CN1003296B - 复合材料的全承载汽车车身及其制造方法 - Google Patents

复合材料的全承载汽车车身及其制造方法 Download PDF

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CN1003296B
CN1003296B CN85101504.2A CN85101504A CN1003296B CN 1003296 B CN1003296 B CN 1003296B CN 85101504 A CN85101504 A CN 85101504A CN 1003296 B CN1003296 B CN 1003296B
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glass fabric
automobile body
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inner tube
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唐锦生
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Abstract

一种轻质高强度的复合材料汽车车身及其制造方法，所述复合材料特别适用于制造全承载的汽车车身。将泡沫复合材料按需要的形状做成内胎模型，再先后用至少一层浸透了环氧树脂的玻璃纤维布，以及至少两层浸透了聚酯的玻璃纤维布全部搭接包裹住内胎模型，待固化后再进行表面处理，由此而制成所需要的复合材料汽车车身。

Description

复合材料的全承载汽车车身及其制造方法
本发明涉及一种高强度、轻质复合材料的汽车车身及其制造方法，特别是涉及一种用上述复合材料制造的全承载汽车车身及其制造方法。
汽车车身一般是用钢板压制而成的。近年来，随着工程塑料及复合工程材料的迅速发展，汽车上应用塑料及复合材料来制造构件的越来越多，例如，用半硬质聚氨酯泡沫塑料及聚氯乙烯制方向盘、仪表盘、门柱、顶蓬等;采用改性硬质聚氨酯塑料制成保险杠;用改性ABC塑料制造护板;用SMC层状塑料制造车门;用碳纤维玻璃钢制造弹簧板及转动轴等等，也有用塑料或复合材料来制造整体车身的，但是由于材料成本高，加工复杂，所以，到目前为止，还没有塑料的或复合材料的车身投放市场，其主要原因有两条：1.塑料的或复合材料的车身，尤其是全承载车身其强度及耐冲击性能一般不够理想;2.其成本高于钢铁生产的汽车。鉴于上述两个原因，尽管复合材料制成的整体车身具有重量轻、消耗低等优点，但还是不能代替钢铁而进行大规模的生产。
本发明的目的就是提供一种轻质高强度的复合材料结构。利用这种材料结构，可以生产车身，尤其是全承载车身，这种整体车身不仅强度高、重量轻、而且经久耐用，造价大大低于钢铁，为大规模生产复合材料全承载车身提供了可能。本发明同时也解决了制造这种车身的方法。
本发明的主要内容就是：用至少是一层浸透了环氧树脂的玻璃纤维布及至少两层浸透了聚酯的玻璃纤维布，分别全部搭接包裹住由复合泡沫材料制成的汽车内胎模型，由此而制成复合材料全承载车身以及制造这种车身的方法。
本发明主要是利用了材料力学的“高惯性矩”原理，并进行了预应力处理，而使车身能具有上述优点。
我们知道，JZ＝bh3/12其中JZ为材料的惯性矩，b为材料的宽度，h为材料的厚度（可参见图1），由公式中可看到，增加材料的厚度，JZ则以三次方的比例提高，所以希望材料能厚一些。若采用玻璃纤维，即俗称的玻璃钢中间夹泡沫塑料，显然能提高材料的惯性矩，同时，抗弯刚度D也可以大幅度提高，这从公式
D=E玻b(H3-h3)/12+E泡b(H3-h3)/12
中也可看出。其中E为材料的弹性模量;H为材料总厚度;h为泡沫夹层厚度。由于高惯性矩的作用，使带泡沫塑料夹层的玻璃纤维布具有很高的强度，但是还没有充分发挥它的特点，因为玻璃钢的最佳特点是抗拉应力最好，（σ拉＝2500公斤/（厘米）2），而且浸透环氧树脂或聚酯的玻璃钢在其固化过程中，会产生千分之八的收缩，巧妙地利用玻璃钢的这两大特点，就使它产生了预应张力，从而获得更高刚度的材料，同时使降低成本、延长使用寿命成为可能。
下面，参考附图对发明进行更详细的说明：
图1：是复合材料的局部断面剖视示意图;
图2：是用方法2制造的复合材料的局部断面剖视示意图;
图3：是用复合材料制造的全承载汽车车身的剖视示意图;
图4：是图3的A向剖视图。
所使用的玻璃纤维布，如图1中的2，3，4，一般是中性、脱蜡的，其厚度不易太厚，一般来讲，厚度在0.1至0.5毫米之间，最好是0.25毫米。
所使用的复合泡沫材料如图1和图2中的1（即加工成内胎模型的材料）不仅要重量轻，而且要易于加工，材料要有弹性，价格要低，一般可以选用聚苯乙烯泡沫板或者是硬质聚氨酯泡沫，其容重可以是大约25公斤/立方米。
复合泡沫材料的厚度可根据应用部位不同而变化，一般来讲，其厚度在10至500毫米之内，多数情况为大约50毫米厚就可以了。
复合材料全承载车身的制造方法如下：
首先，将复合泡沫材料按需要的形状加工成内胎模型（参见图3和图4）。在小批量生产中，可用加工木模型的方法，将泡沫板做成所需形状的各个部件，然后再用粘合剂将各板材拼粘成所需要的整体形状。在大批量生产中，可用注塑法，一次成型为所需要的形状。
然后就要用玻璃纤维布分层次地、全部地包裹这一内胎模型。
玻璃纤维布要剪裁合适，与相应的内胎模型相匹配。然后在环氧树脂溶液中浸透。其中环氧树脂要稀释，同时要在该溶液中加上固化剂，若采用乙二胺固化剂，则乙二胺与环氧树脂的比例应为大约1∶10，比较合适。
将浸透了环氧树脂的玻璃纤维布（如图1中的2）复盖在内胎模型上，用宽度为6厘米以上的硬毛刷将玻璃纤维布刷平。这是第一层玻璃纤维，必须全部、均匀地包裹住内胎模型，其中特别要注意玻璃布的搭接部分，为保证强度，其搭接部分的宽度不能少于50毫米。大约3小时以后，用橡胶滚筒均匀地滚压半固化的玻璃纤维布，使其表面平坦。这种浸透环氧树脂的玻璃纤维布至少要复盖一层。若复盖二层，则在第一层复盖后大约36小时，玻璃钢固化后，再复盖第二层。
再将浸透了聚酯、剪裁合适的玻璃纤维布（如图1中的3）按上述方法互相搭接而全部、均匀地复盖在第一层（或几层）玻璃纤维布上，其搭接宽度也不能小于50毫米。浸透聚酯的玻璃纤维布要至少复盖两层，如图1中的4即为第二层。在最后一层复盖后，大约再过48小时，聚酯树脂玻璃钢就固化了，然后在其表面抛光处理，再喷漆、上光。
上面是制造复合材料的第一种方法。第二种方法与第一种类似，其主要不同点在于：首先将调制好的环氧树脂如图2中的5均匀地喷或刷在泡沫内胎模型（1）上，（其中环氧树脂内也要配上固化剂）。大约20分钟后，当环氧树脂还有相当的粘性时，将第一层玻璃纤维布（6）两端拉平，平稳地铺复在泡沫内胎模型（1）上，用干刷子刷平，并迅速地全部将模型用玻璃纤维布包住。其中每块布之间也要交错搭盖至少50毫米，然后在第一层玻璃纤维布（6）上再喷或刷上环氧树脂溶液如图2所示的7，使该溶液浸透玻璃纤维布层（6），大约20分钟后，用上述方法再铺复第二层玻璃纤维布（8）。在喷刷环氧树脂（如图2所示的9）后再复盖玻璃纤维布的方法。其玻璃纤维布至少要二层。待所需要的层次铺完后，需要大约36小时的固化，然后再将聚酯如图2所示的10喷或刷在上述玻璃钢上，大约20分钟后，铺复上玻璃纤维布（11），其方法和要点与喷刷环氧树脂的类似，但至少要铺二层玻璃纤维布，也就是在聚酯层（12）上面，还要铺复一层玻璃纤维布（13），然后再喷刷一层聚酯（14），待各层都铺复、包裹完毕后，要经过大约48小时的固化，然后再抛光、上漆、上光。
在上述操作中，玻璃纤维布之间的搭接宽度都在50毫米以上，且操作的环境温度要高于25℃，空气湿度要低于70%。
通过实验证明，用这种材料制造的全承载复合材料的汽车车身，具有强度高、质量轻，寿命长和造价低的优点。
而且用这种材料及方法使制造全承载的车身成为可能，实验证明，这种车身整体结构好，重量轻，是一般钢铁结构本身重的三分之一，所以，汽车的耗油量可减少，强度高，在发生碰撞时，一般金属汽车外壳将会产生永久性变形，但“全塑”汽车仅发生一些漆皮破损和局部的碰痕，造价低，从上述材料及其制造方法中可看到，所选用的基本原料价格都较低，制造方法简便，无需广阔的场地和复杂的设备，一般小厂均有能力承担，这种车身隔音、隔热好，无腐蚀，修补容易，具有较高的实用价值。
在不违背本发明精神的前提下，也可用这种制造车身的复合材料来制造各类船、游艇、家具、货箱等等，用途比较广。

Claims (26)

1、一种高强度轻质复合材料的汽车车身，其特征在于：这种车身是由至少一层浸透环氧树脂的玻璃纤维布以及至少是两层浸透了聚酯的玻璃纤维布，完全包裹在其中的复合泡沫材料制成的汽车内胎模型而构制成的。
2、由权利要求1所述的复合材料汽车车身，其特征在于：制造泡沫内胎模型的复合材料为聚苯乙烯。
3、由权利要求1所述的复合材料汽车车身，其特征在于：制造泡沫内胎模型的复合材料为硬质聚氨酯。
4、由权利要求1至3中任意一个所述的复合材料汽车车身，其特征在于：做为内胎模型的泡沫复合材料其容重为25公斤/立方米。
5、由权利要求1至3中任意一个所述的复合材料汽车车身，其特征在于：做为内胎模型的泡沫复合材料其厚度为10至500毫米。
6、按照权利要求5所述的复合材料汽车车身，其特征在于：做为内胎模型的泡沫复合材料其厚度为50毫米。
7、按照权利要求1至3项中任意一项所述的复合材料汽车车身，其特征在于：每层玻璃纤维布的厚度为0.1至4毫米。
8、按照权利要求7所述的复合材料汽车车身，其特征在于：每层玻璃纤维布的厚度为0.25毫米。
9、按照权利要求1至3中任意一项所述的复合材料汽车车身，其特征在于：玻璃纤维布是中性、脱蜡的。
10、按照权利要求7中所述的复合材料汽车车身，其特征在于：玻璃纤维布是中性、脱蜡的。
11、按照权利要求8中所述的复合材料汽车车身，其特征在于：玻璃纤维布是中性、脱蜡的。
12、按照权利要求1至3中任一项所述的复合材料汽车车身，其特征在于：全部包裹内胎模型的玻璃纤维布是5层。
13、按照权利要求7中所述的复合材料汽车车身，其特征在于：全部包裹内胎模型的玻璃纤维布是5层。
14、按照权利要求9中所述的复合材料汽车车身，其特征在于：全部包裹内胎模型的玻璃纤维布是5层。
15、按照权利要求8所述的复合材料汽车车身，其特征在于：全部包裹内胎模型的玻璃纤维布是5层。
16、按照权利要求1至3中任一项所述的复合材料汽车车身，其特征在于：浸透了环氧树脂的玻璃纤维布是两层，浸透了聚酯的玻璃纤维布是四层。
17、按照权利要求7中所述的复合材料汽车车身，其特征在于：浸透了环氧树脂的玻璃纤维布是两层，浸透了聚酯的玻璃纤维布是四层。
18、按照权利要求9中所述的复合材料汽车车身，其特征在于：浸透了环氧树脂的玻璃纤维布是两层，浸透了聚酯的玻璃纤维布是四层。
19、按照权利要求8中所述的复合材料汽车车身，其特征在于：浸透了环氧树脂的玻璃纤维布是两层，浸透了聚酯的玻璃纤维布是四层。
20、一种制造高强度轻质复合材料汽车车身的方法，其特征在于：用泡沫复合材料按需要形状做成内胎模型，再将至少一层浸透了环氧树脂的玻璃纤维布全部搭接包裹住模型内胎，待固化后，再将至少两层浸透了聚酯的玻璃纤维布依次全部搭接包裹住该模型，待固化后再进行表面处理。
21、按照权利要求20所述的方法，其特征在于：每层玻璃纤维布之间的搭接宽度不能少于50毫米。
22、按照权利要求20所述的方法，其特征在于：环氧树脂经稀释后，还要加入固化剂。
23、一种制造高强度轻质复合材料汽车车身的方法，其特征在于：首先用泡沫复合材料按需要的形状做成内胎模型，然后将环氧树脂均匀地喷刷在内胎模型表面，20分钟后，将一层玻璃纤维布平展地全部搭接包裹在模型表面，再喷刷一层环氧树脂，使该层玻璃纤维全部浸透，然后再铺裹上第二层玻璃纤维布，按上述方法做一次以上后，待环氧树脂玻璃钢固化，再在其表面喷刷聚酯，20分钟后，将玻璃纤维布平展地全部搭接包裹模型，再喷刷聚酯，使玻璃纤维布全部浸透，如此重复一次以上，最后待表面固化后，进行表面处理。
24、按照权利要求23所述的方法，其特征在于：每层玻璃纤维布之间的搭接宽度不能少于50毫米。
25、按照权利要求23所述的方法，其特征在于：环氧树脂经稀释后，还要加入固化剂。
26、按照权利要求20或23所述的方法，其特征在于：聚酯内要加入催化剂。
CN85101504.2A 1985-04-01 1985-04-01 复合材料的全承载汽车车身及其制造方法 Expired CN1003296B (zh)

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