CN110356055A - 一种汽车针织布类顶棚及其制造工艺 - Google Patents

一种汽车针织布类顶棚及其制造工艺 Download PDF

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CN110356055A
CN110356055A CN201910537079.4A CN201910537079A CN110356055A CN 110356055 A CN110356055 A CN 110356055A CN 201910537079 A CN201910537079 A CN 201910537079A CN 110356055 A CN110356055 A CN 110356055A
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厉伟
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Chongqing Min Te Auto Parts And Components Co Ltd
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1284—Application of adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B32B5/20—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
    • B60R13/0212—Roof or head liners
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars

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  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
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Abstract

本发明公开了一种汽车针织布类顶棚及其生产工艺，其中，汽车针织布类顶棚，包括依次重叠设置的无纺布层、玻纤层、PU板层、玻纤层及面层；工艺包括以下步骤：(1)PU发泡和PU切片，PU板的厚度为6mm至8mm；(2)滚胶机滚胶、喷水，胶与水的比例为1:1.5，水由喷水系统喷出并为雾状；(3)材料组合，将无纺布层、玻纤层、PU板层、玻纤层及面层重叠组合；(4)组合后的材料夹持后输送到模具压型后取出。本发明提供的汽车针织布类顶棚及其制造工艺一种相对传统产品和工艺，能减少无纺布用料、减少工艺步骤、减少工人数量，且同时能保证产品内的胶不渗透到表面，保证表面光滑而不出现凹凸不平现象。

Description

一种汽车针织布类顶棚及其制造工艺
技术领域
本发明涉及汽车顶棚及其制作方法，具体涉及一种汽车针织布类顶棚及其制造工艺。
背景技术
目前，针对汽车7mm左右后的顶棚类产品成型工艺均采用第一次成型基材、第二次复合面料的工艺来实现产品(以上成型工艺俗称两步法)。这种成型工艺产品需要两次成型，且需要在面层和玻纤层之间需要增设一层无纺布层，来保证产品内部的聚氨酯不被渗到表面。故该种工艺需要投入较多的无纺布面料、面料粘接胶，多出模具和水切胎模各一副，人员数量也相应较多。
发明内容
有鉴于此，本发明的目的在于提供一种相对传统产品和工艺，能减少无纺布用料、减少工艺步骤、减少工人数量，且同时能保证产品内的胶不渗透到表面，保证表面光滑而不出现凹凸不平现象的汽车针织布类顶棚及其制造工艺。
为达到上述目的，本发明提供如下技术方案：
本发明一种汽车针织布类顶棚，包括依次重叠设置的无纺布层、玻纤层、 PU板层、玻纤层及面层。
本发明还提供一种汽车针织布类顶棚的生产工艺，包括以下步骤：(1)PU 发泡和PU切片，PU板的厚度为6mm至7mm；(2)滚胶机滚胶、喷水，胶与水的比例为1:1.5，水由喷水系统喷出并为雾状；(3)材料组合，将无纺布层、玻纤层、PU板层、玻纤层及面层重叠组合；(4)组合后的材料夹持后输送到模具压型后取出。
进一步的，在步骤(1)中，PU发泡室温度保持恒温23℃，AB料配比为1:6。
进一步的，在步骤(1)中，PU切片的厚度误差控制在±0.3mm。
进一步的，在步骤(2)中，PU板上表面的滚胶密度控制在60g/㎡，精度控制在±10g/㎡。
进一步的，在步骤(4)中，控制压型模具的上模温度为130℃，下模温度 115℃，压力8MPa。
本发明的有益效果在于：本发明提供的汽车针织布类顶棚及其制造工艺一种相对传统产品和工艺，能减少无纺布用料、减少工艺步骤、减少工人数量，且同时能保证产品内的胶不渗透到表面，保证表面光滑而不出现凹凸不平现象。
具体实施方式
下面结合具体实施例对本发明作进一步说明，以使本领域的技术人员可以更好的理解本发明并能予以实施，但所举实施例不作为对本发明的限定。
本发明一种汽车针织布类顶棚，包括依次重叠设置的无纺布层、玻纤层(玻璃纤维)、PU板层(聚氨酯材料)、玻纤层及面层(面料针刺无纺布)，各层之间通过胶粘连接。上述结构相对传统的汽车针织布类顶棚，减少了玻纤层与面层之间的无纺布层，从而节省了材料和材料成本。
本发明还提供一种汽车针织布类顶棚的生产工艺，包括以下步骤：(1)PU 发泡和PU切片，PU板的厚度为6mm至7mm，该厚度的设计可以使后续的滚胶更加均匀；(2)滚胶机滚胶、喷水，胶与水的比例为1:1.5，水由喷水系统喷出并为雾状，从而可以保证水与胶之间的充分均匀融合，防止PU板出现水滴，从而避免胶渗透至面层表面，造成胶干后表面出现凹凸不平的后果；(3)材料组合，将无纺布层、玻纤层、PU板层、玻纤层及面层重叠组合，面层的厚度不小于2mm，可以进一步保证不出现胶渗透、造成表面的凹凸不平现象；(4)组合后的材料夹持后输送到模具压型后取出。
产品取出后检查外观，即使发现少量凹陷点，可用针挑起表面凹陷点即可，从而大大减少产品报废率。
在步骤(1)中，PU发泡室温度保持恒温23℃，AB料(异氰酸酯与组合聚醚)配比为1:6。
在步骤(1)中，PU切片的厚度误差控制在±0.3mm。注意PU切板不要出现直立孔洞，即PU板本身内部具有若干孔，切边时注意观察，不要出现轴线沿厚度方向延伸的孔。
在步骤(2)中，PU板上表面的滚胶密度控制在60g/㎡，精度控制在±10g/ ㎡，滚胶机的精度控制在±10g/㎡。
在步骤(4)中，需重点控制模具温度和检查模具间隙；控制压型模具的上模温度为130℃，下模温度115℃，压力8MPa；模具间隙不小于3mm。
传统的汽车针织布类顶棚及其制造工艺需要两次成型，一次基材复合热压成型，一次基材喷胶面料复合热压；需要多投入一台压机、模具及加热系统、水切胎模；需要多增加一层无纺布和粘接胶；需要多指配4名操作人员；需要多支出对应设备的能耗。
与传统工艺相比，本发明减少压机、模具及加热系统、水切胎模一套；减少一层无纺布和粘接胶；减少4名操作人员；减少对应压机、水切、加热系统对应设备的能耗。
本发明的难点在于聚氨酯胶易渗透针织布面料导致表面凹凸不平，若采用传统常规工艺生产减少一层无纺布的顶棚，合格率不超过90％，而采用本发明的工艺，合格率可以达到100％。
本发明汽车针织布类顶棚的生产工艺，实现对汽车顶棚类产品一次成型。相对传统工艺，不仅节省设备，模具，材料，解放劳动力，而且能保证产品产量，使其提升80％。
本发明提供的汽车针织布类顶棚及其制造工艺一种相对传统产品和工艺，能减少无纺布用料、减少工艺步骤、减少工人数量，且同时能保证产品内的胶不渗透到表面，保证表面光滑而不出现凹凸不平现象。
以上所述实施例仅是为充分说明本发明而所举的较佳的实施例，本发明的保护范围不限于此。本技术领域的技术人员在本发明基础上所作的等同替代或变换，均在本发明的保护范围之内。本发明的保护范围以权利要求书为准。
此外，若出现术语“第一”、“第二”等，其仅用于描述目的，而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量。由此，限定有“第一”、“第二”等的特征可以明示或者隐含地包括一个或者更多个该特征。在本发明的描述中，除非另有说明，“多个”的含义是两个或两个以上。
在本发明的描述中，需要说明的是，除非另有明确的规定和限定，若出现术语“安装”、“相连”、“连接”，应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或一体地连接；可以是机械连接，也可以是电连接；可以是直接相连，也可以通过中间媒介间接相连，可以是两个元件内部的连通。对于本领域的普通技术人员而言，可以通过具体情况理解上述术语在本发明中的具体含义。

Claims (6)

1.一种汽车针织布类顶棚，其特征在于，包括依次重叠设置的无纺布层、玻纤层、PU板层、玻纤层及面层。
2.一种如权利要求1所述的汽车针织布类顶棚的生产工艺，其特征在于，包括以下步骤：(1)PU发泡和PU切片，PU板的厚度为6mm至7mm；(2)滚胶机滚胶、喷水，胶与水的比例为1:1.5，水由喷水系统喷出并为雾状；(3)材料组合，将无纺布层、玻纤层、PU板层、玻纤层及面层重叠组合；(4)组合后的材料夹持后输送到模具压型后取出。
3.根据权利要求2所述的汽车针织布类顶棚的生产工艺，其特征在于，在步骤(1)中，PU发泡室温度保持恒温23℃，AB料配比为1:6。
4.根据权利要求2所述的汽车针织布类顶棚的生产工艺，其特征在于，在步骤(1)中，PU切片的厚度误差控制在±0.3mm。
5.根据权利要求2所述的汽车针织布类顶棚的生产工艺，其特征在于，在步骤(2)中，PU板上表面的滚胶密度控制在60g/㎡，精度控制在±10g/㎡。
6.根据权利要求2所述的汽车针织布类顶棚的生产工艺，其特征在于，在步骤(4)中，控制压型模具的上模温度为130℃，下模温度115℃，压力8MPa。
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Application publication date: 20191022