CN107418100B - 一种汽车仪表板pvc搪塑表皮边角余料再利用方法 - Google Patents
一种汽车仪表板pvc搪塑表皮边角余料再利用方法 Download PDFInfo
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Abstract
本发明属于汽车仪表板技术领域,涉及一种PVC搪塑表皮再利用的方法,特别针对搪塑成型过程中产生的边角余料的再次利用加工方法。包括以下步骤:1、擦拭去油污;2、常温撕碎;3、液氮制冷、冷藏;4、粉碎;5、筛网过滤得到PVC搪塑再利用材料;6、按比例将粉碎的PVC搪塑再利用材料与搪塑原材料进行混合形成混合搪塑原料。本发明与现有处理方式相比,一方面可以减少环境污染,另一方面可以充分提升表皮边角余料的利用价值,减少汽车仪表板领域中搪塑原材料的进口需求。
Description
技术领域
本发明属于汽车仪表板技术领域,涉及一种PVC搪塑表皮再利用的方法,特别针对搪塑成型过程中产生的边角余料的再次利用加工方法。
背景技术
近几年,随着我国汽车工业的迅猛发展以及用户要求的提高,汽车仪表板产品的制造工艺也在不断地提髙与发展中。作为一种比较先进的工艺,粉末搪塑工艺产品因花纹均匀性好、无内应力、设计宽容度高等特点越来越受到企业的青睐,许多汽车零件制造商纷纷采用该工艺生产汽车仪表板表皮。但是汽车PVC搪塑表皮制造及后续加工过程中,会产生许多边角余料的浪费,PVC搪塑表皮的真实利用率仅为65%左右,剩余边角余料通常作为工业垃圾报废。目前中国市场的年汽车需求为2500万辆左右,而具有软质仪表板表皮的车辆需求约为每年1000万辆,其中绝大部分仪表板表皮为PVC粉末搪塑。由于汽车PVC搪塑表皮是一种不易降解的材料,边角余料的废弃对社会环境存在较大且长期的污染隐患。
另外,汽车仪表板用PVC原料价格昂贵,市场价值在每公斤40元左右,因此PVC搪塑表皮的边角余料回收再利用具有重要的社会意义及经济价值。但在搪塑领域存在的难点为,PVC搪塑表皮的PVC原料是一种十分细小的粉末颗粒,常规粉碎很难实现颗粒状态,另一方面,由于PVC搪塑表皮中微晶和大分子链缠结起到了物理交联点的作用,PVC搪塑表皮边角余料在粉碎过程中,高分子长链会破坏变短,有报道表明高分子聚合物在粉碎过程中分子量会损失20%左右,这将影响表皮的综合性能。目前仪表板搪塑领域尚未有关于PVC搪塑表皮边角余料循环再利用的相关报道。
发明内容
本发明借鉴中草药常用的低温破壁粉碎技术,将常温粉碎容易出现胶粘的PVC搪塑表皮借助低温环境进行粉碎,从而将PVC搪塑表皮边角余料还原为粉末状PVC原料。通过文献查询,高分子聚合物在低温粉碎过程中分子链尺寸会有一定程度上的破坏变短,其物理性能会受到一定程度的衰减,因此本发明需要进一步控制PVC搪塑表皮边角余料粉碎后的颗粒尺寸及添加比例,从而达到PVC搪塑表皮边角余料安全再利用的目的。
为进一步提升再利用产品的安全性能,本专利在仪表板气囊区域的表皮背面,喷涂一定厚度的聚氨酯涂料,由于聚氨酯材料的低温性能优于PVC材料,而PVC搪塑表皮爆破失效也常常发生在低温环境中,因此该涂料可以起到低温补强作用。同时该涂层的存在,可以整体降低表皮的成型厚度,从而进一步降低PVC搪塑表皮的重量,达到环保、降低成本的目的。
本发明是采用如下技术方案实现的,说明如下:
一种汽车仪表板PVC搪塑表皮边角余料再利用方法,包括以下步骤:
步骤1:擦拭去油污;
擦拭待粉碎PVC搪塑表皮边角余料,去除油脂及杂质;
步骤2:常温撕碎;
将擦拭干净的待粉碎PVC搪塑表皮边角余料使用撕碎机进行常温撕碎,撕碎后的颗粒尺寸不大于20mm;
步骤3:液氮制冷、冷藏;
将步骤2中的撕碎后的颗粒加入液氮制冷的冷藏料仓,冷藏料仓设置温度在-80℃到-100℃之间,冷藏设置时间为12到15分钟之间;
步骤4:粉碎;
将步骤3中按规定时间冷藏后的撕碎后的颗粒传送至冷藏粉碎机工作区粉碎成为冷藏粉碎后的材料,粉碎机主轴转速设置不高于500转/分钟;
步骤5:筛网过滤得到PVC搪塑再利用材料;
步骤4中所述冷藏粉碎后的材料粒径控制在80到120目之间,得到PVC搪塑再利用材料。
步骤6:按比例将粉碎的PVC搪塑再利用材料与搪塑原材料进行混合形成混合搪塑原料。
将PVC搪塑再利用材料按照不高于10%的比例与搪塑原材料进行混合并充分搅拌得到混合搪塑原料;
步骤7:将混合搪塑原料进行加工得到使用混合材料搪塑的表皮;
将步骤6混合搪塑原料进行表皮加工,表皮厚度控制在标准厚度的75%到80%之间;
步骤8:用红外轮廓仪限定使用混合搪塑原料加工的表皮背面气囊区域的位置。
将步骤7中所述使用混合搪塑原料加工的表皮从设备取出,表皮背面向上平铺在仿形支架上,仿形支架上方1米处增加红外轮廓仪,红外轮廓仪是为了限定使用混合搪塑原料加工的表皮背面气囊区域的位置;
步骤9:喷涂聚氨酯涂料;
在红外轮廓仪标注区域喷涂聚氨酯涂料,得到喷涂后的搪塑表皮,喷涂压力3bar到4bar之间,涂层控制厚度为标准厚度的20%到25%之间;
步骤10:固化;
将步骤9中所述喷涂后的搪塑表皮放入80℃恒温箱存放进行固化,10分钟后取出,得到涂层固化后的搪塑表皮。
本发明与现有技术相比有益技术效果:
汽车仪表板搪塑表皮的边角余料通常作为工业垃圾处理,也有部分厂家通过对边角余料进行简单撕碎后用于注塑产品加工,但注塑软质PVC再生材料的价格很低,仅在5元/公斤左右,而汽车仪表板搪塑表皮的PVC原材料由于颗粒加工难度大、材料物理性能要求高,目前主要依赖于进口厂商供应,比如法国阿科玛、日本瑞翁化成等公司,价格在40元/公斤。因此本发明与现有处理方式相比,一方面可以减少环境污染,另一方面可以充分提升表皮边角余料的利用价值,减少汽车仪表板领域中搪塑原材料的进口需求。
附图说明
图1表示为PVC搪塑边角余料转化为PVC搪塑再利用材料的必要制备过程;
图2表示为混合搪塑原料加工后的表皮气囊区域物理性能补偿方法。
具体实施方式
下面结合附图对本发明作详细的描述:
参阅图1,一种汽车仪表板PVC搪塑表皮边角余料再利用方法,包括以下步骤:
步骤1:废料清擦。
为避免待粉碎的PVC搪塑表皮边角余料中潜在的油脂及杂质对再成型PVC搪塑表皮外观的影响,首先使用工业酒精擦拭待粉碎PVC搪塑表皮边角余料,去除油脂及杂质;
步骤2:废料撕碎。
将擦拭干净的待粉碎PVC搪塑表皮边角余料使用撕碎机进行常温撕碎,为保证后续冷藏粉碎效率,撕碎后的颗粒尺寸不大于20mm;
步骤3:低温冷藏。
将步骤2中的撕碎后的颗粒加入液氮制冷的冷藏料仓,由于搪塑PVC低温脆化温度为-50℃左右,脆化温度是指试样开裂几率达到50%时的温度,为保证粉碎效果及经济性,此处冷藏料仓设置温度在-80℃到-100℃之间,冷藏设置时间为12到15分钟之间;
步骤4:低温粉碎。
将步骤3中按规定时间冷藏后的撕碎后的颗粒传送至冷藏粉碎机工作区粉碎成为冷藏粉碎后的材料,为避免高转速产生的剪切热能对表皮的粉碎效果,粉碎机主轴转速设置不高于500转/分钟;
步骤5颗粒筛选:筛网过滤后得到PVC搪塑再利用材料。
步骤4中所述冷藏粉碎后的材料粒径控制在80到120目之间,粒径过大会影响再加工表皮的外观质量,出现融化不好导致的沙眼缺陷,如果粒径过小,会导致PVC单体分子量过短进行影响再加工表皮的物理性能。
步骤6比例混合:按比例将粉碎的PVC搪塑再利用材料与搪塑原材料进行混合。
筛网过滤后的冷藏粉碎材料称之为PVC搪塑再利用材料,将此再利用材料按照不高于10%的比例与PVC搪塑原材料进行混合并充分搅拌得到混合搪塑原料,实验表明,经过粉碎后的再利用材料的颗粒形貌并不像PVC搪塑原材料的颗粒那样规则,如果添加比例过高,将影响混合搪塑原料的流动性,进而导致再加工表皮出现外观瑕疵;
参阅图2,一种汽车仪表板PVC搪塑表皮边角余料再利用方法,还包括以下步骤:
步骤7表皮加工:将混合搪塑原料加工制备搪塑表皮。
将步骤6混合搪塑原料进行表皮加工,表皮厚度控制在标准厚度的75%到80%之间,因为标准厚度主要是为了限定表皮气囊区域的厚度,后面步骤中会通过增加涂层方式在表皮气囊区域补偿另外20%到25%之间的厚度,增加涂层的目的是为了拟补PVC搪塑再利用材料在之前的冷藏粉碎过程中由于分子链变短导致的物理性能衰减,因为气囊区域对表皮的物理性能要求高于其他区域,尤其是对于表皮的低温物理性能,因此需要在气囊区域增加低温性能优异的涂层进行物理性能补偿。
步骤8标注喷涂区域:用红外轮廓仪限定使用混合搪塑原料的表皮背面气囊区域的位置。
将步骤7中所述使用混合搪塑原料的表皮从设备取出,表皮背面向上平铺在仿形支架上,仿形支架上方1米处增加红外轮廓仪,红外轮廓仪是为了限定使用混合搪塑原料的表皮背面气囊区域的位置,因为喷涂增强区域仅限于气囊区域,该轮廓仪可以起到防错目的;
步骤9涂层喷涂:喷涂聚氨酯涂料。
在红外轮廓仪标注区域喷涂聚氨酯涂料,得到喷涂后的搪塑表皮,喷涂压力3bar到4bar之间,实践表明该喷涂压力范围内,涂料的雾化状态更为均匀,涂层控制厚度为标准厚度的20%到25%之间,因为涂层过厚,喷涂过程中会出现涂料流挂、不均匀问题,而涂层过薄又会导致补强能力不足问题。
步骤10涂层制备:固化。
将步骤9中所述喷涂后的搪塑表皮放入80℃恒温箱存放进行固化,10分钟后取出,得到固化后的搪塑表皮。
PVC搪塑表皮边角余料经过撕碎、冷藏、粉碎、筛网过滤后成为PVC搪塑再利用材料,PVC搪塑再利用材料经过混合、加工、喷涂、固化后得到气囊区域物理性能补偿的搪塑表皮,实现了PVC搪塑表皮边角余料的再利用。
Claims (1)
1.一种汽车仪表板PVC搪塑表皮边角余料再利用方法,其特征在于,包括以下步骤:
步骤1:擦拭去油污;
擦拭待粉碎PVC搪塑表皮边角余料,去除油脂及杂质;
步骤2:常温撕碎;
将擦拭干净的待粉碎PVC搪塑表皮边角余料使用撕碎机进行常温撕碎,撕碎后的颗粒尺寸不大于20mm;
步骤3:液氮制冷、冷藏;
将步骤2中的撕碎后的颗粒加入液氮制冷的冷藏料仓,冷藏料仓设置温度在-80℃到-100℃之间,冷藏设置时间为12到15分钟之间;
步骤4:粉碎;
将步骤3中按规定时间冷藏后的撕碎后的颗粒传送至冷藏粉碎机工作区粉碎成为冷藏粉碎后的材料,粉碎机主轴转速设置不高于500转/分钟;
步骤5:筛网过滤得到PVC搪塑再利用材料;
步骤4中所述冷藏粉碎后的材料粒径控制在80到120目之间,得到PVC搪塑再利用材料;
步骤6:按比例将粉碎的PVC搪塑再利用材料与搪塑原材料进行混合形成混合搪塑原料;
将PVC搪塑再利用材料按照不高于10%的比例与搪塑原材料进行混合并充分搅拌得到混合搪塑原料;
步骤7:将混合搪塑原料进行加工得到使用混合材料搪塑的表皮;
将步骤6混合搪塑原料进行表皮加工,表皮厚度控制在标准厚度的75%到80%之间;
步骤8:用红外轮廓仪限定使用混合搪塑原料加工的表皮背面气囊区域的位置;
将步骤7中所述使用混合搪塑原料加工的表皮从设备取出,表皮背面向上平铺在仿形支架上,仿形支架上方1米处增加红外轮廓仪,红外轮廓仪是为了限定使用混合搪塑原料加工的表皮背面气囊区域的位置;
步骤9:喷涂聚氨酯涂料;
在红外轮廓仪标注区域喷涂聚氨酯涂料,得到喷涂后的搪塑表皮,喷涂压力3bar到4bar之间,涂层控制厚度为标准厚度的20%到25%之间;
步骤10:固化;
将步骤9中所述喷涂后的搪塑表皮放入80℃恒温箱存放进行固化,10分钟后取出,得到涂层固化后的搪塑表皮。
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