CN107163810A - 一种低voc的tpo汽车内饰材料及其制备方法 - Google Patents

一种低voc的tpo汽车内饰材料及其制备方法 Download PDF

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CN107163810A
CN107163810A CN201710373825.1A CN201710373825A CN107163810A CN 107163810 A CN107163810 A CN 107163810A CN 201710373825 A CN201710373825 A CN 201710373825A CN 107163810 A CN107163810 A CN 107163810A
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tpo
aqueous polyurethane
automotive interior
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李帅
陈红梅
滕大勇
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Benecke Changshun Automotive Interior Materials Zhangjiagang Co ltd
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Abstract

本发明公开了一种低VOC的TPO汽车内饰材料，包括自下而上的聚烯烃海绵层、TPO表皮层、水性聚氨酯底漆层和水性聚氨酯面漆层，水性聚氨酯底漆层包括按重量份计的如下组分：水性聚氨酯树脂50‑70份、消泡剂0.1‑1份、分散剂0.2‑0.5份、固化剂0.2‑0.6份、纳米二氧化钛3‑10份、硅溶胶2‑5份、去离子水15‑30份。本发明的低VOC的TPO汽车内饰材料，解决了传统溶剂型TPO材料VOC高、气味差的缺点，符合汽车厂商对内饰材料的环保低散发低VOC的高品质的要求。

Description

一种低VOC的TPO汽车内饰材料及其制备方法
技术领域
本发明涉及汽车内饰材料领域，具体涉及一种低VOC的TPO汽车内饰材料及其制备方法。
背景技术
随着家用汽车的逐步普及以及人民对环保意识的不断提高，人们对车内空气质量的要求也越来越高。而车内挥发性有机化合物(VOC)浓度作为表征车内空气质量的重要指标，成为了汽车主机厂以及零部件供应商严格控制的指标。
聚烯烃弹性体材料(TPO)具有可以回收、轻量化且环保的特性，成为新型的汽车内饰材料，为国内汽车厂商提供了汽车内饰材料新的解决方案。其表面通常需要进行涂饰一层油漆，用来提高抗刮擦性能以及提供良好手感。但目前应用在聚烯烃弹性体表面的油漆通常为溶剂型聚氨酯油漆，常以甲苯，丁酮等等材料作为溶剂，而产品残留的溶剂会导致VOC的超标。
发明内容
本发明的目的在于克服现有技术存在的以上问题，提供一种低VOC的TPO汽车内饰材料，本发明的TPO汽车内饰材料，采用挤出法挤出TPO表皮，之后涂覆水性聚氨酯底漆和面漆，再复合聚烯烃海绵，最终制得的聚烯烃弹性体材料。由于使用水性聚氨酯涂覆，最终产品的VOC释放量和挥发性能有了大幅的降低，解决了传统溶剂型TPO材料VOC高、气味差的缺点，符合汽车厂商对内饰材料的高品质要求。
为实现上述技术目的，达到上述技术效果，本发明通过以下技术方案实现：
一种低VOC的TPO汽车内饰材料，包括自下而上的聚烯烃海绵层、TPO表皮层、水性聚氨酯底漆层和水性聚氨酯面漆层，所述水性聚氨酯底漆层包括按重量份计的如下组分：水性聚氨酯树脂50-70份、消泡剂0.1-1份、分散剂0.2-0.5份、固化剂0.2-0.6份、纳米二氧化钛3-10份、硅溶胶2-5份、去离子水15-30份；
所述水性聚氨酯面漆层包括按重量份计的如下组分：水性聚氨酯树脂50-70份、无机填料5-10份、消泡剂0.1-1份、分散剂0.2-0.5份、固化剂0.2-0.6份、纳米二氧化钛3-10份、去离子水15-30份。
优选的，所述固化剂为异氰酸酯类固化剂。
优选的，所述无机填料为碳酸钙、硅灰石、云母石和滑石粉中的至少一种，所述无机填料的粒径为100-400nm。
优选的，所述消泡剂为乳液型硅氧烷消泡剂或聚醚改性有机硅消泡剂。
优选的，所述分散剂为十二烷基硫酸钠、聚丙烯酸钠、十二烷基苯磺酸钠、硬脂酸中的至少一种。
优选的，所述水性聚氨酯底漆层包括按重量份计的如下组分：水性聚氨酯树脂60份、消泡剂0.5份、分散剂0.4份、固化剂0.5份、纳米二氧化钛6份、硅溶胶3份、去离子水25份；
所述水性聚氨酯面漆层包括按重量份计的如下组分：水性聚氨酯树脂60份、无机填料8份、消泡剂0.5份、分散剂0.4份、固化剂0.5份、纳米二氧化钛6份、去离子水25份。
本发明还公开了上述低VOC的TPO汽车内饰材料的制备方法，包括如下的步骤：
1)制备TPO表皮层：将按重量份计的20-40份聚乙烯、20-40份聚丙烯、25-40份乙烯丁烯橡胶或乙烯丙烯橡胶、6-15份硬脂酸类助剂、5-9份色母粒混合均匀，投入挤出机，经挤压形成TPO薄膜；然后对TPO薄膜进行电晕处理，得到TPO表皮层；
2)制备水性聚氨酯底漆：将水性聚氨酯树脂、纳米二氧化钛、硅溶胶和去离子水混合搅拌均匀，然后加入消泡剂和分散剂，继续搅拌均匀；接着加入固化剂，搅拌均匀，得到水性聚氨酯底漆；
3)制备水性聚氨酯面漆：将水性聚氨酯树脂、纳米二氧化钛、无机填料和去离子水混合搅拌均匀，然后加入消泡剂和分散剂，继续搅拌均匀；接着加入固化剂，搅拌均匀，得到水性聚氨酯面漆；
4)向所述TPO表皮层上涂上一层步骤2)制备得到的水性聚氨酯底漆，待漆面固化后，再涂上一层步骤3)制备得到的水性聚氨酯面漆，然后烘干；
5)将步骤4)制备得到的材料在复合设备上与聚烯烃海绵层复合，得到本发明所述的低VOC的TPO汽车内饰材料。
在步骤1)中，所述TPO表皮层经过了电晕处理，增加了TPO表皮层的极性，提高TPO表皮层与面漆层之间的结合强度。
本发明的有益效果是:
1.本发明的低VOC的TPO汽车内饰材料，采用挤出法挤出TPO表皮层，之后涂覆水性聚氨酯底漆和面漆，最后复合聚烯烃海绵，最终制得的聚烯烃弹性体材料。由于使用水性聚氨酯涂覆，最终产品的VOC释放量和挥发性能有了大幅降低，解决了传统溶剂型TPO材料VOC高、气味差的缺点，符合汽车厂商对内饰材料的高品质的要求。
2.本发明的低VOC的TPO汽车内饰材料，采用水性聚氨酯底漆打底，替代溶剂型油漆作为TPO表皮层的表面涂饰，使得底漆在基材上的润湿性更好，提升了面漆与基材的结合强度。此外，TPO表皮层经过电晕处理，进一步增加了面漆与基材的结合强度。
3.本发明的低VOC的TPO汽车内饰材料，水性聚氨酯面漆的配方中包含纳米二氧化钛和无机填料，其中纳米二氧化钛能提高漆膜的光泽度和耐老化性能，而无机填料能增加漆膜的强度，提升漆膜的耐磨性。
上述说明仅是本发明技术方案的概述，为了能够更清楚了解本发明的技术手段，并可依照说明书的内容予以实施，以下以本发明的较佳实施例详细说明如后。本发明的具体实施方式由以下实施例详细给出。
具体实施方式
下面将结合本发明的实施例，对本发明的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例1
本发明公开了一种低VOC的TPO汽车内饰材料，包括自下而上的聚烯烃海绵层、TPO表皮层、水性聚氨酯底漆层和水性聚氨酯面漆层；
其中，水性聚氨酯底漆层包括按重量份计的如下组分：水性聚氨酯树脂60份、乳液型硅氧烷消泡剂0.5份、十二烷基硫酸钠0.4份、异氰酸酯类固化剂0.5份、纳米二氧化钛6份、硅溶胶3份、去离子水25份；
水性聚氨酯面漆层包括按重量份计的如下组分：水性聚氨酯树脂60份、碳酸钙8份、乳液型硅氧烷消泡剂0.5份、十二烷基硫酸钠0.4份、异氰酸酯类固化剂0.5份、纳米二氧化钛6份、去离子水25份。
上述低VOC的TPO汽车内饰材料是经如下的步骤制备而成的：
1)制备TPO表皮层：将按重量份计的30份聚乙烯、30份聚丙烯、35份乙烯丁烯橡胶、12份硬脂酸、8份色母粒混合均匀，投入挤出机熔融，经挤压形成TPO薄膜；然后对TPO薄膜进行电晕处理，得到TPO表皮层；
2)制备水性聚氨酯底漆：将水性聚氨酯树脂、纳米二氧化钛、硅溶胶和去离子水混合搅拌均匀，然后加入乳液型硅氧烷消泡剂和十二烷基硫酸钠，继续搅拌均匀；接着加入异氰酸酯类固化剂，搅拌均匀，得到水性聚氨酯底漆；
3)制备水性聚氨酯面漆：将水性聚氨酯树脂、纳米二氧化钛、碳酸钙和去离子水混合搅拌均匀，然后加入乳液型硅氧烷消泡剂和十二烷基硫酸钠，继续搅拌均匀；接着加入异氰酸酯类固化剂，搅拌均匀，得到水性聚氨酯面漆；
4)向所述TPO表皮层上涂上一层步骤2)制备得到的水性聚氨酯底漆，待漆面固化后，再涂上一层步骤3)制备得到的水性聚氨酯面漆，然后烘干；
5)将步骤4)制备得到的材料在复合设备上与聚烯烃海绵层复合，得到本发明所述的低VOC的TPO汽车内饰材料。
实施例2
本发明公开了一种低VOC的TPO汽车内饰材料，包括自下而上的聚烯烃海绵层、TPO表皮层、水性聚氨酯底漆层和水性聚氨酯面漆层；
其中，水性聚氨酯底漆层包括按重量份计的如下组分：水性聚氨酯树脂50份、聚醚改性有机硅消泡剂1份、十二烷基苯磺酸钠0.2份、异氰酸酯类固化剂0.6份、纳米二氧化钛10份、硅溶胶2份、去离子水15份；
水性聚氨酯面漆层包括按重量份计的如下组分：水性聚氨酯树脂50份、硅灰石5份、聚醚改性有机硅消泡剂1份、十二烷基苯磺酸钠0.2份、异氰酸酯类固化剂0.6份、纳米二氧化钛10份、去离子水15份。
上述低VOC的TPO汽车内饰材料是经如下的步骤制备而成的：
1)制备TPO表皮层：将按重量份计的20份聚乙烯、40份聚丙烯、25份乙烯丁烯橡胶、6份硬脂酸、9份色母粒混合均匀，投入挤出机，经挤压形成TPO薄膜；然后对TPO薄膜进行电晕处理，得到TPO表皮层；
2)制备水性聚氨酯底漆：将水性聚氨酯树脂、纳米二氧化钛、硅溶胶和去离子水混合搅拌均匀，然后加入聚醚改性有机硅消泡剂和十二烷基苯磺酸钠，继续搅拌均匀；接着加入异氰酸酯类固化剂，搅拌均匀，得到水性聚氨酯底漆；
3)制备水性聚氨酯面漆：将水性聚氨酯树脂、纳米二氧化钛、硅灰石和去离子水混合搅拌均匀，然后加入聚醚改性有机硅消泡剂和十二烷基苯磺酸钠，继续搅拌均匀；接着加入异氰酸酯类固化剂，搅拌均匀，得到水性聚氨酯面漆；
4)向所述TPO表皮层上涂上一层步骤2)制备得到的水性聚氨酯底漆，待漆面固化后，再涂上一层步骤3)制备得到的水性聚氨酯面漆，然后烘干；
5)将步骤4)制备得到的材料在复合设备上与聚烯烃海绵层复合，得到本发明所述的低VOC的TPO汽车内饰材料。
实施例3
本发明公开了一种低VOC的TPO汽车内饰材料，包括自下而上的聚烯烃海绵层、TPO表皮层、水性聚氨酯底漆层和水性聚氨酯面漆层；
其中，水性聚氨酯底漆层包括按重量份计的如下组分：水性聚氨酯树脂70份、乳液型硅氧烷消泡剂0.1份、聚丙烯酸钠0.5份、异氰酸酯类固化剂0.2份、纳米二氧化钛3份、硅溶胶5份、去离子水30份；
水性聚氨酯面漆层包括按重量份计的如下组分：水性聚氨酯树脂70份、滑石粉10份、乳液型硅氧烷消泡剂0.1份、聚丙烯酸钠0.5份、异氰酸酯类固化剂0.2份、纳米二氧化钛3份、去离子水30份。
上述低VOC的TPO汽车内饰材料是经如下的步骤制备而成的：
1)制备TPO表皮层：将按重量份计的40份聚乙烯、20份聚丙烯、25份乙烯丁烯橡胶、15份硬脂酸、6份色母粒混合均匀，投入挤出机，经挤压形成TPO薄膜；然后对TPO薄膜进行电晕处理，得到TPO表皮层；
2)制备水性聚氨酯底漆：将水性聚氨酯树脂、纳米二氧化钛、硅溶胶和去离子水混合搅拌均匀，然后加入乳液型硅氧烷消泡剂和聚丙烯酸钠，继续搅拌均匀；接着加入异氰酸酯类固化剂，搅拌均匀，得到水性聚氨酯底漆；
3)制备水性聚氨酯面漆：将水性聚氨酯树脂、纳米二氧化钛、滑石粉和去离子水混合搅拌均匀，然后加入乳液型硅氧烷消泡剂和聚丙烯酸钠，继续搅拌均匀；接着加入异氰酸酯类固化剂，搅拌均匀，得到水性聚氨酯面漆；
4)向所述TPO表皮层上涂上一层步骤2)制备得到的水性聚氨酯底漆，待漆面固化后，再涂上一层步骤3)制备得到的水性聚氨酯面漆，然后烘干；
5)将步骤4)制备得到的材料在复合设备上与聚烯烃海绵层复合，得到本发明所述的低VOC的TPO汽车内饰材料。
实施例4
本发明公开了一种低VOC的TPO汽车内饰材料，包括自下而上的聚烯烃海绵层、TPO表皮层、水性聚氨酯底漆层和水性聚氨酯面漆层；
其中，水性聚氨酯底漆层包括按重量份计的如下组分：水性聚氨酯树脂62份、乳液型硅氧烷消泡剂0.3份、硬脂酸0.3份、异氰酸酯类固化剂0.3份、纳米二氧化钛8份、硅溶胶4份、去离子水28份；
水性聚氨酯面漆层包括按重量份计的如下组分：水性聚氨酯树脂62份、云母石6份、聚醚改性有机硅消泡剂0.3份、硬脂酸0.3份、异氰酸酯类固化剂0.3份、纳米二氧化钛8份、去离子水28份。
上述低VOC的TPO汽车内饰材料是经如下的步骤制备而成的：
1)制备TPO表皮层：将按重量份计的30份聚乙烯、30份聚丙烯、35份乙烯丁烯橡胶、12份硬脂酸、8份色母粒混合均匀，投入挤出机，经挤压形成TPO薄膜；然后对TPO薄膜进行电晕处理，得到TPO表皮层；
2)制备水性聚氨酯底漆：将水性聚氨酯树脂、纳米二氧化钛、硅溶胶和去离子水混合搅拌均匀，然后加入乳液型硅氧烷消泡剂和硬脂酸，继续搅拌均匀；接着加入异氰酸酯类固化剂，搅拌均匀，得到水性聚氨酯底漆；
3)制备水性聚氨酯面漆：将水性聚氨酯树脂、纳米二氧化钛、云母石和去离子水混合搅拌均匀，然后加入乳液型硅氧烷消泡剂和硬脂酸，继续搅拌均匀；接着加入异氰酸酯类固化剂，搅拌均匀，得到水性聚氨酯面漆；
4)向所述TPO表皮层上涂上一层步骤2)制备得到的水性聚氨酯底漆，待漆面固化后，再涂上一层步骤3)制备得到的水性聚氨酯面漆，然后烘干；
5)将步骤4)制备得到的材料在复合设备上与聚烯烃海绵层复合，得到本发明所述的低VOC的TPO汽车内饰材料。
实施例5
本发明公开了一种低VOC的TPO汽车内饰材料，包括自下而上的聚烯烃海绵层、TPO表皮层、水性聚氨酯底漆层和水性聚氨酯面漆层；
其中，水性聚氨酯底漆层包括按重量份计的如下组分：水性聚氨酯树脂68份、乳液型硅氧烷消泡剂1份、十二烷基硫酸钠0.5份、异氰酸酯类固化剂0.4份、纳米二氧化钛4份、硅溶胶4份、去离子水20份；
水性聚氨酯面漆层包括按重量份计的如下组分：水性聚氨酯树脂68份、碳酸钙6份、聚醚改性有机硅消泡剂剂0.5份、聚丙烯酸钠0.2份、异氰酸酯类固化剂0.4份、纳米二氧化钛4份、去离子水20份。
上述低VOC的TPO汽车内饰材料是经如下的步骤制备而成的：
1)制备TPO表皮层：将按重量份计的32份聚乙烯、35份聚丙烯、25份乙烯丁烯橡胶、15份硬脂酸、6份色母粒混合均匀，投入挤出机，经挤压形成TPO薄膜；然后对TPO薄膜进行电晕处理，得到TPO表皮层；
2)制备水性聚氨酯底漆：将水性聚氨酯树脂、纳米二氧化钛、硅溶胶和去离子水混合搅拌均匀，然后加入乳液型硅氧烷消泡剂和十二烷基硫酸钠，继续搅拌均匀；接着加入异氰酸酯类固化剂，搅拌均匀，得到水性聚氨酯底漆；
3)制备水性聚氨酯面漆：将水性聚氨酯树脂、纳米二氧化钛、碳酸钙和去离子水混合搅拌均匀，然后加入聚醚改性有机硅消泡剂剂和聚丙烯酸钠，继续搅拌均匀；接着加入异氰酸酯类固化剂，搅拌均匀，得到水性聚氨酯面漆；
4)向所述TPO表皮层上涂上一层步骤2)制备得到的水性聚氨酯底漆，待漆面固化后，再涂上一层步骤3)制备得到的水性聚氨酯面漆，然后烘干；
5)将步骤4)制备得到的材料在复合设备上与聚烯烃海绵层复合，得到本发明所述的低VOC的TPO汽车内饰材料。
对比例1
表面涂覆溶剂型聚氨酯油漆的TPO汽车内饰材料。
实验例
取实施例1-5所制备的汽车内饰材料以及对比例1的汽车内饰材料，然后按照TS-BD-003(车内零部件挥发性有机化合物的测试方法——袋子法)规定的方法，测定内饰材料的VOC含量，所得结果如表1所示：
表1实施例1-5及对比例1的汽车内饰材料的VOC释放浓度表
由表1公开的结果可知，实施例1-5中的汽车内饰材料，其散发出的苯、甲苯、乙苯等挥发性有机化合物的浓度明显低于对比例1中的汽车内饰材料，其中实施例1的汽车内饰材料散发出的VOC的浓度最低，为最佳实施例。以上结果说明，本发明的低VOC的TPO汽车内饰材料，由于采用了水性聚氨酯底漆和面漆涂敷于TPO表皮层上，大大降低了VOC的排放，解决了传统溶剂型TPO汽车内饰材料VOC高，气味差的缺点，符合汽车厂商对内饰材料的高品质的要求。
对所公开的实施例的上述说明，使本领域专业技术人员能够实现或使用本发明。对这些实施例的多种修改对本领域的专业技术人员来说将是显而易见的，本文中所定义的一般原理可以在不脱离本发明的精神或范围的情况下，在其它实施例中实现。因此，本发明将不会被限制于本文所示的这些实施例，而是要符合与本文所公开的原理和新颖特点相一致的最宽的范围。

Claims (7)

1.一种低VOC的TPO汽车内饰材料，其特征在于，包括自下而上的聚烯烃海绵层、TPO表皮层、水性聚氨酯底漆层和水性聚氨酯面漆层，所述水性聚氨酯底漆层包括按重量份计的如下组分：水性聚氨酯树脂50-70份、消泡剂0.1-1份、分散剂0.2-0.5份、固化剂0.2-0.6份、纳米二氧化钛3-10份、硅溶胶2-5份、去离子水15-30份；
所述水性聚氨酯面漆层包括按重量份计的如下组分：水性聚氨酯树脂50-70份、无机填料5-10份、消泡剂0.1-1份、分散剂0.2-0.5份、固化剂0.2-0.6份、纳米二氧化钛3-10份、去离子水15-30份。
2.如权利要求1所述的低VOC的TPO汽车内饰材料，其特征在于，所述固化剂为异氰酸酯类固化剂。
3.如权利要求1所述的低VOC的TPO汽车内饰材料，其特征在于，所述无机填料为碳酸钙、硅灰石、云母石和滑石粉中的至少一种，所述无机填料的粒径为100-400nm。
4.如权利要求1所述的低VOC的TPO汽车内饰材料，其特征在于，所述消泡剂为乳液型硅氧烷消泡剂或聚醚改性有机硅消泡剂。
5.如权利要求1所述的低VOC的TPO汽车内饰材料，其特征在于，所述分散剂为十二烷基硫酸钠、聚丙烯酸钠、十二烷基苯磺酸钠、硬脂酸中的至少一种。
6.如权利要求1所述的低VOC的TPO汽车内饰材料，其特征在于，所述水性聚氨酯底漆层包括按重量份计的如下组分：水性聚氨酯树脂60份、消泡剂0.5份、分散剂0.4份、固化剂0.5份、纳米二氧化钛6份、硅溶胶3份、去离子水25份；
所述水性聚氨酯面漆层包括按重量份计的如下组分：水性聚氨酯树脂60份、无机填料8份、消泡剂0.5份、分散剂0.4份、固化剂0.5份、纳米二氧化钛6份、去离子水25份。
7.如权利要求1-6任一项所述的低VOC的TPO汽车内饰材料的制备方法，其特征在于，包括如下的步骤：
1)制备TPO表皮层：将按重量份计的20-40份聚乙烯、20-40份聚丙烯、25-40份乙烯丁烯橡胶或乙烯丙烯橡胶、6-15份硬脂酸类助剂、5-9份色母粒混合均匀，投入挤出机，经挤出后形成TPO薄膜；然后对TPO薄膜进行电晕处理，得到TPO表皮层；
2)制备水性聚氨酯底漆：将水性聚氨酯树脂、纳米二氧化钛、硅溶胶和去离子水混合搅拌均匀，然后加入消泡剂和分散剂，继续搅拌均匀；接着加入固化剂，搅拌均匀，得到水性聚氨酯底漆；
3)制备水性聚氨酯面漆：将水性聚氨酯树脂、纳米二氧化钛、无机填料和去离子水混合搅拌均匀，然后加入消泡剂和分散剂，继续搅拌均匀；接着加入固化剂，搅拌均匀，得到水性聚氨酯面漆；
4)向所述TPO表皮层上涂上一层经步骤2)制备得到的水性聚氨酯底漆，待漆面固化后，再涂上一层经步骤3)制备得到的水性聚氨酯面漆，然后烘干；
5)将步骤4)制备得到的材料在复合设备上与聚烯烃海绵层复合，得到本发明所述的低VOC的TPO汽车内饰材料。
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