CN110834448A - 汽车装饰件模内装饰发泡复合工艺 - Google Patents
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Abstract
本发明公开了汽车装饰件模内装饰发泡复合工艺技术领域的汽车装饰件模内装饰发泡复合工艺，装饰件本体包括热塑性树脂基体，所述热塑性树脂基体的外壁上固定装配有无纺布层，所述无纺布层的外壁固定装配有可回弹泡沫棉层，所述可回弹泡沫棉层的外壁上固定装配有保温饰板层，在软质型触感的装饰件本体外壁上均匀铺设有聚氨酯垫块，所述保温饰板层的外壁上装配有微发泡聚氨酯层，所述微发泡聚氨酯层的外壁上安装有金属面板而形成金属保温装饰板，通过层状材料的选择，以及火焰预复合工艺和模塑成型工艺的有机组合，使得使得制品表面一致性好，使得结构压实密度较高，防止在受到高温后形成变形凹坑，保证了产品的加工质量。
Description
技术领域
本发明涉及汽车装饰件模内装饰发泡复合工艺技术领域，具体为汽车装饰件模内装饰发泡复合工艺。
背景技术
随着汽车消费的大众化，一方面为了降低能耗，要求尽可能地降低汽车的整体质量；另一方面乘用人员追求乘用的舒适性，要求内饰件具有软质触感和降噪作用，汽车内饰越来越多地采用泡沫材料作为内衬来实现这两项功能，目前常用的一种方法是先注塑成型热塑性树脂骨架，然后在骨架上喷胶或刷胶，再将聚氨酯泡沫以及表面织物或皮革粘接到热塑性树脂骨架上，这样容易导致粘胶固化时间长，并且需要后续定型处理，采用不好的黏胶剂则会产生有机异味，并且在室外气温冷热变化时，如果是装饰板为金属拉丝面板，则由于金属拉丝面板和保温层的线膨胀系数差异较大，容易造成材料应力变化，很容易使金属拉丝面板和保温层之间出现空鼓变形，同时装饰材料背面的低温热熔胶很容易被热塑性树脂击穿，形成局部硬点，特别是在含有低密度的泡沫时，高温热塑性树脂被引入泡沫后，在表面形成不可恢复的坍陷，形成废品，为此，我们提出汽车装饰件模内装饰发泡复合工艺。
发明内容
本发明的目的在于提供汽车装饰件模内装饰发泡复合工艺，以解决上述背景技术中提出的问题。
为实现上述目的，本发明提供如下技术方案：汽车装饰件模内装饰发泡复合工艺，其中的汽车装饰件包括软质型触感的装饰件本体，装饰件本体包括热塑性树脂基体，所述热塑性树脂基体的外壁上固定装配有无纺布层，所述无纺布层的外壁固定装配有可回弹泡沫棉层，所述可回弹泡沫棉层的外壁上固定装配有保温饰板层，在软质型触感的装饰件本体外壁上均匀铺设有聚氨酯垫块，所述保温饰板层的外壁上装配有微发泡聚氨酯层，所述微发泡聚氨酯层的外壁上安装有金属面板而形成金属保温装饰板。
此种汽车装饰件的复合工艺的具体步骤为：
A：将无纺布层和可回弹泡沫棉层依次预先火焰复合成一体，并且需要将无纺布层和可回弹泡沫棉层需要预先裁切成所铸模塑成型所需要的形状，然后将复合体放置并固定装配在模具型腔中，再闭合模具。
B：将热塑性树脂基体预塑形成基体原料，并将原料注射到无纺布层与模具型腔或芯腔之间的模具空间中。
C：在铸模完成后，进行冷却、开模和取件，然后将保温饰板层通过卡扣卡接装配在可回弹泡沫棉层外侧壁上，并且将内饰膜贴装在保温饰板层的外壁上，即可形成软质型触感的装饰件本体。
D：需要制备金属保温装饰板时，先将金属面板水平放置在具有托辊的预安装平台上，然后在金属面板的板面上均布间隔设置若干组结构相同的聚氨酯垫块，并且将金属面板推入面板预热烘道内实现预热操作。
E：经过预热烘道预热的金属面板再依次经过往复式浇注机以及高密度微发泡聚氨酯浇注机，这样在金属面板的板面上形成高密度的微发泡聚氨酯层，并且微发泡聚氨酯层的厚度与聚氨酯垫块的厚度相同。
F：将步骤C中铸造完成的保温饰板层在不贴附内饰膜的前提下经过PUR热熔胶溶胶机进行环保胶涂抹处理，然后将保温饰板层和微发泡聚氨酯层实现对接挤压，并在对接挤压后经过上下平行间隔布置的层压履带实现相互挤压，提高保温饰板层和微发泡聚氨酯层的挤压稳固性，同时可以提高紧密性，冷却完成后即可完成金属保温装饰板的制作。
优选的，步骤B中的热塑性树脂基体的原料是预塑预定量的热塑性树脂，并且向熔融的热塑性树脂中按热塑性树脂质量的1—3％添加超临界氮气，并在氮气的一个超临界状态下将热塑性树脂和氮气混合形成均相溶液。
优选的，所述可回弹泡沫棉层采用交联聚烯烃泡沫材料，并且可回弹泡沫棉层选择厚度在1mm—5mm之间，密度在30kg/m3--100kg/m3之间的泡沫材料。
优选的，所述无纺布层为热熔性树脂制成的无纺布，且无纺布采用克重为每平方米170克的聚二甲酸乙二酯无纺布。
优选的，步骤D中的预安装平台后部设置着预热烘道，预热烘道下部内均布间隔设置着托辊以及电加热管。
与现有技术相比，本发明的有益效果是：
该发明通过层状材料的选择，以及火焰预复合工艺和模塑成型工艺的有机组合，使得使得制品表面一致性好，使得结构压实密度较高，防止在受到高温后形成变形凹坑，保证了产品的加工质量，具有舒适的软质触感和良好的降噪性能，制造方法具有工序短、效率高的特点，同时预加温温度低，粘接效果好，可以保证结构之间的粘结稳固性，可以有效地防止金属面板与保温饰板层之间出现空鼓变形问题。
附图说明
图1为本发明实施例1结构示意图；
图2为本发明实施例2结构示意图。
图中：1热塑性树脂基体、2无纺布层、3可回弹泡沫棉层、4保温饰板层、5聚氨酯垫块、6微发泡聚氨酯层、7金属面板。
具体实施方式
下面将结合本发明实施例中的附图，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做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例
汽车装饰件模内装饰发泡复合工艺，其中的汽车装饰件包括软质型触感的装饰件本体，装饰件本体包括热塑性树脂基体1，热塑性树脂基体1的外壁上固定装配有无纺布层2，无纺布层2的外壁固定装配有可回弹泡沫棉层3，可回弹泡沫棉层3的外壁上固定装配有保温饰板层4，在软质型触感的装饰件本体外壁上均匀铺设有聚氨酯垫块5，保温饰板层4的外壁上装配有微发泡聚氨酯层6，微发泡聚氨酯层6的外壁上安装有金属面板7而形成金属保温装饰板。
此种汽车装饰件的复合工艺的具体步骤为：
A：将无纺布层2和可回弹泡沫棉层3依次预先火焰复合成一体，并且需要将无纺布层2和可回弹泡沫棉层3需要预先裁切成所铸模塑成型所需要的形状，然后将复合体放置并固定装配在模具型腔中，再闭合模具。
B：将热塑性树脂基体1预塑形成基体原料，并将原料注射到无纺布层2与模具型腔或芯腔之间的模具空间中。
C：在铸模完成后，进行冷却、开模和取件，然后将保温饰板层4通过卡扣卡接装配在可回弹泡沫棉层3外侧壁上，并且将内饰膜贴装在保温饰板层4的外壁上，即可形成软质型触感的装饰件本体。
D：需要制备金属保温装饰板时，先将金属面板7水平放置在具有托辊的预安装平台上，然后在金属面板7的板面上均布间隔设置若干组结构相同的聚氨酯垫块5，并且将金属面板7推入面板预热烘道内实现预热操作。
E：经过预热烘道预热的金属面板7再依次经过往复式浇注机以及高密度微发泡聚氨酯浇注机，这样在金属面板7的板面上形成高密度的微发泡聚氨酯层6，并且微发泡聚氨酯层6的厚度与聚氨酯垫块5的厚度相同。
F：将步骤C中铸造完成的保温饰板层4在不贴附内饰膜的前提下经过PUR热熔胶溶胶机进行环保胶涂抹处理，然后将保温饰板层4和微发泡聚氨酯层6实现对接挤压，并在对接挤压后经过上下平行间隔布置的层压履带实现相互挤压，提高保温饰板层4和微发泡聚氨酯层6的挤压稳固性，同时可以提高紧密性，冷却完成后即可完成金属保温装饰板的制作。
其中，步骤B中的热塑性树脂基体1的原料是预塑预定量的热塑性树脂，并且向熔融的热塑性树脂中按热塑性树脂质量的1—3％添加超临界氮气，并在氮气的一个超临界状态下将热塑性树脂和氮气混合形成均相溶液。
可回弹泡沫棉层3采用交联聚烯烃泡沫材料，并且可回弹泡沫棉层3选择厚度在1mm—5mm之间，密度在30kg/m3--100kg/m3之间的泡沫材料，即可使成型后的制品获得软质的手感，还使制品具有更好的吸音降噪功能。
无纺布层2为热熔性树脂制成的无纺布，且无纺布采用克重为每平方米170克的聚二甲酸乙二酯无纺布，，即可与后续填充的由玻璃纤维填充的聚丙烯共聚合物树脂实现熔体粘接，也能有效地阻止热塑性树脂熔体进入到可回弹泡沫棉层3中。
步骤D中的预安装平台后部设置着预热烘道，预热烘道下部内均布间隔设置着托辊以及电加热管。
尽管已经示出和描述了本发明的实施例，对于本领域的普通技术人员而言，可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型，本发明的范围由所附权利要求及其等同物限定。
Claims (6)
1.汽车装饰件模内装饰发泡复合工艺，其中的汽车装饰件包括软质型触感的装饰件本体，其特征在于：装饰件本体包括热塑性树脂基体(1)，所述热塑性树脂基体(1)的外壁上固定装配有无纺布层(2)，所述无纺布层(2)的外壁固定装配有可回弹泡沫棉层(3)，所述可回弹泡沫棉层(3)的外壁上固定装配有保温饰板层(4)，在软质型触感的装饰件本体外壁上均匀铺设有聚氨酯垫块(5)，所述保温饰板层(4)的外壁上装配有微发泡聚氨酯层(6)，所述微发泡聚氨酯层(6)的外壁上安装有金属面板(7)而形成金属保温装饰板。
2.根据权利要求1所述的汽车装饰件模内装饰发泡复合工艺，其特征在于：此种装饰件的复合工艺的具体步骤为：
A：将无纺布层(2)和可回弹泡沫棉层(3)依次预先火焰复合成一体，并且需要将无纺布层(2)和可回弹泡沫棉层(3)需要预先裁切成所铸模塑成型所需要的形状，然后将复合体放置并固定装配在模具型腔中，再闭合模具。
B：将热塑性树脂基体(1)预塑形成基体原料，并将原料注射到无纺布层(2)与模具型腔或芯腔之间的模具空间中。
C：在铸模完成后，进行冷却、开模和取件，然后将保温饰板层(4)通过卡扣卡接装配在可回弹泡沫棉层(3)外侧壁上，并且将内饰膜贴装在保温饰板层(4)的外壁上，即可形成软质型触感的装饰件本体。
D：需要制备金属保温装饰板时，先将金属面板(7)水平放置在具有托辊的预安装平台上，然后在金属面板(7)的板面上均布间隔设置若干组结构相同的聚氨酯垫块(5)，并且将金属面板(7)推入面板预热烘道内实现预热操作。
E：经过预热烘道预热的金属面板(7)再依次经过往复式浇注机以及高密度微发泡聚氨酯浇注机，这样在金属面板(7)的板面上形成高密度的微发泡聚氨酯层(6)，并且微发泡聚氨酯层(6)的厚度与聚氨酯垫块(5)的厚度相同。
F：将步骤C中铸造完成的保温饰板层(4)在不贴附内饰膜的前提下经过PUR热熔胶溶胶机进行环保胶涂抹处理，然后将保温饰板层(4)和微发泡聚氨酯层(6)实现对接挤压，并在对接挤压后经过上下平行间隔布置的层压履带实现相互挤压，提高保温饰板层(4)和微发泡聚氨酯层(6)的挤压稳固性，同时可以提高紧密性，冷却完成后即可完成金属保温装饰板的制作。
3.根据权利要求2所述的汽车装饰件模内装饰发泡复合工艺，其特征在于：步骤B中的热塑性树脂基体(1)的原料是预塑预定量的热塑性树脂，并且向熔融的热塑性树脂中按热塑性树脂质量的1—3％添加超临界氮气，并在氮气的一个超临界状态下将热塑性树脂和氮气混合形成均相溶液。
4.根据权利要求2所述的汽车装饰件模内装饰发泡复合工艺，其特征在于：所述可回弹泡沫棉层(3)采用交联聚烯烃泡沫材料，并且可回弹泡沫棉层(3)选择厚度在1mm—5mm之间，密度在30kg/m3--100kg/m3之间的泡沫材料。
5.根据权利要求2所述的汽车装饰件模内装饰发泡复合工艺，其特征在于：所述无纺布层(2)为热熔性树脂制成的无纺布，且无纺布采用克重为每平方米170克的聚二甲酸乙二酯无纺布。
6.根据权利要求2所述的汽车装饰件模内装饰发泡复合工艺，其特征在于：步骤D中的预安装平台后部设置着预热烘道，预热烘道下部内均布间隔设置着托辊以及电加热管。
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