A durable composite material transmission shaft

Abstract

The present invention belongs to the technical field of automobile transmission shafts, and specifically relates to a durable transmission shaft made of composite materials. The scheme adopted is: a durable transmission shaft made of composite materials, comprising: a mixed fiber surface strength layer, a first transition layer, a two-dimensional wound fiber mixed composite torsion layer, a second transition layer and a three-dimensional structure rigid layer sequentially sleeved from the outside to the inside, the first transition layer is made of a thermoplastic resin matrix composite material, the second transition layer is made of a multi-dimensional mixed woven composite material, the transmission shaft provided by the present invention greatly enhances the mechanical properties, improves the comprehensive strength, and can meet the requirements of large torque performance.

Description

Technical Field

[0001] The invention belongs to the technical field of automobile transmission shafts, and in particular relates to a durable transmission shaft made of composite materials. Background Art

[0002] The automobile drive shaft is an important power transmission component in the automobile transmission system. Its function is to effectively transmit the power generated during the operation of the engine to the wheels together with the gearbox and drive axle so that the car can generate driving force. The transmission system will consume part of the engine's energy due to its own weight during its own work. Currently, the drive shaft is mostly made of metal, which has a large weight and will consume a large amount of energy from the engine.

[0003] Carbon fiber hybrid composites have excellent properties such as light weight, high strength, and friction resistance. They can be used in drive shaft applications with higher speeds and longer spans. At the same time, the thermal expansion coefficient of composite materials is low, which can reduce transmission noise and vibration friction, and effectively improve automobile fuel efficiency. Although the composite drive shaft prepared by the traditional two-dimensional winding method is light in weight and high in strength, it cannot meet the performance requirements of larger torque. Summary of the invention

[0004] The present invention overcomes the shortcomings of the prior art and provides a durable transmission shaft made of composite material with better mechanical properties and higher comprehensive strength and capable of meeting the requirements of high torque performance.

[0005] In order to solve the above technical problems, the technical solution adopted by the present invention is:

[0006] A durable composite transmission shaft comprises: a mixed fiber surface strength layer, a first transition layer, a two-dimensional wound fiber mixed composite torsion layer, a second transition layer and a three-dimensional structure rigid layer which are sequentially sleeved from the outside to the inside, wherein the first transition layer is made of a thermoplastic resin matrix composite material, and the second transition layer is made of a multi-dimensional mixed woven composite material.

[0007] The mixed fiber surface strength layer is woven from high-strength carbon fibers and high-tenacity fibers in a plain, twill or satin weave. Preferably, the mixing ratio of the two fibers is flexibly adjusted according to actual working conditions.

[0008] The two-dimensional wound fiber hybrid composite torsion layer is wound by high-strength carbon fiber and high-modulus carbon fiber, and the winding method is circumferential winding, spiral winding or longitudinal winding. The winding angle of the circumferential winding is 85° to 90°, the winding angle of the spiral winding is 45° to 70°, and the winding angle of the longitudinal winding is less than or equal to 25°. Preferably, the mixing ratio of the two fibers is flexibly adjusted according to actual working conditions.

[0009] The three-dimensional structural rigid layer is woven from high-strength carbon fiber and high-modulus carbon fiber. The woven structure of the three-dimensional structural rigid layer is three-dimensional four-directional, three-dimensional five-directional, three-dimensional six-directional or three-dimensional seven-directional. Preferably, the mixing ratio of the two fibers is flexibly adjusted according to actual working conditions.

[0010] The thermoplastic resin matrix composite material comprises: fabric, seam-laying fiber and thermoplastic resin, wherein the fabric is woven from fabric fibers, and the weaving method thereof adopts plain weave, twill weave or satin weave, and the fabric fibers are selected from carbon fibers with specifications of T300, T700, T800 or T1000; seam-laying fibers are arranged between multiple layers of fabric by interlayer seam-laying, and the seam-laying fibers are selected from T300 carbon fiber, T700 carbon fiber, T800 carbon fiber, T1000 carbon fiber, aramid fiber or UHMWPE fiber; the thermoplastic resin is selected from polyethylene, polypropylene, polycarbonate, thermoplastic polyester, polyphenylene sulfide, polyetheretherketone, polyetherketone, polyamide or polyimide, and the content of the thermoplastic resin in the thermoplastic resin matrix composite material is 40% to 60%.

[0011] The second transition layer is woven from high-strength carbon fiber and high-modulus carbon fiber. The weaving structure of the second transition layer is three-dimensional four-directional, three-dimensional five-directional, three-dimensional six-directional or three-dimensional seven-directional. Preferably, the mixing ratio of the two fibers is flexibly adjusted according to actual working conditions.

[0012] The specifications of high-strength carbon fiber are T300, T700, T800 or T1000.

[0013] The high tenacity fiber is selected from aramid fibers with specifications of K29, K49 or K129.

[0014] The specifications of high modulus carbon fiber are M40, M40J, M55, M55J, M60 or M60J.

[0015] After the multi-layer structure fabric of the mixed fiber surface strength layer, the two-dimensional winding fiber mixed composite torsion layer, the three-dimensional structure rigid layer or the second transition layer is woven and formed, the multi-layer structure fabric is impregnated and heat-cured;

[0016] The impregnation process uses the VARI vacuum infusion process to quickly impregnate the multi-layer structure fabric with a thermosetting resin adhesive;

[0017] The heat curing process is carried out in a large oven, and vacuum is maintained during the heat curing process. The vacuum degree is 0.06-0.1Mpa. The material of the thermosetting resin adhesive is epoxy resin, phenolic resin or unsaturated polyester resin. The thermosetting resin content is 40%-60%. The heat curing temperature and time are flexibly adjusted according to the characteristics of the thermosetting resin adhesive.

[0018] Compared with the prior art, the present invention has the following beneficial effects.

[0019] 1. The present invention adopts composite materials, which greatly reduces the weight of the automobile transmission shaft and reduces energy consumption;

[0020] 2. The present invention adopts a method of combining a two-dimensional woven structure layer with a three-dimensional woven structure layer. Compared with the composite material transmission shaft prepared by the traditional two-dimensional winding method, the mechanical properties of the transmission shaft are greatly enhanced, the comprehensive strength of the transmission shaft is improved, and it can meet the requirements of high torque performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The present invention will be further described below in conjunction with the accompanying drawings.

[0022] Figure 1 It is a structural schematic diagram of the present invention.

[0023] In the figure: 1 is the mixed fiber surface strength layer, 2 is the two-dimensional winding fiber mixed composite torsion layer, 3 is the three-dimensional structure rigid layer, 4 is the first transition layer, and 5 is the second transition layer. DETAILED DESCRIPTION

[0024] The present invention is further described below in conjunction with specific embodiments.

[0025] Example 1

[0026] A durable composite transmission shaft comprises: a mixed fiber surface strength layer 1, a first transition layer 4, a two-dimensional wound fiber mixed composite torsion layer 2, a second transition layer 5 and a three-dimensional structure rigid layer 3 which are arranged in sequence from outside to inside, wherein the first transition layer 4 is made of a thermoplastic resin matrix composite material, and the second transition layer 5 is made of a multi-dimensional mixed woven composite material.

[0027] The mixed fiber surface strength layer 1 is formed by twill weaving of T300 carbon fiber and K29 ​​aramid fiber in a mixing ratio of 1:1.

[0028] The two-dimensional wound fiber hybrid composite torsion layer 2 is formed by winding T700 carbon fiber and M40 carbon fiber in a mixing ratio of 2:1, and the winding method is 90° hoop winding.

[0029] The three-dimensional structural rigid layer 3 is woven from T800 carbon fiber and M40J carbon fiber in a mixed ratio of 1:1, and its woven structure is three-dimensional and four-directional.

[0030] The thermoplastic resin matrix composite material includes: fabric, seam-laying fiber and thermoplastic resin. The fabric is made of T300 carbon fiber plain weave. Seam-laying fiber is arranged between multiple layers of fabric by interlayer seaming. T1000 carbon fiber is selected as the seam-laying fiber. Polycarbonate is selected as the thermoplastic resin. The content of thermoplastic resin in the thermoplastic resin matrix composite material is 40%.

[0031] The second transition layer 5 is woven from T300 carbon fiber and M60 carbon fiber in a mixed ratio of 1:1, and its woven structure is three-dimensional and five-directional.

[0032] After the multi-layer structure fabric of the hybrid fiber surface strength layer 1, the two-dimensional winding fiber hybrid composite torsion layer 2, and the three-dimensional structure rigid layer 3 or the second transition layer 5 is woven and formed, the multi-layer structure fabric is impregnated and heat-cured;

[0033] The impregnation process uses the VARI vacuum infusion process to quickly impregnate the multi-layer structure fabric with a thermosetting resin adhesive;

[0034] The heat curing process is carried out in a large oven, and vacuum is maintained during the heat curing process with a vacuum degree of 0.08Mpa. The material of the thermosetting resin adhesive is epoxy resin with a thermosetting resin content of 40%. The heat curing temperature is 80°C and the curing time is 3 hours.

[0035] Example 2

[0036] A durable composite transmission shaft comprises: a mixed fiber surface strength layer 1, a first transition layer 4, a two-dimensional wound fiber mixed composite torsion layer 2, a second transition layer 5 and a three-dimensional structure rigid layer 3 which are arranged in sequence from outside to inside, wherein the first transition layer 4 is made of a thermoplastic resin matrix composite material, and the second transition layer 5 is made of a multi-dimensional mixed woven composite material.

[0037] The hybrid fiber surface strength layer 1 is formed by plain weaving of T800 carbon fiber and K49 aramid fiber in a mixing ratio of 2:1.

[0038] The two-dimensional wound fiber hybrid composite torsion layer 2 is formed by winding T300 carbon fiber and M55 carbon fiber in a mixing ratio of 1:1, and the winding method is 20° longitudinal winding.

[0039] The three-dimensional structural rigid layer 3 is woven from T1000 carbon fiber and M60J carbon fiber in a mixed ratio of 1:1, and its woven structure is three-dimensional and five-directional.

[0040] The thermoplastic resin matrix composite material includes: fabric, seam-laying fiber and thermoplastic resin. The fabric is made of T1000 carbon fiber plain weave. Seam-laying fibers are arranged between multiple layers of fabric by interlayer seaming. T800 carbon fiber is used for the seam-laying fiber. Polycarbonate is used for the thermoplastic resin matrix composite material. The content of thermoplastic resin in the thermoplastic resin matrix composite material is 60%.

[0041] The second transition layer 5 is woven from T300 carbon fiber and M60J carbon fiber in a mixed ratio of 2:1, and its woven structure is three-dimensional and six-directional.

[0042] After the multi-layer structure fabric of the hybrid fiber surface strength layer 1, the two-dimensional winding fiber hybrid composite torsion layer 2, and the three-dimensional structure rigid layer 3 or the second transition layer 5 is woven and formed, the multi-layer structure fabric is impregnated and heat-cured;

[0043] The impregnation process uses the VARI vacuum infusion process to quickly impregnate the multi-layer structure fabric with a thermosetting resin adhesive;

[0044] The heat curing process is carried out in a large oven, and vacuum is maintained during the heat curing process with a vacuum degree of 0.06Mpa. The material of the thermosetting resin adhesive is epoxy resin with a thermosetting resin content of 50%. The heat curing temperature is 90°C and the curing time is 3 hours.

[0045] Example 3

[0046] A durable composite transmission shaft comprises: a mixed fiber surface strength layer 1, a first transition layer 4, a two-dimensional wound fiber mixed composite torsion layer 2, a second transition layer 5 and a three-dimensional structure rigid layer 3 which are arranged in sequence from outside to inside, wherein the first transition layer 4 is made of a thermoplastic resin matrix composite material, and the second transition layer 5 is made of a multi-dimensional mixed woven composite material.

[0047] The mixed fiber surface strength layer 1 is formed by satin weaving of T1000 carbon fiber and K129 aramid fiber in a mixing ratio of 2:3.

[0048] The two-dimensional wound fiber hybrid composite torsion layer 2 is formed by winding T300 carbon fiber and M55 carbon fiber in a mixing ratio of 1:1, and the winding method is 85° hoop winding.

[0049] The three-dimensional structural rigid layer 3 is woven from T1000 carbon fiber and M60 carbon fiber in a mixed ratio of 2:1, and its woven structure is three-dimensional and seven-directional.

[0050] The thermoplastic resin matrix composite material includes: fabric, seam-laying fiber and thermoplastic resin. The fabric is made of T700 carbon fiber plain weave. Seam-laying fiber is arranged between multiple layers of fabric by interlayer seam laying. UHMWPE fiber is selected as the seam-laying fiber. Polycarbonate is selected as the thermoplastic resin. The content of thermoplastic resin in the thermoplastic resin matrix composite material is 50%.

[0051] The second transition layer 5 is woven from T300 carbon fiber and M60J carbon fiber in a mixed ratio of 1:1, and its woven structure is three-dimensional and four-directional.

[0052] After the multi-layer structure fabric of the hybrid fiber surface strength layer 1, the two-dimensional winding fiber hybrid composite torsion layer 2, and the three-dimensional structure rigid layer 3 or the second transition layer 5 is woven and formed, the multi-layer structure fabric is impregnated and heat-cured;

[0053] The impregnation process uses the VARI vacuum infusion process to quickly impregnate the multi-layer structure fabric with a thermosetting resin adhesive;

[0054] The heat curing process is carried out in a large oven, and vacuum is maintained during the heat curing process with a vacuum degree of 0.1Mpa. The material of the thermosetting resin adhesive is epoxy resin with a thermosetting resin content of 60%. The heat curing temperature is 85°C and the curing time is 3.5 hours.

[0055] Example 4

[0056] A durable composite transmission shaft comprises: a mixed fiber surface strength layer 1, a first transition layer 4, a two-dimensional wound fiber mixed composite torsion layer 2, a second transition layer 5 and a three-dimensional structure rigid layer 3 which are arranged in sequence from outside to inside, wherein the first transition layer 4 is made of a thermoplastic resin matrix composite material, and the second transition layer 5 is made of a multi-dimensional mixed woven composite material.

[0057] The mixed fiber surface strength layer 1 is formed by satin weaving of T1000 carbon fiber and K129 aramid fiber in a mixing ratio of 1:1.

[0058] The two-dimensional wound fiber hybrid composite torsion layer 2 is formed by winding T300 carbon fiber and M55J carbon fiber in a mixing ratio of 2:3, and the winding method is 70° spiral winding.

[0059] The three-dimensional structural rigid layer 3 is woven from T1000 carbon fiber and M60 carbon fiber in a mixed ratio of 2:1, and its woven structure is three-dimensional and six-directional.

[0060] The thermoplastic resin matrix composite material includes: fabric, seam-laying fiber and thermoplastic resin. The fabric is made of T700 carbon fiber plain weave. Seam-laying fiber is arranged between multiple layers of fabric by interlayer seam laying. Aramid fiber is selected from the seam-laying fiber. Polycarbonate is selected from the thermoplastic resin. The content of thermoplastic resin in the thermoplastic resin matrix composite material is 60%.

[0061] The second transition layer 5 is woven from T300 carbon fiber and M60J carbon fiber in a mixed ratio of 1:1, and its woven structure is three-dimensional and four-directional.

[0062] After the multi-layer structure fabric of the hybrid fiber surface strength layer 1, the two-dimensional winding fiber hybrid composite torsion layer 2, and the three-dimensional structure rigid layer 3 or the second transition layer 5 is woven and formed, the multi-layer structure fabric is impregnated and heat-cured;

[0063] The impregnation process uses the VARI vacuum infusion process to quickly impregnate the multi-layer structure fabric with a thermosetting resin adhesive;

[0064] The heat curing process is carried out in a large oven, and vacuum is maintained during the heat curing process with a vacuum degree of 0.08Mpa. The material of the thermosetting resin adhesive is epoxy resin with a thermosetting resin content of 60%. The heat curing temperature is 80°C and the curing time is 4 hours.

[0065] Example 5

[0066] A durable composite transmission shaft comprises: a mixed fiber surface strength layer 1, a first transition layer 4, a two-dimensional wound fiber mixed composite torsion layer 2, a second transition layer 5 and a three-dimensional structure rigid layer 3 which are arranged in sequence from outside to inside, wherein the first transition layer 4 is made of a thermoplastic resin matrix composite material, and the second transition layer 5 is made of a multi-dimensional mixed woven composite material.

[0067] The mixed fiber surface strength layer 1 is formed by satin weaving of T1000 carbon fiber and K29 ​​aramid fiber in a mixing ratio of 1:2.

[0068] The two-dimensional wound fiber hybrid composite torsion layer 2 is formed by winding T300 carbon fiber and M55J carbon fiber in a mixing ratio of 2:3, and the winding method is 45° spiral winding.

[0069] The three-dimensional structural rigid layer 3 is woven from T1000 carbon fiber and M40J carbon fiber in a mixed ratio of 1:1, and its woven structure is three-dimensional and four-directional.

[0070] The thermoplastic resin matrix composite material includes: fabric, seam-laying fiber and thermoplastic resin. The fabric is made of T700 carbon fiber plain weave. Seam-laying fiber is arranged between multiple layers of fabric by interlayer seam laying. Aramid fiber is selected from the seam-laying fiber. Polycarbonate is selected from the thermoplastic resin. The content of thermoplastic resin in the thermoplastic resin matrix composite material is 60%.

[0071] The second transition layer 5 is woven from T300 carbon fiber and M60J carbon fiber in a mixed ratio of 1:1, and its woven structure is three-dimensional and four-directional.

[0072] After the multi-layer structure fabric of the hybrid fiber surface strength layer 1, the two-dimensional winding fiber hybrid composite torsion layer 2, and the three-dimensional structure rigid layer 3 or the second transition layer 5 is woven and formed, the multi-layer structure fabric is impregnated and heat-cured;

[0073] The impregnation process uses the VARI vacuum infusion process to quickly impregnate the multi-layer structure fabric with a thermosetting resin adhesive;

[0074] The heat curing process is carried out in a large oven, and vacuum is maintained during the heat curing process with a vacuum degree of 0.06Mpa. The material of the thermosetting resin adhesive is epoxy resin with a thermosetting resin content of 60%. The heat curing temperature is 90°C and the curing time is 3.5 hours.

[0075] Example 6

[0076] A durable composite transmission shaft comprises: a mixed fiber surface strength layer 1, a first transition layer 4, a two-dimensional wound fiber mixed composite torsion layer 2, a second transition layer 5 and a three-dimensional structure rigid layer 3 which are arranged in sequence from outside to inside, wherein the first transition layer 4 is made of a thermoplastic resin matrix composite material, and the second transition layer 5 is made of a multi-dimensional mixed woven composite material.

[0077] The mixed fiber surface strength layer 1 is formed by satin weaving of T800 carbon fiber and K29 ​​aramid fiber in a mixing ratio of 1:1.

[0078] The two-dimensional wound fiber hybrid composite torsion layer 2 is formed by winding T300 carbon fiber and M55J carbon fiber in a mixing ratio of 1:1, and the winding method is 45° spiral winding.

[0079] The three-dimensional structural rigid layer 3 is woven from T800 carbon fiber and M40J carbon fiber in a mixed ratio of 2:1, and its woven structure is three-dimensional and four-directional.

[0080] The thermoplastic resin matrix composite material includes: fabric, seam-laying fiber and thermoplastic resin. The fabric is made of T300 carbon fiber plain weave. Seam-laying fiber is arranged between multiple layers of fabric by interlayer seam laying. Aramid fiber is selected from the seam-laying fiber. Polycarbonate is selected from the thermoplastic resin. The content of thermoplastic resin in the thermoplastic resin matrix composite material is 60%.

[0081] The second transition layer 5 is woven from T700 carbon fiber and M60 carbon fiber in a mixed ratio of 1:1, and its woven structure is three-dimensional and four-directional.

[0082] After the multi-layer structure fabric of the hybrid fiber surface strength layer 1, the two-dimensional winding fiber hybrid composite torsion layer 2, and the three-dimensional structure rigid layer 3 or the second transition layer 5 is woven and formed, the multi-layer structure fabric is impregnated and heat-cured;

[0083] The impregnation process uses the VARI vacuum infusion process to quickly impregnate the multi-layer structure fabric with a thermosetting resin adhesive;

[0084] The heat curing process is carried out in a large oven, and vacuum is maintained during the heat curing process with a vacuum degree of 0.1Mpa. The material of the thermosetting resin adhesive is epoxy resin with a thermosetting resin content of 40%. The heat curing temperature is 80°C and the curing time is 3.5 hours.

[0085] The above embodiments are merely illustrative of the principles and effects of the present invention, and are not intended to limit the present invention. Those familiar with the technology may modify or improve the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or changes made by those with ordinary knowledge in the technical field without departing from the spirit and technical ideas disclosed by the present invention should still be covered by the claims of the present invention.

Claims

1. A durable composite transmission shaft, characterized in that: include: A hybrid fiber surface strength layer (1), a first transition layer (4), a two-dimensional wound fiber hybrid composite torsion layer (2), a second transition layer (5) and a three-dimensional structural rigid layer (3) are sequentially sleeved from the outside to the inside, wherein the first transition layer (4) is made of a thermoplastic resin matrix composite material, and the second transition layer (5) is made of a multi-dimensional hybrid braided composite material; The mixed fiber surface strength layer (1) is woven from high-strength carbon fibers and high-tenacity fibers, and the weaving method is plain weave, twill weave or satin weave; The two-dimensionally wound fiber hybrid composite torsion layer (2) is wound by winding high-strength carbon fibers and high-modulus carbon fibers, and the winding method is circumferential winding, spiral winding or longitudinal winding, the winding angle of the circumferential winding is 85° to 90°, the winding angle of the spiral winding is 45° to 70°, and the winding angle of the longitudinal winding is less than or equal to 25°; The three-dimensional structural rigid layer (3) is woven from high-strength carbon fibers and high-modulus carbon fibers, and the woven structure of the three-dimensional structural rigid layer (3) is three-dimensional four-directional, three-dimensional five-directional, three-dimensional six-directional or three-dimensional seven-directional.

2. A composite durable transmission shaft according to claim 1, characterized in that: The thermoplastic resin matrix composite material comprises: fabric, seam-laying fiber and thermoplastic resin, wherein the fabric is woven from fabric fibers, and the weaving method thereof adopts plain weave, twill weave or satin weave, and the fabric fibers are selected from carbon fibers with specifications of T300, T700, T800 or T1000; seam-laying fibers are arranged between multiple layers of fabric by interlayer seam-laying, and the seam-laying fibers are selected from T300 carbon fiber, T700 carbon fiber, T800 carbon fiber, T1000 carbon fiber, aramid fiber or UHMWPE fiber; the thermoplastic resin is selected from polyethylene, polypropylene, polycarbonate, thermoplastic polyester, polyphenylene sulfide, polyetheretherketone, polyetherketone, polyamide or polyimide, and the content of the thermoplastic resin in the thermoplastic resin matrix composite material is 40% to 60%.

3. A durable composite transmission shaft according to claim 1, characterized in that: The second transition layer (5) is woven from high-strength carbon fibers and high-modulus carbon fibers, and the woven structure of the second transition layer (5) is three-dimensional four-directional, three-dimensional five-directional, three-dimensional six-directional or three-dimensional seven-directional.

4. A durable composite transmission shaft according to claim 1 or 3, characterized in that: The specifications of high-strength carbon fiber are T300, T700, T800 or T1000.

5. The durable composite transmission shaft according to claim 1, characterized in that: The high tenacity fiber is selected from aramid fibers with specifications of K29, K49 or K129.

6. A durable composite transmission shaft according to claim 1 or 3, characterized in that: The specifications of high modulus carbon fiber are M40, M40J, M55, M55J, M60 or M60J.

7. A durable composite transmission shaft according to claim 1 or 3, characterized in that: After the multi-layer structure fabric of the mixed fiber surface strength layer (1), the two-dimensional winding fiber mixed composite torsion layer (2), the three-dimensional structure rigid layer (3) or the second transition layer (5) is woven and formed, the multi-layer structure fabric is impregnated and heat-cured; the impregnation treatment adopts the VARI vacuum introduction process, and the multi-layer structure fabric is quickly impregnated with a thermosetting resin adhesive; the heat-curing process is carried out in a large oven, and a vacuum is maintained during the heat-curing process, and the vacuum degree is 0.06-0.1Mpa. The material of the thermosetting resin adhesive is epoxy resin, phenolic resin or unsaturated polyester resin, and the thermosetting resin content is 40%-60%.

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