CN111038042A - Ultra-light high-strength high-sound-absorption fiber reinforced thermoplastic foaming composite board and preparation method thereof - Google Patents
Ultra-light high-strength high-sound-absorption fiber reinforced thermoplastic foaming composite board and preparation method thereof Download PDFInfo
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- CN111038042A CN111038042A CN201911417032.0A CN201911417032A CN111038042A CN 111038042 A CN111038042 A CN 111038042A CN 201911417032 A CN201911417032 A CN 201911417032A CN 111038042 A CN111038042 A CN 111038042A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/06—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/08—Insulating elements, e.g. for sound insulation
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/08—Melt spinning methods
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0253—Polyolefin fibres
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Abstract
The invention discloses an ultralight high-strength high-sound-absorption fiber reinforced thermoplastic foaming composite board and a preparation method thereof. The invention takes the microsphere foaming agent and the thermoplastic resin powder as raw materials to prepare the plastic synthetic fiber uniformly containing the microsphere foaming agent through a melt spinning process. The ultra-light high-strength GMT composite board can be stably, continuously and efficiently produced by fully taking advantage of the non-woven process. And the dropping of the microsphere foaming agent does not exist in the felting link, so that the high-quality composite felt containing the microsphere foaming agent can be prepared more safely in batch without increasing additional investment such as newly added equipment, personnel training and the like, and the manufacturing cost of the working section is obviously reduced.
Description
Technical Field
The invention belongs to the technical field of thermoplastic composite materials, and particularly relates to an ultralight high-strength high-sound-absorption fiber reinforced thermoplastic foaming composite board and a preparation method thereof.
Background
Under the background of global energy conservation and emission reduction, countries in the world put forward higher standards and stricter market admission to the automobile manufacturing industry, particularly, the rapid development of new energy automobiles, the light weight of automobiles is a necessary trend of automobile development, and the composite material is one of the most important light weight materials and has great attention in the automobile industry due to excellent performance. The light glass Fiber Mat Reinforced thermoplastic composite material, referred to as light GMT (glass Fiber Mat Reinforced thermoplastic), has the characteristics of light weight, environmental protection, sound absorption, noise reduction, high strength, high toughness, excellent mildew resistance, chemical corrosion resistance and the like, and is always a focus of attention of automobile host plants and part suppliers at home and abroad. At present, light GMT is widely applied to inner and outer ornaments of roofs, bottom guard plates, coat and hat racks and the like of various types of automobiles, and the preparation method thereof goes through three stages of a wet process, a dry process and a fluidized field process. The dry process is widely favored by domestic manufacturers due to small equipment investment, relatively simple process and low energy consumption, but the dry process mainly has the following defects:
(1) in the carding process, the fiber orientation is obvious, and the mechanical property of the plate shows obvious anisotropy;
(2) the hot-melt resin and the glass fiber are mainly combined in a point connection mode, so that the resin consumption is large for ensuring the mechanical property, the cost is relatively high, and the further ultra-light development is limited;
(3) the air quantity is insufficient, the product design freedom is low, and the NVH performance is originally laggard in the foreign imported products.
The further development and application of the light GMT plate are severely restricted by the problems, and particularly the vigorous development of new energy automobiles. How to further realize the ultra-light weight of the light GMT plate and ensure the excellent comprehensive performance of the plate is a current technical difficulty and a research hotspot in the industry at home.
At present, the technical difficulty of the existing light GMT development is broken through internationally mainly by improving the existing process and developing a new process. For example, a wet process of AZDEL company, a dry process of QPC company and a Lap Form Air-flow lapping process of Cormatox company, when the plate is subjected to hot-press molding, hot-melt resin is uniform and fully infiltrates glass fibers, the resin consumption is reduced, and meanwhile, the excellent comprehensive performance of the plate is ensured. The domestic process is limited by the research and development level of equipment and technology, and the prior process method is mainly optimized and improved. If the technological parameters of carding the mixed fibers are optimized, the fiber mixing uniformity is increased, and the damage to the glass fibers is reduced, so that the mechanical property of the plate is improved; the single-net fiber laying mode is changed, and the difference of longitudinal and transverse mechanical properties of the plate is reduced; the surface of the felt is pretreated to change the heat and electric conductivity of the plate, and the like. However, the point connection mode between the glass fibers is not fundamentally changed by the improvement methods, and the improvement of the comprehensive performance of the plate is limited. The fiber webs are only consolidated by needling layer by layer in the thickness direction of the felt, the combination between the adjacent fiber webs in the high-expansion area of the forming part is insufficient, the resin content is still increased to ensure the mechanical property of the board, the resin consumption is increased, the ultra-light weight of the product is limited, and the design freedom degree and NVH (noise vibration and harshness) performance of the board are limited due to the fact that the expansion ratio of the board is reduced and the air infiltration amount is insufficient.
On the basis of the existing light GMT dry carding felt forming process, a dusting process is added in a patent CN201711451801.X, a microsphere foaming agent is adhered to the surface of a fiber in a patent CN201711451806.2, a dipping process is added in a patent CN201610763845.5, and a microsphere foaming agent-containing felt substrate is prepared by different methods to prepare a light high-strength GMT composite board which takes reinforcing fibers as a reinforcement body, hot-melt fibers as a bonding substrate and a microsphere foaming agent as a filling modification material. The structure fundamentally changes the point connection and support mode between the reinforced fiber and between the reinforced fiber and the hot melt resin. Based on the expansion characteristic of the foaming agent, automobile interior and exterior trim products with different strength, rigidity and sound resistance characteristics can be prepared by adjusting the expansion degree of the plate, the problem that the traditional light GMT cannot be further lightened is solved, and the problem that the product design freedom degree, NVH (noise vibration harshness) and other performances are far behind those of products imported from abroad is effectively solved. However, in the actual production process, the dusting process mentioned in patent No. CN201711451801.x involves serious dust emission, the adhesion method mentioned in patent No. CN201711451806.2 involves uneven adhesion of microsphere foaming agent, the oil volatilizes to cause foaming agent to fall off, the foaming agent falls off seriously in the carding process, the operation is very difficult, the product stability is very poor, and can not meet the level and requirement of batch production, the dipping process mentioned in patent No. CN201610763845.5 has high energy consumption, a large amount of waste liquid is generated in the process, the environment is damaged, and the foaming agent is deposited at the bottom of the felt net to cause uneven distribution, which seriously affects the mechanical properties of the product.
Patent CN200680020471.2 develops a new process, in which reinforcing fibers, thermoplastic resin powder, microsphere foaming agent and surfactant are dispersed in aqueous solution, and a papermaking process is used to make a mesh, but the method has the disadvantages of large equipment investment, complex process, high operation requirement, high-price foaming-containing liquid preparation in the production process, and relatively high product cost.
Disclosure of Invention
In order to solve the problems, the invention discloses an ultra-light high-strength high-sound-absorption fiber reinforced thermoplastic foaming composite board and a preparation process thereof. The ultra-light high-strength high-sound-absorption fiber-reinforced thermoplastic foaming composite board is mainly characterized in that a bonding body and a fiber reinforcement body which uniformly contain a foaming agent are used, and the ultra-light high-strength high-sound-absorption fiber-reinforced thermoplastic foaming composite board is prepared through a non-woven and continuous board-making composite process. The specific technical scheme of the invention is as follows:
the invention discloses an ultralight high-strength high-sound-absorption fiber reinforced thermoplastic foaming composite board, which comprises reinforcing fibers and foaming fibers serving as a bonding body, wherein the foaming fibers contain thermoplastic synthetic fibers and microsphere foaming agents, and are prepared by a melt spinning process.
As a further improvement, the microsphere foaming agent is a core-shell structure foaming agent, wherein the shell is formed by a single-layer or multi-layer acrylate polymer, the core body is one or more of ethane, propane, isobutane, n-pentane, isopentane and petroleum ether, the maximum foaming volume ratio of the microsphere foaming agent is 5-15 times, and the size after foaming is 75-400 microns.
As a further improvement, the difference between the particle size of the microsphere foaming agent and the particle size of the resin powder of the thermoplastic synthetic fiber is in the range of 0-40 μm. The microsphere foaming agent and the thermoplastic resin powder are uniformly mixed, and the foamed fiber has excellent tensile strength.
As a further improvement, the content of the microsphere foaming agent in the foaming fiber used in the invention is 4-45 wt% of the total mass of the thermoplastic synthetic fiber. The content of the microsphere foaming agent is too low, the mechanical property of the product is improved slightly, the cost advantage is avoided, the content of the microsphere foaming agent is too high, the strength of the foamed fiber is poor, and the foamed fiber is easy to break and cannot form a net.
As a further improvement, the thermoplastic synthetic fiber is one or more of polypropylene fiber PP, polyethylene fiber PE, polyester fiber PET, ES fiber and nylon fiber PA; the reinforced fiber is one or more of glass fiber, carbon fiber, basalt fiber and plant fiber.
The invention also discloses a preparation method of the ultralight high-strength high-sound-absorption fiber reinforced thermoplastic foaming composite board, which comprises the following specific steps:
1) the foaming fiber and the reinforcing fiber are processed by non-woven equipment and technology according to proportion, and the composite fiber felt with uniform blending is prepared by opening, mixing, carding, lapping and needling;
2) and then the composite fiber felt is subjected to a continuous plate-making composite process to make a plate: plasticizing the composite felt thermoplastic fiber, pressurizing and cooling to prepare a bare board, heating and pressurizing to cover a glue film and a fabric, cooling and shaping, and cutting to obtain the final ultra-light high-strength high-sound-absorption fiber reinforced thermoplastic foaming composite board, wherein the plasticizing temperature of the composite felt is 150-.
In the preparation method, the plasticizing temperature of the composite felt is 150-.
As a further improvement, the proportion of the foaming fiber and the reinforcing fiber is adjusted between 30 wt% and 70 wt% and 30 wt%.
As a further improvement, the microsphere foaming agent provided by the invention has an initiation temperature higher than the melting processing temperature of the thermoplastic resin and lower than the decomposition temperature of the thermoplastic resin. The foaming fiber is prevented from losing the foaming function in the subsequent use due to the initiation in the preparation process of the foaming fiber, or the foaming agent is not initiated because the thermoplastic resin is decomposed in the baking and forming process of the composite board.
As a further improvement, the fabric compounded in the step of heating and pressurizing the adhesive-coated film and the fabric comprises a compounded upper surface layer and/or lower surface layer fabric, wherein the compounded upper surface layer and/or lower surface layer fabric is selected from one or more of a polypropylene adhesive film, a polyethylene adhesive film, an EVA adhesive film, an EAA adhesive film, a polyester film, a hot melt adhesive powder, a reinforced composite film or non-woven fabric.
The invention has the technical effects and advantages that:
1) and the microsphere foaming agent and the thermoplastic resin powder are blended to be used as raw materials, and the plastic synthetic fiber uniformly containing the microsphere foaming agent is prepared through a melt spinning process. The ultra-light high-strength GMT composite board can be stably, continuously and efficiently produced by fully taking advantage of the non-woven process. In addition, the dropping of the microsphere foaming agent does not exist in the felting link, so that the high-quality composite felt containing the microsphere foaming agent can be safely prepared in batch without increasing additional investment such as newly added equipment, personnel training and the like, and the manufacturing cost of the working section is obviously reduced;
2) the board making process, the composite felt thermoplastic fiber plasticizing working section, the pressurization cooling bare board making working section and the heating and pressurization glue covering film and fabric working section are combined, so that the problem that the production speed of foamed boards prepared by an industry dry method is limited is solved, the problems of uneven thickness of the boards, uneven appearance of the boards and glue leakage of non-woven fabrics are solved, and the production cost is obviously reduced.
3) In the process of baking and forming the GMT composite board, one or more connection modes among the microsphere foaming agent and the microsphere foaming agent, the microsphere foaming agent and the thermoplastic resin, the microsphere foaming agent and the reinforcing fibers, and the thermoplastic resin and the reinforcing fibers are adopted. And the expanded microsphere foaming agent and the reinforced fiber play a supporting role together, and compared with the traditional GMT composite board with the same gram weight, the strength of the composite board is improved by more than 20 percent.
4) The difference range between the particle size of the microsphere foaming agent and the particle size of the thermoplastic resin powder is 0-40 mu m, so that the microsphere foaming agent and the thermoplastic resin powder are uniformly mixed during melt spinning, and the foamed fiber has excellent tensile strength.
5) The microsphere blowing agents used in the present invention must have an initiation temperature above the melt processing temperature of the thermoplastic resin, but below its decomposition temperature. The foaming fiber is prevented from losing the foaming function in the subsequent use due to the initiation in the preparation process of the foaming fiber, or the foaming agent is not initiated because the thermoplastic resin is decomposed in the baking and forming process of the composite board.
6) The content of the microsphere foaming agent in the foaming fiber used by the invention is 4-45 wt% of the total mass of the thermoplastic synthetic fiber, the content of the microsphere foaming agent is too low, the mechanical property of the product is improved slightly, the cost advantage is not achieved, the content of the microsphere foaming agent is too high, the strength of the foaming fiber is poor, and the foaming fiber is easy to break and cannot form a net.
7) In the preparation method, the plasticizing temperature of the composite felt is 150-.
Drawings
FIG. 1 is a diagram of the internal felt structure of an ultra-light high-strength GMT composite board prepared by the invention;
FIG. 2 is a comparison of the internal felt structure of the interior and exterior automotive trim made from the ultra-light high-strength GMT composite panel made in accordance with the present invention and the conventional light GMT composite panel;
FIG. 3 is a comparison chart of sound absorption performance tests of an automobile bottom protective part prepared by using the ultra-light high-strength GMT composite board prepared by the invention and an automobile bottom protective part prepared by using a traditional light GMT composite board;
FIG. 4 is a comparison chart of sound absorption performance tests of automobile ceiling parts prepared by using the ultra-light high-strength GMT composite board prepared by the invention and automobile ceiling parts prepared by using the traditional light GMT composite board;
in the figure, 1 is polypropylene fiber, 2 is glass fiber, and 3 is microsphere foaming agent.
Detailed Description
The invention discloses an ultra-light high-strength high-sound-absorption fiber reinforced thermoplastic foaming composite board, and fig. 1 is a structure diagram of an internal felt net of an ultra-light high-strength GMT composite board prepared by the method; FIG. 2 is a comparison of the internal felt structure of the interior and exterior automotive trim made from the ultra-light high-strength GMT composite panel made in accordance with the present invention and the conventional light GMT composite panel; the composite board comprises reinforcing fibers and foaming fibers serving as bonding bodies, wherein the foaming fibers contain thermoplastic synthetic fibers and microsphere foaming agents 3, and the foaming fibers are prepared through a melt spinning process. The microsphere foaming agent 3 is a core-shell structure foaming agent, wherein a shell is formed by a single-layer or multi-layer acrylate polymer, a core body is one or more of ethane, propane, isobutane, n-pentane, isopentane and petroleum ether, the maximum foaming volume ratio of the microsphere foaming agent 3 is 5-15 times, the size after foaming is 75-400 mu m, the difference range of the particle size of the microsphere foaming agent 3 and the particle size of resin powder of thermoplastic synthetic fibers is 0-40 mu m, the content of the microsphere foaming agent 3 in the used foaming fibers is 4-45 wt% of the total mass of the thermoplastic synthetic fibers, and the thermoplastic synthetic fibers are one or more of polypropylene fibers 1PP, polyethylene fibers PE, polyester fibers PET, ES fibers and nylon fibers PA; the reinforced fiber is one or more of glass fiber 2, carbon fiber, basalt fiber and plant fiber.
The following embodiments of the present invention will be described in detail with reference to the accompanying drawings, but the following embodiments and drawings are only for the understanding of the present invention and do not limit the scope of the application of the present invention, and the present invention can be embodied in many different ways as defined and covered by the claims.
Example 1
A foamable thermoplastic fiber for preparing a fiber reinforced thermoplastic foamed composite board is composed of a polypropylene fiber 1 and an expandable microsphere foaming agent 3, as shown in figure 1. The preparation method comprises the following steps:
on a conventional melt spinning machine, modified polypropylene powder with different particle sizes and a microsphere foaming agent 3 are respectively blended and then sent into a screw extruder, the temperature range of each area on the screw extruder is 170-205 ℃, the generated melt is extruded from a spinneret plate through a metering pump, the melt is wound at the speed of 500-800m/min after being extruded to obtain a winding filament, the winding filament is subjected to pre-drawing and then is subjected to hot drawing at the temperature of 100-140 ℃, and the drawing multiple is 5-9. The fiber is then subjected to 100-temperature heat setting at 120 ℃ and stress retraction at 90-110 ℃ and then wound into finished yarn (foamed fiber for short). The foamed fibers prepared from polypropylene powder and microsphere foaming agent 3 with different particle diameters are summarized in Table 1
TABLE 1 summary of tensile Strength and elongation of foamed fibers prepared from Polypropylene powder and microsphere foaming agent 3 of varying particle size
In example 1, as can be seen from comparison among the foamed fibers 1, 2 and 3, when the difference between the particle size of the modified polypropylene fiber 1 and the particle size of the microsphere foaming agent 3 is more than 40 μm, the foaming agent in the melt is not uniformly distributed and is very easy to agglomerate, and the foaming agent is broken when spinning, so that a stable foamed fiber cannot be prepared; the foaming fibers 3, 4 and 5 are compared to see that the foaming temperature of the microsphere foaming agent 3 is lower than the processing temperature of the modified polypropylene, the foaming agent is initiated, and the finished yarn cannot be manufactured, and when the foaming temperature is higher than the decomposition temperature of the modified polypropylene, the foaming agent is not initiated but the polypropylene fibers are decomposed and smoke; as can be seen from comparison among the foamed fibers 3, 6, 7 and 8, when the content of the microsphere foaming agent 3 is higher than 45 wt%, the breaking strength and the breaking elongation of the foamed fibers are lower than the processing requirements, and web formation cannot be achieved.
Example 2
An ultra-light high-strength GMT composite board for preparing an automobile bottom guard plate is composed of polypropylene fibers 1 serving as a bonding matrix, glass fibers 2 serving as a reinforcement body and a microsphere foaming agent 3 with the effect of changing the connection mode of lattice points of the glass fibers 2 to adjust the expansion ratio of the board, and is shown in figure 1.
The specific preparation method comprises the following steps:
(1) blending, melting and spinning a microsphere foaming agent 3 with the initial foaming temperature of 210 ℃ and polypropylene fibers 1 into thermoplastic foaming polypropylene fibers 1 uniformly containing the microsphere foaming agent 3, wherein the microsphere foaming agent 3 accounts for 4.0 wt% of the total mass of the polypropylene fibers 1 and is used as an example 1, and the microsphere foaming agent 3 accounts for 3.0 wt% of the total mass of the polypropylene fibers 1 and is used as a comparative example 1;
(2) uniformly mixing polypropylene fibers 1 containing a microsphere foaming agent 3 and glass fibers 2 according to the proportion of 60 wt% to 40 wt%, and opening, mixing, carding, lapping and needling the mixture by a non-woven process to prepare a blended composite fiber felt with the microsphere foaming agent 3 uniformly distributed;
(3) and (3) subjecting the blended composite fiber felt to a continuous board making composite process: plasticizing thermoplastic fibers, pressurizing and cooling to prepare a bare board, heating and pressurizing to cover an adhesive film and a fabric, compounding a weather-resistant reinforced composite film on the lower surface layer, compounding a hydrophobic and oil-repellent non-woven fabric on the upper surface layer, cooling, shaping and cutting to obtain the final ultra-light high-strength GMT composite board, wherein the plasticizing temperature of the thermoplastic fibers is 160-DEG C, the heating and pressurizing to cover the adhesive film and the fabric are 160-DEG C, and the areal density of the composite board is 1000g/m 2.
The ultra-light high-strength GMT composite board is prepared into the automobile bottom guard board by the following process:
(1) placing the composite board into a 210 ℃ oven, and expanding the thickness of the board to 6.5 times of the original thickness under the double actions of the internal stress of the glass fiber 2 and the microsphere foaming agent 3;
(2) and adjusting the compression ratio after expansion according to the requirements of the bottom guard plate product, and molding the automobile bottom guard plate product with the impact area thickness of 3.5mm, the bulk density of 0.29g/cm3 and the sound absorption area thickness of 9mm, and the bulk density of 0.11g/cm 3. The preheating temperature of the light GMT composite board is 160-180 ℃, and the surface density of the composite board is 1000g/m 2.
Preparing the automobile bottom guard plate from the obtained traditional light GMT composite board by the following process:
(1) placing the composite board in a 210 ℃ oven, wherein the thickness of the board can only be expanded to 2 times of the original thickness by bulking under the action of the internal stress of the glass fiber 2;
(2) according to the requirements of the bottom guard plate product performance, the compression ratio after expansion is adjusted, and the automobile bottom guard plate product with the impact area thickness of 3.5mm, the bulk density of 0.29g/cm3 and the sound absorption area thickness of 8mm and the bulk density of 0.13g/cm3 is molded.
Comparative example 2
The traditional light GMT composite board for preparing the bottom guard plate of the automobile consists of thermoplastic polypropylene fibers 1 and glass fibers 2 serving as reinforcing materials, and is prepared into the traditional light GMT composite board for the bottom guard plate of the automobile through hot pressing, wherein the surface density of the composite board is 1000g/m 2. The specific preparation method comprises the following steps:
(1) uniformly mixing 60 wt% of thermoplastic polypropylene fiber 1 and 40 wt% of glass fiber 2 in proportion, and carding, lapping and needling to obtain a blended composite fiber felt;
(2) and (3) supplying the blended composite fiber felt into continuous composite pressing plate equipment, preheating, thermally bonding, pressurizing, bonding an EVA (ethylene vinyl acetate) adhesive film on the upper surface layer, cooling and cutting to obtain the traditional light GMT composite board, wherein the preheating temperature is 160-180 ℃.
Preparing the automobile bottom guard plate from the obtained traditional light GMT composite board by the following process:
(1) the composite board is put into a baking oven at 210 ℃, the thickness of the board is expanded to 2.3 times of the original thickness under the action of the internal stress of the glass fiber 2,
(2) the upper surface is covered with non-woven fabric with hydrophobic and oil-repellent functions, and the lower surface is covered with a weather-resistant and reinforced composite film;
(3) according to the requirements of the bottom guard plate product performance, the compression ratio after expansion is adjusted, and the automobile bottom guard plate product with the impact area thickness of 3.5mm, the bulk density of 0.29g/cm3 and the sound absorption area thickness of 8mm and the bulk density of 0.13g/cm3 is molded.
Comparative example 3
A traditional light GMT composite board for preparing an automobile bottom guard board consists of polypropylene fibers 1 serving as a bonding matrix and glass fibers 2 serving as reinforcements.
The specific preparation method comprises the following steps:
(1) mixing the polypropylene fiber 1 and the glass fiber 2 according to the weight percentage of 60 percent: uniformly mixing 40 wt%, opening, mixing, carding, lapping and needling by a non-woven process to obtain a blended composite fiber felt;
(2) and supplying the blended composite fiber felt into continuous composite pressing plate equipment, preheating, thermally bonding, pressurizing, compounding the weather-resistant reinforced composite film on the lower surface layer, compounding the hydrophobic and oil-repellent non-woven fabric on the upper surface layer, cooling and cutting to obtain the traditional light GMT composite board for the automobile bottom guard plate, wherein the preheating temperature is 160-180 ℃, and the areal density of the composite board is 1400g/m 2.
Preparing the automobile bottom guard plate from the obtained traditional light GMT composite board by the following process:
(1) the composite board is placed in a 210 ℃ oven, and the thickness of the board can only be expanded to 2.5 times of the original thickness by bulking under the action of the internal stress of the glass fiber 2;
(2) and adjusting the compression ratio after expansion according to the requirements of the bottom guard plate product, and molding the automobile bottom guard plate product with the impact area thickness of 3.5mm, the bulk density of 0.40g/cm3 and the sound absorption area thickness of 9mm and the bulk density of 0.16g/cm 3.
Comparative example 4
Referring to patent CN201610763845.5, the similar product of this patent is prepared by introducing microsphere foaming agent 3 into GMT felt net through fiber felt impregnation process after the prior light GMT dry carding felt forming process, and is used for preparing ultra-light high-strength GMT composite board of automobile bottom guard plate.
Comparative example 5
Referring to patent CN201711451806.2, in the existing light GMT dry carding felt-forming process, thermoplastic fibers and/or reinforced fibers adhered with microsphere foaming agent 3 are used as raw materials, and the prepared similar product of the same kind in the patent is used for preparing the ultra-light high-strength GMT composite board of the automobile bottom guard plate.
Comparative example 6
Referring to patent CN201711451801.X, in the later stage of the prior light GMT dry carding felt forming process, a microsphere foaming agent 3 is introduced into a GMT felt net through a dusting process to prepare an ultra-light high-strength GMT composite board similar to the patent product.
The following table 2 shows the performance comparison of the ultralight high-strength GMT composite panels prepared by the present invention and the reference patents CN201610763845.5, CN201711451806.2, and cn201711451801.x and the molded baseboard of the conventional light GMT composite panel.
TABLE 2 comparison of properties of molded basesheets of ultra lightweight, high strength GMT composite panels and conventional lightweight GMT composite panels
Example 2 the introduction of the microsphere foaming agent 3 inside the existing light GMT composite board felt, the introduction of the microsphere foaming agent 3 makes the connection mode between the glass fibers 2 more diversified, except the traditional point connection, the microsphere foaming agent 3 is used as a connecting bridge to tie the glass fibers 2 around the connecting bridge, the microsphere foaming agent 3 is connected with each other, as shown in fig. 2, these diversified connection modes make the structure of the felt inside the composite board fundamentally changed, therefore the prepared bottom protection product has obviously improved mechanical properties compared with the comparative example 2 under the same density, and is equivalent to the mechanical properties of the comparative example 3 of the traditional high-density GMT composite board, and on the premise of ensuring the automobile safety and strength characteristics, the material usage amount per se is reduced, and the purpose of ultra-lightening is achieved. In addition, in the process of secondary forming of the bottom protection product, the prepared ultra-light high-strength GMT plate has the thickness bulkiness expanded to 6.5 times of the original thickness under the double effects of the internal stress of the glass fiber 2 and the microsphere foaming agent 3, and is improved by 4.0 times compared with the comparative example 2. In comparison with the mechanical properties, although the foamed composite sheet molded bottom sheet prepared in example 1 was comparable to comparative example 3, the porosity of the sheet in the product obtained in example 1 was high, air was permeated into the product, and the viscous resistance to sound propagation was increased, so that the NVH properties of the product were remarkably improved, as shown in fig. 3. As can be seen from comparison of example 1, comparative example 1 and comparative example 2, the mechanical properties of the sheet are improved very little when the content of the foaming agent is lower than the critical value of 4%, and are improved by at least 20% when the content of the foaming agent is higher than (equal to) the critical value of 4%. The comparison of example 1 and comparative examples 4, 5 and 6 shows that the mechanical properties of the sheets prepared by the comparative example process are greatly different and unstable under the same composition, and the content of the foaming agent in the sheets of the composite sheets prepared by the batch process of example 1 is only about 40% of that of the comparative example process, but the mechanical properties of the composite sheets are higher than those of the sheets prepared by the comparative example process and can reach about 13% at most.
Example 3
An ultra-light high-strength GMT composite board for preparing an automobile ceiling consists of ES fibers serving as a bonding matrix, fibrilia serving as a reinforcement and a microsphere foaming agent 3 with the effect of changing a connection mode of reinforced fiber lattices and adjusting the expansion ratio of the board.
The specific preparation method comprises the following steps:
(1) blending, melting and spinning a microsphere foaming agent 3 with the initial foaming temperature of 210 ℃ and polypropylene fibers 1 into thermoplastic foaming polypropylene fibers 1 uniformly containing the microsphere foaming agent 3, wherein the content of the microsphere foaming agent 3 is 9.5 wt% of the mass of the polypropylene fibers 1;
(2) uniformly mixing polypropylene fibers 1 containing a microsphere foaming agent 3 and glass fibers 2 according to the proportion of 45 wt% to 55 wt%, and opening, mixing, carding, lapping and needling the mixture by a non-woven process to obtain a blended composite fiber felt with the microsphere foaming agent 3 uniformly distributed;
(3) and (3) subjecting the blended composite fiber felt to a continuous board making composite process: plasticizing thermoplastic fibers, pressurizing and cooling to prepare a bare board, heating and pressurizing to cover an adhesive film and a fabric, compounding hot-rolled non-woven fabric on the lower surface layer, adhering a PE hot-melt adhesive film on the upper surface layer, cooling and shaping, and cutting to obtain the final ultra-light high-strength GMT composite board, wherein the plasticizing temperature of the thermoplastic fibers is 160-170 ℃, the heating and pressurizing to cover the adhesive film and the fabric is 130-150 ℃, and the areal density of the composite board is 600g/m 2.
The obtained ultra-light high-strength GMT composite board is used for preparing an automobile ceiling part by the following process:
(1) placing the composite board in a 210 ℃ oven, and expanding the thickness of the board to 9 times of the original thickness under the double actions of the fibrilia internal stress and the microsphere foaming agent 3;
(2) pre-paving a foam fabric for ceiling decoration on the upper surface of the base;
(3) according to the performance requirements of the ceiling product, the automobile ceiling product with the bulk density of 0.12g/cm3 and the large-area thickness of 5mm is molded by adjusting the compression ratio after expansion.
Comparative example 7
A traditional light GMT composite board for preparing car roofs is composed of ES fibers as a bonding matrix and fibrilia as a reinforcement.
The specific preparation method comprises the following steps:
(1) uniformly mixing the ES fibers and the fibrilia according to the proportion of 45 wt% to 55 wt%, and opening, mixing, carding, lapping and needling the mixture by a non-woven process to obtain a blended composite fiber felt;
(2) and (2) supplying the blended composite fiber felt into continuous composite pressing plate equipment, preheating, thermally bonding, pressurizing, bonding a PE hot melt adhesive film on the upper surface layer, compounding a hot rolled non-woven fabric on the lower surface layer, cooling and cutting to obtain the traditional light GMT composite board for the automobile ceiling, wherein the preheating temperature is 160-170 ℃, and the surface density of the composite board is 600g/m 2.
The obtained traditional GMT composite board is used for preparing the automobile ceiling part by the following process:
(1) putting the composite board into a 210 ℃ oven, and expanding the thickness of the board to 3 times of the original thickness by bulking under the action of internal stress of fibrilia;
(2) pre-paving a foam fabric for ceiling decoration on the upper surface of the base;
(3) according to the performance requirements of the ceiling product, the automobile ceiling product with the large surface thickness of 5mm and the density of 0.12g/cm3 is molded by adjusting the compression ratio after expansion.
Comparative example 8
A traditional light GMT composite board for preparing car roofs is composed of ES fibers as a bonding matrix and fibrilia as a reinforcement.
The specific preparation method comprises the following steps:
(1) uniformly mixing the ES fibers and the fibrilia according to the proportion of 45 wt% to 55 wt%, and opening, mixing, carding, lapping and needling the mixture by a non-woven process to obtain a blended composite fiber felt;
(2) and (2) supplying the blended composite fiber felt into continuous composite pressing plate equipment, preheating, thermally bonding, pressurizing, bonding a PE hot melt adhesive film on the upper surface layer, compounding a hot rolled non-woven fabric on the lower surface layer, cooling and cutting to obtain the traditional light GMT composite board for the automobile ceiling, wherein the preheating temperature is 160-170 ℃, and the areal density of the composite board is 800g/m 2.
The obtained traditional GMT composite board is used for preparing the automobile ceiling part by the following process:
(1) putting the composite board into a 210 ℃ oven, and expanding the thickness of the board to 3.5 times of the original thickness by bulking under the action of internal stress of fibrilia;
(2) pre-paving a foam fabric for ceiling decoration on the upper surface of the base;
(3) according to the performance requirements of the ceiling product, the automobile ceiling product with the large surface thickness of 5mm and the bulk density of 0.16g/cm3 is molded by adjusting the compression ratio after expansion.
A comparison of the performance of ultra-light, high strength GMT composite panels made using the present invention versus automotive ceiling components molded from conventional light weight GMT composite panels is shown in table 3 below.
TABLE 3 comparison of properties of molded basesheets for ultra lightweight, high strength GMT composite panels and conventional lightweight GMT composite panels
Example 3 a microsphere foaming agent 3 is introduced into the existing light GMT composite board felt, the introduction of the microsphere foaming agent 3 makes the connection modes between the reinforcing fibers 2 more diversified, except for the traditional point connection, the microsphere foaming agent 3 is used as a connecting bridge to tie the peripheral plant fibers together, the microsphere foaming agents 3 are connected with each other, and the diversified connection modes radically change the structure of the felt inside the composite board, so that the mechanical properties of the prepared ceiling product are obviously improved compared with that of a comparative example 7 of the traditional high-density GMT composite board and are equivalent to that of a comparative example 8 of the traditional high-density GMT composite board, and therefore, on the premise that the safety and strength characteristics of an automobile are guaranteed, the material consumption of the ceiling product is reduced, and the purpose of ultra-lightening is achieved. In addition, in the process of secondary forming of the ceiling product, the prepared ultra-light high-strength GMT plate has the advantages that the thickness is expanded to 9 times and is increased by nearly 4 times compared with a comparative ratio 6 under the dual actions of plant fiber internal stress and a microsphere foaming agent 3, the ceiling product molded by the composite plate is equivalent to the comparative ratio 8 in mechanical property, but the plate in the obtained product has high porosity, a large amount of air is permeated in the product, the viscous resistance of sound transmission is improved, and the NVH performance of the product is obviously improved, as shown in figure 4.
While only certain specific embodiments of the present invention have been shown and described, it will be obvious that the invention is not limited thereto, and that many modifications may be made, all of which may be derived or suggested to one skilled in the art from the disclosure herein.
Claims (9)
1. The ultra-light high-strength high-sound-absorption fiber reinforced thermoplastic foaming composite board is characterized by comprising reinforcing fibers and foaming fibers serving as bonding bodies, wherein the foaming fibers contain thermoplastic synthetic fibers and microsphere foaming agents (3), and are prepared through a melt spinning process.
2. The ultra-light high-strength high-sound-absorption fiber reinforced thermoplastic foaming composite board as claimed in claim 1, wherein the microsphere foaming agent (3) is a core-shell structure foaming agent, wherein the shell is formed by a single layer or multiple layers of acrylate polymers, the core body is one or more of ethane, propane, isobutane, n-pentane, isopentane and petroleum ether, the maximum foaming volume ratio of the microsphere foaming agent (3) is 5-15 times, and the size after foaming is 75-400 μm.
3. The ultra-light high-strength high-sound-absorption fiber-reinforced thermoplastic foamed composite board as claimed in claim 1 or 2, wherein the difference between the particle size of the microsphere foaming agent (3) and the particle size of the resin powder of the thermoplastic synthetic fiber is in the range of 0 to 40 μm.
4. The ultra-light high-strength high-sound-absorption fiber-reinforced thermoplastic foamed composite board as claimed in claim 3, wherein the content of the microsphere foaming agent (3) in the used foamed fibers is 4 wt% -45 wt% of the total mass of the thermoplastic synthetic fibers.
5. The ultra-light high-strength high-sound-absorption fiber reinforced thermoplastic foam composite board as claimed in claim 1, 2 or 4, wherein the thermoplastic synthetic fiber is one or more of polypropylene fiber (1) PP, polyethylene fiber PE, polyester fiber PET, ES fiber and nylon fiber PA; the reinforced fiber is one or more of glass fiber (2), carbon fiber, basalt fiber and plant fiber.
6. The preparation method of the ultralight high-strength high-sound-absorption fiber reinforced thermoplastic foaming composite board as claimed in claim 1, 2 or 4, is characterized by comprising the following specific steps:
1) the foaming fiber and the reinforcing fiber are processed by non-woven equipment and technology according to proportion, and the composite fiber felt with uniform blending is prepared by opening, mixing, carding, lapping and needling;
2) and then the composite fiber felt is subjected to a continuous plate-making composite process to make a plate: plasticizing the composite felt thermoplastic fiber, pressurizing and cooling to prepare a bare board, heating and pressurizing to cover a glue film and a fabric, cooling and shaping, and cutting to obtain the final ultra-light high-strength high-sound-absorption fiber reinforced thermoplastic foaming composite board, wherein the plasticizing temperature of the composite felt is 150-.
7. The method of claim 6, wherein the ratio of the foamed fibers to the reinforcing fibers is adjusted from 30 wt% to 70 wt% to 30 wt%.
8. The method for preparing the ultra-light high-strength high-sound-absorption fiber reinforced thermoplastic foaming composite board as claimed in claim 6, wherein the microsphere foaming agent (3) has an initiation temperature higher than the melting processing temperature of the thermoplastic resin and lower than the decomposition temperature thereof.
9. The method for preparing the ultra-light, high-strength and high-sound-absorption fiber reinforced thermoplastic foaming composite board as claimed in claim 6, wherein the fabric compounded in the step of heating and pressing the adhesive-coated film and the fabric comprises a compound upper surface layer and/or a compound lower surface layer fabric, and the upper surface layer and/or the compound lower surface layer fabric is selected from one or more of a polypropylene adhesive film, a polyethylene adhesive film, an EVA adhesive film, an EAA adhesive film, a polyester film, a hot melt adhesive powder, a reinforced composite film or a non-woven fabric.
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Application publication date: 20200421 |