CN106273856A - 一种降噪型汽车坐垫革及其加工工艺 - Google Patents
一种降噪型汽车坐垫革及其加工工艺 Download PDFInfo
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Abstract
本发明提供了一种降噪型汽车坐垫革及其加工工艺，该降噪型汽车坐垫革，从上到下依次包括涂层、真皮层、玻璃纤维毡层、聚酯纤维吸音棉层、网布表层，其特征在于，涂层为喷涂在真皮层上的油蜡填料，所述玻璃纤维毡层上下表面涂满胶水，聚酯纤维吸音棉层呈波浪状结构，底面的网布表层与聚酯纤维吸音棉层通过胶水粘接连接。聚酯纤维吸音棉层材料为聚酯纤维，材料本身具备一定吸音效果的，而且将聚酯纤维吸音棉层做成波浪状，使噪音穿过吸音层时，朝不同方向被散射开来，使声波得到扩散，减弱了波的振幅，大大提高降噪效果。
Description
技术领域
本发明属于汽车皮革制造技术领域，涉及一种降噪型汽车坐垫革及其加工工艺。
背景技术
皮革多用在轿车的座椅蒙皮、方向盘、门护板等装饰件上，而真皮与人体表皮功能接近，表面光滑，坐上去感觉舒适，所以真皮座椅是皮革作为汽车内饰的最大亮点，能够满足消费者对内饰美感、舒适度的需求，包括手感柔软、触感舒适，光泽花纹与整车设计协调统一等。而且，还能满足功能性的需求，如高强度、耐磨、耐老化、耐汗渍、抗污、透气等，因此，优质汽车皮革成为各个汽车厂家制作座椅面料的首选材料。
各种功能性的皮革应运而生，如中国专利公布的专利号为201420171862.6实用新型专利，该专利公布了一种具有吸音效果的皮革，包括有上到下依次复合的皮革层、吸音层和基布层，所述吸音层由聚酯纤维吸音棉构成，聚酯纤维吸音棉具有优秀的吸音效果，使皮革具有吸音效果；在吸音层上方辊涂有阻燃层，能有效地克服聚酯纤维吸音棉阻燃性差的缺点；皮革层表面印有凹凸不平的纹路能够将没有被吸收的音波散射开来，避免声波的叠加，该皮革能够广泛应用于汽车等要求声音纯粹干净的环境中。
但是上述吸音层为一平面的效果聚酯纤维吸音棉，无法从结构上达到降噪的目的，吸音降噪效果不好。
发明内容
本发明的目的是针对现有的技术存在上述问题，提出了一种从材料和结构上都能达到吸引降噪的效果的一种降噪型汽车坐垫革。
本发明的目的可通过下列技术方案来实现：一种降噪型汽车坐垫革，从上到下依次包括涂层、真皮层、玻璃纤维毡层、聚酯纤维吸音棉层、网布表层，其特征在于，涂层为喷涂在真皮层上的油蜡填料，所述玻璃纤维毡层上下表面涂满胶水，聚酯纤维吸音棉层呈波浪状结构，底面的网布表层与聚酯纤维吸音棉层通过胶水粘接连接。
聚酯纤维吸音棉层材料为聚酯纤维，材料本身具备一定吸音效果的，而且将聚酯纤维吸音棉层做成波浪状，使噪音穿过吸音层时，朝不同方向被散射开来，使声波得到扩散，减弱了波的振幅，大大提高降噪效果。
进一步的，所述聚酯纤维吸音棉层上下两面均具有等腰梯形的沟槽。
进一步的，所述真皮层的厚度为1.2～1.5mm。
进一步的，所述玻璃纤维毡层的厚度为0.5-0.7mm。
进一步的，所述聚酯纤维吸音棉层的高度为1.6-1.8mm。
进一步的，所述网布表层的厚度为为0.5～0.7mm。
本发明还提出了一种降噪型汽车坐垫革加工工艺。
一种降噪型汽车坐垫革的加工工艺，具体步骤如下：
A、前处理：对皮革坯料进行浸水、去除肉粒，然后浸灰、去除肉片皮，最后脱灰；
B、中处理：依次对皮革进行浸酸、鞣制、陈化、回湿、复鞣处理；
C、后处理：依次对皮革进行中和、染色和静电调理；
D、展开处理：先通过挤水伸展机进行挤水伸展处理，然后干燥；
E、摔软处理：先后进行震荡工艺和摔软处理；
F、涂饰表层：将按一定比例在涂层中添加油蜡填料，得到成品皮革；
G、蒸汽加热：将聚酯纤维吸音棉层移到蒸汽加热模具中，将蒸汽加热模具上下模合模，然后用110～150℃的蒸汽，对聚酯纤维吸音棉层进行加热，加热20～30s；
H、粘贴上层：在玻璃纤维毡层中加入胶水，将真皮层和聚酯纤维吸音棉层压紧；
J、粘贴下层：在网布表层涂上胶水，聚酯纤维吸音棉层下表面与网布表层贴合压实；
K：冷压固化成型：将粘贴好后的半成品送入冷压成型模具中进行冷压成型，压力为5～10MPa，模压时间为10～20s。
在所述的步骤A中，浸灰是添加硫氢化钠与浸灰助剂，再添加少许的硫化钠和石灰，之后添加硫化钠、石灰和乳化脱脂剂，分2-3次添加。浸灰又称灰碱膨胀，用一定浓度的石灰水乳液使浸水回鲜的制革原料皮增重、增厚、长度略有缩短而面积几乎不发生变化的操作。灰碱法脱毛工艺中浸灰和脱毛同一浴液中进行，使石灰均匀的渗透和皮身适度的膨胀，以打开皮之胶原纤维并乳化原皮本身的天然动物油脂。除去皮内纤维间质，消弱毛、表皮与真皮的联系，改性弹性纤维、破坏肌肉组织，利于后工序其他材料对皮的作用。
在上述的步骤E中，震荡工艺是在震荡拉软机中完成，摔软处理通过摔软转鼓机完成。
涂饰上油蜡后，皮革表面光泽好，具有较好的平滑性，增强手感。
与现有技术相比，具有以下优点：
1、本真皮层的生产工艺依次为浸水、去肉、浸灰、去肉片皮、脱灰、软化、浸酸、鞣制、陈化、回湿、复鞣、中和、染色、静电调理、挤水伸展、干燥、震荡、摔软、涂饰等，并且在涂饰工序中的喷涂涂层中额外添加特殊手感材料，具有非常优异的耐磨性能，可以使皮革长时间具有弹性、滋润，不仅有效提高产品的手感，还可以减少真皮座椅因自动升降或挤压等导致皮与皮之间的摩擦而产生的噪音，创造舒适的车内环境。
2、本产品具有聚酯纤维吸音棉层，透气性能好，耐老化、具有很强的柔韧性，波浪形结构可以吸收车内噪音，能够将没有被吸收的音波散射开来，避免声波的叠加，降低噪音，该皮革能够广泛应用于汽车等要求声音纯粹干净的环境中，声学NVH综合性能好。
附图说明
图1是本降噪型汽车坐垫革的结构示意图。
图中，1、涂层；2、真皮层；3、玻璃纤维毡层；4、聚酯纤维吸音棉层；5、网布表层；6、沟槽。
具体实施方式
以下是本发明的具体实施例并结合附图，对本发明的技术方案作进一步的描述，但本发明并不限于这些实施例。
如图1所示，本降噪型汽车坐垫革，从上到下依次包括涂层1、真皮层2、玻璃纤维毡层3、聚酯纤维吸音棉层4、网布表层5。
涂层1为喷涂在真皮层2上的油蜡填料，涂饰上油蜡后，皮革表面光泽好，具有较好的平滑性，增强手感。
玻璃纤维毡层3上下表面涂满胶水，聚酯纤维吸音棉层4呈波浪状结构，所述聚酯纤维吸音棉层4上下两面均具有等腰梯形的沟槽6。底面的网布表层5与聚酯纤维吸音棉层4通过胶水粘接连接。
所述真皮层2的厚度为1.2～1.5mm，所述玻璃纤维毡层3的厚度为0.5-0.7mm，所述聚酯纤维吸音棉层4的高度为1.6-1.8mm，所述网布表层5的厚度为为0.5～0.7mm。
聚酯纤维吸音棉层4材料为聚酯纤维，材料本身具备一定吸音效果的，而且将聚酯纤维吸音棉层4做成波浪状，使噪音穿过吸音层时，朝不同方向被散射开来，使声波得到扩散，减弱了波的振幅，大大提高降噪效果。
本发明还包括降噪型汽车坐垫革的加工工艺，具体步骤如下：
A、前处理：对皮革坯料进行浸水、去除肉粒，然后浸灰、去除肉片皮，最后脱灰；
B、中处理：依次对皮革进行浸酸、鞣制、陈化、回湿、复鞣处理；
C、后处理：依次对皮革进行中和、染色和静电调理；
D、展开处理：先通过挤水伸展机进行挤水伸展处理，然后干燥；
E、摔软处理：先后进行震荡工艺和摔软处理；震荡工艺是在震荡拉软机中完成，摔软处理通过摔软转鼓机完成。
F、涂饰表层：将按一定比例在涂层1中添加油蜡填料，得到成品皮革；
G、蒸汽加热：将聚酯纤维吸音棉层4移到蒸汽加热模具中，将蒸汽加热模具上下模合模，然后用110～150℃的蒸汽，对聚酯纤维吸音棉层4进行加热，加热20～30s；
H、粘贴上层：在玻璃纤维毡层3中加入胶水，将真皮层2和聚酯纤维吸音棉层4压紧；
J、粘贴下层：在网布表层5涂上胶水，聚酯纤维吸音棉层4下表面与网布表层5贴合压实；
K：冷压固化成型：将粘贴好后的半成品送入冷压成型模具中进行冷压成型，压力为5～10MPa，模压时间为10～20s。
最后的冷压固化成型也是为了整个汽车坐垫革能够随着聚酯纤维吸音棉层4的结构一起高低起伏，产生凹凸不平的纹路。
浸灰是添加硫氢化钠与浸灰助剂，再添加少许的硫化钠和石灰，之后添加硫化钠、石灰和乳化脱脂剂，分2-3次添加。浸灰又称灰碱膨胀，用一定浓度的石灰水乳液使浸水回鲜的制革原料皮增重、增厚、长度略有缩短而面积几乎不发生变化的操作。灰碱法脱毛工艺中浸灰和脱毛同一浴液中进行，使石灰均匀的渗透和皮身适度的膨胀，以打开皮之胶原纤维并乳化原皮本身的天然动物油脂。除去皮内纤维间质，消弱毛、表皮与真皮的联系，改性弹性纤维、破坏肌肉组织，利于后工序其他材料对皮的作用。
Claims (9)
1.一种降噪型汽车坐垫革，从上到下依次包括涂层、真皮层、玻璃纤维毡层、聚酯纤维吸音棉层、网布表层，其特征在于，涂层为喷涂在真皮层上的油蜡填料，所述玻璃纤维毡层上下表面涂满胶水，聚酯纤维吸音棉层呈波浪状结构，底面的网布表层与聚酯纤维吸音棉层通过胶水粘接连接。
2.根据权利要求1所述的一种降噪型汽车坐垫革，其特征在于，所述聚酯纤维吸音棉层上下两面均具有等腰梯形的沟槽。
3.根据权利要求2所述的一种降噪型汽车坐垫革，其特征在于，所述真皮层的厚度为1.2～1.5mm。
4.根据权利要求3所述的一种降噪型汽车坐垫革，其特征在于，所述玻璃纤维毡层的厚度为0.5-0.7mm。
5.根据权利要求4所述的一种降噪型汽车坐垫革，其特征在于，所述聚酯纤维吸音棉层的高度为1.6-1.8mm。
6.根据权利要求5所述的一种降噪型汽车坐垫革，其特征在于，所述网布表层的厚度为为0.5～0.7mm。
7.一种降噪型汽车坐垫革的加工工艺，具体步骤如下：
A、前处理：对皮革坯料进行浸水、去除肉粒，然后浸灰、去除肉片皮，最后脱灰；
B、中处理：依次对皮革进行浸酸、鞣制、陈化、回湿、复鞣处理；
C、后处理：依次对皮革进行中和、染色和静电调理；
D、展开处理：先通过挤水伸展机进行挤水伸展处理，然后干燥；
E、摔软处理：先后进行震荡工艺和摔软处理；
F、涂饰表层：将按一定比例在涂层中添加油蜡填料，得到成品皮革；
G、蒸汽加热：将聚酯纤维吸音棉层移到蒸汽加热模具中，将蒸汽加热模具上下模合模，然后用110～150℃的蒸汽，对聚酯纤维吸音棉层进行加热，加热20～30s；
H、粘贴上层：在玻璃纤维毡层中加入胶水，将真皮层和聚酯纤维吸音棉层压紧；
J、粘贴下层：在网布表层涂上胶水，聚酯纤维吸音棉层下表面与网布表层贴合压实；
K：冷压固化成型：将粘贴好后的半成品送入冷压成型模具中进行冷压成型，压力为5～10MPa，模压时间为10～20s。
8.根据权利要求7所述的一种降噪型汽车坐垫革的加工工艺，在所述的步骤A中，浸灰是添加硫氢化钠与浸灰助剂，再添加少许的硫化钠和石灰，之后添加硫化钠、石灰和乳化脱脂剂，分2-3次添加。
9.根据权利要求8所述的一种降噪型汽车坐垫革的加工工艺，在上述的步骤E中，震荡工艺是在震荡拉软机中完成，摔软处理通过摔软转鼓机完成。
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