KR101911899B1 - Composite with excellent recycle and lightweight property and automobile floor carpet using the same - Google Patents

Abstract

The present invention relates to a flowable carpet composite material for automobiles having excellent recyclability and light weight, and a product using the same.
The flowable carpet composite substrate of the present invention comprises a skin layer made of PET, a PET heat-sealable layer formed by dissolving PET powder in the skin layer and thermally fused, and a back layer of a PET film, Since the functional layer is further laminated or the composite substrate is made to be multilayered, there is no possibility of generating volatile organic substances (Voc) that can remove indoor air quality because it is bonded without any adhesive for interlayer adhesion, It is possible to provide a needle punch or a tufted carpet to which a flowable carpet composite substrate for an automobile having excellent recyclability, light weight, and moldability due to the same material is applied.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a carpet composite carpet having excellent recyclability and light weight, and a product using the composite carpet composite product. 2. Description of the Related Art Carpet-

The present invention relates to a flowable carpet composite material for automobiles having excellent recyclability and light weight and a product using the flowable carpet composite material. More specifically, the flowable carpet composite material includes a skin layer made of PET, A PET heat-sealable layer and a PET backing layer. Since the heat-sealable layer is melted by heat to perform the interlayer adhesive function, the functional layers can be laminated, or the composite substrate can be multilayered, (100% PET) material. Therefore, it is possible to provide an automobile flow carpet composite material excellent in recyclability, light weight, and moldability due to the same material, Product.

Carpets used in the automotive industry are largely classified as tufted carpets and nonwoven needle punch carpets.

The tufted carpet is a composite structure in which a tuft or a bundle of carpet fibers is stitched and introduced into a first bubble such as a woven fabric or a non-woven fabric, Nonwoven needle punch carpets, that is, nonwoven carpets, consist of fibers that are mechanically entangled by needling, water jet, or other processes.

At this time, the material constituting the carpet is determined by the molding conditions required for the carpet and the required physical properties when the molded carpet is laid on the car.

In addition, in tufted carpets, carpet fibers are generally yarns composed of nylon, polyester, wool or polypropylene, and nylon is the most commonly used. Thereafter, a thermoplastic resin sheet, latex or the like is applied to the back side of the bubble to form the back side layer so that the carpet fibers are firmly held in the first bubble. At this time, the thermoplastic resin sheet, latex and the like can not only stabilize the constitution dimensionally but also can improve the problem of the loosening of the flocked pile in case of combustible delay and tufted carpet. In addition, it can provide greater abrasion and wear resistance and can provide tackiness to additional material layers.

Therefore, in the carpet for automobiles, the back layer has to be molded and arranged in a plasticized state by heating using the thermoplasticity of the material, and it is required to be able to impart shape supportability by proper rigidity while being solidified. Therefore, a resin having a glass transition temperature lower than that of the skin layer material and having rigidity after solidification is preferable.

On the other hand, it is required that a foamed material having high light resistance, heat resistance and abrasion resistance is required, and a material having high glass transition point, which is not damaged by heat during molding, is required.

Therefore, conventionally, in order to simultaneously satisfy the requirements such as light resistance, heat resistance, abrasion resistance, and moldability of the foamed layer and the moldability and shape supportability of the contact layer,

In addition, in the field of carpets, research to replace polyethylene terephthalate (PET) materials has been actively conducted as a material capable of improving the physical properties of automobile carpets without increasing the cost compared to conventionally used nylon materials.

The PET is optically a polyester compound, but has a much higher melting point than polyester and is similar to the melting point of nylon and is stronger than nylon in terms of tear strength, It can provide excellent scratch and tear resistance.

In particular, since PET has the potential to be repeatedly regenerated and has inherent resistance to staining, conventional nylon is susceptible to contamination and needs to be coated with a separate pollution-resistive compound. can do.

The above-mentioned efforts to develop materials have been expanded to the development of materials that can be recycled due to environmental pollution problems caused by industrial development, can be made lighter yet have excellent moldability.

Korean Patent No. 1317819 suggests that polyester is selected as a recycling material and applied to a sound-absorbing layer in the form of a hollow fiber to optimize the noise reduction through the hollow and to improve the sound absorption effect while reducing the total weight of the carpet by forming a hollow And it is possible to improve the fuel efficiency of the vehicle.

In addition, Korean Patent No. 1567777 discloses a base material for a vehicle interior material excellent in lightweight and moldability, which is obtained by applying a PET (polyethylene terephthalate) foam sheet as a core layer and forming a core layer having the same expansion ratio as a reinforcing material on both sides It is possible to obtain a PET foam sheet which is excellent in recyclability due to the same material and provides heat resistance and moldability of a PET material, It is possible to reduce the weight due to weight reduction by applying the sheet.

Accordingly, the present inventors have made efforts to improve physical properties meeting the market demand of automotive flow-through carpet. As a result, it has been found that a PET material that can be repeatedly used is used in place of the nylon material and the layers constituting the carpet are made of the same material, The recyclability is excellent due to the same physical behavior during the heat treatment due to the same material, and since the formulations of the PET materials introduced into the respective layers are provided differently, excellent lightweight property and moldability can be achieved, The sound absorption effect can be enhanced, thereby completing the present invention.

It is an object of the present invention to provide a composite substrate useful for a flow carpet for automobiles made of a PET material.

Another object of the present invention is to provide a carpet using a flowable carpet composite material for automobiles excellent in recyclability and light weight.

In order to achieve the above object, a first preferred embodiment of the present invention is a skin layer made of polyethylene terephthalate (PET); A PET heat-sealable layer on which the PET powder is dispersed and thermally fused to the skin layer; And a back layer formed by coating a PET material on the PET heat-sealable layer, the composite material being excellent in recyclability and light weight.

Also, as a second preferred embodiment, a skin layer made of polyethylene terephthalate (PET); A first thermally fusible layer formed by dispersing a PET powder on the skin layer and thermally fusing the same; A sound-absorbing sound insulating layer on the first heat-sealable layer; A second heat-sealable layer on which the PET powder is dispersed and thermally fused on the sound-absorbing sound insulating layer; And a back layer formed by coating a PET material on the second heat-sealable layer, the composite material being excellent in recyclability and light weight.

In the first or second embodiment, the sound-absorbing sound insulating layer is further laminated on the back layer to complete the composite substrate.

Further, in the second embodiment, the first and second heat-sealable layers perform the interlayer adhesion function, so that the first and second heat-sealable layers can be further laminated in a range not exceeding the desired weight range, or the other functional layers can be further raised.

In the first embodiment and the second embodiment, it is preferable that the skin layer is a PET nonwoven web or a PET napkin.

When the skin layer is a PET nonwoven web, the PET powder having an average particle size of 40 to 1000 mu m is filled in the nonwoven web and a thermally fusing layer is formed in layers.

Also, when the skin layer is a PET napkin yarn, the PET powder having an average particle size of 40 to 1000 mu m is scattered and filled between PET napping yarns, and a heat-sealable layer is formed in layers.

Further, the present invention provides a flow carpet for automobiles in which the composite material described above is applied to a needle punch structure or a tufted structure.

The flowable carpet composite material for an automobile according to the present invention comprises a skin layer made of PET, a PET heat-sealable layer formed by dispersing PET powder in the skin layer, and a back layer coated with a PET material, And thus the functional layers can be laminated or multilayered in a range not exceeding the desired weight range.

Accordingly, since the flowable carpet composite substrate for automobiles of the present invention is realized without a separate adhesive agent for interlayer adhesion, there is no fear of generating volatile organic compounds (VOC) such as formaldehyde and acetaldehyde, which deteriorate indoor air quality.

In addition, since the automobile flow-coated composite material for automobiles of the present invention is made of 100% PET material, it has excellent physical properties such as recyclability, light weight, It is possible to provide the effect of improving the fuel economy by implementing the sound absorption effect while reducing the weight.

Further, the present invention can provide a needle punch carpet or a tufted carpet in which recycling and light weight are achieved by applying a flow carpet composite substrate for an automobile.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic view of an automotive flow-through carpet composite substrate according to a first embodiment of the present invention,
2 is a schematic view of a flowable carpet composite substrate for an automobile according to a second embodiment of the present invention.

Hereinafter, the present invention will be described in detail.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic view of an automotive flow-through carpet composite substrate according to a first embodiment of the present invention, and more particularly, to a skin layer made of PET; A PET heat-sealable layer on which the PET powder is dispersed and thermally fused to the skin layer; And a back layer coated on the PET heat-sealable layer with a PET material.

Further, in the first embodiment, the composite substrate can be completed by adhering it on the PET layer, on the back layer, and further laminating the sound-absorbing sound insulating layer.

2 is a schematic view of a flowable carpet composite substrate for an automobile according to a second embodiment of the present invention, which comprises a skin layer made of PET; A first heat-sealable layer on which the PET powder is dispersed and thermally fused to the skin layer; A sound-absorbing sound insulating layer on the first heat-sealable layer; A second heat-sealable layer on which the PET powder is dispersed and thermally fused onto the sound-absorbing sound insulating layer; And a back layer coated on the second heat-sealable layer with a PET material.

Hereinafter, the structure of each layer will be described.

1) PET skin layer 10

In the first embodiment and the second embodiment, the skin layer 10 is the outermost layer that the consumer sees and feels in the eyes, and is made of PET nonwoven web or PET napkin yarn.

Accordingly, the composite material of the present invention is characterized by being composed of 100% PET material which is superior in tear strength and fouling resistance property than nylon used as a conventional skin layer and can be repeatedly reproduced.

At this time, in the case of a PET nonwoven web, the thickness of the nonwoven fabric should be 1 to 10, more preferably 3 to 5 mm, since it can not withstand the elastic force without a certain thickness when it is used for an automotive sheet or the like. At this time, if the thickness is less than 1 mm, the elastic force tends to be insufficient, which is not preferable tactile. On the other hand, if it exceeds 10 mm, the bending rigidity becomes large and the feel is deteriorated.

In the case of PET napping yarn, the yarn can be produced using fibers having a fineness ranging from 10 to 15 denier, and the PET yarn is a polyester staple fiber.

Also, the fiber diameter of tufted PET is typically thinner than a nylon carpet, resulting in a significant increase in sound absorption due to the use of PET as compared to nylon.

For tactile development of the skin layer, a steaming process may be introduced after the tufting, or a steam box or other similar heating medium may be introduced.

2) PET heat-sealable layer 20

In the first embodiment and the second embodiment described above, the non-woven web of the skin layer, particularly the PET napkin yarn, can be stably fixed by acting as a counterfeiter in an ordinary automotive flow carpet, .

In addition, it can provide greater abrasion and wear resistance, and has the property of melting and solidifying by heat, so that an interlayer adhesion function is performed at the time of melting, so that additional layers can be laminated without a separate adhesive .

With the PET heat-sealable layer 20 of the present invention, in the case of conventionally used latex, VOC (Volatile Organic Compounds) such as formaldehyde and acetaldehyde, which interfere with indoor air quality, are generated, By sucking the evaporated vaporized VOC, the problem of bringing an unpleasant ride feeling can be solved.

In order to achieve the same object of the PET heat-sealable layer 20, 100 g / m 2 of the conventional latex is used. On the other hand, the present invention is characterized in that the PET powder is used in an amount of 60 to 80 g / m 2, It is possible to achieve weight reduction of the final product because the PET heat-sealable layer 20 is formed at a content of 50 g / m < 2 >.

Accordingly, the present invention uses PET, which is the same as the material of the skin layer, in the form of a PET powder, which is then melted and cured by heat, thereby forming a bubble layer of the same PET material, that is, a heat fusion layer.

At this time, the average particle size of the PET powder is adjusted to such a size as to be injected between the PET nonwoven web and the napped yarn. That is, when dispersed in powder form, it is designed to naturally permeate between the nonwoven web or the napped yarn without any separate physical means without vibration due to a high frequency.

Therefore, the particle size of the PET powder may vary depending on the size of the PET nonwoven web of the skin layer or the spacing between the napped yarns.

Preferably, the PET nonwoven fabric web is filled with a PET powder having an average particle size of 4 to 1000 mu m, and a thermally fusing layer is formed in a layered form, which is advantageous in improving the rigidity of the carpet, can do.

If the average particle size of the PET powder is too small, it can not be formed into a lamellar shape due to heat and can not be expected to have interlayer adhesion performance. If the average particle size of the PET powder is too small, The function is weakened.

In order to form the PET heat-sealable layer 20, the average particle size of the PET powder is preferably 20 to 150 g / m < 2 >. After the dispersion, heat treatment is performed at 70 to 200 DEG C, .

At this time, the amount of the PET powder to be applied is determined by the time and productivity of the whole process, taking into consideration the physical properties such as dimensional stability, tensile strength and product thickness in the desired transverse and longitudinal directions, and in particular, .

In addition, since the skin layer 10 and the heat-sealable layer 20 formed of the powder are both made of the same PET material, the heat treatment temperature is brought into thermal contact with the back surface of the skin layer 10 and the contact time is controlled.

After the formation of the heat-sealable layer 20, the surface of the continuous roll (ROLL) work is subjected to the homogenization of the surface in addition to the interlaminar adhesion strengthening.

As described above, it is possible to fundamentally solve the problem of the generation of volatile organic compounds (VOC), which is harmful to the working environment and the human body, by using the same material between the layers but without the adhesive containing the volatile organic solvent for bonding the interlayer material have.

Further, since the PET heat-sealable layer 20 performs an adhesive function when it melts in heat, it can be further laminated in the range not exceeding the weight range required in the carpet field, or the other functional layer can be further raised.

Thus, as shown in FIG. 2, a skin layer made of PET; A first heat-sealable layer on which the PET powder is dispersed and thermally fused to the skin layer; A sound-absorbing sound insulating layer on the first heat-sealable layer; A second heat-sealable layer on which the PET powder is dispersed and thermally fused onto the sound-absorbing sound insulating layer; And a back layer on which the PET film is adhered on the second thermally fusible layer. The multilayer structure may be variously modified in the range of using the characteristics of the PET thermally fusible layer 20.

3) a back layer 30 coated with a PET material;

The back layer 30 coated with the PET material can be formed into a sheet by feeding a PET chip to a hopper and heating and melting under predetermined control conditions and continuously applying a PET melt after forming the PET heat- And solidified to form the back layer 30 coated with the PET material.

Alternatively, the PET thermally fusible layer 20 may be formed by heating a separately prepared PET film on the PET thermally fusible layer 20 by using the property of melting the PET heat-fusible layer 20 by heat and pressing the PET film at a high temperature.

Therefore, the composite substrate of the present invention can be bonded without an adhesive containing a volatile organic solvent for bonding an interlayer material, thereby fundamentally solving the problem of the generation of volatile organic compounds (VOC) harmful to the working environment and the human body.

Further, since the physical properties of the layers of the flow carpet in the scrap car during the scrapping are different and the materials such as polyester, polyamide, and polyolefin are mixed with each other, the melting points of the respective resins are different, It can not be recycled as a homogeneous material and can not be reused if there is no compatibility between the resins. However, since the composite material of the present invention constitutes the same material between the layers, the carpet has excellent regenerability because it has the same physical behavior in the heat treatment process at the time of scrapping.

Accordingly, the present invention provides a flow carpet for automobiles in which the composite substrate is applied to a needle punch structure or a tuft structure.

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

The present invention is intended to more specifically illustrate the present invention, and the scope of the present invention is not limited to these embodiments.

< Example  1> Needle punching For carpet  Composite substrate manufacturing

The PET powder was sprayed on one surface of a PET nonwoven fabric having a thickness of 3 to 5 mm at a weight per unit area of 600 g / m 2 and then subjected to heat treatment at 150 to 180 캜 to melt a part of the PET powder, Thereby forming a cured PET heat-sealable layer. Then, a separately prepared PET film was adhered to the surface of the PET heat-sealable layer to prepare a composite substrate. At this time, the average particle size of the PET powder was 150 to 350 占 퐉.

< Example  2> Needle punching For carpet  Composite substrate manufacturing

A PET powder is sprayed at 100 to 200 g / m 2 on one side of a PET nonwoven fabric prepared to a thickness of 3 to 5 mm and then heat-treated at 150 to 180 캜 to melt a part of the PET powder, PET heat-sealable layer was formed. Thereafter, while moving on the conveyor belt continuously, a PET melt was applied to the surface of the PET heat-sealable layer to produce a composite substrate in which an extruded sheet was laminated.

< Example  3> Needle punching For carpet  Composite substrate manufacturing

In the composite substrate produced in Example 1, a sound-absorbing sound insulating layer was bonded to the back surface layer of the PET film.

< Example  4> Tufted For carpet  Composite substrate manufacturing

The PET powder is sprayed at a surface area of 10 to 200 g / m &lt; 2 &gt; in a unit area weight on the surface formed by tufting of the PET napping yarn, and then heat-treated at 150 to 180 DEG C to melt a part of the PET powder, Layered PET thermally fusible layer was formed.

The PET film layers were fusion-bonded to each other by using the adhesiveness due to heat when the PET heat-sealable layer was formed, thereby producing a composite substrate.

< Comparative Example  1>

The same as in Example 1, except that the PET nonwoven fabric prepared in a thickness of 3 to 5 mm was interlayer-bonded to one surface of the PET nonwoven fabric by using latex (acrylic resin adhesive) and the nonwoven fabric was composed of a back layer coated with a PE material Respectively.

< Experimental Example  1> Property evaluation

The properties required for carpets of the needle punch carpet composite substrate produced in Example 1 and Comparative Example 1 were evaluated, and the results are shown in Table 1 below.

As shown in Table 1, the needle punch carpet composite substrate of Example 1, compared to the conventional needle punch carpet composite substrate produced in Comparative Example 1, had a low tensile strength under similar weight conditions, while the elongation was improved, Tear strength and improved compressive modulus.

As can be seen from the above Table 2, the needle punch carpet of Example 1 is made of the same material of 100% PET, so that it is excellent in recyclability, light weight and moldability are excellent, and the total weight of the carpet is reduced A sound absorbing effect equal to or more than that of the prior art is realized. Furthermore, it was confirmed that excellent flame retardancy was ensured due to the same material of 100% PET.

As described above, the present invention can be repeatedly performed in place of a nylon material composed of a skin layer made of PET, a PET heat-sealable layer formed by dissolving a PET powder in the skin layer and thermally fused, and a back layer of a PET film A flowable carpet composite material composed of a PET material excellent in tear strength and expected to have a damaging effect is provided.

Further, since the flow-coated composite material of the present invention is composed of 100% PET material, it has the same material behavior in the heat treatment process at the time of scrapping due to the same material, and therefore is excellent in recyclability, light weight and moldability, And the sound absorption effect is realized while reducing the total weight, so that it is possible to provide an effect of improving fuel economy.

Further, the present invention can provide a needle punch carpet or a tufted carpet in which recycling and light weight are achieved by applying a flow carpet composite substrate for an automobile.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art.

10: PET skin layer 20: PET heat fusion layer
30: back layer coated with PET material 40: sound-absorbing sound insulating layer

Claims (7)

A skin layer made of polyethylene terephthalate (PET) nonwoven web or PET napkin yarn;
A bubble layer of PET material in which a PET powder having an average particle size of 40 to 1000 占 퐉 is dispersed in the skin layer and a part of the PET powder is melted and cured into a layer; And
And a back layer coated with a PET material on the bubble layer of the PET material, and having excellent recyclability and light weight. A skin layer made of polyethylene terephthalate (PET) nonwoven web or PET napkin yarn;
A bubble layer of PET material in which a PET powder having an average particle size of 40 to 1000 占 퐉 is dispersed in the skin layer and a part of the PET powder is melted and cured into a layer;
A sound-absorbing sound insulating layer on the bubble layer of the PET material;
A second bubble layer of a PET material formed by dissolving a PET powder on the sound-absorbing sound insulating layer and thermally fusing the same; And
And a back layer coated with a PET material on the second bubble layer of the PET material, the automobile flow carpet composite substrate having excellent recyclability and light weight. The automotive flow-through carpet composite substrate according to claim 1 or 2, wherein a sound-absorbing sound-insulating layer is further laminated on the back layer. delete delete delete A flow carpet for automobiles in which the composite material of any one of claims 1 or 2 is applied to a needle punch or tufted structure.

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