CN111873575A - 不同种类材料的集成式结构以及集成不同种类材料的方法 - Google Patents

不同种类材料的集成式结构以及集成不同种类材料的方法 Download PDF

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Publication number
CN111873575A
CN111873575A CN201910962551.9A CN201910962551A CN111873575A CN 111873575 A CN111873575 A CN 111873575A CN 201910962551 A CN201910962551 A CN 201910962551A CN 111873575 A CN111873575 A CN 111873575A
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China
Prior art keywords
plate
integrated structure
region
resin
forming
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English (en)
Inventor
宋元基
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Hyundai Motor Co
Kia Corp
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Hyundai Motor Co
Kia Motors Corp
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Publication of CN111873575A publication Critical patent/CN111873575A/zh
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Abstract

本申请涉及不同种类材料的集成式结构以及集成不同种类材料的方法。本申请公开了通过将金属材料和纤维增强复合材料一体化而形成的不同种类材料的集成式结构,以及集成不同种类材料的方法。可以通过集成不同种类的材料(金属材料和纤维增强复合材料)来形成不同种类材料的集成式结构。该集成式结构包括:包括金属材料的第一板;第二板,其面向第一板并包括纤维增强复合材料,可以通过增强纤维浸渍有树脂而形成所述纤维增强复合材料。具体地,热粘合层可以形成在第一板和第二板的界面处,并且包括热粘合在第一板的表面上的第二板的树脂。

Description

不同种类材料的集成式结构以及集成不同种类材料的方法
技术领域
本申请涉及包括不同种类材料的集成式结构以及制造包括不同种类材料的集成式结构的方法。具体地,可以通过热粘合将金属材料和纤维增强复合材料结合在一起来形成不同种类材料的集成式结构。
背景技术
通过形成各种板来制造车身。例如,作为用于制造车身的板,使用各种材料包括诸如超高强度钢的钢板,诸如铝或镁的非铁金属板,以及诸如纤维增强塑料(FRP)的纤维增强复合材料。
纤维增强复合材料在强度、弹性模量、轻重量和稳定性方面具有优异的属性,因此作为飞机和车辆领域的重要材料之一受到关注。此外,将越来越多地使用纤维增强复合材料,并且制造量将显著增加。
纤维增强复合材料通过用树脂浸渍增强纤维(诸如碳纤维或玻璃纤维)并在增强纤维中硬化树脂而形成,例如,可以通过在无纺布形式或纺织品中形成碳纤维或玻璃纤维,接着用塑料树脂浸渍并使塑料树脂硬化而制造纤维增强复合材料。
同时,最近,随着车身强度的增加和重量的减轻,在粘接后使用了不同种类的材料。
例如,车辆的中柱在相关技术中由钢材料制成,然而,最近,钢材料和纤维增强复合材料已经结合并用于减轻重量。
为了将钢材料和纤维增强复合材料结合,首先分别形成由钢材料制成的钢板和由纤维增强复合材料制成的复合材料板作为单个产品,接着将这些不同种类板结合的方法适用于此,例如,通过热冲压结合的方法。
同时,为了结合不同种类的板,已经应用了使用紧固件的焊接或接合。然而,焊接可能不适合于不同种类的板,因此会引起一些缺陷,例如,即使焊接不同种类的材料,接合力也很小。
此外,根据使用紧固件的接合,其是使用诸如铆钉和螺栓的紧固件来紧固不同类型的板的方法,由于需要进行预处理和紧固的后处理,所以增加了工艺数量。并且,因为部分地应用了紧固件,相应地,不同种类材料的紧固力也不均匀。
上述作为本申请的相关技术的说明仅用于帮助理解本申请的背景技术,不应被理解为包括在本领域技术人员已知的相关技术中。
发明内容
在优选的方面,尤其提供了包括不同种类材料的集成式结构和制造包括不同种类材料的集成式结构的方法。以此,通过热粘合可以使诸如金属材料和纤维增强复合材料的不同种类的材料均匀地结合在一起。例如,纤维增强复合材料的树脂可以在金属材料和纤维增强复合材料之间的界面上熔融并热粘合至金属材料上。
在一个方面,提供了不同种类材料的集成式结构,其可以通过集成作为金属材料和纤维增强复合材料的不同种类材料的板而形成。集成式结构可以包括:第一板,其包括金属材料;以及第二板,其包括纤维增强复合材料。纤维增强复合材料可以包括树脂和增强纤维。优选地,纤维增强复合材料可以通过用树脂浸渍增强纤维而形成。
优选地,热粘合层可以形成在第一板和第二板的界面处,并且可以包括第二板的树脂。例如,第二板的树脂可以热粘合在第一板的表面上。
如本文所提及的,增强纤维可以包括在纤维中形成的具有定向强度(例如,在经度方向上)的材料。示例性增强纤维包括例如玻璃(如纤维玻璃),碳(例如,碳纤维,碳纸,碳纳米管或碳纳米纤维),芳族聚酰胺,玄武岩,纤维素(例如,纸或木材),或石棉。优选的增强纤维可以适当地包括玻璃纤维。
具有第一凹槽形状并且包括第一底面区域和第一侧面区域的第一弯曲部可以形成在第一板处,具有与第一弯曲部对应的第二凹槽形状并且具有第二底面区域和第二侧面区域的第二弯曲部可以形成在所述第二板处。优选地,第二弯曲部可以设置为与第一弯曲部的内侧重叠。
向第二板突出的至少一个或以上的狭缝凸缘可以适当地形成在第一板的第一侧面区域上。在与所述狭缝凸缘的位置相对应的位置处穿过第二板的第二侧面区域可以适当地形成至少一个或以上的供狭缝凸缘插入的连接孔。此外,狭缝凸缘可以适当地插入穿过连接孔,接着其端部可以适当地弯曲以与第二板的表面紧密接触。
第二板的增强纤维可以适当地包括玻璃纤维。
在一个方面,提供了通过集成不同种类的材料来生产集成式结构的方法。所述方法可以包括:准备包括金属材料的第一板和包括纤维增强复合材料的第二板,所述纤维增强复合材料包括增强纤维和树脂;将第一板和第二板依次堆叠在下模的模腔中;对下模和上模进行加热;通过使用经加热的上模对堆叠在下模的模腔中的第一板和第二板进行加热和挤压,将第一板和第二板成形为与模腔的形状对应的形状;并冷却经加热和挤压的第一板和第二板。通过使用由下模和上模组成的热冲压模具来集成不同种类材料(金属材料和纤维增强复合材料)的板以制造集成式结构的方法。
利用纤维增强复合材料中的树脂可以适当地浸渍增强纤维。
在纤维增强复合材料中,第二板的树脂可以在第一板和第二板之间的界面处熔融在第一板的表面上,在冷却时,第二板的熔融树脂可以在第一板的表面上硬化。优选地,通过冷却下模和上模,可以在第一板和第二板之间的界面处一体地形成热粘合层。
具有凹槽形状并且包括底部区域和侧部区域的弯曲部分可以形成在下模的模腔处。该方法还可以包括在准备步骤之后将第一板临时地形成为与所述弯曲部分对应的形状。
具有凹槽形状并且包括底部区域和侧部区域的弯曲部分可以形成在下模的模腔处。上模被分成中心模具部分以及至少一个或以上的侧模具部分,所述中心模具部分用于挤压底部区域,所述至少一个或以上的侧模具部分设置在中心模具部分的侧面以挤压侧部区域。优选地,第一板和第二板通过以下步骤成形,所述步骤包括:第一成形步骤,其在第一板处形成第一底面区域以对应于所述底部区域,并通过用中心模具部分挤压第一板和第二板而在第二板处形成与所述底部区域对应的第二底面区域;第二成形步骤,其在第一板上形成第一侧面区域以对应于所述侧部区域,并通过用侧模具部分横向地挤压第一板和第二板而在第二板处形成与所述侧部区域相对应的第二侧面区域。
具有凹槽形状并且包括底部区域和侧部区域的弯曲部分可以形成在下模的模腔处,在成形步骤中上模的挤压表面可以包括热膨胀系数大于上模的其他区域和下模的热膨胀系数的材料,上模的挤压表面可以通过还吸收经加热的下模的热量并且膨胀而挤压第二板。
具有凹槽形状并且包括底部区域和侧部区域的弯曲部分可以形成在下模的模腔处。在准备第一板和第二板时,优选地,以对应于形成在下模的模腔处的底部区域和侧部区域的形状,可以在第一板处形成具有凹槽形状并且包括第一底面区域和第一侧面区域的第一弯曲部,具有第二凹槽形状并且包括第二底面区域和第二侧面区域的第二弯曲部可以形成于第二板。向第二板突出的至少一个或以上的狭缝凸缘可以形成在第一板的第一侧面区域上,在与所述狭缝凸缘的位置相对应的位置处穿过第二板的第二侧面区域形成至少一个或以上的供狭缝凸缘插入的连接孔。
第一板和第二板可以被堆叠使得第一板的狭缝凸缘可以在堆叠步骤中插入穿过第二板的连接孔,并且在成形时通过上模的挤压可以使狭缝凸缘的端部弯曲,从而与第二板的表面紧密接触。
根据本申请的各种示例性实施方案,由金属材料制成的板和由纤维增强复合材料制成的板可以通过在热冲压模具中加热和挤压两个板而形成最终产品形状,其中,纤维增强复合材料的树脂可以通过加热而热粘合到金属材料上。因此,可以通过一个工艺,以集成式结构或最终产品形状形成不同种类的材料。这样,可以减少使用不同种类的材料制造车辆时的工艺的数量。此外,在不同种类的材料之间的界面整个上可以预期均匀的粘合力。
下面讨论本申请的其它方面。
附图说明
通过随后结合附图所呈现的具体描述将会更为清楚地理解本申请的以上和其它方面、特征以及优点,在这些附图中:
图1示出了根据本申请示例性实施方案的不同种类材料的示例性集成式结构的截面图;
图2示出了根据本申请示例性实施方案的不同种类材料的示例性集成式结构的截面图;
图3示出了根据本申请示例性实施方案的制造不同种类材料的示例性集成式结构的示例性过程;
图4示出了根据本申请示例性实施方案的制造不同种类材料的示例性集成式结构的示例性过程;
图5示出了根据本申请示例性实施方案的不同种类材料的示例性集成式结构的截面;
图6示出了根据本申请示例性实施方案的不同种类材料的示例性集成式结构的截面;
图7示出了根据本申请示例性实施方案的制造不同种类材料的示例性集成式结构的示例性过程;
图8示出了根据本申请示例性实施方案的制造不同种类材料的示例性集成式结构的示例性过程;以及
图9示出了根据本申请示例性实施方案的制造不同种类材料的示例性集成式结构的示例性过程。
具体实施方式
以下将参考所附附图对本申请的实施方案进行具体描述。然而,本申请不限于以下实施方案,并且可以以彼此不同的各种方式实现,并且提供实施方案以完成本申请并且完全地向本领域技术人员告知本申请的范围。在附图中,相同的部件被赋予相同的附图标记。
本文所用的术语仅为了描述特定实施方案的目的,并不旨在限制本申请。正如本文中所使用的,单数形式“一”、“一个”和“该”旨在也包括复数形式,除非上下文另有明确指示。还将理解当在本说明书中使用术语“包含”,“包括”,“具有”等时,指明存在所述特征、范围、数值、步骤、操作、元件和/或组件,但是不排除存在或加入一个或以上其它的特征、范围、数值、步骤、操作、元件、组件和/或其群体。
应当理解,此处所使用的术语“车辆”或“车辆的”或其它类似术语通常包括机动车辆,例如包括运动型多用途车辆(SUV)、大客车、卡车、各种商用车辆的乘用汽车,包括各种舟艇、船舶的船只,航空器等等,并且包括混合动力车辆、电动车辆、插电式混合动力电动车辆、氢动力车辆以及其它替代性燃料车辆(例如源于非石油的能源的燃料)。正如此处所提到的,混合动力车辆是具有两种或更多动力源的车辆,例如汽油动力和电力动力两者的车辆。
此外,除非特别声明或者从上下文显而易见的,本文所使用的术语“约”被理解为在本领域的正常公差范围内,例如在平均值的2个标准偏差内。“约”可被理解为在指定值的10%、9%、8%、7%、6%、5%、4%、3%、2%、1%、0.5%、0.1%、0.05%或0.01%之内。除非从上下文另有明确限定,本文提供的所有数值通过术语“约”来进行修饰。
除非另有声明,本文使用的所有术语(包括技术术语和科技术语)具有正如本申请所属领域的技术人员通常理解的相同含义。将进一步理解,诸如在常用词典中定义的那些术语应被解释为具有与其在相关领域和本申请的上下文中的含义一致的含义,并且将不被解释为理想化的,或者过于字面的意义,除非在本文明确定义。
在下文中,将参考附图给出根据本申请的各种示例性实施方案的示例性无线电波穿透型多层光学涂层的详细描述。
图1示出了根据本申请示例性实施方案的不同种类材料的示例性集成式结构的截面图。
在如图1所示的不同种类材料的集成式结构中,可以通过将金属材料和纤维增强复合材料集成而形成该集成式结构,由金属材料制成的第一板100和面对第一板100的第二板200可以彼此接触地结合,由通过将增强纤维201浸渍有树脂202形成的纤维增强复合材料制成所述第二板200。
诸如超高强度钢的钢板等的钢材料或诸如铝或镁的非铁金属板可以应用于第一板100的金属材料。
与第一板100相比具有低比重和类似强度水平的纤维增强复合材料可以应用于第二板200。
此外,可以通过在增强纤维201中浸渍树脂202来形成第二板200。作为形成第二板200的增强纤维201和树脂202,可以选择性地应用能够形成纤维增强复合材料的各种增强纤维和树脂。
然而,用于第二板200的纤维增强复合材料可以具有非导电性,以防止因与金属材料第一板100(其由金属材料制成)的电位差引起的腐蚀。因此,施加至第二板200的增强纤维201和树脂202可以具有非导电性。
因此,应用至第二板200的增强纤维201可以是玻璃纤维,树脂202可以是各种非导电树脂。作为玻璃纤维,所有类型的短纤维、长纤维和连续纤维可以单独地使用或组合使用。
同时,本申请的特征在于通过热粘合将第一板100和第二板200粘合。例如,不使用特定的粘合剂或紧固件,通过加热和挤压可以形成热粘合。
因此,通过将第二板200的树脂202热粘合在第一板100的表面上,可以在第一板100和第二板200的界面处形成热粘合层203。
同时,第一板100和第二板200可以形成为与要使用的产品对应的形状,并且可以根据产品的形状以各种方式进行调节。例如,通过将第一板100和第二板200彼此结合而形成的不同种类材料的集成式结构可以应用于作为车辆的车身结构的一部分的中柱。因此,通常在相关技术中使用的金属材料的中柱可以由不同种类材料的集成式结构形成的中柱所代替。
通过将第一板100和第二板200彼此结合而形成的不同种类材料的集成式结构不仅可以形成为扁平产品的形状,而且可以形成为各种形状,因此各种形状的弯曲部可以形成在不同种类材料的集成式结构中。
图2示出了根据本申请实施方案的不同种类材料的示例性集成式结构的截面图,其中弯曲部可以形成在不同种类材料的集成式结构中。
构成不同种类材料的集成式结构的第一板100和第二板200可以通过热粘合而一体化,并且弯曲部可以在第一板100和第二板200中以对应的形状形成。
换句话说,具有凹槽形状并由第一底面区域111和第一侧面区域112组成的第一弯曲部110形成于第一板100处,具有与第一弯曲部110对应的凹槽形状并且由第二底面区域211和第二侧面区域212构成的第二弯曲部210形成于第二板200处。因此,第二弯曲部210可以适当地设置为与第一弯曲部110的内侧重叠。
在形成第一弯曲部110和第二弯曲部210的同时,第一板100和第二板200可以适当地通过热粘合而结合。
为此,可以应用现有技术中用于形成金属材料板的热冲压模具,但本申请不限制于此。
图3示出了根据本申请示例性实施方案的制造不同种类材料的集成式结构的示例性过程。
如图3所示,根据本申请示例性实施方案的集成不同种类材料的示例性方法可用于利用由下模10和上模20组成的热冲压模具来制造不同种类材料的集成式结构。具有凹槽形状并由底部区域31a和侧部区域31b组成的弯曲部分31可以形成在热冲压模具的模腔30处,即下模10的模腔30处。
首先,可以准备由金属材料制成的第一板100,并且可以准备第二板200(准备步骤),所述第二板200由通过在增强纤维201中浸渍树脂202而形成的纤维增强复合材料制成。
在该步骤中,第一板100和第二板200可以具有平板形状。
第一板100和第二板200可以依次地堆叠在下模10的模腔30中(堆叠步骤)。
在堆叠第一板100和第二板200之后,可以加热下模10和上模20(加热步骤)。
在该步骤中,可以控制下模10和上模20的加热温度,使得第二板200的树脂202可以熔融并热粘合至第二板200与第一板100(其由金属材料制成)的界面。例如,下模10和上模20的加热温度可以是约200℃,在该温度下树脂可以熔融。显然,下模10和上模20的加热温度可以根据应用至第二板200的树脂202的种类而不同地改变。
在下模10和上模20被加热到期望水平之后,通过使用加热的上模20而对板进行加热,从而堆叠在下模10的模腔30中的第一板100和第二板200可以形成为与模腔30的形状相对应的形状(成形步骤)。
当第一板100和第二板200形成为对应于下模10和上模20的模腔30的形状时,第二板200的树脂202可以熔融并热粘合至与第一板100的界面上。
具体地,通过在由下模10和上模20构成的热冲压模具的模腔30处形成的弯曲部分31,第一弯曲部110和第二弯曲部210可以分别形成于第一板100和第二板200上。
同时,可以首先执行加热步骤,接着可以执行成形步骤,但是也可以同时执行加热步骤和成形步骤。
通过下模10和上模20对板进行挤压而形成所需形状的第一板100和第二板200之后,可以适当地冷却经加热和挤压的第一板100和第二板200(冷却步骤)。因此,在第一板100和第二板200之间的界面处可以形成热粘合层203,由此第一板100和第二板200可以通过热粘合而一体化。
换句话说,当在冷却步骤中冷却下模10和上模20时,第二板200的熔融树脂可以在第一板100的表面上硬化,由此热粘合层203可以一体地形成在第一板100和第二板200之间的界面处。
同时,当具有第一弯曲部110(其具有第一凹槽形状并由第一底面区域111和第一侧面区域112组成)的第一板100和具有第二弯曲部210(其具有对应于第一弯曲部110形状的第二凹槽形状,并且由第二底面区域211和第二侧面区域212组成)的第二板200利用热冲压模具可以热粘合时,由于第一弯曲部110和第二弯曲部210的形状,因此无法对第一侧面区域112和第二侧面区域212施加足够的挤压力,使得第一侧面区域112和第二侧面区域212之间的结合力可能不足。
因此,各种补充手段可以应用于本申请,以防止因第一侧面区域112和第二侧面区域212之间的结合力不足产生的第一板100和第二板200的非一体化。
首先,可以在成形步骤之前临时地形成第一板100,以防止第一侧面区域112和第二侧面区域212之间的非一体化(其因当由金属材料制成的第一板100被上模20挤压时的不充分成形而引起)。
图4示出了根据本申请另一示例性实施方案的制造不同种类材料的集成式结构的示例性过程。
如图所示,在准备步骤之后,第一板100可以临时地形成为与形成在下模10和上模20的模腔30处的弯曲部分31相对应的形状(临时成形步骤)。
当临时地形成第一板100时,可以在第一板100处首先形成第一弯曲部110,其形状与弯曲部分31的形状精确对应,但是相比弯曲部分31的形状第一弯曲部110也可以形成为较少弯曲,即,以弯曲部分31的形状和板形状之间的程度弯曲。
在成形步骤之前将第一板100临时地形成为所需的程度之后,可以在成形步骤中适当地挤压并形成最终所需的形状,从而形成所需尺寸的第一板100并将第一板100和第二板200一体化。
另一方面,可以通过改变第一板100和第二板200的形状来引导机械组合,以作为用于防止第一板100和第二板200的非一体化的补充手段。
图5和图6示出了根据本申请另一示例性实施方案的不同种类材料的示例性集成式结构的截面图;图7示出了根据本申请另一示例性实施方案的制造不同种类材料的示例性集成式结构的示例性过程。
为了引导第一板100和第二板200的机械组合,在本申请中,可以在第一板100的第一侧面区域112上形成向第二板200突出的至少一个或以上的狭缝凸缘120。
此外,可以在与狭缝凸缘120的位置相对应的位置处穿过第二板200的第二侧面区域212形成至少一个或以上的连接孔220,狭缝凸缘120插入穿过所述连接孔220。
因此,当第一板100和第二板200堆叠时,狭缝凸缘120可以插入穿过连接孔220,接着其端部可以弯曲以与第二板200的表面紧密接触。
通过将形成在第一板100上的狭缝凸缘120弯曲并使其接触到第二板的表面上,第一板100和第二板200可以机械地组合而无需诸如铆钉和螺栓的特定紧固件。显然,热粘合层203可以通过热粘合一体地形成在第一板100和第二板200之间的界面处,并且通过弯曲狭缝凸缘120形成的组合补充了热粘合层203的一体化。
为此,在准备步骤中,具有凹槽形状并由第一底面区域111和第一侧面区域112组成的第一弯曲部110可以形成在第一板100处,具有凹槽形状并由第二底面区域211和第二侧面区域212构成的第二弯曲部210可以在第二板200处形成为对应于形成在弯曲部分31处的底部区域31a和侧部区域31b的形状。
此外,向第二板200突出的至少一个或以上的狭缝凸缘120可以形成在第一板100的第一侧面区域112处,并且在第二板200的第二侧面区域212中与狭缝凸缘120的位置对应的位置处可以形成至少一个或以上的连接孔220,狭缝凸缘120插入穿过所述连接孔220。
接下来,在堆叠步骤中,第一板100和第二板200可以堆叠,使得第一板100的狭缝凸缘120可以插入穿过第二板200的连接孔220,并且在成形步骤中狭缝凸缘120的端部通过用上模20挤压而弯曲以紧密接触于第二板200的表面。在成形步骤中,还可以执行第一板100和第二板200的热粘合。
另一方面,可以通过改变由下模10和上模20组成的热冲压模具来提高集成效率,作为用于防止第一板100和第二板200的非一体化的补充手段。
图8和9示出了以另一种方式制造根据本申请示例性实施方案的不同种类材料的示例性集成式结构的示例性过程。
首先,如图8所示,上模20可以被分成用于挤压底部区域31a的中心模具部分21以及至少一个或以上的侧模具部分22,所述侧模具部分22可以设置在中心模具部分21的侧面以挤压侧部区域31b。
在成形步骤中,可以在第一板100处形成第一底面区域111以对应于底部区域31a,并且可以通过利用中心模具部分21对第一板100和第二板200进行挤压而在第二板200处形成对应于底部区域31a的第二底面区域211(第一成形步骤)。
首先形成第一底面区域111和第二底面区域211之后,接着可以在第一板100处形成第一侧面区域112以对应于侧部区域31b,并且可以通过利用侧模具部分22横向地挤压第一板100和第二板200而在第二板200处形成对应于侧部区域31b的第二侧面区域212(第二成形步骤)。
通过分别地形成第一底面区域111和第二底面区域211以及第一侧面区域112和第二侧面区域212,可以将压力充分地施加到第一侧面区域112和第二侧面区域212,第一板100和第二板200可以以所需的尺寸形成,并且可以在界面上充分地发生热粘合。
进一步地,如图9所示,通过利用热膨胀系数大于下模10和上模20的其他区域的热膨胀系数的材料来制造上模20的挤压表面23,使得上模20的挤压表面23在成形步骤中比其它区域膨胀得更多,从而可以增加挤压下模10的挤压力。
因此,上模20的挤压表面23通过还吸收经加热的下模10热量而膨胀并以更大压力对第二板200进行挤压,从而可以对第一底面区域111、第二底面区域211、第一侧面区域112和第二侧面区域212施加足够的压力。以此,第一板100和第二板200可以以期望的尺寸形成并且可以在界面上充分地发生热粘合。
尽管以上参照附图和优选实施方案描述了本申请,但是本申请不限于此,而仅通过所附权利要求而被限定。因此,本领域技术人员可以在不脱离权利要求的精神的情况下以各种方式改变和修改本申请。

Claims (16)

1.一种集成式结构,包括:
第一板,其包括金属材料;以及
第二板,其包括纤维增强复合材料,其中纤维增强复合材料包括树脂和增强纤维;
其中,热粘合层形成在第一板和第二板的界面处,并且包括热粘合在第一板表面上的第二板的树脂。
2.根据权利要求1所述的集成式结构,其中,利用树脂浸渍所述增强纤维。
3.根据权利要求1所述的集成式结构,其中,具有第一凹槽形状并且包括第一底面区域和第一侧面区域的第一弯曲部形成在所述第一板处;具有与所述第一弯曲部对应的第二凹槽形状并且包括第二底面区域和第二侧面区域的第二弯曲部形成在所述第二板处,并且所述第二弯曲部设置成与第一弯曲部的内侧重叠。
4.根据权利要求3所述的集成式结构,其中,向第二板突出的至少一个或以上的狭缝凸缘形成在第一板的第一侧面区域上,
在与所述狭缝凸缘的位置相对应的位置处穿过第二板的第二侧面区域形成至少一个或以上的供狭缝凸缘插入的连接孔;
狭缝凸缘插入穿过所述连接孔,接着其端部弯曲以与第二板的表面紧密接触。
5.根据权利要求1所述的集成式结构,其中,利用树脂浸渍所述增强纤维。
6.一种制造集成式结构的方法,其使用由下模和上模组成的热冲压模具,所述方法包括:
准备包括金属材料的第一板和包括纤维增强复合材料的第二板,其中纤维增强复合材料包括增强纤维和树脂;
将第一板和第二板依次堆叠在下模的模腔中;
对下模和上模进行加热;
通过使用经加热的上模对堆叠在下模的模腔中的第一板和第二板进行加热和挤压,将第一板和第二板成形为与下模的模腔的形状对应的形状;以及
冷却经加热和挤压的第一板和第二板。
7.根据权利要求6所述的制造集成式结构的方法,其中,所述增强纤维浸渍有树脂。
8.根据权利要求6所述的制造集成式结构的方法,其中,在成形第一板和第二板时,第二板的树脂在第一板和第二板之间的界面处熔融在第一板的表面上;
在冷却步骤中,第二板的熔融树脂在第一板的表面上硬化,由此通过冷却下模和上模而在第一板和第二板之间的界面处一体地形成热粘合层。
9.根据权利要求6所述的制造集成式结构的方法,其中,在下模的模腔处形成弯曲部分,所述弯曲部分具有凹槽形状并且包括底部区域和侧部区域。
10.根据权利要求9所述的制造集成式结构的方法,其进一步包括:在准备步骤之后将第一板临时地形成为与所述弯曲部分对应的形状。
11.根据权利要求6所述的制造集成式结构的方法,其中,在下模的模腔处形成弯曲部分,所述弯曲部分具有凹槽形状并且包括底部区域和侧部区域;
上模被分成中心模具部分以及至少一个或以上的侧模具部分,所述中心模具部分用于挤压底部区域,所述至少一个或以上的侧模具部分设置在中心模具部分的侧面以挤压侧部区域。
12.根据权利要求11所述的制造集成式结构的方法,其中,第一板和第二板通过以下步骤成形:
第一成形步骤,其在第一板上形成第一底面区域以对应于所述底部区域,并通过用中心模具部分挤压第一板和第二板而在第二板处形成与所述底部区域相对应的第二底面区域;以及
第二成形步骤,其在第一板上形成第一侧面区域以对应于所述侧部区域,并通过用侧模具部分横向地挤压第一板和第二板而在第二板处形成与所述侧部区域相对应的第二侧面区域。
13.根据权利要求6所述的制造集成式结构的方法,其中,在所述下模的模腔处形成弯曲部分,所述弯曲部分具有凹槽形状并且包括底部区域和侧部区域;
上模的挤压表面包括热膨胀系数大于上模的其它区域和下模的热膨胀系数的材料;
在成形步骤中,上模的挤压表面通过还吸收经加热的下模的热量并且膨胀而对第二板进行挤压。
14.根据权利要求6所述的制造集成式结构的方法,其中,在所述下模的模腔处形成弯曲部分,所述弯曲部分具有凹槽形状并且包括底部区域和侧部区域;
在准备所述第一板和第二板时,
以对应于形成在下模的模腔的底部区域和侧部区域的形状,具有第一凹槽形状并包括第一底面区域和第一侧面区域的第一弯曲部形成于第一板,具有第二凹槽形状并且包括第二底面区域和第二侧面区域的第二弯曲部形成于第二板,
向第二板突出的至少一个或以上的狭缝凸缘形成在第一板的第一侧面区域上,
在与所述狭缝凸缘的位置相对应的位置处穿过第二板的第二侧面区域形成至少一个或以上的供狭缝凸缘插入的连接孔。
15.根据权利要求14所述的制造集成式结构的方法,其中,在堆叠步骤中,堆叠第一板和第二板,使得所述第一板的狭缝凸缘插入穿过所述第二板的连接孔;
在成形步骤中,通过用上模挤压使所述狭缝凸缘的端部弯曲,从而与第二板的表面紧密接触。
16.一种车辆,其包括根据权利要求1所述的集成式结构。
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