KR102043373B1 - Vehicle interior panel comprising low melting polyester fiber - Google Patents

Abstract

The present invention comprises a first polyester fiber containing a low melting polyester resin having a melting point of 180 ° C to 250 ° C or a softening point of 100 ° C to 150 ° C; And a fibrous layer in which a second polyester fiber containing a polyester resin having a melting point higher than 250 ° C. is mixed, wherein the fibrous layer is partially fused to each other to form a fibrous layer, and the low melting polyester resin is terephthalic acid. Or an acid component consisting of an ester forming derivative thereof; And a low melting polyester resin formed of a diol component consisting of 2-methyl-1,3-propanediol (MPD) and ethylene glycol (EG).

Description

Automotive interior material containing low melting polyester resin {VEHICLE INTERIOR PANEL COMPRISING LOW MELTING POLYESTER FIBER}

The present invention relates to an automotive interior material containing a low melting point polyester resin, and having a low melting point polyester fiber, which is excellent in shape stability when used in thermoforming, and includes a low melting point polyester resin having excellent deformation properties under severe conditions. It is about interior materials.

Cars are equipped with exterior parts such as doors and fenders, or interior materials such as seats, door trims, and package tray panels. The vehicle body must provide stability, space and comfort to the occupant including the driver.

BACKGROUND In general, automotive interior materials combine a fiber with a thermoplastic resin or a mixture of a thermoplastic resin and a thermosetting resin to form a sheet, preheat it to about 120 ° C., and heat curable adhesive layer thereon to cure the surface material at a temperature below 120 ° C. After the deposition was carried out, the laminate was manufactured by cold compression molding.

Such a method heats the sheet at a relatively low temperature of approximately 120 ° C., so that no degradation such as surface material deteriorates at high temperature. However, the thermoplastic resin acting as a binder is not sufficiently melted at the above-mentioned low temperature, so that the bonding strength between the fibers is weak, and thus the durability is weak.

Automotive interior materials recently commercialized are mainly manufactured using fiber-reinforced resin boards or polyurethane-based foams.

The fiber reinforced resin board is manufactured by board-forming reinforced polypropylene resin using the natural fiber, such as hemp fiber. However, since the fiber-reinforced resin board uses natural fibers, the working environment is poor due to the odor generated during the molding process of the product, and causes the dissatisfaction due to the odor generated during the vehicle application. In addition, while the microorganisms such as molds are propagated in the natural fibers applied to the fiber-reinforced resin board, there is a fear that odor is generated and the components harmful to the health of the occupants are released. In addition, the fiber-reinforced resin board using the natural fiber has a disadvantage that it is difficult to reduce the weight.

Alternatively, a package tray panel using a polyurethane foam has a problem of emitting toxic gas during incineration. In addition, the polyurethane-based foam has a soft feeling when pressed by hand. To compensate for this, glass fiber or glass pieces may be contained to manufacture a car interior.

Republic of Korea Patent No. 0128075 relates to an interior material for automobiles and a method for manufacturing the same as a needled glass fiber sheet containing a thermoplastic resin binder, the support layer of the needled glass fiber is mainly composed of glass fibers; An air permeable heat sealable adhesive layer provided on the support layer; And it is disclosed in the interior material for automobiles, which is made of an air permeable surface layer, which is installed on the adhesive layer, wherein the support layer further contains foamed microbeads.

Automotive interior materials using glass fibers or glass pieces as described above has a problem that the weight increases, glass dust is generated during the manufacturing and transport process to inhibit the working environment of the operator.

The present invention has been invented to solve the problems of the prior art as described above, and an object of the present invention is to provide an automotive interior material including a low melting point polyester resin excellent in formability while having excellent processability.

In addition, an automotive interior material of the present invention is to provide a vehicle interior material containing a low-melting point polyester resin excellent in sagging (Sagging) to prevent sagging in harsh conditions.

The present invention comprises a first polyester fiber containing a low melting polyester resin having a melting point of 180 ° C to 250 ° C or a softening point of 100 ° C to 150 ° C; And a fibrous layer in which a second polyester fiber containing a polyester resin having a melting point higher than 250 ° C. is mixed, wherein the fibrous layer is in a partially fused form between the fibers forming the fibrous layer, and the low melting polyester resin is terephthalic acid. Or an acid component consisting of an ester forming derivative thereof; And a diol component consisting of 2-methyl-1,3-propanediol (MPD) and ethylene glycol (EG).

In addition, the diol component of the low-melting polyester resin is low, characterized in that formed from 20 to 50 mol% of 2-methyl-1,3-propanediol (MPD), 50 to 80 mol% of ethylene glycol (EG) Provided is an automotive interior comprising a melting point polyester resin.

In addition, the first polyester fiber is a sheath-core composite fiber, the sheath is formed of a low melting polyester resin, the core is a low melting polyester resin, characterized in that the melting point is formed of a polyester resin higher than 250 ℃ It provides a car interior material comprising a.

In addition, the first polyester fiber and the second polyester fiber provides a vehicle interior material comprising a low-melting polyester resin, characterized in that the mixture of the weight ratio 1: 9 to 9: 1 to form a fiber layer.

In addition, the fiber layer provides a vehicle interior material containing a low-melting point polyester resin, characterized in that the form retention during the thermoforming is 98% or more.

In addition, the automotive interior material provides a vehicle interior material containing a low melting polyester resin, characterized in that the sagging (Sagging) is 96% or more.

As described above, the automotive interior material containing the low-melting polyester resin according to the present invention is excellent in bonding between the fibers even in low-temperature thermoforming using low-melting polyester fibers and excellent in form stability.

In addition, the automotive interior material containing the low-melting-point polyester resin of the present invention is excellent in sagging even under the harsh conditions of heat resistance test, cold resistance test, moisture resistance test.

1,2 is a view showing a method for measuring the sagging (Sagging) of the interior materials for automobiles containing the low melting point polyester resin of the present invention.

Hereinafter, a preferred embodiment of the present invention will be described in detail. In describing the present invention, detailed descriptions of related well-known functions or configurations are omitted in order not to obscure the subject matter of the present invention.

As used herein, the terms “about”, “substantially”, and the like, are used at, or in close proximity to, numerical values when manufacturing and material tolerances inherent in the stated meanings are set forth, and an understanding of the present invention may occur. Accurate or absolute figures are used to assist in the prevention of unfair use by unscrupulous infringers.

The present invention relates to a first polyester fiber containing a low melting polyester resin having a melting point of 180 ° C. to 250 ° C. or a softening point of 100 ° C. to 150 ° C., and a second polyester containing a polyester resin having a melting point higher than 250 ° C. It relates to an automotive interior material comprising a low melting polyester resin formed by including a fiber layer mixed with fibers.

The low melting polyester resin is an acid component consisting of terephthalic acid or ester-forming derivatives thereof; And a diol component consisting of 2-methyl-1,3-propanediol (MPD) and ethylene glycol (EG).

2-methyl-1,3-propanediol (MPD) used in the present invention, the methyl group is bonded to the second carbon to facilitate the rotation of the polymer backbone, and acts as if it is a polymer end portion, thereby expanding the free space between the backbones, Increase the flowability of the entire molecular chain. This causes the polymer to be amorphous and has the same thermal properties as isophthalic acid. Due to the flexible molecular chain present in the polymer backbone, it improves the elasticity and serves to improve the tearing property when binding the nonwoven fabric.

That is, 2-methyl-1,3-propanediol includes methyl group (-CH ₃ ) as a side chain in the ethylene chain bonded to terephthalate, thereby freeing space for the main chain of the polymerized resin to rotate, thereby allowing freedom of the main chain. The softening point (Ts) and / or the glass transition temperature (Tg) can be controlled by inducing an increase and a decrease in crystallinity of the resin. This may have the same effect as in the case of using isophthalic acid (IPA) containing an asymmetric aromatic ring in order to lower the crystallinity of the conventional crystalline polyester resin.

The diol component of the low-melting polyester resin is preferably formed of 20 to 50 mol% of 2-methyl-1,3-propanediol (MPD) and 50 to 80 mol% of ethylene glycol (EG). If less than 20 mol% of -1,3-propanediol (MPD) is contained, the melting point of the low melting polyester resin may be increased, and if it exceeds 50 mol%, the physical properties of the low melting polyester resin may be reduced. .

When the content of 2-methyl-1,3-propanediol is contained in 20 mol% or more of the diol component, there is also an effect of suppressing the production of the cyclic compound as a side reaction product in the polyester polymerization process.

The first polyester fiber containing the low melting polyester resin is preferably a sheath-core composite fiber, and the sheath is formed of a low melting polyester resin, and the core is formed of a polyester resin having a melting point higher than 250 ° C. It is possible to improve the physical properties of the automobile interior material is manufactured.

It is preferable that the first polyester fiber is formed of a sheath and a core in a weight ratio of 40:60 to 60:40.

The polyester resin contained in the second polyester resin and having a melting point higher than 250 ° C. capable of forming the core of the first polyester fiber is polyethylene formed of terephthalic acid or its ester-forming derivative and ethylene glycol (EG). It may be terephthalate (PET), and may be a co-polyester resin copolymerized with a functional compound for functionality.

As the polyester resin having a higher melting point than 250 ° C., any polyester resin having a high melting point may be used.

The fiber layer is a partially fused form between the fibers forming the fiber layer, the partially fused form between the fibers are subjected to heat and / or pressure in the process of forming the fiber layer through the thermoforming, and in the process A fused form is achieved. The fiber layer may include a first polyester fiber containing a low melting point polyester resin to form a form in which the fibers are partially fused to each other through low temperature molding.

The fiber layer may further include a functional additive such as a flame retardant, a thickener, and an inorganic filler, depending on the purpose and purpose of use.

The first polyester fibers and the second polyester fibers forming the fibrous layer are preferably mixed in a weight ratio of 1: 9 to 9: 1 to form a fibrous layer. If the content of the first polyester fiber is low, the portion between the fibers Since fusion is weak, the shape stability may be lowered. If the content of the first polyester fiber is high, physical properties such as strength of the automotive interior material may be lowered.

Automotive interior material comprising a low-melting point polyester resin according to the present invention forms a fibrous layer of uniformly mixed with the first polyester fiber and the second polyester fiber and thermoforming at 100 ~ 200 ℃ to partially fusion between fibers To form and to form a certain form.

When the fiber layer has a high form retention rate during thermoforming, the interior material for automobiles has high form stability at high temperature. The fiber layer preferably has a form retention rate of 95% or more during thermoforming, and more preferably, a shape retention rate is 98% or more.

First polyester fiber containing a low melting polyester resin having a melting point of 180 ° C to 250 ° C or a softening point of 100 ° C to 150 ° C and a second polyester containing a polyester resin having a melting point of higher than 250 ° C. Automotive interior material having a fiber layer of the fiber is mixed sagging (Sagging) of more than 96% has excellent shape stability that is not easily deformed even under severe conditions.

Hereinafter, an embodiment of a method for manufacturing a vehicle interior material containing a low melting point polyester resin according to the present invention is shown, but the present invention is not limited to the embodiment.

Example  1 to 4

As the first polyester fiber, a sheath-core composite fiber was used, and the sheath was a low melting polyester resin, and a polyethylene terephthalate having a melting point of about 265 ° C. was used as the core. 50 formed composite fibers.

Terephthalic acid (TPA) was used as the low melting point polyester resin, and 2-methyl-1,3-propanediol (MPD) and ethylene glycol (EG) were used as general polyester polymerization methods as diol components. Prepared by polymerization. The molar ratio of the diol component used was different for each embodiment, the molar ratio of the diol component is shown in Table 1.

The second polyester fiber used polyethylene terephthalate having a melting point of about 265 ° C.

The first polyester fiber and the second polyester fiber were uniformly mixed with a carding machine at a weight ratio of 60:40 and thermoformed at about 130 ° C. to prepare a vehicle interior including a low melting polyester resin according to the present invention. .

Comparative example  1 to 4

The interior materials for automobiles were prepared in the same manner as in Example 1, but the low-melting polyester resins used were terephthalic acid (TPA) and isophthalic acid (IPA) as acid components, and ethylene glycol (EG) was used as the diol component. It was.

The molar ratio of the acid component used was different for each comparative example, the molar ratio of the acid component is shown in Table 1.

Comparative example  5 to 8

As in Example 1, automotive interior materials were manufactured, but the low melting polyester resin used was terephthalic acid (TPA) as an acid component, and ethylene glycol (EG) and diethylene glycol (DEG) were used as diol components. Prepared.

The molar ratio of the diol component used was different for each comparative example, the molar ratio of the diol component is shown in Table 1.

division Acid component (mol%) Diol component (mol%) TPA IPA MPD DEG EG Example 1 100 - 20 - 80 Example 2 100 - 30 - 70 Example 3 100 - 40 - 60 Example 4 100 - 50 - 50 Comparative Example 1 80 20 - - 100 Comparative Example 2 70 30 - - 100 Comparative Example 3 60 40 - - 100 Comparative Example 4 50 50 - - 100 Comparative Example 5 100 - - 20 80 Comparative Example 6 100 - - 30 70 Comparative Example 7 100 - - 40 60 Comparative Example 8 100 - - 50 50

◈ Evaluation of properties of low melting polyester resin and automotive interior

The glass transition temperature (Tg), melting point (or softening point) of the low melting point polyester resins prepared in Examples 1 to 4 and Comparative Examples 1 to 8 were measured, and the shape retention rate and sagging rate of automobile interior materials were measured. 2 is shown.

(1) melting point ( Tm ), Softening point ( Ts ) And glass transition temperature ( Tg ) Measure

Melting point (Tm) and glass transition temperature (Tg) of low-melting-point polyester resins were measured using a differential scanning calorimeter (Perkin Elmer, DSC-7). Softening behavior was measured in TMA mode using a mechanical analyzer (DMA-7, Perkin Elmer).

(2) shape retention rate

After carding process, 5g of mixed fibers are taken and placed in a 300 cm 3 cylindrical case (A), followed by 60sec treatment at 140 ° C. to measure the change in volume (B).

* Shape retention rate (%) = (B / A) × 100

(3) Sagging rate

The sagging rate was measured by the following measurement method after the harsh condition test of the heat test step, the cold test step, and the humidity test step three times in sequence.

Measuring method: After measuring 150 X 150 cm specimen 100 on the frame 10 as shown in Figure 1, the length of the specimen sagging downward

A: Deflection length before harsh condition test (see Fig. 2 (a))

B: Deflection length before harsh condition test (see Fig. 2 (b))

Sagging rate (%) = (A / B) X 100

1) Heat test step: after heating up to 100 ± 2 ℃ for 2 hours at room temperature of 23 ± 2 ℃, and left for 3 hours at 100 ± 2 ℃, cooled to room temperature of 23 ± 2 ℃ for 2 hours and 23 ± 2 ℃ 1 hour at room temperature

2) Cold resistance test step: After cooling to -40 ± 2 ℃ for 1 hour at room temperature of 23 ± 2 ℃, and left for 3 hours at -40 ± 2 ℃, the temperature is raised to 23 ± 2 ℃ room temperature for 1 hour and 23 ± 2 1 hour at room temperature

3) Humidity resistance test step: 90% relative humidity, the temperature of 23 ± 2 ℃ at room temperature to 50 ± 2 ℃ for 1 hour, and left at 50 ± 2 ℃ for 3 hours, then cooled to room temperature of 23 ± 2 ℃ for 1 hour 1 hour at room temperature of 23 ± 2 ℃

division Tg (℃) Tm (℃) Softening point (℃) Shape retention rate (%) Sagging property (%) Example 1 70.3 199.7 - 99.8 96.4 Example 2 67.7 184.9 - 99.7 97.3 Example 3 66.4 - 125 99.1 99.1 Example 4 64.1 - 110 98.9 99.7 Comparative Example 1 75.4 206.5 - 96.5 91.2 Comparative Example 2 71.1 185.1 - 95.8 92.5 Comparative Example 3 69.3 - 128 93.6 94.7 Comparative Example 4 68.1 - 115 91.1 95.5 Comparative Example 5 68.5 221.1 - 95.8 89.1 Comparative Example 6 62.1 203.3 - 92.9 90.2 Comparative Example 7 56.3 187.6 - 87.4 91.1 Comparative Example 8 50.2 170.1 - 84.1 91.8

As shown in Table 2, the low melting point polyester resin of the present invention has a melting point of 200 ° C. or less and a softening point of 150 ° C. or less.

In addition, it can be seen that the interior material for automobiles containing the low-melting point polyester resin of the present invention has a shape retention ratio of 98% or more, which is very superior to Comparative Examples 1 to 8, and a sagging rate of 96% or more. It can be seen that the deflection is prevented even under the harsh conditions of the test and the moisture resistance test.

Claims (6)

A first polyester fiber containing a low melting polyester resin having a melting point of 180 ° C to 250 ° C or a softening point of 100 ° C to 150 ° C; And a fibrous layer in which a second polyester fiber containing a polyester resin having a melting point higher than 250 ° C. is mixed,
The fiber layer is in the form of a partial fusion between the fibers forming the fiber layer,
The low melting polyester resin is an acid component consisting of terephthalic acid or ester-forming derivatives thereof; And a diol component consisting of 2-methyl-1,3-propanediol (MPD) and ethylene glycol (EG),
The fiber layer has a form retention ratio of more than 98% during thermoforming, and the automotive interior material comprises a low melting point polyester resin, characterized in that the sagging (Sagging) 96% or more. The method of claim 1,
Diol component of the low-melting polyester resin is a low-melting poly, characterized in that formed from 20 to 50 mol% 2-methyl-1,3-propanediol (MPD), 50 to 80 mol% ethylene glycol (EG) Interior materials for automobiles comprising an ester resin. The method of claim 1,
The first polyester fiber is a sheath-core composite fiber, and the sheath is formed of a low melting polyester resin, and the core includes a low melting polyester resin, characterized in that the melting point is formed of a polyester resin higher than 250 ° C. Interior materials for cars. The method of claim 1,
The first polyester fiber and the second polyester fiber is a vehicle interior material containing a low-melting polyester resin, characterized in that the mixture in a weight ratio 1: 9 to 9: 1 to form a fiber layer. delete delete

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