PHC cellular board and preparation and assembly method thereof

Abstract

The invention relates to a PHC cellular board and a preparation and assembly method thereof. The PHC cellular board comprises a PHC cellular board base material and a knitted fabric covering material which is bonded and coated on the PHC cellular board base material; the PHC honeycomb board base material comprises a PU layer, a glass fabric layer, a honeycomb paper core, a glass fabric layer and a PU layer which are arranged in sequence; the knitted fabric covering material comprises a knitted fabric layer, a bonding layer and a non-woven fabric layer which are sequentially arranged. Compared with the prior art, the accessory can be fixed in a plastic nail mode, and the pre-burying procedure is omitted; and in the material acceptance and production quality monitoring process, independent verification and acceptance do not need to be carried out on the metal piece, the acceptance process is simplified, and the acceptance cost is saved.

Description

Technical Field

[0001] The invention relates to the technical field of automobile accessories, in particular to a PHC honeycomb panel and a preparation and assembly method thereof. Background Art

[0002] At present, when the design structure of the trunk cover / clothes rack is thicker, most of them use PHC (Paper Honeycomb) obtained by wet molding as the main base material, and the surface is covered with a fabric structure; it has the characteristics of light weight and high load-bearing capacity. However, since the base material PHC uses a honeycomb paper core material in the middle, the interior is a paper core cavity structure, and there is only a very thin layer of glass fiber + PU structure on the upper and lower surfaces. If accessories such as plastic parts need to be installed on its surface, the plastic parts cannot be directly welded to the surface of the glass fiber board base material like the glass fiber board structure. Summary of the invention

[0003] The purpose of the present invention is to provide a PHC honeycomb panel and a preparation and assembly method thereof, which can be assembled using plastic parts and can meet the fastness of fixing accessories.

[0004] The object of the present invention can be achieved by the following technical scheme: a PHC (honeycomb paper core + glass fiber + polyurethane composite material) honeycomb panel, comprising a PHC honeycomb panel substrate and a knitted fabric covering material bonded and coated on the PHC honeycomb panel substrate;

[0005] The PHC honeycomb panel substrate comprises a PU layer, a glass fiber cloth layer, a honeycomb paper core, a glass fiber cloth layer and a PU layer arranged in sequence;

[0006] The knitted fabric covering material comprises a knitted fabric layer, an adhesive layer and a non-woven fabric layer which are arranged in sequence.

[0007] Preferably, the honeycomb paper core uses a hexagonal honeycomb paper core with a side length of 8-12 mm, a thickness of 8-12 mm, and a unit area weight of 630-670 g / m 2 .

[0008] Preferably, the glass fiber cloth layer has a thickness of 0.5-1.0 mm and a weight per unit area of ​​480-520 g / m 2 .

[0009] Preferably, the PU layer has a thickness of 1.0-3.0 mm and a weight per unit area of ​​450-550 g / m 2 .

[0010] Preferably, the knitted fabric layer is made of PET, with a thickness of 0.5-1.0 mm and a unit area weight of 120-140 g / m 2 .

[0011] Preferably, the adhesive layer is made of PES with a unit area weight of 45-55 g / m 2 .

[0012] Preferably, the non-woven fabric layer is made of PET with a unit area weight of 65-75 g / m 2 .

[0013] Preferably, the knitted fabric covering material is bonded and coated with a non-woven fabric layer and a surface of the PHC honeycomb panel substrate by spraying PU hot melt adhesive.

[0014] Preferably, the PHC honeycomb panel further comprises a surface carpet arranged on the knitted fabric layer.

[0015] Further preferably, the surface carpet is made of PET knitted fabric with a thickness of 0.5-1.0 mm and a unit area weight of 240-260 g / m 2 .

[0016] Preferably, the preparation method of the PHC honeycomb panel substrate comprises the following steps: laying a layer of glass fiber cloth on the upper and lower sides of the honeycomb paper core, spraying a layer of PU foaming material on the surface of the glass fiber cloth, and finally placing it in a mold for heat insulation compression molding.

[0017] Preferably, the method for preparing the knitted fabric covering material comprises the following steps: compounding the knitted fabric and the non-woven fabric into an integrated structure via an intermediate adhesive layer.

[0018] A method for preparing the above-mentioned PHC honeycomb panel comprises the following steps:

[0019] S1: placing a knitted fabric covering material sprayed with hot melt adhesive in a covering tooling;

[0020] S2: Start the coating tooling to activate and heat the hot melt adhesive for a second time;

[0021] S3: After the hot melt adhesive is heated and melted, the PHC honeycomb panel substrate and the knitted fabric covering material are bonded and coated;

[0022] S4: After coating is in place, maintain pressure.

[0023] Preferably, in step (1), the hot melt adhesive is sprayed on the non-woven fabric layer of the knitted fabric covering material by heating spraying, and the spraying unit area weight is 90-110 g / m 2 .

[0024] Further preferably, the hot melt adhesive is PU hot melt adhesive.

[0025] Further preferably, the hot melt adhesive is sprayed in a mechanical and automatic granular manner.

[0026] Preferably, the secondary activation heating temperature in step (2) is 240-260° C. and the time is 4-6 seconds.

[0027] Preferably, the holding pressure in step (4) is 0.5-0.8 MPa and the holding time is 28-32 s.

[0028] An assembly method of the above-mentioned PHC honeycomb panel adopts a fixing method of piercing the PHC honeycomb panel with plastic nails to fix and connect the PHC honeycomb panel and plastic accessories.

[0029] Preferably, the plastic nail material is PA6-GF30. PA6-GF30 is a reinforced polyamide plastic consisting of a PA6 (polyamide 6) matrix and 30 wt% glass fiber.

[0030] Preferably, a nailing tool is used to rotate the plastic nails to generate heat by friction, so that the surface of the plastic nails is melted and softened, and viscosity is generated, and the surface of the PHC honeycomb panel is worn through and pressed into the interior. The viscosity generated on the surface of the plastic nails adheres to the contact surface of the internal glass fiber and honeycomb paper core and is fixedly connected together.

[0031] Further preferably, the rotation speed of the nailing tool is 1200-2000 rpm, and the torque is 3-5 N·m.

[0032] Further preferably, the nailing tool comprises an electric drill.

[0033] The traditional reliable connection method requires additional metal accessories (four-claw nuts + screws), and a separate pre-embedded process is required during the production process; during the material approval and production quality monitoring process, the metal accessories need to be subjected to additional verification tests (such as salt spray tests, metal surface protection requirements, etc.).

[0034] Compared with the prior art, the present invention has the following beneficial effects:

[0035] 1. The PHC honeycomb panel of the present invention can use plastic nails to fix accessories, which can save the pre-embedding process; and there is no need to conduct separate verification and approval for metal parts during material approval and production quality monitoring, which simplifies the approval process and saves approval costs.

[0036] 2. The PHC honeycomb panel of the present invention can meet the requirements of the fastness of the accessories. According to verification, the fastness of the fixed connection can reach more than 15kg.

[0037] 3. The present invention can meet various high and low temperature environments, such as: in a temperature cycle test of -40°C to 80°C and 50 cycles (25 days), there is no deformation of parts, no structural and functional damage, etc. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 It is a schematic diagram of the assembly of the PHC honeycomb panel of comparative example 1;

[0039] Figure 2 This is a schematic diagram of the assembly of the PHC honeycomb panel of Example 1;

[0040] In the figure: 1- four-claw nut, 2- screw, 3- plastic nail. DETAILED DESCRIPTION

[0041] The present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. This embodiment is implemented based on the technical solution of the present invention, and provides a detailed implementation method and specific operation process, but the protection scope of the present invention is not limited to the following embodiments.

[0042] Comparative Example 1

[0043] A PHC honeycomb panel comprises a surface carpet, a PU layer, a glass fiber cloth layer, a honeycomb paper core, a glass fiber cloth layer, a PU layer and a surface carpet which are arranged in sequence, wherein the surface carpet is a pile carpet with a gram weight of 300-400g / m 2 ; PU hot melt adhesive layer, sprayed on the upper and lower glass fiber cloth surfaces, with a gram weight of 80-120g / m 2 ; Glass fiber cloth layer, distributed above and below the honeycomb paper core, each layer weighs 400-500g / m 2 Honeycomb paper core, thickness 12-15mm, weight 650-750g / m 2 .

[0044] A method for preparing the above-mentioned PHC honeycomb panel luggage compartment visible parts comprises the following steps:

[0045] (1) Production of PHC honeycomb panels;

[0046] (2) Pre-embedded four-claw nut;

[0047] (3) The surface of the PHC honeycomb panel is coated with a hot melt adhesive;

[0048] (4) Use screws to assemble and fix the accessories into the pre-embedded four-claw nuts.

[0049] A kind of Figure 1 The assembly method of the PHC honeycomb panel shown comprises the following steps:

[0050] (1) Production of PHC honeycomb panels;

[0051] (2) Pre-embed four-claw nuts on the PHC honeycomb board;

[0052] (3) Spray PU hot melt adhesive on the back of the carpet fabric and use tooling to wrap it on the surface of the PHC honeycomb panel;

[0053] (4) On the back, use screws to secure the accessory assembly to the pre-embedded four-claw nut.

[0054] This comparative example is a traditional reliable connection method, which requires additional metal accessories (four-claw nuts + screws), and a separate pre-embedded process needs to be added during production; during the material approval and production quality monitoring process, the metal accessories need to be additionally verified and tested (such as salt spray tests, metal surface protection requirements, etc.).

[0055] Example 1

[0056] A new type of fixed connection method for PHC paper honeycombs and accessories; including face material punching, PHC wet forming, glue spraying and bonding, and accessory assembly. The specific steps are as follows:

[0057] a. Fabric punching

[0058] (1) The surface carpet fabric is knitted style, which is mostly used in mid-to-high-end models. The surface of the fabric is relatively delicate and smooth. The unit weight of the knitted carpet is about: 250g / m 2 .

[0059] (2) The knitted fabric is composed of three layers: the upper layer is a knitted fabric with a unit area weight of about 130 g / m 2 The middle layer is made of PES, and its unit area weight is 50g / m 2 The lower layer is PET non-woven fabric with a unit area weight of 70g / m 2 The three-layer structure is compounded into an integrated structure by heating the middle adhesive layer.

[0060] (3) The knitted fabric is punched out on a punching press using a punching die.

[0061] b. PHC wet molding

[0062] (1) The wet-formed PHC honeycomb panel substrate has the following structure: a middle honeycomb paper core, upper and lower glass fiber cloths, and finally PU sprayed on the upper and lower glass fiber cloths.

[0063] (2) The wet-formed PHC honeycomb panel substrate is composed of a 5-layer structure:

[0064] The middle honeycomb paper core uses a hexagonal honeycomb paper core with a side length of 10mm and a thickness of about 10mm. Its unit area weight is about 650g / m 2 ;

[0065] Lay a layer of fiberglass cloth on the top and bottom, with a unit area weight of about 500g / m 2 ;

[0066] A layer of PU foam is sprayed on the surface of the glass fiber cloth, and the unit area weight of each side is about 500g / m2 .

[0067] (3) The wet-formed PHC honeycomb panel substrate is made by placing the three-layer material of the honeycomb paper core and the upper and lower glass fiber cloth on the material rack of the honeycomb panel production line, and automatically clamping and transferring it to the PU nozzle by a robot. PU foaming material is sprayed on the surface of the upper and lower glass fiber cloths, and finally the material is placed in a mold by a robot for heat insulation and compression molding.

[0068] c. Spray glue bonding and coating

[0069] (1) Place the punched knitted fabric on the hot melt adhesive spray rack.

[0070] (2) Use the hot melt adhesive automatic heating spraying system to evenly spray PU hot melt adhesive on the back of the knitted fabric. The spraying weight per unit area is about 100g / m 2 .

[0071] (3) Place the PHC honeycomb panel in the specified position of the automatic covering tooling, and place the knitted fabric sprayed with hot melt adhesive in the specified position of the automatic covering tooling, and there are position supports on the positions to ensure the correct position.

[0072] Start the automatic covering tooling to activate and heat the hot melt adhesive of the knitted fabric for a second time. The heating temperature is about 250°C and the heating time is about 5s.

[0073] After the hot melt adhesive is heated and melted, the PHC honeycomb panel is bonded and coated with the fabric. After automatic coating in place, the equipment maintains pressure for about 30 seconds to produce stable initial adhesion.

[0074] d. Assembly

[0075] (1) Assemble the two plastic parts on the back of the coat rack. Figure 2 As shown, the assembly of plastic accessories adopts the fixing method of piercing the PHC honeycomb panel with plastic nails.

[0076] (2) The fixing method described above: the material of the plastic nail is PA6-GF30; the electric drill rotates the plastic nail to generate friction heat, melts and softens the surface of the plastic nail, generates viscosity, wears through the surface of the PHC, and presses it into the inside. The viscosity generated on the surface of the plastic nail adheres to the contact surface of the internal glass fiber and honeycomb paper core and is fixedly connected together.

[0077] Furthermore, in this embodiment, the plastic accessory is a fixing frame with a retaining spring, and this accessory can assemble the entire part onto the body sheet metal, thereby playing a role of clamping and fixing.

[0078] This embodiment has the following advantages over Comparative Example 1:

[0079] Comparative Example 1: Since the PHC honeycomb panel has a hollow structure inside and only a very thin layer of glass fiber + PU on the surface, the overall material is relatively brittle and plastic accessories cannot be fixed using traditional welding methods. Currently, the most reliable fixing method used is to use four-claw nuts embedded in the furniture industry and screws on the back. However, this method requires the use of additional metal parts, and approval tests require additional metal parts testing items, such as salt spray tests, and an additional four-claw nut embedding process. The manufacturing process is relatively lengthy and the approval process is relatively complicated. This embodiment uses plastic nails to directly fix to the inside of the PHC honeycomb panel: the material of the plastic nails is PA6-GF30, which can be widely used in interior decoration parts with stable performance. No additional production process is required, and no additional approval test items are required; there are relatively low development and production costs.

[0080] The above description of the embodiments is to facilitate the understanding and use of the invention by those skilled in the art. It is obvious that those skilled in the art can easily make various modifications to these embodiments and apply the general principles described herein to other embodiments without creative work. Therefore, the present invention is not limited to the above embodiments, and improvements and modifications made by those skilled in the art based on the disclosure of the present invention without departing from the scope of the present invention should be within the scope of protection of the present invention.

Claims

1. A PHC honeycomb panel, characterized in that: It includes a PHC honeycomb panel substrate and a knitted fabric covering material bonded and coated on the PHC honeycomb panel substrate; The PHC honeycomb panel substrate comprises a PU layer, a glass fiber cloth layer, a honeycomb paper core, a glass fiber cloth layer and a PU layer arranged in sequence; The knitted fabric covering material comprises a knitted fabric layer, an adhesive layer and a non-woven fabric layer which are arranged in sequence.

2. The PHC honeycomb panel according to claim 1, characterized in that: The honeycomb paper core uses a hexagonal honeycomb paper core with a side length of 8-12 mm and a thickness of 8-12 mm. Its unit area weight is 630-670 g / m 2 ; The glass fiber cloth layer has a thickness of 0.5-1.0 mm and a weight per unit area of ​​480-520 g / m 2 ; The PU layer has a thickness of 1.0-3.0 mm and a weight per unit area of ​​450-550 g / m 2 .

3. The PHC honeycomb panel according to claim 1, characterized in that: The knitted fabric layer is made of PET, with a thickness of 0.5-1.0 mm and a unit area weight of 120-140 g / m 2 ; The adhesive layer is made of PES, with a unit area weight of 45-55g / m 2 ; The non-woven fabric layer is made of PET, and the weight per unit area is 65-75g / m 2 .

4. The PHC honeycomb panel according to claim 1, characterized in that: The knitted fabric covering material is bonded and coated with the PU layer of the PHC honeycomb panel substrate through the non-woven fabric layer.

5. The PHC honeycomb panel according to claim 1, characterized in that: Also includes a surface carpet arranged on the knitted fabric layer, the surface carpet is made of PET, has a thickness of 0.5-1.0 mm, and a unit area weight of 240-260 g / m 2 .

6. The PHC honeycomb panel according to claim 1, characterized in that: The preparation method of the PHC honeycomb panel substrate comprises the following steps: laying a layer of glass fiber cloth on the upper and lower sides of the honeycomb paper core, spraying a layer of PU foaming material on the surface of the glass fiber cloth, and finally placing it in a mold for heat insulation molding; The method for preparing the knitted fabric covering material comprises the following steps: the knitted fabric and the non-woven fabric are compounded into an integrated structure via an intermediate adhesive layer.

7. A method for preparing a PHC honeycomb panel according to any one of claims 1 to 6, characterized in that: The following steps are involved: S1: placing a knitted fabric covering material sprayed with hot melt adhesive in a covering tooling; S2: Start the coating tooling to activate and heat the hot melt adhesive for a second time; S3: After the hot melt adhesive is heated and melted, the PHC honeycomb panel substrate and the knitted fabric covering material are bonded and coated; S4: After coating is in place, maintain pressure.

8. The method for preparing the PHC honeycomb panel according to claim 7, characterized in that: Step (1) spraying hot melt adhesive on the non-woven fabric layer of the knitted fabric covering material, using heated spraying, and the spraying unit area weight is 90-110g / m 2 ; The secondary activation heating temperature in step (2) is 240-260° C. and the time is 4-6 seconds; The holding pressure in step (4) is 0.5-0.8 MPa and the holding time is 28-32 s.

9. An assembly method of a PHC honeycomb panel according to any one of claims 1 to 6, characterized in that: The PHC honeycomb panel and the plastic accessories are fixedly connected by using a plastic nail to pierce the PHC honeycomb panel.

10. The method for assembling a PHC honeycomb panel according to claim 9, characterized in that: The plastic nail material is PA6-GF30; The nailing tool is used to rotate the plastic nails to generate heat through friction, so that the surface of the plastic nails melts and softens, generating viscosity, and then the surface of the PHC honeycomb panel is worn through and pressed into the inside. The viscosity generated on the surface of the plastic nails bonds with the contact surface of the internal glass fiber and honeycomb paper core, thus fixing them together.

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