CN115320185A - 用于汽车内饰材料的椰竹混合纤维复合材料及其制备方法 - Google Patents
用于汽车内饰材料的椰竹混合纤维复合材料及其制备方法 Download PDFInfo
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Abstract
本发明提供了一种用于汽车内饰材料的椰竹混合纤维复合材料及其制备方法，属于汽车内饰材料技术领域。本发明提供的用于汽车内饰材料的椰竹混合纤维复合材料包括椰竹混合纤维毡层；其中，所述椰竹混合纤维毡层为椰棕纤维和竹纤维的混合纤维与有油/无油聚丙烯短纤维经开松、打散、充分混合梳理形成互相勾连在一起的纤维网后，通过针刺为密实毡材而成。本发明提供的用椰竹混合纤维与有油/无油聚丙烯短纤维生产所得的椰竹混合纤维复合材料防腐、防霉、防臭、抗菌、除螨和抗紫外线，并且性价比高，相比用竹纤维与普通聚丙烯短纤维生产的复合材料而言，原料成本低，对人体无害且在气味方面具有显著优势。
Description
技术领域
本发明属于汽车内饰材料技术领域，尤其涉及到一种用于汽车内饰材料的椰竹混合纤维复合材料及其制备方法。
背景技术
目前，汽车内饰材料主要是麻纤板、玻纤板和竹纤板，麻纤板是用麻纤维与聚丙烯短纤维混合，针刺成麻纤毡，然后用压板机压成的板材，麻纤维易发生霉变、产生霉味，影响环境和板材性能；玻纤板是用玻璃纤维与聚丙烯短纤维混合，针刺成玻纤毡，然后用压板机压成的板材，玻璃纤维比重大，不利于汽车轻量化，且玻璃纤维难降解，不利于环保，玻璃纤维对人体皮肤和呼吸道有刺激作用，对人体有害，因此，玻纤板在逐渐被麻纤板或竹纤板取代；竹纤板是用竹纤维与聚丙烯短纤维混合，针刺成竹纤毡，然后用压板机压成的板材，竹纤板具有天然抗菌、抑菌、除螨、防臭和抗紫外线功能，拥有麻纤板和玻纤板无法比拟的优异特性，竹纤维原料价格较贵，竹纤板生产成本较高。因此，如何提供一种对人体无害、在气味上相比麻纤维或玻璃纤维与普通聚丙烯短纤维生产的复合材料，具有明显优势且性价比高的，能够在物理性能上完全能满足汽车内饰材料要求的材料，这将是本领域亟需解决的重要问题。
发明内容
本发明提供了一种用于汽车内饰材料的椰竹混合纤维复合材料及其制备方法，用椰棕纤维、竹纤维与有油/无油聚丙烯短纤维生产所得的椰竹混合纤维复合材料防腐、防霉、防臭、抗菌、除螨和抗紫外线，并且性价比高，相比用麻纤维或玻璃纤维与普通聚丙烯短纤维生产的复合材料而言，对人体无害且在气味上具有显著优势，比纯竹纤维复合材料在原料成本上有不同幅度的降低。
为了达到上述目的，本发明提供了一种用于汽车内饰材料的椰竹混合纤维复合材料，包括椰竹混合纤维毡层；
其中，所述椰竹混合纤维毡层为椰棕纤维和竹纤维的混合纤维与有油/无油聚丙烯短纤维经开松、打散、充分混合梳理形成互相勾连在一起的纤维网后，通过针刺形成的密实毡材。
在上述方案中，所使用的无油聚丙烯短纤维为吉林省华纺静电材料科技有限公司生产的2D-10D无油聚丙烯短纤维，对于不同线密度的纤维而言，需要满足的不同技术要求如表1所示。
表1无油聚丙烯短纤维的技术要求
作为优选，所述椰竹混合纤维毡层的至少一面覆有无纺布或水刺布。
作为优选，所述椰竹混合纤维毡层的至少一面覆有可针刺的无纺布时，可针刺的无纺布通过针刺的方式刺在椰竹混合纤维毡层上。
作为优选，所述椰竹混合纤维毡层的至少一面覆有不可针刺的无纺布或水刺布时，椰竹混合纤维毡层与无纺布或水刺布之间覆有胶膜层。
在上述方案中，根据汽车内饰件制造商的需要，大多需要提供的是混合纤维复合板材，这就需要把混合纤维毡用压板机压成一定厚度的板材，板材表面要求有或无无纺布或水刺布，然后用板材再去压型。此时，根据客户的不同要求，可以选用可针刺的无纺布，这就需要把无纺布针刺到毡材上，然后压板；当然，也可以选用不可针刺的无纺布，这就同时需要胶膜，以通过胶膜将无纺布附着到混合纤维毡上。
作为优选，所述椰竹混合纤维毡层中，所加入的混合纤维的重量为混合纤维和有油/无油聚丙烯短纤维总重量的70-30％，所加入的有油/无油聚丙烯短纤维的重量为总重量的30-70％。
作为优选，为了区别于竹纤维复合材料和椰棕纤维复合材料，所述混合纤维中，椰棕纤维的重量为混合纤维重量的10-60％，竹纤维的重量为混合纤维重量的10-60％。具体的，在混合纤维中，椰棕纤维或竹纤维的重量可以为10％、15％、20％、25％、30％、35％、40％、45％、50％、55％、60％或上述范围内的任意点值，可根据需要进行调整。
在上述方案中，混合纤维与有油/无油聚丙烯短纤维混合时，若混合纤维占比过低，则混合纤维的优异性能难以发挥作用；若聚丙烯短纤维占比过低，则压板后板材中混合纤维之间的粘结力不够，板材强度低。而如果在上述设定范围内，则既能保证混合纤维板具有一定的防腐、防霉、防臭、抗菌、除螨和抗紫外线功能，又能保证混合纤维板具有一定的强度，可有效满足汽车内饰件生产商的需求。
进一步，对于混合纤维中的椰棕纤维和竹纤维的用量也需要符合要求，若椰棕纤维占比过低，竹纤维占比过高，则混合纤维同纯竹纤维已没有明显的差别，实际上属于竹纤维复合材料的范畴；若椰棕纤维占比过高，竹纤维占比过低，则混合纤维同纯椰棕纤维没有明显的差别，实际上属于椰棕纤维复合材料范畴。
本发明可以做500-3000g/㎡之间的任何克重的椰竹混合纤维复合材料，厚度可以按照用户的要求来做，表2中列出了部分椰竹混合复合材料所满足的技术指标。
表2常用椰竹混合纤维复合材料的技术指标
本发明提供了根据权利要求上述任一项技术方案所述的椰竹混合纤维复合板材的制备方法，包括以下步骤：
将椰竹混合纤维毡层按要求放在压板机自动上料设备对应的转轴上，经切割成需要的长度后，自动落到输送帘上，输送帘将其先送入压板机热压区，聚丙烯短纤维遇热熔化，把椰棕纤维和竹纤维粘结在一起的热板材，然后送入压板机冷压区进行冷却固化，得到椰竹混合纤维复合板材。
作为优选，在放置椰竹混合纤维毡层时，还包括根据需要放置可针刺的无纺布、或者胶膜和不可针刺的无纺布或水刺布的步骤。
作为优选，压板机热压区的温度为200-260℃，压板机冷压区的温度为5-30℃。
作为优选，所述椰竹混合纤维毡通过以下方法制备得到：
将椰棕纤维、竹纤维和有油/无油聚丙烯短纤维分别投入到开包机中，经打散后，将三者分别定量、重叠地落到开松机喂入帘上，经开松后，对混合在一起的椰棕纤维、竹纤维和有油/无油聚丙烯短纤维进行除尘，然后被风依次送入气压棉箱和储棉箱，得到混合纤维；
将混合纤维进行梳理后，形成互相勾连在一起的纤维网，将纤维网往复铺叠在铺网机底帘上，然后喂入针刺机，经针刺形成密实的毡材后，根据需要切成一定的幅宽和长度，成卷收集，得到椰竹混合纤维毡。
作为优选，所述无油聚丙烯短纤维采用CN109868515B中方法制备得到，具体为：
将聚丙烯原料加入到挤压机中，形成初生纤维后，初生纤维经过油剂辊、导丝辊、一道牵伸机、二道牵伸机、三道牵伸机、叠丝机、卷曲机、热定型机后得到纤维丝束，纤维丝束通过切断机，得到无油聚丙烯短纤维；其中，所述油剂辊处所上油剂用水替代，并在油剂辊和导丝辊之间、二道牵伸机处、三道牵伸机处、卷曲机前端分别加设喷水单元以向纤维丝束喷水以及在热定型机尾端加设喷雾单元以向纤维丝束喷水雾；
所述喷水单元包括水箱、水泵、接水槽和喷头，水箱中的水经由水泵泵送至喷头，利用喷头将水流喷向纤维丝束整体表面，未被纤维丝束带走的水经由接水槽返回水箱；所述喷雾单元包括水箱、水泵和喷头，水箱中的水经由水泵泵送至喷头，并在压缩空气作用下经由喷头将水雾喷向纤维丝束表面。
与现有技术相比，本发明的优点和积极效果在于：
1、椰棕纤维是从椰子外壳提取出来的丝状物质，是绿色环保的纯天然产品，混合纤维可以降解，有利于环保，椰棕纤维的使用是一种废物再利用的过程；
2、椰棕纤维是天然保健产品，具有防潮、透气、抑菌的功效，加入椰棕纤维生产的复合材料有透气、防腐、不变形、防虫蛀、不闷热等优点，使用寿命长，对人体无害无刺激；从特性上看，椰棕纤维具有与竹纤维极其相似的功效，外观性状也基本相同，但椰棕纤维的价格便宜，大约是竹纤维价格的一半，用椰棕纤维取代部分竹纤维，去加工生产一种新型复合材料，既能降低成本，又能保持竹纤维复合材料的某些特性。
3、本发明用棕纤维与竹纤维和有油/无油聚丙烯短纤维按一定的比例混合，然后针刺成混合纤维复合毡材，通过压板机把毡材压成板材，可具有椰棕纤维和竹纤维的很多原始性能，例如防潮、防腐、防虫蛀、透气、抗菌、抑菌、除螨、防臭和抗紫外线等，具有天然保健功能，比麻纤板和玻纤板有明显的优点，完全可以与竹纤板相媲美，且价格优势明显，在物理性能上也可完全满足汽车内饰材料的要求。
4、本发明提供的混合纤维复合材料使用的聚丙烯短纤维是无油剂的，是本公司自主研发的，其纤维气味低，在与混合纤维混合生产复合材料时，在气味上明显好于用普通(有油)聚丙烯短纤维生产的复合材料，更符合汽车行业对气味的要求。
具体实施方式
下面将对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例1椰竹混合纤维毡的制备
将椰棕纤维、竹纤维和无油聚丙烯短纤维分别投入到开包机中，经打散后，将三者分别定量、重叠地落到开松机喂入帘上，经开松后，对混合在一起的椰棕纤维、竹纤维和有油/无油聚丙烯短纤维进行除尘，然后被风依次送入气压棉箱和储棉箱，得到混合纤维；
将混合纤维进行梳理后，形成互相勾连在一起的纤维网，将纤维网往复铺叠在铺网机底帘上，然后喂入针刺机，经针刺形成密实的毡材后，根据需要切成一定的幅宽和长度，成卷收集，得到椰竹混合纤维毡。
实施例2
在实施例1制备方法中，所加入的混合纤维的重量为混合纤维和无油聚丙烯短纤维总重量的30％，所加入的无油聚丙烯短纤维的重量为总重量的70％，其中，椰棕纤维的重量为混合纤维重量的10％，竹纤维的重量为混合纤维重量的20％。
实施例3
在实施例1制备方法中，所加入的混合纤维的重量为混合纤维和无油聚丙烯短纤维总重量的50％，所加入的无油聚丙烯短纤维的重量为总重量的50％，其中，椰棕纤维的重量为混合纤维重量的25％，竹纤维的重量为混合纤维重量的25％。
实施例4
在实施例1制备方法中，所加入的混合纤维的重量为混合纤维和无油聚丙烯短纤维总重量的60％，所加入的无油聚丙烯短纤维的重量为总重量的40％，其中，椰棕纤维的重量为混合纤维重量的40％，竹纤维的重量为混合纤维重量的20％。
实施例5
在实施例1制备方法中，所加入的混合纤维的重量为混合纤维和无油聚丙烯短纤维总重量的70％，所加入的无油聚丙烯短纤维的重量为总重量的30％，其中，椰棕纤维的重量为混合纤维重量的60％，竹纤维的重量为混合纤维重量的10％。
对比例1
在实施例1制备方法中，所加入的混合纤维的重量为混合纤维和无油聚丙烯短纤维总重量的20％，所加入的无油聚丙烯短纤维的重量为总重量的80％，其中，椰棕纤维的重量为混合纤维重量的0％，竹纤维的重量为混合纤维重量的20％。
对比例2
在实施例1制备方法中，所加入的混合纤维的重量为混合纤维和无油聚丙烯短纤维总重量的80％，所加入的无油聚丙烯短纤维的重量为总重量的20％，其中，椰棕纤维的重量为混合纤维重量的60％，竹纤维的重量为混合纤维重量的20％。
实施例6椰竹混合纤维复合板材的制备
将实施例2制备的混合纤维毡放在压板机自动上料设备对应的转轴上，经切割成需要的长度后，自动落到输送帘上，输送帘将其先送入压板机热压区，聚丙烯短纤维在200-260℃高温下熔化，把椰棕纤维和竹纤维粘结在一起的热板材，然后送入压板机冷压区于5-30℃进行冷却固化，得到椰竹混合纤维复合板材。
实施例7
制备方法同实施例6，区别在于，采用的是实施例3制备的混合纤维毡。
实施例8
制备方法同实施例6，区别在于，采用的是实施例4制备的混合纤维毡。
实施例9
制备方法同实施例6，区别在于，采用的是实施例5制备的混合纤维毡。
对比例3
制备方法同实施例6，区别在于，采用的是对比例1制备的混合纤维毡。
对比例4
制备方法同实施例6，区别在于，采用的是对比例2制备的混合纤维毡。
实施例10
制备方法同实施例6，区别在于，将混合纤维毡(已针刺无纺布)放在压板机自动上料设备对应的转轴上。
实施例11
制备方法同实施例6，区别在于，按混合纤维毡、胶膜、不可针刺的无纺布或水刺布的顺序分别放在压板机自动上料设备对应的转轴上。
实施例12
制备方法同实施例6，区别在于，按胶膜、混合纤维毡(已针刺无纺布)的顺序分别放在压板机自动上料设备对应的转轴上
实施例13
制备方法同实施例6，区别在于，按胶膜、混合纤维毡、胶膜、不可针刺的无纺布或水刺布的顺序分别放在压板机自动上料设备对应的转轴上。
性能测试
1、以克重为1800g/㎡，厚度为5.0mm板材为例，对实施例6-11制备的椰竹混合纤维复合材料的物理性能进行对比，对比数据如表3所示。
表3不同实施例制备的椰竹混合纤维复合材料性能对比
说明：因为竹纤维复合板材和椰竹混合纤维复合板材没有国家或行业标准，本发明参考的是麻纤板的有关行业标准。
基于表3数据可知，在本申请椰棕纤维、竹纤维与无油聚丙烯短纤维的重量设定范围内制备得到的混合纤维复合材料的物理性能对比参考标准来看，具有显著改善，聚丙烯短纤维含量越高，板材抗弯强度和拉伸强度越高，尺寸变化率越低，吸水率越低；而未在设定范围内制备得到的混合纤维复合材料的物理性能则在某些方面并不能完全能满足汽车内饰材料的要求，对比例1制备的板材，抗弯强度、拉伸强度、尺寸变化率、吸水率等指标特别好，但是，因为混合纤维含量太低，聚丙烯短纤维含量太高，聚丙烯短纤维熔化后，所占空间体积急剧变小，所以，板材厚度无法达到要求；对比例2制备的板材，因为聚丙烯短纤维含量太低，椰竹混合纤维含量太高，聚丙烯短纤维熔化后，不足以把椰棕和竹纤维充分的粘结在一起，部分椰棕和竹纤维处于自由松散状态，所以板材在抗弯强度、拉伸强度、吸水率等方面都不能满足要求，同时由于混合纤维含量高，板材的气味主要就取决于混合纤维的气味，气味相应增大。
2、以克重为1800g/㎡，厚度为5.0mm板材为例，对竹纤板和椰竹混合纤维板、普通混合纤维板的物理性能进行对比，对比数据如表4所示，其中：
竹纤板：无油聚丙烯短纤维50％，竹纤维50％；
椰竹混合纤维板：无油聚丙烯短纤维50％，椰棕纤维25％、竹纤维25％；
普通混合纤维板：有油聚丙烯短纤维50％，椰棕纤维25％、竹纤维25％；
表4 1800g/㎡不同板材的物理性能指标
结合表4数据可知，椰竹混合纤维板在抗弯强度、拉伸强度、尺寸变化率、吸水率等方面与竹纤板和用有油聚丙烯短纤维生产的普通混合纤维板非常接近，竹纤板、椰竹混合纤维板在气味上相同，比普通混合纤维板气味低至少0.5个等级，原因是有油聚丙烯短纤维含有油剂，油剂本身有一定的气味。因此加入椰棕的椰竹复合材料在性能上可与单一竹纤维生产的复合材料相媲美，如同对表3数据的分析，对比例3和对比例4制备的复合材料存在相同的问题。
按目前市场价格，竹纤维价格大约7800元/吨，椰棕价格大约4000元/吨，聚丙烯短纤维价格大约11000元/吨。根据原料配比不同，椰竹混合纤维复合材料的原料成本要比竹纤维复合材料有不同程度的降低，对于生产企业来说，会带来可观的经济效益，详细情况见表5。
表5椰竹纤维复合材料与竹纤维复合材料原料成本比较
综上可见，从性能上看，椰竹混合纤维材料对人体无害且在气味上具有显著优势，完全能满足客户需求。
从经济效益(原料成本)看，椰棕与竹纤维总占比越少，原料成本越高，椰棕在椰棕和竹纤维的混合纤维中的占比越少，原料成本越高，随着椰棕在原料中的占比增加，原料成本明显降低。
Claims (10)
1.用于汽车内饰材料的椰竹混合纤维复合材料，其特征在于，包括椰竹混合纤维毡层；
其中，所述椰竹混合纤维毡层为椰棕纤维和竹纤维的混合纤维与有油/无油聚丙烯短纤维经开松、打散、充分混合梳理形成互相勾连在一起的纤维网后，通过针刺为密实毡材而成。
2.根据权利要求1所述的椰竹混合纤维复合材料，其特征在于，所述椰竹混合纤维毡层的至少一面覆有无纺布或水刺布。
3.根据权利要求2所述的椰竹混合纤维复合材料，其特征在于，所述椰竹混合纤维毡层的至少一面覆有可针刺的无纺布时，可针刺的无纺布通过针刺的方式刺在椰竹混合纤维毡层上。
4.根据权利要求2所述的椰竹混合纤维复合材料，其特征在于，所述椰竹混合纤维毡层的至少一面覆有不可针刺的无纺布或水刺布时，椰竹混合纤维毡层与无纺布或水刺布之间覆有胶膜层。
5.根据权利要求1-4任一项所述的椰竹混合纤维复合材料，其特征在于，所述椰竹混合纤维毡层中，所加入的混合纤维的重量为混合纤维和有油/无油聚丙烯短纤维总重量的70-30％，所加入的有油/无油聚丙烯短纤维的重量为总重量的30-70％。
6.根据权利要求5所述的椰竹混合纤维复合材料，其特征在于，所述混合纤维中，椰棕纤维的重量为混合纤维重量的10-60％，竹纤维的重量为混合纤维重量的10-60％。
7.根据权利要求1-6任一项所述的椰竹混合纤维复合材料的制备方法，其特征在于，包括以下步骤：
将椰竹混合纤维毡层按要求放在压板机自动上料设备对应的转轴上，经切割成需要的长度后，自动落到输送帘上，输送帘将其先送入压板机热压区，聚丙烯短纤维遇热熔化，把椰棕纤维和竹纤维粘结在一起的热板材，然后送入压板机冷压区进行冷却固化，得到椰竹纤维复合板材。
8.根据权利要求7所述的制备方法，其特征在于，在放置椰竹混合纤维毡层时，还包括根据需要放置可针刺的无纺布、或者胶膜和不可针刺的无纺布或水刺布的步骤。
9.根据权利要求7或8所述的制备方法，其特征在于，压板机热压区的温度为200-260℃，压板机冷压区的温度为5-30℃。
10.根据权利要求7所述的制备方法，其特征在于，所述混合纤维毡通过以下方法制备得到：
将椰棕纤维、竹纤维和有油/无油聚丙烯短纤维分别投入到开包机中，经打散后，将三者分别定量、重叠地落到开松机喂入帘上，经开松后，对混合在一起的椰棕纤维、竹纤维和有油/无油聚丙烯短纤维进行除尘，然后被风依次送入气压棉箱和储棉箱，得到混合纤维；
将混合纤维进行梳理后，形成互相勾连在一起的纤维网，将纤维网往复铺叠在铺网机底帘上，然后喂入针刺机，经针刺形成密实的毡材后，根据需要切成一定的幅宽和长度，成卷收集，得到混合纤维毡。
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