CN114919249B - 采用雀尾螳螂虾前螯改进结构的保险杠横梁及其制备方法 - Google Patents

采用雀尾螳螂虾前螯改进结构的保险杠横梁及其制备方法 Download PDF

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CN114919249B
CN114919249B CN202210464985.8A CN202210464985A CN114919249B CN 114919249 B CN114919249 B CN 114919249B CN 202210464985 A CN202210464985 A CN 202210464985A CN 114919249 B CN114919249 B CN 114919249B
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杨肖
王明
唐彪
杨家伊
牛士超
倪敬
张雪峰
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Hangzhou Dianzi University
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Abstract

本发明公开了采用雀尾螳螂虾前螯改进结构的保险杠横梁及其制备方法。现有保险杠横梁抗冲击性有待提高。本发明保险杠横梁由从外至内固连的冲击层、缓冲层和吸能层组成；冲击层的内侧面和缓冲层的外侧面为相互嵌合的正交式双正弦曲面；缓冲层的内侧面和吸能层的外侧面均为平面；缓冲层由多层碳纤维浸料布固连而成，且各相邻两层碳纤维浸料布之间的纹理沿同一旋向依次错开旋转角α；吸能层由多层蜂窝层固连而成，蜂窝层由阵列排布连接在一起的多个正方形蜂窝单元组成。本发明通过设置从外至内固连的冲击层、缓冲层和吸能层，外刚内柔，层层减弱外界冲击，且本发明方法制备的保险杠横梁中各层结合力强，使本发明能大大提升保险杠横梁的抗冲击性能。

Description

采用雀尾螳螂虾前螯改进结构的保险杠横梁及其制备方法
技术领域
本发明属于汽车保险杠技术领域，具体涉及一种采用雀尾螳螂虾前螯改进结构的保险杠横梁及其制备方法。
背景技术
汽车保险杠是汽车被动安全系统中的一个重要安全保护装置，主要由保险杠横梁和吸能盒组成。在传统设计中，通常是利用吸能盒的变形来吸收碰撞时的冲击能量。然而在汽车发生正面碰撞时，保险杠横梁会最先接触碰撞对象，承受冲击载荷。为了降低部件的维修或更换成本，以及更好的保护车身免受严重损坏，发明专利公开号CN107150646A设计了具有蜂窝结构的防撞梁，但是在冲击过程中，蜂窝结构的抵抗变形能力较差，能量吸收效果不出色。
在自然界中有一种号称“锤击者”的雀尾螳螂虾，其前螯能产生10000g的加速度来击碎各种贝类生物。这得益于前螯坚硬的外表面和柔软的多层纤维，使它具有极高的抗冲击性能，承受如此剧烈的冲击行为。雀尾螳螂虾前螯外表面由羟基磷灰石和几丁质混合的纳米颗粒覆盖，能够增加表面刚度和阻尼，内层分为冲击区域和周期区域，如图1所示；冲击区域由矿化纤维经正弦排列形成，能够将应力重新分布，防止应力集中；周期区域由矿化纤维经螺旋状排列形成，能显著耗散能量，增强结构韧性。但雀尾螳螂虾的前螯结构形式仍有改进空间，若能基于雀尾螳螂虾的前螯结构提出具有更优异抵抗变形能力和能量吸收效果的结构形式，则能进一步提升保险杠横梁的抗冲击性能。
发明内容
本发明在于解决保险杠横梁低抗冲击性的问题，提供一种采用雀尾螳螂虾前螯改进结构的保险杠横梁及其制备方法，提升保险杠横梁的抗冲击性能。
本发明采用的技术方案为：
本发明采用雀尾螳螂虾前螯改进结构的保险杠横梁，由从外至内固连的冲击层、缓冲层和吸能层组成；所述冲击层的内侧面和缓冲层的外侧面为相互嵌合的正交式双正弦曲面；所述缓冲层的内侧面和吸能层的外侧面均为平面；所述冲击层的材料采用聚脲；所述的缓冲层由多层碳纤维浸料布固连而成，且各相邻两层碳纤维浸料布之间的纹理沿同一旋向依次错开旋转角α；所述的吸能层由多层蜂窝层固连而成，所述的蜂窝层由阵列排布连接在一起的多个正方形蜂窝单元组成。
优选地，正交式双正弦曲面任意横截面和任意纵截面的正弦曲线的波长为1-4mm，振幅为0.5-2mm。
优选地，α在7.2°-22.5°中取值，每次错开旋转超过180°时为一个周期，循环旋转若干个周期。
优选地，所述正方形蜂窝单元的边长为4-7mm，壁厚为0.1-0.3mm。
该采用雀尾螳螂虾前螯改进结构的保险杠横梁的制备方法，包括以下步骤：
步骤一、取质量比为7-8：2-3的碳纤维材料和环氧树脂混合物，将碳纤维材料浸润至环氧树脂混合物中形成碳纤维浸料布；
步骤二、用手工铺排的方式将多层碳纤维浸料布铺成自下而上依次顺时针旋转α的螺旋结构，7.2°≤α≤22.5°；
步骤三、将步骤二制备的螺旋结构裁剪成预设尺寸，采用多点模具成型方法得到缓冲层，使缓冲层内侧面为平面，外侧面为正交式双正弦曲面；
步骤四、将多层碳纤维浸料布堆叠后裁剪成预设尺寸，放入蜂窝模具中热压固化，得到吸能层；
步骤五、将缓冲层和吸能层用环氧树脂混合物浸渍后，将缓冲层内侧面置于吸能层上并一起放入保温箱内进行加热固化，得到缓冲层与吸能层组合件；
步骤六、将聚脲的A、B组分按1：1放入烘箱，加热至65℃后通过喷涂机喷涂在缓冲层的正交式双正弦曲面上形成冲击层，最终制得采用雀尾螳螂虾前螯改进结构的保险杠横梁。
优选地，所述的环氧树脂混合物包括重量比为2：1的环氧树脂和固化剂。
优选地，缓冲层成型过程中设置温度为120-200℃，压力为1-2MPa，固化时间为10-20小时。
优选地，吸能层成型过程中设置温度为120-200℃，压力为1-2MPa，固化时间为10-20小时。
优选地，保温箱加热温度设为80-120℃，加热时间设为10-20小时。
优选地，A组分由重量比为9-10：0-1的半预聚物和稀释剂组成；B组分包括由重量比为4-9：1-5：0-1的端氨基聚醚、液态胺类扩链剂和助剂组成。
本发明具有以下有益效果：
1.本发明的冲击层为聚脲涂层，具有较高的刚度和硬度，能缓冲掉大部分冲击能。
2.本发明的缓冲层外侧面为正交式双正弦曲面，能够均化应力，有效的将动量传递分散到四周，避免局部区域发生过大变形。同时冲击层内侧面和缓冲层外侧面相互嵌合的正交式双正弦曲面能在冲击层和吸能层之间形成机械互锁，有效提高冲击层和吸能层之间的结合力，有助于提高损伤容限。
3.本发明的缓冲层通过特定的铺排角度形成了类似雀尾螳螂虾前螯的螺旋状结构，能够有效延长裂纹扩展路径，使冲击能从外到内逐渐较小，极大程度减弱了传递到吸能层的冲击能。
4.本发明的吸能层通过蜂窝状的压溃变形，吸收剩余的冲击能，进一步提高抗冲击性能。
5.本发明通过设置最外层高刚度和硬度的冲击层、中间层能够均化应力且构成机械互锁和螺旋状层叠结构减弱冲击能的缓冲层，以及最内层蜂窝状吸能结构的吸能层，外刚内柔，且各层结合力强，层层减弱外界冲击，大大提升了保险杠横梁的抗冲击性能。进一步，本发明方法不仅能保证冲击层、缓冲层和吸能层各自内部强大的结合力，还能保证冲击层与缓冲层之间、缓冲层与吸能层之间强大的结合力，为吸附和减弱外界冲击提供坚实的基础。
附图说明
图1为螳螂虾前螯横截面SEM图。
图2为本发明保险杠横梁示意图。
图3为图2的A-A剖面示意图。
图4为本发明保险杠横梁的缓冲层局部示意图。
图5为本发明保险杠横梁缓冲层中各层碳纤维浸料布的螺旋铺排示意图。
图6为采用仿雀尾螳螂虾前螯结构、蜂窝结构和本发明实施例一仿雀尾螳螂虾前螯与蜂窝组合结构制备的相同尺寸保险杠横梁不被破坏所吸收最大能量对比图。
具体实施方式
下面结合附图对本发明进行进一步的说明。
实施例一
本实施例采用雀尾螳螂虾前螯改进结构的保险杠横梁，整体呈U形板状(见图2)，由从外至内固连的冲击层1、缓冲层2和吸能层3组成，如图3所示；冲击层1的内侧面和缓冲层2的外侧面为相互嵌合(冲击层1内侧面横向的正弦曲线与缓冲层2外侧面横向的正弦曲线相位差为90°，冲击层1内侧面纵向的正弦曲线与缓冲层2外侧面纵向的正弦曲线相位差也为90°)的正交式双正弦曲面201；正交式双正弦曲面201的任意横截面和纵截面均为正弦曲线，如图4所示；缓冲层2的内侧面和吸能层3的外侧面均为平面202。其中，正弦曲线的波长为2mm，振幅为2mm；冲击层1的材料采用聚脲。缓冲层2由多层碳纤维浸料布固连而成，且各相邻两层碳纤维浸料布之间的纹理沿同一旋向依次错开旋转角α，如图5所示；取α＝7.2°，旋转180°为一个周期，循环旋转若干个周期，循环旋转周期数可根据设计的保险杠横梁厚度而定；吸能层3由多层蜂窝层固连而成，蜂窝层的层数可根据设计的保险杠横梁厚度而定；蜂窝层由阵列排布连接在一起的多个正方形蜂窝单元组成；正方形蜂窝单元的边长为4mm，壁厚为0.1mm。
该采用雀尾螳螂虾前螯改进结构的保险杠横梁的制备方法，包括以下步骤：
步骤一：取重量比为7：3的碳纤维材料和环氧树脂混合物，将碳纤维材料浸润至环氧树脂混合物中形成碳纤维浸料布；其中，环氧树脂混合物包括重量比为2：1的环氧树脂和固化剂；
步骤二：用手工铺排的方式将多层碳纤维浸料布铺成自下而上依次顺时针旋转α＝7.2°的螺旋结构；
步骤三：将步骤二制备的螺旋结构裁剪成预设尺寸，采用多点模具成型方法(放入多点模具中热压固化)得到缓冲层，使缓冲层内侧面为平面，外侧面为正交式双正弦曲面；其中，缓冲层成型过程中设置温度为160℃，压力为2MPa，固化时间为20小时；
步骤四：将步骤二以外的多层碳纤维浸料布堆叠后裁剪成预设尺寸，放入蜂窝模具中热压固化，得到吸能层；其中，吸能层成型过程中设置温度为120℃，压力为2MPa，固化时间为20小时；
步骤五：缓冲层和吸能层用环氧树脂混合物浸渍后，将缓冲层内侧面置于吸能层上并一起放入保温箱内进行加热固化，得到缓冲层与吸能层组合件；其中，保温箱加热温度设为120℃，加热时间设为15小时。
步骤六：将聚脲的A、B组分按1：1放入烘箱，加热至65℃后通过喷涂机喷涂在缓冲层的正交式双正弦曲面上形成冲击层，最终制得采用雀尾螳螂虾前螯改进结构的保险杠横梁。其中，A组分由重量比为9：1的半预聚物和稀释剂组成；B组分由重量比为4：5：1的端氨基聚醚、液态胺类扩链剂和助剂组成。
采用仿雀尾螳螂虾前螯结构、蜂窝结构和本实施例仿雀尾螳螂虾前螯与蜂窝组合结构制备的相同尺寸保险杠横梁不被破坏所吸收最大能量对比如6所示。由图6可以看出，采用本发明结构吸收的最大能量相比于单独采用仿雀尾螳螂虾前螯结构或单独采用蜂窝结构分别提高了34.90％和56.61％。因此，采用本发明仿雀尾螳螂虾前螯与蜂窝组合结构制备的保险杠横梁具有更好的抗冲击性能。
实施例二
本实施例采用雀尾螳螂虾前螯改进结构的保险杠横梁，与实施例一中保险杠横梁结构的区别为：正弦曲线的波长为1mm，振幅为0.5mm；取α＝12°；正方形蜂窝单元的边长为5mm，壁厚为0.2mm。
该采用雀尾螳螂虾前螯改进结构的保险杠横梁的制备方法，包括以下步骤：
步骤一：取重量比为7.5：2.5的碳纤维材料和环氧树脂混合物，将碳纤维材料浸润至环氧树脂混合物中形成碳纤维浸料布；其中，环氧树脂混合物包括重量比为2：1的环氧树脂和固化剂；
步骤二：用手工铺排的方式将将多层碳纤维浸料布铺成自下而上依次顺时针旋转α＝12°的螺旋结构；
步骤三：将步骤二制备的螺旋结构裁剪成预设尺寸，采用多点模具成型方法得到缓冲层，使缓冲层内侧面为平面，外侧面为正交式双正弦曲面；其中，缓冲层成型过程中设置温度为120℃，压力为1MPa，固化时间为17小时；
步骤四：将步骤二以外的多层碳纤维浸料布堆叠后裁剪成预设尺寸，放入蜂窝模具中热压固化，得到吸能层；其中，吸能层成型过程中设置温度为160℃，压力为1MPa，固化时间为10小时；
步骤五：缓冲层和吸能层用环氧树脂混合物浸渍后，将缓冲层内侧面置于吸能层上并一起放入保温箱内进行加热固化，得到缓冲层与吸能层组合件；其中，保温箱加热温度设为80℃，固化时间设为20小时。
步骤六：将聚脲的A、B组分按1：1放入烘箱，加热至65℃后通过喷涂机喷涂在缓冲层的正交式双正弦曲面上形成冲击层，最终制得采用雀尾螳螂虾前螯改进结构的保险杠横梁。其中，A组分由重量比为9.5：0.5的半预聚物和稀释剂组成；B组分由重量比为6：3：0.5的端氨基聚醚、液态胺类扩链剂和助剂组成。
采用本实施例仿雀尾螳螂虾前螯与蜂窝组合结构制备的保险杠横梁不被破坏所吸收最大能量，相较于采用仿雀尾螳螂虾前螯结构和蜂窝结构制备的相同尺寸保险杠横梁不被破坏所吸收最大能量均有明显提高。
实施例三
本实施例采用雀尾螳螂虾前螯改进结构的保险杠横梁，与实施例一中保险杠横梁结构的区别为：正弦曲线的波长为4mm，振幅为1mm；取α＝20°；正方形蜂窝单元的边长为7mm，壁厚为0.3mm。
该采用雀尾螳螂虾前螯改进结构的保险杠横梁的制备方法，包括以下步骤：
步骤一：取重量比为8：2的碳纤维材料和环氧树脂混合物，将碳纤维材料浸润至环氧树脂混合物中形成碳纤维浸料布；其中，环氧树脂混合物包括重量比为2：1的环氧树脂和固化剂；
步骤二：用手工铺排的方式将多层碳纤维浸料布铺成自下而上依次顺时针旋转α＝20°的螺旋结构；
步骤三：将步骤二制备的螺旋结构裁剪成预设尺寸，采用多点模具成型方法得到缓冲层，使缓冲层内侧面为平面，外侧面为正交式双正弦曲面；其中，缓冲层成型过程中设置温度为200℃，压力为1.5MPa，固化时间为10小时；
步骤四：将步骤二以外的多层碳纤维浸料布堆叠后裁剪成预设尺寸，放入蜂窝模具中热压固化，得到吸能层；其中，吸能层成型过程中设置温度为200℃，压力为1.5MPa，固化时间为17小时；
步骤五：缓冲层和吸能层用环氧树脂混合物浸渍后，将缓冲层内侧面置于吸能层上并一起放入保温箱内进行加热固化，得到缓冲层与吸能层组合件；其中，保温箱加热温度设为100℃，固化时间设为10小时。
步骤六：将聚脲的A、B组分按1：1放入烘箱，加热至65℃后通过喷涂机喷涂在缓冲层的正交式双正弦曲面上形成冲击层，最终制得采用雀尾螳螂虾前螯改进结构的保险杠横梁。其中，A组分为半预聚物；B组分由重量比为9：1的端氨基聚醚和液态胺类扩链剂组成。
采用本实施例仿雀尾螳螂虾前螯与蜂窝组合结构制备的保险杠横梁不被破坏所吸收最大能量，相较于采用仿雀尾螳螂虾前螯结构和蜂窝结构制备的相同尺寸保险杠横梁不被破坏所吸收最大能量均有所提高。

Claims (10)

1.采用雀尾螳螂虾前螯改进结构的保险杠横梁，其特征在于：由从外至内固连的冲击层、缓冲层和吸能层组成；所述冲击层的内侧面和缓冲层的外侧面为相互嵌合的正交式双正弦曲面；所述缓冲层的内侧面和吸能层的外侧面均为平面；所述冲击层的材料采用聚脲；所述的缓冲层由多层碳纤维浸料布固连而成，且各相邻两层碳纤维浸料布之间的纹理沿同一旋向依次错开旋转角α；所述的吸能层由多层蜂窝层固连而成，所述的蜂窝层由阵列排布连接在一起的多个正方形蜂窝单元组成。
2.根据权利要求1所述采用雀尾螳螂虾前螯改进结构的保险杠横梁，其特征在于：正交式双正弦曲面任意横截面和任意纵截面的正弦曲线的波长为1-4mm，振幅为0.5-2mm。
3.根据权利要求1所述采用雀尾螳螂虾前螯改进结构的保险杠横梁，其特征在于：α在7.2°-22.5°中取值，每次错开旋转超过180°时为一个周期，循环旋转若干个周期。
4.根据权利要求1所述采用雀尾螳螂虾前螯改进结构的保险杠横梁，其特征在于：所述正方形蜂窝单元的边长为4-7mm，壁厚为0.1-0.3mm。
5.根据权利要求1至4中任一项所述采用雀尾螳螂虾前螯改进结构的保险杠横梁的制备方法，其特征在于：该方法包括以下步骤：
步骤一、取质量比为7-8：2-3的碳纤维材料和环氧树脂混合物，将碳纤维材料浸润至环氧树脂混合物中形成碳纤维浸料布；
步骤二、用手工铺排的方式将多层碳纤维浸料布铺成自下而上依次顺时针旋转α的螺旋结构，7.2°≤α≤22.5°；
步骤三、将步骤二制备的螺旋结构裁剪成预设尺寸，采用多点模具成型方法得到缓冲层，使缓冲层内侧面为平面，外侧面为正交式双正弦曲面；
步骤四、将多层碳纤维浸料布堆叠后裁剪成预设尺寸，放入蜂窝模具中热压固化，得到吸能层；
步骤五、将缓冲层和吸能层用环氧树脂混合物浸渍后，将缓冲层内侧面置于吸能层上并一起放入保温箱内进行加热固化，得到缓冲层与吸能层组合件；
步骤六、将聚脲的A、B组分按1：1放入烘箱，加热至65℃后通过喷涂机喷涂在缓冲层的正交式双正弦曲面上形成冲击层，最终制得采用雀尾螳螂虾前螯改进结构的保险杠横梁。
6.根据权利要求5所述采用雀尾螳螂虾前螯改进结构的保险杠横梁的制备方法，其特征在于：所述的环氧树脂混合物包括重量比为2：1的环氧树脂和固化剂。
7.根据权利要求5所述采用雀尾螳螂虾前螯改进结构的保险杠横梁的制备方法，其特征在于：缓冲层成型过程中设置温度为120-200℃，压力为1-2MPa，固化时间为10-20小时。
8.根据权利要求5所述采用雀尾螳螂虾前螯改进结构的保险杠横梁的制备方法，其特征在于：吸能层成型过程中设置温度为120-200℃，压力为1-2MPa，固化时间为10-20小时。
9.根据权利要求5所述采用雀尾螳螂虾前螯改进结构的保险杠横梁的制备方法，其特征在于：保温箱加热温度设为80-120℃，加热时间设为10-20小时。
10.根据权利要求5所述采用雀尾螳螂虾前螯改进结构的保险杠横梁的制备方法，其特征在于：A组分由重量比为9-10：0-1的半预聚物和稀释剂组成；B组分包括由重量比为4-9：1-5：0-1的端氨基聚醚、液态胺类扩链剂和助剂组成。
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