Lightweight bacteriostatic seat and manufacturing method thereof

Abstract

The invention provides a light bacteriostatic seat and a manufacturing method thereof, the light bacteriostatic seat is composed of 40 wt.% of epoxy resin, 20-50 wt.% of carbon fiber and 10-40 wt.% of bamboo fiber, the carbon fiber is used as a reinforcing layer, the rigidity and strength of the seat are greatly improved, the mechanical property of the seat is met, the bamboo fiber is used as a bacteriostatic and antibacterial surface layer, and the surface layer is made of plastic. The effects of bacteriostasis and light weight of the seat are achieved; the interface bonding capacity of the fiber layer and resin is enhanced through fiber pretreatment, and the material strength is guaranteed; the vacuum auxiliary bag film technology is adopted for curing forming, the manufacturing technology is simple, cost is low, product performance is excellent, the green and environment-friendly requirements are met, and wide application prospects are achieved.

Description

Technical Field

[0001] The invention belongs to the technical field of automobile seat production, and in particular relates to a lightweight antibacterial seat and a manufacturing method thereof. Background Art

[0002] As fossil resources become increasingly scarce, and traditional glass fiber and carbon fiber composite materials fail to meet the requirements of green environmental protection and recycling, bamboo fiber composite materials have gradually become a key research and development material for automobile manufacturers.

[0003] As a new type of fiber reinforced material, bamboo fiber composite material has excellent properties such as light weight, deodorization and antibacterial, green and environmental protection, high strength, and low price, and can be used as a substitute for traditional fibers. Bamboo fiber has the characteristics of deodorization and antibacterial, light weight, high strength, sound absorption and heat insulation, wide sources, and natural degradation, and is used as a reinforcing material for new energy vehicle seats. Bamboo fiber-carbon fiber composite materials have the characteristics of high strength and high hardness of carbon fiber composite materials and the characteristics of deodorization and antibacterial, green and environmental protection of bamboo fiber composite materials, which are of great significance for the preparation of new energy vehicle seats. Summary of the invention

[0004] In view of the above shortcomings of the prior art, the purpose of the present invention is to provide a lightweight antibacterial seat and a method for manufacturing the same, which adopts bamboo fiber and carbon fiber composite materials to ensure the high strength of the seat while being lighter, and has good antibacterial, antibacterial and deodorizing functions. The manufacturing method is simple, the cost is low, it meets the requirements of green environmental protection, and has broad application prospects.

[0005] To achieve the above-mentioned purpose and other related purposes, the present invention provides a lightweight antibacterial seat, comprising:

[0006] A matrix, wherein the matrix is ​​a resin;

[0007] A reinforcing layer, comprising a carbon fiber layer and a bamboo fiber layer, wherein the carbon fiber layer is laid between the bamboo fiber layers, and the carbon fiber layer and the bamboo fiber layer are cured and formed by the resin;

[0008] Wherein, the mass component of the resin is 40wt.%, the mass component of the carbon fiber is 20-50wt.%, and the mass component of the bamboo fiber is 10-40wt.%.

[0009] The present invention also provides a method for manufacturing a lightweight antibacterial seat, which comprises at least the following steps:

[0010] Mould making: making seat moulds according to the seat structure design;

[0011] Fiber pretreatment: using alkaline solution and silane coupling agent to treat the surface of bamboo fiber, pressing it into bamboo fiber prefabricated blocks, and dehydrating and drying the carbon fiber woven fabric;

[0012] Laying, firstly laying multiple layers of the bamboo fiber prefabricated blocks on the seat mold to obtain a first bamboo fiber layer, then laying multiple layers of the carbon fiber woven cloth to obtain a carbon fiber layer, and finally laying multiple layers of the bamboo fiber prefabricated blocks to obtain a second bamboo fiber layer;

[0013] Curing and molding, using vacuum bagging technology, packaging and vacuuming, and then injecting resin containing curing agent for curing and molding;

[0014] After curing is completed, the product is demoulded and taken out, and post-processing operations are performed to obtain a bamboo fiber-carbon fiber composite material seat.

[0015] According to an embodiment provided by the present invention, the seat mold is a non-metal mold.

[0016] According to an embodiment provided by the present invention, the bamboo fiber has a fineness of 0.3-1.5 mm and a length of 50-100 mm.

[0017] According to an embodiment provided by the present invention, in the fiber pretreatment step, the bamboo fiber is subjected to alkali treatment using a 3-5% NaOH solution, first soaked for 10-15 hours, then rinsed with distilled water until neutral, and finally dried in an oven for 10-15 hours at a drying temperature of 80-120°C;

[0018] Then, the bamboo fiber is surface modified by using a 2% silane coupling agent solution, firstly soaking for 2 hours, and then drying in an oven for 10 hours, at a drying temperature of 80-120° C.;

[0019] Finally, the bamboo fibers are placed in a specially made heatable flat plate mold, heated and pressurized, and pressed into the bamboo fiber prefabricated blocks with a thickness of 1 mm.

[0020] According to an embodiment provided by the present invention, the carbon fiber woven fabric has a specification of 400g, T300, 12K, and is placed in an oven for drying for 1-5 hours at a drying temperature of 80-120°C.

[0021] According to an embodiment provided by the present invention, in the plying step, the number of plies of bamboo fiber layers and carbon fiber layers is determined according to the mass percentage of the bamboo fiber and the carbon fiber, and a special spray glue for fiber composite materials is used to bond the layers during plying.

[0022] According to an embodiment provided by the present invention, in the curing molding step, a vacuum bag is first used for packaging, and the vacuum is evacuated to a negative pressure with a negative pressure value of -0.1-0.2MPa. After checking that there is no air leakage, the pressure is maintained for 10 minutes, and then a resin containing a curing agent is injected. The curing time is 3-10 hours, and the curing temperature is 70-100°C.

[0023] According to an embodiment provided by the present invention, the mass percentage content of the carbon fiber is 20-50wt.%, the mass percentage content of the bamboo fiber is 10-40wt.%, and the mass percentage content of the resin is 40wt.%.

[0024] According to an embodiment provided by the present invention, the resin is one of epoxy resin, unsaturated resin and phenolic resin.

[0025] The lightweight antibacterial seat of the present invention adopts a bamboo fiber-carbon fiber composite material, which is composed of 40wt.% epoxy resin, 20-50wt.% carbon fiber, and 10-40wt.% bamboo fiber by mass components. The carbon fiber is used as a reinforcement layer, which greatly improves the stiffness and strength of the seat and meets the mechanical properties of the seat. The bamboo fiber is an antibacterial and antimicrobial surface layer, which can achieve the antibacterial and deodorizing effects of the seat, while making the seat as a whole lighter. The interface bonding ability between the fiber layer and the resin is enhanced by fiber pretreatment to ensure the strength of the material. The vacuum assisted bag film process is used for curing and molding, and the manufacturing process is simple, the cost is low, the product performance is excellent and meets the green environmental protection requirements, and it has broad application prospects. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for describing the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative work.

[0027] Figure 1 It is a structural schematic diagram of a lightweight antibacterial seat in one embodiment of the present invention;

[0028] Figure 2 It is a schematic diagram of the cross-sectional structure of a lightweight antibacterial seat material in one embodiment of the present invention;

[0029] Figure 3 It is a schematic diagram of the manufacturing process of a lightweight antibacterial seat in one embodiment of the present invention. DETAILED DESCRIPTION

[0030] The following describes the embodiments of the present invention through specific examples, and those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention.

[0031] It should be noted that the illustrations provided in this embodiment are only used to illustrate the basic concept of the present invention in a schematic manner. Therefore, the drawings only show components related to the present invention rather than being drawn according to the number, shape and size of components in actual implementation. In actual implementation, the type, quantity and proportion of each component may be changed arbitrarily, and the component layout may also be more complicated.

[0032] With the development of the new energy vehicle industry, lightweight, economical and green have gradually become the key development directions of composite materials. Bamboo fiber reinforced composite materials can be used as a substitute for traditional fibers because of their excellent properties such as light weight, deodorization and antibacterial, green environmental protection, high strength and low price. Bamboo fiber-carbon fiber composite materials have the characteristics of high strength and high hardness of carbon fiber composite materials, as well as the characteristics of deodorization, antibacterial and green environmental protection of bamboo fiber composite materials. They are used in the preparation of new energy vehicle seats, which is of great significance.

[0033] See also Figure 1 to Figure 2 The present invention proposes a lightweight antibacterial seat 100, which is made of a bamboo fiber-carbon fiber composite material, comprising a matrix and a reinforcement layer, wherein the matrix is ​​resin, and the reinforcement layer comprises a carbon fiber layer 200 and a bamboo fiber layer 300, wherein the carbon fiber layer 200 is laid between the bamboo fiber layers 300, and the carbon fiber layer 200 and the bamboo fiber layer 300 are formed by resin curing; wherein the resin mass component is 40wt.%, the carbon fiber mass component is 20-50wt.%, and the bamboo fiber mass component is 10-40wt.%. A bamboo fiber-carbon fiber composite material is adopted, and carbon fiber is used as a reinforcement to improve the stiffness and strength of the seat. The bamboo fiber is an antibacterial and antibacterial surface layer, so that the seat has good antibacterial, deodorizing and UV resistance properties. It is formed in one piece by resin curing, and the process is simple and the manufacturing cost is low. The seat as a whole is simple, light and has high strength, which conforms to the green environmental protection concept and has broad application prospects.

[0034] See also Figures 1 to 3 The present invention also proposes a method for manufacturing a lightweight antibacterial seat, comprising steps S10 to S50.

[0035] Step S10: mold making: making a seat mold according to the seat structure design;

[0036] Step S20, using an alkaline solution and a silane coupling agent to perform surface treatment on the bamboo fiber, then pressing the bamboo fiber into a bamboo fiber prefabricated block, and performing a dehydration and drying treatment on the carbon fiber woven fabric;

[0037] Step S30, laying layers, first laying multiple layers of bamboo fiber prefabricated blocks on the seat mold to obtain a first bamboo fiber layer 310, then laying multiple layers of carbon fiber woven fabrics to obtain a carbon fiber layer 200, and finally laying multiple layers of bamboo fiber prefabricated blocks to obtain a second bamboo fiber layer 320;

[0038] Step S40, curing and molding, using a vacuum bagging process, packaging and vacuumizing, and then injecting a resin containing a curing agent for curing and molding;

[0039] Step S50: After curing is completed, the product is demoulded and taken out, and post-processing operations are performed to obtain a bamboo fiber-carbon fiber composite material seat.

[0040] See also Figures 1 to 3 According to an embodiment of the present invention, in step S10, the seat mold is a non-metal mold. The seat mold is designed according to the structural form of the product and is used for ply curing. The mold structure is simple, and the non-metal mold is low in cost and light and easy to carry.

[0041] See also Figures 1 to 3 According to an embodiment provided by the present invention, in step S20, bamboo fiber with a fineness of 0.3-1.5mm and a length of 50-100mm is selected, and 3-5% NaOH solution is first used to perform alkali treatment on it, specifically, soaking treatment for 10-15h first, then washing with distilled water to neutrality, and finally drying in an oven for 10-15h, and the drying temperature is 80-120℃; then 2% silane coupling agent solution is used to modify the surface of the bamboo fiber, specifically, soaking treatment for 2h first, and then drying in an oven for 10h, and the drying temperature is 80-120℃; alkali treatment and the use of silane coupling agent can improve the wettability and compatibility of bamboo fiber, enhance its interface bonding ability with resin, and ensure the strength of the material. Finally, the surface-modified bamboo fiber is laid into a special heatable flat mold, heated and pressurized, and the loose bamboo fiber is compacted, and it is pressed into a bamboo fiber prefabricated block with a thickness of 1mm to facilitate the subsequent layering process.

[0042] See also Figures 1 to 3 According to an embodiment provided by the present invention, in step S20, a carbon fiber woven cloth with a specification of 400g, T300, 12K is used, and is placed in an oven for drying for 1-5h at a drying temperature of 80-120°C to ensure good interface properties of the composite material, and to effectively improve material strength by using carbon fiber. A 400g carbon fiber cloth is used as a reinforcement, and a single layer of 400g woven cloth can provide higher strength and thickness, and reduce laying time and material costs.

[0043] See also Figures 1 to 3 According to an embodiment provided by the present invention, in step S30, the seat mold is processed before the layer laying process is performed. Specifically, a mold cleaning agent, a sealing agent, and a mold release agent are sprayed on the mold surface in sequence, and a gel coat is sprayed on the mold surface as required, and the subsequent layer laying process is performed after the gel coat is cured.

[0044] See also Figures 1 to 3According to an embodiment provided by the present invention, in step S30, the number of plies of the bamboo fiber layer 300 and the carbon fiber layer 200 is determined according to the mass percentage of the bamboo fiber and the carbon fiber, and then the first bamboo fiber layer 310, the carbon fiber layer 200 and the second bamboo fiber layer 320 are laid in sequence, and the fiber composite material special spray glue is used between the layers for bonding. For example, the number of plies of the carbon fiber layer 200 can be 3-6, and the number of plies of the bamboo fiber layer 300 can be 2-6.

[0045] See also Figures 1 to 3 According to an embodiment provided by the present invention, the mass percentage content of carbon fiber is 20-50wt.%, the mass percentage content of bamboo fiber is 10-40wt.%, and the mass percentage content of resin is 40wt.%. This mass composition ratio ensures that the seat is light while having good mechanical properties. The use of carbon fiber as a reinforcing layer greatly improves the mechanical properties of the seat. At the same time, the seat also has many excellent properties of bamboo fiber, such as good air permeability, good antibacterial effect, and UV resistance, which meets green environmental protection requirements and has low cost.

[0046] See also Figures 1 to 3 According to an embodiment of the present invention, in step S40, a vacuum bag is used for packaging, and vacuum is evacuated to negative pressure, the negative pressure value is -0.1-0.2MPa, and after checking that there is no air leakage, the pressure is maintained for 10 minutes, and then the resin containing the curing agent is injected, and the curing time is 3-10 hours, and the curing temperature is 70-100°C. Specifically, after the fiber reinforcement layer is laid, a layer of demoulding cloth is first laid on the reinforcement layer, and a guide cloth is laid on the demoulding cloth. The guide pipes are distributed on the guide cloth, and then covered with a vacuum bag and sealed with a sealant. The vacuum is evacuated to negative pressure, and the pressure is maintained. Finally, the guide pipe and the guide cloth are used to guide the resin to flow and distribute to every corner of the layer. After curing, the demoulding cloth can be peeled off. The vacuum-assisted bagging process is adopted, which is simple to manufacture, the resin flows evenly, and the product is easy to demold.

[0047] See also Figures 1 to 3 According to an embodiment of the present invention, the resin is one of epoxy resin, unsaturated resin and phenolic resin.

[0048] See also Figures 1 to 3 According to an embodiment of the present invention, in step S50, after curing is completed, the product is demoulded and taken out, and then post-processing operations such as inspection, cutting, finishing, testing, and assembly are performed to obtain the final seat product.

[0049] The present invention is described in more detail below by introducing specific embodiments.

[0050] Example 1

[0051] Step S10: design and manufacture a non-metallic mold for ply curing according to the structural form of the product.

[0052] Step S20, alkali treatment is performed on bamboo fibers with a fineness of 0.3 mm and a length of 50 mm. The solution used for the alkali treatment is a 3% NaOH solution. After soaking for 10 hours, the fibers are rinsed with distilled water until neutral and dried in an oven for 10 hours. Then, the fibers are modified with a 2% silane coupling agent solution, soaked for 2 hours, and dried in an oven for 10 hours. The pretreated bamboo fibers are laid into a special heatable flat mold, heated and pressurized, and the loose bamboo fibers are compacted into bamboo fiber prefabricated blocks with a thickness of 1 mm. At the same time, the carbon fiber lattice cloth with a specification of 400g, T300, and 12K is dehydrated and dried, and placed in an oven for 5 hours at a drying temperature of 100°C.

[0053] Step S30, spraying a mold cleaning agent, a sealing agent, and a mold release agent on the mold surface in sequence, and spraying a gel coat on the mold surface as required. After the gel coat is cured, the treated bamboo fiber prefabricated blocks and carbon fiber woven cloth are laid on the mold according to the seat design requirements, and the fiber mass percentage content is 30wt.% carbon fiber and 30wt.% bamboo fiber respectively. According to the fiber mass percentage, first lay 2 layers of 1mm thick bamboo fiber prefabricated blocks, then lay 4 layers of carbon fiber woven cloth, and finally lay 2 layers of bamboo fiber prefabricated blocks.

[0054] Step S40: Use vacuum-assisted bagging process for glue injection curing, the curing temperature is 70° C., and the curing time is 10 hours.

[0055] Step S50: After curing is completed, the product is demoulded and taken out, and post-processed to obtain a bamboo fiber-carbon fiber composite material seat.

[0056] Example 2

[0057] The difference between this embodiment and embodiment 1 is that in step S30, the fiber mass percentage contents are 20wt.% carbon fiber and 40wt.% bamboo fiber respectively. According to the fiber mass percentage, three layers of 1mm thick bamboo fiber prefabricated blocks are first laid, then two layers of carbon fiber woven cloth are laid, and finally three layers of bamboo fiber prefabricated blocks are laid.

[0058] Example 3

[0059] The difference between this embodiment and embodiment 1 is that in step S30, the fiber mass percentage contents are 50wt.% carbon fiber and 10wt.% bamboo fiber respectively. According to the fiber mass percentage, firstly, a layer of 1mm thick bamboo fiber prefabricated block is laid, then 7 layers of carbon fiber woven cloth are laid, and finally, a layer of bamboo fiber prefabricated block is laid.

[0060] Example 4

[0061] The difference between this embodiment and embodiment 1 is that in step S20, the bamboo fiber is selected with a fineness of 1 mm and a length of 100 mm.

[0062] The tensile strength, flexural strength and impact strength data of the product materials in Examples 1 to 4 were measured experimentally, as shown in Table 1.

[0063] Table 1 Tensile strength, flexural strength and impact strength of product materials in different embodiments

[0064]

[0065] It can be seen from Table 1 that when the carbon fiber content is 20-50wt.% and the bamboo fiber mass component is 10-40wt.%, the bamboo fiber-carbon fiber composite seat has excellent mechanical properties, so that while meeting the strength requirements, the overall weight is lighter and has many excellent properties of bamboo fiber.

[0066] To sum up, the lightweight antibacterial seat of the present invention uses bamboo fiber and carbon fiber as raw materials, and bamboo fiber as the surface layer of the seat. It utilizes the good air permeability, instantaneous water absorption, strong wear resistance and good dyeing properties of bamboo fiber, so that the seat has natural antibacterial, antibacterial, mite removal, deodorization and UV resistance functions. The carbon fiber is used as a reinforcing layer to greatly improve the strength of the seat, ensuring that the mechanical properties of the seat are good while the overall structure is simpler and lighter. The manufacturing process is simple and the manufacturing cost is low. Compared with traditional seats, it has better mechanical properties and various excellent properties, meets the requirements of green environmental protection, and has broad market prospects in the field of vehicle seats.

[0067] The embodiments described above are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. Such modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be included in the protection scope of the present invention.

[0068] Except for the technical features described in the specification, the remaining technical features are known technologies to those skilled in the art. In order to highlight the innovative features of the present invention, the remaining technical features will not be described here in detail.

Claims

1. A lightweight antibacterial seat, characterized in that: include: A matrix, wherein the matrix is ​​a resin; A reinforcing layer, comprising a carbon fiber layer and a bamboo fiber layer, wherein the carbon fiber layer is laid between the bamboo fiber layers, and the carbon fiber layer and the bamboo fiber layer are cured and formed by the resin; Wherein, the mass component of the resin is 40wt.%, the mass component of the carbon fiber is 20-50wt.%, and the mass component of the bamboo fiber is 10-40wt.%.

2. A method for manufacturing a lightweight antibacterial seat, characterized in that: At least the following steps are included: Mould making: making seat moulds according to the seat structure design; Fiber pretreatment: using alkaline solution and silane coupling agent to treat the surface of bamboo fiber, pressing it into bamboo fiber prefabricated blocks, and dehydrating and drying the carbon fiber woven fabric; Laying, firstly laying multiple layers of the bamboo fiber prefabricated blocks on the seat mold to obtain a first bamboo fiber layer, then laying multiple layers of the carbon fiber woven cloth to obtain a carbon fiber layer, and finally laying multiple layers of the bamboo fiber prefabricated blocks to obtain a second bamboo fiber layer; Curing and molding, using vacuum bagging technology, packaging and vacuuming, and then injecting resin containing curing agent for curing and molding; After curing is completed, the product is demoulded and taken out, and post-processing operations are performed to obtain a bamboo fiber-carbon fiber composite material seat.

3. The method for manufacturing a lightweight antibacterial seat according to claim 2, characterized in that: The seat mould is a non-metal mould.

4. The method for manufacturing a lightweight antibacterial seat according to claim 2, characterized in that: The bamboo fiber has a fineness of 0.3-1.5 mm and a length of 50-100 mm.

5. The method for manufacturing a lightweight antibacterial seat according to claim 2, characterized in that: In the fiber pretreatment step, the bamboo fiber is subjected to alkali treatment using a 3-5% NaOH solution, first soaked for 10-15 hours, then rinsed with distilled water until neutral, and finally dried in an oven for 10-15 hours at a drying temperature of 80-120° C.; Then, the bamboo fiber is surface modified by using a 2% silane coupling agent solution, firstly soaking for 2 hours, and then drying in an oven for 10 hours, at a drying temperature of 80-120° C.; Finally, the bamboo fibers are placed in a specially made heatable flat plate mold, heated and pressurized, and pressed into the bamboo fiber prefabricated blocks with a thickness of 1 mm.

6. The method for manufacturing a lightweight antibacterial seat according to claim 2, characterized in that: The carbon fiber woven fabric has a specification of 400g, T300, 12K, and is placed in an oven for drying for 1-5 hours at a drying temperature of 80-120°C.

7. The method for manufacturing a lightweight antibacterial seat according to claim 2, characterized in that: In the plying step, the number of plies of bamboo fiber layers and carbon fiber layers is determined according to the mass percentage of bamboo fiber and carbon fiber, and a special spray glue for fiber composite materials is used to bond the layers during plying.

8. The method for manufacturing a lightweight antibacterial seat according to claim 2, characterized in that: In the curing molding step, a vacuum bag is first used for packaging, and vacuum is evacuated to a negative pressure of -0.1-0.2MPa. After checking that there is no air leakage, the pressure is maintained for 10 minutes, and then a resin containing a curing agent is injected. The curing time is 3-10 hours and the curing temperature is 70-100°C.

9. The method for manufacturing a lightweight antibacterial seat according to claim 7, characterized in that: The mass percentage content of the carbon fiber is 20-50wt.%, the mass percentage content of the bamboo fiber is 10-40wt.%, and the mass percentage content of the resin is 40wt.%.

10. The method for manufacturing a lightweight antibacterial seat according to claim 2, characterized in that: The resin is one of epoxy resin, unsaturated resin and phenolic resin.

Images