阅读说明：本技术 一种汽车覆盖件复合材料结构及其成型方法 (Composite material structure of automobile covering part and forming method thereof ) 是由 辛朝波 于 2020-04-13 设计创作，主要内容包括：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。(The invention provides a composite material structure of an automobile panel and a forming method thereof, wherein the composite material structure of the automobile panel comprises a fiber-resin composite material layer and a metal shell; the fiber-resin composite layer includes fibers and a resin filled in the fibers; the metal shell is bonded to the outside of the fiber-resin composite layer. The metal shell is arranged outside the fiber-resin composite material layer, so that complicated treatment measures are not required before coating, the production efficiency and the qualification rate are improved, and the cost is reduced; due to the action of the metal shell, the irreversible display of fiber textures can be effectively prevented, and the good overall visual effect of the paint surface of the automobile covering part is ensured.)

1. An automobile panel composite structure comprising a fiber-resin composite layer and a metal shell; the fiber-resin composite layer includes fibers and a resin filled in the fibers; the metal shell is bonded to the outside of the fiber-resin composite layer.

2. The automobile panel composite structure according to claim 1, wherein the fiber-resin composite layer and the metal outer shell are bonded together by a glue.

3. The automobile panel composite structure according to claim 2, wherein the adhesive film has a thickness of 0.1-0.2 mm.

4. The automobile panel composite structure according to claim 1, wherein the thickness of the metal outer shell is 0.1-0.3 mm.

5. The automobile panel composite structure according to claim 1, wherein the metal outer shell is made of aluminum alloy or steel.

6. The automobile panel composite structure according to claim 1, wherein the thickness of the fiber-resin composite layer is 0.6 to 1.5 mm.

7. The automobile panel composite structure according to claim 1, wherein the fiber of the fiber-resin composite layer is one, two or more of a carbon fiber, a glass fiber, a basalt fiber and an aramid fiber.

8. The automobile panel composite structure according to claim 1, wherein the resin of the fiber-resin composite layer is a thermosetting resin or a thermoplastic resin.

9. A method of forming a composite structure for automotive panels as claimed in claim 1, characterized by comprising the steps of:

1) preparing a metal shell: stamping and forming an aluminum alloy plate or a steel plate to obtain a metal shell, and performing oil removal and decontamination treatment on the metal shell;

2) laying and pasting fiber prepreg: fixing the metal shell in a forming mould of a fiber-resin composite material, enabling the metal shell to be tightly attached to the forming mould, flatly and uniformly paving a layer of adhesive film on the metal shell, and paving fiber prepreg layers on the adhesive film layer by layer;

3) curing and forming: and curing and molding the fiber prepreg paving layer, and bonding the adhesive film and the metal shell into a whole to obtain the composite material structure of the automobile covering part.

10. A method of forming a composite structure for automotive panels as claimed in claim 1, characterized by comprising the steps of:

1) preparing a metal shell: stamping and forming an aluminum alloy plate or a steel plate to obtain a metal shell, and performing oil removal and decontamination treatment on the metal shell;

2) preparing a fiber preform: preparing a fiber preformed body by adopting a preforming process;

3) metal shell and preform combination: and fixing the metal shell in a forming mould of a fiber-resin composite material, enabling the metal shell to be tightly attached to the forming mould, and placing the fiber preformed body on the metal shell.

4) Curing and forming: and adding resin to the fiber preformed body, infiltrating the fiber preformed body with the resin, filling gaps of the fiber preformed body to form a fiber-resin composite material layer, and bonding the fiber-resin composite material layer and the metal shell into a whole by using the resin by adopting a liquid forming process to obtain the composite material structure of the automobile covering part.

Technical Field

The invention relates to the technical field of material manufacturing, in particular to an automobile panel composite material structure and a forming method thereof.

Background

With the global energy crisis becoming more severe and the environmental problems becoming more and more prominent, the new energy automobile industry is developing rapidly, and the automobile lightweight technology dominated by composite materials is a necessary way for the development of new energy automobiles. In recent years, composite materials are increasingly applied to outer panels of covering parts such as front covers, rear doors, left and right fenders, and left and right doors of automobiles, and the aim of reducing the weight of automobiles is achieved.

On one hand, the treatment measures of the surface of the composite material before coating are complicated, so that the production efficiency is low, the composite material is easily damaged, the yield is low, and the cost is high; on the other hand, the composite material is a multi-phase heterogeneous material consisting of fibers and resin, and after passing through a high-temperature or low-temperature environment, due to the fact that the thermal expansion coefficients of the fibers and the resin are different, the expansion or contraction amounts of the fibers and the resin are different, fiber textures can be displayed, and the fiber textures on the surface of the composite material can be displayed irreversibly under a long-term high-temperature and low-temperature alternating environment, so that the overall visual effect of the automobile covering part paint surface is influenced.

Disclosure of Invention

The invention aims to solve the problems and provides an automobile panel composite material structure and a forming method thereof.

In a first aspect, the present application provides an automobile panel composite structure comprising a fiber-resin composite layer and a metal outer shell; the fiber-resin composite layer includes fibers and a resin filled in the fibers; the metal shell is bonded to the outside of the fiber-resin composite layer.

According to the technical scheme provided by certain embodiments of the application, the fiber-resin composite material layer and the metal shell are bonded together through an adhesive film.

According to the technical scheme provided by some embodiments of the application, the thickness of the adhesive film is 0.1-0.2 mm.

According to the technical scheme provided by some embodiments of the application, the thickness of the metal shell is 0.1-0.3mm, the thickness of the metal shell is too large, the weight of an automobile cannot be reduced to a large extent, the thickness is too small, and the problem of fiber texture display cannot be solved.

According to the technical solution provided by some embodiments of the present application, the metal housing is made of aluminum alloy or steel.

According to the technical scheme provided by certain embodiments of the application, the thickness of the fiber-resin composite material layer is 0.6-1.5 mm.

According to the technical scheme provided by certain embodiments of the application, the fibers of the fiber-resin composite material layer are one, two or more of carbon fibers, glass fibers, basalt fibers and aramid fibers.

According to the technical solution provided by some embodiments of the present application, the resin of the fiber-resin composite layer is a thermosetting resin or a thermoplastic resin.

In a second aspect, the present application provides a method of forming a composite structure for an automobile panel, comprising the steps of:

1) preparing a metal shell: stamping and forming an aluminum alloy plate or a steel plate to obtain a metal shell, and performing oil removal and decontamination treatment on the metal shell;

2) laying and pasting fiber prepreg: fixing the metal shell in a forming mould of a fiber-resin composite material, enabling the metal shell to be tightly attached to the forming mould, flatly and uniformly paving a layer of adhesive film on the metal shell, and paving fiber prepreg layers on the adhesive film layer by layer;

3) curing and forming: and curing and molding the fiber prepreg paving layer, and bonding the adhesive film and the metal shell into a whole to obtain the composite material structure of the automobile covering part.

In a third aspect, the present application provides another method of forming an automotive panel composite structure, comprising the steps of:

1) preparing a metal shell: stamping and forming an aluminum alloy plate or a steel plate to obtain a metal shell, and performing oil removal and decontamination treatment on the metal shell;

2) preparing a fiber preform: preparing a fiber preformed body by adopting a preforming process;

3) metal shell and preform combination: and fixing the metal shell in a forming mould of a fiber-resin composite material, enabling the metal shell to be tightly attached to the forming mould, and placing the fiber preformed body on the metal shell.

4) Curing and forming: and adding resin to the fiber preformed body, infiltrating the fiber preformed body with the resin, filling gaps of the fiber preformed body to form a fiber-resin composite material layer, and bonding the fiber-resin composite material layer and the metal shell into a whole by using the resin by adopting a liquid forming process to obtain the composite material structure of the automobile covering part.

Compared with the prior art, the invention has the beneficial effects that:

(1) the metal shell is arranged outside the fiber-resin composite material layer, so that complicated treatment measures are not required before coating, the production efficiency and the qualification rate are improved, and the cost is reduced;

(2) because the metal is an isotropic single-phase material, the metal shell can be expanded or contracted integrally and cooperatively under the high-temperature or low-temperature environment, and the texture cannot be formed due to the inconsistent local expansion or contraction amount; in addition, according to the technical scheme provided by some embodiments of the application, the thickness of the metal shell is 0.1-0.3mm, and the thickness is enough to cover the fiber texture display of the fiber-resin composite material layer, so that the fiber texture can not be displayed on the metal shell even in a long-term high-low temperature alternating environment, and the good overall visual effect of the automobile covering part paint surface is ensured.

Drawings

Fig. 1 is a schematic structural diagram of an automobile panel composite structure provided in embodiment 1 of the present application.

The text labels in the figures are represented as:

1. a fiber-resin composite layer; 2. a metal housing; 3. and (5) coating the film.

Detailed Description

The following detailed description of the present application is given for the purpose of enabling those skilled in the art to better understand the technical solutions of the present application, and the description in this section is only exemplary and explanatory, and should not be taken as limiting the scope of the present application in any way.

It should be noted that, the automobile covering part includes an automobile front cover, a rear tail door, a left fender, a right fender, a left door, a right door and the like; the fibers described herein may be in the form of unidirectional tapes or fabrics, such as woven fabrics, which may be in the form of plain, twill or satin; the blank of the fiber-resin composite material layer can be prepreg or dry fiber, and the fiber-resin composite material layer and the metal shell are bonded together by adopting an adhesive film according to the characteristics of the prepreg; aiming at the characteristics of dry fibers, a liquid forming process is adopted, an adhesive film is not required to be paved, and a fiber-resin composite material layer and a metal shell are bonded together by matrix resin.

Example 1

Referring to fig. 1, the present embodiment provides a composite material structure for a front cover of an automobile, which includes a fiber-resin composite material layer 1 and a metal shell 2; the fiber-resin composite material layer 1 includes fibers and a resin filled in the fibers; the fiber is carbon fiber; the resin is epoxy resin; the thickness of the fiber-resin composite material layer 1 is 1.5mm, the metal shell 2 is an aluminum alloy metal shell, the thickness of the metal shell is 0.2mm, the aluminum alloy metal shell is bonded outside the fiber-resin composite material layer 1 and is bonded together through an adhesive film 3, the adhesive film 3 is an epoxy resin adhesive film, and the thickness of the epoxy resin adhesive film is 0.1 mm.

The forming method of the automobile front cover composite material structure specifically comprises the following steps:

1) preparing a metal shell: the aluminum alloy sheet is punched and formed by a traditional punching process to obtain an aluminum alloy metal shell of the front machine cover of the automobile, the thickness of the aluminum alloy metal shell is 0.2mm, and the aluminum alloy metal shell is subjected to oil removal and decontamination treatment;

2) laying and pasting fiber prepreg: fixing an aluminum alloy metal shell in a forming die of a fiber-resin composite material, enabling the aluminum alloy metal shell to be tightly attached to the forming die, flatly and uniformly paving a layer of epoxy resin adhesive film on the aluminum alloy metal shell, wherein the thickness of the epoxy resin adhesive film is 0.1mm, and finally paving a carbon fiber prepreg paving layer prepared in advance layer by layer on the adhesive film;

3) curing and forming: according to the packaging mode of the traditional vacuum bag process, the aluminum alloy metal shell, the epoxy resin adhesive film and the carbon fiber prepreg laying layer are packaged, then the aluminum alloy metal shell, the epoxy resin adhesive film and the carbon fiber prepreg laying layer are placed into a curing furnace together with a forming mold for curing and forming, under the action of vacuum, pressure, temperature and time, the carbon fiber prepreg laying layer is cured and formed, and the epoxy resin adhesive film and the aluminum alloy metal shell are bonded to form a whole, so that the automobile front cover composite material structure is obtained.

In other embodiments of the present application, when the curing molding in step 3) is performed, a process other than a vacuum bag process, such as an autoclave process or a molding industry, may also be used.

According to the automobile front cover composite material structure provided by the embodiment, the metal shell is arranged outside the fiber-resin composite material layer, and complicated treatment measures are not required before coating, so that the production efficiency and the qualification rate are improved, and the cost is reduced; due to the action of the metal shell, the irreversible display of fiber textures can be effectively prevented, and the good overall visual effect of the paint surface of the automobile covering part is ensured.

Example 2

The embodiment provides a composite material structure of an automobile back tail door, which comprises a fiber-resin composite material layer 1 and a metal shell 2; the fiber-resin composite material layer 1 includes fibers and a resin filled in the fibers; the fiber is glass fiber; the resin is polyurethane resin; the thickness of the fiber-resin composite material layer 1 is 0.6mm, the metal shell 2 is a steel metal shell with the thickness of 0.1mm, and the steel metal shell is bonded outside the fiber-resin composite material layer 1.

The forming method of the composite material structure of the automobile rear tail door specifically comprises the following steps:

1) preparing a metal shell: the method comprises the following steps of (1) punching and forming a steel sheet to obtain a steel metal shell of the automobile back tail door by using a traditional punching process, wherein the thickness of the steel metal shell is 0.1mm, and carrying out oil removal and decontamination treatment on the steel metal shell;

2) preparing a fiber preform: paving and pasting glass fiber fabrics layer by layer, and performing the glass fiber fabrics into a glass fiber fabric performing body of the automobile back door by adopting a performing process;

3) metal shell and preform combination: fixing a steel metal shell in an HP-RTM (high pressure-resin transfer molding) forming die of a fiber-resin composite material, enabling the steel metal shell to be tightly attached to the forming die, placing a glass fiber fabric preformed body of the automobile back door on the steel metal shell, and closing an upper die and a lower die of the forming die.

4) Curing and forming: and (2) injecting a polyurethane resin system into the forming mold by adopting an HP-RTM glue injection system, infiltrating the glass fiber fabric preformed body by the polyurethane resin system under the action of vacuum and pressure, filling gaps of the glass fiber fabric preformed body to form a fiber-resin composite material layer, curing the polyurethane resin system under the action of pressure, temperature and time, and simultaneously bonding the fiber-resin composite material layer and the steel metal shell into a whole to obtain the composite material structure of the rear tail door of the automobile.

In other embodiments of the present application, when the curing molding in step 4) is performed, other liquid molding processes besides HP-RTM, such as VARI (vacuum assisted molding), RTM (resin transfer molding), wet molding, etc., may also be used.

According to the composite material structure of the automobile rear tail door, the metal shell is arranged outside the fiber-resin composite material layer, and complicated treatment measures are not needed before coating, so that the production efficiency and the qualification rate are improved, and the cost is reduced; due to the action of the metal shell, the irreversible display of fiber textures can be effectively prevented, and the good overall visual effect of the paint surface of the automobile covering part is ensured.

The principles and embodiments of the present application are explained herein using specific examples, which are provided only to help understand the method and the core idea of the present application. The foregoing is only a preferred embodiment of the present application, and it should be noted that there are no specific structures which are objectively limitless due to the limited character expressions, and it will be apparent to those skilled in the art that a plurality of modifications, decorations or changes can be made without departing from the principle of the present invention, and the technical features mentioned above can be combined in a suitable manner; such modifications, variations, combinations, or adaptations of the invention in other instances, which may or may not be practiced, are intended to be within the scope of the present application.