Composite board

Abstract

The utility model relates to the technical field of boards, in particular to a composite board, which comprises a buffer layer, a heat insulation layer and a heat insulation layer. The modified layers are arranged on the two sides of the buffer layer, and each modified layer comprises a fiber reinforced material layer. The composite board has the advantage of light weight and certain mechanical properties, and has the benefit of reducing cost; compared with a traditional aluminum alloy material, the light weight degree of the composite board can be larger than 92%, and compared with a traditional glass fiber injection molding fiber, the light weight degree of the composite board can be larger than 85%.

Description

Technical Field

[0001] This utility model relates to the field of sheet metal technology, specifically to a composite sheet metal. Background Technology

[0002] In the modern automotive industry, lightweighting and high performance are two major development directions. Lightweight vehicles offer higher fuel efficiency, lower emissions, and better acceleration and handling stability; while high performance means greater strength, rigidity, and impact resistance, resulting in enhanced safety. Compared to components like tires and powertrains, sheet metal used in automotive bodies is easier to achieve in terms of both lightweighting and high performance. Currently, the most commonly used sheet metal materials in the automotive field are alloy materials, glass fiber modified materials, or carbon fiber modified materials. Alloy materials are limited by their density, making it difficult to meet higher lightweighting requirements; glass fiber modified materials and carbon fiber modified materials have poor impact resistance, failing to meet high performance requirements, and carbon fiber materials are more expensive, hindering cost reduction and efficiency improvement. Summary of the Invention

[0003] Therefore, the technical problem to be solved by this utility model is to overcome the fact that the existing automotive body sheet material cannot simultaneously meet the requirements of light weight and corresponding mechanical properties such as high strength, rigidity and impact resistance, thereby providing a composite sheet material.

[0004] Therefore, the present invention provides the following technical solution.

[0005] This utility model provides a composite board, comprising: a buffer layer, which is a honeycomb material layer or a foam material layer; and a modified layer, which is disposed on both sides of the buffer layer and includes a fiber-reinforced material layer.

[0006] Fiber-reinforced materials are a type of composite material made by combining fibers and matrix materials through a certain process.

[0007] Optionally, the fiber-reinforced material layer includes at least one of a carbon fiber-reinforced material layer, a glass fiber-reinforced material layer, an aramid fiber-reinforced material layer, a basalt fiber-reinforced material layer, and a fiber self-reinforced material layer. Typically, but not limited to, the carbon fiber-reinforced material can be a fiber-reinforced material obtained by composited carbon fibers into a polymer matrix; the glass fiber-reinforced material, aramid fiber-reinforced material, and basalt fiber-reinforced material can be fiber-reinforced materials obtained by correspondingly composited glass fibers, aramid fibers, and basalt fibers into a polymer matrix; the fiber self-reinforced material refers to a single material in fiber form as the fiber-reinforced portion and in near-resin form as the matrix portion.

[0008] Optionally, the fiber self-reinforcing material layer includes at least one of a polypropylene fiber self-reinforcing material layer and a polyethylene fiber self-reinforcing material layer. For example, in the polypropylene fiber self-reinforcing material, polypropylene fibers are used as the fiber reinforcing part and polypropylene resin is used as the matrix part; in the polyethylene fiber self-reinforcing material, polyethylene fibers are used as the fiber reinforcing part and polyethylene resin is used as the matrix part.

[0009] Different fiber reinforcement layers can be selected or combined according to the actual mechanical performance requirements. For example, polypropylene fiber self-reinforcing material can be used to obtain better impact performance, and carbon fiber reinforcement material can be used to obtain better rigidity, etc.

[0010] Optionally, the modified layer may have a laminated structure, wherein the number of layers in the laminated layer is 1 to 50. The composition of the laminated layer can be adjusted according to actual needs, such as four layers of polypropylene fiber self-reinforcing material; two layers of polypropylene fiber self-reinforcing material, two layers of carbon fiber reinforcing material, and two layers of polypropylene fiber self-reinforcing material; two layers of carbon fiber reinforcing material, two layers of polypropylene fiber self-reinforcing material, and two layers of carbon fiber reinforcing material; etc.

[0011] Optionally, the structural form of each layer of material in the laminate includes woven fabric. The weaving process of the woven fabric includes plain weave, twill weave, satin weave, etc., which can be selected according to the actual situation.

[0012] Optionally, the thickness of the buffer layer is 3 to 30 mm.

[0013] Optionally, the thickness of the modified layer is 0.3–5 mm. The rigidity and impact resistance of the modified layer increase with increasing thickness, and its thickness can be determined comprehensively based on the requirements for lightweighting and rigidity and impact resistance.

[0014] Optionally, a bonding layer is included, located between the buffer layer and the modified layer, to integrate the buffer layer and the modified layer into a single structure. The bonding layer primarily ensures interlayer bonding between the modified layer and the buffer layer. When the materials used in the modified layer and the buffer layer are similar, a bonding layer is unnecessary; however, when the materials used in the modified layer and the buffer layer differ significantly, a material with minimal difference from both materials is needed as the bonding layer to better bond the modified layer and the buffer layer together.

[0015] Optionally, the thickness of the connecting layer is 0.01 to 0.1 mm.

[0016] Optionally, a protective layer may be included, located on the side of the modified layer opposite to the buffer layer. Typically, but not limited to, the protective layer serves to improve the corrosion resistance, weather resistance, and aging resistance of the board. The protective layer can be formed by coating, painting, film application, etc., and the use or omission of the protective layer and the specific protective layer material can be selected according to the actual application environment. For example, if the composite board is not exposed to the external environment in the actual application, a protective layer may not be required; if only one side of the composite board is exposed to the external environment in the actual application, a protective layer is only provided outside the buffer layer on the exposed side; if both sides of the composite board are exposed to different external environments in the actual application, different protective layers can be provided outside the buffer layers on both sides.

[0017] Optionally, the thickness of the protective layer is 0.01 to 0.3 mm.

[0018] Optionally, the protective layer includes at least one of the following: polyurethane layer, polyurea coating layer, fluorocarbon coating layer, acrylic coating layer, epoxy coating layer, acrylic polyurethane coating layer, tetrafluoroethylene coating layer, silicone coating, polyester film, and polyvinylidene fluoride (PVDF) film.

[0019] In summary, the beneficial effects achieved by this utility model are as follows:

[0020] The composite board provided by this utility model includes: a buffer layer, which is a honeycomb material layer or a foamed material layer; and a modified layer, which is disposed on both sides of the buffer layer and includes a fiber-reinforced material layer. This composite board possesses both lightweight advantages and certain mechanical properties, and also offers cost reduction benefits. Compared to traditional aluminum alloy materials, the composite board's lightweighting level can exceed 92%, and compared to traditional glass fiber injection molding fiber, the lightweighting level can exceed 85%. The buffer layer, being a honeycomb material layer or a foamed material layer, is lightweight and can absorb residual energy in impact scenarios. Honeycomb materials offer superior rigidity and strength compared to foamed materials, making them suitable for applications requiring high rigidity and strength. Foamed materials, on the other hand, provide better buffering performance, resulting in a lighter weight than honeycomb materials, and also offer sound insulation, making them suitable for applications requiring high impact resistance. The modified layer primarily provides the necessary mechanical properties, such as impact resistance, rigidity, and flexural strength. The modified layer includes a fiber-reinforced material layer, which serves as the main lightweight material with certain mechanical properties. The combined use of a buffer layer and a modified layer enables composite panels to possess both lightweight properties and certain mechanical properties, such as impact resistance and rigidity. Attached Figure Description

[0021] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the composite material provided in Embodiments 1 and 3 of this utility model;

[0023] Figure 2 This is a schematic diagram of the composite board provided in Embodiment 2 of this utility model.

[0024] Explanation of reference numerals in the attached figures:

[0025] 1-Buffer layer; 2-Modified layer; 3-Connecting layer; 4-Protective layer. Detailed Implementation

[0026] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0027] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0028] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0029] Example 1

[0030] This embodiment provides a composite board, which will be described below. Figure 1 Provide a detailed description:

[0031] The composite board provided in this embodiment includes: a buffer layer 1, which is a honeycomb material layer or a foamed material layer; and a modified layer 2, which is disposed on both sides of the buffer layer 1, and includes a fiber-reinforced material layer. Fiber-reinforced material refers to a type of composite material formed by combining fibers and matrix materials through a specific process.

[0032] In some embodiments, the fiber-reinforced material layer includes at least one of a carbon fiber-reinforced material layer, a glass fiber-reinforced material layer, an aramid fiber-reinforced material layer, a basalt fiber-reinforced material layer, and a fiber self-reinforced material layer. Typically, but not limited to, the carbon fiber-reinforced material can be a fiber-reinforced material obtained by composited carbon fibers in a polymer matrix; the glass fiber-reinforced material, aramid fiber-reinforced material, and basalt fiber-reinforced material can be fiber-reinforced materials obtained by correspondingly composited glass fibers, aramid fibers, and basalt fibers in a polymer matrix; the fiber self-reinforced material refers to a single material in fiber form as the fiber reinforcement portion and in a near-rubber form as the matrix portion. In some embodiments, the fiber self-reinforced material layer includes at least one of a polypropylene fiber self-reinforced material layer and a polyethylene fiber self-reinforced material layer. For example, in the polypropylene fiber self-reinforced material, polypropylene fibers are used as the fiber reinforcement portion and polypropylene resin is used as the matrix portion; in the polyethylene fiber self-reinforced material, polyethylene fibers are used as the fiber reinforcement portion and polyethylene resin is used as the matrix portion. Different fiber reinforcement materials can be selected or combined according to the actual mechanical performance requirements. For example, polypropylene fiber self-reinforcing material can be used to obtain better impact performance, and carbon fiber reinforcement material can be used to obtain better rigidity, etc.

[0033] In some embodiments, the modified layer 2 comprises a laminate with 1 to 50 layers. The composition of the laminate can be adjusted according to actual needs, such as four layers of polypropylene fiber self-reinforcing material; two layers of polypropylene fiber self-reinforcing material, two layers of carbon fiber reinforcing material, and two layers of polypropylene fiber self-reinforcing material; two layers of carbon fiber reinforcing material, two layers of polypropylene fiber self-reinforcing material, and two layers of carbon fiber reinforcing material; etc.

[0034] In some embodiments, the structure of each layer of material in the laminate includes woven fabric. The weaving process of the woven fabric includes plain weave, twill weave, satin weave, etc., which can be selected according to the actual situation.

[0035] In some embodiments, the thickness of the buffer layer 1 is 3 to 30 mm.

[0036] In some embodiments, the thickness of the modified layer 2 is 0.3–5 mm. The rigidity and impact resistance of the modified layer 2 increase with increasing thickness, and its thickness can be determined comprehensively based on the requirements for lightweighting and rigidity and impact resistance.

[0037] In some embodiments, the composite board includes a connecting layer 3 located between the buffer layer 1 and the modified layer 2, serving to integrate the buffer layer 1 and the modified layer 2 into a single structure. The connecting layer 3 primarily ensures the interlayer bonding force between the modified layer 2 and the buffer layer 1. When the modified layer 2 and the buffer layer 1 are made of similar materials, a connecting layer 3 is unnecessary. However, when the materials used in the modified layer 2 and the buffer layer 1 differ significantly, a material with minimal difference in material between the modified layer 2 and the buffer layer 1 is required as the connecting layer 3 to better bond the modified layer 2 and the buffer layer 1 together.

[0038] In some embodiments, the thickness of the connecting layer 3 is 0.01 to 0.1 mm.

[0039] In some embodiments, the composite board includes a protective layer 4, which is located on the side of the modified layer 2 facing away from the buffer layer 1. The protective layer 4 serves to improve the corrosion resistance, weather resistance, and aging resistance of the board. The protective layer 4 can be formed by coating, painting, film coating, etc., and the use or omission of the protective layer 4 and its specific material can be selected according to the actual application environment. For example, if the composite board is not exposed to the external environment in actual application, the protective layer 4 may not be provided; if only one side of the composite board is exposed to the external environment in actual application, the protective layer 4 is provided only on the buffer layer 1 on the exposed side; if both sides of the composite board are exposed to different external environments in actual application, different protective layers 4 can be provided on the buffer layers 1 on both sides.

[0040] In some embodiments, the thickness of the protective layer 4 is 0.01 to 0.3 mm.

[0041] In some embodiments, the protective layer 4 includes at least one of a polyurethane coating layer, a polyurea coating layer, a fluorocarbon coating layer, an acrylic coating layer, an epoxy coating layer, an acrylic polyurethane coating layer, and a tetrafluoroethylene coating layer.

[0042] Example 2

[0043] This embodiment provides a composite board, as described below. Figure 2 In detail: The composite board includes a buffer layer 1, which is a high-density microporous foamed polypropylene (MPP) layer with a thickness of 3.8 mm.

[0044] Modified layers 2 are disposed on both sides of buffer layer 1. Modified layer 2 is a polypropylene fiber self-reinforcing material layer that uses polypropylene fiber to reinforce the polypropylene matrix. It is formed by hot pressing four layers of woven fabric. The weaving process is twill weave. After hot pressing, the thickness of modified layer 2 on one side is 0.6mm.

[0045] Since both modified layer 2 and buffer layer 1 are made of polypropylene, they can be directly hot-pressed together without the need for a connecting layer 3. Modified layer 2, buffer layer 1, and modified layer 2 are laid sequentially from bottom to top and hot-pressed together to form a single structure.

[0046] The protective layer 4 is disposed on the side of the modified layer 2 away from the buffer layer 1. The protective layer 4 is a thermoplastic TPU (polyurethane) film with a thickness of 0.15mm. The protective layer 4, the modified layer 2, and the buffer layer 1 can be obtained by hot pressing in one step.

[0047] The obtained composite board was cut into 200×200 templates. The thickness was measured to be 5mm using vernier calipers and the mass was measured to be 89.76g using a balance. The impact resistance was tested according to GB / T 11548-1989, "Test Method for Impact Resistance of Rigid Plastic Sheets (Drop Weight Method)," and the result showed that it could not be broken under 60J.

[0048] An aluminum alloy sheet of the same size and 5mm thickness weighs 540g and breaks under 60J. A pure glass fiber injection molded material of the same size and 5mm thickness weighs as much as 320g and breaks under 60J.

[0049] For the same size, the composite sheet material of this invention is lighter and has better impact resistance than aluminum alloy sheet material and pure glass fiber injection molding material, making it more suitable for use as a sheet material for automobile body.

[0050] Example 3

[0051] This embodiment provides a composite board, as described below. Figure 1 In detail: The composite board includes a buffer layer 1, which is an aramid honeycomb material layer with a thickness of 10mm.

[0052] Modified layers 2 are disposed on both sides of buffer layer 1. Modified layer 2 is a carbon fiber board (T300 carbon fiber epoxy resin board) with a thickness of 0.125mm.

[0053] The connecting layer 3 is disposed between the buffer layer 1 and the modified layer 2. The connecting layer 3 is made of epoxy resin hot melt adhesive with a thickness of 0.15mm.

[0054] The modified layer 2, the connecting layer 3, the buffer layer 1, the connecting layer 3, and the modified layer 2 are laid in sequence from bottom to top and then hot-pressed together to form an integral structure.

[0055] The protective layer 4 is disposed on the side of the modified layer 2 away from the buffer layer 1. The protective layer 4 is an acrylic polyurethane coating with a thickness of 0.1 mm. The protective layer 4 is obtained by spraying it onto the upper and lower surfaces of the integral structure obtained above.

[0056] The obtained composite board was cut into 200×200 mm samples. Its thickness was measured to be 10.5 mm using calipers, and its mass was measured to be 67.2 g using a balance. Referring to the national standard GB / T 9341-2008 "Determination of Flexural Properties of Plastics", the flexural strength was measured to be 960 MPa and the flexural modulus to be 26 GPa. This composite board is lightweight while possessing excellent mechanical properties.

[0057] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A composite board, characterized in that, include: A buffer layer, wherein the buffer layer is a honeycomb material layer or a foam material layer; the thickness of the buffer layer is 3~30mm. A modified layer is disposed on both sides of the buffer layer, and the modified layer includes a fiber-reinforced material layer; the thickness of the modified layer is 0.3~5mm. The connection between the buffer layer and the modified layer is achieved by hot pressing.

2. The composite board according to claim 1, characterized in that, The fiber-reinforced material layer includes at least one of the following: carbon fiber reinforced material layer, glass fiber reinforced material layer, aramid fiber reinforced material layer, basalt fiber reinforced material layer, and fiber self-reinforcing material layer.

3. The composite board according to claim 2, characterized in that, The fiber self-reinforcing material layer includes at least one of a polypropylene fiber self-reinforcing material layer and a polyethylene fiber self-reinforcing material layer.

4. The composite board according to claim 3, characterized in that, The modified layer has a structure including a laminate, and the number of layers in the laminate is 1 to 50. And / or, the structural form of each layer of material in the laminate includes woven fabric.

5. The composite board according to any one of claims 1 to 4, characterized in that, It includes a connecting layer, which is located between the buffer layer and the modified layer, and is used to make the buffer layer and the modified layer an integral structure; The connection between the connecting layer and the buffer layer is achieved by hot pressing. The connection between the connecting layer and the modified layer is achieved by hot pressing.

6. The composite board according to claim 5, characterized in that, The thickness of the connecting layer is 0.01~0.1mm.

7. The composite board according to any one of claims 1 to 4, characterized in that, It includes a protective layer located on the side of the modified layer opposite to the buffer layer.

8. The composite board according to claim 7, characterized in that, The thickness of the protective layer is 0.01~0.3mm.

9. The composite board according to claim 7, characterized in that, The protective layer includes at least one of the following: polyurethane layer, polyurea coating layer, fluorocarbon coating layer, acrylic coating layer, epoxy coating layer, acrylic polyurethane coating layer, tetrafluoroethylene coating layer, silicone coating, polyester film, and polyvinylidene fluoride film.

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