CN101130290A - 包括增强面层的轻量复合热塑性片材 - Google Patents
包括增强面层的轻量复合热塑性片材 Download PDFInfo
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Abstract
一种用于机动车辆内部结构组件的多层纤维增强片材,在典型的实施方案中,包括,具有第一表面和第二表面的可渗透的纤维增强热塑性芯层。该芯层包括大量用热塑性树脂粘结在一起的增强纤维,并且它具有约0.1-1.8gm/cc的密度。多层纤维增强片材还包括施加到该芯层第一表面上的至少一第一增强面层,以及施加到该芯层第二表面上的至少一第二增强面层。每个第一和第二增强面层包括增强纤维基体和热塑性树脂,其中施加到第一表面的增强纤维基体以双向取向排列,施加到第二表面的增强纤维基体以双向取向排列。
Description
技术领域
本发明通常涉及轻量多孔纤维增强的热塑性聚合物片材,更尤其涉及包括增强面层的轻量多孔纤维增强的热塑性聚合物片材。
背景技术
在US4978489和US4670331中已经公开了轻量多孔纤维增强的热塑性片材,且由于容易将纤维增强的热塑性片材模制成制品,因此该片材在产品制造工业中被用于各种各样的应用。已经成功使用已知技术,例如,热压,压塑,真空成形,以及热成形将纤维增强热塑性片材形成制品。
苛刻的汽车燃料节约标准正需要降低车辆的总重量以满足这些标准。传统车辆的座椅靠背系统是由模压钢或吹模塑料制得的。钢压制模具是巨大的资本投资。虽然钢座椅靠背薄,但与聚合物比较起来钢材非常致密。钢座椅靠背可达约3-61bs。钢座椅靠背被点焊到座椅框架上,将结构增强件附着在钢座椅靠背的拐角处以防加载时钢材弯曲。吹塑座椅靠背比钢座椅靠背轻,但体积庞大且厚度可达50mm或更大。将吹塑塑料座椅靠背机械连接在座椅框架上。
发明内容
一方面,提供一种用于机动车辆内部结构组件的多层纤维增强片材。该多层纤维增强片材包括具有第一表面和第二表面的可渗透的纤维增强热塑性芯层。该芯层包括大量用热塑性树脂粘结在一起的增强纤维,并且它具有约0.1-1.8gm/cc的密度。多层纤维增强片材还包括施加到芯层第一表面上的至少一第一增强面层,以及施加到芯层第二表面上的至少一第二增强面层。每个第一和第二增强面层包括增强纤维基体和热塑性树脂,其中施加到第一表面的增强纤维基体以双向取向排列,施加到第二表面的增强纤维基体以双向取向排列。
另一方面,提供一种由多层纤维增强材料形成的机动车辆内部结构组件。多层纤维增强片材包括具有第一表面和第二表面的可渗透的纤维增强热塑性芯层。芯层包括大量用热塑性树脂粘结在一起的增强纤维并具有约0.1-1.8gm/cc的密度。该多层纤维增强片材还包括施加到芯层第一表面上的至少一第一增强面层,以及施加到芯层第二表面上的至少一第二增强面层。每个第一和第二增强面层包括增强纤维基体和热塑性树脂,其中施加到第一表面的增强纤维基体以双向取向排列,施加到第二表面的增强纤维基体以双向取向排列。
另一方面,提供一种制造机动车辆内部结构部件的方法。该方法包括形成具有第一表面和第二表面的可渗透纤维增强的热塑性芯层。该芯层包括大量用热塑性树脂粘结在一起的增强纤维并具有约0.1-1.8gm/cc的密度。该方法还包括在第一表面上放置至少一第一增强面层,在第二表面上放置至少一第二增强面层,将至少一第一增强面层附着到第一表面,将至少一第二增强层附着到第二表面以形成多层纤维增强的片材,以及将该多层纤维增强片材模制成预定形状。每个第一和第二增强面层包括增强纤维基体和热塑性树脂,其中施加到第一表面的增强纤维基体以双向取向排列,施加到第二表面的增强纤维基体以双向取向排列。
附图说明
图1是按照本发明一个实施方案的复合热塑性片材的剖面示意图。
图2是按照本发明另一个实施方案的复合热塑性片材的剖面示意图。
图3是图1中的复合热塑性片材的分解透视示意图。
具体实施方式
下面将详述一种具有增强面层的可成形的轻量复合热塑性片材,该片材用来制造机动车辆内部结构组件,例如,座椅靠背。比起所知的钢制设计,可以使用该复合热塑性片材以使载重内部组件的重量减轻至多约达60%而不牺牲强度。该复合片材能在约60秒或更少的循环时间以及约160的温和温度下低压热成形。该低压成形方法用,例如,对模铝制机具代替了用于已知钢设计的钢模压机。在一个实施方案中该复合热塑性片材的厚度为约2-10mm,在另一个实施方案中为约2-4mm,这可降低座椅靠背的组装空间,从而增大机动车辆中的腿部空间和/或存储空间。
参照附图,图1是轻量复合热塑性片材10的剖面示意图。在典型的实施方案中,轻量复合热塑性片材10包括具有第一表面14和第二表面16的轻量多孔芯12。第一增强面层18附着在芯12的第一表面14上。第二增强面层20附着在芯12的第二表面16上。将装饰面层22粘结到第二增强面层20上。在可替代的实施方案中,复合片材10包括粘结在第一和第二增强面层18和20上的装饰面层22,或者没有装饰面层。
芯12由以开孔结构构成的网状物形成,该开孔结构由随机交叉的增强纤维形成的,使用一种或多种热塑性树脂将该增强纤维至少部分固定在一起,其中多孔芯12的孔隙率通常为芯12总体积的约1%-95%,尤其是约30%-80%。在另一个实施方案中,多孔芯12由开孔结构构成,该开孔结构由随机交叉的增强纤维形成,使用一种或多种热塑性树脂将该增强纤维至少部分固定在一起,其中有约40%-100%的泡孔结构是开孔的并允许空气和气体流通。在一个实施方案中,芯12的密度为约0.1-1.8gm/cc,在另一个实施方案中约为0.3-1.0gm/cc。芯12用已知制造方法形成,例如,湿法成网,气流铺置成网法,干混法,起绒和针刺法,以及其它用来制造无纺产品的已知方法。也可使用这些制造方法的组合。
芯12包括约20%-80重量%的具有平均长度约为5-50mm的增强纤维,以及约20%-80重量%的完全或大体上未固结的纤维状或微粒状的热塑性材料,其中百分含量以芯12的总重量为基准。在另一个实施方案中,芯12包括约30%-55重量%的增强纤维。在另一个实施方案中,芯12包括具有平均长度为约5-25mm的增强纤维。合适的纤维包括,但不局限于,金属纤维,金属化无机纤维,金属化合成纤维,玻璃纤维,石墨纤维,碳纤维,陶瓷纤维,矿物纤维,玄武岩纤维,无机纤维,芳族聚酰胺纤维,洋麻纤维,黄麻纤维,亚麻纤维,大麻纤维,纤维素纤维,剑麻纤维,椰纤维,以及上述纤维的混合物。
在一个典型的实施方案中,将具有约5-50mm平均长度的增强纤维和热塑性粉末颗粒,例如聚丙烯粉末,加入到可含表面活性剂的搅动的含水泡沫中。将组分搅动足够时间以形成增强纤维和热塑性粉末在含水泡沫中的分散混合物。然后将分散的混合物放在任何合适的支撑结构上,例如,金属丝网,而后穿过支撑结构排除水形成网状物。在高于热塑性塑料粉末的软化温度下干燥并加热网状物。然后将该网状物冷却并压成预定厚度以生产具有约1-95%孔隙率的复合芯12。
在高于芯12中的热塑性树脂的软化温度下加热网状物以基本软化塑料材料并通过一个或多个固结设备,例如压延辊,双带层压机,定位压机(indexingpresses),多层距层压机,热压罐,以及其它用于层压和固结片材和织物的类似设备以使塑料材料能流动并润湿纤维。在固结设备中固结元件之间的间距设定为小于未固结网状物的尺寸而高于能充分固结网状物的尺寸,因此允许网状物在通过辊之后膨胀并基本保持可渗透。在一个实施方案中,间距设定为大于能完全固结网状物的尺寸的约5%-10%。完全固结的网状物是指完全压实并基本无孔隙的网状物。完全固结的网状物具有小于5%孔隙率并具有可忽略的开孔结构。
在制造过程中微粒状塑料材料包括为增强网状物结构内聚力而包含的短塑料纤维。通过利用网状物结构内的塑性材料的热特性来实现粘合。充分加热网状物结构以足以使得热塑性组分在其邻接颗粒和纤维的表面熔化。
在一个实施方案中,单根增强纤维的平均长度不应短于约5mm,因为短纤维一般不能在最终模制品中提供足够的增强。同样,增强纤维平均长度不应长于约50mm,因为这种纤维在制造过程中难于处理。
在一个实施方案中,为了赋予结构强度,增强纤维具有约7-22微米的平均直径。直径小于约7微米的纤维易于在空气中传播并可能导致环境卫生和安全问题。直径大于约22微米的纤维在制造过程中难于处理并且在模制后不能有效地增强塑料基体。
在一个实施方案中,用于形成芯12的热塑性材料至少部分为粒状形式。合适的热塑性塑料包括,但不局限于,聚烯烃,包括聚亚甲基,聚乙烯,和聚丙烯,聚苯乙烯,丙烯腈苯乙烯,丁二烯,聚酯,包括聚对苯二甲酸乙二醇酯,聚对苯二甲酸丁二醇酯,和聚对苯二甲酸丙二醇酯,聚三氯酸丁烯酯(polybutylene terachlorate),以及聚氯乙烯,增塑和非增塑的,丙烯酸类,包括聚甲基丙烯酸甲酯,以及这些材料之间或与其它聚合材料的混合物。其它合适的热塑性塑料包括,但不局限于,聚芳撑醚,丙烯腈-丙烯酸丁酯-苯乙烯聚合物,无定形尼龙,以及这些材料之间或与其它聚合物材料的合金和共混物。能够预料,可以使用任何热塑性树脂,它不和水发生化学反应并通过加热能充分软化以允许熔融和/或模制而不发生化学或热分解。
热塑性塑料颗粒不必过于精细,但是粗于约1.5mm的颗粒是不适宜的,因为它们不能在模制过程期间充分流动以生产出均相结构。固结时使用较大颗粒会导致材料的弯曲模量降低。
此外参考图2和3,第一增强面层18包括通过热塑性树脂粘结在一起的增强纤维的基体30。增强纤维以双向取向排列。同样地,第二增强面层20包括以双向取向的方式粘结在一起的增强纤维的基体32。双向取向是指至少一些增强纤维的纵轴不平行于其它增强纤维的纵轴。增强纤维之间可互相成90°,45°,30°,等等。增强纤维可以是纺织结构或编织结构。如果增强纤维在第一增强面层18中是单向取向的,就要使用和放置其它带有单向取向增强纤维的第一增强面层18,以便使另外的增强面层18中的增强纤维与第一增强面层18成一角度,从而产生双向的增强纤维的基体。同样地,使用一种以上具有单向取向增强纤维的第二增强面层20形成具有双向取向的增强纤维基体。在可替换的实施方案中,用多个具有单向增强纤维的第一增强面层18形成双向取向的增强纤维基体,以及用多个具有单向增强纤维的第二增强面层20形成双向取向的增强纤维基体。
上述适用于制造芯层12的增强纤维也适于增强面层18和20。同样地,上述适用于芯层12的热塑性树脂也适于增强面层18和20。在制造芯层12的过程中可以将增强面层18和20附着到芯层12上,或者在形成机动车辆结构组件,例如座椅靠背之前可以将增强面层18和20附着。增强面层18和20可在结构组件成形步骤之前层压到芯12上,超声焊接到芯12上,或单纯交叉铺置在芯12上。
在一个代表的实施方案中,为形成车辆结构组件,将复合热塑性片材10加热到足以熔融热塑性树脂的温度。将经加热的复合热塑性片材10置于模具中,例如,铝对模中,加热到约160并用低压压机压成所需形状。在另一个实施方案中,用本技术已知的任何方法,如,热成形,热压,真空成形,压制成形,以及压热器法(autoclaving)可将复合热塑性片材10模制成各种机动车内部结构组件。
在另一个实施方案中,通过任何已知技术,例如,层压,粘合剂粘合等将装饰层22施加在第二增强面层20上。装饰层22由热塑性塑料膜形成,如,聚氯乙烯,聚烯烃,热塑性聚酯,热塑性弹性体,等等。在其它实施方案中,装饰层22是包括由例如聚丙烯,聚乙烯,聚氯乙烯,聚氨酯等制成的泡沫芯的多层结构。将织物粘合到泡沫芯上,例如由天然和合成纤维制成的编织织物,针刺或类似处理后的有机纤维非织造织物,拉绒织物,编织物品,绒屑织物,等等。在其它实施方案中,用热塑性粘合剂,包括压敏粘合剂和热熔粘合剂,例如聚酰胺,改性聚烯烃,氨基甲酸酯和聚烯烃将织物粘合到泡沫芯上。
虽然已经按照各种具体实施方案描述了本发明,但本领域的技术人员能意识到可以在权利要求的主旨和范围内以变体形式实施本发明。
Claims (20)
1.一种用于机动车辆内部结构组件的多层纤维增强片材,所述多层纤维增强片材包括:
可渗透的纤维增强热塑性芯层,包括许多用热塑性树脂粘合在一起的增强纤维,所述可渗透芯层具有约0.1-1.8gm/cc的密度且包括第一表面和第二表面;
至少一施加在所述第一表面的第一增强面层;以及
至少一施加在所述第二表面的第二增强面层;
每个所述第一和第二增强面层包括增强纤维基体和热塑性树脂,其中施加在所述第一表面的所述增强纤维基体按照双向取向排列,施加在所述第二表面的所述增强纤维基体按照双向取向排列。
2.一种按照权利要求1的多层纤维增强片材,其中在任何一个增强面层中的所述增强纤维基体包括单向取向,双向取向,纺织纤维取向,或编织纤维取向。
3.一种按照权利要求1的多层纤维增强片材,其中每个所述第一和第二增强面层包括约50-80重量%的增强纤维。
4.一种按照权利要求1的多层纤维增强片材,其中所述芯层包括约20-80重量%的增强纤维。
5.一种按照权利要求1的多层纤维增强片材,其中所述芯层以及所述第一和第二增强面层中的所述增强纤维包括下述纤维中的至少一种:金属纤维,金属化无机纤维,金属化合成纤维,玻璃纤维,聚酯纤维,聚酰胺纤维,石墨纤维,碳纤维,陶瓷纤维,矿物纤维,玄武岩纤维,无机纤维,芳族聚酰胺纤维,洋麻纤维,黄麻纤维,亚麻纤维,大麻纤维,纤维素纤维,剑麻纤维,以及椰纤维。
6.一种按照权利要求1的多层纤维增强片材,其中所述芯层以及所述第一和第二增强面层中的所述热塑性树脂包括下述树脂中的至少一种,聚烯烃,聚酰胺,聚苯乙烯,丙烯腈苯乙烯,丁二烯,聚酯,聚三氯酸丁烯酯,聚氯乙烯,聚亚苯基醚,聚苯醚,聚醚酰亚胺,聚碳酸酯,聚酯碳酸酯,丙烯腈-丙烯酸丁酯-苯乙烯聚合物,聚对苯二甲酸丁二醇酯,聚对苯二甲酸乙二醇酯,以及无定形尼龙。
7.一种按照权利要求1的多层纤维增强片材,还包括施加于所述第一至少一增强面层和所述第二至少一增强面层中至少一个的外表面的装饰层。
8.一种机动车辆内部结构组件,包括多层纤维增强材料,所述多层纤维增强材料包括:
可渗透的纤维增强热塑性芯层,包括许多用热塑性树脂粘合在一起的增强纤维,所述可渗透芯层具有约0.1-1.8gm/cc的密度且包括第一表面和第二表面;
至少一施加在所述第一表面的第一增强面层;以及
至少一施加在所述第二表面的第二增强面层;
每个所述第一和第二增强面层包括增强纤维基体和热塑性树脂,其中施加在所述第一表面的所述增强纤维基体按照双向取向排列,施加在所述第二表面的所述增强纤维基体按照双向取向排列。
9.一种按照权利要求8的结构组件,其中在任何一个增强面层中的所述增强纤维基体包括单向取向,双向取向,纺织纤维取向,或编织纤维取向。
10.一种按照权利要求8的结构组件,其中每个所述第一和第二增强面层包括约50-80重量%的增强纤维。
11.一种按照权利要求8的结构组件,其中所述芯层包括约20-80重量%的增强纤维。
12.一种按照权利要求8的结构组件,其中所述芯层以及所述第一和第二增强面层中的所述增强纤维包括下述纤维中的至少一种:金属纤维,金属化无机纤维,金属化合成纤维,玻璃纤维,聚酯纤维,聚酰胺纤维,石墨纤维,碳纤维,陶瓷纤维,矿物纤维,玄武岩纤维,无机纤维,芳族聚酰胺纤维,洋麻纤维,黄麻纤维,亚麻纤维,大麻纤维,纤维素纤维,剑麻纤维,以及椰纤维。
13.一种按照权利要求8的结构组件,其中所述芯层以及所述第一和第二增强面层中的所述热塑性树脂包括下述树脂中的至少一种:聚烯烃,聚酰胺,聚苯乙烯,丙烯腈苯乙烯,丁二烯,聚酯,聚三氯酸丁烯酯,聚氯乙烯,聚亚苯基醚,聚苯醚,聚醚酰亚胺,聚碳酸酯,聚酯碳酸酯,丙烯腈-丙烯酸丁酯-苯乙烯聚合物,聚对苯二甲酸丁二醇酯,聚对苯二甲酸乙二醇酯以及无定形尼龙。
14.一种按照权利要求8的结构组件,还包括施加于所述第一至少一增强面层和所述第二至少一增强面层中至少一个的外表面的装饰层。
15.一种制造机动车辆内部结构组件的方法,所述方法包括:
形成可渗透的纤维增强热塑性芯层,包括许多用热塑性树脂粘合在一起的增强纤维,该可渗透芯层具有约0.1-1.8gm/cc的密度且包括第一表面和第二表面;
将至少一第一增强面层放置在第一表面上;
将至少一第二增强面层放置在第二表面上;
将至少一第一增强面层附着在第一表面上;
将至少一第二增强面层附着在第二表面上以形成多层纤维增强片材;以及
将多层纤维增强片材模制成预定形状;
每个所述第一和第二增强面层包括增强纤维基体和热塑性树脂,其中施加在第一表面的增强纤维基体按照双向取向排列,施加在第二表面的增强纤维基体按照双向取向排列。
16.一种按照权利要求15的方法,其中在任何一个增强面层中的增强纤维基体包括单向取向,双向取向,纺织纤维取向,或编织纤维取向。
17.一种按照权利要求15的方法,其中每个第一和第二增强面层包括约50-80重量%的增强纤维。
18.一种按照权利要求15的方法,其中该芯层包括约20-80重量%的增强纤维。
19.一种按照权利要求15的方法,其中所述芯层以及所述第一和第二增强面层中的所述增强纤维包括下述纤维中的至少一种:金属纤维,金属化无机纤维,金属化合成纤维,玻璃纤维,聚酯纤维,聚酰胺纤维,石墨纤维,碳纤维,陶瓷纤维,矿物纤维,玄武岩纤维,无机纤维,芳族聚酰胺纤维,洋麻纤维,黄麻纤维,亚麻纤维,大麻纤维,纤维素纤维,剑麻纤维,以及椰纤维。
20.一种按照权利要求7的方法,还包括将至少一装饰层粘结到多层纤维增强片材上。
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AU2012203228B2 (en) | 2015-03-26 |
US20070238378A1 (en) | 2007-10-11 |
EP1844927A3 (en) | 2007-11-28 |
KR101453081B1 (ko) | 2014-10-27 |
CA2583851C (en) | 2016-06-21 |
ATE489225T2 (de) | 2010-12-15 |
KR20070100134A (ko) | 2007-10-10 |
EP1844927B1 (en) | 2010-11-24 |
JP2007276476A (ja) | 2007-10-25 |
EP1844927B2 (en) | 2019-01-23 |
AU2007201388A1 (en) | 2007-10-25 |
DE602007010688D1 (de) | 2011-01-05 |
CN102873932A (zh) | 2013-01-16 |
JP5571869B2 (ja) | 2014-08-13 |
BRPI0701263A (pt) | 2007-12-11 |
CA2583851A1 (en) | 2007-10-05 |
ES2355529T3 (es) | 2011-03-28 |
BRPI0701263B1 (pt) | 2018-02-14 |
AU2012203228A1 (en) | 2012-06-21 |
EP1844927A8 (en) | 2007-12-19 |
RU2429133C2 (ru) | 2011-09-20 |
AU2007201388B2 (en) | 2012-03-01 |
ES2355529T5 (es) | 2019-07-23 |
RU2007112538A (ru) | 2008-10-10 |
MX2007004150A (es) | 2008-11-27 |
US7759267B2 (en) | 2010-07-20 |
EP1844927A2 (en) | 2007-10-17 |
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