Fibrous component for vehicle exterior and method for manufacturing the same

Abstract

A fibrous component for a vehicle exterior includes a skin layer having a multilayer structure comprising a laminated web including a reinforcing fiber and a binder fiber, the skin layer including pores that absorb sound; a sound absorbing pad layer disposed on an inner side of the skin layer and absorbing sound; and an adhesive layer disposed between the skin layer and the sound absorbing pad layer. The adhesive layer adheres the skin layer and the sound absorbing layer to each other.

What is claimed is: 
     
         1 . A fibrous component for a vehicle exterior comprising:
 a skin layer having a multilayer structure comprising a laminated web including a reinforcing fiber and a binder fiber, the skin layer including pores that absorb sound;   a sound absorbing pad layer disposed on an inner side of the skin layer and absorbing sound; and   an adhesive layer disposed between the skin layer and the sound absorbing pad layer, the adhesive layer adhering the skin layer and the sound absorbing layer to each other.   
     
     
         2 . The fibrous component for a vehicle exterior of  claim 1 , wherein the reinforcing fiber has a diameter of 30 to 60 μm, and the skin layer is 30 to 70% by weight reinforcing fiber and 30 to 70% by weight binder fiber, based on a total weight of the skin layer. 
     
     
         3 . The fibrous component for a vehicle exterior of  claim 1 , wherein the sound absorbing pad layer includes porous polyurethane (PU) foam, and a film surrounding the PU foam. 
     
     
         4 . The fibrous component for a vehicle exterior of  claim 3 , wherein the film is a polyurethane film or polyethylene film, and has a thickness of 20 to 50 μm. 
     
     
         5 . The fibrous component for a vehicle exterior of  claim 1 , wherein the sound absorbing pad layer includes a sound absorbing fiber forming pores that absorb sound, and an adhesive fiber binding the sound absorbing fiber. 
     
     
         6 . The fibrous component for a vehicle exterior of  claim 5 , wherein the sound absorbing fiber has a diameter of 10 to 30 μm, and the sound absorbing pad layer is 60 to 80% by weight sound absorbing fiber and 20 to 40% by weight adhesive fiber, based on a total weight of the sound absorbing pad layer. 
     
     
         7 . The fibrous component for a vehicle exterior of  claim 1 , wherein the adhesive layer is a hot-melt adhesive or a synthetic rubber adhesive. 
     
     
         8 . An oil pan cover including the fibrous component for a vehicle exterior of  claim 1 . 
     
     
         9 . An engine under cover including the fibrous component for a vehicle exterior of  claim 1 . 
     
     
         10 . A floor under cover including the fibrous component for a vehicle exterior of  claim 1 . 
     
     
         11 . A method for manufacturing a fibrous component for a vehicle exterior comprising steps of:
 preparing a skin layer having a multilayer structure comprising a laminated web including a reinforcing fiber and a binder fiber, the skin layer including pores that absorb sound;   preparing a sound absorbing pad layer located on an inner side of the skin layer and absorbing sound; and   adhering the skin layer and the sound absorbing pad layer,   wherein the step of preparing the skin layer includes forming a web by mixing the reinforcing fiber and the binder fiber, laminating the web in a multilayer structure, and then binding the result, the reinforcing fiber has a diameter of 30 to 60 μm, and the skin layer is 30 to 70% by weight reinforcing fiber and 30 to 70% by weight binder fiber, based on a total weight of the skin layer.   
     
     
         12 . The method for manufacturing a fibrous component for a vehicle exterior of  claim 11 , wherein the step of preparing the skin layer further includes, after the preparing of the web, preheating the web by pressing the web for 40 to 100 seconds at 150 to 230° C. with a pressure of 60 to 200 kgf/cm 2 . 
     
     
         13 . The method for manufacturing a fibrous component for a vehicle exterior of  claim 12 , wherein the step of preparing the skin layer further includes, after the preheating of the web, molding the web by pressing the web for 30 to 70 seconds at a temperature of greater than 0° C. and less than or equal to 40° C. with a pressure of 60 to 200 kgf/cm 2  to make the web into a shape of the component. 
     
     
         14 . The method for manufacturing a fibrous component for a vehicle exterior of  claim 13 , wherein the step of preparing the skin layer further includes, after the molding of the web, trimming the web using a method of trimming metallic mold cutting, water jet cutting, or laser cutting. 
     
     
         15 . The method for manufacturing a fibrous component for a vehicle exterior of  claim 11 , wherein the step of preparing the sound absorbing pad layer includes installing a film having a thickness of 20 to 50 μm into upper and lower parts of a metallic mold in which temperature is adjusted from 40 to 80° C. 
     
     
         16 . The method for manufacturing a fibrous component for a vehicle exterior of  claim 15 , wherein the step of preparing the sound absorbing pad layer further includes, after the preparing of the film, injecting a crude polyurethane (PU) solution into the metallic mold, and the crude PU solution includes polyol in 50 to 80% by weight, Isocyanate in 15 to 45% by weight and a catalyst in 1 to 10% by weight, based on a total weight of the crude PU solution. 
     
     
         17 . The method for manufacturing a fibrous component for a vehicle exterior of  claim 16 , wherein the step of preparing the sound absorbing pad layer further includes, after the injecting of the crude PU solution, foaming the crude polyurethane solution for 1 to 3 minutes after closing the metallic mold to prepare PU foam surrounded by the film. 
     
     
         18 . The method for manufacturing a fibrous component for a vehicle exterior of  claim 17 , wherein the step of preparing the sound absorbing pad layer further includes, after the foaming, trimming the polyurethane foam using a method of trimming metallic mold cutting, water jet cutting, or laser cutting. 
     
     
         19 . The method for manufacturing a fibrous component for a vehicle exterior of  claim 11 , wherein the step of preparing the sound absorbing pad layer includes forming a web by mixing a sound absorbing fiber having a diameter of 10 to 30 μm at 60 to 80% by weight and an adhesive fiber at 20 to 40% by weight, based on a total weight of the sound absorbing pad layer, then laminating the web and binding the result. 
     
     
         20 . The method for manufacturing a fibrous component for a vehicle exterior of  claim 19 , wherein the step of preparing the sound absorbing pad layer further includes, after the preparing of the fiber pad, preheating the fiber pad for 40 to 100 seconds at 150 to 230° C. 
     
     
         21 . The method for manufacturing a fibrous component for a vehicle exterior of  claim 20 , wherein the step of preparing the sound absorbing pad layer further includes, after the preheating of the fiber pad, molding the fiber pad by pressing the fiber pad for 30 to 70 seconds at a temperature of greater than 0° C. and less than or equal to 40° C. with a pressure of 60 to 200 kgf/cm 2  to make the fiber pad into a shape of the component. 
     
     
         22 . The method for manufacturing a fibrous component for a vehicle exterior of  claim 21 , wherein the step of preparing the sound absorbing pad layer further includes trimming the fiber pad using a method of trimming metallic mold cutting, water jet cutting or laser cutting.