阅读说明：本技术 一种乘用车内外饰用纤维增强轻质热塑性无界面分层毡材及装置及制备方法 (Fiber-reinforced light thermoplastic non-interface layered felt material for interior and exterior decoration of passenger car, device and preparation method ) 是由 邓丽健 方晶 周立 祝超 章凯翔 应颂颂 张恒源 陈佳扬 吕超目 于 2021-09-01 设计创作，主要内容包括：本发明公开了一种乘用车内外饰用纤维增强轻质热塑性无界面分层毡材及装置及制备方法,毡材至少包括上下两层的外功能层和中间的芯层刚性骨架层,毡材为包括两层外功能层与芯层刚性骨架层的至少三道以上的道彩虹单纤维网之间经过交叉铺网及针刺而成为复合毡。本发明解决了多功能复合毡材在多层合刺固结加工过程中各层功能纤维由于过度针刺带来的磨损及断裂问题；多层合刺毡存在明确界面分层带来界面处的各种性能损耗问题；功能层和骨架层独立生产后再生产合刺毡带来的工序时间成本浪费问题等。另外,对比多梳多铺工艺,节省了多台梳理机和铺网机高昂的设备成本。(The invention discloses a fiber-reinforced light thermoplastic non-interface layered felt material for interior and exterior decoration of a passenger vehicle, a device and a preparation method thereof. The invention solves the problems of abrasion and fracture of functional fibers of each layer caused by excessive needling in the multi-layer combined needling consolidation processing process of the multifunctional composite felt material; the multilayer felted mat has the problems of various performance losses at the interface caused by definite interface layering; the problem of working procedure time cost waste caused by the production of the felted mat after the functional layer and the framework layer are independently produced, and the like. In addition, compared with a multi-carding and multi-lapping process, the high equipment cost of a plurality of carding machines and lapping machines is saved.)

1. The fiber-reinforced light thermoplastic non-interface layered felt material for the interior and exterior trim of a passenger vehicle is characterized by at least comprising an upper outer functional layer, a lower outer functional layer and a middle core layer rigid framework layer, wherein the felt material is a composite felt formed by cross lapping and needling between at least three or more rainbow single fiber nets comprising the two outer functional layers and the core layer rigid framework layer.

2. The fiber-reinforced lightweight thermoplastic interfacial-free layered felt material for interior and exterior trim of passenger cars according to claim 1, characterized in that the outer functional layer is a heat-insulating sound-absorbing layer or a toughening impact-resistant layer or an odor-improving layer or a hydrophobic oil-repellent layer, and the core layer rigid skeleton layer is mainly formed by opening and mixing 35-65% of base material fibers and 65-35% of reinforcing fibers.

3. An apparatus for producing a fiber-reinforced lightweight thermoplastic non-interfacial layered mat for interior and exterior trim of passenger cars according to claim 1 or 2, characterized by comprising at least three or more bale openers (12), an all-in-one cotton feeding box (13) connected to the bale openers (12), a carding machine (14) connected to the cotton feeding box (13), a web laying machine (15) connected to the carding machine (14), and a needling machine (16) connected to the web laying machine (15).

4. The device of passenger car interior and exterior decoration fiber reinforced light thermoplastic interface-free layered felt according to claim 3, wherein the cotton feeding box (13) comprises at least more than three cotton feeding areas, each cotton feeding area comprises an input end, a conveying section and an output end, the input end is connected with the bale opener (12), the output end is connected to the carding machine (14) through a belt scale (11), the cotton feeding areas are separated by movable partition plates, the output end comprises an output port (26) formed by a fixed baffle (19) arranged on two sides of the belt scale (11), a box body protective plate (17) of the cotton feeding box (13) and a small partition plate (18) arranged above the belt scale, and the conveying section is divided into an input bin, a cotton equalizing bin and a cotton conveying bin.

5. The device of the fiber reinforced lightweight thermoplastic non-interface layered felt material for the interior and exterior trim of passenger cars according to claim 3, characterized in that a cotton storage box (2) connected with the condenser (1) is arranged in the input bin, and a delivery roller (3) and an opening roller (4) in the delivery direction of the delivery roller (3) are arranged below the cotton storage box (2); the cotton harvester is characterized in that a feeding sensor (5) is arranged on the lower portion of the input bin, the feeding sensor (5) can be adjusted in height up and down, and a horizontal bottom curtain (6) is arranged at the lower end of the input bin and used for placing and transporting cotton.

6. The device of fiber reinforced light thermoplastic non-interface layered felt material for interior and exterior trim of passenger cars according to claim 4 or 5, characterized in that the cotton equalizing bin connected with the input bin comprises an inclined curtain (7) connected with the horizontal bottom curtain (6) and a cotton equalizing roller (8) forming a gap with the inclined curtain (7), convex needles are distributed on the inclined curtain (7) for hooking cotton to be transported obliquely upwards, and the cotton equalizing roller (8) is positioned on the upper part of the inclined curtain (7) and used for uniformly paving redundant cotton fibers to cotton on the inclined curtain (7).

7. The device of the fiber reinforced light thermoplastic non-interface layered felt material for the interior and exterior trim of passenger cars according to claim 6, characterized in that the output bin connected with the cotton equalizing bin comprises a cotton stripping roller (9) in the output direction of the inclined curtain (7) and a cotton conveying channel (10) with a valve and positioned below the cotton stripping roller (9), stripping needles are distributed on the cotton stripping roller (9) and used for stripping cotton conveyed from the inclined curtain (7) to the cotton conveying channel (10) with the valve, then conveying the cotton to the output port (26) of the cotton feeding box (13) and then conveying the cotton to the belt scale (11).

8. A preparation method of a fiber reinforced light thermoplastic interface-free layered felt material for interior and exterior decoration of passenger cars is characterized by comprising the following steps:

1) respectively designing fiber raw materials and proportions of at least an upper outer functional layer and a lower outer functional layer and a core layer rigid skeleton layer according to functional requirements;

2) each layer of fiber raw materials are respectively unpacked, mixed and opened by a corresponding unpacking machine (12) and then sent into an all-in-one cotton feeding box (13) and sent into a cotton storage box (2) through a condenser (1);

3) the output roller outputs the fibers to fall to the horizontal bottom curtain (6) through the opening roller (4), the fibers are transported through the horizontal bottom curtain (6) and the inclined curtain (7), and the cotton equalizing roller (8) peels the redundant fibers back to the fibers of the inclined curtain (7) at the upper end of the inclined curtain (7);

4) the fiber is stripped from the inclined curtain (7) by a stripping roller (9), sent into a cotton sending channel (10) with a valve to be sent to an output port (26), and then sent to a belt scale (11);

5) and sequentially sending the mixture to a carding machine (14) for carding, a lapping machine (15) for cross lapping and a needle machine (16) for needling through a belt, and finally synthesizing the composite felt.

9. The method for preparing fiber reinforced lightweight thermoplastic non-interfacial layered felt for interior and exterior trim of passenger cars as claimed in claim 8, wherein the feeding amount of the cotton feeding box (13) is 600-900kg/h, and the bulk density of each layer of felt is 0.1-0.6g/cm³。

10. The interior and exterior trim for passenger cars of claim 8The preparation method of the fiber-reinforced light thermoplastic interface-free layered felt is characterized in that the lapping layer number of the lapping machine (15) is 20-40, the plate pitch of the needle machine (16) is 16-20mm, the needle depth is 7-12mm, and the needle density is 40-100 needle punching numbers/cm²。

Technical Field

The invention relates to a composite felt material for interior and exterior decoration of a passenger vehicle, in particular to a fiber-reinforced light thermoplastic non-interface layered felt material for interior and exterior decoration of a passenger vehicle, a device and a preparation method thereof.

Technical Field

With the rapid development of the automobile industry, the requirements of the endurance mileage of new energy automobiles and the fuel economy of fuel automobiles continuously push the lightweight process of automobiles. Under the background, fiber reinforced thermoplastic composite materials are widely applied to automotive interior and exterior trims, and are widely applied to ceilings, hat racks, bottom guards, luggage cases, spare tire cover plates, skylight sliding covers and the like at present. Fiber reinforced thermoplastic composites have different performance requirements for the use of different parts in automobiles. For example, the hatrack is used as an automobile interior part, plays a role of placing articles and the like, and needs good mechanical strength; the bottom guard is an automobile exterior part, has the functions of preventing accumulated water or silt on the road surface from entering an engine cabin, preventing the concave-convex road surface from scraping a chassis system and weakening the influence of driving noise on the comfort in an automobile, and needs good impact toughness and sound absorption; the ceiling is an important component of the automotive interior and plays roles in heat insulation, noise reduction and the like. In addition, automotive interior parts have high requirements for odor and VOC. The abundant automobile application scenes put forward different performance requirements on the fiber reinforced thermoplastic composite material, and even superposition of multiple functions.

Chinese patent CN105479888A discloses a long fiber reinforced lightweight thermoplastic composite board for preparing a full-length body bottom guard plate of a passenger car and a preparation method thereof. The composite board sequentially comprises an anti-seepage scratch-resistant layer, a toughening impact-resistant layer, a rigid framework layer, a sound-absorbing noise-reducing layer and a hydrophobic oil-repellent layer from top to bottom. Firstly blending base material fibers and reinforcing fibers required by the toughening impact-resistant layer and the sound-absorbing noise-reducing layer into a felt according to a proportion, then stacking the toughening impact-resistant layer, the rigid framework layer, the sound-absorbing noise-reducing layer and the hydrophobic oil-repellent layer in sequence when preparing the rigid framework layer composite felt, and finally covering an anti-seepage and scratch-resistant layer on continuous composite board equipment through a heating and prepressing process to form a blank board for bottom protection. The method has the problems of time and cost waste of working procedures caused by the reproduction of the felted mat after the surface layer and the core layer are independently produced, and the like.

Chinese patent CN105437699A discloses a novel felt material for an outer wheel casing of a passenger car, which comprises a damping shock-absorbing layer, a rubber powder layer, a sound-absorbing layer, a buffering shock-absorbing layer and a rigid support shock-resisting layer from top to bottom in sequence. The sound absorption layer, the buffering shock absorption layer and the rigid supporting shock resistance layer are of a three-layer felted structure, and are stacked and enter a needling machine for reinforcement after passing through three sets of unpacking, opening, cotton feeding, carding and lapping systems. Although the composite felt is formed by one-step method, the required equipment cost is huge.

Disclosure of Invention

Aiming at the problems, the invention discloses a fiber-reinforced light thermoplastic non-interface layered felt material for interior and exterior trim of a passenger car, a device and a preparation method thereof, and the invention is realized by the following technical scheme:

the invention discloses a fiber-reinforced light thermoplastic non-interface layered felt material for interior and exterior decoration of passenger vehicles, which at least comprises an upper outer functional layer, a lower outer functional layer and a middle core layer rigid framework layer, wherein the felt material is a composite felt formed by cross lapping and needling between at least three or more rainbow single fiber nets comprising the two outer functional layers and the core layer rigid framework layer.

As a further improvement, the outer functional layer is a heat-insulating sound-absorbing layer or a toughening impact-resistant layer or an odor-improving layer or a hydrophobic oil-repellent layer, and the rigid skeleton layer of the core layer is mainly formed by opening and mixing 35% -65% of base material fibers and 65% -35% of reinforcing fibers.

The invention also discloses a device for preparing the fiber reinforced light thermoplastic non-interface layered felt material for the interior and exterior decoration of the passenger car, which comprises at least more than three bale openers, an all-in-one cotton feeding box connected with the bale openers, a carding machine connected with the cotton feeding box, a lapping machine connected with the carding machine, and a needle machine connected with the lapping machine.

As a further improvement, the cotton feeding box comprises at least more than three cotton feeding areas, each cotton feeding area comprises an input end, a conveying section and an output end, the input ends are connected with a bale opener, the output ends are connected with a carding machine through belt scales, the cotton feeding areas are separated through movable partition plates, the output ends comprise fixed baffle plates arranged on two sides of the belt scales, cotton feeding box body protecting plates and small partition plates arranged above the belt scales, and the conveying sections are divided into a conveying bin, a cotton homogenizing bin and a cotton conveying bin.

As a further improvement, a cotton storage box connected with the condenser is arranged in the input bin, and an output roller and an opening roller in the output direction of the output roller are arranged below the cotton storage box; the lower part of input storehouse is equipped with the feeding sensor, and the height-adjusting is from top to bottom gone up to the feeding sensor, and the lower extreme in input storehouse is equipped with horizontal end curtain and is used for placing and transporting cotton.

As a further improvement, the cotton homogenizing bin connected with the input bin comprises an inclined curtain connected with a horizontal bottom curtain and a cotton homogenizing roller forming a gap with the inclined curtain, convex needles are distributed on the inclined curtain and used for hooking cotton to be transported obliquely upwards, and the cotton homogenizing roller is positioned at the upper part of the inclined curtain and used for uniformly paving redundant cotton fibers to the cotton on the inclined curtain.

As a further improvement, the output bin connected with the cotton equalizing bin comprises a cotton stripping roller in the output direction of the inclined curtain and a cotton conveying channel with a valve and positioned below the cotton stripping roller, wherein stripping needles are distributed on the cotton stripping roller and used for stripping cotton conveyed by the inclined curtain to the cotton conveying channel with the valve, then conveying the cotton to an output port of the cotton feeding box and then conveying the cotton to the belt weigher.

The invention also discloses a preparation method of the fiber reinforced light thermoplastic interfacial-free layered felt material for the interior and exterior decoration of the passenger vehicle, which comprises the following steps:

1) respectively designing fiber raw materials and proportions of at least an upper outer functional layer and a lower outer functional layer and a core layer rigid skeleton layer according to functional requirements;

2) the fiber raw materials of each layer are respectively unpacked, mixed and opened by a corresponding unpacking machine and then are sent into an all-in-one cotton feeding box, and are sent into a cotton storage box through a cotton condenser;

3) the output roller outputs the fibers to fall to the horizontal bottom curtain through the opening roller, the fibers are transported through the horizontal bottom curtain and the inclined curtain, and the cotton equalizing roller peels the redundant fibers back to the fibers of the inclined curtain at the upper end of the inclined curtain;

4) the fiber is stripped from the inclined curtain by a stripping roller, sent into a cotton sending channel with a valve to be sent to an output port and then sent to a belt scale;

5) and sequentially sending the mixture to a carding machine for carding, a lapping machine for cross lapping and a needling machine for needling through a belt to finally synthesize the composite felt.

As a further improvement, the feeding amount of the cotton feeding box is 600-900kg/h, and the bulk density of each layer of felt material is 0.1-0.6g/cm³。

As a further improvement, the lapping layer number of the lapping machine is 20-40 layers, the plate distance of the needle machine is 16-20mm, the needle depth is 7-12mm, and the needle density is 40-100 needling times/cm²。

The invention has the following beneficial effects:

the invention solves the problems of abrasion and fracture of functional fibers of each layer caused by excessive needling in the multi-layer combined needling consolidation processing process of the multifunctional composite felt material; the multilayer felted mat has the problems of various performance losses at the interface caused by definite interface layering; the problem of working procedure time cost waste caused by the production of the felted mat after the functional layer and the framework layer are independently produced, and the like. In addition, compared with a multi-carding and multi-lapping process, the high equipment cost of a plurality of carding machines and lapping machines is saved; specifically, the method comprises the following steps:

1. the multifunctional integrated felt one-step forming process can be completed only by matching with one carding machine, one lapping machine and one needling machine, and the high equipment cost of a plurality of carding machines and lapping machines is saved compared with the multi-carding and multi-lapping needling process in the patent CN 105437699A.

2. The cotton feeder has the advantages that the cotton is simultaneously fed with multiple fibers through the cotton feeder, then the fibers are combed by the carding machine together, the felt materials are multifunctional and flexibly selected, multiple processes required by a multilayer combined needling process and complex processes of material changing and washing equipment are avoided, the fiber raw materials and the proportion of each layer of felt materials are respectively designed according to functional requirements, and the felt materials are put into a corresponding bale opener to be produced.

3. The felt material is endowed with multifunctionality, the production yield is further improved, and the production capacity of equipment is released.

4. The problem of the felt material excessive needling brings the wearing and tearing and the fracture of functional fiber in the multilayer combined needling consolidation processing process is solved to the decline of material mechanical properties that excessive needling brought has been avoided.

5. The invention is formed by a multifunctional integrated felt one-step method, and solves the problem of process time cost waste caused by reproducing the felted felt after independently producing the surface layer and the core layer in the patent CN 105479888A.

6. In the whole process production, the raw materials are combined at a belt scale to form an integral material, the material is crossly lapped, the fiber ratio of the outer functional layer gradually transits from the outside to the inside between the interface layers to the rigid skeleton layer of the core layer, and no obvious interface layering exists. The method reduces various performance losses at the interface caused by definite interface layering of the multi-layer felted needled felt and the multi-comb multi-spread felt.

7. The cotton picking device is provided with an output roller for conveying fibers between two rollers, wherein opening needles are distributed on the opening roller for opening the fibers, convex needles are distributed on an inclined curtain for hooking cotton to be conveyed obliquely upwards, a cotton homogenizing roller is positioned at the upper part of the inclined curtain for uniformly paving redundant cotton fibers to cotton on the inclined curtain, stripping needles are distributed on a cotton stripping roller for stripping the cotton conveyed by the inclined curtain to a cotton conveying channel with a valve, then the cotton conveying channel is conveyed to an output port of a cotton feeding box, and then the cotton conveying channel is conveyed to a belt scale.

8. The invention further improves the production yield and releases the production capacity of equipment while endowing the felt with multiple functions.

Drawings

FIG. 1 is a flow diagram of a dry felting line apparatus for use in the present invention;

FIG. 2 is a schematic diagram of the structure of the apparatus of the present invention;

FIG. 3 is a schematic diagram of the structure of the output end of the present invention;

FIG. 4 is a schematic view of a cross-lapping process of the lapping machine of the present invention;

FIG. 5 is a side cross-sectional schematic view of a felt of the present invention.

In the figure, 1 is a condenser, 2 is a cotton storage box, 3 is an output roller, 4 is an opening roller, 5 is a feeding sensor, 6 is a horizontal bottom curtain, 7 is an inclined curtain, 8 is a cotton homogenizing roller, 9 is a cotton stripping roller, 10 is a cotton conveying channel with a valve, 11 is a belt scale, 12 is an opener, 13 is a cotton feeding box, 14 is a carding machine, 15 is a lapping machine, 16 is a needle machine, 17 is a cotton feeding box body guard plate, 18 is a small partition plate, 19 is a fixed baffle plate, 20 is a rainbow single fiber net, 21 is a directional rotary curtain, 22 is a compensation curtain, 23 is a lapping curtain, 24 is a fluffy rainbow fiber net, 25 is a net forming curtain and 26 is an output port.

Detailed Description

The technical solution of the present invention is further illustrated by the following specific examples:

the invention discloses a cotton feeding box 13 for preparing fiber reinforced light thermoplastic layered felt materials for interior and exterior decoration of passenger cars, and figure 1 is a flow chart of a dry-method felting line device adopted by the invention, and the device comprises three bale openers 12, an all-in-one cotton feeding box 13 connected with the bale openers 12, a carding machine 14 connected with the cotton feeding box 13, a lapping machine 15 connected with the carding machine 14, and a needling machine 16 connected with the lapping machine 15. 3 kinds of fibre enter into trinity of independently reforming transform feed cotton case 13 after opening the package system of opening (A, B, C), send into carding machine 14 in step and comb, then cross lapping through lapping machine 15, and the needle prickling concreties in needle loom 16 at last.

Fig. 2 is a schematic structural diagram of the device of the invention, fig. 3 is a schematic structural diagram of an output end of the invention, and the cotton feeding box 13 is used for preparing fiber reinforced lightweight thermoplastic laminated felt for interior and exterior decoration of a passenger car, the cotton feeding box 13 comprises three cotton feeding areas, the cotton feeding areas comprise an input end, a conveying section and an output end, the input end is connected with a bale opener 12, the output end is connected to a carding machine 14 through a belt scale 11, the cotton feeding areas are separated by movable partition plates, the output end comprises an output port 26 formed by fixed baffle plates 19 arranged at two sides of the belt scale 11, a cotton feeding box body protecting plate 17 and a small partition plate 18 arranged above the belt scale, and the conveying section is divided into an input bin, a cotton homogenizing bin and a cotton conveying bin.

The input end comprises a condenser 1, the condenser 1 is connected with a cotton storage box 2 in the input bin, an output roller 3 and an opening roller 4 in the output direction of the output roller 3 are arranged below the cotton storage box 2 in the input bin, the output roller 3 is two rollers rotating in opposite directions, cotton is conveyed between the two rollers, and opening needles are distributed on the opening roller 4 and used for opening.

The lower part of the input bin is provided with a feeding sensor 5, the feeding sensor 5 can adjust the height up and down, the lower end of the input bin is provided with a horizontal bottom curtain 6 for placing and transporting cotton, the cotton homogenizing bin connected with the input bin comprises an inclined curtain 7 connected with a horizontal bottom curtain 6 and a cotton homogenizing roller 8 forming a gap with the inclined curtain 7, convex needles are distributed on the inclined curtain 7 and used for hooking cotton to be transported obliquely upwards, the cotton homogenizing roller 8 is positioned at the upper part of the inclined curtain 7, the output bin connected with the cotton equalizing bin comprises a cotton stripping roller 9 in the output direction of the inclined curtain 7 and a cotton feeding channel 10 with a valve and positioned below the cotton stripping roller 9, stripping needles are distributed on the cotton stripping roller 9, the cotton conveying device is used for peeling cotton conveyed by the inclined curtains 7 to the cotton conveying channel 10 with a valve, then conveying the cotton to the output port 26 of the cotton feeding box 13, and then conveying the cotton to the belt weigher 11.

The working process of the cotton feeding machine is as follows: the fiber raw materials with different types and proportions are respectively sent into three groups of bale opening and opening systems and then are sent into a cotton storage box 2 by a fan through a cotton condenser 1. At this time, if the feeding sensor 5 is not shielded by the fiber, the delivery roller 3 starts to operate, and the fiber is delivered through the opening roller 4 and falls down to the horizontal bottom curtain 6. And is transported to the back passage through the horizontal bottom curtain 6 and the inclined curtain 7. The cotton homogenizing roller 8 peels the redundant fibers back to the raw material box at the top end of the inclined curtain 7, and the opening and cotton homogenizing work is synchronously carried out. The fiber is stripped from the inclined curtain 7 by a stripping roller 9, sent into a cotton sending channel 10 with a valve and finally gathered into three rainbow cotton in the left, the middle and the right by a belt scale 11.

The cotton feeding box 13 is divided into a left bin, a middle bin and a right bin, and the three bins work independently. Fiber raw materials and proportions of an outer functional layer, a core layer rigid framework layer and an outer functional layer are respectively designed according to functional requirements, fibers in all bins are respectively sent to a belt scale 11 to be combined into rainbow cotton which sequentially corresponds to all layers of a felt material from left to right, then the fibers are uniformly sent to a carding machine 14, and the three rainbow cotton outputs the fibers at an output port 26 of the belt scale 11 and a cotton feeding box 13 respectively. The respective widths of three rainbow cotton can be controlled by controlling a small partition plate 18 in the middle of the output end of a cotton feeding box 13, the three rainbow cotton is converged at the rear end of a belt scale 11 and then transported to the rear channel to form three rainbow cotton which sequentially corresponds to an outer functional layer, a core layer rigid framework layer and an outer functional layer from left to middle and right, the three rainbow cotton is synchronously fed into a carding machine 14, three rainbow single fiber nets are formed in respective regions from left to middle and right after being carded by the carding machine 14, and the rainbow single fiber nets are crosslapped to obtain a composite felt which sequentially comprises the outer functional layer, the core layer rigid framework layer and the outer functional layer from top to bottom.

Fig. 4 is a schematic diagram of a cross lapping process of three rainbow single fiber nets, i.e., three rainbow single fiber nets 20, in which three rainbow cotton fibers are carded by a carding machine 14 to form an outer functional layer (triangle), a core layer rigid skeleton layer (circle) and an outer functional layer (square) in respective left, middle and right regions, and after entering a lapping machine 15, the rainbow single fiber nets are crossed and lapped by a directional rotary curtain 21, a compensation curtain 22 and a lapping curtain 23 to obtain a fluffy rainbow fiber net 24, in which the upper part, the middle part and the lower part are the outer functional layer (triangle), the core layer rigid skeleton layer (circle) and the outer functional layer (square), in a net forming curtain 25.

Fig. 5 is a schematic side cross-sectional view of the felt manufactured by the device of the invention, in which a single fiber net is arranged inside a dotted line frame, and the fluffy rainbow fiber net is consolidated by needling to form the novel fiber-reinforced lightweight thermoplastic non-interface layered felt material for the interior and exterior trim of passenger cars.

The felt material is sequentially provided with an outer functional layer, a core layer rigid framework layer and an outer functional layer from top to bottom, and the multilayer structure is an integral structure in carding, lapping and needling processes and has no obvious interface layering. The sound absorption and noise reduction layer, the toughening and impact resistant layer, the odor improvement layer and the temperature resistant heat insulation layer are composite fiber structures obtained by opening and mixing thermoplastic base material fibers serving as bonding matrixes and chemical fibers, inorganic fibers or natural fibers serving as functional materials, and the rigid framework layer is a composite fiber structure obtained by opening and mixing thermoplastic base material fibers serving as bonding matrixes and reinforcing fibers serving as reinforcing materials.

The outer functional layer or the heat and sound insulation layer and the toughening and impact resistant layer are mainly formed by opening and mixing cotton by 20-60% of base material fiber and 40-80% of polyester fiber, 30-70% of base material fiber and 70-30% of reinforcing fiber or 20-40% of base material fiber, 20-40% of polyester fiber and 20-40% of reinforcing fiber.

The outer functional layer or the odor improving layer is mainly formed by opening and mixing 30% -70% of base material fibers and 70% -30% of natural fibers.

The outer functional layer or the temperature-resistant flame-retardant layer is mainly formed by opening and mixing 20-60% of flame-retardant modified base material fiber and 40-80% of flame-retardant modified polyester fiber, 30-70% of flame-retardant modified base material fiber and 70-30% of reinforcing fiber or 20-40% of flame-retardant modified base material fiber, 20-40% of flame-retardant modified polyester fiber and 20-40% of reinforcing fiber.

The outer functional layer or the hydrophobic oil-repellent layer is mainly formed by opening and mixing 20-60% of hydrophobic modified base material fiber and 40-80% of hydrophobic modified polyester fiber, 30-70% of hydrophobic modified base material fiber and 70-30% of reinforcing fiber or 20-40% of hydrophobic modified base material fiber, 20-40% of hydrophobic modified polyester fiber and 20-40% of reinforcing fiber.

The rigid skeleton layer of the core layer is mainly formed by opening and cotton mixing of 35% -65% of base material fibers and 65% -35% of reinforcing fibers.

The base material fiber is one or more of polypropylene fiber, polyamide fiber, polyethylene terephthalate fiber and polylactic acid fiber, and can even be multicomponent blend fiber; the reinforcing fiber is one or more of glass fiber, hemp fiber, bamboo fiber, basalt fiber and carbon fiber.

The novel fiber-reinforced light thermoplastic non-interface layered felt for interior and exterior trim of passenger cars needs to endow the felt with different functionalities, the gram weight is correspondingly higher than that of a common felt, the feeding amount of a cotton feeding box 13 needs to be correspondingly increased in production, and the adjustment range is adjusted from 500kg/h of 300-type materials to 900kg/h of 600-type materials. Thereby further improving the production capacity.

In addition, the width and the surface density of the left, middle and right parts of the rainbow single fiber net are changed by adjusting the feeding amount of the three bins of the three-in-one cotton feeding box 13 and adjusting the discharging width of different bins through the middle movable partition plate at the output end. Finally, the upper, middle and lower layers of the resulting felt are given different thicknesses and bulk densities. The densities of the upper layer felt, the middle layer felt and the lower layer felt can be freely controlled, and the adjustable range is 0.1-0.6g/cm³. In order to match the high input of the three-in-one cotton feeding box 13, the number of layers of the lapping layer of the lapping machine 15 needs to be lifted from 10-30 layers to 20-40 layers. In order to match the fluffy fiber web output by the lapping machine 15, the plate pitch of the needle machine 16 needs to be lifted from 12-18 to 16-22, and the needle depth and the needle density of the needle machine 16 are respectively lifted by 10-50%.

The following is a comparative example of a felt prepared by the apparatus of the present invention with the rest of the felt.

Implementing one step:

the novel fiber-reinforced light thermoplastic non-interface layered felt material structure for the interior and exterior decoration of the passenger car comprises a toughening layer, a framework layer and a toughening layer from top to bottom, and the specific preparation process comprises the following steps:

firstly, 40% of polypropylene fiber and 60% of polyester fiber are respectively put into a bale opening system A, 45% of polypropylene fiber and 55% of glass fiber are put into a bale opening system B, 40% of polypropylene fiber and 60% of polyester fiber are put into a bale opening system C, after bale opening and opening processes, the materials are sent into a three-in-one cotton feeding box 13 according to the mass ratio of 2:3:2, the width of the position of a belt scale 11 is set to be 2:3:2, then the positions of the belt scale 11 are converged into three rainbow cotton in the left, middle and right, after synchronous feeding into a carding machine 14 for carding, three rainbow single fiber nets (shown in figure 4) corresponding to a toughening layer, a framework layer and the toughening layer in sequence are formed in the respective areas of the left (triangle) and the right (square), and then the rainbow single fiber nets are crossly lapped and needled to be consolidated to obtain a rainbow felt (shown in figure 5).

For comparison, three rolls of felt materials are obtained by unpacking, opening, carding, lapping and needling 40% of polypropylene fibers and 60% of polyester fibers, 45% of polypropylene fibers and 55% of glass fibers and 40% of polypropylene fibers and 60% of polyester fibers respectively, and the surface density ratio of the felt materials is controlled to be 2:3: 2. Then, three rolls of felt materials are sequentially laid and fed into a needling area, and the felt materials are needled and compacted to obtain the multi-layer needled felt.

For comparison, 40% of polypropylene fiber and 60% of polyester fiber, 45% of polypropylene fiber and 55% of glass fiber, and 40% of polypropylene fiber and 60% of polyester fiber are respectively subjected to respective unpacking, opening, carding and lapping systems, and then are sequentially lapped to obtain the fluffy fiber net with the three-layer structure. And then, entering a needling area to compact the felt material to obtain the multi-comb multi-spreading felt.

Ensure the surface density of the three (1400 g/m)²) And (5) under the consistent condition, pressing the pressure to obtain a plate with the thickness of 4mm, and comparing the production differences of the three processes.

The preparation of the multi-layer felts requires the minimum equipment, and only one set of unpacking and opening system, one cotton feeding box 13, one carding machine 14, one lapping machine 15 and one needle machine 16 are needed. However, in the process, structures with different components need to be felted separately, then single-component felts are felted together, four processes are needed to complete felting, and after one component proportion is completed, the residual materials in the equipment need to be cleaned up before the next process can be carried out. Therefore, the process is time-consuming and labor-consuming, has low yield, and is prone to material waste.

The preparation of the multi-comb multi-spreading felt and the rainbow felt is a one-step method, and the preparation of the felt material with the multilayer structure can be completed only by putting the designed fiber proportion into the corresponding bale opener 12. The two methods have simple processes, can greatly improve the production efficiency and realize continuous production. Compared with rainbow felt preparation, the multi-carding and multi-paving process needs to be additionally provided with two carding machines 14 and two lapping machines 15, the two machines are the most expensive machines except a needle machine 16 in the whole production line, the equipment investment is probably doubled, and the energy consumption and the maintenance cost are also increased.

And comparing the mechanical properties of the finally formed plate by the three processes. Among them, the bending strength and the tensile strength of the rainbow boards are optimal. The excessive damage of rigid fibers of each layer in the process of the multi-layer needling process during the needling consolidation obviously reduces the bending strength and the tensile strength of the formed plate. The rainbow felt three-layer structure is an integral structure in carding, lapping and needling processes, and the fiber proportion of the toughening layer gradually transits from the outside to the inside to the rigid framework layer between the interface layers, so the fiber proportion at the interface layers is a gradual change process. The toughness structure and the strength structure of the plate are better combined, so that the mechanical property of the plate is further improved. The three-layer structure interface of the plate obtained by the multi-comb multi-paving process is definite, so that the mechanical property of the plate has certain loss at the interface, and the mechanical property of the plate is slightly inferior to that of a rainbow plate.

The second implementation:

the fiber-reinforced light thermoplastic low-equipment-cost interface-layering-free high-sound-absorption-property integrated felt material structure is provided with a sound insulation layer, a framework layer and a sound absorption layer from top to bottom, and the specific preparation process comprises the following steps:

firstly, 80% of polypropylene fiber and 20% of polyester fiber are respectively put into a bag opening system A, 50% of polypropylene fiber and 50% of glass fiber are put into a bag opening system B, 40% of polypropylene fiber and 60% of polyester fiber are put into a bag opening system C, the materials are sent into a three-in-one cotton feeding box 13 according to the mass ratio of 1:2:4 after bag opening and opening processes, the width of the belt scale 11 is set to be 1:6:3, then the belt scale 11 is converged into three rainbow cotton in the left, middle and right, the three rainbow single fiber nets in the left (triangle) and the right (square) respectively form three rainbow single fiber nets corresponding to a sound insulation layer, a framework layer and a sound absorption layer in sequence after synchronous feeding and carding by a carding machine 14 (as shown in figure 4), and the rainbow single fiber nets are obtained after cross lapping and needle punching consolidation (as shown in figure 5).

For comparison, three rolls of felt materials are obtained by unpacking, opening, carding, lapping and needling 80% of polypropylene fibers and 20% of polyester fibers, 50% of polypropylene fibers and 50% of glass fibers and 40% of polypropylene fibers and 60% of polyester fibers respectively, and the surface density ratio of the felt materials is controlled to be 1:2: 4. Then, three rolls of felt materials are sequentially laid and fed into a needling area, and the felt materials are needled and compacted to obtain the multi-layer needled felt.

For comparison, 80% of polypropylene fiber and 20% of polyester fiber, 50% of polypropylene fiber and 50% of glass fiber, and 40% of polypropylene fiber and 60% of polyester fiber are respectively subjected to respective unpacking, opening, carding and lapping systems, and are sequentially lapped to obtain the fluffy fiber net with the three-layer structure. And then, entering a needling area to compact the felt material to obtain the multi-comb multi-spreading felt.

Ensure the surface density of the three (1400 g/m)²) And (3) under the condition of consistency, pressing the plates into plates with the same thickness (7mm) by the same plate making process, and comparing.

Table 1: impedance tube test sound absorption performance of plate obtained by three processes

The rigid fiber is seriously broken due to excessive needling caused by multi-layer combined needling, so that the rigid fiber cannot reach the designed expansion capacity after the material is molded, a better cavity structure cannot be formed on the plate, and the sound absorption performance of the material is reduced.

The body density of each layer in the felt three-layer structure obtained by the multi-comb multi-paving process cannot be controlled independently, and the felt can be formed freely only by virtue of the expansion capacity of each layer of fiber, so that the structure with obvious difference in body density cannot be obtained.

The rainbow felt has the advantage of controlling the density of each layer in the three-layer structure through the adjustment of the middle movable partition plate at the outlet of the three-in-one cotton feeding box 13. Thereby endowing the board with differentiated bulk density, and having better sound absorption performance in each frequency band. In addition, the three-layer structure of the rainbow felt is an integral structure in the carding, lapping and needling processes, and after cross lapping, the interface layers are gradually transited from the outer part to the inner part to the rigid skeleton layer of the core layer from the fiber proportion of the sound insulation layer or the sound absorption layer, so the change of the bulk density at the interface layers is also a gradual change process. The structural characteristic further improves the energy consumption of sound waves in the plate, and the sound absorption performance of the plate is further improved.

The above description is only a preferred embodiment of the present invention, and the present invention is not limited to the above embodiments, and other modifications and variations directly derived or suggested by those skilled in the art without departing from the spirit and concept of the present invention should be considered to be included in the protection scope of the present invention.