CN106114388A - 轻质高承载汽车衣帽架板及其制造汽车衣帽架的工艺 - Google Patents
轻质高承载汽车衣帽架板及其制造汽车衣帽架的工艺 Download PDFInfo
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Abstract
本发明提供一种轻质高承载汽车衣帽架板及其制造汽车衣帽架的工艺,所述轻质高承载汽车衣帽架板,包括:一纸蜂窝板;一PET面料,层叠设置于所述纸蜂窝板上表面;所述纸蜂窝板包括:一蜂巢芯材层;两玻璃纤维层,分别设置于所述蜂巢芯材层上、下表面;两胶黏层,分别铺设于所述两玻璃纤维层相对蜂巢芯材层的另一面;所述PET面料通过PUR热熔胶与所述纸蜂窝板胶粘层叠。所述汽车衣帽架既能满足使用要求,又能符合社会环保要求的轻质、高承载力的要求,且耐热、隔音性能好,并具有一定的缓冲防震性。
Description
技术领域
本发明属于汽车内饰制造领域,具体地,涉及一种轻质高承载汽车衣帽架板及其制造汽车衣帽架的工艺。
背景技术
随着现代社会的不断发展,汽车已经成为人们生活中不可替代的重要交通工具。汽车内饰行业与汽车制造工业同时起步,有着巨大发展潜力,作为汽车内饰件的重要组成部分—汽车衣帽架,同样越来越受到重视。
汽车衣帽架,也称后置物板,一般指三厢车上,用于覆盖第二排座椅后补、后窗玻璃下部、行李舱上部钣金的装饰板,其主要功能是为所覆盖区域提供遮盖及保护,另外它也是重要的升学零件,可阻隔从行李舱中穿出的噪音。
现有汽车衣帽架根据所装配的附件不同选择不同的基材,基材的种类主要有以下几种:
1.GMT板:PP纤维+玻纤,轻质高强度,成型工艺简单,但是生产环境差,循环使用性低。
2.麻纤毡:PP纤维+麻纤维,强度高,深幅拉伸性能优异,定型性好,耐冲击,产品绿色环保无污染。但质量重、易吸潮,导致发霉和变形。
3.木粉板:木粉+热塑性塑料,易于搭接各种固定件,成型工艺简单,但易于产生气味问题及有机物散发性问题,且产品的韧性和刚性不能达到良好的统一。
综上所述,现有衣帽架很难兼有高隔音效果、轻质高承载等特点,成为阻碍衣帽架发展的最主要因素。
对此,目前国内主要存在如下专利文献:
授权公告号:203198858U,公开了一种汽车衣帽架,包括衣帽架本体,所述衣帽架本体包括PP玻纤板层,所述PP玻纤板层上设置无纺布层。PP玻纤板的强度和刚性均较PP板提高一倍,具有良好的耐热性、低温冲击性、防腐耐电弧性和隔音性,而且收缩率低、无味无毒,不仅增加了衣帽架本体的承载性,而且使车内噪声降低,通过在PP玻纤板上设置无纺布,大大提高了汽车衣帽架的美观性。然而其PP玻纤板层,表面较为紧密,仍属现有GMT板的一种,存在生产环境差、循环使用性低的缺陷。
发明内容
为解决上述存在的问题,本发明的目的在于提供一种轻质高承载汽车衣帽架板及其制造汽车衣帽架的工艺,所述汽车衣帽架既能满足使用要求,又能符合社会环保要求的轻质、高承载力的要求,且耐热、隔音性能好,并具有一定的缓冲防震性。
为达到上述目的,本发明的技术方案是:
一种轻质高承载汽车衣帽架板,包括:一纸蜂窝板;一PET面料,层叠设置于所述纸蜂窝板上表面;所述纸蜂窝板包括:一蜂巢芯材层;两玻璃纤维层,分别设置于所述蜂巢芯材层上、下表面;两胶黏层,分别铺设于所述两玻璃纤维层相对蜂巢芯材层的另一面;所述PET面料通过PUR热熔胶与所述纸蜂窝板胶粘层叠。
进一步,所述PET面料克重为250g/m2,厚度为3mm。
另,所述PUR热熔胶主要成分是端异氰酸酯聚氨酯预聚体。
另有,所述两玻璃纤维层克重分别为450g/m2,玻璃纤维含量为90%;所述两胶黏层分别为聚氨酯层。
再,所述所述蜂巢芯材层由若干正六角形蜂巢单元组成。
再有,所述汽车衣帽架板面密度为2400~2600g/m2。
且,所述汽车衣帽架板弯曲强度为25~45MPa。
同时,本发明还提供一种采用所述轻质高承载汽车衣帽架板制造轻质高承载汽车衣帽架的工艺,包括如下步骤:
1)将蜂巢芯材经拉伸机拉制成干燥的正六角形蜂巢芯材层;
2)将玻璃纤维覆盖于步骤1)所得蜂巢芯材层的上、下表面,形成两玻璃纤维层与蜂巢芯材层的复合层,在所述复合层外表面喷涂聚氨酯;
3)将喷涂后的复合层放置于成型机中定位成型,然后冲切后得到成型材料,成型温度110~130℃,成型压力7~8MPa,成型时间120~160s;
4)取出成型材料,常温冷却定型,冷却时间45~60s,冷却定型后去除周边余料;
5)将聚氨酯均匀的涂覆在步骤4)所得板坯上表面,形成胶黏层,并得到所述纸蜂窝板,将一PET面料通过PUR热熔胶粘于所述纸蜂窝板上表面,然后送入压力机内压合,加热,压合时间35~45s,得所述轻质高承载汽车衣帽架板;
6)将步骤5)所得轻质高承载汽车衣帽架板放置在模具上,固定、冲切、包边后安装所需附件,最终得到所述轻质高承载汽车衣帽架成品。
进一步,步骤2)中采用ABB机械手对所述复合层外表面喷涂聚氨酯。
另,步骤3)中所述成型机为CNC-2500型液压机。
本发明的有益效果在于:
所述汽车衣帽架制造工艺简单,工艺步骤环保,对环境友好,提供一种制造工艺简单、制造成本低且价格低廉;
所述汽车衣帽架板包括纸蜂窝板和PET面料,其中纸蜂窝板主要由蜂巢芯材层、玻璃纤维层、胶黏层组成,胶黏层优选聚氨酯层,面料合理的配方,优质化纤的选用,满足耐高温性能、色牢度要求,同时配蜂窝板吸声性能优秀,所述汽车衣帽架板在满足汽车轻质要求的前提下,获得更高的承载力,汽车衣帽架板面密度仅为2400~2600g/m2,但其承载力(或弯曲强度)却高达25~45MPa;纸蜂窝板蜂巢芯材层中蜂巢单元合理的正六角形结构,拥有很好的耐热、隔音性能,还有一定的缓冲防震性。
附图说明
图1为本发明各实施例所提供的一种轻质高承载汽车衣帽架板的结构示意图。
图2为本发明各实施例所提供的一种轻质高承载汽车衣帽架板中纸蜂窝板蜂巢芯材层的结构示意图。
具体实施方式
参照图1和图2,本发明所述的一种轻质高承载汽车衣帽架板,包括:一纸蜂窝板1;一PET面料2,层叠设置于所述纸蜂窝板1上表面;所述纸蜂窝板1包括:一蜂巢芯材层11;两玻璃纤维层12,12’,分别设置于所述蜂巢芯材层11上、下表面;两胶黏层13,13’,分别铺设于所述两玻璃纤维层12,12’相对蜂巢芯材层11的另一面;所述PET面料2通过PUR热熔胶层14与所述纸蜂窝板1胶粘层叠。
进一步,所述PET面料2克重为250g/m2,厚度为3mm。
另,所述PUR热熔胶14主要成分是端异氰酸酯聚氨酯预聚体。
另有,所述两玻璃纤维层12,12’克重分别为450g/m2,玻璃纤维含量为90%;所述两胶黏层13,13’分别为聚氨酯层。
再,所述所述蜂巢芯材层11由若干正六角形蜂巢单元111组成。
再有,所述汽车衣帽架板面密度为2400~2600g/m2。
且,所述汽车衣帽架板弯曲强度为25~45MPa。
同时,本发明还提供一种采用所述轻质高承载汽车衣帽架板制造轻质高承载汽车衣帽架的工艺,包括如下步骤:
1)将蜂巢芯材经拉伸机拉制成干燥的正六角形蜂巢芯材层11;
2)将玻璃纤维覆盖于步骤1)所得蜂巢芯材层11的上、下表面,形成两玻璃纤维层12,12’与蜂巢芯材层11的复合层,在所述复合层外表面喷涂聚氨酯;
3)将喷涂后的复合层放置于成型机中定位成型,然后冲切后得到成型材料,成型温度110~130℃,成型压力7~8MPa,成型时间120~160s;
4)取出成型材料,常温冷却定型,冷却时间45~60s,冷却定型后去除周边余料;
5)将聚氨酯均匀的涂覆在步骤4)所得板坯上、下表面,形成胶黏层13,13’,并得到所述纸蜂窝板1,将一PET面料2通过PUR热熔胶层14粘于所述纸蜂窝板1上表面,然后送入压力机内压合,加热,压合时间35~45s,得所述轻质高承载汽车衣帽架板;
6)将步骤5)所得轻质高承载汽车衣帽架板放置在模具上,计算好所需面料宽度,制作套模将产品固定完全,裸露在外部的面料则为多余面料,冲切掉多余面料,剩余产品则为所需面料,且边部整齐,完成面料包边工作后再安装所需附件,最终得到所述轻质高承载汽车衣帽架成品。
进一步,步骤2)中采用ABB机械手对所述复合层外表面喷涂聚氨酯。
另,步骤3)中所述成型机为CNC-2500型液压机。
其中,表1为本发明各实施例所提供的一种轻质高承载汽车衣帽架板与现有基材性能参数对比。
表1
面密度(g/m2) | 弯曲强度(MPa) | |
实施例1 | 2450 | 27.25 |
实施例2 | 2500 | 27.36 |
实施例3 | 2550 | 32.28 |
实施例4 | 3600 | 44.54 |
实施例5 | 2400 | 27.31 |
GMT板 | 1800 | 7.87 |
麻纤毡板 | 2400 | 15.66 |
木粉板 | 3200 | 28.82 |
本发明所提供的一种轻质高承载汽车衣帽架板及其制造汽车衣帽架的工艺,汽车衣帽架制造工艺简单,工艺步骤环保,对环境友好,提供一种制造工艺简单、制造成本低且价格低廉;汽车衣帽架板包括纸蜂窝板和PET面料,其中纸蜂窝板主要由蜂巢芯材层、玻璃纤维层、胶黏层组成,胶黏层优选聚氨酯层,面料合理的配方,优质化纤的选用,满足耐高温性能、色牢度要求,同时配蜂窝板吸声性能优秀,所述汽车衣帽架板在满足汽车轻质要求的前提下,获得更高的承载力,汽车衣帽架板面密度仅为2400~2600g/m2,但其承载力(或弯曲强度)却高达25~45MPa;纸蜂窝板蜂巢芯材层中蜂巢单元合理的正六角形结构,拥有很好的耐热、隔音性能,还有一定的缓冲防震性。
需要说明的是,以上实施例仅用以说明本发明的技术方案而非限制。尽管参照较佳实施例对本发明进行了详细说明,本领域的普通技术人员应当理解,可以对发明的技术方案进行修改或者等同替换,而不脱离本发明技术方案的范围,其均应涵盖在本发明的权利要求范围中。
Claims (10)
1.一种轻质高承载汽车衣帽架板,其特征在于,包括:
一纸蜂窝板;
一PET面料,层叠设置于所述纸蜂窝板上表面;
所述纸蜂窝板包括:
一蜂巢芯材层;
两玻璃纤维层,分别设置于所述蜂巢芯材层上、下表面;
两胶黏层,分别铺设于所述两玻璃纤维层相对蜂巢芯材层的另一面;
所述PET面料通过PUR热熔胶与所述纸蜂窝板胶粘层叠。
2.根据权利要求1所述的一种轻质高承载汽车衣帽架板,其特征在于,所述PET面料克重为250g/m2,厚度为3mm。
3.根据权利要求1所述的一种轻质高承载汽车衣帽架板,其特征在于,所述PUR热熔胶主要成分是端异氰酸酯聚氨酯预聚体。
4.根据权利要求1所述的一种轻质高承载汽车衣帽架板,其特征在于,所述两玻璃纤维层克重分别为450g/m2,玻璃纤维含量为90%;所述两胶黏层分别为聚氨酯层。
5.根据权利要求1所述的一种轻质高承载汽车衣帽架板,其特征在于,所述所述蜂巢芯材层由若干正六角形蜂巢单元组成。
6.根据权利要求1所述的一种轻质高承载汽车衣帽架板,其特征在于,所述汽车衣帽架板面密度为2400~2600g/m2。
7.根据权利要求1所述的一种轻质高承载汽车衣帽架板,其特征在于,所述汽车衣帽架板弯曲强度为25~45MPa。
8.一种采用如权利要求1~7中任一项所述的轻质高承载汽车衣帽架板制造轻质高承载汽车衣帽架的工艺,其特征在于,包括如下步骤:
将蜂巢芯材经拉伸机拉制成干燥的正六角形蜂巢芯材层;
将玻璃纤维覆盖于步骤1)所得蜂巢芯材层的上、下表面,形成两玻璃纤维层与蜂巢芯材层的复合层,在所述复合层外表面喷涂聚氨酯;
将喷涂后的复合层放置于成型机中定位成型,然后冲切后得到成型材料,成型温度110~130℃,成型压力7~8MPa,成型时间120~160s;
取出成型材料,常温冷却定型,冷却时间45~60s,冷却定型后去除周边余料;
将聚氨酯均匀的涂覆在步骤4)所得板坯上、下表面,形成胶黏层,并得到所述纸蜂窝板,将一PET面料通过PUR热熔胶粘于所述纸蜂窝板上表面,然后送入压力机内压合,加热,压合时间35~45s,得所述轻质高承载汽车衣帽架板;
将步骤5)所得轻质高承载汽车衣帽架板放置在模具上,固定、冲切、包边后安装所需附件,最终得到所述轻质高承载汽车衣帽架成品。
9.根据权利要求8所述的一种轻质高承载汽车衣帽架的制造工艺,其特征在于,步骤2)中采用ABB机械手对所述复合层外表面喷涂聚氨酯。
10.根据权利要求8所述的一种轻质高承载汽车衣帽架的制造工艺,其特征在于,步骤3)中所述成型机为CNC-2500型液压机。
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