Novel composite material truck cab

Abstract

The novel composite material truck cab comprises a cab bottom plate, a cab rear enclosing plate and a bottom supporting beam, the bottom supporting beam is located on one side of the cab bottom plate and surrounds the edge of the cab bottom plate, and the cab rear enclosing plate is arranged on the side wall of the cab bottom plate and surrounds the edge of the cab bottom plate; the cab bottom plate is connected with one side of the upper surface of the bottom supporting beam through glue; the other side of the upper surface of the bottom supporting beam is connected with the bottom of the cab back panel through glue; the inward surface of the bottom supporting beam is connected with the outer side wall of the cab bottom plate through glue; a closed cavity is formed by the cab bottom plate, the cab rear enclosing plate and the bottom supporting beam. The cab bottom plate, the cab rear wall plate and the bottom supporting beam are formed by mould pressing of composite materials, the composite materials are composed of 30%-35% of glass felt, 22%-25% of carbon fibers, 40%-45% of 994 # pre-promoted orthophthalic unsaturated polyester resin and 1%-2% of BUTANOX-M-50 methyl ethyl ketone peroxide, and the board body is made of the composite materials, so that the development cost of a whole vehicle is reduced; and the weight of the vehicle body is reduced by more than 10% on the basis of ensuring the strength.

Description

Technical Field

[0001] This invention belongs to the field of automotive technology, specifically relating to a novel composite material truck cab. Background Technology

[0002] Currently, in the truck manufacturing industry, traditional cabs mostly use metal materials, such as sheet metal stampings. Metal materials are expensive, and the overall vehicle weight is large, which is detrimental to fuel economy and vehicle performance. In addition, the joining of metal materials often relies on welding processes, which not only increases manufacturing costs but also generates a large amount of air pollutants during the welding process.

[0003] With increasingly stringent environmental protection and energy conservation requirements, the development of lightweight, low-cost, and environmentally friendly cabs has become an urgent need for the industry. In view of this, this solution was developed. Summary of the Invention

[0004] In view of the shortcomings of the prior art, the technical problem to be solved by the present invention is to provide a new type of composite material truck cab, which reduces the overall vehicle development cost and reduces the vehicle body weight by more than 10% while ensuring strength.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a novel composite material truck cab, comprising a cab floor, a cab rear panel, and a bottom support beam. The bottom support beam is located on one side of the cab floor and surrounds the edge of the cab floor. The cab rear panel is disposed on the side wall of the cab floor and surrounds its edge. The cab floor and one side of the upper surface of the bottom support beam, the other side of the upper surface of the bottom support beam and the bottom of the cab rear panel, and the inward side of the bottom support beam and the outer side wall of the cab floor are connected by adhesive. The cab floor, the cab rear panel, and the bottom support beam form a sealed cavity. The cab floor, cab rear panel, and bottom support beam are made of composite material molded from a composite material consisting of 30-35% glass felt, 22-25% carbon fiber, 40-45% 994# pre-accelerated phthalic unsaturated polyester resin, and 1-2% BUTANOX-M-50 peroxide methyl ethyl ketone.

[0006] Furthermore, the cab floor plate and one side of the upper surface of the bottom support beam, the other side of the upper surface of the bottom support beam and the bottom of the rear panel of the cab, and the inner side of the bottom support beam and the outer wall of the cab floor plate are connected by a two-component acrylic structural adhesive.

[0007] Furthermore, the composite material is composed of 32% glass mat, 24% carbon fiber, 43% 994# pre-accelerated phthalic unsaturated polyester resin and 1% BUTANOX M-50 peroxide methyl ethyl ketone.

[0008] Furthermore, the thickness of the cab floor plate, cab rear panel, and bottom support beam after the composite material is molded is 2.5mm-5mm, and the density is 1.65g / cm³.

[0009] Furthermore, the cab floor plate, the cab rear panel, and the bottom support beam are formed by vacuum bag molding. The vacuum bag molding process includes the following steps: S1. Connect the mold to the heating system, clean the mold, and apply release agent evenly to the working surface of the mold; S2. The prepared composite materials are laid flat on the working surface of the mold in sequence. The composite materials include glass mat and carbon fiber. S3. Lay a layer of release cloth on the composite material, and the release cloth completely covers the composite material; S4. Lay a layer of flow guide cloth on the release cloth, and then lay flow guide tubes on the flow guide cloth; S5. Apply sealing strips around the flow guide cloth, release cloth and composite material, forming a closed loop; S6. Lay the vacuum bag film on the release cloth, and attach the vacuum bag film to the sealing strip around the edges; S7. Install the vacuum valve, quick connector and vacuum tube, then turn on the vacuum pump, check for leaks and test the vacuum level. S8. After confirming that there is no air leakage and the vacuum degree meets the requirements, introduce the prepared resin. The resin impregnates the composite material. The resin is a mixture of 994# pre-accelerated phthalic unsaturated polyester resin and BUTANOX-M-50 peroxide methyl ethyl ketone. S9. Start the heating system and vacuum pump, and while drawing a vacuum, continuously extrude the composite material at the inside corner of the mold; S10. Demold after the product has completely cured.

[0010] Furthermore, the vacuum bag process requires a vacuum pressure of at least 10 MPa during the vacuuming process.

[0011] Furthermore, in step S9, a clamping tool is used to extrude the composite material at the inside corner of the mold; The clamping tool includes a clamping strip, which is triangular in shape. The line segment formed by the side of the clamping strip in the vertical section and the line segment formed in the vertical section at the inside corner of the mold are equidistant from each other, and the equidistant distance is the thickness of the product.

[0012] Furthermore, a force-applying handle is provided on the outward-facing side of the clamping strip.

[0013] Furthermore, the clamping strip is made of rubber.

[0014] Furthermore, the specific steps of step S9 are as follows: start the water temperature machine heating system to heat the composite material to a temperature of 60-80℃, start the vacuum pump to evacuate, and during the evacuation process, hold the force application handle and press the composite material at the inside corner of the mold from left to right until curing is complete; when the composite material is found to bulge at a certain position at the inside corner of the mold during the pressing process, immediately perform two compressions.

[0015] Compared with the prior art, the present invention has the following beneficial effects: 1. This invention provides a novel composite material truck cab, which is formed by bonding the cab floor plate, the cab rear panel, and the bottom support beam together. The cab floor plate, the cab rear panel, and the bottom support beam are made of composite materials, which are high in strength, lightweight, and low in cost. Traditional vehicle body manufacturing requires large stamping equipment, welding lines, welding equipment, and large tooling fixtures. Using this composite material process can eliminate expensive equipment costs and welding labor costs.

[0016] 2. The vehicle body achieves a weight reduction of over 10%. Stamped body panels use metal sheets with a thickness between 0.8mm and 1.5mm and a metal density of 7.8 g / cm³, while composite material panels have a thickness between 2.5mm and 5mm (the thickness varies depending on the part), and a density of 1.65g / cm³. Calculations show that for the same component, using this composite material, including the weight of the adhesive, results in a weight reduction of over 10%.

[0017] 3. Compared with traditional processes, the manufacturing of the new composite material cab avoids air pollutants generated during welding, which is beneficial to environmental protection. Attached Figure Description

[0018] Figure 1 This is a three-dimensional structural diagram of a novel composite material truck cab according to the present invention; Figure 2 For the present invention Figure 1 A magnified schematic diagram of the local structure at point A; Figure 3 This is a top view of the molding and extrusion process in step S9 of the vacuum bag manufacturing process of the present invention. Figure 4 For the present invention Figure 3 Schematic diagram of the cross-sectional structure at point AA; Figure 5 This is a partial three-dimensional structural diagram of the clamping tool during its operation in this invention.

[0019] The markings in the diagram are: 1. Cab floor; 2. Cab rear panel; 3. Bottom support beam; 4. Clamping tool; 41. Clamping strip; 42. Force application handle; 5. Two-component acrylic structural adhesive. Detailed Implementation

[0020] To make the above features and advantages of the present invention more apparent and understandable, specific embodiments are described below in conjunction with the accompanying drawings for detailed explanation.

[0021] like Figures 1-2 As shown, this embodiment provides a novel composite material truck cab, including a cab floor 1, a cab rear panel 2, and a bottom support beam 3.

[0022] like Figures 1-2 As shown, the bottom support beam 3 is located on one side of the cab floor 1 and surrounds the edge of the cab floor 1. The cab rear panel 2 is set on the side wall of the cab floor 1 and surrounds its edge. The cab floor 1 and the bottom support beam 3 are connected by adhesive on one side of the upper surface, the bottom of the cab rear panel 2 and the inner side of the bottom support beam 3 and the outer side wall of the cab floor 1. The cab floor 1, the cab rear panel 2 and the bottom support beam 3 form a sealed cavity. The formation of the sealed cavity can greatly reduce the weight of the overall cab. After the cab floor 1, the cab rear panel 2 and the bottom support beam 3 are bonded, the three components form a whole, which can improve the overall structural strength.

[0023] Preferably, the surface of the bottom support beam 3 is designed with concave and convex features to enhance its structural strength.

[0024] The cab floor 1 is connected to one side of the upper surface of the bottom support beam 3, the other side of the upper surface of the bottom support beam 3 to the bottom of the rear cab panel 2, and the inward-facing side of the bottom support beam 3 to the outer wall of the cab floor 1 using a two-component acrylic structural adhesive 5. This two-component acrylic structural adhesive 5 has rapid curing characteristics, typically achieving initial fixation within 5 minutes, reaching 80% strength after 30 minutes, and reaching maximum strength after 24 hours. Its shear strength can reach 70.1 MPa, meeting the high-strength bonding requirements of automotive panels. This connection strength is comparable to that achieved through welding. Furthermore, this structural adhesive possesses excellent weather resistance, high-temperature resistance, and aging resistance, operating within a temperature range of -30℃ to 150℃. It also exhibits acid and alkali resistance, water resistance, and oil resistance, making it suitable for use in complex environments for automotive panels.

[0025] The two-component acrylic structural adhesive 5 used in this embodiment includes component A and component B, with a component ratio of 8:1 to 12:1. In this embodiment, a 10:1 ratio is used. Component A includes 70-80% acrylate, 10-15% crosslinking agent, 5-10% filler, and 5-10% diluent. Component B includes 20-40% curing agent (such as peroxide), 20-40% plasticizer, 20-40% multifunctional epoxy resin, and 0.5-2% pigment (optional). Preferably, component A includes 75% acrylate, 10% crosslinking agent, 7% filler, and 8% diluent, and component B includes 30% curing agent (such as peroxide), 35% plasticizer, 34% multifunctional epoxy resin, and 1% pigment.

[0026] The cab floor 1, cab rear panel 2, and bottom support beam 3 are molded from composite materials. The composite material consists of 30-35% glass felt, 22-25% carbon fiber, 40-45% 994# pre-accelerated phthalic unsaturated polyester resin, and 1-2% BUTANOX-M-50 methyl ethyl ketone peroxide. A more preferred formulation is that the composite material consists of 32% glass felt, 24% carbon fiber, 43% 994# pre-accelerated phthalic unsaturated polyester resin, and 1% BUTANOX M-50 methyl ethyl ketone peroxide. The sheet metal produced using the above-mentioned proportions has a density of 1.65 g / cm³, which significantly reduces weight compared to traditional metal materials (density of 7.8 g / cm³), achieving a vehicle weight reduction of over 10%. Furthermore, stamped body panels use metal sheets with a thickness between 0.8 mm and 1.5 mm, while the sheet metal panels made using composite materials in this solution have a thickness between 2.5 mm and 5 mm (the thickness varies depending on the part used). With similar structural strength, the sheet metal panels made using composite materials in this solution are thicker, have lower density, and are lighter in weight.

[0027] The following are data comparison charts showing that the cab floor 1, cab rear panel 2, and bottom support beam 3 are made of composite materials versus traditional metal sheets: Cab floor 1:

[0028] Rear panel of the cab 2:

[0029] Bottom support beam 3:

[0030] like Figures 1-5 As shown, the cab floor 1, cab rear panel 2, and bottom support beam 3 are formed by vacuum bag molding; the vacuum bag molding process includes the following steps: S1. Connect the mold to the heating system, clean the mold, and evenly apply release agent to the working surface of the mold. The heating system is a water temperature controller. Specific steps are as follows: 1. Connect the heating system: Connect the mold to the water temperature controller heating system, ensuring the mold is heated evenly. 2. Clean the mold: Thoroughly clean the mold surface, removing dust, oil, and other impurities. 3. Apply release agent: Evenly apply release agent to the working surface of the mold, ensuring the release agent covers all areas to prevent the product from adhering to the mold.

[0031] S2. The prepared composite materials are laid flat on the working surface of the mold in sequence. The composite materials include glass mat and carbon fiber. During the laying process, ensure that the materials are flat and wrinkle-free.

[0032] S3. Lay a release cloth on the composite material, and the release cloth completely covers the composite material.

[0033] S4. Lay a layer of flow guide cloth on the release cloth, and then lay flow guide tubes on the flow guide cloth.

[0034] S5. Apply sealing strips around the flow guide cloth, release cloth and composite material. The sealing strips form a closed loop. After installation, the integrity and airtightness of the sealing strips must be checked.

[0035] S6. Lay the vacuum bag film on the release cloth, and attach the vacuum bag film to the sealing strip around the edges.

[0036] S7. Install the vacuum valve, quick connector and vacuum tube, then turn on the vacuum pump, check for leaks and test the vacuum level.

[0037] S8. After confirming that there is no air leakage and the vacuum degree meets the requirements, introduce the prepared resin. The resin impregnates the composite material. The resin is a mixture of 994# pre-accelerated phthalic unsaturated polyester resin and BUTANOX-M-50 peroxide methyl ethyl ketone. S9. Start the heating system and vacuum pump, and while drawing a vacuum, continuously extrude the composite material at the inside corner of the mold; S10. Demold after the product has completely cured.

[0038] Specifically, in the vacuum bag manufacturing process, the vacuuming pressure needs to be at least 10 MPa negative pressure during the vacuuming process.

[0039] Specifically, in step S9, the clamping tool 4 is used to extrude the composite material at the inside corner of the mold; like Figures 3-5As shown, the clamping tool 4 includes a clamping strip 41, which is triangular in shape. The line segment formed by the side of the clamping strip 41 in the vertical section is equidistant from the line segment formed in the vertical section at the inside corner of the mold. The equidistant distance is the thickness of the product. The clamping tool 4 is customized according to different board shapes so that it can adapt to the inside corners of various board shapes. A force-applying handle 42 is provided on the outward side of the clamping strip 41. The clamping strip 41 is made of rubber.

[0040] The specific steps of step S9 are as follows: Start the water temperature machine heating system to heat the composite material at a temperature of 60-80℃. The vacuum pump starts to evacuate the vacuum. During the evacuation process, hold the force application handle 42 and press the composite material at the inside corner of the mold from left to right until curing is complete. When the composite material is found to bulge at a certain position at the inside corner of the mold during the pressing process, immediately perform two compressions.

[0041] The purpose of squeezing the inside corner is to prevent resin from accumulating. When resin is impregnated, it will accumulate in the inside corner. In order to ensure that the thickness of each area of ​​the board is uniform, it is necessary to set up a clamping tool 4 to squeeze and flatten the resin at the inside corner.

[0042] The foregoing has shown and described the basic principles and main features of the present invention, as well as its advantages. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the present invention. Various changes and modifications can be made to the present invention without departing from its spirit and scope. All such changes and modifications fall within the scope of the present invention as claimed, which is defined by the appended claims and their equivalents.

Claims

1. A novel composite material truck cab, characterized in that: The cab includes a cab floor, a cab rear panel, and a bottom support beam. The bottom support beam is located on one side of the cab floor and surrounds the edge of the cab floor. The cab rear panel is set on the side wall of the cab floor and surrounds its edge. The cab floor and one side of the upper surface of the bottom support beam, the other side of the upper surface of the bottom support beam and the bottom of the cab rear panel, and the inward side of the bottom support beam and the outer side wall of the cab floor are connected by adhesive. The cab floor, cab rear panel, and bottom support beam form a sealed cavity. The cab floor, cab rear panel, and bottom support beam are made of composite material molded from a composite material consisting of 30-35% glass felt, 22-25% carbon fiber, 40-45% 994# pre-accelerated phthalic unsaturated polyester resin, and 1-2% BUTANOX-M-50 peroxide methyl ethyl ketone.

2. The novel composite material truck cab according to claim 1, characterized in that: The cab floor and the upper surface of the bottom support beam on one side, the upper surface of the bottom support beam on the other side, the bottom of the rear panel of the cab, and the inner side of the bottom support beam are connected to the outer wall of the cab floor using a two-component acrylic structural adhesive.

3. The novel composite material truck cab according to claim 1, characterized in that: The composite material consists of 32% glass mat, 24% carbon fiber, 43% 994# pre-accelerated phthalic unsaturated polyester resin and 1% BUTANOX M-50 peroxide methyl ethyl ketone.

4. The novel composite material truck cab according to claim 3, characterized in that: The thickness of the molded composite material for the cab floor, rear cab panel, and bottom support beam is 2.5mm-5mm, and the density is 1.65g / cm³.

5. The novel composite material truck cab according to claim 1, characterized in that: The cab floor, cab rear panel, and bottom support beam are formed by vacuum bag molding process. The vacuum bag molding process includes the following steps: S1. Connect the mold to the heating system, clean the mold, and apply release agent evenly to the working surface of the mold; S2. The prepared composite materials are laid flat on the working surface of the mold in sequence. The composite materials include glass mat and carbon fiber. S3. Lay a layer of release cloth on the composite material, and the release cloth completely covers the composite material; S4. Lay a layer of flow guide cloth on the release cloth, and then lay flow guide tubes on the flow guide cloth; S5. Apply sealing strips around the flow guide cloth, release cloth and composite material, forming a closed loop; S6. Lay the vacuum bag film on the release cloth, and attach the vacuum bag film to the sealing strip around the edges; S7. Install the vacuum valve, quick connector and vacuum tube, then turn on the vacuum pump, check for leaks and test the vacuum level. S8. After confirming that there is no air leakage and the vacuum degree meets the requirements, introduce the prepared resin. The resin impregnates the composite material. The resin is a mixture of 994# pre-accelerated phthalic unsaturated polyester resin and BUTANOX-M-50 peroxide methyl ethyl ketone. S9. Start the heating system and vacuum pump, and while drawing a vacuum, continuously extrude the composite material at the inside corner of the mold; S10. Demold after the product has completely cured.

6. A novel composite material truck cab according to claim 5, characterized in that: The vacuum bag process requires a vacuum pressure of at least 10 MPa during the vacuuming process.

7. A novel composite material truck cab according to claim 5, characterized in that: In step S9, a clamping tool is used to compress the composite material at the inside corner of the mold; The clamping tool includes a clamping strip, which is triangular in shape. The line segment formed by the side of the clamping strip in the vertical section and the line segment formed in the vertical section at the inside corner of the mold are equidistant from each other, and the equidistant distance is the thickness of the product.

8. A novel composite material truck cab according to claim 7, characterized in that: The outer side of the clamping strip is provided with a force application handle.

9. A novel composite material truck cab according to claim 7, characterized in that: The clamping strip is made of rubber.

10. A novel composite material truck cab according to claim 8, characterized in that: The specific steps of step S9 are as follows: Start the water temperature machine heating system to heat the composite material to a temperature of 60-80℃. The vacuum pump starts to evacuate the vacuum. During the evacuation process, hold the force application handle and press the composite material at the inside corner of the mold from left to right until curing is complete. When the composite material is found to bulge at a certain position at the inside corner of the mold during the pressing process, immediately perform two compressions.

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