Thermoplastic resin-laminated structure, method for preparation and use thereof

Abstract

Systems and methods consistent with the present invention provide a thermoplastic resin-laminated structure having an exterior layer, a base layer, and a binding layer that is placed between the exterior layer and the base layer. The exterior, base and binding layers include at least one material selected from a group consisting of electric resistance-heat generating materials and heat-conductive materials, and has at least one connection terminal at a certain region for supplying at least one of electricity or heat. The resin-laminated structure has excellent properties such as adhesive strength between a base layer and an exterior layer, and recycling utility as well as surface quality in feeling, thermal durability, acoustic absorptivity, heat-shielding property, and impulse-durability. Therefore, it can be used for interior automotive trims, acoustic absorptive members, heat-insulating members, lagging members, protective coating members, anti-vibration members, and sound-blocking members for civil engineering and construction, anti-vibration and sound-blocking members for sewage and water pipe, soundproofing members for hot-water “ondol”, plastic furniture, various multi-layer mats, handles, sofas, chairs, various toys, middle soles of shoes, and golf bags. A method for preparing the resin-laminated structure is also provided.

1 - 13 . (canceled)  
     
     
         14 . A method for preparing a recyclable thermoplastic resin-laminated structure for interior automotive trim comprising the steps of: 
 (a) intervening a binding layer between an exterior layer and a base layer, wherein the base layer is formed with a polymer resin which is a material selected from a group consisting of thermoplastic resins, and composite resins including at least one filler and at least one thermoplastic resin, the binding layer includes at least one material selected from a group consisting of electric resistance-heat generating materials and heat-conductive materials, and has at least one connection terminal at a certain region for supplying electricity or heat; and    (b) supplying electricity or heat to the binding layer through the terminal to bind the base layer with the exterior layer,    wherein the exterior layer and the base layer can be easily separated with supplying electricity or heat for recycling.    
     
     
         15 . A method for preparing a thermoplastic resin-laminated structure for interior automotive trim comprising the steps of: 
 (a) preparing a double-layer sheet in which an exterior layer is bound to a binding layer that includes at least one material selected from a group consisting of electric resistance-heat generating materials and heat-conductive materials, and has at least one connection terminal at a certain region for supplying electricity or heat;    (b) placing the double layer on a base layer, wherein the base layer is formed with a polymer resin which is a material selected from a group consisting of thermoplastic resins, and composite resins including at least one filler and at least one thermoplastic resin; and    (c) supplying electricity or heat to the binding layer through the terminal to bind the base layer with the exterior layer,    wherein the double layer and the base layer can be easily separated with supplying electricity or heat for recycling.    
     
     
         16 . The method according to  claim 15 , wherein the double layer sheet is prepared using a laminated sheet molding apparatus.  
     
     
         17 . The method according to  claim 14 , wherein the electric resistance-heat generating material has a Curie temperature higher than the melting point of a polymer which constitutes the base or exterior layer, and is selected from a group consisting of tungsten(W), nickel(Ni), chromium(Cr), carbon(C), iron(Fe), titanium(Ti), stainless steel alloys of at least one of tungsten(W), nickel(Ni), chromium(Cr), titanium(Ti), and mixtures of at least two of tungsten(W), nickel(Ni), chromium(Cr), carbon(C), iron(Fe), titanium(Ti).  
     
     
         18 . The method according to  claim 14 , wherein the heat-conductive material is selected from a group consisting of, aluminum(Al), carbon(C), zinc(Zn), manganese(Mn), copper(Cu), silver(Ag), tin(Sn), lead(Pb), stainless steel alloys of at least one of, aluminum(Al), zinc(Zn), manganese(Mn), copper(Cu), silver(Ag), tin(Sn), lead(Pb), and mixtures of at least two of aluminum(Al), carbon(C), zinc(Zn), manganese(Mn), copper(Cu), silver(Ag), tin(Sn), lead(Pb).  
     
     
         19 . The method according to  claim 14 , wherein the binding layer is formed with one material selected from a group consisting of metal mesh or metal plate of at least one material selected from a group consisting of the electric resistance-heat generating materials and the heat-conductive materials having several types of holes or a continuous layer, a layer film formed by coating on at least one side of a polymer resin film with at least one material weighing 0.5% to 80% by weight of the polymer resin film selected from the group consisting of electric resistance-heat generating materials and heat-conductive materials, a layer film formed by infiltrating into a polymer resin film at least one material in the form of powder weighing 0.5% to 80% by weight of the polymer resin film selected from the group consisting of electric resistance-heat generating materials, heat-conductive materials, and the combination thereof.  
     
     
         20 . The method according to  claim 19 , wherein the polymer resin of the binding layer is at least one material selected from a group consisting of thermoplastic resin and thermal adhesive resin.  
     
     
         21 . The method according to  claim 14 , wherein when the exterior layer consists of a single layer, the exterior layer is formed with a polymer resin that is at least one material selected from a group consisting of thermoplastic resins, thermal adhesive resins, and composite resins including at least one filler and at least one resin selected from the group consisting of thermoplastic resins and thermal adhesive resins.  
     
     
         22 . The method according to  claim 14 , wherein when the exterior layer has a multi-layer structure, the lower layer is bound to the binding layer and formed with a polymer resin which is at least one material selected from a group consisting of thermoplastic resins, thermal adhesive resins, and composite resins including at least one filler and at least one resin selected from the group consisting of thermoplastic resins and thermal adhesive resins, the upper layer has single or multi-layer structure, and is formed with at least one material selected from a group consisting of wood or metal films, papers, natural textiles, synthetic textiles, artificial leathers, felts, non-woven fabrics, foaming sheets, honeycomb sheets, polymer sheets or films.  
     
     
         23 . The method according to  claim 14 , wherein the exterior layer, the base layer, or the binding layer includes at least one thermoplastic resin selected from a group consisting of polyethylene (PE), polypropylene (PP copolymer, PP homo-polymer, and PP ter-polymer), polyvinylchloride (PVC), polystyrene (PS), polymethylmetacrylate (PMMA), acrylobutadienestyrene (ABS) resin, styrene-acrylonitrile (SAN) resin, K-resin, SBS block co-polymer resin, PVDC resin, EVA resin, acryl resin, butral resin, silicone resin, polyamide (PA) resin, ethylenetetrafluorethylene copolymer, liquid crystal polymer, polybutyleneterephthalate, polyetheretherketone, polyetherketone, polyetherketoneketone, polyethylenenapthalene, polyethyleneterephthalate, polyimide, polyacetal, polyamideimide, polyphenyleneether, polyphenyleneoxide, polycarbonate, polyphenylsulfide, polysulfone, polythioethylsulfone, polytetrafluoroethylene, polyethersulfone, polyetherimide, ethylenepropylene diene monomer rubber, ethylenepropylene rubber, styrenebutadiene rubber, butadiene rubber, ethylenepropyleneoctene rubber, isoprene rubber, acrylonitrile rubber, and silicone rubber.  
     
     
         24 . The method according to  claim 14 , wherein the exterior layer or the binding layer includes at least one thermal adhesive resin selected from a group consisting of acrylic acid-modified olefin resin, maleic acid-modified olefin resin, chloride-modified olefin resin, silane-modified olefin resin, ionomer resin, nylon-modified olefin resin, epoxy-modified resin, ethylenevinylalcohol (EVOH) resin, ethylenevinylacetate resin, hot melt adhesive resin, and any mixtures of the group.  
     
     
         25 . The method according to  claim 14 , wherein the exterior and the base layer includes at least one filler selected from a group consisting of glass fillers, mica, talc, wollastonite, calcium carbonate, asbestos, kaolin, carbon fibers, nylon fibers, vegetable fibers, sawdust, clay, silica, graphite, fly ashes, waste papers, and waste fibers.  
     
     
         26 . The method according to  claim 15 , wherein the electric resistance-heat generating material has a Curie temperature higher than the melting point of a polymer which constitutes the base or exterior layer, and is selected from a group consisting of tungsten(W), nickel(Ni), chromium(Cr), carbon(C), iron(Fe), titanium(Ti), stainless steel alloys of at least one of tungsten(W), nickel(Ni), chromium(Cr), titanium(Ti), and mixtures of at least two of tungsten(W), nickel(Ni), chromium(Cr), carbon(C), iron(Fe), titanium(Ti).  
     
     
         27 . The method according to  claim 15 , wherein the heat-conductive material is selected from a group consisting of, aluminum(Al), carbon(C), zinc(Zn), manganese(Mn), copper(Cu), silver(Ag), tin(Sn), lead(Pb), stainless steel alloys of at least one of, aluminum(Al), zinc(Zn), manganese(Mn), copper(Cu), silver(Ag), tin(Sn), lead(Pb), and mixtures of at least two of aluminum(Al), carbon(C), zinc(Zn), manganese(Mn), copper(Cu), silver(Ag), tin(Sn), lead(Pb).  
     
     
         28 . The method according to  claim 14 , wherein the binding layer is formed with one material selected from a group consisting of metal mesh or metal plate of at least one material selected from a group consisting of the electric resistance-heat generating materials and the heat-conductive materials having several types of holes or a continuous layer, a layer film formed by coating on at least one side of a polymer resin film with at least one material weighing 0.5% to 80% by weight of the polymer resin film selected from the group consisting of electric resistance-heat generating materials and heat-conductive materials, a layer film formed by infiltrating into a polymer resin film at least one material in the form of powder weighing 0.5% to 80% by weight of the polymer resin film selected from the group consisting of electric resistance-heat generating materials, heat-conductive materials, and the combination thereof.  
     
     
         29 . The method according to  claim 28 , wherein the polymer resin of the binding layer is at least one material selected from a group consisting of thermoplastic resin and thermal adhesive resin.  
     
     
         30 . The method according to  claim 15 , wherein when the exterior layer consists of a single layer, the exterior layer is formed with a polymer resin that is at least one material selected from a group consisting of thermoplastic resins, thermal adhesive resins, and composite resins including at least one filler and at least one resin selected from the group consisting of thermoplastic resins and thermal adhesive resins.  
     
     
         31 . The method according to  claim 15 , wherein when the exterior layer has a multi-layer structure, the lower layer is bound to the binding layer and formed with a polymer resin which is at least one material selected from a group consisting of thermoplastic resins, thermal adhesive resins, and composite resins including at least one filler and at least one resin selected from the group consisting of thermoplastic resins and thermal adhesive resins, the upper layer has single or multi-layer structure, and is formed with at least one material selected from a group consisting of wood or metal films, papers, natural textiles, synthetic textiles, artificial leathers, felts, non-woven fabrics, foaming sheets, honeycomb sheets, polymer sheets or films.  
     
     
         32 . The method according to  claim 15 , The method according to  claim 14 , wherein the exterior layer, the base layer, or the binding layer includes at least one thermoplastic resin selected from a group consisting of polyethylene (PE), polypropylene (PP copolymer, PP homo-polymer, and PP ter-polymer), polyvinylchloride (PVC), polystyrene (PS), polymethylmetacrylate (PMMA), acrylobutadienestyrene (ABS) resin, styrene-acrylonitrile (SAN) resin, K-resin, SBS block co-polymer resin, PVDC resin, EVA resin, acryl resin, butral resin, silicone resin, polyamide (PA) resin, ethylenetetrafluorethylene copolymer, liquid crystal polymer, polybutyleneterephthalate, polyetheretherketone, polyetherketone, polyetherketoneketone, polyethylenenapthalene, polyethyleneterephthalate, polyimide, polyacetal, polyamideimide, polyphenyleneether, polyphenyleneoxide, polycarbonate, polyphenylsulfide, polysulfone, polythioethylsulfone, polytetrafluoroethylene, polyethersulfone, polyetherimide, ethylenepropylene diene monomer rubber, ethylenepropylene rubber, styrenebutadiene rubber, butadiene rubber, ethylenepropyleneoctene rubber, isoprene rubber, acrylonitrile rubber, and silicone rubber.  
     
     
         33 . The method according to  claim 15 , wherein the exterior layer or the binding layer includes at least one thermal adhesive resin selected from a group consisting of acrylic acid-modified olefin resin, maleic acid-modified olefin resin, chloride-modified olefin resin, silane-modified olefin resin, ionomer resin, nylon-modified olefin resin, epoxy-modified resin, ethylenevinylalcohol (EVOH) resin, ethylenevinylacetate resin, hot melt adhesive resin, and any mixtures of the group.  
     
     
         34 . The method according to  claim 15 , wherein the exterior and the base layer includes at least one filler selected from a group consisting of glass fillers, mica, talc, wollastonite, calcium carbonate, asbestos, kaolin, carbon fibers, nylon fibers, vegetable fibers, sawdust, clay, silica, graphite, fly ashes, waste papers, and waste fibers.