KR102100668B1 - Method for producing skin material for interior material of automobile and skin material for interior material of automobile using the same - Google Patents

Abstract

Preparing a nonwoven fabric using a sea-island composite yarn or a split-type composite yarn; Preparing a resin composition comprising an aqueous polyurethane-based resin having a weight average molecular weight of 30,000 g / mol to 70,000 / mol; And forming a nonwoven fabric impregnated with an aqueous polyurethane-based resin using the nonwoven fabric and the resin composition.
In addition, it is manufactured according to a method of manufacturing a skin material for automobile interior materials, and provides a skin material for automobile interior materials including a stable layer formed of a nonwoven fabric impregnated with the aqueous polyurethane resin.

Description

Manufacturing method of skin material for automobile interior materials and skin material for automobile interior materials {METHOD FOR PRODUCING SKIN MATERIAL FOR INTERIOR MATERIAL OF AUTOMOBILE AND SKIN MATERIAL FOR INTERIOR MATERIAL OF AUTOMOBILE USING THE SAME}

It relates to a method for manufacturing a skin material for a car interior material and a skin material for a car interior material.

The skin material that forms the surface of the automobile interior material is an important part in terms of safety and design since the occupant checks with the naked eye and has continuous physical contact.

Such a skin material is made of synthetic or artificial leather, and includes, for example, a layered structure of a skin layer / adhesive layer / stable layer, among which, in the case of a stable layer, for example, a woven or nonwoven fabric made of an organic fiber or an inorganic fiber material Since it is formed of, it can absorb shock from the outside and play a role of expressing the sensibility of automobile interior materials, so research is being conducted in terms of stability and design.

Generally, the stable layer is sequentially immersed in a non-woven fabric in an oily polyurethane-based resin composition and then dried to impregnate the polyurethane-based resin and an organic solvent, and then, a water washing process using water is applied to the organic solvent impregnated into the non-woven fabric. It is produced through the process of washing properly.

At this time, a number of pores may be formed inside the nonwoven fabric as the organic solvent is dissolved in water and discharged by a water washing process.

Thus, by impregnating the polyurethane-based resin, while having a buffer and durability to absorb the impact from the outside, while forming a number of pores by the water washing process, the sensitivity such as flexibility, softness, tangle, etc. required as a skin material Can have

However, when an oil-based polyurethane-based resin composition is used, environmental waste occurs due to the discharge of an organic solvent, and when a skin material is applied to a product, volatile organic compounds are generated therefrom, resulting in very poor air quality inside the vehicle. Can be.

In one embodiment of the present invention, while providing excellent eco-friendliness, excellent stability, and excellent sensibility, the manufacturing process is simplified to provide a method for manufacturing a skin material for automobile interior materials with improved production efficiency and economic efficiency.

In another embodiment of the present invention, there is provided a skin material for automobile interior material that implements excellent eco-friendliness, excellent stability, and good sensitivity.

However, the technical problem to be achieved by the present invention is not limited to the problems mentioned above, and other problems not mentioned will be clearly understood by a person skilled in the art from the following description.

In one embodiment according to the present invention, using the island-in-the-sea composite yarn or split type composite yarn to prepare a non-woven fabric; Preparing a resin composition comprising an aqueous polyurethane-based resin having a weight average molecular weight of 30,000 g / mol to 70,000 / mol; And forming a nonwoven fabric impregnated with an aqueous polyurethane-based resin using the nonwoven fabric and the resin composition.

In another embodiment of the present invention, it is manufactured according to a method of manufacturing a skin material for automobile interior materials, and provides a skin material for automobile interior materials including a stable layer formed of a nonwoven fabric impregnated with the aqueous polyurethane resin.

The manufacturing method of the skin material for automobile interior materials can improve production efficiency and economic efficiency by simplifying the manufacturing process while realizing excellent eco-friendliness, excellent stability, and excellent sensitivity.

In addition, the skin material for automobile interior materials can realize excellent eco-friendliness, excellent stability, and excellent sensitivity.

1 is a schematic process flow diagram of a method of manufacturing a skin material for interior materials according to an embodiment of the present invention.
2 is a schematic cross-sectional view of a skin material for a vehicle interior material according to another embodiment of the present invention.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings so that those skilled in the art to which the present invention pertains can easily practice. The present invention can be implemented in many different forms and is not limited to the embodiments described herein.

In order to clearly describe the present invention, parts irrelevant to the description are omitted, and the same reference numerals are assigned to the same or similar elements throughout the specification.

In the drawings, the thickness is enlarged to clearly express the various layers and regions. In the drawings, thicknesses of some layers and regions are exaggerated for convenience of description.

In the following, an arbitrary configuration is formed on the top (or bottom) of the substrate or on the top (or bottom) of the substrate. And any configuration formed on (or under) the substrate is not limited to not including other configurations.

In one embodiment of the present invention, the step of preparing a non-woven fabric using a sea-island type or a split type composite yarn (S1); Preparing a resin composition comprising an aqueous polyurethane-based resin having a weight average molecular weight of about 30,000 g / mol to about 70,000 g / mol (S2); And forming a nonwoven fabric impregnated with an aqueous polyurethane resin using the nonwoven fabric and the resin composition (S3).

The aqueous polyurethane-based resin may be easily dispersed in an aqueous solvent such as water, including a hydroxy group, a carboxyl group, or both, for example, may be formed by reacting a polyol compound, an isocyanate compound, a carboxylic acid compound, etc. It is not limited.

For example, the aqueous polyurethane-based resin has a weight-average molecular weight of about 30,000 g / mol to about 70,000 g / mol, thereby realizing tackability for securing excellent processability, and shortening the drying time to improve processability. Can be improved. If the weight-average molecular weight of the aqueous polyurethane-based resin is less than the above range, there is a problem that the tack property is deteriorated, and if it exceeds the above range, drying time may be excessively increased, and workability may be deteriorated.

In general, the stable layer included in the skin material used for the interior of the vehicle interior material, sequentially immersed in a non-woven fabric in an oil-based polyurethane resin composition and dried to impregnate the polyurethane-based resin and an organic solvent, followed by using water It is produced through the process of properly washing the organic solvent impregnated into the nonwoven fabric by applying a water washing process.

At this time, a number of pores may be formed inside the nonwoven fabric as the organic solvent impregnated into the nonwoven fabric by the washing process is dissolved in water and discharged.

As described above, by impregnating the polyurethane-based resin, while having cushioning and durability to absorb shock from the outside, a number of pores are formed by a water washing process to provide the softness, softness, and filling sensibility required as a skin material. Can have

However, when an oil-based polyurethane-based resin composition is used, environmental waste occurs due to the discharge of an organic solvent, and when a skin material is applied to a product, volatile organic compounds are generated therefrom, resulting in very poor air quality inside the vehicle. Can be.

Thus, in one embodiment of the present invention, by using a resin composition containing an aqueous polyurethane-based resin having a weight average molecular weight satisfying the above range, the organic solvent discharge problem caused by using an oil-based polyurethane-based resin composition is eliminated, thereby providing excellent eco-friendliness. In addition, since volatile organic compounds are not generated inside the vehicle, there is an advantage of effectively improving air quality and realizing excellent stability.

At the same time, by using an aqueous polyurethane-based resin composition that is not oily, the manufacturing process can be simplified compared to the case of using an oily polyurethane-based resin, and thus production efficiency and economic efficiency can be improved.

1 is a schematic process flow diagram of a method of manufacturing a skin material for interior materials according to an embodiment of the present invention.

Referring to Figure 1, the manufacturing method includes the step (S1) of preparing a non-woven fabric using a sea-island type or a split type composite yarn.

In the above manufacturing method, a non-woven fabric can be prepared using a sea-island type or a split-type composite yarn, and the sea-island type or divided type composite yarn can be appropriately used in a kind known in the art, and is not particularly limited.

In general, the composite yarn can be divided into a sea-island type (sea island type) composite yarn and a split type (split type) composite yarn.

The island-in-the-sea type may consist of a sea component and an island component, and specifically, a structure in which the sea component and island component are copolymerized with each other. At this time, the island-in-the-sea composite yarn can obtain ultrafine fibers by dissolving the sea component.

In one embodiment, the sea component is from a group consisting of polystyrere, 2-ethylhexylacrylate copolymer, polyester, polyethyleneglycol, and combinations thereof. It may include a selected one, the island (島) component is polyamide (Polyamide (Nylon 6)), polyethylene (Polyethylene), polypropylene (Polyproplene), polyphenylene sulfide (Polyphenylene sulfide) and a combination thereof It may include one selected from the group.

In addition, the split type can be obtained by exfoliating two components by performing chemical or physical treatment on the composite fiber, and can be composed of, for example, nylon and polyester (Nylon 6, Polyester).

In one embodiment, the island-in-the-sea composite yarn may be a mixture of 30% by weight to 50% by weight of polyester shrinkage yarn and 50% by weight to 70% by weight of polyester yarn as a microfiber of bicomponent.

In addition, in one embodiment, the divided composite yarn may be a mixture of 30% by weight to 40% by weight of polyester shrinkage yarn and 60% by weight to 70% by weight of polyester yarn as microfibers of bicomponent.

In addition, the nonwoven fabric may be prepared by forming according to a method known in the art, for example, a web forming step, a web bonding step; And may be formed by applying a processing step, and may be formed using a method such as a deposition method, a spray method, a needle punch method, a stitch method, a filament method, an adhesive fiber method, a thermal pressure method, but is not limited thereto. It is not.

In one embodiment, when the non-woven fabric is prepared using the island-in-the-sea composite yarn, a coating composition containing a polyvinyl alcohol (PVA) may be coated on the surface of the nonwoven fabric. At this time, the polyvinyl alcohol-containing coating composition may be penetrated into the inside of the nonwoven fabric, and thus specifically the outer surface of the nonwoven fabric; And the polyvinyl alcohol-containing coating composition may be coated on at least a portion of the inner surface of the nonwoven fabric.

The outer surface of the nonwoven fabric means the outermost surface exposed to the outside, and the inner surface means a surface existing inside the nonwoven fabric, for example, a surface forming pores and a surface connecting a plurality of pores.

The polyvinyl alcohol-containing coating composition may be coated on, for example, all or part of the outer surface of the non-woven fabric, but the inner surface of the non-woven fabric is due to its porous structure in the process of coating the outer surface, resulting in the polyvinyl alcohol As the coating composition is infiltrated into the inside of the nonwoven fabric, as a result, a coating may occur, so that coating may occur on a part of the inner surface, and the range of coating may be appropriately determined according to the purpose and use of the invention, It is not particularly limited.

When the polyvinyl alcohol coating composition is applied to the nonwoven fabric made of the island-in-the-sea composite yarn, the polyvinyl alcohol coating composition fills the porous structure inside the nonwoven fabric, and subsequently voids are generated in the nonwoven fabric by eluting the polyvinyl alcohol. By doing so, it is possible to maximize the soft sensibility in the skin material for automobile interior materials.

For example, the polyvinyl alcohol-containing coating composition may include about 1% to about 30% by weight of polyvinyl alcohol. That is, the polyvinyl alcohol-containing coating composition may be an aqueous solution containing polyvinyl alcohol in the above range.

In addition, when the non-woven fabric is prepared using the island-in-the-sea composite yarn, the method of manufacturing the skin material for automobile interior materials is reduced by drying the nonwoven fabric impregnated with water-based polyurethane resin with hot water or a weakly basic aqueous solution at 40 ° C to 100 ° C and drying it. It may further include;

The 'weight loss' means reducing the weight of the nonwoven fabric impregnated with the aqueous polyurethane resin, and the nonwoven fabric impregnated with the aqueous polyurethane resin is 40? It may be reduced by treating one or both of the hot water and the weakly basic aqueous solution of 100 to 100? In sequential order.

For example, the non-woven fabric impregnated with the aqueous polyurethane resin may have a reduction ratio of about 30% to about 50%. When the weight before the weight loss process of the nonwoven fabric impregnated with the water-based polyurethane resin is A and the weight after the weight loss process is B, the 'loss rate' can be derived by the following equation.

[expression]

Loss rate (%) = (AB) / A × 100

By reducing the reduction ratio of the non-woven fabric impregnated with the water-based polyurethane resin, the skin material for automobile interior materials derived from the non-woven fabric manufactured from the island-in-the-sea composite yarn can embody excellent sensibility such as softness, softness, and tangle. At the same time, it is possible to realize excellent eco-friendliness.

When impregnating the non-woven fabric with the aqueous polyurethane-based resin, unlike the case of impregnating the oil-based polyurethane-based resin, the washing step of washing the organic solvent is omitted, so that the organic solvent inside the non-woven fabric is dissolved in water and discharged. Since pores cannot be formed, the sensitivity, such as softness, softness, and tangle, required as a skin material applied to an automobile interior material may be deteriorated.

However, in one embodiment according to the present invention, it is possible to sufficiently compensate for these drawbacks through a process of reducing the nonwoven fabric with hot water or a weakly basic aqueous solution, as will be described later in detail.

As described above, the nonwoven fabric manufactured using the island-in-the-sea composite yarn may be coated with a polyvinyl alcohol-containing coating composition on the surface to form a polyvinyl alcohol coating layer on the outer surface or the inner surface of the nonwoven fabric. After the non-woven fabric is impregnated with an aqueous polyurethane-based resin, the polyvinyl alcohol coating layer is dissolved by subjecting the non-woven fabric prepared using the island-in-the-sea composite yarn to a 40 ° C to 100 ° C hot water or weak basic aqueous solution. It can be discharged, and accordingly, a number of pores are formed inside the non-woven fabric, so that the structure can be well maintained, so that the sensitivity, such as softness, softness, and feeling of filling required for a car interior material can be sufficiently implemented. .

In addition, when forming a nonwoven fabric impregnated with a polyurethane resin from a nonwoven fabric prepared by using the island-in-the-sea composite yarn, a portion of the sea component of the island-in-the-sea composite yarn may be dissolved to form ultrafine fibers. This may be performed through a process of reducing the non-woven fabric impregnated with the polyurethane resin with a weakly basic aqueous solution.

For example, the weakly basic aqueous solution may be a sodium hydroxide (NaOH) aqueous solution of about 2% to about 10% by weight.

In one embodiment, when the nonwoven fabric is prepared using the divided composite yarn, a nonwoven fabric having a density of about 0.20 g / cm 3 to about 0.40 g / cm 3 may be prepared. By using a non-woven fabric having the above-described density range, it is possible to sufficiently implement sensibility such as softness, softness, and filling.

Specifically, when a non-woven fabric is prepared using the split-type composite yarn, the method of manufacturing a skin material for a vehicle interior includes dividing the split-type composite yarn of the nonwoven fabric impregnated with the aqueous polyurethane-based resin; And a step of buffing the nonwoven fabric.

The nonwoven fabric manufactured using the divided composite yarn may be physically divided through the physical division process using the pressure of the water to provide an excellent touch feeling to the skin material for automobile interior materials.

Specifically, the dividing process may be performed at a water pressure of about 100 bar to about 400 bar. By pressurizing the water pressure with the pressure in the above range, the divided composite yarn can be divided to an appropriate level to sufficiently improve the softness and softness of the skin material for automobile interior materials.

In addition, the non-woven fabric manufactured using the split-type composite yarn may be processed through the buffing process to achieve improved soft sensibility.

Referring to FIG. 1, the manufacturing method includes preparing a resin composition comprising an aqueous polyurethane-based resin having a weight average molecular weight of about 30,000 g / mol to about 70,000 g / mol (S2).

In addition, the resin composition may be prepared by further mixing at least one selected from the group consisting of water, a heat stabilizer, a light stabilizer pigment, and combinations thereof.

In addition, the manufacturing method includes the step (S3) of forming a nonwoven fabric impregnated with an aqueous polyurethane-based resin using the nonwoven fabric and the resin composition.

For example, in the step (S3), the non-woven fabric is supported on the resin composition and then taken out and dried or sprayed on the non-woven fabric and dried to form a non-woven fabric impregnated with the aqueous polyurethane-based resin. However, it is not limited thereto.

In the step of forming the nonwoven fabric impregnated with the aqueous polyurethane-based resin, the aqueous polyurethane-based resin is impregnated to be included in an amount of about 30% to about 60% by weight based on the total weight of the nonwoven fabric impregnated with the aqueous polyurethane-based resin. Can be.

By impregnating the aqueous polyurethane-based resin to be included in the content within the above range, while realizing excellent filling in the nonwoven fabric, at the same time, the nonwoven fabric can realize soft physical properties after drying. For example, when the content of the aqueous polyurethane-based resin is less than the above range, there is a problem of insufficient filling in the nonwoven fabric, and when it exceeds the above range, there is a problem that it becomes too hard after drying.

A method of manufacturing a skin material for automobile interior materials according to an embodiment of the present invention is to use an aqueous polyurethane resin, a process of solidifying a polyurethane resin in an organic solvent when compared with a case in which a nonwoven fabric is impregnated using an oily polyurethane resin. And it may not include a process for washing with water, it is possible to simultaneously implement excellent process efficiency and environmentally friendly effects.

The manufacturing method may further include forming a stable layer having a thickness of about 0.7 mm to about 2.0 mm using a nonwoven fabric impregnated with the aqueous polyurethane resin. In the above step, the nonwoven fabric impregnated with the aqueous polyurethane resin may be formed as a stable layer, or an additional processing process such as cutting may be applied to the prepared nonwoven fabric to form a stable layer.

Since the stable layer is formed to a thickness within the above range, it is possible to sufficiently absorb the impact from the outside and provide sufficient stability to the skin layer without excessively increasing the total thickness of the skin material for automobile interior materials.

In addition, the manufacturing method may further include the step of forming an adhesive layer on top of the stable layer. The adhesive layer may be a solvent-free adhesive layer or a solvent-type adhesive layer.

In general, in the case of forming an adhesive layer containing an organic solvent and an adhesive layer containing an aqueous solvent, there is a problem in that the aqueous polyurethane-based resin contained in the stable layer reacts with the solvent contained in them to promote hydrolysis resistance.

In one embodiment, the manufacturing method effectively prevents a chemical reaction that may occur between the aqueous polyurethane-based resin and the solvent included in the stable layer when the adhesive layer containing the solvent is prepared by forming a solvent-free adhesive layer. As a result, it is possible to effectively prevent the hydrolysis phenomenon. In addition, since volatile organic compounds are not generated, it is possible to further improve eco-friendliness and stability.

The solvent-free adhesive layer may be formed by applying and drying a liquid polyurethane resin, for example, a liquid poly having a viscosity of about 10000 cps to about 5000 cps at a temperature of about 50 ° C. to about 90 ° C. on the top of the stable layer. It can be formed by applying and drying a urethane-based resin. That is, when the temperature of the liquid polyurethane resin is changed from about 50 ° C to about 90 ° C, the viscosity may change from about 10000 cps to about 5000 cps.

By using a liquid polyurethane resin having a viscosity in the above range in the temperature range, it can be more uniformly applied to the top of the stable layer, so that the solvent-free adhesive layer can be stably and easily formed.

At this time, the method for applying the liquid polyurethane resin, for example, die coating method, gravure coating method, knife coating method, bar coating method, spray coating method, or any one selected from screen printing method may be used. However, it is not limited thereto.

Further, for example, the liquid polyurethane resin is applied on top of the stable layer, and then about 30? It can be formed by drying at a temperature of about 130 ?. By drying at a temperature within the above range, it can be sufficiently dried within a suitable time without deterioration of the polyurethane resin.

In another embodiment, the adhesive layer may be a solvent-type adhesive layer. As described above, the solvent-free adhesive layer is preferable in terms of hydrolysis resistance and eco-friendliness, but the solvent-type adhesive layer may be more preferable in terms of coatability and processability. The solvent-type adhesive layer may include an organic solvent and a polyurethane-based resin.

At this time, while using a solvent-type adhesive layer as the adhesive layer, it may be composed of a DMF-free (DMF-free) solvent-type adhesive layer that does not contain dimethylformamide (DMF, Dimethylformamide) to obtain excellent hydrolysis resistance and processability. That is, the adhesive layer according to the embodiment of the present invention may be a solvent-type adhesive layer containing a DMF-free organic solvent or a solvent-type adhesive layer containing an aqueous solvent such as water.

That is, the adhesive layer may be one selected from a solvent-free adhesive layer, a DMF-free organic solvent-type adhesive layer, and an aqueous solvent-containing solvent-type adhesive layer. Through the adhesive layer, the skin material for automobile interior materials can obtain excellent processability, moldability, hydrolysis resistance and eco-friendliness.

The adhesive layer may be formed to a thickness of about 0.1mm to about 1.0mm. By forming to a thickness within the above range, it is possible to firmly bond the upper and lower layers thereof without excessively increasing the total thickness of the skin material for automobile interior materials.

In the manufacturing method, the step of forming a skin layer on the top of the adhesive layer; may further include, further comprising the step of forming a surface treatment layer on top of the skin layer.

An uneven pattern may be formed on the surface of the skin layer, the surface treatment layer, or both of them, and thus, various three-dimensional effects may be produced to achieve excellent decoration effect. At this time, the uneven pattern may be formed using a pair of emboss rolls, but is not limited thereto.

The skin layer may be formed of a thermoplastic resin material, for example, may be formed according to a method known in the art. Specifically, a composition containing a thermoplastic resin is applied to the top of the adhesive layer and then heat cured. It may be formed by photo-curing or drying, or prepared as a separate sheet or film by a calendering process, and then laminated.

The thermoplastic resin may include at least one selected from the group consisting of polyvinyl chloride resin (PVC), thermoplastic polyolefin resin (TPO), thermoplastic polyurethane resin (TPU), polyurethane resin (PU), and combinations thereof. Can be. Specifically, the thermoplastic resin includes water-based thermoplastic polyurethane-based resin (TPU), water-based polyurethane-based resin (PU), or both, and thus can be recycled while further preventing the occurrence of scratches and the occurrence of volatile organic compounds. It is possible to realize the castle and excellent durability at the same time.

The skin layer may be formed to a thickness of about 0.1mm to about 0.5mm. By forming a thickness within the above range, sufficient durability can be realized without excessively increasing the total thickness of the skin material for automobile interior materials.

The surface treatment layer may be a layer that is coated on top of the skin layer to impart various physical properties such as anti-pollution, anti-static, and water-repellent properties.

The surface treatment layer may be formed of, for example, a surface treatment composition containing a binder resin, and specifically, formed by applying the surface treatment composition on top of the skin layer, followed by thermal curing, photocuring, or drying. Or, it can be formed by laminating on top of the skin layer after preparing as a separate film.

The binder resin may include, for example, at least one selected from the group consisting of acrylic resins, epoxy resins, polyurethane resins, polyester resins, fluorine resins, and combinations thereof, and specifically, aqueous polyurethane resins. It can effectively prevent the occurrence of scratches and volatile organic compounds, including, to implement excellent eco-friendly and excellent durability.

The surface treatment composition may further include at least one selected from the group consisting of, for example, a thermal initiator, photoinitiator, flame retardant, thermal stabilizer, reaction accelerator, and combinations thereof, but is not limited thereto.

The surface treatment layer may be formed to a thickness of about 10㎛ to about 40㎛. By forming a thickness within the above range, the total thickness of the skin material for automobile interior materials can be sufficiently protected without excessively increasing it.

The skin material for automobile interior materials manufactured by the manufacturing method may be applied, for example, to form a skin of a dashboard, door trim, or sheet, but is not limited thereto.

In another embodiment of the present invention, it is manufactured according to a method of manufacturing a skin material for automobile interior materials, and provides a skin material for automobile interior materials including a stable layer formed of a nonwoven fabric impregnated with the aqueous polyurethane resin. The stable layer is as described above in one embodiment.

The stable layer may be formed, for example, by using the nonwoven fabric impregnated with the aqueous polyurethane resin as it is, or by applying an additional processing process such as cutting.

As described above, the oil-based polyurethane-based resin composition is prepared by using a resin composition comprising an aqueous polyurethane-based resin having a weight average molecular weight of about 30,000 g / mol to about 70,000 g / mol according to the method for manufacturing a skin material for automobile interior materials. By eliminating the problem of discharging the organic solvent due to the use, it promotes excellent eco-friendliness, and also, since no volatile organic compounds are generated inside the vehicle, there is an advantage of effectively improving air quality and realizing excellent stability.

At the same time, in the manufacturing process, the process of solidifying the polyurethane resin in the organic solvent and a separate water washing process using water may be omitted, so that the manufacturing process may be simplified, thereby improving production efficiency and economic efficiency.

The stable layer formed of the nonwoven fabric impregnated with the aqueous polyurethane resin may include the aqueous polyurethane resin in an amount of about 30% to about 60% by weight.

By impregnating the aqueous polyurethane-based resin to be included in the content within the above range, while realizing excellent filling in the nonwoven fabric, at the same time, the nonwoven fabric can realize soft physical properties after drying. For example, when the content of the aqueous polyurethane-based resin is less than the above range, there is a problem of insufficient filling in the nonwoven fabric, and when it exceeds the above range, there is a problem that it becomes too hard after drying.

The stable layer may have a thickness of about 0.7 mm to about 2.0 mm. By having a thickness within the above range, it is possible to sufficiently absorb the impact from the outside and provide sufficient stability to the skin layer without excessively increasing the total thickness of the skin material for automobile interior materials.

An adhesive layer may be further included on the stable layer. Matters regarding the adhesive layer are as described above, and accordingly, the hydrolysis phenomenon can be effectively prevented in relation to the stable layer. In addition, it is possible to secure excellent eco-friendliness.

The thickness of the adhesive layer may be about 0.1mm to about 1.0mm. By having a thickness within the above range, it is possible to firmly bond the upper layer and the lower layer thereof without excessively increasing the total thickness of the surface material for automobile interior materials.

A skin layer, a surface treatment layer, or both may be further included on the adhesive layer, and when all of them are included, a skin layer and a surface treatment layer may be sequentially included on the adhesive layer.

An uneven pattern may be formed on the surface of the skin layer, the surface treatment layer, or both of them, and thus, various three-dimensional effects may be produced to achieve excellent decoration effect. At this time, the uneven pattern may be formed using a pair of emboss rolls, but is not limited thereto.

The skin layer may include a thermoplastic resin, for example, the thermoplastic resin is a polyvinyl chloride resin (PVC), a thermoplastic polyolefin resin (TPO), a thermoplastic polyurethane resin (TPU), a polyurethane resin (PU) And it may include at least one selected from the group consisting of a combination thereof. Specifically, the thermoplastic resin includes water-based thermoplastic polyurethane-based resin (TPU), water-based polyurethane-based resin (PU), or both, and thus can be recycled while further preventing the occurrence of scratches and the occurrence of volatile organic compounds. It is possible to realize the castle and excellent durability at the same time.

The thickness of the skin layer may be about 0.1mm to about 0.5mm. By having a thickness within the above range, sufficient durability can be achieved without excessively increasing the total thickness of the skin material for automobile interior materials.

The surface treatment layer may be a layer that is coated on top of the skin layer to impart various physical properties such as anti-pollution, anti-static, and water-repellent properties.

The surface treatment layer may be formed of, for example, a surface treatment composition containing a binder resin, and specifically, formed by applying the surface treatment composition to the top of the skin layer and then thermosetting or photocuring it, Or it can be formed by preparing a separate film and then stacking it on top of the skin layer.

The binder resin may include, for example, at least one selected from the group consisting of acrylic resins, epoxy resins, polyurethane resins, polyester resins, fluororesins, and combinations thereof, and specifically, aqueous polyurethane resins. It can effectively prevent the occurrence of scratches and volatile organic compounds, including, to implement excellent eco-friendly and excellent durability.

The surface treatment composition may further include at least one selected from the group consisting of, for example, a thermal initiator, photoinitiator, flame retardant, water repellent, antistatic agent, and combinations thereof, but is not limited thereto.

The surface treatment layer may have a thickness of about 10 μm to about 40 μm. By having a thickness within the above range, it is possible to sufficiently protect the total thickness of the skin material for automobile interior materials without excessively increasing it.

As described above, the skin layer is formed of a material comprising an aqueous thermoplastic polyurethane-based resin (TPU), an aqueous polyurethane-based resin (PU), or both, and the surface treatment layer is a surface treatment comprising an aqueous polyurethane-based resin By being formed of a composition, the skin layer and the surface treatment layer may not include an organic solvent, and accordingly, the skin material for automobile interior materials may realize more excellent eco-friendliness and excellent stability.

2 is a schematic cross-sectional view of a skin material for a vehicle interior material according to another embodiment of the present invention.

Referring to Figure 2, the car interior material 100 for the interior, as described above, includes a stable layer 110, may include an adhesive layer 120 formed on top of the stable layer 110, , May include a skin layer 130 formed on the adhesive layer 120, and may include a surface treatment layer 140 formed on the skin layer 130.

Hereinafter, specific embodiments of the present invention are presented. However, the examples described below are only for specifically illustrating or describing the present invention, and the present invention should not be limited thereby.

< Example  And Comparative example >

Example  One

A nonwoven fabric was prepared using a two-component island-in-the-sea composite yarn composed of 30% by weight of polyester shrinkage yarn and 70% by weight of general yarn nylon, and the surface of the nonwoven fabric contained polyvinyl alcohol containing 7% by weight of polyvinyl alcohol. The coating composition was coated.

In addition, a resin composition was prepared by mixing 30% by weight of an aqueous polyurethane-based resin having a weight average molecular weight of 45000 ± 5000g / mol, 65% by weight of water, and 5% by weight of a pigment.

Subsequently, the nonwoven fabric was impregnated with the resin composition, then taken out and dried, followed by treatment with an aqueous sodium hydroxide solution (NaOH) at a concentration of 3% by weight, followed by drying to form a nonwoven fabric impregnated with an aqueous polyurethane resin, and cut and width A stable layer having a size of × length × thickness of 1600 mm × 10000 mm × 1.2 mm was formed.

In addition, a liquid polyurethane-based resin having a viscosity of 10000 cps to 5000 cps was applied and dried in a temperature range of 50 ° C. to 90 ° C. on the top of the stable layer to form a solvent-free adhesive layer having a thickness of 0.06 ± 0.02 mm.

In addition, an aqueous polyurethane-based water-based polyurethane-based resin layer (PU) that does not contain an organic solvent is formed at a thickness of 0.035 ± 0.005 mm on the upper portion of the solvent-free adhesive layer, and does not contain an organic solvent on an upper portion of the skin layer. A surface treatment layer made of a resin (PU) material was formed to a thickness of 25 ± 15 μm to prepare a skin material for automobile interior materials.

Example  2

A nonwoven fabric was prepared using a split-type composite yarn composed of 35% by weight of polyester shrink yarn and 65% by weight of regular yarn nylon, and the density of the nonwoven fabric was 0.35 g / cm 3.

In addition, a resin composition was prepared by mixing 30% by weight of an aqueous polyurethane-based resin having a weight average molecular weight of 45000 ± 5000g / mol, 65% by weight of water, and 5% by weight of a pigment.

Subsequently, a nonwoven fabric impregnated with an aqueous polyurethane-based resin was finally formed by loading the nonwoven fabric on the resin composition and then taking it out and drying it, and cut it to form a stable layer having a width × length × thickness of 1600mm × 10000mm × 1.2mm. Formed.

In addition, a liquid polyurethane-based resin, which is a liquid polyurethane-based resin having a viscosity of 10000 cps to 5000 cps in a temperature range of 50 ° C. to 90 ° C., was applied to the top of the stable layer and dried to form a 0.06 ± 0.02 mm thick solvent-free adhesive layer. .

In addition, an aqueous polyurethane-based water-based polyurethane-based resin layer (PU) that does not contain an organic solvent is formed at a thickness of 0.035 ± 0.005 mm on the upper portion of the solvent-free adhesive layer, and does not contain an organic solvent on an upper portion of the skin layer. A surface treatment layer made of a resin (PU) material was formed to a thickness of 25 ± 15 μm to prepare a skin material for automobile interior materials.

Example  3

A skin material for automobile interior materials was prepared in the same conditions and methods as in Example 1, except that the polyvinyl alcohol-containing coating composition was not coated on the surface of the nonwoven fabric.

Example  4

An organic solvent-type adhesive composition containing a polyurethane-based resin and a methyl ethyl ketone (MEK) solvent instead of a solvent-free adhesive layer on the top of the stable layer and containing no dimethylformamide (DMF) solvent is applied and dried to 0.06 ± 0.02 A skin material for automobile interior materials was prepared in the same conditions and methods as in Example 1, except that an adhesive layer having a thickness of mm was formed.

Example  5

On top of the stable layer, a solvent-based adhesive composition containing a polyurethane-based resin and a methyl ethyl ketone (MEK) solvent instead of a solvent-free adhesive layer, and no dimethylformamide (DMF) solvent is applied and dried, and 0.06 ± 0.02 mm is dried. Except for forming a thick adhesive layer, a skin material for automobile interior materials was manufactured under the same conditions and methods as in Example 2.

Comparative example  One

30% by weight of an oil-based polyurethane resin having a weight average molecular weight of 45000 ± 5000g / mol instead of the resin composition of Example 1, and 65% by weight of a dimethylformamide (DMF) solvent as an organic solvent, and 5% by weight of a pigment as an additive A skin material for an automobile interior material was prepared in the same conditions and methods as in Example 1, except that the resin composition was prepared by mixing.

< Experimental Example >

To evaluate the various properties of the skin material for automotive interior materials according to Examples 1-5 and Comparative Example 1 are shown in Table 1 below.

Experimental Example  1: Whether volatile organic compounds are generated

For the skin material for automobile interior materials according to each of the examples and comparative examples, a specimen having a size of 4 cmX9 cm was prepared and placed in a sampling bag. Subsequently, the sampling bag was filled with nitrogen gas about 2/3 of the sampling bag volume, and then heated in an oven at 65 ° C. for 2 hours. Thereafter, the specimen was taken out of the sampling bag and left at room temperature (23 ± 2 ° C) for 30 minutes to reach the room temperature, and then nitrogen gas was filled in the sampling bag and volatile organic compounds (VOCs) were analyzed through GC / MS analysis. ) Was measured. In this case, the case where the amount of volatile organic compounds generated is 0 μm / m 3 to 400 μm / m 3 is indicated as “○”, and when it is greater than 400 μm / m 3 and less than 1000 μm / m 3 is indicated as “△”, and 1000 μm The case of more than / m 3 was denoted by “×”.

Experimental Example  2: Hydrolysis resistance

With respect to the skin materials for automobile interior materials according to each of the above Examples and Comparative Examples, the hydrolysis resistance was evaluated after standing at a temperature of 120 ± 3 ° C. and 48 hours by the method specified in TEST J of ASTM D 3574. . Observed with the naked eye, a case where there is no surface change such as discoloration, balance, swelling, or gloss change is indicated by "○", and a case of minute surface change or gloss increase is indicated by "△", and significant surface change is confirmed. The case where it becomes possible is indicated by "x".

Experimental Example  3: car For interior materials As a skin material  Emotion

For the skin materials for automobile interior materials according to the examples and comparative examples, softness was measured using a softness measuring device (SDL Atlas, ST300D). The case where the scale value of the measuring device is 3.6 mm or more is indicated by "○", the case of 3.3 to 3.5 mm is indicated by "△", and the case of less than 3.3 mm is indicated by "X".

Stable layer Adhesive layer Whether VOCs occur Hydrolysis resistance Emotion Example 1 Island
(PVA applied) Solvent-free ○ △ △ Example 2 Dividing yarn Solvent-free △ Ⅹ Ⅹ Example 3 Island
(PVA not applied) Solvent-free ○ △ Ⅹ Example 4 Island
(PVA applied) solvent
(DMF-free) ○ ○ ○ Example 5 Dividing yarn solvent
(DMF-free) △ ○ Ⅹ Comparative Example 1 Island
(PVA applied) DMF solvent △ △ △

100: skin material for automobile interior materials
110: stable layer
120: adhesive layer
130: skin layer
140: surface treatment layer

Claims (18)

Preparing a nonwoven fabric using a sea-island type composite yarn;
Preparing a resin composition comprising an aqueous polyurethane-based resin having a weight average molecular weight of 30,000 g / mol to 70,000 / mol;
Forming a nonwoven fabric impregnated with an aqueous polyurethane resin using the nonwoven fabric and the resin composition;
Forming a stable layer using a nonwoven fabric impregnated with the aqueous polyurethane resin;
Forming an adhesive layer on top of the stable layer;
Forming a skin layer on the adhesive layer; And
Including; forming a surface treatment layer on top of the skin layer;
In the step of preparing a non-woven fabric using the island-in-the-sea composite yarn, a polyvinyl alcohol-containing coating composition is coated on the surface of the non-woven fabric to prepare it,
Further comprising the step of drying after reducing the nonwoven fabric impregnated with the aqueous polyurethane resin with a weakly basic aqueous solution;
The weakly basic aqueous solution is a sodium hydroxide (NaOH) aqueous solution of 2% to 10% by weight,
The weight loss ratio of the nonwoven fabric impregnated with the aqueous polyurethane resin is 30% to 50%,
The forming of the adhesive layer may include a polyurethane resin on top of the stable layer; And a dimethylformamide (DMF) -free organic solvent is applied and dried to form a solvent-type adhesive layer.
The skin layer and the surface treatment layer do not contain an organic solvent
Method for manufacturing skin material for automobile interior materials.
delete According to claim 1,
The polyvinyl alcohol-containing coating composition contains 1 to 30% by weight of polyvinyl alcohol
Method for manufacturing skin material for automobile interior materials.
delete delete delete According to claim 1,
The stable layer has a thickness of 0.7 to 2.0mm
Method for manufacturing skin material for automobile interior materials.
delete delete delete delete delete A stable layer formed of a non-woven fabric impregnated with the aqueous polyurethane resin, manufactured according to a method of manufacturing a skin material for an automobile interior according to any one of claims 1, 3, and 7, and an adhesive layer on top of the stable layer , It includes a skin layer and a surface treatment layer on top of the adhesive layer,
The skin layer and the surface treatment layer do not contain an organic solvent
Skin material for automobile interior materials.
The method of claim 13,
The stable layer has a thickness of 0.7 to 2.0 mm
Skin material for automobile interior materials.
delete The method of claim 13,
The thickness of the adhesive layer is 0.1mm to 1.0mm
Skin material for automobile interior materials.
delete delete

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