CN107031126A - 行李箱承载地毯及其生产工艺 - Google Patents

行李箱承载地毯及其生产工艺 Download PDF

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CN107031126A
CN107031126A CN201710108435.1A CN201710108435A CN107031126A CN 107031126 A CN107031126 A CN 107031126A CN 201710108435 A CN201710108435 A CN 201710108435A CN 107031126 A CN107031126 A CN 107031126A
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carpet
plates
luggage case
decorative layer
edge
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龙踏青
王辉
朱少泽
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Dongfeng Faurecia Automotive Interior Co Ltd
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Dongfeng Faurecia Automotive Interior Co Ltd
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Abstract

本发明涉及汽车零部件制造领域，公开了一种行李箱承载地毯及其生产工艺，行李箱承载地毯从上到下依次由毯面装饰层、玻纤增强PP板、支撑骨架、玻纤增强PP板和无纺布层组成。本发明行李箱承载地毯强度高，具有良好的高温使用性能和VOC释放水平，其生产工艺生产效率高，且减少了胶黏剂使用，安全环保。

Description

行李箱承载地毯及其生产工艺
技术领域
本发明属于汽车零部件制造领域，特别涉及一种行李箱承载地毯及其生产工艺。
背景技术
行李箱地毯安放在汽车行李箱内，随着汽车技术的发展，行李箱内地毯的功能作用日益丰富，除了起到美观装饰作用外，还需要有隔音、承载等作用，通过位置的高低可调、结构的伸展和叠放，创造丰富而多变的装载空间，且随着SUV产品的持续火热，对行李箱地毯的承载能力要求越来越高，尤其是在行李厢内可变化位置的隔板类，需要有高强度，高模量，高刚度。
但现有的行李箱承载地毯，通常使用如下三种骨架结构作为支撑层：
第一种是使用PP蜂窝板作为支撑结构，强度较低，承载能力较差，容易变形，在长期使用后残留变形较大，且需要双面喷胶进行粘结，生产工艺复杂；
第二种是使用纸蜂窝板表面喷涂玻璃纤维增强的硬质聚氨酯作为支撑层，此种结构热态机械性能较差，在高温环境使用后，残余形变较大，且硬质发泡产品的固化时间较长，生产效率较低；
第三种是使用GMT片材作为支撑层，此种结构由于玻纤长度较短，导致连续程度较差，高温状态下使用蠕动变形明显，长期使用不可逆变形较大。
因此，需要一种行李箱承载地毯，强度高，具有良好的高温使用性能和VOC释放水平，且生产效率高，在生产过程中减少胶黏剂的使用。
发明内容
本发明的目的就是要提供一种行李箱承载地毯，强度高，具有良好的高温使用性能和VOC释放水平。
为实现上述目的，本发明所设计的行李箱承载地毯，从上到下依次由毯面装饰层、玻纤增强PP板、支撑骨架、玻纤增强PP板和无纺布层组成。
优选地，所述毯面装饰层为PET针刺毯面，所述毯面装饰层单位面积质量为300～850g/m2。
优选地，所述玻纤增强PP板由PP膜和玻纤布通过层叠方式交替铺放热压而成，共铺放7～15层，其中上下底面均为PP膜，所述PP膜单位面积质量为100～180g/m2，所述玻纤布单位面积质量为100～180g/m2，所述玻纤增强PP板单位面积质量为1120～1800g/m2。
优选地，所述支撑骨架厚度为10～30mm，单位面积质量为1200～1800g/m2。
优选地，所述支撑骨架为蜂窝板支撑骨架。
优选地，所述支撑骨架为瓦楞板支撑骨架。
优选地，所述无纺布层为针刺无纺布层，所述无纺布层单位面积质量为50～100g/m2。
优选地，两角上布置有带有弹簧结构的缓冲块，能够将地毯卡紧，避免行车过程中的振动导致行李箱承载地毯的移动以及摩擦异响。
一种生产上述行李箱承载地毯的生产工艺，包括如下步骤：
A.将所述玻纤增强PP板、所述支撑骨架、所述玻纤增强PP板和所述无纺布层按顺序叠放，通过加热后复合到一起，形成板材，加热后所述玻纤增强PP板的PP树脂熔融后，具有良好的粘结作用，能将所述支撑骨架和所述无纺布层融成整体，其中，加热温度为180～220℃，加热时间为40～60s，压制压力为10～20T，冷却时间为10～20s，上压板模温为25～40℃，下压板模温为25～40℃，形成板材后，将其切割成要求尺寸，形成CMT板；
B.将所述毯面装饰层切割成要求尺寸，然后将其铺放在成型剪切模的下模上，其中，所述成型剪切模下刀口可以上下浮动，所述下刀口下压压住所述毯面装饰层四周；
C.将所述步骤A制成的所述CMT板放置在特氟龙传送带上，移入接触式烘箱中加热，所述特氟龙能确保所述CMT板不粘贴在下板上不易取出，其中上板温度为200～260℃，下板温度为200～260℃，加热时间为50～180s；
D.将所述步骤C加热好的所述CMT板，放入所述成型剪切模中，进行热压成型，并同时在模具内完成扣手的安装孔孔位及CMT板周圈切割，然后由上下刀口配合将两层所述玻纤增强PP板进行封边，保证内部的所述支撑骨架被包裹在里面，不裸露在外，防止水汽浸入受潮，导致强度降低，开模后，所述下刀口上升，取出周圈毯面装饰层未切割的半成品，其中，热压成型上、下模模温均为20～30℃，保压压力为50～65T，保压时间为10～20s，加热后的所述CMT板中的PP树脂熔融后具有良好的粘贴性，在热压成型过程中所述CMT板能够和所述毯面装饰层进行良好粘贴，不需要使用任何胶黏剂，所述成型剪切模下刀口与下模之间设置有3～4mm的间隙，能切断周圈的所述CMT板但不切割所述毯面装饰层，并提供足够压力保证所述CMT板和所述毯面装饰层的粘贴；
E.使用刀片切割模对所述步骤D中的周圈毯面装饰层进行切割，切出包边用的预留边，其中，切割压力为30～40T，保压时间为5～10s；
F.在所述步骤E中包边用的预留边区域喷涂水性包边胶，使用折边包边工装进行包边，折边包边工装上板使用气缸带动，可上下活动，上板上有红外加热灯管，对喷涂水性包边胶的包边区域进行加热活化，其中加热时间为10～15s，加热温度为140～160℃，折边包边工装下板上四周带有仿形的由气缸带动的包边仿形块，当上板压下后，切割出的所述毯面装饰层翻折，仿形块侧入将所述毯面装饰层压入并和反面所述无纺布层粘贴到一起；
G.使用安装工装进行扣手及所述缓冲块的安装，检查后粘贴标签，得到成品。
优选地，在所述步骤D中，通过剪切方式，将粘合的毯面装饰层和CMT板一起切断，形成通孔。
本发明行李箱承载地毯强度高，具有良好的高温使用性能和VOC释放水平；同时，本发明行李箱承载地毯生产工艺，生产效率高，减少了胶黏剂的使用，安全环保。
附图说明
图1为本发明行李箱承载地毯的组成结构示意图；
图2为本发明行李箱承载地毯的外形结构示意图。
图中各部件标号如下：
毯面装饰层1、玻纤增强PP板2、支撑骨架3、无纺布层4、缓冲块5、扣手6。
具体实施方式
下面结合附图和实施例对本发明作进一步的详细说明，便于更清楚地了解本发明，但它们不对本发明构成限定。
行李箱承载地毯实施例1
如图1所示的行李箱承载地毯，从上到下依次由毯面装饰层1、玻纤增强PP板2、支撑骨架3、玻纤增强PP板2和无纺布层4组成，其中，毯面装饰层1为PET针刺毯面，毯面装饰层1单位面积质量为300g/m2，玻纤增强PP板2由PP膜和玻纤布通过层叠方式交替铺放热压而成，共铺放15层，其中上下底面均为PP膜，PP膜单位面积质量为100g/m2，玻纤布单位面积质量为100g/m2，玻纤增强PP板2单位面积质量为1500g/m2，支撑骨架3厚度为10mm，单位面积质量为1200g/m2，支撑骨架3为蜂窝板支撑骨架3，无纺布层4为针刺无纺布层4，无纺布层4单位面积质量为50g/m2。
另外，两角上布置有带有弹簧结构的缓冲块5，能够将地毯卡紧，避免行车过程中的振动导致行李箱承载地毯的移动以及摩擦异响。
行李箱承载地毯实施例2
如图1所示的行李箱承载地毯，从上到下依次由毯面装饰层1、玻纤增强PP板2、支撑骨架3、玻纤增强PP板2和无纺布层4组成，其中，毯面装饰层1为PET针刺毯面，毯面装饰层1单位面积质量为850g/m2，玻纤增强PP板2由PP膜和玻纤布通过层叠方式交替铺放热压而成，共铺放7层，其中上下底面均为PP膜，PP膜单位面积质量为180g/m2，玻纤布单位面积质量为180g/m2，玻纤增强PP板2单位面积质量为1260g/m2，支撑骨架3厚度为30mm，单位面积质量为1800g/m2，支撑骨架3为瓦楞板支撑骨架3，无纺布层4为针刺无纺布层4，无纺布层4单位面积质量为100g/m2。
另外，两角上布置有带有弹簧结构的缓冲块5，能够将地毯卡紧，避免行车过程中的振动导致行李箱承载地毯的移动以及摩擦异响。
行李箱承载地毯实施例3
如图1所示的行李箱承载地毯，从上到下依次由毯面装饰层1、玻纤增强PP板2、支撑骨架3、玻纤增强PP板2和无纺布层4组成，其中，毯面装饰层1为PET针刺毯面，毯面装饰层1单位面积质量为550g/m2，玻纤增强PP板2由PP膜和玻纤布通过层叠方式交替铺放热压而成，共铺放11层，其中上下底面均为PP膜，PP膜单位面积质量为160g/m2，玻纤布单位面积质量为140g/m2，玻纤增强PP板2单位面积质量为1660g/m2，支撑骨架3厚度为20mm，单位面积质量为1500g/m2，支撑骨架3为瓦楞板支撑骨架3，无纺布层4为针刺无纺布层4，无纺布层4单位面积质量为80g/m2。
另外，两角上布置有带有弹簧结构的缓冲块5，能够将地毯卡紧，避免行车过程中的振动导致行李箱承载地毯的移动以及摩擦异响。
行李箱承载地毯生产工艺实施例1
A.将玻纤增强PP板2、支撑骨架3、玻纤增强PP板2和无纺布层4按顺序叠放，通过加热后复合到一起，形成板材，其中，加热温度为180℃，加热时间为40s，压制压力为10T，冷却时间为10s，上压板模温为25℃，下压板模温为25℃，形成板材后，将其切割成要求尺寸，形成CMT板；
B.将毯面装饰层1切割成要求尺寸，然后将其铺放在成型剪切模的下模上，其中，成型剪切模下刀口可以上下浮动，下刀口下压压住毯面装饰层1四周；
C.将步骤A制成的CMT板放置在特氟龙传送带上，移入接触式烘箱中加热，其中上板温度为200℃，下板温度为200℃，加热时间为50s；
D.将步骤C加热好的CMT板，放入成型剪切模中，进行热压成型，并同时在模具内完成扣手6的安装孔孔位及CMT板周圈切割，并通过剪切方式，将粘合的毯面装饰层1和CMT板一起切断，形成通孔，然后由上下刀口配合将两层玻纤增强PP板2进行封边，开模后，下刀口上升，取出周圈毯面装饰层1未切割的半成品，其中，热压成型上、下模模温均为20℃，保压压力为50T，保压时间为10s，成型剪切模下刀口与下模之间设置有3mm的间隙；
E.使用刀片切割模对步骤D中的周圈毯面装饰层1进行切割，切出包边用的预留边，其中，切割压力为30T，保压时间为5s；
F.在步骤E中包边用的预留边区域喷涂水性包边胶，使用折边包边工装进行包边，折边包边工装上板使用气缸带动，可上下活动，上板上有红外加热灯管，对喷涂水性包边胶的包边区域进行加热活化，其中加热时间为10s，加热温度为140℃，折边包边工装下板上四周带有仿形的由气缸带动的包边仿形块，当上板压下后，切割出的毯面装饰层1翻折，仿形块侧入将毯面装饰层1压入并和反面无纺布层4粘贴到一起；
G.使用安装工装进行扣手5及缓冲块6的安装，检查后粘贴标签，得到成品。
行李箱承载地毯生产工艺实施例2
A.将玻纤增强PP板2、支撑骨架3、玻纤增强PP板2和无纺布层4按顺序叠放，通过加热后复合到一起，形成板材，其中，加热温度为220℃，加热时间为60s，压制压力为20T，冷却时间为20s，上压板模温为40℃，下压板模温为40℃，形成板材后，将其切割成要求尺寸，形成CMT板；
B.将毯面装饰层1切割成要求尺寸，然后将其铺放在成型剪切模的下模上，其中，成型剪切模下刀口可以上下浮动，下刀口下压压住毯面装饰层1四周；
C.将步骤A制成的CMT板放置在特氟龙传送带上，移入接触式烘箱中加热，其中上板温度为260℃，下板温度为260℃，加热时间为180s；
D.将步骤C加热好的CMT板，放入成型剪切模中，进行热压成型，并同时在模具内完成扣手6的安装孔孔位及CMT板周圈切割，并通过剪切方式，将粘合的毯面装饰层1和CMT板一起切断，形成通孔，然后由上下刀口配合将两层玻纤增强PP板2进行封边，开模后，下刀口上升，取出周圈毯面装饰层1未切割的半成品，其中，热压成型上、下模模温均为30℃，保压压力为65T，保压时间为20s，成型剪切模下刀口与下模之间设置有4mm的间隙；
E.使用刀片切割模对步骤D中的周圈毯面装饰层1进行切割，切出包边用的预留边，其中，切割压力为40T，保压时间为10s；
F.在步骤E中包边用的预留边区域喷涂水性包边胶，使用折边包边工装进行包边，折边包边工装上板使用气缸带动，可上下活动，上板上有红外加热灯管，对喷涂水性包边胶的包边区域进行加热活化，其中加热时间为15s，加热温度为160℃，折边包边工装下板上四周带有仿形的由气缸带动的包边仿形块，当上板压下后，切割出的毯面装饰层1翻折，仿形块侧入将毯面装饰层1压入并和反面无纺布层4粘贴到一起；
G.使用安装工装进行扣手6及缓冲块5的安装，检查后粘贴标签，得到成品。
行李箱承载地毯生产工艺实施例3
A.将玻纤增强PP板2、支撑骨架3、玻纤增强PP板2和无纺布层4按顺序叠放，通过加热后复合到一起，形成板材，其中，加热温度为200℃，加热时间为50s，压制压力为15T，冷却时间为15s，上压板模温为35℃，下压板模温为30℃，形成板材后，将其切割成要求尺寸，形成CMT板；
B.将毯面装饰层1切割成要求尺寸，然后将其铺放在成型剪切模的下模上，其中，成型剪切模下刀口可以上下浮动，下刀口下压压住毯面装饰层1四周；
C.将步骤A制成的CMT板放置在特氟龙传送带上，移入接触式烘箱中加热，其中上板温度为230℃，下板温度为220℃，加热时间为100s；
D.将步骤C加热好的CMT板，放入成型剪切模中，进行热压成型，并同时在模具内完成扣手6的安装孔孔位及CMT板周圈切割，并通过剪切方式，将粘合的毯面装饰层1和CMT板一起切断，形成通孔，然后由上下刀口配合将两层玻纤增强PP板2进行封边，开模后，下刀口上升，取出周圈毯面装饰层1未切割的半成品，其中，热压成型上、下模模温均为25℃，保压压力为60T，保压时间为15s，成型剪切模下刀口与下模之间设置有3.5mm的间隙；
E.使用刀片切割模对步骤D中的周圈毯面装饰层1进行切割，切出包边用的预留边，其中，切割压力为35T，保压时间为8s；
F.在步骤E中包边用的预留边区域喷涂水性包边胶，使用折边包边工装进行包边，折边包边工装上板使用气缸带动，可上下活动，上板上有红外加热灯管，对喷涂水性包边胶的包边区域进行加热活化，其中加热时间为13s，加热温度为150℃，折边包边工装下板上四周带有仿形的由气缸带动的包边仿形块，当上板压下后，切割出的毯面装饰层1翻折，仿形块侧入将毯面装饰层1压入并和反面无纺布层4粘贴到一起；
G.使用安装工装进行扣手6及缓冲块5的安装，检查后粘贴标签，得到成品。
本发明行李箱承载地毯强度高，具有良好的高温使用性能和VOC释放水平；同时，本发明行李箱承载地毯生产工艺，生产效率高，减少了胶黏剂的使用，安全环保。

Claims (10)

1.一种行李箱承载地毯，其特征在于：从上到下依次由毯面装饰层、玻纤增强PP板、支撑骨架、玻纤增强PP板和无纺布层组成。
2.根据权利要求1所述行李箱承载地毯，其特征在于：所述毯面装饰层为PET针刺毯面，所述毯面装饰层单位面积质量为300～850g/m2。
3.根据权利要求1所述行李箱承载地毯，其特征在于：所述玻纤增强PP板由PP膜和玻纤布通过层叠方式交替铺放热压而成，共铺放7～15层，其中上下底面均为PP膜，所述PP膜单位面积质量为100～180g/m2，所述玻纤布单位面积质量为100～180g/m2，所述玻纤增强PP板单位面积质量为1120～1800g/m2。
4.根据权利要求1所述行李箱承载地毯，其特征在于：所述支撑骨架厚度为10～30mm，单位面积质量为1200～1800g/m2。
5.根据权利要求1所述行李箱承载地毯，其特征在于：所述支撑骨架为蜂窝板支撑骨架。
6.根据权利要求1所述行李箱承载地毯，其特征在于：所述支撑骨架为瓦楞板支撑骨架。
7.根据权利要求1所述行李箱承载地毯，其特征在于：所述无纺布层为针刺无纺布层，所述无纺布层单位面积质量为50～100g/m2。
8.根据权利要求1所述行李箱承载地毯，其特征在于：两角上布置有带有弹簧结构的缓冲块。
9.一种生产权利要求1～8中任一项所述行李箱承载地毯的生产工艺，其特征在于，包括如下步骤：
A.将所述玻纤增强PP板、所述支撑骨架、所述玻纤增强PP板和所述无纺布层按顺序叠放，通过加热后复合到一起，形成板材，其中，加热温度为180～220℃，加热时间为40～60s，压制压力为10～20T，冷却时间为10～20s，上压板模温为25～40℃，下压板模温为25～40℃，形成板材后，将其切割成要求尺寸，形成CMT板；
B.将所述毯面装饰层切割成要求尺寸，然后将其铺放在成型剪切模的下模上，其中，所述成型剪切模下刀口可以上下浮动，所述下刀口下压压住所述毯面装饰层四周；
C.将所述步骤A制成的所述CMT板放置在特氟龙传送带上，移入接触式烘箱中加热，其中上板温度为200～260℃，下板温度为200～260℃，加热时间为50～180s；
D.将所述步骤C加热好的所述CMT板，放入所述成型剪切模中，进行热压成型，并同时在模具内完成扣手的安装孔孔位及所述CMT板周圈切割，然后由上下刀口配合将两层所述玻纤增强PP板进行封边，开模后，所述下刀口上升，取出周圈毯面装饰层未切割的半成品，其中，热压成型上、下模模温均为20～30℃，保压压力为50～65T，保压时间为10～20s，所述成型剪切模下刀口与下模之间设置有3～4mm的间隙；
E.使用刀片切割模对所述步骤D中的所述周圈毯面装饰层进行切割，切出包边用的预留边，其中，切割压力为30～40T，保压时间为5～10s；
F.在所述步骤E中包边用的预留边区域喷涂水性包边胶，使用折边包边工装进行包边，折边包边工装上板使用气缸带动，可上下活动，上板上有红外加热灯管，对喷涂水性包边胶的包边区域进行加热活化，其中加热时间为10～15s，加热温度为140～160℃，折边包边工装下板上四周带有仿形的由气缸带动的包边仿形块，当上板压下后，切割出的所述毯面装饰层翻折，仿形块侧入将所述毯面装饰层压入并和反面所述无纺布层粘贴到一起；
G.使用安装工装进行扣手及所述缓冲块的安装，检查后粘贴标签，得到成品。
10.根据权利要求9所述行李箱承载地毯的生产工艺，其特征在于：在所述步骤D中，通过剪切方式，将粘合的毯面装饰层和CMT板一起切断，形成通孔。
CN201710108435.1A 2017-02-27 2017-02-27 行李箱承载地毯及其生产工艺 Pending CN107031126A (zh)

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