CN103619578A - 复合材料和汽车的结构部件 - Google Patents
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Abstract
本发明涉及一种以镀层材料形式存在的、由平面的相叠的多个涂层构成的复合材料(1、6、8、10、12、14、16、18),该复合材料用于制造结构部件(20)、特别是汽车的结构部件(20),该复合材料包括至少一个金属层(2、3)和至少一个纤维强化的塑料层(4、4’、7、1、13、15)。为了在降低部件成本的情况下一方面可以降低由该复合材料制成的结构部件的重量另一方面可以提高结构部件的强度,提供有,使纤维强化的塑料层(4、4’、7、11、13、15)具有基于聚丙烯、聚乙烯、聚酰胺和/或这些物质的混合物的基层。
Description
技术领域
本发明涉及一种以镀层材料形式存在的、由平面的相叠的多个涂层构成的复合材料,该复合材料用于通过变形制造结构部件、特别是汽车的结构部件,该复合材料包括至少一个金属层和至少一个纤维强化的塑料层。此外,本发明还涉及一种结构部件,该结构部件由这种复合材料制成。
背景技术
针对不同的应用,需要重量轻的部件,不需要使该重量成为部件强度的负担。因此,由文献DE 600 11 917 T2已知一种复合材料和由其构成的结构部件,这种复合材料具有两个金属覆盖层,在这两个金属覆盖层之间设有一个纤维强化的塑料层。此外,由文献DE 10221 582 A1已知一种具有金属层和纤维强化的塑料层的汽车车身部件。
在制造汽车时,重量节省以及部件强度都具有重大意义。出于安全的目的必须注意,在常规的运转过程中避免部件故障以及在碰撞的情况下可以承受高的力并且可以将力转移。同时,特别是在汽车行业中必须高度注重成本效益,始终以较低成本地制造结构部件。为了满足这个特征,需要在已知的复合材料方面进一步进行优化。
发明内容
因此本发明的目的在于,这样提高和进一步扩展开头所述和前面详细描述的复合材料和结构部件,即,在降低部件成本的情况下,一方面可以降低结构部件的重量另一方面可以提高结构部件的强度和/或刚性。
在复合材料方面由此根据权利要求1前序部分实现前述目的,即,通过使纤维强化的塑料层具有基于聚丙烯、聚乙烯、聚酰胺和/或这些物质的混合物的基层。
此外,在结构部件方面由此根据权利要求15实现前述目的,即,复合材料是根据权利要求1至14的复合材料。
本发明已知,通过使用基于聚丙烯、聚乙烯、聚酰胺和/或这些物质的混合物的纤维强化的塑料层的基层可以一方面在降低重量以及另一方面在提高强度和/或提高刚性方面以非常低成本的方式影响复合材料以及结构部件的材料特性。纤维强化的塑料层一方面可以实现低成本并且另一方面实现了这样高的强度和/或刚性,即,降低了对金属层的强度要求和/或刚性要求。因此,该金属层可以由具有薄的层厚度的、成本低的金属构成。即使和具有较便宜的纤维强化的塑料层的复合材料相比,总体上也节省了复合材料和结构部件的成本。
该复合材料和结构部件的另一个优势在于,可以对该复合材料和结构部件进行涂层,特别是进行阴极电泳涂层。
在本发明的范围中将镀层材料理解为复合材料,该镀层材料由平面的相叠的多个涂层构成。对此,这些涂层优选具有恒定的或者至少均匀的层厚度。优选由复合材料通过变形制造结构部件。
本发明中例如将行走机构部件、地板部件、底板、底板总成、门防撞梁、车顶加强板、窗框加强板、保险杆、A立柱加强板、车门B立柱加强板、车门C立柱加强板、A立柱、车门B立柱、车门C立柱、仪表板支座、蓄电池壳、油槽、水箱、备胎槽等看作结构部件。尽管在汽车常规运转时外壳首先没有支承的功能,但是也可以根据需要将汽车的可见的外壳部件理解为结构部件。然而由于材料特性,具有支承功能和/或用于吸收和/或转移在碰撞的情况下作用在汽车上的力的结构部件特别受到重视。车架横梁、副车架、导杆、转盘轴承、稳定器、发动机托架、组合拉杆轴、车轮导向模块和/或轮盘特别适合作为行走机构部件。行走机构部件通常是在功能上和底盘以及汽车动力性能以及随之与汽车的安全要求相关的部件。在本文章中也可以将载货车,例如载重汽车、公共汽车和拖拉机理解为汽车。然而有轨机动车以及在航空行走和宇宙行走的应用也适用。
复合材料和相应的结构部件也可以应用在建筑技术中,例如升降机中,然而也可以应用在使用再生能源(例如风力和太阳能热)的设备中。原则上所有的需要有物质运动以及在高强度和/或刚性的情况下需要降低重量的应用都是可以的。
优选将金属层设置成外部涂层,因为金属层可以保护纤维强化的塑料层以抵抗来自外部的不利冲击(例如撞击)、提高的温度和类似影响。为了在结构部件中实现尽可能均匀和对称的力分布或者为了能够保护纤维强化的塑料层的两侧以抵抗来自外部的冲击,可以设置两个金属层,然后优选将这两个金属层设置成复合结构的外部涂层。此外,这些外部涂层可以有利地影响复合材料变形成结构部件。在使用多个金属层时,由于所述原因以及出于生产技术的观点,如果多个金属层具有相同的厚度和/或相同的材料则是适宜的。
此外,当纤维强化的塑料层在小的张力时就已经出现故障,该一个或多个金属层可以确保安全作用并且防止结构部件的完全故障。
在第一个优选的、复合材料的设计中仍然提供至少一个无纤维的塑料层。可以这样形成该无纤维的塑料层,即,该无纤维的塑料层可以承受较高的张力因此同样防止完全故障。该无纤维的塑料层也可以替代性地或者额外地用于吸收压力。原则上这适用于当该至少一个无纤维的塑料层同样基于聚丙烯、聚乙烯、聚酰胺和/或这些物质的混合物时。这改善复合结构的特征和/或在纤维强化的塑料层和无纤维的塑料层像优选方案那样相邻设置时改善它们之间的粘附性和连接性。特别是当无纤维的塑料层的塑料和纤维强化的塑料层的基层的塑料是相同类型或者完全相同时,则是优选的。
优选基于聚酰胺的、纤维强化的塑料层的基层和/或无纤维的塑料层可以优选具有聚乙烯(PE)。聚酰胺(PA)和聚乙烯对此没有构成单独的涂层。而是由所述塑料所构成的所谓的挡板。聚乙烯(特别是由于其与温度相关的性质)有利于复合材料的加工性,特别是可变形性。聚乙烯在塑料基层或者塑料层中的份额可以是3重量%至40重量%,优选在5重量%至20重量%。
塑料层的基层和/或无纤维的塑料层可以替代性地或者额外地具有苯乙烯-马来酸酐(SMA),以改善相应层的粘附性能。特别是当对聚酰胺加入其他成份,例如聚乙烯,这些成份具有降低的粘附性能时,则是这种情况。在粘附性方面,特别是在金属层上的粘附性可能是难以解决的。通过加入苯乙烯-马来酸酐可以改善分解状况从而使在聚酰胺中的其他成份更均匀地分布。特别是在加入的聚乙烯方面是这种情况。苯乙烯-马来酸酐在塑料基层或者塑料层中的份额可以为0.5重量%至10重量%,优选0.5重量%至5重量%。
至少一个纤维强化的塑料层在纤维强化的塑料层中的纤维份额不高于65体积%并且在复合材料中的纤维份额在5体积%和40体积%之间,优选5体积%和20体积%之间,特别是在5体积%和15体积%之间,以达到复合材料的良好的强度、刚性和/或可加工性。
无机纤维、有机纤维和/或塑料纤维适合作为纤维强化的塑料层的纤维,更确切地说分别取决于所需的特性。优选玻璃纤维、硼纤维和玄武岩纤维可以用作无机纤维,而特别是碳纤维和蛋白质纤维适合作为有机纤维。芳香尼龙纤维或者聚乙烯纤维适合作为塑料纤维。
此外,可以通过在纤维强化的塑料层的基层中的纤维的设置类型调整复合材料和结构部件的特性。原则上可以设置成各向同性的或者各向异性的,可能因为抗拉强度应该是各向同性的或者各向异性的。这些纤维对此可以随机地分布或者整齐地、优选作为鸟窝状、针织物、织物、纤维网和/或单向层存在于纤维强化的塑料层中。特别是在单向层中可以在纤维的优选方向上设置结构部件的最大的抗拉强度,特别是涉及到拉伸力。除此之外,当纤维是单向的并且弯边大体上平行于纤维的方向延伸时,可以毫无困难地通过变形制造特别是复杂的结构部件。
由于材料性质和成本的原因,当至少一个金属层由钢(例如碳素钢或者不锈钢)或者铝材料制成时,则是适合的。相对于钢,铝在成本方面不是优选的,但是在重量方面是优选的。
由于纤维强化的塑料层的高的抗拉强度,当金属层具有这样的抗拉强度,即,该抗拉强度在最大时和纤维强化的塑料层的抗拉强度相一致,特别是具有最大700MPa,优选最大650MPa和特别优选少于450MPa时是合适的。对金属层的抗拉强度的要求越小,可以使用的低成本的金属就越多。在本文章中钢的品质可以是DX 56、HX 220 BD、HC 340 LA和HCT 600 X。
由于纤维强化的塑料层的高的抗拉强度,可以替代性地或者额外地提供非常薄的金属层,该金属层可以具有0.1mm和1mm之间的厚度,优选最大0.75mm。
为了节省金属以及从而节省重量和/或成本,至少一个金属层可以具有凹陷部、压印和/或开口。那么,优选在整个金属层上均匀分布地设置这些凹陷部、压印和/或开口。
为了节省金属以及从而节省重量和/或成本,替代性地至少一个金属层相对于复合材料来说可以具有最大50体积%的份额。可以替代性地或者额外地设有,使复合材料的横截面具有50%的最大金属份额。
为了在总体上保持复合材料的重量和成本小,复合材料的整个厚度可以在0.5mm和4.0mm之间,特别是在1.0mm和3.0mm之间。
当一侧紧邻着纤维强化的或者无纤维的塑料层以及另一侧紧邻着至少一个金属层设置一个特别是具有0.01mm和0.05mm厚度的增附剂层时,可以改善复合材料中在金属和塑料之间的粘附性。
根据下述实例示例性地说明本发明的优势。
实例1
借助根据表格1的金属层的横断面比(混合式)通过计算得到在表格2中所给出的、具有两个厚度为t=0.25mm的外部金属层、两个邻接在金属层上的厚度为t=0.25mm的纤维强化的塑料层和中间的厚度为t=0.5的无纤维的塑料层的复合材料的抗拉强度Rm。
纤维强化的塑料层具有聚酰胺基层和具有相互正交延伸的碳纤维和45体积%的纤维份额的组织。纤维强化的塑料层的抗拉强度和密度为Rm=785MPa和ρ=1.43g/cm3。计算时不考虑由聚酰胺构成的无纤维的塑料层的抗拉强度。
表格1(钢)
钢的品质 | 抗拉强度Rm[MPa] |
DX 56 | 260 |
HX 220 BD | 320 |
HC 340 LA | 410 |
HCT 600 X | 600 |
表格2(复合材料)
钢的品质 | 抗拉强度Rm[MPa] |
DX 56 | 523 |
HX 220 BD | 553 |
HC 340 LA | 444 |
HCT 600 X | 618 |
实例2
对于层厚度为t=1.5mm的具有两个外部金属层、一个中间的基于聚酰胺的纤维强化的塑料层和两个位于两个金属层之间的基于聚酰胺的无纤维的塑料层的复合材料,一方面根据单个金属层的层厚tMS、另一方面根据纤维强化的塑料层的层厚tFK通过计算得到在表格3和4中所给出的抗拉强度。金属层的材料和纤维强化的塑料层的材料和它们在实例1中相一致。计算时不考虑由聚酰胺构成的无纤维的塑料层的抗拉强度。
表格3
表格4
附图说明
下面根据仅对实施例进行描述的图示详细阐述本发明。其中,
图1-8以示意图示出了根据本发明的复合材料的八个实施例的涂层结构以及
图9以立体图示出了根据本发明的结构部件的实施例。
具体实施方式
图1示出了复合材料1的涂层结构,该复合材料具有两个外部的金属层2、3作为外部的覆盖层。紧邻着金属层2、3设有纤维强化的塑料层4、4’,这些纤维强化的塑料层由基于聚酰胺的基层和引入其中的纤维组织构成。以无纤维的塑料层5的形式存在的核心层由纤维强化的塑料层4、4’包围。
图2示出了复合材料6的涂层结构,该复合材料具有两个外部的金属层2、3作为外部的覆盖层。在本实施例中紧邻着金属层2、3设有两个无纤维的塑料层5、5’,这两个无纤维的塑料层从两侧邻接到一个纤维强化的塑料层7上。纤维强化的塑料层7具有聚酰胺基层和具有相互正交延伸的碳纤维和45体积%的纤维份额的组织。纤维强化的塑料层的抗拉强度和密度为Rm=785MPa和ρ=1.43g/cm3。
图3示出了复合材料8的涂层结构,该复合材料具有两个外部的金属层2、3作为外部的覆盖层。在本实施例中紧邻着金属层2、3设有两个无纤维的塑料层5、5’,这两个无纤维的塑料层从两侧邻接到一个纤维强化的塑料层4上。在这种情况下通过基于聚酰胺的基层中的纤维组织构成纤维强化的塑料层4。
图4示出了复合材料10的涂层结构,该复合材料具有两个外部的金属层2、3作为外部的覆盖层。在两个外部的覆盖层之间有一个由纤维强化的塑料11构成的核心层。对此,该基层由基于聚酰胺的塑料构成,在该塑料中分布有在优选方向上的短纤维。
图5示出了复合材料12的涂层结构,该复合材料具有两个外部的金属层2、3作为外部的覆盖层。在两个外部的覆盖层之间有一个由纤维强化的塑料13构成的核心层。对此,该基层由基于聚酰胺的塑料构成,在该塑料中随机分布地设置纤维。
图6示出了复合材料14的涂层结构,该复合材料具有两个外部的金属层2、3作为外部的覆盖层。在两个外部的覆盖层之间有一个核心层,该核心由三个单独的、相互粘附的、纤维强化的塑料层15的涂层构成。这些纤维强化的塑料层15的涂层可以在基于聚酰胺的涂层方面和纤维材料的类型和设置方面有选择地进行相同的或者不同的构造。
图7示出了根据实例1的复合材料16的涂层结构。由相同的、分别具有0.25mm层厚度的金属层2、3构成外部的覆盖层。在外部的覆盖层的内侧上设有同样分别具有0.25mm层厚度的纤维强化的塑料层7、7’,这些纤维强化的塑料层经由增附剂17和金属层相连。在这种情况下,纤维强化的塑料层7、7’具有聚酰胺基层和具有相互正交延伸的碳纤维和45体积%的纤维份额的组织。纤维强化的塑料层7、7’的抗拉强度和密度为Rm=785MPa和ρ=1.43g/cm3。该核心层由0.5mm厚的、无纤维的、聚酰胺层5构成。因为纤维强化的塑料层7、7’的塑料和无纤维的塑料层5的塑料如果不是完全相同就是相同类型的,所以无需使用增附剂将塑料层5、7、7’相互粘附在一起。
图8示出了根据实例2的复合材料18的涂层结构。外部的覆盖层由相同的、分别具有0.5mm或者0.75mm层厚度的金属层2、3构成。在外部的覆盖层的内侧上设有无纤维的聚酰胺层5、5’,这些无纤维的聚酰胺层在没有使用增附剂的情况下粘附在金属层2、3上。核心层由纤维强化的基于聚酰胺的塑料层7构成。纤维强化的塑料层7具有聚酰胺基层和具有相互正交延伸的碳纤维和45体积%的纤维份额的组织。纤维强化的塑料层7的抗拉强度和密度为Rm=785MPa和ρ=1.43g/cm3。因为纤维强化的塑料层7的塑料和无纤维的塑料层5、5’的塑料如果不是完全相同就是相同类型的,所以无需使用增附剂将塑料层相互粘附在一起。
图9示出了由前述类型的复合材料通过变形所形成的结构部件20。在这种情况下是隧道式加强板。
Claims (15)
1.一种以镀层材料形式存在的、由平面的相叠的多个涂层构成的、用于制造结构部件(20)的复合材料(1、6、8、10、12、14、16、18),所述复合材料包括至少一个金属层(2、3)和至少一个纤维强化的塑料层(4、4’、7、11、13、15),其特征在于,所述纤维强化的塑料层(4、4’、7、11、13、15)具有基于聚丙烯、聚乙烯、聚酰胺和/或这些物质的混合物的基层。
2.根据权利要求1所述的复合材料,其特征在于,设有至少一个基于聚酰胺的、无纤维的塑料层(5、5’)。
3.根据权利要求1或2所述的复合材料,其特征在于,所述至少一个纤维强化的塑料层(4、4’、7、11、13、15)的基层和/或所述至少一个无纤维的塑料层(5、5’)具有聚乙烯。
4.根据权利要求1至3的任意一项所述的复合材料,其特征在于,所述至少一个纤维强化的塑料层(4、4’、7、11、13、15)的基层和/或所述至少一个无纤维的塑料层(5、5’)具有苯乙烯-马来酸酐(SMA)。
5.根据权利要求1至4的任意一项所述的复合材料,其特征在于,所述至少一个纤维强化的塑料层(4、4’、7、11、13、15)在所述复合材料中的纤维份额在5体积%和40体积%之间,特别是在5体积%和20体积%之间。
6.根据权利要求1至5的任意一项所述的复合材料,其特征在于,所述至少一个纤维强化的塑料层(4、4’、7、11、13、15)具有例如玻璃纤维和硼纤维这样的无机纤维、例如碳纤维和蛋白质纤维这样的有机纤维和/或例如芳香尼龙纤维或者聚乙烯纤维这样的塑料纤维。
7.根据权利要求1至6的任意一项所述的复合材料,其特征在于,所述至少一个纤维强化的塑料层(4、4’、7、15)的纤维部分作为鸟窝状、针织物、织物、纤维网和/或单向层存在。
8.根据权利要求1至7的任意一项所述的复合材料,其特征在于,所述至少一个金属层(2、3)由钢或者铝材料构成。
9.根据权利要求1至8的任意一项所述的复合材料,其特征在于,所述至少一个金属层(2、3)具有小于450MPa的抗拉强度。
10.根据权利要求1至9的任意一项所述的复合材料,其特征在于,所述至少一个金属层(2、3)具有0.1mm和1mm之间、优选最大0.75mm的厚度。
11.根据权利要求1至10的任意一项所述的复合材料,其特征在于,所述至少一个金属层(2、3)具有凹陷部、压印和/或开口。
12.根据权利要求1至11的任意一项所述的复合材料,其特征在于,所述至少一个金属层(2、3)具有在复合材料中最高50体积%的份额。
13.根据权利要求1至12的任意一项所述的复合材料,其特征在于,所述复合材料(1、6、8、10、12、14、16、18)具有在0.5mm和4.0mm之间、特别是在1.0mm和3.0mm之间的整个厚度。
14.根据权利要求1至13的任意一项所述的复合材料,其特征在于,一侧紧邻着所述纤维强化的或者所述无纤维的塑料层(4、4’、5、5’、7、11、13、15)以及另一侧紧邻着所述至少一个金属层设置一个增附剂层(17),特别是具有0.01mm和0.05mm厚度的增附剂层。
15.一种由复合材料制成的结构部件(20),特别是汽车的结构部件,其特征在于,所述复合材料是根据权利要求1至14的任意一项所述的复合材料(1、6、8、10、12、14、16、18)。
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PCT/EP2012/054940 WO2012126923A1 (de) | 2011-03-24 | 2012-03-21 | Verbundwerkstoff und strukturbauteil für ein kraftfahrzeug |
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WO2012126923A1 (de) | 2012-09-27 |
JP2014509971A (ja) | 2014-04-24 |
DE102011015071A1 (de) | 2012-09-27 |
EP2688743A1 (de) | 2014-01-29 |
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KR20140016952A (ko) | 2014-02-10 |
US20140178633A1 (en) | 2014-06-26 |
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