厚片(pian)吸(xi)(xi)塑(su)(su)(su)在(zai)客(ke)車(che)(che)上(shang)(shang)(shang)的(de)(de)(de)(de)(de)(de)應用　　厚片(pian)吸(xi)(xi)塑(su)(su)(su)成型(xing)(xing)按工(gong)(gong)(gong)藝可分為(wei)板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)吸(xi)(xi)塑(su)(su)(su)和(he)軟(ruan)質表皮(pi)(pi)吸(xi)(xi)塑(su)(su)(su)兩種。厚片(pian)吸(xi)(xi)塑(su)(su)(su)用的(de)(de)(de)(de)(de)(de)材(cai)(cai)(cai)(cai)(cai)料主(zhu)要(yao)是(shi)(shi)-丁二(er)烯(xi)-（ABS）板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)，有(you)小部(bu)分零件用有(you)機(ji)(ji)(ji)玻璃(li)（PMMA）板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)。客(ke)車(che)(che)的(de)(de)(de)(de)(de)(de)駕駛室左右(you)兩側(ce)的(de)(de)(de)(de)(de)(de)內(nei)(nei)板(ban)(ban)(ban)、頂部(bu)內(nei)(nei)板(ban)(ban)(ban)、后(hou)部(bu)內(nei)(nei)板(ban)(ban)(ban)以(yi)及(ji)一(yi)(yi)些(xie)電器(qi)箱蓋(gai)板(ban)(ban)(ban)及(ji)其他蓋(gai)板(ban)(ban)(ban)用的(de)(de)(de)(de)(de)(de)都是(shi)(shi)ABS板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)成型(xing)(xing)。現在(zai)還有(you)一(yi)(yi)種趨(qu)勢就(jiu)(jiu)是(shi)(shi)用復合ABS板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)代替一(yi)(yi)般(ban)ABS板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)，復合ABS板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)就(jiu)(jiu)是(shi)(shi)在(zai)板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)上(shang)(shang)(shang)加(jia)(jia)一(yi)(yi)層(ceng)發泡的(de)(de)(de)(de)(de)(de)聚(ju)或(huo)聚(ju)材(cai)(cai)(cai)(cai)(cai)料，一(yi)(yi)起(qi)滾壓(ya)成帶皮(pi)(pi)紋或(huo)手感(gan)像(xiang)真(zhen)皮(pi)(pi)的(de)(de)(de)(de)(de)(de)板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)。要(yao)求透明的(de)(de)(de)(de)(de)(de)儀表臺(tai)的(de)(de)(de)(de)(de)(de)音響蓋(gai)板(ban)(ban)(ban)，要(yao)求防老化的(de)(de)(de)(de)(de)(de)車(che)(che)身外的(de)(de)(de)(de)(de)(de)透氣格柵，一(yi)(yi)般(ban)用的(de)(de)(de)(de)(de)(de)是(shi)(shi)都有(you)機(ji)(ji)(ji)玻璃(li)成型(xing)(xing)。軟(ruan)質表皮(pi)(pi)厚片(pian)吸(xi)(xi)塑(su)(su)(su)工(gong)(gong)(gong)藝主(zhu)要(yao)用在(zai)客(ke)車(che)(che)儀表臺(tai)上(shang)(shang)(shang)，基體一(yi)(yi)般(ban)是(shi)(shi)玻璃(li)鋼(gang)件（FRP），在(zai)玻璃(li)鋼(gang)件上(shang)(shang)(shang)開吸(xi)(xi)氣孔吸(xi)(xi)表皮(pi)(pi)，表皮(pi)(pi)的(de)(de)(de)(de)(de)(de)材(cai)(cai)(cai)(cai)(cai)料主(zhu)要(yao)有(you)聚(ju)加(jia)(jia)發泡聚(ju)（PVC/PPF）復合材(cai)(cai)(cai)(cai)(cai)料。　　現在(zai)以(yi)客(ke)車(che)(che)內(nei)(nei)側(ce)板(ban)(ban)(ban)吸(xi)(xi)塑(su)(su)(su)件為(wei)例，定(ding)制厚片(pian)吸(xi)(xi)塑(su)(su)(su)，簡(jian)述厚片(pian)吸(xi)(xi)塑(su)(su)(su)的(de)(de)(de)(de)(de)(de)工(gong)(gong)(gong)藝過程(cheng)。零件尺寸(cun)為(wei)1200mm×1000mm×250mm，用到(dao)的(de)(de)(de)(de)(de)(de)ABS板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)是(shi)(shi)尺寸(cun)為(wei)1400mm×1200mm×4mm。首先(xian)要(yao)確(que)認板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)的(de)(de)(de)(de)(de)(de)顏色(se)皮(pi)(pi)紋，因(yin)為(wei)內(nei)(nei)裝飾的(de)(de)(de)(de)(de)(de)顏色(se)和(he)皮(pi)(pi)紋是(shi)(shi)很重要(yao)的(de)(de)(de)(de)(de)(de)，乘客(ke)一(yi)(yi)上(shang)(shang)(shang)車(che)(che)首先(xian)感(gan)受到(dao)的(de)(de)(de)(de)(de)(de)是(shi)(shi)車(che)(che)內(nei)(nei)的(de)(de)(de)(de)(de)(de)環境。再看看板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)是(shi)(shi)否從(cong)剛(gang)開封的(de)(de)(de)(de)(de)(de)包裝袋中(zhong)取(qu)出，厚片(pian)吸(xi)(xi)塑(su)(su)(su)外殼(ke)，若(ruo)不是(shi)(shi)，板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)還需放到(dao)烘房(fang)中(zhong)烘干。因(yin)為(wei)如(ru)果(guo)板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)潮(chao)濕，在(zai)加(jia)(jia)溫時(shi)(shi)會使板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)表面起(qi)氣泡，外觀質量惡化，嚴重時(shi)(shi)還會使板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)在(zai)成型(xing)(xing)過程(cheng)中(zhong)拉裂。同(tong)時(shi)(shi)模(mo)具(ju)(ju)(ju)裝到(dao)吸(xi)(xi)塑(su)(su)(su)機(ji)(ji)(ji)上(shang)(shang)(shang)，調整位置和(he)壓(ya)框，對(dui)(dui)模(mo)具(ju)(ju)(ju)的(de)(de)(de)(de)(de)(de)上(shang)(shang)(shang)升過程(cheng)和(he)時(shi)(shi)間進(jin)行(xing)預先(xian)設定(ding)；模(mo)具(ju)(ju)(ju)頂部(bu)不能超出吸(xi)(xi)塑(su)(su)(su)機(ji)(ji)(ji)工(gong)(gong)(gong)作平臺(tai)，然(ran)后(hou)就(jiu)(jiu)對(dui)(dui)模(mo)具(ju)(ju)(ju)加(jia)(jia)溫，約到(dao)60℃左右(you)。板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)放到(dao)自動送(song)料裝置上(shang)(shang)(shang)，機(ji)(ji)(ji)器(qi)把(ba)板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)送(song)到(dao)吸(xi)(xi)塑(su)(su)(su)機(ji)(ji)(ji)工(gong)(gong)(gong)作臺(tai)上(shang)(shang)(shang)（如(ru)果(guo)沒有(you)此機(ji)(ji)(ji)構(gou)(gou)就(jiu)(jiu)要(yao)用手工(gong)(gong)(gong)把(ba)板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)放到(dao)工(gong)(gong)(gong)作臺(tai)上(shang)(shang)(shang)），壓(ya)框由上(shang)(shang)(shang)而下把(ba)板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)壓(ya)緊。然(ran)后(hou)加(jia)(jia)熱機(ji)(ji)(ji)構(gou)(gou)移(yi)到(dao)工(gong)(gong)(gong)作臺(tai)上(shang)(shang)(shang)方，對(dui)(dui)板(ban)(ban)(ban)材(cai)(cai)(cai)(cai)(cai)進(jin)行(xing)加(jia)(jia)熱，一(yi)(yi)般(ban)加(jia)(jia)熱到(dao)120℃左右(you)，時(shi)(shi)間2~3分鐘；還可以(yi)對(dui)(dui)加(jia)(jia)熱器(qi)進(jin)行(xing)區域溫度設定(ding)，拉伸大的(de)(de)(de)(de)(de)(de)地方適當增大加(jia)(jia)熱溫度；加(jia)(jia)熱完后(hou)，加(jia)(jia)熱機(ji)(ji)(ji)構(gou)(gou)移(yi)開，同(tong)時(shi)(shi)模(mo)具(ju)(ju)(ju)開始向上(shang)(shang)(shang)移(yi)。

對(dui)于厚片吸塑(su)(su)(su)常(chang)用(yong)的(de)(de)(de)原(yuan)材(cai)(cai)料(liao)(liao)(liao)(liao)片材(cai)(cai)主要(yao)(yao)(yao)有(you)(you)(you)HDPE、ABS、ABS+TPU等(deng)(deng)，下(xia)面簡(jian)單介紹一(yi)(yi)(yi)下(xia)這三種材(cai)(cai)料(liao)(liao)(liao)(liao)的(de)(de)(de)基(ji)本特(te)(te)點。（1） HDPE（高(gao)(gao)(gao)密度(du)聚乙烯）材(cai)(cai)料(liao)(liao)(liao)(liao)：它(ta)(ta)具有(you)(you)(you)良(liang)好的(de)(de)(de)耐(nai)(nai)(nai)(nai)熱(re)、耐(nai)(nai)(nai)(nai)寒(han)性(xing)(xing)、化學(xue)穩定性(xing)(xing)、較(jiao)(jiao)高(gao)(gao)(gao)的(de)(de)(de)剛(gang)性(xing)(xing)、韌性(xing)(xing)和(he)優(you)(you)(you)良(liang)的(de)(de)(de)耐(nai)(nai)(nai)(nai)環(huan)境(jing)(jing)應(ying)力開(kai)裂性(xing)(xing)。主要(yao)(yao)(yao)用(yong)途：200升水桶、油箱、托(tuo)板(ban)(ban)(ban)、大型(xing)部件(jian)(jian)(jian)(jian)(jian)、游(you)艇、吸塑(su)(su)(su)托(tuo)盤(pan)頂(ding)蓋(gai)、大部份汽(qi)車(che)(che)零配(pei)件(jian)(jian)(jian)(jian)(jian)的(de)(de)(de)包(bao)裝等(deng)(deng)。（2） ABS（腈(jing)-丁二烯-塑(su)(su)(su)料(liao)(liao)(liao)(liao)）材(cai)(cai)料(liao)(liao)(liao)(liao)：它(ta)(ta)有(you)(you)(you)良(liang)好抗沖擊(ji)性(xing)(xing)、耐(nai)(nai)(nai)(nai)熱(re)性(xing)(xing)、耐(nai)(nai)(nai)(nai)低(di)溫(wen)性(xing)(xing)、耐(nai)(nai)(nai)(nai)化學(xue)藥品(pin)性(xing)(xing)及電氣(qi)性(xing)(xing)能(neng)優(you)(you)(you)良(liang)，相對(dui)HDPE有(you)(you)(you)易形(xing)成、制品(pin)尺(chi)寸(cun)穩定、表(biao)(biao)(biao)面光澤性(xing)(xing)好、承載抗壓性(xing)(xing)能(neng)更好等(deng)(deng)特(te)(te)點。在(zai)耐(nai)(nai)(nai)(nai)低(di)溫(wen)性(xing)(xing)、韌性(xing)(xing)和(he)耐(nai)(nai)(nai)(nai)環(huan)境(jing)(jing)應(ying)力開(kai)裂性(xing)(xing)方面HDPE更有(you)(you)(you)優(you)(you)(you)勢。主要(yao)(yao)(yao)用(yong)途：廣泛應(ying)用(yong)于汽(qi)車(che)(che)、電子電氣(qi)、辦公和(he)通訊設備等(deng)(deng)領(ling)域。在(zai)包(bao)裝領(ling)域主要(yao)(yao)(yao)用(yong)于對(dui)包(bao)裝尺(chi)寸(cun)精度(du)要(yao)(yao)(yao)求(qiu)較(jiao)(jiao)高(gao)(gao)(gao)的(de)(de)(de)機械(xie)手自動(dong)(dong)取件(jian)(jian)(jian)(jian)(jian)項目上。（3） ABS+TPU（熱(re)可塑(su)(su)(su)性(xing)(xing)聚氨酯）材(cai)(cai)料(liao)(liao)(liao)(liao)：它(ta)(ta)具有(you)(you)(you)是一(yi)(yi)(yi)種在(zai)ABS制板(ban)(ban)(ban)工(gong)藝(yi)(yi)過(guo)程增一(yi)(yi)(yi)道特(te)(te)殊的(de)(de)(de)共(gong)擠工(gong)藝(yi)(yi)使ABS板(ban)(ban)(ban)材(cai)(cai)表(biao)(biao)(biao)面覆上一(yi)(yi)(yi)層(ceng)TPU膜新型(xing)板(ban)(ban)(ban)材(cai)(cai)。采用(yong)此(ci)材(cai)(cai)料(liao)(liao)(liao)(liao)的(de)(de)(de)制品(pin)既有(you)(you)(you)ABS優(you)(you)(you)異(yi)的(de)(de)(de)機械(xie)性(xing)(xing)能(neng)還具有(you)(you)(you)TPU的(de)(de)(de)高(gao)(gao)(gao)耐(nai)(nai)(nai)(nai)磨抗撕(si)裂能(neng)力。此(ci)材(cai)(cai)料(liao)(liao)(liao)(liao)的(de)(de)(de)成本是一(yi)(yi)(yi)般(ban)材(cai)(cai)料(liao)(liao)(liao)(liao)的(de)(de)(de)2~3倍。也正因為成本之(zhi)高(gao)(gao)(gao)，此(ci)類材(cai)(cai)料(liao)(liao)(liao)(liao)的(de)(de)(de)應(ying)用(yong)受到一(yi)(yi)(yi)定的(de)(de)(de)限制。TPU特(te)(te)點：耐(nai)(nai)(nai)(nai)磨性(xing)(xing)能(neng)當材(cai)(cai)料(liao)(liao)(liao)(liao)在(zai)使用(yong)過(guo)程中經(jing)常(chang)受摩擦、刮磨、研挫等(deng)(deng)機械(xie)作(zuo)用(yong)，會(hui)引起其表(biao)(biao)(biao)面逐步(bu)磨損，因此(ci)材(cai)(cai)料(liao)(liao)(liao)(liao)的(de)(de)(de)耐(nai)(nai)(nai)(nai)磨耗性(xing)(xing)能(neng)顯得非常(chang)重要(yao)(yao)(yao)。TPU塑(su)(su)(su)膠原(yuan)料(liao)(liao)(liao)(liao)耐(nai)(nai)(nai)(nai)磨性(xing)(xing)能(neng)優(you)(you)(you)異(yi)，較(jiao)(jiao)天然橡膠耐(nai)(nai)(nai)(nai)磨五倍以上，厚片吸塑(su)(su)(su)托(tuo)盤(pan)，是耐(nai)(nai)(nai)(nai)磨制品(pin)的(de)(de)(de)材(cai)(cai)料(liao)(liao)(liao)(liao)之(zhi)一(yi)(yi)(yi)，一(yi)(yi)(yi)般(ban)而(er)言TPU具有(you)(you)(you)較(jiao)(jiao)高(gao)(gao)(gao)的(de)(de)(de)抗撕(si)裂能(neng)力，撕(si)裂強度(du)與一(yi)(yi)(yi)些常(chang)用(yong)的(de)(de)(de)塑(su)(su)(su)膠比(bi)較(jiao)(jiao)是非常(chang)優(you)(you)(you)異(yi)的(de)(de)(de)。主要(yao)(yao)(yao)用(yong)途：主要(yao)(yao)(yao)應(ying)用(yong)于汽(qi)車(che)(che)內飾件(jian)(jian)(jian)(jian)(jian)。在(zai)包(bao)裝領(ling)域主要(yao)(yao)(yao)用(yong)于對(dui)零件(jian)(jian)(jian)(jian)(jian)清潔度(du)要(yao)(yao)(yao)求(qiu)較(jiao)(jiao)高(gao)(gao)(gao)零件(jian)(jian)(jian)(jian)(jian)配(pei)件(jian)(jian)(jian)(jian)(jian)，如發動(dong)(dong)機、變速箱等(deng)(deng)動(dong)(dong)力系(xi)統的(de)(de)(de)零件(jian)(jian)(jian)(jian)(jian)包(bao)裝。

樣品(pin)(pin)(pin)(pin)被客戶認(ren)可后，通常會(hui)下一定(ding)數(shu)量(liang)的(de)(de)(de)生(sheng)(sheng)產(chan)訂單。生(sheng)(sheng)產(chan)調(diao)度(du)會(hui)根據(ju)產(chan)量(liang)、吸塑(su)成(cheng)(cheng)(cheng)(cheng)(cheng)型的(de)(de)(de)復雜程(cheng)(cheng)度(du)決定(ding)采(cai)(cai)用哪種模(mo)(mo)具(ju)(ju)(ju)量(liang)產(chan)：采(cai)(cai)用石膏模(mo)(mo)生(sheng)(sheng)產(chan)，模(mo)(mo)具(ju)(ju)(ju)制(zhi)作(zuo)(zuo)過程(cheng)(cheng)類(lei)似于吸塑(su)打(da)(da)樣，優(you)點在于生(sheng)(sheng)產(chan)周(zhou)期(qi)短，成(cheng)(cheng)(cheng)(cheng)(cheng)本(ben)低，制(zhi)作(zuo)(zuo)一整版(ban)(ban)（60X110cm)模(mo)(mo)具(ju)(ju)(ju)只需一到(dao)兩天(tian)時間(jian)，不(bu)足之處(chu)在于吸塑(su)成(cheng)(cheng)(cheng)(cheng)(cheng)品(pin)(pin)(pin)(pin)表(biao)(biao)面粗糙，生(sheng)(sheng)產(chan)中模(mo)(mo)具(ju)(ju)(ju)容易碎裂，耐用性(xing)差(cha)無法成(cheng)(cheng)(cheng)(cheng)(cheng)型深度(du)大(da)、復雜度(du)高、片(pian)(pian)材(cai)厚的(de)(de)(de)產(chan)品(pin)(pin)(pin)(pin)。采(cai)(cai)用電(dian)(dian)鍍銅(tong)模(mo)(mo)，宣城厚片(pian)(pian)吸塑(su)，其工(gong)(gong)藝是(shi)(shi)將(jiang)打(da)(da)好(hao)樣的(de)(de)(de)泡殼表(biao)(biao)面噴上一層導(dao)電(dian)(dian)劑，再放入電(dian)(dian)解槽內鍍上厚厚的(de)(de)(de)銅(tong)層，電(dian)(dian)鍍過程(cheng)(cheng)需要(yao)72小時，接著(zhu)要(yao)對銅(tong)模(mo)(mo)進行(xing)灌石膏（增加硬度(du)）、拋光、打(da)(da)氣眼(yan)處(chu)理(li)，采(cai)(cai)用電(dian)(dian)鍍銅(tong)模(mo)(mo)生(sheng)(sheng)產(chan)的(de)(de)(de)優(you)點是(shi)(shi)吸塑(su)制(zhi)品(pin)(pin)(pin)(pin)表(biao)(biao)面光滑，成(cheng)(cheng)(cheng)(cheng)(cheng)本(ben)適中，耐用性(xing)適中，缺(que)點是(shi)(shi)模(mo)(mo)具(ju)(ju)(ju)制(zhi)作(zuo)(zuo)周(zhou)期(qi)長，無法完(wan)成(cheng)(cheng)(cheng)(cheng)(cheng)精(jing)密(mi)吸塑(su)制(zhi)品(pin)(pin)(pin)(pin)的(de)(de)(de)生(sheng)(sheng)產(chan)。采(cai)(cai)用吸塑(su)鋁模(mo)(mo)生(sheng)(sheng)產(chan)，模(mo)(mo)具(ju)(ju)(ju)制(zhi)作(zuo)(zuo)需要(yao)先采(cai)(cai)用電(dian)(dian)腦設(she)計圖紙(zhi)，再采(cai)(cai)用CNC數(shu)控銑床加工(gong)(gong)，優(you)點是(shi)(shi)制(zhi)作(zuo)(zuo)周(zhou)期(qi)適中，后期(qi)模(mo)(mo)具(ju)(ju)(ju)處(chu)理(li)時間(jian)短（鉆(zhan)氣眼(yan)工(gong)(gong)作(zuo)(zuo)在CNC加工(gong)(gong)時完(wan)成(cheng)(cheng)(cheng)(cheng)(cheng)），吸塑(su)產(chan)品(pin)(pin)(pin)(pin)尺寸精(jing)度(du)高，模(mo)(mo)具(ju)(ju)(ju)耐用性(xing)強，缺(que)點是(shi)(shi)成(cheng)(cheng)(cheng)(cheng)(cheng)本(ben)高。由于全自動高速(su)吸塑(su)成(cheng)(cheng)(cheng)(cheng)(cheng)型機的(de)(de)(de)成(cheng)(cheng)(cheng)(cheng)(cheng)型范圍是(shi)(shi)66X110cm左右，所以不(bu)管是(shi)(shi)石膏模(mo)(mo)、銅(tong)模(mo)(mo)還是(shi)(shi)鋁模(mo)(mo)，都需要(yao)將(jiang)單個的(de)(de)(de)模(mo)(mo)具(ju)(ju)(ju)拼(pin)在一起，達到(dao)成(cheng)(cheng)(cheng)(cheng)(cheng)型尺寸，我們都稱這(zhe)個過程(cheng)(cheng)為拼(pin)版(ban)(ban)，需要(yao)拼(pin)在打(da)(da)好(hao)氣孔的(de)(de)(de)鋁板(ban)或木板(ban)上，拼(pin)好(hao)后的(de)(de)(de)整版(ban)(ban)模(mo)(mo)具(ju)(ju)(ju)我們稱之為底模(mo)(mo)。對于吸塑(su)成(cheng)(cheng)(cheng)(cheng)(cheng)型深度(du)大(da)的(de)(de)(de)產(chan)品(pin)(pin)(pin)(pin)，還需要(yao)制(zhi)作(zuo)(zuo)上模(mo)(mo)，在底模(mo)(mo)將(jiang)片(pian)(pian)材(cai)真(zhen)空吸成(cheng)(cheng)(cheng)(cheng)(cheng)型的(de)(de)(de)同(tong)時，從片(pian)(pian)材(cai)上方(fang)施加壓(ya)力，將(jiang)片(pian)(pian)材(cai)均勻地拉伸(shen)到(dao)每一個部(bu)位，否則會(hui)引起局部(bu)厚度(du)過薄。生(sheng)(sheng)產(chan)模(mo)(mo)具(ju)(ju)(ju)的(de)(de)(de)整個制(zhi)作(zuo)(zuo)周(zhou)期(qi)應為5至7天(tian)。