CN107107550A - 用于制备具有真实碳外观的装饰件的方法 - Google Patents

用于制备具有真实碳外观的装饰件的方法 Download PDF

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CN107107550A
CN107107550A CN201580061805.XA CN201580061805A CN107107550A CN 107107550 A CN107107550 A CN 107107550A CN 201580061805 A CN201580061805 A CN 201580061805A CN 107107550 A CN107107550 A CN 107107550A
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carbon fiber
fiber layer
decoration
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B·凯勒
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Hib- Antrim Parts Solutions & Co KG GmbH
HIB Trim Part Solutions GmbH
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Abstract

本发明涉及用于制备车辆的具有真实碳外观的装饰件的方法，所述装饰件具有设置在装饰件的可见侧并且从外部可见的碳纤维层，所述碳纤维层通过具有中间空间的预制碳纤维的纤维结构体形成并且特别经历如下方法步骤而得到：用基于聚氨酯、丙烯酸酯或聚乙酸乙烯酯或其混合物的含水聚合物分散液湿浸渍预制的碳纤维层，使得聚合物分散液至少部分地浸入碳纤维层并且提高漆浸入碳层的纤维结构体的中间空间的能力。

Description

用于制备具有真实碳外观的装饰件的方法
技术领域
本发明涉及用于制备车辆的具有真实碳外观的装饰件(Zierteil)的方法，所述装饰件具有设置在装饰件的可见侧并且从外部可见的碳纤维层。
背景技术
碳纤维和碳纤维层在车辆制造中主要用于纤维复合构件。其提供高刚性和低重量的优点并且充当钢制构件和铝制构件的替代物或补充物。通常地，碳纤维或碳纤维层包含所谓的胶料(涂料)或基于反应性环氧树脂的浸渍料，所述胶料或浸渍料作为基质材料在之后的高压处理过程中进行自由基聚合。
除了用于纤维复合构件之外，例如在车辆内部的装饰件/装饰板中，碳纤维和碳纤维层还被用作纯可见碳。用作可见碳的碳纤维和碳纤维层不同于纤维复合构件，因为其不进行高压处理也不进行浸渍，而是以未处理方式施加在至少由合成材料形成的载体结构上并且被透明的面漆层覆盖。
在此发现的问题是，面漆层的表面在施加之后总是具有可见的不平坦性(波纹)或不平整性，只有通过密集且费时的抛光才能磨平从而改进外观。或者必须施加第二面漆层，但是这浪费材料、提高成本并且费时，因为必须首先干燥第一漆层。
发现漆层表面的不平坦性或不平整性的原因是：清漆在施加至碳纤维层时不能充分填充存在于碳纤维或碳纤维束之间并且被空气填充的中间空间，并且在漆的干燥阶段的过程中这些夹带空气间接地影响表面品质。在此，由于温度波动造成的空气体积变化或空气移动和气体析出特别起着突出作用。
发明内容
因此本发明所基于的目的是提供一种方法，通过所述方法可以用于制备车辆的具有可见碳外观和改进表面漆品质的装饰件。
通过根据权利要求1和2的特征组合实现所述目的。
根据本发明，预先用聚合物分散液湿浸渍用于施加在可见侧并且从外部可见的打磨的碳纤维层，从而改进漆(特别是清漆)至碳纤维或碳纤维束的中间空间的浸入并且减少空气析出的倾向。由此还可以免去目前需要的底漆施加。
根据本发明，用于制备具有真实碳外观的装饰件(所述装饰件具有设置在装饰件的可见侧并且从外部可见的打磨的碳纤维层，所述碳纤维层通过具有中间空间的预制碳纤维的纤维结构体形成)的方法包括如下方法步骤：用基于聚氨酯、丙烯酸酯或聚乙酸乙烯酯或其混合物的含水聚合物分散液湿浸渍预制的打磨的碳纤维层，使得聚合物分散液至少部分地浸入碳纤维层并且提高漆浸入碳层的纤维结构体的中间空间的能力，然后干燥湿浸渍的碳纤维层。然后将碳纤维层固定在装饰件载体上并且与装饰件的可见侧对齐，并且在设置于装饰件载体上的碳纤维层上施加漆层从而在装饰件的可见侧上形成透明的表面层，使得漆浸入碳纤维层的中间空间。
用基于聚氨酯、丙烯酸酯或聚乙酸乙烯酯或其混合物的含水聚合物分散液湿浸渍预制的打磨的碳纤维层改变了碳纤维或碳纤维丝的表面结构，使得漆与碳纤维层交联而不会留下气穴。
替代性地，为了湿浸渍整个碳纤维层，在根据本发明的方法的替代性实施方案中，用基于聚氨酯、丙烯酸酯或聚乙酸乙烯酯或其混合物的含水聚合物分散液湿浸渍预制的打磨的碳纤维，然后干燥湿浸渍的碳纤维并且编织成碳纤维层，然后以与上述方法相同的方式对所述碳纤维层进行加工。
待使用的基于聚氨酯、丙烯酸酯或聚乙酸乙烯酯或其混合物的含水分散液具有1-70％，更优选10-60％，更优选25-50％的固体含量。
虽然对于可见碳零件来说基本上不常见，但是在一个实施方案变体中，碳纤维层在设置在装饰件载体上之前包含用于产生粘合的底漆层。
优选以制备过程一体化的方式将碳纤维层运送通过分散液浴从而湿浸渍，从而在具有相互连接的方法步骤的生产线上进行制备。在此以0.5-10m/min，优选1-2m/min的速度将碳纤维层输送通过分散液浴并且在其中经历10-60s的浸泡时间。湿浸渍以一定方式进行，使得碳纤维层取决于织物类型经历1-50g/m2，优选5至20g/m2的单位面积重量增加。
在湿浸渍之后有利地在干燥区段中在20-120℃，特别优选60-120℃的温度下进行干燥步骤。如同经过分散液浴那样，干燥区段允许在相同生产线内进行制备过程一体化的干燥。
在第一变体中通过层压将湿浸渍并且干燥的碳纤维层固定至装饰件载体。在第二变体中，在注塑方法中在碳纤维层上后注塑装饰件载体从而进行固定。在此还整合装饰件载体与固定至装饰件载体的碳纤维层的三维成型过程。使用所述聚合物分散液进行湿浸渍还改进了纤维增强和滑动增强并且减少了层压过程和成型过程中的碳纤维的纤维断裂倾向。
在一个有利的实施方案变体中，通过灌注碳纤维层从而施加漆层。漆层有利地由双组份聚氨酯浇注体系形成，其中可以使用芳族或脂族以及防晒和不防晒的聚氨酯漆。
当碳纤维以单纤维或纤维束或碳纤维织物卷材的形式以制备过程一体化的方式加工(即从卷展开、湿浸渍、干燥和重新缠绕至卷或者根据装饰件载体的尺寸修边从而将碳纤维层直接设置在装饰件载体上)时，所述方法可以特别低成本地实施。
在另一个实施方案变体中，碳纤维层还具有支撑织物，使得碳纤维层更容易加工和设置在装饰件载体上。
除了所述方法步骤之外还进行可能的步骤，例如在施加漆之后铣削装饰件以及抛光表面，其中由于使用根据本发明的方法因此大大减少了所需的抛光成本。
本发明的其它有利的实施方案参见从属权利要求。本发明的实施方案不限于上文所述的优选实施方案。可想到多种变体形式，这些变体形式即使在基本不同种类的实施方案中仍然利用所述解决方案。例如可以以手动或机械方式进行碳纤维层的层压。装饰件载体可以由注塑形成或者是木质层压板。

Claims (15)

1.一种用于制备车辆的具有真实碳外观的装饰件的方法，所述装饰件具有设置在装饰件的可见侧并且从外部可见的、打磨的碳纤维层，所述碳纤维层通过具有中间空间的预制碳纤维的纤维结构体形成，所述方法包括如下方法步骤：
-用基于聚氨酯、丙烯酸酯或聚乙酸乙烯酯或其混合物的含水聚合物分散液湿浸渍预制的、打磨的碳纤维层，使得聚合物分散液至少部分地浸入所述碳纤维层并且提高漆浸入碳层的纤维结构体的中间空间的能力，
-干燥湿浸渍的所述碳纤维层，
-将所述碳纤维层固定设置在装饰件载体上并且与所述装饰件的可见侧对齐，
-在设置于所述装饰件载体上的所述碳纤维层施加漆层从而在所述装饰件的可见侧上形成透明的表面层，其中漆浸入所述碳纤维层的中间空间。
2.一种用于制备车辆的具有真实碳外观的装饰件的方法，所述装饰件具有设置在装饰件的可见侧并且从外部可见的、打磨的碳纤维层，所述碳纤维层通过具有中间空间的预制碳纤维的纤维结构体形成，所述方法包括如下方法步骤：
-用基于聚氨酯、丙烯酸酯或聚乙酸乙烯酯或其混合物的含水聚合物分散液湿浸渍预制的、打磨的碳纤维，使得聚合物分散液至少部分地浸入所述碳纤维并且提高漆浸入碳层的纤维结构体的中间空间的能力，
-干燥湿浸渍的所述碳纤维，
-由湿浸渍并且干燥的所述碳纤维编织成碳纤维层，
-将所述碳纤维层固定设置在装饰件载体上并且与所述装饰件的可见侧对齐，
-在设置于所述装饰件载体上的所述碳纤维层施加漆层从而在所述装饰件的可见侧上形成透明的表面层，其中漆浸入所述碳纤维层的中间空间。
3.根据权利要求1或2所述的方法，其特征在于，含水分散液具有1-70％，特别是10-50％的固体含量。
4.根据前述权利要求任一项所述的方法，其特征在于，所述碳纤维层在设置在所述装饰件载体上之前包含用于产生粘合的底漆层。
5.根据前述权利要求任一项所述的方法，其特征在于，在干燥区段中在20-120℃，特别是60-120℃的温度下进行干燥直至低于1％的剩余水分。
6.根据前述权利要求任一项所述的方法，其特征在于，通过层压将所述碳纤维层固定至所述装饰件载体。
7.根据前述权利要求任一项所述的方法，其特征在于，在所述碳纤维层上后注塑所述装饰件载体。
8.根据前述权利要求任一项所述的方法，其特征在于，通过灌注所述碳纤维层从而施加所述漆层。
9.根据前述权利要求任一项所述的方法，其特征在于，以制备过程一体化的方式将所述碳纤维层运送通过分散液浴从而湿浸渍。
10.根据权利要求9所述的方法，其特征在于，以0.5-10m/min，特别是1-2m/min的速度将所述碳纤维层输送通过分散液浴并且在其中经历10-60s的浸泡时间。
11.根据前述权利要求任一项所述的方法，其特征在于，所述碳纤维层由单纤维、纤维束或碳纤维织物形成。
12.根据权利要求11所述的方法，其特征在于，单纤维、纤维束或碳纤维织物卷材以制备过程一体化的方式湿浸渍然后根据装饰件载体的尺寸修边从而将所述碳纤维层设置在装饰件载体上。
13.根据前述权利要求任一项所述的方法，其特征在于，所述漆层由双组份聚氨酯形成。
14.根据前述权利要求任一项所述的方法，其特征在于，所述碳纤维层还具有支撑织物。
15.根据前述权利要求至少一项制得的具有真实碳外观的装饰件。
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