KR101173061B1 - Thermal Plastic Composition And Manufacturing Method For Hybrid Front End Module - Google Patents

Abstract

The present invention relates to a thermoplastic composite composition for a hybrid front end module carrier and a method for manufacturing the same, the present invention is to reduce the carbon dioxide through the weight reduction of the hybrid front end module carrier, has the effect of improving fuel efficiency.
To this end, the resin mixture is applied to the surface of the fiber mat layer and relates to a thermoplastic composite composite for a hybrid front end module carrier manufactured according to the three-step process of the present invention.

Description

Thermoplastic Composition And Manufacturing Method For Hybrid Front End Module Carrier And Manufacturing Method Thereof

The present invention relates to a thermoplastic composite composition for a hybrid front end module carrier and a method for manufacturing the same, the present invention is to reduce the carbon dioxide through the weight reduction of the hybrid front end module carrier, has the effect of improving fuel efficiency.

To this end, the resin mixture is applied to the surface of the fiber mat layer and relates to a thermoplastic composite composite for a hybrid front end module carrier manufactured according to the three-step process of the present invention.

Recently, the automotive industry is carrying out various technologies for producing eco-friendly vehicles aimed at reducing fuel consumption and carbon dioxide (CO ₂ ). In particular, research on environmentally friendly vehicles is underway in many fields such as electric vehicles, hybrid vehicles, hydrogen vehicles, and solar electric vehicles using alternative energy sources. But is based on a number of sealing and money take is the total amount replacement of the vehicle which use an existing internal combustion engine, so that automobile manufacturers in improved fuel economy via the short term vehicle weight using a weight material, the carbon dioxide green vehicle with a reduction of (CO ₂₎ We are focusing on development.

Meanwhile, automakers are developing modular parts for the purpose of improving assembly performance. That is, in the past, all automobile parts were delivered and assembled in an automobile assembly line, but in recent years, a supplier has assembled some components through module assembly and supplied them to an automobile assembly line for final assembly. It saves time and money. Such modular parts include door modules, headlining modules, and catpit modules, and the front end module of the present invention is also part of this modularization. The following describes the front end module in more detail.

The Front End Module, which modularizes parts of the front end of an automobile, is a assembly of parts mounted at the front of a vehicle, and its components include a radiator, a fan shroud, a cooling fan, and a headlight. It will be packaged in the front end module carrier. Conventional front end module carriers are typically of plastic type, which is made only of plastic, and hybrid types, which are injection molded by inserting steel sheets. The plastic type front end module carrier is light in weight and easy to injection molding, but is less susceptible to collision due to lack of rigidity and durability than the hybrid type, and has a problem in that it is deformed when a heavy object is attached. In addition, the hybrid type front end module carrier is superior in rigidity and durability compared to the plastic type front end module carrier, but has a problem in that the product weight is large due to the weight of the steel sheet. For this reason, plastic type front end modules are mainly applied to small cars, and hybrid type front end modules are applied to more than medium cars.

FIG. 1 shows a hybrid front end module, which shows a front end module carrier 9 mounted at the front end of a vehicle to mount various components.

Accordingly, the present inventors have studied and tried to solve the above problems of the thermoplastic composite for hybrid front end module carriers, and as a result, by replacing the steel sheet application part with a resin mixture of melt viscosity control resin and polycarbonate, The present invention has been completed by discovering that the reduction of the weight of the carbon dioxide and the reduction of the carbon dioxide emission and the improvement of the fuel efficiency can be achieved.

Accordingly, an object of the present invention is to provide a thermoplastic composite composite for a hybrid front end module carrier comprising a resin mixture in which a resin mixture and a polycarbonate are mixed.

The present invention

The fiber mat layer comprises 45 to 65% by volume;

A hybrid front comprising a resin mixture in which a melt viscosity control resin selected from cyclic butylene terephthalate, caprolactam, polyolefin, polyarylate and polyester and a polycarbonate are mixed in a weight ratio of 0.1: 99.9 to 10: 90 A thermoplastic composite for an end module carrier is featured.

In addition,

Mixing a melt viscosity adjusting resin selected from cyclic butylene terephthalate, caprolactam, polyolefin, polyarylate, and polyester and polycarbonate in a weight ratio of 0.1: 99.9 to 10: 90 to obtain a resin mixture;

Uniformly applying the resin mixture to a fiber mat layer; And

Impregnating and polymerizing the resin mixture in the fiber mat layer by heat treatment at a temperature of 250 ° C. to 300 ° C. for 10 minutes to 1 hour on the uniformly coated fiber mat layer;

It characterized by another method for producing a thermoplastic composite composite for a hybrid front end module carrier comprising a.

By introducing a composition of the thermoplastic plastic composite for a hybrid front end module carrier having the above characteristics and a method of manufacturing the same, it is possible to provide vehicle weight reduction and thereby to develop eco-friendly vehicles such as fuel efficiency improvement and carbon dioxide reduction.

FIG. 1 shows a hybrid front end module, showing a front end module carrier 9 for mounting various components installed in the front end of a vehicle.
2 and 3 relates to the manufacturing process of the thermoplastic composite prepared by the present invention.

The thermoplastic plastic composite for a hybrid front end module carrier will be described in more detail as follows.

The thermoplastic composite composition for a hybrid front end module carrier is a composite obtained by applying a resin mixture to the surface of a fiber mat layer, and mixing a melt viscosity controlling resin having a low melt viscosity with a polycarbonate (PC) having high heat resistance and impact strength. A thermoplastic composite composition for a hybrid front end module carrier, wherein a resin mixture is applied to a surface of a fiber mat layer.

The fiber mat layer combines or bonds one or more layers selected from glass fiber or carbon fiber to maintain shape. Since the fiber mat layer is generally arranged in a certain direction, high mechanical properties in a specific direction can be realized, and in the case of using various types of mats such as weave and biax, According to the required physical properties and forms there is an advantage that can optimize the mechanical properties of the fiber mat. The content of the fiber mat layer is 45 to 65% by volume, preferably 48 to 55% by volume. If the content of the fiber mat layer is 45% or less, there is a problem that the product does not have sufficient rigidity and is easily deformed or broken on the product. If the content is more than 65% by volume, excessive stiffness may cause a problem in the next process, thermoforming.

The resin mixture is a material having almost no viscosity at a melt viscosity of 150 ~ 190 ℃ to polycarbonate by mixing a melt viscosity control resin selected from cyclic butylene terephthalate, caprolactam, polyolefin, polyarylate and polyester Can be prepared. In particular, since cyclic butylene terephthalate exhibits a melting temperature of 135 ° C. or higher, there is no problem of eluting at room temperature after mixing with polycarbonate. The melt viscosity control resin and polycarbonate are mixed in a weight ratio of 0.1: 99.9 to 10: 90, preferably mixed in a weight ratio of 1: 99 to 5: 95. If the melt viscosity control resin is contained within the above range, the melt viscosity is not sufficiently low, the compatibility is low, and the mat layer may not be sufficiently impregnated, which may cause a problem of peeling between the mat layers. And impact strength is greatly reduced.

As the melt viscosity controlling resin, cyclic butylene terephthalate (CBT) in the form of a single molecule becomes a polybutylene terephthalate (PBT) in a polymer form through a polymerization reaction, and caprolactam is a polyamide through a polymerization reaction. (Nylon resin).

In general, when manufacturing a composite using a polymer material, the reinforcing material is manufactured in a form in which the polymer material is wrapped, wherein the reinforcing material should be sufficiently impregnated in the polymer material, and the higher the impregnation degree, the better the mechanical properties. However, polymer materials having excellent thermal and mechanical strength, such as heat resistance and impact strength, have viscoelastic properties and have a very high melt viscosity, so that impregnation between the fiber mat layers is very difficult. It is difficult to prepare a composite for the situation. In order to solve the above problems, Sheet Molding Compound (SMC) and Bulk Molding Compound (BMC) methods have been developed and applied to some products, but the polymer resin applied to these methods is not thermoplastic. Since the thermosetting resin is used, not only the cost and time required for manufacturing are consumed, but there are disadvantages in recycling. In addition, the polymer resin is not sufficiently impregnated between the fibers in the fibrous mat layer, and the polymer resin is solidified, thereby imparting a durability problem that is the starting point of fatigue failure in the unfilled portion. In the present invention, as a result of research efforts to solve the disadvantages, it is easy to penetrate the resin between the fibers (Fiber), the impregnation rate is high, and ultimately used a material that can induce physical properties. More specifically, it has a powder-like monomolecular structure, but when it is heated, the viscosity is very low at a temperature above the melting point, and a resin that easily penetrates between fibers at low viscosity is used. . This enables the production of high performance thermoplastic composites with a high fiber content, with a fiber content of 45-65% by volume.

Meanwhile, the resin mixture may further include a UV stabilizer, a color control additive, and the like.

The present invention is also characterized in the manufacturing process of the thermoplastic composite composite for a hybrid front end module carrier for applying the resin mixture on the surface of the fiber mat layer will be described in detail below.

Thermoplastic composites for hybrid front end module carriers are produced in three steps:

A first step of mixing a melt viscosity controlling resin and a polycarbonate in an amount of 0.1: 99.9 to 10: 90 parts by weight to obtain a resin mixture;

A second step of uniformly applying the resin mixture to a fiber mat layer; And

A third step of impregnating and polymerizing the resin mixture in the fiber mat layer by heat-treating the fiber mat layer uniformly coated at a temperature of 250 to 300 ° C. for 10 minutes to 1 hour;

Characterized in that the method for producing a thermoplastic composite composite for a hybrid front end module carrier comprising a.

Each step will be described in detail below.

In the first step, the resin mixture is mixed by mixing 0.1 to 99.9 to 10:90 parts by weight of a melt viscosity adjusting resin and polycarbonate selected from cyclic butylene terephthalate, caprolactam, polyolefin, polyarylate and polyester. Manufacture.

In the second step, the resin mixture 2 is evenly applied on the fibrous mat layer, and in the final three steps, the resin mixture 2 is heated to 250 ° C to 300 ° C for impregnation and polymerization. More preferably, it advances at 260 degreeC-290 degreeC. When the heat treatment temperature is 250 ° C. or less, melting of the resin does not occur, and the resin is present in a solid powder state, which causes a decrease in physical properties. When the temperature is 300 ° C. or more, a problem arises in that physical properties decrease due to deterioration of the resin.

The thickness of the prepreg produced through such a process is 0.7 to 3.0 mm, preferably 1.0 to 2.0 mm. In this case, if the thickness of the prepreg is 0.7 mm or less, a problem of insufficient strength occurs, and if it is 3.0 mm or more, a problem of difficulty in manufacturing a product having a complicated shape occurs.

The thermoplastic composite composite for the hybrid front end module carrier manufactured by the above process is preheated at 200 to 290 ° C. and then inserted into a thermoforming mold to press the pressure of 5 to 10 atm to produce a front end module carrier product. At this time, if the press pressure is 5 atm or less, there is a problem that the mat between the mat is not enough due to the separation between the mat may occur, and if more than 10 atm may cause a problem that the glass fiber is damaged by the press pressure.

Hereinafter, the present invention will be described in more detail with reference to Examples, but the present invention is not limited by the following Examples.

Examples 1-2

A fibrous mat layer was first constructed for the production of hybrid front end module carriers. The glass fiber mat was used, and the laminated structure of the glass fiber mat was laminated in the following order so as to retain maximum rigidity. To have a four-layer structure of weave (0/90 °) + biax (+ 45 / -45 °) + biex (+ 45 / -45 °) + weave (0/90 °) Glass mats were stacked on top of each other.

Cyclic butylene terephthalate (CBT) (manufactured by Cyclics) and polycarbonate (PC) (manufactured by LG Dow) were mixed in a weight ratio of 3:97 to obtain a resin mixture. After the coating evenly applied to the fiber mat layer was heat-treated at 190 ℃ for 10 minutes to proceed with the polymerization. At this time, the content of the glass fiber mat (Glass fiber Mat) was adjusted to 50% by volume (Example 1), 55% by volume (Example 2), respectively.

Through the above process to prepare a mat in the form of prepreg prepreg (prepreg) is melted into the resin mixture flows between the fiber mat (Fiber Mat) is sufficiently impregnated, and then solidified through the cooling process. The thickness of this prepreg was 1.3 mm. The composite prepreg prepared as described above was preheated at 270 ° C., inserted into a thermoforming mold, and pressed at a pressure of 8 atmospheres to prepare a hybrid front end module carrier product.

The physical properties of Examples 1 and 2 were measured by ASTM D3039 method, which is shown in Table 1 below.

division Example 1 Example 2 Tensile Strength (MPa) 428 485 Tensile Modulus (GPa) 20 23

On the other hand, compared to the nylon, polypropylene, steel, aluminum properties of the specific strength (value divided by the density) physical properties of the thermoplastic composite prepared as described in Table 2 below.

division Example 1
nylon
(Nylon) Polypropylene
(PP) Fiberglass 35%
/nylon steal aluminum Nasal strength
(σ / ρ: MPa) 238 69 37 120 42 115 The tensile strength
(MPa) 428 78 33 192 346 312 density
(g / cm ³⁾ 1.8 1.13 0.9 1.6 8.3 2.7

The physical properties of Table 2 show that the plastic for hybrid front end module carrier formed through the composition and the manufacturing method of the present invention has excellent physical properties of specific strength, tensile strength and density.

The molded product manufactured by the above process was inserted into the front end module carrier mold, and the front end module carrier was manufactured through a general injection process using a PA6 material. In this case, the injection process is usually the same as the existing process of manufacturing by inserting the steel sheet.

Comparative Examples 1 and 2

A fibrous mat layer was first constructed for the production of hybrid front end module carriers. The glass fiber mat was used, and the laminated structure of the glass fiber mat was laminated in the following order so as to retain maximum rigidity. To have a four-layer structure of weave (0/90 °) + biax (+ 45 / -45 °) + biex (+ 45 / -45 °) + weave (0/90 °) Glass mats were stacked on top of each other.

Cyclic butylene terephthalate (CBT) (manufactured by Cyclics) and polycarbonate (PC) (manufactured by LG Dow) were mixed in a weight ratio of 3:97 to obtain a resin mixture. After the coating evenly applied to the fiber mat layer was heat-treated at 190 ℃ for 10 minutes to proceed with the polymerization.

Through the above process to prepare a mat in the form of prepreg prepreg (prepreg) is melted into the resin mixture flows between the fiber mat (Fiber Mat) is sufficiently impregnated, and then solidified through the cooling process. The thickness of this prepreg was 1.3 mm. The composite prepreg prepared as described above was preheated at 270 ° C., inserted into a thermoforming mold, and pressed at a pressure of 8 atmospheres to prepare a hybrid front end module carrier product.

At this time, in order to compare the change in physical properties according to the content of the glass fiber mat (30% by volume) (Comparative Example 1), 40% by volume (Comparative Example 2) were prepared and compared with the specimens of the examples, The results are shown in Table 3 below.

division Comparative Example 1 Comparative Example 2 Tensile Strength (MPa) 168 267 Tensile Modulus (GPa) 13.8 16.3

As in the results of Examples 1 and 2 and Comparative Examples 1 and 2, the higher the content of the glass fiber (Glass Fiber) was confirmed that the mechanical properties increase. However, when the glass fiber content exceeds 60% by volume, it is difficult to prepare a specimen, which is likely to partially break the glass fiber during the pressing process. Therefore, considering the product productivity, the content of the glass fiber mat was preferably most suitable for 45 to 60% by volume.

Examples 3-4

In order to confirm the change in physical properties according to the content of cyclic butylene terephthalate, the weight ratio of cyclic butylene terephthalate and polycarbonate was changed to 1:99 (Example 3) and 5:95 (Example 4). Was prepared. The production method was prepared by the same method as shown in Example 1 (glass fiber mat content 50% by volume).

The physical properties of the prepared specimens were measured and shown in Table 4 below.

division Example 3 Example 4 Tensile Strength (MPa) 425 415 Tensile Modulus (GPa) 19 17

As can be seen from Table 4, when the content of the cyclic butylene terephthalate is increased, the content of polycarbonate is reduced, the mechanical strength is somewhat reduced, but the change is not so large.

Claims (4)

The fiber mat layer comprises 45 to 65% by volume;
Melt viscosity control resin and polycarbonate selected from cyclic butylene terephthalate, caprolactam, polyolefin, polyarylate and polyester comprises a resin mixture in a weight ratio of 0.1: 99.9 to 10: 90 Thermoplastic composite for hybrid front end module carriers.
The thermoplastic composite of claim 1, wherein the melt viscosity controlling resin is a cyclic butylene terephthalate.
The thermoplastic mat of claim 1, wherein the fiber mat layer maintains its shape by bonding or bonding one or more layers selected from glass fibers or carbon fibers. Plastic composites.
Mixing a melt viscosity adjusting resin and a polycarbonate selected from cyclic butylene terephthalate, caprolactam, polyolefin, polyarylate, and polyester at 0.1: 99.9 to 10: 90 parts by weight to obtain a resin mixture;
Uniformly applying the resin mixture to a fiber mat layer; And
Impregnating and polymerizing the resin mixture in the fiber mat layer by heat treatment at a temperature of 250 ° C. to 300 ° C. for 10 minutes to 1 hour on the uniformly coated fiber mat layer;
Method for producing a thermoplastic plastic composite for a hybrid front-end module carrier comprising a.

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