A high-strength polyurethane resin composite material for automobiles and its molding method

Abstract

This invention relates to a high-strength polyurethane resin composite material for automotive applications and its molding method. The composite material is prepared from continuous fibers and polyurethane resin, supplemented with a surface felt and a multi-axial fabric. The molding method includes a felter feeding the surface felt into a mandrel and feeding the multi-axial fabric parallel between the two mandrels; the continuous fibers pass through a guide plate and are then filament-planted into the mandrel; the felter feeds the multi-axial fabric into the filament-planted semi-finished part; the product, driven by a traction device, enters a heated mold for resin injection and curing; the product cures and heats up to form a high-strength composite material. This invention's polyurethane resin molding method for pultrusion yields the relationship between the changes in the yarn bundle before and after pultrusion, providing design requirements to ensure uniform stress distribution in each fiber layer of the product, with no obvious defects in the ductwork and no obvious gaps between the yarn bundles; the polyurethane bridge achieves appropriate tension of the winding yarn through spring-controlled high-strength graphite rollers, and contoured high-strength graphite is added to the inside of the yarn guide plate for lubrication and positioning.

Description

Technical Field

[0001] This invention belongs to the field of composite material preparation technology, specifically relating to a high-strength polyurethane resin composite material for automobiles and its molding method. Background Technology

[0002] Composite materials are multiphase materials formed by combining two or more materials with different properties using specific molding processes. The strengths and weaknesses of each material are combined to create a synergistic effect, resulting in composite materials with superior performance compared to the original components, thus leading to their widespread application. Especially in recent years, composite materials have demonstrated significant advantages in lightweighting, environmental friendliness, and durability.

[0003] For decades, the transverse strength of pultruded products has been one of the most critical technical issues determining and restricting the development of the pultrusion industry. Introducing an outer fiberglass stitch-braided layer and an inner multi-axial fiberglass layer into the pultrusion process can effectively increase transverse strength and solve this problem. Physical observation of existing polyurethane products reveals that some pultruded fibers are not fully straightened, severely reducing the compressive strength of the pressure-bearing surface and causing excessive deformation during compression, leading to premature structural instability. Summary of the Invention

[0004] The purpose of this invention is to provide a high-strength polyurethane resin composite material for automobiles, and also to provide a molding method for the high-strength polyurethane resin composite material for automobiles, which uses non-metals to replace metals, thereby achieving the goal of lightweighting while overcoming the problems of poor corrosion resistance, fatigue resistance and complex molding process of existing materials.

[0005] The objective of this invention is achieved through the following technical solution:

[0006] A high-strength polyurethane resin composite material for automobiles is prepared from continuous fibers and polyurethane resin, supplemented with surface felt and multiaxial fabric. The surface felt accounts for 0.2% of the total weight; the multiaxial fabric accounts for approximately 26.8% of the total weight; the continuous fiber accounts for approximately 53% of the total weight; and the polyurethane resin accounts for approximately 20% of the total weight.

[0007] Furthermore, the continuous fiber is glass fiber or carbon fiber.

[0008] Furthermore, the components and weight percentages of the polyurethane resin are as follows:

[0009]

[0010] The molding method for the above-mentioned high-strength polyurethane resin composite material for automobiles includes the following steps:

[0011] S1. A variable frequency speed-controlled felter feeds the surface felt into the mandrel and feeds the multi-axial fabric parallel between the two mandrels, ensuring that the angle of the felt is consistent with that of the mandrel.

[0012] S2. Place the continuous fiber onto the yarn frame and use the yarn guide plate to implant the core rod after step S1.

[0013] S3, the felt wrapper feeds the multi-axial fabric into the semi-finished part after the filament planting in S2, and under the drive of the traction device, it enters the heated mold for injection and curing.

[0014] S4. The product processed in step S3 is cured and heated at the tail end of the segmented heating and impregnation mold. The polyurethane resin is rapidly cured under the action of temperature and catalyst to form a high-strength composite material. The mold adopts a three-temperature zone heating system, and the temperature zones can be displayed online and automatically controlled.

[0015] S5. After the polyurethane resin cures, it will shrink slightly. Under the action of the release agent, it will be demolded at the tail end of the mold and cut and trimmed according to the required profile.

[0016] Further, step S2 specifically includes the following steps:

[0017] S11. The continuous fiber is placed on the yarn rack, and the pultruded yarn is drawn out from the continuous fiber and pre-distributed around the two core molds after passing through the first-stage yarn guide plate.

[0018] S12. Appropriate tension is achieved through a pultrusion yarn tensioning device;

[0019] S13. Enter the secondary yarn guide plate to further clarify the spatial distribution;

[0020] S14, passing through three-stage yarn guide plates and approaching the core mold;

[0021] The inner side of the yarn guide plate is equipped with a graphite roller structure, on which a polyurethane bridge is provided. A spring is set on one side of the graphite roller, and the polyurethane bridge achieves tensioning of the pultruded yarn through the high-strength graphite roller controlled by the spring.

[0022] Further, in step S3, the speed of the traction device is 30-80 cm / min.

[0023] Further, in step S4, the segmented heating and impregnation mold has a total length of 1300cm, with the front section accounting for approximately 50%, the middle section and the tail section each accounting for 25%, and is isolated using heat insulation material.

[0024] Furthermore, in step S4, graphite paper is placed between the heating element and the mold.

[0025] Furthermore, insulation material is added above the heating element.

[0026] Furthermore, the insulation material is rock wool or asbestos.

[0027] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0028] This invention provides a molding method for high-strength polyurethane resin composite materials for automobiles, which yields the relationship between the changes in the yarn bundle before and after pultrusion, provides design requirements to ensure uniform stress on the fibers in each layer of the product, and shows that there are no obvious defects in the pipes and no obvious gaps between the yarn bundles, proving that the designed yarn bundle shape changes are reasonable.

[0029] The polyurethane cable tray achieves appropriate tension of the winding yarn through spring-controlled high-strength graphite rollers;

[0030] There is a risk of fiber breakage and fuzzing when the fiberglass passes through the guide plate after being properly tensioned. High-strength graphite with conformal properties is added to the inside of the guide plate to serve as a lubricant and for positioning. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below in conjunction with specific embodiments. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0032] The present invention relates to a high-strength polyurethane resin composite material for automobiles, which is prepared by continuous fibers and polyurethane resin, supplemented with surface felt and multiaxial fabric. The surface felt accounts for 0.2% of the total weight; the multiaxial fabric accounts for about 26.8% of the total weight; the continuous fiber accounts for about 53% of the total weight; and the polyurethane resin accounts for about 20% of the total weight.

[0033] The continuous fiber is glass fiber or carbon fiber.

[0034] The specific components and weight percentages of the polyurethane resin are as follows:

[0035]

[0036] Specifically, the ultraviolet absorber is UV-328. The light stabilizer is OCTA LS-292. The gel catalyst is Dabco NE1070. The polyurethane pultrusion release agent is CIREXIN 8, WAXOFF 70, or 8161PU.

[0037] The molding method for the above-mentioned high-strength polyurethane resin composite material for automobiles includes the following steps:

[0038] S1. A variable frequency speed-regulating felter feeds the surface felt into the mandrel and feeds the multi-axial fabric parallel between the two mandrels, ensuring that the angle of the felt is consistent with that of the mandrel, and making the angle adjustable.

[0039] S2. Place the continuous fiber onto the yarn frame and use the yarn guide plate to implant the core rod after step S1.

[0040] S3. The felting device feeds the multi-axial fabric into the semi-finished part after the filament planting in S2. Under the drive of the traction device, it enters the heating mold for glue injection and curing. The speed of the traction device is 30-80cm / min.

[0041] S4. The product processed in step S3 is cured and heated at the tail end of the segmented heating impregnation mold. The polyurethane resin is rapidly cured under the action of temperature and catalyst to form a high-strength composite material. The mold adopts a three-temperature zone heating system, and the temperature zones can be displayed online and automatically controlled. The segmented heating impregnation mold has a total length of 1300cm, with the front section accounting for about 50%, the middle section and the tail section each accounting for 25%, and is isolated by heat insulation material.

[0042] S5. After the polyurethane resin cures, it will shrink slightly. Under the action of the release agent, it will be demolded at the tail end of the mold and cut and trimmed according to the required profile.

[0043] Specifically, step S2 includes the following steps:

[0044] S11. The continuous fiber is placed on the yarn rack, and the pultruded yarn is drawn out from the continuous fiber and pre-distributed around the two core molds after passing through the first-stage yarn guide plate.

[0045] S12. Appropriate tension is achieved through a pultrusion yarn tensioning device;

[0046] S13. Enter the secondary yarn guide plate to further clarify the spatial distribution;

[0047] S14, passing through three-stage yarn guide plates and approaching the core mold;

[0048] The guide plate is fitted with a graphite roller structure on its inner side, incorporating high-strength graphite for lubrication and positioning. A polyurethane bridge is mounted on the graphite roller structure, and a spring is installed on one side of the graphite roller. The polyurethane bridge, controlled by the spring, tensions the pultruded yarn through the high-strength graphite roller. The spring serves to secure the pultrusion process.

[0049] Graphite paper is placed between the heating element and the mold to increase the heat conduction area, improve heat conduction efficiency, and expand the isothermal zone. Insulation material is added above the heating element. Specifically, the insulation material is rock wool or asbestos, which reduces energy consumption and expands the isothermal zone.

[0050] The installation and disassembly process of this invention can be carried out by only one worker, reducing manpower consumption.

[0051] In the description of this invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicating orientation or positional relationships, are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0052] Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features.

[0053] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0054] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0055] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0056] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

[0057] The specific embodiments of the present invention described above do not constitute a limitation on the scope of protection of the present invention. Any other corresponding changes and modifications made in accordance with the technical concept of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A method of molding a high-strength polyurethane resin composite for a vehicle, characterized by, Includes the following steps: S1. A variable frequency speed-controlled felter feeds the surface felt into the mandrel and feeds the multi-axial fabric parallel between the two mandrels, ensuring that the angle of the felt is consistent with that of the mandrel. S2. Place the continuous fiber onto the yarn frame and use the yarn guide plate to implant the core rod after step S1. S3, the felt wrapper feeds the multi-axial fabric into the semi-finished part after the filament planting in S2, and under the drive of the traction device, it enters the heated mold for injection and curing. S4. The product processed in step S3 is cured and heated at the tail end of the segmented heating and impregnation mold. The polyurethane resin is rapidly cured under the action of temperature and catalyst to form a high-strength composite material. The mold adopts a three-temperature zone heating system, and the temperature zones can be displayed online and automatically controlled. S5. After the polyurethane resin is cured, it will shrink slightly. Under the action of the release agent, it will be demolded at the tail end of the mold and cut and trimmed according to the required profile. The high-strength polyurethane resin composite material for automotive applications is made of continuous fibers and polyurethane resin, supplemented with surface mat and multiaxial fabric. The surface mat accounts for 0.2% of the total weight; the multiaxial fabric accounts for 26.8% of the total weight; the continuous fiber accounts for 53% of the total weight; and the polyurethane resin accounts for 20% of the total weight. Step S2 specifically includes the following steps: S11. The continuous fiber is placed on the yarn rack, and the pultruded yarn is drawn out from the continuous fiber and pre-distributed around the two core molds after passing through the first-stage yarn guide plate. S12. Appropriate tension is achieved through a pultrusion yarn tensioning device; S13. Enter the secondary yarn guide plate to further clarify the spatial distribution; S14, passing through three-stage yarn guide plates and approaching the core mold; The inner side of the yarn guide plate is equipped with a graphite roller structure, on which a polyurethane bridge is provided. A spring is set on one side of the graphite roller, and the polyurethane bridge achieves tensioning of the pultruded yarn through the high-strength graphite roller controlled by the spring.

2. The molding method of a high-strength polyurethane resin composite material for automobiles according to claim 1, characterized in that: Step S3, the speed of the traction device is 30-80 cm / min.

3. The molding method of a high-strength polyurethane resin composite material for automobiles according to claim 1, characterized in that: Step S4: The segmented heating and impregnation mold has a total length of 1300cm, with the front section accounting for 50%, the middle section and the tail section each accounting for 25%, and is isolated by heat insulation material.

4. The molding method of a high-strength polyurethane resin composite material for automobiles according to claim 1, characterized in that: In step S4, graphite paper is placed between the heating element and the mold.

5. The molding method of a high-strength polyurethane resin composite material for automobiles according to claim 4, characterized in that: Add insulation material above the heating element.

6. The molding method of a high-strength polyurethane resin composite material for automobiles according to claim 5, characterized in that: The insulation material is rock wool or asbestos.

7. The molding method of a high-strength polyurethane resin composite material for automobiles according to claim 1, characterized in that: The continuous fibers are glass fibers or carbon fibers.

8. The molding method of a high-strength polyurethane resin composite material for automobiles according to claim 1, characterized in that, The components and weight percentages of the polyurethane resin are as follows: Isocyanate PM130 40%~60wt%; 2-functionality polyether polyol DL-400 0%~2wt%; Trifunctional polyether polyol TEP-330N 20%~30wt%; Trifunctional polyether polyol TEP-450 5%~15wt%; Aliphatic diol chain extender DPG 0%~5wt%; Aliphatic triol chain extender TMP 0%~2wt%; Aromatic diamine chain extender ML-200 0%~1wt%; UV absorber 0%~1wt%; Light stabilizer 0%~1wt%; Antioxidant 0%~0.1wt%; Fungicide VINYZENE IT 400DIDP 0%~0.1wt%; 1%~3wt% polyurethane pultrusion release agent; Gel catalyst 0%~0.01wt%.

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