Composite material cargo compartment, preparation method thereof and vehicle

Abstract

The invention discloses a composite material cargo compartment, a preparation method thereof and a vehicle, and relates to the technical field of vehicles. The composite material cargo compartment comprises a top plate, side plates, a front plate, a bottom plate, a frame, bottom cross beams and bottom longitudinal beams. The top plate is located above the frame, the side plates are located on the two sides of the frame, the front plate is located in front of the frame, the bottom plate is located below the frame, and the bottom cross beams and the bottom longitudinal beams are located below the bottom plate. The top plate, the side plates, the front plate, the bottom plate, the bottom cross beams and the bottom longitudinal beams are all made of continuous fiber reinforced thermoplastic resin. A light stabilizer and a heat stabilizer are distributed in the thermoplastic resin on the sides, far away from the frame, of the top plate, the side plates and the front plate; wear-resistant auxiliaries are distributed in the thermoplastic resin on the side, close to the frame, of the bottom plate. The cargo compartment is light in weight, compared with a traditional steel cargo compartment, the purpose of weight reduction can be achieved, and the service life of the composite material cargo compartment is long.

Description

Technical Field

[0001] The present invention relates to the technical field of vehicles, and in particular to a composite cargo compartment, a preparation method thereof, and a vehicle. Background Art

[0002] The cargo compartment is an important tool for vehicles to carry cargo, and is usually assembled from a roof, side panels, bottom panel, and door panels. Steel cargo compartments are the mainstream products on the market, and their main advantages are low prices and strong load-bearing capacity. However, steel cargo compartments are heavy. Taking a 4.2m cargo compartment as an example, the weight of a steel cargo compartment is usually 670kg or more, which has a negative impact on the vehicle's cargo economy. At the same time, although the surface of the steel cargo compartment is coated with an anti-corrosion coating, the surface is easily bumped and scratched during the loading and unloading and transportation of goods, which damages the coating. Under the long-term action of media such as water and oxygen, corrosion and rust will occur, affecting the appearance and load-bearing capacity.

[0003] How to achieve significant lightweight while meeting the load-bearing performance of the cargo compartment is an important research direction at present. To this end, some manufacturers have developed composite cargo compartments, with PP honeycomb sandwich panels used for the top, side and bottom panels. Due to the low density of PP honeycomb sandwich panels, the cargo compartment can be reduced in weight, usually weighing about 480kg, but the load-bearing capacity and impact resistance of this solution are average. At the same time, the preparation process of PP honeycomb sandwich panels is complicated, the material price is high, and it is also necessary to spray paint or coat the surface to improve weather resistance, resulting in a significant increase in product prices. In addition, some manufacturers have developed aluminum alloy plug-in panel cargo compartments, with aluminum alloy extruded profiles used for the side and bottom panels. This product has the advantages of lightweight and good corrosion resistance, but due to the high price of aluminum alloy raw materials and the immature commercial chain of aluminum alloy closed-loop recycling, the residual value of aluminum alloy cannot be fully utilized, and the product price remains high. At present, it is difficult to market aluminum alloy plug-in panel cargo compartments.

[0004] Therefore, the current cargo compartment and its preparation method and vehicle still need to be improved. Summary of the invention

[0005] The present invention aims to solve at least one of the technical problems existing in the prior art. To this end, the first aspect of the present invention aims to provide a composite cargo box, which has a light weight and a long service life.

[0006] A second aspect of the present invention aims to provide a method for preparing a composite cargo box.

[0007] A third aspect of the present invention aims to provide a vehicle.

[0008] The composite cargo compartment according to the first embodiment of the present invention includes: a top plate, side plates, a front plate, a bottom plate, a frame, a bottom cross beam, and a bottom longitudinal beam; the top plate is located above the frame, the side plates are located on both sides of the frame, the front plate is located in front of the frame, the bottom plate is located below the frame, and the bottom cross beam and the bottom longitudinal beam are located below the bottom plate; the top plate, the side plates, the front plate, the bottom cross beam, and the bottom longitudinal beam are all made of continuous fiber reinforced thermoplastic resin; light stabilizers and heat stabilizers are distributed in the thermoplastic resin on the side of the top plate, the side plates, and the front plate away from the frame; and wear-resistant additives are distributed in the thermoplastic resin on the side of the bottom plate close to the frame. As a result, the composite cargo compartment is lighter in weight, which can achieve the purpose of weight reduction compared to traditional steel cargo compartments, and the composite cargo compartment has a longer service life.

[0009] According to some embodiments of the composite cargo box of the present invention, the side panels and the front panel are formed by splicing a plurality of bent parts. The side panels and the front panel are spliced ​​by the bent parts, and the bent parts of the bent parts can provide a certain rigidity, which can better support the flat parts of the side panels and the front panel.

[0010] In some embodiments, the width of the bending piece is 100 mm to 500 mm.

[0011] In some embodiments, the thickness of the bending piece is 1 mm to 4 mm.

[0012] According to some embodiments of the present invention, the composite cargo compartment meets at least one of the following conditions: the top plate is a whole plate; the thickness of the top plate is 1 mm to 3 mm; the bottom plate is a whole plate; the thickness of the bottom plate is 1 mm to 10 mm.

[0013] According to the composite cargo compartment described in some embodiments of the present invention, the continuous fiber reinforced thermoplastic resin satisfies at least one of the following conditions: based on the total mass of the continuous fiber reinforced thermoplastic resin, the mass content of the continuous fiber is 30wt% to 80wt%; the resin matrix in the continuous fiber reinforced thermoplastic resin includes at least one of PP, PA6, PA56, PA66 and PMMA; the continuous fiber includes at least one of glass fiber, carbon fiber, basalt fiber, and aramid fiber.

[0014] The composite cargo compartment according to some embodiments of the present invention satisfies at least one of the following conditions: the light stabilizer includes at least one of benzophenones, hindered amines, carbon black, and thiobisphenols; the heat stabilizer includes at least one of phenolic heat stabilizers, amine heat stabilizers, and phosphites; the wear-resistant additive includes at least one of molybdenum disulfide, graphite, polytetrafluoroethylene, and silicone.

[0015] According to the second aspect of the present invention, the method for preparing a composite cargo compartment comprises: heating a resin matrix in an extruder to a melt and extruding it to a die, impregnating continuous fibers in the die, and rolling in a roller press to prepare a first prepreg tape; adding a light stabilizer and a heat stabilizer to the resin matrix, heating the mixture in an extruder to a melt and extruding it to a die, impregnating continuous fibers in the die, and rolling in a roller press to prepare a second prepreg tape; adding a wear-resistant additive to the resin matrix, heating the mixture in an extruder to a melt and extruding it to a die, impregnating continuous fibers in the die, and rolling in a roller press to prepare a third prepreg tape; compounding at least one second prepreg tape on one side of at least one of the first prepreg tapes, and preparing a top plate by a processing method of tape pressing or molding; Compound at least one second prepreg on one side of at least one of the first prepregs, prepare a whole plate by belt pressing or molding, cut the whole plate, locally soften the cut plate by heating, and then bend it by bending equipment to obtain a bent part, splice multiple bent parts to obtain side panels and front panels; Compound at least one third prepreg on one side of at least one of the first prepregs, prepare a bottom panel by belt pressing or molding; Prepare a composite material from a resin matrix and continuous fiber by pultrusion and / or continuous compression molding, and prepare a frame, bottom cross beam and bottom longitudinal beam by the composite profile; Assemble the top panel, side panel, front panel, bottom panel, frame, bottom cross beam and bottom longitudinal beam to prepare a composite cargo compartment. The composite cargo compartment is prepared by the above method, the plate is formed by pressing the prepreg, and the frame and cross and longitudinal beams are prepared by pultrusion and / or continuous compression molding. The process is simple and the preparation cost can be effectively controlled; the cargo compartment is light in weight and can maintain excellent load-bearing performance and high reliability.

[0016] According to the method for preparing a composite cargo compartment described in some embodiments of the present invention, the mass content of continuous fibers in the first prepreg tape, the second prepreg tape and the third prepreg tape is each independently 30wt% to 80wt%; and / or the thickness of the first prepreg tape, the thickness of the second prepreg tape and the thickness of the third prepreg tape are each independently 0.1mm to 1mm.

[0017] According to the method for preparing a composite cargo compartment described in some embodiments of the present invention, in the second prepreg tape, the mass of the light stabilizer is 0.1% to 1% of the mass of the resin matrix, and the mass of the heat stabilizer is 0.1% to 1% of the mass of the resin matrix; and / or, in the third prepreg tape, the mass of the wear-resistant additive is 1% to 15% of the mass of the resin matrix.

[0018] According to some embodiments of the present invention, the method for preparing a composite cargo compartment meets at least one of the following conditions: when preparing the bent parts, the cut sheet material is locally softened by infrared focused linear heating; a plurality of bent parts are spliced ​​together by bonding, riveting and / or ultrasonic welding to obtain side panels and a front panel; the continuous fibers in the frame are axially distributed; the top panel, side panels, front panel, bottom panel, frame, bottom cross beam, and bottom longitudinal beam are assembled by bonding, riveting and / or ultrasonic welding to obtain a composite cargo compartment.

[0019] The vehicle according to the third aspect of the present invention comprises the composite cargo box described in the first aspect or the composite cargo box prepared by the method described in the second aspect.

[0020] Additional aspects and advantages of the present invention will be given in part in the following description and in part will be obvious from the following description, or will be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The above and / or additional aspects and advantages of the present invention will become apparent and easily understood from the description of the embodiments in conjunction with the following drawings, in which:

[0022] Figure 1 It is a schematic diagram of the structure of a composite cargo compartment according to some embodiments of the present invention;

[0023] Figure 2 It is a schematic diagram of the structure of the side panels of some embodiments of the present invention;

[0024] Figure 3 Schematic diagram of the stacked structure of prepreg tapes in some embodiments of the present invention;

[0025] Figure 4 Schematic diagram of the stacked structure of prepreg tapes in some embodiments of the present invention;

[0026] Figure 5 It is a schematic diagram of the structure of preparing side panels in some embodiments of the present invention.

[0027] Reference numerals:

[0028] Top plate 1 , side plate 2 , bending piece 21 , front plate 3 , bottom plate 4 , frame 5 , bottom cross beam 6 , bottom longitudinal beam 7 , side door 8 , rear door 9 , first prepreg tape 11 , second prepreg tape 12 , third prepreg tape 13 . DETAILED DESCRIPTION

[0029] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and cannot be understood as limiting the present invention.

[0030] In the description of the present invention, it should be understood that the terms "upper", "lower", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention. In addition, features defined as "first", "second", and "third" may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "multiple" means two or more.

[0031] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a direct connection, or an indirect connection through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0032] In a first aspect of the present invention, the present invention provides a composite cargo box. The composite cargo box according to an embodiment of the present invention is described below with reference to the accompanying drawings.

[0033] According to some embodiments of the present invention, Figure 1 As shown, the composite cargo compartment includes: a top plate 1, a side plate 2, a front plate 3, a bottom plate 4, a frame 5, a bottom cross beam 6, and a bottom longitudinal beam 7. Among them, the frame 5 is used to fix and install various modules of the cargo compartment, and mainly plays a role in fixing the frame. The top plate 1 is located above the frame 5, the side plates 2 are located on both sides of the frame 5, the front plate 3 is located in front of the frame 5, the bottom plate 4 is located below the frame 5, the bottom cross beam 6 and the bottom longitudinal beam 7 are located below the bottom plate 4, and the bottom cross beam 6 and the bottom longitudinal beam 7 are located at the bottom of the cargo compartment, and mainly play a role in carrying goods.

[0034] According to some embodiments of the present invention, the materials of the top plate 1, the side plate 2, the front plate 3, the bottom plate 4, the bottom cross beam 6 and the bottom longitudinal beam 7 are all continuous fiber reinforced thermoplastic resins, which have high strength and significantly reduced mass compared to steel cargo compartments; light stabilizers and heat stabilizers are distributed in the thermoplastic resins on the side of the top plate 1, the side plate 2 and the front plate 3 away from the frame 5, and the light stabilizers can shield and absorb ultraviolet rays in sunlight, reduce the damage of ultraviolet rays to the chemical bonds of the resin matrix, and the heat stabilizers can improve the heat resistance of the material, prevent the chemical bonds of the resin matrix from being damaged due to high temperature during processing and use, resulting in a decrease in mechanical properties and affecting the service life. Therefore, by adding light stabilizers and heat stabilizers, the light and heat resistance of the board can be improved, and the board can meet the use requirements under the action of light and heat without lamination or painting; wear-resistant additives are distributed in the thermoplastic resin on the side of the bottom plate 4 close to the frame 5, and the wear-resistant additives can reduce the friction coefficient and wear of the resin. After wear-resistant modification, the board can meet the use requirements during cargo loading and unloading and transportation, which is beneficial to extending the service life of the board.

[0035] According to some embodiments of the present invention, in the continuous fiber reinforced thermoplastic resin, the resin matrix may include at least one of PP (polypropylene), PA6 (polyamide 6 or nylon 6), PA56 (nylon 56), PA66 (nylon 66) and PMMA (polymethyl methacrylate). The above resin materials have good chemical stability and thermal stability as well as good processability; the above materials can be combined with reinforcing fibers to form a composite material with high strength; the above materials can be recycled and reused by physical or chemical methods, which is conducive to saving resources. In some embodiments, the resin matrix may be PP, PA6, PA56, PA66 or PMMA. In other embodiments, the resin matrix may include two or more of PP, PA6, PA56, PA66 and PMMA.

[0036] According to some embodiments of the present invention, in the continuous fiber reinforced thermoplastic resin, the continuous fiber may include at least one of glass fiber (e.g., E glass fiber, S glass fiber, etc.), carbon fiber, basalt fiber, and aramid fiber. The above-mentioned continuous fiber has good mechanical properties, is lightweight and high-strength, has good corrosion resistance, and is environmentally friendly. The above-mentioned continuous fiber is used as a reinforcing fiber to form a composite plate with a resin, which can improve the mechanical strength and stability of the composite material. According to some embodiments of the present invention, in the continuous fiber reinforced thermoplastic resin, the continuous fiber may be glass fiber, carbon fiber, basalt fiber, or aramid fiber. According to other embodiments of the present invention, in the continuous fiber reinforced thermoplastic resin, the continuous fiber may include two or more of glass fiber, carbon fiber, basalt fiber, and aramid fiber.

[0037] According to an embodiment of the present invention, in the continuous fiber reinforced thermoplastic resin constituting the top plate 1, the side plate 2, the front plate 3, the bottom plate 4, the bottom cross beam 6, and the bottom longitudinal beam 7, the resin matrix used may be the same or different, and the added continuous fibers may be the same or different.

[0038] According to some embodiments of the present invention, in the continuous fiber reinforced thermoplastic resin constituting the top plate 1, the side plate 2, the front plate 3, the bottom plate 4, the bottom cross beam 6, and the bottom longitudinal beam 7, the mass content of the continuous fiber can be 30wt% to 80wt% based on the total mass of the continuous fiber reinforced thermoplastic resin, for example, the content of the continuous fiber can be 30wt%, 40wt%, 50wt%, 60wt%, 70wt%, 80wt%, etc. The content of the continuous fiber within the above range is conducive to further improving the mechanical strength of the composite material.

[0039] According to some embodiments of the present invention, the frame 5 is used to fix and install various modules of the cargo compartment, and mainly plays the role of fixing the frame. From the perspective of structural rigidity requirements, the reinforcing fibers are distributed axially to improve the components' resistance to bending deformation and ensure structural rigidity.

[0040] According to some embodiments of the present invention, light stabilizers and heat stabilizers are distributed in the thermoplastic resin on the top plate 1, the side plate 2 and the front plate 3 away from the frame 5. Thus, the weather resistance of the top plate, the side plate and the front plate can be improved, which is conducive to extending the service life of the plate.

[0041] According to some embodiments of the present invention, the light stabilizer may include at least one of benzophenones, hindered amines, carbon black, and thiobisphenol. In some embodiments, the light stabilizer may be benzophenones, hindered amines, carbon black, or thiobisphenol. In other embodiments, the light stabilizer may include two or more of benzophenones, hindered amines, carbon black, and thiobisphenol.

[0042] According to some embodiments of the present invention, the heat stabilizer may include at least one of a phenolic heat stabilizer, an amine heat stabilizer, and a phosphite. In some embodiments, the heat stabilizer may be a phenolic heat stabilizer (e.g., p-tert-butylphenol TBP, p-tert-octylphenol TOP, p-tert-butylcarboxyphenol BTCP, p-tert-butylhydroquinone BHT, etc.), an amine heat stabilizer (e.g., cyclohexanecarboxamide, oleic acid amine, allylamine, etc.) or a phosphite (e.g., triphenyl phosphite, tris (2,4-di-tert-butylphenyl) phosphite, diphenyl decyl phosphite, trioctyl phosphite, etc.). In other embodiments, the heat stabilizer may include at least two of a phenolic heat stabilizer, an amine heat stabilizer, and a phosphite.

[0043] Distributing the above-mentioned light stabilizer and heat stabilizer in the thermoplastic resin on the side of the top plate 1, the side plate 2 and the front plate 3 away from the frame 5 can significantly improve the light and heat aging resistance of the plate, eliminate the steps of painting or laminating, and help reduce the cost of the plate.

[0044] According to some embodiments of the present invention, reference Figure 1 The top plate 1 can be a whole plate. The whole plate has no joints, is watertight, and has high structural strength.

[0045] According to some embodiments of the present invention, reference Figure 1 There is a top crossbeam above the frame 5, the top plate 1 can be a whole plate, and the top plate 1 can be connected to a number of top crossbeams by gluing.

[0046] According to some embodiments of the present invention, the thickness of the top plate 1 may be 1 mm to 3 mm, for example, the thickness of the top plate 1 may be 1 mm, 1.6 mm, 2 mm, 2.5 mm, 3 mm, etc. In some specific embodiments of the present invention, the thickness of the top plate 1 may be 1.5 mm.

[0047] According to some embodiments of the present invention, a wear-resistant additive is distributed in the thermoplastic resin on the side of the bottom plate 4 away from the frame 5, thereby improving the wear resistance of the bottom plate, thereby facilitating extending the service life of the bottom plate.

[0048] According to some embodiments of the present invention, the wear-resistant additive may include at least one of molybdenum disulfide, graphite, polytetrafluoroethylene, and silicone. In some embodiments, the wear-resistant additive may be molybdenum disulfide, graphite, polytetrafluoroethylene, or silicone. In other embodiments, the wear-resistant additive may include two or more of molybdenum disulfide, graphite, polytetrafluoroethylene, and silicone. The above-mentioned material has good wear resistance. The above-mentioned wear-resistant additive is distributed in the thermoplastic resin on the side of the bottom plate close to the frame, which reduces the friction coefficient and wear amount of the resin, significantly improves the wear resistance of the side of the bottom plate close to the frame, and thus extends the service life of the bottom plate.

[0049] According to some embodiments of the present invention, reference Figure 1 The bottom plate 4 can be a whole plate. The whole plate has no joints, is watertight, and has high strength.

[0050] According to some embodiments of the present invention, the thickness of the bottom plate 4 may be 1 mm to 10 mm, for example, the thickness of the bottom plate 4 may be 1 mm, 3 mm, 5 mm, 8 mm, 10 mm, etc. The bottom plate has a certain pressure bearing effect and strength within the above range, and can carry heavier goods under the support of the bottom cross beam and the bottom longitudinal beam.

[0051] According to some embodiments of the present invention, the side panels 2 and the front panel 3 may be formed by splicing a plurality of bent parts 21. Figure 2, the side panel 2 can be composed of a plurality of bending parts 21 spliced ​​together. The structure of the front panel 3 is similar to that of the side panel 2, and is also composed of a plurality of bending parts 21 spliced ​​together in sequence. The specific number of bending parts 21 in the side panel 2 and the front panel 3 is not particularly limited in the present invention, and those skilled in the art can select and set them according to actual needs. The bent portion can be used as a reinforcing rib to enhance the overall mechanical properties of the plate, improve the rigidity of the plate, and improve the bending resistance of the plate; the bent portion can provide additional support, enhance the stability of the plate, and prevent deformation or damage caused by uneven force; in addition, the use of bending parts can also adapt to different structural and design needs.

[0052] According to some embodiments of the present invention, reference Figure 2 The width W of the bending piece 21 can be 100 mm to 500 mm. For example, the width W of the bending piece 21 can be 100 mm, 200 mm, 300 mm, 400 mm, 500 mm, etc. A wider bending piece helps to improve the overall structural strength and rigidity of the plate, can better resist bending or deformation of the plate during use, and reduce the risk of bending or breaking; under the premise of ensuring structural strength, a wider bending piece helps to reduce the weight of the carriage.

[0053] According to some embodiments of the present invention, reference Figure 2 The thickness d of the bending part 21 can be 1 mm to 4 mm, for example, the thickness d of the bending part 21 can be 1 mm, 2 mm, 3 mm, 4 mm, etc. The bending part of the above thickness can further reduce the weight of the carriage and reduce the manufacturing cost on the basis of ensuring the structural strength.

[0054] In some specific embodiments of the present invention, the bending member 21 may have a width of 300 mm and a thickness of 2 mm.

[0055] According to some embodiments of the present invention, a certain amount of masterbatch, anti-aging agent and / or lubricant etc. may be added to the resin matrix of the continuous fiber reinforced thermoplastic resin material in each component.

[0056] According to some embodiments of the present invention, reference Figure 1 The composite cargo compartment may further include a side door 8 and a rear door 9. The rear door 9 is arranged opposite to the front panel 3. The side door 8 is arranged on one side of the frame 5. Two side panels 2 may be installed on the side where the side door 8 is located. The two side panels 2 are respectively located on both sides of the side door 8. The specific structure and material of the side door 8 and the rear door 9 are not particularly limited in the present invention. Those skilled in the art may select and set them according to actual needs. According to some embodiments of the present invention, the materials of the side door 8 and the rear door 9 may be independently steel, aluminum, composite materials, etc.

[0057] In the present invention, the top plate, bottom plate, side plates, frame, bottom cross beam and bottom longitudinal beam are made of composite material profiles, which can reduce the weight by more than 200kg compared with the traditional steel corrugated cargo box, effectively control the cost, and the cargo box has high strength, excellent load-bearing capacity and durability.

[0058] In a second aspect of the present invention, the present invention provides a method for preparing the composite cargo box as described above. According to some embodiments of the present invention, the method for preparing the composite cargo box as described above may include:

[0059] Step (1): prepare the top plate, side plates, front plate, bottom plate, frame, bottom cross beam and bottom longitudinal beam.

[0060] Step (1-1): Prepare a prepreg tape.

[0061] The resin matrix is ​​heated in an extruder to be melted and extruded to a die head, continuous fibers are impregnated in the die head, and rolled in a roller press to prepare a first prepreg tape.

[0062] Light stabilizer and heat stabilizer are added to the resin matrix, the mixture is heated in an extruder to be melted and extruded to a die, continuous fibers are impregnated in the die, and rolled in a roller press to prepare a second prepreg tape.

[0063] A wear-resistant additive is added to the resin matrix, the mixture is heated in an extruder to be melted and extruded to a die, continuous fibers are impregnated in the die, and the third prepreg is prepared by rolling in a roller press.

[0064] The materials of the resin matrix, continuous fibers, light stabilizers, heat stabilizers and wear-resistant additives have been described in detail above and will not be repeated here.

[0065] According to some embodiments of the present invention, in the second prepreg, the mass of the light stabilizer is 0.1% to 1% of the mass of the resin matrix, and the mass of the heat stabilizer is 0.1% to 1% of the mass of the resin matrix. For example, the mass of the light stabilizer can be 0.1%, 0.3%, 0.5%, 0.7%, 1%, etc. of the mass of the resin matrix, and the mass of the heat stabilizer can be 0.1%, 0.2%, 0.4%, 0.5%, 0.8%, 1%, etc. of the mass of the resin matrix. Adding the above-mentioned amounts of light stabilizers and heat stabilizers can effectively improve the light and heat aging resistance of the board.

[0066] According to some embodiments of the present invention, in the third prepreg, the mass of the wear-resistant additive is 1% to 15% of the mass of the resin matrix. For example, the mass of the wear-resistant additive can be 1%, 3%, 5%, 8%, 10%, 12%, 15%, etc. of the mass of the resin matrix. When the content of the wear-resistant additive is within the above range, the wear resistance of the plate can be improved at least to a certain extent, thereby facilitating the extension of the service life of the plate.

[0067] According to some embodiments of the present invention, the mass content of continuous fibers in the first prepreg tape, the second prepreg tape and the third prepreg tape can be independently 30wt% to 80wt%, for example, in each prepreg tape, the mass content of continuous fibers can be independently 30wt%, 40wt%, 50wt%, 60wt%, 70wt%, 80wt%, etc. Thus, the continuous fibers combined with the resin matrix can better withstand external loads, thereby improving the mechanical properties of the material; the content of continuous fibers within the above range is conducive to reducing the density of the composite material, improving the heat resistance of the material, and improving the adaptability of the material to the environment.

[0068] According to some embodiments of the present invention, the thickness of the first prepreg tape, the thickness of the second prepreg tape, and the thickness of the third prepreg tape are each independently 0.1 mm to 1 mm. For example, the thickness of each prepreg tape can be independently 0.1 mm, 0.3 mm, 0.5 mm, 0.8 mm, 1 mm, etc. A thinner prepreg tape helps the resin to more evenly impregnate the continuous fiber material, reducing the formation of pores and voids, thereby facilitating the improvement of the yield and performance of the composite material; a thinner prepreg tape can increase the interlayer bonding force during the stacking process, which is beneficial to improving the overall performance of the composite material plate.

[0069] Step (1-2): Prepare the top plate.

[0070] According to some embodiments of the present invention, reference Figure 3 At least one second prepreg tape 12 may be compounded on one side of at least one first prepreg tape 11, and the top plate 1 may be prepared by a tape pressing or molding process. According to some embodiments of the present invention, at least one first prepreg tape 12 may be compounded on one side of a plurality of first prepreg tapes 11, and the top plate 1 may be prepared by a tape pressing or molding process.

[0071] According to some specific embodiments of the present invention, the top plate 1 can be an integral design (whole plate), using a thermoplastic composite material plate, using plastics such as PP, PA6 or PA66 as a matrix, using E glass fiber, S glass fiber, basalt fiber, etc. as reinforcing fiber, preparing a thermoplastic prepreg tape by melt impregnation, etc., and preparing the plate by belt pressing, molding, etc. In some embodiments, the resin matrix of the outermost prepreg tape used in the plate is modified by adding weathering additives (light stabilizers and heat stabilizers) to meet the requirements of light and heat aging resistance.

[0072] According to some embodiments of the present invention, a thermoplastic prepreg tape is prepared by melt impregnation or the like, and then a top plate can be prepared by double steel belt pressing. When the composite material prepreg tape used for the top plate is pressed, the resin matrix of the outermost prepreg tape is a weather-resistant modified plastic (with light stabilizer and heat stabilizer added), which is the same material as other layers but has better weather resistance. The uniform distribution of the resin of the outer tape is controlled by adjusting the molding process parameters, eliminating the need for spray painting or laminating, which is more efficient and low-cost.

[0073] Step (1-3): Prepare a base plate.

[0074] According to some embodiments of the present invention, reference Figure 4 At least one third prepreg tape 13 may be compounded on one side of at least one first prepreg tape 11, and the bottom plate 4 may be prepared by tape pressing or molding. In some embodiments, at least one third prepreg tape 13 may be compounded on one side of a plurality of first prepreg tapes 11, and the bottom plate may be prepared by tape pressing or molding.

[0075] According to some embodiments of the present invention, the bottom plate 4 is an integral plate structure, and can use plastics such as PP, PA6 or PA66 as a matrix, and use E glass fiber, S glass fiber, basalt fiber, carbon fiber, aramid fiber, etc. as reinforcing fiber, and prepare thermoplastic composite material prepreg tape by melt impregnation or other methods, and prepare the plate by belt pressing, molding or other methods. The prepreg tape resin matrix used for the plate facing cargo loading is modified with a wear-resistant additive, and has the same material as other layers but better wear resistance, which is conducive to extending the service life of the plate.

[0076] According to some specific embodiments of the present invention, a thermoplastic composite material prepreg tape is prepared by melt impregnation or the like, and then a base plate can be prepared by double steel belt pressing. When the composite material prepreg tape used for the base plate is pressed, the resin matrix of the upper surface prepreg tape is a wear-resistant modified plastic (with wear-resistant additives added), which is the same material as other layers but has better wear resistance. By adjusting the molding process parameters, the uniform distribution of the resin of the upper surface tape is controlled, and leather coating or painting is avoided, which is more efficient and low-cost.

[0077] Step (1-4): Prepare the side panels and the front panel.

[0078] According to some embodiments of the present invention, the steps of preparing the side plate 2 and the front plate 3 are as follows: at least one second prepreg tape 12 is compounded on one side of at least one first prepreg tape 11, a whole plate is prepared by a processing method of belt pressing or molding, the whole plate is cut, the cut plate is partially softened by heating, and then a bending device is used to bend it to obtain a bent part 21, refer to Figure 5, multiple bending parts 21 are spliced ​​together to obtain side panels 2 and front panels 3. The width and thickness of the bending parts 21 have been described in detail above and will not be repeated here. According to some embodiments of the present invention, the thermoplastic composite material sheet material used for the side panels 2 and the front panel 3 is the same as that of the top panel 1, and the outermost prepreg tape can be a thermoplastic composite material prepreg tape with good light and heat aging resistance.

[0079] According to some embodiments of the present invention, when the composite prepreg tape used for the side panels and the front panel is pressed, the resin matrix of the outermost prepreg tape is a weather-resistant modified plastic (with added light stabilizers and heat stabilizers), which is the same material as other layers but has better weather resistance. The uniform distribution of the resin of the outer tape is controlled by adjusting the molding process parameters, eliminating the need for painting or laminating, which is more efficient and low-cost.

[0080] According to some embodiments of the present invention, when preparing the bent part 21, infrared focused linear heating can be used to partially soften the cut plate, and then the partially softened plate is bent to obtain the bent part.

[0081] According to some embodiments of the present invention, a plurality of bent parts 21 may be spliced ​​together by bonding, riveting and / or ultrasonic welding to obtain the side panels 2 and the front panel 3 .

[0082] In some embodiments, infrared linear heating equipment can be used to perform linear focused heating on thermoplastic composite material sheets, and the heating time can be controlled to locally soften the material and then bend it to prepare a sheet bent part. Several bent parts can be connected by gluing, riveting, ultrasonic welding, etc. to splice into side panels and a front panel.

[0083] Step (1-5): Prepare the frame, bottom cross beam and bottom longitudinal beam.

[0084] According to some embodiments of the present invention, the composite of the resin matrix and the continuous fiber can be prepared into a composite profile by pultrusion and / or continuous compression molding, and the frame 5, the bottom cross beam 6 and the bottom longitudinal beam 7 can be prepared using the composite profile.

[0085] According to some embodiments of the present invention, the frame 5, the bottom cross beam 6, and the bottom longitudinal beam 7 are straight profile structures, and plastics such as PP, PA6, PA56, PA66 or PMMA can be used as the matrix, and E glass fiber, S glass fiber, basalt fiber, carbon fiber, aramid fiber, etc. can be used as reinforcing fibers.

[0086] According to some embodiments of the present invention, the continuous fibers in the frame 5 may be distributed axially. In some specific embodiments, the frame 5 may be prepared by a pultrusion process, and the continuous fibers may be distributed axially, with strong resistance to deformation in a single direction.

[0087] According to some embodiments of the present invention, reference Figure 1The frame 5 may be composed of a plurality of crossbeams and longitudinal beams. The crossbeams and longitudinal beams of the frame may be hollow structures. The continuous fibers in the crossbeams and longitudinal beams may be axially distributed, that is, the extension direction of the continuous fibers in the crossbeams is the same as the length direction of the crossbeams, and the extension direction of the continuous fibers in the longitudinal beams is the same as the length direction of the longitudinal beams. Thus, the strength and stiffness of the continuous fibers can be maximized, thereby improving the load-bearing capacity of the crossbeams and longitudinal beams in the length direction.

[0088] According to some embodiments of the present invention, the bottom cross beam 6 and the bottom longitudinal beam 7 can be prepared by a continuous compression molding process. The continuous fibers are formed according to the structural stress requirements, so that the longitudinal and transverse mechanical properties of the composite material are balanced, and the complex structural load-bearing requirements of the bottom cross beam and the longitudinal beam are met, which is more reliable. The bottom cross beam 6 and the bottom longitudinal beam 7 are located at the bottom of the cargo compartment, and mainly play the role of bearing goods, and require strong resistance to compression deformation. The bottom cross beam 6 and the bottom longitudinal beam 7 are both hollow structures. The bottom cross beam and the bottom longitudinal beam each have four faces, and the four faces are parallel to the extension direction of the beam. When assembling the cargo compartment, the two faces parallel to the ground are horizontal faces, and the two faces perpendicular to the ground are vertical faces. From the perspective of structural rigidity requirements, the reinforcing fibers of the horizontal plane are distributed along the axial direction, that is, the extension direction of the reinforcing fibers of the horizontal plane is the same as the length direction of the beam. The vertical plane uses a certain proportion of a better isotropic fabric form, such as plain weave, twill and other woven fabrics, that is, the reinforcing fibers of the vertical plane have different extension directions, which is more conducive to the improvement of the load-bearing performance.

[0089] Step (2): Assemble the various components.

[0090] In this step, the top plate 1, the side plates 2, the front plate 3, the bottom plate 4, the frame 5, the bottom cross beam 6, and the bottom longitudinal beam 7 are assembled to prepare a composite material cargo compartment.

[0091] According to some embodiments of the present invention, the top panel 1, side panel 2, front panel 3, bottom panel 4, frame 5, bottom cross beam 6, and bottom longitudinal beam 7 can be assembled by bonding, riveting and / or ultrasonic welding to prepare a composite cargo compartment.

[0092] According to some embodiments of the present invention, the top plate 1 can be connected to a number of top cross beams in the frame 5 by gluing, and the whole plate has no joints, is watertight, and has good structural strength.

[0093] According to some embodiments of the present invention, the prepared thermoplastic composite material components are connected by processes such as gluing, riveting and / or ultrasonic welding to be assembled into an integral cargo compartment, which can achieve a weight reduction of more than 200 kg compared with a traditional steel cargo compartment, with a weight reduction ratio of approximately 30%. At the same time, the cost can be effectively controlled.

[0094] According to some embodiments of the present invention, the method for preparing a composite cargo box may further include the step of assembling the side doors 8 and the rear door 9 .

[0095] In a third aspect of the present invention, the present invention provides a vehicle. According to some embodiments of the present invention, the vehicle may include the composite cargo box as described above or the composite cargo box prepared by the method as described above. Therefore, the vehicle has all the features and advantages of the composite cargo box as described above, which will not be described in detail here.

[0096] According to some embodiments of the present invention, the vehicle may be a fuel vehicle, a gas vehicle or a new energy vehicle. The new energy vehicle may be a pure electric vehicle, a hybrid vehicle or an extended-range vehicle, etc.

[0097] The composite cargo box of the embodiment of the present invention is described in detail with reference to the accompanying drawings. It is worth noting that the following description is only an exemplary description and is not a specific limitation of the invention.

[0098] refer to Figure 1 The composite cargo compartment includes a top plate 1, a side plate 2, a front plate 3, a bottom plate 4, a frame 5, a bottom cross beam 6, a longitudinal cross beam 7, a side door 8 and a rear door 9. There may be multiple top cross beams above the frame 5, and the top plate 1 is connected to the multiple top cross beams by gluing, and the top plate 1 is arranged above the frame 5. There may also be multiple cross beams in front of the frame 5, and the front plate 3 is formed by splicing multiple bending pieces, and the front plate 3 and the multiple cross beams in front of the frame may also be connected by gluing, and the front plate 3 is arranged in front of the frame 5. A side plate 2 is arranged on one side of the frame 5, and the side plate 2 is formed by splicing multiple bending pieces; two side plates 2 and a side door 8 are arranged on the other side of the frame 5, each side plate is formed by splicing multiple bending pieces, and the two side plates are located on both sides of the side door 8. The bottom plate 4 is located below the frame 5, and the bottom cross beam 6 and the bottom longitudinal beam 7 are located below the bottom plate 4, which are used to support the bottom plate 4 and carry goods. The materials of the top plate 1, the side plate 2, the front plate 3, the bottom plate 4, the bottom cross beam 6 and the bottom longitudinal beam 7 are all continuous fiber reinforced thermoplastic resin. Light stabilizers and heat stabilizers are distributed in the thermoplastic resin on the side of the top plate 1, the side plate 2 and the front plate 3 away from the frame 5. Wear-resistant additives are distributed in the thermoplastic resin on the side of the bottom plate 4 close to the frame 5.

[0099] In general, the present invention has the following advantages: (1) Multiple components of the composite cargo box are made of thermoplastic composite materials, which can achieve weight reduction compared to traditional steel cargo boxes. (2) Three different thermoplastic prepregs are prepared by melt impregnation and other methods. The first prepreg does not add weathering agents or wear-resistant agents to the resin matrix. The second prepreg adds a certain amount of light stabilizer and heat stabilizer on the basis of the resin matrix to improve weather resistance. The third prepreg adds a certain amount of wear-resistant agent on the basis of the resin matrix to extend the service life of the board. The first prepreg and the second prepreg are combined so that the prepreg used on the side facing the light is an anti-light and heat aging layer, which is used for the cargo box roof, side panels, and front panels without lamination or painting, thereby better controlling costs. (3) For the composite floor, the first prepreg and the third prepreg are combined so that the prepreg used on the side facing the cargo box loading is a wear-resistant layer, thereby extending the service life. (4) The plate bending parts are prepared by infrared linear heating and then bending, and the cargo compartment side panels and front panels are prepared by ultrasonic welding, gluing or riveting. This structure is lighter than corrugated steel sheets and has better corrosion resistance and durability. (5) The composite material frame is prepared by pultrusion, and the composite material bottom cross beam and longitudinal beam are prepared by pultrusion or continuous compression molding. The fiber direction is designed according to the structural stress characteristics to ensure the stability and load-bearing capacity of the cargo compartment frame. (6) The composite material is recyclable and can be crushed and recycled after the cargo compartment is scrapped, which is more environmentally friendly.

[0100] In the description of this specification, the description with reference to the terms "embodiment", "example", etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0101] Although embodiments of the present invention have been shown and described, those skilled in the art will appreciate that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the claims and their equivalents.

Claims

1. A composite cargo compartment, characterized in that: include: Top plate (1), side plate (2), front plate (3), bottom plate (4), frame (5), bottom cross beam (6), bottom longitudinal beam (7); The top plate (1) is located above the frame (5), the side plates (2) are located on both sides of the frame (5), the front plate (3) is located in front of the frame (5), the bottom plate (4) is located below the frame (5), and the bottom cross beam (6) and the bottom longitudinal beam (7) are located below the bottom plate (4); The top plate (1), the side plate (2), the front plate (3), the bottom plate (4), the bottom cross beam (6) and the bottom longitudinal beam (7) are all made of continuous fiber reinforced thermoplastic resin; Light stabilizers and heat stabilizers are distributed in the thermoplastic resin on the top plate (1), the side plate (2) and the front plate (3) at a side away from the frame (5); A wear-resistant additive is distributed in the thermoplastic resin on the side of the bottom plate (4) close to the frame (5).

2. The composite cargo box according to claim 1, characterized in that: The side panels (2) and the front panel (3) are composed of a plurality of bent parts (21) spliced ​​together; Optionally, the width of the bending piece (21) is 100 mm to 500 mm; Optionally, the thickness of the bending piece (21) is 1 mm to 4 mm.

3. The composite cargo box according to claim 1, characterized in that: At least one of the following conditions is met: The top plate (1) is a whole plate; The thickness of the top plate (1) is 1 mm to 3 mm; The bottom plate (4) is a whole plate; The thickness of the bottom plate (4) is 1 mm to 10 mm.

4. The composite cargo box according to claim 1, characterized in that: The continuous fiber reinforced thermoplastic resin satisfies at least one of the following conditions: Based on the total mass of the continuous fiber reinforced thermoplastic resin, the mass content of the continuous fiber is 30wt% to 80wt%; The resin matrix of the continuous fiber reinforced thermoplastic resin includes at least one of PP, PA6, PA56, PA66 and PMMA; The continuous fibers include at least one of glass fibers, carbon fibers, basalt fibers, and aramid fibers.

5. The composite cargo box according to any one of claims 1 to 4, characterized in that: At least one of the following conditions is met: The light stabilizer includes at least one of benzophenone, hindered amine, carbon black and thiobisphenol; The heat stabilizer includes at least one of a phenolic heat stabilizer, an amine heat stabilizer, and a phosphite; The wear-resistant additive includes at least one of molybdenum disulfide, graphite, polytetrafluoroethylene and silicone.

6. A method for preparing a composite cargo box according to any one of claims 1 to 5, characterized in that: include: The resin matrix is ​​heated in an extruder to be melted and extruded to a die, continuous fibers are impregnated in the die, and rolled in a roller press to prepare a first prepreg tape (11); Adding a light stabilizer and a heat stabilizer to a resin matrix, heating the mixture in an extruder to a melt and extruding the mixture to a die, impregnating the continuous fiber in the die, and rolling the mixture in a roller press to prepare a second prepreg tape (12); Adding a wear-resistant additive to a resin matrix, heating the mixture in an extruder to a melt and extruding the mixture to a die, impregnating the continuous fiber in the die, and rolling the mixture in a roller press to prepare a third prepreg tape (13); Compounding at least one second prepreg tape (12) on one side of at least one of the first prepreg tapes (11), and preparing a top plate (1) by a tape pressing or molding process; At least one second prepreg tape (12) is laminated on one side of at least one of the first prepreg tapes (11), and a whole plate is prepared by a processing method of tape pressing or molding, the whole plate is cut, the cut plate is partially softened by heating, and then bent by a bending device to obtain a bent piece (21), and a plurality of bent pieces (21) are spliced ​​to obtain a side plate (2) and a front plate (3); Compounding at least one third prepreg tape (13) on one side of at least one of the first prepreg tapes (11), and preparing a base plate (4) by a tape pressing or molding process; The composite of the resin matrix and the continuous fibers is prepared into a composite profile by pultrusion and / or continuous compression molding, and the frame (5), the bottom cross beam (6) and the bottom longitudinal beam (7) are prepared by using the composite profile; The top plate (1), the side plate (2), the front plate (3), the bottom plate (4), the frame (5), the bottom cross beam (6), and the bottom longitudinal beam (7) are assembled to prepare a composite material cargo compartment.

7. The method according to claim 6, characterized in that In the first prepreg tape (11), the second prepreg tape (12) and the third prepreg tape (13), the mass content of continuous fibers is independently 30 wt% to 80 wt%; And / or the thickness of the first prepreg tape (11), the thickness of the second prepreg tape (12) and the thickness of the third prepreg tape (13) are each independently 0.1 mm to 1 mm.

8. The method according to claim 6, characterized in that In the second prepreg tape (12), the mass of the light stabilizer is 0.1% to 1% of the mass of the resin matrix, and the mass of the heat stabilizer is 0.1% to 1% of the mass of the resin matrix; And / or, in the third prepreg tape (13), the mass of the wear-resistant additive is 1% to 15% of the mass of the resin matrix.

9. The method according to any one of claims 6 to 8, characterized in that: At least one of the following conditions is met: When preparing the bent part (21), the cut plate is locally softened by infrared focused linear heating; The plurality of bent parts (21) are spliced ​​together by bonding, riveting and / or ultrasonic welding to obtain the side panels (2) and the front panel (3); The continuous fibers in the frame (5) are distributed axially; The top plate (1), the side plate (2), the front plate (3), the bottom plate (4), the frame (5), the bottom cross beam (6), and the bottom longitudinal beam (7) are assembled by bonding, riveting, and / or ultrasonic welding to prepare a composite material cargo compartment.

10. A vehicle, characterized in that: A composite cargo box comprising the composite cargo box according to any one of claims 1 to 5 or a composite cargo box prepared by the method according to any one of claims 6 to 9.

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