KR20220073247A - Vehicle interior panel comprising novel polyester fiber for binder - Google Patents

Abstract

The present invention includes a fiber layer in which a first polyester fiber containing a polyester resin having a melting point higher than 250° C. and a second polyester fiber containing a polyester resin for a binder having a softening point of 100° C. to 150° C. are mixed, The second polyester fiber is a polyester fiber for a binder formed of a sheath portion and a core portion, wherein the core portion is formed of a general polyester resin, and the sheath portion contains terephthalic acid or an ester-forming derivative thereof and oxalic acid as an acid component, It is formed of a polyester resin for a binder containing ethylene glycol as a diol component, and the oxansal of the polyester resin for the binder is used in interior materials for automobiles containing polyester fibers for binders containing 30 to 60 mol% of the acid content. it's about

Description

Interior materials for automobiles containing polyester fibers for novel binders {VEHICLE INTERIOR PANEL COMPRISING NOVEL POLYESTER FIBER FOR BINDER}

The present invention relates to an interior material for automobiles comprising a novel polyester fiber for a binder, and is excellent in shape stability during thermoforming using a new polyester fiber for a binder and an automobile comprising a polyester fiber for a binder with excellent sound absorption It relates to interior materials.

In automobiles, exterior parts such as doors and fenders, or interior materials such as seats, door trims, and package tray panels are mounted. The body part of a vehicle should provide stability, space, and comfort to passengers including the driver.

In general, automotive interior materials combine fibers with a thermoplastic resin or a mixture of a thermoplastic resin and a thermosetting resin to form a sheet, preheated to about 120°C, and a thermosetting adhesive layer capable of curing the surface material thereon at a temperature of 120°C or less After attaching through the medium, the laminate was manufactured by cold compression molding.

Since the above method heats the sheet at a relatively low temperature of about 120° C., the surface material does not deteriorate as deteriorated at a high temperature. However, the thermoplastic resin acting as a binder does not melt sufficiently at the above-described low temperature, so the bonding force between the fibers is weak, and thus the durability is weak.

Interior materials for automobiles that have been commercialized in recent years are mainly manufactured using fiber-reinforced resin boards or polyurethane-based foams.

The fiber-reinforced resin board is manufactured by boarding polypropylene resin reinforced with natural fibers such as hemp fibers. However, since these fiber-reinforced resin boards use natural fibers, the working environment is poor due to the odor generated during product molding, and the odor generated during vehicle application causes consumer dissatisfaction. In addition, while microorganisms such as mold grow in the natural fibers applied to the fiber-reinforced resin board, there is a risk of emitting an odor and releasing components harmful to the health of the occupants. In addition, the fiber-reinforced resin board using the natural fiber has a disadvantage in that it is difficult to reduce the weight.

Alternatively, a package tray panel using a polyurethane-based foam has a problem of discharging toxic gas during incineration. In addition, the polyurethane-based foam has a soft property when pressed by hand. In order to compensate for this, glass fiber or glass fragments are sometimes used to manufacture interior materials for private vehicles.

Republic of Korea Patent No. 0128075 is an invention related to an interior material for automobiles and a method for manufacturing the same, comprising: a needled glass fiber sheet containing a thermoplastic resin binder, the needled glass fiber being mainly composed of glass fibers; an air-permeable heat-sealable adhesive layer installed on the support layer; And provided on the adhesive layer, consisting of an air-permeable surface layer, the support layer is a technology disclosed in the interior material for automobiles, characterized in that it further contains foamed microbeads.

As described above, the interior material for automobiles using glass fibers or glass fragments has problems in that the weight increases, and glass dust is generated during the manufacturing and transporting process, thereby impairing the working environment of the operator.

The present invention was invented to solve the problems of the prior art as described above, and a novel polyester fiber for binder with excellent processability and excellent shape stability through improved thermal adhesion of polyester fiber for binder constituting interior materials for automobiles. An object of the present invention is to provide an interior material for a vehicle comprising a.

In addition, an object of the present invention is to provide an interior material for a vehicle comprising a polyester fiber for a binder that improves sound absorption by forming an air layer therein.

The present invention includes a fiber layer in which a first polyester fiber containing a polyester resin having a melting point higher than 250° C. and a second polyester fiber containing a polyester resin for a binder having a softening point of 100° C. to 150° C. are mixed, The second polyester fiber is a polyester fiber for a binder formed of a sheath portion and a core portion, wherein the core portion is formed of a general polyester resin, and the sheath portion contains terephthalic acid or an ester-forming derivative thereof and oxalic acid as an acid component, It is formed of a polyester resin for a binder containing ethylene glycol as a diol component, wherein the oxansal of the polyester resin for the binder contains 30 to 60 mol% of the acid component. It provides interior materials for automobiles.

In addition, the first polyester fiber and the second polyester fiber provides an interior material for a vehicle comprising a polyester fiber for a binder, characterized in that the black yarn.

In addition, the first polyester fiber provides an interior material for a vehicle comprising a polyester fiber for a binder, characterized in that the cross-sectional yarn having any one of three-leaf, four-leaf, six-leaf, and eight-leaf cross-section.

In addition, the second polyester fiber provides an interior material for a vehicle including a polyester fiber for a binder, characterized in that the sheath-core fiber having a hollow.

In addition, the oxane sal of the polyester resin for the binder provides an interior material for automobiles comprising a polyester fiber for a binder, characterized in that it contains 30-50 mol% of the acid component.

In addition, the polyester resin for the binder provides an interior material for a vehicle including a polyester fiber for a binder, characterized in that the softening temperature is 100 ℃ ~ 150 ℃.

In addition, the polyester resin for the binder provides an interior material for automobiles comprising a polyester fiber for a binder, characterized in that the glass transition temperature is 60 ℃ to 90 ℃.

As described above, the interior material for automobiles including the polyester fiber for binder according to the present invention uses polyester fiber for binder with improved thermal adhesion, and thus has excellent bonding between fibers and excellent shape stability even at low temperature thermoforming.

In addition, the interior material for automobiles including the polyester fiber for the binder of the present invention contains a large number of air layers inside the interior material, so that the sound absorption rate is improved.

Hereinafter, a preferred embodiment of the present invention will be described in detail. First, in describing the present invention, detailed descriptions of related known functions or configurations are omitted so as not to obscure the gist of the present invention.

As used herein, the terms 'about', 'substantially' and the like are used in a sense at or close to the numerical value when the manufacturing and material tolerances inherent in the stated meaning are presented, and serve to enhance the understanding of the present invention. To help, precise or absolute figures are used to prevent unfair use by unconscionable infringers of the stated disclosure.

The present invention is a binder in which a fiber layer is formed in which a first polyester fiber containing a polyester resin having a melting point higher than 250° C. and a second polyester fiber containing a polyester resin for a binder having a softening point of 100° C. to 150° C. are mixed. It relates to an interior material for automobiles comprising polyester fibers for use.

The first polyester fiber may be formed of polyethylene terephthalate (PET) formed of terephthalic acid or an ester-forming derivative thereof and ethylene glycol (EG), and may be formed of a copolymerized polyester resin in which a functional compound is copolymerized for functionality. will be able

Any polyester resin having a melting point higher than 250° C. may be used as the first polyester fiber.

The first polyester fiber will preferably be formed of a cross-sectional yarn having a cross-section of any one of three leaves, four leaves, six leaves, and eight leaves in order to improve the sound absorption rate of the interior material of the vehicle.

As described above, the first polyester fiber having a multi-leaf shaped cross-section improves the sound absorption rate by forming many air layers inside the interior of the vehicle.

The second polyester fiber is a polyester fiber for a binder formed of a sheath portion and a core portion. The core portion is formed of a general polyester resin and the sheath portion is formed of a polyester resin for a binder.

Any general polyester resin forming the core may be used, but it is preferable to use a polyethylene terephthalate (PET) resin made of terephthalic acid and ethylene glycol.

The polyester resin for a binder forming the sheath is a polyester resin for a binder containing terephthalic acid or an ester-forming derivative thereof as an acid component and ethylene glycol as a diol component.

In general, polyester resin is a polymer resin produced by polymerization of terephthalic acid or its ester-forming derivative as an acid component and ethylene glycol as a diol component. It has a high melting point because it does not move easily by heat.

The polyester resin for a binder of the present invention uses terephthalic acid or an ester-forming derivative thereof and oxalic acid as an acid component to reduce the flowability of the molecular chain by reducing the number of benzene rings of terephthalic acid, thereby reducing the flowability of the entire molecular chain is increased to lower the melting point.

In addition, the polyester resin for the binder of the present invention may have improved sagging properties when it is formed into fibers, films, and molded articles because packing properties increase due to reduction of benzene rings in the molecular chain.

When the polyester resin for a binder of the present invention contains 30 mol% or more of the acid component of oxalic acid, the polymer becomes amorphous and has thermal properties similar to those of the conventional low-melting-point polyester resin for binders containing isophthalic acid. Due to the flexible molecular chains present in the polymer main chain, the elasticity is improved, thereby improving the tear properties during binding of the nonwoven fabric.

That is, in the novel polyester resin for binder of the present invention, oxalic acid is included in the polyester main chain to induce an increase in the degree of freedom of the main chain and a decrease in the crystallinity of the resin to control the softening point (Ts) and/or the glass transition temperature (Tg) can This may exhibit the same effect as in the case of using isophthalic acid (IPA) containing an asymmetric aromatic ring in order to reduce the crystallinity of the conventional crystalline polyester resin.

The polyester resin for the binder of the present invention formed of the acidic component as described above will preferably contain 30 to 60 mol% of the oxalic acid of the polyester resin for the binder in order to improve low melting point characteristics and adhesion.

If the content of the oxalic acid is too low, the melting point may not be smoothly lowered and thus may not be suitable for a binder, and if the content of the oxalic acid is too high, the physical properties of the polyester resin may be deteriorated.

It will be most preferable for the polyester resin for the binder to contain 30-50 mol% of the acid component.

As described above, the novel polyester resin for a binder according to the present invention has a softening temperature of 100°C to 150°C, and a glass transition temperature of 60°C to 90°C, which has excellent physical properties.

The second polyester fiber is preferably formed as a sheath-core fiber having a hollow, and the air layer through the multi-leaf-shaped release cross-section of the first polyester fiber and the hollow of the second polyester fiber are more in the interior of the vehicle. It will be possible to further increase the sound absorption rate of automobile interior materials by securing more air layers.

In general, automobile interior materials are often manufactured in black color, so the first polyester fiber and the second polyester fiber contain black pigments such as carbon black during fiber production and are manufactured with black dyed yarns to produce black without a separate dyeing process. It may be formed into a colored car interior material.

When the first polyester fiber and the second polyester fiber are manufactured as a raw yarn, a pigment such as carbon black may be contained in an amount of 0.5 to 3% by weight based on the weight of the polyester fiber to prepare a black yarn.

As described above, the present invention is a vehicle interior material formed of a first polyester fiber and a second polyester fiber, wherein the first polyester fiber and the second polyester fiber are partially fused to each other, and the fibers are partially fused to each other. In the formed form, heat and/or pressure are applied in the process of forming the fiber layer through thermoforming, and in the process, the fibers are partially fused to each other to form a form.

The first polyester fiber and the second polyester fiber forming the automobile interior material are preferably mixed in a weight ratio of 1:9 to 9:1 to form a fiber layer. When the content of the second polyester fiber is low, the portion between the fibers Form stability may be reduced due to weak fusion, and if the content of the second polyester fiber is high, physical properties such as strength of interior materials for automobiles may be reduced.

The interior material for automobiles comprising the polyester fiber for a binder according to the present invention forms a fiber layer in which the first polyester fiber and the second polyester fiber are uniformly mixed, and is thermoformed at 100 to 200° C. to partially fusion between the fibers. can be formed and formed into a certain shape.

The automobile interior material has a high shape retention at high temperature when the shape retention rate is high during thermoforming, and preferably has a shape retention ratio of 95% or more during thermoforming, and more preferably a shape retention ratio of 98% or more.

Hereinafter, examples of a method for manufacturing an interior material for a vehicle including a polyester fiber for a binder according to the present invention are shown, but the present invention is not limited to the examples.

◈ Second polyester fiber manufacturing

production example 1 to 5

Terephthalic acid (TPA) and ethylene glycol (EG) were added to an ester reactor, and a conventional polymerization reaction was performed at 258° C. to prepare a polyethylene terephthalate polymer (PET oligomer) having a reaction rate of about 96%.

The prepared polyethylene terephthalate (PET) contained oxalic acid as shown in Table 1, and the transesterification reaction was carried out at 250±2° C. by the addition of a transesterification catalyst. Thereafter, a polycondensation reaction catalyst is added to the obtained reaction mixture, and a polycondensation reaction is performed while controlling the final temperature and pressure in the reaction tank to be 280±2° C. and 0.1 mmHg, respectively, to obtain a novel polyester resin for a binder according to the present invention. prepared.

A polyester fiber for a binder of the present invention was prepared by using the polyester resin for the binder prepared above as a sheath and polyethylene terephthalate formed of terephthalic acid (TPA) and ethylene glycol (EG) as a core.

The polyester fiber for the binder of the present invention was prepared through a general composite spinning process at a weight ratio of 50:50 of the sheath part and the core part.

Preparation Comparative Example 1

Terephthalic acid was used as an acid component, and 2-methyl-1,3-propanediol (40 mol%) and ethylene glycol (60 mol%) were used as diol components to prepare a polyester resin for a binder.

A composite fiber was prepared as in Example 1 using the polyester resin for the binder.

Preparation Comparative Example 2

A polyester resin for a binder was prepared using terephthalic acid (60 mol%) and isophthalic acid (40 mol%) as an acid component, and ethylene glycol as a diol component.

A composite fiber was prepared as in Example 1 using the polyester resin for the binder.

division acid diol ingredient Oxalic Acid (mol%) IPA (mol%) TPA (mol%) MPD (mol%) EG (mol%) Preparation Example 1 10 0 90 0 100 Preparation Example 2 20 0 80 0 100 Preparation 3 30 0 70 0 100 Preparation 4 40 0 60 0 100 Production Example 5 50 0 50 0 100 Produce
Comparative Example 1 0 0 100 40 60 Produce
Comparative Example 2 0 40 60 0 100

◈ Measurement of physical properties of manufacturing examples and manufacturing comparative examples

The following physical properties of the polyester resin for the binder and the polyester fiber for the binder prepared in the Preparation Examples and Preparation Comparative Examples were measured, and the results are shown in Table 2.

(1) Measurement of softening point (or melting point) and glass transition temperature (Tg)

The glass transition temperature (Tg) of the copolymerized polyester resin was measured using a differential scanning calorimeter (Perkin Elmer, DSC-7), and the softening behavior was measured in TMA mode using a dynamic mechanical analyzer (DMA-7, Perkin Elmer). did

(2) Melt viscosity measurement

After melting the polyester resin at the measurement temperature, the melt viscosity was measured using RDA-III manufactured by Rheometric Scientific. Specifically, when measuring from the initial frequency = 1.0 rad/s to the final frequency = 500.0 rad/s under the frequency sweep condition at the set temperature, the value at 100 rad/s was calculated as the melt viscosity.

(3) Measurement of room temperature and high temperature adhesion

The polyester fibers of Examples and Comparative Examples were heat-sealed to prepare a nonwoven fabric having a fixed density of 2g/100cm2, and the prepared nonwoven fabric was subjected to ASTM D1424 at 25±0.5°C (room temperature) and 100±0.5°C (high temperature). Adhesion was measured.

(4) High temperature shrinkage

After preparing a polyester fiber for a binder into a short fiber, it is carded to produce a cylindrical shape. After applying heat at 170℃ for 3 minutes, the reduced volume is measured. The existing volume is 330cm3. Generally, if it is less than 250cm3, the shape stability is inferior, and if it is more than 280cm3, it can be evaluated as excellent.

(5) Compressive hardness measurement

After opening 5 g of polyester fiber and stacking it in a circular mold with a diameter of 10 cm to a height of 5 cm, thermal bonding was performed at a set temperature for 90 seconds to prepare a cylindrical molded article. The manufactured molded article was compressed by 75% through Instron, and the load applied to the compression was measured to measure the compression hardness. In this experiment, the compression hardness was measured by thermal bonding at 140 °C, 150 °C, and 160 °C, respectively.

division Preparation Example 1 Preparation Example 2 Preparation 3 Preparation 4 Production Example 5 Produce
Comparative Example 1 Produce
Comparative Example 2 thermal
characteristic
(℃) softening temperature - - - 124.5 112.7 120 128 Tm 210.3 190.6 176.3 - - - - Tg 78.7 74.1 72.7 70.3 68.9 70.4 70.1 adhesion room temperature adhesive
(kgf) - - 63 77 81 75 64 high temperature adhesive
(kgf) - - 3.1 5.3 5.7 5.5 4.2 peel strength
(kgf-mm) 12.4 16.6 23.8 33.4 36.7 33.5 26.3 tear strength
(N/m) 2210 1875 1265 545 520 564 785 shape
stability high temperature shrinkage
(㎤) 313 308 298 288 283 285 290 compression
Hardness
(kgf) 140℃ 1.4 1.6 2.4 3.6 3.9 3.7 3.7 150℃ 2.7 2.9 3.7 5 5.6 4.7 4.9 160℃ 3.3 4.2 5.1 5.8 6 5.3 5.5

As shown in Table 2, the binder polyester resin contained in the polyester fiber for the binder of the present invention has crystallinity when 10 to 30 mol% of oxalic acid is contained in the acid component, but in Preparation Example 4 exceeding 30 mol%, In the case of 5, it can be seen that the melting point does not exist and has amorphous properties.

Preparation Examples 1 and 2 have a melting point of 190 to 210° C., which is lower than that of general polyester resins, and can be used as a polyester resin for binders for various purposes, and Preparation Examples 3 to 5 are polyester resins for binders at a lower temperature. will be able to use

As in Preparation Examples 4 and 5, when 40-50 mol% of oxalic acid is contained in the acid component, it has similar or superior room temperature and high temperature adhesion to Comparative Examples 1 and 2, which is a polyester fiber for a conventional binder, and has peel strength and It is also excellent in compression hardness, and it can be seen that the polyester fiber for the binder of the present invention has excellent physical properties.

In addition, it can be seen that all of Preparation Examples 1 to 5 and Preparation Comparative Examples 1 and 2 have good high-temperature shrinkability of 260 cm 3 or more.

As described above, the novel polyester fiber for a binder according to the present invention may be used for various purposes with properties similar to or excellent in physical properties to a polyester fiber using a polyester resin for a binder used in the prior art.

◈ Manufacturing of automobile interior materials

Examples 1-3

Polyethylene terephthalate having a melting point of about 265° C. was used for the first polyester fiber, and the cross-sectional shape was changed according to Examples as shown in Table 3 and used.

In the case of the second polyester fiber, the polyester fibers for binders prepared in Preparation Example 4 were used in Examples 1 and 2, and in Example 3, the same as in Preparation Example 4, but a hollow type was used.

After forming the first polyester fiber and the second polyester fiber to a fiber length of 51 mm, respectively, uniformly mixed with a carding machine at a weight ratio of 60:40, and thermoformed at about 130° C. to polyester for a binder according to the present invention An interior material for automobiles including fibers was manufactured.

Table 3 shows the composition of Examples 1 to 3, the shape retention rate, the thickness of the interior material for automobiles, and the average areal density.

Comparative Examples 1 to 3

It was prepared in the same manner as in Example 1, but in the case of the first polyester fiber, in Comparative Examples 1 and 2, a polyester fiber having a circular cross section, and in Comparative Example 3, the same polyester fiber as in Example 1 was used, and the second polyester In the case of fibers, Comparative Examples 1 and 3 were polyester fibers for binders prepared in Preparation Comparative Example 2, Comparative Example 2 was the same as Preparation Comparative Example 2, but a hollow type was manufactured and used.

Table 3 shows the composition of Comparative Examples 1 to 3, the shape retention rate, the thickness of the interior material for automobiles, and the average areal density.

* Measurement of shape retention rate

After the carding process, 5 g of the mixed fibers are taken and placed in a 300 ㎤ cylindrical case (A), and the change in volume (B) is measured by processing at 140 ° C for 60 sec.

* Shape retention (%) = (B/A) × 100

division first polyester fiber
second polyester fiber
Thickness (㎛) average areal density
(㎡) shape retention rate
(%) section Fineness (D) section Fineness (D) Example 1 8-leaf type 4 circle 6 20 1,602 98.3 Example 2 6-leaf type 4 circle 6 20 1,627 99.2 Example 3 3 leaf type 4 hollow 6 20 1,625 98.5 Comparative Example 1 circle 4 circle 6 20 1,621 96.5 Comparative Example 2 circle 4 hollow 6 20 1,598 98.7 Comparative Example 3 8-leaf type 4 circle 6 20 1,604 95.6

As shown in Table 3, the interior material for automobiles including the polyester fiber for binder according to the present invention contains polyester fiber for binder with improved thermal adhesion, and in Examples 1 to 3, the shape retention rate is 98% or more, Comparative Example 1 It can be seen that it has a very good shape retention rate than 3 to 3.

▶ Measurement of sound absorption of Examples and Comparative Examples

Each of the interior materials for automobiles prepared in the Examples and Comparative Examples were cut to 1.2 m in width and 1.0 m in length to prepare a specimen, and then the sound absorption coefficient for each frequency (Hz) was measured in the following manner, and the average measurement results thereof is shown in Table 4 below.

* Measurement of sound absorption coefficient by frequency

In order to measure the sound absorption coefficient, three specimens were prepared as specimens applicable to ISO R 354 and Alpha Cabin method, respectively, and the sound absorption coefficient was measured after leaving them at an external temperature of 0 ° C and 25 ° C for 30 minutes, and the average value of the measured sound absorption coefficient is shown in Table 4. .

division Sound absorption coefficient by frequency
1,000 Hz 2,000 Hz 3,150Hz 5,000Hz Example 1 0.68 0.75 0.79 0.95 Example 2 0.67 0.71 0.74 0.91 Example 3 0.66 0.74 0.73 0.93 Comparative Example 1 0.64 0.68 0.69 0.81 Comparative Example 2 0.64 0.69 0.71 0.80 Comparative Example 3 0.66 0.71 0.78 0.85

As shown in Table 4, Examples 1 to 3, which are interior materials for automobiles including polyester fibers for binders according to the present invention, have a lower sound absorption coefficient than Comparative Examples 1 to 3, and thus it can be seen that the sound absorption properties are excellent.

In addition, it can be seen that the sound absorption is improved as the number of leaves increases through Examples 1 and 2, and through Example 3, it can be seen that the sound absorption is improved when the second polyester fiber is hollow.

Claims (7)

A fiber layer in which a first polyester fiber containing a polyester resin having a melting point higher than 250° C. and a second polyester fiber containing a polyester resin for a binder having a softening point of 100° C. to 150° C. are mixed,
The second polyester fiber is a polyester fiber for a binder formed of a sheath portion and a core portion, wherein the core portion is formed of a general polyester resin, and the sheath portion contains terephthalic acid or an ester-forming derivative thereof and oxalic acid as an acid component, It is formed of a polyester resin for a binder containing ethylene glycol as a diol component,
The interior material for automobiles comprising polyester fibers for binders, characterized in that the oxansal of the polyester resin for the binder contains 30 to 60 mol% of the acid component. According to claim 1,
The first polyester fiber and the second polyester fiber is an interior material for a vehicle comprising a polyester fiber for a binder, characterized in that the black yarn. According to claim 1,
The first polyester fiber is an interior material for a vehicle comprising a polyester fiber for a binder, characterized in that the yarn having a cross-section of any one of three-leaf, four-leaf, six-leaf, and eight-leaf. According to claim 1,
The second polyester fiber is a sheath-core fiber having a hollow interior material comprising a polyester fiber for a binder, characterized in that. The method of claim 1,
The interior material for automobiles comprising a polyester fiber for a binder, characterized in that the oxansal of the polyester resin for the binder contains 30 to 50 mol% of the acid component. The method of claim 1,
The polyester resin for the binder has a softening temperature of 100°C to 150°C. The method of claim 1,
The polyester resin for the binder has a glass transition temperature of 60°C to 90°C.