CN115107340B - 一种汽车地毯、其制备方法及其应用 - Google Patents

一种汽车地毯、其制备方法及其应用 Download PDF

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CN115107340B
CN115107340B CN202110286504.4A CN202110286504A CN115107340B CN 115107340 B CN115107340 B CN 115107340B CN 202110286504 A CN202110286504 A CN 202110286504A CN 115107340 B CN115107340 B CN 115107340B
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carpet
eva
layer
automobile
antioxidant
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CN115107340A (zh
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邵方方
姜进京
高霞
孙晓波
刘茜
郭吟竹
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SAIC Motor Corp Ltd
Shanghai Automotive Industry Corp Group
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Shanghai Automotive Industry Corp Group
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Abstract

本发明提供了一种汽车地毯，包括依次叠加设置的PE膜、PET毯面、EVA层、水刺布和PU发泡层；所述EVA层的原料中包括POE、改性聚乙烯、白云石、滑石粉、分散剂和抗氧剂；所述PU发泡层由A料和B料制备得到，所述A料的原料包括低散发聚醚多元醇、润滑剂、催化剂、硅油、除醛剂和增塑剂，所述B料为异氰酸酯。本申请还提供了汽车地毯的制备方法。本发明通过改善现有地毯的基础配方，筛选出低散发性的原材料，在改善气味和VOC的同时，提高了地毯的回弹速度，得到了一种具有快回弹低气味低VOC的汽车地毯材料。

Description

一种汽车地毯、其制备方法及其应用
技术领域
本发明涉及汽车内饰件技术领域，尤其涉及一种汽车地毯、其制备方法及其应用。
背景技术
PET+EVA+PU地毯是汽车内饰常用的地毯。在制备PET+EVA+PU地毯时，PU发泡材料常采用三乙烯二胺、五甲基二乙烯三胺等胺类物质作为催化剂，导致材料本身具有较刺激的臭味；EVA材料中常采用含有丙烯酸辛酯丙烯酸丁酯的胶黏材料，导致EVA气味差。并且，PET+EVA+PU地毯中的PU发泡料中的A料本身纯度不够会引起甲醛和乙醛超标，EVA老化降解，也会产生甲醛、乙醛问题。
另一方面，PET+EVA+PU地毯作为汽车内饰中一种重要的隔音降噪提升品质的饰件，对发泡的按压后的回弹速度有特殊的要求，但厚度超过50mm的地毯在按压后回弹慢。地毯下方经常会隐藏安装一些大功率的电器件，散热要求高，上覆盖空间避让60mm以上的要求，地毯产生下塌。鉴于上述问题，提供一种解决PET+EVA+PU发泡地毯的气味问题、VOC问题以及回弹慢的问题具有重要意义。
发明内容
本发明解决的技术问题在于提供一种汽车地毯，本申请提供的汽车地毯具有快回弹低气味第VOC的特点。
有鉴于此，本申请提供了一种汽车地毯，包括依次叠加设置的PE膜、PET毯面、EVA层、水刺布和PU发泡层；
所述EVA层的原料中包括POE、改性聚乙烯、白云石、滑石粉、分散剂和抗氧剂；
所述PU发泡层由A料和B料制备得到，所述A料的原料包括低散发聚醚多元醇、润滑剂、催化剂、硅油、除醛剂和增塑剂，所述B料为异氰酸酯；
所述PE膜的内表面设置有高纯度的丙烯酸酯胶。
优选的，所述EVA层中，所述POE的含量为5～20wt％，所述改性聚乙烯的含量为20～40wt％，所述白云石的含量为50～70wt％，所述滑石粉的含量为1～5wt％，所述分散剂的含量为1～5wt％，所述抗氧剂的含量为0.01～0.2wt％。
优选的，所述PU发泡层中，所述低散发聚醚多元醇的含量为90～97wt％，所述润滑剂的含量为0.1～0.5wt％，所述催化剂的含量为1～5wt％，所述硅油的含量为1～5wt％，所述除醛剂的含量为0.2～0.8wt％，所述增塑剂的含量为0.1～0.5wt％。
优选的，所述PU发泡层中，所述A料和所述B料的质量比为1：(0.5～0.8)。
优选的，所述EVA层中，所述POE为低气味低乙醛原料6102，所述改性聚乙烯以马来酸酐接枝聚乙烯，所述分散剂为线性高分子增塑剂，所述抗氧剂选自抗氧剂168和抗氧剂1010中的一种或两种。
优选的，所述PU发泡层中，所述催化剂为反应型凝胶胺催化剂DPA，所述增塑剂为线性高分子增塑剂UN-488。
优选的，所述PE膜的表面涂胶量为50～60g/m2。
本申请还提供了所述的汽车地毯的制备方法，包括以下步骤：
将POE、改性聚乙烯、白云石、滑石粉、分散剂和抗氧剂混合、预加热后再加热、挤出，得到EVA层；
将所述PET毯面、EVA层和水刺布热复合，得到PET+EVA毯面；
将低发散聚醚多元醇、润滑剂、催化剂、硅油、除醛剂和增塑剂混合，得到A料，将A料和B料混合，得到混合料；
将所述混合料涂覆于下模上，将PET+EVA毯面软化后作为上模，闭合模具后发泡，得到EVA+PET+PU地毯总成；
将PT膜贴在所述地毯总成表面，得到汽车地毯。
本申请还提供了一种散热器隔离空间结构，包括地毯表皮和散热器，所述地毯表皮和所述散热器之间不连续设置有若干汽车地毯，所述汽车地毯为所述的汽车地毯或所述的制备方法所制备的汽车地毯。
优选的，所述若干汽车地毯之间为进风空间或出风空间，所述地毯表皮和所述散热器之间的距离大于60mm。
本申请提供了一种汽车地毯，其包括依次叠加设置的PE膜、PET毯面、EVA层、水刺布和PU发泡层，并对其中EVA层和PU发泡层的原理进行了调整；本申请通过在EVA层中采用环保POE代替易降解的EVA原料，并通过选择合理配比的分散剂和抗氧剂等的填料，降低了EVA层的气味和VOC，在PU发泡层调整A料和B料中组分的含量，使汽车地毯气味和VOC水平稳定维持在标准范围内，并通过严格控制PU发泡料的比例和增塑剂的添加量，使汽车地毯回弹速度快。
进一步的，本申请在散热器和地毯表皮之间设置了不连续分布的汽车地毯，在不影响散热器换风散热的基础上有效避免了地毯的塌陷。
附图说明
图1为本发明提供的汽车地毯的结构示意图；
图2为本发明提供的汽车地毯放置位置的具体示意图。
具体实施方式
为了进一步理解本发明，下面结合实施例对本发明优选实施方案进行描述，但是应当理解，这些描述只是为进一步说明本发明的特征和优点，而不是对本发明权利要求的限制。
针对现有技术中汽车地毯存在的问题，本发明提供了一种快回弹低气味低VOC的汽车地毯及其制备方法，通过调整汽车地毯中EVA层和VOC层的组分含量，而使其改善气味和VOC的同时，提高了地毯的回弹速度，由此得到了一种快回弹低气味低VOC的汽车地毯。具体的，本申请汽车地毯的结构示意图如图1所示，其包括依次叠加设置的PE膜、PET毯面、EVA层、水刺布和PU发泡层；
所述EVA层的原料中包括POE、改性聚乙烯、白云石、滑石粉、分散剂和抗氧剂；
所述PU发泡层由A料和B料制备得到，所述A料的原料包括低散发聚醚多元醇、润滑剂、催化剂、硅油、除醛剂和增塑剂，所述B料为巴斯夫CI2151 C-B；
所述PE膜的内表面设置有高纯度的丙烯酸酯胶。
在本申请提供的汽车地毯中，所述EVA层的原料具体包括5～20wt％的POE、20～40wt％的改性聚乙烯、50～70wt％的白云石、1～5wt％的滑石粉、1～5wt％的分散剂、0.01～0.2wt％的抗氧剂；更具体地，所述POE的含量为8～18wt％，更具体地，所述POE的含量为5～10wt％；所述POE具体是一种低气味低乙醛的原料，例如POE6102。所述改性聚乙烯采用马来酸酐接枝聚乙烯，其可增加聚乙烯为填料白云石和滑石粉的相容性，其中聚乙烯的熔点为123℃，是一种低密度聚乙烯；其含量为20～40wt％，更具体地，所述改性聚乙烯的含量为25～38wt％，更具体地，所述改性聚乙烯的含量为25～35wt％。
所述白云石和所述滑石粉用以增加汽车地毯的重量，提高隔音效果；在具体实施例中，所述白云石的含量为50～65wt％，所述滑石粉的含量为1～3wt％。
所述分散剂为本领域技术人员熟知的分散剂，在具体实施例中，所述分散剂的含量为2～4wt％。所述抗氧剂为本领域技术人员熟知的抗氧剂，其具体可选自抗氧剂168和抗氧剂1010中的一种或多种；其含量为0.01～0.2wt％，在具体实施例中，所述抗氧剂的含量为0.03～0.18wt％，更具体地，所述抗氧剂的含量为0.1～0.15wt％。
本申请EVA层中的POE、改性聚乙烯、白云石和滑石粉是汽车地毯的主要成分，其相互作用，增加了汽车地毯的隔音性能，提高了强度，增加了脚感。
在PU发泡层中，其由A料和B料制备得到，所述A料的原料包括低散发聚醚多元醇、润滑剂、催化剂、硅油、除醛剂和增塑剂，所述B料为巴斯夫CI2151 C-B；具体的，在所述A料中，所述低发散聚醚多元醇是一种原料经过挥脱的环保聚醚多元醇，更具体地，其具体选自FA-703；所述低发散聚醚多元醇的含量为90～97wt％，在具体实施例中，所述低发散聚醚多元醇的含量为92～96wt％。
所述润滑剂为本领域技术人员熟知的润滑剂，对此本申请没有特别的限制；所述润滑剂的含量为0.1～0.5wt％。
所述催化剂为一种低气味凝胶催化剂，在实施例中具体选自DPA催化剂。所述催化剂的含量为1～5wt％，更具体地，所述催化剂的含量为1wt％、2wt％、3wt％、4wt％或5wt％。
所述硅油为本领域技术人员熟知的硅油，在具体实施例中，所述硅油选自赢创低气味环保硅油。所述硅油的含量为1～5wt％，更具体地，所述硅油的含量为1wt％、2wt％、3wt％、4wt％或5wt％。
所述除醛剂具体为一种酰胺(盐)类物质，在具体实施例中，所述除醛剂具体选自亨斯曼DPA，所述除醛剂的含量为0.2～0.8wt％，在具体实施例中，所述除醛剂的含量为0.2wt％、0.3wt％、0.4wt％、0.5wt％、0.6wt％、0.7wt％或0.8wt％。
所述增塑剂为高纯度的低挥发性线性高分子增塑剂，其是一种可以调节发泡硬度和回弹率的增塑剂，其具体选自UN-88增塑剂。所述增塑剂的含量为0.1～0.5wt％，更具体地，所述增塑剂的含量为0.1wt％、0.2wt％、0.3wt％、0.4wt％或0.5wt％。
所述PU发泡层中的A料和B料的质量比为1：(0.5～0.8)；所述B料为环保异氰酸酯，更具体地，所述B料为巴斯夫CI 2151 C-B。
所述汽车地毯中，PE膜的内表面设置有高纯度的丙烯酸酯胶，其胶水型号为P-88W-Z，PE膜的表面涂胶量为55～60g/m2。所述PE膜的A料和B料的质量比决定着汽车地毯的密度，而密度决定了汽车地毯的回弹性能。
本申请还提供了所述的汽车地毯的制备方法，包括以下步骤：
将POE、改性聚乙烯、白云石、滑石粉、分散剂和抗氧剂混合、预加热后再加热、挤出，得到EVA层；
将所述PET毯面、EVA层和水刺布热复合，得到PET+EVA毯面；
将低发散聚醚多元醇、润滑剂、催化剂、硅油、除醛剂和增塑剂混合，得到A料，将A料和B料混合，得到混合料；
将所述混合料涂覆于下模上，将PET+EVA毯面软化后作为上模，闭合模具后发泡，得到EVA+PET+PU地毯总成；
将PT膜贴在所述地毯总成表面，得到汽车地毯。
在制备EVA层的过程中，原料已进行了详细说明，此处不进行赘述。所有原料是物理混合，混合后固化制成片材，作为隔音、成型、放置PU发泡层溢至毯面。所述预加热用以去除小分子物质，即将混合的物料进行烘烤，所述烘烤的温度为70～80℃，时间为10～20min。再将预加热后的物料挤出成型，得到EVA层；所述加热的温度为100～200℃。
本申请然后将PET毯面、EVA层和水刺布热复合，即得到PET+EVA毯面。
在本申请中，将低发散聚醚多元醇、润滑剂、催化剂、硅油、除醛剂和增塑剂混合，得到A料，将A料和B料混合，得到混合料，此过程中，原料发生了化学反应，在催化剂的催化作用下生成PU材料，其中硅油保证泡孔的均匀性，增塑剂提升了发泡塑性回弹。然后将得到的混合料喷涂在下模上，同时将PET+EVA毯面软化后放置在上模中，闭合后发泡，得到EVA+PET+PU地毯总成；所述下模的表面喷涂环保性水性有机硅脱模剂，所述发泡时控制下模温度为60～70℃，时间为200～300s。
PE膜的表面涂胶量为55～60g/m2，PE膜的涂胶在烘箱中进行，烘箱的温度为100～120℃，涂胶的速度为20～30m/min。在PE膜涂胶后则将其贴在上述地毯总成表面，即得到汽车地毯。
本申请还提供了一种散热器隔离空间结构，具体如图2所示，其包括地毯表皮和散热器，所述地毯表皮和所述散热器之间不连续设置有若干汽车地毯，所述汽车地毯为上述方案所述的汽车地毯。
对于汽车地毯下部设置有散热器的结构，局部覆盖空间避让60mm以上，应采用图2汽车地毯的覆盖方式，在地毯模具中设计发泡空间，制成单独密封隔离，制成独立发泡空间，这些密封隔离既可以支撑地毯表皮保证地毯表皮不塌陷，又可以使散热器的进气和出气空间隔离，避免散热器局部进气过热经常出现过热保护。
本发明开发了一种快回弹的汽车地毯，通过优选EVA层的原材料，用环保POE原料代替易降解的EVA原料，并通过选择合理分散剂和抗氧化剂，降低EVA的气味和VOC；优选低气味低VOC的原材料，包括A料和B料主料、增塑剂、发泡剂、除醛剂、硅油等，并控制加工工艺和仓储时间，使PET+EVA+PU材料的汽车地毯气味和VOC水平稳定维持在标准范围内，不再出现反复超标的问题；通过严格控制PU发泡料的比例和增塑剂的添加量，使汽车地毯材料快回弹；本申请还降低了地毯PE防尘膜的气味，通过严格控制胶水纯度、施胶量和涂胶速度，有效降低PE防尘膜的气味，从而地毯降低总成的气味。
本发明针对局部覆盖空间避让60mm以上容易塌陷的地毯材料设计开发了一种独立发泡空间结构，在不影响散热器换风散热的基础上有效避免了地毯的塌陷。
为了进一步理解本发明，下面结合实施例对本发明提供的汽车地毯进行详细说明，本发明的保护范围不受以下实施例的限制。
实施例
将POE(低气味低乙醛的原料6102)、改性聚乙烯、白云石、滑石粉、分散剂、抗氧剂168和颜料按照表1中的配比放入转速300转/min的混料桶中10min混合均匀，再放入70～80℃烘料罐中烘烤15min，将得到的物料加热至200℃在挤出机上挤出，然后和PET毯面、水刺布热负荷，得到PET+EVA毯面；
将低散发聚醚多元醇(KONIX FA-703)、润滑剂(具体为EBS腊)、催化剂(DPA)、硅油、除醛剂(亨曼斯X094)和增塑剂(UN 488)按照表2的配比混合，得到A料，将A料和B料(巴斯夫CI2151 C-B)按照1:0.52的质量比混合，得到混合料；
在将PET+EVA毯面软化后放置在上模，在下模表面喷涂环保水性脱模剂，将混合料喷涂在下模上，控制下模温度为60～70℃，闭合模具300秒，发泡；
开模，得到EVA+PET+PU地毯总成，在防尘PE膜的一个表面涂覆高纯度丙烯酸酯(P-88W-Z)，将覆胶的防尘PE膜贴在EVA+PET+PU地毯总成表面；
将地毯总成放置在专门的晾料架上，放置2～3天，得到汽车地毯。
表1 EVA层原料配比数据表
编号 EVA POE 改性聚乙烯 白云石 滑石粉 分散剂 抗氧化剂
实施例1 0％ 5％ 40％ 50％ 3％ 1％ 0.1％
实施例2 0％ 10％ 30％ 50％ 3％ 1％ 0.1％
实施例3 0％ 15％ 25％ 50％ 3％ 1％ 0.1％
对比例1 45％ 0 0％ 50％ 3％ 1.5％ 0.2％
表2 PU发泡层原料配比数据表
注：表1和表2中的实施例1、实施例2和实施例3是EVA层和PU层原料不同下的实施例，对比例1表示EVA层的组分不同，但其他条件与实施例1相同，对比例2和对比例3表示PU发泡层的组分不同，但是其他条件与实施例1相同；EVA层中以颜料补齐100％，PU发泡层中以润滑剂EBS腊补齐100％。
表3汽车地毯EVA层性能对比表
表4汽车地毯的PU层性能对比表
对比例4
与实施例1相同，区别仅在于PE膜表面未涂覆高纯度丙烯酸酯胶，仅为普通PE膜。经对比，实施例1制备的汽车地毯的气味3.5级(80℃，2h)，本对比例制备的汽车地毯的气味为5.5级(80℃，2h)。
以上实施例的说明只是用于帮助理解本发明的方法及其核心思想。应当指出，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，还可以对本发明进行若干改进和修饰，这些改进和修饰也落入本发明权利要求的保护范围内。
对所公开的实施例的上述说明，使本领域专业技术人员能够实现或使用本发明。对这些实施例的多种修改对本领域的专业技术人员来说将是显而易见的，本文中所定义的一般原理可以在不脱离本发明的精神或范围的情况下，在其它实施例中实现。因此，本发明将不会被限制于本文所示的这些实施例，而是要符合与本文所公开的原理和新颖特点相一致的最宽的范围。

Claims (9)

1.一种汽车地毯，包括依次叠加设置的PE膜、PET毯面、EVA层、水刺布和PU发泡层；
所述EVA层的原料中由POE、改性聚乙烯、白云石、滑石粉、分散剂、抗氧剂和颜料组成；
所述PU发泡层由A料和B料制备得到，所述A料的原料包括低散发聚醚多元醇、润滑剂、催化剂、硅油、除醛剂和增塑剂，所述B料为异氰酸酯；所述PU发泡层中，所述低散发聚醚多元醇的含量为90～97wt％，所述润滑剂的含量为0.1～0.5wt％，所述催化剂的含量为1～5wt％，所述硅油的含量为1～5wt％，所述除醛剂的含量为0.4～0.8wt％，所述增塑剂的含量为0.1～0.5wt％；所述催化剂为反应型凝胶胺催化剂DPA；
所述PE膜的内表面设置有高纯度的丙烯酸酯胶。
2.根据权利要求1所述的汽车地毯，其特征在于，所述EVA层中，所述POE的含量为5～20wt％，所述改性聚乙烯的含量为20～40wt％，所述白云石的含量为50～70wt％，所述滑石粉的含量为1～5wt％，所述分散剂的含量为1～5wt％，所述抗氧剂的含量为0.01～0.2wt％。
3.根据权利要求1所述的汽车地毯，其特征在于，所述PU发泡层中，所述A料和所述B料的质量比为1：(0.5～0.8)。
4.根据权利要求1所述的汽车地毯，其特征在于，所述EVA层中，所述POE为低气味低乙醛原料6102，所述改性聚乙烯以马来酸酐接枝聚乙烯，所述分散剂为线性高分子增塑剂，所述抗氧剂选自抗氧剂168和抗氧剂1010中的一种或两种。
5.根据权利要求1所述的汽车地毯，其特征在于，所述PU发泡层中，所述增塑剂为线性高分子增塑剂UN-488。
6.根据权利要求1所述的汽车地毯，其特征在于，所述PE膜的表面涂胶量为50～60g/m2。
7.权利要求1所述的汽车地毯的制备方法，包括以下步骤：
将POE、改性聚乙烯、白云石、滑石粉、分散剂和抗氧剂混合、预加热后再加热、挤出，得到EVA层；
将所述PET毯面、EVA层和水刺布热复合，得到PET+EVA毯面；
将低发散聚醚多元醇、润滑剂、催化剂、硅油、除醛剂和增塑剂混合，得到A料，将A料和B料混合，得到混合料；
将所述混合料涂覆于下模上，将PET+EVA毯面软化后作为上模，闭合模具后发泡，得到EVA+PET+PU地毯总成；
将PT膜贴在所述地毯总成表面，得到汽车地毯。
8.一种散热器隔离空间结构，包括地毯表皮和散热器，所述地毯表皮和所述散热器之间不连续设置有若干汽车地毯，所述汽车地毯为权利要求1～6任一项所述的汽车地毯或权利要求7所述的制备方法所制备的汽车地毯。
9.根据权利要求8所述的散热器隔离空间结构，其特征在于，所述若干汽车地毯之间为进风空间或出风空间，所述地毯表皮和所述散热器之间的距离大于60mm。
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CN107538871A (zh) * 2017-07-25 2018-01-05 芜湖尚唯汽车饰件有限公司 一种轻量化隔音汽车内饰用发泡地毯及其生产工艺

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