WO2018035998A1 - 蜂窝状金属及其制备方法以及含有其的汽车 - Google Patents

蜂窝状金属及其制备方法以及含有其的汽车 Download PDF

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Publication number
WO2018035998A1
WO2018035998A1 PCT/CN2016/106136 CN2016106136W WO2018035998A1 WO 2018035998 A1 WO2018035998 A1 WO 2018035998A1 CN 2016106136 W CN2016106136 W CN 2016106136W WO 2018035998 A1 WO2018035998 A1 WO 2018035998A1
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honeycomb
metal
honeycomb metal
model
sand
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PCT/CN2016/106136
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English (en)
French (fr)
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张晶
武胜军
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北京新能源汽车股份有限公司
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Publication of WO2018035998A1 publication Critical patent/WO2018035998A1/zh

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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/08—Alloys with open or closed pores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/08—Alloys with open or closed pores
    • C22C1/081—Casting porous metals into porous preform skeleton without foaming
    • C22C1/082—Casting porous metals into porous preform skeleton without foaming with removal of the preform

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  • the present invention relates to the field of automotive technology, and in particular to a honeycomb metal, a method of manufacturing the same, and an automobile containing the same.
  • Metal honeycomb panels have a series of advantages such as light weight, high strength, high rigidity, excellent thermal insulation and sound insulation performance.
  • the magnesium alloy has low density and has obvious advantages such as specific stiffness, specific strength and recyclability.
  • the weight of the components plays an important role and has a very broad application prospect.
  • the outer skin of the car, the body structure, the frame structure, the bumper, the seat, the door and the like are all feasible application parts.
  • the preparation methods of the magnesium alloy honeycomb core mainly include a development method, a pressure bonding forming method, a pressure brazing forming method, a stretching method and the like.
  • the pressure bonding forming method is that the material is rolled or punched into a corrugated board, and then the corrugated material is laminated and laminated.
  • the pressure brazing method uses brazing to laminate the corrugated materials.
  • the stretching method is to first apply a strip on the material, then laminate the material, and finally stretch the laminated material into a honeycomb.
  • the first technical bottleneck faced by the development of traditional honeycomb metal is the processing of magnesium alloy sheets.
  • the current honeycomb metal process has not overcome the above problems of conventional honeycomb metal, and thus the current honeycomb metal technology still needs to be improved.
  • an object of the present invention is to provide a honeycomb metal which is integrally formed, has a thin wall thickness or a uniform wall thickness, and a preparation method thereof.
  • the invention provides a honeycomb metal.
  • the honeycomb metal is integrally formed.
  • the inventor has surprisingly found that the honeycomb metal is integrally formed, has good integrity, high strength, and does not need to be formed by cementation, thereby effectively overcoming the technical problem that the existing honeycomb metal cement joint position is not high.
  • the honeycomb metal has a wall thickness of not less than 0.5 mm.
  • the honeycomb metal is formed of a magnesium alloy.
  • the invention provides a method of making the honeycomb metal described above.
  • the method comprises: (1) providing a honeycomb foam molding; (2) forming a refractory coating layer on the foam molding surface; (3) drawing the foam plastic obtained in the step (2) Modeling; and (4) in vacuum The molten metal is poured under the conditions.
  • the inventors have found that the honeycomb metal obtained as described above can be quickly and efficiently prepared by the method, and the obtained honeycomb metal is integrally formed without cementation, and the integrity and strength are remarkably improved, effectively solving the traditional honeycomb metal. Connection strength and process issues between.
  • the foam plastic pattern is prepared by the following steps: a. forming a honeycomb model using polypropylene, the honeycomb model having a hollow chamber, the shape of the chamber a honeycomb shape; b. filling polystyrene pellets in the chamber and closing the chamber; c. heating the honeycomb model until the styrene pellets are foamed and subjected to demolding treatment, The foam plastic appearance is obtained.
  • the thickness of the chamber is not less than 0.5 mm.
  • step c the heating is carried out by placing the honeycomb model in steam.
  • the step (2) further comprises: (2-1) brushing the refractory coating on the foam molding surface; (2-2) placing the foam plastic sample obtained in the step (2-1) Dry naturally in the air; (2-3) Dry the foamed plastic form obtained in the step (2-2) at 40-60 degrees Celsius for 4-8 hours.
  • the styling is performed by: filling the sand tank with the bottom sand and shaking the flat sand; and setting the foam plastic sample obtained in the step (2) On the bottom sand, fill the sand and micro-shock for 30-60 seconds; flatten the molding sand and the sprue.
  • the method of preparing a honeycomb metal further comprises: (5) cleaning and reworking the cast product obtained in the step (4).
  • the present invention provides an automobile. According to an embodiment of the invention, at least a portion of the automobile is formed using the honeycomb metal described above. All of the features and advantages of the previously described honeycomb metal are applicable to the vehicle and will not be described again.
  • FIG. 1 shows a schematic structural view of a honeycomb metal according to an embodiment of the present invention.
  • FIG. 2 shows a schematic flow diagram of a method of preparing a honeycomb metal in accordance with an embodiment of the present invention.
  • the invention provides a honeycomb metal.
  • the honeycomb metal is integrally formed.
  • the inventor was consciously surprised to find that the honeycomb metal is integrally formed, and the integrity is good and strong.
  • the high degree does not need to be formed by cementation, which effectively overcomes the technical problem that the existing honeycomb metal cement joint position is not high.
  • the honeycomb metal has a wall thickness of not less than 0.5 mm.
  • the inventors have unexpectedly found that a honeycomb metal having a thin wall thickness can be obtained by this method, and is not limited by the processing technology of the existing metal thin plate.
  • the wall thickness of the honeycomb metal obtained by the method can be as thin as 0.5 mm.
  • the specific material for forming the honeycomb metal is not particularly limited, and those skilled in the art can select according to actual needs.
  • the honeycomb metal is formed from a magnesium alloy. Therefore, the honeycomb magnesium alloy has ideal strength, has no cementation position, is ideal in overall integrity and strength, and can be effectively applied to automobile outer skin, body structure and the like, and is advantageous for improving automobile weight and improving mechanical properties thereof. And mechanical properties, etc.
  • the invention provides a method of making the honeycomb metal described above. According to an embodiment of the invention, referring to Figure 2, the method comprises the following steps:
  • the honeycomb foam pattern employed in this step conforms to the shape of the target honeycomb metal to be prepared.
  • the honeycomb foam plastic is vaporized, and the molten metal occupies the position of the honeycomb foam plastic shape, and after cooling, forms a honeycomb metal.
  • the specific method of preparing the honeycomb foam plastic pattern is not particularly limited as long as a honeycomb foam pattern satisfying the requirements can be obtained, and those skilled in the art can select as needed.
  • the foam plastic pattern in this step, can be prepared by the following steps: a. forming a honeycomb model using polypropylene, the honeycomb model having a chamber having a honeycomb shape and being hollow; b. The ethylene pellets are filled in the chamber of the honeycomb model, and the chamber is closed; c. The honeycomb model is heated until the polystyrene pellets are foamed, and the mold release treatment is performed to obtain the foam plastic pattern.
  • the specific method of forming the honeycomb model is not particularly limited, as long as the honeycomb model that meets the requirements can be effectively formed, those skilled in the art can flexibly select.
  • the specific shape of the honeycomb model is also not particularly limited as long as it has a honeycomb-like, hollow chamber, and those skilled in the art can adjust the specific shape of the model as needed. For example, it may be honeycomb or other regular or irregular shapes.
  • a honeycomb foam pattern having a thin wall thickness and a uniform thickness can be obtained by the method, that is, the thickness of the chamber in the above model is thin.
  • the thickness of the chamber is not less than 0.5 mm, that is, the wall thickness of the above model can be up to 0.5 mm.
  • the honeycomb model is closed on one side and open on one side. This is set to facilitate processing, which facilitates subsequent processing.
  • the manner of heating the honeycomb model is not particularly limited as long as it can effectively foam the polystyrene pellets, and those skilled in the art can flexibly select according to actual operating conditions.
  • the honeycomb model is preferably placed in steam for heating. Thereby, the heat is uniform, the foaming effect is ideal, the uniformity of the obtained pattern is good, and it is easy to vaporize in the subsequent step, which is advantageous for obtaining a honeycomb metal having a smooth surface, smoothness and few defects.
  • the step may further include: S210: brushing the surface of the foam plastic pattern with a refractory paint; S220: placing the foam plastic sample obtained in step S210 in the air to be naturally dried; S230: at 40- The foamed plastic sample obtained in the step S220 was dried at 60 ° C for 4-8 hours.
  • the refractory coating layer can be formed on the surface of the foam plastic pattern quickly and effectively, and the formed refractory coating layer has uniform thickness and good performance, for example, the surface roughness of the prepared honeycomb metal surface can be lowered, and the surface quality and the use performance can be improved.
  • honeycomb metal grit grit, blisters, etc.
  • it can help prevent or reduce defects such as honeycomb metal grit, blisters, etc., which is beneficial to improve the doffing of honeycomb metal, clear sand efficiency, prevent the generation of pores in honeycomb metal, and improve the strength and rigidity of the foam pattern to prevent the appearance of the pattern. Deformation and damage occur during transportation and sand filling.
  • the specific kind of the refractory paint that can be employed according to the embodiment of the present invention is not particularly limited, and those skilled in the art can flexibly select as needed as long as the corresponding functions can be achieved.
  • the coating composition may be 30-50% of magnesia powder, 20-40% of pearl powder, 15-30% of mica powder, 3-9% of silica sol, 1-5% of white latex, 0.1-0.8% of polyacrylamide, Sodium carboxymethyl cellulose 0.1-0.8%, adsorbent 1-6%, flame retardant 0.3-2%.
  • coatings of other formulations may also be selected.
  • step S300 The foam plastic pattern obtained in step S200 is shaped.
  • the styling is performed by filling the sand box with the bottom sand and shaking the flat sand; placing the foam plastic sample obtained in step S200 on the bottom sand. Fill the sand with a microseism for 30-60 seconds; flatten the sand and the sprue.
  • pouring under vacuum conditions can be carried out under a negative pressure, which is more favorable for filling and feeding of the molten metal, and improves the microstructure density of the obtained honeycomb metal.
  • the method of preparing a honeycomb metal further comprises:
  • the cleaning and reworking includes, but is not limited to, releasing the vacuum after cooling, removing the produced honeycomb metal from the loose sand, and cleaning and grinding the honeycomb metal, subsequent machining, and the like.
  • honeycomb metal obtained as described above can be quickly and efficiently prepared by the method, and the obtained honeycomb metal is integrally formed without cementation, and the integrity and strength are remarkably improved, effectively solving the traditional honeycomb metal. Connection strength and process issues between.
  • the method is particularly suitable for preparing a magnesium alloy honeycomb structure (or a honeycomb magnesium alloy).
  • the method for casting a magnesium alloy honeycomb structure can integrally form a magnesium alloy honeycomb structure. Avoid The rolling of the magnesium alloy sheet and the connection of the later magnesium alloy honeycomb structure can achieve a very low wall thickness and seamless connection of the honeycomb magnesium alloy, greatly improving the performance and strength of the magnesium alloy honeycomb structure.
  • the present invention provides an automobile.
  • at least a portion of the automobile is formed using the honeycomb metal described above. All of the features and advantages of the previously described honeycomb metal are applicable to the vehicle and will not be described again.
  • the automobile has other structures and components that conventional automobiles have in addition to the portion formed of the honeycomb metal described above, and will not be further described herein.
  • a honeycomb model of different forms is fabricated using PP (polypropylene) having a honeycomb-shaped and hollow chamber, and the chambers of the model may have different honeycomb shapes including, but not limited to, a hexagonal honeycomb model. .
  • the wall thickness of the honeycomb model can be as thin as 0.5 mm.
  • the honeycomb model is closed on one side and open on one side for filling the polystyrene pellets in subsequent steps.
  • polystyrene foam is formed by extrusion.
  • the polystyrene (PS) pellets are filled into a cavity in a polypropylene (PP) honeycomb model, and the two sides of the model are closed, placed in steam to be heated until foaming is completed, and the mold release treatment is performed to obtain a honeycomb polystyrene plastic pattern. .
  • the paint was applied to the surface of the polystyrene honeycomb pattern, dried naturally in the air after brushing, and baked in an oven at 50 degrees Celsius for 6 hours.
  • a honeycomb model of different forms is fabricated using PP (polypropylene) having a honeycomb-shaped and hollow chamber, and the chambers of the model may have different honeycomb shapes including, but not limited to, a hexagonal honeycomb model. .
  • the wall thickness of the honeycomb model can be as thin as 0.5 mm.
  • the honeycomb model is closed on one side and open on one side for filling the polystyrene pellets in subsequent steps.
  • polystyrene foam is formed by extrusion.
  • PS polystyrene
  • PP polypropylene
  • the paint was applied to the surface of the polystyrene honeycomb pattern, dried naturally in the air after brushing, and baked in an oven at 40 degrees Celsius for 8 hours.
  • a honeycomb model of different forms is fabricated using PP (polypropylene) having a honeycomb-shaped and hollow chamber, and the chambers of the model may have different honeycomb shapes including, but not limited to, a hexagonal honeycomb model. .
  • the wall thickness of the honeycomb model can be as thin as 0.5 mm.
  • the honeycomb model is closed on one side and open on one side for filling the polystyrene pellets in subsequent steps.
  • polystyrene foam is formed by extrusion.
  • the polystyrene (PS) pellets are filled into a cavity in a polypropylene (PP) honeycomb model, and the two sides of the model are closed, placed in steam to be heated until foaming is completed, and the mold release treatment is performed to obtain a honeycomb polystyrene plastic pattern. .
  • the paint was applied to the surface of the polystyrene honeycomb pattern, dried naturally in the air after brushing, and baked in an oven at 60 degrees Celsius for 4 hours.
  • honeycomb magnesium alloy obtained in the above Examples 1-3 and the conventional honeycomb magnesium alloy (forming a honeycomb shape by cementation) were examined, and the results showed that the strength of the honeycomb magnesium alloy prepared in Example 1-3 was remarkably improved.

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Abstract

一种蜂窝状金属、该金属的制备方法以及含有该金属的汽车。其中该蜂窝状金属是一体成型的，其整体性好、强度高，且无需通过胶结形成，能有效克服现有蜂窝状金属胶结位置连接强度不高及加工复杂等问题。

Description

蜂窝状金属及其制备方法以及含有其的汽车 技术领域
本发明涉及汽车技术领域，具体的，涉及蜂窝状金属及其制备方法以及含有其的汽车。
背景技术
金属蜂窝板具有重量轻、强度高、刚性大、隔热隔声性能优异等一系列优点，镁合金密度小，并具有良好的比刚度、比强度、可循环再利用等非常明显优势，在减轻构件的重量方面发挥重要作用，具有非常广阔的应用前景。在汽车的外蒙皮、车身结构、车架结构、保险杠、座椅、车门等都是可行的应用零部件。
目前镁合金蜂窝芯的制备方法主要有：展开法、压力粘接成形法、压力钎焊成形法、拉伸法等。压力粘接成形法是先将材料辊轧或冲压成波纹板，然后再将波纹状材料叠合胶结而成。压力钎焊成形法，采用钎焊将波纹状材料叠合起来。拉伸法是先在材料上涂胶条，然后将材料叠合胶结起来，最后再将叠合胶结起来的材料拉伸成蜂窝。传统蜂窝状金属的开发面临的第一个技术瓶颈是镁合金板的加工问题。传统镁合金铸锭存在大量枝状晶、晶粒不均匀、夹杂含量多等原因，使得镁合金薄板材的加工质量不易保证、薄板材厚度不均匀。传统蜂窝状金属的第二个问题是蜂窝板之间的连接强度和工艺问题。
目前的蜂窝状金属工艺仍未克服传统蜂窝状金属的上述问题，因而，目前的蜂窝状金属技术仍有待改进。
发明内容
本发明旨在至少在一定程度上解决相关技术中的技术问题之一。为此，本发明的一个目的在于提出一种一体成型、壁厚较薄或者壁厚均匀的蜂窝状金属及其制备方法。
在本发明的一个方面，本发明提供了一种蜂窝状金属。根据本发明的实施例，所述蜂窝状金属是一体成型的。发明人惊喜地发现，该蜂窝状金属一体成型，整体性好，强度高，不需要通过胶结形成，有效克服了现有蜂窝状金属胶结位置连接强度不高的技术问题。
根据本发明的实施例，所述蜂窝状金属的壁厚不小于0.5毫米。
根据本发明的实施例，所述蜂窝状金属是由镁合金形成的。
在本发明的另一方面，本发明提供了一种制备前面所述的蜂窝状金属的方法。根据本发明的实施例，该方法包括：(1)提供蜂窝状泡沫塑料模样；(2)在所述泡沫塑料模样表面形成耐火涂料层；(3)将步骤(2)中得到的泡沫塑料模样进行造型；以及(4)在真空 条件下将金属熔液进行浇注。发明人发现，通过该方法能够快速有效的制备获得前面所述的蜂窝状金属，且获得的蜂窝状金属是一体成型的，不需要胶结，整体性和强度显著提高，有效解决了传统蜂窝状金属之间的连接强度和工艺问题。
根据本发明的实施例，步骤(1)中，所述泡沫塑料模样是通过以下步骤制备的：a.利用聚丙烯形成蜂窝模型，所述蜂窝模型具有中空的腔室，所述腔室的形状呈蜂窝状；b.将聚苯乙烯粒料填充在所述腔室内，并将所述腔室封闭；c.将所述蜂窝模型加热至苯乙烯粒料发泡完成，并进行脱模处理，得到所述泡沫塑料模样。
根据本发明的实施例，步骤a中，所述腔室的厚度不小于0.5毫米。
根据本发明的实施例，步骤c中，所述加热是将所述蜂窝模型置于蒸汽中进行的。
根据本发明的实施例，步骤(2)进一步包括：(2-1)在所述泡沫塑料模样表面刷涂耐火涂料；(2-2)将步骤(2-1)中得到的泡沫塑料模样置于空气中自然干燥；(2-3)于40-60摄氏度下，将步骤(2-2)中得到的泡沫塑料模样烘干4-8小时。
根据本发明的实施例，步骤(3)中，所述造型是通过以下步骤进行的：在砂箱中填入底砂，并震实刮平；将步骤(2)中得到的泡沫塑料模样置于所述底砂上，填满型砂并微震30-60秒；将型砂与直浇道刮平。
根据本发明的实施例，制备蜂窝状金属的方法进一步包括：(5)对步骤(4)得到的浇注产品进行清理及再加工。
在本发明的再一方面，本发明提供了一种汽车。根据本发明的实施例，所述汽车的至少一部分是利用前面所述的蜂窝状金属形成的。前面描述的蜂窝状金属的所有特征和优点均适用于该汽车，在此不再一一赘述。
附图说明
图1显示了根据本发明实施例的蜂窝状金属的结构示意图。
图2显示了根据本发明实施例的制备蜂窝状金属的方法的流程示意图。
具体实施方式
下面详细描述本发明的实施例。下面描述的实施例是示例性的，仅用于解释本发明，而不能理解为对本发明的限制。实施例中未注明具体技术或条件的，按照本领域内的文献所描述的技术或条件或者按照产品说明书进行。所用试剂或仪器未注明生产厂商者，均为可以通过市购获得的常规产品。
在本发明的一个方面，本发明提供了一种蜂窝状金属。根据本发明的实施例，参照图1，该蜂窝状金属是一体成型的。发明人惊喜地发现，该蜂窝状金属一体成型，整体性好，强 度高，不需要通过胶结形成，有效克服了现有蜂窝状金属胶结位置连接强度不高的技术问题。
根据本发明的实施例，蜂窝状金属的壁厚不小于0.5毫米。发明人意外地发现，通过该方法可获得壁厚较薄的蜂窝状金属，不受现有金属薄板材加工工艺的限制，利用该方法得到的蜂窝状金属的壁厚可薄至0.5毫米。
根据本发明的实施例，形成该蜂窝状金属的具体材料不受特别限制，本领域技术人员可以根据实际需要进行选择。在本发明的一些实施例中，该蜂窝状金属是由镁合金形成的。由此，该蜂窝状镁合金具有理想的强度，不存在胶结位置，整体性和强度理想，可以有效应用于汽车外蒙皮、车身结构等等部位，有利于提高汽车轻量化和改善其机械性能和力学性能等。
在本发明的另一方面，本发明提供了一种制备前面所述的蜂窝状金属的方法。根据本发明的实施例，参照图2，该方法包括以下步骤：
S100：提供蜂窝状泡沫塑料模样。
根据本发明的实施例，该步骤中采用的蜂窝状泡沫塑料模样与要制备的目标蜂窝状金属形状一致。在后续浇注步骤中，浇铸金属熔液的同时，该蜂窝状泡沫塑料模样气化，金属熔液占据该蜂窝状泡沫塑料模样的位置，冷却后形成蜂窝状金属。
根据本发明的实施例，制备该蜂窝状泡沫塑料模样的具体方法不受特别限制，只要能够获得满足要求的蜂窝状泡沫塑料模样，本领域技术人员可以根据需要选择。在本发明的一些实施例中，该步骤中，泡沫塑料模样可以通过以下步骤制备：a.利用聚丙烯形成蜂窝模型，该蜂窝模型具有形状呈蜂窝状且中空的腔室；b.将聚苯乙烯粒料填充在蜂窝模型的腔室内，并将腔室封闭；c.将蜂窝模型加热至聚苯乙烯粒料发泡完成，并进行脱模处理，得到所述泡沫塑料模样。
根据本发明的实施例，上述步骤a中，形成蜂窝模型的具体方法不受特别限制，只要能够有效形成符合要求的蜂窝模型，本领域技术人员可以灵活选择。该蜂窝模型的具体形状也不受特别限制，只要具有蜂窝状的、中空的腔室即可，本领域技术人员可以根据需要调整该模型的具体形状。例如可以为蜂窝状，也可以为其他规则或不规则的形状。根据本发明的实施例，通过该方法可以获得壁厚较薄且厚度均匀的蜂窝状泡沫塑料模样，也就是说，上述模型中的腔室的厚度较薄。一些实施例中，腔室的厚度不小于0.5毫米，也就是说，上述模型的壁厚可以达到0.5毫米。具体地，该蜂窝模型一面封闭，一面开放。如此设置，便于加工，其而便于后续进行。
根据本发明的实施例，上述步骤c中，将所述蜂窝模型加热的方式不受特别限制，只要能够有效使得聚苯乙烯粒料发泡，本领域技术人员可以根据实际操作条件灵活选择。在 本发明的一些实施例中，优选将蜂窝模型置于蒸汽中进行加热。由此，受热均匀，发泡效果理想，获得的模样均匀性好，在后续步骤中易于气化，有利于获得表面平整、光滑，缺陷少的蜂窝状金属。
S200：在泡沫塑料模样表面形成耐火涂料层。
根据本发明的实施例，该步骤可以进一步包括：S210：在所述泡沫塑料模样表面刷涂耐火涂料；S220：将步骤S210中得到的泡沫塑料模样置于空气中自然干燥；S230：于40-60摄氏度下，将步骤S220中得到的泡沫塑料模样烘干4-8小时。由此，可以快速有效地在泡沫塑料模样表面形成耐火涂料层，且形成的耐火涂层厚度均匀，性能理想，例如，可以降低制得的蜂窝状金属表面粗糙度值，提高表面质量和使用性能，有助于防止或减少蜂窝状金属粘砂、砂眼等缺陷，有利于提高蜂窝状金属落纱，清砂效率，防止蜂窝状金属产生气孔，以及能提高泡沫模样的强度和刚度，防止模样在运输、填砂振动时产生变形和破坏。
根据本发明的实施例，可以采用的耐火涂料的具体种类不受特别限制，只要能够实现相应功能，本领域技术人员可以根据需要灵活选择。例如，涂料成分可以为镁砂粉30－50％、珠光粉20－40％、云母粉15－30％、硅溶胶3－9％、白乳胶1－5％、聚丙烯酰胺0.1－0.8％、羧甲基纤维素钠0.1－0.8％、吸附剂1－6％、阻燃剂0.3－2％。当然，本领域技术人员可以理解，在其他一些实施例中，也可以选择其他配方的涂料。
S300：将步骤S200中得到的泡沫塑料模样进行造型。
根据本发明的实施例，该步骤中，所述造型是通过以下步骤进行的：在砂箱中填入底砂，并震实刮平；将步骤S200得到的泡沫塑料模样置于所述底砂上，填满型砂并微震30-60秒；将型砂与直浇道刮平。
S400：在真空条件下对金属熔液进行浇注。
根据本发明的实施例，真空条件下进行浇注，可以在负压下浇注，更有利于金属熔液的充型和补缩，提高了获得的蜂窝状金属的组织致密度。
根据本发明的实施例，制备蜂窝状金属的方法进一步包括：
S500：对步骤S400得到的浇注产品进行清理及再加工。
根据本发明的实施例，所述清理及再加工包括但不限于冷却后释放真空，从松散的砂中取出制得的蜂窝状金属，以及对蜂窝状金属的清理打磨、后续机械加工等步骤。
发明人发现，通过该方法能够快速有效的制备获得前面所述的蜂窝状金属，且获得的蜂窝状金属是一体成型的，不需要胶结，整体性和强度显著提高，有效解决了传统蜂窝状金属之间的连接强度和工艺问题。
特别需要指出的是，该方法特别适合用于制备镁合金蜂窝结构(或称蜂窝状镁合金)，与现有技术相比，采用该方法铸造镁合金蜂窝结构能够一体化生成镁合金蜂窝结构，避免 镁合金薄板的轧制和后期镁合金蜂窝结构的连接，能到达到很低的蜂窝镁合金壁厚和无缝连接，极大提高了镁合金蜂窝结构的性能和强度。
在本发明的再一方面，本发明提供了一种汽车。根据本发明的实施例，所述汽车的至少一部分是利用前面所述的蜂窝状金属形成的。前面描述的蜂窝状金属的所有特征和优点均适用于该汽车，在此不再一一赘述。本领域技术人员可以理解，该汽车除了由前面描述的蜂窝状金属形成的部分，还具有常规汽车具有的其他结构和部件，在此不再一一赘述。
下面详细描述本发明的实施例。
实施例1：
1、制作硬纸板蜂窝状模型
采用PP(聚丙烯)制作成不同形式的蜂窝状模型，该蜂窝模型具有形状呈蜂窝状且中空的腔室，模型的腔室可以具有不同的蜂窝状形状，包括但不限于六角形蜂窝状模型。蜂窝模型的壁厚最薄可以达到0.5mm。另外，蜂窝状模型一面封闭，一面开放，以便后续步骤中填充聚苯乙烯粒料。
2、采用挤出法制作聚苯乙烯泡沫塑料模样。
把聚苯乙烯(PS)粒料填充至在聚丙烯(PP)蜂窝模型中空腔室内，将模型两面封闭，放置在蒸汽中加热至发泡完成，脱模处理，得到蜂窝状聚苯乙烯塑料模样。
3、在聚苯乙烯塑料模样上刷涂涂料
在聚苯乙烯蜂窝状模样表面刷涂料，刷好后在空气中自然干燥，并在50摄氏度的烘箱中烘6个小时。
4、造型
在砂箱中填入底砂，震实刮平。再将刷好涂料并经烘干的模样放置在底砂上，填满型砂，微震40s，将型砂与直浇道刮平。
5、抽真空进行镁合金浇注
6、进行清理及再加工，得到蜂窝状镁合金。
实施例2：
1、制作硬纸板蜂窝状模型
采用PP(聚丙烯)制作成不同形式的蜂窝状模型，该蜂窝模型具有形状呈蜂窝状且中空的腔室，模型的腔室可以具有不同的蜂窝状形状，包括但不限于六角形蜂窝状模型。蜂窝模型的壁厚最薄可以达到0.5mm。另外，蜂窝状模型一面封闭，一面开放，以便后续步骤中填充聚苯乙烯粒料。
2、采用挤出法制作聚苯乙烯泡沫塑料模样。
把聚苯乙烯(PS)粒料填充至在聚丙烯(PP)蜂窝模型中空腔室内，将模型两面 封闭，放置在蒸汽中加热至发泡完成，脱模处理，得到蜂窝状聚苯乙烯塑料模样。
3、在聚苯乙烯塑料模样上刷涂涂料
在聚苯乙烯蜂窝状模样表面刷涂料，刷好后在空气中自然干燥，并在40摄氏度的烘箱中烘8个小时。
4、造型
在砂箱中填入底砂，震实刮平。再将刷好涂料并经烘干的模样放置在底砂上，填满型砂，微震60s，将型砂与直浇道刮平。
5、抽真空进行镁合金浇注
6、进行清理及再加工，得到蜂窝状镁合金。
实施例3：
1、制作硬纸板蜂窝状模型
采用PP(聚丙烯)制作成不同形式的蜂窝状模型，该蜂窝模型具有形状呈蜂窝状且中空的腔室，模型的腔室可以具有不同的蜂窝状形状，包括但不限于六角形蜂窝状模型。蜂窝模型的壁厚最薄可以达到0.5mm。另外，蜂窝状模型一面封闭，一面开放，以便后续步骤中填充聚苯乙烯粒料。
2、采用挤出法制作聚苯乙烯泡沫塑料模样。
把聚苯乙烯(PS)粒料填充至在聚丙烯(PP)蜂窝模型中空腔室内，将模型两面封闭，放置在蒸汽中加热至发泡完成，脱模处理，得到蜂窝状聚苯乙烯塑料模样。
3、在聚苯乙烯塑料模样上刷涂涂料
在聚苯乙烯蜂窝状模样表面刷涂料，刷好后在空气中自然干燥，并在60摄氏度的烘箱中烘4个小时。
4、造型
在砂箱中填入底砂，震实刮平。再将刷好涂料并经烘干的模样放置在底砂上，填满型砂，微震30s，将型砂与直浇道刮平。
5、抽真空进行镁合金浇注
6、进行清理及再加工，得到蜂窝状镁合金。
对上述实施例1-3制备获得蜂窝状镁合金和传统蜂窝状镁合金(通过胶结形成蜂窝状)的强度进行检测，结果表明实施例1-3中制备获得的蜂窝状镁合金强度明显提高。
在本说明书的描述中，参考术语“一个实施例”、“一些实施例”、“示例”、“具体示例”、或“一些示例”等的描述意指结合该实施例或示例描述的具体特征、结构、材料或者特点包 含于本发明的至少一个实施例或示例中。在本说明书中，对上述术语的示意性表述不必须针对的是相同的实施例或示例。而且，描述的具体特征、结构、材料或者特点可以在任一个或多个实施例或示例中以合适的方式结合。此外，在不相互矛盾的情况下，本领域的技术人员可以将本说明书中描述的不同实施例或示例以及不同实施例或示例的特征进行结合和组合。
尽管上面已经示出和描述了本发明的实施例，可以理解的是，上述实施例是示例性的，不能理解为对本发明的限制，本领域的普通技术人员在本发明的范围内可以对上述实施例进行变化、修改、替换和变型。

Claims (11)

  1. 一种蜂窝状金属，其特征在于，所述蜂窝状金属是一体成型的。
  2. 根据权利要求1所述的蜂窝状金属，其特征在于，所述蜂窝状金属的壁厚不小于0.5毫米。
  3. 根据权利要求1或2所述的蜂窝状金属，其特征在于，所述蜂窝状金属是由镁合金形成的。
  4. 一种制备权利要求1-3中任一项所述蜂窝状金属的方法，其特征在于，包括：
    (1)提供蜂窝状泡沫塑料模样；
    (2)在所述泡沫塑料模样表面形成耐火涂料层；
    (3)将步骤(2)中得到的泡沫塑料模样进行造型；以及
    (4)在真空条件下将金属熔液进行浇注。
  5. 根据权利要求4所述的方法，其特征在于，步骤(1)中，所述泡沫塑料模样是通过以下步骤制备的：
    a.利用聚丙烯形成蜂窝模型，所述蜂窝模型具有中空的腔室，所述腔室的形状呈蜂窝状；
    b.将聚苯乙烯粒料填充在所述腔室内，并将所述腔室封闭；
    c.将所述蜂窝模型加热至所述聚苯乙烯粒料发泡完成，并进行脱模处理，得到所述泡沫塑料模样。
  6. 根据权利要求5所述的方法，其特征在于，步骤a中，所述腔室的厚度不小于0.5毫米。
  7. 根据权利要求5或6所述的方法，其特征在于，步骤c中，所述加热是将所述蜂窝模型置于蒸汽中进行的。
  8. 根据权利要求4-7中任一项所述的方法，其特征在于，步骤(2)进一步包括：
    (2-1)在所述泡沫塑料模样表面刷涂耐火涂料；
    (2-2)将步骤(2-1)中得到的泡沫塑料模样置于空气中自然干燥；
    (2-3)于40-60摄氏度下，将步骤(2-2)中得到的泡沫塑料模样烘干4-8小时。
  9. 根据权利要求4-8中任一项所述的方法，其特征在于，步骤(3)中，所述造型是通过以下步骤进行的：
    在砂箱中填入底砂，并震实刮平；
    将步骤(2)中得到的泡沫塑料模样置于所述底砂上，填满型砂并微震30-60秒；
    将型砂与直浇道刮平。
  10. 根据权利要求4-9中任一项所述的方法，其特征在于，进一步包括：
    (5)对步骤(4)得到的浇注产品进行清理及再加工。
  11. 一种汽车，其特征在于，所述汽车的至少一部分是利用权利要求1-3中任一项所述的蜂窝状金属形成的。
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