CN106739405A - 单体经编布汽车顶蓬的制造工艺 - Google Patents

单体经编布汽车顶蓬的制造工艺 Download PDF

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CN106739405A
CN106739405A CN201611124664.4A CN201611124664A CN106739405A CN 106739405 A CN106739405 A CN 106739405A CN 201611124664 A CN201611124664 A CN 201611124664A CN 106739405 A CN106739405 A CN 106739405A
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rigid foam
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娄凤娥
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/08—Interconnection of layers by mechanical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
    • B60R13/0212—Roof or head liners
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)

Abstract

本发明涉及一种单体经编布汽车顶蓬的制造工艺，特征是，包括以下工艺步骤：（1）材料铺放：将经编布面料在面料铺放台上铺平；（2）烘温软化：将聚氨酯复合板送入烘箱内进行烘温软化，温度为150～300℃，烘温时间为30～90秒；（3）模压成型：将烘温软化后的聚氨酯复合板送入汽车顶蓬模具型腔内，将步骤（1）的经编布面料输送到聚氨酯复合板上方，压制成型得到汽车顶蓬半成品；成型压力为4～6MPa，成型时间为40～80秒；（4）水刀切割：将模压成型得到的汽车顶蓬半成品从汽车顶蓬模具内取出，转移到切割治具上，切割成所需尺寸，即得到所述的汽车顶蓬；切割水压为40000～50000psi，切割气压为0.4～0.7MPa。本发明产品质地轻，符合现代汽车轻量化，高性能的要求。

Description

单体经编布汽车顶蓬的制造工艺
技术领域
本发明涉及一种汽车顶蓬的制造工艺，尤其是一种单体经编布汽车顶蓬的制造工艺，属于汽车内饰件技术领域。
背景技术
汽车顶蓬具有装饰、吸音、隔音、隔热等特点，在越来越追求高性能，环保型，轻量化的时代，汽车内饰成为人们选车的一个重要因素，因此对汽车内饰件的要求越来越高。目前顶蓬面料主要包括针织复合面料及无纺复合面料。现有复合面料主要存在以下问题：1、易脏污；2、产品重量大，不利于整车轻量化；3、面料延伸率较差，导致加工成型时行腔较深处面料贴不牢，产生起泡等现象；4、单体面料通过火焰或者胶水与PU复合成型，易引起VOC不合格，不能满足主机厂技术要求；5、对于无纺复合面料，外观性较差；6、成本高。而经编布是通过一种经编纺织工艺针织或编织而成，具有延伸率高、外观性好、价格低廉等有点。
发明内容
本发明的目的是克服现有技术中存在的不足，提供一种单体经编布汽车顶蓬的制造工艺，产品质地轻，符合现代汽车轻量化，高性能的要求。
按照本发明提供的技术方案，一种单体经编布汽车顶蓬的制造工艺，其特征是，包括以下工艺步骤：
（1）材料铺放：将经编布面料在面料铺放台上铺平；
（2）烘温软化：将聚氨酯复合板送入烘箱内进行烘温软化，温度为150～300℃，烘温时间为30～90秒；
（3）模压成型：将烘温软化后的聚氨酯复合板送入汽车顶蓬模具型腔内，将步骤（1）的经编布面料输送到聚氨酯复合板上方，压制成型得到汽车顶蓬半成品；成型压力为4～6MPa，成型时间为40～80秒；
（4）水刀切割：将模压成型得到的汽车顶蓬半成品从汽车顶蓬模具内取出，转移到切割治具上，切割成所需尺寸，即得到所述的汽车顶蓬；切割水压为40000～50000psi，切割气压为0.4～0.7MPa。
所述聚氨酯复合板的材料从下至上依次为无纺布、玻璃纤维毡、聚氨酯泡沫、玻璃纤维毡、PE膜。
步骤（3）中，经编布面料与聚氨酯复合板的PE膜一侧接触。
所述经编布面料的克重为100～300g/㎡。
所述聚氨酯复合板的克重为700～1000g/㎡。
所述经编布面料采用涤纶经编布面料。
本发明与已有技术相比具有以下优点：（1）本发明生产的汽车顶蓬，重量轻，成型加工容易，采用经编布面料解决了现有汽车顶篷面料的不耐脏污及VOC不合格问题；（2）外观性好，能够很好地满足主机厂的技术要求和客户使用要求，符合现代汽车轻量化、高性能的要求；（3）本发明采用的经编布面料不需要经过火焰或者胶水复合成型，减少了中间环节一次成型，减少了对环境的污染，符合环保要求。
具体实施方式
下面结合具体实施例对本发明作进一步说明。
本发明中所使用的聚氨酯复合板为市售的汽车顶棚用PU复合板材，在本发明实施例中所采用的为无锡吉兴木桥高分子材料科技有限公司生产的汽车顶棚PU复合板材；该聚氨酯复合板的材料从下至上依次为无纺布、玻璃纤维毡、聚氨酯泡沫、玻璃纤维毡、PE膜。
实施例一：一种单体经编布汽车顶蓬的制造工艺，包括以下工艺步骤：
（1）材料铺放：将涤纶经编布面料在面料铺放台上铺平，涤纶经编布面料的克重为100g/㎡；
（2）烘温软化：将聚氨酯复合板送入烘箱内进行烘温软化，温度为150℃，烘温时间为90秒；所述聚氨酯复合板的材料从下至上依次为无纺布、玻璃纤维毡、聚氨酯泡沫、玻璃纤维毡、PE膜；所述聚氨酯复合板的克重为700g/㎡；
（3）模压成型：将烘温软化后的聚氨酯复合板送入汽车顶蓬模具型腔内，将步骤（1）的涤纶经编布面料输送到聚氨酯复合板上方，涤纶经编布面料与聚氨酯复合板的PE膜一侧接触，压制成型得到汽车顶蓬半成品；成型压力为4MPa，成型时间为80秒；
（4）水刀切割：将模压成型得到的汽车顶蓬半成品从汽车顶蓬模具内取出，转移到切割治具上，切割成所需尺寸，即得到所述的汽车顶蓬；切割水压为40000psi，切割气压为0.4MPa。
实施例二：一种单体经编布汽车顶蓬的制造工艺，包括以下工艺步骤：
（1）材料铺放：将涤纶经编布面料在面料铺放台上铺平，涤纶经编布面料的克重为300g/㎡；
（2）烘温软化：将聚氨酯复合板送入烘箱内进行烘温软化，温度为300℃，烘温时间为90秒；所述聚氨酯复合板的材料从下至上依次为无纺布、玻璃纤维毡、聚氨酯泡沫、玻璃纤维毡、PE膜；所述聚氨酯复合板的克重为1000g/㎡；
（3）模压成型：将烘温软化后的聚氨酯复合板送入汽车顶蓬模具型腔内，将步骤（1）的涤纶经编布面料输送到聚氨酯复合板上方，涤纶经编布面料与聚氨酯复合板的PE膜一侧接触，压制成型得到汽车顶蓬半成品；成型压力为6MPa，成型时间为40秒；
（4）水刀切割：将模压成型得到的汽车顶蓬半成品从汽车顶蓬模具内取出，转移到切割治具上，切割成所需尺寸，即得到所述的汽车顶蓬；切割水压为50000psi，切割气压为0.7MPa。
实施例三：一种单体经编布汽车顶蓬的制造工艺，包括以下工艺步骤：
（1）材料铺放：将涤纶经编布面料在面料铺放台上铺平，涤纶经编布面料的克重为200g/㎡；
（2）烘温软化：将聚氨酯复合板送入烘箱内进行烘温软化，温度为200℃，烘温时间为60秒；所述聚氨酯复合板的材料从下至上依次为无纺布、玻璃纤维毡、聚氨酯泡沫、玻璃纤维毡、PE膜；所述聚氨酯复合板的克重为800g/㎡；
（3）模压成型：将烘温软化后的聚氨酯复合板送入汽车顶蓬模具型腔内，将步骤（1）的涤纶经编布面料输送到聚氨酯复合板上方，涤纶经编布面料与聚氨酯复合板的PE膜一侧接触，压制成型得到汽车顶蓬半成品；成型压力为5MPa，成型时间为60秒；
（4）水刀切割：将模压成型得到的汽车顶蓬半成品从汽车顶蓬模具内取出，转移到切割治具上，切割成所需尺寸，即得到所述的汽车顶蓬；切割水压为45000psi，切割气压为0.5MPa。
本发明生产的汽车顶蓬重量轻，材料之间相容性好，耐洗可回收，成型加工容易，环保，产生的边角料很容易回收再利用，还解决了现有汽车顶篷面料的不耐脏污及气味不合格问题，能够很好地满足客户使用要求，符合现代汽车轻量化、环保化的要求。

Claims (6)

1.一种单体经编布汽车顶蓬的制造工艺，其特征是，包括以下工艺步骤：
（1）材料铺放：将经编布面料在面料铺放台上铺平；
（2）烘温软化：将聚氨酯复合板送入烘箱内进行烘温软化，温度为150～300℃，烘温时间为30～90秒；
（3）模压成型：将烘温软化后的聚氨酯复合板送入汽车顶蓬模具型腔内，将步骤（1）的经编布面料输送到聚氨酯复合板上方，压制成型得到汽车顶蓬半成品；成型压力为4～6MPa，成型时间为40～80秒；
（4）水刀切割：将模压成型得到的汽车顶蓬半成品从汽车顶蓬模具内取出，转移到切割治具上，切割成所需尺寸，即得到所述的汽车顶蓬；切割水压为40000～50000psi，切割气压为0.4～0.7MPa。
2.如权利要求1所述的单体经编布汽车顶蓬的制造工艺，其特征是：所述聚氨酯复合板的材料从下至上依次为无纺布、玻璃纤维毡、聚氨酯泡沫、玻璃纤维毡、PE膜。
3.如权利要求2所述的单体经编布汽车顶蓬的制造工艺，其特征是：步骤（3）中，经编布面料与聚氨酯复合板的PE膜一侧接触。
4.如权利要求1所述的单体经编布汽车顶蓬的制造工艺，其特征是：所述经编布面料的克重为100～300g/㎡。
5.如权利要求1所述的单体经编布汽车顶蓬的制造工艺，其特征是：所述聚氨酯复合板的克重为700～1000g/㎡。
6.如权利要求1所述的单体经编布汽车顶蓬的制造工艺，其特征是：所述经编布面料采用涤纶经编布面料。
CN201611124664.4A 2016-12-08 2016-12-08 单体经编布汽车顶蓬的制造工艺 Pending CN106739405A (zh)

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107685526A (zh) * 2017-10-23 2018-02-13 无锡吉兴汽车部件有限公司 一种汽车顶蓬面料辊胶贴合的生产工艺
CN110625868A (zh) * 2019-09-10 2019-12-31 上海华迎汽车零部件有限公司 一种汽车内饰板的制作方法及汽车后备箱侧饰板
CN113524849A (zh) * 2021-07-21 2021-10-22 湖北吉兴汽车部件有限公司 一种机盖隔音垫及其制备方法和应用

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107685526A (zh) * 2017-10-23 2018-02-13 无锡吉兴汽车部件有限公司 一种汽车顶蓬面料辊胶贴合的生产工艺
CN110625868A (zh) * 2019-09-10 2019-12-31 上海华迎汽车零部件有限公司 一种汽车内饰板的制作方法及汽车后备箱侧饰板
CN110625868B (zh) * 2019-09-10 2022-03-29 上海华迎汽车零部件有限公司 一种汽车内饰板的制作方法及汽车后备箱侧饰板
CN113524849A (zh) * 2021-07-21 2021-10-22 湖北吉兴汽车部件有限公司 一种机盖隔音垫及其制备方法和应用
CN113524849B (zh) * 2021-07-21 2022-05-10 湖北吉兴汽车部件有限公司 一种机盖隔音垫及其制备方法和应用

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