CN85200688U - 全承载复合材料的汽车车身 - Google Patents

全承载复合材料的汽车车身 Download PDF

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CN85200688U
CN85200688U CN198585200688U CN85200688U CN85200688U CN 85200688 U CN85200688 U CN 85200688U CN 198585200688 U CN198585200688 U CN 198585200688U CN 85200688 U CN85200688 U CN 85200688U CN 85200688 U CN85200688 U CN 85200688U
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composite material
glass fabric
automobile body
inner tube
material automobile
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唐锦生
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Abstract

一种轻质高强度的复合材料，该材料特别适用于制造全承载的汽车车身。
将泡沫复合材料按需要的形状做成汽车车身内胎模型，再先后用至少一层浸透了环氧树脂的玻璃纤维布，以及至少两层浸透了聚酯的玻璃纤维布全部搭接包裹住内胎模型，待固化后再进行表面处理，由此而制成所需要的汽车车身。

Description

本发明涉及一种高强度、轻质复合材料，特别是用于制造全承载复合材料的汽车车身，也就是通常所说的全塑料汽车车身。
汽车车身一般是用钢板压制而成的，近年来，随着复合工程材料的迅速发展，汽车上应用复合材料来制造构件的越来越多，例如，用半硬质聚氨酯泡沫塑料及聚氯乙烯制方向盘、仪表盘、门柱、顶蓬等；采用改性硬质聚氨酯塑料制成保险杠；用改性ABC塑料制造护板；用SMC层状塑料制造车门；用碳纤维玻璃钢制造弹簧板及转动轴等等，也有用复合材料来制造整体车身的，但是由于材料成本高，加工复杂，所以，到目前为止，还没有全承载复合材料的车身投放市场，其主要原因有两条：1，全承载复合材料的车身其强度及耐冲击性能一般不够理想；2，其成本高于钢铁生产的汽车。鉴于上述两个原因，尽管复合材料制成的整体车身具有重量轻、耗能低等优点，但还是不能代替钢铁而进行大规模的生产。
本发明的目的就是提供一种轻质高强度的复合材料，利用这种材料，可以生产全承载汽车车身，这种整体车身不仅强度高、重量轻、而且经久耐用，造价大大低于钢铁，为大规模生产全承载复合材料汽车车身提供了可能。
本发明的主要内容就是：用至少是一层浸透了环氧树脂的玻璃纤维布及至少两层浸透了聚酯的玻璃纤维布，分别全部搭接包裹住由复合泡沫材料制成的汽车内胎模型，由此而制成全承载的复合材料汽车车身。
本发明主要是利用了材料力学的“高惯性矩”原理，并进行了预应力处理，而使车身能具有上述优点。
我们知道，JZ＝ (bh3)/12 ；其中JZ为材料的惯性矩，b为材料的厚度；JZ则以三次方的比例提高，所以希望材料能厚一些，若采用玻璃纤维，即俗称的玻璃钢中间夹泡沫塑料，显然能提高材料的惯性矩，同时，抗弯钢度D也可以大幅度提高，这从公式
D＝E玻(b(H3-h3))/12 ＋E泡(b(H3-h3))/12
中也可看出，其中E为材料的弹性模量；H为材料总厚度；h为泡沫夹层厚度。由于高惯性矩的作用，使带泡沫塑料夹层的玻璃纤维布具有很高的强度，但是这还没有充分发挥它的特点，因为玻璃钢的最佳特点是抗拉应力最好，（6拉＝2500公斤／（厘米）2），而且浸透环氧树脂或聚酯的玻璃钢在其固化过程中，会产生千分之八的收缩，巧妙地利用玻璃钢的这两大特点，就使它产生了预应张力，从而获得更高刚度的材料，同时使降低成本、延长使用寿命成为可能。
下面，参考附图对本发明进行更详细的说明：
图1是复合材料的局部断面剖视示意图；
图2是用复合材料制造的全承载汽车车身的剖视示意图；
图3是图2的A向剖视图。
所使用的玻璃纤维布，如图1中的2，3，4，一般是中性、脱蜡的，其厚度不易太厚，一般来讲，厚度在0.1至0.5毫米之间，最好是0.25毫米。
所使用的复合泡沫材料如图1中的1（即加工成内胎模型的材料）不仅要重量轻，而且要易于加工，材料要有弹性，价格要低，一般可以选用聚苯乙烯泡沫或者是硬质聚氨酯泡沫，其容重可以是16公斤／立方米－32公斤／立方米。
复合泡沫材料的厚度可根据应用部位不同而变化，一般来讲，其厚度在10至500毫米之内，多数情况为50毫米厚就可以了。
全承载复合材料汽车车身的制造方法如下：
首先，将复合泡沫材料按需要的形状加工成内胎模型（参见图1和图2）。在小批量生产中，可用加工木模型的方法，将泡沫板做成所需形状的各个部件，然后再用粘合剂将各板材拼粘成所需要的整体形状。在大批量生产中，可用注塑法，一次成型为所需要的形状。
然后就要用玻璃纤维布分层次地、全部地包裹这一内胎模型。
玻璃纤维布要剪裁合适，与相应的内胎模型相匹配。然后在环氧树脂溶液中浸透。
将浸透了环氧树脂的玻璃纤维布（如图1中的2）覆盖在内胎模型上，用宽度为6厘米以上的硬毛刷将玻璃纤维布刷平。这是第一层玻璃纤维，必需全部、均匀地包裹住内胎模型，其中特别要注意玻璃布的搭接部分，为保证强度，其搭接部分的宽度不能少于50毫米，大约3小时以后，用橡胶滚筒均匀地滚压半固化的玻璃纤维布，使其表面平坦。这种浸透环氧树脂的玻璃纤维布至少要覆盖一层。若覆盖两层，则在第一层覆盖后大约36小时，玻璃钢固化后，再覆盖第二层。
再将浸透了聚酯、剪裁合适的玻璃纤维布（如图1中的3）按上述方法互相搭接而全部、均匀地覆盖在第一层（或几层）玻璃纤维布上，其搭接宽度也不能小于50毫米。浸透聚酯的玻璃纤维布要至少复盖两层。如图1中的4即为第二层。在最后一层覆盖后，大约再过48小时，聚酯树脂玻璃钢就固化了，然后在其表层抛光处理，再喷漆、上光。
通过实验证明，用这种材料制造的全承载复合材料的汽车车身，具有强度高、重量轻、寿命长和造价低的优点。
而且用这种材料及方法使制造全承载的车身成为可能，实验表明，这种车身整体结构好，重量轻，是一般钢铁结构本身重的三分之一，所以，汽车的耗油量可减少；强度高，在发生碰撞时，一般金属汽车外壳将会产生永久性变形，但“全塑”汽车仅发生一些漆皮破损和局部的碰痕；造价低，从上述材料及其制造方法中可看到，所选用的基本原料价格都较低，制造方法简便，无需广阔的场地和复杂的设备，一般小厂均有能力承担，这种车身隔音、隔热好，无腐蚀，修补容易，具有较高的实用价值。
在不违背本发明精神的前提下，也可用这种复合材料来制造各类船、游艇、家具、货箱等等，用途比较广。

Claims (19)

1、一种高强度轻质复合材料的汽车车身，其特征在于：这种车身是由至少一层浸透环氧树脂的玻璃纤维布以及至少是两层浸透了聚酯的玻璃纤维布，依次全部搭接包裹复合泡沫材料制成的汽车内胎模型而构制成的。
2、由权利要求1所述的复合材料汽车车身，其特征在于：制造泡沫内胎模型的复合材料为聚苯乙烯。
3、由权利要求1所述的复合材料汽车车身，其特征在于：制造泡沫内胎模型的复合材料为硬质聚氨酯。
4、由权利要求1至3中任意一个所述的复合材料汽车车身，其特征在于：做为内胎模型的泡沫复合材料其容重为16公斤／立方米－32公斤／立方米。
5、由权利要求1至3中任意一个所述的复合材料汽车车身，其特征在于：做为内胎模型的泡沫复合材料其厚度为10至500毫米。
6、按照权利要求5所述的复合材料汽车车身，其特征在于：做为内胎模型的泡沫复合材料其厚度为50毫米。
7、按照权利要求1至3项中任意一项所述的复合材料汽车车身，其特征在于：每层玻璃纤维布的厚度为0.1至4毫米。
8、按照权利要求7所述的复合材料汽车车身，其特征在于：每层玻璃纤维布的厚度为0.25毫米。
9、按照权利要求1至3中任意一项所述的复合材料汽车车身，其特征在于：玻璃纤维布是中性、脱蜡的。
10、按照权利要求7中所述的复合材料汽车车身，其特征在于：玻璃纤维布是中性、脱蜡的。
11、按照权利要求8所述的复合材料汽车车身，其特征在于：玻璃纤维布是中性、脱蜡的。
12、按照权利要求1至3中任一项所述的复合材料汽车车身，其特征在于：全部包裹内胎模型的玻璃纤维布是5层。
13、按照权利要求7中所述的复合材料汽车车身，其特征在于：全部包裹内胎模型的玻璃纤维布是5层。
14、按照权利要求9中所述的复合材料汽车车身，其特征在于：全部包裹内胎模型的玻璃纤维布是5层。
15、按照权利要求8、10或11中所述的复合材料汽车车身，其特征在于：全部包裹内胎模型的玻璃纤维布是5层。
16、按照权利要求1至3中任一项所述的复合材料汽车车身，其特征在于：浸透了环氧树脂的玻璃纤维布是两层，浸透了聚酯的玻璃纤维布是四层。
17、按照权利要求7中所述的复合材料汽车车身，其特征在于：浸透了环氧树脂的玻璃纤维布是两层，浸透了聚酯的玻璃纤维布是四层。
18、按照权利要求9中所述的复合材料汽车车身，其特征在于：浸透了环氧树脂的玻璃纤维布是两层，浸透了聚酯的玻璃纤维布是四层。
19、按照权利要求8、10或11中所述的复合材料汽车车身，其特征在于：浸透了环氧树脂的玻璃布是两层，浸透了聚酯的玻璃纤维布是四层。
CN198585200688U 1985-04-01 1985-04-01 全承载复合材料的汽车车身 Expired - Lifetime CN85200688U (zh)

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