CN105697976A - 碳纤维增强复合材料板及其制造方法 - Google Patents

碳纤维增强复合材料板及其制造方法 Download PDF

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Publication number
CN105697976A
CN105697976A CN201510395151.6A CN201510395151A CN105697976A CN 105697976 A CN105697976 A CN 105697976A CN 201510395151 A CN201510395151 A CN 201510395151A CN 105697976 A CN105697976 A CN 105697976A
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China
Prior art keywords
cfrp
layer
cfrp layer
steel plate
welded nut
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CN201510395151.6A
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Inventor
闵宪植
姜京范
金钟秀
金熙俊
李景勋
李泰和
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Hyundai Motor Co
LG Corp
LX Hausys Ltd
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Hyundai Motor Co
LG Chemical Co Ltd
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Publication of CN105697976A publication Critical patent/CN105697976A/zh
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/28—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer impregnated with or embedded in a plastic substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/046—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/12—Moulds or cores; Details thereof or accessories therefor with incorporated means for positioning inserts, e.g. labels
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
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    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • General Engineering & Computer Science (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Manufacturing & Machinery (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

本公开提供一种CFRP板及其制造方法，该CFRP板整体堆叠有钢板，焊接螺母焊接在该钢板中。CFRP板通过在两个相邻的CFRP层之间置入钢板而形成，焊接螺母焊接至钢板的下表面。泡沫材料介于设置有钢板的第二CFRP层与位于该第二CFRP层下方的第一CFRP层之间。导销安装于钢板、第二CFRP层以及泡沫材料中，在第二CFRP层的定位有焊接螺母的部分中形成有孔。在泡沫材料中形成有容纳焊接螺母的凹槽，该凹槽定位在孔下方。在将临时螺栓安装于焊接螺母中时注入树脂，并且在注入树脂后移除该临时螺栓。

Description

碳纤维增强复合材料板及其制造方法
相关申请的交叉引用
本申请基于2015年12月15日向韩国知识产权局提交的韩国专利申请第10-2014-0180596号并且要求该韩国专利申请的优先权的权益，其全部公开内容通过引证方式结合于此。
技术领域
本公开涉及一种碳纤维增强复合材料板(CarbonFiberReinforcedPolymerplate,碳纤维增强聚合物板)(以下称为“CFRP板”)及该CFRP板的制造方法。更具体地，涉及这样一种CFRP板及其制造方法，该CFRP板上整体堆叠有钢板，钢板上焊接有焊接螺母。
背景技术
总体来说，焊接螺母是一种整体焊接至板材的螺母。焊接螺母用在多种情况下，诸如，当螺母与螺栓耦接时螺母不能定位在所需位置或者手不能到达该所需位置的情况下。换句话说，可能需要将螺栓和螺母彼此连接的过程自动化。
图1是示出根据相关技术的焊接螺母结构的示例性剖视图。图1中示出的结构是一种复杂结构，该结构阻止螺母从外部插入并固定至构件的相对表面。例如，在该结构中，面板80和构件90可相互耦接，同时形成如图1所示的封闭截面。因此，焊接螺母70首先焊接至构件90，并且构件90和面板点焊(S)至彼此。
图2是示出根据相关技术的CFRP的堆叠式成型方法的顺序。如图2所示，在于模具中注入和堆叠之前，将树脂(例如，粘合剂)注入到成形的CFRP纤维中。通过树脂将模具中存留的空气挤出，然后当树脂和CFRP填充到模具内的整个空间时，固化树脂。最终，当移除固化的树脂时，便获得期望的形状。
为了防止与使用薄钢板(steelsheet)制造车辆的情况相比，在使用CFRP板制造车辆时制造过程发生显著变化，使用薄钢板和使用CFRP板制造车辆均使用焊接螺母结构。然而，CFRP并非可进行焊接的材料，并且如图2所示，当注入树脂时，螺母与CFRP纤维一同插入到模具中，螺母填充有树脂，这使得螺母不能被使用。
在本部分中公开的上述信息仅用于加强对本发明背景的理解，因此其可能包含不构成本国内本领域普通技术人员已知的现有技术的信息。
发明内容
本公开提供一种CFRP板结构以及制造该CFRP板的方法，焊接螺母结构可应用于该CFRP板。根据本公开的示例性实施方式，CFRP板可通过在邻近彼此的相邻的CFRP层之间置入钢板并且在将临时螺栓安装于焊接螺母时注入树脂而形成，焊接螺母可焊接至该钢板。泡沫材料可以介于上面布置有钢板的层与设置在上面设置有钢板的层下方的层之间。另外，导销可安装于钢板、第二层以及泡沫材料中。焊接螺母可介于两个层之间，并且焊接螺母可焊接至钢板的下表面，在第二层的可定位有焊接螺母的部分中可形成有孔，并且在泡沫材料中可形成有将焊接螺母容纳在里面的凹槽，该凹槽定位在孔的下方。另外，第三层可具有形成在所述第三层中的孔，该孔使得临时螺栓穿过孔。在树脂注入后，临时螺栓可被移除。
根据另一示例性实施方式，CFRP板的制造方法可包括如下步骤：在下部模具与上部模具之间堆叠至少两个CFRP层，并且在两个层之间置入钢板，焊接螺母焊接至该钢板，临时螺栓可安装于该焊接螺母中；关闭模具并且注入树脂；以及在注入树脂后，打开模具并且移除临时螺栓。在堆叠至少两个CFRP层的过程中，可将这两个CFRP层与泡沫材料堆叠，该泡沫材料介于上面设置有钢板的层与设置在上面设置有钢板的层下方的层之间。可将导销安装于钢板、第二层以及泡沫材料中。
此外，可将钢板堆叠在两个层之间，并且可将焊接螺母安装于第二层的该部分的孔中和泡沫材料的对应于该孔的凹槽中。第三层可具有形成在该第三层中的孔，该孔可以使得临时螺栓穿过该孔。
附图说明
从下面结合附图给出的详细说明中，本公开的上述和其他目的、特征以及优点将变得更清楚。
图1是示出根据相关技术的焊接螺母结构的示例性剖视图；
图2是示出根据相关技术的CFRP堆叠式成型方法的顺序的示例性视图；
图3是示出根据本公开的示例性实施方式的CFRP封闭截面构件的示例性视图；以及
图4是示出根据本公开的示例性实施方式的一状态并且沿线a-a得到的示例性剖视图，在该状态中，焊接有焊接螺母的钢板整体堆叠在图3的CFRP的封闭截面构件内。
具体实施方式
本文使用的术语的目的仅在于描述具体的实施方式，并非旨在限制本发明。如本文中所使用的，单数形式“一(a)”、“一个(an)”和“该(the)”旨在还包括复数形式，除非上下文另有明确说明。应当进一步理解，当在本说明书中使用时，术语“包括(comprises)”和/或“包含(comprising)”表示所陈述的特征、整数、步骤、操作、元件和/或部件的存在，但不排除一个或多个其他特征、整数、步骤、操作、元件、部件和/或其群组的存在或添加。如本文中所使用的，术语“和/或”包括一个或多个相关的所列出的项目的任何以及全部结合。例如，为了清楚地描述本发明，无关部分未示出，并且为了清晰起见放大了区域和层的厚度。此外，当描述一层位于另一层或基板“上”时，该层可能正好在另一层或基板上，或者一第三层可能布置在其中间。
在下文中，将参照附图描述本公开的示例性实施方式。然而，为了有效地解释说明本发明的特征，下文描述的示图和以下详细的描述涉及多个示例性实施方式中的一个示例性实施方式。因此，本发明不应被理解为受限于这些示图和以下描述。
此外，在以下示例性实施方式中，为了有效解释说明本发明的主要技术特征，适当地改变、组合或拆分术语，以使本领域技术人员可清楚地理解这些术语，但本发明不限于此。
图3是示出根据本公开的示例性实施方式的CFRP封闭截面构件的示例性视图，并且图4是示出一状态并且沿线a-a得到的示例性剖视图，在该状态中，焊接有焊接螺母的钢板整体堆叠在图3的CFRP的封闭截面构件内。
参阅图4，根据本公开的示例性实施方式的CFRP板可通过在下部模具10与上部模具20之间的空间中堆叠第一CFRP层31、第二CFRP层32以及第三CFRP层33来制造。另外，在本公开中，为了整体地且牢固地模制要整体模制在一准确位置处的焊接螺母，焊接螺母52可以不单独插入，而是可以焊接至钢板51的形式插入。此外，可能在焊接螺母52的中央部分是空的时插入该焊接螺母，树脂会流入焊接螺母的中空部分，从而堵住该中空部分，并且用于从CFRP板的外表面接近螺母孔的部分也可能被堵住。因此，该焊接螺母不能被使用。
因此，在本公开中，如图4所示，可以在将临时螺栓53暂时地连接至焊接螺母时执行注入树脂的过程。特别地，如图4所示，可以这样的形式来执行该过程，即，使得临时螺栓53的上部部分可向外突伸出，同时穿过可形成CFRP板的外表面的第三CFRP层。上部模具中可以形成有将临时螺栓的突伸部分容纳在其中的凹槽，并且该临时螺栓之后可与CFRP板的外表面分离。
进一步地，如图4所示，可将焊接螺母布置在一期望的位置。在焊接螺母将被整体模制的部分附近(例如，邻近该部分)，可在第一CFRP层与第二CFRP层之间插入支撑钢板51的下表面的泡沫材料40，并且该泡沫材料具有形成于其中的凹槽，以将焊接至钢板51的下表面的焊接螺母容纳于其中。可将第二CFRP层堆叠在泡沫材料40上，并且可将钢板51和焊接螺母52堆叠在该第二CFRP层上。此外，泡沫材料可由聚丙烯材料制成。
此外，为了更加准确地保持堆叠的钢板和焊接螺母的位置，可将导销(guidepin)54安装于钢板51、第二CFRP层32以及泡沫材料40中。如图4所示，可安装至少两个导销，以更加准确地保持这些位置。可堆叠第三CFRP层，并且可注入树脂以模制期望的形状。在模制完该形状后，可移除临时螺栓53。换句话说，可制造出具有如图3所示的形状的CFRP板。
将进一步描述根据本公开的示例性实施方式的CFRP板的制造方法。首先，可打开模具，并且可将第一CFRP层31堆叠在下部模具10上。然后，可将泡沫材料布置并堆叠在基于模具的第一CFRP层31上，并且可将第二CFRP层32堆叠在该泡沫材料上。例如，可将第二CFRP层的孔和泡沫材料的凹槽布置成彼此重合。可将钢板堆叠在第二CFRP层的一布置位置处，而允许将暂时地安装有临时螺栓的焊接螺母(将整体焊接至钢板)插入穿过第二层的孔。然后，可安装导销54以固定钢板的位置。可堆叠第三CFRP层，并且可将临时螺栓安装至第三CFRP层的孔中。接着，可关闭上部模具，并且可注入树脂。当放出空气并且完成模制的产品时，可打开模具，移除该产品，并且可移除临时螺栓53。如上所述，根据该示例性实施方式，可以这种方式来制造整体模制有焊接螺母的CFRP板，即，该方式使得可制造具有CFRP板的车辆而不会显著改变制造过程。
虽然已结合目前被认为是实际的示例性实施方式的内容描述了本公开，但应当理解的是，本公开并不限于已公开的示例性实施方式，而是相反地，本公开旨在涵盖包括在所附权利要求的精神和范围内的各种改进与等同布置。另外，应当考虑到的是，所有这些改进和变化均落入本公开的范围内。
图中各个元件的标号
10：下部模具
20：上部模具
51：钢板
52：焊接螺母
53：临时螺栓
54：导销

Claims (15)

1.一种CFRP板，所述CFRP板通过在彼此邻近的CFRP层之间置入具有焊接的焊接螺母的钢板并且在将临时螺栓安装至所述焊接螺母时注入树脂而形成，所述CFRP层包括第一CFRP层和第二CFRP层。
2.根据权利要求1所述的CFRP板，其中，泡沫材料介于上面设置有所述钢板的所述第二CFRP层与设置在所述第二CFRP层下方的所述第一CFRP层之间。
3.根据权利要求1所述的CFRP板，其中，导销安装于所述钢板以及所述第二CFRP层中。
4.根据权利要求2所述的CFRP板，其中，导销安装于所述钢板、所述第二CFRP层以及所述泡沫材料中。
5.根据权利要求1所述的CFRP板，其中，当所述焊接螺母焊接至所述钢板的下表面时，所述焊接螺母介于所述第一CFRP层与所述第二CFRP层之间，并且在所述第二CFRP层的定位有所述焊接螺母的部分中形成有孔。
6.根据权利要求2所述的CFRP板，其中，当所述焊接螺母焊接至所述钢板的下表面时，所述焊接螺母介于所述第一CFRP层与所述第二CFRP层之间，在所述第二CFRP层的定位有所述焊接螺母的部分中形成有孔，并且在所述泡沫材料中形成有将所述焊接螺母容纳在里面的凹槽，所述凹槽定位在所述孔的下方。
7.根据权利要求1所述的CFRP板，其中，所述CFRP层还包括第三CFRP层，所述第三CFRP层中形成有孔，该孔使得所述临时螺栓穿过其中。
8.根据权利要求1所述的CFRP板，其中，在注入树脂后，所述临时螺栓被移除。
9.一种用于根据权利要求1所述的CFRP板的制造方法，所述方法包括以下步骤：
在下部模具与上部模具之间堆叠至少两个所述CFRP层，并且在两个所述CFRP层之间置入焊接有所述焊接螺母的所述钢板，所述临时螺栓安装于所述焊接螺母中；
关闭所述下部模具和所述上部模具并且注入树脂；以及
在注入树脂后，打开所述下部模具和所述上部模具并移除所述临时螺栓。
10.根据权利要求9所述的CFRP板的制造方法，其中，将所述CFRP层与泡沫材料堆叠，所述泡沫材料介于所述第二CFRP层与设置在所述第二CFRP层下方的所述第一CFRP层之间。
11.根据权利要求9所述的CFRP板的制造方法，其中，将导销安装于所述钢板以及所述第二CFRP层中。
12.根据权利要求10所述的CFRP板的制造方法，其中，将多个导销安装于所述钢板、所述第二CFRP层以及所述泡沫材料中。
13.根据权利要求9所述的CFRP板的制造方法，其中，将所述钢板堆叠在该两个所述CFRP层之间，使得所述焊接螺母安装于所述第二CFRP层的一部分的孔中。
14.根据权利要求10所述的CFRP板的制造方法，其中，将所述钢板堆叠在该两个所述CFRP层之间，使得所述焊接螺母安装于所述第二CFRP层的一部分的孔中，并且在所述孔的对应位置中形成所述泡沫材料的凹槽。
15.根据权利要求9所述的CFRP板的制造方法，其中，所述CFRP层还包括第三CFRP层，所述第三CFRP层中形成有孔，该孔使得所述临时螺栓穿过其中。
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