CN107415351A - 一种具有聚丙烯编织物面层的纤维增强聚合物毡材及其复合板材与制备方法 - Google Patents

一种具有聚丙烯编织物面层的纤维增强聚合物毡材及其复合板材与制备方法 Download PDF

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CN107415351A
CN107415351A CN201710326827.5A CN201710326827A CN107415351A CN 107415351 A CN107415351 A CN 107415351A CN 201710326827 A CN201710326827 A CN 201710326827A CN 107415351 A CN107415351 A CN 107415351A
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fiber
fibre
polypropylene woven
object plane
felt
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刘雪强
蒋剡
李志刚
潘国立
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CHANGCHUN BOCHAO AUTO ACCESSORIES Co Ltd
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CHANGCHUN BOCHAO AUTO ACCESSORIES Co Ltd
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Abstract

本发明公开了一种具有聚丙烯编织物面层的纤维增强聚合物毡材及其复合板材与制备方法，属于汽车材料设计制造领域。本发明中改进的粘接层是把传统的聚丙烯薄膜变成聚丙烯编织布，并通过针刺的方式与纤维复合毡交联到一起。复合板材成型工艺为直接把毡材和面装饰层进行接触式加热，然后置于模具中模压成型，其中聚丙烯编织布起到粘接作用。该发明通过直接把聚丙烯编织布针刺组装在纤维增强基材上，制备成复合毡材，并可以直接利用该毡材和面饰层进行一次性加工成型复合板材，减少了成型工序，降低了生产成本，而且聚丙烯编织布对复合板材的强度和刚度起到增强作用，同时还对纤维增强基材起到封装作用，降低了VOC的释放。

Description

一种具有聚丙烯编织物面层的纤维增强聚合物毡材及其复合 板材与制备方法
技术领域
本发明属于汽车材料设计制造领域。
背景技术
近年来，环保、低易挥发性小分子有机物(VOC)含量、低成本在纤维增强复合材料领域已深入人心，天然纤维以其生态环保、可降解等优良特性被广泛应用，并被广泛应用于汽车内饰材料。但是天然麻纤维在加工和使用过程中，由于外部因素的变化，使得麻纤维表面残留的果胶、半纤维素、木质素等物质分解生成甲醛、乙醛、丙烯醛、苯、甲苯、苯乙烯等对人体有害的易挥发性小分子有机物(VOC)。另外，复合材料基体热塑性树脂在加工和使用过程中，也会在产生部分酮类、醛类低分子等有机化合物。并且汽车内饰用天然纤维增强复合材料产品一般与人体有直接或间接的接触，并处在相对封闭的环境中，这些易挥发的小分子有机物会对使用者的健康造成严重的危害，从而制约了汽车内饰用天然纤维复合材料的应用和发展。因此，如何减少VOC的排放将是行业发展面临的主要问题。
另外，现有的纤维增强基材与面饰层之间，一般采用聚丙烯(PP)纤维薄膜，复合到基材上，起到粘接作用，但存在成本高，需要二次加热，且存在粘接不牢等问题；或者直接涂抹胶，使之粘接在一起，存在外源胶的引入，从而增加了VOC排放源。因此，如何降低生产成本，提高生产效率将是该种材料产业化发展必须解决的难题。
发明内容
为了克服上述技术问题，本发明提出了一种具有聚丙烯编织物面层的纤维增强聚合物毡材，为两层聚丙烯编织物与中间所夹的混合纤维毡层组成的；两层聚丙烯编织物与混合纤维毡通过纤维勾连相互连接在一起；所述混合纤维毡层为增强纤维和树脂纤维的混合纤维毡，其中，增强纤维为经过脱胶处理的天然麻纤维、经过柔顺处理的玻璃纤维、经过精梳理处理的碳纤维和玄武岩纤维中的一种；树脂纤维为聚丙烯或聚乳酸纤维。
在具有聚丙烯编织物面层的纤维增强聚合物毡材的基础上增加面饰层则得到具有聚丙烯编织物面层的纤维增强聚合物复合板材
一种具有聚丙烯编织物面层的纤维增强聚合物毡材及其板材的制备方法具体如下：
1)增强纤维和树脂纤维进行混合制毡得到混合纤维毡；其中增强纤维所占重量比优选为30％～70％，树脂纤维为70％～30％。
2)将聚丙烯编织物置于混合纤维毡的上下表面，通过针刺使混合纤维毡与聚丙烯编织物中的纤维钩连在一起得到具有聚丙烯编织物面层的纤维增强聚合物毡材；聚丙烯编织物和混合纤维毡的厚度比优选为1:(8～10)。
3)把面饰层与具有聚丙烯编织物面层的纤维增强聚合物毡材一起置于模具中，在树脂纤维的熔融温度以上10～20℃的温度条件下，热压成型，得到具有聚丙烯编织物面层的纤维增强聚合物复合板材。
步骤1)中根据增强纤维和树脂纤维的表面极性性质选择对增强纤维进行改性处理，提高界面结合性。改性处理的具体可采用表面接枝法。
本发明的有效果：
环保性能好、质量轻、刚度强度高、加工工艺简单、低成本、用途广泛。可广泛应用于汽车内饰件、家具装饰、包装等领域，具有良好的应用前景，是一种环保轻质多功能的新型复合材料。
附图说明
图1带粘接层的纤维增强毡材及其复合板材制备方法示意图。
图2带粘接层的纤维增强毡材示意图；
图3具有聚丙烯编织物面层的纤维增强聚合物复合板材示意图。
附图标记：1-聚丙烯编织物、2-增强纤维和树脂纤维的混合纤维毡、3-面饰层。
具体实施方式
实施例1汉麻纤维
如图1～3所示，首先把汉麻纤维进行脱胶处理，再对汉麻纤维进行接枝处理，改善其表面极性，然后把汉麻纤维和聚丙烯纤维进行梳理混合，通过制毡设备制备混合纤维毡，接着把聚丙烯编织布安放在纤维毡材两侧，进行针刺处理，通过针刺勾连的作用，使丙烯编织布与混合纤维毡之间充分连接，经过定型设备制备成具有聚丙烯编织物面层的纤维毡材。其中接枝处理，采用1wt％的马来酸酐溶液，对汉麻进行浸泡。混合纤维毡中的比例为汉麻纤维40wt％和树脂纤维60wt％，聚丙烯编织布与混合纤维毡的厚度比例1:10。
复合板材的制备工艺，利用此毡材，进行加热，在聚丙烯熔融温度以上10～20℃的温度条件下，把加热至半熔融状态的毡材置于模具中，再把面饰层置于模具中，进过加压模压成型，一次性制备汽车内饰用零部件。
并经测试，利用该工艺制备出来的板材，由于加设了聚丙烯编织布起到了增强的作用，其力学性能提升了5～20％。同时，由于聚丙烯编织布的封装作用，其VOC释放量维持在一个很低的水平，比传统方式的VOC释放量减低了80％。
实施例2玻璃纤维
首先把玻璃纤维进行柔顺处理，再对玻璃纤维进行接枝处理，然后把玻璃纤维和聚丙烯纤维进行梳理混合，制备混合纤维毡，接着把聚丙烯编织布安放在纤维毡材两侧，进行针刺处理，制备成具有聚丙烯编织物面层的纤维毡材。混合纤维毡中的比例为玻璃纤维60wt％和树脂纤维40wt％，聚丙烯编织布与混合纤维毡的厚度比例1:10。
复合板材的制备工艺，利用此毡材，进行加热，在聚丙烯熔融温度以上10～20℃的温度条件下，把加热至半熔融状态的毡材置于模具中，再把面饰层置于模具中，经过加压，一次性模压成型。
并经测试，利用该工艺制备出来的板材，由于加设了聚丙烯编织布起到了增强的作用，其力学性能提升了10～30％。同时，由于聚丙烯编织布的封装作用，且其增强纤维为玻璃纤维，其VOC释放量维持在一个更低的水平，比传统方式的VOC释放量减低了90％。
实施例3碳纤维
首先把碳纤维进行精梳理处理，再对碳纤维进行接枝处理，然后把碳纤维和聚丙烯纤维进行梳理混合，制备混合纤维毡，接着把聚丙烯编织布安放在纤维毡材两侧，进行针刺处理，制备成具有聚丙烯编织物面层的纤维毡材。混合纤维毡中的比例为碳纤维30wt％和树脂纤维70wt％，聚丙烯编织布与混合纤维毡的厚度比例1:8。
复合板材的制备工艺，利用此毡材，进行加热，在聚丙烯熔融温度以上10～20℃的温度条件下，把加热至半熔融状态的毡材置于模具中，再把面饰层置于模具中，经过加压，一次性模压成型。
并经测试，利用该工艺制备出来的板材，由于加设了聚丙烯编织布起到了增强的作用，其力学性能提升了40～60％。同时，由于聚丙烯编织布的封装作用，且其增强纤维为碳纤维，其VOC释放量维持在一个更低的水平，比传统方式的VOC释放量减低了90％。
经测试，利用该工艺制备出来的板材，综合性能都得到了提升，且实现了低成本、高效率、低VOC的一种新制备工艺。
本发明中聚丙烯纤维也可采用聚乳酸纤维代替。

Claims (10)

1.一种具有聚丙烯编织物面层的纤维增强聚合物毡材，其特征在于，该毡材由两层聚丙烯编织物与中间所夹的混合纤维毡层组成；两层聚丙烯编织物与混合纤维毡通过纤维勾连相互连接在一起；所述混合纤维毡层为增强纤维和树脂纤维的混合纤维毡，其中，增强纤维为经过脱胶处理的天然麻纤维、经过柔顺处理的玻璃纤维、经过精梳理处理的碳纤维和玄武岩纤维中的一种；树脂纤维为聚丙烯纤维或聚乳酸纤维。
2.根据权利要求1所述的一种具有聚丙烯编织物面层的纤维增强聚合物毡材，其特征在于，聚丙烯编织物和混合纤维毡的厚度比为1:(8～10)。
3.根据权利要求1所述的一种具有聚丙烯编织物面层的纤维增强聚合物毡材，其特征在于，混合纤维毡中增强纤维的重量百分比为30％～70％，树脂纤维为70％-30％。
4.一种具有聚丙烯编织物面层的纤维增强聚合物复合板材，其特征在于，所述板材由具有聚丙烯编织物面层的纤维增强聚合物毡材和面饰层构成。
5.一种权利要求1所述的具有聚丙烯编织物面层的纤维增强聚合物毡材的制备方法，具体步骤如下：
1)增强纤维和树脂纤维进行混合制毡得到混合纤维毡；
2)将聚丙烯编织物置于混合纤维毡的上下表面，通过针刺使混合纤维毡与聚丙烯编织物中的纤维钩连在一起得到具有聚丙烯编织物面层的纤维增强聚合物毡材；
其中，增强纤维为经过脱胶处理的天然麻纤维、经过柔顺处理的玻璃纤维、经过精梳理处理的碳纤维和玄武岩纤维中的一种；树脂纤维为聚丙烯纤维或聚乳酸纤维。
6.根据权利要求5所述的一种具有聚丙烯编织物面层的纤维增强聚合物毡材的制备方法，其特征在于，步骤1)中根据增强纤维和树脂纤维的表面极性性质选择对增强纤维进行改性处理。
7.根据权利要求5所述的一种具有聚丙烯编织物面层的纤维增强聚合物毡材的制备方法，其特征在于，步骤1)中增强纤维的重量百分比为30％～70％，树脂纤维为70％-30％。
8.根据权利要求5所述的一种具有聚丙烯编织物面层的纤维增强聚合物毡材的制备方法，其特征在于，聚丙烯编织物和混合纤维毡的厚度比为1:8～10。
9.根据权利要求6所述的一种具有聚丙烯编织物面层的纤维增强聚合物毡材的制备方法，其特征在于，改性处理法为表面接枝法。
10.一种权利要求4所述的具有聚丙烯编织物面层的纤维增强聚合物复合板材的制备方法，具体步骤如下：
把面饰层与具有聚丙烯编织物面层的纤维增强聚合物毡材一起置于模具中，在树脂纤维的熔融温度以上10～20℃的温度条件下，热压成型，得到具有聚丙烯编织物面层的纤维增强聚合物复合板材。
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