WO2015075683A1 - 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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Publication number
WO2015075683A1
WO2015075683A1 PCT/IB2014/066238 IB2014066238W WO2015075683A1 WO 2015075683 A1 WO2015075683 A1 WO 2015075683A1 IB 2014066238 W IB2014066238 W IB 2014066238W WO 2015075683 A1 WO2015075683 A1 WO 2015075683A1
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Prior art keywords
prepreg
layer
semi
finished product
dimensional
Prior art date
Application number
PCT/IB2014/066238
Other languages
English (en)
French (fr)
Inventor
Jy⋅德芒日
Original Assignee
全耐塑料公司
Jy⋅德芒日
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Filing date
Publication date
Application filed by 全耐塑料公司, Jy⋅德芒日 filed Critical 全耐塑料公司
Priority to US15/037,343 priority Critical patent/US20160271901A1/en
Priority to KR1020167016504A priority patent/KR20160096626A/ko
Priority to MX2016006280A priority patent/MX2016006280A/es
Priority to EP14828052.2A priority patent/EP3072683B1/en
Priority to JP2016531996A priority patent/JP6483682B2/ja
Publication of WO2015075683A1 publication Critical patent/WO2015075683A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/06—Making preforms by moulding the material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/40—Removing or ejecting moulded articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00—Layered products having a non-planar shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/02—Layer formed of wires, e.g. mesh
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/085—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/18—Handling of layers or the laminate
    • B32B38/1866—Handling of layers or the laminate conforming the layers or laminate to a convex or concave profile
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C2045/14237—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being deformed or preformed outside the mould or mould cavity
    • B29C2045/14245—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being deformed or preformed outside the mould or mould cavity using deforming or preforming means outside the mould cavity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2623/00—Use of polyalkenes or derivatives thereof for preformed parts, e.g. for inserts
    • B29K2623/10—Polymers of propylene
    • B29K2623/12—PP, i.e. polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
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    • B32B2262/103—Metal fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/07—Parts immersed or impregnated in a matrix
    • B32B2305/076—Prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars

Definitions

  • the present invention relates to the field of prepreg products, and more particularly to a semi-finished product made of a prepreg and a three-dimensional product made of the semi-finished product. Preforms and overmolded parts.
  • a prepreg (“PREPREG" in English) is a commonly used intermediate material for making composite materials, usually composed of a resin matrix and a reinforcement (for example, fiber or fabric) impregnated in the matrix. Due to the inclusion of reinforcements, prepregs have a high mechanical strength and are often used in the manufacture of parts or areas where reinforcement is required, such as automotive parts. Prepregs purchased on the market are usually in the form of sheets or rolls.
  • a method of manufacturing such a three-dimensional component is known to comprise the following steps: Step 1: Cutting the purchased prepreg into a suitable shape and size (usually obtained by two-dimensional expansion of a desired three-dimensional preform) And stacking several layers of prepregs having suitable shapes and sizes as needed to obtain a semi-finished product; Step 2: heating the semi-finished product and then performing hot stamping to obtain a three-dimensional preform; Step 3: The three-dimensional preform is taken out from the hot stamping forming die and machined after cooling, such as contour finishing, drilling, etc., to have the desired final dimensions and geometry; Step 4: Re-repair the three-dimensional preform Heating above the melting point of the prepreg resin matrix for subsequent overmolding in the resin matrix of the prepreg and A good adhesion between the overmolding resin is obtained; Step 5: transferring the hot three-dimensional preform into an overmolding mold, and molding the thermoplastic resin
  • FIG. 1 shows a three-dimensional preform obtained after the step 3 by the above method
  • FIG. 2 shows a three-dimensional preform obtained after the step 4.
  • the three-dimensional preform includes two layers of prepreg. Material layers 10, 12.
  • the present invention provides a semi-finished product made of a prepreg comprising at least a first prepreg layer and a second prepreg layer, characterized in that the first prepreg layer and the A metal layer is laid between the second prepreg layers.
  • prepreg English "PREPREG"
  • PREPREG a commonly used intermediate material for the manufacture of composite materials. It has the usual meaning in the field of composite materials, which is made by impregnating the reinforcement with a resin matrix under strictly controlled conditions. A combination of a resin matrix and a reinforcement.
  • the term "semi-finished product” refers to an intermediate product that has not yet been manufactured as a final product and still requires further processing.
  • the three-dimensional preform formed of the semi-finished product can be obtained during the reheating process before the overmolding
  • the support of the metal layer maintains its three-dimensional shape well without collapse.
  • the added metal layer remains in the finally obtained overmolded product, it can also enhance the mechanical strength of the product and provide a complementary reinforcement.
  • the semi-finished product according to the present invention may further comprise one or more of the following technical features: when the thermoplastic resin contained in the first prepreg layer and the second prepreg layer is softened, the metal The layer remains solid.
  • the metal layer is a metal mesh. Since the metal mesh has mesh, it can reduce the weight of the final product and save production costs.
  • the resin matrix of the adjacent layer prepreg can be welded to each other through the mesh of the metal mesh, thereby fixing the metal mesh more firmly. Between two layers of prepreg.
  • the first prepreg layer and the second prepreg layer have the same shape and size as the metal mesh.
  • the metal mesh can cover the entire prepreg layer, providing support at every location without leaving a "support blind spot.” Therefore, the three-dimensional preform made of the semi-finished product can better maintain its three-dimensional shape during the reheating process before the overmolding.
  • the metal contains iron. This can enhance the mechanical properties of the final product.
  • the metal may be selected from the group consisting of iron, mild steel, copper alloys, and aluminum alloys.
  • a polypropylene film is also laid between the first prepreg layer and/or the second prepreg layer and the metal mesh.
  • the polypropylene film can fill the metal mesh, the air trapped therein is discharged, so that the uniformity of the product can be greatly improved. In addition, this also helps to improve the metal mesh Bonding Force to Prepreg Layer
  • the polypropylene film has the same shape and size as the metal mesh.
  • the reinforcing material in the prepreg is carbon or glass.
  • the present invention also relates to a three-dimensional preform, which is produced by hot stamping from the above-mentioned semi-finished product. Further, the present invention relates to an overmolded molded article characterized in that it comprises at least one three-dimensional preform as described above and a thermoplastic resin portion which is overmolded on the three-dimensional preform.
  • the overmolded part is a component of a motor vehicle, in particular a rear closing part of a motor vehicle.
  • a motor vehicle in particular a rear closing part of a motor vehicle.
  • FIG. 4 is an exploded perspective view of the semifinished product shown in Fig. 3;
  • Fig. 5 is a view showing the process of processing the semifinished product shown in Fig. 3 into a three-dimensional preform;
  • Fig. 6 is a process shown in Fig. 5.
  • Figure 7 shows the internal structure of the three-dimensional preform shown in Figure 6;
  • Figure 8 shows the entire manufacturing process from the commercially available prepreg to the final three-dimensional component;
  • Figure 9 is the final three-dimensional component according to the present invention.
  • Figure 3 shows a perspective view of a semi-finished product 1 made of a prepreg in accordance with one embodiment of the present invention.
  • Figure 4 better illustrates the structure of the semi-finished product 1 in an exploded view.
  • the semi-finished product 1 includes a first prepreg layer 10, a second prepreg layer 12, and a metal layer sandwiched between the two layers. It will be appreciated that the semi-finished product 1 may include more prepreg layers and/or metal layers, which can be determined by those skilled in the art according to specific design goals.
  • the semi-finished product 1 includes first, second, and third prepreg layers stacked in sequence with a metal layer sandwiched between each two adjacent prepreg layers.
  • the semifinished product 1 comprises first, second and third prepreg layers stacked in sequence, but with a metal layer sandwiched between the first and second prepreg layers.
  • prepreg ("PREPREG" in English) is a commonly used intermediate material for the manufacture of composite materials, usually consisting of a resin matrix and a reinforcement (for example: fiber or fabric) impregnated in the matrix.
  • the first prepreg layer 10 and the second prepreg layer 12 are each composed of a thermoplastic resin matrix and a reinforcement impregnated in the matrix, and the reinforcement may be carbon and/or glass fiber or fabric.
  • the metal layer can be composed of any suitable metal or alloy (e.g., iron, mild steel, copper alloy, aluminum alloy, etc.).
  • the metal layer is composed of a ferrous material which enhances the mechanical properties of the final product.
  • the metal layer can be solid or perforated.
  • the metal layer is a meshed metal mesh 14, which reduces the weight of the final product and saves production costs.
  • the resin matrix of the adjacent layer prepreg may be welded to each other through the mesh of the metal mesh, thereby making the metal mesh more firmly It is fixed between two layers of prepreg.
  • a polypropylene film can also be laid between the metal mesh and the prepreg layers 10 and/or 12 adjacent thereto. Since the polypropylene film can fill the metal mesh, the air trapped therein is discharged, so that the uniformity of the product can be greatly improved. In addition, this also helps to improve the bonding force between the metal mesh and the prepreg layer.
  • the first prepreg layer 10 and the second prepreg layer 12 have the same shape and dimensions as the metal mesh 14.
  • the three-dimensional preform obtained from the semi-finished product 1 can be fully supported by the metal layer 14 during reheating, thereby better maintaining its three-dimensional shape.
  • Fig. 5 shows a process of processing the semi-finished product 1 shown in Fig. 3 into a three-dimensional preform 2
  • Figs. 6 and 7 show a three-dimensional preform 2 obtained by the process.
  • a portion of the second prepreg layer 12 is removed in FIG.
  • the semi-finished product is heated before the semi-finished product 1 is placed in a molding die at a heating temperature higher than the melting point of the prepreg resin matrix. Then, the hot semi-finished product 1 is placed in a molding die (for example, the hot stamping dies 20, 22 shown in Fig. 5), and is three-dimensionally formed. It should be noted that in this molding step, the metal layers contained in the semi-finished product 1 are also molded together. Thereafter, demolding is carried out at a temperature lower than the melting point of the prepreg resin matrix to obtain a three-dimensional preform 2 having a desired three-dimensional shape, as shown in Figs. 6 and 7.
  • Step A Cutting the purchased prepreg and metal mesh into a suitable shape and size (usually obtained by two-dimensional expansion of the desired three-dimensional preform)
  • Step B stacking several layers of prepreg and metal mesh of suitable shape and size as needed to obtain a semi-finished product according to the present invention
  • Step C heating the semi-finished product above the melting point of the resin matrix of the prepreg thereof temperature
  • Step D The semi-finished product is three-dimensionally formed in a mold (for example, a hot stamping die);
  • Step E demolding at a temperature lower than the melting point of the prepreg resin matrix to obtain a three-dimensional preform having a desired three-dimensional shape Body 2;
  • Step F After the three-dimensional preform is cooled, it is machined, such as contour finishing, drilling, etc., into a three-dimensional preform 3 having a desired final size and geometric configuration;
  • Step G The three-dimensional preform 3 is reheated to above the melting point of the prepreg resin matrix
  • the three-dimensional component 4 thus obtained can be, for example, a component on a motor vehicle, such as a rear closure component of a motor vehicle.
  • Fig. 9 shows an example of the three-dimensional member, which in this example is a trunk lid closing member 4, consisting of a prepreg three-dimensional preform 3, and a plastic molded resin portion 16, which is formed in a prepreg
  • the three-dimensional preform 3 contains a metal layer. Since the metal layer is added between the prepreg layers, in the above steps G and H, the three-dimensional preform can obtain the support of the metal layer, thereby maintaining its three-dimensional shape well.
  • the metal constituting the metal layer needs to have a melting point higher than that of the prepreg thermoplastic resin matrix, so that in the step G, the metal layer does not become molten, but can support the molten resin matrix.
  • the added metal layer since the added metal layer remains in the finally obtained overmolded product, it can also enhance the mechanical strength of the product and complement it. Function.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Laminated Bodies (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Heat Treatment Of Articles (AREA)
  • Reinforced Plastic Materials (AREA)
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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

说 明 书
预浸料制成的半成品及三維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維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： 纤維或 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維的， 有时还具有复杂的形 状。 已知一种制造这种三維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 望得到的三維预成型体进行二維展开而得到的）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 到三維预成型体； 步骤 3 : 将得到的三維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: 对该三維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 : 将上述热的三維预成型体转移到包塑成型模具中， 在该 三維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 （由所述三維预成型体构成的）和包塑成型树脂部的三 維部件。 图 1示出了采用上述方法在步骤 3后得到的三維预成型体， 图 2 则示出了在步骤 4后得到的三維预成型体， 在本例中， 三維预成型体 包括两层预浸料层 10、 12。 可以清楚地看到， 经过步骤 4后该三維 预成型体原来的三維形状 （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， 当该三維预成型体被重 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 致该三維预成型体变得很软， 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維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 成品制成的三維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維形状， 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 品制成的三維预成型体在包塑成型前的重新加热过程中能够更好地 保持其三維形状。 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維预成型体， 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維预成型体以及在所述三維预成型体上包塑 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維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維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維预成型体的过程； 图 6是经图 5所示过程得到的三維预成型体的立体图； 图 7示出了图 6所示三維预成型体的内部结构; 图 8示出了从市购预浸料到最终三維部件的整个制造过程； 和 图 9是根据本实用新型的最终三維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： 纤維或织物） 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 /或玻璃纤維或织物。 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得到的三維预成型体 （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維形状。 图 5示出了将图 3所示的半成品 1加工成三維预成型体 2的过程， 图 6和图 7 则示出了经该过程得到的三維预成型体 2。为了清除地显 示该三維预成型体 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)， 对其进行三維成 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， 得到具有所需三維形状的三維预成型体 2， 如图 6和图 7所示。 应当 理解的是， 图 6和图 7所示的三維形状仅仅是示意性的， 三維预成型 体 2根据其具体的应用场合可以具有更加复杂的三維形状。 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維 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維预成型体进行二維展开而得到的）； 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） 中进行三維成 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 具有所需三維形状的三維预成型体 2; 步骤 F: 待三維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維预成 型体 3 ; 步骤 G:对该三維预成型体 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: 将上述热的三維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， 在该三維预 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 （由所述三維预成型体 3构 成的） 和包塑成型树脂部 16的三維部件 4。 由此得到的三維部件 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示出了该三維部件的一个示例， 在本例中， 它是 汽车行李箱关闭部件 4，， 由预浸料三維预成型体 3，以及包塑成型树 脂部 16，构成， 在预浸料三維预成型体 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， 三維预成型体能够得到该金属层的支撑， 从而很好地保持其三維形 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

权 利 要 求 书
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. 一种三維预成型体， 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所述的三維预成型体以及在所述三維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 其特征在于， 它是机动
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CN203864106U (zh) 2014-10-08
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