CN108859335A - 一种新型汽车底护板及其生产工艺 - Google Patents

一种新型汽车底护板及其生产工艺 Download PDF

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CN108859335A
CN108859335A CN201810589466.8A CN201810589466A CN108859335A CN 108859335 A CN108859335 A CN 108859335A CN 201810589466 A CN201810589466 A CN 201810589466A CN 108859335 A CN108859335 A CN 108859335A
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lightweight
bottom backplate
film
thermoplastic composite
automobile bottom
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胡进
白滔
李晓明
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Hefei Tai Yu Beijing Great Automotive Components Co Ltd
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Hefei Tai Yu Beijing Great Automotive Components Co Ltd
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Abstract

本发明公开了一种新型汽车底护板及其生产工艺，底护板主体材料为一种轻质增强热塑性复合材料，其中，所述轻质增强热塑性复合材料的制备方法是：制备树脂薄膜，使用双螺杆挤出机对聚丙烯、相容剂和抗氧剂按照一定的比例进行共混，挤出的熔体通过三辊压延机的作用，被压延成薄膜，薄膜的厚度为化65mm，并将薄膜通过平板硫化机模压；然后，制备混合纤维毡，将聚丙烯粒料和相容剂、抗氧剂按照一定的比例加入到混料机中，混合后经过纺丝机纺成丙纶丝束；汽车底护板采用轻质增强热塑性复合材料制成，轻质增强热塑性复合材料的质量更轻，在零部件轻量化方面应用更广，并且，轻质增强热塑性复合材料吸音隔音效果好。

Description

一种新型汽车底护板及其生产工艺
技术领域
本发明属于汽车配件技术领域，涉及一种新型汽车底护板及其生产工艺。
背景技术
汽车底护板主要作用是当车子通过障碍路面时对发动机的油底壳、变速箱下壳体、排气歧管的三元催化部分起到一个防护的作用。防止石头或者其他坚硬的材质将上述部件蹭伤击穿，导致发动机机油泄漏，变速箱壳体损坏漏油，三元催化损坏等故障。现有的汽车底护板通常采用常规热塑性复合材料制成，质量较大，易变形，导致很多品牌的汽车在发动机下方均不设置底护板，影响汽车的使用寿命。
发明内容
本发明的目的在于提供一种新型汽车底护板及其生产工艺，采用轻质增强热塑性复合材料制成，质量更轻，吸音隔音效果好，韧性好，能够保持产品不变形。
本发明的目的可以通过以下技术方案实现：
一种新型汽车底护板，底护板主体材料为一种轻质增强热塑性复合材料，其中，所述轻质增强热塑性复合材料的制备方法是：
首先，制备树脂薄膜，使用双螺杆挤出机对聚丙烯、相容剂和抗氧剂按照一定的比例进行共混，挤出的熔体通过三辊压延机的作用，被压延成薄膜，薄膜的厚度为化65mm，并将薄膜通过平板硫化机模压成厚度为0.26mm待用；
然后，制备混合纤维毡，将聚丙烯粒料和相容剂、抗氧剂按照一定的比例加入到混料机中，混合后经过纺丝机纺成丙纶丝束；将丙绝丝束和玻璃纤维粗纱切断成一定的长度，经过初步混合后送入梳理机，经过梳理机的开松混合输出纤维薄毡，两种纤维分散成单丝状，并均匀地混合在一起；再经过铺层、针刺后得到一定面密度的混合针刺纤维毡；
再次，制备GMT实心胚料，使用三层薄膜和两层长玻璃纤维毡，经过双钢带压机预热段、热压段和冷压段，得到GMT实心胚料。
最后，制备LWRT，将制备的GMT实心胚料放入烘箱中加热，使其充分膨化，然后迅速转移至平板硫化机上，平板硫化机使用垫片定厚，模压后片材冷却定型，取出得到LWRT片材。
进一步地，所述梳理机的梳理工艺中，纤维通过锡林和罗拉的分梳作用，实现撕扯、松解纤维的目的，而针齿间的吸放纤维能够缓和由于喂入量波动导致的输出不均匀，通过反复循环、反复梳理能够使不同种类的纤维均匀混合。
进一步地，一种新型汽车底护板的生产工艺，包括以下步骤：
步骤S1，在电烘箱中将LWRT片材放入，温度控制在200-220℃之间，时间在55-65秒，将LWRT片材加热软化；
步骤S2，将烘烤后的LWRT片材叠放在模具中，然后合模，合模模压保持时间为45-55秒；
步骤S3，开模，取出模压成型的汽车底护板零件，冷却至室温。
本发明的有益效果：本发明提供的一种新型汽车底护板及其生产工艺，汽车底护板采用轻质增强热塑性复合材料制成，相比传统热塑性复合材料，轻质增强热塑性复合材料的质量更轻，在零部件轻量化方面应用更广，并且，轻质增强热塑性复合材料吸音隔音效果好，产品的舒适度方面有着明显提升，再次，轻质增强热塑性复合材料韧性好，能够保持产品不变形。
具体实施方式
下面对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其它实施例，都属于本发明保护的范围。
本发明提供了一种新型汽车底护板，主体材料为LWRT片材，LWRT具体一种轻质增强热塑性复合材料，其中，轻质增强热塑性复合材料的制备方法是：
首先，制备树脂薄膜，使用双螺杆挤出机对聚丙烯、相容剂和抗氧剂按照一定(1：0.2-0.25:0.1-0.12)的比例进行共混，其中加工温度为165℃-220℃，螺杆转速为120r/min，挤出的熔体通过三辊压延机的作用，被压延成薄膜，薄膜的厚度为化65mm，最后将薄膜通过平板硫化机模压成厚度为0.26mm待用。
然后，制备混合纤维毡，将聚丙烯粒料和相容剂、抗氧剂按照一定的比例加入到混料机中，温度为220℃，混合后经过纺丝机纺成丙纶丝束；将丙绝丝束和玻璃纤维粗纱切断成一定的长度，经过初步混合后送入梳理机，经过梳理机的开松混合输出纤维薄毡，两种纤维分散成单丝状，并均匀地混合在一起；再经过铺层、针刺后得到一定面密度的混合针刺纤维毡；其中，梳理工艺中纤维通过锡林和罗拉的分梳作用，实现撕扯、松解纤维的目的，而针齿间的吸放纤维能够缓和由于喂入量波动导致的输出不均匀，齿间的容积越大，均匀作用越强，而通过反复循环、反复梳理能够使不同种类的纤维均匀混合。
再次，使用混合纤维浸渍法制备GMT实心胚料，具体地，使用三层薄膜和两层长玻璃纤维毡，经过双钢带压机预热段、热压段和冷压段，得到GMT实心胚料。预热段的作用是使树脂薄膜加热熔融，因此温度设置为220℃；热压段的作用是在压力的作用下完成树脂熔体对纤维毡的浸溃，温度为220℃，压力位1.0MPa；冷压段的作用是在继续施加压力下通过自然对流散热的作用使片材冷却固化。和薄膜叠层法相比，混合纤维浸渍法具有浸渍容易的优点，尤其对LWRT而言，玻璃纤维含量一般较高，薄膜叠层法中的纤维毡必须满足一定的要求，例如经过充分的针刺提供垂直的浸渍通道，才能实现良好的浸渍。
最后，制备LWRT，将制备的GMT实心胚料放入220℃的烘箱中加热8mi n，使其充分膨化，然后迅速转移至平板硫化机上，平板硫化机使用垫片定厚，压力为10MPa，温度为110℃，模压2mi n后片材冷却定型，取出可得到LWRT片材。
一种新型汽车底护板的生产工艺，包括以下步骤：
步骤S1，在电烘箱中将LWRT片材放入，温度控制在200-220℃之间，时间在55-65秒，将LWRT片材加热软化。
步骤S2，将烘烤后的LWRT片材叠放在模具中，然后合模，合模模压保持时间为45-55秒。
步骤S3，开模，取出模压成型的汽车底护板零件，冷却至室温。
本发明提供的一种新型汽车底护板及其生产工艺，汽车底护板采用轻质增强热塑性复合材料制成，相比传统热塑性复合材料，轻质增强热塑性复合材料的质量更轻，在零部件轻量化方面应用更广，并且，轻质增强热塑性复合材料吸音隔音效果好，产品的舒适度方面有着明显提升，再次，轻质增强热塑性复合材料韧性好，能够保持产品不变形。
在本说明书的描述中，参考术语“一个实施例”、“示例”、“具体示例”等的描述意指结合该实施例或示例描述的具体特征、结构、材料或者特点包含于本发明的至少一个实施例或示例中。在本说明书中，对上述术语的示意性表述不一定指的是相同的实施例或示例。而且，描述的具体特征、结构、材料或者特点可以在任何的一个或多个实施例或示例中以合适的方式结合。
以上内容仅仅是对本发明结构所作的举例和说明，所属本技术领域的技术人员对所描述的具体实施例做各种各样的修改或补充或采用类似的方式替代，只要不偏离发明的结构或者超越本权利要求书所定义的范围，均应属于本发明的保护范围。

Claims (3)

1.一种新型汽车底护板，其特征在于，底护板主体材料为一种轻质增强热塑性复合材料，其中，所述轻质增强热塑性复合材料的制备方法是：
首先，制备树脂薄膜，使用双螺杆挤出机对聚丙烯、相容剂和抗氧剂按照一定的比例进行共混，挤出的熔体通过三辊压延机的作用，被压延成薄膜，薄膜的厚度为化65mm，并将薄膜通过平板硫化机模压成厚度为0.26mm待用；
然后，制备混合纤维毡，将聚丙烯粒料和相容剂、抗氧剂按照一定的比例加入到混料机中，混合后经过纺丝机纺成丙纶丝束；将丙绝丝束和玻璃纤维粗纱切断成一定的长度，经过初步混合后送入梳理机，经过梳理机的开松混合输出纤维薄毡，两种纤维分散成单丝状，并均匀地混合在一起；再经过铺层、针刺后得到一定面密度的混合针刺纤维毡；
再次，制备GMT实心胚料，使用三层薄膜和两层长玻璃纤维毡，经过双钢带压机预热段、热压段和冷压段，得到GMT实心胚料；
最后，制备LWRT，将制备的GMT实心胚料放入烘箱中加热，使其充分膨化，然后迅速转移至平板硫化机上，平板硫化机使用垫片定厚，模压后片材冷却定型，取出得到LWRT片材。
2.根据权利要求1所述的一种新型汽车底护板，其特征在于，所述梳理机的梳理工艺中，纤维通过锡林和罗拉的分梳作用，实现撕扯、松解纤维的目的，而针齿间的吸放纤维能够缓和由于喂入量波动导致的输出不均匀，通过反复循环、反复梳理能够使不同种类的纤维均匀混合。
3.根据权利要求1所述的一种新型汽车底护板的生产工艺，其特征在于，包括以下步骤：
步骤S1，在电烘箱中将LWRT片材放入，温度控制在200-220℃之间，时间在55-65秒，将LWRT片材加热软化；
步骤S2，将烘烤后的LWRT片材叠放在模具中，然后合模，合模模压保持时间为45-55秒；
步骤S3，开模，取出模压成型的汽车底护板零件，冷却至室温。
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