CN113119552B - 一种新型的安全环保轻量化汽车内饰材料及其制备方法 - Google Patents
一种新型的安全环保轻量化汽车内饰材料及其制备方法 Download PDFInfo
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Abstract
本发明涉及一种新型的安全环保轻量化汽车内饰材料及其制备方法,该汽车内饰材料包括依次设置的表面处理层、TPO/TPU共混层、TPO发泡层、聚丙烯发泡层及背面处理层,其中,按重量份计,TPO/TPU共混层的原料配方包括以下组分:第一TPO颗粒90‑95份、改性TPU材料8‑10份、抑制升温材料0‑0.5份、第一助剂0‑5份和第一颜料4‑10份;按重量份计,TPO发泡层的原料配方包括以下组分:第二TPO颗粒90‑95份、发泡剂0.1‑2.5份、第二助剂0‑5份和第二颜料4‑10份。本发明的汽车内饰材料采用TPO/TPU共混层和TPO发泡层替代现有汽车内饰材料的TPO层,在TPO/TPU共混层和TPO发泡层总厚度与TPO层厚度一致的情况下,本发明的汽车内饰材料重量远低于现有的TPO汽车内饰材料,而强度也影响不大,真正做到汽车内饰材料的轻量化。
Description
技术领域
本发明属于汽车内饰表皮技术领域,具体涉及一种新型的安全环保轻量化汽车内饰材料及其制备方法。
背景技术
1886年世界上第一辆内燃机动力汽车诞生,轻量化、安全环保一直是人们所追崇的。回望汽车132年的发展史,轻量化,安全环保这方面,仍然发展缓慢。
现有的轻量化汽车内饰用材料常用的是PVC,然而PVC材料在安全环保上很难达到要求。而其他轻量化材料如PU材料,其生产工艺及配方极其复杂,成本高昂,只有极少部分豪华车才使用。
如今,越来越多的中低档车为博得消费者的喜爱,内饰材料也都非常有档次,PVC材料正慢慢地被TPO、PU等其他环保材料所取代。TPO材质的汽车内饰材料相比PVC材料的汽车内饰材料上已经实现轻量化,且目前使用的真空成型类表皮一般是TPO表皮层+PP Foam材料。
也出现轻量化TPO汽车内饰材料的报道,如中国专利CN109910411A公开的一种轻量化环保型汽车内饰材料极其制备工艺,该汽车内饰材料包括依次设置的上表面处理剂层、TPO表皮层、海绵层、基布层和下表面处理剂层,其通过先将TPO表皮层、海绵层、基布层分别成型,然后通过粘合剂将基布层和海绵层粘合,再通过粘合剂将TPO表皮层与基布层粘合,再进行上表面和下表面处理,工艺及配方都极其复杂,成本高。并且该汽车内饰材料只用于手工包覆工艺,不能用于吸附工艺。
发明内容
本发明目的是为了克服现有技术的不足而提供一种新型的轻量化汽车内饰材料及其制备方法。
为达到上述目的,本发明所采用的技术方案为:
一种轻量化汽车内饰材料,所述汽车内饰材料包括依次设置的表面处理层、TPO/TPU共混层、TPO发泡层、聚丙烯发泡层及背面处理层,其中,
按重量份计,所述TPO/TPU共混层的原料配方包括以下组分:
按重量份计,所述TPO发泡层的原料配方包括以下组分:
进一步地,所述第一助剂为受阻胺类光稳定剂。
进一步地,所述抑制升温材料为球形二氧化硅颗粒。
进一步地,所述第二助剂为受阻胺类光稳定剂。
进一步地,所述发泡剂为AC发泡剂。
进一步地,所述TPO发泡层的厚度占所述TPO/TPU共混层和TPO发泡层总厚度的60±5%。
进一步地,所述表面处理层使用的材料为水性聚氨酯树脂,通过印刷的方式涂覆在TPO/TPU共混层的表面上,烘干,形成该表面处理层,该表面处理层为提高表面耐磨、耐刮性能,同时赋予表面滑爽的肤感。
本发明的TPO/TPU共混层的表面不需电晕处理,可以直接将表面处理剂印刷涂覆在TPO/TPU共混层的表面上,相比传统的需要电晕处理的TPO材料,更加环保,不存在由于电晕处理产生的臭氧污染环境的问题。
进一步地,所述背面处理层的原料配方由背面处理剂与阻燃剂按质量比1:0.06~0.1组合,所述背面处理剂为水性聚氨酯或聚烯烃树脂。该背面处理层不仅增加了汽车内饰材料的阻燃性,还改变了汽车内饰材料的表面极性,使汽车内饰材料与包覆型板粘结性更好。
本发明采取的另一技术方案:上述所述的轻量化汽车内饰材料的制备方法,所述制备方法包括以下步骤:
(1)将制备TPO/TPU共混层的原料和制备TPO发泡层的原料加入挤出机中进行各自混合,然后双层共挤挤出并与聚丙烯泡沫热复合,制得TPO复合材料半成品;
(2)在步骤(1)制得的所述TPO复合材料半成品的TPO/TPU共混层的表面涂覆表面处理层的原料,烘干,形成表面处理层;
(3)经步骤(2)处理后,在所述TPO复合材料半成品的聚丙烯泡沫表面涂覆背面处理的原料,烘干,形成背面处理层;
(4)经步骤(3)处理后的TPO复合材料半成品置于195~210℃条件下高温发泡制得所述汽车内饰材料。
进一步地,步骤(2)中,由步骤(1)制得的所述TPO复合材料半成品的TPO/TPU共混层的表面直接印刷涂覆所述表面处理剂。
由于上述技术方案运用,本发明与现有技术相比具有下列优点:
本发明的汽车内饰材料采用TPO/TPU共混层和TPO发泡层替代现有汽车内饰材料的TPO层,在TPO/TPU共混层和TPO发泡层总厚度与TPO层厚度一致的情况下,本发明的汽车内饰材料重量远低于现有的TPO汽车内饰材料,而强度也影响不大,真正做到汽车内饰材料的轻量化。且本发明的汽车内饰材料可用于吸附工艺。
本发明汽车内饰材料中在TPO/TPU共混层上涂覆表面处理剂时,不需经过电晕处理,即可直接涂覆表面处理剂,更加环保,不存在由于电晕处理产生的臭氧污染环境的问题。
本发明的汽车内饰材料以TPO为主要原料,符合现如今汽车轻量化、安全、环保、舒适的要求。在保证产品外观吸引眼球的情况下,耐刮擦、耐光老化性由于现有的汽车内饰材料。且软硬度可调,满足各类客户要求。本发明的汽车内饰材料还具有手感柔顺,成本低,吸音降噪,阻燃性能好,环保,低VOC,低气味,可连续性生产的优点
本发明汽车内饰材料应用广泛,可用于汽车仪表板、门板、座椅背板等。
本发明汽车内饰材料的制备方法,采用特定的发泡剂配合TPO颗粒及助剂和颜料进行后发泡技术,相比现有的发泡技术成本高,工艺复杂,本发明的制备方法工艺简单。
附图说明
图1为实施例1的轻量化汽车内饰材料的结构示意图;
图中:1、表面处理层;2、TPO/TPU共混层;3、TPO发泡层;4、聚丙烯发泡层;5、背面处理层。
具体实施方式
下面结合具体实施例对本发明的具体实施作进一步详细说明,但本发明的实施和保护范围不限于此。
实施例1
如图1所示,本实施例提供的轻量化汽车内饰材料包括依次设置的表面处理层1、TPO/TPU共混层2、TPO发泡层3、聚丙烯发泡层4和背面处理层5。
表面处理层1的原料采用水性聚氨酯树脂。
背面处理层5的原料为由100份水性聚氨酯树脂和10份阻燃剂混合而成。
在具体用于汽车内饰上时,聚丙烯发泡层4的材料通常是有规定规格的聚丙烯泡沫材料,如1.0mm、1.5mm、2.0mm、2.5mm、3.0mm等规格,宽度400~1300mm之间,发泡倍率有15/20/25/30倍,按不同类型使用要求。本例中,聚丙烯发泡层4采用规格为2.0mm的PPFoam。
TPO/TPU共混层2的原料配方为90份TPO、10份改性TPU、5份受阻胺类光稳定剂和4份颜料和0.1分抑制升温材料。
TPO发泡层3的原料配方为95份TPO、2.5份AC发泡剂、1份受阻胺类光稳定剂和4份颜料。
该汽车内饰材料通过以下方法制备得到:
(1)将制备TPO/TPU共混层的原料和TPO发泡层的原料分别加入挤出机各自混合,利用挤出机熔融双层共挤挤出,形成TPO流延膜;
(2)使步骤(1)制备得到的TPO流延膜保持在150~220℃条件下,使用双辊轧制直接将TPO流延膜与PP Foam热复合,并使未发泡的TPO发泡层位于TPO/TPU共混层和PP Foam之间,制得TPO复合材料半成品;
(3)在步骤(2)制得的TPO复合材料半成品的TPO/TPU共混层的表面直接印刷涂覆水性聚氨酯,在110℃条件下进行烘干,形成表面处理层;
(4)在经步骤(3)处理后的TPO复合材料半成品的PP Foam表面上印刷涂覆水性聚氨酯和阻燃剂的混合物,在110℃条件下进行烘干,形成背面处理层;
(5)将经步骤(4)处理后的TPO复合材料半成品的置于200℃条件下进行高温发泡,制得轻量化汽车内饰材料成品,该汽车内饰材料中TPO/TPU共混层的厚度为0.2mm,TPO/TPU共混层和TPO发泡层的总厚度为0.5mm。
实施例2
本实施例提供的轻量化汽车内饰材料,
表面处理层1的原料采用水性聚氨酯树脂。
背面处理层5的原料为由100份水性聚氨酯树脂和8份阻燃剂混合而成。
在具体用于汽车内饰上时,聚丙烯发泡层4的材料通常是有规定规格的聚丙烯泡沫材料,如1.0mm、1.5mm、2.0mm、2.5mm、3.0mm等规格,宽度400~1300mm之间,发泡倍率有15/20/25/30倍,按不同类型使用要求。本例中,聚丙烯发泡层4采用规格为2.0mm的PPFoam。
TPO/TPU共混层2的原料配方为93份TPO、9份改性TPU、3份受阻胺类光稳定剂和6份颜料和0.3分抑制升温材料。
TPO发泡层3的原料配方为93份TPO、1.5份AC发泡剂、2份受阻胺类光稳定剂和4份颜料。其他同实施例1。
实施例3
本实施例提供的轻量化汽车内饰材料,
表面处理层1的原料采用水性聚氨酯树脂。
背面处理层5的原料为由100份水性聚氨酯树脂和6份阻燃剂混合而成。
在具体用于汽车内饰上时,聚丙烯发泡层4的材料通常是有规定规格的聚丙烯泡沫材料,如1.0mm、1.5mm、2.0mm、2.5mm、3.0mm等规格,宽度400~1300mm之间,发泡倍率有15/20/25/30倍,按不同类型使用要求。本例中,聚丙烯发泡层4采用规格为2.0mm的PPFoam。
TPO/TPU共混层2的原料配方为95份TPO、10份改性TPU、1份受阻胺类光稳定剂和8份颜料和0.5分抑制升温材料。
TPO发泡层3的原料配方为90份TPO、0.5份AC发泡剂、3份受阻胺类光稳定剂和4份颜料。其他同实施例1。
对比例1
本对比例提供的汽车内饰材料,包括依次设置的表面处理层、TPO层、聚丙烯发泡层和背面处理层。
TPO层的原料组成为94份TPO、5份PP、1份受阻胺类光稳定剂和4份颜料。
该汽车内饰材料通过以下方法制备得到:
(1)将制备TPO层的原料加入挤出机混合,利用挤出机熔融挤出,形成TPO流延膜;
(2)使步骤(1)制备得到的TPO流延膜保持在150~220℃条件下,使用双辊轧制直接将TPO流延膜与PP Foam热复合,制得TPO复合材料半成品;
(3)将步骤(2)制得的TPO复合材料半成品的TPO层经电晕处理,然后印刷涂覆水性聚氨酯,在110℃条件下进行烘干,形成表面处理层;
(4)在经步骤(3)处理后的TPO复合材料半成品的PP Foam表面上印刷涂覆水性聚氨酯和阻燃剂的混合物,在110℃条件下进行烘干,形成背面处理层,制得汽车内饰材料成品,该汽车内饰材料中TPO层的厚度为0.5mm。
对实施例1~3和对比例1的汽车内饰材料进行性能测试,具体评价方法如下,结果如表1所示。
评价方法
1、密度 ISO 1183
2、拉伸强度 ISO 37
3、撕裂强度 ISO 34
4、阻燃:GB/T 8410
5、气味:PV3900
6、耐热老化:120℃ 400h
7、耐光性:SAEJ 2412
表1为实施例1~3和对比例1的汽车内饰材料性能测试结果
测试项目 | 要求 | 实施例1 | 实施例2 | 实施例3 | 对比例1 |
密度(kg/m<sup>3</sup>) | / | 0.43 | 0.52 | 0.60 | 0.89 |
拉伸强度(N) | ≥30 | 57.6 | 59.8 | 61.2 | 62.3 |
撕裂强度(N/mm) | ≥10 | 13.98 | 14.25 | 15.12 | 15.3 |
阻燃mm/min | ≤100 | 65 | 63 | 71 | 68 |
气味 | ≤3.5 | 3.0 | 3.0 | 3.0 | 3.5 |
耐热老化 | ≥4 | 4 | 4-5 | 4-5 | 4-5 |
耐光性 | ≥4 | 4 | 4-5 | 4-5 | 4-5 |
上述实施例只为说明本发明的技术构思及特点,其目的在于让熟悉此项技术的人士能够了解本发明的内容并据以实施,并不能以此限制本发明的保护范围。凡根据本发明精神实质所作的等效变化或修饰,都应涵盖在本发明的保护范围之内。
Claims (6)
1.一种轻量化汽车内饰材料,其特征在于:所述汽车内饰材料包括依次设置的表面处理层、TPO/TPU共混层、TPO发泡层、聚丙烯发泡层及背面处理层,其中,
按重量份计,所述TPO/TPU共混层的原料配方包括以下组分:
第一TPO颗粒 90-95份;
改性TPU材料 8-10份;
抑制升温材料 0.1-0.5份;
第一助剂 0-5份;
第一颜料 4-10份;
按重量份计,所述TPO发泡层的原料配方包括以下组分:
第二TPO颗粒 90-95份;
发泡剂 0.1-2.5份;
第二助剂 0-5份;
第二颜料 4-10份;
所述抑制升温材料为球形二氧化硅颗粒;
所述发泡剂为AC发泡剂;
所述表面处理层使用的材料为水性聚氨酯树脂;
所述TPO发泡层的厚度占所述TPO/TPU共混层和TPO发泡层总厚度的60±5%。
2.根据权利要求1所述的轻量化汽车内饰材料,其特征在于:所述第一助剂为受阻胺类光稳定剂。
3.根据权利要求1所述的轻量化汽车内饰材料,其特征在于:所述第二助剂为受阻胺类。
4.根据权利要求1所述的轻量化汽车内饰材料,其特征在于:所述背面处理层的原料配方由背面处理剂与阻燃剂按质量比1:0.06~0.1组合,所述背面处理剂为水性聚氨酯或聚烯烃树脂,所述阻燃剂为膨胀型阻燃剂。
5.权利要求1~4中任一项所述的轻量化汽车内饰材料的制备方法,其特征在于,所述制备方法包括以下步骤:
(1)将制备TPO/TPU共混层的原料和制备TPO发泡层的原料加入挤出机中进行各自混合,然后双层共挤挤出并与聚丙烯泡沫热复合,制得TPO复合材料半成品;
(2)在步骤(1)制得的所述TPO复合材料半成品的TPO/TPU共混层的表面涂覆表面处理层的原料,烘干,形成表面处理层;
(3)经步骤(2)处理后,在所述TPO复合材料半成品的聚丙烯泡沫表面涂覆背面处理层的原料,烘干,形成背面处理层;
(4)经步骤(3)处理后的TPO复合材料半成品置于195~210℃条件下高温发泡制得所述汽车内饰材料。
6.根据权利要求5所述的轻量化汽车内饰材料的制备方法,其特征在于:步骤(2)中,由步骤(1)制得的所述TPO复合材料半成品的TPO/TPU共混层的表面直接印刷涂覆所述表面处理层的原料 。
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