CN111267455A

CN111267455A - Automobile top cover made of honeycomb material

Info

Publication number: CN111267455A
Application number: CN201911140632.7A
Authority: CN
Inventors: 邹峰; 朱玉满; 秦玉洁; 郑文强; 梁卫兴
Original assignee: Plastic Omnium SE
Current assignee: Plastic Omnium SE
Priority date: 2019-11-20
Filing date: 2019-11-20
Publication date: 2020-06-12

Abstract

The invention relates to an automobile roof made of honeycomb materials, which comprises a honeycomb core, a glass fiber felt and a plastic outer plate, wherein the honeycomb core is of a cellular structure, the glass fiber felt comprises a first glass fiber felt layer and a second glass fiber felt layer which are respectively positioned on two sides of the honeycomb core, and the plastic outer plate is connected on the first glass fiber felt layer. According to the invention, the automobile roof uses the honeycomb material to replace the traditional sheet metal material, so that the automobile roof has lighter weight and can achieve good lightweight effect. Moreover, the strength and rigidity of the automobile roof according to the present invention can not only meet the basic requirements of relevant legislation on automobile roofs, but also be superior to conventional sheet metal automobile roofs. In addition, the automobile roof is not easy to corrode and rust, and has better sound insulation effect.

Description

Automobile top cover made of honeycomb material

Technical Field

The present invention relates to automotive roofs, and more particularly to automotive roofs of honeycomb material.

Background

Automobiles are the most common vehicles in modern society, and with the continuous development of the automobile industry and the maturing of the consumer market, the requirements of people on the comfort and the safety of automobiles are higher and higher.

At present, in the motorcycle type on the market, vapour car roof often forms by the panel beating, and the panel beating passes through welded fastening on the automobile body. The thickness of the sheet metal outer plate of the common automobile roof is 0.7mm-0.8mm, and a reinforcing beam is required to be added in the outer plate to ensure the strength of the roof. Meanwhile, in order to meet the comfort requirement of passengers, an interior ceiling is required to be added in the cabin to ensure the attractiveness of the interior. And an energy absorption block or sound absorption cotton is added between the interior ceiling and the top cover outer plate to ensure the noise reduction effect of the cabin. Obviously, such conventional sheet metal roofs suffer from several disadvantages: the sheet metal appearance part needs electrophoresis treatment, and if the process treatment is not good, the vehicle roof is easy to rust in a long-term salt spray environment; the sheet metal outer plate is thin and is easy to deform in an impact state; the sound insulation effect of the metal plate is poor; because the restriction that the panel beating chooseed steel for use, can't reach the purpose of lightweight.

Disclosure of Invention

In order to solve the problems that the self weight of a sheet metal top cover in the prior art is large and the like, the invention provides an automobile top cover made of a honeycomb material.

The invention provides an automobile roof made of a honeycomb material, which comprises a honeycomb core, a glass fiber felt and a plastic outer plate, wherein the honeycomb core is of a cellular structure, the glass fiber felt comprises a first glass fiber felt layer and a second glass fiber felt layer which are respectively positioned on two sides of the honeycomb core, and the plastic outer plate is connected on the first glass fiber felt layer.

Preferably, the vehicle roof further comprises an inner cladding layer connected to the second fiberglass mat layer.

Preferably, the inner coating is a fabric felt or felt.

Preferably, the cross-section of the constituent cells of the honeycomb core is in the shape of a diamond, a hexagon, a rectangle, a sine curve, or a regular octagon and a regular quadrilateral mosaic.

Preferably, the thickness of the honeycomb core is 7-22 mm.

Preferably, the glass fiber content of the glass fiber mat is between 30 wt% and 60 wt%.

Preferably, the thickness of the plastic outer plate is 1.2-2.0 mm.

Preferably, the connection of the vehicle roof and the vehicle body is effected by gluing and/or fastening.

According to the invention, the automobile roof uses the honeycomb material to replace the traditional sheet metal material, so that the automobile roof has lighter weight and can achieve good lightweight effect. Moreover, the strength and rigidity of the automobile roof according to the present invention can not only meet the basic requirements of relevant legislation on automobile roofs, but also be superior to conventional sheet metal automobile roofs. In addition, the automobile roof is not easy to corrode and rust, and has better sound insulation effect.

Drawings

FIG. 1 is a schematic illustration of a vehicle roof of honeycomb material according to a preferred embodiment of the present invention;

FIG. 2A is one example of a cross-section of a constituent cell of the honeycomb core of FIG. 1;

FIG. 2B is another example of a cross-section of a constituent cell of the honeycomb core of FIG. 1;

FIG. 2C is yet another example of a cross-section of a component cell of the honeycomb core of FIG. 1;

FIG. 2D is yet another example of a cross-section of a constituent cell of the honeycomb core of FIG. 1;

FIG. 2E is yet another example of a cross-section of a constituent cell of the honeycomb core of FIG. 1;

FIG. 3 illustrates the connection of the vehicle roof to the vehicle body of FIG. 1;

FIG. 4 is a schematic illustration of a vehicle roof of honeycomb material according to another preferred embodiment of the present invention;

fig. 5 shows the connection of the vehicle roof to the vehicle body of fig. 4.

Detailed Description

The preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

In this context, honeycomb material refers to a material consisting of cells shaped like a honeycomb, while honeycomb structure refers to a sandwich structure, the core layer of which consists of cells shaped like a honeycomb, with further layer structures being connected above and/or below the core layer.

As shown in fig. 1, an automobile roof 6 of a honeycomb material according to a preferred embodiment of the present invention includes a honeycomb core 1, a glass fiber mat 2, and an outer plastic sheet 3, wherein the glass fiber mat 2 includes a first glass fiber mat layer 21 and a second glass fiber mat layer 22 on both sides of the honeycomb core 1, respectively, and the outer plastic sheet 3 is attached to the first glass fiber mat layer 21.

The honeycomb core 1 may be a metal core material, such as a cell structure formed of aluminum or an aluminum alloy. The honeycomb core 1 may also be a non-metallic core material, such as a cellular structure formed of glass reinforced plastic, paper or foam. In this embodiment, the honeycomb core 1 is corrugated paper. In addition, the cross section of the constituent cells of the honeycomb core 1 may be any polygonal shape, such as a diamond shape of fig. 2A, a hexagonal shape of fig. 2B, a rectangular shape of fig. 2C, a sinusoidal shape of fig. 2D, a regular octagonal shape of fig. 2E, and a regular quadrangular mosaic shape. In the present embodiment, the cross-section of the unit cells of the honeycomb core 1 is regular hexagon, which not only is relatively simple to manufacture, saves more material, but also has higher strength. The thickness of the honeycomb core 1 is preferably 7 to 22 mm. In the present embodiment, the thickness of the honeycomb core 1 is 12 mm.

Wherein the glass fiber mat 2 may be a chopped glass fiber mat to reinforce the connection strength between the plastic outer plate 3 and the honeycomb core 1. The first glass fiber felt layer 21 and the second glass fiber felt layer 22 are respectively covered on two sides of the honeycomb core 1 and are compositely adhered together by mould pressing. In particular, the glass fiber content of the glass fiber mat 2 is between 30 wt% and 60 wt%.

The plastic outer plate 3 is generally a co-extruded composite plate, and the material may be polypropylene (PP material), or a mixture of polycarbonate and acrylonitrile-butadiene-styrene (PC + ABS material), or other similar thermoplastic materials such as polymethyl methacrylate (PMMA material). The plastic outer plate 3 is covered on the first glass fiber felt layer 21 and is compositely stuck together by mould pressing. The thickness of the plastic outer plate 3 is preferably 1.2 to 2.0 mm. In the present embodiment, the thickness of the plastic outer panel 3 is 1.6 mm.

The automobile roof panel 6 of honeycomb material of the present embodiment may be formed by a wet process. Specifically, a glass fiber mat 2 is dipped between the glass fiber mat 2 and the honeycomb core 1 (preferably polyurethane here), the glass fiber mat 2 is simply laid on both sides of the honeycomb core 1, then the plastic outer plate 3 is put on the first glass fiber mat layer 21, and then the first glass fiber mat layer is put into a mold cavity to be heated and pressurized, so that the first glass fiber mat layer is cured and molded.

The automobile roof panel 6 of the honeycomb material of the present embodiment may be formed by a dry process. Specifically, a first glass fiber mat layer 21 is laid between the plastic outer plate 3 and the honeycomb core 1, a second glass fiber mat layer 22 is laid on the other side of the honeycomb core 1, and then the materials are sent to a mold cavity to be heated and pressurized, so that the materials are solidified and molded.

In the embodiment, the honeycomb core 1, the glass fiber mat 2 and the plastic outer panel 3 are equivalent to a sheet metal outer panel and a roof reinforcing beam in a conventional automobile roof, and a conventional interior ceiling can be added in a cabin to ensure the beauty of the interior. Obviously, the automobile roof cover uses the honeycomb material to replace the traditional sheet metal material, has lighter weight and can achieve good lightweight effect.

As shown in fig. 3, the molded honeycomb roof 6 is assembled with the vehicle body 5 and fastened to the vehicle body by means of an adhesive 7, and is sealed and waterproof.

As shown in fig. 4, an automobile roof 60 of a honeycomb material according to another preferred embodiment of the present invention includes a honeycomb core 10, a glass fiber mat 20, an outer plastic sheet 30, and an inner cladding 40, wherein the glass fiber mat 20 includes a first glass fiber mat layer 210 and a second glass fiber mat layer 220 respectively located at both sides of the honeycomb core 10, the outer plastic sheet 30 is attached to the first glass fiber mat layer 210, and the inner cladding 40 is attached to the second glass fiber mat layer 220.

The honeycomb core 10 may be a metal core material such as aluminum or an aluminum alloy, among others. The honeycomb core 10 may also be a non-metallic core material such as fiberglass, plastic, paper, or foam. In the present embodiment, the honeycomb core 10 is corrugated paper. In addition, the cross-section of the constituent cells of the honeycomb core 10 may be any polygonal shape, such as a diamond shape, a hexagonal shape, a rectangular shape, a sinusoidal shape, a regular octagonal shape, and a regular quadrangular mosaic shape. In the present embodiment, the honeycomb core 10 has a regular hexagonal cross-section, which is relatively simple to manufacture, uses less material, and has higher strength. The thickness of the honeycomb core 10 is preferably 7 to 22 mm. In the present embodiment, the thickness of the honeycomb core 1 is 12 mm.

Among them, the glass fiber mat 20 may be a chopped glass fiber mat to reinforce the coupling strength between the plastic outer sheet 30 and the honeycomb core 10 and the coupling strength between the inner clad 40 and the honeycomb core 10. The first glass fiber mat layer 210 and the second glass fiber mat layer 220 are respectively covered on two sides of the honeycomb core 10 and are compositely adhered together by mould pressing. In particular, the glass fiber content of the glass fiber mat 20 is between 30 wt% and 60 wt%.

The plastic outer plate 30 is generally a co-extruded composite plate, and the material may be polypropylene (PP material), or a mixture of polycarbonate and acrylonitrile-butadiene-styrene (PC + ABS material), or other similar thermoplastic materials such as polymethyl methacrylate (PMMA material). The plastic outer plate 30 is covered on the first glass fiber felt layer 210 and is compositely adhered together by molding. The thickness of the plastic outer panel 30 is preferably 1.2 to 2.0 mm. In the present embodiment, the thickness of the plastic outer panel 30 is 1.6 mm.

The inner coating layer 40 may be a fabric felt or a felt. The plastic outer plate 30 is covered on the second glass fiber felt layer 220 and is compositely adhered together by molding.

The automobile roof of the honeycomb material of the present embodiment may be formed by a wet process. Specifically, a glass fiber mat 20 is dipped between the glass fiber mat 20 and the honeycomb core 10 (preferably polyurethane here), the glass fiber mat 20 is simply laid on both sides of the honeycomb core 10, then the plastic outer sheet 30 is put on the first glass fiber mat layer 210, and then the first glass fiber mat layer is put into a mold cavity to be heated and pressurized, so that the first glass fiber mat layer is cured and molded. And (3) covering the inner cladding layer 40 on the second glass fiber felt layer 220, then putting the second glass fiber felt layer into a mold cavity, heating and pressurizing to perform secondary curing molding, and finally demolding and finishing.

The automobile roof of the honeycomb material of the present embodiment may be formed by a dry process. Specifically, a first glass fiber mat layer 210 is laid between the plastic outer plate 30 and the honeycomb core 10, a second glass fiber mat layer 220 is laid on the other side of the honeycomb core 10, and the materials are conveyed to a mold cavity to be heated and pressurized, so that the materials are cured and molded. And (3) covering the inner cladding layer 40 on the second glass fiber felt layer 220, then putting the second glass fiber felt layer into a mold cavity, heating and pressurizing to perform secondary curing molding, and finally demolding and finishing.

In the present embodiment, the honeycomb core 10, the glass fiber mat 20, the plastic outer panel 30, and the inner cladding 40 correspond to a sheet metal outer panel, a roof reinforcing beam, and an interior roof in a conventional automobile roof. Thus, the automobile roof cover of the present embodiment integrates a plurality of parts into one part, with significantly reduced production costs. Obviously, the automobile roof cover uses the honeycomb material to replace the traditional sheet metal material, has lighter weight and can achieve good lightweight effect.

As shown in fig. 5, the assembly of the molded honeycomb roof 60 and the body 50 is performed by sealing with the bead 8 and fastening the roof 60 and the body 50 with a fastener.

Specific strength refers to the ratio of the strength of a material to the apparent density. The strength of the traditional top cover sheet metal is generally about 300N/m, the strength of the honeycomb plate is greatly different according to the difference between the honeycomb core material and the thickness, for example, the strength of a corrugated honeycomb plate with 10mm is 280N/m, and honeycomb plates with other materials or thicknesses have higher strength. The apparent density of the sheet metal is larger than that of the honeycomb material, so the honeycomb material has better specific strength.

Specific stiffness refers to the ratio of the elastic modulus of a material to its density. The elastic modulus of the traditional top cover sheet metal is 210GPa, while the elastic modulus of the plate of the honeycomb material is generally more than 300GPa, so the honeycomb material has better specific strength.

The following table shows the comparison of the properties of a conventional sheet metal vehicle roof and a vehicle roof according to the invention:

obviously, the strength and rigidity of the automobile roof according to the present invention not only can satisfy the basic requirements of relevant regulations of automobile roofs, but also are superior to those of conventional sheet metal automobile roofs.

Moreover, the automobile top cover is not easy to corrode and rust, has a better sound insulation effect, and can greatly reduce the weight of the top cover.

The above embodiments are merely preferred embodiments of the present invention, which are not intended to limit the scope of the present invention, and various changes may be made in the above embodiments of the present invention. All simple and equivalent changes and modifications made according to the claims and the content of the specification of the present application fall within the scope of the claims of the present patent application. The invention has not been described in detail in order to avoid obscuring the invention.

Claims

1. The automobile roof cover made of the honeycomb material is characterized by comprising a honeycomb core, a glass fiber felt and a plastic outer plate, wherein the honeycomb core is of a cellular structure, the glass fiber felt comprises a first glass fiber felt layer and a second glass fiber felt layer which are respectively positioned on two sides of the honeycomb core, and the plastic outer plate is connected to the first glass fiber felt layer.

2. The vehicle roof of claim 1, further comprising an inner cladding layer connected to the second fiberglass mat layer.

3. The vehicle roof cover of claim 2, wherein the inner cladding layer is a fabric felt or a felt.

4. The automobile roof panel according to claim 1, wherein the constituent cells of the honeycomb core have a diamond shape, a hexagonal shape, a rectangular shape, a sinusoidal shape, or a regular octagonal and regular quadrilateral mosaic shape in cross section.

5. The automobile roof cover according to claim 1, wherein the honeycomb core has a thickness of 7 to 22 mm.

6. The automotive roof cover of claim 1, wherein the glass fiber mat has a glass fiber content of between 30 wt.% and 60 wt.%.

7. The automobile roof cover according to claim 1, wherein the plastic outer panel has a thickness of 1.2 to 2.0 mm.

8. The vehicle roof according to claim 1, characterized in that the connection of the vehicle roof to the vehicle body is effected by gluing and/or fastening.