CN102821943B - 特别用于顶棚内衬结构的纤维复合结构材料 - Google Patents

特别用于顶棚内衬结构的纤维复合结构材料 Download PDF

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CN102821943B
CN102821943B CN201180015820.2A CN201180015820A CN102821943B CN 102821943 B CN102821943 B CN 102821943B CN 201180015820 A CN201180015820 A CN 201180015820A CN 102821943 B CN102821943 B CN 102821943B
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M·卡尔比
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Abstract

本发明涉及一种纤维复合结构材料，其按顺序(i)-(iii)包括：(i)第一纤维复合层；(ii)软木层；(iii)第二纤维复合层。

Description

特别用于顶棚内衬结构的纤维复合结构材料
本发明涉及纤维复合结构材料，包括两个纤维复合层和它们之间的软木层，以及涉及其作为成型制品——例如用于汽车内饰、更具体地用于顶棚内衬结构——的用途。
用于汽车的大面积内饰组件（例如顶棚内衬）迄今主要由聚氨酯和玻璃纤维的热固性复合材料制成。这类复合材料在热压机下由硬质聚氨酯泡沫塑料——其用基于二苯基甲烷二异氰酸酯（PMDI）的聚氨酯粘合剂浸渍——和在其双面上施用的玻璃纤维无纺布通过模塑和聚合而制备。所使用的材料不是没有问题的。处理PMDI需要保障和遵守严格的工作场所的安全措施。基于聚氨酯泡沫塑料的组分几乎不能循环利用。类似地，使用玻璃纤维具有玻璃纤维飞灰和皮肤刺激的风险并且因此需要特殊的职业卫生措施。包含玻璃纤维的材料的热回收由于玻璃碎渣残留物而存在问题。
因此需要可替代的用于大面积汽车成型体的结构材料。本发明的一个目的是提供这种结构材料。所述材料应通常被职业卫生学者认定是安全的并能循环利用。
我们发现该目的可由一种纤维复合结构材料实现，其按顺序(i)-(iii)包括：
(i)第一纤维复合层；
(ii)软木层；
(iii)第二纤维复合层。
所述纤维复合结构材料包括两个作为外层的纤维复合层。所述纤维复合层可以仅包括合成纤维。优选地，所述纤维复合层包括天然纤维。可存在于所述纤维复合层中的天然纤维的实例有棉纤维、剑麻纤维、亚麻纤维、***纤维、亚麻子纤维和黄麻纤维。
所述纤维复合层(i)和(iii)通常以织物的形式存在。无纺布（人造短纤维或纺粘布）特别合适，但纺织物和针织物也是可行的。优选天然纤维的无纺布，例如棉和剑麻的无纺布。它们的性质接近玻璃纤维无纺布的性质。
所述天然纤维可以以与合成纤维的混合物形式存在，例如与聚丙烯纤维、聚乙烯纤维、聚酯纤维、聚酰胺纤维或聚丙烯腈纤维的混合物。所述制造的聚合物纤维的比例可最高达50重量%，优选最高达30重量%且更优选最高达10重量%。在一个特别优选的实施方案中，除所述天然纤维外没有合成纤维。
在本发明另一个实施方案中，所述纤维复合层仅包括合成纤维，例如上文所述的合成纤维，或PET或PBT的聚酯纤维。
所述无纺布可以处于机械、热或化学预粘合（prebonded）状态。热预粘合无纺布可通过例如搭配使用合成的粘合纤维且在压延机中热处理而得到。
所述无纺布、纺织物和针织物优选经可热交联粘合剂浸渍。合适的可热交联粘合剂为基于以下物质的粘合剂：可交联聚丙烯酸、丙烯酸-马来酸共聚物、甲醛树脂（例如脲醛（UF）树脂、酚醛（PF）树脂、三聚氰胺-甲醛（MF）树脂和三聚氰胺-脲醛（MUF）树脂）、可交联水性分散体（例如可交联苯乙烯-丁二烯分散体、苯乙烯-丙烯酸酯分散体和纯的丙烯酸酯分散体）。甲醛树脂和水性分散体的结合物也是可行的。
在本发明的一个实施方案中，基于丙烯酸-马来酸共聚物和作为交联剂的三乙醇胺的可热交联粘合剂——其记载于例如EP 0 882 093
B1——被用作所述无纺布、纺织物和针织物的粘合剂。
所述纤维复合层的基重通常为≤400g/m2，优选为＜200g/m2且更优选为＜150g/m2。对于汽车顶棚内衬，其更具体地在100至150g/m2的范围内。
所述纤维复合结构材料的中间层是软木层(ii)。所述软木层由粘合剂粘合的软木团块组成，且可由具有不同粒度的粒状软木形成。选择某些粒度使得可实现特定的软木层密度。通常，使用密度为＜200kg/m3的软木层。所述软木层的厚度通常为4-6mm，且所述软木层的基重通常为＜500g/m2。对于汽车顶棚内衬，与两个天然纤维复合层(i)和(iii)形成的整个层状复合材料的基重应为＜800g/m2。
所述软木层与合适的热塑性粘合剂或热固性粘合剂预粘合且优选以未固化的形式使用。因此，所述软木层非常柔软且易于塑型。优选基于以下物质的上述可热交联粘合剂：可交联丙烯酸酯、包含丙烯酸酯的共聚物、可交联水性分散体以及聚氨酯体系，如用于浸渍所述天然纤维复合层的那些。
本发明纤维复合结构材料通过热塑所述层状复合材料且使所述粘合剂热交联而制备。一种可热交联粘合剂至少存在于所述纤维复合层中。为此，将第一纤维复合层、软木层和第二纤维复合层在未固化的状态下依次层叠放置且根据需要进行三维塑形然后在热压机中进行热交联。纤维复合层和软木层的固化在热压机中进行。
根据结构（无纺布重量、软木密度、粘合剂份数），机械性质可以在宽范围内改变且符合需求。
因此本发明的纤维复合结构材料满足相关的规格。
所述纤维复合结构材料可易于循环利用。在热回收中没有玻璃碎渣产生。
本发明的纤维复合结构材料可用于制造大面积的汽车内饰制品。实例有顶棚内衬、行李架和后备箱内衬。所述纤维复合结构材料也可用于制造家具，例如学校家具。通常，它们可用于制造在热压机中成型的成型制品。一种优选的应用是将所述纤维复合结构材料——优选包含由天然纤维制成的纤维复合层的天然纤维复合结构材料——用于制造顶棚内衬。
实施例
由Acrodur粘合的软木载体组成的纤维复合结构材料的制备如下，其中所述Acrodur粘合的软木载体的双面用同样的Acrodur粘合的无纺布加固：
1.制备软木载体
向容器中首先装入206g具有3%的常规含水量的软木。在搅拌下，在2分钟内加入16g固含量为50%的Acrodur可热固化的无苯酚且无甲醛的活性丙烯酸酯树脂。如此设定的软木与粘合剂的比例为100:4（基于干组分计）。软木/Acrodur混合物的含水量为6.4%。
将规格为15×15cm、高10cm且体积为2250cm3的方形金属模具在可加热的压机中于10分钟内加热到130°C。称取216g软木-粘合剂混合物加入如此预热的模具中。用7cm厚的穿孔盖封闭所述模具使内容物压缩至3cm厚。预定的体积是指获得0.24g/cm3的所需密度。在130°C下在热压机中的停留时间是60分钟。加压结束后，所述软木板从模具中移出。顶棚内衬所需的4mm厚的软木载体随后由所述块状材料锯得。
2.浸渍棉-剑麻外层无纺布
将基重为100g/m2的无纺布用Acrodur 950l浸渍。为此，所述Acrodur用水稀释至40%然后通过向其中搅入空气而调整至密度为450g/cm3。在标准条件下用实验室用轧染机（Laborfoulard）将所述无纺布用所述泡沫浸渍。粘合剂量设定为100g/m2。在浸渍后，所述无纺布在干燥箱中在70°C下干燥至残留含水量为18%。
3.制作顶棚内衬件
在200°C，将一个规格为30×30cm的锯得的软木盘——其双侧有Acrodur-粘合的无纺布——模压成型60秒至4mm厚。加压结束后，尺寸稳定的组件可以脱模。其密度为0.24g/cm3且基重为约1000g/m2。
将如此获得的纤维复合结构材料进行机械测试。结果总结于下表：

Claims (7)

1.一种汽车内饰件形式的纤维复合结构材料，按顺序(i)-(iii)包含：
(i)第一纤维复合层；
(ii)软木层；
(iii)第二纤维复合层，
其可通过将包含可热交联粘合剂的第一纤维复合层、包含可热交联粘合剂的软木层和包含可热交联粘合剂的第二纤维复合层各自在未固化的状态下依次层叠放置，根据需要进行成型并在热压机中进行热交联而得到。
2.权利要求1的纤维复合结构材料，其中所述第一纤维复合层和第二纤维复合层包括天然纤维。
3.权利要求1的纤维复合结构材料，其中所述第一纤维复合层和第二纤维复合层包括选自棉纤维、剑麻纤维、亚麻纤维、***纤维、亚麻子纤维和黄麻纤维的天然纤维。
4.权利要求1的纤维复合结构材料，其中所述第一纤维复合层和第二纤维复合层包括天然纤维的无纺布或纺织物。
5.权利要求1的纤维复合结构材料，其中所述第一纤维复合层和第二纤维复合层包括天然纤维的针织物。
6.一种制备权利要求1至5中任一项的纤维复合结构材料的方法，其中将第一纤维复合层、软木层和第二纤维复合层在未固化的状态下依次层叠放置且根据需要进行成型并在热压机中进行热交联。
7.权利要求1至5中任一项的纤维复合结构材料用于制造顶棚内衬的用途。
CN201180015820.2A 2010-04-12 2011-04-07 特别用于顶棚内衬结构的纤维复合结构材料 Expired - Fee Related CN102821943B (zh)

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