CN110481127A - 一种发动机底护板及其生产工艺 - Google Patents
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Abstract
本发明属于汽车零部件制备技术领域，公开了一种发动机底护板，该发动机底护板由连续纤维增强热塑性材料和轻质热塑性增强材料组成，两种材料间通过树脂熔融连接。本发明同时公开了发动机底护板的审查工艺，发动机底护板经烘烤加热、快速转运、叠层铺放、模压成型、后期裁切而成。本发明提供了一种多材料复合发动机底护板的生产工艺，通过材料预热温度控制、转运时长优化解决了多材料间连接强度问题，所制备的发动机底护板具有强度区域可设计性、耐冲击性能优、质量轻等优势。
Description
技术领域
本发明属于汽车零部件制备技术领域，具体涉及一种汽车发动机底护板及生产工艺。
背景技术
发动机底护板是安装于汽车发动机下方，保护发动机底部免受撞击的防护装置。随着汽车技术的发展，对发动机底护板的要求逐渐提高，在满足基本抗冲击性能的前提下，又提出了轻量化、隔音降噪、耐锈蚀、低风阻、易于汽车维护等要求。目前，汽车用发动机底护板主要有树脂底护板、钢制底护板、铝合金底护板，对应的发动机底护板都无法同时满足高强度性能与轻量化设计。
发明内容
本发明的目的是克服现有技术中存在的不足，提供一种发动机底护板及其生产工艺，采用连续纤维增强热塑性材料和轻质热塑性增强材料(LWRT)复合而成，质量轻，抗冲击强度好，吸音隔音效果佳。
本发明的目的可以通过以下技术方案实现：
本发明提供一种发动机底护板，由连续纤维增强热塑性材料和轻质热塑性增强材料(LWRT)复合而成。
进一步的，所述的发动机底护板由下至上依次包括连续纤维增强热塑性材料层、熔接层、轻质热塑性增强材料(LWRT)层、PET无纺布层；
进一步的，所述的连续纤维增强热塑性材料层厚度为0.3mm～1.0mm，所述的轻质热塑性增强材料(LWRT)层厚度为2.5mm～4.0mm；
进一步的，所述的连续纤维增强热塑性材料层面密度为600～1500g/m2，所述的轻质热塑性增强材料(LWRT)层面密度为1200～1600g/m2；
进一步的，所述的连续纤维增强热塑性材料中基体为聚丙烯树脂(PP)；
进一步的，所述的连续纤维增强热塑性材料中增强纤维为玻璃纤维、玄武岩纤维、碳纤维中的一种；
更进一步的，所述的连续纤维增强热塑性材料层中增强纤维为2/2斜纹编织方式；
更进一步的，所述的熔接层由连续纤维增强热塑性材料中聚丙烯树脂和轻质热塑性增强材料(LWRT)中聚丙烯纤维、短切玻璃纤维熔融组成。
本发明同时提供一种发动机底护板的生产工艺，该发动机底护板由连续纤维增强热塑性材料和轻质热塑性增强材料(LWRT)复合而成，该生产工艺包括步骤：
(1)加热：将连续纤维增强热塑性材料置于加热装置中加热，作用于板材表面的温度控制在190℃～220℃之间，加热时间45s～90s；将轻质热塑性增强材料置于另一加热装置中加热，作用于板材表面的温度控制在200℃～230℃之间，加热时间50s～90s；
(2)转运：第一转运步，将预热后的连续纤维增强热塑性材料通过自动化设备转运至模具中，转运步长时间为2s～3s，过程中连续纤维增强热塑性材料暴露在空气中；第二转运步，将预热后的轻质热塑性增强材料通过自动化设备转运至模具中，转运步长时间为2s～5s，过程中连续纤维增强热塑性材料暴露在空气中；第二转运步与第一转运步时间间隔为2s～5s；
(3)铺放：首先，将预热后的连续纤维增强热塑性材料铺放于模具表面；而后，将预热后的轻质热塑性增强材料铺放于模具中，其覆盖于连续纤维增强热塑性材料上方；
(4)模压：末段合模速度为5mm/s，成型压力为15Mpa～20Mpa，成型保压时间为30s～90s，；
(5)裁切：将成型后的发动机底护板置于裁切模具中，裁切冲孔。
本发明的技术优点在于：
本发明提供了一种由连续纤维增强热塑性材料和轻质热塑性增强材料(LWRT)复合而成的发动机底护板及其生产工艺，相比于传统金属和非金属发动机底护板，其具有轻量化、耐冲击强度高、隔音降噪、耐锈蚀等优点。
本发明中发动机底护板的生产工艺，提供了一种两种材料复合成型发动机底护板的自动化、批量化生产工艺，满足作业效率要求；根据所用板材的厚度优选了加热温度、加热时间、转运时间，保证了板材成型性和两种板材间熔融层的连接强度；并针对模压压力、保压时间、合模速度进行优化，以提高熔融层连接质量并避免了板材成型过程中出现褶皱问题。
附图说明
图1为本发明中发动机底护板剖面示意图。
图中：1-连续纤维增强热塑性材料层、2-熔接层、3-轻质热塑性增强材料层、4-PET无纺布层。
具体实施方式
下面结合具体实施例对本发明作进一步说明。
实施例1：
一种发动机底护板及其生产工艺，发动机底护板由连续纤维增强热塑性材料和轻质热塑性增强材料(LWRT)复合而成，包括如下步骤：
(1)加热：将连续纤维增强热塑性材料置于加热装置中加热，作用于板材表面的温度为200℃，加热时间45s；将轻质热塑性增强材料(LWRT)置于另一加热装置中加热，作用于板材表面的温度为220℃，加热时间60s；更进一步的，加热装置选用红外加热箱，已获得更为均匀的加热温度场；
(2)转运：第一转运步，将预热后的连续纤维增强热塑性材料通过自动化设备转运至模具中，转运时间为2s；第二转运步，将预热后的轻质热塑性增强材料(LWRT)通过自动化设备转运至模具中，转运时间为2s；第二转运步与第一转运步时间间隔为2s；更进一步的，转运装置为机械手配合真空吸盘抓取装置；
(3)铺放：首先，将预热后的连续纤维增强热塑性材料铺放于模具表面；而后，将预热后的轻质热塑性增强材料(LWRT)铺放于模具中，其覆盖于连续纤维增强热塑性材料上方；
(4)模压：末段合模速度为5mm/s，成型压力为20Mpa，成型保压时间为45s；
(5)裁切：将成型后的发动机底护板置于裁切模具中，裁切冲孔；
所述的发动机底护板由下至上依次包括连续纤维增强热塑性材料层、熔接层、轻质热塑性增强材料(LWRT)层、PET无纺布层。
进一步的，所述的连续续纤维增强热塑性材料层厚度为0.5mm，所述的轻质热塑性增强材料(LWRT)层厚度为3.0mm；
进一步的，所述的连续续纤维增强热塑性材料层面密度为600g/m2，所述的轻质热塑性增强材料(LWRT)层面密度为1600g/m2；
所述的连续纤维增强热塑性材料中基体为聚丙烯树脂(PP)；
进一步的，所述的连续续纤维增强热塑性材料中增强纤维为玻璃纤维；
更进一步的，所述的连续纤维增强热塑性材料层中增强纤维为2/2斜纹编织方式；所述的连续纤维增强热塑性材料由上层聚丙烯树脂膜、编织纤维层、下层聚丙烯树脂膜复合叠加，并经过浸渍而成；
更进一步的，所述的熔接层由连续纤维增强热塑性材料中聚丙烯树脂和轻质热塑性增强材料(LWRT)中聚丙烯纤维、短切玻璃纤维熔融组成；聚丙烯树脂和短切玻璃纤维熔融混合程度受板材预热程度、板材面密度和成型压力影响。
实施例2：
一种发动机底护板及其生产工艺，选用面密度为1200g/m2的连续续纤维增强热塑性材料，选用面密度为1400g/m2的轻质热塑性增强材料(LWRT)，将两种板材根据制品尺寸裁切至相应大小。
(1)加热：采用红外加热装置，将连续纤维增强热塑性材料置于加热装置中加热，作用于板材表面的温度为210℃，加热时间70s；将轻质热塑性增强材料(LWRT)置于另一红外加热装置中加热，作用于板材表面的温度为210℃，加热时间60s；
(2)转运：第一转运步，机械手配合真空吸盘抓取装置将预热后的连续纤维增强热塑性材料通过自动化设备转运至模具中，转运时间为3s；第二转运步，使用机械手配合真空吸盘抓取装置将预热后的轻质热塑性增强材料(LWRT)通过自动化设备转运至模具中，转运时间为2s；第二转运步与第一转运步时间间隔为2s；
(3)铺放：首先，将预热后的连续纤维增强热塑性材料铺放于模具表面；而后，将预热后的轻质热塑性增强材料(LWRT)铺放于模具中，其覆盖于连续纤维增强热塑性材料上方；
(4)模压：末段合模速度为5mm/s，成型压力为18Mpa，成型保压时间为60s；
(5)裁切：将成型后的发动机底护板置于裁切模具中，裁切冲孔；
进一步的，所述的连续续纤维增强热塑性材料中增强纤维为玻璃纤维；
以上所述是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明所述原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。
Claims (9)
1.一种发动机底护板，其特征在于，发动机底护板由连续纤维增强热塑性材料和轻质热塑性增强材料复合而成。
2.如权利要求1所述的一种发动机底护板，其特征在于，所述发动机底护板由下至上依次包括连续纤维增强热塑性材料层、熔接层、轻质热塑性增强材料层、PET无纺布层。
3.如权利要求2所述的一种发动机底护板，其特征在于，所述连续纤维增强热塑性材料层厚度为0.3mm～1.0mm，所述轻质热塑性增强材料层厚度为2.5mm～4.0mm。
4.如权利要求2所述的一种发动机底护板，其特征在于，所述连续纤维增强热塑性材料层面密度为600～1500g/m2，所述轻质热塑性增强材料层面密度为1200～1600g/m2。
5.如权利要求2所述的一种发动机底护板，其特征在于，所述连续纤维增强热塑性材料中基体为聚丙烯树脂。
6.如权利要求2所述的一种发动机底护板，其特征在于，所述连续纤维增强热塑性材料中增强纤维为玻璃纤维、玄武岩纤维、碳纤维中的任意一种。
7.如权利要求2所述的一种发动机底护板，其特征在于，所述连续纤维增强热塑性材料层中增强纤维为2/2斜纹编织方式。
8.如权利要求2所述的一种发动机底护板，其特征在于，所述熔接层由连续纤维增强热塑性材料中聚丙烯树脂和轻质热塑性增强材料中聚丙烯纤维、短切玻璃纤维熔融组成。
9.一种如权利要求1所述的发动机底护板的生产工艺，其特征在于，包括以下步骤：
(1)加热：将连续纤维增强热塑性材料置于加热装置中加热，作用于板材表面的温度控制在190℃～220℃之间，加热时间45s～90s；将轻质热塑性增强材料置于另一加热装置中加热，作用于板材表面的温度控制在200℃～230℃之间，加热时间50s～90s；
(2)转运：第一转运步，将预热后的连续纤维增强热塑性材料通过自动化设备转运至模具中，转运步长时间为2s～3s；第二转运步，将预热后的轻质热塑性增强材料通过自动化设备转运至模具中，转运步长时间为2s～5s；第二转运步与第一转运步时间间隔为2s～5s；
(3)铺放：首先，将预热后的连续纤维增强热塑性材料铺放于模具表面；而后，将预热后的轻质热塑性增强材料铺放于模具中，其覆盖于连续纤维增强热塑性材料上方；
(4)模压：末段合模速度为5mm/s，成型压力为15Mpa～20Mpa，成型保压时间为30s～90s，；
(5)裁切：将成型后的发动机底护板置于裁切模具中，裁切冲孔。
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