CN104520173A - 两件式胶接车辆组件 - Google Patents

两件式胶接车辆组件 Download PDF

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Publication number
CN104520173A
CN104520173A CN201480002031.9A CN201480002031A CN104520173A CN 104520173 A CN104520173 A CN 104520173A CN 201480002031 A CN201480002031 A CN 201480002031A CN 104520173 A CN104520173 A CN 104520173A
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layer
cured layer
vehicle
vehicle assembly
fiber
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普罗拜尔·库马尔·古哈
迈克尔·J·西瓦杰克
迈克尔·J·希尔图宁
沙恩·什科普
萨蒂什·哈里阿迪
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Kang Tingnan Opens Up Structural Plastic Co Ltd
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Kang Tingnan Opens Up Structural Plastic Co Ltd
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Priority to CN201911197707.5A priority Critical patent/CN110843928A/zh
Publication of CN104520173A publication Critical patent/CN104520173A/zh
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
    • B62D29/043—Superstructures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/13—Single flanged joints; Fin-type joints; Single hem joints; Edge joints; Interpenetrating fingered joints; Other specific particular designs of joint cross-sections not provided for in groups B29C66/11 - B29C66/12
    • B29C66/131—Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7311—Thermal properties
    • B29C66/73111—Thermal expansion coefficient
    • B29C66/73112—Thermal expansion coefficient of different thermal expansion coefficient, i.e. the thermal expansion coefficient of one of the parts to be joined being different from the thermal expansion coefficient of the other part
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7375—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured
    • B29C66/73755—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being fully cured, i.e. fully cross-linked, fully vulcanized
    • B29C66/73756—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being fully cured, i.e. fully cross-linked, fully vulcanized the to-be-joined areas of both parts to be joined being fully cured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/18—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length in the form of a mat, e.g. sheet moulding compound [SMC]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/08—Front or rear portions
    • B62D25/10—Bonnets or lids, e.g. for trucks, tractors, busses, work vehicles
    • B62D25/105—Bonnets or lids, e.g. for trucks, tractors, busses, work vehicles for motor cars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/483—Reactive adhesives, e.g. chemically curing adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2233/00—Use of polymers of unsaturated acids or derivatives thereof, as reinforcement
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2307/00—Use of elements other than metals as reinforcement
    • B29K2307/04—Carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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Abstract

提供一种车辆组件，其包括具有主要纤维填料短切玻璃纤维的模塑组合物的第一固化层，具有主要纤维填料短切碳纤维的模塑组合物的第二固化层，以及具有设置为适应线性热膨胀的微分系数的伸长特性的在所述的第一固化层和所述的第二固化层之间的粘合剂。所述的第二固化层是基本上无玻璃纤维的。所述的粘合剂是弹性粘合，其在-40至205℃之间是有效的。所述的第一固化层形成车辆的外皮层的表面，以及所述的第二固化层形成内部层，在其中，所述的外皮层的表面具有A类处理。

Description

两件式胶接车辆组件
相关申请
本申请要求在2013年6月26日提交的序列号为61/839,434的美国临时申请的优先权；其内容通过引用结合于此。
技术领域
一般地，本发明涉及车辆结构，以及尤其是，由至少两层形成的两件式车辆组件：所述的层之一主要由短切和分布式玻璃纤维加固，以及第二层主要由碳纤维加固，不同的层经树脂加工处理后结合，以形成该组件。
背景技术
使用纤维夹杂物(fiber inclusions)来加固基体对于该领域是众所周知的。用于基体加固的完善建立的机制，包括减缓和延长穿过所述的基体的裂纹扩展的路径，以及与拉伸纤维摆脱周围的基体材料相关的能量分布。在上下文的片状模塑组合物(SMC)制剂、散装模塑组合物(BMC)制剂，以及树脂传递模塑(RTM)纤维加固习惯上包括短切玻璃纤维的应用。在模塑组合物的领域中日益认识到在模塑组合物中用碳纤维部分地，或者全部地代替所述的玻璃纤维能够提供改善的组件性能；然而，技术问题仍然存在，其包括不同层的连接，纤维流，纤维表面能量，以及合成的组件的表面质量。
碳纤维在组合物，片状组合物，以及树脂传递模塑(RTM)的应用的结果是，与玻璃纤维加固材料相比形成具有较低质量的组件。通过碳纤维加固实现的质量的节省源于碳比玻璃具有较低的密度，以及在一定厚度下产生更强和更硬的零件的事实。
在车辆、运输以及基于产业的物流上的重量的节省一直是一个巨大的关注点，以为地面和空中运输制造更多省油的车辆。在车辆零件中采用碳纤维加固的复合材料的质量节省帮助了这些行业实现了有意义的质量节省。然而，高质量的表面处理，像是在车辆行业中的A类表面的特征在于一高的表面光泽，通常只通过包含玻璃纤维的高级定制的树脂制剂获得，像是商业上从康廷南拓结构塑料有限公司(Continental Structural Plastics,Inc.)获得的用于SMC或者RTM的树脂，或者像是铝及其合金的金属。车辆表面面板一般都要求是A类表面：门，罩，围板，行李箱，顶层结构，保险杠等，其构成了车辆的大量的质量。
因此，存在对将碳加固部分应用于车辆表面面板的方法和设计的需要。
发明内容
一车辆组件包括具有主要的纤维填料短切玻璃纤维的模塑组合物的第一固化层，具有主要的纤维填料短切碳纤维的模塑组合物的第二固化层；以及具有设置为适应线性热膨胀的微分系数的伸长特性的在所述的第一固化层和所述的第二固化层之间的粘合剂。所述的第二固化层是基本上无玻璃纤维的，以及是由散装模塑组合物(BMC)、片状模塑组合物(SMC)或者树脂传递模塑(RTM)之一形成。所述的第一固化层或者所述的第二固化层其中至少一个包括相对于全部纤维质量的一少数百分比的自然纤维。所述的第一固化层是外部板，其成形成具有A类处理的车辆的外皮层的表面。所述的第二固化层是内部加固板。所述的粘合剂是一弹性粘合剂，其在-40至400°F(-40至205℃)之间是有效的。
所述的车辆组件可以包括至少一个附加层：具有主要的纤维填料短切玻璃纤维的模塑组合物的第三固化层以及具有主要的纤维填料短切碳纤维的模塑组合物的第四固化层，以及将所述的至少一附加层连接到所述的第一固化层或者所述的第二固化层之一以形成一层压制品的粘合剂的第二层。
附图说明
就下列旨在说明本发明的某些方面的附图，本发明进一步地被详细说明，但是不应该被解释为对本发明在实施上的限制。
图1A-1C为根据本发明的实施例的，一具有玻璃纤维加固的A类片材的外部层的两件式车辆罩，以及具有碳纤维加固的片状模塑组合物或者碳加固树脂传递模塑(RTM)的一内部层的车罩透视图；
图2为根据本发明的实施例的，图1A-1C由玻璃纤维加固处理表面外部板(边界线表面)与碳纤维加固结构内部板在多点粘合形成的车罩；以及
图3为根据本发明的实施例的，一典型的主体面板密封边缘的截面图，在其中，基于玻璃纤维的A类外部板粘合(粘合剂，环氧基树脂等等)或者固定在基于碳纤维的结构内部板的粘合边缘处。
具体实施方式
本发明具有在两件式车辆组件的形成中的应用，其由短切和分布式玻璃纤维在第一固化层以及一粘合的由分布式碳纤维加固的第二固化层加固。虽然本发明在此被详述为涉及一两件式结构，但是其应当理解为在此所述的两件式结构可容易地复制以创建多层层压制品。通过举例的方式，主要为玻璃纤维填料的外皮层与主要为碳纤维填料芯层的芯的相对面结合；反之亦然；或者一系列可替换的主要纤维填料层以A-B-A…B的样式结合。在某些发明实施例中，模塑组合物的固化的内部主要由短切碳纤维加固，与主要由玻璃纤维加固的第二片状组合物的固化外皮结合，在其中，所述的外表面具有车辆表面质量处理，例如A类处理。在此所使用的A类表面处理与表面光泽以及由车辆制造商所要求的外部主体板的反射率有关，在一实施例中，所述的固化的内部是基本上无玻璃纤维的；而所述的外皮是基本上无短切碳纤维的。
在此所用的“模塑组合物”指的是SMC、BMC和RTM树脂制剂，其经得起用玻璃或碳的短切纤维装填(loading)。
在一特定的发明实施例中，在模塑组合物中的碳纤维存在于车辆组件的内部层中，其包括占所述的内部层10到40％重量的碳纤维，具有基于商业上可获得的包括玻璃纤维的(康廷南拓结构塑料有限公司(Continental Structural Plastics,Inc.))的SMC的外皮层，其包括介于所述的部分质量的10至60％之间的玻璃纤维，正如在美国专利7655297中的实施例。内部与外皮的厚度的比率范围介于01-10:1之间。所得到的SMC内部层和外皮层被设置，形成，并且分别固化以及所述的两层随后结合以形成一组件。注意到这样的具有包含碳纤维的内部层的两件式组件具有一密度，其是10、20、30甚至40％地少于完全从或者其它A类表面处理树脂形成的可比较的制品。使用这种方法，一个轻量级的制品形成，其保留了A类表面的高表面光泽。应当理解的是，给定的层，可以包括碳纤维和玻璃纤维的结合，以及其他类型的纤维，像是天然素纤维，作为说明地，在其他类型的纤维的负载被限制的条件下，包括椰子纤维，使得玻璃纤维主要存在于第一层以及碳纤维主要存在于第二层。在此给定类型的纤维的主要存在被使用意味着所述的纤维类型表现出高于在该层中出现的纤维的总质量的50％。在某一实施例中，每一层是100％的给定类型的纤维，然而在其他实施例中，主要纤维在介于51至99％之间存在。
被了解的是，在提供值的范围的实例中，所述的范围旨在不仅包括该范围的终点值，还包括作为明确地被包括在所述的范围内的以及随着所述的范围的最后的有效数字改变的所述的范围的中间值。通过举例的方式，一从1至4的列举范围旨在包括1-2、1-3、2-4、3-4以及1-4。
在本发明的另一个实施例中，碳纤维分散在基于甲基丙烯酸甲酯单体的模塑组合物中。用作说明地，其他的合适的单体，模塑组合物制剂由其产生，包括不饱和聚酯，环氧树脂，以及其组合。用作说明地，基于环氧树脂的模塑组合物制剂包括双酚-A以及酚醛基5环氧封端树脂(Novolac based 5epoxy terminated resins)。用作说明地，用于基于模塑组合物制剂的这样的环氧树脂适合的固化剂包括酸酐，如偏苯三酸酐，甲基四氢邻苯二甲酸酐(MTHPA)，纳迪克甲基酸酐(NMA)，二-和三-官能胺，以及其组合。
在本发明的另一个发明实施例中，碳纤维分散在模塑组合物单体中或者包括具有大于0.26的相对极性的单体的溶液中，并且在某些实施例中大于0.5，但是在其他实施例中介于0.5至0.8之间。相对极性定义于皮·克里斯·蒂赖卡特，溶剂以及在有机化学中的溶剂反应，威利-VCH，第3版，2003。
在另一个发明实施例中，所述的碳纤维在结果是一加固的SMC、BMC或者RTM固化制品的固化前分散在模塑组合物制剂中，当与玻璃纤维加固形成的类似层相比较时，其整体上具有较低的密度，以及在质量上较低的纤维的装填(loading)百分比。此外，通过使用偶联剂，实现了优异的拉伸强度。
在某些发明实施例中，在接触在固化时形成含有碳纤维的基体的模塑组合物之前，在适当的大气压条件下进行加热以去除在所述的碳纤维的表面上的任何胶料或者其他常规的表面覆料。尽管如此，在其他发明实施例中，在惰性或者还原气氛下进行加热以从核心碳纤维(thecore carbon fibers)促进所述的胶料的热解。可以理解的是在一发明的两件式车辆组件中回收碳纤维是可实现的。
正如从相应的线性热膨胀系数(CLTE)所了解的，由于碳的散热比玻璃的好得多，主要碳纤维填料层比其他方面类似的主要玻璃纤维填料层冷却得快得多。固化后在动态冷却中的差异对于更薄的碳纤维填料层是严重的，以使它们特别容易弯曲。因此，由于在CTLE中的差异以及介于所述的主要玻璃纤维填料层和主要碳纤维填料层的材料硬度，结合粘合剂必须具有特殊的伸长能力，以补偿在-40至140°F(40至60℃)的温度范围之上，以及甚至与固化条件以及层的热结合相关的高达400°F(205℃)的所结合的层的相差的CTLE。在具体的发明实施例中，弹性粘合剂可以用于粘结内部层和外部层。用作说明地，此处有效的以结合一发明的组件的不同层的弹性粘合剂包括氨基甲酸酯、环氧树脂，以及其结合。在发明实施例中，所述的粘合边缘的厚度从为了结合相似的纤维填料层在一起的1/4-1/2英尺(0.63-1.27厘米)增加到为了该发明两件式结构的1-1.5英尺(2.54-3.81厘米)。
现在参阅图1A-1C所示的发明的两件式组件形成车辆罩10，具有主要玻璃纤维加固A类片材的外部层12，以及主要碳纤维加固片状模塑材的内部层14。正如所示的，所述的外部层12具有顶部12T，其作为所述的车辆的外部的处理表面被暴露，以及以底部12B，其与内部层14结合。所述的顶部12T是经磨的，以及喷漆以实现A类或者类似的与新的车辆外部相关的高光泽表面处理。在附图1A-1C的层12和14的典型的厚度分别是2.5-2.7毫米(mm)以及1-2mm。正如上述的，可以理解的是，用作说明地，层结合在一起以形成更复杂的层压制品，其分类排列的顺序包括12-14-12、1-14-12-14、12-14-(12-14)n…12以及12-14-(12-14)n，其中n是整数n或者其他。还应理解的是，层12和14的厚度是可变的，取决于期望的强度以及整体层压制品厚度，以具有超出上述提出的典型值的值。
根据本发明的具体实施例，图2示出图1中的由主要玻璃纤维加固处理表面的外部层12(为了视觉清晰示出为透明的)在复合点粘合主要碳纤维加固结构的内部板14形成的组件10。所述的内部层14在各种节点16处，或者沿着层周长18粘合。此外，乳香滴(mastic drops)20可提供准确的粘合以修改连接属性。
根据本发明的具体实施例，图3是一个典型的主体面板密封边缘的截面图，在其中基于玻璃纤维的A类外部层12粘合16(粘合剂，环氧树脂)或者固定在基于碳纤维的结构内部层14的的粘合边缘22处。一般地，车辆围绕框架建造，在其中车辆具有处理的表面面板，其被固定或者被结合至底部构造以形成主体面板，其为结合所述的框架的不规则表面而设计。所述的粘合边缘22挨着相应的密封承载面。所述的结构的内部板14的“帽”部分24延伸至到达并附着在所述的框架上(未示出)。
前面所述的是说明本发明的特定的具体实施例的，但是此处并不意味着在实施中的限制。以下的权利要求，包括此处其中所有的等同物，旨在说明本发明的范围。

Claims (16)

1.一种车辆组件包括：
具有主要的纤维填料短切玻璃纤维的模塑组合物的第一固化层；
具有主要的纤维填料短切碳纤维的模塑组合物的第二固化层；以及
具有设置为适应线性热膨胀的微分系数的伸长特性的在所述的第一固化层和所述的第二固化层之间的粘合剂。
2.根据权利要求1所述的车辆组件，其特征在于，所述的第二固化层是基本上无玻璃纤维的。
3.根据权利要求1所述的车辆组件，其特征在于，所述的粘合剂在-40至205℃之间是有效的。
4.根据权利要求1所述的车辆组件，其特征在于，所述的粘合剂是弹性粘合剂。
5.权利要求1所述的车辆组件进一步地包括一介于2.54～3.81cm之间的粘合边缘。
6.根据权利要求1所述的车辆组件，其特征在于，所述的第二固化层由散装模塑组合物(BMC)、片状模塑组合物(SMC)或者树脂传递模塑(RTM)之一形成。
7.权利要求1至6任意一项所述的车辆组件进一步地包括至少一附加层：具有主要的纤维填料短切玻璃纤维的模塑组合物的第三固化层以及具有主要的纤维填料短切碳纤维的模塑组合物的第四固化层，以及将所述的至少一附加层连接到所述的第一层或者所述的第二层之一以形成一层压制品的粘合剂的第二层。
8.根据权利要求1至6任意一项所述的车辆组件，其特征在于，所述的第一固化层或者所述的第二固化层其中至少一个包括相对于全部纤维质量的一少数百分比的自然纤维。
9.根据权利要求1至6任意一项所述的车辆组件，其特征在于，所述的第一固化层为一外部板。
10.根据权利要求1至6任意一项所述的车辆组件，其特征在于，所述的第二固化层为一内部加固板。
11.根据权利要求1所述的车辆组件，其特征在于，所述的第一固化层形成了一车辆的外皮层的表面以及所述的第二固化层形成了内部层。
12.根据权利要求11所述的车辆组件，其特征在于，所述的外皮层表面具有A类处理。
13.根据权利要求11所述的车辆组件，其特征在于，所述的内部层具有一内层厚度以及所述的外皮层具有一外皮厚度，且所述的内部层的厚度与所述的外皮的厚度的比值介于01-10:1之间。
14.根据权利要求1所述的车辆组件，其特征在于，所述的模塑组合物为A类表面处理树脂。
15.根据权利要求14所述的车辆组件，其特征在于，所述的A类表面处理树脂是基本上无短切碳纤维的。
16.权利要求1至6任意一项所述的车辆组件进一步地包括多层薄片，所述的多层层压制品包括所述的第一固化层和所述的第二固化层的替换层，在其中，所述的替换层和所述的粘合剂结合。
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