Polyester-based laminate, polyethylene terephthalate-based laminate, and manufacturing method therefor

Abstract

One aspect of the present invention provides a laminate comprising a polyester single-material, wherein a mix of a low-melting point polyester and a low-melting point adhesive polyester in a predetermined ratio is applied as an intermediate layer, and thus the laminate ensures physical properties such as draw strength, abrasion resistance, moldability, shape stability, etc.

Description

Polyester-based laminate, polyethylene terephthalate-based laminate and method for producing the same

[0001] The present invention relates to a polyester-based laminate, a polyethylene terephthalate-based laminate, and a method for producing the same.

[0002]

[0003] As shown in Fig. 1, the materials used in the surface layer of existing vehicle flooring materials and laminates are mainly nylon and polyester, latex and polyethylene (PE) are used in the middle layer, and polyethylene, ethylene vinyl acetate (EVA), polyolefin (TPO) are used in the lower layer. Since such flooring materials are made of different materials for each layer, the manufacturing process can be complicated due to the application of a tenter process, as shown in Fig. 5. In addition, it is difficult to process due to the difference in melting point of each resin during melting processing, and even if melting processing is performed, there is a limitation that it cannot be recycled as a homogeneous material due to the lack of compatibility between the resins.

[0004] To overcome the limitations of flooring and laminates made from such disparate materials, if the entire material is made of materials such as polyester, there may be a lack of a substrate that can maintain its shape. Furthermore, the powder-type adhesive layer may have high air permeability, resulting in low noise and vibration shielding performance. Furthermore, the addition of volatile organic solvents to enhance adhesiveness may reduce environmental friendliness. Furthermore, the watertightness may be reduced due to delamination and cracking between layers, and the increased rigidity may make handling difficult after molding.

[0005] Due to these problems, laminates made of a single polyester material are not suitable for use in flooring of vehicles and other means of transportation and have limitations.

[0006]

[0007] (Patent Document 1) Korean Patent Publication No. 10-2021-0133042, published on November 5, 2021, Automotive interior material with excellent sound absorption and light weight.

[0008]

[0009] The present invention is intended to solve the above problems, and its purpose is to provide a laminate comprising a single material, polyester, and having properties such as tensile strength, wear resistance, formability, and dimensional stability.

[0010] Another object of the present invention is to provide a laminate that replaces latex, polyethylene, polyolefin, rubber, ethylene vinyl acetate, etc., which are applied to vehicle interior materials and flooring materials, with a single material and is easy to recycle and allows the introduction of recycled resin.

[0011] Another object of the present invention is to provide a vehicle interior material or floor material comprising the above laminate.

[0012] Another object of the present invention is to provide a method for manufacturing the above laminate.

[0013]

[0014] The purpose of the present invention is not limited to the purposes mentioned above. The purpose of the present invention will become clearer from the following description, and may be realized by the means and combinations thereof described in the claims.

[0015]

[0016] A polyester-based laminate according to one aspect of the present invention comprises: a base layer comprising a polyester-based felt or nonwoven fabric; a first intermediate layer disposed on the base layer and comprising a low-melting polyester and a low-melting adhesive polyester, each having a melting point of 150° C. or lower, in a weight ratio of 1:1 to 1:5; an article disposed on the first intermediate layer and comprising (i) a polyester-based fiber bundle tufted on a polyester-based base material; Or (ii) a surface layer comprising a polyester-based nonwoven fabric; wherein the low-melting adhesive polyester may further comprise a residue derived from a different dicarboxylic acid compared to the low-melting adhesive polyester, and may further comprise a heat-sealing layer or a second intermediate layer between the first intermediate layer and the surface layer, and the heat-sealing layer may comprise at least one of a mixture of a part of the first intermediate layer and a part of the surface layer, or a chemical bonding thereof, and the second intermediate layer may comprise at least one of an adhesive polyester film and a polyester fiber web.

[0017]

[0018] A polyethylene terephthalate-based laminate according to one aspect of the present invention comprises: a base layer comprising a polyethylene terephthalate-based felt or nonwoven fabric; a first intermediate layer disposed on the base layer and comprising a low-melting-point polyethylene terephthalate and a low-melting-point adhesive polyethylene terephthalate, each having a melting point of 150° C. or lower, in a weight ratio of 1:1 to 1:5; an article disposed on the first intermediate layer and comprising (i) a polyethylene terephthalate-based fiber bundle tufted on a polyethylene terephthalate-based base material; Or (ii) a surface layer including a polyethylene terephthalate-based nonwoven fabric; wherein the low-melting adhesive polyethylene terephthalate may further include a residue derived from a different dicarboxylic acid than the low-melting adhesive polyethylene terephthalate, and may further include a heat-sealing layer or a second intermediate layer between the first intermediate layer and the surface layer, and the heat-sealing layer may include at least one of a mixture of a part of the first intermediate layer and a part of the surface layer, or a chemical bonding thereof, and the second intermediate layer may include at least one of an adhesive polyethylene terephthalate and a polyethylene terephthalate fiber web.

[0019]

[0020] A method for manufacturing a polyester-based laminate according to one aspect of the present invention may include: (a) a step of treating the lower portion of a preliminary surface layer at a temperature of 200°C to 380°C for a time of 20 seconds or less; and (b) a step of sequentially arranging a preliminary first intermediate layer and a preliminary base layer on the lower portion of the preliminary surface layer on which step (a) has been performed and subjecting them to heat-bonding treatment; or (a′) a step of treating the lower portion of the preliminary surface layer at a temperature of 100°C to 180°C; And (b′) a step of sequentially arranging and bonding a preliminary second intermediate layer, a preliminary first intermediate layer, and a preliminary base layer under the preliminary surface layer processed in step (a′); wherein the preliminary base layer may include a polyester-based felt or nonwoven fabric, and the preliminary first intermediate layer may include a low-melting-point polyester and a low-melting-point adhesive polyester, each having a melting point of 150° C. or lower, in a weight ratio of 1:1 to 1:5, and the low-melting-point adhesive polyester may further include a residue derived from a different dicarboxylic acid compared to the low-melting-point polyester, and the preliminary surface layer may include (i) an article in which a polyester-based fiber bundle is tufted on a polyester-based base material; or (ii) a polyester-based nonwoven fabric; and the preliminary second intermediate layer may include at least one of an adhesive polyester and a polyester fiber web.

[0021]

[0022] The laminate according to one aspect of the present invention can improve recyclability by including a polyester-based resin, and can solve problems such as peeling and insufficient physical properties due to material unification by satisfying good interlayer bonding properties.

[0023] In addition, by using a vehicle interior material or floor material including a laminate according to one aspect of the present invention, quieter and more comfortable driving can be achieved even when the vehicle is driven for a long time or at high speeds.

[0024]

[0025] The effects of the present invention are not limited to those mentioned above. It should be understood that the effects of the present invention encompass all effects inferred from the following description.

[0026]

[0027] Figure 1 is a schematic diagram showing an example of the structure of interior materials and floor materials for a vehicle.

[0028] Figure 2 is a schematic diagram showing a laminate according to one aspect of the present invention.

[0029] Figure 3 is a schematic diagram showing a felt laminate applied to a laminate according to one embodiment of the present invention.

[0030] FIG. 4 (a) is a schematic diagram showing a laminate according to one aspect of the present invention, and FIG. 4 (b) is a schematic diagram showing a laminate according to another aspect of the present invention.

[0031] Figure 5 is a schematic diagram showing an example of a process for manufacturing vehicle interior materials and flooring materials.

[0032] Figure 6 is a schematic diagram showing a process for manufacturing a laminate according to one embodiment of the present invention.

[0033] Figure 7 is a flowchart showing a process for manufacturing a laminate according to one embodiment of the present invention.

[0034] Figure 8 is a flowchart showing a process for manufacturing a laminate according to another aspect of the present invention.

[0035]

[0036] The above-described purposes, other purposes, features, and advantages of the present invention will be readily understood through the following preferred embodiments, illustrated in the accompanying drawings. However, the present invention is not limited to the embodiments described herein and may be embodied in other forms. Rather, the embodiments presented herein are provided to ensure that the disclosure is thorough and complete, and to ensure that the spirit of the present invention is fully conveyed to those skilled in the art.

[0037] In describing each drawing, similar reference numerals are used to designate similar components. In the attached drawings, the dimensions of structures are shown exaggerated for clarity of the present invention. Terms such as first, second, etc. may be used to describe various components, but the components should not be limited by the terms. The terms are used only to distinguish one component from another. For example, a first component may be referred to as a second component, and similarly, a second component may also be referred to as a first component, without departing from the scope of the present invention. The singular expression includes the plural expression unless the context clearly indicates otherwise.

[0038] In this specification, it should be understood that terms such as "include" or "have" are intended to specify the presence of a feature, number, step, operation, component, part or combination thereof described in the specification, but do not preclude the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts or combinations thereof. In addition, when it is said that a part such as a layer, film, region or plate is "on" another part, this includes not only the case where it is "directly above" the other part, but also the case where there is another part in between. Conversely, when it is said that a part such as a layer, film, region or plate is "under" another part, this includes not only the case where it is "directly below" the other part, but also the case where there is another part in between.

[0039] Unless otherwise specified, all numbers, values, and / or expressions expressing quantities of ingredients, reaction conditions, polymer compositions, and blends used herein are approximations that inherently reflect, among other things, the various uncertainties of measurement that arise in obtaining such values, and therefore should be understood as being modified in all instances by the term "about." Furthermore, whenever a numerical range is disclosed herein, such range is continuous and includes every value from the minimum value to the maximum value inclusive, unless otherwise indicated. Furthermore, whenever such a range refers to an integer, every integer from the minimum value to the maximum value inclusive, unless otherwise indicated, is included.

[0040]

[0041] When applying materials such as polyester to automotive interiors, flooring, and other vibration and noise reduction products, there are potential issues such as shape retention, noise and vibration shielding performance, reduced environmental friendliness due to adhesives, and problems with watertightness and formability. To address these issues, the present invention developed a single polyester, polyethylene terephthalate-based laminate, and an environmentally friendly bonding and manufacturing method, which will be described in detail below.

[0042]

[0043] Polyester-based laminate (100)

[0044] Referring to FIGS. 2, 3, 4 (a), 4 (b), etc., a laminate (100) according to one aspect of the present invention,

[0045] A substrate layer (1) comprising polyester-based felt or non-woven fabric;

[0046] A first intermediate layer (2) disposed on the above-mentioned substrate layer and comprising a low-melting-point polyester and a low-melting-point adhesive polyester, each having a melting point of 150°C or lower, in a weight ratio of 1:1 to 1.5;

[0047] It may include a surface layer (4) disposed on the first intermediate layer and comprising (i) a polyester-based fiber bundle tufted on a polyester-based base material; or (ii) a polyester-based non-woven fabric;

[0048] The above low-melting adhesive polyester may further include a residue derived from a different dicarboxylic acid compared to the above low-melting polyester,

[0049] A heat-sealing layer (3a) or a second intermediate layer (3b) may be further included between the first intermediate layer and the surface layer.

[0050] The above heat-sealing layer (3a) may include at least one of a mixture of a part of the first intermediate layer and a part of the surface layer, or a mixture chemically bonded to each other.

[0051] The above second intermediate layer (3b) may include at least one of an adhesive polyester film and a polyester fiber web.

[0052] The above polyester-based laminate (100) may only contain polyester-based materials and may not contain latex, polyethylene, polyolefin, ethylene vinyl acetate, etc. The polyester may contain some recycled polyester resin.

[0053] The base material of the (i) tufted article of the surface layer (4) above may include a spunbond nonwoven fabric, and the spunbond nonwoven fabric may have an area density of 80 g / m2 to 200 g / m2. The base material of the tufted article can stably fix the fiber bundle.

[0054] The above tufting may correspond to a method of embedding a bundle of fibers, which is a collection of multiple fibers, into a target object, and for example, the bundle of fibers may be implanted into a base material through a needle.

[0055] The fiber bundles of the (i) tufted article of the surface layer (4) above may include bulky continuous filaments (BCFs) in which continuous fiber bundles are twisted with each other, and the bulky continuous filaments may have a total fineness of 800 to 2600 denier, a number of filaments of 50 to 150, and an area density of 150 to 2400 g / m2.

[0056] The above bulky continuous filaments may correspond to fiber bundles twisted and formed into relatively long lengths.

[0057] The (ii) nonwoven fabric of the above surface layer (4) may include a needle-punched nonwoven fabric, and the needle-punched nonwoven fabric may have a single fiber count of 3 to 20 denier and a surface density of 200 to 1500 g / ㎡.

[0058] The surface layer (4) may substantially not contain low-melting point fibers (melting point 100-150°C). For example, the (i) tufted article of the surface layer (4) may not contain the low-melting point fibers. If the surface layer (4) contains some low-melting point fibers, the tensile strength may be reduced and bursting defects may occur due to shrinkage and damage of the low-melting point fibers.

[0059] The above surface layer (4) can secure good appearance, shape stability and stability of the surface portion through (i) a tufted article or (ii) a non-woven fabric that satisfies these properties.

[0060] The above heat-sealing layer (3a) can be formed when the lower part of the surface layer (4) is heat-treated using a heating means or the like and bonded to the remaining members.

[0061] The above heat-sealing layer (3a) can be formed in a state where it physically penetrates, is entangled with, or is chemically bonded to a part of the surface layer (4) when a laminate including the first intermediate layer (2) is applied due to residual heat generated by the heat treatment process of the lower portion of the surface layer (4), or a state where all of these are included can be formed, thereby ensuring a stable bonding force between the surface layer (4) and the first intermediate layer (2).

[0062] The thickness of the above heat-sealing layer (3a) may be 0.1 mm to 0.5 mm.

[0063] The above second intermediate layer (3b) can be bonded by heat-treating the lower portion of the surface layer (4) using a heating means or the like, and can exhibit a stable bonding state at the interface.

[0064] The adhesive polyester film of the second intermediate layer (3b) may be unstretched. The polyester film and fiber web may be a mixture of a low-melting point (melting point 100-150°C) polyester and a high-melting point (180-260°C) polyester, and may be in the form of a low-melting point polyester hot melt film or fiber web. In addition, the polyester of the fiber web may include a dicarboxylic acid-derived component such as 1,3-benzenedicarboxylic acid, 1,4-benzenedicarboxylic acid, or decanedioic acid (1,8-octane dicarboxylic acid)-derived component. The polyester of the fiber web may include a 1,4-butanediol-derived component such as a diol-derived component.

[0065] Through the above heat-sealing layer (3a) and the second intermediate layer (3b), it is possible to prevent a decrease in tensile strength, poor bonding, fiber loss, etc. without a separate acrylic coating and latex.

[0066] The low-melting polyester and low-melting adhesive polyester of the first intermediate layer (2) can be distinguished by the monomer-derived residue during polymerization or the monomer-derived residue after polymerization. For example, the low-melting adhesive polyester may further include a different dicarboxylic acid-derived residue compared to the low-melting polyester, and for example, may further include a dicarboxylic acid-derived residue having a different carboxyl group position. In addition, the low-melting polyester may include a diol-derived residue including a branched alkylene compared to the low-melting adhesive polyester.

[0067] The low-melting point polyester of the first intermediate layer (2) may include a product in which a dicarboxylic acid component and a diol component are polymerized. The dicarboxylic acid component may include terephthalic acid, and the diol component may include ethylene glycol, 2-methyl-1,3-propanediol, neopentyl glycol, 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, and combinations thereof.

[0068] The low-melting point polyester of the first intermediate layer (2) may include, for example, residues derived from terephthalic acid, ethylene glycol, and 2-methyl-1,3-propanediol.

[0069] The low-melting-point polyester of the first intermediate layer (2) may contain the dicarboxylic acid-derived component and the diol-derived component in a molar ratio of 1:1.1 to 1:2.0. In addition, it may contain 35 mol% to 50 mol% of the 2-methyl-1,3-propanediol-derived component and 50 mol% to 65 mol% of the ethylene glycol-derived component relative to the total diol-derived component. In this case, when the molar content of the 2-methyl-1,3-propanediol-derived component relative to the total diol-derived component is less than 35 mol%, the bonding improvement effect may be minimal, and when the molar content of the 2-methyl-1,3-propanediol-derived component exceeds 50 mol%, workability may be reduced.

[0070] The low-melting point adhesive polyester of the first intermediate layer (2) may include a product in which a dicarboxylic acid component and a diol component are polymerized, and the dicarboxylic acid component may include isophthalic acid and terephthalic acid, and the diol component may include ethylene glycol and 1,4-butanediol.

[0071] The low-melting point adhesive polyester of the first intermediate layer (2) may include, for example, residues derived from isophthalic acid and terephthalic acid, residues derived from ethylene glycol and 1,4-butanediol.

[0072] The surface density of the first intermediate layer (2) may be 150 g / ㎡ to 1000 g / ㎡.

[0073] The mixing weight ratio of the low-melting point polyester and the low-melting point adhesive polyester of the first intermediate layer (2) may be 1:1 to 1:5, and may be 1:1.5 to 1:3. By satisfying this weight ratio, delamination between layers can be minimized, and excessive increase in rigidity and breakage can be prevented.

[0074] The melting point of the low-melting-point polyester and low-melting-point adhesive polyester of the first intermediate layer (2) may be 100°C to 150°C, or 100°C to 130°C.

[0075] The felt of the above-mentioned base layer (1) may be formed of a single felt, or may include a felt laminate as shown in FIG. 3, and the felt laminate may include a felt layer formed under the first intermediate layer; a polyester layer formed under the felt; and a soft felt layer formed under the polyester layer and having a lower areal density than the felt layer.

[0076] The above-mentioned base layer (1) may include a high-strength felt or non-woven fabric having a surface density of 300 g / ㎡ to 2500 g / ㎡ and a tensile strength of 0.1 kgf / ㎠ to 1.5 kgf / ㎠.

[0077] The above polyester-based laminate (100) may further include a polyester-based sound-insulating layer (not shown) between the first intermediate layer (2) and the substrate layer (1).

[0078] The above soundproofing layer may have a density of 0.15 g / cm3 to 5 g / cm3, a thickness of 1 mm to 3.5 mm, an elongation of 3% to 6%, a flexural strength of 10 N to 35 N, and an air permeability of more than 0 cm3 / m and less than or equal to 1.5 cm3 / m.

[0079] The polyester included in each of the above-mentioned base layer (1), the first intermediate layer (2), the heat-sealing layer (3a), the second intermediate layer (3b), the surface layer 94), and the sound-insulating layer may include any one selected from the group consisting of polyethylene terephthalate (PET), polycyclohexylenedimethylene terephthalate (PCT), and polybutylene terephthalate (PBT), and may include polyethylene terephthalate (PET) as an example. In this way, the polyester-based laminate (100) may include a single resin, and may be formed of a single resin.

[0080] The above polyester-based laminate (100) can be applied as an interior material or flooring material of a means of transportation, with the surface layer (4) positioned on the top and the base layer (1) positioned on the bottom. The means of transportation may be an internal combustion engine vehicle, an electric vehicle, or the like.

[0081] The above polyester-based laminate (100) contains a polyester-based resin, making it easy to recycle, exhibiting excellent interlayer bonding properties, and minimizing problems such as delamination and insufficient physical properties despite the same material. In addition, vehicle interior and flooring materials containing the above laminate (100) can enable quieter and more comfortable driving.

[0082]

[0083] Polyethylene terephthalate-based laminate (100)

[0084] Referring to FIGS. 2, 3, 4 (a) and 4 (b), a polyethylene terephthalate-based laminate (100) according to another aspect of the present invention,

[0085] A substrate layer (1) comprising a polyethylene terephthalate-based felt or non-woven fabric;

[0086] A first intermediate layer (2) disposed on the above substrate layer and containing a low-melting-point polyethylene terephthalate and a low-melting-point adhesive polyethylene terephthalate, each having a melting point of 150°C or lower, in a weight ratio of 1:1 to 1.5;

[0087] A surface layer (4) disposed on the first intermediate layer and comprising (i) a polyethylene terephthalate-based fiber bundle tufted on a polyethylene terephthalate-based foam; or (ii) a polyethylene terephthalate-based nonwoven fabric;

[0088] The above low-melting adhesive polyethylene terephthalate may further include a residue derived from a different dicarboxylic acid compared to the above low-melting adhesive polyethylene terephthalate,

[0089] Further comprising a heat-sealing layer (3a) or a second intermediate layer (3b) between the first intermediate layer and the surface layer,

[0090] The above heat-sealing layer (3a) includes at least one of a mixture of a part of the first intermediate layer and a part of the surface layer, or a mixture chemically bonded to each other.

[0091] The above second intermediate layer (3b) may include at least one of adhesive polyethylene terephthalate and polyethylene terephthalate fiber web.

[0092] In the above polyethylene terephthalate-based laminate (100), the details of the substrate layer (1), the first intermediate layer (2), the heat-sealing layer (3a), the second intermediate layer (3b), the surface layer (4), and the sound-insulating layer correspond to the polyester-based laminate (100) in which polyester is applied as polyethylene terephthalate, and are substantially the same as the details described, so overlapping descriptions are omitted.

[0093] In one embodiment of the polyethylene terephthalate-based laminate (100), the surface layer (4) may include a product in which a polyethylene terephthalate-based fiber bundle is tufted on the (i) polyethylene terephthalate-based base material, and the heat-sealing layer (3a) may be included between the first intermediate layer (2) and the surface layer (4), and the base layer (1) may include a polyethylene terephthalate-based felt.

[0094] In addition, in another aspect of the polyethylene terephthalate-based laminate (100), the surface layer (4) may include (i) a product in which a polyethylene terephthalate-based fiber bundle is tufted on a polyethylene terephthalate-based foam, and may include the second intermediate layer (3b) between the first intermediate layer (2) and the surface layer (4).

[0095] In another aspect of the polyethylene terephthalate-based laminate (100), the surface layer (4) may include (ii) a polyethylene terephthalate-based needle-punched nonwoven fabric.

[0096]

[0097] Method for manufacturing a polyester-based laminate

[0098] Referring to FIGS. 6 to 8, a method for manufacturing a polyester-based laminate according to one embodiment of the present invention is as follows:

[0099] (a) a step (S10) of treating the lower part of the preliminary surface layer at a temperature of 200°C to 380°C for a time of 20 seconds or less; and (b) a step (S20) of sequentially arranging the preliminary first intermediate layer and the preliminary base layer on the lower part of the preliminary surface layer on which the step (a) has been performed and subjecting them to heat-bonding treatment.

[0100] In addition, a method for manufacturing a polyester-based laminate according to another aspect of the present invention,

[0101] (a′) a step (S11) of treating the lower part of the preliminary surface layer at a temperature of 100°C to 180°C; and (b′) a step (S21) of sequentially arranging and bonding a preliminary second intermediate layer, a preliminary first intermediate layer, and a preliminary base layer on the lower part of the preliminary surface layer treated in step (a′).

[0102] The above-mentioned preliminary substrate layer may include a polyester-based felt or nonwoven fabric, the above-mentioned first intermediate layer may include a low-melting polyester and a low-melting adhesive polyester, each having a melting point of 150° C. or lower, in a weight ratio of 1:1 to 1:5, and the low-melting adhesive polyester may further include a heterogeneous dicarboxylic acid-derived residue relative to the low-melting polyester, the above-mentioned preliminary surface layer may include (i) an article in which a polyester-based fiber bundle is tufted on a polyester-based base material; or (ii) a polyester-based nonwoven fabric, and the above-mentioned second intermediate layer may include at least one of an adhesive polyester and a polyester fiber web.

[0103] These may correspond to the surface layer, first intermediate layer, second intermediate layer, and substrate layer described above, and may include substantially the same material.

[0104] The lower part of the preliminary surface layer of the above (a) step (S10) may be the part where the bubble layer is located when the preliminary surface layer is (i) a tufted product.

[0105] In the case where the preliminary surface layer of the above (a) step (S10) is (i) a tufted article, the process of preparing the same may include a process of planting polyester bulky continuous filaments onto a polyester spunbond nonwoven fabric base material through a plurality of needles.

[0106] The processing of the above (a) step (S10) may be performed such that the preliminary surface layer is moved from the surface layer supply unit (10) between the heating roller (20) and the auxiliary roller (21) having a predetermined gap from the heating roller (20), and the lower part of the preliminary surface layer is in contact with the heating roller (20). The heating roller (20) and the auxiliary roller (21) may have a cylindrical shape, and the heating rollers (20) may be arranged in multiple numbers while being spaced apart from each other along the circumferential direction of the auxiliary roller (21). The heating roller (20) may be an induction heating roller equipped with an internal induction coil and generating heat by forming an eddy current on the surface by a magnetic field line when an alternating current is applied.

[0107] The temperature of the above (a) step (S10) may be 200 ℃ to 380 ℃, or 220 ℃ to 280 ℃.

[0108] The time of the above step (a) (S10) may be 1 second to 20 seconds, or 2 seconds to 10 seconds.

[0109] The gap between the heating roller (20) and the auxiliary roller (21) in the above (a) step (S10) may be 1 mm to 3 mm, and may be 1.2 mm to 2.0 mm.

[0110] The above step (a) (S10) satisfies these conditions so that the preliminary surface layer can be stably thermally bonded to the target object in the subsequent step without being excessively melted.

[0111] The above step (a′) (S11) may be performed through the heating roller (20) and auxiliary roller (21) of the above step (a), and may be controlled at a lower temperature than the above step (a). The above step (a′) may be performed in such a manner that the preliminary surface layer is moved between the heating roller (20) and the auxiliary roller (21) having a predetermined gap, as in the above step (a), but the lower part of the preliminary surface layer is in contact with the heating roller (20), and may be performed in substantially the same manner, except for the processing temperature and the gap between the rollers.

[0112] The temperature of the above (a′) step (S11) may be 100 ℃ to 180 ℃, or 120 ℃ to 180 ℃.

[0113] The time of the above (a′) step (S11) may be 1 second to 20 seconds, or 2 seconds to 15 seconds.

[0114] The gap between the heating roller (20) and the auxiliary roller (21) of the above (a′) step (S11) may be 0.5 mm to 3 mm, and may be 0.8 mm to 2.0 mm.

[0115] The above (a′) step (S11) satisfies these conditions so that the target object can be stably bonded in the subsequent step.

[0116] In the above step (b) (S20), the preliminary first intermediate layer and the preliminary base layer may be sequentially arranged under the preliminary surface layer on which the above step (a) has been performed, and laminated to form a heat-sealing layer. For example, as illustrated in FIG. 6, the preliminary first intermediate layer supplied from the first intermediate layer supply unit (30) and the preliminary base layer supplied from the base layer supply unit (40) may be laminated under the preliminary surface layer on which the above step (a) has been performed and in the lamination unit (50), and the lamination and the formation of the heat-sealing layer may be performed substantially simultaneously. The laminated body may be rolled or punched into a predetermined shape.

[0117] The thermal bonding of the above step (b) (S20) can be carried out through residual heat under the preliminary surface layer.

[0118] In the above (b′) step (S21), a preliminary second intermediate layer, a preliminary first intermediate layer, and a preliminary base layer may be sequentially arranged and laminated below the preliminary surface layer on which the above (a′) step (S11) has been performed. At this time, the preliminary second intermediate layer may be supplied from the second intermediate layer supply unit, and the supply of each other layer may be substantially the same as in the above (b) step.

[0119] The preliminary first intermediate layer of the above (b), (b′) steps (S20, S21) may have the material and content ratio of the first intermediate layer described above, and the first intermediate layer supply unit may include an extruder including a T-die outlet. At this time, the preliminary first intermediate layer may be prepared by mixing low-melting-point polyester chips (masterbatch) and low-melting adhesive polyester chips (masterbatch) in the extruder at a temperature of 130°C to 150°C and extruding through the T-die extruder at a temperature of 150°C to 170°C.

[0120] A polyester-based laminate (100) can be easily implemented through the above method.

[0121]

[0122] Hereinafter, the present invention will be described in detail with reference to the following examples and comparative examples. However, the technical concept of the present invention is not limited or restricted by these examples.

[0123]

[0124] Example 1 - Single PET-based laminate

[0125] (a) PET (polyethylene terephthalate)-based bulky continuous filament (BCF) yarn was prepared. The total fineness of this PET BCF yarn was 1000 denier, the number of filaments was 128, and the weight (areal density) was approximately 237 g / ㎡. The PET BCF yarn was woven and tufted onto a PET spunbond nonwoven fabric having an areal density of approximately 120 g / ㎡ through multiple needles to produce a preliminary surface layer, with the yarn height being approximately 6 mm.

[0126] The lower part of the above preliminary surface layer (PET spunbond nonwoven fabric portion) was moved between a heating roller (20) and an auxiliary roller (21) having a gap of 1.5 mm as shown in Fig. 6, and was treated at a temperature of 259°C for 8 seconds.

[0127] As a preliminary first intermediate layer, PET chips obtained by condensation polymerization of terephthalic acid, ethylene glycol, and 2-methyl-1,3-propanediol were applied as a low-melting-point PET, and as a low-melting-point adhesive PET, PET chips obtained by condensation polymerization of isophthalic acid, terephthalic acid, ethylene glycol, and 1,4-butanediol were applied. The weight ratio of the low-melting-point PET:low-melting-point adhesive PET (LM:LM adhesive) was set to 34:66 (1:1.94), and after putting each chip into an extruder, they were kneaded at a temperature of approximately 145°C and extruded at 170°C to manufacture a preliminary first intermediate layer.

[0128] PET felt with a density of approximately 500 g / ㎡ was applied as a preliminary substrate layer.

[0129] (b) The preliminary first intermediate layer and the preliminary base layer were sequentially placed under the preliminary surface layer on which the step (a) was performed, and heat-sealed with the residual heat under the preliminary surface layer was performed to manufacture a PET-based laminate.

[0130]

[0131] Additionally, during manufacturing, laminates were manufactured under different specific conditions as shown in Table 1 below.

[0132]

[0133]

[0134] Example 2

[0135] In the above Example 1, the weight ratio of LM:LM adhesive (the low-melting point PET: the low-melting point adhesive PET) was changed to 40:60 (1:1.5).

[0136] Example 3

[0137] In the above Example 1, the weight ratio of LM:LM adhesive (the low-melting point PET: the low-melting point adhesive PET) was changed to 50:50 (1:1).

[0138] Example 4

[0139] In the above Example 1, the gap between the heating roller (20) and the auxiliary roller (32) in step (a) was changed to 1 mm, the temperature when moving between these was changed to 160°C, and the processing time was changed to 6 seconds, and the polyethylene terephthalate film (hot melt) was attached through the residual heat under the preliminary surface layer where step (a) was performed.

[0140] Example 5

[0141] In the above Example 4, the weight ratio of LM:LM adhesive (the low-melting point PET: the low-melting point adhesive PET) was changed to 40:60 (1:1.5).

[0142] Example 6

[0143] In the above Example 4, the weight ratio of LM:LM adhesive (the low-melting point PET: the low-melting point adhesive PET) was changed to 50:50 (1:1).

[0144] Example 7

[0145] In the above Example 1, the gap between the heating roller (20) and the auxiliary roller (32) in step (a) was changed to 1 mm, the temperature when moving between them was changed to 160°C, and the processing time was changed to 6 seconds, and the polyethylene terephthalate web (hot melt) was attached through the residual heat under the preliminary surface layer where step (a) was performed.

[0146] Example 8

[0147] In the above Example 7, the weight ratio of LM:LM adhesive (the low-melting point PET: the low-melting point adhesive PET) was changed to 40:60 (1:1.5).

[0148] Example 9

[0149] In the above Example 7, the weight ratio of LM:LM adhesive (the low-melting point PET: the low-melting point adhesive PET) was changed to 50:50 (1:1).

[0150]

[0151] Comparative Example 0

[0152] In the above Example 1, the preparatory surface layer was changed to include 3 wt% of low-melting point (110°C) PET fiber (LM fiber) compared to the entire foam sheet, (a) step heat treatment was not performed, latex was included between the surface layer and the first intermediate layer, PE (polyethylene) was included as the preparatory first intermediate layer, and the preparatory first intermediate layer extrusion temperature was changed to 265°C.

[0153] Comparative Example 1

[0154] In the above comparative example 0, latex is omitted.

[0155] Comparative Example 2

[0156] In the above Example 1, the preparatory surface layer was changed to include 3 wt% of low-melting point (110°C) PET fiber (LM fiber) compared to the entire foam sheet, the heat treatment conditions in step (a) were changed to 253°C, 10 seconds, and 1.8 mm intervals, the preparatory first intermediate layer was changed to include PE (polyethylene), and the preparatory first intermediate layer extrusion temperature was changed to 265°C.

[0157] Comparative Example 3

[0158] In the above Example 1, the heat treatment conditions of step (a) were changed to 253°C for 10 seconds, the preliminary first intermediate layer was changed to include PE (polyethylene), and the preliminary first intermediate layer extrusion temperature was changed to 265°C.

[0159] Comparative Example 4

[0160] In the above Example 1, the heat treatment conditions of step (a) were changed to 10 seconds, 1.8 mm intervals, changed to include PE (polyethylene) as the preliminary first intermediate layer, and changed to 265 ℃ of the preliminary first intermediate layer extrusion temperature.

[0161] Comparative Example 5

[0162] In the above Example 1, the heat treatment conditions in step (a) were changed to 10 seconds, the preliminary first intermediate layer was changed to include PE (polyethylene), and the preliminary first intermediate layer extrusion temperature was changed to 265°C.

[0163] Comparative Example 6

[0164] In the above Example 1, the preliminary first intermediate layer was changed to include PE (polyethylene), and the preliminary first intermediate layer extrusion temperature was changed to 265°C.

[0165] Comparative Example 7

[0166] In the above Example 1, the preliminary first intermediate layer was changed to include PET (polyethylene terephthalate with a melting point of 250°C), and the preliminary first intermediate layer extrusion temperature was changed to 280°C.

[0167] Comparative Example 8

[0168] In the above Example 1, the weight ratio of PET:PETG (polyethylene terephthalate: glycol-modified polyethylene terephthalate with a melting point of 250°C) was changed to 50:50 as the preliminary first intermediate layer, and the extrusion temperature of the preliminary first intermediate layer was changed to 270°C.

[0169] Comparative Example 9

[0170] In the above Example 1, the weight ratio of PET:LM (melting point 250°C polyethylene terephthalate: the above low melting point PET) was changed to 50:50 as the preliminary first intermediate layer, and the extrusion temperature of the preliminary first intermediate layer was changed to 270°C.

[0171] Comparative Example 10

[0172] In the above Example 1, the preliminary first intermediate layer was changed to include LM (the above low-melting point PET), and the preliminary first intermediate layer extrusion temperature was changed to 180°C.

[0173] Comparative Example 11

[0174] In the above Example 1, the preliminary first intermediate layer was changed to include LM adhesive (the above low-melting point adhesive PET).

[0175] Comparative Example 12

[0176] In the above Example 1, the weight ratio of LM:LM adhesive (the low-melting point PET: the low-melting point adhesive PET) was changed to 70:30 (1:0.43).

[0177] Comparative Example 13

[0178] In the above Example 1, the weight ratio of LM:LM adhesive (the low-melting point PET: the low-melting point adhesive PET) was changed to 60:40 (1:0.66).

[0179]

[0180] Experimental examples - Formability, delamination, fabric folding, tensile strength, abrasion resistance, and productivity evaluation

[0181] Each item was evaluated and measured as follows, and the results are shown in Table 2.

[0182] 1) Formability (heat aging resistance)

[0183] According to the automotive material test standard MS300-35, heat aging resistance was measured at a temperature of 80±3℃ and an aging time of 168 hours, and the morphological stability and cracking of the laminate were then rated as good or poor.

[0184] 2) Peeling

[0185] For examples where filming was impossible, evaluation was not conducted. For products rated as intermediate or higher, delamination between the surface layer and the first intermediate layer was checked. Delamination was also checked when lifted or pulled by hand.

[0186] 3) Folding the fabric

[0187] After forming and cooling the laminate using a simple molding machine (atmosphere temperature 180 ℃), it was checked whether cracks occurred when stepped on or bent by hand.

[0188] 4) Tensile strength, elongation at break

[0189] The tensile strength (N / 50 mm) of the laminate was measured according to the automotive material testing standard MS 200-41. The tensile speed was 100 mm / min.

[0190] 5) Pull-out strength, wear resistance

[0191] According to the automotive material test standard MS300-35, the pile pull-out strength and wear grade of the laminate were evaluated and quantified.

[0192] 6) Combustibility

[0193] The combustibility of the laminate was evaluated according to the automotive material testing standard MS 300-08.

[0194] 7) Wrinkle prevention rate (%)

[0195] A test piece measuring 20 × 80 mm was taken in the vertical and horizontal directions from the viewpoint of the upper surface layer of the laminate, with the substrate layer facing inward, folded at a right angle based on the long side, and then sandwiched between flat plates, and a load of 1 kg was applied. After leaving it for 5 minutes, the load was removed, and the folded part was immediately hung on a wire having a diameter of 0.51 mm, or the angle at which the test piece opens was measured after leaving it for 5 minutes using a tester with equivalent performance. The angle (α) formed by the lines connecting the center of the wire and the points 20 mm away from each end of the test piece was measured, and the wrinkle prevention rate (%) was calculated according to the following equation 1.

[0196] [Formula 1]

[0197] Wrinkle prevention rate (%) = (α / 180 °) × 100%

[0198] (In the above equation 1, α is the angle (°) formed by the lines connecting the center of the wire spanning the folded portion and the portion 20 mm away from each end of the test piece 5 minutes after the load applied to the folded test piece is removed.)

[0199] 8) Productivity

[0200] After extrusion, the possibility of film formation, peeling, cracking, etc. were evaluated, and productivity was evaluated and scored based on the results.

[0201] 9) Recyclability

[0202] If it is made of single polyester or PET material, it was evaluated as recyclable.

[0203]

[0204]

[0205] Referring to Tables 1 and 2, Comparative Example 1 showed reduced tensile strength and abrasion resistance due to the non-application of heat-sealing and latex. Comparative Example 2 included low-melting-point fibers in the foam, which caused the fabric to burst during heat-sealing. Comparative Examples 0 to 6 were difficult to recycle due to the inclusion of polyethylene (PE), etc., and among them, Comparative Examples 3 to 5 showed reduced tensile strength. Comparative Examples 7 to 9 contained all or part of a high-melting-point polyester (melting point 180°C or higher) in the first intermediate layer, resulting in poor overall physical properties. Comparative Examples 10 to 13 had low-melting-point PET: low-melting-point adhesive PET ratios outside the appropriate range or contained only one of them, resulting in problems in at least one of formability, delamination, and fabric folding.

[0206] In the case of Examples 1 to 9, good characteristics were satisfied in all aspects such as formability, delamination, fabric folding, tensile strength, elongation, tensile strength, wear resistance, combustibility, wrinkle resistance, productivity, and recyclability, and it was confirmed that suitable properties and eco-friendliness were secured as automotive interior materials and flooring materials.

[0207]

[0208] While the embodiments of the present invention have been described above, those skilled in the art will appreciate that the present invention can be implemented in other specific forms without altering its technical concept or essential features. Therefore, the embodiments described above should be understood as illustrative in all respects and not restrictive.

[0209]

[0210] Description of the symbol

[0211] 1: Substrate layer

[0212] 2: First intermediate layer

[0213] 3a: Heat-sealing layer

[0214] 3b: Second intermediate layer

[0215] 4: Surface layer

[0216] 10: Surface layer supply section

[0217] 20: Heating roller

[0218] 21: Auxiliary roller

[0219] 30: First intermediate layer supply section

[0220] 40: Substrate supply section

[0221] 50: Laminated section

[0222] 100: Laminate

Claims

1. A substrate layer comprising polyester-based felt or non-woven fabric; A first intermediate layer disposed on the above-mentioned substrate layer and comprising a low-melting-point polyester and a low-melting-point adhesive polyester, each having a melting point of 150° C. or lower, in a weight ratio of 1:1 to 1:5; A surface layer comprising (i) a polyester-based fiber bundle tufted on a polyester-based substrate; or (ii) a polyester-based nonwoven fabric; disposed on the first intermediate layer; The above low-melting adhesive polyester further contains a heterogeneous dicarboxylic acid-derived residue compared to the above low-melting polyester, Further comprising a heat-sealing layer or a second intermediate layer between the first intermediate layer and the surface layer, The above heat-sealing layer comprises at least one of a mixture of a part of the first intermediate layer and a part of the surface layer, or a mixture chemically bonded to each other. A polyester-based laminate, wherein the second intermediate layer comprises at least one of an adhesive polyester film and a polyester fiber web.

2. In paragraph 1, (i) The base material of the tufted article of the above surface layer comprises a spunbond nonwoven fabric, The above spunbond nonwoven fabric is a polyester-based laminate having a density of 80 g / ㎡ to 200 g / ㎡.

3. In paragraph 1, (i) The fiber bundles of the tufted article of the surface layer above include bulky continuous filaments in which continuous fiber bundles are twisted with each other, A polyester-based laminate wherein the bulky continuous filaments have a total fineness of 800 to 2600 denier, a filament count of 50 to 150, and an areal density of 150 to 2400 g / m2.

4. In paragraph 1, (ii) The nonwoven fabric of the above surface layer comprises a needle-punched nonwoven fabric, The above needle-punched nonwoven fabric is a polyester-based laminate having a single fiber count of 3 to 20 denier and a surface density of 200 to 1500 g / ㎡.

5. In paragraph 1, A polyester-based laminate, wherein the heat-sealing layer has a thickness of 0.1 mm to 0.5 mm.

6. In paragraph 1, The low-melting point polyester of the first intermediate layer contains a product in which a dicarboxylic acid component and a diol component are polymerized, The above dicarboxylic acid component includes terephthalic acid, A polyester-based laminate, wherein the diol component comprises one selected from the group consisting of ethylene glycol, 2-methyl-1,3-propanediol, neopentyl glycol, 1-3-propanediol, 1,4-butanediol, 1,6-hexanediol, and combinations thereof.

7. In paragraph 1, The low-melting point adhesive polyester of the first intermediate layer contains a product in which a dicarboxylic acid component and a diol component are polymerized, The above dicarboxylic acid component includes isophthalic acid and terephthalic acid, A polyester-based laminate, wherein the above diol component comprises ethylene glycol and 1,4-butanediol.

8. In paragraph 1, The felt of the above-mentioned substrate layer comprises a felt laminate, A polyester-based laminate comprising: a felt layer formed under the first intermediate layer; a polyester layer formed under the felt; and a soft felt layer formed under the polyester layer and having a lower surface density than the felt layer.

9. In paragraph 1, Further comprising a polyester-based sound-insulating layer between the first intermediate layer and the substrate layer, The above soundproofing layer is a polyester-based laminate having a density of 0.15 g / cm3 to 5 g / cm3, a thickness of 1 mm to 3.5 mm, an elongation of 3 % to 6 %, a flexural strength of 10 N to 35 N, and an air permeability of more than 0 cm3 / m and less than or equal to 1.5 cm3 / m.

10. In paragraph 1, The polyester contained in each of the above-mentioned substrate layer, the first intermediate layer, the heat-melting layer, the second intermediate layer, and the surface layer is A polyester-based laminate comprising any one selected from the group consisting of polyethylene terephthalate (PET), polycyclohexylenedimethylene terephthalate (PCT), and polybutylene terephthalate (PBT).

11. A substrate layer comprising polyester-based felt or non-woven fabric; A first intermediate layer disposed on the above-mentioned substrate layer and comprising a low-melting-point polyester and a low-melting-point adhesive polyester, each having a melting point of 150° C. or lower, in a weight ratio of 1:1 to 1:5; A surface layer comprising (i) a polyester-based fiber bundle tufted on a polyester-based substrate; or (ii) a polyester-based nonwoven fabric; disposed on the first intermediate layer; The above low-melting adhesive polyester further contains a heterogeneous dicarboxylic acid-derived residue compared to the above low-melting polyester, Further comprising a heat-sealing layer or a second intermediate layer between the first intermediate layer and the surface layer, The above heat-sealing layer comprises at least one of a mixture of a part of the first intermediate layer and a part of the surface layer, or a mixture chemically bonded to each other. A polyester-based vehicle interior material, wherein the second intermediate layer comprises at least one of an adhesive polyester film and a polyester fiber web.

12. A substrate layer comprising a polyethylene terephthalate-based felt or non-woven fabric; A first intermediate layer disposed on the above-mentioned substrate layer and comprising a low-melting-point polyethylene terephthalate and a low-melting-point adhesive polyethylene terephthalate, each having a melting point of 150° C. or lower, in a weight ratio of 1:1 to 1:5; A surface layer comprising (i) a polyethylene terephthalate-based fiber bundle tufted on a polyethylene terephthalate-based foam base; or (ii) a polyethylene terephthalate-based nonwoven fabric; disposed on the first intermediate layer; The above low-melting point adhesive polyethylene terephthalate further contains a residue derived from a different dicarboxylic acid compared to the above low-melting point polyethylene terephthalate, Further comprising a heat-sealing layer or a second intermediate layer between the first intermediate layer and the surface layer, The above heat-sealing layer comprises at least one of a mixture of a part of the first intermediate layer and a part of the surface layer, or a mixture chemically bonded to each other. A polyethylene terephthalate-based laminate, wherein the second intermediate layer comprises at least one of adhesive polyethylene terephthalate and polyethylene terephthalate fiber web.

13. In paragraph 12, The above surface layer comprises an article in which a polyethylene terephthalate-based fiber bundle is tufted on the (i) polyethylene terephthalate-based foam, Including the heat-sealing layer between the first intermediate layer and the surface layer, The above-mentioned substrate layer is a polyethylene terephthalate-based laminate comprising a polyethylene terephthalate-based felt.

14. In paragraph 12, The above surface layer comprises (i) a product in which a polyethylene terephthalate-based fiber bundle is tufted on a polyethylene terephthalate-based foam, A polyethylene terephthalate-based laminate comprising a second intermediate layer between the first intermediate layer and the surface layer.

15. In paragraph 12, The surface layer is a polyethylene terephthalate-based laminate comprising (ii) a polyethylene terephthalate-based needle-punched nonwoven fabric.

16. (a) a step of treating the lower part of the preliminary surface layer at a temperature of 200°C to 380°C for a time of 20 seconds or less; and (b) a step of sequentially arranging the preliminary first intermediate layer and the preliminary base layer on the lower part of the preliminary surface layer on which the step (a) has been performed and subjecting them to heat-fusing treatment; or (a′) a step of treating the lower part of the preliminary surface layer at a temperature of 100 ℃ to 180 ℃; and (b′) a step of sequentially arranging and bonding a preliminary second intermediate layer, a preliminary first intermediate layer, and a preliminary base layer on the lower part of the preliminary surface layer treated in step (a′). The above preliminary substrate layer comprises a polyester-based felt or non-woven fabric, The above preliminary first intermediate layer comprises a low-melting-point polyester and a low-melting-point adhesive polyester, each having a melting point of 150° C. or lower, in a weight ratio of 1:1 to 1:5, The above low-melting adhesive polyester further contains a heterogeneous dicarboxylic acid-derived residue compared to the above low-melting polyester, The above preliminary surface layer comprises (i) a polyester-based fiber bundle tufted on a polyester-based substrate; or (ii) a polyester-based nonwoven fabric; A method for producing a polyester-based laminate, wherein the second preliminary intermediate layer comprises at least one of an adhesive polyester and a polyester fiber web.

17. In paragraph 16, Comprising steps (a) and (b) above, The processing of step (a) is performed such that the preliminary surface layer is moved between the heating roller and the auxiliary roller having a predetermined gap from the heating roller, such that the lower part of the preliminary surface layer is in contact with the heating roller. A method for manufacturing a polyester-based laminate, wherein the heat bonding in step (b) is performed through residual heat below the preliminary surface layer.

18. In paragraph 16, Comprising steps (a′) and (b′) above, A method for manufacturing a polyester-based laminate, wherein the bonding in step (b′) is performed through residual heat under the preliminary surface layer.

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