Lightweight truck side skirt panel and method of integrally forming

Abstract

This invention relates to a lightweight truck side skirt and its integral molding method; it includes the following steps: placing multiple lightweight core boards at intervals; drawing fiber yarns and fiber fabrics impregnated with a first resin liquid between two adjacent core layers; circumferentially wrapping the multiple lightweight core boards with fiber yarns and fiber fabrics impregnated with a second resin liquid; simultaneously drawing the lightweight core boards, the fiber yarns and fiber fabrics impregnated with the first resin liquid, and the fiber yarns and fiber fabrics impregnated with the second resin liquid into a mold; heating and curing; and obtaining the lightweight truck side skirt through a pultrusion molding process; wherein, the curing temperature of the first resin liquid (T1) is lower than the curing temperature of the second resin liquid (T2), and T2-T1>40℃; the structural design of the lightweight truck side skirt addresses the technical problem that existing mainstream truck side skirts mainly use aluminum alloy materials, which, although having the effect of guiding airflow and reducing wind resistance, are heavy and have high installation costs.

Description

Technical Field

[0001] This invention relates to the field of truck side skirt manufacturing technology, and in particular to a lightweight truck side skirt and a one-piece molding method. Background Technology

[0002] The modern transportation sector has created a demand for low-cost, lightweight development. Meanwhile, with the full implementation of weight-based toll regulations and high domestic oil prices, lightweight truck improvements will significantly reduce operating costs for users.

[0003] The primary function of truck side skirts is to reduce airflow from the sides of the vehicle into the undercarriage, thus providing some aerodynamic protection. Under certain conditions, this can reduce air resistance and enhance crosswind stability during vehicle operation. Additionally, they also contribute to reduced fuel consumption and act as side protection devices. Currently, most mainstream truck side skirts are made of aluminum alloy, which, while effective in guiding airflow and reducing wind resistance, results in higher installation costs.

[0004] Therefore, in order to address the above problems, the present invention urgently needs to provide a lightweight truck side skirt and an integral molding method. Summary of the Invention

[0005] The purpose of this invention is to provide a lightweight truck side skirt and an integral molding method. The integral molding method of the lightweight truck side skirt is designed to solve the technical problem that the existing mainstream truck side skirts are mainly made of aluminum alloy, which has the effect of guiding airflow and reducing wind resistance, but is heavy and has high installation cost.

[0006] The present invention provides a method for integral molding of a lightweight truck side skirt, comprising the following steps:

[0007] Multiple lightweight core boards are placed at intervals. Fiber yarns and fabrics impregnated with the first resin liquid are drawn between two adjacent core layers. Fiber yarns and fabrics impregnated with the second resin liquid are then circumferentially wrapped around the multiple lightweight core boards. The lightweight core boards, the fiber yarns and fabrics impregnated with the first resin liquid, and the fiber yarns and fabrics impregnated with the second resin liquid are simultaneously drawn into a mold, heated and cured, and a lightweight truck side skirt is obtained through a pultrusion molding process.

[0008] The curing temperature of the first resin liquid (T1) is lower than that of the second resin liquid (T2), and T2 - T1 > 40℃.

[0009] Preferably, by weight, the first resin liquid comprises 70-100 parts of bisphenol A type epoxy resin 5245A, 5-15 parts of mixed curing agent, 5-10 parts of filler, and 1-5 parts of release agent, wherein the mixed curing agent is a mixture of anhydride curing agent and imidazole medium-temperature curing agent.

[0010] The second resin solution includes 70-100 parts of type A epoxy resin 5245A, 80-120 parts of acid anhydride curing agent, 3-8 parts of accelerator, 5-10 parts of filler, and 1-5 parts of release agent.

[0011] Preferably, the imidazole-based medium-temperature curing agent includes at least one of 1-methylimidazolium, 2-methylimidazolium, 1-cyanoethyl-2-ethyl-4-methylimidazolium, or 1-cyanoethyl-2-phenylimidazolium;

[0012] Anhydride curing agents include at least one of phthalic anhydride, tetrahydrophthalic anhydride, hexahydrophthalic anhydride, methyltetrahydrophthalic anhydride, or methylhexahydrophthalic anhydride.

[0013] Preferably, the lightweight core board, the fiber yarn and fiber fabric impregnated with the first resin liquid, and the fiber yarn and fiber fabric impregnated with the second resin liquid are simultaneously drawn into the mold. The heating and curing adopts a three-zone heating and curing process, with the temperature of the first zone being 130-150℃, the temperature of the second zone being 150-170℃, and the temperature of the third zone being 170-190℃, to obtain a lightweight truck side skirt.

[0014] Preferably, the lightweight core board is a honeycomb board or a foam board.

[0015] Preferably, the gap between two adjacent lightweight core boards is 0.1% of the total width of the two lightweight core boards.

[0016] Preferably, the upper end face of each lightweight core board is prepared to have a plate body containing trapezoidal bosses.

[0017] The present invention also provides a lightweight truck side skirt obtained by an integral molding method for a lightweight truck side skirt as described in any one of the above-mentioned methods, comprising a plurality of spaced lightweight core boards, fiber-reinforced ribs provided between adjacent lightweight core boards, and a fiber-reinforced resin layer covering the lightweight core boards and the fiber-reinforced ribs.

[0018] Preferably, the thickness of the lightweight core board is 1-2 cm; the thickness of the fiber-reinforced rib is 1-2 cm; and the thickness of the fiber-reinforced resin layer is 1-2 mm.

[0019] Preferably, the lightweight core board includes a base plate, and the upper end face of the base plate is provided with a trapezoidal boss.

[0020] The lightweight truck side skirt integral molding method provided by this invention has the following advantages compared with the prior art:

[0021] 1. The lightweight truck side skirt integral molding method provided by this invention uses a lightweight core board, adds fiber yarns and fiber fabrics impregnated with a first resin liquid between adjacent core boards, and simultaneously wraps the lightweight core board and the fiber yarns and fiber fabrics impregnated with the first resin liquid with fiber yarns and fiber fabrics impregnated with a second resin liquid, and integrally cures to obtain a lightweight truck side skirt. Because the whole uses non-metallic materials, the weight is reduced by 50% compared with metal truck side skirts, thus achieving lightweighting of truck side skirts.

[0022] 2. The integrated molding method for lightweight truck side skirts provided by this invention adds reinforcing ribs between two adjacent lightweight core plates, ensuring the overall rigidity of the truck side skirt. The resulting truck side skirt meets the national requirements for the impact resistance and rigidity of metal truck side skirts, and can replace existing metal truck side skirts, reducing installation costs.

[0023] 3. The integrated molding method for lightweight truck side skirts provided by this invention uses resin-impregnated fiber yarns and fiber fabrics with different curing temperatures and sets them in different positions. This ensures that the fiber yarns and fiber fabrics between the lightweight core panels and the outer wrapping fiber yarns and fiber fabrics are simultaneously cured and molded at a certain curing temperature, thereby achieving rapid mechanized production of truck side skirts and reducing production costs. Attached Figure Description

[0024] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0025] Figure 1 is a flowchart of the steps of the lightweight truck side skirt integral molding method described in this invention;

[0026] Figure 2 This is a structural schematic diagram (sectional view) of the lightweight truck side skirt described in this invention.

[0027] Figure 3 for Figure 2 Enlarged view of point A in the middle;

[0028] Figure 4 This is a schematic diagram of the structure of the lightweight core board described in this invention.

[0029] Explanation of reference numerals in the attached figures:

[0030] 1. Lightweight core board; 101. Base plate; 102. Trapezoidal boss; 2. Fiber-reinforced stiffener; 3. Fiber-reinforced resin layer. Detailed Implementation

[0031] The technical solution of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, 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.

[0032] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for 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. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0033] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; 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; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0034] like Figure 1 As shown, this embodiment provides a method for integrally molding a lightweight truck side skirt, including the following steps:

[0035] Multiple lightweight core boards are placed at intervals. Fiber yarns and fabrics impregnated with the first resin liquid are drawn between two adjacent core layers. Fiber yarns and fabrics impregnated with the second resin liquid are then circumferentially wrapped around the multiple lightweight core boards. The lightweight core boards, the fiber yarns and fabrics impregnated with the first resin liquid, and the fiber yarns and fabrics impregnated with the second resin liquid are simultaneously drawn into a mold, heated and cured, and a lightweight truck side skirt is obtained through a pultrusion molding process.

[0036] The curing temperature of the first resin liquid (T1) is lower than that of the second resin liquid (T2), and T2 - T1 > 40℃.

[0037] The present invention provides a method for integrally molding a lightweight truck side skirt. A lightweight core board is used, and fiber yarns and fabrics impregnated with a first resin solution are added between adjacent core boards. Simultaneously, fiber yarns and fabrics impregnated with a second resin solution are wrapped around the lightweight core board and the fiber yarns and fabrics impregnated with the first resin solution, and then integrally cured to obtain a lightweight truck side skirt. Because the entire structure uses non-metallic materials, the weight is reduced by 50% compared to metallic truck side skirts, achieving a significant reduction in weight.

[0038] The lightweight truck side skirt integral molding method provided by the present invention adds reinforcing ribs between two adjacent lightweight core plates, ensuring the overall rigidity of the truck side skirt. The resulting truck side skirt has impact resistance deformation that meets the existing national requirements for the impact resistance and rigidity of metal truck side skirts (GB11567-2017). It can replace the existing metal truck side skirt and reduce installation costs.

[0039] The lightweight truck side skirt integral molding method provided by this invention uses resin-impregnated fiber yarns and fiber fabrics with different curing temperatures and set in different positions. This ensures that the fiber yarns and fiber fabrics between the lightweight core panels and the outer wrapping fiber yarns and fiber fabrics are simultaneously cured and molded at a certain curing temperature, realizing rapid mechanized production of truck side skirts and reducing production costs.

[0040] Specifically, by weight, the first resin liquid includes 70-100 parts of bisphenol A type epoxy resin 5245A, 5-15 parts of mixed curing agent, 5-10 parts of filler, and 1-5 parts of release agent. The mixed curing agent is composed of anhydride curing agent and imidazole medium-temperature curing agent. The ratio of anhydride curing agent and imidazole medium-temperature curing agent is adjusted according to the required temperature to achieve one-piece molding of lightweight truck side skirts. The second resin liquid includes 70-100 parts of type A epoxy resin 5245A, 80-120 parts of anhydride curing agent, 3-8 parts of accelerator, 5-10 parts of filler, and 1-5 parts of release agent.

[0041] The lightweight truck side skirt panel integral molding method provided by this invention uses a medium-temperature curing agent for the first resin liquid and a high-temperature curing agent for the second resin liquid. By using resin impregnating fiber yarn and fiber fabric at different curing temperatures and placing them at different positions, it can be ensured that the fiber yarn and fiber fabric between the lightweight core board and the outer wrapping fiber yarn and fiber fabric are simultaneously cured and molded at a certain curing temperature, realizing rapid mechanized production of truck side skirt panels and reducing production costs.

[0042] Specifically, imidazole-based medium-temperature curing agents include at least one of 1-methylimidazolium, 2-methylimidazolium, 1-cyanoethyl-2-ethyl-4-methylimidazolium, and 1-cyanoethyl-2-phenylimidazolium;

[0043] Anhydride curing agents include one or two of phthalic anhydride, tetrahydrophthalic anhydride, hexahydrophthalic anhydride, methyltetrahydrophthalic anhydride, and methylhexahydrophthalic anhydride.

[0044] Specifically, a lightweight core board, fiber yarn and fiber fabric impregnated with a first resin solution, and fiber yarn and fiber fabric impregnated with a second resin solution are simultaneously drawn into a mold and heated and cured in three zones: zone one temperature 130-150℃, zone two temperature 150-170℃, and zone three temperature 170-190℃, to obtain a lightweight truck side skirt.

[0045] Specifically, the lightweight core board in this embodiment is a honeycomb board or a foam board, preferably a foam board, which can reduce the weight of the truck side skirts.

[0046] Specifically, in this embodiment, the gap between two adjacent lightweight core boards is 0.1% of the total width of the two lightweight core boards, ensuring the overall rigidity and connection strength.

[0047] Specifically, in this embodiment, the upper surface of each lightweight core board is prepared into a plate with trapezoidal protrusions; this is used to straighten and cut the airflow, reduce the overall vehicle wind resistance and improve crosswind stability.

[0048] like Figure 2 , Figure 3 As shown, this embodiment also provides a lightweight truck side skirt obtained based on the integral molding method of the lightweight truck side skirt as described in any one of the above, including a plurality of spaced lightweight core boards 1, fiber reinforcing ribs 2 provided between adjacent lightweight core boards 1, and a fiber reinforcing resin layer 3 wrapped around the lightweight core boards 1 and the fiber reinforcing ribs 2.

[0049] The lightweight truck side skirt obtained by this invention is lightweight, rigid, and has high impact resistance, meeting the requirements for replacing metal truck side skirts.

[0050] Specifically, in this embodiment, the thickness of the lightweight core board 1 is 1-2 cm; the thickness of the fiber-reinforced stiffener 2 is 1-2 cm; and the thickness of the fiber-reinforced resin layer 3 is 1-2 mm. The design of the above parameters ensures the rigidity of the truck side skirt without increasing the overall weight.

[0051] Specifically, such as Figure 4 As shown, the lightweight core board 1 in this embodiment includes a base plate 101. The upper surface of the base plate 101 is provided with a trapezoidal boss 102. The trapezoidal boss 102 is used to straighten and cut the airflow, reduce the wind resistance of the whole vehicle and improve the crosswind stability.

[0052] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method of integrally forming a lightweight truck side skirt panel, the method comprising: The method comprises the following steps: ​ The plurality of lightweight core plates are arranged at intervals, the fiber yarn and fabric impregnated with the first resin liquid are pulled between two adjacent core layers, the fiber yarn and fabric impregnated with the second resin liquid are circumferentially arranged around the plurality of lightweight core plates, the lightweight core plates, the fiber yarn and fabric impregnated with the first resin liquid, and the fiber yarn and fabric impregnated with the second resin liquid are synchronously pulled into a mold, heating and curing are performed, and a lightweight truck side skirt plate is obtained through a pultrusion process. The first resin liquid has a curing temperature (T1) less than a curing temperature (T2) of the second resin liquid, and T2-T1>40℃. The first resin liquid comprises 70-100 parts of bisphenol A type epoxy resin 5245A, 5-15 parts of mixed curing agent, 5-10 parts of filler, and 1-5 parts of release agent, wherein the mixed curing agent is a mixture of an acid anhydride curing agent and an imidazole medium-temperature curing agent. The second resin liquid comprises 70-100 parts of bisphenol A type epoxy resin 5245A, 80-120 parts of acid anhydride curing agent, 3-8 parts of accelerator, 5-10 parts of filler, and 1-5 parts of release agent. The acid anhydride curing agent comprises at least one of phthalic anhydride, tetrahydrophthalic anhydride, hexahydrophthalic anhydride, methyl tetrahydrophthalic anhydride, or methyl hexahydrophthalic anhydride.

2. The method of one piece forming of a light weight truck side skirt as defined in claim 1, wherein: The synchronous pulling of the lightweight core plates, the fiber yarn and fabric impregnated with the first resin liquid, and the fiber yarn and fabric impregnated with the second resin liquid into the mold is performed by using a three-zone heating and curing process, the first zone has a temperature of 130-150℃, the second zone has a temperature of 150-170℃, and the third zone has a temperature of 170-190℃, thereby obtaining the lightweight truck side skirt plate.

3. The method of one piece forming of a light weight truck side skirt as defined in claim 1, wherein: The lightweight core plate is a honeycomb plate or a foam plate.

4. The method of one piece forming of a light weight truck side skirt of claim 1, wherein: The gap between the two adjacent lightweight core plates is 0.1% of the total width of the two lightweight core plates.

5. The method of one piece forming of a light weight truck side skirt of claim 1, wherein: The upper end surface of each lightweight core plate is prepared to have a plate body containing a trapezoidal boss.

6. A lightweight truck side skirt plate obtained by an integrated forming method based on the lightweight truck side skirt plate according to any one of claims 1-5, characterized in that: The lightweight truck side skirt plate comprises a plurality of spaced lightweight core plates (1), a fiber-reinforced rib plate (2) is arranged between two adjacent lightweight core plates (1), and the lightweight core plates (1) and the fiber-reinforced rib plate (2) are wrapped with a fiber-reinforced resin layer (3).

7. The lightweight truck side skirt of claim 6, wherein: The thickness of the lightweight core plate (1) is 1-2 cm, the thickness of the fiber-reinforced rib plate (2) is 1-2 cm, and the thickness of the fiber-reinforced resin layer (3) is 1-2 mm.

8. The lightweight truck side skirt of claim 7, wherein: The lightweight core plate (1) comprises a bottom plate (101), and the upper end surface of the bottom plate (101) is provided with a trapezoidal boss (102).

Images