CN105946980A - 一种后备箱盖 - Google Patents

一种后备箱盖 Download PDF

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Publication number
CN105946980A
CN105946980A CN201610303165.5A CN201610303165A CN105946980A CN 105946980 A CN105946980 A CN 105946980A CN 201610303165 A CN201610303165 A CN 201610303165A CN 105946980 A CN105946980 A CN 105946980A
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carbon fiber
fiber composite
closed
cell foam
foam material
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张静
唐少俊
陈大华
洪丽
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Chery Automobile Co Ltd
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SAIC Chery Automobile Co Ltd
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    • 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
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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
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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
    • B32B3/30—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 a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B5/02—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 structural features of a fibrous or filamentary layer
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    • B32—LAYERED PRODUCTS
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    • 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
    • B32B5/245—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 another layer next to it being a foam layer
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    • 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
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    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
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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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    • B32B2262/14—Mixture of at least two fibres made of different materials
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
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  • Laminated Bodies (AREA)

Abstract

本发明提供一种重量轻、成本低、结构稳固、强度高的后备箱盖。该后备箱盖包括上下两层碳纤维复合材料层，上下两层碳纤维复合材料层之间设有闭孔泡沫材料层，闭孔泡沫材料层设有贯穿所述闭孔泡沫材料层的上下表面的通孔，碳纤维复合材料层与闭孔泡沫材料层之间以及的闭孔泡沫材料层的通孔内均填充有树脂。本发明通过在闭孔泡沫材料层上设置通孔，从而在上下两层碳纤维复合材料层之间形成树脂通道，提高了成型过程中树脂对上下两层碳纤维复合材料层的浸润性；而且成型过程中树脂会形成贯穿闭孔泡沫材料层的类似铆钉的纽带，这样就更好的将碳纤维复合材料层和闭孔泡沫材料层粘结为一体，极大程度的增加了粘结强度，降低了分层风险。

Description

一种后备箱盖
技术领域
本发明涉及汽车覆盖件制造技术领域，具体涉及一种后备箱盖。
背景技术
随着节能减排要求的提高，汽车的结构轻量化越来越受到人们的重视。由于碳纤维复合材料具有高强度、高模量、低密度、抗疲劳等显著特点，近年来，碳纤维复合材料的应用大大降低了汽车的车身结构重量。然而，高昂的碳纤维生产成本在一定程度上限制了碳纤维复合材料汽车结构的大规模推广和应用。为了降低成本，目前出现了泡沫夹心结构的后备箱盖，其采用纤维织物-泡沫夹心-纤维织物的结构。但是，这种结构的后备箱盖，成型多采用糊、预浸料等工艺成型，效率低下，而即便采用液体成型工艺，闭孔泡沫与纤维织物之间的粘结作用同样较弱，由于闭孔泡沫是无法浸入树脂，工艺过程中极易形成浸胶不良，出现干斑、板-芯脱粘等缺陷。因此，急需采取措施以解决复合材料泡沫夹心的成型工艺问题和提高面板-夹心的粘结强度，降低分层风险。
发明内容
本发明的目的是提出一种重量轻、成本低、结构稳固、强度高的后备箱盖。
根据本发明提供的后备箱盖，包括上下两层碳纤维复合材料层，所述上下两层碳纤维复合材料层之间设有闭孔泡沫材料层，所述闭孔泡沫材料层设有贯穿所述闭孔泡沫材料层的上下表面的通孔，所述碳纤维复合材料层与闭孔泡沫材料层之间以及所述的闭孔泡沫材料层的通孔内均填充有树脂。
本发明的后备箱盖，通过在后备箱盖成型工艺的制造过程中，在闭孔泡沫材料层上设置通孔，从而在上下两层碳纤维复合材料层之间形成树脂通道，提高了成型过程中树脂对上下两层碳纤维复合材料层的浸润性；而且成型过程中树脂会形成贯穿闭孔泡沫材料层的类似铆钉的纽带，这样就更好的将碳纤维复合材料层和闭孔泡沫材料层粘结为一体，极大程度的增加了粘结强度，降低了分层风险，使得成型后的后备箱盖整体性更好，结构更稳固。
进一步的，所述碳纤维复合材料层的纤维的长度方向与所述后备箱盖的左右对称轴方向一致。这样设置有利于后备箱盖的成型，因为在成型的过程中，树脂会沿着碳纤维复合材料层纤维的长度方向流动，这样树脂能很快浸润整个碳纤维复合材料层和闭孔泡沫材料层，从而避免树脂对碳纤维复合材料层和闭孔泡沫材料层的浸润不完全，提高了后备箱盖质量的可靠性。
进一步的，所述通孔的开孔处沿所述闭孔泡沫材料层的表面均匀间隙分布，以保证碳纤维复合材料层和闭孔泡沫材料层之间的连接强度均匀。
进一步的，所述闭孔泡沫材料层的表面还设有沟槽，所述通孔的开孔处位于所述沟槽内，这样可以进一步加强碳纤维复合材料层和闭孔泡沫材料层之间的粘结强度。
具体的说，所述通孔的孔径为1mm～2mm，所述通孔的间距为10mm～30mm。所述沟槽的深度为0.5mm，宽度为1.5mm～2mm。
具体的说，所述后备箱盖采用RTM液体成型工艺或空导入工艺成型。
附图说明
图1为本发明的剖视结构示意图。
图2为本发明设置沟槽处的剖视结构示意图。
具体实施方式
下面对照附图，通过对实施实例的描述，对本发明的具体实施方式如所涉及的各构件的形状、构造、各部分之间的相互位置及连接关系、各部分的作用及工作原理等作进一步的详细说明。
实施例1：
如图1，本发明的后备箱盖，包括上层碳纤维复合材料层10a和下层碳纤维复合材料层10b，上层碳纤维复合材料层10a和下层碳纤维复合材料层10b之间设有闭孔泡沫材料层20，所述闭孔泡沫材料层20设有贯穿所述闭孔泡沫材料层20的上下表面的通孔21，所述上层碳纤维复合材料层10a与闭孔泡沫材料层20之间、下层碳纤维复合材料层10b与闭孔泡沫材料层20之间以及的闭孔泡沫材料层20的通孔21内均填充有树脂。闭孔泡沫材料层20的作用是减少后备箱盖碳纤维的用量，从而降低后备箱盖的原材料成本，而且闭孔泡沫材料层20在后备箱盖的结构中起到支撑刚度的作用，同时还具有优异的隔热性能。由于闭孔泡沫材料层20设有贯穿其上下表面的通孔21，成型时，通孔21在上层碳纤维复合材料层10a和下层碳纤维复合材料层10b之间形成树脂通道，使得树脂能对闭孔泡沫材料层20上下两侧的碳纤维复合材料层10的上层10a和下层10b进行同时浸润，防止碳纤维复合材料层10的浸润不完全，同时，成型过程中树脂会形成贯穿闭孔泡沫材料层20的类似铆钉的纽带，从而增强上层碳纤维复合材料层10a和下层碳纤维复合材料层10b与闭孔泡沫材料层20的粘结性能，降低了分层风险，使得成型后的后备箱盖整体性更好，结构更稳固。作为优选的实施方式，上层碳纤维复合材料层10a和下层碳纤维复合材料层10b的纤维的长度方向与后备箱盖的左右对称轴方向一致。这样设置有利于后备箱盖的成型，因为在成型的过程中，树脂会沿着上层碳纤维复合材料层10a和下层碳纤维复合材料层10b的长度方向流动，这样树脂能很快浸润整个碳纤维复合材料层和闭孔泡沫材料层20，从而避免树脂对碳纤维复合材料层和闭孔泡沫材料层20的浸润不完全，提高了后备箱盖质量的可靠性。优选的，通孔21的开孔处沿闭孔泡沫材料层20的表面均匀间隙分布，以保证上层碳纤维复合材料层10a和下层碳纤维复合材料层10b和闭孔泡沫材料层20之间的连接强度均匀。进一步的，闭孔泡沫材料层20的表面还设有沟槽22，通孔21的开孔处位于沟槽22内，这样可以进一步加强上层碳纤维复合材料层10a和下层碳纤维复合材料层10b和闭孔泡沫材料层20之间的粘结强度。为了防止出现过多的树脂富集，通孔21的孔径为1mm～2mm，通孔21的间距为10mm～30mm。沟槽22的深度为0.5mm，沟槽22的宽度为1.5mm～2mm。
本实施例中，闭孔泡沫材料层20可采用聚酰亚胺（PMI）泡沫材料或聚氯乙烯（PVC）泡沫材料或聚氨酯（PU）泡沫材料，这些闭孔泡沫材料上有众多彼此不连通的泡孔腔，具有优异的隔热性能。作为优选的实施方式，上层碳纤维复合材料层10a和下层碳纤维复合材料层10b均采用12K碳纤和玻纤混纺斜纹织物，在后备箱盖成型工艺中，上层碳纤维复合材料层10a和下层碳纤维复合材料层10b分别由四层12K碳纤和玻纤混纺斜纹织物层层叠加铺贴在模具中。本发明的后备箱盖的结构设计，既可以采用RTM液体成型工艺成型，也可以用于真空导入工艺成型，既实现了低成本，又提高了夹芯结构的力学性能。

Claims (8)

1.一种后备箱盖，其特征在于包括上下两层碳纤维复合材料层，所述上下两层碳纤维复合材料层之间设有闭孔泡沫材料层，所述闭孔泡沫材料层设有贯穿所述闭孔泡沫材料层的上下表面的通孔，所述碳纤维复合材料层与闭孔泡沫材料层之间以及所述的闭孔泡沫材料层的通孔内均填充有树脂。
2.根据权利要求1所述的后备箱盖，其特征在于所述碳纤维复合材料层的纤维的长度方向与所述后备箱盖的左右对称轴方向一致。
3.根据权利要求2所述的后备箱盖，其特征在于所述通孔的开孔处沿所述闭孔泡沫材料层的表面均匀间隙分布。
4.根据权利要求3所述的后备箱盖，其特征在于所述闭孔泡沫材料层的表面还设有沟槽，所述通孔的开孔处位于所述沟槽内。
5.根据权利要求3所述的后备箱盖，其特征在于所述通孔的孔径为1mm～2mm，所述通孔的间距为10mm～30mm。
6.根据权利要求3所述的后备箱盖，其特征在于所述沟槽的深度为0.5mm，宽度为1.5mm～2mm。
7.根据权利要求1至6任一项所述的后备箱盖，其特征在于所述后备箱盖采用RTM液体成型工艺成型。
8.根据权利要求1至6任一项所述的后备箱盖，其特征在于所述后备箱盖采用真空导入工艺成型。
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