CN108978357A - 用于汽车空腔填充材料的纸浆模塑骨架及其制备方法 - Google Patents
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Abstract
本发明涉及一种用于汽车空腔填充材料的纸浆模塑骨架及其制备方法,骨架组分及重量份数为:纸浆100份;去离子水10000份;施胶剂80‑100份;增粘剂10‑15份;4%聚乙烯醇溶液2‑3份;6%水性丙烯酸树脂溶液3‑4份;防水剂0.6‑1份。本发明纸浆模塑骨架强度高,防水,防油可以完美替代现有PA66骨架并且具有加工工艺简单,廉价,轻质,环保的优点。
Description
技术领域
本发明属于汽车空腔填充发泡材料领域,由其是一种用于汽车空腔填充材料的纸浆模塑骨架及其制备方法。
背景技术
随着环境保护的重视度逐年增加,各各行业都加入了“绿水青山就是金山银山”的环保队伍中,当然汽车行业也不会例外,虽然目前汽车行业有各种环保标准进行控制,但是汽车最大的污染源不是各种零部件的VOC释放量,而是汽车尾气的排放量,如何在不减少功率的情况下,降低汽车尾气排放变成了一个主要研究的方向。整车轻量化是在不降低功率的情况下减少尾气排放量的最有效的方式。目前汽车上广泛使用的填充材料为PA66+EVA(骨架为PA66材质,发泡填充材料为EVA材质)PA66的密度为1.1-1.2g/cm3,并且PA66在填充材料中的使用量可以达到60-70%,若将PA66骨架替换成另一种更轻,且具备PA66所有特性的材料则可以大大降低汽车填充材料的质量,从而降低整车重量。目前本发明提供了一种纸浆模塑骨架材料密度为0.7-0.8g/cm3比PA66骨架材料更轻,更加环保。可以完全替换发泡填充材料的PA66骨架材料,且具备PA66防水、强度高、可塑性强等特点,价格上也比PA66更加有优势。
发明内容
针对现有技术存在的不足,本发明提供了用于汽车空腔填充材料的纸浆模塑骨架及其制备方法,该骨架可以完美替代现有PA66骨架并且具有加工工艺简单,廉价,轻质,环保的优点。
实现本发明目的的技术方案为:
纸浆模塑骨架材料的配合比重如下:
纸浆100份;
去离子水10000份;
施胶剂80-100份;
增粘剂10-15份;
4%聚乙烯醇溶液2-3份;
6%水性丙烯酸树脂溶液3-4份;
防水剂0.6-1份。
而且,所述施胶剂为松香与氯丁乳胶的组合物,其中松香50-60份;氯丁乳胶30-40份。
而且,所述增粘剂为淀粉。
而且,所述防水剂为聚甲基氢硅氧烷、聚甲基三乙氧基硅烷、二甲基硅油。纸浆模塑骨
架材料的制备工艺及方法,如下
1粉碎原料:将回收废纸粉碎,研磨处理得到纸浆纤维。再将纸浆纤维素倒能入打浆机,后加入去离子水,搅拌30-40min,搅拌后室温23℃静置25min得到均匀混合液体。2混合:在混合液体中加入淀粉、4%聚乙烯醇溶液、6%水性丙烯酸树脂溶液、松香、氯丁乳胶和硅系防水剂等原料在打浆机中搅拌30-40min,混合均匀得到二次混合液体。3模压成型:在模压机100℃20min的条件下将二次混合液通过水模成型出湿胚初步骨架材料。4冷却脱模:降温至室温23℃冷却,湿胚初步骨架材料脱模。5烘干:将湿胚初步骨架材料放入热空气烘干通道进行烘干脱水,之后进行冷压处理保持结构不变,并进一步脱水成型胚。6喷涂:通过乙醇/异丙醇配制的含有15-20%的贝壳素无水水凝胶均匀喷涂在骨架材料表面。7烘干:将喷涂厚的骨架材料放入热空气烘干通道进行烘干脱水,之后进行冷压处理保持结构不变,并进一步脱水成型胚。8定型:通过热压定型机对上述半成品进行热压定型,在经过摸切机模切成型,形成所需要的骨架结构的纸浆模塑产品。
纸塑骨架整体与PA66卡扣上的插入立柱采用紧配合防止脱落。纸塑骨架带有圆形和跑道圆形抓接点,目的在于可以使EVA注塑到纸塑骨架上后增加抓结力不易脱落;纸塑骨架带有凸台,目的在于增加纸塑骨架强度,不易弯曲或变形。卡扣与纸塑骨架采用插接安装方式,在PA66卡扣上注有3个立柱,在纸塑骨架的相同位置有3个插入孔,便于和纸塑骨架插接。
EVA发泡层的配比,如下EVA树脂100份;发泡剂OBSH20-25份;酸性中和剂氧化镁1-2份;交联剂DCP1-3份;增粘剂C50.1-3份;填充剂碳酸钙0.1-3份;着色剂0.1-0.2份。
EVA发泡层的制备方法:按照上述各组分配比,先混炼机预热30min达到90℃再将EVA树脂放入混炼机中,待EVA树脂彻底熔融后依次加入发泡剂、酸性中和剂、增粘剂、填充剂、着色剂进行初混炼,混炼均匀后加入交联剂混炼一段时间,然后通过挤出的方法成型,混合过程及成型温度控制在95℃左右。
将通过注塑机挤出成型的EVA发泡材料和纸浆模塑骨架进行二次注塑成型,得到一种纸浆模塑骨架材料的发泡填充材料。将注塑成型的卡扣固定在汽车车身空腔内,随后道工序的高温在150-180℃温度范围内膨胀发泡,膨胀物充分填满车身空腔,并与车身钣金件粘合,起到阻隔空腔内空气流通,减少噪声的作用。
所述纸塑骨架整体厚度为2.0mm,三个插入孔的尺寸r=1.5mm;
所述纸塑骨架带有圆形(r=1mm,高度=2mm)和跑道圆形(r=0.5,圆心距=5mm,高度=2mm)抓接点;
所述EVA发泡层的厚度为4-7mm;
本发明的有益效果:
1、本发明纸浆模塑骨架强度高,防水,防油可以完美替代现有PA66骨架并且具有加工工艺简单,廉价,轻质,环保的优点。
2、本发明EVA发泡层与纸浆模塑骨架配合,在150-180℃的条件下包裹纸浆模塑骨架的发泡填充材料在空腔内进行发泡,填满空腔截面,使得空腔分为不同的小空腔结构,阻隔噪声的传播从而达到隔音降噪的效果。
附图说明
图1为骨架的立体结构图;
图2为由骨架、EVA发泡材、卡扣组成的汽车填充材的结构图;
图3为图2填充材的使用状态图。
具体实施方式
下面结合附图并通过具体实施例对本发明作进一步详述,以下实施例只是描述性的,不是限定性的,不能以此限定本发明的保护范围。
实施例1
一种用于汽车空腔填充材料的纸浆模塑骨架,制备方法包括如下步骤:
1粉碎原料:将100kg回收废纸粉碎,研磨处理得到纸浆纤维。再将纸浆纤维素倒入打浆机,后加入去离子水,搅拌30-40min,搅拌后室温23℃静置25min得到均匀混合液体。
2混合:在混合液体中加入淀粉10kg,4%聚乙烯醇溶液2kg,6%水性丙烯酸树脂溶液3kg,去离子水1000kg,松香50kg,氯丁乳胶30kg,聚甲基氢硅氧烷0.6kg等原料在打浆机中搅拌30-40min,混合均匀得到二次混合液体。
3模压成型:在模压机100℃、20min的条件下将二次混合液通过水模成型出湿胚初步骨架材料。
4冷却脱模:降温至室温23℃冷却,湿胚初步骨架材料脱模。
5烘干:将湿胚初步骨架材料放入热空气烘干通道进行烘干脱水,之后进行冷压处理保持结构不变,并进一步脱水成型胚。
6喷涂:通过乙醇/异丙醇配制的含有15-20%的贝壳素无水水凝胶均匀喷涂在骨架材料表面。
7烘干:将喷涂厚的骨架材料放入热空气烘干通道进行烘干脱水,之后进行冷压处理保持结构不变,并进一步脱水成型胚。
8定型:通过热压定型机对上述半成品进行热压定型,在经过摸切机模切成型,形成所需要的骨架结构的纸浆模塑产品。
在骨架1的外圈通过注塑包覆EVA发泡材料5,在EVA发泡材料的内缘骨架的一面制出一凸台2,增加骨架的强度。在EVA发泡材料包覆的骨架上均匀间隔一体制出一圈抓接点3,在骨架的外缘通过插孔4插接安装一卡扣6。
纸塑骨架整体厚度=2.0mm,三个插孔的尺寸r=1.5mm,与PA66卡扣上的插入立柱采用紧配合防止脱落。纸塑骨架带有圆形(r=1mm,高度=2mm)和跑道圆形(r=0.5mm,圆心距=5mm,高度=2mm)抓接点,目的在于可以使EVA注塑到纸塑骨架上后增加抓结力,不易脱落。
卡扣与纸塑骨架采用插接安装方式,在PA66卡扣上注有3个立柱,在纸塑骨架的相同位置有3个插入孔,插入柱尺寸:r=1.5mm,高度=2mm,立柱顶端带有C0.5倒角,便于和纸塑骨架插接。
EVA发泡层的制备方法:先将混炼机预热30min达到90℃再将EVA树脂100kg放入混炼机中,待EVA树脂彻底熔融后依次加入发泡剂OBSH20kg;酸性中和剂氧化镁1kg;交联剂DCP1kg;增粘剂C50.1kg;填充剂碳酸钙0.1kg;着色剂0.1kg进行初混炼,混炼均匀后加入交联剂混炼一段时间,然后通过挤出的方法成型,混合过程及成型温度控制在95℃左右。
再通过注塑机将挤出成型的EVA发泡材料和纸浆模塑骨架进行二次注塑成型,得到一种纸浆模塑骨架材料的发泡填充材料。将注塑成型的卡扣固定在汽车车身空腔内,随后道工序的高温在150-180℃温度范围内膨胀发泡,膨胀物充分填满车身空腔,并与车身钣金件粘合,起到阻隔空腔内空气流通,减少噪声的作用。
实施例2
一种用于汽车空腔填充材料的纸浆模塑骨架,制备方法包括如下步骤:
1粉碎原料:将100kg回收废纸粉碎,研磨处理得到纸浆纤维。再将纸浆纤维素倒入打浆机,后加入去离子水,搅拌30-40min,搅拌后室温23℃静置25min得到均匀混合液体。
2混合:在混合液体中加入淀粉15kg,4%聚乙烯醇溶液3kg,6%水性丙烯酸树脂溶液4kg,去离子水1000kg,松香60kg,氯丁乳胶40kg,二甲基硅油1kg等原料在打浆机中搅拌30-40min,混合均匀得到二次混合液体。
3模压成型:在模压机100℃、20min的条件下将二次混合液通过水模成型出湿胚初步骨架材料。
4冷却脱模:降温至室温23℃冷却,湿胚初步骨架材料脱模。
5烘干:将湿胚初步骨架材料放入热空气烘干通道进行烘干脱水,之后进行冷压处理保持结构不变,并进一步脱水成型胚。
6喷涂:通过乙醇/异丙醇配制的含有15-20%的贝壳素无水水凝胶均匀喷涂在骨架材料表面。
7烘干:将喷涂厚的骨架材料放入热空气烘干通道进行烘干脱水,之后进行冷压处理保持结构不变,并进一步脱水成型胚。
8定型:通过热压定型机对上述半成品进行热压定型,在经过摸切机模切成型,形成所需要的骨架结构的纸浆模塑产品。
纸塑骨架整体厚度=2.0mm,三个插入孔的尺寸r=1.5mm,与PA66卡扣上的插入立柱采用紧配合防止脱落。纸塑骨架带有圆形(r=1mm,高度=2mm)和跑道圆形(r=0.5mm,圆心距=5mm,高度=2mm)抓接点,目的在于可以使EVA注塑到纸塑骨架上后增加抓结力,不易脱落;纸塑骨架带有凹凸槽型加强筋,目的在于增加纸塑骨架强度,不易弯曲或变形。
卡扣与纸塑骨架采用插接安装方式,在PA66卡扣上注有3个立柱,在纸塑骨架的相同位置有3个插入孔,插入柱尺寸:r=1.5mm,高度=2mm,立柱顶端带有C0.5倒角,便于和纸塑骨架插接。
EVA发泡层的制备方法:先将混炼机预热30min达到90℃再将EVA树脂放入混炼机中,待EVA树脂彻底熔融后依次加入发泡剂OBSH25kg;酸性中和剂氧化镁2kg;交联剂DCP3kg;增粘剂C52kg;填充剂碳酸钙3kg;着色剂0.1kg进行初混炼,混炼均匀后加入交联剂混炼一段时间,然后通过挤出的方法成型,混合过程及成型温度控制在95℃左右。
再通过注塑机将挤出成型的EVA发泡材料和纸浆模塑骨架进行二次注塑成型,得到一种纸浆模塑骨架材料的发泡填充材料。将注塑成型的卡扣固定在汽车车身空腔内,随后道工序的高温在150-180℃温度范围内膨胀发泡,膨胀物充分填满车身空腔,并与车身钣金件粘合,起到阻隔空腔内空气流通,减少噪声的作用。
以上所述的仅是本发明的优选实施方式,应当指出,对于本领域的普通技术人员来说,在不脱离发明构思的前提下,还可以做出若干变形和改进,这些都属于本发明的保护范围。
Claims (10)
1.一种用于汽车空腔填充材料的纸浆模塑骨架,其组分及重量份数为:
纸浆100份;
去离子水10000份;
施胶剂80-100份;
增粘剂10-15份;
4%聚乙烯醇溶液2-3份;
6%水性丙烯酸树脂溶液3-4份;
防水剂0.6-1份。
2.根据权利要求1所述的用于汽车空腔填充材料的纸浆模塑骨架,其特征在于:所述施胶剂为松香与氯丁乳胶的组合物,其中松香50-60份;氯丁乳胶30-40份。
3.根据权利要求1所述的用于汽车空腔填充材料的纸浆模塑骨架,其特征在于:所述增粘剂为淀粉。
4.根据权利要求1所述的用于汽车空腔填充材料的纸浆模塑骨架,其特征在于:所述防水剂为聚甲基氢硅氧烷、聚甲基三乙氧基硅烷、二甲基硅油。
5.根据权利要求1~4任一权利要求所述的用于汽车空腔填充材料的纸浆模塑骨架,其特征在于:制备方法步骤如下:
(1)粉碎原料:将回收废纸粉碎,研磨处理得到纸浆纤维,再将纸浆纤维素倒入打浆机,后加入去离子水,搅拌30-40min,搅拌后室温23~25℃静置25~30min得到均匀混合液体纸浆;
(2)混合:在纸浆中加入淀粉、4%聚乙烯醇溶液、6%水性丙烯酸树脂溶液、松香、氯丁乳胶和硅系防水剂,在打浆机中搅拌30-40min,混合均匀得到二次混合液体;
(3)模压成型:在模压机100~110℃、20~30min的条件下将二次混合液通过水模成型出湿胚得到初步骨架材料;
(4)冷却脱模:降温至室温23~25℃冷却,湿胚初步骨架材料脱模;
(5)烘干:将湿胚初步骨架材料放入热空气烘干通道进行烘干脱水,之后进行冷压处理保持结构不变,并进一步脱水成型胚;
(6)喷涂:将通过乙醇/异丙醇配制的含有15-20%的贝壳素无水水凝胶均匀喷涂在骨架材料表面;
(7)烘干:将喷涂后的骨架材料放入热空气烘干通道进行烘干脱水,之后进行冷压处理保持结构不变,并进一步脱水成型胚;
(8)定型:通过热压定型机对上述半成品进行热压定型,在经过摸切机模切成型,形成所需要的骨架结构的纸浆模塑产品。
6.一种包含权利要求1~4任一权利要求所述的用于汽车空腔填充材料,其特征在于:制备方法为:在骨架的外圈通过注塑包覆EVA发泡材料,在EVA发泡材料的内缘骨架的一面制出一凸台,在EVA发泡材料包覆的骨架上均匀间隔一体制出一圈抓接点,在骨架的外缘插接安装一卡扣。
7.根据权利要求6所述的汽车空腔填充材料,其特征在于:所述的插接是在卡扣上制有插柱,在骨架上制有插孔。
8.根据权利要求6所述的汽车空腔填充材料,其特征在于:所述的EVA发泡材料的组分及重量份数为:
EVA树脂100份;
发泡剂20-25份;
酸性中和剂1-2份;
交联剂1-3份;
增粘剂0.1-3份;
填充剂0.1-3份;
着色剂0.1-0.2份。
9.根据权利要求8所述的汽车空腔填充材料,其特征在于:所述的发泡剂为OBSH;所述的酸性中和剂为氧化镁;所述的交联剂为DCP;所述的增粘剂为C5;所述的填充剂为碳酸钙。
10.根据权利要求8或9所述的汽车空腔填充材料,其特征在于:EVA发泡材料制备方法为:先将混炼机预热至90℃,再将EVA树脂放入混炼机中,待EVA树脂彻底熔融后依次加入发泡剂、酸性中和剂、增粘剂、填充剂、着色剂进行初混炼,混炼均匀后加入交联剂混炼一段时间,然后通过挤出的方法成型,混合过程及成型温度控制在95℃左右。
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