CN112519334A - 一种汽车后盖用轻量化内饰材料及其制备方法 - Google Patents

一种汽车后盖用轻量化内饰材料及其制备方法 Download PDF

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CN112519334A
CN112519334A CN202011349540.2A CN202011349540A CN112519334A CN 112519334 A CN112519334 A CN 112519334A CN 202011349540 A CN202011349540 A CN 202011349540A CN 112519334 A CN112519334 A CN 112519334A
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glass fiber
interior material
rear cover
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方诚
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Shanghai Xin'an Car Deadening Felt Co ltd
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Abstract

本发明涉及一种汽车后盖用轻量化内饰材料，该内饰材料从上到下依次包括：表面地毯(1)和玻纤板(2)，所述的表面地毯(1)与玻纤板(2)的厚度之比为(4‑8):1，其制备方法包括以下步骤：(1)玻纤板(2)的加工成型：采用针刺复合工艺，将玻纤层(22)一面缝合PE粘合层(21)，另一面缝合水刺无纺布(23)；(2)表面地毯(1)与玻纤板(2)的热压成型，最终得到汽车后盖用轻量化内饰材料。与现有技术相比，本发明具有力学性能良好、VOC散发量少等优点。

Description

一种汽车后盖用轻量化内饰材料及其制备方法
技术领域
本发明涉及汽车内饰材料领域，具体涉及一种汽车后盖用轻量化内饰材料及其制备方法。
背景技术
目前的后盖内饰材料多使用以PP塑料采取注塑工艺或者PP+麻纤维、PP+PET成型毡作为基材制成。
使用这几种基材制成的后盖内饰零件，虽然有着一定的强度，也基本上能满足汽车后盖内饰零件的功能性要求。但受结构和材料的限制，并不利于零件外观及气味、VOC等散发性能的需要，其单件重量多在1000g左右，不利于汽车零件轻量化的要求。
发明内容
本发明的目的就是为了克服上述现有技术存在的缺陷而提供一种力学性能良好、VOC散发量少的汽车后盖用轻量化内饰材料及其制备方法。
本发明的目的可以通过以下技术方案来实现：
一种汽车后盖用轻量化内饰材料，该内饰材料从上到下依次包括：表面地毯和玻纤板，所述的表面地毯与玻纤板的厚度之比为(4-8):1。表面地毯与玻纤板的厚度比近似可以为单位面积重量的比值，即表面地毯：玻纤板约为1:5；且表面地毯与玻纤板总厚度约为3mm，即表面地毯成型后约0.5mm，玻纤板约2.5mm。
进一步地，所述的表面地毯为针刺平绒，单位面积重量为150-200g/m2。优选180g/m2，该风格面料多用于中端车型，面料表面较为细腻，手感柔和。
进一步地，所述的玻纤板的单位面积重量为880-920g/m2。优选900g/m2。
进一步地，所述的玻纤板从上到下依次包括：PE粘合层、玻纤层和水刺无纺布。
进一步地，所述的PE粘合层的单位面积重量为40-60g/m2。优选50g/m2。
进一步地，所述的玻纤层由玻璃纤维和聚丙烯纤维按重量比为(48-52):(52-48)混纺制成。其中聚丙烯纤维熔点为168℃。
进一步地，所述的水刺无纺布的单位面积重量为40-50g/m2。水刺无纺布可以改善玻纤层的拉伸性能，又能避免玻纤外露的情况发生。
本发明中，贡献力学性能最重要的是玻璃纤维(GF)，玻璃纤维具有优良的力学性能，在塑料粒子中，也常用于改性PP粒子，作为增强型塑料粒子。
但是，玻璃纤维的拉伸性能较差，即如果零件具有较大的拉伸或者延展的型面，使用PP+PET材料是可以实现的，但使用PP+GF的材料，成型会比较困难，玻璃纤维会被拉断。
由于汽车尾门不可避免的会有一定的拉伸，所以，现在很少使用PP+GF材料制作尾门饰板零件；在本发明中，基材背面的水刺无纺布，是有利于提升玻纤板的拉伸性能的。
一种如上所述的汽车后盖用轻量化内饰材料的制备方法，该方法包括以下步骤：
(1)玻纤板的加工成型：采用针刺复合工艺，将玻纤层一面缝合PE粘合层，另一面缝合水刺无纺布；
(2)表面地毯与玻纤板的热压成型：
(2-1)将玻纤板高温加热软化后，此时PE粘合层出现软化，有利于用来实现玻纤板与表面地毯的粘合，放入成型模具中，并铺设表面地毯，保证表面地毯与PE粘合层相互粘合；
(2-2)然后在模具中进行压制成型，期间通过水冷系统，保持模具温度为18±5℃，最终得到汽车后盖用轻量化内饰材料。成型件重量为260-320g/0.53m2，相比于1000g/0.92m2左右的其他基材的后盖内饰类零件，在实现零件功能的前提下，大大降低了零件重量。
进一步地，步骤(2-1)中所述高温加热软化的加热温度为220±10℃，时间为150±10s。
进一步地，步骤(2-2)中所述压制成型的成型压力为12±2Mpa，时间为60±5s。
后续装配过程：将配件装配到得到汽车后盖用轻量化内饰材料上，主要是：规定牌号的3M双面胶，其牌号为：3M BT5010，该牌号的双面胶与得到汽车后盖用轻量化内饰材料的水刺无纺布以及后盖钣金具有十分优秀的粘结性能。3M双面胶与汽车后盖用轻量化内饰材料背面的水刺无纺布胶粘实现装配。
与现有技术相比，本发明具有以下优点：
(1)本发明采用轻量化PP玻纤板基材，在实现零件功能性的前提下，大大降低了零件的重量，相比于类似零件，重量可以降低50％以上，有利于轻量化的实现；
(2)本发明中的PP玻纤板拥有优秀的散发性能，保证VOC，8项物质满足：苯≤10μg/m3；甲苯≤50μg/m3；乙苯≤50μg/m3；二甲苯≤50μg/m3；苯乙烯≤50μg/m3；甲醛≤150μg/m3；乙醛≤50μg/m3；丙烯醛≤20μg/m3；丙酮≤30μg/m3；TVOC≤1800μg/m3；真正有利于汽车内饰零件有害物质的散发和车内环境的净化；
(3)本发明由于主体材料中的玻璃纤维属于矿物纤维，不同于棉纤维、麻纤维等天然纤维，故其具有优质的耐霉菌性能，常温23℃及40℃和100％相对湿度情况下，20天内不会出现霉菌增长；玻璃纤维作为矿物纤维，具有更好的高、低温性能，还能满足各种高低温环境，如：在-40～80℃、30个周期(15天)的温度循环实验中零件无变形，无结构及功能性损伤；
(4)本发明中表面平绒风格地毯应用，使后盖内饰外观目视更加柔和，具有格调感；3M双面胶的使用，有利于后盖内饰零件与环境件的装配性能；
(5)本发明可以改善PP玻纤板的拉伸性能，避免局部拉伸较大的位置拉破零件基材的风险。
附图说明
图1为实施例中汽车后盖用轻量化内饰材料结构示意图；
图中标号所示：表面地毯1、玻纤板2、PE粘合层21、玻纤层22、水刺无纺布23。
具体实施方式
下面结合附图和具体实施例对本发明进行详细说明。
实施例
一种汽车后盖用轻量化内饰材料，如图1，该内饰材料从上到下依次包括：表面地毯1和玻纤板2。
其中，表面地毯1为针刺平绒，单位面积重量为180g/m2，该风格面料多用于中端车型，面料表面较为细腻，手感柔和。
玻纤板2的单位面积重量为900g/m2。玻纤板2从上到下依次包括：PE粘合层21、玻纤层22和水刺无纺布23。
PE粘合层21的单位面积重量为50g/m2。玻纤层22由玻璃纤维和聚丙烯纤维按重量比为(48-52):(52-48)混纺制成。其中聚丙烯纤维熔点为168℃。水刺无纺布23的单位面积重量为45g/m2。水刺无纺布可以改善玻纤层的拉伸性能，又能避免玻纤外露的情况发生。
该汽车后盖用轻量化内饰材料的制备方法，包括以下步骤：
(1)玻纤板2的加工成型：采用针刺复合工艺，将玻纤层22一面缝合PE粘合层21，另一面缝合水刺无纺布23；
(2)表面地毯1与玻纤板2的热压成型：
(2-1)将玻纤板2高温加热软化后，此时PE粘合层21出现软化，有利于用来实现玻纤板2与表面地毯1的粘合，放入成型模具中，并铺设表面地毯1，保证表面地毯1与PE粘合层21相互粘合；其中，高温加热软化的加热温度为220±10℃，时间为150±10s。
(2-2)然后在模具中进行压制成型，期间通过水冷系统，保持模具温度为18±5℃，最终得到汽车后盖用轻量化内饰材料，其中，压制成型的成型压力为12±2Mpa，时间为60±5s。成型件重量为260-320g/0.53m2，相比于1000g/0.92m2左右的其他基材的后盖内饰类零件，在实现零件功能的前提下，大大降低了零件重量。
本实施例中，由于使用玻璃纤维制作，可以在110℃/24h以及120℃/2h的高温实验中，保证零件的性能要求。
本实施例中，材料的弯曲强度可达20-30MPa、弯曲模量可达1800-2000MPa；
而现有的以PP+PET成型毡材料为主体的尾门饰板零件，在1500g/m2的基材重量下，其弯曲强度只有7-8MPa、弯曲模量只有450-550MPa。
以上所述，仅是本发明的较佳实施例而已，并非是对本发明作其它形式的限制，任何熟悉本专业的技术人员可能利用上述揭示的技术内容加以变更或改型为等同变化的等效实施例。但是凡是未脱离本发明技术方案内容，依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与改型，仍属于本发明技术方案的保护范围。

Claims (10)

1.一种汽车后盖用轻量化内饰材料，其特征在于，该内饰材料从上到下依次包括：表面地毯(1)和玻纤板(2)，所述的表面地毯(1)与玻纤板(2)的厚度之比为(4-8):1。
2.根据权利要求1所述的一种汽车后盖用轻量化内饰材料，其特征在于，所述的表面地毯(1)为针刺平绒，单位面积重量为150-200g/m2。
3.根据权利要求1所述的一种汽车后盖用轻量化内饰材料，其特征在于，所述的玻纤板(2)的单位面积重量为880-920g/m2。
4.根据权利要求1所述的一种汽车后盖用轻量化内饰材料，其特征在于，所述的玻纤板(2)从上到下依次包括：PE粘合层(21)、玻纤层(22)和水刺无纺布(23)。
5.根据权利要求4所述的一种汽车后盖用轻量化内饰材料，其特征在于，所述的PE粘合层(21)的单位面积重量为40-60g/m2。
6.根据权利要求4所述的一种汽车后盖用轻量化内饰材料，其特征在于，所述的玻纤层(22)由玻璃纤维和聚丙烯纤维按重量比为(48-52):(52-48)混纺制成。
7.根据权利要求4所述的一种汽车后盖用轻量化内饰材料，其特征在于，所述的水刺无纺布(23)的单位面积重量为40-50g/m2。
8.一种如权利要求1-7任一项所述的汽车后盖用轻量化内饰材料的制备方法，其特征在于，该方法包括以下步骤：
(1)玻纤板(2)的加工成型：采用针刺复合工艺，将玻纤层(22)一面缝合PE粘合层(21)，另一面缝合水刺无纺布(23)；
(2)表面地毯(1)与玻纤板(2)的热压成型：
(2-1)将玻纤板(2)高温加热软化后，放入成型模具中，并铺设表面地毯(1)；
(2-2)然后在模具中进行压制成型，期间通过水冷系统，保持模具温度为18±5℃，最终得到汽车后盖用轻量化内饰材料。
9.根据权利要求8所述的一种汽车后盖用轻量化内饰材料的制备方法，其特征在于，步骤(2-1)中所述高温加热软化的加热温度为220±10℃，时间为150±10s。
10.根据权利要求8所述的一种汽车后盖用轻量化内饰材料的制备方法，其特征在于，步骤(2-2)中所述压制成型的成型压力为12±2Mpa，时间为60±5s。
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