CN112757740B - 一种高强度轻量化车厢板及其制备方法 - Google Patents
一种高强度轻量化车厢板及其制备方法 Download PDFInfo
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- CN112757740B CN112757740B CN202011602547.0A CN202011602547A CN112757740B CN 112757740 B CN112757740 B CN 112757740B CN 202011602547 A CN202011602547 A CN 202011602547A CN 112757740 B CN112757740 B CN 112757740B
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- Laminated Bodies (AREA)
Abstract
本发明属于车厢板的制备技术领域,公开一种高强度轻量化车厢板及其制备方法。包括第一面板层、第二面板层、夹芯层、骨架支撑层;其中夹芯层为一层泡沫层或两层以上的泡沫层叠加而成,每层泡沫层由若干个泡沫块相互拼接而成;所述骨架支撑层为发泡树脂基复合材料。本发明在骨架支撑结构中添加的空心微珠赋予骨架支撑层高的力学强度和轻质的特性,其中可膨胀微球发泡剂的成功发泡促使板材具有更平整光滑的表面,从而所制备的板材具备优异的抗冲抗压和良好的外观;同时,提前将复合泡沫预混料喷涂在泡沫块表面,大大提高了夹心层的浸湿程度,使板材的粘结强度得到增强,进而促使板材具有更稳定、优异的力学性能。
Description
技术领域
本发明属于车厢板的制备技术领域,具体涉及一种高强度轻量化车厢板及其制备方法。
背景技术
在保证一定力学强度的情况下,汽车若实现轻量化,汽车的动力利用率、加速性能等性能将得到提高,而在碰撞时由于惯性小,制动距离也将减少。此外,汽车轻量化还能实现节能环保的效益。因此,汽车轻量化是目前汽车行业及新材料行业研究的热点,随着研究的深入,轻量化的箱体应运而生。
目前轻量化的箱体板材一般由面板层、骨架支撑层和夹心层组成,其中多采用纤维增强复合材料作为面板层和骨架支撑层,泡沫材料作为夹心层,面板层与骨架支撑层可一体固化成型,这较传统的通过树脂胶粘结成型的方式制备的车厢板,具有更好的力学性能。然而通过在层合体中注入液体树脂,再进行一体固化成型的板材制作工艺中会遇到树脂对板材内部浸渍不到位,导致板材内粘结强度下降的问题,尤其在板材面积较大的情况下。且随着人们生活质量的提升,对更高强度、质量更轻的车厢体的制备也提出了要求,因此,优化目前轻量化车厢板的制备工艺,制备性能更优异的板材是重要的研究方向。
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高强度轻量化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:
一种高强度轻量化车厢板,包括第一面板层、第二面板层、夹芯层、骨架支撑层,其中夹芯层为一层泡沫层或两层以上的泡沫层叠加而成,每层泡沫层由若干个泡沫块相互拼接而成;所述夹芯层设置在第一面板层与第二面板层之间,夹心层的下表面和第一面板层之间、夹心层的上表面和第二面板层之间、夹心层的四周边缘以及夹心层中任意两个相邻泡沫块的拼接缝中一体成型填充有骨架支撑层;骨架支撑层与第一面板层、第二面板层一体成型;
所述第一面板层和第二面板层同时为纤维增强树脂复合材料;
所述骨架支撑层为发泡树脂基复合材料;
所述泡沫块为聚氨酯泡沫块、PVC泡沫块或酚醛泡沫块。
进一步地,骨架支撑层为纤维增强发泡树脂基复合材料。
进一步地,在泡沫块与骨架支撑层之间设置有橡胶缓冲层,橡胶缓冲层的结构为高低起伏的波浪形结构。
较好地,橡胶缓冲层中的橡胶为丁苯橡胶、天然橡胶、氯丁橡胶、丁基橡胶、丁腈橡胶、丁二烯橡胶、乙丙橡胶、聚异戊二烯橡胶、氟橡胶或硅橡胶。
较好地,所述发泡树脂基复合材料为纤维增强树脂复合材料中对应的树脂与可膨胀微球发泡剂、空心微球中的一种或两种经过固化得到(固化温度为60-180 ℃,固化时间为0.5-12 h)。
较好地,所述纤维增强树脂复合材料(包括第一面板层、第二面板层)和纤维增强发泡树脂基复合材料中的纤维为玻璃纤维、碳纤维、硼纤维或芳纶纤维,所述纤维增强树脂复合材料中的树脂为不饱和聚酯、乙烯基树脂、聚氨酯树脂、环氧树脂或酚醛树脂。本发明中所述“纤维增强树脂复合材料”可按现有技术制备获得或通过市购获得。
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,夹心层的厚度控制在5-50 mm。
较好地,泡沫块为长方体、正方体、锥体或圆柱体。
所述的高强度轻量化车厢板的制备方法,制备步骤如下:
(1)、将纤维增强树脂复合材料中对应的树脂、空心微球、可膨胀微球发泡剂、固化剂、促进剂以质量比100∶(0-30)∶(0-5)∶(2-100)∶(0-5)的比例在搅拌下进行混合,且空心微球、可膨胀微球发泡剂的质量不能同时为0,混合均匀后,得到复合泡沫预混料;
(2)、将步骤(1)所得复合泡沫预混料喷涂在泡沫块外表面,然后将这些泡沫块相互拼接起来形成与泡沫层层数相同的拼接层,当拼接层为一层时,该拼接层直接作为拼接体,当拼接层为两层以上时,所有拼接层叠加后作为拼接体;然后由下至上依次将离型膜、第一脱模布、第一纤维布、拼接体、第二纤维布、第二脱模布进行铺层,由此获得层叠体;所述第一纤维布和第二纤维布中的纤维对应为纤维增强树脂复合材料中的纤维;
(3)、将纤维增强树脂复合材料中对应的树脂、固化剂、促进剂按照质量比100∶(2-100)∶(0-5)混合均匀,得到树脂胶液;
(4)、采用真空灌注工艺,将步骤(3)所得树脂胶液注入到步骤(2)所得层叠体中;
(5)、固化、脱模,即得轻量化车厢板。
进一步地,步骤(2)中,首先将每个泡沫块各自用第三纤维布包裹起来,第三纤维布为纤维增强树脂基复合材料中对应的纤维,然后将步骤(1)所得复合泡沫预混料喷涂在泡沫块外表面的第三纤维布上,接着进行后续的拼接。
进一步地,步骤(2)中,首先在每个泡沫块的外表面设置一层橡胶缓冲层,所述橡胶缓冲层的结构为高低起伏的波浪形,然后将步骤(1)所得复合泡沫预混料喷涂在泡沫块外表面的橡胶缓冲层上,接着进行后续的拼接。
较好地,步骤(5)中,固化时固化温度为60-180 ℃,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;
较好地,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;
较好地,所述空心微球为空心玻璃微球、硅酸铝空心微球、硼酸盐空心微球、氧化铝空心微球、二氧化硅空心微球、氧化锆空心微球、粉煤灰漂珠或聚苯乙烯空心微球中的一种或几种。
较好地,所述固化剂为甲基四氢苯酐、甲基六氢苯酐、十二烯基琥珀酸酐、双氰胺及其衍生物、二氨基二苯砜、聚醚二胺型固化剂、间苯二甲酸酰肼、异氰酸酯改性咪唑、过氧化甲乙酮、过氧化环己酮或过氧化苯甲酰。
较好地,所述促进剂为有机脲UR300、有机脲UR500、DMP-30、吡啶、液体咪唑、过氧化苯酰胺、三乙胺、钴促进剂体系或N,N二甲基苯胺。
有益效果:
(1)、本发明在骨架支撑结构中添加的空心微球赋予骨架支撑层高的力学强度和轻质的特性,其中可膨胀微球发泡剂的成功发泡促使板材具有更平整光滑的表面,从而所制备的板材具备优异的抗冲抗压和良好的外观;同时,提前将复合泡沫预混料喷涂在泡沫块表面,大大提高了夹心层的浸湿程度,使板材的粘结强度得到增强,进而促使板材具有更稳定、优异的力学性能,整个板材制备工艺简便易行,可实施性强;
(2)、本发明在泡沫块外表面设置一层橡胶缓冲层,根据橡胶缓冲层的结构设置,可以对骨架支撑层、泡沫块起到很好的缓冲作用,在受到外界的冲击作用时,能够降低对泡沫块的冲击损害作用;橡胶缓冲层外表面设置的发泡树脂基复合材料基于其轻质高强的特点,在不提高车厢板材整体密度的情况下,进一步提高了骨架支撑层的承载性能;橡胶缓冲层的存在于泡沫块和发泡树脂基复合材料两层增强层之间,能够对分别对两个增强层起到保护的作用,避免了发泡树脂基复合材料在受到冲击力时直接将其传递给泡沫块;本发明的设计对骨架支撑层起到双重的保证作用,保证板材始终具有高强的骨架支撑层;
(3)、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,扩大了其在板材领域的应用范围。
附图说明
图1:本发明车厢板(夹心层为一层泡沫层)的结构示意图;
图2:本发明车厢板(夹心层为两层泡沫层)的结构示意图;
图中:1-第一面板层;2-第二面板层;3-泡沫块;4-骨架支撑层。
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,一种高强度轻量化车厢板,包括第一面板层1、第二面板层2、夹芯层、骨架支撑层4,所述夹心层为一层泡沫层,该泡沫层由若干个长方体泡沫块3相互拼接而成;所述夹芯层设置在第一面板层1与第二面板层2之间,夹心层的下表面和第一面板层1之间、夹心层的上表面和第二面板层2之间、夹心层的四周(前后左右)边缘以及夹心层中任意两个相邻泡沫块3的拼接缝中一体固化成型填充有骨架支撑层4;骨架支撑层4与第一面板层1、第二面板层2一体固化成型;所述第一面板层1、第二面板层2均为玻璃纤维增强不饱和聚酯复合材料;所述泡沫块3为聚氨酯泡沫块;所述骨架支撑层4为发泡树脂基复合材料,所述发泡树脂基复合材料为不饱和聚酯树脂与可膨胀微球发泡剂、空心玻璃微球经过固化得到;第一面板层1的厚度为1 mm,第二面板层2的厚度为1 mm,泡沫层的厚度为6 mm。
所述高强度轻量化车厢板,制备步骤如下:
(1)、将不饱和聚酯树脂、空心玻璃微球、可膨胀微球发泡剂( EM406(日本油脂制药株式会社生产)、固化剂、促进剂以质量比100∶20∶2∶20∶2比例在高速搅拌机下进行混合,混合均匀后,即得复合泡沫预混料;所述固化剂为过氧化甲乙酮,促进剂为钴促进剂体系;
(2)、取若干个长方体形状的聚氨酯泡沫块,将步骤(1)所得复合泡沫预混料喷涂在聚氨酯泡沫块外表面,然后将聚氨酯泡沫块相互拼接起来形成一拼接层,该拼接层直接作为拼接体;然后由下至上依次将PET离型膜、聚四氟乙烯脱模布、玻璃纤维布、拼接体、玻璃纤维布、聚四氟乙烯脱模布进行铺层,由此获得一层叠体;
(3)、将不饱和聚酯树脂、固化剂、促进剂按照质量比100∶2.5∶0.8混合均匀,即得到胶液;所述固化剂为过氧化甲乙酮,促进剂为钴促进剂体系;
(4)、采用真空灌注工艺,将步骤(3)所得树脂胶液注入到步骤(2)所得层叠体中;
(5)、在80 ℃固化3 h,固化完成后脱模处理,即得轻量化车厢板。
本实施例制备的车厢板的密度为0.21 g/cm3,压缩强度为4.5 Mpa。
实施例2
一种高强度轻量化车厢板,结构与实施例1的不同之处在于:所述骨架支撑层4为发泡树脂基复合材料,所述发泡树脂基复合材料为不饱和聚酯树脂与空心玻璃微球经过固化得到;制备方法与实施例1的不同之处在于:步骤(1)中不加入可膨胀微球发泡剂,复合泡沫预混料为不饱和聚酯树脂、空心玻璃微球、固化剂、促进剂以质量比100∶20∶20∶2的比例混合得到。
本实施例制备的车厢板的密度为0.26 g/cm3,压缩强度为4.7 M pa。
实施例3
一种高强度轻量化车箱板,结构与实施例1的不同之处在于:所述骨架支撑层4为发泡树脂基复合材料,所述发泡树脂基复合材料为不饱和聚酯树脂与可膨胀微球发泡剂经过固化得到;制备方法与实施例1的不同之处在于:步骤(1)中不加入空心玻璃微球,复合泡沫预混料为不饱和聚酯树脂、可膨胀微球发泡剂、固化剂、促进剂以质量比100∶2∶20∶2的比例混合得到。
本实施例制备的车厢板的密度为0.27 g/cm3,压缩强度为4.5 M pa。
实施例4
一种高强度轻量化车箱板,结构与实施例1的不同之处在于:骨架支撑层为玻璃纤维增强发泡树脂基复合材料;制备方法与实施例1的不同之处在于:步骤(2)中,首先将每个聚氨酯泡沫块各自用玻璃纤维布包裹起来,然后将步骤(1)所得复合泡沫预混料喷涂在泡沫块外表面的玻璃纤维布上,接着进行后续的拼接。
本实施例制备的车厢板的密度为0.25 g/cm3,压缩强度4.8 M pa。
实施例5
一种高强度轻量化车箱板,结构与实施例1的不同之处在于:在泡沫块与骨架支撑层之间设置有丁苯橡胶缓冲层,丁苯橡胶缓冲层的结构为高低起伏的波浪形结构;制备方法与实施例1的不同之处在于:步骤(2)中,首先在每个聚氨酯泡沫块的外表面设置一层丁苯橡胶缓冲层,所述丁苯橡胶缓冲层的结构为高低起伏的波浪形,然后将步骤(1)所得复合泡沫预混料喷涂在泡沫块外表面的丁苯橡胶缓冲层上,接着进行后续的拼接。
本实施例制备的车厢板的密度为0.3 g/cm3,压缩强度为5.5 M pa。
实施例6
如图2所示,一种高强度轻量化车厢板,包括第一面板层1、第二面板层2、夹芯层、骨架支撑层4,所述夹心层为两层泡沫层,每层泡沫层由若干个长方体形泡沫块3相互拼接而成;所述夹芯层设置在第一面板层1与第二面板层2之间,夹心层的下表面和第一面板层1之间、夹心层的上表面和第二面板层2之间、夹心层的四周(前后左右)边缘以及夹心层中任意两个相邻泡沫块3的拼接缝中一体固化成型填充有骨架支撑层4;骨架支撑层4与第一面板层1、第二面板层2一体固化成型;所述第一面板层1、第二面板层2均为芳纶纤维增强环氧树脂复合材料;所述泡沫块3为PVC泡沫块;所述骨架支撑层4为芳纶纤维增强发泡树脂基复合材料,所述发泡树脂基复合材料为环氧树脂与可膨胀微球发泡剂、聚苯乙烯空心微球经过固化得到;第一面板层1的厚度为3 mm,第二面板层2的厚度为3 mm,两层泡沫层的厚度之和为12mm。
所述高强度轻量化车厢板,制备步骤如下:
(1)、将环氧树脂、聚苯乙烯空心微球、可膨胀微球发泡剂( EM406(日本油脂制药株式会社生产)、固化剂以质量比100∶20∶2∶50比例在高速搅拌机下进行混合,混合均匀后,即得复合泡沫预混料;所述固化剂为甲基四氢苯酐;
(2)、取若干个长方体形状的PVC泡沫块,将每个PVC泡沫块各自用芳纶纤维布包裹起来,然后将步骤(1)所得复合泡沫预混料喷涂在PVC泡沫块外表面的芳纶纤维布上,然后将芳纶纤维布包裹的PVC泡沫块相互拼接起来形成两层拼接层,这两层拼接层上下对齐叠加后作为拼接体;然后由下至上依次将PET离型膜、聚四氟乙烯脱模布、芳纶纤维布、拼接体、芳纶纤维布、聚四氟乙烯脱模布进行铺层,由此获得一层叠体;
(3)、将环氧树脂、固化剂按照质量比100∶40混合均匀,即得到树脂胶液;所述固化剂为甲基四氢苯酐;
(4)、采用真空灌注工艺,将步骤(3)所得树脂胶液注入到步骤(2)所得层叠体中;
(5)、在130 ℃固化8 h,固化完成后脱模处理,即得轻量化车厢板。
本实施例制备的车厢板的密度为0.25 g/cm3,压缩强度为5.3 Mpa。
Claims (9)
1.一种高强度轻量化车厢板,其特征在于:包括第一面板层、第二面板层、夹芯层、骨架支撑层,其中夹芯层为一层泡沫层或两层以上的泡沫层叠加而成,每层泡沫层由若干个泡沫块相互拼接而成;所述夹芯层设置在第一面板层与第二面板层之间,夹心层的下表面和第一面板层之间、夹心层的上表面和第二面板层之间、夹心层的四周边缘以及夹心层中任意两个相邻泡沫块的拼接缝中一体成型填充有骨架支撑层;骨架支撑层与第一面板层、第二面板层一体成型;
所述第一面板层和第二面板层同时为纤维增强树脂复合材料;
所述骨架支撑层为发泡树脂基复合材料;
所述泡沫块为聚氨酯泡沫块、PVC泡沫块或酚醛泡沫块;
制备步骤如下:
(1)、将纤维增强树脂复合材料中对应的树脂、空心微球、可膨胀微球发泡剂、固化剂、促进剂以质量比100∶(0-30)∶(0-5)∶(2-100)∶(0-5)的比例在搅拌下进行混合,且空心微球、可膨胀微球发泡剂的质量不能同时为0,混合均匀后,得到发泡树脂基复合材料预混料;
(2)、将步骤(1)所得发泡树脂基复合材料预混料喷涂在泡沫块外表面,然后将这些泡沫块相互拼接起来形成与泡沫层层数相同的拼接层,当拼接层为一层时,该拼接层直接作为拼接体,当拼接层为两层以上时,所有拼接层叠加后作为拼接体;然后由下至上依次将离型膜、第一脱模布、第一纤维布、拼接体、第二纤维布、第二脱模布进行铺层,由此获得层叠体;所述第一纤维布和第二纤维布中的纤维对应为纤维增强树脂复合材料中的纤维;
(3)、将纤维增强树脂复合材料中对应的树脂、固化剂、促进剂按照质量比100∶(2-100)∶(0-5)混合均匀,得到树脂胶液;
(4)、采用真空灌注工艺,将步骤(3)所得树脂胶液注入到步骤(2)所得层叠体中;
(5)、固化、脱模,即得轻量化车厢板。
2.如权利要求1所述的高强度轻量化车厢板,其特征在于:骨架支撑层为纤维增强发泡树脂基复合材料。
3.如权利要求1所述的高强度轻量化车厢板,其特征在于:在泡沫块与骨架支撑层之间设置有橡胶缓冲层,橡胶缓冲层的结构为高低起伏的波浪形结构。
4.如权利要求2所述的高强度轻量化车厢板,其特征在于:所述纤维增强树脂复合材料和纤维增强发泡树脂基复合材料中的纤维为玻璃纤维、碳纤维、硼纤维或芳纶纤维,所述纤维增强树脂复合材料中的树脂为不饱和聚酯、乙烯基树脂、聚氨酯树脂、环氧树脂或酚醛树脂。
5.如权利要求1所述的高强度轻量化车厢板,其特征在于:第一面板层的厚度为0.5-5mm,第二面板层的厚度为0.5-5 mm,夹心层的厚度控制在5-50 mm。
6.如权利要求1所述的高强度轻量化车厢板,其特征在于:泡沫块为长方体、正方体、锥体或圆柱体。
7.一种如权利要求1、5-6中任一项所述的高强度轻量化车厢板的制备方法,其特征在于,制备步骤如下:
(1)、将纤维增强树脂复合材料中对应的树脂、空心微球、可膨胀微球发泡剂、固化剂、促进剂以质量比100∶(0-30)∶(0-5)∶(2-100)∶(0-5)的比例在搅拌下进行混合,且空心微球、可膨胀微球发泡剂的质量不能同时为0,混合均匀后,得到发泡树脂基复合材料预混料;
(2)、将步骤(1)所得发泡树脂基复合材料预混料喷涂在泡沫块外表面,然后将这些泡沫块相互拼接起来形成与泡沫层层数相同的拼接层,当拼接层为一层时,该拼接层直接作为拼接体,当拼接层为两层以上时,所有拼接层叠加后作为拼接体;然后由下至上依次将离型膜、第一脱模布、第一纤维布、拼接体、第二纤维布、第二脱模布进行铺层,由此获得层叠体;所述第一纤维布和第二纤维布中的纤维对应为纤维增强树脂复合材料中的纤维;
(3)、将纤维增强树脂复合材料中对应的树脂、固化剂、促进剂按照质量比100∶(2-100)∶(0-5)混合均匀,得到树脂胶液;
(4)、采用真空灌注工艺,将步骤(3)所得树脂胶液注入到步骤(2)所得层叠体中;
(5)、固化、脱模,即得轻量化车厢板。
8.如权利要求7所述的高强度轻量化车厢板的制备方法,其特征在于:步骤(2)中,首先将每个泡沫块各自用第三纤维布包裹起来,第三纤维布为纤维增强树脂基复合材料中对应的纤维,然后将步骤(1)所得发泡树脂基复合材料预混料喷涂在泡沫块外表面的第三纤维布上,接着进行后续的拼接。
9.如权利要求7所述的高强度轻量化车厢板的制备方法,其特征在于:步骤(2)中,首先在每个泡沫块的外表面设置一层橡胶缓冲层,所述橡胶缓冲层的结构为高低起伏的波浪形,然后将步骤(1)所得发泡树脂基复合材料预混料喷涂在泡沫块外表面的橡胶缓冲层上,接着进行后续的拼接。
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