CN1367733A - 生产具有夹心结构的汽车内饰材料的方法 - Google Patents
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Abstract
本发明旨在生产轻质而尺寸稳定性优良的汽车内饰基材,如汽车用顶棚材料或车门修饰材料。采用一种生产具有夹心结构的汽车内饰材料的方法,它包括下列步骤:(I)层叠聚氨酯泡沫、植物纤维和热固性粘合剂,以及,任选的,一层表面装饰皮层和/或一层防止粘合剂渗漏的薄膜,(II)将上述层合物装入温度为80-150℃的模具内,合模以固化粘合剂,以及(III)在粘合剂固化后,脱模该模塑制品,其特征在于将植物纤维的尺寸调节到直径至多为1.0mm以及长度为10mm-100mm。
Description
本发明涉及一种生产轻质而尺寸稳定性优良的汽车内饰基材,如汽车用顶棚材料或车门修饰材料的方法,并涉及一种具有夹心结构、能用作汽车内饰基材的层压板。
作为生产具有夹心结构的汽车内饰基材的一种技术,曾提出过下述一种生产模塑产品的方法:在其中,异氰酸酯浸渍在软质聚氨酯泡沫或硬质聚氨酯泡沫中;在其中加入水和氨酯化催化剂;且两面都用玻璃毡增强(日本专利公开出版号63-7577(7577/1988),题目是“生产轻质和硬质或半硬复合材料板的方法”)
进一步,还曾提出过一种将常温下可模塑的有开孔的聚氨酯泡沫夹在已带有粘合剂的两层玻璃毡之间并使之热成型的方法(日本专利公开出版号04-211416(211416/1992),题目是“在常温下生产可模塑的有开孔的硬质聚氨酯泡沫的方法以及它用于生产模塑制品的用途”)。在所有这类方法中,用玻璃纤维作为增强材料。这类玻璃纤维,虽然增强效果非常出色,但很贵且对操作者的皮肤有刺激性,而且废弃时不可燃烧,因此它们的处理就成了大问题。
已经有一种用加捻大麻制成的编织纤维织成的、网眼尺寸为2-3mm的织造织物用作增强材料的实例(Opel:Vectra等)。但是,如果用织造织物作增强材料,则在受拉成型部分会出现皱折,因为它不能自由地膨胀或收缩。而且,由于粘合剂不易浸进加捻纤维的内部,所以固化不足且表面易出现不均匀性。
为获得不用玻璃纤维作增强材料、容易回收、质轻价廉的模塑产品而进行深入研究的结果,我们发现,可充分利用木纤维、竹纤维、短切大麻和短切槿麻等植物纤维来代替玻璃纤维。
此外,我们已发现,如果将植物纤维切成合适的长度且与粘合剂混合并均匀地分布在聚氨酯泡沫上,则在成本与效果方面是有利的。
本发明提供一种生产具有夹心结构的汽车内饰材料的方法,它包括下列步骤:
(I)叠合下列各层:
(a)一层密度为20-100kg/m3的有开孔的可热成型聚氨酯泡沫,
(b)置于所述聚氨酯泡沫(a)两个主要表面的100g/m2-300g/m2的植物纤维。
(c)在聚氨酯泡沫(a)与植物纤维(b)之间形成粘结以及在植物纤维(b)彼此之间形成粘结的热固性粘合剂,以及任选的
(d)一层表面装饰皮层和/或一层防止粘合剂渗漏的薄膜。
(II)将上述层合材料装入温度为80-150℃的模具内,合模以固化粘合剂,以及
(III)粘合剂固化后,脱模该模塑制品,其特征在于,植物纤维的尺寸被调节到直径至多为1.0mm,长度为10mm-100mm。
本发明还提供一种层压板,它包含
(A)由可热成型的、密度为20-100kg/m3的有开孔的聚氨酯泡沫组成的一层;和
(B)由100g/m2-300g/m2的植物纤维和热固性粘合剂组成的多层,(A)层夹在两个(B)层之间,
其中,植物纤维的直径至多为1.0mm,长度为10mm-100mm。
优选层压板满足下列条件:聚氨酯泡沫是一种硬质聚氨酯泡沫;热固性粘合剂是一种包含芳族多异氰酸酯、水、催化剂和,任选的多元醇的粘合剂;以及植物纤维是大麻、槿麻、剑麻纤维,竹纤维和木纤维经短切或研磨所得到的那些纤维。
可热成型的有开孔的聚氨酯泡沫的密度可以是20-100kg/m3,例如,25-40kg/m3,特别是25-35kg/m3。
优选聚氨酯泡沫是硬质聚氨酯泡沫。
硬质聚氨酯泡沫是一种使多异氰酸酯组分与多元醇组分反应获得的泡沫。
多元醇组分可包含多元醇、催化剂、发泡剂以及任选的阻燃剂、减粘剂和表面活性剂。
聚氨酯泡沫可以呈片状,厚度可以是3-8mm。
植物纤维以100-300g/m2,例如,100-200g/m2的用量均匀地分布在聚氨酯泡沫层的两面,作为增强材料。
植物纤维的尺寸必须调节到直径至多为1.0mm(例如,0.2-0.8mm)、长度为10-100mm(例如,15-50mm)。如果直径超过1.0mm的纤维用作增强材料,则模塑制品表面会出现不均匀性,从而严重损害外观。所谓直径,如本文所用,是指纤维横截面的纵、横尺寸上较小的那个尺寸。纤维可以用简单设备切割成10-100mm长。如果长度小于10mm,则得不到所需的增强效果,而如果纤维太长,则它们会彼此纠缠,因而不能均匀地分布在泡沫上。为使纤维能较容易且均匀地分布在大面积的汽车顶棚材料之类的模塑制品上,也为了获得足够的增强效果,必须将尺寸调节到10-100mm之间。
植物纤维可以是主要含纤维素的植物纤维经短切或研磨所得到的那些。植物纤维可以是,例如,大麻、槿麻、剑麻纤维,竹纤维、木纤维。木纤维从木材获得。木材可以是,例如,雪松木、松木、榉木、sun tree、hiba香柏、樱木、白杨木或冷杉木。
热固性粘合剂在聚氨酯泡沫与植物纤维之间形成粘结并在植物纤维彼此之间形成粘结。在植物纤维彼此粘结的情况下,粘合剂浸在植物纤维之间,形成由植物纤维与粘合剂组成的层。
热固性粘合剂可以是包含芳族多异氰酸酯、水、催化剂和任选的多元醇的粘合剂。
芳族多异氰酸酯可以是,例如,甲苯二异氰酸酯、二苯基甲烷二异氰酸酯或多亚甲基多苯基多异酸酯(聚合MDI),优选聚合MDI。
水可以是以100重量份芳族多异氰酸酯计为10-50重量份,例如,15-30重量份。
催化剂可以是,例如,一元胺、二胺或三胺(例如,双(二甲基氨基乙基)醚、N,N,N′,N′,N″-五甲基二亚乙基三胺、三亚乙基二胺、或二甲基乙醇胺)之类的胺。
催化剂可以是以100重量份芳族多异氰酸酯计为0.1-1.0重量份,例如,0.2-0.5重量份。
要用的多元醇可以是,例如,多元醇(例如,乙二醇、甘油、三羟甲基丙烷、季戊四醇、山梨醇、糖)、聚醚多元醇或聚酯多元醇。
聚醚多元醇的实例包括在多元醇中加入烯化氧(例如,环氧丙烷或环氧乙烷)获得的聚醚多元醇以及在脂肪胺(例如单乙基胺、乙二胺、N,N-二甲基乙基胺或二亚乙基三胺)中加入烯化氧(例如环氧丙烷或环氧乙烷)获得的聚醚多元醇。
聚醚多元醇的羟值可以是100-1000mgKOH/g,例如,300-600mgKOH/g。
多元醇的用量可以是以100重量份多异氰酸酯计至多为10重量份,例如,2-5重量份。
热固性粘合剂的用量可以是以100重量份植物纤维计为50-300重量份,例如,70-150重量份。
任选地,可以在由植物纤维与热固性粘合剂制成的层上盖上一层表面装饰皮层和/或一层防止粘合剂渗漏的薄膜。表面装饰皮层可以是聚烯烃、聚酯或聚酰胺的织造织物或非织造织物、乙烯基皮革等。表面装饰皮层的厚度可以是例如,0.1-3mm。
防止粘合剂渗漏的薄膜可以是一层聚烯烃薄膜或聚酰胺薄膜。防止粘合剂渗漏的薄膜的厚度可以是,例如,10-40m。
层压板的生产方法可以是,例如,在聚氨酯泡沫的两面涂布(例如,喷涂)热固性粘合剂,在两面铺上植物纤维,任选地,盖上一层表面装饰皮层和一层防止粘合剂渗漏的薄膜,形成一个叠层,将该叠层放进加热到80-150℃,例如,120-140℃的模具内,加压,固化粘合剂,从模具中脱模该模塑制品。
或者,在热固性粘合剂或热固性粘合剂中的一个组分(例如,芳族多异氰酸酯)与植物纤维先混好后,将该混合物涂布在聚氨酯泡沫的两面。
在层压材料中,由聚氨酯泡沫组成的那层的厚度可以是4-8mm,由植物纤维与热固性粘合剂组成的那层的厚度可以是0.2-2mm。
本发明的层压板可用作汽车内饰基材,例如,汽车用顶棚材料或车门修饰材料。
下面,将给出实施例并对本发明作具体说明。
实施例
在下列实施例中,模塑制品的评价如下进行。
(1)挠曲模量
挠曲模量按JIS K6301测量。从模塑产品上切下长150mm、宽50mm的样品,以100mm跨距和50mm/min的试验速度测量挠曲模量。
(2)可模塑性
可模塑性用脱模时的刚度、表面装饰皮层的损伤程度等进行判断。
实施例1
在单位面积重量为200g/m2的有开孔的可热成型硬质聚氨酯泡沫板(尺寸:30cm×30cm×5.5mm)的两面,按70g/m2的用量,喷涂上聚合MDI(SBU Isocyanate 0418,Sumitomo Bayer Urethane有限公司制造)。
接着,按20g/m2的用量,喷涂上含1重量%氨酯化催化剂(SBUCatalyst H544,Sumitomo Bayer Urethane有限公司制造)的水。
然后,按约150g/m2的基础重量在两面分布直径为0.7mm长度为10-50mm的木纤维(类型:细磨木浆),并在两面铺上约40g/m2的非织造织物(聚酯:厚度0.1mm),形成层合物,将层合物在模内于130℃加压60秒钟,制成厚度为5mm的模塑产品。
虽然这个密度(表观密度)为0.15g/cm3,单位面积重量为750g/m2的模塑制品非常轻,但其挠曲模量有3,000kg/cm2,完全能作顶棚材料。
实施例2
在一块单位面积重量为200g/m2的有开孔的可热成型硬质聚氨酯泡沫板(尺寸:30cm×30cm×5.5mm)的两面按20g/m2的用量,喷涂上含1重量%氨酯化催化剂(SBU Catalyst H544,Sumitomo BayerUrethane有限公司制造)的水。
在100重量份直径为0.7mm、长度为10-50mm的竹纤维中加入50重量份聚合MDI(SBU Isocyanate 0418,Sumitomo Bayer Urethane有限公司制造),并充分搅拌该混合物。
按约200g/m2的基础重量,在已涂有含氨酯化催化剂的水的聚氨酯泡沫板的两面均匀地分布聚合MDI与竹纤维的混合物。
在其外面,盖上约200g/m2的表面装饰皮层(聚酯:厚1mm),形成一个层合物,将该层合物在模具内于130℃下加压60秒钟,制成厚度为5mm的模塑制品。
虽然这个基材密度(表观密度)为0.14g/cm3、单位基材面积重量为700g/m2的模塑制品非常轻,但其挠曲模量有3,000kg/cm2,且表面装饰皮层完好无损。对比实施例1
在一块单位面积重量为200g/m2的有开孔的可热成型硬质聚氨酯泡沫板(尺寸:30cm×30cm×5.5mm)的两面,按20g/m2的用量,喷涂上含1重量%氨酯化催化剂(SBU Catalyst H544,Sumitomo BayerUrethane有限公司制造)的水。
在100重量份直径约2mm长度为2-15mm的木纤维(细磨木浆)中加入50重量份聚合MDI(SBU Isocyanate 0418,Sumitomo BayerUrethane有限公司制造),并充分搅拌该混合物。
按约200g/m2的基础重量,在已涂有含氨酯化催化剂的水的两面均匀地分布聚合MDI与木纤维的混合物。
在其外面,盖上约200g/m2的表面装饰皮层(聚酯:厚度1mm),形成一个层合物,将该层合物在模具内于130℃下加压60秒钟,制成厚度为5mm的模塑制品。
该模塑制品的基材密度(表观密度)为0.14g/cm3,单位基材面积重量为700g/m2。该模塑制品在脱模时的刚度低,且难以脱模。而且,挠曲模量只有1,000kg/cm2,因此未能得到可用作顶棚材料的模塑产品。
按照本发明获得的模塑制品,尽管非常轻,但具有高刚度。
Claims (2)
1.一种生产具有夹心结构的汽车内饰材料的方法,它包括下列步骤:
(I)叠合下列各层:
(a)一块密度为20-100kg/m3的有开孔的可热成型聚氨酯泡沫,
(b)置于所述聚氨酯泡沫(a)两个主要表面的100g/m2-300g/m2的植物纤维,
(c)在聚氨酯泡沫(a)与植物纤维(b)之间形成粘结以及在植物纤维(b)彼此之间形成粘结的热固性粘合剂,以及任选的
(d)一层表面装饰皮层和/或一层防止粘合剂渗漏的薄膜,
(II)将上述层合物装入温度为80-150℃的模具内,合模以固化粘合剂,以及
(III)粘合剂固化后,脱模该模塑产品,其特征在于,植物纤维的尺寸被调节到直径至多为1.0mm,长度为10mm-100mm。
2.按照权利要求1的方法,其中,所述聚氨酯泡沫是一种硬质聚氨酯泡沫;所述热固性粘合剂是一种包含芳族多异氰酸酯、水、催化剂和,任选的多元醇的粘合剂;以及所述植物纤维是大麻、槿麻、剑麻纤维,竹纤维与木纤维等经短切或研磨所得到的那些纤维。
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- 2000-07-24 HU HU0202086A patent/HUP0202086A2/hu unknown
- 2000-07-24 MX MXPA02001171A patent/MXPA02001171A/es not_active Application Discontinuation
- 2000-07-24 WO PCT/EP2000/007065 patent/WO2001010637A1/en not_active Application Discontinuation
- 2000-07-24 AU AU64370/00A patent/AU767084B2/en not_active Ceased
- 2000-07-24 EP EP00951434A patent/EP1206348A1/en not_active Withdrawn
- 2000-07-24 KR KR1020027001488A patent/KR20020016937A/ko not_active Application Discontinuation
- 2000-07-24 BR BR0012948-8A patent/BR0012948A/pt not_active Application Discontinuation
- 2000-07-24 CA CA002391726A patent/CA2391726A1/en not_active Abandoned
- 2000-07-24 CN CNB008111367A patent/CN1168600C/zh not_active Expired - Lifetime
- 2000-07-24 PL PL00353240A patent/PL353240A1/xx not_active Application Discontinuation
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CN103938486A (zh) * | 2013-01-18 | 2014-07-23 | 三菱自动车工业株式会社 | 竹纤维片材 |
CN103935085A (zh) * | 2013-01-18 | 2014-07-23 | 三菱自动车工业株式会社 | 车辆的内装用基材 |
CN103938486B (zh) * | 2013-01-18 | 2016-08-17 | 三菱自动车工业株式会社 | 竹纤维片材 |
CN103395397A (zh) * | 2013-08-05 | 2013-11-20 | 扬州顺祥汽车内饰材料有限公司 | 一种麻毡复合板及其制造方法 |
CN103450580A (zh) * | 2013-09-16 | 2013-12-18 | 内蒙古大学 | 以废弃聚氨酯泡沫、废弃植物纤维及废弃聚苯乙烯泡沫制备板材的方法 |
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AU6437000A (en) | 2001-03-05 |
HK1047562B (zh) | 2005-05-13 |
BR0012948A (pt) | 2002-04-30 |
KR20020016937A (ko) | 2002-03-06 |
HUP0202086A2 (en) | 2002-10-28 |
CN1168600C (zh) | 2004-09-29 |
HK1047562A1 (en) | 2003-02-28 |
CA2391726A1 (en) | 2001-02-15 |
JP2001047544A (ja) | 2001-02-20 |
AU767084B2 (en) | 2003-10-30 |
EP1206348A1 (en) | 2002-05-22 |
PL353240A1 (en) | 2003-11-03 |
MXPA02001171A (es) | 2002-07-30 |
WO2001010637A1 (en) | 2001-02-15 |
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