Preparation process of automobile instrument desk

Abstract

The invention relates to a preparation process of an automobile instrument desk, and mainly solves the problems of installation defects and safety risks caused by coating an instrument desk with a fiber material in the prior art. When polyether polyol sponge or polyester polyol sponge is used as a sponge layer, the aging resistance is not excellent enough. The novel preparation process of the automobile instrument desk comprises the following steps: (1) preparing a leather layer; (2) preparing a synthetic polyether ester composite sponge layer: cutting the synthetic polyether ester composite sponge layer according to the thickness of a framework pre-buried groove; a first non-woven fabric layer, synthetic polyether ester sponge and a second non-woven fabric layer are sequentially stacked on the synthetic polyether ester composite sponge layer from top to bottom; compounding in a flame compounding manner to obtain a synthetic polyether ester composite sponge layer; (3) weakening is conducted; and (4) coating. According to the technical scheme, the problem is well solved.

Description

Technical Field

[0001] The invention relates to a preparation process of an automobile instrument panel. Background Art

[0002] At present, the surface decoration materials of automobile dashboards generally use two materials: plastic skeleton pre-embedded with low-tear 3dmesh and then PVC skin. In the past, the design used a unified skeleton groove to place the low-tear 3dmesh, that is, the depth of the skeleton groove is the same as the height of the low-tear 3dmesh. Due to the different corresponding tensile areas during the later manual coating, and the low-tear 3dmesh will be compressed, it is easy to cause various appearance defects during the production process, especially the soft and hard junctions are prone to marks. In order to avoid the appearance of soft and hard junction lines and affect the appearance quality, the existing technology adjusts the mold in the area where the soft and hard junction marks are obvious. However, this method will lead to later design changes and mold adjustments of parts, consume manpower, and require a large amount of cost to adjust the mold. In addition, the raw material of low-tear 3dmesh is a fiber structure. After the dashboard is coated with low-tear 3dmesh, the airbag explodes with fiber splashing and cannot explode within the accurate explosion range, posing a risk of threatening personal safety.

[0003] At the same time, when using low-tear 3dmesh materials, the glue will penetrate into the 3dmesh material when pasting with glue, causing the overall material to be uneven and the flatness to be insufficient after pasting.

[0004] Chinese patent CN107298747A discloses a polyurethane foam material for automobile instrument panel, which is composed of the following mass ratio components, isocyanate: combination material = 1:1.6, and the composition of the combination material is calculated according to the following mass parts, and the specific mass parts are as follows: polyether 400 is 75-85 parts, polyether 403 is 15-25 parts; polyether 3320 is 8-12 parts; stabilizer is 2.8-3.5 parts; catalyst is 5-8 parts; foaming agent is 0.5-0.8 parts; water is 3.2-3.9 parts; flame retardant is 35-38 parts. Due to the reasonable combination of formula components and proper preparation method, the prepared foam material has high flame retardant performance and is not easy to burn when exposed to water. In addition, the material structure is compact and has high strength, which makes the instrument panel have good wear resistance and is convenient for use during injection molding. However, the foam sponge prepared by polyether polyol will deteriorate in the tensile and tearing properties of the prepared polyurethane sponge under high temperature conditions.

[0005] Polyester polyurethane sponge has excellent physical properties, but its aging resistance is poor. Under high temperature and high humidity conditions, its related mechanical properties (tensile strength, elongation at break) will decrease by 40-50%. Polyether sponge has good aging resistance. Under high temperature and high humidity conditions, its related mechanical properties are basically not affected much, but its overall performance such as tensile and tear strength is lower than that of polyester sponge. Summary of the invention

[0006] The technical problem to be solved by the present invention is that the use of fiber materials to cover the instrument panel in the prior art has installation defects and safety risks; when polyether polyol sponge or polyester polyol sponge is used as the sponge layer, the aging resistance is not good enough. A new preparation process for an automobile instrument panel is provided, which has the advantages of simple operation, and the prepared automobile instrument panel has excellent aging resistance and physical properties; and there is no risk of fiber splashing threatening personal safety during explosion.

[0007] In order to solve the above technical problems, the technical solution adopted by the present invention is as follows: a preparation process of an automobile instrument panel comprises the following steps in sequence:

[0008] (1) Preparing the leather layer: According to the specific internal dimensions of the vehicle model, the leather is cut into a specified shape according to the size of the instrument panel; the shape of the PVC leather after cutting can completely cover the instrument panel;

[0009] (2) preparing a synthetic polyetherester composite sponge layer: cutting the synthetic polyetherester composite sponge layer according to the thickness of the pre-buried groove of the skeleton; stacking the first non-woven fabric layer, the synthetic polyetherester sponge layer, and the second non-woven fabric layer in order from top to bottom; compounding by flame compounding; then cutting the synthetic polyetherester composite sponge layer into a specified shape according to the size of the pre-buried groove of the instrument panel; the shape of the cut synthetic polyetherester composite sponge layer is exactly consistent with the shape of the pre-buried groove;

[0010] (3) Weakening: First, weaken the skeleton layer of the instrument panel and open a weakening groove; then weaken the corresponding position of the synthetic polyether ester composite sponge layer; that is, weaken the position where the airbag is placed;

[0011] (4) Coating: The surfaces where the synthetic polyether ester composite sponge layer contacts the skeleton layer are sprayed with polyurethane water-based glue; the surfaces where the leather layer contacts the synthetic polyether ester composite sponge layer are also sprayed with polyurethane water-based glue; at room temperature, the leather layer completely covers the synthetic polyether ester composite sponge layer and the skeleton layer.

[0012] In the above technical solution, preferably, the method for preparing the synthetic polyetherester sponge comprises the following steps in sequence:

[0013] a) Preparation of component I: Add 30-70 parts of polyether polyol I, 40-60 parts of polyether polyol II, 10-40 parts of polymer polyol III, 1-4 parts of water, and amine catalyst into container A according to weight parts.

[0014] 0.1-1 part, tin catalyst: 0.1-1 part, foam stabilizer: 0.5-2 parts, flame retardant: 2-12 parts, flame compounding agent: 1-5 parts, stir evenly, stirring speed is 2000-3000rpm, the temperature of the mixture is 20-30℃;

[0015] b) Preparation of component II: Add 20 to 60 parts by weight of isocyanate into container A and stir for 4 to 6 seconds at a stirring speed of 2000 to 4000 rpm to obtain material I;

[0016] c) quickly pouring material I into a foaming box for aging for 10 to 72 hours, and preparing a synthetic polyether ester sponge after aging.

[0017] In the above technical scheme, preferably, polyether polyol I is CHE-5602, polyether polyol II is selected from at least one of CHE-507LF or CHE-214LF; polyether polyol III is selected from at least one of CHE-2045 and CHE-2045D; the amine catalyst is selected from at least one of triethylenediamine or N,N'-dimethylethanolamine; the tin catalyst is at least one of tin octoate, stannous octoate or dibutyltin dilaurate; the foam stabilizer is alkylphenol polyoxyethylene ether; the flame retardant is selected from at least one of organophosphorus flame retardant, melamine, alumina and graphite powder; the flame compounding agent is a phosphite compound; component II is a mixture of 2,4-dimethylphenyl diisocyanate and 2,6-dimethylphenyl diisocyanate.

[0018] In the above technical solution, preferably, the leather layer is selected from low tear PVC, and the thickness of the leather layer is 0.9-1.3 mm. The low tear test is to cut 3 200mm*50mm PVC samples, with the rectangular direction as the test direction, and the tear force is not less than 15N when the test speed is 100mm / min.

[0019] In the above technical solution, preferably, the thickness of the synthetic polyetherester sponge is 2 to 4 mm.

[0020] In the above technical solution, preferably, the material of the instrument panel plastic part is selected from ABS material, and the thickness is 4 to 5 mm.

[0021] In the above technical solution, preferably, the weakened groove completely penetrates the sponge layer, and the weakened groove partially penetrates the plastic part of the instrument panel, and the penetration depth is 1 to 3 mm.

[0022] In the above technical solution, preferably, the weakened groove is U-shaped, square-shaped or double Y-shaped.

[0023] In the above technical solution, preferably, the thickness of the first non-woven fabric layer and the second non-woven fabric layer are both 0.4-1.0 mm.

[0024] In the above technical solution, preferably, the thickness of the polyurethane water-based adhesive is 0.08-0.1 mm.

[0025] The present invention provides a new preparation process for automobile instrument panel, which adopts the technical solution of using low-tear PVC leather to cover a synthetic polyether ester composite sponge layer and an instrument panel plastic part. The preparation process has the advantages of simple operation, excellent aging resistance, physical properties and high surface flatness of the prepared automobile instrument panel, and no risk of fiber splashing threatening personal safety during explosion, and has achieved good technical effects. DETAILED DESCRIPTION

[0026] Table 1 List of raw materials

[0027]

[0028]

[0029] [Example 1]

[0030] Preparation of component I: In container A, add 40 parts of CHE-5602, 30 parts of CHE-507LF, 30 parts of CHE-2045, 2.9 parts of water, 0.2 parts of triethylenediamine, 0.2 parts of stannous octoate, 1.3 parts of DC-5950, 6 parts of YK-80LV, and 1.5 parts of FLE-200LF according to the weight parts, and stir evenly at a stirring speed of 2500 rpm. The temperature of the mixture is 25°C.

[0031] Preparation of component II: Add 45 parts by weight of a mixture of 80% by weight of 2,4-dimethylphenyl diisocyanate and 20% by weight of 2,6-dimethylphenyl diisocyanate into container A, stir for 6 seconds at a stirring speed of 3000 rpm to obtain material I;

[0032] The material I was quickly poured into a foaming box for aging for 48 hours, and a synthetic polyether ester sponge was prepared after aging.

[0033] [Examples 2 to 5, Comparative Examples 1 to 2]

[0034] Examples 2 to 5 and Comparative Examples 1 to 2 were carried out according to the steps in Example 1, with the only difference being the reaction raw materials, reaction type, catalyst type, raw material ratio, reaction time and reaction temperature, as shown in Table 2. The performance data of the prepared synthetic polyether ester sponge are shown in Table 3.

[0035] Table 2 Weight parts of raw materials of each component in Examples 1 to 5 and Comparative Examples 1 to 2

[0036]

[0037]

[0038] Table 3 Performance test data of sponges prepared in Examples 1 to 5 and Comparative Examples 1 to 2

[0039]

[0040]

[0041]

[0042] The testing standards are as follows:

[0043] Density: DIN EN ISO 845-1995

[0044] Indentation hardness (25%) ISO 2439-2008

[0045] Breaking strength DIN EN ISO 1798-2008

[0046] Elongation at break DIN EN ISO 1798-2008

[0047] Compression deformation force (at 40%) DIN EN ISO 1798-2008

[0048] 50% compression set (normal condition) DIN EN ISO 1856-2018

[0049] Flame retardant TL1010

[0050] Odor test PV3900-2019EN

[0051] The test data of indentation hardness change, breaking strength (aging) change rate, breaking elongation (aging) change rate, compression deformation force (at 40%) (aging) deformation rate are all compared with the normal data after the delivery state and 90℃ (100-6)% relative humidity for 200h damp heat aging;

[0052] The 50% compression set (aging) deformation rate test conditions are after 200h of damp heat aging at 90°C (100-6)% relative humidity.

[0053] As can be seen from the table above, the basic physical properties of synthetic polyetherester sponge under normal conditions are close to those of polyester sponge, far exceeding those of polyether sponge. The aging resistance of synthetic polyetherester sponge is better than that of polyester sponge. Synthetic polyetherester sponge can meet the aging requirements of 200h, 90℃, 90% humidity, while polyester sponge cannot meet this requirement.

[0054] [Example 6]

[0055] An automobile instrument panel, comprising, from top to bottom, a leather layer, a first glue layer, a first non-woven fabric layer, a synthetic polyether ester sponge, a second non-woven fabric layer, a second glue layer, and an instrument panel plastic part;

[0056] Wherein, the synthetic polyetherester sponge is prepared according to the method of Example 1.

[0057] The leather layer is selected from low tear PVC and has a thickness of 1.0 mm. The first glue layer and the second glue layer are both selected from polyurethane glue and have a spraying thickness of 0.1 mm.

[0058] The thickness of the first non-woven fabric layer and the second non-woven fabric layer is 0.6 mm, the thickness of the synthetic polyetherester sponge is 2.5 mm, and the material of the instrument panel plastic part is ABS material with a thickness of 5 mm.

[0059] The automobile instrument panel is provided with a weakened groove; the weakened groove is U-shaped; the weakened groove completely penetrates the first non-woven fabric layer, the synthetic polyether ester sponge, and the second non-woven fabric layer; the weakened groove partially penetrates the instrument panel plastic part, and the penetration depth is 3mm.

[0060] The preparation process is:

[0061] (1) According to the specific internal dimensions of the vehicle model, the low-tear PVC skin of the leather layer is cut into a specified shape according to the size of the instrument panel; the shape of the PVC skin after cutting can completely cover the instrument panel; the tear force of the low-tear PVC skin is 15N; the test is to cut 3 200mm*50mm PVC samples, with the rectangular direction as the test direction, and the test speed is 100mm / min.

[0062] (2) According to the thickness of the pre-embedded groove of the skeleton of the instrument panel plastic part, the thickness of the synthetic polyether ester composite sponge layer prepared in Example 1 is cut, and the first non-woven fabric layer, the synthetic polyether ester sponge and the second non-woven fabric layer are compounded by flame from top to bottom, and the thickness of the compounded synthetic polyether ester composite sponge layer is consistent with the depth of the pre-embedded groove; then, according to the size of the pre-embedded groove, the synthetic polyether ester composite sponge layer is cut into a specified shape; the shape of the synthetic polyether ester composite sponge layer is exactly consistent with the shape of the pre-embedded groove;

[0063] (3) First, partially weaken the plastic part of the instrument panel and open a weakening groove; then, fully penetrate and weaken the corresponding position of the synthetic polyether ester composite sponge layer; that is, weaken the position where the airbag is placed;

[0064] (4) The contact surface between the synthetic polyether ester composite sponge layer and the instrument panel plastic part is evenly sprayed with polyurethane water-based glue, and the contact surface between the leather layer and the synthetic polyether ester composite sponge layer is also evenly sprayed with polyurethane water-based glue. At room temperature, the leather layer covers the synthetic polyether ester composite sponge layer and the instrument panel plastic part together, and the automobile instrument panel is completed.

[0065] The prepared automobile dashboard was subjected to an explosion test according to the standard GWT A E72-41:2020-02. No splashes were generated, the airbag deployment time (25°C) was 37.5ms, there were no protruding broken edges in the airbag opening area, the airbag cover did not fly out, and the airbag cover did not break during the explosion test.

[0066] [Example 7]

[0067] An automobile instrument panel, comprising, from top to bottom, a leather layer, a first glue layer, a first non-woven fabric layer, a synthetic polyether ester sponge, a second non-woven fabric layer, a second glue layer, and an instrument panel plastic part;

[0068] Wherein, the synthetic polyetherester sponge is prepared according to the method of Example 3.

[0069] The leather layer is selected from low tear PVC and has a thickness of 1.0 mm. The first glue layer and the second glue layer are both selected from polyurethane glue and have a spraying thickness of 0.08 mm.

[0070] The thickness of the first non-woven fabric layer and the second non-woven fabric layer is 0.5 mm, the thickness of the synthetic polyetherester sponge is 3 mm, and the material of the instrument panel plastic part is ABS material, with a thickness of 5 mm.

[0071] The automobile instrument panel is provided with a weakened groove; the weakened groove is U-shaped; the weakened groove completely penetrates the first non-woven fabric layer, the synthetic polyether ester sponge, and the second non-woven fabric layer; the weakened groove partially penetrates the instrument panel plastic part, and the penetration depth is 3mm.

[0072] The preparation process is:

[0073] (1) According to the specific internal dimensions of the vehicle model, the low-tear PVC skin of the leather layer is cut into a specified shape according to the size of the instrument panel. The shape of the PVC skin after cutting can completely cover the instrument panel; the tear force of the low-tear PVC skin is 16N; the test is to cut 3 200mm*50mm PVC samples, with the rectangular direction as the test direction, and the test speed is 100mm / min.

[0074] (2) According to the thickness of the pre-embedded groove of the skeleton of the instrument panel plastic part, the thickness of the synthetic polyether ester composite sponge layer prepared in Example 3 is cut, and the first non-woven fabric layer, the synthetic polyether ester sponge and the second non-woven fabric layer are compounded by flame from top to bottom, and the thickness of the compounded synthetic polyether ester composite sponge layer is consistent with the depth of the pre-embedded groove; then, according to the size of the pre-embedded groove, the synthetic polyether ester composite sponge layer is cut into a specified shape, and the shape of the synthetic polyether ester composite sponge layer is exactly consistent with the shape of the pre-embedded groove;

[0075] (3) First, partially weaken the plastic part of the instrument panel and open a weakening groove; then, fully penetrate and weaken the corresponding position of the synthetic polyether ester composite sponge layer; that is, weaken the position where the airbag is placed;

[0076] (4) The contact surface between the synthetic polyether ester composite sponge layer and the instrument panel plastic part is evenly sprayed with polyurethane water-based glue, and the contact surface between the leather layer and the synthetic polyether ester composite sponge layer is also evenly sprayed with polyurethane water-based glue. At room temperature, the leather layer covers the synthetic polyether ester composite sponge layer and the instrument panel plastic part together, and the automobile instrument panel is completed.

[0077] The prepared automobile dashboard was subjected to an explosion test according to the standard GWT A E72-41:2020-02. No splashes were generated, the airbag deployment time (85°C) was 31ms, there were no protruding broken edges in the airbag opening area, the airbag cover did not break and did not fly out, and the airbag cover did not break during the explosion test.

[0078] [Comparative Example 3]

[0079] A car dashboard, the car dashboard comprising, from top to bottom, a leather layer, a first glue layer, a 3D mesh layer, a second glue layer, and a dashboard plastic part;

[0080] The leather layer is selected from low-tear PVC, with a thickness of 1.0 mm. The first glue layer and the second glue layer are both selected from polyurethane glue, and the spraying thickness is 0.08 mm. The material of the instrument panel plastic part is selected from ABS material, with a thickness of 5 mm.

[0081] The automobile instrument panel is provided with a weakened groove; the weakened groove is U-shaped; the weakened groove completely penetrates the 3Dmesh layer; the weakened groove partially penetrates the plastic part of the instrument panel, and the penetration depth is 3mm.

[0082] The preparation process is:

[0083] (1) According to the specific interior dimensions of the vehicle model, the low-tear PVC surface of the leather layer is cut into the specified shape according to the size of the instrument panel;

[0084] (2) According to the size of the embedded groove, the 3D mesh layer is cut into a specified shape;

[0085] (3) First, partially weaken the plastic part of the instrument panel and open a weakening groove; then, fully penetrate and weaken the corresponding position of the 3D mesh layer;

[0086] (4) The contact surface between the 3D mesh layer and the plastic part of the instrument panel is evenly sprayed with polyurethane water-based glue, and the contact surface between the leather layer and the 3D mesh layer is also evenly sprayed with polyurethane water-based glue. The leather layer covers the 3D mesh layer and the plastic part of the instrument panel together, and the preparation of the automobile instrument panel is completed.

[0087] The automobile instrument panel prepared in Comparative Example 3 has different corresponding tension areas during the later manual coating, and the low tear 3dmesh will be compressed, which is easy to cause various appearance defects during the production process, especially marks are easy to appear at the junction of soft and hard. At the same time, when glue is used for pasting, the glue will penetrate into the 3dmesh material, which will easily cause the overall material to be uneven and not flat enough after pasting. In addition, the raw material of low tear 3dmesh is a fiber structure. After the low tear 3dmesh is coated, the airbag explodes with fiber splashing and cannot explode within the accurate explosion range, posing a risk of threatening personal safety.

Claims

1. A process for preparing an automobile instrument panel, characterized in that: The following steps are included in sequence: (1) Preparing the leather layer: According to the specific internal dimensions of the vehicle model, the leather is cut into a specified shape according to the size of the instrument panel; the shape of the PVC leather after cutting can completely cover the instrument panel; (2) preparing a synthetic polyetherester composite sponge layer: cutting the synthetic polyetherester composite sponge layer according to the thickness of the pre-buried groove of the skeleton; stacking the first non-woven fabric layer, the synthetic polyetherester sponge, and the second non-woven fabric layer in order from top to bottom; compounding by flame compounding; then cutting the sponge layer into a specified shape according to the size of the pre-buried groove of the instrument panel; the shape of the cut synthetic polyetherester composite sponge layer is exactly consistent with the shape of the pre-buried groove; (3) Weakening: firstly, the skeleton layer of the instrument panel is weakened and a weakening groove is opened; then, the corresponding position of the synthetic polyetherester composite sponge layer is weakened; (4) Coating: The surface where the synthetic polyether ester composite sponge layer contacts the skeleton layer is evenly sprayed with polyurethane water-based glue; the surface where the leather layer contacts the synthetic polyether ester composite sponge layer is evenly sprayed with polyurethane water-based glue; at room temperature, the leather layer completely covers the synthetic polyether ester composite sponge layer and the skeleton layer.

2. The process for preparing the automobile instrument panel according to claim 1, characterized in that: The preparation method of the synthetic polyetherester sponge comprises the following steps: a) Preparation of component I: Add 30-70 parts of polyether polyol I, 40-60 parts of polyether polyol II, 10-40 parts of polymer polyol III, 1-4 parts of water, 0.1-1 parts of amine catalysts, 0.1-1 parts of tin catalysts, 0.5-2 parts of foam stabilizers, 2-12 parts of flame retardants, and 1-5 parts of flame compounding agents to container A by weight, and stir evenly at a stirring speed of 2000-3000 rpm. The temperature of the mixture is 20-30°C. b) Preparation of component II: Add 20 to 60 parts by weight of isocyanate into container A and stir for 4 to 6 seconds at a stirring speed of 2000 to 4000 rpm to obtain material I; c) quickly pouring material I into a foaming box for aging for 10 to 72 hours, and preparing a synthetic polyether ester sponge after aging.

3. The process for preparing the automobile instrument panel according to claim 2, characterized in that: The polyether polyol I is CHE-5602, the polyether polyol II is selected from at least one of CHE-507LF and CHE-214LF; the polyether polyol III is selected from at least one of CHE-2045 and CHE-2045D; the amine catalyst is selected from at least one of triethylenediamine and N,N'-dimethylethanolamine; the tin catalyst is at least one of tin octoate, stannous octoate or dibutyltin dilaurate; the foam stabilizer is alkylphenol polyoxyethylene ether; the flame retardant is selected from at least one of organic phosphorus flame retardant, melamine, aluminum oxide and graphite powder; the flame compounding agent is a phosphite compound; and component II is a mixture of 2,4-dimethylphenyl diisocyanate and 2,6-dimethylphenyl diisocyanate.

4. The process for preparing the automobile instrument panel according to claim 1, characterized in that: The leather layer is selected from low-tear PVC, and the thickness of the leather layer is 0.9-1.3 mm.

5. The process for preparing the automobile instrument panel according to claim 1, characterized in that: The thickness of the synthetic polyetherester sponge is 2-4 mm.

6. The process for preparing the automobile instrument panel according to claim 1, characterized in that: The material of the instrument panel plastic part is selected from ABS material, and the thickness is 4-5mm.

7. The process for preparing the automobile instrument panel according to claim 1, characterized in that: The weakened groove completely penetrates the sponge layer, and partially penetrates the instrument panel plastic part, with a penetration depth of 1 to 3 mm.

8. The process for preparing the automobile instrument panel according to claim 1, characterized in that: The weakened groove is in a U-shape, a square shape or a double Y-shape.

9. The process for preparing the automobile instrument panel according to claim 1, characterized in that: The thickness of the first non-woven fabric layer and the second non-woven fabric layer are both 0.4-1.0 mm.

10. The method for preparing an automobile instrument panel according to claim 1, characterized in that: The thickness of the polyurethane water-based adhesive is 0.08-0.1 mm.

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