WO2023173707A1 - 微纳胶体纤维混凝结构及其加工方法 - Google Patents

微纳胶体纤维混凝结构及其加工方法 Download PDF

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WO2023173707A1
WO2023173707A1 PCT/CN2022/118609 CN2022118609W WO2023173707A1 WO 2023173707 A1 WO2023173707 A1 WO 2023173707A1 CN 2022118609 W CN2022118609 W CN 2022118609W WO 2023173707 A1 WO2023173707 A1 WO 2023173707A1
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micro
colloid
nano
concrete structure
fiber
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PCT/CN2022/118609
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English (en)
French (fr)
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龚炜
过海龙
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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 WO2023173707A1 publication Critical patent/WO2023173707A1/zh

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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • 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
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    • 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
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    • 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
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
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    • 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
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    • 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
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    • B32B7/04—Interconnection of layers
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    • 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
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Definitions

  • the present application relates to the technical field of automobile trim parts, for example, to a micro-nano colloidal fiber concrete structure and its processing method.
  • automotive interior and exterior trims such as ceilings, tailgate trims, and pillars
  • Base materials, lower pillars, bodywork, etc., lightweight materials can effectively reduce vehicle fuel consumption and achieve energy conservation and environmental protection.
  • plastic particles are used for injection molding of automobile pillars and other hard decorations, and the process is carried out as a whole piece.
  • the process is carried out as a whole piece.
  • it is also necessary to consider the product's complex appearance and large curved surface decoration performance. Due to the limitations of the relevant technology, the pillars and other hard decorations need to be injection molded.
  • Other hard decoration segments are mechanically spliced, but gaps will be left at the splicing points, making it difficult to meet the requirements for appearance and decorative performance.
  • This application provides a micro-nano colloidal fiber concrete structure that can produce high-density, high-mechanical-strength, lightweight materials to meet the needs for lightweight production of automotive interior and exterior trim parts.
  • This application also provides a processing method of micro-nano colloidal fiber concrete structure.
  • micro-nano colloid fiber concrete structure including a micro-nano colloid and a fiber bundle layer.
  • the micro-nano colloid is a three-dimensional structure formed by overlapping multiple colloid bone beams, and a volume is formed between the colloid bone beams.
  • the colloid bone beams are set to collapse and deform after being subjected to thermal pressure.
  • the glue space is filled with glue that allows the micro-nano colloid to maintain its deformed shape after cooling and solidification.
  • the fiber bundle layer is set to serve as a supporting skeleton throughout the micro-nano colloid. .
  • One embodiment also provides a processing method for a micro-nano colloidal fiber concrete structure, which is applied to the above-mentioned micro-nano colloidal fiber concrete structure.
  • the method includes: rolling PU soft foam, spraying water, and Attach glass fibers to both sides of the PU soft foam; lay the base fabric, a plurality of the PU soft foams, the glass fiber and the surface fabric from bottom to top; and use a cold material hot mold to layer the layers The laid materials are fed into the pressing mold, hot-pressed and cooled to obtain the product with the target structure.
  • Figure 1 is a schematic diagram of a micro-nano colloidal fiber concrete structure provided by an embodiment of the present application
  • Figure 2 is an exploded view of Figure 1;
  • Figure 3 is a microscopic view of micro-nano colloids in the micro-nano colloid fiber concrete structure provided by an embodiment of the present application;
  • Figure 4 is a schematic diagram of the unit sheet of the micro-nano colloid in Figure 3;
  • Figure 5 is a schematic diagram of stacked paving materials in the processing method of micro-nano colloidal fiber concrete structure provided by an embodiment of the present application;
  • Figure 6 is a flow chart of the processing method of the micro-nano colloidal fiber concrete structure.
  • connection should be understood in a broad sense.
  • it can be a fixed connection, a detachable connection, or a mechanical connection.
  • the connection can also be an electrical connection, it can be a direct connection, or it can be an indirect connection through an intermediary. It can be an internal connection between two components or an interactive relationship between two components.
  • the term “above” or “below” a first feature to a second feature may include the first feature being in direct contact with the second feature, or it may include the first feature being in direct contact with the second feature.
  • the second feature is not in direct contact but is in contact with another feature between them.
  • the terms “above”, “above” and “above” a first feature on a second feature include the first feature being directly above and diagonally above the second feature, or simply mean that the first feature is higher in level than the second feature.
  • “Below”, “under” and “under” the first feature is the second feature includes the first feature being directly below and diagonally below the second feature, or simply means that the first feature is less horizontally than the second feature.
  • this embodiment provides a micro-nano colloid fiber concrete structure, including micro-nano colloid 1, fiber bundle layer 2, surface fabric 3 and base fabric 4.
  • the micro-nano colloid 1 is composed of multiple A three-dimensional structure formed by overlapping colloid bone beams 11, and a glue-containing space 12 is formed between the colloid bone beams 11.
  • the colloid bone beams 11 will collapse and deform after being heated and pressed.
  • the glue-containing space 12 is filled with the glue that is cooled and solidified.
  • the micro-nano colloid 1 maintains the glue 5 in its deformed shape.
  • the fiber bundle layer 2 serves as a supporting skeleton and runs through the micro-nano colloid 1.
  • the surface fabric 3 and the bottom fabric 4 are respectively attached to the upper and lower surfaces of the micro-nano colloid 1.
  • micro-nano colloid 1 (or micro-nano colloid hot-pressed condensate) here is defined as an object formed by a glue-absorbing material that is processed by a hot-press molding process. Although it has a layered structure with obvious boundaries before hot-pressing, But the relationship between the processed object and the fiber layer is like the relationship between concrete and the steel bars that serve as the internal skeleton.
  • the material that can be implemented is PU sponge, which is essentially any object that can accommodate glue and can collapse during hot pressing and solidify after cooling.
  • the micro-nano colloid 1 includes a plurality of unit sheets 13.
  • the unit sheets 13 have a honeycomb network structure, and each unit sheet 13 is staggered and stacked, so that the previous unit sheet 13
  • the colloid bone beam 11 of 13 is located in the area of the glue-accommodating space 12 of the next unit sheet 13, thereby facilitating collapse deformation.
  • the fiber bundle layer 2 here serves as a skeleton to support the micro-nano colloid 1.
  • the fiber bundle layer 2 is composed of multiple fiber bundles 21 interlaced and overlapped.
  • the fiber bundles 21 are formed by untwisted fiber filaments and are condensed after hot pressing. Fixed by glue 5.
  • multiple fiber bundle layers 2 are laid up and down in parallel and spaced apart in the micro-nano colloid 1 .
  • the advantage of forming the fiber bundle 21 without twisting is that since the fiber filaments in the fiber bundle 21 are not connected to each other, they can be freely bent during hot pressing to form various special-shaped decorative parts.
  • the main function of the glue 5 is to keep the micro-nano colloid 1 in its collapsed and deformed shape after cooling and solidification to avoid rebound. It can also fix the fiber filaments during condensation after hot pressing so that the fiber bundle layer 2 maintains its shape.
  • the main components of the glue 5 are isocyanate prepolymer and polyol.
  • the surface layer is non-woven fabric and fiber bundle layer 2
  • the middle layer is micro-nano colloid 1 and fiber bundle layer 2
  • the bottom layer is coated non-woven fabric and fiber bundle layer 2.
  • the base fabric 4 here has a three-layer composite structure, consisting of non-woven fabric, PP and CPP from bottom to top.
  • the melting point of the CPP layer is about 100°C and will melt during hot pressing to act as a bonding agent. , to help the bottom layer and the center layer bond; while the PP layer will not melt and is mainly used to block glue.
  • this embodiment also provides a processing method of micro-nano colloidal fiber concrete structure, as shown in Figure 6, the method includes the following steps:
  • the ratio of glue to water is 1: (0.6 ⁇ 0.8), the total glue amount is set to (440 ⁇ 40)g/m2, and the water amount is set to (300 ⁇ 30)g/m2 .
  • the parameters of each material are as follows: Surface cloth 3: spunlace non-woven fabric 40g/m 2 ; glass fiber A (100 ⁇ 10)g/m 2 ; glass fiber B (150 ⁇ 10)g/m 2 ; PU soft Bubble 14: polyether 35kg/m 3 , 3.2mm; base fabric 4: non-woven fabric 40g/m 2 , PP film 50g/m 2 (including CPP 22g/m 2 ).
  • the layered materials are fed into the pressing mold, hot pressed and formed, and cooled to obtain the product with the target structure.
  • the pressing mold uses oil heating, so that the upper and lower temperatures of the mold are set to (130 ⁇ 10)°C, the holding time is (50 ⁇ 5)s, the holding pressure is 15MPa, the exhaust is once, the exhaust time is 5s, and the exhaust Air pressure 10MPa.
  • the above-mentioned micro-nano colloidal fiber concrete structure and its processing method can obtain a material similar to a reinforced concrete structure, which greatly increases the overall rigidity. Therefore, when forming products with multiple R-angles and negative angles, no splicing is required and the cost is reduced. The splicing seams are eliminated, which improves the integrity of the appearance and can meet more styling needs. More importantly, the structure can also effectively control the material weight, ensuring mechanical strength while achieving lightweight improvements, providing automotive interior and exterior trim parts. A new molding material was developed.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

一种微纳胶体纤维混凝结构，包括微纳胶体和纤维束层，微纳胶体为由多个胶体骨梁搭接而成的立体结构，且胶体骨梁之间形成容胶空间，胶体骨梁设置为受热压后会发生坍塌变形，容胶空间内填充有冷却凝固后使微纳胶体保持变形形状的胶水，纤维束层设置为作为支撑骨架贯穿于微纳胶体中。

Description

微纳胶体纤维混凝结构及其加工方法
本申请要求申请日为2022年3月17日、申请号为202210265353.9的中国专利申请的优先权，该申请的全部内容通过引用结合在本申请中。
技术领域
本申请涉及汽车饰件技术领域，例如涉及一种微纳胶体纤维混凝结构及其加工方法。
背景技术
随着汽车工业迅速发展，人们对汽车的要求不仅仅是造型优美的外观，而且对内外部装饰的舒适度、功能性和抗噪性也有很高的要求。其中，汽车内外饰件在满足机械、噪声、振动和声振粗糙度(Noise、Vibration、Harshmness，NVH)性能要求的前提下，越来越向轻量化发展，如顶棚、尾门饰件、立柱基材、下立柱、车身等，轻质材料可有效降低汽车燃油，实现节能环保。
通常汽车立柱及其它硬饰选择塑料粒子进行注塑成型，且是以一个整体件进行，但是还需要考虑产品实现复杂外观造型和大曲面装饰性能，受相关技术中的工艺所限，需要将立柱及其它硬饰分段进行机械拼接，而拼接处会留下缝隙，难以满足外观造型和装饰性能的要求。
基于相关技术中的材料及其结构考虑，一般在轻质和机械强度上难以兼顾，形状、厚度上也存在限制，难以满足车辆上更高的使用要求，因此，希望研发一种新型的替代材料。
发明内容
本申请提供了一种微纳胶体纤维混凝结构，能够得到高密度、高机械强度、轻质的材料，以满足汽车内外饰件轻量化生产需求。
本申请还提供了一种微纳胶体纤维混凝结构的加工方法。
一实施例提供了一种微纳胶体纤维混凝结构，包括微纳胶体和纤维束层，微纳胶体为由多个胶体骨梁搭接而成的立体结构，且胶体骨梁之间形成容胶空间，胶体骨梁设置为受热压后会发生坍塌变形，容胶空间内填充有冷却凝固后使微纳胶体保持变形形状的胶水，纤维束层设置为作为支撑骨架贯穿于微纳胶 体中。
一实施例还提供了一种微纳胶体纤维混凝结构的加工方法，应用于如上述的微纳胶体纤维混凝结构，所述方法包括：将PU软泡进行滚胶，喷水处理，并将所述PU软泡的两侧面贴附玻璃纤维；将底布、多个所述PU软泡、所述玻璃纤维及表布从下至上层级铺放；及采用冷材热模形式，将层级铺放好的材料送入压制模具中，进行热压成型，并冷却得到目标结构的产品。
附图说明
图1是本申请一实施例提供的微纳胶体纤维混凝结构的示意图；
图2是图1的爆炸图；
图3是本申请一实施例提供的微纳胶体纤维混凝结构中微纳胶体的微观图；
图4是图3中微纳胶体的单元片层的示意图；
图5是本申请一实施例提供的微纳胶体纤维混凝结构的加工方法中层叠铺料的示意图；
图6是微纳胶体纤维混凝结构的加工方法的流程图。
具体实施方式
在本申请的描述中，除非另有明确的规定和限定，术语“相连”、“连接”、“固定”应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，可以是机械连接，也可以是电连接，可以是直接相连，也可以通过中间媒介间接相连，可以是两个元件内部的连通或两个元件的相互作用关系。对于本领域的普通技术人员而言，可以根据具体情况理解上述术语在本申请中的具体含义。
在本申请的描述中，除非另有明确的规定和限定，第一特征在第二特征之“上”或之“下”可以包括第一特征和第二特征直接接触，也可以包括第一特征和第二特征不是直接接触而是通过它们之间的另外的特征接触。而且，第一特征在第二特征“之上”、“上方”和“上面”包括第一特征在第二特征正上方和斜上方，或仅仅表示第一特征水平高度高于第二特征。第一特征在第二特征“之下”、“下方”和“下面”包括第一特征在第二特征正下方和斜下方，或仅仅表示第一特征水平高度小于第二特征。
请参阅图1至图4所示，本实施例提供一种微纳胶体纤维混凝结构，包括微纳胶体1、纤维束层2、表布3和底布4，微纳胶体1为由多个胶体骨梁11搭接而成 的立体结构，且胶体骨梁11之间形成容胶空间12，胶体骨梁11受热压后会发生坍塌变形，容胶空间12内填充有冷却凝固后使微纳胶体1保持变形形状的胶水5，纤维束层2作为支撑骨架贯穿于微纳胶体1中，表布3和底布4分别贴附于微纳胶体1的上表面和下表面。
此处的微纳胶体1(或称微纳胶热压冷凝体)定义为一种吸有胶水的材料经热压模工艺处理后形成的物体，虽热压前是边界明显的层状结构，但加工后的实物和纤维层的关系犹如混凝土和内部作为骨架的钢筋的关系。在相关技术中，可实施的材料为PU海绵，本质上任何是可容纳胶水又可在热压时发生坍塌、冷却后固化定型的物体。
若将该切片微观，该微纳胶体1包括多个单元片层13，在一实施例中，单元片层13呈蜂窝网状结构，每个单元片层13错位层叠，使上一单元片层13的胶体骨梁11处于下一单元片层13的容胶空间12的区域，从而便于坍塌变形。
此处的纤维束层2作为骨架支撑微纳胶体1，纤维束层2由多个纤维束21交错搭接而成，纤维束21由纤维丝无捻约束形成，并在热压后、冷凝时被胶水5固定。在一实施例中，多个纤维束层2上下平行且间隔地铺设于微纳胶体1中。
无捻形成纤维束21的好处在于，由于纤维束21里面的纤维丝互不连接，可在热压时自由弯折以成型多种异形饰件。
胶水5的主要作用是在冷却凝固后使微纳胶体1保持坍塌变形后的形状，避免回弹，还可以在热压后冷凝时固定纤维丝，使得纤维束层2保持形状。在一实施例中，胶水5的主要成分为异氰酸酯预聚物和多元醇。
在一实施例中，此结构中，表层为无纺布及纤维束层2，中间层为微纳胶体1及纤维束层2，底层为覆膜无纺布及纤维束层2。
在一实施例中，此处的底布4为三层复合结构，自下而上为无纺布、PP和CPP，CPP层熔点在100℃左右，在热压时会熔化，起粘接作用，帮助底层与中心层粘接；而PP层不会熔，主要用于挡胶。
对此，本实施例还提供一种微纳胶体纤维混凝结构的加工方法，如图6所示，所述方法包括以下步骤：
1)将PU软泡14进行滚胶，喷水处理，并将PU软泡14的两侧面贴附玻璃纤维。
其中，PU软泡14中，胶与水的配比为1:(0.6～0.8)，总胶量设定为(440±40)g/㎡，水量设定为(300±30)g/㎡。
2)将底布4、多个PU软泡14及玻璃纤维、表布3，从下至上层级铺放。
此处以底布4、玻璃纤维A、PU软泡14、玻璃纤维B、PU软泡14、玻璃纤维A、表布3的层叠方式示例，如图5所示，具体根据不同种类的内外饰件及其形状作相应的调整。
其中，每种材料参数如下：表布3：水刺无纺布40g/m 2；玻璃纤维A(100±10)g/m 2；玻璃纤维B(150±10)g/m 2；PU软泡14：聚醚35kg/m 3、3.2mm；底布4：无纺布40g/m 2、PP膜50g/m 2(含CPP 22g/m 2)。
3)采用冷材热模形式，将层级铺放好的材料送入压制模具中，进行热压成型，并冷却得到目标结构的产品。
其中，压制模具采用油加温形式，使模具的上下温度设置为(130±10)℃，保压时间(50±5)s，保压压力15MPa，排气1次，排气时间5s、排气压力10MPa。
综上，上述的微纳胶体纤维混凝结构及其加工方法可得到一种类似钢筋混凝土结构的材料，大大增加了整体刚性，从而在成型多R角和负角的产品时，无需拼接，减少了拼接缝，提高了外观整体性，能满足更多造型需要，更重要的是该结构在材料重量上也得以有效控制，保证机械强度的同时实现了轻量化改进，为汽车内外饰件提供了一种新的成型材料。

Claims (10)

  1. 一种微纳胶体纤维混凝结构，包括微纳胶体和纤维束层，所述微纳胶体为由多个胶体骨梁搭接而成的立体结构，且胶体骨梁之间形成容胶空间，所述胶体骨梁设置为受热压后会发生坍塌变形，所述容胶空间内填充有冷却凝固后使微纳胶体保持变形形状的胶水，所述纤维束层设置为作为支撑骨架贯穿于所述微纳胶体中。
  2. 根据权利要求1所述的微纳胶体纤维混凝结构，其中：所述微纳胶体包括多个单元片层，所述单元片层呈蜂窝网状结构，每个单元片层错位层叠，使上一单元片层的胶体骨梁处于下一单元片层容胶空间的区域。
  3. 根据权利要求1所述的微纳胶体纤维混凝结构，其中：所述微纳胶体为PU海绵。
  4. 根据权利要求1所述的微纳胶体纤维混凝结构，其中：所述纤维束层由多个纤维束交错搭接而成，所述纤维束由纤维丝无捻约束形成。
  5. 根据权利要求1所述的微纳胶体纤维混凝结构，其中：多个纤维束层上下平行且间隔地铺设于所述微纳胶体中。
  6. 根据权利要求1所述的微纳胶体纤维混凝结构，其中：所述微纳胶体的上下表面对应贴设有表布和底布。
  7. 根据权利要求6所述的微纳胶体纤维混凝结构，其中：所述底布为三层复合结构，自下而上为无纺布、PP和CPP。
  8. 一种微纳胶体纤维混凝结构的加工方法，应用于如权利要求1-7任一项所述的微纳胶体纤维混凝结构，所述方法包括：
    将PU软泡进行滚胶，喷水处理，并将所述PU软泡的两侧面贴附玻璃纤维；
    将底布、多个所述PU软泡、所述玻璃纤维及表布从下至上层级铺放；及
    采用冷材热模形式，将层级铺放好的材料送入压制模具中，进行热压成型，并冷却得到目标结构的产品。
  9. 根据权利要求8所述的微纳胶体纤维混凝结构的加工方法，其中：所述压制模具采用油加温形式，使模具的上下温度设置为(130±10)℃，保压时间(50±5)s，保压压力15MPa，排气1次，排气时间5s、排气压力10MPa。
  10. 根据权利要求8所述的微纳胶体纤维混凝结构的加工方法，其中：所述PU软泡中，胶与水的配比为1:(0.6～0.8)，总胶量设定为(440±40)g/㎡，水量设定为(300±30)g/㎡。
PCT/CN2022/118609 2022-03-17 2022-09-14 微纳胶体纤维混凝结构及其加工方法 WO2023173707A1 (zh)

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