CN102864579B - 使用来自汽车座椅泡沫的聚氨酯泡沫制造隔音材料的方法及通过其制备的组合物 - Google Patents

使用来自汽车座椅泡沫的聚氨酯泡沫制造隔音材料的方法及通过其制备的组合物 Download PDF

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CN102864579B
CN102864579B CN201110332262.4A CN201110332262A CN102864579B CN 102864579 B CN102864579 B CN 102864579B CN 201110332262 A CN201110332262 A CN 201110332262A CN 102864579 B CN102864579 B CN 102864579B
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deadener
foam
polyester fiber
fiber
pet
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CN102864579A (zh
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具洪谟
金庆南
梁埈滈
金容泰
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Gyeongbuk Co ltd
Hyundai Motor Co
Kia Corp
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Abstract

本发明公开通过精细压碎丢弃的汽车座椅，将压碎的汽车座椅与聚酯纤维、例如LM PET的低熔点聚酯纤维、聚丙烯纤维和大麻混合，且梳理所得的混合物而制造隔音材料的方法，及通过该方法制备的隔音材料组合物。所公开的方法使丢弃的汽车座椅的聚氨酯泡沫再循环成具有优异外观质量和隔音性能的隔音材料组合物。所公开的方法还防止过量静电的产生，且允许制备具有光滑表面的隔音材料。

Description

使用来自汽车座椅泡沫的聚氨酯泡沫制造隔音材料的方法及 通过其制备的组合物
技术领域
本发明涉及通过再循环丢弃的汽车座椅中的聚氨酯泡沫而制造隔音材料组合物的方法。
背景技术
通常，隔音材料在需要隔音的汽车发动机室周围的引擎盖隔音垫(hoodinsulation pad)或挡板隔音垫(dash insulation pad)、或底舱的下面或挡板隔音垫中的内部部件(例如后行李箱(trunk)等)中使用。
作为汽车中的典型的隔音材料，经常使用聚对苯二甲酸乙二酯(PET)、纤维材料或氨基甲酸酯泡沫。通常整个丢弃而没有再循环的汽车座椅经常含有用于提供座椅中的缓冲垫支持(cushion support)的热固性聚氨酯泡沫。由于座椅泡沫由热固性材料组成，经常不将其回收而埋于地下或焚化，引起土壤和空气污染。然而，没有商业上可行的从丢弃的座椅中再循环聚氨酯泡沫的方法或从丢弃的座椅泡沫中制备用于汽车隔音部件的外观质量或隔音性能满意的隔音材料的方法。
在国外，Toyota自2002年已研制出再生隔音产品(RSPP)，且将它们用于其日本汽车市场中的汽车Raum中。然而，这些隔音产品不是纯聚氨酯(PU)泡沫，而是其中混合有纤维和塑料的简单纸板型(simple chipboard)产品。因此，它们在技术和质量方面非常低级。当考虑到这些产品的包括气味、VOC、密度、隔音性能和外观的整体质量时，在工业中需要提供回收丢弃的座椅泡沫且从它制造高质量隔音材料的方法。
发明内容
本发明公开通过再循环经预处理、压碎、混合等的丢弃的汽车座椅而制造用于汽车的隔音材料的方法。具体地，本发明提供隔音材料中的PU泡沫的分散性优异以及细度、隔音性能和机械特性优异的隔音材料组合物。
在本发明中，当制造用于汽车发动机室部件(需要耐热性和隔音性能)或内部部件(需要隔音性能和耐火性)的隔音材料以及建筑材料时，使用圆柱形压碎机将聚氨酯(PU)泡沫压碎至适当大小，以在维持PU泡沫的优异的隔音性能的同时保证均匀的分散性和光滑的产品表面。
本发明提供从通常会引起环境问题的丢弃的汽车座椅泡沫中制备隔音材料组合物的方法，通过压碎、混合、梳理(carding)、针刺、热成型、冷却、热轧和切割材料，使汽车座椅再循环为隔音材料且满足物理特性需求。
本发明涉及提供通过将例如聚酯纤维(例如PET纤维)、低熔点聚酯纤维(例如LMPET纤维)、聚丙烯纤维、大麻(例如黄麻)等的新材料加入从丢弃的汽车座椅中回收的精细压碎的聚氨酯泡沫而制备隔音材料组合物的方法。
在一个一般方面，本发明提供再生的隔音材料的制备方法，其包括：在混合机中将从丢弃的汽车座椅中回收的压碎的PU泡沫与聚酯纤维(例如PET纤维)、低熔点聚酯纤维(例如LM PET纤维)、和任选聚丙烯(PP)纤维和大麻(例如黄麻)混合，将混合物梳理、针刺、热成型且冷却成毡，而且热轧且切割毡。而且，在混合过程中加入压碎的PU泡沫的纤维可以是PET和LM PET的混合物或PP纤维和黄麻的混合物。
此外，可以装备水注射喷雾器(water-injecting spray)以防止在混合过程中产生过量静电，且使摆动(swinging)和操作速度最佳化以减少网堆叠(web stacking)混合物过程中的厚度变化，且调节针的数目和深度、针架的宽度和长度以及用于针刺的穿刺数目以提供光滑的表面。
在混合过程中，可以添加PP纤维、大麻(黄麻)和玻璃纤维以提高隔音性能、物理特性和外观质量。而且，可以用无纺织物进行层压，以维持板材(board)的形状且防止PU泡沫的分离。本发明还提供隔音材料组合物，其包括：(1)10-80wt％的压碎的丢弃的座椅泡沫、(2)10-80wt％的聚对苯二甲酸乙二酯(PET)纤维、(3)2-50wt％的低熔点聚对苯二甲酸乙二酯(LM PET)纤维、(4)2-30wt％的聚丙烯(PP)纤维和(5)2-30wt％的大麻(黄麻)，或(1)、(2)和(3)。
下文将描述本发明的上述和其它的方面和特征。
附图说明
现在将参考本发明的某些示例性实施方式来详细地描述本发明的上述和其它目的、特征和优势，其在所附附图中说明，下文给出的这些实施方式仅仅用于说明，因此不是对本发明的限制，其中：
图1显示压碎的丢弃的氨基甲酸酯座椅泡沫；
图2显示根据本发明的示例性实施方式的隔音材料组合物的制备方法，连同关于它的简要说明；
图3将根据本发明的示例性实施方式的压碎、混合和梳理工艺与现有技术的工艺进行比较；
图4显示从6-mm大小的泡沫颗粒制备的隔音材料；
图5显示Toyota的再生隔音产品(RSRP)；
图6显示通过将20wt％的PET纤维和30wt％的LM PET纤维加入50wt％的压碎至3mm的丢弃的座椅PU泡沫而制备的隔音材料；且
图7显示根据本发明的示例性实施方式的隔音材料组合物的制备方法。
具体实施方式
下面将详细地参照本发明的各个实施方式，其实施例图示在附图中，并在下文加以描述。尽管本发明将结合示例性实施方式进行描述，但应当理解，本说明书无意于将本发明局限于这些示例性实施方式。相反，本发明不仅要涵盖这些示例性实施方式，还要涵盖各种替换方式、变化方式、等同方式和其它实施方式，其均可以包括在所附权利要求限定的本发明的精神和范围之内。
本发明提供隔音材料的制备方法，其包括：(a)精细压碎丢弃的汽车座椅；(b)将所得的压碎的聚氨酯(PU)泡沫与聚酯纤维、低熔点聚酯纤维、聚丙烯(PP)纤维、热塑性纤维和大麻混合；(c)梳理所得的混合物；(d)针刺所得的混合物；(e)热成型且冷却生成物；且(f)将生成物成形为毡，然后热轧且切割毡。
在本发明的一些实施方式中，压碎的泡沫可以具有约1-15mm的大小，更具体地约1-6mm，最具体地约2-3mm。在本发明的具体的实施方式中，聚酯纤维可以是聚乙醇酸(PGA)、聚乳酸(PLA)、聚己二酸乙二酯(PEA)、聚羟基链烷酸酯(PHA)、聚对苯二甲酸乙二酯(PET)、聚对苯二甲酸丁二酯(PBT)、聚对苯二甲酸丙二酯(PTT)或聚萘二甲酸乙二酯(PEN)，但不限于此。最具体地，聚酯纤维可以是聚对苯二甲酸乙二酯纤维。
在本发明的一些实施方式中，热塑性塑料可以是尼龙、丙烯腈丁二烯苯乙烯(ABS)、赛璐珞、醋酸纤维素、乙烯醋酸乙烯酯(ethylenevinyl acetate)、乙烯-乙烯醇、聚甲醛、聚丙烯酸酯、聚酰胺、聚酰胺-酰亚胺、聚芳基醚酮、聚丁二烯、聚丁烯、聚对苯二甲酸丁二酯、聚己酸内酯、聚对苯二甲酸乙二酯、聚对苯二甲酸环己烷二甲酯(polycyclohexylenedimethylene terephthalate)、聚碳酸酯、聚乙烯、聚醚酰亚胺、聚酰亚胺、聚乳酸、聚甲基戊烯、聚苯醚、聚苯硫醚、聚邻苯二甲酰胺、聚丙烯、聚苯乙烯、聚砜、聚氨酯、聚醋酸乙烯酯、聚氯乙烯或苯乙烯丙烯腈，但不限于此。
在本发明的示例性实施方式中，大麻可以是黄麻、亚麻(flax、linen)、大麻或苎麻。在本发明的某个实施方式中，混合物可以包括(1)10-80wt％的压碎的座椅泡沫、(2)10-80wt％的聚酯纤维和(3)2-50wt％的低熔点聚酯纤维。更具体地，聚酯纤维可以是PET，且低熔点聚酯纤维可以是LM PET。此外，在本发明的某个实施方式中，混合物还可以包括(4)聚丙烯(PP)纤维和(5)大麻。更具体地，大麻可以是黄麻。在组合物中可以以2-30wt％的量包括聚丙烯和大麻。更具体地，可以以20-25wt％的量包括聚丙烯，且可以以10-15wt％的量包括大麻。
另一方面，本发明提供通过上述制备方法制备的隔音材料组合物。省去关于组合物的描述以避免重复。
下文将详细描述根据本发明的从压碎的丢弃的座椅PU泡沫中再循环的隔音材料组合物及制备方法。
本发明提供隔音材料组合物，其包括使用圆柱形压碎机压碎丢弃的汽车座椅而获得的压碎的PU泡沫作为主要成分。加入其中的纤维可以是聚对苯二甲酸乙二酯(PET)纤维、低熔点聚对苯二甲酸乙二酯(LMPET)纤维或其它用于获得平衡的物理特性的纤维。而且，也可以添加玻璃纤维。可以用于改善隔音材料的物理特性和外观质量的添加剂包括PP纤维、黄麻、玻璃纤维等。
为更详细地描述，隔音材料组合物包括作为基础成分的PU泡沫、PET纤维和LM PET纤维，以及0-40wt％的PP纤维、黄麻和玻璃纤维。通常，所制备的隔音材料的抗张强度在加工方向上为约7.0kgf/cm2，在横向方向上为约20.0kgf/cm2，隔音系数在1.0kHz为0.57，在2.0kHz为0.69，在3.15kHz为0.83。而且，通过在热压机(约200-230℃)之间将所制备的隔音材料预热约30-200秒然后在冷模中成形而制备的隔音板通常具有约17.0kgf/cm2的断裂强度。
由于PU泡沫是不可用热或压力再加工的热固性材料，取而代之的是泡沫本身被压碎成如图1所示的小尺寸(粒径：约1-10mm)。通过将压碎的PU泡沫与PET和LM PET纤维混合，可以制备满足物理特性需求且外观质量改善的隔音材料。
实施例
现在将描述实施例和实验。下述实施例和实验仅仅用于说明目的，而无意于限制本发明的范围。隔音材料的制备方法在图2中示例说明。
实施例1
在40wt％的通过将回收的丢弃汽车座椅压碎成3mm大小而制备的PU泡沫中加入30wt％的PET纤维和30wt％的LM PET纤维。当进一步增加纤维的添加量时，产品外观好但出现纤维的成团，且所得的隔音材料与比较例1相比显示相对差的隔音性能。
实施例2
向50wt％的通过将回收的丢弃汽车座椅压碎成3mm大小而制备的PU泡沫中，加入20wt％的PET纤维和30wt％的LM PET纤维。由图6可见，所得的隔音材料显示PU泡沫均匀分散且每单位面积的量增加。结果，其显示改善的隔音性能和好的外观。
实施例3
为评价取决于PU泡沫大小的可使用性、外观和隔音性能，将PU泡沫压碎成6mm大小，以与实施例2相同的方式制备成隔音材料。由图4可见，PU泡沫分散性、外观和隔音性能均不佳。因在分散的泡沫周围形成大量孔，泡沫粒径的增加导致降级的隔音性能和具有弯曲表面的外观(图4)。
实施例4
向50wt％的通过将回收的丢弃汽车座椅压碎成3mm大小而制备的PU泡沫中，加入10wt％的PET纤维、25wt％的LM PET纤维和15wt％的黄麻。添加黄麻以减少成本。所得的隔音材料在分散性、外观和隔音性能上显示与实施例2相当的结果。
实施例5
向50wt％的通过将回收的丢弃汽车座椅压碎成3mm大小而制备的PU泡沫中，加入10wt％的LM PET纤维、20wt％的大麻和20wt％的PP纤维。添加具有低熔化温度的PP纤维提供了降低产品形成温度的优势。然而，所得的隔音材料显示比实施例2和实施例3差的耐热性。分散性、外观和隔音性能与实施例2相当。
实施例6和实施例7
向60wt％的通过将回收的丢弃汽车座椅压碎成3mm大小而制备的PU泡沫中，加入10-30wt％的PET纤维和10-30wt％的LM PET纤维。为增加再循环量，与实施例2相比，增加PU泡沫的含量。然而，增加的PU泡沫导致稍差的分散性。当粘合剂的量不足时，产品外观差。
比较例1
为评价压碎的PU泡沫的适用性，与市售的隔音材料(PET 60wt％+LM PET 40wt％)做了比较。表1显示将PU泡沫分散性、外观质量和隔音性能进行比较的结果。
表1
(1)对隔音材料中的PU泡沫分散性进行如下评价。使用刀切割隔音材料之后，目测PU泡沫的分散状态。结果评价为优异(5)、好(4)、中等(3)、不足(2)或差(1)。
(2)通过目测隔音材料的表面曲率评价产品外观。此外，在用热压机(200-230℃、1分钟)预热且然后在冷模中成形之后，目测表面曲率。结果评价为优异(5)、好(4)、中等(3)、不足(2)或差(1)。
(3)根据混响室方法评价隔音性能。
详细来说，根据本发明的从压碎的PU泡沫中再循环的隔音材料组合物的组分如下。
(1)丢弃的汽车座椅
在本发明中，将聚氨酯泡沫从丢弃的汽车座椅或废料中回收且精细压碎用于再循环。现在，很少将其再循环，而是埋于地下或焚化，引起环境污染。
(2)聚氨酯(PU)泡沫
在本发明中使用的聚氨酯泡沫是热固性材料，与热塑性材料不同，其难于再循环。其通过将多元醇与异氰酸酯混合且鼓风而制造。从丢弃的汽车中可以获得约10kg。在隔音材料组合物中以10-80wt％的量包括PU泡沫。
(3)聚对苯二甲酸乙二酯(PET)纤维
在本发明中使用的PET纤维具有250-260℃的熔化温度且为2-10丹尼尔(de)。由于优异的机械强度和耐热性，使用它来维持隔音材料的形状且增强耐热性。以10-80wt％的量包括PET纤维。
(4)低熔点聚对苯二甲酸乙二酯(LM PET)纤维
在本发明中使用的LM PET纤维具有130-180℃的熔化温度且为3-8de。使用它起隔音材料中的粘合剂的作用。以5-50wt％的量包括LM PET纤维。
(5)聚丙烯(PP)纤维
在本发明中使用的PP纤维具有130-150℃的熔化温度且为2-10de。使用它起隔音材料中的粘合剂的作用，且通过替换PET纤维降低形成温度。以2-30wt％的量包括PP纤维。
(6)黄麻
在本发明中，可以使用黄麻来提供机械刚性。以2-30wt％的量包括黄麻。除组分(2)、(3)和(4)或(2)、(3)、(4)、(5)和(6)之外，根据目的还可以使用阻燃无纺织物。
通过提供将丢弃的汽车座椅再循环成具有优异隔音性能的隔音材料的可适用的方法，本发明提供显著的成本降低。由于通常会将丢弃的汽车座椅埋于地下或焚化，本发明使汽车的环境友好性提高且符合国际法规。更具体地，由于通过本发明提供的隔音材料组合物与包括60％的PET和40％的LM PET的现有隔音材料相比显示出相当或更好的性能，其能节省约15-20％的成本。此外，如上所示，由于可以将丢弃的汽车座椅再循环，其为环境保护提供益处。
本发明参考其具体实施方式进行了详细描述。然而，本领域技术人员能够理解，可以在不偏离本发明的原理和精神的情况下对这些实施方式进行各种改变和变更，本发明的范围由所附的权利要求及其等同方式限定。

Claims (4)

1.一种隔音材料的制备方法，其包括：
将丢弃的汽车座椅精细压碎至2-3mm大小；
将所得的压碎的聚氨酯(PU)泡沫与聚酯纤维、作为粘合剂的低熔点聚酯纤维、聚丙烯(PP)纤维、以及选自黄麻、亚麻、苎麻和大麻的一种混合；
梳理所得的混合物；
针刺生成物；
将生成物热成型且冷却为毡；且
热轧且切割毡，
其中作为粘合剂的所述低熔点聚酯纤维的含量为2-50wt％，所述聚丙烯(PP)纤维的含量为20-25wt％，且所述选自黄麻、亚麻、苎麻和大麻的一种的含量为10-15wt％。
2.根据权利要求1所述的方法，其中所述聚酯纤维选自聚乙醇酸(PGA)、聚乳酸(PLA)、聚己二酸乙二酯(PEA)、聚羟基链烷酸酯(PHA)、聚对苯二甲酸乙二酯(PET)、聚对苯二甲酸丁二酯(PBT)、聚对苯二甲酸丙二酯(PTT)或聚萘二甲酸乙二酯(PEN)。
3.根据权利要求1所述的方法，其中所述混合物包括10-80wt％的压碎的座椅泡沫、10-80wt％的聚酯纤维和2-50wt％的低熔点聚酯纤维。
4.根据权利要求1所述的方法，其中所述聚氨酯泡沫是丢弃的座椅泡沫或热固性聚氨酯泡沫。
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