KR102058477B1 - Headliner Comprising Polyester Foamed Sheets and Preparation Method thereof - Google Patents

Abstract

A first nonwoven layer; A first inorganic fiber mat layer; Polyester resin foam sheet layer; A second inorganic fiber mat layer; And a second nonwoven layer is sequentially stacked, and a glass chop is dispersed between the first nonwoven fabric layer and the first inorganic fiber mat layer, and between the second nonwoven fabric layer and the second inorganic fiber mat layer. A vehicle headliner substrate and a method for manufacturing the same, the vehicle headliner substrate is excellent in durability, and has excellent bending strength and flexural modulus.

Description

Headliner Comprising Polyester Foamed Sheets and Preparation Method

The present invention relates to a vehicle headliner of a novel laminated structure comprising a polyester foam sheet and a method of manufacturing the same.

In general, the material of the headliner mounted on the inner side of the roof panel of the vehicle is resin felt, paper board, polyurethane rigid foam, polypropylene resin, corrugated cardboard, and the like.

Resin felt and paper board are manufactured by impregnating phenolic resin as a curing agent. The phenolic resin is a kind of thermosetting resin produced by the condensation reaction between phenols and aldehydes. Phenol and aldehyde are released. These phenols and aldehydes act as a pollutant in the living environment, including the working environment, there is a problem that emits toxic gases.

Polyurethane rigid foam is excellent in heat insulation and light weight, but its recyclability is poor and its impact resistance is low, so brittle fracture easily occurs in the molding process for manufacturing the base material. There is a problem that durability is poor, such as the occurrence of crumbs.

In the case of polypropylene resin, there is a limit that the strain is large and the dimensional stability is low depending on the processing process or climatic conditions.

In addition, the above-described conventional headliner material for automobile interiors has a comprehensive problem that the unit price is high, easily deformed when used for a long time, and harmful to a human body and the environment.

Therefore, there is an urgent need for development of automotive headliner materials having good durability and dimensional stability.

Korean Patent Publication No. 2013-0120567

An object of the present invention is to provide a vehicle headliner substrate having a novel laminated structure and a method of manufacturing the same.

The present invention as a means for solving the above problems,

A first nonwoven layer; A first inorganic fiber mat layer; Polyester resin foam sheet layer; A second inorganic fiber mat layer; And a structure in which the second nonwoven fabric layer is sequentially stacked,

Glass chop is dispersed between the first nonwoven fabric layer and the first inorganic fiber mat layer, and between the second nonwoven fabric layer and the second inorganic fiber mat layer.

The weight per unit area ranges from an average of 1,050 to 1,650 g / m ² ,

According to ASTM D 790, a vehicle headliner substrate having a flexural modulus measured in the range of 200 to 1,500 Mpa when the support span of the specimen is fixed to 100 mm and the bending load is applied at a speed of 5 mm / min is provided. can do.

In addition, the present invention, the first nonwoven fabric layer; A layer in which glass chop is dispersed; A first inorganic fiber mat layer; Polyester resin foam sheet; A second inorganic fiber mat layer; Provided is a method of manufacturing a headliner substrate for a vehicle, comprising the step of sequentially laminating a glass chopped layer and a second nonwoven layer, and molding under heating and pressing conditions.

The present invention relates to a vehicle interior and exterior materials with excellent durability, and an object of the present invention is to provide a headliner substrate having a characteristic of excellent flexural strength and flexural modulus and a manufacturing method thereof.

1 is a cross-sectional view showing a laminated structure of a vehicle headliner substrate according to an embodiment of the present invention.

As the invention allows for various changes and numerous embodiments, particular embodiments will be illustrated in the drawings and described in detail in the written description. However, this is not intended to limit the present invention to specific embodiments, it should be understood to include all modifications, equivalents, and substitutes included in the spirit and scope of the present invention.

In the present invention, the terms "comprises" or "having" are intended to indicate that there is a feature, number, step, operation, component, part, or combination thereof described in the specification, and one or more other features. It is to be understood that the present invention does not exclude the possibility of the presence or the addition of numbers, steps, operations, components, components, or a combination thereof.

Hereinafter, the present invention will be described in detail.

TECHNICAL FIELD The present invention relates to interior and exterior materials for vehicles, and in particular, has an object to use as a headliner. In the present invention, the headliner means a material used for the indoor ceiling of the vehicle.

Vehicle headliner substrate according to the present invention,

A first nonwoven layer; A first inorganic fiber mat layer; Polyester resin foam sheet layer; A second inorganic fiber mat layer; And a structure in which the second nonwoven fabric layer is sequentially stacked,

Glass chops are dispersed between the first nonwoven fabric layer and the first inorganic fiber mat layer, and between the second nonwoven fabric layer and the second inorganic fiber mat layer.

The vehicle headliner substrate satisfies excellent flexural strength and flexural modulus without significantly increasing basis weight (weight per unit area). As an example, the weight per unit area of the vehicle headliner substrate may range from an average of 1,050 to 1,650 g / m ² , an average of from 1,050 to 1,350 g / m ² , an average of 1,250 to 1,650 g / m ² , or an average of 1,200 to 1,500 g / m ² range.

The vehicle headliner substrate maintains excellent flexural modulus. As an example, the vehicle headliner substrate has a flexural stiffness of 200 when the support span of the specimen is fixed to 100 mm according to ASTM D 790 and a flexural load is applied at a rate of 5 mm / min. To 1,500 Mpa, 250 to 1,000 Mpa, or 250 to 450 Mpa. The flexural modulus (Stiffness) refers to the degree of rigidity or rigidity of the material, when the flexural modulus satisfies the above range, the rigidity and durability is improved to provide a vehicle headliner with less deformation due to physical impact or force Can be.

In addition, the vehicle headliner substrate has excellent flexural strength. As one example, the vehicle headliner substrate realizes flexural strength in the range of 2.5 to 4.0 kgf when measured at room temperature (25 ° C.). By satisfying the flexural strength of the above range, due to the high strength can be more safe to impact with the outside, it can be easy to molding. Specifically, the flexural strength measurement is based on ASTM D 790, which measures the value at which 10% deformation is obtained with respect to the initial specimen while applying a flexural load at a rate of 5 mm / min, fixing the support span (Span) at 100 mm. Measured.

In addition, the vehicle headliner base material does not include a polypropylene resin. Polypropylene resins have limitations in terms of strain rate and dimensional stability despite various advantages such as price and processability. The present invention solves this limitation by not applying a polypropylene resin. In one example, the present invention was applied to the PET foam sheet having a low strain rate and excellent dimensional stability, by implementing an inorganic fiber mat and a glass chop on both sides of the PET foam sheet to achieve excellent strength.

As one example of the present invention, the foam sheet layer is a layer formed of a polyester resin foam sheet, the weight per unit area is in the range of 350 to 850 g / m ² . Specifically, the weight per unit area of the foam sheet layer is in the range of 400 to 800 g / m ² , 450 to 650 g / m ² , or 650 to 800 g / m ² range. Polyester resin is an environmentally friendly material that is excellent in flame retardancy and chemical resistance and does not release environmental hormones, and in particular, has excellent mechanical strength.

However, since the polyester resin has a sharp drop in melt strength as the temperature increases, the temperature range with the meltable foamable melt viscosity is very narrow. Therefore, in order to foam the polyester resin, a special technique for increasing the melt viscosity and precise temperature control equipment are essential. Therefore, conventionally, there was a difficulty in manufacturing a foam using a polyester resin. In the present invention, the foam was successfully manufactured through precise viscosity and temperature control of the polyester resin.

As one example, the polyester resin foam sheet may be extrusion foamed. Types of foaming methods include bead foaming or extrusion foaming. In general, the bead foaming is generally carried out by heating the resin beads by primary foaming, aging them for a suitable time, and then filling them in a plate-shaped or cylindrical mold and heating them again. It is a method of making a product by fusion and molding by primary foaming. Extrusion foam, on the other hand, by heating and melting the resin and continuously extruding and foaming the resin melt, can simplify the processing steps, enable mass production, and crack and granular fracture between beads during bead foaming. By preventing the phenomenon, it is possible to implement more excellent flexural strength and compressive strength.

In the polyester resin foam sheet according to the present invention, at least 90% of the cells are closed cells (DIN ISO4590), which means that the measured value according to DIN ISO4590 of the foam sheet is at least 90% (v / v) of the closed cells. can do. For example, the proportion of closed cells in the foam sheet may be an average of 90 to 100% or 95 to 99%. Foam seat according to the present invention by having a closed cell within the above range, it can implement excellent durability, rigidity and strength characteristics when manufacturing a vehicle headliner. For example, the number of cells in the foam sheet is 1 mm ² It may comprise 1 to 30 cells, 3 to 25 cells, or 3 to 20 cells per sugar.

In addition, the average size of the cell may range from 100 to 800 μm. For example, the average size of the cell can range from 100 to 700 μm, 200 to 600 μm or 300 to 600 μm. In this case, the cell size deviation may be, for example, 5% or less, 0.1 to 5%, 0.1 to 4% to 0.1 to 3% range. Through this, it can be seen that the foam sheet according to the present invention is uniformly foamed cells of uniform size.

In the present invention, the polyester resin can be produced by terephthalic acid and 1,4-butanediol condensation polymerization reaction. The polyester resin according to the present invention includes both aromatic or aliphatic polyesters. In another aspect, the polyester resins include flame retardant polyesters, biodegradable polyesters, elastic polyesters, reusable polyesters, and the like. For example, the kind of polyester resin usable in the present invention is polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polylactic acid (PLA), polyglyco Polyglycolic acid (PGA), polypropylene (PP), polyethylene (Polyethylene, PE), polyethylene adipate (Polyehtylene adipate, PEA), polyhydroxyalkanoate (PHA), polytrimethylene terephthalate (Polytrimethylene Terephthalate (PTT) and polyethylene naphthalate (PEN) may be one or more selected from the group consisting of. Specifically, the foam sheet according to the present invention may be a polyethylene terephthalate (PET) foam sheet. By using the PET, it may be environmentally friendly and easy to reuse.

In the present invention, the inorganic fiber mat layer means a layer formed of inorganic fibers, and the inorganic fibers may include at least one of glass fiber, acicular form crystal of metal or metal oxide, and carbon fiber. Specifically, the inorganic fiber may be a glass fiber. For example, the inorganic fiber may have an average diameter in the range of 10 to 1000 μm. In the inorganic fiber mat layer, the inorganic fibers may have an average diameter of 10 to 1000 ㎛ range. For example, the average diameter of the inorganic fibers may range in diameter from 100 to 1000 μm, from 100 to 800 μm or from 100 to 500 μm. By bonding an inorganic fiber mat including inorganic fibers having an average diameter within the above range to one or both sides of the foam layer comprising a polyester resin foam, a vehicle headliner having high strength and excellent durability can be provided. In the present invention, the inorganic fiber mat layers bonded to both surfaces of the polyester resin foam are referred to as first and second inorganic fiber mat layers for convenience. The weight per unit area of the first and second inorganic fiber mat layers may be adjusted in the range of 105 to 140 g / m ² , specifically, 110 to 130 g / m ² . By controlling the weight per unit area of the first and second inorganic fiber mat layers in the above range, the hardness of the substrate can be kept excellent while preventing the weight from being excessively increased.

In addition, the present invention further includes a glass chop dispersed between the nonwoven fabric layer and the inorganic fiber mat layer. In the present invention, glass 촙 is a generic term for glass fibers in the form of short fibers. For example, the glass chop is in the form of short fibers having an average length in the range of 1 to 100 mm. In some cases, the glass shock may have a ratio of length to diameter (L / D) in a range of 1 to 50. For example, the glass shock may be chopping glass fibers in the form of long fibers to an average length in the range of 1 to 100 mm.

In one example, the weight per unit area of glass chop dispersed between the first nonwoven fabric layer and the first inorganic fiber mat layer, and between the second nonwoven fabric layer and the second inorganic fiber mat layer, is 95 to 130, respectively. g / m ² range, specifically, satisfies the 100 to 120 g / m ² range. In the present invention, compared to the case where only the inorganic fiber mat layer is applied to the headliner substrate, when the inorganic fiber mat layer and glass 함께 are applied together, it was confirmed that the bending strength of the headliner substrate is improved by 30% or more.

In another example, the glass chops dispersed between the first nonwoven fabric layer and the first inorganic fiber mat layer, and between the second nonwoven fabric layer and the second inorganic fiber mat layer are each a first nonwoven fabric layer. And partially dispersed in the second nonwoven layer. For example, the glass shaping is subjected to a molding process under pressure and heating conditions while being positioned between the nonwoven fabric layer and the inorganic fiber mat layer. In this process, a portion of the glass shock is located between the nonwoven fabric layer and the inorganic fiber mat layer, but the other part is dispersed into the nonwoven fabric layer to have a structure that is mixed with the nonwoven fabric layer.

As one example of the present invention, a polyethylene resin is included in a region where glass chop is partially dispersed in the first nonwoven fabric layer and the second nonwoven fabric layer. The polyethylene resin is dispersed in the form of a powder, and all or part of the polyethylene resin remains in a molten state during the molding process under pressure and heating conditions. The polyethylene resin powder is placed between both layers to increase the adhesion. As one example, the content of the polyethylene resin may be in the range of 0.01 to 5% by weight, or in the range of 1 to 5% by weight, based on the weight of the first nonwoven fabric layer or the second nonwoven fabric layer.

The vehicle headliner substrate further includes a nonwoven fabric layer. The nonwoven fabric layer has a structure in which a first nonwoven fabric layer and a second nonwoven fabric layer are laminated on both surfaces of a vehicle headliner substrate, respectively. The weight per unit area (Wa) of the first nonwoven fabric layer is in the range of 50 to 70 g / m ² , and the weight per unit area (Wb) of the second nonwoven layer is controllable in the range of 25 to 55 g / m ² . In the present invention, the first nonwoven fabric layer may be referred to as a lower nonwoven fabric layer, and means a nonwoven fabric layer in a direction in which the headliner substrate is attached to the ceiling surface in the vehicle. In addition, in the present invention, the second nonwoven fabric layer may be referred to as an upper nonwoven fabric layer, and means a nonwoven fabric layer in a direction in which the headliner substrate is exposed to the in-vehicle boarding area. In some cases, a skin layer may be further formed on the surface of the second nonwoven fabric layer. The skin layer may be formed in various forms such as a resin layer, a leather layer or a fiber layer. In the present invention, the difference Wa-Wb between the weight per unit area Wa of the first nonwoven fabric layer and the weight per unit area Wb of the second nonwoven fabric layer satisfies the range of 10 to 40 g / m ² . For example, the first and second nonwoven layers may be a polyester nonwoven layer formed of polyester fibers.

The average thickness of the nonwoven layer may range from 0.1 to 5 mm. For example, the average thickness of the nonwoven layer can range from 0.1 to 5 mm, 0.1 to 3 mm, 0.1 to 2 mm or 0.1 to 1 mm. Through this, the headliner substrate for a vehicle according to the present invention can realize characteristics such as excellent flexural strength, sound absorption, sound insulation and low dimensional strain despite a relatively thin thickness.

In the present invention, the adhesive layer is disposed between the polyester resin foam sheet layer and the first and second inorganic fiber mat layers, respectively. Through this, it is possible to effectively bond between the polyester resin foam sheet layer and the first and second inorganic fiber mat layer.

Further, in the manufacturing process, glass chop is dispersed between the first nonwoven fabric layer and the first inorganic fiber mat layer, and between the second nonwoven fabric layer and the second inorganic fiber mat layer, and the first and the first Two glass shock layers are formed. In addition, the present invention includes a laminated structure in which an adhesive layer is disposed between the first glass fin layer and the first nonwoven layer, and between the second glass fin layer and the second nonwoven layer, respectively. Then, the laminated structure is subjected to a process of forming under pressure and heating conditions. In the molding process, the adhesive layer is partially or fully melted, and the adhesive component forming the adhesive layer penetrates into the glass shock layer and the nonwoven layer, and one layer of the glass shock, the adhesive component and the nonwoven layer is partially or fully mixed. Will form.

Specifically, the vehicle interior and exterior materials may further include an adhesive layer between the foam layer and the inorganic fiber mat, thereby further improving the adhesion between the foam layer and the inorganic fiber mat, thereby more effectively preventing interlayer peeling, thereby improving durability.

The adhesive layer may include an adhesive resin including at least one resin of an acrylic resin, a polyester resin, an epoxy resin, a silicone resin, and a urethane resin. In addition, the adhesive layer includes a structure in which an adhesive composition is applied or deposited on an adhesive film. As one example, the adhesive layer may include a polyester adhesive resin. For example, the polyester adhesive resin may include a hard segment which is an esterification reaction of diol and dicarbonic acid; And a polyester elastic adhesive resin which is a polycondensation product of a soft segment which is a polyol. In one example, each adhesive layer applied in the present invention may each have a weight per unit area in the range of 20 to 60 g / m ² , or in the range of 35 to 60 g / m ² .

In addition, the vehicle headliner substrate according to the present invention may satisfy the following condition 1.

[Condition 1]

The condition 1 means the rate of change of the dimension (horizontal, vertical, height average) before and after irradiation with light having a wavelength of 255 W / m ² for 90 days in accordance with the accelerated light resistance test of KS R 0021. , Lt ₀ represents the dimension before the treatment, Lt ₁ represents the dimension after the treatment.

In the condition 1, the dimensional change rate may be specifically less than 1%, 0.01 to 0.9%, 0.05 to 0.8%, or 0.1 to 0.6%. In this case, the dimensional change rate may be a dimensional change rate when the volume Tt ₀ before processing (before irradiating light) of the vehicle interior and exterior materials is 1 m ³ . The headliner substrate for a vehicle according to the present invention provides improved durability and light resistance by satisfying the above-described range of dimensional change, and can prevent deformation and damage caused by ultraviolet rays even during long-term use.

The manufacturing method of the vehicle headliner base material is not particularly limited, but may be manufactured by thermal fusion or thermal bonding under pressure and heating conditions.

Vehicle headliner substrate according to the present invention, the first nonwoven fabric layer; A layer in which glass chop is dispersed; A first inorganic fiber mat layer; Polyester resin foam sheet; A second inorganic fiber mat layer; The glass chopped layer and the second nonwoven layer may be sequentially laminated and molded under heating and pressing conditions.

In the method for manufacturing a headliner substrate according to the present invention, each layer description corresponds to the above-mentioned content.

At this time, the forming step may be carried out by pressing for 1 to 3 minutes at a temperature of 150 to 200 ℃. In some cases, the method may further include preheating for 1 to 3 minutes at a temperature of 180 to 220 ° C. before the forming.

In one example, the manufacturing method of the headliner substrate according to the present invention,

Between the first nonwoven layer and the layer in which glass chop is dispersed;

Between the first inorganic fiber mat layer and the polyester resin foam sheet;

Between the polyester resin foam sheet and the second inorganic fiber mat layer; And

Molding is carried out under heating and pressurizing conditions, further comprising an adhesive composition coating layer or an adhesive film formed at an interface between any one of the glass chopped and the second nonwoven layer.

In another example, the manufacturing method of the headliner substrate according to the present invention,

Between the first nonwoven layer and the layer in which glass chop is dispersed; And

Molding is carried out under heating and pressurizing conditions in a state in which the glass chop further comprises polyethylene resin particles dispersed at either interface between the dispersed layer and the second nonwoven layer. The polyethylene resin particles serve to improve the interlayer adhesion.

1 is a cross-sectional view showing a laminated structure of a vehicle headliner substrate according to an embodiment of the present invention. Specifically, Fig. 1 is a laminated structure before molding under heating and pressing conditions. In the vehicle headliner substrate 100 according to the present invention, first and second inorganic fiber mat layers 21 and 22 are laminated on both sides of the polyester resin foam sheet layer 10. On one surface of each of the first and second inorganic fiber mat layers 21 and 22, layers 31 and 32 in which glass chops are dispersed and first and second nonwoven layers 41 and 42 are sequentially disposed. It is a laminated structure. In addition, between the first nonwoven fabric layer 41 and the layer 31 in which glass chop is dispersed; Between the first inorganic fiber mat layer 21 and the polyester resin foam sheet layer 10; Between the polyester resin foam sheet layer 10 and the second inorganic fiber mat layer 22; Adhesive layers 51, 52, 53, and 54 are respectively provided between the layer 32 and the second nonwoven fabric layer 42 in which glass chop is dispersed. The adhesive layers 51, 52, 53, 54 are positioned in the form of a thermal adhesive film. Although not shown in FIG. 1, the polyethylene resin powder is dispersed between the first nonwoven fabric layer 41 and the adhesive layer 51 and between the adhesive layer 54 and the second nonwoven fabric layer 42.

The polyester resin foam sheet layer, the inorganic fiber mat layer and the nonwoven fabric layer and the adhesive layer according to the present invention described above may have a hydrophilic function, a waterproof function, a flame retardant function or an ultraviolet ray blocking function in some cases, Surfactants, sunscreens, hydrophilizers, flame retardants, heat stabilizers, waterproofing agents, cell size enlargers, infrared attenuators, plasticizers, fire protection chemicals, pigments, elastomers, extrusion aids, antioxidants, nucleating agents, antistatic agents and UV absorbers It may further comprise one or more functional additives selected from the group consisting of. Specifically, any one or more layers of the polyester resin foam sheet layer, the inorganic fiber mat layer, the nonwoven fabric layer and the adhesive layer according to the present invention may optionally include a thickener, a nucleating agent, a heat stabilizer and a foaming agent. .

Although the thickener is not particularly limited, for example, pyromellitic dianhydride (PMDA) may be used in the present invention.

Examples of the nucleating agent include talc, mica, silica, diatomaceous earth, alumina, titanium oxide, zinc oxide, magnesium oxide, magnesium hydroxide, aluminum hydroxide, calcium hydroxide, potassium carbonate, calcium carbonate, magnesium carbonate, calcium sulfate, barium sulfate And inorganic compounds such as sodium hydrogen carbonate and glass beads. Such nucleating agents may play a role in providing functionality and reducing prices. Specifically, in the present invention, talc may be used.

The heat stabilizer may be an organic or inorganic phosphorus compound. The organic or inorganic phosphorus compound may be, for example, phosphoric acid and its organic ester, phosphorous acid and its organic ester. For example, the heat stabilizer is a commercially available material, and may be phosphoric acid, alkyl phosphate or aryl phosphate. Specifically, in the present invention, the heat stabilizer may be triphenyl phosphate, but is not limited thereto. If the heat stabilizer is capable of improving thermal stability, the heat stabilizer may be used without limitation within a conventional range.

Examples of the blowing agent may include physical blowing agents such as N ₂ , CO ₂ , freon, butane, pentane, neopentane, hexane, isohexane, heptane, isoheptane, methyl chloride or azodicarbonamide-based compounds, P, P'-oxybis (benzenesulfonylhydrazide) [P, P'-oxy bis (benzene sulfonyl hydrazide)] compound, N, N'-dinitrosopentamethylenetetraamine (N, N'-dinitroso pentamethylene chemical blowing agents such as tetramine-based compounds, and specifically, CO ₂ may be used in the present invention.

The flame retardant in the present invention is not particularly limited, and may include, for example, bromine compound, phosphorus or phosphorus compound, antimony compound. Bromine compounds include, for example, tetrabromo bisphenol A, decabromodiphenylether, and the like, phosphorus or phosphorus compounds include aromatic phosphate esters, aromatic condensed phosphate esters, halogenated phosphate esters, and red, and the like. Antimony trioxide, antimony pentoxide, and the like.

The surfactant is not particularly limited, and anionic surfactants (eg, fatty acid salts, alkyl sulfate ester salts, alkyl benzene sulfonates, alkyl naphthalene sulfonates, alkyl sulfosuccinate salts, polyoxyethylene alkyl sulfate ester salts, and the like) Nonionic surfactants (e.g., polyoxyalkylene alkyl ethers such as polyoxyethylene alkyl ethers, polyoxyethylene derivatives, sorbitan fatty acid esters, polyoxyethylene sorbitan fatty acid esters, polyoxyethylene sorbitol fatty acid esters, Glycerin fatty acid esters, polyoxyethylene alkylamines, alkylalkanolamides, etc.), cationic and zwitterionic surfactants (e.g. alkylamine salts, quaternary ammonium salts, alkylbetaines, amine oxides, etc.) and water-soluble polymers Or protective colloids (eg, gelatin, methylcellulose, hydroxyethylcellulose, Hydroxypropyl cellulose, carboxymethyl cellulose, polyethylene glycol, polyoxyethylene-polyoxypropylene block copolymer, polyacrylamide, polyacrylic acid, polyacrylic acid salt, sodium alginate, polyvinyl alcohol partial saponification, etc.), and the like. have.

In addition, the waterproofing agent is not particularly limited, and for example, silicone-based, epoxy-based, cyanoacrylic acid-based, polyvinyl acrylate-based, ethylene vinyl acetate-based, acrylate-based, polychloroprene-based, polyurethane resin and polyester resin And a mixture of a mixture series of polyol and polyureten resin, a mixture series of acrylic polymer and polyurethane resin, a polyimide series, and a mixture series of cyanoacrylate and urethane.

In addition, the sunscreen is not particularly limited, and may be, for example, an organic or inorganic 'UV' blocking agent. Examples of the organic 'UV' blocking agent include p-aminobenzoic acid derivatives, benzylidene camphor derivatives, cinnamic acid derivatives, benzophenone derivatives, Benzotriazole derivatives and mixtures thereof, and examples of the inorganic-based UV-blocking agent may include titanium dioxide, zinc oxide, manganese oxide, zirconium dioxide, cerium dioxide, and mixtures thereof.

Hereinafter, the present invention will be described in more detail through examples according to the present invention, but the scope of the present invention is not limited thereto.

Example  One

In order to manufacture the headliner substrate for a vehicle according to the present invention, first, 100 parts by weight of polyethylene terephthalate (PET) resin was dried at 130 ° C. to remove water, and the PET resin and water were removed from the first extruder. Based on 100 parts by weight of the PET resin, 1 part by weight of pyromellitic diehydride, 1 part by weight of talc and 0.1 part by weight of Irganox (IRG 1010) were mixed and heated to 280 ° C. to prepare a resin melt. Then, 5 parts by weight of carbon dioxide gas was added to the first extruder as a blowing agent based on 100 parts by weight of the PET resin, followed by extrusion foaming to prepare a polyester resin foam sheet. The weight per unit area of the foam sheet is 525 g / m ² .

Then, a thermal adhesive film having a weight of 45 g / m ² per unit area was placed on both sides of the foam sheet, and then a glass mat layer having a weight of 120 g / m ² per unit area was laminated thereon.

Then, glass 촙 was applied on the opposite side of the surface contacting the foam layer of each of the glass fiber mats in an amount of 110 g / m ² per unit area, respectively. After positioning the heat-adhesive film on the glass-coated surface, the polyethylene resin powder was applied and the nonwoven fabric layer was laminated. One side of the nonwoven layer has a weight per unit area of 60 g / m ² , and the other side of the nonwoven layer has a weight per unit area of 40 g / m ² .

Through this, except that the weight per unit area of both nonwoven fabric layers were different, the same laminated structure was formed on both sides of the polyester foam sheet.

Then, the manufactured laminated structure was preheated at 200 ° C. for 150 seconds, and pressed and molded at 180 ° C. for 120 seconds to manufacture a vehicle headliner. The weight per unit area of the manufactured vehicle headliner is 1,265 g / m ² .

Example  2

A vehicle headliner was manufactured in the same manner as in Example 1, except that the weight per unit area of the polyester foam sheet was 700 g / m ² . The weight per unit area of the manufactured vehicle headliner is 1,440 g / m ² .

Comparative example

On one side of a nonwoven fabric having a weight per unit area of 50 g / m ² , a vehicle headliner substrate having a structure in which a polypropylene resin and a glass fiber were mixed at a weight ratio of 6: 4 and a thermal adhesive film was laminated commercially was obtained. (Product name 'Super Light' of Hanwha Advanced Materials).

Experimental Example  One

Flexural modulus and stiffness were measured for the specimens according to Examples 1, 2 and Comparative Example 1.

Flexural modulus and flexural strength measurements were determined in accordance with ASTM D 790 at 10% deformation relative to the initial specimen during flexural loading at a rate of 5 mm / min. Measured. The results are shown in Table 1 below. In Table 1 below, the flexural modulus was confirmed to be 250 MPa or more, and expressed as O and X.

division Example 1 Example 2 Comparative Example 1 Flexural strength (kgf) 2.8 3.4 2.8 Flexural modulus O O O

Referring to Table 1, the specimens according to Examples 1 and 2, compared with Comparative Example 1 in terms of flexural strength and flexural modulus, it was confirmed that the physical properties do not decrease.

Experimental Example  2

The dimensional change rate of the specimens of Examples 1 and 2 was measured and shown in Table 2 below.

Dimensional change rate measurement measured the dimension change rate before and after irradiating the light of 300-400 nm wavelength with the light of illumination intensity 255 W / m <^2> according to the accelerated light resistance test of KSR0021 for 90 days. At this time, the volume before measurement was 1 m ³ , and the rate of dimensional change is shown according to the following condition 1.

[Condition 1]

Under condition 1, Lt ₀ represents the dimension before the treatment, and Lt ₁ represents the dimension after the treatment.

division Example 1 Example 2 Dimensional rate of change (%) 0.1 0.1

Referring to Table 2, the specimens according to Examples 1 and 2 showed a dimensional change rate of less than 0.1%, through which the vehicle headliner substrate according to the present invention is excellent in light resistance and durability by preventing deformation by ultraviolet rays. The improvement was confirmed.

100: vehicle headliner base material,
10: polyester resin foam sheet layer,
21: first inorganic fiber mat layer,
22: second inorganic fiber mat layer,
31, 32: layer in which glass chop is dispersed,
41: the first nonwoven fabric layer,
42: second nonwoven layer,
51, 52, 53, 54: adhesive layer

Claims (14)

A first nonwoven layer; A first inorganic fiber mat layer; Polyester resin foam sheet layer; A second inorganic fiber mat layer; And a structure in which the second nonwoven fabric layer is sequentially stacked,
Glass chop is dispersed between the first nonwoven fabric layer and the first inorganic fiber mat layer, and between the second nonwoven fabric layer and the second inorganic fiber mat layer to form a first glass chopped layer and a second glass chopped layer, respectively. and,
An adhesive layer between the first glass chopped layer and the first nonwoven layer, and between the second glass chopped layer and the second nonwoven layer, respectively;
The weight per unit area of the polyester resin foam sheet layer is in the range of 350 to 850 g / m ² ,
The weight per unit area of the first and second inorganic fiber mat layer is in the range of 105 to 140 g / m ² , respectively,
The weight per unit area of the first and second glass shock layers is in the range of 95 to 130 g / m ² , respectively,
The weight per unit area (Wa) of the first nonwoven fabric layer is in the range of 50 to 70 g / m ² ,
The weight per unit area (Wb) of the second nonwoven layer ranges from 25 to 55 g / m ² ,
The difference (Wa-Wb) between the weight per unit area (Wa) of the first nonwoven fabric layer and the weight per unit area (Wb) of the second nonwoven fabric layer is in the range of 10 to 40 g / m ² ,
The weight per unit area ranges from an average of 1,050 to 1,650 g / m ² ,
While the adhesive component forming the adhesive layer penetrates the glass chopped layer and the nonwoven layer, the glass chop, the adhesive component and the nonwoven layer form one layer in which part or all of the mixture is mixed,
The adhesive layer may include a hard segment which is an esterification reaction of diol and dicarbonic acid; And it may include one or more of polyester elastic adhesive resin which is a polycondensation of a soft segment of polyol,
A vehicle headliner substrate having a flexural modulus measured in the range of 200 to 1,500 Mpa when the support span of the specimen is fixed to 100 mm and a flexural load is applied at a rate of 5 mm / min according to ASTM D 790.
delete delete delete The method of claim 1,
Glass chop is a vehicle headliner substrate which is a glass fiber in the form of short fibers having an average length in the range of 1 to 100 mm.
The method of claim 1,
The glass chops dispersed between the first nonwoven fabric layer and the first inorganic fiber mat layer, and between the second nonwoven fabric layer and the second inorganic fiber mat layer are respectively part of the first nonwoven fabric layer and the second nonwoven fabric layer. A vehicle headliner substrate having a distributed structure.
The method of claim 6,
The region in which glass chop is partially dispersed in the first nonwoven fabric layer and the second nonwoven fabric layer contains polyethylene resin,
The content of the polyethylene resin, the vehicle headliner substrate is in the range of 0.01 to 5% by weight, based on the weight of the first nonwoven fabric layer or the second nonwoven fabric layer.
delete The method of claim 1,
A vehicle headliner substrate having a structure in which an adhesive layer is placed and laminated between a polyester resin foam sheet and first and second inorganic fiber mat layers, respectively.
The method of claim 9,
The adhesive layer is a vehicle headliner substrate having a structure formed by applying an adhesive composition comprising a resin containing at least one of an acrylic resin, a polyester resin, an epoxy resin, a silicone resin and a urethane resin or being placed on an adhesive film.
The method of claim 1,
A vehicle headliner base material satisfying the following condition 1:
[Condition 1]

The condition 1 means the rate of change of the dimension (horizontal, vertical, height average) before and after irradiation with light having a wavelength of 255 W / m ² for 90 days in accordance with the accelerated light resistance test of KS R 0021. , Lt ₀ represents the dimension before the treatment, Lt ₁ represents the dimension after the treatment.
A method for manufacturing a vehicle headliner base according to claim 1,
A first nonwoven layer; A layer in which glass chop is dispersed; A first inorganic fiber mat layer; Polyester resin foam sheet; A second inorganic fiber mat layer; A method of manufacturing a headliner substrate for a vehicle comprising the steps of sequentially laminating a glass chopped layer and a second nonwoven layer, and molding under heating and pressing conditions.
The method of claim 12,
Between the first nonwoven layer and the layer in which glass chop is dispersed;
Between the first inorganic fiber mat layer and the polyester resin foam sheet;
Between the polyester resin foam sheet and the second inorganic fiber mat layer; And
Between the glass chopped layer and the second nonwoven layer
A method of manufacturing a headliner substrate for a vehicle, which performs molding under heating and pressurizing conditions, further comprising an adhesive composition coating layer or an adhesive film formed at any one interface.
The method of claim 12,
Between the first nonwoven layer and the layer in which glass chop is dispersed; And
Between the glass chopped layer and the second nonwoven layer
A method of manufacturing a headliner substrate for a vehicle, which further comprises molding under heating and pressurizing conditions in a state further comprising polyethylene resin particles dispersed at any one interface.

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