A fiber-reinforced anti-collision beam and its preparation process and application

Abstract

The invention discloses a fiber-reinforced anti-collision beam, including a main beam and a reinforcing rib, the main beam including an outer continuous fiber-reinforced thermoplastic resin layer and an inner short-cut fiber-reinforced thermoplastic resin layer; the continuous fiber-reinforced thermoplastic resin layer is composed of a continuous fiber-reinforced thermoplastic composite material A, and in parts by weight, the continuous fiber-reinforced thermoplastic composite material A includes 30-50 parts of thermoplastic resin, 30-70 parts of continuous fibers, and 1-5 parts of compatibilizer; the short-cut fiber-reinforced thermoplastic resin layer and the reinforcing rib are composed of a short-cut fiber-reinforced thermoplastic composite material B, and in parts by weight, the short-cut fiber-reinforced thermoplastic composite material B includes 20-80 parts of thermoplastic resin, 20-50 parts of short-cut fibers, and 2-6 parts of compatibilizer. The fiber-reinforced anti-collision beam of the present invention has the advantage of higher strength and is suitable for front and rear anti-collision beams of automobiles.

Description

Technical Field

[0001] The invention relates to the technical field of polymer materials, and in particular to a fiber-reinforced anti-collision beam and a preparation process and application thereof. Background Art

[0002] Anti-collision beams are installed around the vehicle to reduce the vibration caused by the collision. Anti-collision beams are usually made of high-strength cold-rolled steel plates to increase the strength of the anti-collision beams to resist external forces. However, due to the heavy weight of cold-rolled steel plates, it is difficult to use them in the trend of lightweight vehicles. In order to reduce the weight of anti-collision beams, more R&D personnel will focus on high-strength fiber-reinforced composite materials.

[0003] In order to maintain a high strength of the anti-collision beam and further reduce the weight of the anti-collision beam, fibers are usually added to the raw materials for preparing the anti-collision beam. For example, Chinese patent application CN108312656A discloses a carbon fiber composite material for an anti-collision beam, including a plain carbon fiber impregnation layer and a twill carbon fiber impregnation layer arranged alternately in sequence, and the number of layers of the plain carbon fiber impregnation layer and the twill carbon fiber impregnation layer are both 4-6 layers. However, the manufacturing methods of anti-collision beams in the prior art are generally the following two: 1. The reinforcing ribs and the main beam are separately formed and then welded, connected by bolts, slots, etc. or other physical methods, 2. The reinforcing ribs are injection molded into the main beam after the main beam is formed. However, the reinforcing ribs of the anti-collision beams obtained by the above two methods are easy to peel off from the main beam during the stress period, thereby reducing the strength of the anti-collision beam. Summary of the invention

[0004] The object of the present invention is to overcome the above technical defects and provide a fiber-reinforced anti-collision beam, which has the advantages of being lightweight and having higher strength than anti-collision beams of the same thickness.

[0005] Another object of the present invention is to provide a preparation method and application of a fiber-reinforced anti-collision beam.

[0006] The present invention is achieved through the following technical solutions:

[0007] A fiber-reinforced anti-collision beam comprises an external main beam of the anti-collision beam and internal reinforcing ribs, the main beam comprising an outer layer of a continuous fiber-reinforced thermoplastic resin layer and an inner layer of a chopped fiber-reinforced thermoplastic resin layer; the continuous fiber-reinforced thermoplastic resin layer is composed of a continuous fiber-reinforced thermoplastic composite material A, which comprises 30-50 parts of a thermoplastic resin, 30-70 parts of continuous fibers, and 1-5 parts of a compatibilizer in parts by weight; the chopped fiber-reinforced thermoplastic resin layer and the reinforcing ribs are composed of a chopped fiber-reinforced thermoplastic composite material B, which comprises 20-80 parts of a thermoplastic resin, 20-50 parts of chopped fibers, and 2-6 parts of a compatibilizer in parts by weight.

[0008] The thickness range of the continuous fiber reinforced thermoplastic resin layer in the main beam is 2-7 mm, the thickness range of the short fiber reinforced thermoplastic resin layer is 0.1-1 mm; the thickness range of the reinforcing rib is 1-6 mm.

[0009] The average length of the chopped fibers ranged from 1 to 3 mm.

[0010] In the continuous fiber reinforced thermoplastic resin layer, the number of layers of continuous fibers is ≥3.

[0011] The main beam and the reinforcement ribs are formed as one piece through mold closing, not through welding or other connection methods.

[0012] The thermoplastic resin is selected from at least one of PP, PA, PBT and PC. In order to ensure the compatibility between the various structures of the anti-collision beam, the main beam and the reinforcing ribs of the present invention use the same type of thermoplastic resin. Among them, PP can have a melt index of 10~60g / 10min (test conditions are 230℃, 2.16kg), PA can have a melt index of 10~60g / 10min (test conditions are 230℃, 2.16kg), PBT can have a melt index of 10~60g / 10min (test conditions are 250℃, 2.16kg), and PC can have a melt index of 10~60g / 10min (test conditions are 300℃, 1.2kg).

[0013] Specifically, the PA resin may be PA6, PA610, or XC030.

[0014] The continuous fiber is selected from at least one of continuous carbon fiber and continuous glass fiber;

[0015] The compatibilizer is selected from at least one of maleic anhydride grafted polypropylene, maleic anhydride grafted POE, ethylene-butyl acrylate grafted maleic anhydride, ethylene-butyl acrylate grafted glycidyl methacrylate, and epoxy resin;

[0016] The chopped fibers are selected from at least one of chopped carbon fibers and chopped glass fibers.

[0017] The continuous fiber reinforced thermoplastic composite material A and / or the chopped fiber reinforced thermoplastic resin composite material B further comprises 0-3 parts of an auxiliary agent by weight; the auxiliary agent is selected from at least one of an antioxidant, a lubricant, and a weathering agent.

[0018] The preparation process of the fiber-reinforced anti-collision beam of the present invention comprises the following steps:

[0019] Step A, rolling up the continuous fiber reinforced thermoplastic composite material A into a coil after melt forced in-mold impregnation, and then cutting to obtain a continuous fiber reinforced thermoplastic resin prepreg sheet of a set width and length;

[0020] Step B, laying a set number of layers of continuous fiber reinforced thermoplastic resin prepreg sheets, and then heat setting to obtain a thermoplastic composite material A plate;

[0021] Step C, placing the preheated thermoplastic composite material A sheet pad on the mold, then extruding the molten short fiber reinforced thermoplastic composite material B on the thermoplastic composite material A sheet, and then closing the mold to obtain a fiber reinforced anti-collision beam.

[0022] The fiber-reinforced anti-collision beam of the present invention is used for vehicle-mounted front / rear anti-collision beams.

[0023] The present invention has the following beneficial effects:

[0024] The preparation process of the present invention enables the main beam of the anti-collision beam to contain an inner layer of short-fiber thermoplastic resin layer of a certain thickness, and the inner layer of short-fiber thermoplastic resin layer and the reinforcing ribs are integrally formed and have the same composite material, so that the reinforcing ribs are firmly connected to the main beam of the anti-collision beam, which significantly improves the overall strength compared to the anti-collision beam of the same thickness. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 : Anti-collision beam structure diagram.

[0026] Figure 2 : Schematic diagram of the anti-collision beam structure, number 1 is the main beam and number 2 is the reinforcement rib.

[0027] Figure 3 : Schematic diagram of the main beam and reinforcing rib composite material structure, number 11 is a continuous fiber thermoplastic resin layer, number 12 is a chopped fiber thermoplastic resin layer.

[0028] Figure 4 : Diagram of anti-collision beam test method. DETAILED DESCRIPTION

[0029] The present invention is described in detail below in conjunction with specific embodiments. The following embodiments will help those skilled in the art to further understand the present invention, but are not intended to limit the present invention in any form. It should be noted that, for those of ordinary skill in the art, several variations and improvements may be made without departing from the concept of the present invention. These all belong to the protection scope of the present invention.

[0030] PA6: XC030, melt index 30g / 10min, Zhuzhou Times;

[0031] PP-1: PPH-MN60, melt index 60g / 10min, Sinopec Beihai Refining and Chemical Co., Ltd.; PP-2: SP179, melt index 11g / 10min, PetroChina Lanzhou;

[0032] Continuous carbon fiber: brand name is T700SC-12000-50C, manufacturer is Toray;

[0033] Continuous glass fiber: brand EDR17-2400-362A (U), manufacturer: Jushi Group;

[0034] Chopped carbon fiber: average length is 3mm, brand is PAN 24t, manufacturer is Mitsubishi Chemical of Japan;

[0035] Chopped glass fiber: average length is 3mm, brand is 560A, manufacturer is Jushi Group;

[0036] Compatibilizer A: PC-28, maleic anhydride grafted ethylene-octene copolymer elastomer, manufacturer: Foshan Bochen;

[0037] Compatibilizer B: YD019, epoxy resin, manufacturer: Shanghai Kane;

[0038] Antioxidant: Commercially available, and the same one was used in the parallel examples and comparative examples.

[0039] Example 1-6 Preparation method of fiber-reinforced anti-collision beam: Step A, after melt-forced in-mold impregnation of continuous fiber reinforced thermoplastic composite material A (the ratio of continuous carbon fiber, PA6, and compatibilizer A is shown in the table), it is rolled into a coil (the temperature is 300°C), and then cut to obtain a continuous fiber reinforced thermoplastic resin prepreg sheet of set width and length; Step B, laying up a set number of continuous fiber reinforced thermoplastic resin prepreg sheets, and then heat-setting to obtain a thermoplastic composite material A plate (the temperature is 280°C); Step C, placing the preheated thermoplastic composite material A plate pad on a mold, and then extruding the molten chopped fiber reinforced thermoplastic composite material B (the ratio of chopped carbon fiber, PA6, and compatibilizer A is shown in the table) on the thermoplastic composite material A plate, and then closing the mold to form (the temperature is 300°C) to obtain a fiber reinforced anti-collision beam.

[0040] The preparation method of the fiber-reinforced anti-collision beam of Example 7 / 8 and Comparative Example 1 is as follows: Step A, the continuous fiber reinforced thermoplastic composite material A (the ratio of continuous glass fiber, PP, and compatibilizer B is shown in the table) is subjected to melt forced in-mold impregnation and then rolled into a coil (the temperature is 280°C), and then cut to obtain a continuous fiber reinforced thermoplastic resin prepreg sheet of set width and length; Step B, layering a set number of continuous fiber reinforced thermoplastic resin prepreg sheets, and then heat-setting to obtain a thermoplastic composite material A plate (the temperature is 220°C); Step C, placing the preheated thermoplastic composite material A plate pad on a mold, and then extruding the molten chopped fiber reinforced thermoplastic composite material B (the ratio of chopped glass fiber, PP, and compatibilizer B is shown in the table) on the thermoplastic composite material A plate, and then closing the mold to form (the temperature is 230°C) to obtain a fiber reinforced anti-collision beam.

[0041] Comparative Example 2: The continuous fiber reinforced thermoplastic composite material A (the ratio of continuous glass fiber, PP and compatibilizer B is shown in the table) is melt-forced in-mold impregnation and then rolled into a coil (temperature is 280°C), and then cut to obtain a continuous fiber reinforced thermoplastic resin prepreg sheet of set width and length; the set number of layers of continuous fiber reinforced thermoplastic resin prepreg sheets are layered, and then heat-set to obtain a thermoplastic composite material A plate (temperature is 230°C), the preheated thermoplastic composite material A plate is placed on the mold, and the mold is closed and formed (temperature is 240°C) to obtain a fiber-reinforced anti-collision beam main beam, and then the chopped fiber reinforced thermoplastic composite material B (the ratio of chopped glass fiber, PP and compatibilizer B is shown in the table) is injection molded into reinforcing ribs by injection molding to obtain a fiber-reinforced anti-collision beam.

[0042] Various test methods:

[0043] (1) Strength test method: Figure 4 , support both ends of the anti-collision beam, apply pressure in the middle, and measure the maximum pressure that the anti-collision beam can withstand before it breaks.

[0044] Table 1: Parameters and test results of the anti-collision beams of Examples 1-6

[0045]

[0046] Table 2: Parameters and test results of anti-collision beams of Examples 7-8 and Comparative Examples 1-2

[0047]

[0048] It can be seen from Example 7 and Comparative Example 1 that when the chopped fiber reinforced thermoplastic resin layer of the main beam is too thin, it is easy to cause the connection between the reinforcing ribs and the main beam to be not firm enough, and the strength is significantly lower.

[0049] It can be seen from Example 7 and Comparative Example 2 that if the reinforcing ribs are prepared by injection molding, the strength is further reduced.

Claims

1. A fiber-reinforced anti-collision beam, comprising a main beam (1) and reinforcing ribs (2), characterized in that: The main beam comprises an outer layer of a continuous fiber reinforced thermoplastic resin layer (11) and an inner layer of a chopped fiber reinforced thermoplastic resin layer (12); the continuous fiber reinforced thermoplastic resin layer (11) is composed of a continuous fiber reinforced thermoplastic composite material A, which comprises, by weight, 30-50 parts of a thermoplastic resin, 30-70 parts of continuous fibers, and 1-5 parts of a compatibilizer; the chopped fiber reinforced thermoplastic resin layer (12) and the reinforcing ribs (2) are composed of a chopped fiber reinforced thermoplastic composite material B, which comprises, by weight, 20-80 parts of a thermoplastic resin, 20-50 parts of chopped fibers, and 2-6 parts of a compatibilizer; The thickness of the continuous fiber reinforced thermoplastic resin layer in the main beam (1) is in the range of 2-7 mm, and the thickness of the short fiber reinforced thermoplastic resin layer is in the range of 0.1-1 mm; the thickness of the reinforcing rib (2) is in the range of 1-6 mm; In the continuous fiber reinforced thermoplastic resin layer (11), the number of layers of continuous fibers is ≥3; The preparation process of the fiber reinforced anti-collision beam comprises the following steps: Step A, rolling up the continuous fiber reinforced thermoplastic composite material A into a coil after melt forced in-mold impregnation, and then cutting to obtain a continuous fiber reinforced thermoplastic resin prepreg sheet of a set width and length; Step B, laying a set number of layers of continuous fiber reinforced thermoplastic resin prepreg sheets, and then heat-setting to obtain a thermoplastic composite material A plate; Step C, placing the preheated thermoplastic composite material A sheet pad on the mold, then extruding the molten short fiber reinforced thermoplastic composite material B on the thermoplastic composite material A sheet, and then closing the mold to obtain a fiber reinforced anti-collision beam.

2. The fiber-reinforced anti-collision beam according to claim 1, characterized in that: The average length of the chopped fibers ranged from 1 to 3 mm.

3. The fiber-reinforced anti-collision beam according to claim 1, characterized in that: The main beam and the reinforcing ribs are integrally formed by mold closing.

4. The fiber-reinforced anti-collision beam according to claim 1, characterized in that: The thermoplastic resin is selected from at least one of PP, PA, PBT and PC; the melt index of PP is 10-60 g / 10 min, and the test conditions are 230° C. and 2.16 kg; the melt index of PA is 10-60 g / 10 min, and the test conditions are 230° C. and 2.16 kg; the melt index of PBT is 10-60 g / 10 min, and the test conditions are 250° C. and 2.16 kg; the melt index of PC is 10-60 g / 10 min, and the test conditions are 300° C. and 1.2 kg.

5. The fiber-reinforced anti-collision beam according to claim 1, characterized in that: The continuous fiber is selected from at least one of continuous carbon fiber and continuous glass fiber; the compatibilizer is selected from at least one of maleic anhydride grafted polypropylene, maleic anhydride grafted POE, ethylene-butyl acrylate grafted maleic anhydride, ethylene-butyl acrylate grafted glycidyl methacrylate, and epoxy resin; the chopped fiber is selected from at least one of chopped carbon fiber and chopped glass fiber.

6. The fiber-reinforced anti-collision beam according to claim 1, characterized in that: The continuous fiber reinforced thermoplastic composite material A and / or the chopped fiber reinforced thermoplastic resin composite material B further comprises 0-3 parts of an auxiliary agent by weight; the auxiliary agent is selected from at least one of an antioxidant, a lubricant, and a weathering agent.

7. Application of the fiber reinforced anti-collision beam according to any one of claims 1 to 6, characterized in that: Used for vehicle-mounted front / rear anti-collision beams.

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