Glass fiber composite felt, pressed product using same and preparation method of pressed product

Abstract

The invention relates to a glass fiber composite felt, a pressed product using the same and a preparation method. The glass fiber composite felt comprises a glass fiber chopped strand mat and a composite layer, the composite layer is provided with pores, the overall porosity of the composite layer is lower than that of the glass fiber chopped strand mat, and the overall thermal shrinkage rate of the composite layer is larger than that of the glass fiber chopped strand mat. The overall thickness of the composite layer is smaller than that of the glass fiber chopped strand mat, the weight of the composite layer per unit area is smaller than that of the glass fiber chopped strand mat per unit area, and the glass fiber composite mat is used for being compounded with a base material in a pressed product formed in a hot pressing mode so as to improve the strength of the pressed product. By comprehensively considering factors such as thermal shrinkage, size and dosage and optimizing materials and interlayer gradient design, the problems of excessive permeation of chemical substances and indentation or damage on the surface of a product can be effectively relieved, the problem of shrinkage deformation in hot-pressing production can be further relieved, and the surface quality and shape precision of the product can be improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of glass fiber materials, and particularly relates to a glass fiber composite mat and a pressed product using the same and a preparation method thereof. Background Art

[0002] Glass fiber chopped strand mat has a wide range of uses in the field of decorative material production. For example, when producing automotive interior parts, the substrate is heated and pressed together with the surface layer material and the back layer material by hot pressing. Glass fiber chopped strand mat is used as a reinforcing material between the substrate and the surface layer material and between the substrate and the back layer material to improve the strength of the product and ensure mechanical properties. Although glass fiber chopped strand mat can significantly improve the strength of the product, it has a high porosity and a rough texture. During the implementation of the hot pressing process, the chemical substances used to bond the substrate and the glass fiber chopped strand mat are prone to excessive penetration. A higher pressing force is also likely to cause indentations or damage to the materials adjacent to the glass fiber chopped strand mat, affecting the appearance quality of the product. Pre-compounding a layer of non-woven fabric on one side of the glass fiber chopped strand mat close to the outer layer material can solve the above problems to a certain extent. However, this layer of non-woven fabric is closely compounded with the glass fiber chopped strand mat, and the difference in thermal shrinkage between the two materials makes the improvement of the surface quality of the hot-pressed product not obvious, and the shape accuracy may even become lower. Summary of the Invention

[0003] To further solve the technical problems, the present invention provides a glass fiber composite mat and a pressed product using the same and a preparation method thereof.

[0004] The technical solution of the present invention is as follows:

[0005] A glass fiber composite mat, the glass fiber composite mat includes a glass fiber chopped strand mat and a composite layer. The composite layer has pores and its overall porosity is lower than the porosity of the glass fiber chopped strand mat, its overall thermal shrinkage rate is greater than the thermal shrinkage rate of the glass fiber chopped strand mat, the overall thickness of the composite layer is lower than the overall thickness of the glass fiber chopped strand mat, and its weight per unit area is less than the weight per unit area of the glass fiber chopped strand mat.

[0006] A glass fiber composite mat as described above, the glass fiber composite mat is used in a pressed product formed by hot pressing to be compounded with a substrate to improve the strength of the pressed product. The glass fiber chopped strand mat is used to be combined with the substrate through an adhesive layer, and the composite layer is arranged on the side of the glass fiber chopped strand mat facing away from the substrate.

[0007] A glass fiber composite mat as described above, the composite layer is a glass fiber surface mat.

[0008] A glass fiber composite mat as described above, the content of glass fiber in the fiber material of the glass fiber surface mat is more than 65%.

[0009] A glass fiber composite felt as described above, wherein the glass fiber surface felt contains regulating fibers with a total content ranging from 0.4% to 11%, and the regulating fibers are cellulose fibers and / or lignin fibers.

[0010] A glass fiber composite felt as described above, wherein the glass fiber surface felt at least comprises a first layer and a second layer. The first layer is composite with the chopped glass fiber mat, and the second layer is composite on the side of the first layer facing away from the chopped glass fiber mat. The fiber material of the first layer does not contain regulating fibers, and the fiber material of the second layer contains regulating fibers. Alternatively, both the fiber materials of the first layer and the second layer contain regulating fibers, and the content of regulating fibers in the fiber material of the first layer is lower than that in the fiber material of the second layer.

[0011] A glass fiber composite felt as described above, wherein the glass fiber surface felt further comprises an Nth layer arranged in sequence with the first layer and the second layer, and the content of regulating fibers in the fiber material increases gradually from the first layer to the Nth layer.

[0012] A glass fiber composite felt as described above, wherein a non-woven fabric layer is further composite on the outermost side of the glass fiber surface felt.

[0013] The present invention also provides a pressed product formed by a hot pressing method, comprising:

[0014] A base material;

[0015] The glass fiber composite felt as described above, wherein the glass fiber composite felt is combined with one side or both sides of the base material through an adhesive layer;

[0016] A product surface layer material and a product back layer material, wherein the product surface layer material and / or the product back layer material are composite with the glass fiber composite felt.

[0017] The present invention also provides a preparation method of the glass fiber composite felt as described above. When producing the chopped glass fiber mat, the composite layer is composite on the chopped glass fiber mat in a pressing manner to form a preform.

[0018] The beneficial effects of the present invention are as follows:

[0019] The glass fiber composite felt disclosed by the present invention composites at least one composite layer with pores and a porosity lower than that of the chopped glass fiber mat on the basis of the chopped glass fiber mat through a prefabrication method. By comprehensively considering factors such as thermal shrinkage, size, and dosage, and optimizing the material and interlayer gradient design, it can not only effectively alleviate the problems of excessive penetration of chemical substances and indentation or damage on the product surface, but also further alleviate the shrinkage deformation problem in hot pressing production, and improve the surface quality and shape accuracy of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] By reading the following detailed description of the preferred embodiments, the solutions and advantages of the present application will become clear to those of ordinary skill in the art. The drawings are only for the purpose of showing the preferred embodiments and are not considered to be a limitation of the present invention.

[0021] In the drawings:

[0022] Figure 1 is a schematic structural diagram of a glass fiber composite mat according to an embodiment of the present invention (composite single-layer surface mat);

[0023] Figure 2 is a schematic diagram of the application of a glass fiber composite mat according to an embodiment of the present invention in the preparation of a pressed part Figure 1 ;

[0024] Figure 3 is a schematic structural diagram of another glass fiber composite mat according to an embodiment of the present invention (composite multi-layer surface mat);

[0025] Figure 4 is a schematic structural diagram of another glass fiber composite mat according to an embodiment of the present invention (composite single-layer surface mat + non-woven fabric);

[0026] Figure 5 is a schematic structural diagram of another glass fiber composite mat according to an embodiment of the present invention (composite multi-layer surface mat + non-woven fabric);

[0027] Figure 6 is a schematic diagram of the application of a glass fiber composite mat according to an embodiment of the present invention in the preparation of a pressed part Figure 2 ;

[0028] Figure 7 is a schematic diagram of the application of a glass fiber composite mat according to an embodiment of the present invention in the preparation of a pressed part Figure 3 .

[0029] The components represented by the reference numerals in the drawings are:

[0030] substrate 10, glass fiber composite mat 20, chopped glass fiber mat 21, composite layer 22, first layer 221, second layer 222, non-woven fabric layer 23, product surface layer material 30, product back layer material 40, intermediate film 50. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0031] Example 1

[0032] See Figure 1 , Figure 2 , the first glass fiber composite mat 20 provided in this embodiment includes a chopped glass fiber mat 21 and a composite layer 22.

[0033] Figure 2 Illustrated is an application of the glass fiber composite mat 20 in preparing a pressed part, which requires hot pressing to heat and press-combine the substrate 10 with the product surface layer material 30 and the product back layer material 40. Among them, the glass fiber composite mat 20 of the present invention is used as a reinforcing material between the substrate 10 and the product surface layer material 30 and between the substrate 10 and the product back layer material 40 to improve the strength of the product and ensure the required mechanical properties.

[0034] The pressed part in this embodiment is used to prepare automotive interior parts, and the substrate 1 is made of polyurethane (PU) material.

[0035] In the above application, the chopped glass fiber mat 21 of the glass fiber composite mat 20 is used to bond with the substrate 10 through an adhesive layer, and the composite layer 22 is arranged on the side of the chopped glass fiber mat 21 facing away from the substrate 10. Specifically, the composite layer 22 is prefabricated on the side of the chopped glass fiber mat 21 facing away from the substrate 10 by a pressing method. The composite layer 22 in this embodiment has pores and its overall porosity is lower than that of the chopped glass fiber mat 21, and its overall thermal shrinkage rate is greater than that of the chopped glass fiber mat 21. Further, in order to better achieve the comprehensive effect, the overall thickness of the composite layer 22 is lower than the overall thickness of the chopped glass fiber mat 21 and its weight per unit area is less than the weight per unit area of the chopped glass fiber mat 21. For example, when the weight per unit area (m 2 ) of the chopped glass fiber mat 21 is above 150 g, the overall weight per unit area (m 2 ) of the composite layer 22 is not more than 100 g.

[0036] In this embodiment, a glass fiber surface mat that meets the above conditions is specifically selected as the preferred material for the composite layer 22. The fiber material of the glass fiber surface mat should be mainly glass fiber, that is, the glass fiber content is above 65%, up to 100% at most.

[0037] The bonding of the chopped strand mat 21 of glass fiber to the substrate 10 and the process of preparing pressure products such as automotive interior parts by hot pressing and laminating multi-layer materials are processes well-known to those skilled in the art, and will not be elaborated here. The innovation of this embodiment lies in that a glass fiber surface mat with pores is used as the composite layer 22 and is laminated with the chopped strand mat 21 of glass fiber, which will not completely block the penetration of the aforementioned chemical substances, allowing the liquid phase substances to have a certain degree of penetration, while making the porosity of the composite layer 22 lower than that of the chopped strand mat 21 of glass fiber, and will not cause excessive penetration of chemical substances and have a great impact on adjacent material layers. Making the porosity of the composite layer 22 lower than that of the chopped strand mat 21 of glass fiber can also ensure that the composite layer 22 has a better texture and a smoother surface. In this way, during the hot pressing process, a higher pressing force will not easily cause indentations or damage to the materials adjacent to the glass fiber composite mat, affecting the appearance quality of the product. Compared with other types of composite layer materials such as non-woven fabrics, the glass fiber surface mat has a lower gradient change in thermal shrinkage rate with the chopped strand mat 21 of glass fiber, thus can well weaken the impact of the hot pressing process on the surface quality and shape accuracy of the product.

[0038] According to production verification, using the glass fiber surface mat as the composite layer 22 has no obvious difference in preventing excessive penetration of chemical substances compared with using non-woven fabric as the composite layer 22, but the surface dark marks of the hot-pressed product using the glass fiber surface mat as the composite layer 22 are reduced, and the edge neatness of the untrimmed blank is better than that using non-woven fabric as the composite layer 22. However, as a more preferred embodiment, the glass fiber surface mat contains regulating fibers with a total content range of 0.4%-11%, specifically selected from cellulose fibers (such as cotton fibers) and lignin fibers, which can more flexibly adjust the thermal shrinkage rate of the composite layer 22, construct a finer transition gradient, and thus obtain a more obvious improvement effect. For example, in Figure 3 In a further improved glass fiber composite mat structure as shown, the glass fiber surface mat is divided into two layers, namely: including the first layer 221 and the second layer 222. The first layer 221 is laminated with the chopped strand mat 21 of glass fiber, and the second layer 222 is laminated on the side of the first layer 221 away from the chopped strand mat 21 of glass fiber. For the purpose of further decomposing the thermal shrinkage rate gradient, the fiber material of the first layer 221 may not contain regulating fibers, and only the fiber material of the second layer 222 contains 0.4%-11% of regulating fibers. Or, both the fiber materials of the first layer 221 and the second layer 222 contain regulating fibers, and the content of regulating fibers in the fiber material of the first layer 221 is lower than that in the fiber material of the second layer 222. For example, the content of regulating fibers in the fiber materials of the first layer 221 and the second layer 222 are 2% and 8% respectively.

[0039] Of course, according to the above improvement principle, the glass fiber surface mat may further include an Nth layer (N≥3) arranged in sequence with the first layer 221 and the second layer 222, and the fiber content is adjusted to increase gradually from the fiber material of the first layer 221 to the Nth layer.

[0040] In fact, it has been observed in production verification that when the glass fiber surface mat is only divided into the first layer 221 and the second layer 222, the gradient difference in the proportion of the adjusted fiber content in the two layers can reach more than 5%, which can significantly reduce the surface dark marks of the hot-pressed product and improve the problem of uneven edges of the untrimmed blank (caused by the difference in material thermal shrinkage rate). The apparent effect that can be increased by continuing to increase the number of layers of the glass fiber surface mat is no longer obvious. Therefore, considering the actual verification effect, actual process requirements, cost, etc. comprehensively, it is best that the glass fiber surface mat does not exceed three layers at most.

[0041] Figure 4 、 Figure 5 is different from Figure 3 Another structural schematic diagram of a glass fiber composite mat, in the Figure 4 、 Figure 5 In the glass fiber composite mat shown, a non-woven fabric layer 23 is further laminated on the outermost side of the single-layer or multi-layer glass fiber surface mat. In the case where the glass fiber surface mat has been adopted, the non-woven fabric material can be used as the final gradient layer, and moreover, the non-woven fabric material also has good isolation advantages for certain chemical adhesives.

[0042] Example 2

[0043] Based on Example 1, this example also proposes a pressed product formed by hot pressing, including:

[0044] Base material 10;

[0045] The glass fiber composite mat 20 described in Example 1, and the glass fiber composite mat is combined with one side or both sides of the base material 10 through an adhesive layer;

[0046] Product surface layer material 30 and product back layer material 40, and the product surface layer material 30 and / or the product back layer material 40 are laminated with the glass fiber composite mat.

[0047] When producing pressed parts such as automotive interior parts, the glass fiber composite mat 20 provided by the present invention can be arranged on both sides of the base material 1 as shown in Figure 2 , or can be arranged on one side of the base material 1 as shown in Figure 6 (that is, the other side of the base material 1 still remains as a single material of glass fiber chopped mat), which is determined according to production needs. For example, in this Figure 6In it, an intermediate film 50 (such as a resin film) is further included inside the surface layer material 30 of the product. For this reason, instead of using the glass fiber composite felt 20 provided by the present invention inside the intermediate film 50, a traditional chopped strand mat of glass fiber is used, and only the glass fiber composite felt 20 provided by the present invention is used inside the back layer material 40 of the product.

[0048] It should be noted that the above examples should not be construed as a limitation to the present technology. According to needs, those skilled in the art can also use the glass fiber composite felt 20 provided by the present invention inside the intermediate film 50 Figure 6 even only inside the intermediate film 50. As shown in Figure 7 , it is also possible to use the glass fiber composite felt 20 provided by the present invention on both the side of the surface layer material 30 of the product and the side of the back layer material 40 of the product according to the respective characteristics or specific needs of the surface layer material 30 of the product and the back layer material 40 of the product, but the number of layers of the glass fiber surface mat used in the glass fiber composite felt 20 is different.

[0049] For the above-mentioned various layers of materials, except that the glass fiber composite felt 20 is a prefabricated product, the rest can be prepared separately. The various layers of materials are laminated by gluing and laying in the order described above, and are formed into a pressed product by heating and pressing in a mold. And, in the production verification carried out in the above Examples 1 to 2, the base material 10 used is a polyurethane material.

[0050] Example 3

[0051] The present invention also provides a preparation method for the glass fiber composite felt of Example 1. Specifically, when producing the chopped strand mat 21 of glass fiber, the composite layer 22 is laminated on the chopped strand mat 21 of glass fiber in a pressing manner to form a prefabricated product. More specifically, when the chopped strand mat 21 of glass fiber exits the oven, the composite layer 22 can be laminated on the chopped strand mat 21 of glass fiber in a pressing manner by a pressing roller to form the glass fiber composite felt 20. The above pressing process generally belongs to cold pressing lamination. Among them, when the composite layer 22 is a multi-layer structure, the multi-layer structure can be pre-laminated to form a prefabricated composite layer 22, or the multi-layer material can be laminated together with the chopped strand mat 21 of glass fiber.

[0052] It should be noted that although the chopped glass fiber mat 21 in the glass fiber composite mat 20 shown in the embodiments of the present invention and the drawings seems to be a conventional single-layer mat, this does not limit the invention patent. According to any other needs, the chopped glass fiber mat 21 can also be selected from single-layer mats or multi-layer mats. For example, if the chopped glass fiber mat 21 is designed as a multi-layer mat, regulating fibers (cellulose fibers and / or wood fibers) are added to the mat layer on the side away from the substrate 10, which is also beneficial to refining the thermal shrinkage gradient. In this case, basalt fibers can also be added to the mat layer close to the substrate 10 for modification.

[0053] The above are only the preferred specific embodiments of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention, according to the technical solution and inventive concept of the present invention, makes equivalent substitutions or changes, and should be covered within the protection scope of the present invention.

Claims

1. A glass fiber composite mat, characterized in that, The glass fiber composite mat (20) includes a chopped glass fiber mat (21) and a composite layer (22). The composite layer (22) has pores and its overall porosity is lower than that of the chopped glass fiber mat (21). Its overall heat shrinkage rate is greater than that of the chopped glass fiber mat (21). The overall thickness of the composite layer (22) is lower than the overall thickness of the chopped glass fiber mat (21), and its weight per unit area is less than the weight per unit area of the chopped glass fiber mat (21).

2. A glass fiber composite mat according to claim 1, characterized in that, The glass fiber composite mat is used for being compounded with a substrate (10) in a pressed product formed by a hot pressing method to improve the strength of the pressed product. The chopped glass fiber mat (21) is used for being combined with the substrate (10) through an adhesive layer. The composite layer (22) is disposed on a side of the chopped glass fiber mat (21) away from the substrate (10).

3. The fiberglass composite felt according to claim 2, wherein The composite layer (22) is a glass fiber surface mat.

4. A fiberglass composite mat according to claim 3, wherein, The glass fiber content in the fiber material of the glass fiber surface mat is above 65%.

5. A glass fiber composite felt according to claim 4, wherein, The glass fiber surface mat contains regulating fibers with a total content range of 0.4% - 11%. The regulating fibers are cellulose fibers and / or lignin fibers.

6. The fiberglass composite mat according to claim 5, wherein, The glass fiber surface mat at least includes a first layer (221) and a second layer (222). The first layer (221) is compounded with the chopped glass fiber mat (21). The second layer (222) is compounded on a side of the first layer (221) away from the chopped glass fiber mat (21). The fiber material of the first layer (221) does not contain regulating fibers. The fiber material of the second layer (222) contains regulating fibers. Or, both the fiber materials of the first layer (221) and the second layer (222) contain regulating fibers, and the content of regulating fibers in the fiber material of the first layer (221) is lower than the content of regulating fibers in the fiber material of the second layer (222).

7. The fiberglass composite felt according to claim 6, wherein, The glass fiber surface mat further includes an Nth layer (N≥3) sequentially arranged with the first layer (221) and the second layer (222). The content of regulating fibers in the fiber material increases from the first layer (221) to the Nth layer.

8. A fiberglass composite mat according to any one of claims 3-7, characterized in that, A non-woven fabric layer (23) is further compounded on the outermost side of the glass fiber surface mat.

9. A pressed product formed by hot pressing, characterized in that, Comprising: A substrate (10); The glass fiber composite mat according to any one of claims 1 - 8, and the glass fiber composite mat is combined with one side or both sides of the substrate (10) through an adhesive layer; A product surface layer material (30) and a product back layer material (40), and the product surface layer material (30) and / or the product back layer material (40) are compounded with the glass fiber composite mat.

10. A method for preparing the glass fiber composite felt according to any one of claims 1-8, characterized in that, When producing the chopped glass fiber mat (21), the composite layer (22) is compounded on the chopped glass fiber mat (21) in a pressing manner to form a pre-product.

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