阅读说明：本技术 包含低熔点聚酯树脂的聚酯复合体及其制备方法 (Polyester composite comprising low-melting polyester resin and method for producing same ) 是由 许娓 咸镇洙 李光熙 金宇镇 河相勳 崔钟汉 于 2019-09-02 设计创作，主要内容包括：本发明涉及包含低熔点聚酯树脂的聚酯复合体、其制备方法及包含其的汽车内饰材料。本发明的聚酯复合体包括在聚酯发泡片材与纤维垫层之间包含低熔点聚酯树脂的树脂层,从而在不降低强度、耐久性等物性的情况下也可以提高层叠体之间的粘结性。(The present invention relates to a polyester composite comprising a low-melting polyester resin, a method for preparing the same, and an automotive interior material comprising the same. The polyester composite of the present invention includes a resin layer containing a low-melting polyester resin between a polyester foamed sheet and a fiber mat layer, and can improve the adhesion between laminates without deteriorating the physical properties such as strength and durability.)

1. A polyester composite comprising:

average weight of 400g/m²To 900g/m²The polyester foamed sheet of (1);

formed on one or both sides of the foamed sheet and having an average weight of 20g/m²To 200g/m²The polyester resin layer of (1); and

a structure in which a fiber mat layer is laminated on one or both surfaces of a polyester resin layer,

the melting point of the polyester resin layer is 180 ℃ to 250 ℃ or the softening point is 100 ℃ to 150 ℃,

the peel strength of the polyester resin layer and the fiber cushion layer was 1kgf/cm²Or more.

2. The polyester composite according to claim 1, wherein the polyester resin layer comprises a polyester resin having one or more forms selected from a powder, a film and a mesh.

3. The polyester composite according to claim 1, wherein the average weight per unit area of the polyester resin layer is 50g/m²To 200g/m ²Within the range.

4. The polyester composite according to claim 2, wherein in the case where the polyester resin layer comprises a resin powder, the average particle diameter of the polyester resin powder is 0.1 μm to 5 μm.

5. The polyester composite according to claim 1, wherein the polyester resin layer comprises repeating units represented by the following chemical formulae 1 and 2:

[ chemical formula 1]

[ chemical formula 2]

In the above chemical formula 1 and chemical formula 2,

m and n represent the mole fraction of the repeating unit contained in the low-melting polyester resin,

n is 0.05 to 0.5 based on m + n being 1.

6. The polyester composite according to claim 1, wherein the polyester foamed sheet is a polyethylene terephthalate foamed sheet.

7. A preparation method of a polyester composite comprises the step of attaching a polyester foaming sheet and a fiber cushion layer,

comprising a polyester resin layer on one or both sides of a polyester foamed sheet or a fiber mat layer,

in the step of attaching the polyester foamed sheet and the fiber mat layer, the polyester resin layer is preheated and the polyester foamed sheet and the fiber mat layer are attached by using a mold,

the average weight of the polyester foamed sheet was 400g/m²To 900g/m²，

The average weight of the polyester resin layer was 20g/m ²To 200g/m²，

The polyester resin layer contains a polyester resin having a melting point of 180 ℃ to 250 ℃ or a softening point of 100 ℃ to 150 ℃.

8. The method of preparing a polyester composite according to claim 7, wherein the surface temperature of the polyester resin layer formed in the polyester foamed sheet or the fiber mat layer preheated in the attaching step is 120 ℃ to 160 ℃.

9. The method of manufacturing a polyester composite according to claim 7, wherein in the laminating step, the molding is performed by applying pressure using a mold having a temperature of 40 ℃ to 120 ℃.

10. The method for preparing a polyester composite according to claim 7, wherein the polyester resin layer comprises repeating units represented by the following chemical formulae 1 and 2:

[ chemical formula 1]

[ chemical formula 2]

In the above chemical formula 1 and chemical formula 2,

m and n represent the mole fraction of the repeating unit contained in the low-melting polyester resin,

n is 0.05 to 0.5 based on m + n being 1.

11. The method of manufacturing a polyester composite according to claim 7, wherein the step of bonding the polyester foamed sheet and the fiber mat layer includes preheating a polyester resin layer formed on the polyester foamed sheet and applying pressure to the fiber mat layer by using a mold.

12. The method of manufacturing a polyester composite according to claim 7, wherein the step of bonding the polyester foamed sheet and the fiber mat layer includes preheating the polyester resin layer formed on the fiber mat layer and applying pressure using a mold to bond the polyester foamed sheet.

13. The method for producing a polyester composite according to claim 7, wherein the polyester resin layer is formed of a resin composition containing a polyester resin, and the polyester resin has one or more forms selected from a powder, a film, and a mesh.

14. An automotive interior material comprising the polyester composite of claim 1.

Technical Field

The present invention relates to a polyester composite comprising a low-melting polyester resin and a method for producing the same.

Background

Automotive interior materials, particularly for application to interior materials, require characteristics such as lightness, cushioning properties, heat insulation properties, moldability, high strength, and energy saving. Low-melting fiber (low-melting fiber) has been used as a conventional automotive interior material. The low-melting-point resin is bonding fiber which is melted at a temperature of 100 ℃ to 200 ℃ lower than that of common polyester fiber melted at a temperature of 265 ℃ or higher, does not need an environment-friendly material of a chemical bonding agent, and has the advantage of easy construction. When the base layer made of a thermoplastic resin, the flexible polyurethane foam layer, and the layer made of a fiber layer are attached to such a low-melting-point resin fiber layer as a laminate, the durability can be improved, and the production cost per unit volume can be reduced. Further, an automotive interior material having a low dimensional change rate and excellent sound absorption can be obtained.

However, when the flexible polyurethane foam layer is used as the laminate, the thickness is increased in order to satisfy the physical properties of the automotive interior material, and a large amount of binder is used in order to achieve the combination of substances having different components during the production process, so that the VOC amount is increased and the laminate cannot be reused.

Therefore, there is a need for an automotive interior material of a single material structure that is excellent in durability and can be produced at a reduced cost.

Disclosure of Invention

Technical problem

The invention provides a polyester composite which comprises a resin layer containing low-melting point polyester resin and has excellent adhesion between the polyester resin layer and a fiber cushion layer, a preparation method thereof and an automobile interior material comprising the same.

Technical scheme

Accordingly, one embodiment of the present invention provides a polyester composite comprising:

average weight of 400g/m²To 900g/m²The polyester foamed sheet of (1);

the average weight of the foamed sheet formed on one or both sides thereof was 20g/m²To 200g/m²The polyester resin layer of (1); and

a structure in which a fiber mat layer is laminated on one or both surfaces of a polyester resin layer,

the melting point of the polyester resin layer is 180 ℃ to 250 ℃ or the softening point is 100 ℃ to 150 ℃,

the peel strength of the polyester resin layer and the fiber cushion layer was 1kgf/cm ²Or more.

In addition, an embodiment of the present invention provides a method for preparing a polyester composite, characterized in that,

comprises the step of attaching a polyester foaming sheet and a fiber cushion layer,

comprising a polyester resin layer on one or both sides of a polyester foamed sheet or a fiber mat layer,

in the step of attaching the polyester foamed sheet and the fiber mat layer, the polyester resin layer is preheated and the polyester foamed sheet and the fiber mat layer are attached by using a mold,

the average weight of the polyester foamed sheet was 400g/m²To 900g/m²，

The average weight of the polyester resin layer was 20g/m²To 200g/m²，

The polyester resin layer contains a polyester resin having a melting point of 180 ℃ to 250 ℃ or a softening point of 100 ℃ to 150 ℃.

In addition, an embodiment of the present invention provides an automotive interior material including the polyester composite.

ADVANTAGEOUS EFFECTS OF INVENTION

The polyester composite of the present invention includes a resin layer containing a low-melting polyester resin between a polyester foamed sheet and a fiber mat layer, and thus can improve the adhesion between the fiber mat layer and the foamed resin without deteriorating the physical properties such as strength and durability.

Drawings

FIG. 1 is a cross-sectional view of a polyester composite of the present invention.

Detailed Description

While the invention is susceptible to various modifications and alternative embodiments, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail.

However, it is not intended to limit the present invention to the specific embodiments, but rather, the present invention is to be construed as including all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention.

In the present invention, terms such as "including" or "having" should be understood to specify the presence of stated features, integers, steps, actions, structural elements, components, or groups thereof, but not to preclude the presence or addition of one or more other features, integers, steps, actions, structural elements, components, or groups thereof.

In the present invention, "part by weight" means a weight ratio between the respective components.

Meanwhile, in the present invention, the "melting point" refers to a temperature at which a resin in a solid phase starts to melt into a liquid phase.

An object of the present invention is to provide a polyester composite and a method for preparing the same, in which a polyester resin layer including a low-melting polyester resin is formed on one surface of a polyester foamed sheet to improve adhesion between a fiber mat layer and the polyester resin layer, and durability is improved by preheating the polyester resin foamed sheet and then bonding the polyester resin foamed sheet to the fiber mat layer.

Specifically, the polyester composite of the present invention includes low melting point polyester resin powder in the polyester foamed sheet, thereby improving the adhesion between the fiber mat layer and the polyester resin foamed sheet, and may improve durability by being attached to the fiber mat layer after preheating the polyester resin foamed sheet.

The foamed sheet of the present invention is described in detail below.

Polyester composite

The present invention provides a polyester composite, comprising:

average weight of 400g/m²To 900g/m²The polyester foamed sheet of (1);

the average weight of the foamed sheet formed on one or both sides thereof was 20g/m²To 200g/m²The polyester resin layer of (1); and

a structure in which a fiber mat layer is laminated on one or both surfaces of a polyester resin layer,

the melting point of the polyester resin layer is 180 ℃ to 250 ℃ or the softening point is 100 ℃ to 150 ℃,

the peel strength of the polyester resin layer and the fiber cushion layer was 1kgf/cm²Or more.

As shown in fig. 1, the polyester composite of the present invention has a structure in which a polyester resin layer 20 is formed between the polyester foamed sheet 10 and the fiber mat layer 30. Specifically, a polyester resin layer having a melting point of 180 to 250 ℃ or a softening point of 100 to 150 ℃ may be formed between the polyester foamed sheet and the fiber mat layer. More specifically, a polyester resin layer containing one or more of powder, film and mesh may be formed between the polyester foamed sheet and the fiber mat layer.

Further, the polyester composite of the present invention may have a peel strength between the polyester resin layer and the fiber mat layer of 1kgf/cm²Or more. Specifically, the peel strength of the polyester resin layer and the fibrous blanket may be 1kgf/cm²Or more, 1.2kgf/cm²Or more, 1.3kgf/cm²Or more, 1.4kgf/cm²Or more, 1.5kgf/cm²Or more than, 1kgf/cm²To 3kgf/cm²、1kgf/cm²To 2.5kgf/cm²、1kgf/cm²To 1.8kgf/cm²、1kgf/cm²To 1.7kgf/cm²、1kgf/cm²To 1.6kgf/cm²、1.3kgf/cm²To 3kgf/cm²、1.3kgf/cm²To 2.5kgf/cm²、1.3kgf/cm²To 1.8kgf/cm²Or 1.3kgf/cm²To 1.7kgf/cm²。

Further, the amount of Volatile Organic Compounds (VOCs) discharged from the polyester composite of the present invention may be 10ppm or less. Specifically, the emission amount of the volatile organic compound of the above-described polyester composite may be 10ppm or less, 8ppm or less, 6ppm or less, 5ppm or less, 4ppm or less, 2ppm or less, 0.5ppm to 10ppm, 0.5ppm to 8ppm, 0.5ppm to 6ppm, 0.5ppm to 5ppm, 0.5ppm to 4ppm, 0.5ppm to 3ppm, 0.5ppm to 2ppm, or 0.5ppm to 1 ppm.

The components of the polyester composite of the present invention will be described in more detail below.

First, the polyester foamed sheet used in the present invention is a layer formed by foaming a polyester resin, and has the effect of improving the bending strength and the bending modulus without increasing the weight per unit area of the polyester composite too much.

In this case, the average weight per unit area of the polyester foamed sheet may be 400g/m²To 900g/m²Within the range of (1). Specifically, the average weight per unit area of the polyester foamed sheet may be 400g/m²To 850g/m²、400g/m²To 800g/m²、400g/m²To 750g/m²、400g/m²To 700g/m²、400g/m²To 650g/m²、400g/m²To 600g/m²、400g/m²To 550g/m²、400g/m²To 500g/m²、500g/m²To 900g/m²、500g/m²To 850g/m²、500g/m²To 800g/m²、500g/m²To 750g/m²、500g/m²To 700g/m²、500g/m²To 650g/m²、500g/m²To 600g/m²、500g/m²To 550g/m²、600g/m²To 900g/m²、600g/m²To 850g/m²、600g/m²To 800g/m²、600g/m²To 750g/m²、600g/m²To 700g/m²、600g/m²To 650g/m²、700g/m²To 900g/m²、700g/m²To 850g/m²、700g/m²To 800g/m²、700g/m²To 750g/m²、450g/m²To 700g/m²、450g/m²To 650g/m²、450g/m²To 600g/m²、550g/m²To 850g/m²Or 550g/m²To 700g/m². Since the polyester foamed sheet is included, it has an advantage of excellent mechanical strength as an environmentally friendly material which is excellent in flame retardancy and chemical resistance and does not emit environmental hormones, in particular.

However, since the melt strength of the polyester resin is rapidly decreased with an increase in temperature and the temperature range having a melt viscosity capable of foaming is very narrow, a special technique for increasing the melt viscosity and a precise temperature control device are required for foaming the polyester resin, and thus it has been difficult to prepare a foamed sheet using the polyester resin in the past. However, in the present invention, the foamed sheet was successfully prepared by finely adjusting the viscosity and temperature of the polyester resin.

For example, the polyester foamed sheet may be formed by extrusion foaming. The foaming method is generally classified into bead foaming or extrusion foaming, and the bead foaming is a method of preparing a product by first foaming resin beads by heating, curing the resin beads for a suitable period of time, injecting the cured resin beads into a plate-shaped or barrel-shaped mold, heating the mold again, and welding and molding the cured resin beads by second foaming. In contrast, extrusion foaming is to melt a resin by heating and continuously extrude and foam the resin melt, so that the process steps can be simplified, mass production can be achieved, cracks, granular fracture phenomena, and the like occurring between beads during bead foaming can be prevented, and more excellent bending strength and extrusion strength can be achieved.

The polyester foamed sheet can have an average thickness within a range in which the weight of the base material is reduced without affecting the bending modulus and the bending strength of the polyester composite. Specifically, the above polyester foamed sheet may have an average thickness ranging from 1mm to 9mm, 1mm to 8mm, 1mm to 7mm, 1mm to 6mm, 1mm to 5mm, 1mm to 4mm, 1mm to 3mm, 2mm to 10mm, 2mm to 9mm, 2mm to 8mm, 2mm to 7mm, 2mm to 6mm, 2mm to 5mm, 2mm to 4mm, 2mm to 3mm, 3mm to 9mm, 3mm to 8mm, 3mm to 7mm, 3mm to 6mm, 3mm to 5mm, 4mm to 9mm, 4mm to 8mm, 4mm to 7mm, 4mm to 6mm, 4mm to 5mm, 5mm to 10mm, 5mm to 8mm, 5mm to 7mm, 6mm to 9mm, 6mm to 8mm, 7mm to 10mm, 8mm to 10mm, or 9mm to 10 mm.

Meanwhile, 90% or more of the cells of the above polyester foamed sheet are closed cells (DIN ISO4590), and the measurement value according to DIN ISO4590 of the above foamed sheet may mean that 90% (v/v) or more of the cells are closed cells. For example, the closed cell ratio in the above foamed sheet may be 90% to 100% or 95% to 99% on average of the entire cells included in the foamed sheet. The polyester foamed sheet of the present invention has closed cells within the above range, and thus can realize excellent durability, rigidity and strength characteristics when a polyester composite is produced.

In this case, the average cell number of the polyester foamed sheet was 1mm²May contain cells from 1 to 30, cells from 3 to 25, or cells from 3 to 20. Also, the average size of the cells may be in the range of 100 μm to 800 μm. For example, the average size of the above cells may be in the range of 100 μm to 700 μm, 200 μm to 600 μm, or 300 μm to 600 μm. Wherein, for example, the deviation in cell size may range from 5% or less, from 0.1% to 5%, from 0.1% to 4%, or from 0.1% to 3%. It can be seen that the polyester foamed sheet of the present invention is formed by uniformly foaming a plurality of cells having a uniform size.

In one aspect, the polyester resin used in the foamed sheet of the present invention may be prepared by a polycondensation reaction of terephthalic acid and 1, 4-butanediol, and each includes an aromatic or aliphatic polyester. On the other hand, the polyester resin may include flame retardant polyester, biodegradable polyester, elastic polyester, reusable polyester, and the like. For example, the polyester resin that may be used in the present invention may be one or more selected from the group consisting of polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polylactic acid (PLA), polyglycolic acid (PGA), polypropylene (PP), Polyethylene (PE), polyethylene adipate (PEA), Polyhydroxyalkanoate (PHA), polytrimethylene terephthalate (PTT), and polyethylene naphthalate (PEN). Specifically, the polyester foamed sheet of the present invention may be a pet (polyethylene terephthalate) foamed sheet. Because of using the PET, the environment-friendly PET is environment-friendly and easy to reuse.

The fiber mat layer used in the present invention is a layer formed of fibers, and serves as a surface layer while increasing the hardness of the base material while controlling the weight per unit area of the polyester composite. In this case, the fibrous blanket may be formed on one or both sides of the polyester foamed sheet.

In this case, the fiber mat layer may be one or more selected from the group consisting of a base fabric, a non-woven fabric, a mesh (Web), a woven fabric, a lamb skin, a velvet, and the like, and more specifically, the fiber mat layer may include polyethylene terephthalate and may be in the form of a base fabric, a non-woven fabric, a mesh (Web). The polyester composite of the present invention includes a fibrous mat layer formed of the polyethylene terephthalate resin, and thus the bending strength and bending modulus of the polyester composite can be improved.

For example, the average weight per unit area of the fibrous mat layer may be 110g/m²To 140g/m²Within the range, specifically, may be 110g/m²To 135g/m²、110g/m²To 130g/m²、110g/m²To 125g/m²、115g/m²To 140g/m²、115g/m²To 135g/m²、115g/m²To 130g/m²Or 118g/m²To 122g/m²The adjustment is carried out within the range. By adjusting the average weight per unit area of the fibrous mat layerWithin the above range, the weight can be prevented from being excessively increased, and the excellent hardness of the base material can be maintained.

Also, the fibrous blanket of the present invention may further comprise inorganic fibers. The inorganic fibers may include one or more of glass fibers, crystals of metal or metal oxide in needle-like form, and carbon fibers. Specifically, the inorganic fiber may be Glass Fiber (GF).

Also, the average diameter of the above inorganic fibers may be in the range of 10 μm to 1000 μm, more specifically, may be in the range of 100 μm to 900 μm, 100 μm to 800 μm, 100 μm to 700 μm, 100 μm to 600 μm, 100 μm to 500 μm, 100 μm to 400 μm, 200 μm to 1, 000 μm, 200 μm to 800 μm, 200 μm to 600 μm, 200 μm to 400 μm, 300 μm to 800 μm, 400 μm to 600 μm, 500 μm to 1000 μm, 300 μm to 500 μm, or 150 μm to 300 μm. In the present invention, the average diameter of the inorganic fibers contained in the fibrous blanket is controlled within the above range even if less than 150g/m is included²The low average weight fibrous blanket of (a) can also provide a polyester composite having high strength and high durability.

Then, in the present invention, the polyester resin layer is disposed between the polyester foamed sheet and the fiber mat layer, and performs a function of improving the adhesive force between the polyester foamed sheet and the fiber mat layer.

For example, the melting point (Tm) of the polyester resin layer may be 180 ℃ to 250 ℃ or the melting point may be absent. Specifically, the above melting point (Tm) may be 180 ℃ to 250 ℃, 185 ℃ to 245 ℃, 190 ℃ to 240 ℃, 180 ℃ to 200 ℃, 200 ℃ to 230 ℃, or 195 ℃ to 230 ℃, or absent.

Also, the softening point of the above polyester resin layer may be 100 ℃ to 150 ℃, specifically, 100 ℃ to 130 ℃, 118 ℃ to 128 ℃, 120 ℃ to 125 ℃, 121 ℃ to 124 ℃, 124 ℃ to 128 ℃, or 119 ℃ to 126 ℃.

Further, the polyester resin layer may have a glass transition temperature (Tg) of 50 ℃ or more. Specifically, the above glass transition temperature may be 50 ℃ to 80 ℃, more specifically, may be 61 ℃ to 69 ℃, 60 ℃ to 65 ℃, 63 ℃ to 67 ℃, 61 ℃ to 63 ℃, 63 ℃ to 65 ℃, 65 ℃ to 67 ℃, or 62 ℃ to 67 ℃.

Also, the polyester resin layer may have an intrinsic viscosity (I.V) of 0.5dl/g to 0.75 dl/g. Specifically, the intrinsic viscosity (I.V) of the above polyester resin layer may be 0.6dl/g to 0.65dl/g, 0.65dl/g to 0.70dl/g, 0.64dl/g to 0.69dl/g, 0.65dl/g to 0.68 dl/g, 0.67dl/g to 0.75dl/g, 0.69dl/g to 0.72dl/g, 0.7dl/g to 0.75dl/g, or 0.63dl/g to 0.67 dl/g.

For example, the average weight per unit area of the polyester resin layer may be 20g/m²To 200g/m²Within the range. Specifically, the average weight per unit area of the polyester resin layer may be 20g/m²To 190g/m²、20g/m²To 180g/m²、20g/m²To 160g/m²、20g/m²To 140g/m²、20g/m²To 120g/m²、20g/m²To 100g/m²、50g/m²To 190g/m²、50g/m²To 180g/m²、50g/m²To 160g/m²、50g/m²To 140g/m²、50g/m²To 120g/m²、50g/m²To 100g/m²、100g/m²To 190g/m²、100g/m²To 180g/m²、100g/m²To 160g/m²、100g/m²To 140g/m²、100g/m²To 120g/m²、80g/m²To 150g/m²Or 80g/m²To 100g/m²Within the range. The present invention can prevent an excessive increase in the weight of the polyester composite by controlling the average weight per unit area of the polyester resin layer within the above range, can realize a suitable adhesive property within the above weight range of the fiber mat layer and the polyester foamed sheet, and can suppress the peeling between the fiber mat layer and the polyester foamed sheet in long-term use.

The polyester resin layer of the present invention comprises a polyester resin having a melting point of 180 to 250 c or a softening point of 100 to 150 c, thereby playing a role of improving the adhesion of the polyester foamed sheet to the polyester resin.

Specifically, the polyester resin layer may include repeating units represented by chemical formulas 1 and 2. Accordingly, the melting point (Tm), softening point and glass transition temperature (Tg) of the polyester resin layer can be adjusted within the above ranges as described above, and the polyester resin layer whose physical properties are adjusted within the above ranges can exhibit excellent adhesion:

[ chemical formula 1]

[ chemical formula 2]

In the above chemical formula 1 and chemical formula 2,

m and n represent the mole fraction of the repeating unit contained in the low-melting polyester resin,

n is 0.05 to 0.5 based on m + n being 1.

The polyester resin layer of the present invention may have a structure including a repeating unit represented by chemical formula 1 and chemical formula 2. The repeating unit represented by the above chemical formula 1 represents a repeating unit of polyethylene terephthalate (PET), and the repeating unit represented by the chemical formula 2 performs a function of improving tear characteristics of a polyester resin including the repeating unit of polyethylene terephthalate (PET). Specifically, the repeating unit represented by the above chemical formula 2 secures a space by including a methyl group (-CH3) as a branch in the propylene chain bound with the terephthalate to rotate the main chain of the polymerized resin, so that the melting point (Tm) can be lowered by increasing the degree of freedom of the main chain and inducing a decrease in crystallinity of the resin. This can produce the same effect as in the case of using isophthalic acid (IPA) containing an asymmetric aromatic ring in order to lower the melting point (Tm) of the crystalline polyester resin in the past.

At this time, in the above polyester resin, a repeating unit represented by chemical formula 2 may be included as a main repeating unit, and the repeating unit of chemical formula 2 serves to lower the melting point (Tm) of the resin together with the repeating unit of chemical formula 1 including an ester repeating unit. Specifically, the polyester resin layer of the present invention may include 0.5 to 1 of the repeating unit represented by chemical formula 1 and chemical formula 2, specifically, 0.55 to 1, 0.6 to 1, 0.7 to 1, 0.8 to 1, 0.5 to 0.9, 0.5 to 0.85, 0.5 to 0.7, or 0.6 to 0.95 of the repeating unit represented by chemical formula 1 and chemical formula 2, based on the total mole fraction of the resin being 1.

And, in the case where the total percentage of the repeating units represented by chemical formula 1 is 1 (m + n ═ 1), the amount of the repeating unit represented by chemical formula 2 contained in the polyester resin layer may be 0.05 to 0.5, specifically, 0.05 to 0.4, 0.1 to 0.4, 0.15 to 0.35, or 0.2 to 0.3.

Specifically, the polyester resin layer may include a polyester resin having one or more forms of powder, film, and mesh. More specifically, the polyester resin layer may include a polyester resin having a form of powder, film, or mesh. For example, the above polyester resin powder may be in the form of a powder of a polyester resin having a melting point of 180 ℃ to 250 ℃ or a softening point of 100 ℃ to 150 ℃.

And, in the case where the polyester resin layer includes the polyester resin powder, the average particle diameter of the polyester resin powder may be in a range of 1 μm to 5 μm, and specifically, the average particle diameter of the polyester resin powder may be in a range of 1 μm to 4.5 μm, 1 μm to 4 μm, 1 μm to 3.5 μm, 1 μm to 3 μm, 1.5 μm to 5 μm, 1.5 μm to 4.5 μm, 1.5 μm to 4 μm, 1.5 μm to 3.5 μm, 1.5 μm to 3 μm, 2 μm to 5 μm, 2 μm to 4.5 μm, 2 μm to 4 μm, 2 μm to 3.5 μm, 2 μm to 3 μm, 3 μm to 5 μm, 3 μm to 4.5 μm, 2.5 μm to 4 μm, 3 μm to 3.5 μm, 4.5 μm to 2.5 μm, or 1.5 μm to 1 μm. In the present invention, the average particle diameter of the polyester resin powder is controlled within the above range, so that it can be uniformly dispersed when dispersed on the surface of the fibrous blanket.

The polyester composite of the present invention can be applied to parts or decorations in the interior of an automobile in various ways. Specifically, the polyester composite can be suitably used for trunk interior materials, ceilings, tire covers, carpets, and covers. For example, when the interior material of the present invention is used for a ceiling of an automobile, the interior material is excellent in bending modulus of elasticity, has excellent durability, and can be reduced in weight, and therefore, can contribute to an improvement in fuel consumption of the vehicle. When the interior material of the present invention is used for a carpet, it is advantageous in that it is safe to the human body because the amount of VOC generated is small compared to conventional PVC.

Method for preparing polyester composite

In one embodiment of the present invention, there is provided a method for producing a polyester composite, the method for producing a polyester composite as described above,

comprises the step of attaching a polyester foaming sheet and a fiber cushion layer,

comprising a polyester resin layer on one or both sides of a polyester foamed sheet or a fiber mat layer,

in the step of attaching the polyester foamed sheet and the fiber mat layer, the polyester resin layer is preheated and the polyester foamed sheet and the fiber mat layer are attached by using a mold,

The average weight of the polyester foamed sheet was 400g/m²To 900g/m²，

The average weight of the polyester resin layer was 20g/m²To 200g/m²，

The polyester resin layer contains a polyester resin having a melting point of 180 ℃ to 250 ℃ or a softening point of 100 ℃ to 150 ℃.

The method for producing the polyester composite of the present invention is not particularly limited, but the polyester composite has a structure in which a polyester resin layer is formed between a polyester foamed sheet and a fiber mat layer. Specifically, a polyester resin layer having a melting point of 180 to 250 ℃ or a softening point of 100 to 150 ℃ may be formed between the polyester foamed sheet and the fiber mat layer. More specifically, a polyester resin layer containing one or more of powder, film and mesh may be formed between the polyester foamed sheet and the fiber mat layer.

For example, the step of attaching the polyester foamed sheet and the fibrous mat layer may be performed by heat fusion or heat bonding under pressure and heating. Specifically, the method comprises the steps of preheating a polyester resin layer which is formed on the polyester foaming sheet or the fiber cushion layer and has the melting point of 180-250 ℃ or the softening point of 100-150 ℃, and bonding the polyester foaming sheet and the fiber cushion layer by using a mould.

For example, in the step of bonding the polyester foamed sheet and the fiber mat layer, the fiber mat layer may be bonded by preheating the polyester resin layer formed on the polyester foamed sheet and applying pressure using a mold. In the step of bonding the polyester foamed sheet and the fiber mat layer, the polyester foamed sheet may be bonded by preheating the polyester resin layer formed on the fiber mat layer and applying pressure using a mold.

At this time, in the attaching step, the surface temperature of the polyester resin layer formed on the preheated polyester foamed sheet or the fiber mat layer may be 120 to 160 ℃. Specifically, the surface temperature of the polyester resin layer may be 120 ℃ to 155 ℃, 120 ℃ to 150 ℃, 120 ℃ to 145 ℃, 120 ℃ to 140 ℃, 120 ℃ to 120 ℃, 130 ℃ to 160 ℃, 130 ℃ to 155 ℃, 130 ℃ to 150 ℃, 130 ℃ to 145 ℃, 130 ℃ to 140 ℃, 140 ℃ to 160 ℃, 140 ℃ to 155 ℃, 140 ℃ to 150 ℃, 140 ℃ to 145 ℃, 125 ℃ to 150 ℃, 125 ℃ to 145 ℃, 125 ℃ to 135 ℃, 150 ℃ to 160 ℃, or 135 ℃ to 155 ℃.

Also, the polyester resin layer may be preheated by heating in a preheater at a temperature of 200 to 400 ℃ for 1 to 3 minutes. Specifically, the polyester resin layer may be preheated by heating in a preheating machine at 200 to 380 ℃, 200 to 360 ℃, 200 to 340 ℃, 200 to 320 ℃, 200 to 300 ℃, 200 to 250 ℃, 250 to 400 ℃, 250 to 380 ℃, 250 to 360 ℃, 250 to 340 ℃, 250 to 320 ℃, 250 to 300 ℃, or 250 to 350 ℃ for 1.5 to 2.5 minutes.

In the step of bonding the polyester foamed sheet and the fiber mat layer, the polyester foamed sheet and the fiber mat layer may be molded by applying pressure using a mold having a temperature of 40 to 120 ℃. At this time, a pressure higher than atmospheric pressure is applied. The molded article can be formed into a desired shape while applying heat and pressure simultaneously. Specifically, the temperature of the mold may be performed in the process of molding by the mold after preheating at a temperature of 40 to 110 ℃, 40 to 100 ℃, 40 to 90 ℃, 40 to 80 ℃, 40 to 70 ℃, 40 to 60 ℃, 50 to 120 ℃, 50 to 110 ℃, 50 to 100 ℃, 50 to 90 ℃, 50 to 80 ℃, 50 to 70 ℃, 50 to 60 ℃, 60 to 120 ℃, 60 to 100 ℃, 60 to 90 ℃, 60 to 80 ℃, 60 to 70 ℃, 70 to 110 ℃, 70 to 100 ℃, 80 to 110 ℃ or 90 to 100 ℃ for 1 to 3 minutes. The range of the applied pressure is not particularly limited, and may be, for example, in the range of 1.5 to 10 atmospheres or 2 to 5 atmospheres.

For example, the average weight per unit area of the polyester foamed sheet may be 400g/m²To 900g/m²Within the range. Specifically, the average weight per unit area of the polyester foamed sheet may be 400g/m ²To 850g/m²、400g/m²To 800g/m²、400g/m²To 750g/m²、400g/m²To 700g/m²、400g/m²To 650g/m²、400g/m²To 600g/m²、400g/m²To 550g/m²、400g/m²To 500g/m²、500g/m²To 900g/m²、500g/m²To 850g/m²、500g/m²To 800g/m²、500g/m²To 750g/m²、500g/m²To 700g/m²、500g/m²To 650g/m²、500g/m²To 600g/m²、500g/m²To 550g/m²、600g/m²To 900g/m²、600g/m²To 850g/m²、600g/m²To 800g/m²、600g/m²To 750g/m²、600g/m²To 700g/m²、600g/m²To 650g/m²、700g/m²To 900g/m²、700g/m²To 850g/m²、700g/m²To 800g/m²、700g/m²To 750g/m²、450g/m²To 700g/m²、450g/m²To 650g/m²、450g/m²To 600g/m²、550g/m²To 850g/m²Or 550g/m²To 700g/m². Since the polyester foamed sheet is included as described above, as an environmentally friendly substance excellent in flame retardancy and chemical resistance without emitting environmental hormones, in particular, an automotive interior material excellent in mechanical strength can be produced.

For example, the polyester resin layer may include repeating units represented by chemical formulas 1 and 2. Accordingly, the polyester resin layer, in which the melting point (Tm), softening point and glass transition temperature (Tg) of the polyester resin layer can be adjusted to the above ranges as described above, and physical properties can be adjusted to the above ranges, can exhibit excellent adhesion:

[ chemical formula 1]

[ chemical formula 2]

In the above chemical formula 1 and chemical formula 2,

m and n represent the mole fraction of the repeating unit contained in the low-melting polyester resin,

n is 0.05 to 0.5 based on m + n being 1.

At this time, in the above polyester resin layer, a repeating unit represented by chemical formula 2 for lowering the melting point (Tm) of the lipid together with a repeating unit represented by chemical formula 1 containing an ester repeating unit may be included as a main repeating unit. Specifically, the polyester resin layer of the present invention may include 0.5 to 1 of the repeating unit represented by chemical formula 1 and chemical formula 2, specifically, 0.55 to 1, 0.6 to 1, 0.7 to 1, 0.8 to 1, 0.5 to 0.9, 0.5 to 0.85, 0.5 to 0.7, or 0.6 to 0.95, based on the total mole fraction of the resin being 1.

In addition, the amount of the repeating unit represented by chemical formula 2 contained in the polyester resin layer may be 0.05 to 0.5, specifically, 0.05 to 0.4, 0.1 to 0.4, 0.15 to 0.35, or 0.2 to 0.3, based on 1(m + n ═ 1) of the total mole fraction containing the repeating unit represented by chemical formula 1.

For example, the melting point (Tm) of the above polyester resin layer may be 180 ℃ to 250 ℃, or the melting point may be absent. Specifically, the above melting point (Tm) may be 180 ℃ to 250 ℃, 185 ℃ to 245 ℃, 190 ℃ to 240 ℃, 180 ℃ to 200 ℃, 200 ℃ to 230 ℃, or 195 ℃ to 230 ℃ or absent.

Further, the softening point of the above polyester resin layer may be 100 ℃ to 150 ℃, specifically, may be 100 ℃ to 130 ℃, 118 ℃ to 128 ℃, 120 ℃ to 125 ℃, 121 ℃ to 124 ℃, 124 ℃ to 128 ℃, or 119 ℃ to 126 ℃.

Specifically, the polyester resin layer may be formed of a resin composition containing a polyester resin having one or more forms of powder, film, and mesh. More specifically, the polyester resin layer may be formed of a resin composition containing a polyester resin in the form of powder, film or web. For example, the above polyester resin powder may be obtained by coating a resin composition containing a powder of a polyester resin having a melting point of 180 ℃ to 250 ℃ or a softening point of 100 ℃ to 150 ℃.

According to the polyester composite prepared by the method for preparing a polyester composite of the present invention, the peel strength of the above polyester resin layer and the fiber mat layer may be 1kgf/cm²Or more. Specifically, the peel strength of the polyester resin layer and the fibrous blanket may be 1kgf/cm²Or more, 1.2kgf/cm²Or more, 1.3kgf/cm²Or more, 1.4kgf/cm²Or more, 1.5kgf/cm²Or more than, 1kgf/cm²To 3kgf/cm²、1kgf/cm²To 2.5kgf/cm²、1kgf/cm²To 1.8kgf/cm²、1kgf/cm²To 1.7kgf/cm²、1kgf/cm²To 1.6kgf/cm²、1.3kgf/cm²To 3kgf/cm²、1.3kgf/cm²To 2.5kgf/cm²、1.3kgf/cm²To 1.8kgf/cm²Or 1.3kgf/cm²To 1.7kgf/cm²。

Further, the amount of Volatile Organic Compounds (VOCs) discharged from the polyester composite produced by the method of the present invention may be 10ppm or less. Specifically, the emission amount of the volatile organic compound of the above-described polyester composite may be 10ppm or less, 8ppm or less, 6ppm or less, 5ppm or less, 4ppm or less, 2ppm or less, 0.5ppm to 10ppm, 0.5ppm to 8ppm, 0.5ppm to 6ppm, 0.5ppm to 5ppm, 0.5ppm to 4ppm, 0.5ppm to 3ppm, 0.5ppm to 2ppm, or 0.5ppm to 1 ppm.

Automobile interior material

Meanwhile, the present invention provides an automotive interior material comprising the polyester composite of the present invention.

As described above, the automotive interior material of the present invention includes a polyester composite, and the polyester composite includes: average weight of 400g/m ²To 900g/m²The polyester foamed sheet of (1);

the average weight of the foamed sheet formed on one or both sides thereof was 20g/m²To 200g/m²The polyester resin layer of (1); and

a structure in which a fiber mat layer is laminated on one or both surfaces of a polyester resin layer,

the melting point of the polyester resin layer is 180 ℃ to 250 ℃ or the softening point is 100 ℃ to 150 ℃,

the peel strength of the polyester resin layer and the fiber cushion layer was 1kgf/cm²Or more.

Since the automotive interior material of the present invention includes the polyester composite as described above, the adhesiveness between the laminate can be improved by improving the adhesiveness between the fiber mat layer and the polyester resin layer without deteriorating the physical properties such as strength and rigidity.