JP2021514315A - Polyester complex containing low melting point polyester resin and its manufacturing method - Google Patents

Abstract

The present invention relates to a polyester composite containing a low melting point polyester resin, a method for producing the same, and an automobile interior material containing the same. The polyester composite of the present invention has a low melting point polyester resin between a polyester foam sheet and a fiber mat layer. By including the resin layer containing the resin layer, the adhesiveness between the laminates can be improved without deteriorating the physical properties such as strength and durability.

Description

The present invention relates to a polyester complex containing a low melting point polyester resin and a method for producing the same.

For application to automobile interior materials, especially interior materials, properties such as light weight, cushioning property, heat insulating property, moldability, high strength and energy saving are required. Low melting fiber may be used as an existing automobile interior material. The low melting point resin is an adhesive fiber that melts at a temperature 100 to 200 ° C lower than general polyester fibers that melt at 265 ° C or higher, and is an eco-material that does not require a chemical adhesive, and has the advantage of being easy to install. .. When a base material layer made of a thermoplastic resin, a soft urethane foam layer, and a layer made of a fiber layer are adhered to such a low melting point resin fiber layer as a laminated material, durability can be improved and the manufacturing cost per volume can be reduced. Can be reduced. Further, it is possible to obtain an interior material for an automobile having a small dimensional change rate and an excellent sound absorption rate.

However, when a soft urethane foam layer is used for the laminated material, the thickness is increased in order to meet the required physical characteristics of the automobile interior material, and an adhesive is used for compounding substances having different components in the manufacturing process. Since a large amount of urethane is used, the amount of VOC increases and there is a disadvantage that it cannot be recycled.

Therefore, there is a need for an automobile interior material having a single material structure, which has excellent durability and can reduce the manufacturing cost.

The present invention provides a polyester composite containing a resin layer containing a low melting point polyester resin and having excellent adhesion between the polyester resin layer and the fiber mat layer, a method for producing the same, and an automobile interior material containing the same. To do.

From this, the present invention, in one embodiment,
With a polyester foam sheet with an average weight of 400-900 g / m ^2;
With a polyester resin layer having an average weight of 20 to 200 g / m ^{2 formed on one or both sides of the foam sheet;}
Including a structure in which a fiber mat layer is laminated on one or both sides of a polyester resin layer;
The polyester resin layer is characterized by having a melting point of 180 ° C. to 250 ° C. or a softening point of 100 ° C. to 150 ° C.
Provided is a polyester composite characterized in that the peel strength between the polyester resin layer and the fiber mat layer is 1 kgf / cm ^{2 or more.}

Further, the present invention, in one embodiment,
Including the step of laminating the polyester foam sheet and the fiber matte layer, and
Contains a polyester resin layer on one or both sides of a polyester foam sheet or fiber matte layer,
In the step of laminating the polyester foam sheet and the fiber mat layer, the polyester resin layer is preheated, and the polyester foam sheet and the fiber mat layer are laminating using a mold.
The polyester foam sheet has an average weight of 400 to 900 g / m ² .
The polyester resin layer has an average weight of 20 to 200 g / m ² .
The polyester resin layer provides a method for producing a polyester composite, which comprises a polyester resin having a melting point of 180 ° C. to 250 ° C. or a softening point of 100 ° C. to 150 ° C.

The present invention provides an automobile interior material containing the polyester composite described above in one embodiment.

By including a low melting point polyester resin layer between the polyester foam sheet and the fiber mat layer, the polyester composite according to the present invention adheres between the fiber mat layer and the foam resin without deteriorating physical properties such as strength and durability. The sex can be improved.

FIG. 1 is a schematic image of a cross-sectional view of the polyester complex according to the present invention.
FIG. 2 is a diagram illustrating a method for measuring peel strength and testing peel strength.

Where various modifications can be made and various embodiments can be made, the present invention exemplifies specific embodiments in the drawings and attempts to explain them in detail.

However, this is not intended to limit the invention to any particular embodiment and must be understood to include all modifications, equivalents or alternatives contained within the ideas and technical scope of the invention. It doesn't become.

In the present invention, terms such as "including" or "having" are intended to specify the existence of features, numbers, stages, actions, components, parts or combinations thereof described herein. It must be understood that it does not preclude the existence or addability of one or more other features or numbers, stages, actions, components, parts or combinations thereof.

Further, in the present invention, the "part by weight" means the weight ratio between each component.

In the present invention, the "melting point" means the temperature at which the solid resin begins to melt into a liquid.

In the present invention, the adhesiveness between the fiber mat layer and the polyester resin layer is improved by including a polyester resin layer containing a low melting point polyester resin on one surface of the polyester foam sheet, and the Porriestes resin foam sheet is first preheated and then the fiber mat. It is intended to provide a polyester composite with improved durability and a method for producing the same by laminating with a layer.

Specifically, in the polyester composite of the present invention, the low melting point polyester resin powder is contained in the polyester foam sheet to improve the adhesiveness between the fiber mat layer and the polyester resin foam sheet, and the polyester resin foam sheet is first preheated. After that, the durability can be improved by laminating with the fiber mat layer.

Hereinafter, the foamed sheet according to the present invention will be described in detail.

With a polyester foam sheet having an average weight of 400 to 900 g / m ² of the polyester complex;
With a polyester resin layer having an average weight of 20 to 200 g / m ^{2 formed on one or both sides of the foam sheet;}
Including a structure in which a fiber mat layer is laminated on one or both sides of a polyester resin layer;
The polyester resin layer is characterized by having a melting point of 180 ° C. to 250 ° C. or a softening point of 100 ° C. to 150 ° C.
Provided is a polyester composite characterized in that the peel strength between the polyester resin layer and the fiber mat layer is 1 kgf / cm ^{2 or more.}

As shown in FIG. 1, the polyester complex according to the present invention has a structure in which a polyester resin layer 20 is formed between the polyester foam sheet 10 and the fiber mat layer 30. Specifically, it may have a structure in which a polyester resin layer having a melting point of 180 ° C. to 250 ° C. or a softening point of 100 ° C. to 150 ° C. is formed between the polyester foam sheet and the fiber mat layer. More specifically, a polyester resin layer containing one or more of powder, film and web forms may be formed between the polyester foam sheet and the fiber matte layer.

Further, in the polyester composite according to the present invention, the peel strength between the polyester resin layer and the fiber mat layer ^{may be 1 kgf / cm 2} or more. Specifically, the peel strength of the polyester resin layer and the fiber mat layer, 1 kgf / cm ² or more, 1.2 kgf / cm ² or more, 1.3 kgf / cm ² or more, 1.4 kgf / cm ² or more, 1.5 kgf / cm ² or ^{more, 1kgf / cm 2 ~3kgf / cm} 2, 1kgf / cm 2 ~2.5kgf / cm 2, 1kgf / cm 2 ~1.8kgf / cm 2, 1kgf / cm 2 ~1.7kgf / cm 2, ^{1kgf / cm 2 ~1.6kgf / cm 2} , 1.3kgf / cm 2 ~3kgf / cm 2, 1.3kgf / cm 2 ~2.5kgf / cm 2, 1.3kgf / cm 2 ~1.8kgf / cm ^{It can be 2} or 1.3 kgf / cm ^{2 to} 1.7 kgf / cm ² .

Furthermore, the polyester complex according to the present invention may release volatile organic compounds (VOCs) of 10 ppm or less. Specifically, the amount of volatile organic compounds released from the polyester complex is 10 ppm or less, 8 ppm or less, 6 ppm or less, 5 ppm or less, 4 pm or less, 2 ppm or less, 0.5 ppm to 10 ppm, 0.5 ppm to 8 ppm, 0.5 ppm. It can be ~ 6 ppm, 0.5 ppm ~ 5 ppm, 0.5 ppm ~ 4 ppm, 0.5 ppm ~ 3 ppm, 0.5 ppm ~ 2 ppm or 0.5 ppm ~ 1 ppm.

Hereinafter, each component constituting the polyester complex according to the present invention will be described more specifically.

First, the polyester foam sheet used in the present invention is a layer formed by foaming a polyester resin, and improves bending strength and flexural modulus without significantly increasing the weight per unit area in the polyester composite. Play the role of making.

At this time, the average weight per unit area of the polyester foam sheet may be in the range of ^{400 to 900 g / m 2.} Specifically, the polyester foam sheet, per unit area average weight ^{400~850g / m 2, 400~800g / m} 2, 400~750g / m 2, 400~700g / m 2, 400~650g / m 2 ^{, 400~600g / m 2, 400~550g /} m 2, 400~500g / m 2, 500~900g / m 2, 500~850g / m 2, 500~800g / m 2, 500~750g / m 2, ^{500~700g / m 2, 500~650g / m} 2, 500~600g / m 2, 500~550g / m 2, 600~900g / m 2, 600~850g / m 2, 600~800g / m 2, 600 ~ 750g / m ² , 600 ~ 700g / m ² , 600 ~ 650g / m ² , 700 ~ 900g / m ² , 700 ~ 850g / m ² , 700 ~ 800g / m ² , 700 ~ 750g / m ² , 450 ~ ^{700g / m 2, 450~650g / m} 2, 450~600g / m 2, it may be 550~850g / ^{m 2} or 550~700g / ^{m 2.} By containing the polyester foam sheet as described above, it is excellent in flame retardancy and chemical resistance, is a pro-environmental substance that does not release environmental hormones, and has an advantage that it is particularly excellent in mechanical strength. There is.

However, since the melt strength of the polyester resin drops sharply as the temperature increases, the temperature range having a foamable melt viscosity is very narrow. Therefore, in order to foam the polyester resin, a special technique for increasing the melt viscosity And precision temperature control equipment is indispensable, and along with this, it has been difficult to manufacture foamed sheets using polyester resin. However, in the present invention, the foamed sheet was successfully produced through precise viscosity and temperature control of the polyester resin.

As an example, the polyester foam sheet may be extruded. The types of foaming methods are broadly divided into bead foaming or extrusion foaming. In the bead foaming, resin beads are generally heated for primary foaming, which is aged for an appropriate time, and then plate-shaped or tubular. This is a method of filling a shaped mold, heating it again, and fusing and molding it by secondary foaming to make a product. On the other hand, in the extrusion foaming, the resin is heated and melted, and the resin melt is continuously extruded and foamed, so that the process step can be simplified, mass production is possible, and the beads are foamed. It is possible to prevent cracks and granular fracture phenomena between the beads and realize more excellent bending strength and compressive strength.

Further, the polyester foam sheet can be applied with an average thickness within a range in which weight reduction of the base material can be realized without affecting the flexural modulus and flexural strength of the polyester composite. Specifically, the polyester foam sheet has 1 mm to 9 mm, 1 mm to 8 mm, 1 mm to 7 mm, 1 mm to 6 mm, 1 mm to 5 mm, 1 mm to 4 mm, 1 mm to 3 mm, 2 mm to 10 mm, 2 mm to 9 mm, 2 mm to 8 mm, 2mm-7mm, 2mm-6mm, 2mm-5mm, 2mm-4mm, 2mm-3mm, 3mm-9mm, 3mm-8mm, 3mm-7mm, 3mm-6mm, 3mm-5mm, 4mm-9mm, 4mm-8mm, 4mm- Has an average thickness in the range of 7 mm, 4 mm to 6 mm, 4 mm to 5 mm, 5 mm to 10 mm, 5 mm to 8 mm, 5 mm to 7 mm, 6 mm to 9 mm, 6 mm to 8 mm, 7 mm to 10 mm, 8 mm to 10 mm or 9 mm to 10 mm. sell.

Along with this, 90% or more of the cells of the polyester foam sheet are closed cells (DIN ISO 4590), which means that 90% (v / v) or more of the cells are measured by DIN ISO 4590 of the foam sheet. It means that it is a closed cell. For example, the proportion of closed cells in the foamed sheet can be an average of 90-100% or 95-99% of all cells contained in the foamed sheet. By having the closed cells within the above range, the polyester foam sheet according to the present invention can realize excellent durability, rigidity and strength characteristics during the production of the polyester complex.

At this time, the average number of cells of the polyester foam sheet can include 1 to 30 cells, 3 to 25 cells, or 3 to 20 cells per 1 ^{mm 2.} Also, the average size of the cells can be in the range of 100-800 μm. For example, the average size of the cells can be in the range of 100-700 μm, 200-600 μm or 300-600 μm. Here, the cell size deviation can be, for example, in the range of 5% or less, 0.1 to 5%, 0.1 to 4% to 0.1 to 3%. From this, it can be seen that in the polyester foam sheet according to the present invention, cells of uniform size are uniformly foamed.

On the other hand, the polyester resin used for the foamed sheet according to the present invention can be produced by a polycondensation reaction of terephthalic acid and 1,4-butanediol, and contains all aromatic or aliphatic polyesters. In other embodiments, the polyester resin can include flame-retardant polyesters, biodegradable polyesters, elastic polyesters, recycled polyesters and the like. For example, the types of polyester resins that can be used in the present invention are polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polylactic acid (PLA), polyglycolic acid (polyglycolic). ), Polypropylene (polypolylane, PP), polyethylene (polyethylene, PE), polyethylene adipate (polyephthaleide, PEA), polyhydroxyalkanoate (polyhydroxyalkanoate, PHA), polytrimethylene terephthalate (polyethylene terephthalate) It can be one or more selected from the group consisting of naphthateate, PEN). Specifically, the polyester foam sheet according to the present invention may be a PET (polyethylene terephthalate) foam sheet. By using the PET, it is environmentally friendly and can be easily reused.

Next, the fiber mat layer used in the present invention means a layer formed from fibers, which controls the weight per unit area in the polyester composite and at the same time increases the hardness of the base material and plays the role of a skin layer. Do. At this time, the fiber mat layer may be formed on one side or both sides of the polyester foam sheet.

At this time, the fiber mat layer may be one or more selected from the group consisting of scrim, non-woven fabric, Web, knit, suede, velvet and the like. Specifically, the fiber mat layer contains polyethylene terephthalate and scrim. , Non-woven or web (Web) form. The polyester composite according to the present invention can contribute to the improvement of the bending strength and the flexural modulus of the polyester composite by including the fiber mat layer made of the polyethylene terephthalate resin.

As an example, the average weight per unit area of the fiber mat layer can be in the range of ^{110-140 g / m 2 , specifically 110-135 g / m 2} , 110-130 g / m ² , 110-125 g / m. It can be adjusted in the range of ² , 115-140 g / m ² , 115-135 g / m ² , 115-130 g / m ² , or 118-122 g / m ^2. By controlling the average weight per unit area of the fiber mat layer within the above range, it is possible to prevent the weight from increasing excessively and maintain the hardness of the base material well.

In addition, the fiber mat layer according to the present invention can further contain inorganic fibers. The inorganic fiber can include one or more of glass fiber, needle-shaped crystals of metal or metal oxide, and carbon fiber. Specifically, the inorganic fiber can be glass fiber (GF).

Further, the inorganic fiber may have an average diameter in the range of 10 to 1,000 μm, and more specifically, 100 to 900 μm, 100 to 800 μm, 100 to 700 μm, 100 to 600 μm, 100 to 500 μm, 100 to 400 μm. , 200-1,000 μm, 200-800 μm, 200-600 μm, 200-400 μm, 300-800 μm, 400-600 μm, 500-1,000 μm, 300-500 μm or 150-300 μm. By controlling the average diameter of the inorganic fibers contained in the fiber mat layer within the above range, the present invention has high strength and high durability even if the fiber mat layer having a low basis weight of less than ^{150 g / m 2 is included.} A polyester composite having the above can be provided.

Next, in the present invention, the polyester resin layer is interposed between the polyester foam sheet and the fiber mat layer, and functions to improve the adhesive force between the polyester foam sheet and the fiber mat layer.

As an example, the melting point (Tm) of the polyester resin layer may be 180 ° C. to 250 ° C., or the melting point may not exist. Specifically, the melting point (Tm) is 180 ° C. to 250 ° C.; 185 ° C. to 245 ° C.; 190 ° C. to 240 ° C.; 180 ° C. to 200 ° C.; 200 ° C. to 230 ° C. or 195 ° C. to 230 ° C. May not exist.

The softening point of the polyester resin layer can be 100 ° C. to 150 ° C., specifically, 100 ° C. to 130 ° C., 118 ° C. to 128 ° C.; 120 ° C. to 125 ° C.; 121 ° C. to 124 ° C.; 124. It can be between ° C. and 128 ° C. or between 119 ° C. and 126 ° C.

As a result, the polyester resin layer may have a glass transition temperature (Tg) of 50 ° C. or higher. Specifically, the glass transition temperature can be 50 ° C. to 80 ° C., and more specifically, 61 ° C. to 69 ° C., 60 ° C. to 65 ° C., 63 ° C. to 67 ° C., 61 ° C. to 63 ° C., 63 ° C. It can be ~ 65 ° C., 65 ° C. to 67 ° C. or 62 ° C. to 67 ° C.

Further, the polyester resin layer may have an intrinsic viscosity (IV) of 0.5 dl / g to 0.75 dl / g. Specifically, the intrinsic viscosity (IV) of the polyester resin layer is 0.6 dl / g to 0.65 dl / g; 0.65 dl / g to 0.70 dl / g; 0.64 dl / g to 0. 69 dl / g; 0.65 dl / g to 0.68 dl / g; 0.67 dl / g to 0.75 dl / g; 0.69 dl / g to 0.72 dl / g; 0.7 dl / g to 0.75 dl / With g; or can be 0.63 dl / g to 0.67 dl / g.

As an example, the average weight per unit area of the polyester resin layer can be in the range of ^{20 to 200 g / m 2.} Specifically, the average weight per unit area of the polyester resin layer is 20 to 190 g / m ² , 20 to 180 g / m ² , 20 to 160 g / m ² , 20 to 140 g / m ² , 20 to 120 g / m ² , 20-100g / m ² , 50-190g / m ² , 50-180g / m ² , 50-160g / m ² , 50-140g / m ² , 50-120g / m ² , 50-100g / m ² , 100 In the range of ~ 190 g / m ² , 100 ~ 180 g / m ² , 100 ~ 160 g / m ² , 100 ~ 140 g / m ² , 100 ~ 120 g / m ² , 80 ~ 150 g / m ² or 80 ~ 100 g / m ² . It is possible. The present invention prevents an excessive weight increase of the polyester composite by controlling the average weight per unit area of the polyester resin layer within the above range, and at the same time, the above-mentioned fiber mat layer and the polyester foam sheet are suitable for adhesion in the weight range. Performance can be realized, and peeling between the fiber mat layer and the polyester foam sheet can be suppressed during long-term use.

The polyester resin layer according to the present invention contains a polyester resin having a melting point of 180 ° C. to 250 ° C. or a softening point of 100 ° C. to 150 ° C., and serves to improve the adhesiveness with the polyester foam sheet. ..

Specifically, the polyester resin layer can contain the repeating units represented by Chemical Formula 1 and Chemical Formula 2. As a result, the melting point (Tm), softening point, and glass transition temperature (Tg) of the polyester resin layer can be adjusted within the above ranges as described above, and the polyester resin layer whose physical properties are adjusted within the above ranges is excellent. Can show adhesiveness:

In the chemical formula 1 and the chemical formula 2,
m and n indicate the mole fraction of the repeating unit contained in the low melting point polyester resin.
With respect to m + n = 1, n is 0.05 to 0.5.

The polyester resin layer according to the present invention may have a structure containing the repeating units represented by the chemical formulas 1 and 2. The repeating unit represented by the chemical formula 1 indicates a repeating unit of polyethylene terephthalate (PET), and the repeating unit represented by the chemical formula 2 has a function of improving the tearing property of the polyester resin containing the polyethylene terephthalate (PET) repeating unit. Do. Specifically, the repeating unit represented by the chemical formula 2 contains a methyl group (-CH ₃ ) as a side chain in the propylene chain bonded to the terephthalate so that the main chain of the polymerized resin can rotate. By securing a space, the melting point (Tm) can be reduced by inducing an increase in the degree of freedom of the main chain and a decrease in the crystallinity of the resin. This can exhibit the same effect as when isophthalic acid (IPA) containing an asymmetric aromatic ring is conventionally used to reduce the melting point (Tm) of the crystalline polyester resin.

At this time, the polyester resin can include the repeating unit of Chemical Formula 1 containing the ester repeating unit and the repeating unit of Chemical Formula 2 for lowering the melting point (Tm) of the resin as the main repeating unit. Specifically, the polyester resin layer of the present invention can contain the repeating units represented by the chemical formulas 1 and 2 in the range of 0.5 to 1, when the mole fraction of the total resin is set to 1, and specifically, 0. .55-1; 0.6-1; 0.7-1; 0.8-1; 0.5-0.9; 0.5-0.85; 0.5-0.7; or 0. It can be included in 6 to 0.95.

The amount of the repeating unit represented by the chemical formula 2 contained in the polyester resin layer is 0.05 to 0.5 when the total fraction including the repeating unit represented by the chemical formula 1 is 1 (m + n = 1). Obtain, specifically, 0.05-0.4, 0.1-0.4, 0.15-0.35; or 0.2-0.3.

Specifically, the polyester resin layer can contain one or more polyester resins in the form of powder, film, or web. More specifically, the polyester resin layer can include a polyester resin in powder, film or web form. For example, the polyester resin powder may be in the form of a polyester resin having a melting point of 180 ° C. to 250 ° C. or a softening point of 100 ° C. to 150 ° C.

When the polyester resin layer contains the polyester resin powder, the average particle size of the polyester resin powder can be in the range of 1 μm to 5 μm, specifically, the average particle size of the polyester resin powder is 1 μm to 4.5 μm. 1 μm to 4 μm, 1 μm to 3.5 μm, 1 μm to 3 μm, 1.5 μm to 5 μm, 1.5 μm to 4.5 μm, 1.5 μm to 4 μm, 1.5 μm to 3.5 μm, 1.5 μm to 3 μm, 2 μm to 5 μm, 2 μm to 4.5 μm, 2 μm to 4 μm, 2 μm to 3.5 μm, 2 μm to 3 μm, 3 μm to 5 μm, 3 μm to 4.5 μm, 2.5 μm to 4 μm, 3 μm to 3.5 μm, 4.5 μm to 5 μm, It can be in the range of 2 μm to 2.5 μm or 1 μm to 1.5 μm. According to the present invention, by controlling the average particle size of the polyester resin powder within the above range, the polyester resin powder can be uniformly dispersed when dispersed on the surface of the fiber mat layer.

The polyester complex according to the present invention can be widely used for parts or interiors of automobiles. Specifically, the polyester composite is applicable to trunk interior materials, headliners, wheel covers or floor carpets, and undercovers. For example, when the interior material according to the present invention is used for an automobile headliner, it has excellent flexural modulus, durability, weight reduction, and improvement of vehicle fuel efficiency can be advantageous. Further, when the interior material according to the present invention is used for a floor carpet, there is an advantage that it is safe for the human body because the amount of VOC generated is smaller than that of PVC, which is an existing material.

Method for Producing Polyester Composite The present invention is the method for producing a polyester complex described above in one embodiment.
Including the step of laminating the polyester foam sheet and the fiber matte layer, and
Contains a polyester resin layer on one or both sides of a polyester foam sheet or fiber matte layer,
In the step of laminating the polyester foam sheet and the fiber mat layer, the polyester resin layer is preheated, and the polyester foam sheet and the fiber mat layer are laminating using a mold.
The polyester foam sheet has an average weight of 400 to 900 g / m ² .
The polyester resin layer has an average weight of 20 to 200 g / m ² .
The polyester resin layer provides a method for producing a polyester composite, which comprises a polyester resin having a melting point of 180 ° C. to 250 ° C. or a softening point of 100 ° C. to 150 ° C.

The method for producing the polyester composite according to the present invention is not particularly limited, but has a structure in which a polyester resin layer is formed between the polyester foam sheet and the fiber mat layer. Specifically, it may have a structure in which a polyester resin layer having a melting point of 180 ° C. to 250 ° C. or a softening point of 100 ° C. to 150 ° C. is formed between the polyester foam sheet and the fiber mat layer. More specifically, a polyester resin layer containing one or more of powder, film and web forms may be formed between the polyester foam sheet and the fiber matte layer.

As an example, the step of laminating the polyester foam sheet and the fiber mat layer can be performed through heat fusion or heat bonding under pressure and heating conditions. Specifically, a polyester resin layer having a melting point of 180 ° C. to 250 ° C. or a softening point of 100 ° C. to 150 ° C. formed on the polyester foam sheet or the fiber mat layer is preheated and a mold is used. Including the step of laminating the polyester foam sheet and the fiber matte layer.

For example, the step of laminating the polyester foam sheet and the fiber mat layer can be performed by preheating the polyester resin layer formed on the polyester foam sheet and laminating the fiber mat layer by applying pressure with a mold. Further, the step of laminating the polyester foam sheet and the fiber mat layer can be performed by preheating the polyester resin layer formed on the fiber mat layer and applying pressure with a mold to lame the polyester foam sheet.

At this time, the surface temperature of the polyester resin layer formed on the polyester foam sheet or the fiber mat layer preheated at the laminating stage can be 120 ° C. to 160 ° C. Specifically, the surface temperature of the polyester resin layer is 120 ° C. to 155 ° C., 120 ° C. to 150 ° C., 120 ° C. to 145 ° C., 120 ° C. to 140 ° C., 120 ° C. to 120 ° C., 130 ° C. to 160 ° C. 130 ° C to 155 ° C, 130 ° C to 150 ° C, 130 ° C to 145 ° C, 130 ° C to 140 ° C, 140 ° C to 160 ° C, 140 ° C to 155 ° C, 140 ° C to 150 ° C, 140 ° C to 145 ° C, 125 ° C. It can be ~ 150 ° C., 125 ° C. to 145 ° C., 125 ° C. to 135 ° C., 150 ° C. to 160 ° C. or 135 to 155 ° C.

Further, the polyester resin layer can be preheated by applying heat for 1 to 3 minutes with a preheater having a temperature of 200 ° C. to 400 ° C. Specifically, the polyester resin layer is 200 ° C. to 380 ° C., 200 ° C. to 360 ° C., 200 ° C. to 340 ° C., 200 ° C. to 320 ° C., 200 ° C. to 300 ° C., 200 ° C. to 250 ° C., 250 ° C. to 400. Heat in a preheater at ° C, 250 ° C to 380 ° C, 250 ° C to 360 ° C, 250 ° C to 340 ° C, 250 ° C to 320 ° C, 250 ° C to 300 ° C or 250 to 350 ° C for 1.5 to 2.5 minutes. In addition, it can be preheated.

Further, the step of laminating the polyester foam sheet and the fiber mat layer can be carried out by molding by applying pressure with a mold having a temperature of 40 ° C. to 120 ° C. At this time, a pressure higher than the atmospheric pressure is applied. It can be molded into a desired form with heat and pressure applied at the same time. Specifically, the temperature of the mold is 40 to 110 ° C; 40 to 100 ° C; 40 to 90 ° C; 40 to 80 ° C; 40 to 70 ° C; 40 to 60 ° C; 50 to 120 ° C; 50 to 110 ° C. 50-100 ° C; 50-90 ° C; 50-80 ° C; 50-70 ° C; 50-60 ° C, 60-120 ° C; 60-100 ° C; 60-90 ° C; 60-80 ° C; 60-70 ° C It can be carried out in the step of preheating at a temperature of 70 to 110 ° C.; 70 to 100 ° C.; 80 to 110 ° C.; or 90 to 100 ° C. for 1 to 3 minutes and then molding through a mold. The range of pressure applied is not particularly limited and may be, for example, 1.5 to 10 atm or 2 to 5 atm.

As an example, the polyester foam sheet may have an average weight in the range of ^{400-900 g / m 2 per unit area.} Specifically, the average weight per unit area of the polyester foam ^{sheet, 400~850g / m 2, 400~800g /} m 2, 400~750g / m 2, 400~700g / m 2, 400~650g / m 2 ^{, 400~600g / m 2, 400~550g /} m 2, 400~500g / m 2, 500~900g / m 2, 500~850g / m 2, 500~800g / m 2, 500~750g / m 2, ^{500~700g / m 2, 500~650g / m} 2, 500~600g / m 2, 500~550g / m 2, 600~900g / m 2, 600~850g / m 2, 600~800g / m 2, 600 ~ 750g / m ² , 600 ~ 700g / m ² , 600 ~ 650g / m ² , 700 ~ 900g / m ² , 700 ~ 850g / m ² , 700 ~ 800g / m ² , 700 ~ 750g / m ² , 450 ~ ^{700g / m 2, 450~650g / m} 2, 450~600g / m 2, it may be 550~850g / ^{m 2} or 550~700g / ^{m 2.} By containing the polyester foam sheet as described above, it is possible to produce an automobile interior material which is excellent in flame retardancy and chemical resistance and is a pro-environmental substance which does not release environmental hormones and which is particularly excellent in mechanical strength. ..

As an example, the polyester resin layer can contain the repeating units represented by Chemical Formula 1 and Chemical Formula 2. As a result, the melting point (Tm), softening point, and glass transition temperature (Tg) of the polyester resin layer can be adjusted within the above ranges as described above, and the polyester resin layer whose physical properties are adjusted within the above ranges is excellent. Can show adhesiveness:

In the chemical formula 1 and the chemical formula 2,
m and n indicate the mole fraction of the repeating unit contained in the low melting point polyester resin.
With respect to m + n = 1, n is 0.05 to 0.5.

At this time, the polyester resin layer can include the repeating unit of Chemical Formula 1 containing the ester repeating unit and the repeating unit of Chemical Formula 2 for lowering the melting point (Tm) of the resin as the main repeating unit. Specifically, the polyester resin layer of the present invention can contain the repeating units represented by the chemical formulas 1 and 2 in the range of 0.5 to 1, when the mole fraction of the total resin is set to 1, and specifically, 0. .55-1; 0.6-1; 0.7-1; 0.8-1; 0.5-0.9; 0.5-0.85; 0.5-0.7 and; or 0 It can be included in the range of 6.6 to 0.95.

The amount of the repeating unit represented by the chemical formula 2 contained in the polyester resin layer is 0.05 to 0.5 when the total fraction including the repeating unit represented by the chemical formula 1 is 1 (m + n = 1). Obtained, specifically, 0.05-0.4, 0.1-0.4, 0.15-0.35; or 0.2-0.3.

For example, the melting point (Tm) of the polyester resin layer may be 180 ° C. to 250 ° C., or the melting point may not exist. Specifically, the melting point (Tm) is 180 ° C. to 250 ° C.; 185 ° C. to 245 ° C.; 190 ° C. to 240 ° C.; 180 ° C. to 200 ° C.; 200 ° C. to 230 ° C. or 195 ° C. to 230 ° C. May not exist.

The softening point of the polyester resin layer can be 100 ° C. to 150 ° C., specifically, 100 ° C. to 130 ° C., 118 ° C. to 128 ° C.; 120 ° C. to 125 ° C.; 121 ° C. to 124 ° C.; 124. It can be between ° C. and 128 ° C. or between 119 ° C. and 126 ° C.

Specifically, the polyester resin layer can be formed of a resin composition containing one or more polyester resins in the form of polyester resin powder, film, or web. More specifically, the polyester resin layer can be formed of a resin composition containing a polyester resin in the form of powder, film or web. For example, the polyester resin powder can be formed by applying a resin composition containing a polyester resin powder having a melting point of 180 ° C. to 250 ° C. or a softening point of 100 ° C. to 150 ° C.

The polyester composite produced by the method for producing a polyester composite according to the present invention ^{may have a peel strength of 1 kgf / cm 2} or more between the polyester resin layer and the fiber mat layer. Specifically, the peel strength of the polyester resin layer and the fiber mat layer, 1 kgf / cm ² or more, 1.2 kgf / cm ² or more, 1.3 kgf / cm ² or more, 1.4 kgf / cm ² or more, 1.5 kgf / cm ² or ^{more, 1kgf / cm 2 ~3kgf / cm} 2, 1kgf / cm 2 ~2.5kgf / cm 2, 1kgf / cm 2 ~1.8kgf / cm 2, 1kgf / cm 2 ~1.7kgf / cm 2, ^{1kgf / cm 2 ~1.6kgf / cm 2} , 1.3kgf / cm 2 ~3kgf / cm 2, 1.3kgf / cm 2 ~2.5kgf / cm 2, 1.3kgf / cm 2 ~1.8kgf / cm ^{It can be 2} or 1.3 kgf / cm ^{2 to} 1.7 kgf / cm ² .

Further, the polyester complex produced by the method for producing a polyester complex according to the present invention may release volatile organic compounds (VOCs) of 10 ppm or less. Specifically, the amount of volatile organic compounds released from the polyester complex is 10 ppm or less, 8 ppm or less, 6 ppm or less, 5 ppm or less, 4 pm or less, 2 ppm or less, 0.5 ppm to 10 ppm, 0.5 ppm to 8 ppm, 0. It can be 5 ppm to 6 ppm, 0.5 ppm to 5 ppm, 0.5 ppm to 4 ppm, 0.5 ppm to 3 ppm, 0.5 ppm to 2 ppm or 0.5 ppm to 1 ppm.

Automotive Interior Material The present invention provides an automobile interior material containing a polyester composite according to the present invention.
As described above, the automobile interior material according to the present invention comprises a polyester foam sheet ^{having an average weight of 400 to 900 g / m 2.}
With a polyester resin layer having an average weight of 20 to 200 g / m ^{2 formed on one or both sides of the foam sheet;}
Including a structure in which a fiber mat layer is laminated on one or both sides of a polyester resin layer;
The polyester resin layer is characterized by having a melting point of 180 ° C. to 250 ° C. or a softening point of 100 ° C. to 150 ° C.
It contains a polyester composite characterized in that the peel strength between the polyester resin layer and the fiber mat layer is 1 kgf / cm ^{2 or more.}

The automobile interior material according to the present invention, which contains the polyester composite as described above, improves the adhesiveness between the fiber mat layer and the polyester resin layer without deteriorating physical properties such as strength and rigidity, and is used between the laminates. Adhesiveness can be improved.

Hereinafter, the present invention will be described in more detail with reference to Examples and Experimental Examples.

However, the following Examples and Experimental Examples merely exemplify the present invention, and the content of the present invention is not limited to the following Examples and Experimental Examples.

Example 1
In order to produce the polyester composite according to the present invention, first, 100 parts by weight of polyethylene terephthalate (PET) resin was dried at 130 ° C. to remove water. Then, together with the PET resin from which water was removed in the first extruder, 1 part by weight of pyromellitic anhydride, 3 parts by weight of calcium carbonate and 0.1 part by weight of Irganox (IRG 1010) were taken as a reference. Was charged and heated at 280 ± 5 ° C. while mixing to produce a resin melt. Next, 1.5 parts by weight of butane gas as a foaming agent was charged into the first extruder based on 100 parts by weight of PET resin, and extruded and foamed to produce a polyester foam sheet. The polyester foam sheet has an average weight of 750 g / m ² per unit area, an average thickness of 2.5 mm, about 97 ± 1% of all cells are closed cells, and an average number of cells per ^{1 mm 2.} The number was 12 ± 5 (average size: 450 ± 20 μm). The produced polyester foam sheet was coated with a polyester resin composition to form a polyester resin layer having ^{a weight per area of 50 g / m 2.} At this time, as the polyester resin, one containing a polyester resin having a melting point of 180 ° C. to 250 ° C. or a softening point of 100 ° C. to 150 ° C. as a main component was used.

The polyester foam sheet on which the polyester resin layer is formed passes through a preheater (300 ° C., 120 seconds) to a surface temperature of 120 ° C., and after the polyester fiber mat layer is charged, the temperature of the high temperature mold is set to 80 ° C. After pressing, the polyester composite was produced by pressing at a cooling die temperature of 20 ° C.

Example 2
A polyester complex was produced under the same conditions as in Example 1 except that the low melting point polyester resin weighs 100 g / m ^2.

Example 3
A polyester complex was produced under the same conditions as in Example 1 except that a low melting point resin powder was used.

Comparative Example 1
A polyester composite was produced under the same conditions as in Example 1 except that a polyester resin having a melting point of 260 ° C. was used instead of the low melting point polyester resin.

Comparative Example 2
A polyester complex was produced under the same conditions as in Example 1 except that a polyethylene resin was used instead of the low melting point polyester resin.

Comparative Example 3
A polyester complex was produced under the same conditions as in Example 1 except that a polyurethane resin was used instead of the low melting point polyester resin.

Experimental Example 1
In order to evaluate the resistance of the polyester composite according to the present invention to external impact and the adhesiveness between the laminates, that is, the durability, the flexural modulus of the polyester composites of Embodiment 1 and Comparative Examples 1 to 3 is targeted. , Bending strength, peeling strength and VOC emission amount were measured, and the results are shown in Table 1 below.

Specifically, the flexural modulus and flexural strength are measured initially while the support interval (Span) of the 50 * 150 mm test piece is fixed at 100 mm and the flexion load is applied at a rate of 5 mm / min based on ASTM D 790. The value when deformed by 10% with respect to the test piece was measured. The results are shown in Table 1 below.

In addition, as shown in the attached FIG. 2, the peel strength is measured by cutting the test piece to 25 * 175 mm by the KS M 3725 evaluation method and then adhering the test pieces so as to overlap each other (after preheating the oven at 300 ° C. for 120 seconds). , Press temperature 80 ° C. 40 seconds) After manufacturing the test piece, peel it off by 10 mm in a tensile strength tester, attach it, and peel it off at a tensile speed of 200 mm / min to obtain the maximum tensile load.

The amount of VOCs generated was calculated by volatilizing the pellets at 120 ° C. for 30 minutes using a static head space sampler and then determining the peak area using GC.

Referring to Table 1, the polyester composites produced in Examples 1 to 3 exhibited a bending strength of 5 to 10 kgf and a flexural modulus of 250 to 400 MPa, and the polyester composites produced in Comparative Examples 1 to 3 showed 6 It can be confirmed that the bending strength of about 7 kgf and the flexural modulus of 280 to 380 MPa show similar levels of strength. Further, the polyester composites produced in Examples 1 to 3 through the peel strength experiment ^{showed a peel strength of 1.3 to 2.0 kgf / cm 2} , and while VOCs of less than 2 ppm were generated, Comparative Examples 1 to 3. in polyester composites prepared showed peel strength of 0.3~0.5kgf / cm ² or 2.0 kgf / cm ^2, it can be seen that 3ppm or 30ppm of VOCs occurs.

As a result, the polyester composite according to the present invention contains a polyester resin layer between the polyester foam sheet and the fiber mat layer, so that the flexural strength is at the same level as that of the conventional automobile interior material including the adhesive layer. It was found that the flexural modulus can be realized, the adhesive strength between the laminated bodies is excellent, and the VOC content is low, so that it is safe for the human body.

Experimental Example 2
In order to evaluate the dimensional stability of the polyester composite according to the present invention, the following experiments were carried out on the polyester composite test pieces (circles having a diameter of 200 mm) produced in Example 1 and Comparative Example 2, and the same. The results are shown in Table 2.

Specifically, according to the accelerated light resistance test of KS R0021, light having a wavelength of 300 to 400 nm was irradiated with light having an illuminance of 255 W / m ² for 90 days, and the dimensional change rate (that is, the average of horizontal, vertical, and height) before and after light irradiation was applied. The rate of change of the value) was calculated and shown in Table 2. At this time, the volume before measurement was 1 m ³ , and the dimensional change rate was shown under the following condition 1.

Under condition 1, Lt ₀ indicates the dimension before processing, and Lt ₁ indicates the dimension after processing.

Referring to Table 2, the polyester composite produced in Example 1 has a dimensional change rate of less than 4%, specifically 2%, whereas the polyester complex produced in Comparative Example 2 has a dimensional change rate of 5. It was confirmed that the polyester composite produced in Comparative Example 2 had a dimensional change rate of more than twice as large as that in Example 1.

From this, it can be seen that the polyester complex according to the present invention has excellent durability under irradiation with light.

Since the polyester composite according to the present invention contains a resin layer containing a low melting point polyester resin, the polyester composite has excellent adhesiveness between the foam sheet and the fiber mat layer, has excellent durability, and is a parent. Although it is environmentally friendly, it is economical because it reduces manufacturing costs and is suitable for use in automobile interior materials.

Claims (14)

With a polyester foam sheet with an average weight of 400-900 g / m ^2;
With a polyester resin layer having an average weight of 20 to 200 g / m ^{2 formed on one or both sides of the foam sheet;}
Including a structure in which a fiber mat layer is laminated on one or both sides of a polyester resin layer;
The polyester resin layer is characterized by having a melting point of 180 ° C. to 250 ° C. or a softening point of 100 ° C. to 150 ° C.
A polyester complex characterized in that the peel strength between the polyester resin layer and the fiber mat layer is 1 kgf / cm ^{2 or more.} The polyester composite according to claim 1, wherein the polyester resin layer contains one or more polyester resins in the form of powder, film, or web. The polyester composite according to claim 1, wherein the average weight per unit area of the polyester resin layer is in ^{the range of 50 to 200 g / m 2.} The polyester composite according to claim 2, wherein when the polyester resin layer contains a resin powder, the average particle size of the polyester resin powder is 0.1 μm to 5 μm. The polyester complex according to claim 1, wherein the polyester resin layer contains the repeating units represented by the following chemical formulas 1 and 2.

In the chemical formula 1 and the chemical formula 2,
m and n indicate the mole fraction of the repeating unit contained in the low melting point polyester resin.
With respect to m + n = 1, n is 0.05 to 0.5. The polyester composite according to claim 1, wherein the polyester foam sheet is a polyethylene terephthalate (PET) foam sheet. Including the step of laminating the polyester foam sheet and the fiber matte layer, and
Contains a polyester resin layer on one or both sides of a polyester foam sheet or fiber matte layer,
In the step of laminating the polyester foam sheet and the fiber mat layer, the polyester resin layer is preheated, and the polyester foam sheet and the fiber mat layer are laminating using a mold.
The polyester foam sheet has an average weight of 400 to 900 g / m ² .
The polyester resin layer has an average weight of 20 to 200 g / m ² .
A method for producing a polyester composite, wherein the polyester resin layer contains a polyester resin having a melting point of 180 ° C. to 250 ° C. or a softening point of 100 ° C. to 150 ° C. The method for producing a polyester composite according to claim 7, wherein the surface temperature of the polyester resin layer formed on the polyester foam sheet or the fiber mat layer preheated in the laminating step is 120 ° C. to 160 ° C. .. The method for producing a polyester complex according to claim 7, wherein the laminating step is formed by applying pressure with a mold having a temperature of 40 ° C. to 120 ° C. The method for producing a polyester complex according to claim 7, wherein the polyester resin layer contains the repeating units represented by the following chemical formulas 1 and 2.

In the chemical formula 1 and the chemical formula 2,
m and n indicate the mole fraction of the repeating unit contained in the low melting point polyester resin.
With respect to m + n = 1, n is 0.05 to 0.5. 7. The step of laminating the polyester foam sheet and the fiber mat layer is performed by preheating the polyester resin layer formed on the polyester foam sheet and applying pressure with a mold to laminate the fiber mat layer. The method for producing a polyester composite according to. 7. The step of laminating the polyester foam sheet and the fiber mat layer is performed by preheating the polyester resin layer formed on the fiber mat layer and applying pressure with a mold to laminate the polyester foam sheet. The method for producing a polyester composite according to. The method for producing a polyester composite according to claim 7, wherein the polyester resin layer is formed of a resin composition containing one or more polyester resins in the form of powder, film, or web. An automobile interior material containing the polyester composite according to claim 1.

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