CN203864106U - 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 PDF

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CN203864106U
CN203864106U CN201320747460.1U CN201320747460U CN203864106U CN 203864106 U CN203864106 U CN 203864106U CN 201320747460 U CN201320747460 U CN 201320747460U CN 203864106 U CN203864106 U CN 203864106U
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semi
finished product
prepreg
preimpregnation bed
dimensional
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Jy·德芒日
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Plastic Omnium SE
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Plastic Omnium SE
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Priority to PCT/IB2014/066238 priority patent/WO2015075683A1/zh
Priority to KR1020167016504A priority patent/KR20160096626A/ko
Priority to JP2016531996A priority patent/JP6483682B2/ja
Priority to MYPI2016701690A priority patent/MY177904A/en
Priority to MX2016006280A priority patent/MX2016006280A/es
Priority to EP14828052.2A priority patent/EP3072683B1/en
Priority to US15/037,343 priority patent/US20160271901A1/en
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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金属层。由于在预浸料层之间加入了金属层，由所述半成品制成的三维预成型体在包塑成型前的重新加热过程中能得到该金属层的支撑，从而很好地保持其三维形状，而不会发生坍塌。另外，由于加入的金属层会保留在最终获得的包塑成型产品中，它还能够提高该产品的机械强度，起到补充的加强作用。

Description

预浸料制成的半成品及三维预成型体和包塑成型件
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。
图1示出了采用上述方法在步骤3后得到的三维预成型体，图2则示出了在步骤4后得到的三维预成型体，在本例中，三维预成型体包括两层预浸料层10、12。可以清楚地看到，经过步骤4后该三维预成型体原来的三维形状（如图1所示）无法得以保持，而是像图2所示那样发生坍塌，这是因为，在该步骤中，当该三维预成型体被重新加热至预浸料树脂基体的熔点以上时，树脂基体变为熔融状态，导致该三维预成型体变得很软，从而在材料自身重力的作用下发生坍塌。这对于制造最终所需的三维部件而言显然是不利的。
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金属层。
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。
根据本实用新型，由于在预浸料层之间加入了金属层，由所述半成品制成的三维预成型体在包塑成型前的重新加热过程中能得到该金属层的支撑，从而很好地保持其三维形状，而不会发生坍塌。另外，由于加入的金属层会保留在最终获得的包塑成型产品中，它还能够提高该产品的机械强度，起到补充的加强作用。
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：
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，所述金属层仍保持固体状态。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金属，使得当所述半成品被加热至热塑性树脂软化时，金属层尚未熔化，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，所述金属层是金属网。由于金属网带有网眼，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金属网的网眼而相互熔接在一起，从而将金属网更牢固地固定在两层预浸料层之间。
优选地，所述第一预浸料层和所述第二预浸料层与所述金属网具有相同的形状和尺寸。这样，金属网能够覆盖整个预浸料层，在每一处都能为其提供支撑，而不会留下“支撑盲点”。因此，由所述半成品制成的三维预成型体在包塑成型前的重新加热过程中能够更好地保持其三维形状。
优选地，所述金属含有铁。这可以增强最终产品的机械性能。
所述金属可以选自铁、低碳钢、铜合金以及铝合金。
在所述第一预浸料层和/或所述第二预浸料层与所述金属网之间还铺有聚丙烯膜。由于聚丙烯膜能填充金属网眼，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网与预浸料层的结合力。
优选地，所述聚丙烯膜具有与所述金属网相同的形状和尺寸。
优选地，所述预浸料中的增强材料为碳或者玻璃。
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是现有技术中预浸料三维预成型体在加热之前的立体图；
图2是现有技术中预浸料三维预成型体在加热之后的立体图；
图3是根据本实用新型的由预浸料制成的半成品的立体图；
图4是图3所示半成品的分解立体图；
图5示出了将图3所示半成品加工成三维预成型体的过程；
图6是经图5所示过程得到的三维预成型体的立体图；
图7示出了图6所示三维预成型体的内部结构；
图8示出了从市购预浸料到最终三维部件的整个制造过程；和
图9是根据本实用新型的最终三维部件的一个实施例的立体图。
具体实施方式
图1和图2已在背景技术部分中进行了描述，这里不再赘述。
图3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4以分解图的方式更好地示出了半成品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金属层。可以理解的是，半成品1可以包括更多的预浸料层和/或金属层，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一金属层。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金属层。
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，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。金属层可以由任何合适的金属或合金（例如：铁、低碳钢、铜合金、铝合金等）构成。优选地，金属层由含铁材料构成，这可以增强最终产品的机械性能。金属层可以是实心的或者是带有穿孔的。在本例中，所述金属层是带有网眼的金属网14，这可以减轻最终产品的重量，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金属网的网眼而相互熔接在一起，从而将金属网更牢固地固定在两层预浸料层之间。优选地，还可以在金属网与和其相邻的预浸料层10和/或12之间铺设聚丙烯膜。由于聚丙烯膜能填充金属网眼，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网与预浸料层的结合力。
在图3和图4所示的实施例中，第一预浸料层10和第二预浸料层12与金属网14具有相同的形状和尺寸。这样，在后续的加工步骤中，由该半成品1得到的三维预成型体（见图6、7）在重新加热的过程中能够得到金属层14的全面支撑，从而更好地保持其三维形状。
图5示出了将图3所示的半成品1加工成三维预成型体2的过程，图6和图7则示出了经该过程得到的三维预成型体2。为了清除地显示该三维预成型体2的内部结构，图7中去除了第二预浸料层12的一部分。在将半成品1放入成型模具中之前，对该半成品进行加热，加热温度高于预浸料树脂基体的熔点。然后，将该热的半成品1放入成型模具（例如：图5所示的热冲压模具20、22），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内所含有的金属层也一同成型。之后，在一低于预浸料树脂基体熔点的温度下进行脱模，得到具有所需三维形状的三维预成型体2，如图6和图7所示。应当理解的是，图6和图7所示的三维形状仅仅是示意性的，三维预成型体2根据其具体的应用场合可以具有更加复杂的三维形状。
下面结合图8来描述制造局部区域或整个区域需要加强的三维部件4的整个过程。为了方便描述，将该过程分为10个步骤：
步骤A：将购买的预浸料和金属网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）；
步骤B：根据需要将若干层具有合适形状和尺寸的预浸料和金属网堆叠在一起，获得根据本实用新型的半成品；
步骤C：将该半成品加热至高于其预浸料树脂基体熔点的温度；
步骤D：将该半成品在模具（例如：热冲压模具）中进行三维成型；
步骤E：在一低于预浸料树脂基体熔点的温度下进行脱模，得到具有所需三维形状的三维预成型体2；
步骤F：待三维预成型体冷却后对其进行机械加工，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3；
步骤G：对该三维预成型体3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；
步骤H：将上述热的三维预成型体转移到包塑成型模具中；
步骤I：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3上包塑成型（例如：通过注塑）热塑性树脂部16；
步骤J：脱模得到最终的包含加强部（由所述三维预成型体3构成的）和包塑成型树脂部16的三维部件4。
由此得到的三维部件4可以例如是机动车上的部件，如机动车的后部关闭部件。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3’以及包塑成型树脂部16’构成，在预浸料三维预成型体3’中含有金属层。
由于在预浸料层之间加入了金属层，因此在上述步骤G和H中，三维预成型体能够得到该金属层的支撑，从而很好地保持其三维形状。为此，构成该金属层的金属需要具有高于预浸料热塑性树脂基体的熔点，使得在步骤G中，该金属层不会变为熔融状态，而是能够支撑熔融的树脂基体。另外，由于加入的金属层会保留在最终获得的包塑成型产品中，它还能够提高该产品的机械强度，起到补充的加强作用。
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 (11)

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金属层。
2.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，所述金属层仍保持固体状态。
3.如权利要求1或2所述的半成品，其特征在于，所述金属层是金属网。
4.如权利要求3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与所述金属网具有相同的形状和尺寸。
5.如权利要求2所述的半成品，其特征在于，所述金属选自铁、低碳钢、铜合金以及铝合金。
6.如权利要求3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金属网之间还铺有聚丙烯膜。
7.如权利要求6所述的半成品，其特征在于，所述聚丙烯膜具有与所述金属网相同的形状和尺寸。
8.一种三维预成型体，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。
9.一种包塑成型件，其特征在于，它包括至少一个如权利要求8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。
10.如权利要求9所述的包塑成型件，其特征在于，它是机动 车的部件。
11.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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