CN108099317A - 一种高耐疲劳复合材料汽车板簧及其制作方法 - Google Patents

一种高耐疲劳复合材料汽车板簧及其制作方法 Download PDF

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CN108099317A
CN108099317A CN201711352759.6A CN201711352759A CN108099317A CN 108099317 A CN108099317 A CN 108099317A CN 201711352759 A CN201711352759 A CN 201711352759A CN 108099317 A CN108099317 A CN 108099317A
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composite material
leaf spring
high endurance
layer
material automobile
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王钧
代巍
杨小利
张斌
苏晓岗
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Wuhan University of Technology WUT
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Abstract

本发明公开了一种高耐疲劳复合材料汽车板簧及其制作方法。该高耐疲劳复合材料汽车板簧包括叠层铺放的至少一层单向纤维层以及套设于单向纤维层外表面的至少一层二维编织套管。制作方法为：叠层铺放至少一层单向纤维层；将所述至少一层单向纤维层外套所述至少一层二维编织套管，制备成纤维预成型体；将纤维预成型体放入成型模具中，采用成型工艺浸渍、固化、脱模、修剪，即得到所述复合材料汽车板簧。本发明利用了二维编织套管中纤维连续、角度可控、附型性好的特性，制备了具有高耐疲劳和抗层间剪切优异的汽车板簧，该制备工艺简单，有效避免了传统纯单向铺放纤维板簧环向没有纤维约束、耐疲劳性差、三维编织预成型体工艺复杂的问题。

Description

一种高耐疲劳复合材料汽车板簧及其制作方法
技术领域
本发明涉及一种汽车行业用的板簧制备技术，特别涉及一种高耐疲劳复合材料汽车板簧及其制作方法。
背景技术
目前汽车多采用钢制板簧作为缓冲和减震结构，钢板结构简单，成本低廉，维修方便。但钢制板簧本身特别重，使得整车的重量增加，从而增大了燃油消耗率，并对车辆的操纵稳定性产生一定影响。另外，汽车钢制板簧是由多片弹簧钢叠加组合而成，相邻的弹簧钢之间不可避免的摩擦会使钢制板簧的寿命变短；并且钢制板簧会出现突然断裂引发安全事故。随着人们追求的不断提高，汽车在兼顾安全，节能，环保的同时，顾客对汽车舒适性的要求也越来越高，钢制板簧的减震效果与人们期待的仍有差距。
由于复合材料轻质高强的特点，复合材料板簧在达到相同使用性能的同时，通常可较钢板弹簧减重50％～70％，这是在其它车用部件轻量化过程中极为少见。除具备卓越的轻量化效果外，复合材料板簧同时具有疲劳寿命高(一般为钢板弹簧的2～10倍)、安全性好(不会出现突然断裂)、弹性行程大、舒适性好、噪声小、耐腐蚀、安装便利等特点，而其轻量化效果更是减少了车辆在行驶过程中的燃油损耗以及CO2排放，具有节能环保的特性，有很高的经济效益和社会效益。
采用复合材料板簧代替钢制板簧，将成为国内汽车行业的一种新型发展趋势。目前国内有部分汽车厂商已经开始着手进行复合材料板簧的研发。专利CN 105172216A公开了一种缠绕强化复合材料汽车板簧制备方法，该复合材料板簧基本结构为二维织物叠层与螺旋缠绕结构相结合，通过模压真空导入一体化工艺固化成型；专利CN 105134849A公开了一种三维编织复合材料汽车板簧的制备方法，由混杂纤维组合编织形成立体织物结构，通过树脂真空传递模塑工艺固化成型；专利CN 105128357A公开了一种层间加强二维/三维编织复合材料汽车板簧制备方法，通过三维立体编织形成不同纤维材质的单层织物，然后再通过层间的纵向缝合将叠层后的单层结构形成整体，最后采用树脂真空传递模塑工艺梯度升温固化成型。
目前复合材料板簧存在在较高疲劳加载条件下层间结合强度较弱的问题，现有解决办法有采用缠绕方法将二维织物叠层结合，此方法存在预成型体工艺繁琐、制品厚度不均，无法达到高层间强度；或者，采用层间的纵向缝合将叠层后的单层结构形成整体，此方法最大缺陷就是工艺繁琐，制作时间长，生产效率低，不满足产业化要求。
发明内容
鉴于此本发明为解决上述技术问题提供一种高耐疲劳复合材料汽车板簧及其制作方法。该汽车板簧具有高抗疲劳、质量轻、强度高、刚度大、尺寸稳定性强、寿命长、抗层间剪切性能优异等优点，而且制备工艺简单。
本发明所采取的技术方案如下：
一种高耐疲劳复合材料汽车板簧，所述高耐疲劳复合材料汽车板簧包括叠层铺放的至少一层单向纤维层以及套设于所述单向纤维层外表面的至少一层二维编织套管。
上述方案中，所述单向纤维层和二维编织套管的材料为人造纤维或合成纤维。
上述方案中，所述人造纤维为玻璃纤维、碳纤维或玄武岩纤维。也可以是两种或两种以上不同纤维的混合编织。
上述方案中，所述合成纤维为聚酯纤维、聚酰胺纤维或聚丙烯腈纤维。也可以是两种或两种以上不同纤维的混合编织。
上述方案中，所述单向纤维层和二维编织套管的材料为芳纶纤维或乙纶。
上述方案中，所述单向纤维层和二维编织套管的纤维束量可选用1K、3K、6K或12k中的一种或多种丝束组合，丝束预先要经过加捻处理，加捻程度根据具体要求而定。
上述方案中，所述汽车板簧的长度范围为0.8-2m。
上述方案中，所述汽车板簧的厚度范围为40-85mm。
上述方案中，所述编织套管的直径为130mm-230mm，厚度为2-3mm。
上述方案中，所述至少一层单向纤维层的厚度为2-3mm，宽度为130-230mm。
所述的高耐疲劳复合材料汽车板簧的制作方法，包括以下步骤：
叠层铺放所述至少一层单向纤维层；
将所述至少一层单向纤维层外套所述至少一层二维编织套管，制备成纤维预成型体；
将所述纤维预成型体放入成型模具中，采用成型工艺浸渍、固化、脱模、修剪，即得到所述复合材料汽车板簧。
上述方案中，所述浸渍采用的树脂为热固性树脂或热塑性树脂；热固性树脂包括环氧树脂、不饱和聚酯树脂、乙烯基树脂、酚醛树脂或聚氨酯树脂。
上述方案中，所述的成型工艺采用真空辅助树脂传递模塑料成型工艺(VRTM)、预浸料模压成型工艺或热压罐成型工艺。
本发明的有益效果为：本发明与现有缠绕，层间纵向缝合工艺相比，增强材料是一个连续整体、力学性能好、且稳定；加工工艺简单、无需后加工，生产效率高，同时间少了材料浪费损耗；制品层间强度非常高。本发明可通过控制纤维层厚度和套管的层数来改变板簧的强度和刚度；制品具有高抗疲劳、质量轻、强度高、刚度大、尺寸稳定性强、寿命长、抗层间剪切优异等特性。同时，本发明利用了套管纤维连续、角度可控、附型性好的特性。
附图说明
以下结合附图对本发明进行进一步的描述：
图1是本发明的二维编织套管的结构示意图。
图2是本发明的纤维预成型体的平面示意图。
图3是本发明的纤维预成型体的立体示意图。
图4是本发明的汽车板簧结构示意图。
具体实施方式
如图4所示，其为本发明提供的一种高耐疲劳复合材料汽车板簧，该高耐疲劳复合材料汽车板簧包括叠层铺放的至少一层单向纤维层以及套设于单向纤维层外表面的至少一层二维编织套管。
如图1至图3所示，本发明还提供该高耐疲劳复合材料汽车板簧的制作方法，包括以下步骤：
叠层铺放所述至少一层单向纤维层1；
将所述至少一层单向纤维层1外套所述至少一层二维编织套管2，制备成纤维预成型体(如图2和图3所示)，可以根据所需刚度、强度和制品厚度调节单向纤维层层数和二维编织套管层数来制备成纤维预成型体；
将纤维预成型体放入成型模具中，采用成型工艺浸渍、固化、脱模、修剪，即得到图4所示的复合材料汽车板簧。
其中，浸渍采用的树脂为热固性树脂或热塑性树脂；热固性树脂包括环氧树脂、不饱和聚酯树脂、乙烯基树脂、酚醛树脂或聚氨酯树脂。成型工艺采用真空辅助树脂传递模塑料成型工艺(VRTM)、预浸料模压成型工艺或热压罐成型工艺。
该单向纤维层和二维编织套管的材料为人造纤维或合成纤维。人造纤维可以为玻璃纤维、碳纤维或玄武岩纤维等。合成纤维可以为聚酯纤维、聚酰胺纤维或聚丙烯腈纤维等。还可以为芳纶纤维或乙纶。单向纤维层和二维编织套管的纤维束量可选用1K、3K、6K或12k中的一种或多种丝束组合，丝束预先要经过加捻处理，加捻程度根据具体要求而定。
该汽车板簧的长度范围为0.8-2m，汽车板簧的厚度范围为40-85mm。编织套管的直径为130mm-230mm，厚度为2-3mm。单向纤维层的厚度为2-3mm，宽度为130-230mm。

Claims (10)

1.一种高耐疲劳复合材料汽车板簧，其特征在于，所述高耐疲劳复合材料汽车板簧包括叠层铺放的至少一层单向纤维层以及套设于所述单向纤维层外表面的至少一层二维编织套管。
2.如权利要求1所述的高耐疲劳复合材料汽车板簧，其特征在于，所述单向纤维层和二维编织套管的材料为人造纤维或合成纤维。
3.如权利要求2所述的高耐疲劳复合材料汽车板簧，其特征在于，所述人造纤维为玻璃纤维、碳纤维或玄武岩纤维。
4.如权利要求2所述的高耐疲劳复合材料汽车板簧，其特征在于，所述合成纤维为聚酯纤维、聚酰胺纤维或聚丙烯腈纤维。
5.如权利要求2所述的高耐疲劳复合材料汽车板簧，其特征在于，所述单向纤维层和二维编织套管的材料为芳纶纤维或乙纶。
6.如权利要求1所述的高耐疲劳复合材料汽车板簧，其特征在于，所述汽车板簧的长度范围为0.8-2m。
7.如权利要求1所述的高耐疲劳复合材料汽车板簧，其特征在于，所述汽车板簧的厚度范围为40-85mm。
8.如权利要求1所述的高耐疲劳复合材料汽车板簧，其特征在于，所述编织套管的直径为130mm-230mm，厚度为2-3mm。
9.如权利要求1所述的高耐疲劳复合材料汽车板簧，其特征在于，所述至少一层单向纤维层的厚度为2-3mm，宽度为130-230mm。
10.如权利要求1至9任一项所述的高耐疲劳复合材料汽车板簧的制作方法，其特征在于，包括以下步骤：
叠层铺放所述至少一层单向纤维层；
将所述至少一层单向纤维层外套所述至少一层二维编织套管，制备成纤维预成型体；
将所述纤维预成型体放入成型模具中，采用成型工艺浸渍、固化、脱模、修剪，即得到所述复合材料汽车板簧。
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