CN108202510A - 一种汽车用pu纸蜂窝板复合材料零件及制作方法 - Google Patents

一种汽车用pu纸蜂窝板复合材料零件及制作方法 Download PDF

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CN108202510A
CN108202510A CN201611176477.0A CN201611176477A CN108202510A CN 108202510 A CN108202510 A CN 108202510A CN 201611176477 A CN201611176477 A CN 201611176477A CN 108202510 A CN108202510 A CN 108202510A
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honeycomb card
automobile
card board
composite material
material parts
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方诚
高翠梅
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Shanghai Xinan Auto Soundproof Blanket Co Ltd
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Shanghai Xinan Auto Soundproof Blanket Co Ltd
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Abstract

本发明涉及汽车用PU纸蜂窝板复合材料零件及制作方法，该零件边缘形状与汽车行李箱左右侧饰护板及尾门锁横梁的形状相匹配，该零件为双层结构，包括从上到下顺次设置的表面地毯和PU纸蜂窝板，PU纸蜂窝板由从上到下依次设置的表层PU层、表层玻璃纤维层、纸蜂窝板、底层玻璃纤维层和底层PU层组成。与现有技术相比，本发明具有强度更高、密度小、散发性能好等优点。

Description

一种汽车用PU纸蜂窝板复合材料零件及制作方法
技术领域
本发明属于高性能复合材料技术领域，尤其是涉及一种汽车用PU纸蜂窝板复合材料零件及其制作方法。
背景技术
目前汽车行业行李箱地毯，大多采用单片地毯压制的结构，因此结构较软，硬度及强度较低，如果需要达到一定的强度要求的话，则需要增加零件的厚度等，造成零件重量偏重，使得汽车的负荷增加，从而不利于汽车启动、行驶，另外还会造成油耗增加，不利于环保。
中国专利CN102336024A公布了一种汽车用木塑材料零件的制作方法，将两层木塑材料放入烘箱内加热软化，上模具及下模具内放置表面材料，烘软的两层木塑材料平铺在下模具内后控制合模并在两层木塑材料中间吹气，最后去除得到零件的边料，然后在零件上粘接塑料件即得到产品。该专利制得的木塑材料零件会带有木塑材料自身的木塑味，气味较大。
发明内容
本发明的目的就是为了克服上述现有技术存在的缺陷而提供一种强度更高、密度小、散发性能好的汽车用PU纸蜂窝板复合材料零件及其制作方法。
本发明的目的可以通过以下技术方案来实现：
一种汽车用PU纸蜂窝板复合材料零件，其边缘形状与汽车行李箱左右侧饰护板及尾门锁横梁的形状相匹配，该零件为双层结构，包括从上到下顺次设置的表面地毯和PU纸蜂窝板，所述的PU纸蜂窝板由从上到下依次设置的表层PU层、表层玻璃纤维层、纸蜂窝板、底层玻璃纤维层和底层PU层组成。
作为优选的技术方案，该零件上还装配有PET拉带。
作为优选的技术方案，所述的表层PU层的克重为400～600g/m2，所述的表层玻璃纤维层的克重为400～600g/m2，所述的纸蜂窝板克重为400g/m2，所述的底层玻璃纤维层的克重为400～600g/m2，所述的底层PU层的克重为400～600g/m2。
PU含量低，难以实现纸蜂窝板与玻纤的粘合；玻璃纤维含量低，则降低了零件的刚度；反之PU和玻璃纤维的含量升高，零件重量也会升高，增大零件密度。
作为优选的技术方案，所述的纸蜂窝板的孔径为3.5～4.5mm，孔壁厚度为1.8～2.2mm。
该孔径和孔壁厚度范围内的纸蜂窝板在具有较高强度的同时密度较为合适，而且有利于在模压过程中的成型过程：过小的孔径和过大的孔壁厚度使得纸蜂窝板的强度过大，而模压需要纸蜂窝板在厚度上有一定的压缩，过大强度的纸蜂窝板使得其不容易压缩，进而影响聚氨酯在模压过程中的发泡，过大的过孔和过薄的孔壁厚度有利于降低密度，但是不利于最终产品的强度。
作为优选的技术方案，所述的表面地毯由聚对苯二甲酸乙二醇酯和丁苯橡胶按质量比为80～85:20～15混纺制成。该表面地毯具有良好的耐磨性能，可以保证表面地毯经1000次圆磨实验后不产生褪色。
所述的一种汽车用PU纸蜂窝板复合材料零件的制备方法，包括以下步骤：
(1)表层玻璃纤维层、纸蜂窝板、底层玻璃纤维层按顺序装订在一起；
(2)使用机械手夹取装订好的材料，并在上下表面喷淋PU；
(3)使用机械手将喷涂好PU的材料放置入成型模具中，合模，控制压力18～20MPa，压制时间120～130s，模具温度120～130℃以实现PU的发泡，进行模压，得到PU纸蜂窝板；
(4)将PU纸蜂窝板和表面地毯放入粘合工装中进行粘合，装配配件，即得到所述的汽车用PU纸蜂窝板复合材料零件。
PU纸蜂窝板可以通过模压、PU发泡工艺与表面地毯复合加以实现，保证成品零件美观。
所述的成型模具包括成型上模和成型下模，所述的成型上模和成型下模匹配形成与所述的汽车用PU纸蜂窝板复合材料零件外形相匹配的模腔，模具温度通过模温机控制，所述的模温机与成型上模及成型下模连接。
作为优选的技术方案，步骤(3)中的模压过程中，控制纸蜂窝板厚度的压缩率为80％～90％。
通过对纸蜂窝进行一定程度的压缩，使得蜂窝板的刚度得到有效地增强。
作为优选的技术方案，PU纸蜂窝板和表面地毯之间采用反应性PUR热熔胶进行粘合，所述的粘合工装包括粘合上模和粘合下模，粘合过程中，粘合工装的压力为1～3MPa，保压时间为150～200s。
作为优选的技术方案，所述的反应性PUR热熔胶为市售的胶王进口热熔胶水，牌号为600.10。该热熔胶水能在保证蜂窝板与表面地毯的粘结力的同时，降低零件的散发性能。
由于PU蜂窝板在模压成型过程中为了方便取出，需要在模具的型腔壁面上涂抹脱模剂，该脱模剂不可避免的会残留在PU蜂窝板表面，从而影响表面地毯与PU蜂窝板的粘合，但是使用上述反应性热熔胶水，其工作原理是将胶水与空气中的水分进行反应，实现粘合，能最大程度上避免脱模剂对胶水的影响；同时，保证胶水的粘结性能和高低温性能：粘结力＞80N/5cm；零件在110℃、24h高温试验以及-30℃、24h低温试验，无脱落。
与现有技术相比，本发明具有以下有益效果：
(1)玻璃纤维具有较强的韧性，但其本身不具有粘性，无法粘结；而使用PU能在高温熔化下起到粘结玻璃纤维的作用。最终通过发泡得到的PU纸蜂窝板材料制作零件可以保证零件的强度和韧性，且不会产生刺鼻的气味。
(2)由于零件纸蜂窝板为中空材料结构，可以节省材料、减轻零件重量；同时由于玻璃纤维具有较高强度的天然优势，能保证制作出来的零件具有较高的强度。
具体实施方式
下面结合具体实施例对本发明进行详细说明。
实施例1
一种汽车用PU纸蜂窝板复合材料零件，边缘形状与汽车行李箱左右侧饰护板及尾门锁横梁的形状相匹配，该零件为双层结构，上表面层为表面地毯，下层为PU纸蜂窝板。PU纸蜂窝板由从上到下依次设置的表层PU层、表层玻璃纤维层、纸蜂窝板、底层玻璃纤维层和底层PU层共计五层组成。与现有技术相比，本发明具有强度高、密度低、散发性能好等优点。
表层PU层的克重为：400～600g/m2，表层玻璃纤维层的克重为：400～600g/m2，纸蜂窝板克重为：400g/m2，纸蜂窝板的孔径为：3.5～4.5mm，孔壁厚度为：1.8～2.2mm，底层玻璃纤维层的克重为：400～600g/m2，底层PU层的克重为：400～600g/m2。表面地毯由聚对苯二甲酸乙二醇酯和丁苯橡胶按质量比为80～85:20～15混纺制成。
一种汽车用PU纸蜂窝板复合材料零件的制备方法，采用由成型上模和成型下模构成的零件模具，包括以下步骤：
(1)利用模温***，控制成型模具的成型上模及成型下模的温度为125℃；
(2)使用订书机将表层玻纤、蜂窝纸芯、底层玻纤装订起来；
(3)使用机械手夹取装订起来的材料的边缘位置，并在上下表面喷淋PU，PU喷涂量为：400～600g/m2；
(4)利用机械手将喷淋PU后的材料放入成型模具中；
(5)机械手退出，闭合模具，控制压力为19MPa，合模时间为120s；
(6)开模将组件取出，去除边料，得到PU蜂窝纸板；
(7)将表面地毯固定在粘合工装上，粘合工装包括粘合上模和粘合下模，使用机械手喷胶(本实施例采用市售的牌号为600.10的胶王进口热熔胶水)，喷胶量为：80～100g/m2、总喷胶时间为：30s；
(8)将PU蜂窝纸板固定在表面地毯上；
(9)闭合粘合工装，粘合工装使用气缸压制，压制时间为：150s，压力约为：2MPa，控制纸蜂窝板厚度的压缩率为85％(即压缩后的厚度为原厚度的85％)；
(10)取出粘合好的零件；
(11)安装PET拉带配件，将PET拉带通过螺钉和四爪螺母与PU纸蜂窝板实现装配。
成品零件的单位面积重量约为：3500g/m2；经过25kg的液压振动试验，零件无变形；苯类(甲苯、乙苯、二甲苯)含量＜5μg/m3；甲醛含量＜80μg/m3；乙醛含量＜100μg/m3；丙烯醛含量为微量，密度小，强度高，安全环保。
实施例2
一种汽车用PU纸蜂窝板复合材料零件，边缘形状与汽车行李箱左右侧饰护板及尾门锁横梁的形状相匹配，该零件为双层结构，上表面层为表面地毯，下层为PU纸蜂窝板。PU纸蜂窝板由从上到下依次设置的表层PU层、表层玻璃纤维层、纸蜂窝板、底层玻璃纤维层和底层PU层共计五层组成。与现有技术相比，本发明具有强度高、密度低、散发性能好等优点。
表层PU层的克重为：500g/m2，表层玻璃纤维层的克重为：500g/m2，纸蜂窝板克重为：400g/m2，纸蜂窝板的孔径为：4mm，孔壁厚度为：2mm，底层玻璃纤维层的克重为：500g/m2，底层PU层的克重为：500g/m2。表面地毯由聚对苯二甲酸乙二醇酯和丁苯橡胶按质量比为83:17混纺制成。
本实施例的汽车用PU纸蜂窝板复合材料零件的制备采用由上模具和下模具构成的零件模具，成型上模和成型下模匹配形成与汽车用PU纸蜂窝板复合材料零件外形相匹配的模腔，制备方法包括以下步骤：
(1)利用模温机，控制成型模具的成型上模及成型下模的温度为130℃；
(2)使用订书机将表层玻纤、蜂窝纸芯、底层玻纤装订起来；
(3)使用机械手夹取装订起来的材料的边缘位置，并在上下表面喷淋PU，PU喷涂量为：400～600g/m2；
(4)利用机械手将喷淋PU后的材料放入成型模具中；
(5)机械手退出，闭合模具，控制压力为18MPa，合模时间为130s；
(6)开模将组件取出，去除边料，得到PU蜂窝纸板；
(7)将表面地毯固定在粘合工装上，粘合工装包括粘合上模和粘合下模，使用机械手喷胶(本实施例采用市售的牌号为600.10的胶王进口热熔胶水)，喷胶量为：80～100g/m2、总喷胶时间为：30s；
(8)将PU蜂窝纸板固定在表面地毯上；
(9)闭合粘合工装，粘合工装使用气缸压制，压制时间为：200s，压力约为：1MPa，控制纸蜂窝板厚度的压缩率为90％；
(10)取出粘合好的零件；
(11)安装PET拉带配件，将PET拉带通过螺钉和四爪螺母与PU纸蜂窝板实现装配。
实施例3
本实施例与实施例1基本相同，不同之处在于，本实施例的汽车用PU纸蜂窝板复合材料零件的制备采用由上模具和下模具构成的零件模具，成型上模和成型下模匹配形成与汽车用PU纸蜂窝板复合材料零件外形相匹配的模腔，制备方法包括以下步骤：
(1)利用模温机，控制成型模具的成型上模及成型下模的温度为120℃；
(2)使用订书机将表层玻纤、蜂窝纸芯、底层玻纤装订起来；
(3)使用机械手夹取装订起来的材料的边缘位置，并在上下表面喷淋PU，PU喷涂量为：400～600g/m2；
(4)利用机械手将喷淋PU后的材料放入成型模具中；
(5)机械手退出，闭合模具，控制压力为20MPa，合模时间为125s；
(6)开模将组件取出，去除边料，得到PU蜂窝纸板；
(7)将表面地毯固定在粘合工装上，粘合工装包括粘合上模和粘合下模，使用机械手喷胶(本实施例采用市售的牌号为600.10的胶王进口热熔胶水)，喷胶量为：80～100g/m2、总喷胶时间为：30s；
(8)将PU蜂窝纸板固定在表面地毯上；
(9)闭合粘合工装，粘合工装使用气缸压制，压制时间为：180s，压力约为：3MPa，控制纸蜂窝板厚度的压缩率为80％；
(10)取出粘合好的零件；
(11)安装PET拉带配件，将PET拉带通过螺钉和四爪螺母与PU纸蜂窝板实现装配。

Claims (10)

1.一种汽车用PU纸蜂窝板复合材料零件，其特征在于，其边缘形状与汽车行李箱左右侧饰护板及尾门锁横梁的形状相匹配，该零件为双层结构，包括从上到下顺次设置的表面地毯和PU纸蜂窝板，所述的PU纸蜂窝板由从上到下依次设置的表层PU层、表层玻璃纤维层、纸蜂窝板、底层玻璃纤维层和底层PU层组成。
2.根据权利要求1所述的一种汽车用PU纸蜂窝板复合材料零件，其特征在于，该零件上还装配有PET拉带。
3.根据权利要求1所述的一种汽车用PU纸蜂窝板复合材料零件，其特征在于，所述的表层PU层的克重为400～600g/m2，所述的表层玻璃纤维层的克重为400～600g/m2，所述的纸蜂窝板克重为400g/m2，所述的底层玻璃纤维层的克重为400～600g/m2，所述的底层PU层的克重为400～600g/m2。
4.根据权利要求1或3所述的一种汽车用PU纸蜂窝板复合材料零件，其特征在于，所述的纸蜂窝板的孔径为3.5～4.5mm，孔壁厚度为1.8～2.2mm。
5.根据权利要求1所述的一种汽车用PU纸蜂窝板复合材料零件，其特征在于，所述的表面地毯由聚对苯二甲酸乙二醇酯和丁苯橡胶按质量比为80～85:20～15混纺制成。
6.如权利要求1～5任一所述的一种汽车用PU纸蜂窝板复合材料零件的制备方法，其特征在于，包括以下步骤：
(1)表层玻璃纤维层、纸蜂窝板、底层玻璃纤维层按顺序装订在一起；
(2)使用机械手夹取装订好的材料，并在上下表面喷淋PU；
(3)使用机械手将喷涂好PU的材料放置入成型模具中，合模，控制压力18～20MPa，压制时间120～130s，模具温度120～130℃，进行模压，得到PU纸蜂窝板；
(4)将PU纸蜂窝板和表面地毯放入粘合工装中进行粘合，装配配件，即得到所述的汽车用PU纸蜂窝板复合材料零件。
7.根据权利要求6所述的一种汽车用PU纸蜂窝板复合材料零件的制备方法，其特征在于，所述的成型模具包括成型上模和成型下模，所述的成型上模和成型下模匹配形成与所述的汽车用PU纸蜂窝板复合材料零件外形相匹配的模腔，模具温度通过模温机控制，所述的模温机与成型上模及成型下模连接。
8.根据权利要求6所述的一种汽车用PU纸蜂窝板复合材料零件的制备方法，其特征在于，步骤(3)中的模压过程中，控制纸蜂窝板厚度的压缩率为80％～90％。
9.根据权利要求6所述的一种汽车用PU纸蜂窝板复合材料零件的制备方法，其特征在于，PU纸蜂窝板和表面地毯之间采用反应性PUR热熔胶进行粘合，所述的粘合工装包括粘合上模和粘合下模，粘合过程中，粘合工装的压力为1～3MPa，保压时间为150～200s。
10.根据权利要求9所述的一种汽车用PU纸蜂窝板复合材料零件的制备方法，其特征在于，所述的反应性PUR热熔胶为市售的胶王进口热熔胶水，牌号为600.10。
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Application publication date: 20180626