Thermoplastic resin composition for interior material of automobiles, and molded product for interior material of automobiles

Abstract

Provided is a thermoplastic resin composition for an interior material of automobiles, comprising a biomass-derived resin. The thermoplastic resin composition for an interior material of automobiles uses a biomass-derived resin, which replaces a petroleum-based thermoplastic resin, so as to reduce the generation of CO2, thereby providing an environmentally friendly effect.

Claims

1. A thermoplastic resin composition for automotive interior materials, comprising: a biomass-derived resin and a non-biomass-derived resin for mixing, wherein the non-biomass-derived resin for mixing comprises a polyolefin in a form of an elastomer-phase rubber, polypropylene, and thermoplastic polyolefin (TPO), wherein the polyolefin in the form of an elastomer-phase rubber comprises a copolymer of ethylene and a C.sub.2 to C.sub.10 α-olefin, and wherein the TPO comprises a completely crosslinked TPO resin, a semi-crosslinked TPO resin and non-crosslinked TPO resins.

2. The thermoplastic resin composition according to claim 1, wherein the thermoplastic resin composition for automotive interior materials has a percent modern carbon (pMC) value of 10 wt % to 90 wt %, as measured in accordance with ASTM D6866.

3. The thermoplastic resin composition according to claim 1, wherein the biomass-derived resin further comprises one selected from the group consisting of a polyolefin, polylactic acid (PLA), cellulose, chitin, starch, thermoplastic starch (TPS), polyhydroxyalkanoates (PHAs), polyvinyl alcohol, polyglycolic acid (PGA), polyethylene terephthalate (PET), polybutylene succinate (PBS), polybutylene terephthalate (PBT), polybutylene adipate terephthalate (PBAT), polybutylene adipate-co-butylene succinate (PBAS), polybutylene adipate-co-butylene succinate terephthalate (PBAST), polytrimethylene terephthalate (PTT), polycaprolactone (PCL), polyamide (PA), polyurethane (PU), poly(ester-amide), poly(ester-urethane), and combinations thereof.

4. The thermoplastic resin composition according to claim 1, wherein the biomass-derived resin is prepared from biofuels processed or extracted from one biomass material selected from the group consisting of corn, Jerusalem artichokes, sugar cane, sugar beet, and combinations thereof.

5. The thermoplastic resin composition according to claim 1, further comprising: a resin for mixing selected from the group consisting of polyolefins, polyvinyl chloride, and combinations thereof.

6. The thermoplastic resin composition according to claim 5, comprising: 1 part by weight to 900 parts by weight of the non-biomass-derived resin for mixing, based on 100 parts by weight of the biomass-derived resin.

7. The thermoplastic resin composition according to claim 1, further comprising: one additive selected from the group consisting of plasticizers, inorganic fillers, stabilizers, lubricants, and combinations thereof.

8. The thermoplastic resin composition according to claim 7, wherein the additive is present in an amount of 5 parts by weight to 100 parts by weight, based on 100 parts by weight of the biomass-derived resin.

9. An automotive interior molded article comprising: a sheet manufactured from the thermoplastic resin composition for automotive interior materials according to claim 1.

10. The automotive interior molded article according to claim 9, further comprising: a surface-treated layer.

11. The automotive interior molded article according to claim 10, wherein the surface-treated layer is formed using an electron beam curable water-based treatment agent or an electron beam curable solvent-free treatment agent.

12. The thermoplastic resin composition according to claim 1, wherein the polyolefin in the form of the elastomer-phase rubber comprises ethylene-propylene rubber (EPR).

13. The thermoplastic resin composition according to claim 1, wherein the polyolefin in the form of the elastomer-phase rubber comprises ethylene-propylene-diene rubber (EPDM).

14. The thermoplastic resin composition according to claim 1, wherein the polyolefin in the form of the elastomer-phase rubber comprises ethylene-butene rubber (EBR).

15. The thermoplastic resin composition according to claim 1, wherein the polyolefin in the form of the elastomer-phase rubber comprises ethylene-octene rubber (EOR).

16. The thermoplastic resin composition according to claim 1, wherein the polyolefin in the form of the elastomer-phase rubber comprises ethylene-propylene rubber (EPR), ethylene-propylene-diene rubber (EPDM), ethylene-butene rubber (EBR), and ethylene-octene rubber (EOR).

Description

EXAMPLES

Examples 1 to 8 and Comparative Examples 1 to 2

(1) In Examples 1 to 8 and Comparative Examples 1 to 2, compositions were prepared according to components and amounts as listed in Tables 1 and 2 using the following compounds. Each of the compositions used in Examples 1 to 8 and Comparative Examples 1 to 2 was measured as to pMC value in accordance with ASTM D6866. Measurement results are shown in Tables 1 and 2.

(2) Each of the mixed compositions was melted and subjected to calendering, wherein the molten mixture was passed through a gap between calender rolls for compression, thereby manufacturing a sheet.

(3) An EB curable water-based treatment agent as a surface treatment agent was coated onto a surface of each of the manufactured sheets using a sprayer, followed by forming a surface-treated layer by curing the surface treatment agent, thereby preparing a specimen of an automotive interior molded article.

(4) Compounds Used in Examples and Comparative Examples Completely crosslinked TPO resin: N65EH, Hwaseung R&A Co., Ltd. Partially crosslinked TPO resin: 8165N, Hyundai EP Co., Ltd. Non-crosslinked TPO resin: Q100F, Baselle Co., Ltd. Ethylene-octene rubber: Engage8180, DOW Co., Ltd. Polypropylene resin: B330F, SK Energy Co., Ltd. Polyethylene resin: SF 316, Lotte Chemical Co., Ltd. Biomass-derived thermoplastic polyolefin (TPO) prepared: Shore Hardness A 80, Specific gravity: 0.93, Tensile strength: 11 MPa, Elongation: 560% Biomass-derived polyethylene (PE) prepared: Melt flow index (MI): 1.0 (190° C./2.16 kg), Specific gravity: 0.92, Tensile strength: 40 MPa, Elongation: 1400% Compatibilizer: WD203, SUMITOMO Co., Ltd. Polylactic acid (PLA): 2002D, NatureWorks Co., Ltd. Polyhydroxyalkanoate (PHA): EM10051, Ecoman Co., Ltd. Cellulose: CA-398-6, EASTMAN Co., Ltd. Inorganic filler: Calcium carbonate

(5) TABLE-US-00001 TABLE 1 Example (parts by weight) Component 1 2 3 4 5 Biomass-derived resin TPO 100 80.7 66.2 79.7 67.4 PE — — 33.8 20.3 32.6 PLA 19.3 — — — PHA — — — — — Cellulose — — — — — Total 100 100 100 100 100 Completely crosslinked TPO 64.3 50 9.2 6.3 — Partially crosslinked TPO 357.1 161.5 29.2 — — Non-crosslinked TPO 57.1 — — — 4.5 Ethylene-octene rubber (EOR) 71.4 30.7 — — — Polypropylene 28.6 — 7.7 7.6 3.4 Polyethylene — — — — — Compatibilizer — 19.2 — — — (Sum of resins for mixing) (578.5) (261.4) (46.1) (13.9) (7.9) Inorganic filler 35.7 23.1 7.7 8.9 4.5 pMC 13 wt % 25 wt % 43 wt % 52 wt % 58 wt %

(6) TABLE-US-00002 TABLE 2 Example Comparative (parts by weight) Example (wt %) Component 6 7 8 1 2 Biomass-derived resin TPO 67.9 65.9 61.1 — — PE 32.1 28.4 33.3 — — PLA — — — — — PHA — 5.7 — — — Cellulose — — 5.6 — — Total 100 100 100 — — Completely crosslinked TPO 2.4 — — 5 10 Partially crosslinked TPO 4.8 — — 25 10 Non-crosslinked TPO 3.6 5.7 — 25 38 Ethylene-octene rubber (EOR) — — — 5 4 Polypropylene 4.8 — — 25 24 Polyethylene — — — 5 4 Compatibilizer — 5.7 5.6 — — (Sum of resins for mixing) (15.6) (11.4) (5.6) Inorganic filler 3.6 2.3 5.6 10 10 Total Total (100 wt %) (100 wt %) pMC 65 wt % 72 wt % 79 wt % 0 0

Experimental Example 1

Hardness

(7) Hardness was measured in accordance with ASTM D2240. Results are shown in Tables 4 and 5.

Experimental Example 2

Tensile Strength and Elongation at Break

(8) A maximum load for a certain area and elongation at break were measured at a test speed of 200 mm/min and at a gauge length of 70 mm using Type 1 specimen and a tensile tester in accordance with ASTM D 638.

Experimental Example 3

Heat Aging Resistance

(9) A specimen was kept in a forced convection oven at a temperature of 110±2° C. for 300 hours, followed by determination of ΔEcmc at an angle of 45° and color change with the naked eye based on the gray scale according to ISO 105-A02 using a spectrophotometer, thereby evaluating a grade.

Experimental Example 4

Light Aging Resistance

(10) A specimen was subjected to light irradiation at an intensity of 126 mJ/m.sup.2 at a black panel temperature of 89±3° C. and a humidity of 50±5% RH using a tester in accordance with ISO 105, followed by determination of color change with the naked eye based on the gray scale according to ISO 105-A02, thereby evaluating a grade.

Experimental Example 5

Chemical Resistance

(11) A surface of a specimen was rubbed back and forth 10 times with a piece of gauze sufficiently wetted in the test liquids listed in Table 3, and left at room temperature for 1 hour. Next, color change was determined with the naked eye based on the gray scale according to ISO 105-A02, thereby evaluating a grade.

(12) TABLE-US-00003 TABLE 3 Test liquid Remarks Glass cleaner Alkalescent glass cleaner Cleaner Mixed liquid of 95% distilled water and 5% neutral detergent Washer liquid Mixed liquid of 50% isopropyl alcohol and 50% distilled water Gasoline Unleaded gasoline Polishing wax HMC

Experimental Example 6

Sunscreen Resistance

(13) In accordance with GMN 10033, two sheets of white cotton cloth having the same size were placed on an aluminum plate (50 mm×50 mm), and 0.25 g of a sunscreen (Coppertone Waterbabies SPF 45) was coated onto a front surface thereof. Next, the coated aluminum plate was placed on a test specimen and brought into close contact therewith by applying a load of 500 g to the aluminum plate. Next, the white cotton cloth and the aluminum plate were removed from the specimen, which in turn was placed in a thermostat at 80±2° C. for about 10 to 15 minutes and left at room temperature. Then, the test specimen was washed with a neutral detergent, dried, and determined as to color change with the naked eye. The test specimen was rated as Excellent when suffering from almost no color change; the test specimen was rated as Good when suffering from insignificant color change; the test specimen was rated as Normal when exhibiting no abnormality in quality although suffering from color change; and the test specimen was rated as Poor when suffering from severe color change.

Experimental Example 7

Odor

(14) A 4 L glass container was heated to 100° C. for about 1 hour and left at room temperature for 1 hour to release volatile compounds from the glass container. Next, the specimen was cut into a size of 50 mm×60 mm, heated to 100° C. in the glass container for 2 hours, and then removed from the glass container. Next, the specimen was left at room temperature (23±2° C.) for 60 minutes for cooling, followed by opening a lid of the glass container by about 3 cm to about 4 cm, thereby evaluating an odor of the specimen. The odor was scored as follows: a severe odor was given 1 point; a normal odor was given 3 points; and almost no odor was given 5 points.

Experimental Example 8

Calendering Processability

(15) A sheet for each blend was produced using a calendering machine in which a bio-molding composition was melted and compressed between rolls and then processed into a sheet form. Then, the sheet was observed with the naked eye to determine workability and surface state. The sheet was determined as Poor when un-melted resins remain on the surface thereof or the sheet had a non-uniform surface due to deterioration in flowability.

(16) Results of properties measured on each of the specimens of the automotive interior molded articles manufactured in Examples 1 to 8 and Comparative Examples 1 to 2 are shown in Tables 4 and 5.

(17) TABLE-US-00004 TABLE 4 Example Properties 1 2 3 4 5 Hardness [Shore A] 80 82 82 77 78 Specific gravity 0.92 0.93 0.91 0.92 0.91 Tensile strength (kgf/cm.sup.2) 142 191 164 164 117 Elongation at break (%) 650 591 572 572 621 Heat aging resistance (gray scale) 4 4 4 4 4 Light aging resistance (gray scale) 4 4 4 4 4 Chemical resistance (gray scale) 4 4 4 4 4 Sunscreen resistance Good Good Good Good Good Odor (grade) 4 4 4 4 4 Calendering processability Good Good Good Good Good

(18) TABLE-US-00005 TABLE 5 Example Comparative Example Properties 6 7 8 1 2 Hardness [Shore A] 79 81 84 81 79 Specific gravity 0.92 0.93 0.93 0.92 0.92 Tensile strength (kgf/cm.sup.2) 202 236 201 124 130 Elongation at break (%) 689 762 723 620 695 Heat aging resistance (gray scale) 4 4 4 4 4 Light aging resistance (gray scale) 4 4 4 4 4 Chemical resistance (gray scale) 4 4 4 4 4 Sunscreen resistance Good Good Good Good Good Odor (grade) 4 4 4 3 3 Calendering processability Good Good Good Good Good

(19) It could be confirmed from the results that the specimens of the automotive interior molded articles manufactured in Examples 1 to 8 realized properties equal to or higher than the specimens of Comparative Examples 1 to 2, which were prepared using only the petroleum-based resins, while securing environmental friendliness due to use of the biomass-derived resins.