CN111002658A - 一种复合材料客车地板及其制造方法 - Google Patents
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Abstract
本发明涉及一种复合材料客车地板及其制造方法,所述复合材料客车地板包括基板和增强层,所述基板是带有很多贯通小孔的长方形塑料板,所述增强层是热塑性预浸料,所述增强层紧密贴合在基板的上下表面;所述基板的原料中包括重量比为20~30%、密度为2.0~5.0克/立方厘米的高密度添加剂,所述基板采用挤出工艺制造;所述增强层采用热塑性预浸料制造工艺制造;所述增强层的纤维方向包括0度、±45度和90度三种角度中的1~3种;所述基板和增强层通过热压工艺复合在一起,形成一个完整的长方体。通过热压设备进行基板和增强层的复合时,在小孔内部具有防止小孔塌陷的支撑。
Description
技术领域
本发明涉及一种复合材料客车地板及其制造方法,属于汽车零部件制造技术领域。
背景技术
地板是客车的一个重要部件,一般说来,一种好的客车地板应该具有以下性能特点:密度低,满足轻量化要求;无甲醛释放;防水,不发霉;便于切割,有良好的握钉力,满足安装要求;具有良好的回收利用性,满足环保要求;具有良好的保温隔热隔音性能,满足汽车NVH要求;还要有较高的强度,因为客车地板是铺在车身龙骨上的,而车身龙骨具有大小不等的间距和跨度;另外,要有较低的全寿命成本,包括较低的维护成本,以满足商务要求。
目前,客车行业使用的地板种类繁多,主要有竹胶版、复合木板、泡沫塑料板以及实心塑料板等等。竹胶版和复合木板是目前使用较多的客车地板,主要是缺点是有甲醛释放、密度较大、容易发霉腐烂、维护成本高、不能回收再利用;泡沫塑料板的主要缺点是强度低、握钉力较差;纤维增强实心塑料板的主要问题是密度较大、纤维增强效果一般。
综上,客车行业需要一种具备前述各项优点的新型地板,这是客车制造行业很多年以来都没有妥善解决的问题。
目前,建筑行业有一种带有很多贯通小方孔的中空塑料板,如图5,这种中空塑料板板通常用作建筑行业的建筑模板。如果把这种板用作客车地板,会带来一些优点,但是整体抗弯强度还不足,用在龙骨跨距较大的位置会有较大变形。另外,这种中空塑料板的小方孔的抗压效果也不好,这种中空塑料板设置小方孔的目的在于减轻重量和降低成本。
纤维预浸料是复合材料工业中一种常用的中间原料,是预先浸渍了热塑性或者热固性树脂的增强纤维,其中的纤维方向一般包含0度、±45度和90度,所述0度通常为长度方向。为了提高前述中空塑料板的抗弯强度,在其表面用热融法复合一层热塑性纤维预浸料是一个有效的手段,因为热塑性预浸料与塑料板复合固化后,预浸料和塑料板的树脂是完全相容的,复合之后浑然一体,可以最大程度发挥纤维的增强效果。但是如果直接采用热压复合工艺,由于中空塑料板受热后失去了抗压能力,在压力作用下,板中的小方孔就会被压塌,整个板材也会失去原有的许多性能和应有的形状。
要解决这个问题,需要行之有效的复合工艺。
发明内容
基于前述背景,本发明提出了一种复合材料客车地板及其制造方法,能够满足客车地板的前述相关要求,可以避免目前常用的客车地板的诸多缺陷。
所述复合材料客车地板的构造如图1所示,包括基板101和增强层102,所述基板101是带有很多贯通小孔103的长方形塑料板,所述增强层102是长方形的热塑性预浸料,所述增强层紧密贴合在基板的上下表面,所述增强层的大小与基板相同;所述基板101的原料中包括重量比为20~30%、密度为2.0~5.0克/立方厘米的高密度添加剂,所述基板101采用挤出工艺制造;所述增强层102采用热塑性预浸料制造工艺制造,所述增强层(102)的纤维方向包括0度、±45度和90度三种角度中的1~3种;所述基板101和增强层102通过热压工艺复合在一起,所述增强层102紧密贴合在基板101的上下表面,形成一个完整的长方体,如图2所示,所述热压工艺的特征在于,通过热压设备301进行基板101和增强层102的复合时,在小孔内部具有防止小孔塌陷的支撑。
优选的,所述基板101的材料是聚丙烯和其他添加剂。
优选的,增强层102的材料为聚丙烯树脂和玻璃纤维。
优选的,所述基板101与增强层102复合前,不切除基板两侧的毛边503。通常,采用挤出工艺制造中空塑料板时需要切除两侧的毛边503。在进行基板101和增强层102的融合时,不切除基板两侧的毛边,可以增加密封盖201和带进气管的密封盖202与基板101之间的密封面积,可以获得更好的气密性。基板101和增强层102的融合完成后,再一次性切除基板101和增强层102的毛边,可以提高生产效率。
基板101的贯通小孔除了可以减轻重量降低成本之外,更重要的作用是增加客车地板的隔音和隔热功能,以提高汽车的NVH性能。优选的,所述基板101的贯通小孔为圆形。客车地板以承受压力为主,按照拱桥原理,圆形孔可以带来更好的抗压效果。
如前述,基板101的原料中包括一定比例的高密度添加剂,所述高密度添加剂的作用有两个,一个是显著提高客车地板宽频隔音的效果,另一个是显著提高客车地板的抗压刚度。优选的,所述所述高密度添加剂为滑石粉。
基板101受热后会软化并失去原有的抗压刚度,如果直接加压融合基板101和增强层102,基板101中的小孔就会塌陷而失去原有的形状和性能。为了避免这种塌陷的发生,需要在小孔内部施加支撑。优选的,所述防止小孔塌陷的内部支撑为压力在0.1~1.0MPa的高压空气204,如图2所示。采用高压空气204对小孔103进行支撑时,用密封盖201和带进气管的密封盖202把基板101的两端密封,如图2所示。
优选的,所述密封盖201包括软质的密封垫301和硬质的端盖302,如图3所示,软质的密封垫301可以确保气密性,硬质的端盖302用来压紧密封垫301。
优选的,所述密封盖202包括软质的密封垫401、硬质的端盖402和进气管403,如图4所示,软质的密封垫401可以确保气密性,硬质的端盖402用来压紧密封垫401,进气管403用来导入高压空气204。
附图说明
图1是本发明提出的客车地板构造示意图,101是基板,102是以热塑性预浸料为原料的增强层,103是基板中的小圆孔。
图2是本发明提出的客车地板制造方法示意图,101是基板,102是增强层,201是密封盖,202是带进气管的密封盖,203是热压设备,204是高压空气。
图3是密封盖201的示意图,301是软质密封垫,302是硬质端盖。
图4是带进气管的密封盖202的示意图,401是软质密封垫,402是硬质端盖,403是进气管,204是高压空气。
图5是现有的一种中空塑料板的示意图,501是中空塑料板,502是中空塑料板中的小方孔,503是基板两侧切除掉的毛边。
具体实施方式
图1是本发明所述的复合材料客车地板的一个具体实施例的示意图,所述的复合材料客车地板包括基板101和增强层102,所述基板101是带有很多贯通小圆孔103的长方形塑料板,所述增强层102是热塑性预浸料,所述增强层紧密贴合在基板的上下表面,所述增强层102的大小与基板101相同。
如图1所示的复合材料客车地板的具体制造方法包括下述两个步骤。
第一步,采用挤出工艺制造基板101,基板的原料为聚丙烯,原料中含有重量比为25%的滑石粉。基板的长度为1830毫米。基板的宽度为915毫米,基板的横截面上有3层圆形贯通小孔,如图1,小孔的直径为2.5毫米。基板的厚度为15毫米。
第二步,采用热压设备对基板101和增强层102进行融合操作。所述增强层102的材料为聚丙烯和玻璃纤维。所述基板101要保留毛边503。在进行所述融合操作时,基板101两端用密封盖201和带进气管的密封盖202进行密封操作。同时,通过进气管403对小孔内部施加压力为0.8MPa的高压空气。 密封垫301和密封垫401的材料为橡胶,端盖302和端盖402的材料为钢。
Claims (10)
1.一种复合材料客车地板,所述复合材料客车地板包括基板(101)和增强层(102),所述基板(101)是带有很多贯通小孔(103)的长方形塑料板,所述增强层(102)是长方形的热塑性预浸料,所述增强层(102)紧密贴合在基板(101)的上下表面。
2.如权利要求1所述的复合材料客车地板,其特征是,所述增强层(102)的纤维方向包括0度、±45度和90度三种角度中的1~3种。
3.如权利要求1所述的复合材料客车地板,其特征是,所述基板(101)的原料是聚丙烯和其他添加剂,所述增强层(102)的原料是聚丙烯树脂和玻璃纤维。
4.如权利要求1所述的复合材料客车地板,其特征是,所述贯通小孔(103)为圆形。
5.一种制造权利要求1所述复合材料客车地板的制造方法,所述复合材料客车地板包括基板(101)和增强层(102),所述基板(101)是带有很多贯通小孔(103)的长方形塑料板,所述增强层(102)是长方形的热塑性预浸料,所述增强层(102)紧密贴合在基板(101)的上下表面;所述制造方法包括:基板(101)的原料包括重量比为20~30%、密度为2.0~5.0克/立方厘米的高密度添加剂,所述基板(101)采用挤出工艺制造,所述增强层(102)是与基板(101)大小一致的长方形平板,所述增强层(102)采用热塑性预浸料制造工艺制造,所述基板(101)和增强层(102)通过热压工艺复合在一起,形成一个完整的长方体。
6.如权利要求5所述的复合材料客车地板的制造方法,其特征是,所述基板(101)和增强层(102)通过热压工艺复合在一起时,在小孔(103)内部具有防止小孔塌陷的支撑。
7.如权利要求5所述的复合材料客车地板的制造方法,其特征是,所述基板(101)不切除基板(101)两侧的毛边(503)。
8.如权利要求5所述的复合材料客车地板的制造方法,其特征是,所述高密度添加剂为滑石粉。
9.如权利要求6所述的复合材料客车地板的制造方法,其特征是,所述支撑为压力在0.1~1.0MPa的高压空气(204);采用高压空气(204)对小孔(103)进行支撑时,用密封盖(201)和带进气管的密封盖(202)把基板(101)的两端密封。
10.如权利要求9所述的复合材料客车地板的制造方法,其特征是,所述密封盖(201)包括软质的密封垫(301)和硬质的端盖(302);所述密封盖(202)包括软质的密封垫(401)、硬质的端盖(402)和进气管(403)。
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