CN108263047A - 一种客车轻量化集成地板及其制备方法 - Google Patents
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Abstract
本发明涉及一种客车轻量化集成地板及其制备方法,属于客车内饰技术领域。本发明的客车轻量化集成地板,从上到下依次包括连续玻纤增强聚丙烯复合板、铝蜂窝层和铝板,所述铝蜂窝层包括铝蜂窝和填充在铝蜂窝的蜂窝结构内的聚氨酯硬泡。本发明的客车轻量化集成地板,采用连续玻纤增强聚丙烯复合板,质轻,价格低廉,在降低零部件的成本和整车质量的同时,还降低了人工成本;此外,连续玻纤增强聚丙烯复合板具有良好的韧性和耐磨性,颜色可调,上层采用连续玻纤增强聚丙烯复合板可省去地板革的使用,从而避免因使用地板革而起包的现象,并且有利于整车环保。
Description
技术领域
本发明涉及一种客车轻量化集成地板及其制备方法,属于客车内饰技术领域。
背景技术
客车轻量化可以带来更好的操控性,发动机输出的动力能够产生更高的加速度,起步加速时加速性能更好,刹车时的制动距离更短,有效提高燃油效率和载重量。实验证明,若汽车整车重量降低10%,燃油效率可提高6%~8%;汽车整备质量每减少100kg,百公里油耗可降低0.3~0.6升;汽车重量降低1%,油耗可降低0.7%。当前,由于环保和节能的需要,汽车的轻量化已经成为世界汽车发展的潮流。地板是安装于地板骨架之上,提供承载、隔音、降噪、隔热、保温及防水等功能的重要的零部件,常用的竹编地板具有重量重、易腐烂、易燃烧的缺点,客车轻量化集成地板在提升地板质量的同时,大大降低地板装配的自重,为整车轻量化做出贡献。
现有技术中,公布号为CN10581887A的中国专利申请文件公开了一种新型的客车地板,包括第一铝板、第二铝板和铝蜂窝,所述第一铝板和第二铝板之间通过聚氨酯树脂硬泡复合有铝蜂窝,各层之间通过热压复合成型。该客车地板比传统竹木地板轻100%,省油耗;杜绝了传统竹木地板遇高温高湿易腐烂的现象。但是该地板采用两层铝板,并且使用前需要胶粘地板革,零部件成本高。
发明内容
本发明的目的是提供一种零部件成本低的客车轻量化集成地板。
本发明还提供了一种客车轻量化集成地板的制备方法。
为了实现以上目的,本发明的客车轻量化集成地板所采用的技术方案是:
一种客车轻量化集成地板,从上到下依次包括连续玻纤增强聚丙烯复合板、铝蜂窝层和铝板,所述铝蜂窝层包括铝蜂窝和填充在铝蜂窝的蜂窝结构内的聚氨酯硬泡。
本发明的客车轻量化集成地板,采用连续玻纤增强聚丙烯复合板,质轻,价格低廉,在降低零部件的成本和整车质量的同时,还降低了人工成本;此外,连续玻纤增强聚丙烯复合板具有良好的韧性和耐磨性,颜色可调,上层采用连续玻纤增强聚丙烯复合板可省去地板革的使用,从而避免因使用地板革而起包的现象,并且有利于整车环保。
本发明的客车轻量化集成地板的铝蜂窝层使用铝蜂窝结构支撑,中间填充聚氨酯硬泡,不同于胶合板,能够保证地板强度。
本发明的客车轻量化集成地板具有质轻、强度高、耐腐蚀、环保、稳定性更好、外形更美观、使用寿命更长、易于安装等的特点;因使用的都是耐腐性的铝材料和高分子材料,还具体有在高温高湿环境下不会腐烂、也不会被虫蛀的优点。
优选的,所述连续玻纤增强聚丙烯复合板和铝蜂窝层之间粘结连接。进一步优选的,所述粘结连接采用PP附着力增强剂连接。采用PP附着力增强剂可以增强连续玻纤增强聚丙烯复合板与铝蜂窝层之间的粘接力,避免地板在长期使用过程中出现脱层现象,延长客车轻量化集成地板的使用寿命。
优选的,所述铝板的朝向连续玻纤增强聚丙烯复合板的一侧的表面开设有凹槽。铝板表面开设的凹槽能进一步增强铝蜂窝层和铝板之间的结合。优选的,所述凹槽为凹设花纹。
优选的,所述凹槽的深度为0.05~0.15mm。所述铝板为7系铝板。所述铝板的厚度为0.5~1mm。所述连续玻纤增强聚丙烯复合板的厚度为1.5~2mm。
铝蜂窝的蜂窝结构延伸方向与铝板表面垂直。
优选的,所述聚氨酯硬泡是在铝蜂窝的蜂窝结构中填充聚氨酯发泡料发泡后形成的。所述聚氨酯发泡料包括A料和B料。所述A料主要成分为聚醚多元醇,所述B料的主要成分为聚合异氰酸酯或异氰酸酯。所述A料和B料的质量比为1:1~1.2。
所述聚醚多元醇的羟值为300~1000mgKOH/g,25℃时粘度≤45000mPa·s。所述聚合异氰酸酯的聚合单体为甲苯二异氰酸酯、二苯基甲烷二异氰酸酯、己二异氰酸酯中的任意一种或多种。
优选的,所述连续玻纤增强聚丙烯复合板中玻璃纤维的含量为30~40%。
优选的,所述客车轻量化集成地板的厚度为9~16mm。进一步优选为12-15mm。
本发明的客车轻量化集成地板的制备方法所采用的技术方案为:
一种上述的客车轻量化集成地板的制备方法,包括如下步骤:在铝板上铺设铝蜂窝,然后在铝蜂窝的蜂窝结构中填充聚氨酯硬泡,再将连续玻纤增强聚丙烯复合板铺在铝蜂窝上,热压,即得;
或者所述客车轻量化集成地板的制备方法包括如下步骤:在连续玻纤增强聚丙烯复合板上铺设铝蜂窝,然后在铝蜂窝的蜂窝结构中填充聚氨酯硬泡,再将铝板铺在铝蜂窝上,热压,即得。
本发明的客车轻量化集成地板的制备方法简单,便于推广,适于工业化生产。
优选的,所述铝板为7系铝板。所述铝板的厚度为0.5~1mm。所述连续玻纤增强聚丙烯复合板的厚度为1.5~2mm。
优选的,所述铝板在使用前,先在铝板表面打磨出0.05~0.15mm深的凹设花纹。在铝板上铺设铝蜂窝或将铝板铺在铝蜂窝上时,使打磨出凹设花纹的一面朝向铝蜂窝。
优选的,所述填充聚氨酯硬泡包括如下步骤:将聚氨酯发泡料填充在铝蜂窝的蜂窝结构中,发泡形成聚氨酯硬泡。所述聚氨酯发泡料包括A料和B料。所述A料的主要成分为聚醚多元醇,所述B料的主要成分为聚合异氰酸酯或异氰酸酯。所述A料和B料的质量比为1:1~1.2。
优选的,所述聚醚多元醇的羟值为300~1000mgKOH/g,25℃时粘度≤45000mPa·s。
优选的,所述聚合异氰酸酯的聚合单体为甲苯二异氰酸酯、二苯基甲烷二异氰酸酯、己二异氰酸酯中的任意一种或多种。
优选的,所述连续玻纤增强聚丙烯复合板朝向铝蜂窝层的一侧表面涂抹有PP附着力增强剂。
优选的,所述连续玻纤增强聚丙烯复合板中玻璃纤维的含量为30~40%。
优选的,所述热压的压力为10~11MPa。热压的温度为35~45℃。热压的保压时间为8~10min。
优选的,所述客车轻量化集成地板的厚度为9~16mm。进一步优选为12~15mm。
附图说明
图1为实施例1的客车轻量化集成地板的截面示意图,其中,1-连续玻纤增强聚丙烯复合板,2-铝蜂窝,3-聚氨酯硬泡,4-铝板;
图2为实施例1的铝蜂窝的结构示意图;
图3为实施例1所采用的模具的示意图,其中,5-阳模,6-阴模。
具体实施方式
以下结合具体实施方式对本发明的技术方案作进一步的说明。
具体实施方式中,所采用的铝板为高强度的7系铝板;所采用的A料为山东联创节能新材料股份有限公司生产的硬泡聚醚LCS-4110B,羟值为440~460mgKOH/g,在25℃时,粘度为4000~6000mPa·s。
实施例1
本实施例的客车轻量化集成地板,如图1所示,包括从上到下依次设置并复合在一起的连续玻纤增强聚丙烯复合板1、铝蜂窝层和铝板4,所述铝蜂窝层包括铝蜂窝2和填充在铝蜂窝的蜂窝结构内的聚氨酯硬泡3,铝蜂窝的结构示意图见图2。连续玻纤增强聚丙烯复合板的厚度为1.5mm,连续玻纤增强聚丙烯复合板中玻璃纤维的质量百分比为35%;铝板的厚度为0.5mm;铝蜂窝的厚度为10mm;客车轻量化集成地板的厚度为12mm。
本实施例的客车轻量化集成地板的制备方法,包括:先在铝板表面打磨出0.1mm深的凹设花纹,再将打磨出凹设花纹的一面朝上置于模具底层;然后在铝板上铺设铝蜂窝,铝蜂窝自然铺开,再在铝蜂窝的蜂窝结构中均匀喷入聚氨酯发泡料发泡形成聚氨酯硬泡;然后在连续玻纤增强聚丙烯复合板上涂抹PP附着力增强剂,再将连续玻纤增强聚丙烯复合板按照涂抹PP附着力增强剂的面朝下,将其铺在铝蜂窝上;最后在40℃、10MPa的条件下热压8min;开模、修边、成型,即得。所采用的模具的示意图见图3,包括阳模5和阴模6。
上述聚氨酯发泡料包括A料和B料,B料的主要成分为聚合异氰酸酯;聚合异氰酸酯的聚合单体为甲苯二异氰酸酯(TDI);A料和B料的质量比为1:1。
实施例2
本实施例的客车轻量化集成地板,包括从上到下依次设置并复合在一起的连续玻纤增强聚丙烯复合板、铝蜂窝层和铝板,所述铝蜂窝层包括铝蜂窝和填充在铝蜂窝的蜂窝结构内的聚氨酯硬泡。连续玻纤增强聚丙烯复合板的厚度为2mm,连续玻纤增强聚丙烯复合板中玻璃纤维的质量百分比为30%;铝板的厚度为1mm;铝蜂窝的厚度为12mm;客车轻量化集成地板的厚度为15mm。
本实施例的客车轻量化集成地板的制备方法,包括:先将连续玻纤增强聚丙烯复合板置于模具底层,然后在朝上的面上涂抹PP附着力增强剂;再将铝蜂窝铺设在连续玻纤增强聚丙烯复合板上,铝蜂窝自然铺开,然后在铝蜂窝的蜂窝结构中均匀喷入聚氨酯发泡料发泡形成聚氨酯硬泡;再在铝板表面打磨出0.1mm深的凹设花纹,再将打磨出凹设花纹的一面朝下铺在铝蜂窝上;最后在40℃、11MPa的条件下热压10min;开模、修边、成型,即得。
上述聚氨酯发泡料包括A料和B料,B料的主要成分为聚合异氰酸酯;聚合异氰酸酯的聚合单体为二苯基甲烷二异氰酸酯(MDI);A料和B料的质量比为1:1.2。B料为亨斯迈公公司生产的型号为SUPRASEC 5005的聚合MDI。
实施例3
本实施例的客车轻量化集成地板,包括从上到下依次设置并复合在一起的连续玻纤增强聚丙烯复合板、铝蜂窝层和铝板,所述铝蜂窝层包括铝蜂窝和填充在铝蜂窝的蜂窝结构内的聚氨酯硬泡。连续玻纤增强聚丙烯复合板中的厚度为1.8mm,连续玻纤增强聚丙烯复合板中玻璃纤维的质量百分比为40%;铝板的厚度为0.8mm;铝蜂窝的厚度为9.4mm;客车轻量化集成地板的厚度为12mm。
本实施例的客车轻量化集成地板的制备方法,包括:先在铝板表面打磨出0.05mm深的凹设花纹,再将打磨出凹设花纹的一面朝上置于模具底层;然后在铝板上铺设铝蜂窝,铝蜂窝自然铺开,再在铝蜂窝的蜂窝结构中均匀喷入聚氨酯发泡料发泡形成聚氨酯硬泡;然后在连续玻纤增强聚丙烯复合板上涂抹PP附着力增强剂,再将连续玻纤增强聚丙烯复合板按照涂抹PP附着力增强剂的面朝下,将其铺在铝蜂窝上;最后在35℃、10.5MPa的条件下热压9min;开模、修边、成型,即得。
上述聚氨酯发泡料包括A料和B料,B料的主要成分为聚合异氰酸酯;聚合异氰酸酯的聚合单体为己二异氰酸酯(HDI);A料和B料的质量比为1:1.1。
实施例4
本实施例的客车轻量化集成地板,包括从上到下依次设置并复合在一起的连续玻纤增强聚丙烯复合板、铝蜂窝层和铝板,所述铝蜂窝层包括铝蜂窝和填充在铝蜂窝的蜂窝结构内的聚氨酯硬泡。连续玻纤增强聚丙烯复合板中的厚度为1.6mm,连续玻纤增强聚丙烯复合板中玻璃纤维的质量百分比为33%;铝板的厚度为0.6mm;铝蜂窝的厚度为12.8mm;客车轻量化集成地板的厚度为15mm。
本实施例的客车轻量化集成地板的制备方法,包括:先将连续玻纤增强聚丙烯复合板置于模具底层,然后在朝上的面上涂抹PP附着力增强剂;再将铝蜂窝铺设在连续玻纤增强聚丙烯复合板上,铝蜂窝自然铺开,然后在铝蜂窝的蜂窝结构中均匀喷入聚氨酯发泡料发泡形成聚氨酯硬泡;再在铝板表面打磨出0.15mm深的凹设花纹,再将打磨出凹设花纹的一面朝下铺在铝蜂窝上;最后在45℃、10MPa的条件下热压8min;开模、修边、成型,即得。
上述聚氨酯发泡料包括A料和B料,B料的主要成分为聚合异氰酸酯;聚合异氰酸酯的聚合单体为甲苯二异氰酸酯(TDI);A料和B料的质量比为1:1。
实施例5
本实施例的客车轻量化集成地板,包括从上到下依次设置并复合在一起的连续玻纤增强聚丙烯复合板、铝蜂窝层和铝板,所述铝蜂窝层包括铝蜂窝和填充在铝蜂窝的蜂窝结构内的聚氨酯硬泡。连续玻纤增强聚丙烯复合板的厚度为1.5mm,连续玻纤增强聚丙烯复合板中玻璃纤维的质量百分比为35%;铝板的厚度为0.72mm;铝蜂窝的厚度为7mm;客车轻量化集成地板的厚度为9.22mm。
本实施例的客车轻量化集成地板的制备方法,包括:先在铝板表面打磨出0.1mm深的凹设花纹,再将打磨出凹设花纹的一面朝上置于模具底层;然后在铝板上铺设铝蜂窝,铝蜂窝自然铺开,再在铝蜂窝的蜂窝结构中均匀喷入聚氨酯发泡料发泡形成聚氨酯硬泡;然后在连续玻纤增强聚丙烯复合板上涂抹PP附着力增强剂,再将连续玻纤增强聚丙烯复合板按照涂抹PP附着力增强剂的面朝下,将其铺在铝蜂窝上;最后在40℃、10MPa的条件下热压8min;开模、修边、成型,即得。
上述聚氨酯发泡料包括A料和B料,B料的主要成分为聚合异氰酸酯;聚合异氰酸酯的聚合单体为甲苯二异氰酸酯(TDI);A料和B料的质量比为1:1。
实施例6
本实施例的客车轻量化集成地板,包括从上到下依次设置并复合在一起的连续玻纤增强聚丙烯复合板、铝蜂窝层和铝板,所述铝蜂窝层包括铝蜂窝和填充在铝蜂窝的蜂窝结构内的聚氨酯硬泡。连续玻纤增强聚丙烯复合板的厚度为1.75mm,连续玻纤增强聚丙烯复合板中玻璃纤维的质量百分比为30%;铝板的厚度为0.5mm;铝蜂窝的厚度为7mm;客车轻量化集成地板的厚度为9.25mm。
本实施例的客车轻量化集成地板的制备方法,包括:先将连续玻纤增强聚丙烯复合板置于模具底层,然后在朝上的面上涂抹PP附着力增强剂;再将铝蜂窝铺设在连续玻纤增强聚丙烯复合板上,铝蜂窝自然铺开,然后在铝蜂窝的蜂窝结构中均匀喷入聚氨酯发泡料发泡形成聚氨酯硬泡;再在铝板表面打磨出0.1mm深的凹设花纹,再将打磨出凹设花纹的一面朝下铺在铝蜂窝上;最后在40℃、11MPa的条件下热压10min;开模、修边、成型,即得。
上述聚氨酯发泡料包括A料和B料,B料的主要成分为聚合异氰酸酯;聚合异氰酸酯的聚合单体为二苯基甲烷二异氰酸酯(MDI);A料和B料的质量比为1:1.2。B料为亨斯迈公公司生产的型号为SUPRASEC 5005的聚合MDI。
实施例7
本实施例的客车轻量化集成地板,包括从上到下依次设置并复合在一起的连续玻纤增强聚丙烯复合板、铝蜂窝层和铝板,所述铝蜂窝层包括铝蜂窝和填充在铝蜂窝的蜂窝结构内的聚氨酯硬泡。连续玻纤增强聚丙烯复合板中的厚度为1.88mm,连续玻纤增强聚丙烯复合板中玻璃纤维的质量百分比为40%;铝板的厚度为0.8mm;铝蜂窝的厚度为6.5mm;客车轻量化集成地板的厚度为9.18mm。
本实施例的客车轻量化集成地板的制备方法,包括:先在铝板表面打磨出0.05mm深的凹设花纹,再将打磨出凹设花纹的一面朝上置于模具底层;然后在铝板上铺设铝蜂窝,铝蜂窝自然铺开,再在铝蜂窝的蜂窝结构中均匀喷入聚氨酯发泡料发泡形成聚氨酯硬泡;然后在连续玻纤增强聚丙烯复合板上涂抹PP附着力增强剂,再将连续玻纤增强聚丙烯复合板按照涂抹PP附着力增强剂的面朝下,将其铺在铝蜂窝上;最后在35℃、10.5MPa的条件下热压9min;开模、修边、成型,即得。
上述聚氨酯发泡料包括A料和B料,B料的主要成分为聚合异氰酸酯;聚合异氰酸酯的聚合单体为己二异氰酸酯(HDI);A料和B料的质量比为1:1.1。
实验例1
实施例5的客车轻量化集成地板的水煮-冰冻-干燥处理后静曲强度测定
测试方法:参照GB/T 17657-2013第4.10节的方法,将250*50.0*9.22mm的试件放入(63±2)℃水中,使水面高于试件10~20mm,水浸6h,取出试件,擦去表面水分,将试件放入(-20±2)℃条件下冰冻24h,取出试件放入(63±2)℃的鼓风干燥箱中,干燥6h,取出试件,在室温下冷却30min,然后在1h内测定静曲强度。测定静曲强度时,设定测试速度为10mm/min,跨距为185mm。
按照上述方法测得式样水煮-冰冻-干燥处理后的静曲强度为79.5MPa。
实验例2
实施例6的客车轻量化集成地板的静曲强度和弹性模量测定(三点弯)
测试方法:参照GB/T 17657-2013第4.7节的方法,取250*50.0*9.25mm的试件,在测试速度为10mm/min,跨距为185mm的条件下,测得试件的静曲强度为86.5MPa,弹性模量为19498MPa。
实验例3
实施例7的客车轻量化集成地板的70℃水中浸渍处理后静曲强度测定
测试方法:参照GB/T 17657-2013第4.9节方法A的方法,使用新鲜自来水进行测试,把250*50.0*9.18mm放入支架内,然后把支架放进水槽,浸泡在温度为(70±3)℃的热水中,并保持水位高于试件上端(75±15)mm,盖上盖板,浸渍2h。从水槽中取出支架并拿出试件,然后把试件放入室温水槽中浸渍1h,取出试件,擦去试件表面的附着的水,测定静曲强度。测定静曲强度时,设定测试速度为10mm/min,跨距为185mm。
按照上述方法测得试件的静曲强度为87.1MPa。
实施例4
实施例5的客车轻量化地板的VOC测试
测试方法:参照VDA277:1995,采用HS-GC-MS进行分析,测试结果见表1。
表1 VOC测试结果
测试项目 | CAS NO. | 单位 | MDL | 001 |
苯 | 71-43-2 | mg/kg | 5 | ND |
甲苯 | 108-88-3 | mg/kg | 5 | ND |
二甲苯 | 1330-20-7 | mg/kg | 5 | ND |
实验例5
实施例5的客车轻量化集成地板的TVOC测试
测试方法:参考VDA277:1995,采用HS-GC-MS进行分析,测试结果见表2。
表2 TVOC测试结果
测试项目 | 单位 | MDL | 001 |
TVOC | μg C/g | 10 | ND |
Claims (10)
1.一种客车轻量化集成地板,其特征在于:从上到下依次包括连续玻纤增强聚丙烯复合板、铝蜂窝层和铝板,所述铝蜂窝层包括铝蜂窝和填充在铝蜂窝的蜂窝结构内的聚氨酯硬泡。
2.根据权利要求1所述的客车轻量化集成地板,其特征在于:所述连续玻纤增强聚丙烯复合板和铝蜂窝层之间粘结连接。
3.根据权利要求1所述的客车轻量化集成地板,其特征在于:所述铝板的朝向铝蜂窝层的一侧表面开设有凹槽。
4.根据权利要求3所述的客车轻量化集成地板,其特征在于:所述凹槽的深度为0.05~0.15mm。
5.根据权利要求3或4所述的客车轻量化集成地板,其特征在于:所述客车轻量化集成地板的厚度为9~16mm。
6.一种如权利要求1所述的客车轻量化集成地板的制备方法,其特征在于:包括如下步骤:在铝板上铺设铝蜂窝,然后在铝蜂窝的蜂窝结构中填充聚氨酯硬泡,再将连续玻纤增强聚丙烯复合板铺在铝蜂窝上,热压,即得;
或者包括如下步骤:在连续玻纤增强聚丙烯复合板上铺设铝蜂窝,然后在铝蜂窝的蜂窝结构中填充聚氨酯硬泡,再将铝板铺在铝蜂窝上,热压,即得。
7.根据权利要求6所述的客车轻量化集成地板的制备方法,其特征在于:所述填充聚氨酯硬泡包括如下步骤:将聚氨酯发泡料填充在铝蜂窝的蜂窝结构中,发泡形成聚氨酯硬泡;所述聚氨酯发泡料包括A料和B料。
8.根据权利要求7所述的客车轻量化集成地板的制备方法,其特征在于:所述聚醚多元醇的羟值为300~1000mgKOH/g,25℃时粘度≤45000mPa·s。
9.根据权利要求7所述的客车轻量化集成地板的制备方法,其特征在于:所述聚合异氰酸酯的聚合单体为甲苯二异氰酸酯、二苯基甲烷二异氰酸酯、己二异氰酸酯中的任意一种或多种。
10.根据权利要求6所述的客车轻量化集成地板的制备方法,其特征在于:所述连续玻纤增强聚丙烯复合板朝向铝蜂窝层的一侧表面涂抹有PP附着力增强剂。
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