CN115515780A - 车辆部件单元和制造车辆部件单元的方法 - Google Patents

车辆部件单元和制造车辆部件单元的方法 Download PDF

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Publication number
CN115515780A
CN115515780A CN202180033282.3A CN202180033282A CN115515780A CN 115515780 A CN115515780 A CN 115515780A CN 202180033282 A CN202180033282 A CN 202180033282A CN 115515780 A CN115515780 A CN 115515780A
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China
Prior art keywords
vehicle component
layer
gloss surface
component unit
surface layer
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CN202180033282.3A
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CN115515780B (zh
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新井司
休·福伦
马特·普劳曼
埃文·弗里曼-吉伯
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Teijin Ltd
Teijin Automotive Technologies Inc
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Teijin Ltd
Continental Structural Plastics Inc
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Abstract

一种车辆部件单元，包括增强中空结构芯层、高光泽表面层和封装塑料层。增强中空结构芯层具有第一侧和相反设置的第二侧以及各自在第一侧与第二侧之间延伸的第一端和相反设置的第二端。高光泽表面层定位于增强中空结构芯层的第一侧。封装塑料层具有第一端和第二端并且定位于增强中空结构芯层的第二侧。封装塑料层的第一端和的第二端以嵌入长度L嵌入高光泽表面层，使得封装塑料层覆盖增强中空结构芯层的第一端和第二端。

Description

车辆部件单元和制造车辆部件单元的方法
相关申请的交叉引用
本申请要求2020年4月6日提交的美国临时专利申请序列号63/005,698的优先权，该申请通过引用并入本文。
技术领域
本发明总体涉及复合材料，并且特别地涉及一种复合夹层结构组件，其具有介于中间的中空结构芯支撑基质和表面片材，该表面片材附着到中空结构芯以提供满足车辆外表面光泽度标准的至少一个表面。
背景技术
以汽车、运输和物流为基础的产业中的轻量化轻一直是主要关注点，以便制造用于地面和空中运输的燃料效率更高的交通工具。为了实现这些轻量化，已经引入轻质复合材料来代替金属结构和表面车身部件和面板。复合材料是由两种以上具有显著不同的物理或化学性质的组成材料所制成的材料，当两种以上具有显著不同的物理或化学性质的组成材料组合时，产生的材料具有与单个组分不同的特性。各个组分在最终结构体中保持独立和区隔。出于多种原因，复合材料可以优选：常见的示例包括与传统材料相比更坚固、更轻或更便宜的材料。夹层结构复合体是通过将两片薄但刚性的表皮附着到轻质但厚的芯而制造的特殊类别的复合材料。芯材料通常为低强度材料，但其较厚的厚度以整体低密度为夹层复合体提供高弯曲刚度。
虽然之前已经开发了夹层结构以提供强度和减轻重量，但是无论表面最外层是热固性树脂还是热塑性塑料，获得车辆外部质量高光泽表面的能力都仍然是一个挑战。常规的是在需要车辆高表面光泽的情况下不使用这种结构，或者求助于额外的外层以提供高光泽的最外层。这样的最外层能够在结构体制造之后或通过在模具涂层中施加，这两者都增加了制造的成本和复杂性。
本领域的另一个传统的问题是夹层结构边缘通常需要从车辆部件切割多余材料的附加加工步骤，导致边缘无效并允许湿气或水汽渗入从而夹带在芯内，并且通常不符合成品车辆表面要求。在极端温度下，这种夹带的水分会缩短结构体的使用寿命，与此同时增加其重量。这些水分渗入的问题在当芯由诸如纸的纤维素材料形成时的实例中尤为明显。
因此，需要一种夹层复合结构车辆部件，其提供高光泽表面、防潮性和良好修整的边缘，而无需在制造后采用额外的加工或添加额外的最外表面层。
发明内容
本发明提供一种车辆部件单元，其包括增强中空结构芯层、高光泽表面层和封装塑料层。增强中空结构芯层具有第一侧和相反设置的第二侧以及各自在第一侧与第二侧之间延伸的第一端和相反设置的第二端。高光泽表面层定位于增强中空结构芯层的第一侧。封装塑料层具有第一端和第二端并且定位于增强中空结构芯层的第二侧。封装塑料层的第一端和的第二端以嵌入长度L嵌入高光泽表面层中，使得封装塑料层覆盖增强中空结构芯层的第一端和第二端。
本发明还提供一种上述车辆部件单元的制造方法。所述方法包括在具有一起界定模腔的上部和下部的模具中层叠所述高光泽表面层、所述中空结构芯层和所述封装塑料层；使用所述模具上的锋利边缘将所述封装塑料层的端部插入所述高光泽表面层中，并且同时使用所述模具上的所述锋利边缘修整所述封装塑料层和所述中空结构芯层；以及将所述模具的上部和所述模具的下部按压到一起以赋予所述车辆部件形状。
附图说明
被视为发明的主题作为说明书的总结的权利要求中被特别指出和明确地要求保护。本发明的上述目的、特征和优点等由于以下结合附图的详细描述而变得显而易见，其中：
图1是根据本发明的实施例的车辆部件的截面图；
图2是示出了插入图1的车辆部件的SMC层中的内部塑料层的端部的截面详细视图；
图3是根据本发明的实施例的车辆部件的截面图；
图4示出了插入图3的车辆部件的SMC层中的内部塑料层的端部的截面详细视图，示出了SMC层的长度L和厚度T1；
图5是根据本发明的实施例的车辆部件的截面图；
图6是根据本发明的实施例的车辆部件的截面图；
图7是示出了插入根据本发明的实施例的车辆部件的SMC层中的内部塑料层的端部的截面详细视图，示出了SMC层的长度L和厚度T1；
图8是示出了插入根据本发明的实施例的车辆部件的SMC层中的内部塑料层的端部的截面详细视图，示出了区域X、厚度T1、T2和长度L；
图9是根据本发明实施例的车辆部件的截面图，示出了车辆部件的厚度Tm和芯层的厚度Tc；
图10是示出了插入根据本发明实施例的车辆部件的SMC层中的内部塑料层的端部的截面详细视图，示出了车辆构造单元的厚度Tm和芯层的厚度Tc；
图11示出了根据本发明实施例的车辆部件的截面图，其示出了车辆部件的厚度Tm和芯层的厚度Tc；
图12示出了根据本发明实施例的车辆部件的截面图，其示出了车辆部件的厚度Tm和芯层的厚度Tc；
图13A是示出合模前利用上模和下模制造根据本发明的实施例的车辆部件的方法的截面图；
图13B是示出合模后利用模具制造根据本发明的实施例的车辆部件的方法的截面图；
图13C是示出合模后利用模具制造根据本发明的实施例的车辆部件的方法的截面图；
图14A是示出了在合模之前的将内部塑料层的端部插入SMC层中的锋利边缘的截面图；
图14B是示出了在合模之后的将内部塑料层的端部插入SMC层中的锋利边缘的截面图；
图15A和图15B是示出根据传统方法的车辆部件的二次修整加工的横截面图；并且
图16A-16C是示出了使用掩模法形成根据本发明的实施例车辆部件的方法的横截面图。
具体实施方式
本发明涉及复合夹层车辆部件，其具有夹在片状模塑料(SMC)层与封装塑料层之间并封装在两者之间的中空结构芯，以及该复合夹层车辆部件的制造方法。SMC层具有高光泽表面光洁度，从而避免了为了获得高光泽表面光洁度而进行的车辆部件的二次精加工。本发明适用于所有由复合材料制成的车辆部件，但尤其适用于：车身外壳部件，诸如车顶模块；车顶打开系统的盖，诸如滑动车顶或扰流板车顶；车顶模块的表面部件；车顶柱；车辆的A柱、B柱、C柱或D柱；车门；车翼；发动机舱盖；行李舱盖；后端模块；敞篷车罩的车顶壳；车辆的饰板部件；或前后扰流板。本发明的实施例还提供了消音和耐温变特性。此外，本发明的创造性的方法和车辆部件提供了一种车辆部件，其在其端部处精加工以额外避免在车辆部件成型后对车辆部件进行二次修整或切割。产生了一种低成本、重量轻、强度高的车辆部件，其在成型加工完成时以高质量的美感精加工。
应当理解，在设置了值的范围的情况下，该范围不仅包括该范围的端点值而且包括明确地包括在该范围中并通过范围的最后一个有效数字而变化的范围的中间值。举例来说，提及从1到4的范围旨在包括1-2、1-3、2-4、3-4和1-4。
如本文所用，术语“高光泽表面”是指当离观察者约24-28英寸并且在良好照明区域中以+/-90度垂直于零件表面地视觉检查约3秒时，具有最小可感知表面缺陷的表面。即，术语“高光泽表面”是指能够被涂漆并被认定为“A级”车体零件的表面。这通常通过ASTMD523测量。在汽车工业中，A类表面是消费者在不运行车辆的情况下(例如，打开发动机罩或行李箱盖)能够看到的表面，而A级表面光洁度通常指的是涂漆的外面板，并且具体地是指零件上的图像清晰度(DOI)和光泽水平。应当理解，表面层可以在接收赋予高光泽的涂料的涂层之前经受打磨、修整和涂底，但是必须保持底漆和涂料的单向度和粘合均匀性，从而实现高光泽面漆。
现在参考附图，根据本发明的实施例的车辆部件100包括高光泽表面层10、增强中空结构芯层20和封装塑料层30。增强中空结构芯20具有第一侧22和相反设置的第二侧24以及各自在第一侧22与第二侧24之间延伸的第一端26和相反设置的第二端28。高光泽表面层10在高光泽表面12定位成使其面向外，即背离中空结构芯层20的状态下定位于增强中空结构芯层20的第一侧22。封装塑料层30定位于增强中空结构芯层20的第二侧24。封装塑料层30具有以嵌入长度L嵌入高光泽表面层10中的第一端32和第二端34，使得封装塑料层30覆盖增强中空结构芯层20的第一端26和第二端28。虽然图1中描绘的结构体100是平面的，但是应当理解，高光泽表面层10和封装塑料层30都能够各自独立地形成非平面的轮廓。
根据本发明的高光泽表面层10由片状模塑料(SMC)、热塑性材料、二环戊二烯(DCPD)、包覆成型聚氨酯(PU)或其组合形成。根据实施例，高光泽表面层10包括填料14以增强高光泽表面层10和/或用于减轻高光泽表面层10的重量。填料14是玻璃纤维、碳纤维、玄武岩纤维、天然纤维、中空或实心玻璃微球、纤维毡或以上的组合中的任一者。纤维可以是定向的或非定向的。可以理解，高光泽层10通常包括添加剂以保持单向度。此类添加剂通常包括：玻璃纤维；碳纤维：无机颗粒填料，诸如碳酸钙、滑石和炭黑；玻璃微球；碳纳米管；石墨烯；低轮廓添加剂；除水剂；以及其组合。本发明中高光泽表面层的典型厚度范围在不考虑边缘的情况下为0.5至5毫米(mm)。根据实施例，高光泽表面层10形成在包含短分散纤维的热固性SMC上。高光泽表面通过模具中的对应高光泽表面或者通过对部件的后续抛光之一而获得。根据模具表面获得高光泽、哑光或结构化的部件表面。根据实施例，高光泽表面层10包括对比色或以最终车辆的喷漆颜色的颜色制成。根据实施例，高光泽表面层10表现出小于1.4kg/dm3并且特别在1.3kg/dm3与1.0kg/dm3之间的降低的密度。
选择高光泽表面层10的厚度以高质量地覆盖下方的结构体，使得在高光泽表面层10的表面不出现膨出等或无可识别的膨出等。当高光泽表面层10的厚度减小时，车辆部件100的重量减轻。然而，当封装塑料层30的端部32、34所插入的周边区域X处的高光泽表面层10的厚度T1太薄时，端部32、34所插入的周边区域X处的高光泽表面层10因开裂而破损。因此，根据实施例，高光泽表面层10在其长度上具有不均匀的厚度，其中厚度在周边区域X中增大，如图4和图8所示。
根据实施例，在区域X中测量高光泽表面层10的厚度Tl，该区域是距封装塑料层30的端部32、34的插入点5.0mm以内的区域，如图2、图4和图8所示。根据实施例，高光泽表面层10的厚度T1在1.0mm与4.0mm之间。根据实施例，在区域X处需要3mm的最小厚度以使用锋利边缘1303，但是当使用不同的SMC等级来形成高光泽表面层10时，该最小厚度可能会有所不同。
根据实施例，周边区域X的厚度Tl与高光泽表面层10的最小厚度T2之间的关系为1.1<Tl/T2。当关系为1.1<T1/T2时，T2充分小于T1。因此，车辆部件100的整体重量通过减小高光泽表面层10的厚度来减轻。根据实施例，关系为1.1<T1/T2<4.0，更优选为1.3<T1/T2<3.5，进一步更优选为1.5<T1/T2<3.0。根据实施例，高光泽表面层10的最小厚度T2为0.5mm至3.0mm，并且更优选地，厚度T2为1.0mm至2.0mm。
根据实施例，中空结构芯层20由轻质材料形成，其界定了多个孔23以减小中空结构芯层20的整体密度。根据本发明的中空结构芯层20由多种材料制成，包括：纤维素材料，诸如瓦楞纤维板、纸板、纸料；酚醛树脂、诸如聚(甲基丙烯酸甲酯)(PMMA)的热塑性塑料、丙烯腈丁二烯苯乙烯(ABS)、聚酰胺、聚交酯、聚苯并咪唑、聚碳酸酯、聚醚砜、聚乙烯、聚丙烯、聚苯乙烯、聚氯乙烯和前述任一种的嵌段共聚物，其中前述中的至少一种构成共聚物的大部分重量，而无视聚合物或共聚物的立构规整度；热固性材料，诸如聚酯、聚脲、聚氨酯、聚脲/聚氨酯、环氧树脂、乙烯基酯；金属，诸如铝、镁和上述任一种的合金，其中至少一种上述金属占合金重量的大部分；由聚氨酯、聚乙烯、乙烯乙酸乙烯酯、聚丙烯、聚苯乙烯、聚氯乙烯、气凝胶形成的泡沫，无论泡沫是开孔还是闭孔。
中空结构芯20包括界定多个孔24的内壁材料21。孔24可以是无序的，例如，当中空结构芯20由泡沫材料形成时；或者孔24可以是有序阵列，其中，孔的形状为蜂窝状、菱形、正方形、三角形、平行四边形、圆形或它们的组合。应当理解，虽然孔被描绘为彼此隔离，其中，壁结构21易于由延伸的折叠带形成，该折叠带界定了几个孔的一部分，并且当与其他这样的折叠带邻接时，界定了沿着邻接的带之间的接触线相互连通的孔阵列。根据实施例，中空结构芯20的至少一些孔23与至少一个其他孔23流体连通。根据实施例，通过形成穿过至少一些孔23的侧壁21的横向孔洞来建立流体连通。这种孔洞能够在材料形成中空结构芯的孔之前形成在中空结构芯20的材料中。
可替换地，允许孔之间的流体连通的孔洞能够在孔23形成之后形成在芯20的壁21中。至少一些孔23之间的流体连通确保在给定孔挤压或以其他方式变形的情况下使孔内捕获的空气能够移动到另一个孔。如以下将更详细描述的，在一些实施例中，当封装塑料层30的端部32、34插入高光泽表面层10中以形成密封边缘时，芯材料的边缘区域被挤压。在这种情况下，在至少一些孔23的壁21中设置横向孔洞是有益的，例如靠近待密封的边缘的孔洞，使得当密封形成并且边缘附近的孔23被挤压时，那些被挤压的孔中的空气能够通过横向孔洞移动进入相邻的孔中。
根据实施例，由中空结构芯层20的壁21界定的孔23在中空结构芯层20的第一侧22与第二侧24之间延伸。在一些实施例中，内壁材料21被处理以改变其性质，例如疏水性或表面能以促进对其的附着性。举例来说，纤维素制品易于水分吸收，并且易于用诸如石蜡的蜡或硅酮涂覆以使纤维素与天然状态相比更疏水。或者，纤维素易于通过诸如与氯乙酸等的常规反应而烷基化。Sarymsakov,A.A等，Chem.Nat.Compd.(1997)33:337.金属类似地用底漆或其它腐蚀抑制剂涂覆。或者，对金属或聚合物进行等离子体处理以改变表面能进而促进对其的附着性。
在某些创造性的实施例中，壁21的厚度与中空结构芯层20的第一侧22与第二侧24之间的最大直线范围的比率在0.01-10:1之间。在这样的创造性的实施例中，壁21的厚度在0.1mm至100mm的范围内。根据实施例，中空结构芯20的孔23包括填充物，该填充物是消音泡沫、阻燃剂或相变材料中的至少一种。
根据实施例，封装塑料层30主要包含聚氨酯或由具有用聚氨酯浸渍的玻璃纤维毡的纤维增强塑料(GFRP)制成。如图1所示，封装塑料层30层叠在中空结构芯20的第二侧24上。根据实施例，封装塑料层30使用粘合剂固定至中空结构芯20的第二侧24。粘合剂为聚氨酯或聚氨酯预聚物粘合剂，其可以是胶水、湿固化粘合剂、反应性热熔粘合剂或聚氨酯树脂的形式。根据实施例，由于施加到封装塑料层30与中空结构芯层20之间的可选粘合剂的压缩力，粘合剂被设计成在与中空结构芯30的第二侧24和壁21的接触部分处具有部分填充中空结构芯层20的孔23的初始粘度。应当理解，涂布时的粘度是包括涂布温度、面处的孔尺寸和固有粘合剂粘度在内的因子的函数。第一粘合层的粘度确保粘合剂在粘合剂达到最终强度之前不会过度地进入中空结构芯层20限定的孔中。
根据实施例，车辆部件100的高光泽表面层10通过内部塑料层40连接到中空结构芯层20。根据实施例，内部塑料层40由片状模塑料(SMC)、热塑性材料、双环戊二烯(DCPD)、聚氨酯(PU)或其组合形成。根据实施例，内部塑料层40包括填料以增强内部塑料层40和/或用于减轻内部塑料层40的重量。填料是玻璃纤维、碳纤维、玄武岩纤维、天然纤维、中空或实心玻璃微球、纤维毡或以上的组合中的任一者。纤维可以是定向的或非定向的。可以理解，内部塑料层40还可以包括其他添加剂以调整其特性。此类添加剂通常包括玻璃纤维；碳纤维；无机颗粒填料，诸如碳酸钙、滑石和炭黑；玻璃微球；碳纳米管；石墨烯；低轮廓添加剂；除水剂；及其组合。根据实施例，如果高光泽表面层10取代了内部塑料层40的结构性质，则可以省略内部塑料层40作为纤维层。在这种情况下，则高光泽表面层10向中空结构芯层20的直接结合仅通过粘合剂进行，粘合剂诸如聚氨酯或聚氨酯预聚物粘合剂，如上所述，其可以是胶、湿固化粘合剂、反应性热熔粘合剂或聚氨酯树脂的形式。
如图所示，将封装塑料层30的第一端32和第二端34向下折叠并包裹在中空结构芯20的端部26、28上，使得封装塑料层30覆盖增强的中空结构芯层20的第一端26和第二端28。利用这种设计，从车辆部件100的外部看不到中空结构芯层20并且车辆部件100的端部的美感优秀并适用于应用在车辆上，而无需额外的修整，诸如修边或切割。此外，当中空结构芯层20由例如纸蜂窝的蜂窝制成时，封装塑料层30不仅覆盖芯20的端部26、28以提高美感，而且封装塑料层30密封中空结构芯层20并防止水和湿气渗入中空结构芯20，这在车辆部件100用作车辆外表面部件时尤其重要，因为这些部件通常直接与雪、雨和露水接触。
如上所述，封装塑料层30的第一端32和第二端34以嵌入长度L嵌入到高光泽表面层10中。封装塑料层30的端部32、34通过摩擦配合或粘合剂而被保持在高光泽表面层10内。此外，塑化剂可以置于高光泽表面层10内的封装塑料层30的端部32、34，以解决各个材料的热膨胀差异。根据实施例，高光泽表面层10的长度L与厚度T1之间的关系为T1×0.7>L。通过这种设计，防止封装塑料层30的第一端32和第二端34分层，并且中空结构芯层20的端部26、28被覆盖而不能看到并且与外部环境隔离。当高光泽表面层10的长度L与厚度T1之间的关系为T1×0.7＞L时，高光泽表面层10不会由于封装塑料层30的端部32、34的插入而开裂。根据实施例，长度L与厚度T1之间的关系为T1×0.5>L，并且更优选为，T1×0.2>L。然而，当插入长度L的下限为L>T1×0.01时，优选地，端部32、34不容易从高光泽表面层30剥离或脱离。根据实施例，插入长度L的下限为L>T1×0.05，并且更优选为L>T1×0.1。
以下，更具体地说明插入长度L。根据实施例，插入长度L在0.1mm与1.0mm之间。换言之，封装塑料层30的端部32、34插入至高光泽表面层10中0.1mm至1.0mm。当插入长度L为0.1mm以上时，端部32、34趋于不容易从高光泽表面层10剥离。此外，当插入长度L为1.0mm以下时，高光泽表面层10不会因插入端部32、34导致的破裂而损毁。插入长度L更优选为0.2mm与0.8mm之间，并且进一步优选为0.3mm与0.6mm之间。
根据实施例，将密封剂50涂布到封装塑料层20的与高光泽表面层10相交的外部。密封剂50用作粘合剂以帮助将封装塑料层20保持在其插入高光泽面层10中的位置，并有助于进一步密封封装塑料层20和高光泽表面层10，以防止水分渗入中空结构芯层20。
在本发明中，车辆部件100具有区域Z，在该区域Z中，车辆部件100的厚度Tm与中空结构芯层20的厚度Tc之间的关系为Tm-Tc>Tc×0.2。根据实施例，区域Z不需要占据整个车辆部件100。车辆部件100的至少一部分具有满足Tm-Tc＞Tc×0.2的区域Z则足矣。例如，如图9至图12所示，车辆部件100的厚度Tm是车辆部件100的厚度并且Tc是中空结构芯层20的厚度。根据实施例，当车辆部件100具有比中空结构芯20的厚度Tc更厚的厚度Tm时，需要用封装塑料层30或内部塑料层40任一上的额外材料填充高光泽表面层10与中空结构芯20之间的空间。例如，当车辆部件100的形状具有向内的突起，如图9至图11所示，在中空结构芯层20与车辆部件100的内表面36之间的空间用封装塑料层30上的额外材料填充。可替换地，当车辆部件100的形状具有向外的突起时，如图12所示，用内部塑料层40上的额外材料填充中空结构芯层20与高光泽表面层20之间的空间。
根据实施例，车辆部件100是车辆外表面部件。这样的车辆外表面部件例如是车身部件、诸如天窗或扰流板车顶这样的车顶打开系统的盖、车顶模块的表面部件或车辆的衬里构造单元。当车辆部件100是车辆外表面部件时，IMC-TOP涂层可以设置于高光泽表面层10。IMC-TOP涂层可以附着在高光泽表面层10的外侧，其与高光泽表面层10一起形成外壳层。
本发明还提供了一种用于制造上述轻质且有弹性的车辆部件100的方法。如图13A至图13C所示，本发明的方法包括在模具1301、1302中堆叠高光泽表面层10、中空结构芯层20和封装塑料层30。根据实施例，该方法还包括在高光泽表面层10和中空结构芯20之间层叠第二塑料层40。如图所示，中空结构芯层20和封装塑料层30以及，在存在的情况下的内部第二塑料层40设置有大于所需的车辆部件100长度的长度。
该方法继续为使用设置于上模1301或下模1302上的锋利边缘1303而将封装塑料层30的端部32、34插入高光泽表面层10中，如图14A和图14B所示。随着端部32、34插入高光泽表面层10中，锋利边缘1303同时切割封装塑料层30、中空结构芯层20以及在存在情况下的第二内部塑料层40，留下在车辆部件100外部并独立于车辆部件100的修剪部1304。其与现有加工形成对比，现有加工诸如图15A和图15B所示的加工，其中，在从模具中取出形成的夹层结构的车辆部件之后，需要至少一个额外的方法步骤，例如修整或切割边缘，以获得美学上合适的部件边缘。因此，本发明的方法针对现有加工的改进之处在于本发明的方法减少了制造步骤，从而增加了制造产量并降低了制造成本。
该方法继续为将上模1301和下模1302按压在一起以赋予车辆部件100形状。根据实施例，将真空施加于模腔以进一步辅助车辆部件100的塑形。
根据实施例，锋利边缘1303的穿透由工具控制，并且具有可调节垫片的硬止动件可以设置穿透距离。此外，根据实施例，IMC薄层能够设置有外表面涂层，或者高光泽表面层10能够设置有可涂漆的IMC薄层，并且因此该方法可以包括涂漆车辆部件100。此外，IMC漆层可以涂布于高光泽表面层10的面向第一模具1302的一侧，以在该加工中形成外皮层。
根据实施例，诸如图16A至图16C所示，该方法包括在成型时用掩模1601遮盖高光泽表面层10的端部，以防止在成型加工期间高光泽表面层10上的任何粘附痕迹或其他划痕。
前面的描述是对本发明的特定实施例的例示，但并不意味着对其实施的限制。以下权利要求，包括其所有的等同表述旨在限定本发明的范围。

Claims (20)

1.一种车辆部件单元，包括：
增强中空结构芯层，该增强中空结构芯层具有第一侧和相反设置的第二侧以及第一端和相反设置的第二端，所述第一端和所述第二端各自在所述第一侧与所述第二侧之间延伸；
高光泽表面层，该高光泽表面层定位于所述增强中空结构芯层的所述第一侧；以及
封装塑料层，该封装塑料层具有第一端和第二端，所述封装塑料层定位于所述增强中空结构芯层的所述第二侧，所述封装塑料层的第一端和第二端以嵌入长度L嵌入所述高光泽表面层中，使得所述封装塑料层覆盖所述增强中空结构芯层的第一端和第二端。
2.根据权利要求1所述的车辆部件单元，其中，所述嵌入长度L与所述高光泽表面层的厚度T1之间的关系为T1×0.7>L。
3.根据权利要求1所述的车辆部件单元，其中，所述嵌入长度L在0.1mm与1.0mm之间。
4.根据权利要求1所述的车辆部件单元，其中，所述增强中空结构芯层为以下至少一个形状的图案的阵列：六边形、圆形、菱形、三角形、平行四边形或规则四边形。
5.根据权利要求1所述的车辆部件单元，其中，所述增强中空结构芯层由以下中的至少一者所形成：纤维素材料、热塑性材料、热固性材料、金属或者泡沫。
6.根据权利要求2所述的车辆部件单元，其中，在距所述封装塑料层的第一端或者第二端插入至所述高光泽表面层中的点5.0mm以内的区域X中，测量所述高光泽表面层的厚度T1。
7.根据权利要求6所述的车辆部件单元，其中，所述区域X的厚度T1与所述高光泽表面层的最小厚度T2之间的关系为1.1<T1/T2。
8.根据权利要求2所述的车辆部件单元，其中，所述厚度T1在1mm与4mm之间。
9.根据权利要求1至5中任一项所述的车辆部件单元，其中，所述车辆部件单元具有区域Z，在该区域Z中，所述车辆部件单元的厚度Tm与所述增强中空结构芯层的厚度Tc之间的关系为Tm-Tc>Tc×0.2。
10.根据权利要求1至5中任一项所述的车辆部件单元，其中，所述增强中空结构芯层与所述高光泽表面层之间的空间被第二塑料层填充。
11.根据权利要求1至5中任一项所述的车辆部件单元，其中，所述高光泽表面片材由下列任一项形成：片状模塑料(SMC)、热塑性片材、二环戊二烯(DCPD)或聚氨酯(PU)。
12.根据权利要求1至5中任一项所述的车辆部件单元，其中，所述高光泽表面片材包括以下中的至少一种的填料：玻璃纤维、碳纤维、碳纳米管、石墨烯、无机颗粒填料、玻璃微球、低轮廓添加剂或者除水剂。
13.根据权利要求1至5中任一项所述的车辆部件单元，所述车辆部件单元在所述增强中空结构芯的孔中还包括填充物，所述填充物是消音泡沫、阻燃剂或相变材料中的至少一种。
14.根据权利要求1至5中任一项所述的车辆部件单元，其中，所述高光泽表面层和所述封装塑料层形成防潮密封。
15.一种权利要求1所述的车辆部件单元的制造方法，该方法包括：
在具有一起界定模腔的上部和下部的模具中层叠所述高光泽表面层、所述中空结构芯层和所述封装塑料层；
使用所述模具上的锋利边缘将所述封装塑料层的端部插入所述高光泽表面层中，并且同时使用所述模具上的所述锋利边缘修整所述封装塑料层和所述中空结构芯层；以及
将所述模具的上部和所述模具的下部按压到一起以赋予所述车辆部件形状。
16.根据权利要求15所述的方法，还包括将真空施加于所述模腔以塑形所述车辆部件。
17.根据权利要求15所述的方法，还包括在所述高光泽表面层10与所述中空结构芯20之间层叠第二塑料层40。
18.如权利要求17所述的方法，其中，所述模具的所述锋利边缘也修整所述第二塑料层。
19.根据权利要求15或16所述的方法，其中，所述中空结构芯层和所述封装塑料层的长度大于所述车辆部件的长度。
20.根据权利要求15或16所述的方法，还包括用掩模遮蔽所述高光泽表面层的端部。
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