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CN1559836A - 生产用于内部衬里的覆盖物的方法 - Google Patents

生产用于内部衬里的覆盖物的方法 Download PDF

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Publication number
CN1559836A
CN1559836A CNA2003101148239A CN200310114823A CN1559836A CN 1559836 A CN1559836 A CN 1559836A CN A2003101148239 A CNA2003101148239 A CN A2003101148239A CN 200310114823 A CN200310114823 A CN 200310114823A CN 1559836 A CN1559836 A CN 1559836A
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CN
China
Prior art keywords
blanket
bed course
thermosetting resin
interlayer
layer
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CNA2003101148239A
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CN100352694C (zh
Inventor
R��������˹��÷˹
R·米尼罗斯戈梅斯
A·阿里斯纳瓦雷塔
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Grupo Antolin Ingenieria SA
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Grupo Antolin Ingenieria SA
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Abstract

本发明涉及生产用于内部衬里的覆盖物的方法，该覆盖物包括一个由半刚性纤维垫层制成的中间层(1)，在其每一个表面上施加有：热固性树脂；由纤维材料制成的加强层(3)；在侧面中的一个上的至少一个保护性片材(4)，覆盖加强层之一，以便形成隐藏的表面；并且在相反一侧施加装饰性衬里层(6)，以便形成外露的表面；最后，在热压机上对所获得的垫层进行成型或模制处理，从而还使得所述热固性树脂聚合。本发明还涉及由此获得的产品。

Description

生产用于内部衬里的覆盖物的方法
技术领域
本发明涉及一种用于生产用于汽车内部，特别是汽车车顶的覆盖物的方法，并且涉及用该方法获得的覆盖物。
背景技术
更具体地讲，本发明的方法涉及覆盖物的生产，该覆盖物包括具有由低密度材料制成的中间层的垫层，通过树脂与所述中间层连接的至少一个加强层，以及覆盖所述加强层的涂敷层。
用于上述目的的覆盖物，必须具有良好的隔热性能，以及良好的吸声和隔声性能。另外，对这种产品的机械要求正日益增加。
在由垫层获得的覆盖物中，所述由低密度材料制成的层通常是聚亚胺酯泡沫等，并且各层之间的连接是通过树脂实现的。这样的覆盖物也是已知的：其中，所述低密度材料由多孔织物组成，该织物具有不同类型的纤维，如玻璃纤维或聚酯纤维。
无论每一种低密度中间层的性质如何，存在有垫层结构的替代形式，包括将不同的额外层放置在所述中间层的表面，所述额外的层的不同性质，所使用的树脂类型等。
还存在着不同的生产方法，这些方法最后的步骤都是在热压机上对所述垫层进行成型加工，在这里，用于连接各层的树脂发生聚合。
具有上述特征的覆盖物及其生产方法业已披露于US4828910，4840832，6291370，EP0832787和BS2157725中。
在上述所有方法中，用于连接所述各层的粘接剂必须在所述垫层成型时施加；另外，这种粘接剂在聚合之后能固定相关形状。所述粘接剂的双重作用，要求在所述低密度材料层的表面或多个表面上提供合适数量的粘接剂，以便充分浸渍该材料。为此，浸渍操作必须在高温下进行，并且要持续较长时间。
另外，由低密度材料制成的中间层的性质在开始覆盖物生产工艺时会导致控制问题，因为从任何意义上讲它都缺乏刚性。
发明内容
本发明的目的是通过简化生产方法，并且提供具有改善了的机械性能的最终产品，甚至使具有较小的垫层厚度的最终产品也能具有改善的机械性能，以便消除上述问题。
US-A-4828910披露了一种大致根据本发明权利要求1序言部分的方法。
EP-A-0671259披露了使用保护性纸片材的方法。
EP-A-0285338披露了通过热熔合间接纤维。
EP-A-2147725披露了使用阻隔层。
根据本发明，将提供一中间层，该中间层由半刚性纤维毯子组成，优选具有均匀的克重。所述中间层的半刚性性质有利于对它的操作，并且能确保在整个垫层生产过程中，在其整个表面上保持均匀的克重，从而改善由此获得的产品的最终性能，并简化对其生产工艺的控制。
在本发明的方法中，在上述半刚性纤维毯子的每一面采用：a)热固性树脂，例如使用辊子涂胶器涂敷；b)由纤维材料制成的加强层；c)覆盖至少一个加强层的保护片材，以便形成所述垫层的隐藏表面；和d)位于相反一侧的装饰性衬里，以便形成外露的表面。
所述加强层可以由玻璃纤维制成，不过该加强层还可以由能提供相同的加强作用的任何其他纤维制成。
在施加所述加强材料层之前，可以让所述半刚性纤维毯子从两个辊之间通过，由此改善事先涂敷在该毯子两面的树脂的浸渍和分布。
在将树脂和加强层施加到所述纤维毯子的每一层上之后，施加保护性片材以覆盖所述加强层之一，以便形成隐藏的表面。该层可以使用用于粘接加强层的相同树脂被粘接，因为加强层是可被渗透的，并且所述粘接剂可以从它里面通过。所述保护性片材可以用各种不同的材料制成，如纸、非织造植物织物、塑料片材等。
在相反一面施加所述装饰性衬层，以便形成可见的表面。根据所使用的装饰性衬里的类型，在某些场合下可能有必要在所述加强层和装饰性衬里之间插入一个额外的阻隔层，以阻止粘接剂通过装饰性衬里从而影响其最终的外观。
如果在所述装饰性衬里和加强层之间不使用这样的阻隔层的话，则可以用与用于加强层的树脂相同的树脂连接所述衬里。如果提供一个阻隔层的话，它可以由热塑性材料制成，以便所述装饰性衬里可以例如，在最终的成型冲压步骤中通过用高温融合所述阻隔层，进行粘接。
如上文所述，在获得所述垫层之后，在热压机上对该组件进行成型，在这里，进一步加固了该组件的最终形状，由于该热固性树脂或这些热固性树脂在所述垫层的成型过程中发生彻底聚合，从而通过在模具中的压力和温度的共同作用加固了其内部结构，使其具有所述衬里的理想的最终形状。
由低密度材料制成的中间层包括由纤维材料制成的填塞物或毯子，优选具有均匀的克重，对其进行一种处理，以便提供纤维的一定程度的初步联结，从而可以获得需要的半刚性状态。所述中央填塞物纤维的初步联结，可以通过两种方式实现：将其浸入呈液体、熔融状态的热塑性树脂的溶液中；或通过机械穿孔工艺对该填塞物的纤维进行重排，从而使其发生交联。这种初步联结提供了填塞物纤维之间的一定程度的连接作用，使得能够在该工艺的随后阶段对其进行操作，保持上文所述的其表面的均匀的克重。
根据本发明，随后都将所述毯子浸入热固性树脂的溶液中，提供将要获得的中央填塞物和覆盖物在该生产工艺最后将要具有的部分刚性和自我支撑特性。为此，在用所述树脂浸渍所述填塞物之后，对该填塞物进行一定时间的定型，在此期间，所述热固性树脂会发生全面或部分聚合作用。如果所述聚合作用仅仅是部分聚合的话，随后将通过在衬里的最终成型步骤中所使用的热压机的热量完成该聚合反应，从而获得成品所需要的最终刚性。
附图的简要说明
通过结合附图对一种实施方案的例子所作的以下说明，可以更好地理解本发明的所有上述特征和优点，以及与本发明相关的其他特征和优点，其中：
图1表示用于获得本发明的覆盖物的垫层复合物的示意性剖视图；
图2是用于生产本发明的覆盖物的方法的示意图；和
图3是与图2类似的生产方法，相当于生产半刚性纤维毯子，该毯子构成了图1所示垫层的中间层。
具体实施方式
图1表示用于获得本发明的覆盖物的垫层复合物的示意图。
所述垫层包括由半刚性纤维毯子组成的中间层1，在该半刚性纤维毯子1的每一个表面涂有一层热固性树脂或涂层，施加在所述热固性树脂层或涂层2上的由纤维材料制成的加强层3，施加在加强层3上面的一个保护性片材4，用于形成衬里的隐藏表面，施加在相反一侧所述加强层3上的阻隔层5，和铺装在阻隔层5上的装饰性衬里层6，用于形成外露的表面。
中间层1可以由纤维材料填充物组成，所述纤维材料是由诸如聚对苯二甲酸乙二醇酯、聚酰胺、聚丙烯的人工纤维，植物纤维等制成的，对其进行穿孔处理，用热塑性材料浸渍，随后用热固性树脂浸渍。所述穿孔的纤维可以是原始纤维或再生纤维。
加强层3可以由玻璃纤维组成，不过，也可以使用能提供相同的加强作用的其他纤维。
阻隔层4可以由塑料片材、胶粘条或非织物组成。
用于生产图1所示垫层的生产工艺是结合图2进行说明的。
用于生产所述垫层的半刚性纤维毯子可以具有辊7的形式，所述毯子是从该辊上拉出的，利用诸如辊子涂胶器8的装置，将热固性树脂层涂在毯子表面。然后施加由诸如玻璃纤维的纤维材料制成的加强层3，该玻璃纤维能够以松散的纤维9、纤维垫10或任何其他的纤维排列或结构形式在一个侧面上输送。然后在一个侧面上施加保护性片材11，例如由纸制成的片材，由它形成图1所示的外露片材或表面4。在相反一侧，在所述加强层上施加一条或一片材料12，由它形成图1所示的阻隔层5，在其顶部铺装装饰层13，由它形成图1所示外露的表面或层6。
然后可以让由此获得的夹层结构从两个辊15，例如由橡胶制成的辊15之间通过，使得由涂胶辊8提供的树脂进一步渗透片材1，并且由该树脂更好地浸渍纤维9。
最后，在压力机16上对所获得的垫层进行模制，例如在120-190℃的温度下模制，模制时间为15-180秒，以便使树脂9聚合，获得要生产的覆盖物的理想形状。
下面结合图3说明的是一种用于获得构成中间层1的纤维半刚性毯子的可行方法。
用一个材料卷17获得纤维毯子18，该毯子可能事先已经进行过穿孔处理。让毯子18通过热固性树脂溶液19，尽管可能事先已经对它进行过穿孔处理。然后，可以通过传送带21输送浸渍过的毯子18通过烘干箱20，在这里，所述树脂完全或部分聚合，以便启动结合图2所披露的过程，然后重新卷绕所述片材，以便获得材料卷7，该材料卷被用作所述方法的原材料，或者可以将其切割成板。
如果所述树脂在烘干箱20中只发生了部分聚合的话，完全聚合将在图2所示方法的最后的压力机16中完成，在结合图2所披露的生产所述垫层的底部所涂敷的树脂9，也是在此时完成完全聚合的。
在结合附图披露的生产所述垫层的生产方法中，可以取消位于隐藏表面一侧的加强层10。还可以根据所使用的衬里6的类型取消图1所示的阻隔层5。图2所示的装饰性衬里13，可以在采用辊15之前或之后放置在所述垫层上。
用于图2所示方法的玻璃纤维9可以用诸如黄麻、大麻、亚麻、剑麻之类的天然纤维代替，或者以玻璃纤维毯子形式提供。
同样在图2所示的方法中，烘干箱可以在压力机16之前、在辊15之后采用，以便预热所述垫层，并缩短在压力机16中的成型时间。出于相同的目的，可以对辊15进行加热，以便在垫层到达压力机16之前，使它发生一定程度的聚合，从而防止加强纤维的脱落或分离，并缩短在压床16中的时间。

Claims (14)

1.用于汽车内部的覆盖物的生产方法，包括形成一个垫层，该垫层包括至少一个由低密度材料制成的中间层(1)，施加在中间层的至少一个表面上的至少一个加强层(3)，在该中间层上连接有热固性树脂(2)，以及施加在一个自由表面上的装饰性衬里层(6)，
该方法包括如下步骤：
提供一中间层(1)，
在所述中间层(1)的每一个表面上涂覆热固性树脂(2)；
涂覆由纤维材料制成的加强层(3)到该中间层的至少一个表面上；
将至少一个保护性片材(4)施加在前述步骤中获得的产品的一个表面上以便决定该垫层的隐藏表面；
将一装饰性衬里层(6)施加到该对置的表面上以便决定该垫层的暴露的表面；和
因此在热压机(16)上对所获得的垫层进行成型或模制处理，从而还使得所述热固性树脂聚合，
其中，提供一中间层(1)的步骤包括如下步骤：
提供一纤维材料制成的毯子(18)；和
使该毯子(18)受到一初步联结过程，该初步联结过程提供了对所述纤维一定程度的联结，
其特征在于，
所述的初步联结过程包括用进一步的热固性树脂(19)浸渍该毯子(18)并且使该毯子受到随后的定型处理以便导致所述的进一步的热固性树脂至少部分进行聚合的步骤，以便制成该半刚性的毯子，从而在所述的方法的后面的阶段中容易处理该毯子(18)。
2.如权利要求1的方法，其中，所述至少一层加强层(3)是由玻璃纤维制成。
3.如权利要求1的方法，其中，所述至少一层加强层(3)是由天然或人造纤维制成。
4.如上述任一项权利要求的方法，其中，所述保护性片材(4)是纸片材。
5.如上述任一项权利要求的方法，其特征在于，在一热压机(16)中对该垫层进行成型或模制步骤之前，让所述垫层从一对辊(15)之间通过，这对辊(15)对所述垫层进行部分压缩，使得涂在所述毯子(18)表面上的树脂(2)穿透所述的毯子并且浸渍所述至少一层加强层(3)。
6如权利要求5所述的方法，其中，所述的辊(15)被加热。
7.如上述任一项权利要求的方法，其中，所述的初步联结过程包括使该毯子(18)受到一熔融的热固性树脂浸渍的步骤。
8.如上述任一项权利要求的方法，其中，所述毯子(18)包括热融合纤维。
9.如上述任一项权利要求的方法，其中，所述初步联结过程包括使该毯子(18)的纤维受到机械穿刺操作的步骤。
10.如权利要求7所述的方法，其中，用进一步的热固性树脂(19)浸渍该毯子的步骤是在用一种熔融热固性树脂浸渍该毯子的步骤之后进行的。
11.如权利要求9所述的方法，其中，用进一步的热固性树脂(19)浸渍该毯子的步骤是在使该毯子(18)的纤维受到一机械穿刺操作的步骤之后进行的。
12.如上述任一项权利要求的方法，其中，该方法包括在所述加强层(3)和该装饰性衬里层(6)之间施加一由胶粘条或片材制成的阻隔层(5)。
13.如权利要求12所述的方法，其中，该阻隔层是由热塑性材料制成，该装饰性衬里层(6)通过加热熔合该阻隔层(5)而被粘接到该垫层上。
14.如权利要求1-11任一项所述的方法，其中，该装饰性衬里层通过热固性树脂(2)粘接到该垫层上。
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CN103702820A (zh) * 2011-06-30 2014-04-02 3M创新有限公司 通过真空加压成形或真空成形整合的结构及其制备方法

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CN100352694C (zh) 2007-12-05
EP1419880A1 (en) 2004-05-19
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