection molding machine forms a light-transmitting layer (60a) over the entire back surface (10b) of the decorative layer (10), and the light-transmitting layer (60a) is injected into the penetration portion (11) of the decorative layer (10).

[0191] Here, when the decorative layer (10) is placed in the injection mold (110, 120), the tape (50) attached to the front surface (10a) of the decorative layer (10) is placed so as to come into contact with the inner surface of the first injection mold (110), and then the product is injected through the second injection mold (120) onto the back surface (10b) of the decorative layer (10) to form a light-transmitting layer (60a).

[0192] Accordingly, when illuminating, light can pass through the light-transmitting layer (60a) formed on the back surface (10b) of the decorative layer (10) and the penetration portion (11) of the decorative layer (10) and be transmitted to the front surface (10a) of the decorative layer (10).

[0193] Here, the injection molded material forming the light-transmitting layer (60a) may include a thermoplastic resin, a pigment, and a strength-reinforcing material.

[0194] The thermoplastic resin may be a transparent PC resin (Polycarbonate, PC), and the thermoplastic resin may include one or more resins selected from transparent PC (Polycarbonate) resin, PCCD (Polycyclohexylenedimethylene Cyclohexyl Dicarboxylate) resin, or Co-Polyester resin.

[0195] The pigment may include one or more of CaCO3 (calcium carbonate), TiO2 (titanium dioxide), or Pigment.

[0196] The strength reinforcing material may be GF (Glass Fiber).

[0197] Here, with respect to 100 weight% of the injection molded product forming the light-transmitting layer (60a), it may include 70 weight% to 80 weight% of a thermoplastic resin, 3 weight% to 10 weight% of a pigment, and 10 weight% to 25 weight% of a strength-reinforcing material.

[0198] Here, referring to [Table 3], the results showing the mechanical properties of the strength reinforcing material for 100% by weight of the injection molded product show that even when the strength reinforcing material is included at 30% by weight, the impact strength (Izod impact strength) is not as great as when the strength reinforcing material is included at 10% or 20% by weight, and therefore, sufficient mechanical properties can be secured even with the strength reinforcing material at 10% to 25% by weight.

[0199] Meanwhile, since a dark or black shielding layer (20) is attached to the back surface (10b) of the decorative layer (10) for shielding before the injection of the molded product, when light is irradiated, the light can pass through the back surface (10b) of the decorative layer (10) and the light-transmitting layer (60a) formed after the injection of the molded product into the penetration part (11) of the decorative layer (10) and then be transmitted to the front surface (10a) of the decorative layer (10).

[0200] Here, the shielding layer (20) may be a layer comprising one or more selected from a nonwoven fabric layer, a shielding coating layer, a film layer, and a coating layer.

[0201] Therefore, separate masking may not be required on the decorative layer (10) during injection.

[0202] As illustrated in FIG. 11, the protruding pattern forming step (S60) removes the tape (50) attached to the decorative layer (10) to form a protruding pattern layer (60b) on the decorative layer (10).

[0203] Specifically, the tape (50) attached to the front (10a) of the decorative layer (10) is removed to form a protruding pattern layer (60b) that protrudes from the light-transmitting layer (60a) toward the front (10a) of the decorative layer (10) by the thickness of the tape (50).

[0204] In addition, the surface of the tape (50) in the decorative layer (10) is sanded and polished to separate and remove the tape (50) from the front surface (10a) of the decorative layer (10) to form a protruding pattern layer (60b).

[0205] In this way, when an injection molded material is injected into the back surface of the decorative layer (10) and the shielding layer (20) to form a light-transmitting layer (60a), a portion of the injection molded material injected into the through-hole (11) formed in the decorative layer (10) extends from the light-transmitting layer (60a) formed on the back surface of the decorative layer (10) and the shielding layer (20) and forms a protruding pattern layer (60b).

[0206] Accordingly, as shown in FIG. 12, a protruding pattern layer (60b) with a thickness equal to that of the tape (50) can be formed protrudingly on the front surface (10a) of the decorative layer (10).

[0207] After processing the surface of the decorative layer (10) by performing processes such as sanding and polishing, the manufacturing is completed by finally applying a finishing coating to the protruding pattern layer (60b) and the front surface (10a) of the decorative layer (10).

[0208] Meanwhile, in one embodiment of the present invention, when a closed curve (or closed surface) is included in the pattern during laser processing, in order to prevent the island portion (15) formed on the inner side of the closed curve (or closed surface) from being separated and detached, a bridge portion (13) is formed on the inner side of the island portion (15) with a through portion (11) in between to prevent the separation and detachment of the island portion (15), but the separation and detachment of the island portion (15) can be prevented through a tape (50) attached to the front (10a) of the decorative layer (10) without forming a separate bridge portion to prevent the separation and detachment of the island portion (15).

[0209] A method for manufacturing an interior material according to another embodiment of the present invention for this purpose, as illustrated in FIG. 3, FIG. 13 to FIG. 15, can be performed by laser processing only a portion of the tape (50) attached to the front surface (10a) of the decorative layer (10) and then injection molding.

[0210] Accordingly, the island portion (15) before injection is attached to the adhesive surface of the tape (50), and the island portion (15) after injection is integrally injected into the light-transmitting layer (60a) formed by the injection molding, thereby maintaining a fixed shape.

[0211] Specifically, as illustrated in FIG. 3 and FIG. 13, when laser processing of a pre-set pattern on a decorative layer (10), a penetration portion (11) corresponding to the pre-set pattern is formed by penetrating the shielding layer (20) and the decorative layer (10), and a penetration portion (11) is formed by partially processing only up to a predetermined depth on the tape (50).

[0212] At this time, the thickness of the tape (50) attached to the front surface (10a) of the decorative layer (10) can be formed to be thicker than the height of the protruding pattern layer (60b) formed protruding from the decorative layer (10).

[0213] In this way, by laser processing only a portion of the tape (50), the upper surface of the island portion (15) is fixed in a bonded state to the adhesive surface of the tape (50) during laser processing, thereby preventing separation and detachment of the island portion (15).

[0214] After processing only a portion of the tape (50) to form a pattern, a light-transmitting layer (60a) is formed on the back surface of the decorative layer (10) and the shielding layer (20), as shown in FIG. 14.

[0215] At this time, the injection molded material injected into the back surface of the decorative layer (10) and the shielding layer (20) is injected into the back surface of the decorative layer (10) and the shielding layer (20) and into the interior of the penetration part (11), and the island part (15) is injected and fixed to the injection molded material injected into the penetration part (11), i.e., the light-transmitting layer (60a), thereby preventing separation and detachment of the island part (15).

[0216] Accordingly, when an injection molding product is injected on the back surface of the decorative layer (10) and the shielding layer (20), a light-transmitting layer (60a) is formed over the entire back surface of the decorative layer (10), and an injection molding product is injected into the partially processed area of ​​the through-hole (11) and tape (50) of the decorative layer (10) to form a protruding pattern layer (60b).

[0217] After forming an injection portion (60a) on the decorative layer (10), as shown in FIG. 15, the tape (50) attached to the front surface (10a) of the decorative layer (10) is separated and removed to form a protruding pattern layer (60b) on the decorative layer (10).

[0218] In this way, a pre-set pattern on the tape (50) is laser-processed, but only a portion of the tape (50) is laser-processed so that the tape (50) is not penetrated in the thickness direction, thereby eliminating the need for a separate bridge section, making laser processing easy and convenient.

[0219] According to the method for manufacturing an interior material according to one embodiment of the present invention as described above, a protruding pattern layer capable of providing a tactile sensation is formed on the surface of a decorative layer applied in various fields such as automotive interior materials, building materials, and electronic products, thereby improving the button operation feel of the driver and user and enhancing the design completeness of the exterior.

[0220] In addition, the part where the protruding pattern layer is formed is transparent, and the shielding layer is made of a black material or has a shielding coating applied so that light irradiated from the back of the decorative layer toward the front passes through the light-transmitting layer forming the protruding pattern layer and is transmitted toward the front. When applied to a vehicle, this allows the driver driving the vehicle during the day or at night to easily check the location of the control parts, and in particular, can improve usability during night driving and enhance the completeness of the interior design of the vehicle through the lighting effect.

[0221] Although the present invention is illustrated and described above in relation to specific embodiments, it will be readily apparent to those skilled in the art that various modifications and changes are possible without departing from the spirit and scope of the invention as set forth in the appended claims.

Claims

1. Decorative layer; At least one shielding layer attached to the above decorative layer; A penetration portion formed by penetrating the shielding layer and the decorative layer, and formed to correspond to a preset pattern; A light-transmitting layer formed by injecting an injection molded material into the lower part of the shielding layer; and A protruding pattern layer formed by passing through the above penetration portion and protruding higher than the surface of the decorative layer in the light-transmitting layer; Interior material characterized by including 2. In Claim 1, The above-mentioned penetration portion is characterized by the formation of a light-transmitting layer through an injection molding process.

3. In Claim 1, The above light-transmitting layer is characterized by being formed through an injection molding process.

4. In Claim 1, An interior material characterized in that the shielding layer is made of black material.

5. In Claim 1, An interior material characterized by the above-mentioned penetration being formed by laser processing.

6. In Claim 1, The above injection molded product is an interior material characterized by comprising a thermoplastic resin, a pigment, and a strength reinforcing material.

7. In Claim 6, An interior material characterized in that the ratio of the thermoplastic resin, the pigment, and the strength reinforcing material is 70% to 80% by weight : 3% to 10% by weight : 10% to 25% by weight with respect to 100% by weight of the injection molded product.

8. In Claim 6, An interior material characterized by comprising one or more selected from transparent PC resin, PCCD resin, or Co-Polyester resin.

9. In Claim 6, The above pigment is characterized by comprising one or more selected from CaCO3, TiO2, or Pigment.

10. In Claim 6, The above strength reinforcing material is an interior material characterized by including GF (Glass Fiber).

11. In Claim 1, The above decorative layer is characterized by being composed of at least one of Real Wood, Carbon, Stone, Fabric, Aluminum, Artificial Leather, or Glass Fiber Reinforced Plastic (GFRP).

12. Press forming step for press forming the decorative layer; Color coating step for applying a color coating to the decorative layer; Tape attachment step for attaching tape to the decorative layer; A laser processing step of irradiating a decorative layer with a laser to form a preset pattern; An injection step of injecting an injection molded product to form a light-transmitting layer on a decorative layer; and A step of forming a protruding pattern layer by removing tape attached to the decorative layer to form a protruding pattern layer on the decorative layer; A method for manufacturing an interior material characterized by including 13. In Claim 12, In the above press forming step, A shielding layer forming step of forming at least one shielding layer on the back surface of the above decorative layer; A method for manufacturing an interior material characterized by including 14. In Claim 12, In the above color coating step, A method for manufacturing an interior material characterized by removing release films attached to the front and back surfaces of the decorative layer and then color-coating the front surface of the decorative layer.

15. In Claim 12, In the above color coating step, A shielding coating step for applying a shielding coating to the above shielding layer; A method for manufacturing an interior material characterized by including 16. In Claim 12, In the above laser processing step, A method for manufacturing an interior material characterized by forming a penetration portion to penetrate the shielding layer, the decorative layer, and the tape when forming the above-mentioned pre-set pattern.

17. In Claim 16, A method for manufacturing an interior material characterized by forming a bridge portion between the inner part of the closed curve and the island portion when the above-mentioned pre-set pattern includes a closed curve.

18. In Claim 12, In the above laser processing step, A method for manufacturing an interior material characterized by forming a penetration portion so that the shielding layer and the decorative layer penetrate when forming the above-mentioned pre-set pattern, and forming a penetration portion in the tape only in a partial area.

19. In Claim 18, In the above laser processing step, A method for manufacturing an interior material characterized in that, when a closed curve is included in the above-mentioned pattern, an island portion disposed on the inner side of the closed curve is attached to and fixed to the adhesive surface of the tape.

20. In Claim 19, In the above injection step, A method for manufacturing an interior material characterized in that, when a closed curve is included in the above-mentioned pattern, the island portion disposed on the inner side of the closed curve is fixed to the light-transmitting layer formed by injecting into the through-hole processed only in a part of the tape.

Images