Vehicle roof, preparation method thereof and vehicle

Abstract

The invention provides a vehicle ceiling, a preparation method thereof and a vehicle. The preparation method of the vehicle ceiling comprises the steps that a ceiling base material layer is coated with polystyrene foam in a roller coating mode; spraying a solution capable of removing formaldehyde to the ceiling base material layer; the ceiling base material layer, the glass fiber layer and the non-woven fabric are subjected to hot compression molding to form a ceiling framework; the ceiling framework, the fabric and the sound absorption layer are subjected to composite mold pressing together to obtain a ceiling body; and post-processing the ceiling body to obtain the vehicle ceiling. According to the preparation method of the vehicle roof, when spraying is carried out after the polystyrene foam is roller-coated on the roof base material layer, the solution for removing the formaldehyde is directly sprayed, foaming of the polystyrene foam is facilitated, the bonding and filling effects are achieved, the solution for removing the formaldehyde can penetrate into the vehicle roof to remove the formaldehyde, and the service life of the vehicle roof is prolonged. Compared with a traditional scheme of spraying a formaldehyde removal agent on a finished vehicle ceiling to remove formaldehyde, the formaldehyde removal device has the advantages of being high in efficiency, low in cost and high in production efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of vehicles, and in particular to a method for preparing a vehicle roof; meanwhile, the present invention also relates to a vehicle roof and a vehicle. Background Art

[0002] As an important part of car interior, the car ceiling has a large exposed area in the car, many types of materials, and many production process links, so its impact on the formaldehyde content in the car cannot be ignored. At present, the way to reduce formaldehyde in car ceilings is usually for manufacturers to spray formaldehyde removers on the ceiling products after they come off the line, and then ventilate for a certain period of time to dry them. However, this method cannot remove formaldehyde deeply, and it no longer has the effect of removing formaldehyde after drying, and cannot meet the continuous formaldehyde removal effect. In addition, in the process of ceiling production, drying the ceiling will increase the storage area and increase the production of work-in-progress, which will increase the production input cost and affect production efficiency. Summary of the invention

[0003] In view of this, the present invention aims to provide a method for preparing a vehicle ceiling to enhance the formaldehyde removal effect and improve the safety of the vehicle ceiling.

[0004] To achieve the above object, the technical solution of the present invention is achieved as follows:

[0005] A method for preparing a vehicle roof, the method comprising:

[0006] Roll-coat the foam glue on the ceiling substrate layer;

[0007] Spraying a solution capable of removing formaldehyde on the ceiling substrate layer;

[0008] The ceiling substrate layer, the glass fiber layer and the non-woven fabric are heat-molded to form a ceiling frame;

[0009] The ceiling frame is composite-molded together with the fabric and the sound-absorbing layer to obtain a ceiling body;

[0010] The roof body is post-processed to obtain the vehicle roof.

[0011] Further, the solution is an amino acid solution containing glutamic acid and / or cysteine, and the concentration of the amino acid solution is 0.5%-5%; and / or,

[0012] The weight ratio of the amount of glue in the foaming glue to the solution is (2-3):1.

[0013] Furthermore, before hot-molding the ceiling substrate layer, the glass fiber layer and the non-woven fabric into a ceiling frame, the preparation method further comprises:

[0014] A porous adsorption material is spread on the ceiling substrate layer to form a formaldehyde adsorption layer.

[0015] Further, the porous adsorption material includes at least one of coconut shell activated carbon and silicon dioxide; and / or,

[0016] The porous adsorption material has a particle size of 80-100 meshes and a specific surface area of ​​980-1020 m2 / g.

[0017] Furthermore, the spreading amount of the porous adsorption material is 80-90 g / m2.

[0018] Furthermore, the step of roller coating the foam adhesive on the ceiling substrate layer comprises:

[0019] Foam glue is rolled on the upper and lower sides of the ceiling substrate layer respectively; wherein the amount of glue rolled on the upper side of the ceiling substrate layer is 65g / m2-75g / m2, and the amount of glue rolled on the lower side of the ceiling substrate layer is 85g / m2-95g / m2.

[0020] Furthermore, the ceiling substrate layer, the glass fiber layer and the non-woven fabric are hot-molded to form a ceiling frame, comprising:

[0021] Using a mold temperature controller, pre-pressing the ceiling substrate layer, the glass fiber layer, and the non-woven fabric at a first preset temperature and a first preset pressure for a first preset time;

[0022] After pre-pressing for the first preset time, the ceiling substrate layer, the glass fiber layer and the non-woven fabric are pre-pressed at a second preset temperature and a second preset pressure, and the pressure is maintained for a second preset time.

[0023] Compared with the prior art, the present invention has the following advantages:

[0024] The method for preparing a vehicle ceiling described in the present invention directly sprays a solution for removing formaldehyde when spraying after rolling foam glue on the ceiling substrate layer, which is not only beneficial to the foaming of the foam glue and plays a bonding and filling role, but also enables the solution for removing formaldehyde to penetrate deeply into the interior of the vehicle ceiling to remove formaldehyde, thereby facilitating improving the formaldehyde removal effect. Compared with the traditional solution of spraying formaldehyde removal agent on the finished vehicle ceiling to remove formaldehyde, the method is not only efficient, but also does not require drying and does not require occupying too much production space. Moreover, the entire preparation method is based on the traditional preparation process and has the advantages of low cost and high production efficiency.

[0025] In addition, glutamic acid and cysteine ​​are both easily soluble in water, and after being dissolved in water, there are free amino groups (-NH2) in the aqueous solution. At room temperature, the aldehyde group (-CHO) of formaldehyde reacts with the amino group (-NH2) to form non-toxic and harmless hydroxymethyl derivatives, thereby achieving the effect of removing formaldehyde; by setting the concentration range of the amino acid solution, it is beneficial to ensure the formaldehyde removal effect and reduce production costs; the weight ratio range of the foam glue to the solution is beneficial to ensure the use requirements of foaming and formaldehyde removal. By spreading porous adsorption materials on the ceiling substrate layer to form a formaldehyde adsorption layer, formaldehyde can be physically adsorbed, thereby further improving the formaldehyde removal effect. Both coconut shell activated carbon and silica have good formaldehyde adsorption effects; the setting of the particle size and specific surface area range of the porous adsorption material is beneficial to ensure the formaldehyde adsorption effect while reducing production costs.

[0026] In addition, the setting of the spreading amount range of the porous adsorbent material is conducive to preventing the problem of poor formaldehyde adsorption effect caused by too little spreading of the porous adsorbent material, and is conducive to preventing excessive spreading amount from causing excessive cost. The setting of the glue amount range on the upper side of the ceiling substrate layer can, on the one hand, ensure sufficient bonding force with the subsequent covering material so that it can be firmly combined, and on the other hand, avoid excessive glue causing uneven thickness, uneven surface or glue overflow after foaming, which affects the appearance and quality of the ceiling; and the lower side of the ceiling substrate layer has a relatively large amount of glue, which makes the ceiling skeleton structure more stable in subsequent use. The ceiling substrate layer, glass fiber layer and non-woven fabric are pre-pressed for a first preset time at a first preset temperature and a first preset pressure by using a mold temperature controller, and maintained for a second preset time at a second preset temperature and a second preset pressure, which is conducive to ensuring the connection effect between the ceiling substrate layer, glass fiber layer and non-woven fabric.

[0027] In addition, another object of the present invention is to propose a vehicle roof made by the preparation method as described above, wherein the vehicle roof includes a ceiling substrate layer, a glass fiber layer and a non-woven fabric arranged in sequence on each side of the ceiling substrate layer, a fabric arranged outside the non-woven fabric on the lower side, and a sound-absorbing layer arranged outside the non-woven fabric on the upper side.

[0028] Furthermore, it also includes a formaldehyde adsorption layer arranged between the ceiling substrate layer and the glass fiber layer on the upper side, and the formaldehyde adsorption layer is made of a porous adsorption material.

[0029] The vehicle ceiling of the present invention is manufactured by adopting the above-mentioned process, which is beneficial to improving the formaldehyde removal effect and efficiency of the vehicle ceiling, thereby improving the safety of the vehicle ceiling.

[0030] In addition, the formaldehyde adsorption layer composed of porous adsorption material is provided to further improve the adsorption and removal effect of formaldehyde.

[0031] In addition, the present invention also provides a vehicle, which is provided with the vehicle roof as described above.

[0032] The vehicle described in the present invention is beneficial to improving the safety of the vehicle by providing the above vehicle roof. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The accompanying drawings constituting a part of the present invention are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the accompanying drawings:

[0034] Figure 1 A schematic diagram of the steps of a method for preparing a vehicle roof according to Embodiment 1 of the present invention;

[0035] Figure 2 This is a schematic structural diagram of a vehicle roof according to a second embodiment of the present invention.

[0036] Description of reference numerals:

[0037] 1. Ceiling substrate layer; 2. Glass fiber layer; 3. Non-woven fabric; 4. Formaldehyde adsorption layer; 5. Sound-absorbing layer; 6. Fabric. DETAILED DESCRIPTION

[0038] It should be noted that, in the absence of conflict, the embodiments of the present invention and the features in the embodiments may be combined with each other.

[0039] In the description of the present invention, it should be noted that the terms "upper", "lower", "inner", "outer", etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance.

[0040] The present invention will be described in detail below with reference to the accompanying drawings and in conjunction with embodiments.

[0041] Embodiment 1

[0042] The present embodiment relates to a method for preparing a vehicle ceiling, so as to solve the problems of low removal efficiency, high removal cost and large space occupation in the prior art method of removing formaldehyde from the vehicle ceiling.

[0043] like Figure 1As shown in the figure, the preparation method of the vehicle ceiling of this embodiment includes: rolling foam glue on the ceiling substrate layer 1; spraying the ceiling substrate layer 1 with a solution that can remove formaldehyde; hot molding the ceiling substrate layer 1, the glass fiber layer 2 and the non-woven fabric 3 into a ceiling frame; composite molding the ceiling frame with the fabric 6 and the sound-absorbing layer 5 to obtain a ceiling body; post-processing the ceiling body to obtain a vehicle ceiling.

[0044] The method for preparing the vehicle ceiling described in this embodiment directly sprays the formaldehyde-removing solution after rolling the foam glue on the ceiling substrate layer 1 and spraying it. This not only facilitates the foaming of the foam glue and plays a bonding and filling role, but also enables the formaldehyde-removing solution to penetrate into the interior of the vehicle ceiling to remove formaldehyde, thereby helping to improve the formaldehyde removal effect.

[0045] Compared with the traditional solution of spraying formaldehyde remover on the finished vehicle ceiling to remove formaldehyde, the preparation method of the vehicle ceiling of this embodiment not only has a high formaldehyde removal efficiency, but also does not require drying and does not need to occupy too much production space. The entire preparation method is based on the traditional preparation process and has the advantages of low cost and high production efficiency.

[0046] Specifically, the ceiling substrate layer 1 in this embodiment can be made of a polyurethane foam board, which contains a large number of closed-cell structures, which can effectively prevent the transfer of heat. During the use of the vehicle, it can reduce the transfer of external heat into the vehicle, and also reduce the heat loss in the vehicle, thereby ensuring the thermal insulation effect of the ceiling substrate layer 1. It also has the advantages of sound insulation, light weight and easy preparation.

[0047] In the step of roller coating the foam glue on the ceiling substrate layer 1, the preparation steps in the prior art can be the same, specifically, the two rubber rollers on the roller coating machine are respectively rotated and arranged on the upper and lower sides of the ceiling substrate layer 1, and the rubber rollers are in close contact with the surface of the ceiling substrate layer 1 and can rotate at a suitable speed. The rubber rollers dipped in glue are in contact with the ceiling substrate layer 1, and the foam glue is transferred to the surface of the ceiling substrate layer 1 through the rotation of the rubber rollers. The rotation speed of the rubber rollers and the transmission speed of the ceiling substrate layer 1 need to be well matched to ensure that the glue can be evenly coated on the substrate layer. In specific operations, the coating thickness of the foam glue can be controlled by adjusting factors such as the pressure between the rubber rollers and the ceiling substrate layer 1, the rotation speed of the rubber rollers, and the viscosity of the glue.

[0048] As a preferred embodiment, the foaming glue is rolled on the ceiling substrate layer 1, including: rolling the foaming glue on the upper side and the lower side of the ceiling substrate layer 1. The amount of glue rolled on the upper side of the ceiling substrate layer 1 is 65-75 g / m2, and the amount of glue rolled on the lower side of the ceiling substrate layer 1 is 85-95 g / m2. The range of the amount of glue rolled on the upper side of the ceiling substrate layer 1 can ensure sufficient adhesion with the subsequent covering material so that it can be firmly combined, and avoid excessive glue causing uneven thickness, uneven surface or glue overflow after foaming, which affects the appearance and quality of the ceiling.

[0049] The amount of glue on the lower side of the ceiling substrate layer 1 is relatively large because the lower side is an important bonding part of the frame structure. More glue helps to enhance the connection strength between the layers of material, making the ceiling frame structure more stable in subsequent use and better able to withstand various external forces.

[0050] The glue amount of the foam glue of the upper roller coating can be, for example, 65g / m2, 68g / m2, 70 / m2, 72g / m2, 73g / m2, 74g / m2 or 75g / m2. The glue amount of the foam glue of the lower roller coating can be 85g / m2, 88g / m2, 89g / m2, 90 / m2, 92g / m2, 93g / m2, 94g / m2 or 95g / m2 etc.

[0051] As a preferred embodiment, the solution is an amino acid solution containing glutamic acid and / or cysteine, and the concentration of the amino acid solution is 0.5%-5%. Among them, glutamic acid and cysteine ​​are both easily soluble in water, and after being dissolved in water, there are free amino groups (-NH2) in the aqueous solution. At room temperature, the aldehyde group (-CHO) of formaldehyde and the amino group (-NH2) undergo nucleophilic addition reaction to generate non-toxic and harmless hydroxymethyl derivatives, thereby achieving the effect of removing formaldehyde.

[0052] In addition, by setting the density range of the amino acid solution, it is beneficial to ensure the formaldehyde removal effect while reducing production costs. When the concentration of the solution is lower than 0.5%, the content of amino acids in the solution is low, and the active sites for reacting with formaldehyde are insufficient, so the formaldehyde in the ceiling substrate layer 1 cannot be effectively removed. A concentration exceeding 5% will increase production costs. In specific implementation, for example, the concentration of the amino acid solution is 0.5%, 1%, 1.5%, 2%, 2.5%, 3%, 3.5%, 4%, 4.5% or 5%.

[0053] The components of the amino acid solution of this embodiment include industrial water, glutamic acid and / or cysteine. In the step of spraying the ceiling substrate layer 1 with a solution capable of removing formaldehyde, the process of spraying water in the prior art can be used, but what is sprayed is not industrial water but a solution capable of removing formaldehyde. In addition, amino acids contain active functional groups such as carboxyl (-COOH) and can react chemically with formaldehyde (HCHO). Specifically, amino groups can react with formaldehyde to form relatively stable compounds. For example, after the amino group of glutamic acid reacts with formaldehyde, a methylene amino compound is generated, and the chemical properties of this compound are much more stable than formaldehyde, thereby effectively reducing the content of formaldehyde.

[0054] When glutamic acid and cysteine ​​are contained in an amino acid residue at the same time, they will produce a synergistic effect. In addition to reacting with formaldehyde like glutamic acid, the thiol group (-SH) contained in cysteine ​​may also participate in other chemical reactions. The thiol group has strong reducing properties and can undergo redox reactions with formaldehyde under certain conditions, further consuming formaldehyde. Moreover, the different chemical structures of the two amino acids will cooperate with each other in the formaldehyde removal process to improve the efficiency of formaldehyde removal. For example, they may change the pH of the solution or the distribution of reactive sites, making formaldehyde easier to capture and convert.

[0055] In addition, in this embodiment, the area of ​​the ceiling substrate layer 1 is the area used to make a vehicle ceiling, and the area of ​​the ceiling substrate layer 1 is 2.5-4.6m 2 The weight ratio of the glue amount of the foam glue to the solution on the ceiling substrate layer 1 is (2-3):1. The foam glue amount here includes the total amount of the foam glue rolled on the upper and lower sides. In specific implementation, the weight ratio of the glue amount of the foam glue to the solution can be, for example, 2:1, 2.5:1, or 3:1. For example, the area of ​​the ceiling substrate layer 1 is 3m 2 The upper roller glue amount is 210g, the upper water amount is 87.5g. The lower roller glue amount is 270g, the lower water amount is 112.5g, and the total water amount is 200g.

[0056] In this embodiment, the setting of the weight ratio range of the glue amount to the solution is conducive to ensuring the foaming effect of the foam glue during the spraying of the solution, thereby forming a foam structure with good filling and cushioning properties on the ceiling substrate layer 1. This foam structure can improve the heat insulation and sound insulation performance of the ceiling, and also enhance the mechanical strength of the ceiling. It is also conducive to ensuring the use requirements of formaldehyde removal, and thus to ensuring the safety of the vehicle ceiling.

[0057] In this embodiment, a spray system is used to spray the amino acid solution. The spray system can be a product in the prior art. The upper and lower sides of the ceiling substrate layer 1 are sprayed with water. The spray amount of the amino acid solution ranges from 10 to 130 g / m2 , water spraying accuracy requirement: ±5g / ㎡, the equipment water spraying CMK≥1.67, the filter element ≤10 mesh, which is conducive to improving the spraying efficiency and spraying uniformity of the amino acid solution, thus providing a good basis for the formaldehyde removal of the amino acid solution. For example, the water spraying range of the amino acid solution is: 10g / m 2 , 50g / m 2 , 800g / m 2 , 100g / m 2 or 130m 2 .

[0058] The amino acid solution in this embodiment not only makes it easier for the glue to flow and diffuse on the surface of the substrate layer, thereby filling the tiny pores and unevenness on the surface of the substrate layer, but also helps to ensure that the glue and the substrate layer are more firmly bonded, and can form a more uniform foam layer after foaming, thereby improving the overall quality of the product. At the same time, it also allows the amino acid solution to react with the internal formaldehyde, achieving a better formaldehyde removal effect.

[0059] Preferably, in this embodiment, before the ceiling substrate layer 1, the glass fiber layer 2 and the non-woven fabric 3 are hot-molded into a ceiling frame, a porous adsorption material is spread on the ceiling substrate layer 1 to form a formaldehyde adsorption layer 4. Although a solution containing amino acids has been sprayed to remove formaldehyde through chemical reactions, adding a physical adsorption formaldehyde adsorption layer 4 can treat formaldehyde from different mechanisms to achieve better formaldehyde removal effects, minimize the formaldehyde content in the vehicle ceiling, ensure the air quality in the vehicle, and reduce its potential harm to the health of drivers and passengers. Here, by spreading a porous adsorption material on the ceiling substrate layer 1 to form a formaldehyde adsorption layer 4, formaldehyde can be physically adsorbed, thereby further improving the formaldehyde removal effect.

[0060] Among them, the porous adsorption material includes at least one of coconut shell activated carbon and silicon dioxide. Among them, coconut shell activated carbon has a highly developed pore structure, a large specific surface area and good adsorption performance, and can effectively adsorb a variety of harmful gases including formaldehyde. Silicon dioxide also has a porous structure and a certain adsorption capacity, which can assist or cooperate with coconut shell activated carbon to enhance the overall adsorption effect. And the combination of coconut shell activated carbon and silicon dioxide can give full play to their respective advantages, broaden the adsorption range and improve the adsorption efficiency.

[0061] During specific implementation, the particle size of the porous adsorption material is 80-100 mesh, and the specific surface area is 980-1020m2 / g. The particle size of the porous adsorption material is controlled at 80-100 mesh, and the particle size has an important influence on the adsorption effect and the process. The appropriate particle size can ensure that the adsorption material is spread more evenly on the ceiling substrate layer 1, and it will not easily agglomerate due to too fine particles, nor will it be unevenly distributed due to too coarse particles, and there will be local vacancies. In addition, this particle size range helps to better integrate and fix the adsorption material with other materials during hot molding, ensuring that the adsorption layer is stably present in the ceiling frame and continues to play an adsorption role.

[0062] In addition, the specific surface area is required to reach 980-1020m2 / g. A larger specific surface area means that the material has more adsorption sites, which can greatly enhance the physical adsorption capacity of formaldehyde. Within this specific surface area range, the adsorbent material can fully utilize its abundant pores and surface to capture formaldehyde molecules at a limited dosage, and efficiently exert the adsorption effect to ensure the removal effect of formaldehyde in the vehicle ceiling.

[0063] In this embodiment, after spreading the porous adsorbent material, hot molding is performed to form the ceiling frame. The temperature, pressure and other conditions during the hot molding process not only help to tightly combine the ceiling substrate layer 1, the glass fiber layer 2 and the non-woven fabric 3, but also better fix the spread porous adsorbent material in the ceiling frame structure, making it a stable formaldehyde adsorption layer 4. Moreover, the hot molding process will not damage the adsorption performance of the porous adsorbent material. On the contrary, to a certain extent, by compacting the material, the contact state between the adsorbent material and other materials may be optimized, further ensuring its effect of adsorbing formaldehyde, so that it cooperates with the previous chemical formaldehyde removal method of spraying the formaldehyde removal solution, and synergizes and enhances the overall environmental performance of the vehicle ceiling.

[0064] Furthermore, the amount of porous adsorption material spread on the ceiling substrate layer 1 is 80-90g / m2. The setting of this range is conducive to ensuring that a sufficiently dense adsorption layer is formed on the surface of the ceiling substrate layer 1, and is conducive to ensuring that there are a sufficient number of adsorption particles per unit area to provide sufficient adsorption sites to cope with the possible release of formaldehyde. If the spreading amount is too low, for example, the spreading amount is less than 80g / m2, the adsorption material is too sparse, resulting in insufficient adsorption sites per unit area, and unable to effectively physically adsorb formaldehyde, thereby affecting the formaldehyde removal effect. On the contrary, if the spreading amount is too high, for example, the spreading amount exceeds 90g / m2, the adsorption material may accumulate, which not only wastes materials and increases costs, but also may affect the bonding effect between materials in the subsequent hot molding process, as well as the overall physical properties of the vehicle roof.

[0065] In the subsequent hot molding process to form the ceiling frame, the adsorption material spreading amount of 80-90g / m2 can better match the hot molding process. This spreading amount can make the adsorption material evenly distributed between the ceiling substrate layer 1, the glass fiber layer 2 and the non-woven fabric 3 under the pressure and temperature of the hot molding, forming a stable formaldehyde adsorption layer 4.

[0066] The amount of porous adsorbent material is 240-270g. Here, the amount of porous adsorbent material is 240-270g. This amount range is a more appropriate interval obtained through practice or experimental verification. When the amount of porous adsorbent material is less than 240g, it may not be able to fully cover the ceiling substrate layer 1, and the density of the adsorption layer formed is insufficient, making it difficult to achieve comprehensive and effective adsorption of formaldehyde that may be released. If the amount of porous adsorbent material is greater than 270g, on the one hand, it may increase costs, and on the other hand, it may have an adverse effect on material bonding and other aspects in subsequent processes such as hot molding, such as affecting the tightness of the fit between materials or causing local accumulation of adsorbent materials.

[0067] In addition, in this embodiment, the amount of porous adsorption material and the amino acid solution to remove formaldehyde work together. On the basis of chemical formaldehyde removal, physical adsorption further improves the formaldehyde removal efficiency with an appropriate amount of spreading. The 80-90g / m2 adsorption material can make full use of its own physical adsorption characteristics without interfering with the chemical formaldehyde removal process, complementing the chemical formaldehyde removal, and minimizing the formaldehyde content in the vehicle ceiling. In specific implementation, the porous adsorption material is spread on the ceiling substrate layer 1 by a spreader.

[0068] During specific operation, the spreading speed of the spreader is 100-300r / min, and the operating speed of the ceiling substrate layer 1 during the spreading process is 8-21m / min. The spreading speed of the spreader directly affects the uniformity of the spreading of the porous adsorption material on the ceiling substrate layer 1. When the rotation speed is too low, such as lower than 100r / min, less adsorption material is spread per unit time, which may lead to insufficient local spreading on the ceiling substrate layer 1, and it is impossible to form a continuous and uniform formaldehyde adsorption layer 4, affecting the subsequent adsorption effect of formaldehyde. When the rotation speed is too high, exceeding 300r / min, the adsorption material may accumulate due to too fast spreading, and a large amount of adsorption material is concentrated in certain areas, which also destroys the uniformity of the adsorption layer, and may also cause material waste and increase costs.

[0069] The running speed of the ceiling substrate layer 1 determines the length of time it passes under the spreader and the area that receives the spread material per unit time. If the running speed is lower than 8m / min, although the adsorption material can be spread more finely and evenly, it will lead to low production efficiency and may cause the same area to receive too much adsorption material, destroying the uniformity of the spreading amount. On the contrary, if the running speed exceeds 21m / min, the adsorption material may not be spread evenly on the substrate layer in time, resulting in some areas not being spread or the spread material being too sparse, and it is impossible to form a complete and effective formaldehyde adsorption layer 4 on the entire ceiling substrate layer 1.

[0070] In addition, the operating speed of the ceiling substrate layer 1 and the spreading speed of the spreader need to work together, and the two together affect the final spreading effect and the distribution of the adsorbent material. For example, when the spreading speed is fast (close to 300r / min), it may be necessary to appropriately increase the operating speed of the ceiling substrate layer 1 (reasonably increase it within the range of 8-21m / min) so that the adsorbent material can be spread out quickly and evenly on the constantly moving substrate layer; conversely, when the spreading speed is slow, the operating speed of the substrate layer should also be reduced accordingly to ensure the uniform spreading of the adsorbent material and to meet the specified spreading amount requirements.

[0071] In this embodiment, the ceiling substrate layer 1, the glass fiber layer 2 and the non-woven fabric 3 are hot-molded into a ceiling frame, including: using a mold temperature controller, pre-pressing the ceiling substrate layer 1, the glass fiber layer 2 and the non-woven fabric 3 at a first preset temperature and a first preset pressure for a first preset time. After pre-pressing for the first preset time, the ceiling substrate layer 1, the glass fiber layer 2 and the non-woven fabric 3 are pre-pressed at a second preset temperature and a second preset pressure, and the pressure is maintained for a second preset time. Hot molding combines operations such as heating, pressing and maintaining pressure, which can make different materials tightly fuse together under specific conditions to form a ceiling frame with good structure and performance, laying the foundation for subsequent processes such as compounding with the fabric 6.

[0072] The ceiling substrate layer 1, the glass fiber layer 2 and the non-woven fabric 3 are hot-molded to form a ceiling frame. Specifically, the glass fiber layer 2 is provided on both sides of the ceiling substrate layer 1, and the non-woven fabric 3 is provided on each glass fiber layer 2 away from the ceiling substrate layer 1. These parts are hot-molded to form a ceiling frame. The first preset temperature is 160-170°C, the actual mold temperature is 135-145°C, the first preset pressure is 14-16MPa, the first pre-pressing time is 10-20s, the second preset pressure is 14-16MPa, the second preset time is 15-25s, and the total holding time reaches 30-40s.

[0073] In a specific implementation, the first preset temperature may be, for example, 160° C., 162° C., 164° C., 166° C., 168° C., 169° C., or 170° C. The actual temperature of the mold may be 135° C., 138° C., 140° C., 142° C., or 145° C. The first preset pressure may be, for example, 14 MPa, 14.5 MPa, 15 MPa, 15.5 MPa, or 16 MPa. The first pre-pressing time may be, for example, 10 s, 12 s, 14 s, 16 s, 18 s, 19 s, or 20 s.

[0074] The second preset temperature is 160-170°C, for example, 160°C, 162°C, 164°C, 166°C, 168°C, 169°C or 170°C. The second preset pressure can be, for example, 14MPa, 14.5MPa, 15MPa, 15.5MPa or 16MPa, and the second preset time can be, for example, 15s, 18s, 20s, 24s or 25s. It should be noted that the numerical range of the second preset temperature and the first preset temperature can be the same or different, as long as the use requirements are met.

[0075] Among them, the setting of the above parameters is crucial, and their coordination directly affects the plasticity of the material and the bonding effect between the materials. Different materials (ceiling substrate layer 1, glass fiber layer 2 and non-woven fabric 3) will undergo corresponding physical changes after being heated, such as becoming softer and easier to shape. The appropriate temperature can enhance the activity of the molecular chains of these materials, making it easier for them to interweave and entangle with each other under pressure, thereby achieving a tight bond.

[0076] Through the above-mentioned standardized hot molding process operation, the ceiling substrate layer 1, the glass fiber layer 2 and the non-woven fabric 3 can be fully integrated into a whole, and the formed ceiling frame has good strength, can withstand external forces such as vibration and bumps during vehicle driving, and is not easy to deform and damage. At the same time, hot molding makes the materials tightly combined, which can effectively avoid the occurrence of stratification and ensure the structural stability of the ceiling frame. In addition, this process also has a positive impact on the appearance flatness of the ceiling frame, so that it can be better composite molded with the subsequent fabric 6, improving the quality and performance of the entire vehicle ceiling.

[0077] In the step of composite molding the ceiling frame, the fabric 6 and the sound absorbing layer 5 together to obtain the ceiling body, specifically, the fabric 6 is arranged at the bottom of the ceiling body, and the sound absorbing layer 5 is arranged at the top of the ceiling body. In this process, the mold temperature controller is set at 120-140°C, the mold body temperature is 105-125°C, the holding pressure is 10-12Mpa, and the holding time is 30-40s. Among them, the set temperature can be, for example, 120°C, 132°C, 134°C, 136°C, 138°C, 139°C or 140°C, and the holding pressure can be 10MPa, 10.5MPa, 11MPa, 11.5MPa or 12MPa. The holding time can be 30s, 32s, 35s, 38s or 40s.

[0078] The sound-absorbing layer 5 is made of sound-absorbing cotton. Through the above-mentioned standardized composite molding process, the mold temperature setting temperature, mold body temperature, holding pressure and holding time and other parameters are strictly controlled, so that the roof frame, fabric 6 and sound-absorbing layer 5 can be successfully composited into one, and the formed roof body has good appearance quality, comfortable touch, reliable structural stability and excellent sound absorption and noise reduction performance. This not only improves the overall quality of the vehicle roof, but also provides a more comfortable and quiet driving environment for the occupants, meeting the various needs of the vehicle roof in actual use.

[0079] In this embodiment, the step of post-processing the ceiling body to obtain the vehicle ceiling specifically refers to cutting the ceiling body using a high-pressure water jet cutting robot. In the specific operation, the high-pressure water jet cutting robot runs along the trajectory and sprays high-pressure water jets to achieve cutting, ensuring that the waste material is slightly adhered to the ceiling body, and the ceiling body and the waste material can be taken out together. After taking out, the waste material is gently pulled to separate it from the ceiling body, and then the ceiling body is hemmed and attached.

[0080] In order to verify the formaldehyde removal effect of the preparation method in this embodiment, a product prepared by a conventional vehicle ceiling preparation process was used as a comparative example and compared with the vehicle ceiling prepared in this embodiment. The specific proportions of Example 1 and Example 30 are shown in Tables 1 to 5.

[0081] Table 1: Proportions of Example 1 to Example 8. Table 2: Proportions of Example 9 to Example 16.

[0082] Table 3: Proportions of Example 17 to Example 24.

[0083]

[0084] Table 4: Proportions of Examples 25 to 32.

[0085]

[0086] Table 5: Proportions of Example 33, Example 34 and Comparative Example.

[0087]

[0088] Table 6: Comparative verification results of various embodiments and comparative examples.

[0089]

[0090] (Wherein, formaldehyde removal rate = [(formaldehyde detection value before removal - formaldehyde detection value after removal) / formaldehyde detection value before removal] × 100%)

[0091] As can be seen from the above tables, each embodiment has an improved effect on formaldehyde removal. Among them, it can be seen from Embodiments 1 to 24 that only glutamic acid or cysteine ​​is set in the amino acid solution. The solutions in which only coconut shell activated carbon or silicon dioxide is set in the formaldehyde adsorption layer all have good formaldehyde removal effects. Comparing Embodiments 25 to 28, the amino acid solution using glutamic acid has a better formaldehyde removal rate than the cysteine ​​solution.

[0092] Comparing Examples 29 to 34, the formaldehyde removal rate of coconut shell activated carbon in the formaldehyde adsorption layer 4 is better than that of silicon dioxide. Comparing Example 30 with Example 31, the coconut shell activated carbon in the formaldehyde adsorption layer 4 is increased from 270g to 320g, and the improvement effect is no longer obvious. The formaldehyde removal effects of Examples 5 and 6 are both good, and the cost of Example 5 is lower.

[0093] The method for preparing the vehicle ceiling described in this embodiment replaces the liquid supply water with an amino acid solution in the spraying step after the rolling glue, so that the amino acid solution can also decompose the formaldehyde in the ceiling body without changing the original catalytic foaming glue function of water. After the spraying step, a porous adsorption material is added for subsequent processes, so that the final ceiling product has the function of self-adsorbing and capturing formaldehyde, without changing the original vehicle ceiling preparation process, the entire preparation method has a low investment cost, and has a good formaldehyde removal effect.

[0094] Embodiment 2

[0095] This embodiment relates to a vehicle roof made by the preparation method described in Example 1. Figure 2As shown in the figure, the vehicle ceiling described in this embodiment includes a ceiling substrate layer 1, a glass fiber layer 2 and a non-woven fabric 3 arranged in sequence on each side of the ceiling substrate layer 1, a fabric 6 arranged outside the lower non-woven fabric 3, and a sound-absorbing layer 5 arranged outside the upper non-woven fabric 3.

[0096] Furthermore, the vehicle roof also includes a formaldehyde adsorption layer 4 disposed between the roof substrate layer 1 and the upper glass fiber layer 2, and the formaldehyde adsorption layer 4 is composed of a porous adsorption material. The porous adsorption material is prepared by the step of "spreading the porous adsorption material on the ceiling substrate layer 1 to form the formaldehyde adsorption layer 4 before hot molding the ceiling substrate layer 1, the glass fiber layer 2 and the non-woven fabric 3 into a ceiling frame" in Example 1.

[0097] The vehicle ceiling of this embodiment is made by adopting the above process, which is conducive to improving the formaldehyde removal effect and efficiency of the vehicle ceiling, thereby improving the use safety of the vehicle ceiling. In addition, by providing a formaldehyde adsorption layer 4 composed of a porous adsorption material, it is conducive to further improving the adsorption and removal effect of formaldehyde.

[0098] Embodiment 3

[0099] The present embodiment relates to a vehicle provided with the vehicle roof as described above.

[0100] The vehicle described in this embodiment is helpful to improve the safety of the vehicle by providing the above vehicle roof.

[0101] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for preparing a vehicle roof, characterized in that: The preparation method comprises: Rolling foam glue onto the ceiling substrate layer (1); Spraying a solution capable of removing formaldehyde onto the ceiling substrate layer (1); The ceiling substrate layer (1), the glass fiber layer (2) and the non-woven fabric (3) are hot-molded to form a ceiling frame; The ceiling frame is composite-molded together with the fabric (6) and the sound-absorbing layer (5) to obtain a ceiling body; The roof body is post-processed to obtain the vehicle roof.

2. The method for preparing a vehicle ceiling according to claim 1, characterized in that: The solution is an amino acid solution containing glutamic acid and / or cysteine, and the concentration of the amino acid solution is 0.5%-5%; and / or, The weight ratio of the amount of glue in the foaming glue to the solution is (2-3):

1.

3. The method for preparing a vehicle roof according to claim 1, characterized in that: Before the ceiling substrate layer (1), the glass fiber layer (2) and the non-woven fabric (3) are hot-molded to form the ceiling frame, the preparation method further comprises: A porous adsorption material is spread on the ceiling substrate layer (1) to form a formaldehyde adsorption layer (4).

4. The method for preparing a vehicle ceiling according to claim 3, characterized in that: The porous adsorption material comprises at least one of coconut shell activated carbon and silicon dioxide; and / or, The porous adsorption material has a particle size of 80-100 meshes and a specific surface area of ​​980-1020 m2 / g.

5. The method for preparing a vehicle ceiling according to claim 4, characterized in that: The spreading amount of the porous adsorbent material is 80-90 g / m2.

6. The method for preparing a vehicle roof according to claim 1, characterized in that: The step of rolling the foam glue on the ceiling substrate layer (1) comprises: Rolling foam glue on the upper side and the lower side of the ceiling substrate layer (1); The amount of glue applied by roller on the upper side of the ceiling substrate layer (1) is 65-75 g / m2, and the amount of glue applied by roller on the lower side of the ceiling substrate layer (1) is 85-95 g / m2.

7. The method for preparing a vehicle roof according to claim 1, characterized in that: The method of hot-molding the ceiling substrate layer (1), the glass fiber layer (2) and the non-woven fabric (3) into a ceiling frame comprises: Using a mold temperature controller, pre-pressing the ceiling substrate layer (1), the glass fiber layer (2) and the non-woven fabric (3) at a first preset temperature and a first preset pressure for a first preset time; After pre-pressing for the first preset time, the ceiling substrate layer (1), the glass fiber layer (2) and the non-woven fabric (3) are pre-pressed at a second preset temperature and with a second preset pressure, and the pressure is maintained for a second preset time.

8. The vehicle roof manufactured by the manufacturing method according to any one of claims 1 to 7, characterized in that: The vehicle roof comprises a roof substrate layer (1), a glass fiber layer (2) and a non-woven fabric (3) arranged in sequence on each side of the roof substrate layer (1), a fabric (6) arranged outside the non-woven fabric (3) on the lower side, and a sound absorbing layer (5) arranged outside the non-woven fabric (3) on the upper side.

9. The vehicle roof according to claim 8, characterized in that: It also includes a formaldehyde adsorption layer (4) arranged between the ceiling substrate layer (1) and the glass fiber layer (2) on the upper side, wherein the formaldehyde adsorption layer (4) is made of a porous adsorption material.

10. A vehicle, characterized in that: The vehicle is provided with the vehicle roof according to claim 8 or 9.

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