CFRP / metal composite paper folding thin wall filled automobile energy absorption box

Abstract

The invention discloses a CFRP / metal composite paper folding thin wall filled automobile energy absorption box, and relates to the technical field of automobile passive protection safety, the CFRP / metal composite paper folding thin wall filled automobile energy absorption box comprises flange plates, and an energy absorption body is fixedly installed between the opposite faces of the two flange plates; the energy absorption body comprises a paper folding metal square tube, a carbon fiber square tube and polyurethane foam, the paper folding metal square tube is arranged on the peripheral face of the carbon fiber square tube in a sleeving mode, and the paper folding metal square tube is in interference fit with the carbon fiber square tube; and the polyurethane foam is filled in the carbon fiber square tube. According to the CFRP / metal composite paper folding thin wall filled automobile energy absorption box, the problems that a traditional energy absorption box is low in specific energy absorption, large in weight, weak in energy absorption capacity, poor in stability and the like are solved, the structure is simple, the initial peak force is low, the energy absorption performance is high, the stability is high, and injuries to passengers during vehicle collision can be relieved to the maximum extent.

Description

Technical Field

[0001] The invention relates to the technical field of automobile passive protection safety, and in particular to a CFRP / metal composite origami thin-wall filled automobile energy absorption box. Background Art

[0002] In recent years, the automobile industry has developed rapidly, the number of traffic accidents has continued to rise, and the casualty rate has increased year by year. It is urgent to enhance the safety performance of automobiles. As one of the components of automobile safety performance, automobile passive safety performance mainly refers to the ability of the car to absorb energy through the passive safety structure when the vehicle is hit, thereby reducing the impact force of the vehicle collision on the occupants. In vehicle collision accidents, frontal collisions account for more than half. As one of the passive safety structures of such collisions, the energy absorption box deforms axially when it is hit, effectively absorbing energy and reducing the impact force. There are many structures and materials used in existing energy absorption boxes, but most of the automobile energy absorption boxes still face many problems such as heavy weight, low specific energy absorption, and unstable energy absorption.

[0003] The automobile energy absorption box with publication number CN104590178A uses carbon fiber composite materials, glass fiber composite materials, and foam aluminum alloy ingots to make the energy absorption box body, which effectively reduces the mass of the energy absorption box. However, this energy absorption box with carbon fiber composite materials as the main body is prone to catastrophic failure when subjected to axial impact, and it is difficult to ensure the stability of energy absorption.

[0004] The automobile energy absorption box manufactured by the automobile energy absorption box manufacturing method with publication number CN118322610A has a specific energy absorption range of 9.5 kJ / kg-9.7 kJ / kg, and still faces the problem of small specific energy absorption.

[0005] Carbon fiber reinforced composite materials have the advantages of high specific energy absorption, low weight, and high specific strength, but they are very sensitive to impact loads and are prone to catastrophic failure. Metal materials have excellent stability and ductility, but they are heavy and have weak energy absorption effects. Under reasonable design, a mixed structure of the two can produce a beneficial interaction and give full play to the advantages of both. The design of various origami structures can effectively improve the compressive mechanical properties of the structure and enhance the crashworthiness of the structure. Lightweight fillers have excellent energy absorption performance and have been widely used in scenarios that require a lot of energy absorption.

[0006] How to develop a CFRP / metal composite origami thin-walled filled automobile energy absorption box, fully combine and give play to the advantages of the above materials and structures, and design a new type of automobile energy absorption box with stronger energy absorption capacity and collision resistance has become a technical problem that needs to be urgently solved by technical personnel in this field. Summary of the invention

[0007] The purpose of the present invention is to provide a CFRP / metal composite origami thin-walled filled automobile energy absorption box to solve the problems listed in the background technology.

[0008] In order to solve the above technical problems, the present invention adopts the following technical solutions:

[0009] The present invention discloses a CFRP / metal composite origami thin-walled filled automobile energy absorption box, comprising a flange, and an energy absorbing body is fixedly installed between the opposite surfaces of two flanges;

[0010] The energy absorbing body comprises an origami metal square tube, a carbon fiber square tube and polyurethane foam, wherein the origami metal square tube is sleeved on the outer peripheral surface of the carbon fiber square tube, and the origami metal square tube and the carbon fiber square tube are interference fit;

[0011] The polyurethane foam is filled in the interior of the carbon fiber square tube.

[0012] Preferably, the flanges are made of aluminum alloy, and one flange is connected to the front bumper of the automobile, and the other flange is connected to the front longitudinal beam of the automobile.

[0013] Preferably, the origami metal square tube is made of 316L steel, and the origami metal square tube is integrally manufactured by 3D printing, and a folded hexagonal pattern is preset on the side wall of the origami metal square tube.

[0014] Preferably, the preset folded hexagonal pattern on the side wall of the origami metal square tube is generated by arranging the same basic pattern, the number of the basic patterns is N, the smaller angle between the α and β faces of the basic pattern is φ, the upper and lower sides of the basic pattern are a, and the height is h. The calculation formula for the upper and lower sides of the basic pattern is a=length of each side of the origami metal square tube / number of columns of the basic pattern required for the array arrangement / 2, and the calculation formula for the height of the basic pattern is h=height of each side of the origami metal square tube / N.

[0015] Preferably, the carbon fiber square tube is formed by winding a T700 carbon fiber bundle pre-impregnated with epoxy resin, and the carbon fiber square tube comprises a carbon fiber ply, and each layer of the carbon fiber ply has the same thickness;

[0016] The ply angle of the carbon fiber on the carbon fiber square tube takes the axial direction of the energy absorption box as 0°, counterclockwise rotation along the axial direction of the energy absorption box as a positive angle, and vice versa as a negative angle, and the maximum angle is 90°.

[0017] Preferably, the polyurethane foam is a polyurethane foam board PU high-density extra-hard powdered foam with a density of 200kg / m 3 .

[0018] Compared with the prior art, the beneficial technical effects of the present invention are:

[0019] 1) Strong energy absorption performance. A folded hexagonal pattern is preset on the origami metal square tube. This crease can guide the deformation mode of the origami metal square tube during axial compression, and then guide and improve the deformation mode of the carbon fiber square tube, so that the destruction of the carbon fiber tube and the deformation of the metal tube are more thorough, and the potential energy is released more fully. The polyurethane foam has a wide strain range in the yield stage, but the stress has almost no fluctuation. At this stage, it can absorb a lot of energy. Filling it into the carbon fiber square tube will greatly improve the energy absorption performance;

[0020] 2) High stability and strong bearing capacity. The energy absorption box combines the advantages of different materials and origami structures and has excellent mechanical properties. The filling of polyurethane foam increases the number of wrinkles on the metal tube and makes them more densely arranged. The reduction in the effective length of the wrinkles leads to an increase in the average force, which greatly increases the load level. The carbon fiber ply angle greater than 45° and less than 90° can make the energy absorption box have good axial bending consistency. The energy absorption stability can be effectively improved through reasonable design. The origami structure has the function of guiding the collapse path of the energy absorption box during failure deformation and improving the failure form of the structure. It can prevent the metal square tube and the carbon fiber square tube from Euler deformation and catastrophic failure, and effectively improve the deformation stability.

[0021] 3) The initial peak force is reduced. Changes in the carbon fiber square tube ply angle, the metal square tube pattern angle, and the number of pattern layers will affect the initial peak force. Through reasonable design, the energy absorption box proposed in the present invention can reduce the initial peak force, so that the initial peak force is not the highest peak force and is in a medium-low position among all peak forces.

[0022] 4) Light weight and high specific energy absorption. On the premise of ensuring the overall performance of the energy absorption box, the carbon fiber reinforced composite material is used, which can effectively improve the energy absorption capacity of the energy absorption box and at the same time greatly reduce the overall mass of the energy absorption box. The enhanced energy absorption performance of the energy absorption box and the reduced overall mass together lead to the energy absorption box proposed by the present invention having a high specific energy absorption value;

[0023] 5) Simple structure and mature manufacturing process. The energy absorption box has a simple structure and does not contain complex internal and external structures. The origami metal square tube is made of 3D printing technology, and the carbon fiber square tube is made of winding molding technology. The polyurethane foam is the common polyurethane foam board PU high-density extra-hard powdered foam on the market. The relevant manufacturing process is mature and can achieve large-scale production.

[0024] In general, the present invention overcomes the problems of low energy absorption, heavy weight, weak energy absorption capacity, and poor stability of traditional energy absorption boxes. It has a simple structure, low initial peak force, strong energy absorption performance, and high stability, and can minimize the damage to occupants during a vehicle collision. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present invention will be further described below in conjunction with the accompanying drawings.

[0026] Figure 1 It is a front view schematic diagram of a CFRP / metal composite origami thin-wall filled automobile energy absorption box of the present invention;

[0027] Figure 2 This is a three-dimensional diagram of the energy absorption box of the present invention (one end has no flange);

[0028] Figure 3 It is a schematic diagram of the basic pattern arrangement of the present invention;

[0029] Figure 4 This is a schematic diagram of the angle of the upper layer of the carbon fiber square tube of the present invention;

[0030] Figure 5 This is a schematic diagram of the basic pattern on the origami metal square tube of the present invention;

[0031] Figure 6 The load-displacement curves of the quasi-static axial compression test of the energy absorbing box related embodiments A1, A2, A3, A5 and the preferred embodiment A4 of the present invention;

[0032] Figure 7 This is a schematic diagram of the compression process of an embodiment of the present invention;

[0033] Figure 8 It is a schematic diagram of compression results of an embodiment of the present invention.

[0034] Explanation of the reference numerals: 1-flange; 2-energy absorber; 21-origami metal square tube; 22-carbon fiber square tube; 23-polyurethane foam.

[0035] a-the length of the upper and lower sides of the basic pattern; h-the height of the basic pattern; α-the α side of the basic pattern; β-the β side of the basic pattern; φ-the smaller angle between the α and β sides of the basic pattern; N-the number of basic patterns arranged vertically on the metal origami square tube is also called the number of pattern layers. DETAILED DESCRIPTION

[0036] In order to make the technical problems, technical solutions and beneficial effects to be solved by the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0037] like Figure 1-8 As shown, a CFRP / metal composite origami thin-walled filled automobile energy absorption box comprises a flange 1, and an energy absorbing body 2 is fixedly installed between the opposite surfaces of two flanges 1;

[0038] The energy absorbing body 2 comprises an origami metal square tube 21, a carbon fiber square tube 22 and a polyurethane foam 23, wherein the origami metal square tube 21 is sleeved on the outer peripheral surface of the carbon fiber square tube 22, and the origami metal square tube 21 and the carbon fiber square tube 22 are interference fit;

[0039] The polyurethane foam 23 fills the interior of the carbon fiber square tube 22 .

[0040] Specifically, the flange 1 is made of aluminum alloy material, and one flange 1 is connected to the front bumper of the car, and the other flange 1 is connected to the front longitudinal beam of the car.

[0041] Specifically, the origami metal square tube 21 is made of 316L steel, and the origami metal square tube 21 is integrally manufactured through 3D printing. A folded hexagonal pattern is preset on the side wall of the origami metal square tube 21. The origami metal square tube material is 316L steel, which has the advantages of high strength and good ductility. It exhibits a positive interaction effect with carbon fiber reinforced materials. This metal composite hybrid structure has a beneficial interactive effect on energy absorption and crash resistance.

[0042] Specifically, the preset folded hexagonal pattern on the side wall of the origami metal square tube 21 is generated by arranging the same basic pattern, the number of the basic patterns is N, the smaller angle between the α and β faces of the basic pattern is φ, the upper and lower sides of the basic pattern are a, and the height is h. The calculation formula for the upper and lower sides of the basic pattern is a=length of each side of the origami metal square tube / number of columns of the basic pattern required for the array arrangement / 2, and the calculation formula for the height of the basic pattern is h=height of each side of the origami metal square tube / N.

[0043] Specifically, the carbon fiber square tube 22 is formed by winding a T700 carbon fiber bundle pre-impregnated with 3234 epoxy resin, thereby achieving a lightweight effect. The carbon fiber square tube 22 includes 6 layers of carbon fiber plies, and each layer of the carbon fiber plies has the same thickness.

[0044] The laying angle of the carbon fiber on the carbon fiber square tube 22 takes the axial direction of the energy absorption box as 0°, and counterclockwise rotation along the axial direction of the energy absorption box as a positive angle, and vice versa as a negative angle. The maximum angle is 90°, and the angle of each layer of carbon fiber laying can be freely designed; further, the laying angle of the carbon fiber square tube from inside to outside is preferably [70° / -70° / 90° / 90° / 70° / -70°], so that the potential energy of the carbon fiber square tube is released more thoroughly and has stronger axial flexure consistency.

[0045] Specifically, the polyurethane foam 23 is a polyurethane foam board PU high-density hard powder foam, and the PU foam density is 200kg / m 3 , strong energy absorption performance and stable failure mode.

[0046] Embodiment 1

[0047] The N of the folded hexagonal pattern preset on the origami metal square tube 21 is 5, and 5×2 basic patterns are arranged in an array on each side. This design effectively reduces the initial peak force of the energy absorption box, reduces the fluctuation amplitude of the energy absorption curve, and increases the average bearing force;

[0048] Furthermore, the basic pattern φ of the preset folded hexagonal pattern formed on the origami metal square tube 21 is 150°, the upper and lower side lengths a=10.75 mm, and the height h=20 mm;

[0049] The new automobile energy absorption box described in this embodiment is subjected to a compression test by a 200KN-class universal testing machine. Before the test begins, the specimen is placed in the middle of the fixed table. During the test, the compression head begins to compress downward at a loading speed of 8mm / min, and the total compression displacement is 60mm. The signal sensor on the compression head records and transmits relevant data to the computer in real time.

[0050] After the experiment, the relevant data were processed and the specific energy absorption was 13.37KJ / kg. Figure 6 It can also be observed that the initial peak force of this embodiment is not the highest peak force but is in a medium-low position among all the peak forces.

[0051] The detailed parameters of the carbon fiber square tube experimental example are shown in the following table:

[0052]

[0053] Explanation of symbols: The angle between the α and β planes is N is the number of basic pattern layers arranged longitudinally on the square tube, ρ is the density of the polyurethane foam filled inside, and the fiber angles from left to right are the layup angles of the square tube from the inside to the outside.

[0054] The energy absorption box assembly method proposed by the present invention is as follows:

[0055] The origami metal square tube 21 and the carbon fiber square tube 22 are connected by interference fit;

[0056] The polyurethane foam 23 is cut according to relevant sizes and filled in the carbon fiber square tube 22;

[0057] The origami metal square tube 21, the carbon fiber square tube 22, the polyurethane foam 23 and the flange 1 are connected by spot welding;

[0058] The flange 1 is connected to the front longitudinal beam of the vehicle and the front bumper of the vehicle through bolts.

[0059] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0060] The embodiments described above are only descriptions of the preferred modes of the present invention, and are not intended to limit the scope of the present invention. Without departing from the design spirit of the present invention, various modifications and improvements made to the technical solutions of the present invention by ordinary technicians in this field should all fall within the protection scope determined by the claims of the present invention.

Claims

1. A CFRP / metal composite origami thin-walled filled automobile energy absorption box, comprising a flange (1), characterized in that: An energy absorbing body (2) is fixedly installed between the opposite surfaces of the two flanges (1); The energy absorbing body (2) comprises an origami metal square tube (21), a carbon fiber square tube (22) and polyurethane foam (23); the origami metal square tube (21) is sleeved on the outer peripheral surface of the carbon fiber square tube (22), and the origami metal square tube (21) and the carbon fiber square tube (22) are in interference fit; The polyurethane foam (23) is filled inside the carbon fiber square tube (22).

2. The CFRP / metal composite origami thin-walled filled automobile energy absorption box according to claim 1, characterized in that: The flange (1) is made of an aluminum alloy material, and one flange (1) is connected to the front bumper of the automobile, and the other flange (1) is connected to the front longitudinal beam of the automobile.

3. The CFRP / metal composite origami thin-walled filled automobile energy absorption box according to claim 1, characterized in that: The origami metal square tube (21) is made of 316L steel, and the origami metal square tube (21) is integrally manufactured by 3D printing. A folded hexagonal pattern is preset on the side wall of the origami metal square tube (21).

4. The CFRP / metal composite origami thin-walled filled automobile energy absorption box according to claim 3, characterized in that: The preset folded hexagonal pattern on the side wall of the origami metal square tube (21) is generated by arranging the same basic pattern, the number of the basic patterns is N, the smaller angle between the α and β faces of the basic pattern is φ, the upper and lower sides of the basic pattern are a, and the height is h, the upper and lower sides of the basic pattern are calculated by a=length of each side of the origami metal square tube / number of columns of the basic pattern required for array arrangement / 2, and the height of the basic pattern is calculated by h=height of each side of the origami metal square tube / N.

5. The CFRP / metal composite origami thin-walled filled automobile energy absorption box according to claim 1, characterized in that: The carbon fiber square tube (22) is formed by winding a T700 carbon fiber bundle pre-impregnated with 3234 epoxy resin, and the carbon fiber square tube (22) comprises 6 layers of carbon fiber plies, and the thickness of each layer of the carbon fiber plies is the same; The laying angle of the carbon fibers on the carbon fiber square tube (22) is 0° in the axial direction of the energy absorption box, and a positive angle is counterclockwise along the axial direction of the energy absorption box, and a negative angle is counterclockwise, with a maximum angle of 90°.

6. The CFRP / metal composite origami thin-walled filled automobile energy absorption box according to claim 4, characterized in that: The polyurethane foam (23) is a polyurethane foam board PU high-density special hard powder foam with a density of 200kg / m 3 .

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