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CN105667014B - 一种客车地板 - Google Patents

一种客车地板 Download PDF

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Publication number
CN105667014B
CN105667014B CN201610194128.5A CN201610194128A CN105667014B CN 105667014 B CN105667014 B CN 105667014B CN 201610194128 A CN201610194128 A CN 201610194128A CN 105667014 B CN105667014 B CN 105667014B
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thermoplastic resin
glass fibre
bus deck
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CN105667014A (zh
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黄险波
陈大华
范欣愉
秦永利
徐光磊
孙雅杰
谭亚辉
孟姗姗
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GUANGZHOU KINGFA CARBON FIBER NEW MATERIAL DEVELOPMENT Co Ltd
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Abstract

本发明公开了一种客车地板，包括芯材及复合在芯材上、下表面复合面层，复合面层是由多层单向连续玻璃纤维增强热塑性树脂预浸片和/或玻璃纤维织物增强热塑性树脂预浸片复合而成，芯材是以聚丙烯、聚酰胺或热塑性聚酯为基体，以玻璃纤维毡为增强体的热塑性轻质复合材料板材，所述芯材的密度为200 kg/m3‑600kg/m3。本发明复合面层由多层单向连续玻璃纤维和/或玻璃纤维织物增强热塑性树脂预浸片层层铺叠，使纤维形成交错的网格状，保证了产品在纵向和横向性能都很高，且强度、抗冲击性和耐久性更好；采用热塑性轻质复合材料板材作为芯材，不仅重量轻,可吸收噪音，而且无需使用胶黏剂便可直接通过热压工艺与面层结合，减少了喷胶工序，绿色环保。

Description

一种客车地板
技术领域
本发明涉及汽车内饰技术领域，具体涉及一种客车地板。
背景技术
随着客运交通的快速发展，人们对客车的轻量化越来越关注，而客车内饰中占比重最大的是座椅和地板，采用竹胶板或木胶板的客车地板密度较大，地板较厚且较重，不能满足客车轻量化的需求。
为了满足客车的轻量化，近些年也出现了各种各样的轻质地板，如采用PVC 或铝蜂窝夹芯结构。该种结构虽在减重方面效果显著，但PVC 材料在低温下性能下降，存在易脆断的危险性；铝蜂窝夹芯结构在安装过程中存在重大问题，需对螺钉安装部位进行特殊处理，以保证足够的把钉力，安装工艺复杂，增加了装配工人的劳动强度和工时，较难实现大批量的应用。
CN201520224051.2公开了一种夹芯结构的客车地板，该客车地板是采用两层玻璃纤维织物增强树脂基复合材料层之间设置芯材的夹芯结构，使客车地板具有足够的力学性能，并保证了客车地板的抗压性能及轻量化。但其芯材采用的是聚氨酯泡沫，需要通过胶粘剂与面层进行粘接，该工序会产生对身体有害的挥发性物质，不利于工人健康和环境保护，且聚氨酯泡沫的回收需要特殊的设备和溶剂的处理，很难做到100%回收。
发明内容
为解决上述现有客车地板存在的问题，本发明的目的在于提供一种具有较好抗压性能、轻量化、绿色环保、易回收的客车地板。
本发明是通过以下技术方案实现：
一种客车地板，包括芯材及复合在芯材上、下表面复合面层，所述复合面层是由多层单向连续玻璃纤维增强热塑性树脂预浸片和/或玻璃纤维织物增强热塑性树脂预浸片复合而成，所述芯材是以聚丙烯、聚酰胺或热塑性聚酯为基体，以玻璃纤维毡为增强体的热塑性轻质复合材料板材，所述芯材的密度为200 kg/m3-600kg/m3。。
其中，所述热塑性轻质复合材料板材是由玻璃纤维和聚合物纤维经过混纺工艺加工生成的毛毡经热压后形成，所述聚合物纤维为聚丙烯纤维、聚酰胺纤维或热塑性聚酯纤维，其中热压成型温度为170℃～300℃，成型压力为0.5 MPa～20 MPa。
其中基于热塑性轻质复合材料板材的总重量，玻璃纤维的含量为40wt%-80wt%。
所述芯材的厚度为4-15mm。
为了提高客车地板的强度、抗冲击性和耐久性，本发明复合面层是由多层单向连续玻璃纤维增强热塑性树脂预浸片和/或玻璃纤维织物增强热塑性树脂预浸片，采用特定的铺层方式层层铺叠，使纤维形成交错的网格状，保证了产品在纵向和横向性能都很高，且强度、抗冲击性和耐久性更好。
优选的，所述复合面层是由多层单向连续玻璃纤维增强热塑性树脂预浸片和/或玻璃纤维织物增强热塑性树脂预浸片按[90°/0°] 、[0°/90°]、 [90°/0°/90°]、[0°/90°/0°]、[90°/0°/0°/90°]、[0°/90°/90°/0°]、[90°/+45°/-45°/0°]、[0°/-45°/+45°/90°]或[0°/±45°/90°/±45°/0°]铺层方式热压复合而成。
其中，所述单向连续玻璃纤维增强热塑性树脂预浸片是以聚丙烯、聚酰胺或热塑性聚酯为基体，以连续玻璃纤维为增强体的片状结构材料，其中基于单向连续玻璃纤维增强热塑性树脂预浸片的总重量，玻璃纤维的含量为40wt%-70wt%。
其中，所述玻璃纤维织物增强热塑性树脂预浸片是以聚丙烯、聚酰胺或热塑性聚酯为基体，以玻璃纤维平纹或斜纹织物为增强体的片状结构材料，其中基于玻璃纤维织物增强热塑性树脂预浸片的总重量，玻璃纤维的含量为40wt%-70wt%。
所述复合面层的厚度为0.5-2mm，密度为1500-2000kg/m3。
所述客车地板的厚度为6-20mm，密度为400～800kg/m3。
本发明与现有技术相比，具有如下有益效果：
本发明的客车地板，复合面层由多层单向连续玻璃纤维增强热塑性树脂预浸片和/或玻璃纤维织物增强热塑性树脂预浸片层层铺叠，使纤维形成交错的网格状，保证了产品在纵向和横向性能都很高，且强度、抗冲击性和耐久性更好；采用玻璃纤维和聚合物纤维经过混纺工艺加工生成的毛毡经热压后形成的热塑性轻质复合材料板材作为芯材，这种轻质复合材料芯材不仅重量轻,可吸收噪音，而且无需使用胶黏剂便可直接通过热压工艺与面层结合，减少了喷胶工序，绿色环保。
附图说明
图1为本发明的客车地板的结构示意图；
其中，1、复合面层；2、芯材。
具体实施方式
下面通过具体实施方式来进一步说明本发明，以下实施例为本发明较佳的实施方式，但本发明的实施方式并不受下述实施例的限制。
实施例1：
如图1所示，一种客车地板，包括芯材2和复合在芯材2上、下表面的复合面层1。所述复合面层1是由3层单向连续纤维增强聚丙烯树脂预浸片按[0°/90°/0°]的铺层方式热压复合而成，所述单向连续纤维增强聚丙烯树脂预浸片中玻璃纤维的含量为60wt%，所述复合面层1的厚度为1mm，密度为1500kg/m3。所述芯材2是以聚丙烯为基体，以玻璃纤维毡为增强体的热塑性轻质复合材料板材，所述热塑性轻质复合材料板材是由玻璃纤维和聚丙烯纤维经过混纺工艺加工生成的毛毡经热压后形成的，其中，热压成型温度为220℃，成型压力为10 MPa。所述热塑性轻质复合材料板材中玻璃纤维的含量为45wt%；所述芯材的厚度为6mm，密度为450kg/m3。所述芯材2和上、下表面的复合面层1通过热压成型工艺形成客车地板，所述客车地板的厚度为8mm ，该实施例客车地板性能见表1 所示。
实施例2：
如图1所示，一种客车地板，包括芯材2和复合在芯材2上、下表面的复合面层1。所述复合面层1是由2层单向连续纤维增强聚酰胺树脂预浸片按[0°/90°]的铺层方式热压复合而成，所述单向连续纤维增强聚酰胺树脂预浸片中玻璃纤维的含量为50wt%，所述复合面层1的厚度为0.6mm，密度为1600kg/m3。所述芯材2是以聚酰胺为基体，以玻璃纤维毡为增强体的热塑性轻质复合材料板材，所述热塑性轻质复合材料板材是由玻璃纤维和聚酰胺纤维经过混纺工艺加工生成的毛毡经热压后形成的，其中，热压成型温度为300℃，成型压力为8MPa。所述热塑性轻质复合材料板材中玻璃纤维的含量为50wt%；所述芯材的厚度为7.8mm，密度为500kg/m3。所述芯材2和上、下表面的复合面层1通过热压成型工艺形成客车地板，所述客车地板的厚度为9mm ，该实施例客车地板性能见表1 所示。
实施例3：
如图1所示，一种客车地板，包括芯材2和复合在芯材2上、下表面的复合面层1。所述复合面层1是由4层单向连续纤维增强热塑性聚酯树脂预浸片按[90°/+45°/-45°/0°]的铺层方式热压复合而成，所述单向连续纤维增强热塑性聚酯预浸片中玻璃纤维的含量为70wt%，所述复合面层1的厚度为1.2mm，密度为1700kg/m3。所述芯材2是以热塑性聚酯为基体，以玻璃纤维毡为增强体的热塑性轻质复合材料板材，所述热塑性轻质复合材料板材是由玻璃纤维和热塑性聚酯纤维经过混纺工艺加工生成的毛毡经热压后形成的，其中，热压成型温度为250℃，成型压力为12MPa。所述热塑性轻质复合材料板材中玻璃纤维的含量为60wt%；所述芯材的厚度为4.6mm，密度为550kg/m3。所述芯材2和上、下表面的复合面层1通过热压成型工艺形成客车地板，所述客车地板的厚度为7mm ，该实施例客车地板性能见表1所示。
对比例1：
一种客车地板，包括芯材2和复合在芯材2上、下表面的复合面层1。所述复合面层1是由3层单向连续纤维增强聚丙烯树脂预浸片按[0°/90°/0°]的铺层方式热压复合而成，所述单向连续纤维增强聚丙烯树脂预浸片中玻璃纤维的含量为60wt%，所述复合面层1的厚度为1mm，密度为1500kg/m3。所述芯材2是以玻璃纤维直接纱为增强体，以聚氨酯树脂发泡而成的硬质聚氨酯泡沫塑料为基体采用模压或滚动模具或拉挤方式制备而成；所述芯材的厚度为6mm，密度为450kg/m3，所述芯材2中玻纤纤维直接纱的含量为45wt%。所述芯材2和上、下表面的复合面层1通过胶黏剂粘接形成客车地板，所述客车地板的厚度为8mm ，该实施例客车地板性能见表1 所示。
表1 实施例和对比例的性能结果数据
测试项目 测试标准 实施例1 实施例2 实施例3 对比例1
纵向弯曲强度（MPa） GB/T 17657-1999 87 52 90 50
纵向弯曲模量（GPa） GB/T 17657-1999 7.5 5.1 8.3 4.5
横向弯曲强度（MPa） GB/T 17657-1999 73 48 77 40
横向弯曲模量（GPa） GB/T 17657-1999 5.8 4.9 6.2 4
密度（kg/m3） GB/T 17657-1999 675 600 690 700
由实施例1和对比例1的结果对比可知，本发明采用玻璃纤维和聚合物纤维经过混纺工艺加工生成的毛毡经热压后形成的热塑性轻质复合材料板材代替聚氨酯泡沫作为芯材，制备得到的客车地板不仅强度、抗冲击性和耐久性更好，且无需使用胶黏剂便可直接通过热压工艺与面层结合，减少了喷胶工序，绿色环保。

Claims (8)

1.一种客车地板，包括芯材及复合在芯材上、下表面复合面层，其特征在于，所述复合面层是由多层单向连续玻璃纤维增强热塑性树脂预浸片和/或玻璃纤维织物增强热塑性树脂预浸片复合而成，所述芯材是以聚丙烯、聚酰胺或热塑性聚酯为基体，以玻璃纤维毡为增强体的热塑性轻质复合材料板材, 所述芯材的密度为200kg/m3-600kg/m3；所述热塑性轻质复合材料板材是由玻璃纤维和聚合物纤维经过混纺工艺加工生成的毛毡经热压后形成，所述聚合物纤维为聚丙烯纤维、聚酰胺纤维或热塑性聚酯纤维，其中热压成型温度为170℃～300℃，成型压力为0.5 MPa～20 MPa。
2.根据权利要求1所述的客车地板，其特征在于：基于热塑性轻质复合材料板材的总重量，玻璃纤维的含量为40wt%-80wt%。
3.根据权利要求1所述的客车地板，其特征在于：所述芯材的厚度为4-15mm。
4.根据权利要求1所述的客车地板，其特征在于：所述单向连续玻璃纤维增强热塑性树脂预浸片是以聚丙烯、聚酰胺或热塑性聚酯为基体，以连续玻璃纤维为增强体的片状结构材料，其中基于单向连续玻璃纤维增强热塑性树脂预浸片的总重量，玻璃纤维的含量为40wt%-70wt%。
5.根据权利要求1所述的客车地板，其特征在于：所述玻璃纤维织物增强热塑性树脂预浸片是以聚丙烯、聚酰胺或热塑性聚酯为基体，以玻璃纤维平纹或斜纹织物为增强体的片状结构材料，其中，基于玻璃纤维织物增强热塑性树脂预浸片的总重量，玻璃纤维的含量为40wt%-70wt%。
6.根据权利要求1所述的客车地板，其特征在于：所述复合面层是由多层单向连续玻璃纤维增强热塑性树脂预浸片和/或玻璃纤维织物增强热塑性树脂预浸片按[90°/0°] 、[0°/90°]、 [90°/0°/90°]、[0°/90°/0°]、[90°/0°/0°/90°] [0°/90°/90°/0°]、[90°/+45°/-45°/0°]、[0°/-45°/+45°/90°]或[0°/±45°/90°/±45°/0°]铺层方式热压复合而成。
7.根据权利要求1所述的客车地板，其特征在于：所述复合面层的厚度为0.5-2mm，密度为1500-2000kg/m3。
8.根据权利要求1所述的客车地板，其特征在于：所述客车地板的厚度为6-20mm，密度为400～800kg/m3。
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