Spraying-free thermoplastic composite material car door outer plate

Abstract

The utility model provides a spraying-free thermoplastic composite material vehicle door outer plate which comprises a spraying-free sheet material modification layer, a vehicle door outer plate body and an auxiliary support which are sequentially connected in a fusion mode from top to bottom, and the vehicle door outer plate body and the auxiliary support are both independently formed. The number of the auxiliary supports and the installation positions of the auxiliary supports and the automobile door outer plate body can be flexibly designed according to the use requirements of different application scenes, so that the automobile door outer plate has sufficient degree of freedom in design; the automobile door outer plate body is made of the continuous fiber reinforced thermoplastic plate, and by means of the light and high-strength characteristics of the continuous fiber reinforced plate, the automobile door outer plate body keeps enough structural strength, and meanwhile light-weight design is achieved; the spraying-free sheet modification layer is made of the spraying-free thermoplastic plastic, so that the spraying-free sheet modification layer obtains an ultra-high smooth finish appearance effect, a subsequent spraying step is not needed, the spraying-free sheet modification layer is fused with the automobile door outer plate body, the outer surface and the edge of the automobile door outer plate body have the spraying-free effect, and the appearance quality is improved.

Description

TECHNICAL FIELD

[0001] The utility model relates to the technical field of automobile manufacturing, especially to a spray-free thermoplastic composite material car door outer plate. BACKGROUND

[0002] Energy saving and emission reduction has always been the design goal of the automobile industry, especially new energy vehicles have more urgent demand for the weight of parts. Replacing steel with plastic has become an important trend in the development of the automobile industry, and car door outer plates have gradually transitioned from metal stamping parts to all-plastic parts. Thermosetting composite materials have relatively mature solutions as exterior parts, such as carbon fiber fabric and epoxy resin formed by HRTM process, glass fiber and unsaturated resin formed by SMC and BMC process, these solutions have achieved significant weight reduction compared to metal. However, thermosetting materials have problems such as non-recyclability and unfriendly raw material storage conditions, making it difficult to widely apply thermosetting materials.

[0003] Thermoplastic materials have the advantages of recyclability and friendly use conditions. However, their strength is relatively low. To enhance strength, inorganic or organic fibers are usually added, but it is often difficult to balance the needs of appearance and strength of car door outer plates. Currently, the commonly used method is to spray paint after injection molding of fiber-reinforced thermoplastic materials, or to use fiber-reinforced thermoplastics as a skeleton, and then glue, weld or integrally mold the thermoplastic skin to obtain non-fiber-reinforced thermoplastic exterior skin parts. Although these methods can obtain exterior parts with specific strength, the post-spraying process is still troublesome and costly.

[0004] Some existing patents attempt to solve these problems, but still have deficiencies. For example, publication numbers CN106080797A, CN106184407A, and CN207550311U all disclose a type of front hood assembly manufacturing method in which the inner and outer plates are both thermoplastic materials, and are connected by positioning glue or welding. However, this method uses thermosetting glue, which cannot be recycled and has the risk of debonding, and hot melt welding is prone to cause bulges or dents on the outer plate.

[0005] Publication numbers CN105922601A, CN218197860U, CN108015923A, and CN218197860U all disclose a type of continuous fiber plate reinforced inner plate, and a method for preparing an integrally injection molded outer skin composite part. Although continuous fiber plate integrally injection molding obtains an outer skin with high efficiency, the smooth outer skin with color obtained by integrally injection molding is prone to shrink marks and injection marks, affecting the appearance quality of the exterior part.

[0006] Publication No. CN105690794A discloses a kind of continuous fiber laminated plate as inner and outer plate, the preparation method of thermoplastic material edge covering automobile outer covering. Although the edge of fiber laminated plate is coated, but the front of fiber-rich laminated plate is easy to appear fiber leakage visible, which leads to significant appearance disadvantage compared with paint spraying parts.

[0007] Publication No. CN110281619A discloses a kind of continuous fiber plate and special outer decoration layer hot-pressing composite after integrated injection molding automobile outer decoration and its preparation method. Although the modification layer and the continuous fiber plate can be directly combined with the modification layer, but the modification layer on the surface is easy to be damaged during molding and injection molding, which needs further paint coating; In addition, the method for preparing outer decoration parts by combining special decoration layer and plate is difficult to ensure that the edge of the plate also has special decoration layer, which affects the appearance quality of the outer decoration parts.

[0008] Therefore, the utility model is proposed. Utility model content

[0009] In view of the above shortcomings of the prior art, the utility model aims to provide a novel spray-free thermoplastic composite car door outer plate and its preparation method, so as to meet the requirements of car door outer plate appearance and strength. The preferred technical solutions in the technical solutions provided by the utility model can produce the technical effects described below.

[0010] To achieve the above-mentioned purpose, the utility model provides the following technical solutions.

[0011] The utility model provides a kind of spray-free thermoplastic composite car door outer plate, including from top to bottom sequentially fused connection's spray-free sheet modification layer, car door outer plate body and accessory support, the car door outer plate body and the accessory support are independently formed, the car door outer plate body is made of continuous fiber reinforced thermoplastic plate material;The spray-free sheet modification layer is made of spray-free thermoplastic plastic.

[0012] Preferably, the thickness of the continuous fiber reinforced thermoplastic plate material ranges from 1.0mm to 5.0mm.

[0013] Preferably, the continuous fiber reinforced thermoplastic plate material is made of a plurality of continuous fiber reinforced thermoplastic unidirectional tapes stacked in a specific angle and order.

[0014] Preferably, the thickness of the continuous fiber reinforced thermoplastic unidirectional tape ranges from 0.1mm to 0.4mm; When stacking, the stacking angle of the continuous fiber reinforced thermoplastic unidirectional tape includes at least four of 0°, ±15°, ±30°, ±45°, ±60°, ±75° and 90°.

[0015] Preferably, the spray-free thermoplastic plastic comprises color powder and at least one of pearl powder, mica powder or metal powder.

[0016] Preferably, the thickness of the spray-free sheet decorative layer ranges from 0.2mm to 4mm.

[0017] Preferably, the inner surface of the outer door panel body is fusedly connected with the auxiliary support through a welding process, and the outer surface of the outer door panel body is fusedly connected with the spray-free sheet decorative layer through a vacuum forming process.

[0018] Preferably, the auxiliary support is formed by using a thermoplastic plastic or a continuous fiber reinforced thermoplastic sheet.

[0019] Preferably, the resin base material of the continuous fiber reinforced thermoplastic sheet, the resin base material of the spray-free thermoplastic plastic and the resin base material of the thermoplastic plastic used by the auxiliary support can be fusedly connected with each other in a heated state.

[0020] The preferred technical solutions of the utility model can at least produce the following technical effects:

[0021] The outer door panel body is made of a continuous fiber reinforced thermoplastic sheet, which makes the most of the lightweight and high-strength characteristics of the continuous fiber reinforced sheet, so that the outer door panel body can be designed to be lightweight while maintaining sufficient structural strength.

[0022] The auxiliary support is independently formed, and the number of auxiliary supports and the mounting positions of the auxiliary supports on the outer door panel body can be flexibly designed according to the use requirements of different application scenarios, so that the outer door panel has sufficient freedom in design.

[0023] The spray-free thermoplastic plastic is used to make the spray-free sheet decorative layer, so that the spray-free sheet decorative layer can obtain a much higher smoothness appearance effect than that obtained by the in-mold injection molding process, and no subsequent spraying step is needed. Moreover, the spray-free sheet decorative layer is fused with the outer door panel body, so that the outer surface and the edges of the outer door panel body have the spray-free effect, which improves the appearance quality of the outer door panel and eliminates the need for in-mold integrated injection molding and painting processes in complex molds. BRIEF DESCRIPTION OF DRAWINGS

[0024] In order to more clearly illustrate the technical solutions in the embodiments of the utility model or the prior art, the following will briefly introduce the drawings needed to be used in the embodiment or the prior art description. Obviously, the drawings in the following description are only some embodiments of the utility model, and those skilled in the art can obtain other drawings according to these drawings without creating any creative labor.

[0025] Figure 1 is a structure schematic view of a spray-free thermoplastic composite material car door outer plate provided by the utility model;

[0026] Figure 2 is Figure 1 a bottom view;

[0027] Figure 3 is Figure 1 a top view;

[0028] Figure 4 is Figure 1 a side view;

[0029] Figure 5 is a structure schematic view of a continuous fiber reinforced thermoplastic unidirectional tape of a spray-free thermoplastic composite material car door outer plate provided by the utility model when laminating;

[0030] Figure 6 is a structure schematic view of a continuous fiber reinforced thermoplastic plate of a spray-free thermoplastic composite material car door outer plate provided by the utility model;

[0031] Figure 7 is a structure schematic view of a spray-free thermoplastic composite material car door outer plate provided by the utility model;

[0032] Figure 8 is a structure schematic view of an accessory support of a spray-free thermoplastic composite material car door outer plate provided by the utility model;

[0033] Figure 9 is a structure schematic view of a car door outer plate and an accessory support of a spray-free thermoplastic composite material car door outer plate provided by the utility model;

[0034] Figure 10 is a structure schematic view of a car door outer plate and a spray-free sheet decorative layer of a spray-free thermoplastic composite material car door outer plate provided by the utility model in a separated state.

[0035] In the drawings:

[0036] 1, continuous fiber reinforced thermoplastic unidirectional tape; 2, continuous fiber reinforced thermoplastic plate; 3, car door outer plate body; 4, spray-free sheet decorative layer; 5, accessory support. DETAILED DESCRIPTION

[0037] In order to make the purpose, technical scheme and advantages of the utility model more clear, the technical scheme of the utility model will be described in detail below. Obviously, the described embodiments are only part of the embodiments of the utility model, rather than all the embodiments. Based on the embodiments in the utility model, all other embodiments obtained by those skilled in the art without creative labor belong to the scope protected by the utility model.

[0038] The utility model provides a kind of spray-free thermoplastic composite material car door outer plate, including from top to bottom sequentially fused connection's spray-free sheet decorative layer, car door outer plate body and accessory support, car door outer plate body and accessory support are independently formed, car door outer plate body is made of continuous fiber reinforced thermoplastic sheet;Spray-free sheet decorative layer is made of spray-free thermoplastic plastic.

[0039] The car door outer plate body of the utility model is made of continuous fiber reinforced thermoplastic sheet by heating softening, die forming step, which makes the most of the lightweight high-strength characteristics of continuous fiber reinforced sheet, so that the car door outer plate body realizes lightweight design while maintaining sufficient structural strength.

[0040] The accessory support of the utility model is independently formed, which can flexibly design the number of accessory support and the mounting position of car door outer plate body according to the use requirements of different application scenarios, so that the car door outer plate has sufficient freedom in design.

[0041] Spray-free sheet decorative layer is made of spray-free thermoplastic plastic by extrusion calendering and casting process, so that the spray-free sheet decorative layer obtains a much higher surface finish than that obtained by in-mold injection molding process, without subsequent spraying steps. Moreover, the spray-free sheet decorative layer is fused with the car door outer plate body, so that the outer surface and edge of the car door outer plate body have spray-free effect, improving the appearance quality of the car door outer plate without in-mold integrated injection molding and painting process in complex mold.

[0042] As an optional embodiment, the thickness of continuous fiber reinforced thermoplastic sheet ranges from 1.0mm to 5.0mm.

[0043] If the thickness of continuous fiber reinforced thermoplastic sheet is too low, it will cause insufficient structural strength of the car door outer plate body, which is difficult to meet the use requirements of the car door outer plate. On the contrary, if the thickness of continuous fiber reinforced thermoplastic sheet is too high, although it can improve the structural strength, it will correspondingly increase the weight of the car door outer plate, which is contrary to the original intention of using continuous fiber reinforced thermoplastic sheet to pursue lightweight.

[0044] Therefore, the thickness range of the continuous fiber reinforced thermoplastic sheet is limited to 1.0mm-5.0mm, so that the continuous fiber reinforced thermoplastic sheet can provide sufficient structural strength to meet the use requirements of the outer panel of the vehicle door, and meanwhile, the outer panel of the vehicle door can maintain a relatively light weight. In addition, the continuous fiber reinforced thermoplastic sheet not only has good structural strength and lightweight characteristics, but also has processing performance of easy cutting, heating softening, mold forming and bending forming.

[0045] As an optional implementation, the continuous fiber reinforced thermoplastic sheet is made of a plurality of continuous fiber reinforced thermoplastic unidirectional tapes which are stacked in a specific angle and order.

[0046] Further, the continuous fiber reinforced thermoplastic sheet is made by stacking a plurality of continuous fiber reinforced thermoplastic unidirectional tapes in a specific angle and order, and then through a hot pressing process.

[0047] As an optional implementation, the thickness range of the continuous fiber reinforced thermoplastic unidirectional tape is 0.1mm-0.4mm; and when stacking, the stacking angle of the continuous fiber reinforced thermoplastic unidirectional tape includes at least four angles of 0°, ±15°, ±30°, ±45°, ±60°, ±75° and 90°.

[0048] The thickness range of the continuous fiber reinforced thermoplastic unidirectional tape is limited to 0.1mm-0.4mm, so that sufficient structural strength can be provided and lightweight design can be realized.

[0049] The design of the stacking angle can avoid the defects of sharp reduction of non-fiber angle direction strength caused by the traditional 0°, 90° and ±45° angle laying to the greatest extent, so that the continuous fiber reinforced thermoplastic sheet can obtain good strength in all directions.

[0050] As an optional implementation, the spray-free thermoplastic plastic includes at least one of color powder, pearlescent powder, mica powder or metal powder.

[0051] Since the spray-free thermoplastic plastic includes color powder, an additional coating coloring step is not needed. In addition, the spray-free thermoplastic plastic further includes at least one of pearlescent powder, mica powder or metal powder, so that the spray-free effect is realized.

[0052] As an optional implementation, the thickness range of the spray-free sheet modification layer is 0.2mm-4mm.

[0053] If the thickness of the spray-free sheet modification layer is too low, the covering and modification effect of the spray-free sheet modification layer will be poor. On the contrary, if the thickness of the spray-free sheet modification layer is too high, although the covering and modification effect will be improved, the difficulty of subsequent plastic uptake forming with the body of the outer panel of the vehicle door will be increased.

[0054] Therefore, the thickness range of the spray-free sheet modification layer is limited to 0.2mm-4mm, so that the spray-free sheet modification layer can provide good covering modification effect, and meanwhile, the subsequent smooth process of the blister forming of the vehicle door outer plate body is ensured.

[0055] As an optional implementation, the inner surface of the vehicle door outer plate body is fusedly connected with the auxiliary support through a welding process, and the outer surface of the vehicle door outer plate body is fusedly connected with the spray-free sheet modification layer through a blister forming process.

[0056] The inner surface of the vehicle door outer plate body is fused with the auxiliary support through a welding process, which can improve the stability of the connection between the two, and also improve the diversity and flexibility of the installation between the vehicle door outer plate body and the auxiliary support, so as to meet the use requirements of different application scenarios.

[0057] The outer surface of the vehicle door outer plate body is fused with the spray-free sheet modification layer through a blister forming process, so that the outer surface and the edge region of the vehicle door outer plate body are covered by the spray-free sheet modification layer.

[0058] As an optional implementation, the forming mode of the auxiliary support includes being made of thermoplastic plastic, or being made of continuous fiber reinforced thermoplastic sheet.

[0059] Further, the forming mode of the auxiliary support includes being made of thermoplastic plastic by one-time injection molding in the same mold, or being made of thermoplastic plastic by injection molding in multiple molds respectively, or being made of continuous fiber reinforced thermoplastic sheet by cutting, heating softening and bending forming steps.

[0060] The utility model provides three forming modes of auxiliary support, which can flexibly select the most suitable forming process according to the specific use requirements of the vehicle door outer plate on the auxiliary support, and improve the flexibility and adaptability.

[0061] As an optional implementation, the resin base material of the continuous fiber reinforced thermoplastic sheet, the resin base material of the spray-free thermoplastic plastic, and the resin base material of the thermoplastic plastic used in the auxiliary support can be fusedly connected with each other under heating state.

[0062] In this way, the spray-free sheet modification layer, the vehicle door outer plate body and the auxiliary support can be effectively and firmly fused together under heating state to form a continuous overall structure.

[0063] The utility model discloses a kind of preparation methods of spray-free thermoplastic composite vehicle door outer plate, comprising the following steps:

[0064] S1: a plurality of continuous fiber reinforced thermoplastic unidirectional tapes are stacked according to specific angle and order, and continuous fiber reinforced thermoplastic sheet is processed by hot pressing process.

[0065] S2: The continuous fiber reinforced thermoplastic sheet is initially cut, and after being heated and softened, it is molded through a molding process, and then further cut to form a specific shape of the car door outer panel body;

[0066] S3: The auxiliary support is made by injection molding of thermoplastic plastic, or by cutting continuous fiber reinforced thermoplastic sheet, heating and softening it and bending it into shape.

[0067] S4: Weld the auxiliary bracket to the inner surface of the outer door panel body;

[0068] S5: A paint-free sheet finishing layer is prepared by extrusion calendering and casting processes using paint-free thermoplastic plastic;

[0069] S6: After simultaneously heating and softening the outer surface of the car door outer panel body and the paint-free sheet trimming layer, the two are fused together using a vacuum forming process and then trimmed and cut to obtain a thermoplastic composite car door outer panel with a paint-free effect.

[0070] Example 1:

[0071] like Figures 1-10 As shown, the present invention provides a paint-free thermoplastic composite car door outer panel, comprising a paint-free sheet trimming layer 4, a car door outer panel body 3, and an auxiliary bracket 5, which are fused together from top to bottom. The car door outer panel body 3 and the auxiliary bracket 5 are both independently formed. The car door outer panel body 3 is made of continuous fiber reinforced thermoplastic sheet 2. The paint-free sheet trimming layer 4 is made of paint-free thermoplastic plastic.

[0072] The outer door panel body 3 of this utility model is made of continuous fiber reinforced thermoplastic sheet 2 through heating and softening and molding steps. It makes full use of the lightweight and high strength characteristics of continuous fiber reinforced sheet, so that the outer door panel body 3 can achieve lightweight design while maintaining sufficient structural strength.

[0073] The auxiliary bracket 5 of this utility model is independently formed, and the number of auxiliary brackets 5 and their installation position with the outer panel body 3 can be flexibly designed according to the usage requirements of different application scenarios, so that the outer panel of the car door has sufficient freedom in design.

[0074] The spray-coated sheet finishing layer is made from paint-free thermoplastic through extrusion calendering and casting processes, resulting in a significantly higher gloss finish than that achieved by in-mold injection molding, eliminating the need for subsequent painting steps. Furthermore, the spray-coated sheet finishing layer is fused to the door outer panel body 3, ensuring that the outer surface and edges of the door outer panel body 3 also have a paint-free effect, improving the appearance quality of the door outer panel and eliminating the need for complex in-mold injection molding and painting processes.

[0075] As an optional implementation manner, as shown in Figure 6 The thickness of the continuous fiber reinforced thermoplastic plate 2 ranges from 1.0 mm to 5.0 mm.

[0076] If the thickness of the continuous fiber reinforced thermoplastic plate 2 is too low, the structural strength of the door outer plate body 3 is insufficient, and it is difficult to meet the use requirements of the door outer plate. On the contrary, if the thickness of the continuous fiber reinforced thermoplastic plate 2 is too high, although the structural strength can be improved, the weight of the door outer plate will be increased accordingly, which is contrary to the original intention of using the continuous fiber reinforced thermoplastic plate 2 to pursue lightweight.

[0077] Therefore, the thickness of the continuous fiber reinforced thermoplastic plate 2 is limited to 1.0 mm to 5.0 mm, so that the continuous fiber reinforced thermoplastic plate 2 can provide sufficient structural strength to meet the use requirements of the door outer plate, while the door outer plate remains relatively light in weight. In addition, the continuous fiber reinforced thermoplastic plate 2 not only has good structural strength and lightweight characteristics, but also has processing performance such as easy cutting, heating softening, mold forming and bending forming.

[0078] As an optional implementation manner, as shown in Figure 5 The continuous fiber reinforced thermoplastic plate 2 is made of a plurality of continuous fiber reinforced thermoplastic unidirectional tapes 1 which are stacked in a specific angle and order.

[0079] Further, the continuous fiber reinforced thermoplastic plate 2 is made by stacking a plurality of continuous fiber reinforced thermoplastic unidirectional tapes 1 in a specific angle and order, and then through a hot pressing process.

[0080] As an optional implementation manner, as shown in Figure 5 The thickness of the continuous fiber reinforced thermoplastic unidirectional tape 1 ranges from 0.1 mm to 0.4 mm; and the stacking angle of the continuous fiber reinforced thermoplastic unidirectional tape 1 includes at least four angles of 0°, ±15°, ±30°, ±45°, ±60°, ±75° and 90°.

[0081] The thickness of the continuous fiber reinforced thermoplastic unidirectional tape 1 is limited to 0.1 mm to 0.4 mm, which can not only provide sufficient structural strength, but also realize lightweight design.

[0082] The design of the stacking angle can maximize the avoidance of the defects of sharp reduction of non-fiber angle direction strength caused by the traditional 0°, 90° and ±45° angle laying, so that the continuous fiber reinforced thermoplastic plate 2 can obtain good strength in all directions.

[0083] As an optional implementation manner, the spray-free thermoplastic plastic includes at least one of color powder, pearl powder, mica powder or metal powder.

[0084] Since the spray-free thermoplastic plastic includes the color powder, an additional coating coloring step is not needed. In addition, the spray-free thermoplastic plastic further includes at least one of the pearl powder, the mica powder or the metal powder, so as to realize the spray-free effect.

[0085] As an optional implementation manner, as shown in Figure 10 The thickness of the spray-free sheet decoration layer 4 ranges from 0.2 mm to 4 mm.

[0086] If the thickness of the spray-free sheet decoration layer 4 is too low, the covering decoration effect of the spray-free sheet decoration layer 4 is poor. On the contrary, if the thickness of the spray-free sheet decoration layer 4 is too high, the covering decoration effect is improved, but the difficulty of subsequent vacuum forming with the door outer plate body 3 is increased.

[0087] Therefore, the thickness of the spray-free sheet decoration layer 4 is limited to 0.2 mm to 4 mm, so that the spray-free sheet decoration layer 4 can provide good covering decoration effect, and at the same time, ensure the smooth process of subsequent vacuum forming with the door outer plate body 3.

[0088] As an optional implementation manner, as shown in Figure 9 , Figure 10 The inner surface of the door outer plate body 3 is fused and connected with the auxiliary support 5 through a welding process, and the outer surface of the door outer plate body 3 is fused and connected with the spray-free sheet decoration layer 4 through a vacuum forming process.

[0089] The inner surface of the door outer plate body 3 is fused with the auxiliary support 5 through a welding process, which can improve the stability of the connection between the two, and also improve the diversity and flexibility of the installation between the door outer plate body 3 and the auxiliary support 5, so as to meet the use requirements of different application scenarios.

[0090] The outer surface of the door outer plate body 3 is fused with the spray-free sheet decoration layer 4 through a vacuum forming process, so that the outer surface and the edge area of the door outer plate body 3 are covered by the spray-free sheet decoration layer 4.

[0091] As an optional implementation manner, as shown in Figure 8 The forming mode of the auxiliary support 5 includes being made of thermoplastic plastic, or being made of continuous fiber reinforced thermoplastic sheet 2.

[0092] Further, the forming mode of the auxiliary support 5 includes being made of thermoplastic plastic by one-time injection molding in the same mold, or being made of thermoplastic plastic by injection molding in multiple molds respectively, or being made of continuous fiber reinforced thermoplastic sheet 2 by cutting, heating softening and bending forming steps.

[0093] This utility model provides three molding methods for the auxiliary bracket 5, which can flexibly select the most suitable molding process according to the specific usage requirements of the auxiliary bracket 5 on the outer panel of the car door, thereby improving flexibility and adaptability.

[0094] As an optional implementation, the resin substrate of the continuous fiber reinforced thermoplastic sheet 2, the resin substrate of the paint-free thermoplastic, and the resin substrate of the thermoplastic used in the auxiliary support 5 can all be fused together when heated.

[0095] This configuration ensures that the paint-free sheet finishing layer 4, the outer door panel body 3, and the auxiliary bracket 5 can be effectively and firmly fused together under heating conditions to form a continuous integral structure.

[0096] This embodiment provides a specific preparation process for a paint-free thermoplastic composite vehicle door outer panel. The preparation steps are as follows:

[0097] S1: As Figure 5 As shown, a continuous fiber-reinforced thermoplastic unidirectional tape 1 with a thickness of 0.3 mm is used, and the tapes are stacked in sequence at angles of 0°, 15°, 30°, 45°, 60°, 75°, 90°, -75°, -60°, -45°, -30°, -15°, and 0°. The tapes are then processed by hot pressing to form a continuous fiber-reinforced thermoplastic sheet 2 with a thickness of 3.9 mm.

[0098] S2: As Figure 6 , Figure 7 As shown, the continuous fiber reinforced thermoplastic sheet 2 is cut into a shape that conforms to the specific dimensions of the car door outer panel; after being heated and softened, it is molded by molding process to obtain the car door outer panel body 3 of the required shape;

[0099] S3: As Figure 8 As shown, thermoplastic particles are melted and then injection molded into a mold in one step to obtain multiple auxiliary supports 5;

[0100] S4: As Figure 9 As shown, the auxiliary bracket 5 is connected to the outer door panel body 3 by hot melt welding process to meet the installation and structural support requirements of the outer door panel body 3;

[0101] S5: The paint-free thermoplastic containing aluminum powder is processed by extrusion calendering and casting to obtain a paint-free sheet trimming layer 4 with a thickness of 1.0 mm; then, the paint-free sheet trimming layer 4 is cut according to the usage requirements of different application scenarios to obtain a specific shape.

[0102] S6: As Figure 10As shown, the vehicle door outer plate body 3 is placed in a special structure of the plastic mold, while the outer surface of the vehicle door outer plate body 3 is heated and the paint-free sheet decoration layer 4 is softened, and the outer surface of the vehicle door outer plate body 3 is quickly heated to a slightly molten state under the condition of maintaining the appropriate rigidity of the vehicle door outer plate body 3; then the softened paint-free sheet decoration layer 4 is transferred to the upper side of the plastic mold using a special clamping device; then the air in the plastic mold is quickly extracted to a specific vacuum degree, and the softened paint-free sheet decoration layer 4 is quickly fused into one body with the outer surface of the vehicle door outer plate body 3 under the action of atmospheric pressure; finally, after sufficient cooling and shaping, the excess paint-free sheet decoration layer 4 is cut to obtain the paint-free thermoplastic composite material vehicle door outer plate as shown. Figures 1-4 The paint-free thermoplastic composite material vehicle door outer plate as shown.

[0103] Embodiment 2: The embodiment provides another specific preparation process of the paint-free thermoplastic composite material vehicle door outer plate.

[0104] The preparation steps are as follows:

[0105] S1: using a continuous fiber reinforced thermoplastic unidirectional tape with a thickness of 0.25mm, sequentially stacking according to the angle sequence of 0°, 30°, 45°, 60°, 90°, -60°, -45°, -30°, 0°, and processing to form a continuous fiber reinforced thermoplastic plate with a thickness of 2.25mm through a hot pressing process;

[0106] S2: cutting the continuous fiber reinforced thermoplastic plate into a shape conforming to the specific outer shape size of the vehicle door outer plate; after heating and softening, forming by a molding process to obtain a vehicle door outer plate body with the required shape;

[0107] S3: cutting the continuous fiber reinforced thermoplastic plate into a specific shape required by the auxiliary support, and bending and forming after heating and softening to obtain the auxiliary support;

[0108] S4: connecting the auxiliary support and the vehicle door outer plate body through a hot melt welding process to meet the installation and structural support requirements of the vehicle door outer plate body;

[0109] S5: the paint-free thermoplastic plastic containing pearl powder is processed by extrusion calendering and casting process to obtain a paint-free sheet decoration layer with a thickness of 1.5mm; then, according to the use requirements of different application scenarios, the paint-free sheet decoration layer is cut to obtain a specific shape;

[0110] S6: placing the door outer plate body in a special structure of the plastic mold, while heating the outer surface of the door outer plate body and the paint-free sheet decoration layer, softening the paint-free sheet decoration layer, quickly heating the outer surface of the door outer plate body to a slightly molten state under the condition of maintaining the appropriate rigidity of the door outer plate body, then using a special clamping device to transfer the softened paint-free sheet decoration layer to above the plastic mold, then quickly pumping the air in the plastic mold to a specific vacuum degree, and the softened paint-free sheet decoration layer is quickly fused with the outer surface of the door outer plate body into an integrated whole under the action of atmospheric pressure, and finally, after sufficient cooling and setting, the excess paint-free sheet decoration layer is cut to obtain the required paint-free thermoplastic composite door outer plate.

[0111] It can be understood that the same or similar parts in the above-mentioned embodiments can be mutually referred to, and the contents not described in detail in some embodiments can refer to the same or similar contents in other embodiments.

[0112] In the description of the present application, it should be explained that, unless otherwise specified, the meaning of "a plurality of" is two or more than two; the directions or position relations indicated by the terms "upper", "lower", "left", "right", "inner", "outer", "front end", "rear end", "head", "tail" and the like are based on the directions or position relations shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and therefore cannot be understood as limiting the indicated devices or elements to have a specific direction, to be constructed and operated in a specific direction, and therefore cannot be understood as limiting the present application. In addition, the terms "first", "second", "third" and the like are only for the purpose of description, and cannot be understood as indicating or implying relative importance.

[0113] In the description of the present application, it should also be explained that, unless otherwise specified and limited, the terms "mounting", "connecting", "connection" should be understood in a broad sense, for example, it can be fixed connection, or detachable connection, or integrally connected; it can be mechanical connection, or electrical connection; it can be directly connected, or indirectly connected through an intermediate medium. For ordinary skilled persons in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0114] In the description of the present application, the description of the terms "one embodiment", "some embodiments", "example", "specific example" or "one example" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. In the present application, the illustrative description of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0115] The above merely describes a specific implementation of the present application, but the protection scope of the present application is not limited thereto, any skilled person in the art can easily think of changes or replacements within the technical range disclosed by the present application, which should be covered in the protection scope of the present application. Therefore, the protection scope of the present application should be subject to the protection scope of the claims.

Claims

1. A spray- free thermoplastic composite vehicle outer door panel, characterized in that, The application relates to a vehicle door outer plate body and an accessory support which are independently formed and are connected by a spray-free sheet decoration layer.

2. A spray-foam-free thermoplastic composite vehicle outer door panel according to claim 1, wherein, The thickness of the continuous fiber reinforced thermoplastic plate ranges from 1.0 mm to 5.0 mm.

3. A spray-foam-free thermoplastic composite vehicle outer door panel according to claim 2, wherein, The continuous fiber reinforced thermoplastic plate is made of multiple layers of continuous fiber reinforced thermoplastic unidirectional tapes which are stacked in a specific angle and order.

4. A spray-foam-free thermoplastic composite vehicle outer door panel according to claim 3, wherein, The thickness of the continuous fiber reinforced thermoplastic unidirectional tape ranges from 0.1 mm to 0.4 mm.

5. A spray-foam-free thermoplastic composite vehicle outer door panel according to claim 1, wherein, The thickness of the spray-free sheet decoration layer ranges from 0.2 mm to 4 mm.

6. A spray-foam-free thermoplastic composite vehicle outer door panel according to claim 1, wherein, The inner surface of the vehicle door outer plate body is connected to the accessory support by a welding process, and the outer surface of the vehicle door outer plate body is connected to the spray-free sheet decoration layer by a vacuum forming process.

7. A spray-foam-free thermoplastic composite vehicle outer door panel according to claim 1, wherein, The accessory support is made of thermoplastic plastic or the continuous fiber reinforced thermoplastic plate.

8. A spray-foam-free thermoplastic composite vehicle outer door panel according to claim 7, wherein, The resin base of the continuous fiber reinforced thermoplastic plate, the resin base of the spray-free thermoplastic plastic and the resin base of the thermoplastic plastic used in the accessory support can be connected to each other in a heated state.

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