阅读说明：本技术 一种汽车麻纤维顶棚及其制造工艺 (Automobile fibrilia ceiling and manufacturing process thereof ) 是由 邓吉雄 于 2019-10-28 设计创作，主要内容包括：本发明涉及一种汽车麻纤维顶棚的制造工艺,包括自上而下依次设置的面料复合材、麻纤维毡基材层,两者热压成型为一体；所述面料复合材是由自上而下设置的上面料层、泡绵和无纺布经烧贴工艺制得；所述麻纤维毡基材层是由自上而下设置的胶膜A、麻纤维毡基材、胶膜B和下面料层经压合工艺制得。本发明采用麻纤维板材替代现有的主体材质,加上面料复合材压合成汽车顶棚,制得的汽车顶棚具有较高的刚性和耐温性,且废料可以回收利用,易于分解,且具有高韧性,低VOC和抗菌防潮的效果。(The invention relates to a manufacturing process of an automobile fibrilia ceiling, which comprises a fabric composite material and a fibrilia felt base material layer which are sequentially arranged from top to bottom, wherein the fabric composite material and the fibrilia felt base material layer are formed into a whole by hot pressing; the fabric composite material is prepared by an upper fabric layer, foamed cotton and non-woven fabric which are arranged from top to bottom through a burning and sticking process; the fibrilia felt base material layer is prepared by a glue film A, the fibrilia felt base material, a glue film B and a lower material layer which are arranged from top to bottom through a laminating process. The automobile ceiling manufactured by adopting the fibrilia plate to replace the existing main body material and the fabric composite material to be pressed into the automobile ceiling has higher rigidity and temperature resistance, and the waste can be recycled, is easy to decompose, and has the effects of high toughness, low VOC (volatile organic compound) and antibiosis and moisture prevention.)

1. An automobile fibrilia ceiling, which is characterized in that: the fabric composite material and the fibrilia felt substrate layer are sequentially arranged from top to bottom and are formed into a whole by hot pressing; the fabric composite material is prepared by an upper fabric layer, foamed cotton and non-woven fabric which are arranged from top to bottom through a burning and sticking process; the fibrilia felt base material layer is prepared by a glue film A, the fibrilia felt base material, a glue film B and a lower material layer which are arranged from top to bottom through a laminating process.

2. The automotive fibrilia ceiling of claim 1 wherein: the fibrilia felt base material is prepared from the following natural fibers in percentage by mass: synthetic fiber = 80-100: 20-0, carding by non-woven equipment, forming a net and needling to obtain the fibrilia felt base material with the thickness of 5-20mm and the gram weight of 300-1500g/m for carrying out the heavy load cultivation.

3. The automotive fibrilia ceiling of claim 2 wherein: the adhesive films A and B are hot-melt adhesive films, the melting point is 105 ℃, the adhesive films can be melted into a colloidal state after being baked by the light wave oven, and the adhesive films are convenient to be adhered with the upper layer material and the lower layer material to form a whole.

4. The automotive fibrilia ceiling of claim 3 wherein: the non-woven fabric is spunlace non-woven fabric or needle-punched non-woven fabric, and the areal density is 40-150 g/m.

5. The automotive fibrilia ceiling of claim 4, wherein: the upper material layer and the lower material layer are all made of composite materials or non-woven fabric composite materials.

6. A manufacturing process of an automobile fibrilia ceiling, which is characterized in that the automobile fibrilia ceiling as claimed in claim 5 is adopted and is carried out according to the following steps: (1) skin feeding: after the fabric composite material is tiled, conveying the fabric composite material into a forming cavity of a forming die by using a fabric composite material feeding mechanism; (2) feeding base materials: after the fibrilia felt base material layer is tiled, conveying the fibrilia felt base material layer into a light wave oven A for preheating by using a fibrilia felt base material layer feeding mechanism, conveying the pre-fibrilia felt base material layer into a light wave oven B for heating after preheating, and then continuously conveying the heated fibrilia felt base material layer into a forming cavity of a forming die by using the feeding mechanism, wherein at the moment, the fabric composite material is arranged on the upper part, and the fibrilia felt base material layer is arranged on the lower part; (3) hot-press molding: automatically pressing down by a four-column oil press to laminate the fabric composite and the fibrilia felt substrate layer to form the ceiling, wherein the molding temperature is 15-25 ℃, the molding pressure is 90-110 kg/cm, the laminating time is 35-45 seconds, and the molded ceiling is automatically returned; (4) cutting with a water jet cutter: adopt the water sword cutting equipment of inverse hanging robot, it is fixed to place the tool upper end with hot pressing bast fiber felt substrate layer, and the rotatory 180 inverse hanging robot of tool is placed to hot pressing bast fiber felt substrate layer cuts bast fiber felt substrate layer, single nozzle diameter pressure: 2700 psi-2900 psi; technical requirements of system water: cutting water supply (matched with a low-pressure pure water system) has the maximum water consumption of 4.0 gpm (15.1L/min), a booster pump sets inlet water pressure of 58 psi (4 bar), outlet water pressure of 120psi (8.3 bar) after boosting, water temperature of a water inlet of 65 DEG F (18 ℃) and water temperature of a water inlet of 85 DEG F (29 ℃); (5) turning up the left side: placing the fibrilia felt base material layer cut by the water jet cutter on a work table, uniformly spraying green glue to a skylight opening and the front end of a ceiling by using a glue spraying gun, placing the ceiling sprayed with the glue on the upper end of an upper reverse wrapping device, automatically wrapping corners, setting the temperature of the device to be 240 +/-10 ℃, baking for 120 seconds, and cooling for 40 seconds after reverse wrapping; (6) and taking out the roof after the reverse packaging, placing the roof on a work table for accessory installation, and checking and warehousing after the accessory installation.

7. The manufacturing process of the automobile fibrilia sun visor according to claim 6, wherein the manufacturing process comprises the following steps: the temperature of the light wave oven A is 100-120 ℃, the baking time is 45-55 s, the temperature of the light wave oven B is 150-200 ℃, and the baking time is 45-55 s.

Technical Field

The invention relates to an automobile fibrilia ceiling and a manufacturing process thereof.

Background

The automobile ceiling inner decoration is an important component of the automobile inner decoration, and has the main functions of improving the decoration in the automobile and improving the heat insulation effect with the outside of the automobile; the noise in the vehicle is reduced, and the sound absorption effect is improved; the riding comfort and safety of the crew are improved.

The currently published production methods for polyurethane car roofs mainly include the following two methods: (1) the production method of the polyurethane multilayer composite board, which is proposed by Chinese patent CN101367287B, comprises the following specific steps: a) scattering the chopped glass fiber and the hot melt adhesive powder on a conveyor belt of a compound machine, carrying out hot-pressing compounding to form a film, cooling and rolling to obtain a glue glass film; b) and unreeling, stacking and flatly paving the adhesive film, the glass adhesive film and the hot melt adhesive film on a workbench of a composite production line from bottom to top at one time, and carrying out hot-pressing compounding and cooling to obtain the polyurethane multilayer composite board. The composite board is baked at 200 ℃, then sent into a cold die for cooling and shaping, and subjected to water cutting to obtain the automobile ceiling. The method is commonly known as a dry-method automobile ceiling production process, and has the defects of high energy consumption and poor sound absorption effect in production, because of the adoption of thermoplastic materials, the rigidity and the temperature resistance of the product are poor, meanwhile, the materials are not easy to recover, and the environmental pollution is easily caused by leftover materials; (2) the wet production process of PU soft foam top lining, which is proposed in Chinese patent CN101337526B, comprises the following steps: a) roll-coating 60-180g/m of single-component polyurethane adhesive on the upper and lower surfaces of the PU foam board by using a glue rolling machine; b) sequentially stacking and paving the non-woven fabric, the glass fiber felt, the PU foam board, the glass fiber felt and the fabric, and putting the materials into a mould for pressing and forming, wherein the temperature of the mould is controlled at 140 ℃ and the pressing time is 55 s; c) the method has the disadvantages that various materials are mutually overlapped in the production, the process is complex, the VOC value of the product is still high, the material is not easy to recover if the product is scrapped, and the environmental pollution is easily caused by leftover materials.

Disclosure of Invention

In view of the above, the invention aims to provide an automobile fibrilia ceiling and a manufacturing process thereof, the automobile fibrilia ceiling is made by adopting fibrilia plates to replace the existing main materials and adding fabric composite materials to be pressed into the automobile ceiling, and the prepared automobile ceiling has higher rigidity and temperature resistance, and the waste materials can be recycled, are easy to decompose, and have the effects of high toughness, low VOC and antibiosis and moisture resistance.

The technical scheme of the invention is as follows: an automobile fibrilia ceiling comprises a fabric composite material and a fibrilia felt base material layer which are sequentially arranged from top to bottom, and the fabric composite material and the fibrilia felt base material layer are formed into a whole by hot pressing; the fabric composite material is prepared by an upper fabric layer, foamed cotton and non-woven fabric which are arranged from top to bottom through a burning and sticking process; the fibrilia felt base material layer is prepared by a glue film A, the fibrilia felt base material, a glue film B and a lower material layer which are arranged from top to bottom through a laminating process.

Further, the fibrilia felt base material is prepared from natural fibers in percentage by mass: synthetic fiber = 80-100: 20-0, carding by non-woven equipment, forming a net and needling to obtain the fibrilia felt base material with the thickness of 5-20mm and the gram weight of 300-1500g/m for carrying out the heavy load cultivation.

Furthermore, the adhesive film A and the adhesive film B are both hot-melt adhesive films, the melting point is 105 ℃, and the adhesive films can be melted into a glue shape after being baked by the light wave oven, so that the adhesive films can be conveniently adhered with the upper layer material and the lower layer material to form a whole.

Further, the non-woven fabric is spunlace non-woven fabric or needle-punched non-woven fabric, and the areal density is 40-150 g/m.

Furthermore, the upper material layer and the lower material layer are both made of composite materials or non-woven fabric composite materials distributed all over.

A manufacturing process of an automobile fibrilia sun shield is carried out according to the following steps: (1) skin feeding: after the fabric composite material is tiled, conveying the fabric composite material into a forming cavity of a forming die by using a fabric composite material feeding mechanism; (2) feeding base materials: after the fibrilia felt base material layer is tiled, conveying the fibrilia felt base material layer into a light wave oven A for preheating by using a fibrilia felt base material layer feeding mechanism, conveying the pre-fibrilia felt base material layer into a light wave oven B for heating after preheating, and then continuously conveying the heated fibrilia felt base material layer into a forming cavity of a forming die by using the feeding mechanism, wherein at the moment, the fabric composite material is arranged on the upper part, and the fibrilia felt base material layer is arranged on the lower part; (3) hot-press molding: automatically pressing down by a four-column oil press to laminate the fabric composite and the fibrilia felt substrate layer to form the ceiling, wherein the molding temperature is 15-25 ℃, the molding pressure is 90-110 kg/cm, the laminating time is 35-45 seconds, and the molded ceiling is automatically returned; (4) cutting with a water jet cutter: adopt the water sword cutting equipment of inverse hanging robot, it is fixed to place the tool upper end with hot pressing bast fiber felt substrate layer, and the rotatory 180 inverse hanging robot of tool is placed to hot pressing bast fiber felt substrate layer cuts bast fiber felt substrate layer, single nozzle diameter pressure: 2700 psi-2900 psi; technical requirements of system water: cutting water supply (matched with a low-pressure pure water system) has the maximum water consumption of 4.0 gpm (15.1L/min), a booster pump sets inlet water pressure of 58 psi (4 bar), outlet water pressure of 120psi (8.3 bar) after boosting, water temperature of a water inlet of 65 DEG F (18 ℃) and water temperature of a water inlet of 85 DEG F (29 ℃); (5) turning up the left side: placing the fibrilia felt base material layer cut by the water jet cutter on a work table, uniformly spraying green glue to a skylight opening and the front end of a ceiling by using a glue spraying gun, placing the ceiling sprayed with the glue on the upper end of an upper reverse wrapping device, automatically wrapping corners, setting the temperature of the device to be 240 +/-10 ℃, baking for 120 seconds, and cooling for 40 seconds after reverse wrapping; (6) and taking out the roof after the reverse packaging, placing the roof on a work table for accessory installation, and checking and warehousing after the accessory installation.

Further, the temperature of the light wave oven A is 100-120 ℃, the baking time is 45-55 s, the temperature of the light wave oven B is 150-200 ℃, and the baking time is 45-55 s.

Compared with the prior art, the invention has the beneficial effects that: according to the invention, the natural fibrilia glue film is compounded to obtain the fibrilia felt base material, and then the fibrilia felt base material is used as the main material of the automobile ceiling, so that the fibrilia felt base material can ensure higher rigidity, toughness and temperature resistance of the automobile ceiling, can reduce the thickness of the ceiling and increase the space in the automobile, the produced ceiling is light in weight, high in bending strength, high in modulus, good in weather resistance, safe and reliable, the finished product is wrinkle-resistant, is not easy to generate acute angles and sections after being damaged, and the fibrilia material not only has an antibacterial effect, but also is an environment-friendly material and low in VOC content, and the waste material of the automobile ceiling prepared by the fibrilia material can be recycled and is easy to decompose.

In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in detail below.

Drawings

FIG. 1 is a front view of a manufacturing process apparatus according to an embodiment of the present invention;

FIG. 2 is a top view of a manufacturing process apparatus according to an embodiment of the present invention;

FIG. 3 is a schematic structural diagram of an inverted robotic water jet cutting device according to an embodiment of the invention;

FIG. 4 is a schematic structural diagram of a conventional upper bag-turning device according to an embodiment of the present invention;

FIG. 5 is a top view of the conventional upper ladle apparatus according to an embodiment of the present invention;

FIG. 6 is a schematic structural view of a fabric composite according to an embodiment of the present invention;

FIG. 7 is a schematic structural diagram of a fibrilia felt substrate layer according to an embodiment of the invention;

in the figure: 1-a fabric composite feeding mechanism; 2-a fibrilia felt substrate layer feeding mechanism; 3-forming a mould; 4-light wave oven A; 5-light wave oven B; 6-four-column oil press; 7-hanging robot water-jet cutting equipment upside down; 8-placing a jig for the hot-pressed fibrilia felt substrate layer; 9-Shi Shang Turn-Up device; 10-fibrilia felt base material layer; 11-a face fabric composite; 12-upper material layer; 13-foamed plastic; 14-non-woven fabric; 15-glue film A; 16-a fibrilia felt substrate; 17-glue film B; 18-lower precoat.

Detailed Description

As shown in fig. 1 to 7, an automobile fibrilia ceiling comprises a fabric composite material 11 and a fibrilia felt base material layer 10 which are sequentially arranged from top to bottom, and the fabric composite material and the fibrilia felt base material layer are formed into a whole by hot pressing; the fabric composite material 11 is prepared by a top fabric layer 12, foam 13 and non-woven fabric 14 which are arranged from top to bottom through a burning and pasting process; the fibrilia felt base material layer 10 is prepared by laminating a glue film A15, a fibrilia felt base material, a glue film B17 and a lower fabric layer 18 which are arranged from top to bottom.

In this embodiment, the fibrilia felt substrate is made of natural fibers by mass: synthetic fiber = 80-100: 20-0, carding by non-woven equipment, forming a net and needling to obtain the fibrilia felt base material with the thickness of 5-20mm and the gram weight of 300-1500g/m for carrying out the heavy load cultivation.

In this embodiment, the adhesive films a15 and B17 are hot-melt adhesive films, the melting point is 105 degrees, and the adhesive films will melt into a glue shape after being baked by a lightwave oven, so as to be conveniently glued with the upper and lower layer materials to form a whole.

In the embodiment, the nonwoven fabric 14 is the spunlace nonwoven fabric 14 or the needle-punched nonwoven fabric 14, and the areal density is 40-150 g/m.

In this embodiment, the upper and lower face plies 12, 18 are both composite materials with the composite material or nonwoven 14 extending over them.

In an embodiment of the invention, the natural fibers comprise: one or more of jute, ramie and flax; the synthetic fiber includes: one or more of polyethylene fiber, polypropylene fiber, nylon fiber and polyester fiber.

A manufacturing process of an automobile fibrilia sun shield is carried out according to the following steps: (1) skin feeding: after the fabric composite material 11 is tiled, the fabric composite material 11 is conveyed into a forming cavity of a forming die 3 by a fabric composite material feeding mechanism 1; (2) feeding base materials: after the fibrilia felt base material layer 10 is tiled, conveying the fibrilia felt base material layer 10 into a light wave oven A4 by using a feeding mechanism 2 for preheating, conveying the fibrilia felt base material layer 10 into a light wave oven B5 for heating after preheating, and then continuously conveying the heated fibrilia felt base material layer 10 into a forming cavity of a forming die 3 by using the feeding mechanism, wherein at the moment, the fabric composite material 11 is arranged above the fibrilia felt base material layer 10 below the forming cavity; (3) hot-press molding: automatically pressing down by a four-column oil press 6 to press the fabric composite material 11 and the fibrilia felt substrate layer 10 to form the ceiling, wherein the forming temperature is 15-25 ℃, the forming pressure is 90-110 kg/cm, the pressing time is 35-45 seconds, and the ceiling is automatically returned after forming; (4) cutting with a water jet cutter: adopt the water sword cutting equipment 7 of inverse hanging robot, it is fixed to place 8 upper ends of tool with hot pressing bast fiber felt substrate layer, and 8 rotatory 180 inverse hanging robots of tool are placed to hot pressing bast fiber felt substrate layer and are cut bast fiber felt substrate layer 10, single nozzle diameter pressure: 2700 psi-2900 psi; technical requirements of system water: cutting water supply (matched with a low-pressure pure water system) has the maximum water consumption of 4.0 gpm (15.1L/min), a booster pump sets inlet water pressure of 58 psi (4 bar), outlet water pressure of 120psi (8.3 bar) after boosting, water temperature of a water inlet of 65 DEG F (18 ℃) and water temperature of a water inlet of 85 DEG F (29 ℃); (5) turning up the left side: placing the fibrilia felt base material layer 10 cut by the water jet cutter on a work table, uniformly spraying green glue to the skylight opening and the front end of the ceiling by using a glue spraying gun, placing the ceiling sprayed with the glue on the upper end of the upper reverse wrapping equipment 9, automatically wrapping corners, setting the equipment temperature at 240 +/-10 ℃, baking for 120 seconds, and cooling for 40 seconds after reverse wrapping; (6) and taking out the roof after the reverse packaging, placing the roof on a work table for accessory installation, and checking and warehousing after the accessory installation.

In the embodiment, the temperature of the light wave oven A4 is 100-120 ℃, the baking time is 45-55 s, the temperature of the light wave oven B5 is 150-200 ℃, and the baking time is 45-55 s.

The above-mentioned operation flow and software and hardware configuration are only used as the preferred embodiment of the present invention, and not to limit the scope of the present invention, and all equivalent changes made by using the contents of the present specification and the drawings, or directly or indirectly applied to the related art, are included in the scope of the present invention.