WO2022134056A1 - 一种可透光表皮材料及其制作工艺和一种可透光复合结构 - Google Patents

一种可透光表皮材料及其制作工艺和一种可透光复合结构 Download PDF

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WO2022134056A1
WO2022134056A1 PCT/CN2020/139571 CN2020139571W WO2022134056A1 WO 2022134056 A1 WO2022134056 A1 WO 2022134056A1 CN 2020139571 W CN2020139571 W CN 2020139571W WO 2022134056 A1 WO2022134056 A1 WO 2022134056A1
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Prior art keywords
parts
light
skin material
olefin copolymer
skin
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PCT/CN2020/139571
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English (en)
French (fr)
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宋伟锋
戴安琪
祁海涛
喻冬青
管世伟
刘建红
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加通汽车内饰(常熟)有限公司
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Priority to PCT/CN2020/139571 priority Critical patent/WO2022134056A1/zh
Publication of WO2022134056A1 publication Critical patent/WO2022134056A1/zh

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/04—Homopolymers or copolymers of ethene
    • C08L23/08—Copolymers of ethene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/16—Elastomeric ethene-propene or ethene-propene-diene copolymers, e.g. EPR and EPDM rubbers

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  • the present application relates to the technical field of decorative materials, in particular to a light-permeable skin material and a manufacturing process thereof, and a light-permeable composite structure.
  • vehicle interior skin materials and interior composite structures with a certain light transmittance are required.
  • the existing interior skin materials of light-transmitting vehicles are mainly made of PVC materials.
  • PVC due to its high density, PVC cannot meet the demand for lightweight vehicles in the future. Therefore, there is an urgent need for a lightweight translucent skin material.
  • the main purpose of the present application is to provide an environmentally friendly and lightweight light-transmitting skin material and its manufacturing process, and a light-transmitting composite structure, taking into account the strength, toughness and light transmittance of the skin material. , and improve comfort and aesthetics.
  • the present application provides a light-transmitting skin material
  • the skin material is a thermoplastic polyolefin material
  • the skin material raw materials include PP, PE, color masterbatch, olefin copolymer, and vulcanized EPDM rubber. and additives; wherein, the vulcanized EPDM rubber is prepared by dispersing the EPDM rubber in PP and/or PE plastic matrix; the weight parts of the skin material raw materials are as follows: PP is not more than 10 parts, and PE is not more than 10 parts.
  • the total weight of the ethylene-propylene rubber is 100 parts; the light transmittances of the PP, PE and the olefin copolymer are all above 80%.
  • the composition of the skin material raw materials by weight is specifically: 5 parts of PP, 5 parts of PE, 70 parts of olefin copolymer, 20 parts of vulcanized EPDM rubber, 1.5 parts of color masterbatch, and 0.4 parts of auxiliary agent.
  • the olefin copolymer is at least one of a propylene-ethylene copolymer, an ethylene-octene copolymer, an ethylene-butene copolymer and an ethylene-butene-octene copolymer.
  • the application provides a manufacturing process of a light-transmitting skin material, and the manufacturing steps are:
  • S100 will not exceed 10 parts of PP, not more than 10 parts of PE, 20-70 parts of olefin copolymer, not more than 30 parts of vulcanized EPDM, 0.5-2 parts of masterbatch, 0.1-0.5
  • the semi-finished product of the transparent skin material is obtained by calendering or extrusion process; wherein, the vulcanized EPDM rubber is prepared by dispersing the EPDM rubber in the PP and/or PE plastic matrix.
  • the total weight of PP, PE, olefin copolymer and vulcanized ethylene propylene rubber is 100 parts; the light transmittances of the PP, PE and olefin copolymer are all above 80%;
  • step S100 specifically includes:
  • step S110 is specifically:
  • a part of the olefin copolymer is premixed and granulated with the color masterbatch, or a part of the vulcanized EPDM rubber is premixed and granulated with the color masterbatch, or the A part of the olefin copolymer and a part of the vulcanized EPDM rubber are premixed and granulated with the color masterbatch.
  • step S110 is specifically:
  • 20%-50% of the olefin copolymer is premixed and granulated with the color masterbatch, or 40%-60% of the vulcanized EPDM rubber is premixed with the color masterbatch.
  • granules, or 20%-30% of the olefin copolymer and 20%-30% of the vulcanized EPDM rubber are premixed and granulated with the color masterbatch.
  • the composition of the skin material raw materials by weight is specifically: 5 parts of PP, 5 parts of PE, 70 parts of olefin copolymer, 20 parts of vulcanized EPDM rubber, 1.5 parts of color masterbatch, auxiliary dose 0.4 servings.
  • the olefin copolymer is at least one of a propylene-ethylene copolymer, an ethylene-octene copolymer, an ethylene-butene copolymer and an ethylene-butene-octene copolymer kind.
  • the present application provides a light-transmitting composite structure, comprising a skin layer formed from the above-mentioned light-transmitting skin material, and further comprising a foam material layer compounded with the skin layer, the foam
  • the foaming ratio of the cotton material layer is 25-35
  • the thickness ratio of the skin layer and the foaming material layer is 1:1-1:40.
  • the thickness of the skin layer is 0.1-1.0 mm
  • the thickness of the foam material layer is 1.0 mm-4.0 mm.
  • a pattern layer is further provided between the skin layer and the foam material layer, and the pattern layer includes a hollow part for transmitting light and a light blocking part for blocking light, the hollow part A pattern is formed together with the light blocking portion.
  • a pattern layer is provided on the side of the foam material layer away from the skin layer, the pattern layer includes a hollow part for light transmission and a light blocking part for blocking light, the hollow part and The light blocking parts together form a pattern.
  • the present application further provides a vehicle interior, comprising the above-mentioned light-permeable skin material or the above-mentioned light-permeable composite structure.
  • the present application also provides a decorative material, comprising the above-mentioned light-permeable skin material or the above-mentioned light-permeable composite structure.
  • the light-transmitting skin material provided by this application, because the ordinary EPDM rubber is first vulcanized into the vulcanized EPDM rubber, the strength performance of the rubber material is significantly improved, and the strength of the skin material in the post-processing process can be guaranteed. While improving the processing performance, the doping amount of the rubber material is greatly reduced, and the olefin copolymer material with high light transmittance is added to the part where the doping amount of the rubber material is reduced to further improve the strength performance of the skin material in the post-processing process, and significantly The light transmittance of the prepared skin material is improved, the light transmittance decorative effect is improved, and the lightweight of the skin material is realized.
  • Fig. 1 is the fabrication flow chart of the transparent skin material of a kind of preferred embodiment provided by this application;
  • Fig. 2 is the fabrication flow chart of the transparent skin material of another preferred embodiment provided by the application.
  • FIG. 3 is a schematic structural diagram of a light-permeable composite structure according to a preferred embodiment of the present application.
  • FIG. 4 is a schematic structural diagram of a light-permeable composite structure according to another preferred embodiment provided by the application.
  • FIG. 5 is a schematic structural diagram of a light-transmitting composite structure according to another preferred embodiment provided by the present application.
  • the tensile strength of skin materials during post-processing is one of the most important mechanical properties of vehicle interior skin materials.
  • the so-called "post-processing process” is represented by the process of wrapping the prepared skin material on the internal frame of the vehicle in a high-temperature environment to complete the production of the vehicle interior.
  • the above-mentioned coating process is completed in a high temperature environment in order to soften the skin material, so as to facilitate the stretching and reshaping of the skin material when the mold is closed, because the processing process is usually carried out in a high temperature environment between 170-230 degrees Celsius. , it is necessary for the skin material to have sufficient tensile strength and other processing properties at this time, so that the vehicle interior can be produced without damage during the implementation of the coating process.
  • Thermoplastic polyolefin is an environmentally friendly low-density material. By selecting appropriate raw materials and processes, it can achieve better elasticity and hand feel, so it can be used as a lightweight skin material for vehicle interiors. However, in the field of light-transmitting vehicle interior skin materials, the development of TPO is relatively slow, and an ideal light-transmitting TPO skin material has not yet appeared.
  • the raw material ratio of the existing TPO skin material has the following problems: in order to ensure the physical properties such as the tensile strength of the skin material in the post-processing process, it is necessary to add a high content of ternary ethyl alcohol to the raw material.
  • the addition amount of propylene rubber and EPDM rubber may be as high as 80%, and the light transmittance of the rubber is extremely low, which significantly affects the light transmittance of the prepared vehicle skin material, resulting in the transparency of the existing TPO skin material.
  • Optical properties are less than 0.5%. If the content of EPDM rubber is directly reduced, it will significantly affect the tensile strength and other indicators of the material, resulting in poor durability and feel.
  • the present application provides a light-transmitting skin material
  • the skin material is a thermoplastic polyolefin material
  • the skin material raw materials include PP, PE, color masterbatch, olefin copolymer, vulcanized ternary Ethylene propylene rubber and auxiliary agent; wherein, vulcanized EPDM rubber is prepared by dispersing EPDM rubber in PP and/or PE plastic matrix; the weight parts of the skin material raw materials are as follows: PP does not exceed 10 parts , PE not more than 10 parts, olefin copolymers 20-70 parts, vulcanized EPDM rubber not more than 30 parts, color masterbatch 0.5-2 parts, additives 0.1-0.5 parts, and PP, PE, olefin copolymer and The total weight of the vulcanized EPDM rubber is 100 parts; the light transmittances of the PP, PE and olefin copolymers are all above 80%.
  • the strength and toughness of the vulcanized EPDM rubber in the subsequent processing of the skin material are significantly improved, although the vulcanization
  • the light transmittance of the EPDM rubber is not high, but compared with the unvulcanized EPDM rubber, higher strength and toughness can be achieved through a lower content, which greatly reduces the rubber material in the skin material.
  • the olefin copolymer material with high light transmittance is used instead, which can effectively reduce the obstruction to light and ensure that more light can pass through, thus greatly improving the skin material.
  • High light transmittance, and the olefin copolymer material also has excellent strengthening and toughening effect. Through the combination with the vulcanized EPDM rubber, the strength and toughness of the skin material in the subsequent processing can still be guaranteed.
  • Transmittance represents the ability of light to pass through a medium and is the percentage of the luminous flux passing through the medium to its incident luminous flux.
  • PP, PE and olefin copolymers are all selected as high light transmittance materials with a light transmittance of more than 80%, and the aforementioned light transmittance is measured under the ASTM E1348 standard. of.
  • the prepared skin material has leather feel and texture on the one hand, and good light transmission physical properties on the other hand.
  • the light transmittance of the prepared thermoplastic polyolefin skin material can be 18%. above.
  • the role of PP and PE materials in this application is to adjust the material elongation rate, tensile strength and hardness of the finished skin material, and to adapt to the processing of various mold shapes.
  • the auxiliary agent is at least one of antioxidant and light stabilizer.
  • These auxiliaries are all materials that can achieve corresponding functions in the art, for example, the antioxidant can be 1024, 1098 or 1330; the light stabilizer is hindered amine, such as UV-P, UV-234 or UV3808. Due to the low level of additives in the auxiliaries, it will not have any significant effect on the light transmittance of the product.
  • Olefin copolymers have the characteristics of abundant raw material sources and excellent comprehensive properties, and are suitable for the preparation of artificial skin materials.
  • the present application selects the olefin copolymer as at least one of propylene-ethylene copolymer, ethylene-octene copolymer, ethylene-butene copolymer and ethylene-butene-octene copolymer, these copolymers are While ensuring high light transmittance as much as possible, it can also ensure that the strength and toughness of the obtained skin material in the post-processing process are at a high level.
  • the present application also provides a manufacturing process of the above-mentioned translucent skin material, and the specific manufacturing steps are:
  • S100 will not exceed 10 parts of PP, not more than 10 parts of PE, 20-70 parts of olefin copolymer, not more than 30 parts of vulcanized EPDM, 0.5-2 parts of masterbatch, 0.1-0.5
  • the semi-finished product of the transparent skin material is obtained by calendering or extrusion process; wherein, the vulcanized EPDM rubber is prepared by dispersing the EPDM rubber in the PP and/or PE plastic matrix.
  • the total weight of PP, PE, olefin copolymer and vulcanized ethylene propylene rubber is 100 parts; the light transmittances of the PP, PE and olefin copolymer are all above 80%;
  • the extrusion process can be extruded through a twin-screw extruder.
  • the mixed raw materials are injected into the extruder through the feeding port, and the temperature of the extruder is controlled within the range of 180-230 ° C to maintain the extruder line.
  • the speed is 0-15m/min, and thermoplastic polyolefin films of corresponding width and thickness are produced according to product requirements.
  • the surface treatment agent is made of water-based polyurethane material. Since the thickness of the surface treatment agent layer formed by the surface treatment agent is relatively thin, it has little effect on the light transmittance of the finished skin material. In addition, the light-transmitting skin material can also be embossed. deal with.
  • the step S100 specifically includes:
  • the skin color of the skin products is often uneven, the color is too dark in parts, and the parts are close to transparent.
  • the appearance of the skin product is greatly affected.
  • the reason for the above situation is that because the content of the color masterbatch in the skin material is significantly lower than that of other main materials, if it is directly mixed with all other raw materials, it will often cause problems.
  • the color masterbatch is unevenly dispersed and agglomeration occurs.
  • a part of the olefin copolymer and/or the vulcanized ethylene-propylene-diene rubber is premixed and granulated with the color masterbatch.
  • the particles obtained by granulation pass through the twin-screw extruder together with other materials in the raw material, which can greatly improve the dispersion uniformity of the color masterbatch in the finished skin material and prevent agglomeration.
  • a part of the olefin copolymer is premixed and granulated with the color masterbatch, or a part of the vulcanized EPDM rubber is premixed and granulated with the color masterbatch, or A part of the olefin copolymer and a part of the vulcanized ethylene propylene rubber are premixed and granulated with the color masterbatch.
  • 20%-50% of the olefin copolymer is premixed and granulated with the color masterbatch, or 40%-60% of the vulcanized EPDM rubber is mixed with the color masterbatch.
  • Pre-mixing and granulating, or pre-mixing and granulating 20%-30% of the olefin copolymer and 20%-30% of the vulcanized EPDM rubber with the color masterbatch If the weight fraction of the olefin copolymer and/or vulcanized ethylene propylene rubber to be premixed and granulated with the color masterbatch is too low, the effect of sufficient premixing cannot be achieved. The proportion by weight of the olefin copolymer and/or vulcanized ethylene propylene rubber is too high, and the phenomenon of uneven dispersion of the color masterbatch may have occurred during this premixing.
  • the present application also provides a light-permeable composite structure, which includes a skin layer 20 formed from the above-mentioned light-permeable skin material, and also includes a foam material compounded with the skin layer.
  • a light-permeable composite structure which includes a skin layer 20 formed from the above-mentioned light-permeable skin material, and also includes a foam material compounded with the skin layer.
  • Layer 10 the foaming ratio of the foam material layer is 25-35, and the thickness ratio of the skin layer and the foam material layer is 1:1-1:40.
  • the composite structure can be applied to vehicle interiors, such as vehicle seats, vehicle door panels, vehicle center consoles, etc.
  • vehicle interiors such as vehicle seats, vehicle door panels, vehicle center consoles, etc.
  • a light source is arranged at the position where the vehicle frame or the like covers the composite structure, and when When the light source is off, the conventional interior effect is presented, and when the light source is on, the light transmission effect can be achieved.
  • the composite structure not only the skin layer is required to have good light transmittance, but also the foam material layer is required to have excellent light transmittance properties.
  • the foam material layer with high foaming ratio is adopted. Specifically, the foaming ratio is 25-35.
  • the foaming ratio can ensure that the average pore diameter inside the foam is large, thereby reducing the refraction and The occurrence of scattering phenomenon effectively shortens the optical path and reduces the loss of light in the process of propagation, and effectively increases the light transmittance of the first buffer layer. 30%, up to more than 50%.
  • the thickness ratio of the thermoplastic polyolefin skin layer and the first buffer layer is set to 1:1 to 1:40, which effectively ensures the sufficient thickness of the buffer layer, so that it can produce sufficient rebound buffering effect without being too thick. If the thickness of the buffer layer is too thick, it will also prolong the optical path and increase the loss of light during the propagation process, making it difficult to achieve high light transmission.
  • the skin material and the foam material are pasted together by transparent glue.
  • transparent glue refers to glue with good permeability such as hot melt glue, which is used after the preparation of the skin material is completed. Coated on it to bond with the foam material.
  • a transparent adhesive film can also be used to stick the skin material and the foam material together.
  • the thickness of the skin layer may be 0.1-1.0 mm, and the thickness of the foam material layer may be 1.0 mm-4.0 mm.
  • a pattern layer 30 is further provided between the skin layer 20 and the foam material layer 10, and the pattern layer 30 includes a hollow part for light transmission and a light blocking part for blocking light, The hollow part and the light blocking part together form a pattern.
  • the pattern layer includes a hollow part for transmitting light and a light blocking part for blocking light, and the hollow part and the light blocking part together form a pattern.
  • the light permeable composite structure is covered on the light source, when the light source is turned off, the light permeable composite structure presents the appearance of conventional artificial leather, and when the light source is on, the surface of the light permeable composite structure presents a pattern.
  • the pattern layer is implanted in the light-transmitting composite structure, so that the pattern layer is very close to the surface of the light-transmitting composite structure, and the light Scattering is almost non-existent, so the pattern presented is very clear.
  • the pattern layer 30 is provided on the side of the foam material layer 10 away from the skin layer 20 , and the pattern layer 30 includes a hollow part for light transmission and a light blocking part for blocking light.
  • the hollow part and the light-blocking part form a pattern together, so that by arranging the skin layer and the pattern layer on both sides of the foam material layer, the foam material is not in direct contact with other structures (such as the internal skeleton of the vehicle), etc. Cotton material forms protection.
  • the present application also provides a vehicle interior, which can be used in vehicles such as automobiles and trains, and adopts the above-mentioned light-permeable skin material or light-permeable composite structure, so as to realize the interior of the vehicle. Translucent effect.
  • the present application also provides a decorative material, which can be used for vehicle decoration, furniture decoration and other application environments such as 3C equipment (communication equipment, computer equipment, consumer electronic equipment), etc.
  • the light-transmitting skin material or the light-transmitting composite structure can realize the light-transmitting effect of the decoration material.

Abstract

一种可透光表皮材料及其制作工艺和一种可透光复合结构，所述表皮材料为热塑性聚烯烃材料，所述表皮材料原料包括PP、PE、色母粒、烯烃共聚物、硫化三元乙丙橡胶和助剂；其中，硫化三元乙丙橡胶是三元乙丙橡胶分散在PP和/或PE塑料基体中制备得到的；所述表皮材料原料重量份组成为：PP不超过10份，PE不超过10份，烯烃共聚物20-70份，硫化三元乙丙橡胶不超过30份，色母粒0.5-2份，助剂0.1-0.5份，且PP、PE、烯烃共聚物和硫化三元乙丙橡胶总重量为100份；所述PP、PE和烯烃共聚物的透光率均为80％以上。在保证表皮材料在后加工过程中的强度和韧性的同时，显著提高了表皮材料自身及采用该表皮材料的装饰材料的透光性，提高了透光装饰效果。

Description

一种可透光表皮材料及其制作工艺和一种可透光复合结构 技术领域
本申请涉及装饰材料技术领域，具体涉及一种可透光表皮材料及其制作工艺和一种可透光复合结构。
背景技术
随着人们对于各种装饰材料特别是交通工具的内饰质量及舒适度要求的不断提升，越来越多的功能被引入到交通工具内饰的开发过程中。为了实现交通工具内饰的透光型应用场景，需要一定透光率的交通工具内饰表皮材料和内饰复合结构。
现有的透光交通工具内饰表皮材料，主要是由PVC材料制成。然而，PVC因其密度较高，无法满足未来交通工具轻量化的需求。因此，急需一种轻量化的可透光表皮材料。
发明内容
基于上述现状，本申请的主要目的在于提供一种环境友好且轻量化的一种可透光表皮材料及其制作工艺和一种可透光复合结构，兼顾表皮材料的强度、韧性与透光性，并提高舒适性和美观性。
为实现上述目的，本申请采用的技术方案如下：
第一方面，本申请提供了一种可透光表皮材料，所述表皮材料为热塑性聚烯烃材料，所述表皮材料原料包括PP、PE、色母粒、烯烃共聚物、硫化三元乙丙橡胶和助剂；其中，硫化三元乙丙橡胶是三元乙丙橡胶分散在PP和/或PE塑料基体中制备得到的；所述表皮材料原料重量份组成为：PP不超过10份，PE不超过10份，烯烃共聚物20-70份，硫化三元乙丙橡胶不超过30份，色母粒0.5-2份，助剂0.1-0.5份，且PP、PE、烯烃共聚物和硫化三元乙丙橡胶总重量为100份；所述PP、PE和烯烃共聚物的透光率均为80％以上。
可选地，所述表皮材料原料重量份组成具体为：PP 5份，PE 5份，烯烃共聚物70份，硫化三元乙丙橡胶20份，色母粒1.5份，助剂0.4份。
可选地，所述烯烃共聚物为丙烯-乙烯共聚物、乙烯-辛烯共聚物、乙烯-丁烯共聚物和乙烯-丁烯-辛烯共聚物中的至少一种。
第二方面，本申请提供了一种可透光表皮材料的制作工艺，制作步骤为：
S100，将不超过10份的PP，不超过10份的PE，20-70份的烯烃共聚物，不超过30份的硫化三元乙丙橡胶，0.5-2份的色母粒，0.1-0.5份的助剂均匀混合，通过压延或挤出工艺获得所述可透光表皮材料的半成品；其中，硫化三元乙丙橡胶是三元乙丙橡胶分散在PP和/或PE塑料基体中制备得到的；PP、PE、烯烃共聚物和硫化三元乙丙橡胶总重量为100份；所述PP、PE和烯烃共聚物的透光率均为80％以上；
S200，在所述半成品的表面涂覆表面处理剂，得到所述可透光表皮材料。
可选地，所述步骤S100具体包括，
S110，将所述硫化三元乙丙橡胶和/或所述烯烃共聚物中的一部分与所述色母粒进行预混造粒，得到初级原料；
S120，将所述初级原料与其余原料混合、搅拌，通过压延或挤出工艺获得所述可透光表皮材料的半成品。
可选地，所述步骤S110具体为，
将所述烯烃共聚物中的一部分与所述色母粒进行预混造粒，或将所述硫化三元乙丙橡胶中的一部分与所述色母粒进行预混造粒，或将所述烯烃共聚物中的一部分和硫化三元乙丙橡胶中的一部分与所述色母粒进行预混造粒。
可选地，所述步骤S110具体为，
将所述烯烃共聚物的20％-50％与所述色母粒进行预混造粒，或将所述硫化三元乙丙橡胶的40％-60％与所述色母粒进行预混造粒，或将所述烯烃共聚物的20％-30％和硫化三元乙丙橡胶的20％-30％与所述色母粒进行预混造粒。
可选地，在所述步骤S100中，所述表皮材料原料重量份组成具体为：PP5份，PE5份，烯烃共聚物70份，硫化三元乙丙橡胶20份，色母粒1.5份，助剂0.4份。
可选地，在所述步骤S100中，所述烯烃共聚物为丙烯-乙烯共聚物、乙烯-辛烯共聚物、乙烯-丁烯共聚物和乙烯-丁烯-辛烯共聚物中的至少一种。
第三方面，本申请提供了一种可透光复合结构，包括如上所述的可透光表皮材料形成的表皮层，还包括与所述表皮层复合在一起的泡棉材料层，所述泡棉材料层的发泡倍率为25-35，所述表皮层和所述泡棉材料层的厚度比为1：1-1：40。
可选地，所述表皮层的厚度为0.1-1.0mm，所述泡棉材料层的厚度为1.0mm-4.0mm。
可选地，在所述表皮层和所述泡棉材料层之间还设有图案层，所述图案层包括用于透光的镂空部和用于挡光的挡光部，所述镂空部和所述挡光部共同形成图案。
可选地，在所述泡棉材料层背离所述表皮层的一面设有图案层，所述图案层包括用于透光的镂空部和用于挡光的挡光部，所述镂空部和所述挡光部共同形成图案。
第四方面，本申请还提供了一种交通工具内饰，包括如上所述的可透光表皮材料或如上所述的可透光复合结构。
第五方面，本申请还提供了一种装饰材料，包括如上所述的可透光表皮材料或如上所述的可透光复合结构。
本申请提供的可透光表皮材料，由于先将普通的三元乙丙橡胶硫化成为硫化三元乙丙橡胶，显著提高了橡胶材料的强度性能，可以在保证表皮材料在后加工过程中的强度等加工性能的同时，大大降低橡胶材料的掺杂量，对橡胶材料掺杂量降低的部分，加入高透光率的烯烃共聚物材料，进一步提高表皮材料后加工过程中的强度性能，且显著提高制得的表皮材料的透光性，提高透光装饰效果，并且实现了表皮材料的轻量化。
本申请的其他有益效果，将在具体实施方式中通过具体技术特征和技术方案的介绍来阐述，本领域技术人员通过这些技术特征和技术方案的介绍，应能理解所述技术特征和技术方案带来的有益技术效果。
附图说明
以下将参照附图对根据本申请的优选实施方式进行描述。图中：
图1为本申请提供的一种优选实施方式的可透光表皮材料的制作流程图；
图2为本申请提供的另一种优选实施方式的可透光表皮材料的制作流程 图；
图3为根据本申请的一种优选实施方式的可透光复合结构的结构示意图；
图4为本申请提供的另一种优选实施方式的可透光复合结构的结构示意图；
图5为本申请提供的另一种优选实施方式的可透光复合结构的结构示意图。
具体实施方式
以下基于实施例对本申请进行描述，但是本申请并不仅仅限于这些实施例。在下文对本申请的细节描述中，详尽描述了一些特定的细节部分，为了避免混淆本申请的实质，公知的方法、过程、流程、元件并没有详细叙述。
此外，本领域普通技术人员应当理解，在此提供的附图都是为了说明的目的，并且附图不一定是按比例绘制的。
除非上下文明确要求，否则整个说明书和权利要求书中的“包括”、“包含”等类似词语应当解释为包含的含义而不是排他或穷举的含义；也就是说，是“包括但不限于”的含义。
在本申请的描述中，需要理解的是，术语“第一”、“第二”等仅用于描述目的，而不能理解为指示或暗示相对重要性。此外，在本申请的描述中，除非另有说明，“多个”的含义是两个或两个以上。
表皮材料在后加工过程中的拉伸强度是交通工具内饰表皮材料最重要的机械性能之一。所谓“后加工过程”，以将制备完成得到的表皮材料在高温环境下包覆在交通工具内部骨架上、完成交通工具内饰制作的过程为代表。使用高温环境完成前述包覆工艺，是为了软化该表皮材料，便于模具合模时对该表皮材料进行拉伸并重新塑型，由于该加工过程通常在170-230摄氏度之间的高温环境下进行，需要表皮材料此时具备足够的拉伸强度等加工性能，方可在包覆工艺实施过程中，不会被拉破，制作出外表无破损的交通工具内饰。
热塑性聚烯烃材料(TPO)是一种环境友好型的低密度材料，通过选择合适的原料和工艺，可以实现较好的弹性和手感，从而可作为交通工具内饰的轻量化表皮材料。然而，在透光性交通工具内饰表皮材料领域，TPO的发展则较为缓慢，尚未出现理想的透光性TPO表皮材料。
本申请的发明人发现，现有的TPO表皮材料的原料配比存在如下问题：为了保证表皮材料的在后加工过程中的拉伸强度等物理性能，需要在原料中添加高含量的三元乙丙橡胶，三元乙丙橡胶的添加量可能高达80％，而该橡胶透光度极低，显著影响了所制得的交通工具表皮材料的透光性，导致现有的TPO表皮材料的透光性低于0.5％。如果直接减少三元乙丙橡胶的含量，则又会显著影响材料的拉伸强度等指标，导致耐用性和手感变差。
基于此，第一方面，本申请提供了一种可透光表皮材料，所述表皮材料为热塑性聚烯烃材料，所述表皮材料原料包括PP、PE、色母粒、烯烃共聚物、硫化三元乙丙橡胶和助剂；其中，硫化三元乙丙橡胶是三元乙丙橡胶分散在PP和/或PE塑料基体中制备得到的；所述表皮材料原料重量份组成为：PP不超过10份，PE不超过10份，烯烃共聚物20-70份，硫化三元乙丙橡胶不超过30份，色母粒0.5-2份，助剂0.1-0.5份，且PP、PE、烯烃共聚物和硫化三元乙丙橡胶总重量为100份；所述PP、PE和烯烃共聚物的透光率均为80％以上。
通过上述的原料配比设置，一方面通过先将三元乙丙橡胶硫化，硫化后的三元乙丙橡胶的对于表皮材料的后续加工过程中的强度和韧性等性能有显著提升，尽管硫化后的三元乙丙橡胶透光性也不高，但是相比未经硫化的三元乙丙橡胶，可以通过更低的含量实现更高的强度和韧性性能，大大降低了在表皮材料中橡胶材料的含量；另一方面，对于橡胶含量降低的部分，采用高透光率的烯烃共聚物材料代替，该材料能够有效降低对光线的阻碍，保证更多的光线能够通过，从而大大提高了表皮材料的透光率，且烯烃共聚物材料也有着优良的增强增韧作用，通过和硫化三元乙丙橡胶的配合，依然可以保证表皮材料的在后续加工过程中的强度和韧性。
透光率表示光线透过介质的能力，是透过该介质的光通量与其入射光通量的百分比。为了提高表皮材料的透光率，需要尽可能提高其各种原料的透光率。因此，在对表皮材料的制备原料进行选择时，将PP、PE和烯烃共聚物均选为透光率为80％以上的高透光率材料，前述透光率是在ASTM E1348标准下进行测定的。如此，所制得的表皮材料一方面具有真皮手感和质感，另一方面有良好的透光物理性能，采用ASTM E1348标准测试，所制得的热塑性聚烯烃表皮材料的透光率可在18％以上。
PP和PE材料在本申请中起到的作用是调节表皮材料成品的材料拉伸率、拉伸强度及硬度等，适应各种模具造型的加工。
所述助剂为抗氧化剂、光稳定剂中的至少一种。这些助剂均为本领域能够实现相应功能的材料，例如，所述抗氧化剂可为1024、1098或1330；光稳定剂为受阻胺类，如UV-P，UV-234或UV3808。由于助剂的添加剂很低，因此不会对产品的透光率有任何明显的影响。
在上述原料配比区间内选取多组不同配比的原料做试验，并分别检测表皮成品的同样的后加工条件下拉伸强度和在ASTM E1348标准下的透光率，申请人进一步发现，在配比为PP 5份，PE 5份，烯烃共聚物70份，硫化三元乙丙橡胶20份，色母粒1.5份，助剂0.4份时，所制备的表皮材料的透光率和在后加工条件下的拉伸强度同时达到极值。
烯烃共聚物性能上具有原料来源丰富、综合性能优良等特点，适用于人造表皮材料的制备。优选地，本申请将烯烃共聚物选为丙烯-乙烯共聚物、乙烯-辛烯共聚物、乙烯-丁烯共聚物和乙烯-丁烯-辛烯共聚物中的至少一种，这些共聚物在尽可能保证高透光率的同时，还能保证所制得的表皮材料在后加工过程中的强度和韧性在较高的水平。
第二方面，参见附图1，本申请还提供了上述可透光表皮材料的制作工艺，具体的制作步骤为：
S100，将不超过10份的PP，不超过10份的PE，20-70份的烯烃共聚物，不超过30份的硫化三元乙丙橡胶，0.5-2份的色母粒，0.1-0.5份的助剂均匀混合，通过压延或挤出工艺获得所述可透光表皮材料的半成品；其中，硫化三元乙丙橡胶是三元乙丙橡胶分散在PP和/或PE塑料基体中制备得到的；PP、PE、烯烃共聚物和硫化三元乙丙橡胶总重量为100份；所述PP、PE和烯烃共聚物的透光率均为80％以上；
S200，在所述半成品的表面涂覆表面处理剂，得到所述可透光表皮材料。
挤出工艺可采用通过双螺杆挤出机挤出，挤出时，将混合后的原料通过喂料口注入挤出机，控制挤出机温度在180-230℃范围内，保持挤出机线速为0-15m/min，根据产品要求生产相应幅宽和厚度的热塑性聚烯烃薄膜。
表面处理剂采用水性聚氨酯材料，由于表面处理剂形成的表面处理剂层厚度较薄，对成品表皮材料的透光性的影响不大，另外，还可制成的可透光表皮 材料进行压花处理。
可选地，参见附图2，所述步骤S100具体包括，
S110，将所述硫化三元乙丙橡胶和/或所述烯烃共聚物中的一部分与所述色母粒进行预混造粒，得到初级原料；
S120，将所述初级原料与其余原料混合、搅拌，通过压延或挤出工艺获得所述透明表皮材料的半成品。
申请人发现，如果按照常规的手段，一次性将所有的原料混合搅拌后通过螺杆挤出机挤出成型，经常会出现表皮制品皮色不均匀，局部颜色过深，而局部接近透明的情况，十分影响表皮制品的美观，经过申请人进一步研究发现，前述情况出现的原因是，由于因为表皮材料中的色母含量显著低于其它主料，若直接将其与所有的其它原料混合就往往会造成色母粒分散不均、出现团聚现象，而本申请中，先将烯烃共聚物和/或硫化三元乙丙橡胶中的一部分与色母粒进行预混造粒，而后在将预混造粒得到的粒子与原料中的其它材料一起通过双螺杆挤出机，能够大大提高色母粒在表皮材料成品中的分散均匀性，防止出现团聚。
优选地，将所述烯烃共聚物中的一部分与所述色母粒进行预混造粒，或将所述硫化三元乙丙橡胶中的一部分与所述色母粒进行预混造粒，或将所述烯烃共聚物中的一部分和硫化三元乙丙橡胶中的一部分与所述色母粒进行预混造粒。
具体地，将所述烯烃共聚物的20％-50％与所述色母粒进行预混造粒，或将所述硫化三元乙丙橡胶的40％-60％与所述色母粒进行预混造粒，或将所述烯烃共聚物的20％-30％和硫化三元乙丙橡胶的20％-30％与所述色母粒进行预混造粒。如果与色母粒进行预混造粒的烯烃共聚物和/或硫化三元乙丙橡胶的重量份数过低，则无法达到充分预混的效果，而如果与色母粒进行预混造粒的烯烃共聚物和/或硫化三元乙丙橡胶的重量份数过高，可能在本次预混时就发生了色母粒分散不均的现象。
第三方面，参见图3，本申请还提供了一种可透光复合结构，其包括如上所述的可透光表皮材料形成的表皮层20，还包括与所述表皮层复合的泡棉材料层10，所述泡棉材料层的发泡倍率为25-35，所述表皮层和所述泡棉材料层的厚度比为1：1-1：40。
该复合结构可应用于交通工具内饰，例如用于交通工具座椅、交通工具门板、交通工具中控台等位置，如此，在交通工具的骨架等包覆该复合结构的位置设置光源，当光源关灭时，呈现常规的内饰效果，而当光源点亮时可实现透光效果。对于该复合结构，不仅要求表皮层有良好的透光率，也要求泡棉材料层有优良的透光性能。
采用高发泡倍率的泡棉材料层，具体来说，发泡倍率为25-35，该发泡倍率可以保证泡棉内部的平均孔径较大，以此，降低了光在泡棉内部的折射和散射现象的发生，有效缩短了光程且减少了光在传播过程中的损失，有效增大了第一缓冲层的透光率，该第一缓冲层的透光率采用ASTM标准测试，不小于30％，可达50％以上。
将热塑性聚烯烃表皮层和第一缓冲层的厚度比例设置为1：1至1：40，有效保证了缓冲层的足够厚度，使其可产生足够的回弹缓冲效果，又不至于过厚，如果缓冲层厚度过厚，也会延长光程和增大光在传播过程中的损失，难于实现高透光效果。
其中的表皮层制备完成后，然后通过透明胶水将表皮材料与泡棉材料粘贴在一起，上述的透明胶水指的是热熔胶等通透性较好的胶水，其是在表皮材料制备完成后涂覆于其上的，以便与泡棉材料粘接。本领域技术人员知晓，也可以采用透明胶膜将表皮材料与泡棉材料粘贴在一起。
也可以通过加热使得泡棉材料表面部分发生融化，趁热将表皮层与泡棉材料粘合，以使得表皮层和泡棉材料层复合。
可选地，根据不同的应用场景需要，所述表皮层的厚度可为0.1-1.0mm，所述泡棉材料层的厚度为1.0mm-4.0mm。
参见图4，在所述表皮层20和所述泡棉材料层10之间还设有图案层30，所述图案层30包括用于透光的镂空部和用于挡光的挡光部，所述镂空部和所述挡光部共同形成图案。
在某些应用场景中，需要在透光性复合结构的表面呈现出具有装饰效果或指示功能的图案，基于此，在一个优选的实施例中，在表皮层和泡棉材料层之间还设有图案层，所述图案层包括用于透光的镂空部和用于挡光的挡光部，所述镂空部和所述挡光部共同形成图案。如此，将该可透光复合结构覆盖在光源上，当光源关灭时，可透光复合结构呈现常规的人造革外观，而当光源点亮时， 在可透光复合结构的表面呈现出图案。这样设置，一方面对光源的形状无要求，无需将光源设置为特定造型，另外，将图案层植于可透光复合结构内，能够使得图案层距离透光性复合结构的表面非常近，光线几乎不会发生散射，因此呈现的图案非常清晰。
参见图5，将图案层30设在在所述泡棉材料层10背离表皮层20的一面，所述图案层30包括用于透光的镂空部和用于挡光的挡光部，所述镂空部和所述挡光部共同形成图案，这样通过将表皮层和图案层分设在泡棉材料层两侧，使泡棉材料不与其它结构(例如交通工具内部骨架)等直接接触，对泡棉材料形成保护。
进一步地，本申请还提供了一种交通工具内饰，该内饰可用在汽车、火车等交通工具中，采用如上所述的可透光表皮材料或可透光复合结构，从而实现交通工具内饰的透光效果。
进一步地，本申请还提供了一种装饰材料，该装饰材料可用于交通工具装饰用，也可用于家具装饰和3C设备(通讯设备、电脑设备、消费类电子设备)等其它应用环境，采用如上所述的可透光表皮材料或可透光复合结构，可实现该装饰材料的透光效果。
本领域的技术人员能够理解的是，在不冲突的前提下，上述各优选方案可以自由地组合、叠加。
应当理解，上述的实施方式仅是示例性的，而非限制性的，在不偏离本申请的基本原理的情况下，本领域的技术人员可以针对上述细节做出的各种明显的或等同的修改或替换，都将包含于本申请的权利要求范围内。

Claims (15)

  1. 一种可透光表皮材料，所述表皮材料为热塑性聚烯烃材料，其特征在于，所述表皮材料原料包括PP、PE、色母粒、烯烃共聚物、硫化三元乙丙橡胶和助剂；其中，硫化三元乙丙橡胶是三元乙丙橡胶分散在PP和/或PE塑料基体中制备得到的；所述表皮材料原料重量份组成为：PP不超过10份，PE不超过10份，烯烃共聚物20-70份，硫化三元乙丙橡胶不超过30份，色母粒0.5-2份，助剂0.1-0.5份，且PP、PE、烯烃共聚物和硫化三元乙丙橡胶总重量为100份；所述PP、PE和烯烃共聚物的透光率均为80％以上。
  2. 根据权利要求1所述的表皮材料，其特征在于，所述表皮材料原料重量份组成具体为：PP 5份，PE 5份，烯烃共聚物70份，硫化三元乙丙橡胶20份，色母粒1.5份，助剂0.4份。
  3. 根据权利要求1所述的表皮材料，其特征在于，所述烯烃共聚物为丙烯-乙烯共聚物、乙烯-辛烯共聚物、乙烯-丁烯共聚物和乙烯-丁烯-辛烯共聚物中的至少一种。
  4. 一种可透光表皮材料的制作工艺，其特征在于，制作步骤为：
    S100，将不超过10份的PP，不超过10份的PE，20-70份的烯烃共聚物，不超过30份的硫化三元乙丙橡胶，0.5-2份的色母粒，0.1-0.5份的助剂均匀混合，通过压延或挤出工艺获得所述可透光表皮材料的半成品；其中，硫化三元乙丙橡胶是三元乙丙橡胶分散在PP和/或PE塑料基体中制备得到的；PP、PE、烯烃共聚物和硫化三元乙丙橡胶总重量为100份；所述PP、PE和烯烃共聚物的透光率均为80％以上；
    S200，在所述半成品的表面涂覆表面处理剂，得到所述可透光表皮材料。
  5. 根据权利要求4所述的制作工艺，其特征在于，所述步骤S100具体包括，
    S110，将所述硫化三元乙丙橡胶和/或所述烯烃共聚物中的一部分与所述 色母粒进行预混造粒，得到初级原料；
    S120，将所述初级原料与其余原料混合、搅拌，通过压延或挤出工艺获得所述可透光表皮材料的半成品。
  6. 根据权利要求5所述的制作工艺，其特征在于，所述步骤S110具体为，
    将所述烯烃共聚物中的一部分与所述色母粒进行预混造粒，或将所述硫化三元乙丙橡胶中的一部分与所述色母粒进行预混造粒，或将所述烯烃共聚物中的一部分和硫化三元乙丙橡胶中的一部分与所述色母粒进行预混造粒。
  7. 根据权利要求6所述的制作工艺，其特征在于，所述步骤S110具体为，
    将所述烯烃共聚物的20％-50％与所述色母粒进行预混造粒，或将所述硫化三元乙丙橡胶的40％-60％与所述色母粒进行预混造粒，或将所述烯烃共聚物的20％-30％和硫化三元乙丙橡胶的20％-30％与所述色母粒进行预混造粒。
  8. 根据权利要求4-7任一项所述的制作工艺，其特征在于，在所述步骤S100中，所述表皮材料原料重量份组成具体为：PP 5份，PE 5份，烯烃共聚物70份，硫化三元乙丙橡胶20份，色母粒1.5份，助剂0.4份。
  9. 根据权利要求4-8任一项所述的制作工艺，其特征在于，在所述步骤S100中，所述烯烃共聚物为丙烯-乙烯共聚物、乙烯-辛烯共聚物、乙烯-丁烯共聚物和乙烯-丁烯-辛烯共聚物中的至少一种。
  10. 一种可透光复合结构，其特征在于，包括由根据权利要求1-3中任一项所述的可透光表皮材料形成的表皮层，还包括与所述表皮层复合在一起的泡棉材料层，所述泡棉材料层的发泡倍率为25-35，所述表皮层和所述泡棉材料层的厚度比为1：1-1：40。
  11. 根据权利要求10所述的复合结构，其特征在于，所述表皮层的厚度为0.1-1.0mm，所述泡棉材料层的厚度为1.0-4.0mm。
  12. 根据权利要求10所述的复合结构，其特征在于，在所述表皮层和所 述泡棉材料层之间还设有图案层，所述图案层包括用于透光的镂空部和用于挡光的挡光部，所述镂空部和所述挡光部共同形成图案。
  13. 根据权利要求10所述的复合结构，其特征在于，在所述泡棉材料层背离所述表皮层的一面设有图案层，所述图案层包括用于透光的镂空部和用于挡光的挡光部，所述镂空部和所述挡光部共同形成图案。
  14. 一种交通工具内饰，其特征在于，包括如权利要求1至3中任一项所述的可透光表皮材料或如权利要求10-13中任一项所述的可透光复合结构。
  15. 一种装饰材料，其特征在于，包括如权利要求1至3中任一项所述的可透光表皮材料或如权利要求10-13中任一项所述的可透光复合结构。
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