CN107672239A - 一种汽车内饰顶棚的生产方法 - Google Patents

一种汽车内饰顶棚的生产方法 Download PDF

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CN107672239A
CN107672239A CN201710891416.0A CN201710891416A CN107672239A CN 107672239 A CN107672239 A CN 107672239A CN 201710891416 A CN201710891416 A CN 201710891416A CN 107672239 A CN107672239 A CN 107672239A
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glued membrane
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韦鹏飞
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Jinling Institute of Technology
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Abstract

本发明提供一种汽车内饰顶棚的生产方法，具体涉及汽车内饰技术领域，包括以下步骤，S1基材复合：将无纺布放卷铺放在复合机工作台上，在无纺布上依次铺放刚性胶膜、玻璃纤维、刚性胶膜、PU泡沫板、刚性胶膜、玻璃纤维和刚性胶膜，再在上面铺放聚氨酯膜，再在上面切撒黄麻纤维、纳米竹纤维、棉纤维和碳纤维，再铺上聚氨酯膜，最后铺上面料粘结胶膜，铺放后进行辊压复合；S2冷膜成型：将内饰面料悬置在顶棚成型模具的上、下模之间，将基材成品烘烤后放置在面料下方，合模，冷模压制成型，启模；S3将内饰顶棚半成品进行余料切割、切孔、粘接附件和修剪后得到内饰顶棚成品。本发明可提高生产效率，提高刚性，减少克重，防止渗胶，提高隔音效果。

Description

一种汽车内饰顶棚的生产方法
技术领域
本发明属于汽车内饰技术领域，具体涉及一种汽车内饰顶棚的生产方法。
背景技术
目前，我国常用于汽车顶棚干法基材的主要结构是：胶膜+玻璃纤维+胶粉+PU+玻璃纤维+胶粉+无纺布，该结构主要采用胶粉作为粘结剂，该结构下的产品需要较高的材料用量，同时克重较重，成型用时较长，胶粉的流动性大，成型时容易造成渗胶，撒粉时容易造成堆积，导致表面不良的产生，大大降低了生产效率，浪费能耗，且生产过程中粉尘多、工作环境差，基材受热后胶粉熔融形成膜层直接影响顶棚透气性以及吸音效果，因此需要研发新的汽车基材，可降低产品重量，避免因胶粉流动性大和撒粉不均造成的表面不平现象，提高生产效率。
专利一种低克重高强度汽车内饰顶棚的生产方法(公告号为CN103434253A)，公开了一种汽车内饰顶棚的生产方法，其特点是包括如下步骤：a.选取PU泡沫板、PET无纺布、胶膜Ⅰ、胶膜Ⅱ和玻璃纤维；将以上材料按PET无纺布、胶膜I、玻璃纤维、胶膜Ⅱ、PU泡沫板、胶膜Ⅱ、玻璃纤维、胶膜I顺序进入复合机，进行复合，复合温度为200℃，带速7m/min，复合完毕后按照要求尺寸去边后作为基材成品；b.基材加热软化并膨胀后与面饰层模压复合；c.通过水切割、热切割或其它切割方式去除废边；d.粘贴附件、修剪边缘后得到顶棚成品；顶棚成品重量轻、成本低，具有外刚度好、耐高温不变形，吸音性能优良，无气味，性能稳定、安全环保等特点，重要的是解决了低克重PU复合板成型顶棚刚性差的问题，该发明生产效率还需提高。
因此，急需一种提高生产效率，提高刚性，防止渗胶的汽车内饰顶棚的生产方法。
发明内容
本发明的目的是针对现有顶棚基材生产效率低，重量较大，产品表面不平等问题，提供一种提高生产效率，提高刚性，防止渗胶的汽车内饰顶棚的生产方法。
本发明提供了如下的技术方案：
一种汽车内饰顶棚的生产方法，包括以下步骤：
S1基材复合：将无纺布放卷铺放在复合机前工作台上，在无纺布上依次铺放刚性胶膜、玻璃纤维、刚性胶膜、PU泡沫板、刚性胶膜、玻璃纤维和刚性胶膜，再在刚性胶膜上铺放聚氨酯膜，再在聚氨酯膜上切撒黄麻纤维、纳米竹纤维、棉纤维和碳纤维，再铺上聚氨酯膜，最后铺上面料粘结胶膜，按上述顺序铺放好后在复合机上进行辊压复合，复合温度160-220℃，压力0.4-0.6mpa，带速8-10m/min，冷却后的复合板材即为基材成品；
S2冷膜成型：将内饰面料通过工装悬置在顶棚成型模具的上、下模之间，再将步骤S1中的基材成品烘烤后放置在面料下方，合模，冷模压制成型，启模，取出内饰顶棚半成品；
S3将步骤S2中的内饰顶棚半成品进行余料切割、切孔、粘接附件、修剪边缘后得到内饰顶棚成品。
优选的，所述步骤S1中黄麻纤维、纳米竹纤维、棉纤维和碳纤维的质量份数为黄麻纤维15-20份、纳米竹纤维9-16份、棉纤维36-45份和碳纤维29-40份。
优选的，所述步骤S1中所用刚性胶膜的主要组分为PE、PP和PA，各组分质量占比：PE为20-40％，PP为20-40％，PA为20-60％。
优选的，所述步骤S1中所用面料粘结胶膜的主要组分为PE和PA，各组分质量占比：PE为40-60％，PA为40-60％。
优选的，所述步骤S2中基材成品烘烤温度为180-220℃，烘烤时间为50-120S。
优选的，所述步骤S2中冷膜压制的压力为5-15Mpa，压制时间30-100S。
本发明的有益效果是：
1、本发明生产的产品与胶粉法生产产品相比刚性高、克重轻，胶粉法生产的产品平均克重为1000g/m2，本发明生产的产品克重范围600-650g/m2，在同等强度的条件下，本发明生产的产品与胶粉法生产产品克重下降300g/m2；
2、本发明生产的产品与胶粉法生产产品相比产品平整度更高，大大减少表面不平整等不良现象，提高产品结构中材料的均匀性。
3、本发明生产的产品与胶粉法生产产品相比杜绝了模压成型后渗胶，由于胶粉的高流动性，传统生产工艺生产的PU复合板无纺布面易渗胶，本发明无渗胶现象。
4、本发明与胶粉生产法相比大大提高了生产效率，胶粉法板材需正反面复合，板材的带速为2m/min，本发明的带速可达8-10m/min，生产效率显著提高。
5、本发明与现有技术相比还增加了两层聚氨酯膜和其中切撒的黄麻纤维、纳米竹纤维、棉纤维和碳纤维，纳米竹纤维抗紫外线，有效反射和吸收声波，起到隔音效果，黄麻纤维吸湿性好，散水快，具有防潮功能。
具体实施方式
实施例1
一种汽车内饰顶棚的生产方法，包括以下步骤：
S1基材复合：将无纺布放卷铺放在复合机前工作台上，在无纺布上依次铺放刚性胶膜、玻璃纤维、刚性胶膜、PU泡沫板、刚性胶膜、玻璃纤维和刚性胶膜，再在刚性胶膜上铺放聚氨酯膜，再在聚氨酯膜上切撒黄麻纤维、纳米竹纤维、棉纤维和碳纤维，再铺上聚氨酯膜，最后铺上面料粘结胶膜，按上述顺序铺放好后在复合机上进行辊压复合，复合温度160-220℃，压力0.4-0.6mpa，带速8-10m/min，冷却后的复合板材即为基材成品；
S2冷膜成型：将内饰面料通过工装悬置在顶棚成型模具的上、下模之间，再将步骤S1中的基材成品烘烤后放置在面料下方，合模，冷模压制成型，启模，取出内饰顶棚半成品；
S3将步骤S2中的内饰顶棚半成品进行余料切割、切孔、粘接附件、修剪边缘后得到内饰顶棚成品。
具体的，步骤S1中黄麻纤维、纳米竹纤维、棉纤维和碳纤维的质量份数为黄麻纤维15份、纳米竹纤维9份、棉纤维36份和碳纤维40份。
具体的，步骤S1中所用刚性胶膜的主要组分为PE、PP和PA，各组分质量占比：PE为20％，PP为20％，PA为60％。
具体的，步骤S1中所用面料粘结胶膜的主要组分为PE和PA，各组分质量占比：PE为40％，PA为60％。
具体的，步骤S2中基材成品烘烤温度为180℃，烘烤时间为50S。
具体的，步骤S2中冷膜压制的压力为5Mpa，压制时间30S。
实施例2
一种汽车内饰顶棚的生产方法，包括以下步骤：
S1基材复合：将无纺布放卷铺放在复合机前工作台上，在无纺布上依次铺放刚性胶膜、玻璃纤维、刚性胶膜、PU泡沫板、刚性胶膜、玻璃纤维和刚性胶膜，再在刚性胶膜上铺放聚氨酯膜，再在聚氨酯膜上切撒黄麻纤维、纳米竹纤维、棉纤维和碳纤维，再铺上聚氨酯膜，最后铺上面料粘结胶膜，按上述顺序铺放好后在复合机上进行辊压复合，复合温度160-220℃，压力0.4-0.6mpa，带速8-10m/min，冷却后的复合板材即为基材成品；
S2冷膜成型：将内饰面料通过工装悬置在顶棚成型模具的上、下模之间，再将步骤S1中的基材成品烘烤后放置在面料下方，合模，冷模压制成型，启模，取出内饰顶棚半成品；
S3将步骤S2中的内饰顶棚半成品进行余料切割、切孔、粘接附件、修剪边缘后得到内饰顶棚成品。
具体的，步骤S1中黄麻纤维、纳米竹纤维、棉纤维和碳纤维的质量份数为黄麻纤维20份、纳米竹纤维16份、棉纤维45份和碳纤维29份。
具体的，步骤S1中所用刚性胶膜的主要组分为PE、PP和PA，各组分质量占比：PE为40％，PP为40％，PA为20％。
具体的，步骤S1中所用面料粘结胶膜的主要组分为PE和PA，各组分质量占比：PE为60％，PA为40％。
具体的，步骤S2中基材成品烘烤温度为220℃，烘烤时间为120S。
具体的，步骤S2中冷膜压制的压力为15Mpa，压制时间100S。
以上所述仅为本发明的优选实施例而已，并不用于限制本发明，尽管参照前述实施例对本发明进行了详细的说明，对于本领域的技术人员来说，其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分技术特征进行等同替换。凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (6)

1.一种汽车内饰顶棚的生产方法，其特征在于，包括以下步骤：
S1基材复合：将无纺布放卷铺放在复合机前工作台上，在无纺布上依次铺放刚性胶膜、玻璃纤维、刚性胶膜、PU泡沫板、刚性胶膜、玻璃纤维和刚性胶膜，再在刚性胶膜上铺放聚氨酯膜，再在聚氨酯膜上切撒黄麻纤维、纳米竹纤维、棉纤维和碳纤维，再铺上聚氨酯膜，最后铺上面料粘结胶膜，按上述顺序铺放好后在复合机上进行辊压复合，复合温度160-220℃，压力0.4-0.6mpa，带速8-10m/min，冷却后的复合板材即为基材成品；
S2冷膜成型：将内饰面料通过工装悬置在顶棚成型模具的上、下模之间，再将步骤S1中的基材成品烘烤后放置在面料下方，合模，冷模压制成型，启模，取出内饰顶棚半成品；
S3将步骤S2中的内饰顶棚半成品进行余料切割、切孔、粘接附件、修剪边缘后得到内饰顶棚成品。
2.根据权利要求1所述的一种汽车内饰顶棚的生产方法，其特征在于，所述步骤S1中黄麻纤维、纳米竹纤维、棉纤维和碳纤维的质量份数为黄麻纤维15-20份、纳米竹纤维9-16份、棉纤维36-45份和碳纤维29-40份。
3.根据权利要求1所述的一种汽车内饰顶棚的生产方法，其特征在于，所述步骤S1中所用刚性胶膜的主要组分为PE、PP和PA，各组分质量占比：PE为20-40％，PP为20-40％，PA为20-60％。
4.根据权利要求1所述的一种汽车内饰顶棚的生产方法，其特征在于，所述步骤S1中所用面料粘结胶膜的主要组分为PE和PA，各组分质量占比：PE为40-60％，PA为40-60％。
5.根据权利要求1所述的一种汽车内饰顶棚的生产方法，其特征在于，所述步骤S2中基材成品烘烤温度为180-220℃，烘烤时间为50-120S。
6.根据权利要求1所述的一种汽车内饰顶棚的生产方法，其特征在于，所述步骤S2中冷膜压制的压力为5-15Mpa，压制时间30-100S。
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