Thermoplastic composite material anti-collision beam and preparation method thereof

Abstract

The invention provides a thermoplastic composite material anti-collision beam and a preparation method thereof, and relates to the technical field of automobile anti-collision beams, the thermoplastic composite material anti-collision beam comprises a main beam and an auxiliary support connected with the main beam, the main beam is made of continuous fiber reinforced thermoplastic plates, and the auxiliary support is made of continuous fiber reinforced thermoplastic plates. The continuous fiber reinforced thermoplastic plate is formed by stacking and hot-pressing a plurality of continuous fiber reinforced thermoplastic unidirectional belts; the angles of the fiber laying layers of the two adjacent continuous fiber reinforced thermoplastic unidirectional belts are different; the main beam made of the continuous fiber reinforced thermoplastic plate is matched with the auxiliary support, the total weight of the anti-collision beam can be remarkably reduced, light weight is achieved, the structural strength of the main beam can be effectively guaranteed, the anti-collision effect is guaranteed, meanwhile, the manufacturing process is simple, and the cost is controllable.

Description

Technical Field

[0001] This invention relates to the field of automotive anti-collision beam technology, specifically to a thermoplastic composite anti-collision beam and its preparation method. Background Technology

[0002] In the automotive manufacturing industry, traditional automotive crash beams are mainly composed of steel or aluminum profiles as the main body, connected by metal auxiliary structures. Traditional automotive crash beams are not only heavy and difficult to further improve in terms of lightweighting, but also require multiple processes such as stamping, bending, trimming, or die casting for metal profiles of different shapes, making the manufacturing process complex and the overall cost high.

[0003] In response, automotive crash beams made of materials such as aluminum alloy and carbon fiber composites have emerged in recent years. Although they have achieved weight reduction to some extent, they still have technical drawbacks such as complex structure and molding process and high cost.

[0004] With the trend of lightweighting in automobiles, more and more metal structural parts are being replaced by composite materials. In particular, recyclable thermoplastic composite materials have a wider range of applications. Continuous fiber reinforced thermoplastic composite materials can have the same or even higher mechanical strength as metals, but their density is much lower than that of metal materials. At the same time, they can be recycled and reused. Therefore, there is an urgent need to invent an automotive anti-collision beam using continuous fiber reinforced thermoplastic composite materials. Summary of the Invention

[0005] The purpose of this invention is to provide a thermoplastic composite anti-collision beam and its preparation method to solve the above-mentioned technical problems in the prior art; the preferred technical solutions among the many technical solutions provided by this invention can produce many technical effects, as detailed below.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] The present invention provides a thermoplastic composite anti-collision beam, comprising a main beam and an auxiliary support connected to the main beam, wherein: the main beam is made of continuous fiber reinforced thermoplastic sheet, the continuous fiber reinforced thermoplastic sheet is made by hot pressing multiple continuous fiber reinforced thermoplastic unidirectional tapes after being stacked; the fiber layup angles of two adjacent continuous fiber reinforced thermoplastic unidirectional tapes are different.

[0008] Preferably, the difference in fiber layup angle between two adjacent continuous fiber-reinforced thermoplastic unidirectional tapes is an integer multiple of 15°.

[0009] Preferably, the main beam is configured as a V-shape or an arch shape.

[0010] Preferably, the main beam includes a front plate-shaped surface layer, a main beam body, and a rear plate-shaped surface layer, wherein: the front plate-shaped surface layer, the main beam body, and the rear plate-shaped surface layer are arranged in layers; and the auxiliary support is fixedly connected to the rear plate-shaped surface layer.

[0011] Preferably, the front plate-shaped surface layer and the rear plate-shaped surface layer are arranged in parallel; the main beam body is configured as an S-shaped structure, the main beam body includes a plurality of parallel reinforcing segments, the same end of two adjacent reinforcing segments is connected by a connecting segment, the reinforcing segments are arranged perpendicularly to the front plate-shaped surface layer and the rear plate-shaped surface layer, the connecting segment is arranged perpendicularly to the reinforcing segments, the connecting segment away from the front plate-shaped surface layer is connected to the rear plate-shaped surface layer, and the connecting segment away from the rear plate-shaped surface layer is connected to the front plate-shaped surface layer.

[0012] Preferably, the number of the auxiliary supports is set to multiple; the auxiliary supports are made of thermoplastic material.

[0013] Preferably, the auxiliary support is welded to the main beam or detachably connected via a connector.

[0014] Preferably, the auxiliary support includes a support body and end plates, wherein: the support body is arranged axially through; the end plates are provided at both ends of the support body, and the main beam is connected to the corresponding end plates.

[0015] Preferably, the support body has a plurality of collapse grooves on at least one side.

[0016] This invention provides a method for preparing a thermoplastic composite anti-collision beam as described above, comprising at least the following steps:

[0017] Step S1: The continuous fiber reinforced thermoplastic unidirectional tape is stacked at a set angle and then hot-pressed into the continuous fiber reinforced thermoplastic sheet.

[0018] Step S2: The continuous fiber reinforced thermoplastic sheet is heated, softened, and bent sequentially to form the main beam;

[0019] Step S3: Fabricate the auxiliary support using thermoplastic material;

[0020] Step S4: The auxiliary support and the main beam are connected and assembled into one unit by welding or connecting parts.

[0021] The thermoplastic composite anti-collision beam and its preparation method provided by the present invention have at least the following beneficial effects:

[0022] The thermoplastic composite anti-collision beam includes a main beam and an auxiliary support connected to the main beam. The main beam is the main anti-collision component, and the auxiliary support is used for both the installation of the main beam and as an auxiliary anti-collision component.

[0023] The main beam is made of continuous fiber reinforced thermoplastic sheet, which is formed by hot pressing multiple continuous fiber reinforced thermoplastic unidirectional strips. On the one hand, it makes full use of the high strength and low density characteristics of continuous fiber reinforced thermoplastic sheet, which can significantly reduce weight and achieve lightweighting compared with traditional metal anti-collision beams. On the other hand, the manufacturing process is simpler than that of traditional metal anti-collision beams.

[0024] The fiber layup angles of two adjacent continuous fiber-reinforced thermoplastic unidirectional strips are different, which can effectively avoid the defect of sharp decrease in strength in non-fiber layup directions, thereby ensuring the structural strength of the main beam and ensuring the anti-collision effect.

[0025] This invention utilizes a main beam made of continuous fiber-reinforced thermoplastic sheet, which works in conjunction with an auxiliary support frame. This not only significantly reduces the total weight of the anti-collision beam, achieving lightweight design, but also effectively ensures the structural strength of the main beam and guarantees the anti-collision effect. Furthermore, the manufacturing process is simple and the cost is controllable. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a schematic diagram of the thermoplastic composite anti-collision beam of the present invention from one perspective;

[0028] Figure 2 This is a structural schematic diagram of the thermoplastic composite anti-collision beam of the present invention from another perspective;

[0029] Figure 3 This is a top view schematic diagram of the thermoplastic composite anti-collision beam of the present invention;

[0030] Figure 4 This is a schematic diagram of the structure of the continuous fiber reinforced thermoplastic sheet of the present invention;

[0031] Figure 5 This is a schematic diagram of the main beam of the present invention;

[0032] Figure 6 This is an exploded view of the main beam of the present invention;

[0033] Figure 7 This is a side view of the main beam of the present invention;

[0034] Figure 8 This is a schematic diagram of the structure of the auxiliary support of the present invention;

[0035] Figure 9 This is a flowchart of the method for preparing continuous fiber reinforced thermoplastic sheets according to the present invention.

[0036] Figure Labels

[0037] 1. Main beam; 11. Continuous fiber reinforced thermoplastic sheet; 111. Continuous fiber reinforced thermoplastic unidirectional strip; 12. Front plate-like surface layer; 13. Main beam body; 131. Reinforcing section; 132. Connecting section; 14. Rear plate-like surface layer; 2. Auxiliary support; 21. Support body; 211. Collapse groove; 22. End plate. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be described in detail below. Obviously, the described embodiments are merely some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0039] Example 1:

[0040] This invention provides a thermoplastic composite anti-collision beam, reference Figures 1 to 8 As shown, the thermoplastic composite anti-collision beam includes a main beam 1 and an auxiliary support 2, with the auxiliary support 2 connected to the main beam 1.

[0041] The main beam 1 is made of continuous fiber reinforced thermoplastic sheet 11, which is made by hot pressing multiple continuous fiber reinforced thermoplastic unidirectional strips 111 after being stacked; the fiber layup angles of two adjacent continuous fiber reinforced thermoplastic unidirectional strips 111 are different.

[0042] In use, the main beam 1 is installed on the auxiliary bracket 2, and the auxiliary bracket 2 is installed on the vehicle frame. The main beam 1 and the auxiliary bracket 2 cooperate with each other to play a role in preventing collisions.

[0043] In practical applications, the main beam 1 uses continuous fiber reinforced thermoplastic sheet 11, which has a density much lower than that of existing metal anti-collision beams. It has the characteristics of high strength and low density, which can effectively reduce weight and achieve lightweighting. In addition, the sheet is made by hot pressing continuous fiber reinforced thermoplastic unidirectional strip 111 in layers, which is simple to manufacture and has controllable cost.

[0044] In addition, the fiber layup angles of the two adjacent continuous fiber-reinforced thermoplastic unidirectional strips 111 of the board are different, which can effectively avoid the defect of drastic reduction in strength in non-fiber angle directions, thereby effectively ensuring the structural strength of the overall main beam 1 and ensuring the anti-collision effect.

[0045] Example 2:

[0046] Example 2 is based on Example 1:

[0047] like Figures 1 to 8 As shown, the difference in fiber layup angle between two adjacent continuous fiber reinforced thermoplastic unidirectional tapes 111 is an integer multiple of 15°.

[0048] All continuous fiber-reinforced thermoplastic unidirectional tapes 111 cover 0–180°, thus minimizing the loss of strength in non-fiber angle directions and further improving structural strength.

[0049] Optionally, the number of continuous fiber reinforced thermoplastic unidirectional tapes 111 is set to 13, arranged from top to bottom along the layer direction, with fiber layup angles of 0°, 15°, 30°, 45°, 60°, 75°, 90°, 105° (-15°), 120° (-30°), 135° (-45°), 150° (-60°), 165° (-70°), and 180° (0°).

[0050] Alternatively, the number of continuous fiber reinforced thermoplastic unidirectional tapes 111 is set to 9, arranged from top to bottom along the layer direction, with fiber layup angles of 0°, 30°, 45°, 60°, 90°, 120° (-30°), 135° (-45°), 150° (-60°), and 180° (0°) for all continuous fiber reinforced thermoplastic unidirectional tapes 111.

[0051] In practical applications, if the plate thickness is too low, the main beam 1 will not be strong enough, while if the thickness is too high, it will not achieve the effect of lightweighting.

[0052] Therefore, it is preferred that the thickness of the continuous fiber reinforced thermoplastic sheet 11 is 1.0-8.0 mm, and the thickness of the continuous fiber reinforced thermoplastic unidirectional tape 111 is 0.1-0.4 mm.

[0053] As an optional implementation, the main beam 1 is configured as a V-shape.

[0054] The V-shaped structure can decompose the frontal impact force into an oblique component and guide it to the auxiliary support 2. On the other hand, its structure itself has higher bending stiffness, which can resist torsional deformation and maintain vehicle stability in offset collisions.

[0055] Alternatively, the main beam 1 can be configured as an arch.

[0056] On the one hand, the arched structure has a two-way collapse energy absorption mechanism. When the collision force acts on the convex surface of the arch, the structure is compressed and collapses, converting the impact kinetic energy into plastic deformation energy. If the impact point is on the concave surface, the arch will unfold and deform in the opposite direction, forming a secondary energy absorption buffer. On the other hand, the arched curve evenly diffuses the stress along the main beam 1, avoiding local fracture caused by excessive stress concentration and improving the overall energy absorption efficiency.

[0057] As an optional implementation, the main beam 1 includes a front plate-like surface layer 12, a main beam body 13, and a rear plate-like surface layer 14, which are arranged in layers; the auxiliary bracket 2 is fixedly connected to the rear plate-like surface layer 14.

[0058] When preparing the anti-collision beam, first make the continuous fiber reinforced thermoplastic sheet 11, then separately make the front plate-like surface layer 12, the main beam body 13, and the rear plate-like surface layer 14, and then weld the three together to form the main beam 1. The manufacturing process is simple and the cost is low.

[0059] As an optional implementation, the front plate-like surface layer 12 and the rear plate-like surface layer 14 are arranged in parallel.

[0060] The main beam body 13 is set as an S-shaped structure. The main beam body 13 includes a plurality of reinforcing segments 131 arranged in parallel. The same ends of two adjacent reinforcing segments 131 are connected by a connecting segment 132. The reinforcing segments 131 are perpendicular to the front plate-like surface layer 12 and the rear plate-like surface layer 14, and the connecting segment 132 is perpendicular to the reinforcing segments 131.

[0061] In the process of preparing the anti-collision beam, first heat and soften the continuous fiber reinforced thermoplastic sheet 11, then bend it in sequence to make it form an S-shaped structure. After that, weld the front plate-like surface layer 12 and the rear plate-like surface layer 14 to the front side and the rear side of the main beam body 13 respectively. Specifically, the connecting segment 132 far from the front plate-like surface layer 12 is welded to the rear plate-like surface layer 14, and the connecting segment 132 far from the rear plate-like surface layer 14 is welded to the front plate-like surface layer 12.

[0062] In this way, the cross-section of the main beam body 13 is similar to a Chinese character "ri" or "mu", and a reinforcing rib structure is formed inside, which can further enhance the structural strength of the main beam 1. The advantage of this structure is that it has extremely high stiffness and strength in its own structure, and there is no need to further inject reinforcing ribs for reinforcement. Moreover, compared with other reinforcing structures, it is more simple to manufacture, can effectively reduce the production cost. At the same time, since the main beam 1 is made of the continuous fiber reinforced thermoplastic sheet 11, it can be made by heating and softening the sheet and then bending and fusing it together. Not only the structural strength is improved, but also the difficulty of the traditional integral injection molding die and the cross-beam structure design is reduced.

[0063] As an optional implementation, the number of auxiliary supports 2 is set to multiple; preferably, two are set symmetrically on the rear side of the main beam 1 and near the end.

[0064] The auxiliary support 2 is made of thermoplastic material.

[0065] Thus, both the main beam 1 and the auxiliary support 2 are resin matrices, and the two can be fused together under heating. The connection between the two can be achieved using various processes, such as hot melt welding, ultrasonic welding, and vibration friction welding, which further endows the thermoplastic composite anti-collision beam of the present invention with the advanced features of simple and efficient molding.

[0066] As an optional implementation, the auxiliary support 2 is welded to the main beam 1 as a whole, resulting in better overall integrity.

[0067] Alternatively, the auxiliary bracket 2 and the main beam 1 can be detachably connected via connectors, specifically via threaded connectors, which makes assembly faster.

[0068] As an optional implementation, the auxiliary support 2 includes a support body 21 and an end plate 22. The support body 21 is arranged axially through the support body 21. Both ends of the support body 21 are provided with end plates 22, and the main beam 1 is connected to the corresponding end plate 22.

[0069] The auxiliary support 2 serves two purposes: firstly, it acts as a mounting bracket for the installation of the main beam 1; secondly, it also has an energy-absorbing function, assisting the main beam 1 and further improving the anti-collision effect.

[0070] As an optional implementation, the support body 21 has a plurality of collapse grooves 211 on at least one side.

[0071] The auxiliary support 2 equipped with a crumple zone 211 can not only absorb impact energy and protect personal safety, but also optimize the energy transfer path, prevent breakage due to excessive stress concentration, improve the stability of offset impact, and reduce the weight of components, balancing protection strength and energy saving requirements.

[0072] Preferably, the collapse groove 211 is an elongated oval groove, and multiple collapse grooves 211 are arrayed on the left and right sides of the support body 21.

[0073] Example 3

[0074] This invention provides a method for preparing a thermoplastic composite anti-collision beam, such as... Figure 9 As shown, the preparation method of the thermoplastic composite anti-collision beam includes at least the following steps:

[0075] Step S1: Stack the continuous fiber reinforced thermoplastic unidirectional tape 111 at a set angle and then hot press it into a continuous fiber reinforced thermoplastic sheet 11;

[0076] Step S2: The continuous fiber reinforced thermoplastic sheet 11 is heated, softened, and bent in sequence to form the main beam 1;

[0077] Step S3: Fabricate the auxiliary support 2 using thermoplastic material;

[0078] Step S4: Connect the auxiliary support 2 and the main beam 1 by welding or using connectors to form a whole, and a thermoplastic composite anti-collision beam can be obtained.

[0079] Example 4

[0080] Example 4 is based on Example 3:

[0081] The preparation method of the thermoplastic composite anti-collision beam includes the following steps:

[0082] Step S1: Lay out 0.3mm thick continuous fiber reinforced thermoplastic unidirectional tape 111 in the following angle sequence: 0°, 15°, 30°, 45°, 60°, 75°, 90°, 105° (-15°), 120° (-30°), 135° (-45°), 150° (-60°), 165° (-70°), 180° (0°), and then hot press to obtain a 3.9mm thick continuous fiber reinforced thermoplastic sheet 11. At the same time, trim the obtained sheet to obtain a rectangular sheet.

[0083] Step S2: The continuous fiber reinforced thermoplastic sheet 11 is heated, softened, bent and hot-melted welded in sequence to make the main beam 1. In specific operation, after heating and softening, the softened sheet is bent into an S-shape by a bending machine to obtain the main beam body 13. Then the main beam body 13 is welded to the front plate surface layer 12 and the rear plate surface layer 14 respectively to obtain the main beam 1.

[0084] Step S3: Using thermoplastic particles, the material is melted and then injection molded into a mold to obtain two auxiliary supports 2.

[0085] Step S4: The auxiliary support 2 and the main beam 1 are hot-melt welded together to obtain the thermoplastic composite anti-collision beam.

[0086] Example 5

[0087] Example 5 is based on step 3:

[0088] The preparation method of the thermoplastic composite anti-collision beam includes the following steps:

[0089] Step S1: Lay out 0.25mm thick continuous fiber reinforced thermoplastic unidirectional tape 111 in the following angle sequence: 0°, 30°, 45°, 60°, 90°, 120° (-30°), 135° (-45°), 150° (-60°), 180° (0°), and then hot press to obtain a 2.25mm thick continuous fiber reinforced thermoplastic sheet 11. At the same time, trim the obtained sheet to obtain a rectangular sheet.

[0090] Step S2: The continuous fiber reinforced thermoplastic sheet 11 is heated, softened, bent and hot-melted welded into the main beam 1. In specific operation, after heating and softening, the softened sheet is bent into an S-shape by a bending machine to obtain the main beam body 13. Then the main beam body 13 is welded to the front plate surface layer 12 and the rear plate surface layer 14 respectively to obtain the main beam 1.

[0091] Then, the first mounting hole is cut at a specific position on the main beam 1 by laser cutting or cutting tools.

[0092] Step S3: Cut the 2.25mm thick continuous fiber reinforced thermoplastic sheet 11 into a specific shape, heat and soften it, and then bend it to obtain the auxiliary support 2;

[0093] Cut a second mounting hole on the auxiliary bracket 2 at the position corresponding to the first mounting hole;

[0094] Step S4: Use threaded fasteners to pass through the first mounting hole and the second mounting hole and tighten them to obtain the thermoplastic composite anti-collision beam.

[0095] In the description of this application, it should be understood that the terms "upper", "lower", "inner", "outer", "top", "bottom", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0096] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" or "several" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0097] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0098] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A thermoplastic composite anti-collision beam, characterized in that, Includes a main beam and an auxiliary support connected to the main beam, wherein: The main beam is made of continuous fiber reinforced thermoplastic sheet, which is made by hot pressing multiple continuous fiber reinforced thermoplastic unidirectional tapes stacked together. The fiber layup angles of two adjacent continuous fiber reinforced thermoplastic unidirectional tapes are different.

2. The thermoplastic composite anti-collision beam according to claim 1, characterized in that, The difference in fiber layup angle between two adjacent continuous fiber-reinforced thermoplastic unidirectional tapes is an integer multiple of 15°.

3. The thermoplastic composite anti-collision beam according to claim 1, characterized in that, The main beam is designed to be V-shaped or arched.

4. The thermoplastic composite anti-collision beam according to claim 1, characterized in that, The main beam comprises a front plate-like surface layer, a main beam body, and a rear plate-like surface layer, wherein: The front plate-shaped surface layer, the main beam body, and the rear plate-shaped surface layer are arranged in a hierarchical manner; The auxiliary support is fixedly connected to the rear plate-shaped surface layer.

5. The thermoplastic composite anti-collision beam according to claim 4, characterized in that, The front plate-shaped surface layer and the rear plate-shaped surface layer are arranged parallel to each other; The main beam body is configured as an S-shaped structure, and the main beam body includes multiple parallel reinforcing sections. The same end of two adjacent reinforcing sections is connected by a connecting section. The reinforcing sections are perpendicular to the front plate-shaped surface and the rear plate-shaped surface. The connecting section is perpendicular to the reinforcing section. The connecting section away from the front plate-shaped surface is connected to the rear plate-shaped surface, and the connecting section away from the rear plate-shaped surface is connected to the front plate-shaped surface.

6. The thermoplastic composite anti-collision beam according to claim 1, characterized in that, The number of the auxiliary supports is set to multiple; The auxiliary support is made of thermoplastic material.

7. The thermoplastic composite anti-collision beam according to claim 6, characterized in that, The auxiliary support is welded to the main beam or detachably connected via connectors.

8. The thermoplastic composite anti-collision beam according to claim 7, characterized in that, The auxiliary support includes a support body and an end plate, wherein: The support body is arranged axially through the entire structure. The support body has end plates at both ends, and the main beam is connected to the corresponding end plates.

9. The thermoplastic composite anti-collision beam according to claim 1, characterized in that, The support body has multiple collapse grooves on at least one side.

10. A method for preparing a thermoplastic composite anti-collision beam according to any one of claims 1 to 9, characterized in that, At least the following steps are included: Step S1: The continuous fiber reinforced thermoplastic unidirectional tape is stacked at a set angle and then hot-pressed into the continuous fiber reinforced thermoplastic sheet. Step S2: The continuous fiber reinforced thermoplastic sheet is heated, softened, and bent sequentially to form the main beam; Step S3: Fabricate the auxiliary support using thermoplastic material; Step S4: The auxiliary support and the main beam are connected and assembled into one unit by welding or connecting parts.

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