CN111267455A - 一种蜂窝材料的汽车顶盖 - Google Patents
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Abstract
本发明涉及一种蜂窝材料的汽车顶盖，其包括蜂窝芯、玻璃纤维毡和塑料外板，其中，蜂窝芯为孔格结构，玻璃纤维毡包括分别位于蜂窝芯的两侧的第一玻璃纤维毡层和第二玻璃纤维毡层，塑料外板连接在第一玻璃纤维毡层上。根据本发明的汽车顶盖用蜂窝材料来替代传统的钣金材料，具有更轻的质量，能够达到很好的轻量化的效果。而且，根据本发明的汽车顶盖的强度和刚度不仅能满足汽车顶盖的相关法规的基本要求，而且优于传统钣金的汽车顶盖。另外，根据本发明的汽车顶盖不易腐蚀生锈，有更好的隔音效果。
Description
技术领域
本发明涉及汽车顶盖，更具体地涉及一种蜂窝材料的汽车顶盖。
背景技术
汽车已经是当今社会最为常见的交通工具，随着汽车工业的不断发展和消费市场的日趋成熟，人们对汽车的舒适性和安全性的要求越来越高。
目前，市场上的车型中，汽车顶盖往往由钣金形成，钣金通过焊接固定在车身上。一般汽车顶盖的钣金外板料厚为0.7mm-0.8mm，且在外板内需要增加加强横梁来保证顶盖的强度。同时为了满足乘客的舒适性要求，座舱内要求增加内饰顶棚来保证内饰的美观。且在内饰顶棚与顶盖外板中间增加吸能块或吸音棉，来保证座舱的降噪效果。显然，这种传统的钣金顶盖存在以下几个缺点：钣金外观件需要过电泳处理，如果工艺处理不佳，极容易造成车辆顶盖在长期盐雾环境下生锈；钣金外板较薄，极容易在冲击状态下变形；钣金的隔音效果较差；由于钣金选用钢材的限制，无法达到轻量化的目的。
发明内容
为了解决上述现有技术中的钣金顶盖的自重较大等问题，本发明提供一种蜂窝材料的汽车顶盖。
本发明提供一种蜂窝材料的汽车顶盖，其包括蜂窝芯、玻璃纤维毡和塑料外板，其中，蜂窝芯为孔格结构，玻璃纤维毡包括分别位于蜂窝芯的两侧的第一玻璃纤维毡层和第二玻璃纤维毡层，塑料外板连接在第一玻璃纤维毡层上。
优选地，该汽车顶盖还包括连接至第二玻璃纤维毡层的内包覆层。
优选地，内包覆层是织物毡或毛毡。
优选地，蜂窝芯的组成单元的截面呈菱形、六边形、矩形、正弦曲线形、或正八边形和正四边形镶嵌形。
优选地，蜂窝芯的厚度为7～22mm。
优选地，玻璃纤维毡的玻璃纤维含量介于30wt％-60wt％之间。
优选地，塑料外板的厚度为1.2～2.0mm。
优选地，该汽车顶盖和车身的连接通过胶粘和/或紧固件来实现。
根据本发明的汽车顶盖用蜂窝材料来替代传统的钣金材料，具有更轻的质量，能够达到很好的轻量化的效果。而且，根据本发明的汽车顶盖的强度和刚度不仅能满足汽车顶盖的相关法规的基本要求，而且优于传统钣金的汽车顶盖。另外，根据本发明的汽车顶盖不易腐蚀生锈，有更好的隔音效果。
附图说明
图1是根据本发明的一个优选实施例的蜂窝材料的汽车顶盖的示意图；
图2A是图1的蜂窝芯的组成单元的截面的一个示例；
图2B是图1的蜂窝芯的组成单元的截面的另一个示例；
图2C是图1的蜂窝芯的组成单元的截面的又一个示例；
图2D是图1的蜂窝芯的组成单元的截面的又一个示例；
图2E是图1的蜂窝芯的组成单元的截面的又一个示例；
图3示出了图1的汽车顶盖与车身的连接；
图4是根据本发明的另一个优选实施例的蜂窝材料的汽车顶盖的示意图；
图5示出了图4的汽车顶盖与车身的连接。
具体实施方式
下面结合附图，给出本发明的较佳实施例，并予以详细描述。
在本文中，蜂窝材料指的是一种由形似蜂窝的孔格组成的材料，而蜂窝结构指的是一种夹层结构，其芯层由形似蜂窝的孔格组成，在芯层的上方和/或下方连接有其他层结构。
如图1所示，根据本发明的一个优选实施例的蜂窝材料的汽车顶盖6包括蜂窝芯1、玻璃纤维毡2和塑料外板3，其中，玻璃纤维毡2包括分别位于蜂窝芯1的两侧的第一玻璃纤维毡层21和第二玻璃纤维毡层22，塑料外板3连接在第一玻璃纤维毡层21上。
其中，蜂窝芯1可以是金属芯材，例如由铝或铝合金形成的孔格结构。蜂窝芯1也可以是非金属芯材，例如由玻璃钢、塑料、纸或泡沫形成的孔格结构。在本实施例中，该蜂窝芯1为瓦楞纸。另外，蜂窝芯1的组成单元的截面可以呈任意多边形，如图2A的菱形，图2B的六边形，图2C的矩形，图2D的正弦曲线形，图2E的正八边形和正四边形镶嵌形。在本实施例中，该蜂窝芯1的组成单元的截面呈正六边形，其不仅制造相对简单，用料更省，而且强度更高。而且，蜂窝芯1的厚度优选为7～22mm。在本实施例中，蜂窝芯1的厚度12mm。
其中，玻璃纤维毡2可以是短切玻璃纤维毡，以加强塑料外板3和蜂窝芯1之间的连接强度。第一玻璃纤维毡层21和第二玻璃纤维毡层22分别覆盖在蜂窝芯1的两侧，通过模压复合粘黏在一起。特别地，玻璃纤维毡2的玻璃纤维含量介于30wt％-60wt％之间。
其中，塑料外板3一般为共挤复合板，材料一般可以是聚丙烯(PP料)或是聚碳酸酯和丙烯腈-丁二烯-苯乙烯共聚物和混合物(PC+ABS料)或是聚甲基丙烯酸甲酯(PMMA料)等其他类似的热塑性材料。塑料外板3覆盖在第一玻璃纤维毡层21上，通过模压复合粘黏在一起。另外，塑料外板3的厚度优选为1.2～2.0mm。在本实施例中，塑料外板3的厚度为1.6mm。
本实施例的蜂窝材料的汽车顶盖6可以通过湿法工艺形成。具体地，在玻璃纤维毡2和蜂窝芯1之间浸胶(这里优选为聚氨酯)，简单地将玻璃纤维毡2铺层在蜂窝芯1的两侧，然后在第一玻璃纤维毡层21上合上塑料外板3，然后放入模腔加热加压，使其固化成型。
本实施例的蜂窝材料的汽车顶盖6可以通过干法工艺形成。具体地，在塑料外板3和蜂窝芯1之间铺上第一玻璃纤维毡层21，在蜂窝芯1的另一侧铺上第二玻璃纤维毡层22，再送料至模腔加热加压，使其固化成型。
在本实施例中，蜂窝芯1、玻璃纤维毡2和塑料外板3相当于传统汽车顶盖中的钣金外板和顶盖加强横梁，其在座舱内可以增加传统的内饰顶棚来保证内饰的美观。显然，本发明的汽车顶盖用蜂窝材料来替代传统的钣金材料，具有更轻的质量，能够达到很好的轻量化的效果。
如图3所示，模压成型后的蜂窝汽车顶盖6与车身5的装配，采用胶粘7的方式与车身进行紧固，其密封防水。
如图4所示，根据本发明的另一个优选实施例的蜂窝材料的汽车顶盖60包括蜂窝芯10、玻璃纤维毡20、塑料外板30和内包覆层40，其中，玻璃纤维毡20包括分别位于蜂窝芯10的两侧的第一玻璃纤维毡层210和第二玻璃纤维毡层220，塑料外板30连接在第一玻璃纤维毡层210上，内包覆层40连接在第二玻璃纤维毡层220上。
其中，蜂窝芯10可以是金属芯材，例如铝或铝合金。蜂窝芯10也可以是非金属芯材，例如玻璃钢、塑料、纸或泡沫。在本实施例中，该蜂窝芯10为瓦楞纸。另外，蜂窝芯10的组成单元的截面可以呈任意多边形，如菱形，六边形，矩形，正弦曲线形，正八边形和正四边形镶嵌形。在本实施例中，该蜂窝芯10的组成单元的截面呈正六边形，其不仅制造相对简单，用料更省，而且强度更高。而且，蜂窝芯10的厚度优选为7～22mm。在本实施例中，蜂窝芯1的厚度12mm。
其中，玻璃纤维毡20可以是短切玻璃纤维毡，以加强塑料外板30和蜂窝芯10之间的连接强度，以及内包覆层40和蜂窝芯10之间的连接强度。第一玻璃纤维毡层210和第二玻璃纤维毡层220分别覆盖在蜂窝芯10的两侧，通过模压复合粘黏在一起。特别地，玻璃纤维毡20的玻璃纤维含量介于30wt％-60wt％之间。
其中，塑料外板30一般为共挤复合板，材料一般可以是聚丙烯(PP料)或是聚碳酸酯和丙烯腈-丁二烯-苯乙烯共聚物和混合物(PC+ABS料)或是聚甲基丙烯酸甲酯(PMMA料)等其他类似的热塑性材料。塑料外板30覆盖在第一玻璃纤维毡层210上，通过模压复合粘黏在一起。另外，塑料外板30的厚度优选为1.2～2.0mm。在本实施例中，塑料外板30的厚度为1.6mm。
其中，内包覆层40可以是织物毡，也可以是毛毡。塑料外板30覆盖在第二玻璃纤维毡层220上，通过模压复合粘黏在一起。
本实施例的蜂窝材料的汽车顶盖可以通过湿法工艺形成。具体地，在玻璃纤维毡20和蜂窝芯10之间浸胶(这里优选为聚氨酯)，简单地将玻璃纤维毡20铺层在蜂窝芯10的两侧，然后在第一玻璃纤维毡层210上合上塑料外板30，然后放入模腔加热加压，使其固化成型。在第二玻璃纤维毡层220上合上内包覆层40，然后放入模腔加热加压，使其二次固化成型，最后进行脱模修整即可。
本实施例的蜂窝材料的汽车顶盖可以通过干法工艺形成。具体地，在塑料外板30和蜂窝芯10之间铺上第一玻璃纤维毡层210，在蜂窝芯10的另一侧铺上第二玻璃纤维毡层220，再送料至模腔加热加压，使其固化成型。在第二玻璃纤维毡层220上合上内包覆层40，然后放入模腔加热加压，使其二次固化成型，最后进行脱模修整即可。
在本实施例中，蜂窝芯10、玻璃纤维毡20、塑料外板30和内包覆层40相当于传统汽车顶盖中的钣金外板、顶盖加强横梁和内饰顶棚。如此，本实施例的汽车顶盖将多个零件集成为一个零件，具有显著降低的生产成本。显然，本发明的汽车顶盖用蜂窝材料来替代传统的钣金材料，具有更轻的质量，能够达到很好的轻量化的效果。
如图5所示，模压成型后的蜂窝汽车顶盖60与车身50的装配，采用密封胶条8实现密封，用紧固件将汽车顶盖60和车身50进行紧固。
比强度是指材料的强度与表观密度的比值。传统顶盖钣金的强度一般约为300N/m，蜂窝板根据蜂窝芯材料和厚度不同的差别，强度也有较大的差异，举例10mm瓦楞纸蜂窝板的强度为280N/m，而其他材料或厚度的蜂窝板材都会有更高的强度。而表观密度钣金要大于蜂窝材料，所以根据本发明的蜂窝材料有更好的比强度。
比刚度是指材料的弹性模量与其密度的比值。传统顶盖钣金的弹性模量为210GPa，而蜂窝材料的板材弹性模量一般都大于300GPa，所以根据本发明的蜂窝材料有更好的比强度。
下表给出了传统钣金的汽车顶盖和根据本发明的汽车顶盖的性能对比：
显然，根据本发明的汽车顶盖的强度和刚度不仅能满足汽车顶盖的相关法规的基本要求，而且优于传统钣金的汽车顶盖。
而且，根据本发明的汽车顶盖不易腐蚀生锈，有更好的隔音效果，且能够大幅降低顶盖重量。
以上所述的，仅为本发明的较佳实施例，并非用以限定本发明的范围，本发明的上述实施例还可以做出各种变化。即凡是依据本发明申请的权利要求书及说明书内容所作的简单、等效变化与修饰，皆落入本发明专利的权利要求保护范围。本发明未详尽描述的均为常规技术内容。
Claims (8)
1.一种蜂窝材料的汽车顶盖，其特征在于，该汽车顶盖包括蜂窝芯、玻璃纤维毡和塑料外板，其中，蜂窝芯为孔格结构，玻璃纤维毡包括分别位于蜂窝芯的两侧的第一玻璃纤维毡层和第二玻璃纤维毡层，塑料外板连接在第一玻璃纤维毡层上。
2.根据权利要求1所述的汽车顶盖，其特征在于，该汽车顶盖还包括连接至第二玻璃纤维毡层的内包覆层。
3.根据权利要求2所述的汽车顶盖，其特征在于，内包覆层是织物毡或毛毡。
4.根据权利要求1所述的汽车顶盖，其特征在于，蜂窝芯的组成单元的截面呈菱形、六边形、矩形、正弦曲线形、或正八边形和正四边形镶嵌形。
5.根据权利要求1所述的汽车顶盖，其特征在于，蜂窝芯的厚度为7～22mm。
6.根据权利要求1所述的汽车顶盖，其特征在于，玻璃纤维毡的玻璃纤维含量介于30wt％-60wt％之间。
7.根据权利要求1所述的汽车顶盖，其特征在于，塑料外板的厚度为1.2～2.0mm。
8.根据权利要求1所述的汽车顶盖，其特征在于，该汽车顶盖和车身的连接通过胶粘和/或紧固件来实现。
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| CN115302892A (zh) * | 2022-07-25 | 2022-11-08 | 东风商用车有限公司 | 一种发动机隔音罩盖及其制备方法 |
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| CN106184399A (zh) * | 2016-08-23 | 2016-12-07 | 北京新能源汽车股份有限公司 | 车辆的顶盖、车辆和车辆的顶盖的制造方法 |
| CN211138428U (zh) * | 2019-11-20 | 2020-07-31 | 延锋彼欧汽车外饰***有限公司 | 一种蜂窝材料的汽车顶盖 |
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| CN106184399A (zh) * | 2016-08-23 | 2016-12-07 | 北京新能源汽车股份有限公司 | 车辆的顶盖、车辆和车辆的顶盖的制造方法 |
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| CN115000445A (zh) * | 2022-06-28 | 2022-09-02 | 一汽解放汽车有限公司 | 一种电池绝缘板及燃料电池 |
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