CN106903953A - 一种汽车用玻璃纤维零件及制备方法 - Google Patents

一种汽车用玻璃纤维零件及制备方法 Download PDF

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CN106903953A
CN106903953A CN201510971794.0A CN201510971794A CN106903953A CN 106903953 A CN106903953 A CN 106903953A CN 201510971794 A CN201510971794 A CN 201510971794A CN 106903953 A CN106903953 A CN 106903953A
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glass fiber
fiber part
woven fabrics
automotive glass
fiber material
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高翠梅
方诚
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Shanghai Xinan Auto Soundproof Blanket Co Ltd
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Abstract

本发明涉及一种汽车用玻璃纤维零件，形状与汽车行李箱左右塑料支架和/或乘客舱后座椅的形状相匹配，该零件为三层结构，上表面层及下表面层分别为地毯和无纺布，中间层为玻璃纤维材料。与现有技术相比，本发明具有强度高、密度小、产生挥发性气体少等优点。

Description

一种汽车用玻璃纤维零件及制备方法
技术领域
本发明涉及一种汽车零件及其制备方法，尤其是涉及一种汽车用玻璃纤维零件及其制作方法。
背景技术
目前汽车行业包裹架护板，大多采用单片地毯压制的结构，因此结构较软，硬度及强度较低，如果需要达到一定的强度要求的话，则需要增加零件的厚度等，造成零件重量偏重，使得汽车的负荷增加，从而不利于汽车启动、行驶，另外还会造成油耗增加，不利于环保。
中国专利CN102336024A公布了一种汽车用木塑材料零件的制作方法，将两层木塑材料放入烘箱内加热软化，上模具及下模具内放置表面材料，烘软的两层木塑材料平铺在下模具内后控制合模并在两层木塑材料中间吹气，最后去除得到零件的边料，然后在零件上粘接塑料件并安装限位绳即得到产品。与现有技术相比，本发明制作得到的零件与普通的单层结构零件相比，一方面可以保证相同强度，另一方面，由于零件仅仅是单层玻璃纤维材料结构，可以节省材料，并减轻零件重量。但是该专利制得的木塑材料零件会带有木塑材料自身的木塑味，气味较大。
发明内容
本发明的目的就是为了克服上述现有技术存在的缺陷而提供一种强度高、密度小、产生挥发性气体少的汽车用玻璃纤维零件及其制作方法。
本发明的目的可以通过以下技术方案来实现：
一种汽车用玻璃纤维零件，形状与汽车行李箱左右塑料支架和/或乘客舱后座椅的形状相匹配。该零件为三层结构，上表面层及下表面层分别为地毯和无纺布，中间层为玻璃纤维材料。
所述的玻璃纤维材料为单层玻璃纤维材料。玻璃纤维材料具有强度高、密度小、产生挥发性气体少的特点，且其可以通过模压工艺与表面地毯复合加以实现，保证成品零件美观。
所述的无纺布的下表面还设有定位塑料件。
所述的玻璃纤维材料由玻璃纤维和聚丙烯纤维按重量比为48～52:52～48混纺制成。由于玻璃纤维自身不具有粘结特性，故如玻璃纤维含量过高，零件主体松散、难以粘结；如玻璃纤维含量过低，零件难以通过模压工艺将主体与表面地毯复合起来，采用发明的配比，能够使得玻璃纤维材料在具有很好的加工性。
所述的玻璃纤维的克重为1980～2420g/m2；所述的聚丙烯纤维的熔点为166～170℃
所述的地毯由聚对苯二甲酸乙二醇酯和丁苯橡胶按重量比为80～85:20～15混纺制成；
所述的无纺布由聚对苯二甲酸乙二醇酯制成。
一种汽车用玻璃纤维零件的制备方法，采用由上模具和下模具构成的零件模具，包括以下步骤：
(1)分别将无纺布和地毯铺设在下模具的上表面及上模具的下表面；
(2)将玻璃纤维材料加热，待其软化后，敷设在无纺布上；
(3)控制压力为18～20MPa进行合模，压制130～170s，即得到汽车用玻璃纤维零件。
所述的步骤(1)和步骤(3)中通过水冷系统控制上模具及下模具的温度为15℃。
所述的步骤(2)中的加热是指将玻璃纤维材料置于200～240℃的平板烘箱中加热至软化。
该方法还包括采用热板焊接设备将定位塑料件焊接在无纺布的下表面。其中，每个定位塑料件的焊接温度为250～270℃，焊接时间为3～8s，冷却时间为20～30s。
所采用的热板焊接设备频率为：50/60Hz；最大功率：20kw；压缩空气压力：5～7kg。
该方法还包括定位绳及缓冲块塑料配件等的安装。
与现有技术相比，本发明具有以下优点：
(1)玻璃纤维具有较强的韧性，但其本身不具有粘性，无法粘结；而使用熔点为166～170℃的聚丙烯纤维能在高温熔化下起到粘结玻璃纤维的作用。最终通过纤维混纺得到的玻璃纤维材料制作零件可以保证零件的强度和韧性，且不会产生刺鼻的气味。
(2)由于零件仅仅是单层玻璃纤维材料结构，可以节省材料、减轻零件重量；同时由于玻璃纤维具有较强的韧性和强度的天然优势，能保证制作出来的零件具有较强的韧性和强度。
(3)相比于胶水粘结，使用热板焊接定位塑料件更加稳定、牢固，同时，不需要新增辅助粘结材料，也更加经济环保。
具体实施方式
下面结合具体实施例对本发明进行详细说明。
实施例1
一种汽车用玻璃纤维材料零件，零件的形状与汽车行李箱左右塑料支架相匹配，上表面层及下表面层分别为地毯和无纺布，中间层为玻璃纤维材料，无纺布的下表面经热板焊接设备焊有定位塑料件。
玻璃纤维材料层由玻璃纤维和聚丙烯纤维按重量比为50:50混纺制成并在玻璃纤维材料背面敷设无纺布，表面地毯层由聚对苯二甲酸乙二醇酯及丁苯橡胶按重量比为80:20混纺制成，无纺布层由聚对苯二甲酸乙二醇酯制成，其中，玻璃纤维的克重为2200g/m2，聚丙烯纤维熔点为168℃。
一种汽车用玻璃纤维零件的制备方法，采用由上模具和下模具构成的零件模具，包括以下步骤：
(1)利用水冷系统，控制成型用上模具及下模具的温度为15℃；
(2)在下模具的上部铺设无纺布；
(3)在上模具的下部铺设表面地毯；
(4)将按配方混纺得到的玻璃纤维材料置于平板烘箱内，控制烘箱温度为220℃，使玻璃纤维材料充分加热软化；
(5)将软化的玻璃纤维材料平铺在无纺布上；
(6)马上闭合模具合模，控制压力为19MPa，合模时间为150s；
(7)开模将组件取出，去除边料，得到汽车用玻璃纤维材料；
(8)将其放入热板焊接设备中，焊接定位塑料件。其中焊接温度约为：260℃，焊接时间：5s，冷却时间：25s；
(9)安装定位绳及缓冲块塑料配件。
实施例2
一种汽车用玻璃纤维材料零件，零件的形状与乘客舱后座椅相匹配，上表面层及下表面层分别为地毯和无纺布，中间层为玻璃纤维材料，无纺布的下表面经热板焊接设备焊有定位塑料件。
玻璃纤维材料层由玻璃纤维和聚丙烯纤维按重量比为52:48混纺制成并在玻璃纤维材料背面敷设无纺布，表面地毯层由聚对苯二甲酸乙二醇酯及丁苯橡胶按重量比为85:15混纺制成，无纺布层由聚对苯二甲酸乙二醇酯制成，其中，玻璃纤维的克重为1980g/m2，聚丙烯纤维熔点为166℃。
一种汽车用玻璃纤维零件的制备方法，采用由上模具和下模具构成的零件模具，包括以下步骤：
(1)利用水冷系统，控制成型用上模具及下模具的温度为20℃；
(2)在下模具的上部铺设无纺布；
(3)在上模具的下部铺设表面地毯；
(4)将按配方混纺得到的玻璃纤维材料置于平板烘箱内，控制烘箱温度为200℃，使玻璃纤维材料充分加热软化；
(5)将软化的玻璃纤维材料平铺在无纺布上；
(6)马上闭合模具合模，控制压力为20MPa，合模时间为170s；
(7)开模将组件取出，去除边料，得到汽车用玻璃纤维材料；
(8)将其放入热板焊接设备中，焊接定位塑料件。其中焊接温度约为：250℃，焊接时间：8s，冷却时间：20s；
(9)安装定位绳及缓冲块塑料配件。
实施例3
一种汽车用玻璃纤维材料零件，零件的形状分别与汽车行李箱左右塑料支架和乘客舱后座椅相匹配，上表面层及下表面层分别为地毯和无纺布，中间层为玻璃纤维材料，无纺布的下表面经热板焊接设备焊有定位塑料件。
玻璃纤维材料层由玻璃纤维和聚丙烯纤维按重量比为48:52混纺制成并在玻璃纤维材料背面敷设无纺布，表面地毯层由聚对苯二甲酸乙二醇酯及丁苯橡胶按重量比为83:17混纺制成，无纺布层由聚对苯二甲酸乙二醇酯制成，其中，玻璃纤维的克重为2420g/m2，聚丙烯纤维熔点为170℃。
一种汽车用玻璃纤维零件的制备方法，采用由上模具和下模具构成的零件模具，包括以下步骤：
(1)利用水冷系统，控制成型用上模具及下模具的温度为10℃；
(2)在下模具的上部铺设无纺布；
(3)在上模具的下部铺设表面地毯；
(4)将按配方混纺得到的玻璃纤维材料置于平板烘箱内，控制烘箱温度为240℃，使玻璃纤维材料充分加热软化；
(5)将软化的玻璃纤维材料平铺在无纺布上；
(6)马上闭合模具合模，控制压力为18MPa，合模时间为130s；
(7)开模将组件取出，去除边料，得到汽车用玻璃纤维材料；
(8)将其放入热板焊接设备中，焊接定位塑料件。其中焊接温度约为：270℃，焊接时间：3s，冷却时间：30s；
(9)安装定位绳及缓冲块塑料配件。
按照上述实施例1～3制作玻璃纤维材料零件单位面积重量约为：2600g/m2；总成零件重量约为：(1300～1580)g，相比于类似木塑材料零件约为：3500g/m2的单位面积重量，玻璃纤维材料具有轻量化的特点；同时，能保证在-40℃～80℃、50个周期(25天)的温度循环实验中零件无变形，具有相当强的功能性。

Claims (10)

1.一种汽车用玻璃纤维零件，其特征在于，形状与汽车行李箱左右塑料支架和/或乘客舱后座的形状相匹配；该零件为三层结构，上表面层及下表面层分别为地毯和无纺布，中间层为玻璃纤维材料。
2.根据权利要求1所述的一种汽车用玻璃纤维零件，其特征在于，所述的玻璃纤维材料为单层玻璃纤维材料。
3.根据权利要求1所述的一种汽车用玻璃纤维零件，其特征在于，所述的无纺布的下表面还设有定位塑料件。
4.根据权利要求1所述的一种汽车用玻璃纤维零件，其特征在于，所述的玻璃纤维材料由玻璃纤维和聚丙烯纤维按重量比为48～52:52～48混纺制成。
5.根据权利要求4所述的一种汽车用玻璃纤维零件，其特征在于，所述的玻璃纤维的克重为1980～2420g/m2；所述的聚丙烯纤维的熔点为166～170℃
6.根据权利要求1所述的一种汽车用玻璃纤维零件，其特征在于，
所述的地毯由聚对苯二甲酸乙二醇酯和丁苯橡胶按重量比为80～85:20～15混纺制成；
所述的无纺布由聚对苯二甲酸乙二醇酯制成。
7.如权利要求1～6任一所述的一种汽车用玻璃纤维零件的制备方法，其特征在于，采用由上模具和下模具构成的零件模具，包括以下步骤：
(1)分别将无纺布和地毯铺设在下模具的上表面及上模具的下表面；
(2)将玻璃纤维材料加热，待其软化后，敷设在无纺布上；
(3)控制压力为18～20MPa进行合模，压制130～170s，即得到汽车用玻璃纤维零件。
8.根据权利要求7所述的一种汽车用玻璃纤维零件的制备方法，其特征在于，所述的步骤(1)和步骤(3)中通过水冷系统控制上模具及下模具的温度为10～20℃。
9.根据权利要求7所述的一种汽车用玻璃纤维零件的制备方法，其特征在于，所述的步骤(2)中的加热是指将玻璃纤维材料置于200～240℃的平板烘箱中加热至软化。
10.根据权利要求7所述的一种汽车用玻璃纤维零件的制备方法，其特征在于，该方法还包括采用热板焊接设备将定位塑料件焊接在无纺布的下表面，其中，每个定位塑料件的焊接温度为250～270℃，焊接时间为3～8s，冷却时间为20～30s。
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