Easily recyclable polyester-based structure for vehicle headliner

Abstract

The present invention relates to a polyester-based structure for a vehicle headliner, the polyester-based structure improving recycling efficiency due to being based on polyester fibers, and having excellent moldability and rigidity due to being composed of a single material. The polyester-based structure according to the present invention comprises: a first scrim layer containing a first polyester fiber; a core layer positioned on the lower surface of the first scrim layer and containing a third polyester fiber and a fourth polyester fiber; and a second resin layer positioned on the lower surface of the core layer and containing a second polyester resin.

Description

Polyester-based structural material for easily recyclable vehicle headliners

[0001] Cross-reference to related applications

[0002] This application claims the benefit of priority to Korean Patent Application No. 2024-0108801, filed August 14, 2024, the contents of which are incorporated herein by reference in their entirety.

[0003] The present invention relates to a polyester-based structure for a vehicle headliner that is easy to recycle.

[0004] Recently, interest in environmental friendliness has grown due to the EU's End-of-Life Vehicles (ELV) regulations. To address this, the use of recycled plastics and the development of recyclable products are required.

[0005] In particular, PP (Polypropylene) accounts for the largest proportion of plastics used in automobiles, at approximately 32%, and it is not easy to recycle because PP is reinforced with GF (Glass fiber) and MF (Mineral filler).

[0006] In comparison, PET (Polyethylene terephthalate) material is used in the form of fabrics and non-woven fabrics and is relatively easy to recycle, so the automobile industry has recently attempted to increase the recycled content by using PET material.

[0007] Additionally, there are attempts to expand the application of parts made from recycled raw materials utilizing scrapped vehicle parts to implement a closed-loop system by manufacturing single-material-based parts that are easy to dismantle and recycle.

[0008] Currently, most headliner molding materials are semi-rigid PU foam-based boards (hereinafter referred to as PU boards), but they have a multilayer structure made of different materials, which makes them difficult to recycle.

[0009] In addition, the PPGF (Polypropylene + Glass fiber) based LWRT (Low weight reinforced thermoplastics) board (hereinafter referred to as PPGF board) product currently used in some vehicle models has problems such as a deterioration of the working environment due to scattering of glass fibers and unevenness of the surface after product production. In addition, the PPGF board also has the problem of low recyclability because it is made of different materials.

[0010] The problem to be solved by the present invention is to provide a polyester-based structure for a vehicle headliner that improves recycling efficiency based on polyester fibers and has excellent formability and rigidity while being composed of a single material.

[0011] The present invention is a polyester structure comprising: a first scrim layer comprising first polyester fibers; a core layer positioned on the lower surface of the first scrim layer and comprising third polyester fibers and fourth polyester fibers; and a second resin layer positioned on the lower surface of the core layer and comprising a second polyester resin.

[0012] In the present invention, the polyester-based structure may further include a first resin layer including a first polyester resin between the first scrim layer and the core layer.

[0013] In the present invention, the polyester-based structure may further include a second scrim layer including a second polyester fiber on the lower surface of the second resin layer.

[0014] In the present invention, the basis weight of the first scrim layer may be 10 to 60 g / ㎡.

[0015] In the present invention, the first polyester fiber may be a polyethylene terephthalate fiber.

[0016] In the present invention, the basis weight of the first resin layer may be 20 to 200 g / ㎡.

[0017] In the present invention, the first polyester resin may be a polyethylene terephthalate resin.

[0018] In the present invention, the basis weight of the core layer may be 700 to 1,200 g / ㎡.

[0019] In the present invention, the core layer may include 20 to 50 wt% of the third polyester fiber and 50 to 80 wt% of the fourth polyester fiber.

[0020] In the present invention, the third polyester fiber may be a low-melting point polyethylene terephthalate fiber, and the fourth polyester fiber may be a regular polyethylene terephthalate fiber.

[0021] In the present invention, the core layer may include one or more nonwoven fabrics.

[0022] In the present invention, the core layer may be formed by laminating two or more nonwoven fabrics.

[0023] In the present invention, the basis weight of the second scrim layer may be 10 to 60 g / ㎡.

[0024] In the present invention, the second polyester fiber may be a polyethylene terephthalate fiber.

[0025] In the present invention, the basis weight of the second resin layer may be 20 to 200 g / ㎡.

[0026] In the present invention, the second polyester resin may be a polyethylene terephthalate resin.

[0027] In the present invention, the polyester-based structure may have a tensile strength ratio of MD / TD of 0.90 to 1.10.

[0028] In the present invention, the polyester-based structure may be for a vehicle headliner.

[0029] The present invention uses a single material of polyethylene terephthalate, so it is easy to recycle and can prevent environmental pollution.

[0030] In addition, the present invention provides rigidity to the structure and can have shape stability after molding by having a resin layer and a scrim layer respectively positioned on the upper and lower portions of the core layer.

[0031] In addition, by including low-melting point polyethylene terephthalate in the core layer, adhesiveness can be enhanced and physical properties can be improved.

[0032] Figure 1 is a drawing showing a polyester structure of the present invention.

[0033] FIG. 2 is a drawing showing a polyester structure including a first resin layer and a second scrim layer.

[0034] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. In general, the nomenclature used herein and the experimental methods described below are well known and commonly used in the art.

[0035] Additionally, when the terms "about," "approximately," or similar expressions such as "at least" are used in connection with a numerical value in the present invention, it is intended that a theoretical, experimental, statistical, or empirical error of ±10%, ±7%, ±5%, ±3%, ±2%, or ±1% based on the numerical value is allowed.

[0036]

[0037] Figure 1 is a drawing showing a polyester structure of the present invention.

[0038] Referring to FIG. 1, the present invention is a polyester-based structure (100) comprising: a first scrim layer (110) including a first polyester fiber; a core layer (130) positioned on the lower surface of the first scrim layer (110) and including a third polyester fiber and a fourth polyester fiber; and a second resin layer (140) positioned on the lower surface of the core layer (130) and including a second polyester resin.

[0039] In the present invention, the first scrim layer (110) including the first polyester fiber is intended to improve the formability of the structure, prevent sagging of the structure after forming, protect the appearance quality of the structure, and supplement rigidity.

[0040] The basis weight of the first scrim layer (110) may be 10 to 60 g / ㎡, and preferably, the basis weight of the first scrim layer (110) may be 20 to 40 g / ㎡. If the basis weight of the first scrim layer (110) is less than 10 g / ㎡, the structure may sag after molding, and if it exceeds 60 g / ㎡, it is not economical due to an increase in cost.

[0041] In addition, the first polyester fiber may be a polyethylene terephthalate fiber, the first polyester fiber may have a diameter of 1 to 4 denier, and the first scrim layer (110) may be a non-woven fabric, and thus the bonding strength with the core layer (130) or the first resin layer (120) described below may be improved.

[0042] In the present invention, the core layer (130) is a layer that controls the weight and thickness of the structure and maintains the shape of the structure after molding.

[0043] The basis weight of the core layer (130) may be 700 to 1,200 g / ㎡, and preferably, the basis weight of the core layer (130) may be 750 to 1,100 g / ㎡. If the basis weight of the core layer (130) is less than 700 g / ㎡, the flexural strength of the structure may be reduced, and if it exceeds 1,200 g / ㎡, the weight of the structure may increase, and the improvement in physical properties relative to the content may be minimal.

[0044] The core layer (130) may contain 20 to 50 wt% of the third polyester fiber and 50 to 80 wt% of the fourth polyester fiber, and preferably 25 to 35 wt% of the third polyester fiber and 65 to 75 wt% of the fourth polyester fiber. If the content of the third polyester fiber is less than 20 wt%, the rigidity of the structure may be reduced, and if it exceeds 50 wt%, the rigidity may be excellent, but the heat resistance may be reduced.

[0045] Additionally, the third polyester fiber may be a low-melting polyethylene terephthalate fiber, and the fourth polyester fiber may be a regular polyethylene terephthalate fiber. The low-melting polyethylene terephthalate fiber may have a diameter of 2 to 15 denier, and the regular polyethylene terephthalate fiber may have a diameter of 3 to 15 denier.

[0046] The melting point of the above low-melting polyethylene terephthalate fiber may be 110 to 180°C, and the melting point of the above regular polyethylene terephthalate fiber may be 240 to 265°C.

[0047] In the present invention, the core layer (130) may include one or more nonwoven fabrics, preferably two or more nonwoven fabrics laminated, and more preferably two to four layers of nonwoven fabrics laminated, and by laminating the two to four layers of nonwoven fabrics, the physical properties of the structure can be improved and the bonding strength with the first resin layer (120) and the second resin layer (140) described below can be improved.

[0048] Additionally, the core layer (130) may include a needle-punched nonwoven fabric.

[0049] In the present invention, the second resin layer (140) is a layer for improving the physical properties of the structure, such as flexural strength and tensile strength.

[0050] In the present invention, the basis weight of the second resin layer (140) may be 20 to 200 g / ㎡, and preferably, the basis weight of the second resin layer (140) may be 40 to 100 g / ㎡. If the basis weight of the second resin layer (140) is less than 20 g / ㎡, the flexural strength of the structure may be reduced, and if it exceeds 200 g / ㎡, the cost increases, making it uneconomical, the improvement in physical properties relative to the content is minimal, and the weight of the structure may increase.

[0051] The second polyester resin may be a polyethylene terephthalate resin, and the hardness of the second polyester resin may be 50 to 80 Shore D. The second polyester resin may be in powder form, and after being applied to the surface of the core layer (130) in powder form, it may take the form of a film by heat.

[0052] FIG. 2 is a drawing showing a polyester structure including a first resin layer and a second scrim layer.

[0053] Referring to FIG. 2, the polyester-based structure (100) may further include a first resin layer (120) including a first polyester resin between the first scrim layer (110) and the core layer (130).

[0054] In addition, the polyester-based structure (100) may further include a second scrim layer (150) including a second polyester fiber on the lower surface of the second resin layer (140).

[0055] In the present invention, the first resin layer (120) is a layer for improving the physical properties of the structure, such as flexural strength and tensile strength.

[0056] The basis weight of the first resin layer (120) may be 20 to 200 g / ㎡, and preferably, the basis weight of the first resin layer (120) may be 40 to 100 g / ㎡. If the basis weight of the first resin layer (120) is less than 20 g / ㎡, the flexural strength of the structure may be reduced, and if it exceeds 200 g / ㎡, the cost increases, making it uneconomical, the improvement in physical properties relative to the content is minimal, and the weight of the structure may increase.

[0057] The first polyester resin may be a polyethylene terephthalate resin, and the hardness of the first polyester resin may be 50 to 80 Shore D. The first polyester resin may be in powder form, and after being applied to the surface of the core layer (130) in powder form, it may take the form of a film by heat.

[0058] In the present invention, the second scrim layer (150) including the second polyester fiber is intended to improve the formability of the structure, prevent sagging of the structure after forming, protect the appearance quality of the structure, and supplement rigidity, similar to the first scrim layer (110).

[0059] The basis weight of the second scrim layer (150) may be 10 to 60 g / ㎡, and preferably, the basis weight of the second scrim layer may be 20 to 40 g / ㎡. If the basis weight of the second scrim layer (150) is less than 20 g / ㎡, the structure may sag after molding, and if it exceeds 60 g / ㎡, it is not economical due to an increase in cost.

[0060] In addition, the second polyester fiber may be a polyethylene terephthalate fiber, the second polyester fiber may have a diameter of 1 to 4 denier, and the second scrim layer (150) may be a non-woven fabric, thereby improving the bonding strength with the second resin layer (140).

[0061] In the present invention, the polyester-based structure (100) may have a MD / TD tensile strength ratio of 0.90 to 1.10, where MD (Machine direction) represents the machine direction, and TD (Transverse direction) represents the direction perpendicular to the machine direction. If the MD / TD tensile strength ratio of the polyester-based structure is less than 0.90 or exceeds 1.10, the quality may deteriorate after molding, and thus, it is not suitable for use as a vehicle headliner, so the above range is preferred.

[0062] In addition, the above tensile strength can be obtained by applying a load to a Type 1 test piece at a rate of 5 mm / min according to ISO D638 and measuring the maximum load until the sample breaks.

[0063] The flexural strength of the polyester structure (100) according to the present invention may be 16 to 50 N, and the flexural modulus may be 400 to 1,100 Mpa.

[0064] If the flexural strength and flexural modulus of the polyester structure (100) are below the above range, the strength is reduced and it cannot be used for a vehicle headliner. If it exceeds the above range, the strength is too high and the formability is reduced and it cannot be used for a vehicle headliner. Therefore, the above range is preferable.

[0065] In addition, the above flexural strength and flexural modulus can be obtained by applying a load to a 50 mm x 150 mm test piece at a rate of 5 mm / min in accordance with ISO D790 and measuring the ratio of the applied stress to the maximum load and the resulting deformation.

[0066] Hereinafter, the composition and effects of the present invention will be described in more detail through examples. These examples are intended solely to illustrate the present invention, and the scope of the present invention is not limited by these examples.

[0067]

[0068] The compositions used in the examples and comparative examples are as follows.

[0069]

[0070] First and second scrim layers: Nonwoven fabric made of polyethylene terephthalate fibers with a diameter of 1 to 2 denier.

[0071] First polyester resin and second polyester resin: polyethylene terephthalate powder with Shore D of 50 to 80

[0072] Core layer nonwoven fabric: Prepared needle-punched nonwoven fabric made of low-melting polyester fibers with a diameter of 6 denier and regular polyester fibers with a diameter of 7 denier.

[0073]

[0074] Example 1

[0075] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A second polyester resin is applied to one surface of the manufactured core layer, and melt-extruded at 210°C to manufacture a second resin layer. Thereafter, a first scrim layer is positioned on the other surface of the core layer, and heat is applied to 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the second resin layer has a basis weight of 100 g / m2, the first scrim layer has a basis weight of 30 g / m2, and the needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0076]

[0077] Example 2

[0078] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A second polyester resin is applied to each surface of the manufactured core layer, and melt-extruded at 210°C to manufacture a second resin layer. Thereafter, a first scrim layer is positioned on the other surface of the core layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 750 g / m2, the second resin layer has a basis weight of 100 g / m2, and the first scrim layer has a basis weight of 30 g / m2. The needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0079]

[0080] Example 3

[0081] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A second polyester resin is applied to one surface of the manufactured core layer, and melt-extruded at 210°C to manufacture a second resin layer. Thereafter, a first scrim layer is positioned on the other surface of the core layer, and heat is applied to 250°C to manufacture a structure. The manufactured core layer has a basis weight of 1,100 g / m2, the second resin layer has a basis weight of 100 g / m2, the first scrim layer has a basis weight of 30 g / m2, and the needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0082]

[0083] Example 4

[0084] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A second polyester resin is applied to one surface of the manufactured core layer, and melt-extruded at 210°C to manufacture a second resin layer. Thereafter, a first scrim layer is positioned on the other surface of the core layer, and heat is applied to 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the second resin layer has a basis weight of 50 g / m2, the first scrim layer has a basis weight of 30 g / m2, and the needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0085]

[0086] Example 5

[0087] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A second polyester resin is applied to one surface of the manufactured core layer, and melt-extruded at 210°C to manufacture a second resin layer. Thereafter, a first scrim layer is positioned on the other surface of the core layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the second resin layer has a basis weight of 150 g / m2, and the first scrim layer has a basis weight of 40 g / m2. The needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0088]

[0089] Example 6

[0090] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A second polyester resin is applied to one surface of the manufactured core layer, and melt-extruded at 210°C to manufacture a second resin layer. Thereafter, a first scrim layer is positioned on the other surface of the core layer, and heat is applied to 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the second resin layer has a basis weight of 100 g / m2, the first scrim layer has a basis weight of 20 g / m2, and the needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0091]

[0092] Example 7

[0093] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A second polyester resin is applied to each surface of the manufactured core layer, and melt-extruded at 210°C to manufacture a second resin layer. Thereafter, a first scrim layer is positioned on the other surface of the core layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the second resin layer has a basis weight of 100 g / m2, and the first scrim layer has a basis weight of 40 g / m2. The needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0094]

[0095] Example 8

[0096] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A second polyester resin is applied to one surface of the manufactured core layer, and melt-extruded at 210°C to manufacture a second resin layer. Thereafter, a first scrim layer is positioned on the other surface of the core layer, and heat is applied to 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the second resin layer has a basis weight of 100 g / m2, and the first scrim layer has a basis weight of 30 g / m2. The needle-punched nonwoven fabric is composed of 25 wt% of low-melting-point polyester fiber and 75 wt% of regular polyester fiber.

[0097]

[0098] Example 9

[0099] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A second polyester resin is applied to one surface of the manufactured core layer, and melt-extruded at 210°C to manufacture a second resin layer. Thereafter, a first scrim layer is positioned on the other surface of the core layer, and heat is applied to 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the second resin layer has a basis weight of 100 g / m2, and the first scrim layer has a basis weight of 30 g / m2. The needle-punched nonwoven fabric is composed of 35 wt% of low-melting-point polyester fiber and 65 wt% of regular polyester fiber.

[0100]

[0101] Example 10

[0102] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A first polyester resin and a second polyester resin are respectively applied to both surfaces of the manufactured core layer, and melt-extruded at 210°C to manufacture a first resin layer and a second resin layer. Thereafter, a first scrim layer and a second scrim layer are positioned on the surfaces of the first resin layer and the second resin layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the first resin layer and the second resin layer each have a basis weight of 100 g / m2, and the first scrim layer and the second scrim layer each have a basis weight of 40 g / m2. The needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0103]

[0104] Example 11

[0105] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A first polyester resin and a second polyester resin are respectively applied to both surfaces of the manufactured core layer, and melt-extruded at 210°C to manufacture a first resin layer and a second resin layer. Thereafter, a first scrim layer and a second scrim layer are positioned on the surfaces of the first resin layer and the second resin layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 750 g / m2, the first resin layer and the second resin layer each have a basis weight of 100 g / m2, and the first scrim layer and the second scrim layer each have a basis weight of 40 g / m2. The needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0106]

[0107] Example 12

[0108] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A first polyester resin and a second polyester resin are respectively applied to both surfaces of the manufactured core layer, and melt-extruded at 210°C to manufacture a first resin layer and a second resin layer. Thereafter, a first scrim layer and a second scrim layer are positioned on the surfaces of the first resin layer and the second resin layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 1,100 g / m2, the first resin layer and the second resin layer each have a basis weight of 100 g / m2, and the first scrim layer and the second scrim layer each have a basis weight of 40 g / m2. The needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0109]

[0110] Example 13

[0111] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A first polyester resin and a second polyester resin are respectively applied to both surfaces of the manufactured core layer, and melt-extruded at 210°C to manufacture a first resin layer and a second resin layer. Thereafter, a first scrim layer and a second scrim layer are positioned on the surfaces of the first resin layer and the second resin layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the first resin layer and the second resin layer each have a basis weight of 50 g / m2, and the first scrim layer and the second scrim layer each have a basis weight of 40 g / m2. The needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0112]

[0113] Example 14

[0114] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A first polyester resin and a second polyester resin are respectively applied to both surfaces of the manufactured core layer, and melt-extruded at 210°C to manufacture a first resin layer and a second resin layer. Thereafter, a first scrim layer and a second scrim layer are positioned on the surfaces of the first resin layer and the second resin layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the first resin layer and the second resin layer each have a basis weight of 150 g / m2, and the first scrim layer and the second scrim layer each have a basis weight of 40 g / m2. The needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0115]

[0116] Example 15

[0117] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A first polyester resin and a second polyester resin are respectively applied to both surfaces of the manufactured core layer, and melt-extruded at 210°C to manufacture a first resin layer and a second resin layer. Thereafter, a first scrim layer and a second scrim layer are positioned on the surfaces of the first resin layer and the second resin layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the first resin layer and the second resin layer each have a basis weight of 100 g / m2, and the first scrim layer and the second scrim layer each have a basis weight of 20 g / m2. The needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0118]

[0119] Example 16

[0120] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A first polyester resin and a second polyester resin are respectively applied to both surfaces of the manufactured core layer, and melt-extruded at 210°C to manufacture a first resin layer and a second resin layer. Thereafter, a first scrim layer and a second scrim layer are positioned on the surfaces of the first resin layer and the second resin layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the first resin layer and the second resin layer each have a basis weight of 100 g / m2, and the first scrim layer and the second scrim layer each have a basis weight of 30 g / m2. The needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0121]

[0122] Example 17

[0123] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A first polyester resin and a second polyester resin are respectively applied to both surfaces of the manufactured core layer, and melt-extruded at 210°C to manufacture a first resin layer and a second resin layer. Thereafter, a first scrim layer and a second scrim layer are positioned on the surfaces of the first resin layer and the second resin layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the first resin layer and the second resin layer each have a basis weight of 100 g / m2, and the first scrim layer and the second scrim layer each have a basis weight of 40 g / m2. The needle-punched nonwoven fabric is composed of 25 wt% of low-melting-point polyester fiber and 75 wt% of regular polyester fiber.

[0124]

[0125] Example 18

[0126] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A first polyester resin and a second polyester resin are respectively applied to both surfaces of the manufactured core layer, and melt-extruded at 210°C to manufacture a first resin layer and a second resin layer. Thereafter, a first scrim layer and a second scrim layer are positioned on the surfaces of the first resin layer and the second resin layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the first resin layer and the second resin layer each have a basis weight of 100 g / m2, and the first scrim layer and the second scrim layer each have a basis weight of 40 g / m2. The needle-punched nonwoven fabric is composed of 35 wt% of low-melting-point polyester fiber and 65 wt% of regular polyester fiber.

[0127]

[0128] Comparative Example 1

[0129] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A second polyester resin is applied to one surface of the manufactured core layer, and melt-extruded at 210°C to manufacture a second resin layer. Thereafter, a first scrim layer is positioned on the other surface of the core layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 600 g / m2, the second resin layer has a basis weight of 100 g / m2, the first scrim layer has a basis weight of 30 g / m2, and the needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0130]

[0131] Comparative Example 2

[0132] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A second polyester resin is applied to one surface of the manufactured core layer, and melt-extruded at 210°C to manufacture a second resin layer. Thereafter, a first scrim layer is positioned on the other surface of the core layer, and heat is applied to 250°C to manufacture a structure. The manufactured core layer has a basis weight of 1,300 g / m2, the second resin layer has a basis weight of 100 g / m2, the first scrim layer has a basis weight of 30 g / m2, and the needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0133]

[0134] Comparative Example 3

[0135] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A second polyester resin is applied to one surface of the manufactured core layer, and melt-extruded at 210°C to manufacture a second resin layer. Thereafter, a first scrim layer is positioned on the other surface of the core layer, and heat is applied to 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the second resin layer has a basis weight of 10 g / m2, the first scrim layer has a basis weight of 30 g / m2, and the needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0136]

[0137] Comparative Example 4

[0138] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A second polyester resin is applied to one surface of the manufactured core layer, and melt-extruded at 210°C to manufacture a second resin layer. Thereafter, a first scrim layer is positioned on the other surface of the core layer, and heat is applied to 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the second resin layer has a basis weight of 250 g / m2, the first scrim layer has a basis weight of 30 g / m2, and the needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0139]

[0140] Comparative Example 5

[0141] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A second polyester resin is applied to one surface of the manufactured core layer, and melt-extruded at 210°C to manufacture a second resin layer. Thereafter, a first scrim layer is positioned on the other surface of the core layer, and heat is applied to 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the second resin layer has a basis weight of 100 g / m2, the first scrim layer has a basis weight of 10 g / m2, and the needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0142]

[0143] Comparative Example 6

[0144] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A second polyester resin is applied to one surface of the manufactured core layer, and melt-extruded at 210°C to manufacture a second resin layer. Thereafter, a first scrim layer is positioned on the other surface of the core layer, and heat is applied to 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the second resin layer has a basis weight of 100 g / m2, and the first scrim layer has a basis weight of 80 g / m2. The needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0145]

[0146] Comparative Example 7

[0147] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A second polyester resin is applied to one surface of the manufactured core layer, and melt-extruded at 210°C to manufacture a second resin layer. Thereafter, a first scrim layer is positioned on the other surface of the core layer, and heat is applied to 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the second resin layer has a basis weight of 100 g / m2, the first scrim layer has a basis weight of 30 g / m2, and the needle-punched nonwoven fabric is composed of 10 wt% of low-melting-point polyester fiber and 90 wt% of regular polyester fiber.

[0148]

[0149] Comparative Example 8

[0150] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A second polyester resin is applied to one surface of the manufactured core layer, and melt-extruded at 210°C to manufacture a second resin layer. Thereafter, a first scrim layer is positioned on the other surface of the core layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the second resin layer has a basis weight of 100 g / m2, and the first scrim layer has a basis weight of 30 g / m2. The needle-punched nonwoven fabric is composed of 60 wt% of low-melting-point polyester fiber and 40 wt% of regular polyester fiber.

[0151]

[0152] Comparative Example 9

[0153] A core layer is manufactured using a needle-punched nonwoven fabric. A second polyester resin is applied to one surface of the manufactured core layer, and melt-extruded at 210°C to manufacture a second resin layer. Thereafter, a first scrim layer is positioned on the other surface of the core layer, and heat is applied to 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the second resin layer has a basis weight of 100 g / m2, the first scrim layer has a basis weight of 30 g / m2, and the needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fibers and 70 wt% of regular polyester fibers.

[0154]

[0155] Comparative Example 10

[0156] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A first polyester resin and a second polyester resin are respectively applied to both surfaces of the manufactured core layer, and melt-extruded at 210°C to manufacture a first resin layer and a second resin layer. Thereafter, a first scrim layer and a second scrim layer are positioned on the surfaces of the first resin layer and the second resin layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 600 g / m2, the first resin layer and the second resin layer each have a basis weight of 100 g / m2, and the first scrim layer and the second scrim layer each have a basis weight of 40 g / m2. The needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0157]

[0158] Comparative Example 11

[0159] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A first polyester resin and a second polyester resin are respectively applied to both surfaces of the manufactured core layer, and melt-extruded at 210°C to manufacture a first resin layer and a second resin layer. Thereafter, a first scrim layer and a second scrim layer are positioned on the surfaces of the first resin layer and the second resin layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 1,350 g / m2, the first resin layer and the second resin layer each have a basis weight of 100 g / m2, and the first scrim layer and the second scrim layer each have a basis weight of 40 g / m2. The needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0160]

[0161] Comparative Example 12

[0162] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A first polyester resin and a second polyester resin are respectively applied to both surfaces of the manufactured core layer, and melt-extruded at 210°C to manufacture a first resin layer and a second resin layer. Thereafter, a first scrim layer and a second scrim layer are positioned on the surfaces of the first resin layer and the second resin layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the first resin layer and the second resin layer each have a basis weight of 10 g / m2, and the first scrim layer and the second scrim layer each have a basis weight of 40 g / m2. The needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0163]

[0164] Comparative Example 13

[0165] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A first polyester resin and a second polyester resin are respectively applied to both surfaces of the manufactured core layer, and melt-extruded at 210°C to manufacture a first resin layer and a second resin layer. Thereafter, a first scrim layer and a second scrim layer are positioned on the surfaces of the first resin layer and the second resin layer, and heat is applied to 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the first resin layer and the second resin layer each have a basis weight of 250 g / m2, and the first scrim layer and the second scrim layer each have a basis weight of 40 g / m2. The needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0166]

[0167] Comparative Example 14

[0168] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A first polyester resin and a second polyester resin are respectively applied to both surfaces of the manufactured core layer, and melt-extruded at 210°C to manufacture a first resin layer and a second resin layer. Thereafter, a first scrim layer and a second scrim layer are positioned on the surfaces of the first resin layer and the second resin layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the first resin layer and the second resin layer each have a basis weight of 100 g / m2, and the first scrim layer and the second scrim layer each have a basis weight of 10 g / m2. The needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0169]

[0170] Comparative Example 15

[0171] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A first polyester resin and a second polyester resin are respectively applied to both surfaces of the manufactured core layer, and melt-extruded at 210°C to manufacture a first resin layer and a second resin layer. Thereafter, a first scrim layer and a second scrim layer are positioned on the surfaces of the first resin layer and the second resin layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the first resin layer and the second resin layer each have a basis weight of 100 g / m2, and the first scrim layer and the second scrim layer each have a basis weight of 80 g / m2. The needle-punched nonwoven fabric is composed of 30 wt% of low-melting-point polyester fiber and 70 wt% of regular polyester fiber.

[0172]

[0173] Comparative Example 16

[0174] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A first polyester resin and a second polyester resin are respectively applied to both surfaces of the manufactured core layer, and melt-extruded at 210°C to manufacture a first resin layer and a second resin layer. Thereafter, a first scrim layer and a second scrim layer are positioned on the surfaces of the first resin layer and the second resin layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the first resin layer and the second resin layer each have a basis weight of 100 g / m2, and the first scrim layer and the second scrim layer each have a basis weight of 40 g / m2. The needle-punched nonwoven fabric is composed of 10 wt% of low-melting-point polyester fiber and 90 wt% of regular polyester fiber.

[0175]

[0176] Comparative Example 17

[0177] A core layer is manufactured by laminating three layers of needle-punched nonwoven fabric. A first polyester resin and a second polyester resin are respectively applied to both surfaces of the manufactured core layer, and melt-extruded at 210°C to manufacture a first resin layer and a second resin layer. Thereafter, a first scrim layer and a second scrim layer are positioned on the surfaces of the first resin layer and the second resin layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the first resin layer and the second resin layer each have a basis weight of 100 g / m2, and the first scrim layer and the second scrim layer each have a basis weight of 40 g / m2. The needle-punched nonwoven fabric is composed of 60 wt% of low-melting-point polyester fiber and 40 wt% of regular polyester fiber.

[0178]

[0179] Comparative Example 18

[0180] A core layer is manufactured using a needle-punched nonwoven fabric. A first polyester resin and a second polyester resin are respectively applied to both surfaces of the manufactured core layer, and melt-extruded at 210°C to manufacture a first resin layer and a second resin layer. Thereafter, a first scrim layer and a second scrim layer are positioned on the surfaces of the first resin layer and the second resin layer, and heat is applied at 250°C to manufacture a structure. The manufactured core layer has a basis weight of 900 g / m2, the first resin layer and the second resin layer each have a basis weight of 100 g / m2, and the first scrim layer and the second scrim layer each have a basis weight of 40 g / m2. The spunbond nonwoven fabric is composed of 30 wt% of low-melting-point polyester fibers and 70 wt% of regular polyester fibers.

[0181]

[0182] Comparative Example 19

[0183] A glass mat and a polyethylene terephthalate nonwoven fabric are placed on each side of a polyurethane foam sheet. At this time, a urethane-based adhesive is applied between the polyurethane foam sheet and the glass mat to attach them, and a polyolefin-based hot melt film is attached between the glass mat and the polyethylene terephthalate nonwoven fabric to manufacture a structure.

[0184]

[0185] In Examples 1 to 9 and Comparative Examples 1 to 9, the basis weights of the core layer, the second resin layer, and the first scrim layer, the content of the low-melting-point polyester fiber constituting the needle-punched nonwoven fabric, and the number of layers of the nonwoven fabric constituting the core layer are as shown in Table 1 below.

[0186]

[0187] Core layer (g / m) 2 )Second resin layer (g / m) 2 )First scrim layer (g / m) 2) Low-melting point fiber content (weight %) Core layer Nonwoven fabric number of layers Example 1 900 100 30 30 3 Example 2 750 100 30 30 3 Example 3 1, 100 100 30 30 3 Example 4 900 50 30 30 3 Example 5 900 150 30 30 3 Example 6 900 100 20 30 3 Example 7 900 100 40 30 3 Example 8 900 100 30 25 3 Example 9 900 100 30 35 3Comparison Example 160010030303Comparison Example 21,35010030303Comparison Example 39001030303Comparison Example 490025030303Comparison Example 590010010303Comparison Example 690010080303Comparison Example 790010030103Comparison Example 890010030603Comparison Example 990010030301

[0188] In Examples 10 to 18 and Comparative Examples 10 to 18, the basis weights of the core layer, the first and second resin layers, and the first and second scrim layers, the content of the low-melting-point polyester fiber constituting the needle-punched nonwoven fabric, and the number of layers of the nonwoven fabric constituting the core layer are as shown in Table 2 below.

[0189]

[0190] Core layer (g / m) 2 )Resin layer (g / m) 2 )Scream layer (g / m) 2 ) Low-melting point fiber content (weight %) Core layer Nonwoven fabric number of layers Example 10 900 100 30 30 3 Example 1 1 7 5 0 100 30 30 3 Example 1 2 1, 100 100 30 30 3 Example 1 3 9 00 50 30 30 3 Example 1 4 9 00 15 0 30 30 3 Example 1 5 9 00 100 20 30 3 Example 1 6 9 00 100 40 30 3 Example 1 7 9 00 100 30 25 3 Example 1 8 9 00 100 30 35 3Comparison Example 1060010030303Comparison Example 111,35010030303Comparison Example 129001030303Comparison Example 1390025030303Comparison Example 1490010010303Comparison Example 1590010080303Comparison Example 1690010030103Comparison Example 1790010030603Comparison Example 1890010030301

[0191] Experimental Example 1 In order to compare the effects according to the basis weight of the core layer, the flexural strength, flexural modulus, and tensile strength ratio (MD / TD) of the structures manufactured in Examples 1 to 3 and Comparative Examples 1 and 2 were measured using the following measurement methods, and the results are shown in Table 3 below.

[0192] [measurement method]

[0193] Flexural strength and flexural modulus: According to ISO D790, a load is applied to a 50 mm x 150 mm test piece at a rate of 5 mm / min, and the ratio of applied stress to the maximum load and the resulting deformation is measured.

[0194] Tensile strength: According to ISO D638, load is applied to the test piece Type 1 at a rate of 5 mm / min and the maximum load until the sample breaks is measured.

[0195]

[0196] Flexural strength (N)Flexural modulus (MPa)Tensile strength ratio (MD / TD)Example 119.2 / 22492 / 4740.92Example 217.3 / 17470 / 4300.90Example 322.9 / 19.3674 / 5520.98Comparative example 18.7 / 11.1314 / 2980.88Comparative example 225.8 / 30.8416 / 3601.13

[0197] Referring to Table 3 above, the basis weight of the core layer is 750 to 1,100 g / m 2 In case (Examples 1 to 3), the basis weight of the core layer is 600 g / m 2 It can be confirmed that the flexural strength and flexural modulus are superior to those of (Comparative Example 1), and the basis weight of the core layer is 1,350 g / m 2 In this case (comparative example 2), it can be confirmed that the flexural modulus is superior and the flexural strength is similar. Meanwhile, when the basis weight of the core layer is 1,350 g / m 2 In this case (comparative example 2), it can be confirmed that the strength ratio is 1.13, exceeding 1.10, and the basis weight of the core layer is 600 g / m. 2In this case (comparative example 1), it can be confirmed that the strength ratio is 0.88, which is less than 0.90.

[0198]

[0199] Experimental Example 2

[0200] In order to compare the effect according to the basis weight of the second resin layer, the flexural strength, flexural modulus, and tensile strength ratio (MD / TD) of the structures manufactured in Examples 1, 4, and 5 and Comparative Examples 3 and 4 were measured using the same measurement method as in Experimental Example 1, and the results are shown in Table 4 below.

[0201]

[0202] Classification Flexural strength (N) Flexural modulus (MPa) Tensile strength ratio (MD / TD) Example 119.2 / 22492 / 4740.92 Example 417.3 / 19490 / 4660.91 Example 524 / 23470 / 4560.94 Comparative example 315.6 / 17443 / 4190.82 Comparative example 422 / 23501 / 5331.13

[0203] Referring to Table 4 above, the basis weight of the second resin layer is 50 to 150 g / m 2 In case (Examples 1, 4, 5), the basis weight of the second resin layer is 10 g / m 2 It can be confirmed that the flexural strength and flexural modulus are superior to those of (Comparative Example 3), and the basis weight of the second resin layer is 250 g / m 2 In this case (comparative example 4), it can be confirmed that the flexural strength and flexural modulus are similar. Meanwhile, when the basis weight of the second resin layer is 250 g / m 2 In this case (comparative example 4), it can be confirmed that the strength ratio is 1.13, exceeding 1.10, and the basis weight of the second resin layer is 10 g / m 2 In this case (comparative example 3), it can be confirmed that the strength ratio is 0.82, which is less than 0.9.

[0204]

[0205] Experimental Example 3

[0206] In order to compare the effect according to the basis weight of the first scrim layer, the flexural strength, flexural modulus, and tensile strength ratio (MD / TD) of the structures manufactured in Examples 1, 6, and 7 and Comparative Examples 5 and 6 were measured using the same measurement method as in Experimental Example 1, and the results are shown in Table 5 below.

[0207]

[0208] Classification Flexural strength (N) Flexural modulus (MPa) Tensile strength ratio (MD / TD) Example 1 19.2 / 22492 / 4740.92 Example 6 17.8 / 19440 / 4140.98 Example 7 19.3 / 20.1449 / 5161.00 Comparative example 5 19 / 20.4398 / 3810.89 Comparative example 6 22.5 / 19.1636 / 4181.15

[0209] Referring to Table 5 above, the basis weight of the first scrim layer is 20 to 40 g / m 2 In case (Examples 1, 6, 7), the basis weight of the first scrim layer is 10 g / m 2 It can be confirmed that the flexural strength and flexural modulus are superior to those of (Comparative Example 5), and the basis weight of the first scrim layer is 80 g / m 2 In this case (comparative example 6), it can be confirmed that the flexural strength and flexural modulus are similar. Meanwhile, when the basis weight of the first scrim layer is 80 g / m 2 In this case (comparative example 6), it can be confirmed that the strength ratio exceeds 1.10 at 1.15, and the basis weight of the first scrim layer is 10 g / m 2 In this case (comparative example 5), it can be confirmed that the strength ratio is 0.89, which is less than 0.90.

[0210]

[0211] Experimental Example 4

[0212] In order to compare the effects according to the content of low-melting polyethylene terephthalate constituting the core layer, the flexural strength, flexural modulus, and tensile strength ratio (MD / TD) of the structures manufactured in Examples 1, 8, and 9 and Comparative Examples 7 and 8 were measured using the same measurement method as in Experimental Example 1, and the results are shown in Table 6 below.

[0213]

[0214] Classification Flexural strength (N) Flexural modulus (MPa) Tensile strength ratio (MD / TD) Example 119.2 / 22492 / 4740.92 Example 817 / 19.3447 / 4260.91 Example 920.8 / 22.5434 / 4170.94 Comparative example 78 / 8133 / 1250.82 Comparative example 825.8 / 30.8547 / 5161.12

[0215] Referring to Table 6 above, when the content of low-melting-point polyethylene terephthalate constituting the core layer is 25 to 35 wt% (Examples 1, 8, 9), it can be confirmed that the flexural strength and flexural modulus are superior to those when the content of low-melting-point polyethylene terephthalate constituting the core layer is 10 wt% (Comparative Example 7), and it can be confirmed that the flexural strength and flexural modulus are similar to those when the content of low-melting-point polyethylene terephthalate constituting the core layer is 60 wt% (Comparative Example 8). Meanwhile, when the content of low-melting-point polyethylene terephthalate constituting the core layer is 60 wt% (Comparative Example 8), it can be confirmed that the tensile strength ratio is 1.12, which is more than 1.10, and when the content of low-melting-point polyethylene terephthalate constituting the core layer is 10 wt% (Comparative Example 7), it can be confirmed that the tensile strength ratio is 0.82, which is less than 0.90.

[0216]

[0217] Experimental Example 5

[0218] In order to compare the effects according to the number of layers of nonwoven fabric constituting the core layer, the flexural strength, flexural modulus, and tensile strength ratio (MD / TD) of the structures manufactured in Example 1 and Comparative Example 9 were measured using the same measurement method as in Experimental Example 1, and are shown in Table 7 below.

[0219]

[0220] Flexural strength (N)Flexural modulus (MPa)Tensile strength ratio (MD / TD)Example 119.2 / 22492 / 4740.92Comparative example 913 / 15374 / 3100.99

[0221] Referring to Table 7 above, it can be confirmed that when the number of layers of nonwoven fabric constituting the core layer is 3 (Example 1), the flexural strength and flexural modulus are superior to when the number of layers of nonwoven fabric constituting the core layer is 1 (Comparative Example 9), and when the number of layers of nonwoven fabric constituting the core layer is 1 (Comparative Example 9), the flexural strength is less than 16N.

[0222] Experimental Example 6

[0223] In order to compare the effects according to the basis weight of the core layer, the flexural strength, flexural modulus, and tensile strength ratio (MD / TD) of the structures manufactured in Examples 10 to 12 and Comparative Examples 10 and 11 were measured using the same measurement method as in Experimental Example 1, and the results are shown in Table 8 below.

[0224]

[0225] Classification Flexural strength (N) Flexural modulus (MPa) Tensile strength ratio (MD / TD) Example 1027.8 / 25.8597 / 5000.90 Example 1122 / 18.1590 / 4910.90 Example 1244.9 / 42.2990 / 8140.93 Comparative example 1010.6 / 13.9362 / 3570.86 Comparative example 1147.1 / 44.31040 / 8551.15

[0226] Referring to Table 8 above, the basis weight of the core layer is 750 to 1,100 g / m 2 In case (Examples 10 to 12), the basis weight of the core layer is 600 g / m 2 It can be confirmed that the flexural strength and flexural modulus are superior to those of (Comparative Example 10), and the basis weight of the core layer is 1,350 g / m 2 In this case (Comparative Example 11), it can be confirmed that the flexural modulus and flexural strength are similar. Meanwhile, when the basis weight of the core layer is 1,350 g / m 2 In this case (Comparative Example 11), it can be confirmed that the strength ratio is 1.15, exceeding 1.10, and the basis weight of the core layer is 600 g / m. 2 In this case (comparative example 11), it can be confirmed that the strength ratio is 0.86, which is less than 0.90.

[0227]

[0228] Experimental Example 7

[0229] In order to compare the effects according to the basis weight of the first and second resin layers, the flexural strength, flexural modulus, and tensile strength ratio (MD / TD) of the structures manufactured in Examples 10, 13, and 14 and Comparative Examples 12 and 13 were measured using the same measurement method as in Experimental Example 1, and the results are shown in Table 9 below.

[0230]

[0231] Flexural strength (N)Flexural modulus (MPa)Tensile strength ratio (MD / TD)Example 1027.8 / 25.8597 / 5000.90Example 1323.3 / 23.3522 / 5060.97Example 1425.6 / 25.6626 / 5310.95Comparative example 1218.1 / 20575 / 5150.81Comparative example 1330.5 / 27.6528 / 4981.15

[0232] Referring to Table 9 above, the basis weight of the first and second resin layers is 50 to 150 g / m 2 In the case of (Examples 10, 13, 14), the basis weight of the first and second resin layers is 10 g / m 2 It can be confirmed that the flexural strength and flexural modulus are superior to those of (Comparative Example 12), and the basis weight of the first and second resin layers is 250 g / m 2 In this case (Comparative Example 13), it can be confirmed that the flexural strength and flexural modulus are similar. Meanwhile, when the basis weight of the first and second resin layers is 250 g / m 2 In this case (Comparative Example 13), it can be confirmed that the strength ratio is 1.15, exceeding 1.10, and the basis weight of the first and second resin layers is 10 g / m 2 In this case (comparative example 12), it can be confirmed that the strength ratio is 0.81, which is less than 0.9.

[0233]

[0234] Experimental Example 8

[0235] In order to compare the effects according to the basis weight of the first and second scrim layers, the flexural strength, flexural modulus, and tensile strength ratio (MD / TD) of the structures manufactured in Examples 10, 15, and 16 and Comparative Examples 14 and 15 were measured using the same measurement method as in Experimental Example 1, and the results are shown in Table 10 below.

[0236]

[0237] Flexural strength (N)Flexural modulus (MPa)Tensile strength ratio (MD / TD)Example 1027.8 / 25.8597 / 5000.90Example 1524.3 / 24.3563 / 4980.94Example 1623.8 / 22.5569 / 5360.98Comparative example 1420.8 / 19.1455 / 3760.87Comparative example 1528.7 / 28598 / 5011.13

[0238] Referring to Table 10 above, the basis weight of the first and second scrim layers is 20 to 40 g / m 2 In the case of (Examples 10, 15, 16), the basis weight of the first and second scrim layers is 10 g / m 2 It can be confirmed that the flexural strength and flexural modulus are superior to those of (Comparative Example 14), and the basis weight of the first and second scrim layers is 80 g / m 2 In this case (Comparative Example 15), it can be confirmed that the flexural strength and flexural modulus are similar. Meanwhile, the basis weight of the first and second scrim layers is 80 g / m 2 In this case (Comparative Example 15), it can be confirmed that the strength ratio is 1.13, exceeding 1.10, and the basis weight of the first and second scrim layers is 10 g / m. 2 In this case (comparative example 14), it can be confirmed that the strength ratio is 0.87, which is less than 0.90.

[0239]

[0240] Experimental Example 9

[0241] In order to compare the effects according to the content of low-melting-point polyethylene terephthalate constituting the core layer, the flexural strength, flexural modulus, and tensile strength ratio (MD / TD) of the structures manufactured in Examples 10, 17, and 18 and Comparative Examples 16 and 17 were measured using the same measurement method as in Experimental Example 1, and the results are shown in Table 11 below.

[0242]

[0243] Flexural strength (N)Flexural modulus (MPa)Tensile strength ratio (MD / TD)Example 1027.8 / 25.8597 / 5000.90Example 1726.4 / 24.5542 / 4960.90Example 1829.2 / 27.1599 / 5150.96Comparative example 168.3 / 10.9156 / 1500.87Comparative example 1734 / 36.1630 / 6511.13

[0244] Referring to Table 11 above, when the content of low-melting point polyethylene terephthalate constituting the core layer is 25 to 35 wt% (Examples 1, 17, 18), it can be confirmed that the flexural strength and flexural modulus are superior to those when the content of low-melting point polyethylene terephthalate constituting the core layer is 10 wt% (Comparative Example 16), and it can be confirmed that the flexural strength and flexural modulus are similar to those when the content of low-melting point polyethylene terephthalate constituting the core layer is 60 wt% (Comparative Example 17). Meanwhile, when the content of low-melting point polyethylene terephthalate constituting the core layer is 60 wt% (Comparative Example 17), it can be confirmed that the tensile strength ratio is 1.13, which is more than 1.10, and when the content of low-melting point polyethylene terephthalate constituting the core layer is 10 wt% (Comparative Example 16), the tensile strength ratio is 0.87, which is 0.90. You can see that it is less than .

[0245]

[0246] Experimental Example 10

[0247] In order to compare the effects according to the number of layers of nonwoven fabric constituting the core layer, the flexural strength, flexural modulus, and tensile strength ratio (MD / TD) of the structures manufactured in Example 10 and Comparative Example 18 were measured using the same measurement method as in Experimental Example 1, and are shown in Table 12 below.

[0248]

[0249] Flexural strength (N)Flexural modulus (MPa)Tensile strength ratio (MD / TD)Example 1027.8 / 25.8597 / 5000.90Comparative example 1814.4 / 13.1407 / 2951.14

[0250] Referring to Table 12 above, it can be confirmed that when the number of layers of nonwoven fabric constituting the core layer is 3 (Example 10), the flexural strength and flexural modulus are superior to when the number of layers of nonwoven fabric constituting the core layer is 1 (Comparative Example 18). Meanwhile, when the number of layers of nonwoven fabric constituting the core layer is 1 (Comparative Example 18), it can be confirmed that the tensile strength ratio is 1.14, exceeding 1.10, and the flexural strength is less than 16 N.

[0251]

[0252] Experimental Example 11

[0253] In order to evaluate the recyclability of the structures manufactured in Example 10 and Comparative Example 19, the structures were crushed into recycled chips and the recyclability was verified through a radioactivity test.

[0254]

[0255] It was confirmed that the structure according to Example 10 did not cause truncation during radiation and had excellent workability.

[0256] On the other hand, it was confirmed that the structure according to Comparative Example 19 was made of heterogeneous composite materials such as polyethylene terephthalate, polyurethane, polyolefin, and glass fiber, and thus radiation and recycling were impossible due to the high foreign matter content.

[0257]

[0258] [Explanation of symbols]

[0259] 100: Polyester structure 110: First scrim layer

[0260] 120: 1st resin layer 130: Core layer

[0261] 140: Second resin layer 150: Second scrim layer

[0262]

[0263] The present invention can provide a polyester-based structure for a vehicle headliner that improves recycling efficiency based on polyester fibers and has excellent formability and rigidity while being composed of a single material.

Claims

A first scrim layer comprising a first polyester fiber; A core layer positioned on the lower surface of the first scrim layer and including a third polyester fiber and a fourth polyester fiber; and A second resin layer located on the lower surface of the core layer and including a second polyester resin; A polyester structure comprising: In the first paragraph, A polyester-based structure, wherein the polyester-based structure further comprises a first resin layer comprising a first polyester resin between the first scrim layer and the core layer. In the first paragraph, A polyester-based structure, wherein the polyester-based structure further includes a second scrim layer including a second polyester fiber on the lower surface of the second resin layer. In the first paragraph, A polyester structure having a basis weight of the first scrim layer of 10 to 60 g / ㎡. In the first paragraph, A polyester structure, wherein the first polyester fiber is a polyethylene terephthalate fiber. In the second paragraph, A polyester-based structure, wherein the basis weight of the first resin layer is 20 to 200 g / ㎡. In the second paragraph, A polyester structure, wherein the first polyester resin is a polyethylene terephthalate resin. In the first paragraph, A polyester structure having a weight of the core layer of 700 to 1,200 g / ㎡. In the first paragraph, A polyester structure, wherein the core layer comprises 20 to 50 wt% of a third polyester fiber and 50 to 80 wt% of a fourth polyester fiber. In the first paragraph, A polyester structure, wherein the third polyester fiber is a low-melting polyethylene terephthalate fiber, and the fourth polyester fiber is a regular polyethylene terephthalate fiber. In the first paragraph, A polyester-based structure, wherein the core layer comprises one or more non-woven fabrics. In the first paragraph, A polyester-based structure in which the core layer is formed by laminating two or more non-woven fabrics. In the third paragraph, A polyester structure having a basis weight of the second scrim layer of 10 to 60 g / ㎡. In the third paragraph, A polyester structure, wherein the second polyester fiber is a polyethylene terephthalate fiber. In the first paragraph, A polyester-based structure, wherein the basis weight of the second resin layer is 20 to 200 g / ㎡. In the first paragraph, A polyester structure, wherein the second polyester resin is a polyethylene terephthalate resin. In the first paragraph, The above polyester-based structure is a polyester-based structure having a tensile strength ratio of MD / TD of 0.90 to 1.

10. In the first paragraph, The above polyester-based structure is a polyester-based structure for use as a vehicle headliner.

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