A dust cover with high wear resistance composite structure for electric vehicles and a preparation process thereof

Abstract

The application discloses a high-wear-resistance composite structure dust cover for an electric vehicle and a preparation process thereof. The dust cover body is a multilayer composite integrated structure, and wear-resistant protective layers, buffer flame-retardant layers, sealing dustproof layers and inner anti-skid layers are sequentially arranged from outside to inside. The application adopts a four-layer differentiated functional composite structure design, breaks through the single performance defect of the traditional single-layer dust cover, and realizes the synergistic effect of the multilayer structure, thereby comprehensively improving the protection performance of the dust cover. Through the integrated structure design of the edge sealing and edge covering, the built-in annular elastic component and the surface flexible buffer convex, the problems of edge cracking and cover body deformation and delamination of the traditional dust cover are effectively solved, the overall tear resistance and deformation resistance are greatly improved, the high and low temperature resistance and aging resistance are excellent, the service life is significantly improved, and the dust cover has the multiple advantages of light weight, flame retardation, noise reduction and corrosion resistance, thereby meeting the use requirements of high-end, long service life and high reliability of new energy vehicles.

Description

Technical Field

[0001] This invention belongs to the field of electric vehicle component protection technology, specifically relating to a high wear-resistant composite structure dust cover for electric vehicles and its manufacturing process. Background Technology

[0002] Existing electric vehicle dust covers are mainly divided into three categories: pure rubber integrated dust covers, plastic dust covers, and ordinary fabric composite dust covers. All types of single-structure products have inherent technical defects that cannot be avoided. Specific defects and comparative issues are as follows: I. Pure rubber dust covers (nitrile rubber, EPDM rubber): These have good flexibility and fit, but extremely low abrasion resistance. Long-term weathering and rain exposure easily lead to surface peeling, thinning, and damage. They also have poor UV resistance and high / low temperature aging resistance, easily hardening, cracking, shrinking, and deforming with long-term outdoor use. Furthermore, they lack flame retardant and cushioning functions, and are prone to accelerated aging and failure under high-temperature environments. 1. Low lifespan; 2. Rigid plastic dust covers (PP, ABS material): High structural strength, not easy to deform, good dustproof effect, but extremely poor flexibility, no cushioning and shock absorption capacity, easy to cause permanent damage after impact, and extremely poor adaptability; 3. Ordinary single-layer fabric dust covers: Lightweight and thin, strong deformation capacity, but loose structure, weak tear resistance, poor waterproof and fine dust protection, fine particles can directly penetrate the fabric pores and accumulate on the vehicle surface, and the bonding process between the fabric and the substrate is simple, mostly simple glue bonding, which is very easy to delaminate, bulge and fall off in high temperature and humid environment, and the consistency of batch use is poor.

[0003] Therefore, this invention designs a novel composite dust cover that is wear-resistant, tear-resistant, weather-resistant, corrosion-resistant, and has excellent protective performance, and optimizes the manufacturing process to solve the technical problems of traditional products having single performance, short service life, and poor stability. Summary of the Invention

[0004] The purpose of this invention is to provide a high wear-resistant composite dust cover for electric vehicles and its manufacturing process. Through a multi-layer functional composite structure design, it takes into account multiple properties such as dustproof, waterproof, wear-resistant, tear-resistant, and aging-resistant, solving the problems of poor wear resistance, easy aging and damage, poor protective effect, and insufficient bonding stability of traditional single-layer dust covers. At the same time, by optimizing the step-by-step composite molding process, the overall structural strength and molding precision of the dust cover are improved, ensuring the reliability and stability of the product for long-term use and adapting to the long-term protection needs of various electric vehicles.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: A high wear-resistant composite dust cover for electric vehicles includes a dust cover body, which is a multi-layer composite integrated structure. From the outside to the inside, a wear-resistant protective layer, a buffer flame-retardant layer, a sealing dust-proof layer, and an inner anti-slip layer are sequentially arranged. The wear-resistant protective layer is made of a high-elasticity wear-resistant modified polyurethane material. The buffer flame-retardant layer is made of a foamed flame-retardant silicone composition. The sealing dust-proof layer is made of a high-density polyester fiber fabric combined with a waterproof and dustproof coating. The inner anti-slip layer is made of a flexible modified nitrile rubber material. The dust cover body has an integrated sealing edge structure on its edge. The lower end of the sealing edge structure is embedded with an annular elastic component. The surface of the dust cover body is uniformly provided with several flexible buffer protrusions, which are integrally formed with the wear-resistant protective layer.

[0006] Furthermore, the thickness of the wear-resistant protective layer is 0.8 to 1.2 mm, and its raw materials include, by weight: 80 to 90 parts of polyurethane resin, 5 to 8 parts of nano-silica wear-resistant filler, 2 to 3 parts of UV-resistant additive, 1 to 2 parts of elastic toughening agent, and 0.5 to 1 part of antioxidant; the surface of the wear-resistant protective layer is provided with micron-level hydrophobic wear-resistant texture.

[0007] Furthermore, the thickness of the buffer flame-retardant layer is 1.5–2.0 mm, and its raw materials, by weight, include: 65–80 parts of vinyl silicone oil, 3–7 parts of low-hydrogen silicone oil, 3–7 parts of high-hydrogen silicone oil, 3–14 parts of fumed silica, 13–15 parts of aluminum hydroxide, 1.5–3.5 parts of alumina, and 2–4 parts of hydroxyl silicone oil. The buffer flame-retardant layer has a porous foam structure with a foam porosity of 30%–40%, and a flame retardant rating of UL94 V-0. It can effectively buffer external impacts, block heat, and prevent parts from being damaged by external forces and aging at high temperatures.

[0008] Furthermore, the thickness of the sealing and dustproof layer is 0.5 to 0.8 mm, and its raw materials include, by weight, 70 to 80 parts of high-density conductive polyester composite yarn and 20 to 30 parts of conventional polyester filament; the waterproof and dustproof coating is a fluorine waterproof coating with a thickness of 20 to 30 μm, which can block the penetration of fine dust and water vapor, while ensuring the flexible deformation capability of the cover.

[0009] Furthermore, the thickness of the inner anti-slip layer is 0.6-1.0 mm, and its raw materials, by weight, include: 60-80 parts of nitrile rubber, 15-25 parts of polyvinyl chloride, 1-2 parts of carbon black (N550), 0.5-1 part of activated calcium carbonate, 2-3 parts of antioxidant (4010NA), 1-2 parts of accelerator, and 3-4 parts of plasticizer (TP-95). The inner anti-slip layer is provided with an anti-slip frosted texture, which can fit tightly with the outer wall of the electric vehicle, preventing the dust cover from shifting or loosening during use and improving assembly stability.

[0010] Furthermore, the annular elastic component is composed of a flexible nylon braided skeleton and a rubber elastomer with a thickness of 0.3 to 0.5 mm. The inner side of the rubber elastomer is embedded with several equally spaced annular magnetic sheets, which can improve the edge structural strength of the dust cover and prevent the edge from cracking or curling. At the same time, the annular magnetic sheets embedded at the bottom are used to attract and fix the dust cover to the metal shell of the electric vehicle, further improving the dustproof and waterproof effect and preventing the dust cover body from easily detaching.

[0011] A manufacturing process for a high wear-resistant composite structure dust cover for electric vehicles includes the following steps: Step S1, Raw material pretreatment: Weigh each raw material component of the wear-resistant protective layer, buffer flame-retardant layer, sealing dustproof layer and inner anti-slip layer according to the ratio, and perform stirring, ultrasonic dispersion and vacuum degassing treatment respectively to remove air bubbles and impurities inside the raw materials and ensure the uniformity of the raw materials; Step S2, Inner Anti-slip Layer Molding: Inject flexible modified nitrile rubber material into a customized mold, preheat at low temperature, and demold after heat preservation and curing to obtain an inner anti-slip layer substrate with anti-slip frosted texture. Step S3, sealing and dustproof layer lamination: Apply a special composite adhesive evenly to the outer surface of the inner anti-slip layer, attach the pretreated high-density polyester fiber fabric to the adhesive layer surface, and compact it using a calender roller. After drying and curing, spray a fluorine waterproof and dustproof coating on the outer surface of the fabric and cure it at a constant temperature to complete the preparation of the sealing and dustproof layer. Step S4, Buffer Flame Retardant Layer Molding and Composite: The foamed flame retardant silicone composition is uniformly coated on the outer surface of the sealing dustproof layer. The foaming process is carried out by segmented foaming, and the foaming temperature and time are controlled to form a uniform porous buffer structure. After cooling and shaping, the composite of the buffer flame retardant layer is completed. Step S5, Wear-resistant protective layer molding: The high-elasticity wear-resistant modified polyurethane material is uniformly coated on the outer surface of the buffer flame-retardant layer. The wear-resistant protective layer with hydrophobic wear-resistant texture and flexible buffer protrusions is prepared by molding integrated molding process and cured at high temperature. Step S6, Edge sealing and installation: The edges of the dust cover blank are neatly arranged, and a ring-shaped elastic component is embedded inside the lower end. The sealing edge structure is formed in one piece by hot pressing edge sealing process. Step S7, Post-processing and molding: Trim the edges, remove dust, and perform low-temperature aging treatment for 24 hours after molding to eliminate internal stress. Test the wear resistance, sealing performance, tensile properties, and flame retardant properties. If the test is qualified, the finished dust cover is obtained.

[0012] Furthermore, in step S3, the composite adhesive is a high-temperature resistant polyurethane adhesive with a coating thickness of 15-30 μm, a drying temperature of 55-90°C, and a drying time of 10-30 min, ensuring that each layer is tightly bonded without air pockets or peeling.

[0013] Furthermore, in step S4, the segmented foaming process specifically includes: a first-stage preheating foaming temperature of 70–85°C and a foaming time of 3–7 min; and a second-stage constant-temperature setting temperature of 90–110°C and a setting time of 8–12 min, to ensure uniform foam pores and stable buffering performance.

[0014] Furthermore, in step S5, the molding temperature is 110–130°C, the molding pressure is 5–7 MPa, and the curing time is 20–30 min, ensuring that the wear-resistant layer and the base layer are integrated and have higher structural strength.

[0015] Compared with the prior art, the beneficial effects of this invention are as follows: 1. This invention adopts a four-layer differentiated functional composite structure design, which breaks through the shortcomings of the traditional single-layer dust cover with limited performance. The outer high wear-resistant protective layer achieves anti-friction, anti-impact, and anti-UV aging; the middle buffer flame-retardant layer achieves impact buffering, heat insulation and flame retardancy, noise reduction and vibration reduction; the sealed dustproof layer achieves high-precision dustproof, waterproof, and sand penetration prevention; and the inner anti-slip layer achieves tight fit and prevents displacement and loosening. The multi-layer structure works together to comprehensively improve the protective performance of the dust cover.

[0016] 2. Through the integrated structural design of edge sealing, built-in ring elastic components, and surface flexible buffer protrusions, the problem of edge cracking and delamination of traditional dust covers is effectively solved, which greatly improves the overall tear resistance and deformation resistance, has excellent high and low temperature resistance and aging resistance, significantly improves service life, and has multiple advantages such as lightweight, flame retardancy, noise reduction and corrosion resistance, meeting the high-end, long life and high reliability requirements of new energy vehicles.

[0017] 3. This invention adopts a step-by-step composite, segmented foaming, and integrated molding process to precisely control the thickness, pore structure, and bonding strength of each functional layer, avoiding problems such as hollowing, delamination, and poor molding accuracy in multi-layer composites. The product has high dimensional accuracy, good structural stability, strong consistency in mass production, and a high yield rate. Attached Figure Description

[0018] Figure 1This is a schematic diagram of the structure of a high wear-resistant composite dust cover for electric vehicles proposed in this invention; Figure 2 This is a cross-sectional schematic diagram of the composite layer of a high wear-resistant composite structure dust cover for electric vehicles proposed in this invention; Figure 3 for Figure 1 A magnified view of a section at point A in the middle; Figure 4 This is a flowchart illustrating the manufacturing process of a high wear-resistant composite dust cover for electric vehicles proposed in this invention.

[0019] In the diagram: 1. Dust cover body, 2. Wear-resistant protective layer, 3. Buffer flame-retardant layer, 4. Sealed dustproof layer, 5. Inner anti-slip layer, 6. Sealed edge structure, 7. Flexible buffer protrusion, 8. Flexible nylon woven skeleton, 9. Rubber elastomer, 10. Annular magnetic sheet. Detailed Implementation

[0020] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Example

[0021] A high wear-resistant composite dust cover for electric vehicles includes a dust cover body 1, which is a multi-layer composite integrated structure. From the outside to the inside, it consists of a wear-resistant protective layer 2, a buffer flame-retardant layer 3, a sealing dust-proof layer 4, and an inner anti-slip layer 5. The wear-resistant protective layer 2 is made of a high-elasticity wear-resistant modified polyurethane material, the buffer flame-retardant layer 3 is made of a foamed flame-retardant silicone composition, the sealing dust-proof layer 4 is made of a high-density polyester fiber fabric combined with a waterproof and dustproof coating, and the inner anti-slip layer 5 is made of a flexible modified nitrile rubber material. The dust cover body 1 has an integrated sealing edge structure 6 on its edge. The lower end of the sealing edge structure 6 is embedded with an annular elastic component. The surface of the dust cover body 1 is uniformly provided with several flexible buffer protrusions 7. The flexible buffer protrusions 7 are integrally formed with the wear-resistant protective layer 2. The thickness of each layer is 1.0mm, 1.8mm, 0.6mm and 0.8mm respectively.

[0022] The raw materials of the wear-resistant protective layer 2, by weight, include: 80 parts of polyurethane resin, 5 parts of nano-silica wear-resistant filler, 2 parts of UV-resistant additive, 1 part of elastic toughening agent, and 0.5 parts of antioxidant; the surface of the wear-resistant protective layer 2 is provided with micron-level hydrophobic wear-resistant texture.

[0023] The raw materials of the buffer flame retardant layer 3, by weight, include: 65 parts of vinyl silicone oil, 3 parts of low-hydrogen silicone oil, 3 parts of high-hydrogen silicone oil, 3 parts of fumed silica, 13 parts of aluminum hydroxide, 1.5 parts of alumina, and 2 parts of hydroxyl silicone oil; the buffer flame retardant layer 3 has a porous foam structure with a foam porosity of 30% and a flame retardant rating of UL94 V-0.

[0024] The raw materials of the sealing and dustproof layer 4, by weight, include: 70 parts of high-density conductive polyester composite yarn and 20 parts of conventional polyester filament; the waterproof and dustproof coating is a fluorine waterproof coating with a coating thickness of 20μm.

[0025] The raw materials of the inner anti-slip layer 5 by weight include: 60 parts of nitrile rubber, 15 parts of polyvinyl chloride, 1 part of carbon black N550, 0.5 parts of activated calcium carbonate, 2 parts of antioxidant (4010NA), 1 part of accelerator, and 3 parts of plasticizer (TP-95); the inner anti-slip layer 5 is provided with an anti-slip frosted texture.

[0026] A manufacturing process for a high wear-resistant composite structure dust cover for electric vehicles includes the following steps: Step S1, Raw material pretreatment: Weigh each raw material component of wear-resistant protective layer 2, buffer flame-retardant layer 3, sealing dustproof layer 4 and inner anti-slip layer 5 according to the ratio, and perform stirring and mixing treatment for 30 minutes, ultrasonic dispersion treatment for 15 minutes, and vacuum degassing treatment for 20 minutes to remove air bubbles and impurities inside the raw materials and ensure the uniformity of the raw materials. Step S2, Inner Anti-slip Layer Molding: Inject flexible modified nitrile rubber material into a custom mold, preheat at 70℃ for 10 minutes to form, keep warm and cure for 20 minutes, and then demold to obtain the inner anti-slip layer 5 substrate with anti-slip frosted texture. Step S3, sealing and dustproof layer composite: uniformly apply 18μm polyurethane high temperature resistant adhesive to the outer surface of the inner anti-slip layer 5, attach the pretreated high-density polyester fiber fabric to the adhesive layer surface, and compact it with a calender roller, dry it at 70℃ for 25min, spray a 25μm fluorine waterproof coating on the outer surface of the fabric, and cure it at a constant temperature of 80℃ for 30min. Step S4, Buffer Flame Retardant Layer Foaming: The foamed flame retardant silicone composition is uniformly coated on the outer surface of the sealing dustproof layer 4, and foamed and molded using a segmented foaming process: the first stage preheating foaming temperature is 70℃ and the foaming time is 3min; the second stage constant temperature setting temperature is 90℃ and the setting time is 8min, forming a uniform porous buffer structure. After cooling and setting, the composite of the buffer flame retardant layer 3 is completed. Step S5, Wear-resistant layer molding: The high-elasticity wear-resistant modified polyurethane material is uniformly coated on the outer surface of the buffer flame-retardant layer 3. The wear-resistant protective layer 2 with hydrophobic wear-resistant texture and flexible buffer protrusions 7 is prepared by molding integrated molding process, and then cured and shaped at high temperature. The buffer protrusions and wear-resistant texture are molded in one piece. The molding temperature is 110℃, the molding pressure is 5MPa, and the molding curing time is 20min. Step S6, Edge sealing and installation: The edges of the dust cover blank are neatly arranged, and a ring-shaped elastic component is embedded inside the lower end. The sealing edge structure 6 is formed in one piece by hot pressing edge sealing process. Step S7, Post-processing and molding: Trim the edges, remove dust, and perform low-temperature aging treatment for 24 hours after molding to eliminate internal stress. Test the wear resistance, sealing performance, tensile properties, and flame retardant properties. If the test is qualified, the finished dust cover is obtained. Example

[0027] A high wear-resistant composite dust cover for electric vehicles includes a dust cover body 1, which is a multi-layer composite integrated structure. From the outside to the inside, it consists of a wear-resistant protective layer 2, a buffer flame-retardant layer 3, a sealing dust-proof layer 4, and an inner anti-slip layer 5. The wear-resistant protective layer 2 is made of a high-elasticity wear-resistant modified polyurethane material, the buffer flame-retardant layer 3 is made of a foamed flame-retardant silicone composition, the sealing dust-proof layer 4 is made of a high-density polyester fiber fabric combined with a waterproof and dustproof coating, and the inner anti-slip layer 5 is made of a flexible modified nitrile rubber material. The dust cover body 1 has an integrated sealing edge structure 6 on its edge. The lower end of the sealing edge structure 6 is embedded with an annular elastic component. The surface of the dust cover body 1 is uniformly provided with several flexible buffer protrusions 7. The flexible buffer protrusions 7 are integrally formed with the wear-resistant protective layer 2. The thickness of each layer is 1.0mm, 1.8mm, 0.6mm and 0.8mm respectively.

[0028] The raw materials of the wear-resistant protective layer 2, by weight, include: 85 parts of polyurethane resin, 6 parts of nano-silica wear-resistant filler, 2.5 parts of UV-resistant additive, 1.5 parts of elastic toughening agent, and 0.5 parts of antioxidant; the surface of the wear-resistant protective layer 2 is provided with micron-level hydrophobic wear-resistant texture.

[0029] The raw materials of the buffer flame retardant layer 3, by weight, include: 70 parts of vinyl silicone oil, 5 parts of low-hydrogen silicone oil, 5 parts of high-hydrogen silicone oil, 9 parts of fumed silica, 14 parts of aluminum hydroxide, 2.5 parts of alumina, and 3 parts of hydroxyl silicone oil; the buffer flame retardant layer 3 has a porous foam structure with a foam porosity of 35% and a flame retardant rating of UL94 V-0.

[0030] The raw materials of the sealing and dustproof layer 4, by weight, include: 75 parts of high-density conductive polyester composite yarn and 25 parts of conventional polyester filament; the waterproof and dustproof coating is a fluorine waterproof coating with a coating thickness of 25μm.

[0031] The raw materials of the inner anti-slip layer 5, by weight, include: 70 parts of nitrile rubber, 20 parts of polyvinyl chloride, 1.5 parts of carbon black N550, 0.5 parts of activated calcium carbonate, 2.5 parts of antioxidant (4010NA), 1.5 parts of accelerator, and 3.5 parts of plasticizer (TP-95); the inner anti-slip layer 5 is provided with an anti-slip frosted texture.

[0032] A manufacturing process for a high wear-resistant composite structure dust cover for electric vehicles includes the following steps: Step S1, Raw material pretreatment: Weigh each raw material component of wear-resistant protective layer 2, buffer flame-retardant layer 3, sealing dustproof layer 4 and inner anti-slip layer 5 according to the ratio, and perform stirring and mixing treatment for 35 minutes, ultrasonic dispersion treatment for 20 minutes, and vacuum degassing treatment for 25 minutes to remove air bubbles and impurities inside the raw materials and ensure the uniformity of the raw materials. Step S2, Inner Anti-slip Layer Molding: Inject flexible modified nitrile rubber material into a custom mold, preheat at 80℃ for 12 minutes to form, keep warm and cure for 25 minutes, and then demold to obtain the inner anti-slip layer 5 substrate with anti-slip frosted texture. Step S3, sealing and dustproof layer composite: uniformly apply 23μm polyurethane high temperature resistant adhesive to the outer surface of the inner anti-slip layer 5, attach the pretreated high-density polyester fiber fabric to the adhesive layer surface, and compact it with a calender roller, dry it at 80℃ for 30min, spray 28μm fluorine waterproof coating on the outer surface of the fabric, and cure it at a constant temperature of 85℃ for 35min. Step S4, Buffer Flame Retardant Layer Foaming: The foamed flame retardant silicone composition is uniformly coated on the outer surface of the sealing dustproof layer 4, and foamed and molded using a segmented foaming process: the first stage preheating foaming temperature is 75℃ and the foaming time is 5min; the second stage constant temperature setting temperature is 100℃ and the setting time is 10min, forming a uniform porous buffer structure. After cooling and setting, the composite of the buffer flame retardant layer 3 is completed. Step S5, Wear-resistant layer molding: The high-elasticity wear-resistant modified polyurethane material is uniformly coated on the outer surface of the buffer flame-retardant layer 3. The wear-resistant protective layer 2 with hydrophobic wear-resistant texture and flexible buffer protrusions 7 is prepared by molding integrated molding process, and then cured and shaped at high temperature. The buffer protrusions and wear-resistant texture are molded in one piece. The molding temperature is 120℃, the molding pressure is 6MPa, and the molding curing time is 25min. Step S6, Edge sealing and installation: The edges of the dust cover blank are neatly arranged, and a ring-shaped elastic component is embedded inside the lower end. The sealing edge structure 6 is formed in one piece by hot pressing edge sealing process. Step S7, Post-processing and molding: Trim the edges, remove dust, and perform low-temperature aging treatment for 24 hours after molding to eliminate internal stress. Test the wear resistance, sealing performance, tensile properties, and flame retardant properties. If the test is qualified, the finished dust cover is obtained. Example

[0033] A high wear-resistant composite dust cover for electric vehicles includes a dust cover body 1, which is a multi-layer composite integrated structure. From the outside to the inside, it consists of a wear-resistant protective layer 2, a buffer flame-retardant layer 3, a sealing dust-proof layer 4, and an inner anti-slip layer 5. The wear-resistant protective layer 2 is made of a high-elasticity wear-resistant modified polyurethane material, the buffer flame-retardant layer 3 is made of a foamed flame-retardant silicone composition, the sealing dust-proof layer 4 is made of a high-density polyester fiber fabric combined with a waterproof and dustproof coating, and the inner anti-slip layer 5 is made of a flexible modified nitrile rubber material. The dust cover body 1 has an integrated sealing edge structure 6 on its edge. The lower end of the sealing edge structure 6 is embedded with an annular elastic component. The surface of the dust cover body 1 is uniformly provided with several flexible buffer protrusions 7. The flexible buffer protrusions 7 are integrally formed with the wear-resistant protective layer 2. The thickness of each layer is 1.0mm, 1.8mm, 0.6mm and 0.8mm respectively.

[0034] The raw materials of the wear-resistant protective layer 2 include, by weight: 90 parts of polyurethane resin, 8 parts of nano-silica wear-resistant filler, 3 parts of UV-resistant additive, 2 parts of elastic toughening agent, and 1 part of antioxidant; the surface of the wear-resistant protective layer 2 is provided with micron-level hydrophobic wear-resistant texture.

[0035] The raw materials of the buffer flame retardant layer 3, by weight, include: 80 parts of vinyl silicone oil, 7 parts of low-hydrogen silicone oil, 7 parts of high-hydrogen silicone oil, 14 parts of fumed silica, 15 parts of aluminum hydroxide, 3.5 parts of alumina, and 4 parts of hydroxyl silicone oil; the buffer flame retardant layer 3 has a porous foam structure with a foam porosity of 40% and a flame retardant rating of UL94 V-0.

[0036] The raw materials of the sealing and dustproof layer 4, by weight, include: 80 parts of high-density conductive polyester composite yarn and 30 parts of conventional polyester filament; the waterproof and dustproof coating is a fluorine waterproof coating with a coating thickness of 30μm.

[0037] The raw materials of the inner anti-slip layer 5 by weight include: 80 parts of nitrile rubber, 25 parts of polyvinyl chloride, 2 parts of carbon black N550, 1 part of activated calcium carbonate, 3 parts of antioxidant (4010NA), 2 parts of accelerator, and 4 parts of plasticizer (TP-95); the inner anti-slip layer 5 is provided with an anti-slip frosted texture.

[0038] A manufacturing process for a high wear-resistant composite structure dust cover for electric vehicles includes the following steps: Step S1, Raw material pretreatment: Weigh each raw material component of wear-resistant protective layer 2, buffer flame-retardant layer 3, sealing dustproof layer 4 and inner anti-slip layer 5 according to the ratio, and perform stirring and mixing treatment for 40 minutes, ultrasonic dispersion treatment for 25 minutes, and vacuum degassing treatment for 30 minutes to remove air bubbles and impurities inside the raw materials and ensure the uniformity of the raw materials. Step S2, Inner Anti-slip Layer Molding: Inject flexible modified nitrile rubber material into a custom mold, preheat at 85℃ for 15 minutes to form, keep warm and cure for 30 minutes, and then demold to obtain the inner anti-slip layer 5 substrate with anti-slip frosted texture. Step S3, sealing and dustproof layer composite: uniformly apply 21μm polyurethane high temperature resistant adhesive to the outer surface of the inner anti-slip layer 5, attach the pretreated high-density polyester fiber fabric to the adhesive layer surface, and compact it with a calender roller, dry it at 75℃ for 30min, spray 28μm fluorine waterproof coating on the outer surface of the fabric, and cure it at a constant temperature of 85℃ for 35min. Step S4, Buffer Flame Retardant Layer Foaming: The foamed flame retardant silicone composition is uniformly coated on the outer surface of the sealing dustproof layer 4, and foamed and molded using a segmented foaming process: the first stage preheating foaming temperature is 85℃ and the foaming time is 7min; the second stage constant temperature setting temperature is 110℃ and the setting time is 12min, forming a uniform porous buffer structure. After cooling and setting, the composite of the buffer flame retardant layer 3 is completed. Step S5, Wear-resistant layer molding: The high-elasticity wear-resistant modified polyurethane material is uniformly coated on the outer surface of the buffer flame-retardant layer 3. The wear-resistant protective layer 2 with hydrophobic wear-resistant texture and flexible buffer protrusions 7 is prepared by molding integrated molding process, and then cured and shaped at high temperature. The buffer protrusions and wear-resistant texture are molded in one piece. The molding temperature is 130℃, the molding pressure is 7MPa, and the molding curing time is 30min. Step S6, Edge sealing and installation: The edges of the dust cover blank are neatly arranged, and a ring-shaped elastic component is embedded inside the lower end. The sealing edge structure 6 is formed in one piece by hot pressing edge sealing process. Step S7, Post-processing and molding: Trim the edges, remove dust, and perform low-temperature aging treatment for 24 hours after molding to eliminate internal stress. Test the wear resistance, sealing performance, tensile properties, and flame retardant properties. If the test is qualified, the finished dust cover is obtained.

[0039] Performance testing experiments: To visually verify the performance advantages of the composite dust cover of this invention, the products of Examples 1-3 of this invention were subjected to standardized working condition tests compared with mainstream traditional single-layer rubber dust covers, plastic dust covers, and ordinary fabric dust covers on the market. The test environment included high and low temperature cycling, ultraviolet aging, sand and gravel abrasion resistance, waterproof and dustproof, tensile tear, and flame retardant tests. The quantitative comparison results are as follows: Wear resistance: The wear loss of the product of this invention is reduced by 72%, 65% and 78% respectively compared with the three types of traditional products, and there is no surface peeling after long-term friction; 2. Mechanical properties: The tensile breaking strength is increased by an average of more than 85% compared with traditional products, the tear resistance is increased by 90%, and there are no stress fracture or deformation problems; 3. Weather resistance and aging performance: It resists ultraviolet aging and has a service life that is more than 3 times longer under high and low temperature cycles. Traditional products crack and harden after 500 hours of aging, while this invention shows no significant performance degradation after 1500 hours. 4. Protection level: The waterproof and dustproof rating of this invention reaches IP67, while traditional rubber and plastic covers are only IP54 and fabric covers are only IP42, demonstrating a significantly superior ability to block fine dust and water vapor. 5. Safety performance: The flame retardant rating of this invention is UL94 V-0. Traditional dust covers do not have flame retardant properties and pose a safety hazard in high-temperature environments for motors. 6. Structural stability: After 1000 cycles of bumpy deformation testing, traditional products all showed problems such as delamination, cracking, and loosening, while the product of this invention showed no delamination, deformation, or displacement, demonstrating excellent structural stability.

[0040] In summary, this invention significantly outperforms existing traditional technologies in terms of core protective performance, structural stability, weather resistance, safety, and service life. It adopts a four-layer differentiated functional composite structure design, breaking through the shortcomings of traditional single-layer dust covers in terms of limited performance. The outer high-wear-resistant protective layer 2 provides anti-friction, anti-impact, and anti-UV aging; the middle buffer and flame-retardant layer 3 provides impact buffering, heat insulation and flame retardancy, and noise reduction and vibration damping; the sealed dustproof layer 4 provides high-precision dustproof, waterproof, and sand and mud penetration prevention; and the inner anti-slip layer 5 ensures a tight fit and prevents displacement and loosening. The multi-layer structure works synergistically to comprehensively improve the protective performance of the dust cover.

[0041] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A high wear-resistant composite structure dust cover for electric vehicles, characterized in that, The dust cover body (1) is a multi-layer composite integrated structure. From the outside to the inside, it is provided with a wear-resistant protective layer (2), a buffer flame-retardant layer (3), a sealing dustproof layer (4) and an inner anti-slip layer (5). The wear-resistant protective layer (2) is made of high-elasticity wear-resistant modified polyurethane material. The buffer flame-retardant layer (3) is made of foamed flame-retardant silicone composition. The sealing dustproof layer (4) is made of high-density polyester fiber fabric combined with a waterproof and dustproof coating. The inner anti-slip layer (5) is made of flexible modified nitrile rubber material. The edge of the dust cover body (1) is integrally provided with a sealing edge structure (6). The lower end of the sealing edge structure (6) is embedded with an annular elastic component. The surface of the dust cover body (1) is uniformly provided with several flexible buffer protrusions (7). The flexible buffer protrusions (7) are integrally formed with the wear-resistant protective layer (2).

2. The dust cover according to claim 1, characterized in that, The wear-resistant protective layer (2) has a thickness of 0.8 to 1.2 mm, and its raw materials include, by weight: 80 to 90 parts of polyurethane resin, 5 to 8 parts of nano-silica wear-resistant filler, 2 to 3 parts of UV-resistant additive, 1 to 2 parts of elastic toughening agent, and 0.5 to 1 part of antioxidant; the surface of the wear-resistant protective layer (2) is provided with micron-level hydrophobic wear-resistant texture.

3. The dust cover according to claim 1, characterized in that, The thickness of the buffer flame retardant layer (3) is 1.5 to 2.0 mm, and its raw materials include, by weight: 65 to 80 parts of vinyl silicone oil, 3 to 7 parts of low-hydrogen silicone oil, 3 to 7 parts of high-hydrogen silicone oil, 3 to 14 parts of fumed silica, 13 to 15 parts of aluminum hydroxide, 1.5 to 3.5 parts of alumina, and 2 to 4 parts of hydroxyl silicone oil; the buffer flame retardant layer (3) has a porous foam structure with a foam porosity of 30% to 40% and a flame retardant rating of UL94 V-0.

4. The dust cover according to claim 1, characterized in that, The thickness of the sealing and dustproof layer (4) is 0.5 to 0.8 mm, and its raw materials include, by weight, 70 to 80 parts of high-density conductive polyester composite filament and 20 to 30 parts of conventional polyester filament; the waterproof and dustproof coating is a fluorine waterproof coating with a coating thickness of 20 to 30 μm.

5. The dust cover according to claim 1, characterized in that, The thickness of the inner anti-slip layer (5) is 0.6-1.0 mm, and its raw materials include, by weight: 60-80 parts of nitrile rubber, 15-25 parts of polyvinyl chloride, 1-2 parts of carbon black (N550), 0.5-1 parts of activated calcium carbonate, 2-3 parts of antioxidant (4010NA), 1-2 parts of accelerator, and 3-4 parts of plasticizer (TP-95); the inner anti-slip layer (5) is provided with an anti-slip frosted texture.

6. The dust cover according to claim 1, characterized in that, The annular elastic component is composed of a flexible nylon braided skeleton (8) and a rubber elastomer (9) with a thickness of 0.3 to 0.5 mm. The inner side of the rubber elastomer (9) is embedded with several equally spaced annular magnetic sheets (10), and the annular magnetic sheets (10) are attracted and fixed to the metal shell of the electric vehicle.

7. A manufacturing process for a high wear-resistant composite structure dust cover for electric vehicles according to any one of claims 1-6, characterized in that, Includes the following steps: Step S1, Raw material pretreatment: Weigh each raw material component of wear-resistant protective layer (2), buffer flame retardant layer (3), sealing dustproof layer (4) and inner anti-slip layer (5) according to the ratio, and perform stirring, ultrasonic dispersion and vacuum degassing treatment respectively to remove air bubbles and impurities inside the raw materials and ensure the uniformity of the raw materials; Step S2, Inner anti-slip layer molding: Inject flexible modified nitrile rubber material into a custom mold, preheat and mold at low temperature, and demold after heat preservation and curing to prepare an inner anti-slip layer (5) substrate with anti-slip frosted texture; Step S3, sealing and dustproof layer composite: Apply special composite adhesive evenly to the outer surface of the inner anti-slip layer (5), attach the pretreated high-density polyester fiber fabric to the adhesive layer surface, and press it with a calender roller. After drying and curing, spray a fluorine waterproof and dustproof coating on the outer surface of the fabric and cure it at a constant temperature to complete the preparation of the sealing and dustproof layer. Step S4, Buffer Flame Retardant Layer Molding and Composite: The foamed flame retardant silicone composition is uniformly coated on the outer surface of the sealing dustproof layer (4), and foamed and molded using a segmented foaming process. The foaming temperature and time are controlled to form a uniform porous buffer structure. After cooling and shaping, the composite of the buffer flame retardant layer (3) is completed. Step S5, wear-resistant protective layer molding: The high elasticity wear-resistant modified polyurethane material is uniformly coated on the outer surface of the buffer flame retardant layer (3), and the wear-resistant protective layer (2) with hydrophobic wear-resistant texture and flexible buffer protrusion (7) is prepared by molding integrated molding process, and then cured and shaped at high temperature. Step S6, Edge wrapping and embedding: The edges of the dust cover blank are neatly arranged and a ring elastic component is embedded in the lower end. The sealing edge structure is formed in one piece by hot pressing edge wrapping process (6). Step S7, Post-processing and molding: Trim the edges, remove dust, and perform low-temperature aging treatment for 24 hours after molding to eliminate internal stress. Test the wear resistance, sealing performance, tensile properties, and flame retardant properties. If the test is qualified, the finished dust cover is obtained.

8. The preparation process according to claim 7, characterized in that, In step S3, the composite adhesive is a high-temperature resistant polyurethane adhesive, with a coating thickness of 15-30 μm, a drying temperature of 55-90°C, and a drying time of 10-30 min.

9. The preparation process according to claim 7, characterized in that, In step S4, the segmented foaming process is as follows: the first stage preheating foaming temperature is 70-85℃, and the foaming time is 3-7 min; the second stage constant temperature setting temperature is 90-110℃, and the setting time is 8-12 min.

10. The preparation process according to claim 7, characterized in that, In step S5, the molding temperature is 110–130°C, the molding pressure is 5–7 MPa, and the curing time is 20–30 min.

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