Carbon fiber ornament structure and automobile
By setting up interlayers in the carbon fiber trim structure and using adhesive materials, combining carbon fiber composite materials and thermoplastic matrix resin materials, the problem of high manufacturing costs of traditional carbon fiber trim is solved, and the effect of reducing costs and maintaining a sense of advancedness is achieved. It is suitable for large-scale applications of ordinary cars.
Patent Information
- Application Number
- CN202420070502.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-01-11
- Publication Date
- 2025-03-21
- Estimated Expiration
- 2034-01-11
AI Technical Summary
Traditional carbon fiber trim is expensive to manufacture, making it difficult to apply on a large scale in ordinary cars.
By setting up interlayers in the carbon fiber trim structure and using adhesive materials at the interlayers, combining carbon fiber composite materials and thermoplastic matrix resin materials, the amount of carbon fiber is reduced while maintaining a sense of technology and high-end.
It has achieved the reduction of the manufacturing cost of carbon fiber trim structures, while ensuring its overall strength and aesthetic effect, and is suitable for large-scale applications of ordinary cars.
Smart Images
Figure CN222645939U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to the field of carbon fiber decorative part molding, in particular to a carbon fiber decorative part structure and an automobile. Background Art
[0002] With the advancement of global technology, the sense of technology is becoming a value trend that is widely accepted by consumers. In the current automotive CMF (color, material and finish) development process, various technological elements are gradually being combined with daily consumer goods, creating a natural sense of technology product image through design elements such as form, material, light and interface, and carbon fiber naturally has technological and advanced attributes.
[0003] Carbon fiber is a material with low density and high strength. It is mainly used in the aviation and aerospace fields. It is also widely used in the structural parts and interior and exterior trims of high-end sports cars due to its excellent lightweight effect. However, due to the high manufacturing cost of carbon fiber trims, it is difficult to achieve large-scale application of carbon fiber trims in ordinary cars. Summary of the invention
[0004] The embodiments of the utility model provide a carbon fiber trim structure and a car to solve the problem of high manufacturing cost of traditional carbon fiber trims.
[0005] In order to solve the above problems, the technical solution adopted by the utility model is:
[0006] In a first aspect, a carbon fiber trim structure includes:
[0007] Main structure and exterior layer;
[0008] An interlayer is arranged between the main structure and the appearance layer, the interlayer is arranged on the main structure, and the appearance layer is arranged on the interlayer;
[0009] The exterior layer comprises a carbon fiber composite material, the main structure comprises a thermoplastic matrix resin material, and the interlayer is provided with an adhesive material.
[0010] Optionally, the carbon fiber composite material of the exterior layer includes a thermoplastic matrix resin material.
[0011] Optionally, the thickness of the appearance layer is not less than 0.3 mm.
[0012] Optionally, the appearance layer is partially embedded in the main structure, and the outer surface of the appearance layer is located outside the outer surface of the main structure.
[0013] Optionally, the projection area of the appearance layer on the main structure covers the main structure. Optionally, the main structure includes a flange structure, the flange structure is located at the edge of the main structure, and the thickness of the flange structure is greater than the thickness of the main structure away from the flange structure.
[0014] Optionally, the main structure further includes reinforcing ribs and connecting columns, and the reinforcing ribs and connecting columns are arranged on the back side of the main structure.
[0015] Optionally, the appearance surface of the appearance layer includes a carbon fiber texture, and the carbon fiber texture is made by hot pressing preforming.
[0016] Optionally, the exterior layer is preformed by a hot pressing process, and the main body structure is compounded on the back of the exterior layer by an injection molding process.
[0017] In a second aspect, a car comprises the carbon fiber trim structure as described above.
[0018] The embodiment of the utility model provides a carbon fiber trim structure and a car, in which the appearance layer is formed by carbon fiber hot pressing, and the main structure is compounded on the appearance layer by an injection molding process. At the same time, a layer of adhesive material is provided between the appearance layer and the main structure to ensure the adhesion between the two and the overall strength of the carbon fiber trim. Further, while replacing the base material of the main structure with a non-carbon fiber material, the use of carbon fiber can be reduced, and the technological and high-end sense of the carbon fiber trim structure can be ensured, thereby reducing the manufacturing cost of the carbon fiber trim structure. BRIEF DESCRIPTION OF THE DRAWINGS
[0019] In order to more clearly illustrate the technical solutions of the embodiments of the utility model, the drawings required for use in the description of the embodiments of the utility model will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the utility model. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.
[0020] Figure 1 It is a structural schematic diagram of a carbon fiber decorative part structure in one embodiment of the utility model.
[0021] Figure 2 This is another structural schematic diagram of the carbon fiber decorative part structure in one embodiment of the utility model;
[0022] Figure 3 This is another structural schematic diagram of a carbon fiber decorative part structure in one embodiment of the utility model;
[0023] Figure 4 It is a plan view of a carbon fiber decorative part structure in one embodiment of the utility model;
[0024] Figure 5 It is another planed schematic diagram of the carbon fiber decorative part structure in one embodiment of the utility model.
[0025] Among them, the reference numerals in the figure are:
[0026] Appearance layer 1; main structure 2; reinforcing ribs 3; connecting columns 4; flange structure 5; interlayer 6. DETAILED DESCRIPTION
[0027] In order to make the technical problems, technical solutions and beneficial effects solved by the utility model more clear, the utility model is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described here are only used to explain the utility model and are not used to limit the utility model.
[0028] In the description of the present invention, it should be understood that the terms "longitudinal", "radial", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention. In the description of the present invention, unless otherwise specified, "plurality" means two or more.
[0029] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installation", "connection" and "connection" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.
[0030] Generally speaking, existing processes are suitable for manufacturing thin-walled structures of carbon fiber trims, but cannot produce complex structures such as reinforcing ribs and connecting columns. In addition, due to process limitations, there is a minimum wall thickness requirement for thin-walled carbon fiber trims, and it is impossible to reduce costs by reducing the amount of carbon fiber material used.
[0031] In order to solve the above problems, the technical solution of the utility model will be described in detail below:
[0032] Please also read Figure 1 and Figure 2The carbon fiber decorative part structure of the embodiment of the utility model is described. The utility model relates to a carbon fiber decorative part structure, which includes a main structure 2 and an appearance layer 1.
[0033] In one embodiment, the main structure 2 is the basic supporting part of the carbon fiber trim structure, and the appearance layer 1 is a surface layer for beautifying and protecting the main structure 2. The appearance layer 1 can be directly arranged on the main structure 2, or connected to the main structure 2 through an interlayer 6. The interlayer 6 is a layer located between the main structure 2 and the appearance layer 1. By arranging an adhesive material in the interlayer 6, the compatibility and adhesion between the appearance layer 1 and the main structure 2 can be increased.
[0034] The appearance layer includes a carbon fiber composite material, and the main structure 2 includes a thermoplastic matrix resin material. By arranging a layer of interlayer 6 between the appearance layer 1 and the main structure 2, and adding an adhesive material at the interlayer 6, the adhesive material is arranged at the interlayer 6 to help enhance the adhesion and compatibility between the appearance layer 1 and the main structure 2, thereby ensuring the overall strength of the carbon fiber decorative part structure. Furthermore, the matrix material of the main structure 2 can be replaced with a non-carbon fiber material, which can not only reduce the use of carbon fiber, but also ensure the technological sense and high-end sense of the carbon fiber decorative part structure, while also ensuring that the adhesive material can firmly bond the appearance layer 1 and the main structure 2, making the carbon fiber decorative part structure easier to manufacture, more efficient, and cheaper, and can meet the needs of mass production. Among them, the adhesive material includes a resin material with hot-melt properties and other adhesive materials, which are not specifically limited by the present utility model.
[0035] In one embodiment, the carbon fiber composite material of the appearance layer 1 includes a thermoplastic matrix resin material, wherein the thermoplastic matrix resin includes polypropylene, nylon and polycarbonate polymers. The polypropylene polymer is a common thermoplastic resin having the characteristics of light weight, excellent chemical stability and mechanical properties. Introducing the polypropylene polymer into the matrix material of the appearance layer 1 helps to achieve lightweighting of the trim while maintaining its strength and stability.
[0036] The nylon polymer is a material with excellent wear resistance and heat resistance, and is suitable for the preparation of the carbon fiber trim structure. Adding the nylon polymer to the base material of the appearance layer 1 can improve the durability and heat resistance of the carbon fiber trim structure, making the carbon fiber trim structure suitable for various environments.
[0037] The polycarbonate polymer is another commonly used thermoplastic resin with excellent optical properties and transparency. Introducing the polycarbonate polymer into the appearance layer 1 matrix material helps to improve the appearance quality of the carbon fiber trim structure, making it highly transparent and glossy. These different types of thermoplastic matrix resin materials can be combined or selected according to the needs of specific applications to meet the performance, strength and appearance requirements of the carbon fiber trim structure, so that the carbon fiber trim structure of the utility model has a wide range of applicability and can be applied to different types of carbon fiber trim structures.
[0038] In one embodiment, if Figure 1 , Figure 2 and Figure 3 As shown, the main structure 2 includes reinforcing ribs 3, connecting columns 4 and flange structures 5. The flange structure 5 is located at the edge of the main structure 2, and the thickness of the flange structure 5 is greater than the thickness of the main structure 2 away from the flange structure 5. The edge portion of the appearance layer 1 is reinforced by the flange structure 5. The flange structure 5 is connected to the appearance layer 1 and extends along the edge portion of the main structure 2, providing additional material support and strength for the appearance layer 1. This reinforcement structure helps to reduce the deflection of the edge of the appearance layer 1 and reduce the risk of deformation, while also increasing the overall rigidity of the carbon fiber trim structure. By using the flange structure 5 to strengthen the edge of the appearance layer 1, the carbon fiber trim structure of the utility model can provide excellent performance and quality while maintaining lightweight.
[0039] In one embodiment, the main structure 2 further includes structures such as the reinforcing ribs 3 and the connecting columns 4, wherein the reinforcing ribs 3 and the connecting columns 4 are arranged on the back of the main structure 2. By arranging the reinforcing ribs 3 and the connecting columns 4 on the back of the main structure 2, it is convenient to assemble with other decorative parts. These structures provide reliable support and connection points, making the subsequent decorative parts assembly process simpler and more efficient, and ensuring that the final assembled carbon fiber decorative parts structure has good structural strength and stability.
[0040] See also Figure 4 and Figure 5 , the carbon fiber decorative part structure of the embodiment of the utility model is further explained.
[0041] In one embodiment, the thickness of the appearance layer 1 is not less than 0.3 mm. When the thickness of the appearance layer 1 is not less than 0.3 mm, it can ensure that the carbon fiber trim structure has sufficient strength, durability and appearance effect to meet the use requirements and provide a good user experience.
[0042] Exemplarily, the thickness t of the appearance layer 1 satisfies the following condition: 0.3mm≤t≤1.5mm. When the thickness t of the appearance layer 1 is less than 0.3mm, the strength and durability of the carbon fiber trim structure will be affected accordingly. On the contrary, when the thickness t of the appearance layer 1 is greater than 1.5mm, the weight of the carbon fiber trim structure will increase significantly, which conflicts with the goal of lightweight design, and at the same time leads to an increase in the use of carbon fiber materials, which goes against the original intention of reducing high manufacturing costs. By controlling the thickness t of the appearance layer 1 within the range of 0.3mm to 1.5mm, the carbon fiber trim structure of the utility model can achieve a balance between lightweight and performance to obtain optimal performance and appearance effects, so that the carbon fiber trim structure can be widely used in ordinary cars.
[0043] It should be noted that the above is only an example, and the specific scope is not limited by the present invention.
[0044] In one embodiment, the appearance layer 1 is partially embedded in the main structure 2, and the outer surface of the appearance layer 1 is located outside the outer surface of the main structure 2, so that the edge of the appearance layer 1 and the fitting position of the main structure 2 are provided with a face difference, which means that a part of the appearance layer 1 is embedded in the main structure 2. This embedding design can increase the connection strength and stability between the appearance layer 1 and the main structure 2, so that the appearance layer 1 is more firmly fixed on the main structure 2. By providing the face difference and partially embedding the appearance layer 1 in the main structure 2, the overall quality and service life of the carbon fiber trim structure can be improved, and the connection between the appearance layer 1 and the main structure 2 can be ensured to be firm and reliable.
[0045] Exemplarily, the face difference h of the edge of the appearance layer 1 and the binding position of the main structure 2 satisfies the following condition: 0.1mm≤h≤0.5t. That is, it is greater than or equal to 0.1mm and less than or equal to 0.5 times the thickness t of the appearance layer 1, which is between the minimum value of 0.3mm and the maximum value of 1.5mm. When the face difference h of the edge of the appearance layer 1 and the binding position of the main structure 2 is less than 0.1mm, the edge of the appearance layer 1 and the binding position of the main structure 2 will become loose, thereby affecting the appearance quality and performance of the carbon fiber decorative part structure. On the contrary, when the face difference h of the edge of the appearance layer 1 and the binding position of the main structure 2 is greater than 0.5t, the embedding depth of the appearance layer 1 will increase, which may lead to waste of materials and increase in manufacturing costs. By controlling the face difference h of the binding position of the edge of the appearance layer 1 and the main structure 2 within the range of 0.1mm to 0.5t, the carbon fiber decorative part structure of the utility model can achieve a close combination between the appearance layer 1 and the main structure 2 while avoiding excessive waste of materials. The surface difference h within this range can be adjusted according to specific design requirements and material properties to achieve the best combination effect. At the same time, this combination method not only ensures the overall strength and rigidity of the carbon fiber trim structure, but also provides higher appearance quality and design freedom, making the carbon fiber trim structure of the utility model suitable for various automotive applications and design requirements.
[0046] It should be noted that the above is only an example, and the specific scope is not limited by the present invention.
[0047] In one embodiment, the projection area of the appearance layer 1 on the main structure 2 covers the main structure 2, and the edge portion of the appearance layer 1 extends beyond the main structure 2. By allowing the edge portion of the appearance layer 1 to extend beyond the main structure 2, better protection, aesthetics and functionality can be provided, thereby improving the overall quality and user experience of the carbon fiber trim structure.
[0048] Exemplarily, the edge of the appearance layer 1 extends beyond the main structure 2 by 3 mm to 5 mm. This range not only allows the appearance layer 1 to completely cover the main structure 2, but also provides additional coverage and design effects outside the extended area. By extending the appearance layer 1 beyond the main structure 2, the carbon fiber trim structure of the utility model can be made more flexible and beautiful in appearance design, which helps to improve the decorativeness and uniqueness of the carbon fiber trim structure.
[0049] It should be noted that the above is only an example, and the specific scope is not limited by the present invention.
[0050] In one embodiment, the appearance surface of the appearance layer 1 has a unique carbon fiber texture, which is made by hot pressing preforming, wherein the carbon fiber texture includes unidirectional, plain, twill or satin, etc., to obtain the desired appearance effect.
[0051] In the hot pressing preforming process, a thermoplastic carbon fiber composite material (such as polypropylene, nylon and polycarbonate polymers, etc.) is placed in a mold and heated and compressed under high temperature and high pressure conditions. The thermoplastic carbon fiber composite material is deformed into a desired shape through the hot pressing preforming process, and a carbon fiber texture is formed on the appearance surface. The obtained appearance layer 1 is cooled and solidified to maintain its desired shape and carbon fiber texture. Through the above preparation steps, the appearance surface of the appearance layer 1 has a highly decorative and unique carbon fiber texture, which not only increases the aesthetics of the carbon fiber trim structure, but also enhances the overall texture of the carbon fiber trim structure.
[0052] In one embodiment, the main structure 2 is compounded on the back of the appearance layer 1 through an injection molding process, so that the appearance layer 1 and the main structure 2 can be tightly combined together to form an integral carbon fiber trim structure, so that the carbon fiber trim structure has the characteristics of high strength, high rigidity and light weight, and can provide excellent appearance effects.
[0053] In one embodiment, a car is provided, comprising the carbon fiber trim structure described in the first aspect embodiment.
[0054] It should be noted that the carbon fiber decorative part structure provided by the utility model can be used in the fields of aircraft, high-speed railways, automobiles, etc., and the utility model does not make specific limitations.
[0055] The following describes a method for preparing a carbon fiber trim structure according to an embodiment of the present invention.
[0056] Step 1: Preprocessing.
[0057] In one embodiment, first, a carbon fiber composite material sheet suitable for the exterior layer 1 is selected. Typically, the carbon fiber composite material sheet is a unidirectional, plain, twill, satin or other texture composite material sheet made of continuous carbon fiber, or a marbled carbon fiber composite material sheet made of chopped fibers, and then the selected carbon fiber composite material sheet is pretreated.
[0058] The pretreatment process includes cutting the carbon fiber composite material sheet to obtain the desired size and shape. Then, the carbon fiber composite material sheet is dried by hot air or vacuum drying. The purpose of doing this is to remove moisture from the carbon fiber composite material sheet to improve the processing performance of the carbon fiber composite material sheet and ensure the surface quality of the appearance surface. By fully drying the carbon fiber composite material sheet, the influence of moisture on the performance and processing of the carbon fiber composite material sheet can be avoided, so as to improve the stability and processability of the carbon fiber composite material sheet, ensure the smooth progress of the subsequent processing process, and ensure that the outer surface of the final appearance layer 1 has good appearance quality. Among them, the commonly used hot air or vacuum drying temperature and recommended time for carbon fiber composite materials are shown in Table 1:
[0059] Table 1:
[0060]
[0061] Step 2: Hot pressing preforming.
[0062] In one embodiment, first, the preforming mold is heated to the preforming temperature of the carbon fiber composite material sheet (the common preforming temperature of the carbon fiber sheet is shown in Table 2) to ensure that the mold temperature is the same as the preforming temperature of the carbon fiber composite material sheet. The mold adopts the instant cooling and heating mold heating technology to ensure the surface quality of the workpiece, for example, electric heating, induction heating, steam heating, etc. to quickly heat the mold and the carbon fiber composite material sheet. This process is to avoid the influence of temperature differences on the molding process of the appearance layer 1 and ensure that the appearance layer 1 can reach the desired shape and size.
[0063] Then, the carbon fiber composite material sheet is placed in the mold. In this process, the carbon fiber composite material sheet is affected by the shape and pressure of the mold to form the shape and size required by the appearance layer 1. After the mold is closed, it is pressurized and cured. The pressure is generally 7-30MPa. This is to ensure that the carbon fiber composite material sheet can be hot-pressed under appropriate pressure to achieve the required strength and density.
[0064] Finally, the hot-pressed preformed appearance layer 1 is processed into a desired shape by punching, die punching or machining. After the processing is completed, the preformed appearance layer 1 is taken out and subjected to subsequent processing and compounding.
[0065] Table 2:
[0066]
[0067] Step 3: Injection molding of the main structure 2.
[0068] In one embodiment, the preformed appearance layer 1 is placed in an injection mold. At the same time, the material of the main structure 2 is melted, and the appearance layer 1 is maintained at a high temperature to ensure good adhesion between the appearance layer 1 and the main structure 2, and then injected into the back of the appearance layer 1 through an injection molding process. The injection mold includes a vacuum adsorption device for applying a vacuum adsorption force to the appearance layer 1 during the injection molding process to ensure that the combination between the appearance layer 1 and the main structure 2 is uniform.
[0069] By means of the vacuum adsorption device, the appearance layer 1 can be more firmly fixed on the main structure 2, avoiding the formation of gaps and bubbles. This helps to ensure the appearance quality and performance of the carbon fiber trim structure. Among them, the parameters of the injection molding process, such as temperature, pressure and vacuum adsorption force, can be adjusted according to specific requirements.
[0070] Finally, after the carbon fiber trim structure is cooled and solidified, it can be taken out and installed on the car. This manufacturing method can be used to produce various types of carbon fiber trim structures to meet the needs of automobile manufacturers and consumers for lightweight and beautiful appearance.
[0071] Step 4: Post-processing.
[0072] In one embodiment, the purpose of post-processing is to conduct a detailed evaluation of the appearance and structure of the carbon fiber trim structure. The purpose is to ensure that the carbon fiber trim structure not only meets the design requirements, but also eliminates any possible defects or flaws. The post-processing step includes inspecting the flash of the carbon fiber trim structure to ensure that the flash of the carbon fiber trim structure is completely removed to avoid adverse effects on the appearance.
[0073] Next, the finished carbon fiber trim structure is rigorously cleaned to remove any residue or dirt that may have been generated during the manufacturing process, including removing dust, grease, or other contaminants to ensure that the appearance and surface quality of the carbon fiber trim structure are maintained to the greatest extent.
[0074] Further, the carbon fiber trim structure is sprayed. This step is to enhance the appearance and durability of the carbon fiber trim structure. In addition, the carbon fiber trim structure can also be customized according to customer needs, making the carbon fiber trim structure more attractive in appearance while protecting it from the external environment. The color and texture of the spray can be selected according to the design requirements of the carbon fiber trim structure to ensure that the carbon fiber trim structure is consistent with the desired appearance. Through careful inspection, cleaning and trim spraying, it can be ensured that the carbon fiber trim structure meets the design requirements while improving the durability of the carbon fiber trim structure.
[0075] The embodiments described above are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. Such modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention, and should be included in the protection scope of the present invention.
Claims
1. A carbon fiber trim structure, characterized in that: include: Main structure and exterior layer; An interlayer is arranged between the main structure and the appearance layer, the interlayer is arranged on the main structure, and the appearance layer is arranged on the interlayer; The exterior layer comprises a carbon fiber composite material, the main structure comprises a thermoplastic matrix resin material, and the interlayer is provided with an adhesive material.
2. The carbon fiber decorative part structure according to claim 1, characterized in that: The carbon fiber composite material of the exterior layer includes a thermoplastic matrix resin material.
3. The carbon fiber decorative part structure according to claim 1, characterized in that: The thickness of the appearance layer is not less than 0.3 mm.
4. The carbon fiber decorative part structure according to claim 3, characterized in that: The appearance layer is partially embedded in the main structure, and the outer surface of the appearance layer is located outside the outer surface of the main structure.
5. The carbon fiber decorative part structure according to claim 4, characterized in that: The projection area of the appearance layer on the main structure covers the main structure.
6. The carbon fiber decorative part structure according to claim 1, characterized in that: The main structure comprises a flange structure, wherein the flange structure is located at an edge of the main structure, and the thickness of the flange structure is greater than the thickness of a region of the main structure away from the flange structure.
7. The carbon fiber decorative part structure according to claim 6, characterized in that: The main structure also includes reinforcing ribs and connecting columns, and the reinforcing ribs and connecting columns are arranged on the back side of the main structure.
8. The carbon fiber decorative part structure according to claim 1, characterized in that: The appearance surface of the appearance layer includes a carbon fiber texture, and the carbon fiber texture is formed by hot pressing preforming.
9. The carbon fiber decorative part structure according to any one of claims 1 to 8, characterized in that: The exterior layer is preformed by a hot pressing process, and the main structure is compounded on the back of the exterior layer by an injection molding process.
10. An automobile, characterized in that: The invention comprises a carbon fiber trim structure as described in any one of claims 1 to 9.