Carbon fiber reinforced automobile rubber inflatable bumper and manufacturing method thereof

Abstract

The invention relates to a carbon fiber reinforced automobile rubber inflatable bumper and a manufacturing method thereof. The carbon fiber reinforced automobile rubber inflatable bumper comprises a shell, and an air storage cavity is formed in the shell; the shell wall of the shell comprises a shell framework, an airtight layer and an impact layer; the airtight layer is attached to the inner wall of the shell framework and defines a gas storage cavity, the impact layer is attached to the outer wall of the shell framework, the shell framework is made of a carbon fiber material, and the airtight layer and the impact layer are both made of a rubber material. During manufacturing, the shell framework is prefabricated by adopting a carbon fiber material; prefabricating a first rubber compound by adopting a first rubber raw material, and prefabricating a second rubber compound by adopting a second rubber raw material; and molding the first rubber compound and the second rubber compound, and performing vulcanization treatment to enable the first rubber compound to form an airtight layer and enable the second rubber compound to form an impact layer. The bumper is light in weight and good in impact resistance; by means of the manufacturing method, the rubber material which is not prone to creep deformation and high in strength can be obtained, so that the deformation resistance of the bumper is improved, and the service life of the bumper is prolonged.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automobile parts, in particular to a carbon fiber reinforced automobile rubber inflatable bumper and a manufacturing method thereof. BACKGROUND

[0002] With the development of automobile technology, in order to reduce the damage caused by vehicle impact to the occupants, bumper technology appears. The bumper is usually arranged at the front and rear of the vehicle body and is used to absorb and mitigate the impact force from the outside.

[0003] In the related art, the existing bumper is usually made of steel hard structure and rubber material. The above two types of bumpers can be arranged on the vehicle body to absorb and mitigate the impact force generated by the impact when the vehicle is impacted, thereby reducing the damage to the occupants.

[0004] However, the steel bumper described above is usually made of thick steel plate to improve the impact resistance, which results in a large weight. In addition, due to the rigidity of the steel structure, the energy absorption and buffering efficiency is limited when impacted. The existing inflatable bumper is usually made of ordinary rubber, which has relatively poor impact resistance and is prone to deformation. In addition, ordinary rubber material is prone to creep after long-term use, which causes the material to be easily deformed and the impact resistance to be greatly reduced. SUMMARY

[0005] Therefore, it is necessary to provide a carbon fiber reinforced automobile rubber inflatable bumper with light weight, strong impact resistance and less deformation and a manufacturing method thereof in view of the above problems.

[0006] In one aspect, the present application provides a carbon fiber reinforced automobile rubber inflatable bumper, which comprises:

[0007] a shell, wherein a gas storage cavity is arranged inside the shell; the shell wall of the shell comprises a shell framework, a gas tight layer and an impact layer; the gas tight layer is attached to the inner wall of the shell framework and forms the gas storage cavity, and the impact layer is attached to the outer wall of the shell framework; the shell framework is made of carbon fiber material, and the gas tight layer and the impact layer are both made of rubber material.

[0008] In some embodiments, the shell framework comprises a plurality of horizontal strips and a plurality of vertical strips, and the plurality of horizontal strips and the plurality of vertical strips are arranged in a cross shape to form a mesh structure; the horizontal strips and the vertical strips are attached to the gas tight layer, and the horizontal strips and the vertical strips are attached to the impact layer.

[0009] In some embodiments, the outer periphery of the horizontal strips and the vertical strips is provided with external threads; the surface of the gas tight layer and the impact layer facing the mesh structure is provided with an embedded groove, and the external threads are connected to the embedded groove.

[0010] In some embodiments, the carbon fiber reinforced automobile rubber inflatable bumper further comprises an air nozzle, at least one of the air-tight layer, the shell framework and the impact layer is connected with the air nozzle, the air nozzle penetrates through the air-tight layer, the shell framework and the impact layer in turn, and the gas storage cavity is in communication with the outside of the shell through the air nozzle.

[0011] In some embodiments, one side of the shell is provided with a connecting assembly, the connecting assembly comprises a bolt and a strap, the bolt is threadedly connected with the outer wall of the shell, and the strap is connected with the outer wall of the shell.

[0012] The carbon fiber reinforced automobile rubber inflatable bumper and the manufacturing method thereof, the shell of the carbon fiber reinforced automobile rubber inflatable bumper is composed of three layers, the outermost layer is the impact layer made of rubber, the middle layer is the shell framework composed of carbon fiber, and the innermost layer is the air-tight layer, and the gas storage cavity is formed in the air-tight layer. The air-tight layer and the impact layer are arranged in close contact with the shell framework, and the shell framework provides support for the impact layer and the air-tight layer, so that deformation of the impact layer and the air-tight layer is prevented. In use, the gas storage cavity stores gas, when impact occurs, the impact layer made of rubber can play a buffering effect, reducing the impact force on the shell framework and the air-tight layer, the shell framework provides support, reducing the deformation amount of the impact layer and the air-tight layer when impacted, and the gas in the gas storage cavity can absorb the impact energy. Through the above multi-layer structure, better anti-impact performance and anti-deformation performance can be provided, and the weight of rubber and carbon fiber is relatively light, facilitating installation and use.

[0013] On the other hand, the application provides a manufacturing method of a carbon fiber reinforced automobile rubber inflatable bumper, comprising the following steps:

[0014] A shell framework is prepared from carbon fiber material;

[0015] A first rubber raw material is used to prepare a first rubber compound, and a second rubber raw material is used to prepare a second rubber compound;

[0016] The first rubber compound is placed on the inner wall of the shell framework, the second rubber compound is placed on the outer wall of the shell framework, and the bumper is formed through a bumper forming mold, and after vulcanization treatment, the first rubber compound forms the air-tight layer on the inner wall of the shell framework, and the second rubber compound forms the impact layer on the outer wall of the shell framework.

[0017] In some embodiments, the rubber material used in the air-tight layer is the first rubber compound, and the first rubber raw material comprises butyl rubber; the rubber material used in the impact layer is the second rubber compound, and the second rubber raw material comprises chloroprene rubber;

[0018] The step of pre-forming the first compound from the first rubber raw material includes: placing the first rubber raw material into an open mill and plasticizing it to the roll-wrapped state; adding stearic acid, antioxidant and carbon black to the first rubber raw material in the roll-wrapped state in sequence; and mixing it evenly to obtain the first compound.

[0019] The step of pre-forming the second compound from the second rubber raw material includes: placing the second rubber raw material into an open mill and plasticizing it to the roll-wrapped state; adding stearic acid, antioxidant, carbon black and chopped carbon fibers to the roll-wrapped second rubber raw material in sequence, and mixing them evenly to obtain the second compound.

[0020] In some embodiments, the second rubber raw material is mixed with the chopped carbon fiber in the following weight parts: 100 parts of the second rubber raw material and 2-16 parts of the chopped carbon fiber.

[0021] In some embodiments, the vulcanization process includes: adding zinc oxide to the first compound and the second compound, and vulcanizing the first compound and the second compound for 15 min to 30 min at a temperature of 140℃-160℃ and a pressure of 10MPa-20MPa.

[0022] In some embodiments, the step of taking a prefabricated shell skeleton of carbon fiber material includes: forming a mesh structure of carbon fiber material by weaving or hot pressing.

[0023] The above-mentioned method for manufacturing carbon fiber reinforced automotive rubber inflatable bumpers, by using different rubber raw materials to form a compound, can obtain rubber materials that are not prone to creep and have good energy absorption effects. This can effectively improve the impact resistance and service life of the carbon fiber reinforced automotive rubber inflatable bumper. The carbon fiber reinforced automotive rubber inflatable bumper composed of rubber materials and carbon fiber materials has good impact resistance and service life. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall structure of a carbon fiber reinforced automotive rubber inflatable bumper according to an embodiment of this application.

[0025] Figure 2 This is a cross-sectional view along the plane containing the centerline of a carbon fiber reinforced automotive rubber inflatable bumper according to an embodiment of this application.

[0026] Figure 3 for Figure 2 Enlarged view of point A in the middle.

[0027] Figure 4 This is a schematic diagram of the shell skeleton on one side of the housing in a carbon fiber reinforced automotive rubber inflatable bumper according to an embodiment of this application.

[0028] Figure 5 for Figure 4 Enlarged view of point B in the middle.

[0029] Figure 6 This is a schematic diagram of the overall structure of a carbon fiber reinforced automotive rubber inflatable bumper according to an embodiment of this application, from another perspective.

[0030] Figure 7 This is a schematic flowchart illustrating a method for manufacturing a carbon fiber reinforced automotive rubber inflatable bumper according to an embodiment of this application.

[0031] Among them, 100 is the shell; 101 is the air storage cavity; 110 is the shell frame; 111 is the horizontal bar; 1111 is the external thread; 112 is the vertical bar; 120 is the airtight layer; 130 is the impact layer; 200 is the air nozzle; 300 is the connecting assembly; 310 is the strap; 320 is the mounting plate; and 321 is the mounting hole. Detailed Implementation

[0032] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0033] In the description of this application, it should be understood that if terms such as "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" appear, these terms indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and 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, and therefore should not be construed as a limitation of this application.

[0034] Furthermore, where the terms "first" and "second" appear, these terms are 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 with "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, where the term "multiple" appears, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0035] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "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 mechanical connection or an electrical connection; 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 based on the specific circumstances.

[0036] In this application, unless otherwise expressly specified and limited, the use of descriptions such as "above" or "below" the second feature indicates that the first and second features are in direct contact or indirect contact via an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. Similarly, "below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0037] It should be noted that if an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. If an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. If so, the terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used in this application are for illustrative purposes only and do not represent the only possible implementation.

[0038] See Figure 1 , Figure 2 and Figure 3 , Figure 1 This illustration shows an overall structural diagram of a carbon fiber reinforced automotive rubber inflatable bumper according to one embodiment of this application. Figure 2 A cross-sectional view of a carbon fiber reinforced automotive rubber inflatable bumper according to an embodiment of this application is shown. Figure 3 It shows Figure 2 Enlarged view at point A. On one hand, this application provides a carbon fiber reinforced automotive rubber inflatable bumper, comprising a housing 100, with an air storage cavity 101 formed inside the housing 100. The housing wall of the housing 100 includes a housing frame 110, an airtight layer 120, and an impact layer 130; the airtight layer 120 is attached to the inner wall of the housing frame 110 and encloses the air storage cavity 101, and the impact layer 130 is attached to the outer wall of the housing frame 110. The housing frame 110 is made of carbon fiber material, and both the airtight layer 120 and the impact layer 130 are made of rubber material.

[0039] like Figure 1 , Figure 2 and Figure 3 As shown, the shell frame 110 is made of carbon fiber, possessing a certain strength. The shell frame 110 provides support for the airtight layer 120 and the impact layer 130, facilitating their molding and installation, and ensuring that the structures of the airtight layer 120 and the impact layer 130 are not easily damaged during an impact. Both the airtight layer 120 and the impact layer 130 are made of rubber, possessing good elasticity and ease of molding. The airtight layer 120 is attached to the inner wall of the shell frame 110, forming an air storage cavity 101, which stores air and other gases to buffer the impact energy during a vehicle collision. The impact layer 130 is attached to the outer wall of the shell frame 110, forming the outer surface of this carbon fiber reinforced automotive rubber inflatable bumper, used to directly contact the impact surface during a vehicle collision to reduce the impact force.

[0040] It should be noted that the rubber materials used for the airtight layer 120 and the impact layer 130 can be ordinary rubber materials or composite rubber materials, etc. Among them, the airtight layer 120 has good airtightness and the impact layer 130 has good impact resistance.

[0041] This carbon fiber reinforced automotive rubber inflatable bumper is located at the front and rear of the vehicle. In the event of a frontal or rear-end collision, the impact layer 130 directly contacts the impact surface. Due to its elasticity, the impact layer 130 buffers the impact force, significantly reducing the impact force on the shell frame 110. The shell frame 110 then provides support for the impact layer 130, preventing it from damaging too quickly under impact. If the impact force is too great, causing deformation or damage to the shell frame 110, the shell frame 110 compresses the airtight layer 120 inward. The gas inside the airtight layer 120 buffers the impact force, reducing the impact on the occupants and mitigating their injuries.

[0042] This carbon fiber reinforced automotive rubber inflatable bumper is made of carbon fiber and rubber materials, which significantly reduces the weight compared to steel structures, making it easier to install and use. It is supported by a high-strength carbon fiber shell frame 110, which is not easily deformed. Together with the impact layer 130, the airtight layer 120, and the gas in the air storage chamber 101, it can provide a good cushioning effect, effectively reducing the impact on passengers and mitigating the injuries they suffer in a collision.

[0043] Furthermore, the thickness of the impact layer 130 can be adjusted according to the vehicle's usage. A thicker impact layer 130 provides better impact resistance. For example, if a vehicle model generates a smaller impact force, a carbon fiber reinforced inflatable rubber bumper with a thinner impact layer 130 can be selected to reduce overall weight. Conversely, if a vehicle model generates a larger impact force, a carbon fiber reinforced inflatable rubber bumper with a thicker impact layer 130 can be selected to effectively protect the safety of passengers.

[0044] like Figure 2 , Figure 3 and Figure 4 As shown, in some embodiments, the shell skeleton 110 includes a plurality of horizontal bars 111 and a plurality of vertical bars 112, which are arranged intersectingly to form a mesh structure. Both the horizontal bars 111 and the vertical bars 112 are attached to the airtight layer 120, and both the horizontal bars 111 and the vertical bars 112 are attached to the impact layer 130.

[0045] Horizontal bars 111 and vertical bars 112 are arranged perpendicularly to each other to form a mesh structure, thereby forming the shell skeleton 110. This reduces the overall weight of the shell skeleton 110 while providing it with better stability. Both horizontal bars 111 and vertical bars 112 are attached to the airtight layer 120, thus providing a more uniform support force to the airtight layer 120 and preventing any area of ​​the airtight layer 120 from receiving insufficient support and becoming easily damaged. Similarly, both horizontal bars 111 and vertical bars 112 are attached to the impact layer 130, providing a more uniform support force to the impact layer 130 and preventing any area of ​​the impact layer 130 from receiving insufficient support and becoming easily damaged.

[0046] It should be noted that the horizontal bars 111 and the vertical bars 112 can also form acute or obtuse angles, as long as the horizontal bars 111 and the vertical bars 112 are arranged to intersect and form a mesh structure. In addition, the strength of the shell skeleton 110 can be adjusted by adjusting the size of the holes formed between the horizontal bars 111 and the vertical bars 112, which can be adjusted according to the needs of use.

[0047] like Figure 4 and Figure 5 As shown, in some embodiments, the outer periphery of both the horizontal bar 111 and the vertical bar 112 is provided with external threads 1111; the surfaces of the airtight layer 120 and the impact layer 130 facing the mesh structure are provided with embedded grooves (not shown in the figure), and the external threads 1111 are engaged in the embedded grooves.

[0048] The external thread 1111 extends helically along the length of the horizontal bar 111 or vertical bar 112 it is located in. The external thread is engaged with the side wall of the internal and external threads 1111 of the embedding groove and abuts against the inner wall of the embedding groove. This can restrict the movement of the airtight layer 120 and the shell frame 110 along the length of the horizontal bar 111 and the vertical bar 112. Similarly, it can also restrict the movement of the impact layer 130 and the shell frame 110 along the length of the horizontal bar 111 and the vertical bar 112. The above configuration can effectively improve the stability of the connection between the airtight layer 120 and the impact layer 130 and the shell frame 110, and prevent the airtight layer 120 and the impact layer 130 and the shell frame 110 from shifting or misaligning during use.

[0049] It should be noted that the external thread 1111 can be located in a specific position, such as the outer periphery of a section of the horizontal bar 111 or the outer periphery of a section of the vertical bar 112. Alternatively, the outer periphery of both the horizontal bar 111 and the vertical bar 112 can be provided with external threads 1111, as long as the airtight layer 120 and the impact layer 130 are stable relative to the shell frame 110. In addition, since the airtight layer 120 and the impact layer 130 are both made of rubber and have a certain degree of elasticity, pressure can be directly applied to the airtight layer 120 and the impact layer 130 towards the shell frame 110 during the machining of the embedding groove, so that the external thread 1111 is embedded into the surface of the airtight layer 120 and the impact layer 130, thereby forming an embedding groove on the surface of the airtight layer 120 and the impact layer 130. This can effectively improve production efficiency and the compatibility between the external thread 1111 and the embedding groove.

[0050] like Figure 1 , Figure 2 and Figure 6 As shown, in some embodiments, the carbon fiber reinforced automotive rubber inflatable bumper also includes an air nozzle 200, at least one of the airtight layer 120, shell frame 110 and impact layer 130 connected to the air nozzle 200, the air nozzle 200 passing through the airtight layer 120, shell frame 110 and impact layer 130 in sequence, and the air storage cavity 101 communicating with the outside of the housing 100 through the air nozzle 200.

[0051] The air nozzle 200 sequentially penetrates the airtight layer 120, the shell frame 110, and the impact layer 130. The airtight layer 120, the shell frame 110, and the impact layer 130 are all connected to the side wall of the air nozzle 200 to fix the air nozzle 200. Air can be injected into the air storage chamber 101 through the air nozzle 200, and gas in the air storage chamber 101 can also be discharged through the air nozzle 200, thereby adjusting the gas pressure in the air storage chamber 101 to obtain a suitable impact resistance effect.

[0052] like Figure 1 and Figure 6As shown, in some embodiments, a connecting assembly 300 is provided on one side of the housing 100. The connecting assembly 300 includes a bolt (not shown) and a strap 310. The bolt is threaded to the outer wall of the housing 100, and the strap 310 is connected to the outer wall of the housing 100.

[0053] The straps 310 and bolts are both located on the side of the housing 100 closest to the vehicle to facilitate connection with structures on the vehicle used for mounting the bumper (such as crossbeams, mounting brackets, etc.), thereby securing the carbon fiber reinforced automotive rubber inflatable bumper. Specifically, bumper mounting brackets are located at the front and rear of the vehicle, and the straps 310 are attached to the mounting brackets to connect and fix the housing 100 to the mounting brackets. The surface of the housing 100 is also provided with mounting plates 320 and mounting holes 321. Bolts mate with the mounting holes 321, meaning that the bolts simultaneously pass through the mounting holes 321 and the holes on the mounting brackets to install the carbon fiber reinforced automotive rubber inflatable bumper in the designated position on the vehicle.

[0054] like Figure 7 As shown, on the other hand, this application provides a method for manufacturing the aforementioned carbon fiber reinforced automotive rubber inflatable bumper, which includes the following steps:

[0055] Step S101: A prefabricated shell skeleton 110 made of carbon fiber material is adopted.

[0056] Step S102: Use the first rubber raw material to pre-prepare the first compound, and use the second rubber raw material to pre-prepare the second compound.

[0057] In step S103, the first compound is placed on the inner wall of the shell frame 110, the second compound is placed on the outer wall of the shell frame 110, and the mixture is formed by a bumper molding mold. After vulcanization, the first compound forms an airtight layer 120 on the inner wall of the shell frame 110, and the second compound forms an impact layer 130 on the outer wall of the shell frame 110.

[0058] like Figure 1 , Figure 2 and Figure 7As shown, carbon fiber material is processed to form the overall structure of the shell skeleton 110. The formed shell skeleton 110 structure is reserved for future use. It should be noted that the carbon fiber material can be processed by pressing or cutting. The first rubber raw material is mixed with the corresponding compounding agent and processed through a refining process to obtain the first compound. Similarly, the second rubber raw material is mixed with the corresponding compounding agent and processed through a refining process to obtain the second compound. The obtained first compound is attached to one side of the inner wall of the shell skeleton 110 and is used to form the airtight layer 120. The second compound is attached to one side of the outer wall of the shell skeleton 110 and is used to form the impact layer 130. It should be noted that the shell skeleton 110, the first compound, and the second compound obtained in the above steps are arranged according to their corresponding positional relationship, that is, from the inside to the outside, the first compound corresponding to the airtight layer 120, the shell skeleton 110, and the second compound corresponding to the impact layer 130. The compound is attached to the shell skeleton 110. The rubber compound and the shell skeleton 110 are placed together in the bumper molding mold, and the first rubber compound and the second rubber compound are formed into an airtight layer 120 and an impact layer 130 respectively through vulcanization treatment.

[0059] It should be noted that the finished carbon fiber reinforced automotive rubber inflatable bumper can be obtained directly through the above steps, or it can be obtained by combining other processing operations (such as deburring, fine finishing, etc.) during or after the above steps; no specific restrictions are placed here. Furthermore, the first rubber raw material and the second rubber raw material can be the same rubber raw material; no restrictions are placed on the specific composition of the first rubber raw material and the second rubber raw material. The inner wall of the shell frame 110 is the side wall of the shell frame 110 near the air storage cavity 101, and the outer wall of the shell frame 110 is the side wall of the shell frame 110 facing away from the air storage cavity 101.

[0060] The above-mentioned method for manufacturing carbon fiber reinforced automotive rubber inflatable bumpers involves processing rubber raw materials to form a compound, which yields a rubber material that is not prone to creep and has good energy absorption. The resulting airtight layer and impact layer have good impact resistance and a longer service life. The carbon fiber reinforced automotive rubber inflatable bumper composed of such rubber material and carbon fiber material has good cushioning and impact resistance.

[0061] In some embodiments, the airtight layer 120 uses a first compound rubber material, the first rubber raw material including butyl rubber; the impact layer 130 uses a second compound rubber material, the second rubber raw material including chloroprene rubber. The step of pre-preparing the first compound rubber using the first rubber raw material includes: placing the first rubber raw material on an open mill and plasticizing it to a roll-wrapped state; sequentially adding stearic acid, antioxidant, and carbon black to the roll-wrapped first rubber raw material; and uniformly mixing to obtain the first compound rubber. The step of pre-preparing the second compound rubber using the second rubber raw material includes: placing the second rubber raw material on an open mill and plasticizing it to a roll-wrapped state; sequentially adding stearic acid, antioxidant, carbon black, and chopped carbon fibers to the roll-wrapped second rubber raw material; and uniformly mixing to obtain the second compound rubber.

[0062] The first compound is used to form the airtight layer 120, and the second compound is used to form the impact layer 130. The process of preparing the compound is as follows: both the first and second rubber raw materials are plasticized using an open mill to bring them to a roll-wrapped state. Stearic acid, an antioxidant, and carbon black are sequentially added to the roll-wrapped first rubber raw material and uniformly mixed to obtain the first compound. Stearic acid, an antioxidant, carbon black, and chopped carbon fibers are sequentially added to the roll-wrapped second rubber raw material and uniformly mixed to obtain the second compound. Stearic acid is used as an accelerator, and carbon black as a reinforcing agent to modify the relevant properties of the rubber raw materials and facilitate subsequent processing. Since the second rubber raw material is used to prepare the second compound to form the impact layer 130, and the impact layer 130 needs to have a certain strength, chopped carbon fibers can be added to the roll-wrapped second rubber raw material during the preparation of the second compound. The chopped carbon fibers can provide a certain strength to the subsequently formed impact layer 130, thereby improving the impact resistance of the impact layer 130 to a certain extent. The first rubber raw material is butyl rubber. The first compound prepared by the above method can obtain an airtight layer 120 structure with good airtightness through vulcanization. The second rubber raw material is chloroprene rubber. The second compound prepared by the above method can obtain an impact layer 130 structure with good impact resistance through vulcanization. Thus, the required rubber materials can be obtained through the above method to form the airtight layer 120 and the impact layer 130.

[0063] It should be noted that the use of butyl rubber as the first rubber material and chloroprene rubber as the second rubber material is only one feasible embodiment. The selected rubber material only needs to ensure that the final airtight layer 120 with good air tightness (ensuring that the air storage cavity 101 does not leak or the amount of leakage meets the standard) and the impact layer 130 with good impact resistance are formed. That is, the first rubber material can be butyl rubber but is not limited to butyl rubber, and the second rubber material can be chloroprene rubber but is not limited to chloroprene rubber.

[0064] Furthermore, in the above preparation process, the weight ratio of stearic acid, antioxidant, carbon black and the first or second rubber raw material is as follows: 1-3 parts stearic acid, 1-3 parts antioxidant, 30-40 parts carbon black, and 100 parts of the first or second rubber raw material, so as to facilitate the subsequent processing and molding of the compound.

[0065] In some embodiments, the second rubber material is mixed with chopped carbon fibers in the following weight proportions: 100 parts of the second rubber material and 2-16 parts of chopped carbon fibers.

[0066] It should be noted that chopped carbon fibers can form rigid support points within the rubber material, inhibiting the slippage of rubber molecular chains, thereby reducing creep and improving the material's strength, toughness, and tear resistance. Tests have shown that when the added chopped carbon fiber weight is less than 2 parts, the effect of reducing creep and improving strength is not significant compared to not adding chopped carbon fibers. However, when the added chopped carbon fiber weight exceeds 16 parts, the rubber material tends to agglomerate, reducing its elasticity, which is detrimental to subsequent molding operations and results in poor cushioning performance. Therefore, the above-described method, as a preferred embodiment, can prepare a compound that meets production requirements.

[0067] Furthermore, the chopped carbon fibers added to the second rubber raw material in the roll-wrapping state can be replaced with carbon fiber powder, or a mixture of carbon fiber powder and chopped carbon fibers, which can also achieve the effect of improving the strength of the rubber material. The length of the chopped carbon fibers and carbon fiber powder can be 0.01mm-50mm, the diameter can be 0.001mm-10mm, the thickness can be 0.001mm-3mm, and the width can be 0.01mm-3mm. It should be noted that the size of the chopped carbon fibers is determined according to the thickness of the impact layer 130, that is, each dimension of the chopped carbon fibers does not exceed the thickness of the impact layer 130, so as to avoid the chopped carbon fibers forming protrusions on the outside of the impact layer 130 after the impact layer 130 is formed, which would cause inconvenience in installation and use.

[0068] In some embodiments, the vulcanization process includes: adding zinc oxide to the first compound and the second compound, and vulcanizing the first compound and the second compound for 15 min to 30 min at a temperature of 140℃-160℃ and a pressure of 10MPa-20MPa.

[0069] Through the above-described vulcanization process, the first and second rubber compounds can be molded to form an airtight layer 120 and an impact layer 130. Before vulcanizing the first and second rubber compounds, zinc oxide is added to them as a vulcanization activator and reinforcing agent, facilitating subsequent vulcanization. The first and second rubber compounds are then pressed into sheets to form the sheet-like airtight layer 120 and impact layer 130. In some preferred embodiments, the treated first and second rubber compounds, along with the shell skeleton 110, are placed in a mold and vulcanized for 20 minutes at a temperature of 150°C and a pressure of 15 MPa, causing the first rubber compound to form the airtight layer 120 and the second rubber compound to form the impact layer 130, thus ultimately obtaining the overall structure of this carbon fiber reinforced automotive rubber inflatable bumper. Furthermore, the weight ratio of zinc oxide to the first or second rubber raw material is 2-5 parts zinc oxide to 100 parts first or second rubber raw material, which can provide a better activation effect for the vulcanizing agent.

[0070] In some embodiments, the step of using a prefabricated carbon fiber skeleton 110 includes: forming a mesh structure from the carbon fiber material by weaving or hot pressing. These steps enable the carbon fiber material to be shaped for subsequent use with a compound.

[0071] Furthermore, after the carbon fiber material is processed into a mesh structure, it can be impregnated into a matrix such as resin to form a prepreg, that is, the outside of the carbon fiber mesh structure is covered with resin. Then the prepreg is cured to cure the resin on the surface of the carbon fiber material, thereby effectively enhancing the overall strength of the shell skeleton 110.

[0072] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0073] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A carbon fiber reinforced automotive rubber inflatable bumper, characterized in that, include: The shell has an internal air storage cavity; the shell wall includes a shell frame, an airtight layer and an impact layer; the airtight layer is attached to the inner wall of the shell frame and surrounds the air storage cavity, the impact layer is attached to the outer wall of the shell frame, the shell frame is made of carbon fiber material, and the airtight layer and the impact layer are both made of rubber material.

2. The carbon fiber reinforced automotive rubber inflatable bumper according to claim 1, characterized in that, The shell skeleton includes multiple horizontal bars and multiple vertical bars, which are intersected to form a mesh structure; both the horizontal bars and the vertical bars are attached to the airtight layer and the impact layer.

3. The carbon fiber reinforced automotive rubber inflatable bumper according to claim 2, characterized in that, The outer periphery of both the horizontal and vertical bars is provided with external threads; the surfaces of the airtight layer and the impact layer facing the mesh structure are provided with embedded grooves, and the external threads are engaged in the embedded grooves.

4. The carbon fiber reinforced automotive rubber inflatable bumper according to claim 1, characterized in that, It also includes an air nozzle, at least one of the airtight layer, the shell frame and the impact layer is connected to the air nozzle, the air nozzle passes through the airtight layer, the shell frame and the impact layer in sequence, and the air storage cavity is connected to the outside of the shell through the air nozzle.

5. The carbon fiber reinforced automotive rubber inflatable bumper according to claim 1, characterized in that, A connecting assembly is provided on one side of the housing. The connecting assembly includes a bolt and a strap. The bolt is threaded to the outer wall of the housing, and the strap is connected to the outer wall of the housing.

6. A method for manufacturing a carbon fiber reinforced automotive rubber inflatable bumper, characterized in that, Includes the following steps: A prefabricated shell frame made of carbon fiber material was adopted; The first rubber compound is prepared by using the first rubber raw material, and the second rubber compound is prepared by using the second rubber raw material. The first compound is placed on the inner wall of the shell frame, and the second compound is placed on the outer wall of the shell frame. The mixture is then formed using a bumper molding mold. After vulcanization, the first compound forms the airtight layer on the inner wall of the shell frame, and the second compound forms the impact layer on the outer wall of the shell frame.

7. The manufacturing method according to claim 6, characterized in that, The airtight layer uses the first compound rubber as the rubber material, and the first rubber raw material includes butyl rubber; the impact layer uses the second compound rubber as the rubber material, and the second rubber raw material includes chloroprene rubber. The step of pre-forming the first compound from the first rubber raw material includes: placing the first rubber raw material into an open mill and plasticizing it to the roll-wrapped state; adding stearic acid, antioxidant and carbon black to the first rubber raw material in the roll-wrapped state in sequence; and mixing it evenly to obtain the first compound. The step of pre-forming the second compound from the second rubber raw material includes: placing the second rubber raw material into an open mill and plasticizing it to the roll-wrapped state; adding stearic acid, antioxidant, carbon black and chopped carbon fibers to the roll-wrapped second rubber raw material in sequence, and mixing them evenly to obtain the second compound.

8. The manufacturing method according to claim 7, characterized in that, The second rubber raw material and the chopped carbon fiber are mixed in the following weight proportions: 100 parts of the second rubber raw material and 2-16 parts of the chopped carbon fiber.

9. The manufacturing method according to claim 6, characterized in that, The vulcanization process includes: adding zinc oxide to the first compound and the second compound, and vulcanizing the first compound and the second compound for 15 min to 30 min at a temperature of 140℃-160℃ and a pressure of 10MPa-20MPa.

10. The manufacturing method according to claim 6, characterized in that, The step of using carbon fiber prefabricated shell skeleton includes: using weaving or hot pressing to form the carbon fiber material into a mesh structure.

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