Automobile anti-collision structure and preparation method thereof

Abstract

The application discloses an automobile anti-collision structure and a preparation method thereof. The automobile anti-collision structure comprises an inner support body, a buffer layer and a paint layer. The buffer layer is arranged on the outer surface of the inner support body, and the paint layer is arranged on the outer surface of the buffer layer. A plurality of carbon fiber balls are arranged in the buffer layer. The application can improve the anti-fracture capability of the anti-collision structure and prolong the service life of the anti-collision structure.

Description

Technical Field

[0001] This application relates to the field of automotive anti-collision structures, and particularly to anti-collision structures and their manufacturing methods. Background Technology

[0002] Collisions frequently occur during vehicle movement. Minor collisions often cause paint to peel off, while major collisions often cause the anti-collision structure to break. How to improve the anti-fracture capability of the anti-collision structure and extend its service life has always been a problem.

[0003] Application content

[0004] To address the problems existing in the prior art, this application discloses an automotive anti-collision structure, which includes an inner support body, a buffer layer, and a paint layer. The buffer layer is disposed on the outer surface of the inner support body, and the paint layer is disposed on the outer surface of the buffer layer.

[0005] The buffer layer contains multiple layers of carbon fiber spheres.

[0006] An adhesive is provided between the carbon fiber spheres in the buffer layer. The buffer layer contains at least three layers of carbon fiber spheres. Carbon fiber is primarily composed of carbon and can be made from acrylic and viscose fibers through high-temperature oxidation and carbonization. It possesses high-temperature resistance, friction resistance, thermal conductivity, and corrosion resistance. Carbon fiber is fibrous and flexible. Due to its graphite microcrystalline structure preferentially oriented along the fiber axis, it exhibits high strength and modulus along the fiber axis. Additionally, carbon fiber also includes multi-walled carbon nanotubes (MWCNTs). Experiments have shown that MWCNTs have superior sphere-forming performance during spray granulation. The diameter of the carbon fiber is 100 nm-10 μm, and the diameter of the carbon fiber spheres is 5-50 μm. The diameter of the carbon fiber spheres can be adjusted according to the solution concentration (carbon fiber content in the solution) and the nozzle size of the spray gun during spray granulation. Because the carbon fiber spheres have a porous structure and high toughness, they can withstand slight impacts. When an impact occurs, it can buffer the impact stress. When the impact force increases, it can break the paint layer and cause the carbon fiber balls to shift, which further buffers the impact stress. As long as the inner support is not broken, the surface scratches caused by the break can be repaired by spraying a carbon fiber ball solution containing adhesive and drying it, which is convenient and equivalent to improving the service life of the anti-collision structure. Compared with some existing technologies that use foam to protect the outside of the anti-collision structure, the service life of the automotive anti-collision structure of this application is not as high because the chemical stability of foam is much lower than that of carbon fiber. In addition, compared with the buffer layer being a solid fiber layer, the fiber layer cannot form the effect of carbon fiber ball displacement, which makes it easy for stress concentration to form at the most severely impacted position during the impact, thus making it easy for the support below (or behind) the buffer layer to break.

[0007] The method for manufacturing the automotive anti-collision structure includes the following steps:

[0008] Step P1: Prepare carbon fiber spheres;

[0009] Step P2: Place carbon fiber spheres on the surface of the inner support.

[0010] Step P3: Apply a coating to the surface of the carbon fiber ball.

[0011] Step P1 includes the following steps:

[0012] Step F1, mixing: Place the carbon fiber and aqueous solution in a mixing container and ultrasonically stir until homogeneous;

[0013] Step F2: Spray granulation. The liquid in the mixed solution is spray-dried using a spray drying device to obtain the first carbon fiber ball. The spray drying process is as follows: the spray drying device adsorbs the mixed solution through a pipe to a high-temperature nozzle. The high-temperature nozzle has many tiny nozzles. The mixed solution in the high-temperature nozzle is sprayed out through the tiny nozzles under high pressure to form atomized droplets. The atomized droplets contain carbon fibers. An air supply device is set outside the high-temperature nozzle. After passing through the air supply device and high-temperature and high-pressure spraying, the water in the atomized droplets is rapidly evaporated, and at the same time, the carbon fibers in the atomized droplets agglomerate into carbon fiber balls.

[0014] Alternatively, step P1 may include the following steps:

[0015] Step F1: Mixing. Place the carbon fiber and soluble salt solution in a mixing container and ultrasonically stir until homogeneous.

[0016] Step F2: Spray granulation. The liquid in the mixed solution is spray-dried using a spray drying device to obtain the second carbon fiber ball. The spray drying process is as follows: the spray drying device adsorbs the mixed solution through a pipe to a high-temperature nozzle. The high-temperature nozzle has many tiny nozzles. The mixed solution in the high-temperature nozzle is sprayed out through the tiny nozzles under high pressure to form atomized droplets. The atomized droplets contain carbon fibers and soluble salts. An air supply device is installed outside the high-temperature nozzle. After passing through the air supply device and high-temperature and high-pressure spraying, the water in the atomized droplets is rapidly evaporated. At the same time, the carbon fibers in the atomized droplets agglomerate into carbon fiber balls and soluble salts precipitate out. Due to the blocking effect of the carbon fibers, the soluble salts precipitate in the form of soluble salt balls between the carbon fibers inside the second carbon fiber ball.

[0017] Step F3, water washing: The second carbon fiber ball formed in step F2 is subjected to a water washing process. During the water washing process, soluble salts dissolve, thereby forming sacrificial pores at the original soluble salt ball positions, thereby increasing the internal space of the carbon fiber ball and improving the buffering capacity.

[0018] Step F4: Drying. The second carbon fiber ball, which has passed through step F3, is dried to obtain the third carbon fiber ball.

[0019] The inner support is cylindrical, and the buffer layer is annular. The equipment used to set the buffer layer on the outer surface of the inner support includes the following structure: a drying chamber, a first heater, a spray gun, a second heater, a stationary roller, and an air extraction device. The first heater and the spray gun are located outside the drying chamber, and the stationary roller is located inside the drying chamber.

[0020] The drying chamber has an opening on one side, and the second heater of the inner support is located at the opening (not shown in the figure). The second heater is located above the inner support and between the inner support and the drying chamber.

[0021] The spray gun is positioned between the first heater and the second heater.

[0022] The process of setting the buffer layer onto the outer surface of the inner support body is as follows: The inner support body is placed at the opening and rotated clockwise; the first heater is turned on and brought close to the inner support body (the surface of the inner support body is made of metal; the first heater can preheat the surface of the inner support body before spraying with the spray gun, thereby accelerating the evaporation of the spray solvent); a solution containing the carbon fiber balls and binder is sprayed onto the surface of the inner support body through the spray gun; the second heater is turned on; the stationary roller is brought close to the inner support body (the distance between the stationary roller and the inner support body is less than the thickness of the buffer layer after drying by the second heater and the vacuum device, thus compacting the buffer layer; after compaction, the carbon fiber balls are more tightly connected, preventing them from falling off during the painting process; the distance between the stationary roller and the inner support body can be adjusted according to the thickness of the buffer layer, the porosity of the carbon fiber balls, the number of layers of carbon fiber balls, and the target buffer stress); the vacuum device is turned on, which can quickly suck away the evaporating solvent from the inside of the drying chamber, thereby accelerating the evaporation of the solvent.

[0023] The adhesive is polyvinylidene fluoride, and the solvent of the solution sprayed by the spray gun is water. The adhesive can enhance the connection between carbon fiber balls and also enhance the adhesion between the carbon fiber balls and the surface of the inner support.

[0024] The method disclosed in this application has the following advantages:

[0025] Because carbon fiber balls have a porous structure and high toughness, they can buffer impact stress during minor impacts. When the impact force increases, they can break through the paint layer or cause the carbon fiber balls to shift, further buffering the impact stress through the shift of the carbon fiber balls. As long as the inner support is not broken, surface scratches caused by breakage can be repaired by spraying a carbon fiber ball solution containing adhesive and drying it, making repair convenient and effectively increasing the service life of the anti-collision structure. Compared with some existing technologies that use foam to protect the anti-collision structure, the service life of the automotive anti-collision structure in this application is not as long as that of the foam because the chemical stability of the foam is much lower than that of carbon fiber. In addition, compared with the buffer layer being a solid fiber layer, the fiber layer cannot form the effect of carbon fiber ball displacement, which makes it easy for stress concentration to form at the most severe impact point during the impact, thus making the support below (or behind) the buffer layer prone to breakage. However, the carbon fiber balls can shift during the impact, which is equivalent to causing the impacting object to slide, thereby buffering the stress concentration. Attached Figure Description

[0026] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below.

[0027] Figure 1 This is a schematic diagram of the overall structure of the vehicle anti-collision structure and a schematic diagram of the position of the AA section.

[0028] Figure 2 This application Figure 1 The diagram shows the cross-section of section AA and the enlarged view of section E.

[0029] Figure 3 This application Figure 2 Enlarged view of the position of E in the middle.

[0030] Figure 4 This is an overall flowchart of the method for preparing the automotive anti-collision structure of this application.

[0031] Figure 5 This is a schematic diagram of the mixing and transition process in step P1 of the first embodiment of this application.

[0032] Figure 6 This is a schematic diagram of the structure of the spray droplets during step P1 spray granulation in the first embodiment of this application.

[0033] Figure 7 This is a schematic diagram of the structure of the first carbon fiber ball after the spray granulation process in step P1 of the first embodiment of this application.

[0034] Figure 8 This is a schematic diagram of step P1 of the first embodiment of this application.

[0035] Figure 9This is a schematic diagram of the mixing and transition process in step P1 of the second embodiment of this application.

[0036] Figure 10 This is a schematic diagram of the spray droplet structure during step P1 spray granulation in the second embodiment of this application.

[0037] Figure 11 This is a schematic diagram of the structure of the second carbon fiber ball after the spray granulation process in step P1 of the second embodiment of this application.

[0038] Figure 12 This is a schematic diagram of the structure of the third carbon fiber ball after water washing and drying in step P1 of the second embodiment of this application.

[0039] Figure 13 This is a schematic diagram of step P1 of the second embodiment of this application.

[0040] Figure 14 This is a schematic diagram of the device used in this application to set the buffer layer on the outer surface of the inner support. Implementation

[0041] The technical solutions of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention;

[0042] The present invention will be further described below with reference to specific embodiments and accompanying drawings. Obviously, the described embodiments are merely some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. The technical solutions of the embodiments of this application will be clearly and completely described below; the directional expressions involved in this application, such as "up" and "down," are all positioned according to the view arrangement of this application.

[0043] To address the problems existing in the current technology, such as Figure 1 As shown, this application discloses an automotive anti-collision structure 1, which includes an inner support 11, a buffer layer 12, and a paint layer 13. The buffer layer 12 is disposed on the outer surface of the inner support 11, and the paint layer 13 is disposed on the outer surface of the buffer layer 12.

[0044] The buffer layer 12 contains multiple layers of carbon fiber balls 121.

[0045] like Figure 2-3As shown, an adhesive is provided between the carbon fiber balls 121 in the buffer layer 12. The buffer layer 12 contains at least three layers of carbon fiber balls 121. Carbon fiber is mainly composed of carbon elements and can be made from acrylic fiber and viscose fiber through high-temperature oxidation and carbonization. It possesses high-temperature resistance, friction resistance, thermal conductivity, and corrosion resistance. Carbon fiber is fibrous and flexible. Due to its graphite microcrystalline structure preferentially oriented along the fiber axis, it has high strength and modulus along the fiber axis. In addition, carbon fiber also includes multi-walled carbon nanotubes. Experiments have shown that multi-walled carbon nanotubes have better spheroidization performance during spray granulation. The diameter of the carbon fiber is 100nm-10µm, and the diameter of the carbon fiber balls 121 is 5-50µm. The diameter of the carbon fiber balls 121 can be adjusted according to the solution concentration (the content of carbon fiber in the solution) and the nozzle size of the spray gun during the spray granulation process. Because the carbon fiber balls 121 have a porous structure and high toughness, they can withstand slight... When an impact occurs, it can buffer the impact stress. When the impact force increases, it can break the paint layer 13 and cause the carbon fiber ball 121 to shift. The shift of the carbon fiber ball 121 further buffers the impact stress. As long as the inner support 11 is not broken, the surface scratches caused by the break can be repaired by spraying a carbon fiber ball 121 solution containing adhesive and drying it, which is convenient for repair and is equivalent to improving the service life of the anti-collision structure. Compared with some existing technologies that set foam on the outside of the anti-collision structure, the service life of the automotive anti-collision structure 1 of this application is not as high because the chemical stability of foam is much lower than that of carbon fiber. In addition, compared with setting the buffer layer 12 as a whole fiber layer, since the fiber layer cannot form the effect of shifting the carbon fiber ball 121, the fiber layer is prone to stress concentration at the most severe impact position during the impact, which makes it easy for the support below (or behind) the buffer layer 12 to break.

[0046] like Figure 4 The method for manufacturing the automotive anti-collision structure 1 shown includes the following steps:

[0047] Step P1: Prepare carbon fiber spheres 121;

[0048] Step P2: Place the carbon fiber ball 121 on the surface of the inner support 11;

[0049] Step P3: Apply paint layer 13 to the surface of carbon fiber ball 121.

[0050] like Figure 5-8 As shown, the first implementation of step P1 includes the following steps:

[0051] Step F1, mixing: carbon fiber 23 and aqueous solution 22 are placed in mixing container 21 and ultrasonically stirred until homogeneous;

[0052] Step F2, spray granulation: The liquid in the mixed solution is spray-dried using a spray drying device to obtain the first carbon fiber ball 1211. The spray drying process is as follows: the spray drying device adsorbs the mixed solution through a pipe to a high-temperature nozzle. The high-temperature nozzle has many tiny nozzles. The mixed solution in the high-temperature nozzle is sprayed out through the tiny nozzles under high pressure to form aqueous solution atomized droplets 24. The atomized droplets contain carbon fibers 23. An air supply device is set outside the high-temperature nozzle. After passing through the air supply device and high-temperature and high-pressure spraying, the water in the atomized droplets is rapidly evaporated. At the same time, the carbon fibers 23 in the atomized droplets agglomerate into carbon fiber balls 121.

[0053] like Figure 9-13 As shown, the second implementation of step P1 includes the following steps:

[0054] Step F1, mixing: carbon fiber 23 and soluble salt solution 25 are placed in mixing container 21 and ultrasonically stirred until homogeneous;

[0055] Step F2: Spray granulation. The liquid in the mixed solution is spray-dried using a spray drying device to obtain the second carbon fiber ball 1212. The spray drying process is as follows: the spray drying device adsorbs the mixed solution through a pipe to a high-temperature nozzle. The high-temperature nozzle has many small nozzles. The mixed solution in the high-temperature nozzle is sprayed out through the small nozzles under high pressure to form salt solution atomized droplets 27. The atomized droplets contain carbon fiber 23 and soluble salt. An air supply device is installed outside the high-temperature nozzle. After passing through the air supply device and high-temperature and high-pressure spraying, the water in the atomized droplets is rapidly evaporated. At the same time, the carbon fibers in the atomized droplets agglomerate into carbon fiber balls 121 and soluble salt is precipitated. Due to the blocking effect of the carbon fibers, the soluble salt is precipitated in the form of soluble salt balls 26 between the carbon fibers inside the second carbon fiber ball 1212.

[0056] Step F3, water washing: The second carbon fiber ball 1212 formed in step F2 is washed with water. During the water washing process, soluble salts dissolve, thereby forming sacrificial holes 260 at the original soluble salt ball 26 position, thereby increasing the internal space of the carbon fiber ball 121 and improving the buffering capacity.

[0057] Step F4: Drying. The second carbon fiber ball 1212, which has passed through step F3, is dried to obtain the third carbon fiber ball 1213.

[0058] like Figure 14As shown, in one embodiment, the inner support 11 is cylindrical, the buffer layer 12 is annular, and the device used to place the buffer layer 12 on the outer surface of the inner support 11 includes the following structure: a drying chamber 31, a first heater 32, a spray gun 33, a second heater 34, a stationary roller 35, and an air extraction device 36. The first heater 32 and the spray gun 33 are disposed outside the drying chamber 31, and the stationary roller 35 is disposed inside the drying chamber 31.

[0059] The drying chamber 31 has an opening on one side, and the second heater 34 of the inner support 11 is located at the opening (not shown in the figure). The second heater 34 is located above the inner support 11 and between the inner support 11 and the drying chamber 31.

[0060] The spray gun 33 is disposed between the first heater 32 and the second heater 34.

[0061] The process of setting the buffer layer 12 onto the outer surface of the inner support 11 is as follows: The inner support 11 is placed at the opening and rotated clockwise; the first heater 32 is turned on and brought close to the inner support 11 (the surface of the inner support 11 is made of metal; the first heater 32 can preheat the surface of the inner support 11 before spraying by the spray gun 33, thereby accelerating the evaporation of the spraying solvent); a solution containing the carbon fiber balls 121 and the adhesive is sprayed onto the surface of the inner support 11 through the spray gun 33; the second heater 34 is turned on; the stationary roller 35 is brought close to the inner support 11 (the... The distance between the stationary roller 35 and the inner support 11 is less than the thickness of the buffer layer 12 after drying by the second heater 34 and the vacuum device 36, so that the buffer layer 12 can be compacted. After compaction, the carbon fiber balls 121 can be more tightly connected, preventing the carbon fiber balls 121 from falling off during the painting process. The distance between the stationary roller 35 and the inner support 11 can be adjusted according to the thickness of the buffer layer 12, the porosity of the carbon fiber balls 121, the number of layers of carbon fiber balls 121, and the target buffer stress. When the vacuum device 36 is turned on, the vacuum device 36 can quickly suck away the evaporating solvent and remove it from the inside of the drying chamber 31, thereby accelerating the evaporation of the solvent.

[0062] The adhesive is polyvinylidene fluoride, and the solvent of the solution sprayed by the spray gun 33 is water. The adhesive can enhance the connection between the carbon fiber balls 121 and also enhance the adhesion between the carbon fiber balls 121 and the surface of the inner support 11.

[0063] The method disclosed in this application has the following advantages:

[0064] Because the carbon fiber balls 121 have a porous structure and high toughness, they can buffer impact stress when a minor impact occurs. When the impact force increases, they can break the paint layer 13 and cause the carbon fiber balls 121 to shift, further buffering the impact stress through the shift of the carbon fiber balls 121. As long as the inner support 11 is not broken, the surface scratches caused by the breakage can be repaired by spraying a carbon fiber ball 121 solution containing adhesive and drying it, which is convenient for repair and equivalent to improving the service life of the anti-collision structure. Compared with some existing technologies that use foam to set the outside of the anti-collision structure, the service life of the automotive anti-collision structure 1 of this application is not as high because the chemical stability of foam is much lower than that of carbon fiber. In addition, compared with the buffer layer 12 being a solid fiber layer, the fiber layer cannot form the effect of shifting the carbon fiber balls 121, which makes it easy for the fiber layer to form stress concentration at the most severe impact position during the impact, thus making it easy for the support below (or behind) the buffer layer 12 to break. However, the carbon fiber balls 121 can shift during the impact, which is equivalent to causing the impacting object to slide, thereby buffering the stress concentration.

[0065] The foregoing should be understood as follows: these embodiments are only used to illustrate the present invention more clearly, and are not intended to limit the scope of the present invention. After reading the present invention, any modifications of the present invention in various equivalent forms by those skilled in the art fall within the scope defined by the appended claims.

Claims

1. A method for manufacturing an automotive anti-collision structure, characterized in that, Includes the following steps: Step P1: Prepare carbon fiber spheres; Step P2: Place carbon fiber spheres on the surface of the inner support. Step P3: Apply a paint layer to the surface of the carbon fiber spheres. Step P1 includes the following steps: Step F1: Mixing. Place the carbon fiber and soluble salt solution in a mixing container and ultrasonically stir until homogeneous. Step F2: Spray granulation, using a spray drying device to spray dry the liquid in the mixed solution to obtain the second carbon fiber ball; Step F3, water washing: The second carbon fiber ball formed in step F2 is subjected to a water washing process. Step F4: Drying. The second carbon fiber ball, after step F3, is dried to obtain the third carbon fiber ball. The automotive anti-collision structure prepared by the method includes an inner support, a buffer layer, and a paint layer. The buffer layer is disposed on the outer surface of the inner support, and the paint layer is disposed on the outer surface of the buffer layer. Multiple layers of carbon fiber spheres are disposed within the buffer layer. An adhesive is provided between the carbon fiber balls in the buffer layer, and at least three layers of carbon fiber balls are provided within the buffer layer. The inner support is cylindrical, and the buffer layer is annular.

2. The method for manufacturing an automotive anti-collision structure according to claim 1, characterized in that, The device used to set the buffer layer on the outer surface of the inner support includes the following structure: a drying chamber, a first heater, a spray gun, a second heater, a stationary roller, and an air extraction device. The first heater and the spray gun are located outside the drying chamber, and the stationary roller is located inside the drying chamber.

3. The method for manufacturing an automotive anti-collision structure according to claim 2, characterized in that, The drying chamber has an opening on one side, and the second heater of the inner support is located at the opening. The second heater is located above the inner support and between the inner support and the drying chamber.

4. The method for manufacturing an automotive anti-collision structure according to claim 3, characterized in that, The spray gun is positioned between the first heater and the second heater.

5. The method for manufacturing an automotive anti-collision structure according to claim 4, characterized in that, The process of setting the buffer layer onto the outer surface of the inner support body is as follows: the inner support body is placed at the opening and rotated clockwise; the first heater is turned on and brought close to the inner support body; a solution containing the carbon fiber balls and adhesive is sprayed onto the surface of the inner support body through the spray gun; the second heater is turned on. Bring the stationary roller close to the inner support; Turn on the air extraction device.

6. The method for manufacturing an automotive anti-collision structure according to claim 5, characterized in that, The adhesive is polyvinylidene fluoride, and the solvent for the solution sprayed by the spray gun is water.

Images