CN117656624A - 织物表皮、内饰面板、制造方法以及安全气囊装置 - Google Patents

织物表皮、内饰面板、制造方法以及安全气囊装置 Download PDF

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CN117656624A
CN117656624A CN202211057961.7A CN202211057961A CN117656624A CN 117656624 A CN117656624 A CN 117656624A CN 202211057961 A CN202211057961 A CN 202211057961A CN 117656624 A CN117656624 A CN 117656624A
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layer
fabric
fabric skin
substrate
strength
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赵丽丽
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Faurecia China Holding Co Ltd
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Faurecia China Holding Co Ltd
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Priority to CN202211057961.7A priority Critical patent/CN117656624A/zh
Priority to EP23194350.7A priority patent/EP4331830A1/en
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  • Engineering & Computer Science (AREA)
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Abstract

本申请提供一种织物表皮、内饰面板、安全气囊装置以及内饰面板的制造方法。其中，所述织物表皮为单层或者多层结构，所述织物表皮的织物拉伸断裂强力的经向强力以及纬向强力均小于或等于480N，所述织物表皮的织物撕破强力的经向强力以及纬向强力均小于或等于48N。

Description

织物表皮、内饰面板、制造方法以及安全气囊装置
技术领域
本申请涉及织物表皮、内饰面板、制造方法、以及安全气囊装置。
背景技术
安全气囊装置，例如在汽车为前排乘客配备的安全气囊装置，包括内饰面板以及位于内饰面板背面对应设置的安全气囊。在发生碰撞时，安全气囊可以充气膨胀。由于内饰面板的背面具有弱化线，受到膨胀气囊的冲击内饰面板可以弱化线为裂开的起点沿该弱化线的延伸方向裂开，从而使得气囊弹出。
发明内容
本发明的一个目的是提供一种织物表皮。
本发明的一个目的是提供一种内饰面板。
本发明的一个目的是提供一种安全气囊装置。
本发明的一个目的是提供一种内饰面板的制造方法。
第一方面，本申请提供一种织物表皮，织物表皮为单层或者多层结构，所述织物表皮的织物拉伸断裂强力的经向强力以及纬向强力均小于或等于480N，以及所述织物表皮的织物撕破强力的经向强力以及纬向强力均小于或等于48N。
本实施例的技术方案中，通过对织物表皮的力学性能的调节，采用织物拉伸断裂强力的经向强力以及纬向强力均小于或等于480N，以及织物撕破强力的经向强力以及纬向强力均小于或等于48N的性能，即以480N作织物拉伸断裂强力的临界点，48N作为为织物撕破强力的临界点，使得织物表皮既可以达到自撕裂的性能，也可以具有良好的观感、触感或耐用性。
在一些实施例中，所述织物表皮为多层结构，包括：第一层，作为所述织物表皮的表面层，所述第一层为各向异性层；以及第二层，位于与所述第一层相邻的背面侧，所述第二层为各向同性层；和/或第三层，位于与所述第二层相邻的背面侧，所述第三层为各向同性层；和/或第四层，位于与所述第三层相邻的背面侧，所述第四层为各向同性层。
在一些实施例中，所述第一层为织物层，和/或所述第二层为底布层，和/或所述第三层为3D网状间隔层或者泡棉层，和/或所述第四层为基布层。
第二方面，本申请提供一种内饰面板，如第一方面所述的织物表皮；以及基体，所述基体的背面具有弱化线；其中，所述织物表皮至少部分地覆盖于所述基体的表面。
本实施例的技术方案中，通过采用第一方面的织物表层，使得内饰面板不但可以在发生碰撞时及时断裂以弹出安全气囊，同时也可以在正常使用时具有较好的观感、触感或耐用性；同时也降低了内饰面板的加工成本。
在一些实施例中，构成所述弱化线的断裂槽由所述基体的厚度方向的孔形成。
在一些实施例中，所述基体的材料包括丙烯腈-丁二烯-苯乙烯共聚物(ABS)、聚碳酸酯与ABS合金(ABS-PC)、滑石粉填充聚丙烯、玻璃纤维增强聚丙烯、自然纤维增强聚丙烯NFPP。
第三方面，本申请提供一种安全气囊装置，包括如第二方面所述的内饰面板，以及气囊；其中，所述内饰面板在其背面对应所述气囊，当所述气囊充气膨胀，所述内饰面板的基体沿所述弱化线断裂以及所述织物表皮自撕裂。
本实施例的技术方案中，安全气囊装置可以在发生碰撞时及时断裂弹出安全气囊，以及在正常使用时具有较好的观感、触感或耐用性。
第四方面，本申请提供一种内饰面板的制造方法，采用如第一方面所述的织物表皮；基体的表面至少部分地被所述织物表皮覆盖，使得所述基体与所述织物表皮结合，所述基体的背面被加工有弱化线。
本实施例的技术方案中，通过采用第一方面的织物表层，可使得制造方法无需进行对织物表皮加工对应弱化线的槽的加工步骤，也无需对应的加工设备，简化了加工过程、降低了加工成本。
在一些实施例中，基材的表面至少部分地被所述织物表皮覆盖形成中间产物，之后所述中间产物的基材在其背面被加工弱化线；或者，基材在其背面被加工弱化线形成基体，之后所述基体被至少部分地被所述织物表皮覆盖。
在一些实施例中，所述基体的背面被加工有弱化线的步骤包括：激光加工或者铣削加工。
附图说明
本发明上述的以及其他的特征、性质和优势将通过下面结合附图和实施例的描述而变得更加明显，在附图中相同的附图标记始终表示相同的特征，需要注意的是，这些附图均仅作为示例，其并非是按照等比例的条件绘制的，并且不应该以此作为对本发明实际要求的保护范围构成限制，其中：
图1为一实施例的内饰面板的结构示意图；
图2为另一实施例的内饰面板的结构示意图；
图3为一实施例的内饰面板的制造方法的流程示意图；
图4为另一实施例的内饰面板的制造方法的流程示意图；
图5为又一实施例的内饰面板的制造方法的流程示意图。
附图标记：
100-内饰面板；
1-织物表皮；
11-第一层；
12-第二层；
13-第三层；
14-第四层；
2-基体；
21-弱化线；
210-断裂槽；
211-孔。
具体实施方式
现在将详细地参考本发明的各个实施方案，这些实施方案的实例被显示在附图中并描述如下。尽管本发明将与示例性实施方案相结合进行描述，但是应当意识到，本说明书并非旨在将本发明限制为那些示例性实施方案。相反，本发明旨在不但覆盖这些示例性实施方案，而且覆盖可以被包括在由所附权利要求所限定的本发明的精神和范围之内的各种选择形式、修改形式、等效形式及其它实施方案。
同时，本申请使用了特定词语来描述本申请的实施例。如“一个实施例”和/或“一实施例”意指与本申请至少一个实施例相关的某一特征、结构或特点。因此，应强调并注意的是，本说明书中在不同位置两次或多次提及的“一实施例”或“一个实施例”并不一定是指同一实施例。此外，本申请的一个或多个实施例中的某些特征、结构或特点可以进行适当的组合。
内饰面板(Instrument Panel,IP)，例如对应安全气囊的内饰面板，一般可以包括位于表面的表皮以及位于背面承载内饰面板的基体，基体与安全气囊对应。此时基体也被称为内饰面板承载体(Instrument Panel Carrier)。
在一对比方案中，为了达到使气囊及时弹出的要求，不仅在基体需要开设弱化线，位于表面的表皮也需要对应该弱化线的位置加工弱化槽。
但发明人发现，如此会使得内饰面板的制造工艺较为复杂，并且需要较高的设备成本。
基于此，发明人经过深入研究，发明了一种织物表皮，其织物拉伸断裂强力的经向强力以及纬向强力均小于或等于480N，以及所述织物表皮撕破强力的经向强力以及纬向强力均小于或等于48N，以480N作为织物拉伸断裂强力的临界点，48N作为织物撕破强力的临界点，即两者的上限值，使得织物表皮既可以达到自撕裂的性能，也可以具有良好的观感、触感或耐用性。可以理解到，织物表皮也需要具有一定的强度，即其物拉伸断裂强力、织物表皮撕破强力具有一定的下限值，该下限值可以根据实际的工程需求调整，例如需要满足作为内饰面板或者其它面板的基本强度要求。
虽然本申请实施例公开的织物表皮的适用对象以汽车前排的内饰面板为例，但不以此为限，只要是可以应用本申请实施例公开的织物表皮既可以达到自撕裂的性能，也可以具有良好的观感、触感或耐用性的优点即可。例如还可以是汽车车身侧部的内饰板以对应侧部气囊，例如其它需要气囊的场合。
参考图1或图2所示的，在一些实施例中，内饰面板100包括织物表皮1以及基体2。织物表皮1至少部分地覆盖于基体2的表面，基体2的背面具有弱化线21。
对于安全气囊装置而言，在内饰面板100的背面一侧对应气囊，当发生碰撞时，气囊充气膨胀，内饰面板100的基体2沿弱化线21断裂并且织物表皮1撕裂，使得膨胀的气囊弹出内饰面板100，以起到保护汽车前排乘客的作用。
继续参考图1或图2所示的，在一些实施例中，织物表皮1为单层或多层的结构。如图1或图2所示的，织物表皮1可以包括从表面至背面方向依次堆叠设置的第一层11、第二层12、第三层13以及第四层14。第一层11作为织物表皮1的表面层，第一层11为各向异性层，第二层12位于与第一层11相邻的背面侧，第二层12为各向同性层，第三层13位于与第二层12相邻的背面侧，所述第三层13为各向同性层，第四层14位于与第三层13相邻的背面侧，第四层14为各向同性层。
此处的“各向异性”的含义为，沿其表面方向的抗张强度是各向异性的，在不同加载方向加载该层具有不同强度和刚度。例如第一层11为采用全部沿同一个方向取向的纤维支承的纤维层。
此处的“各向同性”的含义为，沿其表面方向的抗张强度是各向同性的，即也可以称为“准各向同性”，无论对该层的加载方向如何，其强度和刚度均保持不变。
在一些实施例中，优选地，可以是包括各向异性的第一层11以及各向同性的第二层12、第三层13、第四层14的至少一层。即是第一层11与第二层12、第三层13、第四层14中选择其中之一、之二或者全部进行堆叠组合(例如图1或图2所示的四层结构)，如此可以便于调节织物表皮1的力学性能。但可以理解到，也可以只具有第一层11，甚至也可以是在第四层14的背面侧堆叠设置更多的层，均不以此为限。
在一些实施例中，优选地，第一层11为织物层，和/或第二层12为底布(Fleece)层，和/或第三层13为3D网状间隔(Spacer Fabric)层或者泡棉(Foam)层，和/或所述第四层(14)为基布(Scrim)层。例如可以是第一层11与第三层13的堆叠组合，第一层11为各向异性的涤纶树脂(Polyethylene terephthalate,PET)织物层，第三层13为各向同性的聚氨酯(PU)泡棉或者聚丙烯(PP)泡棉层。如此的结构简单，且易于调节织物表皮1的力学性能。
承上所介绍的，如图1以及图2所示的织物表皮1，发明人经过深入研究发现，织物表皮1的单层或者多层结构，只需要满足织物表皮1的织物拉伸断裂强力的经向强力以及纬向强力均小于或等于480N，以及所述织物表皮1的织物撕破强力的经向强力以及纬向强力均小于或等于48N，即以480N作织物拉伸断裂强力的临界点，48N作为为织物撕破强力的临界点，可以实现织物表皮既可以达到自撕裂的性能，也可以具有良好的观感、触感或耐用性的效果。
此处的“织物撕破强力”的测试方法，例如可以参考中华人民共和国国家标准GB/T3923.1-2013《纺织物织物拉伸性能第一部分：断裂强力和断裂伸长率的测定(条样法)》，但不以此为限，也可以参考其它推荐性标准，或者其它国家或地区的标准进行。
类似地，“织物撕破强力”的测试方法，例如可以参考中华人民共和国国家标准GB/T 3917.1-2009《纺织品织物撕破性能第1部分：冲击摆锤法撕破强力的测定》，但不以此为限，也可以参考其它推荐性标准，或者其它国家或地区的标准进行。
在一些实施例中，继续参考图1或图2所示的，在一些实施例中，在基体2构成弱化线21的结构可以是，在弱化线21的延伸方向的多个断裂槽210构成弱化线21。可以理解到，图1、图2所示的断裂槽210的数量仅为示意。断裂槽210的槽壁由基体2的厚度方向的孔211形成，断裂槽210的槽底由织物表皮1提供。孔211的结构，可以是图中所示的通孔结构，也可以是盲孔结构。在一些实施例中，基体2的材料可以包括丙烯腈-丁二烯-苯乙烯共聚物(ABS)、聚碳酸酯与ABS合金(ABS-PC)、滑石粉填充聚丙烯、玻璃纤维增强聚丙烯，也可以是自然纤维增强聚丙烯(NFPP,Natural fiber reinforcement PP)，如此可以使得基体2轻量化以及制造过程降低碳排放。
承上所介绍地，参考图3所示的，内饰面板100的制造方法可以包括：
采用以上实施例介绍的织物表皮1；
基体2的表面至少部分地被所述织物表皮1覆盖，使得基体2与织物表皮1结合，基体2的背面被加工有弱化线21。
如此可使得制造方法无需进行对织物表皮加工对应弱化线的槽的加工步骤，也无需对应的加工设备，简化了加工过程、降低了加工成本。
参考图1以及图4所示的，在一实施例中，对基体2的背面加工弱化线21的步骤可以是，先将基材在其背面被加工弱化线21形成基体2，之后基体2被至少部分地被所述织物表皮1覆盖，加工弱化线21的方法可以是采用激光打孔，得到通孔或盲孔的孔211；即先加工弱化线21，再将织物表皮1与基体2结合。参考图2以及图5所示的，在另一实施例中，对基体2的背面加工弱化线21的步骤可以，基材2的表面至少部分地被织物表皮1覆盖形成中间产物，之后该中间产物的基材在其背面被加工弱化线21，即先将织物表皮1与基材结合，再加工弱化线21，如图2所示的，加工弱化线21的过程可以是将断裂槽210的槽壁延伸至织物表皮1的一定厚度，可以采用铣削加工的工艺对断裂槽210进行加工。可以理解到，加工弱化线21的方法，除了以上介绍的激光打孔、铣削加工之外，还包括其它工艺，不以上述介绍为限制。
在一些实施例中，基体2的表面至少部分地被织物表皮1覆盖，使得基体2与织物表皮1结合的步骤可以包括但不限于，采用手工包覆工艺、压力复合工艺、背部注塑、NFPP一次成型、或者NFPP二次成型的工艺，将织物表皮1覆盖地与基体2结合。
本发明虽然以较佳实施例公开如上，但其并不是用来限定本发明，任何本领域技术人员在不脱离本发明的精神和范围内，都可以做出可能的变动和修改。因此，凡是未脱离本发明技术方案的内容，依据本发明的技术实质对以上实施例所作的任何修改、等同变化及修饰，均落入本发明权利要求所界定的保护范围之内。

Claims (10)

1.一种织物表皮(1)，其特征在于，所述织物表皮(1)为单层或者多层结构，所述织物表皮(1)的织物拉伸断裂强力的经向强力以及纬向强力均小于或等于480N，以及所述织物表皮(1)的织物撕破强力的经向强力以及纬向强力均小于或等于48N。
2.如权利要求1所述的织物表皮(1)，其特征在于，所述织物表皮(1)为多层结构，包括：
第一层(11)，作为所述织物表皮(1)的表面层，所述第一层(11)为各向异性层；以及
第二层(12)，位于与所述第一层(11)相邻的背面侧，所述第二层(12)为各向同性层；和/或
第三层(13)，位于与所述第二层(12)相邻的背面侧，所述第三层(13)为各向同性层；和/或
第四层(14)，位于与所述第三层(13)相邻的背面侧，所述第四层(14)为各向同性层。
3.如权利要求2所述的织物表皮(1)，其特征在于，所述第一层(11)为织物层，和/或所述第二层(12)为底布层，和/或所述第三层(13)为3D网状间隔层或者泡棉层，和/或所述第四层(14)为基布层。
4.一种内饰面板(100)，其特征在于，包括：
如权利要求1-3任意一项所述的织物表皮(1)；以及
基体(2)，所述基体(2)的背面具有弱化线(21)；
其中，所述织物表皮(1)至少部分地覆盖于所述基体(2)的表面。
5.如权利要求4所述的内饰面板(100)，其特征在于，构成所述弱化线(21)的断裂槽(210)由所述基体(2)的厚度方向的孔(211)形成。
6.如权利要求4所述的内饰面板(100)，其特征在于，所述基体(2)的材料包括丙烯腈-丁二烯-苯乙烯共聚物(ABS)、聚碳酸酯与ABS合金(ABS-PC)、滑石粉填充聚丙烯、玻璃纤维增强聚丙烯、自然纤维增强聚丙烯(NFPP)。
7.一种安全气囊装置，包括：
如权利要求4-6任意一项所述的内饰面板(100)，以及
气囊；
其中，所述内饰面板(100)在其背面对应所述气囊，当所述气囊充气膨胀，所述内饰面板(100)的基体(2)沿所述弱化线(21)断裂以及所述织物表皮(1)自撕裂。
8.一种内饰面板(100)的制造方法，其特征在于，包括：
采用如权利要求1-3任意一项所述的织物表皮(1)；
基体(2)的表面至少部分地被所述织物表皮(1)覆盖，使得所述基体(2)与所述织物表皮(1)结合，所述基体(2)的背面被加工有弱化线(21)。
9.如权利要求8所述的制造方法，其特征在于，基材的表面至少部分地被所述织物表皮(1)覆盖形成中间产物，之后所述中间产物的基材在其背面被加工弱化线(21)；或者，基材在其背面被加工弱化线(21)形成基体(2)，之后所述基体(2)被至少部分地被所述织物表皮(1)覆盖。
10.如权利要求8所述的制造方法，其特征在于，所述基体(2)的背面被加工有弱化线(21)的步骤包括：激光加工或者铣削加工。
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