KR101759062B1 - Interior furnishings of vehicle having excellent light weight property - Google Patents

Abstract

The present invention relates to a vehicle interior material having excellent lightweight properties, and a vehicle interior material having a nonwoven fabric formed on at least one surface thereof according to the present invention has excellent bending strength, light weight, light resistance and moldability, It is possible to prevent deterioration of performance and to realize fuel efficiency reduction, and by using polyester materials in all the constitutions, it can be easily recycled.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to an interior light-

The present invention relates to a vehicle interior material excellent in light weight.

The automotive interiors require favorable properties such as light weight, cushioning, heat insulation, moldability, high strength and energy saving, and mainly used low melting fiber (LMF) as an automobile interior material. The LMF is an adhesive material that melts at a temperature of 100 to 200 ° C lower than that of ordinary polyester fibers melting at 265 ° C or higher. It is an eco-friendly material that does not require a chemical adhesive and has advantages of easy construction, but it is weak in strength, There were disadvantages. As a result, when used as a headliner of an automobile, there is a disadvantage that it is stuck downward when used for a long time.

To comply with this, Korean Patent Laid-Open Publication No. 2013-0120567 discloses a laminate for automobile interior material comprising a base layer made of a thermoplastic resin, a flexible polyurethane foam layer, and an outer layer made of a nonwoven fabric. However, when a flexible polyurethane foam layer is used, the thickness thereof increases to meet the required properties of the automobile interior material, and since a large amount of the adhesive is used for compositing the other components in the manufacturing process, the amount of VOC increases, There are disadvantages.

Korea Patent Publication No. 2013-0120567

The present invention relates to a vehicle interior material having excellent lightweight properties, and an object of the present invention is to provide an environmentally friendly automotive interior material that is lightweight and satisfies physical properties such as excellent bending strength, light resistance and dimensional change ratio, and is recyclable.

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

A resin foam layer; And

And a nonwoven fabric layer formed on at least one side of the resin foam layer,

It is possible to provide a vehicle interior material having a mass per unit area of 500 to 1100 g / m ² .

The vehicle interior material having the nonwoven fabric formed on at least one surface thereof according to the present invention has excellent lightweight property, bending strength, light resistance and moldability, so that it can be used as an automobile interior material to prevent deterioration in performance due to long-term use, By using a polyester-based material as the constitution, it can be easily recycled.

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.

In the present invention, the term "cell" means a microstructure expanded by foaming in a polymer.

Hereinafter, the present invention will be described in detail.

The present invention relates to a vehicle interior material having excellent lightweight properties. As one example of the interior material for a vehicle,

A resin foam layer; And

And a nonwoven fabric layer formed on at least one side of the resin foam layer,

It is possible to provide a vehicle interior material having a mass per unit area of 500 to 1100 g / m ² .

The mass per unit area of the automotive interior material may range from 500 to 1100 g / m < ² >. For example, the mass per unit area of the vehicle interior can be 550 to 1000 g / m ² , 600 to 1000 1100 g / m ^2, or 800 to 900 1100 g / m ² . By satisfying the mass per unit area in the above range, it was confirmed that the vehicle interior material according to the present invention is lightweight.

The resin foam layer may be at least 90% of the closed cells (DIN ISO4590). This means that the measured value of the resin foam layer in accordance with DIN ISO 4590 is that at least 90% (v / v) of the cells are closed cells. For example, the ratio of the closed cells in the resin foam layer may be 90 to 100% or 95 to 99% on average. By controlling the ratio of the closed cell to the above range, it is possible to increase the heat insulating property and the like. Accordingly, the automotive interior material can be widely used in the construction industry for insulation of a part of the building, for example, the foundation, the wall, the floor and / or the roof. For example, the resin foam layer included in the vehicle interior material may include 1 to 30 cells, 3 to 25 cells, or 3 to 20 cells per mm ² .

In addition, the average size of the cells may be in the range of 100 to 800 mu m. For example, the average size of the cells may range from 100 to 700 mu m, 200 to 600 mu m, or 300 to 600 mu m. At this time, the deviation of the cell size may be in a range of, for example, 5% or less, 0.1 to 5%, 0.1 to 4% to 0.1 to 3%. Thus, it can be seen that the cells of uniform size are uniformly foamed in the resin foam layer according to the present invention.

The method for producing the resin foam layer is not particularly limited, but for example, the resin foam layer may be an interior material for an extruded vehicle. 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.

The flexural strength (N) according to ASTM D 790 of the automotive interior material may be 30 to 350 N. [ The flexural strength may range, for example, from 40 to 300 N, from 60 to 200 N, from 90 to 110 N, and from 90 to 100 N. [ By satisfying the flexural strength in the above range, when used as an automobile interior material, it can be more secure against external impact due to high strength, and can be easily molded.

The density of the resin foam layer may be 20 to 230 kg / m < ³ >. For example, the density may range from 25 to 200 kg / m ³ , from 30 to 150 kg / m ³ , from 40 to 75 kg / m ³ , from 50 to 75 kg / m ³ or from 55 to 65 kg / m ³ . The automotive interior material according to the present invention includes a resin foam layer that satisfies the density within the above range, whereby a high density and high strength automotive interior material can be manufactured by controlling the expansion ratio.

According to the accelerated light resistance test (ultraviolet carbon arc light resistance light resistance test) of KS R 0021, the above vehicle interior material had a color difference change ratio of less than 3% before and after irradiation of light having a wavelength of 300 to 400 nm at an irradiation dose of 126 MJ, % ≪ / RTI >

For example, the chrominance change rate and the gray color change rate may be in the range of 0.1 to 3%, 0.1 to 1.5%, or 0.1 to 1%, respectively. By satisfying the above range, it can be seen that the automotive interior material according to the present invention is excellent in light resistance against external light and can prevent a change in physical properties due to long-term use.

Leaving the automotive interior material in a temperature condition of 90 ± 1 ° C for 24 hours; And a step of allowing to stand for 24 hours at a temperature of 50 ± 1 ° C and a relative humidity of 90%, the following equation (1) can be satisfied.

[Equation 1]

| V ₁ -V ₀ | / V ₀ x 100? 5%

In the above equation (1)

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

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

Specifically, the dimensional change rate of the manufactured automotive interior 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 material to the vehicle. For example, the volume may mean a value calculated by multiplying the length of the vehicle interior material by the length of each of the width and thickness. For example, the rate of dimensional change of the formula (1) 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 (1) in the above range, it can be seen that the shape of the automotive interior material according to the present invention does not change even in long-term use in an environment of severe temperature change.

At this time, when the above formula (1) is more than 5%, it may mean that peeling, parts, sagging, discoloration or deformation easily occur in the automotive interior material.

The thermal conductivity of the automotive interior material may be 0.04 W / mK or less. For example, the thermal conductivity of the vehicle interior can range from 0.01 to 0.04 W / mK, from 0.01 to 0.035 W / mK, or from 0.02 to 0.035 W / mK. The automotive interior material according to the present invention has a thermal conductivity within the above range, so that excellent heat insulation can be realized.

In the automotive interior material,

The average thickness of the resin foam layer is 1 to 30 mm,

The average thickness of the nonwoven layer may be 0.1 to 10 mm.

For example, the thickness of the resin foam layer may range from 1.5 to 30 mm, 5 to 30 mm, 5 to 20 mm, or 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. As a result, the automotive interior material according to the present invention can achieve properties such as excellent bending strength, long-term numerical strain, light resistance and / or heat insulation property in spite of a relatively thin thickness. In addition, it is possible to reduce the weight of the automotive interior material, so that when used as an automobile interior material, excellent fuel economy can be realized.

As an example of the structure of the automotive interior material,

Resin foams;

An adhesive film formed on both sides of the resin foam; And

And a nonwoven fabric layer formed on a side opposite to the side where the resin foam of each adhesive film is formed.

This is a structure in which an adhesive film and a nonwoven fabric layer are sequentially laminated on both sides of a resin foam, and the nonwoven fabric layer is formed on both sides of the resin foam together with excellent flexural strength, sound and light weight of the resin foam, Durability can be realized.

As another example of the structure of the automotive interior material,

Resin foams;

An adhesive film formed on one side of the resin foam; And

And a nonwoven fabric layer formed on the opposite side of the surface of the adhesive film on which the resin foam is formed.

This is a structure in which an adhesive film and a nonwoven fabric layer are sequentially laminated on one surface of a resin foam, and the nonwoven fabric layer is formed on one surface of the resin foam together with excellent flexural strength, sound and light weight of the resin foam, It is possible to manufacture a vehicle interior material with a thin thickness.

In the automotive interior material,

And an adhesive film formed between the resin foam layer and the nonwoven fabric layer.

Specifically, by further including an adhesive film formed between the resin foam layer and the nonwoven fabric layer, the adhesive force between the resin foam layer and the nonwoven fabric layer can be improved and the interlayer peeling can be prevented more effectively.

The automotive interior material may be such that the foam layer includes a foam of a polyester resin,

The nonwoven fabric layer comprises a polyester fiber,

The adhesive film may include a polyester-based adhesive resin.

For example, the polyester resin contained in the resin foam layer can be produced 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 layer according to the present invention may be a PET (polyethylene terephthalate) foam.

The polyester fiber contained in the nonwoven fabric layer may be a fiber produced using one or more of the above-described polyester resins.

The polyester-based adhesive resin included in the adhesive film may be a hard segment which is an esterification reaction product of diol and dicarbonic acid; And a polyester-based elastic adhesive resin which is an axial polymer of a soft segment which is a polyol.

Specifically, in the vehicle interior material, the resin foam layer, the nonwoven fabric layer, and the adhesive film may all include a polyester resin. As described above, by using a polyester resin for all the constitutions of the automotive interior material, it can be utilized for the entire industry and easily recycled after use.

The automotive interior material according to the present invention may form a functional additive layer on at least one surface of the resin foam layer. Thus, the desired functionality can be effectively imparted without decreasing the physical properties of the foam, and the process efficiency and degree of freedom can be increased.

The functional additive layer may have an adiabatic function, a flame retardant function, a VOC abatement function, a hydrophilization function, a waterproof function, an antibacterial function, a deodorizing function and / or an ultraviolet ray blocking function. Specifically, the functional coating layer can be formed by coating a functional additive on the resin foam layer, and any additive capable of realizing the above function is not particularly limited. Specifically, 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 kind of the antibacterial agent is, for example, a composite obtained by adding at least one metal selected from the group consisting of silver, zinc, copper and iron to at least one carrier selected from the group consisting of hydroxyapatite, alumina, silica, titania, zeolite, zirconium phosphate and aluminum polyphosphate . ≪ / RTI >

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 resin foam may have a flame retardancy of 3 or more 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 the case of class 3, by having flame retardant or non-flammable characteristics, it can be relatively safe in the event of a fire.

As a result, the automotive interior material according to the present invention can be used without limitation where it requires excellent bending strength, light weight, dimensional change rate, light resistance, cushioning, heat insulation and moldability. Specifically, the automotive interior material may be used as a headliner of a vehicle. The headliner of the vehicle is installed on the upper surface of the vehicle and requires excellent bending strength, light resistance and dimensional change ratio. Therefore, by using the automotive interior material according to the present invention, the above characteristics can be satisfied. In addition, the automotive interior material according to the present invention is lightweight and is effective in reducing fuel consumption of the automobile.

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.

Example  1 to 3

100 parts by weight of the PET resin was dried at 130 DEG C to remove moisture. In the first extruder, 1 part by weight of the water-removed PET resin and pyromellitic dianhydride (PMDA), 1 part by weight of talc and 1 part by weight of Irganox IRG 1010) were mixed and heated to 280 DEG C to prepare a resin melt.

Then, 5 parts by weight of carbon dioxide gas as a foaming agent was added to the first extruder based on 100 parts by weight of the PET resin, and extrusion foaming was performed to form a resin foam layer having a thickness of 5 mm.

Then, a polyester-based adhesive resin was applied to both surfaces of the resin foam layer, and then a PET nonwoven fabric having a thickness of 1.5 mm was adhered to each other to manufacture a vehicle interior material.

At this time, the total thickness of the automotive interior material was 8 mm, and the mass per unit area was adjusted as shown in Table 1 by controlling the amount of foaming agent during foaming.

Mass per unit area (g / m ² ) Example 1 600 Example 2 800 Example 3 1000

Comparative Example  One

A vehicle interior material was fabricated using low melting fiber (LMF). At this time, the thickness of the automotive interior material manufactured in the comparative example was 8 mm, and the mass per unit area was confirmed to be 1200 g / m ² .

Comparative Example  2

The urethane adhesive was applied to both sides of the polyurethane foam, and then the PET nonwoven fabric was adhered to the interior of the vehicle. At this time, the thickness was 8 mm and the mass per unit area was found to be 800 g / m ² .

Experimental Example  1: Measurement of physical properties

The automotive interior materials prepared in Examples 1 to 3 and Comparative Examples 1 and 2 were measured for combustibility, heat resistance and light resistance. The measurement method is described below, and the results are shown in Table 2 below.

1) Measurement of flexural strength

Flexural strength was measured under ASTM D 638 conditions.

2) Flammability measurement

The flammability was measured under KS M ISO 9772 conditions.

3) Light resistance measurement

The gray color change ratio was measured according to the accelerated light resistance test method of KS R 0021.

Flexural strength
(N / cm ² ) combustibility
(mm / min) Gray color change rate
(%) Example 1 32 25 One Example 2 45 18 0.7 Example 3 58 15 0.5 Comparative Example 1 15 50 3.5 Comparative Example 2 20 120 4

Referring to Table 2, it was confirmed that the automotive interior material according to the present invention had excellent flame and light resistance, and had excellent flexural strength as compared with Comparative Example.

Experimental Example  2: Measuring rate of dimensional change

In the above Examples 1 to 3 and Comparative Examples 1 and 2, experiments for measuring the dimensional change rate were carried out on the interior material for automobiles. Specifically, the step of leaving each of the manufactured vehicle interior materials at a temperature of 90 ± 1 ° C for 24 hours; And a step of allowing to stand for 24 hours at a temperature of 50 ± 1 ° C and a relative humidity of 90%, and then the dimensional change ratio was measured by the following equation (1).

[Equation 1]

| V ₁ -V ₀ | / V ₀ x 100

In the above equation (1)

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

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

Dimensional change ratio (%) Example 1 0.5 Example 2 0.3 Example 3 0.2 Comparative Example 1 6.6 Comparative Example 2 8.4

Referring to Table 3, it can be seen that the automotive interior material according to the present invention exhibits a remarkably low dimensional change ratio as compared with the comparative example. Thus, it can be seen that the automotive interior material according to the present invention has excellent durability.

Experimental Example  3: Sound absorption and Sound insulation  Performance measurement

In the above Examples 1 to 3 and Comparative Examples 1 and 2, the sound absorption coefficient and the differential tone were measured for the interior material for a vehicle. The measurement method is described below, and the results are shown in Table 4 below.

1) Sound absorption rate measurement

The absorption coefficient of 0 ~ 10,000 Hz was measured using the 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.

2)

The permeation loss values of frequencies 1 to 8,000 Hz were determined using an Apamat measuring instrument according to KS F 2862. For comparison, the transmission loss values of 8,000 Hz were compared.

Absorption rate
(NRC) Car tone
(dB) Example 1 0.4 10 Example 2 0.4 15 Example 3 0.4 20 Comparative Example 1 0.6 5 Comparative Example 2 0.4 8

Referring to Table 4, it can be seen that the interior trim according to the present invention has a difference in tone of 10 to 20 dB, which is significantly superior to the comparative example.

Experimental Example  4: Measurement of cell characteristics

For the automotive interior materials manufactured in Examples 1 to 3, variations in cell size and cell size were measured. Specifically, the cell size was measured by SEM photographing of the interior material of the vehicle, and the deviation of the cell size within 2 mm and 2 mm was measured. The results are shown in Table 5 below.

Cell Size (탆) Cell size deviation (%) Example 1 300 Less than 5% Example 2 300 Less than 5% Example 3 300 Less than 5%

Referring to Table 5, it can be seen that the foamed molded article according to the present invention has a cell size of 300 μm and a cell size variation of 5% or less, and is very uniformly foamed.

Claims (11)

A polyester resin foam layer; And
And a polyester fiber nonwoven fabric layer formed on at least one side of the polyester resin foam layer,
A mass per unit area of 500 to 1100 g / m ² ,
The flammability measured in the KS M ISO 9772 condition is in the range of 15 to 25 mm / min,
According to the accelerated light resistance test of KS R 0021, the color difference change ratio before and after irradiation of light having a wavelength of 300 to 400 nm at an irradiation dose of 126 MJ was less than 3%, the gray color change ratio was less than 3%
Leaving it at a temperature of 90 ± 1 ° C for 24 hours; And a step of allowing to stand for 24 hours at a temperature condition of 50 占 占 폚 and a relative humidity of 90%, and then satisfying the following formula (1): " (1) "
[Equation 1]
| V ₁ -V ₀ | / V ₀ x 100? 5%
In the above equation (1)
V ₀ is the volume (mm ³ ) of the vehicle interior before exposure to the harsh conditions,
V ₁ is the volume (mm ³ ) of the vehicle interior after exposure to the harsh conditions.
The method according to claim 1,
Wherein the polyester resin foam layer is a closed cell (DIN ISO4590) of at least 90% of the cells.
The method according to claim 1,
The sound absorption rate measured according to KS F 2805 is 0.4 NRC or more,
Car interior material having a transmission loss value of 10 dB or more as measured in accordance with KS F 2862.
delete delete The method according to claim 1,
The polyester resin foam layer has an average thickness of 1 to 30 mm,
Wherein the polyester fiber nonwoven fabric layer has an average thickness of 0.1 to 10 mm.
The method according to claim 1,
And an adhesive film formed between the polyester resin foam layer and the polyester fiber nonwoven fabric layer.
8. The method of claim 7,
A polyester resin foam layer;
An adhesive film formed on both sides of the polyester resin foam layer; And
And a polyester fiber nonwoven fabric layer formed on the opposite side of the surface of the respective adhesive films on which the polyester resin foam layer is formed.
8. The method of claim 7,
A polyester resin foam layer;
An adhesive film formed on one side of the polyester resin foam layer; And
And a polyester fiber nonwoven fabric layer formed on the opposite side of the surface of the adhesive film on which the polyester resin foam layer is formed.
8. The method of claim 7,
The adhesive film includes a polyester-based adhesive resin.
The method according to claim 1,
A vehicle interior material characterized by being used as a headliner for a vehicle.