CN1245286C - 多层产品，它在生产轻质、隔音、自支撑制品中的应用以及用所述多层产品获得的制品 - Google Patents

多层产品，它在生产轻质、隔音、自支撑制品中的应用以及用所述多层产品获得的制品 Download PDF

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CN1245286C
CN1245286C CNB011357908A CN01135790A CN1245286C CN 1245286 C CN1245286 C CN 1245286C CN B011357908 A CNB011357908 A CN B011357908A CN 01135790 A CN01135790 A CN 01135790A CN 1245286 C CN1245286 C CN 1245286C
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spongy
rigid polymer
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G·迪桑特
P·德阿姆布罗希奥
M·比吉奥
C·斯普莱达
C·迪多米尼科
G·吉尔瓦奈里
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SOUTH INDUSTRY JOINT SpA
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Abstract

本发明涉及一种多层产品，它包含：第一构件，该构件包含一层海绵状、半刚性聚合物(A)，它的一面或两面被浸渍了聚氨酯树脂(B)，被夹在两层玻璃纤维和/或天然纤维(C)之间，与中央层(B)(A)(B)连续结合，所述第一构件与至少一个第二构件结合，该第二构件包含一层海绵状、半刚性聚合物(A)，它的一面或两面被浸渍了聚氨酯树脂(B)，所述第二构件又与另一层玻璃纤维和/或天然纤维(C)结合。

Description

多层产品，它在生产轻质、隔音、自支撑制品中的应用 以及用所述多层产品获得的制品
本发明涉及一种多层产品(称为“Multipur”)，它在生产轻质、隔音、自支撑制品中的应用以及用所述多层产品获得的制品。
本发明的多层产品典型的应用可用车辆内部的所有衬里和装配部件(lining and fitting elements)来代表，例如，驾驶室顶板的自支撑衬板，或者很简单的驾驶室，门板，后架，行李箱或窗口后门衬板，门窗侧壁盖，遮阳板，以及通常车辆内部的所有衬里和装配部件，对它们来说必须满足一定的要求，例如，轻便，自支撑性能(即，支承它自己的重量，不需支撑结构)，隔音和/或柔韧性。
用于通过热模塑法生产制品(特别是车辆内部的所有衬里和装配部件)的轻质材料是文献中已知的。供上述应用的一种已知的材料(轻质和可模塑的)例如由“夹心式”产品构成，该夹心产品包含：一层聚氨酯，它被夹在两层浸渍了聚氨酯树脂的玻璃纤维和/或天然纤维之间；两层玻璃纤维和树脂(也称为“垫层”)与包含聚氨酯的中央层连续结合。在玻璃纤维和/或天然纤维和树脂层的外侧，还可存在其它轻质材料、胶或其它织物层：这样获得的夹心式结构的片接着被热模塑而得所需的构件。
具体地说，浸渍了热敏聚氨酯树脂的玻璃纤维和/或天然纤维在聚氨酯层的两面连续结合，导致所谓的夹心结构的形成。
这样获得的夹心结构(任选还与轻质织物和/或其它材料的其它层结合)被送到热模具而生产所需的制品。
这样获得的产品(虽然它具有良好的轻便性、自支撑性和隔音性)阐明了特性的一致。这表明，在经历热模塑处理的结构的每一点，它都具有相似的轻便性、隔音性和自支撑性。
这导致车辆内部一些需要具有更坚硬的区、最小的厚度以及任意厚度下刚性更小的区的部位不适当的顺应性。此外，有一些区特别需要隔音，而一些区却不太需要这个特性。
此外，随着供应技术的改善，车辆生产商要求供应的产品(已经预装配了)具有另外的部件，例如手柄、遮阳板、光板等；在这些情况下，用文献中的已知方法获得的传统产品具有与运动破裂相关的不可忽视的问题，这是由于它们有限的机械强度所致。
本发明的目的是发现一种产品，它能克服现有技术中的缺点，尤其是获得一种制品：其中，存在特别坚硬的区，还有仍然柔韧的区。
本申请人意外地发现了，通过应用一种特定类型的多层产品，有可能生产具有不同物理化学特性的区的构件。
就汽车驾驶室来说，例如，本发明的多层产品使得能生产一种制品：其中，侧面部分是柔性的而且能逐出位于顶部和驾驶室衬板之间的空气囊，而中央部分特别坚硬，能放置光板、开关、遮阳板等。
因此，本发明的目的涉及一种多层产品，它包含：一个第一构件，该第一构件包含一层海绵状、半刚性聚合物(A)，它的一面或两面被浸渍了聚氨酯树脂(B)，并且被夹在两层玻璃纤维和/或天然纤维(C)之间，与中央层(B)(A)(B)连续结合，所述第一构件的特征在于，它与至少一个第二构件结合，该第二构件包含一层海绵状、半刚性聚合物(A)，它的一面或两面被浸渍了聚氨酯树脂(B)，所述第二构件又与另一层玻璃纤维和/或天然纤维(C)结合。
所以，本发明的多层结构具有(B)(A)(B)(C)(B)(A)(B)结构，其中，A、B和C具有上文规定的含义，而且其中，可将包含(A)、(B)和(C)层的其它构件加到该结构的外侧，具有上述交错形式(alternation)，和/或具有不同的交错形式。
具体地说，在这样获得的多层产品中，所述海绵状、半刚性聚合物可选自聚氨酯、聚苯乙烯、聚酯。
所述海绵状、半刚性聚合物优选是聚氨酯。
甚至更优选的是，通过多元醇和异氰酸酯之间的反应获得的、密度为20～40kg/m3的聚氨酯。
形成(A)层的聚合物可以在所有的(A)层中都相同，或者各个(A)层可用具有不同密度和不同厚度的聚合物生产。
玻璃纤维还可被另一种天然纤维(例如黄麻、剑麻、椰纤维或其它相当的材料)替代。
本发明的多层产品的结构(C)(B)(A)(B)(C)(B)(A)(B)(C)包含结合到所述结合构件的两外侧的轻质织物和/或覆盖性绒头织物(covering fleece)(D)，于是获得具有如下结构的产品：(D)(C)(B)(A)(B)(C)(B)(A)(B)(C)(D)。
这样获得的多层产品还可包括在夹心结构(即，已经结合的构件)的两外侧或者只在其中的一侧贴合衬里织物、抗振材料层等。
(A)层的厚度可在4～18mm、优选5～7mm之间变化。
(A)层的厚度甚至更优选等于6mm。
本发明的多层产品中存在的各个海绵状、半刚性聚合物层(A)可具有相同的厚度或不同的厚度。
本发明的又一目的涉及本发明的多层产品在生产轻质、自支撑隔音制品中的应用。
本发明还涉及通过本发明多层产品的热模塑方法获得的轻质、自支撑隔音制品。
具体地说，这些制品是车辆内部的衬里或装配部件。
本发明还涉及一种加工多层产品的方法，所述方法特征在于，在多层产品的不同区施加不同的压力密度(pressure concentration)，于是获得具有不同的抗压强度、柔韧性和隔音性的区。
本发明的多层产品的主要优点在于，它能生产制品(特别是车辆内部的所有衬里和装配部件)，这些制品具有不同的柔韧性和抗弯强度性能(由终产品的不同区而定)。
参照附图，从下文详细的阐释性描述可以更清楚地理解本发明的多层产品的特征和优点。
对附图的描述：
图1表示现有技术产品的实施方案的剖视图。
图2表示本发明的多层产品的实施方案的剖视图。
图3、4和5表示本发明的多层产品的其它实施方案的剖视图。
具体地说，在图1中，1指示海绵状、半刚性聚合物层(A)，它被夹在两层树脂2和2′(B)以及玻璃纤维3和3′(C)之间。4和4′指示轻质织物层或绒头织物层(D)，而5则指示胶层(E)，6指示衬里材料(F)。
图2表示本发明的多层产品的实施方案的剖视图，其中，形成多层结构的各层如下：7是外部衬层材料(F)，8表示胶(E)，9和9′是两层轻质织物或绒头织物层(D)，10、10′和10″表示玻璃纤维或黄麻层(C)，11、11′、11″和11表示树脂层(B)，而12和12′则表示聚氨酯层(A)。
按本发明方法的一个实施方案，采用了如下方法：第一步制备形成所述多层产品的海绵状、半刚性聚合物层的聚氨酯。然后将聚氨酯片送到一个设备，在那里将聚氨酯片与第一层热固性聚氨酯树脂结合，接着敷贴基于玻璃纤维和/或天然纤维的增强纤维。玻璃纤维和/或天然纤维/树脂/聚氨酯片层的这种结合对聚氨酯片的上、下两侧都进行。然后在第二张聚氨酯片上涂一层树脂，随后将该聚氨酯片附着在上述叠板的上侧或下侧。接着在所述叠板的自由侧附着新的一层玻璃纤维和/或天然纤维。
根据终产品所需的层数可重复多次第二构件的附着，即，通过夹入一个或多个图4和5的结构的平板(plane)或构件。
具体地说，图4表示一个双面增强的平板或构件，即，一个这样的平板：它在构件(B)(A)(B)的两面都存在增强纤维层(C)。另一方面，图5却表示一个单面增强的平板或构件，其中，只在构件(B)(A)(B)的一侧存在增强纤维层(C)。
如下所述，然后敷贴保护性绒头织物和/或衬里材料(具有或没有已经结合的海绵状物)。
还可能获得一种这样的制品：其中，多层产品在片的不同部位具有不同的层数，因为第二构件的敷贴只能在片的局部实现。
还可能在一步中操作，在该情况下，图2的绒头织物(9D)和胶(8E)都省去了，获得图3中所示的结构。
在该情况下，也可能如图4和/或图5中那样嵌入不同的层。
将这样获得的多层片输送到90℃～180℃之间的热模具，于是使聚氨酯树脂活化而获得多层产品，然后将它在连续的或半自动的系统中两面结合织物和/或绒头织物。最后，在上侧贴合一层胶和外部衬里材料。将这样获得的多层产品片送到相关的成型模具中，在此利用热模塑处理获得所需的终产品。
本发明的多层产品的主要优点是，它能生产制品(特别是车辆内部的所有衬里和装配部件)，它们根据终产品自身的各个区而定具有不同的柔韧性和抗弯强度特性。
本发明的多层产品的进一步优点是，它特别轻，即使如此，但它还保持高的机械阻力。
本发明产品的其它优点涉及多层产品的通用性，从而有可能生产这样的终产品：具有不同的厚度、几何形状等，具有优异的美观效果、良好的隔音效果和有限的成本。
本发明的产品还使得能获得这样的制品：其特征在于，所要求的区中的自支撑性能致使可贴合光板、按钮等而无需任何支撑构件。
本发明产品的又一个优点是，它还可通过调节所述结构的不同部分的隔音性而获得。
按本发明获得的板的衬里织物可与海绵状物结合，或者可与海绵状物和绒头织物和/或保护膜结合，或者被树脂覆盖；还可能应用具有塑料打光的产品(也与不同的增强材料和/或支撑物结合了)的衬里。

Claims (20)

1.一种多层产品，它包含：一个第一构件，该第一构件包含一层海绵状、半刚性聚合物(A)，它的一面或两面被浸渍了聚氨酯树脂(B)，被夹在两层玻璃纤维和/或天然纤维(C)之间，与中央层(B)(A)(B)连续结合，所述第一构件的特征在于，它与至少一个第二构件结合，该第二构件包含一层海绵状、半刚性聚合物(A)，它的一面或两面被浸渍了聚氨酯树脂(B)，所述第二构件又与另一层玻璃纤维和/或天然纤维(C)结合。
2.权利要求1的多层产品，其特征在于，它具有(B)(A)(B)(C)(B)(A)(B)结构，其中，A、B和C具有上文规定的含义，而且其中，可将包含(A)、(B)和(C)层的其它构件加到该结构的外侧，具有上述交错形式，和/或具有不同的交错形式。
3.权利要求1的多层产品，其特征在于，所述海绵状、半刚性聚合物选自聚氨酯、聚苯乙烯和聚酯。
4.权利要求1的多层产品，其特征在于，所述海绵状、半刚性聚合物是聚氨酯。
5.权利要求1的多层产品，其特征在于，所述海绵状、半刚性聚合物是密度在20～40kg/m3范围内的聚氨酯。
6.权利要求1的多层产品，其特征在于，形成(A)层的所述海绵状、半刚性聚合物在所有的(A)层中是相同的聚合物。
7.权利要求1的多层产品，其特征在于，形成(A)层的所述海绵状、半刚性聚合物在不同的(A)层中是具有不同密度的聚合物。
8.权利要求1的多层产品，其特征在于，所述玻璃纤维可被黄麻、剑麻、椰纤维或其它相当的天然材料替代。
9.权利要求1的多层产品，其特征在于，它包含结合到所述结合构件的两外侧的轻质织物和/或覆盖性绒头织物(D)层，于是获得具有结构(D)(C)(B)(A)(B)(C)(B)(A)(B)(C)(D)的产品。
10.权利要求1的多层产品，其特征在于，它包括在夹心结构-即，已经结合的构件-的两外侧或者只在其中的一侧贴合衬里织物、抗振材料层等。
11.权利要求1的多层产品，其特征在于，(A)层的厚度在4～18mm之间变化。
12.权利要求1的多层产品，其特征在于，(A)层的厚度在5～7mm之间变化。
13.权利要求1的多层产品，其特征在于，(A)层的厚度等于6mm。
14.权利要求1的多层产品，其特征在于，海绵状、半刚性聚合物的各个层(A)具有相同的厚度。
15.权利要求1的多层产品，其特征在于，海绵状、半刚性聚合物的各个层(A)具有不同的厚度。
16.前述权利要求任一项的多层产品在生产轻质、自支撑、隔音制品中的应用。
17.前述权利要求任一项的多层产品在生产用于车辆内部的衬里和装配部件中的应用。
18.通过权利要求1～15任一项的多层产品的热模塑获得的轻质、自支撑、隔音制品。
19.权利要求18的制品，其特征在于，它们是车辆内部的衬里和装配部件。
20.一种加工权利要求1～15任一项的多层产品的方法，所述方法特征在于，在该多层产品的不同区施加不同的压力密度，于是获得具有不同的抗压强度、柔韧性和隔音性的区。
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