CN106393820A - 一种增强型杀菌汽车内衬及其生产工艺 - Google Patents

一种增强型杀菌汽车内衬及其生产工艺 Download PDF

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CN106393820A
CN106393820A CN201610751223.0A CN201610751223A CN106393820A CN 106393820 A CN106393820 A CN 106393820A CN 201610751223 A CN201610751223 A CN 201610751223A CN 106393820 A CN106393820 A CN 106393820A
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CN106393820B (zh
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倪桂龙
杨成利
王志强
桑晓跃
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Shandong Three Ridge Automobile Interior Decoration Co Ltd
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Abstract

本发明涉及一种增强型杀菌汽车内衬及其生产工艺，解决增强汽车内衬强度以及增加杀菌、抑菌功效的技术问题。它包括增强层、杀菌层、无纺布层，增强层固定在杀菌层的底端，无纺布层分别固定在增强层的底端和杀菌层的上端；增强层包括增粘树脂、植物纤维、聚氨酯、偏苯三酸三辛酯等；杀菌层包括等规聚丙烯、马来酸酐接枝聚丙烯、麦饭石、载镧氧化锌、载铈二氧化钛、抗氧剂、蛭石、硅烷偶联剂、单甘脂、聚乙烯蜡等。增强层、杀菌层以及汽车内衬均采用独创的生产工艺。有益效果在于，能够显著提供高汽车内衬的强度，并且汽车内衬具有较好的杀菌和抑菌能力。

Description

一种增强型杀菌汽车内衬及其生产工艺
技术领域
本发明涉及汽车内衬技术领域，具体地说是一种增强型杀菌汽车内衬及其生产工艺。
背景技术
汽车内衬是汽车内部主要起装饰作用的重要配件，近年来随着汽车内衬行业的不断发展。汽车内衬件越来越朝向健康、绿色方向发展，并且对汽车内衬件的强度和可靠性提出了更高要求。
现有技术中的汽车内衬，主要还停留在采用传统材料和工艺来制造汽车内衬，以不能满足人们对汽车内衬件的要求。因此，需要提供一种技术方案，来解决现有技术中的不足。
发明内容
本发明的目的在于提供一种增强型杀菌汽车内衬及其生产工艺，解决增强汽车内衬强度以及增加杀菌、抑菌功效的技术问题。
本发明解决其技术问题所采取的技术方案是：一种增强型杀菌汽车内衬，包括增强层、杀菌层、无纺布层，所述的增强层固定在杀菌层的底端，所述的无纺布层分别固定在增强层的底端和杀菌层的上端；
所述的增强层包括增粘树脂10％～15％、植物纤维10～40％、聚氨酯20～35％、偏苯三酸三辛酯2％～5％、乙烯无规则共聚物1～4％、偶联剂0.3～0.8％、抗氧剂0.2～0.6％、润滑剂0.3～1％；
所述的杀菌层包括等规聚丙烯30％～50％、马来酸酐接枝聚丙烯0.8％～1.2％、麦饭石0.7％～1％、载镧氧化锌0.3％～0.5％、载铈二氧化钛0.2％～0.4％、抗氧剂0.1％～0.2％、蛭石0.6％～0.8％、硅烷偶联剂0.05％～ 0.1％、单甘脂0.01％～0.02％、聚乙烯蜡10％～15％、甲壳素纤维10％～15％、碳纳米纤维15％～18％、竹纤维8％～12％、紫苏油0.1％～0.5％、栀子0.2％～1％、竹茹0.8％～1.1％、厚朴0.9％～2％、油柑叶0.6％～1％、夏枯草1.5％～2％。
增强层的制备方法包括以下步骤：
(1)通过定量泵将储存箱内的增粘树脂10％～15％、植物纤维10～40％、聚氨酯20～35％、偏苯三酸三辛酯2％～5％、1～4％乙烯无规则共聚物、偶联剂0.3～0.8％、抗氧剂0.2～0.6％、润滑剂0.3～1.0％分别抽入搅拌器中搅拌6～10分钟，搅拌器的转速为1200转/分；将混好的原料抽入发泡机中进行发泡处理形成增强材料；
(2)发泡机排出的增强材料然后进入铺网机，在铺网机内铺平；
(3)铺网机上的增强材料进通过针刺机，增强材料通过针刺机进行上下穿插钩连，以使得增强材料形成同一整体；
(4)经过钩连后的增强材料在挤出辊装置处挤压形成增强层，最后通过切割装置将挤压成型后的增强层切割成规定长度尺寸。
杀菌层的制备方法包括以下步骤：
(1)将麦饭石、蛭石混合粗粉碎后，经高温下加热1h，然后放于冷水中淬冷，再进行超微粉碎，过325目筛，得超微粉；
(2)将步骤(1)制得的超微粉与载镧氧化锌、载铈二氧化钛充分混合均匀后，加入其重量的6倍的丙酮水溶液中搅拌，然后加入硅烷偶联剂和单甘脂，在60℃水浴中恒温搅拌4h后，静置10h，过滤洗涤，烘干后，得改性混合粉末；
(3)将等规聚丙烯、聚乙烯蜡混合加热搅拌至完全熔融后，转入双螺杆挤压机中，然后依次加入马来酸酐接枝聚丙烯、抗氧剂和步骤(2)制得的改性混合粉末进行熔融混炼1h后，将混合物加到螺杆纺丝机中进行挤出纺丝， 得改性聚丙烯纤维；
(4)称取栀子、竹茹、厚朴、油柑叶、夏枯草，总重量记为1份，加入6份纯化水，50±5℃下浸泡1h，然后小火煎煮2h，滤过，收集滤液；
(5)将步骤(4)制得的滤液与紫苏油混合后，加入甲壳素纤维、碳纳米纤维、竹纤维进行浸润1h，在浸润时进行超声处理，然后进行脱水和烘干；
(6)分别将步骤(3)制得的改性聚丙烯纤维、步骤(5)处理后的甲壳素纤维、碳纳米纤维、竹纤维由开松机进行开松，然后送入混棉机进行混合至均匀，由梳理机梳理后，由铺网机铺叠成棉网；
(7)将步骤(6)铺叠的棉网由针刺机或水刺机刺合，得到所述汽车内衬用材料；然后经过针刺机后的发泡体在挤出辊装置处挤压成层状形成杀菌层，最后通过切割装置将挤压成型后的杀菌层切割成规定长度尺寸。
一种增强型杀菌汽车内衬的生产工艺包括以下步骤：
(1)首先按照无纺布层、增强层、杀菌层、无纺布层的上下顺序进行逐层叠料；
(2)步骤(1)叠料后的材料放入层压机中进行热压，热压温度200°～220°，热压时间180s～200s；热压后形成内衬板材，从层压机中取出板材，然后进行空冷；
(3)步骤(2)热压后的内衬板材在模具中进行模压成型；所述的模具包括阳模和阴模，首先将内衬板材放入阴模中，通过液压机推动阳模，对内衬板材进行压制成型；成型时间85s～95s，压制成型压力7Mpa～9Mpa；采用液压机从阴模的底端将压制成型后的内衬顶出脱模；
(4)步骤(3)脱模后的内衬在专用工装上进行修边和冲孔。
本发明的有益效果是：
(1)本发明中的汽车内衬采用增强层和杀菌层，能够显著提供高汽车内衬的强度，并且汽车内衬具有较好的杀菌和抑菌能力。
(2)本发明增强层采用最新的组成材料和生产方法，在提高增强层功能的情况下，使得生产流程更加优化。
(3)本发明的杀菌层，采用优选的组合配方和科学的生产工艺，使得杀菌层具有长效抗菌、抑菌的性能。
(4)本发明中涉及的汽车内衬生产工艺，能够增强汽车内衬的质量，提高生产效率。
具体实施方式
一种增强型杀菌汽车内衬，包括增强层、杀菌层、无纺布层，所述的增强层固定在杀菌层的底端，所述的无纺布层分别固定在增强层的底端和杀菌层的上端。
所述的增强层用于增强汽车内衬的强度和抗老化性，所述的增强层包括增粘树脂10％～15％、植物纤维10～40％、聚氨酯20～35％、偏苯三酸三辛酯2％～5％、乙烯无规则共聚物1～4％、发泡剂0.5～1％、催化剂0.1～0.4％、阻燃剂0.2～0.6％、偶联剂0.3～0.8％、抗氧剂0.2～0.6％、润滑剂0.3～1.0％。增粘树脂具有良好的粘性和内部凝聚力；植物纤维经过碱处理，用于去除表面的半纤维和木质素及其它杂质，致使部分原纤维解旋，降低了纤维密度，纤维变得松散能够增强与增粘树脂的粘合能力增强，有利于增强界面的粘合，提高材料的力学性能。聚氨酯具有良好的隔热性能并且具有良好的耐油性、韧性、耐磨性、耐老化性和粘合性。
增强层的制备方法包括以下步骤：
(1)通过定量泵将储存箱内的构成增强层的增粘树脂10％～15％、植物纤维10～40％、聚氨酯20～35％、偏苯三酸三辛酯2％～5％、乙烯无规则共聚物1～4％、发泡剂0.5～1％、催化剂0.1～0.4％、阻燃剂0.2～0.6％、偶联剂0.3～0.8％、抗氧剂0.2～0.6％、润滑剂0.3～1.0％组分抽入搅拌器中搅拌6～10分钟，搅拌器的转速为1200转/分；
将混好的原料置于发泡机中进行发泡处理生成增强材料；
发泡机排出后的增强材料进入铺网机，铺网机对所述的增强材料进行铺平，然后增强材料从铺网机进入针刺机内；
通过针刺机上的倒钩针对增强材料进出上下穿插钩连，以使得增强材料形成同一整体；
经过针刺机钩连后的增强材料，在挤出辊装置处挤压形成增强层，最后通过切割装置将挤压成型后的增强层切割成规定长度尺寸。
杀菌层包括等规聚丙烯30％～50％、马来酸酐接枝聚丙烯0.8％～1.2％、麦饭石0.7％～1％、载镧氧化锌0.3％～0.5％、载铈二氧化钛0.2％～0.4％、抗氧剂0.1％～0.2％、蛭石0.6％～0.8％、硅烷偶联剂0.05％～0.1％、单甘脂0.01％～0.02％、聚乙烯蜡10％～15％、甲壳素纤维10％～15％、碳纳米纤维15％～18％、竹纤维8％～12％、紫苏油0.1％～0.5％、栀子0.2％～1％、竹茹0.8％～1.1％、厚朴0.9％～2％、油柑叶0.6％～1％、夏枯草1.5％～2％。
杀菌层的制备方法包括以下步骤：
(1)将麦饭石、蛭石混合粗粉碎后，经高温下加热1h，然后放于冷水中淬冷，再进行超微粉碎，过325目筛，得超微粉；
(2)将步骤(1)制得的超微粉与载镧氧化锌、载铈二氧化钛充分混合均匀后，加入其重量的6倍的丙酮水溶液中搅拌，然后加入硅烷偶联剂和单甘脂，在60℃水浴中恒温搅拌4h后，静置10h，过滤洗涤，烘干后，得改性混合粉末；
(3)将等规聚丙烯、聚乙烯蜡混合加热搅拌至完全熔融后，转入双螺杆挤压机中，然后依次加入马来酸酐接枝聚丙烯、抗氧剂和步骤(2)制得的改性混合粉末进行熔融混炼1h后，将混合物加到螺杆纺丝机中进行挤出纺丝，得改性聚丙烯纤维；
(4)称取栀子、竹茹、厚朴、油柑叶、夏枯草，总重量记为1份，加入6份纯化水，50±5℃下浸泡1h，然后小火煎煮2h，滤过，收集滤液；
(5)将步骤(4)制得的滤液与紫苏油混合后，加入甲壳素纤维、碳纳米纤维、竹纤维进行浸润1h，在浸润时进行超声处理，然后进行脱水和烘干；
(6)分别将步骤(3)制得的改性聚丙烯纤维、步骤(5)处理后的甲壳素纤维、碳纳米纤维、竹纤维由开松机进行开松，然后送入混棉机进行混合至均匀，由梳理机梳理后，由铺网机铺叠成棉网；
(7)将步骤(6)铺叠的棉网由针刺机或水刺机刺合，得到所述汽车内衬用材料；然后经过针刺机后的发泡体在挤出辊装置处挤压成层状形成杀菌层，最后通过切割装置将挤压成型后的杀菌层切割成规定长度尺寸。
经过上述步骤形成的增强层和杀菌层下一步进入制造内衬板工序。
一种增强型杀菌汽车内衬的生产工艺主要包括以下步骤，所述的增强层、杀菌层和无纺布层首先通过层压机，压缩成内衬板。
首先从下至上按照无纺布层、增强层、杀菌层、无纺布层的方式进行叠料；
叠料后的材料放入层压机中进出热压，热压温度200°～220°，热压时间180s～200s；热压后形成板材，从层压机中取出，然后进行空冷；
在层压机中形成的内衬板材，下一步需要在模具中进行模压成型；所述的模具包括阳模和阴模，首先打开模具将内衬板材放入阴模中，让后通过液压机推动阳模，对内衬板材进行压制成型；成型时间85s～95s，成型压制压力7Mpa～9Mpa。采用液压机，从阴模的底端将压制成型后的内衬顶出脱模。
脱模后的内衬在专用工装上进行修边和冲孔，内衬制造完毕。
实施例1：
所述的增强层包括增粘树脂10％，植物纤维25％，聚氨酯35％，偏苯三酸三辛酯2％，2.5％乙烯无规则共聚物，发泡剂1％、催化剂0.25％、阻燃 剂0.6％，偶联剂0.3％，抗氧剂0.4％，润滑剂1.0％。
增强层的制备方法：通过定量泵将储存箱内的构成增强层的所述各组分抽入搅拌器中搅拌10分钟。
杀菌层包括等规聚丙烯40％、马来酸酐接枝聚丙烯1.2％、麦饭石0.7％、载镧氧化锌0.4％、载铈二氧化钛0.4％、抗氧剂0.1％、蛭石0.7％、硅烷偶联剂0.1％、单甘脂0.075％、聚乙烯蜡15％、甲壳素纤维10％、碳纳米纤维16.5％、竹纤维12％、紫苏油0.1％、栀子0.6％、竹茹1.1％、厚朴0.9％、油柑叶0.81％、夏枯草2％。
杀菌层的制备方法：
称取栀子、竹茹、厚朴、油柑叶、夏枯草，总重量记为1份，加入6份纯化水，45℃下浸泡1h，然后小火煎煮2h，滤过，收集滤液。
一种增强型杀菌汽车内衬的生产工艺：叠料后放入层压机中进出热压，热压温度200°，热压时间200s；对内衬板材进行压制成型，成型时间90s，成型压制压力7Mpa。
其余参照以上叙述，在此不再赘述。
实施例2：
所述的增强层包括增粘树脂12.5％，植物纤维40％，聚氨酯20％，偏苯三酸三辛酯3.5％，4％乙烯无规则共聚物，发泡剂0.5％、催化剂0.4％、阻燃剂0.4％，偶联剂0.55％，抗氧剂0.6％，润滑剂0.3％。
增强层的制备方法：增强层的制备方法为：通过定量泵将储存箱内的构成增强层的所述各组分抽入搅拌器中搅拌8分钟，
杀菌层包括等规聚丙烯30％、马来酸酐接枝聚丙烯1％、麦饭石1％、载镧氧化锌0.3％、载铈二氧化钛0.3％、抗氧剂0.2％、蛭石0.6％、硅烷偶联剂0.075％、单甘脂0.01％、聚乙烯蜡12.5％、甲壳素纤维15％、碳纳米纤维15％、竹纤维10％、紫苏油0.5％、栀子0.2％、竹茹0.95％、厚朴2 ％、油柑叶0.6％、夏枯草1.75％。
杀菌层的制备方法：
称取栀子、竹茹、厚朴、油柑叶、夏枯草，总重量记为1份，加入6份纯化水，50℃下浸泡1h，然后小火煎煮2h，滤过，收集滤液。
一种增强型杀菌汽车内衬的生产工艺：叠料后放入层压机中进出热压，热压温度210°，热压时间180s；对内衬板材进行压制成型，成型时间95s，成型压制压力8Mpa。
其余参照以上叙述，在此不再赘述。
实施例3:
所述的增强层包括增粘树脂15％，植物纤维10％，聚氨酯20.75％，偏苯三酸三辛酯5％，1乙烯无规则共聚物，发泡剂0.75％，催化剂0.1％，阻燃剂0.2％，偶联剂0.8％，抗氧剂0.2％，润滑剂0.65％。
增强层的制备方法：增强层的制备方法为：通过定量泵将储存箱内的构成增强层的所述各组分抽入搅拌器中搅拌6分钟，
杀菌层包括等规聚丙烯50％、马来酸酐接枝聚丙烯0.8％、麦饭石0.85％、载镧氧化锌.5％、载铈二氧化钛0.2％、抗氧剂0.15％、蛭石0.8％、硅烷偶联剂0.05％、单甘脂0.02％、聚乙烯蜡10％、甲壳素纤维12.5％、碳纳米纤维18％、竹纤维8％、紫苏油0.35％、栀子01％、竹茹0.8％、厚朴14.5％、油柑叶1％、夏枯草1.5％
杀菌层的制备方法：
称取栀子、竹茹、厚朴、油柑叶、夏枯草，总重量记为1份，加入6份纯化水，55℃下浸泡1h，然后小火煎煮2h，滤过，收集滤液。
一种增强型杀菌汽车内衬的生产工艺：叠料后放入层压机中进出热压，热压温度220°，热压时间190s；对内衬板材进行压制成型，成型时间85s，成型压制压力9Mpa。
其余参照以上叙述，在此不再赘述。
除说明书所述的技术特征外，均为本专业技术人员的已知技术。
上述虽然对本发明的具体实施方式进行了描述，但并非对本发明保护范围的限制，在本发明技术方案的基础上，本领域技术人员不需要付出创造性的劳动即可做出的各种修改或变形仍在本发明的保护范围内。

Claims (4)

1.一种增强型杀菌汽车内衬，其特征在于，包括增强层、杀菌层、无纺布层，所述的增强层固定在杀菌层的底端，所述的无纺布层分别固定在增强层的底端和杀菌层的上端；
所述的增强层包括增粘树脂10％～15％、植物纤维10～40％、聚氨酯20～35％、偏苯三酸三辛酯2％～5％、乙烯无规则共聚物1～4％、偶联剂0.3～0.8％、抗氧剂0.2～0.6％、润滑剂0.3～1％；
所述的杀菌层包括等规聚丙烯30％～50％、马来酸酐接枝聚丙烯0.8％～1.2％、麦饭石0.7％～1％、载镧氧化锌0.3％～0.5％、载铈二氧化钛0.2％～0.4％、抗氧剂0.1％～0.2％、蛭石0.6％～0.8％、硅烷偶联剂0.05％～0.1％、单甘脂0.01％～0.02％、聚乙烯蜡10％～15％、甲壳素纤维10％～15％、碳纳米纤维15％～18％、竹纤维8％～12％、紫苏油0.1％～0.5％、栀子0.2％～1％、竹茹0.8％～1.1％、厚朴0.9％～2％、油柑叶0.6％～1％、夏枯草1.5％～2％。
2.根据要求1所述的一种增强型杀菌汽车内衬，其特征在于，所述的增强层，其生产方法，包括以下步骤：
(1)通过定量泵将储存箱内的增粘树脂10％～15％、植物纤维10～40％、聚氨酯20～35％、偏苯三酸三辛酯2％～5％、1～4％乙烯无规则共聚物、偶联剂0.3～0.8％、抗氧剂0.2～0.6％、润滑剂0.3～1.0％分别抽入搅拌器中搅拌6～10分钟，搅拌器的转速为1200转/分；将混好的原料抽入发泡机中进行发泡处理形成增强材料；
(2)发泡机排出的增强材料然后进入铺网机，在铺网机内铺平；
(3)铺网机上的增强材料进通过针刺机，增强材料通过针刺机进行上下穿插钩连，以使得增强材料形成同一整体；
(4)经过钩连后的增强材料在挤出辊装置处挤压形成增强层，最后通过切割装置将挤压成型后的增强层切割成规定长度尺寸。
3.根据要求1所述的一种增强型杀菌汽车内衬，其特征在于，所述的杀菌层，其生产方法，包括以下步骤：
(1)将麦饭石、蛭石混合粗粉碎后，经高温下加热1h，然后放于冷水中淬冷，再进行超微粉碎，过325目筛，得超微粉；
(2)将步骤(1)制得的超微粉与载镧氧化锌、载铈二氧化钛充分混合均匀后，加入其重量的6倍的丙酮水溶液中搅拌，然后加入硅烷偶联剂和单甘脂，在60℃水浴中恒温搅拌4h后，静置10h，过滤洗涤，烘干后，得改性混合粉末；
(3)将等规聚丙烯、聚乙烯蜡混合加热搅拌至完全熔融后，转入双螺杆挤压机中，然后依次加入马来酸酐接枝聚丙烯、抗氧剂和步骤(2)制得的改性混合粉末进行熔融混炼1h后，将混合物加到螺杆纺丝机中进行挤出纺丝，得改性聚丙烯纤维；
(4)称取栀子、竹茹、厚朴、油柑叶、夏枯草，总重量记为1份，加入6份纯化水，50±5℃下浸泡1h，然后小火煎煮2h，滤过，收集滤液；
(5)将步骤(4)制得的滤液与紫苏油混合后，加入甲壳素纤维、碳纳米纤维、竹纤维进行浸润1h，在浸润时进行超声处理，然后进行脱水和烘干；
(6)分别将步骤(3)制得的改性聚丙烯纤维、步骤(5)处理后的甲壳素纤维、碳纳米纤维、竹纤维由开松机进行开松，然后送入混棉机进行混合至均匀，由梳理机梳理后，由铺网机铺叠成棉网；
(7)将步骤(6)铺叠的棉网由针刺机或水刺机刺合，得到所述汽车内衬用材料；然后经过针刺机后的发泡体在挤出辊装置处挤压成层状形成杀菌层，最后通过切割装置将挤压成型后的杀菌层切割成规定长度尺寸。
4.根据权利要求1所述的一种增强型杀菌汽车内衬的生产工艺，其特征在于，包括以下步骤：
(1)首先按照无纺布层、增强层、杀菌层、无纺布层的上下顺序进行逐层叠料；
(2)步骤(1)叠料后的材料放入层压机中进行热压，热压温度200°～220°，热压时间180s～200s；热压后形成内衬板材，从层压机中取出板材，然后进行空冷；
(3)步骤(2)热压后的内衬板材在模具中进行模压成型；所述的模具包括阳模和阴模，首先将内衬板材放入阴模中，通过液压机推动阳模，对内衬板材进行压制成型；成型时间85s～95s，压制成型压力7Mpa～9Mpa；采用液压机从阴模的底端将压制成型后的内衬顶出脱模；
(4)步骤(3)脱模后的内衬在专用工装上进行修边和冲孔。
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