CN106573582A - 汽车用内装部件及其制造方法 - Google Patents

汽车用内装部件及其制造方法 Download PDF

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CN106573582A
CN106573582A CN201580038518.7A CN201580038518A CN106573582A CN 106573582 A CN106573582 A CN 106573582A CN 201580038518 A CN201580038518 A CN 201580038518A CN 106573582 A CN106573582 A CN 106573582A
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layer
built component
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CN106573582B (zh
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金宪助
柳茂善
金源国
朴春镐
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LG Corp
LX Hausys Ltd
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LG Chemical Co Ltd
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    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/045—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of natural rubber or synthetic rubber
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    • B05D7/06—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to wood
    • B05D7/08—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to wood using synthetic lacquers or varnishes
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Abstract

本发明提供汽车用内装部件，上述汽车用内装部件在单板层的两面包含涂敷层，在上述单板层的一面的涂敷层包含背面层，在上述单板层的背面的涂敷层包含前面层。本发明提供汽车用内装部件的制造方法，上述汽车用内装部件的制造方法包括：准备单板层的步骤；将水分散性聚氨酯分散液或水分散性丙烯酸聚氨酯分散液涂敷于上述单板层的两面并进行干燥来形成涂敷层的步骤；对在上述单板层的两面形成有涂敷层的实木膜层进行预成形的步骤；通过对在上述单板层的一面的涂敷层进行第一次镶嵌成形来形成背面层的步骤；以及通过对在上述单板层的背面的涂敷层进行第二次镶嵌成形来形成前面层的步骤。

Description

汽车用内装部件及其制造方法
技术领域
本发明涉及汽车用内装部件及其制造方法。
背景技术
通常，在汽车的扶手箱或仪表盘周边的面板等中使用树脂成形部件来用作汽车的内外装部件，并且树脂成形品还广泛利用于电饭锅等的外壳或外罩等的家电产品中。
尤其，在安装于汽车内部的驾驶座及副驾驶座的周边的仪表板(dash board)及音频面板、换档零部件、安全气囊、门锁及车窗开闭部等中，设置有各种控制部及便利装置，并且在各种控制装置及便利装置的外廓和内装部件之间的缝隙上，设置有内装部件的收尾板，可对内装部件进行收尾处理，这些内装部件成为用于决定车辆的室内外观的重要因素。
像这样，由于汽车用内装部件对汽车室内部的美感产生很大的影响，实际情况为，因此在目前的汽车趋向于个性化的趋势下，对外观上的审美要求越来越高。
由此，最近为了取得外观上的精致及高级质感，对以实木等的实木产品作为原材料的汽车用内装部件的需求逐渐增加。
发明内容
本发明要解决的技术问题
本发明一实例提供汽车用内装部件，上述汽车用内装部件为在单板层包含涂敷层，在上述涂敷层的两面包含背面层或前面层的注塑成型的成形品。
本发明的另一实例提供上述汽车用内装部件的制造方法。
技术方案
在本发明一实例中提供汽车用内装部件，上述汽车用内装部件在单板层的两面包含涂敷层，在上述单板层的一面的涂敷层包含背面层，在上述单板层的背面的涂敷层包含前面层。
上述涂敷层可以由水分散性聚氨酯分散液或水分散性丙烯酸聚氨酯分散液形成。
上述水分散性聚氨酯分散液或上述水分散性丙烯酸聚氨酯分散液可包含约10重量百分比至约40重量百分比的固体成分。
上述水分散性聚氨酯分散液或上述水分散性丙烯酸聚氨酯分散液还可包含二氧化硅化合物。
相对于100重量份的固体成分，上述水分散性聚氨酯分散液或上述水分散性丙烯酸聚氨酯分散液可包含5至30重量份的上述二氧化硅化合物。
上述涂敷层的厚度可以为约5μm至约50μm。
上述单板层的厚度可以为约100μm至约600μm。
上述前面层及上述背面层可分别包含选自由丙烯酸树脂、聚碳酸酯树脂、丙烯腈-丁二烯-苯乙烯共聚物(ABS)树脂、聚酯树脂、聚甲基丙烯酸甲酯(PMMA)树脂及它们的组合组成的组中的一种以上的热塑性树脂。
在本发明的另一实例中提供汽车用内装部件的制造方法，上述汽车用内装部件的制造方法包括：准备单板层的步骤；将水分散性聚氨酯分散液或水分散性丙烯酸聚氨酯分散液涂敷于上述单板层的两面并进行干燥来形成涂敷层的步骤；对在上述单板层的两面形成有涂敷层的实木膜层进行预成形的步骤；通过对在上述单板层的一面的涂敷层进行第一次镶嵌成形来形成背面层的步骤；以及通过对在上述单板层的背面的涂敷层进行第二次镶嵌成形来形成前面层的步骤。
在形成上述涂敷层的步骤中，可包括在上述水分散性聚氨酯分散液或上述水分散性丙烯酸聚氨酯分散液中还添加二氧化硅化合物的步骤。
上述二氧化硅化合物可由溶胶-凝胶法形成。
可在100℃至150℃的温度下，且在约20秒钟至约120秒钟的时间内进行上述预成形。
上述汽车用内装部件的制造方法还可包括经过上述预成形之后，对上述实木膜层的不必要的部分进行切割的步骤。
可同时进行上述第一次镶嵌成形及上述第二次镶嵌成形。
可在约200℃至250℃的温度下，进行上述第一次镶嵌成形及上述第二次镶嵌成形。
有益效果
上述汽车用内装部件具有优秀的耐热性、附着性及成形性，因而在外观上可实现高档化质感。
上述汽车用内装部件的制造方法可改善因高额的工序费用和制造工序的复杂性而引起的不合格率，并且可降低制造成本。
附图说明
图1为表示本发明一实例的汽车用内装部件的截面的图。
图2为对本发明另一实例的汽车用内装部件的制造方法进行图式化的图。
图3为在实施例中制造的汽车用内装部件的图像。
具体实施方式
以下，对本发明的实例进行详细的说明。这仅作为示例来提供，本发明并不局限于此，本发明仅根据上述的发明要求保护范围来定义。
汽车用内装部件
在本发明一实例中提供汽车用内装部件，上述汽车用内装部件在单板层的两面包含涂敷层，在上述单板层的一面的涂敷层包含背面层，在上述单板层的背面的涂敷层包含前面层。
在使用包括有实木的产品来作为汽车用内装部件的情况下，由于可使汽车室内的设计高档化，因此使用于防震垫(Crash Pad)或车门装饰件(Door Garnish)等。然而，包括有实木的内装部件的制造工序复杂，且因高额的制造费用，在汽车市场上扩大上存在困难。
由此，上述汽车用内装部件根据如下所述的制造方法来制造，从而可改善由高额的工序费用和制造工序的复杂性引起的高的不合格率，且可降低制造成本，并且因单板层和涂敷层而具有优秀的耐热性、附着性及成形性，从而在外观上可实现高档化质感。
图1为表示本发明一实例的汽车用内装部件的截面的图，参照图1，上述汽车用内装部件100在单板层10的两面可包含涂敷层20，在上述单板层的一面的涂敷层20可包含背面层40，在上述单板层的背面的涂敷层可包含前面层30。
上述汽车用内装部件通过在单板层10的两面包含涂敷层20，从而可确保耐热性、附着性及成形性，并且在上述单板层的两面包含涂敷层，从而可形成实木膜层。
上述涂敷层可以由水分散性聚氨酯分散液或水分散性丙烯酸聚氨酯分散液形成，上述水分散性聚氨酯分散液或上述水分散性丙烯酸聚氨酯分散液分别是指均匀地分散有水分散性丙烯酸聚氨酯树脂粒子或水分散性聚氨酯树脂粒子的溶液。
由此，上述涂敷层可以包含水分散性聚氨酯树脂或水分散性丙烯酸聚氨酯树脂，上述水分散性聚氨酯树脂或水分散性丙烯酸聚氨酯树脂可使上述涂敷层的耐热性提高，因此可在预备成形步骤中维持热稳定性，并且在进行注塑时，可确保附着性及成形性的提高，并通过挤压于单板层可弥补单板层的缺点。
上述水分散性聚氨酯树脂是由多元醇化合物、异氰酸酯化合物的合成，例如，可由聚碳酸酯二醇、异佛尔酮二异氰酸酯、以及二羟甲基丙酸合成。上述水分散性聚氨酯树脂通过平稳地渗透于含有很多亲水基的上述单板层的表面和空隙中，可向具有低成形性的上述单板层赋予伸缩性，并且可容易地实现借助预成形和注塑成型的上述单板层的成形。
并且，上述水分散性丙烯酸聚氨酯树脂可通过在上述水分散性聚氨酯树脂中添加丙烯酸单体化合物来形成，例如，上述丙烯酸单体化合物可包含甲基丙烯酸甲酯。上述水分散性丙烯酸聚氨酯树脂与上述水分散性聚氨酯树脂相同，通过平稳地渗透于含有很多亲水基的上述单板层的表面和空隙中，可向具有低成形性的上述单板层赋予伸缩性，并且可容易地实现借助预成形和注塑成型的上述单板层的成形。
并且，通过向上述单板层赋予热稳定性，可抑制在进行预成形和注塑工序时，由热引起上述单板层与模具相附着的现象，并且通过赋予由注塑成型形成的前面层及背面层与上述实木膜层之间的附着性，来可容易地实现汽车用内装部件的各层之间的紧贴性。
上述水分散性聚氨酯树脂分散液或上述水分散性丙烯酸聚氨酯树脂分散液可包含约10重量百分比至约40重量百分比的固体成分。
当包含小于约10重量百分比的上述固体成分时，因无法在上述单板层的表面及空隙中充分地渗透树脂，因此有可能成形性降低，当包含大于约40重量百分比的上述固体成分时，上述涂敷层的厚度变厚，因此根据成形的形态无法维持而复元，从而维持在上述范围的固体成分有利于确保上述单板层的成形性。
上述涂敷层还可包含二氧化硅化合物。上述二氧化硅化合物是指以二氧化硅为主成分的化合物，因上述二氧化硅化合物可提高上述涂敷层的耐热性。即，用于形成上述涂敷层的上述水分散性聚氨酯分散液或上述水分散性丙烯酸聚氨酯分散液还可包含二氧化硅化合物。
具体地，相对于100重量份的固体成分，上述水分散性聚氨酯分散液或上述水分散性丙烯酸聚氨酯分散液可包含约5至约30重量份的上述二氧化硅化合物，例如，可包含约5至约20重量份的上述二氧化硅化合物。以上述范围的含量来包含上述二氧化硅化合物，从而可提高上述涂敷层的耐热性，并且可提高上述单板层的热分散和耐热性，因此可抑制在预成形和注塑成形时，因由模型传递的热引起的单板层的熏黑现象。
上述涂敷层的厚度可以为约5μm至约50μm。在上述涂敷层的厚度小于约5μm的情况下，可降低单板层的成形性，在上述涂敷层的厚度大于约50μm的情况下，存在根据成形的形态无法维持而复元的问题，因此维持上述范围可维持根据成形的形态。
上述单板(veneer)层意味着实木(real wood)，与一般的木纹胶合板、塑料胶合板等相比，外观华丽、高档，因此可为汽车室内赋予精致美及审美感。
上述单板层的厚度为约100μm至约600μm，例如上述单板层的厚度可以为150μm至约250μm。上述单板层通过在两面包含涂敷层来形成实木膜层，因此尽管厚度薄，但形态不变形。
例如，作为上述单板层的实木可包含单一的天然木层，上述天然木层可包括由将扁柏树、核桃树、非洲红豆树，雀眼树等切割而成薄的单板。
并且，上述单板层可包括形成于基材上的天然木层，上述基材可包括以牛皮纸、纸浆为原料的纸等，从而可使天然木层的开裂现象及裂纹的产生最小化。
根据如下所述的汽车用内装部件的制造方法，以简单的工序在上述单板层的两面形成涂敷层，从而可取得在外观上实现精致美的实木膜层。
在上述单板层的一面的涂敷层可包括背面层40，在上述单板层的背面的涂敷层可包含前面层30。上述前面层及上述背面层为通过使上述热塑性树脂注塑于涂敷层的一面或背面形成的层，具有用于汽车用内装部件的耐久性和形状维持的支架作用，并且上述前面层也可实现装饰性效果。
上述前面层及上述背面层可分别包含选自由丙烯酸树脂、聚碳酸酯树脂、丙烯腈-丁二烯-苯乙烯共聚物树脂、聚酯树脂、聚甲基丙烯酸甲酯树脂及它们的组合组成的组合中的一种以上的热塑性树脂。并且，上述前面层及上述背面层的厚度可分别为约1mm至约3mm。
汽车用内装部件的制造方法
本发明的另一实例提供汽车用内装部件的制造方法，上述汽车用内装部件的制造方法包括：准备单板层的步骤；将水分散性聚氨酯分散液或水分散性丙烯酸聚氨酯分散液涂敷于上述单板层的两面并进行干燥来形成涂敷层的步骤；对在上述单板层的两面形成有涂敷层的实木膜层进行预成形的步骤；通过对在上述单板层的一面的涂敷层进行第一次镶嵌成形来形成背面层的步骤；以及通过对在上述单板层的背面的涂敷层进行第二次镶嵌成形来形成前面层的步骤。
图2为对本发明另一实例的汽车用内装部件的制造方法进行图式化的图，参照图2，上述汽车用内装部件的制造方法包括，在单板层两面形成涂敷层的步骤；进行预成形的步骤；进行背面注塑及前面注塑的步骤，从而可制造出注塑成形品的汽车用内装部件。
形成于上述单板层的两面的涂敷层用于确保在预成形时的耐热性，且用于确保在注塑成形时的附着性，并通过如下方法形成，即，利用线棒涂布机(Mayer Bar coater)，以约20μm至约50μm的厚度将包含约10重量百分比至约40重量百分比的固体成分的水分散性聚氨酯分散液或水分散性丙烯酸聚氨酯分散液涂敷于单板层的两面，并且在约100℃至约150℃的温度下的烘箱中，进行干燥约2分钟至约5分钟。
在形成上述涂敷层的步骤中，可包括在上述水分散性聚氨酯分散液或上述水分散性丙烯酸聚氨酯分散液中还添加二氧化硅化合物的步骤。
为了提高涂敷层的耐热性可添加上述二氧化硅化合物，相对于100重量份的上述水分散性聚氨酯分散液或上述水分散性丙烯酸聚氨酯分散液的固体成分，可添加约5重量份至约30重量份。
上述二氧化硅化合物可由溶胶-凝胶法形成。溶胶-凝胶法为由水解取得的溶胶经由凝胶而形成化合物的工序，上述二氧化硅化合物可以为由溶胶-凝胶法形成的二氧化硅溶胶(Silica sol)。
为了确保单板层的耐热性、附着性及成形性，可包括如下步骤在单板层的两面形成了涂敷层，之后对在形成上述涂敷层的两面形成有涂敷层的单板层，即，实木膜层进行预成形。
上述预成形是为了在进行注塑成型之前确保适当的形态而进行的工序，在约100℃至约150℃的温度下，可在约20秒钟至约120秒钟的时间内进行上述预成形。
通过上述预成形在上述单板层的两面形成上述涂敷层的上述实木膜层可形成为适用于注塑成型的适当的形态，并且因在上述范围的温度及时间内进行预成形，因而可使实木膜层的开裂和折叠现象最小化。
上述汽车用内装部件的制造方法还可包括，在经过上述预成形之后，对上述实木膜层的不必要的部分进行切割的步骤。
将通过上述预成形向上述实木膜层赋予适用于注塑成型的形态，从而有可能产生不包括于成形品的不必要的部分，在这种情况下，可切割上述不必要的部分。上述切割可通过激光切削、刀具切削等的公知的切割工序来进行。
可通过对在上述预成形的实木膜层的一面或背面的涂敷层进行第一次镶嵌成形或第二次镶嵌成形，来确保最终成形品，并且可将上述成形品用于汽车用内装部件。
通过上述第一次镶嵌成形可形成背面层，通过上述第二次镶嵌成形可形成前面层，并且上述第一次镶嵌成形及上述第二次镶嵌成形可分别进行，或可以同时进行。同时进行上述第一次镶嵌成形及上述第二次镶嵌成形，从而可缩短消耗时间，并且通过向上述实木膜层提供规定的温度条件，可使上述前面层及上述背面层的附着顺畅。
上述第一次镶嵌成形及上述第二次镶嵌成形可在约200℃至约250℃的温度下进行。进行上述镶嵌成形的温度可根据所提供的热塑性树脂来调节，并且上述热塑性树脂可包含选自由丙烯酸树脂、聚碳酸酯树脂、丙烯腈-丁二烯-苯乙烯共聚物树脂、聚酯树脂、聚甲基丙烯酸甲酯树脂以及它们的组合组成的组中的一种以上。
在上述温度小于约200℃的情况下，由于热塑性树脂的流动性的降低，因此有可能存在前面层及背面层的形成不顺畅的问题，在上述温度大于约250℃的情况下，在上述实木膜层有可能产生熏黑现象，或上述膜层有可能附着于模具。
通常，由第二次镶嵌成形形成前面层，然而可通过聚氨酯铸造成形工序、喷射工序、粉末涂敷工序等形成前面层。
以下，公开本发明的具体实施例。然而，以下所记载的实施例仅为了具体例示本发明或具体地说明本发明，并不是限制本发明。
实施例
利用雀眼树准备了150μm厚度的单板层。在上述单板层的两面，利用线棒涂布机，涂敷相对于固体成分包含10重量百分比的二氧化硅粒子和包含25重量百分比的固体成分的水分散性丙烯酸聚氨酯分散液，并在130℃温度的烘箱中干燥了4分钟，形成了20μm厚度的涂敷层。
在130℃的温度下，将在上述单板层的两面形成有涂敷层的实木膜层，以适合于注塑成型的形态进行了100秒钟的预成形，并对已完成的形态不必要的部分进行了切割。
之后，在200℃至230℃温度下，在上述实木膜层的一面的涂敷层对聚碳酸酯树脂进行镶嵌成形来形成背面层，并在200℃至220℃温度下，在上述实木膜层的背面的涂敷层对聚甲基丙烯酸甲酯树脂进行镶嵌成形来形成前面层，由此制造了汽车用内装部件。
图3为在实施例中制造的汽车用内装部件的图像。
附图标记的说明
10：单板层
20：涂敷层，
30：前面层，
40：背面层
100：汽车用内装部件

Claims (15)

1.一种汽车用内装部件，其特征在于，
在单板层的两面包含涂敷层，
在上述单板层的一面的涂敷层包含背面层，
在上述单板层的背面的涂敷层包含前面层。
2.根据权利要求1所述的汽车用内装部件，其特征在于，上述涂敷层由水分散性聚氨酯分散液或水分散性丙烯酸聚氨酯分散液形成。
3.根据权利要求2所述的汽车用内装部件，其特征在于，上述水分散性聚氨酯分散液或上述水分散性丙烯酸聚氨酯分散液包含10重量百分比至40重量百分比的固体成分。
4.根据权利要求2所述的汽车用内装部件，其特征在于，上述水分散性聚氨酯分散液或上述水分散性丙烯酸聚氨酯分散液还包含二氧化硅化合物。
5.根据权利要求4所述的汽车用内装部件，其特征在于，相对于100重量份的固体成分，上述水分散性聚氨酯分散液或上述水分散性丙烯酸聚氨酯分散液包含5至30重量份的上述二氧化硅化合物。
6.根据权利要求1所述的汽车用内装部件，其特征在于，上述涂敷层的厚度为5μm至50μm。
7.根据权利要求1所述的汽车用内装部件，其特征在于，上述单板层的厚度为100μm至600μm。
8.根据权利要求1所述的汽车用内装部件，其特征在于，上述前面层及上述背面层分别包含选自由丙烯酸树脂、聚碳酸酯树脂、丙烯腈-丁二烯-苯乙烯共聚物树脂、聚酯树脂、聚甲基丙烯酸甲酯树脂及它们的组合组成的组中的一种以上的热塑性树脂。
9.一种汽车用内装部件的制造方法，其特征在于，包括：
准备单板层的步骤；
将水分散性聚氨酯分散液或水分散性丙烯酸聚氨酯分散液涂敷于上述单板层的两面并进行干燥来形成涂敷层的步骤；
对在上述单板层的两面形成有涂敷层的实木膜层进行预成形的步骤；
在上述单板层的一面的涂敷层进行第一次镶嵌成形来形成背面层的步骤；以及
在上述单板层的背面的涂敷层进行第二次镶嵌成形来形成前面层的步骤。
10.根据权利要求9所述的汽车用内装部件的制造方法，其特征在于，在形成上述涂敷层的步骤中，包括在上述水分散性聚氨酯分散液或上述水分散性丙烯酸聚氨酯分散液中还添加二氧化硅化合物的步骤。
11.根据权利要求10所述的汽车用内装部件的制造方法，其特征在于，上述二氧化硅化合物由溶胶-凝胶法形成。
12.根据权利要求9所述的汽车用内装部件的制造方法，其特征在于，在100℃至150℃的温度下，且在20秒钟至120秒钟的时间内进行上述预成形。
13.根据权利要求9所述的汽车用内装部件的制造方法，其特征在于，还包括经过上述预成形之后，对上述实木膜层的不必要的部分进行切割的步骤。
14.根据权利要求9所述的汽车用内装部件的制造方法，其特征在于，同时进行上述第一次镶嵌成形及上述第二次镶嵌成形。
15.根据权利要求9所述的汽车用内装部件的制造方法，其特征在于，在200℃至250℃的温度下，进行上述第一次镶嵌成形及上述第二次镶嵌成形。
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