KR102316323B1 - Laminate comprising nonwoven fabric layer sandwiched between polyester resin foam sheets and manufacturing method of the same - Google Patents

Abstract

The present invention relates to a laminate in which a low-melting polyester nonwoven fabric is applied between foam sheets and a method for manufacturing the same, and a separate adhesive layer is not required for interlayer adhesion, and excellent noise blocking and vibration reduction properties can be realized.

Description

Laminate comprising a nonwoven fabric layer interposed between polyester resin foam sheets and a manufacturing method thereof

The present invention relates to a laminate comprising a polyester resin foam sheet and a method for manufacturing the same.

In general, as interior and exterior materials for vehicles, such as a headliner mounted on the inner surface of a roof panel of a vehicle, a package tray installed behind a rear seat, and an undercover mounted on the bottom of the vehicle, resin felt, paperboard (paper) board), rigid polyurethane, and corrugated cardboard.

Resin felt and paperboard are manufactured by impregnating phenol resin as a curing agent. The phenol resin is a kind of thermosetting resin produced by the condensation reaction of phenols and aldehydes. As a result, phenols and aldehydes are released. These phenols and aldehydes act as pollutants in the living environment including the working environment, and there is a problem of emitting toxic gases.

In the case of polyurethane rigid foam, heat insulation and lightness are excellent, but recyclability is lowered and rigidity is weak. In order to compensate for this disadvantage, a product in which a glass fiber layer is combined with a polyurethane rigid foam is used, and due to the lack of extensibility in the molding process for manufacturing automobile interior materials, brittle fracture occurs easily during molding, resulting in improved fairness. There is a problem of poor durability such as discoloration or crumbling of foam cells when used for a long time due to poor weather resistance.

The above-mentioned conventional interior and exterior materials for vehicles did not satisfy light weight and durability at the same time, did not have excellent formability, had a high unit price, was easy to deform during long-term use, and had comprehensive problems that it was harmful to the human body and the environment.

Therefore, it is urgently required to develop a sheet capable of realizing high strength, light weight, and excellent molding processability, as well as preventing toxic gas emission and having good durability and impact resistance.

Korean Patent Publication No. 2017-0123486

The present invention has been devised to solve the above problems, and an object of the present invention is to provide a laminate including a polyester resin foam sheet and a method for manufacturing the same.

In one example, the laminate according to the present invention has a structure in which a first polyester resin foam sheet layer, a polyester resin nonwoven fabric layer and a second polyester resin foam sheet layer are sequentially stacked, and the polyester resin nonwoven fabric layer is It has a structure in which the first and second polyester resin foam sheet layers are joined in a partially fused form.

In this case, the first and second polyester resin foam sheet layers have a structure in which n (n is an integer between 1 and 10) polyester resin foam sheets are laminated, each independently.

In another example, the polyester resin forming the polyester resin nonwoven fabric layer is a low-melting-point polyester resin having a melting point in the range of 150 to 200°C.

In one example, the difference (T2-T1) between the melting point (T1) of the polyester resin forming the polyester resin nonwoven fabric layer and the melting point (T2) of the polyester resin forming the polyester resin foam sheet is 10 ~80°C range.

In a specific example, the basis weight of the polyester resin nonwoven fabric layer is 100 g/m ² or more, the basis weight of the polyester resin foam sheet is 400 to 1,500 g/m ² , and the total basis weight of the laminate is 5,000 g/m ² is below.

In another example, the ratio of the expansion ratio (F1) of the polyester resin foam sheet of the first polyester resin foam sheet layer and the expansion ratio (F2) of the polyester resin foam sheet of the second polyester resin foam sheet layer (F1:F2) ranges from 1:1 to 10:1.

For example, the polyester resin forming the polyester resin foam sheet is polyethylene terephthalate (PET).

In another example, the laminate has an impact strength of 5 to 20 kJ/m ² when measured according to ASTM D256, and a sound insulation coefficient measured according to KS F 2862 is 15 dB or less.

In addition, the present invention provides a method for manufacturing the above-described laminate.

In one example, the method of manufacturing the laminate includes the steps of heating and pressing in a state in which the first polyester resin foam sheet layer, the polyester resin nonwoven fabric layer and the second polyester resin foam sheet layer are sequentially laminated. do. In this case, the melting point (T1) of the polyester resin forming the polyester resin nonwoven fabric layer is in the range of 150 to 200 ℃. In addition, the first and second polyester resin foam sheet layers, each independently, has a structure in which n (n is an integer between 1 and 10) polyester resin foam sheets are laminated.

In another example, the difference (T2-T1) between the melting point (T1) of the polyester resin forming the polyester resin nonwoven fabric layer and the melting point (T2) of the polyester resin forming the polyester resin foam sheet is 10 to 80°C range.

In another example, the first and second polyester resin foam sheet layers are each independently k (k is an integer between 2 and 10) of a polyester resin foam sheet laminated structure, and the first And the process of preparing the second polyester resin foam sheet layer, the step of partially fusion-bonding the surface of each polyester resin foam sheet; and laminating the partially fused polyester resin foam sheets.

In another example, the first and second polyester resin foam sheet layers are each independently k (k is an integer between 2 and 10) of a polyester resin foam sheet laminated structure, and the first And the process of manufacturing the second polyester resin foam sheet layer may include the step of contacting the interface by applying an adhesive between each polyester resin foam sheet.

A laminate and a method for manufacturing the same according to an embodiment of the present invention do not require a separate adhesive layer for interlayer adhesion, and have excellent noise blocking and vibration reduction effects.

1 is a cross-sectional view illustrating a laminate structure of a laminate according to an embodiment of the present invention.
2 is a cross-sectional view illustrating a laminate structure of a laminate according to another embodiment of the present invention.

Since the present invention can have various changes and can have various forms, specific embodiments are illustrated in the drawings and described in detail in the text. However, this is not intended to limit the present invention to the specific disclosed form, it should be understood to include all modifications, equivalents and substitutes included in the spirit and scope of the present invention.

In the present application, terms such as “comprise” or “have” are intended to designate that a feature, number, step, operation, component, part, or combination thereof described in the specification exists, but one or more other features It is to be understood that it does not preclude the possibility of the presence or addition of numbers, steps, operations, components, parts, or combinations thereof. Also, terms such as first and second may be used to describe various elements, but the elements should not be limited by the terms. The above terms are used only for the purpose of distinguishing one component from another. For example, without departing from the scope of the present invention, a first component may be referred to as a second component, and similarly, a second component may also be referred to as a first component. The singular expression includes the plural expression unless the context clearly dictates otherwise.

Hereinafter, the present invention will be described in more detail.

In one example, the laminate according to the present invention has a structure in which a first polyester resin foam sheet layer, a polyester resin nonwoven fabric layer and a second polyester resin foam sheet layer are sequentially stacked, and the polyester resin nonwoven fabric layer is It has a structure in which the first and second polyester resin foam sheet layers are joined in a partially fused form. In addition, the first and second polyester resin foam sheet layers, each independently, has a structure in which n (n is an integer between 1 and 10) polyester resin foam sheets are laminated.

In another example, the polyester resin forming the polyester resin nonwoven fabric layer is a low-melting-point polyester resin having a melting point in the range of 150 to 200°C. Specifically, the polyester resin forming the polyester resin nonwoven layer has a melting point in the range of 160 to 200°C, in the range of 170 to 190°C, or in the range of 175 to 185°C. The melting point of the polyester resin forming the polyester resin nonwoven fabric layer is within a range that facilitates partial fusion with the first and second polyester resin foam sheet layers, but does not reduce the heat resistance of the laminate.

In the present invention, by forming the polyester resin nonwoven fabric layer with a low-melting polyester resin, the first and second polyester resin foam sheet layers and partial fusion bonding are possible. Through this, a separate adhesive layer is not required to bond the first and second polyester resin foam sheet layers and the polyester resin nonwoven fabric layer.

In a specific example, the difference (T2-T1) between the melting point (T1) of the polyester resin forming the polyester resin nonwoven fabric layer and the melting point (T2) of the polyester resin forming the polyester resin foam sheet is 10 to 80°C range. Specifically, the difference in the melting point (T2-T1) is in the range of 10 ~ 80 ℃, 10 ~ 50 ℃, 10 ~ 25 ℃ range, 20 ~ 80 ℃ range, 50 ~ 80 ℃ range, or 55 ~ 75 ℃ range.

In one embodiment, the basis weight of the polyester resin nonwoven layer is 100 g/m ² or more. Specifically, the basis weight of the polyester resin nonwoven layer is in the ^{range of 100 to 800 g/m 2 , in the} range of 100 to 600 g/m ^{2 , in the} range of 100 to 500 g/m ^{2 in the} range, in the range of 150 to 1,000 g/m ^{2 in the} range, or in the range of 150 to 450 g/m ^{2 is the} range.

The basis weight of the polyester resin foam sheet is in the ^{range of 400 to 1,500 g/m 2} , respectively, in the range of 500 to 1,500 g/m ^{2 , in the} range of 500 to 1,000 g/m ^{2 in the} range, in the range of 400 to 800 g/m ² or in the range of 450 to 650 g/m ^{2 is the} range.

In addition, the total basis weight of the laminate is 5,000 g/m ² or less. Specifically, the total basis weight of the laminate is in the ^{range of 900 to 5,000 g/m 2 , in the} range of 1,000 to 4,000 g/m ^{2 ,} or in the range of 1,500 to 4,000 g/m ² .

In another embodiment, the polyester resin foam sheet of the first and second polyester resin foam sheet layers may have a different foaming ratio from each other. For example, the ratio of the expansion ratio (F1) of the polyester resin foam sheet of the first polyester resin foam sheet layer and the expansion ratio (F2) of the polyester resin foam sheet of the second polyester resin foam sheet layer (F1: F2) ranges from 1:1 to 10:1, from 1.2:1 to 5:1, from 1.5:1 to 5:1, from 2:1 to 10:1 or from 3:1 to 5:1. The ratio (F1:F2) of the expansion ratio (F1) of the polyester resin foam sheet of the first polyester resin foam sheet layer and the expansion ratio (F2) of the polyester resin foam sheet of the second polyester resin foam sheet layer is The case of 1:1 means that the expansion ratio of the first and second polyester foam sheet layers is the same, and this is also included in the scope of the present invention. However, it is also possible to form different expansion ratios of the first and second polyester foam sheet layers depending on the use of the laminate. For example, by controlling the expansion ratio of the first polyester foam sheet layer to be high, it is possible to increase sound insulation or impact damping characteristics and vibration reduction. In addition, by controlling the expansion ratio of the second polyester foam sheet layer to be low, it is possible to increase the mechanical strength.

In a specific example, the average thickness of the polyester resin foam sheet may be in the range of 1 to 10 mm, respectively. For example, the average thickness of the foam sheet is 1 to 8 mm, 1 to 6 mm, 1 to 5 mm, 1 to 3.5 mm, 1 to 3 mm, 1 to 5.5 mm, 1 to 2 mm, 1 to 1.5 mm, 1.5 to 8 mm, 2 to 8 mm, 3 to 5 mm or 4 to 5 mm.

In addition, in the present invention, it is also possible to form different average thicknesses of the first and second polyester resin foam sheet layers. For example, the first polyester resin foam sheet layer performs high-magnification foaming, but forms a relatively thick thickness, and the second polyester resin foam sheet layer performs low-magnification foaming, but it is also possible to form a relatively thin thickness. . For example, the average thickness of the first polyester resin foam sheet layer is in the range of 2 to 3 mm, and the average thickness of the second polyester resin foam sheet layer is in the range of 1 to 2 mm. In this case, the difference between the average thickness of the first and second polyester resin foam sheet layers is controllable in the range of 0.5 to 1.5 mm.

In addition, the cell size of the polyester resin foam sheet is in an average range of 80 μm to 600 μm. Specifically, the cell size of the foam sheet may be an average of 100 µm to 500 µm, 100 µm to 400 µm, or 350 µm to 500 µm, and more specifically, the cell size of the foam sheet is an average of 200 µm to 350 µm or 350 µm to 500 µm. μm. The cell size of the first and second polyester resin foam sheet layers can be adjusted according to the ratio of the aforementioned expansion ratio.

In one embodiment, the polyester resin foam sheet according to the present invention contains potassium carbonate in an appropriate range. The first and second polyester resin foam sheets can increase the surface uniformity and moldability of the foam sheet by uniformly mixing and foaming calcium carbonate in the polyester resin.

Specifically, the polyester resin foam sheet contains 0.5 wt% to 5 wt% of calcium carbonate. The content of the calcium carbonate is in the range of 0.5% to 5% by weight, 1% to 5% by weight, 1.5% to 4.5% by weight or 2% to 3.5% by weight. More specifically, the calcium carbonate may be added in an amount of 1.0 wt% to 3.0 wt% or 3.0 wt% to 4.5 wt%. For example, calcium carbonate (CaCO ₃ ) may have an amorphous shape. For example, calcium carbonate may be introduced into the extruder in the form of a masterbatch. By adding calcium carbonate as described above, it is possible to manufacture a foam sheet having a uniform surface and excellent thermoformability. In addition, since calcium carbonate is uniformly distributed in the polyester resin, the foam sheet obtained by extruding and foaming the resin has high thermal conductivity, so that it is possible to solve the problem of tearing the foam sheet during molding of the foam sheet.

The thermal conductivity of calcium carbonate may be 1.0 kcal/mh°C to 3.0 kcal/mh°C. Specifically, the thermal conductivity of calcium carbonate may be 1.2 kcal/mh°C to 2.5 kcal/mh°C, 1.5 kcal/mh°C to 2.2 kcal/mh°C, or 1.8 kcal/mh°C to 2.0 kcal/mh°C. More specifically, the thermal conductivity of calcium carbonate may be 1.5 kcal/mh°C to 2.5 kcal/mh°C or 1.8 kcal/mh°C to 2.3 kcal/mh°C. As described above, the foam sheet containing calcium carbonate has a uniform surface by exhibiting excellent thermal conductivity, and can exhibit excellent thermoformability.

In the present invention, the polyester resin forming the polyester resin foam sheet may be at least one selected from the group consisting of aromatic and aliphatic polyester resins synthesized from a dicarboxylic acid component and a glycol component or hydroxycarboxylic acid. The polyester resin is, for example, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polylactic acid (PLA), polyglycolic acid (PGA) , polyethylene adipate (Polyehtylene adipate, PEA), polyhydroxyalkanoate (Polyhydroxyalkanoate, PHA), polytrimethylene terephthalate (Polytrimethylene Terephthalate, PTT) and polyethylene naphthalate (Polyethylene naphthalate, PEN) may be at least one selected from the group consisting of have. Specifically, as the polyester resin according to the present invention, polyethylene terephthalate (PET) may be used.

In addition, the polyester resin may have an intrinsic viscosity (IV) of 0.4 dl/g to 1.2 dl/g. Specifically, the intrinsic viscosity is 0.5 dl/g to 1.1 dl/g, 0.6 dl/g to 1.0 dl/g, 0.7 dl/g to 1.1 dl/g, 0.9 dl/g to 1.1 dl/g, 0.5 dl/g to 0.7 dl/g, 0.6 dl/g to 0.7 dl/g, 0.7 dl/g to 0.9 dl/g, 0.75 dl/g to 0.85 dl/g, 0.77 dl/g to 0.83 dl/g or 0.6 dl/g to It may be 0.8 dl/g.

On the other hand, the laminate according to the present invention has a structure in which a first polyester resin foam sheet layer, a polyester resin nonwoven fabric layer, and a second polyester resin foam sheet layer are sequentially stacked.

The polyester resin forming the polyester resin nonwoven fabric layer has a melting point in the range of 150 to 200° C., and is referred to as a low melting point polyester resin in a relative sense.

Examples of such a low melting point polyester resin include an aromatic or aliphatic polyester resin synthesized from a dicarboxylic acid component, a glycol component, or hydroxycarboxylic acid. Non-limiting examples of the low melting point polyester resin include polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polylactic acid (PLA), polyglycolic acid (Polyglycolic acid) acid, PGA), polyethylene adipate (Polyehtyleneadipate, PEA), polyhydroxyalkanoate (PHA), polytrimethylene terephthalate (PTT) and polyethylene naphthalate (PEN) There may be more than one type.

Specifically, in the present invention, polyethylene terephthalate may be used as the low melting point polyester resin. In this case, the polyethylene terephthalate may include an acid component including terephthalic acid and isophthalic acid; And it is preferably a polymer of a diol component comprising at least one of ethylene glycol and diethylene glycol. In addition, with respect to 100 mol% of the acid component, the content of isophthalic acid may be 10 to 15 mol%.

In addition, the laminate has an impact strength of 5 to 20 kJ/m ² measured according to ASTM D256, and specifically, the impact strength is 7 to 20 kJ/m ² , 9 to 20 kJ/m ² , 10 to 20 kJ/m ² or may range from 12 to 20 kJ/m ^{2 .} The laminate has an amount of shock absorption measured according to KS M ISO 7214 of 1 g/100cm ² or more, 1.3 g/100cm ² or more, 1.5 g/100cm ² or more, 1.3 to 10 g/100cm ² or 1.0 to 5.0 g/ It can be 100 cm ^{2 .} By satisfying the impact strength and the amount of shock absorption of the laminate, it has excellent durability and effectively absorbs impact when an impact is applied, and improved strength performance can be realized. In addition, in the laminate, the sound insulation factor measured according to KS F 2862 may be in the range of 15 dB or less, 0.1 to 13 dB, or 1 to 13 dB.

The present invention also provides a method for producing the aforementioned laminate.

In one embodiment, in the method for manufacturing a laminate according to the present invention, in a state in which the first polyester resin foam sheet layer, the polyester resin nonwoven fabric layer and the second polyester resin foam sheet layer are sequentially laminated, heating and pressurization including the steps of

In this case, the first and second polyester resin foam sheet layers have a structure in which n (n is an integer between 1 and 10) polyester resin foam sheets are laminated, each independently. When n is an integer between 2 and 10, the method may further include laminating the polyester resin foam sheet to prepare a foam sheet layer. When the foam sheet layer has a structure in which several foam sheets are laminated, the strength of the laminate is improved.

The first and second polyester resin foam sheet layers each independently have a structure in which k (k is an integer between 2 and 10) polyester resin foam sheets are laminated,

The process of manufacturing the first and second polyester resin foam sheet layers may be a method of bonding the interface through an adhesive or an adhesive film between each polyester resin foam sheet.

In addition, after melting the surface of the polyester resin foam sheet by heating, by thermal bonding, it is also possible to laminate the polyester resin foam sheet without separately including an adhesive.

Specifically, the polyester resin foam sheet introduced in the step of preparing the first and second polyester resin foam sheet layers by laminating k pieces of polyester resin foam sheet, respectively, is one or both sides of the polyester resin foam sheet. The surface may be in a partially molten state. The surface of the molten polyester resin foam sheet can be easily thermally bonded to each other without an adhesive.

In the step of manufacturing the first and second polyester resin foam sheet layers by laminating k pieces of the polyester resin foam sheet, respectively, k pieces of polyester resin foam sheet in which the surfaces of one or both sides are partially melted are introduced and , the introduced k polyester resin foam sheets may be laminated by a pressure roller in a laminated state.

The heated polyester resin foam sheet surface may be melted to facilitate lamination. The surface of the molten polyester resin foam sheet is in a state in which the surfaces of the foam sheet can be easily thermally bonded to each other without an adhesive, and k polyester resin foam sheets in which the surfaces of one or both sides are partially melted are laminated. By being laminated by a pressure roller in the, it can be strongly adhered.

Specifically, the temperature of heating one or both sides of the polyester foam sheet is 125 to 300 ℃, 130 to 290 ℃, 140 to 280 ℃, 150 to 270 ℃, 160 to 260 ℃, 170 to 250 ℃, 180 to 240 ℃ or 190 to 230°C. When the heating temperature of the polyester foam sheet is in the above range, the heated polyester foam sheet surface may be melted to facilitate lamination. The surface of the molten polyester foam sheet can be easily thermally bonded to each other without an adhesive.

The polyester resin foam sheet can be manufactured through the step of introducing a polyester resin into an extruder and extruding and foaming the foam sheet.

In this case, it is also possible to inject an appropriate amount of calcium carbonate together with the polyester resin to the extruder. The content of the calcium carbonate is in the range of 0.5 to 5% by weight. In the present invention, it was confirmed that when calcium carbonate was appropriately mixed in the extrusion foaming process, the cell uniformity of the foam sheet was improved, and the surface of the foam sheet was uniformly manufactured. The content of calcium carbonate is in the range of 0.5 wt% to 5 wt%, specifically, 0.5 wt% to 5 wt%, 1 wt% to 5 wt%, 1.5 wt% to 4.5 wt% or 2 wt% to 3.5 wt% is the range More specifically, calcium carbonate may be added in an amount of 1.0 wt% to 3.0 wt% or 3.0 wt% to 4.5 wt%. For example, calcium carbonate (CaCO ₃ ) may have an amorphous shape. For example, calcium carbonate may be introduced into the extruder in the form of a masterbatch. By adding calcium carbonate as described above, a foam sheet having a uniform sheet surface and excellent thermoformability can be manufactured. In addition, since calcium carbonate is uniformly distributed in the polyester resin, the foam sheet obtained by extruding and foaming the resin has high thermal conductivity, so that it is possible to solve the problem of tearing the foam sheet during molding of the foam sheet.

In one embodiment, the calcium carbonate may have an average size of 1 μm to 5 μm. Specifically, the calcium carbonate may have an average size of 1.5 μm to 4 μm, 1.5 μm to 2.5 μm, or 3.5 μm to 4.5 μm. More specifically, the calcium carbonate may have an average size of 1.5 μm to 3.5 μm or 2 μm to 3 μm.

In one example, in the step of introducing the polyester resin into the extruder, the polyester resin may have the form of pellets, granules, beads or chips, and in some cases It may be introduced into the extruder in the form of a powder.

The polyester resin may be at least one selected from the group consisting of aromatic and aliphatic polyester resins synthesized from a dicarboxylic acid component and a glycol component or hydroxycarboxylic acid. Examples of the polyester resin are as described above.

The step of introducing a polyester resin into an extruder and extruding and foaming the foam sheet may be performed, for example, by melting a mixture of a polyester resin chip and calcium carbonate and extruding and foaming it. The process of melting the polyester resin and calcium carbonate can be performed at a temperature of 260 °C to 300 °C.

In another embodiment, the process of extruding and foaming the polyester resin may be performed using various types of extruders, for example, using a tandem extruder. Through the process of extrusion foaming, it is possible to continuously extrude and foam the resin melt, which simplifies the process steps and enables mass production.

In one embodiment, various types of additives may be added in the process of manufacturing the polyester resin foam sheet. If necessary, the additive may be added during the fluid connection line or during the foaming process. Examples of the additive, which may have a barrier performance, a hydrophilicity function or a waterproof function, a thickener, a surfactant, a hydrophilic agent, a heat stabilizer, a waterproofing agent, a cell size enlarger, an infrared attenuator, a plasticizer, a fire protection chemical, and at least one functional additive selected from the group consisting of pigments, elastomers, extrusion aids, antioxidants, nucleating agents, antistatic agents and UV absorbers. Specifically, one or more of a thickener, a nucleating agent, a heat stabilizer, and a foaming agent may be added in the process of manufacturing the polyester resin foam sheet, and one or more of the functional additives listed above may be further included.

The thickener is not particularly limited, but in the present invention, for example, pyromellitic dianhydride (PMDA) may be used.

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

As an example of the blowing agent, N ₂ , CO ₂ , Freon, butane, pentane, neopentane, hexane, isohexane, heptane, isoheptane or a physical blowing agent such as methyl chloride may be used. Specifically, in the present invention, butane may be used can

In addition, the waterproofing agent is not particularly limited, and for example, silicone-based, epoxy-based, cyanoacrylic acid-based, polyvinyl acrylate-based, ethylene vinyl acetate-based, acrylate-based, polychloroprene-based, polyurethane resin and polyester resin It may include mixtures such as a mixture series of , a mixture series of polyols and polyurethane resins, a mixture series of acrylic polymers and polyurethane resins, polyimide series, and a mixture series of cyanoacrylate and urethane.

Thereafter, after laminating a low-melting polyester nonwoven fabric between the prepared first and second foam sheet layers, a process of heating and pressing is performed.

As described above, since the low-melting-point polyester nonwoven fabric layer has a melting point of 10-80° C. lower than that of the first foam seat layer and the second foam seat layer, interlayer bonding is possible in the process of heating and pressing. In addition, by forming both the foam sheet and the nonwoven fabric layer constituting the laminate with a polyester-based resin, interlayer bonding properties are improved and the resin can be easily recycled from an environmental point of view.

Hereinafter, the present invention will be described in detail through examples. However, the following examples are merely illustrative of the present invention, and the present invention is not limited by the following examples.

manufacturing example : Manufacture of polyester resin foam sheet

A foam sheet was prepared by extruding and foaming a polyester resin, and at this time, a tandem type extruder in which the first and second extruders were sequentially connected was used.

First, 100 parts by weight of a polyethylene terephthalate (PET) resin having a melting point of 245° C. was dried at 180° C. to remove moisture. 100 parts by weight of PET resin from which moisture has been removed, 1 part by weight of pyromellitic dianhydride (PMDA), 0.1 parts by weight of a heat stabilizer (Iganox 1010), and 3 parts by weight of calcium carbonate having an average particle size of 1 to 5 μm are introduced into the first extruder and heated to 280° C. to prepare a resin melt. Thereafter, the resin melt was transferred to a second extruder, and 1.5 parts by weight of butane as a foaming agent was added based on 100 parts by weight of the PET resin. The temperature of the resin melt in the second extruder was controlled in the range of 250±2°C. Then, the resin melt was extruded and foamed while passing through a die.

The manufactured PET foam sheet has an average thickness of 2 mm, a density of 350 kg/m ³ , and a basis weight of 600 g/m ² .

Example One: laminate Produce

A laminate was prepared by pressing and heating with a PET nonwoven layer interposed between the two foam sheets prepared in Preparation Example. The PET nonwoven layer has a melting point of 180° C. and a basis weight of 400 g/m ² .

The manufactured laminate is shown in FIG. 1 . 1, in the laminate 100 according to the present invention, a first polyester resin foam sheet layer 110, a polyester resin nonwoven fabric layer 120, and a second polyester resin foam sheet layer 130 are sequentially formed. It is a stacked structure. In addition, the polyester resin nonwoven fabric layer 120 has a structure bonded to the first and second polyester resin foam sheet layers 110 and 130 in a partially fused form. In this embodiment, the first polyester resin foam sheet layer 110 , the polyester resin nonwoven fabric layer 120 , and the second polyester resin foam sheet layer 130 all have a structure formed of a PET resin.

Example 2: laminate Produce

A first foam sheet layer was prepared by laminating three foam sheets prepared in Preparation Example, and bonding the interface by applying an adhesive between each foam sheet. A second foam seat layer was prepared in the same manner as the first foam seat layer. Thereafter, a laminate was prepared by pressing and heating in a state in which the PET nonwoven fabric was interposed between the first foam sheet layer and the second foam sheet layer. The PET nonwoven layer has a melting point of 180° C. and a basis weight of 400 g/m ² .

Example 3: laminate Produce

The three foam sheets prepared in Preparation Example were heated to a temperature of 250° C. while continuously passing them through each of the multi-layer heaters to melt the surface of each polyester foam sheet in an easy-to-adhesive state. The three sheets of polyester foam sheet with the molten surface were then moved to a pressure roller and laminated to prepare a first foam sheet layer bonded together. A second foam seat layer was prepared in the same manner as the first foam seat layer. Thereafter, a laminate was prepared by pressing and heating in a state in which the PET nonwoven fabric was interposed between the first foam sheet layer and the second foam sheet layer. The PET nonwoven layer has a melting point of 180° C. and a basis weight of 400 g/m ² .

The manufactured laminate is shown in FIG. 2 . 2, in the laminate 200 according to the present invention, a first polyester resin foam sheet layer 210, a polyester resin nonwoven fabric layer 220, and a second polyester resin foam sheet layer 230 are sequentially formed. It is a stacked structure. In addition, the polyester resin nonwoven fabric layer 220 has a structure bonded to the first and second polyester resin foam sheet layers 210 and 230 in a partially fused form. In this embodiment, the first polyester resin foam sheet layer 210 , the polyester resin nonwoven fabric layer 220 , and the second polyester resin foam sheet layer 230 all have a structure formed of a PET resin. In addition, the first polyester resin foam sheet layer 210 has a structure in which three polyester resin foam sheets 211, 212, 213 are sequentially stacked, and each polyester resin foam sheet 211, 212, 213 is It is a structure joined by partial fusion. The second polyester resin foam sheet layer 230 has a structure in which three polyester resin foam sheets 231, 232, and 233 are sequentially stacked, and each polyester resin foam sheet 231, 232, 233 is partially fused. It is a structure joined by

comparative example One: laminate Produce

Three sheets of foam sheet prepared in Preparation Example were laminated, and an adhesive was applied between each foam sheet to prepare a laminate in which the interface was bonded.

comparative example 2: laminate Produce

However, two sheets of foam sheet prepared in Preparation Example were laminated, and an adhesive was applied between the foam sheets to prepare a laminate in which the interface was bonded.

comparative example 3: laminate Produce

In a state in which the first foam sheet, the first adhesive layer, the PET nonwoven fabric, the second adhesive layer and the second foam sheet were sequentially laminated, the laminate was prepared by pressing and heating. The first and second foam sheets are foam sheets prepared according to Preparation Example, and the PET nonwoven fabric has a melting point of 245° C. and a basis weight of 400 g/m ² .

Experimental example : by laminate Comparison of physical properties

For the laminated specimens prepared in Examples 1 to 3 and Comparative Examples 1 and 2, impact strength, impact absorption, and flaw rate were evaluated. Evaluation for each item was performed by the method described below. The evaluation results are shown in Table 1 below.

1) Impact strength

Impact strength was measured according to ASTM D256.

2) Shock Absorption (Vibration Blocking)

The amount of shock absorption was measured based on the full barrier test, which is the rear part test condition of IIHS.

3) sound insulation rate

Transmission loss values of frequencies of 1 to 8,000 Hz were obtained using Apamat measuring equipment in accordance with KS F 2862.

No. Impact strength (kJ/m ² ) Shock absorption (g/100cm ² ) Sound Insulation (dB) Example 1 10 1.5 13 Example 2 16 2.0 15 Example 3 15 1.9 14 Comparative Example 1 12 0.3 20 Comparative Example 2 3 0.1 27

Referring to Table 1, the laminate according to the embodiment is excellent in all of the impact strength, shock absorption and sound insulation. In particular, when a structure in which three foam sheets were laminated was used as the foam sheet layer (Examples 2 and 3), it was confirmed that the impact strength was very excellent. Comparative Example 1 is a structure in which three foam sheets are sequentially stacked, and the impact strength is excellent, but it can be seen that the shock absorption and sound insulation rate are very low. In the case of Comparative Example 1, since a separate fibrous layer (corresponding to the nonwoven fabric layer of the present application) is not included, it is determined that the shock absorption and sound insulation properties are low. In Comparative Example 2, it was confirmed that all physical properties were at a very low level.

Comparative Example 3 did not perform separate evaluation, but it was confirmed that the manufacturing process was complicated because separate first and second adhesive layers had to be formed, and the thickness of the manufactured laminate was also too thick.

Above, the present invention has been described in more detail through examples and drawings. However, since the configuration described in the drawings described in this specification is only an embodiment of the present invention and does not represent all the technical spirit of the present invention, various equivalents and modifications that can replace them at the time of the present application are provided. It should be understood that there may be

100, 200: laminate
110, 210: first polyester resin foam sheet layer
120, 220: polyester resin non-woven fabric layer
130, 230: second polyester resin foam sheet layer
211, 212, 213, 231, 232, 233: polyester resin foam sheet

Claims (11)

The first polyester resin foam sheet layer, the polyester resin nonwoven fabric layer and the second polyester resin foam sheet layer are sequentially stacked,
The first and second polyester resin foam sheet layers are each independently a structure in which n (n is an integer between 1 and 10) polyester resin foam sheets are laminated,
The polyester resin forming the polyester resin nonwoven layer has a melting point in the range of 150 to 200 °C,
The basis weight of the polyester resin nonwoven fabric layer is 100 to 500 g / m ² ,
The polyester resin nonwoven fabric layer is a laminate having a structure bonded to the first and second polyester resin foam sheet layers in a partially fused form.
delete The method of claim 1,
The difference (T2-T1) between the melting point (T1) of the polyester resin forming the polyester resin nonwoven fabric layer and the melting point (T2) of the polyester resin forming the polyester resin foam sheet is in the range of 10 to 80 ° C. Characterized in a laminate.
The method of claim 1,
The basis weight of the polyester resin foam sheet is 400 to 1,500 g/m ² ,
The laminate has a total basis weight of 5,000 g/m ² or less.
The method of claim 1,
The ratio (F1:F2) of the expansion ratio (F1) of the polyester resin foam sheet of the first polyester resin foam sheet layer and the expansion ratio (F2) of the polyester resin foam sheet of the second polyester resin foam sheet layer is 1 laminates ranging from :1 to 10:1.
The method of claim 1,
The polyester resin forming the polyester resin foam sheet is a laminate of polyethylene terephthalate (PET).
The method of claim 1,
The impact strength measured according to ASTM D256 is 5 to 20 kJ/m ² , and the sound insulation factor measured according to KS F 2862 is 15dB or less.
In a state in which the first polyester resin foam sheet layer, the polyester resin nonwoven fabric layer, and the second polyester resin foam sheet layer are sequentially stacked, heating and pressing,
The first and second polyester resin foam sheet layers are each independently a structure in which n (n is an integer between 1 and 10) polyester resin foam sheets are laminated,
The basis weight of the polyester resin nonwoven fabric layer is 100 to 500 g / m ² ,
The melting point (T1) of the polyester resin forming the polyester resin nonwoven fabric layer is in the range of 150 to 200 °C.
9. The method of claim 8,
The difference (T2-T1) between the melting point (T1) of the polyester resin forming the polyester resin nonwoven fabric layer and the melting point (T2) of the polyester resin forming the polyester resin foam sheet is in the range of 10 to 80 ° C. A method for manufacturing a laminate.
9. The method of claim 8,
The first and second polyester resin foam sheet layers each independently have a structure in which k (k is an integer between 2 and 10) polyester resin foam sheets are laminated,
The process of preparing the first and second polyester resin foam sheet layers,
Partially fusion-bonding the surface of each polyester resin foam sheet; and
A method of manufacturing a laminate comprising the step of laminating the partially fused polyester resin foam sheets.
9. The method of claim 8,
The first and second polyester resin foam sheet layers each independently have a structure in which k (k is an integer between 2 and 10) polyester resin foam sheets are laminated,
The process of preparing the first and second polyester resin foam sheet layers,
A method of manufacturing a laminate comprising the step of contacting the interface by applying an adhesive between the respective polyester resin foam sheets.

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