CN111409315A - 一种一体成型汽车行李箱搁板及其制备方法 - Google Patents

一种一体成型汽车行李箱搁板及其制备方法 Download PDF

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CN111409315A
CN111409315A CN202010286148.1A CN202010286148A CN111409315A CN 111409315 A CN111409315 A CN 111409315A CN 202010286148 A CN202010286148 A CN 202010286148A CN 111409315 A CN111409315 A CN 111409315A
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trunk shelf
polyurethane
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王�华
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Jiangsu Delida New Material Co ltd
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Abstract

本发明公开了一种一体成型汽车行李箱搁板及其制备方法，包括一体成型汽车行李箱搁板由聚氨酯低密度硬质泡沫、纤维增强层以及面料层制得，其中所述聚氨酯低密度硬质泡沫由聚氨酯体系、制得，所述聚氨酯体系包含聚合MDI和组合聚醚多元醇，所述组合聚醚多元醇包括至少一种以环氧丙烷为主聚合单体的多元醇、至少一种催化剂以及如果合适添加的其他助剂。本发明的有益效果是，采用聚氨酯低密度硬质泡沫、纤维增强材料及面料制得一体成型汽车行李箱搁板，使用聚氨酯体系制备聚氨酯低密度硬质泡沫，该泡沫具备极低的挥发物排放，可以改善车内空气质量；同时一体成型汽车行李箱搁板的制备工艺简单，生产效率高。

Description

一种一体成型汽车行李箱搁板及其制备方法
技术领域
本发明涉及行李箱搁板部件技术领域，特别是一种一体成型汽车行李箱搁板及其制备方法。
背景技术
玻璃纤维增强的蜂窝板结构常用于汽车行李箱搁板，传统蜂窝板结构一般采用纸芯结构外层辅以玻璃纤维布，纸芯及所用的胶粘剂带来较高的可挥发物，影响了车内空气质量，因此研究一种具备极低的挥发物排放的汽车行李箱搁板是具有重要意义的，其中聚氨酯是一种性能优异的高分子材料，具有良好的耐油性、韧性、耐磨性、耐老化性和粘接性，其产品涉及轻功、化工、纺织、医疗、电子、建筑、汽车、航天等多个领域；其中聚氨酯硬质泡沫由于其优质的性能，被广泛应用于家电、建筑板材、管道、外墙喷涂等各种领域，在国内外均有广泛应用。
发明内容
本发明的目的是为了解决上述问题，设计了一种一体成型汽车行李箱搁板及其制备方法。
实现上述目的本发明的技术方案为，一种一体成型汽车行李箱搁板由聚氨酯低密度硬质泡沫、纤维增强层以及面料层制得，该制备方法包括以下步骤：
S1.将模具加热至一定温度，并在所述模具内依次预铺上面料层和纤维增强层；
S2.将聚氨酯低密度硬质泡沫喷涂于所述模具内并再次铺上面料层和纤维增强层，并进行固化；
S3.固化成型后得到一种三维构型的部件，将所述部件从所述模具中脱模，并对所述部件加以修边得到一体成型汽车行李箱搁板，如有需要可进一步处理；
其中所述聚氨酯低密度硬质泡沫由聚氨酯体系、制得，所述聚氨酯体系包含聚合MDI和组合聚醚多元醇，所述组合聚醚多元醇包括至少一种以环氧丙烷为主聚合单体的多元醇、至少一种催化剂以及如果合适添加的其他助剂。
作为本发明的进一步说明，所述面料层优选植绒织物或无纺布，所述纤维增强层优选玻璃纤维毡或有机纤维织物，所述模具的温度优选50-100度。
作为本发明的进一步说明，所述聚合MDI的官能度为2.5-2.9，所述组合聚醚多元醇中的聚醚多元醇的平均官能度为3-5、分子量为60-800。
作为本发明的进一步说明，所述聚醚多元醇的官能度可采用不同的起始剂获得，所述起始剂优选含有活性氢的水、多元醇和胺中的一种或多种。
作为本发明的进一步说明，所述催化剂优选有机金属类催化剂和胺类催化剂，所述其他助剂包括扩链剂、交联剂和添加剂，其中所述添加剂包括发泡剂、颜料、染料以及表面活性剂中的一种或者多种，所述交联剂优选活性氢个数大于3的多元醇或者胺。
作为本发明的进一步说明，所述发泡剂优选水，在所聚氨酯体系中所述水的比例占所述组合聚醚多元醇重量的0.3-2.5％。
作为本发明的进一步说明，在S3中进行脱模时优选硅酮类或者蜡质的脱模剂。
作为本发明的进一步说明，所述聚氨酯低密度硬质泡沫具有极低的挥发物释放。
其有益效果在于，本发明采用聚氨酯低密度硬质泡沫、纤维增强材料及面料制得一体成型汽车行李箱搁板，使用聚氨酯体系制备聚氨酯低密度硬质泡沫，采用官能度较高的聚醚多元醇作为原料，其工艺性能优异，制备过程中采用水作为发泡剂，从而做到零污染；同时该泡沫具备极低的挥发物排放，可以改善车内空气质量；一体成型汽车行李箱搁板的制备工艺简单，生产效率高。
具体实施方式
目前汽车行李箱搁板常采用玻璃纤维增强的蜂窝板结构，但是传统蜂窝板结构一般采用纸芯结构外层辅以玻璃纤维布，纸芯及所用的胶粘剂带来较高的可挥发物，影响了车内空气质量。该体系具有极低的挥发物释放，因此本发明提供了可以改善车内空气质量的一体成型汽车行李箱搁板。
上述的一体成型汽车行李箱搁板采用聚氨酯低密度硬质泡沫、纤维增强材料及面料制得，其中聚氨酯低密度硬质泡沫由聚氨酯体系制得，聚氨酯体系由聚合MDI和组合聚醚多元醇采用聚氨酯高压喷涂发泡机混合得到。
下面将对上述的聚合MDI和组合聚醚多元醇进行说明，聚合MDI为异氰酸酯，其通式为R(NCO)x(R为有机基团，x>2)，本发明中优选二苯基甲烷二异氰酸酯及其衍生物，同时本发明中聚合MDI的官能度为2.5-2.9；组合聚醚多元醇包括至少一种以环氧丙烷为主聚合单体的多元醇、至少一种催化剂以及如果合适添加的其他助剂，聚醚多元醇的平均官能度为3-5、分子量为60-800，其中官能度可采用不同的起始剂获得，起始剂可以为含有活性氢的水、多元醇以及胺中的一种或者多种，例如蔗糖，山梨醇，丙二醇，甘油，水，乙二胺，甲苯二胺等；在制备聚醚多元醇时采用碱金属氢氧化物催化、双金属DMC催化等已知方法。
组合聚醚多元醇中催化剂采用制备聚氨酯的常规催化剂，优选有机金属类催化剂和胺类催化剂，例如乙酸亚锡、辛酸亚锡、月桂酸亚锡、三乙胺、三丁胺、二甲基苄胺等。
下面将对组合聚醚多元醇中的助剂作进一步的说明，其他助剂包括扩链剂、交联剂和添加剂，其中扩链剂采用常规的扩链剂，例如乙二醇、丙二醇、丁二醇、二丙二醇等；交联剂采用活性氢个数>3的多元醇或者胺，例如甘油、乙二胺、甲苯二胺等；添加剂包括发泡剂、颜料、染料以及表面活性剂中的一种或者多种，其中本发明聚氨酯体系采用比例为组合聚醚多元醇重量的0.3-2.5％的水作为发泡剂。
本发明还提供了一种一体成型汽车行李箱搁板及其制备方法，该方法包括以下步骤：
S1.将模具加热至一定温度，并在模具内依次预铺上面料层和纤维增强层；
S2.将聚氨酯低密度硬质泡沫喷涂于模具内并再次铺上面料层和纤维增强层，并将其固化；
S3.待S2中固化成型后得到一种三维构型的部件，将其从模具中脱模，并对部件加以修边得到一体成型汽车行李箱搁板，如有需要可进一步处理。
其中面料层采用植绒织物或无纺布，纤维增强层采用玻璃纤维毡或有机纤维织物，面料层和纤维增强层可采用单面或者双面；模具可选择金属制模具，模具的温度优选50-100度；在脱模过程中可选择使用硅酮类或者蜡质的脱模剂。
为了更好地对本发明进行了解，下面将通过实施例对本发明作进一步地说明，首先先例举出在实施例中聚氨酯体系将采用的原料：
多元醇1：羟值为400的聚醚多元醇，通过将环氧丙烷加成于山梨醇/水制得；
多元醇2：羟值为460的聚醚多元醇，通过将环氧丙烷加成于蔗糖/丙二醇制得；
多元醇3：羟值为800的聚醚多元醇，通过将环氧丙烷加成于乙二胺制得；
表面活性剂：Niax L-6900,Momentive；
催化剂1：有机锡类催化剂；
催化剂2：有机胺类催化剂；
催化剂3：有机胺类催化剂；
染料：Isopur 9111,ISL；
异氰酸酯：PM 200，烟台万华；
实施例1：
下表是实施例1中聚氨酯体系采用各原料的用量：
原料 规格(单位：重量份)
多元醇1 40
多元醇2 40
多元醇3 10
表面活性剂 1
催化剂1 0.2
催化剂2 1
催化剂3 1
染料 4
水 1.2
异氰酸酯 150
首先将钢制模具加热至70度，在模具内依次预铺上植绒织物面层及玻璃纤维毡，再采用高压喷涂机混合通过上述原料得到的聚合MDI和组合聚醚多元醇，并将其喷涂于模具内，再次铺上植绒织物面层及玻璃纤维毡，待它们固化5分钟后从模具中脱模取出部件并对其进行修边，从而得到最终制品。
实施例2：将实施例1中的植绒织物面层及玻璃纤维毡替换为无纺布面层及天然椰壳纤维毡，其他的均与实施例1中相同。
上述技术方案仅体现了本发明技术方案的优选技术方案，本技术领域的技术人员对其中某些部分所可能做出的一些变动均体现了本发明的原理，属于本发明的保护范围之内。

Claims (8)

1.一种一体成型汽车行李箱搁板及其制备方法，其特征在于，一体成型汽车行李箱搁板由聚氨酯低密度硬质泡沫、纤维增强层以及面料层制得，该制备方法包括以下步骤：
S1.将模具加热至一定温度，并在所述模具内依次预铺上面料层和纤维增强层；
S2.将聚氨酯低密度硬质泡沫喷涂于所述模具内并再次铺上面料层和纤维增强层，并进行固化；
S3.固化成型后得到一种三维构型的部件，将所述部件从所述模具中脱模，并对所述部件加以修边得到一体成型汽车行李箱搁板，如有需要可进一步处理；
其中所述聚氨酯低密度硬质泡沫由聚氨酯体系、制得，所述聚氨酯体系包含聚合MDI和组合聚醚多元醇，所述组合聚醚多元醇包括至少一种以环氧丙烷为主聚合单体的多元醇、至少一种催化剂以及如果合适添加的其他助剂。
2.根据权利要求1所述的一种一体成型汽车行李箱搁板及其制备方法，其特征在于，所述面料层优选植绒织物或无纺布，所述纤维增强层优选玻璃纤维毡或有机纤维织物，所述模具的温度优选50-100度。
3.根据权利要求1所述的一种一体成型汽车行李箱搁板及其制备方法，其特征在于，所述聚合MDI的官能度为2.5-2.9，所述组合聚醚多元醇中的聚醚多元醇的平均官能度为3-5、分子量为60-800。
4.根据权利要求3所述的一种一体成型汽车行李箱搁板及其制备方法，其特征在于，所述聚醚多元醇的官能度可采用不同的起始剂获得，其中所述起始剂优选含有活性氢的水、多元醇和胺中的一种或多种。
5.根据权利要求1所述的一种一体成型汽车行李箱搁板及其制备方法，其特征在于，所述催化剂优选有机金属类催化剂和胺类催化剂，所述其他助剂包括扩链剂、交联剂和添加剂，其中所述添加剂包括发泡剂、颜料、染料以及表面活性剂中的一种或者多种，所述交联剂优选活性氢个数大于3的多元醇或者胺。
6.根据权利要求5所述的一种一体成型汽车行李箱搁板及其制备方法，其特征在于，所述发泡剂优选水，在所聚氨酯体系中所述水的比例占所述组合聚醚多元醇重量的0.3-2.5％。
7.根据权利要求1所述的一种一体成型汽车行李箱搁板及其制备方法，其特征在于，在S3中进行脱模时优选硅酮类或者蜡质的脱模剂。
8.根据权利要求1所述的一种一体成型汽车行李箱搁板及其制备方法，其特征在于，所述聚氨酯低密度硬质泡沫具有极低的挥发物释放。
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