CN113022043A - 一种汽车顶棚材料及其制备方法 - Google Patents

一种汽车顶棚材料及其制备方法 Download PDF

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CN113022043A
CN113022043A CN202110367234.XA CN202110367234A CN113022043A CN 113022043 A CN113022043 A CN 113022043A CN 202110367234 A CN202110367234 A CN 202110367234A CN 113022043 A CN113022043 A CN 113022043A
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layer
ramie fiber
fiber felt
hot
melt adhesive
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李继丰
杜兆芳
顾殿宽
胡超凡
王浩
陈巍
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Anhui Agricultural University AHAU
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Anhui Agricultural University AHAU
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
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    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
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    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
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    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
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    • B32—LAYERED PRODUCTS
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
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    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
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    • B32B2266/00—Composition of foam
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Abstract

本发明公开了一种汽车顶棚材料及其制备方法，属于汽车配件技术领域，所述材料自上而下依次包括如下结构：装饰层无纺布、上层高分子热熔胶膜层、上层胶粉层、上层改性苎麻纤维毡、上下面涂覆EVA热熔胶发泡PU板层、下层改性苎麻纤维毡、下层胶粉层和下层高分子热熔胶膜层；所述改性苎麻纤维毡为经阳离子改性剂和热固性树脂改性后的苎麻纤维毡；本发明通过对苎麻纤维进行阳离子改性后能显著增强其韧性，之后涂覆热固性树脂，改善苎麻纤维的硬度，避免了因韧性的增强而导致硬度的下降；将改性后的苎麻纤维与发泡PU板复合后，能够使所得复合材料的硬度、冲击韧性和抗弯曲强度显著增强，避免了使用过程层与层之间易发生分离的问题。

Description

一种汽车顶棚材料及其制备方法
技术领域
本发明属于汽车配件技术领域，具体涉及一种汽车顶棚材料及其制备方法。
背景技术
汽车内饰顶棚是汽车不可缺少的重要内饰零部件之一，是用不同种类的非金属材料复合模压制成，具有良好的吸音/隔热性能和独特的装饰效果，并能够满足汽车在装配线上快速装配的需要。内饰顶棚不仅是装饰部件，而且还是要求很高的功能性部件。目前用于制作汽车顶棚的基材主要有半固化纺织棉毡基材、麻纤维板基材、PP基材及PU基材等，其中PU基材因具有吸音、隔热、重量轻、易安装以及无刺激性气味的特点而得到广泛应用。但是随着对顶棚的质量、重量以及强度等要求越来越高，单一的PU基材无法满足使用要求，需要对其进行增强改进。纤维增强复合材料是一种高性能的轻质复合材料，其具有比强度高、比刚度高、抗疲劳性好、成型工艺简单等特点。但由于麻纤维结晶度高、刚度大致使与其他聚合物界面结合效果差，复合后材料强度、韧性差，层与层之间易分离，不利于其作为汽车顶棚用材料的推广应用。
发明内容
本发明的目的在于提供一种汽车顶棚材料及其制备方法，以克服现有技术中存在的上述技术问题。
为实现上述目的，本发明提供了如下技术方案：
本发明提供了一种汽车顶棚材料，自上而下依次包括如下结构：装饰层无纺布、上层高分子热熔胶膜层、上层胶粉层、上层改性苎麻纤维毡、上下面涂覆EVA热熔胶发泡PU板层、下层改性苎麻纤维毡、下层胶粉层和下层高分子热熔胶膜层；
所述改性苎麻纤维毡为经阳离子改性剂和热固性树脂改性后的苎麻纤维毡。
进一步地，所述阳离子改性剂为季铵盐。
进一步地，所述热固性树脂为环氧树脂。
进一步地，所述热固性树脂与苎麻纤维毡的质量比为1∶(80～100)。
进一步地，所述发泡PU板层包括以下重量份的原料：PU 40～60份、发泡剂2～8份、胺类催化剂1～2份、生物质壳聚糖颗粒40～60份和氧化锌50～70份。
本发明还提供了一种上述所述的汽车顶棚材料的制备方法，包括以下步骤：
(1)将苎麻纤维毡浸渍于碱性溶液中，取出后浸渍于阳离子改性剂溶液中，之后取出、水洗并干燥后，在上下两面涂覆热固性树脂，得改性苎麻纤维毡；
(2)自上而下按顺序依次平铺叠放装饰层无纺布、上层高分子热熔胶膜层、上层胶粉层、上层改性苎麻纤维毡、上下面涂覆EVA热熔胶发泡PU板层、下层改性苎麻纤维毡、下层胶粉层和下层高分子热熔胶膜层；
(3)对步骤(2)平铺叠放好的材料进行热压成型，即得所述汽车顶棚材料。
进一步地，所述上层高分子热熔胶膜层的上表面还涂有胶粘剂。
进一步地，所述碱性溶液为浓度为0.5～0.8g/mL的NaOH溶液。
进一步地，所述热压成型的温度为100～120℃。
与现有技术相比，本发明具有以下有益效果：
本发明通过对苎麻纤维进行阳离子改性后能显著增强其韧性，之后涂覆热固性树脂，热固性树脂与苎麻纤维可以交织形成网络结构，改善苎麻纤维的硬度，避免了因韧性的增强而导致硬度的下降；进一步将改性后的苎麻纤维与发泡PU板复合后，能够使所得复合材料的硬度、冲击韧性和抗弯曲强度显著增强，避免了使用过程中因层与层之间结合效果不好，易发生分离的问题。
具体实施方式
现详细说明本发明的多种示例性实施方式，该详细说明不应认为是对本发明的限制，而应理解为是对本发明的某些方面、特性和实施方案的更详细的描述。应理解本发明中所述的术语仅仅是为描述特别的实施方式，并非用于限制本发明。
另外，对于本发明中的数值范围，应理解为还具体公开了该范围的上限和下限之间的每个中间值。在任何陈述值或陈述范围内的中间值以及任何其他陈述值或在所述范围内的中间值之间的每个较小的范围也包括在本发明内。这些较小范围的上限和下限可独立地包括或排除在范围内。
除非另有说明，否则本文使用的所有技术和科学术语具有本发明所述领域的常规技术人员通常理解的相同含义。虽然本发明仅描述了优选的方法和材料，但是在本发明的实施或测试中也可以使用与本文所述相似或等同的任何方法和材料。本说明书中提到的所有文献通过引用并入，用以公开和描述与所述文献相关的方法和/或材料。在与任何并入的文献冲突时，以本说明书的内容为准。
在不背离本发明的范围或精神的情况下，可对本发明说明书的具体实施方式做多种改进和变化，这对本领域技术人员而言是显而易见的。由本发明的说明书得到的其他实施方式对技术人员而言是显而易见的。本发明说明书和实施例仅是示例性的。
关于本文中所使用的“包含”、“包括”、“具有”、“含有”等等，均为开放性的用语，即意指包含但不限于。
实施例1
汽车顶棚材料的制备，包括以下步骤：
(1)将苎麻纤维毡浸渍于0.6g/mL的NaOH溶液中，3h后取出，之后浸渍于55g/L的四丁基硫酸氢氨水溶液中，3.5h后取出、水洗并干燥后，在上下两面涂覆双酚A型E-51环氧树脂，得改性苎麻纤维毡；其中双酚A型E-51环氧树脂与苎麻纤维毡的质量比为1∶90；
(2)自上而下按顺序依次平铺叠放装饰层无纺布、上层高分子热熔胶膜层、上层胶粉层、上层改性苎麻纤维毡、上下面涂覆EVA热熔胶发泡PU板层、下层改性苎麻纤维毡、下层胶粉层和下层高分子热熔胶膜层；其中上层高分子热熔胶膜层的上表面喷涂有水溶性聚氨酯作为胶粘剂，上下面涂覆EVA热熔胶发泡PU板层包括以下重量份的原料：PU 50份、发泡剂5份、胺类催化剂三乙醇胺1.5份、生物质壳聚糖颗粒50份和氧化锌60份，其中发泡剂为水和HCFC-141b按照重量比为1∶8配制而成；
(3)将步骤(2)平铺叠放好的材料放入温度为110℃热模具中进行热压成型，成型后取出模具，冷却至室温，然后使用水刀切割和打孔，即得汽车顶棚复合材料。
实施例2
汽车顶棚材料的制备，步骤如下：
(1)将苎麻纤维毡浸渍于0.8g/mL的NaOH溶液中，2.5h后取出，之后浸渍于50g/L的四丁基硫酸氢氨水溶液中，4h后取出、水洗并干燥后，在上下两面涂覆双酚A型E-55环氧树脂，得改性苎麻纤维毡；其中双酚A型E-55环氧树脂与苎麻纤维毡的质量比为1∶80；
(2)自上而下按顺序依次平铺叠放装饰层无纺布、上层高分子热熔胶膜层、上层胶粉层、上层改性苎麻纤维毡、上下面涂覆EVA热熔胶发泡PU板层、下层改性苎麻纤维毡、下层胶粉层和下层高分子热熔胶膜层；其中上层高分子热熔胶膜层的上表面喷涂有水溶性聚氨酯作为胶粘剂，上下面涂覆EVA热熔胶发泡PU板层包括以下重量份的原料：PU 40份、发泡剂2份、胺类催化剂DPA 1份、生物质壳聚糖颗粒40份和氧化锌50份，其中发泡剂为水和HCFC-141b按照重量比为1∶8配制而成；
(3)将步骤(2)平铺叠放好的材料放入温度为100℃热模具中进行热压成型，成型后取出模具，冷却至室温，然后使用水刀切割和打孔，即得汽车顶棚复合材料。
实施例3
汽车顶棚材料的制备，包括以下步骤：
(1)将苎麻纤维毡浸渍于0.5g/mL的NaOH溶液中，3.5h后取出，之后浸渍于60g/L的四丁基硫酸氢氨水溶液中，3h后取出、水洗并干燥后，在上下两面涂覆双酚A型E-51环氧树脂，得改性苎麻纤维毡；其中双酚A型E-51环氧树脂与苎麻纤维毡的质量比为1∶100；
(2)自上而下按顺序依次平铺叠放装饰层无纺布、上层高分子热熔胶膜层、上层胶粉层、上层改性苎麻纤维毡、上下面涂覆EVA热熔胶发泡PU板层、下层改性苎麻纤维毡、下层胶粉层和下层高分子热熔胶膜层；其中上层高分子热熔胶膜层的上表面喷涂有水溶性聚氨酯作为胶粘剂，上下面涂覆EVA热熔胶发泡PU板层包括以下重量份的原料：PU 60份、发泡剂8份、胺类催化剂三乙醇胺2份、生物质壳聚糖颗粒60份和氧化锌70份，其中发泡剂为水和HCFC-141b按照重量比为1∶8配制而成；
(3)将步骤(2)平铺叠放好的材料放入温度为120℃热模具中进行热压成型，成型后取出模具，冷却至室温，然后使用水刀切割和打孔，即得汽车顶棚复合材料。
实施例4
同实施例1，区别在于，步骤(1)为：将苎麻纤维毡浸渍于0.6g/mL的NaOH溶液中，3h后取出，之后浸渍于55g/L的四丁基硫酸氢氨水溶液中，50℃下浸渍3.5h后取出、水洗并干燥后，在上下两面涂覆双酚A型E-51环氧树脂，得改性苎麻纤维毡；其中双酚A型E-51环氧树脂与苎麻纤维毡的质量比为1∶90。
实施例5
同实施例1，区别在于，步骤(3)为：将步骤(2)平铺叠放好的材料放入热模具中，首先在60℃下热压1h，之后升温至110℃，继续热压成型后取出模具，冷却至室温，然后使用水刀切割和打孔，即得汽车顶棚复合材料。
实施例6
同实施例1，区别在于，步骤(2)中上下面涂覆EVA热熔胶发泡PU板层包括以下重量份的原料：PU 50份、发泡剂5份、胺类催化剂三乙醇胺1.5份、碳纳米纤维3份、生物质壳聚糖颗粒50份和氧化锌60份，其中发泡剂为水和HCFC-141b按照重量比为1∶8配制而成。
对比例1
同实施例1，区别在于，步骤(1)为：将苎麻纤维毡浸渍于0.6g/mL的NaOH溶液中，3h后取出，之后浸渍于55g/L的四丁基硫酸氢氨水溶液中，3.5h后取出、水洗并干燥后，得改性苎麻纤维毡。
对比例2
同实施例1，区别在于，步骤(1)为：将苎麻纤维毡浸渍于0.6g/mL的NaOH溶液中，3h后取出，水洗并干燥后，在上下两面涂覆双酚A型E-51环氧树脂，得改性苎麻纤维毡；其中双酚A型E-51环氧树脂与苎麻纤维毡的质量比为1∶90。
效果验证
对实施例1～6及对比例1～2制备得到的汽车顶棚材料的硬度、冲击韧性和抗弯强度进行测试，结果如表1所示。
表1
Figure BDA0003007650020000051
Figure BDA0003007650020000061
由表1可以看出，本发明提供的汽车顶棚材料具有较高的硬度、冲击韧性和优异的抗弯曲强度，可有效避免使用过程中因层与层之间结合效果不好，易发生分离的问题。
以上所述，仅为本发明较佳的具体实施方式，但本发明的保护范围并不局限于此，任何熟悉本技术领域的技术人员在本发明披露的技术范围内，根据本发明的技术方案及其发明构思加以等同替换或改变，都应涵盖在本发明的保护范围内。

Claims (9)

1.一种汽车顶棚材料，其特征在于，自上而下依次包括如下结构：装饰层无纺布、上层高分子热熔胶膜层、上层胶粉层、上层改性苎麻纤维毡、上下面涂覆EVA热熔胶发泡PU板层、下层改性苎麻纤维毡、下层胶粉层和下层高分子热熔胶膜层；
所述改性苎麻纤维毡为经阳离子改性剂和热固性树脂改性后的苎麻纤维毡。
2.根据权利要求1所述的汽车顶棚材料，其特征在于，所述阳离子改性剂为季铵盐。
3.根据权利要求1所述的汽车顶棚材料，其特征在于，所述热固性树脂为环氧树脂。
4.根据权利要求1所述的汽车顶棚材料，其特征在于，所述热固性树脂与苎麻纤维毡的质量比为1∶(80～100)。
5.根据权利要求1所述的汽车顶棚材料，其特征在于，所述发泡PU板层包括以下重量份的原料：PU 40～60份、发泡剂2～8份、胺类催化剂1～2份、生物质壳聚糖颗粒40～60份和氧化锌50～70份。
6.一种权利要求1～5任一项所述的汽车顶棚材料的制备方法，其特征在于，包括以下步骤：
(1)将苎麻纤维毡浸渍于碱性溶液中，取出后浸渍于阳离子改性剂溶液中，之后取出、水洗并干燥后，在上下两面涂覆热固性树脂，得改性苎麻纤维毡；
(2)自上而下按顺序依次平铺叠放装饰层无纺布、上层高分子热熔胶膜层、上层胶粉层、上层改性苎麻纤维毡、上下面涂覆EVA热熔胶发泡PU板层、下层改性苎麻纤维毡、下层胶粉层和下层高分子热熔胶膜层；
(3)对步骤(2)平铺叠放好的材料进行热压成型，即得所述汽车顶棚材料。
7.根据权利要求6所述的制备方法，其特征在于，所述上层高分子热熔胶膜层的上表面还涂有胶粘剂。
8.根据权利要求6所述的制备方法，其特征在于，所述碱性溶液为浓度为0.5～0.8g/mL的NaOH溶液。
9.根据权利要求6所述的制备方法，其特征在于，所述热压成型的温度为100～120℃。
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