Automotive crash pad and manufacturing method thereof
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 a transverse direction (TD) of 5 to 50 kgf/3 cm and an elongation at break in the transverse direction (TD) of 40 to 220%.
1. 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, wherein the automotive crash pad further comprises 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, 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 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,
wherein the preparing of the intermediate includes forming a second adhesive layer between the cushion layer and the core layer,
wherein the laminate of the skin layer and the fiber-based layer have an adhesive strength of 0.3 to 1.2 kgf/cm to the first adhesive 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 the transverse direction (TD) of 40 to 220%,
wherein the fiber-based layer comprises knitted fabric having a weight of 150 to 200 g/m2 and a density of 0.22 to 0.27 g/cm3, and
wherein the skin layer has a thickness of 0.1 to 0.4 mm and a tearing strength of 2 to 8 kgf/cm.
2. The method of claim 1 , 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.
3. The method of claim 1 , wherein the slab foam is formed by foaming a first composition comprising a polyol compound, an isocyanate-based curing agent, and a foaming agent.
4. The method of claim 1 , wherein the skin layer is not subjected to a skiving or scoring process.