Automotive interior material taking natural bamboo fiber as raw material and preparation method of automotive interior material

Abstract

The invention relates to the technical field of automotive interior materials, in particular to an automotive interior material with natural bamboo fibers as raw materials and a preparation method of the automotive interior material. Comprising the following components in parts by weight: 48-82 parts of modified bamboo fibers, 15-26 parts of modified polylactic acid fibers, 12-18 parts of modified palm fibers, 21-45 parts of polylactic acid, 10-15 parts of modified phenolic resin, 2-5 parts of a dispersant, 2-5 parts of a stabilizer and 1-2 parts of a curing agent. According to the prepared automotive interior material with the natural bamboo fibers as the raw material, the modified natural bamboo fibers are adopted, so that the automotive interior material has multiple functions of light weight, high strength, excellent acoustic and thermal performance, flame retardance, antibiosis, low VOC and the like, has the advantages of reproducibility, low carbon, cost and unique natural aesthetic feeling, and remarkably reduces the automobile weight, oil consumption and environmental load; and greenization, functionalization and cost reduction of the automotive trim are realized.

Description

Technical Field

[0001] This invention relates to the field of automotive interior materials technology, and more specifically, to an automotive interior material using bamboo fiber as a raw material and its preparation method. Background Technology

[0002] As my country's new energy vehicle industry continues to expand and improve, both the production and consumption ends of domestic new energy vehicles are placing increasingly higher demands on their overall performance, especially their safety performance. For new energy vehicle users and potential consumers, the braking system not only needs to possess excellent performance but also requires continuous optimization in terms of cost and environmental performance.

[0003] Bamboo fiber (BF), as a natural material, has a dense and orderly fiber structure. This unique structure endows BF with excellent mechanical properties, giving it high strength and toughness, and enabling it to withstand tensile and bending stresses well. Furthermore, BF has advantages such as wide availability, low price, and biodegradability. Therefore, BF is an ideal filler and modifier for polylactic acid (PLA). BF has achieved good results in improving the mechanical properties, flame retardancy, barrier properties, and thermal properties of polymers. Gong Xinhuai et al. investigated the influence of BF morphology (including bamboo powder fiber, bamboo shavings fiber, bamboo virgin fiber, and bamboo pulp fiber) on the properties of PLA-based composites, finding that bamboo fiber / PLA had the best overall mechanical properties, followed by bamboo shavings fiber / PLA, while bamboo pulp fiber / PLA had the worst.

[0004] As a natural material, bamboo fiber exhibits dimensional inhomogeneity, leading to insufficient uniformity and stability of the mechanical properties of the prepared composite panels. Longer fibers are prone to entanglement when forming areas with small curvatures, resulting in uneven surfaces on both the inner and outer surfaces of the components, making it difficult to meet the surface requirements of automotive interior parts. Furthermore, unmodified bamboo fiber does not bond firmly to the matrix (such as polypropylene), reducing the flexural properties of the composite material. Summary of the Invention

[0005] This invention provides an automotive interior material using bamboo fiber as a raw material and its preparation method. The resulting automotive interior material using bamboo fiber as a raw material incorporates modified bamboo fiber, which combines lightweight, high strength, excellent acoustic and thermal properties with multiple functions such as flame retardancy, antibacterial properties, and low VOCs. It also possesses advantages in renewability, low carbon emissions, cost, and unique natural aesthetics, significantly reducing vehicle weight, fuel consumption, and environmental impact, thus achieving greening, functionalization, and cost-effectiveness of automotive interiors.

[0006] In a first aspect, the present invention provides an automotive interior material using bamboo fiber as raw material, comprising the following components by weight: 48-82 parts of modified bamboo fiber, 15-26 parts of modified polylactic acid fiber, 12-18 parts of modified palm fiber, 21-45 parts of polylactic acid, 10-15 parts of modified phenolic resin, 2-5 parts of dispersant, 2-5 parts of stabilizer and 1-2 parts of curing agent.

[0007] Preferably, the modified bamboo fiber is prepared by adding coconut shell fiber and polypropylene to bamboo fiber and then grafting maleic anhydride, wherein the mass ratio of bamboo fiber, coconut shell fiber, polypropylene and maleic anhydride is 3~8:2~3:1~3:1~2.

[0008] Preferably, the modified polylactic acid fiber is prepared by electrospinning after adding nano-cerium oxide to polylactic acid; the amount of nano-cerium oxide added is 5%~12%.

[0009] Preferably, the modified palm fiber is prepared by adding ceramsite and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) to palm fiber, wherein the mass ratio of palm fiber, ceramsite and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) is 7~11:3~5:1~2.

[0010] Preferably, the modified phenolic resin is prepared by adding nitrile rubber and cashew phenol, wherein the mass ratio of nitrile rubber to cashew phenol is 1~3:1.

[0011] Preferably, the dispersant is at least one of sodium hexametaphosphate, potassium tripolyphosphate, sodium polyacrylate, and polyvinyl alcohol.

[0012] Preferably, the stabilizer is at least one of o-hydroxybenzophenone, benzotriazole, salicylate, and hindered amine.

[0013] Preferably, the curing agent is at least one of ethylenediamine, diaminodiphenylmethane, and polyisocyanate.

[0014] Secondly, the present invention provides a method for preparing automotive interior materials using bamboo fiber as a raw material, comprising the following steps: (1) Modified bamboo fiber, modified polylactic acid fiber, and modified palm fiber are prepared into fiber layers of 0.01~0.05 mm using a fiber spreading device; (2) Mix polylactic acid, modified phenolic resin, dispersant, stabilizer and curing agent at 125~140℃ to obtain a mixture; (3) Inject the mixture obtained in step (2) into the fiber layer obtained in step (1). After injection, keep it warm and pressurized for 10~20 minutes and then reduce the temperature to 60~75℃ to obtain the finished product.

[0015] Thirdly, the present invention provides an application of an automotive interior material using bamboo fiber as a raw material in the preparation of automotive interior parts.

[0016] In summary, the present invention has the following beneficial effects: 1. The modified bamboo fiber in this invention features high strength and high specific strength, providing good impact toughness while maintaining lightweight design. It also possesses natural antibacterial properties and is odorless, enhancing the comfort of the vehicle interior. It is biodegradable and bio-based, reducing reliance on petroleum-based plastics. The modified polylactic acid fiber is biodegradable and also features low odor, UV resistance, flame retardancy, and easy dyeing, making it suitable for colorful interior designs and further reducing reliance on petroleum-based plastics. The modified palm fiber provides high specific modulus and rigidity, further improving the overall stiffness of the composite material. Chemical surface modification improves fiber / matrix bonding, reduces water absorption, and enhances moisture resistance.

[0017] 2. The synergistic toughening effect of modified bamboo fiber and modified phenolic resin in this invention results in a tensile strength ≥350MPa and an impact toughness improvement of 30-50%. Modified polylactic acid fiber further reinforces the material, meeting the impact and scratch resistance requirements of interior components. The low density (≈0.9g·cm⁻³) of the bamboo fiber and modified natural fiber reduces the overall density of the composite material by approximately 15-20% compared to traditional glass fiber / PP ≈1.2g·cm⁻³, significantly reducing the weight of automotive interior components. All raw materials are derived from renewable resources (bamboo, palm, corn starch). The modified polylactic acid fiber is bio-based, and the material can degrade by more than 90% under industrial composting conditions at the end of its service life, reducing its carbon footprint by 25-92% compared to traditional petroleum-based plastics.

[0018] 3. The automotive interior material prepared by this invention, which uses bamboo fiber as raw material, combines modified bamboo fiber, modified polylactic acid fiber, modified palm fiber, PLA matrix, modified phenolic resin, dispersant, stabilizer, and curing agent to form a high-performance automotive interior material that combines lightweight, mechanical strength, thermal flame retardancy, environmental degradation, and cabin comfort.

[0019] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit the scope of protection of the present invention. Attached Figure Description

[0020] Figure 1 This is a physical image of the automotive interior material made from bamboo fiber as raw material, obtained in Example 1 of this invention. Detailed Implementation

[0021] The present invention will be further described in detail below with reference to the embodiments. It should be noted that: unless otherwise specified, the conditions in the following embodiments are carried out according to conventional conditions or the conditions recommended by the manufacturer. Unless otherwise specified, the raw materials used in the following embodiments can be obtained from commercially available sources. Example Example 1

[0022] An automotive interior material using bamboo fiber as raw material comprises the following components by weight: 48 parts modified bamboo fiber, 15 parts modified polylactic acid fiber, 12 parts modified palm fiber, 21 parts polylactic acid, 10 parts modified phenolic resin, 2 parts dispersant, 2 parts stabilizer, and 1 part curing agent.

[0023] Modified bamboo fiber is prepared by blending bamboo fiber with coconut shell fiber and polypropylene, and then grafting with maleic anhydride. The mass ratio of bamboo fiber, coconut shell fiber, polypropylene and maleic anhydride is 3:2:1:1.

[0024] Modified polylactic acid fiber is prepared by electrospinning polylactic acid by adding nano-cerium oxide to the mixture; the amount of nano-cerium oxide added is 5%.

[0025] Modified palm fiber is prepared by adding ceramsite and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) to palm fiber, with a mass ratio of palm fiber, ceramsite and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) of 7:3:1.

[0026] Modified phenolic resin is prepared by adding nitrile rubber and cashew phenol, with a mass ratio of nitrile rubber to cashew phenol of 1:1.

[0027] The dispersant is sodium hexametaphosphate; the stabilizer is o-hydroxybenzophenone; and the curing agent is ethylenediamine.

[0028] A method for preparing automotive interior materials using bamboo fiber as raw material includes the following steps: (1) Modified bamboo fiber, modified polylactic acid fiber, and modified palm fiber were prepared into a fiber layer of 0.01 mm using a fiber spreading device; (2) Polylactic acid, modified phenolic resin, dispersant, stabilizer and curing agent are mixed at 125°C to obtain a mixture; (3) Inject the mixture obtained in step (2) into the fiber layer obtained in step (1). After injection, keep it warm and pressurized for 10 minutes and then reduce the temperature to 60°C to obtain the finished product. Example 2

[0029] An automotive interior material using bamboo fiber as raw material comprises the following components by weight: 52 parts modified bamboo fiber, 16 parts modified polylactic acid fiber, 13 parts modified palm fiber, 25 parts polylactic acid, 11 parts modified phenolic resin, 3 parts dispersant, 3 parts stabilizer, and 1 part curing agent.

[0030] Modified bamboo fiber is prepared by blending bamboo fiber with coconut shell fiber and polypropylene, and then grafting with maleic anhydride. The mass ratio of bamboo fiber, coconut shell fiber, polypropylene and maleic anhydride is 4:3:1:1.

[0031] Modified polylactic acid fiber is prepared by electrospinning polylactic acid by adding nano-cerium oxide to the mixture; the amount of nano-cerium oxide added is 6%.

[0032] Modified palm fiber is prepared by adding ceramsite and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) to palm fiber, with a mass ratio of palm fiber, ceramsite and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) of 8:3:1.

[0033] Modified phenolic resin is prepared by adding nitrile rubber and cashew phenol, with a mass ratio of nitrile rubber to cashew phenol of 2:1.

[0034] The dispersant is sodium hexametaphosphate; the stabilizer is o-hydroxybenzophenone; and the curing agent is ethylenediamine.

[0035] A method for preparing automotive interior materials using bamboo fiber as raw material includes the following steps: (1) Modified bamboo fiber, modified polylactic acid fiber, and modified palm fiber were prepared into a fiber layer of 0.02 mm using a fiber spreading device; (2) Polylactic acid, modified phenolic resin, dispersant, stabilizer and curing agent are mixed at 130°C to obtain a mixture; (3) Inject the mixture obtained in step (2) into the fiber layer obtained in step (1). After injection, keep it warm and pressurized for 10 minutes and then reduce the temperature to 65°C to obtain the finished product. Example 3

[0036] An automotive interior material using bamboo fiber as raw material comprises the following components by weight: 55 parts modified bamboo fiber, 16 parts modified polylactic acid fiber, 14 parts modified palm fiber, 23 parts polylactic acid, 12 parts modified phenolic resin, 3 parts dispersant, 3 parts stabilizer, and 1 part curing agent.

[0037] Modified bamboo fiber is prepared by blending bamboo fiber with coconut shell fiber and polypropylene, and then grafting with maleic anhydride. The mass ratio of bamboo fiber, coconut shell fiber, polypropylene and maleic anhydride is 5:2:2:1.

[0038] Modified polylactic acid fiber is prepared by electrospinning polylactic acid by adding nano-cerium oxide to the mixture; the amount of nano-cerium oxide added is 7%.

[0039] Modified palm fiber is prepared by adding ceramsite and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) to palm fiber, with a mass ratio of palm fiber, ceramsite and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) of 9:3:2.

[0040] Modified phenolic resin is prepared by adding nitrile rubber and cashew phenol, with a mass ratio of nitrile rubber to cashew phenol of 2:1.

[0041] The dispersant is sodium hexametaphosphate; the stabilizer is o-hydroxybenzophenone; and the curing agent is ethylenediamine.

[0042] A method for preparing automotive interior materials using bamboo fiber as raw material includes the following steps: (1) Modified bamboo fiber, modified polylactic acid fiber, and modified palm fiber were prepared into a fiber layer of 0.02 mm using a fiber spreading device; (2) Polylactic acid, modified phenolic resin, dispersant, stabilizer and curing agent are mixed at 135°C to obtain a mixture; (3) Inject the mixture obtained in step (2) into the fiber layer obtained in step (1), keep it warm and pressurized for 10 minutes after injection, and then reduce the temperature to 60°C to obtain the finished product. Example 4

[0043] An automotive interior material using bamboo fiber as raw material comprises the following components by weight: 58 parts modified bamboo fiber, 18 parts modified polylactic acid fiber, 15 parts modified palm fiber, 26 parts polylactic acid, 12 parts modified phenolic resin, 2 parts dispersant, 2 parts stabilizer, and 1 part curing agent.

[0044] Modified bamboo fiber is prepared by blending bamboo fiber with coconut shell fiber and polypropylene, and then grafting with maleic anhydride. The mass ratio of bamboo fiber, coconut shell fiber, polypropylene and maleic anhydride is 5:2:3:1.

[0045] Modified polylactic acid fiber is prepared by electrospinning polylactic acid by adding nano-cerium oxide to the mixture; the amount of nano-cerium oxide added is 8%.

[0046] Modified palm fiber is prepared by adding ceramsite and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) to palm fiber, with a mass ratio of palm fiber, ceramsite and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) of 10:3:2.

[0047] Modified phenolic resin is prepared by adding nitrile rubber and cashew phenol, with a mass ratio of nitrile rubber to cashew phenol of 2:1.

[0048] The dispersant is sodium hexametaphosphate; the stabilizer is o-hydroxybenzophenone; and the curing agent is ethylenediamine.

[0049] A method for preparing automotive interior materials using bamboo fiber as raw material includes the following steps: (1) Modified bamboo fiber, modified polylactic acid fiber, and modified palm fiber were prepared into a fiber layer of 0.03 mm using a fiber spreading device; (2) Polylactic acid, modified phenolic resin, dispersant, stabilizer and curing agent are mixed at 125°C to obtain a mixture; (3) Inject the mixture obtained in step (2) into the fiber layer obtained in step (1), keep it warm and pressurized for 15 minutes after injection, and then reduce the temperature to 72°C to obtain the finished product. Example 5

[0050] An automotive interior material using bamboo fiber as raw material comprises the following components by weight: 62 parts modified bamboo fiber, 21 parts modified polylactic acid fiber, 16 parts modified palm fiber, 32 parts polylactic acid, 13 parts modified phenolic resin, 4 parts dispersant, 4 parts stabilizer, and 1 part curing agent.

[0051] Modified bamboo fiber is prepared by blending bamboo fiber with coconut shell fiber and polypropylene, and then grafting with maleic anhydride. The mass ratio of bamboo fiber, coconut shell fiber, polypropylene and maleic anhydride is 7:3:3:2.

[0052] Modified polylactic acid fiber is prepared by electrospinning polylactic acid by adding nano-cerium oxide to the mixture; the amount of nano-cerium oxide added is 9%.

[0053] Modified palm fiber is prepared by adding ceramsite and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) to palm fiber, with a mass ratio of palm fiber, ceramsite and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) of 10:5:2.

[0054] Modified phenolic resin is prepared by adding nitrile rubber and cashew phenol, with a mass ratio of nitrile rubber to cashew phenol of 2:1.

[0055] The dispersant is sodium hexametaphosphate; the stabilizer is o-hydroxybenzophenone; and the curing agent is ethylenediamine.

[0056] A method for preparing automotive interior materials using bamboo fiber as raw material includes the following steps: (1) Modified bamboo fiber, modified polylactic acid fiber, and modified palm fiber were prepared into a fiber layer of 0.04 mm using a fiber spreading device; (2) Polylactic acid, modified phenolic resin, dispersant, stabilizer and curing agent are mixed at 138°C to obtain a mixture; (3) Inject the mixture obtained in step (2) into the fiber layer obtained in step (1), keep it warm and pressurized for 10 minutes after injection, and then reduce the temperature to 72°C to obtain the finished product. Example 6

[0057] An automotive interior material using bamboo fiber as raw material comprises the following components by weight: 82 parts modified bamboo fiber, 26 parts modified polylactic acid fiber, 18 parts modified palm fiber, 45 parts polylactic acid, 15 parts modified phenolic resin, 5 parts dispersant, 5 parts stabilizer, and 2 parts curing agent.

[0058] Modified bamboo fiber is prepared by blending bamboo fiber with coconut shell fiber and polypropylene, and then grafting with maleic anhydride. The mass ratio of bamboo fiber, coconut shell fiber, polypropylene and maleic anhydride is 8:3:3:2.

[0059] Modified polylactic acid fiber is prepared by electrospinning polylactic acid by adding nano-cerium oxide to the mixture; the amount of nano-cerium oxide added is 12%.

[0060] Modified palm fiber is prepared by adding ceramsite and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) to palm fiber, with a mass ratio of palm fiber, ceramsite and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) of 11:5:2.

[0061] Modified phenolic resin is prepared by adding nitrile rubber and cashew phenol, with a mass ratio of nitrile rubber to cashew phenol of 3:1.

[0062] The dispersant is sodium hexametaphosphate; the stabilizer is o-hydroxybenzophenone; and the curing agent is ethylenediamine.

[0063] A method for preparing automotive interior materials using bamboo fiber as raw material includes the following steps: (1) Modified bamboo fiber, modified polylactic acid fiber, and modified palm fiber were prepared into a fiber layer of 0.05 mm using a fiber spreading device; (2) Polylactic acid, modified phenolic resin, dispersant, stabilizer and curing agent are mixed at 140°C to obtain a mixture; (3) Inject the mixture obtained in step (2) into the fiber layer obtained in step (1), keep it warm and pressurized for 20 minutes after injection, and then reduce the temperature to 75°C to obtain the finished product.

[0064] Comparative Example 1 The difference from Example 1 is that no modified bamboo fiber was added.

[0065] Comparative Example 2 The difference from Example 1 is that no modified polylactic acid fiber was added.

[0066] Comparative Example 3 The difference from Example 1 is that no modified palm fiber was added.

[0067] Comparative Example 4 The difference from Example 1 is that no modified phenolic resin was added.

[0068] Performance testing: The automotive interior materials made from bamboo fiber prepared in Examples 1-6 and Comparative Examples 1-4 were subjected to the following relevant performance tests. Each test was conducted 3 times, and the average value of the 3 test results was taken as the final result. The experimental results are recorded in Table 1.

[0069] The automotive interior material substrates made from bamboo fiber prepared in Examples 1-6 and Comparative Examples 1-4 were placed in an environment of (50±2)°C and 90% relative humidity for 24 hours, and then their bending strength and bending modulus were tested.

[0070] The free expansion height of the automotive interior material substrates made from bamboo fiber, obtained in Examples 1-6 and Comparative Examples 1-4, was measured after heating at 205°C for 2 minutes.

[0071] In accordance with the standards and regulations of PV3900, the odor levels of automotive interior materials made from bamboo fiber as raw material in Examples 1-6 and Comparative Examples 1-4 were tested.

[0072] Table 1 Performance Test Results

[0073] The above description is merely an exemplary embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. An automotive interior material using bamboo fiber as raw material, characterized in that, The composition includes the following components by weight: 48-82 parts modified bamboo fiber, 15-26 parts modified polylactic acid fiber, 12-18 parts modified palm fiber, 21-45 parts polylactic acid, 10-15 parts modified phenolic resin, 2-5 parts dispersant, 2-5 parts stabilizer and 1-2 parts curing agent.

2. The automotive interior material using bamboo fiber as raw material according to claim 1, characterized in that, The modified bamboo fiber is prepared by adding coconut shell fiber and polypropylene to bamboo fiber and then grafting maleic anhydride. The mass ratio of bamboo fiber, coconut shell fiber, polypropylene and maleic anhydride is 3~8:2~3:1~3:1~2.

3. The automotive interior material using bamboo fiber as raw material according to claim 1, characterized in that, The modified polylactic acid fiber is prepared by electrospinning after adding nano-cerium oxide to polylactic acid; the amount of nano-cerium oxide added is 5%~12%.

4. The automotive interior material using bamboo fiber as raw material according to claim 1, characterized in that, The modified palm fiber is prepared by adding ceramsite and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) to palm fiber, wherein the mass ratio of palm fiber, ceramsite and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) is 7~11:3~5:1~2.

5. The automotive interior material using bamboo fiber as raw material according to claim 1, characterized in that, The modified phenolic resin is prepared by adding nitrile rubber and cashew phenol, wherein the mass ratio of nitrile rubber to cashew phenol is 1~3:

1.

6. The automotive interior material using bamboo fiber as raw material according to claim 1, characterized in that, The dispersant is at least one of sodium hexametaphosphate, potassium tripolyphosphate, sodium polyacrylate, and polyvinyl alcohol.

7. The automotive interior material using bamboo fiber as raw material according to claim 1, characterized in that, The stabilizer is at least one of o-hydroxybenzophenone, benzotriazole, salicylates, and hindered amines.

8. The automotive interior material using bamboo fiber as raw material according to claim 1, characterized in that, The curing agent is at least one of ethylenediamine, diaminodiphenylmethane, and polyisocyanate.

9. The method for preparing automotive interior materials using bamboo fiber as raw material according to any one of claims 1 to 8, characterized in that, Includes the following steps: (1) Modified bamboo fiber, modified polylactic acid fiber, and modified palm fiber are prepared into fiber layers of 0.01~0.05 mm using a fiber spreading device; (2) Mix polylactic acid, modified phenolic resin, dispersant, stabilizer and curing agent at 125~140℃ to obtain a mixture; (3) Inject the mixture obtained in step (2) into the fiber layer obtained in step (1). After injection, keep it warm and pressurized for 10~20 minutes and then reduce the temperature to 60~75℃ to obtain the finished product.

10. The application of the automotive interior material using bamboo fiber as raw material as described in any one of claims 1 to 8 in the preparation of automotive interior parts.

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