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.

What is claimed is:  
     
         1 . A thermoplastic resin-laminated structure comprising: 
 an exterior layer;    a base layer; and    a binding layer which is 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, and has at least one connection terminal at a certain region for supplying at least one of electricity and heat.    
     
     
         2 . The thermoplastic resin-laminated structure according to  claim 1 , wherein the electric resistance-heat generating material is selected from a group consisting of tungsten (W), nickel (Ni), chromium (Cr), silicon (Si), aluminum (Al), carbon (C), iron (Fe), magnesium (Mg), zinc (Zn), titanium (Ti), manganese (Mn), cobalt (Co), vanadium (V), zirconium (Zr), molybdenum (Mo), copper (Cu), silver (Ag), cadmium (Cd), tin (Sn), lead (Pb), stainless steel alloys of the group, and mixtures of the group.  
     
     
         3 . The thermoplastic resin-laminated structure according to  claim 1 , wherein the heat-conductive material is selected from a group consisting of tungsten (W), nickel (Ni), chromium (Cr), silicon (Si), aluminum (Al), carbon (C), iron (Fe), magnesium (Mg), zinc (Zn), titanium (Ti), manganese (Mn), cobalt (Co), vanadium (V), zirconium (Zr), molybdenum (Mo), copper (Cu), silver (Ag), cadmium (Cd), tin (Sn), lead (Pb), stainless steel alloys of the group, and mixtures of the group.  
     
     
         4 . The thermoplastic resin-laminated structure according to  claim 1 , wherein the binding layer is formed with one material selected from a group consisting of a metal mesh or metal plate of at least one selected material from a group consisting of the electric resistance-heat generating materials and the heat-conductive materials having several types of holes or a continuous surface, a thin layer film formed by coating at least one material selected from the group consisting of the electric resistance-heat generating materials and the heat-conductive materials on at least one side of a polymer resin film, a thin layer film formed by infiltrating at least one material selected from the group consisting of the electric resistance-heat generating materials and the heat-conductive materials into a polymer resin film, and their combinations.  
     
     
         5 . The thermoplastic resin-laminated structure according to  claim 4 , wherein the polymer resin is at least one material selected from a group consisting of thermoplastic resin, thermal adhesive resins, and composite resins including at least one filler and at least one resin selected from a group consisting of thermoplastic resins and thermal adhesive resins.  
     
     
         6 . The thermoplastic resin-laminated structure according to  claim 1 , wherein the base layer is formed with a polymer resin which is at least one material selected from a group consisting of thermoplastic resins, and 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, 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.  
     
     
         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, thermal adhesive resins, and composite resins including at least one filler and at least one resin 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 wood or metal thin films, papers, 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), polyvinvychloride (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, ethylenet ctrafluoroethylene copolymer, liquid crystal polymer, polybutyleneterephthalate, polyetheretherketone, polyetherketone, polyetherketoneketone, polyethylenenaphthalene, 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.  
     
     
         10 . The thermoplastic resin-laminated structure according to  claim 1 , wherein the exterior layer, the base 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.  
     
     
         11 . The thermoplastic resin-laminated structure according to  claim 1 , wherein the exterior layer, the base layer or the binding 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.  
     
     
         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.  
     
     
         14 . A method for preparing a thermoplastic resin-laminated structure comprising the steps of: 
 intervening a binding layer between an exterior layer and a base layer, wherein 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    supplying electricity or heat to the binding layer through the at least one connection terminal to bind the base layer with the exterior layer.    
     
     
         15 . A method for preparing a thermoplastic resin-laminated structure comprising the steps of: 
 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;    putting a base layer on the binding layer of the double-layer sheet; and    supplying electricity or heat to the binding layer through the at least one connection terminal to bind the base layer with the exterior layer.    
     
     
         16 . The method according to  claim 15 , wherein a laminated sheet molding apparatus is used for preparing the double-layer sheet.