KR20210132510A - Eco friendly foam compounds having excellent flame retardant for vehicle seat and manufacturing method thereof - Google Patents

Abstract

The present invention relates to an eco-friendly foam composite for a car sheet having excellent flame retardancy. The eco-friendly foam composite for a car sheet according to the present invention includes a flame retardant foam member and an air permeable coating layer, and uses a bio-ethylene propylene diene monomer (EPDM) as a substrate for the foam composite for a car sheet to provide eco-friendly characteristics. In addition, a flame retardant master batch containing a phosphorus-based flame retardant mixed with expanded graphite is applied to the foam for a car sheet to reduce the use of the phosphorus-based flame retardant, thereby allowing maintenance of a proper production cost and providing improved self-fire extinguishing property by locking up and interrupting oxygen in the interlayer gaps of the expanded graphite to realize excellent flame retardancy. Further, when preparing the flame retardant master batch, a liquid crosslinking aid is coated on the surface thereof to improve the dispersibility of the flame retardant master batch so that the flame retardant efficiency may be further improved, and to provide a car interior material with excellent air permeability on the whole.

Description

Eco friendly foam compounds having excellent flame retardant for vehicle seat and manufacturing method thereof

The present invention relates to a foam composition for an eco-friendly vehicle seat having excellent flame retardancy and a method for manufacturing the same.

Synthetic resins widely used in daily life are generally polyurethane resins, polyethylene resins, polypropylene resins, polyvinyl chloride resins, or acrylic resins, and these synthetic resins are It is widely used in various plastic molded products and interior and exterior materials of automobiles because of its relatively excellent moldability, lightness, impact resistance, and chemical resistance.

However, when the petroleum-based synthetic resin as described above is applied to automobile seats, it releases volatile organic compounds at high concentrations, which is harmful to the environment and human body, and causes environmental pollution such as photochemical reactions in the atmosphere to generate secondary pollutants such as photochemical oxides. Not only can it cause contamination, but it is also difficult to recycle after use, so post-treatment is very difficult, so it is not environmentally friendly.

Therefore, recently, by replacing the use of petroleum-based synthetic resins, eco-friendly new materials that reduce environmental pollution and emit less volatile organic compounds have been developed.

The bio-thermoplastic vulcanizate includes a bio-polyethylene resin produced from biomass, and more specifically, the bio-polyethylene resin is ethylene produced by dehydrating bio-ethanol (bio-ethanol). The bio-ethanol is obtained by fermenting sugar extracted from biomass such as corn, pork potato, sugar cane and sugar beet with alcohol.

Using this, a technique for applying a biothermoplastic vulcanizate to an automobile seat as in Patent Document 1 has been proposed, but in this case, there is a disadvantage in that the flame retardancy is weak.

In order to solve this problem, in general, flame retardancy can be improved by using a phosphorus-based flame retardant having excellent flame retardancy.

Therefore, as an alternative means, aluminum hydroxide, which is a relatively inexpensive non-halogen-based flame retardant, may be applied, but in the case of a non-halogen-based flame retardant, a large amount of flame retardant must be used to satisfy the required flame retardancy, and this has a problem in that other physical properties are deteriorated.

In addition, with the recent trend of increasing the application of the ventilation sheet to the vehicle seat, a technology for maintaining the ventilation performance of the vehicle seat in an excellent state is required. It includes a padding material, a 3D mesh fabric, and a non-woven fabric, but a separate air outlet has to be formed in the non-breathable non-woven fabric to maintain air permeability. There was no air permeability at all, there was a disadvantage that the vehicle interior material could not have air permeability as a whole.

Registered Patent No. 10-1729083, Registration Date: 2017.04.17., Title of Invention: Bio sheet for automobile interior material

An object of the present invention is to provide an eco-friendly foam composition for an eco-friendly car seat excellent in flame retardancy and a method for manufacturing the same by using bio ethylene propylene diene monomer (EPDM) as a base material of the foam composition for a car seat.

Another object of the present invention is to reduce the amount of phosphorus-based flame retardant used by applying a flame retardant master batch in which a phosphorus-based flame retardant and expanded graphite are mixed to a foam for an automobile seat while maintaining an appropriate production cost, An object of the present invention is to provide a foam composition for an eco-friendly car seat with excellent flame retardancy that enables excellent flame retardancy by improving self-extinguishing properties by trapping and blocking oxygen in the layered gap, and a method for manufacturing the same.

Another object of the present invention is to improve the dispersibility of the flame retardant master batch by coating a liquid crosslinking aid on the surface during the production of the flame retardant master batch, thereby further improving the flame retardant efficiency. It is to provide a foam composition for sheets and a method for producing the same.

Another object of the present invention is to provide a foam composition for an eco-friendly car seat excellent in flame retardancy to have excellent air permeability as a whole for an automobile interior material, and a method for manufacturing the same.

The foam composition for an eco-friendly car seat excellent in flame retardancy according to an aspect of the present invention is applied to a car seat,

Based on 100 parts by weight of bio EPDM, flame retardant foaming member made by mixing 10 to 30 parts by weight of a flame retardant master batch and an additive for foam; and a breathable coating layer formed on the upper end of the flame-retardant foam member to adhere the flame-retardant foam member to other components of the automobile seat, and made of a low-temperature adhesive polyurethane hot melt at a temperature of 20 to 60°C.

The method for producing a foam composition for an eco-friendly car seat excellent in flame retardancy according to an aspect of the present invention is to prepare a foam composition for an eco-friendly car seat having excellent flame retardancy applied to a car seat,

Forming a flame-retardant foam member by mixing 10 to 30 parts by weight of a flame retardant master batch and an additive for foam with respect to 100 parts by weight of the bio EPDM; And adhering the flame-retardant foam member to the other components of the automobile seat, forming a breathable coating layer made of a low-temperature adhesive polyurethane hot melt at a temperature of 20 to 60° C. on the upper end of the flame-retardant foam member.

According to the foam composition for an eco-friendly car seat excellent in flame retardancy and a manufacturing method thereof according to the present invention, as the foam composition for an eco-friendly car seat excellent in flame retardancy includes a flame retardant foam member and a breathable coating layer, the base material of the foam composition for a car seat It is eco-friendly by using bio EPDM (bio ethylene propylene diene monomer) and reduces the use of phosphorus-based flame retardant by applying a flame retardant master batch that is a mixture of phosphorus-based flame retardant and expanded graphite for automobile seat foam. While maintaining an appropriate production cost, oxygen is trapped and blocked in the lamellar gap of the expanded graphite to improve self-extinguishing properties, so that excellent flame retardancy can be realized, and the flame retardant masterbatch can be By coating the liquid crosslinking aid, it is possible to improve the dispersibility of the flame retardant master batch, thereby further improving the flame retardant efficiency, and to have excellent air permeability as a whole for the interior material of the vehicle.

1 is a side view showing a car seat to which a foam composition for an eco-friendly car seat excellent in flame retardancy according to an embodiment of the present invention is applied.
FIG. 2 is an enlarged cross-section of part A shown in FIG. 1;

Hereinafter, a foam composition for an eco-friendly vehicle seat excellent in flame retardancy according to an embodiment of the present invention and a manufacturing method thereof will be described with reference to the drawings.

1 is a side view showing a car seat to which a foam composition for an eco-friendly car seat excellent in flame retardancy is applied according to an embodiment of the present invention, and FIG. 2 is an enlarged cross-section of part A shown in FIG. 1 .

Referring to FIGS. 1 and 2 together, the foam composition 100 for an eco-friendly car seat excellent in flame retardancy according to this embodiment is applied to the car seat 10 , and the flame-retardant foam member 110 and the breathable coating layer 120 ) is included.

Drawing number 20 is a fibrous padding fabric layer in which the fibrous padding material is formed in a fabric form by weaving, etc., which is disposed on the upper side of the foam composition 100 for an eco-friendly car seat having excellent flame retardancy and is coated by application. , has an elongation of 100% or less and a permanent compression set of 10% or less.

Reference numeral 40 denotes a surface material disposed on the upper side of the fibrous padding fabric layer 20, forming the surface of the automobile seat 10, and made of at least one of natural leather, artificial leather, and fabric.

Reference numeral 30 denotes the surface material 40 and the fibrous padding material fabric layer 20 in such a way that the surface material 40 and the fibrous padding material fabric layer 20 are coated by coating on the bottom surface of the surface material 40 or the upper surface of the fibrous padding material fabric layer 20 It is disposed between the fabric layer breathable coating layer for bonding the surface material 40 to the upper end of the fibrous padding fabric layer 20 .

To prevent clogging of the surface of the fibrous padding fabric layer 20 and maintain ventilation performance, the fabric layer breathable coating layer 30 is made of at least one of polyurethane and polyamide (PA), the fiber The type padding material may be coated on the surface of the fabric layer 20 .

The application of the fibrous padding fabric layer 20 and the fabric layer breathable coating layer 30 in the automobile seat 10 is optional.

The laminate of the foam composition 100 for an eco-friendly car seat excellent in flame retardancy, the fibrous padding fabric layer 20, the fabric layer breathable coating layer 30, and the surface material 40 can be defined as an automobile interior material. have.

The flame-retardant foam member 110 is made by mixing 10 to 30 parts by weight of a flame retardant master batch and an additive for foam with respect to 100 parts by weight of the bio EPDM, a detailed description thereof will be described later.

The breathable coating layer 120 is formed on the upper end of the flame-retardant foam member 110, and adheres the flame-retardant foam member 110 to other components of the automobile seat 10, a low-temperature adhesive type at a temperature of 20 to 60 ° C. It is made of polyurethane hot melt.

Here, the other components of the automobile seat 10 refer to the fibrous padding fabric layer 20 or the surface material 40 (the fibrous padding fabric layer 20 and the fabric layer breathable coating layer 30 ). ) may be absent).

In order to maintain the excellent ventilation performance of the vehicle interior material, the low-temperature adhesive polyurethane hot melt constituting the breathable coating layer 120 does not block the pores for ventilation formed in the flame-retardant foam member 110 and the flame-retardant foam member Only the blocked part of the surface of 110 is coated.

The bio-EPDM is produced by alcohol fermentation of sugar extracted from biomass to obtain bioethanol and polymerization of ethylene obtained by dehydrating it, which is a type of already known bioresin, and in the present invention, various types of bio EPDM can be selected and used.

That is, according to the present invention, it is possible to manufacture an eco-friendly foam for automobile seats that is harmless to the human body and minimizes environmental pollution by using bio EPDM instead of conventional petroleum-based synthetic resin.

The flame retardant master batch is made by mixing a phosphorus-based flame retardant and expanded graphite in a weight ratio of 1:1 to 1:2. Here, when the mixing ratio is out of the above range, there is a fear that the production cost is unnecessarily increased or the self-extinguishing property is insufficient.

On the other hand, the phosphorus-based flame retardant is melamine polyphosphate (melamine polyphosphate), ammonium polyphosphate (ammonium polyphosphate), diammonium phosphate (diammonium phophate), monoammonium phosphate (mono ammonium phophate), polyphosphate amide or melamine phosphate (melamine phosphate) Among them, it can be used alone or in combination of two or more, but it is not necessarily limited to the above type, and various types of known phosphorus-based flame retardants can be used.

And the expanded graphite is graphite in which crystalline graphite is expanded to 100 to 700% of the initial volume with chromic acid or sulfuric acid solution, etc., and has a layered layer by expansion. That is, it has self-extinguishing properties by trapping and blocking oxygen in the interlayer gap.

Therefore, the present invention is to realize excellent flame retardancy by self-extinguishing while maintaining proper production cost by reducing the amount of phosphorus-based flame retardant used by applying a flame retardant masterbatch mixed with phosphorus-based flame retardant and expanded graphite to a foam for automobile seat. Here, when the content of the flame retardant masterbatch is less than 10 parts by weight, there is a fear that the flame retardancy improvement efficiency is insufficient, and if it exceeds 30 weight, there is a fear that the production cost increases.

Meanwhile, the flame retardant master batch is coated with a liquid crosslinking aid.

More specifically, with respect to 100 parts by weight of the liquid crosslinking aid, 50 to 100 parts by weight of the flame retardant master batch is immersed and stirred to coat the surface of the flame retardant master batch with the liquid crosslinking aid, and the liquid crosslinking aid is a tree Use allyl cyanurate (triallylcyanurate), triallylisocyanurate (triallylisocyanurate), trimethylol (trimethylol) or propanetrimethacrylate (propanetrimethacrylate). Here, if the immersion content of the flame retardant master batch is out of the above range, there is a risk that the liquid crosslinking aid may not be properly coated on the surface of the flame retardant master batch.

Therefore, it is possible to improve the dispersibility of the flame retardant master batch, thereby further improving the flame retardant efficiency.

The additive for the foam is a general additive used in the foam composition, and for example, a crosslinking agent, a foaming agent, a metal oxide, stearic acid, a filler, an accelerator, and the like may be applied.

More specific examples include 0.1 to 1.5 parts by weight of a sulfur crosslinking agent or an organic peroxide crosslinking agent (dicumyl peroxide, etc.) as a crosslinking agent, azodicarbonamide (ADCA), dinitrosopentamethylenetetramine, etc., based on 100 parts by weight of the base material. 1 to 10 parts by weight of (DPT), etc., 1 to 5 parts by weight of zinc oxide, magnesium oxide, etc., 1 to 5 parts by weight of stearic acid, 1 to 5 parts by weight of stearic acid, 0.5 parts by weight of calcium carbonate, magnesium carbonate, titanium oxide, silica, etc. to 10 parts by weight, the accelerator is 0.1 to 0.5 of triallyl cyanurate (TAC), mercaptobenzothiazole (MBT), dibenzothiazole disulfide (MBTS), dipentamethylenethiuram teprasulfide (DPTT), etc. It can be used in parts by weight, but it is not necessarily limited to the above type and content, and various types and contents of the already known foam can be applied according to the purpose of use of the foam, required physical properties, and the environment of use.

Hereinafter, the present invention will be described in more detail based on the following examples, but the present invention is not limited by the examples.

1. Manufacture of foam for automobile seat

(Example 1)

Based on 100 parts by weight of bio EPDM, 10 parts by weight of flame retardant master batch, 1.5 parts by weight of crosslinking agent (dicumyl peroxide), 4 parts by weight of foaming agent (azodicarbonamide), 3 parts by weight of metal oxide (zinc oxide), 1 weight part of silver stearic acid Part, filler (calcium carbonate) 1 part by weight, and accelerator (triallyl cyanurate) 0.1 part by weight were thoroughly kneaded, and then the kneaded product was molded at 155° C. and 120 kg/cm 2 for 40 minutes to prepare a foam.

Here, the flame retardant master batch is prepared by mixing a phosphorus-based flame retardant (melamine polyphosphate) and expanded graphite in a 1:1 weight ratio, and then 50 parts by weight of the flame retardant master batch with respect to 100 parts by weight of a liquid crosslinking aid (triallyl cyanurate) It was used by coating a liquid crosslinking aid on the surface of the flame retardant master batch by immersion and stirring.

(Example 2)

Based on 100 parts by weight of Bio EPDM, 30 parts by weight of flame retardant master batch, 1.5 parts by weight of crosslinking agent (dicumyl peroxide), 4 parts by weight of foaming agent (azodicarbonamide), 3 parts by weight of metal oxide (zinc oxide), 1 weight part of silver stearic acid Part, filler (calcium carbonate) 1 part by weight, and accelerator (triallyl cyanurate) 0.1 part by weight were thoroughly kneaded, and then the kneaded product was molded at 155° C. and 120 kg/cm 2 for 40 minutes to prepare a foam.

Here, the flame retardant master batch is prepared by mixing phosphorus-based flame retardant (ammonium polyphosphate) and expanded graphite in a 1: 2 weight ratio, and then 100 parts by weight of the flame retardant master batch with respect to 100 parts by weight of a liquid crosslinking aid (triallyl isocyanurate) The part was immersed and stirred to coat the surface of the flame retardant master batch with a liquid crosslinking aid.

(Comparative Example 1)

It was prepared in the same manner as in Example 1, except that only a phosphorus-based flame retardant was used.

(Comparative Example 2)

It was prepared in the same manner as in Example 2, but only expanded graphite was used.

2. Evaluation of Foam

The self-extinguishing properties of the foams according to the Examples and Comparative Examples were measured based on the B2-DIN-4102 standard (self-extinguishing test), and the results are shown in [Table 1] below.

division

self-extinguishing
Example 1

45mm combustion (extinguish after 10 seconds of burning)
Example 2

47mm combustion (fired after 11 seconds)
Comparative Example 1

48mm combustion (fired after 11 seconds)
Comparative Example 2

Continuous combustion (extinguish after 70 seconds of burning)

As shown in [Table 1], the foam for automobile seat according to the embodiment of the present invention is not only environmentally friendly by using bio-EPDM, but also has self-extinguishing properties equal to or greater than that of Comparative Example 1 using only phosphorus-based flame retardants. It can be seen that by reducing the amount of flame retardant used, an excellent flame retardancy is realized while maintaining an appropriate production cost.

Hereinafter, with reference to the drawings, a method of manufacturing the foam composition 100 for an eco-friendly car seat excellent in flame retardancy according to this embodiment will be described.

First, with respect to 100 parts by weight of the bio EPDM, 10 to 30 parts by weight of the flame retardant master batch and the foam additive are mixed to form the flame retardant foam member 110 .

Then, the breathable coating layer 120 made of a low-temperature adhesive polyurethane hot melt at a temperature of 20 to 60° C. is formed on the upper end of the flame-retardant foam member 110 .

The breathable coating layer 120 is to adhere the flame-retardant foam member 110 to other components of the vehicle seat 10 .

As described above, as the foam composition 100 for an eco-friendly car seat excellent in flame retardancy includes the flame-retardant foam member 110 and the breathable coating layer 120, bio EPDM (bio It is eco-friendly by using ethylene propylene diene monomer) and maintains reasonable production cost by reducing the amount of phosphorus-based flame retardant used by applying a flame retardant master batch mixed with phosphorus-based flame retardant and expanded graphite to the foam for automobile seats. At the same time, oxygen is trapped and blocked in the lamellar gap of the expanded graphite to improve self-extinguishing properties, so that excellent flame retardancy can be realized. By coating, it is possible to improve the dispersibility of the flame retardant master batch and thereby further improve the flame retardant efficiency, and to have excellent ventilation as a whole of the interior material of the vehicle.

In the above, the present invention has been shown and described with respect to specific embodiments, but those of ordinary skill in the art can variously modify the present invention within the scope without departing from the spirit and scope of the present invention as set forth in the claims below. and can be changed. However, it is intended to clearly state that all such modifications and variations are included within the scope of the present invention.

According to the foam composition for an eco-friendly car seat excellent in flame retardancy and a manufacturing method thereof according to an aspect of the present invention, by using bio EPDM (bio ethylene propylene diene monomer) as a base material of the foam composition for car seat, it is eco-friendly and foam for car seat By applying a flame retardant master batch mixed with phosphorus-based flame retardant and expanded graphite, the amount of phosphorus-based flame retardant is reduced to maintain appropriate production cost, and Oxygen is trapped and blocked to improve self-extinguishing properties, so that excellent flame retardancy can be realized. Since it is possible to further improve the efficiency and to have excellent air permeability as a whole for the interior material of the vehicle, its industrial applicability is high.

100: Foam composition for eco-friendly car seats with excellent flame retardancy
110: flame retardant foam member
120: breathable coating layer

Claims (5)

As applied to a car seat,
Based on 100 parts by weight of bio EPDM, flame retardant foaming member made by mixing 10 to 30 parts by weight of a flame retardant master batch and an additive for foam; and
It is formed on the upper end of the flame-retardant foam member, and adheres the flame-retardant foam member to other components of the automobile seat, and a breathable coating layer made of a low-temperature adhesive polyurethane hot melt at a temperature of 20 to 60 ° C. Eco-friendly car with excellent flame retardancy, including A foam composition for sheets. The method of claim 1,
The flame retardant master batch is an eco-friendly foam composition with excellent flame retardancy, characterized in that the phosphorus-based flame retardant and expanded graphite are mixed in a weight ratio of 1:1 to 1:2. 3. The method of claim 2,
The flame retardant master batch is coated with a liquid crosslinking aid, and with respect to 100 parts by weight of the liquid crosslinking aid, 50 to 100 parts by weight of the flame retardant master batch is immersed and stirred to apply the liquid crosslinking aid to the surface of the flame retardant master batch. coating,
The liquid crosslinking aid is triallyl cyanurate, triallyl isocyanurate, trimethylol or propane trimethacrylate. 3. The method of claim 2,
The phosphorus-based flame retardant is melamine polyphosphate, ammonium polyphosphate, diammonium phosphate, monoammonium phosphate, polyphosphoric acid amide, phosphoric acid amide, melamine phosphate or a car with excellent flame retardancy, characterized in that used in combination of two or more A foam composition for sheets. For producing a foam composition for an eco-friendly car seat with excellent flame retardancy applied to a car seat,
Forming a flame retardant foam member by mixing 10 to 30 parts by weight of a flame retardant master batch and an additive for a foam with respect to 100 parts by weight of the bio EPDM; and
Adhering the flame-retardant foam member to the other components of the vehicle seat, forming a breathable coating layer made of a low-temperature adhesive polyurethane hot melt at a temperature of 20 to 60° C. on the upper end of the flame-retardant foam member; A method for producing a foam composition for an automobile seat.

Images