CN107599439A - 复合材料活塞销及其制造方法 - Google Patents

复合材料活塞销及其制造方法 Download PDF

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Publication number
CN107599439A
CN107599439A CN201611052179.0A CN201611052179A CN107599439A CN 107599439 A CN107599439 A CN 107599439A CN 201611052179 A CN201611052179 A CN 201611052179A CN 107599439 A CN107599439 A CN 107599439A
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CN
China
Prior art keywords
layer
prepreg
outer layer
reinforcing fiber
piston pin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201611052179.0A
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English (en)
Inventor
朴相润
梁埈滈
车星澈
崔致勋
洪承贤
曺永大
李宰源
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Hyundai Motor Co
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Hyundai Motor Co
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Filing date
Publication date
Application filed by Hyundai Motor Co filed Critical Hyundai Motor Co
Publication of CN107599439A publication Critical patent/CN107599439A/zh
Pending legal-status Critical Current

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16J—PISTONS; CYLINDERS; SEALINGS
    • F16J1/00—Pistons; Trunk pistons; Plungers
    • F16J1/10—Connection to driving members
    • F16J1/14—Connection to driving members with connecting-rods, i.e. pivotal connections
    • F16J1/16—Connection to driving members with connecting-rods, i.e. pivotal connections with gudgeon-pin; Gudgeon-pins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/005—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor characterised by the choice of material
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    • B29C53/56—Winding and joining, e.g. winding spirally
    • B29C53/562—Winding and joining, e.g. winding spirally spirally
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Abstract

本发明公开一种复合材料活塞销及其制造方法，其包括：管状外层，其由增强纤维制得；内层，其沿着外层的内表面联接至外层，所述内层由具有比外层更低的弹性的增强纤维制得；以及树脂材料，其包含环氧树脂组合物和氰酸酯，所述树脂材料浸入外层和内层的增强纤维中。

Description

复合材料活塞销及其制造方法
技术领域
本发明大体上涉及一种复合材料活塞销。更具体地，本发明涉及这样一种复合材料活塞销，其由具有不同弹性的多层管状增强纤维及具有高玻璃化转变温度和良好可成型性的树脂制得。
背景技术
在全部由常规SCM415钢制得的钢材料构成的活塞销的情况中，当活塞销应用于车辆的时候，由于其沉重的重量而不能提高里程数。此外，在活塞销所需的环形方向抗弯强度和纵向抗弯强度方面，常规活塞销的材料性能不符合要求，因此需要制造一种活塞销以替代常规活塞销。
出于这种原因，本发明旨在提供一种由轻质且良好刚度的碳纤维制得的复合材料活塞销。
公开于该发明背景技术部分的信息仅仅旨在加深对本发明的一般背景技术的理解，而不应当被视为承认或以任何形式暗示该信息构成已为本领域技术人员所公知的现有技术。
发明内容
因此，本发明考虑到解决在相关技术中发生的上述问题。本发明提供一种由具有不同弹性的多层管状增强纤维及具有高玻璃化转变温度和良好可成型性的树脂制得的复合材料活塞销。
在本发明的一个方面，本发明提供一种复合材料活塞销，其包括：(1)管状外层，其由增强纤维制得；(2)内层，其沿着外层的内表面联接至外层，并由具有比外层更低的弹性的增强纤维制得；以及(3)树脂材料，其包含环氧树脂组合物和氰酸酯，所述树脂材料浸入外层和内层的增强纤维中。
外层和内层的增强纤维可以由碳纤维制得，其中外层的碳纤维为沥青基碳纤维，内层的碳纤维为PAN基碳纤维。
环氧树脂组合物和氰酸酯的混合比例可以在约1:0.82至约1:1.22的范围内。
环氧树脂组合物可以包括双酚A型(BPA型)环氧树脂和酚醛环氧树脂。
外层的增强纤维可以在外层的纵向方向上平行地布置。内层可以包括：第一层，其构造成使得其增强纤维垂直于外层的增强纤维布置，第一层沿着外层的内表面联接至外层；以及第二层，其构造成使得其增强纤维平行于外层的增强纤维布置，第二层沿着第一层的内表面联接至第一层。
假设外层和内层的总厚度为100％，则外层的厚度可以大于0％至约50％(且不包括0％)(例如，约1％、5％、10％、15％、20％、25％、30％、35％、40％、45％或约50％)，内层的第一层的厚度可以为约40％至约80％(例如，约40％、45％、50％、55％、60％、65％、70％、75％或约80％)，内层的第二层的厚度可以大于0％至约60％(且不包括0％)(例如约1％、5％、10％、15％、20％、25％、30％、35％、40％、45％、50％、55％或约60％)。
根据本发明的另一方面，提供一种复合材料活塞销的制造方法，所述制造方法包括如下步骤：堆叠由包括环氧树脂组合物和氰酸酯的树脂材料和增强纤维构成的第一预浸渍体及由包括环氧树脂组合物和氰酸酯的树脂材料和具有比第一预浸渍体的增强纤维更低的弹性的增强纤维构成的第二预浸渍体；卷曲第一预浸渍体和第二预浸渍体使得第一预浸渍体形成外表面；在烘箱中整体成型围绕模具卷曲的第一预浸渍体和第二预浸渍体。
在卷曲后，所述制造方法可以进一步包括围绕第二预浸渍体的外表面包裹耐热薄膜。
在成型后，所述制造方法可以进一步包括将耐热薄膜和模具从第一预浸渍体和第二预浸渍体分离，然后将第一预浸渍体和第二预浸渍体切割成预定的长度。
在切割后，制造方法可以进一步包括通过抛光来处理第一预浸渍体的表面。
本发明的复合材料活塞销的优点在于其构造成使得销以多层结构形成。此外，构成内层和外层的增强纤维具有不同的弹性，浸入增强纤维的树脂材料包括环氧树脂组合物和氰酸酯，从而因弯曲应力减小而提高弯曲强度，因剪切应力减小而提高剪切强度。
本发明的复合材料活塞销的其他优点在于可以控制椭圆变形的量。
因此，可以制造轻质的活塞销，由此可以通过减少摩擦而提高里程数和耐久性。
本发明的方法和装置具有其它特征和优点，这些特征和优点将在纳入本文的附图以及随后与附图一起用于解释本发明的某些原理的具体实施方式中显现或更详细地阐明。
附图说明
图1为显示根据本发明实施方案的复合材料活塞销的元件之间连接的视图。
图2为根据本发明实施方案通过使用储能模量的曲线图而显示的玻璃化转变温度(Tg)随着温度变化的视图。
图3为通过使用表示第一层厚度、第二层厚度和外层厚度的三轴图表而显示本发明的区域的视图。
图4为显示对比实施例、实施方案1和实施方案2中弯曲应力的进行对比的视图。
图5为显示对比实施例、实施方案1和实施方案2中剪切应力的进行对比的视图。
图6为显示对比实施例、实施方案1和实施方案2中椭圆变形的量的进行对比的视图。
图7为显示根据本发明实施方案的第一卷曲和第二卷曲的视图。
图8为显示根据本发明实施方案的成型的视图。
图9为显示根据本发明实施方案的加工的视图。
应了解，附图并不必须按比例绘制，其示出了某种程度上经过简化了的本发明的基本原理的各个特征。在此所公开的本发明的特定的设计特征，包括例如特定的尺寸、定向、位置和形状，将部分地由特定目的的应用和使用环境加以确定。
在这些图形中，附图标记在贯穿附图的多幅图形中表示本发明的同样的或等同的部件。
具体实施方式
现在将详细提及本发明的各个实施方案，这些实施方案的示例显示在附图中并描述如下。尽管本发明将与示例性实施方案结合加以描述，但是应当理解，本说明书并非旨在将本发明限制为那些示例性实施方案。相反，本发明旨在不但覆盖这些示例性实施方案，而且覆盖可以被包括在由所附权利要求所限定的本发明的精神和范围之内的各种选择形式、修改形式、等价形式及其它实施方案。
在下文中，本发明的示例性实施方案将参照所附附图详细如下描述。在全部附图中，相同的附图标记表示相同或相似的部分。
如图1中所示，根据本发明的复合材料活塞销包括：管状外层100、内层200、以及树脂材料；所述管状外层100由增强纤维制得；所述内层200沿着外层100的内表面联接至外层100，并由具有比外层100更低的弹性的增强纤维制得；所述树脂材料包含环氧树脂组合物和氰酸酯，所述树脂材料浸渍进入外层100和内层200的增强纤维中。
外层100由增强纤维制得，其中增强纤维可以由碳纤维、玻璃纤维、芳族聚酰胺纤维和天然纤维的至少一种制得。此外，外层100为管状，优选地，外层通过卷曲板状增强纤维而形成为管状。
内层200也由增强纤维制得，其中增强纤维可以由碳纤维、玻璃纤维、芳族聚酰胺纤维和天然纤维的至少一种制得。此处，内层由具有比外层100更低的弹性的增强纤维制得。
内层200沿着外层100的内表面联接至外层100从而成为管状，其中具有比内层更高弹性的外层100的内表面支撑外层100并承载施加至其上的负载从而提高环形方向抗弯强度。
树脂材料提高环氧树脂组合物的耐热性，添加提高树脂流动性的氰酸酯，从而在将树脂材料浸入增强纤维的时候可以减少空隙，并可以提高增强纤维的纤维均匀性。
更具体地，通过添加氰酸酯，玻璃化转变温度(Tg)升高，其中玻璃化转变温度(Tg)为聚合物从玻璃态变化为高弹态的温度。此转变被称为玻璃化转变，如图2中的图表所示，在储能模量相对于温度的图表中，玻璃化转变温度(Tg)显示为从低温延伸的线与从高温延伸的线相交的点。在根据本发明的复合材料活塞销中，玻璃化转变温度(Tg)发生在约250℃。
因此，玻璃化转变温度(Tg)升高越多，耐热性提高得越多。在浸入增强纤维的树脂材料中，当耐热性提高的时候，在成型过程中塑性产生不明显，由此可以减少空隙，可以提高增强纤维的纤维均匀性。
然而，当添加更多的氰酸酯从而为了高耐热性而升高玻璃化转变温度(Tg)的时候，树脂材料的粘性明显下降，由此难以制造具有均一形状的复合材料组件。因此，需要环氧树脂组合物和氰酸酯的适当混合比例，这将在下文中说明。
树脂材料除了环氧树脂组合物和氰酸酯之外还包括催化剂，催化剂为金属络合物、乙酰丙酮钴等。
优选地，在树脂材料中，环氧树脂组合物和氰酸酯的混合比例在约1:0.82至约1:1.22的范围内(例如，约1:0.82、1:0.9、1:1、1:1.1或约1:1.22)。当基于环氧树脂组合物的氰酸酯的混合比例低于0.82的时候，玻璃化转变温度(Tg)降低，所以当树脂材料浸入增强纤维的时候，可能产生许多空隙，增强纤维的纤维均匀性可能降低。
相反，当氰酸酯的混合比例高于1.22的时候，树脂材料由于高流动性而具有差的可成形性，树脂材料的粘性显著下降，由此难以制造具有均一形状的复合材料组件。因此，环氧树脂组合物和氰酸酯的混合比例限制在约1:0.82至1:1.22的范围内。
受限范围的原因和效果显示在下文表1中。
表1
玻璃化转变温度(Tg)的标准设定在240℃以上意指在根据本发明的复合材料销的制造方法中，玻璃化转变温度的标准根据烘箱中成型时候的烘箱温度而设定，树脂的流动性通过使用熔体流动指数来评价，其中熔体流动指数越高，树脂的流动性越好。可成形性和可加工性通过制造具有均一形状的复合材料组件的容易程度而设定。
流动性意指相比于参考材料，流体在预定表面上移动的距离的数值，因此数值越大，流体移动的越远。
如表1中所示，当氰酸酯和环氧树脂组合物的混合比例低于0.82的时候，如对比实施例1和对比实施例2所示，可成形性和可加工性符合而耐热性不符合。当氰酸酯和环氧树脂组合物的混合比例高于1.22的时候，如对比实施例3所示，耐热性符合但可成形性和可加工性不符合。
环氧树脂组合物可以包括双酚A型(BPA型)环氧树脂和酚醛环氧树脂。优选地，BPA型环氧树脂占100％的总体环氧树脂组合物的10-40％，其余为占60-90％的酚醛环氧树脂。
同时，外层100的增强纤维和内层200的增强纤维可以由碳纤维制得，其中外层100的碳纤维为沥青基碳纤维，内层200的碳纤维为PAN基碳纤维。
沥青基碳纤维具有高于约640GPa的弹性模量，沥青基碳纤维由于碳百分比较高而通常具有高弹性，由此可以防止引起销变形的因在其上负载重量时候由重量造成的椭圆变形，并通过提高环形方向抗弯强度和材料强度而防止弯曲变形。
PAN基碳纤维具有高于约240GPa的弹性模量，PAN基碳纤维通常具有高压缩强度，由此设置在复合材料活塞销的最内侧，从而支撑外层100并承载置于其上的负载，因此提高环形方向抗弯强度。因此，可以防止由负载引起的椭圆变形。PAN基碳纤维的成本较低，因此可以减少制造成本。
外层100的增强纤维可以在外层的纵向方向上平行地布置，内层200可以包括：第一层210以及第二层220；所述第一层210构造成使得其增强纤维垂直于外层100的增强纤维布置，第一层沿着外层100的内表面联接至外层100；所述第二层220构造成使得其增强纤维平行于外层100的增强纤维布置，第二层沿着第一层210的内表面联接至第一层210。
外层100的增强纤维可以在外层的纵向方向上平行地布置。以多层结构形成的内层200具有这样的构造：联接至外层100的内表面的第一层210构造成使其增强纤维垂直于外层100的增强纤维布置；联接至第一层210的内表面的第二层220构造成使其增强纤维平行于外层100的增强纤维布置，因此，外层100、第一层210和第二层220的增强纤维相对于外层具有0°、90°和0°的纤维定向。
因此，可以提高复合材料活塞销的刚度，并可以使活塞销在复合材料活塞销的宽度方向以及其纵向方向上承载负载。
外层100的外表面用平纹布300包裹从而防止纤维的分离。
更优选地，假设外层100和内层200的总厚度为100％，外层100占0％至50％，第一层210占40％至80％，第二层220占0％至60％。
如图3中所示，在直角三角形的上部区域的情况中，由于基于总厚度第一层210的厚度超过80％，第一层210的百分比较高，因此销的弯曲强度减小，由此发生椭圆变形和弯曲变形。
在直角三角形的左下部区域的情况中，由于基于总厚度，外层100的厚度超过50％，或者第一层210的厚度低于40％，外层100的百分比较高，因此销的剪切强度减小，由此发生椭圆变形。
在直角三角形的下中部区域的情况中，由于基于总厚度第一层210的厚度低于40％，第二层220的百分比较高，因此销的剪切强度和材料强度减小，由此发生椭圆变形和弯曲变形。
在直角三角形的右下部区域的情况中，由于基于总厚度，第二层220的厚度超过60％，或者第一层210的厚度低于40％，外层220的百分比较高，因此销的剪切强度和材料强度减小，由此发生椭圆变形和弯曲变形。
因此，假设外层100和内层200的总厚度为100％，典型的是外层100占0％至50％，第一层210占40％至80％，第二层220占0％至60％。
根据本发明的复合材料活塞销以多层结构形成，其中构成内层和外层的增强纤维具有不同的弹性，且浸入增强纤维的树脂材料包含环氧树脂组合物和氰酸酯。
图4、图5和图6为显示由常规金属材料制得且重约79g的SCM415销、根据本发明实施方案的重约20g的销的实施方案1和重约23g的实施方案2之间的材料性能进行对比的图表。
如图4的图表所示，相比于常规SCM415销，弯曲应力减小约8％至10％，因此提高弯曲强度，如图5的图表所示，相比于常规SCM415销，剪切应力减小约25％至41％，因此提高剪切强度。此外，如图6的图表中所示，相比于常规SCM415销，椭圆变形的量减少约36％至72％。
根据本发明的复合材料活塞销可以用作在发动机中、在变速器的气门机构中、在轴中等等经受摩擦和磨损的组件。具体地，复合材料活塞销可以用于摇臂销、CVVL销、摆臂销、正时链条销、挺杆、变速器的销或轴等等，但并不限于此。
根据本发明的复合材料活塞销的制造方法包括：第一次卷曲由树脂材料(其包含环氧树脂组合物和氰酸酯)和增强纤维构成的第一预浸渍体10，使得第一预浸渍体10围绕圆柱形模具30的外表面；第二次卷曲由树脂材料(其包含环氧树脂组合物和氰酸酯)和增强纤维(其具有比第一预浸渍体10的增强纤维更高的弹性)构成的第二预浸渍体20，使得第二预浸渍体20围绕第一预浸渍体10的外表面；在烘箱中整体成型围绕模具30卷曲的第一预浸渍体10和第二预浸渍体20。
优选地，在卷曲步骤后，所述制造方法进一步包括围绕第二预浸渍体20的外表面包裹耐热薄膜。
首先，由具有较低弹性的增强纤维构成的第一预浸渍体10通过第一次卷曲而围绕圆柱形模具30的外表面。将具有预定宽度的板状第一预浸渍体10完全地展开，然后模具30设置于第一预浸渍体的端部，卷曲第一预浸渍体10从而围绕模具30的外表面。
然后，由具有较高弹性的增强纤维构成的第二预浸渍体20通过第二次卷曲而围绕第一预浸渍体10的外表面。将具有预定宽度的板状第二预浸渍体20完全地展开，然后已经被第一预浸渍体10围绕的模具30设置于第二预浸渍体的端部，卷曲第二预浸渍体20从而围绕第一预浸渍体10的外表面。
通过第一次卷曲步骤和第二次卷曲步骤，由具有较高弹性的增强纤维构成的第二预浸渍体20设置于外层，由具有较低弹性的增强纤维构成的第一预浸渍体10设置于内层。
优选地，如图7中所示，第一预浸渍体10和第二预浸渍体20完全地展开，其中第一预浸渍体10的端部和第二预浸渍体20的端部连接以相互重叠，然后通过使用模具30而卷曲第一预浸渍体10和第二预浸渍体20。
此外，在复合材料活塞销中，通过改变第一预浸渍体10的长度和第二预浸渍体20的长度可以调节内层200的厚度和外层100的厚度。
在第二次卷曲步骤后，将耐热薄膜围绕第二预浸渍体20的外表面包裹。薄膜可以由具有耐热性的热收缩带构成。
然后，如图8中所示，由薄膜包裹的第一预浸渍体10和第二预浸渍体20在烘箱中整体成型。当预浸渍体在烘箱中成型的时候，通过围绕第二预浸渍体20的外表面包裹耐热薄膜，耐热薄膜受热收缩，由此可以去除第一预浸渍体10和第二预浸渍体20中的气孔。
在烘箱中的成型步骤在200-250℃的温度下可以持续约1小时。树脂材料包括氰酸酯，因此提高耐热性。因此，在烘箱中成型过程中产生塑性不明显，因此可以减少空隙，增强纤维的纤维均匀性可以提高。
在成型步骤后，所述制造方法可以进一步包括将耐热薄膜和模具30从第一预浸渍体10和第二预浸渍体20分离，然后将第一预浸渍体和第二预浸渍体切割成预定的长度。此外，在切割后，制造方法可以包括通过抛光来处理第二预浸渍体20的表面。
在成型后将第一预浸渍体10和第二预浸渍体20从烘箱中取出，然后去除围绕第二预浸渍体20的外表面包裹的耐热薄膜，分离被第一预浸渍体10围绕的模具30，然后切割第一预浸渍体10和第二预浸渍体20用于具体目的。
为了处理已经切割的第一预浸渍体10和第二预浸渍体20，第一预浸渍体的表面通过使用磨削机40(如磨石等)而进行抛光。优选地，如图9中所示，彼此以相反方向旋转的一对磨石旋转的同时与第二预浸渍体20的外表面接触，使得第二预浸渍体20的表面被抛光。
尽管出于说明的目的已公开了本发明的示例性实施方案，但是本领域技术人员应当理解，各种修改、增加和删减是可能的，并不脱离所附权利要求中所公开的本发明的范围和主旨。

Claims (10)

1.一种复合材料活塞销，其包括：
管状外层，其由增强纤维制得；
内层，其沿着外层的内表面联接至外层，所述内层由具有比外层更低的弹性的增强纤维制得；以及
树脂材料，其包含环氧树脂组合物和氰酸酯，所述树脂材料浸入外层和内层的增强纤维中。
2.根据权利要求1所述的复合材料活塞销，其中，
环氧树脂组合物和氰酸酯的混合比例在约1:0.82至约1:1.22的范围内。
3.根据权利要求2所述的复合材料活塞销，其中，
环氧树脂组合物包括双酚A型环氧树脂和酚醛环氧树脂。
4.根据权利要求1所述的复合材料活塞销，其中，
外层和内层的增强纤维由碳纤维制得，其中，
外层的碳纤维为沥青基碳纤维，内层的碳纤维为聚丙烯腈基碳纤维。
5.根据权利要求1所述的复合材料活塞销，其中，
外层的增强纤维可以在外层的纵向方向上平行地布置，
内层包括：
第一层，其构造成使其增强纤维垂直于外层的增强纤维布置，第一层沿着外层的内表面联接至外层；以及
第二层，其构造成使其增强纤维平行于外层的增强纤维布置，第二层沿着第一层的内表面联接至第一层。
6.根据权利要求5所述的复合材料活塞销，其中，
设定外层和内层的总厚度为100％，外层的厚度为总厚度的大于0％至约50％，第一层的厚度为总厚度的约40％至约80％，第二层的厚度为总厚度的大于0％至约60％。
7.一种复合材料活塞销的制造方法，所述制造方法包括如下步骤：
第一次卷曲由包含环氧树脂组合物和氰酸酯的树脂材料及增强纤维构成的第一预浸渍体，使得第一预浸渍体围绕圆柱形模具的外表面；
第二次卷曲由包含环氧树脂组合物和氰酸酯的树脂材料及具有比第一预浸渍体的增强纤维更高的弹性的增强纤维构成的第二预浸渍体，使得第二预浸渍体围绕第一预浸渍体的外表面；以及
在烘箱中整体成型围绕模具卷曲的第一预浸渍体和第二预浸渍体。
8.根据权利要求7所述的复合材料活塞销的制造方法，其进一步包括如下步骤：
在第二次卷曲后，围绕第二预浸渍体的外表面包裹耐热薄膜。
9.根据权利要求8所述的复合材料活塞销的制造方法，其进一步包括如下步骤：
在成型后，将耐热薄膜和模具从第一预浸渍体和第二预浸渍体分离，然后将第一预浸渍体和第二预浸渍体切割成预定的长度。
10.根据权利要求9所述的复合材料活塞销的制造方法，其进一步包括如下步骤：
在切割后，通过抛光来处理第二预浸渍体的表面。
CN201611052179.0A 2016-07-11 2016-11-25 复合材料活塞销及其制造方法 Pending CN107599439A (zh)

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