KR20180024652A - Package tray panel comprising low melting polyester resin, preparation method thereof - Google Patents

Abstract

The present invention relates to a package tray panel including a low melting point polyester resin fiber layer which realizes excellent processability without deterioration of physical properties such as strength and durability and is excellent in price competitiveness, and a manufacturing method thereof. The package tray panel comprises: a first polyester resin fiber having a melting point of 180°C to 250°C or a softening point of 100°C to 150°C; and a fiber layer in which a second polyester resin fiber having the melting point higher than 250°C is mixed.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a package tray panel including a low melting point polyester resin and a method for manufacturing the package tray panel.

The present invention relates to a package tray panel comprising a low-melting-point polyester resin and a method of manufacturing the same.

The automobile body portion is equipped with an exterior portion such as a door or a fender, or a built-in portion such as a seat, a door trim, and a package tray panel. The body of the vehicle should provide stability, space and comfort to the occupants including the driver.

Here, the package tray panel is installed at the rear of the rear seat. Specifically, the package tray panel supports the rear seat and blocks the interior of the vehicle and the package tray. Further, in the package tray panel, a passenger who rides on the rear seat stores various parts and documents, and if necessary, functional parts such as a speaker and a fragrance are mounted.

Conventional package tray panels are mainly made of fiber-reinforced resin boards or polyurethane foams.

The fiber-reinforced resin board is manufactured by boarding reinforced polypropylene resin using natural fibers such as hemp fiber. However, since such a fiber-reinforced resin board uses natural fibers, the working environment is poor due to the odor generated in the product molding process, and the odor generated when the vehicle is applied causes a consumer complaint. In addition, microorganisms such as fungi grow on the natural fiber applied to the fiber-reinforced resin board, and there is a fear that odor is generated and harmful components are released to the passenger's health. In addition, the fiber-reinforced resin board using the natural fibers has a disadvantage in that it is difficult to reduce the weight.

Alternatively, a package tray panel using a polyurethane foam has a problem of discharging toxic gas during incineration disposal. In addition, the polyurethane-based foam has the property of being soft and soft when pressed by hand. In order to compensate for this, a package tray panel is made by incorporating glass fiber or glass pieces into a polyurethane foam. However, the package tray panel containing glass fiber or glass pieces has a problem in that the weight thereof increases and glass dust is generated in the manufacturing and transporting processes, thereby hindering the work environment of the operator.

Korean Patent No. 10-0837082.

In order to solve such a problem, an object of the present invention is to provide an environmentally friendly package tray panel having excellent processability and excellent price competitiveness.

In order to achieve the above object,

In one embodiment, the present invention provides a polyester resin composition comprising a first polyester resin fiber having a melting point of 180 ° C to 250 ° C or a softening point of 100 ° C to 150 ° C; And a fiber layer in which a second polyester resin fiber having a melting point higher than 250 캜 is mixed. The mixing ratio of the first polyester resin fiber and the second polyester resin fiber forming the fiber layer can be controlled in the weight ratio of 1: 9 to 9: 1.

Further, in another embodiment of the present invention,

A first polyester resin fiber having a melting point of 180 ° C to 250 ° C or a softening point of 100 ° C to 150 ° C; And thermally molding a fiber layer mixed with a second polyester resin fiber having a melting point of 255 캜 or higher in a temperature range of 80 to 200 캜. The mixing ratio of the first polyester resin fiber and the second polyester resin fiber forming the fiber layer can be controlled in the weight ratio of 1: 9 to 9: 1.

Since the package tray panel according to the present invention uses a low-melting-point polyester resin, excellent workability can be realized without deteriorating physical properties such as strength and durability.

While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail.

It should be understood, however, that the invention is not intended to be limited to the particular embodiments, but includes all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.

In the present invention, the terms "comprising" or "having ", and the like, specify that the presence of a feature, a number, a step, an operation, an element, a component, But do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or combinations thereof.

In the present invention, the term "weight portion" means the weight ratio between the components

Herein, in the present invention, the term "molar part" means a molar fraction of each component.

Further, in the present invention, the "melting point" means the temperature at which the solid phase resin begins to melt in a liquid phase.

In addition, the term "polymer" in the present invention means an oligomer and / or a polymer obtained by performing a polymerization reaction of a monomer or a compound containing a polymerizable reactive group.

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

The present invention provides a package tray panel comprising a low melting point polyester resin fiber layer.

In one embodiment, a package tray panel according to the present invention comprises:

A first polyester resin fiber having a melting point of 180 ° C to 250 ° C or a softening point of 100 ° C to 150 ° C; And a fiber layer in which a second polyester resin fiber having a melting point higher than 250 캜 is mixed.

In the fiber layer, the first polyester resin fiber is a fiber formed of a polyester resin having a melting point of 180 ° C to 250 ° C or a softening point of 100 ° C to 150 ° C. It is also referred to as a low-melting-point polyester resin fiber in a relative sense. The second polyester resin fiber is a polyester resin fiber having a melting point higher than 250 ° C and is also referred to as a high melting point polyester resin fiber in a relative sense.

The fibrous layer is a mixture of the first polyester resin fiber and the second polyester resin fiber. The mixing ratio of the first and second polyester resin fibers can be controlled to a weight ratio of 1: 9 to 9: 1. In some cases, the mixing ratio may range from 1: 9 to 7: 3, or from 1: 9 to 5: 5. By mixing polyester resin having a low melting point and high melting point, bonding strength between fibers can be enhanced and strength can be reinforced at the same time. Concretely, the content of the polyester resin fiber having a low melting point can be controlled to be equal to or lower than the content of the polyester resin fiber having a high melting point. For example, the high-melting-point polyester resin has a melting point higher than 250 ° C, specifically, 251 to 260 ° C. The high-melting-point polyester resin is commercially available. For example, a product (product name: SD, Semi-dull chip) of Huvis Corporation can be used.

Specifically, the shape, the thickness, and the lamination structure of the fibrous layer are not particularly limited. For example, the fibrous layer is a partially fused form between the fibers forming the fibrous layer. In the partially fused form between the fibers, heat and / or pressure is applied during the process of forming the fiber layer by thermoforming, and the fibers are partially fused to each other in the process. Since the fiber layer according to the present invention includes the low-temperature fusion-bondable fiber made of a polyester resin having a low melting point, it can form a partial fusion-bonded form between the fibers through low temperature molding.

As another example, the fibrous layer may further include a functional additive component as needed. For example, a small amount of a flame retardant, a thickener, an inorganic filler or the like may be added as the functional additive component.

As one example, the package tray panel according to the present invention does not include glass fiber. Glass fibers include glass flakes and other powdered glass. Specifically, the term "not containing glass fibers" in the present invention means that the glass fibers are contained in an amount of 1% by weight or less, and substantially does not contain glass fibers. Therefore, the package tray panel according to the present invention can prevent the generation of glass dust during operation and increase the working efficiency.

In yet another embodiment, the package tray panel comprises:

The sound absorption rate measured according to KS F 2805 is 0.4 NRC or higher, and / or

And the transmission loss value measured according to KS F 2080 is 10 dB or more.

For example, the sound absorption rate 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 package tray panel according to the present invention can realize sound absorption and sound insulation at a high level at the same time, and can effectively sound and / or sound the noise inside and outside the vehicle.

In one embodiment, the package tray panel satisfies the following general formula (1).

[Formula 1]

(W ₂ - W ₁ ) / W ₁ x 100? 8 (%)

In the general formula 1,

W ₁ means the flexural strength of the package tray panel prior to exposure to ultraviolet radiation under the conditions according to KS M ISO 11507,

W ₂ means the flexural strength of the package tray panel after 30 days of exposure to ultraviolet rays under the conditions according to KS M ISO 11507,

The flexural strength is measured when the supporting spacing of the interior material specimen for the package tray panel is fixed at 100 mm and the flexural load is applied at a rate of 5 mm / min according to ASTM D 790, when the initial specimen is deformed by 10% (N / cm < ² >).

More specifically, the formula (1) may represent the rate of change in bending strength of the interior material for a package tray panel according to the present invention. This can be confirmed by the initial bending strength (W ₁ ) before the interior of the package tray panel is exposed to the outside and the bending strength change rate when the latter bending strength (W ₂ ) is measured after 30 days of external exposure have.

Specifically, the bending strength change ratio of the interior of the package tray panel according to the present invention represented by the general formula (1) 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, stable form can be maintained even when the interior material for a package tray panel is exposed to the outside for a long period of time, and deterioration of durability can be prevented.

The package tray panel according to the present invention provides excellent tensile strength and / or low combustibility. As an example, the tensile strength may be 10 to 150 MPa, for example 10 to 130 MPa, 30 to 100 MPa or 40 to 100 MPa, based on ASTM D 638. By satisfying the tensile strength within the above range, excellent durability can be realized.

In addition, the flame resistance may be 80 or less based on KS M ISO 9772. Specifically, the package tray panel according to the present invention has a flame retardant or non-flammable property, which can reduce the risk of fire thereafter.

The package tray panel according to the present invention has excellent durability. Specifically, the package tray panel is left at a temperature of 90 ± 1 ° C for 24 hours; And a step of allowing to stand for 24 hours at a temperature of 50 ± 1 ° C and a relative humidity of 90%, the following general formula (2) can be satisfied.

[Formula 2]

| V ₁ -V ₀ | / V ₀ x 100? 5%

In the general formula 2,

V ₀ is the volume (mm ³ ) of the package tray panel before exposure to harsh conditions,

V ₁ is the volume (in mm ³ ) of the package tray panel after exposure to the harsh conditions.

Specifically, the dimensional change rate of the prepared package tray panel sample before and after the severe condition was measured. This is a measurement value corresponding to the long-term dimensional change rate after the package tray panel is applied to the vehicle. For example, the volume may mean a value calculated by multiplying the length of each package tray panel by the length, width, and thickness, respectively. For example, the rate of dimensional change of the formula (1) may range from 0.01 to 5%, from 0.01 to 3%, or from 0.01 to 1%. By satisfying the value of the expression (1) in the above range, it can be seen that the package tray panel according to the present invention does not change its shape even in long-term use in an environment of severe temperature change.

At this time, if the above formula (1) is more than 5%, it may mean that peeling, parts, sagging, discoloration or deformation may easily occur on the package tray panel.

Hereinafter, the first polyester resin fiber forming the fiber layer according to the present invention will be described in more detail.

The first polyester resin fiber comprises a polyester resin containing a repeating unit represented by the following general formula (1) and general formula (2) and having a melting point of 180 ° C to 250 ° C or a softening point of 100 ° C to 150 ° C.

[Chemical Formula 1]

(2)

In the above formulas (1) and (2)

m and n represent mole fractions of the repeating units contained in the low melting point polyester resin,

n is 0.05 to 0.5 based on m + n = 1.

And the first polyester resin fiber is a fiber of a low melting point polyester resin. The low-melting-point polyester resin may have a structure containing repeating units represented by formulas (1) and (2). The repeating unit represented by the formula (1) represents a repeating unit of polyethylene terephthalate (PET), and the repeating unit represented by the formula (2) improves the tear property of a polyester resin containing a polyethylene terephthalate (PET) repeating unit Function. Specifically, the repeating unit represented by the formula (2) includes a methylene group (-CH ₃ ) as a side chain in a propylene chain bonded to terephthalate, thereby securing a space in which the main chain of the polymerized resin can rotate, It is possible to lower the melting point (Tm) by inducing 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 melting point (Tm) of the crystalline polyester resin.

At this time, the low-melting-point polyester resin may contain, as a main repeating unit, a repeating unit represented by the following formula (2), which decreases the melting point (Tm) of the resin together with the repeating unit represented by the formula (1) Specifically, when the molar fraction of the total resin is 1, the low melting point polyester resin of the present invention may contain 0.5 to 1 as repeating units represented by the formulas (1) and (2), specifically 0.55 to 1; 0.6 to 1; 0.7 to 1; 0.8 to 1; 0.5 to 0.9; 0.5 to 0.85; 0.5 to 0.7; Or from 0.6 to 0.95.

The amount of the repeating unit represented by the formula (2) contained in the low melting point polyester resin may be 0.05 to 0.5 when the total fraction including the repeating unit represented by the formula (1) is 1 (m + n = 1) 0.05 to 0.4, 0.1 to 0.4, 0.15 to 0.35; Or from 0.2 to 0.3.

The melting point (Tm) of the low melting point polyester may be 180 ° C to 250 ° C, or the melting point may not be present. Specifically, the melting point (Tm) is 180 占 폚 to 250 占 폚; 185 DEG C to 245 DEG C; 190 DEG C to 240 DEG C; 180 DEG C to 200 DEG C; 200 < 0 > C to 230 [deg.] C or 195 [deg.] C to 230 [deg.] C or absent.

In addition, the softening point of the low melting point polyester may be 100 ° C to 150 ° C, specifically 100 ° C to 130 ° C, 118 ° C to 128 ° C; 120 DEG C to 125 DEG C; 121 DEG C to 124 DEG C; 124 DEG C to 128 DEG C or 119 DEG C to 126 DEG C. [

Further, the low melting point polyester resin may have a glass transition temperature (Tg) of 50 DEG C or more. Specifically, the glass transition temperature may be from 50 캜 to 80 캜, and more specifically from 61 캜 to 69 캜, 60 캜 to 65 캜, 63 캜 to 67 캜, 61 캜 to 63 캜, 63 캜 to 65 캜, 65 Deg.] C to 67 [deg.] C or 62 [deg.] C to 67 [deg.] C.

The low melting point resin may have an intrinsic viscosity (IV) of 0.5 dl / g to 0.75 dl / g. Specifically, the intrinsic viscosity (I.V) is from 0.6 dl / g to 0.65 dl / g; 0.65 dl / g to 0.70 dl / g; 0.64 dl / g to 0.69 dl / g; 0.65 dl / g to 0.68 dl / g; 0.67 dl / g to 0.75 dl / g; 0.69 dl / g to 0.72 dl / g; 0.7 dl / g to 0.75 dl / g; Or from 0.63 dl / g to 0.67 dl / g.

The melting point (Tm), the softening point, and the glass transition temperature (Tg) of the low melting point polyester resin according to the present invention can be controlled within the above range by including the repeating unit represented by the general formula (2) Excellent adhesion can be exhibited.

The low-melting-point polyester resin may further include a repeating unit represented by the following formula (3) together with the repeating units represented by the formulas (1) and (2).

(3)

In Formula 3,

X is a 2-methylpropylene group, an ethylene group or an oxydiethylene group,

r is the mole fraction of the repeating units contained in the low melting point polyester resin, and is not more than 0.3.

Specifically, in Formula 3, r may be 0.25 or less, 0.2 or less, 0.15 or less, or 0.1 or less.

The present invention can reduce the melting point (Tm) of the polyester resin by controlling the repeating unit represented by the formula (3) contained in the low-melting-point polyester resin to the above-mentioned fraction range, The content of the cyclic compound of < RTI ID = 0.0 > 3 < / RTI >

As one example, the content of the cyclic compound having a degree of polymerization of 2 to 3 in the low melting point polyester resin according to the present invention is remarkably decreased and can be contained in an amount of 1% by weight based on the total resin weight. Specifically, 0.5% by weight or less, 0.4% by weight or less, 0.3% by weight or less, or 0.2% by weight or less based on the total weight of the composition.

In yet another example, at least one of the first and second polyester resin fibers may be a hollow fiber of a modified cross-section. In the present invention, all of the second polyester resin fibers may be hollow fibers having a modified cross-section, but these may include partially mixed hollow fibers. For example, the second polyester resin fiber is a modified cross-section hollow fiber. In this case, 20 to 85% (v / v) of the total second polyester resin fibers may be hollow fibers having a modified cross section. The modified hollow fiber has a hollow portion, a shape retaining portion, and a volume control portion, and the volume control portion may protrude in a direction opposite to the center of the fiber. Specifically, the protruding end portion is formed in a round shape.

In the present invention, the cross-sectional structure of the modified hollow fiber is described as a hollow portion, a shape retaining portion, and a volume control portion, but this is for convenience of explanation. The cross-sectional structure of the modified hollow fiber includes a hollow portion formed therein along the longitudinal direction of the fiber, and a shape retaining portion surrounding the hollow portion. Also, the shape retaining portion is formed with concavo-convex on the outer circumferential surface on the opposite side of the hollow portion with respect to the end face, and the portion protruding from the concavo-convex portion is referred to as a volume control portion. And a mesh structure formed by the fibers by using a hollow fiber having a uniform cross section. The mesh structure absorbs sound, so that the sound absorption performance can be improved.

In one embodiment, the production process of the low melting point polyester resin will be described in detail as follows.

A process for producing a low-melting-point polyester resin comprising the step of carrying out an ester exchange reaction of a mixture comprising polyethylene terephthalate (PET) and 2-methyl-1,3-propanediol.

The method for producing a low melting point polyester resin according to the present invention is a method for producing a low melting point polyester resin comprising an aromatic dicarboxylic acid such as phthlic acid, terephthalic acid, isophthalic acid (IPA) and the like; A polyester polymer obtained by polymerizing a diol compound such as ethylene glycol (EG), propylene glycol (PG), diethylene glycol (DEG), dipropylene glycol (DPG) Methyl-1,3-propanediol may be mixed with the mixture, followed by transesterification of the mixture according to a method commonly used in the art.

As one example, the low-melting-point polyester resin is obtained by mixing 2-methyl-1,3-propanediol with a polyethylene terephthalate oligomer (PET oligomer), adding an ester exchange reaction catalyst, Exchange reaction.

At this time, the 2-methyl-1,3-propanediol may be mixed in a proportion of 5 to 50 parts by mol per 100 parts by mol of polyethylene terephthalate (PET) which is a polyester polymer. Specifically, it is used in an amount of 5 to 40 molar parts relative to 100 molar parts of polyethylene terephthalate (PET); 10 to 30 molar parts; 20 to 40 molar parts; 25 molar to 50 molar parts; Or from 30 moles to 50 moles. In the present invention, by adjusting the content of the additive for low-melting-point resin to the above range, the melting point of the resin is not sufficiently lowered due to the low content of the additive, or the crystallinity exceeds the critical point at which the crystallinity of the resin is reduced due to excessive additives Can be prevented from increasing.

Further, the mixture in which the transesterification reaction is carried out may further comprise at least one of isophthalic acid (IPA) and diethylene glycol (DEG) together with polyethylene terephthalate (PET) and 2-methyl- . Specifically, the mixture may contain polyethylene terephthalate (PET), 2-methyl-1,3-propanediol and diethylene glycol (DEG), or may contain polyethylene terephthalate (PET) , Diethylene glycol (DEG) and isophthalic acid (IPA).

The isophthalic acid (IPA) may be contained in an amount of 30 moles or less based on 100 moles of polyethylene terephthalate (PET). More specifically, not more than 25 moles, not more than 20 moles, not more than 15 moles, or not more than 10 moles, based on 100 moles of polyethylene terephthalate (PET). The content of the isophthalic acid (IPA) is 0.1 mol or more or 1 mol or more, or does not contain isophthalic acid. For example, 0.5 to 0.001 part by mole of isophthalic acid (IPA) may be contained.

The polyethylene glycol (DEG) may be contained in an amount of 1 to 20 moles relative to 100 moles of polyethylene terephthalate (PET). Specifically, the amount of the diethylene glycol (DEG) may be 5 to 15 moles per 100 moles of polyethylene terephthalate 15 moles, 15 moles to 20 moles, 12 moles to 18 moles, 13 moles to 17 moles, or 14 moles to 16 moles.

The present invention can reduce the production cost by controlling the content of isophthalic acid (IPA) within the above range, and can also minimize the content of the cyclic compound having a polymerization degree of 2 to 3 in the low melting point polyester resin to be produced, By controlling the content of the DEG in the above range, it is possible to suppress the decrease of the glass transition temperature (Tg) remarkably while the melting point (Tm) of the resin is optimized, thereby preventing the problem of aging caused during spinning.

In one embodiment, the package tray panel according to the present invention may include a resin foam layer, and may have a structure in which the fiber layers described above are laminated on one or both sides of the resin foam layer. Specifically, the package tray panel comprises: a polyester resin foam layer; And a polyester resin fiber layer formed on both sides of the polyester resin foam layer.

The polyester resin foam layer may be in the form of a foam board or a foam sheet. Specifically, the package tray panel has a structure in which a polyester resin fiber layer is laminated on both sides of a polyester resin foam sheet.

For example, in the package tray panel according to the present invention, the flexural modulus (flexural modulus) measured when the flexural load is applied at a rate of 5 mm / min while the support spacing (Span) of the specimen is fixed at 100 mm according to ASTM D 790 ) May range from 400 to 30,000 MPa. The package tray panel according to the present invention provides excellent bending elasticity, thereby preventing sagging when applied to a package tray panel and providing excellent durability.

For example, the polyester resin foam layer may be a polyethylene terephthalate (PET) foam sheet, and the fiber layer may be a polyethylene terephthalate fiber. By forming various components or all components constituting the laminate from a PET series resin, it is possible to improve the interlaminar bondability and to regenerate the resin from the environmental viewpoint.

In addition, the mass per unit area of the package tray panel may range from 500 to 1100 g / m ^{2 on} average. For example, the mass per unit area of the package tray panel may be 550 to 1000 g / m ² , 600 to 1000 1100 g / m ^2, or 800 to 900 1100 g / m ² . By satisfying the mass per unit area in the above range, it was confirmed that the package tray panel according to the present invention is light in weight.

The package tray panel according to the present invention can be used variously in interior parts or interior of an automobile. Specifically, the package tray panel is applicable as a floor under cover or a car mat. For example, when the interior material according to the present invention is used as a floor under cover of an automobile, it can be installed at the bottom of an engine, a transmission, or a cooling fan to effectively protect the engine and the transmission from impacts externally applied thereto.

The present invention also provides a method of manufacturing the package tray panel as described above.

As one example, the manufacturing method of the package tray panel may include: a polyester resin first polyester resin fiber having a melting point of 180 ° C to 250 ° C or a softening point of 100 ° C to 150 ° C; And thermosetting a fiber layer comprising a polyester resin second polyester resin fiber having a melting point of 255 캜 or higher in a temperature range of 80 to 200 캜.

The fibrous layer is a mixture of the first polyester resin fiber and the second polyester resin fiber. The mixing ratio of the first and second polyester resin fibers may be 1: 9 to 9: 1. Optionally, the blending ratio may range from 1: 9 to 7: 3, or from 1: 9 to 5: 5. By mixing polyester resin having a low melting point and high melting point, bonding strength between fibers can be enhanced and strength can be reinforced at the same time. Concretely, the content of the polyester resin fiber having a low melting point can be controlled to be equal to or lower than the content of the polyester resin fiber having a high melting point. For example, the high-melting-point polyester resin has a melting point higher than 250 ° C, specifically, 251 to 260 ° C. The high-melting-point polyester resin is commercially available. For example, a product (product name: SD, Semi-dull chip) of Huvis Corporation can be used.

The package tray panel manufactured by the above method satisfies the condition of the following general formula (1). The contents of the general formula 1 are as described above.

[Formula 1]

(W ₂ - W ₁ ) / W ₁ x 100? 8 (%)

In the general formula 1,

W ₁ means the flexural strength of the package tray panel prior to exposure to ultraviolet radiation under the conditions according to KS M ISO 11507,

W ₂ means the flexural strength of the package tray panel after 30 days of exposure to ultraviolet rays under the conditions according to KS M ISO 11507,

The flexural strength is measured when the supporting spacing of the interior material specimen for the package tray panel is fixed at 100 mm and the flexural load is applied at a rate of 5 mm / min according to ASTM D 790, when the initial specimen is deformed by 10% (N / cm < ² >).

In addition, the package tray panel manufactured by the above method satisfies the property (sound insulation) that the sound absorption coefficient measured according to KS F 2805 is 0.4 NRC or more, and / or the transmission loss value measured according to KS F 2080 is 10 dB or more . The contents of the sound absorption rate and the difference sound are as described above.

Specifically, the first polyester resin fiber includes repeating units represented by the following general formulas (1) and (2).

[Chemical Formula 1]

(2)

In the above formulas (1) and (2)

m and n represent mole fractions of the repeating units contained in the low melting point polyester resin,

n is 0.05 to 0.5 based on m + n = 1.

The step of thermoforming can be controlled in a range in which the low melting point polyester resin as the first polyester resin fiber is partially melted. For example, the thermoforming step may be performed at a temperature range of 100 to 150 ° C. Further, in the step of thermoforming, a pressure higher than atmospheric pressure is applied. It can be molded into a desired shape while simultaneously applying heat and pressure. The range of the applied pressure is not particularly limited, and may be, for example, 1.5 to 10 atm, and 2 to 5 atm.

In one embodiment, after the thermoforming step, a first polyester resin fiber layer; A polyester resin foam layer; And a second polyester resin fiber layer in this order. In the present invention, by introducing a polyester resin foam layer, it is possible to supplement the sound insulation and strength. The polyester resin foam may be in the form of a board or a sheet.

Optionally, before the thermoforming step, a first polyester resin fiber layer; A polyester resin foam layer; And a second polyester resin fiber layer are sequentially laminated to form a laminate. In this case, in the thermoforming step, the first polyester resin fiber layer; A polyester resin foam layer; And the second polyester resin fiber layer is thermally formed to form a desired shape.

A first polyester resin fiber layer; A polyester resin foam layer; And a second polyester resin fiber layer are laminated in this order. Although the structure in which the polyester resin foam layer is exposed to the outer layer is not excluded, in this case, the sound absorption property may be deteriorated. The first and second polyester resin fiber layers correspond to the polyester resin fiber layers described above. The polyester resin foam layer is also as described above.

For example, the first and second polyester resin fiber layers and the polyester resin foam layer may all be formed of PET (polyethylene terephthalate) resin.

Hereinafter, the present invention will be described in more detail with reference to Examples and Experimental Examples.

However, the following Examples and Experimental Examples are merely illustrative of the present invention, and the present invention is not limited to the following Examples and Experimental Examples.

Manufacturing example  1 to 25: Low melting point  Production of polyester resin fiber

Terephthalic acid (TPA) and isophthalic acid (IPA), which are acidic components, are added to the ester reaction tank. Methylene-1,3-propanediol (MPD), ethylene glycol (EG) and diethylene glycol (DEG) were mixed in the molar ratio shown in Table 1 below, The esterification reaction was carried out at 250 ± 5 ° C after the addition of the catalyst. When the esterification reaction rate reached about 96%, the esterification reaction was terminated and a condensation polymerization catalyst was added, and the condensation polymerization reaction was carried out so that the final temperature and vacuum pressure in the reaction vessel were 280 ± 5 ° C. and 0.1 mmHg, respectively. After the viscosity of the resin is converted to the stirrer torque meter, the viscosity of the resin can be adjusted in this manner by terminating the condensation polymerization at the desired viscosity.

The decompression was gradually broken and pressure was applied to the outside of the reactor. The resin was cooled and cut into pellets to measure the resin properties. The resultant resin was co-spun in the form of a sheath-core, The resin was flowed, and the polyethylene terephthalate was flown through the core to produce a first polyester resin fiber which was a low melting point resin fiber.

The contents of the components added to the respective examples were varied as shown in Table 1 below.

Production Example No. Acid content (mol%) Diol component (mol%) IPA TPA MPD DEG EG One 0 100 40 0 60 2 15 85 30 0 70 4 5 95 30 0 70 5 0 100 30 0 70 6 0 100 30 15 55 7 0 100 25 15 60 8 10 90 20 0 80 9 10 90 20 10 70 10 10 90 20 15 65 11 0 100 20 0 80 12 0 100 20 20 60 13 0 100 15 25 60 14 20 80 10 15 75 15 0 100 10 0 90 16 40 60 0 0 100 17 35 65 0 10 90 18 30 70 0 0 100 19 30 70 0 15 85 20 20 80 0 0 100 21 20 80 0 15 85 22 20 80 0 20 80 23 15 85 0 25 75 24 10 90 0 0 100 25 0 100 0 30 70

Experimental Example  One.

The properties of the samples prepared in Preparation Examples 1 to 25 were evaluated by the following items. The evaluation results are shown in Table 2 below.

(1) Determination of content of cyclic compounds

10 mg of each polyester resin is injected into a Pyrex tube having a diameter of 5 mm and a length of 20 cm in a solvent of trifluoroacetic acid (TFA) to have a height of about 5 cm. ¹ H-NMR spectra were measured using Nuclear Magnetic Resonance (NMR, Bruker). From the measured results, the content of the cyclic compound having a degree of polymerization of 2 to 3 remaining in the low melting point resin was derived.

(2) Softening temperature , Melting point ( Tm ) And glass transition temperature ( Tg ) Measure

The melting point (Tm) and the glass transition temperature (Tg) of the low melting point polyester resin were measured using a differential scanning calorimeter (Perkin Elmer, DSC-7). When the heat absorption peak was not observed during the measurement of the melting point (Tm) The softening behavior was measured in a TMA mode using a dynamic mechanical analyzer (DMA-7, Perkin Elmer).

(3) Intrinsic viscosity ( I.V ) And melt viscosity measurement

The polyester resin was dissolved in a solution of phenol and tetrachloroethane in a weight ratio of 1: 1 at a concentration of 0.5 wt%, respectively, and intrinsic viscosity (I.V) was measured at 35 캜 using a Ube load viscometer. Further, melt viscosity was measured using a conventional method.

Example No. Ring compound
[wt%] Softening temperature
[° C] Tm
[° C] Tg
[° C] IV
(dl / g) Melting point
(Poise) One 0 120 - 70.4 0.581 913.0 2 0.25 110 - 68.0 0.581 853.0 4 0 - 178 68.0 0.580 847.0 5 0 - 196.3 72.1 0.582 851.0 6 0 118 - 60.8 0.580 864.0 7 0 121 63.5 0.582 847.0 8 0.2 - 181 70.0 0.582 811.0 9 0.19 120 - 62.0 0.579 815.0 10 0.17 115 - 60.7 0.582 831.0 11 0 - 210.5 74.6 0.583 818.0 12 0 129 - 61.4 0.581 811.0 13 0 - 176 55.7 0.581 781.0 14 0.36 125 - 60.5 0.579 754.0 15 0 - 235.3 76.5 0.581 736.0 16 0.86 128 - 70.1 0.580 673.0 17 0.73 108 - 67.1 0.581 654.0 18 0.73 - 195.2 71.0 0.582 687.0 19 0.53 112 - 61.0 0.579 659.0 20 0.41 - 208.6 71.6 0.580 677.0 21 0.39 - 178 63.0 0.581 697.0 22 0.32 119 - 63.0 0.582 643.0 23 0.27 125 - 60.0 0.581 657.0 24 0.25 - 232.5 74.2 0.583 687.0 25 0 - 199.7 57.7 0.581 690.0

According to Table 2, it can be seen that the content of the cyclic compound in the resin of the fibrous layer forming the package tray panel according to the present invention is 1 wt% or less, specifically 0 to 0.86 wt%. It is also understood that the resin has a melting point of 180 ° C to 250 ° C or a softening point of 100 ° C to 150 ° C. The intrinsic viscosity (I.V) corresponds to from 0.5 dl / g to 0.75 dl / g, specifically from 0.55 dl / g to 0.6 dl / g. It is also understood that the glass transition temperature is in the range of 50 캜 to 80 캜, specifically in the range of 57 to 77 캜.

Example  1 to 25: Fibrous  Produce

The first polyester resin fibers prepared in Production Examples 1 to 25 were mixed with a polyester resin second polyester resin fiber having a melting point of 255 캜 or higher and thermoformed while pressing at 130 캜 to form a fiber layer .

The second polyester resin fiber was obtained by obtaining a product (product name SD, Semi-dull chip) of Huvis Co., Ltd., and fabricated in the same manner as in Production Example 1.

The mixing ratios of the first polyester resin fibers and the second fibers are shown in Table 3 on the basis of parts by weight.

Example No. 2. The first polyester resin fiber content Second polyester resin fiber content 1-5 3.5 6.5 6 to 10 4 6 11 ~ 15 5 5 16-20 6 4 21 ~ 25 7 3

Experimental Example  2.

The flexural strength (W ₁ ) of the samples of Examples 1 to 5 before exposure to ultraviolet rays under the conditions according to KS M ISO 11507 was measured. Then, the bending strength (W ₂ ) was measured 30 days after the samples were exposed to ultraviolet rays under the same conditions.

The flexural strength was measured at 10% strain on the initial specimen while flexural loads were applied at a rate of 5 mm / min with the span of the interior specimen of the package tray panel fixed at 100 mm in accordance with ASTM D 790 (N / cm ² ).

The rate of change of the measured bending strength was calculated and is shown in Table 4 below.

division Flexural strength (MPa) Change rate (%) Example 1 1.2 Example 2 1.3 Example 3 1.5 Example 4 1.1 Example 5 1.3

Referring to Table 4, it was confirmed that the interior material for the package tray panel according to the embodiment has excellent durability by minimizing the change of the bending strength in the ultraviolet ray exposure environment.

Experimental Example  3.

The basis weight, flexural modulus (stiffness) and flexural strength of the fiber layer samples prepared in Example 1 were measured.

The flexural modulus and flexural strength were measured according to ASTM D 790 when the support spacing (Span) of the specimen was fixed at 100 mm and the flexural load was applied at a rate of 5 mm / min. The results are shown in Table 5 .

division Example 1 Basis weight (g / m ² ) 980 Flexural modulus (MPa) 450 Flexural Strength (MPa) 12

In the same manner as in Table 5 above, the basis weight of the samples of Examples 2 to 25 was measured, and it was confirmed that all the samples had a basis weight of 1,000 g / m ² or less.

The flexural modulus of the samples of Examples 2 to 25 was measured, and it was confirmed that they were within the range of ± 10% as compared with the case of Example 1. [

Experimental Example  4: Evaluation of dimensional change rate

The samples according to Examples 11 to 13 were subjected to experiments for measuring dimensional change. Specifically, the step of leaving each of the manufactured vehicle interior materials at a temperature of 90 ± 1 ° C for 24 hours; And a step of allowing to stand for 24 hours at a temperature of 50 ± 1 ° C and a relative humidity of 90%, and then the dimensional change ratio was measured by the following equation (1). The results are shown in Table 6 below.

[Equation 1]

| V ₁ -V ₀ | / V ₀ x 100

In the above equation (1)

V ₀ is the volume (mm ³ ) of the vehicle interior before exposure to the harsh conditions,

V ₁ is the volume (mm ³ ) of the vehicle interior after exposure to the harsh conditions.

division Dimensional change ratio (%) Example 11 0.5 Example 12 0.3 Example 13 0.2

Referring to Table 6, it was confirmed that the package tray panel according to the present invention exhibits a low dimensional change ratio of 0.5% or less. Thus, it can be seen that the automotive interior material according to the present invention has excellent durability.

Experimental Example  5: Sound absorption and Sound insulation performance  Measure

For the samples according to Examples 16 to 18, the sound absorption rate and the differential tone were measured. The measurement method is described below, and the results are shown in Table 7 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) Car tone  Measure

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 16 0.4 11 Example 17 0.4 14 Example 18 0.4 18

Referring to Table 7, it can be seen that the fibrous layer according to the present invention is excellent in both the sound absorption ratio and the differential tone.

Experimental Example  6: Evaluation of tensile strength and flammability

For the samples according to Examples 1 to 25, tensile strength and combustibility were evaluated. Tensile strength was evaluated according to ASTM D 638, and flammability was evaluated according to KS M ISO 9772.

As a result of the evaluation, it was confirmed that the samples of Examples 1 to 25 had a tensile strength of 70 MPa or more and a combustibility of 70 or less.

Example  26 to 28

The fibrous layers according to Examples 6 to 8 were laminated on both sides of the PET resin foam sheet. Specifically, a PET resin foam sheet was prepared by the following procedure.

First, 100 parts by weight of a polyethylene terephthalate (PET) resin was dried at 130 캜 to remove moisture. In the first extruder, 100 parts by weight of the PET resin from which the moisture was removed and 100 parts by weight of the PET resin from which the water had been removed were mixed with 100 parts by weight of pyromellitic acid 1 part by weight of hydride, 1 part by weight of talc and 0.1 part by weight of Irganox (IRG1010) were mixed and heated to 280 DEG C to prepare a resin melt. Then, carbon dioxide gas and pentane were mixed as a blowing agent in a ratio of 5: 5 to the first extruder, and 5 parts by weight of 100 parts by weight of the PET resin was added thereto, followed by extrusion foaming to prepare a polyester resin foam layer. The density of the polyester resin foam layer prepared was about 300 kg / m ³ , the thickness was about 2 mm, and the basis weight was about 600 g / m ² .

At this time, the total thickness of the manufactured laminate was 8 mm, and mass per unit area was adjusted as shown in Table 8 below.

division Mass per unit area (g / m ² ) Example 26 1500 Example 27 1700 Example 28 2000

Referring to Table 8, it can be seen that the mass per unit area ranges from 1500 to 2000 g / m ² .

Claims (8)

A first polyester resin fiber having a melting point of 180 ° C to 250 ° C or a softening point of 100 ° C to 150 ° C; And a fiber layer in which a second polyester resin fiber having a melting point higher than 250 캜 is mixed,
Wherein a mixing ratio of the first polyester resin fiber and the second polyester resin fiber forming the fiber layer is in the range of 1: 9 to 9: 1 by weight, wherein the fiber layer is a partially fused Package tray panel in the form.
The method according to claim 1,
The sound absorption rate measured according to KS F 2805 is 0.4 NRC or more,
A package tray panel having a transmission loss value of at least 10 dB measured in accordance with KS F 2080.
The method according to claim 1,
A package tray panel satisfying the following general formula (1):
[Formula 1]
(W ₂ - W ₁ ) / W ₁ x 100? 8 (%)
In the above general formulas 2 and 3,
W ₁ means the flexural strength of the package tray panel prior to exposure to ultraviolet radiation under the conditions according to KS M ISO 11507,
W ₂ means the flexural strength of the package tray panel after 30 days of exposure to ultraviolet rays under the conditions according to KS M ISO 11507,
The flexural strength is measured when the supporting spacing of the interior material specimen for the package tray panel is fixed at 100 mm and the flexural load is applied at a rate of 5 mm / min according to ASTM D 790, when the initial specimen is deformed by 10% (N / cm < ² >).
The method according to claim 1,
Leaving it at a temperature of 90 ± 1 ° C for 24 hours; And leaving it for 24 hours at a temperature of 50 짹 1 째 C and a relative humidity of 90%, the package tray panel satisfying the following general formula 2:
[Formula 2]
| V ₁ -V ₀ | / V ₀ x 100? 5%
In the general formula 2,
V ₀ is the volume (mm ³ ) of the package tray panel before exposure to harsh conditions,
V ₁ is the volume (in mm ³ ) of the package tray panel after exposure to the harsh conditions.
The method according to claim 1,
A package tray panel characterized in that the resin forming the first polyester resin fiber comprises a repeating unit represented by the following general formula (1) and general formula (2)
[Chemical Formula 1]

(2)

In the above formulas (1) and (2)
m and n represent mole fractions of the repeating units contained in the low melting point polyester resin,
n is 0.05 to 0.5 based on m + n = 1.
The method according to claim 1,
A package tray panel characterized in that the resin forming the first polyester resin fiber further comprises any one or more of repeating units represented by the following formula (3)
(3)

In Formula 3,
X is a 2-methylpropylene group, an ethylene group or an oxydiethylene group,
r is the mole fraction of the repeating units contained in the low melting point polyester resin, and is not more than 0.3.
10 to 90 parts by weight of a first polyester resin fiber having a melting point of 180 캜 to 250 캜 or a softening point of 100 캜 to 150 캜; And thermally molding a fiber layer in which 90 to 10 parts by weight of a second polyester resin fiber having a melting point of not less than 255 占 폚 is mixed in a temperature range of 80 to 200 占 폚.
8. The method of claim 7,
A method for manufacturing a package tray panel satisfying the following general formula (1)
[Formula 1]
(W ₂ - W ₁ ) / W ₁ x 100? 8 (%)
In the general formula 1,
W ₁ means the flexural strength of the package tray panel before exposure to ultraviolet light under the conditions according to KS M ISO 11507,
W ₂ means the flexural strength of the package tray panel after 30 days of exposure to ultraviolet rays under the conditions according to KS M ISO 11507,
The flexural strength was determined by fixing the support spacing (Span) of the package tray panel specimen at 100 mm and applying a flexural load at a rate of 5 mm / min, according to ASTM D 790, (N / cm ² ).