Appearance part plate, preparation method of appearance part plate, appearance part, forming process of appearance part and vehicle

Abstract

The invention discloses an exterior part plate and a preparation method thereof, an exterior part and a forming process thereof, and a vehicle, and belongs to the technical field of vehicles. The core layer in the exterior part plate provided by the invention comprises the fibers and the resin matrix, and the fibers and the resin matrix are compounded, so that the rigidity and the strength of the exterior part plate can be enhanced, the linear expansion coefficient of the plate can be reduced, and the performance of an exterior part is improved. The tensile strength of an outer part prepared from the outer part plate provided by the invention is 250-650 MPa, the tensile modulus is 10-25 GPa, and the bending modulus is 8-30 GPa, so that the rigidity and the strength of the outer part are well improved. Meanwhile, the linear expansion coefficient ranges from 7 * 10 <-6 > m / (m.k) to 25 * 10 <-6 > m / (m.k), so that the thermal dimensional stability of the outer part can be effectively controlled, and the fit clearance of the outer part is improved.

Description

Technical Field

[0001] The present application relates to the field of vehicle technology, and in particular to an appearance component plate and a preparation method thereof, an appearance component and a molding process thereof, and a vehicle. Background Art

[0002] At present, lightweighting is an important trend in vehicle development. Therefore, more and more vehicles use plastics instead of steel in their exterior parts.

[0003] In the related art, the appearance parts of vehicles are mainly made of composite plastics of PC (polycarbonate) and ABS (acrylonitrile-styrene-butadiene copolymer) or talc-filled plastics of PP PP+EPDM-T30 (polypropylene + ethylene-propylene rubber, in which the mass fraction of talc is 30%) / PP+EPDM-T20 (polypropylene + ethylene-propylene rubber, in which the mass fraction of talc is 20%). However, this type of plastic has poor rigidity and large linear expansion coefficient, resulting in poor performance of the appearance parts. Summary of the invention

[0004] The embodiment of the present application provides an appearance component plate and a preparation method thereof, an appearance component and a molding process thereof, and a vehicle, which can improve the performance of the appearance component. The technical solution is as follows:

[0005] In one aspect, an appearance component sheet is provided, the appearance component sheet comprising a film layer and a core layer;

[0006] The film layer includes at least one of a composite of acrylonitrile-styrene-butadiene copolymer and polycarbonate and polycarbonate;

[0007] The core layer includes a resin matrix and fibers, wherein the resin matrix includes at least one of polycarbonate, nylon and modified polypropylene, and the fibers include at least one of glass fibers and carbon fibers.

[0008] In a possible implementation, the raw material for preparing the modified polypropylene includes the following components in parts by mass:

[0009] 80-100 parts of polypropylene, 3-20 parts of maleic anhydride, 3-7 parts of silane coupling agent, 2-7 parts of antioxidant, and 0.3-2 parts of cumene peroxide.

[0010] In another possible implementation, the method for preparing the modified polypropylene includes:

[0011] Weigh the polypropylene, the maleic anhydride, the silane coupling agent, the antioxidant and the cumene peroxide according to the mass fraction of each component;

[0012] The polypropylene, the maleic anhydride, the silane coupling agent, the antioxidant and the cumene peroxide are uniformly mixed and reacted at 190 to 230° C. for 10 to 20 minutes to obtain the modified polypropylene.

[0013] In another possible implementation, the mass fraction of the fibers in the core layer is 10% to 80%.

[0014] In another possible implementation, the thickness of the core layer is 0.25 to 2.5 mm, and the thickness of the film layer is 0.2 to 1 mm.

[0015] In another possible implementation manner, the film layer includes: a first film layer and a second film layer, and the core layer is located between the first film layer and the second film layer.

[0016] In another aspect, a method for preparing an appearance component sheet is provided, the method comprising:

[0017] Laying the core layer and the membrane layer in sequence, and pressing the core layer and the membrane layer together;

[0018] The preliminarily pressed sheet is conveyed to a pressurizing area for pressurization, so that the thickness of the sheet reaches 0.65 to 4.5 mm;

[0019] The plate having the required thickness is conveyed to the cooling zone, and the appearance part plate is obtained after consolidation and forming.

[0020] In a possible implementation, if the resin matrix in the core layer is the polycarbonate, the pressing temperature is 240-280° C.;

[0021] If the resin matrix in the core layer is nylon, the pressing temperature is 240-300°C;

[0022] If the resin matrix in the core layer is the modified polypropylene, the pressing temperature is 180-220°C.

[0023] On the other hand, an appearance part is provided, wherein the appearance part is a curved surface structure, including an appearance main body and a decorative coating;

[0024] The appearance body adopts the appearance part plate described in any of the above items, and the back of the appearance body is injection-molded with ribs and a target material layer, and the target material in the target material layer is the same as the material of the resin matrix in the core layer of the appearance part plate.

[0025] In a possible implementation manner, the appearance part has a thickness of 1 to 6.5 mm.

[0026] In another possible implementation, the rib has a thickness of 0.8 to 2.5 mm;

[0027] The thickness of the target material layer is 0.25 to 2 mm;

[0028] The thickness of the decorative coating is 60-500 μm.

[0029] On the other hand, a molding process of an appearance part is provided, the process comprising:

[0030] Cutting the appearance part sheet into a target shape, wherein the target shape is a two-dimensional unfolded shape of the appearance part;

[0031] Softening the appearance part sheet of the target shape;

[0032] The softened appearance part sheet is moved to the mold cavity, and the mold is closed and molded into the shape of the appearance part. At the same time, during the molding process, a rib position and a target material layer are injected on the back to obtain the appearance body;

[0033] A decorative coating is sprayed on the surface of the appearance main body to obtain the appearance part.

[0034] In a possible implementation, the injection molding pressure is 400-1000 bar, and the injection molding temperature is 180-250°C.

[0035] In another possible implementation, the mold temperature is 50-75°C and the clamping force is 750-950T;

[0036] After injection molding is completed, the holding pressure is 45-85 MPa, the holding time is 5-18 s, and the cooling time is 20-120 s.

[0037] On the other hand, a vehicle is provided, wherein at least one of a front hood, a door and a fender of the vehicle adopts the appearance part described in any one of the above items.

[0038] The embodiment of the present application provides a sheet material for an appearance part, in which the core layer includes fibers and a resin matrix. The composite of the fibers and the resin matrix can not only enhance the rigidity of the sheet material for the appearance part, but also reduce the linear expansion coefficient of the sheet material, thereby improving the performance of the appearance part. Among them, the tensile strength of the appearance part prepared by the appearance part sheet material provided by the present application is 250-650MPa, the tensile modulus is 10-25GPa, and the bending modulus is 8-30GPa. It can be seen that the rigidity of the appearance part is well improved. At the same time, the linear expansion coefficient ranges from 7×10 -6 ~25×10 -6 m / (m·k), which can effectively control the thermal dimensional stability of the appearance parts and improve the fitting clearance of the appearance parts.

[0039] It is to be understood that the foregoing general description and the following detailed description are exemplary only and are not restrictive of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 is a schematic diagram of the back side of an appearance component provided in an embodiment of the present application;

[0041] Figure 2 is a side schematic diagram of an appearance component provided in an embodiment of the present application;

[0042] Figure 3 It is a partial cross-sectional schematic diagram of an appearance component provided in an embodiment of the present application. DETAILED DESCRIPTION

[0043] In order to make the technical solutions and advantages of the present application clearer, the implementation methods of the present application are described in further detail below.

[0044] On the one hand, an embodiment of the present application provides an appearance component plate, the appearance component plate comprising a film layer and a core layer;

[0045] The film layer includes at least one of a composite of acrylonitrile-butadiene-styrene copolymer (ABS) and polycarbonate (PC) and polycarbonate (PC);

[0046] The core layer includes a resin matrix and continuous fibers, the resin matrix includes at least one of polycarbonate (PC), nylon (PA) and modified polypropylene (PP), and the continuous fibers include at least one of glass fibers (GF) and carbon fibers (CF).

[0047] The film layer may be one layer or two layers. If the film layer is one layer, the film layer may be a composite of ABS and PC, may be PC, or may include a composite of ABS and PC and PC at the same time, which is not specifically limited.

[0048] If the film layer is two layers, the film layer includes a first film layer and a second film layer, and the core layer is located between the first film layer and the second film layer.

[0049] The first film layer includes at least one of a composite of ABS and PC and PC, and the second film layer includes at least one of a composite of ABS and PC and PC. The first film layer and the second film layer may be the same or different. If the first film layer and the second film layer are the same, and the first film layer is a composite of ABS and PC, the second film layer is also a composite of ABS and PC; if the first film layer is PC, the second film layer is also PC. If the first film layer and the second film layer are different, and the first film layer is a composite of ABS and PC, the second film layer is PC; if the first film layer and the second film layer are different, and the first film layer is PC, the second film layer is a composite of ABS and PC. In the embodiments of the present application, only the example that the first film layer and the second film layer are the same is used for illustration.

[0050] In a possible implementation, the resin matrix is ​​any one of PC, PA and modified PP, and the fiber is any one of GF and CF.

[0051] In this implementation, if the resin matrix is ​​PC and the fiber is GF, the core layer is a composite of PC and GF; if the resin matrix is ​​PC and the fiber is CF, the core layer is a composite of PC and CF. If the resin matrix is ​​PA and the fiber is GF, the core layer is a composite of PA and GF; if the resin matrix is ​​PA and the fiber is CF, the core layer is a composite of PA and CF. If the resin matrix is ​​modified PP and the fiber is GF, the core layer is a composite of modified PP and GF; if the resin matrix is ​​modified PP and the fiber is CF, the core layer is a composite of modified PP and CF.

[0052] The core layer can be obtained by the following method: weaving glass fiber or carbon fiber into 0° / 90° or 45° / 135° interwoven fiber woven cloth, then impregnating the interwoven fiber woven cloth with a resin matrix, and then curing to form the core layer.

[0053] In the embodiment of the present application, the core layer obtained by the above method has higher rigidity and lower linear expansion coefficient, thereby improving the performance of the appearance component sheet.

[0054] In the examples of the present application, the modified PP is obtained by modifying PP with maleic anhydride. The raw materials for preparing the modified PP include the following components in parts by weight:

[0055] 80-100 parts of polypropylene, 3-20 parts of maleic anhydride, 3-7 parts of silane coupling agent, 2-7 parts of antioxidant, and 0.3-2 parts of cumene peroxide.

[0056] Among them, the mass fraction of polypropylene can be 80 parts, 82 parts, 85 parts, 88 parts, 90 parts, 92 parts, 95 parts, 98 parts, and 100 parts, the mass fraction of maleic anhydride can be 3 parts, 5 parts, 8 parts, 10 parts, 13 parts, 15 parts, 18 parts, and 20 parts, the mass fraction of silane coupling agent can be 3 parts, 4 parts, 5 parts, 6 parts, and 7 parts, the mass fraction of antioxidant can be 2 parts, 3 parts, 4 parts, 5 parts, 6 parts, and 7 parts, and the mass fraction of cumene peroxide can be 0.3 parts, 0.5 parts, 0.8 parts, 1 parts, 1.2 parts, 1.5 parts, 1.8 parts, and 2 parts.

[0057] The type of antioxidant can be set and changed as needed. For example, the antioxidant is antioxidant 1010, antioxidant 9228 or other types of antioxidants, which are not specifically limited.

[0058] In a possible implementation, the modified PP can be prepared by the following preparation method:

[0059] (1) Weigh polypropylene, maleic anhydride, silane coupling agent, antioxidant and cumene peroxide according to the mass fraction of each component.

[0060] (2) Polypropylene, maleic anhydride, silane coupling agent, antioxidant and cumene peroxide are uniformly mixed and reacted at 190-230° C. for 10-20 minutes to obtain modified PP.

[0061] In step (2), polypropylene, maleic anhydride, silane coupling agent, antioxidant and cumene peroxide can be added to a reaction container, and the components are mixed evenly by stirring, and then heated to 190-230° C. and reacted for 10-20 minutes under the catalytic action of cumene peroxide to obtain modified PP.

[0062] Among them, the reaction temperature can be 190°C, 200°C, 210°C, 220°C, or 230°C, and the reaction time can be 10 min, 15 min, 16 min, 17 min, 18 min, 19 min, or 20 min.

[0063] In the embodiment of the present application, maleic anhydride is grafted onto the PP molecular chain to increase the polarity of PP, which is beneficial to improving the bonding strength between the core layer and the first film layer and the second film layer.

[0064] In a possible implementation, the mass fraction of the fibers in the core layer is 10% to 80%.

[0065] The mass fraction of the fiber may be 10%, 20%, 30%, 40%, 50%, 55%, 60%, 65%, 70%, 75%, or 80%.

[0066] In the embodiment of the present application, fibers are added to the core layer and the fibers are compounded with a resin matrix, which can improve the rigidity of the core layer and reduce the linear expansion coefficient.

[0067] In a possible implementation, the thickness of the core layer is 0.25-2.5 mm, and the thickness of the film layer is 0.2-1 mm.

[0068] The thickness of the core layer can be 0.25mm, 0.3mm, 0.5mm, 0.8mm, 1mm, 1.3mm, 1.5mm, 1.8mm, 2mm, 2.3mm, 2.5mm. The thickness of the film layer can be 0.2mm, 0.3mm, 0.4mm, 0.5mm, 0.6mm, 0.7mm, 0.8mm, 0.9mm, 1mm.

[0069] If the film layer includes a first film layer and a second film layer, the thickness of the first film layer and the second film layer are both 0.2-1 mm.

[0070] The thickness of the first film layer and the second film layer may be the same or different, and there is no specific limitation on this. For example, the thickness of the first film layer and the second film layer is the same, which is 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm or 1 mm.

[0071] In the embodiment of the present application, providing the first film layer and the second film layer can improve the decoratability of the appearance component plate.

[0072] The embodiment of the present application provides a sheet material for an appearance part, in which the core layer includes fibers and a resin matrix. The composite of the fibers and the resin matrix can not only enhance the rigidity of the sheet material for the appearance part, but also reduce the linear expansion coefficient of the sheet material, thereby improving the performance of the appearance part. Among them, the tensile strength of the appearance part prepared by the appearance part sheet material provided by the present application is 250-650MPa, the tensile modulus is 10-25GPa, and the bending modulus is 8-30GPa. It can be seen that the rigidity of the appearance part is well improved, the high and low temperature dimensional stability of the part is increased, and the deformation is significantly reduced. At the same time, the linear expansion coefficient ranges from 7×10 -6 ~25×10 -6 m / (m·k), which can effectively control the thermal dimensional stability of the appearance parts and improve the thermal dimensional stability of the fitting clearance / face difference of the appearance parts.

[0073] On the other hand, an embodiment of the present application provides a method for preparing an appearance component plate, the preparation method comprising:

[0074] (1) Lay the core layer and the membrane layer in sequence and press the core layer and the membrane layer together.

[0075] If the membrane layer is a single layer, the core layer is laid first, and then the membrane layer is laid, and then the core layer and the membrane layer are pressed together by a double steel belt press. The core layer and the membrane layer enter between the upper and lower steel belts, are heated and melted in the heating zone, and then pressed together.

[0076] If the film layer is two layers, that is, the film layer includes a first film layer and a second film layer, the first film layer, the core layer and the second film layer are laid in sequence, and then the first film layer, the core layer and the second film layer are pressed together by a double steel belt press. The first film layer, the core layer and the second film layer enter between the upper and lower steel belts, are heated and melted in the heating zone, and then pressed together.

[0077] If the resin matrix in the core layer is PC, the pressing temperature is 240-280°C.

[0078] The pressing temperature may be 240° C., 250° C., 260° C., 270° C., or 280° C. Specifically, the pressing temperature may be 260° C.

[0079] If the resin matrix in the core layer is PA, the pressing temperature is 240-300°C.

[0080] The pressing temperature may be 240° C., 250° C., 260° C., 270° C., 280° C., 290° C., or 300° C. Specifically, the pressing temperature may be 280° C.

[0081] If the resin matrix in the core layer is modified PP, the pressing temperature is 180-220°C.

[0082] The pressing temperature may be 180° C., 190° C., 200° C., 210° C., or 220° C. Specifically, the pressing temperature may be 200° C.

[0083] In the embodiment of the present application, different pressing temperatures are used for pressing according to different types of resin substrates, so that the sheet material can be formed in a short time, thereby increasing the forming speed of the sheet material.

[0084] (2) The initially pressed sheet is transferred to a pressurizing area for pressurization, so that the thickness of the sheet reaches 0.65 to 4.5 mm.

[0085] The pressurization pressure is 0.5 to 2 MPa. For example, the pressurization pressure is 0.5 MPa, 0.8 MPa, 1 MPa, 1.2 MPa, 1.5 MPa, 1.8 MPa, or 2 MPa.

[0086] The thickness of the plate can be 0.65mm, 0.8mm, 1mm, 1.5mm, 1.8mm, 2mm, 3mm, 1mm, 2mm, 3mm, 4mm, and 4.5mm.

[0087] In the embodiment of the present application, the plate is first preliminarily pressed and then further pressed so that the thickness of the plate reaches the requirement.

[0088] (3) The plate having the required thickness is transferred to the cooling zone, and after consolidation and forming, the appearance plate is obtained.

[0089] The cooling temperature of the cooling zone is 40 to 60°C, for example, the cooling temperature is 40°C, 42°C, 45°C, 50°C, 52°C, 55°C, 58°C, or 60°C.

[0090] In a possible implementation, the conveying speeds of the plates corresponding to different types of resin matrices are the same. For example, the conveying speed of the plates in the double steel belt press is 0.3 to 1.5 m / min. Specifically, the conveying speeds of the plates are 0.3 m / min, 0.45 m / min, 0.5 m / min, 0.8 m / min, 1 m / min, 1.3 m / min, and 1.5 m / min.

[0091] In another possible implementation, the conveying speeds of the plates corresponding to different types of resin matrices are different. For example, if the resin matrix is ​​PC, the conveying speed is 0.5 m / min; if the resin matrix is ​​PA, the conveying speed is 0.45 m / min; if the resin matrix is ​​modified PP, the conveying speed is 0.8 m / min.

[0092] It should be noted that the tensile strength of the appearance parts of PC+ABS materials in the related art is 50-110 MPa, the tensile modulus is 2.1-5 GPa, the bending modulus is 2.3-6 GPa, and the linear expansion coefficient ranges from 70×10 -6 ~85×10 -6 m / (m·k). Some related technologies also use talcum powder to fill PP materials. The tensile strength of the appearance parts of talcum powder filled PP materials is 20-60MPa, the tensile modulus is 3-5GPa, the bending modulus is 3-6GPa, and the linear expansion coefficient ranges from 50×10 -6 ~90×10 -6 m / (m·k).

[0093] The tensile strength of the appearance parts prepared by the appearance parts sheet provided by this application is 250-650MPa, the tensile modulus is 10-25GPa, and the bending modulus is 8-30GPa. It can be seen that the rigidity of the appearance parts is well improved, the high and low temperature dimensional stability of the parts is increased, and the deformation is significantly reduced. At the same time, the linear expansion coefficient ranges from 7×10 -6 ~25×10 -6 m / (m·k), which can effectively control the thermal dimensional stability of the appearance parts and improve the thermal dimensional stability of the fitting clearance / face difference of the appearance parts.

[0094] On the other hand, an embodiment of the present application further provides an appearance part, which is a curved surface structure and includes an appearance main body and a decorative coating;

[0095] The appearance body adopts the appearance part plate mentioned above, and the back of the appearance body is injection molded with ribs and a target material layer, and the target material in the target material layer is the same as the material of the resin matrix in the core layer of the appearance part plate.

[0096] It should be noted that if the resin matrix in the core layer is PC, the target material is PC; if the resin matrix is ​​PA, the target material can be PA, or PA reinforced with glass fibers, that is, PA is added with glass fibers, and the glass fibers are used to enhance the strength of PA. If the resin matrix is ​​modified PP, the target material can be PP, modified PP, PP reinforced with glass fibers, or modified PP reinforced with glass fibers, that is, PP or modified PP is added with glass fibers, and the glass fibers are used to enhance the strength of PP or modified PP.

[0097] In a possible implementation, the appearance part has a thickness of 1 to 6.5 mm.

[0098] Among them, the thickness of the appearance part can be 1mm, 1.5mm, 2mm, 2.5mm, 3mm, 3.5mm, 4mm, 4.5mm, 5mm, 5.5mm, 6mm, and 6.5mm.

[0099] In a possible implementation, the thickness of the rib is 0.8 to 2.5 mm;

[0100] The thickness of the target material layer is 0.25 to 2 mm;

[0101] The thickness of the decorative coating is 60 to 500 μm.

[0102] The decorative coating may be a polyurethane coating or a paint film layer.

[0103] In this implementation, the thickness of the ribs is 0.8mm, 1mm, 1.2mm, 1.5mm, 1.8mm, 2mm, 2.2mm, and 2.5mm; the thickness of the target material layer is 0.25mm, 0.5mm, 0.8mm, 1mm, 1.2mm, 1.5mm, 1.8mm, and 2mm; if the decorative coating is a polyurethane coating, the thickness of the polyurethane coating is 100 to 500μm, specifically It can be 100μm, 150μm, 200μm, 250μm, 300μm, 350μm, 400μm, 450μm, 500μm; if the decorative coating is a paint film layer, the thickness of the paint film layer is 60-150μm, specifically 60μm, 70μm, 80μm, 90μm, 100μm, 110μm, 120μm, 130μm, 140μm, 150μm.

[0104] See also Figure 1 , Figure 2 and Figure 3 , Figure 1 This is a schematic diagram of the back side of an appearance component provided in an embodiment of the present application. Figure 2 is a side view of the appearance part. Figure 3 for Figure 2 Schematic diagram of the local section at point A in the middle. Figure 3 The structure includes a paint film layer 301, an appearance component plate 302, a target material layer 303 and a rib position 304.

[0105] In the embodiment of the present application, the appearance part sheet has a relatively high rigidity and requires a relatively high temperature to be molded into a complex curved surface structure. In addition, there is a resin film layer on the surface of the appearance part sheet, which is prone to large flow at high temperatures, which is not conducive to the surface appearance. Therefore, the appearance part designed in the present application is a curved surface structure, which is convenient for meeting the requirements of the curved surface molding structure and achieving a good appearance.

[0106] On the other hand, an embodiment of the present application provides a molding process of an appearance part, the process comprising:

[0107] Step 1: Cut the appearance part sheet into the target shape.

[0108] The target shape is the two-dimensional unfolded shape of the exterior part. For example, if the exterior part is the front hood of the vehicle, the target shape is the two-dimensional unfolded shape of the front hood. If the exterior part is the left door of the vehicle, the target shape is the two-dimensional unfolded shape of the left door. If the exterior part is the fender of the vehicle, the target shape is the two-dimensional unfolded shape of the fender.

[0109] The appearance component sheet can be cut into a target shape by a cutting machine, a plate cutting machine or other cutting equipment, which is not specifically limited.

[0110] Step 2: Soften the target shape appearance part sheet.

[0111] In this step, the appearance part sheet of the target shape can be grabbed by a robot and put into an infrared oven for softening. The softening temperature is 100 to 300° C. and the softening time is 10 to 50 seconds.

[0112] Among them, the softening temperature can be 100°C, 150°C, 200°C, 250°C, or 300°C, and the softening time can be 10s, 15s, 20s, 25s, 30s, 35s, 40s, 45s, or 50s.

[0113] Step 3: Move the softened appearance part sheet to the mold cavity, close the mold and mold it into the shape of the appearance part. At the same time, during the molding process, inject ribs and target material layers on the back to obtain the appearance body.

[0114] After softening is completed, the softened appearance part is moved to the mold cavity by a robot for adsorption and fixation, and the mold is closed and molded into the shape of the appearance part. At the same time, during the molding process, the ribs and the target material layer are injected on the back to obtain the appearance main body.

[0115] Among them, the injection pressure is 400-1000 bar, the injection temperature is 180-250°C, the mold temperature is 50-75°C, and the clamping force is 750-950T.

[0116] The injection pressure can be 400bar, 500bar, 600bar, 700bar, 800bar, 900bar, and 1000bar. The injection temperature can be 180℃, 190℃, 200℃, 210℃, 220℃, 230℃, 240℃, and 250℃. The mold temperature can be 50℃, 52℃, 55℃, 60℃, 62℃, 65℃, 70℃, and 72℃. The clamping force can be 750T, 800T, 820T, 850T, 900T, 920T, and 950T.

[0117] After injection molding is completed, the holding pressure is 45-85 MPa, the holding time is 5-18 s, and the cooling time is 20-120 s.

[0118] The holding pressure can be 45MPa, 50MPa, 55MPa, 60MPa, 65MPa, 70MPa, 72MPa, 75MPa, 80MPa, 82MPa, 85MPa, the holding time can be 5s, 6s, 8s, 10s, 12s, 15s, 16s, 18s, and the cooling time can be 20s, 30s, 40s, 50s, 60s, 70s, 80s, 90s, 100s, 110s, 120s.

[0119] One thing that needs to be explained is that compression molding and back injection molding are a process. During the compression molding process, the back injection molding ribs and the target material layer are simultaneously performed, thereby quickly realizing the molding of the appearance parts and obtaining the appearance main body.

[0120] Step 4: Spray a decorative coating on the surface of the appearance main body to obtain an appearance part.

[0121] If the decorative coating is a paint film layer, after compression molding, the mold can be opened to take out the part, and the surface of the appearance body can be sprayed with paint to obtain the appearance part.

[0122] If the decorative coating is a polyurethane coating, after compression molding, the mold can be opened and rotated or translated to another mold cavity, and the mold can be closed to inject the polyurethane coating to obtain an appearance part.

[0123] The injection pressure is 1000-1800 bar, wherein the injection pressure can be 1000 bar, 1100 bar, 1200 bar, 1300 bar, 1400 bar, 1500 bar, 1600 bar, 1700 bar, 1800 bar.

[0124] Injection speed is 30~80cm 3 / s, where the injection speed can be 30cm 3 / s, 40cm 3 / s, 50cm 3 / s, 60cm 3 / s, 70cm 3 / s、80cm 3 / s.

[0125] In the embodiment of the present application, the molding of the appearance parts can be achieved through the molding and in-mold painting process, especially the curved surface modeling part. The process and structure can achieve good surface molding of the curved surface, small structural deviation, and good curved surface effect. Most of the composite materials in the related art use molding technology and post-processing procedures, the fibers are easy to leak out and are uneven, and it is difficult to achieve both good appearance and curved surface effects at the same time in structural molding. The structural modeling and digital model are prone to deviations and cannot meet the design requirements.

[0126] On the other hand, an embodiment of the present application further provides a vehicle, at least one of the front hood, doors and fenders of the vehicle adopts the appearance parts provided by the embodiment of the present application.

[0127] The vehicle door includes at least one of a left front door, a left rear door, a right front door and a right rear door.

[0128] The technical solution of the present application will be described in detail below through specific embodiments.

[0129] In the following specific examples, operations involved without specifying conditions were performed under conventional conditions or conditions recommended by the manufacturer.

[0130] Example 1

[0131] The thickness of the appearance part sheet is 1.5 mm, wherein the thicknesses of the first film layer, the second film layer and the core layer are the same, which are all 0.5 mm.

[0132] The first film layer and the second film layer are the same, both are PC, and the core layer includes modified PP and glass fiber, wherein the mass fraction of the glass fiber is 60%.

[0133] The appearance part sheet is cut into the target shape by laser, and is grabbed by the KUKA manipulator fixture to the infrared oven for softening. The softening temperature is 130℃ and the softening time is 30s. After softening, the sheet is moved to the first cavity mold and molded into the shape of the appearance part. At the same time, the back is injected with ribs and target material layer. The ribs and target materials can be PP, modified PP, glass fiber reinforced PP, or glass fiber reinforced modified PP. The injection temperature is 210℃, the injection pressure is 600bar, the mold temperature is 50℃, the clamping force is 800T, the holding pressure is 33MPa, the holding time is 6s, the cooling time is 80s, the rib thickness is 0.8mm, and the target material layer thickness is 0.5mm. After the injection molding is completed, the mold is opened and the parts are taken out for painting.

[0134] The performance of the appearance part provided in this embodiment was tested, and the test results were as follows: the tensile strength was 270 MPa, the tensile modulus was 12.3 GPa, the bending modulus was 11.2 GPa, and the linear expansion coefficient was 16×10 -6 m / (m·k).

[0135] Example 2

[0136] The thickness of the appearance part sheet is 1.5 mm, wherein the thicknesses of the first film layer, the second film layer and the core layer are the same, which are all 0.5 mm.

[0137] The first film layer and the second film layer are the same, both are PC, and the core layer includes PC and glass fiber, wherein the mass fraction of the glass fiber is 65%.

[0138] The appearance part sheet is cut into the target shape by laser, and is grabbed by the KUKA manipulator fixture to the infrared oven for softening. The softening temperature is 200℃ and the softening time is 38s. After softening, the sheet is moved to the first cavity for mold pressing into the shape of the appearance part. At the same time, the back is injected with ribs and target material layer. The ribs and target material can be PC. The injection temperature is 260℃, the injection pressure is 750bar, the mold temperature is 60℃, the clamping force is 840T, the holding pressure is 45MPa, the holding time is 8s, the cooling time is 95s, the rib thickness is 0.8mm, and the target material layer thickness is 0.5mm. After the injection molding is completed, the mold is opened and the parts are taken out for painting.

[0139] The performance of the appearance part provided in this embodiment was tested, and the test results were as follows: the tensile strength was 320 MPa, the tensile modulus was 15.1 GPa, the bending modulus was 13.8 GPa, and the linear expansion coefficient was 13×10 -6 m / (m·k).

[0140] Example 3

[0141] The thickness of the appearance part sheet is 2 mm, wherein the thickness of the first film layer and the second film layer are the same, both 0.5 mm, and the thickness of the core layer is 1 mm.

[0142] The first film layer and the second film layer are the same, both are PC, and the core layer includes PA-66 and glass fiber, wherein the mass fraction of the glass fiber is 80%.

[0143] The appearance part sheet is cut into the target shape by laser, and is grabbed by the KUKA manipulator fixture to the infrared oven for softening. The softening temperature is 210℃ and the softening time is 43s. After softening, the sheet is moved to the first cavity for mold pressing into the shape of the appearance part. At the same time, the back is injected with ribs and target material layer. The ribs and target material can be PA or PA reinforced with glass fiber. The injection temperature is 250℃, the injection pressure is 1000bar, the mold temperature is 65℃, the clamping force is 950T, the holding pressure is 62MPa, the holding time is 12s, the cooling time is 10s, the rib thickness is 0.8mm, and the target material layer thickness is 0.5mm. After the injection is completed, the mold is opened and the part is taken out for painting.

[0144] The performance of the appearance part provided in this embodiment was tested, and the test results were as follows: the tensile strength was 410 MPa, the tensile modulus was 18.7 GPa, the bending modulus was 18.3 GPa, and the linear expansion coefficient was 11×10 -6 m / (m·k).

[0145] Comparative Example 1

[0146] The exterior parts are made of PC+ABS with a thickness of 2.8mm. Under the same conditions, the tensile strength is 63MPa, the tensile modulus is 2.7GPa, the bending modulus is 3GPa, and the linear expansion coefficient is 78×10 -6 m / (m·k).

[0147] Comparative Example 2

[0148] The appearance parts are made of PP+EPDM-T30 (polypropylene + ethylene propylene rubber, in which the mass fraction of talc is 30%), with a thickness of 2.8mm. Under the same conditions, its tensile strength is 22MPa, tensile modulus is 2.4GPa, bending modulus is 2.6GPa, and linear expansion coefficient is 65×10 -6 m / (m·k).

[0149] According to the test results of Examples 1 to 3 and Comparative Examples 1 to 2, it can be seen that the rigidity of the appearance part provided by the present application is significantly improved, and the linear expansion coefficient is significantly reduced. Therefore, the appearance part provided by the present application has better performance.

[0150] The above description is only for the purpose of facilitating those skilled in the art to understand the technical solution of the present application and is not intended to limit the present application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A sheet material for an appearance part, characterized in that: The appearance component sheet material comprises a film layer and a core layer; The film layer includes at least one of a composite of acrylonitrile-styrene-butadiene copolymer and polycarbonate and polycarbonate; The core layer includes a resin matrix and fibers, wherein the resin matrix includes at least one of polycarbonate, nylon and modified polypropylene, and the fibers include at least one of glass fibers and carbon fibers.

2. The appearance member sheet according to claim 1, characterized in that: The raw materials for preparing the modified polypropylene include the following components in parts by mass: 80-100 parts of polypropylene, 3-20 parts of maleic anhydride, 3-7 parts of silane coupling agent, 2-7 parts of antioxidant, and 0.3-2 parts of cumene peroxide.

3. The appearance member sheet according to claim 2, characterized in that: The preparation method of the modified polypropylene comprises: Weigh the polypropylene, the maleic anhydride, the silane coupling agent, the antioxidant and the cumene peroxide according to the mass fraction of each component; The polypropylene, the maleic anhydride, the silane coupling agent, the antioxidant and the cumene peroxide are uniformly mixed and reacted at 190 to 230° C. for 10 to 20 minutes to obtain the modified polypropylene.

4. The appearance member sheet according to claim 1, characterized in that: The mass fraction of the fibers in the core layer is 10% to 80%.

5. The appearance member sheet according to claim 1, characterized in that: The thickness of the core layer is 0.25-2.5 mm, and the thickness of the film layer is 0.2-1 mm.

6. The appearance member sheet according to claim 1, characterized in that: The film layer comprises: a first film layer and a second film layer, and the core layer is located between the first film layer and the second film layer.

7. A method for preparing the appearance component sheet according to any one of claims 1 to 6, characterized in that: The preparation method comprises: Laying the core layer and the membrane layer in sequence, and pressing the core layer and the membrane layer together; The preliminarily pressed sheet is conveyed to a pressurizing area for pressurization, so that the thickness of the sheet reaches 0.65 to 4.5 mm; The plate having the required thickness is conveyed to the cooling zone, and the appearance part plate is obtained after consolidation and forming.

8. The preparation method according to claim 7, characterized in that: If the resin matrix in the core layer is the polycarbonate, the pressing temperature is 240-280°C; If the resin matrix in the core layer is nylon, the pressing temperature is 240-300°C; If the resin matrix in the core layer is the modified polypropylene, the pressing temperature is 180-220°C.

9. An appearance part, characterized in that: The appearance part is a curved surface structure, including an appearance body and a decorative coating; The appearance body adopts the appearance part plate material as described in any one of claims 1 to 6, and the back of the appearance body is injection-molded with ribs and a target material layer, and the target material in the target material layer is the same as the material of the resin matrix in the core layer of the appearance part plate material.

10. The appearance part according to claim 9, characterized in that: The appearance part has a thickness of 1 to 6.5 mm.

11. The appearance part according to claim 10, characterized in that: The thickness of the rib is 0.8 to 2.5 mm; The thickness of the target material layer is 0.25 to 2 mm; The thickness of the decorative coating is 60-500 μm.

12. A molding process for the appearance part according to any one of claims 9 to 11, characterized in that: The process comprises: Cutting the appearance part sheet into a target shape, wherein the target shape is a two-dimensional unfolded shape of the appearance part; Softening the appearance part sheet of the target shape; The softened appearance part sheet is moved to the mold cavity, and the mold is closed and molded into the shape of the appearance part. At the same time, during the molding process, a rib position and a target material layer are injected on the back to obtain the appearance body; A decorative coating is sprayed on the surface of the appearance main body to obtain the appearance part.

13. The process according to claim 12, characterized in that The injection molding pressure is 400-1000 bar, and the injection molding temperature is 180-250°C.

14. The process according to claim 12, characterized in that The mold temperature is 50-75°C, and the clamping force is 750-950T; After injection molding is completed, the holding pressure is 45-85 MPa, the holding time is 5-18 s, and the cooling time is 20-120 s.

15. A vehicle, characterized in that: At least one of the front hood, the door and the fender of the vehicle adopts the appearance part according to any one of claims 9 to 11.

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