Automotive crash pad and manufacturing method thereof

Abstract

An automotive crash pad and a method for manufacturing the same. The automotive crash pad includes: a skin layer forming the outer surface of the crash pad including an airbag module; a fiber-based layer formed on the lower surface of the skin layer; a cushion layer formed on the lower surface of the fiber-based layer and including slab foam; and a core layer formed on the lower surface of the cushion layer, wherein a laminate of the skin layer and the fiber-based layer has a tensile strength in transverse direction (TD) of 5 to 50 kgf/3 cm and an elongation at break in transverse direction (TD) of 40 to 220%.

What is claimed is: 
     
         1 . An automotive crash pad comprising:
 a skin layer forming an outer surface of the crash pad including an airbag module;   a fiber-based layer formed on a lower surface of the skin layer;   a cushion layer formed on a lower surface of the fiber-based layer and comprising slab foam; and   a core layer formed on a lower surface of the cushion layer,   wherein a laminate of the skin layer and the fiber-based layer has a tensile strength in a transverse direction (TD) of 5 to 50 kgf/3 cm and an elongation at break in a transverse direction (TD) of 40 to 220%.   
     
     
         2 . The automotive crash pad of  claim 1 , wherein the skin layer has a thickness of 0.1 to 0.7 mm, the fiber-based layer has a thickness of 0.3 to 0.7 mm, the cushion layer has a thickness of 1 to 10 mm, and the core layer has a thickness of 1 to 6 mm. 
     
     
         3 . The automotive crash pad of  claim 1 , wherein the cushion layer has a density of 0.05 to 5 g/cm 3 , a porosity of 5 to 80%, a tensile strength of 3 to 20 kgf/cm 2 , an elongation of 50 to 200%, and a tearing strength of 0.2 to 1.5 kgf/cm. 
     
     
         4 . The automotive crash pad of  claim 1 , wherein the skin layer comprises one or more of thermoplastic polyurethane, thermoplastic polyolefin, polyvinyl chloride, and thermosetting polyurethane. 
     
     
         5 . The automotive crash pad of  claim 1 , wherein the skin layer is formed using a skin layer composition comprising 65 to 75 wt % of a polyol compound, 15 to 25 wt % of an isocyanate-based curing agent, and 10 to 15 wt % of a chain extender. 
     
     
         6 . The automotive crash pad of  claim 1 , wherein the slab foam is formed by foaming a first composition comprising 40 to 75 wt % of a polyol compound, 15 to 45 wt % of an isocyanate-based curing agent, and 1 to 15 wt % of a foaming agent. 
     
     
         7 . The automotive crash pad of  claim 1 , further comprising one or more of a first adhesive layer formed between the fiber-based layer and the cushion layer, and a second adhesive layer formed between the cushion layer and the core layer. 
     
     
         8 . The automotive crash pad of  claim 1 , further comprising a surface treatment layer formed on at least a portion of the skin layer. 
     
     
         9 . The automotive crash pad of  claim 1 , wherein the fiber-based layer has a density of 0.22 to 0.27 g/cm 3  and is in the form of knitted or nonwoven fabric. 
     
     
         10 . A method for manufacturing an automotive crash pad, the automotive crash pad including: a skin layer forming an outer surface of the crash pad including an airbag module; a fiber-based layer formed on a lower surface of the skin layer; a cushion layer formed on a lower surface of the fiber-based layer and including slab foam; and a core layer formed on a lower surface of the cushion layer, the method comprising:
 preparing an intermediate by laminating the cushion layer and the core layer together; and   laminating the fiber-based layer and the skin layer onto the intermediate,   wherein a laminate of the skin layer and the fiber-based layer has a tensile strength in transverse direction (TD) of 5 to 50 kgf/3 cm and an elongation at break in transverse direction (TD) of 40 to 220%.   
     
     
         11 . The method of  claim 10 , wherein the laminating of the fiber-based layer and the skin layer onto the intermediate includes forming a first adhesive layer between the fiber-based layer and the cushion layer. 
     
     
         12 . The method of  claim 10 , wherein the preparing of the intermediate includes forming a second adhesive layer between the cushion layer and the core layer. 
     
     
         13 . The method of  claim 10 , further comprising, after the laminating of the fiber-based layer and the skin layer onto the intermediate covering the fiber-based layer, the cushion layer, and the core layer with the skin layer. 
     
     
         14 . The method of  claim 10 , wherein the slab foam is formed by foaming a first composition comprising a polyol compound, an isocyanate-based curing agent, and a foaming agent. 
     
     
         15 . The method of  claim 10 , wherein the skin layer is not subjected to a skiving or scoring process.