WO2022170653A1 - 一种轻量化复合材料推力杆制作方法及结构 - Google Patents

一种轻量化复合材料推力杆制作方法及结构 Download PDF

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Publication number
WO2022170653A1
WO2022170653A1 PCT/CN2021/079675 CN2021079675W WO2022170653A1 WO 2022170653 A1 WO2022170653 A1 WO 2022170653A1 CN 2021079675 W CN2021079675 W CN 2021079675W WO 2022170653 A1 WO2022170653 A1 WO 2022170653A1
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Prior art keywords
composite material
reinforced thermoplastic
fiber reinforced
thermoplastic composite
outer peripheral
Prior art date
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PCT/CN2021/079675
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English (en)
French (fr)
Inventor
杨军
杨威
彭超义
郭春杰
李晓晔
Original Assignee
博戈橡胶塑料（株洲）有限公司
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Priority claimed from CN202110176555.1A external-priority patent/CN113043527B/zh
Priority claimed from CN202120360763.2U external-priority patent/CN214874078U/zh
Application filed by 博戈橡胶塑料（株洲）有限公司 filed Critical 博戈橡胶塑料（株洲）有限公司
Priority to DE212021000507.1U priority Critical patent/DE212021000507U1/de
Priority to DE112021006327.8T priority patent/DE112021006327T5/de
Publication of WO2022170653A1 publication Critical patent/WO2022170653A1/zh

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    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • 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
    • B29C45/14467—Joining articles or parts of a single article
    • 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
    • B29C45/14631—Coating reinforcements
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/681—Component parts, details or accessories; Auxiliary operations
    • B29C70/682—Preformed parts characterised by their structure, e.g. form
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/72—Encapsulating inserts having non-encapsulated projections, e.g. extremities or terminal portions of electrical components
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G7/00—Pivoted suspension arms; Accessories thereof
    • B60G7/001—Suspension arms, e.g. constructional features
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/003—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised by the matrix material, e.g. material composition or physical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2206/00—Indexing codes related to the manufacturing of suspensions: constructional features, the materials used, procedures or tools
    • B60G2206/01—Constructional features of suspension elements, e.g. arms, dampers, springs
    • B60G2206/10—Constructional features of arms
    • B60G2206/11—Constructional features of arms the arm being a radius or track or torque or steering rod or stabiliser end link
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2206/00—Indexing codes related to the manufacturing of suspensions: constructional features, the materials used, procedures or tools
    • B60G2206/01—Constructional features of suspension elements, e.g. arms, dampers, springs
    • B60G2206/70—Materials used in suspensions
    • B60G2206/71—Light weight materials
    • B60G2206/7101—Fiber-reinforced plastics [FRP]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2206/00—Indexing codes related to the manufacturing of suspensions: constructional features, the materials used, procedures or tools
    • B60G2206/01—Constructional features of suspension elements, e.g. arms, dampers, springs
    • B60G2206/70—Materials used in suspensions
    • B60G2206/71—Light weight materials
    • B60G2206/7104—Thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60G—VEHICLE SUSPENSION ARRANGEMENTS
    • B60G2206/00—Indexing codes related to the manufacturing of suspensions: constructional features, the materials used, procedures or tools
    • B60G2206/01—Constructional features of suspension elements, e.g. arms, dampers, springs
    • B60G2206/80—Manufacturing procedures
    • B60G2206/85—Filament winding

Definitions

  • the invention relates to a manufacturing method and structure of a thrust rod, in particular to a manufacturing method and structure of a lightweight composite material thrust rod.
  • Thrust rod is an auxiliary element widely used in automobile suspension system, including rod body, both ends of the rod body have rod heads, and the rod head has a support shaft connected with the double axle of the car to transmit the longitudinal force or lateral direction of the vehicle. At the same time, it can also transmit forces and moments in other directions to ensure a definite motion relationship between the wheels and the body, so that the vehicle has good motion characteristics, preventing the body from excessive lateral roll when turning and improving the balance of the car sex.
  • the application number CN201510739066.7 the invention patent titled "a method for lightweight thrust rod and lightweight thrust rod” is that the rod body and the mandrel of the elastic spherical hinge are made of polymer materials and are molded at one time by injection molding, and the rod body is formed at one time.
  • the opposite sides of the rod body are provided with a side surface with an intermittent groove one, and the intermittent groove one includes a plurality of sub-grooves distributed in sequence along the length direction of the rod body, and in each sub-groove one A plurality of convex ribs are arranged on the bottom surface of the groove, so that each sub-groove is divided into a plurality of small grooves by a plurality of convex ribs.
  • the present invention can reduce the weight of the thrust rod as much as possible on the premise of satisfying the use requirements of the thrust rod, so as to meet the requirement of light weight of the thrust rod.
  • the present invention proposes a manufacturing method and structure of a lightweight composite thrust rod.
  • a manufacturing method and structure of a lightweight composite thrust rod By using continuous fibers to preform a continuous closed special-shaped peripheral layer reinforcement to provide external support A lightweight composite material thrust rod with outer peripheral layer reinforcement is formed, and the tensile strength of the thrust rod is improved.
  • the method adopted by the present invention to solve the above problems is as follows: a method for manufacturing a lightweight composite material thrust rod, which uses a continuous fiber-reinforced thermoplastic composite material in a belt shape to wind a continuous peripheral layer reinforcement that is closed in the circumferential direction, and then is The inside of the outer peripheral layer reinforcement is filled with long fiber reinforced thermoplastic composite material or short fiber reinforced thermoplastic composite material by injection molding, and finally the rubber metal ball is hinged into both ends to form a complete thrust rod.
  • a tooling including a central body and a pressing block is set up, and the continuous fiber-reinforced thermoplastic composite material in strip shape is wound around the periphery of the central outer body for multiple turns, and the continuous winding after the pressing is squeezed by the pressing block.
  • Fiber reinforced thermoplastic composite material the continuous fiber reinforced thermoplastic composite material after winding is pressed together with the central body through the compact, so that the continuous fiber reinforced thermoplastic composite material after winding is the same as the outer circumference shape and size of the thrust rod, forming the outer circumference layer reinforcement pieces.
  • the central body is a mold core part that limits the molding shape of the long fiber reinforced thermoplastic composite material or the short fiber reinforced thermoplastic composite material during the injection molding process, and the metal steel sleeve located between the outer peripheral layer reinforcement and the rubber metal spherical hinge is designed.
  • the two ends of the center body are wound, and the continuous fiber reinforced thermoplastic composite material in strip shape is directly contacted with the outside of the metal steel sleeve.
  • a groove is provided on the outer periphery of the metal steel sleeve.
  • the long fiber reinforced thermoplastic composite material or the short fiber reinforced thermoplastic composite material flows between the metal steel sleeve and the outer peripheral layer reinforcement along the groove to integrate the two into a whole.
  • a metal steel sleeve is also provided between the outer peripheral layer reinforcement and the rubber-metal spherical hinge, and the distance between the outer peripheral layer reinforcement and the metal steel sleeve is controlled, so that the injection-molded long fiber reinforced thermoplastic composite material or short Fiber-reinforced thermoplastic composites have a thickness of 0-5mm.
  • edge of the outer peripheral layer reinforcement in contact with the long fiber reinforced thermoplastic composite material or the short fiber reinforced thermoplastic composite material is wrapped in the cavity of the mold core enclosure, so that the rubber material extends outward to form a package at the edge. edge structure.
  • the long fiber reinforced thermoplastic composite material or the short fiber reinforced thermoplastic composite material injected into the outer peripheral layer reinforcement is designed into a grid structure to reduce the overall quality.
  • the direction of the ribs of the grid structure is designed to be the same as the direction of the load transmission path to improve the overall strength.
  • the step of heating the outer peripheral layer reinforcement is further included before the injection molding of the long fiber reinforced thermoplastic composite material or the short fiber reinforced thermoplastic composite material in the outer peripheral layer reinforcement.
  • a lightweight composite thrust rod structure comprising an outer peripheral layer reinforcement located at the outermost periphery and a long fiber reinforced thermoplastic composite material or a short fiber reinforced thermoplastic composite material which is injection-molded inside the outer peripheral layer reinforcement and integrated with the outer peripheral layer reinforcement,
  • the two ends surrounded by the outer peripheral layer reinforcement are provided with metal steel sleeves, the metal steel sleeve is provided with a rubber metal spherical hinge, and the long fiber reinforced thermoplastic composite material or the short fiber reinforced thermoplastic composite material is injected between the outer peripheral layer reinforcement and the metal steel sleeve.
  • the outer peripheral layer reinforcement is a continuous integral structure closed in the circumferential direction, which is formed by winding the continuous fiber-reinforced thermoplastic composite material in the form of a belt and pressing it.
  • the thickness of the long fiber reinforced thermoplastic composite material or the short fiber reinforced thermoplastic composite material injected between the outer peripheral layer reinforcement and the metal steel sleeve is 0-5 mm.
  • the injection-molded long-fiber-reinforced thermoplastic composite material or short-fiber-reinforced thermoplastic composite material has a edging structure at the edge portion in contact with the outer peripheral layer reinforcement.
  • the long-fiber-reinforced thermoplastic composite material or the short-fiber-reinforced thermoplastic composite material injected between the two metal steel jackets has a grid structure.
  • the direction of the ribs of the grid structure is the same as the direction of the transmission path of the load borne by the thrust rod.
  • the direction of the ribs of the grid structure is at 45° to the center line of the two metal steel sleeves.
  • the outer peripheral surface of the metal steel sleeve is provided with grooves, and the long fiber reinforced thermoplastic composite material or the short fiber reinforced thermoplastic composite material combines the metal steel sleeve and the outer peripheral layer reinforcement along the grooves during the injection molding process.
  • the rubber-metal spherical hinge includes a jacket, a rubber vulcanized body and a mandrel from the outside to the inside, and the rubber vulcanized body vulcanizes the mandrel and the jacket into a whole.
  • a continuous outer peripheral layer reinforcement that is closed in the circumferential direction is first wound out of a belt-shaped continuous fiber-reinforced thermoplastic composite material as the surrounding structure of the entire push-pull rod, and then injected into the outer peripheral layer reinforcement by injection molding. Filled with long fiber reinforced thermoplastic composite material or short fiber reinforced thermoplastic composite material, the thrust rod formed by this method has superior performance, high strength, and can withstand greater tensile strength without being easily torn.
  • the outer peripheral layer reinforcement is sufficient to ensure the strength of the thrust rod, so that a lightweight grid structure can be easily realized inside, and the grid structure can be designed. There is no need to think too much about providing support for the tension and loads experienced by the thrust rod.
  • the present invention can improve the overall fatigue performance of the thrust rod by controlling the plastic thickness between the outer peripheral layer reinforcement and the metal steel sleeve to be 0-5mm, so as to avoid the defects of the injection molding process caused by the excessive thickness of the plastic wall.
  • the present invention forms a U-shaped cladding and increases the contact surface between the two materials by designing the edging structure at the edge portion of the long fiber reinforced thermoplastic composite material or the short fiber reinforced thermoplastic composite material in contact with the outer peripheral layer reinforcement. , so as to further improve the strength of the welding interface of the two different materials, so that the welding interface is not easy to peel off, thus improving the overall performance of the thrust rod.
  • the present invention improves the compressive and shear strength of the thrust rod by designing the rib direction of the grid structure in the outer peripheral layer reinforcement to be the same as the direction of the transmission path of the load borne by the thrust rod.
  • Fig. 1 is a schematic diagram of the structure of a thrust rod according to the first embodiment
  • FIG. 2 is a schematic structural diagram of the outer peripheral layer reinforcement in Embodiment 1;
  • FIG. 3 is a schematic view of the structure of the steel sleeve in Embodiment 1;
  • FIG. 4 is a schematic structural diagram of a rubber-metal spherical hinge in Embodiment 1;
  • FIG. 5 is a schematic diagram of a tooling structure in Embodiment 1;
  • Fig. 6 is the structural representation after removing the center body of Fig. 5;
  • FIG. 7 is a schematic diagram of the structure of a center body in Embodiment 1;
  • FIG. 8 is a schematic diagram of the structure of the metal steel sleeve in the second embodiment
  • Fig. 9 is a graph of tensile strength of the thrust rod and conventional thrust rod of the first embodiment
  • Thrust rod 11. Outer peripheral layer reinforcement, 12. Metal steel sleeve, 121. Groove, 13. Rubber metal spherical hinge, 131. Outer shell, 132. Rubber vulcanized body, 133. Mandrel, 14. Grid structure, 15. Hemming structure, 2. Tooling, 21. Fixed plate, 22. Center body, 23. Press block, 24. Cylinder, 25. Positioning groove, 26. Positioning plate.
  • a lightweight composite material thrust rod as shown in Figures 1-4, the outermost layer of the thrust rod 1 is the outer peripheral layer reinforcement 11, and the inner two ends of the outer peripheral layer reinforcement 11 are provided with metal steel sleeves 12.
  • the metal steel sleeves 12 is internally pressed with a rubber metal ball hinge 12, and a long fiber reinforced thermoplastic composite material or a short fiber reinforced thermoplastic composite material is injected and filled between the outer peripheral layer reinforcement 11 and the metal steel sleeve 12.
  • the long fiber reinforced thermoplastic composite material or the short fiber reinforced thermoplastic composite material between the two metal steel sleeves 12 is the grid structure 14 , and the direction of the ribs of the grid structure 14 is the direction of the transmission path of the load borne by the thrust rod 1 . same. As shown in FIG.
  • the outer peripheral layer reinforcement 11 is a closed annular structure wound and pressed into a belt-shaped continuous fiber-reinforced thermoplastic composite material. Since the material formed is continuous and complete, when it is used as a peripheral structure to wrap the interior , the tensile strength of the formed thrust rod is greatly improved, and at the same time, it meets the requirements of light weight and high strength. Therefore, when injecting and filling long fiber reinforced thermoplastic composite materials or short fiber reinforced thermoplastic composite materials, it does not need to be considered too much.
  • the tension and load borne by the thrust rod 1 provide support, so the grid structure 14 can be designed to further reduce the weight. At the same time, the direction of the ribs of the grid structure 14 is designed to be the direction of the transmission path of the load on the thrust rod 1.
  • the same structure is used to improve the compressive and shear strength of the thrust rod 1, thereby ensuring the overall performance of the thrust rod 1.
  • the thrust rod 1 mainly bears three kinds of loads: tensile, compressive, torsional, tensile and compressive loads are transmitted along the length direction of the product, by placing the continuous fiber reinforced thermoplastic composite material in the length direction and arranging At the periphery, it can bear tensile and compressive loads; and for torsional loads, it is mainly resisted by the grid structure 14 in the middle.
  • the direction of the ribs can be arranged at an inclination angle of about 45° with the center line, that is, the direction of the ribs is the same as the direction of load transmission, so as to improve the torsional strength of the thrust rod 1 .
  • the rubber metal ball hinge 12 is composed of a mandrel 133 , a rubber vulcanized body 132 and an outer casing 131 from the inside to the outside.
  • the rubber vulcanized body 132 vulcanizes the outer casing 131 and the mandrel 133 into a whole.
  • the tooling structure is shown in Figures 5 to 7, including a fixing plate 21.
  • the fixing plate 21 is provided with a central body 22, a pressing block 23 and a cylinder 24.
  • the central body 22 can be designed as a structure that can be separated from the fixing plate 21 , and the pressing block 23 is arranged at the periphery of the central body 22 and can be moved toward or away from the central body 22 under the driving of the cylinder 24 .
  • the continuous fiber reinforced thermoplastic composite material is wound several times around the center body to ensure that its strength can meet the load requirements during the use of the thrust rod, and then the cylinder 24 pushes the pressing block 23 to move toward the center body 22.
  • the material is formed into the outer peripheral layer reinforcement 11 after the pressing is completed.
  • the material needs to be heated before or after pressing, so that it can be shaped into the shape of the outer peripheral layer reinforcement 11.
  • This heating method can use the existing method, such as heating the material separately before or during the winding, Or after the winding is completed, it can be heated together with the tooling, etc.
  • the outer peripheral layer reinforcement 11 After the outer peripheral layer reinforcement 11 is formed, it is removed and transferred to the injection mold, and metal steel sleeves 12 are placed inside the two ends of the outer peripheral layer reinforcement 11, and then the long fiber reinforced thermoplastic composite material or short fiber reinforced thermoplastic composite material is injected and filled. composite material.
  • the outer peripheral layer reinforcement 11 When removing the outer peripheral layer reinforcement 11 from the tooling, it is best to wait for it to cool to avoid deformation during removal; and before putting it into the injection mold, heat it again to avoid the outer peripheral layer reinforcement 11 and injection molding. The temperature difference between the materials is too large, which affects the fusion between the two.
  • the distance between the metal steel sleeve 12 and the outer peripheral layer reinforcement 11 should be minimized, and the distance between the metal steel sleeve 12 and the outer peripheral layer reinforcement 11 should be controlled to 0-5mm, so as to avoid defects in the injection molding process due to excessive thickness of the adhesive layer. , which in turn affects the overall performance of the thrust rod.
  • wrap the end of the outer peripheral layer reinforcement 11 connected with the injection molding material in the mold cavity and form a wrapping structure at the contact edge to form a U-shaped wrapping, increasing the two materials. Therefore, the strength of the welding interface between the two different materials is further improved, so that the welding interface is not easy to peel off, thus improving the overall performance of the thrust rod.
  • This embodiment also relates to a method for manufacturing a lightweight composite material thrust rod.
  • the outer peripheral layer reinforcement 11 is fabricated through the tooling 2. As shown in FIG. A continuous surrounding structure closed in the circumferential direction is formed to provide integral support for the entire thrust rod 1. Since the entire outer peripheral layer reinforcement 11 is wound as a whole with a continuous and complete material strip, it is used as the peripheral structure of the thrust rod. When the inside is wrapped, the tensile strength of the formed thrust rod 1 is greatly improved, and at the same time, it meets the requirements of light weight and high strength.
  • the tooling 2 includes a fixing plate 21 and a center body 22 , a pressing block 23 , and a cylinder 24 arranged on the fixing plate 21 .
  • a positioning groove 25 is formed on the upper surface of the fixing plate 21 , and the lower surface of the center body 22 is provided with a positioning groove 25 .
  • a positioning plate 26 is provided, the size of the positioning plate 26 and the positioning groove 25 are matched, and there is a clearance fit between the two, the center body 22 can be separated from the fixing plate 21, and the center body 22 can be inserted after the positioning plate 26 is inserted into the positioning groove 25.
  • There are four pressing blocks 23 which are respectively arranged at two sides and two ends of the positioning groove 25 .
  • the central body 22 is a metal part made according to the outer peripheral shape of the thrust rod 1, so the specific manufacturing method of the thrust rod 1 is as follows:
  • the first step after winding the continuous fiber reinforced thermoplastic composite material in strip shape on the outer periphery of the central body 22 for several turns, heat the wound continuous fiber reinforced thermoplastic composite material, and then use the cylinder 24 to push the pressing block 23 toward the central body. Squeeze at 22 places to shape the continuous fiber reinforced thermoplastic composite material, then cool, loosen the cylinder 24 to separate the compact 23 from the central body 22, and remove the continuous fiber reinforced thermoplastic composite material from the central body 22 to become the outer peripheral layer Reinforcement 11.
  • Step 2 After reheating the outer peripheral layer reinforcement 11, put it into the injection mold, and place a metal steel sleeve 12 at both ends of the inner part, and then connect the outer peripheral layer reinforcement 11 and the metal steel sleeve 12.
  • the long fiber reinforced thermoplastic composite material or the short fiber reinforced thermoplastic composite material is injected into the space between the two, and after demolding, the rubber metal spherical hinge 13 is pressed into the two metal steel sleeves 12, so far, the production of the thrust rod 1 is completed.
  • Figure 9 shows the comparison between the thrust rod 1 made in this embodiment and the thrust rod tensile strength curve currently produced by the applicant in a conventional manner.
  • line a is a graph of the thrust rod in this embodiment
  • line b is As can be seen from the graph of the conventional thrust rod, the thrust rod of this embodiment can bear a larger ultimate load, and has stronger structural strength under the same conditions, so the trial models are wider.
  • the above-mentioned first step can also be changed to: a heating device such as an infrared heating device is installed near the tooling 2, and the belt-shaped continuous fiber-reinforced thermoplastic composite material is heated and wound around the outer periphery of the central body 22 for multiple turns, and then the cylinder 24 is used to push the The pressing block 23 is pressed towards the central body 22 to shape the continuous fiber reinforced thermoplastic composite material, then cooled, and the cylinder 24 is released to remove the continuous fiber reinforced thermoplastic composite material from the central body 22 to become the outer peripheral layer reinforcement 11 .
  • This method of heating and winding can save the time of separate heating before pressing, and improve the production efficiency.
  • the wound continuous fiber reinforced thermoplastic composite can be cold-pressed first, and then the entire tool 2 is heated together with the material.
  • the belt-shaped continuous fiber reinforced thermoplastic composite material is a commercially available product, and its width is not necessarily exactly equal to the width of the outer circumference of the thrust rod 1. Therefore, the continuous fiber reinforced thermoplastic composite material needs to be cut in width before winding. While maintaining its original length in length, the outer peripheral layer reinforcement 11 thus formed is formed by a complete continuous fiber-reinforced thermoplastic composite material belt, which improves its tensile strength.
  • the gap between the metal steel sleeve 12 and the outer peripheral layer reinforcement 11 is controlled within 0-5mm. Since the thicker the adhesive layer during injection molding, the more defects caused by the injection molding process, which will lead to the performance of the product being degraded. Therefore, by controlling the distance between the metal steel sleeve 12 and the outer peripheral layer reinforcement 11, the injection amount is reduced, thereby reducing the Or eliminate the defects at the connection and improve the performance of the thrust rod 1 .
  • the edge of the outer peripheral layer reinforcement 11 in contact with the long fiber reinforced thermoplastic composite material or the short fiber reinforced thermoplastic composite material is wrapped in the cavity of the mold core enclosure, so that the rubber material extends outward during the injection molding process to form a bonding edge
  • the wrapping structure at the place is the same as the injection molding material matrix, they use different molding methods, and their bonding performance is worse than that of the same molding process, so the joints are easy to separate in the subsequent long-term loading process.
  • the layer is peeled off, and the enveloping structure forms a U-shaped cladding, which increases the contact surface between the two materials and increases the fusion strength of the interface of different materials, so that the structure can bear a larger load, so it is not easy to peel off, and the thrust rod is improved. 1 performance, while injection molding is easy for fully automated production.
  • the long-fiber-reinforced thermoplastic composite material or the short-fiber-reinforced thermoplastic composite material is formed into a grid structure 14 after injection molding, which further reduces the quality of the thrust rod 1, and the direction of the ribs forming the grid structure 14 is the same as the direction of the thrust rod 1. Beared loads transfer paths in the same direction.
  • the structure of the central body 22 consists of two parts: the middle part is the core part of the injection mold that restricts the molding shape of the long fiber reinforced thermoplastic composite material or the short fiber reinforced thermoplastic composite material, and the two ends are the metal steel sleeves 12 .
  • the metal steel sleeve 12 as a part of the center body 22 of the tooling, the continuous fiber reinforced thermoplastic composite material is directly wound on the outer side of the metal steel sleeve 12, and after the winding and pressing are completed, the outer peripheral layer reinforcement 11 and the center body 22 are directly wound. It is removed from the tooling and placed into the injection mold for injection molding, so it does not need to be cooled before taking it out, thus saving production time.
  • a plurality of grooves 121 are provided on the outside of the metal steel sleeve 12.
  • the injection molding material can flow between the metal steel sleeve 12 and the outer peripheral layer reinforcement 11 along the grooves 121, and the two combined into a whole.
  • the manufacturing method of this embodiment is as follows: the center body 22 is a mold core part that restricts the molding shape of the long fiber reinforced thermoplastic composite material or the short fiber reinforced thermoplastic composite material during the injection molding process, and the metal steel sleeve 12 is used as the center body 22. Therefore, the specific production method of the thrust rod 1 is as follows:
  • the first step set up a heating device such as an infrared heating device near the tooling 2, while heating the belt-shaped continuous fiber reinforced thermoplastic composite material, winding multiple turns around the outer periphery of the central body 22 formed by the metal steel sleeve 12 and the mold core, Then use the cylinder 24 to push the pressing block 23 towards the central body 22 to press the continuous fiber reinforced thermoplastic composite material to shape, release the cylinder 24 to separate the pressing block 23 from the central body 22 , and complete the fabrication of the outer peripheral layer reinforcement 11 .
  • a heating device such as an infrared heating device near the tooling 2
  • Step 2 Put the outer peripheral layer reinforcement 11 together with the central body 22 into the injection mold, and inject the long fiber reinforced thermoplastic composite material or the short fiber reinforced thermoplastic composite material into the space between the outer peripheral layer reinforcement 11 and the metal steel sleeve 12 , after demoulding, press the rubber metal ball hinge 13 into the two metal steel sleeves 12 to complete the production of the thrust rod 1 .
  • this embodiment does not need to take out the outer peripheral layer reinforcement 11 from the center body 22 before injection molding, so it does not need to be cooled and then heated, which saves time and improves the production speed, and is suitable for mass production.
  • a groove 121 is provided on the outer periphery of the metal steel sleeve 12. During the injection molding process, the rubber material can flow between the metal steel sleeve 12 and the outer peripheral layer reinforcement 11 along the groove 121, thereby Bring the two together to form a whole.
  • the first step of this embodiment can also be changed to: winding the continuous fiber-reinforced thermoplastic composite material in the form of a ribbon around the outer circumference of the central body 22 formed by the metal steel sleeve 12 and the mold core for multiple turns, and the wound continuous fiber
  • the reinforced thermoplastic composite material is heated, and then the cylinder 24 is used to push the pressing block 23 towards the central body 22 to extrude the continuous fiber reinforced thermoplastic composite material, and the cylinder 24 is released to separate the pressing block 23 from the central body 22 to complete the reinforcement of the outer peripheral layer.
  • the wound continuous fiber reinforced thermoplastic composite can be cold-pressed first, and then the entire tool 2 is heated together with the material.

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Abstract

一种轻量化复合材料推力杆制作方法及结构，先设置一个包括中心体（22）和压块（23）的工装（2），再将带状的连续纤维增强热塑性复合材料沿中心体（22）外周缠绕多圈后，用压块（23）压制出一个在周向上封闭的连续式异形外周层增强件（11），然后在外周层增强件（11）内部以注塑方式填充长纤维增强热塑性复合材料或短纤维增强热塑性复合材料，最后将橡胶金属球铰（13）压装入两端处，形成完整的推力杆（1）。该方法形成的推力杆（1）性能优越，强度更高，能够承受更大的拉伸强度而不容易被撕裂，同时外周层增强件（11）边缘处设置有U形包边结构，保证两种不同材料的熔接强度，推力杆（1）的整体疲劳性能也更加优越。

Description

一种轻量化复合材料推力杆制作方法及结构 技术领域
本发明涉及一种推力杆制作方法及结构，具体涉及一种轻量化复合材料推力杆制作方法及结构。
背景技术
推力杆是广泛应用于汽车悬架系统中的一种辅助性元件，包括杆体，杆体的两端具有杆头，杆头上具有与汽车双桥连接的支承轴，以传递车辆的纵向力或横向力，同时还可传递其他方向的力和力矩，保证车轮和车身之间有确定的运动关系，使车辆具有良好的运动特性，防止车身在转弯时发生太大的横向侧倾和改善汽车的平衡性。
当前，为了减少汽车的燃料消耗，降低排气污染，大力推行汽车的轻量化，所以也出现了轻量化的推力杆。如申请号CN201510739066.7，名称为“一种推力杆轻量化方法及轻量化推力杆”的发明专利是将杆体和弹性球铰的芯轴均采用高分子材料利用注射模一次成型，将杆体本体的相对两侧面均设置成带有断续状凹槽一的侧面，所述断续状凹槽一包括沿杆体本体的长度方向依次分布的多个分凹槽一，在每个分凹槽一的凹槽底面上设置有多条凸筋，从而使得每个分凹槽一又被多条凸筋分割成多个小凹槽。本发明能在满足推力杆使用要求的前提下，尽可能的降低推力杆的重量，达到推力杆轻量化的要求。
另有申请号CN201510735238.3，名称为“纤维增强热塑性复合材料在成型制备汽车零部件中的应用”的发明专利提到使用长纤维增强热塑性复合材料和连续纤维增强热塑性复合材料来制备轻量化的汽车零部件。
上述专利都没有提到采用先形成外周层增强件的方式来制作轻量化的推力杆，因此，申请人提出了另一种性能更加优异的推力杆的制作方式及结构。
发明内容
本发明针对当前轻量化推力杆性能有待提高的问题，提出了一种轻量化复合材料推力杆制作方法及结构，通过利用连续纤维预先成型一个连续封闭的异形外周层增强件提供外部支撑的方式来形成一种具有外周层增强件的轻量化复合材料推力杆，提高了推力杆的拉伸强度。
本发明为解决上述问题所采用的手段为：一种轻量化复合材料推力杆制作方法，利用带状的连续纤维增强热塑性复合材料缠绕出一个在周向上封闭的连续式外周层增强件，然后在外周层增强件内部以注塑方式填充长纤维增强热塑性复合材料或短纤维增强热塑性复合材料，最后将橡胶金属球铰压装入两端处，形成完整的推力杆。
进一步地，在缠绕外周层增强件时，设置一个包括中心体和压块的工装，将带状的连续 纤维增强热塑性复合材料沿中心体外周缠绕多圈后，利用压块挤压缠绕后的连续纤维增强热塑性复合材料，通过压块与中心体一起对缠绕后的连续纤维增强热塑性复合材料进行压制，使缠绕后的连续纤维增强热塑性复合材料与推力杆的外周形状及尺寸相同，形成外周层增强件。
进一步地，中心体为注塑过程中限制长纤维增强热塑性复合材料或短纤维增强热塑性复合材料的成型形状的模芯部分，且将位于外周层增强件与橡胶金属球铰之间的金属钢套设计成中心体的两个端部，缠绕时，将带状的连续纤维增强热塑性复合材料直接与金属钢套的外侧接触，注塑时，将中心体与外周层增强件一起放入模具中进行注塑。
进一步地，在金属钢套外周设有凹槽，注塑时，长纤维增强热塑性复合材料或短纤维增强热塑性复合材料沿凹槽流入金属钢套与外周层增强件之间将二者结合成整体。
进一步地，外周层增强件与橡胶金属球铰之间还设有金属钢套，控制外周层增强件与金属钢套之间的距离，使二者之间注塑的长纤维增强热塑性复合材料或短纤维增强热塑性复合材料厚度为0-5mm。
进一步地，在注塑时，将外周层增强件与长纤维增强热塑性复合材料或短纤维增强热塑性复合材料接触的边缘包裹在模芯围城的型腔内，使胶料往外延伸，形成边缘处的包边结构。
进一步地，将外周层增强件内注塑的长纤维增强热塑性复合材料或短纤维增强热塑性复合材料设计成网格结构，以降低整体质量。
进一步地，将网格结构的筋条方向设计成与载荷传递路径方向相同的结构以提高整体强度。
进一步地，在外周层增强件内注塑长纤维增强热塑性复合材料或短纤维增强热塑性复合材料前还包括对外周层增强件进行加热的步骤。
一种轻量化复合材料推力杆结构，包括位于最外周的外周层增强件和注塑在外周层增强件内部与外周层增强件结合为一体的长纤维增强热塑性复合材料或短纤维增强热塑性复合材料，外周层增强件包围的两端处设有金属钢套，金属钢套内设有橡胶金属球铰，长纤维增强热塑性复合材料或短纤维增强热塑性复合材料注塑在外周层增强件与金属钢套之间；其中外周层增强件为利用带状的连续纤维增强热塑性复合材料缠绕后压制成的在周向上封闭的连续式整体结构。
进一步地，注塑在外周层增强件与金属钢套之间的长纤维增强热塑性复合材料或短纤维增强热塑性复合材料的厚度为0-5mm。
进一步地，注塑的长纤维增强热塑性复合材料或短纤维增强热塑性复合材料在与外周层 增强件接触的边缘部位具有包边结构。
进一步地，注塑在两个金属钢套间的长纤维增强热塑性复合材料或短纤维增强热塑性复合材料为网格结构。
进一步地，网格结构的筋条方向与推力杆所承受的载荷的传递路径方向相同。
进一步地，网格结构的筋条方向与两个金属钢套中心连线成45°。
进一步地，金属钢套的外周面设有凹槽，注塑过程中长纤维增强热塑性复合材料或短纤维增强热塑性复合材料沿凹槽将金属钢套和外周层增强件结合。
进一步地，橡胶金属球铰由外到内包括外套、橡胶硫化体和芯轴，橡胶硫化体将芯轴和外套硫化成整体。
本发明的有益效果是：
1.本发明采用先将带状的连续纤维增强热塑性复合材料缠绕出一个在周向上封闭的连续式外周层增强件作为整个推拉杆的包围结构件，然后再往外周层增强件内以注塑方式填充长纤维增强热塑性复合材料或短纤维增强热塑性复合材料，此方法形成的推力杆性能优越，强度高，能够承受更大的拉伸强度而不容易被撕裂。
2.本发明通过将外周层增强件设置在推力杆的最外周，该外周层增强件就足以保证推力杆的强度，因而能够方便地在内部实现轻量化的网格结构，在设计网格结构时不需要过多考虑为推力杆承受的拉伸和载荷提供支撑。
3.本发明通过将外周层增强件与金属钢套之间的塑胶厚度控制在0-5mm，避免此处塑胶壁厚度过大导致注塑工艺缺陷，因而能提升推力杆的整体疲劳性能。
4.本发明通过在长纤维增强热塑性复合材料或短纤维增强热塑性复合材料在与外周层增强件接触的边缘部位处设计包边结构，形成U形包覆，增加两个材料之间的接触面，从而进一步提升两种不同材料熔接界面的强度，使得熔接界面不容易剥离，因而提高了推力杆的整体性能。
5.本发明通过将外周层增强件内的网格结构的筋条方向设计成与推力杆所承受的载荷的传递路径方向相同的结构，提高了推力杆的抗压和抗剪切强度。
附图说明
图1为实施例一推力杆结构示意图；
图2为实施例一外周层增强件结构示意图；
图3为实施例一钢套结构示意图；
图4为实施例一橡胶金属球铰结构示意图；
图5为实施例一工装结构示意图；
图6为图5去除中心体后的结构示意图；
图7为实施例一中心体结构示意图；
图8为实施例二金属钢套结构示意图；
图9位实施例一的推力杆与常规推力杆拉伸强度曲线图；
图中：1.推力杆，11.外周层增强件，12.金属钢套，121.凹槽，13.橡胶金属球铰，131.外套，132.橡胶硫化体，133.芯轴，14.网格结构，15.包边结构，2.工装，21.固定板，22.中心体，23.压块，24.气缸，25.定位槽，26.定位板。
具体实施方式
下面结合附图对本发明进一步说明。其中，附图仅用于示例性说明，表示的仅是示意图，而非实物图，不能理解为对本专利的限制；为了更好地说明本发明的实施例，附图某些部件会有省略、放大或缩小，并不代表实际产品的尺寸；对本领域技术人员来说，附图中某些公知结构及其说明可能省略是可以理解的。
实施例一
一种轻量化复合材料推力杆，如图1-图4所示，推力杆1的最外层为外周层增强件11，外周层增强件11内部两端处有金属钢套12，金属钢套12内压装有橡胶金属球铰12，外周层增强件11与金属钢套12之间注塑填充有长纤维增强热塑性复合材料或短纤维增强热塑性复合材料。其中两个金属钢套12之间的长纤维增强热塑性复合材料或短纤维增强热塑性复合材料为网格结构14，且网格结构14的筋条方向与推力杆1所承受的载荷的传递路径方向相同。如图2所示，外周层增强件11为由带状的连续纤维增强热塑性复合材料缠绕并压制成型的闭合环状结构，由于其成型的材料是连续完整的，在作为外围结构对内部包裹时，形成的推力杆抗拉伸强度大大提高，同时满足轻量化及高强度的需求，因而当在其内部注塑填充长纤维增强热塑性复合材料或短纤维增强热塑性复合材料时，不需要过多考虑为推力杆1承受的拉伸和载荷提供支撑，所以可以设计成网格结构14进一步实现轻量化，同时，将网格结构14的筋条方向设计成与推力杆1所承受的载荷的传递路径方向相同的结构，以提高推力杆1的抗压和抗剪切强度，进而保证推力杆1的整体性能。在推力杆1在使用过程中，主要承受三种载荷：拉伸，压缩，扭转，拉伸和压缩载荷是沿着产品的长度方向传递，通过将连续纤维增强热塑性复合材料放在长度方向且布置在外围，因而能够承受拉伸和压缩的载荷；而对与扭转载荷来说，主要是靠中间的网格结构14来抵抗，产品在受到扭转时，对于复合材料这种塑性比较差的材料，其抗拉强度低于抗压、抗剪强度，在受扭过程中变形始终会比较小，最 后在与两个金属钢套12中心连线约成45°倾角的斜面被拉断，所以网格结构14在工艺允许的情况下，筋条方向就可以与中心连线约成45°倾角布置，也就是使筋条方向与载荷传递方向相同，以提高推力杆1的抗扭转强度。
如图4所示，橡胶金属球铰12由内到外依次为芯轴133、橡胶硫化体132和外套131，橡胶硫化体132将外套131和芯轴133硫化成一个整体。
外周层增强件11的制作过程中，需要使用工装，工装结构如图5-图7所示，包括固定板21，在固定板21上设有中心体22、压块23和气缸24，中心体22可以设计成能够与固定板21相分离的结构，压块23设置在中心体22的外围处且能在气缸24的带动下朝向或远离中心体22移动。制作时，将连续纤维增强热塑性复合材料在中心体外周缠绕数圈，保证其强度能够满足推力杆使用过程中的载荷要求，然后气缸24推动压块23朝中心体22方向运动，挤压缠绕后的材料，压制完成后即成型为外周层增强件11。当然，在压制前或压制后需要对材料进行加热，以使其定型为外周层增强件11的形状，此加热方式采用现有方式即可，如单独对材料在缠绕前或缠绕过程中加热，或者缠绕完成后与工装一起进行加热等。
外周层增强件11成型后，将其取下并转移至注塑模具内，在外周层增强件11两端处内部放入金属钢套12，然后注塑填充长纤维增强热塑性复合材料或短纤维增强热塑性复合材料。在将外周层增强件11从工装上取下时，最好是待其冷却避免在取下的过程中变形；而放入注塑模具前，再将其加热，避免外周层增强件11与注塑的材料之间温差过大，影响二者之间的融合。且在将金属钢套12放置入外周层增强件11内时，尽量缩小金属钢套12与外周层增强件11之间的距离，控制在0-5mm，避免由于胶层过厚导致注塑工艺缺陷，进而影响推力杆的整体性能。同时，在设计注塑模具时，将外周层增强件11与注塑材料连接的末端处包裹在模具型腔内，在接触的边缘部位处形成包边结构，形成U形包覆，增加两个材料之间的接触面，从而进一步提升两种不同材料熔接界面的强度，使得熔接界面不容易剥离，因而提高了推力杆的整体性能。
本实施例还涉及一种轻量化复合材料推力杆制作方法先通过工装2制作外周层增强件11，如图2所示，外周层增强件11为采用带状的连续纤维增强热塑性复合材料缠绕而成的在周向上封闭的连续式包围结构，为整个推力杆1提供整体支撑，由于整个外周层增强件11位一条连续完整的材料带缠绕成的整体，以其作为推力杆的外围结构对将内部包裹时，形成的推力杆1抗拉伸强度大大提高，同时满足轻量化及高强度的需求。如图5所示，工装2包括固定板21和设置在固定板21的中心体22、压块23、和气缸24，在固定板21的上表面开设有定位槽25，中心体22的下表面设置有定位板26，定位板26与定位槽25的尺寸相匹配，两者 之间间隙配合，中心体22可与固定板21分离，将定位板26嵌入定位槽25后又可将中心体22定位在固定板21上。压块23有四块，分设在定位槽25的两侧和两端处，每个压块23各有一个气缸24推动其靠近或远离中心体22运动。当带状的连续纤维增强热塑性复合材料缠绕在中心体22外周，且气缸24推动压块23靠近中心体22对缠绕的连续纤维增强热塑性复合材料进行挤压时，中心体22外周的形状与推力杆1外周的形状相同，四个压块23靠近中心体22的表面组合成的形状也与推力杆1外周的形状相同。本实施例中，中心体22为依据推力杆1外周形状而制作的金属部件，因而推力杆1的具体制作方式为：
第一步：将带状的连续纤维增强热塑性复合材料在中心体22的外侧周缠绕多圈后，将缠绕后的连续纤维增强热塑性复合材料进行加热，再用气缸24推动压块23朝中心体22处挤压使连续纤维增强热塑性复合材料定型，然后冷却，松开气缸24，使压块23与中心体22分离后，将连续纤维增强热塑性复合材料从中心体22上取下后成为外周层增强件11。
第二步：对外周层增强件11再次加热后将其放入注塑模具内，并在其内部的两端处各放置一个金属钢套12，然后向外周层增强件11与金属钢套12之间的空间内注塑长纤维增强热塑性复合材料或短纤维增强热塑性复合材料，脱模后在两个金属钢套12中压入橡胶金属球铰13，至此，完成推力杆1的制作。
如图9示出了本实施例制作的推力杆1与申请人当前采用常规方式制作的推力杆拉伸强度曲线对比，图中a线为本实施例中的推力杆的曲线图，b线为常规推力杆的曲线图，从图中可以看出，本实施例的推力杆可承受更大的极限载荷，同等条件下具有更强的结构强度，因而试用的车型更广。
上述第一步也可以改成：在工装2附近设置加热装置如红外加热装置等，对带状的连续纤维增强热塑性复合材料边加热边在中心体22外侧周缠绕多圈，再用气缸24推动压块23朝中心体22处挤压使连续纤维增强热塑性复合材料定型，然后冷却，松开气缸24，将连续纤维增强热塑性复合材料从中心体22上取下后成为外周层增强件11。这种边加热边缠绕的方式能够省去压制前单独加热的时间，提高了生产的效率。或者可以先对缠绕后的连续纤维增强热塑性复合材料进行冷压，然后将整个工装2与材料一起进行加热。此外，带状的连续纤维增强热塑性复合材料为市购产品，其宽度不一定刚好与推力杆1外周处的宽度相等，因此在缠绕前，需要对连续纤维增强热塑性复合材料进行宽度上的裁剪，而在长度上保持其原有长度，这样形成的外周层增强件11是有一条完整的连续纤维增强热塑性复合材料带形成，提高了其抗拉伸强度。
上述第二步中，将金属钢套12放置到外周层增强件11时，将金属钢套12与外周层增强 件11之间的间隙控制在0-5mm之内。由于注塑时胶层越厚，注塑工艺引发的缺陷越多，会导致产品的性能下降，因此，通过控制金属钢套12与外周层增强件11之间的距离，减少其注胶量，从而减少或消除连接处的缺陷，提高推力杆1的性能。同时，注塑时，将外周层增强件11与长纤维增强热塑性复合材料或短纤维增强热塑性复合材料接触的边缘包裹在模芯围城的型腔内，使注塑过程中胶料往外延伸，形成结合边缘处的包边结构。虽然外周层增强件11与注塑材料基体相同，但二者采用的是不同的成型方法，其结合性能与同种成型工艺相比要差一些，因此在后续长期的受载过程中结合处容易分层剥离，而包边结构形成U形包覆，增加了两个材料之间的接触面，增加不同材料界面融合强度，使得结构所能承受的载荷更大，因而不容易剥离，提高了推力杆1的性能，同时注塑成型易于全自动化生产。此外，长纤维增强热塑性复合材料或短纤维增强热塑性复合材料注塑后成型的结构为网格结构14，进一步降低推力杆1的质量，而且形成此网格结构14的筋条方向与推力杆1所承受的载荷传递路径方向相同。
实施例二
本实施例中，中心体22的结构由两部分组成：中间部分是注塑模具中限制长纤维增强热塑性复合材料或短纤维增强热塑性复合材料成型形状的模芯部分，两端是金属钢套12。通过将金属钢套12设计成工装的中心体22的一部分，直接将连续纤维增强热塑性复合材料缠绕在金属钢套12的外侧处，缠绕并压制完成后直接将外周层增强件11及中心体22一起从工装上取下并放入注塑模具中进行注塑，因而不需要待其冷却后再取，因此能够节约生产时间。
此时，如图8所示，在金属钢套12外侧设置多条凹槽121，在注塑过程中，注塑材料能够沿凹槽121流入金属钢套12与外周层增强件11之间，将二者结合成一个整体。
因此，本实施例的制作方法为：中心体22为注塑过程中限制长纤维增强热塑性复合材料或短纤维增强热塑性复合材料的成型形状的模芯部分，且将金属钢套12作为中心体22的两个端部，因而推力杆1的具体制作方式为：
第一步：在工装2附近设置加热装置如红外加热装置等，对带状的连续纤维增强热塑性复合材料边加热边在由金属钢套12与模芯形成的中心体22外侧周缠绕多圈，再用气缸24推动压块23朝中心体22处挤压使连续纤维增强热塑性复合材料定型，松开气缸24，使压块23与中心体22分离，完成外周层增强件11的制作。
第二步：将外周层增强件11与中心体22一起放入注塑模具，向外周层增强件11与金属钢套12之间的空间内注塑长纤维增强热塑性复合材料或短纤维增强热塑性复合材料，脱模后在两个金属钢套12中压入橡胶金属球铰13，完成推力杆1的制作。
本实施例与实施例一相比，注塑前不需要将外周层增强件11从中心体22上取出，因而不需要冷却后再加热，节省了时间，提高了生产速度，适合批量生产。且如图8所示，本实施例中在金属钢套12外周设有凹槽121，在注塑过程中，胶料可以沿凹槽121流入金属钢套12与外周层增强件11之间，从而将二者结合在一起形成一个整体。
当然，本实施例的第一步也可以改成：将带状的连续纤维增强热塑性复合材料在由金属钢套12与模芯形成的中心体22外侧周缠绕多圈，对缠绕后的连续纤维增强热塑性复合材料进行加热，再用气缸24推动压块23朝中心体22处挤压使连续纤维增强热塑性复合材料定型，松开气缸24，使压块23与中心体22分离，完成外周层增强件11的制作。或者可以先对缠绕后的连续纤维增强热塑性复合材料进行冷压，然后将整个工装2与材料一起进行加热。
以上实施例仅供说明本发明之用，而非对本发明的限制，有关技术领域的技术人员在不脱离本发明的精神和范围的情况下，还可以做出各种变化或变换，因此所有等同的技术方案也应该属于本发明的保护范围，本发明的保护范围应该由各权利要求限定。

Claims (15)

  1. 一种轻量化复合材料推力杆制作方法，其特征在于：利用带状的连续纤维增强热塑性复合材料缠绕出一个在周向上封闭的连续式异形外周层增强件(11)，然后在外周层增强件(11)内部以注塑方式填充长纤维增强热塑性复合材料或短纤维增强热塑性复合材料，最后将橡胶金属球铰(13)压装入两端处，形成完整的推力杆。
  2. 如权利要求1所述的轻量化复合材料推力杆制作方法，其特征在于：在缠绕外周层增强件(11)时，设置一个包括中心体(22)和压块(23)的工装，将带状的连续纤维增强热塑性复合材料沿中心体(22)外周缠绕多圈后，利用压块(23)挤压缠绕后的连续纤维增强热塑性复合材料，通过压块(23)与中心体(22)一起对缠绕后的连续纤维增强热塑性复合材料进行压制，使缠绕后的连续纤维增强热塑性复合材料与推力杆(1)的外周形状及尺寸相同，形成异形外周层增强件(11)。
  3. 如权利要求2所述的轻量化复合材料推力杆制作方法，其特征在于：中心体(22)为注塑过程中限制长纤维增强热塑性复合材料或短纤维增强热塑性复合材料的成型形状的模芯部分，且将位于外周层增强件(11)与橡胶金属球铰之间的金属钢套(12)设计成中心体(22)的两个端部，缠绕时，将带状的连续纤维增强热塑性复合材料直接与金属钢套(12)的外侧接触，注塑时，将中心体(22)与外周层增强件(11)一起放入模具中进行注塑。
  4. 如权利要求1所述的轻量化复合材料推力杆制作方法，其特征在于：外周层增强件(11)与橡胶金属球铰(13)之间还设有金属钢套(12)，控制外周层增强件(11)与金属钢套(12)之间的距离，使二者之间注塑的长纤维增强热塑性复合材料或短纤维增强热塑性复合材料厚度为0-5mm。
  5. 如权利要求1所述的轻量化复合材料推力杆制作方法，其特征在于：在注塑时，将外周层增强件(11)与长纤维增强热塑性复合材料或短纤维增强热塑性复合材料接触的边缘包裹在模芯围城的型腔内，使胶料往外延伸，形成边缘处的包边结构。
  6. 如权利要求1所述的轻量化复合材料推力杆制作方法，其特征在于：将外周层增强件(11)内注塑的长纤维增强热塑性复合材料或短纤维增强热塑性复合材料设计成网格结构，以降低整体质量；并将网格结构的筋条方向设计成与载荷传递路径方向相同的结构以提高整体强度。
  7. 如权利要求1所述的轻量化复合材料推力杆制作方法，其特征在于：在外周层增强件(11)内注塑长纤维增强热塑性复合材料或短纤维增强热塑性复合材料前还包括对外周层增强件(11)进行加热的步骤。
  8. 如权利要求2所述的轻量化复合材料推力杆制作方法，其特征在于：推力杆(1)的具体制作方式为：
    第一步：将带状的连续纤维增强热塑性复合材料在中心体(22)的外侧周缠绕多圈后，对缠绕后的连续纤维增强热塑性复合材料进行加热，再推动压块(23)朝中心体(22)处挤压使连续纤维增强热塑性复合材料定型，然后冷却，将压块(23)与中心体(22)分离，再将连续纤维增强热塑性复合材料从中心体(22)上取下后成为外周层增强件(11)；或者先对缠绕后的连续纤维增强热塑性复合材料进行冷压，然后将整个工装(2)与缠绕后的连续纤维增强热塑性复合材料一起进行加热；
    第二步：对外周层增强件(11)再次加热后将其放入注塑模具内，并在其内部的两端处各放置一个金属钢套(12)，然后向外周层增强件(11)与金属钢套(12)之间的空间内注塑长纤维增强热塑性复合材料或短纤维增强热塑性复合材料，脱模后在两个金属钢套(12)中压入橡胶金属球铰(13)，完成推力杆(1)的制作。
  9. 如权利要求2所述的轻量化复合材料推力杆制作方法，其特征在于：推力杆(1)的具体制作方式为：
    第一步：在工装(2)附近设置加热装置，对带状的连续纤维增强热塑性复合材料边加热边在中心体(22)外侧周缠绕多圈，再推动压块(23)朝中心体(22)处挤压使连续纤维增强热塑性复合材料定型，然后冷却，将压块(23)与中心体(22)分离，再将连续纤维增强热塑性复合材料从中心体(22)上取下后成为外周层增强件(11)；
    第二步：对外周层增强件(11)再次加热后将其放入注塑模具内，并在其内部的两端处各放置一个金属钢套(12)，然后向外周层增强件(11)与金属钢套(12)之间的空间内注塑长纤维增强热塑性复合材料或短纤维增强热塑性复合材料，脱模后在两个金属钢套(12)中压入橡胶金属球铰(13)，完成推力杆(1)的制作。
  10. 如权利要求2所述的轻量化复合材料推力杆制作方法，其特征在于：推力杆(1)的具体制作方式为：
    第一步：在工装(2)附近设置加热装置，对带状的连续纤维增强热塑性复合材料边加热边在由金属钢套(12)与模芯形成的中心体(22)外侧周缠绕多圈，再将压块(23)朝中心体(22)处挤压使连续纤维增强热塑性复合材料定型，然后将压块(23)与中心体(22)分离，完成外周层增强件(11)的制作；
    第二步：将外周层增强件(11)与中心体(22)一起放入注塑模具，向外周层增强件(11)与金属钢套(12)之间的空间内注塑长纤维增强热塑性复合材料或短纤维增强热塑性复合材料，脱模后在两个金属钢套(12)中压入橡胶金属球铰(13)，完成推力杆(1)的制作；
  11. 如权利要求2所述的轻量化复合材料推力杆制作方法，其特征在于：推力杆(1)的具体 制作方式为：
    第一步：将带状的连续纤维增强热塑性复合材料在由金属钢套(12)与模芯形成的中心体(22)外侧周缠绕多圈，对缠绕后的连续纤维增强热塑性复合材料进行加热，再推动压块(23)朝中心体(22)处挤压使连续纤维增强热塑性复合材料定型，然后将压块(23)与中心体(22)分离，完成外周层增强件(11)的制作；或者先对缠绕后的连续纤维增强热塑性复合材料进行冷压，然后将整个工装(2)与缠绕后的连续纤维增强热塑性复合材料一起进行加热；
    第二步：将外周层增强件(11)与中心体(22)一起放入注塑模具，向外周层增强件(11)与金属钢套(12)之间的空间内注塑长纤维增强热塑性复合材料或短纤维增强热塑性复合材料，脱模后在两个金属钢套(12)中压入橡胶金属球铰(13)，完成推力杆(1)的制作。
  12. 一种轻量化复合材料推力杆，其特征在于：包括位于最外周的外周层增强件(11)和注塑在外周层增强件(11)内部与外周层增强件(11)结合为一体的长纤维增强热塑性复合材料或短纤维增强热塑性复合材料，外周层增强件(11)包围的两端处设有金属钢套(12)，金属钢套(12)内设有橡胶金属球铰(13)，长纤维增强热塑性复合材料或短纤维增强热塑性复合材料注塑在外周层增强件(11)与金属钢套(12)之间；其中外周层增强件(11)为利用带状的连续纤维增强热塑性复合材料缠绕后压制成的在周向上封闭的连续式整体结构。
  13. 如权利要求12所述的轻量化复合材料推力杆，其特征在于：注塑在外周层增强件(11)与金属钢套(12)之间的长纤维增强热塑性复合材料或短纤维增强热塑性复合材料的厚度为0-5mm。
  14. 如权利要求12所述的轻量化复合材料推力杆，其特征在于：注塑的长纤维增强热塑性复合材料或短纤维增强热塑性复合材料在与外周层增强件(11)接触的边缘部位具有包边结构(15)。
  15. 如权利要求12所述的轻量化复合材料推力杆，其特征在于：注塑在两个金属钢套(12)间的长纤维增强热塑性复合材料或短纤维增强热塑性复合材料为网格结构(14)，且网格结构(14)的筋条方向与推力杆(1)所承受的载荷的传递路径方向相同。
PCT/CN2021/079675 2021-02-09 2021-03-09 一种轻量化复合材料推力杆制作方法及结构 WO2022170653A1 (zh)

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