KR101743844B1 - Interior and exterior furnishings of vehicle having excellent sound absorbing and excluding - Google Patents

Abstract

The interior and exterior material for a vehicle according to the present invention is characterized by having a nonwoven fabric layer comprising an aggregate of modified hollow fiber fibers formed on at least one surface of a foam layer formed of a polyester resin foam, Sound absorption and sound insulation characteristics, and at the same time, excellent lightweight property, heat resistance and durability can be obtained.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vehicle interior and exterior material having excellent sound absorption and sound insulation performance,

The present invention relates to a vehicle interior and exterior material having excellent sound absorption and sound insulation performance.

Generally, a floor under cover mounted on the bottom surface of a vehicle is installed at the bottom of an engine or a transmission and a cooling fan to protect the engine and transmission from impacts externally, and also to prevent noise generated from the engine or transmission Thereby preventing foreign matter from being discharged from the outside to the inside of the automobile.

Conventionally, GMT (glass fiber mat thermoplastic) was used as the material of the floor undercover. The GMT sheet refers to a composite material in the form of a plate composed of a polypropylene resin and a glass fiber mat reinforcement. The thermoplastic resin is used as a matrix ) And a glass fiber mat is reinforced therebetween.

Such GMT is a composite material for component molding having both light weight of plastic and mechanical properties of reinforcement material, and it is advantageous to obtain desired physical properties comparatively cheaply by proper combination of matrix resin and reinforcement material.

However, since the GMT material has no pores and can not be produced in different thicknesses depending on the region, it has almost no sound absorbing performance and it is impossible to realize an integral full under cover according to the compression and injection molding method , The density of the material itself is high, which increases the overall weight of the vehicle, and the workability is deteriorated due to the glass fiber.

As a result, it can be said that this is a road noise (all the noise generated in the under vehicle at the time of driving the vehicle, for example, a sound coming out from the bottom of the vehicle when sand or gravel protrudes from the bottom of the vehicle, (E.g., noise generated when air is blown into the vehicle), and in particular, a sand noise (high frequency noise generated when sand or gravel bounces) coming from the lower portion of the vehicle is generated.

Korea Patent Publication No. 2011-0104948

An object of the present invention is to provide a vehicle interior and exterior material having excellent sound absorption and sound insulation performance, and to provide a vehicle interior and exterior material having excellent sound absorption and sound insulation performance and excellent light weight, heat resistance and durability.

The present invention provides, as means for solving the above problems,

A foam layer containing a polyester resin foam; And

A nonwoven fabric layer is formed on at least one surface of the foam layer,

The sound absorption rate measured according to KS F 2805 is 0.4 NRC or more,

It is possible to provide a vehicle interior and exterior material having a transmission loss value measured according to KS F 2080 of 20 dB or more at 1,000 Hz, 25 dB or more at 2,000 Hz, and 40 dB or more at 5000 Hz.

The vehicle interior and exterior material according to the present invention can provide excellent sound absorption and sound insulation characteristics by forming a nonwoven fabric layer including an aggregate of hollow fibers having at least one side surface of a foam layer formed on a foam layer formed of a polyester resin foam and having excellent light weight, Durability.

1 to 6 are fiber cross-sectional views, respectively, according to one embodiment of the present invention.
7 is a conceptual diagram of spinning and detaching corresponding to a volume control unit according to an embodiment of the present invention.
8 is a cross-sectional view of a fibrous assembly according to one embodiment of the present invention.
9 and 10 are sectional views showing a laminated structure of an automotive interior and exterior material according to an embodiment of the present invention, respectively.

While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail.

It should be understood, however, that the invention is not intended to be limited to the particular embodiments, but includes all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.

In the present invention, the terms "comprising" or "having ", and the like, specify that the presence of a feature, a number, a step, an operation, an element, a component, But do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or combinations thereof.

As used herein, the terms "substantially", "substantially", and the like are used herein to refer to a value in or near the numerical value when presenting manufacturing and material tolerances inherent in the meanings mentioned, Absolute numbers are used to prevent unauthorized exploitation by unauthorized intruders of the mentioned disclosure.

As used herein, the term fibrous aggregate includes long fibers and / or short fibers and includes, without limitation, fabrics, knits, fabrics, nonwoven fabrics, webs, slivers or tows, Including species or more.

Hereinafter, the present invention will be described in detail.

The present invention relates to an automobile interior and exterior material having excellent durability, and as one example of the vehicle interior and exterior materials,

A foam layer containing a polyester resin foam; And

A nonwoven fabric layer is formed on at least one surface of the foam layer,

The sound absorption rate measured according to KS F 2805 is 0.4 NRC or more,

It is possible to provide a vehicle interior and exterior material having a transmission loss value measured according to KS F 2080 of 20 dB or more at 1,000 Hz, 25 dB or more at 2,000 Hz, and 40 dB or more at 5000 Hz.

Specifically, the automotive interior and exterior material according to the present invention is characterized in that a non-woven fabric layer including an aggregate of hollow-section hollow fibers is formed on at least one surface of a foam layer containing a polyester resin foam to provide excellent strength and sound absorption and sound insulation performance It can be excellent.

In the vehicle interior and exterior materials,

The polyester resin can be prepared by condensation polymerization reaction of 1,4-butanediol with terephthalic acid. The polyester resin according to the present invention includes both aromatic and aliphatic polyesters. In another aspect, the polyester resin includes a flame retardant polyester, a biodegradable polyester, an elastic polyester, and a reusable polyester. For example, the resin foam according to the present invention may be a PET (polyethylene terephthalate) foam. By using the PET, it is eco-friendly and can be easily reused.

At this time, the sound absorption coefficient measured according to KS F 2805 is 0.4 NRC or more, and the transmission loss value measured according to KS F 2080 may be 10 dB or more.

For example, the sound absorption rate may be in the range of 0.4 to 1 NRC or 0.4 to 0.6 NRC, 20 dB or more at 1,000 Hz, 25 dB or more at 2,000 Hz, and 40 dB or more at 5000 Hz. As described above, the vehicle interior and exterior vehicle according to the present invention can realize sound absorption and sound insulation at the same time with excellent levels, so that noise due to an external impact and noise of the engine can be effectively sounded or absorbed.

The foam layer may satisfy the following general formula (1).

[Equation 1]

X / Y ≥ 1.5

X represents the flexural strength (N / cm ² ) of the resin foam layer according to KS M ISO 844, and Y represents the density (kg / m ³ ) of the resin foam layer according to KS M ISO 845.

The density-to-density ratio of the resin foam layer may satisfy the above-mentioned formula (1). For example, the density to flexural strength ratio of the resin foam layer may be in the range of 1.5 or more, 1.5 to 2, 1.6 to 1.8 or 1.5 to 1.6. The foamed molded article according to the present invention satisfies the density-to-density ratio of the resin foam layer within the above range, thereby realizing an expanded molded article having a high foaming ratio and high strength. This means that in the foamed molded article according to the present invention, the foaming agent is well trapped in the resin foamed layer, and the pores are not bonded to each other, and the closed cells are formed independently. Thus, excellent excellent car sound and high heat insulation can be expected .

In the above formula (1), X may be 70 to 110 N / cm ² , and Y may be 40 to 80 kg / m ³ . For example, X (bending strength) is 75 to 110 N / cm ^2, 80 to 110 N / cm ^2, 80 to 100 N / cm ² may be in the range, Y (density) from 40 to 75 kg / m ³ , 50 to 75 kg / m ³ or 55 to 65 kg / m ³ .

Wherein the nonwoven fabric layer is formed of an aggregate of modified hollow fibers,

Wherein the modified hollow fiber has a hollow portion, a shape retaining portion, and a volume control portion,

The volume control part may protrude in a direction opposite to the center of the fiber, and the protruding end may be round.

Specifically, the volume control part may protrude in a direction opposite to the center of the fiber, and more specifically, the protruding end part may have a round shape.

In the present invention, the cross-sectional structure of the modified hollow fiber is described as a hollow portion, a shape retaining portion, and a volume control portion, but this is for convenience of explanation. The cross-sectional structure of the modified hollow fiber includes a hollow portion formed therein along the longitudinal direction of the fiber, and a shape retaining portion surrounding the hollow portion. Also, the shape retaining portion is formed with concavo-convex on the outer circumferential surface on the opposite side of the hollow portion with respect to the end face, and the portion protruding from the concavo-convex portion is referred to as a volume control portion.

The automotive interior and exterior material can simultaneously enhance the sound insulation and sound absorption performance by composing the foam layer and the nonwoven fabric layer. The foam layer may be in the form of a rigid board, and the rigid board layer may enhance sound insulation by blocking sound. In addition, the nonwoven fabric layer includes a network structure formed by the used fibers, and the network structure absorbs sound, thereby enhancing the sound absorption performance. In the present invention, sound insulation and sound absorption characteristics can be realized at the same time by composing the foam layer in the hard board form and the nonwoven fabric layer in the network structure.

(I) a structure in which a nonwoven fabric layer is formed on one surface of a foam layer, (ii) a structure in which a nonwoven fabric layer is formed on both surfaces of the foam layer, (iii) a structure in which a foam layer (Iv) a structure in which 2 to 5 layers of foamed layers are laminated, and a nonwoven fabric layer is formed on an interface and an outer surface between the layers, and the like. Further, another adhesive film may be formed on the interface between the respective layers forming the automotive interior and exterior material.

The modified hollow fiber according to one embodiment of the present invention may be made of any material that can be formed into a fibrous shape.

For example, polyethylene terephthalate (PET) may be used, but the present invention is not limited thereto. For example, polypropylene (PP), polypropylene Nylon and the like may be used. The melt viscosity of the melt-spun PET polymer may range from 0.60 to 0.64, and an in-out type radiation cylinder capable of maximizing the cooling effect is suitable. The thickness of the fibers can be varied from 4 to 15 denier and the fiber length can be from 22 to 64 mm.

FIG. 1 is a conceptual view of a modified hollow fiber according to an embodiment of the present invention. The fiber 10 may be formed of a hollow part 100, a shape retaining part 200, and a volume control part 300. The void fraction of the hollow portion 100 may range from about 15% to about 30% of the entire fiber area. Above the above range, there may be a problem in fiber formability, and if it is less than the above range, the hollow retention property and the various functionalities of the present invention may be limited. The shape retaining part 200 refers to a fibrous shape between the hollow part 100 and the volume control part 300.

The volume control part 300 may protrude in a direction opposite to the center of the fiber, and the distal end may be round. At this time, the uppermost part of the distal end can be defined as the peak 310, and the space between the volume control parts can be defined as the valley 330. In this case, the radius of curvature of the peak can be defined as R, the radius of curvature of the valley as r, and R and r values that are different from each other can be determined for each volume control (FIG. 2).

A value T1 is the largest distance from the center point M of the hollow portion 100 to the peak 310 and T2 the smallest distance from the center point M to the peak 310 is the center point M And the distance from the center point M to the valley 330 is defined as t2. On the other hand, a circle formed by connecting the tangent of the volume controller 300 having the next higher order distance from the center point M to the peak 310 on the basis of T1 is referred to as CTmax and T2 is defined as a peak from the center point M A circle formed by connecting the tangent of the volume controller 300 having a smaller distance from the center point M to the peak 310 is referred to as a CTmin and a distance from the center point M to the peak 310 on the basis of t1 is larger And a tangent line of the volume control unit 300 having a smaller distance from the center point M to the peak 310 is connected to the tangent line of the volume control unit 300 When the formed circle is Ctmin; The difference value between the center point CTmaxM of the CTmax and the center point M is denoted by CTmax-R and the difference between the center point CTminM of the CTmin and the center point M is denoted by CTmin-R and the center point CtmaxM of the Ctmax, When the difference between the center point CtminM and the center point M is defined as Ctmin-r, the fiber according to the present invention can satisfy the following condition 3 to 6).

The interior and exterior materials for vehicles may have a heat resistance of more than grade 3 based on KS F ISO 5660-1. Specifically, according to the KS F ISO 5660-1 standard, flame retardant materials for grade 3, quasi-fireproof materials for grade 2, and fireproof materials for grade 1 are classified as grade 3 or higher based on KS F ISO 5660-1, In case of class 3, by having flame-retardant or non-flammable characteristics, the risk of fire can be reduced thereafter.

Leaving the automotive interior and exterior materials at a temperature of 90 ± 1 ° C for 24 hours; And leaving it for 24 hours at a temperature of 50 ± 1 ° C and a relative humidity of 90%, the following equation (2) can be satisfied.

&Quot; (2) "

| V ₁ -V ₀ | / V ₀ x 100? 5%

In Equation (2)

V ₀ is the volume (mm ³ ) of the interior and exterior materials of the vehicle before exposure to the harsh conditions,

V ₁ is the volume (mm ³ ) of the vehicle interior and exterior material after exposure to the harsh conditions.

Specifically, the dimensional change rate of the manufactured vehicle interior / exterior material samples before and after the severe condition was measured. This is a measurement value corresponding to the long-term dimensional change rate after application of the vehicle interior / exterior material to a vehicle. For example, the volume may mean a value calculated by multiplying the length of each of the vehicle interior and exterior materials, the length of each of the vehicle interior and exterior materials, and the length of the thickness. For example, the rate of dimensional change of the formula (2) may range from 0.01 to 5%, from 0.01 to 3%, or from 0.01 to 1%. By satisfying the value of the expression (2) in the above range, it can be seen that the shape of the vehicle interior and exterior material according to the present invention does not change even in long-term use in an environment with severe temperature change.

If the formula (2) is more than 5%, it may mean that peeling, parts, sagging, discoloration or deformation may easily occur on the vehicle interior and exterior materials.

The vehicle interior and exterior materials may have a mass per unit area of 500 to 2000 g / m ² . For example, the mass per unit area of the vehicle interior and exterior materials may be 550 to 2000 g / m ² , 600 to 1500, 700 to 1300 g / m ^2, or 700 to 1000 g / m ² . By satisfying the mass per unit area in the above range, it can be confirmed that the vehicle interior and exterior material according to the present invention is lightweight.

In the vehicle interior and exterior materials, the average thickness of the foamed layer may be 1 to 30 mm, and the average thickness of the nonwoven fabric layer may be 0.1 to 10 mm.

For example, the thickness of the foam layer may range from 1.5 to 30 mm, from 5 to 30 mm, from 5 to 20 mm, or from 5 to 10 nm. In addition, the thickness of the nonwoven layer may range from 0.5 to 10 mm, from 0.5 to 8 mm, from 0.5 to 5 mm. Accordingly, the automotive interior and exterior material according to the present invention can realize properties such as excellent heat resistance, bending strength, long-term numerical strain, sound absorption and car sound even though it is relatively thin. Further, the interior and exterior materials for a vehicle according to the present invention can be lightened, and excellent fuel economy can be realized.

The modified cross-

At least one of the following conditions (1) and (2) can be satisfied when the uppermost part of the distal end, which is a protruding form of the volume control part, is defined as a peak and the protruded form of the volume control part is defined as a valley.

(1) -3? Z? 4

≤ 1.8(2) 0.9?

1.8

here,

R represents the radius of curvature of the peak,

r represents the radius of curvature of the valley.

Many tests by the present inventors through fiber cross-sectional morphology analysis showed that the volume control portion of one fiber was inserted into the valley between the volume control portions of the adjacent fibers in the outside of the above range to show a structural characteristic as if the gears were engaged, And it is analyzed that it has a bad influence on the uniformity of the fiber aggregate. The volume control part between the fibers interferes with each other within the above range, and the bulky property is maintained. Even if the volume control part is inserted into the valley of the adjacent fiber, the fiber control part can be easily detached by flow or the like, thereby improving uniformity in the fiber aggregate.

The fibers according to the preferred embodiment of the present invention may satisfy any one of the following conditions (3) and (4): CTmax-R, CTmin-R, Ctmaxr and Ctmin-r.

≥ 0.80(3)

≥ 0.80

≥ 0.30(4)

≥ 0.30

here,

T1 is the largest distance from the center point M to the peak 310,

T2 is the smallest distance from the center point M to the peak 310,

t1 is the largest distance from the center point M to the valley 330,

t2 is the smallest distance from the center point M to the valley 330,

CTmax is a circle formed by connecting tangential lines of the volume controller 300 having a larger distance from the center point M to the peak 310 on the basis of T1,

CTmin is a circle formed by connecting the tangent of the volume controller 300 having a distance from the center point M to the peak 310 to a next smaller value,

Ctmax is a circle formed by connecting the tangent of the volume controller 300 having the next highest order distance from the center point M to the peak 310 on the basis of t1,

Ctmin is a circle formed by connecting the tangent of the volume controller 300 having a smaller distance from the center point M to the peak 310,

CTmax-R represents the difference value between the center point (CTmaxM) and the center point (M) of CTmax,

CTmin-R represents the difference value between the center point CTminM of the CTmin and the center point M,

Ctmax-r represents a difference value between a center point (CtmaxM) and a center point (M) of Ctmax,

Ctmin-r represents a difference value between the center point (CtminM) and the center point (M) of Ctmin.

The above conditions (3) and (4) may relate to the formation of fibers according to an embodiment of the present invention. Ideally, the value should be 1, but not 1 due to the rheological properties of the polymer. The condition (3) may be related to formation of the volume control portion. Outside of the above range, the deviation of the volume control portion may be large and the variation of the r value may be large, which may affect the carding property in the process or the bulkiness in the fiber aggregate. Condition (4) can be interpreted as fiber morphology, which can affect the formability of hollow portion 100 and shape retaining portion 200. Outside of the above range, hollow formation and fiber shape retention may be unstable.

In order to form the fiber cross-section as described above, the spinneret of the volume controller 300 may be formed in a radial shape as shown in FIG. At this time, an angle (?) Of 10 to 17 degrees with respect to the center point M may be formed. As a result of a number of tests by the present inventors, a fiber cross-sectional shape has been realized which can satisfy the above requirements for manifesting the function of the member 300 as a volume control element of the modified cross section while maintaining the hollowness within the above range.

On the basis of the cross section of the fibers, the modified cross-section hollow fibers may have an average of 4 to 12 volume control portions.

The fibers according to an embodiment of the present invention may be made of polyester which is a thermoplastic resin as a non-limiting example. The fibers may be spun in a short fiber state or in a nonwoven form through spontaneous crimp development due to a difference in crystallization speed during cooling and solidification, It can contribute to improving elasticity.

The fiber according to the present invention can be produced by forming a fibrous assembly including a binding material for forming a binding structure between fibers or only the fibers according to the present invention into a nonwoven fabric through a needle punching process, a heat bonding process, or a meltblowing process have.

The fibrous aggregate to which the modified hollow fiber according to the present invention is applied may be a binding material generally used for binding between fibers. In the short fiber form, a low melting point PET staple fiber having a cis-core type may be used in the heat bonding process. In the blowing process, polypropylene (PP) fibers of three islands can be used.

The material to be produced in the heat bonding step is composed of a composition comprising 60 to 90 parts by weight of the hollow fiber of the modified cross section and 40 to 10 parts by weight of the binding material, wherein the length of the modified hollow fiber is 51 to 64 mm , And the thickness (fineness) of the fibers may be 6 to 8 denier. When the length of the hollow fiber cross-section is less than 51 mm in the heat bonding step, the gap between the fibers is widened, making it difficult to form a matrix structure, and it becomes difficult to form and produce into a fibrous aggregate. Also, due to excessive porosity, sound absorption and sound insulation performance may be deteriorated.

The compositional weight ratio of the modified cross-section hollow fiber to the binding material is preferably from 6: 4 to 9: 1. If the content of the hollow fiber of the cross-section is less than 60 parts by weight, the surface area of the fiber is reduced and the physical properties can not be realized. In particular, since the content of the low melting point PET used in the heat bonding process is relatively high, The fibrous aggregate is hardened because it can not maintain the key property. On the other hand, when the content of the hollow fibers of the cross-section exceeds 90 parts by weight, the content of the binder fibers, that is, the binding material is less than 10 parts by weight, so that the sufficient binding force between the fibers can not be maintained. It becomes difficult to do.

The material to be produced in the melt blowing step is composed of 20 to 60 parts by weight of the cross-section hollow fiber, and 80 to 40 parts by weight of the polypropylene fiber, wherein the length of the modified hollow fiber is 32 to 51 mm And the thickness (fineness) of the fibers is 6 to 8 deniers. If it exceeds 51 mm, uneven web is formed due to entanglement between fibers in the blowing process due to post-sagging air. Therefore, it is necessary to select a suitable fiber sheet in the range of 32 ~ 64 ㎜ fiber length according to the post - process applied to sound - absorbing materials and fillers.

The vehicle interior and exterior material may further include an adhesive film formed between the foamed layer and the nonwoven fabric layer. For example, the polyester-based adhesive resin may be a hard segment, which is an esterification reaction product of a diol and a dicarbonic acid; And a polyester-based elastic adhesive resin which is an axial polymer of a soft segment which is a polyol.

In the vehicle interior and exterior material according to the present invention, the functional additive may be foamed by foaming the foam layer, or the functional additive layer may be formed on at least one surface of the foam layer using the functional additive. Thus, the desired functionality can be effectively imparted without lowering the physical properties of the foam layer, and the process efficiency and degree of freedom can be increased.

The functional additive includes at least one of an insulating agent, a hydrophilizing agent, a waterproofing agent, a flame retardant, an antibacterial agent, a deodorant, and an ultraviolet screening agent.

The heat insulating material may include a carbonaceous component. For example, the adiabatic agent may include graphite, carbon black, graphene, and the like, and may be specifically graphite.

The flame retardant is not particularly limited and may include, for example, a bromine compound, a phosphorus compound, an antimony compound, a metal hydroxide, and the like. The bromine compound includes, for example, tetrabromobisphenol A and / or decabromodiphenyl ether. The phosphorus compound may include an aromatic phosphoric acid ester, an aromatic condensed phosphoric acid ester, a halogenated phosphoric acid ester, and / or the like, and the antimony compound may include antimony trioxide and antimony pentoxide. Examples of the metal element in the metal hydroxide include aluminum (Al), magnesium (Mg), calcium (Ca), nickel (Ni), cobalt (Co), tin (Sn), zinc (Zn) ), Iron (Fe), titanium (Ti), and boron (B). Among them, metal hydroxides of aluminum or magnesium can be used. The metal hydroxide may be composed of one kind of metal element or two or more kinds of metal elements. For example, the metal hydroxide may include at least one of aluminum hydroxide and magnesium hydroxide.

The VOC reducing agent may include Graf and / or Bactoster Alexin and the like. At this time, the toast alecine is a natural sterilizing material extracted from propolis.

The hydrophilic agent is not particularly limited, and examples thereof include anionic surfactants (for example, fatty acid salts, alkylsulfuric acid ester salts, alkylbenzenesulfonic acid salts, alkylnaphthalenesulfonic acid salts, alkylsulfosuccinic acid salts and polyoxyethylene alkylsulfuric acid ester salts) , Nonionic surfactants (for example, polyoxyalkylene alkyl ethers such as polyoxyethylene alkyl ethers, polyoxyethylene derivatives, sorbitan fatty acid esters, polyoxyethylene sorbitan fatty acid esters, polyoxyethylene sorbitol fatty acid esters, (E.g., alkylamine salts, quaternary ammonium salts, alkylbetaines, amine oxides, etc.), and water-soluble polymers such as polyoxyethylene alkylamines and alkylalkanolamides), cationic and amphoteric surfactants Or a protective colloid (e.g., gelatin, methyl cellulose, hydroxyethyl cellulose, Polyoxyethylene-polyoxypropylene block copolymer, polyacrylamide, polyacrylic acid, polyacrylic acid salt, sodium alginate, and polyvinyl alcohol partial saponification), and the like. can do.

The kind of the waterproofing agent is not particularly limited, and examples thereof include silicone, epoxy, cyanoacrylic acid, polyvinyl acrylate, ethylene vinyl acetate, acrylate, polychloroprene, A mixture of polyurethane and polyurethane resin, a mixture of polyol and polyurethane resin, a mixture of acrylic polymer and polyurethane resin, a polyimide, and a mixture of cyanoacrylate and urethane. .

The type of the antibacterial agent may be, for example, a vehicle in which at least one metal selected from the group consisting of silver, zinc, copper and iron is added to at least one carrier selected from the group consisting of hydroxyapatite, alumina, silica, titania, zeolite, zirconium phosphate and aluminum polyphosphate And may include interior and exterior materials.

The deodorant may be a porous material. Since the porous material has a strong tendency to physically adsorb a fluid flowing around the porous material, it is possible to adsorb a volatile organic compound (VOC). The deodorant may be selected from, for example, silica, zeolite and calcium (Ca), sodium (Na), aluminum (Al), silver (Ag), copper (Cu), tin (Zn), iron (Fe), cobalt ) And nickel (Ni), or a mixture of two or more thereof.

The ultraviolet screening agent is not particularly limited and may be, for example, an organic or inorganic ultraviolet screening agent. Examples of the organic ultraviolet screening agent include p-aminobenzoic acid derivatives, benzylidene camphor derivatives, cinnamic acid derivatives, Benzotriazole derivatives, and mixtures thereof. Examples of the inorganic ultraviolet screening agent may include titanium dioxide, zinc oxide, manganese oxide, zirconium dioxide, cerium dioxide, or a mixture thereof.

The vehicle interior and exterior material may be an engine room cover. When the vehicle interior and exterior material according to the present invention is used as an engine room cover, it can be effective for absorbing or shielding noise inside the engine.

The production method of the foam layer is not particularly limited, but for example, the foam layer may be an extruded foam. Specifically, there are types of foaming methods largely bead foaming or extrusion foaming. In general, the bead foaming is a method of heating a resin bead to form a primary foam, aging the resin bead for a suitable time, filling the resin bead in a plate-shaped or cylindrical mold, heating the same again, and fusing and forming the product by secondary foaming. On the other hand, the extrusion foaming can simplify the process steps by heating and melting the resin and continuously extruding and foaming the resin melt, and it is possible to mass-produce, and the cracks, Development and the like can be prevented, and more excellent bending strength and compressive strength can be realized.

Hereinafter, the present invention will be described in detail by way of Examples and the like according to the present invention, but the scope of the present invention is not limited thereto.

Manufacturing example  1 to 3

The polyester having the intrinsic viscosity of 0.64 was used to produce four, six and twelve fibers each having a volume control portion. After spinning at a spinning temperature of 285 ° C at a spinning speed of 1,000 m / min, the fibers were stretched at a stretching ratio of 3.8 and crimped through a crimper to produce fibers having a fiber size of 7 De and a fiber length of 64 mm.

Comparative Manufacturing Example  1 to 3

Circular hollow fiber having a circular cross section fiber, a circular hollow cross section fiber and a polyester intrinsic viscosity of 0.64 and 0.50 were produced in the same manner as in Production Example 1.

Experimental Example  One

The properties of the fibers prepared in Production Examples and Comparative Production Examples were measured. The concrete physical property measurement method was carried out as follows.

* Of composite fibers Bulkite

end. Test Methods

- Quantify 20 ± 2g of the prepared sample.

- The sample is opened for one minute using the carding mechanism.

- Insert the opened sample into a measuring beaker and down (4 cm) down to the end to be filled uniformly.

- Set the electronic balance to 0 "after placing the pressure plate on top of the container.

- Record the weight of the balance as it descends in 1 cm steps from the first 10 cm to the 4 cm.

- Go back to 10 cm and record the weight.

(Graduation speed 2 sec / cm)

I. Bulkite

- Initial bulky: Bulk properties of fibers, value at 10 cm compression

- Compression Bulk: Resistance of fiber (Compression 10 ~ 5 cm value + 4 cm value) / 2

- Recovery Bulk: elastic recovery properties of fiber (recovery 10 ~ 5 cm value + 4 cm value) / 2

* Hollow rate

The hollow ratio of the fibers was calculated as the ratio of the area occupied by the hollow to the total area of the fibers. The hollow fiber with the volume control was measured as the ratio of the area occupied by the hollow relative to the area of the contact with the pinion.

The measurement results are shown in Table 1 below.

Manufacturing example Comparative Manufacturing Example One 2 3 One 2 3 Unit shape 4
The volume controller
Hollow 6
The volume controller
Hollow 12
The volume controller
Hollow circle Circular hollow Circular hollow Hollowness (%) 19 21 18 - 22 6 Bulky Early 390 380 20 47 280 compression 11050 11900 11000 6500 8800 9000 recovery 4600 4900 4800 2500 3400 3900

As shown in Table 1, the fibers according to Production Examples 1 to 3 were tested to have excellent glue property due to the interference effect of the volume control portion. In addition, in the fibrous aggregates, the fibers according to Production Examples 1 to 3 were found to have improved bulky properties while ensuring a space while the volume control interferes with the volume control portion of the adjacent fibers as shown in FIG.

Example  One

75 weight parts of the cross-section hollow fiber prepared in Preparation Example 2 and 25 weight parts of binding agent were mixed to prepare a nonwoven fabric layer.

The resultant nonwoven fabric layer was laminated on one side of the polyester foamed layer to produce a vehicle interior and exterior material.

Example  2

40 weight parts of the cross-section hollow fiber prepared in Production Example 1 and 60 weight parts of the cemented polypropylene fiber were mixed to prepare a nonwoven fabric layer.

The produced nonwoven fabric layer was laminated on both sides of the polyester foamed layer to prepare a vehicle interior and exterior material.

Example  3

75 weight parts of the cross-section hollow fiber prepared in Preparation Example 2 and 25 weight parts of binding agent were mixed to prepare a nonwoven fabric layer.

A polyester film and a nonwoven fabric layer prepared above were sequentially laminated on one side of the polyester foamed layer to prepare a vehicle interior and exterior material.

Example  4

75 weight parts of the cross-section hollow fiber prepared in Preparation Example 2 and 25 weight parts of binding agent were mixed to prepare a nonwoven fabric layer.

The polyester film and the nonwoven fabric layer prepared above were sequentially laminated on both sides of the polyester foam layer to prepare a vehicle interior and exterior material.

Comparative Example  One

75 weight parts of the cross-section hollow fiber prepared in Preparation Example 2 and 25 weight parts of binding agent were mixed to prepare a nonwoven fabric layer. A separate polyester foam layer was not laminated.

Comparative Example  2

A polyester foam layer was formed singly, and a separate nonwoven fabric layer was not laminated.

Experimental Example  2

* Sound absorption measurement method: The absorption coefficient of 0 ~ 10,000 Hz was measured using KS F 2805 reverberation method and NRC (noise reduction coefficient) was calculated. NRC is the average value of sound absorption rate at 250, 500, 1,000 and 2,000 Hz.

* Method of measuring car sound: Determine the transmission loss value of frequency 1 ~ 8,000 Hz by using Apamat measuring equipment according to KS F 2862. For comparison, the transmission loss values of 8,000 Hz were compared.

The measurement results are shown in Table 2 below.

division Example 1 Example 2 Comparative Example 1 Comparative Example 2 Condition Nonwoven fabric layer The hollow fiber content (parts by weight) 75 40 75 - Content of binding agent (parts by weight) 25 60
(PP fiber) 25 - thickness 5 5 15 - PET foaming foam (mm) 10 10 - 15 Properties Sound absorption NRC 0.5 0.4 0.32 0.16 Car voice dB 33 29 5 22

Referring to the results of Table 2, it can be seen that the automotive interior and exterior materials of Examples 1 and 2 are excellent in both sound and sound. In the case of Comparative Example 1 in which only the nonwoven fabric layer was formed, it was confirmed that the difference in soundness was remarkably lowered, and in the case of forming only the foamed layer, the sound absorption property was remarkably lowered.

Though not shown in Table 2 above, in Examples 3 and 4, it was confirmed that sound absorption and sound insulation performance were further improved by placing a polyester film.

Experimental Example  3

Tensile strength, bending strength and heat resistance of the vehicle interior and exterior materials manufactured in Examples 1 to 4 were measured. The measurement method is described below, and the results are shown in Table 3 below.

1) Tensile strength measurement

Flexural strength was measured under ASTM D 638 conditions.

2) Measurement of flexural strength

Flexural strength was measured under ASTM D 638 conditions.

3) Heat resistance

Flame retardancy was measured under KS F ISO 4724 conditions.

Tensile Strength (MPa) Flexural Strength (N) Heat resistance (grade) Example 1 45 59 2 Example 2 49 62 One Example 3 55 65 2 Example 4 61 67 2

Referring to Table 3, it can be seen that the vehicle interior and exterior materials according to the present invention have excellent tensile strength, bending strength and heat resistance.

10: Cross-section hollow fiber
M: Center point
100: hollow part
200: Shape retaining portion
300:
310: Peak
330: Valley
400: foam layer
510, 520: Nonwoven fabric layer
610, 620: Adhesive film

Claims (12)

A foam layer containing a polyester resin foam; And
A nonwoven fabric layer is formed on at least one surface of the foam layer,
The nonwoven fabric layer is formed of an aggregate of modified hollow fibers,
Wherein the modified hollow fiber has a hollow portion, a shape retaining portion, and a volume control portion,
The volume control part may be protruded in a direction opposite to the center of the fiber, the protruding end part may be formed in a round shape,
(3) and (4) below when the uppermost portion of the distal end portion, which is a protruding form of the volume control portion, is defined as a peak and the protruded form of the volume control portion is defined as a valley In addition,
The sound absorption rate measured according to KS F 2805 is 0.4 NRC or more,
Car interior and exterior materials measured according to KS F 2080: 20 dB or more at 1,000 Hz, 25 dB or more at 2,000 Hz, and 40 dB or more at 5000 Hz:
(3)

≥ 0.80
(4)

≥ 0.30
here,
T1 is the largest distance from the center point M to the peak 310,
T2 is the smallest distance from the center point M to the peak 310,
t1 is the largest distance from the center point M to the valley 330,
t2 is the smallest distance from the center point M to the valley 330,
CTmax is a circle formed by connecting the tangent of the volume controller 300 having the T1 and the tangent of the volume controller 300 having the next highest order distance from the center point M to the peak 310,
CTmin is a circle formed by connecting the tangent of the volume controller 300 having the T2 and the tangent of the volume controller 300 having the distance from the center point M to the peak 310 having the next lower order value,
Ctmax is a circle formed by connecting the tangent of the volume control unit 300 having t1 and the tangent of the volume control unit 300 having a distance from the center point M to the valley 330 with a next higher order value,
Ctmin is a circle formed by connecting the tangent of the volume control unit 300 having t2 and the tangent of the volume control unit 300 having the distance from the center point M to the valley 330 with a smaller value of the next order,
CTmax-R represents the difference value between the center point (CTmaxM) and the center point (M) of CTmax,
CTmin-R represents the difference value between the center point CTminM of the CTmin and the center point M,
Ctmax-r represents a difference value between a center point (CtmaxM) and a center point (M) of Ctmax,
Ctmin-r represents a difference value between the center point (CtminM) and the center point (M) of Ctmin.
The method according to claim 1,
Wherein the foam layer satisfies the following formula (1): " (1) "
[Equation 1]
X / Y ≥ 1.5
X represents the flexural strength (N / cm ² ) of the resin foam layer according to KS M ISO 844, and Y represents the density (kg / m ³ ) of the resin foam layer according to KS M ISO 845.
delete The method according to claim 1,
Heat resistance is grade 3 or higher based on KS F ISO 5660-1.
The method according to claim 1,
Leaving it at a temperature of 90 ± 1 ° C for 24 hours; And a step of allowing to stand for 24 hours under a temperature condition of 50 占 占 폚 and a relative humidity of 90%, and then satisfying the following formula (2): " (2) "
&Quot; (2) "
| V ₁ -V ₀ | / V ₀ x 100? 5%
In Equation (2)
V ₀ is the volume (mm ³ ) of the interior and exterior materials of the vehicle before exposure to the harsh conditions,
V ₁ is the volume (mm ³ ) of the vehicle interior and exterior material after exposure to the harsh conditions.
The method according to claim 1,
And the mass per unit area is 500 to 2000 g / m < ² >.
delete delete The method according to claim 1,
Wherein the modified hollow fiber has an average of 4 to 12 volume control parts on the basis of the cross section of the fiber.
The method according to claim 1,
Wherein the modified hollow fiber has an average hollow ratio of 15 to 30% based on the cross-sectional area of the hollow fiber.
The method according to claim 1,
And an adhesive film formed between the foamed layer and the nonwoven fabric layer.
The method according to claim 1,
Interior and exterior interior parts for automobiles are engine room covers.

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