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KR-20260065028-A - High heat resistance, high strength and lightweight composite, and automotive interior parts using the same

KR20260065028AKR 20260065028 AKR20260065028 AKR 20260065028AKR-20260065028-A

Abstract

The present invention relates to a high-heat-resistant, high-rigidity lightweight composite material and an automotive interior part to which the same is applied, comprising: a foamed sheet having a first surface and a second surface and formed from a polyester resin composition; and a composite material comprising a nonwoven fabric laminated on at least one of the first surface and the second surface of the foamed sheet and comprising natural fibers and low-melting point fibers.

Inventors

  • 허미
  • 서영훈
  • 박준우

Assignees

  • 주식회사 휴비스

Dates

Publication Date
20260508
Application Date
20241031

Claims (16)

  1. A foamed sheet having a first surface and a second surface and formed of a polyester resin composition; and A composite material comprising a nonwoven fabric including natural fibers and low-melting point fibers, laminated on at least one of the first and second surfaces of a foam sheet.
  2. In paragraph 1, The nonwoven fabric is a composite material laminated on both sides of the first and second surfaces of the foam sheet.
  3. In paragraph 1, A composite material in which the weight of the nonwoven fabric is 200 to 500 g/m².
  4. In paragraph 1, The nonwoven fabric is a composite material comprising 10 to 90 weight% of natural fibers and 10 to 90 weight% of low-melting point fibers.
  5. In paragraph 1, The nonwoven fabric is a composite material further comprising 0 to 50 weight percent of polypropylene fibers.
  6. In paragraph 1, A composite material in which a nonwoven fabric is manufactured through needle punching, and a nonwoven fabric and a foam sheet are laminated.
  7. In paragraph 6, A composite material in which the closed cells of a foam sheet are destroyed to form open cells through needle punching.
  8. In paragraph 1, A composite material in which the natural fiber is linen fiber and the low-melting point fiber is low-melting point polyester fiber.
  9. In paragraph 1, The polyester resin composition of the foamed sheet is a composite material comprising a polyester resin, a thickener, a nucleating agent, and a foaming agent.
  10. In Paragraph 9, A composite material having an intrinsic viscosity of 0.65 to 1 dL/g of polyester resin and a molecular ratio of 10,000 or more with a molecular weight of 60% or more based on the total weight of the polyester resin.
  11. In paragraph 1, A composite material having a foam sheet weight of 200 to 500 g/m², a foam sheet density of 80 to 400 kg/m³, a foam sheet thickness of 1 to 3.5 mm, or a foam sheet cell size of 100 to 700 μm.
  12. In paragraph 1, A composite material having a weight of 600 to 1500 g/m².
  13. Automotive interior parts using a composite material according to Paragraph 1.
  14. In Paragraph 13, Automotive interior parts using composite materials, wherein the peel strength between the foam sheet and the non-woven fabric is 5 N/25 mm or more.
  15. In Paragraph 13, Automotive interior parts made of composite materials have a flexural strength of 29 N or more under a maximum load.
  16. In Paragraph 13, An automotive interior part having a change in height of detachment from a flat surface of 1 mm or less due to warping occurring during a heat resistance test of an automotive interior part made of composite material under conditions of 90°C and 3 hours.

Description

High heat resistance, high strength and lightweight composite, and automotive interior parts using the same The present invention relates to a high-heat-resistant, high-rigidity lightweight composite material and an automotive interior part applying the same. Automotive interior materials use PP (Polypropylene) boards, natural fiber reinforced boards (HS Felt), glass fiber PP boards, PU (Polyurethane) foam, etc. as base materials, and PET nonwoven fabrics, etc. as surface and backing materials. Automotive parts are manufactured through a molding process using composite materials formed by combining the base material and the surface material. Recently, due to eco-friendly trends, there is an increasing need for lightweight materials that can reduce fuel consumption, recyclable materials that can comply with European ELV regulations, and single materials that can be recycled after scrapping the vehicle. Automotive interior materials utilize a foamed layer as a substrate for lightweighting, and a single material can be manufactured by combining a PET foamed layer substrate with a PET nonwoven fabric. The molding process in the domestic automotive industry primarily uses cold forming, and single-material composites combining a PET foamed layer substrate and a PET nonwoven fabric exhibit heat resistance performance of approximately 80°C when this conventional molding method is applied. To achieve high heat resistance of over 90°C using a single PET material, the molding process must be changed to a hot forming process; however, due to the high equipment investment costs involved, commercialization in Korea is currently difficult. In domestic molding processes, a PET foam substrate can be utilized to manufacture a composite material with a reinforcing nonwoven fabric to complement high rigidity and heat resistance. Required performance characteristics for application as automotive interior materials include, for example, physical properties such as moldability, peel strength, flexural strength, and heat resistance. Figure 1 is a schematic diagram of a composite material according to the present invention. FIG. 2 is a schematic diagram of a needle punching process according to the present invention. The present invention will be described in detail below. The present invention relates to a high-heat-resistant, high-rigidity, lightweight composite material, and the composite material according to the present invention may be composed of a foamed sheet and a non-woven fabric, etc. The foam sheet may be formed from a polyester resin composition, having a core substrate layer having a plurality of cells and a predetermined thickness, a first surface (e.g., an upper surface) and a second surface (e.g., a lower surface). The nonwoven fabric can be laminated on at least one of the first and second sides of a foamed sheet as a surface layer and/or back layer having a predetermined thickness, and preferably can be laminated on both sides of the first and second sides of the foamed sheet. Preferably, as shown in FIG. 1, the composite material may have a three-layer laminated structure composed of nonwoven fabric/foamed sheet/nonwoven fabric from the top or bottom, and more preferably, may have a three-layer laminated structure composed of natural fiber nonwoven fabric/PET foamed sheet/natural fiber nonwoven fabric. The nonwoven fabric laminated on the upper surface of the foam sheet and the nonwoven fabric laminated on the lower surface of the foam sheet may be the same or different in terms of material, composition, specifications, physical properties, etc., and preferably may be the same. By combining a foam sheet and a non-woven fabric, it is possible to achieve weight reduction while maintaining rigidity compared to cases where the foam sheet or the non-woven fabric is used alone. For example, if only the non-woven fabric is used without a foam sheet, the lightness and rigidity (e.g., maximum bending load) may be reduced. In addition to the foamed sheet and nonwoven fabric described above, the composite material may optionally include other layers, such as a coating layer, a resin layer, a fiber layer, and/or an adhesive layer, as needed. The nonwoven fabric may be a natural fiber nonwoven fabric containing natural fibers. By using a natural fiber nonwoven fabric, heat resistance of 90°C can be secured even with cold forming. For example, linen fibers can be used as natural fibers. The content of natural fibers in the nonwoven fabric may be 10 to 90 weight%, 15 to 80 weight%, 20 to 70 weight%, 25 to 60 weight%, or 30 to 50 weight% based on the total weight of the nonwoven fabric. In addition to natural fibers, the nonwoven fabric may additionally include low melting point (LM) fibers. LM fibers may refer to fibers with a melting point of 230°C or lower. The content of LM fibers in the nonwoven fabric may be 10 to 90 weight%, 15 to 80 weight%, 20 to 70 weight%, 25 to 60 weight%, or 30 to 50 weight% based on the total wei