CN107521203A - 一种超细碳酸钙改性苎麻纤维毡增强pu的汽车顶棚材料及其制备方法 - Google Patents

一种超细碳酸钙改性苎麻纤维毡增强pu的汽车顶棚材料及其制备方法 Download PDF

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CN107521203A
CN107521203A CN201710824386.1A CN201710824386A CN107521203A CN 107521203 A CN107521203 A CN 107521203A CN 201710824386 A CN201710824386 A CN 201710824386A CN 107521203 A CN107521203 A CN 107521203A
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杜兆芳
李继丰
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Anhui Agricultural University AHAU
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Abstract

本发明公开了一种碳酸钙改性麻纤维毡增强PU汽车顶棚材料及其制备方法，其制备方法包括以下步骤：将发泡PU板上下两面涂覆EVA热熔胶，然后在PU板上下两面分别依次平铺叠放超细碳酸钙改性苎麻纤维毡、高分子热熔胶膜层、胶粉层，然后在其上面层喷涂胶粘剂、叠放平铺装饰层无纺布，并放入温度为100～180℃热模具中进行热压成型，取出模具，冷却至室温；水刀切割、打孔，即得汽车顶棚，本发明在PU板中添加了柔顺剂，使其具有轻质、绿色环保、高强度、高韧性及耐冲击性，提升麻纤维与汽车顶棚用其他聚合物材料界面结合效果，增强了材料尺寸稳定性，添加了生物质壳聚糖、氧化锌颗粒，使顶棚材料具有抗菌、除臭、除异味及防霉变的优势。

Description

一种超细碳酸钙改性苎麻纤维毡增强PU的汽车顶棚材料及其 制备方法
技术领域
本发明涉及汽车配件技术领域，具体涉及一种超细碳酸钙改性苎麻纤维毡增强PU的汽车顶棚材料及其制备方法。
背景技术
在生产汽车内饰材料时，常使用玻璃纤维作为增强体材料。然而，玻璃纤维价格昂贵、质重，其中夹杂的玻璃短纤维，在制作生产中容易吸入体内等对环境和人体产生危害。同时由于玻璃纤维质重，限制轻质汽车的开发。纤维增强复合材料是一种高性能的轻质复合材料，其具有比强度高、比刚度高、抗疲劳性好、成型工艺简单等特点。苎麻纤维具有接近玻璃纤维的强力性能，是一种优良的增强体材料。但由于麻纤维结晶度高、刚度大致使与其他聚合物界面结合效果差，复合后材料强度、韧性、耐冲击性差，不利于轻质、环保、复合性能较好的汽车顶棚用材料的应用。
当前公布的关于麻纤维增强聚氨酯汽车顶棚生产方法主要包括：
中国专利CN106881919A所提到的一种麻纤维毡增强聚氨酯汽车顶棚及其制备方法，该方法包括的步骤：a)将麻纤维毡通过聚氨酯滚胶机，使其上下两面均涂覆聚氨酯胶水，然后在麻纤维毡的上下两面同时喷水；b)依次将无纺布或淋膜无纺布、上述麻纤维毡、无纺布或淋膜无纺布叠放，c)放入温度100～180℃的热模具中进行热压成型，时间30～120秒，取出半成品，并冷却；d)在上述半成品的表面喷涂胶粘剂或平铺热熔胶膜，然后在其上面平铺装饰层，在80～ 140℃的模具中热压20～90秒，取出冷却，并进行水刀切割，即得到汽车顶棚。该方法的缺点在于由于麻纤维亲水性好、聚合物亲水性差在生产中未考虑到苎麻纤维材料与聚氨酯聚合物之间的界面结合稳定性问题以及纤维吸湿后容易滋生细菌霉变、产生异味的问题，致使产品的尺寸稳定性差、抗疲劳性差、韧性与刚度低、易霉变、产生异味，使用寿命大大缩短。
发明内容
为解决上述麻纤维增强汽车顶棚材料及其制备方法的存在的缺点问题，本发明提供了一种尺寸稳定性好、抗菌、防霉变、除异味、韧性和耐冲击性优异的改性麻纤维增强PU汽车顶棚材料及其制备方法。
为实现本发明目的，采用的技术方案是：一种超细碳酸钙改性苎麻纤维毡增强PU的汽车顶棚材料及其制备方法，所述汽车顶棚复合材料包括自上而下依次分布的材料结构：装饰层无纺布、上层高分子热熔胶膜层、上层胶粉层、上层碳酸钙改性后苎麻纤维毡、上下面涂覆EVA热熔胶发泡PU板层、下层碳酸钙改性后苎麻纤维毡、下层胶粉层和下层高分子热熔胶膜层。
优选的，所述上层高分子高分子热熔胶膜层喷涂有胶粘剂。
优选的，所述胶粘剂为重量份数是10～20份的水溶性聚氨酯。
优选的，所述上下面涂覆EVA热熔胶发泡PU板层涂覆有柔顺剂。
优选的，所述柔顺剂为重量份数是5～10份的氨基硅油。
优选的，所述上下面涂覆EVA热熔胶发泡PU板层包括下述重量份的原料：PU 40～60份、发泡剂2～8份、胺类催化剂1～2份、生物质壳聚糖颗粒40～60份和氧化锌50～70份。
优选的，所述上层碳酸钙改性后苎麻纤维毡和下层碳酸钙改性后苎麻纤维毡均包括下述重量份的原料：水刺苎麻纤维毡70～75份、无水氯化钙16～21份、无水碳酸钠16～20份、氢氧化钠14～21份、乙酸2～6份、乙醇24～30份、四水合乙酸镁17～25份、乙二胺四乙酸二钠12～20份和JFC渗透剂10～15份。
优选的，所述汽车顶棚复合材料的制备方法包括以下步骤：
1).将发泡PU板上下两面涂覆EVA热熔胶制得上下面涂覆EVA热熔胶发泡PU板层，然后在上下面涂覆EVA热熔胶发泡PU板层上下两面分别依次平铺叠放上层碳酸钙改性后苎麻纤维毡和下层碳酸钙改性后苎麻纤维毡，在上层碳酸钙改性后苎麻纤维毡的上表面平铺叠放上层胶粉层；
2).再平铺叠放在下层胶粉层的上表面，在上层胶粉层平铺叠放上层高分子热熔胶膜层，再平铺叠放在下层高分子热熔胶膜层的上表面，然后在上层高分子热熔胶膜层表面喷涂胶粘剂和平铺叠放装饰层无纺布；
3).将已经平铺叠放好的超细碳酸钙改性苎麻纤维毡增强PU的汽车顶棚复合材料放入温度为100～180℃热模具中进行热压成型，成型后取出模具，冷却至室温，在使用水刀切割和打孔，即得汽车顶棚复合材料。
本发明的有益效果为：本发明的超细碳酸钙改性苎麻纤维毡增强 PU的汽车顶棚材料在PU板中添加了柔顺剂，使其具有轻质、绿色环保、高强度、高韧性及耐冲击性，提升麻纤维与汽车顶棚用其他聚合物材料界面结合效果，增强了材料尺寸稳定性，以及在PU板中添加了生物质壳聚糖、氧化锌颗粒，使顶棚材料具有抗菌、除臭、除异味及防霉变的优势。
附图说明
图1是本发明所用的苎麻纤维改性前后表面形态观察结构示意图。
图2是本发明超细碳酸钙改性苎麻纤维毡增强PU的汽车顶棚材料的抑菌率示意图。
图3是本发明超细碳酸钙改性苎麻纤维毡增强PU的汽车顶棚材料结构示意图。
图中：1、装饰层无纺布；2、上层高分子热熔胶膜层；3、上层胶粉层；4、上层碳酸钙改性后苎麻纤维；5、上下面涂覆EVA热熔胶发泡PU板层；6、下层碳酸钙改性后苎麻纤维；7、下层胶粉层；8、下层高分子热熔胶膜层；9、热压模具；10、汽车顶棚材料。
具体实施方式
下面将结合本发明实施例中的附图，对本发明实施例中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
请参阅图1-3所示，本发明采用的技术方案为：一种超细碳酸钙改性苎麻纤维毡增强PU的汽车顶棚材料及其制备方法，所述汽车顶棚复合材料包括自上而下依次分布的材料结构：装饰层无纺布1、上层高分子热熔胶膜层2、上层胶粉层3、上层碳酸钙改性后苎麻纤维毡4、上下面涂覆EVA热熔胶发泡PU板层5、下层碳酸钙改性后苎麻纤维毡6、下层胶粉层7和下层高分子热熔胶膜层8。
进一步地，所述上层高分子高分子热熔胶膜层2喷涂有胶粘剂。
进一步地，所述胶粘剂为重量份数是15份的水溶性聚氨酯。
进一步地，所述上下面涂覆EVA热熔胶发泡PU板层5涂覆有柔顺剂。
进一步地，所述柔顺剂为重量份数是8份的氨基硅油。
进一步地，所述上下面涂覆EVA热熔胶发泡PU板层5包括下述重量份的原料：PU 45份、发泡剂6份、胺类催化剂1.5份、生物质壳聚糖颗粒50份和氧化锌60份。
进一步地，所述上层碳酸钙改性后苎麻纤维毡4和下层碳酸钙改性后苎麻纤维毡6均包括下述重量份的原料：水刺苎麻纤维毡72份、无水氯化钙18份、无水碳酸钠17份、氢氧化钠19份、乙酸5份、乙醇26份、四水合乙酸镁20份、乙二胺四乙酸二钠17份和JFC渗透剂16份。
进一步地，所述汽车顶棚复合材料的制备方法包括以下步骤：
1).将发泡PU板上下两面涂覆EVA热熔胶制得上下面涂覆EVA热熔胶发泡PU板层5，然后在上下面涂覆EVA热熔胶发泡PU板层5上下两面分别依次平铺叠放上层碳酸钙改性后苎麻纤维毡4和下层碳酸钙改性后苎麻纤维毡6，在上层碳酸钙改性后苎麻纤维毡的上表面平铺叠放上层胶粉层3；
2).再平铺叠放在下层胶粉层7的上表面，在上层胶粉层3平铺叠放上层高分子热熔胶膜层2，再平铺叠放在下层高分子热熔胶膜层 8的上表面，然后在上层高分子热熔胶膜层2表面喷涂胶粘剂和平铺叠放装饰层无纺布1；
3).将已经平铺叠放好的超细碳酸钙改性苎麻纤维毡增强PU的汽车顶棚复合材料放入温度为120℃热模具中进行热压成型，成型后取出模具，冷却至室温，在使用水刀切割和打孔，即得汽车顶棚复合材料。
实施例2
本实施例与实施例1的区别在于：
所述胶粘剂为重量份数是20份的水溶性聚氨酯。
所述柔顺剂为重量份数是10份的氨基硅油。
所述上下面涂覆EVA热熔胶发泡PU板层5包括下述重量份的原料：PU 40份、发泡剂8份、胺类催化剂2份、生物质壳聚糖颗粒60 份和氧化锌70份。
所述上层碳酸钙改性后苎麻纤维毡4和下层碳酸钙改性后苎麻纤维毡6均包括下述重量份的原料：水刺苎麻纤维毡75份、无水氯化钙21份、无水碳酸钠20份、氢氧化钠21份、乙酸6份、乙醇30 份、四水合乙酸镁25份、乙二胺四乙酸二钠20份和JFC渗透剂15 份。
实施例3
本实施例与实施例1的区别在于：
所述胶粘剂为重量份数是10份的水溶性聚氨酯。
所述柔顺剂为重量份数是5份的氨基硅油。
所述上下面涂覆EVA热熔胶发泡PU板层5包括下述重量份的原料：PU 40份、发泡剂2份、胺类催化剂1份、生物质壳聚糖颗粒40 份和氧化锌50份。
所述上层碳酸钙改性后苎麻纤维毡4和下层碳酸钙改性后苎麻纤维毡6均包括下述重量份的原料：水刺苎麻纤维毡70份、无水氯化钙16份、无水碳酸钠16份、氢氧化钠14份、乙酸2份、乙醇24 份、四水合乙酸镁17份、乙二胺四乙酸二钠12份和JFC渗透剂10 份。
实施例4
本实施例与实施例1的区别在于：
所述胶粘剂为重量份数是20份的水溶性聚氨酯。
所述柔顺剂为重量份数是5份的氨基硅油。
所述上下面涂覆EVA热熔胶发泡PU板层5包括下述重量份的原料：PU 60份、发泡剂2份、胺类催化剂2份、生物质壳聚糖颗粒40 份和氧化锌70份。
所述上层碳酸钙改性后苎麻纤维毡4和下层碳酸钙改性后苎麻纤维毡6均包括下述重量份的原料：水刺苎麻纤维毡70份、无水氯化钙21份、无水碳酸钠16份、氢氧化钠21份、乙酸2份、乙醇30 份、四水合乙酸镁17份、乙二胺四乙酸二钠20份和JFC渗透剂10 份。
所得产品性能指标测试如下：
1.得到的复合板的表面质量密度500～1000g/m2(根据生产任意设计)；
2.弯曲强度大于60MPa；
3.超细碳酸钙改性苎麻纤维表面，增加了改性后苎麻纤维的韧性因此提升了耐冲击性，冲击性比未改性苎麻纤维复合材料提升了约 50％；
4.邵氏硬度(D型)达到大于90；
5.超细碳酸钙改性苎麻纤维毡增强PU的汽车顶棚材料含有壳聚糖及氧化锌颗粒，因此具有一定的抑菌性能够防止霉变，经过多次洗涤后对金黄色葡萄球菌抑菌率达到90.13％、对大肠杆菌的抑菌率达到86.09％。(洗涤方法：在自来水中搅拌，每次搅拌30分钟)；
6.壳聚糖及复合板材的多孔结构实现对异味的吸收、去除甲醛，除臭、异味达到效果：甲醛去除率约85％；
7.综合的尺寸稳定性指标，体现在该复合材料结合后的在强度、韧性及耐冲击性、使用寿命等方面比未改性苎麻纤维增强的复合板好，(上面已有数据说明)，超细碳酸钙改性苎麻纤维增强顶棚材料，易加工、使用时不易变形，层间结合牢固。
在本发明中，本发明的超细碳酸钙改性苎麻纤维毡增强PU的汽车顶棚材料在PU板中添加了柔顺剂，使其具有轻质、绿色环保、高强度、高韧性及耐冲击性，提升麻纤维与汽车顶棚用其他聚合物材料界面结合效果，增强了材料尺寸稳定性，以及在PU板中添加了生物质壳聚糖、氧化锌颗粒，使顶棚材料具有抗菌、除臭、除异味及防霉变的优势。
尽管已经示出和描述了本发明的实施例，对于本领域的普通技术人员而言，可以理解在不脱离本发明的原理和精神的情况下可以对这些实施例进行多种变化、修改、替换和变型，本发明的范围由所附权利要求及其等同物限定。

Claims (8)

1.一种超细碳酸钙改性苎麻纤维毡增强PU的汽车顶棚材料及其制备方法，其特征在于，所述汽车顶棚材料包括自上而下依次分布的材料结构：装饰层无纺布(1)、上层高分子热熔胶膜层(2)、上层胶粉层(3)、上层碳酸钙改性后苎麻纤维毡(4)、上下面涂覆EVA热熔胶发泡PU板层(5)、下层碳酸钙改性后苎麻纤维毡(6)、下层胶粉层(7)和下层高分子热熔胶膜层(8)。
2.根据权利要求1所述的超细碳酸钙改性苎麻纤维毡增强PU的汽车顶棚材料及其制备方法，其特征在于，所述上层高分子高分子热熔胶膜层(2)喷涂有胶粘剂。
3.根据权利要求2所述的超细碳酸钙改性苎麻纤维毡增强PU的汽车顶棚材料及其制备方法，其特征在于，所述胶粘剂为重量份数是10～20份的水溶性聚氨酯。
4.根据权利要求1所述的超细碳酸钙改性苎麻纤维毡增强PU的汽车顶棚材料及其制备方法，其特征在于，所述上下面涂覆EVA热熔胶发泡PU板层(5)涂覆有柔顺剂。
5.根据权利要求4所述的超细碳酸钙改性苎麻纤维毡增强PU的汽车顶棚材料及其制备方法，其特征在于，所述柔顺剂为重量份数是5～10份的氨基硅油。
6.根据权利要求1所述的超细碳酸钙改性苎麻纤维毡增强PU的汽车顶棚材料及其制备方法，其特征在于，所述上下面涂覆EVA热熔胶发泡PU板层(5)包括下述重量份的原料：PU40～60份、发泡剂2～8份、胺类催化剂1～2份、生物质壳聚糖颗粒40～60份和氧化锌50～70份。
7.根据权利要求1所述的超细碳酸钙改性苎麻纤维毡增强PU的汽车顶棚材料及其制备方法，其特征在于，所述上层碳酸钙改性后苎麻纤维毡(4)和下层碳酸钙改性后苎麻纤维毡(6)均包括下述重量份的原料：水刺苎麻纤维毡70～75份、无水氯化钙16～21份、无水碳酸钠16～20份、氢氧化钠14～21份、乙酸2～6份、乙醇24～30份、四水合乙酸镁17～25份、乙二胺四乙酸二钠12～20份和JFC渗透剂10～15份。
8.根据权利要求1所述的超细碳酸钙改性苎麻纤维毡增强PU的汽车顶棚材料及其制备方法，其特征在于，所述汽车顶棚复合材料的制备方法包括以下步骤：
1).将发泡PU板上下两面涂覆EVA热熔胶制得上下面涂覆EVA热熔胶发泡PU板层(5)，然后在上下面涂覆EVA热熔胶发泡PU板层(5)上下两面分别依次平铺叠放上层碳酸钙改性后苎麻纤维毡(4)和下层碳酸钙改性后苎麻纤维毡(6)，在上层碳酸钙改性后苎麻纤维毡(4)的上表面平铺叠放上层胶粉层(3)；
2).再平铺叠放在下层胶粉层(7)的上表面，在上层胶粉层(3)平铺叠放上层高分子热熔胶膜层(2)，再平铺叠放在下层高分子热熔胶膜层(8)的上表面，然后在上层高分子热熔胶膜层(2)表面喷涂胶粘剂和平铺叠放装饰层无纺布(1)；
3).将已经平铺叠放好的超细碳酸钙改性苎麻纤维毡增强PU的汽车顶棚复合材料放入温度为100～180℃热模具中进行热压成型，成型后取出模具，冷却至室温，在使用水刀切割和打孔，即得汽车顶棚复合材料。
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