CN114953661A - 汽车顶棚用防霉阻燃玄武岩纤维复合材料及其制造方法 - Google Patents

汽车顶棚用防霉阻燃玄武岩纤维复合材料及其制造方法 Download PDF

Info

Publication number
CN114953661A
CN114953661A CN202210913848.8A CN202210913848A CN114953661A CN 114953661 A CN114953661 A CN 114953661A CN 202210913848 A CN202210913848 A CN 202210913848A CN 114953661 A CN114953661 A CN 114953661A
Authority
CN
China
Prior art keywords
composite material
basalt fiber
fiber composite
retardant
flame
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CN202210913848.8A
Other languages
English (en)
Other versions
CN114953661B (zh
Inventor
李全明
张万喜
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Jilin Xinwei Material Technology Co ltd
Original Assignee
Jilin Xinwei Material Technology Co ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Jilin Xinwei Material Technology Co ltd filed Critical Jilin Xinwei Material Technology Co ltd
Priority to CN202210913848.8A priority Critical patent/CN114953661B/zh
Publication of CN114953661A publication Critical patent/CN114953661A/zh
Application granted granted Critical
Publication of CN114953661B publication Critical patent/CN114953661B/zh
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Images

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • 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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/071—Preforms or parisons characterised by their configuration, e.g. geometry, dimensions or physical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • 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
    • 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
    • B32B5/08—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 the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • 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
    • B32B5/22—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
    • B32B5/24—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
    • B32B5/26—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 also being fibrous or filamentary
    • B32B5/265—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 also being fibrous or filamentary characterised by one fibrous or filamentary layer being a non-woven fabric layer
    • B32B5/266—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 also being fibrous or filamentary characterised by one fibrous or filamentary layer being a non-woven fabric layer next to one or more non-woven fabric layers
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/485—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with weld-bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2949/00—Indexing scheme relating to blow-moulding
    • B29C2949/07—Preforms or parisons characterised by their configuration
    • B29C2949/0715—Preforms or parisons characterised by their configuration the preform having one end closed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • B32B2262/144—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars

Abstract

本发明提供了一种汽车顶棚用防霉阻燃玄武岩纤维复合材料及其制造方法，所述的汽车顶棚用防霉阻燃玄武岩纤维复合材料包括玄武岩纤维与低有害物质释放PP纤维复合板材、无纺布与胶膜复合材料、阻燃聚氨酯片材，主体为玄武岩纤维与低有害物质释放PP纤维复合板材。其制造工艺主要包括：玄武岩纤维与低有害物质释放PP纤维复合板材的制造工艺、防霉阻燃玄武岩纤维复合材料制造工艺。本发明制备的防霉阻燃玄武岩纤维复合材料制备工艺简单，可以很好的满足复合材料在汽车顶棚上的应用，特别是可以有效改善汽车顶棚的阻燃性、防霉能力和有害物质的释放，并实现产品的轻量化。

Description

汽车顶棚用防霉阻燃玄武岩纤维复合材料及其制造方法
技术领域
本发明涉及一种汽车顶棚用复合材料制造技术领域，具体是一种汽车顶棚用防霉阻燃玄武岩纤维复合材料制造方法。
背景技术
中国已经成为汽车产销量大国，每年的汽车产销量已经突破2000万辆/年，虽然现有汽车用内饰材料基本可以满足汽车产业的需求，但也面临着内饰材料废弃后无法循环利用和对环境造成巨大的影响，特别是随着近年来国家提出的新能源汽车发展战略和“双碳”发展目标的实现，迫切需要轻量化和环保型的新材料来解决上述问题。
现有汽车顶棚用复合材料主要是化学纤维与化学纤维复合、化学纤维与玻璃纤维复合。尽管上述复合材料基本可以满足汽车产业的需要，但也都面临着各种各样的问题。以玻纤复合材料为例，主要存在着加工过程中产生的细小颗粒对生产人员会产生一定的危害，长期接触会产生尘肺病等疾病，并且不可逆转。产品废弃后玻纤也无法降解，会对环境产生巨大影响，为此国外很多国家已经明令禁止在汽车上使用玻纤产品。化学纤维与化学纤维复合化学纤维的使用量过大，而化学纤维来源于石油，所以各国都在减少其用量。
本发明采用玄武岩纤维、低有害物质释放PP纤维和聚氨酯等复合制备汽车顶棚。玄武岩纤维是利用玄武岩矿石在1450℃左右利用拉丝漏板制备的矿物纤维，我国有巨大的玄武岩矿储备，所以材料来源广泛，同时玄武岩纤维对环境友好废弃后不会对环境造成影响，也不会对生产者产生任何的伤害。低有害物质释放PP纤维是我们自己开发的新材料，它和现有市场上销售的PP纤维相比，气味等级更低，VOC释放更低，同时低有害物质释放PP纤维具有不吸收水分的特点。聚氨酯是经过我们改性处理的聚氨酯材料，具有阻燃和抗菌防霉的功能。因此利用这三者材料通过特殊工艺成型的复合材料不但可以满足汽车顶棚对产品性能的要求，同时还可以实现产品的轻量化和环保，解决现有汽车顶棚材料存在的弱点，是非常理想的汽车顶棚替代新材料。
发明内容
本发明的目的在于提供一种汽车顶棚用防霉阻燃玄武岩纤维复合材料制造方法，以解决背景技术中的问题。
为实现上述目的，本发明提供如下技术方案：
本发明首先提供一种汽车顶棚用防霉阻燃玄武岩纤维复合材料，包括玄武岩纤维与低有害物质释放PP纤维复合板材、无纺布与胶膜复合材料和聚氨酯片材，其中，玄武岩纤维与低有害物质释放PP纤维复合板材为主体，玄武岩纤维与低有害物质释放PP纤维复合板材由低有害物质释放的PP纤维和经γ射线辐照改性和表面涂层处理的玄武岩纤维通过针刺法加工成型，按照质量百分比，低有害物质释放的PP纤维占40%～60%，改性玄武岩纤维占40%～60%，低有害物质释放的PP纤维通过材料改性技术、挥脱技术和复合成型技术相结合的方法制备而成。
在上述技术方案的基础上，本发明还提供以下可选技术方案：
在一种可选方案中：所述汽车顶棚用防霉阻燃玄武岩纤维复合材料中的玄武岩纤维与低有害物质释放PP纤维复合板材的克重为500～2600g/m2，无纺布克重为50～150g/m2，胶膜的克重为30～80g/m2。
在一种可选方案中：所述的复合材料是由两层玄武岩纤维与低有害物质释放PP纤维复合板材、两层无纺布与胶膜复合材料和一层阻燃聚氨酯片层组成。
在一种可选方案中：所述汽车顶棚用防霉阻燃玄武岩纤维复合材料的极限氧指数为23%～28%、霉菌防治效率大于90%、气味等级小于3级。
本发明还提供一种如上述所述的汽车顶棚用防霉阻燃玄武岩纤维复合材料制造方法，包括以下步骤；
步骤1：玄武岩纤维与低有害物质释放PP纤维复合板材的制造工艺，将低有害物质释放PP纤维和玄武岩纤维按照质量百分比为40%～60%：40%～60%进行充分混合，得到原材料，然后采用针刺法制备出复合材料，最后经烘箱软化后在压板机上按照一定的工艺参数制备成厚度为12～25mm的板材，所述的烘烤温度为200～250℃，烘烤时间为80～100s，所述的压板机的压力为20～40MPa，保压时间为40～50s，将上述获得的复合板材经分切机进行纵向切边、横向分切得到所需要尺寸的产品；
步骤2：无纺布与胶膜复合材料的制造工艺，将无纺布、胶膜依次铺好，然后放入到烘箱中进行烘烤，经压辊冷却后得到复合材料，所述的烘箱的温度为40～50℃，时间1～3min；
步骤3：汽车顶棚用防霉阻燃玄武岩纤维复合材料的制造工艺，具体的步骤为对步骤2所获得的材料在烘箱1中软化处理，然后按照步骤1所获得的材料、经软化处理的步骤2所获得的材料、聚氨酯片材、经软化处理的步骤2所获得的材料、步骤1所获得的材料按顺序铺层，再一起放到烘箱2中，最后经压板机制得所需要的复合材料，所述的烘箱一的烘箱上板温度为60～100℃，下板温度为40～50℃，所述的烘箱二的上下板温度均为100～120℃，所述的压板机的压力为20～40MPa，保压时间为120～180s；
在一种可选方案中：所述的步骤1中的低有害物质释放PP纤维和玄武岩纤维按照质量百分比为40%～60%：40%～60%。
在一种可选方案中：所述的步骤2中的无纺布克重为50～150g/m2，胶膜的克重为30～80g/m2。
在一种可选方案中：所述的步骤3中所使用的步骤2的材料也可以变成无纺布、胶膜其中的一种。
相较于现有技术，本发明的有益效果如下：
本发明制得的汽车顶棚用防霉阻燃玄武岩纤维复合材料由于采用了低有害物质释放PP纤维、玄武岩纤维和具有防霉、阻燃功能的聚氨酯材料，所制备的复合材料性能优良，测试结果表明剥离力为100～140N、尺寸变化率小于0.5%、弯曲强度100～228MPa、极限氧指数23～28%、霉菌防治效率大于90%、气味等级（80℃测试）≤3级，非常适合汽车顶棚产品，跟现有汽车顶棚用材料相比可以实现减重20%以上。
附图说明
图1为本发明制备的玄武岩纤维与低地有害物质释放PP纤维复合板材的制备工艺流程图。
图2为本发明制备的汽车顶棚用防霉阻燃玄武岩纤维复合材料的制备工艺流程图。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白，以下结合附图及实施例，对本发明进行进一步详细说明。本发明所列举的各实施例仅用以说明本发明，并非用以限制本发明的范围。对本发明所作的任何显而易知的修饰或变更都不脱离本发明的精神与范围。
实施例1
一种汽车顶棚用防霉阻燃玄武岩纤维复合材料，包括玄武岩纤维与低有害物质释放PP纤维复合板材、无纺布与胶膜和聚氨酯片材，玄武岩纤维与低有害物质释放PP纤维复合板材为主体。
所述汽车顶棚用防霉阻燃玄武岩纤维复合材料中的低有害物质释放PP纤维和玄武岩纤维按照质量百分比为50%：50%。
低有害物质释放的PP纤维通过材料改性技术、挥脱技术和复合成型技术相结合的方法制备而成。具体地，首先将气味改性剂和PP颗粒按照质量百分比30%：70%喂入搅拌机中进行混合，得到混料；然后将混料通过气流输送到添加了挥脱装置的造粒机经熔融混炼后由双螺杆挤出，冷却后经过切断从而制得低有害物质挥发的PP颗粒。再将低有害物质挥发的PP颗粒加入熔融螺杆B中作为皮层，将PP颗粒加入熔融螺杆A中作为芯层，皮层和芯层按照质量百分比50%：50%加入到纺丝计量泵中，经过喷丝板纺成纤维，成型后的纤维依次经过油剂槽上油辊、多步牵伸机、去油剂装置、定型机、卷曲机定型后得到纤维丝束，上述熔融螺杆B中加入的低有害物质挥发的PP颗粒的熔融指数为30g/10min，熔融螺杆A中加入的PP颗粒的熔融指数为70g/10min。将上述制得的纤维丝束通过纤维整形机和切断机，最终制得复合纺皮芯结构的低有害物质释放的PP纤维，其中纤维长度控制在40～60cm、纤维细度控制在2.01dtex～8.22dtex，整形机的喷头压力控制在2.6kg/cm2～3.6kg/cm2范围内。
所述汽车顶棚用防霉阻燃玄武岩纤维复合材料中的玄武岩纤维与低有害物质释放PP纤维复合板材的克重为1200g/m2。
所述汽车顶棚用防霉阻燃玄武岩纤维复合材料中的无纺布克重为100g/m2，胶膜的克重为45g/m2。
所述汽车顶棚用防霉阻燃玄武岩纤维复合材料的剥离力为110N、尺寸变化率0.2%、弯曲强度150MPa、极限氧指数为25%、霉菌防治效率98%、气味等级3级。
一种如上述所述的汽车顶棚用防霉阻燃玄武岩纤维复合材料的制造方法，如图1所示，包括以下步骤；
步骤1：玄武岩纤维与低有害物质释放PP纤维复合板材的制造工艺，低有害物质挥发PP纤维和玄武岩纤维按照质量分数比为50%：50%进行投料，然后依次经过开松、梳理、铺网、叠网等工艺，然后采用针刺法制备出克重为1200g/m2的复合材料毡，最后经烘箱（烘烤温度为220℃，时间120s）软化后在压板机（压力为30MPa，保压时间为40s）上制备成厚度为15mm的板材，将上述获得的复合板材经分切机进行纵向切边、横向分切得到所需要尺寸的产品；
步骤2：无纺布与胶膜复合材料的制造工艺。将克重为100g/m2的无纺布、克重为20g/m2的胶膜依次铺好，然后放入到烘箱（烘箱的温度为70℃）中烘烤60s，经压辊冷却后得到复合材料；
步骤3：汽车顶棚用防霉阻燃玄武岩纤维复合材料的制造工艺，具体的步骤为对步骤2所获得的材料在烘箱（烘箱上板温度为90℃，下板温度为50℃）中软化处理50s，然后按照步骤1所获得的材料、经软化处理的步骤2所获得的材料、阻燃防霉聚氨酯片材、经软化处理的步骤2所获得的材料、步骤1所获得的材料按如图2所示的顺序铺层，再一起放到烘箱（上下板温度均为110℃）中烘烤120s，最后经压板机（压力为40MPa，时间为180s）制得所需要的复合材料。
实施例2
一种汽车顶棚用防霉阻燃玄武岩纤维复合材料，包括玄武岩纤维与低有害物质释放PP纤维复合板材、无纺布与胶膜、聚氨酯片材，玄武岩纤维与低有害物质释放PP纤维复合板材为主体。
所述汽车顶棚用防霉阻燃玄武岩纤维复合材料中的低有害物质释放PP纤维和玄武岩纤维按照质量百分比为40%：60%。低有害物质释放PP纤维采用实施例1的方法制备。
所述汽车顶棚用防霉阻燃玄武岩纤维复合材料中的玄武岩纤维与低有害物质释放PP纤维复合板材的克重为1000g/m2。
所述汽车顶棚用防霉阻燃玄武岩纤维复合材料中的无纺布克重为100g/m2，胶膜的克重为60g/m2。
所述汽车顶棚用防霉阻燃玄武岩纤维复合材料的剥离力为120N、尺寸变化率0.1%、弯曲强度142MPa、极限氧指数为27%、霉菌防治效率99%、气味等级2.5级。
一种如上述所述的汽车顶棚用防霉阻燃玄武岩纤维复合材料的制造方法，包括以下步骤；
步骤1：玄武岩纤维与低有害物质释放PP纤维复合板材的制造工艺，低有害物质释放PP纤维和玄武岩纤维按照质量分数比为40%：60%进行投料，然后依次经过开松、梳理、铺网、叠网等工艺，然后采用针刺法制备出克重为1000g/m2的复合材料毡，最后经烘箱（烘烤温度为220℃，时间90s）软化后在压板机（压力为30MPa，保压时间为40s）上制备成厚度为12mm的板材，将上述获得的复合板材经分切机进行纵向切边、横向分切得到所需要尺寸的产品；
步骤2：无纺布与胶膜复合材料的制造工艺，将克重为100g/m2的无纺布、克重为30g/m2的胶膜依次铺好，然后放入到烘箱（烘箱的温度为60℃）中烘烤60s，经压辊冷却后得到复合材料；
步骤3：汽车顶棚用防霉阻燃玄武岩纤维复合材料的制造工艺，具体的步骤为对步骤2所获得的材料在烘箱（烘箱上板温度为90℃，下板温度为50℃）中软化处理50s，然后按照步骤1所获得的材料、经软化处理的步骤2所获得的材料、阻燃防霉聚氨酯片材、经软化处理的步骤2所获得的材料、步骤1所获得的材料按顺序铺层，再一起放到烘箱（上下板温度均为110℃）中烘烤120s，最后经压板机（压力为40MPa，时间为180s）制得所需要的复合材料。
实施例3
一种汽车顶棚用防霉阻燃玄武岩纤维复合材料，包括玄武岩纤维与低有害物质释放PP纤维复合板材、无纺布与胶膜、聚氨酯片材，玄武岩纤维与低有害物质释放PP纤维复合板材为主体。
所述防霉汽车顶棚用防霉阻燃玄武岩纤维复合材料中的低有害物质释放PP纤维和玄武岩纤维按照质量百分比为40%：60%。低有害物质释放PP纤维采用实施例1的方法制备。
所述汽车顶棚用防霉阻燃玄武岩纤维复合材料中的玄武岩纤维与低有害物质释放PP纤维复合板材的克重为1800g/m2。
所述汽车顶棚用防霉阻燃玄武岩纤维复合材料中的无纺布克重为120g/m2，胶膜的克重为80g/m2。
所述汽车顶棚用防霉阻燃玄武岩纤维复合材料的剥离力为130N、尺寸变化率0.1%、弯曲强度218MPa、极限氧指数为28%、霉菌防治效率99%、气味等级2.5级。
一种如上述所述的汽车顶棚用防霉阻燃玄武岩纤维复合材料的制造方法，包括以下步骤；
步骤1：玄武岩纤维与低有害物质释放PP纤维复合板材的制造工艺，低有害物质释放PP纤维和玄武岩纤维按照质量分数比为40%：60%进行投料，然后依次经过开松、梳理、铺网、叠网等工艺，然后采用针刺法制备出克重为1800g/m2的复合材料毡，最后经烘箱（烘烤温度为220℃，时间150s）软化后在压板机（压力为40MPa，保压时间为40s）上制备成厚度为20mm的板材，将上述获得的复合板材经分切机进行纵向切边、横向分切得到所需要尺寸的产品；
步骤2：无纺布与胶膜复合材料的制造工艺。将克重为120g/m2的无纺布、克重为30g/m2的胶膜依次铺好，然后放入到烘箱（烘箱的温度为80℃）中烘烤60s，经压辊冷却后得到复合材料；
步骤3：汽车顶棚用防霉阻燃玄武岩纤维复合材料的制造工艺，具体的步骤为对步骤2所获得的材料在烘箱（烘箱上板温度为100℃，下板温度为50℃）中软化处理50s，然后按照步骤1所获得的材料、经软化处理的步骤2所获得的材料、阻燃防霉聚氨酯片材、经软化处理的步骤2所获得的材料、步骤1所获得的材料按顺序铺层，再一起放到烘箱（上下板温度均为110℃）中烘烤150s，最后经压板机（压力为40MPa，时间为180s）制得所需要的复合材料。
实施例4（低有害物质释放PP纤维和玄武岩纤维按照质量百分比为60%：40%，其他同实施例3）
一种汽车顶棚用防霉阻燃玄武岩纤维复合材料，包括玄武岩纤维与低有害物质释放PP纤维复合板材、无纺布与胶膜、聚氨酯片材，玄武岩纤维与低有害物质释放PP纤维复合板材为主体。
所述防霉汽车顶棚用防霉阻燃玄武岩纤维复合材料中的低有害物质释放PP纤维和玄武岩纤维按照质量百分比为60%：40%。低有害物质释放PP纤维采用实施例1的方法制备。
所述汽车顶棚用防霉阻燃玄武岩纤维复合材料中的玄武岩纤维与低有害物质释放PP纤维复合板材的克重为1800g/m2。
所述汽车顶棚用防霉阻燃玄武岩纤维复合材料中的无纺布克重为120g/m2，胶膜的克重为80g/m2。
所述汽车顶棚用防霉阻燃玄武岩纤维复合材料的剥离力为125N、尺寸变化率0.2%、弯曲强度198MPa、极限氧指数为26%、霉菌防治效率97%、气味等级3级。
一种如上述所述的汽车顶棚用防霉阻燃玄武岩纤维复合材料的制造方法，包括以下步骤；
步骤1：玄武岩纤维与低有害物质释放PP纤维复合板材的制造工艺，低有害物质释放PP纤维和玄武岩纤维按照质量分数比为60%：40%进行投料，然后依次经过开松、梳理、铺网、叠网等工艺，然后采用针刺法制备出克重为1800g/m2的复合材料毡，最后经烘箱（烘烤温度为220℃，时间150s）软化后在压板机（压力为40MPa，保压时间为40s）上制备成厚度为20mm的板材，将上述获得的复合板材经分切机进行纵向切边、横向分切得到所需要尺寸的产品；
步骤2：无纺布与胶膜复合材料的制造工艺。将克重为120g/m2的无纺布、克重为30g/m2的胶膜依次铺好，然后放入到烘箱（烘箱的温度为80℃）中烘烤60s，经压辊冷却后得到复合材料；
步骤3：汽车顶棚用防霉阻燃玄武岩纤维复合材料的制造工艺，具体的步骤为对步骤2所获得的材料在烘箱（烘箱上板温度为100℃，下板温度为50℃）中软化处理50s，然后按照步骤1所获得的材料、经软化处理的步骤2所获得的材料、阻燃防霉聚氨酯片材、经软化处理的步骤2所获得的材料、步骤1所获得的材料按顺序铺层，再一起放到烘箱（上下板温度均为110℃）中烘烤150s，最后经压板机（压力为40MPa，时间为180s）制得所需要的复合材料。
以上所述，仅为本公开的具体实施方式，但本公开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公开揭露的技术范围内，可轻易想到变化或替换，都应涵盖在本公开的保护范围之内。因此，本公开的保护范围应以权利要求的保护范围为准。

Claims (7)

1.汽车顶棚用防霉阻燃玄武岩纤维复合材料，其特征在于，包括玄武岩纤维与低有害物质释放PP纤维复合板材、无纺布与胶膜复合材料和阻燃聚氨酯片材，其中，玄武岩纤维与低有害物质释放PP纤维复合板材为主体，玄武岩纤维与低有害物质释放PP纤维复合板材由低有害物质释放的PP纤维和经γ射线辐照改性和表面涂层处理的玄武岩纤维通过针刺法加工成型，按照质量百分比，低有害物质释放的PP纤维占40%～60%，改性玄武岩纤维占40%～60%，低有害物质释放的PP纤维通过材料改性技术、挥脱技术和复合成型技术相结合的方法制备而成。
2.根据权利要求1所述的汽车顶棚用防霉阻燃玄武岩纤维复合材料，其特征在于，所述的复合材料是由两层玄武岩纤维与低有害物质释放PP纤维复合板材、两层无纺布与胶膜复合材料和一层阻燃聚氨酯片层组成。
3.根据权利要求1所述的汽车顶棚用防霉阻燃玄武岩纤维复合材料，其特征在于，所述的复合材料中，玄武岩纤维与低有害物质释放PP纤维复合板材的克重为500～2600g/m2，无纺布克重为50～150g/m2，胶膜的克重为30～80g/m2。
4.根据权利要求1所述的汽车顶棚用防霉阻燃玄武岩纤维复合材料，其特征在于，所述的复合材料的极限氧指数为23%～28%、霉菌防治效率大于90%、气味等级≤3级。
5.汽车顶棚用防霉阻燃玄武岩纤维复合材料的制造方法，其特征在于，用于制造如权利要求1～4任一所述的汽车顶棚用防霉阻燃玄武岩纤维复合材料，所述方法包括以下步骤：
步骤1：玄武岩纤维与低有害物质释放PP纤维复合板材的制造工艺：将低有害物质释放PP纤维和玄武岩纤维按照质量百分比为40%～60%：40%～60%进行充分混合，得到混合原材料，然后采用针刺法制备出复合材料无纺布，最后经烘箱软化后在压板机上按照以下的工艺参数制备成厚度为12～25mm的板材，所述的烘烤温度为200～250℃，烘烤时间为80～100s，所述的压板机的压力为20～40MPa，保压时间为40～50s，将上述获得的复合板材经分切机进行纵向切边、横向分切得到所需要尺寸的产品；
步骤2：无纺布与胶膜复合材料的制造工艺：将不同克重的无纺布、胶膜依次铺好，然后放入到烘箱中进行烘烤，经保压冷却后得到复合材料，所述的烘箱的温度为40～50℃，时间1～3min；
步骤3：汽车顶棚用防霉阻燃玄武岩纤维复合材料的制造工艺：将步骤2所获得的材料在烘箱1中软化处理，然后依次将步骤1所获得的材料、经软化处理的步骤2所获得的材料、聚氨酯片材、经软化处理的步骤2所获得的材料、步骤1所获得的材料按顺序铺层，再一起放到烘箱2中，最后经压板机制得所需要的复合材料，所述的烘箱1的烘箱上板温度为60～100℃，下板温度为40～50℃，所述的烘箱2的上下板温度均为100～120℃，所述的压板机的压力为20～40MPa，保压时间为120～180s。
6.根据权利要求5所述的汽车顶棚用防霉阻燃玄武岩纤维复合材料的制造方法，其特征在于，所述的步骤2中的无纺布克重为50～150g/m2，胶膜的克重为30～80g/m2。
7.根据权利要求5所述的汽车顶棚用防霉阻燃玄武岩纤维复合材料的制造方法，其特征在于，所述的步骤3中所使用的步骤2的材料替换成无纺布、胶膜其中的一种。
CN202210913848.8A 2022-08-01 2022-08-01 汽车顶棚用防霉阻燃玄武岩纤维复合材料及其制造方法 Active CN114953661B (zh)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CN202210913848.8A CN114953661B (zh) 2022-08-01 2022-08-01 汽车顶棚用防霉阻燃玄武岩纤维复合材料及其制造方法

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CN202210913848.8A CN114953661B (zh) 2022-08-01 2022-08-01 汽车顶棚用防霉阻燃玄武岩纤维复合材料及其制造方法

Publications (2)

Publication Number Publication Date
CN114953661A true CN114953661A (zh) 2022-08-30
CN114953661B CN114953661B (zh) 2022-10-25

Family

ID=82969799

Family Applications (1)

Application Number Title Priority Date Filing Date
CN202210913848.8A Active CN114953661B (zh) 2022-08-01 2022-08-01 汽车顶棚用防霉阻燃玄武岩纤维复合材料及其制造方法

Country Status (1)

Country Link
CN (1) CN114953661B (zh)

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102050062A (zh) * 2010-11-19 2011-05-11 烟台正海汽车内饰件有限公司 一种汽车内饰顶棚的生产方法
CN102145553A (zh) * 2010-11-15 2011-08-10 长春博超汽车零部件股份有限公司 一种环保可回收汽车内饰件玄武岩纤维和麻纤维复合板材及其生产方法
CN102145554A (zh) * 2010-11-15 2011-08-10 长春博超汽车零部件股份有限公司 一种环保可回收玄武岩纤维和麻纤维汽车门板及其制备工艺
CN102431228A (zh) * 2011-09-30 2012-05-02 江苏紫荆花纺织科技股份有限公司 汽车顶篷内饰复合板材
CN102649334A (zh) * 2012-06-01 2012-08-29 丹阳市新美龙汽车软饰件有限公司 玄武岩纤维麻塑复合板及其制备方法
CN103101256A (zh) * 2013-02-28 2013-05-15 浙江华江科技发展有限公司 一种轻量化高强度高吸音聚氨酯复合板及其全胶膜成型工艺
CN103434253A (zh) * 2013-08-22 2013-12-11 烟台正海汽车内饰件有限公司 一种低克重高强度汽车内饰顶棚的生产方法
CN203779977U (zh) * 2013-12-31 2014-08-20 浙江华江科技发展有限公司 一种低克重及高剥离强度纤维增强热塑性树脂复合板材
CN106906526A (zh) * 2017-04-20 2017-06-30 吉林省华纺静电材料科技有限公司 复合纺皮芯层结构聚丙烯静电短纤维的制备方法
CN107385558A (zh) * 2017-08-10 2017-11-24 吉林省华纺静电材料科技有限公司 一种多功能聚丙烯短纤维及其生产工艺
CN209683605U (zh) * 2019-04-01 2019-11-26 重庆华博汽车饰件有限公司 一种含玄武岩纤维针刺毡的汽车顶棚

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102145553A (zh) * 2010-11-15 2011-08-10 长春博超汽车零部件股份有限公司 一种环保可回收汽车内饰件玄武岩纤维和麻纤维复合板材及其生产方法
CN102145554A (zh) * 2010-11-15 2011-08-10 长春博超汽车零部件股份有限公司 一种环保可回收玄武岩纤维和麻纤维汽车门板及其制备工艺
CN102050062A (zh) * 2010-11-19 2011-05-11 烟台正海汽车内饰件有限公司 一种汽车内饰顶棚的生产方法
CN102431228A (zh) * 2011-09-30 2012-05-02 江苏紫荆花纺织科技股份有限公司 汽车顶篷内饰复合板材
CN102649334A (zh) * 2012-06-01 2012-08-29 丹阳市新美龙汽车软饰件有限公司 玄武岩纤维麻塑复合板及其制备方法
CN103101256A (zh) * 2013-02-28 2013-05-15 浙江华江科技发展有限公司 一种轻量化高强度高吸音聚氨酯复合板及其全胶膜成型工艺
CN103434253A (zh) * 2013-08-22 2013-12-11 烟台正海汽车内饰件有限公司 一种低克重高强度汽车内饰顶棚的生产方法
CN203779977U (zh) * 2013-12-31 2014-08-20 浙江华江科技发展有限公司 一种低克重及高剥离强度纤维增强热塑性树脂复合板材
CN106906526A (zh) * 2017-04-20 2017-06-30 吉林省华纺静电材料科技有限公司 复合纺皮芯层结构聚丙烯静电短纤维的制备方法
CN107385558A (zh) * 2017-08-10 2017-11-24 吉林省华纺静电材料科技有限公司 一种多功能聚丙烯短纤维及其生产工艺
CN209683605U (zh) * 2019-04-01 2019-11-26 重庆华博汽车饰件有限公司 一种含玄武岩纤维针刺毡的汽车顶棚

Also Published As

Publication number Publication date
CN114953661B (zh) 2022-10-25

Similar Documents

Publication Publication Date Title
KR101434077B1 (ko) 섬유 복합 재료의 편평한 반제품의 제조 방법
CN103465572B (zh) 天然纤维/热塑性树脂复合材料汽车内饰板的生产方法
CN101096134A (zh) 一种夹层结构纤维板
CN102953231B (zh) 一种天然纤维增强热塑性复合材料及其制备方法和用途
CN103950251A (zh) 一种高阻燃性的轻质纤维增强热塑性树脂复合板材的配方及制备工艺
CN102978830A (zh) 一种玻璃纤维/阻燃丙纶纤维轻质复合板材及其制备方法
CN102896843A (zh) 用于制作汽车内饰件的竹纤维复合基材及内饰件制造方法
CN104805593A (zh) 一种阻燃混纺纤维毡的制造方法
CN109159500A (zh) 一种以竹纤维为基材的汽车顶棚及其制备方法
CN106239937B (zh) 一种制备连续纤维增强热塑性预浸带的装置
CN1295074C (zh) 纳米钙塑纤维毡复合汽车内饰衬板及其制造方法
CN101514510A (zh) 一种活性炭纤维复合材料及其制备方法
CN1125710C (zh) 一种非织造的纤维板材及其制造方法
CN105799294A (zh) 一种汽车内饰用淋膜复合材料的制造方法
CN107261643A (zh) 一种泡沫涂层复合耐高温滤料及其制备方法
CN114953661B (zh) 汽车顶棚用防霉阻燃玄武岩纤维复合材料及其制造方法
CN103361883B (zh) 玻璃纤维/聚苯硫醚纤维复合板材及其制备方法和用途
CN108384107B (zh) 一种竹纤维为主增强体的车用复合材料及其制备方法
KR101228143B1 (ko) 자동차 내장용 생분해성 복합패널의 제조방법
CN113152112A (zh) 人工皮革及其制造方法
KR20110035728A (ko) 자동차 내장용 복합패널의 제조방법
CN111058190A (zh) 包装材料、其制备方法和复合包装材料
CN103287028A (zh) 一种新型gmt板材及其生产工艺
CN110466226A (zh) 飞机内饰板用针刺无纺布复合板
CN110053275B (zh) 一种碳纤维复合材料的制备方法和加工设备

Legal Events

Date Code Title Description
PB01 Publication
PB01 Publication
SE01 Entry into force of request for substantive examination
SE01 Entry into force of request for substantive examination
GR01 Patent grant
GR01 Patent grant