An impact-resistant carbon fiber composite automotive bumper

Abstract

The application discloses an anti-impact carbon fiber composite automobile bumper, and belongs to the technical field of automobile anti-impact components, which comprises a composite material panel and a composite material support beam; the composite material panel and the composite material support beam are both in a half-box shape, and are combined and connected oppositely to form a hollow box structure, and the hollow box structure is filled with an energy-absorbing sandwich structure; the composite material panel and the composite material support beam are overlapped on two sides, and are fixedly connected at the overlapping parts. The panel and the support beam of the bumper are both made of lightweight composite materials, and the middle filled energy-absorbing sandwich structure can improve the impact energy absorption efficiency.

Description

Technical Field

[0001] This invention belongs to the technical field of automotive impact-resistant components, specifically relating to an impact-resistant carbon fiber composite automotive bumper. Background Technology

[0002] The statements herein provide only background information in relation to this invention and do not necessarily constitute prior art.

[0003] Bumpers are protective devices used in automobile transportation to absorb and cushion external impacts, ensuring the safety of the front and rear of the vehicle. With the increasing emphasis on lightweight automotive design, the lightweight and impact-resistant structural design of car bumpers has become a research hotspot. Traditional car bumpers are primarily made of metal, mainly lightweight and impact-resistant aluminum alloys. These bumpers typically employ a combination of a front panel and a rear beam. The front panel provides overall impact resistance, while the rear beam uses a specific structure to provide rigid support for the entire bumper assembly. A buffer core material is used between the front panel and the rear beam to ensure overall impact energy absorption, thus guaranteeing safety.

[0004] Traditional metal materials suffer from high density and unstable rigidity. With the increasing application of new high-performance fiber-reinforced resin matrix composites in structural and impact-resistant components, bumper components made of new carbon fiber composites have become a promising alternative. Meanwhile, multi-structural combination carbon fiber composite bumper products, with their combined impact resistance and rigidity, are increasingly becoming the mainstream in bumper design. However, this type of composite bumper structure inevitably requires the connection of multiple components, primarily using mechanical bolts or rivets. This can lead to stress concentration at the connection points, potentially causing damage during service. Summary of the Invention

[0005] In view of the shortcomings of the existing technology, the purpose of this invention is to provide an impact-resistant carbon fiber composite car bumper. The bumper's panel and support beam are both made of lightweight composite materials, and the energy-absorbing sandwich structure in the middle can improve the impact energy absorption efficiency.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solution:

[0007] In a first aspect, the present invention provides an impact-resistant carbon fiber composite car bumper, comprising a composite material panel and a composite material support beam; both the composite material panel and the composite material support beam are semi-box-shaped, and the two are combined and connected to form a hollow box-shaped structure, the hollow box-shaped structure being filled with an energy-absorbing sandwich structure; the composite material panel and the composite material support beam overlap on both sides, and the overlapping parts are fixedly connected.

[0008] As a further technical solution, the overlapping parts of the composite material panel and the composite material support beam are connected by co-curing connection technology combined with mechanical anchoring structure.

[0009] As a further technical solution, the top of the composite material panel is provided with multiple grooves, and the bottom center of the composite material support beam is provided with a groove. The groove depth of the support beam is greater than the groove depth of the panel.

[0010] As a further technical solution, the energy-absorbing sandwich structure includes multiple core layers arranged in sequence, and the core layers are connected by carbon fiber composite rods.

[0011] As a further technical solution, the composite material panel is prepared by combining carbon fiber or hybrid fiber as reinforcing fabric with a thermoplastic resin matrix; the thermoplastic resin matrix content is 40-60%; the carbon fiber is any one of T300, T700, T800, and T1000, and the hybrid fiber is any one of glass fiber, aramid fiber, UHMWPE fiber, basalt fiber, and nylon fiber.

[0012] As a further technical solution, the composite material support beam is prepared by combining carbon fiber and hybrid fibers as reinforcing fabrics with a thermoplastic resin matrix, with the thermoplastic resin matrix content being 40-60%; the carbon fiber adopts a hybrid fabric structure of high-strength carbon fiber and high-modulus carbon fiber, the high-strength carbon fiber adopts any one of T300, T700, T800, and T1000, and the high-modulus carbon fiber adopts any one of M40, M60, M55, M40J, M55J, and M60J.

[0013] As a further technical solution, the fabric structure of the carbon fiber and hybrid fiber adopts a two-dimensional woven structure or a three-dimensional structure, and the two sides are reinforced by a combined fabric structure; the thermoplastic resin matrix adopts any one of polyethylene, polystyrene, ABS resin, polypropylene, nylon, polycarbonate, polyphenylene sulfide, polyetherketone, and polyetheretherketone resin; the thermoplastic resin matrix adopts the form of a film, and the thickness of the resin film is 0.01-1mm.

[0014] As a further technical solution, the thickness of the composite material support beam and the thickness of the composite material panel are 3-15mm.

[0015] As a further technical solution, the energy-absorbing sandwich structure 3 adopts a lightweight energy-absorbing foam core layer as the main structure, with a porous structure evenly arranged in the main structure, and multiple layers of lightweight energy-absorbing foam core layers are connected by carbon fiber composite connecting rods.

[0016] As a further technical solution, the energy-absorbing foam core layer of the energy-absorbing sandwich structure is made of any one of polymethacrylimide, aluminum honeycomb, or PVC foam, and the materials of the multiple lightweight energy-absorbing foam core layers may be the same or different.

[0017] The beneficial effects of the present invention are as follows:

[0018] The impact-resistant carbon fiber composite car bumper of the present invention utilizes co-curing connection technology and mechanical anchoring structure at the semi-box-shaped joint of the composite material panel and composite material support beam, which can effectively improve the overall stability and mechanical performance of the hollow box structure bumper of composite materials.

[0019] The impact-resistant carbon fiber composite car bumper of the present invention uses a composite material consisting of a thermoplastic resin matrix and a carbon fiber hybrid fabric structure reinforced preform as a lightweight alternative material to form the composite material panel and composite material support beam of the bumper; wherein, the composite material panel adopts a thermoplastic resin-based carbon fiber hybrid composite preform structure design to provide the bumper with impact resistance; the composite material support beam adopts a thermoplastic resin-based carbon fiber hybrid irregular structure design to provide rigid support for the bumper.

[0020] The present invention relates to an impact-resistant carbon fiber composite car bumper. The bumper has a hollow box-shaped structure filled with lightweight energy-absorbing foam. The multiple energy-absorbing core layers are connected by thin carbon fiber composite rods to form a whole, which effectively improves the impact energy absorption efficiency of the energy-absorbing core layers under complex impact conditions and ensures the overall impact resistance and safety. Attached Figure Description

[0021] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0022] Figure 1 This is a schematic diagram of an impact-resistant carbon fiber composite car bumper according to one or more embodiments of the present invention;

[0023] In the diagram: the spacing or dimensions between parts have been exaggerated to show their positions; the diagram is for illustrative purposes only.

[0024] Among them, 1 is an impact-resistant composite material panel, 2 is a high-rigidity composite material support beam, 3 is an energy-absorbing sandwich structure, 4 is a carbon fiber composite material rod, and 5 is an overlapping part. Detailed Implementation

[0025] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0026] In a typical embodiment of the present invention, such as Figure 1 As shown, an impact-resistant carbon fiber composite car bumper includes three parts: an impact-resistant composite panel 1, a high-rigidity composite support beam 2, and an energy-absorbing sandwich structure 3.

[0027] Among them, the impact-resistant composite panel 1 and the high-rigidity composite support beam 2 adopt an irregular semi-box section design, and the two can be combined into a hollow box structure. The overlapping part of the impact-resistant composite panel 1 and the high-rigidity composite support beam 2 adopts co-curing connection technology combined with mechanical anchoring structure to form an integral structure. The energy-absorbing sandwich structure 3 is filled in the hollow box structure.

[0028] Both the impact-resistant composite panel 1 and the high-rigidity composite support beam 2 are semi-box-shaped, and they are combined and connected to form a hollow box structure. The overall shape of the impact-resistant composite panel 1 and the high-rigidity composite support beam 2 is the same as the required shape of a car bumper. The impact-resistant composite panel 1 has two grooves at the top, and the high-rigidity composite support beam 2 has a groove in the middle of its bottom. The groove depth of the support beam is greater than the groove depth of the panel.

[0029] The impact-resistant composite panel 1 and the high-rigidity composite support beam 2 overlap on both sides, and the overlapping part 5 is fixedly connected. Specifically, co-curing connection technology combined with mechanical anchoring structure can be used for connection.

[0030] The energy-absorbing sandwich structure 3 adopts a multi-layer composite structure, that is, the energy-absorbing sandwich structure 3 includes multiple core layers arranged in sequence, and the core layers are connected by carbon fiber composite rods 4.

[0031] The impact-resistant composite panel 1 adopts a thermoplastic resin-based carbon fiber hybrid prefabricated structure design to provide the bumper with impact resistance; the high-rigidity composite support beam 2 adopts a thermoplastic resin-based carbon fiber hybrid irregular structure design to provide rigid support for the bumper; the energy-absorbing sandwich structure 3 adopts a low-density foam material, which is lightweight and can effectively improve the impact energy absorption efficiency of the bumper, ensuring overall impact resistance and safety.

[0032] Impact-resistant composite panel 1 is prepared by combining carbon fiber hybrid high-performance fiber as reinforcing fabric with thermoplastic resin matrix. The content of thermoplastic resin matrix is ​​controlled in the range of 40-60%, which can be flexibly adjusted according to the requirements of the product.

[0033] The carbon fiber in the impact-resistant composite panel 1 can be any type from T300, T700, T800, T1000, etc., and the hybrid fibers used can be any type from glass fiber, aramid fiber, UHMWPE fiber, basalt fiber, nylon fiber, etc., and are not limited to the above types. Among them, carbon fiber is the main fiber, and the combination ratio of hybrid fibers and carbon fiber is flexibly adjusted according to the application requirements.

[0034] The fabric structure of carbon fiber hybrid fabrics can adopt a two-dimensional weave structure or a three-dimensional structure. The two-dimensional weave structure can use plain weave, twill weave, satin weave and other fabric structures. The two-dimensional planar fabric adopts a layered combination structure, and the number of lay-up layers can be flexibly adjusted according to the thickness of the panel. The three-dimensional fabric can use a three-dimensional four-way, three-dimensional five-way, three-dimensional six-way, three-dimensional seven-way or more combined weave structure.

[0035] The fabric structure of the carbon fiber hybrid fabric adopts a transitional design with an irregular semi-box structure. It can adopt a single two-dimensional fabric laminated combination structure or a three-dimensional structure, or a two-dimensional and three-dimensional combination structure. The two sides of the irregular semi-box cross section are reinforced with a combined fabric structure.

[0036] The combined fabric reinforcement structure on both sides of the carbon fiber irregular semi-box cross section can be a fabric structure with a relatively high porosity that differs from the fabric structure of the panel body, forming a transitional combination structure with the body fabric structure to facilitate subsequent melt infiltration and curing bonding.

[0037] The thermoplastic resin matrix can be any one of the following types, and is not limited to: polyethylene, polystyrene, ABS resin, polypropylene, nylon, polycarbonate, polyphenylene sulfide, polyetherketone, polyetheretherketone resin, etc.

[0038] The thermoplastic resin matrix is ​​in the form of a film, and the thickness of the resin film is controlled within the range of 0.01-1mm, which can be flexibly adjusted according to the design requirements of the laminated structure and the resin matrix content.

[0039] The thickness of the impact-resistant composite panel 1 is controlled within the range of 3-15mm. The thickness can be flexibly adjusted according to the product design requirements. The panel cross-sectional shape can be designed with grooves at specific positions on the panel to increase impact stiffness.

[0040] The high-rigidity composite support beam 2 is prepared by combining carbon fiber hybrid high-performance fiber as reinforcing fabric with thermoplastic resin matrix. The content of thermoplastic resin matrix is ​​controlled within the range of 40-60%, which can be flexibly adjusted according to the requirements of the product.

[0041] The carbon fiber hybrid composite fabric structure used in the high rigidity composite support beam 2 adopts the same combination structure type as the panel. The fabric structure design of the connection part of the irregular cross-section half box of the rigid support beam is also the same as that of the panel. The carbon fiber type can be a hybrid fabric structure of high strength carbon fiber and high modulus carbon fiber, and the mixing ratio can be flexibly adjusted according to the product design requirements.

[0042] High-strength carbon fiber can be any of the following types: T300, T700, T800, T1000, etc., and high-modulus carbon fiber can be any of the following types: M40, M60, M55, M40J, M55J, M60J, etc., and is not limited to the above types.

[0043] The thermoplastic resin matrix type and material structure design are the same as those of the panel.

[0044] The thickness of the high-rigidity composite material support beam 2 is the same as that of the impact-resistant composite material panel 1. According to the product design requirements, the rigid composite material support beam can adopt a specific part bending groove structure design to increase the deformation resistance of the rear beam. Its cross-sectional shape can be flexibly adjusted according to the design requirements.

[0045] The impact-resistant composite panel 1 and the high-rigidity composite support beam 2 are respectively made by combining the above-mentioned thin film resin matrix with the multidimensional hybrid fiber fabric preform in a predetermined composite structure, laying it inside a specific mold, and pressing the parts into shape using a high-temperature heating furnace under certain temperature and pressure process parameters. The final pressure heating time is flexibly adjusted according to design requirements.

[0046] The co-curing connection technology at the joint between the panel and the supporting beam, combined with the mechanical anchoring structure, is operated as follows:

[0047] The first step involves hot-pressing the impact-resistant composite panel and the high-rigidity composite support beam separately, then assembling the irregularly shaped semi-box sections of the panel and support beam products in a specific support assembly mold to pre-form an integral structure.

[0048] The second step is to use an infrared radiation heating device (carbon fiber heating element, ceramic heating element, etc.) to heat and soften the overlapping parts of the irregular cross section. The softening temperature is flexibly designed based on the hot melt temperature of the thermoplastic resin matrix used in the panel and support beam, and is generally 5-10℃ higher than the hot melt temperature.

[0049] The third step is to install a pressure-tightening fixture at a specific connection point after the connection has been heated and softened. The connection is then subjected to a secondary melting and infiltration treatment using a localized pressure-tightening method. The pressure is controlled within the range of 1-10 MPa, and the pressure application time is flexibly adjusted according to the connection design requirements.

[0050] The fourth step is to use refrigeration equipment to quickly cool the hot melt impregnation connection after the pressure time is met, and the cooling time is controlled within the range of 10-30 seconds.

[0051] The fifth step involves using specific hole-making equipment (such as a high-speed ceramic cutter or water jet cutter) to make holes in the connection area and fastening them with mechanical rivets. The number of rivets can be flexibly adjusted according to design requirements.

[0052] The energy-absorbing sandwich structure 3 uses a lightweight energy-absorbing foam core layer as the main structure. A porous structure is evenly arranged in a specific part of the main structure. The multiple foam core layers are connected by carbon fiber composite connecting rods to form a foam core layer energy-absorbing structure.

[0053] The energy-absorbing foam of the energy-absorbing sandwich structure 3 can be any one of polymethacrylimide (PMI), aluminum honeycomb, or PVC foam. The energy-absorbing layers of multiple layers of energy-absorbing foam can be designed to be combined with energy-absorbing layers of the same or different materials.

[0054] The self-tensioning composite material sheet molding tooling of the present invention will be described below with reference to specific embodiments.

[0055] Example 1:

[0056] In this embodiment, the impact-resistant carbon fiber composite panel uses a hybrid plain weave fabric of T300 carbon fiber and high-strength glass fiber reinforced with polypropylene resin. The carbon fiber and glass fiber are mixed and woven in a 2:1 ratio, and then laminated with a 0.05mm thick film resin. The ratio of the film resin to the carbon fiber hybrid fabric is 1:1. After the raw material is laminated, it is placed in a molding mold, and the mold containing the raw materials is placed in a hot press furnace for hot pressing molding. The heating temperature is 220℃, and a pressure of 3MPa is applied during the heating process for 80 minutes to complete the hot melt impregnation and composite molding of resin and fiber fabric, finally forming a composite panel with a resin content of 50%. The final impact-resistant panel adopts a local groove structure design in the middle, the overall panel cross-sectional thickness is 5mm, and the panel length is 80mm.

[0057] The high-rigidity carbon fiber composite support beam is made of polypropylene resin reinforced with a 1:1 hybrid ratio of high-strength T300 carbon fiber and M40 high-modulus carbon fiber mixed twill fabric. The resin is a 0.05mm thick film. The resin film and the hybrid fiber fabric are laminated in a 1:1 ratio. The laminated material is placed in a molding mold and heated and pressurized in a furnace at 220℃. During the heating process, a pressure of 3MPa is continuously applied, and the molding time is 90min. The final composite support beam has a resin content of 40%. A specially shaped protruding rigid structure is designed in the middle of the support beam. The overall cross-sectional thickness of the support beam is 6mm, and the length of the support beam is 80mm.

[0058] The impact-resistant panel and rigid support beam, which are respectively hot-pressed into irregular semi-box structures, are placed into the support assembly mold and snapped together to form a hollow box structure. Then, infrared radiation ceramic heating elements are used to heat and soften the overlapping parts of the irregular cross-section. The heating temperature is controlled at 230℃. After heating, a pressure of 5MPa is applied to the overlapping position through a clamping fixture. The pressure is continuously applied and heated for 30 minutes to co-cur and connect them. After continuous connection and pressure, the overlapping connection is cooled for 10 seconds by a refrigerator to form a whole. A high-speed ceramic drilling tool is used to drill holes in the overlapping part. Six sets of mechanical rivets are evenly arranged along the connection length of the panel and support beam for fastening.

[0059] Inside the hollow box structure formed by the impact-resistant panel and the rigid support beam, a three-layer, 4mm thick polymethacrylamide (PMI) low-density foam core is used. Six sets of 2mm diameter holes are evenly distributed along the length of the hollow structure of the bumper in the core layer. Thin carbon fiber composite rods are inserted into the holes to connect the foam core into a whole.

[0060] Example 2:

[0061] In this embodiment, the impact-resistant carbon fiber composite panel uses a hybrid plain weave fabric of T700 carbon fiber and aramid fiber reinforced with polypropylene resin. The carbon fiber and aramid fiber are mixed and woven in a 3:1 ratio, and then laminated with a 0.06mm thick film resin. The ratio of the film resin to the carbon fiber hybrid fabric in the laminate is 2:1. After the raw material is laminated, it is placed in a molding mold, and the mold containing the raw materials is placed in a hot press furnace for hot pressing molding. The heating temperature is 220℃, and a pressure of 2MPa is applied during the heating process for 85 minutes to complete the hot melt impregnation and composite molding of the resin and fiber fabric, finally forming a composite panel with a resin content of 50%. The final impact-resistant panel adopts a local groove structure design in the middle, the overall panel cross-sectional thickness is 6mm, and the panel length is 70mm.

[0062] The high-rigidity carbon fiber composite support beam is made of polypropylene resin reinforced with a 2:1 hybrid ratio of high-strength T700 carbon fiber and M55 high-modulus carbon fiber mixed twill fabric. The resin is a 0.06mm thick film. The resin film and the hybrid fiber fabric are laminated in a 2:1 ratio. The laminated material is placed in a molding mold and heated and pressurized in a furnace at 220℃. A pressure of 2MPa is continuously applied during the heating process, and the molding time is 90min. The final product is a composite support beam with a resin content of 50%. A specially shaped protruding rigid structure is designed in the middle of the support beam. The overall cross-sectional thickness of the support beam is 6mm and the length of the support beam is 70mm.

[0063] The impact-resistant panel and rigid support beam, which are respectively hot-pressed and formed into irregular semi-box structures, are placed into the support assembly mold and snapped together to form a hollow box structure. Then, carbon fiber infrared heating elements are used to heat and soften the overlapping parts of the irregular cross-section. The heating temperature is controlled at 230℃. After heating, a pressure of 5MPa is applied to the overlapping position through a clamping fixture. The pressure is continuously applied and heated for 30 minutes to co-cur and connect them. After continuous connection and pressure, the overlapping connection is cooled for 10 seconds by a refrigerator to form a whole. A water jet is used to make holes in the overlapping part, and 8 sets of mechanical rivets are evenly arranged along the connection length of the panel and support beam for fastening.

[0064] Inside the hollow box structure formed by the impact-resistant panel and the rigid support beam, a low-density foam core material of polymethacrylamide (PMI) with a thickness of 3mm is used to fill the core. Eight sets of holes with a diameter of 2mm are evenly distributed along the length of the hollow structure of the bumper in the core layer. Thin rods of carbon fiber composite material are inserted into the holes to connect the foam core material into a whole.

[0065] Example 3:

[0066] In this embodiment, the impact-resistant carbon fiber composite panel uses a hybrid twill fabric of T1000 carbon fiber and UHMWPE fiber reinforced with polyamide resin. The carbon fiber and UHMWPE fiber are mixed and woven in a 4:1 ratio, and then laminated with a 0.08mm thick film resin. The ratio of film resin to carbon fiber hybrid fabric in the laminate is 3:1. After the raw material is laminated, it is placed in a molding mold, and the mold containing the raw materials is placed in a hot press furnace for hot pressing molding. The heating temperature is 250℃, and a pressure of 2MPa is applied during the heating process for 90 minutes to complete the hot melt impregnation and composite molding of resin and fiber fabric, finally forming a composite panel with a resin content of 60%. The final impact-resistant panel adopts a local groove structure design in the middle, the overall panel thickness is 8mm, and the panel length is 90mm.

[0067] The high-rigidity carbon fiber composite support beam is made of high-strength T1000 carbon fiber and M60J high-modulus carbon fiber hybrid twill fabric reinforced with polyamide resin in a 4:3 hybrid ratio. The resin is a 0.08mm thick film. The resin film and the hybrid fiber fabric are laminated in a 3:1 ratio. The laminated material is placed in a molding mold and heated and pressurized in a furnace at 250℃. During the heating process, a pressure of 2MPa is continuously applied, and the molding time is 90min. The final composite support beam has a resin content of 60%. A specially shaped protruding rigid structure is designed in the middle of the support beam. The overall cross-sectional thickness of the support beam is 8mm, and the length of the support beam is 90mm.

[0068] The impact-resistant panel and rigid support beam, which are respectively hot-pressed and formed, are placed into a support assembly mold and then snapped together to form a hollow box structure. Then, an infrared radiation heating device (carbon fiber and ceramic heating element) is used to heat and soften the overlapping part of the irregular cross section. The heating temperature is controlled at 230℃. After heating, a pressure of 4MPa is applied to the overlapping part by a clamping tool. The pressure is continuously applied and heated for 30 minutes to co-cur and connect them. After continuous connection and pressure, the overlapping part is cooled by a refrigerator for 8 seconds to form a whole. A high-speed ceramic hole opener is used to open the overlapping part. Six sets of mechanical rivets are evenly arranged along the connection length of the panel and support beam for fastening.

[0069] Inside the hollow box structure formed by the impact-resistant panel and the rigid support beam, four layers of 4mm thick PVC low-density foam core material are used for filling. Six sets of 3mm diameter holes are evenly distributed along the length of the hollow structure of the bumper in the core layer. Thin rods made of carbon fiber composite material are inserted into the holes to connect the foam core material into a whole.

[0070] Example 4:

[0071] In this embodiment, the impact-resistant carbon fiber composite panel uses a hybrid three-dimensional four-way woven fabric of T300 carbon fiber mixed with high-strength glass fiber to reinforce polyphenylene sulfide resin. The carbon fiber and glass fiber are mixed and woven in a 2:1 ratio, and then laminated with a 0.3mm thick film resin. The ratio of the film resin to the carbon fiber hybrid woven fabric is 2:1. After the raw material is laminated, it is placed in a molding mold, and the mold containing the raw materials is placed in a hot press furnace for hot pressing molding. The heating temperature is 260℃, and a pressure of 3MPa is applied during the heating process for 120 minutes to complete the hot melt impregnation and composite molding of resin and fiber fabric, finally forming a composite panel with a resin content of 40%. The final impact-resistant panel adopts a local groove structure design in the middle, the overall panel thickness is 5mm, and the panel length is 80mm.

[0072] The high-rigidity carbon fiber composite support beam is made of polypropylene resin reinforced with a 2:1 hybrid ratio of high-strength T700 carbon fiber and M40J high-modulus carbon fiber in a three-dimensional four-way woven fabric. The resin is a 0.3mm thick film. The resin film and the hybrid fiber fabric are laminated in a 2:1 ratio. The laminated material is placed in a molding die and heated and pressurized in a furnace at 260℃. During the heating process, a pressure of 3MPa is continuously applied, and the molding time is 120min. The final composite support beam has a resin content of 40%. A specially shaped protruding rigid structure is designed in the middle of the support beam. The overall cross-sectional thickness of the support beam is 5mm, and the length of the support beam is 80mm.

[0073] The impact-resistant panel and rigid support beam, which are respectively hot-pressed and formed, are placed into a support assembly mold and then snapped together to form a hollow box structure. Then, carbon fiber infrared radiation heating elements are used to heat and soften the overlapping parts of the irregular cross-section. The heating temperature is controlled at 260℃. After heating, a pressure of 4MPa is applied to the overlapping position through a clamping tool. The pressure is continuously applied and heated for 40 minutes to co-cur and connect them. After continuous connection and pressure, the overlapping connection is cooled for 10 seconds by a refrigerator to form a whole. A high-speed ceramic hole opener is used to open the overlapping part, and 7 sets of mechanical rivets are evenly arranged along the connection length of the panel and support beam for fastening.

[0074] Inside the hollow box structure formed by the impact-resistant panel and the rigid support beam, a low-density foam core material with a thickness of 4mm aluminum honeycomb is used to fill the core. Seven sets of 2mm diameter holes are evenly distributed along the length of the hollow structure of the bumper in the core layer. Thin rods made of carbon fiber composite material are inserted into the holes to connect the foam core material into a whole.

[0075] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An impact-resistant carbon fiber composite vehicle bumper, characterized by, The composite material panel and the composite material support beam are both half-box-shaped, and are combined and connected to form a hollow box-shaped structure, and the hollow box-shaped structure is filled with an energy-absorbing sandwich structure; the composite material panel and the composite material support beam are overlapped on two sides, and are fixedly connected at the overlapping parts; The overlapping parts of the composite material panel and the composite material support beam are connected by using a co-curing connection technology combined with a mechanical anchoring structure; A plurality of grooves are arranged on the top of the composite material panel, and a groove is arranged in the middle of the bottom of the composite material support beam, and the groove depth of the support beam is greater than the groove depth of the panel; The composite material panel is prepared by using carbon fibers and hybrid fibers as reinforcing fabrics and combining with a thermoplastic resin matrix; The composite material support beam is prepared by using carbon fibers and hybrid fibers as reinforcing fabrics and combining with a thermoplastic resin matrix; The operation mode of the co-curing connection technology combined with the mechanical anchoring structure is as follows: The overlapping parts are heated and softened, and the softening temperature is 5-10℃ higher than the heat melting temperature of the thermoplastic resin matrix used in the composite material panel and the composite material support beam; The overlapping parts are subjected to secondary infiltration treatment by using a local pressing method, and the pressure is 1-10MPa; Fast cooling is performed by using refrigeration equipment, and the cooling time is 10-30s; The overlapping parts are holed and fastened by mechanical rivets.

2. The impact-resistant carbon fiber composite automotive bumper of claim 1, wherein, The energy-absorbing sandwich structure comprises a plurality of core layers arranged in sequence, and the core layers are connected by carbon fiber composite material thin rods.

3. The impact-resistant carbon fiber composite automotive bumper of claim 1, wherein, The composite material panel is prepared by using carbon fibers and hybrid fibers as reinforcing fabrics and combining with a thermoplastic resin matrix; the content of the thermoplastic resin matrix is 40-60%; the carbon fibers are any one of T300, T700, T800 and T1000, and the hybrid fibers are any one of glass fibers, aramid fibers, UHMWPE fibers, basalt fibers and nylon fibers.

4. The impact-resistant carbon fiber composite automotive bumper of claim 1, wherein, The composite material support beam is prepared by using carbon fibers and hybrid fibers as reinforcing fabrics and combining with a thermoplastic resin matrix, and the content of the thermoplastic resin matrix is 40-60%; the carbon fibers are in the form of hybrid fabric structure of high-strength carbon fibers and high-modulus carbon fibers, the high-strength carbon fibers are any one of T300, T700, T800 and T1000, and the high-modulus carbon fibers are any one of M40, M60, M55, M40J, M55J and M60J.

5. The impact-resistant carbon fiber composite automotive bumper of claim 3 or 4, wherein, The fabric structure of the carbon fibers and the hybrid fibers adopts a two-dimensional woven structure or a three-dimensional solid structure, and the two side edges adopt a combined fabric reinforcement structure; the thermoplastic resin matrix is any one of polyethylene, polystyrene, ABS resin, polypropylene, nylon, polycarbonate, polyphenylene sulfide, polyether ketone and polyether ether ketone resin; the thermoplastic resin matrix is in the form of a film, and the thickness of the resin film is 0.01-1mm.

6. The impact-resistant carbon fiber composite automotive bumper of claim 1, wherein, The thickness of the composite material support beam and the thickness of the composite material panel are 3-15mm.

7. The impact-resistant carbon fiber composite automotive bumper of claim 1, wherein, The energy-absorbing sandwich structure (3) adopts a light-weight energy-absorbing foam core layer as a main structure, a hole structure is uniformly arranged in the main structure, and a plurality of light-weight energy-absorbing foam core layers are connected by carbon fiber composite material connecting thin rods.

8. The impact-resistant carbon fiber composite automotive bumper of claim 7, wherein, The energy-absorbing foam core layer of the energy-absorbing sandwich structure adopts any one of polymethylacrylimide, aluminum honeycomb and PVC foam, and the materials of the multiple light energy-absorbing foam core layers are the same or different.

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