CN109291595A - 复合材料、汽车备胎盖及其制备方法 - Google Patents

复合材料、汽车备胎盖及其制备方法 Download PDF

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CN109291595A
CN109291595A CN201811107092.8A CN201811107092A CN109291595A CN 109291595 A CN109291595 A CN 109291595A CN 201811107092 A CN201811107092 A CN 201811107092A CN 109291595 A CN109291595 A CN 109291595A
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composite material
layer
epoxy resin
carpet
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郑伟
夏新坤
刘启超
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SHANGHAI HUAYING AUTO PARTS Co Ltd
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SHANGHAI HUAYING AUTO PARTS Co Ltd
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Abstract

本发明涉及汽车材料技术领域，具体来说是一种复合材料、汽车备胎盖及其制备方法，所述的复合材料为多层的复合层结构，所述的复合层结构由交替设有的环氧树脂层和玻纤毡层构成，所述的复合层结构为奇数层，且所述的复合层结构的顶层、底层、及复合层结构的中间一层为环氧树脂层。本发明同现有技术相比，其优点在于：本发明设计的技术方案可以有效利用目前成熟的环氧树脂预浸料工艺，改变目前现有市场上备胎盖板材的材料结构分层，使得汽车行李箱备胎盖产品重量轻了20%、厚度减少了35%，承载力达到200kg，气味的散发类得到提高，同时满足了客户在设计数据时更多的选择性，降低了成本，提高了产品竞争力优势。

Description

复合材料、汽车备胎盖及其制备方法
技术领域
本发明涉及汽车材料技术领域，具体来说是一种复合材料、汽车备胎盖及其制备方法。
背景技术
汽车行李厢备胎盖主要是用来承载物品，同时吸收从车外传来的噪音的作用，所以具有更好的承载性能，轻量化、环保的备胎盖产品将会是顾客选购汽车的一个选择因素。目前备胎盖广泛使用的材料主要为PU玻纤纸蜂窝，PP木粉板等。现在市场上的备胎盖主要面临着以下问题:
1、产品克重及厚度高：为了满足一定的承载性能要求，部分备胎盖使用高克重材料，如3000g/㎡木粉板；而对于目前使用较多的PU玻纤纸蜂窝板材，由于纸芯的存在，要满足规定的承载力设计要求，导致整个零件的厚度变厚，因此现有板材往往克重高或者厚度厚。由此造成一部分用户，特别是女性客户在拿取备胎盖时相当的费力。
2、承载力不达标：当下各大汽车厂家都在推介轻量化，但是单纯的为了零件的轻量化，使得备胎盖产品的承载力不能满足180kg的承载要求，造成顾客在使用时，当放置较重的物品时，备胎盖出现变形，甚至断裂等故障。
3、大量有害气体散发：现在汽车厂广泛使用的PU玻纤纸蜂窝板，由于蜂窝层采用的是纸芯，目前国内的纸芯来源多是加入一些粒子辅料的包装纸回料制成的瓦楞纸，而这样的芯层在高温如夏天的环境下，容易释放出甲醛，乙醛，丙酮等致癌物质，顾客尤其是妇孺长期暴露其中，会严重影响其身体健康。
发明内容
本发明的目的在于解决现有技术的不足，提供一种复合材料、汽车备胎盖及其制备方法，使得制备的备胎盖产品承载力更好，更轻量化、更低气味、克重及厚度设计范围广，成本也相对降低。
为了实现上述目的，设计一种复合材料，所述的复合材料为多层的复合层结构，所述的复合层结构由交替设有的环氧树脂层和玻纤毡层构成，所述的复合层结构为奇数层，且所述的复合层结构的顶层、底层、及复合层结构的中间一层为环氧树脂层。
优选地，所述的复合材料为五层的复合层结构，所述的五层的复合层结构依次为第一层环氧树脂层、第二层玻纤毡层、第三层环氧树脂层、第四层玻纤毡层以及第五层环氧树脂层。
本发明还设计一种所述的复合材料的制备方法，所述的方法具体如下：采用预浸料工艺，将连续玻纤毡预先浸渍树脂，然后将预浸过树脂的连续玻纤毡叠放在模具中，而后对模具加热，使树脂在熔融状态下具有流动性，并经过流动充满整个模具，冷却固结后即得到所述的复合材料。
本发明还设计一种采用所述的复合材料制备汽车备胎盖的方法，所述的方法具体如下:
a.定位：将所述的复合材料在正反面分别喷涂胶水，并对切好轮廓的毯面进行定位，然后把喷涂完胶水的复合材料放置于毯面上，而后放入保压工装中进行保压。
b.包边：待保压完成后，取出有毯面和复合材料构成的半成品，在半成品边缘处进行喷胶，然后进行包边。
c.附件装配：将步骤完成包边的半成品取出，并安装附件，以形成备胎盖成品。
优选地，所述的方法采用的毯面的克重为200-550g/m2，复合材料的克重为 1200-2400g/m2。所述的毯面为PET针刺涤纶地毯或PET针刺起绒地毯。
本发明还设计一种采用所述的复合材料制成的汽车备胎盖，所述的备胎盖包括所述的复合材料及复合材料上侧设有的毯面层。
本发明同现有技术相比，其优点在于：本发明设计的技术方案可以有效利用目前成熟的环氧树脂预浸料工艺，改变目前现有市场上备胎盖板材的材料结构分层，使得汽车行李箱备胎盖产品重量轻了20％、厚度减少了35％，承载力达到200kg，气味的散发类得到提高，同时满足了客户在设计数据时更多的选择性，降低了成本，提高了产品竞争力优势。
附图说明
图1是一实施方式中本发明复合材料的结构示意图a。
图2为一实施方式中本发明复合材料的结构示意图b。
图3为一实施方式中本发明玻纤毡的编织结构示意图。
图中：1.第一层结构 2.第二层结构 3.第三层结构 4.第四层结构 5. 第五层结构。
具体实施方式
下面结合附图对本发明作进一步说明，这种装置及方法的结构和原理对本专业的人来说是非常清楚的。应当理解，此处所描述的具体实施例仅仅用以解释本发明，并不用于限定本发明。
实施例1
参见图1和图2，在本实施方式中，本发明设计的复合材料，有五层结构，自上而下依次为高强度环氧树脂层，玻纤毡层，高强度环氧树脂层，玻纤毡层，高强度环氧树脂层，各层之间通过胶水粘接。第三层的高强度环氧树脂层为奇数层的芯层的中间一层，所述的中间一层的环氧树脂层被上下两侧的玻纤毡层上下包覆。所述的复合材料的优点在于：采用玻纤毡和环氧树脂结合，可以在满足其承载力性能下，有效降低材料的克重和厚度，实现轻量化的目的；同时还能防潮，防霉，防蛀等，同时有效降低材料的VOC散发性能。
参见图3，所述的玻纤毡层所采用的玻纤毡为长玻纤，并按照经纬方向由编织机编织而成。在所述玻纤毡内能加入一定比例的碳纤维，编织成玻纤混合毡，进一步达到轻量化的目的。
实施例2
采用本发明的方法制备某车型备胎盖，其零件尺寸为:1000*840mm，所使用复合材料，包括环氧树脂、玻纤毡，所述环氧树脂玻纤板采用五层复合层结构，分别为第一层环氧树脂、第二层玻纤毡层、第三层环氧树脂、第四层玻纤毡层以及第五层环氧树脂，即连续型玻纤通过预浸料工艺模具成型。
本实施方式中采用所述复合材料制备汽车备胎盖的方法具体如下:
1)制备环氧树脂玻纤板复合材料：采用预浸料工艺，将连续玻纤毡预先浸渍树脂，经过模腔复合冷却，贮存备用的半成品，然后将半成品料，叠放在模具中。模具加热融熔，使树脂具有一定的流动性，流动充模，冷却固结得到所需要的热塑性材料，使其具所需要的零件特征的一种复合材料。
2)定位：将得到的复合材料在正反面喷涂胶水，把切好轮廓的毯面定位好，然后把喷涂完胶水的环氧树脂板放在毯面上，在这之后放入保压工装。
3)包边：待保压完成后，取出半成品，边缘处进行喷胶，然后放入自动包边设备上进行包边。
4)附件装配：将步骤3)中完成包边的产品取出，安装拉手，装配垫块等附件，形成备胎盖成品，拉手分为上下两部分，装配时通过自身的卡接结构，将备胎盖成品卡接在上下两部分之间，进行卡接固定即可。
5)检验：对完成装配好的备胎盖成品进行质量检验，贴上合格标志，包装入库。
在一个优选的实施方式中，采用的毯面克重为200-550g/m2；采用的复合材料的克重1200-2400g/m2。
在一个优选的实施方式中，所述地毯为PET针刺涤纶地毯或PET针刺起绒地毯
实验性能:产品承載性能试验按照GMW14278-2011标准,在环境循环试验过程中加入200Kg载荷，备胎盖总成表现出的永久变形量≤3mm；产品气味性要求满足SGM TS-BD-003-2015标准要求≥6级，可达到6.5级。
产品重量比较:传统Pu玻纤纸蜂窝板工艺生产的行李箱备胎盖重量约在 2.55Kg,本材料工艺生产的备胎盖在同样厚度的情况下重量约1.85Kg，相比之下，产品重量轻27％。
用此复合材料做基材的备胎盖，气味，承载，轻量化和其它材料做基材的备胎盖性能提高20％以上，能更好的提高内饰件的品质感，让此产品在同类产品更具有竞争力。
实施例3
本实施例中，申请人通过静态滥用试验(分布载荷试验)，采用PHV1450-DV 高低温环境试验箱，在200公斤负载的情况下对本申请的复合材料进行测试，测试结果如下表：
实施例3.1的测试结果
实施例4
本实施例中，申请人通过气味袋子法，采用透明的、厚度≥0.08mm的、低密度PE薄膜包装袋作为气味袋，气味袋采用塑料扎带密封，在通风良好、没有气味干扰、温度在25度左右的室内对本申请的复合材料进行测试，测试结果如下表：
表4.1实施例4的测试结果
表4.2测试等级的划分
等级 描述
10 无味
9 刚能察觉的气味
8 明显的气味
7 明显气味，但不让人讨厌
6 可以容忍的气味
5 容忍限度的气味
4 令人反感的气味
3 令人讨厌的气味
2 很严重的气味
1 无法忍受的气味

Claims (7)

1.一种复合材料，其特征在于所述的复合材料为多层的复合层结构，所述的复合层结构由交替设有的环氧树脂层和玻纤毡层构成，所述的复合层结构为奇数层，且所述的复合层结构的顶层、底层、及复合层结构的中间一层为环氧树脂层。
2.如权利要求1所述的一种复合材料，其特征在于所述的复合材料为五层的复合层结构，所述的五层的复合层结构依次为第一层环氧树脂层、第二层玻纤毡层、第三层环氧树脂层、第四层玻纤毡层以及第五层环氧树脂层。
3.一种如权利要求1所述的复合材料的制备方法：其特征在于所述的方法具体如下：采用预浸料工艺，将连续玻纤毡预先浸渍树脂，然后将预浸过树脂的连续玻纤毡叠放在模具中，而后对模具加热，使树脂在熔融状态下具有流动性，并经过流动充满整个模具，冷却固结后即得到所述的复合材料。
4.一种采用如权利要求1所述的复合材料制备汽车备胎盖的方法，其特征在于所述的方法具体如下:
a.定位：将所述的复合材料在正反面分别喷涂胶水，并对切好轮廓的毯面进行定位，然后把喷涂完胶水的复合材料放置于毯面上，而后放入保压工装中进行保压；
b.包边：待保压完成后，取出有毯面和复合材料构成的半成品，在半成品边缘处进行喷胶，然后进行包边；
c.附件装配：将步骤完成包边的半成品取出，并安装附件，以形成备胎盖成品。
5.如权利要求4所述一种复合材料及采用该复合材料制备汽车备胎盖的方法，其特征是在于采用的毯面的克重为200-550g/m2，复合材料的克重为1200-2400g/m2。
6.如权利要求4所述一种复合材料及采用该复合材料制备汽车备胎盖的方法，其特征在于所述的毯面为PET针刺涤纶地毯或PET针刺起绒地毯。
7.一种采用如权利要求1所述的复合材料制成的汽车备胎盖，其特征在于所述的备胎盖包括所述的复合材料及复合材料上侧设有的毯面层。
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