CN111516303A - 一种车厢板及其制备方法 - Google Patents

一种车厢板及其制备方法 Download PDF

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CN111516303A
CN111516303A CN202010259197.6A CN202010259197A CN111516303A CN 111516303 A CN111516303 A CN 111516303A CN 202010259197 A CN202010259197 A CN 202010259197A CN 111516303 A CN111516303 A CN 111516303A
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潘广镇
余启勇
董会娜
刘光亚
姚栋嘉
李倩
杨红霞
张东生
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Gongyi Van Research Yihui Composite Material Co Ltd
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Abstract

本发明属于车厢板的制备技术领域，公开一种车厢板及其制备方法。包括第一及第二面板层、夹芯层、骨架支撑层，夹芯层包括若干个泡沫块，骨架支撑层为网格状，所述骨架支撑层设置在第一面板层与第二面板层之间，泡沫块填充于骨架支撑层的网格中，骨架支撑层与第一面板层、第二面板层一体成型。制备步骤如下：由下至上依次将离型膜‑第一脱模布‑第一纤维增强树脂预浸带‑网格状纤维增强树脂预浸带框进行铺层；将树脂泡沫组合物倒入网格状纤维增强树脂预浸带框中；铺设第二纤维增强树脂预浸带‑第二脱模布；热压固化成型，脱模处理，即可。本发明车厢板，力学性能大大提高。

Description

一种车厢板及其制备方法
技术领域
本发明属于车厢板的制备技术领域，具体涉及一种车厢板及其制备方法。
背景技术
随着社会发展的需求，汽车已经成为生活不可或缺的一种交通工具。为了满足高质量的生活使用需求，汽车轻量化是目前汽车行业及新材料行业研究的热点。汽车轻量化是保证汽车硬度和安全性能的前提下，尽可能地降低汽车的整体质量，从而提高汽车的动力利用率，减少燃料消耗，降低排气污染。另外汽车轻量化后其加速性能也将得到提高，而在碰撞时由于惯性小，制动距离也将减少。此外，车辆每减轻100公斤，二氧化碳排放可减少约5g/公里。可见汽车轻量化的节能环保效益不亚于汽车发动机节油技术产生的效益。在车身及其附件材料，新材料及新工艺的需求逐步提升，轻量化的箱体应运而生。
厢式货车是一类具有独立封闭结构的车厢，或与驾驶室连成一体的整体式封闭结构车厢，主要用于载运货物的商用车。传统厢式货车的车厢板可采用彩钢板、铝平板或铝合金瓦楞制成，不仅重量重、价格贵，且热传导速度快，不利于保持车厢板的低温。
与金属骨架相比，目前多采用玻璃纤维增强复合材料作为面板层，泡沫材料作为夹心层的车厢体。玻璃纤维增强复合材料车厢板既符合汽车整车轻量化时代发展的趋势，又复合国家环保节能方针政策，更重要的是符合我国目前的国情，因此具有良好的发展应用前景。然而目前制备得到的玻璃纤维增强复合材料具有粘结强度低、易鼓泡等缺点。夹心材料多采用蜂窝芯材、木质芯材、有机泡沫等，但是目前普遍存在其与玻璃纤维增强复合材料面板结合强度较低，出现分层等现象，从而降低整体车厢板的力学性能。
发明内容
为克服现有技术中存在的不足之处，本发明的目的旨在提供一种车厢板及其制备方法。
为实现上述目的，本发明采取的技术方案如下：
一种车厢板，包括第一面板层、第二面板层、夹芯层、骨架支撑层，夹芯层包括若干个泡沫块，骨架支撑层为网格状，所述骨架支撑层设置在第一面板层与第二面板层之间，泡沫块填充于骨架支撑层的网格中，骨架支撑层与第一面板层、第二面板层一体成型；所述第一面板层、第二面板层和骨架支撑层同时为纤维增强树脂复合材料；所述泡沫块为聚氨酯泡沫块、PVC泡沫块或酚醛泡沫块。
较好地，所述纤维增强树脂复合材料中的纤维为玻璃纤维、碳纤维、硼纤维或芳纶，树脂为不饱和聚酯、乙烯基树脂、聚氨酯树脂、环氧树脂或酚醛树脂。
较好地，第一面板层的厚度为0.5-5 mm，第二面板层的厚度为0.5-5 mm，骨架支撑层的厚度为5-50 mm。
较好地，骨架支撑层的网格形状为四边形、五边形或六边形。
制备方法，制备步骤如下：
（1）、由下至上依次将离型膜-第一脱模布-第一纤维增强树脂预浸带-网格状纤维增强树脂预浸带框进行铺层；
（2）、将与泡沫块对应的树脂泡沫组合物倒入网格状纤维增强树脂预浸带框的网格中；
（3）、在网格状纤维增强树脂预浸带框上表面依次铺设第二纤维增强树脂预浸带-第二脱模布，至此获得层叠体；
（4）、将步骤（3）铺层完成的层叠体置于热压机上热压固化成型；
（5）、固化完成后脱模处理，即得到车厢板；
较好地，所述第一纤维增强树脂预浸带、第二纤维增强树脂预浸带和网格状纤维增强树脂预浸带框中的纤维和树脂分别对应为纤维增强树脂复合材料中的纤维和树脂。
较好地，所述网格状纤维增强树脂预浸带框的网格形状为四边形、五边形或六边形。
较好地，步骤（4）中，热压固化成型的压力为0.5-5 Mpa，固化温度为20-180 ℃，固化时间为0.5-12 h。
较好地，所述离型膜为PET膜、PE膜、PI膜或OPP膜；所述第一脱模布和第二脱模布为聚四氟乙烯脱模布、尼龙66脱模布、尼龙6脱模布或聚酯脱模布。
本发明中，所述“与泡沫块对应的树脂泡沫组合物”为聚氨酯泡沫组合物、PVC泡沫组合物、酚醛泡沫组合物，是指发泡前的原料组成，可从现有技术中成熟的泡沫制备工艺中任选一种。比如聚氨酯泡沫组合物参考中国发明专利“一种耐温硬质聚氨酯泡沫的制备方法”，专利号ZL200610130410.3；PVC泡沫组合物参考中国发明专利“一种抗静电PVC泡沫塑料及其制备方法”，专利号ZL201410257506.0；酚醛泡沫组合物参考中国发明专利“一种酚醛泡沫板材的制备方法”，专利号ZL201110010748.6。本发明所述“第一纤维增强树脂预浸带”、“第二纤维增强树脂预浸带”和“网格状纤维增强树脂预浸带框”均可按现有技术制备获得或通过市购获得。
有益效果：
（1）、本发明制备得到的车厢板，除了具有轻质保温的特点，其力学性能相比现有的车厢板制备技术力学性能大大提高；
（2）、本发明对夹芯层采用泡沫块相互拼接的方式，通过将树脂发泡组合物在网格状纤维增强树脂预浸带框中原位发泡成型，经过热压将其与面板层一体化固化成型，在各泡沫块之间形成骨架支撑层，骨架支撑层为纤维增强树脂复合材料，其良好的力学性能能够对泡沫块起到支撑作用，大大提高片夹心层的力学性能，进而提高整个芯材的力学性能，使得到的车厢板材具备优异的抗冲抗压性能，扩大板材的应用场合；
（3）、本发明采用骨架支撑层与面板层一体固化成型的方式大大提高了夹心层与面板层的结合强度，避免传统的粘结方法造成的夹心层与面板层由于结合强度低分层的现象；
（4）、本发明车厢板的制备一体固化成型，成型周期短，操作简单方便，制备得到的厢体表面平整光洁，增加美观度，能够满足大规模产业化的需求，可以根据需求制备得到不同大小、厚度的车厢板，扩大其在不同车型车厢体上的应用范围。
附图说明
图1：本发明车厢板的结构示意图；
图2：网格状纤维增强树脂预浸带框（网格形状为正四边形）的主视结构示意图；
图3：网格状纤维增强树脂预浸带框（网格形状为正四边形）的俯视结构示意图；
图中：1-第一面板层；2-第二面板层；3-泡沫块；4-骨架支撑层；5-纤维增强树脂预浸带；6-网格。
具体实施方式
以下结合具体实施例，对本发明做进一步说明。应理解，以下实施例仅用于说明本发明而非用于限制本发明的范围。
实施例1
如图1所示，一种车厢板，包括第一面板层1、第二面板2、夹芯层、骨架支撑层4，所述夹芯层设置在第一面板层1与第二面板2之间，夹芯层包括若干个泡沫块3，骨架支撑层4为网格状（网格形状为正四边形），所述骨架支撑层4设置在第一面板层4与第二面板层4之间，泡沫块3填充于骨架支撑层4的网格中，骨架支撑层4与第一面板层1、第二面板2一体固化成型；
所述第一面板层1、第二面板2和骨架支撑层4同时为玻璃纤维增强不饱和聚酯复合材料；所述泡沫块3为PVC泡沫块；第一面板层1的厚度为5 mm，第二面板2的厚度为5 mm，所述骨架支撑层4的厚度为5 mm。
所述车厢板的制备方法，制备步骤如下：
（1）、铺层：由下至上依次将离型膜-第一脱模布-第一纤维增强树脂预浸带（片状）-网格状纤维增强树脂预浸带框（网格形状为正四边形）进行铺层；所述网格状纤维增强树脂预浸带框的结构见图2和图3，包括纤维增强树脂预浸带5，纤维增强树脂预浸带5上均布有若干个网格6；
（2）、将与泡沫块3对应的PVC树脂泡沫组合物（参考专利号ZL201410257506.0中的实施例1所公开的原料组成）倒入网格状纤维增强树脂预浸带框的网格6中；
（3）、在网格状纤维增强树脂预浸带框上表面依次铺设第二纤维增强树脂预浸带（片状）-第二脱模布，至此获得层叠体；
（4）、将步骤（3）铺层完成的层叠体置于热压机上在1 Mpa、80 ℃条件下固化1.5 h；
（5）、固化完成后脱模处理，即得车厢板；
所述第一纤维增强树脂预浸带、第二纤维增强树脂预浸带为玻璃纤维增强不饱和聚酯预浸带，网格状纤维增强树脂预浸带框为网格状玻璃纤维增强不饱和聚酯预浸带框。
所述离型膜为PI膜；所述第一脱模布和第二脱模布为尼龙66脱模布；
本实施例制备的车厢板的密度为0.30 g/cm3，压缩强度为3.6 Mpa。

Claims (8)

1.一种车厢板，其特征在于：所述车厢板包括第一面板层、第二面板层、夹芯层、骨架支撑层，夹芯层包括若干个泡沫块，骨架支撑层为网格状，所述骨架支撑层设置在第一面板层与第二面板层之间，泡沫块填充于骨架支撑层的网格中，骨架支撑层与第一面板层、第二面板层一体成型；所述第一面板层、第二面板层和骨架支撑层同时为纤维增强树脂复合材料；所述泡沫块为聚氨酯泡沫块、PVC泡沫块或酚醛泡沫块。
2.如权利要求1所述的车厢板，其特征在于：所述纤维增强树脂复合材料中的纤维为玻璃纤维、碳纤维、硼纤维或芳纶，树脂为不饱和聚酯、乙烯基树脂、聚氨酯树脂、环氧树脂或酚醛树脂。
3.如权利要求1所述的车厢板，其特征在于：第一面板层的厚度为0.5-5 mm，第二面板层的厚度为0.5-5 mm，骨架支撑层的厚度为5-50 mm。
4.如权利要求1所述的车厢板，其特征在于：骨架支撑层的网格形状为四边形、五边形或六边形。
5.一种如权利要求1~4之任一项所述的车厢板的制备方法，其特征在于，制备步骤如下：
（1）、由下至上依次将离型膜-第一脱模布-第一纤维增强树脂预浸带-网格状纤维增强树脂预浸带框进行铺层；
（2）、将与泡沫块对应的树脂泡沫组合物倒入网格状纤维增强树脂预浸带框的网格中；
（3）、在网格状纤维增强树脂预浸带框上表面依次铺设第二纤维增强树脂预浸带-第二脱模布，至此获得层叠体；
（4）、将步骤（3）铺层完成的层叠体置于热压机上热压固化成型；
（5）、固化完成后脱模处理，即得车厢板；
所述第一纤维增强树脂预浸带、第二纤维增强树脂预浸带和网格状纤维增强树脂预浸带框中的纤维和树脂分别对应为纤维增强树脂复合材料中的纤维和树脂。
6.如权利要求5所述的车厢板的制备方法，其特征在于：所述网格状纤维增强树脂预浸带框的网格形状为四边形、五边形或六边形。
7.如权利要求5所述的车厢板的制备方法，其特征在于：步骤（4）中，热压固化成型的压力为0.5-5 Mpa，固化温度为20-180 ℃，固化时间为0.5-12 h。
8.如权利要求5所述的车厢板的制备方法，其特征在于：所述离型膜为PET膜、PE膜、PI膜或OPP膜；所述第一脱模布和第二脱模布为聚四氟乙烯脱模布、尼龙66脱模布、尼龙6脱模布或聚酯脱模布。
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CN112726855A (zh) * 2020-12-30 2021-04-30 巩义市泛锐熠辉复合材料有限公司 一种高效隔热保温板及其制备方法
CN113547765A (zh) * 2021-07-12 2021-10-26 重庆泛锐科技有限公司 高强度复合板材及其制备方法
CN117141012A (zh) * 2023-10-31 2023-12-01 廊坊市飞泽复合材料科技有限公司 一种泡沫材料增强方法

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112726855A (zh) * 2020-12-30 2021-04-30 巩义市泛锐熠辉复合材料有限公司 一种高效隔热保温板及其制备方法
CN113547765A (zh) * 2021-07-12 2021-10-26 重庆泛锐科技有限公司 高强度复合板材及其制备方法
CN117141012A (zh) * 2023-10-31 2023-12-01 廊坊市飞泽复合材料科技有限公司 一种泡沫材料增强方法
CN117141012B (zh) * 2023-10-31 2024-05-24 廊坊市飞泽复合材料科技有限公司 一种泡沫材料增强方法

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