WO2023045817A1 - 一种顶蓬及其制备方法和用途 - Google Patents

一种顶蓬及其制备方法和用途 Download PDF

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Publication number
WO2023045817A1
WO2023045817A1 PCT/CN2022/118914 CN2022118914W WO2023045817A1 WO 2023045817 A1 WO2023045817 A1 WO 2023045817A1 CN 2022118914 W CN2022118914 W CN 2022118914W WO 2023045817 A1 WO2023045817 A1 WO 2023045817A1
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Prior art keywords
layer
glass fiber
preparation
glue
adhesive
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PCT/CN2022/118914
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English (en)
French (fr)
Inventor
钱旺
杨子晔
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无锡吉兴汽车声学部件科技有限公司
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Publication of WO2023045817A1 publication Critical patent/WO2023045817A1/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/003—Interior finishings

Definitions

  • the embodiment of the present application relates to the technical field of automobile interior decoration, such as a headliner and its preparation method and application.
  • the car roof is installed on the top of the car and belongs to the car interior products. With the strengthening of people's safety awareness, people's requirements for car roofs are also getting higher and higher. Therefore, the production of high-performance car roofs has gradually become a development trend.
  • the current automotive roof molding process is mainly divided into dry process and wet process.
  • the roof produced by the dry process is a hard top, and the hardness of the roof is high, which can meet the loading requirements by itself.
  • the scope of application of the dry process is small, so the wet process has become the best choice for the production of automotive roofs.
  • CN102381256A discloses a process for producing a ceiling by wet glass fiber rolling, which includes the following process steps: (1) rolling polyurethane glue on one side of the glass fiber felt on the glue rolling machine to obtain the glued glass fiber felt; (2) Lay the non-woven fabric, glued glass fiber felt, rigid polyurethane, glued glass fiber felt, and non-woven fabric in order from top to bottom, and perform press molding to obtain a semi-finished product; (3) Press and shape to obtain The semi-finished product is cooled and shaped at room temperature to obtain a formed semi-finished product; (4) spread the fabric, film, and formed semi-finished product in order from top to bottom, and then bond the fabric after spreading; (5) Laminate the fabric to obtain The molded semi-finished product is cooled and shaped at normal temperature; (6) the molded semi-finished product after cooling and shaped is subjected to water jet cutting to obtain the canopy.
  • This application greatly reduces the weight of the roof, and adopts single-sided glass fiber rolling glue, which can accurately control the amount of glue
  • CN110091560A discloses a production process for a car roof capable of installing an invisible microphone, comprising the following process steps: (1) putting each component raw material of the car roof into a hot punching die for compression molding to obtain the car roof base material Semi-finished products; (2) Carry out water jet cutting on the invisible microphone hole of the semi-finished car roof base material to obtain the finished car roof base material; (3) Put the fabric into the laminating mold for fabric bonding to obtain the car roof Semi-finished products; (4) Carry out the second water jet cutting process on the semi-finished car roof, and obtain the finished car roof after the water jet cutting process is completed.
  • the production process ensures the consistency of the appearance of the top lining fabric, but the amount of deformation of the ceiling needs to be further reduced.
  • the embodiment of the present application provides a canopy and its preparation method and application.
  • the preparation method of the canopy is to obtain the base material by pressing the composite layer with glue and the glass fiber felt layer with glue, and the base material and the fabric layer are subjected to secondary molding to obtain the canopy, which is different from the same type of canopy. Compared with this method, the process flow is simplified, and the mechanical performance of the roof can be improved without additional skylight frame.
  • the embodiment of the present application provides a method for preparing a canopy, and the method includes the following steps:
  • glue is coated on both sides of polyurethane material, obtains the composite layer that comprises first adhesive layer, polyurethane layer, second adhesive layer;
  • step (2) successively stacking the non-woven fabric layer, the first glued glass fiber felt layer, the composite layer obtained in step (1), the second glued glass fiber felt layer, and the film-coated base cloth layer, and molding to obtain the base material;
  • step (3) Laminating the fabric layer with the base material obtained in step (2) to obtain the canopy.
  • the mechanical properties of the canopy can be further improved, breaking through the limitations of traditional preparation methods, and the deformation of the canopy is low, and there are no wrinkles and color changes on the surface , stable in nature.
  • the polyurethane material in step (1) is a polyurethane foam board.
  • the foaming density of the polyurethane foam board is 30-34kg/m 3 , for example, 30kg/m 3 , 31kg/m 3 , 32kg/m 3 , 33kg/m 3 , 34kg/m 3 and so on.
  • the adhesive amount of the first adhesive layer in step (1) is 100-150 g, for example, 100 g, 110 g, 120 g, 130 g, 140 g, 150 g, etc.
  • the adhesive amount of the second adhesive layer in step (1) is 550-650g, such as 550g, 560g, 570g, 580g, 590g, 600g, 610g, 620g, 630g, 640g, 650g, etc.
  • the first adhesive layer is close to the fabric layer, and the amount of glue carried by the first adhesive layer is greater than 150g, which may cause glue bleeding, which is not conducive to the use of the ceiling.
  • the glue described in step (1) is polyurethane glue.
  • the coating method in step (1) is roll coating.
  • the equipment for rolling coating is a rubber rolling machine.
  • the roller temperature of the rubber rolling machine is 35-45°C, such as 35°C, 36°C, 37°C, 38°C, 39°C, 40°C, 41°C, 42°C, 43°C, 44°C, 45°C etc.
  • the gaps between the upper and lower rollers of the rubber rolling machine are independently 0.4-0.6 mm, for example, 0.4 mm, 0.45 mm, 0.5 mm, 0.55 mm, 0.6 mm and so on.
  • spraying water on the surface of the composite layer is also included.
  • the amount of water sprayed on the surface of the first adhesive layer in step (1) is 60-80 g, for example, 60 g, 65 g, 70 g, 75 g, 80 g, etc.
  • the amount of water sprayed on the surface of the second adhesive layer in step (1) is 70-90 g, for example, 70 g, 75 g, 80 g, 85 g, 90 g, etc.
  • the amount of water sprayed is less than 60g, which cannot make the glue and polyurethane material work better, and reduces the bonding ability, resulting in poor rigidity of the material; the amount of water sprayed is greater than 90g, which is not conducive to molding processing.
  • the time for spraying water is 8-12s, such as 8s, 9s, 10s, 11s, 12s and so on.
  • the catalyst reaction is triggered by spraying water, and the water can be used as a catalyst to promote the action of the glue and the polyurethane material, so that the glue and the polyurethane material are bonded more firmly and the rigidity of the material is improved.
  • the weight per unit area of the non-woven fabric layer in step (2) is 30-50 g/m 2 , for example, 30 g/m 2 , 35 g/m 2 , 40 g/m 2 , 45 g/m 2 , 50 g/m 2 , or 50 g/m 2 . m 2 etc.
  • the first glued glass fiber mat layer in step (2) includes a layer of glued glass fiber mat.
  • the second glued glass fiber mat layer in step (2) includes two layers of glued glass fiber mats.
  • the first glued glass fiber felt layer is two layers of glued glass fiber felt, which will cause glue seepage, which is not conducive to use;
  • the second glued glass fiber felt is a layer of glass fiber felt, and the top The rigidity of the tent is poor.
  • the preparation method of the glued glass fiber mat includes: coating glue on one side of the glass fiber mat and standing it to obtain the glued glass fiber mat.
  • the weight per unit area of the glass fiber mat is 160-200g/m 2 , for example, 160g/m 2 , 170g/m 2 , 180g/m 2 , 190g/m 2 , 200g/m 2 and so on.
  • the amount of glue attached to the glued glass fiber mat is 30-60g, such as 30g, 35g, 40g, 45g, 50g, 55g, 60g, etc.
  • the adhesive amount of the adhesive glass fiber felt is greater than 60g, and there will be glue seepage; less than 30g, the rigidity of the roof is poor.
  • the glue is polyester glue.
  • the standing time is 20-480 min, for example, 20 min, 40 min, 80 min, 100 min, 120 min, 150 min, 200 min, 250 min, 300 min, 350 min, 400 min, 450 min, etc.
  • the glue after the glue is coated on the surface of the glass fiber mat, it needs to be allowed to stand still so that the glue penetrates into the inside of the glass fiber mat, thereby improving the rigidity of the glass fiber mat; if the standing time is greater than 480min, the glue will deteriorate and the use will be invalid; If the time is less than 20 minutes, the glue cannot completely penetrate into the glass fiber mat, which is not conducive to the improvement of the rigidity of the glass fiber mat.
  • the film-coated base fabric layer in step (2) includes a polymer composite film and/or base fabric.
  • the polymer composite film is a combination of three layers of polyethylene film, polyester film and polyethylene film arranged in sequence.
  • the weight per unit area of the film-coated base fabric layer is 60-80 g/m 2 , for example, 60 g/m 2 , 65 g/m 2 , 70 g/m 2 , 75 g/m 2 , 80 g/m 2 , etc. .
  • the molding in step (2) is carried out in a mold.
  • the temperature of the upper mold and the lower mold in step (2) are independently 110-130°C, for example, 110°C, 115°C, 120°C, 125°C, 130°C, etc.
  • the molding time in step (2) is 60-100s, for example, 60s, 70s, 80s, 90s, 100s, etc.
  • the forming pressure in step (2) is 10-12 MPa, for example, 10 MPa, 11 MPa, 12 MPa, etc.
  • the fabric layer in step (3) includes knitted fabric and/or polyurethane foam board.
  • the weight per unit area of the fabric layer is 280-320g/m 2 , for example, 280g/m 2 , 285g/m 2 , 290g/m 2 , 295g/m 2 , 300g/m 2 , 305g/m 2 2 , 310g/m 2 , 315g/m 2 , 320g/m 2 .
  • the bonding temperature in step (3) is 90°C to 110°C, for example, 90°C, 92°C, 94°C, 98°C, 100°C, 102°C, 104°C, 106°C, 108°C, 110°C °C and so on.
  • the bonding time in step (3) is 60-100s, for example, 60s, 70s, 80s, 90s, 100s, etc.
  • the bonding pressure in step (3) is 10-12 MPa, for example, 10 MPa, 11 MPa, 12 MPa, etc.
  • post-processing is also included after the pasting in step (3).
  • said post-processing includes shaping and cutting.
  • the setting time is 60-100s, such as 60s, 70s, 80s, 90s, 100s and so on.
  • the cutting method is water jet cutting.
  • the cutting water pressure is 4-6 bar, for example, 4 bar, 5 bar, 6 bar and so on.
  • the cutting air pressure is 3400-3600 bar, for example, 3400 bar, 3420 bar, 3460 bar, 3480 bar, 3500 bar, 3520 bar, 3550 bar, 3580 bar, 3600 bar and so on.
  • the preparation method comprises the following steps:
  • the first glued glass fiber mat layer includes a glass fiber mat
  • the second glued glass fiber mat layer includes Two laminated glued fiberglass mats
  • step (3) stacking the non-woven fabric layer, the first glued glass fiber felt layer, the composite layer obtained in step (1), the second glued glass fiber felt layer, and the film-coated base cloth layer in 10 Molding at ⁇ 12MPa for 60 ⁇ 100s to obtain the base material;
  • step (3) Laminating the fabric layer with the substrate obtained in step (3), shaping and cutting with a water jet to obtain the canopy.
  • the embodiment of the present application provides a canopy, and the canopy is manufactured by the preparation method as described in the first aspect.
  • the embodiment of the present application provides an application of the roof as described in the second aspect in a car roof.
  • the method for preparing a roof uses glued glass fiber felt and coats glue on both sides of the polyurethane material, and the roof made by secondary compression molding has excellent mechanical properties and peel strength. High, the amount of deformation is less than 3mm, no wrinkles and discoloration will appear on the surface of the ceiling, and it is easy to form and process.
  • This embodiment provides a canopy and a preparation method thereof, and the specific steps of the preparation method are as follows:
  • BASF glue brand name Elastocoat cc 1977c -b
  • the temperature of the roller is 40°C
  • the gap between the upper and lower rollers is 0.48mm and 0.52mm respectively.
  • step (2) Apply 48g of 0418 glue (DESMODUR 0418 of Covestro) to one side of the glass fiber felt (with a unit area weight of 180g/m 2 ) using a glue rolling machine, and let it stand at room temperature for 20 minutes to obtain a glued glass fiber felt;
  • the setting parameters of the melter are the same as step (1);
  • step (3) sequentially make non-woven fabric (weight per unit area is 45g/m 2 ), one layer of glued glass fiber felt, the composite layer obtained in step (1), two layers of glued glass fiber felt, and film-coated base cloth (unit: The area weight is 75g/m 2 ) stacked, under the condition that the temperature of the upper mold and the lower mold of the mold is 120°C, and the molding pressure is 11MPa, press molding for 80s to obtain the substrate;
  • This embodiment provides a canopy and a preparation method thereof, and the specific steps of the preparation method are as follows:
  • step (2) Apply 30g of 0418 glue (DESMODUR 0418 of Covestro) to one side of the glass fiber felt (with a unit area weight of 160g/m 2 ) using a glue rolling machine, and let it stand at room temperature for 240min to obtain a glued glass fiber felt;
  • the setting parameters of the melter are the same as step (1);
  • step (3) sequentially make non-woven fabric (weight per unit area is 30g/m 2 ), one layer of glued glass fiber felt, the composite layer obtained in step (1), two layers of glued glass fiber felt, and film-coated base cloth (unit: The area weight is 60g/m 2 ) stacked, under the condition that the temperature of the upper mold and the lower mold of the mold is 110°C, and the molding pressure is 10MPa, press molding for 60s to obtain the base material;
  • This embodiment provides a canopy and a preparation method thereof, and the specific steps of the preparation method are as follows:
  • step (2) Apply 60g of 0418 glue (DESMODUR 0418 of Covestro) to one side of the glass fiber felt (weight per unit area: 200g/m 2 ) with a glue rolling machine, and let stand at room temperature for 480min to obtain the glued glass fiber felt;
  • the setting parameters of the melter are the same as step (1);
  • step (3) sequentially make non-woven fabric (weight per unit area is 50g/m 2 ), one layer of glued glass fiber felt, the composite layer obtained in step (1), two layers of glued glass fiber felt, and film-coated base cloth (unit: The area weight is 80g/m 2 ) stacked, under the condition that the temperature of the upper mold and the lower mold of the mold is 130°C, and the molding pressure is 12MPa, press molding for 100s to obtain the base material;
  • This embodiment provides a ceiling and a preparation method thereof, which differ from Embodiment 1 only in that the adhesive amount of the second adhesive layer is 700g; other raw materials, structures and process parameters are the same as those in Embodiment 1. same.
  • This embodiment provides a kind of roof and its preparation method.
  • the only difference between it and Embodiment 1 is that the adhesive amount of the first adhesive layer is 180g; other raw materials, structures and process parameters are the same as those of Embodiment 1. same.
  • This embodiment provides a canopy and a preparation method thereof, which is different from Embodiment 1 only in that the amount of glue attached to the glass fiber mat is 70 g; other raw materials, structures and process parameters are the same as in Embodiment 1.
  • This embodiment provides a ceiling and a preparation method thereof.
  • the difference between it and Embodiment 1 is that the amount of water sprayed on the lower surface of the polyurethane foam board with glue is 50 g; other raw materials, structures and process parameters are the same as those in Embodiment 1. 1 is the same.
  • This embodiment provides a canopy and a preparation method thereof.
  • the difference between it and Embodiment 1 is that the amount of water sprayed on the lower surface of the polyurethane foam board with glue is 110 g; other raw materials, structures and process parameters are the same as those in Embodiment 1. 1 is the same.
  • This embodiment provides a ceiling and a preparation method thereof, and its difference from Example 1 is that the second glued glass fiber felt layer is a layer of glued glass fiber felt; other raw materials, structures and process parameters are all Same as Example 1.
  • This comparative example provides a canopy and its preparation method.
  • the only difference between it and Example 1 is that there is no roll-coated glue on the polyurethane foam board, and other raw materials, structures and process parameters are the same as in Example 1.
  • Peeling force The canopy is pretreated at 23°C and 65% RH for 24 hours, and then undergoes 5 cycles of cooling and heating (90°C ⁇ 4h ⁇ room temperature ⁇ 0.5h ⁇ -30°C ⁇ 1.5h ⁇ room temperature ⁇ 0.5 h ⁇ 70°C, 95%RH ⁇ 3h ⁇ room temperature ⁇ 0.5h ⁇ -30°C ⁇ 1.5h ⁇ room temperature ⁇ 0.5h is one cycle), take three sheets of 200mm ⁇ 50mm horizontally and vertically from the flat area of the roof, The decorative layer at one end is peeled off from the substrate by about 100mm, the distance between the jaws is 100mm, the upper and lower jaws are 180°, and the speed is 100mm/min.
  • the canopy has excellent peel strength and low deformation, and has good aging resistance, and the surface will not appear. Wrinkles, color changes and other phenomena, to meet the performance requirements of the car roof field for the roof.
  • Examples 1 to 3 it can be seen from Examples 1 to 3 that the peeling force of the roof provided by the application is about 36N, the deformation of the roof is ⁇ 3mm, the deformation is low, and there will be no wrinkles, color changes, etc. on the surface, and the molding state is good; by implementing Examples 1-3 are compared with Examples 4-9 and it can be seen that when the glue content on the polyurethane material or glass fiber mat is too high, it is not conducive to molding processing, and the molding state is poor; and the amount of water sprayed on the surface of the polyurethane material and the glass fiber mat The number of layers will also affect the overall performance of the canopy.
  • Example 1 From the comparison of Example 1 and Comparative Example 1, it can be seen that when the polyurethane material is not coated with glue, the peeling force of the roof is small, the deformation is >10mm, and wrinkles appear on the surface, which is not conducive to use.
  • the application provides a ceiling and its preparation method.
  • the prepared ceiling has high peel strength, low deformation and no surface damage. Wrinkles appear and the color does not change.

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  • Lining Or Joining Of Plastics Or The Like (AREA)
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Abstract

本文公布一种顶蓬及其制备方法和用途，所述制备方法包括以下步骤：(1)在聚氨酯材料的两面涂覆胶水，得到包括第一粘结剂层、聚氨酯层和第二粘结剂层的复合层；(2)依次将无纺布层、第一带胶玻璃纤维毡层、所述复合层、第二带胶玻璃纤维毡层、覆膜底布层堆叠、成型，得到基材；(3)将面料层与所述基材贴合，得到所述顶蓬。本申请通过使用带胶玻璃纤维毡和在聚氨酯材料的两面涂覆胶水，制备得到的顶蓬具有优异的机械性能，变形量低，且顶蓬表面不会出现皱纹、变色现象。

Description

一种顶蓬及其制备方法和用途 技术领域
本申请实施例涉及汽车内饰技术领域，例如一种顶蓬及其制备方法和用途。
背景技术
汽车顶蓬安装于汽车顶部，属于汽车内饰产品。随着人们安全意识的增强，人们对汽车顶蓬的要求也越来越高。因此，生产高性能汽车顶蓬也逐渐成为发展趋势。
当前汽车顶蓬成型工艺主要分为干法工艺与湿法工艺。干法工艺生产的顶蓬为硬顶，顶蓬的硬度大，自身就能达到装车要求。但是干法工艺的适用范畴较小，因此，湿法工艺成为生产汽车顶蓬的最佳选择。CN102381256A公开了一种湿法玻纤滚胶生产顶蓬的工艺，包括以下工艺步骤：(1)在滚胶机对玻璃纤维毡的一面滚上聚氨酯胶，得到带胶玻璃纤维毡；(2)将无纺布、带胶玻璃纤维毡、硬质聚氨酯、带胶玻璃纤维毡、无纺布按从上至下的顺序进行铺料，进行压制成型，得到半成品；(3)将压制成型后得到的半成品在常温下冷却定型，得到成型半成品；(4)将面料、胶膜、成型半成品按从上至下的顺序进行铺料，铺料后进行面料贴合；(5)将面料贴合得到的成型半成品在常温下进行冷却定型；(6)将冷却定型后的成型半成品进行水刀切割，即得到所述的顶篷。本申请大大降低了顶蓬重量，采用单面玻纤滚胶，可精确的控制上胶量。但是，所述工艺只在玻璃纤维上滚胶，使得顶蓬的刚性有一定的限制。
CN110091560A公开了一种能安装隐形麦克风的汽车顶蓬的生产工艺，包括以下工艺步骤：(1)将汽车顶蓬各组分原材料放入热冲切模具中进行压制成型，得到汽车顶蓬基材半成品；(2)对汽车顶蓬基材半成品的隐形麦克风孔位进行水刀切割处理，得到汽车顶蓬基材成品；(3)将面料放入贴合模具中进行面料贴合得到汽车顶蓬半成品；(4)将汽车顶蓬半成品进行第二次水刀切割处理，水刀切割处理结束后得到汽车顶蓬成品。所述生产工艺保证了顶衬面料外观的一致性，但顶蓬变形量有待进一步降低。
因此，为提高顶蓬的剥离强度、降低顶蓬变形量、节约成本，开发一种高效的制备方法用于制备汽车顶蓬是本领域亟待解决的问题。
发明内容
以下是对本文详细描述的主题的概述。本概述并非是为了限制权利要求的保护范围。
本申请实施例提供一种顶蓬及其制备方法和用途。所述顶蓬的制备方法通过将带胶的复合层和带胶玻璃纤维毡层经压制成型得到基材，将基材与面料层经二次成型制得所述顶蓬，与同类型顶蓬相比，简化了工艺流程，不需要另加天窗框，就可以提高顶蓬的机械性能。
第一方面，本申请实施例提供一种顶蓬的制备方法，所述制备方法包括以下步骤：
(1)在聚氨酯材料的两面涂覆胶水，得到包括第一粘结剂层、聚氨酯层、第二粘结剂层的复合层；
(2)依次将无纺布层、第一带胶玻璃纤维毡层、步骤(1)得到的复合层、第二带胶玻璃纤维毡层、覆膜底布层堆叠，成型，得到基材；
(3)将面料层与步骤(2)得到的基材贴合，得到所述顶蓬。
本申请中，通过使用带胶复合层和带胶玻璃纤维毡层，能够进一步提升顶蓬的机械性能，突破了传统制备方法的局限性，并且顶蓬的变形量低，表面无皱纹和颜色变化，性质稳定。
作为本申请优选的技术方案，步骤(1)所述聚氨酯材料为聚氨酯发泡板材。
优选地，所述聚氨酯发泡板材的发泡密度为30～34kg/m 3，例如可以为30kg/m 3、31kg/m 3、32kg/m 3、33kg/m 3、34kg/m 3等。
优选地，步骤(1)所述第一粘结剂层的带胶量为100～150g，例如可以为100g、110g、120g、130g、140g、150g等。
优选地，步骤(1)所述第二粘结剂层的带胶量为550～650g，例如可以为550g、560g、570g、580g、590g、600g、610g、620g、630g、640g、650g等。
本申请中，所述第一粘结剂层靠近面料层，第一粘结剂层带胶量大于150g，会出现渗胶现象，不利于顶蓬的使用。
优选地，步骤(1)所述胶水为聚氨酯胶水。
优选地，步骤(1)所述涂覆的方法为滚涂。
优选地，所述滚涂的设备为滚胶机。
优选地，所述滚胶机的滚筒温度为35～45℃，例如可以为35℃、36℃、37℃、38℃、39℃、40℃、41℃、42℃、43℃、44℃、45℃等。
优选地，所述滚胶机的上、下滚筒的间隙各自独立地为0.4～0.6mm，例如可以为0.4mm、0.45mm、0.5mm、0.55mm、0.6mm等。
优选地，步骤(1)所述涂覆完成后还包括在复合层表面喷洒水。
优选地，步骤(1)所述第一粘结剂层表面喷洒的水量为60～80g，例如可以为60g、65g、70g、75g、80g等。
优选地，步骤(1)所述第二粘结剂层表面喷洒的水量为70～90g，例如可以为70g、75g、80g、85g、90g等。
本申请中，所述喷洒的水量小于60g，不能使胶水与聚氨酯材料更好的作用，降低粘结能力，从而导致材料刚性差；所述喷洒的水量大于90g，不利于成型加工。
优选地，所述喷洒水的时间为8～12s，例如可以为8s、9s、10s、11s、12s等。
本申请中，通过喷洒水引发触媒反应，水可作为催化剂促进胶水与聚氨酯材料的作用，使得胶水与聚氨酯材料粘结更牢固，提升材料的刚性。
优选地，步骤(2)所述无纺布层的单位面积重量为30～50g/m 2，例如可以为30g/m 2、35g/m 2、40g/m 2、45g/m 2、50g/m 2等。
优选地，步骤(2)所述第一带胶玻璃纤维毡层包括一层带胶玻璃纤维毡。
优选地，步骤(2)所述第二带胶玻璃纤维毡层包括两层带胶玻璃纤维毡。
本申请中，所述第一带胶玻璃纤维毡层为两层带胶玻璃纤维毡，会出现渗胶现象，不利于使用；所述第二带胶玻璃纤维毡为一层玻璃纤维毡，顶蓬的刚性差。
优选地，所述带胶玻璃纤维毡的制备方法包括：在玻璃纤维毡的一面涂覆胶水，静置，得到所述带胶玻璃纤维毡。
优选地，所述玻璃纤维毡的单位面积重量为160～200g/m 2，例如可以为160g/m 2、170g/m 2、180g/m 2、190g/m 2、200g/m 2等。
优选地，所述带胶玻璃纤维毡的带胶量为30～60g，例如可以为30g、35g、40g、45g、50g、55g、60g等。
本申请中，所述带胶玻璃纤维毡的带胶量大于60g，会出现渗胶现象；小 于30g，顶蓬的刚性差。
优选地，所述胶水为聚酯胶水。
优选地，所述静置的时间为20～480min，例如可以为20min、40min、80min、100min、120min、150min、200min、250min、300min、350min、400min、450min等。
本申请中，在玻璃纤维毡表面涂覆胶水后，需要静置使得胶水渗透到玻璃纤维毡内部，从而提升玻璃纤维毡的刚性；所述静置时间大于480min，胶水变质，使用无效；静置时间小于20min，胶水不能完全渗透到玻璃纤维毡内部，不利于玻璃纤维毡刚性的提升。
优选地，步骤(2)所述覆膜底布层包括高分子复合膜和/或底布。
优选地，所述高分子复合膜为依次设置的聚乙烯膜、聚酯膜和聚乙烯膜三层膜的组合。
优选地，所述覆膜底布层的单位面积重量为60～80g/m 2，例如可以为60g/m 2、65g/m 2、70g/m 2、75g/m 2、80g/m 2等。
优选地，步骤(2)所述成型在模具中进行。
优选地，步骤(2)所述成型的上模温度、下模温度各自独立地为110～130℃，例如可以为110℃、115℃、120℃、125℃、130℃等。
优选地，步骤(2)所述成型的时间为60～100s，例如可以为60s、70s、80s、90s、100s等。
优选地，步骤(2)所述成型的压力为10～12MPa，例如可以为10MPa、11MPa、12MPa等。
优选地，步骤(3)所述面料层包括针织布和/或聚氨酯发泡板。
优选地，所述面料层的单位面积重量为280～320g/m 2，例如可以为280g/m 2、285g/m 2、290g/m 2、295g/m 2、300g/m 2、305g/m 2、310g/m 2、315g/m 2、320g/m 2。
优选地，步骤(3)所述贴合的温度为90～110℃，例如可以为90℃、92℃、94℃、98℃、100℃、102℃、104℃、106℃、108℃、110℃等。
优选地，步骤(3)所述贴合的时间为60～100s，例如可以为60s、70s、80s、90s、100s等。
优选地，步骤(3)所述贴合的压力为10～12MPa，例如可以为10MPa、11MPa、12MPa等。
优选地，步骤(3)所述贴合后还包括后处理。
优选地，所述后处理包括定型和切割。
优选地，所述定型的时间为60～100s，例如可以为60s、70s、80s、90s、100s等。
优选地，所述切割的方法为水刀切割。
优选地，所述切割的水压为4～6bar，例如可以为4bar、5bar、6bar等。
优选地，所述切割的气压为3400～3600bar，例如可以为3400bar、3420bar、3460bar、3480bar、3500bar、3520bar、3550bar、3580bar、3600bar等。
作为本申请优选的技术方案，所述制备方法包括以下步骤：
(1)在聚氨酯材料的两面涂覆胶水，得到包括第一粘结剂层、聚氨酯层和第二粘结剂层的复合层；
(2)在玻璃纤维毡的一面涂覆胶水，静置20～480min，得到带胶玻璃纤维毡；第一带胶玻璃纤维毡层包括一张玻璃纤维毡，第二带胶玻璃纤维毡层包括两张叠合的带胶玻璃纤维毡；
(3)依次将无纺布层、所述第一带胶玻璃纤维毡层、步骤(1)得到的复合层、所述第二带胶玻璃纤维毡层、覆膜底布层堆叠，在10～12MPa下成型60～100s，得到基材；
(4)将面料层与步骤(3)得到的基材贴合，经定型、水刀切割，得到所述顶蓬。
第二方面，本申请实施例提供一种顶蓬，所述顶蓬采用如第一方面所述的制备方法制得。
第三方面，本申请实施例提供一种如第二方面所述的顶蓬在汽车顶蓬中的用途。
本申请所述的数值范围不仅包括上述列举的点值，还包括没有列举出的上述数值范围之间的任意的点值，限于篇幅及出于简明的考虑，本申请不再穷尽列举所述范围包括的具体点值。
与相关技术相比，本申请的有益效果为：
本申请实施例提供的一种顶蓬的制备方法，通过使用带胶玻璃纤维毡，以及在聚氨酯材料的两面涂覆胶水，经二次压制成型制得的顶蓬具有优异的机械性能，剥离强度高，变形量小于3mm，顶蓬表面不会出现皱纹、变色现象，便 于成型加工。
在阅读并理解了详细描述后，可以明白其他方面。
具体实施方式
为便于理解本申请，本申请列举实施例如下。本领域技术人员应该明了，所述实施例仅仅是帮助理解本申请，不应视为对本申请的具体限制。
实施例1
本实施例提供一种顶蓬及其制备方法，所述制备方法的具体步骤如下：
(1)以靠近面料的一面为上，采用滚胶机在聚氨酯发泡板材(发泡密度为32kg/m 3)的上、下表面分别涂覆巴斯夫胶水(牌号Elastocoat cc 1977c-b)120g、600g，设置滚胶机的参数：滚筒的温度为40℃，上、下滚筒的间隙分别为0.48mm、0.52mm，涂覆完成后，在带胶聚氨酯发泡板材上下表面分别喷洒水70g、80g，喷洒10s，得到包括第一粘结剂层、聚氨酯层和第二粘结剂层的复合层；
(2)采用滚胶机对玻璃纤维毡(单位面积重量为180g/m 2)的一面涂覆0418胶水(科思创的DESMODUR 0418)48g，室温静置20min，得到带胶玻璃纤维毡；滚胶机的设置参数与步骤(1)相同；
(3)依次将无纺布(单位面积重量为45g/m 2)、一层带胶玻璃纤维毡、步骤(1)得到的复合层、两层带胶玻璃纤维毡、覆膜底布(单位面积重量为75g/m 2)堆叠，在模具的上模温度和下模温度为120℃，成型压力为11MPa的条件下，压制成型80s，得到基材；
(4)将面料(针织布和聚氨酯板材，单位面积重量为300g/m 2)与所述基材在温度为100℃，压力为11MPa的条件下贴合80s，定型80s、经气压为5bar，水压为3500bar的水刀切割，得到所述顶蓬。
实施例2
本实施例提供一种顶蓬及其制备方法，所述制备方法的具体步骤如下：
(1)以靠近面料的一面为上，采用滚胶机在聚氨酯发泡板材(发泡密度为30kg/m 3)的上、下表面分别涂覆巴斯夫胶水(牌号Elastocoat cc 1977c-b)100g、550g，设置滚胶机的参数：滚筒的温度为35℃，上、下滚筒的间隙分别为0.4mm、0.6mm，涂覆完成后，在带胶聚氨酯发泡板材上下表面分别喷洒水60g、 70g，喷洒8s，得到包括第一粘结剂层、聚氨酯层和第二粘结剂层的复合层；
(2)采用滚胶机对玻璃纤维毡(单位面积重量为160g/m 2)的一面涂覆0418胶水(科思创的DESMODUR 0418)30g，室温静置240min，得到带胶玻璃纤维毡；滚胶机的设置参数与步骤(1)相同；
(3)依次将无纺布(单位面积重量为30g/m 2)、一层带胶玻璃纤维毡、步骤(1)得到的复合层、两层带胶玻璃纤维毡、覆膜底布(单位面积重量为60g/m 2)堆叠，在模具的上模温度和下模温度为110℃，成型压力为10MPa的条件下，压制成型60s，得到基材；
(4)将面料(针织布和聚氨酯板材，单位面积重量为280g/m 2)与所述基材在温度为90℃，压力为10MPa的条件下贴合60s，定型60s、经气压为4bar，水压为3400bar的水刀切割，得到所述顶蓬。
实施例3
本实施例提供一种顶蓬及其制备方法，所述制备方法的具体步骤如下：
(1)以靠近面料的一面为上，采用滚胶机在聚氨酯发泡板材(发泡密度为34kg/m 3)的上、下表面分别涂覆巴斯夫胶水(牌号Elastocoat cc 1977c-b)150g、650g，设置滚胶机的参数：滚筒的温度为45℃，上、下滚筒的间隙分别为0.48mm、0.52mm，涂覆完成后，在带胶聚氨酯发泡板材上下表面分别喷洒水80g、90g，喷洒12s，得到包括第一粘结剂层、聚氨酯层和第二粘结剂层的复合层；
(2)采用滚胶机对玻璃纤维毡(单位面积重量为200g/m 2)的一面涂覆0418胶水(科思创的DESMODUR 0418)60g，室温静置480min，得到带胶玻璃纤维毡；滚胶机的设置参数与步骤(1)相同；
(3)依次将无纺布(单位面积重量为50g/m 2)、一层带胶玻璃纤维毡、步骤(1)得到的复合层、两层带胶玻璃纤维毡、覆膜底布(单位面积重量为80g/m 2)堆叠，在模具的上模温度和下模温度为130℃，成型压力为12MPa的条件下，压制成型100s，得到基材；
(4)将面料(针织布和聚氨酯板材，单位面积重量为320g/m 2)与所述基材在温度为110℃，压力为12MPa的条件下贴合100s，定型100s、经气压为6bar，水压为3600bar的水刀切割，得到所述顶蓬。
实施例4
本实施例提供一种顶蓬及其制备方法，其与实施例1的区别仅在于，所述第二粘结剂层的带胶量为700g；其他原料、结构及工艺参数均与实施例1相同。
实施例5
本实施例提供一种顶蓬及其制备方法，其与实施例1的区别仅在于，所述第一粘结剂层的带胶量为180g；其他原料、结构及工艺参数均与实施例1相同。
实施例6
本实施例提供一种顶蓬及其制备方法，其与实施例1的区别仅在于，所述玻璃纤维毡的带胶量为70g；其他原料、结构及工艺参数均与实施例1相同。
实施例7
本实施例提供一种顶蓬及其制备方法，其与实施例1的区别仅在于，所述带胶聚氨酯发泡板材下表面喷洒的水量为50g；其他原料、结构及工艺参数均与实施例1相同。
实施例8
本实施例提供一种顶蓬及其制备方法，其与实施例1的区别仅在于，所述带胶聚氨酯发泡板材下表面喷洒的水量为110g；其他原料、结构及工艺参数均与实施例1相同。
实施例9
本实施例提供一种顶蓬及其制备方法，其与实施例1的区别仅在于，所述第二带胶玻璃纤维毡层为一层带胶玻璃纤维毡；其他原料、结构及工艺参数均与实施例1相同。
对比例1
本对比例提供一种顶蓬及其制备方法，其与实施例1的区别仅在于，所述聚氨酯发泡板上没有滚涂胶水，其他原料、结构及工艺参数均与实施例1相同。
性能测试
(1)剥离力：所述顶蓬在23℃、65％RH中预处理24h，再经历5个冷热循环(90℃×4h→室温×0.5h→-30℃×1.5h→室温×0.5h→70℃、95％RH×3h→室温×0.5h→-30℃×1.5h→室温×0.5h为1个循环)后，顶蓬平坦区域横纵向各取3片200mm×50mm的板材，一端的装饰层与基材剥开约100mm，夹口距离100mm，上下夹口180°，速度100mm/min，曲线均值为粘结力，报告每个方向的均值，总平均值记录在表1。
(2)变形程度：所述顶蓬经5个冷热循环(90℃×4h→23℃×0.5h→30℃×1.5h→23℃×0.5h→70℃、95％RH×3h→23℃×0.5h→30℃×1.5h→23℃×0.5h为1个冷热循环)后，记录顶蓬的变形量。其中，一般区域变形量最大值小于等于3mm，标记为“优”；一般区域变形量最大值大于3mm小于等于10mm，标记为“良好”；一般区域变形量最大值大于10mm，标记为“差”。
(3)表面形貌、颜色：经过5个冷热循环(90℃×4h→23℃×0.5h→30℃×1.5h→23℃×0.5h→70℃、95％RH×3h→23℃×0.5h→30℃×1.5h→23℃×0.5h为1个冷热循环)后，通过目测观察表面是否有皱纹，是否颜色发生变化。
(4)成型状态：加工过程中如未出现渗胶或黏模的情况，标记为“好”；反之，标记为差。
具体测试结果如表1所示：
表1
Figure PCTCN2022118914-appb-000001
由上表可知，本申请中通过使用带胶玻璃纤维毡以及在聚氨酯材料两面涂覆胶水，使得所述顶蓬具有优异的剥离强度和低的变形量，并且耐老化性能好，表面不会出现皱纹、颜色变化等现象，满足汽车顶蓬领域对顶蓬的性能要求。
由实施例1～3看出，本申请提供的顶蓬，剥离力在36N左右，顶蓬变形量≦3mm，变形量低且表面不会出现皱纹、颜色变化等现象，成型状态好；由实 施例1～3和实施例4～9对比可知，当聚氨酯材料或玻璃纤维毡上涂覆胶水含量过高时，不利于成型加工，成型状态差；而聚氨酯材料表面喷洒水的量及玻璃纤维毡的层数也都会影响顶蓬的综合性能。
由实施例1和对比例1比较可知，当所述聚氨酯材料未涂覆胶水时，顶蓬的剥离力小，变形量＞10mm，且表面出现皱纹，不利于使用。
综上所述，本申请提供的一种顶蓬及其制备方法，通过带胶玻璃纤维毡和带胶聚氨酯材料的配合使用，所制得的顶蓬剥离强度高，变形量低且表面不会出现皱纹，颜色不会发生变化。
申请人声明，以上所述仅为本申请的具体实施方式，但本申请的保护范围并不局限于此，所属技术领域的技术人员应该明了，任何属于本技术领域的技术人员在本申请揭露的技术范围内，可轻易想到的变化或替换，均落在本申请的保护范围和公开范围之内。

Claims (13)

  1. 一种顶蓬的制备方法，其中，所述制备方法包括以下步骤：
    (1)在聚氨酯材料的两面涂覆胶水，得到包括第一粘结剂层、聚氨酯层、第二粘结剂层的复合层；
    (2)依次将无纺布层、第一带胶玻璃纤维毡层、步骤(1)得到的复合层、第二带胶玻璃纤维毡层、覆膜底布层堆叠，成型，得到基材；
    (3)将面料层与步骤(2)得到的基材贴合，得到所述顶蓬。
  2. 根据权利要求1所述的制备方法，其中，步骤(1)所述聚氨酯材料为聚氨酯发泡板材。
  3. 根据权利要求1或2所述的制备方法，其中，所述聚氨酯发泡板材的发泡密度为30～34kg/m 3。
  4. 根据权利要求1～3任一项所述的制备方法，其中，步骤(1)所述第一粘结剂层的带胶量为100～150g。
  5. 根据权利要求1～4任一项所述的制备方法，其中，步骤(1)所述第二粘结剂层的带胶量为550～650g；
    优选地，步骤(1)所述胶水为聚氨酯胶水；
    优选地，步骤(1)所述涂覆的方法为滚涂；
    优选地，所述滚涂的设备为滚胶机；
    优选地，所述滚胶机的滚筒温度为35～45℃；
    优选地，所述滚胶机的上、下滚筒的间隙各自独立地为0.4～0.6mm。
  6. 根据权利要求1～5所述的制备方法，其中，步骤(1)所述涂覆完成后还包括在复合层表面喷洒水；
    优选地，步骤(1)所述第一粘结剂层表面喷洒的水量为60～80g；
    优选地，步骤(1)所述第二粘结剂层表面喷洒的水量为70～90g；
    优选地，所述喷洒水的时间为8～12s。
  7. 根据权利要求1～6任一项所述的制备方法，其中，步骤(2)所述无纺布层的单位面积重量为30～50g/m 2；
    优选地，步骤(2)所述第一带胶玻璃纤维毡层包括一层带胶玻璃纤维毡；
    优选地，步骤(2)所述第二带胶玻璃纤维毡层包括两层带胶玻璃纤维毡；
    优选地，所述带胶玻璃纤维毡的制备方法包括：
    在玻璃纤维毡的一面涂覆胶水，静置，得到所述带胶玻璃纤维毡；
    优选地，所述玻璃纤维毡的单位面积重量为160～200g/m 2；
    优选地，所述带胶玻璃纤维毡的带胶量为30～60g；
    优选地，所述胶水为聚酯胶水；
    优选地，所述静置的时间为20～480min。
  8. 根据权利要求1～7任一项所述的制备方法，其中，所述覆膜底布层包括高分子复合膜和/或底布；
    优选地，所述高分子复合膜为依次设置的聚乙烯膜、聚酯膜和聚乙烯膜三层膜的组合；
    优选地，所述覆膜底布层的单位面积重量为60～80g/m 2；
    优选地，步骤(2)所述成型在模具中进行；
    优选地，步骤(2)所述成型的上模温度、下模温度各自独立地为110～130℃；
    优选地，步骤(2)所述成型的时间为60～100s；
    优选地，步骤(2)所述成型的压力为10～12MPa。
  9. 根据权利要求1～8任一项所述的制备方法，其中，步骤(3)所述面料层包括针织布和/或聚氨酯发泡板；
    优选地，所述面料层的单位面积重量为280～320g/m 2；
    优选地，步骤(3)所述贴合的温度为90～110℃；
    优选地，步骤(3)所述贴合的时间60～100s；
    优选地，步骤(3)所述贴合的压力10～12MPa。
  10. 根据权利要求1～9任一项所述的制备方法，其中，步骤(3)所述贴合后还包括后处理；
    优选地，所述后处理包括定型和切割；
    优选地，所述定型的时间为60～100s；
    优选地，所述切割的方法为水刀切割；
    优选地，所述切割的水压为4～6bar；
    优选地，所述切割的气压为3400～3600bar。
  11. 根据权利要求1～10任一项所述的制备方法，其包括以下步骤：
    (1)在聚氨酯材料的两面涂覆胶水，得到包括第一粘结剂层、聚氨酯层和第二粘结剂层的复合层；
    (2)在玻璃纤维毡的一面涂覆胶水，静置20～480min，得到带胶玻璃纤维 毡；第一带胶玻璃纤维毡层包括一张带胶玻璃纤维毡，第二带胶玻璃纤维毡层包括两张叠合的带胶玻璃纤维毡；
    (3)依次将无纺布层、所述第一带胶玻璃纤维毡层、步骤(1)得到的复合层、所述第二带胶玻璃纤维毡层、覆膜底布层堆叠，在10～12MPa下成型60～100s，得到基材；
    (4)将面料层与步骤(3)得到的基材贴合，经定型、水刀切割，得到所述顶蓬。
  12. 一种顶蓬，其中，所述顶蓬采用如权利要求1～11任一项所述的制备方法制得。
  13. 一种如权利要求12所述的顶蓬在汽车顶蓬中的用途。
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