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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