KR101885366B1 - Article for car - Google Patents

Abstract

A thermoplastic polyester elastomer having a melting point of 150 to 155 DEG C and an intrinsic viscosity of 1.0 to 2.0 as a fiber component according to the present invention and a polyester having a melting point of 255 to 265 DEG C and an intrinsic viscosity of 0.45 to 0.80 (PTMG), 1,4-butanediol (1,4-butanediol), 1,4-butanediol (1,4-butanediol) and 1,4-butanediol -BD), ethylene glycol (EG), or a mixture thereof, wherein the composite fiber comprises a thermally adhesive composite fiber formed by polymerizing a diol component selected from the group consisting of ethylene glycol (EG) And more than 50% relative to each other is arranged in a relatively vertical manner.

Description

Automotive Interior Materials {Article for car}

TECHNICAL FIELD The present invention relates to an automotive interior material, and more particularly, to an automotive interior material that is environmentally friendly and excellent in elasticity and shape stability without using a polyurethane foam.

Nonwoven fabrics are widely used as a kind of fiber structure. Non-woven fabrics refer to fabrics made by mechanical bonding or by bonding or tangling fibers using thermal bonding or chemical agents. A felt, a nonwoven fabric, a needle punch, a spun bond, a spun lace, an embossed film, and a wet (nonwoven) nonwoven fabric. The term " nonwoven fabric " refers to a nonwoven fabric using polyester staple fibers as a material replacing urethane. The term " nonwoven fabric " It is used for a wide range of applications such as soundproofing materials, insulation materials and filters, and the use thereof is gradually expanding. However, the development of nonwoven fabrics having high physical properties such as shape stability, elastic recovery rate and compression rebound characteristics including durability is more demanded due to expansion of applications.

For example, although polyurethane foam and polyethylene foam are conventionally used as cushioning materials, these materials need to be separated from the skin material and cushioning material in order to be used as a different material from the skin material, but this is practically impossible. Also, in the case of a polyurethane foam which is most widely used as a cushioning material for an automobile interior, there is a problem that a certain period of time has elapsed or is gradually decomposed and broken when exposed to direct sunlight for a long time. Even when used as an automobile interior material, it absorbs a certain amount of moisture inside the automobile, and when the internal temperature of the automobile rises, it emits moisture, which causes the glass surface of the automobile interior to be frozen, which causes the operation to be interrupted. Further, in the case of polyurethane, a portion having a low density is pressed against a mold due to a partial density difference of a foam foamed during molding, and a defect that a portion having a low density is depressed often occurs.

In order to solve these problems, development of a nonwoven cushioning material has been progressing in recent years in Europe. However, when a nonwoven fabric having a single-layer structure is adhered to a skin material or a barrier layer and a cushion layer are separately prepared and adhered to each other as a cushioning material In this case, however, there is a problem that the weight of the nonwoven fabric is high and the manufacturing cost is high, and the cushioning property is relatively low as compared with the conventional polyurethane foam and polyethylene foam.

On the other hand, known nonwoven fabrics include filters, wicks, shoulder pads, furniture packing materials such as backrests and cushions for sofas and chairs, nonwoven fabrics obtained by point bonding of fibers, Is used. Particularly, in the production of a fiber structure used for a padding used in a mattress, an automobile interior or a vinyl house, hot-melt type binder fibers adhering to heat for mutual adhesion have been widely used. For example, U.S. Patent No. 3,589,956 discloses a method for producing a fiber capable of morphologically and stably producing a low-density nonwoven fabric and a cis-core composite yarn prepared from the method. However, And the problem that the adhesive strength is lowered is still not solved. Japanese Unexamined Patent Application, First Publication No. 10-298271 discloses that adipic acid is used instead of terephthalic acid in the polymerization process and 1,4-butanediol is used as a diol component instead of ethylene glycol in order to improve the crystallinity and heat resistance. -Butanediol (BD) was used to increase the adhesiveness, and the strength of the fiber was not lowered even in a high-temperature atmosphere, but the copolymerized polyester fiber produced by the above-mentioned production method also had a low glass transition temperature , It is pointed out that it is necessary to control various process temperatures when used in a high temperature condition in summer.

As another example, as the binder fiber which has conventionally been used mainly, polyethylene terephthalate / isophthalate copolymer polyester is used as a binder component. This polyester has high rigidity and is an amorphous polymer and does not exhibit a definite crystalline melting point, and softening is started when the glass transition point (about 65 to 70 ° C) or more is reached. The nonwoven fabric which is heat-welded using both the fibers and the binder fibers, which are the main bodies of such known materials, lacks softness of touch and is hard to feel. Further, when subjected to repeated compression or bending, the bonding point is destroyed and permanently deformed, and when used under a high-temperature atmosphere, the bonding strength is lowered and deformed. It is known that polyurethane foam is mainly used as a packing material for furniture such as a backrest or a cushion of a sofa or a chair, and a cushioning material for a mat or a car seat. However, polyurethane foams are problematic in terms of safety and environmental protection, such as the generation of toxic nitrogen-containing gas during combustion, or the flon gas used in manufacturing destroys the ozone layer in the upper atmosphere have. Therefore, it is conceivable to use a nonwoven fabric mainly composed of polyester fibers as a material to replace the polyurethane foam. As a known technique relating to this point, there are knee ring processed wafers of polyester fibers, and those obtained by fusion processing using binder fibers (for example, Japanese Patent Application Laid-open No. 57-35047) And a polyester elastomer is used as in the case of a nonwoven fabric (for example, Japanese Patent Application Laid-Open No. 4-240219). However, in the known polyester nonwoven fabrics, a part of the fibers is liable to fall off or scatter when the polyester fiber woven is subjected to needle ring processing. In order to prevent these drawbacks, the heat-fusion process using the binder fibers in combination also lacks softness of the feel, resulting in a hard feeling. Both of them are liable to be permanently deformed repeatedly under compression or in a high-temperature atmosphere, and cushioning is deteriorated with the lapse of time in use. For the purpose of solving the drawbacks of known binder fibers, there has been developed use of the above polyester elastomer as a binder component. The polyester elastomer disclosed in Japanese Patent Laid-Open No. 4-240219 is a poly Dioxane, styrene oxide, styrene oxide, styrene oxide, styrene oxide, styrene oxide, styrene oxide, and styrene oxide).

Korean Patent No. 553957 discloses an automobile interior material which can be used as a cushioning material by adhering to the back of a skin material such as a headliner, a door trim and a seat, and a manufacturing method thereof Specifically, in a method of manufacturing a nonwoven cushioning material adhering between a skin material of an automobile interior material and a base material, two cards are used to supply fibers different from each other to make the fibers into a web state, A nonwoven fabric having a thick thickness made of fiber of the same weight by mixing and supplying 10% by weight to 50% by weight of a hollow fiber having an empty central portion of the fiber cross-section in comparison with a nonwoven fabric using 100% In one card machine, a binary cross-section yarn composed of a general polyester and a low-melting-point polyester is prepared at 10% by weight to 50% by weight, A method for fabricating a nonwoven fabric, comprising the steps of: bonding two fiber layers having different performances produced by different carding machines to one another; modifying the nonwoven fabric mixed with 10 wt% to 50 wt% of the two- A method for manufacturing an automobile interior material comprising the step of heat-treating the automobile interior material is disclosed.

However, in the case of a low-melting-point polyester, the nonwoven fabric itself is stiff when the nonwoven fabric is thermoformed, which causes a problem in that a sound absorption and a cushion function are manifested.

In order to solve the above problems, an object of the present invention is to provide a non-polyurethane automotive interior material having shape stability while maintaining a sound absorption or cushion function.

A thermoplastic polyester elastomer having a melting point of 150 to 155 DEG C and an intrinsic viscosity of 1.0 to 2.0 as a fiber component according to the present invention and a polyester having a melting point of 255 to 265 DEG C and an intrinsic viscosity of 0.45 to 0.80 (PTMG), 1,4-butanediol (1,4-butanediol), 1,4-butanediol (1,4-butanediol) and 1,4-butanediol -BD), ethylene glycol (EG), or a mixture thereof, wherein the composite fiber comprises a thermally adhesive composite fiber formed by polymerizing a diol component selected from the group consisting of ethylene glycol (EG) And more than 50% relative to each other is arranged in a relatively vertical manner.

The present invention also provides an automotive interior material characterized in that the thermoplastic polyester-based elastomer has an elastic recovery rate within a range of 85 to 100%.

The present invention also relates to a thermoplastic polyester elastomer wherein the acid component of the thermoplastic polyester elastomer is a mixture of 70 to 80 mol% terephthalic acid and 20 to 30 mol% isophthalic acid, the diol component is 80-95 mol% 1,4-butanediol, And 20 mol% of a poly (tetramethylene ether) glycol.

The present invention also provides an automotive interior material characterized in that the composite fiber is a circular eccentric side-by-side type heat-adhesive composite fiber.

Further, the present invention provides an automotive interior material characterized in that the composite fiber is an eccentric side-by-side type heat-adhesive composite fiber of a hollow hollow.

An automotive interior material and a method for manufacturing the same according to an embodiment of the present invention are non-polyurethane based, and are environmentally friendly, and are excellent in sound absorption, cushioning, and shape stability.

In addition, there is an advantage that the fairness is improved in that the fiber itself has elasticity and weldability without using only a low melting point.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a photograph of a cross section of a circular eccentric side-by-side type thermally adhesive composite fiber which can be used in an interior material according to an embodiment of the present invention;
FIG. 2 is a photograph of a cross-section of an eccentric side-by-side type thermo-adhesive conjugate fiber of a release hollow that can be used in an interior material according to an embodiment of the present invention.
FIGS. 3 and 4 are photographs of the state where the composite fibers of FIGS. 1 and 2 are bonded together by heating and pressing. FIG.

Hereinafter, a preferred embodiment of the present invention will be described in detail. In the following description of the present invention, a detailed description of known functions and configurations incorporated herein will be omitted so as to avoid obscuring the subject matter of the present invention.

The terms " about ", " substantially ", etc. used to the extent that they are used herein are intended to be taken to mean an approximation of, or approximation to, the numerical values of manufacturing and material tolerances inherent in the meanings mentioned, Accurate or absolute numbers are used to help prevent unauthorized exploitation by unauthorized intruders of the referenced disclosure.

The automotive interior material according to an embodiment of the present invention may include a thermally adhesive composite fiber.

The thermosetting conjugate fiber has a thermoplastic polyester elastomer having a melting point of 150 to 155 占 폚 and an intrinsic viscosity of 1.0 to 2.0 as a fiber component and a polyester having a melting point of 255 to 265 占 폚 and an intrinsic viscosity of 0.45 to 0.80 Wherein the thermoplastic polyester elastomer comprises an acid component selected from the group consisting of terephthalic acid (TPA), isophthalic acid (IPA), and mixtures thereof, poly (tetramethylene ether) glycol (PTMG), 1,4- (1,4-BD), ethylene glycol (EG), or a mixture thereof, and is therefore characterized in that it has heat-sealability by heating and pressure and has a high elastic recovery rate . The thermosetting conjugate fiber according to the present invention can be particularly useful in the production of nonwoven fabrics and the like.

The fiber components constituting the thermosetting conjugate fiber according to the present invention are mainly composed of a mixture of a thermoplastic polyester elastomer and a polyester and have a fiber cross-sectional shape and a difference in intrinsic viscosity of the polymer, The latent crimp development in which the crimp is formed leads to the structural elasticity in the staple fiber state and the chemical structural elasticity and the elastic recovery rate due to the hard segment and the soft segment structure of the thermoplastic polyester elastomer. Here, in the case of the conjugate fiber, the crimp developability due to the cross-sectional shape may be different, and in general, the crimp expression is better in the order of the sheath-core structure and the eccentric side-by-side structure.

The thermoplastic polyester-based elastomer may have a melting point of 150 to 155 캜 and an intrinsic viscosity of 1.0 to 2.0. Such an elastomer has a function of imparting elasticity to the resultant conjugate fiber and a function of adhering to be adhered to adjacent conjugate fibers by a heating and pressing process.

The polyester may have a melting point of 255 to 265 DEG C and an intrinsic viscosity of 0.45 to 0.8. Such polyesters have the function of imparting strength and form stability to the resulting composite fibers and nonwoven products to a level that allows for post-processing operations.

As the polyester, a recycled polyester which regenerates waste polyester as a scrap generated during the production process of a polyester product instead of a new polyester may be used.

In the composite fiber according to the present invention, there is a difference in intrinsic viscosity in the range of 0.5 to 1.6 between the fiber components constituting the composite fiber, that is, between the thermoplastic polyester elastomer and the polyester. And has a function of imparting a latent crimping property to allow crimp to be formed in the composite fiber by a subsequent heat treatment process. The formation of the crimp by such a heat treatment can give high elasticity and bulkiness particularly when the composite fibers obtained according to the present invention are used for the production of nonwoven fabrics and the like.

Wherein the thermoplastic polyester elastomer is selected from the group consisting of an acid component selected from the group consisting of terephthalic acid, isophthalic acid and mixtures thereof and a diol selected from the group consisting of poly (tetramethylene ether) glycol, 1,4-butanediol, ethylene glycol, The acid component and the diol component are reacted at a reaction molar ratio of 1: 1, and in general, some diol components are added in excess to improve the polymerization reactivity. In general, the polymerization is carried out at a ratio of 1: 1.2 to 1.4 in the case of the process using terephthalic acid and 1: 1.4 to 1.8 in the process using dimethyl terephthalate to improve the polymerization reactivity. Mostly recovered through the process. When the amount of the diol component is less than the above-mentioned molar ratio, the polymerization proceeds very slowly and the esterification reaction does not proceed sufficiently because the acid component and the diol component can not be reacted at a ratio of 1: 1. .

In particular, the thermoplastic polyester elastomer may have an elastic recovery rate within a range of 85 to 100%. When the elastic recovery rate of the thermoplastic polyester elastomer is less than 85%, there is a problem that the elasticity and / or elastic recovery rate and the shape stability of the nonwoven fabric product to which the conjugate fiber and the conjugate fiber are applied according to the present invention are lowered .

The acid component constituting the thermoplastic polyester elastomer is a mixture of 70 to 80 mol% of terephthalic acid and 20 to 30 mol% of isophthalic acid, and the diol component is 80 to 95 mol% of 1,4-butanediol, A mixture of 20 mol% of poly (tetramethylene ether) glycol and ethylene glycol (EG). When the content of isophthalic acid in the acid component constituting the thermoplastic polyester elastomer is less than 20 mol%, it is preferable that the melting point of the elastomer is 170 DEG C or higher, and the heat treatment is carried out under general annealing conditions for nonwoven fabric (180 to 190 DEG C for 10 to 20 minutes) There is a possibility that the adhesion between the fibers is insufficient and the morphological stability of the nonwoven fabric may be deteriorated. On the contrary, when the content is more than 30 mol%, the elastomer has a high melting point of 150 DEG C or lower, The specific gravity of the amorphous region is high, so that the possibility of deformation at room temperature and storage property may be deteriorated due to low Tg. When the content of poly (tetramethylene ether) glycol in the diol component is less than 5 mol%, the specific gravity of the hard segment in the elastomer may be high and the elasticity of the composite fiber may be deteriorated. On the other hand, , The strength of the composite fibers may be lowered, resulting in poor processability and shape stability after the nonwoven fabric.

The composite fiber may be formed of a heat-adhesive composite fiber of a circular cis-core type, a thermosetting conjugate fiber of a circular eccentric side-by-side type or a thermosetting conjugate fiber of an eccentric side- . However, it should be understood by those skilled in the art that these are listed as preferred embodiments, and that the present invention is not limited to these cross-sectional shapes,

Particularly, in the production of the conjugate fiber according to the present invention, polyester, which is one of the fiber components constituting the conjugate fiber, is used as a new polyester, and regenerated polyester is used instead of the new polyester to save resources and reduce the production cost In addition, there is an advantage that it is possible to manufacture an eco-friendly product according to the regeneration and recycling of polyester.

In forming the heat-bondable composite fiber as an inner material, various types of blend may be present. Preferably, the heat-bondable composite fiber may be formed in a vertical form in the interior material. It is preferable that the composite fibers have a relative arrangement of at least 50% relative to the other components contained in the interior material. In this case, the thermosetting conjugate fibers are fused with the fibers mixed together in the interior material to maintain the shape stability, and at the same time, the elasticity and bulge property can be maintained through the vertical arrangement.

Hereinafter, embodiments of the method for producing the heat-sealable conjugate fiber according to the present invention will be described, but the present invention is not limited to these embodiments.

Example 1

In order to prepare a composite fiber comprising a thermoplastic polyester elastomer and a general polyester as a fiber component, a mixture obtained by mixing 75 mol% of terephthalic acid and 25 mol% of isophthalic acid as an acid component is used and a poly Methylene ether) glycol and 92.0 mol% of 1,4-butanediol, the acid component and the diol component were mixed at a molar ratio of 1: 1 and polymerized to obtain a copolymer having a melting point of 155 DEG C, an intrinsic viscosity of 1.4, % Of a thermoplastic polyester elastomer having an elastic recovery of 60% and an intrinsic viscosity of 0.65. The thermoplastic polyester elastomer and the recycled polyester were mixed with two-component polymers Using composite spinneret capable of composite spinning, spinning at a spinning temperature of 275 ° C, spinning speed of 1,000 m / min, and spinning at 77 , And subjected to a final heat treatment at 140 DEG C to obtain a circular eccentric side-by-side type heat-bondable conjugate fiber as shown in Fig. In Fig. 1, the part denoted by A is a thermoplastic polyester elastomer, and the part denoted by B is a general polyester part. The obtained conjugate fiber had a staple fiber having a fineness of 5.5 denier, a strength of 3.45 g / denier, an elongation of 56%, a crimp number of 11 / inch, and a fiber length of 64 mm.

Example 2

Except that the thermosetting conjugated fiber of circular eccentric side-by-side type as shown in Fig. 1 was used instead of the thermosetting conjugated fiber of eccentric side-by-side type of heterogeneous hollow as shown in Fig. 2 Was carried out in the same manner as in Example 1 above. In Fig. 2, a portion denoted by A is a thermoplastic polyester elastomer, and a portion denoted by B is a general polyester portion. The obtained conjugate fiber had a staple fiber having a fineness of 6 denier, a strength of 3.3 g / denier, an elongation of 47%, a number of crimps of 12 / inch, and a fiber length of 64 mm.

Example 3

30% of the staple yarn of Example 1, 10% of the staple yarn of Example 2 and 60% of the 7de elastic yarn were mixed, and the nonwoven fabric was produced by cross-lapping, needle punching and thermally adhering. The permanent compression recovery rate of the produced nonwoven fabric is 80%.

Example 4

40% of the staple yarn of Example 1, 10% of the staple yarn of Example 2, and 50% of the 7de elastic yarn were mixed, and the nonwoven fabric was produced by cross-lapping, needle punching and thermally adhering. The permanent compression recovery rate of the manufactured nonwoven fabric is 85%.

Example  5

50% of the staple yarn of Example 1 and 50% of the 7de elastic yarn were mixed, and the nonwoven fabric was produced by cross-lapping, needle punching, and heat bonding. The permanent compression recovery rate of the produced nonwoven fabric is 90%.

Comparative Example 1

Thermally adhesive polyester 30%, and 7de elastic yarn 70% were mixed, and cross-wraps, needle punching, and heat bonding were performed to produce a nonwoven fabric. The permanent compression recovery rate of the manufactured nonwoven fabric is 30%.

While the present invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, It will be clear to those who are.

Claims (5)

A thermoplastic polyester elastomer having a melting point of 150 to 155 캜 and an intrinsic viscosity of 1.0 to 2.0 as a fiber component and a polyester having a melting point of 255 to 265 캜 and an intrinsic viscosity of 0.45 to 0.80,
Wherein the thermoplastic polyester elastomer comprises an acid component selected from the group consisting of terephthalic acid (TPA), isophthalic acid (IPA) or a mixture thereof, poly (tetramethylene ether) glycol (PTMG), 1,4- (EN) Disclosed is an automotive interior material comprising a thermally adhesive conjugated fiber formed by polymerizing a diol component selected from the group consisting of ethylene glycol (BD), ethylene glycol (EG), and mixtures thereof,
Wherein the acid component of the thermoplastic polyester elastomer is a mixture of 70 to 80 mol% of terephthalic acid and 20 to 30 mol% of isophthalic acid, the diol component is 80 to 95 mol% of 1,4-butanediol, 5 to 20 mol% Is a mixture of poly (tetramethylene ether) glycols,
Wherein at least 50% of the composite fibers are relatively vertically arranged relative to the other components contained in the interior material. The method according to claim 1,
Wherein the thermoplastic polyester-based elastomer has an elastic recovery rate within a range of 85 to 100%. delete 3. The method according to claim 1 or 2,
Wherein the composite fiber is a circular eccentric side-by-side type thermo-adhesive composite fiber. 3. The method according to claim 1 or 2,
Wherein the composite fiber is an eccentric side-by-side type heat-sealable composite fiber of a hollow hollow.

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