Thermoplastic band and method of making same, can body assembly, and vehicle

Abstract

This application discloses a thermoplastic hoop, its manufacturing method, a tank assembly, and a vehicle, relating to the field of automotive technology. The thermoplastic hoop includes a hoop body and through-hole mounting sections at both ends of the hoop body along its length for mounting pins. The hoop body is made of thermoplastic resin and continuous fibers; the continuous fibers are arranged in multiple layers along the thickness of the thermoplastic hoop, with at least two layers of continuous fibers arranged at an angle. This fully utilizes the ultra-high axial tensile strength of the fibers, significantly reducing the cross-sectional thickness while meeting the binding tension, achieving lightweighting and a substantial weight reduction compared to traditional steel hoops. Furthermore, the thermoplastic resin and continuous fibers prevent corrosion of the hoop body, improving its service life.

Description

Technical Field

[0001] This application relates to the field of automotive technology, and in particular to a thermoplastic band and its preparation method, a tank assembly, and a vehicle. Background Technology

[0002] As an important mechanical fastening component, clamps are widely used in the fixing and connection of pipeline systems or storage tanks. With the development of commercial vehicle and heavy equipment technology, higher requirements are placed on the load-bearing capacity, vibration resistance, and structural adaptability of tank fasteners.

[0003] Existing steel clamps are heavy, waste energy, do not conform to the trend of vehicle lightweighting, and are difficult to avoid surface corrosion; while existing composite clamps / bands have high energy consumption, long molding cycle, high process cost, rely on single molding with molds, and have high mold costs. Summary of the Invention

[0004] This application provides a thermoplastic hoop and its preparation method, a tank assembly, and a vehicle to solve the problems of existing hoops being prone to corrosion and costly.

[0005] In a first aspect, this application provides a thermoplastic hoop, including a hoop body and through-hole mounting sections for mounting pins at both ends along the length of the hoop body, wherein: The material of the band body includes thermoplastic resin and continuous fibers; The continuous fibers are arranged in multiple layers in the direction of the thickness of the thermoplastic band, with at least two layers of continuous fibers arranged at an angle to each other.

[0006] The core load of the hoop is axial tensile load. The hoop tightens and wraps around the tank, and is under tension throughout the entire process. This application utilizes the material of the hoop body, which includes thermoplastic resin and continuous fibers. The continuous fibers are arranged in multiple layers along the thickness of the thermoplastic hoop, with at least two layers of continuous fibers arranged at an angle. This fully utilizes the ultra-high axial tensile strength of the fibers, significantly reducing the cross-sectional thickness while meeting the binding tension, thus achieving lightweighting and a substantial weight reduction compared to traditional steel hoops. Furthermore, the thermoplastic resin and continuous fibers can prevent corrosion of the hoop body, improving the service life of the hoop.

[0007] In some embodiments, the thermoplastic resin material includes at least one of nylon 6, nylon 66, nylon 56, nylon 6T, nylon 10T, PP, and PBT. These thermoplastic resin materials have advantages such as low cost, high temperature resistance, and creep resistance; and / or, The continuous fiber material includes at least one of glass fiber, carbon fiber, basalt fiber, and aramid fiber. These continuous fiber materials have significant advantages such as low cost, excellent 0° strength, superior specific strength compared to metals, and lightweight, making them naturally suitable for applications requiring high tensile forces, such as hoops.

[0008] In some embodiments, the included angle ranges from 30° to 60°. The core working load of the hoop is the axial tensile load brought by binding the can body. Some fibers are arranged parallel to the direction of tension to give full play to the ultra-high tensile strength of the fibers. Under the premise of meeting the design binding tension (64kN), the cross-sectional size of the hoop is reduced, achieving a significant weight reduction compared to steel hoops. The symmetrical fiber layup with an included angle range of 30° to 60° can eliminate the internal stress of the blank after molding and avoid the natural warping of the blank. Simultaneously bearing the shear load of the hole, after the pin is inserted into the round hole and locked, vehicle bumps and the thermal expansion and contraction of the tank will generate lateral shear force on the contact position of the through hole and the locking parts. The 30°~60° fibers are arranged along the direction of shear stress to specifically disperse the shear around the hole and prevent splitting and interlayer peeling around the opening. It can also resist torsional and alternating loads. Commercial vehicles experience multi-directional vibration and irregular torsional loads. The 30°~60° oblique fibers form a three-dimensional force-bearing skeleton to improve the torsional and impact fatigue resistance of the hoop. Furthermore, interlayer limiting is adopted: the fibers parallel to the tensile direction and the fibers with an angle range of 30°~60° are arranged crosswise to further limit the lateral slippage of the single layer of fibers and improve the overall interlayer bonding stability.

[0009] In some embodiments, the through-hole mounting section includes a plurality of mounting holes and through-hole mounting portions disposed along the thickness direction of the band body and located at both ends of the length direction of the band body, wherein: The through-hole mounting portion is clamped on both sides of multiple mounting hole areas, and a mounting through hole is formed in the area outside the clamping area. The through-hole mounting part is connected to the hoop body by multiple mounting hole bolts; The material of the through-hole mounting part includes metal.

[0010] Two sheet metal pieces are respectively attached to the upper and lower surfaces of the end of the hoop body. Bolts are vertically inserted through the mounting holes of the sheet metal and the hoop body. Tightening the bolts achieves a rigid connection between the metal end and the hoop body.

[0011] The sandwich clamping force principle is adopted. The bolt preload makes the upper and lower metal plates clamp the end face of the band body, dispersing the single-point shear load concentrated by the bolt to the entire clamping surface, avoiding the end face of the band body being crushed by the bolt locally. At the same time, the load dispersion principle is also adopted. The shear force caused by vehicle vibration and tank expansion and contraction is distributed by the metal plate surface, which greatly reduces the stress concentration at the mounting hole of the band body and reduces the probability of the mounting hole of the band body splitting failure.

[0012] In some embodiments, the number of mounting holes is 4 to 16. This range of mounting holes can improve the connection strength between the clamp body and the through-hole mounting portion, reduce the probability of through-hole splitting failure, and improve connection stability.

[0013] In some embodiments, the through-hole mounting section includes through-hole mounting portions located at both ends of the band body along its length direction, connected to the band body, and forming mounting through holes, wherein: The through-hole mounting part is fused to the hoop body; The through-hole mounting part and the hoop body are made of the same material.

[0014] The thermoplastic resin prepreg fiber composite integrated hoop has no metal fittings. It is made by symmetrical multi-directional prepreg layup and molding into a flat composite board. The 0° fiber bears the axial binding tension, and the angled fiber bears the shear load of the installation hole. The all-thermoplastic resin prepreg fiber structure completely eliminates the risk of metal corrosion and reduces weight by up to 90%.

[0015] Secondly, this application provides a method for preparing a thermoplastic hoop, which includes the following steps: The continuous fiber prepreg of thermoplastic resin is laid at different layup angles to obtain the hoop body; Cut through holes at both ends of the length of the hoop body, and fold each through hole area toward the middle of the hoop body to form a through hole mounting part, thus obtaining a hoop body with through holes; The hoop body with through holes is integrally molded with the folded area to obtain a thermoplastic hoop.

[0016] Thermoplastic resins melt upon heating and solidify upon cooling, allowing for both initial molding into flat blanks and subsequent overall hot bending into irregular shapes, unlike thermosetting resins which cannot undergo secondary deformation due to cross-linking. The thermoplastic resin matrix completely encapsulates the continuous fibers, isolating them from oil, moisture, and alkalis, eliminating the need for anti-rust coatings and reducing corrosion defects. Continuous fibers exhibit significantly superior tensile strength compared to chopped fibers. During tank binding, the hoops are subjected to axial tension throughout the entire process, and the continuous fibers, arranged along the direction of force, maximize the material's specific strength, leveraging the low material density (1.8 g / cm³). 3 Compared to steel (7.9 g / cm³) 3 This achieves weight reduction and lightweighting.

[0017] High-temperature short-time molding (around 30 seconds) can be used to fully impregnate single continuous fibers such as glass fibers with molten thermoplastic resin, such as nylon, extruding interlayer bubbles, densifying the blank, and improving the overall fatigue resistance and resistance to media erosion. Thermoplastic molding does not require long curing time, and its production efficiency is much higher than that of thermosetting composites. The circular through-hole section at both ends (pin installation bend area) uses pre-drilled mounting holes at the ends of the molded straight section. Local heating is applied based on the openings, and the sheet metal is folded inward to form a double-layered structure. The overlapping surfaces are welded together by hot pressing, forming a flange through-hole section with mounting holes in one piece, without the use of metal sheet metal parts.

[0018] Thirdly, this application provides a method for preparing a thermoplastic hoop, which includes the following steps: The continuous fiber prepreg of thermoplastic resin is laid at different layup angles to obtain the hoop body; Cut through holes at both ends of the length of the hoop body, and fold each through hole area toward the middle of the hoop body to form a through hole mounting part, thus obtaining a hoop body with through holes; The folded area is molded to obtain a thermoplastic band.

[0019] Specifically, the following process is adopted: Machined holes at the ends of the billet: Mechanical drilling of pin assembly holes at the ends of flat blanks allows for standardized hole diameters, ensuring assembly tolerances with the vehicle pins and meeting assembly line interchangeability requirements. Pre-reserved hole positions allow for subsequent bending to form flanges centered on the holes, ensuring the holes remain at the overlap center.

[0020] Local heating and hot bending at the opening form a bend-overlap structure: Only the area around the opening is locally heated to the softening temperature of nylon, and then bent inward along the axis of the opening to make the double-layered sheet material around the opening overlap and form an overlapping area; the thermoplastic nylon enters a high-elastic state when heated, the molecular chains relax and there is no brittle fracture, and after cooling, it is shaped to maintain the double-layered structure of bending back. Local fixed-point heating avoids the long straight section of the main body of the hoop from being deformed by heat, and ensures that the original ply strength of the main body is not damaged.

[0021] Hot-melt welding of the overlapping area / Local molding and integral consolidation Localized pressure heating of the double-layered overlapping surface melts and fuses the nylon contact surfaces together. After cooling, the overlapping layers fuse into a whole, making the circular through-hole section and the long straight section seamlessly integrated. The unique thermoplastic material has the characteristic of hot melting and mutual melting. After the same material melts, the interface is integrated, without adhesive glue or interlayer gaps, eliminating delamination and cracking. The overlapping and thickened through-hole area improves the hole's resistance to compression and shear when the pin is locked, replacing the reinforcement function of traditional metal plates and achieving metal-free single material.

[0022] The finished product can also undergo a secondary thermoforming process. The integrated blank is softened by heating and bent into U-shaped and L-shaped hoopes according to the outer contour of the fuel tank / air reservoir. The nylon molecular chains relax under heat, deforming with the mold surface under external force, and permanently maintaining the required curvature upon cooling and setting. In contrast, existing thermosetting composites, after cross-linking and curing, cannot be bent a second time; secondary bending is a unique characteristic of thermoplastic materials. All hoop specifications are mass-produced using flat molds, eliminating the need for separate shaped dies for different U / L shapes. Only simple bending fixtures are required, significantly reducing mold development costs. The same flat blank can be adapted to tanks of different diameters through different bending curvatures, reducing the number of part types and facilitating standardized management of vehicle components.

[0023] Fourthly, this application provides a tank assembly, including a tank and a thermoplastic band as described in the first aspect, or a thermoplastic band prepared by the method described in the second or third aspect, which is clamped onto the tank.

[0024] Fifthly, this application provides a vehicle including the tank assembly described in the fourth aspect. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of the structure of a thermoplastic hoop according to an embodiment of this application.

[0027] Figure 2 This is a schematic diagram of the structure of a thermoplastic hoop according to an embodiment of this application.

[0028] Figure 3 This is a physical image of a thermoplastic hoop according to an embodiment of this application.

[0029] Figure 4 This is a schematic diagram of a secondary heating and shaping structure of a thermoplastic hoop according to an embodiment of this application.

[0030] Figure 5 This is a schematic diagram of the molding process of the thermoplastic hoop in Embodiment 1 of this application.

[0031] Figure 6 This is a schematic diagram of the molding process of the thermoplastic hoop in Embodiment 2 of this application.

[0032] Figure 7 This is a schematic diagram of the molding process of the thermoplastic hoop in Embodiment 2 of this application.

[0033] Figure 8 This is a schematic diagram of the molding process of the thermoplastic hoop in Embodiment 3 of this application.

[0034] Figure 9 This is a schematic diagram of the molding process of the thermoplastic hoop in Embodiment 3 of this application.

[0035] Figure 10 This is a physical image of a thermoplastic band used according to an embodiment of this application.

[0036] Figure 11This is a photograph of the actual corrosion condition of the hoop in Comparative Example 1 of this application.

[0037] Figure 12 This is a photograph of the actual rust and peeling of the hoop in Comparative Example 1 of this application.

[0038] Figure 13 This is a photograph of the actual product used in Comparative Example 1 of this application.

[0039] Explanation of icon numbers: 100 Thermoplastic hoop; 1 Hoop body; 2 Through-hole mounting section; 21 Mounting hole; 22 Through-hole mounting part; 23 Mounting through hole. Detailed Implementation

[0040] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below in conjunction with the embodiments of this application. Obviously, the described embodiments are only some, not all, of the embodiments of this application. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0041] As an important mechanical fastening component, clamps are widely used in the fixing and connection of pipeline systems or storage tanks. With the development of commercial vehicle and heavy equipment technology, higher requirements are placed on the load-bearing capacity, vibration resistance, and structural adaptability of tank fasteners.

[0042] Existing steel clamps are heavy, waste energy, do not conform to the trend of vehicle lightweighting, and are difficult to avoid surface corrosion; while existing composite clamps / bands have high energy consumption, long molding cycle, high process cost, rely on single molding with molds, and have high mold costs.

[0043] For example, a composite material clamp designed with continuous fiber reinforced resin is mainly used for fixing pipes or cables under low load. Its single bolt hole fastening method cannot meet the working conditions of commercial vehicle tanks with high vibration and impact (parts weighing thousands of kilograms). Moreover, it relies on thermosetting resin autoclave molding process, which has defects such as high cost, long cycle and no secondary processing. Furthermore, its integral structure is difficult to adapt to the fastening scenario of L / U-shaped tanks with multiple anchor points (≥2 bolt holes). The high mold cost of thermosetting materials further limits its economic application in large irregular shaped clamps (such as U, L-shaped and other shapes with a certain depth).

[0044] For example, a composite material band is mainly used for bundling battery pack modules. It has a U-shaped structure and requires a huge inner lining to fill the inside of the U-shape when it is molded. This makes it difficult to mold and the mold cost is high. It is a thermosetting resin solution, which has high process cost and long cycle.

[0045] In view of this, this application provides a thermoplastic hoop and its preparation method, a tank assembly and a vehicle, to solve the problems of existing hoops being prone to corrosion and having high costs.

[0046] Firstly, such as Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, this application provides a thermoplastic hoop 100, including a hoop body 1 and through-hole mounting sections 2 for mounting pins at both ends of the hoop body 1 along its length, wherein: The material of the band body 1 includes thermoplastic resin and continuous fiber; The continuous fibers are arranged in multiple layers in the direction of the thickness of the thermoplastic hoop 100, with at least two layers of continuous fibers arranged at an angle to each other.

[0047] The core load of the hoop is axial tension load. The hoop tightens and wraps around the tank, and is under tension throughout the entire process. This application utilizes the material of the hoop body 1, which includes thermoplastic resin and continuous fibers. The continuous fibers are arranged in multiple layers along the thickness direction of the thermoplastic hoop 100, with at least two layers of continuous fibers arranged at an angle. This fully utilizes the ultra-high axial tensile strength of the fibers, significantly reducing the cross-sectional thickness while meeting the binding tension, thus achieving lightweighting and a substantial weight reduction compared to traditional steel hoops. Furthermore, the thermoplastic resin and continuous fibers can prevent corrosion of the hoop body 1, improving the service life of the hoop.

[0048] In conjunction with the first aspect, in some embodiments provided in this application, the thermoplastic resin material includes at least one of nylon 6, nylon 66, nylon 56, nylon 6T, nylon 10T, PP and PBT. The above thermoplastic resin materials have the advantages of low cost, high temperature resistance, creep resistance and corrosion resistance.

[0049] In conjunction with the first aspect, in some embodiments provided in this application, the continuous fiber material includes at least one selected from glass fiber, carbon fiber, basalt fiber, and aramid fiber. The aforementioned continuous fiber materials have significant advantages such as low cost, excellent 0° axial strength, superior specific strength compared to metals, and lightweight, making them naturally suitable for applications such as hoops that require high tensile forces.

[0050] In conjunction with the first aspect, in some embodiments provided in this application, the included angle ranges from 30° to 60°. The core working load of the hoop is the axial tensile load brought by binding the can body. Some fibers are arranged parallel to the direction of tension, which fully utilizes the ultra-high tensile strength of the fibers. Under the premise of meeting the design binding tension (64kN), the cross-sectional size of the hoop is reduced, achieving a significant weight reduction compared to steel hoops. The symmetrical fiber layup with an included angle range of 30° to 60° can eliminate the internal stress of the blank after molding and avoid the natural warping of the blank. Simultaneously bearing the shear load of the hole, after the pin is inserted into the round hole and locked, vehicle bumps and the thermal expansion and contraction of the tank will generate lateral shear force on the contact position of the through hole and the locking parts. The 30°~60° fibers are arranged along the direction of shear stress to specifically disperse the shear around the hole and prevent splitting and interlayer peeling around the opening. It can also resist torsional and alternating loads. Commercial vehicles experience multi-directional vibration and irregular torsional loads. The 30°~60° oblique fibers form a three-dimensional force-bearing skeleton to improve the torsional and impact fatigue resistance of the hoop. Furthermore, interlayer limiting is adopted: the fibers parallel to the tensile direction and the fibers with an angle range of 30°~60° are arranged crosswise to further limit the lateral slippage of the single layer of fibers and improve the overall interlayer bonding stability.

[0051] In conjunction with the first aspect, in some embodiments provided in this application, the through-hole mounting section 2 includes a plurality of mounting holes 21 and through-hole mounting portions 22 disposed along the thickness direction of the band body 1 and located at both ends of the length direction of the band body 1, wherein: The through-hole mounting portion 22 is clamped on both sides of the multiple mounting hole 21 areas, and a mounting through hole 23 is formed in the area outside the clamping area. The through-hole mounting part 22 is bolted to the band body 1 through multiple mounting holes 21; The material of the through-hole mounting part 22 includes metal.

[0052] Two metal sheet pieces are respectively attached to the upper and lower surfaces of the end of the clamp body 1. The bolts penetrate vertically through the mounting holes 21 of the metal sheet pieces and the clamp body 1. The bolts are tightened to achieve a rigid connection between the metal end and the clamp body 1.

[0053] The sandwich clamping force principle is adopted. The bolt preload makes the upper and lower metal plates clamp the end face of the hoop body 1, dispersing the single-point shear load concentrated by the bolt to the entire clamping surface, avoiding the local crushing of the end face of the hoop body 1 by the bolt. At the same time, the load dispersion principle is also adopted. The shear force caused by vehicle vibration and tank expansion and contraction is distributed by the metal plate surface, which greatly reduces the stress concentration at the mounting hole 21 of the hoop body 1 and reduces the probability of splitting failure at the mounting hole 21 of the hoop body 1.

[0054] In conjunction with the first aspect, in some embodiments provided in this application, the number of mounting holes 21 is 4 to 16. The number of mounting holes 21 within this range can improve the connection strength between the clamp body 1 and the through-hole mounting portion 22, reduce the probability of through-hole splitting failure, and improve connection firmness.

[0055] In conjunction with the first aspect, in some embodiments provided in this application, the through-hole mounting section 2 includes through-hole mounting portions 22 located at both ends of the band body 1 along its length direction, connected to the band body 1, and forming mounting through holes 23, wherein: The through-hole mounting part 22 is fused to the band body 1; The through-hole mounting part 22 and the band body 1 are made of the same material.

[0056] The thermoplastic resin prepreg fiber composite integrated hoop has no metal fittings. It is made by symmetrical multi-directional prepreg layering and molding into a flat composite board. The axial binding tension is borne by 0° fibers and the shear load is borne by 21 mounting holes with angled fibers. The all-thermoplastic resin prepreg fiber structure completely eliminates the risk of metal corrosion and reduces weight by up to 90%.

[0057] Secondly, this application provides a method for preparing a thermoplastic hoop, which includes the following steps: The continuous fiber prepreg of thermoplastic resin is laid at different layup angles to obtain the hoop body; Cut through holes at both ends of the length of the hoop body, and fold each through hole area toward the middle of the hoop body to form a through hole mounting part, thus obtaining a hoop body with through holes; The hoop body with through holes is integrally molded with the folded area to obtain a thermoplastic hoop.

[0058] Thermoplastic resins melt upon heating and solidify upon cooling, allowing for both initial molding into flat blanks and subsequent overall hot bending into irregular shapes, unlike thermosetting resins which cannot undergo secondary deformation due to cross-linking. The thermoplastic resin matrix completely encapsulates the continuous fibers, isolating them from oil, moisture, and alkalis, eliminating the need for anti-rust coatings and reducing corrosion defects. Continuous fibers exhibit significantly superior tensile strength compared to chopped fibers. During tank binding, the hoops are subjected to axial tension throughout the entire process, and the continuous fibers, arranged along the direction of force, maximize the material's specific strength, leveraging the low material density (1.8 g / cm³). 3 Compared to steel (7.9 g / cm³) 3 This achieves weight reduction and lightweighting.

[0059] High-temperature short-time molding (around 30 seconds) can be used to fully impregnate single continuous fibers such as glass fibers with molten thermoplastic resin, such as nylon, extruding interlayer bubbles, densifying the blank, and improving the overall fatigue resistance and resistance to media erosion. Thermoplastic molding does not require long curing time, and its production efficiency is much higher than that of thermosetting composites. The circular through-hole section at both ends (pin installation bend area) uses pre-drilled mounting holes at the ends of the molded straight section. Local heating is applied based on the openings, and the sheet metal is folded inward to form a double-layered structure. The overlapping surfaces are welded together by hot pressing, forming a flange through-hole section with mounting holes in one piece, without the use of metal sheet metal parts.

[0060] Thirdly, this application provides a method for preparing a thermoplastic hoop, which includes the following steps: The continuous fiber prepreg of thermoplastic resin is laid at different layup angles to obtain the hoop body; Cut through holes at both ends of the length of the hoop body, and fold each through hole area toward the middle of the hoop body to form a through hole mounting part, thus obtaining a hoop body with through holes; The folded area is molded to obtain a thermoplastic band.

[0061] Specifically, the following process is adopted: Machined holes at the ends of the billet: Mechanical drilling of pin assembly holes at the ends of flat blanks allows for standardized hole diameters, ensuring assembly tolerances with the vehicle pins and meeting assembly line interchangeability requirements. Pre-reserved hole positions allow for subsequent bending to form flanges centered on the holes, ensuring the holes remain at the overlap center.

[0062] Local heating and hot bending at the opening form a bend-overlap structure: Only the area around the opening is locally heated to the softening temperature of nylon, and then bent inward along the axis of the opening to make the double-layered sheet material around the opening overlap and form an overlapping area; the thermoplastic nylon enters a high-elastic state when heated, the molecular chains relax and there is no brittle fracture, and after cooling, it is shaped to maintain the double-layered structure of bending back. Local fixed-point heating avoids the long straight section of the main body of the hoop from being deformed by heat, and ensures that the original ply strength of the main body is not damaged.

[0063] Hot-melt welding of the overlapping area / Local molding and integral consolidation Localized pressure heating of the double-layered overlapping surface melts and fuses the nylon contact surfaces together. After cooling, the overlapping layers fuse into a whole, making the circular through-hole section and the long straight section seamlessly integrated. The unique thermoplastic material has the characteristic of hot melting and mutual melting. After the same material melts, the interface is integrated, without adhesive glue or interlayer gaps, eliminating delamination and cracking. The overlapping and thickened through-hole area improves the hole's resistance to compression and shear when the pin is locked, replacing the reinforcement function of traditional metal plates and achieving metal-free single material.

[0064] The finished product can also undergo a secondary thermoforming process. The integrated blank is softened by heating and bent into U-shaped and L-shaped hoopes according to the outer contour of the fuel tank / air reservoir. The nylon molecular chains relax under heat, deforming with the mold surface under external force, and permanently maintaining the required curvature upon cooling and setting. In contrast, existing thermosetting composites, after cross-linking and curing, cannot be bent a second time; secondary bending is a unique characteristic of thermoplastic materials. All hoop specifications are mass-produced using flat molds, eliminating the need for separate shaped dies for different U / L shapes. Only simple bending fixtures are required, significantly reducing mold development costs. The same flat blank can be adapted to tanks of different diameters through different bending curvatures, reducing the number of part types and facilitating standardized management of vehicle components.

[0065] Fourthly, this application provides a tank assembly, including a tank and a thermoplastic band as described in the first aspect, or a thermoplastic band prepared by the method described in the second or third aspect, which is clamped onto the tank.

[0066] Fifthly, this application provides a vehicle including the tank assembly described in the fourth aspect.

[0067] The technical solutions provided in this application will be described in detail below with reference to the embodiments and accompanying drawings.

[0068] Example 1 Embodiment 1 of this application provides a thermoplastic hoop, the preparation method of which is as follows: A continuous glass fiber prepreg impregnated with thermoplastic nylon is laid in straight sections at a layup angle of 45° / -45° / 0° / 0° / -45° / 45° (0° in the length direction). At the same time, reinforcement is applied to both sides of the straight sections at layup angles of 45° / -45° / 45° / -45° / 45° / -45° / 45° / 45° on both sides. After completion, the material is sent into a hot molding press. After the mold is closed and heated, it is taken out after 30 seconds. Six bolt holes were drilled in the reinforcement areas on both sides. Figure 5 As shown, there are two rows of M13 through holes with a hole spacing of 20mm.

[0069] A steel plate with circular through holes is sandwiched between two sides of a straight section, and then fastened with bolts through the through holes. Figure 1 As shown; The long straight section is adapted to the shape of the part and then subjected to secondary heating and forming to a suitable U, L, or other shape.

[0070] Example 2 Embodiment 2 of this application provides a thermoplastic hoop, which is prepared by the following method: Continuous glass fiber prepreg impregnated with thermoplastic nylon is laid in straight sections at a layup angle of -45° / 45° / -45° / 45° / -45° / 0° / 0° / -45° / 45° / -45° / 45° / -45° / 0° / 0° / -45° / 45° / -45° / -45° / 0 ... The pre-formed blank is shaped and circular through holes are pre-cut on both sides of the straight section (for the installation of the clamp pin). like Figure 6 As shown: After completion, it is sent into a hot molding press. After the circular through holes on both sides are folded, it is molded as a whole through the embedded teardrop-shaped mold. After the mold is closed and heated, it is taken out after 30 seconds. like Figure 7 As shown: After molding, the teardrop-shaped mold is removed, the band is initially formed, and the circular through-hole sections on both sides are integrally molded with the straight sections, as shown. Figure 2 As shown; The long straight section is adapted to the shape of the part and then subjected to secondary heating and forming to a suitable U, L, or other shape, such as... Figure 4 As shown.

[0071] Example 3 Embodiment 3 of this application provides a thermoplastic hoop, the preparation method of which is as follows: Continuous glass fiber prepreg impregnated with thermoplastic nylon is laid in straight sections at a layup angle of -45° / 45° / -45° / 45° / -45° / 0° / 0° / -45° / 45° / -45° / 45° / -45° / 0° / 0° / -45° / 45° / -45° / -45° / 0 ... The pre-formed blank is shaped, and circular through holes are pre-cut on both sides of the straight section (for mounting the pin on the hoop). Figure 6 As shown; The circular through holes on both sides allow the heating mold to pass through. Figure 8 As shown, hot bending achieves the following: Figure 9 modeling; Then, only the overlapping region I is hot-molded to obtain a circular through-hole segment, such as... Figure 2 As shown; The long straight section is adapted to the shape of the part and then subjected to secondary heating and forming to a suitable U, L, or other shape, such as... Figure 4 As shown.

[0072] Example 4 Embodiment 4 of this application provides a thermoplastic band, which is similar to Embodiment 3, except that the thermoplastic resin material is polypropylene (PP) and the continuous fiber material is glass fiber.

[0073] Lay straight sections of continuous glass fiber prepreg impregnated with thermoplastic PP at a layup angle of -45° / 45° / -45° / 45° / -45° / 0° / 0° / 0° / 0° / -45° / 45° / -45° / -45° / -45° / 0° / -45° / 0° / -45° / 0° / -45° / 0° / 0° / -45° / 0° / 0° / 0° / -45° / 45° / 0° (0° in the length direction); The pre-formed blank is shaped, and circular through holes are pre-cut on both sides of the straight section (for mounting the pin on the hoop). Figure 6 As shown; The circular through holes on both sides allow the heating mold to pass through. Figure 8 As shown, hot bending achieves the following: Figure 9 modeling; Then, only the overlapping region I is hot-molded to obtain a circular through-hole segment, such as... Figure 2 As shown; The long straight section is adapted to the shape of the part and then subjected to secondary heating and forming to a suitable U, L, or other shape, such as... Figure 4 As shown.

[0074] Comparative Example 1 The band in Comparative Example 1 is made of traditional metal material, specifically SAPH440, which is formed by stamping, cutting holes, bending, and welding. It is 2mm thick and 80mm wide.

[0075] Comparative Example 2 The band of Comparative Example 2 is a continuous glass fiber impregnated with thermosetting resin. Specifically, it is made of epoxy thermosetting resin (Baling Petrochemical E-51), and straight segment A is laid according to the layup angle (0° in the length direction) of -45° / 45° / -45° / 45° / -45° / 0° / 0° / -45° / 45° / -45° / -45° / -45° / 0° / 0° / -45° / 45° / -45° / 0° / 0° / 0° / 45° / 45° / 45° / -45° / 0 ...

[0076] Comparative Example 3 The band in Comparative Example 3 is similar to that in Example 3, except that the layup angle is 0°.

[0077] Comparative Example 4 The band in Comparative Example 4 is similar to that in Example 3, except that the layup angle is 45°.

[0078] Performance testing The hoops of Examples 1 to 4 and Comparative Examples 1 to 4 were subjected to performance tests, including tests on their weight, corrosion resistance, tensile strength, and fatigue strength. The specific test methods are as follows: Weight: Direct weighing using a platform scale with an accuracy of ±0.01kg.

[0079] Corrosion resistance: Complies with GB / T 2423.17-2024 neutral salt spray test for 480 hours, and appearance is inspected.

[0080] Tensile strength: A universal tensile testing machine was used at a tensile rate of 20 mm / min. The band was clamped after the pins were inserted through the pin holes at both ends. The maximum breaking force of the band was recorded.

[0081] Fatigue strength: A vibration test bench was used. The pins were inserted through the pin holes at both ends of the hoop and clamped to simulate part assembly. The vibration direction was perpendicular to the length of the hoop, the vibration frequency was 10Hz, the amplitude was ±4mm, and the vibration duration was 320h. If the sample was damaged during the vibration, it would fail.

[0082] The test results are shown in Table 1.

[0083] Table 1 Performance of the hoops in Examples 1 to 4 and Comparative Examples 1 to 4

[0084] As shown in Table 1, Examples 1 to 4 exhibit advantages such as lightweight, corrosion resistance, high tensile strength, and fatigue resistance. In Example 1, the straight section uses a composite material, but the circular through-holes on both sides remain metal, exhibiting some corrosion, though significantly better than Comparative Example 1. Examples 2 and 3 have similar overall structures, similar corrosion resistance, lightweight, tensile strength, and fatigue resistance, and are superior to Comparative Examples 1 to 4. Example 4 uses a PP resin substrate, with slightly lower strength than Examples 2, 3, and Comparative Example 1, but achieves the best lightweight effect.

[0085] Comparative Example 1 uses metal material, such as Figures 11 to 13 As shown, the drawbacks are poor corrosion resistance, heavy weight, and poor lightweighting effect.

[0086] The drawbacks of Comparative Example 2 are long molding time, high process cost, expensive molding mold, and poor process flexibility.

[0087] The drawback of Comparative Example 3 is its poor fatigue resistance perpendicular to the hoop direction.

[0088] The drawback of Comparative Example 4 is its poor tensile strength, which makes it unable to withstand the tightening torque of the clamp bolts, resulting in a low safety factor under operating conditions.

[0089] In summary, the material of the hoop body includes thermoplastic resin and continuous fibers. The continuous fibers are arranged in multiple layers along the thickness of the thermoplastic hoop, with at least two layers of continuous fibers arranged at an angle. This fully utilizes the ultra-high axial tensile strength of the fibers, significantly reducing the cross-sectional thickness while meeting the binding tension, thus achieving lightweighting and a substantial weight reduction compared to traditional steel hoops. Furthermore, the thermoplastic resin and continuous fibers prevent corrosion of the hoop body, extending its service life.

[0090] In the description of this specification, the references to terms such as "one embodiment / mode," "some embodiments / modes," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment / mode or example is included in at least one embodiment / mode or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment / mode or example. Moreover, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments / modes or examples. Furthermore, without contradiction, those skilled in the art can combine and integrate the different embodiments / modes or examples described in this specification, as well as the features of different embodiments / modes or examples.

[0091] It should be noted that in this application, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element. In this application, "a plurality of" means at least two, such as two, three, etc., unless otherwise expressly specified.

[0092] The above description is merely a specific embodiment of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. A thermoplastic cuff characterized in that, It includes a clamp body and through-hole mounting sections at both ends of the clamp body along its length for mounting pins, wherein: The material of the band body includes thermoplastic resin and continuous fibers; The continuous fibers are arranged in multiple layers in the direction of the thickness of the thermoplastic band, with at least two layers of continuous fibers arranged at an angle to each other.

2. The thermoplastic hoop as described in claim 1, characterized in that: The thermoplastic resin material includes at least one of nylon 6, nylon 66, nylon 56, nylon 6T, nylon 10T, PP, and PBT; and / or, The continuous fiber is made of at least one of glass fiber, carbon fiber, basalt fiber and aramid fiber.

3. The thermoplastic cuff of claim 1 wherein, The included angle ranges from 30° to 60°.

4. The thermoplastic cuff of claim 1 wherein, The through-hole mounting section includes multiple mounting holes and through-hole mounting portions located at both ends of the length direction of the hoop body, along the thickness direction of the hoop body. The through-hole mounting part is clamped on both sides of multiple mounting hole areas, and a mounting through hole is formed in the area outside the clamping area; The through-hole mounting part is connected to the hoop body by multiple mounting hole bolts; The material of the through-hole mounting part includes metal.

5. The thermoplastic cuff of claim 4, wherein The number of mounting holes ranges from 4 to 16.

6. The thermoplastic cuff of claim 1 wherein, The through-hole mounting section includes through-hole mounting portions located at both ends of the band body along its length direction, connected to the band body, and forming mounting through holes, wherein: The through-hole mounting part is fused to the hoop body; The through-hole mounting part and the hoop body are made of the same material.

7. A method of producing a thermoplastic cuff according to claim 6, characterized in that Includes the following steps: The continuous fiber prepreg of thermoplastic resin is laid at different layup angles to obtain the hoop body; Cut through holes at both ends of the length of the hoop body, and fold each through hole area toward the middle of the hoop body to form a through hole mounting part, thus obtaining a hoop body with through holes; The hoop body with through holes is integrally molded with the folded area to obtain a thermoplastic hoop.

8. A method of making a thermoplastic cuff according to claim 6, wherein, Includes the following steps: The continuous fiber prepreg of thermoplastic resin is laid at different layup angles to obtain the hoop body; Cut through holes at both ends of the length of the hoop body, and fold each through hole area toward the middle of the hoop body to form a through hole mounting part, thus obtaining a hoop body with through holes; The folded area is molded to obtain a thermoplastic band.

9. A can body assembly characterized by, The thermoplastic band includes a tank body and a thermoplastic band as described in any one of claims 1 to 6, or a thermoplastic band as described in any one of claims 7 to 8, prepared by the same method.

10. A vehicle characterized by comprising: Includes the tank assembly as described in claim 9.

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