CN118061622A - 一种汽车顶棚复合布及其制备工艺 - Google Patents
一种汽车顶棚复合布及其制备工艺 Download PDFInfo
- Publication number
- CN118061622A CN118061622A CN202410209939.2A CN202410209939A CN118061622A CN 118061622 A CN118061622 A CN 118061622A CN 202410209939 A CN202410209939 A CN 202410209939A CN 118061622 A CN118061622 A CN 118061622A
- Authority
- CN
- China
- Prior art keywords
- layer
- flame
- retardant
- hot melt
- melt adhesive
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000004744 fabric Substances 0.000 title claims abstract description 171
- 239000002131 composite material Substances 0.000 title claims abstract description 141
- 238000002360 preparation method Methods 0.000 title claims abstract description 52
- 239000003063 flame retardant Substances 0.000 claims abstract description 157
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 claims abstract description 145
- 239000004814 polyurethane Substances 0.000 claims abstract description 112
- 229920002635 polyurethane Polymers 0.000 claims abstract description 112
- 239000004831 Hot glue Substances 0.000 claims abstract description 111
- 238000009413 insulation Methods 0.000 claims abstract description 58
- 239000004745 nonwoven fabric Substances 0.000 claims abstract description 54
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- 239000000126 substance Substances 0.000 claims abstract description 31
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- 125000002887 hydroxy group Chemical group [H]O* 0.000 claims abstract description 19
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- OWIKHYCFFJSOEH-UHFFFAOYSA-N Isocyanic acid Chemical compound N=C=O OWIKHYCFFJSOEH-UHFFFAOYSA-N 0.000 claims abstract description 7
- XLJMAIOERFSOGZ-UHFFFAOYSA-N anhydrous cyanic acid Natural products OC#N XLJMAIOERFSOGZ-UHFFFAOYSA-N 0.000 claims abstract description 7
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- XEKOWRVHYACXOJ-UHFFFAOYSA-N Ethyl acetate Chemical group CCOC(C)=O XEKOWRVHYACXOJ-UHFFFAOYSA-N 0.000 claims description 19
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 claims description 14
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 claims description 14
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- 239000000203 mixture Substances 0.000 claims description 13
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- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 claims description 12
- SNAAJJQQZSMGQD-UHFFFAOYSA-N aluminum magnesium Chemical compound [Mg].[Al] SNAAJJQQZSMGQD-UHFFFAOYSA-N 0.000 claims description 12
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- 229920001276 ammonium polyphosphate Polymers 0.000 claims description 12
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- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 10
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- 238000004381 surface treatment Methods 0.000 claims description 10
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 9
- 239000011248 coating agent Substances 0.000 claims description 9
- 238000000576 coating method Methods 0.000 claims description 9
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 9
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 claims description 8
- 239000012792 core layer Substances 0.000 claims description 8
- 239000012948 isocyanate Substances 0.000 claims description 8
- 150000002513 isocyanates Chemical class 0.000 claims description 8
- 239000007788 liquid Substances 0.000 claims description 8
- UKLDJPRMSDWDSL-UHFFFAOYSA-L [dibutyl(dodecanoyloxy)stannyl] dodecanoate Chemical group CCCCCCCCCCCC(=O)O[Sn](CCCC)(CCCC)OC(=O)CCCCCCCCCCC UKLDJPRMSDWDSL-UHFFFAOYSA-L 0.000 claims description 7
- 239000006096 absorbing agent Substances 0.000 claims description 7
- 238000006243 chemical reaction Methods 0.000 claims description 6
- 239000012975 dibutyltin dilaurate Substances 0.000 claims description 6
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 claims description 6
- 230000002745 absorbent Effects 0.000 claims description 5
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- 229910021578 Iron(III) chloride Inorganic materials 0.000 claims description 4
- QGBSISYHAICWAH-UHFFFAOYSA-N dicyandiamide Chemical compound NC(N)=NC#N QGBSISYHAICWAH-UHFFFAOYSA-N 0.000 claims description 4
- RRAMGCGOFNQTLD-UHFFFAOYSA-N hexamethylene diisocyanate Chemical compound O=C=NCCCCCCN=C=O RRAMGCGOFNQTLD-UHFFFAOYSA-N 0.000 claims description 4
- RBTARNINKXHZNM-UHFFFAOYSA-K iron trichloride Chemical compound Cl[Fe](Cl)Cl RBTARNINKXHZNM-UHFFFAOYSA-K 0.000 claims description 4
- 238000004519 manufacturing process Methods 0.000 claims description 4
- 238000009987 spinning Methods 0.000 claims description 4
- UPMLOUAZCHDJJD-UHFFFAOYSA-N 4,4'-Diphenylmethane Diisocyanate Chemical group C1=CC(N=C=O)=CC=C1CC1=CC=C(N=C=O)C=C1 UPMLOUAZCHDJJD-UHFFFAOYSA-N 0.000 claims description 3
- 239000005057 Hexamethylene diisocyanate Substances 0.000 claims description 3
- 238000009960 carding Methods 0.000 claims description 3
- 229920001451 polypropylene glycol Polymers 0.000 claims description 3
- 229920000909 polytetrahydrofuran Polymers 0.000 claims description 3
- 239000002904 solvent Substances 0.000 claims description 3
- 238000003756 stirring Methods 0.000 claims description 3
- BIKXLKXABVUSMH-UHFFFAOYSA-N trizinc;diborate Chemical compound [Zn+2].[Zn+2].[Zn+2].[O-]B([O-])[O-].[O-]B([O-])[O-] BIKXLKXABVUSMH-UHFFFAOYSA-N 0.000 claims description 3
- 238000005098 hot rolling Methods 0.000 claims description 2
- 239000012943 hotmelt Substances 0.000 abstract description 5
- 230000000694 effects Effects 0.000 description 20
- 230000000052 comparative effect Effects 0.000 description 17
- 150000001875 compounds Chemical class 0.000 description 11
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 8
- 238000002844 melting Methods 0.000 description 8
- 230000008018 melting Effects 0.000 description 8
- 229910052760 oxygen Inorganic materials 0.000 description 8
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- 239000000463 material Substances 0.000 description 6
- 238000012360 testing method Methods 0.000 description 6
- 239000012796 inorganic flame retardant Substances 0.000 description 5
- 230000002195 synergetic effect Effects 0.000 description 5
- 230000004069 differentiation Effects 0.000 description 3
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- 238000010409 ironing Methods 0.000 description 2
- IQPQWNKOIGAROB-UHFFFAOYSA-N isocyanate group Chemical group [N-]=C=O IQPQWNKOIGAROB-UHFFFAOYSA-N 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- XZZNDPSIHUTMOC-UHFFFAOYSA-N triphenyl phosphate Chemical compound C=1C=CC=CC=1OP(OC=1C=CC=CC=1)(=O)OC1=CC=CC=C1 XZZNDPSIHUTMOC-UHFFFAOYSA-N 0.000 description 2
- BJZYYSAMLOBSDY-QMMMGPOBSA-N (2s)-2-butoxybutan-1-ol Chemical compound CCCCO[C@@H](CC)CO BJZYYSAMLOBSDY-QMMMGPOBSA-N 0.000 description 1
- WUKNPIYSKBLCQI-UHFFFAOYSA-N CC(C=C1)=CC=C1C1=CC=C(C)C=C1.N=C=O.N=C=O Chemical compound CC(C=C1)=CC=C1C1=CC=C(C)C=C1.N=C=O.N=C=O WUKNPIYSKBLCQI-UHFFFAOYSA-N 0.000 description 1
- 239000002202 Polyethylene glycol Substances 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- 230000006750 UV protection Effects 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000012790 adhesive layer Substances 0.000 description 1
- 150000001298 alcohols Chemical class 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000000295 complement effect Effects 0.000 description 1
- 230000000536 complexating effect Effects 0.000 description 1
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- 238000011056 performance test Methods 0.000 description 1
- 229920001223 polyethylene glycol Polymers 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 239000002689 soil Substances 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
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- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
- B60R13/0212—Roof or head liners
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
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Abstract
本发明涉及汽车内饰用无纺布复合材料领域,特别是涉及一种汽车顶棚复合布及其制备工艺。其中,一种汽车顶棚复合布为由无纺布层、聚氨酯热熔胶、隔热阻燃层、聚氨酯热熔胶及防紫外线层依次层叠设置,经热压后制备得到,其中,隔热阻燃层包括复合玻纤层、基布层及隔热层,聚氨酯热熔胶的制备原料包括异氰酸物质、羟基物质、阻燃剂及光屏蔽剂、有机溶剂及催化剂;通过聚氨酯热熔粘结使得汽车顶棚复合布的无纺布层、隔热阻燃层及防紫外线层成为一个整体,各层功能上彼此协同,使得汽车顶棚复合布具有优异的隔热及阻燃性能。
Description
技术领域
本发明涉及汽车内饰用无纺布复合材料领域,特别是涉及一种汽车顶棚复合布及其制备工艺。
背景技术
近年来无纺布在汽车中的应用越来越广泛,无纺布常做成GMT材料,GMT材料易热塑定型,布面均匀,耐热和易成型,常应用于汽车顶棚覆盖材料、汽车地板革等汽车内饰材料。
顶棚复合布是汽车整车顶棚的重要组成部分,它的主要作用是提高车内的装饰性,随着汽车制造业在向经济型、舒适型发展的同时,也朝着安全性方向发展,即除了要求汽车本身具有很高的安全性能外,同时对汽车内饰材料的功能性提出了更多、更高的要求,要求汽车顶棚复合布具有阻燃隔热、防紫外线﹑等特殊功能。然而,目前汽车顶棚复合布不仅隔热性能差,而且其阻燃性能也不能满足先行汽车高的安全性能的要求。
发明内容
为了改善现有汽车顶棚复合布隔热及阻燃性能差的问题,本申请提供了一种汽车顶棚复合布及其制备工艺。
第一方面,本申请提供一种汽车顶棚复合布,采用如下的技术方案:
一种汽车顶棚复合布包括质量比为1:(2-7)的无纺布层及隔热阻燃层;
所述无纺布层由阻燃涤纶纤维经热压制备得到,所述阻燃涤纶纤维具有皮芯结构,所述芯层与皮层的质量比为(0.5-2.5):1;
所述隔热阻燃层的原料包括质量比为2:(1-5)的基布层及玻璃纤维,所述基布层是由质量比为(3.5-9):1的阻燃涤纶短纤维与聚乙烯醇纤维热压制备得到,所述玻璃纤维通过聚氨酯热熔胶复合于基布层上,制备得到隔热阻燃层;
所述无纺布层通过聚氨酯热熔胶复合于隔热阻燃层的基布层上,制备得到汽车顶棚复合布,所述汽车顶棚复合布中聚氨酯热熔胶的用量为50-90g/m3;
所述聚氨酯热熔胶的原料包括异氰酸物质、羟基物质、阻燃剂、光屏蔽剂、有机溶剂及催化剂;
所述聚氨酯热熔胶的制备步骤如下:
将异氰酸物质及催化剂加入羟基物质、阻燃剂、光屏蔽剂及有机溶剂组成的混合物中,反应后制备得到聚氨酯热熔胶,所述羟基物质为二元醇及壳聚糖的混合物,有机溶剂为乙酸乙酯,催化剂为二月桂酸二丁基锡。
通过聚氨酯热熔胶复合使得无纺布层及隔热阻燃层连接成为一个整体,隔热阻燃层中玻璃纤维未不燃材料,遇高温会融化吸收热量,进而对高温进行阻隔,与无纺布层中阻燃涤纶纤维的阻燃性能相互协同,使得汽车顶棚复合布具有良好的隔热效果及阻燃效果。
通过优选聚氨酯热熔胶的用量,使得汽车顶棚复合布的各层之间有良好的粘结性能,使得汽车顶棚复合布的各层相互协同具有优异的隔热及阻燃效果;优化聚氨酯热熔胶的用量,使得无纺布热熔胶具有优异的剥离性能;另一方面,聚氨酯热熔胶的热熔性能,使得汽车顶棚复合布在高于热熔胶熔点的温度下,处于熔融状态,便于汽车顶棚复合布热成型,优选聚氨酯热熔胶的用量,使得聚氨酯热熔胶很好将玻璃纤维包裹,使得热成型后汽车顶棚复合布的表面光滑,转折的位置线条流畅。
优选的,所述隔热阻燃层的原料还包括预氧化纤维及隔热层;
所述预氧化纤维与玻璃纤维的质量比为(0.5-0.9):1,所述预氧化纤维与玻璃纤维混合后经聚氨酯热熔胶复合于基布层上形成复合玻纤层;
所述隔热层经聚氨酯热熔胶复合于隔热阻燃层的基布层上;所述隔热层由质量比为(2-3):1的黑色阻燃涤纶纤维及白色天丝纺织制得;
所述隔热阻燃层中基布层、复合玻纤层及隔热层的质量比2:(1-5):1。
通过采用上述技术方案,在汽车顶棚复合布中添加预氧化纤维搭配玻璃纤维使用,玻璃纤维对车顶棚发射的红外线进行反射,而预氧化纤维对未反射的红外线转化成的热量进行吸收,预氧化纤维与玻璃纤维搭配使用进一步提升了汽车顶棚复合布的隔热。
汽车顶棚复合布还包括隔热层,隔热层由黑色阻燃涤纶纤维及白色天丝纺织制得,隔热层中白色天丝反射光波及黑色阻燃涤纶纤维将光波转化为热量,隔热层由黑色阻燃涤纶纤维对光波转化的热量进行吸收,进一步减少汽车顶棚复合布中的红外线及减少进入车内的热量;进入汽车顶棚复合布中的红外线经复合玻纤层及隔热层几次反射及吸收,使得汽车顶棚复合布具有优异的隔热效果。
预氧化纤维的与玻璃纤维配伍使用及与阻燃涤纶纤维协同作用,进一步提升汽车顶棚复合布的阻燃效果。
优选的,所述汽车顶棚复合布还包括防紫外线层,所述防紫外线层通过聚氨酯热熔胶复合于隔热阻燃层的隔热层上;所述防紫外线层为由质量比为(1-4):1的抗紫外锦纶纤维及阻燃涤纶纤维纺织制得;
所述无纺布层、隔热阻燃层及防紫外线层的质量比为1:(2-7):1。
通过上述技术方案,汽车顶棚复合布还包括防紫外线层,防紫外线层中的抗紫外锦纶纤维使得汽车顶棚复合布具有吸收紫外线的功能,降低车内紫外线的含量,进一步降低车内紫外线带来的热量,增强车内的舒适感。
本申请中汽车顶棚复合布通过设置隔热阻燃层协同聚氨酯热熔胶中的光屏蔽剂及防紫外线层及无纺布层使得车顶棚发射的红外线经多次反射及吸收使得车顶棚复合布具有隔热效果;本申请中汽车顶棚复合布通过设置隔热阻燃层、聚氨酯热熔胶中的阻燃剂、无纺布层及防紫外线层中的阻燃涤纶纤维配伍使用,使得汽车顶棚复合布具有优异的隔热性能的同时具有良好的阻燃效果。
另外,基布层中添加天丝及防紫外线层添加锦纶纤维,增强热熔型聚氨酯与基布层与防紫外线层之间的粘结力,进而增强汽车顶棚复合布整体的协同效果及剥离强度。
优选的,所述二元醇为聚四氢呋喃醚二醇及聚环氧丙烷醚二醇中的一种或两种的混合物,所述羟基物质中壳聚糖与二元醇的摩尔比为(0.1-0.3):1。
通过采用上述技术方案,二元醇选用含有醚键的二元醇,增强阻燃剂及光屏蔽剂在聚氨酯热熔胶中的分散性及增强聚氨酯热熔胶粘结力;另外,优化二元醇与壳聚糖的质量比,提高阻燃剂及光屏蔽剂在聚氨酯热熔胶中的分散性。
优选的,所述异氰酸物质为二苯基甲烷二异氰酸酯或六亚甲基二异氰酸酯,所述异氰酸物质与二元醇的摩尔比为(2-5):1。
通过采用上述技术方案,优化异氰酸酯物质及优化异氰酸物质的异氰酸基团与羟基物质的羟基基团的摩尔比,提高制备得到的聚氨酯热熔胶与汽车顶棚复合布中的无纺布层、基布层、隔热阻燃层、隔热层及防紫外线层之间的结合力及协同性能。
优选的,所述阻燃剂为聚磷酸铵、双氰胺、硼酸锌及氢氧化铝中至少一种;所述光屏蔽剂为硅酸镁铝、红外线吸收剂IR880中至少一种;所述聚氨酯热熔胶中阻燃剂的质量占比为4-12%,所述聚氨酯热熔胶中光屏蔽剂的质量占比为3-10%。
通过采用上述技术方案,优选阻燃剂及光屏蔽剂及优化阻燃剂及光屏蔽剂的用量,使得阻燃剂及光屏蔽剂在聚氨酯热熔胶中有较好的分散性及相互协同效果,进而增强聚氨酯热熔胶及汽车顶棚复合布的隔热性能及阻燃性能。
优选的,所述阻燃剂由质量比为(0.5-1.6):1的聚磷酸铵及氢氧化铝组成;所述光屏蔽剂由质量比为(0.4-1.2):1的硅酸镁铝及红外线吸收剂IR880组成。
通过采用上述技术方案,设置有机阻燃剂及无机阻燃剂配伍使用,提高聚氨酯热熔胶的阻燃性能;通过设置有机光屏蔽剂及无机光屏蔽剂配伍使用,提高聚氨酯热熔胶对红外线的吸收及提升汽车顶棚复合布的隔热性能。
阻燃剂选择聚磷酸铵及氢氧化铝配伍使用,设置氢氧化铝与壳聚糖络合及优化聚磷酸铵及氢氧化铝的用量,三者相互协同提高阻燃剂在聚氨酯热熔胶中的分散性,及提高聚氨酯热熔胶以及汽车顶棚复合布的阻燃性能。
选择硅酸镁铝及红外线吸收剂IR880配伍使用,设置氢硅酸镁铝与壳聚糖络合及优化硅酸镁铝及红外线吸收剂IR880的用量,三者相互协同提高光屏蔽剂在聚氨酯热熔胶中的分散性,及提高聚氨酯热熔胶以及汽车顶棚复合布的隔热性能。
第二方面,本申请提供一种汽车顶棚复合布的制备工艺,采用如下的技术方案:
一种汽车顶棚复合布的制备工艺,包括如下制备步骤:
聚氨酯热熔胶的制备:将乙酸乙酯溶剂、羟基物质、阻燃剂及光屏蔽剂混合均匀,在混合温度40-80℃、转速200r/min的条件下混合1h,然后加入异氰酸物质及二月桂酸二丁基锡,在反应温度65-90℃、搅拌转速300r/min的条件下反应8-14h制得聚氨酯热熔胶;
无纺布层的制备:无纺布层由阻燃涤纶纤维经热轧辊,在200±3℃,的条件下热压制得;基布层的制备:将阻燃涤纶短纤维及聚乙烯醇短纤维梳理成网后经过热轧辊热轧制备得到,所述热轧辊的温度为200±3℃;
隔热阻燃层的制备:在基布层上涂覆聚氨酯热熔胶,再将玻璃纤维铺设于聚氨酯热熔胶上,经热压后制备得到隔热阻燃层,热压温度为140-170℃;
汽车顶棚复合布的制备:将无纺布层、聚氨酯热熔胶及隔热阻燃层依次层叠设置,然后在140-170℃的条件下热压,制备得到的汽车顶棚复合布。
优选的,聚氨酯热熔胶的熔点为130-140℃。
通过采用上述技术方案,将无纺布层及隔热阻燃层通过聚氨酯热熔胶粘结复合,使得无纺布层及隔热阻燃层成为一个整体,增强无纺布层及隔热阻燃层之间的协同性能,使得汽车顶棚复合布具有优异的隔热、阻燃及力学性能。
优选的,所述隔热阻燃层的原料还包括预氧化纤维及隔热层;
隔热层制备:由黑色阻燃涤纶纤维及白色天丝纺织制得;
隔热阻燃层的制备:在基布层上涂覆聚氨酯热熔胶,再将预氧化纤维与玻璃纤维混合后铺设于聚氨酯热熔胶上,然后依次涂覆聚氨酯热熔胶及铺设隔热层后,经热压制备得到隔热阻燃层,热压温度为140-170℃;
所述汽车顶棚复合布还包括防紫外线层;
防紫外线层的制备:由抗紫外锦纶纤维为经纱,阻燃涤纶纤维为纬纱,经纺织制得;
汽车顶棚复合布的制备:将无纺布层、聚氨酯热熔胶、隔热阻燃层、聚氨酯热熔胶及防紫外线层依次层叠设置,然后在140-170℃的条件下热压,制备得到的汽车顶棚复合布。
通过采用上述技术方案,将无纺布层及隔热阻燃层通过聚氨酯热熔胶粘结复合,使得无纺布层及隔热阻燃层成为一个整体,增强无纺布层及隔热阻燃层之间的协同性能,使得汽车顶棚复合布具有优异的隔热、阻燃及力学性能。
可选的,所述隔热阻燃层中的预氧化纤维在汽车顶棚复合布使用之前,使用表面处理液对预氧化纤维进行表面处理,所述表面处理液中硫酸的质量百分比为20%,氯化铁的质量百分比为15%,处理温度为40℃。
通过采用上述技术方案,将预氧化纤维表面经过处理后,使得预氧化纤维表面的亲水基团增加,增强预氧化纤维与聚氨酯热熔胶之间的结合力,进而增强汽车顶棚复合布的隔热及力学性能。
综上所述,本申请具有以下有益效果:
1、一种汽车顶棚复合布为由无纺布层、聚氨酯热熔胶、隔热阻燃层、聚氨酯热熔胶及防紫外线层依次层叠设置,经热压后制备得到,其中,隔热阻燃层包括复合玻纤层、基布层及隔热层,聚氨酯热熔胶的制备原料包括异氰酸物质、羟基物质、阻燃剂及光屏蔽剂、有机溶剂及催化剂;通过聚氨酯热熔粘结使得汽车顶棚复合布的无纺布层、隔热阻燃层及防紫外线层成为一个整体,各层功能上彼此协同,使得汽车顶棚复合布具有优异的隔热及阻燃性能。
2、通过设置在聚氨酯热熔胶中通过无机阻燃剂搭配有机阻燃剂配伍使用,在隔热阻燃层中添加预氧化纤维与玻璃纤维配伍使用;通过在汽车顶棚复合布中设置无纺布层、隔热阻燃层及防紫外线层,使汽车顶棚复合布的各层之间功能上相辅相成,进而进一步增强汽车顶棚复合布的隔热及阻燃性能。
3、本申请通过壳聚糖络合无机阻燃剂及无机光屏蔽剂,改善了使得无机阻燃剂及无机光屏蔽剂在聚氨酯热熔胶的分散性,进一步优化汽车顶棚复合布的隔热及阻燃性能。
具体实施方式
聚四氢呋喃醚二醇(CAS:25190-06-1,分子量约为1000,纯度≥99.5%)、聚环氧丙烷醚二醇(CAS:9003-11-6,分子量约为3000,纯度≥99.5%)、聚乙二醇(CAS:25322-68-3,分子量约为800)、壳聚糖(CAS:9012-76-4,分子量约为1500)、二苯基甲烷二异氰酸酯(CAS:5101-68-8,分子量:366)、六亚甲基二异氰酸酯(CAS:822-06-0,分子量:168)、二甲基联苯二异氰酸酯(CAS:91-97-4,分子量:264)、二月桂酸二丁基锡(CAS:77-58-7、锡含量为:18.5土0.5%)、乙酸乙酯(CAS:141-78-6)、聚磷酸铵(CAS:68333-79-9、M>1000)、双氰胺(CAS:461-58-5)、硼酸锌(粒径为3μm-6μm)、氢氧化铝(粒径为3μm-6μm)、磷酸三苯酯(CAS:115-86-6)、红外线吸收剂IR880(型号:880)、硅酸镁铝(型号:HT-1、CAS:11097-59-9)、阻燃涤纶纤维(50D、氧指数约25,皮芯层结构,皮层的熔点为180±5℃,所述芯层的熔点为280±5℃)、阻燃涤纶短纤维(2.0D、38-55mm、氧指数约25、熔点为190℃-200℃)、预氧化纤维(1.5d*38)、聚乙烯醇短纤维(平均直径18μm,长8mm,熔点约170℃)、玻璃纤维(平均直径15μm、长度5mm)、预氧化纤维(直径8μm、长度5mm)、黑色阻燃涤纶纤维(50D、氧指数约25)、白色天丝(1.2D/40s)、抗紫外锦纶纤维(DTY、40D/24F、UPF≥40)、抗紫外涤纶纤维(DTY、40D/24F、UPF≥40)。
实施例
制备例1
一种聚氨酯热熔胶:
一种聚氨酯热熔胶的制备中使用的原料成分如表1和表2,制备工艺如下:
将乙酸乙酯溶剂1.5L、羟基物质、阻燃剂及光屏蔽剂在混合温度70℃、转速200r/min的条件下混合1h,然后加入异氰酸物质及二月桂酸二丁基锡,在反应温度60℃、搅拌转速300r/min的条件下反应10h制得聚氨酯热熔胶,制备得到的聚氨酯热熔胶固化后热熔温度为130℃。
制备例2-5
一种聚氨酯热熔胶,与制备例1的区别在于,使用的反应原料、阻燃剂及光屏蔽剂的种类、重量、制备工艺参数及聚氨酯热熔胶的重量及厚度设置不同,具体如表1、表2及表3所示:
表1制备例1-5聚氨酯热熔胶使用的反应原料的种类及重量设置列表
表2制备例1-5聚氨酯热熔胶膜中阻燃剂及光屏蔽剂的种类及重量设置列表
表3制备例1-5聚氨酯热熔胶的制备工艺参数设置列表
制备例6-9
一种聚氨酯热熔胶,与制备例2的区别在于,阻燃剂中聚磷酸铵及氢氧化铝重量比设置不同,具体如表4所示:
表4制备例6-9及制备例2的聚磷酸铵与氢氧化铝的重量设置列表
制备例10-13
一种聚氨酯热熔胶,与制备例2的区别在于,光屏蔽剂中红外线吸收剂IR880及硅酸镁铝重量比设置不同,具体如表5所示:
表5制备例10-13及制备例2的光屏蔽剂中红外线吸收剂IR880及硅酸镁铝的重量设置列表
实施例1
一种汽车顶棚复合布,使用的原料成分如表6,制备步骤如下:
无纺布层的制备:无纺布层由阻燃涤纶纤维经200±3℃,热轧辊的压力75±3Pa的条件下热压制得。
其中,制备无纺布层的阻燃涤纶纤维具有皮芯层结构,皮层的熔点为180±5℃,所述芯层的熔点为280±5℃。
基布层的制备:将阻燃涤纶短纤维及聚乙烯醇短纤维梳理成网,形成网面的纤维经过热轧辊,使纤维熔融并相互联结形成无纺布待用,热轧辊的温度为200±3℃,热轧辊的压力75Pa。
其中,制备基布层的阻燃涤纶短纤维包括皮层结构及芯层结构,皮层结构及芯层结构的质量比为(1-3):1,皮层结构的熔点为180±5℃,所述芯层结构的熔点为280±5℃。
隔热层的制备:由黑色阻燃涤纶纤维及白色天丝纺织制得。
隔热阻燃层的制备:在基布层上涂覆聚氨酯热熔胶,再将玻璃纤维与预氧化纤维混合后涂覆在基布层上,然后依次涂覆聚氨酯热熔胶与隔热层,在五辊烫平机上进行热压,制备得到隔热阻燃层,热压温度160℃。
防紫外线层的制备:以抗紫外锦纶纤维为经纱,阻燃涤纶纤维为纬纱经纺织制得。
汽车顶棚复合布的制备:无纺布层、聚氨酯热熔胶、隔热阻燃层、聚氨酯热熔胶及防紫外线层依次层叠设置,然后在五辊烫平机上在160℃的条件下热压、复合得到汽车顶棚复合布,制备得到的汽车顶棚复合布中聚氨酯热熔胶用量70g/m3。
其中,实施例1使用制备例1制备的聚氨酯热熔胶。
实施例2-5
一种汽车顶棚复合布,与实施例1的区别在于汽车顶棚复合布中无纺布层、隔热阻燃层及防紫外线层的重量设置不同,具体如表6;隔热阻燃层中基布层、复合玻纤层及隔热层的重量设置不同,具体表7;无纺布层、基布层、复合玻纤层、隔热层、防紫外线层中组成纤维、及热压温度设置不同,具体表8所示:
表6实施例1-5汽车顶棚复合布中无纺布层、隔热阻燃层及防紫外线层的重量设置列表
表7实施例1-5隔热阻燃层中基布层、复合玻纤层及隔热层的重量设置列表
表8实施例1-5无纺布层、基布层、复合玻纤层、隔热层、防紫外线层中组成纤维、及热压温度设置列表
实施例1-5中,质量比(1)为无纺布层中阻燃涤纶纤维的芯层与皮层的质量比;质量比(2)为基布层中阻燃涤纶短纤维与聚乙烯醇纤维的质量比;质量比(3)为复合玻纤层中玻璃纤维及预氧化纤维的质量比;质量比(4)为隔热层中黑色阻燃涤纶纤维及白色天丝的质量比;质量比(5)为防紫外线层中抗紫外锦纶纤维及阻燃涤纶纤维的质量比;质量比(6)为汽车顶棚复合布中无纺布层、隔热阻燃层及防紫外线层的质量比;质量比(7)为隔热阻燃层的基布层、复合玻纤层及隔热层的质量比。
实施例6
一种汽车顶棚复合布,与实施例1的区别在于,隔热阻燃层中的预氧化纤维在进行汽车顶棚复合布复合之前,使用表面处理液对预氧化纤维进行表面处理,表面处理液由硫酸、氯化铁及水组成的混合液,表面处理液中硫酸的质量百分比为20%,氯化铁的质量百分比为15%,处理温度为40℃,浴比为6:1,处理时间为5h。
实施例7-18
一种汽车顶棚复合布,与实施例1的区别在于,采光用汽车顶棚复合布制备中,依次采用制备例2-13制得的聚氨酯热熔胶。
实施例19-22
一种汽车顶棚复合布,与实施例1的区别在于,汽车顶棚复合布中聚氨酯热熔胶用量设置不同,具体如表9所示:
表9实施例19-22及实施例1的汽车顶棚复合布中聚氨酯热熔胶用量设置列表
区分 | 实施例1 | 实施例19 | 实施例20 | 实施例21 | 实施例22 |
聚氨酯热熔胶用量g/m3 | 70 | 50 | 60 | 80 | 90 |
实施例23
一种汽车顶棚复合布,与实施例1的区别在于:汽车顶棚复合布不包括预氧化纤维,汽车顶棚复合布不包括隔热层及防紫外线层。
对比例24
一种汽车顶棚复合布,与实施例1的区别在于:聚氨酯热熔胶中不采用无机燃剂、无机光屏蔽剂及壳聚糖。
对比例
对比例1
一种汽车顶棚复合布,与实施例23的区别在于:聚氨酯热熔胶中不采用阻燃剂及光屏蔽剂。
对比例2
一种汽车顶棚复合布,与实施例23的区别在于:聚氨酯热熔胶中不采用有壳聚糖。
对比例3
一种汽车顶棚复合布,与实施例23的区别在于:汽车顶棚复合布不设置玻璃纤维。
对比例4
一种汽车顶棚复合布,与实施例23的区别在于:无纺布层中阻燃涤纶纤维不设置皮层结构;基布层中阻燃涤纶短纤维等量代替聚乙烯醇纤维。
性能检测试验
1.隔热性能:参照GB/T10294-2008对实施例1-24及对比例1-3的导热系数进行测定,测试样品为5个,取测试平均值,测试结果如表10所示。
2.极限氧指数:按照GB/T5454-1997《纺织品燃烧性能试验氧指数法》,采用氧指数测定仪对实施例1-24及对比例1-3的极限氧指数进行测试,测试结果如表10所示。
表10实施例1-24及对比例1-3的导热系数及极限氧指数测试结果列表
结合实施例1-24及对比例1-3并结合表10可以看出:
实施例1-24的导热系数在0.036-0.1W/(m·℃)范围低于对比例1-3导热系数0.18-0.3W/(m·℃),表明本申请汽车顶棚复合布中无纺布层、隔热阻燃层及防紫外线层之间功能相互协同,使得汽车顶棚复合布具有优异的隔热性能。可能是因为汽车顶棚复合布中设置有无纺布层、隔热阻燃层及防紫外线层,隔热阻燃层中包括基布层、复合玻纤层及隔热层,汽车顶棚复合布中的各层功能相互协同作用相辅相成,使得进入汽车顶棚复合布中的红外线经几次被反射及被吸收,使得汽车顶棚复合布具有优异的隔热效果,进一步汽车顶棚复合布中防紫外线层吸收汽车乘坐室内的紫外线,降低乘坐室内紫外线带来的温度上升及提升乘坐的舒适感。
实施例1-5、实施例7、实施例15-18及实施例24表明,有机光屏蔽剂及无机光屏蔽剂搭配使用时汽车顶棚复合布的隔热效果较好;
实施例15-18及实施例7实验数据可以看出,随着红外线吸收剂IR880及硅酸镁铝质量比增大时,汽车顶棚复合布的隔热效果先增大后减小,表明当红外线吸收剂IR880及硅酸镁铝的质量比为0.8:1时,红外线吸收剂IR880及硅酸镁铝的复配效果较好。
实施例11-14的隔热效果有上升趋势可能是随着阻燃剂中的氢氧化铝的占比减少,壳聚糖为定量的情况下,光屏蔽剂中的无机光屏蔽剂的分散性有提升,导致汽车顶棚复合布的隔热效果有上升趋势。
实施例1-24的极限氧指数在32%-38%范围高于对比例1-3极限氧指数25%-28%,表明汽车顶棚复合布中无纺布层、隔热阻燃层及防紫外线层之间功能相互协同,使得汽车顶棚复合布具有优异的阻燃性能。可能是因为汽车顶棚复合布中玻璃玻璃纤维、预氧化纤维的隔热效果与阻燃涤轮纤维及聚氨酯热熔胶中阻燃剂的阻燃效果相辅相成,使得汽车顶棚复合布具有优异的阻燃效果。
实施例11-14及实施例7实验数据可以看出,随着聚磷酸铵与氢氧化铝质量比增大时,汽车顶棚复合布的阻燃效果先增大后减小,表明当聚磷酸铵与氢氧化铝的质量比为1.2:1时,聚磷酸铵与氢氧化铝的复配效果较好。
实施例15-18的隔热效果有上升趋势可能是随着光屏蔽剂中的硅酸镁铝的占比减少,壳聚糖为定量的情况下,阻燃剂中的无机阻燃剂的分散性有提升,导致汽车顶棚复合布的阻燃效果有上升趋势。
3.剥离强度测试:参照GB/T2792-1998采用剥离强度试验机对实施例1、实施例6-10、实施例19-23及对比例4制备得到的汽车顶棚复合布进行剥离强度测试,测试结果如表11所示。
表11实施例1、实施例6-10、实施例19-23及对比例4制备得到的汽车顶棚复合布的剥离强度测试结果列表
区分 | 剥离强度(N/cm) | 区分 | 剥离强度(N/cm) |
实施例1 | 7.1 | 实施例19 | 6.7 |
实施例6 | 7.4 | 实施例20 | 6.9 |
实施例7 | 7.4 | 实施例21 | 7.1 |
实施例8 | 7.2 | 实施例22 | 7.1 |
实施例9 | 7.1 | 实施例23 | 6.9 |
实施例10 | 6.9 | 对比例4 | 5.5 |
结合实施例1、实施例7-10及对比例4并结合表11可以看出:
实施例1、实施例7-10及实施例19-23有较高的剥离强度6.7-7.4N/cm,可能是因为聚氨酯热熔胶的合成过程中选用含较多醚键的羟基物质,以及聚氨酯热熔胶中异氰酸基团与羟基物质的羟基基团合理的摩尔比,增强了聚氨酯热熔胶与汽车顶棚复合布各层之间的剥离强度,进而提升汽车顶棚复合布的剥离强度。
实施例23、实施例7-10的剥离强度在6.9-7.1N/cm范围高于对比例4的剥离强度5.5/cm,可能是因为本申请中,基布层中的聚乙烯醇纤维及防紫外线层中的抗紫外锦纶纤维与聚氨酯热熔胶有较强的作用力,增强了聚氨酯热熔胶与汽车顶棚复合布各层之间的剥离强度,进而提升汽车顶棚复合布的剥离强度。
从实施例19-23及实施例1可以看出,聚氨酯热熔胶用量50-90g/m3范围内,汽车顶棚复合布的剥离强度先增大后基本不变,可能是因为当聚氨酯热熔胶用量50-60g/m3,时,聚氨酯热熔胶用量较少与汽车顶棚复合布的各层之间接触不充分或聚氨酯热熔胶中的基团与纺布汽车顶棚复合布的各层上含有的羟基反应不足,导致剥离强度较低;当聚氨酯热熔胶用量90g/m3,时,聚氨酯热熔胶较厚,胶层之间的内聚力增大,聚氨酯热熔胶与汽车顶棚复合布各层之间的结合力减弱,使得汽车顶棚复合布的剥离强度略有下降。
本具体实施例仅仅是对本申请的解释,其并不是对本申请的限制,本领域技术人员在阅读完本说明书后可以根据需要对本实施例做出没有创造性贡献的修改,但只要在本申请的权利要求范围内都受到专利法的保护。
Claims (10)
1.一种汽车顶棚复合布,其特征在于,包括质量比为1:(2-7)的无纺布层及隔热阻燃层;
所述无纺布层由阻燃涤纶纤维经热压制备得到,所述阻燃涤纶纤维具有皮芯结构,所述芯层与皮层的质量比为(0.5-2.5):1;
所述隔热阻燃层的原料包括质量比为2:(1-5)的基布层及玻璃纤维,所述基布层是由质量比为(3.5-9):1的阻燃涤纶短纤维与聚乙烯醇纤维热压制备得到,所述玻璃纤维通过聚氨酯热熔胶复合于基布层上,制备得到隔热阻燃层;
所述无纺布层通过聚氨酯热熔胶复合于隔热阻燃层的基布层上,制备得到汽车顶棚复合布,所述汽车顶棚复合布中聚氨酯热熔胶的用量为50-90g/m3;
所述聚氨酯热熔胶的原料包括异氰酸物质、羟基物质、阻燃剂、光屏蔽剂、有机溶剂及催化剂;
所述聚氨酯热熔胶的制备步骤如下:
将异氰酸物质及催化剂加入羟基物质、阻燃剂、光屏蔽剂及有机溶剂组成的混合物中,反应后制备得到聚氨酯热熔胶,所述羟基物质为二元醇及壳聚糖的混合物,有机溶剂为乙酸乙酯,催化剂为二月桂酸二丁基锡。
2.根据权利要求1所述的一种汽车顶棚复合布,其特征在于,所述隔热阻燃层的原料还包括预氧化纤维及隔热层;
所述预氧化纤维与玻璃纤维的质量比为(0.5-0.9):1,所述预氧化纤维与玻璃纤维混合后经聚氨酯热熔胶复合于基布层上形成复合玻纤层;
所述隔热层经聚氨酯热熔胶复合于隔热阻燃层的基布层上;所述隔热层由质量比为(2-3):1的黑色阻燃涤纶纤维及白色天丝纺织制得;
所述隔热阻燃层中基布层、复合玻纤层及隔热层的质量比2:(1-5):1。
3.根据权利要求2所述的一种汽车顶棚复合布,其特征在于,所述汽车顶棚复合布还包括防紫外线层,所述防紫外线层经聚氨酯热熔胶复合于隔热阻燃层的隔热层上;所述防紫外线层为由质量比为(1-4):1的抗紫外锦纶纤维及阻燃涤纶纤维纺织制得;
所述无纺布层、隔热阻燃层及防紫外线层的质量比为1:(2-7):1。
4.根据权利要求1所述的一种汽车顶棚复合布,其特征在于,所述二元醇为聚四氢呋喃醚二醇及聚环氧丙烷醚二醇中的一种或两种的混合物,所述羟基物质中壳聚糖与二元醇的摩尔比为(0.1-0.3):1。
5.根据权利要求4所述的一种汽车顶棚复合布,其特征在于,所述异氰酸物质为二苯基甲烷二异氰酸酯或六亚甲基二异氰酸酯,所述异氰酸物质与二元醇的摩尔比为(2-5):1。
6.根据权利要求1所述的一种汽车顶棚复合布,其特征在于,所述阻燃剂为聚磷酸铵、双氰胺、硼酸锌及氢氧化铝中至少一种;所述光屏蔽剂为硅酸镁铝、红外线吸收剂IR880中至少一种;所述聚氨酯热熔胶中阻燃剂的质量占比为4-12%,所述聚氨酯热熔胶中光屏蔽剂的质量占比为3-10%。
7.根据权利要求6所述的一种汽车顶棚复合布,其特征在于,所述阻燃剂由质量比为(0.5-1.6):1的聚磷酸铵及氢氧化铝组成;所述光屏蔽剂由质量比为(0.4-1.2):1的硅酸镁铝及红外线吸收剂IR880组成。
8.权利要求1-7任一项所述的一种汽车顶棚复合布的制备工艺,其特征在于,制备步骤如下:
聚氨酯热熔胶的制备:将乙酸乙酯溶剂、羟基物质、阻燃剂及光屏蔽剂混合均匀,在混合温度40-80℃、转速200r/min的条件下混合1h,然后加入异氰酸物质及二月桂酸二丁基锡,在反应温度65-90℃、搅拌转速300r/min的条件下反应8-14h制得聚氨酯热熔胶;
无纺布层的制备:无纺布层由阻燃涤纶纤维经热轧辊,在200±3℃,的条件下热压制得;
基布层的制备:将阻燃涤纶短纤维及聚乙烯醇短纤维梳理成网后经过热轧辊热轧制备得到,所述热轧辊的温度为200±3℃;
隔热阻燃层的制备:在基布层上涂覆聚氨酯热熔胶,再将玻璃纤维铺设于聚氨酯热熔胶上,经热压后制备得到隔热阻燃层,热压温度为140-170℃;
汽车顶棚复合布的制备:将无纺布层、聚氨酯热熔胶及隔热阻燃层依次层叠设置,然后在140-170℃的条件下热压,制备得到的汽车顶棚复合布。
9.权利要求8所述的一种汽车顶棚复合布的制备工艺,其特征在于,制备步骤如下:
所述隔热阻燃层的原料还包括预氧化纤维及隔热层;
隔热层制备:由黑色阻燃涤纶纤维及白色天丝纺织制得;
隔热阻燃层的制备:在基布层上涂覆聚氨酯热熔胶,再将预氧化纤维与玻璃纤维混合后铺设于聚氨酯热熔胶上,然后依次涂覆聚氨酯热熔胶及铺设隔热层后,经热压制备得到隔热阻燃层,热压温度为140-170℃;
所述汽车顶棚复合布还包括防紫外线层;
防紫外线层的制备:以抗紫外锦纶纤维为经纱,阻燃涤纶纤维为纬纱,经纺织制得;
汽车顶棚复合布的制备:将无纺布层、聚氨酯热熔胶、隔热阻燃层、聚氨酯热熔胶及防紫外线层依次层叠设置,然后在140-170℃的条件下热压,制备得到的汽车顶棚复合布。
10.根据权利要求8所述的一种汽车顶棚复合布的制备工艺,其特征在于,所述隔热阻燃层中的预氧化纤维在汽车顶棚复合布使用之前,使用表面处理液对预氧化纤维进行表面处理,所述表面处理液中硫酸的质量百分比为20%,氯化铁的质量百分比为15%,处理温度为40℃。
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