CN104260259B - 一种汽车内饰件边角料模压制品的制备方法 - Google Patents

一种汽车内饰件边角料模压制品的制备方法 Download PDF

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CN104260259B
CN104260259B CN201410387571.5A CN201410387571A CN104260259B CN 104260259 B CN104260259 B CN 104260259B CN 201410387571 A CN201410387571 A CN 201410387571A CN 104260259 B CN104260259 B CN 104260259B
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leftover pieces
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automotive upholstery
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CN104260259A (zh
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金平
金一平
陈子蛟
程太品
雷飞
夏洪涛
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NINGBO HUAYE MATERIAL TECHNOLOGY Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
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    • B29B17/0412—Disintegrating plastics, e.g. by milling to large particles, e.g. beads, granules, flakes, slices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/52—Heating or cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/58—Measuring, controlling or regulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/50—Details of extruders
    • B29C48/505—Screws
    • B29C48/52—Screws with an outer diameter varying along the longitudinal axis, e.g. for obtaining different thread clearance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/50—Details of extruders
    • B29C48/505—Screws
    • B29C48/53—Screws having a varying channel depth, e.g. varying the diameter of the longitudinal screw trunk
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/50—Details of extruders
    • B29C48/505—Screws
    • B29C48/535—Screws with thread pitch varying along the longitudinal axis
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
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    • B29C43/58—Measuring, controlling or regulating
    • B29C2043/5816—Measuring, controlling or regulating temperature
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    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
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    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/62—Plastics recycling; Rubber recycling

Abstract

本发明涉及一种汽车内饰件边角料模压制品的制备方法，包括：(1)将回收的汽车内饰件边角料破碎得破碎料；(2)将上述破碎料热压熔融、或挤出熔融物料模压、冷却得模压制品。本发明利用汽车内饰件边角废料制备模压制品，原料环保且成本低，不产生二次污染，模压制品质量轻、强度高，可再次循环回收利用，在工业上有广泛用途，具有很高的经济和社会价值。

Description

一种汽车内饰件边角料模压制品的制备方法
技术领域
本发明涉及汽车内饰件边角废料回收制备领域，特别是涉及一种汽车内饰件边角料模压制品的制备方法。
背景技术
近年来，汽车内饰件越来越多地使用轻质GMT和丙纶麻毡板等热塑性复合材料，而汽车内饰件在成型过程中会产生约15％的边角料，比如汽车顶棚成型时，一周约15公分的边角料以及整个天窗的面积都会成为边角料。为了使汽车内饰更美观和舒适，在轻质GMT和丙纶麻毡板的表面都复合有每平方米200克以上的PET无纺布、PU海绵、皮革等隔热吸音和装饰层，使得内饰件材料的组分越来越复杂，分类回收变得越来越困难，特别是轻质GMT材料中约有30-40％的玻璃纤维，而且轻质GMT材料中的玻璃纤维与聚丙烯纤维之间处于蓬松状态，密度一般都在0.5左右，玻璃纤维很容易分离掉落，与人体接触会致痒，如果焚烧，一部分玻璃纤维会被烟气带出排放在空气中，造成环境污染，填埋的话需要场地成本，而且也不太容易降解。汽车内饰件制造厂为解决这些边角料的出路而发愁。
CN200410103100.3《一种聚丙烯复合废料的回收成型工艺》，该发明涉及一种聚丙烯复合废料的回收成型工艺，具体地说是用于汽车内饰件边角料的回收再利用。本发明将聚丙烯复合废料经破碎后，加入纯聚丙烯、偶联剂及助剂均匀混合后，制成混合料，混合料经加热，保温至混合料进入熔融态，先在模具中放入玻璃纤维布，再将熔融态混合料加入模具中模压，冷却脱膜后得到制品成品。但该方法采用化学制备，成本高，有污染。
发明内容
本发明所要解决的技术问题是提供一种汽车内饰件边角料模压制品的制备方法，该方法利用汽车内饰件边角料制备模压制品，一方面边角废料的回收循环利用，环保且成本低，无二次污染，另一方面模压制品质量轻、强度高，可再次循环回收利用，在工业上有广泛用途，本方法具有很高的经济和社会价值。
本发明是通过如下技术方案实现的：一种汽车内饰件边角料模压制品的制备方法，包括：
(1)将回收的汽车内饰件边角料破碎，得到破碎料；
(2)将上述破碎料挤出熔融物料，通过挤出口模模压成型，得到模压制品。
所述步骤(1)中的汽车内饰件边角料为轻质GMT、丙纶麻毡板中的一种或两种。
所述步骤(1)中边角料投入筛网网眼直径为10mm-40mm的破碎机中破碎。
所述挤出螺杆，在加料段、挤出行程段和排气段上设置有螺棱，所述的加料段与挤出行程段相连，所述的排气段布置在挤出行程段中部，所述的加料段和挤出行程段上的螺棱宽度与螺槽宽度的比值的变化范围为0.24-0.62，整根螺杆的螺槽宽度之和是螺槽深度之和的1.2倍以上，所述的加料段的最大螺槽的体积和其他段最小螺槽体积之比为1.8:1，所述的挤出行程段中布置有塑化混炼段，该塑化混炼段的长度少于整根螺杆长度的10％。
传统的异向锥形双螺杆主要用于型材和管材等制品的挤出，因其需要将物料在稳定的高压力条件下挤出，所以螺杆的导程通常设计得较小，同时螺纹数量多，剪切强，但是极大地限制了螺杆的有效容积，进而限制挤出产量。对于GMT材料而言，螺纹多意味着螺槽的容积受到限制，进而影响到产量的提升，同时螺槽容积过小带来的压力过大、剪切过强将影响到纤维的长度，降低制品性能，所以将加料段和挤出行程段上的螺棱宽度与螺槽宽度的比值的变化范围为0.24-0.62，且螺槽宽度之和占整根螺杆长度的66％～75％，螺槽的容积得到很大扩展，挤出压力适当降低，物料内部因压力带来的层流和剪切减小，纤维的长度得到了保留。
整根螺杆的螺槽宽度之和是螺槽深度之和的1.2倍以上，使材料所受到的剪切小，特别是加料段采用宽螺槽、深螺槽以便堆积密度在0.3吨/立方米以下的材料的喂入，而传统锥形双螺杆则相反，一般是槽深之和大于槽宽之和、螺纹数量多，剪切强。
在传统的锥形双螺杆的设计中,喂料段螺槽的容积是中间阻流段螺槽的最小容积的3倍，压缩比例达到1:3左右，较大的压缩比有利于建立较高的挤出压力，但是料流内部会带来强烈的层流，导致料流内部剪切很大，玻纤的长度遭到破坏，进而影响到制品的质量。在本专利所述的螺杆的实际的生产使用中，主要依靠下游压机来保证制品的致密性，所以在挤出机中，将加料段的最大螺槽的体积和其他段最小螺槽体积之比为1.8:1，从而有效控制料流内部的剪切，较小的压缩是减少了材料之间的内摩擦，以尽量保留纤维强度，达到了尽量保留玻纤长度的目的，保证制品的力学性能。
传统螺杆在加工过程中，物料塑化的能量来自于主电机的机械能转化和机筒传热能量。这就需要在螺杆上设置限流段(如锥形双螺杆的小导程螺纹、平行双螺杆的反旋元件、单螺杆的主/副螺纹段、屏障头和销钉混合段等)，塑化混炼的组件都具有较强的剪切功能，在塑化混炼的同时会加大料流内部的压力,增强物料内部的层流，剪断玻纤。在由本专利申请的螺杆组成的锥形双螺杆中，起限流作用的小导程螺纹由传统螺纹的10个导程缩小到2－3个导程，在本专利申请的挤出单螺杆中，所述的挤出行程段中布置的塑化混炼段的长度少于整根螺杆长度的10％，并且该塑化混炼段是分散的分布在挤出行程段中或者是集中分布在挤出行程段上的任何位置。
所述的挤出螺杆为平螺杆或者锥形螺杆，两根并排布置且螺纹方向相反的螺杆就可以组成平行双螺杆或者锥形双螺杆，增强挤出效果。
所述的挤出行程段上靠近排气段的位置上的若干个螺棱导程中均沿着圆周布置有一圈销钉，物料在流经销钉段的时候，会被分成很多股，而接下来在流经第二个销钉段的时候，又会经历一次被分开的情况，从而造成多次的分流与混合，这样有利于加大已经熔融的物料与未熔融的颗粒的接触面积，改善传热，改善物料的均匀性。同时适当匹配螺杆转速，控制物料的停留时间，保证物料的熔融。
进一步的，所述的螺棱导程中的销钉围成的圈与螺杆的横截面平行布置或者与螺棱平行布置，两种布置方式都可以，根据实际需要进行选择。
所述的排气段的直径小于挤出行程段的直径，增加与物料接触的表面积，考虑到原料来源较复杂，原料内部水分含量较多，因此辅以真空排气，抽除原料中水分，该排气段上布置有双头螺纹，其目的是扩大物料的表面积，增加材料内部气体排出的可能。该段基本不影响塑化效果，剪切力也更弱。材料中的水分大部分在这里排出。
本发明要求粉碎的玻璃纤维在10-40mm之间即可，不需要更细的如2-6mm，节约成本，通过热压熔融或螺杆加热挤出达到塑化作用。
有益效果
本发明工艺简便，节能环保，其制备的模压制品在工业上有广泛用途。
(1)本发明制备的砖机托板，具有质量轻、强度高，耐磨，使用寿命长等特点。与密度1800kg/立方米的高分子PVC托板相比，砖机托板的密度为1200kg/立方米，减轻重量约35％。同样尺寸如850mm*680mm*18mm的托板，PVC托板为18kg/张，而本发明托板为12kg/张。本托板耐候性好：在零下20度时，托板强度变化小，而PVC托板在零度以下时变脆，容易断裂，损耗大。本发明托板无缺口冲击强度大于25MJ/m2，PVC托板的冲击强度约为20MJ/m2。所以本发明托板的使用寿命较PVC托板增加三分之一以上。
(2)本发明制备的建筑模板，具有质量轻、强度高、耐磨、使用寿命长等特点，一般周转使用次数在30次以上，而胶合板建筑模板只能周转5-6次，发泡PVC建筑模板只能周转10次左右。平整光洁，模板拼接严密平整，脱模后混凝土结构表面度、光洁度均超过现有清水模板的技术要求，不须二次抹灰，省工省料。轻便易装。重量轻，工艺适应性强，可以锯、刨、钻、钉，可随意组成任何几何形状，满足各种形状建筑支模需要。脱模简便。混凝土不沾板面，无需脱模剂，轻松脱模，容易清灰。稳定耐候。机械强度高，在-20℃至60℃气温条件下，不收缩，不湿胀、不开裂、不变形、尺寸稳定、耐碱防腐、阻燃防水，拒鼠防虫，利于养护。模板不吸水，不用特殊养护或保管。可变性强。种类、形状、规格可根据建筑工程要求定制。低成本。周转次数多，平面模不低于30次，柱梁模不低于40次，节能环保。边角料和废旧模板全部可以回收再造。
(3)本发明制备的漏粪板，强度可以和BMC玻璃钢相当，具有抗腐蚀，抗老化，冬暖夏凉，导热系数低；利于猪生长发育，外表美观等优点。平整光滑，抗酸碱度。不伤脚、不伤奶头、重量轻、安装方便。自清洁功能，即不粘粪便，易清洗，长期使用过程中不会有细菌产生。可回收再利用。
(4)本发明还可以生产很多种类的模压产品，如沟盖板、托盘、垫仓板等模压制品。
附图说明
图1为本发明的工艺流程图。
图2为为本发明的挤出螺杆的结构示意图。
具体实施方式
下面结合具体实施例，进一步阐述本发明。应理解，这些实施例仅用于说明本发明而不用于限制本发明的范围。此外应理解，在阅读了本发明讲授的内容之后，本领域技术人员可以对本发明作各种改动或修改，这些等价形式同样落于本申请所附权利要求书所限定的范围。
一种汽车内饰件边角料模压制品的制备方法，包括：
(1)将回收的汽车内饰件边角料破碎，得到破碎料；
(2)将上述破碎料挤出熔融物料，通过挤出口模模压成型，得到模压制品；
所述步骤(2)中的挤出熔融物料所采用的挤出螺杆的结构为：在加料段C、挤出行程段A和排气段B上设置有螺棱；所述的加料段C与挤出行程段(A)相连，所述的排气段B布置在挤出行程段A中部，所述的加料段C和挤出行程段A上的螺棱宽度与螺槽宽度的比值的变化范围为0.24-0.62，整根螺杆的螺槽宽度之和是螺槽深度之和的1.2倍以上，所述的加料段C的最大螺槽的体积和其他段最小螺槽体积之比为1.8:1，所述的挤出行程段A中布置有塑化混炼段，该塑化混炼段的长度少于整根螺杆长度的10％。
所述步骤(1)中的汽车内饰件边角料为轻质GMT、丙纶麻毡板中的一种或两种。
所述步骤(1)中边角料投入筛网网眼直径为10mm-40mm的破碎机中破碎。
实施例1
(1)将轻质GMT汽车内饰件边角料投入直径为30mm筛网的破碎机中破碎物料，得到物料直径25mm的破碎料；
(2)取上述破碎料100％投入挤出螺杆中挤出熔融物料；
(3)使熔融物料通过口模挤出宽度为400mm，高度为40mm的熔融物料12.5公斤；
(4)再将12.5公斤的熔融物料投入模压机模具中、闭合模压机模压成型、冷却定型，即得砖机托板。

Claims (4)

1.一种汽车内饰件边角料模压制品的制备方法，包括：
(1)将回收的汽车内饰件边角料破碎，得到破碎料；
(2)将上述破碎料挤出熔融物料，通过挤出口模模压成型，得到模压制品；
挤出熔融物料所采用的挤出螺杆的结构为：在加料段、挤出行程段和排气段上设置有螺棱，所述的加料段与挤出行程段相连，所述的排气段布置在挤出行程段中部；所述的加料段(C)和挤出行程段(A)上的螺棱宽度与螺槽宽度的比值的变化范围为0.24-0.62；整根螺杆的螺槽宽度之和是螺槽深度之和的1.2倍以上；所述的挤出行程段(A)中布置有塑化混炼段，该塑化混炼段的长度少于整根螺杆长度的10％。
2.根据权利要求1所述的一种汽车内饰件边角料模压制品的制备方法，其特征在于：所述步骤(1)中的汽车内饰件边角料为轻质GMT、丙纶麻毡板中的一种或两种。
3.根据权利要求1所述的一种汽车内饰件边角料模压制品的制备方法，其特征在于：所述步骤(1)中边角料投入筛网网眼直径为10mm-40mm的破碎机中破碎。
4.根据权利要求1所述的一种汽车内饰件边角料模压制品的制备方法，其特征在于：所述步骤(2)中的挤出熔融物料所采用的挤出螺杆的结构为：所述的加料段(C)的最大螺槽的体积和其他段最小螺槽体积之比为1.8:1。
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