CN115674565A - Manufacturing process of thermoplastic composite material new energy automobile shell component - Google Patents
Manufacturing process of thermoplastic composite material new energy automobile shell component Download PDFInfo
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- CN115674565A CN115674565A CN202211319497.4A CN202211319497A CN115674565A CN 115674565 A CN115674565 A CN 115674565A CN 202211319497 A CN202211319497 A CN 202211319497A CN 115674565 A CN115674565 A CN 115674565A
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Abstract
The invention relates to the field of new energy automobiles, in particular to a manufacturing process of a thermoplastic composite material new energy automobile shell component, which comprises the following steps: preparing a thermoplastic prepreg tape composite plate; one or more layers of thermoplastic prepreg tape boards are laminated and fixed according to requirements, and then are cut and processed; heating the cut thermoplastic prepreg tape composite material plate until the resin is softened or melted, quickly transferring the thermoplastic prepreg tape composite material plate to a specified position in a mould by a manipulator or a manual mode, paving the thermoplastic prepreg tape composite material plate and well performing effective lap joint of the material at the part of a product to be connected; and (3) closing the die, pressurizing and cooling, injecting the short fiber thermoplastic composite material into the die on line according to the requirement, and finally obtaining the required shell component product after demolding and post-processing. The invention can effectively strengthen the high mechanical property and the light weight effect of the shell component, realizes the reproducibility of materials and products, reduces the product cost and improves the efficiency.
Description
Technical Field
The invention relates to the field of new energy automobiles, in particular to a manufacturing process of a thermoplastic composite material new energy automobile shell component.
Background
The driving range of the new energy automobile is always one of the most important reasons influencing the high-speed development of the industry and the selection of the user for purchasing the automobile, and the improvement of the driving range of the automobile depends on the improvement of the energy density of a battery on one hand and the improvement of the energy utilization rate and the reduction of the energy consumption of the whole automobile in the driving process of the automobile on the other hand. The automobile is light, and is an effective means for reducing the energy consumption of the automobile and improving the driving range of the new energy automobile.
Due to excellent light weight and high strength, the composite material is widely applied to battery pack shell parts such as battery boxes and battery pack protection plates and new energy automobile interior and exterior trim shell parts such as engine covers, tail doors, bumpers, empennages, fenders, door panels, instrument panels and ceilings. However, although such composite materials or thermosetting materials have high mechanical properties, they cannot meet the increasingly stringent environmental requirements of material renewability (recycling) in the automobile industry; or the thermoplastic material, but because the injection molding pure short fiber reinforced material, its mechanical performance is naturally insufficient, for the safety of the product must increase the product design wall thickness, which in turn counteracts the product lightweight effect to a certain extent.
Therefore, how to solve the problem of reproducibility (recycling) of materials and products on the premise of ensuring and even continuously improving the mechanical performance and the light weight effect of the housing part of the new energy automobile becomes an important subject in the field of light weight of the new energy automobile.
Disclosure of Invention
The invention aims to provide a manufacturing process of a thermoplastic composite material new energy automobile shell component, which effectively strengthens the high mechanical property and the light weight effect of the new energy automobile shell component, realizes the reproducibility (recycling) of materials and products, reduces the production cost of the products and improves the production efficiency.
The technical scheme of the invention is as follows: a manufacturing process of a thermoplastic composite material new energy automobile shell component comprises the following steps:
(1) Preparing a thermoplastic prepreg tape composite material plate, wherein the thermoplastic prepreg tape composite material contains fibers and thermoplastic resin, and the content of the fibers is 5-85%;
(2) According to the design wall thickness requirement of a shell component product, one or more layers of thermoplastic prepreg tape composite plates are laminated and fixed as required, and then cutting is carried out, or the one or more layers of thermoplastic prepreg tape composite plates which are cut and processed are laminated and fixed as required;
(3) Heating the laminated and cut thermoplastic prepreg tape composite board until the resin is softened or melted; or, the thermoplastic prepreg tape composite material plate of which the resin is in a softened or molten state due to heating and which is cut continues to maintain the hot state;
(4) Rapidly transferring the thermoplastic prepreg tape composite material plate with the resin in a softened or molten state to a specified position in a mould by a manipulator or a manual mode, paving, and well performing effective lap joint of the material at the position of a product to be connected;
(5) Closing the die, pressurizing, cooling the product to the demolding temperature through circulating cooling water, and molding the product in the die;
(6) And opening the die, demolding the product, and post-processing to obtain the required shell component product.
Further, the thickness of the thermoplastic prepreg tape composite material plate is 0.05mm to 15mm.
Further, in the step (1), the preparation process of the thermoplastic prepreg tape composite material plate comprises a spraying method and an impregnation method, or is formed by mixing and weaving fibers and thermoplastic resin filaments, and directly applying or further performing hot pressing, wherein the thermoplastic resin filaments are formed by melting and drawing thermoplastic resin; the fibers in the thermoplastic prepreg tape composite material plate comprise one or more of carbon fibers, glass fibers, basalt fibers, aramid fibers and ultrahigh molecular weight polyethylene fibers; the thermoplastic resin comprises one or more of polypropylene PP, polyethylene PE, polystyrene PS, polyvinyl chloride PVC, polyamide PA, polycarbonate PC, polyether ether ketone PEEK, polyphenylene oxide PPO, polyphenylene sulfide PPS, polyformaldehyde POM, polymethyl methacrylate PMMA, acrylonitrile-butadiene-styrene copolymer ABS and modified materials thereof.
Further, in the step (1), the form of the fiber includes one or more of continuous fiber, fiber fabric, fiber mat and chopped fiber.
Further, in the step (2), the length and width of the peripheral edge of the laminated and cut thermoplastic prepreg tape composite material plate are smaller than the edge of the mould at the corresponding position by 0.5-20mm; the lapping position of the materials can be properly thinned, so that the overlarge thickness of the materials after lapping is avoided.
Further, injecting a short fiber thermoplastic composite material into the mold on line between the step (5) and the step (6) when the product is cooled to 80-150 ℃ according to requirements, wherein the short fiber thermoplastic composite material contains short fibers and thermoplastic resin, and the content of the short fibers is 5-60%.
Further, the chopped fibers in the chopped fiber thermoplastic composite material comprise one or more of carbon fibers, glass fibers, basalt fibers, aramid fibers and ultrahigh molecular weight polyethylene fibers; the thermoplastic resin comprises one or more of polypropylene PP, polyethylene PE, polystyrene PS, polyvinyl chloride PVC, polyamide PA, polycarbonate PC, polyether ether ketone PEEK, polyphenyl ether PPO, polyphenylene sulfide PPS, polyformaldehyde POM, polymethyl methacrylate PMMA, acrylonitrile-butadiene-styrene copolymer ABS and modified materials thereof.
Further, in the step (5), the demolding temperature is 28-75 ℃.
Further, the shell component comprises a battery shell component and an interior and exterior decoration shell component of the new energy automobile.
Furthermore, the battery box shell part comprises a battery box and a battery box protection plate, wherein the battery box is of a closed or unsealed curved surface structure and comprises an upper cover and a lower box body; the interior trim shell parts of new energy automobile include bonnet, tail-gate, bumper, fin, fender, door plant, instrument board and ceiling.
Compared with the prior art, the invention has the following advantages:
1. according to the invention, the new energy automobile shell component is manufactured by adopting a thermoplastic prepreg tape mould pressing process, and the short fiber thermoplastic composite material is injected on line according to the requirement, so that the ultrahigh mechanical property of the thermoplastic prepreg tape can be fully utilized to improve the mechanical property of the main structure part of the shell component, and the light weight effect of the shell component is further strengthened; meanwhile, the formability and the high efficiency of the short-fiber thermoplastic material injection molding process can be utilized, on one hand, secondary structure parts such as the peripheral edge of the product and complex structure parts such as reinforcing ribs which are difficult to form can be smoothly formed, on the other hand, the production efficiency of the product is further improved, and the fast-paced supply requirement of the new energy automobile industry can be met.
2. According to the invention, the thermoplastic resin is used as the matrix resin of the prepreg and short fiber composite material, so that the specific gravity of the composite material is lower than that of the thermosetting composite material (the specific gravity of the thermosetting composite material is usually 1.8-2.0, and the specific gravity of the thermoplastic composite material is usually less than 1.5), and the lightweight effect of the new energy automobile shell component is further enhanced.
3. The invention adopts thermoplastic resin as the matrix resin of the prepreg tape and the short fiber composite material, so that the material and the product have the property of being recycled, and can meet the increasingly severe environmental protection requirement of the automobile industry.
4. The thermoplastic resin is used as the matrix resin of the prepreg tape and the short fiber composite material, so that the material and the product have the property of being recycled, and the utilization rate of the material is close to 100 percent, thereby reducing the product cost, improving the market competitiveness of the product and achieving the aim of effectively saving social resources.
5. The invention has simple and convenient manufacturing process, high production efficiency and wide application range, and can be widely applied to the production of battery pack shell parts such as a battery box and a battery pack protection plate and new energy automobile interior and exterior decoration shell parts such as an engine hood, a tail door, a bumper, an empennage, a fender, a vehicle door panel, an instrument panel, a ceiling and the like.
Drawings
FIG. 1 is a schematic diagram of a laminating process for preparing a thermoplastic prepreg tape composite;
FIG. 2 is a schematic illustration of a dipping process for making a thermoplastic prepreg tape composite;
FIG. 3 is a schematic structural diagram of a blank material of a battery case product after cutting a thermoplastic prepreg tape composite material plate;
FIG. 4 is a diagram of a battery pack product;
in the figure: 1-fiber 2-resin layer 3-laminating die head 4-hot roller 5-strip 6-strip rolling 7-dipping die 8-resin extrusion die head 9-forming pair roller 10-elevation R angle 11-flange face R angle.
Detailed Description
In order to make the aforementioned features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in detail below, but the present invention is not limited thereto.
Example one
A manufacturing process of a thermoplastic composite material new energy automobile shell component comprises the following steps:
(1) Preparing a thermoplastic prepreg tape composite material plate, wherein the thickness of the thermoplastic prepreg tape composite material plate is 0.2mm; the thermoplastic prepreg tape composite board contains fibers and thermoplastic resin, wherein the fiber content is 75%.
(2) And (3) according to the design wall thickness requirement of the shell component product, laminating and fixing one or more layers of thermoplastic prepreg tape composite plates according to the requirement, and then cutting, or laminating and fixing the one or more layers of thermoplastic prepreg tape composite plates which are cut according to the requirement. The length and width of the edges of the laminated and cut thermoplastic prepreg tape composite material plate are smaller than the edge of a mould at the corresponding position by 1mm; the lapping position of the materials can be properly thinned, so that the overlarge thickness of the materials after lapping is avoided.
(3) Heating the laminated and cut thermoplastic prepreg tape composite material plate until the resin is softened or melted; alternatively, the thermoplastic prepreg tape composite material sheet, which is a laminate whose resin is in a softened or molten state by heating and is cut, is continuously maintained in this heated state.
(4) The thermoplastic prepreg tape composite material plate with the resin in a softened or molten state is quickly transferred to a designated position in a mould by a mechanical arm or a manual mode, and is laid flat, and effective lap joint of the materials is well made at the position where the products need to be connected.
(5) And (5) closing the die, pressurizing, and cooling the product to 32 ℃ by circulating cooling water so as to shape the product in the die.
(6) And opening the die, demolding the product, and post-processing to obtain the required shell component product.
In this embodiment, in step (1), the preparation process of the thermoplastic prepreg tape composite material plate may be a laminating method (see fig. 1) or an impregnation method (see fig. 2), or a process in which fibers and thermoplastic resin filaments are mixed and woven and directly applied or further hot-pressed, wherein the thermoplastic resin filaments are formed by melting and drawing thermoplastic resin; the morphology of the fibers includes one or more of continuous fibers, fiber fabrics, fiber mats, and chopped fibers.
In this embodiment, in the step (1), the fibers in the thermoplastic prepreg tape composite material plate include one or more of inorganic fibers such as carbon fibers, glass fibers, basalt fibers, and the like, and organic fibers such as aramid fibers, ultra-high molecular weight polyethylene fibers, and the like, and the thermoplastic resin includes one or more of polypropylene PP, polyethylene PE, polystyrene PS, polyvinyl chloride PVC, polyamide PA, polycarbonate PC, polyether ether ketone PEEK, polyphenylene oxide PPO, polyphenylene sulfide PPs, polyoxymethylene POM, polymethyl methacrylate PMMA, ABS (acrylonitrile-butadiene-styrene copolymer), and modified materials thereof. Among them, the fibers may preferably be composed of carbon fibers and ultra-high molecular weight polyethylene fibers, and the thermoplastic resin may preferably be polyethylene PE.
In this embodiment, between the step (5) and the step (6), a short fiber thermoplastic composite material containing a short fiber and a thermoplastic resin, in which the content of the short fiber is 52%, is injected into the mold in-line while the product is cooled to 85 ℃.
In the embodiment, the mold is provided with the injection molding sprue, the flow channel and the circulating cooling water path, and the molding and injection molding requirements of the product can be met simultaneously. The injection molding sprue is arranged on the parting surface of the mold, so that the flange edge, the material connecting part, the reinforcing rib and other designed parts of the product can be effectively filled and bonded quickly.
In this embodiment, the chopped fibers in the chopped fiber thermoplastic composite material include one or more of inorganic fibers such as carbon fibers, glass fibers and basalt fibers, and organic fibers such as aramid fibers and ultra-high molecular weight polyethylene fibers; the thermoplastic resin comprises one or more of polypropylene PP, polyethylene PE, polystyrene PS, polyvinyl chloride PVC, polyamide PA, polycarbonate PC, polyetheretherketone PEEK, polyphenylene oxide PPO, polyphenylene sulfide PPS, polyoxymethylene POM, polymethyl methacrylate PMMA, ABS (acrylonitrile-butadiene-styrene copolymer) and modified materials thereof. Among them, the chopped fibers may preferably be composed of ultra-high molecular weight polyethylene fibers and glass fibers, and the thermoplastic resin may preferably be polyethylene PE.
In this embodiment, the housing part includes a battery housing part and a new energy automobile interior and exterior casing part. The battery case body part comprises a battery case and a battery case protecting plate, wherein the battery case is of a closed or non-closed curved surface structure and comprises an upper cover and a lower case body. The interior trim shell parts of new energy automobile include bonnet, tail-gate, bumper, fin, fender, door plant, instrument board and ceiling.
Example two
A manufacturing process of a thermoplastic composite material new energy automobile shell component comprises the following steps:
(1) Preparing a thermoplastic prepreg tape composite material plate, wherein the thickness of the thermoplastic prepreg tape composite material plate is 4mm; the thermoplastic prepreg tape composite board contains fibers and thermoplastic resin, wherein the fiber content is 30%.
(2) And (3) according to the design wall thickness requirement of the shell component product, laminating and fixing one or more layers of thermoplastic prepreg tape composite plates as required, and then cutting, or laminating and fixing one or more layers of thermoplastic prepreg tape composite plates which are cut as required. The length and width of the edges of the laminated and cut thermoplastic prepreg tape composite material plate are 5mm smaller than the edge of the mould at the corresponding position; the lapping position of the materials can be properly thinned, so that the overlarge thickness of the materials after lapping is avoided.
(3) Heating the laminated and cut thermoplastic prepreg tape composite board until the resin is softened or melted; alternatively, the thermoplastic prepreg tape composite material sheet, which is a laminate whose resin is in a softened or molten state by heating and is cut, is continuously maintained in this heated state.
(4) The thermoplastic prepreg tape composite material plate with the resin in a softened or molten state is rapidly transferred to a designated position in a mould by a mechanical arm or a manual mode, and is laid flat, and effective lap joint of the material is well made at the position where a product needs to be connected.
(5) And (5) closing the die, pressurizing, and cooling the product to 70 ℃ by circulating cooling water so as to shape the product in the die.
(6) And opening the mold, demolding the product, and post-processing to obtain the required shell component product.
In this embodiment, in step (1), the preparation process of the thermoplastic prepreg tape composite material plate may be a laminating method (see fig. 1) or an impregnation method (see fig. 2), or a process in which fibers and thermoplastic resin filaments are mixed and woven and directly applied or further hot-pressed, wherein the thermoplastic resin filaments are formed by melting and drawing thermoplastic resin; the morphology of the fibers includes one or more of continuous fibers, fiber fabrics, fiber mats, and chopped fibers.
In this embodiment, in the step (1), the fibers in the thermoplastic prepreg tape composite material sheet are composed of basalt fibers and glass fibers. The thermoplastic resin is polyetheretherketone PEEK.
In this embodiment, between step (5) and step (6), a short fiber thermoplastic composite material containing short fibers and a thermoplastic resin is injected in-line into the mold while the product is cooled to 140 ℃, wherein the content of the short fibers is 25%.
In the embodiment, the mold is provided with the injection molding sprue, the flow channel and the circulating cooling water path, and the molding and injection molding requirements of the product can be met simultaneously. The injection molding sprue is arranged on the parting surface and the upper die of the die, so that the flange edge, the material connecting part, the reinforcing rib and other designed parts of the product can be effectively filled and bonded quickly.
In this embodiment, the chopped fibers in the chopped fiber thermoplastic composite material are aramid fibers; the thermoplastic resin is polyphenylene oxide PPO.
In this embodiment, the housing part includes a battery housing part and a new energy automobile interior and exterior casing part. The battery box shell component comprises a battery box and a battery pack protection plate, wherein the battery box is of a closed or unsealed curved surface structure and comprises an upper cover and a lower box body. The interior trim shell parts of new energy automobile include bonnet, tail-gate, bumper, fin, fender, door plant, instrument board and ceiling.
EXAMPLE III
A manufacturing process of a thermoplastic composite material new energy automobile shell component comprises the following steps:
(1) Preparing a thermoplastic prepreg tape composite material plate, wherein the thickness of the thermoplastic prepreg tape composite material plate is 8mm; the thermoplastic prepreg tape composite board contains fibers and thermoplastic resin, wherein the fiber content is 15%.
(2) And (3) according to the design wall thickness requirement of the shell component product, laminating and fixing one or more layers of thermoplastic prepreg tape composite plates according to the requirement, and then cutting, or laminating and fixing the one or more layers of thermoplastic prepreg tape composite plates which are cut according to the requirement. The length and width of the edges of the periphery of the laminated and cut thermoplastic prepreg tape composite material plate are 16.5mm smaller than the edge of a mould at the corresponding position; the lapping position of the materials can be properly thinned, so that the overlarge thickness of the materials after lapping is avoided.
(3) And heating the laminated and cut thermoplastic prepreg tape composite material plate until the resin is softened or melted, transferring the thermoplastic prepreg tape composite material plate to a heat-insulating conveying belt, and finally conveying the thermoplastic prepreg tape composite material plate to a forming and feeding operation station.
(4) After the thermoplastic prepreg tape composite material plate reaches a forming and feeding operation station, the thermoplastic prepreg tape composite material plate is quickly transferred to a designated position in a die on a hydraulic press by a manipulator or a manual mode, and is paved, and effective lap joint of the material is well made at the position where the product needs to be connected.
(5) And (5) closing the die, pressurizing, and cooling the product to 40 ℃ by circulating cooling water so as to shape the product in the die.
(6) And opening the die, demolding the product, trimming and post-processing to obtain the required shell component product.
In this embodiment, in step (1), the preparation process of the thermoplastic prepreg tape composite material plate may be a laminating method (see fig. 1) or an impregnation method (see fig. 2), or a process in which fibers and thermoplastic resin filaments are mixed and woven and directly applied or further hot-pressed, wherein the thermoplastic resin filaments are formed by melting and drawing thermoplastic resin; the form of the fiber comprises one or more of continuous fiber, fiber fabric, fiber felt and chopped fiber
In this embodiment, in the step (1), the fibers in the thermoplastic prepreg tape composite material sheet are composed of glass fibers and aramid fibers, and the thermoplastic resin is polyamide PA66.
In this embodiment, between the step (5) and the step (6), a short fiber thermoplastic composite material containing short fibers and a thermoplastic resin is injected in-line into the mold while the product is cooled to 95 ℃ as required, wherein the content of the short fibers is 15%.
In the embodiment, the mold is provided with the injection molding sprue, the flow channel and the circulating cooling water path, and the molding and injection molding requirements of the product can be met simultaneously. The injection molding sprue is arranged on the mold parting surface and the lower mold, so that the flange edge, the material connecting part, the reinforcing rib and other designed parts of the product can be effectively filled and bonded quickly.
In this embodiment, the chopped fibers in the chopped fiber thermoplastic composite material are aramid fibers; the thermoplastic resin is polyphenylene sulfide (PPS).
In this embodiment, the housing part includes a battery housing part and a new energy automobile interior and exterior casing part. The battery box shell component comprises a battery box and a battery pack protection plate, wherein the battery box is of a closed or unsealed curved surface structure and comprises an upper cover and a lower box body. The interior trim shell parts of new energy automobile include bonnet, tail-gate, bumper, fin, fender, door plant, instrument board and ceiling.
Example four
A manufacturing process of a thermoplastic composite material battery box comprises the following steps:
(1) Preparing a thermoplastic prepreg tape composite material plate, wherein the thickness of the thermoplastic prepreg tape composite material plate is 1.5mm; the thermoplastic prepreg tape composite board contains fibers and a thermoplastic resin, wherein the fiber content is 55%.
(2) One or more layers of thermoplastic prepreg tape composite material plates are laminated and fixed as required according to the design wall thickness requirements of the shell component product, and then are cut, or the one or more layers of thermoplastic prepreg tape composite material plates which are cut are laminated and fixed as required, see fig. 3. The length and width of the edges of the laminated and cut thermoplastic prepreg tape composite material plate are 10mm smaller than the edge of the mould at the corresponding position; the lapping position of the materials can be properly thinned, so that the overlarge thickness of the materials after lapping is avoided.
(3) Heating the laminated and cut thermoplastic prepreg tape composite material plate until the resin is softened or melted; or, the thermoplastic prepreg tape composite material plate whose resin is in a softened or molten state due to heating and cut is continuously maintained in the hot state;
(4) The thermoplastic prepreg tape composite material plate with the resin in a softened or molten state is quickly transferred to a designated position in a mould by a manipulator or a manual mode, and is paved, and effective lap joint of the material is made at positions needing to be connected, such as a product vertical surface corner R, a flange surface corner R (see figure 4) and the like.
(5) And (4) closing the die, pressurizing, and cooling the product to 50 ℃ by circulating cooling water so as to shape the product in the die.
(6) And (5) opening the mold, demolding the product, and post-processing to obtain the required shell component product, which is shown in figure 4.
In this embodiment, in step (1), the preparation process of the thermoplastic prepreg tape composite material plate may be a laminating method (see fig. 1) or an impregnation method (see fig. 2), or a process in which fibers and thermoplastic resin filaments are mixed and woven and directly applied or further hot-pressed, wherein the thermoplastic resin filaments are formed by melting and drawing thermoplastic resin; the form of the fiber comprises one or more of continuous fiber, fiber fabric, fiber felt and chopped fiber;
in this embodiment, in step (1), the fibers in the thermoplastic prepreg tape composite material plate include one or more of inorganic fibers such as carbon fibers, glass fibers, basalt fibers, and the like, and organic fibers such as aramid fibers, ultra-high molecular weight polyethylene fibers, and the thermoplastic resin includes one or more of polypropylene PP, polyethylene PE, polystyrene PS, polyvinyl chloride PVC, polyamide PA, polycarbonate PC, polyether ether ketone PEEK, polyphenylene oxide PPO, polyphenylene sulfide PPs, polyoxymethylene POM, polymethyl methacrylate PMMA, ABS (acrylonitrile-butadiene-styrene copolymer), and modified materials thereof. Among them, the fiber may preferably be a carbon fiber; the thermoplastic resin may preferably be polypropylene PP.
In this embodiment, between the step (5) and the step (6), a short fiber thermoplastic composite material containing short fibers and a thermoplastic resin, in which the content of the short fibers is 35%, is injected into the mold in-line while the product is cooled to 90 ℃.
In the embodiment, the mold is provided with the injection molding sprue, the flow channel and the circulating cooling water path, and the molding and injection molding requirements of the product can be met simultaneously. The injection molding sprue is arranged on the parting surface of the mold, so that the flange edge, the material connecting part, the reinforcing rib and other designed parts of the product can be effectively filled and bonded quickly.
In this embodiment, the chopped fibers in the chopped thermoplastic composite material include one or more of inorganic fibers such as carbon fibers, glass fibers, basalt fibers and the like and organic fibers such as aramid fibers, ultra-high molecular weight polyethylene and the like, and the thermoplastic resin includes one or more of polypropylene PP, polyethylene PE, polystyrene PS, polyvinyl chloride PVC, polyamide PA, polycarbonate PC, polyetheretherketone PEEK, polyphenylene oxide PPO, polyphenylene sulfide PPs, polyoxymethylene POM, polymethyl methacrylate PMMA, ABS (acrylonitrile-butadiene-styrene copolymer) and modified materials thereof. Among them, the chopped fibers may preferably be composed of glass fibers and carbon fibers, and the thermoplastic resin may preferably be polypropylene PP.
In this embodiment, the battery case is a closed or non-closed curved structure, and includes an upper cover and a lower case.
The above description is only a preferred embodiment of the present invention, and it should be understood by those skilled in the art that the manufacturing process of the new energy automobile shell component made of thermoplastic composite material in different forms according to the teachings of the present invention does not require creative efforts, and all equivalent changes, modifications, substitutions and variations made according to the claims of the present invention should be covered by the scope of the present invention without departing from the principle and spirit of the present invention.
Claims (10)
1. A manufacturing process of a thermoplastic composite material new energy automobile shell component is characterized by comprising the following steps:
(1) Preparing a thermoplastic prepreg tape composite material plate, wherein the thermoplastic prepreg tape composite material plate contains fibers and thermoplastic resin, and the content of the fibers is 5-85%;
(2) According to the design wall thickness requirement of a shell component product, one or more layers of thermoplastic prepreg tape composite material plates are laminated and fixed as required, and then cutting processing is carried out, or the one or more layers of thermoplastic prepreg tape composite material plates which are cut and processed are laminated and fixed as required;
(3) Heating the laminated and cut thermoplastic prepreg tape composite board until the resin is softened or melted; or, the thermoplastic prepreg tape composite material plate of which the resin is in a softened or molten state due to heating and which is cut continues to maintain the hot state;
(4) Rapidly transferring the thermoplastic prepreg tape composite material plate with the resin in a softened or molten state to a specified position in a mould by a manipulator or a manual mode, paving, and well performing effective lap joint of the material at the position of a product to be connected;
(5) Closing the mold, pressurizing, cooling the product to the demolding temperature through circulating cooling water, and molding the product in the mold;
(6) And opening the mold, demolding the product, and post-processing to obtain the required shell component product.
2. The manufacturing process of the thermoplastic composite material new energy automobile shell component as claimed in claim 1, wherein the thickness of the thermoplastic prepreg tape composite material plate is 0.05mm to 15mm.
3. The manufacturing process of the thermoplastic composite material new energy automobile shell component according to claim 1, characterized in that in the step (1), the manufacturing process of the thermoplastic prepreg tape composite material plate comprises a laminating method and an impregnation method, or is formed by mixing and weaving fibers and thermoplastic resin filaments, and directly applying or further performing hot pressing, wherein the thermoplastic resin filaments are formed by melting and drawing thermoplastic resin; the fiber in the thermoplastic prepreg tape composite material plate comprises one or more of carbon fiber, glass fiber, basalt fiber, aramid fiber and ultrahigh molecular weight polyethylene fiber, and the thermoplastic resin comprises one or more of polypropylene PP, polyethylene PE, polystyrene PS, polyvinyl chloride PVC, polyamide PA, polycarbonate PC, polyether ether ketone PEEK, polyphenylene oxide PPO, polyphenylene sulfide PPS, polyformaldehyde POM, polymethyl methacrylate PMMA, acrylonitrile-butadiene-styrene copolymer ABS and modified materials thereof.
4. The manufacturing process of the thermoplastic composite material new energy automobile shell component according to claim 1, wherein in the step (1), the form of the fibers comprises one or more of continuous fibers, fiber fabrics, fiber mats and chopped fibers.
5. The manufacturing process of the thermoplastic composite material new energy automobile shell component as claimed in claim 1, 2, 3 or 4, wherein in the step (2), the length and width dimensions of the peripheral edge of the thermoplastic prepreg tape composite material plate after lamination and cutting are 0.5mm to 20mm smaller than the edge dimensions of the mould at the corresponding position; the lapping position of the materials can be properly thinned, so that the overlarge thickness of the materials after lapping is avoided.
6. The manufacturing process of the thermoplastic composite material new energy automobile shell component as claimed in claim 1, 2, 3 or 4, characterized in that between the step (5) and the step (6), a short fiber thermoplastic composite material is injected into the mold on line when the product is cooled to 80-150 ℃, wherein the short fiber thermoplastic composite material contains short fibers and thermoplastic resin, and the content of the short fibers is 5% -60%.
7. The manufacturing process of the thermoplastic composite new energy automobile shell component according to claim 6, wherein the chopped fibers in the chopped thermoplastic composite comprise one or more of carbon fibers, glass fibers, basalt fibers, aramid fibers and ultrahigh molecular weight polyethylene fibers, and the thermoplastic resin comprises one or more of polypropylene (PP), polyethylene (PE), polystyrene (PS), polyvinyl chloride (PVC), polyamide (PA), polycarbonate (PC), polyether ether ketone (PEEK), polyphenylene oxide (PPO), polyphenylene sulfide (PPS), polyoxymethylene (POM), polymethyl methacrylate (PMMA), acrylonitrile-butadiene-styrene copolymer (ABS) and modified materials thereof.
8. The manufacturing process of the thermoplastic composite material new energy automobile shell component according to claim 1, wherein in the step (5), the demolding temperature is 28 ℃ to 75 ℃.
9. The manufacturing process of the thermoplastic composite material new energy automobile shell component according to the claim 1, 2, 3, 4, 7 or 8, characterized in that the shell component comprises a battery shell component and a new energy automobile interior and exterior shell component.
10. The manufacturing process of the thermoplastic composite material new energy automobile shell component according to claim 9, wherein the battery shell component comprises a battery box and a battery shell protection plate; the battery box is a closed or unsealed curved surface structure and comprises an upper cover and a lower box body; interior trim housing part includes bonnet, tail-gate, bumper, fin, fender, door plant, instrument board and ceiling in the new energy automobile.
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| CN116238097A (en) * | 2023-05-11 | 2023-06-09 | 北京维盛复合材料有限公司 | Segmented full-automatic injection molding process based on manipulator control |
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2022
- 2022-10-26 CN CN202211319497.4A patent/CN115674565A/en active Pending
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116238097A (en) * | 2023-05-11 | 2023-06-09 | 北京维盛复合材料有限公司 | Segmented full-automatic injection molding process based on manipulator control |
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