CN203792726U - 预浸料制成的半成品及三维预成型体和包塑成型件 - Google Patents
预浸料制成的半成品及三维预成型体和包塑成型件 Download PDFInfo
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Abstract
本实用新型涉及预浸料制成的半成品及三维预成型体和包塑成型件。具体而言,提供了一种由预浸料制成的半成品,它至少包括第一预浸料层和第二预浸料层,其特征在于,在所述第一预浸料层和所述第二预浸料层之间铺有磁性材料层。由于在预浸料层之间加入了磁性材料层,由此制成的所述半成品在被制成三维成型体以及进一步制成包塑成型件的过程中能通过模具上的磁体对该磁性材料层的吸引来获得良好的支承及定位,从而能够精确成型。
Description
技术领域
本实用新型涉及预浸料制品领域,更具体地,涉及由预浸料制成的半成品及由该半成品制成的三维预成型体和包塑成型件。
背景技术
预浸料(英文为“PREPREG”)是一种常用的制造复合材料的中间材料,通常由树脂基体与浸渍在该基体中的增强体(例如:纤维或织物)构成。由于包含增强体,预浸料具有较高的机械强度,经常用于制造局部区域或整个区域需要加强的部件,例如机动车部件。市场上购买到的预浸料通常是片状或者卷状。
机动车上需要加强的部件通常是三维的,有时还具有复杂的形状。已知一种制造这种三维部件的方法包含以下步骤:
步骤1:将购买的预浸料切割成合适的形状和尺寸(通常是由期望得到的三维预成型体进行二维展开而得到的)并根据需要将若干层具有合适形状和尺寸的预浸料堆叠在一起,从而获得半成品;
步骤2:对上述半成品进行加热并随后进行热冲压成形,从而得到三维预成型体;
步骤3:将得到的三维预成型体从热冲压成形模具中取出,待冷却后进行机械加工,例如轮廓精加工、钻孔等,使其具有期望的最终尺寸和几何构造;
步骤4:对该三维预成型体重新加热至预浸料树脂基体的熔点以上,以便在后续的包塑成型(overmolding)中在预浸料的树脂基体和 包塑成型树脂之间获得良好的粘结力;
步骤5:将上述热的三维预成型体转移到包塑成型模具中,在该三维预成型体上通过注塑法而包塑成型热塑性树脂部,从而得到最终的包含加强部(由所述三维预成型体构成的)和包塑成型树脂部的三维部件。
其中,在加工过程中通常使用机器臂来抓取预浸料制成的半成品或三维预成型体,然后将其放置于模具内可收回的针上,从而将预浸料制成的半成品或三维预成型体支承并保持在与模具的塑型部分相对的位置。当机器臂抓取运送预浸料制成的半成品或三维预成型体的距离远,或者模具尚处于打开状态时,这样的针更显得尤为必要。
然而,为了控制上述针,在设备内还必须包括针控制装置,从而需要提供额外的空间。此外,这些锥形的针会在半成品上留下孔洞,或者在三维预成型体上注入热塑性塑料后留下锥体。而且,当预浸料制成的半成品或三维预成型体被加热至预浸料树脂基体软化时,它的操纵变得更加棘手,仅使用上述针难以对其提供良好的支承和定位。
为了在加工过程中支承及定位预浸料制成的半成品或三维预成型体,除了上述使用针的技术方案,还已知一种使用模塑框架的方案,其中使用预浸料浮动悬挂系统。然而,半成品或三维预成型体在成形时可能在模腔之间发生滑动。因此,该系统不能始终在模具中对半成品或三维预成型体进行精确的定位。
因此,需要提供一种能够在所述半成品或在所述三维预成型体的加工过程中,尤其是在热加工过程中,更好地支承和定位所述半成品或三维预成型体的替代方式。
实用新型内容
本实用新型的目的在于解决上述技术问题。
为此,本实用新型提供了一种由预浸料制成的半成品,至少包括第一预浸料层和第二预浸料层,其特征在于,在所述第一预浸料层和所述第二预浸料层之间铺有磁性材料层。
术语“预浸料(英文为“PREPREG”)”是一种常用的制造复合材料的中间材料,具有复合材料领域的通常含义,即用树脂基体在严格控制的条件下浸渍增强体而制成的树脂基体与增强体的组合物。
术语“半成品”是指尚未制造完工为最终产品,仍需进一步加工的中间产品。
术语“磁性材料”是指能够被磁体吸引的材料。
根据本实用新型,由于在预浸料层之间加入了磁性材料层,由此制成的半成品在被制成三维成型体以及进一步制成包塑成型件的过程中能通过模具上的磁体对该磁性材料层的吸引来获得良好的支承及定位,从而能够精确成型。
按照本实用新型的半成品还可以另外包含以下技术特征中的一个或多个:
所述第一预浸料层和所述第二预浸料层中的至少一方具有镂空,所述磁性材料层至少被铺设在至少一个所述镂空处。这样,可将模具上的磁体布置得在模具闭合时至少部分地嵌入所述镂空处,于是磁体与所述磁性材料层在所述镂空处直接接触,从而提供对所述半成品或所述三维预成型体的足够大的磁力,以便更好地支承及定位所述半成品或所述三维预成型体。
优选地,当所述第一预浸料层和所述第二预浸料层中所含的热塑性树脂软化时,所述磁性材料层仍具有磁性而能够被磁体吸引。这样,在所述半成品经过热成型工艺(例如热冲压)而被制成三维预成型体以及进一步制成包塑成型件的过程中,也能够由于模具上磁体对所述 磁性材料层的吸引而得到支承和定位。
优选地,当所述第一预浸料层和所述第二预浸料层中所含的热塑性树脂软化时,所述磁性材料层仍保持固体状态。本领域技术人员能够根据所使用的热塑性树脂的特性来选择合适的磁性材料,使得当所述半成品被加热至热塑性树脂软化时,磁性材料层尚未熔化,这样能够在热成型过程中对预浸料层提供更好的支撑。
优选地,所述磁性材料层是磁性金属网或磁性金属片或磁性金属网与磁性金属片的组合。由于金属通常具有较高的机械强度,且加入的金属层会保留在最终获得的包塑成型产品中,因此还能够提高该产品的机械强度,起到补充的加强作用。特别地,当所述磁性材料层是磁性金属网或不连成整片而是具有空隙的金属片时,由于存在网眼或空隙,可以减轻最终产品的重量,并且节约生产成本。另外,在所述半成品的后续加工过程(例如,热冲压成型)中,相邻层预浸料的树脂基体可以穿过网眼或空隙而相互熔接在一起,从而将金属层更牢固地固定在两层预浸料层之间。
优选地,在所述第一预浸料层和/或所述第二预浸料层与所述磁性材料层之间还铺有聚丙烯膜。特别地,由于聚丙烯膜能填充金属网眼或金属片间的空隙,将困在其中的空气排出,因此能大大提高产品的均匀性。另外,这还有利于提高金属层与预浸料层的结合力。
本实用新型还涉及一种三维预成型体,其特征在于,它由上述半成品通过热冲压成形而制成。
此外,本实用新型还涉及一种包塑成型件,其特征在于,它包括至少一个如上所述的三维预成型体以及在所述三维预成型体上包塑成型的热塑性树脂部。
优选地,所述包塑成型件是机动车的部件,尤其是机动车的后部关闭部件。
附图说明
下面将参照附图对本实用新型作进一步的详细说明。本领域技术人员容易理解的是,这些附图仅仅用于说明的目的,而并非意在对本实用新型的保护范围构成限制。图中相同的附图标记表示相同或相似的部件。为了说明的目的,这些图并非完全按比例绘制。
图1是根据本实用新型一个实施例的由预浸料制成的半成品的立体图;
图2是图1所示半成品的分解立体图;
图3是根据本实用新型一个实施例的半成品分别在包含或不包含聚丙烯膜的情况下的剖视图;
图4示出了将根据本实用新型两个不同实施例的半成品加工成三维预成型体的过程;
图5示出了图4所示过程中使用的成型模具;
图6与图7分别是图4所示过程中的成型设备的剖视图;以及
图8是根据本实用新型一个实施例的三维预成型体的立体图;
图9是图8中三维预成型体的包塑成型件的立体图。
具体实施方式
图1示出了根据本实用新型一个实施例的由预浸料制成的半成品1的立体图。图2以分解图的方式更好地示出了该半成品1的结构。在本例中,半成品1包括第一预浸料层10、第二预浸料层12以及夹在这两层之间的磁性材料层14。可以理解的是,半成品1可以包括更多的预浸料层和/或其它材料层,这些其它材料层中至少有一部分可被磁体吸引,即至少有一部分是磁性材料层,本领域技术人员可以 根据具体的设计目标来确定。例如,在一个实施例中,半成品1包括依次堆叠的第一、第二和第三预浸料层,在每两个相邻的预浸料层之间均夹有磁性材料层。在另一个实施例中,半成品1包括依次堆叠的第一、第二和第三预浸料层,但仅仅在第一和第二预浸料层之间夹有磁性材料层。要注意的是,该磁性材料层可以覆盖预浸料层的整个表面,也可以离散地设置在一个或多个部位。
术语“预浸料”(英文为“PREPREG”)是一种常用的制造复合材料的中间材料,通常由树脂基体与浸渍在该基体中的增强体(例如:纤维或织物)构成。在本例中,第一预浸料层10、第二预浸料层12均由热塑性树脂基体和浸渍在该基体中的增强体构成,所述增强体可以是碳和/或玻璃纤维或织物。磁性材料层14可以由任何合适的能够被磁体吸引的磁性材料(例如铁、钴、镍及其合金等)构成。在本例中,磁性材料层14是带有网眼的金属网,这可以减轻最终产品的重量,节约生产成本。应理解磁性金属网可以由磁性金属片代替,在这种情况下,磁性金属片可以不连成整片而是具有空隙,从而也能减轻最终产品的重量,并且节约生产成本。另外,在半成品的后续加工过程(例如,热冲压成型)中,相邻层预浸料的树脂基体可以穿过网眼或者空隙而相互熔接在一起,从而将金属层更牢固地固定在两层预浸料层之间。
可观察到在图1和图2所示的实施例中,第一预浸料层10上具有镂空部分18,在镂空18处磁性金属网14是可见的,第二预浸料层12与磁性金属网14具有相同的形状和尺寸。而在图3所示的实施例中,镂空部分18在第二预浸料层12上。这样,在后续的加工步骤中,模具上的磁体可被布置得在模具闭合时至少部分地嵌入半成品或三维预成型体的预浸料层上的镂空处,于是磁体与所述磁性材料层在镂空处直接接触,从而提供足够大的磁力,以便更好地支承及定位半成品或三维预成型体。并且,由该半成品1得到的三维预成型体(见图4-7)在加热的过程中也能够得到材料层14至少部分的支撑,从而更好地保持其三维形状。
应理解,预浸料层中的这些镂空可以具有简单的或更复杂的几何形状,在有镂空的情况下,磁性材料层将至少被铺设在至少一处镂空处。然而也可以没有镂空,并且磁性材料层的铺设范围也不限于该实施例。实际上,根据本实用新型,只要在加工过程中磁体与磁性材料层之间的磁力足以良好地支承及定位半成品或三维预成型体即可。
此外,如图3(b)所示,优选地,还可以在磁性材料层14和与其相邻的预浸料层10和/或12之间铺设聚丙烯膜16。由于聚丙烯膜能填充金属网眼或金属片之间的空隙,将困在其中的空气排出,因此能大大提高产品的均匀性。另外,这还有利于提高材料层与预浸料层的结合力。
图4示出了将图1所示的半成品1和1’加工成三维预成型体2和2’的过程。如图所示,半成品1与半成品1’的区别在于其中的磁性材料层是磁性金属网14还是磁性金属片14’,它们各自加工得到的三维预成型体则分别被标示为2和2’。为了清除地显示该三维预成型体2、2’的结构,图4中去除了第二预浸料层12的一部分。
在将半成品1、1’放入成型模具中之前,对该半成品进行加热,然后,将该热的半成品1放入图5示出的成型模具(包括图5所示的热冲压凸模20),使得凸模20上的磁体22对准半成品预浸料层上露出磁性材料层的镂空,从而利用磁力将半成品保持并定位在合适的位置,以对其进行三维成型。应当注意的是,在这一成型步骤中,半成品1、1’内所含有的磁性材料层也一同成型。之后进行脱模,得到三维预成型体2、2’。应当理解的是,图4所示的三维形状仅仅是示意性的,三维预成型体2、2’根据其具体的应用可以具有更加复杂的三维形状。
图6与图7示意性地示出了这一过程中的成型设备的剖视图,其中图6示出了模具上的模塑部分30。应理解模具的形状不限于该图示,该示意图同样适用于对三维预成型体进行包塑成型的过程。特别 地,可注意到图7所示的磁性金属片14’只被铺设在预浸料层上的镂空处并完全覆盖该镂空,这样模具闭合时模塑部分上的磁体22部分地嵌入镂空并与磁性金属片14’直接接触,从而提供对半成品或三维预成型体足够大的吸力。但磁性金属片14’的铺设范围不限于该实施例。
可以在三维预成型体2或2’冷却后再对其进行机械加工,例如轮廓精加工、钻孔等,使其成为具有期望的最终尺寸和几何构造的三维预成型体。图8示出了该三维预成型体的一个示例,在本例中,它是汽车后部加强件3,其中示意性地示出了在加工过程中接纳模具上的磁体以提供支承的上述镂空18。
然后,将该三维预成型体重新加热至预浸料树脂基体的熔点以上,以便在后续的包塑成型中在预浸料的树脂基体和包塑成型树脂之间获得良好的粘结力。再将上述热的三维预成型体转移到包塑成型模具中,在包塑成型模具中进行包塑成型步骤,即,在该三维预成型体上包塑成型(例如:通过注塑)热塑性树脂部。脱模得到最终的包含加强部(由三维预成型体构成的)和包塑成型树脂部的三维部件。由此得到的三维部件可以例如是机动车上的部件,图9示出了该三维部件的一个示例,在本例中,它是汽车行李箱关闭部件4,由预浸料三维预成型体(即汽车后部加强件3)以及包塑成型树脂部构成,在预浸料三维预成型体中含有磁性材料层。
附图和以上说明描述了本实用新型的非限制性特定实施例。为了教导发明原理,已简化或省略了一些常规方面。本领域技术人员应该理解源自这些实施例的变型落在本实用新型的范围内。本领域技术人员应该理解上述特征能够以各种方式结合以形成本实用新型的多个变型。由此,本实用新型并不局限于上述特定实施例,而仅由权利要求和它们的等同物限定。
Claims (10)
1.一种由预浸料制成的半成品,至少包括第一预浸料层和第二预浸料层,其特征在于,在所述第一预浸料层和所述第二预浸料层之间铺有磁性材料层。
2.如权利要求1所述的半成品,其特征在于,所述第一预浸料层和所述第二预浸料层中的至少一方具有镂空,所述磁性材料层至少被铺设在至少一个所述镂空处。
3.如权利要求1所述的半成品,其特征在于,当所述第一预浸料层和所述第二预浸料层中所含的热塑性树脂软化时,所述磁性材料层仍具有磁性而能够被磁体吸引。
4.如权利要求3所述的半成品,其特征在于,当所述第一预浸料层和所述第二预浸料层中所含的热塑性树脂软化时,所述磁性材料层仍保持固体状态。
5.如上述权利要求中任一项所述的半成品,其特征在于,所述磁性材料层是磁性金属网或磁性金属片或磁性金属网与磁性金属片的组合。
6.如权利要求5所述的半成品,其特征在于,在所述第一预浸料层和/或所述第二预浸料层与所述磁性材料层之间还铺有聚丙烯膜。
7.一种三维预成型体,其特征在于,它由上述权利要求中任一项所述的半成品通过热冲压成形而制成。
8.一种包塑成型件,其特征在于,它包括至少一个如权利要求7所述的三维预成型体以及在所述三维预成型体上包塑成型的热塑性树脂部。
9.如权利要求8所述的包塑成型件,其特征在于,它是机动车的部件。
10.如权利要求9所述的包塑成型件,其特征在于,它是机动车的后部关闭部件。
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2014
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- 2014-11-21 EP EP14828053.0A patent/EP3072684B1/en active Active
- 2014-11-21 MX MX2016006393A patent/MX2016006393A/es unknown
- 2014-11-21 MY MYPI2016701713A patent/MY175862A/en unknown
- 2014-11-21 WO PCT/IB2014/066239 patent/WO2015075684A1/zh active Application Filing
- 2014-11-21 US US15/037,803 patent/US10427386B2/en not_active Expired - Fee Related
- 2014-11-21 KR KR1020167016502A patent/KR20160096625A/ko not_active Application Discontinuation
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Also Published As
Publication number | Publication date |
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EP3072684B1 (en) | 2020-08-12 |
EP3072684A1 (en) | 2016-09-28 |
KR20160096625A (ko) | 2016-08-16 |
US20160297183A1 (en) | 2016-10-13 |
MX2016006393A (es) | 2016-08-01 |
US10427386B2 (en) | 2019-10-01 |
JP2016539826A (ja) | 2016-12-22 |
JP6482555B2 (ja) | 2019-03-13 |
WO2015075684A1 (zh) | 2015-05-28 |
MY175862A (en) | 2020-07-14 |
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