CN110497657A - 用于制造多层纤维增强树脂复合材料的方法和使用该方法的模制产品 - Google Patents
用于制造多层纤维增强树脂复合材料的方法和使用该方法的模制产品 Download PDFInfo
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- CN110497657A CN110497657A CN201811362350.7A CN201811362350A CN110497657A CN 110497657 A CN110497657 A CN 110497657A CN 201811362350 A CN201811362350 A CN 201811362350A CN 110497657 A CN110497657 A CN 110497657A
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Classifications
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Textile Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Moulding By Coating Moulds (AREA)
- Laminated Bodies (AREA)
Abstract
本发明涉及用于制造多层纤维增强树脂复合材料的方法和使用该方法的模制产品。一种用于制造多层纤维增强树脂复合材料的方法,所述方法可包括通过依次设置和连接多个增强纤维片材来制备多片材,其中增强纤维在多片材的纵向上以不同的排列方向制备;将多片材滚压以制备具有多层的管状多芯;以及用树脂浸渍多芯。
Description
技术领域
本发明涉及一种用于制造多层纤维增强树脂复合材料的方法和使用该方法的模制产品,更具体地,涉及其中通过滚压工艺而不使用堆叠工艺来实现堆叠结构的用于制造多层纤维增强树脂复合材料的方法,以及使用该方法的模制产品。
背景技术
常规地,通常使用钢材制造车身结构和车辆的各种部件。近来,使用复合材料(例如纤维增强树脂复合材料)作为钢材的替代物,以根据重量的减轻来提高燃料效率。
纤维增强树脂复合材料的基本结构可包括增强材料和基础材料,所述增强材料起到负责施加至材料中的负荷的作用,所述基础材料与增强材料结合以实现材料的整体形状并用于将施加至材料的负荷传递至增强材料。此处,作为增强材料,通常使用诸如碳纤维、玻璃纤维、芳纶纤维等纤维增强材料;作为基础材料,通常使用诸如热固性树脂或热塑性树脂的树脂型基础材料,所述热固性树脂包括酚醛树脂、环氧树脂等,所述热塑性树脂包括聚氯乙烯(PVC)、聚乙烯(PE)、聚丙烯(PP)等。
取决于增强材料或基础材料的选择,这种纤维增强树脂复合材料可以通过各种方法进行制造,例如通过在模具中用树脂浸渍纤维纱而连续生产具有预定形状的产品的拉挤成型,将编织状态的增强材料供应至模具中并用树脂浸渍增强材料的树脂压铸(RTM)方法,以及在模具中直接聚合树脂的反应注塑(RIM)方法等。
同时,用作增强材料的纤维增强材料根据其长度分为短纤维、长纤维和连续纤维,其中,连续纤维根据其排列方向表现出不同的物理性质。近年来,为了通过使用根据纤维的排列方向的各向异性性质来获得更多改善的物理性质,将具有不同排列方向的编织状态的增强材料堆叠在期望的排列方向上以便使用。
至于用于制造多层纤维增强树脂复合材料的方法,通过用树脂浸渍以不同排列方向编织的织物状态纤维片材来制备特定排列方向的增强片材,然后将如此制备的增强片材以期望的排列方向堆叠并粘合以便使用。
然而,这种多层纤维增强树脂复合材料的缺点在于,在粘合各层的过程中发生分散,并且在每个区域中发生缺陷粘合。
此外,形成纤维增强树脂复合材料的每层的增强纤维之间的连续性被切断,并且在实现块状产品而不是板状产品方面存在限制。
公开于该发明背景技术部分的信息仅仅旨在加深对本发明的一般背景技术的理解,而不可以被视为承认或以任何形式暗示该信息构成已为本领域技术人员所公知的现有技术。
发明内容
本发明的各个方面旨在提供一种用于制造多层纤维增强树脂复合材料的制造方法,其中通过滚压工艺而不使用堆叠工艺以不同方向设置增强纤维来实现堆叠结构,以及使用该方法的模制产品。
根据本发明的示例性实施方案,用于制造多层纤维增强树脂复合材料的方法可包括:通过依次设置和连接多个增强纤维片材来制备多片材,其中增强纤维在多片材的纵向上以不同的排列方向来制备;将多片材滚压以制备具有多层的管状多芯;以及用树脂浸渍多芯。
在制备多片材时,多个增强纤维片材可以在纵向方向上依次地设置在同一平面上并连续地连接。
在制备多片材时,可以通过连接多个相邻增强纤维片材的端部来制备多片材,其中增强纤维以不同的排列方向编织。此处,相邻增强纤维片材的端部可以通过预定长度而重叠,并且可以缝合重叠部分以连接相邻增强纤维片材的端部。
在制备多片材时,可以通过将增强纤维连续编织为按区域具有不同的排列方向来制备多片材。此处,增强纤维可以连续编织,同时使用定制纤维铺放(TFP)设施改变其编织方向以按区域具有不同的排列图案。
在制备多芯时,可以通过在围绕旋转轴线旋转的内模的外周表面上连续滚压多片材来形成多层。
在制备多片材时,每个增强纤维片材的长度可以确定为对应于在制备多芯时使用的内模的外周表面的周长。
在制备多片材时,每个增强纤维片材的长度可以确定为在制备多芯时使用的内模的外周表面的周长倍数的长度。
多芯的制备可以包括准备一对内模,将内模分别设置在多片材的两个端部处,然后使一对内模朝向多片材的中心部分滚压以使得多片材在每个内模的外周表面上缠绕为多层。
浸渍可以包括将多芯放置在通过结合上模和下模而制得的腔体中,并将树脂注入至腔体中以用树脂浸渍多芯。
根据本发明的示例性实施方案,通过用于制造多层纤维增强树脂复合材料的方法而制得的模制产品可包括:通过将多片材滚压成具有多层的管状而形成的多芯,所述多片材通过依次设置并连续连接多个增强纤维片材而形成,其中增强纤维在多片材的纵向方向上以不同的排列方向而制得,多芯浸渍有树脂。
多芯可以通过将多片材从其一个端部沿其另一侧的方向滚压而形成为管状。
多芯可包括一对连续的滚压部分,其通过将多片材从其两个端部沿朝向其中心部分的方向滚压而形成。
多芯的内部可以在多片材的宽度方向上具有中空部分。
本发明的方法和装置具有其它特征和优点,这些特征和优点将在纳入本文的附图以及随后与附图一起用于解释本发明的某些原理的具体实施方式中显现或更详细地阐明。
附图说明
图1是说明根据本发明示例性实施方案的用于制造多层纤维增强树脂复合材料的方法的视图;
图2是通过根据本发明示例性实施方案的用于制造多层纤维增强树脂复合材料的方法而制得的模制产品的横截面视图;
图3A和图3B示出了根据本发明示例性实施方案的用于制备多片材的方法;
图4和图5是示出通过根据本发明示例性实施方案的制造多层纤维增强树脂复合材料的方法制造车辆后梁的方法的视图;和
图6A和图6B是示出通过根据本发明示例性实施方案的制造多层纤维增强树脂复合材料的方法制得的车辆后梁的视图。
可以理解,附图并不必须按比例绘制,其示出某种程度上经过简化了的本发明的基本原理的各个特征。在此所公开的本发明的特定的设计特征,包括例如特定的尺寸、定向、位置和形状,将部分地由特定目的的应用和使用环境加以确定。
在这些图形中,附图标记在贯穿附图的多幅图形中指代本发明的同样的或等同的部件。
具体实施方式
现在将详细提及本发明的各个实施方案,这些实施方案的示例显示在附图中并描述如下。尽管本发明将与本发明的示例性实施方案相结合进行描述,但是应当理解,本说明书并非旨在将本发明限制为那些示例性实施方案。另一方面,本发明旨在不仅覆盖本发明的示例性实施方案,而且还覆盖可以被包括在由所附权利要求所限定的本发明的精神和范围之内的各种选择形式、修改形式、等价形式及其它实施方案。
下面将参考所附附图对本发明的实施方案进行具体描述。然而,本发明可以以不同的形式具体表达,且不应被解释为局限于本文所述的示例性实施方案。相反,提供这些实施方案是为了使本公开彻底和完整,并且向本领域技术人员充分传达本发明的范围。在整个说明书中,相同的数字表示相同的元件。
图1是说明根据本发明示例性实施方案的用于制造多层纤维增强树脂复合材料的方法的视图;图2是根据本发明示例性实施方案的多层纤维增强树脂复合材料的横截面图;图3A和图3B是示出根据本发明示例性实施方案的用于制备多片材的方法的视图。
如图所示,根据本发明示例性实施方案的用于制造多层纤维增强树脂复合材料的方法包括形成连接多个增强纤维片材111、112和113的多片材110的步骤,将多片材110滚压以制备具有多层的管状多芯210的步骤;和用树脂120浸渍多芯210的步骤。
制备多片材的步骤是制备沿其纵向方向按区域具有不同排列方向的多片材110的步骤。例如,多个增强纤维片材111、112和113可以在同一平面上沿纵向顺序设置以形成连续连接的多片材110,片材中规则设置的增强纤维以在0°、±45°和±90°中的任一角度进行编织。
此处,制备多片材110的具体过程可以通过各种方法实现。
例如,如图3A所示,为了制备多片材110,首先单独制备第一增强纤维片材111(其中增强纤维以0°编织)、第二增强纤维片材112(其中增强纤维以45°编织)和第三增强纤维片材113(其中增强纤维以90°编织)。如此,第一增强纤维片材111、第二增强纤维片材112和第三增强纤维片材113依次选择性地沿纵向方向设置然后连接。此处,彼此相邻设置的增强纤维片材111、112和113的端部彼此以预定长度重叠,以形成重叠部分110a和110b。缝合重叠部分110a和110b以连续地连接彼此相邻的增强纤维片材111、112和113。此处,第一增强纤维片材111、第二增强纤维片材112和第三增强纤维片材113不限于所示的排列角度,而是也可以以各种其它角度实施,并且也可以对增强纤维片材的数量和排列顺序进行各种修改。
如图3B所示,包括多个约束销20的定制纤维铺放(tailored fiber placement,TFP)设施用于提供多片材110。因此,连续编织增强纤维以按区域具有不同的排列方向。此处,在按区域改变编织方向的同时连续地进行编织,以按区域具有不同的排列图案。例如,在编织的早期阶段,增强纤维以0°进行编织以形成第一增强纤维片材111,以45°编织以形成第二增强纤维片材112,随后以90°编织以形成第三增强纤维片材113,从而制备按区域以不同排列方向连续连接的多片材110。而且,在这种情况下,增强纤维片材不限于所示的排列角度,而是可以以各种其它角度进行编织。
同时,用于制备多片材110的增强纤维可以是例如碳纤维、玻璃纤维和芳纶纤维的各种纤维增强材料,其配置用于形成连续纤维。
制备多芯的步骤可以是将多片材110滚压成具有多层的管形的步骤。例如,可以使用围绕旋转轴线旋转的内模10来制备多芯210。此处,作为内模10,可以使用具有与产品的最终形状相对应的各种形状的内模。
例如,如图1所示,制备圆柱形内模10,然后将制备的多片材110在内模10的外周表面上连续地缠绕以形成多层。此处,由于多片材110通过连续地连接增强纤维片材111、112和113而形成,所述增强纤维片材111、112和113在多片材110的纵向方向上沿排列方向以预定长度编织,因此沿预定排列方向以预定长度编织的增强纤维片材111围绕内模10缠绕,随后沿不同排列方向编织的增强纤维片材112和113围绕内模10缠绕。该过程重复实行。因此,可以通过调整每个增强纤维片材111、112和113的长度以对应于内模10的外周表面的长度来调整在形成多芯210的每层中设置的增强纤维的排列方向。例如,如果将增强纤维片材111、112和113的长度制备为对应于内模的外周表面的长度,则相应的增强纤维片材111、112和113在多芯210中形成一层。此外,如果将增强纤维片材111、112和113的长度准备为对应于内模的外周表面长度的两倍,则相应的增强纤维片材111、112和113形成多芯210中的两层。因此,每个增强纤维片材111、112和113的长度可以确定为内模10的外周表面长度的倍数长度。
同时,多芯210不限于使用单个内模10的单个中空部分221,而是可以具有不同数量的中空部分110a。
例如,可以提供一对内模10,内模10设置在多片材110的两个端部处,因此,一对内模10朝向多片材110的中心部分滚压,使得多片材110可以在内模10的外周表面上缠绕为多层。
用树脂浸渍多芯210的步骤是用树脂120浸渍多芯210以模制最终或中间模制产品的步骤。
此处,可以选择性地使用设置为用于实现复合材料的各种树脂作为树脂120。例如,可以使用热固性树脂或热塑性树脂,所述热固性树脂包括酚醛树脂、环氧树脂等,所述热塑性树脂包括聚氯乙烯(PVC)、聚乙烯(PE)、聚丙烯(PP)等。
用树脂120浸渍多芯210的方法可以通过各种方法实现。例如,可以通过将多芯210设置在通过结合上模30a和下模30b而形成的腔体中,将树脂120注入腔体中,并固化树脂120来实现。
如图2所示,通过上述制造方法制得的模制产品包括多芯210,该多芯210由多片材110滚压成具有多层的管形,并浸渍有树脂而形成。此处,将浸渍到多芯210中的树脂称为模制层220。其中多片材110被滚压的多芯210的中心实现为中空部分221。此处,多芯210的整体横截面形状由内模10的外周表面的形状确定,但是其可以实施为具有基本圆形或多边形封闭端面的管形。此处,在多芯210中,以不同排列方向编织的增强纤维片材111、112和113实现为多层。
在图2中,出于描述的目的,分别由增强纤维片材111、112和113形成的层表示为具有不同直径的同心圆。然而,由于通过滚压多片材110形成多芯210,因此多芯可以实现为其中层以连续方式彼此连接的卷状。
通过固化浸渍在多芯210中的树脂来形成模制层220。此处,模制层220的形状可以通过改变注入树脂的空间来不同地实现,所述空间例如当上模30a和下模30b结合时制备的腔体的形状。
通过如上所述的制造方法制得的模制产品可以应用于诸如侧密封件、构件、支柱等的形成车身的部件,所述部件需要强度和刚度而同时具有条形形状。
例如,图4和图5是示出通过根据本发明示例性实施方案的制造多层纤维增强树脂复合材料的方法制造车辆后梁的方法的视图。图6A是示出通过根据本发明示例性实施方案的制造多层纤维增强树脂复合材料的方法制造的车辆后梁的视图,并且图6B是沿图6A的A-A线的横截面图。
为了制造用于车辆的后梁200,首先,制备沿纵向方向按区域具有不同排列方向的多片材110。此后,如图4所示,内模10设置在多片材110的两个端部处。如此,一对内模10朝向多片材110的中心滚压,以使得多片材110在每个内模10的外周表面上缠绕为多层,从而形成多芯210。
当多芯210完成时,将制得的多芯210放置在通过结合上模30a和下模30b形成的腔体中。如此,树脂120通过树脂供应设备40注入腔体中并固化。当完成树脂的固化时,从上模30a和下模30b中移除模制产品,并且内模10从多芯210的内部中分离。此处,模制产品模制成与腔体形状相对应的形状,然后进行后处理以用作后梁200。
此处,可以通过调整分离内模10的时机来确定在多芯210内部形成的中空部分211的形成。例如,如果不形成中空部分211,则在使用内模10制备多芯210之后,在浸渍树脂120之前将内模10与多芯210分离,并且可以进行树脂120的浸渍以用树脂120填充形成中空部分211的空间。
同时,如图6B所示,在后梁200的中心处增强刚度的多芯210具有在其中形成的两个中空部分211,因此,由于多芯210形成为连续连接,因此可以增强强度和刚度,同时实现后梁重量的减少。
根据本发明的示例性实施方案,多个增强纤维片材(其中增强纤维以不同的排列方向设置)在纵向方向上依次设置在同一平面上并连接以制备多片材,然后将制得的多片材在内模的外周表面上缠绕,由此可以实现堆叠结构而无需堆叠工艺。因此,可以减少工艺数量,并且可以解决在堆叠工艺期间可能发生的材料中的分散问题。
此外,通过将形成多片材的每个增强纤维片材的长度调整为与内模的外周表面的长度相对应,因此可以容易地制造在期望位置处具有期望排列方向的增强纤维片材。
此外,可以满足部件的物理性质,同时容易制造形成车身的诸如侧密封件、构件、支柱等的部件,所述部件需要强度和刚度的并同时具有条形形状。
为了便于解释和精确限定所附权利要求,术语“上部”、“下部”、“内部”、“外部”、“上”、“下”、“上方”、“下方”、“向上”、“向下”、“前面”、“后面”、“背面”、“内”、“外”、“向内”、“向外”、“内部的”、“外部的”、“里面的”、“外面的”、“向前”、“向后”用于参考附图中显示的这些特征的位置来描述示例性实施方案的特征。
前面对本发明具体示例性实施方案所呈现的描述是出于说明和描述的目的。它们并不会毫无遗漏,也不会将本发明限制为所公开的精确形式,显然,根据上述教导很多修改和变化都是可能的。选择示例性实施方案并进行描述是为了解释本发明的某些原理及其它们的实际应用,使得本领域的其它技术人员能够实现并利用本发明的各种示例性实施方案及其不同的选择形式和修改形式。本发明的范围旨在由所附权利要求书及其等同方案加以限定。
Claims (19)
1.一种用于制造多层纤维增强树脂复合材料的方法,所述方法包括:
制备多片材,所述多片材通过在多片材的纵向上依次设置并连接多个增强纤维片材而连接,其中多个增强纤维片材中的每一个的增强纤维在它们之间以不同方向排列;
将多片材滚压以形成具有多层的管状多芯;
用树脂浸渍管状多芯。
2.根据权利要求1所述的用于制造多层纤维增强树脂复合材料的方法,其中,在制备多片材时,多个增强纤维片材在纵向方向上依次地设置在同一平面上并连续地连接。
3.根据权利要求1所述的用于制造多层纤维增强树脂复合材料的方法,其中,在制备多片材时,通过连接相邻增强纤维片材的端部来制备多片材,其中增强纤维以不同的排列方向编织。
4.根据权利要求3所述的用于制造多层纤维增强树脂复合材料的方法,其中,在制备多片材时,相邻增强纤维片材的端部以预定长度重叠,并缝合相邻增强纤维片材的重叠部分以连接相邻增强纤维片材的端部。
5.根据权利要求1所述的用于制造多层纤维增强树脂复合材料的方法,其中,在制备多片材时,通过将增强纤维连续编织为按其区域具有不同的排列方向来制备多片材。
6.根据权利要求5所述的用于制造多层纤维增强树脂复合材料的方法,其中,在制备多片材时,将增强纤维连续编织,同时通过使用定制纤维铺放设施改变其编织方向以按区域具有不同的排列图案。
7.根据权利要求1所述的用于制造多层纤维增强树脂复合材料的方法,其中,在制备管状多芯时,通过在内模的外周表面上连续地缠绕多片材而形成多层,所述内模从多片材的第一侧沿多片材的第二侧的方向围绕内模的旋转轴线旋转。
8.根据权利要求7所述的用于制造多层纤维增强树脂复合材料的方法,其中,在从多片材中移除内模之后,多芯内部在多片材的宽度方向上具有中空部分。
9.根据权利要求7所述的用于制造多层纤维增强树脂复合材料的方法,其中,在制备多片材时,每个增强纤维片材的长度确定为对应于在制备管形多芯时使用的内模的外周表面的周长。
10.根据权利要求8所述的用于制造多层纤维增强树脂复合材料的方法,其中,在制备多片材时,每个增强纤维片材的长度确定为对应于在制备管形多芯时使用的内模的外周表面的多倍周长的长度。
11.根据权利要求1所述的用于制造多层纤维增强树脂复合材料的方法,其中,在制备管状多芯时,通过在围绕每个内模的旋转轴线旋转的一对内模的外周表面上连续地缠绕多片材而形成多层。
12.根据权利要求11所述的用于制造多层纤维增强树脂复合材料的方法,其中,在从多片材中移除内模之后,多芯内部由在多片材的宽度方向上的中空部分形成。
13.根据权利要求10所述的用于制造多层纤维增强树脂复合材料的方法,其中,管形多芯的制备进一步包括:
将一对内模分别设置在多片材的第一端部和第二端部;
在将一对内模分别放置在多片材的第一端部和第二端部之后,使一对内模朝向多片材的中心部分滚压,以使得多片材在一对内模的每一个的外周表面上缠绕为多层。
14.根据权利要求1所述的用于制造多层纤维增强树脂复合材料的方法,其中,浸渍包括将管形多芯放置在通过结合上模和下模而制得的腔体中,并将树脂注入至腔体中以用树脂浸渍管形多芯。
15.一种模制产品,其包括:
通过将多片材滚压成具有多层的管状而形成的多芯,所述多片材通过在多片材的纵向方向上依次设置并连续地连接多个增强纤维片材而形成,
其中,多个增强纤维片材中的每一个的增强纤维在它们之间以不同的方向排列,并且
多芯浸渍有树脂。
16.根据权利要求15所述的模制产品,其中,多芯通过将多芯的端部从多片材的第一侧沿多片材的第二侧的方向滚压成而形成为管状。
17.根据权利要求16所述的模制产品,其中,多芯的内部在多片材的宽度方向上具有中空部分。
18.根据权利要求15所述的模制产品,其中,多芯包括一对连续的滚压部分,所述连续的滚压部分通过将多片材从所述多片材的第一端部和第二端部朝向所述多片材的中心部分滚压而形成。
19.根据权利要求18所述的模制产品,其中,多芯的内部在多片材的宽度方向上具有中空部分。
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