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CN103180141A - 用于汽车内装材料的多层构造物以及其制造方法 - Google Patents

用于汽车内装材料的多层构造物以及其制造方法 Download PDF

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Publication number
CN103180141A
CN103180141A CN2010800697561A CN201080069756A CN103180141A CN 103180141 A CN103180141 A CN 103180141A CN 2010800697561 A CN2010800697561 A CN 2010800697561A CN 201080069756 A CN201080069756 A CN 201080069756A CN 103180141 A CN103180141 A CN 103180141A
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sheet
layer structure
interior material
manufacture method
oligomer
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CN103180141B (zh
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金东原
金基成
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Seoyon E Hwa Co Ltd
Han Il E HWA Co Ltd
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Han Il E HWA Co Ltd
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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)

Abstract

本发明涉及一种用于汽车内装材料的多层构造物及其制造方法。根据本发明的一实施例的用于汽车内装材料的多层构造物，包括：聚丙烯发泡片材；加强片材，其层叠于所述聚丙烯发泡片材的至少一面，包含天然纤维及合成纤维进行针刺后，通过热轧辊工程而制造；涂层膜，其形成在所述加强片材的外侧面。

Description

用于汽车内装材料的多层构造物以及其制造方法
技术领域
本发明涉及一种多层构造物，更详细而言，涉及一种用于汽车内装材料的多层构造物。
背景技术
汽车的内装材料是决定乘车时的舒适感的主要零件，一般主要使用柔软的树脂或纤维等。
所述汽车内装材料适用于汽车的面积相对宽，形成为复杂的结构，因此必须要求材料的形态稳定性（或尺寸稳定性）。即，在各种温度及适湿度等外部环境下也不得发生形态变形及层间剥离。
最近，随着对绿色环保的要求，要求一种耐热性及刚性出色，且能提高能源效率的轻量的材料。
一般，用于汽车内装材料的构造物是层叠保持形态及安装性的芯材层、具有设计性、吸音性及缓冲感的加强层以及表皮层的构造而成。
关于加强层，现有仅通过针刺天然纤维及合成纤维的方法制造加强层（加强片材）时，由于表面张力弱，因此存在很难满足汽车内装材料所要求的弯曲强度及弯曲弹性率的问题。
并且，仅通过针刺将所述加强层结合在发泡体两面时，存在不仅发泡体被针受损，而且，由于加强层的密度减少而物性降低，从而其适用范围受限制的问题。
因此，需要一种能够解决如上所述的问题的方案。
发明内容
本发明的实施例提供一种弯曲特性出色的用于汽车内装材料的多层构造物。
根据本发明的一侧面，提供一种用于汽车内装材料的多层构造物，包括：聚丙烯发泡片材；加强片材，其层叠于所述聚丙烯发泡片材的至少一面，包含天然纤维及合成纤维进行针刺后，通过热轧辊工程而制造；涂层膜，其形成在所述加强片材的外侧面。
进一步包括无纺布形态的表皮层，所述表皮层层叠于所述涂层膜的外侧面，并由聚烯烃类或聚酯类而形成。
所述聚丙烯发泡片材对50～80重量份的聚丙烯混合20～50重量份的线型低密度聚乙烯或弹性体而形成。
所述聚丙烯发泡片材的发泡倍率为3～40倍。
所述聚丙烯发泡片材是层压1层或2层而形成。
所述加强片材中天然纤维及合成纤维的混合比率为1:9～9:1。
所述天然纤维及所述合成纤维的长度可为40～120mm。
所述加强片材的密度为0.3～1.0g/cm3。
所述天然纤维可为黄麻、洋麻（KENAF）、剑麻或竹子中的至少一个。
所述合成纤维可为低熔点聚酯、聚对苯二甲酸乙二醇酯（PET）、聚丙烯或生物可降解树脂纤维中的至少一个。
所述生物可降解树脂纤维可为聚乳酸（polyactic acid，PLA）或醋酸纤维素（cellulose acetate，CA）。
所述涂层膜可由紫外线固化树脂或热固型生物胶而形成。
所述紫外线固化树脂含有光引发剂、光聚合低聚物、光聚合单体及添加剂，所述光聚合低聚物可为一液型氨基甲酸酯丙烯酸类低聚物、二液型氨基甲酸酯丙烯酸类低聚物、聚酯丙烯酸类低聚物或混合型丙烯酸类低聚物中的至少一个。
根据本发明的另一侧面，可以提供用于汽车内装材料的多层构造物的制造方法，包括：形成聚丙烯发泡片材的第一步骤；包含天然纤维及合成纤维进行针刺后，通过热轧辊工程制造加强片材的第二步骤；在所述加强片材的外侧面形成涂层膜的第三步骤；以及在所述聚丙烯发泡片材的至少一面层叠所述加强片材的第四步骤。
在所述第四步骤以后可进一步包括在所述涂层膜的外侧面层叠由聚烯烃类或聚酯类而形成的无纺布形态的表皮层的第五步骤。
所述第三步骤可为在所述加强片材的外侧面涂布紫外线固化树脂，照射紫外线形成涂层膜的步骤。
所述第三步骤可为在所述加强片材的外侧面涂布热固型生物胶，加热固化而形成涂层膜的步骤。
所述第二步骤和第三步骤可通过连续工程进行。
发明效果
本发明的实施例具有如下效果：
在用于汽车内装材料的多层构造物中，通过在加强片材用紫外线固化树脂或热固型生物胶形成涂层膜，提高弯曲特性。
通过针刺天然纤维及合成纤维之后，利用热轧辊制造加强片材，从而由于加强片材的密度减少，而防止物性降低的效果。
附图说明
图1是根据本发明的实施例的用于汽车内装材料的多层构造物的截面图。
图2是根据本发明的实施例的用于汽车内装材料的多层构造物的制造方法的顺序图。
图3是图2的形成涂层膜的方法的顺序图。
图中：
100：用于汽车内装材料的多层构造物，120：聚丙烯发泡片材，140：加强片材，160：涂层膜
具体实施方式
图1是根据本发明的实施例的用于汽车内装材料的多层构造物100的截面图。
根据图1，用于汽车内装材料的多层构造物100，包括：聚丙烯发泡片材120；加强片材140，其层叠于聚丙烯发泡片材120的一面或两面；涂层膜160，其形成在加强片材140的外侧面。
聚丙烯发泡片材120是将聚烯烃类的一种的聚丙烯作为主成分的发泡片材。所述聚丙烯，其组成成分仅由碳氢化合物组成，因此没有极性，疏水性大，而具有对极性污染物质的抵抗性高的特征。
聚丙烯发泡片材120，例如对于50～80重量份的聚丙烯混合20～50重量份的线型低密度聚乙烯或弹性体而组成。
聚丙烯发泡片材120的发泡倍率（expansion ratio）可为3倍～40倍。当聚丙烯发泡片材120的发泡倍率小于3倍时，存在不能提高聚丙烯发泡片材120的吸音性，而且，重量变高的问题。当聚丙烯发泡片材120的发泡倍率超过40倍时，存在强度及形态稳定性降低的问题。
聚丙烯发泡片材120的尺寸并没有限定。例如，将聚丙烯发泡片材120可以形成为宽度300mm～2000mm、厚度1mm～15mm。
聚丙烯发泡片材120可层压1层或2层而形成。例如，将聚丙烯发泡片材120形成为宽度1000mm～1700mm、厚度3mm～5mm之后，将聚丙烯发泡片材120可层压2层。
将聚丙烯发泡片材120层压2层时，具有形态稳定性得以提高的效果。
加强片材140层叠于聚丙烯发泡片材120的一面或两面而形成。加强片材140具有提高汽车内装材料对外部冲击的吸收性，加强强度及形态稳定性的作用。
加强片材140含有天然纤维及合成纤维。所述天然纤维及合成纤维具有提高加强片材140的耐久性、耐水性、耐腐蚀性及强度的作用。
加强片材140中天然纤维和合成纤维的配合比率并没有限定。例如，在加强片材140中，天然纤维和合成纤维的混合比率可为1:9～9:1。
并且，加强片材140的厚度并没有限定。例如，加强片材140可用厚度为0.5mm～1mm的薄膜片材制造。
加强片材140的密度可为0.3～1.0g/cm3。也可以具有此外的密度，但是，当加强片材140的密度小于0.3g/cm3时，存在刚性稍微变弱的问题。相反，当加强片材140的密度高于1.0g/cm3时，存在不利于轻量化的问题。
一方面，所述天然纤维的种类或尺寸中的至少一个并没有限定。例如，所述天然纤维可为黄麻、洋麻（KENAF）、剑麻或竹子中的至少一个。另外所述天然纤维可以使用粗细为40～120μm，长度为40～80mm的纤维。
所述加强片材140中，所述天然纤维及所述合成树脂的长度可为40～120mm。当所述天然纤维及合成纤维的长度分别小于40mm时，存在加强片材140的物性及表面张力变弱的问题。相反，当所述天然纤维及所述合成纤维的长度长于120mm时，在为制造加强片材140的梳理（carding）工程中，存在不仅各纤维互相缠绕，而且，在成型汽车的内装材料时，发生天然纤维被断落的现象，从而汽车内装材料的弯曲强度及弯曲弹性率降低的问题。
所述合成纤维可为低熔点聚酯、聚对苯二甲酸乙二醇酯（PET）、聚丙烯或生物可降解树脂纤维中的至少一个。
此处，所述生物可降解树脂纤维意味着通过微生物分泌的霉进行分解的纤维。所述生物可降解树脂的种类并没有限定。例如，可为聚乳酸（polyacticacid，PLA）或醋酸纤维素（cellulose acetate，CA）。
涂层膜160形成在加强片140的外侧面，具有提高加强片材140的弯曲特性的作用。
涂层膜160可用紫外线固化树脂或热固型生物胶形成。
所述紫外线固化树脂是指接受紫外线（200mm～400mm）的光线来固化的树脂。所述紫外线固化树脂含有光引发剂、光聚合低聚物、光聚合单体及添加剂，所述光聚合低聚物可为一液型氨基甲酸酯丙烯酸类低聚物、二液型氨基甲酸酯丙烯酸类低聚物、环氧丙烯酸类低聚物、聚酯丙烯酸类低聚物或混合型丙烯酸类低聚物中的至少一个。
所述热固型生物胶（生物树脂）是基于生物（动物或植物），被热固化的物质。所述热固型生物胶可以使用公知的物质，在此省略对此的详细说明。
用于汽车内装材料的多层构造物100进一步包括层叠于涂层膜160的外侧面的表皮层180。表皮层180可制造为由聚烯烃类或聚酯类形成的无纺布形态。
将表皮层180制造为无纺布形态时，不利用溶剂型粘接剂或热熔胶型粘接剂，也能与涂层膜160热粘合，因此存在工程变简单的优点。而且，由于不使用粘接剂，因此存在也不会发生因粘接剂而导致的恶臭的优点。
以下，说明根据本发明的实施例的用于汽车内装材料的多层构造物100的制造方法。相同的符号表示相同的构件。此处，聚丙烯发泡片材120、加强片材140、涂层膜160及表皮层180的构成与所述构成相同，因此，以下为了方便说明仅记载制造方法。
图2是根据本发明的实施例的用于汽车内装材料的多层构造物100的制造方法的顺序图。图3是图2的形成涂层膜的的方法的顺序图。
根据图2及图3，用于汽车内装材料的多层构造物的制造方法，首先形成聚丙烯发泡片材120。聚丙烯发泡片材120可由通常的方法形成。例如，混合聚丙烯树脂或包含聚丙烯树脂的2种树脂，并混合交联剂及发泡剂等添加剂，可通过挤压成型装置挤压出预定厚度的片材形态。
然后，照射电子束，将照射电子束的片材可通过微波炉形成连续的发泡片材。并且，在挤压机模直接挤压发泡，从而可以形成聚丙烯发泡片材（以上S100步骤）。
接着制造加强片材140。加强片材140，通过针刺方法混合天然纤维及合成纤维，通过热轧辊工程可以制造成薄膜片材形态。另外，所述合成纤维是在热轧辊工程中可被所述热轧辊温度融化的合成纤维。所述合成纤维的例如上所述。
仅通过针刺方法制造加强片材140时，由于表面张力变弱，因此存在很难满足弯曲特性的问题。因此，进行针刺后通过热轧辊工程制造加强片材140，从而可以解决所述问题（以上，S200步骤）。
接着，在加强片材140的外侧面形成涂层膜160。涂层膜160可用紫外线固化树脂或热固型生物胶形成。
利用所述紫外线固化树脂形成涂层膜160时，在加强片材140的外侧面涂布所述紫外线固化树脂，并照射紫外线而形成涂层膜160。
例如，在加强片材140的外侧面涂布氨基甲酸酯丙烯酸类紫外线固化型树脂，涂布厚度为5～30μm，照射800～1200mJ/cm2（50～60度）的紫外线进行固化，从而可以形成涂层膜160。
利用所述热固化型生物胶形成涂层膜160时，在加强片材140的外侧面涂布所述热固型生物胶，然后加热进行固化，从而可以形成涂层膜。
并且，形成有涂层膜160的加强片材140可通过连续工程制造。例如，可通过针刺工程、热轧辊工程、紫外线固化树脂涂布工程及紫外线照射工程连续制造加强片材140。还可以通过针刺工程、热轧辊工程、生物胶涂布工程及热固化工程制造加强片材140（以上，S300步骤）。
接着，在聚丙烯发泡片材120的至少一面层叠形成有涂层膜160的加强片材140。所述层叠方法，可通过热连续层压聚丙烯发泡片材120及加强片材140。还可以将聚丙烯发泡片材120形成为双重后与加强片材140进行层压。
另外，当通过热层压聚丙烯发泡片材120和加强片材140时，还可以用不同的温度预热聚丙烯发泡片材120和加强片材140后进行层压。此时，可以抑制层压后有可能发生的皱纹及重叠现象（以上，S400步骤）。
用于汽车内装材料的多层构造物的制造方法可以进一步包括在涂层膜160的外侧面层叠由聚烯烃类或聚酯类形成的无纺布形态的表皮层180的步骤。表皮层160可通过由热的熔接方式与涂层膜160进行层叠（以上，S500步骤）。
如上所述，本发明的实施例，在用于汽车内装材料的多层构造物中，通过在加强片材用紫外线固化树脂或热固型生物胶形成涂层膜，从而可以提高弯曲特性。
而且，针刺天然纤维及合成纤维之后，利用热轧辊制造加强片材，从而可以防止因加强片材的密度减低而物性降低。
以上，虽说明了本发明的实施例，但是，本领域的技术人员在不脱离权利要求范围中所记载的本发明的技术思想范围内，可通过附加、变更或增加构成要素来进行各种修改及变更，这些理应属于本发明的权利要求范围内。

Claims (28)

1.一种用于汽车内装材料的多层构造物，其特征在于，包括：
聚丙烯发泡片材（120）；
加强片材（140），其层叠于所述聚丙烯发泡片材（120）的至少一面，包含天然纤维及合成纤维进行针刺后，通过热轧辊工程而制造；
涂层膜（160），其形成在所述加强片材（140）的外侧面。
2.根据权利要求1所述的用于汽车内装材料的多层构造物，其特征在于，进一步包括无纺布形态的表皮层（180），所述表皮层层叠于所述涂层膜（160）的外侧面，并由聚烯烃类或聚酯类而形成。
3.根据权利要求1所述的用于汽车内装材料的多层构造物，其特征在于，所述聚丙烯发泡片材（120）对50～80重量份的聚丙烯混合20～50重量份的线型低密度聚乙烯或弹性体而形成。
4.根据权利要求1所述的用于汽车内装材料的多层构造物，其特征在于，所述聚丙烯发泡片材（120）的发泡倍率为3～40倍。
5.根据权利要求1所述用于汽车内装材料的多层构造物，其特征在于，所述聚丙烯发泡片材（120）是层压1层或2层而形成。
6.根据权利要求1所述的用于汽车内装材料的多层构造物，其特征在于，所述加强片材（140）中天然纤维及合成纤维的混合比率为1:9～9:1。
7.根据权利要求1所述的用于汽车内装材料的多层构造物，其特征在于，所述天然纤维及所述合成纤维的长度为40～120mm。
8.根据权利要求1或6所述的用于汽车内装材料的多层构造物，其特征在于，所述加强片材（140）的密度为0.3～1.0g/cm3。
9.根据权利要求1或6所述的用于汽车内装材料的多层构造物，其特征在于，所述天然纤维是黄麻、洋麻（KENAF）、剑麻或竹子中的至少一个。
10.根据权利要求1或6所述的用于汽车内装材料的多层构造物，其特征在于，所述合成纤维是低熔点聚酯、聚对苯二甲酸乙二醇酯（PET）、聚丙烯或生物可降解树脂纤维中的至少一个。
11.根据权利要求10所述的用于汽车内装材料的多层构造物，其特征在于，所述生物可降解树脂纤维是聚乳酸（polyactic acid，PLA）或醋酸纤维素（cellulose acetate，CA）。
12.根据权利要求1所述的用于汽车内装材料的多层构造物，其特征在于，所述涂层膜（160）是由紫外线固化树脂或热固型生物胶而形成。
13.根据权利要求12所述的用于汽车内装材料的多层构造物，其特征在于，所述紫外线固化树脂含有光引发剂、光聚合低聚物、光聚合单体及添加剂，
所述光聚合低聚物是一液型氨基甲酸酯丙烯酸类低聚物、二液型氨基甲酸酯丙烯酸类低聚物、环氧丙烯酸类低聚物、聚酯丙烯酸类低聚物或混合型丙烯酸类低聚物中的至少一个。
14.一种用于汽车内装材料的多层构造物的制造方法，其特征在于，包括：
形成聚丙烯发泡片材（120）的第一步骤（S100）；
包含天然纤维及合成纤维进行针刺后，通过热轧辊工程制造加强片材（140）的第二步骤（S200）；
在所述加强片材（140）的外侧面形成涂层膜（160）的第三步骤（S300）；以及
在所述聚丙烯发泡片材（120）的至少一面层叠所述加强片材（140）的第四步骤（S400）。
15.根据权利要求14所述的用于汽车内装材料的多层构造物的制造方法，其特征在于，进一步包括在所述涂层膜（160）的外侧面层叠由聚烯烃类或聚酯类而形成的无纺布形态的表皮层（180）的第五步骤（S500）。
16.根据权利要求14所述的用于汽车内装材料的多层构造物的制造方法，其特征在于，所述聚丙烯发泡片材（120）对50～80重量份的聚丙烯混合20～50重量份的线型低密度聚乙烯或弹性体而形成。
17.根据权利要求14所述的用于汽车内装材料的多层构造物的制造方法，其特征在于，所述聚丙烯发泡片材（120）的发泡倍率为3～40倍。
18.根据权利要求14所述用于汽车内装材料的多层构造物的制造方法，其特征在于，所述聚丙烯发泡片材（120）是层压1层或2层而形成。
19.根据权利要求14所述的用于汽车内装材料的多层构造物的制造方法，其特征在于，所述加强片材（140）中天然纤维及合成纤维的混合比率为1:9～9:1。
20.根据权利要求14所述的用于汽车内装材料的多层构造物的制造方法，其特征在于，所述天然纤维及所述合成纤维的长度为40～120mm。
21.根据权利要求14或19所述的用于汽车内装材料的多层构造物的制造方法，其特征在于，所述加强片材（140）的密度为0.3～1.0g/cm3。
22.根据权利要求14或19所述的用于汽车内装材料的多层构造物的制造方法，其特征在于，所述天然纤维是黄麻、洋麻（KENAF）、剑麻或竹子中的至少一个。
23.根据权利要求14或19所述的用于汽车内装材料的多层构造物的制造方法，其特征在于，所述合成纤维是低熔点聚酯、聚对苯二甲酸乙二醇酯（PET）、聚丙烯或生物可降解树脂纤维中的至少一个。
24.根据权利要求23所述的用于汽车内装材料的多层构造物的制造方法，其特征在于，所述生物可降解树脂纤维是聚乳酸（polyactic acid，PLA）或醋酸纤维素（cellulose acetate，CA）。
25.根据权利要求14所述的用于汽车内装材料的多层构造物的制造方法，其特征在于，所述第三步骤是在所述加强片材（140）的外侧面涂布紫外线固化树脂，照射紫外线形成涂层膜（160）的步骤。
26.根据权利要求25所述的用于汽车内装材料的多层构造物的制造方法，其特征在于，所述紫外线固化树脂含有光引发剂、光聚合低聚物、光聚合单体及添加剂，
所述光聚合低聚物是一液型氨基甲酸酯丙烯酸类低聚物、二液型氨基甲酸酯丙烯酸类低聚物、环氧丙烯酸类低聚物、聚酯丙烯酸类低聚物或混合型丙烯酸类低聚物中的至少一个。
27.根据权利要求14所述的用于汽车内装材料的多层构造物的制造方法，其特征在于，所述第三步骤是在所述加强片材（140）的外侧面涂布热固型生物胶，加热固化而形成涂层膜（160）的步骤。
28.根据权利要求25或27所述的用于汽车内装材料的多层构造物的制造方法，其特征在于，所述第二步骤和第三步骤通过连续工程进行。
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