US20030003317A1 - Thermoplastic resin-laminated structure, method for preparation and use thereof - Google Patents

Thermoplastic resin-laminated structure, method for preparation and use thereof Download PDF

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Publication number
US20030003317A1
US20030003317A1 US10/175,008 US17500802A US2003003317A1 US 20030003317 A1 US20030003317 A1 US 20030003317A1 US 17500802 A US17500802 A US 17500802A US 2003003317 A1 US2003003317 A1 US 2003003317A1
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United States
Prior art keywords
resin
layer
group
heat
laminated structure
Prior art date
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Abandoned
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US10/175,008
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English (en)
Inventor
Hong-Geun Chang
Jung-Sook Kang
Mi-Hyang La
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CHANG HONG-GUEN
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CHANG HONG-GUEN
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Assigned to CHANG, HONG-GUEN reassignment CHANG, HONG-GUEN ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: KANG, JUNG-SOOK, LA, MI-HYANG
Publication of US20030003317A1 publication Critical patent/US20030003317A1/en
Priority to US11/123,186 priority Critical patent/US20050205203A1/en
Priority to US11/982,098 priority patent/US7479313B2/en
Abandoned legal-status Critical Current

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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal
    • Y10T428/31692—Next to addition polymer from unsaturated monomers
    • Y10T428/31699—Ester, halide or nitrile of addition polymer

Definitions

  • the present invention relates to a resin-laminated structure, method for preparation and use thereof, and in particular to a thermoplastic resin-laminated structure which has excellent properties such as adhesive strength between a base layer and an exterior layer, and recycling utility as well as surface quality in feeling, thermal durability, acoustic absorptivity, heat-shielding property, and impulse-durability, method for preparation and use thereof.
  • Polymer resin-laminated structures are designed pursuant to their application purposes. Generally, resin moldings having different properties and/or made by different molding methods are bound to form a resin-laminated structure having new features. For preparing an interior automotive trim (e. g., instrument panel), an exterior layer of soft resin prepared by sheet molding and a base layer of quite hard resin prepared by injection molding are bound to form a resin-laminated structure having excellent strength, impulse-durability and acoustic absorptivity together with soft surface quality in feeling.
  • an interior automotive trim e. g., instrument panel
  • an exterior layer of soft resin prepared by sheet molding and a base layer of quite hard resin prepared by injection molding are bound to form a resin-laminated structure having excellent strength, impulse-durability and acoustic absorptivity together with soft surface quality in feeling.
  • the resin-laminated structures consisting of the exterior layer and the base layer are fabricated by independently molding the exterior layer and the base layer and binding them to each other. This binding between the exterior layer and the base layer is performed with thermal vacuum molding or thermal adhesion molding. These binding methods are described below.
  • Vacuum molding methods are disclosed in Korean Patent Laid-Open No. 199958663 and Japanese Patent Laid-Open No. Hei11-343477. According to these patent applications, an exterior layer of soft polyvinylchloride sheet is fixed to a mold with vacuum adsorption, and a base layer of polycarbonate composite resin is also fixed to the mold. After the objects to be adhered are sufficiently pre-heated, polyurethane foaming material including adhesive material is injected between the exterior layer and the base layer to perform foaming and compression molding.
  • This vacuum molding method has an advantage that the adhesive strength between the exterior layer and the base layer is good, because the objects, namely polyvinylchloride, polycarbonate and polyurethane, are all polar resins.
  • thermo adhesion molding method which is more advanced in view of recycling used materials than the vacuum molding method as described above, is disclosed in Japanese Patent Laid-Open No. Hei12-282001 and Korean Patent Laid-Open No. 199943059.
  • the thermal adhesion molding method is a method that after an exterior layer of polyolefin resin and a base layer of polyolefin composite resin are sufficiently preheated, the objects are compressed at high pressure using an adhesive agent therebetween or heat to form a resin-laminated structure.
  • This thermal adhesion molding method has an advantage that the resin-laminated structure can be recycled.
  • the base layer consists of polyolefin resin as a non-polar resin which lacks strength and whose adhesive force to the exterior layer is not good; thus the exterior layer may be stripped from the base layer, the working environment is not pleasant due to a malodor of adhesive agent and the like, the objects may be deformed during the pre-heating, and equipment operated at high temperature and pressure is additionally required.
  • a method proposed is that a primer layer should be previously coated on the base layer, or that the base layer or the exterior layer be surface-treated with plasma, corona, electron ray, high frequency wave, heating by hot air, or flame treatment.
  • the above-mentioned method can improve the adhesive force between the base layer and the exterior layer.
  • the method has shortcomings. In the former case of previously coating the primer layer on the base layer some processes should be added and thus the productivity decreases, whereas in the latter case of surface-treating the base layer and the exterior layer, additional expensive equipment is essential and thus the fabrication cost increases.
  • thermoplastic resin-laminated structure that has excellent properties such as adhesive strength between a base layer and an exterior layer, and recycling utility as well as surface quality in feeling, thermal durability, acoustic absorptivity, heat-shielding property, and impulse-durability.
  • Another object of the present invention is to provide a preparation method for the thermoplastic resin-laminated structure, in which no extra expensive vacuum apparatus is needed, the manufacturing process is simple enough to reduce the manufacturing cost and productivity is very good, as well as, decrease the use of harmful chemicals such as adhesive agents to the extent that unpleasantness due to malodor is decreased during production processes and use of the final product.
  • thermoplastic resin-laminated structure It is also another object of the present invention to provide uses of the thermoplastic resin-laminated structure.
  • a thermoplastic resin-laminated structure comprises an exterior layer, a base layer, and a binding layer which is placed between the exterior layer and the base layer, wherein the binding layer includes at least one material selected from a group consisting of electric resistance-heat generating materials and heat-conductive materials, and has at least one connection terminal at a certain region for supplying electricity and/or heat.
  • a method for preparing a thermoplastic resin-laminated structure comprises the steps of intervening a binding layer between an exterior layer and a base layer, wherein the binding layer includes at least one material selected from a group consisting of electric resistance-heat generating materials and heat-conductive materials, and has at least one connection terminal at a certain region for supplying electricity or heat, and supplying electricity or heat to the binding layer through the terminal to bind the base layer with the exterior layer.
  • a method for preparing a thermoplastic resin-laminated structure comprises the steps of preparing a double-layer sheet in which an exterior layer is bound to a binding layer which includes at least one material selected from a group consisting of electric resistance-heat generating materials and heat-conductive materials, and has at least one connection terminal at a certain region for supplying electricity or heat, putting a base layer on the binding layer of the double-layer sheet, and supplying electricity or heat to the binding layer through the terminal to bind the base layer with the exterior layer.
  • a laminated sheet molding apparatus should be used for preparing the double-layer sheet.
  • thermoplastic resin-laminated structure is used for interior automotive trims, members for civil engineering and construction such as acoustic absorptive members, heat-insulating members, lagging members, protective coating members, anti-vibration members and sound-blocking members, anti-vibration and sound-blocking members for sewage and water pipe, soundproofing members for hot-water “ondol”, (i. e., Korean word indicating floor heating system), plastic furniture, various multi-layer mats, handles, sofas, chairs, various toys, middle soles of shoes, and golf bags.
  • members for civil engineering and construction such as acoustic absorptive members, heat-insulating members, lagging members, protective coating members, anti-vibration members and sound-blocking members, anti-vibration and sound-blocking members for sewage and water pipe, soundproofing members for hot-water “ondol”, (i. e., Korean word indicating floor heating system), plastic furniture, various multi-layer mats, handles, sofas, chairs, various toys,
  • the electric resistance-heat generating material or the heat-conductive material is selected from a group consisting of tungsten (W), nickel (Ni), chromium (Cr), silicon (Si), aluminum (Al), carbon (C), Iron (Fe), magnesium (Mg), zinc (Zn), titanium (Ti), manganese (Mn), cobalt (Co), vanadium (V), zirconium (Zr), molybdenum (Mo), copper (Cu), silver (Ag), cadmium (Cd), tin (Sn), lead (Pb), stainless steel, their alloys, and their mixtures, and is used in the form of plate type, mesh, solid powder, and thin film coated on a resin film.
  • the binding layer is selected from a group consisting of i) a metal mesh or metal plate of at least one selected from a group consisting of the electric resistance-heat generating materials and the heat-conductive materials with or without several types of holes; ii) a thin layer film formed by coating at least one material selected from a group consisting of the electric resistance-heat generating materials and the heat-conductive materials on at least one side of a polymer resin film (or sheet); iii) a thin layer film formed by infiltrating at least one material selected from a group consisting of the electric resistance-heat generating materials and heat-conductive materials into a polymer resin film (or sheet); and iv) any combinations of i, ii, or iii.
  • the electric resistance-heat generating material or the heat-conductive material should be infiltrated in the form of powder. It is also preferable that the amount of the electric resistance-heat generating material or the heat-conductive material used in the thin film of ii and iii is 0.5 to 80 parts by weight per 100 parts by weight of the polymer resin film (or sheet) or polymer resin for forming sheet. If the used amount of the electric resistance-heat generating material or the heat-conductive material is less than 0.5 part by weight, the thermal characteristic of the binding layer is deficient to decrease the adhesive force between the base layer and the exterior layer. If the used amount is more than 80 parts by weight, sheet (film) molding cannot be performed.
  • the polymer resin used in i through iv may be at least one material selected from a group consisting of thermoplastic resins and thermal adhesive resins.
  • the thermoplastic resin used in this invention may be selected from the group consisting of polyethylene (PE, HDPE, LDPE, LLDPE, VLDPE, ULDPE, UHDPE), polypropylene (PP co-polymer, PP homo-polymer, and PP ter-polymer), polyvinylchloride (PVC), polystyrene (PS), polymethyl-metacrylate (PMMA), acrylobutadienestyrene (ABS) resin, styrene-acrylonitrile (SAN) resin, K-resin, SBS block co-polymer resin, PVDC resin, EVA resin, acryl resin, butral resin, silicone resin, polyamide (PA, PA6, PA66, PA46, PA610, PA6/66, PA6/12, PA6T, PA12, PA1212, PAMXD6) resin, ethylenetetrafluoroethylene co-polymer, liquid crystal polymer, polybutyleneterephthalate, polyetheretherketone, poly
  • the thermal adhesive resin used in this invention may be a modified resin with a polar functional group or groups, and selected particularly from a group consisting of acrylic acid-modified olefin resin, maleic acid-modified olefin resin, chloride-modified olefin resin, silane-modified olefin resin, ionomer resin, nylon-modified olefin resin, epoxy-modified resin, ethylenevinylalcohol (EVOH) resin, ethylenevinylacetate resin, hot melt adhesive resin, and their mixtures and combinations.
  • a polar functional group or groups selected particularly from a group consisting of acrylic acid-modified olefin resin, maleic acid-modified olefin resin, chloride-modified olefin resin, silane-modified olefin resin, ionomer resin, nylon-modified olefin resin, epoxy-modified resin, ethylenevinylalcohol (EVOH) resin, ethylenevinylacetate resin
  • the base layer may be formed with the thermoplastic resin as described above or a composite resin formed by mixing the thermoplastic resin with at least one filler reinforcing heat-durability.
  • the filler used in this invention may be selected from a group consisting of glass fillers (glass fibers, glass mats, glass beads, milled glass fibers, and chopped glass fibers), mica, talc, wollastonite, calcium carbonate, asbestos, kaolin, carbon fibers, nylon fibers, vegetable fibers, sawdust, clay, silica, graphite, fly ashes, waste papers, and waste fibers.
  • the exterior layer consists of a single layer
  • the exterior layer is formed with at least one material selected from a group consisting of thermoplastic resins, thermal adhesive resins, and composite resins including at least one filler and at least one resin selected from a group consisting of thermoplastic resins and thermal adhesive resins.
  • the lower layer is bound to the binding layer and formed with a polymer resin which is selected from a group consisting of thermoplastic resins, thermal adhesive resins, and composite resins including at least one filler and at least one resin selected from a group consisting of thermoplastic resins and thermal adhesive resins; and the upper layer has a single or multi-layer structure, and is formed with at least one material selected from a group consisting of wood or metal thin films, papers, natural textiles, synthetic textiles, artificial leathers, felts, nonwoven fabrics, foaming sheets, honeycomb sheets, polymer sheets or films.
  • a polymer resin which is selected from a group consisting of thermoplastic resins, thermal adhesive resins, and composite resins including at least one filler and at least one resin selected from a group consisting of thermoplastic resins and thermal adhesive resins
  • the upper layer has a single or multi-layer structure, and is formed with at least one material selected from a group consisting of wood or metal thin films, papers, natural textiles, synthetic textiles, artificial leathers, felts,
  • additives may be added to the polymer resin used for forming the base, exterior, and binding layers.
  • the additives can be suitably selected according to molding method and use.
  • the amounts of the additives vary according to the additive purpose.
  • the additive used in this invention may be selected from the group consisting of heat-stabilizing agents, antioxidants, ultraviolet ray-stabilizing agents, carbon black, conductive materials, nucleus agents, release agents, fire retardants, agents for preventing static electricity, processing-assistant agents, coloring agents, functional pigments or dyes, cross-linking agents, plasticizer, and vulcanizing agents.
  • the thickness of the base layer may vary according to the use and molding method, and thus not limited to specific range.
  • the thickness of the exterior layer may be maximally 200 mm regarding a multi-layer sheet having cushion function, and preferably less than 50 mm to exhibit good adhesive power at curved parts of binding face.
  • the thickness of binding layer is preferably less than half of the thickness of exterior layer to obtain good appearance of the exterior layer in the completed laminated structure.
  • FIG. 1 is a cross-sectional view showing an example of the thermoplastic resin-laminated structure according to the present invention.
  • the adhesive strength between the base and exterior layers is based on the chemical properties of the objects to be adhered.
  • substantially the adhesive strength is tightly related to the miscibilities of the objects to be adhered and the mobilities at the boundary.
  • water and alcohol may have similar miscibility coefficients that enable the substances to mix well with each other (namely, to bind well to each other).
  • water and oil have very different miscibility coefficients causing the substances not to mix well with each other (namely, not to bind well to each other).
  • ice does not bind to other ice because of a low mobility of water molecules at their boundary.
  • the important fact in the binding between the base and exterior layers is not that the binding feature is affected by the entire objects to be adhered, but rather affected by the boundary features between the objects to be adhered.
  • the boundary features are very important for binding the polymer resin molding materials, which are generally known as having poor thermal conductivity. Therefore, in the fabrication of a polymer resin-laminated structure, supplying heat, pressure, and vacuum adsorption to the entire object to be adhered through a mold causes deformation of the previously molded base and exterior layers as well as wastes energy.
  • the resin-laminated structure of the present invention can be formed by the method characterized in that a binding layer including electric resistance-heat generating material and/or heat-conductive material intervenes between a base layer and an exterior layer, and electricity or heat is supplied through a connection terminal or terminals equipped at the binding layer to cause fusion of the objects to be adhered at the boundary between the base and exterior layers, thus binding the objects.
  • this invention intentionally and reversibly controls heat-generation (namely, fusion of resin) and cooling (namely, solidification of resin) at the binding boundary. Therefore, the resin-laminated structure according to the present invention improves adhesive strength between the base and exterior layers and uses heat to separate the base and exterior layers hereby providing good recycling utility of material.
  • FIG. 1 is a cross-sectional view showing an example of the thermoplastic resin-laminated structure according to the present invention.
  • the thermoplastic resin-laminated structure according to the present invention includes a base layer 1 , a binding layer 2 formed on the base layer 1 , and an exterior layer 3 formed on the binding layer 2 .
  • At least one connection terminal 4 for supplying electricity or heat is mounted on a part of the binding layer 2 .
  • the at least one terminal connection is located on an edge portion of the resin laminated structure that is exposed to the outside.
  • the base layer used in the present invention can be fabricated into various forms using known molding methods such as injection molding, sheet molding, extrusion molding, blow molding, or compression molding.
  • the base layer may be formed with polymer resins such as thermoplastic resins or composite resins.
  • Composite resins are formed by mixing thermoplastic resins with fillers.
  • the thermoplastic resin used in this invention may be selected from the group consisting of polyethylene (PE, HDPE, LDPE, LLDPE, VLDPE, ULDPE, UHDPE), polypropylene (PP co-polymer, PP homo-polymer, and PP ter-polymer), polyvinylchloride (PVC), polystyrene (PS), polymethylmetacrylate (PMMA), acrylobutadienestyrene (ABS) resin, styrene-acrylonitrile (SAN) resin, K-resin, SBS block co-polymer resin, PVDC resin, EVA resin, acryl resin, butral resin, silicone resin, polyamide (PA, PA6, PA66, PA46, PA610, PA6/66, PA6/12, PA6T, PA12, PA1212, PAMXD6) resin, ethylenetetrafluoroethylene co-polymer, liquid crystal polymer, polybutyleneterephthalate, polyetheretherketone, polyether
  • the filler used in this invention may be selected from the group consisting of glass fillers (glass fibers, glass mats, glass beads, milled glass fibers, and chopped glass fibers), mica, talc, wollastonite, calcium carbonate, asbestos, kaolin, carbon fibers, nylon fibers, vegetable fibers, sawdust, clay, silica, graphite, fly ashes, waste papers, and waste fibers.
  • the exterior layer used in this invention may be fabricated with a sheet or film formed as a single or multi-layer structure according to known molding methods, such as sheet molding, film molding, foam sheet molding or laminated co-compression molding.
  • the exterior layer consists of a single layer
  • the exterior layer is formed with at least one polymer resin selected from a group consisting of materials used for forming the base layer and thermal adhesive resins.
  • the thermal adhesive resin used in this invention may be a modified resin with a polar functional group or groups, and particularly selected from a group consisting of acrylic acid-modified olefin resin, maleic acid-modified olefin resin, chloride-modified olefin resin, silane-modified olefin resin, ionomer resin, nylon-modified olefin resin, epoxymodified resin, ethylenevinylalcohol (EVOH) resin, ethylenevinylacetate resin, hot melt adhesive resin, and their mixtures and combinations.
  • the lower layer is bound to the binding layer and formed with at least one polymer resin selected from a group consisting of materials used for forming the base layer and thermal adhesive resins
  • the upper layer has single or multi-layer structure, and is formed with at least one material selected from the group consisting of woods or metal thin films, papers, natural textiles, synthetic textiles, artificial leathers, felts, nonwoven fabrics, foaming sheets, honeycomb sheets, polymer sheets or films.
  • the binding layer is located between the base and exterior layers and functions to bind the base layer to the exterior layer in a heat generating method such as an electric resistance or heat-conductive method.
  • the binding layer formed using electric resistance may be fabricated as follows:
  • a sheet of a single or multi-layer structure is prepared with electric resistance heat generating material, which is a material used to generate heat by electric resistance. Accordingly, any material may be used as an electric resistance-heat generating material if it generates heat through electric resistance.
  • the examples include tungsten (W), nickel (Ni), chromium (Cr), silicon (Si), aluminum (Al), carbon (C), Iron (Fe), magnesium (Mg), zinc (Zn), titanium (Ti), manganese (Mn), cobalt (Co), vanadium (V), zirconium (Zr), molybdenum (Mo), copper (Cu), silver (Ag), cadmium (Cd), tin (Sn), lead (Pb), stainless steel, their alloys, and their mixtures.
  • the binding layer is formed from a type of material selected from a group consisting of i) a metal mesh or metal plate of at least one material selected from a group consisting of the electric resistance-heat generating materials with or without several types of holes; ii) a thin layer film formed by coating at least one material selected from the group consisting of the electric resistance-heat generating materials on at least one side of a polymer resin film (or sheet); iii) a thin layer film formed by infiltrating at least one material selected from the group consisting of the electric resistance-heat generating materials with a polymer resin film (or sheet); and iv) any combinations of materials i, ii, and iii.
  • the metal used in this invention should have a Curie temperature higher than the melting point of a polymer resin for constructing the binding boundary of the base or exterior layer.
  • the polymer resin used in the binding layer may be selected from a group consisting of materials for forming the base layer, materials for forming the exterior layer, and thermal adhesive resins, and preferably may be a thermal adhesive resin to obtain excellent adhesive ability.
  • two terminals connectable to a power supply are molded to the sheet to obtain a binding layer that can adhere to the base and exterior layers via the electricity resistance-heat generating method.
  • the position of the terminal is not fixed but can be located, for example, at an edge portion of the sheet that is to be exposed to the outside.
  • the binding layer formed via the heat-conductive method may be fabricated as follows:
  • a sheet of single or multi-layer structure is prepared with heat-conductive material.
  • any material may be used as a heat-conductive material if it has heat conductive property.
  • the examples include tungsten (W), nickel (NO, chromium (Cr), silicon (Si), aluminum (Al), carbon (C), Iron (Fe), magnesium (Mg), zinc (Zn), titanium (Ti), manganese (Mn), cobalt (Co), vanadium (V), zirconium (Zr), molybdenum (Mo), copper (Cu), silver (Ag), cadmium (Cd), tin (Sn), lead (Pb), stainless steel, their alloys, and their mixtures.
  • the binding layer formed via the heat conductive method is formed with materials selected from a group consisting of i) a metal mesh or metal plate of at least one material selected from a group consisting of heat-conductive materials with or without several types of holes; ii) a thin layer film formed by coating at least one material selected from the group consisting of the heat-conductive materials on at least one side of a polymer resin film (or sheet); iii) a thin layer film formed by infiltrating at least one material selected from the group consisting of the heat-conductive materials into a polymer resin film (or sheet); and iv) any combinations of material i, ii, and iii.
  • the polymer resin used in the heat-conductive manner may be selected like that in the electric resistance-heat generating manner.
  • At least one terminal connectable to a heat source is mounted on the sheet to obtain a binding layer that adheres to the base and exterior layers via a heat-conductive method.
  • the electric resistance-heat generating material and the heat-conductive material may be used in combination with each other.
  • additives may be added to the polymer resin used for forming the base, exterior, and binding layers.
  • the additives can be suitably selected according to molding method and use.
  • the amounts of the additives vary according to the additive purpose.
  • the additive used in this invention may be selected from the group consisting of heat-stabilizing agents, antioxidants, ultraviolet ray-stabilizing agents, carbon black, conductive materials, nucleus agents, release agents, fire retardants, agents for preventing static electricity, processing-assistant agents, coloring agents, functional pigments or dyes, cross-linking agents, plasticizer, and vulcanizing agents.
  • the combined layers may be fabricated together by using a sheet molding apparatus.
  • the exterior and binding layers may be also previously adhered in the form of a multi-layer sheet, which allows rolling work and the width of the exterior layer to be similar to the width of the binding layer.
  • Advantages of this process include a decreased number of processes and enhanced productivity in comparison with independent fabrications for the exterior and binding layers.
  • the binding layer including the electric resistance-heat generating material or heat-conductive material is placed on the base layer, and the exterior layer is placed on the binding layer so the stacked layers are then fixed in a mold.
  • the resin-laminated structure according to the present invention is low in deformation and has a good surface quality, thermal durability, acoustic absorptivity, heat-shielding property, and impulse-durability, as well as, can be easily and simply fabricated.
  • a thermoplastic resin-laminated structure therefore, can be used in materials, such as, interior automotive trims, acoustic absorptive members, heat-insulating members, lagging members, protective coating members, anti-vibration members, and sound-blocking members for civil engineering and construction, anti-vibration and sound-blocking members for sewage and water pipe, soundproofing members for hot-water “ondol” (i. e., Korean word indicating floor heating system), plastic furniture, various multi-layer mats, handles, sofas, chairs, various toys, middle soles of shoes, and golf bags.
  • plastic furniture various multi-layer mats, handles, sofas, chairs, various toys, middle soles of shoes, and golf bags.
  • a resin-laminated structure is fabricated with the electric resistance-heat generating manner according to the present invention as follows:
  • a composite resin is prepared by adding 20% by weight of a glass fiber to a polypropylene copolymer and by extruding the mixture with a dual-axial extruding machine.
  • a base layer is fabricated by injecting the composite resin into an injection molding apparatus.
  • a Lameskin product of soft coating sheet available from Montell Company was used as an exterior layer.
  • the Lameskin product is a sheet with a triple-layer structure of toughened polyolefin (TPO; skin layer)/foaming polypropylene/polypropylene.
  • TPO toughened polyolefin
  • a metal mesh is fabricated with a 1 mm ⁇ 1 mm square hole of using metal wires of stainless steel having a 0.1 mm diameter.
  • Two electric terminals are equipped at two ends of the metal mesh to use as a binding layer.
  • the base, binding and exterior layers are thereafter placed into a cavity of the press molding apparatus, and electricity is supplied through the terminals to the binding layer in order to adhere the base and exterior layers to one another so that the resin-laminated structure can be formed.
  • a resin-laminated structure is fabricated via the heat-conductive method according to the present invention as follows:
  • a composite resin is prepared by adding 20% by weight of a glass fiber to a acrylonitrile butadiene styrene resin and by extruding the mixture with a dual-axial extruding machine.
  • a base layer is fabricated by injecting the composite resin into an injection molding apparatus.
  • An exterior layer is fabricated with the sheet forming a double-layer structure of soft polyvinylchloride and foaming urethane.
  • a laminated sheet is fabricated using a laminated molding apparatus in the form of a metal mesh of copper adhered to a hot melt adhesive resin sheet.
  • the hot melt adhesive resin sheet includes 30% by weight of conductive carbon black.
  • At least one terminal is mounted to the laminated sheet to form a binding layer.
  • the base, binding and exterior layers are thereafter placed into a cavity of the press molding apparatus, and heat is supplied by a heater via the at least one terminal to the binding layer so that the base and exterior layers adhere to one another thus forming the resin-laminated structure.
  • a composite resin is prepared by adding 20% by weight of a glass fiber to a polypropylene copolymer and by extruding the mixture with a dual-axial extruding machine.
  • a base layer was fabricated by injecting the composite resin into an injection molding apparatus.
  • a Lameskin product of soft coating sheet available from Montell Company is used as an exterior layer.
  • the Lameskin product is a sheet with a triple-layer structure of toughened polyolefin (TPO; skin layer)/foaming polypropylene/polypropylene.
  • TPO toughened polyolefin
  • an adhesive agent of chloride-modified resin is coated on the base layer.
  • a thermal press molding apparatus is used.
  • the base layer is placed into a cavity of the mold and pre-heated to a temperature of 150° C.
  • the mold is then continuously heated at a temperature of 150° C.
  • the exterior layer is pre-heated to a temperature of 150 to 180° C. using a heating chamber.
  • the exterior layer is placed on top of the base layer under the condition that the pre-heating temperature is maintained. A thermal press molding is then performed to complete the resin-laminated structure.
  • the completed resin-laminated structure is pre-heated to a temperature of 150 to 200° C., and the base and exterior layers are separated from one another. The cut section of the separated base layer is then observable to the naked eye for assessment.
  • a composite resin is prepared by adding 20% by weight of a glass fiber to a acrylonitrile butadiene styrene resin and by extruding the mixture with a dual-axial extruding machine.
  • a base layer is fabricated by injecting the composite resin into an injection molding apparatus.
  • a soft polyvinylchloride sheet is fabricated using a sheet molding apparatus.
  • the soft polyvinylchloride sheet is vacuum-molded using a vacuum molding apparatus to make a skin layer with a form of product.
  • the base layer is placed in the cavity of a foaming compression molding apparatus pre-heated to a temperature of 100 to 150° C., and continuously heated at the pre-heated temperature.
  • the skin layer fabricated with the vacuum molding is placed over the preheated base layer, and then the liquefied raw material for foaming polyurethane (polyol and isocyanate) is injected between the base and skin layers.
  • the polyol and isocyanate is compressed for predetermined hours in the foaming compression mold to complete the cross-link polymerization and foaming reaction obtaining the resin-laminated structure.
  • the completed resin-laminated structure is pre-heated to a temperature of 150 to 200° C., and the base and exterior layers are then separated from one another. The cut section of the separated base layer is then observable to the naked eye for assessment.
  • the boundary adhesive strength between the base and exterior layers is measured when a test piece is prepared having a 25 mm width and 150 mm length. After one end of the test piece about 30 mm along the direction of length is stripped off, the test piece is bitten by a tensile force tester and then an attempt is made to strip off with a tensile velocity of 200 m/min to measure the boundary adhesive strength.
  • the resin-laminated structure of comparative example 1 has good recycling utility, but poor boundary adhesive strength and impulse-durability.
  • the resin-laminated structure of comparative example 2 has good boundary adhesive strength and impulse-durability, but poor recycling utility.
  • the resin-laminated structures of examples 1 and 2 all have good recycling utility (ease of breaking up), impulse-durability, bending strength and boundary adhesive strength.
  • the method for preparing the thermoplastic resin-laminated structure according to the present invention does not require a preheating process nor expensive vacuum equipment. It can be also performed at room temperature and low pressure to simplify the processes and to increase productivity. It also adheres the base and exterior layers without any organic adhesives between the base and exterior layers, thus providing a pleasant work atmosphere and use conditions. It also does not generate negative effects regarding any foaming agents and adhesives, because it does not use them. It also provides good recycling performance of materials, because the binding and breaking up of the base and exterior layers can be intentionally undertaken through melting the resin at the binding boundary by supplying electricity or heat through the terminals of the binding layer.
  • the binding method of the present invention is useful in binding the same kind materials of nonpolar polymer resins such as polyolefins known to have poor adhesive strength.
  • the metal mesh functions as a high resistance to the external impulse to increase impulse-durability. Therefore, when the resin-laminated structure according to the present invention is applied to a product required to have impulse-durability, for example, interior automotive trims such as an instrument panel, the safety of passengers is greatly enhanced in the result of a car crash.
  • thermoplastic resin-laminated structure of the present invention also has excellent properties such as surface quality, thermal durability, acoustic absorptivity, heat-shielding property, and impulse-durability.
  • thermoplastic resin-laminated structure can be used as an element in manufacturing interior automotive trims, acoustic absorptive members, heat-insulating members, lagging members, protective coating members, anti-vibration members, and sound-blocking members for civil engineering and construction, anti-vibration and soundblocking members for sewage and water pipe, soundproofing members for hot-water “ondol”, plastic furniture, various multi-layer mats, handles, sofas, chairs, various toys, middle soles of shoes, and golf bags.

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  • Laminated Bodies (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
US10/175,008 2001-06-20 2002-06-20 Thermoplastic resin-laminated structure, method for preparation and use thereof Abandoned US20030003317A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US11/123,186 US20050205203A1 (en) 2001-06-20 2005-05-06 Thermoplastic resin-laminated structure, method for preparation and use thereof
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US7479313B2 (en) 2009-01-20
KR100446313B1 (ko) 2004-08-30
CN1255274C (zh) 2006-05-10
US20080063847A1 (en) 2008-03-13
CN1393336A (zh) 2003-01-29
JP2003048268A (ja) 2003-02-18
KR20020096479A (ko) 2002-12-31

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