KR102013203B1 - A resin composition for automobile interior floor carpet and automobile floor carpet prepared using the same - Google Patents

Abstract

The present invention relates to a resin composition for an automobile interior floor carpet having excellent wearing resistance and mechanical and physical strength, and to an automobile floor carpet prepared by using the same. The resin composition for an automobile interior floor carpet comprises: 100 parts by weight of a base resin; 5-50 parts by weight of a flame retardant; and 5-50 parts by weight of a filler. The base resin comprises 20-80 wt% of a polyolefin resin and 20-80 wt% of a thermoplastic elastomer.

Description

Resin composition for car interior floor carpet and car floor carpet manufactured using the same {A RESIN COMPOSITION FOR AUTOMOBILE INTERIOR FLOOR CARPET AND AUTOMOBILE FLOOR CARPET PREPARED USING THE SAME}

The present invention relates to a resin composition for automobile interior floor carpets and automobile floor carpets produced using the same.

Car carpet is a built-in material installed on the floor or the bottom of the vehicle interior. The vehicle carpet blocks and absorbs various noises and engine noises generated while the vehicle is in operation, and is installed for the purpose of providing a comfortable ride comfort such as cushioning and warmth to the occupant.

Conventional vehicle carpet is manufactured in a single layer form using a thermoplastic resin composition, or a skin layer; A felt layer provided on a lower surface of the skin layer; And a back coating layer formed on the lower surface of the felt layer.

On the other hand, the skin layer of the conventional single-layered carpet, or multi-layered carpet is formed using a thermoplastic resin composition containing PVC (Polyvinyl chloride), etc., mainly manufactured using recycled PVC resin to reduce the manufacturing cost Have been. However, these PVC resins contain heavy metals that are harmful to the human body and not only cause odors, but also generate harmful gases such as dioxins during vehicle fire or incineration.

Background art related to the present invention is disclosed in Republic of Korea Utility Model Publication No. 20-0471751 (2014.03.11, the name of the invention: three-structure vehicle mat).

An object of the present invention is to provide a resin composition for automotive interior floor carpet having excellent light weight, wear resistance and mechanical and physical strength.

Another object of the present invention is to provide a resin composition for automobile interior floor carpet having excellent sound absorption and sound insulating properties, and having no off-flavor and toxic gas generation.

Still another object of the present invention is to provide a resin composition for automobile interior floor carpet having excellent processability, productivity and economy.

Another object of the present invention is to provide an automobile floor carpet manufactured using the resin composition for automobile interior floor carpet.

One aspect of the present invention relates to a resin composition for automobile interior floor carpet. In one embodiment the resin composition for automotive interior floor carpet 100 parts by weight of the base resin; 5 to 50 parts by weight of flame retardant; And 5 to 50 parts by weight of a filler; wherein the base resin includes 20 to 80% by weight of polyolefin resin and 20 to 80% by weight of thermoplastic elastomer.

In one embodiment the polyolefin resin may comprise one or more of polyethylene, polypropylene and ethylene-propylene copolymer resin.

In one embodiment, the thermoplastic elastomer may include one or more of olefin-based, styrene-based, urethane-based, and ester-based elastomers.

In one embodiment, the flame retardant comprises at least one of magnesium hydroxide (Mg (OH) ₂ ) and aluminum hydroxide (Al (OH) ₃ ), and the filler is silica, magnesium carbonate (MgCO ₃ ), titanium dioxide ( TiO ₂ ), barium sulfate (BaSO ₄ ), talc (talc) and calcium carbonate (CaCO ₃ ) may include one or more.

In one embodiment, 0.05 to 5 parts by weight of lubricant based on 100 parts by weight of the base resin; 0.05-5 parts by weight of antioxidant; 0.05 to 5 parts by weight of carbon black; It may further include one or more of.

Another aspect of the present invention relates to an automobile floor carpet manufactured using the resin composition for automobile interior floor carpet.

The resin composition for automobile interior floor carpet according to the present invention is excellent in light weight, abrasion resistance and mechanical and physical strength, excellent sound absorption and sound insulation, no odor and toxic gas generation, when recycling the resin composition, recycling and Eco-friendly, can be excellent in productivity and economic efficiency.

1 shows a car floor carpet manufactured according to one embodiment of the invention.
Figure 2 shows the specimen for elongation evaluation of the automotive floor carpet prepared according to one embodiment of the present invention.

In the following description of the present invention, when it is determined that detailed descriptions of related well-known technologies or configurations may unnecessarily obscure the subject matter of the present invention, the detailed description will be omitted.

The terms to be described below are terms defined in consideration of functions in the present invention, and may be changed according to intentions or customs of users or operators, and the definitions should be made based on the contents throughout the specification for describing the present invention.

Car built Follower Carpet  Resin composition

One aspect of the present invention relates to a resin composition for automobile interior floor carpet. In one embodiment the resin composition for automotive interior floor carpet 100 parts by weight of the base resin; 5 to 50 parts by weight of flame retardant; And 5 to 50 parts by weight of a filler.

Hereinafter, the components of the resin composition for automobile interior floor carpet according to the present invention will be described in more detail.

Base resin

The base resin includes a polyolefin resin and a thermoplastic elastomer. In one embodiment the polyolefin resin may comprise one or more of polyethylene, polypropylene and ethylene-propylene copolymer resin. For example, it may include polyethylene and polypropylene.

When the base resin of the present invention is applied, the density is lower than that of PVC, so that the weight of the product can be reduced, and the hardness can be controlled by the copolymer ratio. Does not have the advantage.

In one embodiment, the polyolefin resin may have a weight average molecular weight of 50,000 to 350,000 g / mol measured by gel permeation chromatography (GPC). In the above range, the impact resistance and heat resistance of the present invention may be excellent. For example, it may be 100,000 to 350,000 g / mol.

When the polyethylene is included, wear resistance and impact resistance of the resin composition may be improved. In one embodiment the polyethylene may comprise one or more of high density polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE). For example, it may comprise high density polyethylene.

When the polypropylene is included, the rigidity of the resin composition may be excellent.

The polypropylene may be propylene homopolymerized homo polypropylene; Random polypropylenes in which one or more comonomers are randomly copolymerized; It may comprise one or more of impact polypropylene consisting of blocks of homopolymers and ethylene-propylene copolymers. For example, it may include random polypropylene.

The thermoplastic elastomer (TPE) is a polymer in which a comonomer of a hard monomer and a soft monomer is polymerized in one molecular chain. The thermoplastic elastomer is a polymer material having both elasticity of rubber and plasticity of plastic, and has similar moldability to soft PVC used in the manufacture of conventional carpets for vehicles.

In one embodiment, the thermoplastic elastomer may include one or more of olefin-based, styrene-based, urethane-based, and ester-based elastomers.

The olefin elastomer (TPO) may include one or more of ethylene-butene rubber, ethylene-octene rubber, ethylene-propylene rubber, ethylene-propylene diene rubber (EPDM) and propylene-butene rubber.

The styrene-based elastomer (SBC) is at least one of styrene-isoprene-styrene block copolymer (SIS), styrene-ethylene-butylene-styrene block copolymer (SEBS), styrene-ethylene-propylene-styrene copolymer (SEPS) It may include.

In an embodiment, the base resin includes 20 to 80% by weight of polyolefin resin and 20 to 80% by weight of thermoplastic elastomer. When included in the weight range may be excellent in rigidity, ductility and sound insulation. When the thermoplastic elastomer is included in less than 20% by weight, the impact strength and cushioning are reduced, and when the thermoplastic elastomer is included in excess of 80% by weight, the stiffness, shape stability, and tensile properties may be reduced.

In one embodiment, the base resin may have a melt-flow index (MI) measured at 190 ° C. and a load condition of 2.16 kg, according to ASTM D 1238, of 0.05˜30 g / 10 min. It is possible to satisfy excellent mechanical properties, flowability and formability at the same time in the above range. For example, it may be 0.1-20 g / 10min.

Flame retardant

The flame retardant is included for the purpose of securing heat resistance, flame resistance. In one embodiment, the flame retardant may include a metal hydroxide flame retardant. For example, one or more of magnesium hydroxide (Mg (OH) ₂ ) and aluminum hydroxide (Al (OH) ₃ ) may be included.

In addition, the metal hydroxide flame retardant may be a surface treated with alkyl silane, vinyl silane, stearic acid, oleic acid, amino polysiloxane and the like. The surface treatment may be excellent in dispersibility and mixing when preparing the composition.

In one embodiment, the average particle diameter of the metal hydroxide flame retardant may be 0.1 ~ 80㎛. When applied in the above range may be excellent in moldability of the composition of the present invention.

In one embodiment, the flame retardant is 5 to 50 parts by weight based on 100 parts by weight of the base resin. When the flame retardant is included in less than 5 parts by weight, it is difficult to secure flame retardancy and heat resistance, and when it is included in more than 50 parts by weight, the mixing properties and mechanical strength of the resin composition may be reduced.

Filler

The filler improves the heat resistance and mechanical strength of the resin composition of the present invention. The filler may include one or more of silica, magnesium carbonate (MgCO ₃ ), titanium dioxide (TiO ₂ ), barium sulfate (BaSO ₄ ), talc, and calcium carbonate (CaCO ₃ ). For example, it may include one or more of talc, calcium carbonate, barium sulfate, and titanium dioxide.

In one embodiment, the specific surface area (BET method) of the filler may be 5mm ² / g ~ 300mm ² / g. In the above range, the dispersibility, moldability and mechanical strength of the present invention can be excellent.

In one embodiment, the filler may be a surface treated. The surface treatment may be to coat the filler surface with one or more of a silane coupling agent, a titanate coupling agent, a fatty acid, a metal hydrate (metal hydroxide), an amine, and a metal salt of an amine. The compatibility and mechanical strength of the filler in the surface treatment may be excellent at the same time.

In one embodiment, the filler is 5 to 50 parts by weight based on 100 parts by weight of the base resin. When the filler is included in less than 5 parts by weight, it is difficult to secure the cost competitiveness of the resin composition, and when included in more than 50 parts by weight, the mixing properties, moldability, light weight, tensile properties and stretching properties of the resin composition may be lowered.

In one embodiment, the flame retardant and the filler may be included in a weight ratio of 1: 1 to 1: 4. When included in the weight ratio range, the moldability may be excellent, and the mechanical strength may be excellent. For example, the flame retardant and the filler may be included in a weight ratio of 1: 1.5 to 1: 2.5.

In one embodiment, 0.05 to 5 parts by weight of lubricant based on 100 parts by weight of the base resin; 0.05-5 parts by weight of antioxidant; 0.05 to 5 parts by weight of carbon black; It may further include one or more of.

The lubricant may be included for the purpose of improving processability, flowability and formability. In one embodiment, the lubricant may include one or more of stearic acid and fatty acid-based lubricant.

In one embodiment, the stearic acid-based lubricant may include one or more of zinc stearate, calcium stearate, and magnesium stearate. For example, it may include calcium stearate.

In one embodiment, the fatty acid-based lubricant may include at least one of montanic acid, oleic acid, animal fatty fatty acid, and vegetable higher fatty acid.

In one embodiment, the lubricant may be included from 0.05 to 5 parts by weight based on 100 parts by weight of the base resin. When included in the above range may be excellent in processability, fluidity and moldability of the resin composition.

The antioxidant may improve the heat resistance of the resin composition to prevent aging or deterioration of the resin composition components in a high temperature environment. In one embodiment, the antioxidant may include one or more of phosphorus, phenol, amine, sulfur and metal-based antioxidants.

The phenolic antioxidants are stericly hindered phenolic stabi1izers that are stericly hindered, for example, alkylated monophenol compounds, alkylthiomethylphenol compounds, hydroquinone compounds, alkylated hydroquinone compounds, tocopherol compounds, and hydroxylated compounds. One or more of thiodiphenyl ethyr compounds and alkylidene bisphenol compounds.

The phosphorus antioxidant may include at least one of a phosphorus ester compound and an aromatic phosphine compound.

Examples of the amine antioxidant include N'-diisopropyl-p-phenylenediamine, N, N'-di-secondarybutyl-p-phenylenediamine, and N, N'-bis (1,4-dimethylpentyl) -p-phenylenediamine, N, N'-bis (1-ethyl-3-methylpentyl) -p-phenylenediamine, N, N'-bis (1-methylheptyl) -p-phenylenediamine, N , N'-dicyclohexyl-p-phenylenediamine, N, N'-diphenyl-p-phenylenediamine, N, N'-bis (2-naphthyl) -p-phenylenediamine, N-iso Propyl-N'-phenyl-p-phenylenediamine, N- (1,3-dimethylbutyl) -N'-phenyl-p-phenylenediamine, N- (1-methylheptyl) -N'-phenyl-p -Phenylenediamine, N-cyclohexyl-N'-phenyl-p-phenylenediamine, 4- (p-toluenesulfonamido) diphenylamine and N, N'-dimethyl-N, N'-di-secondary One or more of butyl-p-phenylenediamine.

As the sulfur-based antioxidant, dilauryl 3,3-thiodipropionate, dimyristyl 3,3'-thiodipropionate, distearyl 3,3-thiodipropionate, lauryl stearyl 3,3-thiodipropionate, pentaerythritol-tetrakis- (β-lauryl-thio-propionate) and 3,9-bis (2-dodecylthioethyl) -2,4, One or more of 8,10-tetraoxaspiro [5,5] undecane.

The metal-based antioxidant may include at least one of copper-based antioxidant, molybdenum-based antioxidant, lead chloride, magnesium chloride and zinc chloride.

In one embodiment the antioxidant is a chain reaction of radicals. Instead of the polymer may include a primary antioxidant to stabilize the polymer, stabilize the polymer, and peroxide decomposition, the removal of oxygen atoms of the already oxidized polymer, the secondary antioxidant having a polymer stabilizing effect. For example, the primary antioxidant may include a phenolic antioxidant, and the secondary antioxidant may include a phosphorus antioxidant. For example, the primary antioxidant and the secondary antioxidant may be included in a weight ratio of 1: 3 to 3: 1.

In one embodiment, the antioxidant may be included 0.05 to 5 parts by weight based on 100 parts by weight of the base resin. When included in the range, deterioration or aging can be prevented without inhibiting the mechanical properties of the resin composition.

The carbon black is included as a black pigment. In one embodiment, the carbon black may be included in an amount of 0.05 to 5 parts by weight based on 100 parts by weight of the base resin.

additive

In another embodiment of the present invention, the resin composition may further include a conventional additive depending on the use within a range that does not impair the desired effect. The additive may further include one or more of antimicrobial agents, surfactants, flame retardant aids, anti-dripping agents, weathering agents, ultraviolet absorbers and sunscreen agents.

In one embodiment, the additive may be included in an amount of 0.01 to 20 parts by weight based on 100 parts by weight of the base resin.

In one embodiment, the resin composition for automobile interior floor carpet may have a specific gravity of 1.0 to 1.3. Light weight may be excellent in the above conditions. In one embodiment, the resin composition for automobile interior floor carpet may have a hardness (Shore A) of 95 or less.

The resin composition for automobile interior floor carpet according to the present invention is excellent in light weight, abrasion resistance and mechanical and physical strength, excellent sound absorption and sound insulation, no odor and toxic gas generation, when recycling the resin composition, recycling and Eco-friendly, can be excellent in productivity and economic efficiency.

Car built Follower Carpet  Automobile manufactured using the resin composition Follower carpet

Another aspect of the present invention relates to an automobile floor carpet manufactured using the resin composition for automobile interior floor carpet.

1 shows a car floor carpet manufactured according to one embodiment of the invention. Referring to FIG. 1, the car floor carpet 100 may include a skin layer 10; A felt layer 20 provided on the lower surface of the skin layer 10; And a back coating layer 30 formed on the lower surface of the felt layer 20. In one embodiment, the skin layer 10 may be prepared using the resin composition for automotive interior floor carpet of the present invention. In another embodiment, the car floor carpet may be manufactured in a single layer form using the resin composition for the car interior floor carpet.

In an embodiment, the skin layer of the car floor carpet or the car floor carpet is first kneaded by adding a component of the resin composition for car interior floor carpet to a mixer, and then second kneaded using a roll mill to form a sheet. The intermediate molded body may be prepared, the intermediate molded body may be drawn, then cooled and wound up to prepare the intermediate molded body.

The resin composition for automobile interior floor carpet according to the present invention is excellent in light weight, abrasion resistance and mechanical strength, excellent sound insulation, no odor and toxic gas generation, excellent eco-friendliness, productivity and economics can be excellent. .

Hereinafter, the configuration and operation of the present invention through the preferred embodiment of the present invention will be described in more detail. However, the following examples are provided to help the understanding of the present invention, and the scope of the present invention is not limited to the following examples. Details that are not described herein will be omitted since those skilled in the art can sufficiently infer technically.

Example  And Comparative example

The components used in the Examples and Comparative Examples are as follows.

(A) Base Resin

(A1) Polyolefin Resin: A polypropylene random copolymer and a high density polyethylene (HDPE) resin were used.

(A2) Thermoplastic elastomer: An olefin elastomer and an ethylene-propylene rubber were used.

(A3) Polyvinyl chloride (PVC) resin was used.

(B) Flame retardant: Magnesium hydroxide (Mg (OH) ₂ ) was used.

(C) filler

(C1) talc was used.

(C2) calcium carbonate (CaCO ₃ ) was used.

(D) Glidants: Calcium stearate was used.

(E) Carbon black was used.

(F) Antioxidant: A phenolic antioxidant and phosphorus antioxidant were used.

Example  1 and 2 and Comparative example  1 to 3

The ingredients and contents shown in Table 1 below were added to a mixing mixer, followed by first kneading, followed by second kneading using a first roll mill, and third kneading using a second roll mill to prepare an intermediate shaped body in a sheet form. The intermediate body was stretched (TD direction), and then cooled and wound to prepare a skin layer (sound insulation layer) for automobile floor carpet having a thickness of 1.2 mm.

Property and Reliability Evaluation

About Examples 1 to 2 and Comparative Examples 1 to 3, physical properties were evaluated based on the following test methods, and the results are shown in Table 2 below.

(1) Melt Index (g / 10min): Based on ASTM D 1238 standard, the melt index of the base resin was measured under conditions of 190 ° C and 2.16 kg.

(2) Specific gravity: It tested under the conditions of temperature (20-25 degreeC) and relative humidity (40-60% R.H) based on KS M ISO 1183-1 standard.

(3) Hardness (Shore A): Measured according to ASTM D-2240 by Shore A hardness tester (Shore A).

(4) Tensile strength (kgf / cm ² ): 10TON UTM was used, referring to the ASTM D5035 standard (strip method), was tested at a tensile speed of 200mm / min.

(5) Tear strength (kgf / cm): The DUMBBELL type test piece was taken, pinched by a tensile tester, and the load at the time of tearing at a tensile speed of 200 mm / min was measured at the average value of the maximum value.

(6) Elongation (%): Elongation was the same as the tensile strength test method and apparatus, the elongation was calculated according to the following formula.

[Equation]

In addition, the specimen was applied to the specimen in the form as shown in Figure 2, and the average value of each of the test examples and the comparative examples.

(7) Odor test: The test apparatus used a desiccator (4 liters), the specimen size was 30mm x 30mm, the test conditions were left for 2 hours in DRY conditions (80 ± 2 ℃), 20ml of WET conditions distilled water A glass beaker containing was added thereto and left for 2 hours at (60 ± 2) ° C., and the criterion was calculated as follows.

- Criteria

Level 1-No Smell

Level 2-I don't know what the smell is, but I feel the smell

Level 3-The smell is weak and you can see what the smell is

Class 4-Strong, easy to detect odor

5 star-very strong smell

Grade 6-Intense, strong smell of breathing difficulties

(8) TVOC and HCHO test: Sampling bags with a capacity of 3 liters to maintain airtightness with cock type and stopper were used for Tedlar, Polyester and Fluoropolymer materials. , TVOC measuring instrument is a device with a measuring range of 0.01 ~ 100ppm or more, TOVC is measured at a resolution below 0.01ppm, and formaldehyde measuring instrument is a device with a measuring range of 0.01 ~ 30ppm or more It was.

(9) Abrasion resistance test: The abrasion resistance test was performed by using TABER abrasion tester, abrasion wheel was H-18 TYPE, load was applied by 1Kg, and the number of abrasion was performed 300 times. The criteria for determination were established.

- Criteria

Class 5-No signs of wear at all.

Level 4-Traces of abrasion are identified, but the amount is less pronounced.

Class 3-slight surface abrasion but no breakage of epidermal layer

Class 2-The destruction of the epidermis is 50% or less.

Class 1-Surface damage is evident, and the surface failure is almost the entire friction surface.

Referring to the results shown in Table 2, in Examples 1 to 2 to which the resin composition for automobile interior floor carpets of the present invention was applied, the specific gravity was low, and the light weight was excellent, and the tensile strength, elongation and wear resistance were excellent, and odor was generated. It was found to be low and minimize the emission of harmful substances during combustion. On the other hand, in the case of Comparative Example 1 in which the PVC resin is applied instead of the base resin of the present invention, the specific gravity is increased compared to Examples 1 and 2, and the light weight property is lowered. The tensile strength, tear strength and elongation are significantly lowered, and odor is generated. In addition, it was found that emissions of harmful substances increased during combustion. In addition, in the case of Comparative Examples 2 to 3 outside the content of the resin composition constituents of the present invention, it was found that the tensile strength, tear strength and elongation were significantly lower than those of Examples 1 and 2 above.

Simple modifications or changes of the present invention can be easily carried out by those skilled in the art, and all such modifications or changes can be seen to be included in the scope of the present invention.

10: skin layer 20: felt layer
30: back coating layer 100: car floor carpet

Claims (6)

100 parts by weight of the base resin;
10 to 50 parts by weight of flame retardant;
10 to 50 parts by weight of the filler;
0.05-5 parts by weight of lubricant;
0.05-5 parts by weight of antioxidant; And
Contains 0.05 to 5 parts by weight of carbon black;
The flame retardant and filler will be included in a weight ratio of 1: 1 to 1: 4,
The base resin is 20 to 80% by weight of polyolefin resin and 20 to 80% by weight of thermoplastic elastomer, the resin composition for automobile interior floor carpet.
The resin composition of claim 1, wherein the polyolefin resin comprises at least one of polyethylene, polypropylene, and ethylene-propylene copolymer resin.
The resin composition of claim 1, wherein the thermoplastic elastomer comprises at least one of an olefin-based, styrene-based, urethane-based, and ester-based elastomer.
The method of claim 1, wherein the flame retardant comprises at least one of magnesium hydroxide (Mg (OH) ₂ ) and aluminum hydroxide (Al (OH) ₃ ),
The filler comprises at least one of silica, magnesium carbonate (MgCO ₃ ), titanium dioxide (TiO ₂ ), barium sulfate (BaSO ₄ ), talc (talc) and calcium carbonate (CaCO ₃ ). Resin composition for interior floor carpets.
According to claim 1, based on 100 parts by weight of the base resin
0.05-5 parts by weight of lubricant;
0.05-5 parts by weight of antioxidant; And
0.05 to 5 parts by weight of carbon black; The resin composition for automobile interior floor carpet further comprising at least one of.
Automobile floor carpet manufactured using the resin composition for automobile interior floor carpet of any one of Claims 1-5.

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