KR20180013360A - Headliner Panel Comprising Polyester Foamed Seets - Google Patents

Abstract

The present invention relates to a headliner panel. The headliner panel realizes excellent sound absorption and sound insulation properties, shows excellent durability due to improvement on bending elastic modulus and bending strength, can realize fuel saving through weight lightening of a car, has excellent durability, light resistance and dimensional stability and can improve workability by preventing risks of dust occurrence during operation since it does not contain glass fibers.

Description

[0001] The present invention relates to a headliner panel including a polyester foam sheet,

The present invention relates to a headliner panel.

In general, headliner materials mounted on the inner side of a roof panel of an automobile include resin felts, paper boards, glass fibers, natural fiber reinforced boards, wood fibers, Rigid polyurethane, corrugated cardboard, and the like.

Resin felts and paper boards are prepared by impregnating a phenol resin or the like as a curing agent. The phenol resin is a type of thermosetting resin produced by a condensation reaction between a phenol and an aldehyde. When the phenol resin is incinerated, 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.

In the case of automobile interior headliner substrates containing glass fiber or glass chop, the glass dust which may be generated during the manufacturing process and transportation may have a detrimental effect on the workers. Further, when an adhesive containing a volatile organic solvent for adhering a material is used, there is a problem that it is harmful to the working environment and the human body.

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 headliner materials for automobiles have not been excellent in sound insulation and heat insulation, have a high cost, have a high weight, are easily deformed during long-term use, and are harmful to the human body and the environment.

Therefore, it is urgently required to develop a headliner material for automobiles that can realize high sound absorption, low noise and light weight, prevent toxic gas emission, reduce the risk of dust generation during operation, and have good durability and dimensional stability have.

Korean Patent No. 10-1227628.

It is an object of the present invention to provide a resin composition which realizes good sound-absorbing property and sound insulation, exhibits excellent durability, realizes weight saving of an automobile as well as excellent durability, light resistance and dimensional stability, And to provide a headliner panel capable of preventing danger.

In order to solve the above problems, the present invention provides a headliner panel comprising a polyester foam sheet, wherein a sound absorption coefficient measured according to KS F 2805 is 0.4 NRC or more and a transmission loss value measured according to KS F 2080 is 10 dB or more to provide.

The headliner panel according to the present invention realizes good sound-absorbing properties and sound insulation, exhibits excellent durability due to an improvement in flexural modulus and flexural strength, achieves reduction in fuel consumption through reduction in weight of automobiles, durability, light resistance and dimensional stability And does not contain glass fibers, thereby preventing the risk of dust generation during work and improving workability.

1 to 4 are sectional views of headliner panels according to different embodiments 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. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.

The terminology used in this application is used only to describe a specific embodiment and is not intended to limit the invention. The singular expressions include plural expressions unless the context clearly dictates otherwise.

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.

Therefore, the configurations shown in the embodiments described herein are merely the most preferred embodiments of the present invention and are not intended to represent all of the technical ideas of the present invention. Therefore, various equivalents And variations.

The present invention relates to a headliner panel.

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

Resin felts and paper boards, which are one of the conventional headliner materials, have a problem that toxic gases such as phenol and aldehyde are emitted. In the case of a material containing glass fiber, in the manufacturing process and transportation, Resulting in detrimental effects on workers, and in the case of polyurethane hard foam materials, impact resistance, weather resistance and durability are deteriorated.

Disclosure of the Invention The present invention is to solve the above problems, and it is an object of the present invention to provide a resin composition which realizes good sound-absorbing property and sound insulation, exhibits excellent durability by improvement of flexural modulus and flexural strength, Provided is a headliner panel which is excellent in dimensional stability and does not contain glass fibers and can prevent the risk of generation of dust during operation.

The headliner panel according to the present invention includes a polyester foam sheet and has a sound absorption coefficient of 0.4 NRC or more as measured according to KS F 2805 and a transmission loss value as measured according to KS F 2080 of 10 dB or more.

Specifically, the sound absorption rate of the headliner panel according to the present invention may range from 0.4 to 1 NRC or 0.4 to 0.6 NRC, and the difference tone may range from 10 to 30 dB or 15 to 25 dB. As described above, the headliner panel according to the present invention can realize sound absorption and sound insulation at a high level at the same time, so that it is possible to effectively sound or sound the noise in and from the vehicle. As an example, the average NRC may mean an average value of each absorption coefficient measured at 250, 500, 1000, 2000 Hz according to KS F 2805-1972 (method of sound absorption rate measurement of reverberation method) .

The headliner panel according to the present invention has a color difference change ratio of less than 3% before and after irradiating light having a wavelength of 300 to 400 nm at an irradiation dose of 126 MJ according to the accelerated light resistance test (ultraviolet carbon arc light resistance test) of KS R 0021, The rate of color change may be less than 3%. For example, the chrominance change rate and the gray color change rate may be in the range of 0.1 to 3%, 0.1 to 1.5%, or 0.1 to 1%, respectively. By satisfying the above range, it can be seen that the headliner panel according to the present invention is excellent in light resistance against external light and can prevent changes in physical properties due to long-term use.

Further, the headliner panel according to the present invention has a flexural modulus (Stiffness) measured at a flexural load of 5 mm / min when the supporting spacing of the specimen is fixed at 100 mm according to ASTM D 790 To 3,000 MPa. In addition, the flexural modulus may be measured when the specimen has a span width of 100 mm and a measurement speed of 5 mm / min according to ASTM D 790 while being subjected to 10% strain on the initial specimen while applying a flexural load. Specifically, the flexural modulus may be at least 450 MPa, 500 to 30,000 MPa, 550 to 25,000 MPa, 600 to 20,000 MPa, 650 to 10,000 MPa, 700 to 5,000 MPa, 750 to 4,000 MPa, 800 to 3,000 MPa, or 860 to 1,000 MPa And therefore, it is possible to satisfy the improved rigidity. Stiffness means a degree of rigidity or hardness of a material. When the flexural modulus satisfies the above range, rigidity and durability are improved, and a head liner panel having less physical deformation due to impact or force can be provided .

In addition, the headliner panel had a flexural strength measured at 10% strain on the initial specimen while applying a flexural load at a span width of 100 mm and a measuring speed of 5 mm / min according to ASTM D 790 20 N Or more. Specifically, the flexural strength may be in the range of 22 to 45 N, 23 to 43 N, 25 to 40 N, or 26 to 35 N. The head liner panel according to the present invention satisfies the flexural strength in the above range, thereby improving the strength and durability of the headliner panel, thereby providing a headliner panel having less physical deformation due to impact or force.

The headliner panel according to the present invention can satisfy the following general formula (1) or (2).

[Formula 1]

(W ₂ - W ₁ ) / W ₁ x 100? 8 (%)

[Formula 2]

(W ₄ - W ₃ ) / W ₃ x 100 8 (%)

In the general formulas 1 and 2,

W ₁ denotes the bending strength before the head liner panel is exposed to the outside,

W ₂ means the flexural strength after 30 days after the headliner panel is exposed to the outside,

W ₃ means the flexural strength of the headliner panel before exposure to ultraviolet radiation under the conditions according to KS M ISO 11507,

W ₄ means the flexural strength of the headliner panel after 30 days of exposure to ultraviolet light under the conditions according to KS M ISO 11507,

The flexural strength is the strength (N) measured when a flexural load is applied at a rate of 5 mm / min with the support spacing (Span) of the specimen being fixed at 100 mm in accordance with ASTM D 790.

Specifically, the general formulas 1 and 2 may represent the rate of change in bending strength of the headliner panel according to the present invention. This is because the bending strength change rate when the initial bending strength (W ₁ ) before the head liner panel is exposed to the outside and the late bending strength (W ₂ ) which is the bending strength after being exposed to the outside for 30 days is measured or the head liner panel The initial flexural strength (W ₃ ) prior to exposure to ultraviolet light under the conditions according to KS M ISO 11507 and the head liner panel were exposed to ultraviolet light under the conditions according to KS M ISO 11507 and the post-bending flexural strength W ₄ ) Can be confirmed through the rate of change in flexural strength when measured. Specifically, the bending strength change rate of the head liner panel according to the present invention represented by the general formula 1 or 2 may be 8% or less, 0.01 to 7.5%, 0.1 to 6%, 0.4 to 5% or 0.5 to 2% . When the bending strength change rate is in the above range, even if the headliner panel is exposed to the outside for a long period of time, a stable shape can be maintained, and a decrease in durability can be prevented.

As one example, the headliner panel according to the present invention can satisfy Condition 1 below.

[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 headliner panel (before light irradiation) is 1 m ³ . When the dimensional change ratio of the headliner panel 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.

As an example, the average basis weight of the polyester foam sheet according to the present invention may range from 200 to 2000 g / m < ² >. Specifically, an average basis weight of the polyester foamed sheet is from 250 to 1500 g / m ^2, 300 to 1000 g / m ^2, 350 to 950 g / m ^2, 400 to 900 g / m ^2, 450 to 880 g / m ² , 500 to 850 g / m ^2, or 550 to 810 g / m ² . The weight of the polyester foam sheet according to the present invention satisfies the above range, the lightness is improved. Accordingly, it is easy to carry and construct the head liner of the vehicle according to the present invention, It is effective to reduce fuel consumption.

Further, the headliner panel according to the present invention is characterized in that it does not contain glass fibers. The composite laminate used in the conventional automotive industry has a problem that dust generated from the glass fiber is generated during the processing because it contains glass fiber. Since the headliner panel according to the present invention does not contain glass fibers, the headliner panel can be lightweight and can prevent the generation of glass dust generated during processing. In the present invention, the absence of glass fibers means that the content of glass fibers is 1 wt% or less, 0.01 wt% or less, 1 to 0.001 wt%, or 0.01 to 0.001 wt%, for example, , And specifically means that it is substantially free of glass fibers.

As one example, the headliner panel according to the present invention may include a polyester resin layer laminated on one or both sides of the polyester foam sheet.

Specifically, the polyester resin layer is stretched 2 to 8 times in the longitudinal direction (machine direction = MD), 1.1 to 6 times in the transverse direction (perpendicular to the machine direction = TD), and the total stretch magnification is 1.5 to 7 times Polyester biaxially stretched film.

The polyester biaxially stretched film is obtained by stretching a stretched polyester film in a longitudinal direction (machine direction = MD) in a temperature range of about 90 to 120 占 폚 to about 2 to 8 times and stretching in the transverse direction = TD) of about 1.1 to 6 times at a temperature of about 100 to 140 캜, and then heat-treated at a temperature of about 220 to 240 캜. When such a biaxially stretched film is used, it is possible to realize excellent durability, rigidity and strength without increasing the thickness of the headliner panel according to the present invention, and at the same time, it is possible to reduce the weight, and thus it is easy to reduce the fuel consumption of the vehicle.

The headliner panel may be a structure in which a polyester resin foam sheet and a polyester biaxially stretched film are thermally fused or thermally bonded to each other without an adhesive material. 1 is a cross-sectional view of a headliner panel 100 having a structure in which a polyester biaxially stretched film 20 is bonded to a polyester foam sheet 10.

The headliner panel according to the present invention may have a structure in which an adhesive material is interposed between the foam sheet and the biaxially stretched film.

As one example, the headliner panel according to the present invention may further include a polyester-based adhesive resin layer interposed between the polyester foam sheet and the polyester biaxially stretched film. Specifically, the polyester-based adhesive resin can be produced from various types of injection-molded products, film moldings. In addition, the polyester-based elastic adhesive resin according to the present invention can be produced from a web. The polyester-based elastic bonding resin may have a low melting point characteristic and may be provided as a nonwoven fabric of a film or web structure by being pressed in several layers.

The headliner panel according to the present invention may be manufactured by interposing the adhesive resin layer between the foam sheet and the biaxially stretched film, and then pressing the film with a pressure roller, or by heat bonding with heat.

2 is a view showing an example of a head liner panel 200 having a structure in which a polyester foam sheet 11, a polyester adhesive resin layer 31, and a polyester biaxially stretched film 21 are sequentially bonded, FIG.

As one example, the polyester-based adhesive resin layer may include a hard segment, which is an esterification reaction product of a diol and a dicarbonic acid; And a polyol soft segment, which is a polycondensate of a polyester-based elastic adhesive resin.

As an example, the average thickness of the headliner panel according to the present invention may range from 1.1 to 5.2 mm. Specifically, the average thickness of the headliner panel may be in the range of 1.3 to 5 mm, 1.5 to 4.8 mm, 2 to 4.6 mm, 2.4 to 4.4 mm, 2.8 to 4.2 mm, 3 to 4.1 mm or 3.5 to 4 mm. When the average thickness of the headliner panel according to the present invention is in the above range, it is possible to reduce the strength and rigidity while realizing weight reduction.

As an example, the thickness of the polyester foam sheet according to the invention may range from an average of 1 to 5 mm. Specifically, the foam sheet may have an average thickness of 1.3 to 4.5 mm, 1.5 to 4 mm, 1.8 to 3.5 mm, 2 to 3 mm, or 2 to 2.5 mm. When the thickness of the polyester foam sheet according to the present invention is in the above range, the weight reduction of the headliner panel can be satisfied.

As an example, the polyester biaxially stretched film according to the present invention may have an average thickness of 60 to 350 占 퐉, 90 to 340 占 퐉, 100 to 330 占 퐉, 120 to 320 占 퐉, 130 to 310 占 퐉, 150 to 300 占 퐉, 280 탆, 200 - 270 탆 or 250 탆. The headliner panel according to the present invention includes the biaxially stretched film having the above-mentioned thickness range, thereby increasing the flexural modulus and simultaneously achieving significantly improved rigidity and strength.

The polyester foam sheet according to the present invention may be a polyethylene terephthalate (PET) foam sheet, and the polyester biaxially stretched film may be a polyethylene terephthalate biaxially stretched film. Since the polyester foam sheet and the biaxially stretched film are both made of PET, the headliner panel having such a structure can be melted and reused at once without needing to separate each layer at the time of reuse, Simplification can be realized.

The polyester resin mainly used so far is a high molecular weight aromatic polyester resin produced by the condensation polymerization reaction of 1,4-butanediol with terephthalic acid. Here, the high molecular weight polyester may mean a polymer having an intrinsic viscosity [?] Of 0.8 (dL / g) or more. However, the aromatic polyester resin is excellent in physical properties such as high molecular weight, thermal stability and tensile strength, but it is not decomposed in a natural ecosystem after disposal, causing serious environmental pollution problem for a long time.

Specific examples of the polyesters usable in the present invention include polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polylactic acid (PLA), polyglycolic acid Polyglycolic acid (PGA), polypropylene (PP), polyethylene (PE), polyethylene adipate (PEA), polyhydroxyalkanoate (PHA), polytrimethylene terephthalate (PTT), polyethylene naphthalate (PEN), or the like.

Specifically, polyethylene terephthalate (PET) may be used as the polyester in the present invention.

The polyester foam sheet according to the present invention is characterized in that at least 90% of the cells are closed cells (DIN ISO4590), which means that at least 90% (v / v) It can mean. For example, the percentage of closed cells in the polyester foam sheet may be an average of 90 to 100% or 95 to 99%. The polyester foam sheet according to the present invention has closed cells within the above range, so that it is possible to realize excellent durability, rigidity and strength characteristics in manufacturing with a headliner panel. For example, the number of cells of the polyester foam sheet 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%. As a result, it can be seen that the polyester foam sheet according to the present invention has uniformly foamed cells of a uniform size.

As one example, the polyester foam sheet according to the present invention may be an extrusion foam molded article. Specifically, there are types of foaming methods largely bead foaming or extrusion foaming. In general, the bead foaming is a method of heating a resin bead to form a primary foam, aging the resin bead for a suitable time, filling the resin bead in a plate-shaped or cylindrical mold, heating the same again, and fusing and forming the product by secondary foaming. 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.

As one example, the headliner panel according to the present invention may be a structure further comprising a fiber layer laminated on one or both sides.

The fibrous layer may be at least one kind selected from the group consisting of scrim, nonwoven fabric and natural fiber. More specifically, the fibrous layer may be a polyethylene terephthalate fiber layer. At this time, the fibrous layer may be formed on one side or both sides of the polyester foam sheet on which the polyester biaxially stretched film is formed. The headliner panel according to the present invention may include a fibrous layer made of the polyethylene terephthalate fibers, thereby contributing to improvement in flexural strength and flexural modulus of the headliner panel.

The headliner panel having a structure in which the polyethylene terephthalate foam sheet, the polyethylene terephthalate biaxially stretched film and the polyethylene terephthalate fiber layer are laminated is characterized in that each layer is made of polyethylene terephthalate so that it is not necessary to separate each layer at the time of reuse It can be melted and reused at one time, so that the manufacturing process can be simplified and the recycling process can be simplified.

3 is a cross-sectional view of a headliner panel 300 having a structure in which a polyester foam sheet 12, a polyester biaxially stretched film 22 and a polyester fiber layer 42 are thermally fused as one example according to the present invention Respectively.

The headliner panel according to the present invention may have a structure in which an adhesive material is interposed between the foam sheet and the biaxially stretched film or an adhesive material is interposed between the biaxially stretched film and the fiber layer. Here, the polyester foam sheet and the polyester biaxially stretched film may be the same as those described above.

As one example, it may further comprise a polyester-based adhesive resin layer interposed between the polyester foam sheet and the polyester biaxially stretched film and / or between the polyester biaxially stretched film and the polyester fiber layer.

The polyester-based adhesive resin layer may be made of various types of extrudates, film moldings. In addition, the polyester-based adhesive resin layer according to the present invention can be made of a web. The polyester-based adhesive resin layer according to the present invention has a low melting point characteristic and may be provided as a nonwoven fabric of a film or a web structure by pressing in multiple layers. The headliner panel according to the present invention is manufactured by interposing the polyester-based adhesive resin layer between the polyester resin foam layer and the biaxially stretched film and pressing the film with a pressure roller, or by heat- .

Specifically, the polyester-based adhesive resin layer may be a polyester-based elastic adhesive resin which is an axial polymer of a hard segment which is an esterification reaction product of a diol and a dicarbonic acid and a soft segment which is a polyol have.

Specifically, the diol is composed of a mixture of ethylene glycol (EG), ethylene glycol (EG) and 2-methyl 1,3-propanediol (MPO), and the dicarbonic acid is terephthalic acid ) Or a mixture of terephthalic acid (TPA) and anhydride resin.

The diol is composed of a mixture of 1,4-butanediol (1,4-BD) or 1,4-butanediol (1,4-BD) and 2-methyl 1,3-propanediol (MPO) The dicarbonic acid may be composed of dimethyl terephthalate (DMT) or a mixture of dimethyl terephthalate (DMT) and anhydride resin.

The polyol may include at least one of poly (tetramethylene ether) glycol (PTMG), polyethylene glycol (PEG), and polypropylene glycol (PPG).

The anhydride resin may be selected from the group consisting of methyl tetrahydrophthalic anhydride (MeTHPA), methylhexahydrophthalic anhydride (MeHHPA), terahydrophthalic anhydride (THPA) and hexahydrophthalic anhydride (HHPA). ≪ / RTI >

The molar ratio of the terephthalic acid (TPA) and the anhydride resin mixture may be 40 to 99 to 60 to 1.

The molar ratio of the dimethyl terephthalate (DMT) and the anhydride resin mixture may be 40 to 99 to 60 to 1.

Specifically, when the head liner panel according to the present invention further comprises a polyester-based adhesive resin layer interposed between the polyester foam sheet and the polyester biaxially stretched film and / or between the polyester biaxially stretched film and the polyester fiber layer, Polyester foam sheet; A first polyester-based adhesive resin layer; Polyester biaxially oriented film; A second polyester adhesive resin layer; And a polyester fiber layer may be sequentially laminated.

Fig. 4 shows, as an example according to the present invention, a polyester foam sheet 13, a first polyester-based adhesive resin layer 33; A polyester biaxially stretched film 23; A second polyester adhesive resin layer 34; And a polyester fiber layer 43 are sequentially laminated on the headliner panel 400. The headliner panel 400 shown in FIG. The headliner panel of the present invention having such a structure can realize an improved strength and durability while preventing the overall thickness from becoming thick.

In the headliner panel according to the present invention having the above structure, the polyester foam sheet, the polyester adhesive resin layer, the polyester biaxially stretched film, and the polyester fiber layer are all made of PET. When the headliner panel is reused It is not necessary to separate each layer and can be reused at one time, so that the manufacturing process can be simplified and the recycling process can be simplified.

As one example, the headliner panel according to the present invention may further comprise one or more fiber layers laminated on one or both sides. The fibrous layer may be laminated in place of the polyester fiber layer according to the present invention, or may be laminated on top of the polyester fiber layer. In this case, the fibrous layer may be a thermally fused or thermally bonded structure, or may be a structure bonded via an adhesive material. Here, the adhesive material may be a polyester-based adhesive resin according to the present invention. The fibrous layer may be a polyester fiber layer, specifically, a polyethylene terephthalate fiber layer.

The fibrous layer may be at least one selected from the group consisting of a nonwoven fabric and a natural fiber. The headliner panel according to the present invention can contribute to improvement in flexural strength and flexural modulus by including the nonwoven fabric or the natural fiber layer.

As one example, the polyester foam sheet according to the present invention may have a hydrophilizing function, a waterproof function, a flame retarding function, or an ultraviolet shielding function and may be a surfactant, an ultraviolet screening agent, a hydrophilizing agent, a flame retardant, a heat stabilizer, The composition may further comprise at least one functional additive selected from the group consisting of sizing agents, infrared attenuating agents, plasticizers, fire retardants, pigments, elastic polymers, extrusion aids, antioxidants, nucleating agents, antistatic agents and UV absorbers. Specifically, the polyester foam sheet of the present invention may 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 the price of the polyester foam sheet. 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 can be used within a usual range without limitation as long as it can improve the thermal stability of the polyester foam sheet.

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 more detail with reference to Examples and Comparative Examples. However, the scope of the present invention is not limited by the following description.

Example : Headliner  Panel manufacture

In order to manufacture the headliner panel according to the present invention, first, 100 parts by weight of a polyethylene terephthalate (PET) resin was dried at 130 DEG C to remove moisture, and the PET resin from which the moisture was removed and the water- 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 PET resin and heated to 280 캜 to prepare a resin melt. Then, carbon dioxide gas and pantane as a foaming agent were mixed in a ratio of 5: 5 as a foaming agent to the first extruder, and 5 parts by weight based on 100 parts by weight of PET resin was added and extruded and foamed to prepare a polyester foam sheet. The density of the fabricated polyester foam sheet was about 300 kg / m ³ , the thickness was about 1.8 mm, and the basis weight was about 580 g / m ² .

Then, the biaxially stretched film having a polyester longitudinal elongation rate of 3 times, a transverse elongation rate of 1.5 times and a thickness of 150 탆 was heat-treated for 5 seconds at a pressure of 3 kgf and a temperature of 250 캜, and then a nonwoven fabric was laminated to manufacture a headliner panel Respectively. The thickness of the final headliner panel was about 3 mm and the basis weight was 800 g / m ² .

Comparative Example : Polypropylene composite panel manufacturing

40 parts by weight of a glass fiber mat laminated with four layers was impregnated with 60 parts by weight of polypropylene, followed by laminating a nonwoven fabric to prepare a polypropylene composite panel.

Experimental Example  One: Headliner  Evaluation of panel properties

In order to evaluate the physical properties of the headliner panel and the composite panel manufactured in the comparative example, the basis weight, flexural modulus (stiffness), flexural strength and light resistance were measured.

The flexural modulus and flexural strength were measured according to ASTM D 790 when the support spacing of the specimen was fixed at 100 mm and the flexural load was applied at a rate of 5 mm / min.

The light resistance was measured according to the accelerated light resistance test method of KS R 0021.

The results are shown in Table 1 below.

division Basis weight
(g / m ² ) Flexural modulus
(Mpa) Flexural strength
(N) Gray color change rate
(%) Example 800 830 35 One Comparative Example 1000 850 10 3.5

Referring to Table 1, it is confirmed that the weight of the headliner panel according to the embodiment is lower than that of the comparative example, so that the light weight of the vehicle can be easily realized. Even though the glass fiber is not used, the flexural modulus and flexural strength Showed an improved result as compared with the comparative example, and the gray color change ratio was less than 3%, showing excellent light resistance. Accordingly, it is confirmed that the headliner panel according to the present invention can prevent deformation due to ultraviolet rays, and has improved flexural modulus and flexural strength, thereby remarkably improving light resistance and durability.

Experimental Example  2: Measuring rate of dimensional change

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. The results are shown in Table 2 below

Dimensional change ratio (%) Example 0.1 Comparative Example 15

Referring to Table 2, it was confirmed that the headliner panel according to the present invention exhibits a remarkably low dimensional change ratio as compared with the comparative example. Thus, it can be seen that the durability of the headliner panel according to the present invention is excellent.

Experimental Example  2: Sound absorption and Sound insulation  Performance measurement

The sound absorption ratio and the differential tone were measured for the headliner panel according to the above embodiment and the composite panel according to the comparative example. The measurement method is described below, and the results are shown in Table 3 below.

1) Sound absorption rate measurement

The absorption coefficient of 0 ~ 10,000 Hz was measured using the 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.

2)

The permeation loss values of frequencies 1 to 8,000 Hz were determined using an Apamat measuring instrument according to KS F 2862. For comparison, the transmission loss values of 8,000 Hz were compared.

division Sound absorption rate (NRC) Differential tone (dB) Example 0.4 10 Comparative Example 0.6 5

Referring to Table 3, it can be seen that the headliner panel according to the present invention is remarkably superior to the comparative example in terms of the sound absorption rate difference of 0.4 and the difference of 10 dB. Therefore, it can be seen that excellent sound absorption and sound insulation performance can be exhibited when applied to a vehicle.

100, 200, 300, 400: Headliner panel
10, 11, 12, 13: Polyester foam sheet
20, 21, 22, 23: polyester resin layer
31, 33, 34: a polyester-based elastic adhesive resin layer
42, 43: polyester fiber layer

Claims (11)

And a polyester foam sheet,
The sound absorption rate measured according to KS F 2805 is 0.4 NRC or more,
A headliner panel having a transmission loss value of at least 10 dB measured according to KS F 2080.
The method according to claim 1,
The headliner panel has a color difference change ratio of less than 3% before and after irradiation of light having a wavelength of 300 to 400 nm at an irradiation dose of 126 MJ according to an accelerated light resistance test of KS R 0021, and a gray color change rate of less than 3%.
The method according to claim 1,
The headliner panel has a head with a flexural modulus (Stiffness) in the range of 400 to 3,000 MPa, measured when a supporting span of a specimen is fixed at 100 mm and a flexural load is applied at a speed of 5 mm / min, according to ASTM D 790 Liner panel.
The method according to claim 1,
The headliner panel has a flexural strength of at least 20 N measured when a specimen support span is fixed at 100 mm and a flexural load is applied at a speed of 5 mm / min according to ASTM D 790.
The method according to claim 1,
Wherein the headliner panel satisfies the following general formula (1) or (2):
[Formula 1]
(W ₂ - W ₁ ) / W ₁ x 100? 8 (%)
[Formula 2]
(W ₄ - W ₃ ) / W ₃ x 100 8 (%)
In the general formulas 1 and 2,
W ₁ denotes the bending strength before the head liner panel is exposed to the outside,
W ₂ means the flexural strength after 30 days after the headliner panel is exposed to the outside,
W ₃ means the flexural strength of the headliner panel before exposure to ultraviolet radiation under the conditions according to KS M ISO 11507,
W ₄ means the flexural strength of the headliner panel after 30 days of exposure to ultraviolet light under the conditions according to KS M ISO 11507,
The flexural strength is the strength (N) measured when a flexural load is applied at a rate of 5 mm / min with the support spacing (Span) of the specimen being fixed at 100 mm in accordance with ASTM D 790.
The method according to claim 1,
Wherein the head liner panel satisfies 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 average basis weight of the polyester foamed sheet is from 200 to 2,000 g / m ² range of the headliner panel.
The method according to claim 1,
Wherein the headliner panel comprises a polyester resin layer laminated on one or both sides of the polyester foam sheet.
9. The method of claim 8,
The polyester resin layer is stretched 2 to 8 times in the longitudinal direction (machine direction = MD), 1.1 to 6 times in the transverse direction (perpendicular to the machine direction = TD), and the total stretch ratio is 1.5 to 7, Wherein the film is a stretched film.
The method according to claim 1,
Wherein the headliner panel further comprises a fibrous layer laminated on one or both sides.
11. The method of claim 10,
Wherein the fibrous layer comprises polyethylene terephthalate fibers.

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