CN105525510A - 一种具有吸音降噪功效的汽车内饰件用仿皮材料及其制备方法 - Google Patents

一种具有吸音降噪功效的汽车内饰件用仿皮材料及其制备方法 Download PDF

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CN105525510A
CN105525510A CN201610048785.9A CN201610048785A CN105525510A CN 105525510 A CN105525510 A CN 105525510A CN 201610048785 A CN201610048785 A CN 201610048785A CN 105525510 A CN105525510 A CN 105525510A
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parts
imitation leather
leather material
minutes
base cloth
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陈峻
章云
张娉
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WUHU HUANRUI AUTO INTERIOR DECORATION CO Ltd
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Abstract

本发明公开了一种具有吸音降噪功效的汽车内饰件用仿皮材料，由下列重量份的原料制成：聚酰胺-675-77、碱溶性聚酯切片25-26、浓度为20%氢氧化钠溶液适量、水性聚氨酯50-53、纳米氢氧化镁5-6、聚磷酸铵3-4、十二烷基苯磺酸钠5-6、金红石钛白色浆3-4、水适量、聚二甲基硅氧烷0.5-0.6、四针状氧化锌晶须3-4、聚丙二醇5-6.5、粉煤灰1-2、锯末3-4、聚乙烯吡咯烷酮0.7-0.8、十二烷基聚氧乙烯醚硫酸钠0.8-1、二甲基硅油1-1.2。本发明制成的仿皮材料阻燃抗晒、手感仿真，透气防水，吸引降噪，非常适合用在高档汽车内饰件的制造中，安全无挥发。

Description

一种具有吸音降噪功效的汽车内饰件用仿皮材料及其制备方法
技术领域
本发明涉及合成革材料技术领域，尤其涉及一种具有吸音降噪功效的汽车内饰件用仿皮材料及其制备方法。
背景技术
随着经济的高速发展，人们的生活水平越来越高，对生活质量的要求也逐渐提高。皮革制品的需求量越来越大，档次也越来越高。我国人口多资源少，真皮来源有限，难以满足人们的需求。如今汽车内饰革已广泛地应用在乘用汽车、运输汽车的内饰件中。随着生活水平的提高，人们对汽车内饰革的质量要求、环保要求、舒适要求也越来越高。汽车内饰用革，最佳选择为真皮，但真皮在其自身生产过程中污染环境严重，重金属含量容易超标，在内饰件加工过程中成材率较低，其造价高昂，难以为中低档乘用车所接受；而且人们对环境保护逐渐重视，在提倡环保节能、可持续发展的今天，人们也开始开发出仿皮面料来取代动物皮革，以避免对野生动物的伤害和对自然环境的破坏。
目前，汽车门板、汽车座椅面料、仪表板、车厢内壁、车顶篷、方向盘把套等部位，主要采用非织造布等与聚氯乙烯、聚氨酯等复合的材料。普通的聚氯乙烯人造皮革存在手感硬、舒适性差、耐老化性能差、气味重、增塑剂易迁移析出等缺陷，所以目前汽车内饰中的普通PVC人造革已逐渐被聚氨酯（PU）合成革所取代。而聚氨酯合成革的生产采用溶剂型的生产系统，大量有机溶剂的使用，不仅污染环境，而且也严重地损害了人们的健康。随着环保法规和人们环保意识的加强，水性聚氨酯合成革技术成为该领域的研究热点。
因此，制造一种与真皮具有同样触感，同样舒适，且对环境友好、各项物理性能与真皮相同或超过真的仿皮汽车内饰革成为人造革生产领域的研究开发任务。
四针状氧化锌晶须于20世纪40年代被发现，最早由日本松下产业于1989年研制成功。四针状氧化锌晶须外观呈白色疏松状粉体，微观为三维四针状立体结构，即晶须有一核心，从核心径向方向伸展出四根针状晶体，它是迄今所有晶须中唯一具有空间立体结构的晶须，因其独特的立体四针状三维结构，很容易实现在基体材料中的均匀分布，从而各向同性地改善材料的物理性能，同时赋予材料多种独特的功能特性。它具有普通氧化锌所无法比拟的优良性能。如耐磨、增强、减振、防滑、降噪、吸波、抗老化、抗静电、抗菌等性能，可广泛用于国防、电子、化工、轻工、交通等国民经济领域，被称为21世纪的重要新材料。
发明内容
本发明目的就是为了弥补已有技术的缺陷，提供一种具有吸音降噪功效的汽车内饰件用仿皮材料及其制备方法。
本发明是通过以下技术方案实现的：
一种具有吸音降噪功效的汽车内饰件用仿皮材料，由下列重量份的原料制成：聚酰胺-675-77、碱溶性聚酯切片25-26、浓度为20%氢氧化钠溶液适量、水性聚氨酯50-53、纳米氢氧化镁5-6、聚磷酸铵3-4、十二烷基苯磺酸钠5-6、金红石钛白色浆3-4、水适量、聚二甲基硅氧烷0.5-0.6、四针状氧化锌晶须3-4、聚丙二醇5-6.5、粉煤灰1-2、锯末3-4、聚乙烯吡咯烷酮0.7-0.8、十二烷基聚氧乙烯醚硫酸钠0.8-1、二甲基硅油1-1.2。
根据权利要求1所述一种具有吸音降噪功效的汽车内饰件用仿皮材料，由下列具体方法制备而成：
（1）将聚酰胺-6切片后与碱溶性聚酯切片分别进行干燥，控制含水量小于1%，分别通过各自的单螺杆纺丝机搅拌熔融进入海岛型喷丝组件进行喷丝，得到的丝束经过牵伸（在温度为75℃下牵伸3.5倍）、上油、卷绕、干燥（55-65℃烘干5-10分钟）、切断（控制纤维长度为50-55mm，纤度为5-7dtex）得到复合超细短纤维；将复合超细短纤维经过开松棉之后采用梳理机梳理成单层纤维网，然后经过交叉铺网机形成复合层纤维网，再在针刺机上穿刺，最后利用切边机裁剪整齐，在120-140℃的条件下进行热收缩定型，得到超细纤维合成革基布；
（2）将十二烷基苯磺酸钠溶于5倍量的水中，加入纳米氢氧化镁、金红石钛白色浆聚磷酸铵以及一半量的水性聚氨酯，加热至50℃，以500转/分的速度搅拌15分钟后，再以1000转/分的速度搅拌10分钟，得到纳米改性材料乳液，将其放入浸渍槽中，然后将上述超细纤维合成革基布浸渍其中，充分浸渍后经轧辊挤压，将基布取出放入烘箱中，在120-130℃的温度下充分干燥，得到阻燃抗晒改性超细纤维合成革基布；
（3）将上述阻燃抗晒改性超细纤维合成革基布浸入浓度为20%氢氧化钠溶液中，加热至60-70℃，浸泡40分钟，抽出碱溶性聚酯进行开纤处理，用水洗净后干燥待用；
（4）将锯末干燥后粉碎成400目粉末与粉煤灰、四针状氧化锌晶须混合后放入球磨机中球磨，将聚乙烯吡咯烷酮溶于3倍量的水中，直接喷洒在混合粉体表面，继续球磨20分钟后送入造粒机中挤出造粒，将得到的颗粒放入400-450℃中烧结2小时，取出冷却后粉碎，过800目筛，将得到的粉末与聚丙二醇混合；将十二烷基聚氧乙烯醚硫酸钠溶于10倍量的水中，继续加入余量的水性聚氨酯、上述混合物以及其余剩余成分，放入发泡机中，边搅拌边鼓入空气，直至泡沫稳定停止搅拌，得到微泡水性聚氨酯浆料；
（5）将步骤（3）得到的基布浸渍在上述微泡水性聚氨酯浆料中，充分浸渍后经轧辊挤压，将基布取出放入烘箱中，先以80℃的温度干燥5分钟，使其水分在可控条件下挥发，再升温至100℃继续干燥5分钟，最后升温至140℃，使表面其完全交联固化成膜，之后经过磨毛、染色、压花、后整理等工序制成本发明材料。
本发明的优点是：本发明首先添加纳米氢氧化镁、金红石钛白色浆等耐碱成分配合水性聚氨酯对聚酰胺-6、聚酯混合纤维制成的合成革基布进行第一次浸渍改性，使纳米粒子均匀的覆盖在基布的表面以及缝隙中，形成良好的阻燃、防晒效果；之后不再采用甲苯而是利用氢氧化钠对改性后的基布进行开纤，在形成多空经的表面的同时不会在产品中造成有机溶剂残留，对人体以及环境安全友好。本发明两次浸渍液均采用水性聚氨酯，摒弃传统的溶剂型聚氨酯，具有无毒不残留、不燃、不污染环境的优点，而且保留了溶剂型聚氨酯的加工性能好、产品力学强度高、弹性好、耐磨的优良性能。
本发明在微泡水性聚氨酯浆料的制备过程中添加四针状氧化锌晶须、锯末、聚乙烯吡咯烷酮等成分，通过烧结，得到多孔的复合填料，进一步增强了填料的吸音降噪的功能；本发明制成的仿皮材料阻燃抗晒、手感仿真，透气防水，吸引降噪，非常适合用在高档汽车内饰件的制造中，安全无挥发。
具体实施方式
一种具有吸音降噪功效的汽车内饰件用仿皮材料，由下列重量份（公斤）的原料制成：聚酰胺-675、碱溶性聚酯切片25、浓度为20%氢氧化钠溶液适量、水性聚氨酯50、纳米氢氧化镁5、聚磷酸铵3、十二烷基苯磺酸钠5、金红石钛白色浆3、水适量、聚二甲基硅氧烷0.5、四针状氧化锌晶须3、聚丙二醇5、粉煤灰1、锯末3、聚乙烯吡咯烷酮0.7、十二烷基聚氧乙烯醚硫酸钠0.8、二甲基硅油1。
根据权利要求1所述一种具有吸音降噪功效的汽车内饰件用仿皮材料，由下列具体方法制备而成：
（1）将聚酰胺-6切片后与碱溶性聚酯切片分别进行干燥，控制含水量小于1%，分别通过各自的单螺杆纺丝机搅拌熔融进入海岛型喷丝组件进行喷丝，得到的丝束经过牵伸（在温度为75℃下牵伸3.5倍）、上油、卷绕、干燥（55℃烘干5分钟）、切断（控制纤维长度为50mm，纤度为5dtex）得到复合超细短纤维；将复合超细短纤维经过开松棉之后采用梳理机梳理成单层纤维网，然后经过交叉铺网机形成复合层纤维网，再在针刺机上穿刺，最后利用切边机裁剪整齐，在120℃的条件下进行热收缩定型，得到超细纤维合成革基布；
（2）将十二烷基苯磺酸钠溶于5倍量的水中，加入纳米氢氧化镁、金红石钛白色浆聚磷酸铵以及一半量的水性聚氨酯，加热至50℃，以500转/分的速度搅拌15分钟后，再以1000转/分的速度搅拌10分钟，得到纳米改性材料乳液，将其放入浸渍槽中，然后将上述超细纤维合成革基布浸渍其中，充分浸渍后经轧辊挤压，将基布取出放入烘箱中，在120℃的温度下充分干燥，得到阻燃抗晒改性超细纤维合成革基布；
（3）将上述阻燃抗晒改性超细纤维合成革基布浸入浓度为20%氢氧化钠溶液中，加热至60℃，浸泡40分钟，抽出碱溶性聚酯进行开纤处理，用水洗净后干燥待用；
（4）将锯末干燥后粉碎成400目粉末与粉煤灰、四针状氧化锌晶须混合后放入球磨机中球磨，将聚乙烯吡咯烷酮溶于3倍量的水中，直接喷洒在混合粉体表面，继续球磨20分钟后送入造粒机中挤出造粒，将得到的颗粒放入400℃中烧结2小时，取出冷却后粉碎，过800目筛，将得到的粉末与聚丙二醇混合；将十二烷基聚氧乙烯醚硫酸钠溶于10倍量的水中，继续加入余量的水性聚氨酯、上述混合物以及其余剩余成分，放入发泡机中，边搅拌边鼓入空气，直至泡沫稳定停止搅拌，得到微泡水性聚氨酯浆料；
（5）将步骤（3）得到的基布浸渍在上述微泡水性聚氨酯浆料中，充分浸渍后经轧辊挤压，将基布取出放入烘箱中，先以80℃的温度干燥5分钟，使其水分在可控条件下挥发，再升温至100℃继续干燥5分钟，最后升温至140℃，使表面其完全交联固化成膜，之后经过磨毛、染色、压花、后整理等工序制成本发明材料。
本发明制得的仿皮革材料经过一系列的检测，数据如下：撕裂负荷大于80N，剥离负荷大于70（N/20mm），23℃10万次耐折牢度为五级，-10℃4万次耐折牢度为五级，干擦等级五级，湿擦等级四级，耐碱10%的氢氧化钠中浸泡24小时后的剥离强度保持在80%以上，1000g负重条件下磨500次的情况下无破损。

Claims (2)

1.一种具有吸音降噪功效的汽车内饰件用仿皮材料，其特征在于，由下列重量份的原料制成：聚酰胺-675-77、碱溶性聚酯切片25-26、浓度为20%氢氧化钠溶液适量、水性聚氨酯50-53、纳米氢氧化镁5-6、聚磷酸铵3-4、十二烷基苯磺酸钠5-6、金红石钛白色浆3-4、水适量、聚二甲基硅氧烷0.5-0.6、四针状氧化锌晶须3-4、聚丙二醇5-6.5、粉煤灰1-2、锯末3-4、聚乙烯吡咯烷酮0.7-0.8、十二烷基聚氧乙烯醚硫酸钠0.8-1、二甲基硅油1-1.2。
2.根据权利要求1所述一种具有吸音降噪功效的汽车内饰件用仿皮材料，其特征在于，由下列具体方法制备而成：
（1）将聚酰胺-6切片后与碱溶性聚酯切片分别进行干燥，控制含水量小于1%，分别通过各自的单螺杆纺丝机搅拌熔融进入海岛型喷丝组件进行喷丝，得到的丝束经过牵伸（在温度为75℃下牵伸3.5倍）、上油、卷绕、干燥（55-65℃烘干5-10分钟）、切断（控制纤维长度为50-55mm，纤度为5-7dtex）得到复合超细短纤维；将复合超细短纤维经过开松棉之后采用梳理机梳理成单层纤维网，然后经过交叉铺网机形成复合层纤维网，再在针刺机上穿刺，最后利用切边机裁剪整齐，在120-140℃的条件下进行热收缩定型，得到超细纤维合成革基布；
（2）将十二烷基苯磺酸钠溶于5倍量的水中，加入纳米氢氧化镁、金红石钛白色浆聚磷酸铵以及一半量的水性聚氨酯，加热至50℃，以500转/分的速度搅拌15分钟后，再以1000转/分的速度搅拌10分钟，得到纳米改性材料乳液，将其放入浸渍槽中，然后将上述超细纤维合成革基布浸渍其中，充分浸渍后经轧辊挤压，将基布取出放入烘箱中，在120-130℃的温度下充分干燥，得到阻燃抗晒改性超细纤维合成革基布；
（3）将上述阻燃抗晒改性超细纤维合成革基布浸入浓度为20%氢氧化钠溶液中，加热至60-70℃，浸泡40分钟，抽出碱溶性聚酯进行开纤处理，用水洗净后干燥待用；
（4）将锯末干燥后粉碎成400目粉末与粉煤灰、四针状氧化锌晶须混合后放入球磨机中球磨，将聚乙烯吡咯烷酮溶于3倍量的水中，直接喷洒在混合粉体表面，继续球磨20分钟后送入造粒机中挤出造粒，将得到的颗粒放入400-450℃中烧结2小时，取出冷却后粉碎，过800目筛，将得到的粉末与聚丙二醇混合；将十二烷基聚氧乙烯醚硫酸钠溶于10倍量的水中，继续加入余量的水性聚氨酯、上述混合物以及其余剩余成分，放入发泡机中，边搅拌边鼓入空气，直至泡沫稳定停止搅拌，得到微泡水性聚氨酯浆料；
（5）将步骤（3）得到的基布浸渍在上述微泡水性聚氨酯浆料中，充分浸渍后经轧辊挤压，将基布取出放入烘箱中，先以80℃的温度干燥5分钟，使其水分在可控条件下挥发，再升温至100℃继续干燥5分钟，最后升温至140℃，使表面其完全交联固化成膜，之后经过磨毛、染色、压花、后整理等工序制成本发明材料。
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Application publication date: 20160427