CN118046603A - Preparation method of integrally formed thermoplastic composite material automobile structural member - Google Patents
Preparation method of integrally formed thermoplastic composite material automobile structural member Download PDFInfo
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- CN118046603A CN118046603A CN202410185422.4A CN202410185422A CN118046603A CN 118046603 A CN118046603 A CN 118046603A CN 202410185422 A CN202410185422 A CN 202410185422A CN 118046603 A CN118046603 A CN 118046603A
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- integrally formed
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- 239000002131 composite material Substances 0.000 title claims abstract description 32
- 229920001169 thermoplastic Polymers 0.000 title claims abstract description 28
- 239000004416 thermosoftening plastic Substances 0.000 title claims abstract description 28
- 238000002360 preparation method Methods 0.000 title claims abstract description 15
- 239000010410 layer Substances 0.000 claims abstract description 69
- 238000001746 injection moulding Methods 0.000 claims abstract description 34
- 239000000463 material Substances 0.000 claims abstract description 32
- 238000000465 moulding Methods 0.000 claims abstract description 25
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- 238000013461 design Methods 0.000 claims abstract description 19
- 239000011199 continuous fiber reinforced thermoplastic Substances 0.000 claims abstract description 16
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 16
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- 238000000748 compression moulding Methods 0.000 claims abstract description 7
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Classifications
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- 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
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- B29C45/78—Measuring, controlling or regulating of temperature
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- 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
- B29C70/34—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 and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
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- B32B3/02—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 features of form at particular places, e.g. in edge regions
- B32B3/08—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 features of form at particular places, e.g. in edge regions characterised by added members at particular parts
- B32B3/085—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 features of form at particular places, e.g. in edge regions characterised by added members at particular parts spaced apart pieces on the surface of a layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
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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
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2262/101—Glass 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
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/546—Flexural strength; Flexion stiffness
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B2307/00—Properties of the layers or laminate
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- B32B2605/003—Interior finishings
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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
- B32B2605/00—Vehicles
- B32B2605/08—Cars
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
Abstract
The invention discloses a preparation method of an integrally formed thermoplastic composite material automobile structural member, which comprises the following steps: laying a plurality of layers of continuous fiber reinforced thermoplastic sheets, and then performing mould pressing to obtain a panel layer; preheating the panel layer, transferring the panel layer into a molding cavity, and then performing compression molding and injection molding to obtain an injection molding layer; adopting reaction injection molding in a molding die cavity to obtain a paint surface layer; demoulding to obtain an integrally formed automobile structural member; the invention adopts an integrated structural design, can greatly improve the degree of freedom of design generation and meets the requirement of functional diversity of parts. By adjusting the structure and layering mode of the panel layer material and the structural size design and distribution of the reinforcing ribs of the injection molding layer, the adjustability of the performance parameters such as 200-800MPa of the tensile strength of the panel, 25-55Hz of the component mode, 40-100N/mm of bending rigidity and the like is realized, and the mass is reduced by 20-50% compared with the mass of the raw materials.
Description
Technical Field
The invention relates to the technical field of manufacturing of new energy automobile parts, in particular to a method for preparing an integrally formed thermoplastic composite automobile structural part.
Background
Under the background of carbon neutralization and large scale, the entity economy and green transformation is carried out, and the automobile industry as the carbon emission 'large household' is first strived for, and formally enters into the 'light weight era'. The automobile weight reduction has important significance on energy conservation and emission reduction, performance improvement, cost reduction and healthy development of the automobile industry, and is an important direction of technical development of the modern automobile industry.
The plastic steel is one of the most effective ways to realize the weight reduction of automobiles. Thermoplastic composite materials which can be recycled, have short molding cycle and low cost have great application potential in automobile lightweight design. At present, the thermoplastic composite material is mainly applied to non-bearing parts or interior trim parts, but is mainly applied to vehicle bearing exterior trim parts (such as engine cover plates, top plates, rear covers and the like) and is mainly formed by hot stamping of metal materials or injection molding of long fiber reinforced thermoplastic composite materials, so that the problems of heavy component quality, complex structural process, low structural rigidity or low production efficiency and the like exist, and the requirements of high-efficiency functions of automobile components are difficult to meet.
In the prior art, as disclosed in chinese patent No. CN217074534U, a steel cover plate for an automobile engine is provided for resisting extrusion stress, and the structural strength of the metal cover plate body is reinforced by using an arc-shaped metal cover plate and a reinforcing mechanism with an arc-shaped structure, so as to protect the metal cover plate from deformation and ensure that the engine is not damaged. The technology can improve the strength of the whole cover plate, but the metal cover plate has heavier mass, and is difficult to meet the requirement of an automobile on light weight; the Chinese patent No. 105922601A discloses a preparation method of a fiber reinforced thermoplastic composite material part, which comprises the steps of preheating a composite plate, compression molding a semi-finished product, and performing injection molding and edging in an embedded injection mold through laser cutting, wherein the shrinkage rate difference between the composite plate and an injection molding material is large, obvious sink mark or warping phenomenon is formed, and an additional pretreatment process is required to be added as an automobile exterior trim part, so that the technology is complicated and the production efficiency is low. Therefore, the prior art can not realize the integral molding of the thermoplastic composite material with a complex structure, and the development of the lightweight manufacturing technology in the automobile industry is hindered.
Disclosure of Invention
According to the preparation method of the integrally formed thermoplastic composite material automobile structural part, the integrated forming of the automobile bearing exterior trim part is realized through a one-step method on the basis of structural design, the subsequent paint spraying processing procedures of the product are reduced, the product quality and industrialized batch manufacturing of the exterior trim part can be ensured, and the requirements of light weight and high efficiency of the automobile are met.
The technical scheme of the invention is as follows:
In a first aspect of the present invention, there is provided a method of making an integrally formed thermoplastic composite automotive structural member comprising the steps of:
laying a plurality of layers of continuous fiber reinforced thermoplastic sheets, and then performing mould pressing to obtain a panel layer;
preheating the panel layer, transferring the panel layer into a molding cavity, and then performing compression molding and injection molding to obtain an injection molding layer;
adopting reaction injection molding in a molding die cavity to obtain a paint surface layer;
and demolding to obtain the integrally formed automobile structural member.
The preparation method effectively solves the problems of difficult formation of a complex structure, high equipment requirement and complicated process in the traditional exterior trimming part preparation, realizes one-step formation of a product structure and painting, has smooth outer surface and low warpage, and can be continuously produced in batch and has recycling property.
In a second aspect of the present invention, there is provided an integrally formed thermoplastic composite automotive structural member comprising a paint finish layer, a panel layer and an injection molded layer disposed in that order from the outside to the inside.
The embodiment adopts integrated into one piece's structural design, can improve greatly and produce the design degree of freedom, satisfies part function diversity demand. The structure and the layering mode of the panel layer material and the structural size design and distribution of the reinforcing ribs of the injection molding layer are adjusted, so that the strength of the automobile structural member is improved, and the quality of the automobile structural member is reduced.
One or more of the technical schemes of the invention has the following beneficial effects:
(1) The invention adopts an integrated structural design, can greatly improve the degree of freedom of design generation and meets the requirement of functional diversity of parts. By adjusting the structure and layering mode of the panel layer material and the structural size design and distribution of the reinforcing ribs of the injection molding layer, the adjustability of the performance parameters such as 200-800MPa of the tensile strength of the panel, 25-55Hz of the component mode, 40-100N/mm of bending rigidity and the like is realized, and the mass is reduced by 20-50% compared with the mass of the raw materials.
(2) The integrated forming preparation method can effectively solve the problems of difficult forming of a complex structure, high equipment requirement and complicated process in the traditional exterior trimming part preparation, realizes one-step forming of a product structure and painting, has smooth outer surface and low warpage, can realize continuous batch production and recycling, can process a single part for 2-8min, improves the production beat efficiency by 50-80%, saves energy by 20-40% and realizes the rapid manufacturing of the exterior trimming member with complex functions; meanwhile, the problem of high energy consumption/high emission of the traditional automobile coating can be effectively solved, and the in-mold painting of large-size parts and components can be realized, wherein the thickness of a paint film is 0.3-0.8mm, and the appearance of the A-level surface is realized.
(3) The invention greatly shortens the preparation flow of the integrally formed thermoplastic composite material automobile structural member, reduces the equipment requirement, does not need later bonding, has high degree of freedom and strength of product design, can be used for preparing automobile front cover, front end, top plate, rear cover and other members, and realizes the light and green manufacturing of parts.
Drawings
FIG. 1 is a flow chart of a method of making an integrally formed thermoplastic composite automotive structural member of the present invention;
FIG. 2 is a schematic illustration of a continuous fiber reinforced thermoplastic sheet lay-up of a panel layer of the present invention;
FIG. 3 is a schematic view of the structure of an integrally formed thermoplastic composite automotive structural member of the present invention;
FIG. 4 is a schematic front view of a reinforcing rib structure design of an injection layer according to an embodiment of the present invention;
fig. 5 is a schematic top view of a rib structure design of an injection layer according to an embodiment of the present invention.
In the figure: 1-paint surface layer, 2-panel layer and 3-injection layer.
Detailed Description
The invention will be further described with reference to the drawings and examples.
In an exemplary embodiment of the present invention, a method for preparing an integrally formed thermoplastic composite automotive structural member is provided, as shown in fig. 1, comprising the steps of:
laying a plurality of layers of continuous fiber reinforced thermoplastic sheets, and then performing mould pressing to obtain a panel layer;
preheating the panel layer, transferring the panel layer into a molding cavity, and then performing compression molding and injection molding to obtain an injection molding layer;
adopting reaction injection molding in a molding die cavity to obtain a paint surface layer;
and demolding to obtain the integrally formed automobile structural member.
The integrally formed automobile structural member is formed by compounding the paint surface layer, the panel layer and the injection molding layer in a set of equipment without subsequent processing.
In this embodiment, the panel layer is obtained by cross-laying molding of a plurality of continuous fiber reinforced thermoplastic sheets, specifically, as shown in fig. 2, the plurality of continuous fiber reinforced thermoplastic sheets adopt a balanced symmetrical cross-laying mode of 0 °/45 °/-45 °/90 °, the performance of the panel layer can be increased or decreased by the cross-laying direction and the number of layers, and from the viewpoints of the performance and the light weight of the automotive exterior trim, the number of layers is generally 1-8, preferably 2-6.
In this embodiment, the molding pressure in the process of preparing the panel layer is 5-10MPa, the molding temperature is 100-500 ℃, preferably 100-300 ℃, and the molding time is 10-40min, which can be properly adjusted according to different sheet materials.
In this embodiment, the preheating process of the panel layer includes: placing the panel layer in an infrared oven, setting four transverse temperature areas of the oven, wherein the transverse temperature gradient is 110-200 ℃, and the preheating time is 1-10min.
Further, in the injection molding process of the injection molding layer, the preheated panel layer is vertically moved into a molding cavity, the panel sheet is fixed on the surface of a mold by utilizing a top block, the mold clamping pressure is determined by the size of a part, generally 1000-4000T, the temperature of the mold is controlled to be 30-90 ℃, multi-gate injection molding is adopted, the rib position and the panel are rapidly completed, the injection pressure is 500-1200bar, the temperature of an injection molding screw is 200-260 ℃, the dwell time is 3-15s, the dwell pressure is 100-500bar, and the cooling time is 10-40s.
Further, the injection molding process of the paint surface layer comprises the following steps: the material A and the material B are respectively added into A, B storage tanks, circulated before mixing, the temperature of the material liquid is regulated, and the material liquid is respectively metered by a high-pressure pump and then enters a mixing chamber, the material liquid is collided and mixed at a high speed in the mixing chamber, and then quickly enters a die cavity, the material liquid is polymerized while being filled into the die cavity, the pressure of the die cavity is 0.3-1.0Mpa, the forming beat is 60-240s, when the stripping strength is reached, the material liquid is stripped and taken out, and the integral type automobile structural part is obtained, 1, the thickness of a paint film is 0.3-0.8mm, and the material liquid meets the A-level surface required by the automobile surface.
In an exemplary embodiment of the present invention, an integrally formed thermoplastic composite automotive structural member is provided, as shown in fig. 3, comprising a paint finish layer 1, a panel layer 2 and an injection molded layer 3, which are sequentially arranged from the outside to the inside.
Specifically, the panel layer 2 is obtained by compression molding a plurality of layers of continuous fiber reinforced thermoplastic sheets, the continuous fiber reinforced thermoplastic sheets are formed by taking continuous fibers as a reinforcing component and thermoplastic resin as a base resin, wherein the volume content of the fibers is 35-70%, the thickness is 0.1-1mm, the length is 5-20mm, the volume content of the fibers is preferably 45-55%, the thickness is preferably 0.3-0.6mm, and the length of the fibers is preferably 10-15mm.
Further, the continuous fiber reinforced thermoplastic sheet is one or more of unidirectional tape, plain weave, twill weave, or satin weave; preferably a unidirectional tape.
Further, the continuous fiber is one or more of glass fiber, carbon fiber, basalt fiber, aramid fiber or boron fiber, preferably glass fiber, basalt fiber, and more preferably glass fiber.
Further, the thermoplastic resin is one or more of polypropylene (PP), modified PP, nylon (PA), polycarbonate (PC), polyethylene (PE) or ABS plastic, polycarbonate (PC) +ABS plastic, preferably ABS, PC, PC +ABS, more preferably PC+ABS.
In this embodiment, the injection-molded layer 3 is made of a short-fiber/long-fiber-reinforced thermoplastic material, preferably a long-fiber-reinforced thermoplastic material, and the fiber content is generally 10 to 50%, preferably 35 to 40%. In this embodiment, the injection molding layer is a comprehensive reinforcing rib structure, including strip-shaped, round and line-shaped rib positions, so as to ensure structural strength and glue flow direction, as shown in fig. 4 and 5, the injection molding layer is a plurality of reinforcing ribs, the slope α of the reinforcing ribs is 0.5 ° to 1.5 °, the wall thickness B of the reinforcing ribs is less than 0.7T of the thickness of the face plate, the top thickness C is not less than 1mm, and the height H is less than 3T of the thickness of the face plate; the bonding part between the bottom of the reinforcing rib and the panel adopts a fillet or crater design, the fillet R is 0.25T-0.5T, the distance between the reinforcing ribs is 2T-4T, and the defects of sink mark warping and the like of the product after injection molding can be prevented.
In this embodiment, the paint surface layer 1 may be a polyurethane or polyurea, nylon, dicyclopentadiene or epoxy type paint, preferably a polyurethane, polyurea or epoxy type paint, and more preferably a polyurethane type paint. The paint surface layer is divided into a material A and a material B by adopting paint surface materials. Materials a and B may be purchased directly from a pestle or related suppliers. Taking polyurethane as an example: the polyurethane coating consists of a material A and a material B, wherein the component A mainly comprises isocyanate, and the component B comprises polyester polyol or polyether polyol, a diamine chain extender, trimethylolpropane, dihydroxyethyl disulfide, a catalyst and an auxiliary agent. The polyurethane coating adopts reaction injection molding to form a stable coating on the panel layer.
According to the preparation method of the integrally formed thermoplastic composite material automobile structural member, provided by the invention, the structural design and distribution of panel layer materials, the layering mode and the structural size of reinforcing ribs of an injection molding layer are adjusted, so that the adjustability of performance parameters such as 200-800MPa of panel tensile strength, 15-55Hz of structural member mode, 40-100N/mm of bending stiffness and the like is realized, and the mass is reduced by 20-50% compared with that of raw materials; meanwhile, the problems of difficult forming, high equipment requirement and complicated process in the traditional exterior trimming part preparation can be effectively solved, the single-piece processing of a single product is realized for 2-8min, the production beat efficiency is improved by 50-80%, the energy conservation and consumption reduction are realized by 20-40%, and the green rapid batch manufacturing of the high-quality complex-function exterior trimming part is realized.
The automobile structural member comprises an automobile interior trim part and an automobile exterior trim part, wherein the automobile exterior trim part comprises, but is not limited to, a front bumper, a rear bumper, a front door, a rear door, a door handle or the like. The automotive interior trim parts include, but are not limited to, instrument desk, door trim strips, auxiliary instrument desk trim panels, key panels, engine cover plates, trunk covers and the like.
Example 1
Taking the preparation of an automobile engine cover plate as an example, the specific steps comprise:
(1) Continuous fiber reinforced thermoplastic sheet panel layer preparation
The continuous fiber reinforced thermoplastic sheet is molded into a continuous fiber panel according to a balanced symmetrical cross-ply of 0/45/90, the thickness of the continuous fiber reinforced thermoplastic sheet being 0.3-0.5mm. The number and the direction of the layers of the sheet are increased or reduced according to the performance and the light weight requirement of the automobile exterior trim part, a unidirectional belt is preferred, 4 layers of the sheet are paved, and the thickness of the sheet is preferably 0.5mm. The molding pressure is 8MPa, the temperature is 210 ℃, the molding time is 30min, and the fiber reinforced thermoplastic sheet panel layer is prepared, and can be properly adjusted by referring to the sheet process provided by a merchant.
(2) And (3) vertically clamping the continuous fiber panel on the clamping frame by adopting a clamp controlled by a servo motor, and moving the continuous fiber panel into a vertical infrared oven for panel preheating treatment. The panel preheating adopts a zonal preheating method, and is particularly divided into four temperature zones along the transverse direction, wherein the transverse temperature gradient is 150-180 ℃, and the preheating time is generally controlled to be 1-2min.
(3) And vertically moving the preheated continuous fiber panel into a molding die cavity, and fixing the panel sheet on the surface of the die by utilizing a top block, so as to keep the clamping plane flat.
And (3) closing the die and starting injection molding, wherein the die locking pressure is 2000T, and the die temperature is controlled at 50 ℃ in order to ensure the molding of the component characteristic structure. The multi-gate injection molding is adopted to rapidly finish the composite molding of the rib position and the panel, the injection molding pressure is 700bar, the injection molding temperature is 225 ℃, the pressure maintaining time is 6-8s, the pressure maintaining pressure is 100-200bar, the cooling time is 20-30s, the thickness of the rib position is generally set to be less than 0.7 times of the thickness of the panel, the height is less than 3 times of the thickness of the panel, and the thickness is less than 0.8 times of the thickness of the panel.
(4) And (5) in-mold painting. The material A and the material B are respectively added into A, B storage tanks, circulated before mixing, the temperature of the material liquid is regulated, the material liquid is respectively metered by a high-pressure pump and then enters a mixing chamber, the material liquid is collided and mixed at a high speed in the mixing chamber, the material liquid rapidly enters a die cavity, the material liquid is polymerized while being filled into the die cavity, the pressure of the die cavity is about 0.5MPa, the forming beat is 180s, when the stripping strength is reached, the material liquid is stripped and taken out, the integrally formed automobile bearing exterior trimming part is obtained, the thickness of a paint film is 0.8mm, and the surface of the A grade of the material liquid meets the surface requirement of an automobile.
The automobile exterior trimming part integrally molded by compression molding, injection molding and in-mold painting in the embodiment has no shrinkage mark, no warpage, high member mode (45 Hz) and high rigidity (80N/mm) from four aspects of materials, structural design, mold design and molding process, and the quality is reduced by about 25% compared with the raw materials, so that the automobile exterior trimming part is an excellent choice for light weight of the automobile exterior trimming part.
While the foregoing description of the embodiments of the present invention has been presented in conjunction with the drawings, it should be understood that it is not intended to limit the scope of the invention, but rather, it is intended to cover all modifications or variations within the scope of the invention as defined by the claims of the present invention.
Claims (10)
1. The preparation method of the integrally formed thermoplastic composite material automobile structural member is characterized by comprising the following steps of:
laying a plurality of layers of continuous fiber reinforced thermoplastic sheets, and then performing mould pressing to obtain a panel layer;
preheating the panel layer, transferring the panel layer into a molding cavity, and then performing compression molding and injection molding to obtain an injection molding layer;
adopting reaction injection molding in a molding die cavity to obtain a paint surface layer;
and demolding to obtain the integrally formed automobile structural member.
2. The method of making an integrally formed thermoplastic composite automotive structural member of claim 1, wherein said plurality of layers of continuous fiber reinforced thermoplastic sheets are laid in a balanced symmetrical cross-lay pattern of 0 °/45 °/-45 °/90 °.
3. The method for manufacturing an integrally formed thermoplastic composite automotive structural member according to claim 1, wherein the molding pressure in the process of manufacturing the panel layer is 5 to 10MPa, the molding temperature is 100 to 500 ℃, and the molding time is 10 to 40 minutes.
4. The method of making an integrally formed thermoplastic composite automotive structural member of claim 1, wherein said preheating of said panel layer comprises: placing the panel layer in an infrared oven, setting four transverse temperature areas of the oven, wherein the transverse temperature gradient is 110-200 ℃, and the preheating time is 1-10min.
5. The method for preparing an integrally formed thermoplastic composite material automobile structural member according to claim 1, wherein in the injection molding process of the injection molding layer, the temperature of a mold is controlled to be 30-90 ℃, multi-gate injection molding is adopted to rapidly complete rib position and panel composite molding, the injection pressure is 500-1200bar, the temperature of an injection molding screw is 200-260 ℃, the dwell time is 3-15s, the dwell pressure is 100-500bar, and the cooling time is 10-40s.
6. The method of making an integrally formed thermoplastic composite automotive structural member of claim 1, wherein said injection molding of said paint finish comprises: respectively adding the material A and the material B into A, B storage tanks, respectively circulating before mixing, regulating the temperature of the material liquid, respectively metering by a high-pressure pump, then entering a mixing chamber, performing high-speed collision mixing in the mixing chamber, rapidly entering a die cavity, filling the die while polymerizing, wherein the pressure of the die cavity is 0.3-1.0Mpa, forming the beat for 60-240s, and demoulding and taking out when the demoulding strength is reached, thus obtaining the integral automobile structural member.
7. An integrally formed automotive structural part of thermoplastic composite material obtained by the method according to any one of claims 1 to 6, comprising a paint surface layer, a panel layer and an injection layer arranged in sequence from the outside to the inside.
8. The integrally formed thermoplastic composite automotive structural member of claim 7, wherein the paint finish is molded from a plurality of layers of continuous fiber reinforced thermoplastic sheets having continuous fibers as a reinforcing component and thermoplastic resins as a base resin, wherein the fibers have a volume content of 35% to 70%, a thickness of 0.1 to 1mm and a length of 5 to 20mm.
9. The integrally formed thermoplastic composite automotive structural member of claim 8, wherein said continuous fiber reinforced thermoplastic sheet is one or more of a unidirectional tape, a plain weave, a twill weave, or a satin weave;
Or the continuous fiber is one or more of glass fiber, carbon fiber, basalt fiber, aramid fiber or boron fiber;
or the thermoplastic resin is one or more of polypropylene, modified PP, nylon, polycarbonate, polyethylene or polycarbonate+ABS plastics.
10. The integrally formed thermoplastic composite automotive structural member of claim 7, wherein the injection molded layer is a plurality of ribs having a rib slope α of 0.5 ° -1.5 °, a rib wall thickness B of less than 0.7T panel thickness, a top thickness C of not less than 1mm, and a height H of less than 3T panel thickness; the joint of the bottom of the reinforcing rib and the panel adopts a fillet or a volcanic mouth design, the fillet R is 0.25T-0.5T, and the interval between the reinforcing ribs is 2T-4T.
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN118991085A (en) * | 2024-10-09 | 2024-11-22 | 长春英利汽车部件有限公司 | Manufacturing method of automobile electronic module unit and electronic module unit |
| CN119682111A (en) * | 2024-12-23 | 2025-03-25 | 奇瑞新能源汽车股份有限公司 | An integrated molding process of injection molding and painting for large-size exterior covering parts of automobiles |
| CN120606543A (en) * | 2025-06-24 | 2025-09-09 | Oppo广东移动通信有限公司 | Method for preparing structural part, structural part and electronic equipment |
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- 2024-02-19 CN CN202410185422.4A patent/CN118046603A/en active Pending
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN118991085A (en) * | 2024-10-09 | 2024-11-22 | 长春英利汽车部件有限公司 | Manufacturing method of automobile electronic module unit and electronic module unit |
| CN119682111A (en) * | 2024-12-23 | 2025-03-25 | 奇瑞新能源汽车股份有限公司 | An integrated molding process of injection molding and painting for large-size exterior covering parts of automobiles |
| CN120606543A (en) * | 2025-06-24 | 2025-09-09 | Oppo广东移动通信有限公司 | Method for preparing structural part, structural part and electronic equipment |
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