Carbon fiber composite material hub assembly, forming mold and forming method

Abstract

The invention provides a carbon fiber composite hub assembly for an automobile, a forming mold and a forming method. A hub comprises a spoke, a rim and center aluminum, and the spoke comprises spokes and hollow areas between the adjacent spokes; the central aluminum is arranged in the center of the spoke; the spoke comprises a first SMC layer, a first continuous carbon fiber layer, a second SMC layer, a second continuous carbon fiber layer and a third SMC layer which are sequentially arranged, and the first SMC layer serves as an appearance layer; the rim comprises a third continuous carbon fiber layer and a sixth SMC layer which are arranged from inside to outside; the raw material weight ratio of the continuous carbon fibers to the SMC layer is (1: 2)-(1: 2.3); and the spoke and the rim are co-cured and molded through a set of molds. According to the scheme, through the structural design, on the basis that the structural performance of the hub assembly is met, light weight is achieved, the production cost is reduced, and industrialization can be achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of composite materials, and particularly relates to a carbon fiber composite material hub assembly, a forming die and a forming method. BACKGROUND

[0002] In recent years, traditional automobile hubs are mostly made of metal forging, casting and other processes, which have no obvious effect on overall weight reduction and cannot be significantly lightweighted. Carbon fiber has higher specific strength and specific stiffness than aluminum, steel, cast iron and other metal materials, and is lighter in weight, which is suitable for lightweighting of automobile products, can reduce carbon emissions of fuel vehicles and increase the endurance of electric vehicles. The carbon fiber composite material hub assembly disclosed in the prior art mainly has two technical problems, one is insufficient lightweighting, and the other is unable to meet the mechanical properties of the hub assembly. For example: The prior art discloses a method for manufacturing a coated carbon fiber aluminum alloy hub, discloses a hub coated with carbon fiber material on the outer surface of the aluminum alloy hub, and the main material is still aluminum alloy, which has no obvious weight reduction.

[0003] The prior art also discloses a full-carbon fiber hub, which comprises a hub, left and right sides of the hub are fixedly installed with rims, an enhanced ring is added inside the left and right side rims, a spoke is installed in the hub, and a metal ring gasket is added at the locking position of the spoke and the rim. The utility model enhances the overall rigidity of the hub and improves the durability by adding two enhanced rings at the rim part and adding a metal ring gasket at the locking part of the rim and the spoke. In this scheme, the spoke and the rim are not integrally formed, the spoke is installed on the rim through bolts, the strength at the bolt connection is insufficient, and the spoke is prone to cracking. SUMMARY

[0004] The present application aims to provide a carbon fiber composite material hub assembly, a forming die and a forming method to solve the problem of insufficient local mechanical properties of the carbon fiber composite material hub.

[0005] To solve the above technical problems, the present application provides a carbon fiber composite material hub for automobile, comprising spokes, a rim, and a center aluminum; the spokes comprise spokes and hollowed areas between adjacent spokes; the center aluminum is arranged at the center of the spokes and is used for mounting and connecting the hub assembly and the vehicle body; the spokes and the rim each comprise a continuous carbon fiber layer and an SMC layer; the spokes comprise a first SMC layer, a first continuous carbon fiber layer, a second SMC layer, a second continuous carbon fiber layer, and a third SMC layer arranged in sequence, and the first SMC layer serves as an appearance layer; the rim comprises a third continuous carbon fiber layer and a sixth SMC layer arranged from inside to outside; the inner side of the third continuous carbon fiber layer of the rim is provided with a fourth SMC layer at one end of a profile surface of the hub assembly, and the outer side of the third continuous carbon fiber layer is provided with a fifth SMC layer at one end of an outer contour surface of the hub assembly; the weight ratio of the continuous carbon fiber layer and the SMC layer is 1:2-1:2.3; and the rim and the spokes are co-cured and formed.

[0006] In another embodiment, the first continuous carbon fiber layer and the second continuous carbon fiber layer are arranged in a U shape on the cross section of the spoke.

[0007] In another embodiment, a carbon fiber winding belt is arranged along the spoke hollowed area between the first continuous carbon fiber layer and the second SMC layer of the spoke.

[0008] In another embodiment, the first continuous carbon fiber layer and the second continuous carbon fiber layer are connected on both sides of the spoke.

[0009] In another embodiment, a triangular area is arranged at the position corresponding to the spoke root of the spoke.

[0010] In another embodiment, the center aluminum comprises a body and a flange, and the flange is arranged between the first SMC layer and the first continuous carbon fiber layer.

[0011] In another embodiment, a glass fiber layer is further arranged on the surface of the center aluminum.

[0012] In a second aspect, the present application provides a forming mold for a composite material hub assembly for automobile, comprising an upper mold, a lower mold, and a side slide block; the upper mold is provided with a mold cavity for forming a spoke; and the lower mold and the side slide block cooperate to form a mold cavity for a rim.

[0013] In a third aspect, the present application provides a forming method for a composite material hub for automobile, comprising: S1, laying a spoke preform and a rim preform on the upper mold and the lower mold of the forming mold, respectively; S2, closing the upper mold on which the spoke preform is laid and the lower mold on which the rim preform is laid, then circumferentially winding a sheet of the sixth SMC layer on the entire width of the rim preform, and then integrally closing the side slide block with the upper mold and the lower mold; S3, compression molding; S4, post-processing.

[0014] In another embodiment, the step S1 of preparing the spoke comprises the following steps: Preparation of the spoke preform: in the upper die of the hub forming die, lay the first SMC layer sheet, and make the first SMC layer sheet arranged in U shape on the cross section of the spoke; place the center aluminum at the center position of the first SMC layer sheet, and make the flange of the center aluminum adhere to the first SMC layer sheet; continue to lay the first continuous carbon fiber layer sheet on the first SMC layer sheet, and make the first continuous carbon fiber layer sheet arranged in U shape on the cross section of the spoke, and make the sheet end near the center aluminum adhere to the flange of the center aluminum and the outer side of the main body of the center aluminum; make the sheet end far from the center aluminum arranged as a reserved section, and suspended outside the die; lay the carbon fiber winding tape along the hollow area of the spoke on the first continuous carbon fiber layer sheet; then lay the second SMC layer sheet on the first continuous carbon fiber layer sheet and the continuous carbon fiber; continue to lay the second continuous carbon fiber layer sheet on the second SMC layer sheet, and make the second continuous carbon fiber layer sheet arranged in U shape on the cross section of the spoke, and make the sheet end near the center aluminum adhere to the sheet end of the first continuous carbon fiber layer; lay the third SMC layer sheet on the second continuous carbon fiber layer sheet; and compact the whole lay-up.

[0015] Preparation of the rim preform: lay the fourth SMC layer sheet on one end of the hub assembly profile surface of the lower die of the hub forming die; then lay the third continuous carbon fiber layer sheet on the whole width of the rim, and make a reserved section arranged on one end of the hub assembly profile surface; lay the fifth SMC layer sheet on the third continuous carbon fiber layer on one end of the rim profile surface; and fold the reserved section of the third continuous carbon fiber layer sheet to cover outside the fifth SMC layer sheet.

[0016] Compared with the prior art, the carbon fiber composite hub for automobile has the following beneficial effects: (1) in the whole hub structure, except the center aluminum, the rest of the structure is formed by carbon fiber composite material, and the lightweight effect is obvious, and the weight is reduced by about 30-40% compared with cast aluminum material; (2) the spoke and the rim are co-cured, which avoids the defects of stress concentration caused by bolt fixing in the prior art, and the mechanical properties are more excellent; (3) SMC and continuous carbon fiber are combined, and through structural design, the hub can reduce the cost on the basis of meeting the structural performance; (4) the spoke and the rim are preformed, and then co-cured in the die, which can improve the production rhythm and production efficiency. BRIEF DESCRIPTION OF DRAWINGS

[0017] ATTACHMENT Figure 1 is a schematic view of the hub assembly structure; ATTACHMENTFigure 2 It is a schematic view of the front structure of the hub assembly; Figure 1 is a schematic view of the hub assembly; Figure 3 It is a schematic view of the A-A section structure of the hub assembly; Figure 2 is a schematic view of the B-B section structure of the hub assembly; Figure 4 It is a schematic view of the B-B section structure of the hub assembly; Figure 3 is a schematic view of the center aluminum structure; Figure 5 Figure 4 is a schematic view of the spoke preform section; Figure 5 is an enlarged view of the I part; Figure 6 Figure 6 is a schematic view of the rim preform section; Figure 7 is a schematic view of the rim preform section; Figure 7 Figure 8 is a schematic view of the hub assembly forming die structure; Figure 9 is a schematic view of the hub assembly forming die structure; Figure 8 Figure 10 is a schematic view of the hub assembly forming die structure; Figure 11 is a schematic view of the hub assembly forming die structure; Figure 9 Figure 12 is a schematic view of the hub assembly forming die structure; Wherein: 1-spoke; 11-spoke; 111-triangle area; 12-hollow area; 13-first SMC layer; 14-first continuous carbon fiber layer; 15-carbon fiber winding belt; 16-second SMC layer; 17-second continuous carbon fiber layer; 18-third SMC layer; 19-glass fiber layer; 2-rim; 21-fourth SMC layer; 22-third continuous carbon fiber layer; 23-fifth SMC layer; 24-sixth SMC layer; 3-center aluminum; 31-body; 32-flange; 4-upper die; 5-lower die; 6-side slide. DETAILED DESCRIPTION

[0018] In order to make the technical problems, technical solutions and beneficial effects of the present application clearer, the present application will be described in detail below in combination with the drawings and examples. Obviously, the described examples are part of the examples of the present application, not all examples. Based on the examples in the present application, all other examples obtained by those skilled in the art without creative labor belong to the scope of protection of the present application.

[0019] In the description of the present embodiment, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present embodiment and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, therefore cannot be understood as a limitation of the present embodiment.

[0020] In the present application, the following definitions are made: Hub assembly outer contour surface: refers to the end surface of the hub assembly towards the inside of the car when installed on the car.

[0021] The embodiments of the present application will be described below in combination with the drawings.

[0022] Referring to the accompanying drawings Figures 1-8 , a composite material wheel hub assembly for automobile is shown, comprising spoke 1, rim 2, center aluminum 3; the spoke 1 comprises spoke 11 and hollow area 12 between adjacent spokes 11; the spoke 1 and the rim 2 both comprise continuous carbon fiber layer and SMC layer; the spoke 1 comprises first SMC layer 13, first continuous carbon fiber layer 14, second SMC layer 16, second continuous carbon fiber layer 17, third SMC layer 18, the first SMC layer 13 as the appearance surface layer; the rim 2 comprises third continuous carbon fiber layer 22 and sixth SMC layer 24 arranged from inside to outside; the inner side of the third continuous carbon fiber layer 22 of the rim is provided with fourth SMC layer 21 at one end of the profile surface of the wheel hub assembly, and the outer side of the third continuous carbon fiber layer 22 is provided with fifth SMC layer 23 at one end of the outer contour surface of the wheel hub assembly; the weight ratio of the continuous carbon fiber layer and the SMC layer is 1:2~1:2.3; the rim and the spoke are co-cured and formed.

[0023] Referring to the accompanying drawings Figure 4 , the first continuous carbon fiber layer 14 and the second continuous carbon fiber layer 17 are arranged in U shape on the cross section of the spoke 1; the first continuous carbon fiber layer 14 and the second continuous carbon fiber layer 17 are connected on both sides of the spoke 1; the carbon fiber winding belt 15 is arranged along the circumferential direction of the hollow area 12 of the spoke 1 between the first continuous fiber layer 14 and the second SMC layer 16.

[0024] Referring to the accompanying drawings Figures 1-2 , the spoke 1 is provided with triangular area 111 corresponding to the position of the spoke 11.

[0025] The fiber direction of the first continuous carbon fiber layer 14 and the second continuous carbon fiber layer 17 is arranged along the length direction of the spoke.

[0026] Referring to the accompanying drawings Figure 3 , the rim 2 comprises third continuous carbon fiber layer 22 and sixth SMC layer 24 arranged from inside to outside; the inner side of the third continuous carbon fiber layer 22 is provided with fourth SMC layer 21 at one end of the profile surface of the wheel hub assembly; the outer side of the third continuous carbon fiber layer 22 is provided with fifth SMC layer 23 at one end of the outer contour surface of the wheel hub assembly; the tail end of the third continuous carbon fiber layer 22 is folded and wrapped outside the fifth SMC layer 23.

[0027] The fiber direction of the third continuous carbon fiber layer 22 is arranged along the circumferential direction of the rim 2.

[0028] Referring to the accompanying drawings, the center aluminum 3 comprises body 31 and flange 32, and the flange 32 is arranged between the first SMC layer 13 and the first continuous carbon fiber layer 14.

[0029] Referring to the accompanying drawings, the first continuous carbon fiber layer 14 is partially connected to the body 31 of the central aluminum 3. The second continuous carbon fiber layer 17 is bonded to the first continuous carbon fiber layer 14 at one end near the central aluminum 3.

[0030] A fiberglass layer is also provided on the surface of the central aluminum 3.

[0031] The aforementioned carbon fiber composite wheel assembly underwent a 13° impact simulation analysis of the spoke and valve positions according to GB / T 15704-2012 / ISO 7141:2005 "Impact Test Method for Light Alloy Wheels of Road Vehicles", which showed no fracture failure. The wheel assembly was also subjected to a 90° impact simulation analysis of the spoke and valve positions according to QC / T 991-2015 "90° Impact Test for Light Alloy Wheels of Passenger Cars", which showed no fracture failure.

[0032] See appendix Figure 9 As shown, the molding die for the carbon fiber composite wheel hub is shown, including an upper die 4, a lower die 5 and a side slider 6; the upper die 4 is provided with a cavity for forming the spokes 1, and the lower die 5 and the side slider 6 are provided with a cavity for forming the rim 2.

[0033] The molding method of the above-mentioned carbon fiber composite wheel assembly includes: S1. Prepare the spoke preform and the rim preform in the upper and lower molds of the forming mold, respectively; S2. Close the upper mold for laying the spoke preform and the lower mold for laying the rim preform, and circumferentially wind the material of the sixth SMC layer on the rim preform across its entire width. Then close the side slider with the upper and lower molds as a whole. S3, Compression molding; S4, Post-processing.

[0034] Specifically, step S1 includes: S11, on the upper die of the hub assembly forming die, lay the first SMC layer sheet, so that the first SMC layer sheet is arranged in U shape on the cross section of the spoke; place the center aluminum at the center position of the first SMC layer sheet, and the flange of the center aluminum is attached to the first SMC layer sheet; continue to lay the first continuous carbon fiber layer sheet on the first SMC layer sheet, so that the first continuous carbon fiber layer sheet is arranged in U shape on the cross section of the spoke, and the end of the sheet close to the center aluminum is attached to the flange of the center aluminum and the outer side of the center aluminum body; on the first continuous carbon fiber layer, the carbon fiber winding belt is arranged in the circumferential direction along the hollow area of the spoke; then lay the second SMC layer sheet; lay the second continuous carbon fiber layer sheet on the second SMC layer sheet, so that the second continuous carbon fiber layer sheet is arranged in U shape on the cross section of the spoke, and the end of the sheet close to the center aluminum is attached to the end of the first continuous carbon fiber layer sheet; lay the third SMC layer sheet on the second continuous carbon fiber layer sheet, and compact the whole layer; S12, on the lower die of the hub assembly forming die, lay the fourth SMC layer sheet at one end of the hub assembly forming surface; then lay the third continuous carbon fiber layer sheet on the entire width of the rim, and set a reserved section at one end of the outer contour surface of the hub assembly; then lay the fifth SMC layer sheet on the outside of the third continuous carbon fiber layer sheet at one end of the outer contour surface of the hub assembly; fold the reserved section of the third continuous carbon fiber layer sheet to cover the fifth SMC layer.

[0035] Step S2 includes: first, the upper die for laying the spoke preform is combined with the lower die for laying the rim preform, the reserved section of the first continuous carbon fiber of the spoke preform is folded and attached to the rim preform, then the SMC layer sheet is wound on the entire width of the rim preform in the circumferential direction, and then the mold slider is combined with the upper and lower dies as a whole.

[0036] The above is the preferred embodiment of the present application, which does not limit the protection scope of the present application in sequence, therefore: all equivalent changes made according to the structure, shape, principle of the present application should be covered in the protection scope of the present application.

Claims

1. A carbon fiber composite material wheel hub assembly for an automobile, comprising a spoke, a rim, a center aluminum, the spoke comprising a spoke bar and a hollowed area between adjacent spoke bars; the center aluminum is arranged at the center of the spoke; characterized in that, The spoke comprises a first SMC layer, a first continuous carbon fiber layer, a second SMC layer, a second continuous carbon fiber layer, and a third SMC layer arranged in sequence, and the first SMC layer serves as an appearance layer; the rim comprises a third continuous carbon fiber layer and a sixth SMC layer arranged from inside to outside; a fourth SMC layer is arranged at one end of the hub assembly profile on the inner side of the third continuous carbon fiber layer of the rim, and a fifth SMC layer is arranged at one end of the outer profile of the hub assembly on the outer side of the third continuous carbon fiber layer; the weight ratio of the continuous carbon fiber layer to the SMC layer in the hub is 1:2-1:2.3; and the spoke and the rim are co-cured.

2. The carbon fiber composite material wheel hub assembly for an automobile according to claim 1, characterized by, The first continuous carbon fiber layer and the second continuous carbon fiber layer are arranged in a U-shaped manner in the cross section of the spoke.

3. The carbon fiber composite material wheel hub assembly for an automobile according to claim 1, characterized by, A carbon fiber winding belt is arranged along the hollow area of the spoke between the first continuous carbon fiber layer and the second SMC layer.

4. The carbon fiber composite material wheel hub assembly for an automobile according to claim 2, characterized by The first continuous carbon fiber layer and the second continuous carbon fiber layer are connected on both sides of the spoke.

5. The carbon fiber composite material wheel hub assembly for an automobile according to claim 1, characterized by, A triangular area is arranged at the spoke root corresponding to the spoke position.

6. The carbon fiber composite material wheel hub assembly for an automobile according to claim 1, characterized by The center aluminum comprises a body and a flange, and the flange is arranged between the first SMC layer and the first continuous carbon fiber layer.

7. The carbon fiber composite material wheel hub for an automobile according to claim 1, characterized by A glass fiber layer is further arranged on the surface of the center aluminum.

8. A molding die for a carbon fiber composite material wheel hub assembly for an automobile, characterized by, A molding mold for molding the hub assembly of any one of claims 1-7 is provided, comprising an upper mold, a lower mold, and a side slide block, wherein the upper mold is provided with a cavity for molding the spoke, and the lower mold and the side slide block cooperate to form a cavity for molding the rim.

9. A molding method of a carbon fiber composite material wheel hub assembly for an automobile, characterized by, The hub assembly of any one of claims 1-7 is prepared by using the molding mold of claim 8, comprising the steps of: S1, preparing a spoke preform and a rim preform in the upper mold and the lower mold of the molding mold, respectively; S2, closing the upper mold for laying the spoke preform and the lower mold for laying the rim preform, and winding a piece of the sixth SMC layer around the rim preform in the whole width in a circumferential direction, and then closing the side slide block with the upper mold and the lower mold as a whole; S3, mold pressing and molding; S4, post-processing.

10. The molding method of the carbon fiber composite material hub for automobiles according to claim 9, wherein the step S1 comprises: S11, on the upper die of the hub assembly forming die, lay the first SMC layer sheet, so that the first SMC layer sheet is arranged in U shape on the cross section of the spoke; place the center aluminum at the center position of the first SMC layer sheet, and the flange of the center aluminum is attached to the first SMC layer sheet; continue to lay the first continuous carbon fiber layer sheet on the first SMC layer sheet, so that the first continuous carbon fiber layer sheet is arranged in U shape on the cross section of the spoke, and the end of the sheet close to the center aluminum is attached to the flange of the center aluminum and the outer side of the center aluminum body; the end of the sheet away from the center aluminum is provided with a reserved section, which is suspended outside the mold; then lay the second SMC layer sheet on the first continuous carbon fiber layer; lay the second continuous carbon fiber layer sheet on the second SMC layer sheet, so that the second continuous carbon fiber layer sheet is arranged in U shape on the cross section of the spoke, and the end of the sheet close to the center aluminum is attached to the end of the first continuous carbon fiber layer sheet; then lay the third SMC layer sheet on the second continuous carbon fiber layer sheet, and compact the whole layer; S12, on the lower die of the hub assembly forming die, lay the fourth SMC layer sheet on one end of the hub assembly forming surface; then lay the third continuous carbon fiber layer sheet on the whole width of the rim, and provide a reserved section at one end of the outer contour surface of the hub assembly; then lay the fifth SMC layer sheet on the outer side of the third continuous carbon fiber layer sheet at one end of the outer contour surface of the hub assembly; fold the reserved section of the third continuous carbon fiber layer sheet to cover the fifth SMC layer; The step S2 comprises: First, the upper die for laying the spoke preform is combined with the lower die for laying the rim preform, the reserved section of the first continuous carbon fiber layer of the spoke preform is folded and attached to the rim preform, then the SMC layer sheet is wound on the whole width of the rim preform, and then the mold slider is combined with the upper and lower dies.

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