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

• US 20080063847A1
• Filed: 10/31/2007
• Published: 03/13/2008
• Est. Priority Date: 06/20/2001
• Status: Active Grant

• Current Assignee: Hong-Geun Chang, Jung-Sook Kang, Mi-Hyang La
• Original Assignee: Hong-Geun Chang, Jung-Sook Kang, Mi-Hyang La
• Inventors: Chang, Hong-Geun, La, Mi-Hyang, Kang, Jung-Sook
• Granted Patent: US 7,479,313 B2
• Time in Patent Office: Days
• US Class Current: 428/213
• CPC Class Codes: B29C 65/344 being a woven or non-woven fabric or being a mesh
• CPC Class Codes: B29C 65/3444 being a ribbon, band or strip
• CPC Class Codes: B29C 65/3448 said ribbon, band or strip being perforated
• CPC Class Codes: B29C 65/3468 characterised by the means for supplying heat to said heated elements which remain in the join, e.g. special electrical connectors of windings B29C65/3668 takes precedence
• CPC Class Codes: B29C 65/3476 being metallic
• CPC Class Codes: B29C 65/348 with a polymer coating
• CPC Class Codes: B29C 65/3492 being carbon
• CPC Class Codes: B29C 65/4815 Hot melt adhesives, e.g. thermoplastic adhesives
• CPC Class Codes: B29C 65/76 Making non-permanent or releasable joints
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/45 Joining of substantially the whole surface of the articles methods or apparatus for laminating B32B37/00
• CPC Class Codes: B29C 66/721 Fibre-reinforced materials B29C66/729 takes precedence
• CPC Class Codes: B29C 66/7392 characterised by the material of at least one of the parts being a thermoplastic
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 2037/148 whereby layers material is selected in order to facilitate recycling of the laminate
• CPC Class Codes: B32B 2307/302 Conductive
• CPC Class Codes: B32B 2310/022 Electrical resistance
• CPC Class Codes: B32B 2605/003 Interior finishings
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: Y10T 428/12097 : Nonparticulate component encloses particles
• CPC Class Codes: Y10T 428/24917 : including metal layer
• CPC Class Codes: Y10T 428/2495 : Thickness [relative or absolute]
• CPC Class Codes: Y10T 428/30 : Self-sustaining carbon mass or layer with impregnant or other layer
• CPC Class Codes: Y10T 428/31678 : Of metal
• CPC Class Codes: Y10T 428/31681 : Next to polyester, polyamide or polyimide [e.g., alkyd, glue, or nylon, etc.]
• CPC Class Codes: Y10T 428/31692 : Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31699 : Ester, halide or nitrile of addition polymer

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.

Claims

1. A thermoplastic resin-laminated structure comprising:

an exterior layer having a thickness of less than 50 mm;

a base layer; and

a binding layer placed between the exterior layer and the base layer, including at least one material selected from a group consisting of electric resistance-heat generating materials and heat-conductive materials, wherein the binding layer has a thickness of less than half of the thickness of the exterior layer and has at least one connection terminal at a certain region for supplying at least one of electricity and heat,

wherein the binding layer is formed with one material selected from a group consisting of metal mesh or metal plate a film formed by coating on at least one side of a polymer resin film at least one of an electric resistance-heat generating material and a heat-conductive material having a weight 0.5% to 80% of the weight of the polymer resin film, a film formed by infiltrating into a polymer resin film at least one of an electric resistance-heat generating material and a heat-conductive material in the form of a powder having a weight 0.5% to 80% of the weight of the polymer resin film, and combinations thereof, and wherein the exterior layer and the base layer can be separated easily by melting the inner surfaces thereof with heat generated from the binding layer.

2. The thermoplastic resin-laminated structure according to claim 1, 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 the group at least two of tungsten (W), nickel (Ni), chromium (Cr), carbon (C), iron (Fe), titanium (Ti).

3. The thermoplastic resin-laminated structure according to claim 1, 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 at least two of aluminum (Al), carbon (C), zinc (Zn), manganese (Mn), copper (Cu), silver (Ag), tin (Sn), lead (Pb).

5. The thermoplastic resin-laminated structure according to claim 1, wherein the polymer resin is a thermoplastic resin.

6. The thermoplastic resin-laminated structure according to claim 1, wherein the base layer is formed with composite resins including at least one filler and at least one thermoplastic resin.

7. The thermoplastic resin-laminated structure according to claim 1, 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 and thermal adhesive resins.

8. The thermoplastic resin-laminated structure according to claim 1, 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 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 natural textiles, synthetic textiles, artificial leathers, felts, nonwoven fabrics, foaming sheets, honeycomb sheets, polymer sheets or films.

9. The thermoplastic resin-laminated structure according to claim 1, 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), polystyrene (PS), acrylobutadienestyrene (ABS) resin, styrene-acrylonitrile (SAN) resin, K-resin, SBS block co-polymer resin, EVA resin, silicone resin, polyamide (PA) resin, polybutyleneterephthalate, polyethyleneterephthalate, polyacetal, polyphenyleneether, polyphenyleneoxide, polycarbonate, polyphenylsulfide, ethylenepropylene diene monomer rubber, ethylenepropylene rubber, styrenebutadiene rubber, butadiene rubber, ethylenepropyleneoctene rubber, isoprene rubber, acrylonitrile rubber, and silicone rubber.

10. The thermoplastic resin-laminated structure according to claim 1, wherein the exterior 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.

11. The thermoplastic resin-laminated structure according to claim 1, wherein the base layer includes at least one filler selected from a group consisting of glass fillers, mica, talc, wollastonite, calcium carbonate, kaolin, vegetable fibers, sawdust, clay, silica, graphite, fly ashes, waste papers, and waste fibers.

12. The thermoplastic resin-laminated structure according to claim 1, wherein the exterior layer, the base layer or the binding layer includes at least one additive selected from a group consisting of heat-stabilizing agents, antioxidants, ultraviolet ray-stabilizing agents, carbon black, conductive materials, nucleus agents, release agents, fire retardants, agents for preventing static electricity, processing-assistant agents, coloring agents, functional pigments or dyes, cross-linking agents, plasticizer, and vulcanizing agents.

13. The thermoplastic resin-laminated structure according to claim 1, wherein the thermoplastic resin-laminated structure is at least used as an element in manufacturing 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.

4. (canceled)

14-16. -16. (canceled)