CN101348098A - 车顶衬板的基础材料 - Google Patents

车顶衬板的基础材料 Download PDF

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CN101348098A
CN101348098A CNA2007101357764A CN200710135776A CN101348098A CN 101348098 A CN101348098 A CN 101348098A CN A2007101357764 A CNA2007101357764 A CN A2007101357764A CN 200710135776 A CN200710135776 A CN 200710135776A CN 101348098 A CN101348098 A CN 101348098A
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basic material
roof liner
liner plate
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expanded polyolefin
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金基成
吴映赞
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Han Il E HWA Co Ltd
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    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/02—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/06—Fixed roofs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B60—VEHICLES IN GENERAL
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    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
    • B60R13/0212—Roof or head liners
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract

本发明公开了用于车顶衬板的基础材料，其包含由交联的聚烯烃泡沫板制成的芯板、以及置于所述芯板上部和下部并且由天然纤维和合成纤维制成的强化层。

Description

车顶衬板的基础材料
相关申请的交叉引用
本发明基于2007年7月18日在韩国知识产权局提交的韩国专利申请No.10-2007-71638并且要求其优先权，其公开内容整体引入本文作为参考。
技术领域
本发明涉及车顶衬板的基础材料，更具体地，涉及具有高度可回收性和极好物理性能比如重量轻和高强度的车顶衬板基础材料。
背景技术
通常，车顶衬板的基础材料包含树脂毡、用天然纤维强化的板材、纸板、木纤维、刚性聚氨酯泡沫等。
通过酚醛树脂的浸渍来制造所述树脂毡和纸板。用作固化剂的酚醛树脂是通过酚和醛的缩合反应制备的一类热固性树脂。酚醛树脂的一个缺点是，未反应或酚醛树脂焚烧过程中不完全燃烧产生的酚和醛被认为是有毒气体，其是包括工作场所在内的生存环境的污染物质。
在常规的车顶衬板包含玻璃纤维或玻璃屑的情况下，在生产和运输过程中产生的玻璃粉尘对工人有不利的影响，而且用于结合材料的包含挥发性有机溶剂的粘合剂也危害健康。
尽管刚性聚氨酯泡沫具有良好的耐热性而且重量轻，但是它的可回收性差，由于其差的冲击强度，在制造顶衬板的成型过程中容易变脆。
常规的车顶衬板基础材料具有下列缺点：其隔音效果不太好；相对昂贵和沉重；长期使用易于变形；对健康有害；并且材料难以回收。
发明内容
因此，进行了本发明以解决现有技术中出现的上述问题，同时完好无损地保留了现有技术实现的优点。
本发明的一个目的是提供由于重量轻而能够提高燃料效率的车顶衬板的基础材料。
本发明的另一个目的是提供车辆废弃时可以易于回收的车顶衬板的基础材料。
本发明的又一个目的是提供具有高强度并对人体无害的车顶衬板的基础材料。
为了实现这些目的，本发明提供了一种车顶衬板的基础材料，其包含由交联的聚烯烃泡沫板制成的芯板；和置于所述芯板上层和下层并且由天然纤维和合成纤维制成的强化层。
在一个实施方案中，交联的聚烯烃泡沫板以5至30的放大率发泡，并且厚度为3至8mm。
为了提高强度，将强化层层合在聚烯烃泡沫板的上部和下部。优选，所述强化层由天然纤维和合成纤维制成。
用作芯板的聚烯烃泡沫板可以是交联的聚烯烃泡沫板。交联的聚烯烃泡沫可以分类为化学交联的和物理交联的。本发明应用的聚烯烃泡沫不限于交联的类型，但是优选在本发明中使用物理交联的制造方法。
优选地，用于制造交联的聚烯烃泡沫的树脂是聚丙烯和线性低密度聚乙烯的混合物。在只使用聚丙烯的情况下，在将射线辐照到树脂上作为物理交联方法时，聚丙烯链易断裂，并且交联效率不高。因此加入给定量的线性低密度聚乙烯。由于使用线性低密度聚乙烯时产品的拉伸率急剧增加，因此改善了可成形性。
除了低密度聚乙烯以外，还可以使用高密度聚乙烯、三元乙丙(EPDM)橡胶和二元乙丙(EPM)橡胶、弹性体。
应该加入助剂试剂(co-agent agent)以交联聚烯烃树脂。所述助剂试剂优选多官能的乙烯基单体，比如二乙烯基苯、氰尿酸三烯丙酯、三丙烯酸三羟甲基丙烷酯、亚硝基苯、二苯胍和二甲基丙烯酸乙二醇酯、以及三甲基丙烯酸三羟甲基丙烷酯。优选地，助剂的含量为0.5至3.0重量份，更优选0.8至1.5重量份。在所述重量份范围内，可以加入至少两种助剂。
优选地，通过辐照交联的聚烯烃泡沫的凝胶含量为30％至60％。可以通过ASTM D-2765测量凝胶含量。
用于制造交联的聚烯烃泡沫板的发泡剂通常是可热分解的发泡剂，例如偶氮二甲酰胺(ADCA)。ADCA的含量基于发泡膨胀度而改变，但是优选其含量为5至25phr。
如果必要，除了添加剂之外，还可以加入无机填充物、抗氧化剂、UV-吸收剂、抗静电剂、着色剂。
根据交联泡沫板的制造方法，在混合器中混合树脂和添加剂之后，通过挤出装置将混合物以指定厚度的板的形状挤出。用辐射辐照所述板。随后使挤出的板通过发泡炉来制造泡沫板。交联的泡沫板的厚度为3至8mm，宽度为700至1600mm。
附图说明
通过以下结合附图的详细说明，本发明的上述和其它目的、特征以及优点将更显而易见，其中：
图1是说明常规的车顶衬板的视图；
图2是说明根据本发明一个实施方案的车顶衬板的基础材料的视图；和
图3是说明应用了根据本发明的基础材料结构的车顶衬板的放大视图。
具体实施方式
在下文中，将参考附图描述本发明的优选实施方案。本说明书中限定的内容，比如详细的结构和要素只是用以帮助本领域普通技术人员全面理解本发明的具体细节，因此本发明不限于此。
图1是说明常规的车顶衬板的视图。所述顶衬板包含基础材料层10和保护层11。图2是说明根据本发明的一个实施方案的车顶衬板的基础材料的视图。本发明的顶衬板包含由聚烯烃泡沫板制成的芯层和由天然纤维和聚丙烯制成的强化层30。
优选地，根据本发明的一个实施方案用于基础材料层10中的聚烯烃泡沫板20发泡5至30倍。更具体而言，如果发泡小于5倍，泡沫板20的吸声能力变差，并且变重。如果发泡超过30倍，吸声能力得到改善并变轻。但是，其形状稳定性变差。由于聚烯烃泡沫板20用于车顶衬板中，它应该具有指定的尺寸。也就是说，优选厚度为3至8mm，更优选3至6mm。可以层合两个聚烯烃泡沫板以具有6至8mm的厚度。
根据本发明的一个实施方案的用于车顶衬板的基础材料10包含层合在聚烯烃泡沫板20的一侧或两侧的强化层30，如图3所示。强化层30由天然纤维和合成纤维制成。例如，所述强化层可以是由天然纤维和聚丙烯树脂制成的板层。优选地，聚烯烃泡沫和天然纤维的混合比为30∶70至70∶30(重量百分比)，厚度为1至3mm。优选地，提供直径为40至120μm，长度为40至80mm的天然纤维。在混合过程中将天然纤维切丝(scutched)，使得直径变为20至60μm，长度变为3至15mm。优选，聚烯烃纤维的直径为6至15丹尼尔，长度为40至80mm。
根据本发明用于车顶衬板的基础材料10通过在上下纤维层之间引入泡沫层制造，例如通过针刺方法结合泡沫层和纤维层。当层合下纤维层、泡沫层和上纤维层时，如果需要，可以在上纤维层上层合高强度保护层。在混合天然纤维和聚烯烃纤维以形成泡沫层并将所述泡沫层插入上下纤维层之间以后，分别通过针刺结合上纤维层和泡沫层、以及泡沫层和下纤维层。
因此，根据本发明用于车顶衬板的基础材料具有多层结构，其中通过粘合剂和热压或针刺处理上纤维层、泡沫层、和下纤维层，使强化材料的纤维和芯层彼此物理结合。
用于车顶衬板的基础材料层合于聚烯烃泡沫板20的一侧或两侧，以改善基础材料层10的强度和形状稳定性。另外，通过模具形成由天然纤维和聚丙烯树脂构成的板层时，增加可脱模性以改善可加工性。
参考图3，将保护层40层合在强化层30的部分上，所述强化层30层合在结合于车顶的聚烯烃泡沫板20的一侧或两侧。保护层40由聚烯烃无纺织物或聚酯基无纺织物制成。
如根据本发明所述的，通过层合强化层30和保护层40与作为芯板的聚烯烃泡沫板20制成的车顶衬板，由如图3所示的模式加工。用于车顶衬板的基础材料10具有极好的尺寸稳定性和强度。
由聚烯烃无纺织物制成的保护层40层合在由天然纤维和PP树脂组成的板层上时，可以使用热来融合，而不使用溶剂基粘合剂或热熔型粘合剂，使得层合过程变得非常简单。另外，可以消除使用粘合剂时产生的不好气味。由于使用聚烯烃泡沫板20作为芯板，并使用无纺织物作为保护层40，所以当拆毁汽车时，保护层40和芯板不分离，这可以节约资源并且是环境友好的。
通过上面的描述，用于车顶衬板的基础材料的隔音和耐热性能优良，强度非常高。并且对人体无害。
在车辆内衬结构由聚烯烃材料组成的情况下，当车辆报废的时候易于回收。
尽管出于说明目的已经描述了本发明的优选实施方案，但是本领域的技术人员应该理解，不背离如所附权利要求中公开的本发明的范围和精神，可以进行各种改变、添加和替换。

Claims (9)

1.一种车顶衬板的基础材料，其包含：
由交联的聚烯烃泡沫板制成的芯板；和
置于所述芯板的上部和下部并且由天然纤维和合成纤维制成的强化层。
2.权利要求1的车顶衬板的基础材料，其中所述交联的聚烯烃泡沫板包含选自聚丙烯、线性低密度聚乙烯、低密度聚乙烯、高密度聚乙烯、三元乙丙(EPDM)橡胶、弹性体和二元乙丙(EPM)橡胶的至少一种。
3.权利要求1的车顶衬板的基础材料，其中所述交联的聚烯烃泡沫板的宽度为700至1600mm。
4.权利要求1的车顶衬板的基础材料，其中所述交联的聚烯烃泡沫板以5至30的放大率发泡，并且厚度为3至8mm。
5.权利要求1的车顶衬板的基础材料，其中所述聚烯烃泡沫板的厚度为3至8mm，并且层合两个聚烯烃泡沫板以具有6至8mm的厚度。
6.权利要求1的车顶衬板的基础材料，其中所述聚烯烃纤维和天然纤维的混合比以重量百分比为30∶70至70∶30，所述强化层的厚度为1至3mm。
7.权利要求1的车顶衬板的基础材料，其中所述天然纤维的直径为40至120μm，长度为40至80mm，所述聚烯烃纤维的直径为6至15丹尼尔，长度为40至80mm。
8.权利要求1的车顶衬板的基础材料，其中所述天然纤维包含选自黄麻、洋麻和剑麻的至少一种。
9.权利要求1的车顶衬板的基础材料，其中所述合成纤维包含选自低熔点聚酯、聚酯、和聚乙烯的至少一种。
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