CN112537103A - 一种汽车覆盖件复合材料结构及其成型方法 - Google Patents
一种汽车覆盖件复合材料结构及其成型方法 Download PDFInfo
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Abstract
本发明提供一种汽车覆盖件复合材料结构及其成型方法,所述汽车覆盖件复合材料结构包括纤维‑树脂复合材料层和金属外壳;所述纤维‑树脂复合材料层包括纤维和填充在纤维中的树脂;所述金属外壳粘结在所述纤维‑树脂复合材料层的外部。通过在纤维‑树脂复合材料层的外部设置金属外壳,在涂装前无需再采取繁琐的处理措施,从而提高了生产效率以及合格率,降低了成本;由于金属外壳的作用,能有效防止纤维纹理的不可逆显现,确保汽车覆盖件漆面的整体视觉效果良好。
Description
技术领域
本发明涉及材料制造技术领域,尤其涉及一种汽车覆盖件复合材料结构及其成型方法。
背景技术
随着全球能源危机愈演愈烈及环境问题日益凸显,新能源汽车行业发展迅速,由复合材料主导的汽车轻量化技术是新能源汽车发展的必由之路。近年来,复合材料逐渐在汽车前机盖、后尾门、左右翼子板、左右车门等覆盖件外板上有所应用,实现了汽车减重的目标。
但是一方面,由于复合材料的表面在涂装前的处理措施繁琐,导致生产效率低,并且容易对复合材料造成损坏,导致合格率低,进而成本高;另一方面,复合材料是由纤维和树脂组成的多相异质材料,经过高温或低温环境,由于纤维和树脂的热膨胀系数不一致,导致两者膨胀或收缩量不一致,进而会导致纤维纹理显现,而长期的高低温交变环境会导致复合材料表面的纤维纹理显现不可逆,影响汽车覆盖件漆面的整体视觉效果。
发明内容
本发明的目的是针对以上问题,提供一种汽车覆盖件复合材料结构及其成型方法。
第一方面,本申请提供一种汽车覆盖件复合材料结构,包括纤维-树脂复合材料层和金属外壳;所述纤维-树脂复合材料层包括纤维和填充在纤维中的树脂;所述金属外壳粘结在所述纤维-树脂复合材料层的外部。
根据本申请某些实施例提供的技术方案,所述纤维-树脂复合材料层和所述金属外壳之间通过胶膜粘结在一起。
根据本申请某些实施例提供的技术方案,所述胶膜的厚度为0.1-0.2mm。
根据本申请某些实施例提供的技术方案,所述金属外壳的厚度为0.1-0.3mm,金属外壳的厚度过大,无法确保汽车较大程度减重,厚度过小,无法消除纤维纹理显现的问题。
根据本申请某些实施例提供的技术方案,所述金属外壳由铝合金或钢制成。
根据本申请某些实施例提供的技术方案,所述纤维-树脂复合材料层的厚度为0.6-1.5mm。
根据本申请某些实施例提供的技术方案,所述纤维-树脂复合材料层的纤维为碳纤维、玻璃纤维、玄武岩纤维和芳纶纤维中的一种、两种或多种。
根据本申请某些实施例提供的技术方案,所述纤维-树脂复合材料层的树脂为热固性树脂或热塑性树脂。
第二方面,本申请提供一种汽车覆盖件复合材料结构的成型方法,包括如下步骤:
1)准备金属外壳:将铝合金板或钢板冲压成型,得到金属外壳,对所述金属外壳进行除油除污处理;
2)铺贴纤维预浸料:将所述金属外壳固定在纤维-树脂复合材料的成型模具中,并使所述金属外壳与所述成型模具紧密贴合,在所述金属外壳上平整、均匀地铺贴一层胶膜,在所述胶膜上逐层铺贴纤维预浸料铺层;
3)固化成型:所述纤维预浸料铺层固化成型,并通过所述胶膜与所述金属外壳粘结形成一体,得到汽车覆盖件复合材料结构。
第三方面,本申请提供另一种汽车覆盖件复合材料结构的成型方法,包括如下步骤:
1)准备金属外壳:将铝合金板或钢板冲压成型,得到金属外壳,对所述金属外壳进行除油除污处理;
2)准备纤维预成型体:采用预成型工艺制得纤维预成型体;
3)金属外壳与预成型体组合:将所述金属外壳固定在纤维-树脂复合材料的成型模具中,并使所述金属外壳与所述成型模具紧密贴合,将所述纤维预成型体放置在所述金属外壳上。
4)固化成型:向所述纤维预成型体上加入树脂,所述树脂浸润所述纤维预成型体,并填充所述纤维预成型体的间隙,形成纤维-树脂复合材料层,采用液体成型工艺,利用所述树脂将所述纤维-树脂复合材料层与所述金属外壳粘结形成一体,得到汽车覆盖件复合材料结构。
与现有技术相比,本发明的有益效果:
(1)通过在纤维-树脂复合材料层的外部设置金属外壳,在涂装前无需再采取繁琐的处理措施,从而提高了生产效率以及合格率,降低了成本;
(2)由于金属为各向同性的单相材料,经过高温或低温环境,金属外壳整体协同的膨胀或收缩,不会因为局部膨胀或收缩量不一致而形成纹理;另外,根据本申请某些实施例提供的技术方案,金属外壳的厚度为0.1-0.3mm,该厚度足以掩盖纤维-树脂复合材料层的纤维纹理显现,即使长期的高低温交变环境,也不会在金属外壳显现纤维纹理,从而确保汽车覆盖件漆面的整体视觉效果良好。
附图说明
图1为本申请实施例1提供的汽车覆盖件复合材料结构的结构示意图。
图中所述文字标注表示为:
1、纤维-树脂复合材料层;2、金属外壳;3、胶膜。
具体实施方式
为了使本领域技术人员更好地理解本申请的技术方案,下面结合附图对本申请进行详细描述,本部分的描述仅是示范性和解释性,不应对本申请的保护范围有任何的限制作用。
需要说明的是,本申请所述汽车覆盖件包括汽车前机盖、后尾门、左右翼子板、左右车门等;本申请所述纤维的形式可以为单向带或者织物,如为织物,织物的形式可以为平纹、斜纹或者缎纹;本申请所述纤维-树脂复合材料层的坯料可以为预浸料或者干纤维,针对预浸料的特点,采用胶膜将纤维-树脂复合材料层与金属外壳粘结在一起;针对干纤维的特点,采用液体成型工艺,无需铺贴胶膜,利用基体树脂将纤维-树脂复合材料层与金属外壳粘结在一起。
实施例1
请参考图1,本实施例提供一种汽车前机盖复合材料结构,包括纤维-树脂复合材料层1和金属外壳2;纤维-树脂复合材料层1包括纤维和填充在纤维中的树脂;纤维采用碳纤维;树脂采用环氧树脂;纤维-树脂复合材料层1的厚度为1.5mm,金属外壳2为铝合金金属外壳,其厚度为0.2mm,铝合金金属外壳粘结在纤维-树脂复合材料层1的外部,并通过胶膜3粘结在一起,胶膜3采用环氧树脂胶膜,环氧树脂胶膜的厚度为0.1mm。
该汽车前机盖复合材料结构的成型方法具体包括:
1)准备金属外壳:利用传统的冲压工艺,将铝合金薄板冲压成型得到汽车前机盖的铝合金金属外壳,铝合金金属外壳的厚度为0.2mm,对铝合金金属外壳进行除油除污处理;
2)铺贴纤维预浸料:将铝合金金属外壳固定在纤维-树脂复合材料的成型模具中,并使铝合金金属外壳与成型模具紧密贴合,在铝合金金属外壳上平整、均匀地铺贴一层环氧树脂胶膜,环氧树脂胶膜的厚度为0.1mm,最后在胶膜上逐层铺贴提前准备好的碳纤维预浸料铺层;
3)固化成型:按照传统真空袋工艺的封装方式,对铝合金金属外壳、环氧树脂胶膜以及碳纤维预浸料铺层进行封装,随后连同成型模具一起放入固化炉进行固化成型,在真空、压力、温度以及时间的作用下,碳纤维预浸料铺层固化成型,并通过环氧树脂胶膜与铝合金金属外壳粘结形成一体,从而得到汽车前机盖复合材料结构。
在本申请的其他实施例中,上述步骤3)固化成型时,也可以采用除真空袋工艺以外的工艺,比如热压罐工艺或者模压工业等。
本实施例提供的汽车前机盖复合材料结构,通过在纤维-树脂复合材料层的外部设置金属外壳,在涂装前无需再采取繁琐的处理措施,从而提高了生产效率以及合格率,降低了成本;由于金属外壳的作用,能有效防止纤维纹理的不可逆显现,确保汽车覆盖件漆面的整体视觉效果良好。
实施例2
本实施例提供一种汽车后尾门复合材料结构,包括纤维-树脂复合材料层1和金属外壳2;纤维-树脂复合材料层1包括纤维和填充在纤维中的树脂;纤维采用玻璃纤维;树脂采用聚氨酯树脂;纤维-树脂复合材料层1的厚度为0.6mm,金属外壳2为钢制金属外壳,其厚度为0.1mm,钢制金属外壳粘结在纤维-树脂复合材料层1的外部。
该汽车后尾门复合材料结构的成型方法具体包括:
1)准备金属外壳:利用传统的冲压工艺,将钢制作薄板冲压成型得到汽车后尾门的钢制金属外壳,钢制金属外壳的厚度为0.1mm,对钢制金属外壳进行除油除污处理;
2)准备纤维预成型体:逐层铺贴玻璃纤维织物,然后采用预成型工艺,将玻璃纤维织物预成型为汽车后尾门玻璃纤维织物预成型体;
3)金属外壳与预成型体组合:将钢制金属外壳固定在纤维-树脂复合材料的HP-RTM(高压-树脂传递模塑工艺)成型模具中,并使钢制金属外壳与成型模具紧密贴合,将汽车后尾门玻璃纤维织物预成型体放置在钢制金属外壳上,闭合成型模具的上模和下模。
4)固化成型:采用HP-RTM注胶***向成型模具的内部注射聚氨酯树脂体系,聚氨酯树脂体系在真空及压力的作用下,浸润玻璃纤维织物预成型体,并填充玻璃纤维织物预成型体的间隙,形成纤维-树脂复合材料层,在压力、温度及时间的作用下,聚氨酯树脂体系固化,同时将纤维-树脂复合材料层与钢制金属外壳粘结成一体,得到汽车后尾门复合材料结构。
在本申请的其他实施例中,上述步骤4)固化成型时,也可以采用除HP-RTM以外的其他液体成型工艺,比如VARI(真空辅助成型工艺)、RTM(树脂传递模塑工艺)、湿法模压等。
本实施例提供的汽车后尾门复合材料结构,通过在纤维-树脂复合材料层的外部设置金属外壳,在涂装前无需再采取繁琐的处理措施,从而提高了生产效率以及合格率,降低了成本;由于金属外壳的作用,能有效防止纤维纹理的不可逆显现,确保汽车覆盖件漆面的整体视觉效果良好。
本文中应用了具体个例对本申请的原理及实施方式进行了阐述,以上实施例的说明只是用于帮助理解本申请的方法及其核心思想。以上所述仅是本申请的优选实施方式,应当指出,由于文字表达的有限性,而客观上存在无限的具体结构,对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下,还可以作出若干改进、润饰或变化,也可以将上述技术特征以适当的方式进行组合;这些改进润饰、变化或组合,或未经改进将发明的构思和技术方案直接应用于其他场合的,均应视为本申请的保护范围。
Claims (10)
1.一种汽车覆盖件复合材料结构,其特征在于,包括纤维-树脂复合材料层和金属外壳;所述纤维-树脂复合材料层包括纤维和填充在纤维中的树脂;所述金属外壳粘结在所述纤维-树脂复合材料层的外部。
2.根据权利要求1所述的汽车覆盖件复合材料结构,其特征在于,所述纤维-树脂复合材料层和所述金属外壳之间通过胶粘结在一起。
3.根据权利要求2所述的汽车覆盖件复合材料结构,其特征在于,所述胶膜的厚度为0.1-0.2mm。
4.根据权利要求1所述的汽车覆盖件复合材料结构,其特征在于,所述金属外壳的厚度为0.1-0.3mm。
5.根据权利要求1所述的汽车覆盖件复合材料结构,其特征在于,所述金属外壳由铝合金或钢制成。
6.根据权利要求1所述的汽车覆盖件复合材料结构,其特征在于,所述纤维-树脂复合材料层的厚度为0.6-1.5mm。
7.根据权利要求1所述的汽车覆盖件复合材料结构,其特征在于,所述纤维-树脂复合材料层的纤维为碳纤维、玻璃纤维、玄武岩纤维和芳纶纤维中的一种、两种或多种。
8.根据权利要求1所述的汽车覆盖件复合材料结构,其特征在于,所述纤维-树脂复合材料层的树脂为热固性树脂或热塑性树脂。
9.一种如权利要求1所述的汽车覆盖件复合材料结构的成型方法,其特征在于,包括如下步骤:
1)准备金属外壳:将铝合金板或钢板冲压成型,得到金属外壳,对所述金属外壳进行除油除污处理;
2)铺贴纤维预浸料:将所述金属外壳固定在纤维-树脂复合材料的成型模具中,并使所述金属外壳与所述成型模具紧密贴合,在所述金属外壳上平整、均匀地铺贴一层胶膜,在所述胶膜上逐层铺贴纤维预浸料铺层;
3)固化成型:所述纤维预浸料铺层固化成型,并通过所述胶膜与所述金属外壳粘结形成一体,得到汽车覆盖件复合材料结构。
10.一种如权利要求1所述的汽车覆盖件复合材料结构的成型方法,其特征在于,包括如下步骤:
1)准备金属外壳:将铝合金板或钢板冲压成型,得到金属外壳,对所述金属外壳进行除油除污处理;
2)准备纤维预成型体:采用预成型工艺制得纤维预成型体;
3)金属外壳与预成型体组合:将所述金属外壳固定在纤维-树脂复合材料的成型模具中,并使所述金属外壳与所述成型模具紧密贴合,将所述纤维预成型体放置在所述金属外壳上。
4)固化成型:向所述纤维预成型体上加入树脂,所述树脂浸润所述纤维预成型体,并填充所述纤维预成型体的间隙,形成纤维-树脂复合材料层,采用液体成型工艺,利用所述树脂将所述纤维-树脂复合材料层与所述金属外壳粘结形成一体,得到汽车覆盖件复合材料结构。
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