CN101450543B - 车辆油底壳及其制备方法 - Google Patents

车辆油底壳及其制备方法 Download PDF

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CN101450543B
CN101450543B CN2007102028603A CN200710202860A CN101450543B CN 101450543 B CN101450543 B CN 101450543B CN 2007102028603 A CN2007102028603 A CN 2007102028603A CN 200710202860 A CN200710202860 A CN 200710202860A CN 101450543 B CN101450543 B CN 101450543B
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magnesium alloy
alloy substrate
layer
oil sump
vehicle oil
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CN101450543A (zh
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李鼐一
钟国荣
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Hongfujin Precision Industry Shenzhen Co Ltd
Hon Hai Precision Industry Co Ltd
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Hongfujin Precision Industry Shenzhen Co Ltd
Hon Hai Precision Industry Co Ltd
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Priority to CN2007102028603A priority Critical patent/CN101450543B/zh
Priority to US12/107,778 priority patent/US8609224B2/en
Priority to GB0820151A priority patent/GB2455394B/en
Priority to DE200810060794 priority patent/DE102008060794A1/de
Publication of CN101450543A publication Critical patent/CN101450543A/zh
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Abstract

一种车辆油底壳，其包括一镁合金基体，至少部分包覆该镁合金基体的至少一有机材料层。本发明还提供一种上述镁合金复合件的制备方法。该制备方法包括以下步骤：提供一镁合金基体；形成至少部分包覆该镁合金基体的至少一有机材料层。上述镁合金复合件具有可避免镁合金基体与异种金属接触时产生伽凡尼腐蚀的优点。

Description

车辆油底壳及其制备方法
技术领域
本发明涉及一种车辆油底壳及其制备方法，尤其涉及一种可应用于汽车领域的车辆油底壳及其制备方法。
背景技术
镁合金具有轻量化、高强度、耐压、散热佳、抗振动、能吸收电磁辐射以及可加工性强等优点。另外，80%以上的镁合金可再回收利用，对环境污染小，因此镁合金被誉为“绿色节能材料”。目前，镁合金广泛地应用在国防、汽车工业、航天航空、3C产业、体育用品等多个领域。
然而，镁合金为密排六方晶体结构，因变形滑移系较少，室温下可塑性差、成型困难。另外，由于镁合金还原电位较低，所以当镁合金件与其他金属缔结、锁附、结合时，往往会因为环境湿度等原因产生接触电位差，从而产生接触腐蚀，也称为伽凡尼腐蚀(Galvanic Corrosion)。
如图1所示，一种现有的AZ91D镁合金件12与其他金属件14经由螺栓螺帽16，17锁附的连接结构。其中为减少镁合金件12与其他金属件14和螺栓螺帽16在使用中产生伽凡尼腐蚀，镁合金件12、其他金属件14和螺栓螺帽16之间需分别增加一隔绝垫圈18进行隔绝。
然而，对镁合金件12采用垫圈18隔绝处理的方法仅能理论上解决接触腐蚀问题，而实际上，特别是应用于汽车领域时，多数汽车零件随着使用时间增加，将于其外表蒙上尘土或脏污。此类尘土或脏污层与使用环境的湿气或水相结合时，使得镁合金与其锁附对手件（即其他金属件14）将再度形成电池效应通路而产生接触腐蚀。因此，单利用隔绝垫圈18进行隔绝已无法永久性防止接触腐蚀问题。
发明内容
鉴于上述状况，有必要提供一种有效防止因接触电位差引起的接触腐蚀的车辆油底壳及其制备方法。
一种车辆油底壳，其包括一镁合金基体，至少部分包覆该至少一镁合金基体的一二苯基甲烷二异氰酸脂发泡层和一聚氨脂硬质层，该二苯基甲烷二异氰酸脂发泡层和该聚氨脂硬质层依次完全包覆该镁合金基体。
一种车辆油底壳，其包括一镁合金基体，其特征在于：该车辆油底壳还包括至少部分包覆该镁合金基体的一聚乙烯发泡层和一聚乙烯硬质层，该聚乙烯发泡层以及该聚乙烯硬质层依次完全或部分包覆该镁合金基体。
一种车辆油底壳的制备方法，其包括以下步骤：提供一镁合金基体；形成至少部分包覆该镁合金基体的一二苯基甲烷二异氰酸脂发泡层和一聚氨脂硬质层，该二苯基甲烷二异氰酸脂发泡层和该聚氨脂硬质层依次完全包覆该镁合金基体。
一种车辆油底壳的制备方法，其包括以下步骤：
提供一镁合金基体；
形成至少部分包覆该镁合金基体的一聚乙烯发泡层和一聚乙烯硬质层，该聚乙烯发泡层以及该聚乙烯硬质层依次完全或部分包覆该镁合金基体。
上述车辆油底壳采用有机材料层进行完全或部分包覆的设计可避免镁合金基体与异种金属接触时产生接触腐蚀。
附图说明
图1是一种现有的镁合金件与其他金属件的连接结构的剖面示意图。
图2是本发明较佳实施例一的镁合金复合件与其他金属件的连接结构的剖面示意图。
图3是制备图2所示镁合金复合件所采用模具以及镁合金基体的剖面示意图。
图4是本发明较佳实施例二的镁合金复合件与其他金属件的连接结构的剖面示意图。
图5是制备图4所示镁合金复合件所采用模具以及镁合金基体的剖面示意图。
具体实施例
下面将结合附图及实施例对本发明的镁合金复合件及其制备方法作进一步的详细说明。
请参见图2，所示为本发明较佳实施例一的镁合金复合件20与其他金属件29的连接结构剖面图。
该镁合金复合件20包括一镁合金连接部21，一聚乙烯(Polyethylene,PE)发泡层23以及一聚乙烯硬质层25。该镁合金连接部21为一镁合金基体的一折弯端部。该镁合金连接部21的上下表面分别形成有至少一个突柱212。该聚乙烯发泡层23以及该聚乙烯硬质层25依次部分包覆该镁合金基体，即该聚乙烯发泡层23以及该聚乙烯硬质层25依次包覆该镁合金连接部21。其中，该聚乙烯发泡层23的厚度高于该突柱212的高度。另外，可以选择于镁合金基体形成沟槽、肋鳍片、压花、通孔等结构来替代突柱212的设计，同样可达到提高聚乙烯发泡层23与镁合金基体21之间的结合力的作用。
该镁合金复合件20于包覆区钻孔后形成通孔214。通过螺栓27，螺帽28将该镁合金复合件20与其他金属件29进行紧密锁附。通孔214的直径比螺栓27的直径大，可保证螺栓27不与镁合金基体接触。可以选择的是，可用塑料套筒装入通孔214内防止螺栓27与镁合金基体接触。
由于该镁合金复合件20主要以镁合金连接部21为螺栓锁附位置，采用聚乙烯发泡层23和该聚乙烯硬质层25进行包覆的设计可避免异种金属与镁合金基体相接触时产生伽凡尼腐蚀。本实施例的镁合金复合件20可应用于汽车领域零部件，而无须进行繁琐的表面耐蚀处理，或使用过渡金属(如:铝合金材料)所制成之阻隔层，或特殊涂装处理来解决异种金属相结合问题。
本实施例镁合金复合件20的制备方法包括以下步骤：
(1)提供一镁合金基体，该镁合金基体具有一镁合金连接部21，该镁合金连接部21形成多个突柱212。该镁合金基体可利用铸造、挤出、锻造等各种金属生产方法制备。
(2)形成一包覆该镁合金连接部21的聚乙烯发泡层23。此步骤包括以下分步骤：如图3所示，首先，提供一模具30，其具有第一闭合模穴32。将镁合金连接部21放置于该第一闭合模穴内。接着，将聚乙烯均匀混和10%重量比的碳酸氢钠（发泡剂）后填充于一射出成型机（图未示）的加热料筒内，加热熔融上述聚乙烯和碳酸氢钠的混合料后由螺杆迅速在高压下使其通过喷嘴注入该第一闭合模穴32内。本实施例中该加热料筒的加热温度为90℃左右。上述混合料加热过程中，碳酸氢钠产生二氧化碳气体于熔融的聚乙烯中产生许多气孔形成发泡材料。最后，熔融的发泡材料于第一闭合模穴内冷却后，固化成包覆该镁合金连接部21的聚乙烯发泡层23。
(3)形成一包覆该聚乙烯发泡层23的聚乙烯硬质层25。此步骤包括以下分步骤：提供另一模具（图未示），其具有第二闭合模穴（图未示）。将具有聚乙烯发泡层23的镁合金连接部21放置于该第二闭合模穴内。接着，将聚乙烯填充于一射出成型机（图未示）的加热料筒内，加热熔融上述聚乙烯后由螺杆迅速在高压下使其通过喷嘴注入该第二闭合模穴内。本实施例中该加热料筒的加热温度为95℃左右。最后，熔融的聚乙烯于第二模穴内冷却后，固化成包覆该聚乙烯发泡层23的聚乙烯硬质层25。此步骤中，由于注入的熔融聚乙烯温度较高，其与聚乙烯发泡层23相接处时可产生融熔接合。
请参见图4，所示为本发明较佳实施例二的镁合金复合件40与其他金属件49的部分连接结构剖面图和局部放大示意图。
该镁合金复合件40包括一具有帽沿的帽子型镁合金基体41，一二苯基甲烷二异氰酸脂(MDI)发泡层43（下文简称为MDI发泡层）以及一聚氨脂（Polyurethane,PU）硬质层45（下文简称为PU硬质层）。该MDI发泡层43以及该PU硬质层45依次完全包覆该镁合金基体41，其中该MDI发泡层43的厚度大于该PU硬质层45的厚度。
该镁合金件40的两端分别通过两螺栓47，螺帽48与两其他金属件49进行紧密锁附。镁合金复合件40采用MDI发泡层43和PU硬质层45进行包覆的设计可避免异种金属相接触而与其镁合金基体41产生伽凡尼腐蚀。本实施例的镁合金复合件40可作为车辆油底壳安装于引擎下部，所以该镁合金复合件40需有较佳的耐热性能。由于MDI发泡层43具有很好的绝热和吸振性能以及PU硬质层45为一耐高温硬壳层，从而使整个镁合金复合件40适用于高温场合而无须变更镁合金配方。在高温使用环境下，相比业界采用价格昂贵、铸造性差、易产生热裂的耐热镁合金来替代普通镁合金的方法，本实施例的镁合金复合件40除了可有效避免镁合金基体在高于120℃时发生尺寸精度变异，产生蠕变现象等缺陷外，还具有价格低、制备简单、不易产生热裂等优点。
本实施例镁合金复合件40的制备方法包括以下步骤：
(1)制备一镁合金基体41。可利用铸造、挤出、锻造等各种金属生产方法制备该镁合金基体41。
(2)形成一完全包覆该镁合金基体41的MDI发泡层43。此步骤包括以下分步骤：如图5所示，首先，提供一模具60，其具有第一闭合模穴62，将镁合金基体41放置于该第一闭合模穴内。该第一闭合模穴62能容纳镁合金基体41且留预定空间用于形成MDI发泡层43。其次，于第一闭合模穴62内设置多个定位销（图未示）用于限定该镁合金基体41于第一闭合模穴内的适当位置。接着，将MDI塑料均匀混和15%重量比的三氯氟甲烷（发泡剂）后填充于一射出成型机（图未示）的加热料筒内，加热熔融上述MDI塑料和三氯氟甲烷的混合料后由螺杆迅速在高压下使其通过喷嘴注入该第一闭合模穴内。本实施例中该加热料筒的加热温度为160℃左右。上述混合料加热过程中，三氯氟甲烷产生的气体于熔融的MDI塑料中形成许多气孔，形成发泡材料。最后，熔融的发泡材料于第一模穴内冷却后，固化成包覆该镁合金基体41的MDI塑料发泡层43。
(3)形成一包覆该MDI发泡层43的PU硬质层45。此步骤包括以下分步骤：提供另一模具(图未示)，其具有相应将要包覆的部份（具有MDI发泡层43的镁合金基体41）设计成的第二闭合模穴，将具有MDI发泡层43的镁合金基体41放置于该第二闭合模穴内。接着，将PU塑料填充于一射出成型机（图未示）的加热料筒内，加热熔融上述PU塑料后由螺杆迅速在高压下使其通过喷嘴注入该第二闭合模穴内。最后，熔融的PU塑料于第二模穴内冷却后，固化成包覆该MDI发泡层43的PU硬质层45。
可以理解的是，上文所述两实施例的制备方法也可采用具有可调节闭合模穴的模具，可避免使用两套具有不同固定模穴的模具，从而相应降低制备成本。
需要重点指出的是：本发明可采用单层或不限于两层的多层具有不同机能的有机材料层（如上述实施例的聚乙烯发泡层23、聚乙烯硬质层25、MDI发泡层43和PU硬质层45）对镁合金基体进行完全包覆或部分包覆。部分包覆包括针对镁合金基体的局部位置进行功能性局部包覆（如较佳实施例一），或对镁合金基体的部分表面进行局部被覆。
制备该有机材料层的材料可适当选择塑胶材料或高分子材料。例如：聚乙烯（PE）、聚丙烯（PP）、聚氯乙烯（PVC）、聚苯乙烯（PS）、聚氨脂（PU）、脲醛树脂（UF）、酚醛树脂（PF）、乙烯橡（ER）、丙烯腈-丁二烯丙烯-苯乙烯共聚物（ABS）、聚甲基丙烯酸甲酯（PMMA）、聚碳酸脂（PC）、聚四氟乙烯（PTFE）、聚酰亚胺（PI）等。该有机材料层还可为各种溶胶凝胶层、类涂装膜等。
而且上述有机材料层中可依实际需要，进行改质或添加各种添加剂。例如：发泡剂、增塑剂、润滑剂、稳定剂、阻燃剂、著色剂、成核剂、交联剂等，用以改进相应添加层的特性。其中，添加发泡剂可改变塑料被覆层的密度、硬度、隔音、吸振、隔热与轻量等特性。添加阻燃剂可使被覆层产生耐燃特性。添加剂可根据需要进行添加比例的调整或改变添加剂种类以达到需要的功能特性。例如最外层可采用无发泡剂塑胶进行包覆，使表面硬度、强度与韧性提升，保护内部镁合金基材与被覆层等。
被覆层的成型方式可通过以下方法制备：注射（发泡）成型法、挤出（发泡）成型法、浇注（发泡）成型法、模压充填成型法、反应注射成型法、旋转（发泡）成型法与中空吹塑成型法等。各层间的接合主要通过以下方式实现：热压融接、物理接合、添加溶剂接合或胶合等。
另外，本领域技术人员还可在本发明精神内做其它变化，当然，这些依据本发明精神所做的变化，都应包含在本发明所要求保护的范围内。

Claims (6)

1.一种车辆油底壳，其包括一镁合金基体，其特征在于：该车辆油底壳还包括至少部分包覆该镁合金基体的至少一有机材料层，该至少一有机材料层包括一二苯基甲烷二异氰酸脂发泡层和一聚氨脂硬质层，该二苯基甲烷二异氰酸脂发泡层和该聚氨脂硬质层依次完全包覆该镁合金基体。
2.一种车辆油底壳，其包括一镁合金基体，其特征在于：该车辆油底壳还包括至少部分包覆该镁合金基体的至少一有机材料层，该至少一有机材料层包括一聚乙烯发泡层和一聚乙烯硬质层，该聚乙烯发泡层以及该聚乙烯硬质层依次完全或部分包覆该镁合金基体。
3.如权利要求1至2任一项所述的车辆油底壳，其特征在于：该镁合金基体形成有以下结构至少一种或多种：沟槽、压花、通孔、肋鳍片或突柱，该至少一有机材料层包覆该肋鳍片或突柱，或填充该沟槽、压花或通孔。
4.一种车辆油底壳的制备方法，其包括以下步骤：
提供一镁合金基体；
形成至少部分包覆该镁合金基体的一二苯基甲烷二异氰酸脂发泡层和一聚氨脂硬质层，该二苯基甲烷二异氰酸脂发泡层和该聚氨脂硬质层依次完全包覆该镁合金基体。
5.一种车辆油底壳的制备方法，其包括以下步骤：
提供一镁合金基体；
形成至少部分包覆该镁合金基体的一聚乙烯发泡层和一聚乙烯硬质层，该聚乙烯发泡层以及该聚乙烯硬质层依次完全或部分包覆该镁合金基体。
6.如权利要求4至5任一项所述的车辆油底壳的制备方法，其特征在于：该镁合金基体通过铸造、挤出或锻造制备。
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