CN116198149A - 用于制造装饰元件的方法和相关的装饰元件 - Google Patents

用于制造装饰元件的方法和相关的装饰元件 Download PDF

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Publication number
CN116198149A
CN116198149A CN202211516731.2A CN202211516731A CN116198149A CN 116198149 A CN116198149 A CN 116198149A CN 202211516731 A CN202211516731 A CN 202211516731A CN 116198149 A CN116198149 A CN 116198149A
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China
Prior art keywords
mixture
mat
needling
fibers
thermoforming
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CN202211516731.2A
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English (en)
Inventor
何塞·安东尼奥·罗迪利亚·加尔多
欧塞维奥·德拉普恩特-努内兹
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Faurecia Interieur Industrie SAS
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Faurecia Interieur Industrie SAS
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Publication of CN116198149A publication Critical patent/CN116198149A/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N1/00—Pretreatment of moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/08—Moulding or pressing
    • B27N3/18—Auxiliary operations, e.g. preheating, humidifying, cutting-off
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N5/00—Manufacture of non-flat articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/006—Pressing and sintering powders, granules or fibres
    • 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
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    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • 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
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    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
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    • B29C70/467—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements during mould closing
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    • 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
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/74—Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding
    • B29C70/76—Moulding on edges or extremities of the preformed part
    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

本发明涉及制造车辆装饰元件的方法，包括以下步骤：将包含木纤维、聚丙烯酸粘合剂和聚酯纤维，优选PET纤维的混合物进行混合(100)；将所述混合物进行针刺(110)，以获得垫子；将所述垫子热成型(120)为装饰部件；和将附加元件背部注射(130)在所述装饰部件上，以形成装饰元件。热成型(120)和背部注射(130)步骤在同一模具中进行。本发明还涉及相关的装饰元件。

Description

用于制造装饰元件的方法和相关的装饰元件
技术领域
本发明涉及一种用于制造车辆装饰元件的方法和相关的装饰元件。
背景技术
DE 102016106124 A1描述了用于生产模制品的方法，所述模制品具有包含合成纤维和/或天然纤维和至少一个附接塑料部件的纤维增强载体。
该方法包括在两个工具部件之间插入纤维增强的垫子，并闭合工具部件，因此垫子被加压和压制以生产纤维增强载体，其中塑料同时通过喷嘴穿过垫子注射腔体中。
然而，由于塑料是穿过垫子注射的，该技术可能需要预先从垫子上打孔或切孔，这导致额外的操作。此外，这会留下由注射喷嘴产生的突出或凹陷。
本发明的目的是克服这些缺点。
发明内容
为此，本发明的主题是一种制造车辆装饰元件的方法，包括以下步骤：
·将包含木纤维、聚丙烯酸粘合剂和聚酯纤维，优选PET纤维的混合物进行混合；
·将所述混合物进行针刺，以获得垫子；
·将所述垫子热成型为装饰部件；和
·将附加元件背部注射在所述装饰部件上，以形成装饰元件，
所述成型和背部注射步骤在同一模具中进行。
得益于背部注射技术，无需在垫子上打孔或切孔的准备步骤。此外，针刺步骤可以缠结纤维，为后续模制增加可塑性和拉伸性能。
根据本发明方法的其他特征，考虑单独或根据任何技术上可能的组合：
-成型在120℃至160℃的温度下进行，优选在130℃至140℃的温度下进行；
-该混合物包含55％至70％的木纤维、15％至20％的聚丙烯酸粘合剂和12％至22％的聚酯纤维，优选PET纤维；
-该方法包括在针刺步骤前，在混合物的一侧加入羊毛；
-羊毛是密度为30g/m2至100g/m2的非织造PET羊毛；
-混合物包含0.5％至3％的蜡或石蜡或生物蜡，优选1％至1.5％的石蜡；
-在针刺中，被针刺的混合物有两个侧面，且从两个侧面都进行针刺；
-在背部注射步骤中，例如装饰部件仅部分地填充模具的模制腔体，以限定出至少一个空部分，产品被直接注射到至少一个空部分内；和/或
-在热成型步骤中，垫子经过热压的压缩模塑。
本发明还涉及根据前述类型的方法制造的装饰元件。
附图说明
本发明的其他方面和优点将在阅读以下描述时显现，作为实例提供，并参考附图完成，其中：
图1是根据本发明的一种实施方式的方法的示意框图，和
图2是根据本发明的一种实施方式的方法的背部注射步骤的示意图。
具体实施方式
下面描述一种制造车辆装饰元件的方法。
该方法包括以下步骤：
·将混合物进行混合100；
·将混合物进行针刺110，以获得垫子；
·将垫子热成型120为装饰部件；和
·将附加元件背部注射130在装饰部件上。
该混合物包含木纤维、聚丙烯酸粘合剂和聚酯纤维。
木纤维具有3至12mm的长度。
使用木纤维可以实现良好的透气性和粘合性能，以便后续在装饰元件上使用胶水进行胶粘和覆盖过程。
此外，木纤维价格低廉且可获得，并增加了生物含量。
聚丙烯酸粘合剂是例如聚丙烯酸热固性树脂。聚丙烯酸热固性树脂是例如低温热固性树脂。
聚丙烯酸热固性树脂例如具有135℃至160℃的固化温度。
当固化时，所述树脂更耐高温。
与仅具有天然纤维和聚丙烯纤维相比，聚丙烯酸粘合剂为垫子增加了重要的粘合力和孔隙率优势，并允许有更高的木纤维含量。
聚酯纤维是例如聚对苯二甲酸乙二醇酯(PET)纤维。
聚酯纤维比木纤维更长。
聚酯纤维具有60至90mm的长度。
使用聚酯纤维，特别是PET纤维，增加了拉伸性能，特别是具有更高的拉伸强度和可塑性。
该混合物包含例如：
-55％至70％的木纤维，
-15％至20％的聚丙烯酸粘合剂，和
-12％至22％的聚酯纤维，更准确地是PET纤维。
在第一实施方式中，混合物例如包含：
-55％至65％的木纤维，
-15％至18％的聚丙烯酸粘合剂，和
-21％至22％的聚酯纤维，更准确地是PET纤维。
或者，在第二实施方式中，混合物例如包含：
-65％至70％的木纤维，
-18％至20％的聚丙烯酸粘合剂，和
-12％至15％的聚酯纤维，更准确地是PET纤维。
混合物的组成例如适合于要获得的最终部件的形状。特别是，最终部件的形状越复杂，混合物中的聚酯纤维和/或聚丙烯酸粘合剂就越多。
在一种实施方式中，该混合物包含0.5％至3％的蜡或石蜡或生物蜡。
特别地，该混合物包含例如石蜡，例如1％至1.5％的石蜡。
这提高了木纤维基材料的耐水性并防止其受潮。
混合该混合物的各组分，直到各组分均匀分布。
例如，该混合物通过气流成网系统制备，可选地由梳理系统补充。
在气流成网系统中，例如在纤维分离机后，木纤维通过空气输送到料仓中，然后通过气流成网法与聚酯纤维混合。
特别地，在纤维分离机和料仓之间，该系统包括管道，其上的风道适于将添加剂加入到木纤维中。木纤维在管道中输送，例如通过干燥的饱和蒸汽流。
聚丙烯酸粘合剂，例如在气流成网之前加入到木纤维中，例如在所述风道中。
如果相关的话，在气流成网之前将蜡或石蜡或生物蜡加入到木纤维中，例如在所述风道中或在纤维分离机之前。
梳理系统适用于对聚酯纤维进行定向并有利地分布所述纤维。
任选地，在针刺步骤110之前，在混合物的一侧加入羊毛，特别是非织造PET羊毛。
这种羊毛例如适用于集成固定特征和/或加强肋的车辆内部装饰组件，如门板支架、中央控制台支架或仪表板结构部件。
非织造PET羊毛的密度为30至100g/m2，例如等于35g/m2。
所述羊毛提高了抗拉性能并便于运输，特别是运输至如下所述的针刺机。
另外，任选地，将混合物放置在传送带上，特别是钢网传送带上，并送入下述针刺机中。
将混合物放入针刺机中。
当适用时，羊毛位于混合物的底侧，以便与它一起进行针刺。
针刺机包含针具。
针具有例如鱼叉的形状。
针刺机还包含两个彼此平行延伸且彼此相对的板。
两个板间隔开，混合物在两个板之间送入，例如用进料输送机。
每个板都设有穿孔，供针具穿过板。
针刺机中的混合物具有两个侧面，更具体地，一侧抵靠各板延伸。
混合物针刺或也称为针穿孔。
针穿孔能够通过针具的反复刺入以机械方式缠结混合物的纤维以生产非织造织物，特别是在垫子的所有宽度上。
通过缠结，针刺有助于PET纤维固定木纤维。
当适用时，将羊毛与混合物针刺在一起。
在本实施方式中，混合物从两个侧面针刺。
或者，混合物仅从一侧针刺。
在一种实施方式中，该方法包括在混合步骤100和热成型步骤120之间的两个不同机器中的两个连续针刺步骤110。
这增加了垫子的可成形性和拉伸性能，使得它可以更好地模制并提供更好的抗撕裂性。
因此，针刺能够获得更高质量的垫子。
此外，针刺对于稍后将描述的背部注射步骤也是有利的，因为与背部注射相比，它增加了均匀性，具有正确的密度，并且限制垫子另一侧的材料泄漏。
从两个侧面针刺特别地改善垫子的拉伸性能，特别是对于伸长率和力。
针刺的混合物形成垫子。
垫子具有8mm至14mm的厚度。
垫子的单位面积质量或表面密度为1000g/m2至2000g/m2。
这些参数旨在改善装饰元件的机械性能。
然后将垫子转移到具有模制腔体的模具中。
模具还包括至少一个注射喷嘴，优选多个喷嘴，用于将产品注射到模制腔体内。
模具在打开配置和闭合配置之间是可移动的，打开配置中模制腔体是可进入的。
更具体地，模具处于打开配置时，垫子放置在模制腔体中。
热成型步骤120包括将垫子热成型为装饰部件。
特别是，垫子在模具中热成型。更准确地说，垫子经过热压的压缩模塑。
更准确地说，模具10在闭合配置中移动，使得垫子被压制以生产装饰部件40，如图2所示。
成型120在120℃至160℃、优选在130℃至150℃、优选在130℃至140℃的温度下进行。
在成型120中，模具10在所述温度下被加热。
模制后，装饰部件具有1.4至2.4mm的厚度。
装饰部件40具有0.85g/cm3至0.95g/cm3的体积密度。
装饰部件具有1000g/m2至2000g/m2的单位面积质量或表面密度。
这些参数旨在改善装饰元件的机械性能。
装饰部件仅部分地填充模制腔体20。
因此模制腔体20的至少一部分50是空的。
在所示的实施方式中，空部分50具有不同的局部厚度，例如待注入的用于加强肋的第一较薄部分和待注入的用于保持器或固定元件的第二较厚部分。
注射喷嘴30设置为将产品注射到模制腔体20的所述部分内。
背部注射130在与成型120步骤相同的模具10中进行。
模具10保持在闭合配置中。
产品被注射到模制腔体20的空部分50内侧，特别是通过注射喷嘴30。
该产品例如包含聚合物，例如聚酰胺或聚碳酸酯，例如具有如玻璃纤维增强材料。该产品是例如由聚合物，例如聚酰胺或聚碳酸酯，任选地具有如玻璃纤维增强材料制成。
该产品例如具有190℃至210℃的软化温度。
附加元件因此通过背部注射加入到装饰部件上，以形成装饰元件。
附加元件对应于模制腔体的空部分中的背部注射产品。
因此，注射产品不会穿过垫子，因为它直接注射到模制腔体的空部分中。
注射温度取决于使用的产品及其熔体流动指数。
背部注射产品例如在高于200℃，例如210℃至250℃的温度下注入。
模具仍基本上在成型温度下。
背部注射开始于模具闭合后少于30s、更准确地少于10s、更准确地4至8s。
本发明还涉及根据前述方法制造的装饰元件。
如聚丙烯纤维等的纤维的缺失，使得能够实现在装饰元件上使用常规胶水的后续胶合和覆盖过程的令人满意的粘合性能。此外，这种缺失也能实现良好的透气性，例如用于装饰元件的真空覆层和高级包装，例如用皮革或织物，和木质饰面。
在生产线上所需的工具和必要的时间方面，使用一个模具进行热成型和背部注射简化了该方法。这降低了生产所述元件的成本。
混合物的组分，特别是聚丙烯酸粘合剂的使用，能够在比其他传统方法更低的温度下使用模具对垫子进行成型，例如使用天然聚丙烯纤维，其成型步骤是在校准后于210℃下完成的。这进一步简化了方法并能够实现节省能量和时间。

Claims (10)

1.制造车辆装饰元件的方法，包括以下步骤：
·将包含木纤维、聚丙烯酸粘合剂和聚酯纤维的混合物进行混合(100)；
·将所述混合物进行针刺(110)，以获得垫子；
·将所述垫子热成型(120)为装饰部件(40)；和
·将附加元件背部注射(130)在所述装饰部件(40)上，以形成所述装饰元件，
所述热成型(120)和背部注射(130)步骤在同一模具(10)中进行。
2.根据权利要求1所述的方法，其中，所述热成型(120)在120℃至160℃的温度下进行。
3.根据权利要求1所述的方法，其中，所述混合物包含55％至70％的木纤维、15％至20％的聚丙烯酸粘合剂和12％至22％的聚酯纤维。
4.根据权利要求1所述的方法，包括在针刺(110)步骤前，在混合物的一侧加入羊毛。
5.根据权利要求4所述的方法，其中，所述羊毛是密度为30g/m2至100g/m2的非织造PET羊毛。
6.根据权利要求1所述的方法，其中，所述混合物包含0.5％至3％的蜡或石蜡或生物蜡。
7.根据权利要求1所述的方法，其中，在针刺(110)中，被针刺的混合物有两个侧面，且从两个侧面都进行针刺。
8.根据权利要求1所述的方法，其中，在背部注射(130)步骤中，所述装饰部件(40)仅部分地填充模具(10)的模制腔体(20)，以限定出至少一个空部分(50)，产品被直接注射到至少一个空部分(50)内侧。
9.根据权利要求1所述的方法，其中，在热成型(120)步骤中，垫子经过热压的压缩模塑。
10.根据权利要求1至9中任一项所述的方法制造的装饰元件。
CN202211516731.2A 2021-11-30 2022-11-29 用于制造装饰元件的方法和相关的装饰元件 Pending CN116198149A (zh)

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