KR101997617B1 - Interior and exterior furnishings of vehicle having excellent durability and light-weight - Google Patents

Abstract

The present invention relates to a vehicle interior and exterior material excellent in light weight and durability. The interior and exterior material for a vehicle according to the present invention is characterized in that an inorganic fiber mat is formed on one side or both sides of a foam layer formed of a polyester resin foam, And an object of the present invention is to provide an automotive interior and exterior material having properties such as strength, ductility, bending strength, sound absorption and sound insulation.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a vehicle interior and exterior material having excellent lightweight and durability,

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

Generally, vehicle interior and exterior materials such as a headliner mounted on the inner side of a roof panel of a vehicle, a package tray installed on the rear of a rear seat, and an under cover mounted on the bottom surface of a vehicle include low melting fiber (LMF) Resin felts, paper boards, rigid polyurethane, corrugated board, and the like.

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. Therefore, when used as an interior and exterior material for a vehicle, there is a disadvantage in that the product falls down when used for a long period of time.

Resin felts and paper boards are prepared by impregnating a phenol resin or the like as a curing agent. The phenol resin is a kind of thermosetting resin produced by the condensation reaction of phenols and aldehydes. When the phenol resin is incinerated, the phenol resin is not reacted or incompletely burned Resulting in release of phenol and aldehyde. These phenols and aldehydes act as pollutants in the living environment including the working environment and have a problem of emitting toxic gases.

The polyurethane hard foam is excellent in heat insulation and light weight but has a low recyclability and a low impact resistance so that brittle fracture tends to occur easily in a molding process for producing a substrate and the weather resistance is poor, There is a problem that the durability such as occurrence of sagging is low.

The above-mentioned conventional vehicle interior and exterior materials can not satisfy light weight and durability at the same time, has a problem of being poor in sound insulation and heat insulation, high in unit price, easy to be deformed during long-term use, and harmful to human body and environment.

Accordingly, there is a desperate need to develop a vehicle interior and exterior material that can realize high strength, light weight, high sound absorption and sound insulation, prevent toxic gas emission, and have good durability and dimensional stability.

Korea Patent Publication No. 2013-0120567

An object of the present invention is to provide a vehicle interior and exterior material having a thin thickness and excellent lightweight properties, flame resistance, flexural strength, sound absorption and sound insulation, and the like, which is excellent in light weight and durability.

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

A foam layer containing a polyester resin foam; And

And an inorganic fiber mat formed on one or both surfaces of the foam layer,

According to ASTM D 790, when the supporting spacing of the specimen is fixed at 100 mm and the flexural load is applied at a speed of 5 mm / min, the measured flexural strength is in the range of 20 to 200 N,

The inorganic fibers have an average diameter in the range of 10 to 1000 mu m,

The density of the foam layer (KS M ISO 845) may be in the range of 30 to 700 kg / m ³ .

An automotive interior and exterior material according to the present invention is characterized in that an inorganic fiber mat is formed on one side or both sides of a foam layer formed of a polyester resin foam to provide a thin film having excellent lightweight properties such as flame retardancy, An object of the present invention is to provide an automobile interior and exterior material.

1 to 3 are schematic views of an automotive interior and exterior material according to an embodiment of the present invention.

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.

Hereinafter, the present invention will be described in detail.

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an interior and exterior material for a vehicle, and more particularly to a headliner, a package tray or an undercover.

In the present invention, the head liner means a material used in a room ceiling of an automobile.

In the present invention, the package tray is installed in the rear portion of the rear seat of the vehicle body, and the occupant holding the rear seat holds various parts and documents, and functional components such as a speaker and a fragrance are mounted if necessary.

The undercover in the present invention is mounted on the bottom surface of a vehicle and is installed at the bottom of an engine or a transmission and a cooling fan to protect the engine and the transmission from impacts externally, And prevents foreign matter from entering the interior of the vehicle from the outside.

As a conventional vehicle interior and exterior material, low melting fiber (LMF), resin felt, paper board, rigid polyurethane, corrugated board and the like have been used.

However, the LMF has a disadvantage that it is weak in strength and heavy in weight. As a result, there has been a disadvantage in that when it is used as an interior and exterior material for a vehicle, it tends to fall down when used for a long period of time.

Also, the resin felt and the paper board have a problem that toxic gases such as phenol and aldehyde are emitted.

Further, in the case of a polyurethane hard foam material, the impact resistance, weather resistance and durability are deteriorated.

The present invention is intended to solve the problems encountered when using the low melting fiber (LMF), resin felt, paper board, rigid polyurethane, corrugated cardboard,

It is possible to provide a vehicle interior and exterior material which is excellent in durability, light resistance and dimensional stability as well as being lightweight and capable of realizing excellent sound-absorbing property and sound insulation by improving the flexural modulus and flexural strength, .

Hereinafter, the present invention will be described more specifically.

In the automotive interior and exterior material according to the present invention,

A foam layer containing a polyester resin foam; And

And an inorganic fiber mat formed on one or both surfaces of the foam layer,

According to ASTM D 790, when the supporting spacing of the specimen is fixed at 100 mm and the flexural load is applied at a speed of 5 mm / min, the measured flexural strength is in the range of 20 to 200 N,

The inorganic fibers have an average diameter in the range of 10 to 1000 mu m,

The density of the foam layer (KS M ISO 845) is in the range of 30 to 700 kg / m ³ .

Polyester resin is an eco-friendly material that has excellent flame retardancy and chemical resistance and does not release environmental hormone.

However, since the melt strength of the polyester resin is rapidly lowered as the temperature is increased, the temperature range having a melt viscosity that is foamable is very narrow. Therefore, in order to foam the polyester resin, a special technique for increasing the melt viscosity and a precise temperature control facility are indispensably required. Therefore, conventionally, it has been difficult to produce a foam using a polyester resin.

However, in the present invention, the foam was successfully produced by controlling the viscosity and temperature of the polyester resin.

The polyester resin foam may be extruded foamed.

The bead foaming is generally performed by first heating the resin beads, aging the resin beads for a suitable period of time, filling the resin beads in a plate-shaped or cylindrical mold, heating them again to obtain 2 And fusing and molding by car foaming to form a product. 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 foam layer comprising the polyester resin foam according to the present invention is characterized in that at least 90% of the cells are closed cells (DIN ISO4590), as measured according to DIN ISO 4590 of the foam layer is not less than 90% (v / v) It may mean a closed cell. For example, the percentage of closed cells in the foam layer may be on the average 90 to 100% or 95 to 99%. The foamed layer according to the present invention has a closed cell within the above range, so that excellent durability, rigidity and strength characteristics can be realized in manufacturing an automobile interior and exterior material. For example, the number of cells in the foam layer is 1 mm < ^{2 >} 1 to 30 cells, 3 to 25 cells, or 3 to 20 cells per cell.

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 foam layer according to the present invention.

In the present invention, the polyester resin 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 types of the polyester resin usable in the present invention may be selected from the group consisting of polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polylactic acid (PLA) Polyglycolic acid (PGA), polypropylene (PP), polyethylene (PE), polyethylene adipate (PEA), polyhydroxyalkanoate (PHA), polytrimethylene terephthalate (PTT), polyethylene naphthalate (PEN), or the like. Specifically, 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.

Specifically, the vehicle interior and exterior material according to the present invention can be produced by laminating a foam layer containing a polyester resin foam and an inorganic fiber mat on one or both surfaces of the foam layer. The foamed layer and the inorganic fiber mat may be thermally fused or thermally bonded to each other without using an adhesive material. A schematic diagram of this structure is shown in Fig. Referring to FIG. 1, the automotive interior and exterior material 100 according to the present invention has a structure in which an inorganic fiber mat 20 is bonded to a foam layer 10 including a polyester resin foam. The interior and exterior material 100 for a vehicle according to the present invention is formed of a foamed layer 10 including a polyester resin foam and is formed on both surfaces of the foamed layer 10, And the inorganic fiber mat 20 is bonded to the inorganic fiber mat 20.

In the inorganic fiber mat, the inorganic fibers may have an average diameter ranging from 10 to 1000 mu m. For example, the average diameter of the inorganic fibers may range from 100 to 1000 mu m in diameter, 100 to 800 mu m, or 100 to 500 mu m.

It is possible to provide a vehicle interior and exterior material that is lightweight and has excellent durability by bonding an inorganic fiber mat containing inorganic fibers having an average diameter within the above range to one surface or both surfaces of a foam layer containing a polyester resin foam.

The vehicle interior and exterior materials may have a flexural strength ranging from 20 to 200 N when the supporting spacing of the specimen is fixed at 100 mm and the flexural load is applied at a speed of 5 mm / min according to ASTM D 790. For example, the flexural strength may range from 20 to 150 N, from 20 to 100 N, from 20 to 80 N, or from 30 to 80 N. By satisfying the flexural strength in the above range, when used as an internal and external material of an automobile, it can be more secure against external impact due to high strength, and can be easily molded.

In the vehicle interior and exterior materials, the density of the foam layer (KS M ISO 845) may range from 30 to 700 kg / m ³ . For example, the density of the foam layer may range from 75 to 600 kg / m ³ , from 90 to 500 kg / m ³ , from 100 to 350 kg / m ^3, or from 300 to 400 kg / m ³ . The automotive interior and exterior material according to the present invention includes a foamed layer that satisfies the density within the above range, thereby controlling the expansion ratio, thereby manufacturing a high-density and high-strength automotive interior and exterior material.

According to ASTM D 790 of the present invention, the flexural modulus (Stiffness) measured when the supporting span of the specimen is fixed at 100 mm and the flexural load is applied at 5 mm / min is in the range of 400 to 2000 MPa Lt; / RTI > Specifically, the flexural modulus may range from 500 to 2000 MPa, from 700 to 2000 MPa, or from 1000 to 2000 MPa, thereby satisfying more rigidities. Stiffness means a degree of rigidity or hardness of a material. When the flexural modulus satisfies the above range, rigidity and durability are improved, thereby providing a vehicle interior and exterior material having little physical shock or deformation due to force.

In the present invention, the inorganic fibers may include at least one of needle-shaped crystals of glass fiber, metal or metal oxide, and carbon fibers. Specifically, the inorganic fibers may be glass fibers.

By joining the inorganic fiber mat containing such inorganic fibers to one surface or both surfaces of the foam layer, the strength of the automotive interior and exterior material according to the present invention can be increased and the durability can be improved.

The average thickness of the foam layer may range from 1 to 10 mm. For example, the average thickness of the foam layer may range from 1 to 7 mm, from 1 to 5 mm, or from 1 to 3 mm. As described above, the interior and exterior material for a vehicle according to the present invention can achieve light weight and high strength at the same time, while forming a foamed layer containing a polyester resin foam in a thin thickness.

The mass per unit area of the automotive interior and exterior materials may range from 300 to 3000 g / m ² . For example, the mass per unit area of the automotive interior and exterior materials may range from 400 to 2500 g / m ² , from 400 to 2000 g / m ² , from 400 to 1500 g / m ^2, or from 500 to 800 g / m ² . Accordingly, it can be confirmed that the vehicle interior and exterior vehicle according to the present invention is lightweight.

As another example of the automotive interior and exterior material structure, it may further include a polyester nonwoven fabric layer formed on the opposite side of the surface of the inorganic fiber mat in contact with the foam layer. For example, the polyester nonwoven layer may comprise a polyester fiber. At this time, the polyester fiber may be a fiber produced using at least one of the above-described polyester resins.

The polyester nonwoven fabric layer may be attached on one side by an inorganic fiber adhesive having an average length in the range of 5 to 100 mm. The kind of the inorganic fibers may be the same as described above. For example, inorganic fibers adhered to one surface of the polyester nonwoven fabric layer with an adhesive may be chopped with an average length in the range of 5 to 100 mm.

The adhesive may include at least one of an acrylic resin, an epoxy resin, a silicone resin, and a urethane resin.

When the adhesive resin containing inorganic fibers is dispersed in the polyester nonwoven fabric layer, the adhesive resin containing the inorganic fibers can improve the adhesion between the polyester nonwoven fabric layer and the inorganic fiber mat. In some cases, the adhesive resin containing inorganic fibers can be partially absorbed by the inorganic fiber mat to improve the adhesion between the foam layer and the inorganic fiber mat.

In the vehicle interior and exterior materials, the average thickness of the nonwoven fabric layer may range from 0.1 to 5 mm. For example, the average thickness of the nonwoven layer may range from 0.1 to 5 mm, from 0.1 to 3 mm, from 0.1 to 2 mm, or from 0.1 to 1 mm.

Accordingly, the automotive interior and exterior material according to the present invention can realize properties such as excellent bending strength, sound absorption, sound insulation and low dimensional strain, despite the relatively thin thickness. Further, the interior and exterior materials for a vehicle according to the present invention can be lightened, and excellent fuel economy can be realized.

A schematic diagram of this structure is shown in Fig. 2, an automotive interior and exterior material 200 according to the present invention includes an inorganic fiber mat 20 bonded on a foam layer 10 including a polyester resin foam, And a polyester nonwoven fabric layer (30) formed on the opposite side of the side contacting the layer (10). 2 shows a structure in which an inorganic fiber mat 20 and a polyester nonwoven fabric layer 30 are formed on one surface of a foam layer 10, but an inorganic fiber mat 20 is formed on both surfaces of the foam layer 10, And the non-woven fabric layer 30 are formed.

As another example of the automotive interior and exterior material structure, it may further include an adhesive layer formed between the foamed layer and the inorganic fiber mat.

Specifically, the automotive interior and exterior material further includes an adhesive layer between the foamed layer and the inorganic fiber mat, thereby further improving the adhesion between the foamed layer and the inorganic fiber mat, thereby effectively preventing the delamination between layers and improving durability.

As one example, the adhesive layer may include a polyester-based adhesive resin. 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.

As another example, an adhesive resin containing at least one of an acrylic resin, an epoxy resin, a silicone resin and a urethane resin containing the inorganic fibers may be used.

A schematic diagram of this structure is shown in Fig. 3, an automotive interior and exterior material 300 according to the present invention includes an adhesive layer 40 formed on a foam layer 10 including a polyester resin foam, and an inorganic fiber mat 20 ). 3 shows the structure in which the adhesive layer 40 and the inorganic fiber mat 20 are formed on one surface of the foam layer 10 but the adhesive layer 40 and the inorganic fiber mat 20 are formed on both surfaces of the foam layer 10 20) is not excluded.

The vehicle interior and exterior material according to the present invention can satisfy the following condition (1).

[Condition 1]

The above Condition 1 means the rate of change (average value of width, length, height) before and after irradiating light having a wavelength of 300 to 400 nm with light having an illuminance of 255 W / m ² for 90 days according to the accelerated light resistance test of KS R 0021 , Lt ₀ represents the dimension before the treatment, and Lt ₁ represents the dimension after the treatment.

The rate of dimensional change under Condition 1 may be specifically less than 1%, 0.01 to 0.9%, 0.05 to 0.8% or 0.1 to 0.6%. At this time, the dimensional change rate may be a dimensional change rate when the volume (Tt ₀ ) before the treatment of the interior and exterior materials for vehicles (before light irradiation) is 1 m ³ . When the dimensional change ratio of the vehicle interior / exterior material according to the present invention satisfies the above range, it provides improved durability and light resistance, and can be prevented from being deformed or damaged by ultraviolet rays even during long-term use.

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 2862 may be 10 dB or more in the vehicle interior and exterior materials according to the present invention.

For example, the sound absorption rate may range from 0.4 to 1 NRC or 0.4 to 0.6 NRC, and the transmission loss value may range from 10 to 30 dB or 15 to 25 dB. 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 high level, and can effectively sound or sound the noise in and from the vehicle.

The manufacturing method of the vehicle interior / exterior material is not particularly limited, but it can be manufactured through heat fusion or thermal bonding.

For example, at least one of a foam layer, an inorganic fiber mat, a polyester nonwoven fabric layer and an adhesive layer comprising a polyester resin foam according to the present invention constituting an automotive interior and exterior material according to the present invention is laminated and bonded through a thermal bonding process The interior and exterior materials for a vehicle can be manufactured.

At this time, the thermal bonding process may be performed by pressing at a temperature of 150 to 200 DEG C for 1 to 3 minutes.

Also, optionally, preheating may be performed for 1 to 3 minutes at a temperature of 180 to 220 캜 before the pressing process.

The foam layer, the inorganic fiber mat, the polyester nonwoven fabric layer and the adhesive layer comprising the polyester resin foam according to the present invention may have a hydrophilizing function, a waterproof function, a flame retarding function or an ultraviolet shielding function, Consisting of an ultraviolet light blocking agent, a hydrophilic agent, a flame retardant, a heat stabilizer, a waterproofing agent, a cell size expanding agent, an infrared attenuating agent, a plasticizer, a fire retardant chemical, a pigment, an elastic polymer, an extrusion aid, an antioxidant, Lt; RTI ID = 0.0 > additive < / RTI > Specifically, the foam layer, the inorganic fiber mat, the polyester nonwoven fabric layer and the adhesive layer comprising the polyester resin foam according to the present invention of the present invention may optionally contain a thickener, a nucleating agent, a heat stabilizer and a foaming agent.

Although the thickening agent is not particularly limited, for example, pyromellitic dianhydride (PMDA) may be used in the present invention.

Examples of the nucleating agent include at least one of talc, mica, silica, diatomaceous earth, alumina, titanium oxide, zinc oxide, magnesium oxide, magnesium hydroxide, aluminum hydroxide, calcium hydroxide, potassium carbonate, calcium carbonate, magnesium carbonate, , Sodium hydrogencarbonate, and glass beads. These nucleating agents can play a role in imparting functionality and reducing costs. Specifically, Talc may be used in the present invention.

The heat stabilizer may be an organic or inorganic compound. The organic or inorganic phosphorus compound may be, for example, phosphoric acid and organic esters thereof, phosphorous acid and organic esters thereof. For example, the heat stabilizer may be a commercially available material, such as phosphoric acid, alkyl phosphate or aryl phosphate. Specifically, in the present invention, the heat stabilizer may be triphenyl phosphate, but it is not limited thereto and may be used within a conventional range without limitation as long as it can improve thermal stability.

Examples of the foaming agent include physical foaming agents such as N ₂ , CO ₂ , freon, butane, pentane, neopentane, hexane, isohexane, heptane, isoheptane and methyl chloride, azodicarbonamide- (P, P'-oxy bis (benzene sulfonyl hydrazide)], N, N'-dinitroso pentamethylene tetramine-based compounds, and the like. Specifically, CO ₂ can be used in the present invention.

The flame retardant in the present invention is not particularly limited, and may include, for example, a bromine compound, phosphorus or phosphorus compound, and antimony compound. The bromine compound includes, for example, tetrabromobisphenol A and decabromodiphenyl ether, and the phosphorus or phosphorus compound includes an aromatic phosphoric acid ester, an aromatic condensed phosphoric acid ester, a halogenated phosphoric acid ester, and the like, and the antimony compound Antimony trioxide, antimony pentoxide, and the like.

The surfactant is not particularly limited, and examples thereof include anionic surfactants (e.g., 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 protective colloids (e.g., gelatin, methylcellulose, hydroxyethylcellulose, Polyoxyethylene-polyoxypropylene block copolymer, polyacrylamide, polyacrylic acid, polyacrylic acid salt, sodium alginate, polyvinyl alcohol partial saponification, etc.), and the like have.

The waterproofing agent is not particularly limited and includes, for example, silicone, epoxy, cyanoacrylate, polyvinyl acrylate, ethylene vinyl acetate, acrylate, polychloroprene, polyurethane and polyester resins , 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 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, and mixtures thereof.

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  One

100 parts by weight of a polyethylene terephthalate (PET) resin was dried at 130 ° C to remove water. In the first extruder, the water-removed PET resin and the water-removed PET resin 1 part by weight of pyromellitic dianhydride, 1 part by weight of talc and 0.1 part by weight of Irganox (IRG 1010) were mixed with 100 parts by weight of the resin 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 PET resin, and extrusion foaming was carried out to prepare a polyester resin foam. The density of the foamed layer was 350 kg / m ³ , the mass per unit area was 700 g / m ² , and the thickness was 2 mm.

Then, a glass fiber mat having a mass per unit area of 80 g / m ² was laminated on both surfaces of the foamed layer.

Then, a polyester nonwoven fabric having a chopped glass fiber having a mass per unit area of 120 g / m < ² > on one side thereof was laminated on the opposite side of the surface of the glass fiber mat contacting with the foam layer, And then hot pressed at 180 DEG C for 120 seconds to manufacture the vehicle interior and exterior materials according to the present invention.

Example  2

The foamed layer was prepared in the same manner as in Example 1 except that the foamed layer had a density of 200 kg / m ³ , a mass per unit area of 500 g / m ² , The thickness was 2.5 mm.

Then, a glass fiber mat having a mass per unit area of 80 g / m ² was laminated on both surfaces of the foamed layer.

Thereafter, a polyester nonwoven fabric having a chopped glass fiber having a mass per unit area of 120 g / m ² on one side thereof was laminated on the opposite side of the surface of the glass fiber mat which was in contact with the foam layer, The inner and outer cover materials for automobiles according to the present invention were manufactured through thermal bonding by pressing for 2 seconds.

Example  3

The foam layer was prepared in the same manner as in Example 1 except that the foam layer had a density of 190 kg / m ³ , a mass per unit area of 625 g / m ² , The thickness was 2.5 mm.

Then, a polyester adhesive resin was applied on both surfaces of the foamed layer to a thickness of 150 μm, and then a glass fiber mat having a mass per unit area of 80 g / m ^{2 was} laminated.

Then, a polyester nonwoven fabric having a chopped glass fiber having a mass per unit area of 120 g / m < ² > on one side thereof was laminated on the opposite side of the surface of the glass fiber mat contacting with the foam layer, And then hot pressed at 180 DEG C for 120 seconds to manufacture the vehicle interior and exterior materials according to the present invention.

Comparative Example  One

The foam layer was prepared in the same manner as in Example 1 except that the foam layer had a density of 350 kg / m ³ , a mass per unit area of 800 g / m ² , The thickness was 2 mm and the interior and exterior materials of the vehicle were manufactured without forming a separate glass fiber mat and nonwoven fabric layer.

Comparative Example  2

A lightweight reinforced thermoplastic composite material, LWRT (Low Weight Reinforced Thermoplastics) (MS 383-04), was used to manufacture a vehicle interior and exterior material having a thickness of 8 mm and a mass per unit area of 850 g / m ² .

Experimental Example  One

Flexural stiffness and flexural strength were measured for the vehicle interior and exterior materials of Examples 1 to 3 and Comparative Examples 1 and 2.

The flexural modulus and flexural strength were measured according to ASTM D 790 by setting the support spacing of the specimen at 100 mm and applying a flexural load at 5 mm / Respectively. The results are shown in Table 1 below.

Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2 Flexural Strength (N) 33.4 24.9 23.6 12.3 22.0 Flexural modulus (Mpa) 1295.8 1072.3 1387.9 223.8 590.0

Referring to Table 1, the automotive interior and exterior materials of Examples 1 to 3 according to the present invention were produced by thermally bonding a foam layer, a glass fiber mat, and a nonwoven fabric layer, and had a flexural strength of 23.6 N or more, a flexural modulus of 1072.3 Mpa or more , It can be confirmed that both excellent bending strength and flexural modulus are satisfied at the same time.

Experimental Example  2

The dimensional change rates of the vehicle interior and exterior materials of Examples 1 to 3 and Comparative Examples 1 and 2 were measured and shown in Table 2 below.

The rate of dimensional change was measured before and after irradiating light having a wavelength of 300 to 400 nm with light having an illuminance of 255 W / m ² for 90 days according to the accelerated light resistance test of KS R 0021. At this time, the volume before measurement was 1 m ³ , and the rate of dimensional change was expressed by the following condition 1.

[Condition 1]

In condition 1, Lt ₀ represents the dimension before the treatment, and Lt ₁ represents the dimension after the treatment.

Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2 Dimensional change ratio (%) 0.1 0.1 0.1 18 26

Referring to Table 2, in the vehicle interior and exterior materials of Examples 1 to 3 according to the present invention, the dimensional change ratio was 0.1% or less. Thus, the vehicle interior and exterior materials according to the present invention prevent deformation due to ultraviolet rays, Respectively.

Experimental Example  3

The sound absorption rate and the differential tone were measured for the vehicle interior and exterior materials of Examples 1 to 3 and are shown in Table 3 below.

The absorption coefficient was measured from 0 to 10,000 Hz 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.

The attenuation was obtained by using an Apamat measuring instrument based on KS F 2862 to determine the transmission loss value at a frequency of 1 to 8,000 Hz. For comparison, the transmission loss values of 8,000 Hz were compared.

Example 1 Example 2 Example 3 Sound absorption rate (NRC) 0.4 0.4 0.4 Differential tone (dB) 20 18 19

100, 200, 300: interior and exterior materials for vehicles
10: foam layer
20: inorganic fiber mat
30: polyester nonwoven fabric layer
40: adhesive layer

Claims (12)

A foam layer containing a polyester resin foam; And
And an inorganic fiber mat formed on one side or both sides of the foam layer,
The inorganic fibers have an average diameter in the range of 10 to 1000 mu m,
The density of the foam layer (KS M ISO 845) is in the range of 30 to 700 kg / m ³ ,
The vehicle interior and exterior materials have flexural strengths in the range of 20 to 200 N when the bending load is applied at a rate of 5 mm / min with the span of the specimen being fixed at 100 mm in accordance with ASTM D 790,
An automotive interior and exterior material satisfying the following condition 1:
[Condition 1]

The above Condition 1 means the rate of change (average value of width, length, height) before and after irradiating light having a wavelength of 300 to 400 nm with light having an illuminance of 255 W / m ² for 90 days according to the accelerated light resistance test of KS R 0021 , Lt ₀ represents the dimension before the treatment, and Lt ₁ represents the dimension after the treatment.
The method according to claim 1,
The vehicle interior and exterior materials have a flexural modulus (Stiffness) ranging from 400 to 2000 MPa when the supporting span of the specimen is fixed at 100 mm and the flexural load is applied at a speed of 5 mm / min according to ASTM D 790.
The method according to claim 1,
The inorganic fiber includes at least one of a glass fiber, a metal or a metal oxide, and carbon fibers.
The method according to claim 1,
Wherein the foam layer has an average thickness of 1 to 10 mm.
The method according to claim 1,
Wherein the mass per unit area of the vehicle interior and exterior materials is in the range of 300 to 3000 g / m ² .
The method according to claim 1,
Wherein the vehicle interior and exterior material further comprises a polyester nonwoven fabric layer formed on an opposite surface of the inorganic fiber mat which is in contact with the foam layer.
The method according to claim 6,
The vehicle interior and exterior material is characterized in that inorganic fibers having an average length of 5 to 100 mm are attached to one side of the polyester nonwoven fabric layer with an adhesive.
The method according to claim 1,
And an adhesive layer formed between the foamed layer and the inorganic fiber mat of the vehicle interior / exterior material,
Wherein the adhesive layer comprises a polyester-based resin.
The method according to claim 1,
And an adhesive layer formed between the foamed layer and the inorganic fiber mat of the vehicle interior / exterior material,
Wherein the adhesive layer comprises an adhesive resin containing at least one of an acrylic resin containing an inorganic fiber, an epoxy resin, a silicone resin and a urethane resin.
delete The method according to claim 1,
The sound absorption rate measured according to KS F 2805 is 0.4 NRC or more,
An interior and exterior material for a vehicle having a transmission loss value of 10 dB or more as measured in accordance with KS F 2862.
The method according to claim 1,
Vehicle interior and exterior materials are intended for use as head liner, package tray and under cover.

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