CN109050431B - 一种环保型汽车内饰的制备方法及汽车内饰 - Google Patents
一种环保型汽车内饰的制备方法及汽车内饰 Download PDFInfo
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Abstract
本发明提供一种环保型汽车内饰的制备方法及汽车内饰,其中,所述制备方法为:使胶膜层与骨架融合,形成带有胶膜层的骨架结构,使所述骨架结构与表皮层结合,使所述骨架结构的胶膜层与所述表皮层连接形成所述环保型汽车内饰。所述制备方法制备得到的汽车内饰具有良好的贴合性能和机械性能,该方法具有的优点是可简化工艺、节约成本、节能环保和节省人工。
Description
技术领域
本发明属于汽车内饰制备领域,涉及一种环保型汽车内饰的制备方法。
背景技术
汽车内饰包括仪表板、侧门板、手衬、储物件等,其中,仪表板是汽车内饰的重要组成部分。近年来,随着技术的不断进步,更多的操作功能被集成到了仪表板中。显然,为了确保所支撑的各种仪表和零件能够在高速行驶及振动状态下正常工作,仪表板必须具有足够的刚性,而为了减少发生意外时外力对正、副驾驶的冲击,还要求仪表板具有良好的吸能性。同时,出于舒适和审美的要求,仪表板的手感、皮纹、色泽和色调等也日益受到人们的重视。
总之,作为一种独特的内饰部件,仪表板集安全性、功能性、舒适性和装饰性于一身,这些性能的好坏已成为评判整车等级的重要标准之一。一般,不同的车型所配备的仪表板等级是完全不同的。根据车型的配置要求,可选择适合的仪表板生产工艺,以达到降低生产成本的目的。
传统的汽车车门、仪表盘等内饰板材料一般通过多次成型,工艺复杂,设备昂贵、生产成本高、不够环保。
发明内容
针对现有技术中存在的技术问题,本发明提供一种环保型汽车内饰的制备方法,所述制备方法制备得到的汽车内饰具有良好的贴合性能和机械性能,该方法也可简化工艺、节约成本,提高环保性能。
为达到上述目的,本发明采用以下技术方案:
本发明提供一种环保型汽车内饰的制备方法,所述制备方法为:使胶膜层与骨架融合,形成带有胶膜层的骨架结构,使所述骨架结构与表皮层结合,使所述骨架结构的胶膜层与所述表皮层连接形成所述环保型汽车内饰。本方案通过先将胶膜层与骨架结合,然后再与表皮层结合,一方面在保证表皮层与骨架结合力的情况下,尽可能节约了胶膜层的用量,节约了成本,提高了环保性能;另一方面,胶膜层按需设置,也提高连接可靠性。根据本方案的发明构思,本方案的胶膜层可铺满所述骨架需要粘合的区域。可选地,所述胶膜层也可呈分散状设置于所述骨架需要粘合的区域。本方案并未对骨架材料做限定,所述骨架可为木质材料、塑料或铁质等刚性材料。
优选地,所述骨架结构与所述表皮层结合之前进行加热步骤。通过所述设计,先对骨架结构和表皮层进行预热,可进一步简化工艺步骤,节约时间和提高效率。
优选地,所述加热温度为10℃-350℃,如10℃、20℃、50℃、80℃、100℃、150℃、200℃、250℃、300℃或350℃等,但并不仅限于所列举的数值,该数值范围内其他未列举的数值同样适用。更加优选地,所述加热温度为50℃-200℃。
优选地,所述加热时间优选为1秒-15分钟。更加优选地,所述加热时间优选为5秒-2分钟,如5秒、10秒、20秒、30秒、40秒、50秒、1分钟、1.2分钟、1.5分钟、1.8分钟或2分钟等,但并不仅限于所列举的数值,该数值范围内其他未列举的数值同样适用。
其中,加热温度可以是110℃、111℃、112℃、113℃、114℃、115℃、116℃、117℃、118℃、119℃或120℃等,但并不仅限于所列举的数值,该数值范围内其他未列举的数值同样适用。
作为本发明优选的技术方案,所述加热时间为5秒-2分钟,如1分钟、1.1分钟、1.2分钟、1.3分钟、1.4分钟、1.5分钟、1.6分钟、1.7分钟、1.8分钟、1.9分钟或2分钟等,但并不仅限于所列举的数值,该数值范围内其他未列举的数值同样适用。
本发明所述制备方法严格控制加热的时间以及温度,如果加热温度低于10℃,会导致胶膜层热固化不完全,导致胶膜层与骨架结构层的黏合力降低,如果加热温度高于350℃,可能会导致胶膜层固化过度,导致胶膜层的韧性下降,从而导致拉伸强度等机械性能下降。如果加热时间低于5秒可能会导致胶膜层中热熔胶颗粒不能完全融化,胶膜层中出现颗粒状物质,影响胶膜层的粘合性,而如果加热时间高于2分钟可能会导致增粘材料的增粘性能下降,同样会导致胶膜层的粘合性下降。
优选地,所述加热步骤在真空条件下实施。如果骨架结构非平面结构时,为了使胶膜层、表皮层与骨架结构更紧密的结合,优选地需要在真空条件进行加热步骤。可通过在骨架结构上开设用于抽真空的微孔实现表皮层与骨架结构之间真空环境,即表皮层与骨架结构结合时,通过所述微孔进行抽真空,以使表皮层与骨架结构充分有效的结合。
优选地,所述胶膜层为TPU热熔胶、EVA热熔胶、PE热熔胶、PA热熔胶或EAA热熔胶中任一种;或者,所述胶膜层为TPU热熔胶改性体、EVA热熔胶改性体、PE热熔胶改性体、PA热熔胶改性体或EAA热熔胶改性体中任一种。优选地,所述改性材料为增粘树脂、增粘乳液、增粘粉或增粘松香树脂中的任意一种或至少两种的组合,优选增粘树脂。
优选地,所述胶膜层为TPU热熔胶、EVA热熔胶、PE热熔胶、PA热熔胶、EAA热熔胶或EPS热熔胶中任一种;或者,
所述胶膜层为TPU热熔胶改性体、EVA热熔胶改性体、PE热熔胶改性体、PA热熔胶改性体、EAA热熔胶改性体或EPS热溶胶改性体中任一种。
作为本发明优选的技术方案,所述胶膜层的原料包括如下成分:
TPU热熔胶颗粒 70-100重量份;
滑剂 0-5重量份;
改性增粘材料 0-30重量份。
其中,所述TPU热熔胶颗粒的含量可以是70重量份、73重量份、75重量份、78重量份、80重量份、82重量份、85重量份、88重量份、90重量份、93重量份、95重量份、98重量份或100重量份等;所述滑剂的用量可以是0重量份、0.5重量份、0.8重量份、1重量份、1.2重量份、1.5重量份、2重量份、2.5重量份、3重量份、3.5重量份、4重量份、4.5重量份或5重量份;所述改性增粘材料的含量可以是0重量份、5重量份、10重量份、15重量份、20重量份、25重量份或30重量份等,但并不仅限于所列举的数值,上述各数值范围内其他未列举的数值同样适用。
作为本发明优选的技术方案,所述TPU热熔胶颗粒的原料包括如下组分:
其中,二异氰酸酯的重量份可以是50重量份、55重量份、60重量份、65重量份、70重量份、75重量份或80重量份等,多元醇的重量份可以是35重量份、36重量份、38重量份、40重量份、42重量份、45重量份、48重量份或50重量份等,催化剂的重量份可以是0.1重量份、0.2重量份、0.5重量份、1重量份、1.5重量份、2重量份、2.5重量份、3重量份、3.5重量份、4重量份、4.5重量份或5重量份等,扩链剂的重量份可以是3重量份、5重量份、8重量份、10重量份、12重量份或15重量份等,抗氧剂的重量份可以是0.1重量份、0.2重量份、0.5重量份、1重量份、1.5重量份、2重量份、2.5重量份、3重量份、3.5重量份、4重量份、4.5重量份或5重量份等,但并不仅限于所列举的数值,上述各数值范围内其他未列举的数值同样适用。
优选地,所述二异氰酸酯为六甲基二异氰酸酯、环己烷二亚甲基二异氰酸酯、1,6-己二异氰酸酯或异佛尔酮二异氰酸酯中的任意一种或至少两种的组合,优选六甲基二异氰酸酯与1,6-己二异氰酸酯的组合。
优选地,所述六甲基二异氰酸酯与1,6-己二异氰酸酯的组合中六甲基二异氰酸酯与1,6-己二异氰酸酯的质量比为1:(5-10),例如1:5、1:5.5、1:5.8、1:6、1:6.3、1:6.5、1:6.8、1:7、1:7.3、1:7.5、1:7.8、1:8、1:8.5、1:8.8、1:9、1:9.4、1:9.8或1:10。
优选地,所述多元醇为聚醚多元醇和聚酯多元醇的组合。
优选地,所述多元醇中聚醚多元醇和聚酯多元醇的质量比为(7-9):1,例如7:1、7.3:1、7.5:1、7.8:1、8:1、8.3:1、8.5:1、8.8:1或9:1。
在本发明中优选利用两种特定的二异氰酸酯,配合多元醇来使用,增强TPU热熔胶层的柔软性以及韧性,增强该层的粘合效果。
优选地,所述多元醇的数均分子量为500-2000,例如500、700、900、1000、1200、1400、1600、1800或2000,优选500-1000。
优选地,所述催化剂包括三乙醇胺、N,N'-双吗琳基二乙基醚、四正丁基锡、氯化亚锡、辛酸亚锡、羟基三甲基锡或二丁基二月桂酸锡中任意一种或至少两种的组合,所述组合典型但非限制性实施例有:三乙醇胺和N,N'-双吗琳基二乙基醚的组合、三乙醇胺和四正丁基锡的组合、四正丁基锡和氯化亚锡的组合、氯化亚锡和辛酸亚锡的组合、辛酸亚锡和羟基三甲基锡的组合、羟基三甲基锡和二丁基二月桂酸锡的组合或三乙醇胺、氯化亚锡和二丁基二月桂酸锡的组合等。
优选地,所述扩链剂包括1,4-丁二醇、1,6-己二醇、二甘醇、二乙氨基乙醇、N,N-二羟基(二异丙基)苯胺、乙二胺或3,3'-二氯-4,4'二氨基-二苯基甲烷中任意一种或至少两种的组合,所述组合典型但非限制性实例有:1,4-丁二醇和1,6-己二醇的组合、1,6-己二醇和二甘醇的组合、二甘醇和二乙氨基乙醇的组合、N,N-二羟基(二异丙基)苯胺和乙二胺的组合、1,4-丁二醇和3,3'-二氯-4,4'二氨基-二苯基甲烷的组合或1,4-丁二醇、二乙氨基乙醇和N,N-二羟基(二异丙基)苯胺的组合等。
优选地,所述抗氧剂包括抗氧剂1010、抗氧剂1076、抗氧剂168或2,6-二叔丁基-4-甲基苯酚中任意一种或至少两种的组合,所述组合典型但非限制性实例有:抗氧剂1010和抗氧剂1076的组合、抗氧剂1076与抗氧剂168的组合、抗氧剂168与2,6-二叔丁基-4-甲基苯酚的组合或抗氧剂1010、抗氧剂1076和抗氧剂168的组合等。
优选地,所述改性增粘材料为增粘树脂、增粘乳液、增粘粉或增粘松香树脂中的任意一种或至少两种的组合,优选增粘树脂。
另一方面,本方案还提供了一种根据上述方法制备的汽车内饰。
与现有技术方案相比,本发明至少具有以下有益效果:
本发明提供一种环保型汽车内饰的制备方法,所述制备方法制备得到的环保型汽车内饰具有优异的机械性能,其具有优异的层间粘合力,粘合力可达6.0N/mm以上。
附图说明
图1是本发明制备方法的流程图。
下面对本发明进一步详细说明。但下述的实例仅仅是本发明的简易例子,并不代表或限制本发明的权利保护范围,本发明的保护范围以权利要求书为准。
具体实施方式
为更好地说明本发明,便于理解本发明的技术方案,本发明的典型但非限制性的实施例如下:
如图1所示,本发明实施例的汽车内饰的制备方法为:使胶膜层与骨架融合,形成带有胶膜层的骨架结构,使所述骨架结构与表皮层结合,使所述骨架结构的胶膜层与所述表皮层连接形成所述环保型汽车内饰。其中,本方案的胶膜层可铺满所述骨架需要粘合的区域。在其他实施例中,所述胶膜层也可呈分散状设置于所述骨架需要粘合的区域。具体实施时,首选将骨架放置于注塑机中,然后在其表面注塑一层厚度不等的胶膜层,然后通过加热使胶膜层与骨架融合。其中,胶膜层的厚度不作限制,能达到粘合表皮层为佳。胶膜层的形状也不作限制,可以为膜状、网状、点状或丝状等。
所述骨架结构与所述表皮层结合之前进行加热步骤。通过先对骨架结构和表皮层进行预热,可进一步简化工艺步骤,节约时间和提高效率。所述加热温度为10℃-350℃,所述加热时间优选为5秒-2分钟。本实施例中,所述加热温度为110℃,加热时间为1.5分钟。
本实施例中,所述加热步骤在真空条件下实施。由于本实施例的骨架结构具有凹槽结构,为非平面结构,为了使胶膜层、表皮层与骨架结构更紧密的结合,优选地需要在真空条件进行加热步骤。可通过在骨架结构上开设用于抽真空的微孔实现表皮层与骨架结构之间真空环境,即表皮层与骨架结构结合时,通过所述微孔进行抽真空,以使表皮层与骨架结构充分有效的结合。本领域技术人员可知的是,在其他实施例中,所述加热步骤也可以在常温常压的环境下实施。
本实施例中,所述胶膜层为TPU热熔胶。所述表皮层为TPO皮革。
申请人声明,本发明通过上述实施例来说明本发明的详细结构特征,但本发明并不局限于上述详细结构特征,即不意味着本发明必须依赖上述详细结构特征才能实施。所属技术领域的技术人员应该明了,对本发明的任何改进,对本发明所选用部件的等效替换以及辅助部件的增加、具体方式的选择等,均落在本发明的保护范围和公开范围之内。
另外需要说明的是,在上述具体实施方式中所描述的各个具体技术特征,在不矛盾的情况下,可以通过任何合适的方式进行组合,为了避免不必要的重复,本发明对各种可能的组合方式不再另行说明。
Claims (3)
1.一种层间粘合力在6.0N/mm以上的环保型汽车内饰的制备方法,其特征在于,所述制备方法为:使胶膜层与骨架融合,形成带有胶膜层的骨架结构,使所述骨架结构与表皮层结合,使所述骨架结构的胶膜层与所述表皮层连接形成所述环保型汽车内饰;
所述胶膜层呈分散状设置于所述骨架需要粘合的区域;
所述骨架结构与所述表皮层结合之前进行加热步骤;
加热温度为110℃-120℃;
加热时间为5秒-2分钟;
所述加热步骤在真空条件下实施;
所述表皮层为皮革层与泡棉织物层的复合层,所述皮革层为TPU皮革、PVC皮革、真皮革或TPO皮革。
2.根据权利要求1所述的制备方法,其特征在于,所述胶膜层为TPU热熔胶、EVA热熔胶、PE热熔胶、PA热熔胶、EAA热熔胶或EPS热熔胶中任一种;或者,所述胶膜层为TPU热熔胶改性体、EVA热熔胶改性体、PE热熔胶改性体、PA热熔胶改性体、EAA热熔胶改性体或EPS热熔胶改性体中任一种。
3.一种汽车内饰,其特征在于,由权利要求1至2中任一项所述的方法制备。
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