Spraying-free thermoplastic composite material automobile exterior trimming part and preparation method thereof

Abstract

The invention provides a spraying-free thermoplastic composite material automobile exterior trimming part and a preparation method thereof. The spraying-free thermoplastic composite material automobile exterior trimming part comprises a spraying-free sheet material modification layer, an exterior trimming part body and an auxiliary bracket which are sequentially fused and connected from top to bottom, the exterior trimming part body is made of a continuous fiber reinforced thermoplastic plate through the steps of heating, softening and compression molding, and the lightweight design is achieved while enough structural strength is kept by means of the light and high-strength characteristics of the continuous fiber reinforced plate; the auxiliary supports are independently formed and can be flexibly designed according to the use requirements of different application scenes. The spraying-free sheet modification layer is made of spraying-free thermoplastic plastics through extrusion calendering and tape casting processes so as to obtain the appearance effect of ultrahigh smooth finish, and the spraying-free sheet modification layer is fused with the exterior trimming part body, so that the outer surface and the edge of the exterior trimming part body have the spraying-free effect, the appearance quality is improved, and the working procedures are simplified. The composite material can be widely applied to automobile body exterior trimming parts such as an automobile front hatch cover, an automobile door plate, a fender, an automobile roof plate and a fairing.

Description

Technical Field

[0001] The invention relates to the technical field of automobile manufacturing, and in particular to a spray-free thermoplastic composite automobile exterior trim and a preparation method thereof. Background Art

[0002] Energy conservation and emission reduction have always been the design goals of the automotive industry, especially new energy vehicles have a more urgent need for the weight of parts. Replacing steel with plastic has become an important trend in the development of materials in the automotive industry, and automotive exterior parts have gradually transitioned from metal stampings to all-plastic parts. Thermosetting composite materials are relatively mature solutions for exterior parts. For example, carbon fiber fabrics and epoxy resins are molded using the HRTM process, and glass fiber and unsaturated resins are molded using the SMC and BMC processes. Although these solutions have achieved significant weight reduction effects compared to metals, they are difficult to be widely used due to problems such as non-recyclability and unfriendly storage conditions for raw materials.

[0003] Thermoplastic materials have the advantages of being recyclable and user-friendly. However, their strength is relatively low. In order to enhance the strength, inorganic or organic fibers are usually added, but this often makes it difficult to take into account both the appearance and strength requirements of automotive exterior parts. At present, the commonly used methods are mainly to spray paint after injection molding of fiber-reinforced thermoplastic materials, or to use fiber-reinforced thermoplastics as a skeleton, and then glue, weld, or integrally mold them with a thermoplastic skin to obtain non-fiber-reinforced thermoplastic outer skin trim. Although these methods can obtain exterior trims of a certain strength, the subsequent painting process still brings troubles and is costly.

[0004] Although some existing patents attempt to solve these problems, they still have shortcomings. For example, publication numbers CN106080797A, CN106184407A, and CN207550311U all disclose a method for manufacturing a front hood assembly in which both inner and outer panels are made of thermoplastic materials and are welded or welded by positioning glue. However, this method uses thermosetting glue that cannot be recycled and has the risk of debonding; and hot melt welding is prone to causing defects such as bulges or pits on the outer panel.

[0005] Publication Nos. CN105922601A, CN218197860U, CN108015923A, and CN218197860U all disclose a method for preparing a composite material component of a continuous fiber sheet reinforced inner plate and then integrally injection molded outer skin. Although the efficiency of integrally injection molding the outer skin of the continuous fiber sheet is high, the integrally injection molded smooth outer skin with color is prone to shrinkage marks and injection flow marks, which affects the appearance quality of the exterior parts.

[0006] Publication No. CN105690794A discloses a method for preparing a type of automotive exterior covering with continuous fiber laminates as inner and outer panels and thermoplastic material edging. Although the edging of the fiber laminate edges is avoided, the fiber-rich laminate front side is prone to visible fiber leakage, resulting in a significant appearance disadvantage compared to painted parts.

[0007] Publication No. CN110281619A discloses a type of automobile exterior that is formed by hot-pressing and compounding a continuous fiber sheet with a special exterior decorative layer and then integrally injection-molded, and a method for preparing the same. Although the decorative layer and the continuous fiber sheet can be fully fused by directly compounding the decorative layer with the continuous fiber sheet, the decorative layer on the outer surface is easily damaged during the molding and injection molding stages, requiring further painting; in addition, the method for compounding the special decorative layer with the sheet to prepare the exterior decorative part is difficult to ensure that the edge of the sheet also has the special decorative layer, which affects the appearance quality of the exterior decorative part.

[0008] In view of this, the present invention is proposed. Summary of the invention

[0009] In view of the above-mentioned deficiencies in the prior art, the present invention aims to propose a novel spray-free thermoplastic composite automotive exterior trim and a preparation method thereof, so as to meet the requirements of both the appearance and strength of the automotive exterior trim. The preferred technical solutions among the many technical solutions provided by the present invention can produce many technical effects as described below.

[0010] To achieve the above object, the present invention provides the following technical solutions:

[0011] The present invention provides a spray-free thermoplastic composite automotive exterior trim, comprising a spray-free sheet material modification layer, an exterior trim body and an auxiliary bracket which are fused and connected in sequence from top to bottom, wherein the spray-free sheet material modification layer is made of spray-free thermoplastic plastic through extrusion calendering and casting processes; the exterior trim body is made of a continuous fiber reinforced thermoplastic sheet through heating softening and compression molding steps; the exterior trim body and the auxiliary bracket are both independently molded.

[0012] Preferably, the continuous fiber reinforced thermoplastic sheet has a thickness ranging from 1.0 mm to 5.0 mm.

[0013] Preferably, the continuous fiber reinforced thermoplastic sheet is made by laminating multiple layers of continuous fiber reinforced thermoplastic unidirectional tapes at a specific angle and in a specific order and then performing a hot pressing process;

[0014] Preferably, the thickness range of the continuous fiber reinforced thermoplastic unidirectional tape is 0.1 mm-0.4 mm; when stacking, the stacking angles of the continuous fiber reinforced thermoplastic unidirectional tape include at least 4 angles of 0°, ±15°, ±30°, ±45°, ±60°, ±75°, and 90°.

[0015] Preferably, the spray-free thermoplastic plastic includes color powder and at least one of pearl powder, mica powder or metal powder.

[0016] Preferably, the thickness of the spray-free sheet material modification layer is in the range of 0.2 mm to 4 mm.

[0017] Preferably, the inner surface of the exterior trim body is fused with the auxiliary bracket by a welding process, and the outer surface of the exterior trim body is fused with the spray-free sheet material modification layer by a blister process.

[0018] Preferably, the resin substrate of the continuous fiber reinforced thermoplastic sheet, the resin substrate of the spray-free thermoplastic plastic, and the resin substrate of the thermoplastic plastic used in the auxiliary bracket can all be fused to each other in a heated state.

[0019] Preferably, the auxiliary bracket is formed by one-time injection molding of thermoplastic plastic in the same mold, or by injection molding of thermoplastic plastic in multiple molds, or by cutting, heating, softening and bending the continuous fiber reinforced thermoplastic sheet.

[0020] Preferably, a method for preparing a spray-free thermoplastic composite automotive exterior trim is used to prepare the aforementioned automotive exterior trim, comprising the following steps:

[0021] The steps include:

[0022] S1: Multiple layers of continuous fiber reinforced thermoplastic unidirectional tapes are stacked at a specific angle and in a specific order, and processed by hot pressing to obtain a continuous fiber reinforced thermoplastic sheet;

[0023] S2: preliminarily cutting the continuous fiber reinforced thermoplastic sheet, and molding it through a molding process after heating and softening to obtain an exterior trim body;

[0024] S3: using thermoplastic plastics to make the auxiliary bracket through an injection molding process, or cutting the continuous fiber reinforced thermoplastic sheet, heating it to soften it, and bending it to make the auxiliary bracket;

[0025] S4: welding and fusing the auxiliary bracket to the inner surface of the exterior trim body;

[0026] S5: using spray-free thermoplastic plastics through extrusion calendering and casting process to prepare a spray-free sheet material modification layer;

[0027] S6: After the outer surface of the exterior trim body and the spray-free sheet modification layer are heated and softened at the same time, they are fused by a vacuum forming process, and trimmed and cut to obtain a finished product.

[0028] The preferred technical solution of the present invention can at least produce the following technical effects:

[0029] The exterior trim body of the present invention is made of a continuous fiber reinforced thermoplastic sheet through heating, softening and compression molding steps, making maximum use of the light weight and high strength characteristics of the continuous fiber reinforced sheet, so that the exterior trim body can achieve a lightweight design while maintaining sufficient structural strength.

[0030] The auxiliary bracket of the present invention is independently formed, and the number of the auxiliary brackets and the installation position with respect to the exterior trim body can be flexibly designed according to the use requirements of different application scenarios, so that the automobile exterior trim has sufficient freedom in design.

[0031] The spray-coated sheet modification layer of the present invention is made of spray-free thermoplastic plastic through extrusion calendering and casting process, so that the spray-coated sheet modification layer can obtain an ultra-high finish appearance effect far exceeding that obtained by the in-mold injection molding process, and no subsequent spraying step is required, simplifying the process. In addition, the spray-coated sheet modification layer is fused with the exterior trim body, so that the outer surface and edge of the exterior trim body have a spray-free effect, improving the appearance quality of the automobile exterior trim, and no in-mold integrated injection molding and painting process are required in a complex mold.

[0032] The automobile exterior trim of the present invention can be widely used in automobile front hoods, doors, fenders, roofs, air ducts and other vehicle body exterior trims to meet the use requirements of different application scenarios. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0034] Figure 1 It is a structural schematic diagram of a spray-free thermoplastic composite automotive exterior trim provided by the present invention;

[0035] Figure 2 yes Figure 1 Bottom view of

[0036] Figure 3 yes Figure 1 A top view of

[0037] Figure 4 yes Figure 1 Side view of

[0038] Figure 5It is a schematic structural diagram of a continuous fiber reinforced thermoplastic unidirectional tape of a spray-free thermoplastic composite automotive exterior trim provided by the present invention when being stacked;

[0039] Figure 6 It is a structural schematic diagram of a continuous fiber reinforced thermoplastic sheet material for a spray-free thermoplastic composite automotive exterior trim provided by the present invention;

[0040] Figure 7 It is a structural schematic diagram of an automobile exterior trim part of a spray-free thermoplastic composite automobile exterior trim part provided by the present invention;

[0041] Figure 8 It is a structural schematic diagram of an auxiliary bracket of a spray-free thermoplastic composite material automobile exterior trim provided by the present invention;

[0042] Fig. 9 It is a structural schematic diagram of an automobile exterior trim and an auxiliary bracket of a spray-free thermoplastic composite automobile exterior trim provided by the present invention;

[0043] Fig.10 The present invention provides a structural schematic diagram of a spray-free thermoplastic composite automobile exterior trim provided by the present invention, in which an automobile exterior trim and a spray-free sheet material finishing layer are in a separated state.

[0044] In the figure:

[0045] 1. Continuous fiber reinforced thermoplastic unidirectional tape; 2. Continuous fiber reinforced thermoplastic sheet; 3. Automobile exterior parts; 4. Spray-free sheet finishing layer; 5. Accessory bracket. DETAILED DESCRIPTION

[0046] To make the purpose, technical solution and advantages of the present invention clearer, the technical solution of the present invention will be described in detail below. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other implementation methods obtained by ordinary technicians in this field without creative work belong to the scope of protection of the present invention.

[0047] The present invention provides a spray-free thermoplastic composite automotive exterior trim, comprising a spray-free sheet material modification layer, an exterior trim body and an auxiliary bracket which are fused and connected in sequence from top to bottom. The spray-free sheet material modification layer is made of spray-free thermoplastic plastic through extrusion, calendering and casting processes; the exterior trim body is made of a continuous fiber reinforced thermoplastic sheet through heating, softening and compression molding steps; the exterior trim body and the auxiliary bracket are both independently molded.

[0048] The exterior trim body of the present invention is made of a continuous fiber reinforced thermoplastic sheet through heating, softening and compression molding steps, making maximum use of the light weight and high strength characteristics of the continuous fiber reinforced sheet, so that the exterior trim body can achieve a lightweight design while maintaining sufficient structural strength.

[0049] The auxiliary bracket of the present invention is independently formed, and the number of the auxiliary brackets and the installation position with respect to the exterior trim body can be flexibly designed according to the use requirements of different application scenarios, so that the automobile exterior trim has sufficient freedom in design.

[0050] The spray-coated sheet modification layer is made of spray-free thermoplastic plastic through extrusion calendering and casting process, so that the spray-coated sheet modification layer can obtain an ultra-high finish appearance effect far exceeding that obtained by the in-mold injection molding process, without the need for subsequent spraying steps. In addition, the spray-coated sheet modification layer is fused with the exterior trim body, so that the outer surface and edge of the exterior trim body have a spray-free effect, improving the appearance quality of automotive exterior trims, without the need for in-mold integrated injection molding and painting processes in complex molds.

[0051] As an optional embodiment, the thickness of the continuous fiber reinforced thermoplastic sheet is in the range of 1.0 mm to 5.0 mm.

[0052] If the thickness of the continuous fiber reinforced thermoplastic sheet is too low, the structural strength of the exterior parts will be insufficient, making it difficult to meet the requirements of automotive exterior parts. On the contrary, if the thickness of the continuous fiber reinforced thermoplastic sheet is too high, although the structural strength can be improved, the weight of the automotive exterior parts will be increased accordingly, which is contrary to the original intention of using continuous fiber reinforced thermoplastic sheets to pursue lightweight.

[0053] Therefore, the present invention limits the thickness range of the continuous fiber reinforced thermoplastic sheet to 1.0 mm-5.0 mm, so that the continuous fiber reinforced thermoplastic sheet can provide sufficient structural strength to meet the use requirements of automobile exterior parts, while keeping the automobile exterior parts light in weight. In addition, the continuous fiber reinforced thermoplastic sheet not only has good structural strength and lightweight characteristics, but also has processing properties such as easy cutting, heating softening, compression molding and bending molding.

[0054] As an optional implementation, the continuous fiber reinforced thermoplastic sheet is made by laminating multiple layers of continuous fiber reinforced thermoplastic unidirectional tapes at a specific angle and in a specific order and then performing a hot pressing process.

[0055] As an optional embodiment, the thickness range of the continuous fiber reinforced thermoplastic unidirectional tape is 0.1mm-0.4mm; when stacking, the stacking angles of the continuous fiber reinforced thermoplastic unidirectional tape include at least 4 angles of 0°, ±15°, ±30°, ±45°, ±60°, ±75°, and 90°.

[0056] The present invention limits the thickness range of the continuous fiber reinforced thermoplastic unidirectional tape to 0.1 mm-0.4 mm, which can provide sufficient structural strength and achieve lightweight design.

[0057] The design of the stacking angle of the present invention can avoid the defect of a sharp decrease in strength in non-fiber angle directions caused by traditional 0°, 90°, and ±45° angle plying to the greatest extent, so that the continuous fiber reinforced thermoplastic sheet can obtain good strength in all directions.

[0058] As an optional embodiment, the spray-free thermoplastic plastic includes color powder and at least one of pearl powder, mica powder or metal powder.

[0059] Since the spray-free thermoplastic includes color powder, no additional painting and coloring step is required. In addition, the spray-free thermoplastic also includes at least one of pearl powder, mica powder or metal powder to achieve a spray-free effect.

[0060] As an optional embodiment, the thickness of the spray-free sheet material modification layer ranges from 0.2 mm to 4 mm.

[0061] If the thickness of the spray-free sheet modification layer is too low, the covering and modification effect of the spray-free sheet modification layer will be poor. On the contrary, if the thickness of the spray-free sheet modification layer is too high, although the covering and modification effect will be improved, it will increase the difficulty of subsequent vacuum forming with the exterior trim body.

[0062] Therefore, the present invention limits the thickness range of the spray-free sheet material decoration layer to 0.2 mm-4 mm, so that the spray-free sheet material decoration layer can provide a good covering and decoration effect, while ensuring the smooth subsequent vacuum forming process between the spray-free sheet material decoration layer and the exterior trim body.

[0063] As an optional implementation, the inner surface of the exterior trim body is fused with the auxiliary bracket through a welding process, and the outer surface of the exterior trim body is fused with the spray-free sheet material modification layer through a blister process.

[0064] The inner surface of the exterior trim body is fused with the auxiliary bracket through a welding process, which can improve the stability of the connection between the two and also improve the installation diversity and flexibility between the exterior trim body and the auxiliary bracket to meet the usage requirements of different application scenarios.

[0065] The outer surface of the exterior trim body is fused with the spray-free sheet material modification layer through the blister process, so that the outer surface and edge area of ​​the exterior trim body are covered by the spray-free sheet material modification layer.

[0066] As an optional embodiment, the resin substrate of the continuous fiber reinforced thermoplastic sheet, the resin substrate of the spray-free thermoplastic plastic, and the resin substrate of the thermoplastic plastic used in the auxiliary bracket can all be fused to each other in a heated state.

[0067] Such an arrangement can ensure that the spray-free sheet material modification layer, the exterior trim body and the auxiliary bracket can be effectively and firmly fused together under heating to form a continuous integral structure.

[0068] As an optional embodiment, the forming method of the auxiliary bracket includes one-time injection molding of thermoplastic plastic in the same mold, or injection molding of thermoplastic plastic in multiple molds, or continuous fiber reinforced thermoplastic sheet through cutting, heating softening and bending molding steps.

[0069] The present invention provides three molding methods for the auxiliary bracket, and the most suitable molding process can be flexibly selected according to the specific use requirements of the automobile exterior decoration for the auxiliary bracket, thereby improving flexibility and adaptability.

[0070] A method for preparing a spray-free thermoplastic composite automotive exterior trim, used for preparing the aforementioned automotive exterior trim, comprises the following steps:

[0071] S1: Multiple layers of continuous fiber reinforced thermoplastic unidirectional tapes are stacked at a specific angle and in a specific order, and processed by hot pressing to obtain a continuous fiber reinforced thermoplastic sheet;

[0072] S2: The continuous fiber reinforced thermoplastic sheet is preliminarily cut, and after being softened by heating, it is formed by a molding process, and further cut to form an exterior trim body of a specific shape;

[0073] S3: The auxiliary bracket is manufactured by injection molding of thermoplastic plastics, or the auxiliary bracket is manufactured by cutting a continuous fiber reinforced thermoplastic sheet, heating it to soften it, and bending it to form it;

[0074] S4: welding and fusing the auxiliary bracket to the inner surface of the exterior trim body;

[0075] S5: using spray-free thermoplastic plastics through extrusion calendering and casting process to prepare a spray-free sheet material modification layer;

[0076] S6: After the outer surface of the exterior trim body and the spray-free sheet modification layer are heated and softened at the same time, they are fused by a vacuum forming process, and trimmed and cut to obtain a thermoplastic composite automotive exterior trim with a spray-free effect.

[0077] Embodiment 1:

[0078] like Figure 1-Figure 10As shown, this embodiment provides a spray-free thermoplastic composite automotive exterior trim, especially for the door outer panel, including a spray-free sheet material modification layer 4, an exterior trim body 3 and an auxiliary bracket 5 which are fused and connected in sequence from top to bottom. The spray-free sheet material modification layer 4 is made of spray-free thermoplastic plastic through extrusion calendering and casting processes; the exterior trim body 3 is made of a continuous fiber reinforced thermoplastic sheet 2 through heating softening and compression molding steps; the exterior trim body 3 and the auxiliary bracket 5 are both independently molded.

[0079] The exterior trim body 3 of the present invention is made of a continuous fiber reinforced thermoplastic sheet 2 through heating, softening and compression molding steps, making maximum use of the lightweight and high-strength characteristics of the continuous fiber reinforced sheet, so that the exterior trim body 3 can achieve a lightweight design while maintaining sufficient structural strength.

[0080] The auxiliary bracket 5 of the present invention is independently formed, and the number of the auxiliary bracket 5 and the installation position with respect to the exterior trim body 3 can be flexibly designed according to the use requirements of different application scenarios, so that the automobile exterior trim has sufficient freedom in design.

[0081] The spray-coated sheet modification layer is made of spray-free thermoplastic plastic through extrusion calendering and casting process, so that the spray-coated sheet modification layer can obtain an ultra-high finish appearance effect far exceeding that obtained by the in-mold injection molding process, and no subsequent spraying step is required. In addition, the spray-coated sheet modification layer is fused with the exterior trim body 3, so that the outer surface and edge of the exterior trim body 3 have a spray-free effect, which improves the appearance quality of the automobile exterior trim, and does not require in-mold integrated injection molding and painting processes in complex molds.

[0082] As an optional implementation, Figure 6 As shown, the thickness of the continuous fiber reinforced thermoplastic sheet 2 is in the range of 1.0 mm to 5.0 mm.

[0083] If the thickness of the continuous fiber reinforced thermoplastic sheet 2 is too low, the structural strength of the exterior trim body 3 will be insufficient, and it will be difficult to meet the use requirements of the automotive exterior trim. On the contrary, if the thickness of the continuous fiber reinforced thermoplastic sheet 2 is too high, although the structural strength can be improved, the weight of the automotive exterior trim will be increased accordingly, which is contrary to the original intention of using the continuous fiber reinforced thermoplastic sheet 2 to pursue lightweight.

[0084] Therefore, the present invention limits the thickness of the continuous fiber reinforced thermoplastic sheet 2 to 1.0 mm-5.0 mm, so that the continuous fiber reinforced thermoplastic sheet 2 can provide sufficient structural strength to meet the use requirements of automobile exterior parts, while keeping the automobile exterior parts light in weight. In addition, the continuous fiber reinforced thermoplastic sheet 2 not only has good structural strength and lightweight characteristics, but also has processing properties such as easy cutting, heating and softening, compression molding and bending molding.

[0085] As an optional implementation, Figure 5 As shown, the continuous fiber reinforced thermoplastic plate 2 is made by laminating multiple layers of continuous fiber reinforced thermoplastic unidirectional tapes 1 at a specific angle and in a specific order and then performing a hot pressing process.

[0086] As an optional implementation, Figure 5 As shown, the thickness range of the continuous fiber reinforced thermoplastic unidirectional tape 1 is 0.1mm-0.4mm; when stacked, the stacking angles of the continuous fiber reinforced thermoplastic unidirectional tape 1 include at least 4 angles of 0°, ±15°, ±30°, ±45°, ±60°, ±75°, and 90°.

[0087] The present invention limits the thickness range of the continuous fiber reinforced thermoplastic unidirectional tape 1 to 0.1 mm-0.4 mm, which can provide sufficient structural strength and achieve lightweight design.

[0088] The design of the stacking angle of the present invention can avoid the defect of a sharp decrease in strength in non-fiber angle directions caused by traditional 0°, 90°, and ±45° angle plying to the greatest extent, so that the continuous fiber reinforced thermoplastic sheet 2 can obtain good strength in all directions.

[0089] As an optional implementation, Fig.10 As shown, the spray-free thermoplastic includes color powder and at least one of pearl powder, mica powder or metal powder.

[0090] Since the spray-free thermoplastic includes color powder, no additional painting and coloring step is required. In addition, the spray-free thermoplastic also includes at least one of pearl powder, mica powder or metal powder to achieve a spray-free effect.

[0091] As an optional embodiment, the thickness of the spray-free sheet material modification layer 4 is in the range of 0.2 mm to 4 mm.

[0092] If the thickness of the spray-free sheet material modification layer 4 is too low, the covering and modification effect of the spray-free sheet material modification layer 4 will be poor. On the contrary, if the thickness of the spray-free sheet material modification layer 4 is too high, although the covering and modification effect will be improved, it will increase the difficulty of subsequent vacuum forming with the exterior trim body 3.

[0093] Therefore, the present invention limits the thickness range of the spray-free sheet material decoration layer 4 to 0.2 mm-4 mm, so that the spray-free sheet material decoration layer 4 can provide a good covering and decoration effect, while ensuring the smooth subsequent suction molding process between it and the exterior trim body 3 .

[0094] As an optional implementation, Fig. 9 , Fig.10As shown, the inner surface of the exterior trim body 3 is fused with the auxiliary bracket 5 through a welding process, and the outer surface of the exterior trim body 3 is fused with the spray-free sheet material modification layer 4 through a vacuum forming process.

[0095] The inner surface of the exterior trim body 3 is fused with the auxiliary bracket 5 through a welding process, which can improve the stability of the connection between the two and also improve the installation diversity and flexibility between the exterior trim body 3 and the auxiliary bracket 5 to meet the usage requirements of different application scenarios.

[0096] The outer surface of the exterior trim body 3 is fused with the spray-free sheet material modification layer 4 through the vacuum forming process, so that the outer surface and edge area of ​​the exterior trim body 3 are covered by the spray-free sheet material modification layer 4 .

[0097] As an optional embodiment, the resin substrate of the continuous fiber reinforced thermoplastic sheet 2, the resin substrate of the spray-free thermoplastic plastic, and the resin substrate of the thermoplastic plastic used in the auxiliary bracket 5 can all be fused with each other in a heated state.

[0098] Such an arrangement can ensure that the spray-free sheet material decoration layer 4, the exterior decoration body 3 and the auxiliary bracket 5 can be effectively and firmly fused together in a heated state to form a continuous integral structure.

[0099] As an optional implementation, Figure 8 As shown, the auxiliary bracket 5 is formed by one-time injection molding of thermoplastic plastic in the same mold, or by injection molding of thermoplastic plastic in multiple molds, or by cutting, heating, softening and bending a continuous fiber reinforced thermoplastic sheet 2.

[0100] The present invention provides three molding methods for the auxiliary bracket 5 , and the most suitable molding process can be flexibly selected according to the specific use requirements of the automobile exterior parts for the auxiliary bracket 5 , thereby improving flexibility and adaptability.

[0101] This embodiment provides a specific preparation process of a spray-free thermoplastic composite automotive exterior trim, and the preparation steps are as follows:

[0102] S1: Figure 5 As shown, a continuous fiber reinforced thermoplastic unidirectional tape 1 with a thickness of 0.3 mm is used, and is stacked in the order of 0°, 15°, 30°, 45°, 60°, 75°, 90°, -75°, -60°, -45°, -30°, -15°, and 0°, and is processed through a hot pressing process to form a continuous fiber reinforced thermoplastic sheet 2 with a thickness of 3.9 mm;

[0103] S2: Figure 6 , Figure 7As shown, the continuous fiber reinforced thermoplastic sheet 2 is cut into a shape that meets the specific dimensions of the automobile exterior trim; after being heated and softened, it is formed by a molding process to obtain an exterior trim body 3 of a desired shape;

[0104] S3: Figure 8 As shown, thermoplastic plastic particles are used, melted, and then injected into a mold to obtain multiple auxiliary brackets 5 at one time through an injection molding process;

[0105] S4: Fig. 9 As shown, the auxiliary bracket 5 is connected to the exterior trim body 3 by a hot-melt welding process to meet the installation and structural support requirements of the exterior trim body 3;

[0106] S5: The spray-free thermoplastic plastic containing metal aluminum powder is subjected to extrusion calendering and casting processes to obtain a spray-free sheet modification layer 4 with a thickness of 1.0 mm; then, the spray-free sheet modification layer 4 is cut according to the use requirements of different application scenarios to obtain a specific shape;

[0107] S6: Fig.10 As shown, the exterior trim body 3 is placed in a blister mold with a specific structure. At the same time, the outer surface of the exterior trim body 3 and the spray-free sheet modification layer 4 are heated to soften the spray-free sheet modification layer 4. Under the condition of maintaining the appropriate rigidity of the exterior trim body 3, the outer surface of the exterior trim body 3 is quickly heated to a slightly melted state; then a specific clamping device is used to transfer the softened spray-free sheet modification layer 4 to the top of the blister mold; then the air in the blister mold is quickly evacuated to a specific vacuum degree, and the softened spray-free sheet modification layer 4 is quickly fused to the outer surface of the exterior trim body 3 under the action of atmospheric pressure; finally, after sufficient cooling and shaping, the excess spray-free sheet modification layer 4 is cut off to obtain the following Figure 1-Figure 4 The paint-free thermoplastic composite automotive exterior parts shown.

[0108] Example 2: This example provides another specific preparation process of a spray-free thermoplastic composite automotive exterior trim.

[0109] The preparation steps are as follows:

[0110] S1: Use a continuous fiber reinforced thermoplastic unidirectional tape with a thickness of 0.25 mm, stack it in the order of 0°, 30°, 45°, 60°, 90°, -60°, -45°, -30°, and 0°, and then process it through a hot pressing process to form a continuous fiber reinforced thermoplastic sheet with a thickness of 2.25 mm;

[0111] S2: Cutting the continuous fiber reinforced thermoplastic sheet into a shape that meets the specific dimensions of the automobile exterior trim; after heating and softening, forming it through a molding process to obtain the exterior trim body of the desired shape;

[0112] S3: cutting the continuous fiber reinforced thermoplastic sheet into a specific shape required by the auxiliary bracket, and bending it into shape after heating and softening to obtain the auxiliary bracket;

[0113] S4: Connect the auxiliary bracket to the exterior trim body through a hot melt welding process to meet the installation and structural support requirements of the exterior trim body;

[0114] S5: The spray-free thermoplastic containing pearlescent powder is processed by extrusion calendering and casting process to obtain a spray-free sheet modification layer with a thickness of 1.5 mm; then, the spray-free sheet modification layer is cut according to the use requirements of different application scenarios to obtain a specific shape;

[0115] S6: placing the exterior trim body in a blister mold of a specific structure, and at the same time, heating the outer surface of the exterior trim body and the spray-free sheet modification layer to soften the spray-free sheet modification layer, and quickly heating the outer surface of the exterior trim body to a slightly melted state while maintaining the appropriate rigidity of the exterior trim body; then using a specific clamping device to transfer the softened spray-free sheet modification layer to the top of the blister mold; then quickly evacuating the air in the blister mold to a specific vacuum degree, and the softened spray-free sheet modification layer is quickly fused to the outer surface of the exterior trim body under the action of atmospheric pressure; finally, after sufficient cooling and shaping, cutting off the excess spray-free sheet modification layer to obtain the desired spray-free thermoplastic composite automotive exterior trim.

[0116] It can be understood that the same or similar parts of the above embodiments can be referenced to each other, and the contents not described in detail in some embodiments can refer to the same or similar contents in other embodiments.

[0117] In the description of the present invention, it should be noted that, unless otherwise specified, the meaning of "plurality" is two or more; the orientations or positional relationships indicated by the terms "upper", "lower", "left", "right", "inner", "outer", "front end", "rear end", "head", "tail", etc. are based on the orientations or positional relationships shown in the 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 limiting the present invention. In addition, the terms "first", "second", "third", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance.

[0118] In the description of the present invention, it is also necessary to explain that, unless otherwise clearly specified and limited, the terms "installation", "connection", and "connection" 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 mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0119] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example" or "an 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 application. 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 may be combined in any one or more embodiments or examples in a suitable manner.

[0120] The above is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art can easily think of changes or substitutions within the technical scope disclosed by the present invention, which should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention should be based on the protection scope of the claims.

Claims

1. A spray-free thermoplastic composite automotive exterior trim, characterized in that: It includes a spray-free sheet modification layer, an exterior trim body and an auxiliary bracket that are fused and connected in sequence from top to bottom. The spray-free sheet modification layer is made of spray-free thermoplastic plastic through extrusion calendering and casting processes; the exterior trim body is made of continuous fiber reinforced thermoplastic sheet through heating softening and compression molding steps; the exterior trim body and the auxiliary bracket are independently molded.

2. The spray-free thermoplastic composite automotive exterior part according to claim 1, characterized in that: The thickness of the continuous fiber reinforced thermoplastic sheet is in the range of 1.0 mm to 5.0 mm.

3. The spray-free thermoplastic composite automotive exterior part according to claim 2, characterized in that: The continuous fiber reinforced thermoplastic plate is prepared by laminating multiple layers of continuous fiber reinforced thermoplastic unidirectional tapes at a specific angle and in a specific sequence and then performing a hot pressing process.

4. The spray-free thermoplastic composite automotive exterior part according to claim 3, characterized in that: The thickness of the continuous fiber reinforced thermoplastic unidirectional tape ranges from 0.1 mm to 0.4 mm; when stacked, the stacking angles of the continuous fiber reinforced thermoplastic unidirectional tape include at least four angles of 0°, ±15°, ±30°, ±45°, ±60°, ±75°, and 90°.

5. The spray-free thermoplastic composite automotive exterior part according to claim 1, characterized in that: The spray-free thermoplastic plastic includes color powder and at least one of pearl powder, mica powder or metal powder.

6. The spray-free thermoplastic composite automotive exterior part according to claim 1, characterized in that: The thickness of the spray-free sheet modification layer ranges from 0.2 mm to 4 mm.

7. The spray-free thermoplastic composite automotive exterior part according to claim 1, characterized in that: The inner surface of the exterior trim body is fused with the auxiliary bracket through a welding process, and the outer surface of the exterior trim body is fused with the spray-free sheet material modification layer through a blister process.

8. The spray-free thermoplastic composite automotive exterior part according to claim 1, characterized in that: The resin substrate of the continuous fiber reinforced thermoplastic plate, the resin substrate of the spray-free thermoplastic plastic, and the resin substrate of the thermoplastic plastic used in the auxiliary bracket can all be fused to each other in a heated state.

9. The spray-free thermoplastic composite automotive exterior part according to claim 1, characterized in that: The auxiliary bracket is formed by one-time injection molding of thermoplastic plastic in the same mold, or by injection molding of thermoplastic plastic in multiple molds, or by cutting, heating, softening and bending the continuous fiber reinforced thermoplastic sheet.

10. A method for preparing a spray-free thermoplastic composite automotive exterior trim, used for preparing the automotive exterior trim as claimed in any one of claims 1 to 9, characterized in that: The steps include: S1: Multiple layers of continuous fiber reinforced thermoplastic unidirectional tapes are stacked at a specific angle and in a specific order, and processed by hot pressing to obtain a continuous fiber reinforced thermoplastic sheet; S2: preliminarily cutting the continuous fiber reinforced thermoplastic sheet, and molding it through a molding process after heating and softening to obtain an exterior trim body; S3: using thermoplastic plastics to make the auxiliary bracket through an injection molding process, or cutting the continuous fiber reinforced thermoplastic sheet, heating it to soften it, and bending it to make the auxiliary bracket; S4: welding and fusing the auxiliary bracket to the inner surface of the exterior trim body; S5: using spray-free thermoplastic plastics through extrusion calendering and casting process to prepare a spray-free sheet material modification layer; S6: After the outer surface of the exterior trim body and the spray-free sheet modification layer are heated and softened at the same time, they are fused by a vacuum forming process, and trimmed and cut to obtain a finished product.

Images