CN100364761C - Method for mfg. covering unit of composite material for vehicle - Google Patents
Method for mfg. covering unit of composite material for vehicle Download PDFInfo
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- CN100364761C CN100364761C CNB2005101354729A CN200510135472A CN100364761C CN 100364761 C CN100364761 C CN 100364761C CN B2005101354729 A CNB2005101354729 A CN B2005101354729A CN 200510135472 A CN200510135472 A CN 200510135472A CN 100364761 C CN100364761 C CN 100364761C
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Abstract
The present invention discloses a method for manufacturing a composite material covering component for automobiles, which has the steps of mould set, mould surface cleaning and solidifying treatment after demoulding agent is coated. The surface of a female mould is sprayed with a gel coat layer with the thickness of 0.2 to 0.4mm. Then a reinforcing material layer is paved along the gel coat of the female mould, and then a movable block and a reinforcing rib are placed. The circumference of the female mould is inlaid with sealing ribs. The female mould and a male mould are closed and sealed, and the inner part of a mould cavity is evacuated. When the vacuum degree is from 0.092 to 0.096, the pressurizing operation is stopped after the pressure is maintained for 3 minutes, and the gel liquid is injected into the mould cavity. The mould is heated and solidified by a heating tube, and then the mould is opened. A produced product and the movable block are together demoulded and then are striped to be the product after treatment. The manufacturing process changes the traditional process that the original large structure component for automobiles uses the combination of a plurality of components. The present invention has the advantages of low equipment investment, low forming pressure and simplified technology. The present invention is suitable for the manufacture of the structure component with core and rib sandwiching integration and the structure component in a complicated shape which are larger than 5 square meters. The present invention can be easily popularized.
Description
Technical field
The present invention relates to a kind of manufacture method of large-scale covering, particularly a kind of manufacture method of composite large-scale covering.Be mainly used in the production field of car industry large-scale covering.
Background technology
Composite structure has fabulous toughness and anti-collision performance, thus become the traffic transport industry light weight, at a high speed, safe, energy-conservation, development trend that reduce to pollute, be considered as the ideal material of vehicle structure by the auto industry of developed country always.The research of U.S. Ford has confirmed that composite is in the vehicular field Application feasibility.Show that according to relevant report it is original 80% that composite can be kept to parts, the relative steel of processing charges reduce by 60%, and the bonding expense is welded relatively and reduced 25% to 40%.At present, the conventional hand that adopts of the production of composite material for vehicle parts, particularly automobile panel is stuck with paste technology, but hand paste quality stability is poor, and labour intensity is big, the requirement of incompatibility automotive industry production.The gunite that grows up afterwards, the quality of production and efficient all increase, but only limit to be applied to the production of simple shape parts.The appearance of the SMC sixties (sheet molding compound moulding) and BMC (BMC moulding) technology is for the automobile-used covering of suitability for industrialized production provides actuality.In subsequently 20 years, SMC and BMC technology develop maturation rapidly, and have obtained extensive use in the vehicle manufacturing industry.But for covering unit of composite material for vehicle, particularly in the production of large-scale covering or special-shaped sandwich, reinforcement covering, higher because of its performance requirement, adopt above-mentioned technological forming not only to be subjected to the restriction of article construction and type, and equipment investment height, equipment operation and process control complexity; Can not adapt to need of industrial production.
Summary of the invention
In order to solve the defective that exists in the above-mentioned prior art, the purpose of this invention is to provide a kind of suitable batch and make the oversize vehicle parts, can with core, muscle, built-in fitting and composite one-body molded be the manufacture method of large-scale covering.
To achieve these goals, the present invention adopts following technical scheme: a kind of manufacture method of covering unit of composite material for vehicle is characterized in that: it comprises the steps:
1) be provided with one comprise by the corresponding former that is provided with of cavity shape with in be provided with the mould that the formpiston of built-in groove is formed, and releasing agent is cleared up, smeared to the land area of its former and formpiston, put curing processing under the room temperature then, standby;
2) spray gel coat: on the die surface after the processing, spray the thick gel coating resin of 0.2-0.4mm respectively, described gel coating resin by coloured gel coat and curing agent with 100: 2.0-3.0wt% ratio mixed preparing forms, the gel time of this gel coating resin is 10-20 minute, and gelling temp is 50 ℃;
3) shop layer: layers of reinforcement is covered in the shop, gel coating resin surface behind its described former gel, lays loose piece and reinforcement on it;
4) matched moulds is prepared: have gum outlet and gum-injecting port on formpiston, its gum outlet is offered 4 at least, be distributed in described formpiston around; Described gum-injecting port is offered 1 at least, is positioned at the center of this formpiston;
5) matched moulds: at former edge mosaic seal, matched moulds pressurizes then;
6) vacuumize: the gum outlet place at formpiston inserts out sebific duct, and vacuum tube is gone out sebific duct and links to each other with described, and the vavuum pump of this vacuum tube by peripheral hardware be the airtight die cavity shape that is evacuated, when vacuum reaches 0.092-0.096MPa, and pressurize at least 3 minutes; In die cavity, inject glue by gum-injecting port again;
7) solidify: give mold heated by the heating tube that former is laid down, its temperature is 50 ℃, and described glue solidifies, at least 2 hours its hardening times;
8) die sinking: the breakdown formpiston, goods and loose piece are deviate from together, again loose piece and this goods are peeled off, carry out post processing at last.
Above-mentioned steps 1) cleaning of Yao Qiuing adopts clean mould agent to clean, and this clean mould agent is the CW-200HS solvent; Described releasing agent is an XTEND802 air drying type external release agent, and this releasing agent is smeared the 3-6 layer, and be 15-20 minute every layer of blanking time of smearing, and the releasing agent model of selecting for use is XTEND802; Whenever be coated with one deck releasing agent, solidify after 15-20 minute, renew and be coated with down one deck.
Above-mentioned steps 2) the total consumption of described gel coat is 1.8-2.0kg, and the curing agent that adds in its gel coat is the methyl ethyl ketone peroxide curing agent.
Above-mentioned steps 3) described layers of reinforcement comprises composite felt and core, and core is selected in polyurethane foamed material or the timber any for use; The best is selected polyurethane foamed material for use; Composite felt comprises bottom composite felt and top layer composite felt, and this bottom composite felt is laid at least 3 layers on described gel coating resin, lays loose piece then thereon, places core, lays at least 3 layers of composite felt again on its core, places reinforcement on it again.
Above-mentioned loose piece adopts glass-reinforced plastic material, and this loose piece also needed to carry out removing surface with perching knife before laying; Loose piece surface after cleaning coating thickness again is the wax layer of 0.4～1mm, and this wax is car wax, aligns use with being positioned in the cavity space and with its formpiston cavity after its wiping evenly then.
Above-mentioned steps 4) matched moulds is prepared, and the position of reinforcement in the step 3) and the built-in groove position of formpiston are oppositely arranged, and the shape of reinforcement and die cavity shape match, and guarantee that former and formpiston matched moulds are tight; Used reinforcement material is selected polyurethane foamed material for use, and polyurethane foam material is foaming in the foaming mould of special use, neat through repairing, and takes out to be placed in the mould of completing composite felt, and the built-in groove of leaving with formpiston aligns.
Above-mentioned steps 5) glue of Zhu Ruing adds curing agent 1.25-1.5ml again by unsaturated polyester (UP) 100g, and promoter 0.4～0.5ml mixed preparing forms; This curing agent is a diacetone peroxide, and this promoter is naphthoic acid cobalt.
After this covering unit of composite material curing molding and the demoulding,, also need on this covering unit of composite material, to add sticking metalwork according to the actual requirement of product; At last, the covering unit of composite material that is stained with metalwork is placed back curing on the frock.
The back condition of cure of the unsaturated polyester resin system that adopts in the above-mentioned gel coat is: solidified at least 7 days under the room temperature, solidified 24 hours under 50 ℃ of conditions, 60 ℃ solidified 4 hours, solidified 2 hours under 80 ℃ of temperature, then cooling naturally.
The present invention adopts above technical scheme, and the technique effect that is had is as follows: 1) solved the conventional art that the automobile engine covering adopts a plurality of parts to combine in the prior art, be applicable to massive article one-body molded of structure and forming shape complexity; This special use preformed equipment investment is little, and the research and development time is short, and can realize that the goods two sides is bright and clean, and briquetting pressure is low, and the volatile quantity of harmful substance is little; 2) for satisfying the intensity of large-scale covering unit of composite material for vehicle; the requirement of aspect such as the rigidity and the demoulding; adopt the in-flanges sandwich; the organization plan of large tracts of land reinforcement; formation has high performance integrated sandwich reinforced composite material large component; be applied to large complicated parts; as surface area one-body molded greater than 5 square metres complex component; effectively simplified manufacture process; improved production efficiency; under the prerequisite that does not reduce parts rigidity, effectively alleviate the quality of parts again; these meet current automobile loss of weight requirements of saving energy just; for the goods batch process provides the reliable technique support, can be satisfied with the integrated of automobile component; the requirements such as environmental protection of shortening the construction cycle and increasing day by day.
Specific embodiments
Processing step of the present invention is as follows:
1) be provided with one and comprise the mould of forming by corresponding former that is provided with of cavity shape and formpiston, and releasing agent is cleared up, smeared to the land area of its former and formpiston, put then to solidify under the room temperature and handle, standby;
2) spray gel coat: on the die surface after the processing, spray the thick gel coating resin of 0.2-0.4mm respectively, described gel coating resin by coloured gel coat and curing agent with 100: 2.0-3.0wt% ratio mixed preparing forms, the gel time of this gel coating resin is 10-20 minute, and gelling temp is 50 ℃;
3) shop layer: layers of reinforcement is covered in the closely knit shop, gel coating resin surface behind its described former gel, lays loose piece and reinforcement on it;
4) matched moulds is prepared: have gum outlet and gum-injecting port on formpiston, its gum outlet is offered 4 at least, be distributed in described formpiston around; Described gum-injecting port is offered 1 at least, is positioned at the center of this formpiston;
5) matched moulds: at former edge mosaic seal, matched moulds pressurizes then;
6) vacuumize: the gum outlet place at formpiston inserts out sebific duct, and vacuum tube is gone out sebific duct and links to each other with described, and the vavuum pump of this vacuum tube by peripheral hardware be the airtight die cavity shape that is evacuated, when vacuum reaches 0.092-0.096MPa, and pressurize at least 3 minutes; In die cavity, inject glue by gum-injecting port again;
7) solidify: give mold heated by the heating tube that former is laid down, its temperature is 50 ℃, and described glue solidifies, at least 2 hours its hardening times;
8) die sinking: the breakdown formpiston, goods and loose piece are deviate from together, again loose piece and this goods are peeled off, carry out post processing at last.
Above-mentioned steps 1) clean mould agent is adopted in the cleaning in, and the CW-200HS solvent is selected in this clean mould agent for use, residual releasing agent and surface contaminant and other dirt on the cleaning die; Whether the result who cleans can adopt adhesive tape test to check its die surface to clean totally; Releasing agent adopts the external release agent of air drying type, and its product type is XTEND802, and this releasing agent applies the 3-6 layer, overlapping coating between layer and the layer, and every layer interval between coating 15-20 minute, be 15-20 minute its hardening time; Releasing agent after the curing forms one deck semipermanent coating at die surface, can realize the demoulding of at least 30 products.Above-mentioned clean mould agent and releasing agent are by the production and sales of U.S. AXEL company.
Be provided with locating slot in the former that step 1) adopts; Be provided with the reference column with the corresponding setting of former locating slot in the formpiston, on formpiston, also offer the built-in groove that can put reinforcement.
Above-mentioned steps 2) step of spray gel coat: utilize portable gel coat spray gun spraying gel coat, the total consumption of gel coat is controlled at 1.8-2.0kg, wherein, curing agent is selected methyl ethyl ketone peroxide for use, adjust the consumption of curing agent and the hot water temperature that adds of former is 50 ℃ according to environment temperature and humidity, the control gel time is 10-20min, then its gel coat is poured in the spray cup, build lid, handle is the nozzle cocking that makes progress, and turns over hand after the gas ejection is arranged, make nozzle spray gel coat downwards, nozzle should be about 30 centimeters apart from mould, even mobile spray gun on mould, and a coating thickness is 0.1～0.4mm.
Also need with special baffle die joint and sealing strip place to be hidden before the spraying gel coat, present embodiment only need spray gel coat one time, and thickness is 0.2-0.4mm.
In addition, after former has sprayed gel coat, also to be that the in-flanges place of product brushes gel coat on the formpiston both sides.
Step 2) used gel coat total amount is 1.8-2.0kg; Wherein curing agent adopts methyl ethyl ketone peroxide.
The used layers of reinforcement of step 3) comprises composite felt and core, and wherein core is selected in polyurethane foamed material or the timber any for use; Composite felt is divided into bottom composite felt and top layer composite felt among the present invention, and its total consumption is 7-8kg; In actual production, earlier at least 3 layers of bottom composite felt are covered on the gel coating resin upper berth of former, best shop is covered 3 layers, lays loose piece then thereon, places core, and the built-in groove shape of offering on its shape and the formpiston is coincide and is aligned placement; This material foams in foaming mould and forms, and will use behind its taking-up finishing corner; The built-in groove that the position of core and formpiston lower surface are offered aligns, and according to the position of specific product regulation metal embedded part is inlayed on core again; Lay at least 3 layers of top layer composite felt again on its core, only need cover core just, best shop is covered 3 layers.
The fiberglass loose piece need carry out removing surface earlier before laying, cull and pit can not be arranged; And the loose piece surface-coated one deck car wax after cleaning, then its wiping is evenly used in the back placement former.
Above-mentioned steps 4) matched moulds is prepared, and has built-in groove in formpiston in advance, and the built-in groove position of the placement location of reinforcement and formpiston is oppositely arranged in the step 3), and the shape of reinforcement and die cavity shape match, and guarantee that former and formpiston matched moulds are tight; Used reinforcement material is selected polyurethane foamed material for use, and polyurethane foam material is foaming in the foaming mould of special use, neat through repairing, and takes out to be placed in the mould of completing composite felt, and the built-in groove of leaving with formpiston aligns, then matched moulds.
The matched moulds process of step 5) is former to be pushed under the press and with pilot pin together with dolly block, start press with formpiston and former to locked die, matched moulds to matched molds is located to stop at a distance of 15 centimeters, whether location and inner loose piece align around checking, confirm that normal back matched moulds puts pressurization in place.If in this process abnormal conditions are arranged, the inspection of die sinking is in time fixed a breakdown.The operation of press will can not be with air pressure opening and closing mould in strict accordance with its operational procedure.
Step 6) links to each other with vacuum tube by the sebific duct that goes out that inserts, and die cavity is vacuumized, and the diameter that goes out sebific duct is 6～8mm.Then, inject glue by gum-injecting port in die cavity again, this glue is by unsaturated polyester resin 100g, and the consumption of curing agent is 1.25-1.5g, and accelerator dosage forms for the 0.4-0.5ml mixed preparing; Wherein, the 988# unsaturated polyester resin that unsaturated polyester resin selects for use Nanjing, Nanjing DSM resin Co., Ltd to produce, curing agent is selected diacetone peroxide curing agent or methyl ethyl ketone peroxide curing agent for use, and the best is selected the diacetone peroxide curing agent for use; Promoter is selected naphthoic acid cobalt for use; The ambient humidity of injecting resin is 40-80%.The employed water temperature of heating mould is 50 ℃, and the temperature of resin heater is 30 ℃.When injecting, when going out seals when the sebific duct plastic emitting there is no big or continuous air bubbles, last stops injection after going out the sebific duct plastic emitting, closes valve, washes rifle, last two to three go out sebific duct needn't shutoff, appoint glue to flow out to release cavity pressure; Its injection speed be the 15-20 rifle/minute; The filling gun number is the 730-780 rifle, 50 ℃ of water temperatures; Requiring not have the injection of leakage limit rifle number is 800 rifles.
The demoulding step of step 8) requires to pull out out earlier sebific duct, releases press air pressure, the patrix of slowly slinging, when counterdie moves with dolly, stop immediately, press once falls, sling once more, can repeat This move when confirming that upper and lower mould can separate, rise patrix, release the counterdie dolly, naturally cool to room temperature, the resin bed excision loose piece two of cleaning on the loose piece edge-on to pure resin glue stubble,, re-use to eject and make product product and mould delamination with timber wedge with the loose piece demoulding.
Postprocessing working procedures is considered the resin solidification degree to the product quality influence degree, solidifies 1-2 week then certainly in 25 ℃ environment in case of necessity, and attention will place product carries out back curing on the frock;
Use the back condition of cure of unsaturated polyester resin system to have following several:
When 25 ℃ of room temperatures, solidified at least 7 days; Under 50 ℃ of conditions, solidified 24 hours; Solidified 4 hours under 60 ℃ of conditions; Solidified 2 hours under 80 ℃ of conditions; Naturally cooling then.
The covering unit of composite material that adopts the present invention to make is tested according to the company standard of the Chinese heavy-duty car QZZ111541996JT of group company, can satisfy its performance indications requirement fully.
Claims (8)
1. the manufacture method of a covering unit of composite material for vehicle, it is characterized in that: it comprises the steps:
1) be provided with one comprise by the corresponding former that is provided with of cavity shape with in be provided with the mould that the formpiston of built-in groove is formed, and releasing agent is cleared up, smeared to the land area of its former and formpiston, put curing processing under the room temperature then, standby;
2) spray gel coat: on the die surface after the processing, spray the thick gel coating resin of 0.2-0.4mm respectively, described gel coating resin by coloured gel coat and curing agent with 100: 2.0-3.0wt% ratio mixed preparing forms, the gel time of this gel coating resin is 10-20 minute, and gelling temp is 50 ℃;
3) shop layer: layers of reinforcement is covered in the shop, gel coating resin surface behind its described former gel, lays loose piece and reinforcement on it;
4) matched moulds is prepared: have gum outlet and gum-injecting port on formpiston, its gum outlet is offered 4 at least, be distributed in described formpiston around; Described gum-injecting port is offered 1 at least, is positioned at the center of this formpiston;
5) matched moulds: at former edge mosaic seal, matched moulds pressurizes then;
6) vacuumize: the gum outlet place at formpiston inserts out sebific duct, and vacuum tube is gone out sebific duct and links to each other with described, and the vavuum pump of this vacuum tube by peripheral hardware be the airtight die cavity shape that is evacuated, when vacuum reaches 0.092-0.096MPa, and pressurize at least 3 minutes; In die cavity, inject glue by gum-injecting port again;
7) solidify: give mold heated by the heating tube that former is laid down, its temperature is 50 ℃, and described glue solidifies, at least 2 hours its hardening times;
8) die sinking: the breakdown formpiston, goods and loose piece are deviate from together, again loose piece and this goods are peeled off, carry out post processing at last.
2. the manufacture method of covering unit of composite material for vehicle according to claim 1, it is characterized in that: clean mould agent cleaning is adopted in the described cleaning of step 1), and this clean mould agent is the CW-200HS solvent; Described releasing agent is an XTEND802 air drying type external release agent, and this releasing agent is smeared the 3-6 layer, and be 15-20 minute every layer of blanking time of smearing, and solidifies 15-20 minute follow-up one deck that is coated with down.
3. as the manufacture method of covering unit of composite material for vehicle as described in the claim 2, it is characterized in that: step 2) the total consumption of described gel coat is 1.8-2.0kg; Curing agent adopts the methyl ethyl ketone peroxide curing agent.
4. as the manufacture method of covering unit of composite material for vehicle as described in the claim 3, it is characterized in that: the described layers of reinforcement of step 3) comprises composite felt and core, and this core is selected in polyurethane foamed material or the timber any for use; This composite felt is divided into bottom composite felt and top layer composite felt, and the bottom composite felt is laid at least 3 layers on described gel coating resin, lays described loose piece then thereon, places core, lays at least 3 layers of composite felt again on its core.
5. as the manufacture method of covering unit of composite material for vehicle as described in the claim 4, it is characterized in that: the shape that the shape of the described reinforcement of step 3) and described built-in groove are offered is coincide.
6. as the manufacture method of covering unit of composite material for vehicle as described in the claim 5, it is characterized in that: the material of described reinforcement is a polyurethane foamed material.
7. as the manufacture method of covering unit of composite material for vehicle as described in the claim 6, it is characterized in that: the described glue of step 6) adds curing agent 1.25-1.5ml again by unsaturated polyester (UP) 100g, and promoter 0.4～0.5ml mixed preparing forms; This curing agent is a diacetone peroxide, and this promoter is naphthoic acid cobalt.
8. as the manufacture method of covering unit of composite material for vehicle as described in the claim 7, it is characterized in that: described loose piece also need carry out removing surface before laying, and the loose piece surface-coated one deck wax after cleaning, then its wiping was evenly used the back.
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| CNB2005101354729A CN100364761C (en) | 2005-12-31 | 2005-12-31 | Method for mfg. covering unit of composite material for vehicle |
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| CNB2005101354729A CN100364761C (en) | 2005-12-31 | 2005-12-31 | Method for mfg. covering unit of composite material for vehicle |
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| CN1792619A CN1792619A (en) | 2006-06-28 |
| CN100364761C true CN100364761C (en) | 2008-01-30 |
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| CN1792619A (en) | 2006-06-28 |
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