INTERIOR MATERIAL FOR VEHICLE HAVING EXCELLENT LIGHT WEIGHT PROPERTY

The present invention provides various modification can apply various embodiments are which may have bar, Figures and detailed description specific embodiments example broadcast receiver.

However, this is the present invention but is to be defined with respect to certain embodiments, the inventive idea and techniques all changing range, should it will so that uniform water to replacement.

In the present invention, the term "comprising" or "having disclosed" description of a feature, number, step, operation, components, parts or specify a combination not present included, another aspect of one or more moveable number, step, operation, component, component or a combination of these items will advance the possibility or not should the presence of or additionally.

In the present invention, "cell" RM, expanded by means of a big microstructures in polymer foam.

Or less, to specifically describe intended to less than 1000.

The present invention provides light interior material is excellent, the automobile interior material of one example,

Resin foam layer; and

The resin foam an apertured nonwoven layer which at least one side,

500 to 1100 g/m is the mass per unit area² In automobile interior material can be provided.

The automobile interior material per unit area of mass makes the 500 to 1100 g/m² May be in the range disclosed. For example, automobile interior material per unit area of mass makes the 550 to 1000 g/m² , 600 to 1000 1100 g/m² Or 800 to 900 1100 g/m² Implementation being. By satisfying mass per unit area of said range, the interior material weight is reduced confirming that the first call request.

The resin foam layer more cells 90% closed cell (DIN ISO4590) implementation being. This, the resin foam layer depends on the value 90% closed cell is selected DIN ISO4590 big it will count being, (v/v) or more. For example, 90 to 100% or 95 to 99% closed cell ratio the resin foam layer average implementation being. By closed cell ratio range above, insulation can be up height. Through, a portion of the automobile interior material construction, e.g., based on, wall, floor and/or roof construction industry for thermal insulation of possible available disclosed. For example, the automobile interior material contained in the resin foam layer 1 mm² 1 to 30 per cell, 3 to 25 cell, or can be 3 to 20 cells.

Also, average cell size in the range 100 to 800 micro m can be. For example, average cell size to 700 micro m 100, 200 or 300 to 600 micro m to 600 micro m can range disclosed. The, cell size deviation of for example, less than 5%, 0. 1 to 5%, 0. 1 to 4% to 0. 1 to 3% can range disclosed. Through, a uniformly foamed resin foam can be that of a uniform layer of tasks cells.

The resin foam producing is in particular but not limited to, e.g., the resin foam layer be a automobile interior material extrusion. Specifically, foaming method way kind of extruded foam bead foam or flow tides. The bead foaming may, generally, resin beads so that at appropriate times after aged thereby heating same petal wool 1 difference amount, the retractable mold filling is effected by 2 difference foam by fusion, molding in exact are disclosed. While, the extruded foam, and heating and melting the resin, the resin melt continuously extruding and foaming, process steps can be simplified, and mass production, in flaws in a bead foam bodies, granular destruction in parallel to a better bending strength, compressive strength can be implementing.

The automobile interior material of flexural strength according to ASTM D 790 (N) is 30 to 350 N implementation being. The flexure strength e.g., 40 to 300 N, 60 to 200 N, 90 to 110 N, 90 to 100 N can range disclosed. By satisfying the GPS flexural strength, for interior material of vehicle functions, high strength due to impact can be more safely outside, molding can be easily.

The resin foam layer 20 to 230 kg/m density³ Implementation being. For example, the density 25 to 200 kg/m³ , 30 to 150 kg/m³ , 40 to 75 kg/m³ , 50 to 75 kg/m³ Or 55 to 65 kg/m³ May be in the range disclosed. The density of the interior material within a range satisfying the resin foam layer by, control high density and high expansion ratio can be interior materials for vehicle.

The light according to the acceleration test (ultraviolet carbon arc equation light resistance test) interior material KS R 0021, 300 to 400 nm is irradiated with light of a wavelength of 126 MJ dose less than 3% of the chrominance front and rear of the rate of change, the rate of change of color gray can be less than 3%.

For example, the rate of change of a color difference and the rate of change each gray 0. 1 to 3%, 0. 1 to 1. 5% or 0. 1 to 1% can range disclosed. Also the by, according to the invention are excellent in the resistances to interior material for external light, to prevent long-term physiological properties can be produced using will find.

The automobile interior material is, 90 ± 1 °C temperature conditions 24 in time steps; and 90% relative humidity conditions and temperature conditions comprising the steps of 50 ± 1 °C 24 after time reports, expressions can be satisfying to 1.

[Mathematical equation 1]

V|₁ - V₀ |/ V₀ X 100 ≤ 5%

In the expressions 1,

V₀ The volume of the exposed interior material prior reports (mm³ ) And,

V₁ The volume of the interior material after exposure reports (mm³ ) Are disclosed.

Specifically, interior samples pass for vehicle produced reports a dimensional change before and after a long time. This, vehicle interior material applied to corresponding measurements after enabling dimensions and the rate of change among others. For example, whereby the volume is, automobile interior material length, width and thickness means the calculated value can be multiplied by a respective length. For example, the rate of change of the dimensions of the expressions 1 0. 01 to 5%, 0. 01 to 3% or 0. 01 to 1% can range disclosed. In equations by satisfying said range value of 1, the interior material having the lowest temperature change in form do not vary even-term use can be boosted.

The, the expressions 1 is 5% is exceeded is the peeling of the interior material, component, sag, discoloration to deformations can be can be connected to a means.

The automobile interior material of thermal conductivity of 0. 04 W/mK or less disclosed. For example, the automobile interior material of thermal conductivity of 0. 01 to 0. 04 W/mK, 0. 01 to 0. 035 W/mK or 0. 02 to 0. 035 W/mK can range disclosed. According to the present invention by having the thermal conductivity in the range of interior material, cold-insulating material can be implementing.

In the interior material,

Resin foam layer has average thickness and 1 to 30 mm,

Nonwoven fabric layer has average thickness 0. 1 to 10 mm implementation being.

For example, the resin foam layer has a thickness 1. 5 to 30 mm, 5 to 30 mm, 5 to 20 mm or 5 to 10 nm can range disclosed. Also, nonwoven fabric layer has a thickness 0. 5 to 10 mm, 0. 5 to 8 mm, 0. 5 to 5 mm may be in the range disclosed. Through, the interior material despite a relatively thin thickness, excellent flexural strength, long-term numerical strain, light resistance and/or adiabatic characteristics can be implementing. Also, automobile interior material weight of a second conductive type, interior functions, can be implementing excellent fuel economy.

One example of the structure of the automobile interior material,

Resin foam;

Both faces of resin foam adhesive film; and

Each adhesive film resin foam is formed an apertured nonwoven layer removed for a motor vehicle interiors can be provided.

This, resin foam adhesive film and non-woven fabric layer sequentially deposited on both sides about structure, resin foam excellent flexural strength, and lightweight difference tone characteristic together, by forming the resin foam on both sides of the fabric layer, a crystal and durability can be implemented.

As another example of the automobile interior material of the structure,

Resin foam;

Resin foam formed on one surface of adhesive film; and

An adhesive film resin foam is formed an apertured nonwoven layer removed for a motor vehicle interiors can be provided.

This, resin foam adhesive film and non-woven fabric layer about one sequentially deposited structure, resin foam excellent flexural strength, and lightweight difference tone characteristic together, by forming one side of the fabric layer and the resin foam, a crystal can be interior materials for vehicle with thinner width.

In the interior material,

Resin foam layer can be formed between the adhesive film further comprises a nonwoven fabric.

Specifically, the resin foam layer nonwoven fabric formed between the divided into adhesive film, resin foam layer to improve adhesion between the nonwoven fabric layer, can be further effectively prevent delamination.

The automobile interior material a, and foam layer comprises a foam of polyester resin,

Nonwoven fabric layer has polyester fiber which,

The adhesive film is polyester-based adhesive resin can be.

For example, 1, 4 - butanediol condensation polymerization with terephthalic acid polyester resin contained in the resin foam layer producible by disclosed. According to the invention both aromatic or aliphatic polyester comprises a polyester resin. In another aspect, the polyester resin flame-retardant polyester, biodegradable polyester, polyester etc. elastic polyester and reuse. For example, PET (polyethylene terephthalate) resin foam layer be a foam according to the present invention.

Also, polyester fiber is a core part of the nonwoven fabric, at least one of polyester resin described above be a fiber manufactured using 1.

Also, the adhesive film contained in the polyester-based adhesive resin, diol (Diol) esterification of dicarboxylic acid and n (Dicarbonic acid) manufactured by hard segment; and a polyol (Polyol) it is a condensation polymerization water polyester-based elastic adhesive resin in the soft segment can be.

Specifically, the automobile interior material a, resin foam layer, a nonwoven fabric and adhesive film both can be polyester resin. As such, automobile interior material all configured by using the polyester resin, utilizing a same throughout the industry, can be easily recycled after use.

The functional additive layer resin foam interior material can be at least one side. As a result, the physical properties of a foam without reduction, and can impart the desired functional effectively, can be process efficiency and flexibility.

The functional additive layer and insulation, flame retardant function, VOC functioning, a hydrophilization function, waterproof, antibiotics, deodorizing and/or ultraviolet blocking function may have. Specifically, resin foam layer can be coated on the functional form a coating layer on functional additive, additive is not limited particularly if the function can be implemented. Specifically, the second insulating functional additive, water dispersible lipophilic, water repellant agent, flame retardant, antimicrobial agent, 1 comprises at least one of rice bran and use sunscreens.

The insulating agent, can be carbonaceous component. For example, the insulating zero graphite, carbon black, or the like yes pin and, specifically, can be graphite.

Also, flame retardants does not specifically defined, e.g., harmless, phosphorus compound, antimony compound and the metal hydroxide or the like can be. The bromine compounds are, for example, tetra bromo bisphenol A and/or by car [pu[pu] wool D phenyl ether etc.. The phosphorus compound is aromatic phosphate ester, aromatic condensed phosphate ester, a halogenated phosphoric acid esters and/or less number, antimony compound is antimony trioxide and antimony pentoxide can be like. Also, as the metal element in the metal hydroxide, aluminum (Al), magnesium (Mg), calcium (Ca), nickel (Ni), cobalt (Co), tin (Sn), zinc (Zn), copper (Cu), iron (Fe), titanium (Ti) and boron (B) comprising at least one species can be 1. Among all, using metal hydroxide can be aluminum or magnesium. The metal hydroxide, metal species or elements 1, 2 can be one or more metal elements. For example, as metal hydroxide, aluminum hydroxide and magnesium hydroxide can be more species during 1.

The VOC reducing agent, and/or sphingosine (Bactoster Alexin) grafted (Graf) the rack which will know scene can be stud like. The, sphingosine is an extracted from natural sterilization material characterized stud the rack which will knowit put on propolis.

A particularly defined does not contribute to the hydrating, anionic surfactant (e.g., fatty acid salts, alkyl sulfuric acid S reel [lu[lu] salt, alkyl the benzene alcoholic beverage phone it buys the salt, alkyl naphthalene sulfonic acid salt, alkyl the alcoholic beverage gun [swuk[swuk] new it buys the salt, such as poly jade hour ethylene alkyl sulfuric acid S reel [lu[lu] salt), nonionic surfactant (e.g., a polyoxyethylene alkyl ether such as poly jade hour alkyl [leyn[leyn] alkyl ether, polyoxyethylene derivatives, sorbitan fatty acid ester, and the middle-fatty acid esters, poly jade hour ethylene small [lu[lu] expense [thol[thol] fatty acid esters, glycerin fatty acid esters, polyoxyethylene alkyl amines, such as alkyl the alkane the amide which comes), cationic material and positive ion-based surfactant (e.g., alkyl amine salt, 4 first quaternary ammonium salts, alkyl betain, amine oxide or the like) and a water-soluble polymer or a protective colloid (e.g., gelatin, methyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethylcellulose, polyethylene glycol, a polyoxyethylene - poly jade hour propylene block nose Polymer, polyacrylamide, polyacrylic acid, polyacrylic acid salt, sodium alginate, polyvinyl alcohol portion soap-dry) can be at least one of comprising 1.

The kind of water, and particularly limited drug, e.g., silicon-based, epoxy-based, cyanoacrylic acid based, polyvinyl acrylate-based, ethylene vinyl acetate series, acrylate-based, pawl [lu[lu] claw rope [leyn[leyn] sequence, a mixture of polyester resin and polyurethane resin based, thereby gloss audience operates a prescribed one resin mixture of polyol based, acrylic polymer and a mixture of polyurethane resin based, polyimide-based and cyanoacrylate can be a mixture of at least one of a urethane based 1.

The anti-microbial agent types include, for example, hydroxyapatite, alumina, silica, titania, zeolite, zirconium phosphate and ammonium 1 during at least one carrier such as silver, zinc, copper and iron can be added during 1 comprising at least one composite.

The-bacterial porous materials can be used. The porous material is a physically adsorbed fluid flowing around its periphery therefore be properties strong, volatile organic compounds (VOC) adsorption disclosed. The-bacterial, e.g., silica, zeolite and calcium (Ca), sodium (Na), aluminum (Al), is (Ag), copper (Cu), tin (Zn), iron (Fe), selected from the group consisting of cobalt and nickel (Ni) (Co) 2 can be a mixture of one or more of these materials.

Also, ultraviolet blocking agents not specifically defined, e.g., an organic or inorganic sunscreens may be, the organic based sunscreens include p - amino benzoic acid derivatives, benzyl the cam gun which is burnt derivatives, cinnamic acid derivatives, benzophenone derivative, benzotriazole derivatives and mixtures thereof cited, the inorganic sunscreens include titanium dioxide, zinc oxide, manganese oxide, zirconium dioxide, dioxide cerium or mixtures thereof can be.

The resin foam that are flame retardant KS F ISO 5660 - 1 be a class or more reference 3. Specifically, KS F ISO 5660 - 1 according to the reference, the brilliant material class 3, class 1 and class 2 is the the non yearly material which it gives as a welding tile, based on the class or more 3 KS F ISO 5660 - 1, i.e., when 1 to class 3, flame retardant to a constituent of the anti-properties, after a fire, can be relatively safe.

As a result, the interior material excellent flexural strength, light weight, dimensional change, light resistance, buffer properties, can be used without restriction in the aqueous where property and require. Specifically, the automobile interior material of a vehicle headliner (Headliner) can be used. The upper surface of the outer body of a vehicle headliner, excellent flexural strength, light resistance and dimensional change C. like. Thus, according to the present invention by using interior material, the characteristics can be, according to the present invention that are equipped with interior material with lightweight, cigar jack of vehicle flow tides and other industrial applications.

Or less, the above-mentioned embodiments in accordance with the like but more which utilizes the present invention, defined by of the invention it are not correct.

Embodiments 1 to 3

PET resin 100 parts by weight of 130 °C have added in removing moisture, the moisture are removed first extruder 1 (pyromellitic dianhydride, PMDA) 1 parts by weight of PET resin fatigue adopts d id leading under freezes, talc 1 0 parts by weight of Irganox (IRG 1010). 1 parts by weight of mixing, heating the resin melt 280 °C prepared.

Then, 5 parts by weight of carbonic acid gas as a foaming agent in an extruder 1 first PET resin 100 which can be a transparent conductive layer extruded foam, resin foam layer has a thickness of 5 mm weight percent.

Then, the polyester-based adhesive resin is applied the resin foam sides, 1. The thickness of the PET non-woven fabric 5 mm are attached respectively to automobile interior material with a reinforcing agent.

The, the automobile interior material has a total thickness of 8 mm when the made, when foam, mass per unit area in the lower part of the blowing agent such as for table 1 can be regulated.

Comparison example 1

Low-melting-point fiber (low melting fiber, LMF) using automobile interior material with a reinforcing agent. The, 8 mm and the thickness of the interior material made in comparison example, 1200 g/m per unit area is made² Been identified.

Comparison example 2

Urethane based adhesive is applied on both sides of polyurethane foams PET non-woven fabric are attached respectively to automobile interior material with a reinforcing agent. The, the mass per unit area and thickness 8 mm 800 g/m² Been identified.

Experiment example 1: measuring properties

The embodiments 1 to 3 and comparison example 1 to 2 for production of interior material, combustible, heat resistance and light resistance were measured. When the measuring method comprises the substrate, the result is shown in the table 2.

1) measuring flexural strength

ASTM D 638 flexural strength under conditions were measured.

2) burning rate meter

KS M ISO 9772 conditions burning rate were measured.

3) measuring light

The rate of change of acceleration of KS R 0021 to reduce a testing light gray color were measured.

The reference table 2, in the case of interior material according to the present invention, combustion and which are excellent in the resistances, comparison is made by making sure that the capable of coping flexural strength.

Experiment example 2: dimension-rate measurements

The embodiments 1 to 3 and comparison example 1 to 2 in automobile interior material for, conducting a dimensional change rate measuring experiment. Specifically, process for the automobile interior material for each, in steps of 90 ± 1 °C 24 time temperature conditions; and 90% relative humidity conditions and temperature conditions comprising the steps of 50 ± 1 °C 24 reports a time after, when the dimensional change under the expressions through to 1, the result shown in the table 3.

[Mathematical equation 1]

V|₁ - V₀ |/ V₀ X 100

In the expressions 1,

V₀ The volume of the exposed interior material prior reports (mm³ ) And,

V₁ The volume of the interior material after exposure reports (mm³ ) Are disclosed.

3 the table reference surface, according to the invention in the case of interior material, make sure that the coping significantly lower dimension which represents the changes compared were compared. Through, the interior material can be excellent than that.

Experiment example 3: sound absorption and Sound Performance measurement

The embodiments 1 to 3 and comparison example 1 to 2 for automobile interior material in, sound absorbing rates and difference tone rate were measured. When the measuring method comprises the substrate, the result is shown in the table 4.

1) sound absorbing rate measurement

KS F 2805 reverberation the thread law measuring method using 0 - 10, 000 Hz [hup[hup] Eup rate of measuring, NRC (noise reduction coefficient) value was calculated. The average value of 250, 500, 1,000 and 2,000 Hz is NRC in sound absorption rate are disclosed.

2) measuring difference tone rate

KS F 2862 Apamat measuring equipment utilizing frequency 1 to 8,000 Hz based on transmission of save the loss. For comparison and, transmission loss value of 8,000 Hz was.

Referencing the table 4, in the case of interior material according to the present invention, 10 to 20 dB to difference tone rate, coping significantly excellent comparison compares were confirmed.

Experiment example 4: cell characteristic measuring

The embodiments 1 to 3 for production of interior material, cell size and cell size deviation of measured. Specifically, the data is picked up SEM for vehicle interiors have measuring cell size, cell size deviation of 2 mm to 2 mm in longitudinal cross were measured. The result is shown in the table 5.

The referencing the table 5, the cell size of expansion molding and 300 micro m level, cell size deviation below 5%, very uniformly such that blistering can be confirmed.