CN112549676A - 一种厢式运输车用轻量化板材及其制备方法 - Google Patents
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Abstract
本发明公开了一种厢式运输车用轻量化板材及其制备方法，属于板材生产技术领域，该轻量化板材由内外层为碳纤布玻璃钢单板和芯板为铝蜂窝芯通过胶粘剂在高温辊压连续成型制得；碳纤布玻璃钢单板由内外层为透明胶衣和内层为碳纤布与乙烯基树脂固化而成的加强层制得；通过本发明制得的轻量化板材本发明的制备的轻量化板材单位面积重量只有3‑4kg/㎡，轻量化板力学性能高，且具有优良的耐化学腐蚀性能和机械强度，保证轻量化板材具有防雨、防晒、防止货物散落的功能。可以全面应用于轻卡、中重卡及厢式半挂车的车厢上，具有广泛的应用前景。
Description
技术领域
本发明涉及板材生产技术领域，具体涉及一种厢式运输车用轻量化板材及其制备方法。
背景技术
厢式运输车是指在二类底盘的基础上安装封闭厢体用于货物运输的一种商用运输车，由于厢式运输车封闭厢体具有防盗、防雨、防晒、防止货物散落等功能，深受物流运输客户的喜爱。随着近几年物流运输行业的迅猛发展，厢式运输车的销售市场得到迅速扩大。目前市场上的厢式运输车车厢板材主要采用钢瓦楞板、铝型材扣板、热固型玻璃钢蜂窝复合板、热塑性塑料蜂窝复合板等几种。钢瓦楞板由于重量重(12-16kg/㎡)、易腐蚀、表面不平风阻大等缺点，已逐步淘汰。铝型材扣板单位面积重量大约在8-12kg/㎡，主要应用于重型厢式运输车、厢式半挂车等方面。铝型材扣板组装车厢时需要焊接和油漆，工艺相对复杂，生产效率较低，重量偏重。热固型玻璃钢蜂窝复合板单位面积重量大约在7-10kg/㎡，是目前市场上主流的厢式车车厢板材，基本覆盖中型、重型厢式运输车、厢式半挂车，但热固型玻璃钢蜂窝复合板与铝型材扣板一样，整体重量仍然偏重。热塑型塑料蜂窝复合板单位面积重量大约在4-6kg/㎡，重量相对较轻，但在外观、刚性等方面不如铝型材扣板和热固型玻璃钢蜂窝复合板，在轻卡上运用相对较多，很少应用于中型、重型厢式运输车、厢式半挂车上。为满足现有技术对板材要求重量轻、刚性好、耐腐蚀、外观平整光洁、安装方面快捷的轻量化板材，能够全面应用于轻卡、中重卡及厢式半挂车上，为此本发明公开了一种厢式运输车用轻量化板材及其制备方法及其制备方法。
发明内容
针对上述存在的问题，本发明提出了一种厢式运输车用轻量化板材及其制备方法。
为了实现上述的目的，本发明采用以下的技术方案：
一种厢式运输车用轻量化板材及其制备方法，所述轻量化板材由内外层为碳纤布玻璃钢单板和芯板为铝蜂窝芯通过胶粘剂在高温辊压连续成型制得；所述碳纤布玻璃钢单板由内外层为透明胶衣和内层为碳纤布与乙烯基树脂固化而成的加强层制得。
优选的，所述透明胶衣为间苯新戊二醇胶衣，所述透明胶衣层湿膜厚度为 0.3-0.5mm。
优选的，所述碳纤布为200-600g/㎡碳纤维方格布。
优选的，所述乙烯基树脂单位面积用量为300-900g/㎡。
优选的，所述铝蜂窝芯为正六边形，边长为5-8mm，铝箔厚度为0.04-0.06mm，所述铝蜂窝芯厚度为10-20mm，所述铝蜂窝芯的单位面积重量0.3-0.8kg/㎡。
优选的，所述胶粘剂为双组份聚氨酯胶，双组份聚氨酯胶AB料重量比为4:1、 5:1或6:1。
优选的，厢式运输车用轻量化板材的制备方法具体包括以下步骤：
(1)启动碳纤布玻璃钢单板自动连续生产线，牵引下层涤纶薄膜以2-5m/min 的运动速度向前运动，在下层涤纶薄膜上喷射透明胶衣，透明胶衣厚度控制在 0.3-0.5mm，透明胶衣固化剂采用过氧化甲乙酮，透明胶衣进入烘箱进行固化，胶衣固化烘箱温度控制在70-90℃；
(2)固化完全的透明胶衣出烘箱后进入冷却区冷却，然后喷射乙烯基树脂和树脂固化剂，乙烯基树脂喷射量控制在控制在300-900g/㎡，树脂固化剂采用过氧化甲乙酮，再自动铺放碳纤维方格布，碳纤维方格布克重控制在200-600g/ ㎡，再经过浸胶辊辊压，保证乙烯基树脂完全浸润碳纤维方格布，自动铺放上层涤纶薄膜，经过挤胶轴挤压，进入树脂固化烘箱进行固化，烘箱温度控制在 80-100℃；
(3)固化好的碳纤布玻璃钢单板再进入后固化处理烘箱，然后进入冷却区进行冷却，碳纤布玻璃钢单板的下层涤纶薄膜通过收集器进行收卷，两边按宽度要求进行切边，然后进行自动打卷，打卷后的碳纤布玻璃钢单板2卷，放置到复合板自动连续生产线上，启动生产线，下层的碳纤布玻璃钢单板以3-6m/min的运动速度向前行进，在碳纤布玻璃钢单板上自动淋洒胶粘剂，调节好AB料混合比例，淋胶量控制在200-500g/㎡。
(4)碳纤布玻璃钢单板继续向前，芯板自动铺放机将铝蜂窝芯轻轻放在胶面上，开动上层碳纤布玻璃钢单板牵引，运动速度与下层单板一致，在上层单板上自动淋洒胶粘剂，调节好AB料混合比例，淋胶量控制在200-500g/㎡，淋胶的上层单板通过压辊压到铝蜂窝芯上，与铝蜂窝芯及下层单板一起进入自动复合区，铝蜂窝芯的厚度为10-20mm，蜂窝边长5-8mm，铝箔厚度0.04-0.06mm；
(5)通过牵引压辊带动特氟龙传送带运动，传送带夹带复合板进入加热固化区，上下的加热压辊紧紧压住特氟龙传送带，传送带压住上下碳纤布玻璃钢单板和芯板一起前进，加热温度控制在60-80℃，保证胶粘剂能够完全固化；
(6)将已固化的复合板进入冷却定型区，冷却压辊紧紧压住特氟龙传送带，对复合板进行冷却，复合板走出自动复合区后，上下面板上的涤纶薄膜通过自动收集器打卷收集，边锯按宽度要求进行切边，横向铣刀按板材长度要求截断板材，得到轻量化板材。
由于采用上述的技术方案，本发明的有益效果是：
(1)本发明的制备的轻量化板材单位面积重量只有3-4kg/㎡，轻量化板力学性能高，且具有优良的耐化学腐蚀性能和机械强度，保证轻量化板材具有防雨、防晒、防止货物散落的功能。此外本发明的轻量化板材外观平整光洁，可以全面应用于轻卡、中重卡及厢式半挂车的车厢上。
(2)本发明制备的轻量化板材的重量低于目前市场上所有类型板材的重量，能够有效降低厢式车车厢重量，增加厢式车载货量，降低运输能耗，节约成本、降低排放，具有广泛的应用前景。
附图说明：
图1：本发明轻量化板材的结构示意图。
图2：本发明碳纤布玻璃钢单板的工艺生产流程图。
图3：本发明轻量化板材的工艺生产流程图。
图中：1、透明胶衣，2、碳纤维方格布，3、乙烯基树脂，4、胶粘剂，5、铝蜂窝芯，6、下层涤纶薄膜，7、透明胶衣固化烘箱，8、浸胶辊，9、上层涤纶薄膜，10、挤胶轴，11、树脂固化烘箱，12、后固化处理烘箱，13、涤纶薄膜收集器，14、碳纤布玻璃钢单板，15、牵引压辊，16、特氟龙传送带，17、加热压辊，18、冷却压辊，19、边锯，20、横向铣刀，21、轻量化板材。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚，下面将结合本发明实施例，对本发明实施例中的技术方案进行清楚、完整地描述。基于本发明的实施例，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他实施例，都属于本发明保护的范围。
实施例1：
本实施例1的厢式运输车用轻量化板材的制备方法具体包括如下：
(1)启动碳纤布玻璃钢单板自动连续生产线，牵引下层涤纶薄膜6向前运动，运动速度5m/min，在下层涤纶薄膜6上喷射透明胶衣1，透明胶衣1厚度控制在0.35mm，透明胶衣1固化剂采用过氧化甲乙酮。透明胶衣1进入透明胶衣固化烘箱7进行固化，透明胶衣固化烘箱7温度控制在70℃。
(2)固化完全的透明胶衣1出烘箱后进入冷却区冷却，然后喷射乙烯基树脂3和树脂固化剂，乙烯基树脂3喷射量控制在控制在480g/㎡，树脂固化剂采用过氧化甲乙酮。自动铺放碳纤维方格布2，克重控制在320g/㎡，经过浸胶辊8 辊压，保证树脂完全浸润碳纤维方格布2。自动铺放上层涤纶薄膜9，经过挤胶轴10挤压，进入树脂固化烘箱11进行固化，烘箱温度控制在80℃。
(3)固化好的单板再进入后固化处理烘箱12，然后进入冷却区进行冷却，单板的下层涤纶薄膜6通过涤纶薄膜收集器13进行收卷，两边按宽度要求进行切边，然后进行自动打卷。打卷后的碳纤布玻璃钢单板14，放置到复合板自动连续生产线上，启动生产线，下层的碳纤布玻璃钢单板14向前行进，运动速度 5m/min。在单板上自动淋洒胶粘剂4，胶粘剂4为双组份聚氨酯胶，调节好AB 料混合比例为4:1，淋胶量控制在300g/㎡。
(4)碳纤布玻璃钢单板继续向前，芯板自动铺放机将铝蜂窝芯5轻轻放在胶面上。铝蜂窝芯5厚度12mm，蜂窝边长7.5mm，铝箔厚度0.04mm。开动上层碳纤布玻璃钢单板14牵引，运动速度与下层单板一致，在上层单板上自动淋洒胶粘剂4，胶粘剂4为双组份聚氨酯胶，调节好AB料混合比例为4:1，淋胶量控制在300g/㎡。淋胶的上层单板通过压辊压到铝蜂窝芯5上，与铝蜂窝芯5及下层单板一起进入自动复合区。牵引压辊15带动特氟龙传送带16运动，传送带夹带复合板进入加热固化区，上下的加热压辊17紧紧压住特氟龙传送带16，传送带压住上下碳纤布玻璃钢单板和芯板一起前进，加热温度控制在60℃，保证胶粘剂能够完全固化。
(5)将已固化的复合板进入冷却定型区，冷却压辊18紧紧压住特氟龙传送带16，对复合板进行冷却。复合板走出自动复合区后，上下面板上的涤纶薄膜通过涤纶薄膜收集器13打卷收集。边锯19按宽度要求进行切边，横向铣刀21按板材长度要求截断板材，得到的轻量化板材再进行检验、贴膜、打包、包装。
本实施例1中的轻量化板材单位面积重量为3.8kg/㎡
实施例2：
本实施例2的厢式运输车用轻量化板材的制备方法具体包括如下：
(1)启动碳纤布玻璃钢单板自动连续生产线，牵引下层涤纶薄膜6向前运动，运动速度4m/min。在下层涤纶薄膜上喷射透明胶衣1，透明胶衣1厚度控制在0.45mm，透明胶衣1固化剂采用过氧化甲乙酮。透明胶衣1进入透明胶衣固化烘箱7进行固化，透明胶衣固化烘箱7温度控制在70℃。
(2)固化完全的透明胶衣出烘箱后进入冷却区冷却，然后喷射乙烯基树脂3 和树脂固化剂，乙烯基树脂3喷射量控制在控制在600g/㎡，树脂固化剂采用过氧化甲乙酮。再自动铺放碳纤维方格布2，克重控制在400g/㎡，经过浸胶辊8 辊压，保证乙烯基树脂3完全浸润碳纤维方格布2。自动铺放上层涤纶薄膜9，经过挤胶轴10挤压，进入树脂固化烘箱11进行固化，烘箱温度控制在90℃。
(3)固化好的单板再进入后固化处理烘箱12，然后进入冷却区进行冷却，单板的下层涤纶薄膜通过涤纶薄膜收集器13进行收卷，两边按宽度要求进行切边，然后进行自动打卷。打卷后的碳纤布玻璃钢单板14，放置到复合板自动连续生产线上，启动生产线，下层的碳纤布玻璃钢单板14向前行进，运动速度4m/min。在单板上自动淋洒胶粘剂4，胶粘剂4为双组份聚氨酯胶，调节好AB料混合比例为5:1，淋胶量控制在400g/㎡。
(4)碳纤布玻璃钢单板14继续向前，芯板自动铺放机将铝蜂窝芯5轻轻放在胶面上。铝蜂窝芯5厚度18mm，蜂窝边长6mm，铝箔厚度0.05mm。开动上层碳纤布玻璃钢单板14牵引，运动速度与下层单板一致，在上层单板上自动淋洒胶粘剂4，胶粘剂4为双组份聚氨酯胶，调节好AB料混合比例为5:1，淋胶量控制在400g/㎡。淋胶的上层单板通过压辊压到铝蜂窝芯5上，与铝蜂窝芯5及下层单板一起进入自动复合区。
(5)牵引压辊15带动特氟龙传送带16运动，传送带夹带复合板进入加热固化区，上下的加热压辊17紧紧压住特氟龙传送带16，传送带压住上下单板和芯板一起前进，加热温度控制在80℃，保证胶粘剂能够完全固化。
(6)将已固化的复合板进入冷却定型区，冷却压辊18紧紧压住特氟龙传送带16，对复合板进行冷却。复合板走出自动复合区后，上下面板上的涤纶薄膜通过涤纶薄膜收集器13打卷收集。边锯19按宽度要求进行切边，横向铣刀21按板材长度要求截断板材，得到的轻量化板材再进行检验、贴膜、打包、包装。
本实施例2中的轻量化板材单位面积重量为3.5kg/㎡。
需要说明的是，在本文中，术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含，从而使得包括一系列要素的过程、方法、物品或者设备不仅包括那些要素，而且还包括没有明确列出的其他要素，或者是还包括为这种过程、方法、物品或者设备所固有的要素。
本文中应用了具体个例对本发明的原理及实施方式进行了阐述，以上实例的说明只是用于帮助理解本发明的方法及其核心思想。以上所述仅是本发明的优选实施方式，应当指出，由于文字表达的有限性，而客观上存在无限的具体结构，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进、润饰或变化，也可以将上述技术特征以适当的方式进行组合；这些改进润饰、变化或组合，或未经改进将发明的构思和技术方案直接应用于其它场合的，均应视为本发明的保护范围。
Claims (7)
1.一种厢式运输车用轻量化板材及其制备方法，其特征在于，所述轻量化板材由内外层为碳纤布玻璃钢单板和芯板为铝蜂窝芯通过胶粘剂在高温辊压连续成型制得；所述碳纤布玻璃钢单板由内外层为透明胶衣和内层为碳纤布与乙烯基树脂固化而成的加强层制得。
2.根据权利要求1所述的厢式运输车用轻量化板材，其特征在于，所述透明胶衣为间苯新戊二醇胶衣，所述透明胶衣层湿膜厚度为0.3-0.5mm。
3.根据权利要求1所述的厢式运输车用轻量化板材，其特征在于，所述碳纤布为200-600g/㎡碳纤维方格布。
4.根据权利要求1所述的厢式运输车用轻量化板材，其特征在于，所述乙烯基树脂单位面积用量为300-900g/㎡。
5.根据权利要求1所述的厢式运输车用轻量化板材，其特征在于，所述铝蜂窝芯为正六边形，边长为5-8mm，铝箔厚度为0.04-0.06mm，所述铝蜂窝芯厚度为10-20mm，所述铝蜂窝芯的单位面积重量0.3-0.8kg/㎡。
6.根据权利要求1所述的厢式运输车用轻量化板材，其特征在于，所述胶粘剂为双组份聚氨酯胶，双组份聚氨酯胶AB料重量比为4:1或5:1或6:1。
7.根据权利要求1-6任一所述的厢式运输车用轻量化板材的制备方法，其特征在于，具体包括以下步骤：
(1)启动碳纤布玻璃钢单板自动连续生产线，牵引下层涤纶薄膜以2-5m/min的运动速度向前运动，在下层涤纶薄膜上喷射透明胶衣，透明胶衣厚度控制在0.3-0.5mm，透明胶衣固化剂采用过氧化甲乙酮，透明胶衣进入烘箱进行固化，胶衣固化烘箱温度控制在70-90℃；
(2)固化完全的透明胶衣出烘箱后进入冷却区冷却，然后喷射乙烯基树脂和树脂固化剂，乙烯基树脂喷射量控制在控制在300-900g/㎡，树脂固化剂采用过氧化甲乙酮，再自动铺放碳纤维方格布，碳纤维方格布克重控制在200-600g/㎡，再经过浸胶辊辊压，保证乙烯基树脂完全浸润碳纤维方格布，自动铺放上层涤纶薄膜，经过挤胶轴挤压，进入树脂固化烘箱进行固化，烘箱温度控制在80-100℃；
(3)固化好的碳纤布玻璃钢单板再进入后固化处理烘箱，然后进入冷却区进行冷却，碳纤布玻璃钢单板的下层涤纶薄膜通过收集器进行收卷，两边按宽度要求进行切边，然后进行自动打卷，打卷后的碳纤布玻璃钢单板2卷，放置到复合板自动连续生产线上，启动生产线，下层的碳纤布玻璃钢单板以3-6m/min的运动速度向前行进，在碳纤布玻璃钢单板上自动淋洒胶粘剂，调节好AB料混合比例，淋胶量控制在200-500g/㎡；
(4)碳纤布玻璃钢单板继续向前，芯板自动铺放机将铝蜂窝芯轻轻放在胶面上，开动上层碳纤布玻璃钢单板牵引，运动速度与下层单板一致，在上层单板上自动淋洒胶粘剂，调节好AB料混合比例，淋胶量控制在200-500g/㎡，淋胶的上层单板通过压辊压到铝蜂窝芯上，与铝蜂窝芯及下层单板一起进入自动复合区，铝蜂窝芯的厚度为10-20mm，蜂窝边长5-8mm，铝箔厚度0.04-0.06mm；
(5)通过牵引压辊带动特氟龙传送带运动，传送带夹带复合板进入加热固化区，上下的加热压辊紧紧压住特氟龙传送带，传送带压住上下碳纤布玻璃钢单板和芯板一起前进，加热温度控制在60-80℃，保证胶粘剂能够完全固化；
(6)将已固化的复合板进入冷却定型区，冷却压辊紧紧压住特氟龙传送带，对复合板进行冷却，复合板走出自动复合区后，上下面板上的涤纶薄膜通过自动收集器打卷收集，边锯按宽度要求进行切边，横向铣刀按板材长度要求截断板材，得到轻量化板材。
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| CN207550332U (zh) * | 2017-11-13 | 2018-06-29 | 苏州贝芯蜂窝科技有限公司 | 一种轻质货车厢体 |
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| CN114446143A (zh) * | 2021-12-31 | 2022-05-06 | 台州卡乐包装材料有限公司 | 一种免复合单层膜内标签及其生产工艺 |
| CN114701217A (zh) * | 2022-03-21 | 2022-07-05 | 江苏奇一科技有限公司 | 连续纤维增强热塑性复合板及其制备方法与生产设备 |
| CN115157724A (zh) * | 2022-07-16 | 2022-10-11 | 广东皓强科技有限公司 | 一种多层玻璃纤维增强中空塑料板复合工艺和系统 |
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