KR102253807B1 - Backcoating resin composite having height acoustic-absorptivity, and carpet using the same, and method of fabricating of the same - Google Patents

Abstract

A high sound-absorbing resin composition for back coating is provided. The high sound-absorbing resin composition for back coating can include: a base resin including low-density polyethylene and polyolefin elastomer; a filler mixed with the base resin; a flame retardant mixed with the base resin; a lubricant mixed with the base resin; a coupling agent mixed with the resin; an antioxidant mixed with the base resin; and an additive mixed with the base resin.

Description

High-absorption resin composition for back coating, carpet using the same, and manufacturing method thereof {Backcoating resin composite having height acoustic-absorptivity, and carpet using the same, and method of fabricating of the same}

The present application relates to a resin composition, and more particularly, to a resin composition for a high-absorption back coating, a carpet using the same, and a method of manufacturing the same.

According to a report by Coherent Market Insights, the global automotive interior market size reached $6.69 billion in 2016 and is expected to exceed $117.6 billion in 2025.

As the market size for automotive interior materials increases, automotive interior materials having various functions are being developed.

For example, Korean Patent Registration No. 10-0911573 discloses a composite consisting of 70 to 95% by weight of a polyolefin resin, 2 to 10% by weight of glass bubbles as an inorganic filler, and 3 to 28% by weight of other inorganic fillers. Disclosed is a polyolefin-based composite resin composition for automobile interiors, characterized in that it contains 0.001 to 0.5 parts by weight of turpentine and 0.003 to 0.8 parts by weight of resin acid based on 100 parts by weight of the resin composition.

For another example, Korean Patent Registration No. 10-1615764 discloses a biomass-derived thermoplastic polyolefin (TPO) composite resin, a biomass-derived polyethylene, or a biomass-derived resin including both; And a biomass-non-derived thermoplastic polyolefin (TPO) composite resin, wherein the biomass-non-derived TPO composite resin is an olefin-based composite resin formed by dispersing rubber-like particles using a thermoplastic polyolefin-based resin as a matrix. It is a thermoplastic elastomer, and the composition has a pMC value of 15 to less than 36 wt% according to ASTM D6866, and a thermoplastic resin composition for automobile interior materials is disclosed.

One technical problem to be solved by the present application is to provide a resin composition for a high-absorption back coating, a carpet using the same, and a method of manufacturing the same.

Another technical problem to be solved by the present application is to provide a lightweight, high-absorption resin composition for back coating, a carpet using the same, and a method of manufacturing the same.

Another technical problem to be solved by the present application is to provide an eco-friendly, high-absorption resin composition for back coating, a carpet using the same, and a method of manufacturing the same.

Another technical problem to be solved by the present application is to provide a resin composition for a high-absorption back coating with improved NVH characteristics, a carpet using the same, and a method of manufacturing the same.

Another technical problem to be solved by the present application is to provide a resin composition for a high-absorption back coating with reduced manufacturing cost, a carpet using the same, and a manufacturing method thereof.

Another technical problem to be solved by the present application is to provide a resin composition for a high-absorption back coating with a simplified manufacturing process, a carpet using the same, and a manufacturing method thereof.

The technical problem to be solved by the present application is not limited to the above.

In order to solve the above technical problem, the present application provides a resin composition for back coating with high sound absorption.

According to an embodiment, the resin composition for a high-absorption back coating includes a base resin including a low-density polyethylene and a polyolefin elastomer, a filler mixed with the base resin, a flame retardant mixed with the base resin, and the base resin. A mixed lubricant, a coupling agent mixed with the base resin, an antioxidant mixed with the base resin, and an additive mixed with the base resin may be included.

According to an embodiment, the filler is added 25 to 40 wt% of the base resin, wood powder and calcium carbonate (CaCO ₃ ), and the flame retardant is added 15 to 30 wt% of the base resin, and hydroxylated Including magnesium (MgOH ₂ ), the lubricant is added 0.8 to 2 wt% relative to the base resin, and includes calcium stearate and polyethylene wax, the coupling agent is added 3 to 5 wt% compared to the base resin, anhydrous It includes polyethylene maleate, and the antioxidant may include those added in an amount of 0.3 to 0.5 wt% compared to the base resin.

In order to solve the above technical problem, the present application provides a method of manufacturing a highly sound-absorbing backcoat.

According to an embodiment, the method of manufacturing the high-absorption backcoat comprises the steps of compounding the resin composition according to the above-described embodiment, and providing the compounded resin composition on a substrate to prepare a high-absorption backcoat. It may include the step of.

The resin composition for a high-absorption back coating according to an embodiment of the present application includes a base resin including low-density polyethylene and polyolefin elastomer, a filler mixed with the base resin, a flame retardant mixed with the base resin, and the base resin. A mixed lubricant, a coupling agent mixed with the base resin, an antioxidant mixed with the base resin, and an additive mixed with the base resin may be included.

The carpet for automobile interiors manufactured using the resin composition for high-absorption back coating may have high sound-absorbing properties, can be reduced in weight by the composition and combination ratio of the resin composition for high-absorption back-coating, and NVH characteristics can be improved. I can.

In addition, the resin composition for high-absorption backcoating is manufactured by a simple process using inexpensive materials, so that mass production is easy and the resin composition for high-absorption backcoating having high price competitiveness, a carpet using the same, and a manufacturing method thereof Can be provided.

1 is a view for explaining wood powder contained in a resin composition for a high-absorption back coating according to a first modified example of the embodiment of the present application.
2 is a view for explaining the wood powder contained in the resin composition for high-absorption back coating according to the second modified example of the embodiment of the present application.
3 is a flow chart illustrating a method of manufacturing a carpet using a resin composition for back coating having high sound absorption according to an exemplary embodiment of the present application.
4 is a view for explaining a carpet manufactured by using the resin composition for high-absorption back coating according to an embodiment of the present application.
5 is a sound absorbing and insulating test result for specimens prepared using the high sound absorption back coating resin composition according to Experimental Example 2 and Experimental Example 5 of the present application.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. However, the technical idea of the present invention is not limited to the embodiments described herein and may be embodied in other forms. Rather, the embodiments introduced herein are provided so that the disclosed contents may be thorough and complete, and the spirit of the present invention may be sufficiently conveyed to those skilled in the art.

In addition, in various embodiments of the present specification, terms such as first, second, and third are used to describe various elements, but these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. Accordingly, what is referred to as a first component in one embodiment may be referred to as a second component in another embodiment. Each embodiment described and illustrated herein also includes its complementary embodiment. In addition, in the present specification,'and/or' has been used to mean including at least one of the elements listed before and after.

In the specification, expressions in the singular include plural expressions unless the context clearly indicates otherwise. In addition, terms such as "comprise" or "have" are intended to designate the presence of features, numbers, steps, components, or a combination thereof described in the specification, and one or more other features, numbers, steps, or configurations. It is not to be understood as excluding the possibility of the presence or addition of elements or combinations thereof. In addition, in the present specification, "connection" is used to include both indirectly connecting a plurality of constituent elements and direct connecting.

In addition, in the following description of the present invention, if it is determined that a detailed description of a related known function or configuration may unnecessarily obscure the subject matter of the present invention, a detailed description thereof will be omitted.

1 is a view for explaining the wood powder contained in the resin composition for high-absorption back coating according to the first modified example of the embodiment of the present application, and FIG. 2 is a high sound-absorbing back coating according to the second modified example of the embodiment of the present application It is a drawing for explaining the wood powder contained in the resin composition for use.

A resin composition for back coating with high sound absorption according to an embodiment of the present application will be described.

The resin composition for a high sound absorption back coating according to an embodiment of the present application may include a base resin, a filler mixed with the base resin, a flame retardant, a lubricant, a coupling agent, an antioxidant, and an additive.

According to an embodiment, the base resin may include low-density polyethylene and polyolefin elastomer. Low-density polyethylene is a synthetic resin made of ethylene and has low crystallinity, and low-density polyethylene is produced at high pressure and is also called high-pressure polyethylene. In general, a small amount of oxygen and peroxide react with ethylene and are polymerized at high pressure Can be. Low-density polyethylene may have excellent water resistance, insulation, cold resistance, and transparency. Polyolefin elastomer is a compound having C=C (carbon double bond), a kind of VLDPE (Very Low Density Polyethlene) among polyethylene, and is a copolymer of ethylene (CH2=CH2) and octene or butene using a metallocene catalyst. Polyolefin elastomers have low density and high elasticity, while low brittleness, and, as described above, can be used with low density polyethylene.

According to an embodiment, the filler may be added in an amount of 25 to 40 wt% compared to the base resin.

In addition, the filler may contain at least one of wood flour and calcium carbonate (CaCO3).

When the filler includes the wood powder, a carpet manufactured by using the resin composition for high-absorption back coating may be lightened. In addition, due to the plurality of pores present in the wood powder, the sound absorbing property of the carpet manufactured by using the resin composition for high-absorption back coating may be improved. In addition, the wood flour can be secured at a lower price compared to the inorganic fillers that are generally used, and accordingly, the manufacturing cost of a carpet manufactured using the resin composition for high sound absorption back coating can be reduced.

The wood flour may contain a large amount of moisture. In this case, the physical properties of the carpet manufactured using the resin composition for high-absorption back coating may be deteriorated due to moisture contained in the wood powder, or the adhesion between the base resin and the wood powder may be reduced. Accordingly, according to the exemplary embodiment of the present application, before mixing the wood powder with the base resin, the drying process of the wood powder may be sufficiently performed. Accordingly, the physical properties of the carpet due to the moisture contained in the wood powder You can minimize the deterioration. In addition, as described above, by adding the coupling agent to the base resin, the adhesion between the wood powder and the base resin may be improved.

According to a modified example, as shown in FIG. 1, the filler may include core-shell particles including the wood powder and the flame retardant. Specifically, the core-shell particles may include a core 10 including the wood powder and a shell 20 including the flame retardant and surrounding the core. The steps of preparing the core-shell particles include: placing the wood powder in a container, adding the flame retardant to the container in which the wood powder is disposed, adding a solvent to the container, and vibrating the container. It may include the step of coating the flame retardant on the surface of the wood powder while rotating while adding. For example, the solvent may be an alcohol (specifically, ethanol) that can be easily volatilized. Accordingly, the core 10 including the wood powder can be coated with the shell 20 including the flame retardant, and thus, the core-shell particles including the wood powder can be easily combined with the base resin. As well as being bonded, due to the plurality of pores present in the wood powder, the carpet manufactured using the resin composition for high-absorption back coating can be lightened, sound-absorbing property can be improved, and manufacturing cost can be reduced. .

According to another modified example, as shown in FIG. 2, the core-shell particles include a core 12 including an agglomerate in which the wood powder in a plate shape is agglomerated, and surrounding the core 12 and including the flame retardant. It may include a shell 22. A plurality of pores may exist in the agglomerate in which the plate-shaped wood powder is agglomerated, and accordingly, the carpet manufactured using the resin composition for high sound absorption including the core-shell particles is reduced in weight, as well as high sound absorption. Characteristics can be implemented. In this case, the step of preparing the core-shell particles includes preparing the wood powder in a plate shape, placing the wood powder in a plate shape in a container and adding a solvent, and rotating the container while applying vibration to the plate shape. Preparing an agglomerate in which the form of wood powder is agglomerated, adding a flame retardant to the container, adding a solvent to the container, and applying the flame retardant on the surface of the agglomerate while rotating while applying vibration to the container. It may include a step of coating. The solvent may be an alcohol as described above.

According to an embodiment, the flame retardant may be added in an amount of 15 to 30 wt% compared to the base resin.

In addition, the flame retardant may _{include magnesium hydroxide (MgOH 2} ). Alternatively, the flame retardant may _{include aluminum hydroxide (AlOH 3} ). The carpet manufactured by using the resin composition for high-absorption back coating including the flame retardant may have flame retardant properties, and thus, it is possible to easily protect the occupant from the fire of the vehicle.

According to an embodiment, the lubricant may be added in an amount of 0.8 to 2 wt% compared to the base resin.

In addition, the lubricant may include calcium stearate and polyethylene wax. Alternatively, the lubricant may include zinc stearate and magnesium stearate. The lubricant may improve processability, dispersibility, fluidity, and moldability of the resin composition for high-absorption backcoating. Accordingly, the resin composition for high-absorption back coating can be easily extruded into a shape desired by a user.

According to an embodiment, the coupling agent may be added in an amount of 3 to %wt% compared to the base resin.

In addition, the coupling agent may include polyethylene maleate anhydride. As described above, the adhesion between the wood powder and the base resin may be improved by the coupling agent, and thus, physical properties of the carpet manufactured using the resin composition for high sound absorption back coating may be improved.

According to an embodiment, the antioxidant may be added in an amount of 0.3 to 0.5 wt% compared to the base resin.

In addition, the antioxidant may include at least one of phosphorus-based, phenol-based, amine-based, sulfur-based, and metal-based antioxidants.

The additive may include at least one of an antibacterial agent, a pigment, a heat stabilizer, a surfactant, a flame retardant aid, an anti-drip agent, a weathering agent, an ultraviolet absorber, or a sunscreen.

Hereinafter, a method of manufacturing a carpet using the resin composition for high sound absorption back coating will be described with reference to FIG. 3.

3 is a flow chart for explaining a method of manufacturing a carpet using a resin composition for high-absorption back coating according to an embodiment of the present application, and FIG. 4 is a flow chart showing a resin composition for back coating with high sound absorption according to an embodiment of the present application. It is a drawing for explaining the manufactured carpet.

3 and 4, the base resin, the filler, the flame retardant, the lubricant, the coupling agent, the antioxidant, and the resin for the high-absorption back coating including the additive described in the above-described embodiment The composition may be prepared (S110).

The resin composition may be compounded (S120).

By providing the compounded resin composition on the first and second substrates 110 and 120, respectively, a first coating layer and a second coating layer may be formed (S130).

In other words, the first coating layer may be formed on the first substrate 110, and the second coating layer may be formed on the second substrate 120.

For example, the first substrate 110 may be a nonwoven fabric layer, and the second substrate 120 may be a skin layer. As shown in FIG. 3, the second substrate 120 may be in a state in which the nylon yarn 140 is flocked, and the second coating layer is formed on the opposite side of the face on which the nylon yarn 140 is flocked. I can.

The first coating layer and the second coating layer may be formed on the first substrate 110 and the second substrate 120 using a roll-to-roll process.

The first substrate 100 and the second substrate 120 are laminated so that the first coating layer of the first substrate 110 and the second coating layer of the second substrate 120 are adhered to each other, thereby providing high sound absorption A carpet according to the embodiment of the present application having the back coating layer 115 may be manufactured (S140).

The first substrate 110 having the first coating layer and the second substrate 120 having the second coating layer may be laminated to each other using a roll-to-roll process.

As described above, the high sound absorption back coating layer 120 according to the embodiment of the present application may be prepared by using the above-described resin composition for high sound absorption back coating, and included in the resin composition for high sound absorption back coating. , As well as weight reduction by the wood powder of the filler, sound-absorbing properties can be improved, it can be made of an eco-friendly material, and NVH (noise, vibration, harshness) properties can be improved. In addition, manufacturing process cost and raw material cost can be reduced.

According to a modified example, the core-shell particles having the core 10 and the shell 20 described with reference to FIG. 1 and/or the core 12 and the shell described with reference to FIG. A first resin composition comprising the core-shell particles having 22) is prepared, and the above-described base resin, the filler including the wood powder, the flame retardant, the lubricant, the coupling agent, the antioxidant, and the A second resin composition including an additive may be prepared. The first resin composition may be provided on the first substrate 110 to form the first coating layer, and the second resin composition may be provided on the second substrate 120 to form the second coating layer Can be. Thereafter, the first substrate 110 having the first coating layer and the second substrate 120 having the second coating layer are laminated to each other to manufacture a carpet having the high-absorption back coating layer 115. In this case, the core-shell particles may be disposed at a high ratio in the lower region of the high sound absorption back coating layer 115, that is, the region adjacent to the bottom surface of the vehicle, and the upper region of the high sound absorption back coating layer 115, That is, the core-shell particles may not be disposed in an area adjacent to the occupant or may be disposed at a low ratio. Accordingly, noise and vibration directed toward the occupant from the bottom surface of the vehicle can be easily blocked by the core-shell particles having a plurality of pores. That is, by intensively forming a high ratio of pores in the lower region of the high-absorption back coating layer 115, noise and vibration transmitted from the bottom of the vehicle can be effectively blocked.

If, unlike the modified example of the present application described above, when the ratio of the core-shell particles is increased to increase the ratio of pores, the defect rate may be increased due to moisture contained in the wood powder contained in the core-shell particles. And moldability may deteriorate.

However, as described above, according to the modified example of the present application, by intensively arranging the core-shell particles in the lower region of the high sound-absorbing back coating layer 115, the amount of the wood powder is minimized to improve the process yield. At the same time, it is possible to maximize the sound insulation effect according to the use of the wood powder.

Hereinafter, a resin composition for a high-absorption back coating according to a specific experimental example of the present application, and a result of evaluation of properties according thereto will be described.

Preparation of resin composition for back coating with high sound absorption according to Experimental Examples 1 to 5

Prepare low density polyethylene and polyolefin elastomer as a base resin, prepare wood powder and calcium carbonate as a filler, prepare magnesium hydroxide as a flame retardant, prepare calcium stearate and polyethylene wax as a lubricant, prepare polyethylene maleate anhydride as a coupling agent, An antioxidant was prepared.

By varying the composition ratio of the base resin, the filler, the flame retardant, the lubricant, the coupling agent, and the antioxidant as shown in Table 1 below, a resin composition for a high sound absorption back coating according to Experiments 1 to 5 was prepared. Was prepared.

Experimental Example 1 Experiment Example 2 Experiment Example 3 Experiment Example 4 Experimental Example 5 Low density polyethylene 100wt% 70wt% 70wt% 40wt% 80wt% Polyolefin elastomer 0 wt% 30wt% 30wt% 60wt% 20wt% Wood flour 20.0 phr 30.0 phr 10.0 phr 10.0 phr 20.0 phr Calcium carbonate 20.0 phr 10.0 phr 15.0 phr 15.0 phr 10.0 phr Magnesium hydroxide 15.0 phr 15.0 phr 30.0 phr 30.0 phr 25.0 phr Calcium stearate 0.3 phr 0.5 phr 1.0 phr 0.5 phr 0.5 phr Polyethylene wax 0.5 phr 1.0 phr 1.0 phr 0.5 phr 1.0 phr Polyethylene maleate anhydride 3.0 phr 5.0 phr 3.0 phr 3.0 phr 5.0 phr Antioxidant 0.3 phr 0.5 phr 0.5 phr 0.3 phr 0.3 phr

For the resin composition for high-absorption back coating according to Experimental Examples 1 to 5 described above, as shown in Table 2 below, density, MI, combustibility, heavy metal (MS202-02), odor (MS300-34), VOC ( MS300-55) and sound absorbing and insulating properties were evaluated.

Experimental Example 1 Experiment Example 2 Experiment Example 3 Experiment Example 4 Experimental Example 5 density 1.09 1.02 1.10 1.09 1.08 MI(g/10min) 8.8 5.3 10.7 12.4 11.6 Combustibility (mm/min) Good Bad Good Good Good Heavy Metal (MS201-02) Good Good Good Good Good Smell (MS300-34) Good Good Good Good Good VOC(MS300-55) Good Good Good Good Good

5 is a sound absorbing and insulating test result for specimens prepared using the high sound absorption back coating resin composition according to Experimental Example 2 and Experimental Example 5 of the present application.

Referring to FIG. 5, a specimen was prepared using the high-absorption back coating resin composition according to Experimental Example 2 and Experimental Example 5, and a resin composition on the market (Comparative Example in FIG. Transmission loss according to frequency was measured for a specimen using 50 wt% of inorganic substances (barium sulfide, aluminum oxide, etc.).

As can be seen in Figure 5, compared to the comparative example, it can be confirmed that the resin compositions of Experimental Example 2 and Experimental Example 5 have high sound-absorbing and sound-absorbing properties, especially in the 500 ~ 1250Hz band. I can confirm.

In addition, in the case of Experimental Example 5, it can be confirmed that it has high sound-absorbing and sound-insulating properties even compared to Experimental Example 2.

As described above, the present invention has been described in detail using preferred embodiments, but the scope of the present invention is not limited to specific embodiments, and should be interpreted by the appended claims. In addition, those who have acquired ordinary knowledge in this technical field should understand that many modifications and variations are possible without departing from the scope of the present invention.

10, 12: core
20, 22: shell
110: first substrate
115: high sound absorption back coating layer
120: second substrate
130: nylon yarn

Claims (3)

Base resins including low-density polyethylene and polyolefin elastomers;
A filler mixed with the base resin, added 25 to 40 wt% of the base resin, and containing wood powder and calcium carbonate (CaCO _{3 );}
A flame retardant mixed with the base resin, added 15 to 30 wt% of the base resin _{, and containing magnesium hydroxide (MgOH 2 );}
A lubricant mixed with the base resin, added in an amount of 0.8 to 2 wt% compared to the base resin, and including calcium stearate and polyethylene wax;
A coupling agent mixed with the base resin and added in an amount of 3 to 5 wt% compared to the base resin, and comprising polyethylene maleic anhydride;
An antioxidant mixed with the base resin and added in an amount of 0.3 to 0.5 wt% compared to the base resin; And
A resin composition for back coating with high sound absorption, comprising an additive mixed with the base resin.
Compounding the resin composition according to claim 1; And
A method for producing a high-absorption backcoat comprising the step of providing the compounded resin composition on a substrate to prepare a backcoat with high sound-absorption.

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