CN110802887A - 一种汽车麻纤维顶棚及其制造工艺 - Google Patents

一种汽车麻纤维顶棚及其制造工艺 Download PDF

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CN110802887A
CN110802887A CN201911033285.8A CN201911033285A CN110802887A CN 110802887 A CN110802887 A CN 110802887A CN 201911033285 A CN201911033285 A CN 201911033285A CN 110802887 A CN110802887 A CN 110802887A
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fibrilia
ceiling
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邓吉雄
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Fuzhou Lianhong Motor Parts Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
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Abstract

本发明涉及一种汽车麻纤维顶棚的制造工艺，包括自上而下依次设置的面料复合材、麻纤维毡基材层，两者热压成型为一体；所述面料复合材是由自上而下设置的上面料层、泡绵和无纺布经烧贴工艺制得；所述麻纤维毡基材层是由自上而下设置的胶膜A、麻纤维毡基材、胶膜B和下面料层经压合工艺制得。本发明采用麻纤维板材替代现有的主体材质，加上面料复合材压合成汽车顶棚，制得的汽车顶棚具有较高的刚性和耐温性，且废料可以回收利用，易于分解，且具有高韧性，低VOC和抗菌防潮的效果。

Description

一种汽车麻纤维顶棚及其制造工艺
技术领域
本发明涉及一种汽车麻纤维顶棚及其制造工艺。
背景技术
汽车顶棚内饰是汽车整车内饰的重要组成部分，它的主要作用是提高车内的装饰性，及顶棚内饰还可提高与车外的隔热、绝热效果；降低车内噪声，提高吸音效果；提高乘务员乘坐的舒适性与安全性。
目前公布的关于聚氨酯汽车顶棚的生产方法主要有以下两种：（1）中国专利CN101367287B所提到的一种聚氨酯多层复合板的生产方法，该方法的具体步骤：a）将短切的玻璃纤维和热熔胶粉播撒在复合机的传送带上，热压复合成膜，冷却、收卷、得到胶玻膜；b）在复合生产线的工作台上自下而上一次放卷、叠放、平铺粘接膜、胶玻膜和热熔胶膜，经热压复合，冷却，得到聚氨酯多层复合板。该复合板在经过200℃的烘烤，然后送入冷模中进行冷却定型，经水切割后得到汽车顶棚。该方法是俗称的干法汽车顶棚生产工艺，该方法的缺点在于生产的能耗高，吸音效果差，由于采用热塑性材料，产品的刚性以及耐温性能都不好，同时材料不容易回收，边角废料容易造成环境污染；（2）中国专利CN101337526B所提到的一种PU软泡顶衬的湿法生产工艺，该工艺包括如下步骤：a）采用滚胶机在PU泡沫板的上下表面滚涂60-180g/m²的单组份聚氨酯胶黏剂；b）自下而依次叠铺淋膜无纺布、玻纤毡、PU泡沫板、玻纤毡、面料，放入模具中压制成型，其中模具温度控制在130-140℃，压制时间55s；c）冷却定型，水切得到汽车顶棚，该方法的缺点在于生产中多种材料互相叠加，工艺较为复杂，产品的VOC值仍然较高，产品如有报废，材料不容易回收，边角废料容易造成环境的污染。
发明内容
有鉴于此，本发明的目的在于提供了一种汽车麻纤维顶棚及其制造工艺，本发明采用麻纤维板材替代现有的主体材质，加上面料复合材压合成汽车顶棚，制得的汽车顶棚具有较高的刚性和耐温性，且废料可以回收利用，易于分解，且具有高韧性，低VOC和抗菌防潮的效果。
本发明的技术方案是：一种汽车麻纤维顶棚，包括自上而下依次设置的面料复合材、麻纤维毡基材层，两者热压成型为一体；所述面料复合材是由自上而下设置的上面料层、泡绵和无纺布经烧贴工艺制得；所述麻纤维毡基材层是由自上而下设置的胶膜A、麻纤维毡基材、胶膜B和下面料层经压合工艺制得。
进一步的，所述的麻纤维毡基材是按照质量比天然纤维：合成纤维=80-100：20-0混合，经过无纺设备梳理、成网、针刺，得到厚度5-20mm，克重300-1500g/m³的麻纤维毡基材。
进一步的，所述胶膜A、胶膜B均为热熔胶膜，熔点为105度，经过光波烘箱烘烤之后胶膜会融化成胶水状，便于与上下层材料胶粘在一起形成整体。
进一步的，所述无纺布为水刺无纺布或者针刺无纺布，面密度40-150g/m²。
进一步的，所述上面料层、下面料层均为经遍布复合材或者无纺布复合材。
一种汽车麻纤维遮阳板的制造工艺，并按以下步骤进行：（1）表皮送料：将面料复合材平铺后，利用面料复合材送料机构将所述面料复合材输送至成型模具的成型腔内；（2）基材送料：将麻纤维毡基材层平铺后，利用麻纤维毡基材层送料机构将麻纤维毡基材层输送至光波烘箱A内进行预热，预热之后再将前麻纤维毡基材层输送至光波烘箱B内进行加热，接着送料机构继续将加热后的麻纤维毡基材层输送至成型模具的成型腔内，此时，面料复合材在上，麻纤维毡基材层在下；（3）热压成型：四柱油压机自动下压将所述面料复合材与麻纤维毡基材层压合形成顶篷，成型温度为15~25℃，成型压力为90~110kg/cm²，压合时间为35~45秒，成型后顶篷自动退料；（4）水刀切割：采用倒挂机器人水刀切割设备，将热压麻纤维毡基材层放置治具上端固定，热压麻纤维毡基材层放置治具旋转180°倒挂机器人对麻纤维毡基材层进行切割，单喷嘴直径压力：2700 psi-2900 psi；系统用水的技术要求：切割水供水 (配低压纯水系统)最大水消耗量 4.0 gpm (15.1 L/min)，增压泵设定进口水压58 psi (4 bar)，增压后出口水压120 psi (8.3 bar)，设定进水口水温 65°F (18°C)，进水口水温 85° F (29°C)；（5）仕上反包：将水刀切割后的麻纤维毡基材层放置工作桌，取喷胶枪将绿胶均匀喷涂至天窗口与顶篷前端，将喷涂胶水后的顶篷放置仕上反包设备上端，进行自动反包边角，设备温度设定240±10℃，烘烤时间120秒，反包后冷却时间40秒；（6）将反包后顶篷取出放置仕上工作桌进行装附件作业，完成后检查入库。
进一步的，所述光波烘箱A的温度为100~120℃，烘烤时间为45~55s，所述光波烘箱B的温度为150~200℃，烘烤时间为45~55s。
与现有技术相比，本发明的有益效果是：本发明将天然麻纤维胶膜复合得到麻纤维毡基材，再将麻纤维毡基材作为汽车顶棚的主材，麻纤维毡基材可保证汽车顶棚较高的刚性，韧性和耐温性，可以降低顶棚的厚度，增加车内空间，生产出来的顶棚重量轻，弯曲强度高，模量高，耐气候性好，成品还具有耐皱褶，破坏后不易产生锐角和断面，安全可靠，且麻纤维材料不仅具有抗菌作用，还是环保材料、VOC含量低，通过麻纤维材料制备的汽车顶棚的废料可以回收利用，易于分解。
为使得本发明的上述目的、特征和优点能够更明显易懂，下面结合附图对本发明的具体实施方式做详细说明。
附图说明
图1为本发明实施例制造工艺装置的主视图；
图2为本发明实施例制造工艺装置的俯视图；
图3为本发明实施例的倒挂机器人水刀切割设备的结构示意图；
图4为本发明实施例的仕上反包设备的结构示意图；
图5为本发明实施例的仕上反包设备的俯视图；
图6为本发明实施例面料复合材的结构示意图；
图7为本发明实施例麻纤维毡基材层的结构示意图；
图中：1-面料复合材送料机构；2-麻纤维毡基材层送料机构；3-成型模具；4-光波烘箱A；5-光波烘箱B；6-四柱油压机；7-倒挂机器人水刀切割设备；8-热压麻纤维毡基材层放置治具；9-仕上反包设备；10-麻纤维毡基材层；11-面料复合材；12-上面料层；13-泡绵；14-无纺布；15-胶膜A；16-麻纤维毡基材；17-胶膜B；18-下面料层。
具体实施方式
如图1~7所示，一种汽车麻纤维顶棚，包括自上而下依次设置的面料复合材11、麻纤维毡基材层10，两者热压成型为一体；所述面料复合材11是由自上而下设置的上面料层12、泡绵13和无纺布14经烧贴工艺制得；所述麻纤维毡基材层10是由自上而下设置的胶膜A15、麻纤维毡基材、胶膜B17和下面料层18经压合工艺制得。
本实施例中，所述的麻纤维毡基材是按照质量比天然纤维：合成纤维=80-100：20-0混合，经过无纺设备梳理、成网、针刺，得到厚度5-20mm，克重300-1500g/m³的麻纤维毡基材。
本实施例中，所述胶膜A15、胶膜B17均为热熔胶膜，熔点为105度，经过光波烘箱烘烤之后胶膜会融化成胶水状，便于与上下层材料胶粘在一起形成整体。
本实施例中，所述无纺布14为水刺无纺布14或者针刺无纺布14，面密度40-150g/m²。
本实施例中，所述上面料层12、下面料层18均为经遍布复合材或者无纺布14复合材。
在本发明实施例中，所述天然纤维包括：黄麻，苎麻，青麻，亚麻中的一种或者多种组成；合成纤维包括：聚乙烯纤维、聚丙烯纤维、尼龙纤维、涤纶纤维中的一种或几种。
一种汽车麻纤维遮阳板的制造工艺，并按以下步骤进行：（1）表皮送料：将面料复合材11平铺后，利用面料复合材送料机构1将所述面料复合材11输送至成型模具3的成型腔内；（2）基材送料：将麻纤维毡基材层10平铺后，利用送料机构2将麻纤维毡基材层10输送至光波烘箱A4内进行预热，预热之后再将麻纤维毡基材层10输送至光波烘箱B5内进行加热，接着送料机构继续将加热后的麻纤维毡基材层10输送至成型模具3的成型腔内，此时，面料复合材11在上，麻纤维毡基材层10在下；（3）热压成型：四柱油压机6自动下压将所述面料复合材11与麻纤维毡基材层10压合形成顶篷，成型温度为15~25℃，成型压力为90~110kg/cm²，压合时间为35~45秒，成型后顶篷自动退料；（4）水刀切割：采用倒挂机器人水刀切割设备7，将热压麻纤维毡基材层放置治具8上端固定，热压麻纤维毡基材层放置治具8旋转180°倒挂机器人对麻纤维毡基材层10进行切割，单喷嘴直径压力：2700 psi-2900 psi；系统用水的技术要求：切割水供水 (配低压纯水系统)最大水消耗量 4.0 gpm (15.1 L/min)，增压泵设定进口水压 58 psi (4 bar)，增压后出口水压120 psi (8.3 bar)，设定进水口水温65°F (18°C)，进水口水温 85° F (29°C)；（5）仕上反包：将水刀切割后的麻纤维毡基材层10放置工作桌，取喷胶枪将绿胶均匀喷涂至天窗口与顶篷前端，将喷涂胶水后的顶篷放置仕上反包设备9上端，进行自动反包边角，设备温度设定240±10℃，烘烤时间120秒，反包后冷却时间40秒；（6）将反包后顶篷取出放置仕上工作桌进行装附件作业，完成后检查入库。
本实施例中，所述光波烘箱A4的温度为100~120℃，烘烤时间为45~55s，所述光波烘箱B5的温度为150~200℃，烘烤时间为45~55s。
上述操作流程及软硬件配置，仅作为本发明的较佳实施例，并非因此限制本发明的专利范围，凡是利用本发明说明书及附图内容所作的等同变换，或直接或间接运用在相关技术领域，均同理包括在本发明的专利保护范围内。

Claims (7)

1.一种汽车麻纤维顶棚，其特征在于：包括自上而下依次设置的面料复合材、麻纤维毡基材层，两者热压成型为一体；所述面料复合材是由自上而下设置的上面料层、泡绵和无纺布经烧贴工艺制得；所述麻纤维毡基材层是由自上而下设置的胶膜A、麻纤维毡基材、胶膜B和下面料层经压合工艺制得。
2.根据权利要求1所述的汽车麻纤维顶棚，其特征在于：所述的麻纤维毡基材是按照质量比天然纤维：合成纤维=80-100：20-0混合，经过无纺设备梳理、成网、针刺，得到厚度5-20mm，克重300-1500g/m³的麻纤维毡基材。
3.根据权利要求2所述的汽车麻纤维顶棚，其特征在于：所述胶膜A、胶膜B均为热熔胶膜，熔点为105度，经过光波烘箱烘烤之后胶膜会融化成胶水状，便于与上下层材料胶粘在一起形成整体。
4.根据权利要求3所述的汽车麻纤维顶棚，其特征在于：所述无纺布为水刺无纺布或者针刺无纺布，面密度40-150g/m²。
5.根据权利要求4所述的汽车麻纤维顶棚，其特征在于：所述上面料层、下面料层均为经遍布复合材或者无纺布复合材。
6.一种汽车麻纤维顶棚的制造工艺，其特征在于，采用如权利要求5所述的汽车麻纤维顶棚，并按以下步骤进行：（1）表皮送料：将面料复合材平铺后，利用面料复合材送料机构将所述面料复合材输送至成型模具的成型腔内；（2）基材送料：将麻纤维毡基材层平铺后，利用麻纤维毡基材层送料机构将麻纤维毡基材层输送至光波烘箱A内进行预热，预热之后再将前麻纤维毡基材层输送至光波烘箱B内进行加热，接着送料机构继续将加热后的麻纤维毡基材层输送至成型模具的成型腔内，此时，面料复合材在上，麻纤维毡基材层在下；（3）热压成型：四柱油压机自动下压将所述面料复合材与麻纤维毡基材层压合形成顶篷，成型温度为15~25℃，成型压力为90~110kg/cm²，压合时间为35~45秒，成型后顶篷自动退料；（4）水刀切割：采用倒挂机器人水刀切割设备，将热压麻纤维毡基材层放置治具上端固定，热压麻纤维毡基材层放置治具旋转180°倒挂机器人对麻纤维毡基材层进行切割，单喷嘴直径压力：2700 psi-2900 psi；系统用水的技术要求：切割水供水 (配低压纯水系统)最大水消耗量 4.0 gpm (15.1 L/min)，增压泵设定进口水压 58 psi (4 bar)，增压后出口水压120psi (8.3 bar)，设定进水口水温 65°F (18°C)，进水口水温 85° F (29°C)；（5）仕上反包：将水刀切割后的麻纤维毡基材层放置工作桌，取喷胶枪将绿胶均匀喷涂至天窗口与顶篷前端，将喷涂胶水后的顶篷放置仕上反包设备上端，进行自动反包边角，设备温度设定240±10℃，烘烤时间120秒，反包后冷却时间40秒；（6）将反包后顶篷取出放置仕上工作桌进行装附件作业，完成后检查入库。
7.根据权利要求6所述的一种汽车麻纤维遮阳板的制造工艺，其特征在于：所述光波烘箱A的温度为100~120℃，烘烤时间为45~55s，所述光波烘箱B的温度为150~200℃，烘烤时间为45~55s。
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