KR101839743B1 - Roof of automobile using carbon fiber prepreg and foam core and manufacturing method thereof - Google Patents

Abstract

The present invention relates to a vehicle roof using carbon fiber prepregs and foam cores and a method for manufacturing the same, and more particularly, to a vehicle roof using carbon fiber prepregs and foam cores, wherein the foam cores are applied on the carbon fiber prepregs so as to simplify a stacking process and enhance the hardness, and a method for manufacturing the same. The vehicle roof using carbon fiber prepregs and foam cores comprises: a first prepreg layer having a central part, an upper part formed on the left and right sides of the central part at a higher position than the central part, and having the carbon prepregs stacked in multiple layers; a foam core layer separately coupled between the central part and the upper part of the first prepreg layer; and a second prepreg layer covering the first prepreg layer and the foam core layer, and having the carbon fiber prepregs stacked in multiple layers.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a carbon fiber prepreg and a foam core,

The present invention relates to an automobile loop using a carbon fiber prepreg and a foam core and a method of manufacturing the same, and more particularly to a carbon fiber prepreg having a carbon fiber prepreg and a carbon fiber prepreg, To an automobile loop using a foam core and a manufacturing method thereof.

Recently, in the fields of automobiles and airplanes, research and development on plastic composite materials, which replace metal materials in order to improve fuel economy and lighten weight, are actively underway. Metal materials have excellent heat resistance and mechanical strength, but they are heavy in weight and have a disadvantage in improving fuel economy or light weight, while plastic materials are lighter than metal materials and can improve fuel economy. Prepreg is one of these plastic materials and is an intermediate substrate for fiber-reinforced composite materials, which is preliminarily impregnated with a matrix resin into reinforcing fibers and molded into a semi-cured state. The composite material produced using the prepreg can improve various properties such as strength, stiffness, corrosion resistance, fatigue life, abrasion resistance, impact resistance, and light weight as compared with other materials.

Foam Core is mainly used to make sandwich structure. Carbon fiber, glass fiber, aramid fiber, carbon fiber-aramid hybrid fiber, carbon fiber-glass fiber hybrid fiber, and veneer plywood are used as skins. Examples of the foam core material include polystyrene, PVC, polyurethane, polypropylene, polyethylene, PET, polyethylenetherphthalate (PMI), and polymethacrylimide (PMI) Etc. are used.

Korean Patent No. 10-1996-0000327 filed a patent application for automobile plastic hoods and loops that satisfy the weight reduction of automobiles by laminating prepregs. Korean Patent Laid-Open Nos. 10-2017-0082163 and Korean Patent Laid- -00133605 filed an application for an automotive component reinforcing material using a prepreg, and in Korean Patent Laid-open No. 10-2015-0044187, an automobile bumper was developed and applied using a prepreg.

KR 1019960000327 B1 (1998.08.07) KR 10-2017-0082163 A (2017.07.14) KR 10-2016-0133605 A (2016.11.23) KR 10-2015-0044187 A (2014.04.24)

SUMMARY OF THE INVENTION It is an object of the present invention to provide an automobile loop using a carbon fiber prepreg and a foam core in which a foam core is joined to a prepreg to alleviate a laminated curved surface and the undercut is minimized, and a manufacturing method thereof.

Another object of the present invention is to improve the adhesion between the prepreg and the mold by applying a foam core to the prepreg, thereby minimizing the surface pinhole phenomenon of the loop edge.

The objects of the present invention are not limited to the above-mentioned objects, and other objects not mentioned can be clearly understood by those skilled in the art from the following description.

In order to achieve the above object, the automobile roof using the carbon fiber prepreg and the foam core has a central portion and an upper portion formed at a position higher than the central portion on the left and right sides of the central portion, A first prepreg layer to be laminated; A foam core layer coupled between the central portion and the upper end of the first prepreg layer, respectively; And a second prepreg layer covering the first prepreg layer and the foam core layer and having carbon fiber prepregs laminated in multiple layers.

The foam core may be formed of a material such as PMI, PolyMethacrylImide, PVC, PolyVinyl Chloride, PET, PolyStyrene, Polyurethane, Polyethylene, Polypropylene, And at least one of them.

The carbon fiber prepreg is characterized in that the carbon fiber is impregnated in one of an epoxy resin, a polyester resin and a thermoplastic resin.

And the foam core is a polygonal columnar section having a polygonal cross-section in order to smooth the laminated curved surface of the second prepreg layer.

And the polygon which is a cross section of the foam core is a right triangle or an acute angle triangle.

In order to achieve the above object, the present invention provides a method of manufacturing a carbon loop for a vehicle using a prepreg and a foam core, comprising the steps of preparing a mold and a foam core (S10); (S20) forming a first prepreg layer by laminating a carbon fiber prepreg on the mold; (S30) coupling a foam core between a center portion and an upper end of the first prepreg layer; And forming a second prepreg layer by stacking a carbon fiber prepreg so as to cover the first prepreg layer and the foam core layer (S40); .

A method of manufacturing an automobile loop using a carbon fiber prepreg and a foam core includes the steps of: (S50) vacuum packing a loop formed by laminating the carbon fiber prepreg and the foam core; Molding the vacuum packed loop (S60); And a step (S70) of shaping and processing the shaped loop after demoulding.

The step (S50) of vacuum-packing a loop of the carbon fiber prepreg and the foam core laminated is characterized by coating the release film on the product.

In the step S50 of vacuum packing the loop of the carbon fiber prepreg and the foam core laminated, a breather is applied to the upper surface of the release film to facilitate vacuum packaging.

The foam core may be formed of a material such as PMI, PolyMethacrylImide, PVC, PolyVinyl Chloride, PET, PolyStyrene, Polyurethane, Polyethylene, Polypropylene, And at least one of them.

And the foam core is a polygonal columnar section having a polygonal cross-section in order to smooth the laminated curved surface of the second prepreg layer.

And the polygon which is a cross section of the foam core is a right triangle or an acute angle triangle.

The foam core is formed by injection molding using a shape or a mold.

As described above, the automobile loop using the carbon fiber prepreg and the foam core according to the present invention and the manufacturing method thereof can simplify the prepreg lamination process of the undercut portion and the loop corner portion by alleviating the laminated curved surface.

Further, the vacuum packaging operation can be facilitated.

In addition, the adhesion between the mold and the prepreg can be increased to minimize the pinhole phenomenon on the corner surface.

FIG. 1 is a cross-sectional view showing an automobile loop using a prepreg and a foam core according to a preferred embodiment of the present invention, wherein (a) shows a case where a prepreg and a foam core are laminated, (b) Fig.
2 is a view showing an automobile loop using a carbon fiber prepreg and a foam core in which a laminated curved surface is laminated as shown in Fig. 1 (a).
FIG. 3 is a sectional view showing an automobile loop using a prepreg and a foam core according to another preferred embodiment of the present invention, wherein (a) shows a case where a prepreg and a foam core are laminated, (b) And FIG.
FIG. 4 is a view showing an automobile loop using a carbon fiber prepreg and a foam core laminated as shown in FIG.
5 is a flowchart of a method of manufacturing an automobile loop using a prepreg and a foam core according to a preferred embodiment of the present invention.
FIG. 6 is a cross-sectional view illustrating a vacuum packaging step according to a preferred embodiment of the present invention. FIG. 6 (a) shows a case where both ends of the mold protrude vertically, and FIG. 6 FIG.

BRIEF DESCRIPTION OF THE DRAWINGS The advantages and features of the present invention, and the manner of achieving them, will be apparent from and elucidated with reference to the embodiments described hereinafter in conjunction with the accompanying drawings. The present invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Is provided to fully convey the scope of the invention to those skilled in the art, and the invention is only defined by the scope of the claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. &Quot; and / or "include each and every combination of one or more of the mentioned items. ≪ RTI ID = 0.0 >

The terminology used herein is for the purpose of illustrating embodiments and is not intended to be limiting of the present invention. In the present specification, the singular form includes plural forms unless otherwise specified in the specification. The terms " comprises "and / or" comprising "used in the specification do not exclude the presence or addition of one or more other elements in addition to the stated element.

Unless defined otherwise, all terms (including technical and scientific terms) used herein may be used in a sense commonly understood by one of ordinary skill in the art to which this invention belongs. Also, commonly used predefined terms are not ideally or excessively interpreted unless explicitly defined otherwise.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

FIG. 1 is a cross-sectional view showing an automobile loop using a prepreg and a foam core according to a preferred embodiment of the present invention, wherein (a) shows a case where a prepreg and a foam core are laminated, (b) Fig.

1 (a), an automobile loop using a carbon fiber prepreg and a foam core according to a preferred embodiment of the present invention includes a first prepreg layer 20, a foam core layer 30, a second prepreg layer (40).

The first prepreg layer 20 needs a mold 10 capable of laminating carbon fiber prepregs. The mold 10 is formed of a rigid material so that carbon fiber prepregs can be laminated, Vertically protruding. The first prepreg layer 20 has a central portion 22 and an upper portion 24 formed on the left and right of the central portion 22 at a higher position than the central portion 22, Respectively. More specifically, the first prepreg layer is formed to connect the center portion 22 and the upper end portion 24, and has a right angle corner between the center portion 22 and the upper end portion 24.

The carbon fiber prepreg is impregnated with one of epoxy resin, polyester resin and thermoplastic resin, and is in the form of a prepreg having fluidity.

The foam core layer 30 is formed of a polygonal columnar foam core having a polygonal cross section, which is coupled between the central part 22 and the upper end part 24, respectively. Preferably a right triangle, and a right angle portion of the foam core is engaged with a corner portion of the first prepreg layer 20.

The foam core may be formed of a material such as PMI, PolyMethacrylImide, PVC, PolyVinyl Chloride, PET, PolyStyrene, Polyurethane, Polyethylene, Polypropylene, And at least one of them.

The foam core is formed by injection molding using a shape or a mold.

The second prepreg layer 40 has a plurality of carbon fiber prepregs laminated so as to cover the first prepreg layer 20 and the foam core layer 30. More specifically, it can be laminated so as to cover the oblique surfaces of the center portion 22, the upper end portion 24, and the foam core layer 30, so that the laminated curved surface and the right corner can be relaxed to simplify the prepreg lamination and the vacuum packaging operation.

The automobile roof using the prepreg and the foam core is preferably formed symmetrically with respect to the center of the central portion 22, but may not be symmetrical.

1 (b) is an automobile loop in which prepregs are stacked in multiple layers without a foam core layer. As shown in Fig. 1 (b), there is a disadvantage that it is difficult to work the corner portions at both ends of the automobile loop without the foam core layer.

2 is a view showing an automobile loop using a carbon fiber prepreg and a foam core in which a laminated curved surface is laminated as shown in Fig. 1 (a).

Referring to FIG. 2, an automobile roof using a carbon fiber prepreg and a foam core may be combined with a triangular prismatic foam core having a triangular cross section so that the laminated curved surface is alleviated to simplify prepreg lamination and vacuum packaging operations. It is possible to reduce the occurrence of pinholes at the edges by increasing the adhesion between the prepreg 10 and the prepreg.

FIG. 3 is a sectional view showing an automobile loop using a prepreg and a foam core according to another preferred embodiment of the present invention, wherein (a) shows a case where a prepreg and a foam core are laminated, (b) And FIG.

3 (a), an automobile loop using a prepreg and a foam core according to another preferred embodiment of the present invention includes a first prepreg layer 20, a foam core layer 30, a second prepreg layer 40).

The first prepreg layer 20 requires a mold 10 capable of laminating carbon fiber prepregs. The mold 10 is formed of a rigid material so that carbon fiber prepregs can be stacked. Both ends of the mold 10 protrude in a Z-shape, and protrusions at both ends are formed in different directions.

The first prepreg layer 20 has a central portion 22 and an upper portion 24 formed on the left and right of the central portion 22 at a higher position than the central portion 22, . More specifically, the first prepreg layer is formed to connect the center portion 22 and the upper end portion 24, and has an acute angle between the center portion 22 and the upper end portion 24.

The foam core layer 30 is coupled between the central portion 22 and the upper end portion 24, and has a polygonal columnar shape with a polygonal cross section. Preferably a triangular prismatic shape having an acute-angled triangle, and one corner portion of the triangular column is engaged with the corner portion of the first prepreg layer 20.

The second prepreg layer 40 has a plurality of carbon fiber prepregs laminated so as to cover the first prepreg layer 20 and the foam core layer 30. More specifically, it can be laminated so as to cover the oblique surfaces of the central portion 22, the upper end portion 24, and the foam core layer 30 to simplify the prepreg lamination and the vacuum packaging operation by alleviating the laminated curved surface and acute angle edge, Can be minimized.

3 (b) is an automobile loop formed by stacking prepregs in multiple layers without a foam core layer. As shown in Fig. 1 (b), a car roof without a foam core layer is disadvantageous in that it is difficult to undercut both edges.

FIG. 4 is a view showing an automobile loop using a carbon fiber prepreg and a foam core laminated as shown in FIG.

Referring to FIG. 4, a car loop using a carbon fiber prepreg and a foam core combines a triangular prismatic foam core having an acute-angled triangle section to reduce the curved surface, minimizing the undercut and simplifying the prepreg lamination and vacuum packaging operations And the adhesion between the mold and the prepreg can be enhanced to reduce the occurrence of corner pinholes.

5 is a flowchart of a method of manufacturing an automobile loop using a prepreg and a foam core according to a preferred embodiment of the present invention.

First, a mold and a foam core preparing step (S10). A mold 10 having a rigid material and protruding at both ends in a vertical or Z-shape is prepared and a mold release agent is applied to the mold 10. This prevents the loop from adhering to the mold 10 and allows it to fall easily.

The foam core is processed into a triangular prism shape having a right triangle or an acute angle triangle according to the shape of protrusions at both ends of the mold 10, or prepared by injection molding.

Next, step (S20) of forming a first prepreg layer by laminating a carbon fiber prepreg on the mold. Carbon fiber prepregs are stacked on the mold 10 as described above with reference to FIGS. 1 to 4. The carbon fiber prepregs are formed on the left and right sides of the center portion 22 and the upper portion 24), and a first prepreg layer laminated in multiple layers is formed.

The first prepreg layer is formed such that the center portion 22 and the upper end portion 24 are connected to each other and a corner between the central portion 22 and the upper end portion 24 is perpendicular or acute depending on the shape of the mold 10. [ .

Next, a step (S30) of joining a foam core between a center portion and an upper end portion of the first prepreg layer is performed. The foam core is coupled between the central portion 22 and the upper end portion 24. More specifically, when both ends of the mold 10 are vertically protruded, the foam core is coupled with a triangular column having a right triangle in cross section, The triangular column having an acute-angled triangular cross-section is joined.

Next, a carbon prepreg is laminated to cover the first prepreg layer and the foam core layer to form a second prepreg layer (S40). The second prepreg layer 40 covers one side of the foam core layer 30 and is laminated to facilitate the lamination of the laminated curved surface than the first prepreg layer 20.

Next, a step (S50) of vacuum packing the loop in which the carbon fiber prepreg and the foam core are laminated is performed.

FIG. 6 is a cross-sectional view illustrating a vacuum packaging step according to a preferred embodiment of the present invention. FIG. 6 (a) shows a case where both ends of the mold protrude vertically, and FIG. 6 FIG.

Referring to FIG. 6, a method of manufacturing an automobile loop using a carbon fiber prepreg and a foam core includes a release film 50, a breather 60, a vacuum film 70, and a sealant tape 80 to facilitate vacuum packaging. .

The release film 50 is bonded to the upper surface of the loop, and the breather 60 is coupled to the upper surface of the release film 50. The breather 60 helps the inner vacuum pressure to act uniformly throughout the vacuum film 70 and serves as a passage for air during vacuum packaging.

The vacuum film 70 covers the mold 10 and the breather 60 and is fixed by the sealant tape 80 coupled to the protruding portions at both ends of the mold 10, .

The loop formed by laminating the carbon fiber prepreg and the foam core may not include the step S50 of vacuum packing the loop formed by laminating the carbon fiber prepreg and the foam core, The blower 60 or the release film 50 may not be applied during the vacuum packaging step S50 of the loop in which the foam cores are laminated.

The following is a step (60) of molding the vacuum packed loop. The vacuum packed loop is molded under high temperature and high pressure conditions through an autoclave operation. At this time, the first prepreg layer 20, the foam core layer 30, and the second prepreg layer 40 are co-cured to form a loop.

Finally, the shaped loop is deformed and processed (S70) after demoulding. The molded loops are demoulded in the mold 10 and then subjected to finishing work by finishing or fine finishing.

The method of manufacturing an automobile loop using a carbon fiber prepreg and a foam core further includes a step of washing and packaging the loop fabricated through the steps described above, and the fabric is washed, packaged and delivered.

While the present invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, It will be understood. It is therefore to be understood that the above-described embodiments are illustrative in all aspects and not restrictive.

10: Mold
20: First prepreg layer
22:
24:
30: foam core layer
40: second prepreg layer
50: release film
60: Breather
70: Vacuum film
80: sealant tape

Claims (13)

In a car loop using a carbon fiber prepreg and a foam core,
A first prepreg layer having carbon fiber prepregs laminated in multiple layers, the carbon fiber prepregs having a central portion and upper ends formed on the left and right sides of the central portion higher than the central portion;
A foam core layer coupled between the central portion and the upper end of the first prepreg layer, respectively; And
And a second prepreg layer covering the first prepreg layer and the foam core layer and having carbon fiber prepregs laminated in multiple layers,
Wherein the foam core is formed in a columnar shape of a right triangle or acute angle triangle so that the cross-section of the foamed core of the second prepreg layer is gentle so as to increase the adhesion between the mold and the prepreg to reduce the occurrence of pinholes. And a car loop using a foam core. The method according to claim 1,
The foam core may be formed of a material such as PMI, PolyMethacrylImide, PVC, PolyVinyl Chloride, PET, PolyStyrene, Polyurethane, Polyethylene, Polypropylene, Wherein the carbon fiber prepreg comprises at least one carbon fiber prepreg. The method according to claim 1,
Wherein the carbon fiber prepreg is impregnated with one of an epoxy resin, a polyester resin and a thermoplastic resin. delete delete A method of manufacturing a carbon loop for a vehicle using a prepreg and a foam core,
Preparing a mold and a foam core (S10);
(S20) forming a first prepreg layer by laminating a carbon fiber prepreg on the mold;
(S30) coupling a foam core between a center portion and an upper end of the first prepreg layer; And
A step (S40) of forming a second prepreg layer by laminating a carbon fiber prepreg so as to cover the first prepreg layer and the foam core layer; , ≪ / RTI &
The mold and the foam core preparation step (S10) may include preparing a foam core having a center portion and a top portion formed at a position higher than the central portion on the right and left sides of the central portion and having a columnar shape of a right angle triangle or acute angle triangle, And increasing the adhesion between the mold and the prepreg to reduce the occurrence of pinholes, and a method for manufacturing an automobile loop using the carbon fiber prepreg and the foam core. The method according to claim 6,
A method of manufacturing an automobile loop using a carbon fiber prepreg and a foam core
A step (S50) of vacuum-packing a loop in which the carbon fiber prepreg and the foam core are laminated;
Molding the vacuum packed loop (S60); And
(S70) a step of shaping and processing the shaped loop after demoulding the carbon fiber prepreg and the foam core. 8. The method of claim 7,
(S50) of vacuum-packing a loop in which the carbon fiber prepreg and the foam core are laminated is characterized in that a release film is applied to the fabricated loop, and a method for manufacturing an automobile loop using the foam core . 9. The method of claim 8,
(S50) of vacuum-packing a loop of the carbon fiber prepreg and the foam core is performed by applying a breather to the upper surface of the release film to facilitate vacuum packaging. Method for manufacturing automotive roof using core. The method according to claim 6,
The foam core may be formed of a material such as PMI, PolyMethacrylImide, PVC, PolyVinyl Chloride, PET, PolyStyrene, Polyurethane, Polyethylene, Polypropylene, Wherein the carbon fiber prepreg comprises a carbon fiber prepreg and a foam core. delete delete The method according to claim 6,
Wherein the foam core is formed by injection molding using a mold or a mold. ≪ RTI ID = 0.0 > 11. < / RTI >

Images