CN1693068A - 顶蓬内部衬里的生产工艺 - Google Patents

顶蓬内部衬里的生产工艺 Download PDF

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CN1693068A
CN1693068A CNA2005100699074A CN200510069907A CN1693068A CN 1693068 A CN1693068 A CN 1693068A CN A2005100699074 A CNA2005100699074 A CN A2005100699074A CN 200510069907 A CN200510069907 A CN 200510069907A CN 1693068 A CN1693068 A CN 1693068A
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stratified material
lining
thermosetting resin
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拉蒙·米罗内斯·戈麦斯
弗朗西斯科·哈维尔·阿里斯纳瓦雷特·埃斯泰邦
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Grupo Antolin Ingenieria SA
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Abstract

本发明涉及一种汽车内部顶蓬的生产工艺，更具体而言，涉及一种利用层状材料而成产汽车内部顶棚的生长工艺，其中，中央层(2)由两层以上的低密度纤维衬层材料垫(1)构成，且其每层表面均浸润有热固性树脂(3)。经过热压机的作用后，构成所述层状材料的各层之间相互粘接。

Description

顶蓬内部衬里的生产工艺
本发明涉及一种汽车内部顶蓬的生产工艺，更具体而言，本发明涉及一种由层状材料制成的顶蓬的生产工艺，该层状材料的中央层由低密度纤维材料制成。
背景技术
汽车顶蓬应具有良好的绝热性，同时还应具有隔音和绝缘功能。另一方面，由于人们对此类产品的机械性能的要求也在日益提高，从而，如何找到一种高效、低成本的生产工艺，便成为人们很感兴趣的一个课题。
目前，在已公布的、关于生产汽车顶蓬的专利申请中，已有几种相关的背景文献，其申请号分别为：US4828910、4840832、6291370、6124222、6156682以及EP0832787、EP1199154和ES2157725。这些相关专利的最显著的特点将在下文中进行概括说明。
US6124222：其层状材料的中央层由两层胶合纤维和非胶合纤维组成。同时构成层状材料的还有其它层(加强层、衬层，……)，对上述层状材料进行加热，从而使粘合层发挥作用，便可将所有层胶合在一起。在以下步骤中，所述层状材料是在模具中形成的。
该工艺需要安装加热炉和工厂中的压力机，从而生产顶蓬的生产空间增大，使工艺过程的经济性不合要求。
EP1199154：在该工艺中，层状材料的中央层由几层泡沫材料构成，在泡沫层上继续放置其它层(加强层、衬层，……)。
由于中央层由泡沫材料构成，从而在较薄的顶蓬部位，其硬度不足。因此，在装卸顶蓬时，由于边部区域厚度很小，从而非常容易发生破裂。
对于泡沫材料制成的顶蓬而言，在装卸过程中可能出现的另一个问题是，由于汽车体身的尺寸往往比顶蓬要小，有时候会需要将顶蓬折叠才能放入汽车体身内。当对顶蓬进行折叠时，由于顶蓬自身强度不够，从而就会使顶蓬的中央层发生破裂，从而会在其可见面留下一些不需要的痕迹。
另外，考虑到其它材料的可用性，用于汽车顶蓬中的泡沫的使用也受到一定限制。
US6156682：在该工艺中，层状材料的中央层由不同重量的聚合纤维构成，且其表面涂覆有一层热固性树脂，然后继续放置其它层材料(加强层，衬层，……)。
该工艺的中央层由一个单独层开始形成，之后添加不同重量的其它层材料，共同构成中央层。这些层事先已经通过挤压或热胶合的方法粘接在一起，从而，该汽车顶蓬成产工艺是从一个单独层开始进行的。
由于该工艺使用的不同规格纤维材料，从而使其生产成本增加，而且使各层材料间的粘合过程的控制变得更为困难。
发明内容
本发明的目的在于减少前文所述中出现的各种缺陷，简化生产工艺，使成品具有更为良好的机械性能，同时，降低生产成本。
根据本发明所述，中央层至少由两层低密度纤维垫(表层重量为200-600g/m2)构成，优选的，这两层纤维重量相同。与已知的泡沫基顶蓬相比，本发明中顶蓬的较薄区域也具有较高的硬度。从而，在装卸过程中，顶蓬对外力具有更为良好的抵抗力，而且使其外形有更多的选择余地。
在本发明工艺中，中央层由连续的纤维垫构成，并且用诸如胶粘辊这样的设备在每个纤维垫表面涂覆热固性树脂，从而使这些纤维垫只是发生表面浸润；一旦几层纤维材料垫的重叠形成后，便可在中央层的至少一面添加纤维材料制成的加强层；然后向该层状材料的至少一面添加保护层，从而在该层状材料上形成一层非可见表面；最后，在该层状材料的另一面添加装饰衬层或装饰表面，形成一层可见表面；在添加装饰衬层之前，可选择性的添加一层隔离层，用于保护装饰衬层。
由于纤维垫可放置在卷筒上，实现连续进料，从而本发明工艺可在流水生产线上实现自动生产。而对于中央层为泡沫的生产工艺而言，由于其需要在独立的工作台上切割泡沫，并将切割下的泡沫送入顶蓬生产线中，因此不能进行连续生产。
根据本发明所述，热固性树脂是利用胶粘辊或其它类似设备进行施加的，从而每个纤维垫只是在其表面被树脂浸润。从而在后续步骤中就可以在热压机中将这些纤维垫胶合并成形，由于压力机的作用，每个纤维垫表面的热固性树脂会渗入垫内，从而以几乎连续的方式形成中央层。这样形成的中央层与用浴槽完全浸润的单层纤维材料垫类似，但与完全浸润的单层纤维垫相比，上述中央层使用的热固性树脂量较少。这样就可节省大量的热固性树脂，同时与现有材料相比，利用本发明工艺生产出的层状材料具有更为良好的机械性能，而且节约了大量费用。
可选择的，将一个单独的纤维材料垫(1)连续自我折叠，然后沿至少一个平行于其折叠轴线的方向进行切割，并切成所需尺寸，从而便可得到构成中央层(2)的所有纤维材料垫(1)的重合位置的重叠。在上一段落所述的工艺中，每个纤维材料垫(1)都是从独立的卷筒中生产出的，而本方法可获得与此相同的中央层(2)。
构成加强层的材料可以是人工纤维，如玻璃纤维，也可以是天然纤维，如黄麻，大麻，亚麻，剑麻等，其强化作用是相同的。
可选的，在施加装饰衬层之前，层状材料可通过压辊改善先前施加的树脂的浸润和分布。这也可以在所有形成顶蓬的层都施加后将层状材料进行成形操作之前进行。
一旦热固性树脂施加到中央层，并且根据需要施加加强层之后，保护层也随之施加，形成非可见表面。该层也被用于粘合加强层的相同树脂粘合，利用加强层的可渗透性，可让粘合剂渗透过加强层。保护层材料的成分和结构都可以迥然不同，例如，它可由纸，植物纤维，塑料层等构成。
装饰衬层施加在相反的另一表面形成可见表面。根据所选用装饰衬层的不同，可在必要情况下添加隔离层，它是一层粘性贴片或粘性带，配置在装饰衬层前，可以防止粘合剂渗透过装饰衬层，从而对最终外观造成影响。
当没有使用隔离层时，用于粘结加强层的热固性树脂同时还起到粘接装饰衬层的作用。而当使用隔离层时，由于隔离层有热塑性材料构成，从而可依照前文所述的任何方法，对隔离层进行加热，从而粘结装饰衬层。
一旦获得层状材料后，立刻将其引入热压机中，同时，开始粘合各层的树脂发生聚合作用，从而形成其最终形状。由于模具内压力、温度的共同作用，从而使层状材料的内部结构发生固化，进而可以获得一定形状的顶蓬。换句话说，与美国申请6124222中所述不同，本发明中的层状材料的形成以及各层之间的粘合，是在压力机中同时进行的。由于在用压力机挤压之前并不需要加热炉对粘合剂进行融化，也不需要其对各层进行粘合，从而可为生产厂房节省很大空间。
附图说明
参看本发明一个实施例的附图，可以更好的理解前文所提到的、以及本发明的其它特点和优点，附图包括：
图1所示为根据本发明所制得层状材料成分的示意性剖视图。
图2所示为本发明所述顶蓬的生产工艺的示意图。
具体实施方式
该层状材料包括：中央层(2)，加强层(4)，配置在加强层(4)之一上的保护层(7)，形成了汽车顶蓬的非可见侧；一个隔离层(5)，配置在加强层(4)上与保护层相反的一面；以及一个装饰衬层(6)，位于隔离层(5)上，形成可见侧。
中央层由纤维材料垫(1)构成，且仅在其表面涂覆有热固性树脂(3)，然后在重合位置彼此重叠放置。所述的纤维材料垫(1)可由天然纤维或回收纤维构成，例如聚乙烯对苯二酸盐，聚胺，聚丙烯，植物纤维等，并预先经过冲压和/或热压作用。
图1所示的层状材料的生产过程可参看图2。
纤维材料垫(1)可放置在卷筒(11)中，将其抽出后，可利用胶粘辊(13)在其两面涂覆热固性树脂。之后，施加玻璃纤维加强层(4)，其可以以松散纤维(12)、衬垫(17)或其它结构的纤维的形式来提供。在一侧，施加纸基层(16)形成如图1的保护层(7)，构成非可见面。在另一侧，构成如图1的隔离层(5)的条或层(14)施加到加强层(4)上，隔离层表面上施加一个层(15)形成装饰衬层(6)，构成图1所示的可见面。
如上所述的层状材料须经过例如橡胶辊的压辊(18)的作用，以使辊(13)涂覆到层状材料上的热固性树脂(3)能与基体均匀结合。
最后，形成的层状材料放入挤压机(19)中成型，挤压温度控制在120℃-190℃之间，成型时间控制在15秒-180秒之间，以获得期望外形，同时，由于热固性树脂发生聚合作用，从而使层状材料各层之间粘接。
在图2所述层状材料的生产过程中，可根据所使用装饰衬层(16)类型的需要，可以将图1中的隔离层(5)去除。图2中的装饰衬层(16)可在挤压辊(18)作用前或后放置在层状材料上部。
图2所述工艺中，所使用的玻璃纤维(12)可由天然纤维代替，例如黄麻，大麻，亚麻，剑麻，或者是以玻璃纤维衬层的形式使用。
同时，在图2所述工艺中，可加热挤压辊(18)，使层状材料发生一定的聚合作用，缩短其在挤压机(19)中的成型时间，同时防止图1中加强层(4)发生疏松。

Claims (15)

1.一种汽车内部顶蓬的生产工艺，包括：形成层状材料，其包括一中央层(2)，由经过冲压或热压的低密度纤维材料构成；热固性树脂层(3)；至少一层保护层(7)，形成非可见侧；以及至少一层装饰衬层(6)，形成可见侧，所述工艺包括以下步骤：
(i)通过包括至少下列步骤(a)、(b)和(c)的工艺获得层状材料：
(a)获得中央层(2)；
(b)施加至少一层装饰衬层(6)，以形成可见面；
(c)在层状材料的与装饰衬层(6)相反的一面上，施加至少一层保护层(7)，
其特征在于：
所获得的中央层(2)包括在重合位置重叠的至少两层纤维材料垫(1)，并在所述纤维材料垫(1)的两面均涂覆热固性树脂(3)，仅使其表层发生浸润；
并且在于，
在后续步骤(ii)中，层状材料在足够温度和压力下经过压力机(19)，，同时由于热固性树脂(3)发生聚合作用，层状材料成形并且各层之间发生粘接。
2.如权利要求1中所述的工艺，其特征在于，构成中央层(2)的纤维材料垫(1)可从单独的卷筒中抽出。
3.如权利要求1中所述的工艺，其特征在于，将一个单个的纤维材料垫反复自我重叠后，便可获得所有构成中央层(2)的纤维材料垫。
4.如权利要求3中所述的工艺，其特征在于，在后续工艺中，将中央层(2)沿至少一个平行与其折叠轴线进行切割。
5.如以上全部权利要求所述的工艺，其特征在于，应在中央层(2)的至少一面配置至少一个加强层(4)。
6.如权利要求5所述的工艺，其特征在于，至少一个加强层(4)由人造纤维构成。
7.如权利要求5、6所述的工艺，其特征在于，至少一个加强层(4)由天然纤维构成。
8.如以上全部权利要求所述的工艺，其特征在于，层状材料进入压力机(19)之前，先经过压力辊(18)。
9.如以上任何一个权利要求所述的工艺，其特征在于，在生成装饰衬层(6)之前，层状材料先经过压力辊(18)。
10.如权利要求8、9所述的工艺，其特征在于，在对层状材料进行部分挤压时，挤压辊已加热至一定温度，能使热固性树脂(3)发生聚合作用。
11.如以上任何权利要求所述的工艺，其特征在于，在生成装饰衬层(6)之前，施加至少一层隔离层(5)。
12.如权利要求11所述的工艺，其特征在于，通过粘性贴片或粘性带应形成至少一层隔离层(5)。
13.如权利要求12所述的工艺，其特征在于，将隔离层(5)融化后，可将装饰衬层(6)和层状材料粘接在一起。
14.如权利要求1至10所述的工艺，其特征在于，装饰衬层(6)通过热固性树脂(3)与层状材料粘接在一起。
15.如以上任何一个权利要求所述的工艺，其特征在于，保护层(7)通过热固性树脂(3)与层状材料粘接在一起。
CNA2005100699074A 2004-05-03 2005-05-08 顶蓬内部衬里的生产工艺 Pending CN1693068A (zh)

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CN103231557A (zh) * 2013-04-02 2013-08-07 浙江联洋复合材料有限公司 一种汽车顶棚用玻璃纤维增强无纺毡及其制造方法
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CN102615886A (zh) * 2012-03-19 2012-08-01 常熟江南玻璃纤维有限公司 一种玄武岩纤维增强聚丙烯复合材料成型工艺
CN103231557A (zh) * 2013-04-02 2013-08-07 浙江联洋复合材料有限公司 一种汽车顶棚用玻璃纤维增强无纺毡及其制造方法
CN105292011A (zh) * 2014-07-23 2016-02-03 Nvh韩国株式会社 热固性高分子树脂增强汽车内饰用顶棚材料

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