CN115139608B - 一种汽车内饰包覆材料及其制备方法 - Google Patents
一种汽车内饰包覆材料及其制备方法 Download PDFInfo
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Abstract
本发明属于汽车内饰材料技术领域,涉及一种汽车内饰包覆材料,依次包括:聚丙烯泡棉、第一TPO层、第二TPO层和涂层。第一TPO层包括以下重量份原料:低密度聚乙烯:40~65份,聚丙烯:10~20份,乙烯‑辛烯共聚物:5~15份,三元乙丙橡胶:5~15份,聚硅氧烷:2~6份,无机填料:0~10份,助剂:0~3份。第二TPO层包括以下重量份原料:聚乙烯:40~65份,聚丙烯:10~20份,乙烯‑辛烯共聚物:5~15份,三元乙丙橡胶:5~15份,硬脂酸改性玻璃纤维:2~8份,无机填料:0~10份,助剂:0~3份。
Description
技术领域
本发明属于汽车内饰材料技术领域,涉及一种汽车内饰包覆材料及其制备方法。
背景技术
随着人们物质生活水平的逐渐提高,汽车产业链的迅速发展,人们对汽车的需求和依赖也越来越多,人们对汽车内饰个性化和多样化的视觉和触觉追求越来越明显。对于大部分首次购车者来说,优越的外观追求甚至要比性能要求高。舒适、豪华、高质感的汽车内饰成为了人们购车的选择条件之一。汽车内部的蒙皮是制作汽车内饰的重要材料,蒙皮的好坏决定了汽车内部装饰效果和质感的高低。因此,人们对汽车内饰个性化和多样化的视觉和触觉提出了更高的要求。
目前大多数汽车内饰,以硬塑为主,触感较硬,且气囊爆破区域表面有一道缝纫线类似的印记,目视效果不佳。
发明内容
本发明针对现有技术中的不足,提供一种汽车内饰包覆材料,赋予汽车内饰柔软的触感和高质感,满足人们个性化和多样化的需求。
本发明的一个目的通过以下技术方案来实现:
一种汽车内饰包覆材料,依次包括:聚丙烯泡棉、第一TPO层、第二TPO层和涂层。
作为优选,聚丙烯泡棉、第一TPO层、第二TPO层和涂层的厚度分别为1~4mm、0.1~0.5mm、0.1~0.5mm和8~30μm。
聚丙烯泡棉(PP泡棉)就是一种PP发泡材料,作为优选,PP泡棉密度为50~90kg/cm3,拉伸强度>6kg/cm2,撕裂强度>5kg/cm。PP泡棉可以选自映甫:EVHJ43/EVHJ53/EVHJ63,东丽:SR18 15025/15015,SR28 15020/15025/15030。
作为优选,第一TPO层包括以下重量份原料:
低密度聚乙烯:40~65份,
聚丙烯:10~20份,
乙烯-辛烯共聚物:5~15份,
三元乙丙橡胶:5~15份,
聚硅氧烷:2~6份,
无机填料:0~10份,
助剂:0~3份。
作为优选,低密度聚乙烯的密度为0.90~0.93g/cm3,熔点为105~112℃,190℃/2.16kg条件下熔融指数为1.0~5.0g/10min。
作为优选,聚硅氧烷的结构式为:
其中,R1、R2分别为H、C1-C6烷基中的一种,m为0~1000的整数。
第一TPO层的原料:聚丙烯、乙烯-辛烯共聚物、三元乙丙橡胶不做具体限制。
作为优选,第二TPO层包括以下重量份原料:
聚乙烯:40~65份,
聚丙烯:10~20份,
乙烯-辛烯共聚物:5~15份,
三元乙丙橡胶:5~15份,
硬脂酸改性玻璃纤维:2~8份,
无机填料:0~10份,
助剂:0~3份。
作为优选,硬脂酸改性玻璃纤维的制备方法包括以下步骤:
将玻璃纤维分散于无水乙醇中,然后加入硬脂酸和浓硫酸,加热回流反应2~4h,反应结束后,过滤、洗涤、干燥,得到硬脂酸改性玻璃纤维。
作为优选,硬脂酸与玻璃纤维的质量比为(5~20):1。
第二TPO层的原料:聚乙烯、聚丙烯、乙烯-辛烯共聚物、三元乙丙橡胶不做具体限制。
本发明第一TPO层和第二TPO层原料中的助剂优选为光稳定剂和润滑剂等,光稳定剂和润滑剂不做具体限制,其中光稳定剂列举为双(2,2,6,6-四甲基-4-哌啶基)癸二酸酯、3,5-二叔丁基-4-羟基-苯甲酸十六烷基酯、2-(2H-苯并三唑-2-基)-4-(1,1,3,3-四甲基丁基)-苯酚、2-[4,6-双(2,4-二甲基苯基)-1,3,5-三嗪-2-基]-5-(辛氧基)-苯酚、2-羟基-4-正辛氧基二苯甲酮、2-(2-羟基-3-叔丁基-5-甲基苯基)-5-氯代苯并三唑、2-(2-羟基-3,5双(a,a-二甲基苄基)苯基)苯并三唑、2,2'-(1,4-亚苯基)双-4H-3,1-苯并恶嗪-4-酮、2,4-二-叔丁基-6-(5-氯代苯并三唑-2-基)苯酚、2-氰基-3,3-二苯基丙烯酸乙酯等;润滑剂列举为硬脂酸、硬脂酸钙、硬脂酸锌、石蜡、N,N'-亚乙基双硬脂酰胺、聚乙烯蜡等。
本发明第一TPO层和第二TPO层原料中的无机填料也不做具体限制,可以列举为玻璃纤维、碳纤维、碳酸钙、云母、二氧化硅、硫酸钙、高岭土、碳化硅晶须、粘土、珍珠岩、滑石、硫酸钡等等。
如果仅采用单层TPO层,则该TPO层的一侧贴合聚丙烯泡棉,另一侧涂覆涂料,采用单层TPO层,很难做到TPO与PP泡棉和涂料同时具有优异的粘附性。因此,本发明将TPO层分成第一TPO层和第二TPO层,且第一TPO层和第二TPO层的原料不同,第一TPO层原料为:低密度聚乙烯、聚丙烯、乙烯-辛烯共聚物、三元乙丙橡胶、聚硅氧烷等,通过低密度聚乙烯和聚硅氧烷与其它组分的相互作用,获得的第一TPO层与PP泡棉具有优异的粘附性;第二TPO层采用的原料为:聚乙烯、聚丙烯、乙烯-辛烯共聚物、三元乙丙橡胶、硬脂酸改性玻璃纤维等,硬脂酸在挤出成型过程中较容易从材料内部迁移至表面,并在表面排列,玻璃纤维通过硬脂酸改性,在硬脂酸迁移至表面时,玻璃纤维也会一同迁移至材料表面,第二TPO层表面玻璃纤维的存在使得第二TPO层较容易粘附涂料,提高第二TPO层与涂层之间的附着性。
本发明的另一个目的通过以下技术方案来实现:
一种上述汽车内饰包覆材料的制备方法,包括以下步骤:
S1、将第一TPO层的原料按照配比混合,将第二TPO层的原料按照配比混合,然后分别加入单螺杆挤出机中,通过共挤出成型为第一TPO层和第二TPO层的复合层;
S2、将复合层与聚丙烯泡棉通过辊轮挤压贴合在一起,复合层的第一TPO层与聚丙烯泡棉贴合;
S3、在复合层的第二TPO层表面涂覆聚氨酯水性涂料,固化后形成涂层。
两台单螺杆挤出机的分成6个加工温度区,第一加工温度区:170~180℃,第二加工温度区:180~190℃,第三加工温度区:190~200℃,第四加工温度区:200~210℃,第五加工温度区:210~220℃,第六加工温度区:210~220℃;单螺杆挤出机转速为50~300r/min。
作为优选,聚氨酯水性涂料包括以下重量份原料:
水性聚氨酯分散体:70~90份,
水:10~20份,
异氰酸酯类固化剂:5~15份,
消泡剂:0.5~1.5份,
增稠剂:1~5份。
水性聚氨酯分散体可以列举为大日精华D-1916PNV、大日精华D-1918PNV、大日精华D-8620、斯塔尔WF-43-025、斯塔尔WF-13-789、斯塔尔EVO WF-3800。
消泡剂可以列举为大日精化D-72D、斯塔尔DF-2459、斯塔尔DF-2903。
增稠剂可以列举为大日精华D-890T、斯塔尔RM-4456、斯塔尔RM-13-622。
异氰酸酯类固化剂可以列举为大日精华D-59C、大日精华D-501、斯塔尔XR-5580、斯塔尔XR-13-554。
按上述重量份称取水性聚氨酯分散体、异氰酸酯类固化剂、消泡剂、增稠剂和水,经混合后形成聚氨酯水性涂料。
将聚氨酯水性涂料涂覆于复合层的第二TPO层表面,具体涂覆方法如下所述:
将聚氨酯水性涂料经过内部的循环装置使用管道输送至滚胶槽中,上胶辊浸入滚胶槽中使其表面填满水性涂料,同时上胶辊表面使用刮刀刮出多余的聚氨酯水性涂料使其上胶辊表面带有定量的聚氨酯水性涂料。上胶辊上方为橡胶辊,其与上胶辊产生相对移动,当待涂覆产品经过上胶辊与橡胶辊时,上胶辊与橡胶辊处于关闭状态,并相对转动,让上胶辊表面的聚氨酯水性涂料均匀地辊涂至第二TPO层表面。然后经过烘箱加热至(135~160)℃将表面的涂料烘干,然后冷却至室温。聚氨酯水性涂料涂布于第二TPO层表面的流程参见图1。
与现有技术相比,本发明具有以下有益效果:
(1)本发明提供的汽车内饰包覆材料,依次包括:聚丙烯泡棉、第一TPO层、第二TPO层和涂层,采用不同材料分别制备第一TPO层和第二TPO层,可以提高TPO层与PP泡棉以及TPO层与涂层之间的粘附性,层与层之间结合牢固,提高产品使用寿命;
(2)本发明第一TPO层中通过添加低密度聚乙烯和聚硅氧烷与其它组分相互作用,获得的第一TPO层与PP泡棉具有优异的粘附性;
(3)本发明第二TPO层中添加硬脂酸改性玻璃纤维,硬脂酸改性玻璃纤维迁移至材料表面,使得第二TPO层较容易粘附涂料,提高第二TPO层与涂层之间的附着性;
(4)本发明提供的汽车内饰包覆材料应用于硬塑表面,其中PP泡棉可以起到隔音、缓冲的效果,涂层可以有效保护TPO表皮增强TPO的耐刮擦性,抵抗各种化学试剂的腐蚀且提高质感;
(5)本发明提供的汽车内饰包覆材料应用于硬塑表面,提供软质的触感,增强人们的优质体验感,满足人们个性化和多样化的需求。
附图说明
图1为聚氨酯水性涂料涂布于第二TPO层表面的流程示意图。
具体实施方式
下面通过具体实施例,对本发明的技术方案作进一步描述说明,应当理解的是,此处所描述的具体实施例仅用于帮助理解本发明,不用于本发明的具体限制。如果无特殊说明,本发明的实施例中所采用的原料均为本领域常用的原料,实施例中所采用的方法,均为本领域的常规方法。
以下实施例和对比例中,采用的低密度聚乙烯为燕山石化:LD200BW;PP泡棉为东丽:SR18 15025;聚硅氧烷为聚二甲基硅氧烷,购买至道康宁有限公司;聚丙烯为中石化T30S;聚乙烯为日本三井3300F;乙烯-辛烯共聚物为沙特C0570D;三元乙丙橡胶为三井5033NHS;水性聚氨酯分散体为大日精华:D-1916PNV;异氰酸酯类固化剂为大日精华D-59C;消泡剂为大日精化:D-72D;增稠剂为大日精华:D-890T。
采用的硬脂酸改性玻璃纤维通过以下制备方法制备而得:将100g玻璃纤维分散于10L无水乙醇中,800r/min搅拌1h,然后加入1000g硬脂酸和1L 98%浓硫酸,800r/min搅拌条件下,于80℃加热回流反应3h,反应结束后,过滤、洗涤、干燥,得到硬脂酸改性玻璃纤维。
实施例1
本实施的汽车内饰包覆材料依次包括聚丙烯泡棉、第一TPO层、第二TPO层和涂层。
第一TPO层由以下重量份原料制备而得:低密度聚乙烯:45份,聚丙烯:20份,乙烯-辛烯共聚物:14份,三元乙丙橡胶:13份,聚二甲基硅氧烷:6份,2-[4,6-双(2,4-二甲基苯基)-1,3,5-三嗪-2-基]-5-(辛氧基)-苯酚:1份,硬脂酸锌:1份。
第二TPO层由以下重量份原料制备而得:聚乙烯:45份,聚丙烯:20份,乙烯-辛烯共聚物:14份,三元乙丙橡胶:13份,硬脂酸改性玻璃纤维:6份,2-[4,6-双(2,4-二甲基苯基)-1,3,5-三嗪-2-基]-5-(辛氧基)-苯酚:1份,硬脂酸锌:1份。
本实施的汽车内饰包覆材料由以下步骤制备而得:
S1、分别将第一TPO层和第二TPO层的原料按照配比混合后,分别加入单螺杆挤出机中,通过共挤出成型为第一TPO层(厚度为0.2mm)和第二TPO层(厚度为0.2mm)的复合层;
S2、将复合层与聚丙烯泡棉(厚度为2mm)通过辊轮挤压贴合在一起,复合层的第一TPO层与聚丙烯泡棉贴合;
S3、在复合层的第二TPO层表面涂覆聚氨酯水性涂料,固化后形成涂层(厚度为10μm)。
两台单螺杆挤出机的分成6个加工温度区,第一加工温度区:170℃,第二加工温度区:180℃,第三加工温度区:190℃,第四加工温度区:200℃,第五加工温度区:210℃,第六加工温度区:210℃;单螺杆挤出机转速为100r/min。
步骤S3的聚氨酯水性涂料由以下重量份原料混合形成:水性聚氨酯分散体:70份,水:12份,异氰酸酯类固化剂:6份,消泡剂:0.8份,增稠剂:2份。
实施例2
本实施的汽车内饰包覆材料依次为聚丙烯泡棉、第一TPO层、第二TPO层和涂层。
第一TPO层由以下重量份原料制备而得:低密度聚乙烯:50份,聚丙烯:15份,乙烯-辛烯共聚物:10份,三元乙丙橡胶:12份,聚二甲基硅氧烷:5份,碳酸钙:6份,双(2,2,6,6-四甲基-4-哌啶基)癸二酸酯:1份,硬脂酸钙:1份。
第二TPO层由以下重量份原料制备而得:聚乙烯:50份,聚丙烯:15份,乙烯-辛烯共聚物:10份,三元乙丙橡胶:12份,硬脂酸改性玻璃纤维:5份,碳酸钙:6份,双(2,2,6,6-四甲基-4-哌啶基)癸二酸酯:1份,硬脂酸钙:1份。
本实施的汽车内饰包覆材料由以下步骤制备而得:
S1、分别将第一TPO层和第二TPO层的原料按照配比混合后,分别加入单螺杆挤出机中,通过共挤出成型为第一TPO层(厚度为0.3mm)和第二TPO层(厚度为0.3mm)的复合层;
S2、将复合层与聚丙烯泡棉(厚度为3mm)通过辊轮挤压贴合在一起,复合层的第一TPO层与聚丙烯泡棉贴合;
S3、在复合层的第二TPO层表面涂覆聚氨酯水性涂料,固化后形成涂层(厚度为15μm)。
两台单螺杆挤出机的分成6个加工温度区,第一加工温度区:175℃,第二加工温度区:185℃,第三加工温度区:195℃,第四加工温度区:205℃,第五加工温度区:215℃,第六加工温度区:215℃;单螺杆挤出机转速为120r/min。
步骤S3的聚氨酯水性涂料由以下重量份原料混合形成:水性聚氨酯分散体:80份,水:15份,异氰酸酯类固化剂:8份,消泡剂:1份,增稠剂:2.5份。
实施例3
本实施的汽车内饰包覆材料依次为聚丙烯泡棉、第一TPO层、第二TPO层和涂层。
第一TPO层由以下重量份原料制备而得:低密度聚乙烯:65份,聚丙烯:12份,乙烯-辛烯共聚物:8份,三元乙丙橡胶:8份,聚二甲基硅氧烷:4份,3,5-二叔丁基-4-羟基-苯甲酸十六烷基酯:1.5份,聚乙烯蜡:1.5份。
第二TPO层由以下重量份原料制备而得:聚乙烯:65份,聚丙烯:12份,乙烯-辛烯共聚物:8份,三元乙丙橡胶:8份,硬脂酸改性玻璃纤维:4份,3,5-二叔丁基-4-羟基-苯甲酸十六烷基酯:1.5份,聚乙烯蜡:1.5份。
本实施的汽车内饰包覆材料由以下步骤制备而得:
S1、分别将第一TPO层和第二TPO层的原料按照配比混合后,分别加入单螺杆挤出机中,通过共挤出成型为第一TPO层(厚度为0.4mm)和第二TPO层(厚度为0.4mm)的复合层;
S2、将复合层与聚丙烯泡棉(厚度为4mm)通过辊轮挤压贴合在一起,复合层的第一TPO层与聚丙烯泡棉贴合;
S3、在复合层的第二TPO层表面涂覆聚氨酯水性涂料,固化后形成涂层(厚度为20μm)。
两台单螺杆挤出机的分成6个加工温度区,第一加工温度区:180℃,第二加工温度区:190℃,第三加工温度区:200℃,第四加工温度区:210℃,第五加工温度区:220℃,第六加工温度区:220℃;单螺杆挤出机转速为80r/min。
步骤S3的聚氨酯水性涂料由以下重量份原料混合形成:水性聚氨酯分散体:90份,水:20份,异氰酸酯类固化剂:12份,消泡剂:1.3份,增稠剂:4份。
对比例1
对比例1与实施例1的区别在于:对比例1的第二TPO层原料采用玻璃纤维替代硬脂酸改性玻璃纤维,其它与实施例1相同。
对比例2
对比例2与实施例1的区别在于:对比例2的第一TPO层原料采用聚乙烯替代低密度聚乙烯,且不加聚二甲基硅氧烷,其它与实施例1相同。
对比例3
对比例3的汽车内饰包覆材料依次为聚丙烯泡棉、第一TPO层和涂层。
第一TPO层由以下重量份原料制备而得:低密度聚乙烯:45份,聚丙烯:20份,乙烯-辛烯共聚物:14份,三元乙丙橡胶:13份,聚二甲基硅氧烷:6份,2-[4,6-双(2,4-二甲基苯基)-1,3,5-三嗪-2-基]-5-(辛氧基)-苯酚:1份,硬脂酸锌:1份。
对比例3的汽车内饰包覆材料由以下步骤制备而得:
S1、将第一TPO层的原料按照配比混合后,加入单螺杆挤出机中,挤出成型为第一TPO层(厚度为0.4mm);
S2、将第一TPO层与聚丙烯泡棉(厚度为2mm)通过辊轮挤压贴合在一起;
S3、在第一TPO层的另一表面(即未贴合聚丙烯泡棉的表面)涂覆聚氨酯水性涂料,固化后形成涂层(厚度为10μm)。
螺杆挤出机的加工温度、挤出机转速,以及氨酯水性涂料同实施例1。
对比例4
对比例4的汽车内饰包覆材料依次为聚丙烯泡棉、第二TPO层和涂层。
第二TPO层由以下重量份原料制备而得:聚乙烯:45份,聚丙烯:20份,乙烯-辛烯共聚物:14份,三元乙丙橡胶:13份,硬脂酸改性玻璃纤维:6份,2-[4,6-双(2,4-二甲基苯基)-1,3,5-三嗪-2-基]-5-(辛氧基)-苯酚:1份,硬脂酸锌:1份。
对比例4的汽车内饰包覆材料由以下步骤制备而得:
S1、将第二TPO层的原料按照配比混合后,加入单螺杆挤出机中,挤出成型为第二TPO层(厚度为0.4mm);
S2、将第二TPO层与聚丙烯泡棉(厚度为2mm)通过辊轮挤压贴合在一起;
S3、在第二TPO层的另一表面(即未贴合聚丙烯泡棉的表面)涂覆聚氨酯水性涂料,固化后形成涂层(厚度为10μm)。
螺杆挤出机的加工温度、挤出机转速,以及氨酯水性涂料同实施例1。
按照标准GMW14122 3.2.12GMW3220检测实施例1-3以及对比例1-4的汽车内饰包覆材料的TPO层与PP泡棉的附着性,结果如表1所示。按照GMW14122 3.3.7GMW3402/GMW15377检测实施例1-3以及对比例1-4的汽车内饰包覆材料的TPO层与表面涂层的粘附性,结果如下表2所示。
表1
实施例 | 标准要求:>6N/5cm |
实施例1 | 46 |
实施例2 | 48 |
实施例3 | 44 |
对比例1 | 45 |
对比例2 | 28 |
对比例3 | 47 |
对比例4 | 25 |
表2
从表1和表2可以看出,本发明实施例1-3采用不同材料制备第一TPO层和第二TPO层,可以提高TPO层与PP泡棉以及TPO层与涂层之间的粘附性,层与层之间结合牢固,提高产品使用寿命。对比例2和对比例4的TPO层与PP泡棉粘附性较差,对比例1和对比例3的TPO层与表面涂层的粘附性较差。
最后应说明的是,本文中所描述的具体实施例仅仅是对本发明精神作举例说明,而并非对本发明的实施方式的限定。本发明所属技术领域的技术人员可以对所描述的具有实施例做各种各样的修改或补充或采用类似的方式替代,这里无需也无法对所有的实施方式予以全例。而这些属于本发明的实质精神所引申出的显而易见的变化或变动仍属于本发明的保护范围,把它们解释成任何一种附加的限制都是与本发明精神相违背的。
Claims (8)
1.一种汽车内饰包覆材料,其特征在于,依次包括:聚丙烯泡棉、第一TPO层、第二TPO层和涂层;
第一TPO层包括以下重量份原料:
低密度聚乙烯:40~65份,
聚丙烯:10~20份,
乙烯-辛烯共聚物:5~15份,
三元乙丙橡胶:5~15份,
聚硅氧烷:2~6份,
无机填料:0~10份,
助剂:0~3份;
第二TPO层包括以下重量份原料:
聚乙烯:40~65份,
聚丙烯:10~20份,
乙烯-辛烯共聚物:5~15份,
三元乙丙橡胶:5~15份,
硬脂酸改性玻璃纤维:2~8份,
无机填料:0~10份,
助剂:0~3份。
2.根据权利要求1所述的汽车内饰包覆材料,其特征在于,聚丙烯泡棉、第一TPO层、第二TPO层和涂层的厚度分别为1~4mm、0.1~0.5mm、0.1~0.5mm和8~30μm。
3.根据权利要求1所述的汽车内饰包覆材料,其特征在于,低密度聚乙烯的密度为0.90~0.93g/cm3,熔点为105~112℃,190℃/2.16kg条件下熔融指数为1.0~5.0g/10min。
5.根据权利要求1所述的汽车内饰包覆材料,其特征在于,硬脂酸改性玻璃纤维的制备方法包括以下步骤:
将玻璃纤维分散于无水乙醇中,然后加入硬脂酸和浓硫酸,加热回流反应2~4h,反应结束后,过滤、洗涤、干燥,得到硬脂酸改性玻璃纤维。
6.根据权利要求5所述的汽车内饰包覆材料,其特征在于,硬脂酸与玻璃纤维的质量比为(5~20):1。
7.一种如权利要求1所述的汽车内饰包覆材料的制备方法,其特征在于,包括以下步骤:
S1、将第一TPO层的原料按照配比混合,将第二TPO层的原料按照配比混合,然后分别加入单螺杆挤出机中,通过共挤出成型为第一TPO层和第二TPO层的复合层;
S2、将复合层与聚丙烯泡棉通过辊轮挤压贴合在一起,复合层的第一TPO层与聚丙烯泡棉贴合;
S3、在复合层的第二TPO层表面涂覆聚氨酯水性涂料,固化后形成涂层。
8.根据权利要求7所述的制备方法,其特征在于,聚氨酯水性涂料包括以下重量份原料:
水性聚氨酯分散体:70~90份,
水:10~20份,
异氰酸酯类固化剂:5~15份,
消泡剂:0.5~1.5份,
增稠剂:1~5份。
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