Fiber composite material and preparation method therefor, protective structural member, and vehicle

Abstract

A fiber composite material and a preparation method therefor, a protective structural member, and a vehicle. The fiber composite material comprises: a plurality of fiber layers; and a resin matrix, wherein the resin matrix infiltrates the plurality of fiber layers by undergoing high-pressure resin transfer molding together with the plurality of fiber layers.

Description

Fiber composite material, preparation method thereof, protective structural member and vehicle

[0001] Cross-reference to Related Applications

[0002] The present application claims priority to the Chinese Patent Application No. 202410601094.1, filed on May 15, 2024, entitled “Fiber composite material, preparation method thereof, protective structural member and vehicle”, the entire contents of which are incorporated herein by reference. TECHNICAL FIELD

[0003] The present application relates to the technical field of vehicles, and in particular to a fiber composite material, a preparation method thereof, a protective structural member and a vehicle. BACKGROUND

[0004] At present, the protective structure in the vehicle mainly uses metal parts (such as metal plates, etc.), which leads to a large weight of the vehicle.

[0005] In the related art, the composite material used in the vehicle is mainly a fiber-reinforced thermosetting composite material, which leads to a large brittleness and poor impact resistance of the structural member, limiting the use of the composite material structural member in the protective component. At the same time, the fiber-reinforced elastomer composite structural member is mainly prepared by the method of spraying first and then molding, the resin is not uniformly mixed, and the porosity is large, which is not conducive to improving the overall impact resistance of the material.

[0006] SUMMARY

[0007] The present application aims to at least solve one of the technical problems in the related art to some extent.

[0008] One purpose of the present application is to provide a fiber composite material with high structural strength and good impact resistance.

[0009] According to the fiber composite material of the first aspect of the present application, the fiber composite material comprises: a plurality of fiber layers; and a resin matrix, the resin matrix and the plurality of fiber layers are infiltrated by high-pressure resin transfer molding.

[0010] In the present application, the resin and the plurality of fiber layers are prepared by a high-pressure resin transfer molding process to form a resin matrix on the plurality of fiber layers. The fiber composite material in the present application has good mechanical properties, good impact resistance, wear resistance, aging resistance and corrosion resistance, can meet the use requirements of vehicle collision resistance and wear resistance, and does not need to be provided with a metal reinforcing structure, so that the weight can be reduced while the mechanical properties of the fiber composite material are ensured. At the same time, in the preparation process of the fiber composite material in the present application, the raw material utilization rate is high, the forming process is simple, the forming time and manufacturing cost can be reduced, and the production efficiency can be improved.

[0011] The protective structure according to the second aspect of the present application comprises an embedding member and the fiber composite material as described above. The embedding member is embedded in the plurality of fiber layers along the stacking direction of the plurality of fiber layers.

[0012] The vehicle according to the third aspect of the present application comprises the fiber composite material or the protective structure as described above.

[0013] The method for preparing the fiber composite material according to the fourth aspect of the present application comprises a fiber preform and a resin matrix. The method comprises placing the fiber preform in a mold, and after the mold is closed and vacuumized, injecting a resin material into the fiber preform, and the resin material is high-pressure resin transfer molded with the fiber preform.

[0014] Additional aspects and advantages of the present application will be made apparent from the following description. BRIEF DESCRIPTION OF DRAWINGS

[0015] Fig. 1 is a sectional view of a fiber composite material according to a first embodiment of the present application;

[0016] Fig. 2 is a sectional view of a fiber composite material according to a second embodiment of the present application;

[0017] Fig. 3 is a sectional view of a fiber composite material according to a third embodiment of the present application;

[0018] Fig. 4 is a sectional view of a fiber preform according to an embodiment of the present application;

[0019] Fig. 5 is a schematic view of fiber layer layup one according to an embodiment of the present application;

[0020] Fig. 6 is a schematic view of fiber layer layup two according to an embodiment of the present application;

[0021] Fig. 7 is a schematic view of fiber layer layup three according to an embodiment of the present application;

[0022] Fig. 8 is a schematic view of fiber layer layup four according to an embodiment of the present application;

[0023] Fig. 9 is a schematic view of a fiber layer according to an embodiment of the present application. DETAILED DESCRIPTION

[0024] The embodiments of the present application are described in detail below with reference to the accompanying drawings, wherein the same or similar components are denoted by the same or similar reference numerals throughout. The embodiments described below are exemplary only, and are merely intended to explain the present application, and should not be understood as limiting the present application.

[0025] The fiber composite material 100 according to the embodiments of the present application is described below with reference to FIGS. 1-9. The fiber composite material 100 according to the embodiments of the present application is applied to a vehicle, and can be configured as a vehicle floor, a battery pack bottom guard plate, a battery pack side guard plate, a battery pack cover plate, a battery pack protection beam, a battery pack tray, a battery pack shell, a crash beam (e.g., a front crash beam, a rear crash beam), a bumper (a front bumper, a rear bumper), a trunk cover plate, a motor shell, a motor guard plate, a pedal (e.g., a throttle pedal, a brake pedal, etc.), and an energy absorption box, etc., which are structural components of a vehicle that are prone to impact or wear.

[0026] The fiber composite material 100 according to the embodiments of the present application includes a resin matrix and a plurality of fiber layers 1, and the resin matrix infiltrates the plurality of fiber layers 1 by high-pressure resin transfer molding.

[0027] The plurality of fiber layers 1 are stacked to form a fiber preform 10 by stacking the plurality of fiber layers 1, and the resin matrix infiltrates the plurality of fiber layers 1 by high-pressure resin transfer molding of the fiber preform 10, thereby obtaining a fiber composite material 100 with good impact resistance, wear resistance, and aging resistance.

[0028] The resin matrix is resin formed on the fiber preform 10 by a high-pressure resin transfer molding process. The resin impregnates the reinforcing fibers and is cured to form a structure after the resin fully infiltrates the fibers. The fiber layer 1 refers to a structural layer formed by fibers 101, and is not limited to a fiber structure composed of a single layer of fibers 101, but also includes a fiber structure formed by interlacing the fibers 101.

[0029] In the present application, the plurality of fiber layers 1 are first stacked to form a fiber preform 10, and the fiber composite material 100 is formed by resin molding with the fiber preform 10, so that the resin can fully infiltrate the fiber preform 10, and the mechanical properties of the fiber composite material 100 can be improved, and the quality of the fiber composite material 100 is more easily controlled.

[0030] The fiber composite material 100 in the application is formed by a high pressure resin transfer molding (HP-RTM) process. The resin is mixed and injected into the mold under high pressure. The resin can fully impregnate the fiber preform 10 in the mold under the action of high pressure. The resin can impregnate the fibers 101 in the fiber preform 10 and coat the fibers 101, thereby improving the mechanical properties of the fiber composite material 100. At the same time, when the fiber composite material 100 is prepared by the high pressure resin transfer molding process, there is basically no release of small molecule volatile substances in the forming process of the fiber composite material 100, which is environmentally friendly and environmentally friendly. In addition, the raw material utilization rate of the protective part can be improved, and the forming process is simple, which can reduce the forming time and manufacturing cost of the fiber composite material 100, and meet the production demand of high efficiency and batch.

[0031] At present, the protective structure in the vehicle is mostly made of metal parts (such as metal plates, etc.), which results in a large weight of the vehicle. In the related art, the composite material used in the vehicle is mainly a fiber-reinforced thermosetting composite material, which results in a large brittleness and poor impact resistance of the structural part, thereby limiting the use of the composite material structural part in the protective part. At the same time, the fiber-reinforced elastomer composite structural part is mostly prepared by the method of spraying first and molding later. The resin is not uniformly mixed, and the porosity is large, which is not conducive to improving the overall impact resistance of the material.

[0032] In the application, a plurality of fiber layers 1 are arranged in layers to form a fiber preform 10, and a resin is prepared into a fiber composite material 100 by a high pressure resin transfer molding process. The resin impregnates the fiber preform 10 and forms a resin matrix after curing. The fiber composite material 100 in the application has good mechanical properties, good impact resistance, wear resistance, aging resistance, and corrosion resistance, and can meet the use requirements of vehicle impact resistance and wear resistance. In addition, the fiber composite material 100 does not need to be provided with a metal reinforcing structure, and the weight can be reduced while the mechanical properties of the fiber composite material 100 are ensured. At the same time, the raw material utilization rate is high during the preparation of the fiber composite material 100 in the application, the forming process is simple, the forming time and manufacturing cost can be reduced, and the production efficiency can be improved.

[0033] In the application, the fiber composite material 100 is formed by a high pressure resin transfer molding process.

[0034] When the fiber preform 10 is arranged in the mold, the resin injection pressure is 0-25 MPa (for example, 10 MPa-25 MPa). When the resin injection pressure reaches the above parameter range, the resin can be uniformly mixed, the mold can be filled faster, and the resin can impregnate the fibers well. The fiber composite material 100 can significantly reduce the air bubbles and reduce the porosity of the fiber composite material 100.

[0035] The resin injection time is 5s-180s (for example: 10s-30s).

[0036] The production and molding steps of the fiber composite material 100 in the present application are as follows: a plurality of fiber layers 1 are stacked to form a fiber preform 10, the fiber preform 10 is arranged in a mold, the mold is closed and vacuumized, and the resin (for example: two reaction components of isocyanate and amino compound) is injected under pressure, rapid reaction and polymerization, and continues to be pressure-keeping so that the resin fully infiltrates the fiber preform 10 under pressure, and finally solidifies and demolds to obtain the fiber composite material 100.

[0037] Compared with the prior art, the fiber composite material 100 in the present application is lighter in quality and has better impact resistance and wear resistance.

[0038] The fiber preform 10 is formed by stacking a plurality of fiber layers 1 in the thickness direction, so as to obtain the fiber preform 10 by stacking a plurality of fiber layers 1.

[0039] As shown in FIGS. 5, 6 and 7, in some embodiments of the present application, the fiber layer 1 includes at least one of a unidirectional fiber layer 11 and a fiber fabric layer 12. The fiber preform 10 is formed by stacking at least one of the unidirectional fiber layer 11 and the fiber fabric layer 12, and by stacking a plurality of fiber layers 1 (unidirectional fiber layer 11 or fiber fabric layer 12), the impact resistance of the fiber composite material 100 can be improved.

[0040] It should be understood that the fiber fabric layer 12 is a structure layer formed by weaving the fibers 101, and the fiber fabric layer 12 can be formed by weaving a plurality of fibers 101, and the weaving method of the fiber fabric layer 12 is not specifically limited herein.

[0041] Referring to FIG. 5, the fiber fabric layer 12 has a plurality of fibers 101 arranged in an interlaced manner; referring to FIG. 6, the unidirectional fiber layer 11 has a plurality of fibers 101 extending in the same direction and arranged in sequence. The fiber fabric layer 12 is a structure formed by weaving the fibers 101.

[0042] Due to the different arrangement of the fibers 101 in the fiber fabric layer 12 and the unidirectional fiber layer 11, the transmission and buffering of the impact force when the fiber fabric layer 12 and the unidirectional fiber layer 11 are impacted are also different, so that the fiber layer 1 can be configured as the fiber fabric layer 12 or the unidirectional fiber layer 11 according to the buffering requirement of the impact force, so as to improve the buffering effect of the fiber composite material 100 on the impact force.

[0043] Referring to FIG. 5, the fiber preform 10 is formed by stacking a plurality of fiber fabric layers 12; referring to FIG. 6, the fiber preform 10 is formed by stacking a plurality of unidirectional fiber layers 11; referring to FIG. 7, the fiber preform 10 is formed by stacking the fiber fabric layers 12 and the unidirectional fiber layers 11 together. Thus, the arrangement of the fiber layers 1 can be designed to improve the cushioning effect of the fiber composite material 100 against impact forces in different directions.

[0044] As shown in FIG. 6, in some embodiments of the present application, the fiber layers 1 include a plurality of unidirectional fiber layers 11, and the fiber preform 10 is formed by stacking the plurality of unidirectional fiber layers 11.

[0045] Referring to FIG. 6, in the plurality of unidirectional fiber layers 11, the fibers 101 in two adjacent unidirectional fiber layers 11 extend in parallel to each other. In the example shown in FIG. 6, the fibers 101 in the unidirectional fiber layers 11 extend in the width direction of the fiber preform 10 (also the left-right direction in FIG. 6) and are arranged in sequence in the length direction of the fiber preform 10, which can improve the impact resistance of the fiber preform 10. In this case,

[0046] Referring to FIG. 6, in the projection in the stacking direction, the fibers 101 in two adjacent unidirectional fiber layers 11 extend at an included angle, and the included angle a satisfies the relationship: 45°≤a≤90°.

[0047] In the example shown in FIG. 6, the fibers 101 in the two unidirectional fiber layers 11 extend in the length direction and the width direction of the fiber preform 10, respectively, that is, the fibers 101 in the two stacked unidirectional fiber layers 11 are arranged perpendicular to each other, which can improve the impact resistance of the fiber preform 10 in multiple directions.

[0048] The fiber preform 10 is usually arranged to be subjected to impact forces in the thickness direction (i.e., the stacking direction of the fiber layers 1). Since the unidirectional fiber layers 11 have different cushioning effects against impact forces in different directions, the arrangement of the fiber layers 1 can be designed according to the direction of the impact forces to which the fiber composite material 100 is likely to be subjected when the fiber composite material 100 is applied, to improve the impact resistance of the fiber composite material 100.

[0049] As shown in FIG. 3 and FIG. 9, in some embodiments of the present application, the fiber composite material 100 is provided with a reinforcing rib 4, and the reinforcing rib 4 is arranged on the fiber layer 1 located at the outermost side in the stacking direction, such as the unidirectional fiber layer 11 or the fiber fabric layer 12, to improve the impact resistance of the fiber composite material 100.

[0050] As shown in FIG. 3, in some embodiments of the present application, the reinforcing rib 4 is arranged on the fiber fabric layer 12, and in the stacking direction, at least one fiber fabric layer 12 is arranged at the outermost side of the plurality of fiber layers 1, and the outer side surface of the outermost fiber fabric layer 12 is provided with the reinforcing rib 4, so as to form the reinforcing rib 4 on the outer side surface of the fiber composite material 100, improve the impact resistance of the outer side area of the fiber composite material 100, and prevent interference between the reinforcing rib 4 and other fiber layers 1, thereby facilitating the molding of the fiber preform 10.

[0051] As shown in FIG. 9, in some embodiments of the present application, the fiber composite material 100 is provided with a plurality of reinforcing ribs 4, and the plurality of reinforcing ribs 4 are arranged in a staggered manner to improve the strength of the fiber composite material 100. The reinforcing ribs 4 are arranged perpendicular to each other, for example, arranged in a "cross" staggered manner.

[0052] As shown in FIGS. 2 and 8, in some embodiments of the present application, the fiber composite material 100 further comprises a core layer 3, which is arranged between two fiber layers 1 in the stacking direction of the plurality of fiber layers 1. By arranging the core layer 3, the stiffness of the fiber composite material 100 can be improved. By arranging the core layer 3, the complex impact force can be better resisted, and the impact resistance of the fiber composite material 100 can be improved.

[0053] Referring to FIGS. 2 and 8, in the stacking direction of the fiber layers 1, the core layer 3 is arranged in the middle of the fiber preform 10, that is, the core layer 3 is arranged on both sides in the stacking direction and is provided with fiber layers 1, and the fiber preform 10 is provided with at least two fiber layers 1, and the two fiber layers 1 are arranged on both sides of the core layer 3.

[0054] In some embodiments of the present application, the core layer 3 is configured as a foam structure. The foam structure has the advantages of light weight and high strength, and can improve the strength of the fiber composite material 100 while reducing the weight of the fiber composite material 100.

[0055] In the embodiments of the present application, the foam structure comprises at least one of polyethylene foam, light wood material (i.e. light wood), foamed aluminum, foamed magnesium, polypropylene foam and polyurethane foam. That is, the foam structure can be made of one of polyethylene foam, light wood material (i.e. light wood), foamed aluminum and polyurethane foam, and can also be made of a plurality of polyethylene foam, light wood material (i.e. light wood), foamed aluminum and polyurethane foam, so that the foam structure has the advantages of high strength, good cushioning performance, easy molding and light weight (small density).

[0056] In some other embodiments of the present application, the core layer 3 is configured as a dot matrix structure, so as to ensure the structural strength of the core layer 3. The dot matrix structure includes a two-dimensional dot matrix structure and a three-dimensional dot matrix structure.

[0057] The lattice structure is configured as one of a honeycomb structure, a polygonal structure, a cross structure, and a polyhedral structure. Referring to FIG. 2, the lattice structure is configured as a honeycomb structure, and the honeycomb structure reserves a mounting area for arranging the embedded part 2.

[0058] In some embodiments of the present application, the material of the lattice structure includes at least one of an aluminum alloy, a fiber reinforced polymer (FRP), aramid, polypropylene, and ultra-high molecular weight polyethylene. Among them, the FRP composite material is a high-performance material formed by mixing the fiber material and the matrix material (resin) in a certain proportion, so as to ensure the strength of the lattice structure.

[0059] The lattice structure can be made of the above-mentioned materials, so as to ensure the strength of the lattice structure while preventing the weight of the lattice structure from being too high, and meet the lightweight design requirements of the protection assembly. Among them, the core layer 3 can be composed of a plurality of lattice structures spliced.

[0060] In some embodiments of the present application, the resin matrix is made of an elastomer resin material, and the elastomer resin material includes at least one of polyurethane, polyurea, semi-polyurea, silicone resin, and ethylene-propylene rubber.

[0061] The elastomer resin material includes but is not limited to the above-mentioned materials.

[0062] Compared with the prior art in which only resin materials (such as polyurethane) are used as the coating skin of the structural part, the resin matrix is fully matched with the fiber preform 10 in the present application, so as to improve the structural strength and impact resistance of the fiber composite material 100.

[0063] In some embodiments of the present application, the fiber material in the fiber layer 1 includes at least one of carbon fiber, glass fiber, aramid fiber, basalt fiber, ultra-high molecular weight polyethylene fiber, and boron nitride fiber.

[0064] Referring to FIG. 1, in the first embodiment of the present application, the fiber composite material 100 is configured as a battery pack bottom guard plate of a vehicle.

[0065] The plurality of fiber layers 1 include a unidirectional fiber layer 11 and a fiber fabric layer 12, the unidirectional fiber layer 11 and the fiber fabric layer 12 are laid by hybrid laying, and the plurality of fiber layers 1 are embedded with the embedded part 2 (such as a metal embedded part).

[0066] As shown in FIG. 1, the fiber layer 1 is six layers, and the six-layer fiber layer 1 includes two layers of fiber fabric layers 12 and four layers of unidirectional fiber layers 11. The two layers of fiber fabric layers 12 are arranged on both sides in the stacking direction, i.e., the upper and lower fiber layers 1 are fiber fabric layers 12, and the four layers of unidirectional fiber layers 11 are stacked between the two layers of fiber fabric layers 12, and the middle four layers of unidirectional fiber layers 11 are arranged in a normal direction.

[0067] The layering sequence of the six-layer fiber layer 1 is in turn: a fiber fabric layer 12, a unidirectional fiber layer 11 arranged at 90°, two layers of unidirectional fiber layers 11 at 0°, a unidirectional fiber layer 11 arranged at 90°, and a fiber fabric layer 12.

[0068] The fiber layer 1 is stacked and cut into a battery pack bottom guard shape according to the above sequence, and the fiber layer 1 after cutting embeds the embedding member 2 in the fiber layer 1 to obtain a fiber preform 10. The fiber preform 10 is arranged in a mold and then transferred to a molding device (such as a high-pressure resin transfer molding (HR-RTM) machine), the mold is closed and vacuumized, and two reaction components of isocyanate and amino compound are injected at a pressure of 10-25 MPa. The reaction component injection can be completed in about 25 s, and the two reaction components are fully mixed and polymerized in the mold cavity under vacuum. The pressure is continuously maintained, and the resin (such as polyurea resin) fully impregnates the fiber layer 1 under pressure and solidifies to obtain a battery pack bottom guard.

[0069] In the first embodiment, the fiber preform 10 adopts a hybrid layering structure of unidirectional fiber layers 11 and fiber fabric layers 12, which can improve the effect of the battery pack bottom guard resisting complex impact forces, and the resin is injected and formed by the HP-RTM process, which can fully impregnate the fibers and better play the advantages of the resin matrix when subjected to impact forces.

[0070] The fiber fabric layer 12 is configured as a glass fiber cloth, and the unidirectional fiber layer 11 is configured as a glass fiber unidirectional tape.

[0071] In the first embodiment, the thickness of the battery pack bottom guard is 4 mm, which can resist 400 J of energy without penetration in the drop hammer impact test, and the deformation of the battery pack bottom guard caused by impact can be partially recovered.

[0072] Referring to FIG. 2, in the second embodiment of the present application, the fiber composite material 100 is configured as a motor lower guard.

[0073] The plurality of fiber layers 1 include a plurality of fiber fabric layers 12, the plurality of fiber fabric layers 12 have embedding members 2 (such as metal inserts) embedded therein, and a core layer 3 is arranged between the fiber fabric layers 12.

[0074] As shown in FIG. 2, the fiber layer 1 is four layers, and the four layers of fiber layer 1 are all fiber fabric layers 12. In the stacking direction, two layers of fiber fabric layers 12 (such as glass fiber cloth) are arranged on both sides of the core layer 3. The core layer 3 is configured as an aluminum honeycomb core with a three-dimensional lattice structure to improve the stiffness of the core layer 3.

[0075] The fiber layer 1 is stacked and cut into a battery pack bottom guard plate shape in the above order, and the fiber layer 1 after cutting embeds the embedding piece 2 in the fiber layer 1 to obtain a fiber preform 10. The fiber preform 10 is arranged in a mold and then transferred to a molding device (such as a high-pressure resin transfer molding (HR-RTM) machine) together. The mold is vacuumed, and the two reaction components of isocyanate and amino compound are injected at a pressure of 10-25 MPa. The reaction component injection can be completed in about 25 s, and the two reaction components are fully mixed and polymerized in the mold cavity under vacuum. The pressure is continuously maintained, and the resin (such as polyurea resin) fully impregnates the fiber layer 1 under pressure and solidifies to obtain a motor lower guard plate.

[0076] In the second embodiment, the fiber preform 10 adopts a sandwich structure. Compared with a single form of layer structure, the sandwich structure has better strength and can improve the impact resistance of the fiber composite material 100.

[0077] In the second embodiment, the motor lower guard plate has a thickness of 6 mm, and the aluminum honeycomb core has a thickness of 4 mm. In the drop hammer impact test, the motor lower guard plate can resist 400 J of energy without penetration.

[0078] Referring to FIG. 3, in the third embodiment of the present application, the fiber composite material 100 is configured as a battery pack bottom guard plate of a vehicle. Compared with the first embodiment, the battery pack bottom guard plate in the third embodiment is provided with a reinforcing rib 4 on one side of the thickness direction. The reinforcing rib 4 has a thickness of 1 mm. The battery pack bottom guard plate in the third embodiment can also resist 400 J of energy without penetration in the drop hammer impact test, and the deformation of the battery pack bottom guard plate caused by impact can be partially recovered.

[0079] In the fourth embodiment of the present application, the resin material is replaced by a polyurethane elastomer resin, and other features are the same as in the first embodiment. In the fourth embodiment, the battery pack bottom guard plate has a thickness of 4 mm. In the drop hammer impact test, the battery pack bottom guard plate can resist 400 J of energy without penetration, and the deformation of the battery pack bottom guard plate caused by impact can be partially recovered.

[0080] In Comparative Example 1, the composite material is a thermosetting epoxy resin (i.e., a thermosetting composite material used in the prior art), and the injection pressure in the molding process is 2-5 MPa, the injection time is 180 s, the curing temperature is 110±5°C, and the curing time is 5 min.

[0081] When the structural member in Comparative Example 1 is also configured as a battery pack bottom guard plate, when the thickness of the battery pack bottom guard plate is 4 mm, the battery pack bottom guard plate can be penetrated by 150 J of energy in the drop hammer impact experiment.

[0082] In Comparative Example 2, the structural member is an aluminum plate with the same size (thickness of 4 mm) as the first embodiment, and the aluminum plate is configured as a battery pack bottom guard plate, and the aluminum plate can be penetrated by 180 J of energy.

[0083] In Comparative Example 3, the structural member is prepared by a method of first spraying and then molding, the structural member uses the fiber layer 1 in the first embodiment, and before each fiber layer 1 is laid, the upper and lower surfaces of the fiber layer 1 are sprayed with polyurea elastomer by a high-pressure spraying device, the spraying pressure is 25 M, and the gel is completed after 25 s of spraying. The reinforced material with a polyurea coating is placed in a mold, vacuum is applied, 1 MPa pressure is applied and maintained for 90 min to obtain a composite material plate. The composite material plate in Comparative Example 3 is 4 mm thick, and can be penetrated by 250 J of energy in the drop hammer impact experiment.

[0084] Among them, the performance comparison table of the first embodiment, the second embodiment, the third embodiment, the fourth embodiment and Comparative Examples 1, 2 and 3 is as follows:

[0085] Note: The drop hammer impact experiment in the embodiments and comparative examples of the present application uses a 25 mm diameter spherical punch. The mass wear test uses the ASTM G65-04 standard test, with carbon steel as 1 as the reference, and the smaller the value, the more wear-resistant the material.

[0086] In summary, in the present application, by designing the laying method, the core layer 3, the process and the material, a fiber composite material 100 with good impact resistance can be obtained. Among them, the reinforcing rib or the core layer 3 in the honeycomb structure can improve the overall stiffness of the fiber composite material 100, and the impact resistance is consistent. Under the action of impact load, the resin matrix (elastic resin) undergoes glass transition effect and viscous dissipation, hydrogen bond dissipation, and at the same time, the fiber in the fiber layer 1 and the resin matrix undergo interface slip, which can dissipate impact energy.

[0087] Among them, the polyurea material alternates soft and hard segments in the molecular structure, and at the same time has the characteristics of elastomer and plastic, which is a microphase separation structure, has good wear resistance, and is significantly better than polyurethane, epoxy resin aluminum and other materials.

[0088] According to the protective structural member 200 provided by the embodiment of the present application, the protective structural member 200 comprises the embedding member 2 and the fiber composite material 100, the embedding member 2 is embedded in the fiber preform 10 along the stacking direction of the plurality of fiber layers 1, the local strength of the fiber composite material 100 can be improved by designing the embedding member 2, and a mounting structure can be formed at the embedding member 2 to form a mounting point on the fiber composite material 100, so as to facilitate the connection and cooperation of the fiber composite material 100 with other components.

[0089] In some embodiments of the present application, the embedding member 2 is configured as a metal member, the metal member has high structural strength, and the influence of high-pressure resin transfer molding on the embedding member 2 can be reduced. In the forming process of the fiber composite material 100, the embedding member 2 is pre-buried in the fiber preform 10, that is, the embedding member 2 is arranged in the mold together with the fiber layers 1 and is subjected to high-pressure resin transfer molding.

[0090] As shown in FIGS. 1-4, in some embodiments of the present application, the embedding member 2 is provided with a connecting hole 21 to form a mounting structure on the fiber composite material 100 through the connecting hole 21. The connecting hole 21 can be configured as a through hole arranged along the stacking direction, or can be configured as a non-through hole, so that the fiber composite material 100 can be assembled and fixed through the connecting hole 21. For example, the connecting hole 21 is used for allowing a connecting member (such as a bolt) to pass through, so as to cooperate with a mounting position (such as a threaded hole) through the connecting member to fix the fiber composite material 100 at the mounting position. The mounting structure formed on the embedding member 2 is not limited to a hole structure, and can also be a connecting groove and the like.

[0091] According to the vehicle provided by the embodiment of the present application, the vehicle comprises the fiber composite material 100 or the protective structural member 200 described above, the resin matrix in the fiber composite material 100 sufficiently impregnates the reinforcing fibers, so that the fiber composite material 100 has good mechanical properties and the product quality is easy to control. Meanwhile, the fiber composite material 100 is subjected to high-pressure resin transfer molding, almost no small molecule volatile substances are released in the forming process, the raw material utilization rate is high, the forming process is simple, the forming time and manufacturing cost are greatly reduced, the fiber composite material 100 can be efficiently mass-produced, and the fiber composite material 100 has a lighter weight compared with a metal protective structure under the same protective performance, so as to reduce the weight of the fiber composite material 100.

[0092] In some embodiments of the present application, the vehicle comprises a battery pack, and the fiber composite material 100 is configured as a battery pack protective plate. By configuring the fiber composite material 100 described above as the battery pack protective plate, the impact resistance of the battery pack can be improved.

[0093] In some embodiments of the present application, the vehicle comprises a driving motor, the fiber composite material 100 is configured as a lower guard plate, and the lower guard plate is arranged below the driving motor. By configuring the fiber composite material 100 as the lower guard plate of the motor, the motor can be protected by the lower guard plate.

[0094] According to the preparation method of the fiber composite material 100, the fiber composite material 100 comprises a fiber preform 10 and a resin matrix, and the preparation method comprises: placing the fiber preform 10 in a mold, and after the mold is closed and vacuumized, injecting a resin material into the fiber preform 10, and high-pressure resin transfer molding the resin material and the fiber preform 10 to prepare the fiber composite material 100.

[0095] The fiber preform 10 can be configured as the preform structure formed by stacking a plurality of fiber layers 1 as mentioned in the above embodiments.

[0096] In the preparation of the fiber composite material 100, the fiber preform 10 is first arranged in the mold, and the mold is closed and vacuumized. After the vacuumizing action is completed, the resin material is injected at a preset pressure for a preset time, and the pressure is maintained, so that the resin material fully impregnates the fibers in the fiber preform under pressure, and finally solidifies to obtain the fiber composite material 100.

[0097] The resin material can be two reactants, such as: injecting two reaction components of isocyanate and amino compound, and the two reaction components are fully mixed and complete polymerization reaction in the high-pressure resin transfer molding equipment to generate a polyurea resin.

[0098] After the fiber preform is arranged in the mold, the mold and the fiber preform arranged in the mold are transferred to the high-pressure resin transfer molding equipment together, and steps such as mold closing, vacuumizing, and resin injecting are performed.

[0099] In some embodiments of the present application, the resin material injection pressure is 0-25 MPa, and the resin material injection pressure is 10-25 MPa, so that the resin material (such as the above-mentioned isocyanate and amino compound) can be fully mixed, the resin material filling speed can be improved, the resin material impregnation effect on the fibers can be improved, and the air bubbles and porosity can be reduced.

[0100] In some embodiments of the present application, the resin material injection time is 5s-180s, for example: 10s-30s. The resin material injection time refers to the duration of injecting the resin material.

[0101] After the resin material is injected at the maintained injection pressure, the resin material can be fully impregnated into the fiber preform under pressure by continuing to maintain the pressure, and finally solidified to obtain the fiber composite material 100.

[0102] In the description of the present application, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "circumferential" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only used to facilitate the description of the present application and simplify the description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application.

[0103] In the description of the present application, "first feature" and "second feature" can include one or more of the features.

[0104] In the description of the present application, "a plurality of" means two or more.

[0105] In the description of the present application, "above", "over" and "on" of a first feature to a second feature can include that the first and second features are in direct contact, or that the first and second features are not in direct contact but are in contact through another feature between them.

[0106] In the description of the present application, "above", "over" and "on" of a first feature to a second feature include that the first feature is directly above and obliquely above the second feature, or only means that the first feature is higher than the second feature in horizontal height.

[0107] In the description of the present application, the description of the terms "one embodiment", "some embodiments", "exemplary embodiment", "example", "specific example", or "some examples" and the like means that the specific features, structures, materials or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present application. In the present specification, the exemplary description of the above terms does not necessarily mean the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0108] Although the embodiments of the present application have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, replacements and variations can be made to the embodiments without departing from the principles and spirit of the present application, and the scope of the present application is defined by the claims and their equivalents.

Claims

1. A fiber composite material, comprising: a plurality of fiber layers (1); a resin matrix, the resin matrix infiltrating the plurality of fiber layers (1) by high pressure resin transfer molding with the plurality of fiber layers (1).

2. The fiber composite material according to claim 1, wherein, the resin matrix infiltrating the plurality of fiber layers (1) by high pressure resin transfer molding with a fiber preform composed of the plurality of fiber layers (1).

3. The fiber composite material according to claim 1 or 2, wherein, the plurality of fiber layers (1) are arranged in a stack.

4. The fiber composite material according to any one of claims 1 to 3, wherein, the plurality of fiber layers (1) comprise: a unidirectional fiber layer (11) having a plurality of fibers (101) extending in the same direction and arranged in sequence; and / or, a fiber fabric layer (12) having a plurality of fibers (101) arranged in interweaving.

5. The fiber composite material of claim 4, wherein, the plurality of fiber layers (1) comprise a plurality of the unidirectional fiber layers (11); wherein, the fibers (101) in two adjacent unidirectional fiber layers (11) extend in parallel directions to each other; and / or, in a projection in a stacking direction, the fibers (101) in two adjacent unidirectional fiber layers (11) extend in directions having an included angle, and the included angle a satisfies the relationship: 45°≤a≤90°.

6. The fiber composite material according to claim 4 or 5, wherein, the fiber composite material (100) is provided with a reinforcing rib (4), the reinforcing rib (4) being provided on the fiber layer (1) located at the outermost side in the stacking direction.

7. The fiber composite material according to any one of claims 1 to 6, wherein, further comprising a core layer (3), the core layer (3) being provided between two fiber layers (1) in the stacking direction of the plurality of fiber layers (1).

8. The fiber composite material according to claim 7, wherein, the core layer (3) is configured as a foam structure.

9. The fiber composite material according to claim 8, wherein, the foam structure comprises at least one of polyethylene foam, balsa wood material, foamed aluminum and polyurethane foam, polypropylene foam, foamed magnesium.

10. The fiber composite material of claim 7, wherein, the core layer (3) is configured as a dot matrix structure.

11. The fiber composite material of claim 10, wherein, the dot matrix structure is configured as one of a honeycomb structure, a polygonal structure, a horai structure, a polyhedral structure.

12. The fiber composite material according to claim 10 or 11, wherein, a material of the dot matrix structure comprises at least one of an aluminum alloy, a fiber-reinforced composite material, aramid, polypropylene and ultra-high molecular weight polyethylene.

13. The fiber composite material according to any one of claims 1 to 12, wherein, the resin matrix is made of an elastomer resin material, and the elastomer resin material comprises at least one of polyurethane, polyurea, semi-polyurea, silicone resin, ethylene-propylene rubber; and / or, a fiber material in the fiber layer (1) comprises at least one of carbon fiber, glass fiber, aramid fiber, basalt fiber, ultra-high molecular weight polyethylene fiber, boron nitride fiber.

14. A protective structural member, comprising an embedded member (2) and the fiber composite material according to any one of claims 1-13, the embedded member (2) being embedded in the plurality of fiber layers (1) in the stacking direction of the plurality of fiber layers (1).

15. The protective structural member of claim 14, wherein, the embedded member (2) is configured as a metal member.

16. The protective structural member of claim 14 or 15, wherein, the embedded member (2) is provided with a connecting hole (21).

17. A vehicle comprising the fiber composite material according to any one of claims 1-13, or the protective structural member according to any one of claims 14-16.

18. A method for manufacturing a fiber composite material, for manufacturing the fiber composite material according to any one of claims 1 to 13, the fiber composite material comprising a resin matrix and a plurality of fiber layers (1), the method comprising: placing a fiber preform (10) composed of the plurality of fiber layers (1) in a mold, and after the mold is closed and vacuumed, injecting a resin material into the fiber preform (10), and high-pressure resin transfer molding the fiber preform (10) with the resin material.

19. The method of making a fiber composite material of claim 18, wherein, The resin material injection pressure is 0-25 MPa. And / or, the resin material injection time is 5 s-180 s.

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