CN110696449B - 一种客车顶棚用干法聚氨酯玻纤复合材料 - Google Patents

一种客车顶棚用干法聚氨酯玻纤复合材料 Download PDF

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CN110696449B
CN110696449B CN201911070886.6A CN201911070886A CN110696449B CN 110696449 B CN110696449 B CN 110696449B CN 201911070886 A CN201911070886 A CN 201911070886A CN 110696449 B CN110696449 B CN 110696449B
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李虎
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Anhui Ankai Automobile Co Ltd
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Abstract

本发明公开了一种客车顶棚用干法聚氨酯玻纤复合材料，该复合材料由面料层和基材层通过干法复合制备得到，所述面料层是聚氨酯海绵和针织面料复合制备得到，所述基材层由以质量百分比计的四层结构组成：基材层一层为12％‑16％的玻璃纤维和12％‑16％的聚乙烯粉，基材层二层为19％‑23％的聚氨酯泡沫，基材层三层为21％‑25％的玻璃纤维和21％‑25％的聚乙烯粉，基材层四层为3.5％‑4.1％的PET无纺布，可以解决客车顶棚材料吸音性能差，影响乘客乘车体验的问题，同时解决客车内饰材料本身强度不足的问题。

Description

一种客车顶棚用干法聚氨酯玻纤复合材料
技术领域
本发明属于复合材料技术领域，具体涉及一种客车顶棚用干法聚氨酯玻纤复合材料。
背景技术
客车顶棚作为客车最大的内饰，客车顶棚的吸音性能的优劣直接关系到乘客的舒适度体验，目前市场，客车顶棚内饰的吸音性能较差，外界的噪音很容易穿过客车外壳进入客车内部，使得噪音不断在客车内回响，严重影响乘车体验的情况，一些内饰材料隔音效果合格，但是会出现材料本身强度不足的情况。
公开号：CN105294972B，该发明提供的聚氨酯泡沫，不能解决客车顶棚内饰的吸音性能较差，外界的噪音很容易穿过客车外壳进入客车内部，使得噪音不断在客车内回响，严重影响乘车体验的情况，也不能解决一些内饰材料隔音效果合格，但是会出现材料本身强度不足的情况。
发明内容
本发明的目的在于提供一种具有超强耐腐蚀的锂电池内层复合膜及其制备方法，以解决上述背景提到的客车顶棚材料吸音性能差，影响乘客乘车体验的问题，同时解决了客车内饰材料本身强度不足的问题。
为实现上述目的，本发明提供如下技术方案：
一种客车顶棚用干法聚氨酯玻纤复合材料，其特征在于：该复合材料由面料层和基材层经干法复合制备得到，所述面料层是聚氨酯海绵和针织面料复合制备得到，所述基材层由四层结构组成，从上到下以质量百分比计依次是：基材层一层由12％-16％的玻璃纤维和12％-16％的聚乙烯粉制备得到，基材层二层为19％-23％的聚氨酯泡沫，基材层三层由21％-25％的玻璃纤维和21％-25％的聚乙烯粉制备得到，基材层四层为3.5％-4.1％的PET无纺布。
优选的，所述面料层克重范围为140-220g/m2，基材层克重范围在1200-1400g/m2。
优选的，基材的制备步骤包括以下：
步骤一、制备基材层二层，制备步骤包括以下：
1)、准备以重量份计的聚氨酯泡沫原材料为：四羟基聚醚多元醇30-60份、八羟基聚醚多元醇20-40份、硅藻土8-35份、去离子水2.1-3.5份，甲苯二异氰酸酯1.1-2.4份，催化剂为1,4-二氮杂二环[2.2.2]辛烷0.4-0.8份和二月桂酸二丁基锡0.1-0.3份；泡沫稳定剂为脂肪酰二乙醇胺1.3-2.2份；
2)、将聚氨酯泡沫原材料混和搅拌均匀，立即倒入泡沫成型模具中使原材料自由发泡，发泡结束后，在环境温度为20-25℃下，熟化70-80h，得到聚氨酯泡沫；将聚氨酯泡沫进行切片制得基材层二层；
步骤二、制备基材层一层和基材层三层：
制备基材层一层：将12％-16％的玻璃纤维和12％-16％的聚乙烯粉混合搅拌均匀，一同放入双螺杆挤出机进料口，经双螺杆挤出机挤出，得到玻璃纤维和聚乙烯粉的混合材料，即为基材层一层；
制备基材层三层：将21％-25％的玻璃纤维和21％-25％的聚乙烯粉混合搅拌均匀，一同放入双螺杆挤出机进料口，经双螺杆挤出机挤出，得到玻璃纤维和聚乙烯粉的混合材料，即为基材层三层；
步骤三：制备基材层，准备基材层一层、基材层二层、基材层三层和基材层四层依次放入顶棚成型模具中进行复合，得到基材层；
优选的，所述步骤二双螺杆挤出机的压缩段温度为100-120℃，均化段温度为140℃，机头以及口模段温度为135-150℃，螺杆转速为30-36r/min；步骤三中顶棚成型模具的温度为140℃。
优选的，聚氨酯玻纤复合材料制备方法包括以下步骤：
S1、面料层的制备步骤包括以下：将多孔聚氨酯海绵和无纺布通过火焰复合的方法进行复合得到面料层；
S2、将步骤四中得到的基材层和S1中得到的面料层依次放入顶棚成型模具中，基材层和面料层复合得到聚氨酯玻纤复合材料。
优选的，所述S2中顶棚成型模具温度为140℃。
本发明的有益效果：
本发明中使用的聚氨酯泡沫，采用聚醚多元醇自由发泡的方法制备得到，在自由发泡过程中加入了硅藻土，使得制备得到的聚氨酯泡沫的孔洞变多，孔径变小的同时，使得孔的深度变浅，声音从外界进入聚氨酯泡沫内部时，使得声音的频率提高，减弱了声音的能量，使得聚氨酯玻纤复合材料的吸音性能得到提高。
为了解决聚氨酯泡沫本身强度不足的问题，本发明在不影响聚氨酯玻纤复合材料吸音性能的前提下，提高了玻璃纤维在基材层原材料中的占比，从而达到提高聚氨酯玻纤复合材料自身的强度，利用高温下聚乙烯粉有粘结剂的作用，使得玻璃纤维和聚氨酯泡沫能有更好的复合效果，另外本发明使用顶棚成型模具，将基材层和面料层一次性压合得到聚氨酯玻纤复合材料，利用干法制备的聚氨酯玻纤复合材料避免了粘结剂的使用，减少汽车内部有机物质的挥发，避免了粘结剂的使用对人体自身造成的伤害。
具体实施方式
下面将对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其它实施例，都属于本发明保护的范围。
一种客车顶棚用干法聚氨酯玻纤复合材料，该复合材料由面料层和基材层经干法复合制备得到，面料层是聚氨酯海绵和针织面料复合制备得到，面料层克重范围为140-220g/m2，基材层克重范围在1200-1400g/m2，基材层由四层结构组成，从上到下以质量百分比计依次是：基材层一层由12％-16％的玻璃纤维和12％-16％的聚乙烯粉制备得到，基材层二层为19％-23％的聚氨酯泡沫，基材层三层由21％-25％的玻璃纤维和21％-25％的聚乙烯粉制备得到，基材层四层为3.5％-4.1％的PET无纺布。
基材的制备步骤包括以下：
步骤一、制备基材层二层，制备步骤包括以下：
1)、准备以重量份计的聚氨酯泡沫原材料为：四羟基聚醚多元醇30-60份、八羟基聚醚多元醇20-40份、硅藻土8-35份、去离子水2.1-3.5份，甲苯二异氰酸酯1.1-2.4份，催化剂为1,4-二氮杂二环[2.2.2]辛烷0.4-0.8份和二月桂酸二丁基锡0.1-0.3份；泡沫稳定剂为脂肪酰二乙醇胺1.3-2.2份；
2)、将聚氨酯泡沫原材料混和搅拌均匀，立即倒入泡沫成型模具中使原材料自由发泡，发泡结束后，在环境温度为20-25℃下，熟化70-80h，得到聚氨酯泡沫；将聚氨酯泡沫进行切片制得基材层二层；
步骤二、制备基材层一层和基材层三层：
制备基材层一层：将12％-16％的玻璃纤维和12％-16％的聚乙烯粉混合搅拌均匀，一同放入双螺杆挤出机进料口，经双螺杆挤出机挤出，得到玻璃纤维和聚乙烯粉的混合材料，即为基材层一层；
制备基材层三层：将21％-25％的玻璃纤维和21％-25％的聚乙烯粉混合搅拌均匀，一同放入双螺杆挤出机进料口，经双螺杆挤出机挤出，得到玻璃纤维和聚乙烯粉的混合材料，即为基材层三层；
双螺杆挤出机的压缩段温度为100-120℃，均化段温度为140℃，机头以及口模段温度为135-150℃，螺杆转速为30-36r/min。
步骤三：制备基材层，准备基材层一层、基材层二层、基材层三层和基材层四层依次放入顶棚成型模具中进行复合，顶棚成型模具的温度为140℃，得到基材层；
聚氨酯玻纤复合材料制备方法包括以下步骤：
S1、面料层的制备步骤包括以下：将多孔聚氨酯海绵和无纺布通过火焰复合的方法进行复合得到面料层；
S2、将步骤四中得到的基材层和S1中得到的面料层依次放入顶棚成型模具中，顶棚成型模具温度为140℃，基材层和面料层复合得到聚氨酯玻纤复合材料。
实施例1
一种客车顶棚用干法聚氨酯玻纤复合材料，该复合材料由面料层和基材层经干法复合制备得到，面料层是聚氨酯海绵和针织面料复合制备得到，面料层克重范围为150g/m2，基材层克重范围在1350g/m2，基材层由四层结构组成，从上到下以质量百分比计依次是：基材层一层由13％的玻璃纤维和13％的聚乙烯粉制备得到，基材层二层为20％的聚氨酯泡沫，基材层三层由25％的玻璃纤维和25％的聚乙烯粉制备得到，基材层四层为4.0％的PET无纺布。
基材的制备步骤包括以下：
步骤一、制备基材层二层，制备步骤包括以下：
1)、准备以重量份计的聚氨酯泡沫原材料为：四羟基聚醚多元醇42份、八羟基聚醚多元醇25份、硅藻土12份、去离子水3.0份，甲苯二异氰酸酯1.3份，催化剂为1,4-二氮杂二环[2.2.2]辛烷0.2份和二月桂酸二丁基锡0.15份；泡沫稳定剂为脂肪酰二乙醇胺1.5份；
2)、将聚氨酯泡沫原材料混和搅拌均匀，立即倒入泡沫成型模具中使原材料自由发泡，发泡结束后，在环境温度为22℃下，熟化72h，得到聚氨酯泡沫；将聚氨酯泡沫进行切片制得基材层二层；
步骤二、制备基材层一层和基材层三层：
制备基材层一层：将13％的玻璃纤维和13％的聚乙烯粉混合搅拌均匀，一同放入双螺杆挤出机进料口，经双螺杆挤出机挤出，得到玻璃纤维和聚乙烯粉的混合材料，即为基材层一层；
制备基材层三层：将25％的玻璃纤维和25％的聚乙烯粉混合搅拌均匀，一同放入双螺杆挤出机进料口，经双螺杆挤出机挤出，得到玻璃纤维和聚乙烯粉的混合材料，即为基材层三层；
双螺杆挤出机的压缩段温度为100℃，均化段温度为140℃，机头以及口模段温度为140℃，螺杆转速为32r/min。
步骤三：制备基材层，准备基材层一层、基材层二层、基材层三层和基材层四层依次放入顶棚成型模具中进行复合，顶棚成型模具的温度为140℃，得到基材层；
聚氨酯玻纤复合材料制备方法包括以下步骤：
S1、面料层的制备步骤包括以下：将多孔聚氨酯海绵和无纺布通过火焰复合的方法进行复合得到面料层；
S2、将步骤四中得到的基材层和S1中得到的面料层依次放入顶棚成型模具中，顶棚成型模具温度为140℃，基材层和面料层复合得到聚氨酯玻纤复合材料。
对聚氨酯玻纤复合材料进行吸音性能测试。
实施例2
一种客车顶棚用干法聚氨酯玻纤复合材料，该复合材料由面料层和基材层经干法复合制备得到，面料层是聚氨酯海绵和针织面料复合制备得到，面料层克重范围为200g/m2，基材层克重范围在1400g/m2，基材层由四层结构组成，从上到下以质量百分比计依次是：基材层一层由12.5％的玻璃纤维和12.5％的聚乙烯粉制备得到，基材层二层为21.5％的聚氨酯泡沫，基材层三层由25％的玻璃纤维和25％的聚乙烯粉制备得到，基材层四层为3.5％的PET无纺布。
基材的制备步骤包括以下：
步骤一、制备基材层二层，制备步骤包括以下：
1)、准备以重量份计的聚氨酯泡沫原材料为：四羟基聚醚多元醇60份、八羟基聚醚多元醇30份、硅藻土20份、去离子水3.5份，甲苯二异氰酸酯2.0份，催化剂为1,4-二氮杂二环[2.2.2]辛烷0.6份和二月桂酸二丁基锡0.2份；泡沫稳定剂为脂肪酰二乙醇胺2.2份；
2)、将聚氨酯泡沫原材料混和搅拌均匀，立即倒入泡沫成型模具中使原材料自由发泡，发泡结束后，在环境温度为25℃下，熟化80h，得到聚氨酯泡沫；将聚氨酯泡沫进行切片制得基材层二层；
步骤二、制备基材层一层和基材层三层：
制备基材层一层：将12.5％的玻璃纤维和12.5％的聚乙烯粉混合搅拌均匀，一同放入双螺杆挤出机进料口，经双螺杆挤出机挤出，得到玻璃纤维和聚乙烯粉的混合材料，即为基材层一层；
制备基材层三层：将25％的玻璃纤维和25％的聚乙烯粉混合搅拌均匀，一同放入双螺杆挤出机进料口，经双螺杆挤出机挤出，得到玻璃纤维和聚乙烯粉的混合材料，即为基材层三层；
双螺杆挤出机的压缩段温度为110℃，均化段温度为140℃，机头以及口模段温度为140℃，螺杆转速为35r/min。
步骤三：制备基材层，准备基材层一层、基材层二层、基材层三层和基材层四层依次放入顶棚成型模具中进行复合，顶棚成型模具的温度为140℃，得到基材层；
聚氨酯玻纤复合材料制备方法包括以下步骤：
S1、面料层的制备步骤包括以下：将多孔聚氨酯海绵和无纺布通过火焰复合的方法进行复合得到面料层；
S2、将步骤四中得到的基材层和S1中得到的面料层依次放入顶棚成型模具中，顶棚成型模具温度为140℃，基材层和面料层复合得到聚氨酯玻纤复合材料。
对聚氨酯玻纤复合材料进行吸音性能测试。
对比实施例1
聚氨酯泡沫使用普通聚氨酯泡沫，基材层三层与四层之间增加聚乙烯膜；其他与实施例1保持一致。
对比实施例2
聚氨酯泡沫使用普通聚氨酯泡沫，其他与实施例2保持一致。
根据测试结果得到以下表1数据：
Figure GDA0003355480760000091
表1
(注：消音系数越大，说明材料的吸音效果越好)
由表1数据可知结论：目前市场上的聚氨酯纤复合材料中添加有聚乙烯膜，聚乙烯膜的存在会导致聚氨酯玻纤复合材料的吸音性能下降，经过硅藻土作用下得到的聚氨酯泡沫，吸音性能优于普通聚氨酯泡沫。
以上内容仅仅是对本发明的构思所作的举例和说明，所属本技术领域的技术人员对所描述的具体实施例做各种各样的修改或补充或采用类似的方式替代，只要不偏离发明的构思或者超越本权利要求书所定义的范围，均应属于本发明的保护范围。

Claims (6)

1.一种客车顶棚用干法聚氨酯玻纤复合材料，其特征在于：该复合材料由面料层和基材层经干法复合制备得到，所述面料层是聚氨酯海绵和针织面料复合制备得到，所述基材层由四层结构组成，从上到下以质量百分比计依次是：基材层一层由12％-16％的玻璃纤维和12％-16％的聚乙烯粉制备得到，基材层二层为19％-23％的聚氨酯泡沫，基材层三层由21％-25％的玻璃纤维和21％-25％的聚乙烯粉制备得到，基材层四层为3.5％-4.1％的PET无纺布。
2.根据权利要求1所述一种客车顶棚用干法聚氨酯玻纤复合材料，其特征在于：所述面料层克重范围为140-220g/m2，基材层克重范围在1200-1400g/m2。
3.根据权利要求1所述一种客车顶棚用干法聚氨酯玻纤复合材料，其特征在于：基材的制备步骤包括以下：
步骤一、制备基材层二层，制备步骤包括以下：
1)、准备以重量份计的聚氨酯泡沫原材料为：四羟基聚醚多元醇30-60份、八羟基聚醚多元醇20-40份、硅藻土8-35份、去离子水2.1-3.5份，甲苯二异氰酸酯1.1-2.4份，催化剂为1,4-二氮杂二环[2.2.2]辛烷0.4-0.8份和二月桂酸二丁基锡0.1-0.3份；泡沫稳定剂为脂肪酰二乙醇胺1.3-2.2份；
2)、将聚氨酯泡沫原材料混和搅拌均匀，立即倒入泡沫成型模具中使原材料自由发泡，发泡结束后，在环境温度为20-25℃下，熟化70-80h，得到聚氨酯泡沫；将聚氨酯泡沫进行切片制得基材层二层；
步骤二、制备基材层一层和基材层三层：
制备基材层一层：将12％-16％的玻璃纤维和12％-16％的聚乙烯粉混合搅拌均匀，一同放入双螺杆挤出机进料口，经双螺杆挤出机挤出，得到玻璃纤维和聚乙烯粉的混合材料，即为基材层一层；
制备基材层三层：将21％-25％的玻璃纤维和21％-25％的聚乙烯粉混合搅拌均匀，一同放入双螺杆挤出机进料口，经双螺杆挤出机挤出，得到玻璃纤维和聚乙烯粉的混合材料，即为基材层三层；
步骤三：制备基材层，准备基材层一层、基材层二层、基材层三层和基材层四层依次放入顶棚成型模具中进行复合，得到基材层。
4.根据权利要求1所述一种客车顶棚用干法聚氨酯玻纤复合材料，其特征在于：所述步骤二双螺杆挤出机的压缩段温度为100-120℃，均化段温度为140℃，机头以及口模段温度为135-150℃，螺杆转速为30-36r/min；步骤三中顶棚成型模具的温度为140℃。
5.根据权利要求1所述一种客车顶棚用干法聚氨酯玻纤复合材料，其特征在于：聚氨酯玻纤复合材料制备方法包括以下步骤：
S1、面料层的制备步骤包括以下：将多孔聚氨酯海绵和无纺布通过火焰复合的方法进行复合得到面料层；
S2、将步骤四中得到的基材层和S1中得到的面料层依次放入顶棚成型模具中，基材层和面料层复合得到聚氨酯玻纤复合材料。
6.根据权利要求1所述一种客车顶棚用干法聚氨酯玻纤复合材料，其特征在于：所述S2中顶棚成型模具温度为140℃。
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CN107415855A (zh) * 2017-09-13 2017-12-01 江淮汇通库尔特（合肥）有限公司 一种干法汽车吸音顶棚及其制备方法
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